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Chapter Three
Load Bank Operation

This chapter explains how to operate the load bank’s local control panel. It describes the function of
each control and explains the operation of the status indicator lamps. It then provides specific examples
of how the control panel is used to carry out a load function test and how it can be used to operate the
load bank when an external control system (such as the Hand-held) is not available.

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Summary of Contents for Froment 8800 Series

Page 1: ...8800 SERIES High Voltage Load Banks User Manual Power Technologies ...

Page 2: ......

Page 3: ...cifications are subject to change without notice The Company retains exclusive rights to the intellectual property in any designs specifications publications and software described or included herein The property shall not be used in whole or part for any purpose other than in connection with the Company s particular products that this document is intended to accompany The Company s identification...

Page 4: ...5 User control interfaces Non unity Power Factor Testing 1 8 When is non unity power factor testing required Multiple generator testing What equipment is required Movable Load Banks 1 10 Load Bank Applications 1 12 Generating set testing Testing UPS systems and batteries 1 13 Site load correction Using Multiple load banks 1 15 Introducing Froment 8800 SERIES Load Banks 1 16 8800 SERIES Load Bank S...

Page 5: ...st general points Control System Connections 2 15 High Voltage HV instrumentation mode Low Voltage LV instrumentation mode System monitor control Optional remote connections Commissioning 2 14 Chapter Three Load Bank Operation Before Operating the Load Bank 3 2 Safety warning Controlling the Load Bank 3 3 The Control Room 3 4 The external power inlet compartment Main control panel System monitor O...

Page 6: ... Sigma Hand held 4 8 Hand held Quick Start 4 9 Using the Settings Pages 4 10 The Options Page 4 15 The Test Pages 4 19 Manual Test Mode 4 23 Auto Test Mode 4 27 Chapter Five Maintenance Troubleshooting Safety Warning 5 2 Routine Maintenance Procedures 5 3 Daily Monthly Annually Ring Main Unit RMU Maintenance 5 4 Housing exterior Housing interior Leakage of SF6 gas Service life Transformer Maintena...

Page 7: ...Froment Load Bank System Monitor 5 11 Startup Screen Navigation The Meters Screen I O Screen Status Screen Appendices 8800 Installation Diagrams A 2 Transformer Commissioning A 3 Transformer Maintenance Schedule A 4 Certificate of Conformity A 7 Electromagnetic Compatibility A 8 Useful Equations A 9 ...

Page 8: ...ess easier safer and more reliable It then provides an introduction to the 8800 SERIES load banks and their main features Chapter Two covers all of the procedures that need to be carried out before a load bank can be put into operation It explains how to install the unit safely and how to commission it to check that it will operate correctly Chapter Three explains the basics of how to operate the ...

Page 9: ...ting the cooling air Ensure the air inlet and outlets are completely unobstructed and that there is no loose paper plastic bags or other debris that may be drawn on to the air inlet grille obstructing the airflow Combustible material left near the air discharge should be removed Only operate the load bank with all the guards in place with doors closed and with all of the covers and protective scre...

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Page 11: ...ntroduction to the general principles of power supply testing and then it explains how a Froment load bank makes the process easier safer and more reliable If you are an experienced load bank user you may want to skip the earlier sections but you should certainly read the introduction to Froment 8800 SERIES load banks which appears at the end of the chapter ...

Page 12: ...is also a requirement for regular testing for existing equipment particularly those that provide emergency or standby power supplies How can a generator be tested effectively The answer to this is very straightforward apply a load that is equivalent to the generator s maximum output and then run the generator and observe how it performs The careful measurement of the generator s output will reveal...

Page 13: ...oad can be applied safely and in a way that will not cause damage to the generator and its control circuits or injury to the personnel running the test 3 The fan in the fan heater provides a method of safely dissipating the considerable amount of heat generated by the test 4 The voltmeter and ammeter provide instrumentation that will allow the results of the test to be monitored Of course this kin...

Page 14: ...s that the heat generated during testing is vented safely to atmosphere Fuses and safety interlocks that ensure that the test can be shut down in a controlled fashion if any problems occur A microprocessor based control and three phase instrumentation system connected to a number of highly accurate voltage and current transformers This provides automatic precision control of the test and allow the...

Page 15: ... which shut down the load bank safely should a problem occur Figure 1 3 Sigma 2 load bank control unit User control interfaces The wide variety of different applications for load banks require a wide variety of user control interfaces These range from a very basic switch controlled system through to sophisticated computerised control instrumentation and data logging systems All Froment load banks ...

Page 16: ... way with minimum of calculation Sigma PC Load Control Software As an alternative to the Hand held the load bank can be connected to a PC running Froment Sigma PC Load Control software This Windows application provides all of the facilities of the Hand held with an enhanced user interface improved instrumentation and facilities for response analysis data acquisition and reporting Test data can be ...

Page 17: ... This will allow the load bank to be integrated with a wide range of test automation supervisory and monitoring systems Modbus control is beyond the scope of this manual If you need more information please contact the Froment technical support department Note Both the Hand held and the PC soft ware can control up to 14 Sigma controlled load banks simultaneously Tests can be run manu ally or automa...

Page 18: ...wer to the circuit and the circuit is said to have a low or non unity power factor For instance to get 1kW of real power a load with a power factor of 0 8 will require 1 25 kVA apparent power to be supplied Figure 1 7 Typical power curve for power factor of 0 8 A low power factor puts additional stresses on alternators voltage regulators and switch gear without necessarily putting additional load ...

Page 19: ...ltiple generating sets are running in parallel or where it is necessary to simulate the start up of a large motor Multiple generator testing Multiple generating sets running in parallel can present a problem for installers when it comes to setting up load sharing and voltage regulation on a new system A purely resistive load will not provide the required load characteristics and a combined load is...

Page 20: ...tion and one intended to be movable These include External power supply inlet The load bank s fans and control electronics can be powered by the generator under test or as recommended by Froment a completely separate external power source To make providing external power simple on a movable load bank a suitably rated IEC60309 connector is mounted on the unit either externally or behind a lockable ...

Page 21: ...ptions Throughapre punched non metallicplatefittedwithprotectingshuttersorgrommets Through a protected slot Through a nonferrous gland plate Via optional externally mounted multipole IEC60309 or single pole plug and socket connectors Figure 1 9 Typical movable load bank control panel OUT IN Sigma 2 Control Fan and controls supply isolator Emergency Stop Fan and controls supply source selector Manu...

Page 22: ...nt criteria G1 is the least stringent and applies to small generating sets intended to supply simple loads G2 is broadly equivalent to commercially available power G3 is intended for sets which are powering loads which particularly require a stable and accurate power supply A further class G4 allows for performance criteria agreed between the supplier and the buyer In addition to the testing that ...

Page 23: ...any applications a generator may be required to run for extended periods with little or no load applied For a diesel generator this may mean that the engine does not reach its optimum operating temperature and this can cause a problem sometimes known as wet stacking so called because unburnt fuel can make its way through to the exhaust stack This can lead to serious maintenance problems including ...

Page 24: ... the optimum range If the current increases in response to an increase in site load the load bank will remove load accordingly The load bank can do this very quickly in response to sudden changes of site load such as a lift or pump motor starting up SLC is a specialist application for a load bank and it requires careful configuration Please contact Froment for more information and advice if you ar...

Page 25: ...e where a purely resistive load bank is to be permanently installed for ongoing routine maintenance engine tests A load bank with inductive elements could be added for a short period so that commissioning and acceptance tests can be carried out Note When multiple load banks of different capacities are used the load applied is shared proportionally depend ing on the ratio of the load banks capacity...

Page 26: ...ovide a conventional four point lift The units are of all steel construction and are insulated to minimise condensation The internal cabinets are manufactured from corrosion resistant zinc plated mild steel using the Froment standard construction method The resistive elements are mounted in the top half of the duct and forced air cooling for them is provided by a pair of axial fans mounted in the ...

Page 27: ...irement Introducing Froment Load Banks 1 17 8800 SERIES Load Bank Specifications 8800 Nominal capacity 0 8pf 11kV 50Hz kVA 2750 Terminal quantity phase size mm 1 x M12 Containerised ISO style 20ft Length mm 6058 Width mm 2438 Height mm 2591 Weight approximate kg 20000 Fan s No x diameter mm 2 x 900 Fan poles 4 Fan motor kW Ph 10 5 3 Fan Control current max A 38 4 Total current max Starting A 124 F...

Page 28: ... 12 Froment 8800 load bank cutaway view showing major components Ring Main Unit Control room access door Switchgear cabinet Hot air exhaust Transformer Transformer air exhaust CT s Reactive load elements Resistive load elements ...

Page 29: ...eration It explains how to install the unit safely and how to commission it to check that it will operate correctly Important The chapter contains a number of important safety instructions Do not attempt to install or operate your Froment Load bank until you have read and understood this chapter Misuse could result in serious injury and damage to the equipment ...

Page 30: ...serious injury if you come into contact with it when it is in operation Heat hazards When a test is in progress the resistive elements can glow cherry red The heat they produce is removed by the air that the fan forces past them but that air in turn can become very hot To avoid these hazards pay particular attention to the following points Make use of the correct handling equipment and ensure that...

Page 31: ...t Make sure that the air inlet and outlets are completely unobstructed and that there is no loose material that could be drawn in to the air inlet grille Ensure that there are no combustible material near the air discharge Keep an approved electrical fire extinguisher present at all times when the load bank is in operation Noise Hazard The load bank s operating noise level is above 85dB and ear pr...

Page 32: ...s are not suitable for over stowing on the deck of the ship They require a top loading slot under the deck for insurance purposes refer to the CSC certification plate attached to the unit for details Storage The original transport packaging should be left in place on the load bank and it should be storedundercover inaheatedwarehouse untilitisreadytobeinstalledandcommissioned This recommendation ap...

Page 33: ... IP23 A standard 8800 SERIES load bank can be used in ambient temperature between 10 C and 35 C at 90 relative humidity non condensing and at altitudes up to 1000m above sea level Loading The load bank is heavy and must be installed on a level surface that is capable of supporting its weight see nameplate Space There must be sufficient space to provide access for maintenance to all of the doors an...

Page 34: ...lation Other nearby air handling plant can also interfere with the airflow to or from the load bank Equipment should be spaced well apart and positioned so that their airflows tend to complement each other rather than compete When multiple load banks are being used it is important to ensure that the hot air from one load bank does not exhaust directly or indirectly on to any other load bank Load B...

Page 35: ...ience All cables should be appropriately rated and installed in accordance with current standards and accepted practice The connections to the load bank may be intended to be temporary but it is essential to apply the same standards to the cable glands and terminations as if the installation were permanent Note The Load Bank supply cables must be protected by a Short Circuit Protective Device SCPD...

Page 36: ...s power source To use this load bank you are required to use an external power supply that is independent of the Supply on Test Refer to the load bank s rating plate for the external power supply requirements The supply must be capable of supplying the fan motor starting current and must be fused accordingly Connecting the external supply The external supply socket for the 8800 is mounted external...

Page 37: ...ow Care should be taken to ensure the phases of the CTs and connection point correspond For the 8800 there is one M12 connection per phase Figure 2 4 8800 RMU power terminal compartment Protective earth connection Earth conductors must always be bonded to the frame of the Supply on Test and connected to the grounding terminal of the load bank marked PE The cables used must be suitably sized for th...

Page 38: ... the risk of sudden and violent cable movements Please ensure local regulations are followed If the connections are made using more than one conductor for each phase connection all the cables on any one phase should be of exactly the same length and laid along a similar route To minimise eddy current losses etc the conductors should be distributed equally between the terminals and the cable entry ...

Page 39: ...closed in whole or part without prior written authority NJ Froment Co Ltd This document may not be copied or disclosed in whole or part without prior written authority OUT IN Sigma 2 Control an and controls upply isolator Emergency Stop Fan and controls supply source selector Manual stop start buttons Sigma c interfac sockets Supply on test status indicator LOAD When than on mus numbe S All doors ...

Page 40: ...ower inlet compartment This provides the user with options to start stop and reset faults for the load bank from a remote location Also included is a remote trip for the ring main unit and a signal to indicate if the load bank is running Figure 2 10 The ten pole connector and table of connections definitions Note If the remote stop signal is not required then this must be linked out Poles 1 2 6 7 ...

Page 41: ...h on the external power supply to the fan and control circuit Rotate the Fan and Controls Supply Isolator to the ON position Press the START button The fan will start Check the fan rotation which should result in airflow from the fan towards the heating elements Press the STOP button the fan will stop immediately Rotate the Fan and Controls Supply Isolator to the OFF position Troubleshooting If th...

Page 42: ...Load Bank Installation and Setup 2 14 ...

Page 43: ...scribes the function of each control and explains the operation of the status indicator lamps It then provides specific examples of how the control panel is used to carry out a load function test and how it can be used to operate the load bank when an external control system such as the Hand held is not available ...

Page 44: ...air can be very hot and can cause serious burns Do not touch the outlet grille while the load bank is running or for a few minutes afterwards Only operate the load bank with all the guards in place with doors closed and with all of the covers and protective screens securely in position Ensure that there is no risk of the hot discharge air re circulating back to the air inlet of the load bank exten...

Page 45: ...using the Sigma 2 load control system Alternatively the load bank may be controlled with third party software using the HMI ethernet output You can find full instructions for the use of the Hand held in Chapter Four of this manual For instructions on using the Sigma PC Load Control Software refer to the application s built in help system Modbus control is beyond the scope of this manual If you nee...

Page 46: ...ee NJ Froment Co Ltd This document may not be copied or disclosed in whole or part without prior written authority 1 2 3 4 5 6 7 8 9 10 11 12 13 6 14 15 16 13 RCD 14 Lighting on off switch 15 The fan and control supply isolator 16 Fuses for external fan control supply 7 Sigma control system in out connections 8 Air vents Ensure this is not obstructed 9 Reset button 10 Instrumentation selection swi...

Page 47: ...r see the rating plate for supply details more details on page 2 8 External fan and controls supply connector For use when the fan and controls are to be powered by an supply that is independent from the Supply on Test This is a three phase supply inlet connector see the rating plate for supply details Sigma control system in out connections These provide the plug in connectors for the Sigma inter...

Page 48: ...he upper panel and Figure 3 4 shows a typical arrangement for the lower panel Figure 3 3 Typical arrangement of lamps and switches for the upper panel Emergency stop Operating this causes the load bank to immediately shut down The fans control circuits and load elements will be isolated but the Supply on Test may remain live Chapter Three START RESET EMERGENCY STOP All doors must be shut and guard...

Page 49: ...st run This lamp indicates the HV module is functioning correctly HV inst stop warning This lamp indicates there may be a problem with the LV load bank or the HV instrumentation RMU closed This lamp illuminates when the RMU is in the closed position Bund Warning This lamp illuminates when a high level of liquid is present in the bund If not emptied the RMU will trip Figure 3 4 Typical arrangement ...

Page 50: ...ance functions for the load bank These functions include providing a real time display of the load bank s operational status with instrumentation read outs for both the supply on test and the external supply In addition the System Monitor provides detailed diagnostic information regarding the status of the control system s inputs and outputs and full details of any error messages that may occur Th...

Page 51: ...ccurs the Start indicator lamp will be extinguished and the Reset indicator lamp will begin to flash An error code will be displayed on Sigma controller LED see See Sigma 2 Load Bank Status Display on page 5 6 for more details If a Hand held or PC system is connected to the load bank the error message will be displayed on the screen See Sigma 2 Load Bank Status Display on page 5 6 for more on this...

Page 52: ...k power supply off On On On Start up lamp test Off On On Load bank in stopped state ready for start Supply on Test healthy On Off On Load bank is operational Supply on Test healthy Flashing Supply on Test fault warning The load bank will remain operational and can be operated if required Off Flashing Load bank in error condition If the error occurs when the load bank is operating the load bank wil...

Page 53: ...n it is in the off position It can be used to perform an emergency stop but it can also be padlocked in the off position and this means it can be used to secure the load bank from unauthorised operation Figure 3 6 The Fan and Controls Supply Isolator Warning If the fan is stopped when the load elements are hot the temperature with the load bank will increase considerably The load bank is designed ...

Page 54: ...shing 7 Press the Start button The Start button indicator will illuminate and the Reset button indicator will go out 8 Apply HV Power source 9 Now apply some load You can do this using the Sigma PC Load Control Software 10 Check the voltage current and power readings are as expected and that none of the load bank indicator lamps are flashing 11 Check the direction of the fan as it is rotating Mova...

Page 55: ... very simple to use direct means of controlling the operation of Sigma controlled load banks whilst simultaneously monitoring the performance of the generator under test This chapter provides an in depth look at the hand held control system with an overview of its more advanced features ...

Page 56: ...boardand 4 3 colour TFT screen These provide a simple control panel interface and instrumentation to allow the progress of load tests to be monitored In operation the hand held synchronises the load events and ensures that the load is shared proportionally between each connected load banks Instrumentation information from all load banks is summed and displayed on screen This manual describes Versi...

Page 57: ...e latest firmware sig file on a USB flash drive This can be downloaded from www froment co uk firmware updates 1 Connect Sigma Hand held to power supply or use supply from load bank Hand held power supply can be ordered directly from froment sales ascopower com 2 Connect USB drive to micro USB connector using USB OTG Adapter order from RS Part 790 3647 see below 3 Power on hand held and check boot...

Page 58: ...articular load bank is assigned during manufacture or on commissioning If there is a number selector switch on the load bank this can be used to change the number to any value from 1 to 11 Setting the selector switch to 0 selects the default number as stored in the load bank Sigma control cable testing With the addition of a small mains powered adaptor the Hand held can be used as a Sigma control ...

Page 59: ...ncrease or decrease values that are highlighted or displayed on screen Pressing I applies load if in Manual Test mode or starts an automatic test if in Automatic Test Mode If a load is already applied pressing I forces the Hand held to carry out a load correction that is to say that it will adjust the number of load elements applied to correct for changes in voltage or temperature etc Pressing O a...

Page 60: ...our function keys F1 to F4 The screen shows details of the supply settings built in help and also provides access to instrumentation to allow monitoring during testing Figure 4 3 The Hand held screen display Sigma Status Messages A message window is used to display status information and other messages from the load banks Figure 4 4 Typical Sigma status message Page Title Function Key Labels Statu...

Page 61: ... generator rating is incorrect run the load bank from an auxiliary supply Check the Fans and Controls Supply Selector switch is in the correct position Load bank fan supply VT fuses blown or VT s faulty Check fuses and VT output Over Temperature On LoadBank nn Over Temperature signal not present Load bank is over temperature Ensure that the load bank ambient temperature is not exceeded and check h...

Page 62: ...g and will allow the percentage loads applied to be calculated accurately The second part is concerned with carrying out the test itself Various percentage loads are applied and the Sigma instrumentation is used to view the generator s response However there is much more to the Hand held than the ability to conduct basic manual tests We will explain all this in more detail and cover the use of aut...

Page 63: ...t the supply size Press F4 OK when the values match those on the generators rating plate Test 1 4 is the first of the four test instrumentation pages provided by the Hand held Select the percentage load required using the or keys A pop up will appear show ing the adjusted value and this is also displayed on the right of the status line Apply the load by pressing the I key The LED will light indica...

Page 64: ...he settings menu pages Settings 1 This page is the starting point of the Hand held menu system It is displayed immediately after start up and shows details of the supply on test New supply on test Press F2 NEW to measure and reset the supply on test voltage frequency and number of phases Edit settings Use the or keys or F1 PRE SET to adjust the supply Press F3 SELECT to change the value being edit...

Page 65: ...ence of operation Check the voltage and frequency on each load bank connected Check voltage and frequency stability Check phase rotation on each load bank Checks voltages to determine whether this is a three or single phase connection At the end of this sequence the Hand held will Display a warning message if any of the above checks fail Automatically set the supply voltage frequency and number of...

Page 66: ...alues are acceptable and you can usually do this by comparing them to those on the generator s rating plate Figure 4 8 Typical generator rating plate The voltage frequency number of phases apparent power kVA and power factor cos φ values shown on the Supply on Test page are all adjustable from the Supply on Test Edit page You can reach this page directly by pressing F3 EDIT or after automatically ...

Page 67: ...are using are adequate It can also be useful if the generator does not have a kVA value on its rating plate 4 Press F4 OK when the values are set correctly The load bank will be set to operate at the supply ratings set and the display will return to the Settings 1 page A warning symbol will be displayed if the load bank is not large enough to carry out a test to at least 110 of the supply Figure 4...

Page 68: ...d bank page Checking for load banks Pressing F2 CHECK will cause the Hand held to check the number of load banks connected It should be used to clear any errors on a load bank or when changing the number of load banks connected to the Hand held The status bar shows the total number of load banks that are connected The load bank rating kVA and power factor displayed on the lower left of the screen ...

Page 69: ...tions pages press F3 OPTIONS from the Settings 2 load bank page Figure 4 11 The Options Pages Navigate between the options pages by pressing F1 PAGE Pressing F3 SELECT selects a list item for adjustment You can enable or disable the selected option by pressing the or key Press F4 OK at any time to exit the options pages and return to Settings 2 Chapter Four ...

Page 70: ...status line on the Test pages will show the total accumulated test time Otherwise it will show the time since the current load was applied Options 2 Display Figure 4 12 The Options 2 page Language Select the default language Five languages are supported as standard These are English French German Spanish and Italian Changing the language setting will change all of the text on the display including...

Page 71: ...damage Unless you have a good reason for doing so we recommend that these three options remain selected Load Correction Provides closed loop load control This adjusts the load applied to compensate for variations caused by changes in voltage frequency or temperature Load correction will also compensate for the fan load if the fan is being powered by the Supply on Test See Using load correction on ...

Page 72: ...to cycle through each of the pages in turn As the generator test runs the instrumentation will show the generators response to the load applied in real time The three test pages offer different views of the instrumentation each of which can be useful at different stage of the generator testing process Note The Test pages Test 1 to Test 3 are available for viewing at any time irrespective of whethe...

Page 73: ... 16 Test 2 page The second and third Test pages display the electrical data required for full load testing from different perspectives Test 2 displays true rms three phase measurements of the line to line voltage VL and current A in the central column of the display with the calculated instrumentation powers in the left hand column Apparent Power Power Factor Actual Power Real time voltage and fre...

Page 74: ...the phase to neutral voltage VP and current A in the central column of the display Again the calculated instrumentation powers are shown in the left hand column Apparent Power Power Factor Actual Power Real time voltage and frequency display RMS line to line voltage RMS Current Maximums and minimums Hand held Reference Guide ...

Page 75: ...ting plate For example in Figure 4 8 the generating set is rated G3 ISO8528 3 Rating Operating Limit Values Performance class Parameter Unit G1 G2 G3 Transient fre quency devia tion from rated frequency 100 sudden power decrease 18 12 10 Sudden power increase 15 10 7 Frequency recovery time 100 sudden power decrease s 10 5 3 Sudden power increase s 10 5 3 Transient volt age deviation 100 sudden po...

Page 76: ...st mode manual or automatic as shown in Figure 4 20 Figure 4 18 The Test screen status bar showing the differences between automatic and manual modes Page Title Test Mode Manual Auto Auto Test Step Number Time elapsed since last load step Current Load Selected kW kVA or cos φ Auto test status running paused stopped Hand held Reference Guide ...

Page 77: ... look up in its internal load table to see if it has a stored correction for that load value If so it will apply the stored correction If no correction is found then it will calculate the load correction based on the actual power measured with a compensation for the actual voltage and frequency If the same load is applied a second time the Hand held will always calculate a new load correction This...

Page 78: ...ues If a resistive only load bank is used then the selection will be percentage load and kW only Power factor can be set between 0 00 and 1 00 cos φ on the Hand held most generators are rated at 0 8 cos φ However non unity power factor values are dependant on the load bank capacity and the supply size Figure 4 19 Setting load values for the manual test sequence Use the or keys to set the percentag...

Page 79: ...f the Settings screens to get to the Test 1 page 2 Use the and keys to select the percentage size of the required load 3 The pop up window will disappear after a few seconds but the newly set value will be shown at the top right of the status bar 4 Press F3 SELECT and use the and keys to adjust the kVA value 5 Press F3 SELECT and use the and keys to adjust the power factor value Note The load sele...

Page 80: ... a few minutes until the fan delay has completed This will allow the equipment to cool If the Ramp Down on Reject function is enabled see page 4 16 the load will ramp down for 12 seconds before the fan delay starts The Hand held s LED will flash to indicate this Press O a second time to reject the load immediately Note If load correction is turned on then the load applied will be adjusted for volt...

Page 81: ...epeated test sequence is required Figure 4 20 The Hand held automatic test sequence Press F2 AUTO to select automatic testing mode Press I to apply the load and start the automatic test sequence When the test is running use the and keys to adjust the load Press I to apply the new load If necessary press O to remove the load before the end of the automatic test sequence Use F3 SELECT and the or key...

Page 82: ...of the load bank that the Hand held is connected to If the load bank is unable to apply the load that has been set the stage in the sequence will be marked with an exclamation mark Figure 4 22 A warning is shown if the connected load bank cannot apply the load This may be shown for a resistive only load setting where the load bank is simply not large enough or where a non unity power factor settin...

Page 83: ...ext sequence stage 5 Press F3 SELECT to choose the next value to be changed 6 When all values are edited press F1 NEXT to choose the next sequence stage to be programmed 7 Press F4 OK to return to the Test pages when programming is complete Note Setting the time value to 0 will cause the Hand held to ignore the step Setting the load percentage for the first step at 0 will allow the fan to start wi...

Page 84: ...equence by going back into Automatic mode and pressing the I key The sequence will restart with the time remaining for the load step The and keys can be used to adjust the percentage load applied as the sequence is running Press the I key to apply the new load This can be useful if you need to reduce the load because the preset load is causing the generator to stall Press O at any time to stop the...

Page 85: ...oubleshooting This chapter describes both the routine maintenance procedures needed to keep Froment load banks operating correctly and the procedures you may need to troubleshoot the equipment if you run in to a problem using it ...

Page 86: ...You should remain alert at all times when the unit is in operation There are three main sources of danger Electricity can kill Serious injury or death could result from contact with electrically live parts Even though the connections to the load bank may be temporary they must always be made to the same standards as if they were permanent Load banks contain fast moving parts The fan in particular ...

Page 87: ...e or corrosion and touch up as necessary Check that there is no build up of dirt or debris on the load elements Check that the fan rotates freely Check that the fan blades are tight and that the fan boss is securely fastened to the motor shaft Check that the anti condensation heaters if fitted are working Isolate the supply and then inspect both the inductive and resistive load element terminals e...

Page 88: ...of water or contamination by animal or plant life Check that the gas indicator is reading in the green zone Clean the units thoroughly and touch up paint work as necessary Housing interior Open the main and pilot cable box door Check that the gas indicator is in the green zone and the protector cap is fitted over the gas filler valve Forcircuitbreakerpanelschecktheelectricalprotectionsystem refert...

Page 89: ...eration The cooling fan may not run until load is applied Apply the load and verify that the fan starts No power to fan Check the fan and control isolator switch is in the correct position and the Start button has been pressed Confirm that the control supply fuses are not blown Fan thermal overload tripped Allow the load bank to cool and then stop the load bank Press the reset button followed by t...

Page 90: ...or Frequency Ensure the Supply on Test settings are correct Excessive volt drop Check rating of cables or if an MV test transformer Check AVR droop setting Single phase operation or phase missing When testing a single phase generator check the method of connection Refer to Chapter two For three phase operation verify that all of the phases are present Loading problem Check the load fuses Check the...

Page 91: ...ormal operation a single character status code is displayed on the LED Warnings If an event occurs that generates a warning the load bank Reset button lamp will begin to blink and a warning code sequence will be displayed on the Sigma 2 control unit LED Each character in the four step sequence is displayed for 500ms with the code repeating every 2s The end of the sequence is indicated with the dec...

Page 92: ...nated before press ing the Start button External emergency stop buttons if fitted are depressed Release all emergency stop buttons and press the Start button E02 Lost communications with Hand held or PC Hand held or Sigma PC system has disconnected from load bank while a load is applied Hand held or load bank interconnecting cable fault Check and replace E03 Load contactor switching fault A load c...

Page 93: ...ructed the inlet is clear and is free to rotate Confirm the over load is set to the correct current setting by referring to the load bank drawings E34 Fan supply voltage and or frequency limits exceeded Fan supply voltage or frequency is out of limits Check control voltage and frequency If the generator rating is incorrect run the load bank from an external supply Check the Fans and Controls Suppl...

Page 94: ...ctly wired The Supply on Test is wired incorrectly when using remote Modbus load control Check the Supply on Test connection possible phase rota tion or phase missing E60 E61 Ring main unit 0 tripped Ring main unit 1 tripped The load bank Supply on Test ring main unit is tripped Ensure the ring main unit is closed before pressing the load bank Start button If the load bank ring main unit trips whi...

Page 95: ...ief overview which should introduce you to the most important points Startup Screen When it is first powered the System Monitor displays the startup screen If load is applied the display will switch automatically to the Meters Overview screen Otherwise tap one of the four navigation keys to select one of the four main screens Navigation Each System Monitor screen contains four touch sensitive keys...

Page 96: ...ur tabs Overview Supply Control and HV Meter By default the meter screen will automatically display the screen below Figure 5 2 LV Overview provides a real time visualisation of the load bank s LV operation Figure 5 3 The LV Supply screen provides a more detailed view of the Supply on Test instrumentation ...

Page 97: ...ntrol status To access the HV metering press HV meter HV has three tabs Overview Supply and LV meter By default the screen below will be automatically displayed when entering HV mode Figure 5 5 HV Overview provides a real time visualisation of the load bank s HV operation Maintenance Troubleshooting ...

Page 98: ... of the Supply on Test instrumentation To return to the LV metering tap the LV meter tab I O Screen Tapping the I O key provides an interactive listing of all the Sigma 2 Load Bank Module inputs and outputs Figure 5 7 The I O screen Each input or output state is shown in real time ...

Page 99: ...he input or output s dependencies by listing the component identifications for the selected circuit In the example above Load Bank Module output OP37 drives relay K137 which in turn drives the load step contactor K37 K37 is 465kVAr inductive load step rated at 690V 50Hz The load step fuse is F37 rated at 500A The location of each component is also detailed along with the Froment drawing number whi...

Page 100: ...reen which normally has two tabs Overview and History Figure 5 9 The Status Overview screen provides a view of the current activity and any active errors or warnings Figure 5 10 The Status History screen provides a detailed listing of system events such as errors or warnings ...

Page 101: ...o diagnose the issue Load Screen Tapping the Load key will bring up a screen with two tabs that can be used to operate the load bank during maintenance procedures Figure 5 12 The Load Supply screen contains operating settings and a Load Control source selector Maintenance Troubleshooting Note It is important to confirm that the voltage and frequency shown in the Operating Settings are correct Tap ...

Page 102: ...n Accept Reject I key to apply the load Once the load is applied you can visit any of the other System Monitor screens that we have described to monitor the progress of the test When testing is completed return to this screen and tap the red Accept Reject O key to remove the load In an emergency press the load bank Emergency stop button to remove load immediately and stop the fans See Emergency Sh...

Page 103: ...l information that may be useful but does not easily fit in with the rest of the text This includes a specification for each of the 8000 SERIES load banks and a number of installation diagrams that show dimensions and space requirements for each unit ...

Page 104: ...A 2 8800 Installation Diagrams Figure A 1 8800 Side view showing maintenance access Figure A 2 8800 End view showing control room door access Appendices ...

Page 105: ...A 3 Appendices Figure A 3 8800 Plan view showing access clearance requirements Figure A 4 8800 Side view showing cable entry sock location ...

Page 106: ...A 4 Appendices Figure A 5 8800 Transformer view ...

Page 107: ...tings and readings noted Between HV Winding and Earth use 5000V or 2500V Insulation Tester Megger Between HV and LV Winding use 5000V or 2500V Insulation Tester Megger Between LV Winding and Earth use 1000V or 500V Insulation Tester Megger d IR values obtained should be similar to those indicated in the manufacturers test report furnished with the handing over documents In humid weather IR values ...

Page 108: ... shall be checked with marshalling box scheme drawing furnished with the handing over documents b During testing of accessories like buchholz relay etc operation of all the alarm trip contacts shall be checked at marshalling box terminal blocks ensuring both operation and wiring are checked correct 5 2 6 Buchholz Relay Test a Relay operation for alarm and trip contact shall be checked by injecting...

Page 109: ...ing or Before Commissioning AT LEAST 12hrs should be allowed for the oil to settle down and air is released from all points at 2 hourly intervals 5 3 2 It is recommended that the transformer is initially energised at NO LOAD only and checked for any abnormalities for the next 6 to 8 hours 5 3 3 AFTER SWITCHING on no load if the Primary Side Circuit Breaker is tripped investigate the cause thorough...

Page 110: ...A 8 Appendices Transformer Maintenance Schedule ...

Page 111: ...8 EC Electromagnetic Compatibility Directive 2014 35 EU Low Voltage Directive References to the relevant harmonised standards used or references to the other technical specifications in relation to which conformity is declared EN60204 1 2006 A1 2009 EN 61000 6 3 2001 EN 61000 6 2 2001 Safety of Machinery Electrical Equipment of Machines Electromagnetic Compatibility Generic Emission Standard Elect...

Page 112: ... transmitter close to the remote controller may result in out of tolerance readings on the instrumentation Electromagnetic emissions EN 61000 Part 6 3 2001 Electromagnetic disturbances generated by this equipment do not exceed the prescribed levels that could cause interference to radio telecommunications or television reception apparatus There will be no interference provided the reception equipm...

Page 113: ...r kVA kW pf I V kW pf kVA kW Reactive Power kVAr 2 2 2 2 1000 3 1 1 kW kVA kVAr pf I V kVAr pf kVA kVAr Power Factor pf kVA kW pf φ cos Current A 3 1000 3 1000 pf V kW I V kVA I De rate from Nominal Voltage and Frequency nom nom nom nom nom kVAr F F V V kVAr kW V V kW 2 2 Note All voltages are phase to phase values and assume a 3 phase system ...

Page 114: ... ascopower com 2018 ASCO Power Technologies All Rights Reserved All rights reserved Publication No 5051 v1 1 ASCO Power Technologies Froment Load Banks Cliffe Road Easton on the Hill Stamford United Kingdom Tel 44 0 1780 480033 froment sales ascopower com ...

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