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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

DANGER

Forbidding operating the main breaker after starting the device

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.

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:

jiahe@jiahegy.com

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

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
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

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

4.4

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

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

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

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

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

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.

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,

current/voltage.
1

choice

once current/voltage,

secondary

JHB ESP H.V rectifier device use manual


z

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:
z

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
2

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.

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

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 :


z

Rating secondary voltage is 72KV


3

JHB ESP H.V rectifier device use manual


z

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

capability
Unit:A

60KV and 66KV device capability

Primary current

Input power

66KV
V V-1cable
2

Primary current

Input power

V V-1 cable

KVA

mm

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

2250

1.0

230

87.4

2250

253

96.1

2270

1.1

260.8

99.1

2270

286.9

109

2270

1.2

276

104.9

2270

304

115.5

2295

1.3

308.2

117.1

2295

339

128.8

2295

1.4

322

122.4

2295

355

134.9

2295

1.5

345

131.1

2295

380

144.4

22120

1.6

368

139.8

2295

405

153.9

22120

1.7

403

153.1

22120

443.3

168.5

22150

1.8

414

157.3

22120

456

173.3

22150

1.9

450.5

171.2

22150

495.5

188.3

22185

2.0

460

174.8

22150

506

192.3

22185

Secondary voltage (KV)

Secondary current

(A)

Wiring

A-X1

A-X2

A-X3

A-X1

A-X2

A-X3

Voltage

60

54

48

66

60

54

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 and 80KV device capability

72KV
capability
Unit A

Primary current
A

Input
power
KVA

80KV
V V-1cable

Primary current

mm2

Input

V V-1

power

cable

KVA

mm2

0.1

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

250

126.4

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

2250

0.8

221

84

2250

253

96.1

2270

0.9

249

94.6

2270

284.5

108.1

2270

1.0

276

104.9

2270

316.1

120.1

2295

1.1

312.9

118.9

2295

347.7

132.1

2295

1.2

331

125.8

2295

379.3

144.1

22120

1.3

369.8

140.5

2295

410.9

156.1

22120

1.4

386

146.7

22120

442.5

168.2

22150

1.5

414

157.3

22120

474.2

180.2

22150

1.6

442

168

22150

505.8

192.2

22185

1.7

483.6

183.8

22150

537.4

204.2

22185

1.8

497

188.9

22185

569

216.2

32120

1.9

540.5

205.4

22185

600.6

228.2

32120

2.0

552

209.8

22185

632.2

240.2

32150

Secondary voltageKV

Secondary currentKV

Wiring

A-X1

A-X2

A-X3

A-X1

A-X2

A-X3

Voltage

72

64

56

80

72

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 and

100KV device capability

90KV
capability
Unit A

Primary current
A

Input
power
KVA

100KV
V V-1cable

Primary current

mm2

Input
power
KVA

V V-1cable
mm2

0.1

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

270

154

58.5

295

0.5

175

66.5

295

193

77.3

2120

0.6

210

79.8

2120

231

87.8

2150

0.7

245

93.1

2270

270

102.6

2270

0.8

280

106.4

2270

308

117

2295

0.9

315

119.7

2295

347

131.8

2295

1.0

350

133

2295

385

146.3

22120

420

159.6

22120

462

175.5

22150

1.4

490

186.2

22150

539

204.8

22185

1.5

525

199.5

22185

578

219.6

32120

1.6

560

212.8

32120

616

234

32120

630

239.4

32150

693

263.3

32150

700

266

32150

770

292.6

32185

1.1
1.2
1.3

1.7
1.8
1.9
2.0

Secondary voltageKV

Secondary currentKV

Wiring

A-X1

A-X2

A-X3

A-X1

A-X2

A-X3

Voltage

90

80

72

100

90

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:
z

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

36
30 16
29
17

28
12

1
18
32 14

31

19
20
9
2

38
6
7
22

21
3
11
10

33

13
34
23
5

a.

Front

c. Main loop unit

b. front inside

35

d.

back

e. back inside

Picture 2 H.V control cabinet Structure


Control loop
Main loop

1. Main loop unit

2. Input copper row

3. Ouput copper row

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

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
9

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


10

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
11

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


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.

13

JHB ESP H.V rectifier device use manual


Digital part

Analog part
I2
U1

Filtering
enlarge
Filtering
enlarge

RMS
filter
RMS
filter

Filtering
enlarge

RMS
filter

U2

Filtering
enlarge

RMS
filter

Turbidity

Filtering
enlarge

I1

Reset
MAX809
2.5V Precision
power

Key

CPU
LPC2129

CAN bus
MCP2551

CAN COM

Optocoupler
High-speed
Optocoupler

RS485
MAX485

RS485

Toggle
switch

2.5V Precision
power

JTAG

CPU

I/O part

LPC2132

Toggle switch

Optocoupler

BK2

Oil surface
Light gas

3.3V Battery

R-V rapping

JTAG

Trigger part

DA output1
DA output2

High-speed

Linear

Oil temperature

Trigger output1
Trigger output2

Communication and DA

converters

Optocoupler

I/O port
Main loop
Safety lock
Over-current

LCD

Optocoupler

AD

Optocoupler

Output
drive

Trip output

Spark

LED

Output
filtering

+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

trigger
shield

Optocoupler

analog
switches

Ready
Run/Stop
Fault alarm
Start
Stop

Optocoupler

Commnucition and DA
picture 6

CON working princple

14

DA and COM
+5V
power
Digital output
+24V
power

TR.

voltage
regulator
voltage
regulator

12V
input

AC220V
input

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.

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


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:

8)

Communicate rate:

CAN bus port and RS485 port.

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
z

Input voltage :

0 ~ AC400V

Output voltage:

Rating DC voltageUnit:KVis 60,66,72,80,90,100.

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%

Transformer Oil :

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

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

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
Class

current

voltage

KV

2.0
Ab

Aa

60

72

1.9

72

1.7

72

1.9

60

1.8

60

1.7

60

1.6

60

72

1.5

60

72

1.4

72

1.3

72

1.4

60

1.3

60

1.2

60

72

1.1

60

72

1.0

60

0.9

60

72

0.8

60

72

Oil

Core

wight

weight

weight

820

2000

950

700

880

720

1520

660

600

1595

880

720

1400

660

650

800

1545

880

720

1250

550

430

1070

650

1405

830

670

1000

450

340

100

940

650

1275

790

630

800

350

250

120

940

650

1275

740

580

600

290

210

750

888

1660

252

1320

800

1720

980

650

800

1100

150

1320

800

1695

650

800

1100

150

1220

800

650

800

1100

150

1170

560

750

950

100

560

710

910

560

660

748

72

0.7

60

0.6

60

72

0.5

60

72

0.4
D

Total

72

0.7

Weight(unit :Kg)

72

1.9

1.0

Main dimension (unit mm)

72

0.4

60

0.3

60

72

0.2

60

72

0.1

60

72

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
Clas
s

curren

voltage

tA

KV

2.0
Ab

Aa

60

Total

Oil

Core

weigh

weigh

weigh

2000

950

700

1520

660

600

1400

660

560

1250

550

430

1000

450

340

800

350

250

600

290

210

72
75

90

120

132

191

98

82

1.9

72

1.7

72

65

80

132

191

88

72

65

80

122

181

88

72

176

88

72

107

166

83

67

149

79

63

149

74

58

1.9

60

1.8

60

1.7

60

1.6

60

72

1.5

60

72

1.4

72

1.3

72

1.4

60

1.3

60

1.2

60

72

1.1

60

72

1100

1100

72

1.0

60

0.9

60

72

65

80

0.8

60

72

1100

1170

72

0.7

60

0.6

60

72

56

75

0.5

60

72

56

71

0.4
D

72

0.7

Weight (unit :Kg)

1.9

1.0

Main Dimension (unit: mm)

950

72

0.4

60

0.3

60

72

0.2

60

72

56

66

0.1

60

72

910

940

748

940

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.

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.

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.

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:
z

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
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
<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


z

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


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.

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.

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
z

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


z

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


z

Consult relevant units to make clear whether the earth net is laid in accordance with
31

JHB ESP H.V rectifier device use manual


standards and specifications, or if the value of earth resistance confirms to the standard
(<2).
z

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


z

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

DANGER

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

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)

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

3)

Cut the air switch QF2,stop done with.

the air switch QF1

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

5.7

UP

DEC_U

LEFT DOWN RIGHT

Fig.21 The panel of Controller

36

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

ESC: use input to esc or returu above menu.

REAL

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
37

JHB ESP H.V rectifier device use manual


CON have six LED lights:
/ POWER

Power light: when open QF2 of control loop, CON have power, light

/ RUN

Run light: when start up equipment, when run normal, run light will light.

/ LOCK

Lock light: when open H.V Switchgear, when run low-voltage control cabinet,

safety chain have effective signal, lock light will light.


/ SPARK

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

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

CAN

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
z

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
z

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


z

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:
z

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

Troubleshooting

phenomenon
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

Equipment

6)

Check security chain signals whether validity

can not start

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
1)

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

Equipment

2)

Check power phase of the control loop whether reversal phase

does not start

3)

Check CON and signal conditioning and 12V DC of trigger whether up to


snuff

after the
step-up

4)

Stop equipment, cut switch QF1, check the connection between trigger
circuit and SCR, consult figure 1 to analyse.

Instant access
on the main
circuit output
voltage
Other
equipment

5)

Replacing JHB CON to test

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.

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

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 .

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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
energization for the unit, follow the full-time principals instructions, do not supply
After
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.
41

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:

3)

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%.

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.

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
z

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.
z

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:

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:

Jiahe@Jiahegy.com

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JHB ESP H.V rectifier device use manual

10 Annex A
Current sampling, damping resistance, currentLimiting resistance
Current Sampling

Unit Capacity A

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


Primary-to-Crust

Negativehigh-handed
Voltage Rank

Output-to-
Forward

Adverse

60,66,72

52M

80

65M

90,100

78M

44

UH2-to-

IH2 -to-

6.67K

2K

Secondary-to-Shell
Once -to-Shell

100M