SAFWAY MATCOR Cathodic Protection Rectifier Manual

OPERATION & MAINTENANCE MANUAL
Cathodic Protection Rectier

OPERATING INSTRUCTIONS
MATCOR Rectier
NOTICE: You have purchased the nest rectier available. In order to have this unit function as designed —
READ THIS MANUAL BEFORE ENERGIZING THE RECTIFIER! Keep the manual with the rectier and order
only MATCOR replacement parts.
I. SAFETY PRECAUTIONS - Observe at all times!
A. Beware of the AC Line Voltage within the rectier cabinet! Turn the AC power “OFF” outside before working inside.
B. Never exceed the AC or DC ratings.
C. Correct any overload that activates a circuit breaker or fuse. Do not bypass these protective devices.
D. To prevent severe corrosion, ensure that the rectier's positive terminal is connected to the anode and the negative
terminal is connected to the structure to be protected (i.e. cathode). This can be conrmed by checking the
structure's potential after energizing the rectier. Be sure that it shifts toward the NEGATIVE when the rectier is
turned ON.
II. PRE-OPERATING PRECAUTIONS
A. Look for and repair shipping or installation damages: after uncrating unit, check all terminals for loose connections
due to handling from shipping. Carefully inspect unit for any possible damage resulting from shipping.
B. Be certain the rectier is connected to the properly rated AC line voltage, phase and frequency. If the rectier will
accept more than one AC line voltage, verify the correct setting. Connect the AC line supply through the AC
circuit breaker.
C. Set the DC meters to zero. Digital meters are pre-set at the factory.
D. Connect the POSITIVE rectier output terminal to the anode bed or anodes. Connect the NEGATIVE rectier output
terminal to the metallic structure receiving cathodic protection.
E. Make certain that all electrical connections are tight.
F. For oil-immersed rectiers only:
1. Make certain the enclosure is clean inside.
2. Fill it to the recommended level with electrical insulating oils complying to ANSI/ASTM D-3487 and
NEMA TR-PB-1975.
III. INITIAL TURN-ON PROCEDURES
A. For three-phase rectiers only, set the adjustment taps for all three phases identically BEFORE energizing the rectier.
B. Turn off the unit's circuit breaker prior to making any adjustments to the tap settings.
C. Never exceed the rectier input or output ratings.
D. PROCEED AS FOLLOWS:
1. Place the adjusting taps at their lowest setting (Coarse tap A, Fine tap 1).
2. With the rectier’s circuit breaker “OFF” switch the external AC power to “ON”.
3. Energize the rectier by switching the rectier circuit breaker to “ON” and observe the DC output volts and
amperes.
4. Increase the tap settings in small increments until the desired DC output is achieved.
IV. MAINTENANCE
A. Keep the rectier free of excessive dust, insect and bird nests, spider webs, etc.
B. Keep ventilation openings clear.
C. Periodically check the electrical connections.
D. Visually inspect the oil in oil-immersed rectiers. Replace dirty looking oil. (A pale amber tint is normal.) Check for
water build-up in the bottom of oil-immersed rectiers; drain out accumulated water. Dispose of contaminated oil in
accordance with applicable environmental safeguards.
E. Maintain a permanent record of DC volts, DC amperes, AC line volts and tap settings.

OPERATING INSTRUCTIONS
MATCOR Rectier
[phone]
matcor.com
CONTACT A CORROSION EXPERT
SYMPTOM REMEDY
No DC current and no DC voltage output. Check AC overload protection for blown fuses or tripped
circuit breakers. Check AC power supply.
No DC current but DC voltage is present. Check DC ammeter. Check DC connections and external
DC circuit for continuity.
DC current reading but no DC voltage. Check DC voltmeter.
Maximum DC current cannot be obtained at maximum DC
voltage.
Check load resistance of external DC circuit. Check shunt
and ammeter.
Maximum DC voltage cannot be obtained. Check AC line voltage. Check voltage adjustment taps for
maximum setting. Check accuracy of DC voltmeter.
TWO-YEAR GUARANTEE
Each and every cathodic protection rectifier of MATCOR, Inc. design is guaranteed against defects in design,
workmanship or material for a period of two full years from the date of shipment from the factory.
The obligation of MATCOR, Inc. is limited to the adjustment, repair or replacement, at its factory, of any rectifier or part
thereof which shall be found by MATCOR, Inc. to be defective.
This guarantee does not cover costs or loss for engineering, storage, handling, shipping, installation and removal
associated with the damaged rectifier or part, or any other costs, loss or damage of any kind.
UNDER NO CIRCUMSTANCES SHALL MATCOR, INC. BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES.
FIVE-YEAR TRANSFORMER GUARANTEE
Each and every transformer installed as original equipment in a cathodic protection rectifier of MATCOR, Inc. design is
guaranteed against defects in design, workmanship or material for a period of five full years from the date of shipment
from the factory. The obligation of MATCOR, Inc. is limited to the adjustment, repair or replacement, at its factory, of any
transformer which shall be found by MATCOR, Inc. to be defective.
This guarantee does not cover costs or loss for engineering, storage, handling, shipping, installation and removal
associated with the damaged transformer or any other costs, loss, or damage of any kind.
UNDER NO CIRCUMSTANCES SHALL MATCOR, INC. BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES.
V. TROUBLE SHOOTING
Refer to the rectier circuit diagram.
When contacting MATCOR regarding this rectifier, be sure to have both the model number and serial number on hand.

The MITIGATOR®
Engineered AC Mitigation System
[phone]
[e-mail]
matcor.com
REGIONAL OFFICES
OK 405 293 9777
PA 215 348 2974
TX-Gulf 682 666 2128
TX-West 832 755 2714
LA/MS-Gulf 225 828 7987
WY 307 401 2534
MATCOR Rectier Test Record
RECTIFIER MODEL NO.
SERIAL NO.
MECHANICAL & VISUAL INSPECTION
UNIT COMPLETE PER PARTS LIST
PARTS SECURELY FASTENED
WIRING CORRECT PER DIAGRAM
GENERAL APPEARANCE
ELECTRICAL TEST
AC INPUT VOLTAGE (RATED): ______VOLTS ______AMPS
AC INPUT VOLTAGE (ACTUAL): ___RMS VOLTS ___PHASE
AC INPUT CURRENT (ACTUAL): ______RMS AMPS
AC INPUT APPARENT WATTS (V x A): ______WATTS
POWER FACTOR ON WATT METER: __________
AC INPUT ACTUAL WATTS (V x A x P.F.): _____WATTS
DC RATED VOLTAGE: _______________VOLTS
DC OUTPUT VOLTAGE: _______________VOLTS
DC RATED CURRENT: _______________AMPS
DC OUTPUT CURRENT: _______________AMPS
DC OUTPUT POWER: _______________VA
CONVERSION EFFICIENCY: _____%
INSPECTED BY:
TESTED BY:
Date
AC
Watts
DC
Volts
DC
Amps
DC
V.A. % Eff.