A company with a broadly distributed set of networks and machines depended on strategically placed generators to keep operations underway in the event of a power failure. The idea was sound, and the system worked well. That is, it worked well as long as the generators that were vital to keeping the system running had fuel in them – sort of a "no brainer." When the day came along that the system failed and the generator was not able to save the day, maintenance personnel discovered an empty generator fuel tank was to blame.

This problem was brought to the attention of Advanced Automation Products (AAP), which had worked with the firm on other projects. The goal was obvious — the generator fuel tanks needed to be monitored for fuel consumption and fuel availability.

The company asked AAP’s Steve Brown to assist. Steve developed a system for the customer that relies on Control Technology Corporation (CTC) Blue Fusion Controllers in combination with SymCom Corporation’s enhanced overload relays to keep a constant stream of information flowing, alerting the company to failures and, better yet, impending failures, to protect valuable assets and ensure 100% uptime.

SymCom enhanced overload relays are often used as “smart sensors” to monitor three-phase voltage, current, power, and power factor. In this project, the module’s compact package was important since control panel space was limited. In addition, the relays are easily installed and configured in the field for a wide range of voltages and currents. The built-in communications port was networked to a CTC Blue Fusion controller, programmed to continuously monitor all parameters within the relay. Real-time data is used to provide alarms for immediate notification of a problem, monitored to alert of a pending problem, or logged for later analysis for preventive and predictive maintenance.

When a SymCom unit is added to a transfer switch, the utility power conditions can be monitored. And since most transfer switches have status contacts, these can be connected to the controller so the electrical feed (generator or utility power) can easily be identified. Like the generator, the utility power can be monitored so a log can be created and email alarms sent for predefined out-of-tolerance power conditions.

It did not take long to determine the I/O requirements for the generator monitoring application, and SymCom monitoring modules handled all the hardware connections. Using the Modbus TCP protocol and Ethernet cables, the SymCom data is pulled directly into the Blue Fusion controller’s Ethernet port.

The Blue Fusion controller receives the real-time data, and creates log files, which are served at regular intervals to a centrally located computer on a network hundreds of miles away. The data is provided in a comma-delimited file format to allow seamless importing to corporate reports. Customized web pages created and stored in the Blue Fusion controller can be viewed by anyone with a browser and an authorized username and password. Multiple page views display the data being monitored by the SymCom sensors. The Blue Fusion is designed to allow multiple browser connections at the same time, just like a typical Internet web page. The connection is two-way so maintenance personnel can do more than just view the information — they can interact with the controller and change settings, limits, and resets, or make any other necessary changes remotely. This capability is predicated on the authorization code access and the design of the web pages themselves. The distance limit for the connection is limited only by the Internet.

In some cases a customer may want to receive an email notifying them of a power outage so maintenance can be dispatched. Blue Fusion controllers support the ability to send "customized" emails, which can be event driven and contain "live" data when transmitted. The unit can be programmed to log data and send email alarms in the event of abnormal conditions or simply to notify the fuel supplier it is time to schedule a refill.

Steve Brown noted that the Blue Fusion Controller could be used as a power monitor device at a generator site to monitor any number of conditions. The Blue Fusion can be connected to any generator with Modbus connectivity to monitor electrical output of the generator, engine data, or battery voltage to name a few key parameters. Since many generators only have a low-fuel contact, a level sensor can be added to display level conditions over the Internet.

When Advanced Automation Products completed the project, the customer could be confident that system failures in the event of a power outage would not be an issue. Generators installed to kick in are ready and waiting — and always have fuel to generate power and keep the machines running until power is restored.

For questions or for additional information about this application, contact Steve Brown, Advanced Automation Products, 904-215-3816 or email This email address is being protected from spambots. You need JavaScript enabled to view it..