.

Kraft Elektronik AB
Vendor instruction

Technical description

ESP power supply, 3 phase T/R Unit

Created by: KOEM

Created date: 27-Oct-08

Doc. No: 60059133-1.0

 Technical description

ESP POWER SUPPLY

3-phase TR-unit
Type G_QE

TB-77-109.077 GB

Revision Designed by / Date Checked by / Date Approved by / Date

A BWa / 071024 /BRh / 071102 /SSj / 071102
 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

SAFETY INSTRUCTIONS

This product is solely for use as H.V. power supply for

Electrostatic Precipitators.

Read entirely this technical description before any action

is undertaken regarding the product or the Precipitator.

All warnings and safety instructions must be followed to

ensure the highest possible safety and efficiency in using
this product. The user is responsible for following the
warnings and instructions in this technical description and
on the product as well.

This product contains hazardous voltages that may cause

electric chock, fatal injury or cause fire. Mainly two
voltage categories are involved, with different level of
safety measures:

a) Low voltage, mains related less than 1000 V AC

b) High voltage, up to 150 000 V DC

Only duly qualified personnel shall carry out any work on

the product, e.g. installation, operation and service. Before
opening any cubicle doors or removing any shields, always
make sure that the mains supply is switched off and
securely locked. Please also make sure that the precipitator
H.V. system is properly earthed.

109.077 GB FLS RevA.doc Page 2(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

TABLE OF CONTENTS

1.0 TECHNICAL DATA

1.1 Type designation

1.2 Data, standard equipment
1.3 Weights and dimensions
1.4 Documentation
1.5 Recommended spare parts

2.0 DESIGN AND FUNCTION

2.1 General
2.2 Transformer Rectifier, TR-unit

3.0 INSTALLATION

3.1 Placing
3.2 Electrical connections

4.0 OPERATION

4.1 Commissioning
4.2 Functional check
4.3 Adjustments

5.0 MAINTENANCE

5.1 Preventive maintenance

5.2 Storing instructions
5.3 Trouble shooting

109.077 GB FLS RevA.doc Page 3(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

1. 0 TECHNICAL DATA

1. 1 Type designation

The type designation of the transformer rectifier (TR-unit) is a combination of letters

and figures as shown in the following example.

GBQE 90/600 A

Variant
Nominal DC current in mA arithmetic mean value
Nominal DC voltage in kV peak value at nominal
mains voltage and no load
Primary voltage

C = 220 V 0 = 440 V D = 575 V

B = 380/400 V A = 480 V X = 660 V
E = 415 V P = 500 V S = Special

The letter combination G-QE means an electrostatic precipitator rectifier and variant A
a hermetically sealed unit with the current limiting reactors placed in the tank. The
example above describes an TR-unit for connection to mains power supply of 400 V,
with a DC current of 600 mA and with a DC peak voltage of 90 kV at no load.

1.2 Data, standard equipment

Power supply voltage: Nominal ± 10 %

Short circuit voltage: 30 % ± 5%

Temperature range: -40 °C to +40 °C

Degree of protection: IEC 144, IP 65

Flash over frequency range,

Continuous: 30 per minute
Intermittent: 200 per minute

109.077 GB FLS RevA.doc Page 4(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

1.3 Weight and dimensions

Total weight, weight of oil and overall dimensions of the TR-unit are shown in the set
of contract drawings. All weights have a tolerance of ±5 % on values stated.

1.4 Documentation
The documentation comprises of this technical description together with a set of
drawings etc. specific for each contract.

1.5 Recommended spare parts

In general the quantity of different components and the number of each of these
components to be kept in stock, are mainly dependent on the following:

- Total number of units where the component is fitted

- How important the equipment is for the process
- How important the component is to continue the operation
- The stock held by the supplier
- Location of the plant

Considering the above, spare part list is compiled for each rectifier type and order. The
spare part list is included in the set of documentation.

2.0 DESIGN AND FUNCTION

2.1 General
A complete electrostatic precipitator power supply, comprises of the transformer
rectifier unit (TR-unit), described in this manual, and the control cubicle (CC) with
control equipment manufactured by others.

The CC- and TR-units are normally installed at a distance of 10-100 meter from each
other.

The CC-unit contains the main power control parts and the control electronics together
with necessary instrumentation, controls and alarm indicators.

The TR-unit contains the high voltage (HV) transformer, Current Limiting Reactor
(CLR), rectifier bridge, alarm sensing devices, measurement adapters and terminals for
the supply and interconnecting cabling.

109.077 GB FLS RevA.doc Page 5(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

2.2 Transformer rectifier, TR-unit

The TR-unit is constructed as a steel tank and filled with suitable coolant. The liquid
compartment is hermetically sealed and sufficient cooling area is attained through fol-
ded tank-sides. These special designed tank-sides also take care of the oil expansion
caused by temperature differences.
A plugged filling hole is located on the tank lid, and a combined drain and sample
valve is located at the bottom of the tank. The valve is plugged upon delivery.

Standard coolant used is mineral transformer oil of naphtenic type and meets the
specifications according to IEC 296 Class 2. Type of oil used is labelled on each TR-
unit. The oil is used as an insulating medium for the appearing high voltage
components and also acts as a heat transfer medium.

Immersed in oil are the HV transformer T1, Current Limiting Reactors L1, rectifier
bridge V1, HV choke L2 and the voltage divider R2 for the output voltage
measurement.

An enclosure fitted on the side of the tank is used as the Low Voltage Junction Box
(LVJB). The LVJB contains the measuring shunt R1 for the output current
measurement, and low voltage bushings together with terminals for all interconnection
and supply cabling.

Two different variants of the HV outlet are available. One on the tank side (hori-
zontally) and one on the tank lid (vertically). In both cases the bushing insulator is
normally covered by a protection bus duct, this provides protection during transporta-
tion and also serves as a suitable connection to the precipitator bus duct.

For actual design and size, see the specific contract documentation!

A TR-unit with horizontal HV outlet is shown in figure 1 and consists of the following
main parts:

E= LV junction box
F= Cooling fins
G= Monitoring device
H= HV bushing insulator
I= Protection bus duct
K= Grounding switch

The block schematic diagram (figure 2) shows the main components and each of them
is described separately below.

109.077 GB FLS RevA.doc Page 6(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

HV TRANSFORMER T1

The high voltage (HV) transformer is a three-phase core type transformer with the
windings (D/Y) vertically mounted on the three core leg. The HV windings are of a
special design to secure a proper distribution of the surge voltages, occurring at flash
over in the precipitator.

CURRENT LIMITING REACTORS (CLR) L1

On the primary side of the HV transformer are primary chokes or Current Limiting
Reactors CLR as current limitation. They are normally designed for a total short circuit
voltage of 30%, and limit the current at short circuit and flash-over in the precipitator.
The iron-cored chokes can alternatively be of three separate winded chokes or in some
cases a single three-phase choke.

RECTIFIER BRIDGE V1

The three-phase full wave rectifier bridge is made up of a large number of avalanche
rectifier diodes, mounted on six printed circuit boards. A capacitor is connected in
parallel with each diode, to ensure proper voltage distribution within a wide frequency
range.

HV CHOKE L2

The choke attenuates surge voltages and currents occurring at flash overs in the
precipitator, especially at high frequencies.

VOLTAGE DIVIDER R2

The voltage divider that senses the output voltage, consists of resistors and capacitors
mounted on a printed circuit board. The equivalent total impedance is like a resistor
and a capacitor connected in parallel. This gives a frequency compensated voltage
divider suitable for the control electronics and instruments. Together with the lower
part of the voltage divider the signal level will be 10 V DC at nominal DC-voltage.

MEASURING SHUNT R1

The shunt detects the precipitator current to suit the control electronics and the mA-
meter. Signal level is 1.0 V DC at nominal DC-current.

109.077 GB FLS RevA.doc Page 7(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

MONITORING DEVICE

All monitoring detectors of the TR-unit are placed in a common housing on the tank
lid. Refer to item G, figure 1. Two fixed thermostats are together with the level switch
combined to a common device, sensing both the top oil temperature and the oil level.
The temperature alarm levels are 80°C (B1.4) and 90°C (B1.2).
The gas monitor consists of above mentioned oil level switch (B1.3) and a pressure
switch (B1.1). The level switch indicates small amounts of gas or air and acts as a
combined gas and level detector, which gives an alarm. The pressure switch detects the
pressure in the tank and trips the rectifier, if the factory pre-set value of 30-50 kPa is
exceeded. An additional safety valve is released at 60-80 kPa.

If air or gas has entered, the device has to be restored, the procedure is as follows:

If an overpressure exists in the tank, open the air bleeder until the oil flows through the
bleeder. Then close the bleeder again.

If an underpressure exists in the tank, open the air bleeder and more air will enter the
tank and the oil level will fall even lower.
Remove the oil filling plug and add transformer oil until completely filled. Close the
air bleeder and replace the oil filling plug. Make sure that they are tightened
sufficiently to avoid air ingress when underpressure occurs.
Fit a 5-10 mm diameter hose, preferably transparent, to the drain valve and put the free
end into a small container and sample the oil to be drained. Locate the hose opening at
a level about mid of the height of the tank and open the drain valve. When the oil
draining stops, the zero pressure level is established at the same level as the hose
opening and the drain valve shall be closed. The above mentioned pressure level is
only valid at an oil temperature of 20°C. For other temperatures the level has to be
adjusted about 100 mm per 10°C of the difference. For temperatures above 20° C, the
level shall be adjusted higher and for temperatures below it shall be adjusted lower.

109.077 GB FLS RevA.doc Page 8(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

Figure 1. Transformer/rectifier unit (TR-unit)

109.077 GB FLS RevA.doc Page 9(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

Figure 2. Block schematic diagram TR-unit

109.077 GB FLS RevA.doc Page 10(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

3.0 INSTALLATION

3.1 Placing

The TR-unit is preferably placed on rails with blocking facilities, ensuring a minor
movement in all directions. When several TR-units are placed close to each other, the
minimum distance between the units, in any direction, must be 0.5 m. If the units are
placed under environmental conditions, causing a drop in the cooling efficiency, the
coolers must be cleaned more frequently. Also refer to Clause 5.

3.2 Electrical connections and grounding

Cable entry into the LV junction box, is from below. The power line is directly
connected to the LV bushings.

NOTE! When tightening, use counterforce to ensure that the bushing bolt is
not moved. This to minimise the risks for bad connections inside the
tank and oil leakage as well.

Flash-overs in the precipitator are generating surge currents and voltages in the system.
To avoid surges between different units in the system (may be kV), it is very important
that the ground wiring is made up according to figure 3.

The main ground terminal of the TR-unit is the positive DC-connection of the rectifier
as well. The main ground terminal is located on the LV junction box and has to be con-
nected to the precipitator ground terminal via the tank ground terminal. A grounding
link has to be made over every HV bus duct joint between the rectifier and the
precipitator. Before commissioning, make a special check on every ground connection.

When a safety switch is installed for disconnecting the primary side of the TR-unit
during maintenance work, the auxiliary contact of this switch preferably has to
interlock the main contactor. For complete information, refer to the specific contract
documentation.

109.077 GB FLS RevA.doc Page 11(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

Figure 3. Ground connection

109.077 GB FLS RevA.doc Page 12(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

4.0 OPERATION

4.1 Commissioning

Generally, check the following:

- No transport damages have occurred.

- No loose components or connections have occurred during transportation.
- The cabling is made up according to contract documentation
and according to mandatory requirements of the authorities
if applicable.

PLEASE OBSERVE THAT WRONG CONNECTION MAY CAUSE SERIOUS

DAMAGES ON THE EQUIPMENT, WITH A LOT OF COSTS INVOLVED,
NOT COVERED BY THE WARRANTY. WHEN IN DOUBT, DO NOT
HESITATE TO CONTACT THE MANUFACTURER!

Check in the TR-unit that

- No oil leaks are visible.

- The grounding is made up according to clause 3.2.
- The ground connection to the measuring shunt R1 is intact.
- The HV bus duct is connected to ground.

START UP

Please refer to the separate detailed controller manual!

4.2 Functional check

WARNING! AVOID CONTACT WITH LIVE PARTS AT ALL TIME! WHEN

WORKING WITH THE EQUIPMENT, SWITCH OFF THE MAIN SWITCH
AND CONNECT THE HV OUTPUT TO GROUND, IF APPLICABLE!

In connection with the commissioning, it is advisable to check functions important for

the operation and for security reasons.

109.077 GB FLS RevA.doc Page 13(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

ALARMS

Simulate faults according to the different procedures below to check the cable
installation. Check that alarm is indicated on the control panel, as well as in the
management computer system, if applicable. Also refer to the contract documentation
to avoid incorrect steps.

1. Gas/level alarm

Disconnect one of the connections on the level indicator B1.3, located in

the monitoring device. Check that alarm indication is obtained. Restore the
level indicator.

2. Over-pressure alarm

Disconnect one of the connections on the pressure switch B1.1, located in

the monitoring device. Check that alarm indication is obtained. Restore the
pressure switch.

3. High temperature alarm

Disconnect one of the connections on the thermostat B1.2 (90°C, NC),

located in the monitoring device. Check that alarm indication is obtained.
Restore the thermostat.
If the thermostat B1.4 (80°C, NO) is connected according to the circuit
diagram in the contract documentation, it can be tested with a short circuit
link across it.

4. Grounding switch alarm

Turn the grounding switch handle until the auxiliary switch is activated.
Check that alarm indication is obtained. Restore the grounding switch.

4.3 Adjustments

All parameters and presettings are made in the control equipment. The maximum
precipitator current limit setting must be below or equal to the secondary current stated
on the rating plate.

109.077 GB FLS RevA.doc Page 14(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

5.0 MAINTENANCE

5.1 Preventive maintenance

WARNING! BEFORE STARTING ANY MAINTENANCE ON THE

EQUIPMENT, MAKE SURE THAT NO LIVE PARTS ARE ACCESSIBLE BY
ANY PERSONNEL!

GENERAL

This rectifier needs normally very little maintenance, but to ensure proper duty and to
minimise the total maintenance costs, it is advisable to carry out some activities. The
period of time between each maintenance depends on the environmental conditions
and duty. Accordingly, the time interval must be determined by operational
experience.

CLEANING

To minimise the risks for excess temperature in the TR-unit, clean the cooling
elements and the tank walls at necessary time intervals, minimum annually.

OIL TEST

To avoid damaged HV components, check the isolation condition of the oil every fifth
year. The oil samples must be taken at dry weather and in dry containers. A suitable
sample volume is about 200-300 millilitres, taken out at the bottom test/drain valve.
The samples may preferably be sent to a suitable laboratory to make analyses of
mainly the flash over limit, the isolation characteristics, the loss factor and the water
content. If the analyses shows that the oil does not meet the specification, or at least
very close to, it has to be exchanged or filtered. Water together with particles can be
removed in a paper filtering press. The filtering is preferably carried out during about
10 hours, with the rectifier in short circuit operation.

OIL LEAKAGE CHECK

Larger oil leaks are monitored by the oil level indicator which also indicates gas alarm.
Visual check is preferably carried out regularly.

If leaks occur in the bushing insulator during the first period of duty, the top nut has to
be re-tightened to the correct torque stated in the table below. Exchanging of the top O-
ring of the bushing insulators can be done without draining any oil. However, a small
amount of air will leak during the exchange. Proceed as follows:

109.077 GB FLS RevA.doc Page 15(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

1. Make sure that the power supply is switched OFF and locked before starting any
work on the unit.

2. Disconnect the wiring to the bushing.

3. Prepare tools and O-ring for a quick exchange. Preferably apply Permatex on the
O-ring tightening surfaces.

4. Loosen the fixing nut and washer on top of the bushing. Make sure that the bolt is
not turned.

5. Remove the top porcelain ring and the rubber O-ring. Make sure that the bolt is
always pulled towards you in order to minimise the leak of liquid.

6. Fit the new O-ring.

7. Fit the porcelain top ring, the washer and the nut. Before tightening, make sure that
the bolt is centred to the hole in the porcelain body.

8. Tighten with torque’s as follows:

Designation Bolt size Torque

Bushing X6 M12 10 Nm (7.35 lbfft)

Bushing X6 M20 20 Nm (14.7 lbfft)
Bushing X7 M8 5 Nm (3.70 lbfft)
Bushing X8 M12 10 Nm (7.35 lbfft)

9. After 48 hours, re-tighten with torque’s according to item 8 above.

10. If the distance between the porcelain, on both sides of the O-ring, after the final
tightening is less than about 1 mm, an additional plain rubber washer may pre-
ferably be placed on the top of the O-ring. This will equalise the difference in size
of the concave space for the O-ring and give better tightening.

11. Reconnect the wiring.

109.077 GB FLS RevA.doc Page 16(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

5.2 Storing instructions

Store the equipment preferably in a dry well ventilated space. If this type of area is not
available, make provisions for avoiding humidity to make any harm on the equipment.
This can be achieved e g by wrapping with waterproof paper with sufficient desiccant
inside. If to be stored in the transport packing, open the packing and check for tran-
sport damages, entered water or oil leaks. By approved checks, place some desiccant
inside and restore the package. The package must not be placed outdoors.

5.3 Trouble shooting

WARNING! TO AVOID PERSONNEL INJURY, DO NOT PERFORM ANY

SERVICING UNLESS YOU ARE QUALIFIED TO DO SO!

Methods for electrical trouble shooting, described in the following chapter, are based
on use of an ohmmeter with maximum 6 V measuring voltage and a multimeter with
input resistance of minimum 20000 ohm/volt DC and 1000 ohm/volt AC. Instruments
with other data are possible to use if the influences on measured values are calculated.

At any error indication in an ESP installation, the error must be localised to either the
rectifier or the precipitator with surrounding equipment. When an error is indicated to
be in the rectifier, start to carry out the open circuit and short circuit tests described
below. If both tests are approved, the rectifier is in all probability correct. If any of the
tests are not approved, proceed on suitable trouble shooting according to error
indication occurred.

OPEN CIRCUIT TEST

Procedure:

1. Switch off the rectifier.

2. Isolate the precipitator from the HV output. If an isolator is not available, a part of
the HV busbar has to be removed. Please note that ground connections are properly
made on both sides of the part to be removed. After the busbar removal, remove the
ground connection on the rectifier HV output.

3. Set the precipitator current limit to about 20 %.

109.077 GB FLS RevA.doc Page 17(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

4. Switch on the rectifier.

5. If the kV-meter shows more than 80 % of the rectifier nominal precipitator voltage,
the test is approved.

6. If the voltage is limited to a low value, proceed the trouble shooting in the
controlling and regulating circuits.

SHORT CIRCUIT TEST

1. Switch off the rectifier.

2. Connect the HV output to ground.

3. Set the precipitator current limit to about 20 %.

4. Switch on the rectifier.

5. Check that the current is increasing and is limited to a value corresponding to the
set current limit.

6. Increase the current limit setting to 100 %.

7. If the precipitator current increases up to rectifier nominal value, the test is

approved.

8. If the current is limited to a low value, proceed the trouble shooting in the
controlling and regulating circuits.

109.077 GB FLS RevA.doc Page 18(19)

 TECHNICAL DESCRIPTION TB-77-
ESP POWER SUPPLY 109.077 GB
3-phase TR-unit G-QE Rev. A

TEST ON HV TRANSFORMER AND RECTIFIER BRIDGE

1. Switch off the rectifier.

2. Disconnect the incoming power line on the three LV bushing insulators.

3. Isolate the precipitator from the HV output. Also refer to open circuit test procedure
above.

4. Connect a 3-phase variac in series with three A-meters (0-10 A) to the LV bushing
insulators for the power line connection.

5. Increase the variac voltage to about 90 % of nominal input line voltage. The output
voltage shall be minimum 70 % of nominal output voltage and primary currents
shall be low (<10A) and equal between the phases.

6. Low voltage as a result of item 5 may depend on interruption in HV transformer,

rectifier bridge or voltage divider for the kV-meter. Also the kV-meter itself may be
faulty.

7. If any A-meter reading are already maximum at a very low variac voltage, the
rectifier bridge is very likely to be short circuited. Also the HV transformer may be
faulty at the same indications but it is more unlikely.

As an alternative a 1-phase variac can be used together with an A-meter and be

connected in order of priority between the phases. The output voltage will now be
lower, but both the output voltage and the primary current shall be equal for the
different phase connections. If any primary current become high in one phase at low
input voltage, it is probably an internal short circuit in association to this phase.

109.077 GB FLS RevA.doc Page 19(19)