F.L.

Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 1

F.L.Smidth Airtech ESP troubleshooting manual.

For PIACS-DC mkII/III.
Page
List of contents

1. Troubleshooting on T/R-tank 2
1.1 Short-circuit test 2
1.2 No-load test 2
2. Troubleshooting on PIACS control unit 2
2.1 Instruments deflect in wrong direction 2
2.2 No remote indication signal 3
2.3 Fault in the control panel 3
2.4 Fault in the control unit 3
2.5 Missing or faulty spark detection 3
2.6 Missing or faulty spark detection: 3
2.7 Fault in the keyboard 3
3. Troubleshooting in the control cabinet 3
3.1 Checking the thyristors 3
3.2 PIACS doesn`t regulate up 3
3.3 Checking thyristor resistance 5
3.4 Check of current 5
3.5 Saturation 5
3.6 Remote indication 6
4. Faults during ESP operation 6
4.1 ESP section draws no current 6
4.2 PIACS software faults 9
5. Checking ESP current and voltage 9
5.1 Adjustment of shunt 9
5.2 Voltage divider 10
6. Oscilloscope readings of current and voltage 14
7. Obtainable ESP-voltages 16

GENERAL

Before starting any kind of troubleshooting, the safety instruction, 52051-xx, for
electrostatic precipitators must be read and understood.

When troubleshooting, one must always make a distinction between plants which have been in
operation and plants which are to be started for the first time.
If the plant has been in operation the fault can usually be found in one of the components, for
example, a PC board, a contact, or in the ESP or the transformer/rectifier. To determine
whether the fault is in the ESP or in the electrical system, a short-circuit test and a no-load test
is carried out, see section 1.
If the plant has not yet been in operation the fault can also be caused by incorrect wiring or
electrical interference.

Note: This manual is valid specifically for PIACS-DC mk II. The manual for PIACS-DC mkIII is
under elaboration.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 2

1. Troubleshooting on T/R tank

1.1 Short-circuit test :
-Short-circuit the ESP with the earthing cable.
-Set parameter ’Manual mode’ to 2 - (’operation without voltage signal’). Set parameter ’IDC
limit’ to 50% of ‘IDC rated’.
-If the current slowly increases to adjusted value of ’IDC limit’ the short circuit test is
succesful.
1.2 No-load test :
Warning: This test may have to be interrupted manually after 1 s.
-Disconnect the high voltage connection from the T/R tank to the ESP. Be aware that the
distance between HV- bushing and the lead through insulator is sufficient so the test can be
conducted without sparks.
- In order to minimize the risk of generating voltage surges internally in the T/R tank under this
test the following parameters shall be set according to the table below:

Parameter PIACS Mrk III

# 47  limit =135 º

-If UDC and UDCmax are of considerable values and primary current and ESP current
(IDC) is negligible the No-load test is succesful.
Conclusion:
-If both Short-circuit and No-load test are succesful the electrical equipment is in order and
the fault should be found inside the ESP.
-If UDC is low while primary current is high the fault is most likely a short circuit inside the
T/R tank. Be aware that the fault may be a short-circuited shunt.
-If both UDC and UDCmax are low while both IDC and primary current are considerable the
fault is most likely a faulty voltage divider or voltage signal.
-A further test: Set parameter ’Manual Mode’ to 2, disconnect the kV-signal on HX02, start
T/R and measure the kV-signal. If the signal is considerable the fault is most likely in the PCB
HX02 or multi-cables or in PCB CS 28.1.
In case of assistance is needed the table below must be filled in and returned.
-------------------- IDC Limit=50% UDC/UDCmax I ac U ac   Rem
.
Short-circuit test mA 0 kV A V 
No-load test 0 mA kV A V

ESP connected mA kV A V

2. Troubleshooting on PIACS control unit
2.1 Instruments deflect in wrong direction :
-Check the fuses F2 and F3 on CS28. The fuses F2 and F3 supply the control relays from the
PIACS with  12V, which is also used by the alarms on the HV unit, the safety switch for the
rapping motors, etc. Possible causes for the fuses burning out are :
-The control relays (K15,K16,K25-K29) draw too much current, max. 200 mA (applies only to
older units).
-An earth leakage at the HV unit, safety switches, etc.
-Defect voltage supply on CS28 (replace the board).
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 3

2.2 No remote indication signal:

-Check F1 on CS28 ( four fuses soldered in a socket, see Manual PIACS DC).
-Remember, to shortcircuit the socket pins in which the picofuses are mounted. This in order
to discharge a capacitor. Failing to do so may cause a new burn out of F1.
2.3 Fault in the control panel:
-Check the connecting plugs for bend pins: From the keyboard to CU19, and from
HS13/HS15 to CS28.

2.4 Fault in the control unit:

-It may be useful to try another PIACS unit, including the cables, (the cables from the
adjacent cabinet can usually reach). If the fault is in the PIACS, locate the defect print board.

2.5 Missing or faulty spark detection:

-This can be rectified with a minor adjustment of R85 (see Manual PIACS-DC). An
oscilloscope must be used to observe the sparks and ensure that they are all detected.

2.6 No text in display:

-This can be caused by low or high temperature in the control room.
-Replace CU19.

2.7 Fault in the keyboard:

-Can be caused by incorrect placing of the connecting plug from the keyboard to PCB CU19.
Check for damaged pins in the connection.

3 Troubleshooting in the control cabinet

3.1 Checking the thyristors:

-Connect two or three (observe mains voltage) 100W bulbs in serie (if necessary in parallel
with a 2-3 kW heating element), and connect them to main terminals instead of the HV unit.
-Place jumper J2 on AA30 on 2-3. The firing angle can now be adjusted manually with R30.
Remember to start with R30 in full CW position.The current is increased by turning CCW.
-Switch on the main contactor (manually if necessary). In order to prevent disconnection due
undervoltage set parameter ’Manual mode’ to 2
It should now be possible to regulate the light 0-100%. Remember to double check by
connecting the bulbs directly to the mains supply.
Can the light be regulated to 100%, both the thyristors and PCB AA30 are in order. If this is
not possible the thyristors or/and PCB AA30 may be faulty.
-Check gate signals (Umean) with a multimeter or better use an oscilloscope and a 100 ohm
resistor connected across the output signal. Compare with a unit functioning.
It is possible to check for a short circuited thyristor by removing the firing signal (X3) and
switch on. If the bulbs are 100% alight one of the thyristors is shortcircuited.

3.2 PIACS doesn`t regulate up:

-Check the feedback from the contacts on the terminals X15-20 og X15-13. By missing signal
the green start button is not alight.
-Ensure that there is voltage at the transformer by measuring across the terminals.
-If the main contactor can`t be switched on, check the start/stop circuit. The problem may be
caused by an interlocking in the central control unit.
-Check the thyristors during manual operation (see “check of thyristors”).
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 4

-Check the signal from the voltage divider.

-Check that the overvoltage protection including possibly parallel connected spark-gaps are
not short-circuited. Spark-gaps are connected across the shunt and the base part of the voltage
divider.
-Carry out measurements on the voltage divider (see “voltage divider”).
-Check that the synchronization voltage is correct, see fig. 1.
-Check that the thyristors are in the phase shown on the drawings, see fig.1 and the supply to
terminals X1-1- and X1-4.
-Check that the gate wires are correctly installed and have good contact.
-Check that wires and connections on AA30 are correctly installed.
-The fault can also be caused by a fault in the ESP, for example sparks at very low voltage,
e.g 3-6 kV. These will not be detected, but they can be seen on an oscilloscope. This can be
verified by carrying out a short-circuit test without earthing the . The ESP current ’IDC
Limit’ must be set to around 10 % of ’IDC rated’, as a very low voltage can cause short-
circuit current.

Fig 1: Eksempel fra PIACS mk II

F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 5

Note: In units of more recent date the synchronization voltage is taken from a 24 V secondary
winding.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 6

3.3 Checking the thyristor resistance:

A thyristor can be checked using an ohmmeter. Fig 2. shows a Semipack, so the thyristors
must be checked one at a time.

Fig 2: Example of a IR-tyristor .

+ - on instrument
A - K infinite (20 k- 10 M) K - A infinite (20 k- 10 M)
G - A infinite (5 M- 20 M) K - G app.35(may vary between 10 og 700 )
G - K app. 35  ( may vary between 10 og 700)

3.4 Check of current:

Check of consistancy between primary current (Ipr) by measuring True-RMS and ESP mean
current (Idc):
Formula: Udc rated  F Idc rated  2 Upr rated  Ipr

F = 1,4 @ full load and increases at lower current.

Ipr is measured at output terminals in the control panel.
Idc is read on PIACS display.
Udc rated and Upr rated are read on T/R-unit rating plate.

If the result is incorrect the shunt in the terminal box must be checked.
The problem could also be caused by saturation, see section 3.5. Check with an oscillscope,
see Fig. 8.

3.5 Saturation
Saturation of the transformer core can cause the primary fuses to burn out or circuit breaker to
trip. This is a common problem with France Transfo transformers operating in Nec mode. The
software versions 4.6 and higher have incorporated a limitation of the firing angle to avoid
this.
Setting the firing angle limitation
The normal range used by the current controller when calculating the firing angle is 150o, i.e.
from 180o to the earliest firing at 30o in the half-cycle. This range can be limited to, for
example, 120o so the earliest firing occurs at 60o.
This facility is activated with the parameter ' Aux.Min'. The range is calculated using the
parameter ' Aux/Main' with an offset of 30o. Activation of the auxiliary firing will occur
only when ' Aux.Min' is less than, or equal to 175o, instead of before 180o.

Example:' Aux.Min' = 177o implies a) “no auxiliary firing” and b) a “firing angle range”
equals to ' Aux/Main' + 30o.
Consult the PIACS Manual for other setpoints.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 7

3.6 Remote indication:

Tolerances:
The PIACS analogue outputs are manufactured with a tolerance of ±1,5%, corresponding to
class 1.5. This means that any deviations are no higher than 1,5% of maximum deflection, i.e.:
( 20 - 4 ) x 1.5 / 100 = 0.24mA. Therefore, the signal for zero is between 3.76 and 4.24 mA
and the signal for 100% deflection is between 19.76 and 20.24mA.
The PIACS is made with reasonably large tolerances, finer tolerances would place
improportionately high demands on the components in the unit. It is also impractical to carry
out measurements with finer tolerances on high voltage units.
Resolution:
The customer should use the same resolution as used in the PIACS for remote indication of
mA and kV in the central control unit, for example 10mA and 1kV.
Possible causes of faults:
Interference at the inputs will give a signal at the outputs, as current and voltage signals from
the rectifiers are sent directly to the central control unit. Interference at the inputs come to the
signal cables from the T/R-tanks. This can`t be completely avoided, but it can be kept to a
minimum by ensuring the different types of cables are kept apart from each other as specified
in the electrical documentation. Interference of the remote indication signals can be evaluated
by short-circuiting the input terminals X12-18 and X21 and noting the readouts for mA and
kV on the central control unit before and after the short circuit.

Some central control units give an alarm when the analogue input reaches, for example, 20.24
mA, even though the maximum is set to 20mA. This can be remedied by changing the current
shunt, so that it gives 1.25 V at IDC rated, and setting the parameter ’IDC ScaleFac’
(parameter 4) to 0.8. The PIACS will still react as if it gets 1.0 V at’’IDC Rated’.
The instruments in the central control unit will show 1250 mA at full deflection, i.e. 20mA,
but with a red line at 1000 mA.

If the central control unit is giving indications even when the plant is turned off, the same
method as used internally in the PIACS can be used, that is, the display is set to zero when
there is no signal from the switches. The operating signal is already sent to remote from
terminal X8-7.

4. Faults during ESP operation

4.1 ESP section draws no current:

If the problem occurs in a esp`s first field, when Udc max = Udc mid. = Udc min, the cause
is probably one of the following:
-Dust build-up on the collecting plates or discharge electrodes due to insufficient rapping.
-Bad gas distribution.
-Too high corona start voltage, i.e the rectifier`s rated voltage is too low.
F.L.Smitdh Airtech`s ESP Troubleshooting manual
HIGH P OIL TANK
Overpressure in T/R-tank
HIGH T OIL TANK
High temperature in T/R-tank.
LOW OIL LEVEL
Low oil level in the HV oil tank.
T/R SET GROUNDED
Transformer earthed
MAINS OVERLOAD
Overcurrent in the mains supply or
no voltage to T/R-tank.
12-08-2002 page 8
- Check alarm circuit from X12-13 to X12-14 (see
electrical documentation).
- If the 24 VDC for the alarm circuit is missing, the PIACS
will also give this alarm, usually because either F2 or F3
on CS28 have burnt out. see also paragraph 2.1.
- Gas generation, audible sparkover in the transformer
- If it isn`t a false alarm, the cooling ribs will be visibly
deformed (compare with another transformer)
- Incorrect amount of oil, see transformer manual.
- Check the alarm circuit from X12-13 to X12-15
- Check the alarm circuit from X1-5 to X1-6 in the HV
unit.
- Insufficient cooling, dust build-up.
- Measure the primary current (true RMS ) for possible
overload.
- Check the alarm circuit from X12-13 to X12-16
- Check the alarm circuit from X1-7 to X1-8 in the HV
unit.
- Oil leakage.
- The transformer takes in air at low pressure.
- Check alarm circuit from X12-13 til X12-17
- Check alarm circuit from X1-9 til X1-10 in the HV unit
- Check the microswitch on the HV unit.
Check:
- The alarm circuit from X15-16 to X15-17 (see el-doc).
- Main fuses / circuit breaker, measure the primary current
(true RMS) for overload.
- 24V AC to PC Board AA30 terminals X2-1 og X2-2
(green LED is on ). The voltage might be too low, it must
be min. 21V. Saturation of the transformer,check:
-Loose gate wires on thyristor and AA30 (see el-doc).
-Thyristor short circuited. Check thyristor acc. to §3.3.
-Activate auxiliary firing (see §3.5 and el-doc).
Diodebridge short circuited or partly s.c. Check by osc. on
current shunt terminals X12-20 and X12-19 that the size of
the current half periods are of the same size (see fig.8).
F.L.Smitdh Airtech`s ESP Troubleshooting manual
OPTIONAL ALARM
Extra alarm, usually an indication
of high temperature in the control
cabinet.
µP CHECK ERROR
Fault in microprocessor units.
UNDERVOLTAGE
Low voltage for 30 seconds.
OVERVOLTAGE
Overvoltage for more than 1
second.
UNSYMMET. CURRENT
Unsymmetrical primary current.
EXT. INTERLOCKING
Key- or external interlock
MAIN SYNC. FAIL.
Mains supply
synchronisation fault.
Terminal numbers in above alarm table is only valid for PIACS DC mkII.
12-08-2002 page 9
Check the alarm circuit from X12-1 to X12-2 or X15-18 to
X15-19.
- If the alarm is due to high temperature in the control
cabinet, ensure that the fans are working and, if an air esp
is fitted, it is clean.
Check that D13, D14 and D17 are correctly positioned in
their sockets.Remove the voltage from the PIACS
- Check that the check-sum under code 90 is correct.
The PIACS can calculate the check-sum with the
command : 9090 enter, after which the number is inserted
under code 90.
30s - Usually caused by a fault in the ESP, carry out short
circuit and no-load tests to verify this (see 1.1 and 1.2).
- Check for a signal from the voltage divider, the no-load
test will show whether there is a signal or not.
- Can be caused by a defect PC board CS28.
See also 3.2.
1s - Usually caused by a fault in the ESP, incorrect rapping
(typically where there is dust build-up on the discharge
electrodes). Set the over voltage alarm up to 100% and set
the voltage limiter to 90% (parameter Udclimit).
- Check the high voltage connection to the ESP. Carry out
a short circuit test.
- Check the voltage divider, particularly the base part, see
5.2.
This alarm is based on a measurement of the secondary
current and is set off if two consecutive cycles vary too
much.
- Check the primary and secondary current with an
oscilloscope.
- Check the thyristors
- Check the PC boards AA30 and CS28.
- Check the alarm circuit X12-3 to X12-6
- Check the primary voltage, it can occasionally be too low
or not sinus-shaped.
- Check the PC boards CS28 and AA30.
-
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 10

4.2 PIACS software faults :

Versions before 4.0 Unsuitable for measuring back corona

Versions before 4.6 Poor back corona measuring
Version 4.6 EMCS does not work
Versions 4.0 - 4.6 Continuous rapping does not work
Versioner  5.3 In the present version use of auxiliary firing and Back Corona detection
is not possible.
Version 6.2 Only used by L&S. Simultaneous use of Auxiliary Firing and Back
Corona detection is possible. This version permits use of “full cycle” IE-
energization.

5 Checking ESP current and voltage

The PIACS control unit bases all of its control functions on the two signals of ESP current and
voltage. These two values can be shown in a current-voltage curve and give an indication of the
ESP`s efficiency. These measurements must therefore be accurate. This is especially important
where a PIACS has been installed in an existing plant, but they should also be checked on units
which aren`t functioning properly.
Check that the overvoltage protection including possibly parallel connected spark-gaps are not
short-circuited. Spark-gaps are connected across the shunt and the base part of the voltage
divider.

Fig. 3: Old model of France-Transfo T/R unit

F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 11

5.1 Adjustment of shunt:

The current shunt is usually a resistance which gives a voltage drop of 1 V at rated current, eg.
a ESP with ’I DC rated’ of 1000 mA will have a 1 shunt. There are however, exceptions.
France Transfo have made a model which uses a potentiometer in the terminal strip, see fig 3.
The models manufactured between 1989 and 1995 were unreliable, usually due to a defect
potentiometer, which ought to be changed with a PCB AP33.
The AP33 includes the base part for the voltage divider. See section 5.2.
In case of emergency the framed part can be exchanged with a single resistor.

The PIACS must receive a signal of 1V at rated current, although it can receive a signal of up
to 1,33 V, which can be compensated for with the parameter ’IDC ScaleFac’ (0,75 til 1,25).
’IDC ScaleFac’ can also be used to get extra power out of the T/R-tank if the maximum
primary current has been reached. This is however, an overloading of the transformer, and
must only be done under special circumstances.

5.2 Voltage divider:

If the PIACS DC displays extremely high voltages the base part of the voltage divider (or, in
the case of T/R units from France Transfo, the 182 k resistance) can be burnt out.

Rico Transformers:
The top part (R2) of the voltage divider is usually about 80-125 M, depending on ’UDC
rated’, and the base resistance (R3) is usually around 10 k. The base resistance is checked
with an ohmmeter, measuring between “n” and earth. The top resistance is harder to measure.
If the divider is made as shown in fig. 4, the high voltage bushing (marked HV) is earthed by
means of the earthing switch Q1 and the wires on “n” disconnected, and an ohmmeter set in
the conductance (Siemens) range is used. Alternatively a megger can be used.

Fig. 4: Diagram of Rico T/R unit

F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 12

France Transfo T/R unit:

This is more difficult, as there is a 182 k resistance inside the tank, see fig 5.
Follow these steps:
w The earth switch Q1 must NOT be earthed.
w Remove the HV connection between the HV bushing and lead through insulator..
w Remove the wires from terminals “+” and “m”( be carefull not to turn the bolt).
w Measure using a megger or an ohmmeter in conductance (Siemens) range between “m-
bushing” and “HV-bushing”. The resistance depends on ’UDC rated’. See fig. 5.
w Measure with an ohmmeter between “m” and earth. It should be about 182 k.
w Measure with an ohmmeter between the “m-wire” and “earth”. It should be about 10 k.
As it is very difficult to measure the top part of the divider accurately, this measurement will
only give a rough guide.

Fig. 5: New model of France-Transfo T/R unit

Note: The voltage divider has been designed to a current of 1 mA at ’UDC rated’ which means that
the base part is approx. 10 k in order give 10 V at ’UDC rated’.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 13

External voltage divider:

When installing a PIACS in an existing unit an external voltage divider is often used, see figure
6, as well as a print board AP33 for the current shunt, see figure 7.

Note: The top part consists of 4 pcs resistors each 100 M connected in series. The base part
(RB) is in the terminal box on the small PCB including overvoltage protection.
The base part is calculated with the formula given in Fig 6 depending on 'UDC rated'.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 14

Fig. 6: External Voltage divider .

On AP33 the current shunt and the base resistance can be adapted. This is only done where a
PIACS-DC is installed on an old HV unit with a built-in top resistance (remember to measure
the resistance, see 5.2). The shunt is adapted by using the jumpers W1-W12, which are made of
0 - resistors (see fig. 7).
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 15

The base resistance is made-up by using R, and the calculation is shown on figure 6, where RT
is the resistance of the top part. If there are capacitors in the top part, capacitors in the base part
must also be adapted, by using W13- W16. There must be the same ratio between the
resistances and the capacitors.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 16

Fig. 7: Printboard AP33

Note: Presently, France Transfo is using PCB AP33 in T/R- tanks however, not marked so.
In this case the current-shunt and the and base part of the voltage divider must be
checked according to rated values.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 17

Fig. 8: Billede 1: Primærstrøm ved Nec=1.

Picture 2: Primary current with Nec=1.

Fig. 9: Billede 2: Filterstrøm ved Nec=1, målt mellem X12-20 og X12-19.

Picture 2: ESP-current at Nec=1 measured between X12-20 and X12-19.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 18

Fig 10: Billede 3: Filterspænding ved Nec = 1, målt mellem X12-21 og X12-19.
Picture 3: ESP-voltage at Nec =1 measured between X12-21 and X12-19.

Fig 11: Billede 4: Filterspænding ved overslag.

Picture 4: ESP-voltage at spark.
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 19

7. Obtainable ESP-voltages.
A T/R unit with the following rated values given according to DIN norms: 90 kV/600mA has
an output of 90kV peak value and 600mA mean value (however, not simultaneously). The
obtainableESP-voltages at various 'UDC rated' and current are shown on fig. 12 and 13.

Note: That there is a big difference between the DIN norms and f.ex the american norms. F.ex.
concerning 'UDC rated' the conversion factor is 1,68. Example: 55 kV american T/R unit
corresponds to a 1,68 x 55= 92kV according to DIN norms.

Fig. 12: Opnåelige filterspændinger (middelværdi) som funktion af mærkespændingen

Obtainable ESP-voltages (mean value) related to 'UDC rated'
F.L.Smitdh Airtech`s ESP Troubleshooting manual 12-08-2002 page 20

Fig. 13: Opnåelige filterspændinger (middelværdi) som funktion af filterstrømmen

Obtainable ESP-voltages (mean value) related to ESP-current.

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