Our Order FO:18289, Dated 09-07-2009

Client’s Ref:PO:MBI077/0090/0/S, Dated 06-07-2009

SUPPLIED TO

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LIST OF CONTENTS
Chapter DESCRIPTION OF CHAPTER Drg/Page
1 General Specification 3
2 Bill of materials 4
3 Do’s and DON’TS for your (ESP) Electrostatic 5
precipitator power supply unit.
4 Silicone oil safety data sheet 6
5 Introduction, Description and operating 9
principle for Electrostatic Precipitator Power
Supply Unit
6 Description of Control Cards
6.1 Firing Module Card 12
6.2 Power Supply Card 12
7 Design and Functions 13
8 Constructional Details 14
9 Installation 16
10 Commissioning and Operations 19
11 Maintenance 21
12 Specification and system description of 28
microprocessor based Automatic Control
System for Electrostatic Precipitator Unit.
13 LIST OF COMPONENTS
13.1 Transformer Rectifier Unit CR-8779,CR-7840
13.2 Electronic Controller Panel CR-8778,CR-7841
14 CIRCUIT DIAGRAMS
14.1 Power & Control Schematics (Sh 1-2) 3C-7175
14.2 Firing Module Card 4C-6280
14.3 Power Supply Card 4C-6180
14.4 Relay Driver Card 4C-4682
15 GENERAL ARRANGEMENTS
15.1 Electronic Controller Panel 3B-8460
15.2 Transformer Rectifier Unit (Sh 1&2) 3T0-4005

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CHAPTER - 1
GENERAL SPECIFICATION

1.1 INPUT
Voltage 415 Volts AC
Phase Single
Voltage Variation ±10%
Frequency 50 Hz
1.2 OUTPUT
Voltage 120kV DC Peak corresponding to
74kV DC mean
Current 1100mA DC mean
Current Regulation ±5% for load variation full load
Configuration Single phase back to back
connected Silicon Controlled
Rectifiers (SCRs)
1.3 METHOD OF By means of Silicon Controlled
CONTROL Rectifier (SCRs)
1.4 AMBIENT TEMP. Ambient : 50°C maximum

1.5 INSTALLATION Electronic Controller suitable for

indoor installation only. Preferably
in Air-conditioned Room
Transformer Rectifier Unit suitable
for indoor/outdoor installation.
1.6 ATMOSPHERE Dusty

1.7 COOLING Transformer Rectifier Oil cooled

Electronic Controller Air cooled
1.8 SCOPE OF SUPPLY Transformer Rectifier Unit
Electronic Controller Panel
1.9 TOTAL WEIGHT Transformer Rect. Unit 2200 kg
Electronic Controller 330 kg

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CHAPTER - 2
BILL OF MATERIALS
2 The Precipitator power supply equipment mainly consists of the TWO
parts viz.;
1. Transformer Rectifier Unit
2. Electronic Controller.
2.1 The transformer Rectifier Unit accommodates HT Transformer, Rectifier,
Linear Reactor, H F Choke, H V measuring module and is equipped
with:
a) Pressure switch
b) Dial thermometer and thermometer pocket
c) Enclosed cable end box for PVC cable in input side and housing the
following
1 AC Input bushing, primary voltage sensing bushing, DC, +VE
bushing and HV sensing bushing.
2 Feedback shunt and Glow tube.
3 Earthing bus and Terminal block.
d) Lifting lugs
e) HV Bushing (DC –VE) of rectified voltage.
f) Pressure release valve.
g) Rating and diagram plate.

The Transformer Rectifier Unit shall be vacuum dried and oil as per IS-
335 shall be filled in vacuum in the transformer. The transformer will be
provided with proper Earthing terminals.
2.2 Electronic Controller mainly consists of the following items:
a) Main Isolating Switch-fuse unit (SW1), Main contactor (K1),
thermal overload relays (O/L1).
b) Silicon Controlled Rectifiers (SCRs) for controlling AC voltage to
the HV transformer primary.
c) Microprocessor Controller (ACE-16)
d) Metering consisting of -
1 AC Voltmeter for measuring transformer Primary voltage.
2 AC Ammeter for measuring transformer Primary current.
3 DC Voltmeter for measuring Output DC voltage.
4 DC milli Ammeter for measuring Output DC current.

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CHAPTER - 3
DO’S AND DON’TS
FOR YOUR POWER SUPPLY UNIT
(Please ensures all the safety interlocks before switching 'ON’)

1 Try to maintain your Panel room ambient low.

2 Keep your panel and Panel room clean, dust free.

3 Go through the instruction and maintenance manual carefully, before

you start working on equipment.

4 Whenever connection is removed and made again, ensure that the

connection is made properly. Avoid loose joints, joint heating and
consequent system shutdown.

5 Trouble shooting chart for transformer rectifier is given in manual. Follow

the thumb rules given in these pages, in case of problem with supply.

6 Adhere to the maintenance schedule for electronic controller/T R Unit

given in maintenance.

7 During trouble shooting, try to use proper tools/ instruments as given in

maintenance section.

8 If the panel trips due to any fault, before switching on the panel, rectify
the fault.

9 Keep the records of all readings including ambient temperature,

transformer oil temperature, etc. regularly. History card shall be
maintained to analyze the cause of failure.

10 In case the user requires services of manufacturer, a detail report of

problem faced shall be sent for analyzing the problem and prompt
service.

11 Transformer shall be lifted to ESP rooftop after ensuring the healthiness.

12 You find that there is a problem in ESP field, do not repeatedly switch on
power supply. This will do good both to your power supply and ESP.

13 Never pull out or inserts plug in connector in live condition. Switch off
contactor and switch fuses unit before you insert/ take out connectors.

14 Do not operate the equipment if there is a malfunctioning of control or

protective circuit.

15 When earth switch is in earth position please do not SWITCH ON TR

Unit

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CHAPTER - 4
TRANSFORMER OIL SAFETY DATA SHEET
4.1 GENERAL

PRODUCT Transformer mineral oil as per

IS:335 or IEC:296 class-I
MANUFACTURER’S NAME Apar Industries Ltd. (Power Oil)
Savita Chemicals Ltd.
4.2 HAZRDOUS INGREDIENTS /IDENTIFY INFORMATION

HAZARDOUS COMPONENTS (SPECIFIC CHEMICAL IDENTITY :

CAS 64742-65-0
COMPOSITION Pure hydrocarbon mineral oil
CAS NAME Medium napphthenic hydrotreated
distillate

4.3 PHYSICAL/CHEMICAL CHARACTERISTICS

SPECIFIC GRAVITY(H2O= 1) ≤ 0.89
VAPOUR PRESSURE(mm Hg) < 0.1
VAPOUR DENSITY (AIR = 1) > 10
APPEARANCE AND ODOUR Water white with peculiar smell
SOLUBILITY IN WATER Insoluble in water
4.4 FIRE AND EXPLOSION DATA
FLASH POINT (METHOD 140°C (ASTM-D 93)
USED)
BOILING POINT Above 250°c

FIRE AND EXPLOSIVE HAZARDS

Slightly combustible liquid when heated above its Flash Point. This
material will release flammable vaporous which can burn in the open
or be explosive in confined spaces if exposed to an ignition source,
must kept away from extreme heat and open flame.
EXTINGUISHING MEDIA
Dry chemical and carbon dioxide foam and water fog are effective but
cause frothing.
SPECIAL FIRE FIGHTING PROCEDURES
Water may be effective but can be used to cool containers exposed to
heat or flame. Caution should be exercised when using water foam as
frothing may occur, especially if spread into containers of hot, burning
liquid.

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4.5 HEALTH HAZARDS
SUMMARY OF ACTUAL HAZARDS
Not expected to present a significant health hazard upon short term
exposure.
ROUTE OF EXPOSURE SIGNS AND SYMPTOMS
INHALATION No significant adverse health effects
EYE CONTACT This product is practically non irritating
to the eyes upon direct contact.
SKIN ABSORPTION No significant adverse health effects are
expected to occur upon short-term
exposure
SKIN IRRITATION No irritation from short-term exposure.
INGESTION Do not ingest. Ingestion is relatively
non-toxic unless aspiration occurs. No
significant adverse health effects are
expected to occur upon short-term
exposure.
CHRONIC HAZARDS Prolonged and/or repeated contact with
the material produces skin irritation and
inflammation.
SPECIAL HEALTH Personnel with pre existing skin
EFFECTS disorders should avoid contact.
4.6 PROTECTIVE EQIPMENTS AND OTHER CONTROL MEASURES
RESPIRATORY Respiratory protection is not required
under normal conditions of use. If vapor
or mist is generated when the material is
heated or handled. Use vapor respirator
with dust and mist filter.
EYE Eye protection is not required under
condition of normal use.
SKIN Avoid prolonged and/or repeated skin
contact, or wear impervious protective
clothing. While leaving work, wash
hands/exposed skin with soap & water.
ENGINEERING CONTROL Use adequate ventilation to keep oil
mists of materials below applicable
standards.
OTHER HYGENIC AND Wash hands with plenty of soap and
WORK PRACTICES water before eating, drinking etc. Take a
shower after work. If general contact
occurs, remove oil soaked clothing.

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4.7 EMERGENCY AND FIRST AID

INHALATION Vaporization is not expected at ambient

temperature and this material is not
expected to be an inhalation problem
under anticipated condition of use. In
case of over exposure move person to
fresh air.
EYE CONTACT Immediately flush eyes with large
amount of water and continue flushing
for 15 minutes, occasionally lifting the
eye lids. If pain or redness persists after
flushing, obtain medical attention.
SKIN CONTACT Remove contaminated clothing. Wash
contaminated area thoroughly with soap
and water. If redness or irritation
persists seek medical attention.

4.8 SPILL AND DISPOSAL

WASTE DISPOSAL Remove to storage or salvage vessels if

METHODS permitted incineration may be practical.
Shut off ignition sources contains spill
and prevents it from entering waterways
and sewers. Maximize product recovery
for reuse or recycling.

4.9 ADDITIONAL PRECAUTIONS

HANDLING STORAGE To avoid product degradation water

AND ECONTAMINATION contamination should be avoided and
PROCEDURES minimum feasible handling temperature
should be maintained. Period of
exposure to high temperature (>150°C)
should be minimized. Product
degradation might increase health
hazard risks.
GENERAL COMMENTS All information is based on data available
from the mineral oil manufacturer. All the
information is based on results gained
from manufacturer’s experience and
tests and is believed to be accurate. We
undertake no responsibility either for the
results derived from their adoption or
possible position in apparent contrast.

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CHAPTER – 5
INTRODUCTION, DESCRIPTION & PRINCIPLE OF OPERATION
5.1 INTRODUCTION
Electrostatic Precipitation is the leading and most effective method for
removal of solid particles from the industrial flue gases. The Electrostatic
Precipitator consists of a large steel chamber and the electrode system.
The high voltage DC supply applied between the emitting and collecting
electrodes, with the emitting electrode connected to negative terminal.
The collecting electrodes are connected to the positive terminal, which
earthed. When flue gas pass through the chamber because of the high
DC voltage the solid particles are ionized and travel towards collecting
electrodes and collected. The rapping mechanism raps the collecting
electrodes and the dust drops in the hoppers. This is finally disposed off.
5.2 PRINCIPLE OF OPERATION
The efficiency in the precipitation in the electrostatic precipitator is
directly related to the level of attainable precipitation voltage. Therefore,
the voltage appearing across electrodes should be maintained at the
maximum level. That can be achieved without producing several
sparking within the precipitator. This voltage level is defined as the
`THRESHOLD of SPARKING’ and it varies with the configuration of the
precipitator and the characteristic, temperature and velocity of the gas
and other process parameter. Hence output current of power supply unit
shall be capable of being varied over wide range to achieve the optimum
condition.
The control unit regulates the average value of the precipitator current in
a closed loop control system. The current is measured by means of a
current shunt. The precipitator current and thereby the corona power is
adjusted by means of two anti-parallel Thyristor, which control AC
voltage applied to the high-voltage transformer. The secondary voltage of
transformer is rectified in a single-phase bridge rectifier and then applied
directly to the electrostatic precipitator with a negative polarity. The SCR
has fast response characteristics. This characteristic of SCR is utilized in
control of ESP power supply. The precipitator voltage/current is brought
down to zero, after every spark/arc and maintained it at zero for preset
period and then built it at a fast rate, to the predetermined value. This
method of control result in effective spark/arc quenching and at the same
time helps in maintaining a higher average precipitator voltage. This
results in higher precipitator efficiency.
5.3 DESCRIPTION OF POWER CIRCUIT
The SCR controlled precipitator power supply system consists of Two
units, the TRANSFORMER RECTIFIER UNIT (TRU) and ELECTRONIC
CONTROLLER (EC).
The T R Unit consists of HT transformer, linear reactor and Rectifier
diode stack with voltage sharing resistor, hole storage condenser, HT
feed back resistors and high frequency choke. All these components are
oil immersed, and housed in a Tank.

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The components in the electronic controller are shown in the power
circuit diagram. SW1 is the main fuse switch unit consisting of switch
SW1 and HRC Fuses FS1-2. Aux. Transformer TR2 is provided for
Cubicle light and socket supply. This transformer is provided with fuse
FS3 and FS4 on input side. When the auxiliary power supply of 110V
AC is made available through this transformer, the cubicle light
switches ON in case of front door open. The cubicle light is interlocked
to the front door by means of micro switch MS1 When the main switch-
fuse unit. SW1 is made ON; the power is made available to Aux.
Transformers TR1 and TR3, ACE16, control card and also control for
contactor coil, hooter, indicating lamps for various functions. K1 is main
contactor. Switching ON and Off this contactor controlled by ACE16
Various interlocks are provided in the contactor circuit so that Incase of
faults, the contactor will be switched OFF. When the contactor is
switched ON, the AC supply is made available to the SCR regulator.
This single-phase regulator consists of SCR1-SCR2 connected back to
back. The snubber network consists of R1a, C1a, R1b & C1b provided
across the SCRs for surge protection. Also Input surge suppression
network is provided for the AC regulator protection. Current
transformers (CT1-CT2) are sensing primary current to monitor primary
current and sensing PY overload through thermal overload relay O/L.
VM1 is the AC Voltmeter, which monitor the primary voltage of the
transformer. DC meters are provided across the shunt and HT
resistance column and are shown in circuit as AM2, VM2. All the
interconnections for remote indication and alarm are wired to the
terminal block TB1. Potential free contacts are made available for
REMOTE ALARM, TRIP and HT ON. Facility is also available for
REMOTE START, STOP.
The ACE16 is also interlocked in such a way that in case of Process
Fault, the unit is made to trip. For this purpose, NC contact from
process fault has to be made available as shown in circuit diagram.
MTR is the main transformer stepping up regulator output voltage to
required kV. This Main Transformer Secondary voltage is rectified by
means of Rectifier Bridge MR.
This Rectifier stack consists of number of silicon diodes connected in
series by means of suitable voltage sharing resistors and hole storage
capacitors. The linear reactor L1 connected in series with primary of
Main transformer for reducing the short circuit currents under sparking/
Arcing conditions. L2 is a high frequency reactor used for limiting the
rectifier discharge current due to transformer capacitance during
sparking. The Shunt (R) is secondary current sensing resistor and is
connected in positive terminal of rectifier and GND. Overvoltage
protector glow tube is used as backup protection in case of shunt open.
High voltage DC sensing circuit consists of a number of high voltage
resistors in series (RX) which convert high DC voltage to microampere.
A micro ammeter calibrated in DC kV measures the DC output voltage.
The HV resistance column is located in the TRU and Meter is mounted
on the front panel of the control cubicle. Protection by means of over
voltage protector is provided to this circuit.
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5.4 BUILT-IN TYPE EARTHING SWITCH
The Earthing switch provided is oil immersed and is housed in the T R Unit
tank. The switch is single Pole two way type. One position of switch is
connected to earth and other position is connected to H T output terminal
inside tank. The pole is connected to HT output bushing, which is ultimately
connected to the field. The whole switch assembly is mounted on a plate,
which is housed inside the transformer tank. The moving blade i.e. pole and
fixed H T contact is mounted on suitable H T epoxy insulators. The earth
position of switch is brought out through LT aux bushing for earth connection.
For changeover, a handle is provided on the top of the T R Unit tank
and is projected out on the T R Unit lid. This is manually operated
handle. The field can be either connected to HT DC output or earthed by
operation of this switch. A limit switch is provided such a way that when
the switch pole is connected to earth position, NC contact of the limit
switch which is wired in series with the starting circuit of main contactor
will open and the T R Unit will be tripped. As long as switch is in the
earth position the T R Unit cannot be switched ON. A mechanical
stopper is provided for the switch handle at both positions on the T R
Unit lid. This is to ensure that the switch blade does not over travel
beyond its contact positions inside the tank. A provision is also made on
T R Unit lid to mount the castle key interlock (Castle key interlock is not
in HIRECT scope). The castle key interlock can be provided such a way
that the switch can not be earthed when the T R Unit is in ON condition
or if the switch is in earth position it can not be put back to H T position
unless all ESP doors are closed and all safety interlock are complete.
Thus with operation of this, Earthing Switch field can be earthed or can
be connected to HT output internally with proper safety interlock.
NOTE WHEN EARTH SWITCH IS IN EARTH POSITION
PLEASE DO NOT SWITCH ON THE T R UNIT
5.5 GENERAL OPERATING INSTRUCTIONS
The SCR Controlled Power Supply Unit has sophisticated control and
hence proper care has to be exercised in utilising the same.
1 Before switching ON the unit please see that all the connections from
main supply to the Electronic Controller and Transformer Rectifier Unit
are properly made. See that the relays are properly placed and control
cards are properly inserted in the proper place.
2 Terminals 8, 9 and 10 of The Electronic Controller shall be connected to
the terminals 8, 9 and 10 of Transformer Rectifier Unit respectively by
means of a three core shielded cables.
3 SCRs are mounted on the suitable heat sinks for cooling. When Unit is
ON these heat sinks will be LIVE and hence DO NOT TOUCH THESE
HEAT SINKS ON LIVE CONDITIONS. IT MAY RESULT IN SHOCK.
4 It is recommended that no printed card is removed or inserted with the
unit energised i.e. with SW1 in ON condition. Always switch OFF the
SW1 before you insert or pull out the card.
5 The power supply adjust it self to the varying Precipitator conditions by
operating the constant current or spark rate spark rate mode. Hence no
attention is normally required.

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6.0 DESCRIPTION OF 2 Way FIRING MODULE Ref.4C-6280
2-way firing module card consists of two channels for generating HF
train of pulses for firing of Thyristors. The output (G-K) of each channel
is isolated from the input side by the use of pulse transformers.
Connect 17VAC at J1-3, J1-4 to generate +12V regulated power
supply with help of diodes D1 - D4, L1, C1, C3 and regulated IC U1
(LM7812). Unregulated supply of +20V is available at point B, which
feed to both section of the pulse transformer.
Negative going variable Thyristor firing pulses (F = 50Hz) is applied
between J1-1 and J1-2 of channel-1. U2 (IC LM555) generates high
frequency pulses of frequency ranges form 8 to 10 kHz for a duration
when Q2 is OFF. MOSFET Q1 (IRF 540) is driven by output of U2. Q1
switches at HF and acts as a buffer to drive the pulse transformer T1.
This in turn energizes the pulse transformer T1. An isolated train of
pulses is obtained at G1-K1, which can be used to fire an SCR.
Operation of channel 2 is same as channel-1, same negative going
variable Thyristor firing pulses (F = 50Hz) is applied between J1-6 and
J1-5. Output train of pulses is obtained at G2-K2.
LED1 = +12V ON indication.
LED2 = Channel 1 ON indication.
LED3 = Channel 2 ON indication.
6.2 +5V/0.6A, ±12V/0.5A POWER SUPPLY CARD (Ref.4C-6180)
The 8V AC signal is apply to connector J1-1 and 2, which fed to +5VDC
regulated IC (U1) after rectified (D1-D4) and filter by capacitor (C1-C2). The
Plastic package IC LM317T gives +5VDC-regulated supply and +5Vdc will
be adjusted with help of VR1. The LED1 will indicates healthiness of the
power supply.
The 15V - 0 - 15Vac signal is apply to connector J1-4, 5 & 6. Diodes D6 to
D9 rectify this AC signal and capacitors C6, C7, C10 & C11 filter the same.
These unregulated signals are fed to the IC U2 (LM7812) and U3 (LM7912),
which give regulated ±12V Vdc power supply. The LED2 & 3 will indicate
healthiness of the power supply.
NOTE Same card can be use for other ± Power Supply using
following components and input signal.
OUTPUT VOLTAGE INPUT SIGNAL AT J1 4-6 COMPONENT
FOR ± 5Vdc 8V - 0 - 8V LM7805 & LM7905
FOR ± 8Vdc 11V - 0 - 11V LM7808 & LM7908
FOR ± 12Vdc 15V - 0 - 15V LM7812 & LM7912
FOR ± 15Vdc 18V - 0 - 18V LM7815 & LM7915
FOR ± 24Vdc 25V- 0 - 25V LM7824 & LM7924

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CHAPTER - 7
DESIGN AND FUNCTION
7.1 TRANSFORMER RECTIFIER UNIT
The Transformer Rectifier Unit is build-up like a welded steel tank and filled with
suitable coolant. The Tank is with totally sealed type construction provided with
corrugated wall panels welded to the tank body. The T R Unit is provided without
conservator and breather and there is no air column present in the tank. The cooling
oil is filled upto the top of the T R Unit the marking on the oil level Indicator. The
specially designed corrugated wall panel provides sufficient cooling area and also
takes care of the oil expansion/contraction caused by the temperature differences in
T R Unit.
The corrugated wall panel gives more compactness to the Transformer
Rectifier Unit and saving in steel and oil. The oil expansion and contraction is
taken care of by below action of the corrugation itself. Thus with the
elimination of the contact of the oil with external air, the whole arrangement
becomes totally sealed type. Standard cooling liquid used is mineral
transformer oil and meets the specifications according to IS-335. The oil is
used as an insulating medium for the appearing high voltage and as a heat
transfer medium as well. Immersed in the oil are the H V transformer M TR,
Current limiting reactor L1, Rectifier bridge MR, HF choke L2, and the voltage
divider network RX. This whole assembly is mounted at the bottom of the T R
Unit and the lid is used just to cover the tank. Suitable neoprene gasket is
provided between the lid and tank top flange to make it airtight.
7.2 THE H T TRANSFORMER MTR
The HT transformer is a step-up single Phase core type transformer. The
windings are vertically mounted on the two limbs of the core. The HV windings
are of a special design to secure a proper distribution of the surge voltage
occurring at flashover in the precipitator. The HV coils are wound in the form
of disks and are connected in series to get required secondary voltage. An
earth shield is provided between primary and secondary winding for
protection.
7.3 CURRENT LIMITING REACTOR L1
The separate Iron cored choke is connected in series with the primary winding
of the H T transformer and fitted on the top of the transformer.
7.4 H V RECTIFIER BRIDGE MR
The single phase full wave rectifier bridge is made up of a large number of
silicon rectifier diodes mounted on PCBs. Number of such PCBs are
connected in series depending on the secondary voltage to form a rectifier
bridge. A capacitor is provided in parallel with each diode for hole storage
protection and a resister is provided in parallel with each diode to ensure
equal voltage distribution across each diode.
7.5 H F CHOKE L2
The H F Choke is an air cored. The HF choke attenuates surge voltage and
currents occurring at flashover in precipitator, especially at high frequencies.
7.6 VOLTAGE DIVIDER RX
The voltage divider (RX) consists of number of thick film resistors connected in series
to form a high voltage resistor. The resistors are mounted on PCBs and the PCBs are
connected in series to get required voltage feedback.
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CHAPTER - 8
CONSTRUCTIONAL DETAILS

8.1 TRANSFORMER RECTIFIER UNIT

The Transformer Rectifier Unit houses the linear reactor L1, High
Voltage step-up transformer MTR; the high voltage diode bridge
rectifier modules MR, high frequency choke L2 and high voltage
resister column RX. All these components are oil immersed natural
cooled. In a completely covered weather proof, air cooled terminal box
on side of transformer unit are housed the following components.
1 AC input terminals in the form of porcelain bushing marked C & D
where the incoming power cables are to be connected.
2 Auxiliary bushing terminals for HV measurement marked 01, terminal
for Py voltage sensing marked 02 and terminal for DC positive marked
+VE.
3 Single pair protector box housing glow tube GLT2.
4 Aux. terminal blocks where the incoming control cables are to be
connected. The wiring of the terminals of oil temperature indicator, dial
type thermometer, sensing circuit is terminated on this Aux Terminal
block, TB4.
5 The high voltage negative terminal of the DC output is by means of
side mounted HV bushing insulator of 52kV class. The termination of
the -VE is in the form of M12 stud.
6 The tank is made-up of robust leak proof welded steel structure
rectangular in shape with suitable stiffeners wherever required. It is
filled with adequate quantity mineral oil for insulation and cooling.
Adequate cooling arrangement is provided wherever required by
corrugated walls for ONAN cooling. The following fittings are provided
on TR Unit tank.
7 Two Earthling terminals of M12 size near bottom end of side wall. The
main earth bus is to be connected to these terminals for positive
earthing of unit.
8 Tank lifting lugs
These are provided for use during unloading of the T R Unit at site and
for lifting the unit for installing at its place.
9 Top filter valve
This is provided with a plug and is fitted on topside of transformer tank.
10 Drain cum filter valve
This is provided at the bottom side of the tank wall and is of 1" size. Plug
is also provided on this valve to protect it from mechanical damage and
ingress of dirt.

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11 Dial Thermometer:
The dial thermometer senses the temperature of the oil in transformer
and gives indication on the dial fitted in pocket mounted on lid. The
thermometer has two electrically free auxiliary contacts, which close at
preset temp. The recommended settings are 95°C for the alarm and
100°C for trip contact. These terminals are wired to auxiliary terminal
block for extending signal to control panel.
12 Pressure release valve
This is a pressure release device mounted on the tank lid to protect
against abnormal pressure build up inside the oil tank. This consists of
an opening connecting the tank to a bypass. The opening is normally
blanked by a spring loaded plunger. In case the tank inside pressure
builds up to a value exceeding the pressure setting of the spring, the
opening gets connected to the bypass relieving the tank inside of
excessive pressure build up. The bypass is connected to outside
atmosphere by means of an L bend pipe so that the oil which comes
out does not spill over lid of a Transformer.
13 Pressure Switch
This is a pressure sensing device mounted on the top of the
Transformer Rectifier Unit, which trips the TR Set in case of excessive
pressure in the TR Unit. The range of the pressure switch is 0-1.6 Bar
adjustable. The switch is set to trip at 4PSI pressure and reset at 2PSI
pressure. The changeover contact provided with pressure switch trips
the T R sets when the pressure switch operates.

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CHAPTER – 9
INSTALLATION
9.0 TRANSFORMER RECTIFIER UNIT
9.1 GENERAL
The transformer rectifier unit is oil filled (ONAN) cooled. It is designed for
outdoor duty suitable for mounting on the top of the precipitator as
required. However it can be installed indoors also in the room. The
electronic controller is of freestanding type suitable for floor mounting and
is designed for indoor duty. Both, Control cubicle and Transformer
Rectifier is designed to operate in a maximum ambient temp of 50°C.
9.2 INSTALLATION
The T R Unit is preferably placed on rails with blocking facilities, ensuring
the minor movement in all directions. When several T R Units are placed
close to each other, the minimum distance between the two units must be
500mm. If the units are placed under environmental conditions, causing a
drop in the cooling efficiency, the coolers must be cleaned more
frequently.
Cable entry into the LV junction box, is from bottom. The power line is
directly connected to the LV bushings.
9.3 ELECTRICAL COMMISSIONING

NOTE When tightening, use counter force to ensure that the

bushing bolt is not moved. This is to minimize the risks
for bad connections inside and oil leakage as well.
Flashover in the precipitator is generating surge currents and voltages in the
system. To avoid surge between different units in the system (May be kV), it is
very important that the ground wiring is made up according to figures.
The main ground terminal of the T R Unit in the positive DC connection of
the rectifier as well. The ground terminal is has to be connected to the
precipitator ground terminal via the tank ground terminal. A grounding link
has to be made over every bus duct joint, between the rectifier and
precipitator, before commissioning. When a safety switch is installed for
disconnecting the primary side of the T R Unit during maintenance work,
the aux. contact of this switch preferably has to interlock main contactor.
9.4 PRE-INSTALLATION CHECKS/TESTS - RECTIFIER TRANSFORMER
Check the di-electric strength of oil in the main tank. Samples should be
taken through the drain/sampling valve provided at the bottom of the
transformer tank. It should not break down below 50kV across 2.5mm
gap. If the transformer oil fails this test, it should be filtered till the above
values are achieved.
1 Checking of insulation resistance with 1000 V DC megger
2 Remove all bushing external connections. Short primary side bushing
i.e., C, and 02. Short Secondary side bushing i.e. 01, +VE and -VE.
Connect the Meggar between primary to earth, Secondary to earth and
primary to secondary. The minimum value of insulation resistance
should be as follows:

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Primary to Earth – 100mΩ
Secondary to Earth - 750mΩ.
Primary to Secondary – 750mΩ
4 If any of the above IR values are low the transformer oil should put on
circulation through filter plant till IR value comes to required value.
5 Reconnect the earth connection to the +VE bushing
6 Check oil level and top up if found necessary.
7 Carry out no load test as mentioned by applying rated primary
voltage(As indicated on the T R Unit rating plate). This voltage shall be
applied between terminals C and D in a terminal box. Note that the no
load current should be less than 6% of the full load current
The voltage should be applied for At least 10 minutes in which time
neither the input current should rise nor should there be any unusual
noise from the transformer tank. If the current is high or any
tracking/arcing noise is heard from the tank, the Marketing
Division/Branch Office should be informed and the transformer should
not be lifted to ESP.
CARE MUST BE TAKEN TO ISOLATE THE AREA WHEN
CARRYING OUT NO LOAD TEST, AS FULL RATE HV APPEARS
AT -VE BUSHING. UNAUTHORISE PERSON SHOULD NOT BE
ALLOW NEAR THE AREA.
9.4.8 After completing above steps the transformer can be lifted to ESP.
9.5 PRE-INSTALLATION CHECKS/TESTS : CONTROL CUBICLE
9.5.1 Checking of insulation resistance with 500V DC Meggar.
1 Remove ACE16 controller from panel.
2 Remove auxiliary contactors
3 Remove firing module and other controller card
4 Remove fuses of auxiliary transformer wired to cubicle light
5 Switch ON Switch fuse unit SFU.
6 Mechanically short Main Contactor K1
7 Short input and output terminals i.e. A, B and C, D.
8 Short Gate, Cathode & Anode of the SCRs.
9 Short input surge suppression condenser.
Connect Meggar between line & earth. The minimum value of
insulation resistance should be 5MΩ. If IR value is less than 5MΩ.
2KW heater may be placed inside the cubicle for drying it till the IR
value comes to required level, Considerable improvement in IR value
can be obtained by thoroughly cleaning the insulation parts and making
it free from dust and moisture by clean cloth.
9.5.2 CHECKING OF OTHER COMPONENTS
1 Checking of all the fuses and their correct rating.
2 Ensure that all control cards are pushed in properly.
3 Ensure that all the contactors are connected properly.
4 Clean the cubicle using cloth and blower to remove all the rust from the
surface of all components especially SCR and heat sinks.
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9.6 INSTALLATION - CONTROL CUBICLE
The control cubicle is suitable for floor mounting and foundation holes
are provided for fixing the cubicle to the foundation of necessary. The
control room shall be air conditioned for proper cooling to make it dust
free. Before making interconnection to the Main switch board, control
cubicle, the TR. Unit and the precipitator, the circuit enclosed in the this
manual shall be carefully studied for familiarizing with interconnections.
All wedges and the like of which are fitted by the manufacturer to
prevent damage during transit and are identified by caution label,
should be removed and all items which have been tie-up to prevent
movement during transit must be released.
9.7 INTERCONNECTIONS/CABLING :-
The various power and control connections in the control cubicle and T
R Unit are terminated on suitable terminal board and the high voltage
connections on suitable bushings. All the control interconnections shall
be done by means of shielded cables. The power connections shall be
done by means of suitable power cables as per standard practice. The
cable sizes for various ratings are given in the table in the General
Arrangement Drg. for the control cubicle.
The HT connections are done in an enclosed ducting. Earthing of T R
Unit and the control cubicle should be done properly and for this
purpose the stud has been provided on the T R Unit whereas in the
control cubicle an earthing bus and two numbers of studs have been
provided.
9.8 PRE-COMMISSIONING CHECK UPS
The following pre-commissioning check-ups may be carried out on
transformer
1 Disconnect the transformer rectifier from the control cubicle as well as
from the precipitator. Check IR value of primary and secondary
windings as outlined.
2 Apply a variable AC voltage to the transformer Primary terminals C &
D/C in the terminal box by means of an Auto Transformer. A voltmeter
and an ammeter may be used for measuring the voltage and current
shown in the circuit. An HRC fuse of 10A capacity must be
incorporated in series with the transformer primary to protect the
variac. Increase the voltage gradually and note the increase in the
current. Observe a current at the rated voltage. This reading shall be
as per the reading in the test profarma and is always less than 6% of
the rated Py current. If the T R Unit is faulty then a ammeter may kick
suddenly at some point. The voltage shall be brought to zero
immediately. This shall be notified to our Marketing Div./Branch office.
3 Testing of the control cubicle separately on resistive load. Refer ACE-
16 controller’s installation instruction.

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CHAPTER - 10
COMMISSIONING AND OPERATION
10.1 OPERATION
Generally check the following
No transit damage.
No loose components or connections during transportation.
The cabling is made up according to contract documentation and
according to mandatory requirements of the authorities if applicable.

PLEASE OBSERVE THAT WRONG CONNECTION

MAY CAUSE SERIOUS DAMAGES ON THE
EQUIPMENT, WITH A LOT OF COSTS INVOLVED,
NOT COVERED BE THE WARRANTY. WHEN IN
DOUBT, DO NOT HESITATE TO CONTACT US.
Check in the T R Unit that >
Check that the Bushings are not damaged or moved.
No oil leaks are visible. Retighten the top nut if necessary.
The grounding is made as follows >
The main ground terminal of the T R Unit is the POSITIVE DC
connection of the Rectifier as well. The main ground terminal is located
on the LV junction box and has to be connected to the precipitator
ground terminal via the tank ground terminal. The grounding link has to
be made over every LV bus duct joint between the rectifier and
precipitator. Before commissioning, make a special check on every
ground connection. When the safety switch is installed for the
disconnecting the primary side of the T R Unit during maintenance
work, the auxiliary contact of this switch preferably has to interlock the
Main Contactor.
The ground connection to the measuring shunt is intact.
The H V bus duct is connected to ground.

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10.2 FUNCTIONAL CHECK

WARNING AT ANY OCCATION AT POSIBLE CONTACT WITH
LIVE PARTS, WHEN WORKING WITH EQUIPMENT,
SWITCH OFF THE MAIN SWITCH AND CONNECT THE
H V OUTPUT TO GROUND, IF APPLICABLE.
All the check functions important for the operation and for security
reasons are available in connection with the commissioning.
ALARMS
Simulate faults according to the different procedures below and check
that alarm is indicated on the control Panel. Also refer the Circuit
diagram to avoid wrong steps.
1 Oil gas Alarm
Link the connections on level indicator, located in the monitoring
device. Check that alarm indication is obtained. Restore the level
indicator.
2 Oil High Temperature Alarm
Link the connections on thermostat located in the monitoring
device. Check that alarm indication is obtained. Restore the
thermostat.
AUXILIARY CIRCUIT
The tripping facilities in the interlocking circuit have to be checked after
the installation, to ensure proper functioning. Make sure that loosens
wires do not touch any live parts. Proceed as below.
1 Disconnect the one of the connections on the dial thermometer
located in the monitoring device. Check that the Rectifier cannot be
switched on. Restore the thermostat.
2 Disconnect the one of the connections on the pressure Switch
located on the monitoring device. Check that the Rectifier cannot be
switched on. Restore the pressure switch.
3 If both the Control Cubicle and the T R Unit are found all right then
the connections to the Control Cubicle, T R Unit and the
precipitator chamber shall be made again.

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CHAPTER - 11
MAINTENANCE
11.1 PREVENTIVE MENTENANCE
Warning BEFORE STARTING ANY MAINTENANCE ON THE
EQUIPMENT, MAKE SURE THAT NO LIVE PARTS ARE
ACCESSIBLE BY ANY PERSONEL.
GENERAL
This Rectifier needs normally very little maintenance, but to ensure
proper duty and to minimize the total maintenance coasts, it is
advisable to carry out some activities. The period of time between each
maintenance depends on the environmental conditions and duty.
Accordingly, the time interval must be determined by operational
experience.
CLEANING
To minimize the risks for excess temperature in the T R Unit, clean the
cooling elements and the tank-sides at necessary time intervals.
Minimum annually.
OIL TESTS
To avoid damaged HV components, check the insulation condition of
the oil every fifth year. The oil sample must be taken at dry weather
and in dry containers. The suitable volume sample is about 200-300
milliliters, taken out from the bottom test/drain valve. The sample may
preferably be sent to a suitable laboratory to make analyses of mainly
the flash over limits, the isolation characteristics, the loss factor and the
water content. If the analysis shows that the oil does not meet the
specification, or at least very closed to, it has to be exchanged/ filtered.
Water together with particles can be removed in the paper filtering
press. The filtering is preferably carried out during about 10 hours, with
the Rectifier in short circuit operation.
OIL LEAKAGE CHECKS
Larger oil leaks are monitored by oil level indicator and indicates low oil
level alarm. Visual check is preferably carried out regularly.
If leaks occur in the bushing insulator during the first period of duty, the
top nut has to be retighten to the correct torque stated below.
Exchanging of the top O ring of the bushing insulators can be done
without draining any oil/ However, a small amount of air will leak during
the exchange. Proceed as follows.
1 Make sure that the power supply is switched OFF and locked
before starting any work on the unit.
2 Disconnect the wiring to the bushing.
3 Prepare tools and O-ring for a quick exchange. Preferable apply
perma-tex. on the O-ring tightening surfaces.
4 Disconnect the fixing nut and washer on top of bushing.
5 Remove the top porcelain ring the rubber O-ring. Make sure that
the bolt is always towards you in order to minimize leak of liquid.

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6 Fit the new O-ring.
7 Fit the porcelain top ring and the rubber O-ring, the washer and the
nut. Before tightening, make sure that the bolt is centered to the
hole in porcelain body.
8 After 48 hours, retighten with torque according No. 8
9 If the distance between the porcelain, on both sides of the O ring,
after the final tightening is less than above 1mm, an additional plain
rubber washer may preferably be placed on the top of O-ring. This
will equalize the difference in size of the concave space for the O-
ring and give better tightening.
10 Reconnect the wiring.
11.2 STORING INSTRUCTIONS
Store the equipment preferably in a dry well ventilated space. If this type
of area is not available, make provisions for avoiding humidity to make
any harm on the equipment. This can be achieved by wrapping with
water proof paper with sufficient desiccant inside. If to be store in the
transport packing, open the packing and check for transport damages,
entered water or oil leaks. By approved checks, place some desiccant
inside and restore the package. The package must not be placed
outdoors.
11.3 TROUBLE SHOOTING

WARNING TO AVOID PERSSONAL INJURY, DO NOT PERFORM ANY

SEVICING UNLESS YOU ARE QUALIFIED TO DO SO.
Methods for electrical trouble shooting, described in the following
chapter, are base on use of an ohmmeter with maximum 6 Volts
measuring voltage and a multi-meter with input resistance of minimum
20000 ohms/Volt DC and 1000 Ohm/V AC. Instruments with other data
are possible to use if influences on measured values are calculated. At
any error indication in the ESP installation, the error must be localized
to either the rectifier or the precipitator with surrounding equipment.
When an error is indicated to be in the rectifier, start to carry out the
open circuit and short circuit test described below. If both tests are
approved the rectifier is in all probability correct. If any of the tests are
not approved, proceed on suitable trouble shooting according to error
indication occurred.
11.4 OPEN CIRCUIT TESTS PROCEDURE
1 Switch OFF the Rectifier.
2 Isolate the precipitator from the HV output. If an isolator is not
available, a part of the HV busbar has to be removed. Please note
that ground connections are properly made of both sides of parts to
be removed. After the busbar removal, remove ground connection
on rectifier HV output
3 Set the precipitator current limit to about 20%.
4 Switch ON the Rectifier.
5 Set the precipitator voltage limit to maximum.

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6 If the kV-meter shows more than 80% of the Rectifier nominal
precipitator voltage, the test is approved.
7 If the voltage is limited to a low value, proceed the trouble shooting
in the controlling and regulating circuits.
11.5 SHORT CIRCUIT TESTS
1 Switch OFF the Rectifier.
2 Connect the H V output to the ground.
3 Set the precipitator current limit to about 20%.
4 Set the precipitator voltage limit to maximum.
5 Switch ON the Rectifier.
6 Check that the current is increasing slowly and is limited to a value,
the corresponding to set current limit.
7 Increase the current limit setting to 100%.
8 If the precipitator current increase to the Rectifier nominal
precipitator value, the test is approved.
9 If the current is limited to a low value, proceed the trouble shooting
in the controlling and regulating circuits.
11.6 TESTS ON H V TRANSFORMER
1 Switch OFF the Line voltage.
2 Switch OFF the Rectifier.
2 Disconnect the incoming power line on the LV bushing insulators
3 Isolate the precipitator from the H V output. Also refer to open circuit
test Item-2.
4 Connect an single phase variac in series with an A-meter. (0-15A)
to the LV bushing insulators for the power line connections.
5 Increase the variac voltage to about 90 % of nominal input line
voltage. The output HV shall be minimum 70% of nominal HV.
6 Low voltage as a result of item 5 may depend on interruption in HV
transformer, Rectifier bridge or voltage divider for the kV-meter. Also
the kV-meter itself may be faulty.
7 In a A-meter reading is already maximum at a very low variac
voltage, the Rectifier bridge is very likely to be short circuited. Also
the kV-meter itself may be faulty at the same indications but it is
more unlikely.

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11.7 INTERCONNECTIONS/CABLING
The various power and control connections in the control cubicle and
transformer rectifier are terminated on suitable terminal boards and the
HV connections on suitable bushings. All the control connections shall
be done by means of 2.5mm2 control cables. However the connections
from the shunt and HV metering circuit on the transformer rectifier unit
to the control cubicle should be done by means of shielded cables. The
power connections shall be done by means of the cable sizes for
various ratings are given in the table in the General Arrangement
drawing for the cubicle. The HT connections are done in an enclosed
ducting. Earthing of The T R Unit and the Control Cubicle should be
done properly and for this purpose a M12 stud has been provided on
the transformer rectifier unit whereas in the control cubicle an earthing
bus and two numbers of M12 studs have been provided.
1 Disconnect the transformer rectifier from the control cubicle as well as
from the precipitator. Check IR value of primary and secondary
windings as outlined.
2 Apply a variable AC voltage between the transformer primary terminals
(C-0 in terminal box) by means of an Auto transformer. A voltmeter and
an Ammeter may be used for measuring the voltage and current as
shown in the circuit diagram fig.2. An HRC fuse of 10A capacity must
be incorporated in series with the transformer primary to protect the
variac. Increase voltage gradually and note the increase in the current.
Observe the current at the rated voltage. This reading shall be as per
the reading in test Performa and is always less than 6% of rated
primary current. If the transformer rectifier is faulty then the ammeter
may kick suddenly at some point. The voltage shall be brought to zero
immediately. This shall be notified to our Marketing Div./Branch office.

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11.8.1 CONTROL CUBICLE MAINTENANCE SCHEDULE

SR. INSPECTION ITEMS TO INSPECTION ACTION TO BE TAKEN IF

NO. FREQUENCY INSPECT NOTES INSPECTION IS
UNSATISFACTORY
1. Monthly Heat Sink Clean If required these may be
thoroughly touched up with black paint
Matt finished to improve heat
dissipation.
2 Monthly SCRs Connections Tight connection is required.
3 Monthly Electrolytic Leakage of Replace condenser.
capacitor electrolyte

4 Monthly Paper Oil leakage Replace condenser.

condenser
5 Monthly Resistor/ Burning Replace resistor.
surface
condenser
6 Quarterly Contactor Pitting on Replace pitted contacts of
contactor contactor.
7 Quarterly Switches Free If not replace.
operation
8 Quarterly Push Free If not replace
Buttons Operation
9 Yearly Meters Calibrate Overhaul/recalibrate or replace
as required.
10 Yearly Power Tightness If mechanical tightening does
not improve bad joints, its
surface should be cleaned with
00 size emery paper, smeared
with silicon grease and then
tightened
11 Yearly Contactor Coil Replace/rewired overheated
connection coil.
12 Yearly Complete Insulation Clean or dry out if value is
system resistance low.

11.8.2 TRANSFORMER RECTIFIER.

The transformer rectifier shall be maintained as per standard practice
for the maintenance of HT Transformer as per IS-1886, code of
practice for maintenance of transformers may be used as
guidance. The Transformer may be cleaned and repainted if
necessary, Clause 12.2 of IS-1886 is taken as the guidance in
preparing following.

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11.8.3 TRANSFORMER MAINTENANCE SCHEDULE

Sr. Inspection Items to Inspection Action to be taken if

No. Frequency Inspect Notes inspection is
unsatisfactory

1 Monthly Oil Level in Check Transformer oil If low, top up with dry oil.
Transformer level Examine transformer for
leaks.

2 Monthly Relays, Alarm Examine relays. Clean components and

Circuit etc. replace contacts.

3 Monthly Loads (Amps) Check against rated *

fig.

4 Monthly Voltage Check against rated *

fig.

5 Monthly Bushings Examine for crack Clean or replace

and dirt deposit

6 Quarterly Pressure Operating and Loosen the check nut,

release valve resetting pressure adjust pressure screw and
lock by check-nut.

7 Yearly Oil in Check for di-electric Take suitable action to

transformer strength restore qty. content of oil

8 2 Yearly Oil in Check for Acidity Take suitable action to

transformer strength restore qty. content of oil

9 5 Yearly --- Overall inspection Wash by housing down with

including lifting of core clean dry oil.
coils.

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11.8.4 Trouble Shooting Chart for Transformer Rectifier Unit

Sr. Symptoms Probable cause Remedy

1 Operation of oil Output current drawn is Reduce operative current

temp-HIGH-I excess of rated capacity
alarm
2 Operation of Oil 1 Overloading of unit Check temp. of transformer. Oil
Temp-HIGH-II 2 Overheating of windings Ensuring separate thermometer
alarm in thermometer pocket provided
3 Operation of 1 Internal short circuit Check for any blackened turns.
Pressure switch between turns Replace complete section
2 Short circuit between Check clearance between core
phase and earth. & Py/Sy winding. Make adequate
clearance if found short.
3 Insulation break-down Remove Py/Sy coils. Insulating
of major nature material & replace by new one.
4 Dielectric strength of Filter/centrifuge the oil till
Oil. dielectric strength as per IS-335
is achieved
4 TRU draws 1 HT -VE lead may be Check and replace the HT
heavy current touched earth connection leads.
when energized 2 Replace arm by new module.
Rectifier stack arm
separately by shorted.
dimmerstat
5 Low oil level 1 Leakage of oil through Tight top filter valve & bottom
even after drain/filter valve. drain/ valve. Apply sealing
topping up. compound if leakage found
between pipe treads
2 Oil leakage through BH Tighten the petcocks and
relay petcock. replace if found faulty.
3 Oil leakage through Change gasket by fresh one.
gasket.
6 Dust collected 1 Input cable gland may Change the gland plate and
in input box. not be matching. gland to suit cable glands.
2 Seal on cable gland for Fill with M seal gap between
BH relay wiring may be cable and its glands. Tighten
removed cover bolt.
3 Loose cover bolts. Tight the cover bolt
4 Gasket on gland plate/ Put gasket on gland plate &
cover might has cover.
removed

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CHAPTER-12
AUTOMATIC CONTROLLER FOR ELECTROSTATIC PRECIPITATOR
12.1 INTRODUCTION OF ACE-16
The 'ACE-16' controller is an advanced microprocessor based system
to monitor, execute certain algorithms and adjust automatically the
ESP operating conditions and to provide optimum usable power to ESP
at all times. Once programmed by the operator, it automatically
accommodates the changing load, and input conditions without any
manual adjustments. Field programmability of wide range of operating
parameters permits an extremely high degree of flexibility. It
automatically selects and optimizes ESP electrical operation based on
field programmable parameter settings and feed backs from load.
12.2 HARDWARE DESCRIPTION
The 'ACE-16' is a microprocessor based fully digital controller used for
control and optimized operation of Electrostatic precipitator (ESP). It
consists of power supply, logic circuits, microprocessor, peripherals,
buffers, opto-couplers and Analog circuits, key board and LCD display
housed in one box. It has removable printed circuit boards; all are
interconnected through flat cables. The controller consists of following
boards.
1 Front Facia board.
2 Power Supply Board.
3 Main PCB Board.
FRONT FACIA BOARD:
Front Facia Board consists of
A A 5 x 7 matrix , 2x16 character LCD module
B Dome type keyboard, with 32 keys.
C Individual LEDs are provided for some specific indication
All these are mounted on the front facia of the controller and connected to
the Main PCB through easily removable flat cable assemblies.
Individual LEDs are provided for some specific indications such as ON,
OFF, REMOTE/LOCAL and READY TO START signals on the front
facia. In addition, separate LEDs are provided to identify each of the
external fault conditions on the Main PCB.
KEYBOARD:
The keyboard has 32 keys and a window for LCD display. The keys are
arranged as below on front facia.
ON IDC 1 2 3 INR IDC T-QNCH
OFF VDC 4 5 6 DCR IDC SETBACK T-RCVRY
READY TO SPARK 7 8 9SPARK MAX-PARK T-FRST
START RATE TEST RATE RAMP
LAMP STATUS 0 PASS ENTER/ RMT/ ENERGY BACK CRNA
TEST WORD RESET LOCAL CTRL CNTL

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2 POWER SUPPLY BOARD:
Power supply is industrial grade SMPS with following specification. Input :
230VAC,50Hz.Output:+5V,4A,+12V,1A,-12V,0.5A. Regulation: 1%
3 MAIN PCB BOARD:
The main PCB contains all the digital logic, analog circuit opto-isolators
and static relays. The ACE-16 main PCB has a high level of integration of
components, and also designed to provide good noise immunity. Display
and keyboard are connected through flat cable to main PCB.
The hardware modules on the main PCB are as follows
MICROPROCESSO74R:
The `ACE-16' is based on Intel 8088, which has an internal 16-bit
architecture with external 8-bit data interface.
READ/WRITE MEMORY (RAM):
32KB static RAM. In addition to this, there is 2KB of EEPROM /battery
backup RAM.
READ ONLY MEMORY (ROM):
This is 64KB EPROM contains program codes & is non volatile
ANALOG INPUTS:
Two analog inputs are used for control.
1 0 - 1V corresponding to 0 100% rated current
2 0-400 micro Amp corresponding to 0 100% rated voltage
A/D CONVERSION:
Analog to Digital conversion is done by 8 bit ADC that gives better than
1% accuracy.
INPUT /OUTPUT PORTS :
It is used for sensing external alarm and status conditions. These inputs
are optically isolated. Conditions include, Oil pressure high, Ext. overload,
SCR Over temperature, Transformer Over temperature, Rapper ON,
Remote ON/OFF, Process fault, Remote ACCEPT/ RESET. Potential free
contacts are required for faults and status signals. Output ports are used
for switching ON/OFF trip relay and annunciation relay. At the back of the
controller the following LEDs are visible.
LED INDICATION LED INDICATION LED INDICATION
L1 Spark L12 Not used L24 Remote ON/OFF
L2 Under voltage L13 Not used L25 Oil Temp. 1
L3 Over Voltage L14 Contactor ON L26 Remote Reset
L4 TXDA L15 Contactor OFF L27 Oil Pressure High
L5 RXDA L16 Alarm Trip L28 Contactor ON
L6 TXDB L17 Alarm Non trip L29 Safety Line
L7 RXDB L18-19 Not used L30 Oil Temp 2
L8 SCR1 ON L20 Not used L31 SCR Temp High
L9 SCR2 ON L21 Not used L32 Thermal overload
L10 Not used L22 Beeper ON L33 Ext. Overload
L11 Not used L23 Local/Remote ON L34 Process Fault

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MECHANICAL DATA:
Box Dimension 275mm X 235mm
Panel Cut out 285mm X 244mm
Full Frame 327mm X 267mm X 180mm
12.3 START UP PROCEDURE:
The moment the power is applied to controller it goes into "SELF TEST "
routine. In this routine it carries out following tests.
1 EPROM Test is carried out by check sum verification.
2 RAM and EEPROM test during which there are several writing and
reading operations to/from the RAM cells and EPROM are carried out.
3 ADC test is carried out by several reading operations and comparison of
readings.
If any of these tests fails error message will be displayed on LCD
module.
SAFETY LINES
Safety line is hardware interlock for fault. Unless safety line is healthy
unit can be switched ON. Healthiness of safety line is indicated by
'READY TO START' LED. Whenever fault is persisting 'READY TO START
LED blinks.
OPERATION
This section explains functions of keys and different access levels of
parameters.
The control keys provided for switching on and off Rectifier Unit are ON
and OFF. Indication key READY TO START is provided for checking
status of healthiness of Unit. LAMP TEST key is provided for checking
healthiness of LED provided on front facia.
The keys dedicated for displaying measured values and the statuses of
the System are IDC, VDC, SPARK RATE and STATUS. The access to
parameter changes is limited at various levels, however, parameters
can be viewed by INR and DCR keys without password.
LEVEL1 This is a normal operator level. (Setting up the current limit,
NEC, IDC SETBACK etc.).
LEVEL 2 This is engineering level.(Setting of blocking time, quench
time etc)
LEVEL 3 This is specialist level.(Setting of start up & testing
parameters, rated values etc.)
Changing parameters related to level 2 and level 3 require keying in of
Passwords.
All parameters on level 1 and level 2 have relevant keys, whereas level
3 parameters require a table reference and special code.
Example <PASSWORD> 74 <ENTER/RESET>
Keying in of an illegal value for a parameter results in the following
display indication "ILLEGAL VALUE"
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Keying in a key not expected by the system in a given context. For e.g.
an attempt to change a level 2 parameter from level 1, the display will
indicate the following text " ILLEGAL KEY ".
The keys dedicated for displaying and changing level 1 parameters are
IDC LIMIT
IDC SETBACK
MAX SPARK RATE
ENERGY CONTROL
The keys dedicated for displaying and changing level 2 parameters are
T QUENCH
T RECOVERY
T FAST RAMP
BACK CORONA CONTROL
The keys to be pressed for displaying and changing level parameters
are combinations of :
PASSWORD
CODE
ENTER/RESET
INR/DCR
ENTER/RESET
KEYS FUNCTIONS:
CONTROL KEYS:
1 ON: The depression of the key turns on the power contactor.
2 OFF: The depression of the key turns off the power contactor.
READOUT KEYS:
Given below is the listing of the various keys, which are used for readout
of measuring values and the status of the system.
1 I DC
Display indication of the mean value of the precipitator current
" IDC xxxxmA 1. "
Range is from 0 to nominal value.
2 V DC
Display indication of the mean value of the precipitator voltage.
" VDC xxx.x kV"
3 SPARK RATE
Display indication of the Sparkover frequency.
" SPKRATE xx/m"
The default display of the system is always IDC. If the user has pressed
any other key to display a required parameter, but hasn't changed the
value and if three minutes have elapsed, then system switches back to
default display IDC.
12.4 LEVEL 1 PARAMETERS:
All parameters can be displayed by depressing the concerned function
key. Once the parameter is displayed, it can be changed by simply
keying the new value followed by ENTER/RESET.

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No password is required when changing these parameters. Keying in of
the first digit passes from left to right. The acceptance of the keyed
parameter is indicated by switching off the display for one second and
the same parameter is displayed for three min. (changes in the same
value can be done within min).
However, in case of wrong keying in or illegal value a fault indication
message is displayed and the original value of the parameter is
retained. The keys which result in a read outs of level-1parameters are
listed below.
1 IDC LIMIT:
Displays the current limit of the system. The value ranges from 0 to
nominal value. "IDC LIMIT xxxxmA" Default value 99 mA
2 IDC SET BACK:
The depression of the key results in the display of current setback. The
setback values ranges from 5mA to 20% of I DC NOM.
" SET BACK xxxmA " Default value 30 mA.
3 MAX SPARK RATE :
The key serves to set the maximum Sparkover frequency.
"MAX SPKRT xx/m" Default value 12/m
The value ranges from 1 to 60 Sparkovers /min.
4 ENERGY CONTROL:
This key activates the energy control mode. Initial activation of the key
results in the following display
"NEC xx " Default value = 1.
This parameter sets the cycle time for energy control operation. NEC is
entered only in odd values from 1 to 99.
<NEC> = 1 corresponds to normal operation.
12.5 LEVEL 2 PARAMETERS
All parameters can be displayed by depressing the concerned function
key. Changing parameters related to level 2 requires special password.
The keys which result in the read out of the level 2 parameters are
listed below :
1 T QUENCH :
Displays "quench time" after type 2 Sparkover.
"T QUENCH xxxms" Default value 40 mS.
The value ranges from 5 to 100 m sec.
2 T RECOVERY :
Displays the parameter” rise time” after a Sparkover. The value ranges
from 40ms to 1000ms. "T RECOVERY xxxxms" Default value 99 mS
3 T FAST RAMP :
The depression of the keys results in the display of time parameter
after a Sparkover. If the measured time exceeds the parameter "T FTS
RAMP", there is a change from nominal rise of the current to the rise
equal to 200% of nominal value per minute.

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The lower limit of the parameter is 2 and upper limit is 300 sec
" T FST RAMP xxx s " Default value 10s
4 BACK CORONA MODE :
Displays number of back corona detection per hour. The working range
is from 0.1-6 times per hour. Detection can be stopped by keying in 0
"BC MEANS x.x/hr" Default value 0.
Non-Zero value of BC MEANS enables BC detection mode.
PROCEDURE FOR CHANGE OF LEVEL 2 PARAMETERS :
PASSWORD - By pressing this key, the display will show
" ENTER PASSWORD "
Keying in of illegal password will result in the following text
" ILLEGAL PASSWORD "
Keying in more digits than expected by the system for a parameter will
indicate
" TOO MANY DIGITS "
After entering the relevant password, the parameter can be changed by
simply keying in the new value followed by <ENTER/RESET>.
Keying in the sequence for the level-2 parameter.

KEY DISPLAY INDICATION

PASSWORD 'ENTER PASSWORD'
2 *
2 **
2 ***
ENTER/RESET "T QUENCH xxxmS"
When changing another level 2 parameter within min, one can simply
depress the parameter key, the new value and finally
<ENTER/RESET>.
The user has the freedom of changing the level 1 parameters even
though, he is on level 2.
One can return to level-1, Automatically, if the keyboard is not operated
for 3 minutes.
12.6 LEVEL3 PARAMETERS
There are no keys for these parameters, so they can be only displayed
by keying the 2-digit code, after keying in <PASSWORD>. The level
parameters correspond to factory adjustments.
The following 2 digits code serves to display a corresponding level
parameter.
Depress <PASSWORD> 2 digit code and <ENTER/RESET>

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66 ENTER/RESET ( IDC – nom )
This parameter serves to indicate the nominal current of the
system.(Limit range 101-2001 mA)
"IDC NOM xxxxmA" Default value 200mA.
67 (ENTER/RESET) ( V DC - nom )
This parameter serves to indicate the nominal DC voltage of the
system. Limits are from 45 - 150kV
"VDC NOM xxxkV" Default value 150kV.
68 (ENTER/RESET) ( V DC- max )
This is for setting the overvoltage limit. The limit is from 0 - (VDC
nom -1). Exceeding the overvoltage limit for more than one sec will
cut off the system.
"VDC MAX xxxkV" Default value 149 kV.
69 (ENTER/RESET) ( V DROP Ty1 )
This parameter serves to adjust the detection response of voltage
drops in the precipitator. The range is from 3-20kV the parameter is
to be considered as response adjustment rather than as voltage
drop measured in absolute kV. 3 kV gives high and 20 kV gives low
response.
"V drop Ty1 xxkV" Default value 3kV.
70 (ENTER/RESET) ( SPEC RE )
This parameter is called special reduction and serves as an
additional set back for the Sparkovers, which time wise are closer
than 1 sec. The range is from 0 - 200mA
"SPEC RE xxxmA" Default value 20mA
71 (ENTER/RESET): (BC CHECK TOL.)
This parameter is used in Back carona detection while conforming
back carona. This tolerance is used for comparing voltage. Min
value 0.0%. Max. Value 5.0%.
" BC CHK TOL x.x %. Default value is 0.0%.
72 (ENTER/RESET) : ( BC MAX NEC )
This parameter is used in Back carona detection. This parameter
sets upper limit of NEC in back carona detection. It can accept only
values 1,3,5,7. "BC MAX. NEC x ". Default value 1.
73 ENTER/RESET ( UNDER V DC )
This parameter is used to set under voltage limit. If output DC
voltage remains below set limit for more than 30 sec, then unit will
be switched OFF. Min Value is 0.0 kV. Max. Value is 25.0 kV.
" UNDER VDC xxx kV" Default value is 9.0 kV
74 (ENTER/RESET): ( BC - add )
This parameter is the allowance, given to the current set point
relative to the last measuring stage, when the last back corona is
detected. The allowance is adjustable from - 0 to 400 mA.
"BC add xxxmA" Default value 250mA
Actual allowance = BC add value less 200 Suppose for "BC add
0mA is entered then actual allowance = 0 - 200mA = - 200 mA.
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75 (ENTER/RESET) (POWER)
This parameter is read only parameter and shows instantaneous
output power of the unit.
Maximum value is 999.99 kW.
76 (ENTER/RESET) ( SPARKS T1 )
This read out shows the number of type 1 Sparkovers. Maximum
value is 9999. Exceeding the maximum value, the counter will
restart from 0.
77 (ENTER/RESET) ( SPARKS T2 )
This read out shows the number of type 2 Sparkover. Maximum
value is 9999. Exceeding the maximum value, the counter will
restart from 0.
"SPARKS T2 xxxx " Default value 0
78 (ENTER/RESET) ( TEST LIMIT)
This parameter serves to set percentage of conduction angle in
test mode.
" TEST LIMIT x x x % Default value 0 %
79 (ENTER/RESET) ( VDC – START )
This parameter indicates to which the DC voltage is to be stepped
up, just after the contactor is switched on.
"VDC START xxkV" Default value 5kV
Range is from 0 to 25 kV.
80 (ENTER/RESET) (PRST LIMIT )
This parameter displays the present current limit. This depends on
back carona detection and energy control (NEC) Range is 0 mA to
I DC nominal value.
" PRST LIMIT xxx mA "
Default value is I DC limit value.
81 (ENTER/RESET) ( dALFA res )
This parameter gives the firing angle for the reset firing before the
actual main firing. Reset firing range is from 100-180°.
"dAlfa Res xxxdg" Default value 120°.
82 (ENTER/RESET) ( ALFA res min )
This parameter gives the range upto, which the minimum reset
firing angle is permissible. This parameter ranges from 90 to 180°.
“AlfaResMin xxxdg”
Default value 180° C.
83 (ENTER/RESET) ( d ALFA Nec )
This parameter serves to increase the firing angle instantaneously
while changing from higher NEC value to a lower value. Range is 0
to 40°.“ d ALFA Nec xxx “ Default value 40°
84 (ENTER/RESET) ( TEST MODE ON )
This parameter is used to enable/disable test mode by 1/0
respectively.

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85 (ENTER/RESET) (HINERGY)
This parameter maintains minimum voltage level in case of energy
control mode ("NEC>1"). It is the % of nominal voltage. If the
output voltage goes below this level then additional pulses are
generated between main firing to maintain this level.
Minimum value is 0.0 %. " HINERGY " xx %
Maximum value is 50 % Default value is 0 %.
86 (ENTER/RESET) ( KwH )
This parameter shows output Energy and the value is store in the
EEPROM so that during power OFF, data is not erased. This value
can be reset by pressing simultaneously ENTER and 0 keys. Max.
Value is 99999.9KWH. Exceeding the maximum value, the counter
will restart from 0.
87 (ENTER/RESET) ( R WAIT )
This parameter indicates delay pulses after Rapper bit is disabled
before actual build up. Min value is 0 cycles. Maximum value is 99
cycles.
" R WAIT x x x % " Default value 20 Cycles.
88 (ENTER/RESET) ( FIRING )
This parameter displays SCR firing angle in %.
Minimum value is 0.0 %. " FIRING x x x % "
Maximum value is 100%. Default value is 100%.
89 (ENTER/RESET) ( VERSION )
This will shows the version of programs and date of modification.
90 (ENTER/RESET) ( HT ON )
This parameter shows ON time duration of the unit in hour
( NODE ADDR)
This parameter used to set address of the controller for serial
communication in RS-485. The NODE ADDR should be unique in a
system.
This parameter range is 1 to 231.
Default value 1 ( BAUD RATE )
This parameter is used set the communication speed of unit.
Setting values are 1200,2400,4800,9600 and 19200
Default Value 9600.
CHANGE OF LEVEL PARAMETERS
Change of level parameters requires pressing of keys in the following
sequence.
PASSWORD 'ENTER PASSWORD'
3 *
3 **
3 ***
RESET/ENTER "T QUENCH x x x mS.

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12.7 MISCELLANEOUS PROVISIONS INR / DCR :
These two keys facilitate the user to view the desired parameters. By
depressing the INR key the user is able to view the next parameter, in
sequence after the currently displayed one. By depressing the DCR
key the user is able to view the earlier parameter, that was displayed,
before the currently displayed one.
SPARK TEST
Depression of this key simulates the spark action.
RMT/LOCAL
This key gives indication of controller status when LED ON indicates
controller is in REMOTE MODE.
12.8 ANNUNCIATION :
The alarm texts are flashed on occurrence of certain faults in the
system. In case of several simultaneous alarms, only the latest alarm is
flashed and hooter is switched ON. Fault is accepted and pressing
ENTER/RESET key cuts OFF hooter. By pressing again ENTER/
RESET key next preset alarm is displayed. If the cause of alarm is
removed, alarm text is removed.
List Of Alarms

Sr.No. NAME TYPE

1 High oil Pressure Trippable
2 Ext. Overload Trippable
3 TX Oil temp high Non Trippable
4 TX Oil Temp high II. Trippable
5 SCR temp high. Trippable
6 Thermal overload. Trippable
7 Process fault. Trippable
8 Under voltage Trippable
9 Over voltage Trippable
10 Safety Line Trippable
11 Con OFF Trippable
12.9 Starting sequence: ( Refer Fig. 1)
Starting sequence begins when the main contactor is switched on (1).
Thyristors are blocked for first 2 Sec (2) after that the voltage is raised
to set value of parameters, 'VDC START' immediately (3). Then the DC
current is raised from VDC start value with current rate of 200% per
minute (100% corresponds to rated current) (4). If there is a Sparkover
(5) during the starting sequence the control will react as described
under automatic control & the rate of rise (6) is applied which
corresponds to a calculated value based on IDC SET BACK, MAX
SPARK RATE and actual Sparkover frequency. The rise is discontinued
when current reaches the current limit (7).
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The rate of rise is calculated internally in controller so that it will just
reach the set Sparkover frequency i.e. MAX SPARK RATE. Key for
setting SPARK RATE is MAX SPARK RATE and for set back is IDC SET
BACK. The set back is adjustable between 5mA to 20% of IDC NOM. The
Sparkover frequency is adjustable from 1-60 sparks per minute.
Automatic Control: (Refer Fig. 2)
The DC current is increased by the calculated rate of the rise until a
Sparkover takes place or a current limit is reached. If the Sparkover is
interpreted as type-1 Sparkover (8), the current set point is reduced by a
value corresponding to the set back (9), current is then increased again
by the same calculated rate of rise as before the Sparkover (10). If the
Sparkover is interpreted as type II (11) the primary current is blocked
(12) for a preset time (T QUENCH) adjustable between 5 -100mS.
Current set point is reduced by the set back value (9) and then
increased again by the rate of rise before the Sparkover.
Definition of Type I & Type II Sparkovers: (Refer Fig.3, 4 & 5)
Sparks are detected by sensing the precipitator voltage. The sparks are
classified as type I or II according to their intensities. At voltage drops
(12) of more than parameter "V drop TY1" a time measurement of 500
ms (13) is started for Type-I spark detection. If the voltage exceeds the
limit before the time measurements finish, no Sparkover signal (14) is
given otherwise type I (15) is signaled. If the voltage drops below the
under voltage limit a time measurement of 20mS (17) is activated for
type II. If the voltage rises above under voltage limit (16) before the time
measurement finishes type I (18) is signaled, otherwise type II (19).
T RECOVERY: (Refer Fig. 6)
After Sparkover (21) the current is raised to reduced value (i.e. value
before spark-over less setback) within set time (22) which is determined
by the parameters (T RECOVERY). Then the current is increased at the
calculated rate of rise. Rise time parameter (T RECOVERY) can be
selected from 40mS upto 1S. During this period precipitator voltage is
regulated and increased to a value corresponding to the mean voltage
before Sparkover. At this point (23) there is changeover to current
regulation and voltage rise to the value corresponding to the reduced
current value takes place according to the shown function with (T
RECOVERY) as parameter. When (T RECOVERY) has expired, the
normal calculated rate of rise is proceeded with.
Fast Ramp Mode (FRM): (Refer Fig.7)
In case of fast process changes, especially with high Sparkover
frequency and low rate of rise, current will reduce to very low value, it
may take long time to reach normal value. In this case there is a need to
reestablish the precipitator voltage quickly. This is done by parameter
fast ramp (T FAST RAMP) being adjustable from 2 – 300S. This time is
measured from last Sparkover and if it exceeds the set time (24), the
rate of rise will change to 200% per min until the next Sparkover occurs
(25), at this point the rate of rise is changed back to normal (26) or until
current limit is reached.

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Spark-over limitation: (Refer Fig.7)
The Spark Rate (MAX SPARK RATE) is adjustable between 1 spark/min and 60
sparks/min. The sets Spark rate will not be reached if long quench time and rise times are
selected.
The spark rate limited to 60 sparks/min. To safeguard that this value is not exceed, a
progressive current reduction has been included in the automatic control. This is
achieved by adding special reduction to normal current setback. If the time interval
between the sparks is shorter than 0.75 seconds.
Then special reduction (0-200mA) is added (27) progressively until this condition exits.
If time interval between two sparks is more than 0.75 seconds, the current is reduced by
normal (28) set back value. When parameter spec. Reduction is set to 0 mA, this
function is not active.
Back Corona Detection: (Refer Fig.8)
To overcome the deterioration in precipitator performance, the precipitator
should be operated at the current level I BC (29) at which the negative slope just
starts. The level of current I BC varies with the varying condition in the
precipitator. HIRECT microprocessor controller ACE16, in back carona mode of
operation, tracks the level of current I BC and automatically operates the
precipitator at this level to avoid wasteful energy. Back corona detection can be
activated from the control keyboard with key "BACK CARONA CONTROL".
The detection can be activated from 0.1 to 6 times/hour. Detection is made
inactive by inserting 0 times/hour. After activation the periodic back corona
detection are made according to the following principle. The set point of the
precipitator current is set for predetermined values which each are retained for
10 S. The set point may assume the following values during detection:
7,10,15,20,30,40,60 &100% of rated current. The set point cannot exceed the
set current limit. The starting set point is found by going 3 steps towards lower
values in the set point sequence than the actual value of the set point before the
detection of back carona. In Fig.8, three steps down is 60-40-30% for 10 sec.
And then increased to 40% for 10 sec and 60% for 10 sec.
The mean precipitator voltage is measured during last 640ms of each retention. If
2 subsequent measurements have shown that the mean voltage is stationary or
dropping with increasing current then values of set point is retained at last
measurement i.e. if the mean voltage at 60% retention is equal to or less than the
mean voltage at 40% retention then the value at 40% set point is retained. This
value plus an allowance (30) is used as a new upper limit of current(BC limit) The
allowance is variable from -200 to +200mA (parameter BC add)
Voltage Alarms:
If the precipitator voltage drops below the under voltage limit for more than
30Sec, under voltage alarm is displayed and unit is switched OFF.
If the precipitator voltage exceeds set value of parameter UDC MAX for more
than 1 Sec, overvoltage alarm is displayed and unit is switched OFF. Overvoltage
can be adjusted from 0 kV to peak rated kV.
12.10 RELAY DRIVER CARD (CIRCUIT 4C-4682)
The isolated signal from ACE-16 control card is brought on Relay Driver Card.
This isolated signal is used to trigger triac TD1 to TD4. These triacs operate
relays when ACE16 controller triggers them. 24V AC power supply is connected
between pin 2 and pin No.14 of Relay driver card. One end of relay coil is
connected to 24V AC power supply directly and other end of relay coil is
connected to triacs of relay driver Card through ACE16 controller. Whenever triac
is switched ON through ACE16 controller it switches ON the relay.

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