METAL DEPLOYE RESISTOR
Resistor for load bank
Forced cooling
Installation & Maintenance Instructions
METAL DEPLOYE RESISTOR
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
METAL DEPLOYE RESISTOR
I N S TA L L AT IO N
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
LOAD BANK
AIR INLET
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:
RT = R20° (1 + α (T - 20))
T
Actual ambient temperature
R20° Resistor value at 20°C
RT
Resistor value at T °C
α
Temperature coefficient of the alloy
METAL DEPLOYE RESISTOR
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.
METAL DEPLOYE RESISTOR
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
METAL DEPLOYE RESISTOR
TIGHTENING TORQUE TABLE
BOLT
Diameter (mm)
6
8
10
12
16
TORQUE (daN.m)
steel class 6.6
0,28
0,66
1,30
2,30
5,50
TORQUE (daN.m)
Stainless steel class A2-70
0,40
0,90
1,80
3,30
8,40
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°
Not Good
a < 60°
Good
For Equipment weighting more than 500kG, A lifting Beam must be used.
The Best Solution
METAL DEPLOYE RESISTOR
METAL DEPLOYE RESISTOR
You can reach us at the following:
METAL DEPLOYE RESISTOR
1 Route de Semur – BP 150 – 21501 MONTBARD
Tel 33(0)3 80 89 58 58 – Fax 33 (0)3 80 92 24 33
E mail : info@mdresistor.com
Web site : www.mdresistor.com