MODEL GGAj02(DJ-96)

MICROCOMPUTER CONTROLLED HIGH VOLTAGE

ENERGIZATION EQUIPMENT FOR ESP

OPERATION MANUAL

ZHEJIANG JIAHUAN ELECTRONIC CO.,LTD.

CHINA
GENERAL DESCRIPTION
Upgraded from Model GGAj02(DJ-1), GGAj02(DJ-96) microcomputer
controlled HV energization equipment is an advanced power supply which
has the following advantages:
q Using advanced 80C196KBH SCM and peripheral interface chips, it
has advantages of good performance, compact structure and reliable
operation.
q Detect flashover sensitively and accurately by analyzing the voltage
and current wave in electric field. When flashover occurs, it does not
need to block the thyristors, but with a small voltage drop then follows
a fast ramp voltage recovery, and hence maximum effective power can
be achieved.
q Various operation modes provided so as to meet the varied operating
conditions.
q Easy to control. Running or stopping, setting operation parameters,
parameter display and change of operation modes can be completed
simply through the keys on the control panel.
q Abundant displays of more than ten parameters or information.
q Setting parameters can be recalled after switching off the mains
without the needs of reset.
q Perfectly protective functions provided. Eleven kinds of trouble, such
as SEC.SHORT CIRCUIT, SEC.BREAK, SCR UNBLANCE, etc, can be
protected with corresponding alarms.
q Remote control can easily be realized by using communicating
interface RS485.

TECHNICAL SPECIFICATIONS
ENVIRONMENT

1. Operating temperature:
Control cabinet: 0~40℃.

1
 HV T/R set: less than 40℃ and not lower than the coagulation point
temp of transformer oil.
2. Operating relative humidity:
no greater than 90% (at temperature 20±5℃).
3. Without conductive particles and corrosive gas or steam in the vicinity of
the equipment.
4. Neither explosive dangers nor violent vibration around the control room
is permitted.
5. Power source:
Rated voltage: 380 V (361~399V) A.C.
Frequency: 50Hz(49~51Hz)
Waveform: Sine wave
Instantaneous voltage fluctuation: not exceed±10%.
6. ESP grounding resistance is less than 2Ω,and it could be grounded
independently, and will not share with other grounding networks.

MEANINGS OF THE MODEL

G G Aj 02 (DJ-96) □/□-□
Operating environment
Rated sec. voltage (kV)(mean value)
Rated sec. current (A)(mean value)
Product designation
Design serial number
Oil-immersed spontaneous cooling mode
For high voltage rectification
Semiconductor material - silicon

Operating Environment:
HW — for outdoor use HN —for indoor use.
Both output D.C. voltage and current values are average.

2
PRIM. & SEC. PARAMETERS

Prim/Sec Parameters of DJ Series

Microcomputer Controlled HV Power Supply for ESP

Prim. Prim. Sec. Sec. Sec. Prim .

No. Capacity Voltage Current Voltage Current Power Power
AC (V) AC (A) DC (kV) DC (A) DC (kW) AC (kV A)
1 0.2A/(60-72) kV 380 45/54 60/72 0.2 12/14 18/20

2 0.4A/(60-72) kV 380 90/108 60/72 0.4 24/29 34/41

3 0.6A/(60-72) kV 380 135/162 60/72 0.6 36/43 51/62

4 0.8A/(60-72) kV 380 180/216 60/72 0.8 48/58 68/82

5 1.0A/(60-72) kV 380 225/270 60/72 1.0 60/72 86/103

6 1.2A/(60-72) kV 380 270/325 60/72 1.2 72/86 103/123

7 1.4A/(60-72) kV 380 316/379 60/72 1.4 84/101 120/144

8 1.6A/(60-72) kV 380 360/433 60/72 1.6 96/115 137/165

9 1.8A/(60-72) kV 380 405/486 60/72 1.8 108/140 154/185

10 2.0A/(60-72) kV 380 450/540 60/72 2.0 120/144 172/206

OPERATION MODES

Six operation modes are provided.

q Optimum working point detection (Mode A)
q Intermittent energization (Mode B)
q Simple pulse energization (Mode C)
q Spark rate setting (Mode D)
q Common spark tracking (Mode E)
q Spark rate auto-control (Mode F)

3
PARAMETERS DISPLAY

q SCR conduction angle

q Primary voltage running value
q Primary current running value
q Secondary voltage running and setting value
q Secondary current running and setting value
q T/R oil temperature
q Spark rate running and setting value
q SCR off intervals
q Amplitude ratio
q Duty ratio
q Time
q Unit address
q Auxiliary parameter

PROTECTION AND ALARM FUNCTIONS

q Secondary break protection

q Secondary short-circuit protection
q SCR unbalance protection
q Secondary under-voltage protection
q Primary over-current protection
q Primary break protection
q T/R critical temperature alarm
q T/R high temperature protection
q T/R slight gas alarm
q T/R serious gas protection
q T/R low oil level protection

INSTALLATION
4
UNPACKING
q After unpacking, examine the assembly accessories, spare parts and
technical documents of the equipment as a complete set.
q Check the intactness of meters, tightness of fasteners and firmness of
accessories in the control cabinet after transportation. If abnormalities
occur, please deal with them at once. If you cannot handle a problem,
contact us at (86) 579–2337406.
q Examine whether the oil tank, conservator, porcelain insulator of the
HV T/R set is free from damage and oil leakage.

INSTALLATION

q The control cabinet should be installed horizontally. We suggest it

should be installed on a pair of channel steel, welding fixed, so as to fix
and ground it reliably.
q The T/R set could be installed on a pair of rail or channel steel. For
outdoor location, we suggest that a simple roof be covered above it.
q Connect wires according to the drawings. Wires of suitable cross
section with corresponding rated current should be selected between
power input wires and control cabinet. Wires should not be too short to
change transformer LV taps, for too thick wires, we suggest you adapt
fastening measures to prevent porcelain insulators damaged.
q Shielded wires should be used as secondary voltage, secondary
current and oil temp sampling wires, and connect wires according to
wire number.
q Oil level on the conservator should be equivalent with corresponding
temperature scale, or it will cause abnormal phenomenon such as oil
level too high or too low.
q When installing a breather, take off the bottom cover firstly, fill oil to
half level of the breather so as to insulate the gas inside and outside,
and screw it tightly.
q Examine if there is gas in the gas relay, or let gas out firstly.

q Damping resistor should be erected on the wall bushing, and building

on HV porcelain insulator should be avoided as possible as you can,

5
 and erection should be done tightly and reliably.
q ESP should reliably connect to ground with resistance less than 2Ω.
The shells of T/R set and control cabinet should be grounded reliably
also .All their grounds should be connected together.
q T/R should be grounded reliably, connection between grounding point
at the underside of oil tank and earth screen should adapt naked
copper braided wires with cross section no less than 25mm2 or
galvanized flat iron of 3mm×30mm; “+” terminal on the transformer
tank should be connected with ESP earth screen solely, and the
grounding point could not be used for other purpose, grounding wire
uses leads of no less than 16 mm2, if you find loose, corrosive, break or
other problems, please take remedial measures, meanwhile the “+”
terminal should also be connected with control cabinet. Resistance
between transformer shell and positive pole should be less than 2Ω
q All connected wires must be perfectly correct and reliable by meter
measurements.

6
ADJUSTMENTS
After installation, adjust the equipment as following steps:
1. Check all connected wires with a multi-meter to assure them tally with
the wiring drawing.
2. Turn the main-circuit switch off, power the control cabinet. First turn the
switch QS2 on, then put door lock-switch SA1 on. The control power
should be normal.
3. In order to check the trigger circuit of SCR, press the RUN/STOP key to
start the control cabinet. The LED lights on the interface board should
light up at the same time. After about fifteen seconds, PRIM. BREAK
alarm is to be given.
4. Make sure no person is in the ESP and around the T/R set, let the T/R
energize the bus section of ESP.
5. Turn the main circuit-switch QS1 on, then press the RUN/STOP key to
start the HV energization equipment. AC voltmeter, AC ammeter, DC
kV-meter, DC mA-meter indicate output.
6. Calibrate DC kV-meter and DC mA-meter, if required, through adjusting
potentiometers R20 and R17 on the interface board respectively with
standard meters.
7. As for digit display calibration on the controller, see Figure (6).
8.Select proper input joints for HV silicon rectifier when equipment works
normally, so that the sec voltage is able to match field load perfectly and to
save energy. For HV silicon rectifier with rating 72kV, switch to 60kV when
operating voltage is less than 60kV; and when operating voltage is
between 60kV and 66kV, switch to 66kV; and when operating voltage is
greater than 66 kV, switch to 72kV.

OPERATION
RUN

1. Turn the main switch QS1(QF1) off.

2. Turn the control power switch QS2 and the door-lock-switch on.
3. Press the RESET key on the control panel. All eight digital code tubes in
the right display H.

7
4. Turn on the main-circuit-switch QS1(QF1).
5. Press the RUN/STOP key on the control panel.
Note: For more information, see Model DJ-96 Controller Operation
Instructions.

STOP

1. Press the RUN/STOP key (or RESET key) on the control panel.
2. Turn the main switch QS1 off.

MAINTENANCE
CONTROL CABINET

q Sweep the floor everyday and keep the room clean.

q Close the control cabinet doors to keep sealing and assure the cooling
fans to run normally.
q Sweep the control cabinet periodically by dry and compressed air and
keep the cabinet inside clean. And sweep the controller periodically
with a brush when dust is heavily covered.

HV T/R SET

q Person on duty should periodically make an inspection tour of HV T/R

set when running. These examinations include:
1. Watch the meter indications, load variations, temperature rise and
electromagnetic sound of T/R set.
2. At regular intervals, verify that oil level, accessories and desiccator of
T/R sets are normal and that there is no oil leakage.
q Clean the porcelain bushings and T/R itself periodically with a soft
cloth. Keep T/R as clean as possible.
q Sample T/R oil and perform insulate pressure test (higher than 45kV)
every half a year (maximum interval not longer than one year), verify

8
 that humidity of T/R oil is within permissible range.
q T/R core out-hanging examination should be done every five years,
precautions include:

1. Select a fine day (relative humidity no higher than 75%) and a clean
place without flue gas and dust, examination time as short as possible,
so as to protect T/R and its oil from moisture and pollution.

2. When lifting, a commander and tank corner inspectors are needed to

prevent T/R core, windings and insulating parts from colliding with oil
tank.
3. When lifting an outdoor T/R-set, take care of that the negative HV
copper bar is just pressed into the clip.

9
MODEL DJ-96
CONTROLLER OPERATION INSTRUCTIONS
The model DJ-96 controller display, indicator lights and keyboard are
shown as follows:

RUN REMOTE STOP

COND.A U1 I1 U2 I2
SET RESET
0 1 2 3 4

T/R T SPAR.R SCR OFF AMPL.R DUTY R TIME RUN

5 6 7 8 9 A STOP

ADDR Fn KEEP DECR INCR LOCAL

MODE
B C D E F REMOTE

LED DISPLAY

The display consists of 9 digital code tubes, the first one on the left
displaying operation mode, and the other 8 tubes displaying running
parameters and status information.

INDICATOR LIGHTS

Three indicators are availble for Run, Remote control and Stop
respectively.

10
RUNNING INDICATOR

This indicator lights on when the equipment is running, otherwise lights

off.

STOPPING INDICATOR

This indicator lights on when equipment stops, otherwise lights off.

REMOTE CONTROL INDICATOR

This indicator lights on when the equipment is controlled by a remote

computer, otherwise lights off.

CONTROL PANEL KEYS

21 keys on the control panel keys are avaible with functions as following .
q This key is used to reset the equipment.
RESET
q When this key is pressed while running, the equipment is at
stop status.
q When this key is pressed while alarming, the alarm signal is
removed.

RUN q When this key is pressed while stopping, start the

STOP q equipment.
When this key is pressed while running, stop the equipment.

LOCAL q When this key is pressed while being at local control state,
REMOTE the equipment is controlled by a remote computer.
q When this key is pressed while being at remote control state,
the equipment is at local control state and can’t be controlled
by a remote computer.

q Used to modify setting parameters.

SET

11
 q Used to change operating modes.
MODE

COND.A q Used to select conduction angle displaying.

0 q Used to input digit 0.

U1 q Used to select primary voltage displaying

1 q Used to input digit 1.

I1 q Used to select primary current displaying.

2 q Used to input digit 2.

U2 q Used to select secondary voltage displaying.

3 q Used to input digit 3.

I2 q Used to select secondary current displaying.

4 q Used to input digit 4.

T/R T q Used to select T/R oil temperature displaying.

5 q Used to input digit 5.

SPAR.R q Used to select spark ratio displaying.

6 q Used to input digit 6.

SCR OFF q Used to select SCR off number of half waves after a spark.
7 q Used to input digit 7.

AMPL.R q Used to select amplitude ratio of low half wave to high half
8 wave.
q Used to input digit 8.

DUTY R q Used to select duty ratio.

9 q Used to input digit 9.

TIME q Used to select time displaying.

A q Used to input alphabet A.

12
ADDR q Used to give device address.
B q Used to input alphabet B.

Fn q Used to select auxiliary parameter.

C q Used to input alphabet C.

KEEP q When this key is pressed while running, output keep

D unchanging.
q Used to input alphabet D.

DECR q When this key is pressed while running, the equipment

E output decreases.
q Used to input alphabet E.

INCR q When this key is pressed while running, cancel KEEP or

F DECR command.
q Used to input alphabet F.

13
DISPLAY PRESENT VALUES AND SETTINGS
Present values and settings are displayed on the 8 digital code tubes of
the right side with format as following:

Press Display

COND.A
0
SCR conduction angle ( ° )
Key name

U1
1
Power voltage (V)
Key name
Primary voltage (V)

I1
2
Over-current limit (A)
Key name
Primary current (A)

U2
3
Secondary voltage setting (kV)
Key name
Operating sec. voltage (kV)

I2 When rated sec. current＜1A

4
Secondary current setting (mA)
Key name Operating sec. current (mA)

When rated sec. current≥1A

Secondary current setting (mA)

Operating sec. current (mA)

14
 T/R T
5
High oil temperature (℃)
Key name
T/R oil temperature (℃)

SPAR.R
6
Spark rate setting (min-1)
Key name Present spark count

SCR OFF
7 SCR off number
Key name

AMPL.R
8 Amplitude ratio setting
Key name

DUTY R
9
Disenergized half-wave count
Key name
Energized half-wave count

TIME
A
Minutes
Key name Hours

ADDR
B
Device address
Key name

15
 Fn
C
Auxiliary parameter
Key name

PARAMETERS SETTING

1. Press the key of parameter selection.

2. Press the SET key.
3. Input the value required.
4. Press the SET key again.

For example, set secondary voltage to 65kV.

Operating order is as follows:

U2 SPAR.R T/R T
SET SET
3 6 5

Note: The parameter settings can be recalled after turn the mains off
when it was set at stopping state, but can’t be recalled at
running state.

ADDR SETTING

ADDR setting steps include:

1. Press the ADDR, SET, C, 5, and SET keys in sequence.

2. Press the SET key again.
3. Input the digits required.

4. Press the SET key once again.

16
 For example: set address to 09.
Operating order is as follows:

ADDR Fn T/R T COND.A DUTY R

SET SET SET SET
B C 5 0 9

Note: ADDR is the address No. to communicate with a host computer,

don’t wantonly modify it. When required, modify it at stopping
state.

OPERATION MODE SETTING

Operation mode setting steps include:

1. Press the MODE key.

3. Input the required operation mode.

4. Press the MODE key again.

17
 For example, set the operation mode to Mode A.

Operation steps are as follows

TIME
MODE MODE
A

Note: The operation mode setting can be recalled after turn the mains
off, but can’t otherwise.

CLEAR THE SETTINGS

Clear abnormally displayed parameter settings according to the following

steps:
Fn COND.A COND.A
SET SET
C 0 0

TROUBLE SHOOTING

POWER SUPPLY

If all digital code tubes and indicator lights go out, carry out the following
procedure:

1. Check the input power.

2. Check the control power switch QS2(QF2)。

3. Check the button with a key on control cabinet.

4. Check the fuse on controller.

18
TROUBLE CODES
The controller carries out trouble protection and displays trouble codes.

No Code Description
1
Prim. Over-current

2 Sec. Short circuit

3 Sec. break

4 Sec. Under-voltage

5 Prim. break

6 SCR unbalance

7 T/R critical temp.

8 T/R high temp.

9 Slight gas

10 Serious gas

11 Low oil

19
SOLVING PROBLEMS

If there is a malfunction, find out the probable causes according to

prompts

SEC. BREAK

Check secondary break circuit according to figure 1.

SEC. SHORT CIRCUIT

Check secondary short circuit according to figure 2.

SCR UNBALANCE

Check SCR unbalance according to figure 4.

SEC. UNDER VOLTAGE

Check secondary under voltage according to figure 3.

PRIM. OVER CURRENT

q Verify that digital displaying is consistent with AC Ammeter. If there is

difference between them, adjust primary current potentiometer.

q If the problem persists, then contact our Marketing Department. (Tel:

86 579-2339437,2339388)

PRIM. BREAK

Check primary break according to figure 5.

T/R CRITICAL TEMPERATURE

q Check the correctness of oil temperature displaying.

20
 q T/R temperature rise lower than 40K is normal.

q If T/R temperature rise is higher than 40K,

T/R HIGH TEMPERATURE

q Check the correctness of oil temperature display; if not, examine the

temperature sensor.
q If T/R temperature rise is close to 40K, suitably decrease output.

q If T/R temperature rise is bigger than 40K, find the cause or contact
our Marketing Department.

SLIGHT GAS
q Check short circuit between signal wires 411 and 413.
q Find out the cause of the trouble and remove it.

SERIOUS GAS

q Check short circuit between signal wires 411 and 412.

q If the problem persists, contact our Marketing Department.

LOW OIL

q Check short circuit between signal wires 411 and 413.

q If low oil level occurs, suitably refill T/R oil (the oil to be refilled must
be the same as original with breakdown voltage higher than 45kV).

ASSEMBLY
1. One HV control cabinet (provided with Model DJ-96 controller.)

2. One HV T/R set.

3. One HV damp resistor (two resistors for indoor type).

21
 4. Operation manual, 1 copy.

5. Conformity certificate, 1 copy.

6. Accessories: two fuse-links of main circuit, two fuse-links of control

circuit.

22
APPENDIXES

1 Fig.1 Check flow chart for SEC. BREAK.

2 Fig.2 Check flow chart for SEC. SHORT CIRCUIT.

3 Fig.3 Check flow chart for SEC. UNDER VOLTAGE.

4 Fig.4 Check flow chart for SCR UNBALANCE.

5 Fig.5 Check flow chart for PRIM. BREAK.

6 Fig.6 Adjustable illustration of circuit board inside Model DJ-96 controller

7 Interface trigger circuit board layout

8 Main circuit board layout in the DJ-96 controller

9 Circuit Diagram for GGAj02(Dj-96) series micro-computer controlled HV

Energization equipment for ESP

10 HV control cabinet external view for model GGAj02(Dj-96)□/□-S

11 HV control cabinet external view for model GGAj02(Dj-96)□/□-X

12 HV energization equipment wiring diagram for model DJ-96

13 HV T/R set external view for Model GGAj02(0.2-0.4)A/(60-72)kV-HN

14 HV T/R set external view for Model GGAj02(0.4-2.0)A/(60-72)kV-HN

15 HV T/R set external view for Model GGAj02(0.2-0.4)A/(60-72)kV-HW

16 HV T/R set external view for Model GGAj02(0.4-2.0)A/(60-72)kV-HW

17 Model DJAj02 (DJ-96) HV energization equipment circuit diagram for ESP

(vacuum contactor)

18 Model DJAj02 (DJ-96) HV energization equipment circuit diagram for ESP

(breaker)

23
 Check the sec. current sampling wire
whether open circuit or short circuit to
ground

No
Is it normal? Replace sampling wire

Yes

Check damp resistor

Yes
Is it open circuit? Replace damp resistor

No

Check HV disconnecting switch

Is the switch at No
Turn the switch on
ON status?
Yes

Check HV cable leading to bus section

Fig.1 Check flow-chart for SEC. BREAK

24
Examine secondary voltage
sampling wire

Is it short circuit Yes

to ground? Replace sampling wire

No

Check HV isolation switch

Is the switch at Yes

Turn the switch on
ground position?

No

Short circuit within

electric field

Fig.2 Check flow-chart for SEC. SHORT-CIRCUIT

25
 Press the RESET key and
restart the equipment

Yes
Does it run normally? Normal operation

No

Check ESP

Fig.3 Check flow-chart for SEC. UNDER-VOLTAGE

26
 Check operating status of V4
and V7 on interface board

When stop V4 and V7 go out

When running, V4 and V7 light

No Check triodes V6 and V9 on

Normal ?
interface board
Yes

Check the pulse transformers on

trigger board whether input & Yes Normal ?
output is open circuit or not

No

Yes
Normal ? Replace triodes

No

Contact Our Technical Support

Replace or repair trigger board
Department

Fig.4 Check flow-chart for SCR. UNBALANCE

27
28
 Verify that V4 and V7
light when running

Check DC voltage between

No
Is it normal? terminals 12 and 4 on interface
board XT3 with a multi-meter
Yes

Verify that mains safety Is the voltage No

breaker is at ON status equal to +22V?

Yes

Is it at ON No
Check connected cable
position?

Yes

Check fuses
in main circuit Turn the breaker on

No
Are they good? Replace fuses

Yes

Check SCR and

trigging signal Check fuse on interface board

Fig.5 Check flowchart for PRIM.BREAK

29
 RX8

80C196

RX8 is used to adjust secondary current

range. When adjusting, press the RESET key
to verify that secondary current display agrees
with required range.

RX1 is used to calibrate RX4 is used to calibrate RX7 is used to calibrate T/R
secondary current display. primary current display. oil temperature display.

RX2 RX1 RX3 RX4 RX7

RX6

RX2 is used to calibrate RX3 is used to calibrate

secondary voltage display. primary voltage display.

Fig.6 Adjustable illustration of circuit board inside Model DJ-96 controller

30