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.

Qualified 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

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: ESP installation, commissioning, maintenance, operation and maintenance personnel. 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: Zip Code: Phone: Fax: Web: E-mail: No.41 torch road, High-tech zone, Dalian City 116023 0411-84799990 0411-84795956 http://www.jiahegy.com jiahe@jiahegy.com

III

JHB ESP H.V rectifier device use manual

Contents
1 OVERVIEW .............................................................................................................................1 1.1 1.2 1.3 1.4 1.5 PRODUCT FEATURES ..........................................................................................................1 THE MAIN PURPOSE ............................................................................................................2 THE SCOPE OF APPLICATION................................................................................................2 PRODUCT MODEL ...............................................................................................................3 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 1.7 2 WRKING ENVIRONMENT ......................................................................................................7 WORKING CONDITIONS .......................................................................................................7

STRUCTURE AND WORKING PRINCIPLE ...........................................................................8 2.1 2.2 THE WHOLE STRUCTURE AND WORKING PRINCIPLE ...............................................................8 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 4 MAIN PARAMETERS ...........................................................................................................19

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
IV

JHB ESP H.V rectifier device use manual 4.2.1 Outdoors kind .............................................................................................................23 4.2.2 Indoor kind ..................................................................................................................25 4.3 4.4 5 H.V. ISOLATION SWITCH CABINET .......................................................................................27 CONNECTION BETWEEN TRANSFORMER AND H.V. ISOLATION SWITCH CABINET .....................28

INSTALLATION AND DEBUGGING .....................................................................................29 5.1 5.2 5.3 5.4 5.5 INSTALLATION CONDITION AND TECHNICAL REQUIRMENT ......................................................29 INSTALLATION METHOD .....................................................................................................29 INSTALLATION CHECKING ...................................................................................................30 DEBUGGING EQUIPMENT...................................................................................................32 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 6.2 READY FOR USE AND SECURITY .........................................................................................35 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 7 8 EQUIPMENT MONITOR AND RECORD ...................................................................................39

FAILURE ANALYSIS AND TROUBLESHOOTING ..............................................................40 EQUIPMENT MAINTENANCE AND LIFTING ......................................................................41 8.1 8.2 8.3 8.4 MAINTENANCE OF UNIT .....................................................................................................41 REPAIR OF UNIT ................................................................................................................41 PROCEDURES FOR HANGING CORE OF OUTDOOR TRANSFORMER ........................................42 LIFTING EQUIPMENT .........................................................................................................42

ORDER NOTICE...................................................................................................................43 9.1 9.2 9.3 UNIT CAPACITY, SPECIFICATIONS AND MODEL ......................................................................43 INLET AND OUTLET DIRECTIONS OF HIGH-VOLTAGE ISOLATION SWITCH CABINET ...................43 OTHER SPECIAL REQUIREMENTS.......................................................................................43

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

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: The CPU of the main control board is an ARM 32bit processor, main frequency is 44MHz, the instruction speed is 22ns. Use 5.7-inch LCD display, operation simple and parameters show in detail. Communicate supports CAN and RS485. Both software and hardware have self-test function. Low voltage rapping function, Energy Conservation. 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 Use watchdog design, to protect the CPU beyond death at any situation. All I / O ports, communications ports are over-current, over-voltage protection. With the calendar clock. Power isolation design, enhance system reliability. Current and voltege signal use high-speed sampling after isolation, wave clearly, spark detecyion and control in a timely manner. Main loop, safety lock, run/stop, trigger power locked by hardware and software, to ensure the mistake does not trigger the SCR trigger. Synchronous signal detection has anti-jamming design and phase compensation by hardware and software, to ensure the accuracy of detection. Hardware over current detection and software voer current detection are independent of each other, to ensure reliable detection of over-current. 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. Soft start design, to avoid rapid step-up equipment on the impact. 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. Secondary current display, real-time secondary voltage curve display, V-I sampling curve display. Failures history inquiry, include the type of fault and Failure happened time. 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: Electric power industry: the boiler flue dust. Metallurgical industry: black, non-ferrous metal smelting of dust, metal smelting materials recycling. 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. The chemical industry demist, dedust and recycling the useful components of the Industrial emissions dust. Petrochemical industry: separate the salt, water or other impurities from crude oil. Textile industry: recycling the alkali in the proccing of textile production and dedust. Paper-making industry: recycling the alkali in the proccing of paper-making production and dedust. 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: 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 Product specifications deviding as its rating secondary voltage 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 KVJHB2HW, it is mean : Rating secondary voltage is 72KV

3

JHB ESP H.V rectifier device use manual Rating secondary current is 1.0A

1.5.1 60KV and 66KV device capability

GGAJ02-JHB H.V rectifier device 60KV and 66KV device capability as shown in table 1 Table 1 60KV
Primary current Input power V V-1cable Primary current

60KV and 66KV device capability 66KV

Input power V V-1 cable

capability Unit:A A 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 23 46 69 92 115 138 161 184 207 230 260.8 276 308.2 322 345 368 403 414 450.5 460

KVA 8.7 17.5 26.2 35 43.7 52.4 61.2 69.9 78.7 87.4 99.1 104.9 117.1 122.4 131.1 139.8 153.1 157.3 171.2 174.8

mm 216 216 225 235 250 270 295 2120 2120 2250 2270 2270 2295 2295 2295 2295 2 2120 2 2120 2 2150 2 2150

A 25.3 50.6 75.9 101 126 152 177 202 227 253 286.9 304 339 355 380 405 443.3 456 495.5 506

KVA 9.6 19.2 28.8 38.4 47.9 57.8 67.3 76.8 86.3 96.1 109 115.5 128.8 134.9 144.4 153.9 168.5 173.3 188.3 192.3

mm2 216 225 235 250 270 295 295 2120 2250 2270 2270 2295 2295 2295 2 2120 2 2120 2 2150 2 2150 2 2185 2 2185 (A) A-X3 54

Secondary voltage (KV) Wiring Voltage A-X1 60 A-X2 54 A-X3 48

Secondary current A-X1 66 A-X2 60

JHB ESP H.V rectifier device use manual

1.5.2 72KV and 80KV device capability

GGAJ02-JHB H.V rectifier device 72KV and 80KV device capability as shown in table 2 Table 2 72KV capability Unit A Primary current A 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 27.6 55.2 82.8 110 138 166 193 221 249 276 312.9 331 369.8 386 414 442 483.6 497 540.5 552 Input power KVA 10.5 21 31.5 41.8 52.4 63.1 73.3 84 94.6 104.9 118.9 125.8 140.5 146.7 157.3 168 183.8 188.9 205.4 209.8 V V-1cable mm2 216 225 235 250 270 295 2120 2250 2270 2270 2295 2295 2295 2 2120 2 2120 2 2150 2 2150 2 2185 2 2185 2 2185 Primary current A 31.6 63.2 94.8 126.4 158 189.7 221.6 253 284.5 316.1 347.7 379.3 410.9 442.5 474.2 505.8 537.4 569 600.6 632.2 72KV and 80KV device capability 80KV Input power KVA 12 24 36 48 60 72.1 84.2 96.1 108.1 120.1 132.1 144.1 156.1 168.2 180.2 192.2 204.2 216.2 228.2 240.2 V V-1 cable mm2 216 225 250 270 295 2120 2250 2270 2270 2295 2295 2 2120 2 2120 2 2150 2 2150 2 2185 2 2185 3 2120 3 2120 3 2150

Secondary voltageKV Wiring Voltage A-X1 72 A-X2 64 A-X3 56

Secondary currentKV A-X1 80 A-X2 72 A-X3 64

JHB ESP H.V rectifier device use manual

1.5.3 90KV and 100KV device capability

GGAJ02-JHB H.V rectifier device 90KV and 100KV device capability as shown in table 3 Table 3 90KV capability Unit A Primary current A 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 700 266 3 2150 770 292.6 3 2185 630 239.4 3 2150 693 263.3 3 2150 490 525 560 186.2 199.5 212.8 2 2150 2 2185 3 2120 539 578 616 204.8 219.6 234 2 2185 3 2120 3 2120 420 159.6 2 2120 462 175.5 2 2150 35 70 105 140 175 210 245 280 315 350 Input power KVA 13.3 26.6 39.9 53.2 66.5 79.8 93.1 106.4 119.7 133 V V-1cable mm2 216 225 250 270 295 2120 2270 2270 2295 2295 Primary current A 38.5 77 116 154 193 231 270 308 347 385 90KV and 100KV device capability 100KV Input power KVA 14.6 29.2 44.1 58.5 77.3 87.8 102.6 117 131.8 146.3 V V-1cable mm2 225 235 270 295 2120 2150 2270 2295 2295 2 2120

Secondary voltageKV Wiring Voltage A-X1 90 A-X2 80 A-X3 72

Secondary currentKV A-X1 100 A-X2 90 A-X3 80

JHB ESP H.V rectifier device use manual

1.6 Wrking environment

1 Air condition: make sure there are no Conductive, gas, corrosion metal and the gas or steam damaged insulation around. 2 Wrking temperature: H.V control cabinet: -10 +40

H.V rectifier transformer: below +40, not less then the condensate temperature of tranformer oiliness. 3 Relative humidity: 85%. 4 Altitude: 2000m

ATTENTION
If you want the product works in the special environment, please order with manufacturer links.

1.7 Working conditions

1 Input AC power: single-phase 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 4 The H.V control cabinet, H.V rectifier transformer, HV Switchgear need reliable ground, in any climate, the grounding resistance must below 2.

ATTENTION

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

JHB ESP H.V rectifier device use manual

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.

JHB ESP H.V rectifier device use manual

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.
24 25 26 27 37 15 4

28 12 31

36 30 16 29 17 1 18 32 14 33 34 23 5 13

38 6 7 22 8

19 20 9 2 21 3 11 10

35

a.

Front Control loop Main loop

b. front inside

c. Main loop unit 2. Input copper row 5. SCR models 8. SCR heat sink 11.heat sink fan 13.Signal and trigger unit 16.Fuse 19. 24V power supply 22.voltage sampling TR 25. Primary voltage meter 28. Failure light 31. Start button 34.Grounding row
9

d.

back

e. back inside

Picture 2 H.V control cabinet Structure 1. Main loop unit 4. Main breaker QF1 7. RC absorption Capacitance 10. Output protect device 12. CON 15.Control loop breaker QF2 18.TR.TC2220:15 21. Current transformer 24. Primary ammeter 27. Secondary voltage meter 30. Alarm 33. Local / manual switch 3. Ouput copper row 6. RC absorption resistance 9. Input protect device

14.Relay unit 17.TR.TC1380:220 20.Control power box 23.Secondary sampling unit 26.Secondary ammeter 29.main loop power on light 32. Stop button 35.Grounding pole

JHB ESP H.V rectifier device use manual 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

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JHB ESP H.V rectifier device use manual 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.
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JHB ESP H.V rectifier device use manual 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.

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JHB ESP H.V rectifier device use manual Analog part I2 U1 I1 U2

Turbidity

Digital part

Filtering enlarge Filtering enlarge Filtering enlarge Filtering enlarge Filtering enlarge

RMS filter RMS filter RMS filter RMS filter

AD
converters

Optocoupler

LCD Reset MAX809

Communication and DA
High-speed Optocoupler

CAN bus MCP2551 RS485 MAX485

CAN COM RS485

2.5V Precision power

Key

CPU LPC2129

High-speed Optocoupler

Linear
Optocoupler

Toggle switch

I/O port Main loop Safety lock Over-current

Oil temperature

CPU LPC2132

JTAG I/O part Ready Run/Stop Fault alarm Start Stop

Trip output

2.5V Precision power

Optocoupler

Toggle switch

BK2 3.3V Battery JTAG LED

Optocoupler Optocoupler

Oil surface Light gas R-V rapping Trigger part

Trigger output1 Trigger output2

Output drive

Spark +3.3V Precision power SPX1117-3.3V Digital power voltage +5V regulator +1.8V Precision power SPX1117-1.8V +5V voltage Analog power -5V regulator DA and COM +5V power Digital output +24V power voltage regulator voltage regulator

trigger shield analog switches

DA output1 DA output2

Output filtering

Optocoupler

TR.

12V input

Commnucition and DA
picture 6 CON working princple

AC220V input

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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.

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

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

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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. 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. 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. CON design using watchdog to ensure that the CPU is not under any circumstances death. All of the I/O port and commnication port have over-current and over voltage protection. All of the Power supply design, analog, digital, communications and so on, the part of the power to trigger are mutual isolation. 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 Synchronous signal detection has multiple anti-jamming designs and phase

compensation, and a combination of hardware and software to ensure the accuracy of detection. 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) 2) 3) 4) 5) 6) 7) 8) Input voltage: 380V 10%. Power supply frequence: 50Hz 2% or 60Hz 2%. Output voltage: Output current: Trugger angle : Spark rate set: 0~100% rating voltage 0~100% rating current 0~153 10 times /min ~ 120 times/min CAN bus port and RS485 port.

Communication ports: Communicate rate:

CAN bus:the highest rates of CAN bus is 500Kbps 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 Input voltage : Output voltage: Output voltage: 0 ~ AC400V Rating DC voltageUnit:KVis 60,66,72,80,90,100. 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 Impedance of the voltage: Transformer Oil : 30%~40%

25# oil ,pressure value more then 40KV/2.5mm.

Sampling resistance: secondary voltage is 5.00K,Secondary current is 2.00K. Negative H.V to grouding: the value of positive resistance is zero, the negative resistance is 52/65/78 M. Insulation resistance: Primary side to grouding
19

: 100M

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.

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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

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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.

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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
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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 Class current A 2.0 Ab 1.9 1.9 1.7 1.9 1.8 1.7 Aa 1.6 1.5 1.4 1.3 1.4 1.3 A 1.2 1.1 1.0 1.0 B 0.9 0.8 0.7 0.7 C 0.6 0.5 0.4 D E 0.4 0.3 0.2 0.1 60 60 60 60 72 72 72 60 60 60 72 72 72 560 560 710 660 910 748 100 120 940 940 650 650 1275 1275 790 740 630 580 800 600 350 290 250 210 560 750 950 100 1070 650 1405 830 670 1000 450 340 60 60 60 72 72 72 650 800 1100 150 1170 800 1545 880 720 1250 550 430 60 60 60 60 72 72 72 650 800 1100 150 1220 800 1595 880 720 1400 660 650 60 60 60 60 60 72 72 72 72 650 800 1100 150 1320 800 1695 880 720 1520 660 600 voltage KV 60 72 72 72 72 750 888 1660 252 1320 800 1720 980 820 2000 950 700 a b Main dimension (unit mm) c D H h G W T Weight(unit :Kg) Total wight Oil weight Core weight

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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 Clas s curren tA 2.0 Ab 1.9 1.9 1.7 1.9 1.8 1.7 Aa 1.6 1.5 1.4 1.3 1.4 1.3 A 1.2 1.1 1.0 1.0 B 0.9 0.8 0.7 0.7 C 0.6 0.5 0.4 D E 0.4 0.3 0.2 0.1 60 60 60 60 72 72 72 60 60 60 72 72 72 56 0 56 0 71 0 66 0 910 748 940 940 149 0 149 0 79 0 74 0 63 0 58 0 800 600 350 290 250 210 56 0 75 0 950 107 0 166 0 83 0 67 0 1000 450 340 60 60 60 72 72 72 65 0 80 0 1100 1170 176 0 88 0 72 0 1250 550 430 60 60 60 60 72 72 72 65 0 80 0 1100 122 0 181 0 88 0 72 0 1400 660 560 60 60 60 60 60 72 72 72 72 65 0 80 0 1100 132 0 191 0 88 0 72 0 1520 660 600 voltage KV 60 72 72 72 72 75 0 90 0 120 0 132 0 191 0 98 0 82 0 2000 950 700 a Main Dimension (unit: mm) b c H F W T Weight (unit :Kg) Total weigh t Oil weigh t Core weigh t

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

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JHB ESP H.V rectifier device use manual

5 Installation and debugging

5.1 Installation condition and technical requirment
1 Installation condition
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. 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. All the electrical and insulator products like porcelain, cables, electronics switches should take the experiment of voltage endurance and insulation. 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. 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<JB/T 8536-1997 PRECIPITATOR MECHANISM INSTALLATION TECHNOLOGY REQUIRMENT>.

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: Indoor kind: the surroundings should keep at least 1m away from the H.V. output terminal. 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
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JHB ESP H.V rectifier device use manual The selection of cable and on-site wiring connection of unit should carry on according to <Matching Design Diagram of High and Low-Voltage Electricity>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

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

2 Check for Controlling Cabinet

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. Whether the device body is earthed and what its resistance is.
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JHB ESP H.V rectifier device use manual

3 Check and Meterage for Transformer 1) Check

Whether the power lines, sampling lines and temperature signal lines are connected correctly. 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. Whether the transformer has oil leakage phenomenon or whether all parts of insulating rubber ring is complete or aging. Whether there are damages in the large and small insulators. Whether the binding post is loose. Whether the oil level is normal. Take down the breather lid of transformer.

2) Measurement
Negative high voltage output to earth: forward: 0. adverse: 523M(60/66/72 KV), 654M(80KV). (Measured with 2500VM meter) UH2 To earth : 6.670.3K. (Measured with multi-meter) IH2 to earth: 20.1K. (Measured with multi-meter) The resistance of terminal A to X1,X2,X3 :<1 (Measured with multi-meter). The primary power supply input terminal to device body,the secondary high voltage output terminal to device body, and the primary power supply input terminal to the secondary high voltage output terminal are all 100M(Measured with 2500VM meter). Whether the oil thermometer can be closed and opened normally.

4 Check for Isolation Switch Cabinet

Whether the switch can be operated flexibly and whether all points can reach the designated position. Whether the damping resistance is broken. Whether the wires are connected correctly and regularly, or become loose. Whether the wall bushing is damaged or broken or installed correctly.

5 Check for the Local Earth Resistance

Consult relevant units to make clear whether the earth net is laid in accordance with
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JHB ESP H.V rectifier device use manual standards and specifications, or if the value of earth resistance confirms to the standard (<2). The insulation resistance of cathode wire should be larger than 200M.

5.4 Debugging Equipment

1) Start-up Unit
The sequence to start the equipment is: first close the control loop breaker QF2, then close the main loop breaker QF1, and at last press the run button, the device will be on.

2) Stop Unit
The sequence to stop the equipment is: first press the stop button, then cut off the breaker of the main loop, and at last cut off the breaker of the control loop, the equipment will be off.

5.5 Operating Equipment 5.5.1 Debugging of Dummy Load

1) Before the electric transmission, the breaker of the control loop (QF2) and the breaker of the main loop (QF1) in the control cabinet should be at the off position. 2) Connect two 220V/100W incandescent bulbs in series to the primary output terminals of the control cabinet. 3) After the electric power distributing to the control cabinet, measure the distribution voltage with multi-meter to see if it is AC380V. 4) Close the air switch of the control loop, measure the magnitude of voltage and signal waveforms.(refer to chapter 7.3.8).Close the breaker of main loop ,and the main power on light on the cabinet door shines. 5) The bus will brighten up gradually in the event of boosting after start-up, and the primary voltage finally will rise up to 380V or so, then measure the trigger impulse. Stop the equipment and cut off the power, and the debugging of dummy load is finished. Warning Test for Unit Failure 1) Warning Test for Oil Temperature

Adjust the lower limit item of oil thermometer on the transformer to make it closed with pointer, then trouble of transformer Light on the cabinet door and V7 light on the master control board shine.Adjust again the upper limit of oil thermometer to make it closed with pointer, then the alarm bell rings, the unit stops and the V5 light on the master control board shines. Cut off the breaker of control loop (QF2) to relieve the bell. (Here the reset button AJ1 on the master control board is
32

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 Make sure that the low-voltage control unit normal before throw-in of fume. 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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JHB ESP H.V rectifier device use manual

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
35

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

Stop equipment, operation order 1) 2) 3) Push the button stop on the door to stop equipment. QF1.cut the air switch QF1

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

/ POWER / RUN / LOCK / SPARK CAN RS485 ENT REAL INC_U

ESC

UP DEC_U

5.7

LEFT DOWN RIGHT

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

ESC

ENT: use input to enter

REAL

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.

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

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.

DEC_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.

UP

UP: 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 / RUN / LOCK

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

safety chain have effective signal, lock light will light.

/ SPARK CAN

Spark light: when CON judge spark breakdown, spark light will light.

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.
RS485

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.

6.2.3 Management purview is divided into three grades

1) Operator purview Purview is bigger,it can operate equipment normally, usually scene operators have this purview. 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 The purview has the largest rights, which can manage and operate equipment normally. The administrator has this purview. 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 Purview is biggest,it can manage and operate equipment complete, usually manufacturer's technical staff have super powers Management 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.
38

JHB ESP H.V rectifier device use manual 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: The sampling line of secondary current signal and sampling line of secondary voltage signal on the contrary Signal line of High-voltage rectifier transformer control cabinet and the signal line high-voltage did not corresponding Oecondary current signal of High-voltage rectifier transformer with transformer shell, whether the dust catcher enter into earth. Over High-voltage rectifier transformer rated running. Equipment usually run empty field state, it easy damage transformer. 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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JHB ESP H.V rectifier device use manual

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 1) 2) 3) 4) 5) Equipment can not start 6) 7) 8) Check control Troubleshooting Check the air control loop switch is connected to QF2 power ,whether voltage output is normal DC12V,AC12V,AC15V Check CON voltage whether that is 24V. Check switch QF1 of circuit whether is closed Check CON Self-inspect whether overpass Check security chain signals whether validity Check the main circuit connected signal whether validity 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 1) Equipment does not start after the step-up 4) 5) Instant access on the main circuit output voltage Other equipment failures 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 . 1) 2) 3) 4) 5) 2) 3) Check RC limit of turn-on angle and RC settings set whether are less than 27 degree. Check power phase of the control loop whether reversal phase Check CON and signal conditioning and 12V DC of trigger whether up to snuff Stop equipment, cut switch QF1, check the connection between trigger circuit and SCR, consult figure 1 to analyse. Replacing JHB CON to test Cut switch QF1 of main loop immediately. Cut switch QF2 of main loop Check Kai-point of relay KD1 whether disconnect normal. Use multimeter to measure resistance of SCR whether breakdown. Replacement two V1 and V2 of SCR.

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

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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
unit, follow After energization for theauthorization.the full-time principals instructions, do not supply or cut off power without

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: In the air should be no more than 12 hours if the air relative humidity is less than 75%. 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.

High-voltage transformer suspended operation of the transformer core itself may have
an adverse effect on the operation must be cautious.

WARNING

8.4 Lifting Equipment

Hoisting equipment to be hanging on both sides of the equipment of the four hooks. Handle with care when lifting equipment, to avoid rattling. High-voltage transformer rectifier heat sink can not be collisions with other objects, or even deformation caused by oil spill.
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JHB ESP H.V rectifier device use manual

9 Order notice
9.1 Unit capacity, specifications and model
Designate the unit capacity, i.e. secondary rated current and secondary rated voltage. 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. Designate the installation position of the high-voltage rectifying transformer, i.e. indoor mode or outdoor mode. 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. Side in and back out :right in and back out ,left in and back out. Side in and lower out :right in and lower out,left in and lower out Side in and side out :right in and left out,left in and right out. Back in and side out :back in and right out,back in and left out . 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: Company Address: Zip Code: Technical Services: Business Advisory: Fax: Company Web site: Email: DALIAN JIAHE INDUSTRIAL CONTOL TECHNIQUE CO.,LTD. High-tech park in Dalian torch route 41 116023 0411-8479 9990 0411-8479 9993 0411-8479 9992 http://www.Jiahegy.com Jiahe@Jiahegy.com

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JHB ESP H.V rectifier device use manual

10 Annex A
Current sampling, damping resistance, currentLimiting resistance Unit Capacity A 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.4 1.5 1.6 1.8 2.0 Current Sampling R11() 2.7//2.7 0.68 0.5//4.3 0.68//0.68 0.5//0.5 0.2 0.2//4.3 0.2//1 0.2//0.68 0.18//0.5 0.2//0.2 0.18//0.2 0.18//0.18 0.15//0.18 0.15//0.15 0.13//0.13 Samping Resistance 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 180/800W 150/1000W 150/1000W 150/1000W 150/1000W CurrentLimiting Resistance 1000/500W 1000/500W 1000/500W 1000/500W 1000/500W 500/800W 500/800W 500/800W 500/800W 500/800W 300/1000W 300/1000W 300/1000W

Measured Value of Insulation Resistance of Transformer Negativehigh-handed Voltage Rank Output-to- Forward 60,66,72 80 90,100 0 0 0 Adverse 52M 65M 78M 6.67K 2K 100M UH2-to- IH2 -to- Primary-to-Crust Secondary-to-Shell Once -to-Shell

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