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Powercon 900 User Manual

1. 10 1 Typical Connection Diagram CONTROL XFMR POWER f E 150 oon 120VAC T 1 12 B TB509 Geet ON f Ka el 6 Bi 2 PO P IT E G E i Ts 1 ES 311 J3 e A om i Du ey i 7 TO CONTROL XFMR i TB508 DB9 e T lt CONTROL MAIN LOGIC BOARD CABLE CONTACTOR H TOUCH SCREEN DISPLAY i TB504 18501 i _ LOGIC INPUT T R POWER me ol SA AS T RETURN RT P 4 EI IREMOTE ENABLE am W 13 IsTOP y O K lt lt lt E E Lu A ALARM 4 i SCR2 2 ST ALARM 3 i CR1 TETS SE G2 y MA si ia epee EG 6 ALARM 2 WS sas ag s 7 ALARM 1 K bjm EC WARNING 4 i o 5 WARNING 3 i o TO WARNING 2 rl SEA AT WARNING 1 Li 7 ooo AA INTERLOCK RETURN e 3 INTERLOCK H _ l_u IM POR RETURN i 3 5 POR CLR Ea TB505 AUTO MAN AND j MANUAL CONTROL METER OUTPUT EE eg 7 au o ACA
2. Da RR TUU pri an poca 3 4 wm provoco nm 8 9 10 11 12 13 14 6 1 4 2 Prepare the precipitator accept power from the T R Set This includes inspecting the internal sections of the precipitator for any objects that may short the high voltage on the discharge section to ground and any safety grounds etc The T R must than be connected to the High Voltage Discharge Electrodes 6 1 2 3 Return to Operational State by Plant Procedure 6 1 2 4 Set Front Door Operators as follows Auto Manual Switch Manual Manual Potentiometer 0 Fully Counter Clockwise 6 1 5 Apply Power Close All Circuit Breakers so 380 480 575 Volts AC is available in the enclosure If there is a separate power supply for the logic apply control power to the logic Then close the Page 48 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RT
3. 120 575 VA AOS PRECIPITATOR SUPERVISORY SERVICE ON ES OFF CONTACTOR DB9 CABLE lt T Ji T STOP Ge INPUT feci FIRING AA REC TRANSMIT H LED16 ALARM 4 i ALARM 3 Ly LED21 LED20 LEDT SCR2 See ALARM 2 EDs ALARM 1 i i I insane S e WARNING 3 T di 8 ZERO CROSS WARNING 2 tens lt 3 WARNING 1 a aC MAIN LOGIC i INTERLOCK SO ven i wi CLR POR i 2 MANUAL I CONTROL da La i i OUTPUT o H FEEDBACK T R SET i 1 amp 1 No a N A 71 METERING I E Ll CALIBRATION VOLTAGE YIISS i CN i b I i i I I i j 1 I n LEDAS i LED13 a I START a 1 i i LED14 I 1 K2 IE STOP i I i I LED13 i i l RF CHOKE l K3 i NT 4 INTERNAL I i I A LED12 I I I I ALARM e I I os a e E 4 lee INDICATES LED mi INDICATES NEON LAMP B 121703 REVISED FOR 900 A 023901 RELEASE l PRECIPITATOR CONTROL MAIN POWER HIGH VOLTAGE PRECIPITATOR POWER FEEDBACK POWER CONTROL AMC SPECIALISTS INC TITLE POWERCON 900 LOGIC BLOCK DIAGRAM DATE SHEET 10 08 02 M G N OF DWG NO REV CASTD811 B Page 66 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 10 3 POWE
4. POWERCON MODEL 900 A CECO ENVIRONMENTAL COMPANY AUTOMATIC VOLTAGE CONTROL USER MANUAL MAIN FEED TOUCH SCREEN DISPLAY s Dit an 5146 G COMMERCE AVE MOORPARK CA 93021 Phone 805 531 8900 FAX 805 531 8903 SPECIALISTS INC A V C Specialists Inc 5146 Commerce Ave Suite G Moorpark CA 93021 Phone 805 531 8900 Fax 805 531 8903 www avcspecialists com sales avcspecialists com Buell FER AS Buell APC 200 North 7 Street Suite 2 Lebanon PA 17046 Phone 717 274 7104 Fax 717 274 7342 Notices and Installation Considerations Notices Danger During normal operation of this device hazardous voltages are present which can cause severe injury or death High voltages are present on the terminal blocks circuit boards power distribution and control devices These voltages are present beyond the control enclosure in which this e
5. DCimA 82 M as i E DCiKY 65 P Z 265 0 E 207 0 a 55 0 o 0 CndAn 137 De ManPot 1 Sec1 KV Sec1 mA Fo 12 mn so e e 0 120 140 30 se 70 N L 180 65 11 3 2010 6 05 PM CO N yatli hiy CU 200 o o Stop Press STOP Button This key is active from any screen and functions no matter what condition is displayed on the status line Pressing STOP will immediately stop the gate signal to the anti parallel SCRs 25 milliseconds later the Stop Relay K2 will toggle for four seconds This will interrupt main power by opening the contactor or imposing a signal to the STOP input The control will then lose LOCK on the Zero Cross and the TSD will first display READY TO START Page 22 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Clear Press CLR Button 1 If POWERCON RUNNING The control while continuing to apply power to the T R set will perform a limited internal self check to verify that the operating parameters in the logic board RAM equal the programmed parameters in the TSD The TSD will only change the display if a problem is encountered 2 If POWERCON RUNNING REMOTE When the POWERCON control is running remote the local default operating parameters will be temporarily overwritten by a remote device such as the a PSS The re
6. Also on the main logic board the general Limit LED 4 will illuminate Primary Voltage Limit Primary Voltage Limit is the maximum limit of the RMS AC voltage that may be applied to the T R Set primary input and may be adjusted in one volt increments between 0 and 600 volts Similar to the current limit the control will freeze the conduction angle of the SCRs when the PV limit equals the measured PV and reduce the conduction angle when the measured PV exceeds the PV limit The Primary Voltage Limit is easily visible on the TSD Status screen analog meter by noting the red band on the AC Volt meter face Also the Status Box will change color to Magenta from Red and a message will appear in the second line if the limit is reached Also on the main logic board the general Limit LED 4 will illuminate Primary Kilowatt Limit The Primary Kilowatt Limit is the maximum real power that may be applied to the primary input of the T R set It operates in similar fashion to the above limits and is adjustable in one kilowatt increments between 0 and 300 KW The Primary Kilowatt Limit is easily visible on the TSD Status screen analog meter by noting the red band on the KW meter face Also the Status Box will change color to Magenta from Red and a message will appear in the second line if the limit is reached Also on the main logic board the general Limit LED 4 will illuminate Secondary Kilovolt Limit The Kilovolt Limit is
7. Page 60 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 9 1 5 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Alarm and Warning Messages These standard messages are furnished with every control unless the customer has requested special messages The messages are externally generated when one of the alarm or warning inputs is activated External sensing equipment is required to detect these conditions Message Input Action A1 ALARM 1 TB504 7 Stop K2 and Alarm K4 Relays energized A2 ALARM 2 TB504 6 Stop K2 and Alarm K4 Relays energized A3 ALARM 3 TB504 5 Stop K2 and Alarm K4 Relays energized A4 ALARM 4 TB504 4 Stop K2 and Alarm K4 Relays energized W1 WARN 1 TB504 11 Message Only W2 WARN 2 TB504 10 Message Only W3 WARN 3 TB504 9 Message and Reduced Power Operation W4 WARN 4 TB504 8 Message and Reduced Power Operation INTERLOCK Stop K2 and Alarm K4 Relays energized RAPPING POWER Reduce power level as programmed STOPPED Output to SCR 0 Stop K2 relay energized Limit Messages These messages appear in the lower right area of the display only if the control reaches one of the maximum programmed operating limits The control will stop Ramp Rate and hold conduction angle change to zero If the value of the measured parame
8. comi L MODE E CODE usBHOST sw 5 LL COM1 RS485 USB DEVICE ol PWR t S W 8 13 j 207 TOUCH SCREEN DISPLAY REAR Page 8 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 144 00 3658 z DB9 COMUNICATION CABLE I Below is the screen normally displayed home screen by the system Pressing the tabs will allow the display of additional information Ual utility 900 Rev x5 Powercon 900 Rev_z4 Sn Status Trend SixMin Parameters 7a Profile Scope Events RMS Primary Volts RMS Primary Amps Primary KW Auto Sii sa 5 e ACN 265 vlt yo 30 lee 70 ACA 207 Geet ECH S TC SI IZ KW 55 lt DCIMA 82 i RE D DEIKA G a 265 0 va 55 0 o CndAn 137 De ManPot 1 50 12 f min 40 60 80 120 SU helt Sect mA 100 11 3 2010 6 05PM No o ES o CO N yatli Whigs wili tg Dn uw o o Page 9 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 2 4 1 Front Panel On the front side of the TSD there is a 7 color LCD display The left 2
9. J26 This is the DC power connection point from the external power supply Page 44 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 5 11 Relay Connections TB507 This provides the connection point to four C form contact relays K1 Start K2 Stop K3 Pick and K4 Alarm If the relays are to operate any inductive devices such as relays or contactors then external snubbers must be installed across their coils It is recommended that a small ice cube relay be used between these small board relays and the main line contactor Page 45 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 6 INITIAL STARTUP PROCEDURE A Warning The Startup of the POWERCON control requires that the technician performing this task will be working within the high voltage environment of the enclosure and possibly at the T R set Only qualified personnel trained in the operation of the precipitator should perform these tasks Caution Initial startup of the POWERCON Model 900 control requires personnel with a working knowledge of the control Start up is not necessarily a linear step by step event and requires that the person be able to recognize unusual operation and responses by the
10. help information Automatic Spark Rate Mode Spark rates may be set directly in Sparks per Minute with three different response levels to sparking low medium and high The control will calculate and apply the required ramp and setback parameter values using the programmed quench recovery and hold number selected by the operator Spark Estimator If Automatic Spark Rate Mode is not selected then the spark estimator feature is active As different values for Ramp Setback Quench Recovery and Hold are entered the expected spark rate is displayed on the programming screen The actual measured spark rate will closely follow the estimated rate Security Access Code A four digit security access code is required to change the values of operating parameters limit set points and selection of operating features However these values can be viewed at any time without using any security code MODBUS RTU Communications The POWERCON Model 900 may be connected to a communications network utilizing MODBUS RTU communications protocol The physical connection is an RS 422 two twisted pair fully duplex connection optically isolated connection Details of the Communications Protocol are available on a separate document RASTD890 POWERCON 700 800 900 and RAPPERCON MODBUS Protocol Event Log An event log is maintained on the control so the history of its operation can be recalled This includes when the control is started stopped
11. property of their respective owners The information contained in this document is believed to be accurate at the time of publication however A V C Specialists Inc assumes no responsibility for any errors that may appear here and reserves the right to make changes without notice Page a 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com Installation and Maintenance Considerations Installation and maintenance of the POWERCON control and auxiliary equipment should only be performed by qualified competent personnel that have appropriate training and experience with high voltage and current devices Every effort has been made to ensure the installation instructions presented in this document are clear and easy to understand however if you are not sure how to perform any of the instruction provided DO NOT CONTINUE THE INSTALLATION OPERATION OR REPAIR of this equipment Contact A V C Specialists Inc A Warning Failure to observe the following information may result in severe injury or death During normal operation of this device hazardous voltages are present on the terminal strips circuit boards auxiliary equipment and external circuits Follow standard safety precautions while performing any installation or service work A Warning This equipment should be installed in a switchgear cabinet or similar enclosure to ensure that the equipment is not accessible to non q
12. 6 A 2 MAN POT i CT CH ACA i BI El 3 AUTO MAN SWITCH M MA B P 4 COMMON 7 5 KW f ma ARE ss L Di esos ER GER IGNAL INPUT R2 ef Le Y RI Lai T I i 6 KW li 4 I i li MA In y y 7 SPk i ela E CS A Il ee ke E l Kv fT Ehi DE DE ors ES Re a RF CHOKE 8 SPK a i i INTERNAL SS i po Dl I RS MODBUS pe LON R6 I E R4 MODBUS i k d 1 RIU la KV 2 KV Lor Losi RS422 Ve Za HN TB503 TB507 OPTIONAL RELAYS SECOND PRECIPITATOR 214 CHANNEL mH START el TOH y s 2mat 3 GL __ WS a K2 2mA 4 St STOP 157 TH I I 5 sl i 2KV A K3 Lil AI GR i 4 ao H _ Es CONTROL WIRING ES a K4 FOR DUAL POWER WIRING 2 ALARM BUSHING REMOTE WIRING TH TIR HIGH VOLTAGE Ss Pe rs OPTIONAL EQUIPMENT CIRCUITS AUTOMATIC VOLTAGE CONTROL TITLE POWERCON 900 THYRISTOR SYSTEM SCHEMATIC ES gt TYPICAL SPECIALISTS INC B 121704 REVISED FOR 900 DATE BY SHEET OF DWG NO REV A 023902 RELEASE 08 03 11 M G N 1 1 SASTD812 B Page 65 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 10 2 Block Diagram Functional POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 KEYBOARD DISPLAY MODULE
13. 800 systems The display is often flush mounted on the front door of the control enclosure so that the control may be operated programmed calibrated and configured by the operator without exposing him to a high voltage environment within the enclosure Page 7 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 l TU Utility 900 Rev x5 Powercon 900 Rev_z4 Runnin atus Trend SixMin Parameters Trip Profile Scope Events g Status Trend SixMinP ti Trip Profile S Event RMS Primary Volts RMS Primary Amps Primary KW 265 200 A 200 150 I 250 a 5 w 207 150 Auuluu 350 whi s Ali 7 265 207 d 5 97 gee PO AA e RO 152 ManPot 1 Sec1 KV Sect mA O 12 min a CH Li 40 D 80 120 11 8 2010 6 05PM AVG i 2 wlw 60 NU z B LU aS so EN o Cir Srart SPECIALISTS INC a 10 E 2 180 KZ 2 Stop o 65 Yoo om a 200 Y SA 8 78 ral 223 j TOUCH SCREEN DISPLAY FRONT CA CARD COM3 RS232 COM2 RS232 ETHERNET 5 38 Si COMI RS232
14. Box of the TSD must display READY TO START Press the START Button to initiate operation The Start Relay K1 will activate for four seconds closing the contactor or removing the Stop input Main power will be applied across the SCRs and the control will then detect Zero Cross events to Synchronize The control will then provide power to the precipitator according to its programming The diagrams below illustrate the resulting power applied to the precipitator Detailed explanation of the diagram follows the illustrations ZE LIMIT PRECIPITATOR SPARKOVER LEVEL FA SETBACK as PROCESS UPSET TIME SPARK QUENCH pei Pe REDUCED PRECIPITATOR SPARKOVER Page 26 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 PRECIPITATOR CURRENT __ SPARK 2 SETBACK RECOVERY 3 6 1 3 6 2 3 6 3 Quick Ramp Quick Ramp is used to rapidly increase the power output to the T R set It will slew the conduction angle from zero output to full power within three seconds The control will utilize Quick Ramp upon receipt of a LOCK signal or after 20 seconds of operation without a spark or limit being reached Quick Ramp ends at either a limit being reached or a spark in the precipit
15. FAX 805 531 8903 www avcspecialists com 3 2 3 2 1 3 2 2 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Feed Back Circuits All feedback circuits are monitored continuously There are four feedback circuits Zero Cross AC Amps AC Volts and DC Milliamps required for the control to function properly If a fifth DC Kilovolts is available it enables several additional control features In the Appendix there is a detailed discussion about the selection of feedback components to provide the correct magnitude of signal for the POWERCON control HIGH VOLTAGE MLLIAMPS KILOVOLTS Mains Zero Cross Detection A direct connection is made from the mains power to the high voltage input block of control at TB501 7 and TB501 9 at full voltage If voltage is present Neon Lamp 12 illuminates indicating mains power is applied to the anti parallel SCRs On the POWERCON an internal timer PPL is synchronized to the zero cross of the mains power Successful synchronization will be indicated by either LED 4 illuminating 60 Hertz or LED 5 illuminating 50 Hertz An internal permissive signal is then generated that will allow the control to provide output gate signals to the SCRs AC Volts The AC voltage applied to the primary winding of the T R set is measured by the control and is displayed on the TSD and forwarded to the PSS The value of the A
16. POR is communications port sensitive That is all RAPPERCONs that send POR addresses and POWERCONS that will receive instructions must be on the same communications port This is to prevent POR instructions being transmitted to another precipitator Note that all the MODBUS addresses for any precipitator are blocked into groups of eight Each POWERCON control must be programmed on the PSS with a POR TIMER Value 1 30 seconds This value is only available on the Remote Programming Screen and only when the correct programming password has been entered This POR TIMER Value is transmitted to the POWERCON and the POR is only active for the time POR will operate any time a valid MODBUS address is received from a RAPPERCON POR cannot be disabled by the PSS Page 78 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 7 1 3 POWERCON a The POWERCON Y when it receives a POR command will reduce operating power by reducing it Primary Current to a percentage of the programmed Primary Current Limit Those values are programmed exactly the same way on the POWERCON for Default Mode operation and on the PSS for Remote Mode operation b Percentage Reductions are programmed as follows 0 of Primary Current Limit 25 of Primary Current Limit 50 of Primary Current Limit 100 of Pr
17. Primary Current Kilovolt etc or a spark occurs The message on the TSD is then replaced with the current operating status To display graphically results of the data select the two values of data to be displayed on the X and Y axis and simply press the Get Profile Button on the TSD display Page 35 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Auto AC V 243 ACA 189 Records 106 DE E Y Axis Bcim si ema DON si Secky C Pri KW C Pri RMS Y CndAn 121De p Pri RMS A ManPot 1 X Axis me de Sec mA 11 3 2010 617PM C Sec KV C Pri K C Pri RMS V C Pri RMS A Any two values may be plotted by simply touching the parameter to plot for the Y and the X Axis and then to display touch the Get Profile tab Cond Ang C Rec Numb Page 36 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 4 4 1 4 2 4 2 1 4 3 4 4 4 5 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 FEATURES Ease of Use The POWERCON control has an optional simple to use man machine interface the Touch Screen Display TSD The 7 color display simultaneously shows a wealth of information from current operating status programming operating parameters or detailed
18. RCON 900 INLbak GravityCal BAK File J AVC Storage 1 00 KB _Storag Ji Storage RCON_900 PUP PUP File Gu Network 26 5 KB i JAKSTIS HP y RCONS00_Rev 1Ak exe Ml 11 11 2001 53200 CS 161 ke lt b Bn EE O ARP File Open the file tree until the AutoRun folder is available Paste the new file into that folder Unpluge the cables oo Page 82 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com
19. accomplished by skipping the application of complete cycles of AC power by the main line SCRs followed by a number of half or full cycles of power applied to the T R set After skipping a cycle s power is applied to the other anti parallel SCR To prevent a high inrush of recharge current to the precipitator that first half cycle of power will have a reduced conduction angle This feature is enabled by programming command at either the TSD Parameters then OP1 Screen or remotely by the PSS When the control is operating in IE mode the TSD Status Box will change color to Blue and IE DUTY CYCLE XX will be displayed The information will then be made available to network devices such as the PSS 3 7 2 Arc Quench Arc Quench is a period of power input to the precipitator that is a user adjustable value from 15 to 50 250 833 milliseconds cycles of AC power The Arc Quench routine is initiated by the control logic as a result of a sustained spark over in the precipitator spark detection of 2 or more half cycles of AC power that may develop into a power arc Power Page 33 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 7 3 3 7 4 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 arc occurrences in most precipitators are very rare When this does occur the control recognizes the possible presence of a continuous arc and applies this extra
20. alarm are available on the TSD Trip and Event tabs Page 23 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 W CuWin x2 Powercon 900 Rev_zi pe Status Trend SixMin Parameters Trip Profile Scope Events l RMS Primary Volts RMS Primary Amps Primary KW ven Auto 7 200 n 300 80 i 120 40 60 150 MH 350 60 ALE 140 30 LEE 70 ACA 1 SN Uy Q DE a ih Sa S CR Get CR KW 0 100 gt 400 160 20 gt En 2 D 450 SE 180 10 E Dciky 1 COSO 0 0 Fasi 500 0 200 CndAn 0 Deg ManPot 26 Sect KY E o m ao 5 eo 3422 2010 2 07 PM BI CuWin x2 Powercon 900 Rev_zi Status Trend SixMin Parameters Trip Profile Scope Events 3 22 2010 3 11 58 PM 30 WA ty 70 ys gt 240 Val 560 Ah Zo y Le 640 K 4 N o 80 SS a e Ain co Q o Stopped Auto 3 22 2010 3 11 58 PM A2 TB504 6 ACV 0 3 22 2010 3 10 35 PM Started ACA 1 3 22 2010 3 07 48 PM Stopped Ge 5 3 22 2010 3 07 48 PM A2 TB504 6 DCIKY 1 3 22 2010 1 14 02 PM Started 3 22 2010 1 13 55 PM Stopped 3 22 2010 1 12 21 PM Started CndAn ODeg 3 22 2010 1 12 17 PM Stopped ManPot 26 3 22 2010 1 11 13 PM Started M o m 3 22 2010 1 11 08 PM Stopped 222010 mem 3 22 2010 12 25 08 PM Started 3 22 2010 12 20 17 PM Stop Input ee Ea Event
21. and cathode connection to each SCR should use either a twisted pair or shielded cable rated at 600 volts minimum 20 gauge wire Main Line Power Connection TB501 7 and TB501 9 This connection is needed to provide the Zero Cross signal to the control that synchronizes the firing of the main line thyristors with the applied line frequency 50 or 60 Hertz The connection to the main line power must be made afterthe main breaker ana if installed after the contactor The connection must be made before any other devices including the SCRs CLR or T R so no phase shift of the voltage or current from the supplied main power The POWERCON input voltage jumpers must be set to most closely match the main power voltage Jumper Location Line Voltage if not listed select next higher 41 150 B 6 One jumper and one jumper 120 Volt Main Power 41 300 only must be inserted This 240 Volt Main Power J1 500 must be set to the voltage of 380 Volt Main Power J1 600 the Mains power 480 Volt Main Power J1 750 575 Volt Main Power T R Primary Voltage TB501 11 The voltage applied to the T R set is monitored by the control for both the primary voltage limit and undervoltage condition Feedback Circuits TB506 AC Amps TB506 5 and TB506 6 The primary current feedback signal to the control is derived from a current transformer CT installed in the primary circuit of the mains power The CT isolates sign
22. arrangement If a jumper has just two posts then it is permissible to either have or not have a jumper inserted If a location has three posts then a jumper must be inserted between two of the posts Two Post Jumpers Jumper Location J1 150 B 6 One jumper and one jumper only 120 Volt Main Power J1 300 must be inserted This must be 240 Volt Main Power J1 500 set to the voltage of the Mains 380 Volt Main Power J1 600 power 480 Volt Main Power J1 750 575 Volt Main Power J2 B 7 Low Voltage 30V AC Volt Meter Low Voltage 30V AC Volt Meter CONNECTED at TB503 6 and ABSENT at TB503 6 and TB503 5 then TB503 5 then NO JUMPER ADD JUMPER J4 B 10 MODBUS Communications Insert only if com problems Ground J7 K1 H 14 Allow connection of the Output Links TB 507 12 to common bus J7 K2 Relays Common Pin to be linked Links TB 507 9 to common bus J7 K3 together To be used only on Links TB 507 6 to common bus J7 K4 legacy system replacing P 700 Links TB 507 3 to common bus J9 RET B 15 Allow connection of the Input Common Return for all inputs except J9 ILR Signal Common Returns to be Common Return for Interlock J9 PRR linked together To be used Common Return for POR power off only on legacy system replacing raping P 700 If a jumper has three posts then a jumper must be inserted either between posts 1 and 2 or posts 2 and 3 or
23. at lower than expected voltages There are many potential causes for this problem including Dust build up Poor electrical clearance between the high voltage discharge electrodes and ground Tracking insulators Over filling of hoppers 10 5 3 3 Power Hog Indication Low valves of voltages and high values of current indicated on the meters This is usually accompanied by little or no sparking Page 75 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Discussion This is an indication of very low resistivity in the material being collected In some cases this type of reading will be observed during air load testing especially with a clean precipitator The cause is usually associated with change in the combustion process Another cause is over conditioning the material to be collected However this can also be caused by some of the same problems listed just above such as 1 Tracking insulators 2 Over filling of hoppers Once the primary voltage falls below the undervoltage set point either a Warning message will be produced or an Undervoltage Trip will occur 10 5 3 4 Broken Electrode N DC KILOVOLTS NZ ANG Y me LLIAMPERES AVE JU A C AMPERES ANG 2 Indication T
24. block should be between 2 5 and 5 amps The value of the feedback also needs to provide a signal that will give the equipment operator useful information Again the analog metering circuit should display full load operation with a meter deflection between 60 and 80 of full scale The Current Transformer CT used to provide the proportional signal must have a minimum burden of 4 Volt Amps VA at full load The feedback current will be applied across a 0 1 ohm resistor on the POWERCON to develop a 0 0 5 volt DC signal which is processed by the POWERCON If the CT does not meet the minimum 4 VA burden then the current feedback signal may not be linear nor be of the proper proportion to the AC current flowing in the primary circuit When constructing a POWERCON system for small current T R sets it is often necessary to use a CT with a current ratio higher than required for the current at which the system operates This is because small ratio CTs 50 5 do not have sufficient burden to operate the feedback system correctly If that is the case then the high current CT will have multiple passes through the winding to produce the correct current ratio The final consideration of this circuit is the selection of the Circuit Breaker CB As a minimum the circuit breaker must have a trip value of 125 of the expected full load current of the system This is to prevent the false tripping of the CB due to long term eight hour thermal operation
25. display will have two additional analog meters displayed on the Main Screen High Low Current Range The control can be used on a wide range of TR sets 90 of TR set are High Range Use Low Range only if the Primary Ampere and Secondary Milliamperes are both less the maximum value Parameter Adjustment Limits Parameter Units Low Range High Range Primary Amps AC Amperes 0 51 0 510 Primary Volts AC Volts 0 600 0 600 KVA KVA 0 50 0 300 Secondary Volts DC Kilovolts 0 127 0 127 Secondary Amps DC Milliamperes 0 255 0 2550 MODBUS Settings The local connection DB9 for the TSD is fixed at Baud Rate 38 4 MODBUS Address 0 The remote MODBUS port may be programmed from the TSD Below are the values that the remote port may be set Parameter Label Range of Adjustment BAUD Rate Bits Second 4800 9600 19 2K 38 4K MODBUS Address 0 240 Page 58 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 9 9 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 TROUBLESHOOTING A Warning Maintenance of the POWERCON Model 900 automatic voltage control should only be performed by a qualified competent person that has appropriate training and experience with high voltage and current equipment The POWERCON control is part of a precipitator high voltage power supply Trou
26. e FAX 805 531 8903 www avcspecialists com A Vv C POWERCON Model 900 Instruction Manual SPECIALISTS INC Modbus RTU Software Version 6 10 5 1 Normal Meters Readings 10 5 1 1 Inlet Field a coo 10 5 2 2 Middle Fields 10 5 2 3 Outlet FieldS rpniona tale ia ail 10 5 3 Examples of Precipitator Process Conditions on Meter Readings coccococcnnccononooaonnnnnnnnnnnnannnnnononnns 10 5 3 1 Corona SUppressiON cidcid ad rie 10 5 3 2 Low Voltage Sparking nro nn non n non RR nn RR RR RR RR RR RR RR NR RR nn RR nan rn nan n non nrn nn nar rnrnnannno 10 5 3 3 Power e TE 10 5 3 4 Broken Electrode 10 7 POWER OFF RAPPING Using MODBUS 10 7 1 Basic Control Configuration 10 7 1 1 RAPPERCON ips lega i iaia ee 10 7 1 2 Pale Aaa anne 10 7 1 3 POWERCON Y usina a a e Page iv 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 1 1 1 1 2 1 3 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 GENERAL INFORMATION Introduction The A V C Specialists Inc POWERCON Model 900 is the latest in a series of precipitator automatic high voltage controls The POWERCON Model 900 has been designed to be a simple replacement and upwardly and downwardly compatible with the previous versions of the POWERCON 700 and 800 microprocessor controls It is also simple to retr
27. erratic or no operation will occur Three Post Jumpers Jumper Location Function with Jumper 1 2 Function with Jumper 2 3 J5 ES Insert_here if J1 is 300 500 600 750 Insert here if J1 is 150 Page 6 www avcspecialists com 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 2 3 2 4 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Fuses There are two fuses at location B 2 They are used to protect the hot inputs from the two power connection terminal blocks TB 508 and 509 Power Supply The POWERCON 900 requires a well regulated low ripple 1 5 amp 24 Volt DC power for reliable operation The 24 volt power is plugged in J10 Below is the standard power supply used by A V C Specialists although many other acceptable supplies are acceptable l D eZ SOS 22 5 29 5V Output DC 24V 1 75A DC OK 3 53 LU 90 O ka a ul Er Ve Input AC 100 240V U L L 2 19 P N A 1453 24 VDC 1 75 A Color Touch Screen Display A NEMA 4 Color Touch Screen Display TSD is the most common of the human interfaces used with the POWERCON 900 system Many TSDs may be used For this manual the operation and screen shown are using A V C Specialists P N A 1445 a 7 inch TSD It is very simple to install in the existing location when upgrading POWERCON 700 and
28. event occurs the display will turn red and display Triggered A few seconds later the data will be transferred from the main circuit board and be displayed on the TSD Page 39 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 utility 900 Rev x5 Powercon 900 Rev_24 A MEN Status Trend SixMin Parameters Trip Profile Scope Events Sweep f Auto 20 D ACV 241 ACA ie re D Kw 49 Pri A DCimA 75 Sect DCiKY 60 Se CndAn 136 De Gm i ManPot 1 Trigger 21 min ON Spark 11 3 2010 6 21PM Pre tigger ol el Page 40 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 5 INSTALLATION INSTRUCTIONS A Warning This control should be installed in a switchgear cabinet or similar enclosure to ensure that the control is not accessible during normal operation Installation of the POWERCON Model 900 Automatic Voltage Control should only be performed by qualified competent personnel that have appropriate training and experience with high voltage and current devices 5 1 General Information Before proceeding review all drawings both former and upgrade versions as well as any specific installation instructions that were pro
29. is present the Start Button is disabled and the control will stay stopped When the signal is no longer present the K2 relay will deactivate and the control may be restarted as normal Manual Mode Selection and Adjustment An optional Auto Manual control switch and potentiometer may be connected to TB505 1 through 4 The Auto Manual control switch and potentiometer may be permanently mounted in the control enclosure or on a portable control box that may be plugged in when needed If no switch or potentiometer is installed the control will default to Automatic Mode When the control is switched to Manual Mode the control potentiometer may be used to directly control the conduction angle of the anti parallel thyristors To prevent damage to the precipitator certain protection methods are still in effect in Manual Mode Sparks will be detected quenched and a rapid but smooth increase in conduction angle will occur to the value selected with the manual potentiometer The AC Current DC KV DC MA and Conduction Angle Limits are monitored and the output cannot be advanced beyond those values that produce limiting conditions Page 20 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 5 3 5 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Touch Screen Display The Touch Screen Display TSD is the most common device used to operate and program th
30. log after alarm cleared and control as been restarted Page 24 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 BM cuwin x2 Powercon 900 Rev_z1 fi Status Trend SixMin Parameters Trip Profile Scope Events 3 22 2010 3 14 58 PM Started Auto 3 22 2010 3 11 58 PM Stopped _Clear ACV 312 3 22 2010 3 11 58 PM A2 TB504 6 ACA 116 3 22 2010 3 10 35 PM Started Ge lt A 3 22 2010 3 07 48 PM Stopped DCIKY 705 3 22 2010 3 07 48 PM A2 TB504 6 3 22 2010 1 14 02 PM Started 3 22 2010 1 13 55 PM Stopped CndAn 131De 3 22 2010 1 12 21 PM Started ManPot 26 3 22 2010 1 12 17 PM Stopped M ofmin 3 22 2010 1 11 13 PM Started armo rm 3 22 2010 1 11 08 PM Stopped 3 22 2010 12 25 08 PM Started ce Sar 3 22 2010 12 20 17 PM Stop Input _Stop y Page 25 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 PRECIPITATOR POWER POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 6 Automatic Mode Automatic control of the power delivered to the precipitator is selected by placing the Auto Manual Switch in the Auto Position If no manual switch is installed then the control will default to Automatic Mode To initiate operation of the high voltage power supply the Status
31. logic board LED 6 will illuminate Conduction Angle Limit Conduction Angle Limit is the maximum value of conduction of the main line SCRs It is adjustable between 129 and 176 The limit is annunciated on the TSD by the Status Box turning Magenta from Red and the second line displaying Full Power The main logic board LESD 4 will illuminate Primary Under Voltage UVR Primary Under Voltage is a condition of low voltage in the precipitator with significant current flowing Primary Under Voltage is an indication of a problem in the precipitator such as arcing insulators close clearance between electrodes and ground high hopper Page 31 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 7 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 levels etc The voltage is monitored on the primary of the T R set since the secondary voltage is directly proportional Two conditions need to be met to determine the existence of an Under Voltage condition The primary voltage must be below the Voltage set point and the conduction angle of the main line SCRs must exceed its set point If these two factors are met then the control will initiate an Arc Quench routine to clear a tracking or arcing problem If the abnormal condition is cleared then the POWERCON will continue normal operation If the abnormal condition persists then the control will act a
32. mains power current reverses Alternately the other anti parallel SCR is fired at very close to the same time period to provide balanced AC power The length of time that an SCR is conducting power determines the amount of power applied to the primary winding of the transformer rectifier set The mains current that is permitted to flow through the anti parallel SCRs then passes a series current limiting reactor CLR before being applied to the T R set primary winding The CLR is used to limit the current when spark occurs in the precipitator and to provide a smoother AC power to the T R set primary The AC voltage applied to the T R set primary is stepped up in proportion to the winding ratio of the transformer while the AC current is stepped down in proportion to the winding ratio On the secondary winding of the T R set AC voltages as high as 80 000 volts are produced with AC currents in the range of 1 to 2 amperes This AC voltage and current is applied to the input of a rectifier that produces a DC voltage and current output In most of precipitator power systems the positive output of the rectifier is connected to ground through a low ohm resistor 5 to 100 ohms thus holding the positive DC output of the T R set to within a few volts of ground The negative DC voltage output is at a very high potential above ground and is connected to the precipitator discharge electrodes Page 14 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e
33. needed to change the Reading Remember that the change in the Scale Factory must be written to effect the change Page 56 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 7 6 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 To Change Parameter Values Whenever a value is to be changed use stylus to access the touchscreen Slide the stylus across the value to be changed and the background color will change to light blue Use the spin tabs or drop down menu to change the value In order for that new value to become effective it must be written to the memory by touching the Write box in the lower right of the screen The background color of that parameter will become White again indicating a successful write C d e Slowly advance the Manual Potentiometer until the various analog meters begin to deflect upwards The first meter advancing should be the AC Volt meter Adjust the Scale Factor as needed so that the Digital Reading equals the Analog Meter Readings Continue slowly advancing the potentiometer and adjusting the calibration of the meters Note if the control output is advanced and if sparking occurs defection in the meters will occur Do not advance the manual potentiometer beyond this point Set the TSD to the Status Screen by touching the appropriate Tab Switch the Auto Manual to Auto Observe the control fo
34. set An 18 gauge or larger twisted shielded pair is recommended for this circuit Control Power TB508 A TB509 The control power circuit may be derived from a step down transformer connected to the main power supply or a completely separate source of power The standard POWERCON logic is designed to operate from 120 V 50 60 Hertz power Logic Card Firing Circuit Power 120 VAC 1 Amp power must be connected to TB508 to provide power for the SCR firing circuits and a source for the power supply at TB509 Power Supply The input to the DC power supply is connected to the 100 240 VAC 50 60 Hz power at TB509 A permanently attached cable connects the single voltage 24 VDC at 1 Amp to the logic board at plug J26 A second pair of wires may be connected to the TSD Touch Screen Display TSD The connection between the logic card and the TSD is made with a standard 9 conductor DB9 cable The cable length should not exceed 15 feet nor be routed with any cables operating above 120V External Inputs TB504 These inputs are optional and are not required for the basic operation of the control Inputs TB504 2 through TB504 11 have a single common return circuit connected at TB504 1 Power for these external contacts must be from the same source but may be between 24 and 120 Volts either AC or DC Input at TB504 12 and 13 Interlock and TB504 14 and 15 Power Off Rapping are isolated and may be powered from independent sources DC Power
35. 0 of the display always shows the current operating status and metering values of the control There are always operator STOP START and CLEAR buttons available Other user screens such as programming history oscilloscope functions etc are selected and available on the right 80 of the screen utility 900 Rev x5 Powercon 900 Rev z4 essi Status Trend SixMin Parameters Trip Profile Scope Events 11 3 2010 6 20 26 PM Started Auto 11 3 2010 6 19 19 PM Stopped ACV 265 11 3 2010 6 19 19 PM A2 TB504 6 ACA 206 11 3 2010 6 19 09 PM Started Ge x i 11 3 2010 6 18 12 PM Stopped Geen eg 11 3 2010 6 18 11 PM Al TB504 7 11 3 2010 6 15 23 PM Started CndAn 138 De ManPot 1 m iim 11 3 2010 6 22 PM LC Always Displayed User Selectable Display Page 10 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com Auto Green Standby Ready to Start ACY 265 Red High Voltage On Running ACA 206 Magenta High Voltage On Running at High Limit KW 55 Yellow Flashing Alarm DCimA 84 Yellow Alarm Operator Acknowledged DCIK Y 66 Blue Special Operation see script in box PRECIPITATOR METERING CndAn 138 De ManPot 1 E 21 min 11 3 2010 2 4 2 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 6 22 PM Reverse Side The reverse side of the TSD has a powe
36. 1314 5 1617 1819 10 11 112 1138 114 1 15 5 H G S 00000000000 n re Y 0000009 BOBDA 000000290 KR GGG wm A 5 6 7 8 9 10 11 12 13 14 Page 3 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 18 501 T R SET VOLTAGE 2 2 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Wiring Connections The logic section contains terminal blocks for all wiring The terminals are segregated into several groups by both voltage and functions There are three groups of terminal blocks TB 501 TB 508 and TB509 that may be connected to voltage sources above 120V These terminal block
37. 31 8900 e FAX 805 531 8903 www avcspecialists com 3 3 2 3 3 3 3 3 3 1 3 3 3 2 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Alarm Inputs There are four configurable alarm inputs that will accept 24 120 Volt AC or DC input The logic of the input can be changed to alarm at either the presence or absence of voltage at the input by programming from the TSD or PSS M If an alarm condition is detected during operation the control will first make sure that the input is not spurious by determining that the signal voltage or lack thereof exists for three zero cross events 25 milliseconds Then the control will stop the firing signal to the SCRs wait for three more zero cross timings 25 milliseconds and then open the main line contactor and annunciate the alarm When an Alarm is present it is annunciated by illuminating an LED 8 on the logic board latching the Alarm Relay K4 LED 9 and the Stop Relay K2 LED 11 on the logic board Detailed information as to which input has been triggered is displayed on the TSD and forwarded to the PSS The user may access the operating readings just prior to the trip with the Trip Recall feature on the TSD by pressing several of the tabs Trip and Events Once an alarm condition has been activated it remains latched in place even though the signal that initiated the alarm may no longer be present The alarm condition may only be cleared and reset by pre
38. 4 Current Limit Thumbwheel SwitchesS iii 6 22 5 le UA PPP i 6 A A TEE 7 2 3 POWER SUPPLY E 7 2 4 COLOR ele eg ed H 241 ege 10 24 2 AS A la a 11 2 4 2 2 Programming Switches ie 12 2 5 MANUAL CONTROL POTENTIOMETER SWITCH i nn nn ttute nke nn nr nano naar anno rra narrar rca rnnnnnnn 12 THEORY OF OPERATION sa snittente 13 351 Ge el DIE 13 3 2 FEED BACK CIRCUS E 15 3 2 1 Mains Zero Cross Detechon 15 3 22 eg iii iii ein 15 E Ane Ee EE 16 3 2 4 ooo NT 16 Fi DC KiIOVOIES iris AAA Add a o 16 SE Ee elle ETC 16 EE DE EE 18 3 32 ANCCMOCK IN PUt cinica lella iaia iaia 18 3 3 3 Warning el EE 18 3 3 3 1 Annunciate nisi anioni 18 3 3 3 2 Reduced OUtput Operation a sabe Ra 18 3 3 4 Power Off Rapping Input i ciiiriaiicionanaa iaia iaia ella 19 ES fis aS 0 TE 20 3 5 TOUCH SCREEN DISPLAY 20x iccninsosssncensdedsexdovsseacetdedhondesssnaneedestanceds Ai 21 Page i 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com A V C POWERCON Model 900 Instruction Manual SPECIALISTS INC Modbus RTU Software Version 6 3 5 1 Basic Operation with the Te 21 3 6 AUTOMATIC MODE 26 30 1 A Te EE 27 3 6 2 E A ii na 27 3 6 3 O cia aaa 3 6 4 Recovery 3 6 5 Set Back 3 6 6 Hold 3 6 7 RAMP IA 3 6 8 Operating Limits 3 6 8 1 Primary Current Limit 3 6 8 2 Primary Volta
39. A value of CB is then selected which is as close to the 125 value as possible Ideally the trip value of the CB used will still be within the upper range of the ammeter that is used A second refinement of the metering values may need to be done to incorporate all these requirements Kilovolt Signal KV Limit TB506 1 and TB506 2 The primary purpose of this circuit is to measure the kilovolt level and set the KV limit The feedback signal is sensed at TB506 1 and TB506 2 This circuit is designed to accept a current signal between 50 and 200 micro amps at full T R rating with the ideal input at 100 micro amps The input circuit on the POWERCON is a zero impedance circuit In series with this input are two items If an analog meter is used then it must also have an impedance of 500 ohms or less A safety shunt resistor and lightning arrester should be installed between the output KV metering terminal to ground This will limit the voltage on the KV metering signal set if an open circuit were to occur Typical value for this resistor would be 100 to 1000 times as great as the resistance of the analog meter Page 69 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 10 4 5 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Primary Voltage Under Voltage Detection TB501 9 and TB501 11 The primary purpose of this input is to measure the voltage applied to t
40. C voltage is used to determine if there is an under voltage condition in the precipitator It is also used to determine if an unbalanced AC high levels of DC power is being applied to the T R primary The voltage applied to the T R is monitored and limited to prevent damage to the T R set A direct connection is made from T R set primary winding to the high voltage Page 15 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 2 3 3 2 4 3 2 5 3 3 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 input block at TB501 9 and TB501 11 The relative amplitude of the power is also displayed by neon lamp l1 AC Amps The AC current flowing to the primary of the T R set is measured by the control from a Current Transformer CT inserted in the power circuit The CT produces a current that is isolated from the power circuit voltage and current but is in proportion to the current flowing in the power circuit The current flowing in the primary circuit is limited by the control not to exceed the ratings of the electrical equipment The output from the CT is a connected to the control at TB506 5 and TB506 6 Caution The input from the CT must not be grounded The CT must have a current output in of 5 Amps AC at full ratio 100 5 150 5 etc DC Milliamps The current flowing in the precipitator is measured to provide both the value of the current and to de
41. Manual Switch An Auto Manual Switch and control potentiometer must be plugged into TB5005 Some systems do not have this feature permanently installed 6 1 4 Initial Switch Settings Place all switches to prevent a start of the control output to the main line SCRs Put the Auto Manual switch in the manual position and the manual potentiometer to 0 Place any external Start Stop switches to Stop Set Max Current Limit Thumbwheel Switch on Circuit Board Rated System AC Current Set Thumbwheel Switch Programmed Range Setting 1 50 1 50 Low 51 60 06 High 61 70 07 High 71 80 08 High 81 90 09 High 91 100 10 High 101 110 11 High 111 120 12 High i High 501 510 51 High See diagram for thumbwheel location Page 47 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 6 1 4 1 Check Jumper is inserted on POWERCON 900 Circuit Card J1 To equal the mains line voltage J2
42. OPERATION AND FEEDBACK SIGNALS ei 7 CALIBRATION AAA Ra 53 AAA Ag II I 58 81 Non volatile Memory clan lla elia lai ie add oi 58 8 2 RUE TREIE 58 9 TROUBLESHOOTING l 11 33133 dees 59 9 1 TOUGH SCREEN DISPLAY E 59 9 1 1 Status MessageS des kd A A di 60 9 1 2 Error Messages a 60 9 13 Alarm and Warning MessagesS iii 61 DA E te UE viteria till lai piaci iii 9 1 5 Status Messages SIE Features Eae 9 2 INTERPRETATION OF METERING READINGS ccccessenncceceeeseessnannecenecesnonsncaceesenersnsonseneecnensadnnneearenesenensonseseseaee 62 9 3 CONTROL TROUBLESHOOTING gien ge eegdiee aaae rae euer ENEE dese oidor 63 10 A OS 64 10 1 TYPICAL CONNECTION DIAGRAM 10 2 BLOCK DIAGRAM FUNCTIONAL s ssssssessseresreesseeee 10 3 UNDERVOLTAGE OPERATION AND ADJUSTMENT 10 4 FEEDBACK CIRCUIT REQUIREMENTS iii 10 4 1 Milliamp Signal Spark Detection TB506 3 and TB506 4 10 4 2 Primary Amps Current Limit Over Current Trip TB506 5 and TB506 6 10 4 3 Kilovolt Signal KV Limit TB506 1 and TB506 2 iii 10 4 4 Primary Voltage Under Voltage Detection TB501 9 and TB501 11 10 4 5 Line Voltage Zero Cross Detection TB501 7 and TB501 9 ii 10 5 PRECIPITATOR TROUBLE SHOOTING BY INTERPRETATION OF METER READINGS i Page ili 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900
43. Off and the values of Ramp Rate or Setback are changed Page 55 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 7 5 Calibration Initial Set Press the Calibration tab and enter the appropriate data Calibration of the metering of the POWERCON 900 requires operation of the control with the TR and powering the precipitator The control should be operated in Manual Mode and in turn each meter reading should be calibrated by verify the value with appropriate external metering Initial Factory Settings Offset Scale Factor 1 Primary Amps 0 1445 2 Primary Volts 0 410 3 Sec 1 KV 0 390 4 Sec 1 mA 0 3780 5 Sec 2 KV 0 301 6 Sec 2 MA 0 200 7 Mains 0 1478 utility 900 Rev x5 Powercon 900 Bee 24 Gsm Status Trend SixMin Parameters Trip Profile Scope Events Spark Response op 1 Op 2 Limits 1 Limits 2 Time TR Calibration SCH Channel Offset Scale Factor Reading ACV 22 c z Pri Volts 30 4 1011 242 Volts Deimi gt Pri Amps 40 H 17 725 4 188 Amps DCIKV ei Sec KV lo E 3 300 a 61 KV SeclmA b ko 4a 77 mA Sec2 KV lo a 300 62 KV Sec2 mA o 4 200 oa 76 mA tane Mains lo sso 3 376 Volts N ol Srl Initialize All Parameter CndAn 136 De ManPot 1 C Enable Write Change the Scale Factor as
44. RCON Model 900 Instruction Manual Modbus RTU Software Version 6 Undervoltage Operation and Adjustment The POWERCON control monitors voltage input to the precipitator to determine the existence of abnormally low voltage on the high voltage discharge electrode system Low voltage on the precipitator high voltage grid is an indication of various problems with the precipitator such as Broken discharge electrode Close clearance between the high voltage components and the collecting curtains Arcing insulators High hopper levels Incorrect water wash timing It can also be an indication of problems with the electrical power supply system such as Thyristor SCR failure Transformer Rectifier set problems Current Limiting Reactor problems The POWERCON monitors the AC Voltage applied to the primary side of the transformer rectifier T R set The primary side is chosen because many T R sets have no provision for monitoring the high voltage DC output The winding ratio of the transformer allows the voltage on the primary side to be monitored since it is directly proportional to the secondary voltage The user adjusts the set point for the Primary Undervoltage value and the Conduction Angle that will declare an Undervoltage condition The software will determine that an undervoltage condition exists only when the voltage is below the set point and the conduction angle is greater than the set value This prevents false undervoltage
45. Rev x5 Powercon 900 Rew_24 _____ WE Status Trend SixMin Parameters Trip Profile Scope Events 300 0 R e up 7 x Auto _Clear ACY 264 ACA 204 240 0 Last Upda KW 54 7 15PM DCimA 81 DCIKY 645 180 0 Cndin 132 De ManPot 1 420 0 L 4 L 4 E 20 mn 11 3 2010 7 10PM 60 0 n t ep n AE Vi E Pri Volts E Pri Amps O Pri kw 0 0 i i p Sect kv _ Stop 915 1015 11 15 1215 1 15 2 15 3 15 4 15 5 15 615 715 MSecima In both cases above the latest data collected is displayed on the left side of the graph and all data points are shifted to the left as new data is entered The oldest data on the right side of the screen is eventually removed at the end of the time period displayed Oscilloscope The TSD has a built in oscilloscope function for signal analysis without the necessity of opening the control enclosure Any data that is recorded may be displayed On the next page is a typical display that might be of interest In this case it is Primary AC Volts and Secondary Kilovolts that are displayed for a period of 20 cycles of AC Power The display was trigged when a spark was detected and a pre trigger display period of 4 cycles of power is shown These display values are selected by using the TSD Display Then to collect data simply touch the Button on the lower left side of the display marked GO The box above when then turn Green and display the message Ready When a spark
46. S PRI RMS AMPS SEC KVOLTS and SEC mAMPS If not stop at this point to troubleshoot the circuitry See Section 9 If the values on the digital displays are all present and somewhat near the analog metering values then the potentiometer can be slowly advanced to raise the output At this point there should be a reading on the display for PRI POWER KW If the value is zero then the Primary Voltage and Current inputs are out of phase To correct the problem turn off the power to the enclosure swap the wires at TB506 5 and 6 and resume testing The manual potentiometer can be further advanced until a limit is reached or sparking occurs The presence of sparking is indicated by the display indicating a SPK MIN value by the pulsation of the other metering and readings and by the flashing of the spark LEDs Page 52 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 7 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 CALIBRATION Warning Calibration of the metering circuits requires that the technician performing the adjustments will be working within the high voltage environment of the enclosure while the equipment is operating and possibly at the T R set Only qualified personnel trained in the operation of the precipitator should perform these tasks Calibration of the POWERCON metering is done individually in each control enclosure This is be
47. Spark Rate has been established Other boxes display information from other screens to aid in programming variables on the displayed screen Press the Parameter tab on the Touch Screen Display A submenu bar will appear showing the different categories of parameters to be programmed Page 53 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 7 1 7 2 T R Set POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Press the T R tab and enter the appropriate data The slider should be set for the value of the T R set or just slightly above the T R set nameplate value Setting the valve will set the upper end of the meter display of the status screen This is not the operating limits Below is a useful chart to collect the values of a T R set TR Set 1 TR Set 2 TR Set 3 TR Set 4 TR Set Identification Primary Amps Primary Volts Primary KW Secondary KV Secondary MA Amp Range NO Go PO Bushing Limits 1 Press the Limits1 tab and enter the appropriate data These limits can be set below the TR ratings for safe operation It is not recommended practice but the limits may be set above the rating of the TR set TR Set 1 TR Set 2 TR Set 3 TR Set 4 Total Installed Primary Amps Primary Volts Primary KW Secondary KV Secon
48. TU Software Version 6 Then the control increases the conduction angle of the main line SCR to increase the power applied to the precipitator Indication The control has advanced the power to the T R set Note the very high voltage levels compared to the current Discussion This indicates that there is a problem in the precipitator with producing corona at moderate voltages If VI curves have been taken note the increase in kilovolts required for the same amount of DC milliamps In dry type precipitators this usually is an indication of increasing the effective diameter of the discharge electrodes due to heavy particulate build up There may also be an increase in voltage when ammonia is injected in the gas stream ahead of the precipitator In wet acid mist precipitators the same shift in the VI curve is an indication of a cloud of very fine acid or water vapor surrounding the discharge electrodes suppressing corona formation Page 74 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 5 3 2 Low Voltage Sparking Indication There are low values indicated at all meters and the spark rate is as programmed for this control section Discussion This indicates that there is a problem with spark over
49. U Software Version 6 Message Description of Message and Control Action SELF TESTING Self diagnostic test cycle is under way READY TO START All circuits test normal awaiting application of precipitator mains power RUNNING Operation normal precipitator is providing controlled power to the T R set STOPPED STOP input is detected control output to the main line SCR is halted Stop Relay K2 energized Used in systems without a main line contactor or in to prevent operation when the Auto Start Feature is enabled or from a remote system CAUTION Mains Hot RAPPING POWER Rapper system input activated The control operation has been modified to provide reduced power to the T R set as programmed from a hard wired or remote communications input IE DUTY CYCLE Intermittent Energization is ON Power output to the T R set is ata reduced duty cycle using pulse blocking BACK CORONA DETECTED Back corona has been detected Control output has been modified at set by the automatic back corona test RUNNING REMOTE The Precipitator Supervisory System is controlling the parameters Local adjustment mode is disabled GENERATING PROFILE The control is in the process of slowly increasing output one degree at a time while recording the meter readings for analysis CLOCK BATTERY LOW The battery for the real time clock chip on the Keyboard Display Unit needs to be replace
50. U Software Version 6 main or preferably the limited power arrangement power circuit breaker At the application of power the logic board should The POWERCON 900 will self check and communication will be activated H cuwin x2 Powercon 900 Rev_z1 ae Status Trend SixMin Parameters Trip Profile Scope Events RMS Primary Volts RMS Primary Amps Primary KW rn Auto 200 0 300 a MES ei so en Ly 0 150 350 ACA 1 WS OS E WS 70 KW 0 gt Z 400 DCimA 2 SR DCIKV 1 0 Cnd n 0 Deg ManPot 2 O of min 50 320 aso 30 ula 70 240 ula 3 22 2010 11 22AM I ud th S 640 160 SET 2 DS E A Ze vlt 0 CH e Meter readings will be displayed and all value should be 0 e Conduction Angle will equal 0 e Manual Control will equal 0 If any ALARM or WARNING messages are displayed review the input conditions and the jumper settings The input configuration table on the POWERCON System Schematic for the particular installation or the Programming Jumper Table in Section 2 2 5 may be used Correct or insert temporary jumpers as required to display POWERCON READY TO START 6 1 5 1 Test SCR Gating Press the Start Button The following changes should occur on the MLB a Relay K1 Start Toggles for 4 seconds b 12 Mains Illuminates The TSD should within four seconds change the Status Box from green to red and the top Page 49 5146 G COMMERCE AVENUE
51. al from the mains voltage and provides an AC current that is a ratio of the primary current The CT current secondary output is in the range of 0 5 amps with a minimum burden of 10 VA The secondary must not be grounded The output is to be connected to TB 506 5 and 6 This circuit must use a minimum 14 gauge wire to minimize resistive losses in circuit Careful attention must be paid to crimping and terminating the low resistance circuit DC Milliamp Spark Detection TB506 3 and TB506 4 Atthe T R set the secondary current sensing resistor usually designated as R1 must be installed between the positive output of the T R set bridge rectifier and ground Select the Page 43 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 5 7 2 3 5 8 5 8 1 5 8 2 5 8 3 5 9 5 10 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 value of R1 to provide a feedback signal voltage of between 5 and 10 Volts at full T R milliamp output see Appendix The negative wire of this signal pair must be grounded at the T R set An 18 gauge or larger twisted shielded pair is recommended for this circuit DC Kilovolts Optional TB506 1 and TB506 2 The secondary voltage shunt resistor usually designated as R5 must be installed between the negative voltage sensing output and ground at the T R set The positive wire of this signal pair must be grounded at the T R
52. and any alarm events that have occurred Page 37 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 4 6 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Auto ACY 265 ACA 206 KW 55 DCIMA 84 DCiKY 66 CndAn 138 De ManPot 1 O 21 min 11 3 2010 6 22 PM Trending 11 3 2010 6 20 26 PM Started 11 3 2010 6 19 19 PM Stopped 11 3 2010 6 19 19 PM A2 TB504 6 11 3 2010 6 19 09 PM Started 11 3 2010 6 18 12 PM Stopped 11 3 2010 6 18 11 PM Al TB504 7 11 3 2010 6 15 23 PM Started The TSD has two displays that trend the operation of the POWERCON The first graph shows the instantaneous values of the metered values collected over the last six minutes of operation utility 900 Rev x5 Powercon 900 Rev z4 DCIKY 66 5 CndAn 138 De ManPot 1 O 21 min 11 3 2010 6 07 PM Status Trend Simin Parameters Trip Profile E _ Events E Pri Volts A Pri Amps D Pri Kw O Sec 1 ky 2 E Sec 1 mA Page 38 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 4 7 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 The second display shows the trending of operation for each the average of metered values for one minute periods over the last 10 hours of operation utility 900
53. art Press STRT Button This button is only active if it is colored red Indicating there are no alarm conditions If there is an alarm condition the button will be colored gray indicating that it will not function and the status box will be colored yellow If the button is red then the status will be green and will read POWERCON READY TO START Page 21 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Pressing the button will cause the Start Relay K1 to activate for four seconds The control will then detect Zero Cross events to Synchronize to the line frequency of the main power The control will then operate according to its programming The display will now change the color of the buttons and status box to reflect the current operating condition Both the Clear Button and Status Box will change color to red to indicate the high voltage power is being applied to the precipitator The digital displays on the left side will indicate the output and will be available no matter what changes on the right side of the display In the case of starting from the status screen the analog displays will be active utility 900 Rev x5 Powercon 900 Bee 24 RMS Primary Amps Primary KW 50 Auto 200 AC H 265 ve A a 150 250 i A Ve ul 30 ulf 70 Ga e gt i ez e u 300 NS i Mig KW 55 100
54. ary T R H V Bus switches 14 H 0 0 0 0 Open Primary T R CLR Power Cable 15 0 lt gt H 0 lt gt CL 0 0 0 Shorted Secondary T R 16 L 0 L 0 0 No Firing Pulses SCR not firing leakage power passed SCR snubber circuit H High N Normal L Low CL Current Limit VL KV Limit lt gt Indicates rapid changes Page 62 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 9 3 Control Troubleshooting POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Symptom Possible Causes 1 Display Blank 1 No Control Power feed No output from AVC 2 Logic Fuse open F1 or F2 3 Power Supply Fuse open 4 Harness H101 TSD to MLB 5 Control Power at Logic Board LED 11 6 Control Power at TSD 2 Display Blank 1 TSD On Off Switch in Off Position AVC operating 3 Control Continuously resets 1 Watch dog timer is operating too quickly Mismatch in software display version between MLB and TSD 4 Digital Reading do not match 1 AVC Calibration Recalibrate panel meters 2 Panel meters out of calibration 5 Display ON 1 Mains Power missing AVC won t run 2 Relay K1 Inoperative No alarms are present 3 Main Contactor circuit inoperative 4 Mains power not detected by logic card Lamp 12 indicates main power is present 5 Jumper J5 not inserted 6 Output full 1 Thyristor SCR failed shorted N
55. ator Quick Ramp is a non user adjustable parameter Spark Detection A spark occurs in the precipitator when there is a rapid breakdown of the resistance between the high voltage discharge electrodes and the grounded components collecting plates This results in a rapid increase in both the primary and secondary current and a reduction in the primary and secondary voltage The current flow from the high voltage supply is no longer distributed over all the discharge electrodes but becomes concentrated at the point causing a spark The current heats the surrounding gas further lowering the resistance spark over voltage The rapid change in secondary current is detected and the control will then stop the gate signal to the SCRs flash the Spark LEDs increment the spark counter and jump to the quench routine Quench Quench is period of time after a spark has been detected that no power is applied to the precipitator This no power period allows the ionized gas created by spark discharge to cool thus raising the voltage required to initiate another spark This prevents multiple Page 27 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 6 4 3 6 5 3 6 6 3 6 7 3 6 8 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 sparking at one location which prevents damage to precipitator electrodes and raises the overall power delivered by the h
56. bleshooting system malfunctions require that the source of the malfunction must be determined and the problem then corrected Malfunctions during the initial start up may be caused by incorrect installation and calibration of the control All wire terminations should be examined to ensure that they have been properly made Control calibrations and operational adjustments should be carefully reviewed Maintaining a record of precipitator voltage and current reading is also very useful Electrical readings are very helpful in the determination of control and precipitator problems Caution Do not HIPOT Dielectric test the inputs outputs or communication terminals of this control Touch Screen Display Messages The Touch Screen Display TSD will provide many useful messages that are an aid to troubleshooting the high voltage system The top line of the Home Screen will display the status of the control The message in the center position can be of four types Status Error Alarms or Warnings Following are tables of each message and it s meaning Also during operation if an output limit is reached Current Limit KV Limit Conduction Angle Limit etcetera a message will appear in the lower right of the display along with the date and time Page 59 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 9 1 1 Status Messages POWERCON Model 900 Instruction Manual Modbus RT
57. cause the control measures feedback signals that are derived from devices selected to match the wide variations in T R set sizing For operational purposes itis only necessary to have the POWERCON digital meter readings match the readings of the panel meters If greater accuracy is desired then the calibration must be done with a device that provides true RMS AC readings with an accuracy of 0 5 The procedure outlined below will work in most circumstances It may be necessary to modify the procedure in cases of sparking at low levels undervoltage condition etc To Change Parameter Values Whenever a value is to be changed use stylus to access the touchscreen Slide the stylus across the value to be changed and the background color will change to light blue Use the spin tabs or drop down menu to change the value In order for that new value to become effective it must be written to the memory by touching the Write box in the lower right of the screen The background color of that parameter will become White again indicating a successful write Default value must be set If an equivalent Remote value exists than it is to be programmed with the same value as the Default value if possible Not every box displayed on an adjustment screen is a programmable variable Some boxes are information only such as Spark Estimate which is calculated by the POWERCON when the Ramp Rate Set Back Hold are changed so that the user knows what
58. ccording to the user selected programming Base operation is to annunciate the problem on the TSD by changing the Status Box color to Blue and placing the message Undervoltage on the second line and displaying messages on the PSS Also LED 5 will illuminate on the main logic board If the UVR Alarm box on the TSD OP1 tab has been checked then POWERCON will elevate the Warning to an Alarm and trip the control off line The TSD will change the Status Box to Flashing Yellow along with the message Under voltage The CLR button will become yellow and the Start Button will be inactive and Gray LA Utility 900 Rev x5 Powercon 900 ev zs I a Status Trend SixMin Parameters Trip Profile Scope Events Spark Response Op 1 Jon 2 Limits 1 Limits 2 Time TR Calibration ACY em Parameter Default Remote Range Features Input Logic ACA 188 IE Duty Cycle 20 100 I UVR Alam F Alarm 1 KW 49 Are Quench 15 50C IT Not Assign F Alarm 2 DCimA 74 POR 0 100 I Auto Start FT Alarm 3 DCiKY 60 O 100 Sec I Auto Start FT Alarm 4 IT Not Assign IT Warn 1 T Not Assign FT Warn 2 FT Not Assign FT Warn 3 2 9 T Not Assign T Warn 4 y r POR Auto Start Delay UVR Angle 50 CndAn 135De UVR Voltage ManPot 1 Max A Imbalance 7 20 min Max V Imbalance so 11 3 2010 6 08PM ee BAUD 9600 T InterLock Write Modbtis Add lo ol Star Temperature C 37 T Stop Operating Modes There are several special
59. computer and follow the installation instructions from the web site 10 8 1 Connection Laptop to POWERCON 900 1 The Laptop must have Windows Mobile Device on board 2 Plug a USB cable from the Laptop USB A to the RAPPERCON 900 or POWERCON 900 USB B connector 3 The following program should launch on the Laptop Page 80 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 x Connected Windows Mobile Device Center Home gt Quick Connect St ag LEE Mobile Device Settings wer 5 Click on the File Management box 6 Open Windows explorer Page 81 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 on Computer CUWIN Storage Card AutoRun Organize y Wr Favorites GravityCal File folder TA Libraries Documents Ci ColorButton dil Ah Music td El Pictures E Videos Sa MwGraph dll P Computer ae e s amp Local Disk C Dea ca RECOVERY DI 8 DVD RW Drive E MSPROJECTO Ex Merenda b SD Card H TT Ka RCON_900 ARP a E ARP File em Flash Disk Pe Network b RCON 900 INI 22 Configuration settings Storage Card Z SC Get AutoRun
60. control The initial startup procedure outlined below is a guide to performing a successful installation and startup Check all interlock tag and safety systems to ensure that the precipitator system is ready to start up 6 1 Basic Function Test The basic function test will exercise many control functions without power being applied to the T R set However the full main line power 480 600 volt is still present within the control enclosure Recommend Practice If possible initial testing of the POWERCON installation tests in Section 6 1 should be performed with a limited power source Such a source can be provided by a 1 KVA transformer powered from a low voltage source and back feeding to supply the required 380 460 600 Volt Mains Power Recommend Practice All special software features should be disabled unchecked This includes but is not limited to I E Auto Start POR Undervoltage etc Page 46 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 6 1 1 Install Limited Mains Power Optional Highly Recommended 6 1 2 Lamp Load Test Disconnect the two large gauge wires that carry the main power to the T R set primary In their place install a Lamp Load see Appendix To prevent Undervoltage Alarms disable the Undervoltage alarm programming 6 1 3 Auto
61. d This does not effect the POWERCON programming of parameters or operation of the control 9 1 2 Error Messages These self diagnostic messages are internally generated during the initial self test period or any time the conditions are detected during normal operation Message Description of Symptom and Control Action CHECKSUM ERROR MLB Logic board microprocessor circuitry malfunctioning Stop K2 and Alarm K4 Relays energized CHECKSUM ERROR DSP Keyboard Display microprocessor circuitry malfunctioning Stop K2 and Alarm K4 Relays energized MISSING PHASE LOCK Control cannot sync and lock to mains zero cross no output to the T R set MISSING ZERO CROSS Unable to detect mains zero cross no output to the T R set NOT RESPONDING Data exchange between the logic board and the keyboard display is incomplete Stop K2 and Alarm K4 Relays energized PRIMARY UNDERVOLTAGE Primary voltage is too low for the conduction angle of the main line SCRs possible short in the precipitator UNBALANCED SCR TRIP Excessive difference in conduction between main line SCRs resulting in a protective shutdown Stop K2 and Alarm K4 Relays energized WRONG SOFTWARE VERSION There are different versions of operating systems on the logic card and keyboard display Stop K2 and Alarm K4 Relays energized LCD MODULE FAILURE Keyboard display malfunctioning message may only appear on PSS
62. d interrupting device The main line contacts of the contactor are in the open position until electrically closed with a continuous power from the latching control circuit and main power is then available to the rest of the system Ina system that does not have a main line contactor a signal is applied to the Stop input of the controlat TB 504 through a normally closed contact of a signal relay used to mimic the contactor function In a similar fashion to the energizing of the contactor coil the control determines that it is functioning normally and there are no alarm conditions then the signal relay is energized thus removing the Stop input signal and allowing the POWERCON to operate An external Stop input at TB504 3 may also be used to both Stop an operating unit and then prevent any command from any source to allow the POWERCON to apply power to the T R set Power is now present throughout the main power system The POWERCON detects the presence of main power at the anti parallel SCRs and synchronizes its timing to each reversing of the AC power Zero Cross Upon successfully synchronizing to the mains the POWERCON will determine the line frequency and illuminate LED 4 if 60 Hertz power or LED 5 for 50 Hertz power The control then will fire one of a pair of anti parallel thyristors to conduct power to the primary of the T R set for a calculated period of time Conduction Angle That thyristor will then turn off when the applied
63. dary MA W3 Primary Amps W4 Primary Amps CO Ni gt O01 B Go Po Max Conduction Angle UVR Volts 0 UVR Angle Page 54 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 7 3 Opt Press the OP tab and enter the appropriate data Below are the initial factory settings that will be changed to obtain the best operation by the precipitator chief operator Initial Factory Settings 1 IE Duty Cycle 100 2 Arc Quench 50 3 POR 100 4 Auto Start Delay 0 5 UVR Angle 50 6 UVR Voltage 120 7 Max A Imbalance 100 8 Max V Imbalance 100 9 Network BAUD 19 200 10 MODBUS Address 0 There are two tables of functions that are enabled by checking the appropriate box l Features Check appropriate boxes li Input Logic Check appropriate boxes Spark Response Press the Spark Response tab and enter the appropriate data To set the Ramp Rate and Setback Value the Auto Spark Response must be OFF Below are the factory settings Initial Factory Settings 1 Ramp Rate 1 0 2 Set Back 5 3 Auto Spark Rate 20 4 Auto Spark Response Off 5 Quench 2 6 Recovery 2 7 Hold 10 The Spark Estimator should change value when the Auto Spark Response is
64. determinations during spark quench arc quench ramp up etc Before an undervoltage condition is declared the POWERCON will perform an Arc Quench to possibly clear the short circuit The power is again applied If the undervoltage condition still exists then the following actions occur 1 Annunciate A message will be displayed on the TSD and the Status color will be changed to Blue If programmed by the TSD the control will then also 2 Trip SCR conduction angle will be reduced to zero the Stop Relay K2 will activate and the Alarm Relay K4 will activate A trip message will be sent to the KDU and PSS The undervoltage sub routine operates in both the automatic and manual modes Page 67 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 10 4 10 4 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Feedback Circuit Requirements Reference Items POWERCON Typical System Schematic SASTD780 POWERCON Logic Block Diagram CASTD781 In order for the POWERCON automatic voltage control to function correctly the value of the feedback signals must correct The first criteria is to select circuit components that provide the signal strength level for the POWERCON Automatic Voltage Control to operate correctly The second is to select values of the metering circuits that will provide the equipment operator with usable data A V C Specialists d
65. e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 6 1 5 2 6 1 5 3 6 1 5 4 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 line within the box will display RUNNING Slowly rotate the manual potentiometer to raise the manual control percent When the manual control percent exceeds approximately 15 the control will begin to send gating signals to the main line SCRs Continue to rotate the potentiometer and the lamp load will begin to glow Continue to increase the potentiometer As the conduction angle passes through the undervoltage set points AC Vollts and Conduction Angle the lamps will dim for about one second and the Status Box on the display will change color to Blue and indicate UNDERVOLTAGE Rotate to full conduction and the lamp load will glow brightly Note LED 17 SCR1 and LED 18 SCR2 should be illuminated These LED intensities will vary with the output of the control Rotate potentiometer to 0 Set the Auto Manual Switch to Auto The lamp load should quickly brighten dim for one second as the undervoltage subroutine again operates and then the lamps should glow brightly Test Alarm and Warning Inputs Alarms and Warnings can be tested with the control in the Stopped condition In turn force each of the external inputs into the alarm condition by mechanically closing opening the different circuit contacts associated with this particular in
66. e POWERCON Automatic Voltage Control It is connected to the J3 RS232 DB9 connector on the main logic section with a standard 9 pin shielded cable Basic Operation with the TSD When power is applied two start ups occur The main board of the POWERCON 900 control will self check begin to monitor the external alarm inputs and toggle the Stop Relay K2 for a period of four seconds At that time the main board will Auto Start if programmed or wait for a Start command from one of several sources the TSD network command or local pushbutton control similar to a motor start Simultaneously the TSD will self start with a self check and loading of the operating POWERCON firmware and then the Status display screen will become active On the left side of the display are three operating buttons Clear Start and Stop The status box will be green with the words READY TO START The Status Screen is the Home Screen Status Meter Readings etc H cuwin x2 Powercon 900 Rev_z1 ess Status Trend SixMin Parameters Trip Profile Scope Events RMS Primary Volts RMS Primary Amps Primary KW 250 100 200 300 80 120 a T w ACV 0 150 350 140 xi WS a 60 gd o 30 WS Mita 70 KW 0 100 5 Z 400 40 gt 160 gt dai 50 E 450 20 180 DCIKY 1 Lao SE EA SC 0 500 H 200 CndAn 0 Deg ManPot 0 Sec1 KV Sec1 mA 0 Of min fy Zil aan sn i 240 alo 560 3 22 2010 11 01 AM Sy hy y PI i x 30 ba Sen e gt St
67. e TSD Status screen analog meter by noting the red band on the DCMA meter face Also the Status Box will change color to Magenta from Red and a message will appear in the second line if the limit is reached Also on the main logic board the general Limit LED 4 will illuminate Warning 3 Limit Warning 3 Limit is a special case of Primary Current Limit Whenever the Warning 3 input is detected the primary current value of Warning 3 is substituted for the Primary Current Limit However that value cannot exceed the value of the thumbwheel switch Upon removal of the Warning 3 input the control will revert to the normal Primary Current Limit It is easy to note if this limit is in effect The Status Box and the CLR Button will change to blue and a message Warning 3 will be displayed in the status box On the main logic board LED 6 will illuminate Warning 4 Limit Warning 4 Limit is a special case of Primary Current Limit Whenever the Warning 4 input is detected the primary current value of Warning 4 is substituted for the Primary Current Limit and Warning 3 Limit However that value cannot exceed the value of the thumbwheel switch Upon removal of the Warning 4 input the control will revert to the normal Primary Current Limit or the Warning 3 Limit It is easy to note if this limit is in effect The Status Box and the CLR Button will change to blue and a message Warning 4 will be displayed in the status box On the main
68. e high voltage power supply Records of past performance are a great aid in determining how the precipitator is working and if the trend is toward better or worse operation The POWERCON Model 900 Automatic Voltage Control will detect many of the abnormalities indicated below and will take action to minimize damage to electrical power supply or precipitator components In order to duplicate the actions of the meters shown below it may be necessary to temporarily modify the operation of the control Most often this will mean that it will be necessary to operate the control in manual and possibly disable the undervoltage trip The use of the four analog or digital meters can enable the troubleshooter to quickly identify probable the cause of the problem The AC ammeter and DC milliamp meter should act as a pair The needles of both meters should move upscale indicating approximately the same percentage of deflection at any output level The AC voltmeter and DC kilovolt meter will also act like a pair but the DC kilovolt meter will indicate deflection before the AC voltmeter As the output of the power supply is increased both meters will increase but the AC voltmeter at a faster rate catching up with the DC Kilovolt meter If any of the meters stay at a zero indication while the remaining three meter move upscale at an expected rate with an increase in power then the problem is with the electrical power supply system not the internal condition of the
69. e the upper set points beyond which increases in power will lead to undesirable effects Limits may be imposed due to the equipment ratings or precipitator responses or reactions Operating Limits are adjustable on the TSD by clicking the Parameter Tab then the Limits 1 sub tab Page 28 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com SPECIALISTS INC Modbus RTU Software Version 6 3 6 8 1 C POWERCON Model 900 Instruction Manual utility 900 Rev x5 Powercon 900 Rey_24 E Status Trend SixMin Parameters Trip Profile Scope Events Spark Response Op 1 Jop 2 Limits 1 Limits 2 Time TR Calibration Auto Parameter Default Remote Range aca des Pri Amps 300 0 NPCL Amps Kw 49 Pri Volts 400 0 599 Volts DCimA 75 s Sec KV 80 O 120 KV Sec mA 150 0 2550 mA OndAn 135 D meeot 1 W3 Pri Amps 100 2 O NPCL Amps M 21fmin W4 Pri Amps lso 4 O NPCL Amps m z0o em Max Cond Ang 176 20126 129 1 6 Degrees UVR Volts 5 0 599 Volts UVR Angle 50 y 10 176 Degrees Write Primary Current Limit Primary Current Limit is a maximum limit value of RMS AC current flowing to the T R set primary The value for this limit is set to the value of the smallest rating of any device or wiring in the mains power circuit There are two ways that the current limit value is programmed in the control The first is an absolute lim
70. een the low voltage side of the T R set rectifier and ground For safety purposes it is best if two parallel resistors of twice the resistance required are used Each resistor should be of sufficient wattage that if the other parallel resistor were to be an open circuit that the single surviving resistor could operate This serves two purposes The first is to prevent an open circuit on the return end of the rectifier An open circuit at that point would tend to float towards the high voltage limit of the T R set The second reason is to provide an indication to the operator that there is a problem The feedback circuit would double to near 20 volts The POWERCON will continue to operate but at lower output levels In addition to the two parallel feedback resistors a lightning arrester should also be used from the low side rectifier output to ground Page 68 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 10 4 3 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Primary Amps Current Limit Over Current Trip TB506 5 and TB506 6 The first function of this input is to provide Current Limit operation The feedback signal is sensed at TB506 5 and TB506 6 For correct functioning of this circuit when the primary amperage of the T R setis at full nameplate value the proportional signal produced by the sensing current transformer CT and applied at the terminal
71. ersion 6 DESCRIPTION Component Parts The basic POWERCON 900 is comprised of two components the Main Logic Board MLB and a 24 VDC power supply This forms an operating control that will function with external Start and Stop hardwired operators such as switches and push buttons Other components devices are needed to change operating programming and to assess the operation of the POWERCON 900 but these item may or may not be permanently installed This manual will describe the use of a permanently mounted Touch Screen Display TSD but other items may be used such as a Laptop computer or a remote system such as the Precipitator Supervisory System PSS The MLB is connected to various electrical devices that either control power applied to the precipitator or provide feedback from the precipitator high voltage system Logic Section The logic section of the POWERCON 900 has terminals for all the field connections voltage and noise isolation metering circuits SCR firing circuits and the microprocessor unit All these items are mounted on a single circuit board that is in turn mounted ona 14 gauge carrier plate This assembly weighs 5 pounds measures 16 25 long by 8 wide by 2 5 tall It is installed in the control enclosure that houses the two main SCRs and other control components 16 38 2
72. esigns the metering circuits so that when a metered parameter is at full value the data displayed on the meters is between 60 and 80 of the full scale of that meter This means that if the power levels are low there is still a readable deflection of the meter If the power level is somewhat greater than the nameplate data of the transformer rectifier T R set those values are also readable The selection of the meter values and feedback components must meet the above criteria but the exact values will change with different jobs because of the sizes and values of components available from commercial sources Milliamp Signal Spark Detection TB506 3 and TB506 4 The primary function of this input is spark detection This feedback signal is sensed at TB506 3 and TB506 4 For the correct functioning of the spark detector at full load current the signal should be between the values of 6 10 Volts DC and as close to 10 as possible without exceeding 10 Volts If the signal exceeds 11 Volts DC then the POWERCON will process that as sparking event even though no sparking exists On the other hand operating with too small feedback signal sparking may not be detected This is because the spark signal is often mixed with electrical noise and a poor signal to noise ratio occurs The POWERCON may either detect normal electrical noise as sparks or not react when a spark occurs The feedback signal is developed across a resistor placed in series betw
73. ge Limit 3 6 8 3 Primary Kilowatt LiMit ii 3 6 8 4 Secondary Kilovolt Limit 3 6 8 5 Secondary Milliamp Limit 3 6 8 6 Warning 3 Limit 3 6 8 7 VE vU E lr EE 3 6 8 8 Conduction Angle Limit A 3 6 89 Primary Under Voltage UVR 3 7 OPERATING MODES sssccici cieca 3 7 1 Intermittent Energization I E 3 7 3 Power Off Rapping Reduced Power Rapping 3 74 BOCK COLONG EE E e 4 FEATURES cacicccccanecsaaaescastesessssasanscassasesenssansuenssasneasasanusnsseaesensssasusasessseasasasseasseasseasuenasaasuaasasasasasseassaasseseasaes 37 4 0 el n 37 4 2 Automatic Spark Rote Mode areri aa ai 37 E EE E dE 37 4 3 a A EE 37 4 4 MODBUS RTU COMMUMICOTIONS csescesvesasessuronssnssneeseasvnsaserssvendonsshenseusenasnessinensonssnseseadensonecsanssasnsensaveds 37 4 5 EVONE LOG NON 37 4 6 Tending oaren cxancidictctcavastasscactesdesasaassainescesnga E E E A E 38 5 INSTALLATION INSTRUCTIONS een 41 5 1 GENERAL INFORMATION EE 5 2 INSTALL LOGIC SECTION 533 INSTALL POWER SUPPLY iii 5 4 INSTALL THE TOUCH SCREEN DISPLAY OPTIONAL 5 5 OTHER DEVICES eege A ERROR ta 5 6 A A E EAA 5 7 VIII 5 7 1 High Voltage 600 VAC Terminal Strip Connections TBSOI 5 7 1 1 Thyristors SCR Gate Connections TB501 1 TB501 2 and TB501 4 TB501 5 5 7 1 2 Main Line Power Connection TB501 7 and TB501 9 in 5 7 1 3 T R Prima
74. he primary of the T R set to determine if an under voltage condition exists in the precipitator Under voltage is measured on the primary of the transformer The voltage on the primary is proportional to the voltage on the secondary The measurement is done on the primary side of the T R set since many of the older T R sets have no KV feedback signal The POWERCON decides if an under voltage condition exists by comparing the primary voltage to the conduction angle of the power applied Provisions are made in the software for spark recovery start up and short term phenomenon The input voltage range to the POWERCON is selected with jumper settings on the logic board Line Voltage Zero Cross Detection TB501 7 and TB501 9 This is a non scaled signal that is used to synchronize the control to the applied line voltage Until the control detects and synchronizes with the line voltage no power will be applied to the T R set Page 70 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 10 5 10 5 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Precipitator Trouble Shooting by Interpretation of Meter Readings One of the best troubleshooting tools to determine the condition of the precipitator is the interpretation of the value of the meter readings Changes in voltage current or power levels can often identify problems in the precipitator or with th
75. his condition can usually only be duplicated by disabling the undervoltage trip and the spark detection and operating the control in low value of manual output Both voltmeters will have a low to moderate voltage indication while both ammeters will read near zero A second or so later both voltmeters will drop to zero while both ammeters will read at moderate levels A second or so later the situation will again revert to the first condition Discussion This is a condition that is almost always caused by a discharge electrode that is broken at the tensioning weight When voltage is applied to the electrode it is pulled to Page 76 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 the collecting plate When the electrode touches the plate the voltage is shorted out to zero and short circuit current is drawn through the system Since there is now no voltage to attract the discharge electrode to the plate it again hangs plumb in the gas passage breaking the current path but again allowing the electrode to become charged Page 77 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 7 POWER OFF RAPPING Using MODBUS Power Off Rapping POR using the PSS requires the correct config
76. icators on the circuit board Power Circuit Power to energize a precipitator high voltage power supply is taken from a single phase 50 or 60 Hertz AC power source Mains Power After the proper safety procedures have been taken mains power is applied to the high voltage power supply by closing an interrupting device such as a circuit breaker or fused disconnect switch Power must also be applied to the POWERCON logic by either tapping the mains through a step down transformer or from a separate supply Upon application of power to the control logic it performs a self check begins to monitor the external alarm inputs and toggle the Stop Relay K2 for a period of four seconds The TSD will display READY TO START and await an external command to operate the Start Relay K1 to apply power If so Page 13 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 programmed at the application of control power the control will behave as if an external start command has been applied Next a STRT command is entered manually at the TSD or remotely by PSS or by internal programming at application of control power the control will activate 1 a main line contactor or 2 a signal relay Many systems have a main line contactor that is used as a secon
77. igh voltage power supply Duration ofthe Quench period is programmable by the user from zero zero causes the POWERCON to jump to the setback conduction angle to seven full cycles of AC power Recovery Recovery is the controlled restoration of power applied to the precipitator at the end of the Quench period Recovery will rapidly increase the conduction angle of the SCRs to the set back conduction angle The recovery rate is adjustable from one to one hundred cycles of AC power Set Back Set Back is the reduced operating conduction angle at which the POWERCON will operate after a spark The Set Back value is adjustable from 1 to 15 of SCR conduction angle in 1 increments The control will at the next zero cross either enter a Hold period or jump to the Ramp subroutine Hold The conduction angle can remain at the Set Back value for an adjustable Hold period from O to 255 cycles before resuming the ramp This allows lower spark rate and further discourages multiple sparking Ramp Ramp is a uniform increase in the conduction angle of the SCRs Ramping begins at the end of the series of events that occur after a spark has been detected Set Back Point or End of the Hold Period or if an operating limit no longer is in effect Ramp will increase the conduction angle at a user selectable rate of between 0 1 per second and 25 5 per second until either a spark occurs or a limit is reached Operating Limits Operating limits ar
78. imary Current Limit OM 0 Page 79 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 8 Local Data Logging on Touch Screen Display Active Sync The POWERCON 900 will record 6 minute average operating data in csv files readable by Microsoft Excel The files maybe extracted from the Touch Screen Display TSD using a Laptop with a USB cable The Laptop must have Microsoft Mobile Device installed 9 Lal Control Panel E B Mobile Device Application Data 3 17 Flash Disk My Documents 5 Network H E Program Files C3 Recycled El Storage Card FM AutoRun 5 AVC_Store CH Data og Profile MD Temp _ 5 Windows This means that when a computer is connected to the POWERCON via a USB cable may transfer files using Windows Explorer The POWERCON 900 will save up to approximately 1 year of data logging files in the DataLog folder The file format is CSV coma separated values In example Mar06_2012_SixMin CSV The POWERCON 900 will save the profile data in CSV format in the Profile folder Because of the file naming convention only one file may be saved per day In example Mar01_2012_Profile CSV You may need to install Microsoft Mobile Device onto your computer it is a free download from the Microsoft web site You will need to identify which version is appropriate for your
79. it that is set with the current limit thumb wheel switches on the main logic board This absolute limit cannot be exceeded by any programming method The second is a current limit value equal or lower than the thumb wheel values programmed from the TSD or PSS There are two Current Limit Ranges available High Range is adjustable between 0 and 510 amperes in one ampere increments The thumbwheel limit setting uses the thumbwheel value multiplied by 10 Low Range is adjustable between 0 and 51 ampere in one ampere increments and the thumbwheel limit setting is directly readable When the value of the AC current flowing equals the current limit the control will stop increasing the conduction angle of the SCRs If the AC current exceeds the value of current limit set point the control will reduce the conduction angle until the two values are equal If the current flowing is less than the current limit value then control will again begin to ramp The Primary Current Limit is easily visible on the TSD Status screen analog meter by noting the red band on the AC Amp meter face Also the Status Box will change color to Magenta from Red and a message will appear in the second line if the limit is reached Page 29 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 6 8 2 3 6 8 3 3 6 8 4 3 6 8 5 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6
80. l default and operate in Automatic Mode The manual control is to gate the main line SCRs ata given firing angle and to provide a steady output from the T R set Page 12 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 1 MAIN POWER HIGH VOLTAGE ON di CONTACTOR d gt RF CHOKE Leg y INTERNAL AC i LAL SCR1 CLR CH a GATE ERO SIGNAL CROSS POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 THEORY OF OPERATION The POWERCON is a feed forward control that automatically applies incremental increases in power to the precipitator measures the resulting feedback and adjusts its power output and operation accordingly The adjustment of power output is bounded by limits set to protect the electrical supply equipment and feedback from the precipitator that indicates various conditions within the precipitator The control monitors inputs from the electrical devices associated with the high voltage power supply system such as interlock switches temperature switches overloads etc and will provide warnings or alarms as required The control will also operate or modify its operation upon requests from the touch screen display or remote computer system The POWERCON will provide information about its operational status to the touch screen display TSD Precipitator Supervisory System PSS computer and to various ind
81. limit setting There are four percentage values that may be selected by the customer 100 50 25 or 0 Reducing power is used to improve the effectiveness of the rapping or to allow an automatic wash system to operate This input may be isolated from any other voltage source by removing Jumper J9 PRR Page 19 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com eg utility SEN Status Trend SixMin Parameters Trip Profile Scope Events Spark Response Op 1 op 2 Limits 1 Limits 2 Time TR Calibration POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 900 Rev x5 Powercon 900 Rev_24 Auto Parameter Default Remote Range Features Input Logic AC H 241 ACA 188 IE Duty Cycle 20 100 I UVR Alarm l Alarm 1 KW 49 Arc Quench 4 15 50C TF Not Assign T Alarm 2 DCIMA 74 0 100 T Auto Stat I Alarm 3 i PI 0 100 ze I Auto Start M Alarm4 UVR Angle I Not Assign T Warn 1 CndAn 135De UVR Voltage I Not Assign Warn 2 ManPot 1 Max A Imbalance 5 C Not Assign M Warn 3 20 f min MaxV Imbalance 9 TC Not Assign 11 3 2010 6 08PM ek BAUD be Gm Modbtis Add lo 2 I InterLock Temperature C 37 T Stop 3 3 5 3 4 Write Stop Input This configurable input will accept 24 120 Volt AC or DC input A signal at this input will disable the firing pulses to the SCRs operate and hold the stop relay K2 When the signal
82. long quench The arc quench routine is also executed when the POWERCON has made and initial determination that an Undervoltage condition exists see 3 6 8 9 The duration of the Arc Quench is programmable at the TSD Parameter OP1 Screen Power Off Rapping Reduced Power Rapping Certain collected materials are very difficult to remove from the precipitator collecting plates When the rappers that are associated with a particular T R set are operating the POWERCON control can reduce or halt power to that T R set lowering electric field intensity in that precipitator section while those rappers operate This power reduction helps release the particles to improve the effectiveness of rapping When an external signal between 24 and 120 Volts AC or DC is received at the control input TB504 14 and 15 the control will display receipt of the signal by illuminating main board LED 3 and changing the color on the TSD Status Box to Blue displaying a message RAPPING POWER XX and making the status known to network devices Another method to initiate the POR function is by command from the PSS This has a slight variation in that the POR function will only last for a time period of between 1 and 30 seconds as determined by the PSS Depending upon the value selected by the user the control will temporarily change the value of the Primary Current Limit to a percentage of the current limit 0 25 50 or 100 and operate at this level
83. mote device must communicate with the main logic board once every two minutes or the POWERCON will revert to the default parameters While the control is operating pressing the Clear Button will overwrite all the operating parameters that the remote system PSS has written in logic board with the Default parameters This immediately changes the characteristic of the operation The TSD display will only change if there a problem is encountered Then the PSS will reload operating parameters into the logic board during the next communication cycle 3 If POWERCON ALARM The control has detected an alarm condition and stopped its output to the T R set The Stop Relay K2 and Alarm Relay K4 have been activated and the Status Box will be flashing yellow and the Start button will be disabled and colored gray Pushing the CLR button will cause the control to perform a limited internal self check to verify the operating parameters in the logic board The control will check all the external inputs then the internal alarm conditions a If the Alarm condition has been cleared then the TSD will change the Status Box to green and display READY TO START and the Start Button will be reactivated and change its color from gray to red The POWERCON will await a start command b Ifthe Alarm condition still exists then the Stop Relay K2 and Alarm Relay K4 will stay activated but the Status Box will change to steady yellow Details of the
84. mps Initial Programming Page 50 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 The basic programming parameters of the system are to be entered at this time Detailed programming instructions are Section 7 and 8 of the manual The control may be programmed whenever powered regardless of the operating status Stopped Running Alarm with the single exception of being under control of a remote device such as the Precipitator Supervisory System PSS If under control of the PSS the parameters displayed on the local TSD will be the remote values and not indicative of the local default value programmed at the TSD Therefore make sure that the control is not connected to any remote devices for initial programming from the TSD 6 1 6 Basic Testing 6 1 6 1 6 1 6 2 6 1 6 3 6 1 6 4 6 2 Manual Potentiometer The screen should indicate a Man Pot value of 0 Rotate the potentiometer thru its full range and the display value should track the dial value behind the control knob Return to 0 Auto Manual Switch The screen should display Manual with a blue back ground color Set switch to Auto and the display should change to Auto and the background color will change to Gray Set switch back to Manual Press the Start Pushbutton All mete
85. o control 2 Firing circuit failed on 7 Excessive Sparking 1 Improper parameter values 2 Control in Manual Mode 3 T R feed back signal milliamp incorrect 4 Logic board failing to recognize spark input 8 Unbalance SCR Trip 1 Thyristor malfunctioning short or open 2 Firing circuit failed 3 Open in gate signal wiring 9 Missing Phase Lock 1 Mains power not detected by logic card Lamp 12 Jumper J1 10 Missing Zero Crossing 1 Display harness failure 2 Logic board malfunction 11 Not Responding 1 Display harness failure 2 KDU malfunction 3 Logic board malfunction 12 Alarm Message 1 Alarm present troubleshoot system as indicated Page 63 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 Appendix 10 1 Typical POWERCON Connection Diagram 10 2 Block Diagram Functions 10 3 Under Voltage Details 10 4 Feedback Circuit Requirements 10 5 Precipitator Trouble Shooting by Interpretation of Meter Readings 10 5 Component Value Chart 10 6 10 7 Power Off Rapping Using MODBUS 10 8 POWERCON 900 and Mobile Devices Page 64 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com A Vv C POWERCON Model 900 Instruction Manual SPECIALISTS INC Modbus RTU Software Version 6
86. ofit as a replacement for other voltage controls This manual describes the installation operation and adjustment of the POWERCON Model 900 automatic voltage control and associated components that will apply and control power to an electrostatic precipitator The control may be utilized as a stand alone unit for control of individual high voltage power supplies It may also be integrated with the A V C Specialists Inc PRECIPITATOR SUPERVISORY SYSTEM PSS for the automatic reporting of control conditions remote starting stopping or adjustment and participation in an energy management routine The control also may be remotely operated with an external system using an RS 422 physical layer and with software utilizing MODBUS RTU Precipitator High Voltage Power Supply The precipitator performs at maximum efficiency when the highest voltage is maintained on the discharge electrodes The voltage is supplied by the main line power components that are controlled by the POWERCON Model 900 A typical high voltage power supply system is a single phase power system connected to a main power feed of between a 220 and 600 volts and 25 to 350 amperes 50 or 60 Hertz alternating current supply System components may include a circuit breaker contactor two anti parallel thyristors silicon controlled rectifiers SCRs used to throttle the mains power a current limiting reactor CLR and a transformer rectifier T R set The T R set steps up the AC
87. ogic Section The Logic Section is installed inside the control enclosure Consideration needs to be given to the placement of the control for ease of viewing of LEDs from outside the enclosure Locating and drilling mounting holes is simplified by using the included drilling template see Appendix The chassis mounts with six 8 32 x machine screws Page 41 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 5 3 5 4 5 5 5 6 5 7 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Install Power Supply The power supply is to be mounted inside the enclosure preferably near the logic section Use the paper drilling template to locate the mounting holes see the Appendix Install the Touch Screen Display Optional The Touch Screen Display TSD may be installed anywhere within a ten foot cable reach ofthe supplied DB9 molded cable In no case should the cable length be greater than 15 feet If possible locate the TSD near eye level for best viewing If being permanently installed on the door of the enclosure remember that the unit will project back into the enclosure 2 4 inches Make certain that it does not contact any devices in the enclosure Locating and drilling the mounting holes and making the necessary cutout is simplified by using the included template see Appendix Power must be provided forthe display and it is recommended that
88. ol will operate with the new limit whenever one of these Warnings is present If both Warning 3 and 4 are present Warning 4 limit will supersede the Warning 3 limit MJ utility 900 Rev x5 Powercon 900 Rev z4 ei Status Trend SixMin Parameters trip Profile Scope Events Spark Response Op 1 Qp 2 Limits 1 Limits 2 Time TR Calibration Sp Auto Parameter Default Remote Range lt iss Pri Amps O NPCL Amps Si e 2 Pri Volts O 599 Volts Gen 60 5 Pri KW O 255 KW Sec KV O 120 KV Sec mA O 2550 mA Cnd n 135 De ManPot 1 21 min O NPCL Amps O NPCL Amps W3 Pri Amps W4 Pri Amps 11 3 2000 emm Max Cond Ang 176 gay 129 1 6 Degrees UVR Volts 0 599 Volts ol Stan UVR Angle 50 10 176 Degrees Write 3 3 4 Power Off Rapping Input This is a configurable and programmable input It may operate either with a hard wire input by accepting a 24 120 Volt AC or DC input at TB 504 terminals14 and15 or by receiving a command over the MODBUS Network If the Power Off Rapping POR command is received over the network there is a time element involved that will only allow the control to stay in POR mode for a maximum of 15 seconds without receiving another command When commanded the control will reduce or eliminate power to the precipitator lowering the electric field intensity The AC current to the precipitator is immediately lowered to a percentage of the current
89. operating modes that can be superimposed upon the normal automatic mode All the functions described in Section 3 6 remain in effect when these modes are selected Page 32 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com AG Status Trend SixMin Parameters Trip Profile Scope Events POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Spark Response Op 1 Op 2 Limits i Limits 2 Time TR Calibration ACY SW 41 Parameter Default Remote Range Features Input Logic ACA 188 IE Duty Cycle 20 100 MF UVR Alarm F Alarm 1 KW 49 Arc Quench 50 4 i15 50C TF NotAssign T Alarm 2 DCimA 74 100 gt 0 100 I Auto Start I Alarm 3 dng 59 a O 100Sec I AutoStart I Alarm4 UVR Angle I Not Assign T Warn 1 CndAn 135De UVR Voltage T Not Assign T Warm 2 ManPot 1 Max A Imbalance 5 F Not Assign Warn 3 Po 20 min Max V Imbalance n 9 I Not Assign Warn 4 11 3 2010 6 08 PM Ge BAUD gt T POR Modbtis Add I InterLock Temperature C l Stop Write Intermittent Energization I E 3 7 1 This feature improves the collection of certain high resistivity dusts by slowing the development and propagation of back corona and also permits large energy savings The applied power to the T R set can be reduced from 100 in seven steps to 20 duty cycle while maintaining high peak secondary voltage The reduction in duty cycle is
90. ors The POWERCON 900 displays the metering values status and messages on both the TSD and the remote Precipitator Supervisory System To simplify troubleshooting there are 22 LEDs and 2 neon lamps on the logic board to indicate status when operating in stand alone mode with no communications attached Symbol Labeling Location Description 1 1 Output D 2 Variable Controlled Voltage Present at T R Set Primary 1 2 Mains E 2 Main Power Line Voltage Present at SCRs LED 1 Interlock E 14 External Interlock Alarm LED2 Stop E 14 External Stop Input LED3 POR E 14 POR Rapping External Input or Network Generated LED 4 Limit E 14 Upper Operating Limit in Effect LED5 Internal Warning E 15 POWERCON Generated Internal Warning LED 6 External Warning E 15 External Warning Input LED 7 Internal Alarm E 15 POWERCON Generated Internal Alarm LED 8 External Alarm E 15 External Alarm Input LED 9 Alarm Relay H 14 K4 Alarm Relay Activated LED 10 Pick Relay G 14 K3 Programmable Relay Activated LED 11 Stop F 14 K2 Stop Relay Activated LED 12 Start F 14 K1 Start Relay Activated LED 13 Spark G 7 Spark Detected LED 14 60 Hz G 7 60 Hertz Main Power Control Must be Running I 2 Illuminated LED 15 50 Hz G 7 50 Hertz Main Power Control Must be Running l 2 Illuminated LED 16 H 2 SCR 1 Firing Pulse LED 17 G 2 SCR 2 Firing Pulse LED 18 P
91. ower C 15 24 VDC Power LED19 R C 11 Receiving Communication on RS 422 Remote LED 20 X C 11 Transmitting Communication of RS 422 Remote LED 21 X C 8 Transmitting Communication of RS 232 Local LED 22 R C 8 Receiving Communication of RS 232 Local GE EE liane via SEET sua A A se N EA LR Le j GEN INP WARN EX WARN INP ALARM D EXT ALARM side LED 1 LED 21 XMIT RECEIV LED 11 24 POWER Page 5 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 2 2 3 Reserved 2 2 4 2 2 5 Current Limit Thumbwheel Switches There are two thumbwheel switches at location D 11 that should be set to the primary amp rating of the T R set In low amp range operation the value indicated by the switches is the value of the primary amp rating of the T R set In the high amp range the value indicated by the switches is ten times greater than indicated This is the maximum value of amps that can be applied programmed in the Primary Amp Limit and cannot be exceeded by any software command Programming Jumpers There are jumper locations on the logic board that are used to initially set the configuring for wiring the POWERCON 900 Main Logic Card to the enclosure components This includes the voltage of the main power etc All configuring jumpers use a common 0 1 inch spacing square post
92. precipitator The examples below are based on the correct selection of the scale and range of the analog meters to the values being measured It is assumed that at full value the data displayed on the meters is between 75 and 80 of the full scale of that meter This means that if the power levels are low there is still a readable deflection of the meter If the power level is somewhat greater than the nameplate data of the transformer rectifier T R set those values are also readable Normal Meters Readings For the purpose of discussion the following three sets of meters are connected to precipitator fields that are physically the same size with identically sized high voltage power supplies Page 71 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 5 1 1 Inlet Field Indication The meters indicate electrical levels that are within normal range of the transformer rectifier set Voltages are somewhat higher than the following fields with current that are somewhat lower Spark rate in the middle to upper range of the settings 10 5 2 2 Middle Fields A C AMPERES UI Indication The meters indicate electrical levels that are within normal range of the transformer rectifie
93. quipment is installed Limitation of Liability A V C Specialists Inc reserves the right to make changes in the devices or the device specifications identified in this Installation and Operating Manual without notice A V C Specialists advises customers to obtain the latest versions of device specification and operating firmware before installing this equipment In the absence of written agreement to the contrary A V C Specialists Inc assumes no liability for A V C Specialists Inc applications assistance customer s system design or infringement of patents or copyrights of third parties by or arising from the use of devices described herein A V C Specialists does not warrant or represent that any license either expressed or implied is granted under any patent right copyright or other intellectual property right of A V C Specialists Inc covering any combination machine or process in which such device might be used Except to the extent prohibited by applicable law under no circumstances shall A V C Specialists Inc be liable for consequential damages sustained in connection with said product A V C Specialists Inc neither assumes nor authorizes any representative or other person to assume for it any obligation or liability other than such as is expressly set forth herein POWERCON RAPPERCON PRECIPITATOR SUPERVISORY SYSTEM PSS and HOPPER HAMMER are trademarks of A V C Specialists Inc All other trademarks are
94. r connection terminal block DB9 communication connections and an on off switch that should always be in the ON position The TSD should be connected from COM 2 to the DB9 connector on the POWERCON 900 main logic board The 24 volt power should be connected to the same power supply as the POWERCON The TSD basic operating programming is contained on the plug in SD located on the left side of the display As such it always must be installed Updating the programming is simply done by inserting a new SD card Page 11 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 o A CARD COM3 RS232 T SD Y 9 Ki dl CARD O COM2 RS232 ETHERNE _ COM PORT POWER INPUT SWITCH 2 4 2 2 Programming Switches There is a single programming switch on the TSD It should be set to configure the Com communications port to RS 485 422 Switch Setting 1 On 2 Off 3 Off 4 Off 2 5 Manual Control Potentiometer Switch Mounted separately is a manual control potentiometer and switch that are wired to TB 505 of the logic board If these items are not present the control wil
95. r proper operation for at least a ten minute period Time and Date Press the Time Tab Set the time and date with spin wheels and write to memory Page 57 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 8 1 8 2 8 3 8 4 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 GENERAL INFORMATION The control may be programmed whenever powered regardless of the operating status Stopped Running Alarm with the single exception of being under control of a remote device such as the Precipitator Supervisory System PSS If the control is being operated by the PSS a new set of operating parameters may have been downloaded to the control and the remote operating parameter will be displayed If communication to the remote system is lost for 120 seconds the control will revert to the local default parameters Non volatile Memory The control stores any programming changes in a non volatile memory device on the Main Logic Board MLB At start up or upon pressing the CLR key the control will reload the operating parameterfrom the non volatile memory The control may be operated without the TSD using the last programming values Dual Bushing If the T R set has only one high voltage output bushing select single If the T R set has two high voltage output bushings and a feedback signal from each bushing select Duel If Dual is selected the
96. r set Voltage and currents readings are in the middle of the metering range Spark rate is low to moderate Page 72 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 10 5 2 3 Outlet Fields 10 5 3 Indication The meters indicate electrical levels that are within the normal range of the transformer rectifier set Voltages are lower than the normal fields and currents at are or near maximum The spark rate will be in the low range and often 0 Examples of Precipitator Process Conditions on Meter Readings 10 5 3 1 Corona Suppression A C AMPERES AMO Y AVE UI Indication With power present at the mains but with the control output at 0 there is significant KV reading without any other readings Discussion There is some leakage of power around the main line SCRs through the parallel Resistor Capacitor Snubber Network In small systems that power leakage may be enough to provide power to charge the discharge electrodes to a voltage just where corona forms around the discharge electrodes Page 73 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus R
97. readings Changes in voltage current or power levels can often identify problems in the precipitator or with the high voltage power supply Good records of past operation are an important aid in troubleshooting the current operation Below is a summary table of meter indications A more complete troubleshooting discussion is found in Section 10 5 of this manual ACV ACA KV mA S CONDITION POSSIBLE CAUSE 1 0 0 0 0 0 OFF Main Circuit Breaker Trip Loss of Control Power 2 N N N N H Poor Control Spark Rate out of adjustment 3 H N VL N 0 OK Change in Plant Process 4 H CL VL CL 0 OK Change in Plant Process 5 0 N N N N False Undervoltge Open voltage return Logic Board J10 not inserted 6 L N L L 0 Unbalanced AC Logic board firing ckt SCRs T R Power half waving set open in dual bushing T R ckt 7 0 lt gt N N lt gt CL 0 lt gt N N lt gt H N Swinging Short Broken discharge electrode 8 L L L L N Poor Operation Dust build up poor rapping tracking insulator 9 H L H L N Poor Operation High Resistivity Low sulfur coal Conditioning System malfunction lower or higher precipitator temps 10 L CL L H N Low Impedance Full hopper tracking insulator 11 L N L N N Very Low Full hopper tracking insulator Impedance 12 O lt gt L CL 0 H 0 Dead Short Broken Electrode full hopper tracking insulator T R debris 13 H L VL L 0 Open Second
98. rs analog and digital should remain essentially 0 The status screen will display Running and the background color will change to Red If there are front door indicator lamps they should mimic the display Press the Stop push button T R Operation and Feedback Signals Caution If an existing control enclosure has been upgraded the POWERCON metering circuits are not calibrated Rely on the analog metering to operate the control until the digital meters have been calibrated The control will function and detect sparks but limit circuits may not operate correctly See Section 7 for Calibration Make sure the Auto Manual Switch is in Manual and that the Manual Potentiometer is set at 0 Page 51 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 If there is a separate power supply for the logic apply control power to the logic then close the main power circuit breaker Atthe application of power the control should repeat the procedures as outlined above in section 6 1 5 Press the STRT key and the display should then read POWERCON RUNNING Slowly rotate the manual potentiometer until output and feedback are noted That should be at a potentiometer value no greater than 20 conduction angle of approximately 37 9 On the display there should be values for PRI RMS VOLT
99. ry Voltage TB501 11 i 5 7 2 Feedback Circuits TB506 iii 5 7 2 1 AC Amps TB506 5 and TB506 6 e 5 7 2 2 DC Milliamp Spark Detection TB506 3 and TB506 4 5 7 2 3 DC Kilovolts Optional TB506 1 and TB506 2 Page ii 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com A Vv C POWERCON Model 900 Instruction Manual SPECIALISTS INC Modbus RTU Software Version 6 5 8 CONTROL POWER TROESCH take Eege EENEG 44 5 8 1 Logic Card Firing Circuit EE 44 SIE IE RR E EE EEEE 44 5 8 3 Touch Screen Display TS 44 59 au ONE EM EE 44 5 10 DG POWER 126 porse aa inni 44 5 11 RELAY CONNECTIONS TBSO7 cose ccssseiseassnosaazsvncisssannes a An a saaceaeuueneteg 45 6 INITIAL STARTUP PROCEDURE vaicccccscdecucescsecccatutecnsesssesssetedesscscndasesecedesscesudnsacesesecucestdasusessdeshendacesssssadeseceseses 46 6 1 BASIC A cascades aaa ea 6 1 1 Install Limited Mains Power Optional Highly Recommended 6 1 2 Lamp Load Test 0 6 1 3 Auto Manual Switch 6 1 4 Initial Switch Setting 61S NN NA sansateveissshdsdascacss a aa aa E lavessuesisicaoedaezasab da 6 1 5 1 A learn 6 1 5 2 Test Alarm and Warning Inputs 6 1 5 3 Set Maximum Primary Current Limit ccceeeeeeeesnceceeeeeeeeeeaaeeeeeeeeenaaeeeeeeeeeaaaeeeeeeesenaaeeeeeeeeeesaeeeeeeens 6 1 5 4 initial Ell LTE 6 2 T R
100. s have strap screw terminals that will accept bare stripped wire or wire terminated with 8 ring or 8 forked terminals Other wires will be landed on removable compression terminal blocks TB 503 TB 504 TB 505 TB 506 and TB 507 that accept one 12 gauge stripped wire or two 16 gauge stripped wires The 24 VDC external power supply is connected to the board at 4 26 using a plug in Phoenix type plug There are two independent communication connection points a RS232 DB9 plug to the local TSD and a RS 422 J6 MODBUS connection for a network communications to the Precipitator Supervisory System A Bee ee 18509 S S S _ISTS we dea 3 RS 232 lo MOD BUSS EECHER N pocos eoocoaeooaaooa O SS O 0a pocos povovcnsVsVVVavaa 18507 TB 507 000000000000 RELAY OUTPUTS Go PONER ENCLOSURE J esisino AI aos SJ LOCAL TS NETWORK EXTERNAL DEVICE TB 508 INPUTS mam INPUT 78 506 MANUAL 7B 505 DISPLAY 4 3 COMM Ae INPUT TB 504 CONTROL Page 4 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 2 2 2 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Indicat
101. se see the following diagram Page 16 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 GENERAL FORMAT OF SWITCH INPUTS V TB 504 2 10 TYP 100K e DSP INPUT 24 120V AC OR DC 1 2 milliAmps Configuration is done on the TSD by selecting the Parameter Screen and then the sub screen Op1 Check the appropriate configuration box A check mark in the box in this column absence of voltage triggers action utility 900 Rev x5 Powercon 900 Rev z4 J ca VE Status Trend SixMin Parameters Trip Ea Scope Events Spark Response Op 1 op 2 Limits 1 Limits 2 Time TR Calibration Auto AC Y 241 Parameter Default Remote Range Features Input Logic ACA 188 IE Duty Cycle 100 gt 20 100 I UVR Alarm l Alarm 1 KW 49 Arc Quench z 2 15 50C JT Not Assign T Alarm 2 DCimA 74 POR 100 0 100 I Auto Start T Alarm 3 DCIKV 60 Auto Start Delay 0 100 Sec I AutoStart M Alarm 4 UVR Angle F Not Assign T Warn 1 Cnd n 135De UVR Voltage T Not Assign Warn 2 ManPot 1 Max A Imbalance T Not Assign Warn 3 20 min MaxVImbalance sg 9 T Not Assign T Warn 4 11 3 2010 6 08 PM Ge BAUD 9600 y l POR Modbtis Add o T InterLock Temperature 37 T Stop Write Page 17 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 5
102. sion 6 returns to Automatic Mode operation If the kilovolt reading decreases with advancing conduction angle then the control will retard the conduction angle an additional five degrees and repeat the test The control will establish a Conduction Angle Limit at the point of maximum Kilovolts The contro will post a message on the TSD BACK CORONA DETECTED and forward a message to the PSS Profile Profile is a subroutine that is built into the POWERCON to aid in the analysis of the internal condition of the precipitator The subroutine will generate a set operating data one time when triggered That data will remain in the POWERCON until another set is generated To initiate a profile use the TSD screen Parameters Profile Press the Generate Profile Button When the Generate Profile subroutine is initiated the control will immediately reduce output power to zero and the TSD Status Box will display a message GENERATING PROFILE The control willthen begin to advance the conduction angle in 1 degree steps every second and create a record of operating data Primary Volts Primary Amps Primary Kilowatts Secondary Kilovolts 1 Secondary Kilovolts 2 Secondary Milliamps 1 Secondary Milliamps 2 and Conduction Angle The control will continue to advance the conduction angle of the main line thyristors in 1 degree steps creating additional records The control will advance until either it reaches an upper limit
103. ssing CLR on the TSD from the PSS or by interrupting the power to the POWERCON for at least five seconds Caution All alarm and warning inputs have the same common return Therefore the voltage source for all alarms and warning must be power from the same source Interlock Input This configurable input will accept 24 120 Volts and works identically to the alarm inputs described above in Sections 3 3 1 The only difference is that the signal input and return may be isolated from any other voltage source by removing Jumper J9 2 ILR Warning Inputs There are four configurable warning inputs similar to the alarm inputs described in Section 3 3 1 Any warning message and any action taken will be automatically cancelled if the warning signal input is removed and normal operation will proceed There are two types of Warning Inputs Annunciate Only Warning Numbers 1 and 2 will only display a message on the top line of the TSD and transfer the Warning Message to the PSS Reduced Output Operation Page 18 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Warning Numbers 3 and 4 operate in the same fashion as the above Warnings 1 and 2 plus the output of the control may be reduced A reduced primary current may be programmed from the TSD by selecting Parameter and the sub screen Limits 1 and the contr
104. stallation Each contact or switch should provide the alarm or warning as indicated When an Alarm occurs the POWERCON will active and hold Relays K2 Stop and K4 Alarm The TSD Status Box will flash Yellow and a particular Alarm Message will be displayed This message and time will also be logged in the event recorder Press the Clear Button to acknowledge the Alarm If the condition has been alleviated the Status Box will again be colored Green If not it will become solid Yellow to denote that the alarm condition is still present but has been acknowledged Repeat until all alarms have been tested Warnings are tested in a similar fashion except the control will continue operation and the Status Box color will be Blue Set Maximum Primary Current Limit Set the maximum primary current limit by adjusting the thumbwheel switch SW2 on the logic card The thumbwheel must be set slightly different depending on the size of the T R set and the operating range of the software If the T R set Primary AC Amp rating is less than 50 and Secondary DC Milliamp rating is less than 250 then Low Amp range will be used Simply adjust the thumbwheel switch to the Maximum AC Amps If the T R set is larger with a Primary AC Amp rating greater than 50 or Secondary DC Milliamps rating greater than 250 then High Amp range will be used Then the software multiplies the thumbwheel switch setting by 10 Round this setting upward 15 on the thumbwheel for 146 actual a
105. stant output while monitoring the feedback inputs for changes If a spark over is detected in the precipitator then a series of control steps will follow Those steps may include quench a no power output period recovery rapid ramping of power setback recovery to power level just below the level of power at which a spark over occurred and hold no change in power from the setback point for a period of time The control will then return to normal ramping Safety The POWERCON 900 control is designed with safety in mind All adjustments calibration of the digital metering and configuration of external input logic are externally programmed via one of three methods The most common being a dedicated color touch screen display TSD a laptop computer or a remote system such as the A V C Specialists Precipitator Supervisory System PSS There are no adjustment potentiometers on the circuit board CAUTION Voltages on the POWERCON 900 logic card can be as high as 600 volts Therefore it is recommended that only personnel fully trained in the operation and maintenance of electrical equipment have access into the enclosure where the POWERCON and other power control equipment is located Please follow all applicable safety procedures Page 2 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 2 1 2 2 POWERCON Model 900 Instruction Manual Modbus RTU Software V
106. tect if there are spark over events occurring in the precipitator The secondary T R DC current passes through a low ohm high wattage resistor s that produces a DC voltage proportional to the current One side of the resistor is at ground potential and the other at a low voltage DC The secondary current is limited by the control not to exceed the rating of the T R set This voltage is applied to TB 506 3 and TB506 4 DC Kilovolts This feedback connection is not necessary for the basic functioning of the control However if it is present there are several very useful control functions that can be utilized such as the detection of back corona in the precipitator or exceeding the kilovolt limit of the T R set The output of the high voltage output of the T R set is measured with a 80 400meg ohm voltage divider that produces a current output in proportion to the voltage output of the T R set This signal is applied to TB506 1 and TB502 2 Control Inputs There are various inputs that allow the control to be programmed automatically change modes of operation start and stop operation and to annunciate alarm warning or other operating conditions Section 3 3 1 to 3 3 5 describes binary type external switch inputs The binary external control inputs are configurable so that action is generated either when a DC or AC voltage signal in the range of 24V to 120 V signal is present or conversely if programmed the absence of a voltage signal Plea
107. ter exceeds the programmed limit the control will retard the conduction angle If the value of the measured parameter is below the programmed limit the control will advance the conduction angle at the programmed Ramp Rate Message Meaning Pri Cur Limit Operating at Primary AC Current Limit Pri Volt Limit Operating at Primary AC Voltage Limit to T R Set KW Limit Operating at Primary KW Input Limit Sec KV Limit Operating at Secondary DC Kilovolt Limit Sec mA Limit Operating at Secondary DC milliamp Limit Full Power Operating at Conduction Angle Limit Status Messages Features Features are modifications to the operating firmware that are activated by checking a box on the OP1 screen Page 61 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 9 2 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Feature Action Comments J6 1 Trip on Undervoltage Condition J6 2 Ye Values for Undervoltage Reduces undervoltage trip points J6 3 Auto Start Close Contactor on Logic Power Up J6 4 None Spare Jumper Location J6 5 None Spare Jumper Location J6 6 None Spare Jumper Location J6 7 None Spare Jumper Location J6 8 None Spare Jumper Location Interpretation of Metering Readings One of the best troubleshooting tools is the interpretation of the value of the meter
108. the maximum value of average DC voltage at the output of the T R set Itis set at the maximum desired output from the T R set Similar to current limit the control will freeze the conduction angle of the SCRs when the KV limit equals the measured KV and reduce the conduction angle when the measured KV exceeds the KV limit If the control is operating a transformer with dual bushings and feedback from each then the secondary KV Limit is determined by the highest operating bushing The Secondary Kilovolt Limit is easily visible on the TSD Status screen analog meter by noting the red band on the DCKV meter face Also the Status Box will change color to Magenta from Red and a message will appear in the second line if the limit is reached Also on the main logic board the general Limit LED 4 will illuminate Secondary Milliamp Limit The Secondary Milliamp Limit is the maximum value of average DC milliamps output of the Page 30 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 6 8 6 3 6 8 7 3 6 8 8 3 6 8 9 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 T R set It is set to the maximum value output from the T R set If the POWERCON is operating a transformer with dual bushings and feedback from each then the secondary MA Limit is determined by the highest operating bushing The Secondary Milliamp Limit is easily visible on th
109. the same power supply for the main circuit board be utilized Caution Make sure that the power connection to the TSD has the correct polarity Other Devices Install any other devices required SCRs relays resistors etc T R Set Install and or remove feedback resistors as required Assure sound condition of the wiring and components especially the surge suppressors and grounding circuits Wiring Review the Typical Connection Diagram SASTD812 review the Feedback Circuit Requirement see Appendix Follow any specific directions on the specific job drawings Connect wiring as required A review of circuit connections between the POWERCON logic board and other devices follows Unless noted minimum of 16 gauge wire with 600V insulation should be used for all wiring A Warning The feedback circuit need to be configured for the correct feedback voltage and current Improper operation or damage to the control may result Page 42 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 5 7 1 2 5 7 1 3 5 7 2 5 7 2 1 5 7 2 2 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 High Voltage 600 VAC Terminal Strip Connections TB501 Thyristors SCR Gate Connections TB501 1 TB501 2 and TB501 4 TB501 5 Prior to making this connection ascertain the proper orientation of the anode and cathode and identity of SCR1 and SCR 2 The gate
110. ualified personnel Do not use this device for primary protection functions These include applications where the device performs energy limiting functions or provides protection of people from injury Primary protective equipment includes but is not limited to circuit breakers ground fault interrupters fuses etc The POWERCON control may be used to provide secondary protection functions Do not HIPOT Dielectric test this equipment Do not remove or install any circuit board with power applied to the control The field devices operated by this equipment are often attached to equipment that operates at very high voltages Proper grounding of field devices is essential to provide protection of this equipment and service personnel Page b 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 1 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 POWERCON Model 900 Software Versions 6A MODBUS RTU OPERATING INSTRUCTIONS GENERAL INFORMATION 3ccurcarcr iii nari anoressia acacia viva NENNEN 1 A AA na 1 1 2 PRECIPITATOR HIGH VOLTAGE POWER SUPPLY iii 1 1 3 POWERCON OPERATION SUMMARY ceccescssessesesscescscsucescersucescersucessersuceesersucessuvsucersessusassessusarsessesacsessesaseesanseeeeees 1 1 4 RR 2 DESCRIPTION RS O 3 2 1 COMPONENT PARTS O O AA 3 2 2 LOGIESEGTION una ea 3 2 2 1 Wiring ee E de EEN 4 2 22 o iaia 5 2 2
111. until the input signal is removed or the function times out These functions are programmable on the TSD screen Parameters OP1 Back Corona Back Corona is a phenomenon that is associated with the collection of high resistivity particles As additional high resistivity poor electrical conductivity material is deposited on the collecting plates it in effect insulates the discharge electrodes from ground The layer of material develops a strong voltage gradient between its outer surface and the grounded plate Back corona occurs when there is localized reverse ionization from the plate Back Corona is evidenced by a reduction in secondary voltage with the application of increasing secondary current This results in a decrease in precipitator collection efficiency even with an increase in power consumption This feature may be turned on with the TSD or from the PSS When activated the control at programmed intervals will stop ramping for a few seconds to stabilize the operation and then the control will retard the conduction angle of the SCRs by five degrees The control will then advance the conduction in one degree steps each time recording the secondary kilovolt reading If the kilovolt reading is increasing then the control stops the test and Page 34 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 3 7 5 POWERCON Model 900 Instruction Manual Modbus RTU Software Ver
112. uration of the RAPPERCON that will initiate the process the PSS that will communicate the commands and the POWERCON that will receive the instruction to reduce power 10 7 1 Basic Control Configuration 10 7 1 1 RAPPERCON a b C System Screen 4 the POR over MODBUS is set to YES System Screen 4 the POR Time Delay is set to a value between 1 and 30 seconds Eight 8 seconds is a recommended value at the beginning Use of sequential type program only is recommended for RAPPERCON controls that operate more than 24 rappers This is due to the added time before each rapper is operated due to the POR Time Delay when Round Trip Programming is used With Sequential Program the POR Time Delay is only added at the beginning of the group to be rapped than all rappers are operated without further delay POR is only transmitted to PSS when a GROUP has a POR address other than 0 in its GROUP Parameters The MODBUS address in the GROUP Parameter must be carefully programmed to control the POWERCON associated with the rappers to be operated by that group It is strongly recommended that special GROUPs be written for POR and that the GROUP only be associated with a specially named POR program only Anytime a POR GROUP is operated the associated POWERCON will reduce power 10 7 1 2 PSSM The communications network cabling must be configured per the addressing scheme and terminated in the correct numbered ports
113. vided A Warning High voltage feedback from the Transformer Rectifier T R Set may be present without powering the T R set from its own power source If there are other precipitator sections operating charged particles can carry a high voltage charge to the discharge electrode grid that is connected to the T R set high voltage output and the feedback circuitry Make certain that the high voltage output bushings are grounded and the milliamp and kilovolt signal lines are grounded There is also a strong possibility that induced voltage will be present on the main power circuit between the control enclosure and the T R set Again install a small jumper between these power lines and ground to bleed any voltage After this preparation shut down all power to the selected precipitator section using the proper established safety lockout procedures There may be alarm circuits present that cannot be de energized If safety requirements allow the circuits may be disconnected or bypassed to allow safe installation of the new control If this is not a retrofit installation into an existing control enclosure then skip to step 5 5 Identify what equipment will no longer be used Make sure that all wires and cables terminated on this equipment are marked according to the original drawings Disconnect these wires and set them aside to later be connected to other equipment or to be removed from the enclosure Remove the abandoned equipment 5 2 Install L
114. voltage by a factor of 100 to 200 and then converts that high voltage to a direct current for application to the precipitator discharge electrode system POWERCON Operation Summary The POWERCON 900 automatic voltage control is a 32 bit microprocessor control that regulates the gating conduction angle phase angle of the anti parallel thyristors that throttle power applied to the T R set It continually monitors the feedback from the T R set input current and voltage secondary output current and optionally it s high voltage to adjust the conduction angle of the thyristors The output power applied to the T R will be determined by the algorithm of the microprocessor as adjusted and limited by the operator Additionally the control may also monitor other items concerning the high voltage power supply system including over temperature alarms low cooling fluid levels and other external devices that require control annunciation or action Page 1 5146 G COMMERCE AVENUE e MOORPARK CA 93021 e 805 531 8900 e FAX 805 531 8903 www avcspecialists com 1 4 POWERCON Model 900 Instruction Manual Modbus RTU Software Version 6 Normal operation will consist of ramping increasing the conduction angle of the thyristors at successive time periods to increase the power to the precipitator until either a system maximum limit is reached or there is a spark over in the precipitator If a system limit is reached the control will maintain a con

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