.
23478 -VOO-EYIO-OOO02-OI
m No.
BechtelCmofation
23A71t
SUPPLIERDOCUMENTREVIEW STATUS
RewsoandmsuhIL
.Rememdmsutmt
4Jq
R@w.#notqned
I STATUS
NO.
1 WJdcmayplumcd
2 a
WofkmYkm=d
MINYmtPIuc-4
Watimypruyad.
wbPC4bmWalIOM
0fdunge4mdrabd
.. ,
s
,.
..,;
cc
,
. .
.i.
,....
,.
,:~;;g$g
OP
,.
.,.
.,
.,
.,,.
.-,
!.
CAT
.
;.,
-.,
MADE
IN CANADA
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
A. INTRODUCTION
This Operation
the serial number
Manual
Protection
staff
use the
in reliable
with
should
Rectifiers
as identified
it be kept inside the Rectifier
Do not place it so that
are built by skilled personnel
years of experience
components,
with reasonable
RTS maintains
NUMBER
rectifier
by
case
it will impede
the case.
an engineering
consistent
that
Store it in the space provided.
RTS Cathodic
latest
for the specific
It is recommended
on the unit.
for quick reference.
air flow through
has been prepared
Every effort
in the field.
so that
these
and are designed
rectifiers
by
has been made to
are of the
highest
quality
costs.
a file on every rectifier
be specified
when
by serial number
requesting
information
only,
Therefore
on or ordering
the SERIAL
parts
for this
rectifier,
B. DELlVERY INSPECTION
If
damage
IMMEDIATELY.
damaged
Number,
has
occurred
in
If it is necessary
or missing
Purchase
proper and expeditious
Number
FILE
CLAIM
your supplier
be sure
components,
Order
shipment,
to contact
to
and Invoice
include
Number.
WITH
THE
CARRIER
or the manufacturer
ALL
information
concerning
such
This will ensure
that
as Serial
you obtain
service.
C. INSTALLATION
Proper
cathodic
1.
2.
rectifier
protection
installation
system.
procedures
These procedures
Check all electrical
connections
to re-tighten
all bolts, especially
Select
the
mounting
accessibility,
proper
temperatures,
protection
and
site
to ensure
the integrity
of the
are as follows:
to make-sure
those which
for
the
they are tight.
importantly,
It is a good idea
carry electrical
rectifier;
shielding
ventilation,
most
paying
from
current.
special
sources
convenience
to
of
A.C.
attention
to
high
ambient
and
cathodic
connections.
3.
Mount
rectifier securely
4.
Have
electrical
are necessary
qualified
on mounting
electrician
and local codes.
make
pad, wall or post.
electrical
A disconnect
input to the rectifier.
1
switch
connections,
is required
following
ahead
the
of the A.C.
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
5.
BEFORE ENERGIZING,
double check to ensure the rectifier
is sized to take the
A.C. input being applied.
6.
ENSURE
CORRECT
to the structure
7.
BEFORE
ON D.C.
being protected
turning
on the
CONNECTIONS,
the lowest
setting
input
the output
fuse.
to prevent
breaker,
ensure
damage
the
moved
to bring output
should always
The COARSE adjustment
Then
output.
to desired
the unit to run for several
negative
minutes
are at their
lowest
be made from
or prematurely
half of the desired output
step higher; turn unit on and check output
is close to desired
taps
to the rectifier
Initially set the rectifier to approximately
the tap bars as required.
connecting
and positive to the anode leads.
COARSE A, FINE 7. Tap adjustments
setting:
8.
POLARITY
blowing
moving
by
bar should be moved
and repeat
as required
the
FINE adjustment
level.
If everything
one
until output
bar can be similarly
appears
to allow for examination,
normal,
then
allow
proceed
to
set the Rectifier to your desired output.
9.
The Rectifier
should be operated
one hour to determine
A.C.
OFF at the disconnect
power
carrying
connections
may be warm,
10.
Air cooled
are
D.C, output
switch
current
and immediately
to see that none of them
for about
in the connections.
feel
are overheating.
Shut the
all current
Connections
but should not feel hot.
rectifiers
manufactured
vents
at the required
that there are no defects
with
never
utilize natural air convection
screened
obstructed
openings
by plugged
top
for cooling,
and
screens
bottom.
or by
and are typically
Make sure these
laying
the
rectifier
manual on the bottom.
11,
Periodically
monitor
level of cathodic
the
rectifier,
protection
re-adjusting
as necessary
to maintain
the
current required.
D. MAINTENANCE
C.P,
maintenance
conditions
rectifiers
have
is largely
which
1.
Excessive
Voltage
3.
Excessive
moving
of a preventative
will affect
2.
no
and therefore
(other that the meters),
primarily
three
Bear
in
mind
there
are
nature.
parts
the life of a C.P. rectifier:
component
temperatures.
surges and lightning.
current
output.
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
Meter
ammeter
readings should be checked
accuracy
can be made
high input resistance
against an accurate
by measuring
the millivolt
meter such as an electronic
voltmeter
meter.
A quick calibration
drop across the shunt
set to the millivolt
for
with
scale.
The
actual reading is given by:
E x I(shunt)
I(d.c, ) =
50
Where:
I(d.c.)
= Actual
E = Millivolt
I(shunt)
Meter
allowance
in amperes
D.C. output
reading across shunt
= Shunt size(corresponds
accuracy
should
for temperature
be within
of 0.85%
to the full scale deflection
of full scale
2%
per 10 degrees
deflection,
of ammeter)
combined
C. for temperature
other
with
an
that
25
degrees C.
A periodic
functioning
meter.
check
properly.
This,
of rectifier
If an A.C.
of course,
conversion
wattmeter
efficiency
is unavailable,
is if no other electrical
will also indicate
if the rectifier
use the pole mounted
loads are drawing
power
when
the A.C.
draw is being determined.
A.C. Power
(in watts)
= 3600
KN
T
Where:
K = Watt-hour
N=
T=
meter constant
D.C. Power
Rectifier
Out x 100
A.C.
In
silicon
75?Aofor single phase will indicate
of VOLTS
efficiency
D.C. Power
For tap-adjusting
of 60 seconds for best accuracy)
is the product
conversion
Power
(on meter face)
Number of revolutions of watt-hour meter disk
Time in seconds for the number of revolutions
(minimum
D.C. x AMPERES
diode
D.C.
will be:
= % conversion
rectifiers,
efficiency
conversion
a properly functioning
efficiencies
rectifier.
is
watt-hour
of approximately
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
Maintenance
temperatures.
can
be the
Regular checks
Periodic
be undertaken.
best
deterrent
against
for blocked venting
re-tightening
rectifier
failure
due to excessive
or heat from a man-made
of electrical
connections
is good
source should
insurance
against
future trouble,
CAUTION: Hazardous voltages are present within the rectifier. ALWAYS interrupt
the A.C. power at the nearby disconnect. The rectifier A.C. breaker DOES NOT totally
remove all incoming A. C. power from the rectifier.
A temperature
probe is a very useful
is a guide for maximum
ambient,
testing
These
temperatures.
The difference
between
should be subtracted
45 degrees
maintenance
temperatures
tool.
are based on a 45 degree
C. and the ambient
TEMPERATURE
COMPONENT
MEASUREMENT
Moulded
moulded
temperature
MAX
POINT
body
110 degrees
C,
stud
115 degrees
C.
Transformer
primary winding
160 degrees
C.
160 degrees
C.
80 degrees
C.
130 degrees
C,
Filter Choke
winding
Filter Capacitor
case
Output
Fuse
metal ends caps
Current
Shunt
resistive element
75 degrees
C,
Electrical Corm.
bolt or screw
90 degrees
C.
Electrical Wiring
wiring harness
90 degrees
C,
against voltage
supplied
with
the
unit
electrical
equipment
Lightning
rods may prove valuable
is intact. .
against
device
to the same A.C.
excessive
or component
(input breaker
failure.
Always
Keep - motor
and
power
the lightning
similar
surge
and surge
producing
possible.
lines wherever
in high lightning strike areas.
current
and logging data so as to predict
protective
rectifier
surges is largely one of ensuring
from being attached
Maintenance
outputs,
at time of
TEMPERATURE
mounting
protection
C.
TABLE
Silicon Diode
Maintenance
The following
from the readings in this table:
COMPONENT
Bridge
preventative
or output
replace
diode bridge before re-energizing
when
output
requires
an over current
fuse) has operated,
fuses with
the same
monitoring
situation
it is an indication
rating
and type.
to ensure all diodes are operative,
of
rectifier
may arise.
If a
of overload
Check
the
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
E. TROUBLE SHOOTING
Although
down
time,
quality
failures
enable a potential
construction
and
will occasionally
preventative
maintenance
A good knowledge
happen.
will
reduce
of rectifier
rectifier
operation
will
problem to be quickly traced and repaired.
RECTIFIER TEST EQUIPMENT:
The following
1.
equipment
Electronic
is essential
multimeter,
for basic rectifier trouble-shooting.
preferably
that has a diode check range.
2.
Clamp-on
3.
Temperature
4,
Dummy
A.C. ammeter,
one which
can measure
up to 750
VAC
and
( Fluke 75 or 25)
Fluke 801-600
probe, Fluke 80T-I
or Amprobe
ACD-I
50 degrees C.; range of 50 to + 150 C.
resistive load, 2-5 ohms,
1000
watt
capacity.
.
5.
Hand
tools.
1/4
nutdrivers;
- 3/4
socket screwdrivers;
6,
The majority
blown
fuses,
faulty
3/8
cathodic
of rectifier
loose
faulty
load connections,
to
determine
CAUTION:
the
rectifier.
Beware
[f doing
meters,
and lightning
of a faulty
should be followed
( refer to the schematic
measurements,
1/4
#l,
- 1/2
S.A. E.
#2 and #2 long
drive S.A. E. socket set with deep sockets.
faults are easy to diagnose.
terminals,
The initial inspection
the
wrenches;
blade screwdrivers;
PROCEDURE:
very useful for the initial examination
follows
and 5/16
Small set of clip-leads.
TROUBLE SHOOTING
components
S.A. E. combination
3/1 6, 1/4
cause
of
blown
M.O.V.
suppressors,
open circuits,
Visual inspection and smell can be
damage.
rectifier for the above faults.
by a systematic
non-operation.
work
on
electrical
a rectifier
voltages
other
DISCONNECT THE A.C. POWER, preferably
just using the rectifier
input,
This
isolation
should
of various
rectifier
be conducted
as
for test point locations).
of hazardous
any
They include loss of A.C.
circuit breaker.
and where
than
taking
they
are present
voltage
at the rectifier
or
in
current
disconnect,
not
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
1.
Check whether
A.C, voltage
it is the correct
level for the rectifier
has not tripped
OFF, this voltage
This will eliminate
2.
is present
line entering
If the
breaker
input
indicates
isolate
continues
bridge,
b)
the input breaker
reading such as might
to
trip
OFF
the rectifier.
Again
holds, the problem
Provided
and that
check should be done with the rectifier
both tap bars (shown
the
input terminals
ON.
be experienced
if
the rectifier is broken.
a short circuit within
Remove
a)
input rating.
any static voltage
only one A.C.
at the rectifier
is a shorted
diode(s).
With the rectifier
disconnected
energized,
this
usually
Proceed as follows;
by Coarse
energize
replace defective
when
& Fine taps on schematic)
the
breaker.
diode(s)
If the
in the stack.
breaker
Check
to
now
stack
and
(See #7 below)
from the A.C.
supply,
do an ohmmeter
check
between
ground lug and the load side(s) of the input breaker
Any detectable
resistance
will
(right side of CB1 on schematic).
indicate a primary to ground breakdown.
A Megger test instrument is
preferred
for
replacement
Visually
c)
this
test
if
Any
available.
fault
will
necessitate
of the transformer.
inspect
the
transformer
for any
signs
of burned
or shorted
windings.
Check for shorted
d)
3.
An
intermittent
A.C.
voltage
lightning arrestors.
reading
nearly
always
indicates
a loose
or burned
connection.
4.
Verify
there is transformer
secondary
voltage.
A measurement
across COARSE E to FINE 5 should be 1.35
voltage
5.
Verify
the COARSE
Measure
steps
output
20%
of the measurement
20%
of the voltage
step.
the A.C.
voltage
on schematic).
bars, otherwise
as being approximately
and that the FINE steps are approximately
of each COARSE
MOVI
the D.C.
rating of the rectifier,
(item 4 above)
6.
to 1.6 times
of the voltage
at the diode stack
It should
be the same
the fuse has operated
(same
as connection
as measured
across
or the wire is burned or broken,
points
of
the tap
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
7.
a diode check of the stack as follows:
Conduct
a)
Disconnect
power from the rectifier and remove
b)
With the multimeter
set on the diode check
(Red) lead on the stack negative
schematic)
terminals
and touch
250
Similarly,
range,
(negative
(Black)
points of MOVI
to 1000
This will check
place the POSITIVE
side of shunt on the
lead to the
stack
on schematic).
ohms and the Fluke meter
diodes
A good
will give a
or short
place the NEGATIVE meter lead on the stack positive
terminal
a faulty
D3 and D4.
A.C.
An open
BEEP.
circuit reading will indicate
c)
NEGATIVE
(same as connection
diode will measure
single
the
terminal
the tap bars.
diode.
(connection point between DI & D2 on schematic) and now touch the
other lead to the stack A.C. terminals.
This will check diodes D1 and
D2.
d)
Replace
tighten
faulty
diodes with
stud mount diodes.
the same type
and polarity.
Recommended
torques
1/4 Stud Type
8,
of voltage
of the stack and at the rectifier
D.C. fuse).
NOTE:
With
no load,
potential
electronic
9,
10.
meter
Verify
meters
{ectifier
terminals
is present
in the wiring
may
the actual
read
D.C.
at
(or a
a static
voltage.
It
to place a small test load across the rectifier
which
will
eliminate
the
false
reading
of
the
voltmeter,
If the correct D.C. voltage is present at the rectifier
current flows,
and negative
If the voltage
electronic
is much higher that
may be necessary
lugs
positive
lugs.
check for open circuits
a sensitive
which
output
at the D.C.
D.C. output
but not at the terminals,
blown
are:
30 inch-pounds
Check for the presence
the stack
Do not over-
output
terminals
but no
there is an open circuit in the cables leading to the C.P. load.
meter
may indicate
readings
are correct
with
an electronic
meter.
a rectifier fault when no actual fault exists.
Rectifier
RTS MANUFACTURING DIVISION
CATHODIC PROTECTION RECTIFIER
OPERATION MANUAL
Meter
11.
corrosive
are
H2S
environmentally
sealed
Their
switches
or
added
carefully
cost
placed
may
switches
save
future
be used
repair
contacts
to replace
work
and
down
of a suspect
normal
time.
types.
Jumpers
switch
will isolate
contacts.
Lightning
and surge suppressors
from
circuit
the
of meter reading faults, especially
in
on-going
problems,
If
these
are
should
across the closed
any high resistance
12.
often a source
environments.
and checking
can be checked
with
for shorts
an ohmmeter.
by isolating
them
these should
Normally
exhibit an open circuit (infinite resistance).
F. SAFETY
Cathodic
unfamiliar
with
protection
rectifiers
the workings
do
of a unit.
shock hazards to personnel
Electrical safety can be enhanced by following a
present
electrical
few guidelines:
1.
When
approaching
a rectifier
to inspect
or repair,
always
remember
to touch
the case latch with the BACK of your hand first. If you feel any voltage
Tingle DO NOT grab the lock or latch with your hand as you may not be able
to let go,
You should turn off the A.C. power at the external disconnect
and
call an electrician.
2.
Understand
where
potential
hazards exist so as not to contact
them
bodily or
with tools.
3.
Work in pairs when
4.
Use a rubber mat to stand on.
5.
When taking
6.
Lock
out
energizing
on energized
equipment.
readings use only one hand if possible.
a supply
disconnect
or circuit
breaker
to
prevent
accidental
re-
of the circuit.
7.
Wear safety
8.
When
glasses when soldering
in doubt
technician
working
on
particular
or the factory.
any connection.
test
procedure,
contact
an
experienced
CORRPRO CANADA, INC. RTS MFG.
RECTIFIER SPECIFICATION
DIV.
CUSTOMER:
HARCO TECH., MEDINA
P. O.:
MODEL NO:
CSAYSE
SERIAL NO.:
A.C. VOLTS:
A.C. AMPS.:
60-12
115/230
9.5/4.75
QTY.
D.C. VOLTS:
D.C. AMPS :
DATE:
34704
60
12
PH.:
W.o.: 13339-1
CYCLES:
60
SINGLE
PART NUMBER
ITEM
DECEMBER 01, 1997
C-972092
O/P CKTS:
V. A.: 1095
TAP-ADJUSTED
INPUT
TYPE:
DESCRIPTION
ENCLOSURE
A-1
STANDARD,
14 GAUGE
MILL
GALV.
STEEL,
CHASSIS
A-1
STANDARD
14 GAUGE
MILL
GALV.
STEEL,
WHITE
A-1
STANDARD
14 GAUGE
MILL
GALV.
STEEL,
WHITE
A-1
STANDARD,
1 -PR
PHENOLIC
MTG.
FRONT
TRANSFORMER
BKT.
PANEL
T-601
CT&D
RTS
NEMA
2-E
DIODE
BRIDGE
HEATSINK
#1024
35 MB60A
AC BREAKER
JAI-SD3ABOI
3.5/EQUlV.
VOLTS
9.75
5-FINE
WHITE
14.00
TAPS
F. S. D., /
60 RED LINE
YOKOGAWA
AMMETER
1
3/16
5-COARSE,
0-75
260-300-E50
1/1
XX,
RTS,
VOLTMETER
1
0-15
AMPERES
INTL.
RECTIFIER,
WAKEFIELD,
DAW-1015.O
F. S. D./ 12 RED LINE
35 AMPERE,
ALUMINUM,
HEINEMANN,
10/5,0
600
BLACK
AMP.
SHUNT
15 AMPERE,
A.C.
ARRESTOR
SIOV-S20K250
SIEMENS,
130
VOLTS,
D.C.
ARRESTOR
SIOV-S20K130
SIEMENS,
130
VOLTS,
68 JOULE
SECONDARY
SIEMENS,
130
VOLTS,
68 JOULE
50 MV.
SIOV-S20KI
HOLLOWAY
30
TYPE
VOLTS
PIV.
ANODIZED
230VAC,
SURGE
SHEET
2-POLE
SW
130
JOULE
.
2
FUSE CLIPS
C-10,
PLATED,
FOR 9/1 6 DIA.
FUSE
NON-1 5/Equivalent
EDISON,
15-AMPERE
RHEOSTAT
RHEOSTAT
RHI 50-1.0
MEMCOR,
KNOB
2514-010-017
MEMCOR
PLATE
A-1
DIALPLATE
RHEOSTAT
ILSCO
2491-020-001
1.0 OHM,
C. T.&D.
1/8
NKK
DPDT,
SWITCH
SWITCH
S-338 /EQUIV.
NKK
DPDT,
AMPERES
TERM.
1
2
BLOCK
BLOCK
BKT.
10-142,
150
WATT
AC
ALUMINUM
S-335 /EQUIV.
TERMINAL
2 FUSES
VOLTS
MEMCOR
STANDARD,
SWITCH
1
1
250
JONES
30 AMPERE,
66-X-0050
FOR El-225
AC TERMINAL
8-142,
JONES
30 AMPERE,
DC LUGS
XT #4
- #14,
ILSCO
PLATED,
300
#2 - VOLTS
- VOLTS
VAC,
& EI-300
300
VAC,
(1) POSITIVE
COARSE-FINE
TAPS
LAMINATION
C/VV
BARRIER
(1) NEGATIVE
II
NOTES:
1. RECTIFIER
EQUIPPED
AC WIRE SIZE: #
WITH
14 TEW
SINGLE
OUTPUT
CIRCUIT.
SEC./DC WIRE SIZE:
# 14 TEW
---
ANODE
LBI
MAIN
AC
TRANSFORMER
BREAKER
iNOTE
----------
21
~--1
1
I
1
1
;
TI
LI
336
1
VAC
PH.
NEUT
[
1
l,,
1,
1,2;
L.;
AC
T F
OUTPUT
FUSE
SECONDARY
SUROE
ARRESTOR
ARRESTOR
Ir
LI
1
1,
1
22
t,
VAC
PH.
I
1
1
1
{,
=ii~b
.--.!
---+1
I
1
4t
D3
O.c
SURGE
ARRESTOR
hA
D4
1
L------_.
D1ODE
BRIDGE
4SSEMBLY
GND
SI
%+
AMPERES
VOLTS
I
11
SURGE
A
,.
~;
L2
D2
II
230
!
01
SHUNT
G(-)
STRUCT
Y
$!,*
NOTES:
3.)
2 .)
CONSULT
SPEC1FICATION
SHEET
PART
NUMBERS
AND
OU4NT1T1ES
FOR
FOR
? t5
230
VAC
VAC
lNPUV.
INPUF
JUMPER
J.IMpER
FOR
1-2
2-3
13ET A1LLE0
c 3-4
ONLy.
TAP
m..
ADJUST,
Docummnt
ltB/230
.te:
VAC.
3-cIRCUIT
Number
UE
E? ST D.SCH
B
July
6.
1998
I S,r,. .t
3.
~
of
