LOAD BANK PART NUMBER / OPERATIONS AND MAINTENANCE MANUAL

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1 LOAD BANK PART NUMBER / OPERATIONS AND MAINTENANCE MANUAL Prepared by: 5455 N River RD W Geneva, OH Phone: HDT 1 TM /

2 TABLE OF CONTENTS 1.0 INTRODUCTION SAFETY CONSIDERATIONS CONNECTION PROCEDURE OPERATING PROCEDURES SPECIFICATION MAINTENANCE PROCEDURES FAULT FINDING 5 HDT 2 TM /

3 1.0 INTRODUCTION The / kw load bank is designed for applying load for testing or to prevent wet-stacking on a Diesel Engine Generator Set (DEG). It is designed to operate on 208VAC at 60Hz. The unit is comprised of pre-set, force air cooled, high powered resistor elements. Safety features include internal fuse protection, fan motor overload protection, and auxiliary circuit protection. The load bank is force air cooled by a three phase powered fan which is internally connected to the 3 phase load circuit, which represents a permanent load while the unit is in use. The enclosure is designed for outdoor use. 2.0 SAFETY CONSIDERATIONS 1. The load bank is designed for indoor or outdoor use. 2. The unit should only be operated by competent electrical engineers who are completely familiar with the operation and specification of the load bank. 3. The equipment is designed for AC operation only. 4. Operators must ensure that interconnecting cables are correctly rated to carry the required load current and adequately insulated to prevent the possibility of electric shock when operating at high voltages. 5. When in use the load bank should be isolated using safety barriers. 6. The load bank should only be operated in an area with adequate ventilation. 7. Care should be taken as the exhaust air outlet will be hot during operation. 8. Cables must be positioned away from the air exhaust. 9. During operation the load bank should not be covered or positioned to restrict air flow. 10. Caution some metal surfaces will be hot during operation 11. At the end of any test the fans should be kept running for 5 10 minutes at no load to remove the residual heat from the load bank case and elements. 12. There is a Power Distribution Block (PDB) located in the unit to permit the load cable to be hardwired to the load bank. 3.0 CONNECTION PROCEDURE 1. Ensure the power source to be tested is compatible with the load bank operating voltage. 2. Ensure the power source is de-engaged. 3. Do not attempt to operate the load bank above the maximum operating voltage. 4. Check that all panel mounted control switches are in the OFF position. 5. Connect phase A, B and C to L1, L2 and L3 respectively and connect the Neutral and Ground to the corresponding positions on the PDB in the load bank. 6. Connect cable to power source. 4.0 OPERATING INSTRUCTIONS HDT 3 TM /

4 Operators should read the SAFETY CONSIDERATIONS and CONNECTION PROCEDURE before carrying out the following operating instructions. 1. Ensure all panels are in place on the load bank. 2. Ensure all panel mounted switches are in the OFF position. 3. Energize the power source from the generator. 4. Switch on the panel mounted toggle switch. 5. Ensure the fan rotates in correct direction with exhaust air being expelled from the exhaust grill. If the fan rotates incorrectly the cables have been connected in the wrong phase rotation and the following procedure should be performed. a) Disconnect and isolated the power source. b) Change over any two phase connections c) Continue the operating procedure from 1 above 6. During running mode the load can be adjusted by moving the toggle switches to on. There is a 10kw load step and a 20kw load step. There is an indicator light that illuminates when the load step is activated. 7. Do not exceed the maximum rating of the load bank. 8. At the end of use switch the load bank to fan only (off load) for between 5 and 10 minutes to cool the resistor elements. 9. Isolate the generator power source. 10. DO NOT remove the power circuit with the load circuit energized. 5.0 SPECIFICATION Part Number: / Max operating voltage: 208V three phase 60 Hz Max current rating: 100A per phase Max power rating: 30 KW Connection: 1 five point PDB for hardwired connection Resistor tolerance: +/-5% Operating ambient temperature: -40 to +55 deg C Storage ambient temperature: -40 to +60 deg C Dimensions Length in Width in Height in 6.0 MAINTENANCE PROCEDURES HDT 4 TM /

5 The load bank should not require any special maintenance; however as with any electrical equipment periodic checks should be carried out to ensure the equipment is in a safe and satisfactory condition. The following periodic checks are recommended on the load bank; 1) Check the inlet and outlet grills are free from obstruction or debris. 2) Check that the controls and terminals are undamaged and secure. 3) Check the fan rotates freely without resistance. 4) Check connection cables are undamaged. 7.0 FAULT FINDING PROCEDURES The following fault finding procedure is intended to identify simple operational errors and has been categorized into possible problem areas as follows; Note: Isolate the load bank from any power source before removing any covers. Testing the load bank with the covers removed is not recommended as high voltages can be present on power resistors or terminals. Repair or replacement should be carried out by the manufacturer or trained personnel at the direction of the manufacturer. Issue/Symptom Cause Solution Cooling Fan not operational Fan contactor faulty. Circuit breaker not closed. Power coming to unit is not proper. Fan is faulty. Fuse is blown. Loose Wire. Check to see that control voltage is coming into the contactor and that all three phases of power are also available. If the contactor engages the problem is elsewhere. If not replace the contactor. Close the Circuit Breaker. If the breaker will not close check for continuity to ground. If continuity exists there is a short, investigate that. If no continuity exists replace the breaker. Ensure the power coming into the unit is 208 VAC 60Hz three phase with at least 100Amps supply. Replace the fan motor. Check and replace the fuse. Inspect the system for a loose wire connection. Issue/Symptom Cause Solution HDT 5 TM /

6 Does not provide sufficient Load Current Thermal Overload tripped Resistive element is open (faulty) Either load bank circuit breaker is off. Check to see if S4 or S5 are open. If there has been an over temperature condition the overload may need to cool before the unit will come back on line. If no over temperature condition exists the overload could be faulty. Isolate the overload and check to see if it is closed at room temperature (70F).It should be closed, if not replace the overload. Isolate the element and check for continuity. If there is no continuity the element is faulty. If there is continuity connect the wires and check at the top of the resistive element to see if the proper voltage is present. Check to see that amperage is present with an Amp Clamp. If amperage is present the element is ok. Engage the circuit breaker for the 10k or 20k. If the circuit breaker will not engage check for a short in the system. If the breaker will not close check for continuity to ground. If continuity exists there is a short, investigate that. If no continuity exists replace the breaker. Indicator light not functional Contactor faulty. Switch is faulty. Loose Wire. The bulb is blown. The fuse is blown. Improper input power. Replace the contactor. Replace the switch. Inspect the system for a loose wire connection. Replace the light. Check and replace the fuse. Restore input power to 208VAC 60Hz three phase. HDT 6 TM /

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