LOADTEC® Load Banks
Contents
1. Current Calibration Screen ae u sau up eoim pa E UI NUR MARAE 2 P ole 24 Sean O S ECO a a a a Pd PIOHRO 29 2 Curen ALC DC li a 28 Figure 26 Generator Current Calibration Screen sse 28 Figure 27 Default Generator Current Screen sse 29 Figure 28 Generator Current Zero Screen aaassrssssssssssss asa 29 AA IN Is uuu nu A a unassus 30 Figure 30 Mandal lLogdiSettin0 uyu uuu nasa pas maqa A A A 32 Pioure sala Loud Dump Active Scheenu uu q E NNN 33 PI OI O RAN OME Os IS US e ei 34 Pisure 33 5 Message VICW P uu ul ds aaa 40 Figure 34 Message Detail Window esses eene 4 Programmable Digital Controller 111 2004 Load Technology Inc 1 0 System Description LOADTEC s Load Banks with the Programmable Digital Controller are designed to provide and advanced test and measurement functions These systems work in concert with the power generation system They provide automated testing constant load control quick loading in response to regenerative surges and initial startup load to bring turbo boost up quickly The Load Bank control system is made up of a DMC Digital Metering Controller OIP Operator Interface Panel LSC Load Step Controller and LMC Load Module Controller The OIP Operator Interface Panel communicates with the internal DMC Digital Metering Controller and can be mounted integral to the Load Bank or remote mounted at a separa2. an external device can then be used to start the generator As long as the transfer switch is in the Normal position the test will be run Since in this case the Load Bank did not start the generator the generator start contact will remain in the off position and it is the responsibility of the external device to turn off the generator when the test has completed The test sequence is performed exactly as tt would be in the internal clock mode and thus all of the alarms and message described in the internal clock section apply Page 36 Programmable Digital Controller 10 3 2004 Operator Manual 5 2 1 3 Auto Sequence Manual Start A configured Auto Exercise sequence can be started manually by pressing the Start key Ifthe Auto Exercise system is configured to operate from the internal clock and the generator is off then pressing the Start key requests that the system run the Auto Exercise sequence now Auto Exercise Start HutoExercise Press Start to contirm or other key to abort When the Start key is pressed the message shown above will be displayed Press the Start key again to start the test This effect changes the systems internal test start date and time to the current time and date Once the test has been completed a new test will be scheduled based on the configured Auto Exercise parameters 5 2 2 Auto Loading Auto Loading is the other major automated feature of the Load Bank As the name implies Auto L
3. values Operator Manual Default Holts Zero Woltsae Channels tYeHa He Ensure no voltase is Present Figure 22 Voltage Zero Screen Press the Zero Volt Soft Key to zero the voltage sensor channels Warning Zeroing a sensor value is used to NULL any offsets in the value Zeroing voltages or currents when there 1s voltage or amperage applied will yield unpredictable results as the system will NULL a real measurement Page 26 Programmable Digital Controller 10 3 2004 Operator Manual 4 8 1 2 Current Calibration The current measurement values can be calibrated to a given value reset to their default calibration values or zeroed Press the Cal Amps Soft Key to access the Current Calibration Screen Enter actual Ame Values Figure 23 Current Calibration Screen The amperage values shown Al A2 and A3 indicate the current readings at the time the Cal Amps Soft Key was pressed Adjust these values as required Perform the following to calibrate each current measurement channel 1 Place the desired load on the system under test 2 Wait for readings to stabilize 3 Measure each phase current by a external current 4 From the Current Calibration Screen change the required values s 5 Exit to save the calibration settings Press the Def Amps Soft Key to set the calibration coefficients for each of the amperage channels to their default values Default AmP Def Current HAme Channels tYe
4. Hbri aa AM su ee 9 3 3 The Status Indicator LEDS ui 13 d US STC CIN 14 AUCTION 14 an aaa A o oo m 15 2 2 Dhe Torg le Enry Pilar tii 16 41 7 Auto Exercise Setup iiec ive seen eso euet coisa vue PE SE Ne rede Us e sa ns eee Pe RUE 16 42 Auto Exercise C loecle Be pu u u uu decime ovem ee tene eae a petet nina tinens 16 42 2 2 Auto Bxercise Sequence DEP cidos 18 4 2 3 Auto Exercise Alarm Setup Screcen 19 4 5 Auto LOadine Setup Sireti escarnio 20 4 4 Base Loading Setup SCEeGD 296 l iu lu llul Eon o Poe o Ho als b epa gane 22 IN PA u u aa NS VR AE A eR SERRE 23 4 6 5tepn Y alte Setup STEC uuu ciet oisi ae aa 23 A Ser COCK e a A e sii 24 Programmable Digital Controller 1 2004 Load Technology Inc AS Sensor CAIDA ION tit 24 AAA JO 24 49 The License Munapr uuu ios 30 5 0 OPETAN A O 31 SI Manual Moda E NEU Iq Le 31 5 I Manual LOL 56b HIP idad 32 3 12 Logd ata Overrides A M Mete dos depu did 33 Jlo Jogging the Load COMMA iii 33 32 AGO Mod ica 34 SPAM NONI EP S RO INTE 34 SNAP A S UU UU UM 37 06 0 The Messaeiuo S VSEM k aiias d s coi eid i ede ral i eet a eid 40 O I VieWine MESS TES s ecesedVeIo e e aia 40 LI Vie wins Message Detallg iq ice o ble e A eina dett ten He De Men idee da 4 6 2 Operational IVICSSAGES Su u u Sim in a Si S PEN EF is 42 6 3 Exerceise Messgqpewsuru uuu u dada 44 GIOSSUL A E scene caaeeaeseuetemeceues 47 in uya
5. I i i e _ lt ac La Load of generator size Figure 14 Load Unload rate 4 4 Base Loading Setup screen The Base Loading feature of the Load Bank is setup by the Base Loading Setup Screen This screen is accessed by pressing the Base Load Soft Key from the Setup Menu Figure 15 Base Loading Setup Screen Enabled This parameter is used to Enable or Disable the Base Loading features of the Load Bank Voltage This parameter defines the voltage at which the base load 1s applied This value is entered as a percentage of the nominal Load Bank voltage For instance on a 480 volt Load Bank with the configuration shown above the Base Load will be applied when the generator voltage reaches 408 volts 85 of 480 This value should not be set at less then 85 Load This parameter is used to configure the load to be applied while Base Loading is active This value is entered in KW Time The Time parameter defines the amount of time that the configured Base Load will be applied This value can be set from 0 to 99 99 seconds Page 22 Programmable Digital Controller 10 3 2004 Operator Manual 4 5 Regen Load Setup Screen The Regenerative load control function is enabled or disabled by the Regen Screen This screen is accessed by pressing the Regen Load Soft Key from the Setup Menu Figure 16 Regen Setup Screen The only setting in this scr
6. it closing This error will only be generated as the fan is being commanded on The most probable cause for this fault 1s a failed RAC or RBC contactor Once the fan 1s operational an RAC or RBC failure will generate a RAC or RBC failure message Fan door s closed If the fan door s are detected as being closed while the Load Bank is in the On state this message will be displayed and the fans will be turned off Not all Load Banks have fan doors Programmable Digital Controller 10 3 2004 Fan Start Failure This fault indicates that the cooling motor start contactor did not close as expected This contactor will not be present on Load Banks without cooling fans Invalid control voltage As stated previously the Load Bank requires a valid Control Voltage configured tolerance bands before the system can turn on If no valid control voltage is detected this error will be displayed What control voltages are valid is completely dependant on your Load Bank model and options KAC Contactor Failure This fault indicates that the KAC rotation contactor did not close as expected This contactor is not used in all systems KBC Contactor Failure This fault indicates that the KBC rotation contactor did not close as expected This contactor 1s not used in all systems Load over current This message can only occur on a system that contains inductive load steps It indicates that an excessive current has been detected in the
7. load command is set to 200KW and the Load Bank is producing 200K W of load as can be seen by the measured KW value Whenever the Load Bank is commanding load the Load On LED will be lit Pressing the Load On Off key will toggle the load on and off zero and 200KW in our example Press the Func Select key to access the Meter Select Menu then pressing any ofthe Soft Keys will cycle through the different metering channels Page 32 Programmable Digital Controller 10 3 2004 5 1 2 Load Dump Override If the Load Dump LED 1s lit transfer switch is in the Emergency position when the Set Load Soft Key is pressed the Load Dump Active Screen is shown Load Dumr Active Onverride CYeHa He Figure 31 Load Dump Active Screen Selecting Yes Y will override the Load Dump signal and allow manual load setting Whenever the Load Dump signal is overridden in this manner the Load Dumped LED will flash on and off Once Load Dump has been overridden manual load settings can be made without the Load Dump Active screen being shown again Selecting No N will abort the load command and remove the Load Dump Active screen from the display If the Load Dump signal goes active transfer switch in the Emergency position while load 1s already being applied in the Manual mode then the load will be dropped 5 1 3 Jogging the Load Command When in the Manual mode and the Load Bank is in the On state Operation Normal LED is lit
8. performed to start the system vary based on the system type The function of the Start Key depends on the current operational mode ofthe system If in the Manual mode then the Start Key 1s used to Start the system Starting the system can be thought of as preparing it for loading turning fans on check control voltages etc If the system is in the Auto mode and Auto Exercising has been configured and enabled then pressing the Start Key will cause an Auto Exercise test to be started now 3 1 6 The Load On Off Ke LOAD This key is only used when the system is in the Manual mode oworf Pressing the Load On Off Key when in the Manual mode with load applied causes the system to save the current load setting then disconnect the load Pressing this key again causes the load value to be returned to its previous setting In essence this key toggles the load On Off 3 1 7 The Function Select Ke This key controls the Soft Key function menus Soft Key functions are arranged in logical groups that make up a menu P system The Function Select Key is used to cycle between iiec groups or menus There are three main Soft Key menus These are 1 The Main Menu 2 The Status Menu 3 The Meter Select Menu 3 1 8 The Clear Reset Ke This key has multiple functions If an error message is being CLEAR shown in th fth h ing this k Resgr S own in the message area ol the screen then pressing this key will clear the
9. then pressing the Up and Down Arrow keys can be used to jog the load up and down The size of the jog the Jog Value is setup via the Step Value Setup Screen see section 4 6 5 2 Auto Mode When in the Automatic Mode the Load Bank will automatically make adjustments to the load placed on the generator These adjustments are based on a variety of measurements and the current configuration of the Load Bank There are two main automatic functions provided by the Load Bank Auto Exercise and Auto Loading These functions are only active if enabled via the configuration screens and the Load Bank is in the Auto Mode The MODE key is used to select the current operating mode and the System Auto LED will be lit woo whenever the Load Bank is in the Auto mode 5 2 1 Auto Exercise The Auto Exercise features of the Load Bank provide a method in which an automated test of the generator can be performed by the Load Bank Based on configuration these tests can be scheduled at given intervals day of the week and time of the day or by an external stimulus The Auto Exercise functions are configured via the Auto Exercise Setup Screens see section 4 2 Auto Exercise Setup for additional information The test itself 1s a sequence of up to 8 load step and time settings While the Auto Exercise test sequence is running the generator s voltage and frequency are constantly monitored against the configured warning and alarm values If an al
10. this mode no operations will be performed by the Load Bank Source Connected This greed indicator is lit when the test source is powered and connected to the Load Bank Operation Normal This green indicator is lit when the Load Bank is in the On state and capable of applying load Operation Alarm This red LED is used to indicate that an alarm condition has occurred and loads cannot be applied In most cases when the Alarm LED is lit an error message will be shown on the Message Line of the LCD display Press the Clear Reset key to clear the Alarm state Load Dumped This amber LED 1s used to indicate that the transfer switch has transferred the load is in the Emergency position and 1t 1s Dumped disconnected Load On This green LED 1s used to indicate that load 1s currently being applied by the Load Bank Operator Manual 4 0 System Setup In order to perform the various automated functions and measurements the Load Bank must be setup These settings are all accessed via the Setup Menu The Setup Menu provides access to various setup screens These screens are made up of groups of parameters that are logically organized based on their function 4 1 Setup Screens Page 14 HutoLosdings Set Enabled tYerAo Ye Selection Marker Genset size Load x 33 00 LT Size HE Delay mind 3 8 More Parameter Indicator Figure 10 Setup Screen Setup screens are lists of configurable parameters
11. Figure 10 shows the setup screen for the Auto Loading system Each setup screen has a Selection Marker that is used to select a parameter Pressing the Up or Down Arrow Keys will cause the Selection Marker to be moved up or Enabled YeHaa Y down previous or next parameter Genset size Poke In the example of Figure 10 pressing the Down Arrow Key moves the Selection Marker to the Genset size parameter Most setup screens contain more parameters than can fit on a HutaLoadins SsetuF single screen In these cases the EMabled C i Wa Y screen must be scrolled up and Genset sizes down to allow access to these Load 4 33 HE additional parameters In the CT Size Hue example shown in Figure 10 the Delay mins 3 8 small arrow marker shown at the bottom of the screen indicates that there are more parameters available Pressing the Down Arrow Key will cause the screen to scroll up Programmable Digital Controller 10 3 2004 As shown after pressing the Down Arrow key the screen is HutoLoadins Setur scrolled up a new parameter is Genset size added at the bottom of the Load z 3 3 HH screen and the Selection Marker T Size HK is placed at the new parameter Delas mina In this case the LD Res Load Ld Rez ot Resolution parameter 1s added to the screen and the Selection Marker is pointing to it Note that there is a marker added at the top ofthe screen that indicates there are more parameters above Pres
12. Graphics LCD display The screen Is divided into 4 distinct areas as shown in figure 4 Soft Key Menu Data Section Ways Hava mode Manual Load cmd SHEL Status Section Message Line Figure 4 The LCD Display 3 2 1 The Soft Key Menus The top two lines ofthe display are used to label the Soft Key functions Soft key functions are arranged in logical groups each group of functions is called a menu 3 2 1 1 The Main Menu Figure 5 The Main Menu Set Load This function is only available when the control system is in the Manual mode Pressing this key when the Load Bank is in the On state Operation Normal LED is lit will allow for setting of the commanded load System Msgs This key is used to gain access to the System Message Menu Setup This key is used to gain access to the Setup Menu Press the Func Select key to move to the Status Menu Operator Manual 3 2 1 2 The Status Menu Page 10 SoT tur Clack Figure 6 The Status Menu Wer The Status Menu is used to access the system functions by pressing the Func Select Key while in the Main Menu These functions are used to show various system information screens Show Clock Press the Clock Show Clock Soft Key to stint asta view the current real time Thr B gt G 7BB4 clock settings The system PAIS 3 x 9 29 89 15pm Press any key clock is set from the Setup Menu Press any key to close this window Sys Tests Press
13. Ha He Figure 24 Default Current Screen Select Y Yes to cause the amperage calibration coefficients to be set to their default values Operator Manual ero Hmrz Zero Current Homes Channels tYeHa He Ensure no Current is Present Figure 25 Current Zero Screen Press the Zero Amps Soft Key to zero the amperage sensor channels Warning Zeroing a sensor value 1s used to NULL any offsets in the value Zeroing voltages or currents when there is voltage or amperage applied will yield unpredictable results as the system will NULL a real measurement 4 8 1 3 Generator Amperage Calibration The generator amperage measurement values can be calibrated to a measured value set to default calibration or zeroed Press the Cal GenAmp Soft Key to access the Generator Amperage Calibration Screen GenHAmr Lal GenHl H GenHAiz m GenH31 HB Enter actual Ame Values Figure 26 Generator Current Calibration Screen The amperage values shown GenA1 GenA2 and GenA3 indicate the generator amperage readings at the time the Cal GenAmp Soft Key was pressed Adjust these values as required Page 28 Programmable Digital Controller 10 3 2004 Operator Manual Perform the following to calibrate each amperage measurement channel 1 Place the desired load on the system under test 2 Wait for readings to stabilize 3 Measure each phase amperage via a an external meter at the generator 4 From the Cur
14. LUTION By accessing this document you agree that the laws of the State of Nevada will govern all disputes that arise concerning the use of this document Any disputes brought concerning the terms of this agreement shall be in a state or federal court located in the State of Nevada Clark County DocUseTerms11032010 2 doc Contents At a Glance 1 System Description 2 Functional Overview 3 The Control Panel 4 System Setup 5 Operation 6 The Messaging System Glossary Index Programmable Digital Controller 2004 Load Technology Inc Table of Contents Load Bank Programmable Digital Control System Table of Contents USO BITTER R ili J 0 System DES CHIPIION cera 1 2 0 unc Unal Baur A AAA S sun usss 2 2 1 The Power Meter eMac 2 3 0 The O LP Operator Interface Panel 4 31 The Front Panel Keysu uuu u u u f 5 3L POWer On OIL Ran 5 AA VS sfc dieses acted assess es reset caesar ees a eens 5 321 3 DAS MOE REV 6 E LDO S 0 68 E DE E ETT QS y De loos LING SUI La uuu x Z x M UE Ud E Ub gui AU LIEU 7 SL LA DOS On OIL K oaaae t Eme e 7 DA The Function Select Gy tessuto ott tex rehenes ottenuta d 7 SLS he C O A AE AEE N 8 oe ABI desee e eee enn re ere LUUD 8 AI A o a r 8 SITAS Lampu LES Qu pene E muna am ana am aa T 8 iz The LCD Seremi cacao TEE uE 9 S421 Phe SOmeaK Cy METUS cn in
15. PROGRAMMABLE DIGITAL CONTROLLER ar SYSTEM euro SYSTEM O MANUAL aus mode Manual e SEM Load cmd zia G SOURCE Fe CONNECTED OPERATION VCPERATION POWER gy OPERATION i ELS ALARM ENTER START eni LOAD x O DUMPED LOAD FUNC CLEAR ars ONOFF SELECT RESET LOAD BANK PROGRAMMABLE CONTROLLER USER MANUAL LOAD BANKS WITH THE DIGITAL SOLUTION 2004 Load Technology Inc 11 18 2004 Information in this document is subject to change without notice and does not represent a commitment on the part of Load Technology Inc LOADTEC No part of this Operator Manual may be reproduced stored in a retrieval system except as provided for by Load Technology Inc or transmitted in any form or by any means electronic or mechanical including photocopying and or recording for any purpose without the express written consent of Load Technology Inc Copyright 2004 by Load Technology Inc All Rights Reserved Printed in the United States of America Load Technology Inc 4225 Production Court Las Vegas NV 89115 U S A LoadView 1s a trademark of Load Technology Inc Microsoft is a registered trademark Windows and Excel are trademarks of the Microsoft Corporation DOCUMENTATION DRAWING LOAD TECHNOLOGY INC TERMS OF USE This documentation and drawings document provided are subject to the following rules guidelines policies and conditions OWNERSHIP Load Technology LOAD
16. TEC owns the contents of this document The inclusion with equipment or supply after in support of purchased equipment or parts does not transfer ownership to the purchaser or owner of the equipment that this document details Specific payment or purchase of copy s of this document does not transfer ownership COPYRIGHT All content included on these pages are protected by U S and international copyright laws Further even if not specifically noted as copyrighted we consider this document in its entirety as copyrighted By using this document you agree to honor all applicable copyright laws and practices USE OF PROPRIETARY INFORMATION This document includes detailed design information that is confidential proprietary and may include trade secrets of LOADTEC This information is not meant for public dissemination but made available only to you the customer for repair and maintenance purposes only By accessing this information you are representing that your use is for repair and or maintenance only You further represent that you will not use any of the information for any purpose other then repair and or maintenance or disseminate to any third party or competitor for any reason WARRANTIES AND DISCLAIMERS The contents of this document are provided without any warranties either express or implied and it explicitly disclaims any implied warranties of merchantability or fitness for a particular purpose APPLICABLE LAW AND DISPUTE RESO
17. The metering system is a true R M S root mean square measurement system The R M S value of each voltage and current input is computed as shown These computations are updated at the high sample rate The calculations are completed at each zero crossing of the phase A voltage Input ME V V t dt m t Note When comparing or calibrating the voltage and current measurements of the Metering System be sure to use a true rms reading DVM Many meters are average reading type and will not provide an accurate reading they do not compensate for typical distortions present in the sinusoid waveform l H AA NE r peak L effective or RAS maximum pos ti we Maximum negative YOLTAGE 5 The voltage measurement system is capable of measuring voltages as high as 660 Vims at a crest factor of 1 414 As the measured voltage decreases the maximum crest factor allowed increases the limit 1s the peak voltage Operator Manual 3 0 The O I P Operator Interface Panel Page 4 Havsa Hawa mode Manual Load cmd zik SOURCE TE I Caen gt OPERATION x POWER 9 NORMAL O MODE STOP OPERATION NNNM ALARM ENTER START LOAD O reo LOAD FUNC CLEAR Loan oNorr SELECT RESET LOAD BANK PROGRAMMABLE CONTROLLER Figure 2 The O LP Operator Interface Panel The OIP is the interface to the Load Bank system From this
18. Unload rate parameters The larger the rate the more ageressive the load change This rate is adjusted based on how close the current load 1s to the capacity of the generator Therefore even with a slow rate the load is adjusted rather quickly when running near the generators capacity Figure 14 Load Unload rate table shows the effect of the different rate settings 5 2 2 1 Regen Loading Page 38 Regenerative Loading Regen Loading 1s an extension to the normal Auto Loading functions It is enabled via the Regen Load Setup Screen see section 4 5 When the following conditions are true Regen Loading is functional Generator 1s on Source Connected Transfer switch in the Emergency position Auto Loading is enabled Regen Loading is enabled a a The Load Bank constantly monitors the load on the generator If this load is sensed as being negative regenerative load then load will immediately be added by the Load Bank The load added will be enough to offset this regenerative load As the facility load increases or the regenerative load decreases the load commanded by the Load Bank will be adjusted as described in the Auto Loading section Sensing regenerative load will Programmable Digital Controller 10 3 2004 cause the system to ignore the Auto Loading delay and thus it would become active immediately 5 2 2 2 Base Loading Base Loading is another extension to the Auto Loading functions Base Loading is used to
19. age will be recorded The same applies to the frequency and the Under Over Frequency alarm settings If the voltage or frequency goes above or below the warning parameters a warning message will be recorded but the test will continue to operate 4 3 Auto Loading Setup Screen The Auto Loading feature ofthe Load Bank is setup from the Auto Loading Setup Screen This screen 1s accessed by pressing the Auto Load Soft Key from the Setup Menu HutoLosdings Setue Enabled Year Y Genset size 5H Load x 43 00 LT Size Hb Delay mind 5 H Ld Res 5 Load rate 1H j Unload rate Z Figure 13 Auto Loading Setup Screen Enabled This variable is used to enable disable the Auto Loading features Genset Size This variable is used to configure the size ofthe generator It is entered in KW kilowatts Load This parameter is used to define the amount of load to be placed on the generator when Auto Loading is active It is entered as a percentage of the configured generator rating Genset size For example if the Genset size is set to 500 KW and the Load is set to 33 then the system will attempt to maintain 165 KW of load on the generator CT Size This parameter is used to configure the size of the Current Transformer s installed at the generator to measure the phase currents It is specified as the primary current ratio to the 5 amps of the secondary Delay This parameter defines the amount of time from the sta
20. arm occurs the sequence is aborted and an error message will be recorded If a warning level is exceeded then a message will be recorded but the test sequence will continue Ians Hauva mode Auto Exercise Load cmd SHEL Stee 1 time 33 Figure 32 Auto Exercise Status Whenever an Auto Exercise sequence is running the current load step number and time are shown on the screen The time value indicates the time left in the current step Page 34 Programmable Digital Controller 10 3 2004 5 2 1 1 Internal Clock When the Internal Clock mode is selected Auto Exercise sequences are run based on the configured start time of day the interval and day of the week Int Clock yy N yx Y Gen Timecuto 15 Start hrs s 2 many 2s O Int days 14 Day 1 2Sunday 1 Using example settings shown above the Auto Sequence will be run every other Sunday at 2 00am Setting the Day value to zero will cause the test to be run every 2 weeks 14 days regardless of the day of the week When any of these parameters are changed a new test date and time are computed from the time and date that the changes were made If the settings shown above were made on Sept 14 2004 then the next scheduled test date will be Sunday Oct 3 2004 at 2 00am Note that 2 weeks from Sept 14 1s actually Sept 28 Since this date 1s a Tuesday and the Day value was set for Sunday then the test date must be moved to Oct 3 the next Sunday followin
21. at the Load Bank was in the On state and the maintenance doors were detected as being open Again not all Load Banks have maintenance doors normally found on trailer units MCH Contactor Failure This fault indicates that the high voltage motor contactor did not close as required This contactor may not exist in your system MCL Contactor Failure This fault indicates that the low voltage motor contactor did not close as required This contactor may not exist in your system No AirFlow This error indicates that no airflow has been detected in the required time since the fan was turned on It does not indicate a failure of the fan to turn on but rather indicates a failure of the fan s ability to produce airflow A fan failure an airflow pressure switch failure or a heavily restricted air inlet can cause this fault No control power check CtrlPwr fuses This error indicates that the Load Bank turned on the control power transformer but did not detect the 24 VAC control power Blown control power fuses will most likely be the cause of this fault Reset fan overloads This fault indicates that the fan is commanded on and the thermal overloads are detected as open Check the overloads and try again Temperature limit n at xxx x This fault indicates a temperature reading n has exceeded its maximum The actual temperature is shown as xxx x 6 3 Exercise Messages The following is a complete list of the possible Exerci
22. ates that an Auto Exercise Sequence was running then stopped either from the generator dropping out or Load Dump asserted transfer switch in the Emergency position This message 1s also copied to the Auto Exercise message list BiDir node inactive This fault indicates that one of the I O Control Modules is not responding These I O Control Modules also known as the BiDirectional Controller stopped responding and therefore the safety interlocks cannot be processed Cntrl over voltage This fault indicates that the Control Voltage has exceeded the maximum allowed voltage The actual voltage will depend on the type and configuration of the Load Bank This value is normally set to be 10 above the nominal running voltage Note that on dual voltage machines the nominal voltage is the currently operating voltage i e 240 or 480 Control voltage unstable This error indicates that the Control Voltage has not been stable for a sufficient time prior to commanding the Load Bank on The system requires that the control voltage be stable change less than 5 for 1 5 seconds Since many of Load Technology s Load Banks are capable of operating on a wide range of voltages the system must ensure that it is turning on at the right control voltage If this error occurs wait for the Control Power source to be stable then try again Fan did not start This fault is generated when the system turns on the fan control contactor s and does not sense
23. easured value Each variable can be independently calibrated by measuring the values and entering them into the calibration screens Pressing Sensor Cal from the Setup Menu opens the Calibration Menu 4 8 1 The Calibration Menu Page 24 The Calibration Menu is accessed by pressing the Sensor Cal Soft Key from the Setup Menu This menu contains 9 functions Only 3 Soft Keys can be displayed on the screen the Left and Right Arrow Keys are used to scroll the functions to the left and right Programmable Digital Controller 10 3 2004 Operator Manual Figure 19 The Calibration Menu Keys Press the Func Select Key to exit the Calibration Menu and return to the Setup Menu 4 8 1 1 Voltage Calibration The voltage measurement values can be calibrated to a given value reset to their default calibration values or zeroed Press the Cal Volts Soft Key to access the Voltage Calibration Screen Woltsaae Cal II tobe 45H 5 daB Enter actual Woltage Values Figure 20 Voltage Calibration Screen The voltage values shown indicate the voltage readings at the time the Cal Volts Soft Key was pressed Change these values as required Press the Def Volts Soft Key to set the calibration coefficients for each of the voltage channels to their default values Default Holts Default Woltage Channels tYeHa He Figure 21 Default Voltage Screen Select Y Yes to set the voltage calibration coefficients to their default
24. een 1s the Enabled parameter Setting this parameter to Y Yes will enable the Regenerative Loading function Note that Auto Loading MUST also be enabled for the Regen loading functions to operate 4 6 Step Value Setup Screen The Step Value Setup Screen is used to set the Jog Value This value is used to Jog the load up and down when operating in the Manual mode This screen is accessed by pressing the Step Value Soft Key from the Setup Menu Figure 17 Step Setup Screen The only parameter on this screen is the Jog Value If the value entered is not an interval of the smallest step size then an error message screen will be shown Operator Manual For example a system that L1 PIN contains 4 50KW load steps Invalid Entr has a minimum load step size Inval ig Josa WS l We of 50 KW Entering a Jog Hu st be an Value of 125 is not valid and interval of SHEL the Invalid Entry screen will Fress any keu be shown Press any key to close this screen and you will be returned to the Step Setup Screen to enter a valid value 4 7 Set Clock Screen The real time clock of the system is set via the Set Clock Screen This screen is accessed by pressing the Set Clock Soft Key from the Setup Menu 1 1 ay 1 31 1H Year bee Hours 12 Seconds al Figure 18 Set Clock Screen Enter the date and time values as required 4 8 Sensor Calibration The voltage and current measurement system can be calibrated to a m
25. elect Menu 1s active pressing a Soft Key cycles through the metering value choices for that field In the Figure 7 example pressing the F1 Meter Select Soft Key will change the metering value display in the left position to V1 Voltage of A B Pressing the F2 and F3 Soft Keys has a similar effect on the data values being shown beneath each of the respective menu functions The selection choices for each Meter Select Menu field are as follows F1 left data value Vavg V1 V2 V3 F2 middle data value Aavg Al A2 A3 F3 right data value KW Hz GenKW Press the Func Select Key to return to the Main Menu V1 94 0B V2 9B 9C and V3 9C 94 are the phase voltages Vavg is the average of all voltages Al A2 and A3 are the individual phase currents and Aavg is the average of all currents KW is the power absorbed by the Load Bank in kilowatts Hz 1s the sources voltage frequency GenKW is the total power generator power output in kilowatts This value is only available when the Automatic Loading function is enabled Operator Manual 3 2 1 4 The System Message Menu Figure 8 The System Message Menu Pressing the System Msgs Key from within the Main Menu accesses the System Message Menu The Load Bank maintains a list of two different types of messages these are the Operational Messages and the Exercise Messages To view the Operational Messages press the Op Msgs Soft Key F1 To view the Exercise Mes
26. error and reset the Alarm indicator LED If entering numerical values pressing this key will clear the numeric entry field Pressing this key in an input screen will exit that screen 3 1 9 The Enter Key In general the Enter Key is used to Enter the given selection or ENTER x lt data When editing a numeric value in a Numeric Entry Field the Enter Key is used to accept the value and place it in the value field When viewing messages the Enter Key is used to view detailed information of the selected message 3 1 10 The Arrow Keys There are four Arrow Keys on the front panel These are the Up Arrow Down Arrow Left Arrow and Right Arrow Keys These keys have multiple uses depending on the operational mode of the system When in the Manual Mode and not in a Numeric Entry Field the Up and Down Arrow Keys are used to jog the load setting up and down When in a Numeric Entry Field the Left and Right Arrow Keys are used to move the cursor within the field and the Up and Down Arrow Keys are used to increment decrement the selected digit 3 1 11The Lamp Test Key LAMP The Lamp Test Key 1s used to perform a simple LED and DISPLAY LCD display test Each of the LED indicators will be cycled TEST J on off and the LCD display will show a pattern that tests each of the pixels of the display Page 8 Programmable Digital Controller 10 3 2004 Operator Manual 3 2 The LCD Screen The OIP incorporates a 128 x 64 Monochrome
27. erruptible Power Supply This is known as the Test Source The electrical load is provided by the resistive elements contained within the Load Bank These elements are designed to provide accurate and stable loads for controlled testing of the power source Resistive elements are sized by the amount of Real Power KW kilowatts they absorb at a given voltage This is also known as a Load Step Once configured the Programmable Digital Control System will automatically add or remove load as a function of the measurements made by the system and the selected operational mode In order to make these load adjustments both the Load Bank and generator power are measured as well as the voltage and frequency 2 1 The Power Meter System A dedicated processor in the DMC Digital Metering Controller performs the Power Meter functions the metering The metering system is Page 2 Programmable Digital Controller 10 3 2004 responsible for measuring the output of the voltage and current sensors and making all required calculations The Metering System scans each of the voltage V1 V2 and V3 inputs current A1 A and As inputs and the generator current inputs at a minimum high sample rate of 8 KHz The real power is calculated from the instantaneous power as follows 12 KW pdt ri Depending on the system type there may be a power measurement made for each phase in a 3 phase system or a single CT may be used on one phase
28. eset Key will clear the numeric field and sets the value to zero Pressing the Right Arrow Key while the cursor is in the far right position will exit the Numeric Entry Field without making any changes 4 1 2 The Toggle Entry Field Toggle Entry Fields are used to select an Enabled or Disabled state of the function For example the first parameter in the Auto Loading Setup screen in Figure 10 is the Enabled variable This variable can have the value of Y Yes or N No Like the numeric values use the Up and Down Arrow Keys to position the Selection Marker on the variable and press the Enter Key Brackets will be placed around the Enabled Yebo 0 variable indicating that it can be y changed Press the Up or Down Arrow Keys to toggle the setting between Y and N Press the Enter Key when the desired value is shown 4 2 Auto Exercise Setup The Auto Exercise Features of the Load Bank are setup via three different setup screens These are the Clock Sequence and Alarm setup screens 4 2 1 Auto Exercise Clock Setup Page 16 Press the Exrsze Clock Soft Key from the Setup Menu to access the Auto Exercise Clock setup screen HutoExercise Setur AUS Int Clock Ext Clock YZ Start rthrz mins Int dassi 3H Das 1 sunda 1 Figure 11 Auto Exercise Clock Setup Screen Programmable Digital Controller 10 3 2004 Int Clock nternal Clock When the Internal Clock 1s enabled Auto Exercise seque
29. everything else These pertain mostly to error events that may occur that effect the operation of the Load Bank From the Main menu press the System Msgs Soft Key to access the Message Menu Press the OP Msgs Soft Key to access the Operational Messages press the Exrsze Msgs Soft Key to access the Exercise Messages or press the exit soft key to exit the Message Menu and return to the Main Menu 6 1 Viewing Messages Page 40 When either the Op Msgs or Exrsze Msgs Soft Keys are pressed the Message Viewer window 1s opened allowing you to view all of the messages in the list Oreration Maas Message Selector 3 99 Load Bank On B Load Bank Tur Load Bank Urn Load Bank Tur Load Bank Urn Figure 33 Message Viewer Both of these message lists can contain up to 99 messages When the 100th message is recorded the oldest message is lost and the system will save the last 99 messages When a new Load Bank is started it may be some time before 99 messages will be recorded This window will show all of the messages or just the last 99 Programmable Digital Controller 10 3 2004 Operator Manual The messages are listed in reverse chronological order messages at the top of the list are the most recent The Message Selector arrow is used to select a given message Since most messages are larger than what will find on the screen the selected message will continuously scroll across the screen Use the Up and Down A
30. g 46 inductor 43 instantaneous power 3 Internal Clock 17 35 Invalid control voltage 43 Jog Value 23 24 33 KAC Contactor Failure 43 KBC Contactor Failure 43 kilowatts 2 KVA 47 KVAR 47 KW 2 47 License Manager 30 Load Bank Controller 30 Load over current 43 Page 48 Index Load over voltage 43 Load Power 47 load step 2 43 47 Load Step 47 LoadView 2 30 Loss of control power 43 Low Cntrl voltage 43 Low Frequency 43 Low volt alarm seq stopped 45 Low voltage warning 46 Maintenance door s opened 44 maintenance doors 44 MCH Contactor Failure 44 metering 2 3 Metering Data 47 No AirFlow 44 No control power check CtrlPwr fuses 44 Normal 17 35 36 On state 42 43 44 On State 47 Operational Messages 12 40 42 Over freq alarm seq stopped 45 Over frequency warning 46 Power Meter 2 47 pre start 18 36 reactive power 47 Reactive Power 47 real power 2 3 47 Real Power 47 Reset fan overloads 44 rms 3 47 starting AutoExcersize seq 45 Temperature limit n at xxx x 44 Test Source 2 47 Under freq alarm seq stopped 45 Under frequency warning 46 Programmable Controller 10 3 2004
31. g the calculated date If the Day value was instead set to 0 then the test date would in fact be set to Sept 28 Given our example settings 1f on Oct 3 2004 at 02 00am the Load Bank senses that the generator is already on and the transfer switch is in the Emergency position then the test will not be started The Load Bank will continue attempting to run the test through the remainder of the day If at no time during the test day Sunday Oct 3 2004 in our example the test can be run then the system will give up and record an AutoExercise date missed message A new test will be scheduled two weeks later sunday Oct 17 2004 in our example If on Sunday Oct 3 2004 at 02 00am in our example the generator is not on and the transfer switch is in the Normal position then the Load Bank will turn on the generator start contactor and wait for the generator to start If after the generator timeout period 15 seconds in our example settings no generator voltage is sensed then the system will abort the test A generator did not start message will be recorded and a new test will be scheduled based on the configurations Sunday Oct 17 2004 in our example If the generator starts and source voltage is detected then the configured test sequence will be executed The test sequence is defined via the Auto Exercise Sequence Setup screen see section 4 2 2 The test sequence can contain up to 8 load and time settings If as the test is bei
32. ge exceeds the configured the Over Voltage alarm setting then this message will be recorded and the test sequence will be stopped Low volt alarm seq stopped If the generator voltage goes below the configured the Under Voltage alarm setting then this message will be recorded and the test sequence will be stopped Over freq alarm seq stopped If the generator frequency goes above the configured the Over Freq alarm setting then this message will be recorded and the test sequence will be stopped Under freq alarm seq stopped If the generator frequency goes below the configured the Under Freq alarm setting then this message will be recorded and the test sequence will be stopped High voltage warning If the generator voltage goes above the configured the Over Voltage warning setting then this message will be recorded The test sequence will not be stopped Low voltage warning If the generator voltage goes below the configured the Under Voltage warning setting then this message will be recorded The test sequence will not be stopped Over frequency warning If the generator frequency goes above the configured the Over Freq warning setting then this message will be recorded The test sequence will not be stopped Under frequency warning If the generator frequency goes below the configured the Under Freq warning setting then this message will be recorded The test sequence will not be stopped Page 46 Pr
33. inductive load steps of the Load Bank Since the current in the inductor is a function of both the applied voltage and frequency the lower the frequency the higher the current both the voltage and frequency are monitored to prevent an over current condition When this fault occurs the Load Bank s fan 1s turned off and all loads are dropped Load over voltage This error indicates that an excessive voltage was applied to the resistive load steps This trip point 1s normally configured to be 10 of the nominal running voltage The system will not allow an excessive voltage to be applied for any extended period of time thus protecting the load elements Loss of control power This fault occurs when the Load Bank is in the On state and the 24 VAC control power is not present This normally occurs as a side effect of another error that shuts down the fan controls Low Cntrl voltage This fault occurs when the Load Bank is in the On state and the control voltage is sensed to be below the minimum for the given operational mode The minimum is normally configured to be 10 below the nominal running voltage Low Frequency It indicates that the Load Bank was in the On state and detected a frequency that is below the minimum The minimum frequency 1s normally configured to be 40 Hz This error will most often occur if the power source sags excessively when hit with an increased load Maintenance door s opened This fault indicates th
34. load H min H 2 load amp min HE 6 load B min HB fe load B min fo load min HE Figure 12 Auto Exercise Sequence Page 18 Programmable Digital Controller 10 3 2004 a BET Wb Y In the example the load will be set to 55 KW for one minute and then will be changed to 155 KW The load will remain at 155 KW for one minute at which time the load will be disconnected because the time value for step 3 1s set to Zero A test sequence can contain up to 8 steps The sequence will stop the first zero time value is encountered This will be end of the test A zero value for the load can be entered and will not stop test sequence 4 2 3 Auto Exercise Alarm Setup Screen 5 alarm Hz 36 4 Warn CHa 93 H Over Frey alarm Hz 62 4 Warn CHza 61 8 The Over Under Voltage and Over Under Frequency parameters are setup via the Auto Exercise Alarm setup screen These parameters define the minimum and maximum voltage and frequencies that are allowed during an Auto Exercise test The voltage values are entered as percents and the frequencies in Hertz Hz The voltage percentages are with respect to the Load Bank s nominal voltage For instance on a 240 volt Load Bank a 10 Under Voltage alarm would occur at 216 volts Nominal 10 If the voltage goes below the Under Voltage Alarm value or above the Over Voltage Alarm value then the Auto Exercise Test will be stopped the load disconnected and an error mess
35. n Court O atl da Las Vegas Nv 89115 Hanie Loadllisu License Enabled 1 800 LOADTEC 1 702 643 8750 service loadtec com Figure 29 License Manager Page 30 Programmable Digital Controller 10 3 2004 5 0 Operation The Load Bank is designed to be an integral part of the power generation system and is intended to work in concert with the generator When operating in one of the automated control modes it will add remove load from the generator based on various system measurements and conditions The Load Bank can be in one of three main operational modes These are Off Manual and Auto The current operational mode Is indicated by the three System LEDs on the Control Panel The operational mode is selected by pressing the Mode key on the Control Panel Each time this key is pressed the Load Bank will cycle from Off to Manual Manual to Auto and Auto to Off When the Load Bank is in the Off mode all loads will be removed the fan s turned off note not all system have cooling fans and all automated load functions will be disabled 5 1 Manual Mode When the Load Bank is placed in the Manual mode it can be used as a simple Test amp Measurement device to place loads on the generator and measure the results In the Manual mode the operator selects the desired load value The generator must be running and providing voltage before any testing can be done in the Manual mode When voltage is present from the generat
36. nces will be scheduled based on the start time interval and day of the week variables Ext Clock External Clock When the generator is sensed as being connected and the transfer switch is in the Normal position then an Auto Exercise test sequence will be started 1f External Clock is enabled Thus an external source can be used to force the generator on and start an Auto Exercise test sequence Gen Timeout Generator Timeout This variable 1s used to define the amount of time In seconds that the Load Bank will wait for the generator to start When an Auto Exercise sequence 1s started from the internal clock it will turn on the generator start contact If no generator voltage 1s detected in the amount of time defined by this variable then the Auto Exercise sequence will be aborted and the generator start contact will be turned off A Generator did not start error will be sent to the system message lists Start Start hrs amp min The Start Time defines the time of day in which the scheduled Auto Exercise sequence will be initiated It 1s actually made up of two separate variables the hours and minutes Together they form the time of day The Hour variable is based on a 24 Hr clock so 2 00 is 2 AM and 14 00 is 2 PM Int Interval This variable defines the interval in days between Auto Exercise sequence tests The number of days between tests will always be at least as many as this value Ifa day of week for the test 1s also se
37. ng executed a step with a zero time value is encountered it 1s considered the end of the test When the end of the test is reached the Load Bank will drop the load and wait for 1 minute to turn off the generator by releasing the generator start contactor An AutoExercise seq completed message will be recorded upon a successful completion of the test sequence 5 2 1 1 Generator Prestart A generator pre start contactor may be designed into your Load Bank This 1s an optional signal If it exists then the Auto Exercise Clock Setup screen will contain an additional parameter PreStart time This pre start signal is used to inform the operator that an automated test 1s about to start The pre start contactor will normally be wired to an external indicator such as a warning light When the Auto Exercise sequence 1s about to start the pre start contactor will be activated for the configured PreStart time in seconds before the generator start contactor will be closed 5 2 1 2 External Clock The Auto Exercise system can also be configured to perform its automated tests based on external stimuli Ifthe Ext Clock parameter in the Auto Exercise Clock Setup screen is set to Y then the external clock mode is enabled If this parameter is enabled and the generator is sensed to be on Source Voltage is present and the transfer switch is in the Normal position then the system will perform the Auto Exercise test sequence Given this setup
38. ns to select For example in the setup mode there are 8 functions When there are more than 3 Soft Key functions markers will be shown to indicate there are more functions to the right or left In the example shown there are more al Se Aan TE mode Manual More VERGI Load cmd Zhaku cetur mode actiue functions to the right Pressing the Right Arrow Key gt will scroll the functions one position to the right When a marker is shown on the left side it indicates that there are more functions to the left Pressing the Left Arrow Key causes the functions to scroll one position to the left sss anual Load cmd SHE Setur mode active 3 1 3 The Mode Key The control system can function in one of three operating modes Off Manual and Auto automatic The Mode Key is used to cycle between each of these modes Pressing this key while in the Off mode moves the system to the Manual mode If in Manual pressing this key will move the system to the Auto mode and pressing the key while in Auto returns the system to the Off mode Page 6 Programmable Digital Controller 10 3 2004 3 1 4 The Stop Key The Stop Key is used to stop any action being performed by the control system and disconnect the load If the Load Bank has J cooling fans they will also be turned off when this key is pressed The LCD screen will be restarted at its power up state 3 1 5 The Start Key The functions
39. oading 1s used to automatically load the generator There are two sub parts to the Auto Loading functions Base Loading and Regen Loading Base Loading 1s used to apply and immediate load to the generator as it is starting up Regenerative Loading is used to add load very quickly if the system detects regenerative power power going into the generator Ians Hauva Huta Load Load cmd BEM The main Auto Loading features are configured via the Auto Loading Setup screen see section 4 3 for further information If Auto Loading 1s enabled and the generator is sensed as on Source Connected and the transfer switch is in the Emergency position then Auto Loading will be active Enabled Y N Y Genset size 1000 Load 33 00 ES Sizes 7000 Delay min 5 0 Ld Res 50 Load rate 10 Unload rate 2 The list above shows an example set of Auto Loading parameters Given these settings 5 minutes after the generator is started with the transfer switch in the Emergency position 330 KW 33 of 1000 KW will be placed on the generator The Load Bank will monitor the load on the generator and will add remove load as the facility load goes up and down The Ld Res Load Resolution parameter is used to define the minimum load that can be added or removed at a time This parameter will normally be set to the size of the smallest load step of the Load Bank The rate in which load is added and removed is controlled via the Load rate and
40. ogrammable Digital Controller 10 3 2004 Glossary Control Power Control Power 1s the power source used to provide power for the internal electronics 24 VAC and the cooling fan s When the control power is taken from the Load Power the Test Source the Load Bank 1s powered from the Test Source directly Genset Size This is a user entered parameter that defines the size of the system under test the Test Source This parameter Is used throughout the system for scaling load commands and displaying warning messages when an excessive load command is requested KVA Apparent Power The complex power that is made up of the vector sum of the real and reactive power KVA KW KVAR In a balanced three phase system AVA d Where V the phase to phase rms voltage and I the rms line current KVAR Reactive Power The power required to transport energy to from the reactive elements of a circuit It is normally expressed as KVAR kilovolt amp reactive In AC circuits it is computed from the voltage and out of phase current KW Real Power The power the does real work 1 e produces power at a motor shaft In AC circuits it is computed from the voltage and the in phase current A load that is purely resistive no reactance provides only real power load Load Step Load Banks are constructed using discrete load elements know as load steps Loadtec s Load Banks can be constructed with resistive and or inductive load ste
41. or the voltage values will be shown on the LCD screen and the source Connected LED will be lit Before any loads can be placed on the generator the Load Bank must be brought to the On state When in the Manual mode press the Start key to start the system When this key is pressed a start message will be shown on the LCD screen and the Load Bank will go through the process of turning on Starting sustem Some Load Banks will contain cooling fans others will not If the system has cooling fans they will be started at this time Once the system 1s in the On state and ready to apply loads the Operation Normal LED will be lit and a System Started message will be scrolled across the display If any errors occurred while starting the system the Operational Alarm LED will be lit and an error message will be recorded Operator Manual 5 1 1 Manual Load Setting Once the Load Bank is in the On state the left Soft Key F1 in the Main Menu will be labeled as Set Load Press this Soft Key to allow the load to be entered Seat Load Ians Hawa mode Manual Load cmd L Enter desired load Figure 30 Manual Load Setting As shown in the above example a Numeric Entry Field is opened allowing you to enter the desired load to be applied For instance entering 200 will request that the Load Bank place 200K W of load on the generator Ians Hawa mode Manual Load cmd zhBibBkl In our example shown above the
42. panel the system can be programmed and controlled It is made up ofa 16 key keypad a 128 x 64 Graphic LCD Display and 8 status indicators The OIP can be integrally mounted to the Load Bank or remote mounted via a standard CAT 5 cable interface Programmable Digital Controller 10 3 2004 Operator Manual 3 1 The Front Panel Keys The OIP contains 16 special function keys as shown in figure 2 The following is a description of each of these keys 3 1 1 Power On Off Ke power The Power On Off Key is used to toggle the power on and off ONOrr Turning the power off simply powers down the OIP The DMC Digital Metering Controller electronics will always be powered on if a power source is provided When the OIP 1s powered down none of the automated load functions will be active and no loads will be applied 3 1 2 The Soft Keys F3 Soft Keys Soft key definitions mode Manual Load cmd SHEL Figure 3 The Soft Keys Fl F2 and F3 are the Soft Keys These are called Soft Keys because their function is defined by the software and will change based on the current operational mode of the system The function of each of these keys 1s indicated by the top lines of the LCD display In the example shown in figure 3 the F1 Key is used to set the load F2 is used to access the system messages and F3 is used to access the setup functions Operator Manual Some of the operational modes have more than 3 functio
43. ps Resistive load steps are resistors that provide a real power load KW at a given voltage Inductive load steps provide a reactive power load K VAR kilovolt amp reactive at a given voltage and frequency The resolution of any Load Bank 1s determined by the size of its smallest load step Metering Data Metering Data 1s the data measured and calculated by the Power Meter system of the Load Bank control electronics system It is made up primarily of the phase voltages currents and power On State When the Load Bank is in a state that loads can be applied they are said to be in the On State To be in this state the internal cooling fan s must be on and flowing air and the internal 24 VAC power bus must be operational It can be thought of as the fan s being on although the process is more complicated than simply turning on the cooling fan s airflow 44 apparent power 47 Auto Mode 34 AutoExcersize seq completed 45 AutoExcersize seq interrupted 42 45 AutoExercise seq aborted 44 AutoExrsze date missed 45 BiDir node inactive 42 Calibration Menu 24 Cntrl over voltage 42 Control Power 42 47 control voltage 42 43 Control voltage unstable 42 cooling fan 47 Emergency 13 33 35 Exercise Messages 12 40 44 Fan did not start 42 Fan door s closed 42 fan doors 42 Fan Start Failure 43 Generator did not start 45 High Speed Data license 30 High volt alarm seq stopped 45 High voltage warnin
44. quickly place load on the generator as it is starting This in turn helps build boost pressure faster and in the end gets the generator up and running more quickly Base Loading is enabled via the Base Loading Setup screen see section 4 4 Enabled Y N Y Voltage 85 00 Load KW 50 Time sec 20 00 The parameters shown above are an example set of the Base Loading setup parameters Given these settings as the generator 1s starting up when the voltage reaches 85 of the nominal 50 KW of load will be added by the Load Bank If our generator 1s a 480 volt system then the load will be added as soon as the generator voltage reaches 408 volts 85 of 480 The load will remain at 50 KW for 20 seconds In order for Base Loading to have the desired effect 1t must be capable of turning on very quickly Therefore 1t cannot wait for the transfer switch or any internal cooling fan s to start up It must add load regardless of these items After the configured time has expired the load will be dropped and the Load Bank will go into Auto Loading or Auto Exercise based on the transfer switch and the system configurations Operator Manual 6 0 The Messaging System The Load Bank software contains two distinct message systems These are the Operational Messages and the Exercise Messages As the name implies the Exercise messages are all of the messages that pertain to the Auto Exercise system The Operational Messages are basically
45. rent Calibration Screen change the required values s 5 Exit to save the calibration settings Press the Def GenAmp Soft Key to set the calibration coefficients for each of the generator amperage values to their default values Default GenHAmr Det GenHme Channel TYH H Figure 27 Default Generator Current Screen Select Y Yes to cause the generator amperage calibration coefficients to be set to their default values cero benAmFE Zero GenBmrF Channels tYeHa He Ensure no current 1z Present Figure 28 Generator Current Zero Screen Press the Zero GenAmp Soft Key to zero the generator amperage sensor values Warning Zeroing a sensor value 1s used to NULL any offsets in the value Zeroing voltages or currents when there is voltage or amperage applied will yield unpredictable results as the system will NULL a real measurement 4 9 The License Manager The Load Bank Controller electronics must be registered for use The LoadView interface is a separately licensed system option These settings are accessed via the License Manager Screen Press the Reg Codes Soft Key from the Setup Menu to access the License Manager Screen Use this screen to enter the registration codes for the system and optional for LoadView These registration and license codes are only available from Load Technology Inc The System s serial number will be required oe License Manager Load Technology Inc I 4225 Productio
46. rrow keys to move the Message Selector up and down on the screen If the Down Arrow key is pressed when the Message Selector is at the bottom of the screen then the entire list will be scrolled up if there are more messages below tho Ctr lPwr c Turnins on at Bibir com los Load Bank Tur ibir mode in Alarm Message Indicator In the example shown above the Down Arrow key was pressed to get to message number 49 It is the selected message The asterisk to the left side of the message indicates that the given message is an Alarm as opposed to a simple informational message Alarms always cause the loads to be dropped and the Load Bank turned to the Off state fans off on systems that contain cooling fans Press the Clear Reset key to close the Message Viewer window 6 1 1 Viewing Message Details Pressing the Enter key will allow the details of the selected message to be viewed v Check Figure 34 Message Detail Window In the example shown the No CtrlPwr check fuses message was recorded at 2 00 12PM on Sep 13 2004 Press any key to close the Message Detail Window 6 2 Operational Messages Page 42 The following is a complete list of the possible Operational messages Note that not all systems can produce all of these messages For example many systems will not contain cooling fans In these systems no cooling fan messages will ever be generated AutoExcersize seq interrupted This message indic
47. rt of the Auto Loading mode until load is actually applied In effect this parameter defines the delay from the startup until Auto Loading is active Ld Res Load Resolution This parameter defines the resolution of the Auto Loading system When Auto Loading is active the system will make adjustments to the load whenever the difference in load 1s more than this configured value This value can not be set to a value less the smallest load step in the Load Bank Page 20 Programmable Digital Controller 10 3 2004 Time seconds Load Rate amp Unload Rate These parameters are used to adjust the rate in which load is added Load Rate or removed Unload Rate from the generator when the Auto Loading mode is active The values entered range from 1 to 10 A value of 1 provides the least aggressive rate A value of 10 1s the most aggressive rate In most cases the Unload Rate will be set to a more aggressive setting than the Load Rate This will cause the Load Bank to unload more quickly then it loads The rates are accelerated as the generator gets closer to is load capacity Thus at any configured rate the Load Bank will load or unload faster when the actual load value is near the generator s capacity than it will at lighter loads Rate 1 least aggressive Rate 10 most aggressive I I I I I i I I I I I l E I I I I l i I I I i l l I l l I l I I l i I
48. sages press the Exrsze Msg Soft Key F2 To exit the System Message Menu and return to the Main Menu press the Exit Soft Key F3 See Section 6 0 The Messaging System for more information 3 2 1 5 The Setup Menu Page 12 The Setup Menu is accessed by pressing the Setup Soft Key from the Main Menu This menu contains 10 functions Only 3 functions can be shown on the screen at any given time Use the Left and Right Arrow Keys to scroll the functions to the left and right as needed Clock Figure 9 The Setup Menu Keys See Section 4 0 System Setup for information on each of the setup screens accessed from the Soft Keys Press the Func Select Key to exit the Setup Menu and return to the Main Menu Programmable Digital Controller 10 3 2004 3 3 The Status Indicator LEDs The Control Panel contains 8 LED status indicators The following is a description of the function of each of these indicators System Auto This green indicator 1s lit whenever the system 1s in the Automatic Auto mode When in the Auto mode the Load Bank will automatically load the generator and perform automated test sequences based on the programmed configuration System Manual This amber indicator is lit when the system 1s m the Manual mode In Manual mode the Load Bank can be used as a test and measurement device to perform manual loading of the test source System Off This red indicator is lit when the Load Bank is in the Off mode In
49. se messages AutoExercise seq aborted This message indicates that an Auto Exercise was executing and the operator pressed the Stop key to abort test Page 44 Programmable Digital Controller 10 3 2004 AutoExrsze date missed This message indicates that an Auto Exercise test was scheduled to be run but there was no time on that date that the Load Bank was allowed to run the test If for example the generator is running and the transfer switch is in the Emergency position then the Auto Exercise test 1s not allowed to run If this condition persists from the time of day the test was scheduled through the end of the day then the test is considered missed A new test will be scheduled based on the configured parameters Starting AutoExcersize seq This message is recorded when the Auto Exercise test is started AutoExcersize seq interrupted This message indicates that a test sequence was running and the transfer switch moved to the Emergency position This message will also be recorded if a test is running and the generator voltage has gone away the generator is turned off AutoExcersize seq completed This message is recorded upon the successful completion of the Auto Exercise test sequence Generator did not start This message indicates that the generator did not start after the generator start contactor has been closed for the configured generator timeout period High volt alarm seq stopped If the generator volta
50. sing the Up Arrow Key when the Selection Marker is at the top of the screen will cause the screen to scroll down To change the values of the selected parameter press the Enter Key If the selected item is a numerical value then a Numerical Entry Field will be displayed that allows the valued to be changed If the selected item 1s a non numeric value a Toggle Entry Field will be displayed Press the Clear Reset Key to exit the Setup Screen 4 1 1 The Numeric Entry Field Numeric Entry Fields are used to Numeric Field edit numeric values When this field is Genset zize fob opened brackets Cursor will be placed around the value indicating the size of the field The cursor indicates the selected digit Use the Left and Right Arrow Keys to position the cursor under the digit to be changed and use the Up and Down Arrow Keys to increment or decrement the digit As an example we will enter a Genset size A Genset size value of 500 KW In our example the current value is zero Press the Left Arrow Key twice to move the cursor to the Genset size _ K hundredths position Press the Up Arrow Key to increment the digit Note that when the hundredth digit 1s incremented the digits to the right the tenths and units digits are Genset size lun filled in with zeros Press the Up Arrow Key 4 more times to increment the value to 500 Press the Enter Genset sizezl 290 Key to accept the value Pressing the Clear R
51. te location A simple to more complex system can be constructed using these modules A Load Bank system can contain up to eight 8 LMC Load Module Controller These modules provide the safety and main I O control in the system 1 e internal power control fan s control etc A system may not use this module while a more complex system can use a number of these devices The control of each of the load steps 1s provided for by the LSC Load Step Controller A system may contain only one of these modules while more complex system can contain many of the LSCs Both the LMC Load Module Controller and the LSC Load Step Controller are commanded and controlled by the DMC Digital Metering Controller Load Bank Programmable Digital Controller DMC Digital Metering Controller Dual Processor based Metering and Control Module O LP Operator Interface LSC Load LMC Load mana Step Controller Module Controller Safety inputs Resistive Load Steps Power Control Fan Controls Inductive Load Steps LSC Load LMC Load Etc Step Controller Module Controller Figure 1 Load Bank System Diagram The Load Bank is operated via the OIP Operator Interface Panel Again this control panel may be mounted integrally to the Load Bank or remote mounted at a separate location 2 0 Functional Overview The main function ofa Load Bank is to place an electrical load on a power source usually a generator generator system or a UPS Unint
52. this Soft Key to view the results of the system s startup tests The Fam l System Tests screen shows FLASH Alzk the size of the RAM and Clock runnins FLASH memory of the system Press any key to Press ana keu close this window Softwr Ver Press this Soft Key to view the current oftware Wersions Software Version numbers RTOS This information may be System requested by Loadtec s Fem TOS customer service personnel Remotas Htr Suz during troubleshooting procedures RTOS is the Real Time Operating System version of the OIP System is the version number of the OIP Software RemRTOS is the operating system version of the DMC and RemSys is the DMC software version MtrSys is the version number of the metering system software in the DMC Press any key to close this window Press the Func Select Key to move to the Meter Select menu Programmable Digital Controller 10 3 2004 3 2 1 3 The Meter Select Menu The Meter Select functions are accessed by pressing the Func Select Key Load e 1 200 Hana Kl mode Manual Load cmd 266K Figure 7 The Meter Select Menu The Meter Select Menu is shown in Figure 7 Since there are only 3 positions in the Data Section of the screen in which metering data can be shown and there are more than three values of metering data a method for selecting metering data values is required This function is provided for by the Meter Select Menu Whenever the Meter S
53. tup then the number of days between tests can be larger that this value As an example if the Interval value is set to 10 and the Day variable is set to Sunday a test is performed on the next Sunday after 10 days have passed The system will then calculate that the next test should occur in 10 days However 10 days from Sunday is not another Sunday In this case the system will schedule the next test for the Sunday following the tenth day from the last test Operator Manual Day Day of the week This value defines what day of the week the system should perform the Auto Exercise test If this value is set to zero then the day of the week for the test will be determined by the interval value only If this value is set to a 1 through 7 then the tests will be performed on the specific day of the week No day specified Sunday Monday Tuesday Wednesday Thursday Friday Saturday 18 M E au a Pre Start Time This value is only available on systems that have been configured with a Generator Pre Start circuitry 1s installed and enabled This time in seconds determines the amount of time that the status signal output is turned on before the test 1s started 4 2 2 Auto Exercise Sequence Setup An Auto Exercise test is determined by defining 8 sequential load and time values The Test Sequence is entered via the Auto Exercise Sequence setup screen H X l load 3225 mim 1 Z4 load 155 mim 1 4 load BE min HB 4
54. ua a 48 2004 Load Technology Inc 11 Programmable Digital Controller 10 3 2004 Table of Contents List of Illustrations Figure Ts Load Bank System DIQergm usi a raices sd ense sds eene Eee eoa edes 2 Figure 2 The O I P Operator Interface Panel sse 4 RISHFEO 21 NC SO LAOS tit tie Ud TO CY BW DRY SES 9 F on Ne Tho VIO VICI apt aerate Sea es neat a lero nisqapa mauka 9 Fu oure TNO Status Menu dd 10 Figure 7 The Meter Select Mellon id 11 PIQUE edo vsrem Messaee Mella Sun u uuu unsi unun sas 12 Pioure Y Ine Seip MeCN CVS uuu au suysu asus nra a aispa qia naqa 12 FLOURE TU ES CHU Drech u ua eR Dare tata canoe u aod apt da lo adi ias 14 Figure 11 Auto Exercise Clock Setup Screen sese 16 Figure 12 o AUTO Exercise Seguente A e 18 NN nu uuu nu u uyu kD asss 20 PISUre 14 c Toad Unodd TOTO tati ted 21 Figure 1y Base L adine SCtup CO s wni uns aqhapa eie eel douce de edi detegit Dart 22 LIOHFOUTO co CCH SCID IS yama umanuan aa shut E IE H OUI 2 3 Foure dTa SIChiSolli SOV CN esti suben potu b EO petu EL lac usin apt dct pe subaudi uat 23 FIGURE lS Ser CLOS CO niei oH u Rw uM MSN A M or AM M aD uM UND 24 Figure 19 The Calibration Menu K OVS uices heroas RAI Rer o xS Ua d so Eheu ha dete de 22 Figure 20 Volage Calibration Screeners oot tese t ht a tbe ert apaun 25 Peme qp ego ol Se Cr e en o ceci 25 i1oure 22 Voll oe Lero Screen ui dtusbo sto dob it 26 Figure 252
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