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. 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. The control is done by
diverting the excess power to the dummy load (ballast). 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.

Generator

Consumer

ELC

Ballast Load
Power turbin

= Pconsumer + Pballast

20.000 watt

= 15.000 Watt + 5.000 Watt

Protel Multi Energys Electronic load controller (ELC-PME) is designed to suit with different type of
generators and various application of micro hydro, 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, and large load)

Grid interconnection

Suitable with most of turbine type (Cross low, Kaplan, Propeller, Pelton, Francis, etc)
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)

2. 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, such as:

Generated Frequency and Voltage are stable

(220-230 V / 50 Hz)

Avoid the damage on electrical and electronic

appliances such as lamps, TVs, radio, motors,
etc. 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, since no need of water low adjustment or closing

Fast recovery time, capable in handling sudden large load change in very quick time 10 ms.

Simple, robust and easy in installation, operation and maintenance

ELC is much cheaper comparing to other type of controller, thus affordable for low budget
project and village electri ication scheme

3. DISADVANTAGE OF ELC

Our ELC works with phase angle control

regulation, thus the voltage/current
generated will be distorted (harmonic)
which might effect on some electrical
appliances (generator, light bit lickering,
heating on induction motor). To minimize
the effect its suggested to reduce the
power diverted into dummy load!

Plant with ELC requires larger generator

than its expected out put by 1.2-1.5 times,
it is needed to compensate the higher currents and Thyristor effect as well as safety reasons.

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)

4. WORKING PRINCIPLES
Protel Multi Energys (ELC-PME) is developed based on microcontroller technology that make it simpler
and smaller electronic circuit comparing to analog system, the control characteristic is done with
programming software which allow the

lexibility in setting and parameterization. The ELC

continuously read the signal every half cycles (10 ms), ensuring the fast recovery and smooth
operation. Once ELC is installed, no need of parameters adjustment/setting during commissioning, all
parameter already con igured and tasted at factory before shipment according to customer
requirements or national standard.
Basic electrical protection such as short circuit and overload protection is included on the cubicle and
customized based on customer requirement. In addition, cubicle is provided with nine (9) analog panel
meter (customized) to monitor the operation of plant and data recording. No need of additional
electrical panel required with our ELCs.
The main board of ELC-PME is
made per phase, intended to make
it easier in replacement and
maintenance in case of failure,
meaning that if only one main
board damaged no need to replace
three of it, only replace the broken
one and avoid the disturbance of
one phase to the other.
One main board can be utilized up to four channel of Triac output or 2 channel of Thyristor module. The
control of power diversion to dummy/ballast load is done with phase angle regulation, it will adjust the
phase angle triggering based on the frequency error from the setting. This method allows the power
control from 0-100% with ine regulation up to 0.33 ms triggering angle possibility. The frequency
reading is done every half cycle of the signal or every 10 ms on positive and negative cycles. This means
that frequency error on positive cycle will immediately be compensated on the following negative cycle
and vice versa.
To minimize the harmonic (voltage/current distortion) of the signal output, the diversion of power is
made with two step system, this mean that only 50% of dummy load capacity is connected at the
beginning, and then the next 50% will only be used if the excess power exceeds the irst 50%.

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)

This approach has resulting in signi icant reduce of total harmonic distortion of the electricity output.
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.
ELC-PME is provided with manual or
automatic mode switch/MCB.
switch/
In case of
damage on ELC main board or dummy
load, the system still can run without
control (manual) while the problem is
being repaired. Nevertheless that this is
not an ideal option,
option since running the
plant without control can be dangerous
to generator,, turbine, and electrical
appliances connected. This mode only
provided for an emergency case.

5. 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,, 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, ELC+ballast load or complete set (ELC+

(ELC+ballast+cable)

Guarantee period

: 1 year of components and ELC main board upon failure.

Term and condition applied.

Jl. Pesantren No.92 (Global) Cibabat

Cimahi 40513 Jawa Barat, Indonesia.
Telp/fax :+62 22 6631608.
66
www.pme
www.pme-bandung.com

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,A,

Hz,kW,kVA,cos phi,kWh,%THD)

Pilot Lamps-3P

MCCB consumer

Contactor consumer

Over/undervoltage

Over/underfrequency

Cooling fan

4 mm

6 mm

10 mm

16 mm 25 mm

35 mm

50 mm

Ballast cables (NYAF) in mm 1.5 mm 2.5 mm 4 mm

6 mm

10 mm

16 mm

25 mm

THYRISTOR - 6 pcs

TM55

TM90

METERING

PROTECTION

CABLES & DIMENSION

Main cables (NYAF) in mm

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. 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)

6. MAIN COMPONENTS OF ELC-PME

1
11
2

12

10

14
13

6
8
15

18

16

19

17

20

21

1. PILOT LAMP
220 volt lamps, indicating the presence of electric power on each phase.
2. AMPERE METER BALLAST (A)
Showing the current lowing to the ballast load, on normal operation its suggested to maintain the
current on ballast at minimal value to prevent overheating and continuously overloading generator.
3. AMPERE METER CONSUMER (A)
Showing the current lowing to the consumer. Its suggested to maintain the equal current on each
phase (balanced load)
4. VOLTMETER (V)
Showing the voltage of generator.
5. HOURMETER (h)
Recording the operational hour of the plant. This is useful for maintenance schedule and monitor
the components lifetime.
6. FREQUENCY METER (Hz)
Showing the generated frequency of generator
7. PUSH BUTTON ON
Connecting the consumer load (main load), switch on the contactor
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)

8. PUSH BUTTON OFF

Disconnecting the consumer load (main load), switch off the contactor
9. TRANSFORMER
Power supply for ELC main board
10. HEATSINK
Cooling and support of Thyristor/Triac (heat distribution)
11. SCR /TRIAC
Power electronic switch (Thyristor) controlled by ELC main board to control the switching of
current to ballast load.
12. FAN
Air circulation and heat evacuation from heatsink / cubicle
13. CURRENT TRANSFORMER
Measure the current to consumer and dummy/ballast load
14. MAINBOARD
The heart of control system, its sense, process and controlling the current low to the
dummy/ballast load to maintain the steady condition of power plant
15. 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. MCCB / NFB
Protection against short circuit and overload on consumer side
17. MCB
As switch manual/automatic of ELC, protection panel meter instrument, pilot lamps and
powerhouse installation
18. GENERATOR TERMINAL
Connection terminal to generator
19. CONSUMER TERMINAL
Connection terminal to consumer
20. NEUTRAL AND POWERHOUSE
Connection for neutral and power house installation
21. BALLAST TERMINAL
Connection to dummy/ballast load

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)

7. DUMMY/BALLAST LOAD
Ballast or dummy load is a complement load to divert the excess power. It can be the water heater or air
heater type. Never use normal electrical appliances such as pump, lamps, fridge, fan, cooking machine
as a dummy load since the voltage/current applied to it is not sinusoidal signal but modi ied signal with
variable voltage, which might damaged the appliances.
For some reasons air heater is preferred, since it
required less maintenance, easier in installation
and last longer. Water heater need special tank
and required continuous low to prevent from
drying and overheating which might be neglected
in the remote area. The heater supplied from us, is
the tubular air heater type for industrial standard,
this type normally used as heating or drying
element on industrial process and proved for its
quality and lifetime. Air heater types do not need
forced air (fan/blower), appropriate room ventilation is suf icient.
The ballast load consisting of six heater (two step) which is R1,S1,T1 ( irst step) and R2,S2,T2 (second
step). 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). The heater can be made up from
parallel of small heater to reach desired power capacity.

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)

8. PROJECTS REFERENCES PICTURES

During 2011-2012 we have deliver 219 units of ELC through out archipelago of Indonesia and abroad.
From 3 kW 300 kW with the total capacity of 3.965 MW. Following are some pictures of our projects:

Pic.1 Components layout of 3 phase ELC ( 20-40 kW)

Pic.2 Testing & setting of ELC before shipment

Pic.3 ELC cubicle for 150 kVA MHP

Pic.4 our ELC Main board assembly

Pic.5 Stock ELC cubicles and ballast load

Pic.6 ELC-PME in operation

Jl. Pesantren No.92 (Global) Cibabat

Cimahi 40513 Jawa Barat, Indonesia.
Telp/fax :+62 22 6631608.
www.pme-bandung.com

10

400

220

12

350

BALLAST

CONSUMER

AS

AS

G1 K1 G2 K2 G3 K3 G4 K4

G1 K1 G2 K2 G3 K3 G4 K4

G1 K1 G2 K2 G3 K3 G4 K4

ELC1P

ELC1P

ELC1P

h
12V 0V N

500

12V 0V N

K K1

12V 0V N

K K1

450

K K1

MCCB-1

hz

MCB ELC

F-1

F-2

OTOMATIS

MANUAL

GENERATOR

CONSUMER

R1 R2 S1 S2 T1 T2

BALLAST

CUBICLE LAYOUT 5-10 kW

Notes :
Specifications, layout and dimension are subject to
change with/without notice

Scale

Designed

02.11.2010

Komarudin

Not to scale

Checked

Format

Approved __________

__________

A4
Jl. Pesantren No.92 (Global)
Cibabat-Cimahi 40513,Jawa Barat
Telp/Fax : +62 22 6611753
www.pme-bandung.com
admin@pme-bandung.com

Version

Project :

24.01.2013

1.0
Sheet

5-10
1/6

500

220

12

450

BALLAST
G1 K1 G2 K2 G3 K3 G4 K4

AR

AS

AT

G1 K1 G2 K2 G3 K3 G4 K4

ELC1P

CONSUMER

AR

AS

12V 0V N

G1 K1 G2 K2 G3 K3 G4 K4

T
ELC1P

ELC1P

12V 0V N

K K1

12V 0V N

K K1

K K1

AT

650

700

Hz

MCCB-1

KONTAKTOR

MCB ELC

F-1

F-2

OTOMATIS

MANUAL

ON CONSUMER

OFF CONSUMER

GENERATOR

CONSUMER

N R1 R2 S1 S2 T1 T2

PH

CUBICLE LAYOUT 10-20 kW

Notes :
Specifications, layout and dimension are subject to
change with/without notice

BALLAST

Scale

Designed

02.11.2010

Komarudin

Not to scale

Checked

Format

Approved __________

__________

A4
Jl. Pesantren No.92 (Global)
Cibabat-Cimahi 40513,Jawa Barat
Telp/Fax : +62 22 6611753
www.pme-bandung.com
admin@pme-bandung.com

Version

Project :

24.01.2013

1.0
Sheet

10-20
2/6

500

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
ELC1P

CONSUMER

AR

AS

12V 0V N

ELC1P

ELC1P

12V 0V N

K K1

G1 K1 G2 K2 G3 K3 G4 K4

12V 0V N

K K1

K K1

AT

650

700

MCCB-1

KONTAKTOR

Hz

MCB ELC

F-1

F-2

OTOMATIS

MANUAL

ON CONSUMER

OFF CONSUMER

GENERATOR

CONSUMER

N R1 R2 S1 S2 T1 T2

PH

CUBICLE LAYOUT 20-40 kW

Notes :
Specifications, layout and dimension are subject to
change with/without notice

BALLAST

Scale

Designed

02.11.2010

Komarudin

Not to scale

Checked

Format

Approved __________

__________

A4
Jl. Pesantren No.92 (Global)
Cibabat-Cimahi 40513,Jawa Barat
Telp/Fax : +62 22 6611753
www.pme-bandung.com
admin@pme-bandung.com

Version

Project :

24.01.2013

1.0
Sheet

20-40
3/6

600

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

ELC1P

CONSUMER

AR

AS

12V 0V N

G1 K1 G2 K2 G3 K3 G4 K4

T
ELC1P

ELC1P

12V 0V N

K K1

12V 0V N

K K1

K K1

AT

750

800

MCCB-1

KONTAKTOR

Hz

MCB ELC

F-1

F-2

OTOMATIS

MANUAL

ON CONSUMER

OFF CONSUMER

GENERATOR

CONSUMER

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

02.11.2010

Komarudin

Not to scale

Checked

Format

Approved __________

__________

A4
Jl. Pesantren No.92 (Global)
Cibabat-Cimahi 40513,Jawa Barat
Telp/Fax : +62 22 6611753
www.pme-bandung.com
admin@pme-bandung.com

Version

Project :

24.01.2013

1.0
Sheet

40-60
4/6

600

1
2
3

1
2
3

12

AS

550

220

BALLAST

AR

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

G1 K1 G2 K2 G3 K3 G4 K4

ELC1P

T
ELC1P

ELC1P

800
V

ON KONSUMEN

750
12V 0V N

Hz

12V 0V N

K K1

12V 0V N

K K1

K K1

OFF KONSUMEN
KONTAKTOR

MCCB-1
MCB ELC

F-1

F-2

OTOMATIS

MANUAL

GENERATOR

CONSUMER

PH

CUBICLE LAYOUT 60-80 kW

Notes :
Specifications, layout and dimension are subject to
change with/without notice

BALLAST
Scale

Designed

02.11.2010

Komarudin

Not to scale

Checked

Format

Approved __________

__________

A4
Jl. Pesantren No.92 (Global)
Cibabat-Cimahi 40513,Jawa Barat
Telp/Fax : +62 22 6611753
www.pme-bandung.com
admin@pme-bandung.com

Version

Project :

24.01.2013

1.0
Sheet

60-80
5/6

800

750

220

12

1
2
3

BALLAST

AR

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

ELC1P

ON KONSUMEN

OFF KONSUMEN

12V 0V N L

1000

T
ELC1P

ELC1P

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

GENERATOR

CONSUMER

PH

S
N

BALLAST

CUBICLE LAYOUT 80-100 kW

Notes :
Specifications, layout and dimension are subject to
change with/without notice

S
N

Scale

Designed

02.11.2010

Komarudin

Not to scale

Checked

Format

Approved __________

__________

A4
Jl. Pesantren No.92 (Global)
Cibabat-Cimahi 40513,Jawa Barat
Telp/Fax : +62 22 6611753
www.pme-bandung.com
admin@pme-bandung.com

Version

Project :

24.01.2013

1.0
Sheet

80-100
6/6