338-3 e
Corrosion Detector Portable
CDP EXProof ATEX
Operating Instructions
Content
1 Preface
2 General instructions
2.1 Intended use
2.2 Warnings contained in the
operating instructions
2.3 Notes on deliveries
2.4 Transport and storage
2.5 Notes on warranty
2.6 Notes on return deliveries
3 Safety
3.1 Proper use
3.2 Qualified personnel
3.3 Maintenance
4 Technical description
4.1 Components of the
measuring device
4.2 Mode of functioning of the
Corrosion Detector Portable
CDP EXProof
4.3 Properties of the measuring
device
4.4 Construction of the
immersion probe
4.5 Function of the grounding clamp
4.6 Limits of application
4.7 Menu structure: Corrosion
4.8 Operating concept
4.9 Start-up
4.10 Measurement
4.10.1 User
4.10.2 Test
4.10.3 Conductivity calculator
4.10.4 Setup
4.10.5 Archive:
4.11 Device status
4.12 Software
5 Replacing the batteries
6
Technical data
of Corrosion Detector
Portable CDP EXProof
2
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
1 Preface
The present operating instructions are
designed to familiarize users with the
equipment of the Corrosion Detector
Portable CDP EXProof and its use.
The operating instructions (OI) should
be accessible to the operating and
maintenance personnel in order to
ensure that all necessary information is
available for using the device.
By knowing these OI, you can avoid
damage to the measuring equipment
and prevent incorrect operation. The
information contained in the operating
instructions corresponds to the state
of the art at the time it is printed and
is provided to the best of our knowledge.
We reserve the right to include any
improvements, amendments and new
developments in the operating instructions without prior notice.
The actual design of products may
differ from the information provided
in the catalog if warranted by technical
modifications resulting from product
improvements.
The proposal submitted by Pfaudler for
a concrete application will be binding
in this case.
The latest edition will always supersede
all previous ones.
The present operating instructions are
made available to our customers and
interested parties free of charge.
Reprints and copies as well as transformation into electronic forms, in whole
or in part, shall require our written
approval.
All rights reserved.
2 General instructions
2.1 Intended use
The Corrosion Detector Portable (CDP)
may only be used for the inspection
of glass-lined vessels and internal parts
for damages and the resulting metal
corrosion. Apart from glass-lined reactors
and internal parts, it is also possible
to check reactors and internal parts with
other coatings (e.g., plastic material,
PTFE or rubber) for corrosion of metal.
The proper use of the device is described
in the present operating instructions.
All other applications of the device,
which are not described in the operating
instructions, are not permitted.
The measuring device is designed for use in potentially explosive
atmospheres zone 1 and 2 according
to the directive 1999/92/EC. Noncompliance with these instructions
may lead to dangerous consequences. Please read the operating
instructions completely prior to using
the measuring device.
2.2 Warnings contained in the
operating instructions
In the operating instructions, the danger
symbol
m is used to draw your attention
to especially important safety instructions.
Compliance with these instructions
is mandatory, because adherence to the
instructions can avoid serious mistakes.
2.3 Notes on deliveries
The respective scope of delivery
is specified on the shipping documents
attached to the shipment and corresponds to the valid purchase agreement.
Check that the items delivered are
complete and intact.
2.4 Transport and storage
The Corrosion Detector Portable CDP
EXProof should be exclusively transported and stored in its closed original
case. In order to ensure an as-new condition of the device and accessories,
the following storage conditions should
be maintained:
Storage/transport temperature:
–25 to +70 °C without batteries
2.5 Notes on warranty
Any warranty claims shall not be extended
or limited by the information contained
in the present operating instructions.
For the exact warranty conditions,
please refer to the Terms of Sale of
Pfaudler Werke GmbH as amended.
All warranty claims will be void if the unit
is opened.
2.6 Notes on return deliveries
Before sending used immersion probes
to Pfaudler Werke GmbH, all parts must
be cleaned and decontaminated first.
To protect our staff and for insurance
reasons, your return shipment must
be accompanied by a clearance certificate on which you confirm that the
immersion probes were properly
cleaned and decontaminated. You may
obtain a form sheet for this purpose
from us on request (OI332).
Since the device may be used
in potentially explosive atmospheres, all explosion protection
requirements must be satisfied.
Repairs or modifications of the device are not permitted.
3
© Pfaudler GmbH
CDP EXProof
3 Safety
ATEX safety information
The present operating instructions contain safety information and safety provisions which must be complied with
in order to ensure the safe, reliable
operation of the CDP in potentially
explosive atmospheres under the conditions described. Non-observance of the
information and instructions may lead
to serious consequences or violate applicable laws. Please read the operating
instructions carefully prior to using the
measuring device. All instructions and
warnings in the manual must be observed
to ensure the safe operation of this
measuring device.
To avoid electric shocks or injuries while
working in potentially explosive atmospheres, please follow and comply with
the following instructions:
■ Do not open the CDP within poten-
tially explosive atmospheres.
■ Replace the batteries of the CDP
outside potentially explosive atmospheres only.
■ Do not take spare batteries along into
potentially explosive atmospheres.
■ Only use permitted batteries for the
C D P.
■ Do not place the measuring device
in zone 0.
■ The CDP may only be repaired by the
manufacturer.
■ Use the CDP as described in the oper-
ating instructions exclusively, otherwise the protective devices integrated
in the CDP may be impaired.
■ Do not use the CDP when damaged.
Prior to using the CDP check the
housing for cracks or broken off plastic parts.
■ Prior to using the CDP always make
sure that the battery cover is closed
and fixed.
■ Do not use the CDP in case of mal-
functions. The safety precautions
may be impaired. Have the CDP
checked by the manufacturer in cases
of doubt.
■ For operation of the CDP, only use the
permitted batteries and install them
properly in the housing. Please note the
instructions “Replacing the batteries”
in Section 5.
■ Examine the measuring lines for dam-
aged insulation and exposed metal.
Test the continuity of the measuring
lines. Replace damaged measuring
lines prior to using the CDP.
■ The storage case may not be taken
along into the potentially explosive
atmosphere.
Errors and inadmissible loads: If the safety
or integrity of the device is doubtful
or impaired, the device must be put
out of operation immediately and
removed from the potentially explosive
atmosphere. In addition, measures
must be taken to avoid the device from
being started up inadvertently before
it has been checked and declared to be fit
for operation. It is recommended to send
the measuring device to the manufacturer
for inspection.
In the following cases, safety and reliability of the measuring device may be
impaired and the device must not be
used anymore:
■ Apparent damage to the housing of the
measuring device.
■ The measuring device was exposed
to excessive loads for which it is not
designed.
■ The device was stored inappropriately.
■ The device has transport damages.
■ Illegible display/labeling on the meas-
uring device.
■ A measuring device malfunction
occurs.
3.1 Proper use
Any use of the equipment for purposes
other than those described in the present
operating instructions will adversely
affect the safety and functioning of the
measuring device and is therefore not
allowed.
It is important to note the safety instructions applicable to the electrical systems
and equipment and all explosion protection
provisions, if any.
3.2 Qualified personnel
The unit may only be operated
by authorized technical personnel
in strict compliance with the present
operating instructions as well as the
valid standards and provisions.
The failure to observe these instructions – no matter whether intentionally
or negligently – releases Pfaudler Werke
GmbH from all liability and warranty
claims.
3.3 Maintenance
The Corrosion Detector Portable CDP
EXProof is maintenance-free. We recommend an annual function test of the
device by the manufacturer. The function
test is documented at our company based
on the serial number and confirmed
by a test certificate.
4
© Pfaudler GmbH
4 Technical description
4.1 Components of the
measuring device
Check the items delivered for completeness.
The following items are included in the
delivery:
■ Hard-sided case with molded insert
taking up the measuring device
■ Corrosion Detector Portable CDP
EXProof including batteries
■ Immersion probe and reference
electrode
■ Grounding clamp with contact moni-
toring
■ Reference electrode (spare)
■ File for cleaning contacts
■ Operating instructions
■ Software and hardware
4.2 Mode of functioning of the
Corrosion Detector Portable
CDP EXProof
If metal gets in contact with a conductive
liquid (electrolyte), the result is a voltaic
cell. That means that a voltage is generated at the contact surface between the
metal and the electrolyte. The value
of the voltage is subject to the type of the
metal, temperature and the chemical
properties of the electrolyte. If the voltage
exceeds a certain value, metal ions are
dissolved, i.e. the metal is corroded.
In other words, the metal is decomposed.
The voltage value as of which a certain
metal is decomposed (corroded) is
referred to as the decomposition voltage. Since the corrosion resistance
depends on the type of metal, the
decomposition voltage also differs
between metals. As a result, each metal
is characterized by its own specific
decomposition process which can be
electrically distinguished from that of
other metals.
The measuring device with the Corrosion
Detector Portable CDP EXProof as the
central element works with AC voltage,
thus avoiding electrochemical reactions
and the associated polarization at the
measuring electrodes.
The measuring loop consists of 4 electrodes the 2 measuring electrodes,
the reference electrode and the reactor
wall as the 4
th
electrode.
OE = reference electrode
KW = reactor wall
4.3 Properties of the measuring
device
The device works according to the prin ciple of impedance analysis. That means:
the Corrosion Detector Portable CDP
EXProof will output an alarm only if
metal corrosion has actually occurred
on the reactor or the internal parts.
Compared to conventional glass monitoring equipment which works according
to the principle of conductivity analysis,
this method offers fundamental advantages. Conventional systems are not
capable of distinguishing between a real
alarm and a false alarm when an alarm
is signaled.
A real alarm is present if the coat
is strongly damaged, resulting in a conductive link between the product and
the metal (and thus the equipotential
bonding system). Such a damage will
always be accompanied by corrosion
in the damaged spot.
A false alarm is defined as a conductive
link bet ween the product and the equipotential bonding system that is not
caused by glass damage.
Such links to other plant sections not
resistant to corrosion may be the result
of production-specific operating conditions, e.g., condensate bridges built up
via the reactor’s nozzles, or when filling
or draining the reactor.
Conductive plant components made
of tantalum, titanium, Hastelloy C4,
graphite, conductive gaskets or repair
plugs made of noble metals do not
trigger a corrosion alarm if they have been
properly installed and as long as the acids
used are corrosion-resistant.
4.4 Construction of the
immersion probe
The body of the immersion probe is
made of PTFE, the highly flexible,
shielded cable with a length of 10 m
is insulated with an acid-resistant
silicone coat. In the upper part of the
probe, the two corrosion-resistant measuring electrodes have been arranged
at a 180 ° offset. The exchangeable reference electrode (OE) has been screwed
into the lower part, which is closed
by a bulgy PTFE plug that prevents
contact between the reference electrode made of steel and the glass.
Resistors have been integrated into the
immersion probe that enable the unit
to check whether contact has been
made with all electrodes through the
cable prior to each measurement as soon
as the probe is connected.
4.5 Function of the grounding
clamp
The grounding clamp is connected to
the device through a silicone-insulated
cable 3 m in length. Special stainless
steel contacts have been integrated into
the clamp which enable the unit to monitor the cable and the positive contact
with the reactor or potential bonding
system.
4.6 Limits of application
Inappropriate products
Organic solvents, acetic acid, liquid
products or water with insufficient
conductivity.
Aggressive media with insufficient conductivity, such as bromine or hydrogen
bromide.
Chemical resistance of the
immersion probe
The silicone cable and the measuring
electrodes are not suitable for permanent use, however, they are resistant
to corrosion during short measurements in acids at room temperature.
The exchangeable reference electrode
(OE) is not corrosion-resistant and will
be subject to varying degrees of attack,
depending on the acid. If erosion has
reached the O-ring seal, the reference
electrode must be renewed.
Corrosion Detector Portable CDP EXProof
5
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
4.7 Menu structure: Corrosion
Initial start-up
ON
Select language
OK
Date/Time
OK
Owner
OK
Corrosion Detector
Menu
Conductivity calc.
OK
Test
OK
Archive
OK
Setup
OK
User
OK
Select user
New record
OK
Select test location
New record
OK
Edit location
Company: …………...
Bldg: …………………
Reactor: ……………..
OK
Start-up
ON
Prepare measurement
Grounding clamp: connect
Immersion probe: connect
Prepare measurement
Grounding clamp: OK
Immersion probe: OK
Test
Test running
Aborted
Test finished
No corrosion
Save test?
No Yes
Test running
300 sec remaining
Test not possible - Add acid
Archive
Test finished
CORROSION
Save test?
YesNo
Test finished
CORROSION
Locate spot?
No Yes
Locate spot 44 sec
No corrosion
Finished
Locate spot 44 sec
CORROSION
Prepare test
Grounding clamp: OK
Immersion probe: OK
Conductivity too low
Wait short time until
electrodes have
been reconditioned,
then repeat
measurement
Add salt and/or
acid
Conductivity calc.
Calculate conductivity
of approx. 1 mS
OK
Conductivity calculator
Material
: HCL
37%
Reactor vol.: 1.0m³
Required 1.08 kg
quantity:0.72L
ES
C
Measurements archive
Select measurement
OK
Entry XYZ
Company/Bldg./Reactor
Date/Time
Measured result
Note
ESC
Edit User name
Company: ……….
Name: …………...
ESC
Press 0 key to turn the
“OE” and “KW” measured
values on or off
Setup
System status
Set time
Language selection
LCD contrast
Owner
Corrosion limit
Select
OK
Status
Firmware: ……….
Battery: ... mV ... %
ESC
Status
Memory allocation
User: ……………...
Locations: ………..
Measured data: ....
ESC
Enter owner
Text: ………………..
ESC
LCD contrast
+ / -
ESC
Select language
German
English
ESC
Set time
Date: … Time …
ESC
Corrosion limit
Factory setting -20
Range: 0 to -160mV
ESC
Corrosion Detector Portabel
Finished
HCL (hydrochloric acid)
H2SO4 (sulphuric acid)
CH2O2 (formic acid)
KCL (potassium chloride)
Fig. 1 Corrosion Detector Portable
6
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
4.8 Operating concept
4.9 Start-up
Check the safety provisions and read
the operating instructions completely
before you switch on the CDP. Press the
ON key to switch on the device.
When starting up the unit for the first
time, you are requested to enter the
language, date/time and the new owner.
The owner’s name can be changed
whenever necessary in the SETUP
menu, refer to Section 4.10.5 Owner
Please observe the limits of application
in Section 4.6.
Fill the reactor with water and set the
conductivity value to 1 mS by adding
various chemicals specified in the
device; use the conductivity calculator
for this purpose. Select material and
reactor volume, the quantity of material
is displayed automatically (refer to
Section 4.10.3 Conductivity calculator).
Then switch on the agitator briefly
to mix the reactor content; switch the
agitator off again. Enter yourself as user
in the main menu (refer to Section 4.10.1
User). Immerse the probe in the reactor
content and fix it. Connect the grounding clamp to the reactor’s equalization
strip (refer to Figure 3 Reactor with
CDP) and start the test (refer to Section
4.10.2).
After the test, additional information may
be entered under Note (refer to Section
4.10.4 Archive).
The test results are saved and managed
in the archive. With the aid of the supplied software, the stored data can
be edited and archived conveniently
at the PC (refer to Section 4.12)
Fig. 2 Connection and keyboard
Immersion probe (red)
The sockets and connectors
are marked by different colors
Grounding clamp
(gre en)
The respective sof tkey function
is shown in the display
Arrow or cursor keys are
used to move the cursor
OK is used to select
menu items or
conrm entries
Key to delete
incorrect entrie s
ON is used to switch
on the device or activate
the display illumination
The 0 key is used
to show measured values
or as spac e bar
when making entries
ESC is used to abor t an action
or return to the main menu
step by s tep
Keys for entering numbers
or letters
OFF is used to switch
off the device
7
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
4.10 Measurement
4.10.1 User
Switch the device on. The user may
enter his name in the main menu, a max.
of 50 users are possible. This entry is
made once, whenever the unit is used
again, the relevant user may select his
name from the list.
4.10.2 Tes t
Do not select Test unless the reactor is
ready for the measurement. The Select
test location menu is displayed. Select
New record if no measurements have
been stored in the archive yet.
If a reactor has been tested before, it
may be selected, and a new record and
index no. is generated by pressing Copy.
When New record has been selected,
the Edit location window appears. E.g.
the company, the building and the reactor
may be entered here. The Reactor line
is mandatory.
m Up to 500 locations can be
stored.
Corrosion Detector
User:.dler/Tabert
Test
Conductivity calculator
Archive
Setup
29.06.07 08:00:00
Select User
<New Ent ry>
Pfaudler\Schulz
Meier
Friedrich
Edit
Edit User
Company: Pfaudler
Name: Schulz
A/a ABC A/1
Selec t test location
<New record>
Chemic al\G22\R12345
Chemic al\G22\R12361
Pf au dl er \G98\R12379
Pfaudler\G99\R9988
Copy
Edit
Edit location
Company: Chemical
Bldg: G22
Reac tor: R12345
A/a ABC A/1
Fig. 3 Reactor with CPD
8
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
Once this data has been entered and confirmed, you will be requested to connect
the grounding clamp and the immersion
probe. If they have not been connected.
Start measurement.
When the measurement has been
started, the system checks whether
the conductivity and the acid value
of the reactor contents are sufficient for
he measurement. If the corrosion potential is too low, the message Test not
possible – Add acid will be displayed
after a short while.
Add or remove the OE and KW measured
values by pressing the 0 key.
When the display appears red, the
message Test finished, CORROSION
will be displayed. Select No to repeat the
measurement and restart the process,
or save the values by hitting Yes.
LCD: red
After saving, the display will show Locate
spot? You now have the opportunity
to locate the corroded spot inside the
reactor. If Yes is selected, the display
starts flashing.
LCD: red
Connect the grounding clamp to the
equipotential bonding system or a bare
conductor at the reactor. OK will be displayed if the clamp has been properly
connected.
For measurement it is necessary that
the immersion probe is fully immersed
in the medium. To locate the damage,
however, the immersion probe has
to be immersed to the deepest point.
Caution! Previously turn off the
ag i ta t o r.
When the display appears green, the
message Test finished, No corrosion
will be displayed. Select No to repeat the
measurement and restart the process,
or save the values by hitting Yes.
LCD: green
m Up to 10,000 measurements
can be stored (circulating).
Now empty the reactor in batches; there
is no longer any contact if the display
flashes green.
m Caution! Make sure that the
immersion probe does not get stuck
in the bottom valve.
LCD: flashing red or green
Test nished
CORROSION
Locate spot?
No Yes
Test nished
No corrosion
Save test?
No Yes
Locate spot 44 s
CORROSION
Finished
Prepare measurement
Chemic al\G22\R12345
Prepare measurement
Chemic al\G22\R12345
Grounding clamp: OK
Immersion probe: OK
MEASURE
Test running
300 s remaining
Cancel
Test nished
CORROSION
Save test?
No Yes
9
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
4.10.3 Conductivity calculator
If water is used for testing the reactor,
the conductivity or acid value first has
to be set to approx. 1 mS in order
to obtain a reliable measurement.
The most common acids and salts have
been stored under the Materials option
of the calculator. For the acids, you can
set a percentage and then enter the
reactor volume in m³. The necessary
quantity is indicated in kilos, and additionally in liters for the acid.
Select desired measurement and make
the desired entries using the Edit option
of the Note menu.
4.10.4 Setup
The following settings and controls can
be entered in the Setup menu.
System status: Software version, battery
voltage display, capacity and memory
allocation.
Language selection: Currently, German
and English are available.
LCD contrast: Individual contrast setting
adjustment.
Set time: Date and time input.
Owner: A new name can be entered
here if the owner changes.
Corrosion limit: The factory setting
is uncompensated. If materials are
used that are characterized by slight corrosion under normal conditions already,
the sensitivity can be “compensated”
by selection.
4.10.5 Archive:
All measurements are stored in the
archive. When the measurement has
been completed, additional information
can be input under Note.
m Only the measurements per-
formed by the active user will be
displayed in the archive.
m If the alarm threshold
is changed, the proper functioning
of the unit should be verified by
simulating a damage.
4.11 Device status
In the main menu, the 0 key can be used
to turn on and off all measuring data,
battery voltage and time.
4.12 Software
Refer to enclosed manufacturer’s instructions.
Conductivity calculator
Material: HCl
37 %
Reactor vol: 1.0 m 3
Required 1.08 kg
quantity: 0.72 L
Entry 1/19
Chemic al\G22\R12345
03 . 04.0 7 11:11:11
CORROSION
<Note>
Edit
En tr y 1/ 19
Chemic al\G22\R12345
03 .0 4.07 11:11:11
CORROSION
Tex t
A/a ABC A /1
Status
Firmware: 1.0.10
Batterie: 4319 mV 81%
LCD contrast
>>> +2 <<<
>>> +1 <<<
>>> 0 <<<
>>> –1 <<<
>>> –2 <<<
Default
A/a ABC A /1
10
© Pfaudler GmbH
Corrosion Detector Portable CDP EXProof
5 Replacing the batteries
Do not open the measuring
device within potentially explosive atmospheres. Replace the batteries outside
potentially explosive atmospheres only.
Use permitted batteries only.
Open the battery compartment on the
back of the unit and replace the batteries.
Use permitted batteries only.
6 Technical data of Corrosion Detector Portable CDP EXProof
EC type examination certificate: EX5 12 02 45670 008
Ex-identification:
II 2 G Ex ib IIB T3 –10 °C ≤ Ta ≤ +50 °C
Power su pply: 4.5 VDC
Current input: max. 60 mA
Minimum conductivit y: 0,8 mS/cm
Measuri ng volta ge: 3,3 Veff
Measuring current: max. 1,3 mA
Measuri ng freque ncy: 10 Hz
Working temperature: –10 °C bis +50 °C
Storage temperature: –25 °C bis +70 °C (without batteries)
Housing: Vestamide/black (antistatic)
LxWxH: 180 x 85/62 x 30/25.5 mm
Weight: 390 g
Degree of protection: IP 54
Memory: Owner: 1 entry
User: 50 entries
Locations: 500 entries
Measurements: 10,000 entries (circulating)
Sealed keypad: 21 keys (shielded)
Battery compartment for: 3 batteries size R6
Permitted batteries: AA 1.5 V size R6 LR6 No. 4106 AM3 MN 1500
VARTA Microbattery GmbH
Graphic display 128x64 and acryl glass cover (metalized)
Connectors for the immersion probe and grounding clamp on face side of enclosure
Electromagnetic compatibility (to IEC 801)
CE mark
Fig. 5 Battery compar tment open
Fig. 4 Backside Corrosion Detector
11
© Pfaudler GmbH
Annex
EC Declaration of Conformity
12
© Pfaudler GmbH
Annex
EC Type Examination Certificate
13
© Pfaudler GmbH
Annex
EC Type Examination Certificate
EG-Baumusterprüfung
14
© Pfaudler GmbH
Notes
15
© Pfaudler GmbH
Notes
The information provided in this documentation corresponds
to the state of the art at the time of printing. It is published
in good faith. However, we will accept no warranty claims
based on the information provided in this documentation. We
reserve the right to include improvements, amendments and
new findings in this documentation without prior notice. The
actual design of products may deviate from the information
contained in the calatoge if technical alterations and product
improvements so require. The proposal made by Pfaudler for
a concrete application will be binding in such cases.
The present documentation is made available free of charge
to our customers and other interested parties. The right to
print or copy this documentation, or any parts there of, or to
convert the same into electronic form shall be subject to our
written permission.
All rights reserved by us.
Pfaudler GmbH
P.O. Box 1780 D-68721 Schwetzingen
Pfaudlerstraße D-68723 Schwetzingen
Phone +49 6202 85-233
Telefax +49 6202 85-273
E-mail info@pfaudler-instrumentation.com
www.pfaudler-instrumentation.com
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