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Summary of Contents for Chromalox DirectConnect
- Page 1 Installation and Operating Instructions Chromalox DirectConnect High Voltage Converter System PK526 Doc Rev: 13 AUG 2022 Software Rev 2.60...
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Page 2: Table Of Contents
Table of Contents A: INTRODUCTION AND SAFETY ........................ 3 B: RECEIPT, HANDLING, STORAGE and INSTALLATION ..............6 C: COMMISSIONING ............................11 D: OPERATION ............................... 12 E: INSPECTION and MAINTENANCE ......................16 FASTENER TORQUES ..........................18 ANNEX 1: HMI SCREENS ..........................19 ANNEX 2: ARC CONTROL SHROUD ...................... -
Page 3: A: Introduction And Safety
1...General 1.1 Scope This manual provides instructions for receiving, handling, storage, installation, startup (commissioning), operation, and maintenance (including troubleshooting) of Chromalox High Voltage Converter Systems designed and built to IEC or UL standards. __________________________________________________________________________ FAILURE TO ADHERE TO ANY OF THE 2...Introduction... - Page 4 and a CT connected around all three phases to The Disconnector Switches mentioned above measure residual current leakage to earth each provide an isolation gap between the [ground]. It will usually also contain the MV Supply/Line power and the associated Load Terminals, though these could be Heater(s).
- Page 5 SUPPLY LINE AND LOAD SIDE The Chromalox DirectConnect system is CIRCUITS, AS REQUIRED / PERMITTED comprised of both a Chromalox MV Converter System and a Chromalox MV BY ALL CODES AND STANDARDS. Heater. One may not be employed without the other. All written and implied warranties...
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Page 6: B: Receipt, Handling, Storage And Installation
B: RECEIPT, HANDLING, STORAGE and INSTALLATION 3...Receiving & Handling Ensure that lifting equipment can handle the weight of the system. Care should be exercised when moving Converter Systems as they are heavy and can tip over. Do to attempt to handle systems Keep the system secured to prevent distortion without securing properly and using only proper of the frame during moving and to minimize... - Page 7 5.2.2 Converter Systems may be shipped in 5...Installation one or more Transport Units / Shipping Sections. Each section is equipped with lifting Precautions & Warnings angles allowing the System or Transport Unit to READ AND UNDERSTAND be removed from the pallet. All four lifting SECTION A ABOVE BEFORE angles in the corners of the System should be CARRYING OUT THE WORK...
- Page 8 Do not install Arc Resistant Systems below IEC sections must be brought together, and the catwalks or other elevated access routes. fasteners (and any associated washers) must be installed from the inside of the section to the To ensure that water does not enter the System left of the slit through into holes where the from below, adequate drainage should be fasteners were originally installed.
- Page 9 5.3.1 Incoming MV cable terminals are mounted in the Controller section, or DOL section, and provide easy termination of incoming power wiring. Space is provided for the spreading, bending, and termination of over-size cables if these are needed to minimize voltage drops. Follow instruction provided by the cable or cable termination manufacturer.
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Page 11: C: Commissioning
Carry out Power Frequency (Hi-pot) tests to 6.1 Before Powering Up ensure that there is no hidden damage in the Chromalox takes great pride in knowing that we insulation system as follows: have provided to you a product of premium quality and workmanship. -
Page 12: D: Operation
D: OPERATION point on the sine wave, resulting in much lower 7...Startup and Operation harmonic distortion & EMI. The ZC control is based on a 1 second time base so in the 50% Precautions & Warnings demand example, the SCR switches would be READ AND UNDERSTAND conducting full Sine of power for ½... - Page 13 Manual: If Manual Dry-out is selected from the will signal the PLC to trip the MV Contactor to HMI, the system will dry out the selected Heater disable the affected load. The relay must be until it is turned off from the HMI. manually reset (via HMI or remote input), and the alarm condition cleared before the heater Automatic: The Automatic Dry-out mode utilizes...
- Page 14 7.4 HMI Screens The HEATER screen shows an overall view of the system, displaying system demand, permissive signals, measured output voltages, phase currents, leakage currents, and status for each heater load. This screen also displays DRYOUT control, as well as START/STOP functionality. The following shows an example of a 3 SCR system in AUTO mode, with the demand coming from a temperature controller or remote demand signal.
- Page 15 7.5 HMI Screens (Steam Generator Systems) The STEAM GENERATOR screen shows an overall view of the system, displaying system demand, permissive signals, measured output voltages, phase currents, leakage currents, and status for each heater load. This screen also displays DRYOUT control, as well as START/STOP functionality. The following shows an example of a 2 circuit Stepper system with an internal PID loop in AUTO mode.
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Page 16: E: Inspection And Maintenance
E: INSPECTION and MAINTENANCE every six months until experience allows the 8...Inspection & Maintenance schedule to be adjusted. Precautions & Warnings It is recommended that the maintenance READ AND UNDERSTAND interval should never exceed 5 years. SECTION A ABOVE BEFORE CARRYING OUT THE WORK Enclosure Exterior Inspect the Converter System’s exterior:... - Page 17 SCR Stacks and associated electronics boards n. Inspect door gaskets and replace if worn and wiring harnesses are designed for long and/or deteriorated. Repair or replace if trouble-free operation. Refer to Chromalox for found. maintenance instructions. p. Make sure that moving parts move freely and do not stick.
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Page 18: Fastener Torques
completes, the system will stop, and the HMI 8.4 Renewal Parts will indicate the fault. See spares list supplied separately. Contactor Welded If a Contactor is released but the status remains, a timer will begin. If this timer completes, the system will stop, and the HMI will indicate the fault. -
Page 19: Annex 1: Hmi Screens
ANNEX 1: HMI SCREENS The following pages give a full description of all the screens available on the HMI for full SCR systems. Note that actual layout may vary slightly. A1.1 Set-Up Screen NOTE: The Low Voltage Section should be checked and verified, and the following settings should be set before energizing the High Voltage Energize the Low Voltage Supply. - Page 20 “AUTO DRYOUT LEAKAGE TRIP POINT”: This is the amount of leakage current (Amps) that will trigger and Auto-Dryout sequence. The maximum allowed is 3.0A. “AUTO DRYOUT RETRY ATTEMPTS”: If the number of dry-out attempts for an element reaches this number and the element is still not dry, dry-out will be disabled for this load, preventing any further dry-out cycles, and a ‘Dry-out Fault’...
- Page 21 Pressing the ‘DATE/TIME’ pushbutton will allow the user to adjust date and time settings as shown below. To update the system, touch one of the fields and enter the new value and press the UPDATE button. The clock on the bottom right will show the updated time.
- Page 22 Pressing the ‘AUTO(MANUAL) MODE ENABLED’ pushbutton allows the user to switch between AUTO mode (system demand is supplied by temperature controller) or MANUAL mode (system demand is controlled manually by the user on the MAIN screen). Note: the system must be stopped to switch between these modes.
- Page 23 Selecting the SCR firing mode button displays a warning popup window. Read the warning and understand the potential dangers before selecting OK.
- Page 24 A1.2 Control Screens A1.2.1 Dry-out Operation Touch (HEATER) The DRYOUT CONTROL section is used to monitor and control Dry-out Mode. The leakage current values are displayed as well as the elapsed run time for each load. Full SCR System To manually dry-out a heater element, select the desired load(s) within the ‘DRYOUT CONTROL’ box, then press ‘START DRYOUT’.
- Page 25 For SCR Stepper systems, the SCR is used to Dryout contactor loads. Therefore, if a contactor load is selected load 1 will automatically be selected as well. In the example below, load 2 was selected for MANUAL DRYOUT, which will automatically mean that load 1 will be in DRYOUT as well. SCR Stepper System...
- Page 26 A1.2.2 Heater Control Touch (HEATER) The HEATER screen below shows a system that has been energized. The status of each SCR and its current output (0-100%) is displayed, along with the system demand. The overall system status is displayed as well. The following shows the system in AUTO mode, with the demand coming from the temperature controller.
- Page 27 For SCR Stepper systems, only the first heater load has an SCR, while the remaining loads are energized by a contactor. The contactor loads do not measure output voltage and do not display the % output, as they are fully on or fully off. Stepper System...
- Page 28 The following shows the system in MANUAL mode, where the demand is adjustable by the user. The demand signal is adjustable with the UP and DOWN arrow buttons, or by touching on the number (with blue border) and entering a number from 0-100. Full SCR System with external PID control...
- Page 29 For systems with an internal PID controller, MANUAL mode is displayed as follows. The red UP and DOWN arrows pop up and the PID MODE text changes to yellow. Stepper system with internal PID control...
- Page 30 Load Status Indicators: the following conditions are possible for each load. “NOT READY”: A condition is present that will not permit this load to turn on. Check the CONTROL screen. “READY”: All conditions are met for this load to turn on. “ENABLED”: This is an SCR load that is currently on.
- Page 31 The following shows the system in REMOTE mode (selected on the SETUP screen). In this mode, the local START button on the HMI is disabled, and the remote start command input from the customer will energize the heater. When this mode is active, text will be visible and the START button will be gray. Note that when this mode is active the STOP button will de-energize the heater.
- Page 32 A1.2.3 Leakage Current Trend Screen Touch (LEAKAGE) This screen displays a live charted value of leakage current for all loads simultaneously. The trip point is displayed as well to show how close an element is to entering Automatic Dry-out Mode. This is the only screen where access to other screens is not available from the left side menu.
- Page 33 Pressing the HIST button will switch to historical mode, where you can use the PREV, FWD, + and - buttons to look at previous trend data. ________________________________________________________________________...
- Page 34 A1.2.4 Heater Trip When a resettable alarm is present, the TRIP RESET button becomes available that will reset the alarm if the condition has been cleared. When the trip condition is cleared and the TRIP RESET button is pressed, the button will disappear.
- Page 35 A1.2.5 PID Tuning If the PID loop is internal to the PLC, the PID tuning settings can be adjusted by pressing the PID SETTINGS button on the main screen.
- Page 36 A1.2.6 Steam Generator Pump control For Steam Generator systems, the pump settings can be accessed by pressing the PUMP CONTROL button on the main screen...
- Page 37 A1.2.7 Screen Saver When no activity has been detected on the HMI for 15 minutes, the Screen Saver will activate. Normal operation can resume by touching anywhere on the screen.
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Page 38: Annex 2: Arc Control Shroud
ANNEX 2: ARC CONTROL SHROUD If the Converter System has parts for an arc control shroud supplied separately, the following procedure should be used to install the shroud. The purpose of the shroud is to ensure that arc products escaping through flaps on the roof of the system are guided upwards and do they don’t roll over onto the heads of personnel standing around the system. - Page 40 Install the rear of the shroud using 15 of the thread rolling screws provided. Leave the screws finger tight to allow the panel to move as other panels are attached. The screws at the top and bottom of each vertical flange, and at the left and right hand ends of the bottom flange should have internal star washers (provided) fitted under the head of the screw to ensure that the panel is electrically bonded to the section.
- Page 41 Install the second intermediate panel (with a cut-out) using 6 of the thread rolling screws provided. Leave the screws finger tight to allow the panel to move as other panels are attached. The screws at the front and rear end should have internal star washers (provided) fitted under the head of the screw to ensure that the panel is electrically bonded to the section.
- Page 42 Install the third intermediate panel and the rear panel as for the first section. Leave the screws finger tight to allow the panel to move as other panels are attached. Continue to the end of the board, leaving all the screws finger tight except for those securing the intermediate panels.
- Page 43 Install the front of the shroud for the section at one end of the system using 15 of the thread rolling screws provided. Leave the screws finger tight to allow the panel to move as other panels are attached. The screws at the top and bottom of each vertical flange, and at the left and right hand ends of the bottom flange should have internal star washers (provided) fitted under the head of the screw to ensure that the panel is electrically bonded to the section.
- Page 44 Continue attaching front panels until all sections have front panels in place. Tighten all screws securing the front and rear panels.
- Page 45 Limited Warranty: Please refer to the Chromalox limited warranty applicable to this product at http://www.chromalox.com/customer-service/policies/termsofsale.aspx. Chromalox, Inc. 1347 Heil Quaker Boulevard LaVergne, TN 37086 (615) 793-3900 www.chromalox.com © 2022 Chromalox, Inc.
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