The Polarization Cell Replacement (PCR)

Technical Literature

INTRODUCTION COMMON APPLICATIONS

The Polarization Cell Replacement (PCR) is a solid-state device
commonly used in conjunction with cathodically protected AC Voltage Mitigation
structures. The PCR is an ideal replacement for electrochemi- As an AC mitigation device, the PCR can collapse the steady-
cal polarization cells because the solid-state design elimi- state voltage between the connected points to a negligible
nates the maintenance requirements and the potentially level by providing continuous AC grounding for pipelines with
hazardous electrolytes associated with polarization cells.
­ induced AC while leaving cathodic protection unaffected.
Furthermore, the operating parameters offer a number of
distinct advantages. Because the device has a higher DC Decoupling Electric Equipment Grounding Systems
blocking voltage, one device can often replace two or more When electrical equipment is mounted on a cathodically pro-
polarization cells. The product is easy to apply because its tected structure, the PCR can provide DC isolation with fault
operating parameters are precisely defined. rated AC continuity. As grounding codes apply, the PCR is
listed by UL for meeting the requirements of an effective AC
This product is available in two different versions to most grounding path per U.S. and Canadian electric codes.
economically accommodate the two different hazardous loca-
tion listings which are available. In many applications, these Insulated Joint Protection
products are used in a hazardous location; hence, the reason Insulated joints often need over-voltage protection against
for hazardous location listings. All model numbers with a PCR lightning and AC fault current, and in some cases, steady-
prefix are listed for use in Class I, Division 2 hazardous loca- state induced AC voltage. Due to the small clearance between
tions and for Zone 2. opposite sides of the insulated flange, a protective device
must provide a low clamping voltage, including the voltage
All model numbers with a PCRH prefix are listed for Class I, effects of the conductors or bus bars used to connect the
Division 1, hazardous locations. For more information on the product
PCRH, please visit the PCRH section on our website, and
view the separate PCRH literature. Decoupling from Utility Grounding Systems
When a cathodically protected structure is tied into the site
These products prevent the flow of DC current when grounding grid, CP values may be unacceptably low, due to
the absolute voltage (i.e., the DC plus peak AC volt- the bond between the site grounding system and the power
age) across the terminals is between -3.0 volts and company grounding system. The PCR can be installed by the
+ 1.0 volt while simultaneously providing a grounding (or power company at the transformer, to provide DC isolation
coupling) path for steady-state AC current, if AC current is and AC grounding between the two systems. This minimizes
present. A symmetrical version, which blocks +/-2.0 volts is the CP current requirements and allows acceptable CP volt-
available as an option. Custom versions with other voltage age for protection.
blocking levels will be considered upon request. These prod-
ucts also provide over-voltage protection to both lightning and
AC fault current.

Did You Know?

The PCR has been certified by independent laboratories
Underwriters Laboratories and Demko for compliance

PCR
to worldwide standards and codes, and is certified for
use in Div 2 and Zone 2 hazardous locations. For more
information on certifications and listings, visit
Polarization Cell
www.dairyland.com
Replacement

Dairyland Electrical Industries • P.O. Box 187 Stoughton, WI 53589 • 608-877-9900 • www.dairyland.com • [email protected]

PCR Technical Literature Rev. B

PRODUCT OVERVIEW is often induced on the pipeline. The PCR can mitigate this
voltage by p­ roviding a low AC impedance path for AC current
AC Fault Current Ratings to flow to ground while simultaneously preventing the flow of
Some applications may have conditions where an over-voltage DC current.
device such as the PCR is subject to fault current. For this rea-
son, the PCR was designed to have AC fault current carrying The steady-state AC impedance of the PCR at 60 Hz is 9.8
capability. The PCR will limit the voltage between its connec- milliohms for the standard 45 ampere rating and 4.9 milliohms
tion points to less than 10 volts AC under the maximum fault for the optional 80 ampere rating. At 50 Hz, the comparable
current ratings listed below. impedances are 11.9 milliohms for the standard 45 ampere rat-
ing and 5.8 ­milliohms for the optional 80 ampere rating. Under
Four different fault current ratings are offered at 60Hz and 50Hz an AC fault or lightning current condition, these impedances
with the f­ollowing current-time relationship: momentarily become virtually zero. For more information on
steady-state current view our web article: Measuring Steady-
State AC Current
AC Fault Current Ratings
(Amps AC-RMS Symmetrical) DC Blocking Voltage Rating
The standard, and most commonly ­specified, PCR model has
60 Hz Cycles 3.7kA 5kA 10kA 15kA an asymmetrical voltage blocking rating of -3.0 volts to +1.0
1 6500 8800 20000 35000 volt. Either model can also be furnished with a symmetrical
voltage blocking rating of +/- 2.0 volts. Other voltage blocking
3 5000 6800 15000 27000
ratings will be considered upon request.
10 4200 5700 12000 21000
The reasons for symmetrical and asymmetrical choices are
30 3700 5000 10000 15000
best described with an example. If the PCR is used to pro-
50 Hz Cycles 3.7kA 5kA 10kA 15kA vide over-voltage protection for an insulated joint and both
1 6500 8800 19000 33000 sides of the joint are cathodically protected, the DC voltage
across the joint will be the ­difference in voltage between the
3 5000 6800 14000 25000 two cathodic protection systems, normally near zero volts.
10 4200 5700 11000 20000 For this application it is desirable to select the symmetrical
+/- 2.0 volt blocking rating. In the event that the cathodic pro-
30 3700 5000 9000 14000 tection system is OFF on one side of the joint, the device can
block 2.0 VDC in either direction.
Note: Select a PCR fault current rating that encompasses the
fault current available. For more information on sizing for avail-
If one side of the insulated joint is cathodically protected and
able fault current, view our web article: Determining AC Fault
the other side is grounded, then it is preferable to select the
Current.
asymmetrical version which blocks from -3.0 volts to +1.0 volt
Steady-State AC Current Ratings since one side has been shifted to a more negative voltage.
Whenever one side is referenced to ground, the ­asymmetrical
This rating represents the maximum steady-state AC current
version is suggested because the CP voltage is situated in the
that is allowed to flow through the device while still blocking
center of the threshold voltage range.
the flow of DC current. Two ratings are available for the PCR.
Lightning Surge Current Rating
The table represents maximum values. As the DC volt-
All models have the same lightning surge current rating which is
age approaches the maximum blocking voltage rating select-
shown in the following table.
ed, the allowable steady-state AC current is reduced as shown
in Figures 1 and 2.
Lightning Surge Current Rating
All PCR Models
Steady-State Current Ratings
(Amps AC-RMS Symmetrical) Peak Amperes: 100,000
50/60 Hz Ratings Note: 8x20 microsecond waveform

Ambient Temp Standard 45A Rating Optional 80A Rating

Keep the Conductors Short!
20°C 50A 90A The PCR is designed to keep the voltage between the device
terminals to a limited value. During lightning conditions, a more
65°C 40A 70A important factor than the PCR voltage clamping capability is
the voltage developed in the conductors or bus used to attach
There are a number of applications where a PCR may be the device. Use low inductance bus bars or conductors ideally
required to block DC while simultaneously carrying steady-state less than 6 inches (150 mm) long for best results. More infor-
mation on conductor length is available at www.dairyland.com.
AC current. For example, when a pipeline is in the same cor-
ridor as an electrical transmission line, steady-state AC voltage

Dairyland Electrical Industries • P.O. Box 187 Stoughton, WI 53589 • 608-877-9900 • www.dairyland.com • [email protected]
ORDERING INSTRUCTIONS Solid-State Design
The PCR is built with proven solid-state components which
AC Fault Current Blocking Threshold Submersible have an instantaneous response with respect to voltage, there-
Choose: 3.7kA Blocking Threshold Options:
5kA Add “-S” for -2/+2
Optional: Add “-CS2” for
NEMA 6P Version by initiating voltage clamping immediately when the voltage
10kA
15kA
Add “-4/1” for -4/+1
Add “-6/1” for -6/+1
attempts to exceed the blocking level selected.

PCR-3.7KA Fail-Safe
An important safety feature for the PCR is that if subject to AC
Steady-State Current Rating
Certification System fault current or lightning surge current in excess of rating such
Optional: Add “/80A” to choose alternate 80A rating
Leave blank for standard certifications that failure occurs, failure will occur in the shorted mode. In
Add “-EAC” for EAC version for
Compact Connectors Zone Class 2 Group IIC the shorted mode, the unit can carry greater than rated fault
Optional: Add “-CC” to choose
compact connectors
current or lightning surge current and still provide an effective
Add “-4H” to choose grounding (or conducting) path.
4 hole terminals

NOTE: The EAC version is a separate product from standard Enclosure

models, with a Cyrillic nameplate and instruction manual, and The PCR enclosure is made of a light gray fiberglass-reinforced
references GOST standards only. To purchase, order model with polyester material suitable for outdoor non-submersible appli-
“EAC” suffix. See separate Russian/English EAC manual. cations and is rated NEMA 4X (comparable to IP 66). Optionally,
the PCR can be supplied as a submersible device with the
FEATURES AND CERTIFICATIONS
same dimensions rated NEMA 6P (comparable to IP68). The
optional submersible version of the PCR must not be installed
Certifications
such that it may be submerged in freezing conditions.
Underwriters Laboratories (UL) has listed the PCR
as meeting the criteria for “an effective grounding path”
Terminals
as defined in Section 250.2 and 250.4(A)(5) of the U.S.
Two-hole spade terminals are standard, but compact con-
National Electrical Code (NFPA 70), thereby enabling its
nectors and 4 hole NEMA terminals are available. Compact
use as an AC grounding device. The PCR is also
connectors are recommended where necessary to insulate the
C-UL listed in Canada as meeting the criteria for “an effective
connections to the PCR after installation (for example, with a
grounding path” as defined in C22.1-12, Section 10-500.
user furnished heat-shrink sleeve). Add “CC” to the end of any
model number only if compact connectors are required, or “4H”
The PCR is also listed by UL as meeting:
for 4 hole terminals.
• The requirements of a DC isolating/AC coupling device suit-
able for the isolation of objectionable DC current from cath-
PCR terminals have preinstalled 1/2” stainless hardware (bolts,
odically protected systems to ground as defined in NFPA 70
nuts, washers). See Accessories for various attachment
Article 250.6(E) and C22.1-12 Section 10-806.
options.
• An over-voltage protective device, having been tested to the
applicable requirements of ANSI C62.11.
Examples:
PCR-10KA (Standard connector)
Listings specific to hazardous locations are summarized as fol-
PCR-10KA-CC (Compact connector)
lows:
PCR-15KA-4H (4 hole terminal)
The PCR is listed by Underwriters ­Laboratories (UL) for use in
Polarity / Electrical Connection
hazardous locations in accordance with NFPA 70 (U.S. National
Polarity marks (+) and (-) are provided near the terminals to aid
Electric Code), Articles 500-505 for Class I, Division 2, Groups
in proper installation. Connect the (-) to the structure with CP
A, B,  C,  and  D.  The  applicable s­ tandard to which the PCR is
or more negative structure and the (+) to the grounded, or more
listed is ANSI/ISA 12.12.01-2011 which deals with non-spark-
positive, system.
ing products to meet Class I, Division 2 requirements. The PCR
is also C-UL listed to the above classifications per Canadian
Size and Weight
code C22.2 No. 213-M1987 (R2008).
Refer to outline drawings for dimensional data. Packaged
weight varies from approximtely 12-22 pounds (5.5-10kg)
The PCR has been certified to ATEX Directive 94/9/EC and
depending on model selected.
IECEx requirements for use in Zone 2, Group IIC hazardous
locations by UL/DEMKO to: EN 60079-0:2012, EN 60079-
Number of Operations
15:2010, IEC 60079-0: 6th Ed, IEC 60079-15: 4th Ed.
Virtually unlimited under maximum ratings, provided the opera-
tions are not immediately repetitive.
The EAC version of the PCR, available by ordering a PCR model
with an “-EAC” suffix, is certified to the EAC requirements of the
Energy Requirements
Customs Union (Russia, Kazakhstan, etc) for use in Zone Class
None. The devices are totally passive.
2, Group IIC hazardous locations by NANIO-CCVE to: GOST R
IEC 60079-15-2010, GOST R IEC 60079-0-2011.

Dairyland Electrical Industries • P.O. Box 187 Stoughton, WI 53589 • 608-877-9900 • www.dairyland.com • [email protected]
Ambient Temperature
-45º C to +65º C

MOUNTING OPTIONS
The PCR is made to mount on a flat surface (e.g., a wood post,
unistrut, panel) with two 3/8” (≈10mm) diameter bolts furnished
by user; however, a number of optional mounting methods and
accessories are available for specific applications.

Mounting Accessories
Numerous mounting accessories are available from Dairyland
to aid in the proper installation of the PCR. Detailed acces-
sory information, including complete installation instructions are
available on the Dairyland website here: Dairyland Accessories

Specific Installation Guidance

The Dairyland website contains detailed information on the
installation methods specific to a given application. For wiring
diagrams and/or application guidance, see Dairyland Applica-
tions.

Dairyland Electrical Industries • P.O. Box 187 Stoughton, WI 53589 • 608-877-9900 • www.dairyland.com • [email protected]
FIGURE 1  PCR Operating Characteristics @ 43°C FIGURE 2  PCR Operating Characteristics @ 43°C
(Standard 45A @ 50/60 Hz) (Optional 80A @ 50/60 Hz)

KEY KEY
Allowable Steady-State Operating Region Allowable Steady-State Operating Region
Operation in this region only allowed for Operation in this region only allowed for
transient conditions (AC faults and/or lightning) transient conditions (AC faults and/or lightning)
100 100

80 80
70
IAC-RMS Amps

IAC-RMS Amps
60 60
45
40 40
Asymmetrical Asymmetrical
Version Version
20 20
Symmetrical Symmetrical
Version Version
0 -0.5 -1 -1.5 -2 -2.5 -3.0 -3.5 0 -0.5 -1 -1.5 -2 -2.5 -3.0 -3.5
VDC Volts VDC Volts
(Allowable AC Current vs. DC Voltage) (Allowable AC Current vs. DC Voltage)

FIGURE 3  DC Voltage vs. DC Leakage Current

(Standard Asymmetrical PCR with -3V / +1V Blocking Voltage)

10000

1000
@ 65˚ C
DC Leakage in milliamperes

100

@ 20˚ C
10

0 .1

0 .0 1
0 0 .5 1 1 .5 2 2 .5 3 3 .5 4 4 .5

DC Volts

Dairyland Electrical Industries • P.O. Box 187 Stoughton, WI 53589 • 608-877-9900 • www.dairyland.com • [email protected]
 1.75
44.5

1.00
25.4

4.98
126.6

1.13 7.32
28.6 185.9

2.69 3.07 14.88

3.00
68.3 77.9 378.0
76.2
12.63
320.8

9.50
241.3 8.75
222.3

15.54
394.8
1/2" HARDWARE

2X .56
2.35 1.00 14.3
59.8 25.4
1.75 ALTERNATE TERMINAL
44.5 SPECIFIED BY ADDING "-CC"
TO ANY PCR MODEL NUMBER
1.75
2X .44 44.5
3.00 .38
11.1 1.04
76.2 9.7 .83
26.4
21.0 ANSI Y14.5M 1994 APPLIES
DAIRYLAND DESCRIPTION
ELECTRICAL
INDUSTRIES, INC. PCR 3.7KA THRU 10KA OUTLINE DRAWING
UNLESS NOTED 63 P.O. BOX 187 DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
STOUGHTON,
UNITS: INCHES
3-PLACE: .005 WI 53589 100060 A 2014-06-20 B
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 1:3 DRAWN: JPW SHEET: 1 OF 1 DWG APPROVAL:
 1.75
44.5

1.00
25.4

5.43
137.9

1.13 9.31 3.07

28.6 236.5 77.9

2.69
3.00 16.88
68.3
76.2 428.8

17.5
445

11.50
292.1 10.75
273.1

14.63 1/2" HARDWARE

371.6

2X .56
14.3
2.35 1.00
59.7 25.4
1.75 ALTERNATE TERMINAL
SPECIFIED BY ADDING "-CC"
44.5 TO ANY PCR MODEL NUMBER
5.0 1.75
2X .44
127 44.5
11.1 .38 1.04 ANSI Y14.5M 1994 APPLIES
DAIRYLAND DESCRIPTION
ELECTRICAL
9.7 .59 26.4 INDUSTRIES, INC. PCR-15KA OUTLINE DRAWING
UNLESS NOTED 63 P.O. BOX 187 DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
15.1 UNITS: INCHES STOUGHTON,
100085 A 2015-08-18 B
3-PLACE: .005 WI 53589
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 3:10 DRAWN: JPW SHEET: 1 OF 1 DWG APPROVAL:
 15.46
392.6
9.32
236.6
.44
11.1
7.32
185.8

2.49 3.00
63.3 76.2

.25
6.4

12.63 1.13
.38 320.8 28.6
9.7
ALTERNATE TERMINAL

1.00
25.4
7.51
190.8
1.75
44.5 1.00
25.4

1.04
26.4 14.88
378.0
.56
14.3 ALTERNATE TERMINAL
SPECIFIED BY ADDING "-CC" TO ANY PCR MODEL NUMBER
1.75
44.5
ANSI Y14.5M 1994 APPLIES
DAIRYLAND DESCRIPTION
ELECTRICAL
INDUSTRIES, INC. PCR 3.7KA THRU 10KA-80A OUTLINE DRAWING
P.O. BOX 187 DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
APPLIES TO MODELS: UNLESS NOTED 63
STOUGHTON,
PCR-3.7KA/80A, PCR-5KA/80A and PCR-10KA/80A
UNITS: INCHES
3-PLACE: .005 WI 53589 100081 A 2015-05-29 B 2015-06-02
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 1:3 DRAWN: JPW SHEET: 1 OF 1 DWG APPROVAL: TC
 1.75
44.5

1.00
25.4

6.98
177.3

9.31
1.13 3.07
236.5
28.6 77.9

3.00 2.69
68.3 16.88
76.2
428.8

17.4
442

11.50
292.1 10.75
273.1

1/2" HARDWARE
14.63
371.6

2X .56
14.3
2.22 1.00
56.5 25.4
1.75 ALTERNATE TERMINAL
SPECIFIED BY ADDING "-CC"
44.5 TO ANY PCR MODEL NUMBER
1.75
2X .44 5.0
44.5
11.1 127 .38 1.04 ANSI Y14.5M 1994 APPLIES
DAIRYLAND DESCRIPTION
9.7 26.4 ELECTRICAL
INDUSTRIES, INC. PCR-15KA/80A OUTLINE DRAWING
.59
UNLESS NOTED 63 P.O. BOX 187 DOCUMENT # REV DATE DRAWN DWG SIZE DATE APPROVAL
15.1 UNITS: INCHES
3-PLACE: .005
STOUGHTON,
WI 53589 100087 A 2015-08-17 B
2-PLACE: .015 608-877-9900
1-PLACE / FRAC:
ANGULAR: 1
.03 DAIRYLAND.COM SCALE 3:10 DRAWN: JPW SHEET: 1 OF 1 DWG APPROVAL: