H.v Rectifier Device Use Manual

50
GGAJ02JHB ESP H.V Rectifier Device Use Manual DA LIAN JIA HE INDUSTRIAL CONTROL TECHNOLOGY CO.,LTD.

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Transcript of H.v Rectifier Device Use Manual

  • GGAJ02JHB

    ESP H.V Rectifier Device Use Manual

    DA LIAN JIA HE INDUSTRIAL CONTROL TECHNOLOGY CO.,LTD.

  • Safety manual The manual includes installation, commissioning, operation.The meaning of the mark you

    must understand clearly blow:

    DANGER It will result in death, serious harm to life or significant property damage,if you do not take preventive measures.

    WARNING It may result death, serious harm to life or significant property damage,if you do not take preventive measures.

    CAUTION It mar result light harm to life or property damage,if you do not preventive measures. ATTENTION Attention to the important information of the product and Specific parts.

    Qual i f ied staff Only trained and qualified personnel should be allowed to install and operate the

    equipment. Qualified personnel must compliance with safety practices and eligible to

    install, debug, transport, repair, mark for the circuit and equipments.

    Correct Application Notice below:

    DANGER The device and its components can only be used to our product.

    The product performs their functions correctly and safely only through correct transport,

    restore, install and running, repairing by our proposed steps.

    Safety Notes

    Warning Non-associated ESP staff to prohibit the operation of this equipment

    I

  • DANGER

    Before you start the divice,please make sure there was no peoplein side the ESP body , HV switchgear and transformer and related system was on the correct stations,and the

    staff of power supply were evacuated Safety.

    WARNING Forbidding operating the main breaker after starting the device

    DANGER Please cut off power supply before Commissioning. ATTENTION Read the instruction manual before installation, commissioning, operation, repairing,

    and understand every part of the information.

    All Rights Reserved Dalian jiahe industrial control technology CO.,LTD.copyright 2008,All rights

    reserved.Without the express written authorization is prohibited to copy, transfer or use

    of the manual or its contents.Rights reserved, including the right to retain all the patents,

    utility models exclusive.

    Solemnly Declare We have checked this with the contents of the manual referred to in line with the

    hardware and software, but mistakes do happen and can not guarantee exactly the

    same. The manual will be reviewed on a regular basis and in the next edition of the

    amendment, welcome to suggest improvements.

    WARNING Not to read and understand the information provided in this statement

    may cause personal injury, product damage or bad operations. To start

    with, or any steps before the operation, please read the complete

    chapter, and make sure to understand each chapter and section of the

    information.

    II

  • Foreword The purpose

    This manual is designed to provide GGAJ02-JHB ESP high-voltage rectifier equipment

    included H.V control cabinets, rectifier transformers, high voltage switchgear

    separation of functions and instructions. In the appendix gives the wiring-related

    equipment, size, electrical schematics.

    The readers This manual written for the operation and design staff of ESP device is applied to have

    the necessary basic knowledge of electrical system or learn more about ESP

    knowledge of the following persons:

    z ESP installation, commissioning, maintenance, operation and maintenance personnel.

    z In the field of management, sales staff.

    Attention In the appendix of the chart gives only part of the specifications of the equipment size

    and technical parameters For other specifications of the technical information, please

    contact our company.

    Address: No.41 torch road, High-tech zone, Dalian City

    Zip Code: 116023

    Phone: 0411-84799990

    Fax: 0411-84795956

    Web: http://www.jiahegy.com

    E-mail: [email protected]

    III

  • JHB ESP H.V rectifier device use manual

    Contents

    1 OVERVIEW .............................................................................................................................1

    1.1 PRODUCT FEATURES ..........................................................................................................1

    1.2 THE MAIN PURPOSE............................................................................................................2

    1.3 THE SCOPE OF APPLICATION................................................................................................2

    1.4 PRODUCT MODEL ...............................................................................................................3

    1.5 PRODUCT SPECIFICATIONS..................................................................................................3

    1.5.1 60KV and 66KV device capability .................................................................................4

    1.5.2 72KV and 80KV device capability .................................................................................5

    1.5.3 90KV and 100KV device capability ...............................................................................6

    1.6 WRKING ENVIRONMENT ......................................................................................................7

    1.7 WORKING CONDITIONS .......................................................................................................7

    2 STRUCTURE AND WORKING PRINCIPLE...........................................................................8

    2.1 THE WHOLE STRUCTURE AND WORKING PRINCIPLE...............................................................8

    2.2 H.V CONTROL CABINET STRUCTURE AND WORKING PRINCIPLE ..............................................9

    2.2.1 main loop ....................................................................................................................10

    2.2.2 Control loop ................................................................................................................10

    3 TECHNICAL CHARACTERISTICS.......................................................................................16

    3.1 MAIN CHARACTERISTICS ...................................................................................................16

    3.1.1 Control method ...........................................................................................................16

    3.1.2 Equipment soft start function ......................................................................................17

    3.1.3 Current limit control.....................................................................................................17

    3.1.4 High-impedance transformer ......................................................................................17

    3.1.5 LCD display ................................................................................................................17

    3.1.6 History fault information query ....................................................................................18

    3.1.7 Communication Network.............................................................................................18

    3.1.8 Analog output .............................................................................................................18

    3.1.9 Reliability design.........................................................................................................18

    3.2 MAIN PARAMETERS...........................................................................................................19

    4 DIMENSION AND WEIGHT ..................................................................................................21

    4.1 H.V. CONTROL CABINET ....................................................................................................21

    4.1.1 GGAJ02-JHB-2...........................................................................................................21

    4.1.2 GGAJ02-JHB-D ..........................................................................................................22

    4.2 H.V. RECTIFIER TRANSFORMER .........................................................................................22

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  • JHB ESP H.V rectifier device use manual

    4.2.1 Outdoors kind .............................................................................................................23

    4.2.2 Indoor kind..................................................................................................................25

    4.3 H.V. ISOLATION SWITCH CABINET .......................................................................................27

    4.4 CONNECTION BETWEEN TRANSFORMER AND H.V. ISOLATION SWITCH CABINET .....................28

    5 INSTALLATION AND DEBUGGING.....................................................................................29

    5.1 INSTALLATION CONDITION AND TECHNICAL REQUIRMENT......................................................29

    5.2 INSTALLATION METHOD .....................................................................................................29

    5.3 INSTALLATION CHECKING...................................................................................................30

    5.4 DEBUGGING EQUIPMENT...................................................................................................32

    5.5 OPERATING EQUIPMENT ...................................................................................................32

    5.5.1 Debugging of Dummy Load ........................................................................................32

    5.5.2 Debugging of Electric Field.........................................................................................33

    5.5.3 Power supply in parallel of two high voltage units.......................................................33

    5.5.4 Debugging for transformers tap .................................................................................34

    6 USE AND OPERATION ........................................................................................................35

    6.1 READY FOR USE AND SECURITY.........................................................................................35

    6.2 OPERATE EQUIPMENT .......................................................................................................35

    6.2.1 Startup and stop..........................................................................................................35

    6.2.2 CON panel ..................................................................................................................36

    6.2.3 Management purview is divided into three grades......................................................38

    6.2.4 Equipment common fault ............................................................................................39

    6.3 EQUIPMENT MONITOR AND RECORD ...................................................................................39

    7 FAILURE ANALYSIS AND TROUBLESHOOTING ..............................................................40

    8 EQUIPMENT MAINTENANCE AND LIFTING ......................................................................41

    8.1 MAINTENANCE OF UNIT .....................................................................................................41

    8.2 REPAIR OF UNIT................................................................................................................41

    8.3 PROCEDURES FOR HANGING CORE OF OUTDOOR TRANSFORMER ........................................42

    8.4 LIFTING EQUIPMENT .........................................................................................................42

    9 ORDER NOTICE...................................................................................................................43

    9.1 UNIT CAPACITY, SPECIFICATIONS AND MODEL......................................................................43

    9.2 INLET AND OUTLET DIRECTIONS OF HIGH-VOLTAGE ISOLATION SWITCH CABINET...................43

    9.3 OTHER SPECIAL REQUIREMENTS.......................................................................................43

    10 ANNEX A ..............................................................................................................................44

    V

  • JHB ESP H.V rectifier device use manual

    1 Overview

    With modern industrial development, increasing environmental pollution, environmental protection

    is receiving increasing attention from all sectors of society and the importance of industrial gas

    pollution is a major source of environmental pollution, ESP as the prevention of industrial pollution

    in an effective way to Industrial emissions, through the provision of H.V electrostatic precipitator

    body, making the body through the flue gas ionization occurred, and charged dust in force under

    the electric field to a collecting campaign to re-use device for collecting dust. The collection has

    been widely used in electric power, metallurgy, building materials industries.

    ESP usually include ontology and control equipment consists of two parts, the ontology is the

    closed room for Industrial emissions dust through,it is a workplace for ESP, anode and

    cathode-ray board is an important part of the body, when the HV power supply to the anode and

    cathode-ray, there will be an Electric field between the Anode and cathode-ray, it makes the flue

    dust ionizate,the ionizating dust will moving to collecting board (cathode-ray board). The H.V

    control device suplly H.V DC power and such control for ESP. The H.V control device usually

    include H.V control cabinet and L.V control cabinet, H.V control by H.V rectifier device, include H.V

    control cabinet, H.V rectifier transformer, H.V switchgear, it responsible for ontology with power

    suplly, L.Vcontrol device incude L.V control cabinet and related executing agency, it responsible

    for ontology bolew: cathode rapping, anode rapping, porcelain axis heating, porcelain set heating,

    de-dust control etc.

    GGAJ02-JHBreferred to as JHBESP H.V rectifier control device was developed on the base of WA and JHA product, it has greatly improved in the real-time control, communicate,

    human-operation.

    1.1 Product Features GGAJ02-JHB ESP H.V rectifier device has the following characteristics:

    z The CPU of the main control board is an ARM 32bit processor, main frequency is 44MHz, the instruction speed is 22ns.

    z Use 5.7-inch LCD display, operation simple and parameters show in detail. z Communicate supports CAN and RS485. z Both software and hardware have self-test function. z Low voltage rapping function, Energy Conservation. z Two loops standard 4-20mA output, choice once current/voltage, secondary

    current/voltage.

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  • JHB ESP H.V rectifier device use manual

    z Use watchdog design, to protect the CPU beyond death at any situation. z All I / O ports, communications ports are over-current, over-voltage protection. z With the calendar clock. z Power isolation design, enhance system reliability. z Current and voltege signal use high-speed sampling after isolation, wave clearly, spark

    detecyion and control in a timely manner.

    z Main loop, safety lock, run/stop, trigger power locked by hardware and software, to ensure the mistake does not trigger the SCR trigger.

    z Synchronous signal detection has anti-jamming design and phase compensation by hardware and software, to ensure the accuracy of detection.

    z Hardware over current detection and software voer current detection are independent of each other, to ensure reliable detection of over-current.

    z Use high impedance transformer, to improve the output voltage waveform, to avoid short-circuit load, the spark breakdown at the time of the impact of over-current.

    z Soft start design, to avoid rapid step-up equipment on the impact. z Support automatic / manual mode step-up, in auto mode, set the Current primary, the

    voltage secondary, the turn-on angle setting, turn-on angle to limit the maximum value at

    the same time to participate in the four control, with a current limit control features.

    z Secondary current display, real-time secondary voltage curve display, V-I sampling curve display.

    z Failures history inquiry, include the type of fault and Failure happened time. z Data history inquiry, include primary current, primary voltage, secondary current,

    secondary voltage.

    1.2 The main purpose GGAJ02-JHB ESP H.V rectifier device should match ontology, it provides ontology with H.V DC

    power, for industrial gas purification, it was a very important device.

    1.3 The scope of application GGAJ02-JHB ESP H.V rectifier device should match ontology, applies to the following range:

    z Electric power industry: the boiler flue dust. z Metallurgical industry: black, non-ferrous metal smelting of dust, metal smelting materials

    recycling.

    z Building materials: industry cement, the production of refractory materials in the dust

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  • JHB ESP H.V rectifier device use manual

    removal and recycling of raw materials.

    z The chemical industry demist, dedust and recycling the useful components of the Industrial emissions dust.

    z Petrochemical industry: separate the salt, water or other impurities from crude oil. z Textile industry: recycling the alkali in the proccing of textile production and dedust. z Paper-making industry: recycling the alkali in the proccing of paper-making production

    and dedust.

    z Other Industry: clean air.

    DANGER Forbid to use this product other than the ESP system.

    1.4 Product model The product model of H.V rectifier device as follows:

    GGAJ02XX A / XX KVJHB2DHWN The product composition and significance as follows:

    duct specifications deviding as its rating secondary voltage

    2HW, it is mean :

    G G AJ 02XX A / XX KVJHB2DH WN W: Outdoor Transformer N : Indoor Transformer

    Syncytial Transformer H.V cabinet hight 2: Hight: 2000mm D: Hight: 2200mm Product design code Rating voltage, unit: kV Rating current, unit: A SCR regulate voltage Cooling by oil inside For the H.V occasion Diode rectifier current

    1.5 Product specifications GGAJ02-JHB H.V rectifier device Pro

    and rating secondary current,it is the capability of the device,Rating voltage is divided into six

    level :60KV,66KV,72KV,80KV,90KV,100KV,Each level H.V rectifier transformer has three wiring

    poles:A-X1,A-X2,A-X3,There are three different secondary voltage ouput.Rating current is from

    0.1A to 2.0A step 0.1A. For example as follows:

    Product model is :GGAJ021.0 A / 72 KVJHBz Rating secondary voltage is 72KV

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    z Rating secondary current is 1.0A

    1.5.1 60KV and 66KV device capability ice capability as shown in table 1

    60KV 66KV

    GGAJ02-JHB H.V rectifier device 60KV and 66KV dev

    Table 1 60KV and 66KV device capability

    capability

    Primary current wer V V-1cable Primary current wer V V-1 cableUnit:AA

    Input po

    KVA mm2 A Input po

    KVA mm2 0.1 23 8.7 216 25.3 9.6 216

    0.2 46 17.5 216 50.6 19.2 225

    0.3 69 26.2 225 75.9 28.8 235

    0.4 92 35 235 101 38.4 250

    0.5 115 43.7 250 126 47.9 270

    0.6 138 52.4 270 152 57.8 295

    0.7 161 61.2 295 177 67.3 295

    0.8 184 69.9 2120 202 76.8 2120

    0.9 207 78.7 2120 227 86.3 2 2501.0 230 87.4 2 250 253 96.1 22701.1 2 2 60.8 99.1 2270 86.9 109 22701.2 276 104.9 2270 304 115.5 22951.3 3 08.2 117.1 2295 339 128.8 22951.4 322 122.4 2295 355 134.9 22951.5 345 131.1 2295 380 144.4 221201.6 368 139.8 2295 405 153.9 221201.7 403 153.1 22120 4 43.3 168.5 221501.8 414 157.3 22120 456 173.3 221501.9 4 4 50.5 171.2 22150 95.5 188.3 221852.0 460 174.8 22150 506 192.3 22185

    Secondary (K econdary ( voltage V) S current A)

    Wiring A-X1 A-X2 A-X3 A-X1 A-X2 A-X3

    Voltage 60 54 48 66 60 54

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    1.5.2 72KV and 80KV device capability GGAJ02-JHB H.V rectifier device 72KV and 80KV device capability as shown in table 2

    V device capability

    72KV 80KV

    Table 2 72KV and 80K

    capability

    Unit A Primary current A

    t

    power

    V V-1cable

    mm2 Primary current

    A

    t

    power

    V V-1

    cable

    Inpu

    KVA

    Inpu

    KVA mm20.1 27.6 10.5 216 31.6 12 216

    0.2 55.2 21 225 63.2 24 225

    0.3 82.8 31.5 235 94.8 36 250

    0.4 110 41.8 126.4 250 48 270

    0.5 138 52.4 270 158 60 295

    0.6 166 63.1 295 189.7 72.1 2120

    0.7 193 73.3 2120 221.6 84.2 2 2500.8 221 84 2 2 250 253 96.1 2700.9 249 94.6 2 270 284.5 108.1 2 2701.0 276 104.9 316.1 120.1 2 270 2 2951.1 312.9 1 18.9 2 295 347.7 132.1 2 2951.2 331 125.8 2 295 2 379.3 144.1 2 1201.3 369.8 140.5 2 295 2 410.9 156.1 2 1201.4 386 146.7 2 1202 442.5 168.2 221501.5 414 157.3 2 1202 474.2 180.2 221501.6 442 168 22150 505.8 192.2 221851.7 483.6 183.8 22150 537.4 204.2 221851.8 497 188.9 22185 569 216.2 321201.9 540.5 205.4 22185 600.6 228.2 321202.0 552 209.8 22185 632.2 240.2 32150

    Secondary volt KV Secondary curre KV age nt Wiring A-X1 A-X2 A-X3 A-X1 A-X2 A-X3

    Volt 72 64 56 80 72 64 age

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    1.5.3 90KV and 100KV device capability GGAJ02-JHB H.V rectifier device 90KV and 100KV device capability as shown in table 3

    device capability

    100KV

    Table 3 90KV and 100KV

    90KV

    capability

    Unit A Primary current A

    t

    power

    V V-1cable

    mm2 Primary current

    A

    power

    V V-1cable

    mm2

    Inpu

    KVA

    Input

    KVA0.1 35 13.3 216 38.5 14.6 225

    0.2 70 26.6 225 77 29.2 235

    0.3 105 39.9 250 116 44.1 270

    0.4 140 53.2 154 58.5 270 295

    0.5 175 66.5 295 193 77.3 2120

    0.6 210 79.8 2120 2150 231 87.8

    0.7 245 93.1 2 2 270 270 102.6 2700.8 280 106.4 2 2 270 308 117 2950.9 315 1 19.7 2 295 347 131.8 2 2951.0 350 133 2 295 2 385 146.3 2 1201.1

    1.2 420 159.6 2 2 120 462 175.5 221501.3

    1.4 490 186.2 22150 539 204.8 221851.5 525 199.5 22185 578 219.6 321201.6 560 212.8 32120 616 234 321201.7

    1.8 630 239.4 32150 693 263.3 321501.9

    2.0 700 266 32150 770 292.6 32185 Secondary voltageKV Secondary currentKV

    Wiring A-X1 A-X2 A-X3 A-X1 A-X2 A-X3

    Volt 72 100 80 age 90 80 90

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  • JHB ESP H.V rectifier device use manual

    1.6 Wrking environment

    here are no Conductive, gas, corrosion metal and the gas or

    steam damaged insulation around.

    +40

    0, not less then the condensate temperature of

    3 Relative 4 Altitude:

    If you want the product works in the special environment, please order with

    1.7 Wo

    hase 380V/400V 10%

    2 Power frequence: 50Hz 2% or 60Hz 2% 3 Anti-vibration and tilt: No strong vibration and shock, the vertical gradient is less than 5 , HV Switchgear need reliable ground, in

    If you want the product works in the special conditiont, please order with manufacturer

    1 Air condition: make sure t

    2 Wrking temperature:

    z H.V control cabinet: -10 z H.V rectifier transformer: below +4

    tranformer oiliness.

    humidity: 85%.

    2000m

    ATTENTION

    manufacturer links.

    rking conditions

    1 Input AC power: single-p

    4 The H.V control cabinet, H.V rectifier transformer

    any climate, the grounding resistance must below 2.

    ATTENTION

    links.

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    2 Structure and working principle

    2.1 The whole Structure and working principle

    The whole structure of JHB H.V rectifier device includes three ports: H.V control cabinet, H.V

    rectifier transformer, H.V switchgear, the working princple is shown in picture 1.

    Picture 1 JHB H.V rectifier device working princple

    After the power (AC 380V) through the main breaker (QF1) of the H.V control cabinet, it had been

    regulated voltage by anti-parallel SCR (V1, V2), re-export to the high-voltage rectifier transformer

    primary ciol, through the high-voltage transformer rectifier boost, after transform rectifier, a

    negative high-voltage output in the secondary, and then through the high-voltage switchgear and

    isolation body connected to the body in order to supply the electric field. The H.V control cabinet

    control the trigger of SCR (V1 and V2), and then control the input voltege of tranformer, tranformer

    suplly ontology changes of the voltage.

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    2.2 H.V control cabinet Structure and working principle

    H.V control cabinet as a whole is the core of JHB-H.V rectifier device,and CON is a core of H.V

    control cabinet,it is the Central processing unit.H.V control cabinet include mian loop and control

    loop two ports,main loop include main loop unit,main loop Copper row and protection

    device,control loop includesignal board,trigger board,signal smpling board,CON unit,control loop

    power,relay unit,Service circuit.

    The H.V control cabinet working princple as shown in picture 2.

    a. Front b. front inside c. Main loop unit d. back e. back inside

    Picture 2 H.V control cabinet Structure

    24 25

    12

    26 27

    28 29

    31 3233

    30

    1

    34

    16

    37 15 4

    36 1920

    17

    18 14

    23

    13

    67

    8

    5

    38 9

    222

    213

    10

    35

    11

    1. Main loop unit 2. Input copper row 3. Ouput copper row

    Control loop

    4. Main breaker QF1 5. SCR models 6. RC absorption resistance

    7. RC absorption Capacitance 8. SCR heat sink 9. Input protect device

    10. Output protect device 11.heat sink fan

    12. CON 13.Signal and trigger unit 14.Relay unit

    15.Control loop breaker QF2 16.Fuse 17.TR.TC1380:220 18.TR.TC2220:15 19. 24V power supply 20.Control power box Main loop

    21. Current transformer 22.voltage sampling TR 23.Secondary sampling unit

    24. Primary ammeter 25. Primary voltage meter 26.Secondary ammeter

    27. Secondary voltage meter 28. Failure light 29.main loop power on light

    30. Alarm 31. Start button 32. Stop button

    33. Local / manual switch 34.Grounding row 35.Grounding pole

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    36. Lighting 37. Overhaul power socket 38.Dust defend cover

    2.2.1 main loop The power supply (AC380V) connects to the copper row (L1 and L2), through main breaker QF1, it

    had been regulated voltage by anti-parallel SCR (V1, V2), SCR connect to H.V rectifier

    transformer at primary side by the out wire. There is a RC absorptiondevice In parallel on SCR, the

    device can absorpte peak voltage and protect SCR.There are two Varistors (RV1 and RV2) at

    input /output, they absorpte peak voltage above 1000V. It usually has a compensate resistance

    then the capability is bolew 0.5A, it used to maintain a fixed current for SCR. Heat sink and fan for

    cooling SCR.

    2.2.2 Control loop 1 Signal conditioning and trigger unit Signal conditioning and triggers unit is used to smply primary current, primary voltage, and

    hardware over-current detection, the unit also sends the trigger signal from the CON unit to trigger

    pulse transformer isolation after output in order to trigger the SCR V1 and V2.

    2 Primary current sampling After a main loop current transformer sampling, 0~5A output signal to trigger and signal

    conditioning unit, then the 0~5A signal changed into two groups 0~250mA signal by

    current-reduce transformer, one group signal used for over-current detection by hardware, another

    group signal is rectified and chaged into DC current signal, the DC current signal flows in the

    sampling resistance and then get a 0~300mV voltage signal, input the CON unit.

    3 Primary voltage sampling The ouput voltage of SCR connect to transformer TC3, then the voltage reduce to 0~11V voltage

    signal, the signal input the signal conditioning and triggers unit, after choke coils and full-wave

    rectifier, voltage separate resistance, we get a 0~300mV signal into the CON unit.

    4 Hardware over-current detection Signal conditioning and trigger unit has a hardware over-current detection circuit, it detects the

    primary current, if the current is over the rating value, the relay KD4 power on, and the main loop

    breaker QF1 will be released by its solenoid coils, QF1 disconnect, power supply cut off to protect

    the device. The switch signal of over-current input the CON unit at the same time, in order to CON

    unit detecting.

    5 SCR trigger driver 10

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    Signal conditioning and trigger unit receive two groups trigger signal form CON unit, after pulse

    transformer isolation, driver the SCR V1 and V2, controlled the output voltage.

    6 Secondary signal sampling unit This unit sampling signal secondary current, secondary voltage, sampling resistance R25 and R26

    in parallel, this circuit changes the secondary current to 0~300mV voltage signal, and then the

    signal input CON unit. The secondary voltage sampling resistance R27 with the resistance RM

    voltage divided to be carried out 0~300mV of the second sample voltage signal, input CON unit.

    The diode 1N5408 of the sampling unit as same as the diode of the diode unit, the protective effect

    of diode make you away from H.V, avoid danger, the secondary signal sampling unit install inside

    the H.V control cabinet, the diode protectin unit install at the output of H.V rectifier transformers

    secondary signal sampling.

    7 Control loop power supply AC400V power connect from power grid, through breaker QF2 and fuse FU1, FU2, connect to TR.

    TC1, TC1 ouput two groups AC220V power, one is the H.V control cabinet, fan, solenoid coils,

    relay KA1 and KA2s power supply. Another is the control power box, DC24V power, and CON

    analog circuits units power supply.

    Control power box output three groups power, include AC15V, AC12V AC and DC12V .AC15V

    suppply power for signal conditioning and trigger unit. AC12V supply power for CON digital part,

    communicate part and DA ouput part. DC12V supplies power for trigger circuit between CON

    trigger part and trigger unit from signal conditioning and trigger unit. Three sets of power are

    mutual isolation.

    DC24V supply power for relay unit (KD1-KD6,K A3), CON switch I/O part (fault input, safety switch

    input, alarm ouput, start/stop output).

    TC2 supply AC15V power, AC15V is the power of CON analog circuits, phase and synchronous

    signal also comes from the power.

    8 CON unit

    CON is the control core of the H.V control cabinet, when the control loop power is on, CON analog

    circuits produces phase and synchronous signal, and sends it to the CON digital circuit, CPU of

    the CON digital circuit sampling the primary current, primary voltage ,secondary current secondary

    voltage signal by A/D converter at the same time.and then press start button,the H.V control

    cabinet start, CON according to the pre-set parameters and feedback signals, closed loop

    feedback-controll, CPU calculates the trigger turn-on angle next cycle wave, timings the trigger

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  • JHB ESP H.V rectifier device use manual

    angle and to control the SCR trigger signal, and then control the output voltage of SCR. CON can

    detectes the spark happened in the ontology field by feedback signal, when the spark happening,

    the programme get into spark closed loop feedback-controll. CON includes 5 ports, analog circuits

    part, digtal part, trigger part, communicate and D/A output part, switch I/O signal part, all of the

    parts using isolation design, CON working princple is shown in picture 6.

    1) Analog circuits part

    Primary current, primary voltage, secondary current, secondary voltage, turbidity sampling signals

    deal with input filtering and amplification RMS filter, for AD conversion, in order to calculation of

    RMS and turbidity control, at the same time, primary current, secondary sampling signal had been

    amplified and filtered before linear optocoupler, the signal ouput of linear optocoupler connect to

    the control CPU, using the CPU high-speed AD conversion to converse primary current,

    secondary voltage, control CPU use the data of the result to detect spark. Besides, phase and

    synchronous signal also comes from the power analog circuits.

    2) Digital ciicuit part

    CON use double 32-bit ARM CPU, LPC2132 and LPC2129,both main frequence is 44MHz, 22ns

    command speed, LPC2132 used to control voltage output ,LPC2129 used to control LCD, key,

    communicate networks and HMI, as well as historical data storage, calendar clock count.

    LPC2132 control spark by the signal of primary current and secondary voltage sampling,support

    spark rate set.support manual/automatic control model, at automatic model, control with the value

    primary current set, secondary voltage set, trigger angle set,max trigger angel set at same time,

    has current limit control. CPU and detect H.V rectifier transformer faut, ontology field faut, device

    faut and also can protect the system by cutoff the related power, fault for exampleontology field

    open circuit, short circuit, abnormal excitation, oil temperature high, oil Limits temperature, limits

    gas, light gas, oil serface has safety lock function, in order to ensure personal safety.when the fault

    happend, there will generate a report to store.

    LPC2129 control a 5.7-inch LCD, LPC2132 and the LCD communicate data, LCD display the

    running data, support history fault Query and history data store, 32K primary current /voltage,

    secondary current/voltage data store space.

    3) Trigger unit

    The trigger unit of CON power supply seperate, LPC2132 send trigger pulse signal to isolation

    Optocoupler, the output signal of isolation optocoupler into MC1413, and then into signal

    conditioning and trigger unit, then through pulse transformer the signal get into SCR finally, two

    loops trigger output have over-voltage protect.

    12

  • JHB ESP H.V rectifier device use manual

    13

    4) Communicate and D/A unit

    Support CAN bus and RS485 communication, the highest rates of CAN bus is 500Kbps, the

    highest rates of RS485 is 115.2Kbps, support the standard communication protocol Modbus

    ASCII/RTU, have 2 loops Isolated analog output, output 4~20mA signal, the signal can choose

    primary current /voltage, secondary current/voltage.

  • JHB ESP H.V rectifier device use manual

    14

    Filtering enlarge

    Filtering enlarge

    Filtering enlarge

    Filtering enlarge

    U1

    I1

    U2

    I2 RMS filter

    RMS filter

    RMS filter

    RMS filter

    AD

    converters

    2.5V Precision power

    Optocoupler

    Linear Optocoupler

    Turbidity Filtering enlarge

    CPU

    LPC2132

    Optocoupler

    Main loop Safety lock Over-current Oil temperature

    Oil surface Light gas R-V rapping

    trigger shield

    Optocoupler Trigger output1 Trigger output2

    Optocoupleranalog switches

    Output filtering

    DA output1 DA output2

    CPU

    LPC2129

    3.3V Battery

    Toggle switchBK2

    JTAG

    2.5V Precisionpower

    Reset MAX809

    LED

    Key

    LCD

    High-speedOptocoupler

    CAN busMCP2551

    CAN COM

    High-speedOptocoupler

    RS485 MAX485

    RS485

    Toggle switch

    JTAG

    Optocoupler

    Output drive

    Ready Run/Stop Fault alarm Start Stop rip output

    Spark T

    Analog partDigital part

    Trigger part

    Commnucition and DA

    TR. 12V input

    voltage regulator

    Precision powerSPX1117-3.3V

    Precision powerSPX1117-1.8V

    +5V

    +3.3V

    +1.8VDigital power

    voltage regulator

    +5V-5V

    Analog power

    voltage regulator

    +5VDA and COM

    power

    voltre

    age gulator

    AC220V input +24V

    Digital outputpower

    I/O part

    picture 6 CON working princple

    I/O port

    DA Communication and

  • JHB ESP H.V rectifier device use manual

    5) Switch I/O signal unit

    The signal of this unit includes H.V rectifier transformer fault, start/stop input etc, and alarm,

    control output etc. DI has a hardware filter can effectively prevent the jitter signal. The control

    output and alarm output are perfect over-current over-voltage protection.

    9 Relay unit This unit has a number of relay, include ready, alarm output, over-curent, start, stop etc, it makes

    the wiring inside cabinet easy.

    10 Auxiliary circuit This part incudes cooling fan M1 and M2, coil excitation of main breaker, lighting, AC220V power

    outlet, lighting and overhaul outlet power supplied by L>V control cabinet.

    15

  • JHB ESP H.V rectifier device use manual

    3 Technical characteristics

    3.1 Main characteristics

    3.1.1 Control method CON support Sparks track, spark rate track, turbidity feedback, reduce-voltage rapping control

    model etc.

    1) Sparks track model

    When ontology field produce spark breakdown, in order to avoid short-current, cutoff the SCR,

    quickly restored to 90% of the original breakdown voltage at several cycle-wave, and then

    approach the original breakdown voltage slowly, the characteristics are called second-line spark

    track, this model of control is a very good approach to the restoration of media curve, and also

    guarantes the maximum output power.

    2) Sparks rate track model

    CON controls spark rate at setting spark rate.

    3) Reduce-voltage rapping

    H.V control cabinet and L.V control cabinet works together, when rapping, the PLC cabinet(L.V

    control cabinet) sends a signal to H.V control cabinet, if the CON of H.V control cabinet detects the

    signal of rapping, it reduces the output voltage by controlling SCR, and when the rapping over, it

    restorate voltage to original value.

    4) Turbidity feedback control

    In order to achieve the concentration of gas emissions required by environmental protection

    departments of the concentration of dust emission standards, and also can reduce power

    consumption as much as possible, CON with the dust concentration monitor support for achieving

    the concentration of dust on the closed-loop control.

    5) Fualt running

    Debugging equipment, by setting the master switch with dial code, the device can run a short

    period of time with the fault which includes open-circuit running and short-current runnig. When

    open-circuit, equipment detects open-circuit failure, only the alarm, non-stop machine. When

    short-current, equipment detects short-current failure, only the alarm, non-stop machine. At the

    same time equipment allow running at short-current and open-circuit, but in any case, rquipment

    will detect over-current, if over-current, alarm, stop equipment immediately, and drive coil

    excitation, make the main breaker cut off.

    By setting, equipment can also run on a current rating of 110% and 115% both cases.

    16

  • JHB ESP H.V rectifier device use manual

    The equipment has sef-test function, when the control power on, it will detect A/D converter,

    current and voltage signal sampling, transformer failure, the main circuit connection, the security

    chain of 5 parts of the self-test hardware, the programme will sef-test the parameters of Flash

    ROM store, only software and hardware self-test success, the equipment can start .

    3.1.2 Equipment soft start function Our machine can soft start, and angle of trip pin largen gradully during the system power on,

    voltage promote, voltage drop, rapping, recover and other normal voltage promote process, it

    makes voltage largen gradully, and this process avoids system damaged by voltage promote

    rapidly, increase the voltage from 0 to rating, that is mean increase trigger angle from 0 to 153, it

    needs 10 seconds, when the trigger angle greater than or equal to 27, SCR begin to work.

    3.1.3 Current limit control Ontology field short-current,breakdown sparksmake the current sharp rise, in order to make it no

    more than ratings, to take control of the current limit, to ensure that in any case conditions, the

    second largest of the current restrictions limit the rating of its equipment to ensure safe and stable

    operation of equipment.

    3.1.4 High-impedance transformer In order to avoid short-current, caused by the breakdown spark of equipment over-current shocks,

    and to improve the rectifier output voltage waveform, to increase power corona, H.V transformer

    rectifier high-impedance design, the impedance of transformer is 35%~40%, H.V rectifier

    transformer silicon avalanche high-pressure reactor using silicon reactor, the ability to shock, the

    reverse will automatically resume after breakdown.

    3.1.5 LCD display The equipment uses 5.7-inch 320240 LCD,built-in LCD controller there is a 512K byte, font ROM code, you can display Chinese fonts, the number of symbols, such as letters and Britain on

    owen, and also a two page display cache. In the text mode, to receive the standard Chinese

    language code directly to display Chinese without having to enter the graphics mode to the

    drawing depicts it can greatly save time for the microprocessor to improve the efficiency of liquid

    crystal display Chinese characters. LCD screen is simple, rich show, it has data display in time,

    V-A sampling, Historical data, Historical fault, sef-test, run parameters set, real-time data

    calibration, product mamual, contact the company a total of 8 major categories show, In-time data,

    real-time display screen can show primary current, primary voltage, secondary current, secondary

    17

  • JHB ESP H.V rectifier device use manual

    voltage, trigger angle, spark rate, trigger angle set, spark rate set, run state, control model,

    calendar clock, etc. and show the secondary current, secondary voltage curve.

    3.1.6 History fault information query CON can see the history of fault information, including the history and types of failures occur at all

    times, 32K flash can also be stored historical data, each time record of 30 minutes, can be

    recorded successive 85 days of data, include primary current, primary voltage, secondary current,

    secndary voltage, after the overflow storage, now data will cover the earliest data, and can view

    historical data curve.

    3.1.7 Communication Network The device supports CAN bus and RS485 comunication, the highest rates of CAN bus is 500Kbps,

    the highest rates of RS485 is 500Kbps is 115.2Kbps, supports the standard communication

    protocol Modbus ASCII/RTU, the median data, parity check, stop bits, and other communications

    format can be set up.

    3.1.8 Analog output CON has two loops analog output, it output 4~20mA standard signal, send content is two of

    primary current,primary voltage,secondary current, secondary voltage signal, when connect with

    control, it can avoid the use of separate transmitter.

    3.1.9 Reliability design Various measures have been adopted to improve the reliability of the H.V rectifier device.

    z H.V rectifier transformer, H.V control cabinet has called for a reliable connection with the earth, groud resistance must be below 4, and connect with ontology grouding.

    z All of secondary signal sampling hava protection by diode, the protection diode prevents the string of High-voltage into the control cabinet, secondary sampling signal

    transmission by RVVP Shielding wire.

    z CON design using watchdog to ensure that the CPU is not under any circumstances death.

    z All of the I/O port and commnication port have over-current and over voltage protection. z All of the Power supply design, analog, digital, communications and so on, the part of the

    power to trigger are mutual isolation.

    z Main loop switch, safety lock, start/stop, trigger power supply has hardware lock, to ensure the mistake does not trigger SCR.

    18

  • JHB ESP H.V rectifier device use manual

    z Synchronous signal detection has multiple anti-jamming designs and phase compensation, and a combination of hardware and software to ensure the accuracy of

    detection.

    z Hardware and software over-current detect independent of each other, ensure over-current detect reliable, when it is over-current,the main loop breaker QF1 will cut off.

    3.2 Main parameters 1) Input voltage: 380V 10%.

    2) Power supply frequence: 50Hz 2% or 60Hz 2%.

    3) Output voltage: 0~100% rating voltage

    4) Output current: 0~100% rating current

    5) Trugger angle : 0~153

    6) Spark rate set: 10 times /min ~ 120 times/min

    7) Communication ports: CAN bus port and RS485 port.

    8) Communicate rate:

    z CAN bus:the highest rates of CAN bus is 500Kbps z RS485:support 1200 bps,2400 bps,4800 bps,9600 bps,19200 bps,38400bps,57600

    bps,115200 bps

    9) Working model: Allows continuous operation under the rating current.

    10) Cooling: Cabinet cooling by air, H.V rectifier transformer cooling by oil inside.

    11) Protection level: the Protection level of control cabinet is IP52, the protection level of

    H.V rectifier transformer is IP54.

    12) H.V rectifier transformer parameters

    z Input voltage : 0 ~ AC400V z Output voltage: Rating DC voltageUnit:KVis 60,66,72,80,90,100. z Output voltage: Rating output current Unit:Ais 0.1, 0.2, 0.3, 0.4, 0.5, 0.6,

    0.7, 0.8, 1.0, 1.2, 1.4, 1.6, 1.8, 2.0

    z Impedance of the voltage: 30%~40% z Transformer Oil : 25# oil ,pressure value more then 40KV/2.5mm. z Sampling resistance: secondary voltage is 5.00K,Secondary current is 2.00K. z Negative H.V to grouding: the value of positive resistance is zero, the negative

    resistance is 52/65/78 M.

    z Insulation resistance: Primary side to grouding : 100M

    19

  • JHB ESP H.V rectifier device use manual

    Secondary side to grouding : 100M Primary side to Secondary side : 100M

    13) H.V control cabinet structure: cold-used steel structure, surface electrostatic spray,

    power connect Copper row at the top of cabinet use standard GGD.

    14) National Institute of Standards: the product JB/T 9588-1999 ESP H.V Rectifier Device

    National Standard.

    20

  • JHB ESP H.V rectifier device use manual

    4 Dimension and weight

    4.1 H.V. control cabinet

    According to the height, the H.V. control cabinets can be separate into two kinds: GGAJ02-JHB-2

    and GGAJ02-JHB-D.

    4.1.1 GGAJ02-JHB-2 Dimension: 600mm 600mm 2000mm, refer to figure 15. Weight :200kg For cable input

    Diagram 15: dimensions diagram of GGAJ-JHB-2

    21

  • JHB ESP H.V rectifier device use manual

    4.1.2 GGAJ02-JHB-D Dimension: 600mm 600mm 2200mm, refer to diagram 16. For bus bar input

    Diagram 16 Outline dimension diagram of GGAJ02JHB-D H.V. control cabinet

    4.2 H.V. rectifier transformer According to the position installed to,the H.V. rectifier transformer can be seperated into indoors

    kind and outdoors kind.

    22

  • JHB ESP H.V rectifier device use manual

    4.2.1 Outdoors kind According to the different capicity, the outdoors H.V. rectifier transformer has different dimension

    and weight, and the dimensions of 60KV and 72KV outdoors rectifier transformer is showed as

    diagram 17.

    1) flat wheel and rail wheel can be replaced by the other as well,and the angle of veer can be 90 degree.

    235KV standard porcelain is needed in some dirty areas. Diagram 17 outline dimension of 60KV and 72KV outdoors rectifier transformer

    335KV enhanced porcelain is needed in some heavy dirty areas. 4The length of 35KV standared is 495mm,and 582mm for the enhanced ones.

    Fig.17 Dimensions of 60KV and 72KV outdoors rectifier transformer

    The outline dimension of 60KV and 72KV outdoors H.V. rectifier transformer can be separate into

    total 7 kinds of Ab, Aa, A, B, C, D, E according to the rated secondary current. And the detailed

    23

  • JHB ESP H.V rectifier device use manual

    data is showed in table 4, please contact us if you have the requirements for the dimension of

    transformer of other capacity.

    Table 4 dimension of 60KV and 70KV outdoors H.V. rectifier transformer

    Capacity Main dimension (unit mm) Weight(unit :Kg)

    Class current

    A voltage

    KV a b c D H h G W T Total

    wight

    Oil

    weight

    Core

    weight

    2.0 60 72

    1.9 72

    1.9 72 Ab

    1.7 72

    750 888 1660 252 1320 800 1720 980 820 2000 950 700

    1.9 60

    1.8 60

    1.7 60

    1.6 60 72

    1.5 60 72

    1.4 72

    Aa

    1.3 72

    650 800 1100 150 1320 800 1695 880 720 1520 660 600

    1.4 60

    1.3 60

    1.2 60 72

    1.1 60 72

    A

    1.0 72

    650 800 1100 150 1220 800 1595 880 720 1400 660 650

    1.0 60

    0.9 60 72

    0.8 60 72 B

    0.7 72

    650 800 1100 150 1170 800 1545 880 720 1250 550 430

    0.7 60

    0.6 60 72

    0.5 60 72 C

    0.4 72

    560 750 950 100 1070 650 1405 830 670 1000 450 340

    0.4 60 D

    0.3 60 72 560 710 910 100 940 650 1275 790 630 800 350 250

    0.2 60 72 E

    0.1 60 72 560 660 748 120 940 650 1275 740 580 600 290 210

    24

  • JHB ESP H.V rectifier device use manual

    4.2.2 Indoor kind The dimension and weight of indoor H.V. rectifier transformer differs according to the different

    capacity, and the dimension of 60KV and 70KV transformer is as diagram 18 shows.

    Fig.18 Dimensions of 60KV and 72KV outdoors rectifier transformer

    The outline dimension of 60KV and 72KV indoor H.V. rectifier transformer can be separate into

    total 7 kinds of Ab, Aa, A, B, C, D, E according to the rated secondary current as well. And the

    detailed data is showed in table 5, please contact us if you have the requirements for the

    dimension of transformer of other capacity.

    25

  • JHB ESP H.V rectifier device use manual

    Table 5 dimension of 60KV and 72KV rectifier transformer

    Capacity Main Dimension (unit: mm) Weight (unit :Kg)

    Clas

    s curren

    tA voltage

    KV a b c H F W T Total

    weigh

    t

    Oil

    weigh

    t

    Core

    weigh

    t

    2.0 60 72

    1.9 72

    1.9 72 Ab

    1.7 72

    75

    0

    90

    0

    120

    0

    132

    0

    191

    0

    98

    0

    82

    0 2000 950 700

    1.9 60

    1.8 60

    1.7 60

    1.6 60 72

    1.5 60 72

    1.4 72

    Aa

    1.3 72

    65

    0

    80

    0 1100

    132

    0

    191

    0

    88

    0

    72

    0 1520 660 600

    1.4 60

    1.3 60

    1.2 60 72

    1.1 60 72

    A

    1.0 72

    65

    0

    80

    0 1100

    122

    0

    181

    0

    88

    0

    72

    0 1400 660 560

    1.0 60

    0.9 60 72

    0.8 60 72 B

    0.7 72

    65

    0

    80

    0 1100 1170

    176

    0

    88

    0

    72

    0 1250 550 430

    0.7 60

    0.6 60 72

    0.5 60 72 C

    0.4 72

    56

    0

    75

    0 950

    107

    0

    166

    0

    83

    0

    67

    0 1000 450 340

    0.4 60 D

    0.3 60 72

    56

    0

    71

    0 910 940

    149

    0

    79

    0

    63

    0 800 350 250

    0.2 60 72 E

    0.1 60 72

    56

    0

    66

    0 748 940

    149

    0

    74

    0

    58

    0 600 290 210

    26

  • JHB ESP H.V rectifier device use manual

    4.3 H.V. isolation switch cabinet The H.V. isolation switch cabinet is uses for connecting the output of transformer to the discharge

    pole,and the dimension of it is as diagram 19 shown.

    Fig.19 Dimension diagram of H.V. isolation switch cabinet

    Inlet and outlet directions of high-voltage isolation switch cabinet When the rectifier adopts the

    outdoor mode ,the high-voltage isolation switch cabinet should be ordered in addition .And when

    ordering the high-voltage isolation switch cabinet, please clarify its inlet and outlet directions .Here

    27

  • JHB ESP H.V rectifier device use manual

    are the styles of inlet and outlet directions:

    z Side in and back out: right in and back out, left in and back out. z Side in and lower out: right in and lower out, left in and lower out z Side in and side out: right in and left out, left in and right out. z Back in and side out: back in and right out, back in and left out. z Back in and lower out.

    Fig.20 Connection between transformer and H.V. isolation switch cabinet

    4.4 Connection between transformer and H.V. isolation switch cabinet The connection diagram is just as Figure 20 shown, please contact us if need more information.

    28

  • JHB ESP H.V rectifier device use manual

    5 Installation and debugging

    5.1 Installation condition and technical requirment 1 Installation condition z The construction unit should master tne structure, performance, technical file, the

    dimension and connection of H.V. control cabinet, H.V. rectifier transformer, H.V. isolation

    switch cabinet as well, and finally make out a scheme of installation.

    z Check the amount of device according to the delivery list of GGAJ02-JHB H.V. rectifier device.make sure there is no any part missed.

    z All the electrical and insulator products like porcelain, cables, electronics switches should take the experiment of voltage endurance and insulation.

    z The installation site should be hree on and one off (water on, electricity on, road on, ground level off), and possess the device of fireproof, anti freeze, waterproof and so on.

    z Reinforced concrete base and support should be checked out with the anti-pressure experiment before device installation.

    2 Technical requirment GGAJ02-JHB H.V. rectifier units installing technology obeys the state standard.

    5.2 Installation method 1 Inlet mode of H.V. control cabinet The inlet mode of H.V. control cabinet has two ways: up busbar inlet and down cable inlet,

    GGAJ02-JHB-2 (2000mm height) adapts down cable inlet mode, while the GGAJ02-JHB-D

    (2200mm height) adapts up busbar inlet mode.

    2 Installation of H.V. rectifier transformer The H.V. rectifier transformer can be separated into two kinds: indoor and outdoors, and the

    installation method for each one is as follows:

    z Indoor kind: the surroundings should keep at least 1m away from the H.V. output terminal.

    z Outdoors kind: plus the H.V. isolation switch cabinet through which the H.V. rectifier transformer output terminal connects with the discharge pole of case.

    3 Wiring

    29

  • JHB ESP H.V rectifier device use manual

    The selection of cable and on-site wiring connection of unit should carry on according to

    and Instruction of Unit

    Connecting in the Instruction Manual. The sampled signal of secondary current and secondary

    voltage must be connected with screened cable. The screened layer should be well earthed at the

    rectifier terminal and the control cabinet terminal. The direct-current resistance of the conducting

    wire should not be larger than 2, while the wire size should not be smaller than 1.5 mm2.

    4 Unit earthing The earthing of the control cabinet, high voltage rectifier and the case must be surely earthed. The

    operation earthing must be connected with precipitator case through the special ground wire.

    Connection line shouldnt be smaller than 16 mm2.

    5 Installation of damping resistance The damping resistance can be installed inside the high voltage isolation switch cabinet when the

    transformer is installed outdoors. And when the transformer is installed indoors, the damping

    resistance can be installed at the high voltage entrance of precipitator.

    5.3 Installation checking All the lines should be checked after installation to find out whether they are well connected, or the

    electric devices are broken.

    1 Apparatus instrument, and tools z Oscillograph z multi-meter z common electrical tools z two incandescent bulbs(220/100w) for dummy load testing z 2500VMmeter z static bar and static electric meter

    2 Check for Controlling Cabinet z Whether the appearance is damaged, or if there are any foreign matters in the cabinet.

    whether the components and circuit boards are lost. whether the lines and contacting

    points are loose or sealed off. whether the connector assembly is firmly connected, or if

    the screws and nuts are tightened, or if there are any damage to the indicating gauge.

    Screw up the loose screws and parts with spanner or screwdriver.

    z Whether the device body is earthed and what its resistance is.

    30

  • JHB ESP H.V rectifier device use manual

    3 Check and Meterage for Transformer 1) Check z Whether the power lines, sampling lines and temperature signal lines are connected

    correctly.

    z Whether the casing of transformer is connected to the casing of electrostatic precipitator firmly. The transformer end and the earth should be connected with ground line of 16mm2 at least.

    z Whether the transformer has oil leakage phenomenon or whether all parts of insulating rubber ring is complete or aging.

    z Whether there are damages in the large and small insulators. z Whether the binding post is loose. z Whether the oil level is normal. z Take down the breather lid of transformer.

    2) Measurement z Negative high voltage output to earth: forward: 0. adverse: 523M(60/66/72

    KV), 654M(80KV). (Measured with 2500VM meter) z UH2 To earth : 6.670.3K. (Measured with multi-meter) z IH2 to earth: 20.1K. (Measured with multi-meter) z The resistance of terminal A to X1,X2,X3 :

  • JHB ESP H.V rectifier device use manual

    standards and specifications, or if the value of earth resistance confirms to the standard

    (

  • JHB ESP H.V rectifier device use manual

    not available to relieve)

    2) Warning Test for Open Circuit

    Hang up the negative high-voltage output terminal of rectiformer, and the unit should alarm in the

    event of boosting after start-up. And then the light of trouble of precipitator shines, alarm bell

    rings, the unit stops and the V9 light on the master control board shines. Press reset button AJ1

    to disarm the bell.

    3) Warning Test for Short Circuit

    Make the high-voltage isolation switch at grounding position, and the unit should alarm in the

    event of boosting after start-up. Meanwhile, the light of trouble of precipitator shines, alarm bell

    rings, the unit stops and the V10 light on the master control board shines. Press reset button AJ1

    to relieve the bell.

    5.5.2 Debugging of Electric Field 1) Debugging of empty field (before throw-in of fume)

    At first ,adopt manual boosting mode. After the voltage has boosted up to the rating value, adjust

    the adjustment boards potentiometer of secondary voltmeter in the cabinet according to the

    indicated value of static-electricity meter in order to make the indicated value of secondary

    voltmeter on the cabinet door the same as the value of the the static-electricity meter. In case

    there is no static-electricity meter at site,adjust it by the means of efficiency calculation.

    2) Loading OperationAfter throw-in of fume z Make sure that the low-voltage control unit normal before throw-in of fume. z The heater should be put into operation 8 hours before supply of high-voltage from

    high-voltage unit.

    The procedures for power-on and power-off are the same as above-mentioned. (In the event of

    long-term operation, the unit should be operated under the mode of automatic control except for

    special operating conditions on site).

    5.5.3 Power supply in parallel of two high voltage units In the event of boosting in the empty field, the current value of unit is correspondingly bigger due to

    the resistance of the air in the electric field is less than the magnitude of the resistor. If the current

    of unit exceeds the rated capacity while the secondary voltage does not reach the specified

    requirement,then can make two units supply power in parallel according to the site situation (After

    connecting the high-voltage output terminals of the two rectiformers, only supply power to one

    electric field). When power is on, try to supply the same phase power in order to avoid the

    33

  • JHB ESP H.V rectifier device use manual

    transformers circulation. while boosting, make slow sync boosting to avoid damage to the unit

    caused by surcharge of single unit.

    5.5.4 Debugging for transformers tap If the transformation ratio tap is selected too high, electrostatic precipitator may run in a small

    angle of current flow for a long term. Then the efficiency of dust precipitation will be reduced and

    the resistance of transformer to shock will also be weakened. On the contrary, if the transformation

    ratio tap is selected too low, although the controlled silicons angles of current flow are all opened,

    the output voltage of rectiformer can not reach the puncture voltage of the electric field. Therefore

    it can also cause the voltage, current and the corona power in the electric field reduced. Through

    altering transformation ratio tap of transformer, we can improve the ratio between peak value and

    valid value as well as supply waveform, enhance supply efficiency, reduce the strike to unit and

    disturbances to electricity net, and lower primary current and the depreciation in the loop.

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    6 Use and operation

    6.1 Ready for use and security The equipment must be according to 5.3 section of inspection to finish to check the installation , if

    the installation results accord with the requirements, after according to 5.4 section of inspection to

    finish to debug the equipment, including debug to light load , equipment failure , test alarm, load

    test (including debug the empty electric field and load Debugging), if the results of debugging

    accord with request that can use to operate the equipment.

    WARNING Check whether high-voltage isolation switch is closed before supply, and it is prohibited to operate high-voltage isolation switch after operation.

    ATTENTION Its not allowed for the equipment to be operated in the empty load or open circuits condition that avoid over-voltage to destroy equipment.

    DANGER Prohibit to operat the air switch QF1 after start-up equipment.

    DANGER Must obey principal order and forbid presume to give power or cut power , must affirm nobody in electric field before run equipment

    ATTENTION Must inform principal to manage all people away from dust when give power. Operators should strengthen safety consciousness and strict administer to according

    to operation steps.

    6.2 Operate equipment

    6.2.1 Startup and stop When equipment want startup and stop that the same as 5.4.1 section to operate, Concrete steps

    are as follows:

    Startup equipment, operation order

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  • JHB ESP H.V rectifier device use manual

    1) Check control loop of the equipment and the air switch keep cut state such as QF2 and

    QF1

    2) When open the air switch QF2 small air switch, LCD screen will display 3) When open the air switch QF1 big air switch,the light of the door will lignt green. 4) Push the button startup on the door to run equipment.

    Stop equipment, operation order

    1) Push the button stop on the door to stop equipment. 2) QF1.cut the air switch QF1

    3) Cut the air switch QF2,stop done with.

    6.2.2 CON panel CON panel include LCD screen, key-press, LED display ,such as picture 21

    ENT

    REAL

    INC_U

    ESC

    UP DEC_U

    LEFT DOWN RIGHT

    5.7

    / POWER / RUN / LOCK / SPARKCAN

    RS485

    Fig.21 The panel of Controller

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  • JHB ESP H.V rectifier device use manual

    1 LCD screen CON use 5.7 inch LCD screen, Chinese characters, display Resolution 320 240

    2 Key-Press CON have nine keys, respectively:

    ENT

    ENT: use input to enter

    ESC

    ESC: use input to esc or returu above menu.

    REAL: press the real key to enter real data monitoring, process date monitoring,when

    the current menu is the real data monitoring,press the key ,then enter work mode,set

    RC amend.

    REAL

    INC_U: when run equipment,press this key one time (key button), RC value add

    one,turu-onangle value add one degreesmost 153 degrees,And then increase the voltage. continued press the button 1s (L button),one key per 200ms effective, RC value

    add one, Until button put up.when equipment is stop, this key is invalid.

    INC_U

    DEC_U: when run equipment,press this key one time (key button),,RC value minus

    one,,turu-onangle value minus one degreesleast zero degrees, and then lower the voltage continuous press the button 1s (L button),one key per 200ms effective,RC

    value minus one,Until button put up. When equipment is stop, this key is invalid.

    DEC_U

    UPUP: cursor move cursor up or data entry.

    DOWN

    DOWN: cursor move cursor down or data entry

    LEFT

    LEFT: cursor move cursor left or data entry.

    RIGHT

    RIGHT: cursor move cursor right or data entry.

    3 LED light

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  • JHB ESP H.V rectifier device use manual

    CON have six LED lights:

    Power light: when open QF2 of control loop, CON have power, light / POWER Run light: when start up equipment, when run normal, run light will light. / RUN Lock light: when open H.V Switchgear, when run low-voltage control cabinet,

    safety chain have effective signal, lock light will light.

    / LOCK

    Spark light: when CON judge spark breakdown, spark light will light. / SPARK CAN communication light: two-color indicator light, when CAN communicate, when

    receive data, then red light will light.when send data, then green light will light.

    CAN

    RS485 communication light: two-color indicator light, when RS485 communicate,

    when receive data, then red light will light.when send data, then green light will be light.

    RS485

    6.2.3 Management purview is divided into three grades 1) Operator purview

    z Purview is bigger,it can operate equipment normally, usually scene operators have this purview.

    z Operator can carry out operation, including set system model, RC settings, RC limited value, turbidity settings, spark rate settings, I1upper limit settings, U2 upper

    limit settings, system language, system time, communication baud rate,

    communications formats, communication protocols, LCD backlight time, etc.,Voltage

    step-up, step-down, start, stop and so on .

    2) Administrator purview

    z The purview has the largest rights, which can manage and operate equipment normally. The administrator has this purview.

    z Administrator can operate all equipment, another, also it can set default operating parameters, the parameters of the system back up and restore the system

    parameters, the failure to delete information, delete historical data, calibration data,

    data retention, and other operations.

    3) Super administrator purview

    z Purview is biggest,it can manage and operate equipment complete, usually manufacturer's technical staff have super powers Management

    z Super administrator can operate all equipment, also it can set I2 rating, U2 rating. Different operatore purview has different operational authority distinguished through the password.

    All operating systems set three way to enter your password, If input a different password that all

    operator purview will different.

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    1) When set the operating parameters screen, such as Figure 32. move the cursor to the

    "default value" option.If the system needs to set the default operating parameters,you

    must input password

    2) When set the system parameters screen, such as Figure 41. Move the cursor to "set the

    system password" option, please input the password, after input the correct password,

    administrators can back up the system parameters and restore the system parameters,

    delete failure information, delete operation historical data,super-administrator can also

    set I2 and U2 rating rating.

    3) When set real-time picture data, such as Figure 41. Move the cursor to "save data" option,

    if need to preserve all the calibration data, it must be input password, administrator and

    super administrator can carry out the calibration data and save.

    6.2.4 Equipment common fault When equipment works, the usual faults include:

    z The sampling line of secondary current signal and sampling line of secondary voltage signal on the contrary

    z Signal line of High-voltage rectifier transformer control cabinet and the signal line high-voltage did not corresponding

    z Oecondary current signal of High-voltage rectifier transformer with transformer shell, whether the dust catcher enter into earth.

    z Over High-voltage rectifier transformer rated running. z Equipment usually run empty field state, it easy damage transformer. z Equipment usually run short circuit state, it easy damage transformer.

    6.3 Equipment monitor and record

    Users according to actual situation ,regular inspection equipment and record data when electric

    field happen open circuit, Electric short-circuit, over-current devices, silicon-excitation, transformer

    oil temperature super-cap, ultra-high surface of transformer oil and so on ,it induce alarm and

    bounce brake, record the reason of fault ,in order to repair.

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    7 Failure analysis and troubleshooting

    Equipment failure and rule out common method as shown in table 6.

    Table 6 Equipment failure and rule out common approach Failure

    phenomenon Troubleshooting

    Equipment can not start

    1) Check the air control loop switch is connected to QF2 2) Check control power ,whether voltage output is normal

    DC12V,AC12V,AC15V 3) Check CON voltage whether that is 24V. 4) Check switch QF1 of circuit whether is closed 5) Check CON Self-inspect whether overpass 6) Check security chain signals whether validity 7) Check the main circuit connected signal whether validity 8) Check relay unit start-up link such as figure 1,including the relay start KD1,

    the relay KA1 contact, contact KD2 relay, relay contacts KD3, as well as start button SB1 and wiring terminal controller JHB

    9) Check trigger of CON whether give power 10) Open the CON door ,check short-chain whether right 11) Replacing JHB CON to test

    Equipment does not start

    after the step-up

    1) Check RC limit of turn-on angle and RC settings set whether are less than 27 degree.

    2) Check power phase of the control loop whether reversal phase 3) Check CON and signal conditioning and 12V DC of trigger whether up to

    snuff 4) Stop equipment, cut switch QF1, check the connection between trigger

    circuit and SCR, consult figure 1 to analyse. 5) Replacing JHB CON to test

    Instant access on the main circuit output

    voltage

    1) Cut switch QF1 of main loop immediately. 2) Cut switch QF2 of main loop 3) Check Kai-point of relay KD1 whether disconnect normal. 4) Use multimeter to measure resistance of SCR whether breakdown. 5) Replacement two V1 and V2 of SCR.

    Other equipment

    failures

    If the device have trouble in other place ,you can test false load , specific methods to consult section 5.4.2

    Transformer Fault

    High-voltage rectifier transformer has been tested before leave factory , failure probability will less,if think transformer trouble, specific methods to consult section 5.4.2 to test ,and message us .

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  • JHB ESP H.V rectifier device use manual

    8 Equipment maintenance and lifting

    8.1 Maintenance of unit

    1) A month to deal with high-pressure control cabinet, high-voltage rectifier transformers for

    electrical lines to inspect the terminal interface cable link any loosening.

    2) Wipe the control cabinet and high-voltage rectifier once a month, and clean the

    high-voltage casing pipe and renewal or recover desiccant.

    3) The transformer oil should be 25# oil in case of no special requirements. Make a

    withstand voltage test of transformer oil per six months, requiring experimental voltage

    average larger than 40KV/2.5mm,If fail, it would take to replace filter or high-pressure

    rectification Baptist internal transformer oil.

    4) Every 6 months to deal with high-pressure control cabinet,high-voltage rectifier

    transformers,high voltage switchgear isolation and dust collector body to conduct a

    ground resistance measurement, requiring that their resistance should be less than 2.

    5) Every 6 months should be a measurement of high-voltage rectifier transformer insulation

    resistance, the resistance of the insulation resistance should be in line with the

    requirements of Table 7.

    6) Keep the cabinet door airtight and ensure the cooling fan operate normally.

    8.2 Repair of unit

    DANGER After energization for the unit, follow the full-time principals instructions, do not supply

    or cut off power without authorization.

    DANGER When repairing components, break off firstly, confirm them without electricity by multi

    meter, electroprobe and so on. It is advisable to detect with the back of fingers, and

    then begin to repair.

    DANGER When checking and repairing in the electric field, break off all high or low voltage unit

    power. Cut off all connections between high-voltage output terminals of rectifier and

    electric fieldand the electric field should be earthed well.

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  • JHB ESP H.V rectifier device use manual

    DANGER After electric fields earth through high-voltage isolation switch, connect the cathodic

    frame and body casing with wire or conductor at the manhole door when entering into

    electric field.

    8.3 Procedures for hanging core of outdoor transformer

    Equipment maintenance check, when the need for hanging on the transformer core test, the

    following steps should be carried out:

    1) Lower the oil level until the distance between it and the handhole cover located at the upside

    of the high-voltage protective cover become at least 100mm, then open handhole cover and

    remove the negative high-voltage tie wires. Now open the upper cover and hanging core is

    permitted.

    2) When being inspected, the sojourn time (counting from the moment of leaving oil level) of unit

    body:

    z In the air should be no more than 12 hours if the air relative humidity is less than 75%. z No more than 16 hours if the air relative humidity is less than 65%.

    3) After hanging core, check whether fasteners on each part are loose, whether loops hold down,

    whether leading wires break off and whether the joints between the components of

    high-voltage rectifier and other electronic devices are dependable. Check whether

    high-voltage silicon rectifier stacks crack or break off. Check whether the connectings of all

    parts like the high-voltage leading wires, other outlets etc. and whether the insulation distance

    of other components confirm to the requirement.

    4) The puncture voltage of packaged or unpackaged transformer oil has to be no less than

    40KV/2.5mm.

    WARNING High-voltage transformer suspended operation of the transformer core itself may have

    an adverse effect on the operation must be cautious.

    8.4 Lifting Equipment

    z Hoisting equipment to be hanging on both sides of the equipment of the four hooks. z Handle with care when lifting equipment, to avoid rattling. z High-voltage transformer rectifier heat sink can not be collisions with other objects, or

    even deformation caused by oil spill.

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    9 Order notice

    9.1 Unit capacity, specifications and model

    z Designate the unit capacity, i.e. secondary rated current and secondary rated voltage. z Designate the inlet mode of power supply for control cabinet, i.e. the height of control

    cabinet. When the cabinet height is below 2m, it uses down cable inlet. When the cabinet

    height is over 2.2m, it uses upper bus inlet.

    z Designate the installation position of the high-voltage rectifying transformer, i.e. indoor mode or outdoor mode.

    z In case of outdoor mode, the high-voltage isolation switch cabinet should be added in corresponding quantity.

    9.2 Inlet and Outlet Directions of High-voltage Isolation switch cabinet

    When ordering the high-voltage isolation switch cabinet, please clarify its inlet and outlet directions.

    Import and export orientation can generally be classified into the following.

    z Side in and back out :right in and back out ,left in and back out. z Side in and lower out :right in and lower out,left in and lower out z Side in and side out :right in and left out,left in and right out. z Back in and side out :back in and right out,back in and left out . z Back in and lower out.

    9.3 Other Special Requirements

    For other special requirements, both parties can enter into technical agreement by means of fax or

    other forms. Company Contact

    Company Name: DALIAN JIAHE INDUSTRIAL CONTOL TECHNIQUE CO.,LTD.

    Company Address: High-tech park in Dalian torch route 41

    Zip Code: 116023

    Technical Services: 0411-8479 9990

    Business Advisory: 0411-8479 9993

    Fax: 0411-8479 9992

    Company Web site: http://www.Jiahegy.com

    Email: [email protected]

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  • JHB ESP H.V rectifier device use manual

    10 Annex A

    Current sampling, damping resistance, currentLimiting resistance

    Unit Capacity A Current Sampling

    R11() Samping Resistance

    CurrentLimiting Resistance

    0.1 2.7//2.7 180/800W 1000/500W

    0.2 0.68 180/800W 1000/500W

    0.3 0.5//4.3 180/800W 1000/500W

    0.4 0.68//0.68 180/800W 1000/500W

    0.5 0.5//0.5 180/800W 1000/500W

    0.6 0.2 180/800W 500/800W

    0.7 0.2//4.3 180/800W 500/800W

    0.8 0.2//1 180/800W 500/800W

    0.9 0.2//0.68 180/800W 500/800W

    1.0 0.18//0.5 180/800W 500/800W

    1.2 0.2//0.2 180/800W 300/1000W

    1.4 0.18//0.2 180/800W 300/1000W

    1.5 0.18//0.18 150/1000W 300/1000W

    1.6 0.15//0.18 150/1000W

    1.8 0.15//0.15 150/1000W

    2.0 0.13//0.13 150/1000W

    Measured Value of Insulation Resistance of Transformer

    Negativehigh-handed Output-to-

    Voltage Rank Forward Adverse

    UH2-to- IH2 -to-

    Primary-to-Crust Secondary-to-ShellOnce -to-Shell

    60,66,72 0 52M 80 0 65M 90,100 0 78M

    6.67K 2K 100M

    44