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ADOR RK3000 Manual

High frequency power supply microprocessor transformer control for electrostatic precipitators
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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

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  • Page 1 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...

  • Page 2: Table Of Contents

    RK3000 High Frequency Power Supply Operating Manual 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 ..............................
  • Page 3 RK3000 High Frequency Power Supply Operating Manual 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 ............................
  • Page 4 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 ...........

  • Page 5: Introduction: Maximum Flexibility With Minimum 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.

  • Page 6: 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.

  • Page 7: Control Unit

    RK3000 High Frequency Power Supply Operating Manual 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.

  • Page 8: Control Communications Cable

    RK3000 High Frequency Power Supply Operating Manual 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.

  • Page 9: Potential Transformer

    RK3000 High Frequency Power Supply Operating Manual 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.

  • Page 10: Quick Start Chart

    RK3000 High Frequency Power Supply Operating Manual 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.

  • Page 11: Quick Start Chart

    RK3000 High Frequency Power Supply Operating Manual QUICK START CHART For One-to-Many System Configuration (See page 24) A one-to-many system configuration is defined as a system where there is one or more Keypad and Display Units communicating with one or more Control Units, regardless of location.

  • Page 12: Chapter 2 Operating Parameters And Features

    OPERATING PARAMETERS AND FEATURES The following is a list of the operating parameters and features incorporated in the RK3000 control. This list is followed by definitions (broken into programmable and non- programmable groups), and later in this manual, detailed instruction on how the parameters are programmed.

  • Page 13: Average Readings

    The types of transients that the control detects are: Spit – Low current, fast rise time electrical discharge that extinguishes itself instantaneously. Due to self-extinguishing characteristics, the RK3000 takes no control action when a spit is detected. Spark – Low current, relatively slow rise time electrical discharge that persists for one half cycle or less before extinguishing.

  • Page 14: External Alarm Message Text

    RK3000 High Frequency Power Supply Operating Manual External Alarm Message Text In conjunction with the external alarm inputs, there are preprogrammed tags (descriptions) that can be assigned to each input. . Max Set Size The same microprocessor control components are used regardless of the size of the TR they are connected to.

  • Page 15: Quench Mode

    RK3000 High Frequency Power Supply Operating Manual period of time from the last spark or arc occurrence. (For a more detailed description of Process Sense, see Discussion of Typical Control Waveforms, page 52). This control feature assures stable and rapid recovery after a process upset has subsided.

  • Page 16: Secondary Current Limit

    RK3000 High Frequency Power Supply Operating Manual conduction percentage versus the maximum permissible conduction percentage (100%). The conduction percentage will also be affected by the level of sparking and arcing being detected. Secondary Current Limit The Secondary Current Limit is typically programmed for the nameplate secondary current rating of the transformer-rectifier being controlled.

  • Page 17: Definition Of Non-Programmable Features

    Manual bias potentiometer located in the mid right area of the Control Unit Non-Volatile Memory The RK3000 utilizes EEPROM (electronically erasable programmable read only memory) for storage of all preprogrammed and field-programmed information. EEPROMs do not require battery backups and are a nonvolatile memory with indefinite storage life.

  • Page 18: Chapter 3 Digital Display

    RK3000 High Frequency Power Supply Operating Manual CHAPTER 3 DIGITAL DISPLAY The digital display is an integral part of the Keypad and Display Unit (see page 6) and is located on the control cabinet front door. All operating and programmable parameters are viewed on this 4 line by 20-character liquid crystal display (LCD).

  • Page 19: Prompt Screen

    RK3000 High Frequency Power Supply Operating Manual The “Mode” area will display various messages (such as Stop, Avg., and Inst. as they occur – these abbreviations will be explained later in the manual). When in the Stop mode a decimal point will flash after the “p” to indicate the Keypad and Display unit is working.
  • Page 20 RK3000 High Frequency Power Supply Operating Manual Status Messages Average Readings -electrical readings are 5 second averaged values Energy Mgt Mode -energy management mode active Manual Mode -manual mode of operation active Peak Readings -electrical readings are peak value Open Contactor...

  • Page 21: Keypad Description

    RK3000 High Frequency Power Supply Operating Manual CHAPTER 4 KEYPAD DESCRIPTION The keypad (see below) contains 16 hermetically sealed keys. All operating parameters, status checks, and On/Off functions are programmed into the memory through keypad. Most keys have two functions. One is a parameter choice and the other is a number or scroll choice.
  • Page 22 RK3000 High Frequency Power Supply Operating Manual QUENCH key – Used to check (or in conjunction with a security code to program) the value of the Quench time. (For programming ranges, see Preprogrammed Levels And Operating Ranges, page 68.) IE key –Not Used UP key –...
  • Page 23 RK3000 High Frequency Power Supply Operating Manual In addition to the keys on the keypad, an ON/OFF or push button switch on the control cabinet is provided. This switch is used to energize and de-energize the control components and in turn the power to the Transformer Rectifier.To de-energize the power to the cabinet control circuits, the breaker must be opened.

  • Page 24: Chapter 5 Programming Instructions

    CHAPTER 5 PROGRAMMING INSTRUCTIONS There are two different ways that the RK3000 control can be configured. The first configuration is a one-to-one configuration where there is one Keyboard and Display unit, and one Interface Board, on each control cabinet. The second configuration is a one-to- many configuration where one or more Keypad and Display Units are connected to many Interface Boards in an equal number of control cabinets.

  • Page 25: Id Set-Up

    RK3000 High Frequency Power Supply Operating Manual entered, the message “Invalid Code” will appear on the status line, remain for a few seconds, then return to the previous screen. Range: 0000-9999 Enter CODE: #### Invalid Code If a code has not been entered and you attempt to change a parameter that requires a code, an icon of a padlock will appear in the Parameter Screen’s bottom line to remind...

  • Page 26: Coordination System

    RK3000 High Frequency Power Supply Operating Manual The Interface Unit End ID number is the last Interface Unit that you wish this Keypad and Display Unit to communicate with. The acceptable range for the ID is presented to the right of the word “Range”. In this example, the range is 1to 99.

  • Page 27: Programming Discrete Key Parameters

    RK3000 High Frequency Power Supply Operating Manual The End ID Number represents the last Interface Unit that the Keyboard and Display Unit will coordinate. The acceptable range for the End ID is presented to the right of the word “Range”. In this example, the range is 1to 99.
  • Page 28 RK3000 High Frequency Power Supply Operating Manual If the operating value is to be changed, simply press the numeric keys corresponding to the new value (the old value will be overwritten) and press ENTER. If the present operating value is acceptable, simply press ENTER without making any changes. The Primary Current Limit display will now appear.

  • Page 29: Ramp

    RK3000 High Frequency Power Supply Operating Manual The present operating value for the Secondary Current Limit is presented to the right of the word “Enter.” In this example the present operating value is 1500 mA. If the operating value is to be changed, simply press the numeric keys corresponding to the new value (the old will be overwritten) and press ENTER.

  • Page 30: Quench

    RK3000 High Frequency Power Supply Operating Manual If the operating value is to be changed, simply press the numeric keys corresponding to the new value (the old value will be overwritten) and press ENTER. If the present operating value is acceptable, simply press ENTER without making any changes. The screen will now revert to either the Device Status Screen or the Electrical Reading Screen depending which screen was active when the PED key was pressed.

  • Page 31: Programming "Prompt Key" Parameters

    RK3000 High Frequency Power Supply Operating Manual Programming “Prompt Key” Parameters PROMPT Key The functions not found on the discrete keys are programmed through the use of the PROMPT key. Pressing the PROMPT key brings up the first of twenty (20) prompts of additional programmable parameters.

  • Page 32: Pre-Spark Readings

    RK3000 High Frequency Power Supply Operating Manual are averaged over a five (5) second period. The mode area of the Electrical Reading Screen will display “Avg.” RED-01 205 V 161 A 026 kW 56kV1 00kV2 1887mA 000sp 000ar Avg. If the operating value is to be changed, simply press the numeric keys corresponding to the new value (the old value will be overwritten) and press ENTER.

  • Page 33: Conduction Display

    RK3000 High Frequency Power Supply Operating Manual If the operating value is to be changed, simply press the numeric keys corresponding to the new value (the old value will be overwritten) and press ENTER. If the present operating value is acceptable, simply press ENTER without making any changes.

  • Page 34: Quench Mode

    RK3000 High Frequency Power Supply Operating Manual Press ENTER and the ‘”Spark Rate Control” Parameter Screen will appear. RED-01 Spark Rate Control 0=Disable, 1=Enable Enter: 1 The Spark Rate Control is used when it is desirable to set a maximum number of sparks the control will allow, rather than have the control determine the optimum number of sparks.

  • Page 35: Process Sense

    RK3000 High Frequency Power Supply Operating Manual The normal operating mode for the Quench parameter is Arc mode. In that mode, only when an Arc occurs will the control Quench (turn-off) the power for the number of cycles programmed into the Quench Time (under the discrete Quench key). Under some circumstances, like extreme upset conditions, it may be desirable to quench the power when either an Arc or a Spark occurs.

  • Page 36: Reinitialize Keyboard And Display Unit

    RK3000 High Frequency Power Supply Operating Manual Press ENTER and the ‘Re-init Interface” Parameter Screen will appear. RED-01 Re-init Interface 0=No, 1=Yes Enter: 0 To reinitialize the Interface Unit, press the 1 key and then the ENTER key. The Interface Unit will reinitialize and the screen will change to the display shown below.

  • Page 37: Software Version

    RK3000 High Frequency Power Supply Operating Manual After a 2 second delay, the display will change to the Device Select Screen. From this screen press the HELP key and reprogram the ID parameters (page 27). If a re-initialization is not desired, press the 0 key and the ENTER key. The Re-init Keypad/Disp Prompt Screen will appear.
  • Page 38 RK3000 High Frequency Power Supply Operating Manual Press ENTER and the ‘Max Set Size” Parameter Screen will appear. Note: The values for the max TR ratings can be found on the TR nameplate. Use values for the output of the diode bridge and not the AC transformer (if both are shown).

  • Page 39: External Alarm Trip

    The user has the option of having four external alarm inputs (Alarm 1 through Alarm 4) “trip” or “not trip” the RK3000 control. A trip alarm results in the IGBTs shutting off, the alarm relay closing, an alarm message appearing in the Device Status Screen, and the control cabinet contactor de-energizing.

  • Page 40: External Alarm Message Text

    RK3000 High Frequency Power Supply Operating Manual selection will appear opposite the word Enter, and become active when the ENTER key is pressed. If the present operating mode is acceptable, simply press ENTER without making any changes. Either way, the display will now change to the Alarm 4 Trip Parameter Screen.
  • Page 41 RK3000 High Frequency Power Supply Operating Manual The numbers in the range correspond to the numbers assigned to the various text messages. If the text message is to be changed, simply press the numeric keys corresponding to the new text desired (the old value will be overwritten) and press ENTER. If the present text is acceptable, simply press ENTER without making any changes.

  • Page 42: Under Voltage Setup

    RK3000 High Frequency Power Supply Operating Manual Press the DOWN or UP keys to view more prompt screens or press ESC to return the display to either the Electrical Reading Screen or the Device Status Screen depending on the screen you were in prior to pressing the PROMPT key.

  • Page 43: Energy Mgt Setup

    RK3000 High Frequency Power Supply Operating Manual If an under voltage trip level is detected (primary or secondary voltage level below the level programmed above) the control will delay tripping until the time period programmed here has passed. This allows time for the condition that caused the low voltage condition (usually a partial ground) to clear, eliminating control trips for random occurrences.

  • Page 44: Wet Precipitator Wash Down System

    RK3000 High Frequency Power Supply Operating Manual made or not, after the ENTER key is pressed the “Energy Mgt Setup” Prompt Screen will appear. Press the DOWN or UP keys to view more prompt screens or press ESC to return the display to either the Electrical Reading Screen or the Device Status Screen depending on the screen you were in prior to pressing the PROMPT key.

  • Page 45: Rapping System Set-Up For Motor Timers (Option)

    RK3000 High Frequency Power Supply Operating Manual Pressing “1” will bring up the MRC ID screen: RED-01 MRC ID for Pwr Down Range: 1-9 Enter: 1 This screen is used to tell the TR control which of the microprocessor rapper controls (MRC), if there are more than one, is to activate the TR control’s power down system.

  • Page 46: Soft Arc Detection

    RK3000 High Frequency Power Supply Operating Manual Soft Arc Detection Press the PROMPT key and then the  key until the “Soft Arc Detection” Prompt Screen appears. RED-01 Soft Arc Detection Due to low signal to noise ratios, poor electrical grounding, heavy electrical noise, etc. it may be necessary to detect arcs (soft arcs) from secondary electrical values in place of primary electrical values.
  • Page 47 RK3000 High Frequency Power Supply Operating Manual The power level in the Manual mode is adjusted by turning the Manual potentiometer, also located on the Interface Unit(see page 58). When in the Manual mode, the power can be adjusted to between 0% and 100% IGBT conduction.

  • Page 48: Chapter 6 Air Load Instructions

    RK3000 High Frequency Power Supply Operating Manual CHAPTER 6 AIR LOAD INSTRUCTIONS The following steps must be performed prior to energizing the control in the automatic mode for the first time. If at all possible, this procedure should be performed without process gas entering the precipitator and under stack draft condition.
  • Page 49 RK3000 High Frequency Power Supply Operating Manual Place the Automatic-Manual switch on the Interface Unit in the Automatic position. Place the On-Off switch on the front of the control cabinet to the on position. The control will slowly power up and display increasingly larger values of primary voltage, primary current, and secondary current.

  • Page 50: Chapter 8 Gas Load Adjustments

    RK3000 High Frequency Power Supply Operating Manual CHAPTER 8 GAS LOAD ADJUSTMENTS The following adjustments are to be made with the process gas flowing through the precipitator. These adjustments are presented as starting points after the air load adjustments have been completed.

  • Page 51: Chapter 9 Optimizing The Rk3000 Precipitator Control Operation

    Swings in process conditions can mask optimization. Once the RK3000 is optimized, observe the opacity to ensure it does not slowly start to increase. If the opacity does slowly increase, readjust the rapper lifts and timing. If the RK3000 is optimized and precipitator efficiency increases, the rapping system must be re- optimized to handle the additional collected particulate load.

  • Page 52: Chapter 10 Discussion Of Typical Control Waveforms

    Starting in the upper left-hand corner, the precipitator current is at its maximum rating. The current is stable at this level until a Spark occurs. The RK3000 sense the Spark and reduces the conduction angle of the IGBTs, causing an almost instantaneous reduction in precipitator current.

  • Page 53: Waveform #2, Quench Mode, Arc Only, Pedestal Programmed To 5 Cycles

    RK3000 High Frequency Power Supply Operating Manual Waveform #2, Quench Mode, Arc Only, Pedestal Programmed to 5 Cycles This waveform is generated by the same parameter responses as described for Waveform #1. The only difference is the Pedestal Rate is now longer than 1 cycle;...

  • Page 54: Waveform #3 And #4, Quench Mode, Arcs And Sparks, Pedestal Programmed To 1 And 10 Cycles

    Sketch 3: Quench Mode Arc And Spark Sketch 4: Quench Mode Arc And Spark One of the outstanding features of the RK3000 is its ability to automatically readjust the programmable parameters, after initial adjustments have been made, based on actual operating current levels.

  • Page 55: Waveforms #5 And #6, Automatic Parameter Adjustment With Sparking And Arcing

    RK3000 High Frequency Power Supply Operating Manual Waveforms #5 and #6, Automatic Parameter Adjustment with Sparking and Arcing The percentage Phase Back and the Ramp Rate should be different for each electrical field within the precipitator. The least Phase Back and greatest Ramp Rate are in the inlet fields;...

  • Page 56: Waveform #7, Typical Control Waveform

    The leading part of this waveform shows the gradual reduction of precipitator current due to an upset operating condition. When an Arc is encountered, the RK3000 Quenches the current for a programmed Quench Time, then the Pedestal is initiated and the RK3000 again tries to reach normal operating power levels.

  • Page 57: Waveforms #8 And #9, Back Corona Control

    RK3000 High Frequency Power Supply Operating Manual Waveforms #8 and #9, Back Corona Control Waveform #8 shows a typical secondary voltage versus secondary current curve for moderate and low resistivity precipitator operation. Sketch 8: Precipitator Operating Voltage (kV) Waveform #9 shows a typical secondary voltage versus secondary current curve for high- resistivity precipitator operation where the precipitator is experiencing Back Corona.

  • Page 58: Chapter 11 Description Of Interface Unit Connections, Leds, And Relays

    RK3000 High Frequency Power Supply Operating Manual CHAPTER 11 DESCRIPTION OF INTERFACE UNIT CONNECTIONS, LEDs, AND RELAYS Discription of Interface Unit Connections and Components Page 58 of 73...

  • Page 59: Chapter 12 Technical Help

    RK3000 High Frequency Power Supply Operating Manual CHAPTER 12 TECHNICAL HELP Technical help and parts can be obtained by contacting Ador Powertron Limited by any of the following ways: Phone: +91 20 27473778 / 27472532 Fax: +91 20 27475817 E-mail: customercarehvr@adorpower.com...

  • Page 60: Warranty Return Authorization

    RK3000 High Frequency Power Supply Operating Manual WARRANTY Return Authorization Redkoh Industries warrants to Purchaser that the products manufactured by Redkoh Industries are free from defects in material and/or workmanship under normal use and service for 36 months from date of shipment.

  • Page 61: Appendix I - Wet Precipitator Wash Down System (Optional Feature)

    RK3000 High Frequency Power Supply Operating Manual APPENDIX I – Wet Precipitator Wash Down System (Optional Feature) Wet Precipitator Wash Down System Timer If this control is being used in conjunction with a wet electrostatic precipitator with a wash down system, optional relays on the Interface Unit and relay timers designed into the Keyboard and Display Unit can be used to control the wash down system.
  • Page 62 RK3000 High Frequency Power Supply Operating Manual RED-01 Wash-down Delay Range: HH:MM:SS Enter: 00:15:30 The wash-down delay is the time interval between the control being de- energized and the start of the Wash-down Duration. In actuality, the relay contact between the Live 1 / 2 and OP1 (on the Interface Unit terminal strip) is open until the wash-down delay times out.
  • Page 63 RK3000 High Frequency Power Supply Operating Manual the right of the word “ENTER”. In this example the present operating value is 0 hours, 8 minutes, 45 seconds. If the operating value is to be changed, simply press the numeric keys corresponding to the new value (the old value will be overwritten) and press ENTER.

  • Page 64: Appendix Ii - Timers For Motor Operated Cleaning Devices (Optional Feature)

    RK3000 High Frequency Power Supply Operating Manual Appendix II – Timers for Motor Operated Cleaning Devices (Optional Feature) Motor Operated Electrode Cleaning Equipment Timers If this control is being used in conjunction with motor driven rapping systems, four (4) optional relays built into the Interface Unit and relay timers designed into the Keyboard and Display Unit can be used to control the on and off times of the various motors.
  • Page 65 RK3000 High Frequency Power Supply Operating Manual The Range of the program number is 1 to 6. The present operating value for the Rapper Program # is presented to the right of the word “ENTER”. In this example the present program is program # 1.
  • Page 66 RK3000 High Frequency Power Supply Operating Manual the relays assigned to Mode 2 can be On at the same time, however any relay in Mode 1 can be On when any relay in Mode 2 is On. Mode 0 is...

  • Page 67: Appendix Iii - List Of Alarm Texts

    RK3000 High Frequency Power Supply Operating Manual Appendix III – List of Alarm Texts The following alarm messages can be assigned to any of the four external alarm inputs on the Interface Unit. Enter the appropriate number of your choice during Alarm programming.
  • Page 68 RK3000 High Frequency Power Supply Operating Manual TABLE 1 PREPROGRAMMED LEVELS AND OPERATING RANGES The Max Set Size and the LIMITS must be programmed for the control to energize. All other parameters will operate on the preset values shown below.

  • Page 69: Index Quick Reference

    RK3000 High Frequency Power Supply Operating Manual Rapper System / Wash Down System Global Rapper System 0 or 1 (0) Disable, (1) Enable 1 – 6 Rapper Program # 1 unit increments 1 – 99:59:59 Rapper 1 Interval 00:02:00 1 second increments 1 –...
  • Page 70 RK3000 High Frequency Power Supply Operating Manual Energy Mgt Mode · 21  key · 23 Energy Mgt Setup · 46  Key · 23 Enter Key · 24 Esc Key · 23 External Alarm Message Text · 14, 34, 43 External Alarm Trip ·...
  • Page 71 RK3000 High Frequency Power Supply Operating Manual Liquid Crystal Display · 19 MManual Control · 18 Quench · 32 Quench Key · 23 Quench Mode · 15, 34, 37, 49 Manual Mode · 21, 51 Quench Time · 15 Manual Overload · 62 Manual Position ·...
  • Page 72 RK3000 High Frequency Power Supply Operating Manual Update In Progress · 20 Viewing Parameters · 26 Warranty Repair · 64 Wash Down System · 47, 65 Wash-Down Delay · 65 Wash-Down Duration · 65, 66 Wash-Down Interval · 65 Watt Meter · 18 Web Site ·...
  • Page 73 RK3000 High Frequency Power Supply Operating Manual FOR PROFIBUS / PROFINET Please refer document no:- 5003-0004-13-89. Page 73 of 73...

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