USER PRODUCT INSTRUCTION

UPI 0128

Model
DCU3

ELECTRICAL RESISTANCE TRANSMITTER

Teledyne Cormon Ltd.

Unit 26-28
Decoy Road
Worthing
West Sussex BN14 8ND
United Kingdom
Phone: +44 (0)1903 854800
Fax: +44 (0)1903 703603
Email: support@cormon.com
Web: www.cormon.com

USER PRODUCT INSTRUCTION No 0011

REVISION CHANGE Change by Approved by

2 IP rating info added to paragraph 4.1 07/11/08 AEE PS

1 First Issue 21/7/05 BD

Page 1 of 16
1. SAFETY INSTRUCTIONS ............................................................................................................ 3
1.1 Important safeguards............................................................................................................... 3
1.2 Intrinsic Safety Labelling.......................................................................................................... 3
2. INTRODUCTION .......................................................................................................................... 4
3. PRINCIPLE OF OPERATION ....................................................................................................... 4
4. INSTALLATION ............................................................................................................................ 5
4.1 Mounting.................................................................................................................................. 5
4.2 Field Termination..................................................................................................................... 5
4.3 Safe Area termination.............................................................................................................. 5
4.4 Probe connection..................................................................................................................... 5
4.5 Configuration ........................................................................................................................... 6
4.6 Intrinsic Safety......................................................................................................................... 6
5. MAKING MEASUREMENTS.........................................................................................................6
6. INTRINSIC SAFETY CERTIFICATION AND LABELLING INFORMATION .................................. 8

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1. SAFETY INSTRUCTIONS

1.1 Important safeguards

All safety instructions must be read carefully understood, before attempting to use your Cormon
(instrument/probe/equipment). This manual contains the safety instructions that must be observed
in order to avoid potential hazards that could result in personal injuries or could damage your
(instrument/ probe/ equipment). The safety instructions have been classified according to the
seriousness of the risk, as follows and all identified risks categorised accordingly:

“DANGER” indicates the existence of a hazard that could

DANGER result in death or serious bodily injury, if the safety instruction
is not observed.

“WARNING” indicates the existence of a hazard that could

WARNING result in bodily injury if the safety instruction is not observed.

“CAUTION” indicates the existence of a hazard that could

CAUTION result in property damage if the safety instruction is not
observed.

A “Notice” contains general information that relates to the

Notice safe operation of the equipment.

1.2 Intrinsic Safety Labelling

The unit has IS labels attached stating the applicable

DANGER certification. Always confirm that the certification is
compatible with the intended application

See Section 6. for label drawing

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2. INTRODUCTION

The equipment uses ER metal loss measurement circuitry to make corrosion (or erosion) rate
measurements in the field. The Transmitters are certified for use in hazardous areas by allowing the
physical separation of the IS certified transmitter and probe from the power supply and certified
barriers. The equipment comprises:

• DCU3 measurement/transmitter instrument c/w probe cable or rigid probe adapter

• Barrier sets – ordered separately
• Documentation

The following warnings relating to intrinsic safety must be observed:

This Instrument must not be used in an environment where the ambient

DANGER temperature limit(s) or the maximum surface temperature stated in the
certification may be exceeded. Failure to observe this requirement may
result in death or serious injury

This Instrument must not be used in a gas atmosphere above the rating
DANGER given in the certification. Failure to observe this requirement may result in
death or serious injury

The isolating barrier devices specified in the certification must be used.

DANGER Failure to observe this requirement may result in death or serious injury

Do not attempt to make repairs to the instrument, it has no user

DANGER serviceable parts and unauthorised intervention will invalidate the safety
certification and warranty. Failure to observe this requirement may result in
death or serious injury

3. PRINCIPLE OF OPERATION

The exposed sample element of an ER probe is subject to corrosion or erosion at the same rate as
any other example of the element material subjected to the same environment. A carbon steel ER
probe placed in a carbon steel pipe carrying a fluid in a uniform condition will corrode as fast as the
wall of the pipe. Care is needed when working in non-uniform fluids to ensure that the probe is
placed to contact the component that is of interest – the water in multi-phase flow for example.

The ER instrument, operating on a ratiometric principle, makes measurements of the sample

element and a protected reference piece inside the probe body. The instrument can detect changes
in the resistance of the two components (nominally1 part per thousand) allowing the loss of material
from the sample to be detected when the result is computed.

The close proximity of the sample and reference piece keeps the two at approximately the same
temperature, cancelling out the resistivity changes in the material caused by temperature.

Measurements made by the instrument are transmitted back via the data link to the safe area
barriers and data acquisition system.

Page 4 of 16
4. INSTALLATION

4.1 Mounting

Mount the stainless steel housing securely in a suitable position so that the probe cable will reach
the probe. Avoid mounting the unit or placing the probe cable in positions of unnecessary
mechanical or environmental hazard. The version with a rigid probe adapter is mounted directly
onto the probe connector (or extension adapter connection for AC series). The closed housing
when securely mated to the probe connector will seal to at least IP65 (early production sample
tested successfully to IP67. Atex I.S. minimum requirement is to IP20).

4.2 Field Termination.

Power and data links are connected to the pre-wired terminal strip inside the case supplied with the
instrument.

A row of terminals can be seen with labels 24vdc, 0vdc and scr for the external supply cable (2 core
+ screen) and terminals labelled Tx, 0v,Rx and scr (3 core + screen) for the data cable. NOTE:
project specific labelling is possible; please refer to the project interconnection drawings if labelling
does not conform to above.

If other multi-core cables are utilised, any unused cores should be terminated to the Overall Screen
connection.

Failure to seal and secure instrument housings may result in ingress of

CAUTION moisture or solids that impair the life or performance of the unit and may
lead to irreparable damage.

4.3 Safe Area termination

Power supply (MTL5025 barrier) connect instrument 24vdc to Terminal 2, connect 0vdc to
Terminal 1.

Data link Opto Isolator (PCI) terminals are labelled Tx, 0v,Rx and Scr as per the field termination
drawing Fig 1.

The isolating barrier devices specified in the certification must be used.

DANGER Failure to observe this requirement may result in death or serious injury

4.4 Probe connection

The Transmitter Units are supplied with a factory-fitted probe connection cable and female
connector that mates with the probe male connector. Probes containing the letter AC in the product
code will require an extension adapter because of the specific requirements of the 2” high-pressure
access fitting assembly. The version with a rigid probe adapter is mounted directly onto the probe
connector (or extension adapter connection for AC series).

Threaded probe connectors should have silicone grease applied sparingly to the male thread before
mating. Threaded connectors must be made up fully to hand tight.

When installing probes into pressurised systems or systems containing

DANGER hazardous material always follow safety instructions for the installation of the
probe type in use. Failure to do so may result in death or serious bodily injury.
If in doubt contact Cormon for technical support

Always record the serial number of the probe installed at each location and
Notice keep the information with the Probe Certificate in a safe place.

Page 5 of 16
4.5 Configuration

The Transmitter is supplied configured to the order requirement. RE-configuration may be carried
out using a PC.

4.6 Intrinsic Safety

The probe and DCU3 transmitter/instrument may be placed in a hazardous area, as the equipment
is certified intrinsically safe (see back of manual) when the isolating barriers are installed and
connected correctly.

1. Altering wiring and cable connections on this equipment will invalidate the
DANGER system’s intrinsically safe status and may result in a configuration capable of
causing an explosion in a hazardous environment.

2. To operate the equipment in an intrinsically safe mode the barriers must be

located in a safe area. Always consult the safety authority for the installation before
installing the equipment.

5. MAKING MEASUREMENTS

When power is supplied to the instrument it will commence making and transmitting measurements
to the data acquisition system connected in the safe area. Consult the manual for the data
acquisition system in use for further information.

Fig 1 Field Termination Diagram (below)

Page 6 of 16
Page 7 of 16
6. INTRINSIC SAFETY CERTIFICATION AND LABELLING INFORMATION

DCU3 Intrinsically Safe ER Transmitter

Cormon Ltd. Robell Building, Chartwell Rd. Model DCU3 EEx ia IIC T4 (Tamb = -40 to +50°C)
Lancing, West Sussex, BN15 8TU UK ITS 05 ATEX 23471X
www.cormon.com support@cormon.com Serial No:
CE 0359 EX II 1G CE
cormon Year of Manufacture: 20

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