Wärtsilä JOVYLOAD CONCEPT. Load resistors 100 kw kw. as a modular system

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1 Wärtsilä JOVYLOAD CONCEPT Load resistors 100 kw kw as a modular system

Load Resistors Wärtsilä JOVYLOAD CONCEPT The load resistor as construction kit - Select the individual components from a variety of options and create YOUR personalized load bank!

The modular principle affords the customer to create an individual, personal load bank based on a variety of standard modules, accessories, options and designs.

operations. CONFIGURATION OF THE INDIVIDUAL, PERSONALIZED LOAD BANK As a modular system, the new load bank series Wärtsilä JOVYLOAD CONCEPT offers maximum flexibility.

By independent selection out of a wide range of standard modules, options, accessories and designs the personal load bank can be created according to the individual needs.

Based on these basic modules performances from 100 up to 500 kw can be selected and different designs, such as transport frames, mobile trailer versions or stand-alone versions can be composed.

2 Load Resistors Wärtsilä JOVYLOAD CONCEPT The load resistor as construction kit - Select the individual components from a variety of options and create YOUR personalized load bank! The new load bank series Wärtsilä JOVYLOAD CONCEPT offers test resistors from 100 kw to 500 kw as a modular system. The modular principle affords the customer to create an individual, personal load bank based on a variety of standard modules, accessories, options and designs. The load resistors of this new load bank series impress with an excellent price / performance ratio and technical features and offer a cheap and convenient solution for generating tests and other operations. CONFIGURATION OF THE INDIVIDUAL, PERSONALIZED LOAD BANK As a modular system, the new load bank series Wärtsilä JOVYLOAD CONCEPT offers maximum flexibility. The customer can choose from a variety of possibilities those components that are most appropriated for the specific application. By independent selection out of a wide range of standard modules, options, accessories and designs the personal load bank can be created according to the individual needs. Basis of the newly developed modular system is a compact load resistor with tubular heating elements as resistance elements. Based on these basic modules performances from 100 up to 500 kw can be selected and different designs, such as transport frames, mobile trailer versions or stand-alone versions can be composed. The basic module consists of the load tunnel with the resistor elements and the switchgear. In the control cabinet the load fuses and contactors are housed. The last stages are wired in star connection to copper connecting rails. The star point is also designed and loaded with 100% power. For the basic module a number of substructures (feet, rollers, trailers, etc.) are available for selection. Even constructions that protect the load resistance against any environmental influences can be selected for the individual application. A variety of control systems enables the user-friendly and simple monitoring of the equipment, a remote control is possible, too. Moreover, various accessories e.g. protective covers, special cable versions, etc. can be selected. HIGH ACCURACY OF RESISTANCE VALUES AND HIGH ROBUSTNESS The systems of the new load bank series Wärtsilä JOVY- LOAD CONCEPT are ideally suited for generator tests in a power range from 100 kw to 500 kw. If higher power is required, a combination of several load banks with a single common control unit via master-slave connection is realizable. The use of NiCr 8020, a nickel-chromium alloying with a very high thermal stability, ensures that the resistor elements of Wärtsilä JOVYLOAD CONCEPT systems have a very high precision of the resistance values. The high protection class IP 55 allows the use of these load banks even under difficult conditions. Fig.1 Different types of Wärtsilä JOVYLOAD CONCEPT 2

Wärtsilä JOVYLOAD CONCEPT TECHNICAL DETAILS - OVERVIEW Power range 100 kw up to 500 kw COMPACT AND LIGHT CONSTRUCTION Connection voltage Load steps Ventilation Fans voltage Operation mode Protection

3 Wärtsilä JOVYLOAD CONCEPT TECHNICAL DETAILS - OVERVIEW Power range 100 kw up to 500 kw COMPACT AND LIGHT CONSTRUCTION Connection voltage Load steps Ventilation Fans voltage Operation mode Protection degree IP 55 3 x 400 V, 50 Hz / 60 Hz 5 W, cascading 1 kw load steps, cascading, optional forced vertical air outlet very silent fans 3 x 400 V; 50/60 Hz Material resistor elements NiCr 8020 Material cabinets Permanent operation galvanized powder coated steel, coating according to RAL / customer VERY GOOD PRICE / PER- FORMANCE RATIO PROTECTION CLASS IP 55 HIGH PRECISION OF RESISTANCE VALUES THANKS TO NICR8020 LOW EXHAUST AIR TEMPERATURE AND VERTICAL AIR OUTLET no safety distances alongside the system neccessary WÄRTSILÄ JOVYLOAD CONCEPT The perfect load resistor for generator tests, or the check of transformers, battery systems power supply systems and the like. MOBILE TRAILER VERSIONS ensure the easy transport to the site of operation LOW NOISE LEVEL <70 db(a) at a distance of 3 m EXTREMELY ROBUST useable even under difficult conditions ROBUST STAND ALONE VERSION with stable pedestals, smooth running rolls or robust transport frame with crane eyes EXTENSIVE ACCESSORIES AND NUMEROUS OPTIONS Easy implementation of generator tests with Wärtsilä JOVYLOAD CONCEPT load banks 3

Load Resistors Wärtsilä JOVYLOAD CONCEPT The Load Resistor as Modular Kit - Choose YOUR individual components for a personalised loadbank!

available. Optionally load steps of 1 kw (cascading) are available, too.

The load fuses and contacts are installed in the control cabinet. The load steps are wired in star connection on to copper connecting rails.

2 Basic Modules Wärtsilä JOVYLOAD CONCEPT BASIC MODULES Article Dimensions Weight W x H x D [mm] [kg] Basic Module CONCEPT 100/5kW 4.900.

4 Load Resistors Wärtsilä JOVYLOAD CONCEPT The Load Resistor as Modular Kit - Choose YOUR individual components for a personalised loadbank! SELECTION BASIC MODULE 100kW - 500kW There are five different power ranges of 100 kw up to 500 kw with load steps of 5 kw (cascading) available. Optionally load steps of 1 kw (cascading) are available, too. The basic module consists of a load tunnel with resistor elements and the switch element. The load fuses and contacts are installed in the control cabinet. The load steps are wired in star connection on to copper connecting rails. The star point is implemented too and can tolerate full (100%) current load. Basis Modul Tab.2 Basic Modules Wärtsilä JOVYLOAD CONCEPT BASIC MODULES Article Dimensions Weight W x H x D [mm] [kg] Basic Module CONCEPT 100/5kW x 1000 x Basic Module CONCEPT 200/5kW x 1000 x Basic Module CONCEPT 300/5kW x 1000 x Basic Module CONCEPT 400/5kW x 1200 x Basic Module CONCEPT 500/5kW x 1400 x Fig.2 Inside views Basic Modules Wärtsilä JOVYLOAD CONCEPT 4

Wärtsilä JOVYLOAD CONCEPT SELECTION OF SUBSTRUCTURES For the basic module a substructure with integrated fan is required.

The stationary version (base frame with integrated fan) necessitates pedestals or a base frame with castors or forklift pockets as a substructure.

forwarding agent. For capacities up to 300 kw, you can choose a single-axle trailer, for higher power rates (400-500 kw) you need a twin-axle trailer as substructure.

5 m length is safely housed in the trailer console. The console is painted black (RAL 9005). The color of the storage box and the base module can be selected according to RAL colors.

EG-FGV All trailer versions include a built-in fan, which is housed within the trailer bracket, therefore a base housing is not required for trailer versions.

In case the system is mainly used at different locations, moved by lorry or loaded by crane, than we recommend the (optional) shock absorber frame.

5 Wärtsilä JOVYLOAD CONCEPT SELECTION OF SUBSTRUCTURES For the basic module a substructure with integrated fan is required. The fan is either mounted into the base frame (stationary version) or into the trailer (mobile version). The stationary version (base frame with integrated fan) necessitates pedestals or a base frame with castors or forklift pockets as a substructure. For a mobile design different types of trailers are available to enable the use of your load bank Wärtsilä JOVYLOAD CONCEPT at different locations, without the need for a forklift, a crane or forwarding agent. For capacities up to 300 kw, you can choose a single-axle trailer, for higher power rates ( kw) you need a twin-axle trailer as substructure. Basic frame with built-in fan The trailers with brakes with a gross vehicle weight of 1350 kg are equipped with a storage box for load cable and tools. A grounding rod of 1.5 m length is safely housed in the trailer console. The console is painted black (RAL 9005). The color of the storage box and the base module can be selected according to RAL colors. All trailers include: - Drawbar Ø45mm for passenger cars - Support wheel at front and 2 supports at the rear - Illuminating device 12V with 13-pin plug - Individual approval according to 13 EG-FGV All trailer versions include a built-in fan, which is housed within the trailer bracket, therefore a base housing is not required for trailer versions. For an easy transport of Wärtsilä JOVYLOAD CONCEPT systems with a fork lift or lift trucks we offer as a further substructure solution a stable transport base with welded forklift pockets. In case the system is mainly used at different locations, moved by lorry or loaded by crane, than we recommend the (optional) shock absorber frame. The shock absorber frame is mounted at the transport base and protects the load bank with its external rubber dampers and stable edge profile. At the lateral cable retention supports the load cable can be transported conveniently and the 4 crane eyes/handle blocks ensure a secure crane handling. Basic frame with pedestrals Basic frame with forklift pockets and rolls Fig 3. Transportable versions Wärtsilä JOVYLOAD CONCEPT Transport frame Transport socket with mounted transport frame with rubber dampers and crane eyes 5

Tab.3 Substructures Wärtsilä JOVYLOAD CONCEPT SUBSTRUCTURE Article Dimensions Weight W x H x L [mm] [kg] Basic frame with fan 4.900.

492 1000 x 300 x 860 mm 53 kg CONCEPT 400-500 (3~400V 50Hz) Pedestrals 200mm height (1 set = 4 pieces) 4.900.

900.511 1820 x 720* x 2300** mm 290 kg Trailer, tandem, CONCEPT 400-500 (without whiffletree/ drawbar) 4.900.512 1820 x 720* x 2300** mm 380 kg *) Console Height (without storage box/load resistance) **) plus control device/drawbar Whiffletree/ drawbar without height adjustment 4.

900.507 1520 x 1760* x 1520 mm 72 kg CONCEPT 100-300 Transport frame with dampers and crane eyes (for montage onto the transport socket) 4.900.506 1520 x 1960* x 1520 mm 75 kg CONCEPT 400 Transport frame with dampers and crane eyes (for montage onto the transport socket) 4.

6 Tab.3 Substructures Wärtsilä JOVYLOAD CONCEPT SUBSTRUCTURE Article Dimensions Weight W x H x L [mm] [kg] Basic frame with fan x 300 x 860 mm 53 kg CONCEPT (3~400V 50/60Hz) Basic frame with fan x 300 x 860 mm 53 kg CONCEPT (3~400V 50Hz) Pedestrals 200mm height (1 set = 4 pieces) ,0 kg Pedestrals 300mm height (1 set = 4 pieces) ,5 kg Transport rolls and forklift pockets (2 fixed/2 swivel castors with stop Ø200mm) x 310 x 1240 mm 37 kg Trailer, single-axle, CONCEPT (without whiffletree/ drawbar) x 720* x 2300** mm 290 kg Trailer, tandem, CONCEPT (without whiffletree/ drawbar) x 720* x 2300** mm 380 kg *) Console Height (without storage box/load resistance) **) plus control device/drawbar Whiffletree/ drawbar without height adjustment kg Whiffletree/ drawbar with height adjustment kg Transport socket x 300 x 1420 mm 85 kg CONCEPT Transport frame with dampers and crane eyes (for montage onto the transport socket) x 1760* x 1520 mm 72 kg CONCEPT Transport frame with dampers and crane eyes (for montage onto the transport socket) x 1960* x 1520 mm 75 kg CONCEPT 400 Transport frame with dampers and crane eyes (for montage onto the transport socket) x 2160* x 1520 mm 78 kg CONCEPT 500 *) incl. transport substructure Fig.4 Trailer versions Wärtsilä JOVYLOAD CONCEPT Singe-axle trailer Tandem trailer 6

Wärtsilä JOVYLOAD CONCEPT SELECTION OF STRUCTURES In order to adapt your Wärtsilä JOVYLOAD CONCEPT to different applications the base module requires a structure.

The strong but very quiet fans guarantee optimal ventilation forced the resistance elements.

Minimum one could be a perforated plate cover as protection against accidental contact or as protection e.g. against rough dirt, leaves etc.

The optional weather protection edge ensures further protection. It keeps rainwater away from the door seal (above) the control cabinet.

7 Wärtsilä JOVYLOAD CONCEPT SELECTION OF STRUCTURES In order to adapt your Wärtsilä JOVYLOAD CONCEPT to different applications the base module requires a structure. As the air current is vertical, the load tunnel is open on its upper part. Thereby there is no horizontal safety distance necessary. The strong but very quiet fans guarantee optimal ventilation forced the resistance elements. The mounted resistor elements and fans do not need further protection, but it is advised in case of permanent outdoor operation or outdoor storing. Minimum one could be a perforated plate cover as protection against accidental contact or as protection e.g. against rough dirt, leaves etc. For stationary systems in outdoor operation we alternatively recommend the air scoop or the high roof. Moreover, additional protection devices such as air scoops or high roofs are available. The optional weather protection edge ensures further protection. It keeps rainwater away from the door seal (above) the control cabinet. The weather protection edge provides additional safety especially when the load bank counts a lot of years. It s your choice - select the assemblies according to your needs and the field of application. Tab.4 Structures Wärtsilä JOVYLOAD CONCEPT STRUCTURES Article Dimensions Weight W x H x D [mm] [kg] Perforated plate cover above x 1 x 860 mm 3,5 Air scoop with weather protection gri d *) approx. 440mm overlap at the back of the base module x 500 x 1300* mm 36 High roof with vertical weather protection grid x 320 x 860 mm 31 Weather protection edge for the control cabinet x 40 x 100 mm 1,6 kg Fig. 5 Structures Wärtsilä JOVYLOAD CONCEPT Air scoop High roof Perforated plate cover above Whather protection edge 7

8 SELECTION OF CONTROL AND DATA LOGGING For your JOVYLOAD CONCEPT a choice of different control data logging possibilities is available: Rotary Switch Control: All really ingenious things are usually surprisingly simple. The rotary switch control does not require any elaborate explanation and in case of malfunction it is easy to inspect and repair. Optionally you can choose amongst several multifunctional meters. Control LOGO : The Siemens control LOGO serves as a basis. The operation takes place via the panel TDE, mounted at the front door or alternatively via remote control with 25 m cable. The operating is very simple. The load steps can be shifted up or down in in 1kW-/ 10kW- und 100kW increments. The operating states are indicated via text messages. Optionally the measured performance value can be Tab.5 Control possibilites Wärtsilä JOVYLOAD CONCEPT displayed via the multifunctional meter MFA 2001 (mounted in the front door of the control cabinet). Control / SPS S : The Siemens SPS control S serves as basic element. The operation takes place via different HMI panels, which differ in size and fittings. The panel are mounted optionally in the front door of the control cabinet or delivered as remote control with 50m cable. The included software enables both manual control or operation according to programmed load curves. On request the data is recorded for evaluation at a later stage. The MASTER- SLAVE Control can control several load banks jointly. Customer-specific programming or adaptations to existing SPS systems are possible upon consultation. Control via web browser: Control via web browser enables the operation of the load bank via PC with an installed internet browser (not part of the scope of delivery). CONTROL SYSTEMS Article Remarks Rotary Switch Control incl. fan control, all versions Transformer (3 pieces) CONCEPT Required for all multifunctional meters/data Multifunctional meter UMG 96L Multifunctional meter UMG 96RM With data storage and USB connector Multifunctional meter MFA Measured performance value via operating panel LOGO TDE Control LOGO, 12 outputs All versions besides 500kW with load steps 1kW (500/1kW) (without operation panel) Control LOGO, 16 outputs For Basic Module 500kW with load steps 1kW (500/1kW) (without operation panel) Operation panel LOGO TDE Mounted in front door of the control cabinet Remote control LOGO TDE With 25m cable and industrial connect at the loadbank cable Control SPS S7-1200, 10 outputs For Basic Modules kW with load steps 5kW (without operation panel) Steuerung/ SPS S7-1200, 18 outputs For Basic Modules kW with load steps 1kW and kW with load steps 5kW or 1kW (without operation panel) Operation panel KTP 400 Mono Mounted in front door of the control cabinet Remote control KTP 400 Mono With 50m cable and industrial connector at the load bank Operation panel KTP 600 Color Mounted in front door of the control cabinet Remote control KTP 600 Color With 50m cable and industrial connector at the load bank Operation panel TP 700 comfort Mounted in front door of the control cabinet Remote control TP 700 comfort With 50m cable and industrial connector at the load bank Data logging for SPS S Solely in connection with transformers Web browser control for SPS S

Wärtsilä JOVYLOAD CONCEPT SELECTION OF OPTIONS For the Wärtsilä JOVYLOAD CONCEPT load banks a variety of options is available.

For all load banks that are stored or operated outdoors or in unheated rooms, we recommend the configuration with an anti-condensation heating (optional).

During non-operation of the load resistor the power supply of the anti-condensation heater has to be ensured. Tab.

568 W 1520 x D 1520 x H 1400mm, different colours available PVC protection cover CONCEPT 400 with transport and shock absorber frame 4.900.

570 W 1520 x D 1520 x H 1800mm, different colours available PVC protection cover for CONCEPT 100-300 (Basic module) 4.900.

9 Wärtsilä JOVYLOAD CONCEPT SELECTION OF OPTIONS For the Wärtsilä JOVYLOAD CONCEPT load banks a variety of options is available. For the different versions we provide among others protective covers made of durable PVC, so that your equipment is protected and kept safe outdoors. For all load banks that are stored or operated outdoors or in unheated rooms, we recommend the configuration with an anti-condensation heating (optional). The space heater is thermostatically controlled and is powered by the auxiliary power supply. During non-operation of the load resistor the power supply of the anti-condensation heater has to be ensured. Tab.6 Options Wärtsilä JOVYLOAD CONCEPT OPTIONS Article Remarks PPVC protection cover for CONCEPT with transport and shock absorber frame W 1520 x D 1520 x H 1400mm, different colours available PVC protection cover CONCEPT 400 with transport and shock absorber frame W 1520 x D 1520 x H 1600mm, different colours available PVC protection cover CONCEPT 500 with transport and shock absorber frame W 1520 x D 1520 x H 1800mm, different colours available PVC protection cover for CONCEPT (Basic module) W 1000 x D 1160 x H 1000mm, different colours available PVC protection cover for CONCEPT 400 (Basic module) W 1000 x D 1160 x H 1200mm, different colours available PVC protection cover for CONCEPT 500 (Basic module) W 1000 x D 1160 x H 1400mm, different colours available Space heaters 200W incl. thermostat control incl. thermostat control Toggle switch for intern/ OFF/ extern Load voltage and frequency must be suitable Fig. 6 Options Wärtsilä JOVYLOAD CONCEPT PVC protection cover Space heater Toggle switch CEE appliance inlets PEN bridge 9

10 SELECTION OF LOAD CABLES AND ACCESSORIES We generally use heavy rubber cables of the type NS- SHÖU-O for mobile application. This type of cable has a very high current carrying capacity with low weight and small cross section. This simplifies transportation and handling. Our basic price calculation is made under the assumption of a connection of 3 external conductors L1, L2, L3 and of the protective conductor PE with a length of 10m. The load cables are securely connected to the switchboard. The opposite side can optionally be fitted with cable lugs or plugs. The auxiliary power supply takes place via a separate 5-pin cable H07RN-F 5x1,5mm² with CEE plug connection. The cables are designed for an ambient temperature of up to +30 C when laying single core cables outside. For dual installed cables (2x L1, L2, L3) an even current load must be ensured for both cables. Depending on the application the N-conductor might be required as the auxiliary power supply could be necessary for the use of a test device or for the case that singlephase tests are to be executed. For our trailer versions additional 1,5m cables are used for the internal connection of the storage box. Eventually different length is required, e.g. 15, 20 or 25m. Tab.7 Load cables and accessories Wärtsilä JOVYLOAD CONCEPT Load Cables Article Remarks Set of load cable, general Design according to customer specification Set of load cable CONCEPT per 1x L1, L2, L3 + 1x PE NSSHÖU-O 25mm² + 1x H07RN-F 5x1,5mm², Weight with 10m = ca. 18,5 kg Set of load cable CONCEPT per 1x L1, L2, L3 + 1x PE NSSHÖU-O 70mm² + 1x H07RN-F 5x1,5mm², weight with 10m = ca. 38,5 kg Set of load cable CONCEPT per 1x L1, L2, L3 + 1x PE NSSHÖU-O 120mm² + 1x H07RN-F 5x1,5mm², weight with 10m = ca. 60,0 kg Set of load cable CONCEPT per 2x L1, L2, L3 + 1x PE NSSHÖU-O 70mm² + 1x H07RN-F 5x1,5mm², weight with 10m = ca. 65,5 kg Set of load cable CONCEPT per 2x L1, L2, L3 + 1x PE NSSHÖU-O 95mm² + 1x H07RN-F 5x1,5mm², weight with 10m = ca. 83,0 kg Cable lugs Ø13mm for load cable, per cable Plug connector POWERLOCK F6S, up to 400A, per cable Fig. 7 Set of load cable in stowing box of trailer 10

Our sales engineers are happy to advise about the feasibilities and technical backgrounds. The production of our resistors is based on our state-of-the-art manufacturing methods.

11 State-of-the-art production processes Wärtsilä JOVYLOAD CONCEPT Whether on land or at sea the application of our resistors is manifold. The examples of utilisation on the following pages provide an insight into the scope of application in different industries and business sectors. Our sales engineers are happy to advise about the feasibilities and technical backgrounds. The production of our resistors is based on our state-of-the-art manufacturing methods. By means of simulation models resistant materials are optimally utilized in the manufacturing process permitting a cost optimized production of resistors directly benefitting our customers. Implementing high-end machines like CNC-controlled laser and die-cutting systems working in shifts round the clock permits satisfaction for high demands of units, even on short notice. Experienced Technicians 11

12 Wärtsilä JOVYATLAS supports you during the entire product cycle. From concept to the final product: we supply you with the individual solution for your requirements, from the individual resistance components to the complete resistor unit with or without control, as standard or customised solution. The reliable quality of our components guarantees the secure operation throughout the entire product live cycle. In case upgrades or modification are necessary or parts are needed, we will be glad to assist you with our know-how and this for decades to FROM THE IDEA TO THE PRODUCT WE ACCOMPANY YOU! Wärtsilä is a global leader in advanced technologies and complete lifecycle solutions for the marine and energy markets. By emphasising sustainable innovation and total efficiency, Wärtsilä maximises the environmental and economic performance of the vessels, power plants and LNG infrastructure of its customers. In 2015, Wärtsilä s net sales totalled EUR 5 billion with approximately 18,800 employees. The company has operations in over 200 locations in more than 70 countries around the world. Wärtsilä is listed on Nasdaq Helsinki. info.jovyatlas@wartsila.com WÄRTSILÄ is a registered trademark. Copyright 2016 Wärtsilä Corporation. Specifications are subject to change without prior notice. 08/2016

Wärtsilä JOVYLOAD CONCEPT

Wärtsilä JOVYLOAD CONCEPT THE LOAD RESISTOR as Modular Kit 1 [Wärtsilä JOVYLOAD CONCEPT / Wolfgang Pastoor Wärtsilä JOVYLOAD CONCEPT Product Range: Product: Technology: Design: Versions: Power Range: Principle: