UPS/Generator maintenance with load banksfiles.schneider-electric.com.au/events/innovation-day... · 2019-04-10 · Maintenance/Periodic Testing • Service Schedules and Diagnostics

UPS/Generator maintenance with load banks

#DigitalEvolution#InnovationDay#EcoStruxure

Page 2Schneider Electric |

Presenter

Spilios Rigopoulos

Spilios RigopoulosNational ASCO Business Development Manager, Australia & New ZealandASCO Power Technologies

SCHNEIDER ELECTRIC

Confidential Property of Schneider Electric

A Load Bank provides a consistent and repeatable electrical load, that can be accurately controlled, measured and recorded.

SIGMA LT & SIGMA 2 Module

Supply-on-Test

SIGMA. The ASCO load bank control and instrumentation platform.

Network multiple load banks. Numerous interfaces and options to meet market & application.

Intelligent Hand-Held Terminal

Sigma Software Control

ModBus

What is a Load Bank?


All industrial load banks utilize a fan and use the corresponding airflow to cool the resistive elements.

What is a Load Bank?

The air flow can be Vertical or Horizontal discharge

It must accurate controls to place appropriate load on to the power system. “Accurate load bank step”

Must have rugged and reliable resistive elements. ASCO load bank elements can be either the helically wound “Avtron HelidyneTM or Froment style non finned sheathed elements


Why Does The World Need Load Banks?

• Gen-Set Testing & Compliance:• Commissioning• Verify performance• Prevention of wet stacking• Engine maintenance• Meeting emission standards including Tier 4• Testing to ISO8528

• AVR (Automatic Voltage Regulator) and governor setup

• UPS / DC – Capacity testing

• HVAC Commissioning – data centres / server heat profiling

• Power Factor Correction Testing - 0.8 lagging or leading

• To Test Infrastructure – Breakers, power distribution

An ASCO load bank testing two diesel gen-sets

“The best way to replicate, prove and verify the real life demands on critical power systems.”


Load Testing affects all major Genset ComponentsRunning the generator at 100% load, ensures all components of the generator are tested.

By running the generator at full load for a period, the generator will reach the optimal running temperature to ensures;1. The cooling system is tested2. To remove unburnt fuel and carbon

build up in the generator – a condition call ‘WET STACKING’

3. Testing the performance of the AVR, Governor (frequency) and controls.


Why Test Under Load?Prevent Wet Stacking• Unburned hydrocarbons produced when engine

temperatures are below optimum (typically <30% of nameplate capacity.

• Reduced HP and efficiency. • Increased emissions.• Carbon buildup leads to ‘frozen’ piston rings

resulting in hot gasses slipping between the piston and the cylinder wall eroding away the piston and losing compression.*

• Will eventually lead to engine failure Technically, the carbon builds up in the ring slot, preventing the ring from moving freely in the slot, locking the ring into one position.

9


Regulations & Load Testing

AS/NZ 3009: 1998 B3 MAINTENANCE AND TESTINGB3.1 Regular running Both automatic and manually operated plant should be run on load for at least 4 on a regular basis but not less than once a month

ISO 8528 New genset operational standards


ISO 8528• Performance Standard for new gensets• Genset is tested to a Profile of V and HZ responses

during • Load acceptance• Load rejection• Motor starting

• 4 Classes: G1, G2, and G3 Profiles are pre-defined. G4 for custom

• Preferred to test at nameplate PF, often 0.8 lagging: Exception reporting required if testing done at unity PF


ISO 8528


Site Load Correction (SLC)Site Load Correction (SLC) is an automaticcontrol feature for SIGMA-equipped ASCOLoad Banks that automatically applies load toelectrical circuits to maintain the minimumamount of load required by diesel generators.The following describes SLC features,benefits, and operation.

THE NEED FOR SLC

Wet stacking is the accumulation of unburned fuel residue that develop inthe exhaust systems of diesel engines when they operate below minimumlevels of load, which is commonly 30% of nameplate capacity. Under theseconditions, engines may not reach optimal operating temperature. Theresulting fuel combustion process is incomplete, resulting in increasedemission of particulates as well as carbon monoxide and other greenhouse gasses. Operating under no-load or light loaded conditions forextended periods promotes wet stacking. Maintaining minimum load levelsavoids wet stacking and thus promotes reliability and longevity.


Controls Options – Site Load Control

Load Bank Load

Facility Load

Engine Generator Desired Loading 50% to 70%


Heat Simulation• Portable Load Banks – Mobile units that allow network testing in multiple aisles

Verify – Heating Ventilation Air Conditioning (HVAC)• Load banks produce heat that simulate the server’s thermal output.• Tests effectiveness of the HVAC system prior to server installation.

Commissioning• Load test critical power components to identify any performance issues.• Ensure power system is working as designed.• UPS systems and testing inverter output

Maintenance/Periodic Testing• Service Schedules and Diagnostics• Gen-Set Health

• Wet Stacking Prevention• Ensuring Tier Emission Standards are Met• Diesel Particulate Filter (DPF) Burn Off

Uninterruptible Power Supplies (UPS) Maintenance & Testing• Inverter performance Back-up Battery String• DC Load Banks for battery capacity testing

Typical Data Center Layout

Load Bank Utilization in the Data Center Sector


Key Market: Data CentresTypical Data Centre Load Test Applications

• Data capture and reporting

• Range of portable & static options

• Networking and individual control

• Automatic testing to ISO8528

Key Product Features

Up to 25 Sigma LT load banks controlled by a single hand-held

• Current presence: moderate

• Key customers: Rental, end users and commissioning companies

Presence & Customers

• Commissioning• HVAC systems• LV & MV gen-sets – ISO8528• UPS• Electrical equipment

• Maintenance• UPS battery discharge• ISO8528 Standards• Prevention of wet stacking

• Server rack simulation


Compact and Portable

Model 2705 – Suited Features

• Manoeuvrability. Load Bank fits through doors and into elevators.

• Lightweight. Easy for one operator to move with swivel casters, fork pockets, and lifting eyes.

• Best-in-Class Packaging. 80 kW at 400 V, 50 Hz, weighs only 48kg.

• SIGMA LT. Controls allow for flexibility, features, benefits and capabilities when compared to competitive digital control platforms.

• Networking: SIGMA LT allow 25 load banks to be networked together for increased total capacity

Compact and Portable

ModelName

Capacity FrequenciesAvailable (Hz)

Voltage Range(V)

Ambient TemperatureRange

Hot Air DischargeDirection

ControlOptions

Optional Extras

2705 80 kW 50 400 V -20°F to 120°F Horizontal Local Digital Toggle

SIGMA LT Hand-Held Control,Cable Set, Transport Case


Battery Capacity (Discharge) Testing

One means for avoiding these losses is accurately identifying batteries that are at risk of failure, then servicingor replacing them as needed.• The necessary data can only be derived from performance testing.• In order to obtain this data, a UPS battery string is typically tested using a DC load bank or by an AC load

bank via the UPS inverter.• The type of load test will depend on the type of batteries used in the UPS.• The most meaningful tests record battery current, voltage, and temperature under load conditions.

Note: Dissimilar voltages from cell-to-cell or string-to-string are a clear indication of battery degradation.

Data Centers/Uninterruptible Power Supplies

• Uninterruptible power supplies (UPSs) provide emergencypower when main power fails.

• UPS systems utilize strings of batteries for backup power duringan outage.

• Failure of a data center UPS can impact or interrupt operationsand result in substantial business losses.

• At these facilities, battery condition and performance areconsistently found to be leading causes of failures.


Load Bank Utilization in the Healthcare MarketCode Compliance Testing

AS/NZS 3009:1998, B3.1 Regular runningNFPA 99 - Healthcare Facilities CodeNFPA 110 - Standard for Emergency Generator SystemsNEC Article 700 - Emergency SystemsNEC Article 708 - Critical Operations Power SystemsThe Joint Commission Standards

Portable Load Banks – Mobile units that allow network testing in multiple locationsPermanent Load Banks – Dedicated units installed outdoors for back up power testingRadiator Mounted Load Banks – Dedicated units mounted on radiator generator set for backup power testingCombined Resistive/Reactive Load Banks – Designed for 0.8 pf testing & verification of power source(s). Testing to ISO8528 G3 classification pass or fail.

Commissioning• Load test critical power components to identify any performance issues.• Ensure power system is working as designed.• UPS systems and testing invertor output

Maintenance/Periodic Testing• Service Schedules and Diagnostics• Gen-Set Health

• Wet Stacking Prevention• Ensuring Tier Emission Standards are Met• Diesel Particulate Filter (DPF) Burn Off

Uninterruptible Power Supplies (UPS) Testing• Inverter performance

Back-up Battery String• DC Load Banks for battery capacity testing


Key Features Key Benefit

High capacity (kW) in a small mobile design.

Test multiple power sources in various locations.

Accurate and recordable load data with Sigma Control Platform

Essential for Code Compliance.

Resistive and Resistive/Reactive Load Banks available

Allows for steady and controllable 0.8 PF testing compared to unsteady building load

Load Dump Circuitry Load bank will automatically drop its load when emergency back up power is activated

Portable load banks can easily fit thru man doors and into freight elevators

Easy to move and transport.

Radiator mounted load banks for supplemental loading of generator set

Cost effective means to keep a minimum supplemental load on generator set to reduce wet stacking of exhaust system.

Key Features for Healthcare Market


• SIGMA LT & SIGMA 2 Options suited for any load test application

• Networking multiple units of any size and type with individual unit control where required.

• Fast, automated data capture and reporting.• Integration to into existing BMS systems.• Reporting to ISO8528.• Automated testing.

Best-in-Class Control

Key Features for Healthcare Market – Control & Monitoring


The SIGMA Digital Control Platform facilitates:

• Interfacing with EcoStruxureto provide the customer with “single pane of glass” view

• The collection and presentation of power quality information downstream of power infrastructure

• The use of data and communication with other power products to make enhanced decisions

Load Bank Control Building Integration


The most common type of load bank

Used for full engine testing of gen-sets and verifying power supplies

NRTL (UL, CSA or CE) certifications available on most models

Key Features

• 1000 – Radiator mount

• 2000 – Compact portables

• 3000 – Permanent, movable or trailer mount

• 4000 – Permanent

• 5000 – Trailer mount

Applicable Series Numbers

Engine maintenance, lightly loaded gen conditions, data centres / HVAC verification, R&D

Key Applications

Load Banks – Overview - 1000 Through 5000 SeriesCategory RESISTIVE RESISTIVE / COMBINED


Load Banks – Overview - 6000 Through 8000 Series

Combination of resistive and reactive load – fully test real life conditions on alternators and distribution

Unity or 0.8 PF for full gen-set testing

Purely inductive or capacitive models available

UL and or CE marked for global use (dependent on model)

Test to ISO8528 G1/G2/G3 standards

Key Characteristics

• 6000 – Permanent or movable

• 7000 – Permanent

• 8000 – Containers, permanent or movable


Key Applications

Product verification,non-unity power factor testing

RESISTIVE RESISTIVE / COMBINED Category


Load Banks – Overview – Containerised - 8000 Series

Combination of resistive and reactive load – fully test real life conditions on alternators and distribution

Purely resistive, inductive or capacitive models available

Unity or 0.8 PF for full gen-set testing

Test to ISO8528 G1/G2/G3 standards

Key Characteristics

• 8000 –Containerized permanent/movable


Product verification, non-unity power factor testing, harsh environments

Key Applications

Category RESISTIVE RESISTIVE / COMBINED


The Emergency back-up system

The Thermal Management system

The UPS system

The Electrical Infrastructure

Using a load bank provides “peace of mind”

It ensures the correct & efficient operation of the systems & infrastructure

saving you MONEY


Website: loadbanks.ascopower.com


loadbanks.ascopower.com


loadbanks.ascopower.com: Engineering Specifications


loadbanks.ascopower.com


Videos

https://www.youtube.com/watch?v=Z3xF7gLQCJQ

https://www.youtube.com/watch?v=vL_gUr7h_PE

https://www.youtube.com/watch?v=Cd6QPqHgls0&t=0s


Load Bank User & Training Guides


Monthly Output | Social Media

https://www.google.com.br/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjb35WS4cfVAhXja5oKHYeODBcQjRwIBw&url=https://twitter.com/oldtwitlogo&psig=AFQjCNG0_MieM9OI5S46qlcE34JZB-7pZg&ust=1502285874798801

https://www.google.com.br/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjq6YuJpMjVAhVmzFQKHdfRCS0QjRwIBw&url=https://autodo.info/pages/l/linkedin-logo-png-download/&psig=AFQjCNFsFMpdY3xM5RA1X45ESbwyJ80NPQ&ust=1502303840271127


#DigitalEvolution #EcoStruxure #InnovationDay

Join the conversation

Visit our Innovation Hub.

©2018 Schneider Electric. All Rights Reserved. Schneider Electric | Life Is On and EcoStruxure are trademarks and the property of Schneider Electric SE,its subsidiaries, and affiliated companies. All other trademarks are the property of their respective owners.

Documents

UPS/Generator maintenance with load banksfiles.schneider-electric.com.au/events/innovation-day... · 2019-04-10 · Maintenance/Periodic Testing • Service Schedules and Diagnostics