XS500 Load Bank. Read all instructions before using the load bank. Contents

Transcription

1 XS500 Load Bank

2 Read all instructions before using the load bank Contents Contents ) Receiving... 4 a. Load Bank... 4 b. Manual ) Specifications... 5 a. Mechanical... 5 i. Lifting... 5 ii. Enclosure... 5 iii. Cooling... 5 b. Electrical... 5 i. Control power... 5 ii. Load power... 6 iii. Cooling ) Safety... 7 a. Grounding... 7 b. Power Connection... 7 c. Intake and Exhaust Ports... 7 d. Misuse of Product... 7 e. Common Best Practices ) Operation... 9 a. Pre-Start Up... 9 b. Auto Load Dump... 9 i. Using the auto load dump feature... 9 ii. Bypassing the auto load dump feature... 9 c. Start Up... 9 i. Using internal control and fan power... 9 ii. Using external control and fan power d. Applying Load e. Acuvim II Power Quality Meter f. Shut Down ) Troubleshooting a. Load bank will not turn on b. Blower will not turn on c. Load steps will not turn on d. Over temperature fault ) Maintenance a. Replacing a fuse i. Main Power Fuse ii. Control Fuse iii. Blower Fuse b. Replacing Resistors

3 c. Preventative Maintenance ) Service Parts ) Copyright

4 1) Receiving Check the unit for obvious damage and report any exterior damage to the carrier immediately a. Load Bank 1x b. Manual 1x XS500 Owner s Manual 4

5 2) Specifications a. Mechanical i. Lifting The XS500 load bank is equipped with fork tubes for lifting. DO NOT lift the unit by any other means; this could cause severe damage. Fork Tubes ii. Enclosure iii. Cooling b. Electrical 1. Electro-statically applied powder coat, Blue: PPG PCUP Air inlet and exhaust are covered by metal screens and rain deflecting louvers 3. Heat is discharged horizontality The unit is equipped with one 30 inch panel fan providing CFM. The unit is equipped with an air flow sensors to ensure adequate cooling air is getting to the resistors. i. Control power The unit is equipped with a step down transformer to convert the load power to 120VAC single phase 60 Hz. The unit is also equipped with auxiliary terminal blocks in cases where the control and fan power cannot be sources internally from the load power. 5

6 ii. Load power 1. The unit is designed to accept 0-528VAC 3-Phase 60 Hz load power with external control power ( / VAC 3- Phase 60 Hz when control and fan power are sourced internally) Resolution (kw) Capacity (kw) Current at Capacity (Amps) 480VAC 240VAC 208VAC 480VAC 240VAC 208VAC 480VAC 240VAC 208VAC iii. Cooling 2. The kw output at each step is subject to a manufacturing tolerance of ±5% 3. Each circuit is connected in a delta configuration 4. The unit is designed for continuous duty at 1.0 power factor 1. The fan equipped in the unit is powered either directly off of the load power or off of the auxiliary plug. The acceptable voltage range for the fan is: / VAC 3-Phase 60 Hz 2. The power associated with each fan is 3.73 kw maximum 6

7 3) Safety a. Grounding The load bank must be firmly and electrically connected to earth ground via the grounding cam on the unit. Failure to do so could allow deadly voltage to be present on the surface of the enclosure. The grounding connection provides a low resistance path to ground. This grounding protects the operator from the possibility of electrical shock. b. Power Connection All power connection must be connected or guarded. Failure to do so will expose the operators to shock, causing severe damage or death. Without properly guarded connections, the unit is in danger of grounding-out or shorting-out the test power source. c. Intake and Exhaust Ports The unit must have free-flowing air through the intake and exhaust ports to provide adequate cooling to the resistive elements. The resistive elements convert electrical energy into heat. If the unit does not have a free flowing intake and exhaust port, the heat will build up inside of the unit and cause mechanical failure, leading to an electrical short circuit, ultimately damaging the unit and test power source. To increase the life of the resistive elements, allow the fans to run at least three minutes after the load is removed. No ductwork is permitted on the intake or exhaust of this unit as it will cause backpressure and limit the cooling of the resistive elements. Keep intake clear for 5 ft. and exhaust port for 20 ft. to allow full free-flowing. d. Misuse of Product This unit is equipped to provide up to a 500kW electrical load; if the test power source cannot sustain 500kW of load, DO NOT apply a 500kW load. Do not exceed the recommended load limit of the test power source equipment manufacturer. Damage of the test power source equipment will occur if overpowered. e. Common Best Practices i. Read all instructions before using this load bank. ii. This load bank is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. Keep combustible materials at least 6 feet (1.8 meters) from the front of the load bank and keep them away from the sides and rear. 7

8 iii. Do not operate any load bank with a damaged cord or plug or after the load bank malfunctions or has been dropped or damaged in any manner. Discard load bank or return to authorized service facility for examination and/or repair. iv. Always unplug load bank when not in use. v. Do not operate any load bank with a damaged cord or plug or after the load bank malfunctions or has been dropped or damaged in any manner. Discard load bank or return to authorized service facility for examination and/or repair. vi. Do not run cord under carpeting. Do not cover cord with throw rugs, runners, or similar coverings. vii. Arrange cord away from traffic areas and where it will not be tripped over. viii. Connect to properly grounded outlets only. ix. Do not insert or allow foreign objects to enter any ventilation or exhaust opening as this may cause an electric shock or fire, or damage the heater/load bank. x. To prevent a possible fire, do not block air intakes or exhaust in any manner. xi. Do not use it in areas where gasoline, paint, or flammable liquids are used or stored. xii. Use this load bank only as described in this manual. Any other use not recommended by the manufacturer may cause fire, electric shock, or injury to persons. xiii. Always plug load banks directly into a wall outlet/receptacle. Never use with a re-locatable power tap (outlet/power strip). xiv. This load bank includes a visual alarm to warn that parts of the load bank are getting excessively hot. If the alarm light goes on, immediately turn the load bank off and inspect for any objects on or adjacent to the load bank that may cause high temperatures. DO NOT OPERATE THE LOADBANK WITH THE ALARM LIGHT ON. xv. SAVE THESE INSTRUCTIONS 8

9 4) Operation Please contact Mosebach Manufacturing if you are planning operations in ambient temperatures above 46 ºC. Ambient plus heat generated by the resistive elements can cause electrical components to possible malfunction a. Pre-Start Up i. Check housekeeping in the operational area and correct all unsafe conditions. ii. Failure to do this may result in debris being blown around and may cause a fire hazard. iii. Check the switch panel and move all switches to the OFF position. iv. Position the load bank so that air will flow freely into the intake and out of the exhaust port v. All air intakes and exhaust ports must be clear. b. Auto Load Dump c. Start Up i. Using the auto load dump feature 1. Connect grid power to the 3 external terminal blocks located on the Cam Lock connection panel behind the swing door (L Line, N Neutral, G Ground) 2. Turn the Load Dump switch to On 3. If the grid power fails, the load bank will shut down and drop all electrical load form the test power source ii. Bypassing the auto load dump feature 1. To bypass the auto load dump feature, simply place the Load Dump switch to Bypass ; this will now bypass the load dump feature and allow the load bank to operate without any grid power being applied to the 3 external terminal blocks i. Using internal control and fan power 1. Connect the ground Cam Lock to the unit. The ground Cam Lock must be connected directly to a known earth-ground 2. Connect the 12 de-energized load power Cam Locks (4 Cam Locks per phase) to the unit 3. Turn the Blower Power Source switch to proper Int position. 4. Energize the load power source with an acceptable voltage 9

10 5. Turn the MAIN on/off power switch to the ON position. The unit will not run if an acceptable voltage is not supplied. The meter, green Main Power switch light, and Voltage Acceptable light will turn on when an acceptable voltage is supplied. ii. Using external control and fan power d. Applying Load 1. Connect the ground Cam Lock to the unit. The ground Cam Lock must be connected directly to a known earth-ground 2. Connect the 12 de-energized load power Cam Locks (4 Cam Locks per phase) to the unit 3. Connect the external power source cables to the external terminal blocks located on the Cam Lock connection panel behind the swing door (A A phase, B B phase, C C phase, G - Ground) 4. Turn the Blower Power Source switch to the proper Ext position. 5. Energize the external power source with an acceptable voltage 6. Energize the load power source with an acceptable voltage 7. Turn the MAIN on/off power switch to the ON position. The unit will not run if an acceptable voltage is not supplied. The meter, green Main Power switch light, and Voltage Acceptable light will turn on when an acceptable voltage is supplied. i. Start with the Main Power located in the ON position with the required voltage and Master in the OFF position. ii. Place the desired test step switches in the ON position. iii. Place the Master switch ON to engage the resistors. iv. Repeat tests as needed e. Acuvim II Power Quality Meter i. Press the VA button on the front of the meter to view and cycle through the line voltage and current options. ii. Press the P button on the front of the meter to view and cycle through the Power Reading and Power Factor options. iii. You will find more detailed instructions on the use of your meter on the CD disk that was supplied with your load bank manual or by visiting the accuenergy.com website. 10

11 f. Shut Down i. Place all step switches in the OFF position. Put Master in the OFF position. ii. Allow fans to operate at least three minutes or until exhaust air is cool before shutting them off. This cooling period will extend the life of your load bank. iii. Turn Main Power Switch to the OFF Position iv. De-energize the external power source (if applicable) and the load power source v. Remove the de-energized external power source cables from the external terminal blocks vi. Remove the 12 de-energized load power Cam Locks from the unit vii. Remove the ground Cam Lock from the unit viii. Close and secure all doors to protect delicate hardware ix. Move load bank to a safe and secure storage area 11

12 5) Troubleshooting a. Load bank will not turn on i. Make sure the main switch is in the ON position ii. Make sure the Blower Power Source switch is in the correct position iii. Check the control fuses iv. Check if the auto load dump grid power is energized or the auto load dump switch is in the bypass position b. Blower will not turn on i. Make sure the load bank is turning on ii. Check for debris preventing the fan from turning iii. Check the blower fuses iv. Make sure you are in local mode c. Load steps will not turn on i. Make sure the load bank is turning on ii. Make sure the test power source is energized iii. Check the main power fuses iv. Make sure the Master step switch is in the ON position v. Check if the over temperature red light is on vi. Check for resistor continuity vii. Ensure the airflow is suitable and the pressure sensor is not malfunctioning viii. Make sure you are in local mode d. Over temperature fault i. Turn off the unit and disable the source power immediately ii. This is an indication that the internal cabinet temperature has exceeded 150 ºF iii. Make sure the cabinet is ventilated iv. Make sure the temperature sensor is operating. The temperature sensor should be normally closed below 150 ºF 12

13 6) Maintenance a. Replacing a fuse To get into the control component area; use a 7/16 nut driver, remove the 10 bolts from the lid of the load bank. Gently remove the lid front the unit, taking care to not damage the grounding cable attached to the panel. i. Main Power Fuse The main power fuses are located on a series of bus bar attached to the Cam Lock panel. To remove any of the main fuses, remove the respective bolts holding the fuse to the bus bar and cable(s). Be sure to not lose any hardware as it can be detrimental to the unit if left inside during operation. ii. Control Fuse The control fuses are located on the switch panel labeled FC (main control fuse) and FM (meter fuse). Twist the black head of the fuse holder until the spring load forces the fuse out. Service to the fuse can now be completed. iii. Blower Fuse The blower fuses are located on a din rail on the main control panel near the Cam Lock panel. To remove a fuse from the holder, pry the fuse out of the spring locked fuse holder. Blower Fuses Main Power Fuses Control Fuses 13

14 b. Replacing Resistors Contact Mosebach Manufacturing Co. if there is a problem with the resistors or if a resistor needs to be replaced. c. Preventative Maintenance Do not use a power washer to clean off the exterior of the unit. It is high voltage electrical equipment. Action Walk around the unit and inspect for: a) Obvious damage b) Loose hardware Cold Resistance Check Air Flow Test Power Test Open Control Panel and Inspect for: a) Loose wire connections b) Visually damaged components Inspect Fan Inspect Resistors for: a) Damage to coils b) Delamination of the mica Contactors are opening and closing Meter Calibration Frequency Every use Every 6 months Every 6 months Every 6 months Every 6 months Annually Annually Annually Annually 14

15 7) Service Parts Power Fan Resistor Elements Fuses Meter Part Number BLWR RA RA RA RA A Type AGC = AGC-10-R 1A = EC A = EC A = EC A = EC EC

16 8) Copyright Copyright 2017 Mosebach Manufacturing Company MOSEBACH MANUFACTURING COMPANY 1417 McLaughlin Run Road Pittsburgh, PA USA T: Customer Care F: OM-XS500 (1).doc December 6, 2017 SAVE THESE INSTRUCTIONS 16