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2013

CATALOG OF
ELECTRONIC LOAD
CONTROLLER (ELC)
For micro hydro power plant

Frequency and voltage control of micro hydro generator with microcontroller
technology to maintain the stability and sustainable electricity supply with simple
and affordable solution.

PROTEL MULTI ENERGY
Small Hydro Control and Renewable Energy
Jl. Pesantren No. 92 (Global) Cibabat
Cimahi 40513, Jawa Barat, Indonesia
Telp/fax : +62 22 6631608
www.pme-bandung.com

PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 1. The control is done by diverting the excess power to the dummy load (ballast).com 2 . and large load) · Grid interconnection · Suitable with most of turbine type (Cross low. The diversion is controlled by the ELC main board based on frequency deviation through electronic switch (thyristor). In principle the purpose of ELC is to make sure that power generated by the turbine is the same with power consumed. etc) Jl. Telp/fax :+62 22 6631608.pme-bandung. Indonesia. www. such as: · Synchronous generator with AVR (brushless) (1 Phase/3 Phase) · Synchronous generator without AVR (brushless) (1 Phase/3 Phase) · Productive use of generator (motors. Generator Consumer ELC Ballast Load Power turbin = Pconsumer + Pballast 20.000 Watt Protel Multi Energy’s Electronic load controller (ELC-PME) is designed to suit with different type of generators and various application of micro hydro. Propeller. Kaplan.92 (Global) Cibabat Cimahi 40513 Jawa Barat. Francis. DEFINITION OF ELECTRONIC LOAD CONTROLLER Electronic load controller can be de ined as electronic control system used to stabilized the output of generator (frequency and voltage) when the consumer/main load is change. Pelton.000 Watt + 5.000 watt = 15. Pesantren No.

pme-bandung. heating on induction motor).com 3 . TVs. it is needed to compensate the higher currents and Thyristor effect as well as safety reasons. www. capable in handling sudden large load change in very quick time 10 ms. thus the voltage/current generated will be distorted (harmonic) which might effect on some electrical appliances (generator.92 (Global) Cibabat Cimahi 40513 Jawa Barat. motors. etc. robust and easy in installation. such as: · Generated Frequency and Voltage are stable (220-230 V / ±50 Hz) · Avoid the damage on electrical and electronic appliances such as lamps. operation and maintenance · ELC is much cheaper comparing to other type of controller. Due to frequency and voltage luctuation · Avoid the damage of generator due to runaway speed when the consumer is off or decreased · No water hammer effect. · Simple. radio.2-1. To minimize the effect it’s suggested to reduce the power diverted into dummy load! · Plant with ELC requires larger generator than it’s expected out put by 1.5 times. Telp/fax :+62 22 6631608. light bit lickering. Indonesia. Pesantren No. thus affordable for low budget project and village electri ication scheme 3. Jl. DISADVANTAGE OF ELC · Our ELC works with phase angle control regulation.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 2. since no need of water low adjustment or closing · Fast recovery time. BENEFIT OF ELECTRONIC LOAD CONTROLLER (ELC) There are many bene its with the utilization of ELC on the micro hydro scheme comparing to other type of controls.

the control characteristic is done with programming software which allow the lexibility in setting and parameterization. and then the next 50% will only be used if the excess power exceeds the irst 50%. Once ELC is installed. The control of power diversion to dummy/ballast load is done with phase angle regulation. The ELC continuously read the signal every half cycles (10 ms). No need of additional electrical panel required with our ELC’s. Indonesia. this mean that only 50% of dummy load capacity is connected at the beginning. meaning that if only one main board damaged no need to replace three of it. www. The frequency reading is done every half cycle of the signal or every 10 ms on positive and negative cycles.com 4 . only replace the broken one and avoid the disturbance of one phase to the other. the diversion of power is made with two step system. This means that frequency error on positive cycle will immediately be compensated on the following negative cycle and vice versa.33 ms triggering angle possibility. One main board can be utilized up to four channel of Triac output or 2 channel of Thyristor module. it will adjust the phase angle triggering based on the frequency error from the setting. To minimize the harmonic (voltage/current distortion) of the signal output.92 (Global) Cibabat Cimahi 40513 Jawa Barat.pme-bandung. Pesantren No. This method allows the power control from 0-100% with ine regulation up to 0. no need of parameters adjustment/setting during commissioning. WORKING PRINCIPLES Protel Multi Energy’s (ELC-PME) is developed based on microcontroller technology that make it simpler and smaller electronic circuit comparing to analog system. all parameter already con igured and tasted at factory before shipment according to customer requirements or national standard. ensuring the fast recovery and smooth operation. Basic electrical protection such as short circuit and overload protection is included on the cubicle and customized based on customer requirement.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 4. Telp/fax :+62 22 6631608. intended to make it easier in replacement and maintenance in case of failure. cubicle is provided with nine (9) analog panel meter (customized) to monitor the operation of plant and data recording. Jl. The main board of ELC-PME is made per phase. In addition.

92 (Global) Cibabat Cimahi 40513 Jawa Barat.. Jl. over frequency/voltage § Generator type : Synchronous ynchronous with or without AVR (brushes less and brushes) § Dummy/ballast load : Tubula ubular air heater industrial standard come with the frame and Connection with the size of 130% of design power capacity § Type of supply : ELC cubicle only. This mode only provided for an emergency case. Limited disturbance and radio interference to electronic device have been observed at certain phase angle triggering due to the fast switching thyristor especially on the radius of 1 meter from the equipment. Nevertheless that this is not an ideal option. Pesantren No. switch/ In case of damage on ELC main board or dummy load.pme www. Term and condition applied. 5. ELC+ballast load or complete set (ELC+ (ELC+ballast+cable) § Guarantee period : 1 year of components and ELC main board upon failure. the system still can run without control (manual) while the problem is being repaired.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) This approach has resulting in signi icant reduce of total harmonic distortion of the electricity output..pme-bandung. ELC-PME is provided with manual or automatic mode switch/MCB. and electrical appliances connected.com 5 . turbine. option since running the plant without control can be dangerous to generator. Indonesia. Telp/fax :+62 22 6631608. SPECIFICATIONS GENERAL SPECIFICATION : § Rated voltage : 220/380 V or 230/400V § Phase : 1 or 3 phase § Rated frequency : 50 / 60 Hz § Frequency range : 50 50-54 Hz / 60-64 Hz § Power output : 1— —250 kW § Recovery time : 10 millisecond § Basic protection : short circuit an and overload on consumer. 66 www.

Indonesia.%THD) - - - - - - √ Pilot Lamps-3P √ √ √ √ √ √ √ MCCB consumer √ √ √ √ √ √ √ Contactor consumer - √ √ √ √ √ √ Over/undervoltage - o o o o o o Over/underfrequency - o o o o o o Cooling fan - √ √ √ √ √ √ 4 mm² 6 mm² 10 mm² 16 mm² 25 mm² 35 mm² 50 mm² Ballast cables (NYAF) in mm² 1.kW.A.6 pcs TM55 TM90 METERING PROTECTION CABLES & DIMENSION Main cables (NYAF) in mm² Cubicle dimension (cm) Weight (approximate) TG35 TG35 TM55 40x50x20 50x70x20 50x70x20 50x70x20 60x80x25 15 kg 20 kg 24 kg 31 kg 37 kg SKKT162 SKKT162 60x80x25 80x100x30 48 kg 52 kg NOTES * (o) customized upon request only * ballast cables are 2 pcs /phase * Speci ications are subject to change if required with/without notice See last pages for dimensioning and layout! Jl.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) DETAILED SPECIFICATIONS: DESCRIPTIONS SPECIFICATIONS 5-10 kW 10-20 kW 20-30 kW 30-40 kW 40-60 kW 60-80 kW 80-100 kW Voltmeter generator-1P √ √ √ √ √ √ - Frequency meter √ √ √ √ √ √ - Hourmeter √ √ √ √ √ √ √ Ampermeter consumer-3P √ √ √ √ √ √ - Ampermeter ballast load-3P √ -1P √ √ √ √ √ √ Digital multimeter (V.kWh.92 (Global) Cibabat Cimahi 40513 Jawa Barat.5 mm² 2. Telp/fax :+62 22 6631608. Pesantren No.pme-bandung.com 6 .5 mm² 4 mm² 6 mm² 10 mm² 16 mm² 25 mm² THYRISTOR .kVA. Hz. www.cos phi.

PUSH BUTTON ON Connecting the consumer load (main load). PILOT LAMP 220 volt lamps.pme-bandung. MAIN COMPONENTS OF ELC-PME 1 11 2 9 12 10 3 14 13 4 5 7 6 8 15 18 16 19 17 20 21 1. www. It’s suggested to maintain the equal current on each phase (balanced load) 4.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 6.92 (Global) Cibabat Cimahi 40513 Jawa Barat. HOURMETER (h) Recording the operational hour of the plant. VOLTMETER (V) Showing the voltage of generator. Pesantren No. This is useful for maintenance schedule and monitor the components lifetime.com 7 . on normal operation it’s suggested to maintain the current on ballast at minimal value to prevent overheating and continuously overloading generator. switch on the contactor Jl. 2. AMPERE METER CONSUMER (A) Showing the current lowing to the consumer. Telp/fax :+62 22 6631608. 5. Indonesia. AMPERE METER BALLAST (A) Showing the current lowing to the ballast load. FREQUENCY METER (Hz) Showing the generated frequency of generator 7. 3. indicating the presence of electric power on each phase. 6.

protection panel meter instrument. switch off the contactor 9. MCCB / NFB Protection against short circuit and overload on consumer side 17. SCR /TRIAC Power electronic switch (Thyristor) controlled by ELC main board to control the switching of current to ballast load. CURRENT TRANSFORMER Measure the current to consumer and dummy/ballast load 14. process and controlling the current low to the dummy/ballast load to maintain the steady condition of power plant 15.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 8. CONSUMER TERMINAL Connection terminal to consumer 20. TRANSFORMER Power supply for ELC main board 10.92 (Global) Cibabat Cimahi 40513 Jawa Barat. CONTACTOR To switch on/off the consumer load through push button ON/OFF or automated with relay from ELC main board (over/under frequency & voltage) 16.pme-bandung. pilot lamps and powerhouse installation 18.com 8 . NEUTRAL AND POWERHOUSE Connection for neutral and power house installation 21. www. Telp/fax :+62 22 6631608. MAINBOARD The heart of control system. FAN Air circulation and heat evacuation from heatsink / cubicle 13. HEATSINK Cooling and support of Thyristor/Triac (heat distribution) 11. PUSH BUTTON OFF Disconnecting the consumer load (main load). GENERATOR TERMINAL Connection terminal to generator 19. its sense. MCB As switch manual/automatic of ELC. 12. BALLAST TERMINAL Connection to dummy/ballast load Jl. Indonesia. Pesantren No.

Pesantren No. www. The ballast load consisting of six heater (two step) which is R1. The heater supplied from us. It can be the water heater or air heater type. fan.92 (Global) Cibabat Cimahi 40513 Jawa Barat. this type normally used as heating or drying element on industrial process and proved for its quality and lifetime. lamps. The heater can be made up from parallel of small heater to reach desired power capacity. Telp/fax :+62 22 6631608. fridge. Water heater need special tank and required continuous low to prevent from drying and overheating which might be neglected in the remote area. since it required less maintenance. Indonesia.pme-bandung.T1 ( irst step) and R2. For some reasons air heater is preferred. The total power capacity should be at least 130% of design capacity of the plant since capacity of the heater is less with lower voltage and for safety reason (overrated).S2. cooking machine as a dummy load since the voltage/current applied to it is not sinusoidal signal but modi ied signal with variable voltage. DUMMY/BALLAST LOAD Ballast or dummy load is a complement load to divert the excess power. Air heater types do not need forced air (fan/blower).T2 (second step). Never use normal electrical appliances such as pump.com 9 . Jl. is the tubular air heater type for industrial standard. appropriate room ventilation is suf icient.S1. which might damaged the appliances. easier in installation and last longer.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 7.

Following are some pictures of our projects: Pic.PROTEL MULTI ENERGY CATALOG OF ELECTRONIC LOAD CONTROLLER (ELC) 8.pme-bandung. Telp/fax :+62 22 6631608.2 Testing & setting of ELC before shipment Pic.3 ELC cubicle for 150 kVA MHP Pic. Pesantren No. www.4 our ELC Main board assembly Pic. PROJECTS REFERENCES PICTURES During 2011-2012 we have deliver 219 units of ELC through out archipelago of Indonesia and abroad.5 Stock ELC cubicles and ballast load Pic.965 MW.1 Components layout of 3 phase ELC ( 20-40 kW) Pic. Indonesia.com 10 .92 (Global) Cibabat Cimahi 40513 Jawa Barat.6 ELC-PME in operation Jl. From 3 kW – 300 kW with the total capacity of 3.

Pesantren No.com admin@pme-bandung.11.2010 Komarudin Not to scale Checked Format Approved __________ __________ A4 Jl.0 Sheet 5-10 1/6 . layout and dimension are subject to change with/without notice Scale Designed 02.Jawa Barat Telp/Fax : +62 22 6611753 www.01.0 1 2 3 4 5 6 7 400 8 9 220 12 350 BALLAST CONSUMER AS AS G1 K1 G2 K2 G3 K3 G4 K4 G1 K1 G2 K2 G3 K3 G4 K4 R G1 K1 G2 K2 G3 K3 G4 K4 S ELC–1P T ELC–1P ELC–1P h 12V 0V N 500 V L 12V 0V N K K1 12V 0V N K K1 L L 450 K K1 MCCB-1 hz MCB ELC F-1 F-2 OTOMATIS MANUAL R S T GENERATOR N R S T CONSUMER N R1 R2 S1 S2 T1 T2 BALLAST CUBICLE LAYOUT 5-10 kW Notes : Specifications.2013 1.pme-bandung.com Version Project : 24.92 (Global) Cibabat-Cimahi 40513.

92 (Global) Cibabat-Cimahi 40513.com admin@pme-bandung.0 Sheet 10-20 2/6 .0 1 2 3 4 5 6 7 500 8 9 220 12 450 BALLAST G1 K1 G2 K2 G3 K3 G4 K4 AR AS AT G1 K1 G2 K2 G3 K3 G4 K4 R S ELC–1P CONSUMER AR AS 12V 0V N G1 K1 G2 K2 G3 K3 G4 K4 L T ELC–1P ELC–1P 12V 0V N K K1 L 12V 0V N K K1 L K K1 AT 650 700 V h Hz MCCB-1 KONTAKTOR MCB ELC F-1 F-2 OTOMATIS MANUAL ON CONSUMER OFF CONSUMER R S GENERATOR T N R S T N CONSUMER L N N R1 R2 S1 S2 T1 T2 PH CUBICLE LAYOUT 10-20 kW Notes : Specifications.2010 Komarudin Not to scale Checked Format Approved __________ __________ A4 Jl. layout and dimension are subject to change with/without notice BALLAST Scale Designed 02.11.2013 1.01.pme-bandung.Jawa Barat Telp/Fax : +62 22 6611753 www. Pesantren No.com Version Project : 24.

0 1 2 3 4 5 6 7 500 8 9 450 220 12 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 K1 K2 K1 K2 K1 K2 K1 K2 K1 K2 K1 K2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 BALLAST G1 K1 G2 K2 G3 K3 G4 K4 AR AS AT G1 K1 G2 K2 G3 K3 G4 K4 R ELC–1P CONSUMER AR AS 12V 0V N L S T ELC–1P ELC–1P 12V 0V N K K1 G1 K1 G2 K2 G3 K3 G4 K4 L 12V 0V N K K1 L K K1 AT 650 700 V h MCCB-1 KONTAKTOR Hz MCB ELC F-1 F-2 OTOMATIS MANUAL ON CONSUMER OFF CONSUMER R S T GENERATOR N R S T N CONSUMER L N N R1 R2 S1 S2 T1 T2 PH CUBICLE LAYOUT 20-40 kW Notes : Specifications.2013 1.92 (Global) Cibabat-Cimahi 40513.01.com admin@pme-bandung. layout and dimension are subject to change with/without notice BALLAST Scale Designed 02.com Version Project : 24. Pesantren No.2010 Komarudin Not to scale Checked Format Approved __________ __________ A4 Jl.pme-bandung.0 Sheet 20-40 3/6 .11.Jawa Barat Telp/Fax : +62 22 6611753 www.

2013 1.com admin@pme-bandung.11.com Version Project : 24.2010 Komarudin Not to scale Checked Format Approved __________ __________ A4 Jl.92 (Global) Cibabat-Cimahi 40513. Pesantren No.0 1 2 3 4 5 6 7 600 8 9 550 220 12 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 K1 K2 K1 K2 K1 K2 K1 K2 K1 K2 K1 K2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 BALLAST G1 K1 G2 K2 G3 K3 G4 K4 AR AS AT G1 K1 G2 K2 G3 K3 G4 K4 R S ELC–1P CONSUMER AR AS 12V 0V N G1 K1 G2 K2 G3 K3 G4 K4 L T ELC–1P ELC–1P 12V 0V N K K1 L 12V 0V N K K1 L K K1 AT 750 800 V h MCCB-1 KONTAKTOR Hz MCB ELC F-1 F-2 OTOMATIS MANUAL ON CONSUMER OFF CONSUMER R S T GENERATOR N R S T N CONSUMER L N N R1 R2 S1 S2 T1 T2 PH CUBICLE LAYOUT 40-60 kW Notes : Specifications. layout and dimension are subject to change with/without notice BALLAST Scale Designed 02.0 Sheet 40-60 4/6 .01.Jawa Barat Telp/Fax : +62 22 6611753 www.pme-bandung.

2010 Komarudin Not to scale Checked Format Approved __________ __________ A4 Jl.com R Version Project : 24.pme-bandung.92 (Global) Cibabat-Cimahi 40513. layout and dimension are subject to change with/without notice T N S T N BALLAST Scale Designed 02.11.0 1 2 3 4 5 6 7 600 1 2 3 1 2 3 12 AS 9 550 220 BALLAST AR 8 AT K1 K2 K1 K2 G1 G2 G1 G2 1 2 3 1 2 3 1 2 3 1 2 3 K1 K2 K1 K2 K1 K2 K1 K2 G1 G2 G1 G2 G1 G2 G1 G2 KONSUMEN AR AS AT G1 K1 G2 K2 G3 K3 G4 K4 G1 K1 G2 K2 G3 K3 G4 K4 R G1 K1 G2 K2 G3 K3 G4 K4 S ELC–1P T ELC–1P ELC–1P 800 V ON KONSUMEN h 750 12V 0V N Hz L 12V 0V N K K1 L 12V 0V N K K1 L K K1 OFF KONSUMEN KONTAKTOR MCCB-1 MCB ELC F-1 F-2 OTOMATIS MANUAL R S T GENERATOR N R S T CONSUMER N R S PH CUBICLE LAYOUT 60-80 kW Notes : Specifications. Pesantren No.com admin@pme-bandung.2013 1.01.Jawa Barat Telp/Fax : +62 22 6611753 www.0 Sheet 60-80 5/6 .

0 Sheet 80-100 6/6 .0 1 2 3 4 5 6 7 800 9 750 220 12 1 2 3 BALLAST AR 8 AS 1 2 3 K1 K2 K1 K2 G1 G2 G1 G2 1 2 3 1 2 3 1 2 3 1 2 3 K1 K2 K1 K2 K1 K2 K1 K2 G1 G2 G1 G2 G1 G2 G1 G2 AT G1 K1 G2 K2 G3 K3 G4 K4 G1 K1 G2 K2 G3 K3 G4 K4 G1 K1 G2 K2 G3 K3 G4 K4 CVM R S ELC–1P ON KONSUMEN OFF KONSUMEN 12V 0V N L 1000 T ELC–1P ELC–1P 12V 0V N L K K1 12V 0V N L K K1 K K1 950 MCCB-1 KONTAKTOR MCB ELC F-1 F-2 OTOMATIS MANUAL R S T GENERATOR N R S CONSUMER T N R PH S N T R T BALLAST CUBICLE LAYOUT 80-100 kW Notes : Specifications.2013 1.Jawa Barat Telp/Fax : +62 22 6611753 www.2010 Komarudin Not to scale Checked Format Approved __________ __________ A4 Jl. Pesantren No.01. layout and dimension are subject to change with/without notice S N Scale Designed 02.com Version Project : 24.11.pme-bandung.com admin@pme-bandung.92 (Global) Cibabat-Cimahi 40513.