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JOVYLOAD CONCEPT

Load resistors

100 kW - 500 kW

as a modular system

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 pri-ce / performance ratio and technical features and offer a cheap and convenient solution for generating tests and other operations.

CONFIGURATION OF THE INDIVIDUAL, PERSONALIZED LOAD BANKAs 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 com-pact load resistor with tubular heating elements as re-sistance elements. Based on these basic modules per-formances from 100 up to 500 kW can be selected and dif ferent 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 re-sistor 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. protecti-ve covers, special cable versions, etc. can be selected.

HIGH ACCURACY OF RESISTANCE VALUES AND HIGH ROBUSTNESSThe 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 sing-le common control unit via master-slave connection is re-alizable. 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 dif ficult conditions.

Load ResistorsWärtsilä JOVYLOAD CONCEPT

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Fig.1 Dif ferent types of Wärtsilä JOVYLOAD CONCEPT

COMPACT AND LIGHT CONSTRUCTION

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

LOW NOISE LEVEL <70 dB(A) at a distance of 3 m

EXTREMELY ROBUST useable even under dif f icult conditions

TECHNICAL DETAILS - OVERVIEW

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Power range 100 kW up to 500 kW

Connection voltage 3 x 400 V, 50 Hz / 60 Hz

Load steps 5 W, cascading 1 kW load steps, cascading, optional

Ventilation forced vertical air outletvery silent fans

Fans‘ voltage 3 x 400 V; 50/60 Hz

Operation mode Permanent operation

Protection degree IP 55

Material resistor elements NiCr 8020

Material cabinets galvanized powder coated steel,coating according to RAL / customer

WÄRTSILÄ JOVYLOAD CONCEPTThe 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

ROBUST STAND ALONE VERSIONwith 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

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 dif ferent 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 con-tacts 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.

Load ResistorsWärtsilä JOVYLOAD CONCEPT

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BASIC MODULES Article Dimensions Weight W x H x D [mm] [kg]

Basic Module CONCEPT 100/5kW 4.900.401 1000 x 1000 x 1160 245 Basic Module CONCEPT 200/5kW 4.900.402 1000 x 1000 x 1160 270 Basic Module CONCEPT 300/5kW 4.900.403 1000 x 1000 x 1160 295 Basic Module CONCEPT 400/5kW 4.900.404 1000 x 1200 x 1160 345

Basic Module CONCEPT 500/5kW 4.900.405 1000 x 1400 x 1160 390

Tab.2 Basic Modules Wärtsilä JOVYLOAD CONCEPT

Fig.2 Inside views Basic Modules Wärtsilä JOVYLOAD CONCEPT

Basis Modul

Fig 3. Transportable versions Wärtsilä JOVYLOAD CONCEPT

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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 forklif t pockets as a substructure.

For a mobile design dif ferent types of trailers are available to enable the use of your load bank Wärtsilä JOVYLOAD CONCEPT at dif ferent locations, without the need for a forklif t, a crane or 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.

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 conso-le 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 lif t or lif t trucks we offer as a further substructure solution a stable transport base with welded forklif t pockets. In case the system is mainly used at dif ferent locations, moved by lorry or loaded by crane, than we recommend the (optional) shock ab-sorber 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 built-in fan

Basic frame with pedestrals

Basic frame with forklif t pockets and rolls

Transport frame

Transport socket with mounted transport frame with rubber dampers and crane eyes

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Transport socket 4.900.504 1420 x 300 x 1420 mm 85 kgCONCEPT 100-500 Transport frame with dampers and crane eyes (for montage onto the transport socket) 4.900.507 1520 x 1760* x 1520 mm 72 kgCONCEPT 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 kgCONCEPT 400 Transport frame with dampers and crane eyes (for montage onto the transport socket) 4.900.505 1520 x 2160* x 1520 mm 78 kgCONCEPT 500 *) incl. transport substructure

SUBSTRUCTURE Article Dimensions Weight W x H x L [mm] [kg]

Basic frame with fan 4.900.491 1000 x 300 x 860 mm 53 kgCONCEPT 100-300 (3~400V 50/60Hz) Basic frame with fan 4.900.492 1000 x 300 x 860 mm 53 kgCONCEPT 400-500 (3~400V 50Hz) Pedestrals 200mm height (1 set = 4 pieces) 4.900.501 8,0 kg

Pedestrals 300mm height (1 set = 4 pieces) 4.900.502 10,5 kg Transport rolls and forklif t pockets(2 fixed/2 swivel castors with stop Ø200mm) 4.900.503 1080 x 310 x 1240 mm 37 kg

Trailer, single-axle, CONCEPT 100-300 (without whif fletree/ drawbar) 4.900.511 1820 x 720* x 2300** mm 290 kg

Trailer, tandem, CONCEPT 400-500 (without whif fletree/ drawbar) 4.900.512 1820 x 720* x 2300** mm 380 kg

*) Console Height (without storage box/load resistance)**) plus control device/drawbar

Whif fletree/ drawbarwithout height adjustment 4.900.521 40 kg

Whif fletree/ drawbar with height adjustment 4.900.522 125 kg

Tab.3 Substructures Wärtsilä JOVYLOAD CONCEPT

Fig.4 Trailer versions Wärtsilä JOVYLOAD CONCEPT

Singe-axle trailer Tandem trailer

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SELECTION OF STRUCTURES

In order to adapt your Wärtsilä JOVYLOAD CONCEPT to dif ferent applications the base module requires a struc-ture. As the air current is vertical, the load tunnel is open on its upper part. Thereby there is no horizontal safety di-stance necessary. The strong but very quiet fans guaran-tee 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 pro-

tection 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 pro-tection. 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.

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STRUCTURES Article Dimensions Weight W x H x D [mm] [kg]

Perforated plate cover above 4.900.481 1000 x 1 x 860 mm 3,5

Air scoop with weather protection gri d*) approx. 440mm overlap at the back of the base module 4.900.482 1000 x 500 x 1300* mm 36

High roof with vertical weather protection grid 4.900.483 1000 x 320 x 860 mm 31

Weather protection edge for the control cabinet 4.900.485 1080 x 40 x 100 mm 1,6 kg

Tab.4 Structures Wärtsilä JOVYLOAD CONCEPT

Fig. 5 Structures Wärtsilä JOVYLOAD CONCEPT

Air scoop

High roof

Whather protection edge

Perforated plate cover above

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CONTROL SYSTEMS Article Remarks

Rotary Switch Control 4.900.420 incl. fan control, all versions

Transformer (3 pieces)CONCEPT 100-500 4.900.440 Required for all multifunctional meters/data Multifunctional meter UMG 96L 4.900.451

Multifunctional meter UMG 96RM 4.900.452 With data storage and USB connector

Multifunctional meter MFA 2001 4.900.453 Measured performance value via operating panel LOGO TDE

Control „LOGO“, 12 outputs 4.900.461 All versions besides 500kW with load steps 1kW (500/1kW) (without operation panel) Control „LOGO“, 16 outputs 4.900.462 For Basic Module 500kW with load steps 1kW (500/1kW) (without operation panel) Operation panel „LOGO TDE“ 4.900.463 Mounted in front door of the control cabinet

Remote control „LOGO TDE“ 4.900.464 With 25m cable and industrial connect at the loadbank cable Control SPS „S7-1200“, 10 outputs 4.900.471 For Basic Modules 100-300kW with load steps 5kW (without operation panel)

Steuerung/ SPS „S7-1200“, 18 outputs 4.900.472 For Basic Modules 100-300kW with load steps 1kW and 400-500kW with load steps 5kW or 1kW (without operation panel)

Operation panel „KTP 400 Mono“ 4.900.473 Mounted in front door of the control cabinet

Remote control „KTP 400 Mono “ 4.900.474 With 50m cable and industrial connector at the load bank

Operation panel „KTP 600 Color“ 4.900.475 Mounted in front door of the control cabinet

Remote control „KTP 600 Color “ 4.900.476 With 50m cable and industrial connector at the load bank

Operation panel „TP 700 comfort“ 4.900.479 Mounted in front door of the control cabinet Remote control „TP 700 comfort “ 4.900.480 With 50m cable and industrial connector at the load bank

Data logging for SPS S7-1200 4.900.477 Solely in connection with transformers

Web browser control for SPS S7-1200 4.900.478

Tab.5 Control possibilites Wärtsilä JOVYLOAD CONCEPT

SELECTION OF CONTROL AND DATA LOGGING

For your JOVYLOAD CONCEPT a choice of dif ferent con-trol 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 incre-ments. The operating states are indicated via text messa-ges. Optionally the measured performance value can be

displayed via the multifunctional meter MFA 2001 (moun-ted in the front door of the control cabinet).

Control / SPS „S7-1200“:The Siemens SPS control „S7-1200“ serves as basic ele-ment. The operation takes place via dif ferent HMI panels, which dif fer in size and fittings. The panel are mounted optionally in the front door of the control cabinet or de-livered as remote control with 50m cable. The included software enables both manual control or operation ac-cording 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).

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SELECTION OF OPTIONS

For the Wärtsilä JOVYLOAD CONCEPT load banks a va-riety of options is available. For the dif ferent 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 po-wered by the auxiliary power supply. During non-operation of the load resistor the power supply of the anti-conden-sation heater has to be ensured.

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OPTIONS Article Remarks PPVC protection cover for CONCEPT 100-300with transport and shock absorber frame 4.900.568 W 1520 x D 1520 x H 1400mm, dif ferent colours available

PVC protection cover CONCEPT 400 with transport and shock absorber frame 4.900.569 W 1520 x D 1520 x H 1600mm, dif ferent colours available

PVC protection cover CONCEPT 500 with transport and shock absorber frame 4.900.570 W 1520 x D 1520 x H 1800mm, dif ferent colours available

PVC protection cover for CONCEPT 100-300 (Basic module) 4.900.571 W 1000 x D 1160 x H 1000mm, dif ferent colours available

PVC protection cover for CONCEPT 400 (Basic module) 4.900.572 W 1000 x D 1160 x H 1200mm, dif ferent colours available

PVC protection cover for CONCEPT 500 (Basic module) 4.900.573 W 1000 x D 1160 x H 1400mm, dif ferent colours available Space heaters 200W incl. thermostat control 4.900.574 incl. thermostat control Toggle switch for intern/ OFF/ extern 4.900.575 Load voltage and frequency must be suitable

Tab.6 Options Wärtsilä JOVYLOAD CONCEPT

Fig. 6 Options Wärtsilä JOVYLOAD CONCEPT

PVC protection cover Space heater Toggle switch CEE appliance inlets PEN bridge

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Load Cables Article Remarks

Set of load cable, general 4.900.540 Design according to customer specification

Set of load cable CONCEPT 100 4.900.541 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 200 4.900.542 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 500 4.900.545 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 4.900.560 Plug connector POWERLOCK F6S, up to 400A, per cable 4.900.566

Tab.7 Load cables and accessories Wärtsilä JOVYLOAD CONCEPT

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 tem-perature 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 single-phase tests are to be executed.

For our trailer versions additional 1,5m cables are used for the internal connection of the storage box. Eventually dif ferent length is required, e.g. 15, 20 or 25m.

Fig. 7 Set of load cable in stowing box of trailer

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The production of our resistors is based on our state-of-the-art manufacturing methods. By me-ans of simulation models resistant materials are optimally utilized in the manufacturing process – permitting a cost optimized production of resis-tors directly benefitting our customers. Implemen-ting 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.

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.

State-of-the-artproduction processes

Experienced Technicians

WÄRTSILÄ® is a registered trademark. Copyright © 2016 Wärtsilä Corporation.Specifications are subject to change without prior notice.

[email protected]

www.wartsila.com

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FROM THE IDEA TOTHE PRODUCT – WEACCOMPANY YOU!

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 compo-

nents

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 modifica-

tion

are necessary or parts are needed,

we will be glad to assist you with our

know-how – and this for decades to

Wärtsilä is a global leader in advanced technologies andcomplete lifecycle solutions for the marine and energy markets.By emphasising sustainable innovation and total efficiency,Wärtsilä maximises the environmental and economic performanceof the vessels, power plants and LNG infrastructure of itscustomers. In 2015, Wärtsilä’s net sales totalled EUR 5 billion withapproximately 18,800 employees. The company has operationsin over 200 locations in more than 70 countries around the world.Wärtsilä is listed on Nasdaq Helsinki.

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