Manual Controlled CP Rectifier User Manual - HI
Contents
1. Timer circuit Intervals ON 3 200 Sec OFF 333 200 Terminals AC 3X M6 Alan Stud type Terminal DC Outgoing 2 X M8 Stud type Terminal LWPSHEISISEG D Induced filter C Capacitive filter E FWD D Surge Protection AC and DC Accessories sides D Sunshade DX silica gel breather x Lifting Hugs BY Oil drain Valve xX Oil level Indicator ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 6 of 28 3 CODES TR units are under manufacturing and testing meeting recognized standards and regulations of Cathodic protection and electrical and electronic system and devices a BS 7361 Cathodic Protection b IEC 60051 Recommendation for Indicating Electrical Measuring Instruments and Their Accessories c IEC 60439 1 Low voltage switchgear and control gear assemblies d IEC 60076 Power Transformers e BS 2914 Surge Diverters f IEC 60144 Degree of Protection of Enclosures for Low Voltage Switchgear and Control Gear g IEC 60146 Semiconductor Converters h IEC 60269 Low Voltage Fuses i IEC 60391 Marking of Insulated Conductors j IEC 60445 Identification if Apparatus Terminal Marking Using an Alphanumeric Notation k IEC 60529 Classification of degrees of protection provided by Enclosures D IEC 60117 Recommended Graphical Symbols m IEC 61024 Protection of structures against lightning TR unit2. and output fuses Silica gel Check the oil level The oil level in operational condition should wa be between min and max indication of the oil level gauge Six months checks Inspect complete surface of unit and restore 1f necessary damage Coating UM Function calibration is required Table 3 Regular Checks T If one or more of the above mentioned inspections fails the manual should be studied or the supplier should be contacted APPENDIX 1 Major Components ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 25 of 28 MAJOR COMPONENTS s PL 80v aska Taput ising sunge arrestor L DEW xYS Stud Type Free wheel Piode 140A ENC HiTec CTR OCVIIP S TREnelosure and accessories VLV Kiz Gate Valve 1 2 OilDrainGatewawe ons Fume ere Sight Gage BRT Silicagel Breather FUSE NO RATING DESCRIPTION 584 3 mA Metering Fs APPENDIX 2 Wiring Diagram z e z u ki 6 a Co 14 I S E ren LJOLIJ3HS a n 5 TAT B sawo nding G2 puewwog powo Jeydnueyur euu OL aur s du ug 8 1 R EEE owen E i WIDI paranuos MWANYA d318 9 joya MANG 62 qan smejs pasi6sua dno GL Gun 34 duen ud l AHS 1 USS a e Q37 184 aunyevadwiay io 2 uS aul
3. Analogue C Digital Surface Preparation Sand Blast SA 2 5 D AC Input Voltmeter scaled from O to 500 V Primer cold galvanized by zinga AC input Ammeter scaled from Mounting Finishing ct O DC output Voltmeter scaled from O to 60 V DC output Ammeter scaled from O to 60A Oil Temperature meter scaled from 0 to 120 C Reference cell voltage scaled from to Finish modify poly urethane Width 1100 mm Height 1600 mm Depth 1260 mm Oil capacity 230 lit Net Weight 420 kg Dimensions lt 0 ELECTRICAL CHARACTERISTICS AC Input Ph 3 Current 5 A Voltage 380 440 rating Reference cell Type N A Reference cell Qty N A Connectivity C RS232 RS485 GSM L Wireless Frequency 50 Hz 5 Protections DC Output Voltage 50 V Current 50 A D Input MCCB Rating amp DC output control Rectifier HRC fuse Control type D manual C Auto Output HRC fuse C Constant voltage D Voltmeter fuse Constant Current Controller fuse Reference potential control Overload protection by HRC D Manual Voltage Controlled TR TEST RESULTS Rectifying Stack elements Transformer Insulation Test Unit C Selenium X Silicon References Prime amp Sec Rectification Test Value gt 2 KVac gt 2 KVac gt 2 KVAC 50HZz 50Hz 50HZz Mode Full Wave Result lt 5 mA Ratings 3P Full bridge 6 Pulse TR Load ability test C External A Interna E Internal Synchronized 50 Load L Rk de i ee Paoa O
4. Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS 063 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 22 of 28 6 3 Energizing Prior to energizing the following steps should be followed and the results should be satisfactory If any problems occur during this procedure energizing should not take place and the supplier should be contacted Onsite situation 1s stable and safe Oil drain valve is closed and secured Oil tank is filled to the given level with transformer oil See 6 1 Air silicagel Breather is installed and filled with silica gel See 6 2 Check if DC circuit is properly installed and not causing short circuiting Check if TR unit is connecter to an AC power circuit in accordance to the rating plate information Check all cable glands are installed correct Make a full visual inspection to assure TR unit is in an optimal state S Rotate Manual Voltage Control Switches S1 S2 and S3 to Position Marked 1 When all precautions are taken and satisfactory energizing operating can take place refer to section 7 Operating mode to select one of most suitable position for each of Coarse S1 Medium S2 and Fine S3 switches Da H t BE SN cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 23 of 28 7 OPERATING MODES 7 1 Transformer oil The energized TR un
5. is also meeting all of the equivalent EN and BS standards directives and recommendations 4 SYSTEM COMPONENTS ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 7 of 28 The transformer rectifier TR have been composed of separated sections Control Cabinet Consist of Metering and Control devices The AC Terminal Cabinet Consist of AC terminal with Protection amp Auxiliary devices The DC Terminal Cabinet Consist of DC Terminal with Protection amp Auxiliary devices 4 Oil Tank Consist of Auto Transformer T1 Step down transformer T2 Rectification Unit and Filter Maintenance Cabinet A special tool and document container with a 240V AC socket to provide single phase AC power for maintenance proposes The Oil Tank is a heavy duty welded steel enclosure A top steel enclosure consists of Terminal Cabinet Control Cabinet and Maintenance Cabinet along the Chaise for installation of all oil immersed components is bolted and sealed to the top of the Oil Tank An Auto Transformer main step down transformer rectifier unit and all components producing heat loss are fixed on fabricated steel chaise The Top enclosure has a front Control Cabinet and AC DC Terminal Cabinets on sides along the Maintenance Cabinet on the rear side An Auto Transformer main step down transformer rectifier unit
6. the actual operational values AC Phase Signal Lamp Indicators Used to Check the existence of AC input Power An AC Voltmeter MT3 72X72 mm Used to Monitor actual AC Input voltage between 2 pair of input phases A DC Voltmeter MT2 72X72 mm Moving Coil Analogical Panel Meter Used to Monitor actual DC output voltage of TR to Anode Cathode Circuit A DC ammeter MT1 72X72 mm Moving Coil Analogical Panel Meter Used to Monitor actual DC output Current of TR to Anode Cathode Circuit The DC Output voltage and current a measuring instruments of the TR unit conform to IEC 60051 standard Recommendation for Indicating Electrical Measuring Instruments and Their Accessories TE Hietec aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 10 of 28 4 1 3 Current Interrupter amp System Monitor Unit INT INT unit is a combined Control and monitory device Current Interrupter ON OFF Switch ST2 Used to switch between Continues and None continues Operations modes of TR unit Set ON Time One Turn Potentiometer PS1 Used to set ON Time period form 3 200 S for None continuous Operation mode 3 Set OFF Time One Turn Potentiometer PS2 Used to set OFF Time period form 3 200 S for None continuous Operation mode 3 Interrupter Operational Indicator LED1 Red Or Green 2 way LED lamp Emitting Red during the off t
7. C Terminal Box This box have been fixed on the right side of control cabinet to maintain required connections and protection for incoming AC supply line Following devices are accessible via this box 4 AC input Terminal R S T N Suitable to connect 3 Wire or 4 Wire AC supply to the rectifier 4 Main Thermo magnetic Circuit Breaker MCCB Mechanical Thermal and Magnetic Actuated main input switch to On Off the rectifier and maintain Thermo Magnetic over current protection of TR mains 4 AC side Surge Lightning Arresters SD1 SD2 SD3 Suitable rated spark gaps to protection the TR input from unwanted AC surges and lightning strikes and possible transient over voltage sparks of supply lines NEUTRAL Figure 3 AC Terminal Box Details and Components Located on right side of top enclosure ER Hi tec aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 13 of 28 4 2 20 DC Terminal Box This box have been fixed on the right side of control cabinet to maintain required connections and protection for incoming AC supply line Following devices are accessible via this box DC Output Terminal PIPE STRUCTURE GROUNDBED Suitable rated 3 Blue Negative amp 3 Red Positive Terminals 3 Main Thermo magnetic Circuit Breaker MCCB Mechanical Thermal and Magnetic Actuated main input switc
8. ER Hi tec Aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 1 of 28 MANUAL CP RECTIFIER 50V 50A 63 Manual Voltage Controlled Oil Natural USER MANUAL Nov 2010 04 08 10 DESCRIPTION PREPARED CHECKED APPROVED DATE ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 2 of 28 CONTENTS 1 INTRODUCTION 2 SCOPE 3 CODES 4 SYSTEM COMPONENTS 5 HANDELING amp INSTALLATION 6 COMMISSIONING 7 OPERATION MODES 8 RECOMMENDATIONS APPENDIX 1 Major Components APPENDIX 2 Wiring Diagram APPENDIX 3 Mechanical Details DECLARATIONS AND WARRANTY ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 3 of 28 1 INTRODUCTION A DC Power equipment such as transformer rectifier supplies current that 1s applied for Cathodic Protection of buried or immersed metal structure The transformer rectifiers TR are normally used when AC power from the mains is available Hi Tec s Manual Cathodic Protection TR Units Oil Cooled are specially designed for safe and long term operation in environments such as desert and tropical locations The t
9. HODE Right Side View Left Side view Showing AC input and Earth connection Showing DC inputs of Anode and Cathode Circuit Ero It shall be assured that the applicable AC breaker at the associated sub station is locked off prior to connecting TR unit e Connect the earth terminal to an appropriate earth facility Install all necessary cables properly Route the AC supply cable from conduit to AC Terminal Box and follow the same for DC negative Cathode Structure and DC positive Anode Groundbed Cable s to DC Terminal box e Seal the entry of each Conduit within mastic of Polyurethane spray seal 5 5 Connections e Connect the Anode and Cathode cables to the output terminals with the correct polarity PIPE STRUCTURE GROUNDBED DC Terminal Arrangement TE Hietec aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 19 of 28 e Connect the AC cable to the input terminals H S T NEUTRAL AC Terminal Arrangement o It shall be assured that the supplied line voltage is in conformity with the one specified on the rating plate of the TR unit If any of the above listed instructions is not completed satisfactorily please do not activate TR unit before consulting supplier Faulty connections can cause serious failures in operation or damage to the TR unit 5 6 Sunroof e Mount sunroof on
10. Rectifier User Manual COARSE MEDIUM Figure 1 Control amp Measuring Instruments Front amp Side View Accessible via Control Cabinet door on front side of Top enclosure TE Hietec ea gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 9 of 28 4 1 1 Control Devices The following devices are providing the full range of controls on nominal operational parameters of TR Es Phase Selection Switch ST3 5 Position switch used to Apply line voltages sequentially to the AC input Voltmeter MT3 Coarse Adjustment Switch S1 3 ways 4 Position switch used to select one of the positions on Auto winding of Control Auto Transformer T1 which have been divide on 4 coarse taps Medium Adjustment Switch S2 3 way 4 Position switch used to select one of the positions on Buck winding of Control Auto Transformer T1 which have been divide on 4 Medium taps Fine Adjustment Switch S3 3 way 4 Position switch used to select one of the positions on Buck winding of Control Auto Transformer T1 which have been divide on 4 fine taps Current Interrupter amp System Monitor INT Used to provide controlled interruption on rectifier output via solid stated relay SSR in Timer mode amp while any System failure would be happened 4 1 2 Measuring Instruments While the following devices used to monitor
11. abilized voltage and current direct current The output voltage and current can be regulated to meet rated Impressed Current Cathodic Protection System requirements which normally defines by client contractor CP specialist and designers The Scope of this documents is to descript details of 63 Step Manually Controlled Cathodic Protection trans rectifier unit TR and to be a guide line of Installation commissioning Operation and maintenance of the system which could be summarizes within the following details a Input Voltage 440 VAC 396 484 V Three Phase at 50 Hz b Input Frequency variation 05 c Output voltage From 0 50 Vdc d Output Current From 0 50 Adc a Cooling Oil Cooled Natural Convention b Operating Modes Manual Voltage Regulation None Continues Operation by Timer Interrupter c Control Manual compensation of output voltage by 3X4 Position tap changer switch d Compensation 3 Nos of 3 way 4 position switches Coarse medium fine giving control over 63 steps of output voltage that could be adjusted via Auto transformer T1 which have been linked to the Primary of main double wounded Transformer T2 to change the input of T2 from 0 up to Nominal rated input voltage e Rectification Full wave Silicon diode f Ambient temperature 0 up to 55 lt C Shade Temperature 2 Location Outdoor 0 to 2500 meters altitude h Protection Overload and short circuit protection by Input circuit breaker
12. and all components producing heat loss are fixed on fabricated steel chaise to immerse all of the components producing heat loss while have been bolted on the top of the Oil Tank Hinged pad lockable door of the Control Cabinet on the Front of Top Enclosure which have a viewing window of toughened glass to facilitate readings of the meters without opening the door allows the user to easily access to the all of the controls and metering devices such as tap changer switch panel meters and built in timer interrupter unit 4 I The Control Cabinet Hinged pad lockable door with quick release toggle latches of the Control Cabinet on the Front of Top Enclosure which have a viewing window of toughened glass to facilitate readings of the meters without opening the door allows the user to easily access to the all of the controls and metering devices such as tap changer switch panel meters and built in current interrupter amp System monitor unit The Metering device such as DC Voltmeter DC Ammeter AC input signal Lamps Metering fuses and 2 pares of Plug in for external Voltmeter Ammeter along controls for built in Current Interrupter amp System Monitor Unit have been installed on a internal hinged door while the Controls of Tap changing switches have been installed on a 45 degree angular support on the bottom of Top Enclosure ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT Manual Controlled CP
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14. eps Remove oil filler cap Remove the cap from the oil drain device Connect suitable pipe to oil drain device Then connect the pipe to the oil regenerator station Turn the spindle with a spanner to open en close the drain Remove pipe and reinstall the cap onto the oil drain device WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS 063 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 21 of 28 6 2 Silicagel Breather To ensure the transformer oil keeps it optimal condition a silicagel breather should be installed During cooling down or heating up of the oil the tank is breathing air in and out The silica gel dehumidifies this air To install the breather follows the below steps e Place gasket and the dehumidifier on the tank e Install metal guard rating plate To Re fill the silicagel cartridge follow the below steps Remove cap of the dehumidifier 2 Fill container with the silica gel Take out the oil reservoir 1 Place the oil reservoir back and fill it with 0113 Close the dehumidifier Depending on humidity and temperature the silicagel shall deteriorate At the start the gel is dark orange Or Dark Blue during saturation the gel becomes lighter Replacement should take place before the gel is almost white Silicagel should be check regularly on its condition color to prevent deterioration of the transformer oil ER Hi tec pd gt Cathodic Protection
15. h to On Off the rectifier and maintain Thermo Magnetic over current protection of TR mains DC Side Surge Lightning Arresters SD4 Suitable rated spark gaps to protection the TR output from unwanted surges and lightning strikes and possible transient over voltage sparks to Cathode Anode circuit PIPE STRUCTURE GROUNDBED Figure 4 DC Terminal Box Details and Components Located on Left side of top enclosure Various levels of protection recommended by International standards such as IEC and EC have been provided for TR Units ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS 063 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 14 of 28 A Over intensities MCCB Mould Cast Circuit breaker module which operates on both of thermal and magnetic intensities of over current effects on AC side have been provides to protect TR input stage The MCCB module a Hold 100 of rated load b May trip between 101 and 124 of rated current c And must trip at 125 rated current or above Suitable rated HRC fuses Marked as HRC1 HRC2 HRC3 for Rectification Transformer secondary and HRC4 for DC output have been provided on both of rectification and output stages of TR unit those Conform to IEC 60269 Low Voltage Fuses B Personnel Safety EC safety Directives have be applied to TR unit to prevent direct contacts of human and operator to AC supp
16. ic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT Manual Controlled CP Rectifier User Manual 6 1 Cabinet When the TR unit is located in a free accessible place be sure unauthorized people cannot access the TR unit T Make sure that the TR unit is mounted as free as possible for optimal cooling Do not place objects very near lt 50 cm to the TR unit T Always try to prevent any contact with water or other fluids Control Panel shall be face to the North 8 2 Operate T Before switch ON the TR unit make sure the connected installation is installed properly T The TR unit should be checked for accuracy on a regular basis K Never short circuit the TR unit K Never energize the TR unit without the transformer oil Maintenance Only quantified personnel should undertake maintenance testing to the TR unit Before maintenance please disconnect line voltage use MCCB for small maintenance The TR unit enclosures covers shall not be left open for longer than necessary When cover is open remember this is an electrical device For lifting TR unit frame use all lifting eyes Never short circuit the TR unit for testing when the device is running K Never penetrate the oil tank more then 15 cm K Never use spare parts from none authorized suppliers by manufacturer eo om oom oom m S 8 4 Regular checks and measurements Period Object Remark amp F Monthly checks C E
17. ime period and Green while the rectifier applies current while operating on Timer mode only on while ST2 is in TIMED position to indicated TR operates on None continues mode Phase status signals LED2 LED3 LED4 Green LED lamps Emitting while input mains are exist Failure on each phase will result LEDS to emits red AC input Fault signal Phase status signals LED5 LED6 LED7 Red LED lamps Emitting sequentially while any Failure on irregular AC input mains or oil level reduction and oil Temperature rises with providing Potential Free Contacts to SCADA PSI ST2 LEDI PS2 Su c 20 80 e uy dh een TIMED CONT A p OFF CURRENT INTERRUPTER HI Tee CATHODIC PROTECTION SYSTEMS FAULT MONITOR 1A STATUS SIGNALS FAULT SIGNALS 000 O06 R S T AC ONL OIL AG INPUT SUPPLY INPUT LEVEL TEMP LED2 LED3 LED4 LEDS LED6 LED7 Figure 2 Current Interrupter amp System Monitor unit WORLDWIDE CORROSION ENGINEERING DOC NO TCS O63 50V 50A 3P 440 Page 11 of 28 DOCUMENT SUBJECT Manual Controlled CP Rectifier User Manual ER Hi tec i gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS 063 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 12 of 28 4 2 The Terminal Cabinets The Terminal Cabinets have been installed on left amp right sides to provide separated connection for AC and DC connections 4 2 1 A
18. it is ready to apply the Cathodic current to anode cathode circuit connected to the DC output terminals The system functions in 2 different operating modes a Manual Continues Operation Mode None Continuous operation mode Timer Mode 7 2 Manual Continuous Operation Mode In Manual Continuous Operation Mode TR output would be adjusted to operate at reasonable voltage output to provide required protective current to polarize the structure pipeline subjected to be cathodically protected using Coarse S1 Medium S2 and Fine S3 3 way 4 position tap changer switches The following table can be used to select reasonable output voltage for each combination of switch positions S1 S2 S3 Output S1 S2 S3 Output S1 S2 S3 Output S1 S2 S3 Output Position Voltage Position Voltage Position Voltage Position Voltage ES Es 3 EN EN EF 4 EE FA ES 4 Ew 2 31 In AIIN wN 4 Wy l lt 2 E Combination amp _ Output Voltage Level for 10 lowered nominal Input voltage supply and full load 7 3 None Continuous Operation Mode Embedded None Synchronized Electronic Interrupter would be switched on via ST2 Timed Continuous operation selector ST2 would be switched back to Continuous position after inspections have been managed On Off Intervals can be manually adjusted between 5 200 Second using PS1 and PS2 Potentiometers on Front panel 8 RECOMMENDATIONS ER Hi tec pd gt Cathod
19. l tank have suitable channel and bolting facilities to be fixed to the Top Enclosure to act as a hosing shell to allow the oil immersion of all the power components producing heat loss mounted and fixed under the Top enclosure fabricated steel chaise such as Auto Transformer main step down transformer rectifier unit output filter and ect ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 15 of 28 An external Oil level site glass to make the cooling oil level and the recommended oil level visible during normal operation of the rectifier has been provide along a minimum 2 dia Dial Type Thermometer on the front top side of the Oil Tank An oil fill pipe minimum 1 5 in I D with threaded cap on rear top side and an accessible drain gate valve with a threaded outlet and galvanized steel plug placed at the lowest area of the rear side of the tank have been provided to remove oil and drain moisture The drain valve have been also protected and shielded by surrounding thick plates extended to the end of the valve on each side A suitable sized Silicagel Breather is also placed to the top same side of the oil tank 4 3 1 Rectification unit Rectification have been performed by a 3 phase full bridge connection of silicon diodes which reverse tension are above 1200 V and conforms to IEC 60146 Semiconductor Converters P
20. lied voltage All metallic parts have been electrically continuous and one Earthing Grounding terminal will allow their connection to an external earth circuit An external ground M8 stud ground terminal corrosion resistant has been provided to be linked 25 sq mm copper ground conductor An internal equipment grounding terminal adjacent to the AC terminal block has been also provided to earth all of the auxiliaries C Over Voltages Protections The Surge arresters connected between the anode and Cathode Terminals and AC input of the TR unit Conforms BS 2914 Surge Diverters Additional Metal oxide varistors have been installed in parallel to the diode bridge rectifier 4 3 The Oil Tank The Oil Tank which conform toa NEMA 8 with Ingress protection to IP55 rating at least will be fabricated from minimum of 2 5 mm thick which exceeds 11 gauge steel sheet conforming to ASTM A36 Oil tank seams have been welded on the outside with continuous filet weld according to the latest edition of AWS D 1 1 Accessible seams inside of the Oil Tank have been also welded with continuous filet weld Plinth montage and standing on ground have been provided for TR unit within welding two 5 mm thick structural channels under the Oil Tanks bottom Minimum of 100 mm type channels have been used for underside clearance Suitable inner and outer reinforcements have been provide to prevent warp age during the construction welding of oil tank The top side of oi
21. ower rectifying diodes have been mounted on anodized aluminum heat sinks and sized for temperature of 55 C degree ambient and rated load The Diodes have been selected to comply to the minimum of 50 greater than the full rated rectifier output 4 2 1 Step Down Transformer T2 Double wounded Step down Transformer have been rated for Magnetic wire and insulation materials to comply to minimum of Class F insulation within minimum of 95 of efficiency to provide Lowered AC voltage to the rectification form the incoming AC leads of the T1 auto transformer Copper earth shield have been provided between primary and secondary winding to provide appropriate earthing requirements The Transformer unit complies to IEC 60076 Power Transformers recommendations 4 4 Finishing After degreasing and Chemical cleaning the surface preparation will followed up by shut blasted process and the following finish will be applied Cold Galvanized by Zinga Epoxy Polyamide Modify Polyurethane 40 50 micro meters TDFT 195 205 micro meters Color Shade to be RAL 7033 Cement Gray WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 16 of 28 5 HANDELING amp INSTALLATION The designated location for installation shall be verified on site prior to installation works taking place The mounting details should conform to the details of plinth mounting channels under the Oil Tanks bot
22. ransformer rectifier components are housed in steel enclosures divided into two main sections namely oil tank and control cabinet The transformer rectifier is supplied complete with bolted type base frame and fixing bolts for plinth mounting The outdoor control cabinets are normally provided with sunshade STANDARD FEATURES OF THE 63 STEP MAUAL CONTROLLED RECTIFIERS 1 Manual Voltage Control over the 63 steps of Nominal rated voltage Automatic 2 Coarse Medium and fine adjustment by 3 X 4 step tap changer switches rated to operate while system is energized even on full load condition 3 Compact design and easy to use and installation 4 Minimum maintenance requirements and long operation time 5 Weather Proof construction and corrosion resistive finish with UV protection 6 AC input voltage DC output voltage and current monitoring by moving coil analogical meters 7 Over voltage and current protection for both of AC and DC sides 8 Surge Protection on D C side lightning protection on Ac side 9 Cooling by Natural Convention of Transformer Oil 10 Suitable for either 3 Wire or 4 wire connection for 3Phase 380 440 Volt 50 and or 60 Hz systems ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 4 of 28 2 SCOPE Transformer Rectifier A DC power source to rectify an alternating current into a st
23. shipment handling storage or accidental misuse The original purchaser of the product must obtain a Return Material Authorization RMA number from Hi Tec prior to returning any defective product When purchased through an Authorized Distributor the Distributor should supply an RMA number to their customer The maximum liability of this warranty is limited to the purchase price of the product In no event regardless of cause shall Hi Tec be liable a for penalties or penalty clauses of any description or b for certification not otherwise specifically provided herein and or indemnification of purchaser or others for costs damages or expenses each arising out of or related to the product or services of any order or c for any damages resulting from loss of profits use of products or for any incidental indirect or consequential damages even if advised of the possibility of such damages Description of Goods Automatic Cathodic Protection Rectifier Serial No TR0630110 TCS O63 ONAN Aug 2010
24. thermo magnetic DC output and Rectification and fuses Over voltage and Surge protection on DC side and lighting protection on AC and DC sides Over heat Protection by Oil Temperature Sensor Oil Leakage protection by Oil Level Sensor i Indicators DC output voltage analogical meter DC output Current and AC input voltage analogical meter Oil Level Gauge Dial Type Oil Temperature indicator AC mains Oil level Oil Temperature failure p Transformer Double wounded Class F min of 9546 efficiency k Ingress Protection IP 55 I Safety Conforming EC safety Directives WORLDWIDE CORROSION ENGINEERING DOC NO TCS O63 50V 50A 3P 440 Page 5 of 28 DOCUMENT SUBJECT Manual Controlled CP Rectifier User Manual Table 1 Details of TR unit Ambient temp max 55 C min 20 C Bono eee sn di NG DN a Humidity 98 96 P Frequency 50 Hz Cos D 0 95 Altitude 0 2500 m above sea level Apparent Power 3 5 KVA Active Power 3 34 KW Environmental Condition E Area C Ex Proof x Safe Primary input voltage 440 V Primary input current 5A Description C Indoor Xx Outdoor Second output voltage 50 V Second output current 50 A Protection Control Panel IP55 Oil Tank IP55 Isolation Double wounded Electro static shield 2 5K V Cooling AN D ONAN C INAF Temperature class F Maximum Inrush current 10A C Pole mounted Ml Plinth mounted WYCENA a eerie C Wall mounted Freestanding Measurement device D
25. tom of TR units which have been defined on this document Bottom View Following procedure should be followed in given order 5 1 Check gt eee j al o VET Dial Type Thermometer ca uve a e o o eoan Qo outside of TR unit on transport damage if so please contact the supplier before continuing installation 5 2 Mounting ER Hi tec aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS 063 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 17 of 28 Place the TR Unit on the specified location Control panel shall faced to North always Secure the TR Unit with the appropriate fixing materials Make sure no foreign objects are located within 50 cm of TR Unit Install the air Silicagel Breather Secure the oil drain valve with a suitable end cap Control panel shall faced to North always to reduce direct sunlight emission to control panel 5 3 Coating inspection E i 6 mom o Check outside of TR unit on coating damage if so please treat area immediately with a zinc cure 5 4 Installing cables ER Hi tec aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 18 of 28 AC EARTH 4 ANODE CAT
26. top of TR unit to protect the unit against direct sunlight and rain ER Hi tec pd gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT DOC NO TCS O63 50V 50A 3P 440 Manual Controlled CP Rectifier User Manual Page 20 of 28 6 COMMISSIONING 6 1 Transformer oil The main power components of the TR unit are immersed in transformer oil Immediately on site the TR unit should be filled with a BS 148 IEC 60296 Transformer oil It shall be assured that the applicable AC breaker at the associated sub station is locked off prior to filling TR unit Itis advisable to install first the TR unit before continuing x Never energize the TR unit without the transformer oil To fill transformer oil inside the TR unit oil tank follow the below steps Remove oil filler cap amp gasket Install a hose in the tank Fill the tank until the oil level reaches 1 3 of the oil level indication Remove the hose from the tank Reinstall the gasket amp oil filler cap After a few hours the oil level can drop due to release of air bubbles from the oil Add oil if necessary Maximal oil level can be exceeded due to high ambient temperatures c H ng ou Depending on humidity and temperature the transformer oil can deteriorate To prevent deteriorating of the oil use a silica gel dehumidifier x Never penetrate the oil tank more then 15 cm To Drain transformer oil follow the below indicated st
27. ue days 9 ER Hi tec aa gt Cathodic Protection Limited WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT Manual Controlled CP Rectifier User Manual Certificate of Conformity According to IEC 60146 The Semiconductor Converters amp IEC 60076 Power Transformers Hi tec Industries Co declares to comply with the standard requirements for following equipment Description of Goods Serial No Production Date Model Type For the evaluation of the compliance with this standard the following Test was applied Test Description Standard Measurement of inherent Voltage IEC 60146 480 1 Regulation Insulation Test IEC 60146 492 1 Power factor Measurement IEC 60146 480 2 Power loss Measurement amp Ratio amp Polarity Test Functional Test SSS WORLDWIDE CORROSION ENGINEERING DOCUMENT SUBJECT Manual Controlled CP Rectifier User Manual DOC NO TCS O63 50V 50A 3P 440 Page 29 of 28 Warranty Hi Tec Cathodic Protection LTD warrants the product delivered in the Hi Tec ship package to be free from defects in material and workmanship under normal use and service for twenty four 24 months from date of manufacturing Products that fail during this period will be repaired at Hi Tec s discretion provided the original purchaser A returns the failed product and B provides proof of original date of purchase This warranty does not apply in the judgment of Hi Tec to damage caused during
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