CATH-TECH Hexcorder Pro User manual

Operation Manual for Hexcorder Pro
Cathodic Technology Ltd.
15-1 Marconi Court
Bolton, Ontario
Canada L7E 1E2
Ph: ++1-905-857-1050
[e-mail]
www.cath-tech.com
CIPS/DCVG/ACVG/GIS Survey Instrument

Rev 6 –Feb 2022
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Table of Contents
Limited Warranty................................................................................................................................3
Tablet User Account.....................................................................................................................3
Welcome.............................................................................................................................................4
Testing & Calibration...................................................................................................................5
Charging the Battery ....................................................................................................................5
GPS Engine..................................................................................................................................5
Connections.........................................................................................................................................7
Setting Up ...........................................................................................................................................8
Using Another Tablet...................................................................................................................9
Tablet and App Language ............................................................................................................9
Survey Configuration........................................................................................................................10
Survey Settings Screen...............................................................................................................10
Parameters Screen......................................................................................................................13
Interruption Cycle & Timing Settings........................................................................................14
Survey Screen Settings...............................................................................................................17
Map Settings ..............................................................................................................................18
Settings Overview......................................................................................................................19
Conserving Tablet Battery Life..................................................................................................19
Survey...............................................................................................................................................20
Calculated Gradients ..................................................................................................................20
Start the Survey..........................................................................................................................21
Scope Mode ......................................................................................................................................23
Data Files ...................................................................................................................................25
GPS Datum .......................................................................................................................................27
Changing the Datum...................................................................................................................27
Available Earth Datums .............................................................................................................27
Pipe Locator......................................................................................................................................29
Pipe Locator Features.................................................................................................................29
RadioDetection Pairing ..............................................................................................................30
Vivax Metrotech Pairing ............................................................................................................31

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Rigid SR-24................................................................................................................................32
Optional Wired Connection...............................................................................................................34
Survey Techniques............................................................................................................................35
CIPS...........................................................................................................................................35
DCVG and ACVG .....................................................................................................................35
Combined Surveys .....................................................................................................................36
Cables.........................................................................................................................................37
Replacement Parts / Accessories.......................................................................................................39
Troubleshooting ................................................................................................................................42
Service Bulletin –Battery not charging......................................................................................42
Environmental Protection..................................................................................................................43
RN42 Bluetooth Transceiver Regulatory Information.......................................................................44

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Limited Warranty
All Cathodic Technology Limited (Cath-Tech) instruments and equipment are warranted against
defects in materials, design, or workmanship for a period of two years from date of sale. This
warranty excludes damage due to misuse, abuse, tampering or acts of God such as fires, floods, wind
damage, lightning etc.
We will repair or replace at our option any defective component, after examination in our
manufacturing facility, if the fault is due to defective materials or labour, within two years of the
purchase date. For warranty repair, a Returned Goods Authorization (RGA) must be obtained from
Cathodic Technology Ltd prior to shipping the defective unit pre-paid to our location.
Note: There is no warranty expressed or implied on batteries.
Cath-Tech Policy
•Cath-Tech extends a two-year in use warranty on all units, which have been designed and
manufactured by Cath-Tech.
•Cath-Tech reserves the right to make any changes in design or specification which it deems an
improvement, with no liability to make the same changes on existing equipment.
•This warranty is in lieu of all other warranties or guaranties, expressed or implied, which might
otherwise exist. The purchaser is relying only upon this guarantee and not upon any
representations not herein expressed.
•Any material or equipment being returned to the factory must first have a Returned Goods
Authorization (RGA) from Cath-Tech.
Cathodic Technology Limited cannot offer support or warranty coverage for user-supplied tablets.
Cathodic Technology Limited is not responsible for any damage or issue caused to a user-supplied
tablet while using the Hexcorder Pro.
Tablet User Account
The Zebra tablet is provided pre-configured for use, with the Hexcorder Pro app installed. The tablet
is configured to a unique Google account created specifically for it, named as
SERIALNU[email protected]om. The user may opt to change the account if they wish.
To avoid over-discharging the battery in the future, please do not store the
Hexcorder Pro without fully charging the battery first, and please recharge
it every 3 months if not in active use. This will promote battery health and
lifespan and keep the battery from becoming severely discharged.

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Welcome
Thank you for selecting the Hexcorder Pro CIPS and DCVG survey instrument.
The Hexcorder Pro utilizes GPS for synchronization with current interrupters and other data logging
equipment. This ensures that everything happens at the same time no matter how far apart
equipment is or how long it has been out in the field. GPS coordinates are logged for each reading
and stored to memory.
Open and inspect your Hexcorder Pro upon receipt. If any damage occurred during shipping, file a
claim with the carrier immediately.
The Hexcorder Pro comes complete with:
•Hexcorder Pro on mounting
plate with GPS antenna
•Rugged Zebra/Xplore* Android
tablet (if ordered)
•Wire dispenser/chainage counter
assembly, either hip pack or
back pack
•Hexcorder Pro to wire dispenser
cable (attached to back pack or
in the box for hip pack)
•Battery charger
•2 x Cu/CuSO4half cells
•2 x half cell extension poles
•2 x Hexcorder Pro to survey pole
cables
•Spool of 32AWG survey wire
•4 point harness
•Hip pack strap (if applicable)
•Carrying case
•Mini USB cable
•Operation manual
*As of August 2020, all Hexcorder Pro units come with the new rugged Zebra L10
Android tablet.
Figure 1 - Hexcorder Pro with Hip Pack
Figure 2 - Hexcorder Pro with Backpack

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Testing & Calibration
This instrument has been thoroughly tested at the factory to ensure it will perform correctly. A
certificate of calibration is included. The calibration is traceable to the National Institute of
Standards and Technology (NIST) or the National Research Council of Canada (NRC). Cath-Tech
recommends that the Hexcorder Pro be re-calibrated on a yearly basis; contact Cath-Tech for more
information.
Charging the Battery
The battery inside the Hexcorder Pro box is the latest generation of rechargeable Lithium Ion battery,
rated for 9000mAh. High quality Samsung-brand lithium cells are used. Do not allow the battery to
freeze, also do not store in a hot location. Fully charge the battery before storing long-term.
To avoid over-discharging the battery, please do not store the Hexcorder
Pro without fully charging the battery first, and please recharge it every 3
months if not in active use. This will promote battery health and lifespan
and keep the battery from becoming severely discharged.
It is recommended that you charge the battery for 24 hours upon receiving the unit. When the
charger is connected and the Hexcorder Pro is charging, a red LED on the control panel will light up.
When charging is complete, this LED will turn green. When connected to the tablet, the Hexcorder
Pro will display the battery life near the top right corner as a percentage. The Hexcorder Pro will
automatically power down when the battery has been fully depleted. If there are any issues charging
the battery, please refer to the Troubleshooting section on page 42 for detailed instructions to revive
the battery.
The tablet also includes rechargeable Lithium Ion batteries, which require charging prior to use. The
charging port is located behind a water-tight door on the right-hand side of the tablet (See Figure 4).
Under normal survey use (100% brightness, screen always on, Wi-Fi turned off) the battery will last
approximately 11 hours. Additional external batteries and a reconditioning charger are available for
purchase if a longer run time is needed. External battery packs can be changed without shutting the
tablet off.
GPS Engine
A standard GPS engine/antenna as shown in Figure 3 is
supplied with the Hexcorder Pro. It is capable of resolving
position information with an accuracy better than 3 meters if
the WAAS differential correction is being received. Optional
sub-meter GPS accuracy antenna is available upon request.
The GPS engine is connected to the Hexcorder Pro by a
metal circular connector on the outside of the case.
Normally the GPS will lock within 5 minutes, however, if
the GPS has been moved far from its last position, has not been used for a long period or if the signal
is weak, it may take over 10 minutes to lock.
Figure 3 - GPS Engine / Antenna

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If the GPS engine will not lock:
•Place it in a position that has a good view of the sky in all directions, on the roof of a
parked car is usually good
•Power on the Hexcorder Pro
•Leave it alone for 10 minutes or so
•Usually, the GPS will lock in this situation
If the GPS loses lock while in survey mode, this is not a problem. The PPS (Pulse Per Second)
signal will be internally generated by the receiver’s real-time clock and the ON/OFF measurements
will still be accurate. The GPS will typically regain lock long before timing drift has any influence
on the recorded data.
NOTE: The Hexcorder Pro uses the UTC date and time supplied by the GPS satellite system. The
displayed time and time stored in the data can be set to your local time zone in the “parameters”
screen, accessed from the Settings tab.

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Connections
Figure 6 - Hexcorder Pro assembly - Bottom view
Figure 4 - Hexcorder Pro
assembly - right view
Figure 5 - Hexcorder Pro
assembly - left view
Tablet Power
Button
Hexcorder Pro
power button
Half Cell –
Voltage Gradient
Right / Back
Battery Charge
Wire Dispenser
Half Cell –Pipe
Half Cell –
Voltage Gradient
Left / Front
USB Mini
GPS Antenna

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Threading the Wire
From the spool, the wire passes through the
plates of the lower tensioner. Then the wire is
wound clockwise around the drum twice.
Finally, it passes through the plates of the upper
tensioner and out the side of the wire dispenser
to be attached to the pipe at the test station.
Connect the lead from the bottom of the spool
to the terminal at the base of the wire dispenser.
The wire has a fine enamel coating on it that
must be removed with sandpaper to make a
good electrical connection.
Figure 7 - Wire path through chainage counter

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Setting Up
To turn on the Hexcorder Pro black box, press the red power button on the left side of the case. Turn
the tablet on by pressing the power button on the right side of the tablet. When the survey day is
done, hold the red power button for 5 seconds to turn the Hexcorder Pro black box off and turn the
tablet off.
Important Note:
The Hexcorder Pro should be powered on only when you are ready for it to be connected to the
tablet; too much idle time and the Bluetooth will no longer be “findable”. Simply power cycle the
Hexcorder Pro if this occurs.
Run the Hexcorder Pro app from the tablet home screen.
Using Another Tablet
For the best user experience, we strongly recommend only using the rugged Android tablet supplied
by Cath-Tech. The app can run on other tablets, however battery life, water resistance and daylight
readability are not optimal. The minimum specifications to run are Android 6.0 with screen
resolution of 1366 x 768 or better, and a 10” diagonal screen size. The tablet must also have
Bluetooth 2.0 or better to communicate with the Hexcorder Pro box.
Connecting to Tablet
In the app, select the “CONNECT A DEVICE” button, the Select Device window
will appear. Select the Hexcorder Pro, identified by its serial number as the
Bluetooth name. A connecting window will appear and then disappear when
successful. The app will now show the status of the Hexcorder Pro
unit (serial number, status icons, and battery power) near the top
middle of screen.
Important Note:
When the app attempts to turn on the tablet Bluetooth receiver, the app will ask for permission to use
your “Location”. It is required that you allow the app permission otherwise the Bluetooth receiver
cannot scan for local Bluetooth devices.
Tablet and App Language
Multiple languages are implemented in the Hexcorder Pro app. They are activated by switching the
tablet language to the desired language. If the language selected is supported by the app, it will
automatically change. If the language is not supported by the app, it will remain in English. Contact
Cath-Tech to explore adding additional languages.
To change the language on the tablet, select the Settings (gear icon), scroll down to the Personal
section, select “Language & Input” and select the first option “Language”, then select your desired
language from the list. Re-open the Hexcorder Pro app to see the chosen language implemented.
Figure 9 –Hexcorder Pro
app icon

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Survey Configuration
Before a survey can be performed, the Hexcorder Pro must be configured for the type of survey to be
done. The Hexcorder Pro will recall the previous survey settings. Settings are accessed and edited
via the SETTINGS tab.
Survey Settings Screen
From this screen, many survey options are accessible.

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Operator
The operator can enter their name. This is an advantage later in data analysis to track the
performance of individual operators and follow up with possible issues. Operator name can be up to
32 characters.
Survey Title
Enter information about this section of survey. It is often used to identify the line surveyed, starting
point, direction, etc. up to 32 characters long. Example: Line 2 upstream from TP16874
Survey Type
The Hexcorder Pro can perform eighteen different survey configurations, based on three different
types of survey. CIPS (CIS) Close Interval Potential Survey measures the level of cathodic
protection on a structure. Direct Current Voltage Gradient (DCVG) and Alternating Current Voltage
Gradient (ACVG) surveys both detect flaws or holidays in the coating.
NOTE: ACVG survey is only available in units manufactured after January 2022. Contact the
factory at [e-mail] to find out about upgrading older Hexcorder Pro units.
The Hexcorder Pro can measure all survey types at the same time, as well as various combinations of
the three. The user can select the number of input channels and input impedances, among other
options. Allowable combinations of survey types will be selectable in the Hexcorder Pro application.
•CIPS (CIS) –standard pipe to soil potential survey. Centre and Right poles are used
together so only one pole is required to be on the ground at the time of measurement. One
channel (Centre and Right connected) or two channel (Centre and Right independent).
Input impedance is selectable from the settings menu at 25Mohm, 250Mohm, or both
25Mohm and 250Mohm *NOTE: Only can be used in areas with <10V AC*.
Additionally, the input range can be configured for ±5V DC or ±10V DC.
•DCVG –Direct current voltage gradient survey (pole to pole Center to Right, Center to
Left). One, two, or four channel.
•ACVG –Alternating current voltage gradient survey (pole to pole Center to Right, Center
to Left) –one or two channels, requires the same number of DCVG channels to be active.
Figure 10 - Survey mode configuration menu

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Sync Type
The user can set the Hexcorder Pro to perform in three different synchronization modes
•GPS synchronized, for synchronized timing with GPS enabled interrupters
•High/Low synchronized, for using non-GPS interrupters
•Unsynchronized, for non-interrupted surveys
Units
The user can display and record chainage for the CIPS survey in Metric (meters) or Imperial (feet).
Only applicable to surveys with CIPS.
Trigger
The user can set the Hexcorder Pro to be triggered in one of three ways
•Pushbutton trigger –The reading will be activated by pressing the survey pole button
oMost common selection, allows the surveyor to check the reading is accurate
prior to saving
•Time –the reading will be activated by the passage of a user-selected number of cycles
oTakes the reading regardless of half cell position and accuracy
•Distance –the reading will be triggered when the chainage increases/decreases by a
user-selected amount
oIf moving fast, will only take 1 reading per interruption cycle, even if
surveyor has travelled 2 to 3 times the distance specified.
It is always recommended that surveyors begin with the Pushbutton trigger until they are used to the
equipment and survey techniques. If an automated survey is desired, it is recommended to automate
based on Time rather than Distance. This provides a reading based on the interruption cycle.
Readings based on Distance can be missed if the surveyor is moving faster than the cycle.
Start
Set the starting chainage. Only applicable to surveys with CIPS. This information can be found for
many test points from the official pipeline map.
Direction
User can set the chainage to count upwards (increment) or count downwards (decrement). Only
applicable to surveys with CIPS. The surveyor can walk upstream from a test point, return and then
walk downstream with the chainage calculating correctly.

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Parameters Screen
This screen allows many of the parameters of the Hexcorder Pro to be set, such as alarms, GPS, etc.
AC Frequency
The Hexcorder Pro uses software filtering in conjunction with hardware filtering. For the software
filtering to work properly it needs to be configured to the local AC frequency. Select either 50Hz or
60Hz depending on the power grid in your area.
Alarms
The Hexcorder Pro has 3 separate alarm features to help you detect and diagnose potential survey
issues or equipment problems. Each alarm can be activated or disabled by tapping on it.
•Low Potential Alarm –sounds if the CIPS potential changes by 50% from the previous
reading. This may indicate poor ground contact causing a misread, or a cable failure.
•Broken Wire Alarm –sounds if three readings are taken without a change in the
chainage count. Under normal conditions multiple readings without the chainage
increasing would indicate a broken trailing wire.
•DCVG Defect Alarm –sounds if the DCVG levels exceed the user-selected value. The
alarm threshold value is below the DCVG defect enable/disable button.
oTap on the value to enter a new value in mV.
Show GPS Coordinates in DMS Format
The user can choose to have the GPS coordinates displayed and stored in the Degrees, Minutes and
Seconds (DMS) or the more commonly used Decimal Degrees (DD) during the survey.

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Time Zone
The user can select their local time zone to correct the GPS time from UTC to local time. All data is
then stored in local time.
Interruption Cycle & Timing Settings
Cycle TimeSet the cycle time to match the same settings you have applied on your current
interrupters. The cycle time must be evenly divisible into 60 seconds. Common cycles are 1s, 2s, 4s,
5s, etc.
OFF Time
The OFF time is set by the user, which should match the off time used by the current interrupters.
Typically, the OFF time is about ¼ of the total cycle time. The ON time is calculated from the cycle
time minus the OFF time.
ON/OFF First
The Hexcorder Pro can measure the OFF or the ON measurement first. Most interrupters function
with the OFF occurring at the start of the cycle. Select the correct setting to match YOUR
interrupters.

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Delay Times
There are six delay time options for controlling the exact time that the Hexcorder Pro takes its DC
measurements within a cycle. The addition of ACVG does not affect the timing of the DC readings
or the overall cycle time. The delay times are in milliseconds and are timed from the start of their
respective portion of the cycle. i.e. an OFF delay of 100 ms means the reading will occur 100ms
after the interrupters turn off. An ON delay of 300ms means the reading will be taken 300ms after
the interrupters turn on.
In GPS synchronized mode, the use of delays can improve survey accuracy. When the cathodic
protection is first turned on or off, there can be an inductance spike in the voltage due to the
capacitance of the coating. A more accurate reading can be obtained by delaying the reading, instead
of taking the reading right as the rectifiers turn off. Inductive spikes can be seen on any waveforms
taken; this information can be used to adjust delay settings accordingly.
The SCOPE tab can be used to confirm the correct delay time setting. View the AC and DC scope
and verify that enough time is allowed to remove any influence from other sources.
The Hexcorder Pro will notify the user of any errors when the settings are saved.

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Cycle and DC Delay Times
Minimum cycle times and DC reading delay times depend on the number of readings being taken.
More readings per cycle take longer to read and store, requiring longer times. The addition of
ACVG does not affect the timing of the DC readings or the overall cycle time.
Survey Type
Cycle
Delay (ms)
OFF(ms)
Cycle(s)
DCVG
CIPS1
CIPS2
CIPS only
Minimum
200
1
100
Recommended
200
1
150
CIPS + DCVG
Minimum
200
1
100
170
Recommended
200
1
100
200
CIPS + 2 x DCVG
Minimum
250
1
100
220
Recommended
300
1
100
250
2Ω CIPS /
Parallel CIPS
Minimum
250
1
100
200
Recommended
400
2
150
300
2Ω CIPS + DCVG
Minimum
300
1
100
170
270
Recommended
500
2
100
250
400
2Ω CIPS + 2 x DCVG
Minimum
350
1
100
220
320
Recommended
500
2
100
300
450
DCVG /
2 x DCVG
Minimum
200
1
100
Recommended
200
1
100
4 x DCVG
Minimum
300
1
100
Recommended
300
1
100

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Survey Screen Settings
Survey Layout Options
The Hexcorder Pro offers five different “widgets” to use during the survey. The screen is split into
two halves which can be configured to the user’s needs. Simply touch and drag the widget you want
from the selector bar at the bottom to the location you want it and release.
•Digital Table –a simple table view which
shows the readings in numerical format.
(either actual or calculated)
•Charts –a real-time graphing view which
displays the readings as a line chart as they
are recorded. Unlike the digital table
display, the chart only shows the recorded
readings, not the real-time values. This
allows the operator to easily see trends in
the survey data.
•Map –an openmaps.org-based map screen
which uses the Hexcorder Pro GPS to plot
the user’s path.
•Analog Meters –a DCVG view using
virtual analog meters instead of digital
values, for users who prefer the analog
DCVG meters.
•Bird’s eye view –a DCVG view which
shows the arrangement of the survey team measurements from above. This makes it
easy for the user to see the flow of stray currents in the soil.

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Map Settings
The Hexcorder Pro uses Openmaps.org for mapping purposes. A Wi-Fi internet connection prior to
the survey is necessary for this function to work. Map data can be saved (cached) on the tablet for
later use in the field when Wi-Fi is not available.
•Turn on Wi-Fi on the tablet by pulling down the dropdown menu from the top of the
screen and toggling the Wi-Fi icon to “On”.
•Connect to a local Wi-Fi network
•Select the “Adjust Capture Bounds” box and use pinch-zoom and drag to move and
shape the red box to fit your survey area. (see above screenshot)
•Load KML/Clear KML –Using the buttons in the top right corner of the Map Settings
screen, create your own google KML map files from previous survey data and place the
file on the tablet memory. Then, select the “Load KML” button and navigate to the
KML file you want to load. It will be loaded as a visible line of waypoints on the map,
which can give a guiding route during the survey.
•Use pinch zoom until the desired map region is included inside the red box. Press the
“SAVE” button in the top right corner and this section of the map will be cached in
memory.
Later, when the tablet does not have internet access, this map section will still be available to view in
the map survey widget.
•When surveying out of Wi-Fi range, turn off Wi-Fi to save battery.