ADOR RK3000 Manuel utilisateur

RK3000

High Frequency Power Supply

Microprocessor Transformer Control

for Electrostatic Precipitators

ADOR POWERTRON LIMITED

RAMNAGAR COMPLEX,

PLOT NO 51, D-II BLOCK,

MIDC, CHINCHWAD,

PUNE 411019

INDIA

Version 1.02

DRG NO: 5003-0004-13-06/1

 RK3000 High Frequency Power Supply 
Operating Manual 
 
Page 2 of 73 
TABLE OF CONTENTS 
 
INTRODUCTION:MAXIMUM FLEXIBILITY WITH MINIMUM EMISSIONS.......................................................5
CHAPTER 1 COMPONENTS AND CONFIGURATIONS ...............................................................................6
Major System Components................................................................................................................................................6 
Keypad and Display Unit........................................................................................................................................6 
Control Unit .............................................................................................................................................................7 
Control Communications Cable.............................................................................................................................8 
Current Transformer..............................................................................................................................................8 
Potential Transformer.............................................................................................................................................9 
Secondary Signal Conditioning Resistors..............................................................................................................9 
QUICK START CHART.................................................................................................................................... 10 
For One-to One System Configuration................................................................................................................ 10 
QUICK START CHART.................................................................................................................................... 11 
For One-to-Many System Configuration............................................................................................................. 11 
CHAPTER 2 OPERATING PARAMETERS AND FEATURES.................................................................... 12 
DEFINITIONS OF PROGRAMMABLE PARAMETERS...............................................................................12 
Average Readings.................................................................................................................................................. 13 
Coordination System ............................................................................................................................................. 13 
Definition of Control Responses........................................................................................................................... 13 
Display ID............................................................................................................................................................... 13 
Energy Management (Mgt) Setup (Optional Feature)....................................................................................... 13 
External Alarm/Trip ............................................................................................................................................. 13 
External Alarm Message Text ..............................................................................................................................14 
Max Set Size........................................................................................................................................................... 14 
Pedestal Rate.......................................................................................................................................................... 14 
Phase Back ............................................................................................................................................................. 14 
Power Down Rapping............................................................................................................................................14 
Pre-Spark Readings............................................................................................................................................... 14 
Primary Current Limit .........................................................................................................................................14 
Primary Voltage Limit.......................................................................................................................................... 14 
Process Sense.......................................................................................................................................................... 14 
Quench Mode......................................................................................................................................................... 15 
Quench Time.......................................................................................................................................................... 15 
Ramp Rate.............................................................................................................................................................. 15 
Rapping System Set-up ......................................................................................................................................... 15 
Re-initialize............................................................................................................................................................. 15 
Relay Timers.......................................................................................................................................................... 15 
Conduction Display ...............................................................................................................................................15 
Secondary Current Limit...................................................................................................................................... 16 
Secondary Voltage Limit....................................................................................................................................... 16 
Spark and Arc Control Response......................................................................................................................... 16 
Spark Rate Control ...............................................................................................................................................16 
Spark Sensitivity.................................................................................................................................................... 16 
Soft Arc................................................................................................................................................................... 16 
Software Version.................................................................................................................................................... 16 
Under Voltage Trip –Primary / Secondary ........................................................................................................ 16 
Under Voltage Timer.............................................................................................................................................16 
DEFINITION OF NON-PROGRAMMABLE FEATURES.............................................................................. 17 
Arc Numerical Display..........................................................................................................................................17 

 RK3000 High Frequency Power Supply 
Operating Manual 
 
Page 3 of 73 
Automatic Display Calibration............................................................................................................................. 17 
IGBT Firing Delay................................................................................................................................................. 17 
Soft Start................................................................................................................................................................. 17 
Spark Indicator and Numerical Display.............................................................................................................. 17 
True RMS Primary Voltage and Current Displays............................................................................................ 17 
Manual Control...................................................................................................................................................... 17 
Non-Volatile Memory............................................................................................................................................ 17 
Watt Meter.............................................................................................................................................................17 
CHAPTER 3 DIGITAL DISPLAY.................................................................................................................. 18 
Device Selection Screen.........................................................................................................................................18 
Device Status Screen..............................................................................................................................................18 
Electrical Reading Screen ..................................................................................................................................... 18 
Prompt Screen........................................................................................................................................................19 
Parameter Screen ..................................................................................................................................................19 
Alarm Summary Screen........................................................................................................................................ 19 
CHAPTER 4 KEYPAD DESCRIPTION ........................................................................................................ 21 
CHAPTER 5 PROGRAMMING INSTRUCTIONS........................................................................................ 24 
Viewing Parameters...............................................................................................................................................24 
Security Programming Code Entry .....................................................................................................................24 
ID Set-Up................................................................................................................................................................ 25 
Coordination System ............................................................................................................................................. 26 
Programming Discrete Key Parameters.........................................................................................................................27 
Limits key............................................................................................................................................................... 27 
RAMP.....................................................................................................................................................................29 
PHASE BACK ....................................................................................................................................................... 29 
PED......................................................................................................................................................................... 29 
QUENCH................................................................................................................................................................ 30 
PROMPT................................................................................................................................................................ 30 
Clear Alarm............................................................................................................................................................ 30 
Programming “Prompt Key” Parameters......................................................................................................................31 
PROMPT Key........................................................................................................................................................ 31 
Average Readings.................................................................................................................................................. 31 
Pre-Spark Readings............................................................................................................................................... 32 
Conduction Display ...............................................................................................................................................33 
Spark Rate Control ............................................................................................................................................... 33 
Quench Mode......................................................................................................................................................... 34 
Process Sense.......................................................................................................................................................... 35 
Reinitialize Interface Unit..................................................................................................................................... 35 
Reinitialize Keyboard and Display Unit .............................................................................................................. 36 
Software Version.................................................................................................................................................... 37 
Max Set Size........................................................................................................................................................... 37 
External Alarm Trip.............................................................................................................................................. 39 
External Alarm Message Text ..............................................................................................................................40 
Under Voltage Setup..............................................................................................................................................42 
Energy Mgt Setup..................................................................................................................................................43 
Wet Precipitator Wash Down System.................................................................................................................. 44 
Power Down Rapping............................................................................................................................................44 
Rapping System Set-up for Motor Timers (Option)........................................................................................... 45 
Spark Sensitivity.................................................................................................................................................... 45 
Soft Arc Detection.................................................................................................................................................. 46 
Switching to Manual Operation ...........................................................................................................................46 
CHAPTER 6 AIR LOAD INSTRUCTIONS ................................................................................................... 48 
Pre-Operating Checkout:...................................................................................................................................... 48 

 RK3000 High Frequency Power Supply 
Operating Manual 
 
Page 4 of 73 
CHAPTER 8 GAS LOAD ADJUSTMENTS.................................................................................................. 50 
Normal Operation.................................................................................................................................................. 50 
High –Resistivity Ash Operation......................................................................................................................... 50 
Process Upset Operation.......................................................................................................................................50 
CHAPTER 9 OPTIMIZING THE RK3000 PRECIPITATOR CONTROL OPERATION................................ 51 
CHAPTER 10 DISCUSSION OF TYPICAL CONTROL WAVEFORMS........................................................ 52 
Waveform #1, Quench Mode, Arc Only, Pedestal Programmed to 1 Cycle.....................................................52 
Waveform #2, Quench Mode, Arc Only, Pedestal Programmed to 5 Cycles ...................................................53 
Waveform #3 and #4, Quench Mode, Arcs and Sparks, Pedestal Programmed to 1 and 10 Cycles ..............54 
Waveforms #5 and #6, Automatic Parameter Adjustment with Sparking and Arcing................................... 55 
Waveform #7, Typical Control Waveform.......................................................................................................... 56 
Waveforms #8 and #9, Back Corona Control ..................................................................................................... 57 
CHAPTER 11 DESCRIPTION OF INTERFACE UNIT CONNECTIONS, LEDS, AND RELAYS.................. 58 
CHAPTER 12 TECHNICAL HELP ................................................................................................................. 59 
WARRANTY RETURN AUTHORIZATION................................................................................................... 60 
APPENDIX I –WET PRECIPITATOR WASH DOWN SYSTEM (OPTIONAL FEATURE) ............................. 61 
Wet Precipitator Wash Down System Timer.................................................................................................................61 
APPENDIX II –TIMERS FOR MOTOR OPERATED CLEANING DEVICES (OPTIONAL FEATURE).......... 64 
Motor Operated Electrode Cleaning Equipment Timers .............................................................................................64 
APPENDIX III –LIST OF ALARM TEXTS ....................................................................................................... 67 
TABLE 1 PREPROGRAMMED LEVELS AND OPERATING RANGES............................................... 68 
INDEX QUICK REFERENCE .................................................................................................................. 69 
 

RK3000 High Frequency Power Supply

Operating Manual

Page 5 of 73

INTRODUCTION: Maximum Flexibility with Minimum Emissions

Ador’s RK3000 High Frequency transformer-rectifier control is designed specifically for

use on electrostatic precipitators.

An extremely high degree of control flexibility is available through the RK3000’s many

easily programmed operating parameters and automatic features. This flexibility, in turn,

results in maximum precipitator efficiency and minimum outlet emissions.

This manual will define all the pre-programmed and field programmable features of the

RK3000 control, as well as provide a description of the control components. A description

of typical waveforms, and suggestions for optimizing the control’s operation, are also

included.

RK3000 High Frequency Power Supply

Operating Manual

Page 6 of 73

CHAPTER 1 COMPONENTS AND CONFIGURATIONS

Major System Components

The following descriptions and pictures are presented to familiarize the user with the six

components that make up the RK3000 High Frequency transformer-rectifier control: The

photos shown are typical and may vary slightly from those shown.

The following is a list and definition of the major control components.

oKeypad and Display Unit

oControl Unit

oInterface Communications Cable

oCurrent Transformer

oPotential Transformer

oSecondary Signal Conditioning Resistors

Keypad and Display Unit

The Keypad and Display Unit is the user interface to the various operating modes and

variable parameters of the system. It communicates with one or more Interface Boards.

Electrical readings, programming screens, alarm messages, operating messages, and

communication information, are displayed on the face of this unit. A keyboard, for

programming purposes, is also located on the face of this unit.

Figure 1: Keypad and Display Unit

RK3000 High Frequency Power Supply

Operating Manual

Page 7 of 73

Control Unit

The Control Unit is the interface between the analog and digital signals present in the

control and feedback circuits. The IGBT firing circuit is located on this Unit. It responds

to precipitator operating conditions based on the parameters programmed into the

Keyboard and Display Unit. The switches for setting the Control Unit ID number are

also located on this Unit.

Figure 2: Control Unit

RK3000 High Frequency Power Supply

Operating Manual

Page 8 of 73

Control Communications Cable

This cable is used between the Keypad and Display Unit, and the Control Unit to provide

a communications link for passing data.

Figure 3: Control Communications Cable

Current Transformer

The Current Transformer (CT) and load resistor combination, when properly set, provides

a 5V signal, at rated current, to the Control Unit. The signal is used for primary current

display and limit.

Figure 4: Current Transformer

RK3000 High Frequency Power Supply

Operating Manual

Page 9 of 73

Potential Transformer

The Potential Transformer (PT) measures the transformer primary voltage and provides a

reference signal to the Control Unit. The PT has a ratio of 600 volts to 20 volts. The

signal is used for primary voltage display and limit.

Figure 5: Potential Transformer

Secondary Signal Conditioning Resistors

Signal conditioning resistors are provided for both the secondary current and secondary

voltage reference signals. Their values will vary depending on the transformer-rectifier

rating. See schematic diagrams for proper values. These signals are sent to the Control

Unit for secondary voltage and current display and limits, as well as spark pickup. Full

scale is represented by a 5V signal.

Figure 6: Secondary Signal Conditioning Resistors

RK3000 High Frequency Power Supply

Operating Manual

Page 10 of 73

QUICK START CHART

For One-to One System Configuration

(See page 24)

A one-to-one system configuration is defined as a system where there is

one Keypad and Display Unit, and one Control Unit physically installed

on each control cabinet. If you have more than one Keypad and Display

Unit associated with more than one Control Unit see the Quick Start Chat

for a One-to Many Configuration (next page).

Not all parameters and operating modes need to be programmed in order

to get the control(s) up and running. To get started quickly, for each

control cabinet, follow the instructions in the order that they appear

below.

1. Enter the Programming security code (page 24).

2. Program the Max Set Size (page 41).

3. Program the Limits (page 27).

The other parameters and operating modes have default values, based

on typical precipitator operation. They will allow the control and

precipitator to operate, but at less than optimum efficiency. All default

values should be reprogrammed, as needed, to optimize the precipitator

efficiency and minimize outlet emissions.

At this point all the control IDs and Names will be the same. Reprogram

the control ID set-up (page 25) to give each TR control a unique name, if

desired.

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