Technical data Sheet Hillstone PowerBank HPB54 Series ( 400A 700A ) Ref. HPB54-400-700 Page 1 of 6 Features Electronic variable control Manual constant current Full current control range Digital ammeter / voltmeter option Safety isolation contactor High power Compact size Portable The Hillstone HPB54 Series load banks are designed specifically for the Telecom s industry to provide a cost effective, high current discharge test equipment for 48 volt lead acid battery systems or continuous rectifier testing up to 55 volts. Sizes up to 1400 amps are available each incorporating light weight, force cooled high power resistor elements. For details of high current units please apply to our sales office. The design includes the unique Hillstone PowerBank electronic controller which provides accurate adjustment of the discharge current throughout the test with full constant current control over the total current rating. Standard units include shrouded voltmeter and current sockets for direct measurement of the battery voltage and discharge current via external multi-meters. A liquid crystal back-lit display to monitor the battery voltage and discharge current is available as an optional extra. The HPB54 Series load banks incorporates contactor isolation which in the event of mains interruption will automatically terminate the test and stop the discharge. All units are light weight, robust, portable and come complete with mains cable swivel castors and carrying handle and include DC power cables. A comprehensive operating manual is supplied with each unit.
Ref. HPB54-400-700 Page 2 of 6 Specification Type ref. HPB54-400 HPB54-500 HPB54-600 HPB54-700 Max current ( see note 1 ) 436 amps 502 amps 635 amps 700 amps Max power dissipated 24000W 27600W 34900W 38540W Max constant current at 43 volts 342A 394A 496A 547A Variable channel ( see note 4 ) 0-26 amps 0-26 amps 0-26 amps 0-26 amps Switched steps ( see note 4 ) 1 x 66 amps 2 x 132 amps 2 x 66 amps 2 x 132 amps 1 x 66 amps 2 x 132 amps 1 x 198 amps 1 x 66 amps 1 x 132 amps 2 x 198 amps Nominal battery voltage 50volts DC Current adjustment ( see note 1 ) Zero to max amps Max operating voltage ( note 1) 55 volts DC Min volts at constant amps 43 volts DC Max number of lead acid cells 24 Test voltage sockets (see note 9) Test current sockets 4 mm shrouded ( DC volts direct reading ) 4 mm shrouded ( DC amps 4mV or 10mV per amp ) Protection Isolation contactor Auto test stop on mains interruption Auxiliary mains supply fuse Digital meter ( see notes 7 & 8 ) Ammeter / voltmeter ( see optional extras ) Auxiliary mains supply 230V single phase 50 Hz ( 110V option see note 5 ) Auxiliary mains connection IEC fused socket with switch Mains cable 2 metres with IEC and 13 amp plug ( see note 5 ) DC power cable set ( see note 10 ) 2.5 metres of twin cable via industrial plug and socket HPB54-400 HPB54-500 HPB54-600 HPB54-700 800mm 800mm 800mm 800mm 450mm 500mm 500mm 500mm 600mm 600mm 700mm 850mm 45Kgs 50Kgs 60Kgs 80Kgs Case size Length Width Height Weight ( approx. ) Finish Environmental protection rating Movement Operating temperature range Storage temperature range Light grey 00A05 textured finish IP21 Carrying handle and swivel castors 0 40 deg C 0 80 deg C
Ref. HPB54-400-700 Page 3 of 6 Notes 1) The maximum current is stated at the maximum operating voltage and the equipments are designed for continuous operation at the maximum voltage. 2) Discharges can be achieved below 43 volts with proportionally reduced output current ( see performance tables ) 3) Units are designed for indoor use only in a clean, dry and well ventilated environment. 4) Rated at 55 volt nominal. 5) Alternative mains input voltages are available ( see table 2 ) 6) The HPB54 Series load banks are designed for battery discharge testing and rectifier testing on a DC power source only. UPS & gen-sets testing with an AC power source can be provide on request. 7) The digital panel meter option is a non calibrated instrument for general indication only. 8) When a digital meter is fitted as an option the test sockets are omitted. 9) External digital multimeters are not supplied with the load bank. 10) Information in technical literature, quotations or data sheets are intended to be correct at the time of publication, however, Hillstone Products Ltd bears no responsibility for the accuracy of any information given. 11) We reserve the right to make detail changes to specification, components, dimensions or weights at the time of design or manufacture without prior notice. 12) All information in this data sheet is the copyright of Hillstone Products Ltd. 13) All designs are the intellectual property of Hillstone Products Ltd. Table 1 High Powered Resistor Element Specification Resistor tolerance +/ - 5% Grid Type EN or HPR 50/0.5 Mounting Non-Hydroscopic bush insulators Insulation 2.5 kv Element material Stainless steel Table 2 Optional Extras Alternative mains input Meter display ( see note 7 & 8 ) 110 volt single phase 50 or 60 Hz 11mm character back-lit switched to display either : Voltage 99.9 volts f.s.d. +/-0.5% ( +/- one digit ) Current 999 amps f.s.d. +/- 0.5% ( +/- one digit )
Hillstone PowerBank HPB54 Series Application notes Ref. HPB54-400-700 Page 4 of 6 Lead acid battery discharge testing All types of lead acid batteries ( with the exception of Plante cells ) fall in capacity during their service life. The end of life is normally determined when the battery falls to 80% of its original capacity. This assumes the battery is float charged at the correct voltage and operated in the correct ambient temperature between 20 25 degc. Incorrect charging voltage may reduce service life and high ambient temperature ( without adjustment of the charge voltage ) will seriously reduce capacity and service life. An increase of 10 deg C ambient could reduce the service life by half. It is therefore important to determine the actual capacity of a standby battery, periodically during its service life, so that the end of life can be estimated and any premature failure can be detected. This procedure ensures reliability of the emergency system and provides information to allow financial allocation of resources prior to battery replacement. A general guide to carrying out a full capacity test Battery capacity tests on lead acid batteries are normally carried out at the 3 hour rate of discharge and should be at a constant current down to 1.8 volts per cell. When testing 24 lead acid cells this equates to 43.2 volts at the battery terminals, at the end of the discharge test. Ideally a capacity discharge test should be carried out annually. It is important to perform the discharge until the battery voltage reaches 43.2 volts, this may be greater than three hours. The actual battery capacity is calculated by multiplying the constant discharge current by the time taken to reach 43.2 volts. This capacity figure should then be recorded and compared during the service life to determine if the capacity is reducing at the expected rate. The fall in capacity is approximately linear, i.e. 90% capacity after 5 years ( for a 10 year service life battery ) Note : 1) ensure the battery is fully charged prior to a capacity test. 2) refer to the battery manufacturers performance data to determine the required discharge current. 3) discharge performance should be corrected dependant on temperature 4) Alternative discharge rates can be used to determine capacity, however comparisons should only be made at the same discharge rate and end voltage. Load bank operating procedure The standard HPB54 Series load banks allow manually controlled battery discharge to be carried out at any discharge current within the load bank rating. Energising the mains supply will operate the cooling fan and allow the operator to energise the load isolation contactor via panel mounted switches. Discharge current selection is made by the operator selecting the required current from the panel mounted switches and the fine current adjustment channel. During the discharge, as the battery voltage falls the operator adjusts the discharge current via the panel mounted control of the electronic variable channel.
Hillstone PowerBank HPB54 Series Application notes cont. Ref. HPB54-400-700 Page 5 of 6 Lead Acid Battery Discharge Testing The HPB54 Series load banks can be used to discharge test a wide range of lead acid cells at different system voltages. The performance data below details the constant current loads available on each unit down to different end voltages. HPB54-400 Performance table Nominal No. of lead HPB54-400 maximum constant current available at ; 50V 25 LA 377A 367A 357A 347A 337A 48V 24 LA 361A 352A 342A 333A 323A 30V 15 LA 226A 220A 214A 208A 202A 24V 12 LA 181A 176A 171A 166A 162A 12V 6 LA 90A 88A 86A 83A 81A HPB54-500 Performance table Nominal No. of lead HPB54-500 maximum constant current available at ; 50V 25 LA 434A 422A 411A 399A 388A 48V 24 LA 416A 405A 394A 383A 372A 30V 15 LA 260A 253A 246A 240A 233A 24V 12 LA 208A 203A 197A 192A 186A 12V 6 LA 104A 101A 99A 96A 93A HPB54-600 Performance table Nominal No. of lead HPB54-600 maximum constant current available at ; 50V 25 LA 548A 534A 520A 505A 491A 48V 24 LA 526A 513A 496A 485A 471A 30V 15 LA 329A 320A 312A 303A 294A 24V 12 LA 263A 256A 249A 242A 236A 12V 6 LA 132A 128A 125A 121A 118A HPB54-700 Performance table Nominal No. of lead HPB54-700 maximum constant current available at ; 50V 25 LA 605A 589A 573A 557A 541A 48V 24 LA 580A 565A 547A 535A 519A 30V 15 LA 363A 353A 344A 334A 325A 24V 12 LA 290A 283A 275A 267A 260A 12V 6 LA 145A 141A 137A 134A 130A
Ref. HPB54-400-700 Page 6 of 6 Rectifier & Battery Charger Testing The HPB54 Series load banks can be used for continuous testing of rectifier & chargers in line with the following table. DC HPB54-400 HPB54-500 HPB54-600 HPB54-700 test voltage 54.5V 432A 497A 629A 694A 50V 396A 456A 577A 636A 48V 381A 438A 554A 611A 43V 342A 394A 500A 547A 36V 285A 329A 416A 458A 27V 214A 246A 312A 344A 24V 190A 219A 277A 305A 21V 166A 192A 242A 267A 15V 119A 137A 173A 191A 12V 95A 110A 139A 153A 10V 79A 91A 115A 127A Hillstone Products Ltd Tel. +44 (0) 161 763 3100 Unit D2 Greenbrook Business Park Fax. +44 (0) 161 763 3158 Greenbrook Street, Chesham, Bury e-mail sales@hillstone.co.uk Lancashire England BL9 6LZ www.hillstone.co.uk