Ador Corona

ADOR POWERTRON LIMITED, PUNE, INDIA
PRECICON-III
OPERATION AND INSTRUCTIONAL MANUAL FOR
V1.07/2009
Page 1 of 32 2600-0000-13-21/04
IMPORTANT INSTRUCTIONS
NOTES FOR SAFE OPERATION
! CAUTION : Which indicates potentially hazardous situation, which if not avoided may result in
damage of the controller or its intended properties.
1 WARNING : Which indicates situations or conditions, if ignored may result in personnel injury or
death.
1. As soon as the controller is received at site, the same should be unpacked carefully and should be
checked for any transit damages. Damages should be immediately reported to the concerned
authorities.
2. ! CAUTION : Read and understand the manual carefully before operating the PRECICON-III
3. Environment in the control room where the equipment is installed should be Air conditioned /
pressurized.
4. ! CAUTION :The various parameters should not be disturbed excepting which are related to TR
Set rating before proper reading and understanding.
5. Controller shall be operated properly and in accordance with the instructions given in the manual.
Components and circuits in the controller should not be tampered for experimentation beyond the
scope of working of equipment. Any such tampering will void the warranty.
6. It is preferable that a faulty controller be replaced by healthy controller. The faulty controller
should be send to :
ADOR POWERTRON LIMITED

PLOT NO 51, D-II BLOCK, MIDC
RAMNAGAR COMPLEX,
CHINCHWAD,
PUNE - 411 019
MAHARASHTRA ,INDIA
: (020) 27472532, 27473778 , 27471682

Fax : (020) 27475817
Email : customercare@adorpower.com
7. In case the user requires services of the manufacturer's Engineer, a detailed report of problems
Faced should be sent in the enclosed format to the above address for correct spares and prompt
services.
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Content Page No.
Important Instructions 1
1. Introduction 3
2. Technical Data 3
3. Control & User Interface 4
4. Default display 6
5. Parameter Programming 7
6. Alarm Messages 15
7. Installations 16
8. Operation 17
9. Principle of Operation 17
10. Modes of Operation 18
11. Fault finding & Trouble shooting 31
12. Special Instructions 32
13. Complaint Form 33
14. G. A. Drawing of Precicon – III 34
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1.0 INTRODUCTION:
Ador Powertron Ltd. (an ISO 9001 company), a member company of Ador group, is a leading
manufacturer of Power Electronic Equipments for various industrial applications.
‘PRECICON-III’ (Precipitator Controller) is a Micro-Controller based automatic controller for
Electrostatic Precipitator (E.S.P) applications. This regulates monitors and optimizes the Electric
Power Input to E.S.P.
2.0 TECHNICAL DATA
ENVIRONMENT :
Ambient Temperature : 0 to 50°C (Max.)
Storage Temperature : 0 to 80° C
Duty : Continuous operation (24 hours a day)
Installation : Indoor (Pressurized or AC Room)
2.1 MAINS REQUIREMENT
Nominal Input Voltage : 24 VAC, 50 Hz / 60 Hz, 1φ
Variations :
Voltage : ± 20%
Frequency : ± 7.5%
Current : 2Amps (RMS) (Max.) , 48 VA
2.2 FEEDBACK’S FOR OPERATION
Output Current Feedback (IDC) : 1 V DC at rated mA Average (Mean) DC
Output Voltage Feedback (VDC) : 400 μA DC at rated KV (Peak)
Primary Current Signal (IP) : 80mA (RMS) at rated Primary Input Current.
2.3 DIGITAL INPUTS : Potential Free Contacts

(Refer Interface drawing)
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2.4 OUTPUTS :
Digital Outputs : Potential free contacts of 3A @ 24VAC (Max.)

(Refer Interconnection Drawing)
! CAUTION : Do not exceed these ratings
Analog Outputs : 4mA to 20mA. Average (Mean) DC, Rated KV
(Peak) respectively for 680 Ohms (Max.) Load.
SERIAL INTERFACE FOR : RS-485 MODBUS Protocol: Multiple unit
COMMUNICATION connection
3.0 CONTROLS &USER INTERFACE :
3.1 CONTROLS :
LED’s on the Front Fascia of the Keyboard:
Sr. No. Description Status Function Default Condition

1. HT ON-OFF Key Indication Contactor ‘ON’ HT Off
2. COM/CON Key Indication Local / Remote As per the settings of
Mode Selection and Parameter No: 97 &
Comm. mode Com/Con key.
3. Watchdog LED Indication Unit Healthy Flashing
4. RAP ON/OFF RAP. ON Indication Rapping ON RAP. OFF.
3.2 DISPLAY:
The Display module is a LCD alpha numeric with 2 lines of 16 characters, with 5 x 7 dot
matrix having back-lit facility for operations in poor light conditions.
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3.3 KEYS:
Non- tactile key pad are used for all the control function
The functions of the keypad are as follows:
HT – ON / OFF : For Switching ON/OFF of the HT Contactor (Toggle)
RAP ON/OFF : Rapper mode selection
COM/CON : Communication and controller mode as well as Remote

mode selection.
ISET : Output mA Average (Mean) DC Current set.

INC ( ) & DEC ( ) : Scrolling the parameters and Editing Programmable
Alarm / Trip Faults.
TEST : Test Mode Functions in `HT-OFF’ condition and

“Type - 1 spark Simulation” in ‘HT-ON’ condition.
RESET : Accept and Reset of Alarm / Trip Faults
PASS/PARA : Password or Parameter Programming

ENTER ( ↵ ) : Confirming and storing the parameter values.
1-9 : Numeric Keys
0 : Numeric Key & “TYPE-2 Spark Simulation” in‘HT-

ON’ Condition.
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BC : Back Corona Mode ON / OFF
EMS : Energy Management System
CR : Charge Ratio Setting
S : IDC Setback
TF : T-FAST RAMP
MSR : Maximum Spark Rate

SA : Totalisation of number of `Type -1’ & `Type - 2’
flashovers.
The display will be,
xxxxxxxx
ACCUM.SPARKS
TT : Totalisation of time for which the ‘HT’ is ‘ON’
xxxxxxx.xh
TIME TOTAL.
RAP : Rapper Status for 3 Rapper Motor Controls.
OFF OFF OFF OFF OFF OFF
RAPPER STATUS
DEFAULT DISPLAY : KV 000, mA 0000
KVp 000, S X Y Z
KV : Output KV DC (mean) Voltage

mA : Output mA average (mean) DC Current
KVP : Output KV DC (Peak) Voltage
S : Status of operating condition as follows
X=N : Unit under normal mode
X=L : Unit under Load Status-1 mode
X=R : Unit under Rapper mode
X= B0: Unit under `Back Corona' mode ON &
Not detected.
X=B1 : Unit under `Back Corona' mode ON &
Back corona detected
X=E0 : Unit under ÈMS' mode ON & optimum
Point not detected.
X=E1 : Unit under ÈMS' mode ON & optimum
Point detected.
X= C : Unit under charge ratio mode
Y=V : Unit under Voltage limit mode
Z=1 : Occurrence of Type 1 flash-over
Z=2 : Occurrence of Type 2 flash-over
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3.3.2 DUAL FUNCTION KEYS :
Certain keys like < 0 > to < 9 > have dual functions i.e. data entry mode or control parameter
viewing mode.
4.0 DEFAULT DISPLAY:
After Switching ‘ON’ the LCD indicates as follows:
KV 000, mA 0000
KV(P)000, S N
5.0 PARAMETER PROGRAMMING :
5.1 PASSWORD PROTECTION :
It has built in security feature, that allows two separate levels of operation, which prevents
unauthorized changes to the control settings. The level -I operation is commonly needed and can be
operated without a password by operator. Where as the level -II operations needs a password code
and should be operated by Authorized personnel, who is conversant with the implication of the
changes being made on the operation & safety of the system.
5.1.1 PARAMETER PROGRAMMING INSTRUCTIONS :
The user must refer to the parameter settings mentioned in clause No. 5.4 for programming various
parameters. This list also indicates the factory programmed values.
For editing level I parameters no password is required.

For editing level II parameters, press `PASS/PARA' key enter password for level II parameters.
and press ‘ENTER’ key. (Password is valid for 3 minutes only)
For editing level III parameters, press `PASS/PARA' key enter password for level III parameters.
and press ‘ENTER’ key. (Password is valid for 3 minutes only)
For editing level IV parameters, press `PASS/PARA' key enter password for level IV parameters.
and press ‘ENTER’ key. (Password is valid for 3 minutes only).
For parameter settings:
Press `PASS/PARA' key.
Enter parameter number
Enter relevant parameter setting.
Use keys to scroll the parameters
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5.1.2 IMPORTANT TO THE USER :
The T/R sizing parameters provides the basis for the operating values of the
controller. If these settings are changed and no longer reflect the actual name plate
rating of the T/R Set, the performance of the controller will be seriously affected and
equipment may malfunction.
5.2 READ OUT PARAMETERS :
The user can only view the following parameters ( No editing is possible).
5.2.1 KEY SA : Totalisation of number of `Type -1’ & `Type – 2” flashovers.

sparks. The Display will be:
xxxxxxxx
L1 P 17 ACCUM.SPARKS
5.2.2 KEY TT : Totalisation of time for which the ‘HT’ is ‘ON’

The Display will be:
xxxxxxx.xh
L1 P 19 TIME TOTAL.
5.3 EDITING AND STORING OF T/R SET PARAMETERS :
5.3.0TRANSFORMER / RECTIFIER DATA:
The operating parameters of the controller are based on the ratings of the T/R set.
! CAUTION :
The T/R sizing parameters provides the basis for the operating values of the controller. If
these settings are incorrect / modified and no longer reflect the actual name plate rating of
the T/R Set, the performance of the equipment shall be seriously affected and permanent
damages can be caused to the T/R set and the control panel.
5.3.1 NOMINAL IDC (MEAN) CURRENT RATING OF T/R SET: (PARAMETER NO. : 77 )
LOWER LIMIT: 10 mA UPPER LIMIT: 3000 mA
This is a level II parameter. Enter Level II Password.

Enter the parameter No.77
Enter the rated DC current rating of the T/R set.
e.g. For T/R set having 800mA DC as output current , the display before entering & after entering
the rated mA will be as follows.
L-2 P77= xxxxmA L-2 P77= 800mA
NOM. IDC MEAN NOM. IDC MEAN
Where ‘L’represents the level of operation (i.e. ‘L1’ represents level 1 operation & ‘L2’ represents
level 2 operation), ‘P’ represents the Parameter No. For e.g. ‘P77’ represents Parameter No. 77.
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5.3.2 NOMINAL VDC (PEAK) VOLTAGE RATING OF T/R SET: (PARAMETER NO. : 76)
LOWER LIMIT: 10 KV UPPER LIMIT: 220 KV

Enter the parameter No. 76
Enter the rated DC Peak Voltage rating of the T/R set.
e.g. For T/R set having 78 KV DC as peak Voltage rating , the display before entering & after
entering the value will be as follows.
L-2 P76= xxxKV L-2 P76= 78KV
NOM. VDC PEAK NOM. VDC PEAK
5.3.3 NOMINAL PRIMARY AC (RMS) CURRENT RATING OF T/R SET :( PARAMETER

NO: 78)
LOWER LIMIT: 10 A UPPER LIMIT: 950 A

Enter the parameter No.78
Enter the rated primary current rating of the T/R set.
e.g. For T/R set having 149 A as the primary current rating , the display before entering & after
entering the value will be as follows.
L-2 P78= xxx A L-2 P78= 149 A

NOM. IP NOM.IP
5.3.4 NO LOAD / ON LOAD SETTINGS FOR THE T/R SET :(PARAMETER NO.: 80 )
LOWER LIMIT: 0 UPPER LIMIT: 1
This is the Level II parameter. This is to be set depending upon the rating of the T/R set. If the KV
Peak rating is at No Load then enter `0' and if it is On load then enter `1'
L-2 P80= 0 L-2 P80= 1

NO LOAD ON LOAD
These parameters are factory set for the controller supplied along with the control panel. For spare
Controller the settings need to be done as explained.
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5.4 EDITING & STORING OF CONTROL PARAMETERS:

The various control parameters, their password levels, ranges, description, default values & display is
shown in the following table.
Parameter Parameter Password Description Lower Upper Default Display
type No. level Limit Limit value
Control 25 1 Output current 0 mA Nominal Nominal L1 P25 = XXXX mA
parameters limit IDC IDC Mean IDC LIMIT
Mean
26 1 Step reduction 4 mA 300 mA 10% of L1 P26 = XXX mA
in current after Nominal IDC SETBK
flashover IDC mean
27 2 Special current 0 mA 300 mA 10% of L2 P27 = XXX mA
step reduction Nominal IDC SPL. SETBK
after follow-up IDC mean
flashover
28 1 Maximum spark 0.2 / m 60.0 / m 10.0 / m L1 P28 = XX.X / m
rate per minute MAX SPARK RATE
29 2 Blocking time 2 10 2 L2 P29 = XXX mS
after a type 2 T QUENCH CYC
spark over
30 2 Stabilization 4 100 10 L2 P30 = XXXX mS
time after T RECOVERY CYC
blocking
31 1 Fast ramp 200 30000 2000 L1 P31 = XXX S
T FAST RAMP CYC
32 1 Number of 1 255 1 L1 P32 = XXX
blocked half CHARGE RATIO (CR)
cycle during
Charge pulsing mode of
ratio operation
parameter
33 2 No.of half 0 CR-1 0 L2 P33 = XXX
cycles under RECHARGE HW
conduction of
total blocked
cycles
34 2 Firing angle of 1500 1800 1800 L2 P34 = XXX
Recharge HW RECHARGE FIRING
35 1 Back Corona 0 1 0 L1 P 35 = X
Back mode BC ON / OFF
Corona 0 : Inactive
1 : Active
36 2 Frequency of 1m 600 m 60 m L2 P 36 = XXX m
initiation of BACK CORONA MEAS
back corona
detection cycle
37 2 Minimum 10% Nominal 80 mA L2 P37=XXXX mA
output current in of IDC BC IDC MIN
back corona nomin Mean
detection cycle al IDC
Mean
38 2 Output current 10 mA 300 mA 100 mA L2 P 38=XXX mA
step reduction in BC IDC STEP
back corona
detection cycle
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39 2 Hold time at 5S 60 S 10 S L2 P 39 = XX S
Back current set point BC HOLD TIME
Corona before changing
of set point
40 2 Maximum 1 255 17 L2 P 40 = XXX
charge ratio in BC CR MAXIMUM
back corona
detection cycle
EMS 41 1 EMS mode 0 1 0 L1 P 41 = X
parameters 0 : Inactive EMS ON / OFF
1 : Active
initiation of EMS MEAS
EMS detection
cycle
Load 43 2 Output current 0 mA Nominal Nominal L2 P43 = XXXX mA
Status 1 limit during IDC IDC Mean LS-1 IDC LIMIT
load status 1 Mean
44 2 Output Voltage 15% of Nom. Nom. L2 P44 = XXX mA
limit during Nom. VDC VDC peak LS-1 VDC LIMIT
load status 1 VDC Peak
Peak
45 2 Current step 4 mA 300 mA 40mA L2 P45= XXX mA
reduction after a LS-1 IDC SETBK
flashover in
Load status 1
46 2 Number of 1 255 1 L2 P46 = XXX
blocked half LS-1 CR
cycles in Load
Status-1 during
pulsing mode of
operation
47 1 Indicates status - - - L1 P47= OFF OFF
Rapper of Rapper OFF OFF
control system RAPPER STATUS
48 1 Rapper motor 1 0 1 0 L1 P48=X
On/Off RAP MOT1 ON/OFF
51 2 Rapper motor 1 0 720 1 L2 P51=XXX Min
Off time RAP TM1 PAUSE
52 2 Rapper motor 1 0 400 120 L2 P52=XXX Sec
On time RAP TM1 RUN
On time RAP TM2 RUN
On time RAP TM3 RUN
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57 2 ALL Rappers 0 1 0 L2 P57=X

operated in RAP-CONT.ON/OFF
continuous
mode
starting delay RAP-TM1-STR-DLY
stop delay RAP-TM1-STP-DLY
64 2 Rapper 1 in 0 1 0 L2 P64=X
reduction Mode RAP-RED ON/OFF
65 2 Current limit 0 NOM. NOM. L2 P65=XXXX mA
during rapping IDC IDC RAP IDC LIMIT
MEAN MEAN
66 2 Time for current 0 99 1 L2 P66=XX Min
limit during RAP DELAY TIME
rapping
Heater 67 2 Heater1 On/Off 0 1 0 L2 P67=X
On/Off HEATER1 ON/OFF
68 2 Heater2 On/Off 0 1 0 L2 P68=X
HEATER2 ON/OFF
Trip limits 69 2 Voltage limit set 15% of NOM NOM L1 P69=XXX KV
CAUTION Nom VDC VDC V LIMIT
This is VDC PEAK PEAK
factory PEAK
preset & is 70 2 Trip level 30 165 80% NOM L2 P 70=XXX KV
not setting for over VDC OV LIMIT
advisable voltage PEAK
to change L2 P 71=XXX KV
71 1 Trip level 1 26 1
setting for under UV LIMIT
voltage
72 2 Under voltage 10 120 30 L2 P72=XXX Sec
sensing time UV TRIP TIME
73 2 Trip level 50% of 150% of 110% of L2 P 73 = XXX A
setting for Nominal nominal nominal Ip IP LIMIT
primary current. Ip Ip
Control 74 2 1:Conventional 0 1 1 L2 P 74 = X
parameters Transformer TX : C / H
0: Hermetically
sealed
transformer
75 2 0 : NO 0 1 1 L2 P 75 = X
1 : NC TX : NC / NO
(For Bottom
Float & Oil
Temp.High )
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76 2 NOMINAL 10 220 78 L2 P76=XXX KV

VDC (PEAK) NOM. VDC PEAK
VOLTAGE
RATING OF
T/R SET
77 2 NOMINAL IDC 10 4000 400 L2 P77=XXX mA
(MEAN) NOM. IDC MEAN
CURRENT
RATING OF
T/R SET
78 2 NOMINAL 10 950 150 L2 P78=XXX A
PRIMARY AC NOM. IP
(RMS)
CURRENT
RATING OF TR
SET
79 2 Primary current 10 900 10 L2 P79=XXX
ratio(CT ) CT RATIO
80 2 KVPeak rating 0 1 0 L2 P 80 = X
is at No Load NO LOAD
then enter `0'
and if it is On
load then enter
`1'
Programm 81 2 Programmable -- -- -- L2 P 81 = AL1 TEXT
able Alarm Alarm fault. EDIT TEXT?
/ Trip Edit with ( )
Faults key ( )proceed
to next character
with ( ) key
82 2 Programmable -- -- -- L2 P 82 = AL2 TEXT
Alarm fault. EDIT TEXT?
Edit with ( )
key ( )proceed
to next character
with ( ) key
83 2 Programmable -- -- -- L2 P 83 = TR1 TEXT
Trip fault EDIT TEXT?
84 2 Frame selection 0 1 0 L2 P 84=X
0=ASCII, FRAME 0=AS 1=RTU
1=RTU
85 2 Communication 0 99 0 L2 P 85=X
address of each COMM ADDRESS
controller
86 2 Baud rate 0 3 3 L2 P 86=X
selection BAUD 0=1200,…3
0=1200,1=2400
… 3=9600
87 2 Parity bit 0 2 0 L2 P 87=X
0=No parity PAR. 0=NO,1=EV,2
1=Even
2=Odd
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6.0 ALARM / TRIP MESSAGE:
The Alarm/Trip message is displayed on the bottom line. In case of Alarms/Trips, the Alarm
message remains on the screen until Acknowledged/Reset by the operator with “RESET” key.
ALARM / TRIP ALARM / TRIP MESSAGE DESCRIPTION

MESSAGE
AC CURRENT HIGH PRIMARY AC CURRENT HIGH TRIP

DC UNDER VOLTAGE SEC. DC VOLTAGE LOW TRIP
DC OVER VOLTAGE SEC. DC VOLTAGE HIGH TRIP
H/W SCR FIRING SINGLE SCR FIRING TRIP
SYNC FAIL SYNCHRONISING SIGNAL FAIL TRIP
TOP FLOAT or TOP FLOAT ALARM
(Oil level low for (Oil level low for Hermetically sealed TR)
Hermetically sealed TR)
BOTTOM FLOAT or BOTTOM FLOAT TRIP
(TR pressure high for (TR pressure high for Hermetically sealed TR)
Hermetically sealed TR)
TX OIL TEMP HIGH - 1 TX OIL TEMP HIGH ALARM
TX OIL TEMP HIGH - 2 TX OIL TEMP HIGH TRIP
SCR TEMP HIGH SCR TEMP HIGH TRIP
OVERLOAD OVERLOAD TRIP
SAFETY LOOP FAIL SAFETY LOOP FAIL
Apart from these alarm / trip faults the Optional Alarms & Trips faults will be displayed as they are
programmed
6.1 ALARM / TRIP ACKNOWLEDGE AND ALARM / TRIP RESET FUNCTIONS:
Whenever Alarm / Trip fault occurs corresponding Alarm / Trip text message appears on the
LCD (as shown below)
KV xxx, mA xxxx The text message represents the

Text Message actual Alarm/Trip Fault occurred.
The reset key is used for Accepting & then Resetting the fault.
On occurrence of Trip faults ‘HT’ is made ‘OFF’. If the Alarm/Trip fault persists
then ‘HT’ cannot be made ‘ON’ & if the reset key is pressed again, the relays will remain
in energized condition & the text message will continue appearing on the LCD.
Similar operations can be performed through remote using the Remote Acknowledge / Reset’ Push
Button.
7.0 INSTALLATION:
7.1 MOUNTING AND CONNECTION:
7.1.1 Connect the Main J3 to J10 connector, the power supply connector properly as shown in
the following sketch.
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Rear view of PRECICON-III
Mounting studs
J16 , J17
J3 TO J10 Connector
CONTROLLER CARD
Earthing Stud
POWER SUPPLY CARD

Power supply
connector
7.1.2 Check the earthing wire to the controller.

7.1.3 Ensure that the 4 mounting screws are fitted to the Controller from the sides.
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7.2 INITIAL START:

Before starting “PRECICON-III”, all safety measures & preparations applicable to the Electrostatic
Precipitator High Voltage Power Supply must be ensured.
7.2.1. Switch ‘ON’ the supply to the control panel.
7.2.2. Check the Input supply voltage as per the nameplate.
7.2.3. Switch ‘ON’ the ‘MCB’ to the “PRECICON – III Controller.
7.2.4. Check the Remote / Local function by observing the COM/CON key LED & parameter no
97 is not selected for remote mode
7.2.5. Now the unit is ready to start.
NOTE : Apart from the Nominal values of the T/R set ( Excepting in case of Retro-fits),
All the other parameters values are factory set. These settings shall be changed by
authorized personnel having knowledge about the operation, and only if required.
8.0 OPERATIONS:
8.1 Select the COM/CON key in CON mode.

8.2 Select the desired current limit. (Parameter No: 25 IDC Limit).
8.3 To make HT ‘ON’ press the <HT ON-OFF> key, LED lights on the keypad, so that the
Secondary DC Voltage & Secondary DC Current starts rising.
8.4 To make HT ‘OFF’, Press the <HT ON-OFF> Key (LED extinguishes) on the keypad.
9.0 PRINCIPLE OF OPERATION:
9.1 SPARK REGULATION

Flashovers of extremely low intensity are difficult to detect using the conventional
comparator techniques. Non detection of these results in sustained arcing which may
damage the collecting electrodes. For detecting such flashovers, the digital detection
system is adopted.
The sensing philosophy being of a digital nature is able to sense pits, sparks and arcs .In
addition to the digital (Software based) sensing, Hardware sensing is also employed.
The flashover sensing is of a digital nature, where samples of KV signals are compared
in a half wave. This enables detection of flashovers of very low intensity, which is not
possible using the conventional threshold method.
The flashover sensing differentiates between the types of flashovers. This

differentiation is based on the intensity of the flashover. A flashover is termed as
‘Spark Type-1’, when there is a instantaneous drop in the output voltage, where as
‘Spark Type-2’ is for sensing of the arcing condition.
Additionally the output current excursions are also taken into consideration.
This control action differentiates between the ‘Spark Type-1’ & ‘Spark Type-2’.
This control action also differentiates between a ‘NORMAL’ flashover and ‘FOLLOW
UP’ flashover (a flashover occurring within a defined period of time after detection of
a ‘NORMAL’ flashover).
The objective is to eliminate further ‘FOLLOW UP’ flashovers thus increasing the
‘VOLT-TIME’ integral, resulting in improved collection efficiency.
Thus the control action automatically optimizes the response to the flashover with a
objective to maximize the ‘VOLT-TIME’ integral, there by contributing to increase in
the efficiency of the precipitator.
The following sketch shows the Current Vs Time characteristics during various
flashovers.
Page 17 of 32 2600-0000-13-21/04
Follow up
Spark flashover
Spark
type 1
Type 1
Spark
Normal
Type 2
Slope S : IDC Set back
S S1: IDC Spl.
S
S+S1 Fast Ramp Setback
I DC
T Follow up
recovery flashover
T Quench
Time
9.2 FAST RAMP CONTROL
In case of fast changes in the operating conditions of the precipitator many sparks may
occur within a short time reducing the current to a low value, when the disturbance
disappears, it may take a relatively long time before the current can assume its normal
value. This is the case, particularly if the selected rate of rise is low.
The fast Ramp control quickly reestablishes (200 % / Min.) to the limiting value much
faster than the normal rate of rise, incase the power level to the precipitator can be
increased , due to favorable operating conditions. This increases the efficiency of the
precipitator.
The control comes into operation after preset adjustable delay, since the occurrence of
the last spark.
10. MODES OF OPERATION

Depending upon the selection by the user , apart from the Normal Mode of Operation,
the following modes of operations can be selected either through keyboard or through
actualization of Digital Inputs.
SELECTION THROUGH KEYPAD:
1. BACK CORONA MODE
2. CHARGE RATIO MODE
3. EMS MODE
4. RAPPER CONTROL MODE
SELECTION THROUGH DIGITAL INPUT:
5. RAPPER REDUCTION MODE
6. LOAD STATUS MODE

6.1 LOAD STATUS - 1 MODE
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10.1 BACK CORONA MODE
During ‘Back Corona’ the precipitator voltage decreases with increase in precipitator current.
This reduces the efficiency of the precipitator and consumes unnecessary increased power.
Back Corona is detected by comparing the ‘PEAK’ values of the precipitator voltage during the
scanning cycles.
The controller responds to both the ‘NORMAL’ mode (i.e. Charge Ratio (CR) =1) as well as the
‘CHARGE RATIO’ mode of operation.
The controller scans the ‘V-I’ curve and regulates to operate at the maximum peak voltage region.
(i.e. Maximum efficiency point).
Under the ‘NORMAL’ mode it backs the power down the V-I curve to establish an optimal
operating point, whereas under ‘CHARGE RATIO’ mode it adjusts the duty cycle to find the most
optimal condition.
Under the ‘NORMAL’ mode, the IDC set point is reduced by a programmable amount in an
attempt to raise the ‘KV PEAK’ voltage to a higher value. This repeats until the ‘KV PEAK’
decreases or the minimum IDC set point is reached. Then the previous set point is the one
maintained for the hold time.
Under the ‘Charge Ratio’ mode, the ‘CR’ is increased in steps of ‘2’, after each iteration. After
each iteration, the ‘KV PEAK” is compared against the previous value, until the ‘KV PEAK’
decreases or the maximum programmed ‘CR’ is reached. When the comparison value decreases
the previous set point of ‘CR’ is maintained for the hold time.
Back Corona region
V-I Characteristics
IDC Step of ESP
Optimum
point
mA
Charge ratio : 1 KV
Page 19 of 32 2600-0000-13-21/04
The parameter which can be programmed for Back Corona Mode & their limits are as follows:-

Back 35 1 Back Corona 0 1 0 L1 P 35 = X
Corona mode BC ON / OFF
0 : Inactive
1 : Active
initiation of BACK CORONA
back corona MEAS
detection cycle
37 2 Minimum 10% of Nominal 80mA L2 P37=XXXX mA
output current nominal IDC BC I DC MIN
in back corona IDC Mean
detection cycle Mean
38 2 Output current 10 mA 300 mA 100 mA L2 P 38 = XXX mA
step reduction BC IDC STEP
in back corona
detection cycle
39 2 Hold time at 5S 60 S 10 S L2 P 39 = XX S
current set BC HOLD TIME
point before
changing of set
point
40 2 Maximum 1 255 17 L2 P 40 = XXX
charge ratio in BC CR MAXIMUM
back corona
detection cycle
10.2 CHARGE RATIO MODE
The user can program and operate charge ratio settings. Pulse operation can be used for improving
precipitator and / or for energy saving depending upon the type of process, Dust resistivity etc.
In a high resistive dust, a potential gradient is created within the dust layers which cause the
occurrence of local sparks in the dust layer. This spurious discharges or ‘BACK CORONA’ occurs
as soon as the potential gradient is sufficiently high. The potential gradient depends on the
precipitator current. This has negative impact on the efficiency of the ESP. The local sparks in the
dust deposits also cause the dust particulates already precipitated to be re-entrained in the gas flow.
The ‘CHARGE RATIO’ mode supplies current in pulses which provide a dense corona for a short
time & at the same time gives a low average current to avoid back corona.
In this mode, the pulses to the thyristor are blocked for certain full cycles after conduction of one
half cycles and this is called as ‘CHARGE RATIO’.
Charge Ratio =1 represents Normal operation (No Blocking).
Charge Ratio = 3 represents blocking for 2 half cycles, after conduction of 1 half cycle. This is
elaborated in details as follows:
Page 20 of 32 2600-0000-13-21/04
The parameter charge ratio can be set from 1 to 255.

AC Input
Non
Conducting
Conducting Half Half Cycles
Cycle CR=3
DC Output
Thus the average power input to the ESP is reduced and energy is saved, apart from increase in
collection efficiency of the ESP.
The longer the time between each current pulse, the lower is the average current as may be
required for the high resistive dust.
However, the ESP trough voltage also reduces pulling down the average voltage. To improve the
trough / average voltage small current pulses are pumped during the blocked periods of the main
current pulse. This facility of operating at a ‘RECAHRGE VOLTAGE’ during the blocked periods
increases the trough / average ESP voltage, thus further increasing the collection efficiency. This
also protects the T/R set against possible core saturation during higher charge ratios.
This is more elaborated in the following sketch.

Charge ratio 5 with recharge
voltage charging AC Input
Voltage Conducting
half cycles
Recharge half cycles

DC Output
Page 21 of 32 2600-0000-13-21/04
The Parameter which can be programmed for Charge Ratio mode are as follows :
Charge 32 1 Number of 1 255 1 L1 P32 = XXX
ratio blocked half CHARGE RATIO (CR)
parameter cycle during
pulsing mode of
operation
33 2 No. of half 0 CR-1 0 L2 P33 = XXX
cycles under RECHARGE HW
conduction of
total blocked
cycles
34 2 Firing angle of 1500 1800 1800 L2 P34 = XXX
Recharge HW RECHARGE FIRING
10.3 EMS MODE

In some type of loads the load characteristics is such that with slight increase in the Voltage, the
current increase is very high. However this increase in voltage is not contributing substantially to
increase in collection efficiency. `PRECICON-III' has built in Energy Management System which
tracks the load characteristics & if the increase in KV is less than the set increase (δ KV), for a set
step change in output current, then it holds the output at this point irrespective of Is Setting.
As the load characteristics

changes from A to B for set
Load
δ KV the increase in mA
δ mA
Characteristics
Load
goes on increasing. For load
`B'
Characteristics characteristics À' the
À'
increase in current is less as
that compared for load
mA
Characteristics `B'. From this

δ KV figure it is evident that for
same increase in KV the
KV
energy requirement for load
having characteristics `B' is
The Parameter which can be programmed for EMS mode are as follows :

EMS 41 1 EMS mode 0 1 0 L1 P 41 = X
parameters 0 : Inactive EMS ON / OFF
1 : Active
initiation of EMS MEAS
EMS detection
cycle
Page 22 of 32 2600-0000-13-21/04
10.4 RAPPER MODE
During Rapping the output can be lowered automatically to a preset level and restored back to
its original level when the rapping cycle is completed. This helps in avoiding occurrence of
undesirable flashovers as well as unwanted dust puffing during the rapping cycle.
A Digital Input is provided for this purpose. The restoring back to the Original level is after a
certain Programmable time delay on completion of the rapping cycle.
The Parameter which can be programmed for Rapper Mode are as follows:

Rapper 65 2 Current limit 0 NOM. NOM. L2 P65=XXXX mA
parameters during rapping IDC IDC RAP IDC LIMIT
MEAN MEAN
66 2 Time for current 0 99 1 L2 P66=XX Min
limit during RAP DELAY TIME
rapping
Page 23 of 32 2600-0000-13-21/04
10.5 LOAD STATUS MODE (LS-1):
Plants which have been designed for varying operating conditions need varying parameter values.
This mode permits the precipitator operations to be adapted to the prevailing operating conditions,
through usage of the optional 2 digital inputs (LS-1). This allows selection between additional 2
sets of the important operating parameters (IDC current limit, Voltage Limit, spark rate, IDC
setback, T-Recovery, Charge Ratio, Recharge Half wave & Recharge Firing). This selection is
made by means of a potential free contacts connected to the digital input.
10.5.1 LOAD STATUS -1
The Load Status Mode of operations greatly helps under different process conditions.
For e.g.: Initial starting of Precipitator, 50% boiler load operation etc.
In this case, based on the actualization of the digital input ( LS-1) the operating conditions can
be set, depending on a group of parameters.
The Parameter which can be programmed for Load Status -1 (LS-1) Mode is as follows:

Load 43 2 Output current 0 mA Nominal Nominal L2 P43 = XXXX mA
Status 1 limit during IDC IDC LS-1 IDC LIMIT
load status 1 Mean Mean
44 2 Output Voltage 15% Nom. Nom. L2 P44 = XXX mA
limit during of VDC VDC LS-1 VDC LIMIT
load status 1 Nom. Peak peak
VDC
Peak
45 2 Current step 4 mA 300 mA 40mA L2 P45= XXX mA
reduction after a LS-1 IDC SETBK
flashover in
Load status 1
46 2 Number of 1 255 1 L2 P46 = XXX
blocked half LS-1 CR
cycles in Load
Status-1 during
pulsing mode of
operation
Page 24 of 32 2600-0000-13-21/04
10.5.2 MODBUS SERIAL COMMUNICATION:

PARAMETER SETTINGS:
PARAMETER LEVEL PARAMETER MIN. MAX DEFAULT

NUMBER. DESCRIPTION VALUE VALUE VALUE
84 2 FRAME: 0 1 0
ASCII/RTU
0 = ASCII
1 = RTU
85 2 COMM. ADDRESS 0 99 0
86 2 BAUD RATE 0 3 3
0 = 1200
1 = 2400
2 = 4800
3 = 9600
87 2 PARITY 0 2 0
0 = NO PARITY
1 = EVEN
2 = ODD
NOTE:
1. FOR ASCII FRAME: NUMBER OF BITS PER CHARACTER
: 1 START BIT
: 7 DATA BITS (LSB FIRST)
: 1 EVEN / ODD PARITY BIT OR NO BIT FOR
NO PARITY
: 1 STOP BIT IF PARITY IS USED AND 2
STOP BITS IF NO PARITY IS USED.
2. FOR RTU FRAME: NUMBER OF BITS PER CHARACTER

: 1 START BIT
: 8 DATA BITS (LSB FIRST)
: 1 EVEN / ODD PARITY BIT OR NO BIT FOR
NO PARITY
: 1 STOP BIT IF PARITY IS USED AND 2
STOP BITS IF NO PARITY IS USED
PARAMETER ADDRESS FOR DCS:

(a) FUNCTION CODE: 01
FOR READING (COIL) STATUS:
ADDRESS: 100 FOR HT-ON / HT-OFF STATUS
(b) FUNCTION CODE: 05

FOR FORCE (WRITE) SINGLE COIL:
ADDRESS: 100 FOR HT-ON / HT-OFF
1 = HT-ON
0 = HT-OFF
ADDRESS: 106 FOR ALARM ACCEPT ON / OFF
1 = ALARM ACCEPT
ADDRESS: 107 FOR ALARM RESET ON /OFF
1 = ALARM RESET
(c) FUNCTION CODE: 03

FOR READING HOLDING REGISTERS:
ADDRESS: 5 FOR READING IDC (MEAN)
ADDRESS: 6 FOR READING VDC (MEAN)
(16 BIT UNSIGNED INTEGER FORMAT)
ADDRESS: 1 FOR READING TRIP STATUS
ADDRESS: 2 FOR READING ALARM STATUS
ADDRESS: 3 FOR READING ACKNOWLEDGE STATUS
ADDRESS: 4 FOR READING RESET STATUS
Page 25 of 32 2600-0000-13-21/04
11.0 FAULT FINDING & TROUBLE SHOOTING:
11.1 TEST MODE
Following are the various hardware & software diagnostic tests which shall be conducted on
PRECICON-III. For Test mode operation press Test key. For changing the tests press Test key and
then press Ï or Ð key, to select the required test mode press enter key
Following is the test mode description.
Test Mode Expected Display
EPROMS PASS Csum = 0000
RAM PASS Ramadr = E800
KEYPAD For numeric key 0-9 display will indicate the particular number. For other
keys following codes will be indicated.
Ï :+
Ð :-
HT ON/OFF : H
COM / CON : C
RAP ON /OFF : R
PASSWORD :P
RESET : r
ENTER : (Blank)
I SET : I
TEST : T
NOVRAM NV PASS
EEPROM EE PASS
LC Display ABCDEFGHIJKLMNOPQRSTUVWXYZ
Abcdefghijklmnopqrstuvwxyz
DIGITAL I/P Display will scan all trip faults. If all trip faults are NC then it will indicate `
OPTIONAL TRIP 1'. If all trip faults made NO then the display will indicate
ÀLL OFF'
Page 26 of 32 2600-0000-13-21/04
Test Mode Expected Display
RELAYS Display will indicate `RELAY # 1 ON' on further pressing enter key relay 2
to 8 will be energized and display will update accordingly.
FIRING Alpha = 18
Fir Time = 1000 Us
By pressing Ï key Alpha & firing time increases and by pressing Ð key
Alpha & firing time decreases.( Step for alpha is 9 & for FirTime it is 500)
ANALOG I/P IS = 20000, VS = 20000

IP = 20000, KW = 20000
The upper limit for all these values is 22000
ANALOG O/P PWM=25%, 50%

Check the 4-20 m A output these should be
For Is = 6 m A ( +/- 0.2 m A)
For Vs = 12 m A ( +/- 0.2 m A)
11.2 FAULT FINDING :
S.NO SYMPTOMS PROBABLE CAUSE REMEDY
1. No LCD Fuse blown, No supply Check fuses

Indication voltage Check input supply
Check SMPS output
2. Keyboard not Keyboard connector Replace controller
responding
3. Faults can not be Check faults does not Remove fault
reset locally exists
4. Faults can not be Check faults does not Remove fault
reset from exists
Remote Check reset function Replace controller
locally
5. Main contactor Check the supply Replace controller

can not be connector connections.
switched ON or Check supply voltage
OFF Check any trip fault
exists
Page 27 of 32 2600-0000-13-21/04
12.0 SPECIAL INSTRUCTIONS FOR

PRE-COMMISSIONING / COMMISSIONING OF T/R SETS
WITH PRECICON-III CONTROLLER
STORAGE:-
1. Store the PRECICON-III Controllers in the corrugated box provided.
2. Do not open the boxes unless all other equipments are ready for
commissioning.
3. Store the PRECICON-III Controllers in normal room temperature, in a

dry weather & dust proof room.
! CAUTION
PRECICON-III CONTROLLER IS A SOPHISTICATED MICRO-CONTROLLER BASED

CONTROLLER. DUE CARE IS TO BE TAKEN DURING HANDLING / STORAGE /
TRANSPORTATION / COMMISSIONING.
Page 28 of 32 2600-0000-13-21/04
COMPLAINT FORM FOR A PRECICON-III
1. Customer / Project :
2. Serial Number of Precicon-III :
3. Details of complaints. :
4. Panel Sr. No. & Rating of the panel :
5. Environment of the room where panel is : Air Conditioned / Pressurized / Non

Ventilated Kept corrosive/dusty.
6. Maximum temperature of the room :

Where panels are kept.
7. Test mode results as per manual :
8. Feedback Voltages measured : Current:

Voltage:
9. Previous repairs carried out if any :

(Please give details)
10. Any other observations:
Sign. : Date:
Page 29 of 32 2600-0000-13-21/04
7. INSTALLATION:
7.1 MOUNTING AND CONNECTION:
7.1.1 Check the main J3 to J10 connector & the power supply connector are connected
properly.
7.1.2 Check the earthing wire to the controller.
7.2 INITIAL START :
Before starting “PRECICON-III”, all safety measures & preparations applicable to the
Electrostatic Precipitator must be performed.
7.2.1. Switch ‘ON’ the supply to the control panel.
7.2.2. Check the supply voltages.
7.2.3. Switch ‘ON’ the control supply to the “PRECICON - III” Controller.
7.2.4. Check if any Alarm / Fault exist.
7.2.5. Check the default parameter are as per the parameter programming list.
7.2.6. Check the Remote / Local function with the help of COM/CON Key so that the
LED on the key becomes ‘OFF’.
7.2.7. Now the unit is ready for starting.
NOTE : Apart from the nominal values of the T/R set, all the other parameters values are
factory set. These settings are in most cases sufficient for perfect operations.
7.3 REMOVING THE “PRECICON-III”
7.3.1 Switch ‘OFF’ the control supply to the “PRECICON-III” Controller.

7.3.2 Switch ‘OFF’ the supply to the control panel.
7.3.3 Remove the main J3 to J10 connector, earth connection & the power supply connector.
7.3.4 Remove the 4 side screws.
7.3.5 Remove “PRECICON-III” from the control panel.
8. OPERATIONS:
START:
8.1.1 Select the Remote / Local key in local mode, by pressing the <COM /CON
> key on the keypad, so that the LED on the key becomes ‘OFF’.
Select the desired current limit. (Parameter No: 25, IDC Limit).
8.1.2 To make HT ‘ON’ press the <HT ON-OFF> key, LED lights on the
keypad, so that the Secondary DC Voltage & Secondary DC Current starts
rising.
8.1.3 To make HT ‘OFF’, press the <HT ON-OFF> Key (LED extinguishes) on the
Keypad.
Page 30 of 32 2600-0000-13-21/04
9. FAULT FINDING & TROUBLE SHOOTING:
TEST MODE / FAULT FINDING:
S.NO. ACTIVITY FUNCTION HEALTHY IF NOT, REMEDY

RESULT PROBABLE
CAUSE
1. SWITCH ‘ON’ THE ---- DEFAULT MAIN FUSE REPLACE FUSE,
CONTROL SUPPLY LCD SCREEN & POWER CHECK SMPS
TO “PRECICON-III” SUPPLY
2. PRESS <TEST>
KEY
2.1 EPROM TEST CHECK SUM 0000 CHECK REPLACE
EPROM CONTROLLER
2.2 RAM TEST CHECK PASS RAM CHECK REPLACE
SUM adr E800 SRAM CONTROLLER
2.3 EEPROM TEST CHECK EEPROM CHECK REPLACE
SUM PASS EEPROM CONTROLLER
2.4 NVRAM TEST CHECK NVRAM PASS CHECK REPLACE
SUM NVRAM CONTROLLER
2.5 KEYPAD TEST KEYBOARD SHORTFORM CHECK REPLACE
CHECK OF KEYS KEYBOARD CONTROLLER
INTERFACE
& CABLE
2.6 LCD TEST DISPLAY 16 CHECK LCD REPLACE
CHECK CHARACTER INTENSITY CONTROLLER
X 2 LINES OR LCD
2.7 DIGITAL I/P TEST FAULT OPTIONAL CHECK THE REPLACE
CHECK TRIP 1 CKT CONTROLLER
2.8 RELAY TEST RELAY ---- CHECK REPLACE
CONTACTS RELAY CONTROLLER
CHECK LOGIC CKT
2.9 ANALOG I/P TEST FEEDBACK FREQUENCY CHECK THE REPLACE
SIGNALS VALUES CKT CONTROLLER
2.10 ANALOG O/P TEST 4mA - 20mA mA O/P CHECK THE REPLACE
CKT CONTROLLER
2.11 FIRING FIRING -------- CHECK REPLACE
PULSES SYNC. CONTROLLER
SIGNAL &
FIRING CKT
Page 31 of 32 2600-0000-13-21/04
9.2 FAULT FINDING:
S.NO SYMPTOMS PROBABLE CAUSE REMEDY

1. NO LCD FUSE BLOWN. CHECK FUSES, MEASURE
INDICATION NO SUPPLY SUPPLY VOLTAGES. CHECK
VOLTAGE SMPS O/P VOLTAGES
2. KEYBOARD NOT CHECK KEYBOARD, REPLACE CONTROLLER
RESPONDING KEYBOARD CABLE
3. FAULTS CAN CHECK FAULTS TO CHECK THE CONNECTIONS
NOT BE RESET THE CONTROLLER
LOCALLY DOES NOT EXIST.
4. FAULTS CAN CHECK FAULTS TO CHECK RESET FUNCTION
NOT BE RESET THE CONTROLLER LOCALLY. CHECK THE
FROM REMOTE DOES NOT EXIST CONNECTIONS.
5. MAIN CHECK THE CHECK THE 24V AC LOGIC CKT
CONTACTOR SUPPLY VOLTAGE,
CAN NOT BE RELAY
SWITCHED OPERATIONS.
‘ON/OFF’
NOTE:
Remedy is given with probable primary cause of problem. However APL recommends to replace
the “PRECICON-III” Controller.
CHECKED BY : GBG APPROVED BY : KVT
DATE : 14 / 04 /09 DATE : 14 / 04 /09
Page 32 of 32 2600-0000-13-21/04

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ADOR POWERTRON LIMITED, PUNE, INDIA

NOTES FOR SAFE OPERATION

ADOR POWERTRON LIMITED

: (020) 27472532, 27473778 , 27471682

Content Page No.

3. Control & User Interface 4

10. Modes of Operation 18

11. Fault finding & Trouble shooting 31

12. Special Instructions 32

13. Complaint Form 33

14. G. A. Drawing of Precicon – III 34

2.0 TECHNICAL DATA

Ambient Temperature : 0 to 50°C (Max.)

Storage Temperature : 0 to 80° C

Duty : Continuous operation (24 hours a day)

Installation : Indoor (Pressurized or AC Room)

2.1 MAINS REQUIREMENT

Nominal Input Voltage : 24 VAC, 50 Hz / 60 Hz, 1φ

Current : 2Amps (RMS) (Max.) , 48 VA

2.2 FEEDBACK’S FOR OPERATION

Output Current Feedback (IDC) : 1 V DC at rated mA Average (Mean) DC

Output Voltage Feedback (VDC) : 400 μA DC at rated KV (Peak)

2.3 DIGITAL INPUTS : Potential Free Contacts

Digital Outputs : Potential free contacts of 3A @ 24VAC (Max.)

3.0 CONTROLS &USER INTERFACE :

Sr. No. Description Status Function Default Condition

The functions of the keypad are as follows:

HT – ON / OFF : For Switching ON/OFF of the HT Contactor (Toggle)

RAP ON/OFF : Rapper mode selection

COM/CON : Communication and controller mode as well as Remote

ISET : Output mA Average (Mean) DC Current set.

TEST : Test Mode Functions in `HT-OFF’ condition and

PASS/PARA : Password or Parameter Programming

0 : Numeric Key & “TYPE-2 Spark Simulation” in‘HT-

BC : Back Corona Mode ON / OFF

EMS : Energy Management System

CR : Charge Ratio Setting

MSR : Maximum Spark Rate

KV : Output KV DC (mean) Voltage

3.3.2 DUAL FUNCTION KEYS :

4.0 DEFAULT DISPLAY:

After Switching ‘ON’ the LCD indicates as follows:

5.0 PARAMETER PROGRAMMING :

5.1 PASSWORD PROTECTION :

5.1.1 PARAMETER PROGRAMMING INSTRUCTIONS :

For editing level I parameters no password is required.

5.1.2 IMPORTANT TO THE USER :

5.2 READ OUT PARAMETERS :

5.2.1 KEY SA : Totalisation of number of `Type -1’ & `Type – 2” flashovers.

5.2.2 KEY TT : Totalisation of time for which the ‘HT’ is ‘ON’

5.3 EDITING AND STORING OF T/R SET PARAMETERS :

5.3.0TRANSFORMER / RECTIFIER DATA:

This is a level II parameter. Enter Level II Password.

This is a level II parameter. Enter Level II Password.

5.3.3 NOMINAL PRIMARY AC (RMS) CURRENT RATING OF T/R SET :( PARAMETER

This is a level II parameter. Enter Level II Password.

L-2 P78= xxx A L-2 P78= 149 A

LOWER LIMIT: 0 UPPER LIMIT: 1

L-2 P80= 0 L-2 P80= 1

5.4 EDITING & STORING OF CONTROL PARAMETERS:

Parameter Parameter Password Description Lower Upper Default Display

57 2 ALL Rappers 0 1 0 L2 P57=X

76 2 NOMINAL 10 220 78 L2 P76=XXX KV