Control Panel Manual1X25

YTEK CONTROLS, INC.
1
Volume
Dehradun, Uttarakhand, INDIA
Control Panel for 1X50KW
MHP
0
Schematic & Wiring
Diagrams
1
YT E K CON T R OLS, I NC.
Schematic, Wiring diagrams &

Quick Reference
 Ytek Controls, Inc.

Dehradun
Uttarakhand, INDIA 248001
Phone 0135-2733250 • Fax 0135-2733250
1
Feature of Automatic
1
Chapter
Control Panel for HEP
A comprehensive Hydro Electric Plant’s
automation and governing system.
Eigenschaften
 Microprocessor based automatic monitoring and

control.
 Governing of Turbine through microprocessor
based electronic load controller for reliable and
easy operation.
 BFV controlled through Hydraulic control and
auto trip.
 Protection relays for Turbine and Generator
safety.
 On panel microprocessor based alarm
annunciator for visual indication of system
status.
 Ready to install assembled unit for easy
installation.
 Front panel push button user input for different
parameter input in manual mode.
The system is capable for performing the automatic

start-up, speed regulation, load regulation, automatic
shut-down, as well as controlling of all other devices
in the hydro power plant.
The most modern methods for achieving the highest

performance and reliability are incorporated. The
2
system includes self test diagnostic circuits and
programs, error handling routines and alarm
messages handling.
System includes microprocessor based ELC

(Electronic Load Controller) Programmable Logic
Controller (PLC) that ensure safe operation of the
generator according to the status of protection relay,
limit switches and front panel manual switches.
Function of this ELC controller could not be in any
case interrupted or failed by an error of software or
hardware on system card or other process interface
cards.
In case of accidentally failing of application software

there is a speed switch provided on the panel will trip
BFV (Butterfly Valve) and shut down the system.
System has its own self testing watch-dog facilities

which will watch the system status, in case of
software failure or hang-up, this watch dog is able to
reset the system and bring it to normal operation
mode.
General Notes for 1 X 50 KW MHP.

FABRICATION
APPLICATION :INDOOR
OPERATION :SINGLE FRONT
TYPE :FIXED TYPE
ACCESS :FRONT OPERATED WITH FRONT AND REAR
OPEN
DEGREE OF PROTECTION :IP-54
INSTALLATION :FREE STANDING FLOOR MOUNTED
PAINT SHADE :EXTERNAL - GREY, INTERNAL - GREY,
BASE - BLACK, MOUNTING PLATE –
PURPLE/ORANGE
REAR SIDE :ACCESSIBLE
DOOR GASKET :FOAM RUBBER
3
FABRICATION :MS CRCA SHEET STEEL THICKNESS 14 SWG,
LOAD BEARING MEMBER – 14 SWG, BASE ISMC
– 75
DOOR LOCK :FRONT FEEDER DOOR WITH SPECIAL LOCK &
KEY OPERATION THE REAR BIG DOOR ON SIDE
HINGED OTHER SIDE LOCK
HARDWARE :ZINC PLATED AND PASSIVATED WITH ONE
SPRING WASHER AND TWO PLAIN WASHERS
CABLE ENTRY :INCOMMER - BOTTOM OUTGOING – BOTTOM
& SIDE
LEGEND PLATE :TYPE - ALUMINIUM BLACK COVER ANODISED /
PVC
SIZE – MAIN LEGEND – 200X50
FEEDER – 150X40
METER – 60X20
LIGHTS – 22.5 DIA/ 60X20
MCB’S – 35X20
TAGS – 12X20
ELECTRICAL
DOOR EARTHING :EVERY FEEDER HINGED DOOR WITH
FLEXIBLE COPPER GREEN WIRE(2.5Sq.mm)

SUPPLY SYSTEM :POWER – 3 PHASE 4 WIRE, 415V AC, 50,
CONTROL – 24V DC
FAULT LEVEL :18 KA/ 1 SEC.
FREQUENCY :50 Hz.
EARTH BUS :ALUMINIUM- 50mm x 10mm
POWER WIRES :GREY WITH FERRULE FOR RESPECTIVE
PHASE IN COPPER FLEXIBLE WIRE

CONTROL WIRE :CURRENT CIRCUITS – COPPER FLEXIBLE
WIRE
2.5 Sq.mm
VOLTAGE CIRCUITS – COPPER FLEXIBLE WIRE
1 Sq.mm
SLEEVE COLOUR :WHITE
DC CONTROL : 1- DC +VE – GREY

2- DC –VE - GREY
EARTH : GREEN 2.5 Sq.mm
TERMINAL :POWER MIN. SIZE 10 Sq.mm
4
 CONTROL MIN. SIZE 2.5 Sq.mm
POWER TERMINAL STUD TYPE
CONTROL TERMINAL CLIP ON TYPE
MAIN BUS BAR E91E
ELECTROLYTIC GRADE :ALUMINIUM 50mm x 10mm FOR PHASE - BUS
50mm x 10mm FOR NEUTRAL –
BUS
PROTECTION & CONTROL

Protection relays are continuously tested and served
for safe performance of the system. Each relay is
microprocessor based for intelligent control.
Electronic Load Controller

Over/Under Voltage protection relay
Over/Under frequency protection relay
3POL over current relay
Earth fault relay
Master trip relay
SYSTEM OPERATION
5

As the system is switched to Auto Mode or main
system key is brought to on condition, Protection
status of the system is monitored for normal
conditions. Then on condition of all faults condition
clear, BFV are opened by manually pumping the
hydraulic unit. Turbine is allowed to rotate and
achieve appropriate rpm. When the appropriate rpm
are reached the ELC (Electronic Load Controller)
takes over and governs the speed of the turbine. For
Isolated mode frequency of the generator is regulated
at 50Hz. On achieving rated RPM/Frequency main
Breaker (MCCB) can be switched on by Pushing the
manual liver on MCCB.
A comprehensive metering is available to indicate
power, volts, current, power factor and ballast load.
TRIPING - CONTROL CIRCUIT
 When there is fault in the system, Protection relay

will command Master trip relay and Annunciator
for tripping main breaker and visual indication
through RL4.
 Main trip relay RL4 also energizes from Master
trip relay 86G2.
6

 Main trip relay RL4 breaks the closing circuit of
generator MCCB, closes BFV and sounds Hooter.
ELECTRONIC LOAD CONTROLLER (ELC)
 When BFV is open, turbine starts rolling, generator

AVR builds up Voltage through residual magnetism.
When system reached 50Hz ELC energises in
control mode and controls the frenquency to be
stable at 50.0 Hz.
 ELC controls the speed / frequency of system by
diverting excess load to ballast heaters. If speed is
lower than rated speed/frequency, no power will be
diverted to ballast heaters and as soon as turbine
7
speed tries to increase beyond rated
speed/frequency ELC starts diverting load to
ballast heaters thus controls the speed.
 It should be noted that ELC governs the speed
/frequency of the system by diverting the excess
load to heaters, which is actually wasting of
available water resources. At startup of system
operator can open water to accommodate
maximum load. Suppose there is tentative load of
40KW then water should be opened seeing ELM-
104 for reading of 50% (i.e. 50% of 54KW = 27KW).
When machine is already loaded and is in
operation, water through main inlet valve should
be opened in such a manner that ELM display is
between 15-25% which has been seen as optimum
for incomming load acceptance in operation.
 ELM-104 ELC monitor displays the percent of load

transferred to Ballast heaters in this 1x50KW 6
heaters of 9KW each are incorporated, which
means total ballast capacity to be 54KW. If ELM-
104 displays 25% it means 13.5KW of power is
being diverted to Ballast Heaters, if it displays 50%
it means 27KW of power is being diverted to
Ballast Heaters, on 100% total 54KW is diverted to
heaters. ELM-104 display range is 0-100% with
least count of 1%. ELM-104 can be attached to
remote COMPUTER/PLC/SCADA system through
provided RS-485 port on MODBUS protocol.
 50KW ELC has 6 heaters of 9KW each, connected

through 6 MCBs of 80A. While operation it should
8
be seen that all the MCBs are ON. If any MCB is
tripped it should be switched on, if it keeps on
tripping, heaters or wiring should be checked for
any faults.
INDEX OF DRAWINGS
SCHEMETICS
9
SINGLE LINE DIAGRAM 1 OF 20
SYSTEM CONTROL PANEL 2 OF 20
CONTROL PANEL DIMENSIONS & LAYOUT 3 OF 20
DC DISTRIBUTION BOARD DRAWING 4 OF 20
AC AUX. DISTRIBUTION DRAWING 5 OF 20
GEN THREE LINE DIAGRAM CT & PT 6 OF 20
RELAY CONTACT DETAILS 7 OF 20
MASTER TRIP RELAY 86G2 8 OF 20
BREAKER CLOSING AND TRIPING CIRCUIT 9 OF 20
BFV OPENING & CLOSING SCHEME 10 OF 20
ANNUNCIATOR SCHEMATIC 11 OF 20
ELC SCHEMETIC 12 OF 20
ELC DRIVER CARD SCHEMETIC 13 OF 20
ELC DRIVER I THYRISTOR SCHEMETIC 14 OF 20
THYRISTOR SCHEMETIC 15 OF 20
BALLAST LOAD SCHEMETIC 16 OF 20
BALLAST LOAD DIMENSIONS 17 OF 20
BATTERY CHARGER 18 OF 20
TERMINAL BLOCK ARRANGEMENT 19 OF 20
BILL OF MATERIAL PANEL 20 OF 20
10

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YTEK CONTROLS, INC.

Dehradun, Uttarakhand, INDIA

Control Panel for 1X50KW

Schematic, Wiring diagrams &

 Ytek Controls, Inc.

 Microprocessor based automatic monitoring and

The system is capable for performing the automatic

The most modern methods for achieving the highest

System includes microprocessor based ELC

In case of accidentally failing of application software

System has its own self testing watch-dog facilities

General Notes for 1 X 50 KW MHP.

FLEXIBLE COPPER GREEN WIRE(2.5Sq.mm)

PHASE IN COPPER FLEXIBLE WIRE

DC CONTROL : 1- DC +VE – GREY

PROTECTION & CONTROL

Electronic Load Controller

TRIPING - CONTROL CIRCUIT

 When there is fault in the system, Protection relay

ELECTRONIC LOAD CONTROLLER (ELC)

 When BFV is open, turbine starts rolling, generator

 ELM-104 ELC monitor displays the percent of load

 50KW ELC has 6 heaters of 9KW each, connected

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