.

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