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MANUAL CP RECTIFIER (50V / 50A)

(63 Manual Voltage Controlled- Oil Natural)
USER MANUAL

Nov 2010

1 As-Built M.E C.A.B. A..C.B. 04/08/10

REV DESCRIPTION PREPARED CHECKED APPROVED DATE
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CONTENTS

1. INTRODUCTION

2. SCOPE

3. CODES

4. SYSTEM COMPONENTS

5. HANDELING & INSTALLATION

6. COMMISSIONING

7. OPERATION MODES

8. RECOMMENDATIONS

APPENDIX-1. Major Components

APPENDIX-2. Wiring Diagram
APPENDIX-3. Mechanical Details

DECLARATIONS AND WARRANTY

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1. INTRODUCTION

A DC Power equipment such as transformer rectifier supplies current that is 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 transformer 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.
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2. SCOPE

Transformer Rectifier, A DC power source to rectify an alternating current into a stabilized (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 55ْ C Shade Temperature.
g) Location : Outdoor, 0 to 2500 meters altitude
h) Protection:
- Overload and short circuit protection by Input circuit breaker (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
j) Transformer: Double wounded, Class F, min of 95% efficiency
k) Ingress Protection : IP-55
l) Safety : Conforming EC safety Directives
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Table-1. Details of TR unit

o o
Environmental Ambient temp: max +55 C min -20 C Double Wound Transformer Rating
Condition Humidity: 98 % Ph: 3 Frequency: 50 Hz Cos : 0.95
Altitude: 0~2500 m above sea level Apparent Power: 3.5 KVA Active Power: 3.34 KW
Area Ex-Proof Safe Primary input voltage: 440 V Primary input current: 5 A
Description Indoor Outdoor Second output voltage: 50 V Second output current: 50 A
Protection Control Panel : IP55 Oil Tank : IP55 Isolation : Double wounded Electro static shield: 2.5 K
V
Cooling AN ONAN INAF Temperature class : F Maximum Inrush current: 10A
Mounting Pole mounted Plinth mounted Measuring Instruments
Wall mounted Freestanding Measurement device Analogue Digital
Finishing Surface Preparation: Sand Blast SA 2.5 AC Input Voltmeter scaled from 0 to 500
V
Primer:cold galvanized by zinga AC input Ammeter scaled from to
A
Finish : modify poly urethane DC output Voltmeter scaled from 0 to 60 V
Dimensions Width:1100 mm Height:1600 mm DC output Ammeter scaled from 0 to 60 A
o
Depth: 1260 mm Oil capacity: 230 lit Oil Temperature meter scaled from 0 to 120 C
Net Weight: 420 kg Reference cell voltage scaled from to
V
ELECTRICAL CHARACTERISTICS Reference cell Type : N/A Reference cell Qty: N/A
AC Input Ph:3 Current:5 A Voltage: 380/440 Connectivity : RS232 RS485 GSM
rating Wireless
Frequency: 50 Hz  5% Protections
DC Output Voltage: 50 V Current: 50 A Input MCCB
Rating & DC output control: Rectifier HRC fuse
Control type manual Auto Output HRC fuse
Constant voltage Voltmeter fuse
Constant Current Controller fuse
Reference potential control Overload protection by HRC
Manual Voltage Controlled TR TEST RESULTS
Rectifying Stack elements Transformer Insulation Test
Unit Selenium Silicon References Prime & Yoke Sec & Yoke Prime & Sec
Rectification Test Value > 2 KVAC >2 KVAC > 2 KVAC
50Hz 50Hz 50Hz
Mode: Full Wave Result < 5 mA < 5 mA < 5 mA
Ratings: 3P, Full-bridge, 6 Pulse TR Load ability test
Timer circuit External Internal Iin Vin Pin Iout Vout Pout  %
□ Internal
Internal None Synchronized
Synchronized 50% Load
Intervals ON: 3-200 Sec OFF: 3-200 Full Load
Terminals AC : 3  M6 Alan Stud type Terminal,
Sec DC Outgoing: 2  M8 Stud type Terminal
Auxiliaries & Induced filter Capacitive filter FWD Surge Protection (AC and DC
Accessories sides)
Sunshade silica gel breather Lifting Hugs Oil drain Valve, Oil level
Indicator
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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
l) IEC 60117 Recommended Graphical Symbols
m) IEC 61024 Protection of structures against lightning

TR unit is also meeting all of the equivalent EN and BS standards, directives and recommendations

4. SYSTEM COMPONENTS
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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 & Auxiliary devices.

The DC Terminal Cabinet.

Consist of DC Terminal with Protection & Auxiliary devices.

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 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.

4.1. 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 & 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 & 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.
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Figure-1. Control & Measuring Instruments Front & Side View

(Accessible via Control Cabinet door on front side of Top enclosure)
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4.1.1. Control Devices

The following devices are providing the full range of controls on nominal operational parameters of TR;

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 & System Monitor (INT).
Used to provide controlled interruption on rectifier output via solid stated relay (SSR) in Timer mode
& while any System failure would be happened.

4.1.2. Measuring Instruments

While the following devices used to monitor 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.
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4.1.3. Current Interrupter & 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
Set OFF Time One Turn Potentiometer (PS2)
Used to set OFF Time period (form 3-200 S) for None continuous Operation mode
Interrupter Operational Indicator (LED1) Red Or Green 2 way LED lamp,
Emitting Red during the off time 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 LED5 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.

Figure-2. Current Interrupter & System Monitor unit

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4.2. The Terminal Cabinets

The Terminal Cabinets have been installed on left & right sides to provide separated connection for AC and DC
connections.

4.2.1. AC 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;

AC input Terminal (R, S, T, N)

Suitable to connect 3 Wire or 4 Wire AC supply to the rectifier
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.
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.

Figure-3. AC Terminal Box Details and Components

(Located on right side of top enclosure)
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4.2.2. 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 & 3 Red Positive Terminals
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.
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.

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.
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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
supplied 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 to a 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 oil 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.
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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.

Power 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® Min 75 micro-meters

Epoxy Polyamide Min 80 micro-meters
Modify Polyurethane 40~50 micro-meters
TDFT 195~205 micro-meters

Color Shade to be RAL 7033 Cement Gray

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5. HANDELING & 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 bottom of TR units which have
been defined on this document.

Bottom View

Following procedure should be followed in given order

5.1. Check

Check outside of TR unit on transport damage, if so please contact the supplier before continuing installation.

5.2. Mounting
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 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

Check outside of TR unit on coating damage, if so please treat area immediately with a zinc cure

5.4. Installing cables

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Right Side View Left Side view

(Showing AC input and Earth connection) (Showing DC inputs of Anode and Cathode Circuit)

It shall be assured that the applicable AC breaker at the associated sub-station is locked off prior to connecting
TR unit.

 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;
 Seal the entry of each Conduit within mastic of Polyurethane spray seal.

5.5. Connections
 Connect the Anode and Cathode cables to the output terminals with the correct polarity;

DC Terminal Arrangement
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 Connect the AC cable to the input terminals;

AC Terminal Arrangement

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
 Mount sunroof on top of TR unit to protect the unit against direct sunlight and rain.
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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.

It is advisable to install first the TR unit before continuing.

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 & 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 & 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.
Depending on humidity and temperature the transformer oil can deteriorate. To prevent deteriorating of the oil
use a silica gel dehumidifier,

Never penetrate the oil tank more then 15 cm.

To Drain transformer oil follow the below indicated steps;

 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.
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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;

 Place gasket and the dehumidifier on the tank
 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 oil3;
 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.
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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 is 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;

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.
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7. OPERATING MODES

7.1. Transformer oil

The energized TR unit 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:

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
1 1 1 0.0 2 1 1 12.8 3 1 1 25.6 4 1 1 38.4
1 1 2 0.8 2 1 2 13.6 3 1 2 26.4 4 1 2 39.2
1 1 3 1.6 2 1 3 14.4 3 1 3 27.2 4 1 3 40.0
1 1 4 2.4 2 1 4 15.2 3 1 4 28.0 4 1 4 40.8
1 2 1 3.2 2 2 1 16.0 3 2 1 28.8 4 2 1 41.6
1 2 2 4.0 2 2 2 16.8 3 2 2 29.6 4 2 2 42.4
1 2 3 4.8 2 2 3 17.6 3 2 3 30.4 4 2 3 43.2
1 2 4 5.6 2 2 4 18.4 3 2 4 31.2 4 2 4 44.0
1 3 1 6.4 2 3 1 19.2 3 3 1 32.0 4 3 1 44.8
1 3 2 7.2 2 3 2 20.0 3 3 2 32.8 4 3 2 45.6
1 3 3 8.0 2 3 3 20.8 3 3 3 33.6 4 3 3 46.4
1 3 4 8.8 2 3 4 21.6 3 3 4 34.4 4 3 4 47.2
1 4 1 9.6 2 4 1 22.4 3 4 1 35.2 4 4 1 48.0
1 4 2 10.4 2 4 2 23.2 3 4 2 36.0 4 4 2 48.8
1 4 3 11.2 2 4 3 24.0 3 4 3 36.8 4 4 3 49.6
1 4 4 12.0 2 4 4 24.8 3 4 4 37.6 4 4 4 50.4
Table-2 Switch Combination & correspondence 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
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8.1. Cabinet

When the TR unit is located in a free accessible place, be sure unauthorized people cannot access the TR unit.
Make sure that the TR unit is mounted as free as possible for optimal cooling. Do not place objects very near (< 50
cm) to the TR unit.
Always try to prevent any contact with water or other fluids. Control Panel shall be face to the North .

8.2. Operate

Before switch ON the TR unit, make sure the connected installation is installed properly.
The TR unit should be checked for accuracy on a regular basis.
Never short-circuit the TR unit.
Never energize the TR unit without the transformer oil.

8.3. 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.
Never penetrate the oil tank more then 15 cm.
Never use spare parts from none authorized suppliers by manufacturer.

8.4. Regular checks and measurements

Period Object Remark
Fuses Check in-and output fuses.
Monthly checks
Silica gel Condition.
Check the oil level. The oil level (in operational condition) should
Oil level
be between min and max indication of the oil level gauge.
Six months checks
Inspect complete surface of unit and restore if necessary damage
Coating
coating.
Annual Panel meters Function, calibration is required.
Table-3 Regular Checks
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

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MAJOR COMPONENTS
Code M/S Type/Model Description
MCCB Legrand 16 A Mould case Circuit Breaker
SL1,2,3 Telemecanique 220V M22 Input power indicator lamps
SD4 PL 660 V , 2.5 KA Input lightning, surge arrestor
SSR Crydom 3P-500 V 50A Solid State Relay
T1 Hi-Tec 440V 5 KW 63 Auto Transformer
S1,2,3 Hi-Tec 500V 50A 3Phase 4 Position Tap Changer Switch
T2 Hi-Tec 440V 5KW Step-down Transformer
D1,2,3,4,5,6 IXYS Isotope Module Diode 1200V 100A
V1,2,3,4,5,6 Any suitable 270V, 10KA Surge Protector (Metal Oxide Varistor)
DFW IXYS Stud Type Free wheel Diode 140A
L1 Hi-Tec Self Inductance Output Filter (500mircoH)
SD1,2,3 PL 660 V , 2.5 KA Output lightning, surge arrestor
MT1 SEW Moving Coil Analogical DC Voltmeter 60 Volt 72X72mm
MT2 SEW Moving Coil Analogical DC Ammeter 60A/75mV 72X72mm
SHT Compply Manganous Current Measuring Shunt 60A/75mV
ST3 BEREMAS 500V 16 A Phase Selection Switch ( for RS,0,RT,0,TS steps)
MT3 RISESUN Moving Coil Analogical AC Voltmeter 500 Volt 72X72mm
T3 Hi-Tec 440 V 200W Electronic Supply Transformer 1 Phase 380/440 V
INT Hi-Tec Electronic Built-In Current Interrupter
ENC Hi-Tec CTR-OCV1-IP65 TR Enclosure, and accessories
VLV Kizz Gate Valve 1/2" Oil Drain Gate valve
OLS Fume --- Oil Level Sight Gage
BRT --- --- Silicagel Breather

FUSE NO. RATING DESCRIPTION

HRC1,2,3 50A Rectification HRC Fuse
HRC4 63A Output HRC Fuse
FS1 250mA Metering Fuse
FS2 250mA Metering Fuse
FS3 250mA Metering Fuse
FS4 250mA Metering Fuse
FS4 250mA Metering Fuse

APPENDIX-2. Wiring Diagram

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APPENDIX-3. Mechanical Details

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Certificate of Conformity

According to IEC 60146 The Semiconductor Converters

& IEC 60076 Power Transformers
Hi-tec Industries Co., declares to comply with the standard requirements for following equipment;

Description of Goods
Automatic Cathodic Protection Rectifier
Serial No: TR0630110
Production Date: Aug. .2010
Model : TCS-O63
Type: ONAN

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 &
IEC 60146/480.3
Efficiency Test
Temperature Rise Test IEC 60146/480.4
Load Test IEC 60146/492.7
Ratio & Polarity Test -
Functional Test -
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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 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
Production Date: Aug. .2010
Model : TCS-O63
Type: ONAN