Automatic Load Bank Controller
Contents
1. AD INTELLIGENT LOAD BANKS Automatic Load Bank Controller TEE THERMAL ELECTRIC ELEMENTS AUSTRAUA THE SPECIALISTS IN CUSTOM HEATING Table of Contents Automatic Load Bank Controller A EPEN EE PER E E E Operational PERENNEM EI MUEVE EN MN PN Oe Bank Exerci eos eto tier END UF DAHIN IURE Ida Ri ERR C PR ERU RR vicc M eee ee enn eee ee ee Ae eee ene ee dais nee is one eee eee T TFT BLESENSIS ooa a apes ee ec wr hh eng aca aM MM REM EMI MI MEE P PIENE lys EET RR DONNERA Long E P Memory Stick Logging ROSE aE EEA AE teenie Loadbank Setup Page 1 12 Loadbank setup Page 2 Bookmark not defined 2 Loadbank Setup NI IT TTE Loadbank Setup Page 4 Bookmark not defined 4 Eere UT Load Bank BEIM eei pit pee Automotie KOCE NR TT T TT RU Manual2. NT oup UM AREAN PAI N MU HERI AEN TE AAE NAA Pub AI dii RE ER T Measured VOR EE Miscellaneous Measurements etes Trengs FARE en ee EAE ee ee di MR TNT OR RIO rr rt REA GU ORBE iu i Logging with Vijeo Data Manager 000000000000000000000000000000000000000000000000000090000900 25 AOGITAOUS SETUD Lu e nol REM EDO PEU CN Automatic Load Bank Controller Description The TEE Automatic Load Bank Controller Controller is a fully featured and programmable load bank controller that monitors and controls the electrical load of any generator in conjunction with Resistive Load Banks to ensure the minimum load requirements of the generator are maintained as set by the manufacture to prevent possible mechanical damage and load testing of generator sets Through accurate measurement of the generator load the Controller algorithms will call for load steps to be switched in or out from a Load Bank The Controller also set to run in a load bank exercising mode for maintenance or testing purposes A menu driven operator panel HMI allows easy access to set parameters and utilise the features of the Controller as required for the generator used its minimum load setting the load bank and step sizes For Example 1000kW
3. 24 2013 kW Engaged 52556 j 50 00 150 00 50 0 10 28 33 10 29 16 10 30 01 AM 10 30 49 10 31 36 10 32 20 10 33 03 10 33 54 10 34 43 10 35 34 10 36 21 AM 10 37 05 AM 10 37 55 10 38 44 10 39 33 10 40 21 10 41 05 10 41 55 10 42 38 HH HH HH BH HB HH HH In the example above the data in column A was changed to time so as to get the best increments for the data chart There are many options available in Excel to produce data in useable formats BE IEE 8 THERMAL ELECTRIC ELEMENTS AUSTRALIA THE SPECIALISTS IN CUSTOM HEATING
4. Format ES V TXT Field Delimiter Bergomi E E Create Multiple CSV Files Far files that exceed row limit Delete Files on Target after retrieval Logging Recorded viden _ Alarm Captured Images Recipe File Options Convert Recipe files ACF after retrieval Convert ta simplified Format Convert Eo common recipe Convert to full format Keep retrieved Recipe files REP after conversion Data conversion status Finished processing files Source file Status D SPLIBLIC amp PROJECTSSHMISST Success Launch Explorer Input folder DE SPUIBLICAPR DJECTSAHMISSTADATA Output Folder EAD ata Lag Select Convert and you should see a successful data conversion to a text file which will be located in your Output Folder created earlier Formulas Data Review View 8 E Connections AJ Y Properties From Other Existing Refresh __ 4 Sort Filter ext Sources Connections Edit Links Get External Data Connections Sort amp Fil 1 Get External Data From Text Import data from a text file Press F1 for more help ee __ l a _ 2 idi Datalog LOG SOM MYCONTROLLER APPLICATION HMI INTERFACE HMIREQ LOAD v 4 Search SOM MYCONTROLLE gt o A U E ee Organize New folder e xj ft Excel Nam
5. if the Load needs to increase from 100kW to 102kW It can be seen below that there will be four steps kW Values gt 100 100 5 101 101 5 102 1 Step Delay be adjusted to allow a time delay between each increment A Step Delay is available for Stepping Up and Stepping Down The Step delay is the time between each step in seconds Temperature Alarm A Temperature probe can be added to the system to allow a Temperature Alarm to be set A Temperature switch can also be added This monitors the resistors and can be used to trip the Load Bank if the Temperature goes over the desired temperature Flow Alarm A Flow Switch can be added to the system which can be used to trip the Load Bank if there is no flow over the resistors Data Logging The Measured Kilowatts from the Power Meter and the Load that is stepped in via the controller are logged and stored Wiring Inputs Outputs inputs Description 0 Digital Inputs Automatic Mode N C Auto 7 Analogue Module TM2ALM3LT Temperature 1 Thermocouple Type K Temperature 2 Thermocouple Type K Outputs 2 Digital Outputs ___ Out 8 Load Bank Setup Initial Power Up On initial power up the following screen will prompt for the date The date is required to be set if data logging is required during the operation such as generating a report for generator exercising The current date can be se
6. wish to retain Date and Time including minutes and seconds In the example here we needed to add s to get the seconds to display p 1 Timestamp Data Quality 2 24 10 2013 10 28 33 1 5 3 24 10 2013 10 28 35 3 5 4 24 10 2013 10 28 36 5 5 24 10 2013 10 28 38 6 5 6 7 8 24 10 2013 10 28 40 8 5 24 10 2013 10 28 42 11 24 10 2013 10 28 44 13 9 24 10 2013 10 28 46 15 10 24 10 2013 10 28 48 16 5 11 24 10 2013 10 28 49 18 12 24 10 2013 10 28 51 19 5 13 24 10 2013 10 28 52 21 14 24 10 2013 10 28 54 22 5 15 24 10 2013 10 28 55 24 16 24 10 2013 10 28 57 25 5 17 24 10 2013 10 28 58 27 18 24 10 2013 10 29 0 29 19 24 10 2013 10 29 2 31 20 24 10 2013 10 29 4 32 5 21 24 10 2013 10 29 65 34 5 22 24 10 2013 10 29 13 36 5 23 24 10 2013 10 29 15 38 5 24 24 10 2013 10 29 16 40 25 24 10 2013 10 29 18 41 5 e e BP EF BF ee This view shows the date and time including hours minutes and seconds A B C D E mum uH K L M Timestamp Data Quality 10 28 33 AM 1 5 10 28 35 AM 3 5 10 28 35 5 10 28 38 6 5 10 28 40 8 5 10 28 42 11 10 28 44 AM 13 10 28 45 15 10 28 48 16 5 10 28 49 18 10 28 51 19 5 10 28 52 AM 21 10 28 54 AM 22 5 10 28 55 AM 24 10 28 57 AM 25 5 10 28 58 AM 27 10 29 00 AM 29 10 29 02 AM 31 10 29 04 AM 32 5 10 29 06 AM 34 5 10 29 13 AM 36 5 Load Bank Exercise Oct
7. Automatic Mode Load Dump The Load Bank has been placed in Load Dump Mode Temp Trip The temperature Sensor or Switch has tripped the Load Bank Flow Alarm The Flow Switch has operated and tripped the Load Bank o n Temp Alarm The temperature sensor has reached the warning level The user can also see that the Cooling Fan is either running or Not Running via the indicator on the Status Fan NOT Running e Fan On Fan Running Fan Remaining Running Remaining Time NOTE 1 There is also an output configured that can be used to Flash an external lamp to indicate that the Fan is still Running N OTE If Power is Switched off to the Load Bank Controller the Fan may be switched off too soon without allowing the resistors to cool down correctly This is not advisable The following pages show various readings from the installed Power Meter Measured Currents From the Menu Screen Page select Monitor Measured Voltages Select Next Miscellaneous Measurements The Trend Page indicates the Measured Load and the Engaged Load Fault Page Full access to this page is only accessible when logged in From the below page select Faults Li Exercise X Faults Close KW KW EL Measured Engaged Designed by Electronic Power Solutions Pty Ltd The Faults page is shown LU Fault L
8. Generator requires a minimum load of 3096 300kW If the measured load in the generator is only 200kW the Controller will automatically add an additional 100kW from the load bank by switching in the required combination of resistors If the load increases say to 250kW then the Controller will shed 5OkW Once the building load goes above the minimum load of the generator 300kW in this example no additional load is required from the load bank In this example the following resistors are used where the Load Bank is engineered to enable load to be added in 0 5kW steps A contactor will be used to bring in each resistor value The following are examples of different loads and the contactors being used Contactor no 12 11 10 9 8 7 6 5 4 3 2 1 5 20 50 150 200 300 Operational Features Automatic Mode When in Automatic Mode the Load Bank will respond to load changes automatically Manual Mode When in Manual Mode the operator can enter the required load or step up down manually Load Bank Exercising This feature allows an operator to put the Load Bank Controller into Exercise Mode The operator can then select what maximum load to put onto the generator how long to run the exercising what step increases the generator will make and how long the load will stay on each step Step Delay A step is classed as the Load Bank switching from one value to the next up or down For example
9. SS dE Cycle Time n As Remaining Time BEEN min Steps 1 Step Time NEN Sec This screen shall only be configured if Load Bank Exercising is being used Test Load This is the maximum load the Load Bank will bring on Cycle Time This is the time that the Load Bank exercising will run for Remaining Time The time remaining for the exercise mode No Of Steps This will be the number of steps that the load bank will bring in between zero load and Max Load Example If 300kW is selected as the Test Load and No Of Steps is 10 Then the Loadbank will pause for Step Time every 30kW 300kW 10 30 Step Time This is the time the Load Bank will pause on each step going up and down Engaged This shows how much load is currently online stepped in The Auto Exercise button will start or stop the Exercise Mode The Trend button will take the user to the Trends page where engaged load and measured load are being trended and stored NOTE Auto Exercise only works when not in Auto or Man Load Bank Operation To operate the Load Bank Controller in Automatic Mode or Manual Mode the following steps shall be followed TEE Controller AUST RAL UE HEATING PANTERAS Auto BB o f Load Han OFF iz c k uy ig i Vy AME Measured Engaged Designed by Electronic Power Solutions Pty Ltd Automatic Mode Select Auto Man
10. The following screen is displayed Mode Selection VE Auto a Enter Manual 22 0 com Load Here a OFF ie k uy ie c Em Measured Engaged Designed by Electronic Power Solutions Pty Ltd Select Auto Off to run in Auto Mode Auto Off will change to Auto On when in Automatic Mode The Load Bank Controller will now adjust the Load on the Generator Automatically by stepping in the applicable resistors from the Load Bank Manual Mode Select Man Off to run in Manual Mode Man Off will change to Man On when in Manual Mode operator now enter value straight into the screen to adjust the Load Bank Load Manually or the operator can step up or down in increments of the smallest resistor in the setup screens Monitoring From the controllers Main Screen the following information can be seen eae Ky a Measured The operator can monitor the Measured Loa of the supplied installation From the Main Screen from the Load Bank This is The operator can monitor the Engaged Load Engaged the total load stepped in by the Load Bank The Status EL UN of the Load Bank is displayed The following statuses are displayed depending on the status of the Load Bank OFF Load Bank is Off Manual Mode The Load Bank is operating in Manual Mode Exercise Mode The Load Bank is operating in Exercise Mode Auto Mode The Load Bank is operating in
11. d bank controller to be viewed in an Excel format for the purpose of reporting based on time stamping The Vijeo Designer Data Manager program must be loaded on to a suitable PC prior to beginning the data transfer The data file being used is a DAT file that will be located in the USB memory stick located in the HMI of the load bank controller Select the medium you want to work with Local Files m Create Delete Open the Vijeo Designer Data Manager program select Local Files as the media and click next run 3 87 0 Convert Recipe or Data Logging Files Edit Recipe Files Select Convert Recipe or Data Logging Files and click next 71 Recipes wi Data Logging Merge Data Logging into single Use date range From 24 10 2013 Ta 24 10 2013 Options Output folder Select the DATA folder of the memory stick files from the load bank controller as the Input Folder Recipes ub Data Logging Menge Data Logging inta sinale file Use date range From 24 10 2013 Gy To 24 10 2700 Options Input folder D APUBLIEXPRBJECTSSHMISSTSDATA Output Folder C Data Log Create a destination folder for your converted files E g C Data Log File Options Data Logging Options Overwrite exists Add Header Create Folder Convert time stamp to date string Build Tree
12. e Date modified Type Size E 01310240 24 10 2013 216 PM Microsoft Excel 25 KB X Favorites Desktop 8 Downloads Dropbox Recent Places Libraries ES Documents i Pictures Videos 4 Computer Local Disk C USB DISK D 7 E Tools gt m Click Open once you have located the file ae Import Wizard Step 1 of 3 The Text Wizard has determined that your data is Delimited If this is correct choose Next or choose the data type that best describes your data Choose the file type that best describes your data e Characters such as commas or tabs separate each field Fixed width Fields are aligned in columns with spaces between each field Start importatrow 1 origin Windows ANST Preview of file C Data LogiLOGl SOM MYCONTROLLER APPLICATION HMI INTER 1D1310240 csv imestamp Date Quality 24 10 13 10 28 33 1 500000 1 24 10 13 10 28 35 3 500000 1 4 10 13 10 8 3 5 000000 1 5 p4 10 13 10 28 38 6 500000 1 Follow the Text Import Wizard Text Import Wizard Step 2 of 3 Treat consecutive delimiters as one Text qualifier x Data preview Timestamp 4 10 13 10 28 33 1 500000 24 10 13 10 28 35 8 500000 24 10 13 10 28 36 6 000000 24 10 13 10 28 38 f amp 500000 Select in the Delimiters Text Import Wizard Step 3 of 3 This scre
13. eatures a sophisticated and intuitive human machine interface HMI with signaling LEDs a graphic display and contextual menu buttons for accessing the information required to operate the power meter and modify parameter settings The Navigation menu allows the user to display configure and reset parameters General Display The general display of the power meters is shown in the following picture Current Per Phase 4 999 2 000 Main title Configuration mode Cancellation Confirmation Up Down Values Parameters sub menu gl mg M o Enter the Configuration Mode The diagram below illustrates the various elements for operating the power meters or 8 Selection button to change or select parameter values Confirmation button Cancellation button To enter the configuration mode hold and tor 2 seconds Configuration Mode Menu Tree for 3200 Wie Ratio Nom D T Tariff WD Low 1 C Important parameters to setup Wire Type of wiring connection e g 3 3Ct Ratio The ratio of the Current Transformers Cts being used For further information on the PM3250 please see document PIVI3200 series Power Meters User Manual Communications setup for PIVI3250 to PLC PM3250 Address 2 Baudrate 19200 Parity EVEN Using Vijeo Designer Data Manager The following procedure allows for the data logged from the loa
14. en lets you select each column and set the Data Format Column data format General converts numeric values to numbers date values to dates and all remaining values to text pate DMY Advanced 71 Do not import column skip In de H 1 1 xL Where you want to put the data Existing worksheet Click OK to import the data to the page es File Insert Page Layout Formulas Data Review View Cut Calibri 1l 7 A A Ser ep Wrap Text 7 LE Format Painter B Z f Merge amp Center Wu 0 Clipboard Fant Alignment Humber a AL Timestamp gt 16 1 Timestamp Data Quality 24 10 2013 10 28 1 5 1 3 5 1 5 1 6 5 1 24 10 2013 102 8 5 l 24 10 2013 10 28 11 1 24 10 2013 10 28 13 1 Highlight Column select More Number Formats from the drop down menu for the cell format HB urs Hi 74a ci uri Data Quality 1 5 3 5 5 6 5 8 5 11 13 15 16 5 18 19 5 21 22 5 24 25 5 27 29 31 32 5 34 5 36 5 38 3 the number format code using of the existing codes as a starting point 41 5 43 5 com Pm HEB HB HH B B BH HB H HB HB B HH HB HB Select Custom if you
15. og Loadbank Runhaurs Fan Run Hours Hi Temp Flo From this page the Total Run Time of the Load Bank Controller can be seen The Run Hours of the Fan is also recorded The Fan Power Fail Count is used to record if the Power has been switched off while the Fan is still running The Fault Log records the instances the High Temperature or Low Flow Alarm has occurred A High Temperature Alarm is indicated by a 1 A Flow Alarm is indicated by a 2 The Hi Temp indicates how many High Temperature Faults have occurred The No Flo indicates how many low Flow Faults have occurred Both the Hi Temp and the No Flo totals can be reset by touching the total number to bring up a numerical pop up PM3250 Power Meter The Power Meter must be setup to correctly read the Supplied Power to the utility being fed from the Generator The Power Meter is used to measure the Voltage and the Current It then calculates various readings for use in the Load Bank Controller Therefore it is critical that the Power Meter is setup correctly The Power Meter must be installed correctly and this may vary depending on the application If in doubt contact Thermal Electric Elements Please consult with PM3200 series Power Meters User Manual when setting up Power Meter Of the more common setups the 3 Phase Voltages and 3 Phase Currents are connected back to the Power Meter See diagram below Setup The power meter f
16. t Then Press OK Memory Stick Provision for Data Logging The HMI Touch Screen has a USB port on the rear that enables a memory stick to be connected for the purpose of collecting data When a memory stick is inserted into the USB 1 port the screen will show a message confirming the logging volume or that there is no medium or for logging This message can be closed by touching the X Fan Setup Fan Setup Fan Run On Time mins Fan Remaining Cn Time mins Fan Off lt lt Enter a time here that Fan will continue to operate after the Load Bank is switched out of Auto Manual or Exercise Mode Example if you want to run the Fan for 10 minutes enter 10 Fan Remaining Time After the Load Bank has been switched out of Auto Manual or Exercise Mode a countdown of remaining time will be displayed here and on the Main Display The FAN OFF button is used to manually start and stop the Fan WARNING The fan run on time is critical to the resistor temperature limits and values should only be entered based on the resistor manufacturer s recommendations Loss of power to the fan during operation due to power failure fuel capacity or by manual operator command will void manufacturer s warranty Loadbank Exercising From the Main Monitor Screen select Menu then Exercise Loadbank Exercising Test Load 1 KW EXCE
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