Resistor for load bank Forced cooling

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1 Resistor for load bank Forced cooling Installation & Maintenance Instructions

2 Installation & Maintenance Instructions Installation 3 I Checking For Transportation Damage. 3 II Frame Assembly 3 Commissioning 3 I Electrical Resistor Checking 3 II Resistor Connections 4 III Final Observation 4 Maintenance 4 I Safety Operations 4 II Rate of Maintenance Operations 4 III Operations 5 IV Measurement of Cold Resistance Value 5 Tightening Torque Table 6 Handling 6

3 INSTALLATION I CHECKING FOR TRANSPORTATION DAMAGE. Unpack the resistor frames according to the packing list. Check the frames, the insulators and the spare parts to ensure that they have not been damaged during transportation. Open front and rear doors. Check the active parts (make sure that they are free of foreign bodies). Check internal insulators (if any contamination occurs please refer to chapter cleaning of maintenance instruction). Any broken insulator must be replaced. Check if the welded connections are free of cracks and check the tightness of all bolted electrical connections. Refer to the tightening table. If the material is damaged informs the carrier and Metal Deploye Resistor on damages. II FRAME ASSEMBLY Use the lifting lugs (if applicable) provided on the resistor frame to handle the resistor. Do not handle the resistor with door opened or without the louvered panels. It is compulsory to provide a gap of 1 m from the fan entrance (to allow the cooling air to enter the resistor without pressure drop) and a gap of 2 m from the exhaust air panel (to prevent any equipment from hot air damage). Tighten the fixing bolts. The resistor should be preferably placed in the direction of the dominating winds, in order to cause minimum disturbance during the cooling. DOMINANT WIND AIR INLET LOAD BANK AIR OUTLET COMMISSIONING I ELECTRICAL RESISTOR CHECKING I.1 MEASUREMENT OF THE COLD RESISTANCE VALUE : Refer to final test certificate to get the appropriate value. After the transport, the cold resistance value must not differ from 2 % of the recorded value. This measurement must be done with a 4 wires apparatus with the appropriate accuracy class. -If the ambient temperature T is far from 20 C, a correction on measurement must be done to compensate this temperature variation: Reminder: R T = R 20 (1 + α (T - 20)) T Actual ambient temperature R 20 Resistor value at 20 C R T Resistor value at T C α Temperature coefficient of the alloy

4 I.2 MEASUREMENT OF THE INSULATION RESISTANCE UNDER 500 V DC : Measure of the insulation resistance under 500 V DC. It must be higher than 50 Megaohm. Close the doors and tighten the closing bolts II RESISTOR CONNECTIONS CAUTION! CHECK THAT THE MAINS ARE NOT ALIVE AND THAT THE CONTROL VOLTAGE IS OFF BEFORE ANY INTERVENTION. A BAD USE OF THE EQUIPEMENT CAN CAUSE SEVERE BODY DAMAGES AND INJURES. FIRSTLY, READ THE FOLLOWING BEFORE STARTING WITH THE INSTALLATION. Proceed to the connections of the resistor, of the fan motor and of the air speed sensor. Check that the fan blows towards the resistor and the air speed sensor operates properly. Connect the frame mass terminal. III FINAL OBSERVATION The resistor is ready to operate. During the first energising some smoke (grease) may exhaust from the resistor during a couple of minutes. This will not affect the resistor. MAINTENANCE I SAFETY OPERATIONS Before starting any maintenance operations, make sure that according to local safety rules and regulations, the resistor cannot be energised. It is necessary to wait for 30 minutes after power cut off to allow the resistor active parts and the frame to cool. The staff must be protected against hazard due to hot resistor enclosure and hot air exhaust and to moving parts mainly against rotation part of fans and motors. Protection must be provided against hazard due to solid particles in the air flow, papers, plastic which may be sucked and burn resulting in fire hazard. The load bank must not operate without airflow. It would result in immediate destruction of the heating grids. BE CAREFUL: The temperature load bank enclosure can cause some burning II RATE OF MAINTENANCE OPERATIONS The resistor can operate with little maintenance: approximately every six months on each frame under normal environment, but with a higher frequency under severe pollution conditions. In order to determine the normal rate of maintenance operations, they should be carried on a more frequent basis during the first year: approx. every three months on new frames.

5 III OPERATIONS III.1 CLEANING Under normal pollution conditions, remove panels and check the cleanness of the internal insulators. They must be wiped off (use a duster and a rapidly evaporating diluter for greasy or sticky contamination). Identify the cracked or broken insulators and replace the active parts group. It is recommended to blow (compressed air) the active parts of the resistor and their own insulating rings-washer. Check that the air inlet and outlet of the frame are not clogged (any foreign body should be removed by hand). III.2 TIGHTENING Check the visual aspect of the welded connections and the tightening torque of all bolted electrical connections. Refer to the Tightening table. IV MEASUREMENT OF COLD RESISTANCE VALUE After heating, the cold resistance must not differ from 2 % of the initial value

6 TIGHTENING TORQUE TABLE BOLT Diameter (mm) TORQUE (dan.m) steel class ,28 0,40 8 0,66 0, ,30 1, ,30 3, ,50 8,40 TORQUE (dan.m) Stainless steel class A2-70 This torques will result in tensile stress in bolts equal to 3/4 of yield strength, if the bolts are fitted with washers and if the bolts are not damaged. HANDLING For Equipment weighting less than 500kG, rope lashings can be used but take care of the angle. It shall not overpass 60 a a a < 60 Good a > 60 Not Good For Equipment weighting more than 500kG, A lifting Beam must be used. The Best Solution

7 METAL DEPLOYE RESISTOR You can reach us at the following: METAL DEPLOYE RESISTOR 1 Route de Semur BP MONTBARD Tel 33(0) Fax 33 (0) E mail : Web site :

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