Hillstone HAC240 User manual
OPERATING MANUAL
for
AC LOAD BANK
type
HAC240/415-100
iHHC3 hand held controller,
single & three phase operation,
50 Hz
issue 3
OMHAC415-100
CONTENTS
INTRODUCTION 3
SAFETY CONSIDERATIONS 4
CONNECTION PROCEDURE 4
CONNECTION DIAGRAM FOR 3PHASE TEST 5
SINGLE PHASE CONNECTION - up to 33kW 6
SINGLE PHASE CONNECTION - up to 100kW 7
OPERATING INSTRUCTIONS 8
CONTROLLING THE LOAD BANK WITH THE iHHC3 CONTROLLER 9
SPECIFICATION 10
TYPICAL PERFORMANCE TABLE 10
MAINTENANCE PROCEDURES 11
FAULT FINDING PROCEDURES 11
FAN COOLING NOT OPERATIONAL 11
LOAD BANK DOES NOT PROVIDE SUFFICIENT LOAD CURRENT 11
The information contained in this document is considered correct at the time of
printing and given in good faith.
Hillstone Products bears no responsibility for the accuracy of the data given or any
responsibility resulting from the use of the equipment.
Unit 1&2, Freetown Business Park,
Hudcar Lane,
Bury,
Lancashire, BL9 6HD, U.K.
Tel: +44(0)161 763 3100
Email: [email protected]
Web : www.hillstone.co.uk
2
OMHAC415-100
INTRODUCTION
The load bank HAC415-100 is designed for testing 415 volt, three phase, 50 Hz
UPS or generators on a 4 wire, star, connection, plus earth.
The load bank can also test 240 volt, single phase supplies.
The user features of this load bank includes
● The unit comprises of pre-set, force cooled, high powered resistor channels
which allows manual adjustment of the load current via a hand held controller
● Safety features include:
○ internal fuse protection
○ fan motor overload protection
○ auxiliary circuit protection
○ auto shutoff in the event of a mains interruption
● The load bank is force cooled by a single phase powered fan which is
connected to the load circuit under test.
● The case is designed for outdoor use.
3
OMHAC415-100
SAFETY CONSIDERATIONS
●The unit should only be operated by a competent person who is completely
familiar with the operation and specification of the load bank.
●The equipment is designed for AC operation @ 50Hz only and therefore must not
be used on DC loads such as batteries.
●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 in use the load bank should be cordoned off using safety barriers.
●The load bank should only be operated in an area with adequate ventilation.
●Care should be taken as the exhaust air outlet will be hot.
●Cables must be positioned away from the air exhaust
●During operation the load bank should not be covered or positioned to restrict air
flow
●Caution – some metal surfaces will be hot during operation
●At the end of any test the fan should be kept running for 10 minutes without load
to remove the residual heat from the load bank case.
CONNECTION PROCEDURE
● Ensure the power source to be tested is compatible with the load bank
operating voltage and frequency.
● Ensure the power source is de-energised.
● Do not attempt to operate the load bank above the maximum operating
voltage or frequency
● Check all panel mounted control switches are in the OFF position.
● Connect the hand held controller to the load bank
● Ensure the neutral and earth are connected correctly to the power source
● Ensure the neutral and earth are connected correctly
● Ensure the power cables are correctly connected to the power source
● Connect powerline connectors to the load bank
4
OMHAC415-100
CONNECTION DIAGRAM FOR 3PHASE TEST
5
OMHAC415-100
SINGLE PHASE CONNECTION - up to 33kW
6
OMHAC415-100
SINGLE PHASE CONNECTION - up to 100kW
7
OMHAC415-100
OPERATING INSTRUCTIONS
Before carrying out the following operating instructions operators should read the
SAFETY CONSIDERATIONS and CONNECTION PROCEDURE
1. Ensure all panels are in place on the load bank.
2. Ensure all panel mounted switches are in the OFF position.
3. Energise the power source from the UPS or generator.
4. Switch on the green panel mounted rocker switch.
5. Ensure the fan rotates in the correct direction with exhaust air being expelled
from the exhaust grill.
6. Do not exceed the maximum rating of the load bank.
7. At the end of a test, the mains control rocker switch should be left on for
a few minutes until the resistors have cooled.
8. Ensure the power source is isolated before opening the terminal cover or
removing the load power cables from the load bank
8
OMHAC415-100
CONTROLLING THE LOAD BANK WITH THE iHHC3 CONTROLLER
Select the appropriate load using the iHHC3 hand held controller as follows;
1. The hand held controller counts down from 7 to 0
when first powered up and displays:
a. Number of multiple Load Banks that can be
linked together and controlled from the single
controller.
b. Maximum Load - this is the maximum kW
load of one or multiple load banks linked
together.
c. Run kW - this shows the running load of the
load bank.
2. Set the required kW load using the X1, X10 and X100 buttons and press the
green ACCEPT push button.
3. The controller will display the accepted load in “ running mode “
4. The load can be adjusted on the ‘fly’ by pressing the black buttons to increase
and decrease the load in 1kW steps for each button press.
5. New load profiles can be set by pressing the X1 , X10 or X100 push buttons
and accepting or reverting ( yellow button ) back to the existing load.
6. The load can be disconnected from the power source in two ways
a. SLOW STOP – orange push button this feature removes the total load
in sequence, in a few seconds.
b. QUICK STOP – red push button this feature removes the total load
instantaneously.
7. At the end of the test the load bank should be run off load for between 5 and
10 minutes to cool the resistor elements.
8. Only isolate the UPS or generator power source when the load bank is
switched off.
9. DO NOT remove the power circuit with the load circuit energised.
The red EMERGENCY STOP button can be used as an Emergency Disconnect at
any time during a test to disconnect all load circuits and the fan supply.
9
OMHAC415-100
SPECIFICATION
Type ref
HAC240/415-100
Nominal voltage rating
415 V three phase 4 wire plus earth
Operating voltage tolerance
+6%, -10%, based on nominal 415V
Nominal current rating
149 A per phase
Nominal power rating
107 KW three phase and single phase
Operating Frequency
50 Hz only
Connection
star 4 wire, plus earth, balanced load
Controller
iHHC3
Resistor tolerance
+5 / -10%
Operating ambient temperature
0 to +40 °C
Storage ambient temperature
0 to +80 °C
Load bank size
length 1150mm, width 620mm, height 1100mm
Load Bank Weight
168 kgs approx
Movement
5” swivel castors
Load Bank Environmental
Designed for outdoor operation,
Electrical control chamber IP54,
Element chamber IP21.
TYPICAL PERFORMANCE TABLE
RATING TABLE
Internal
Channels
415VAC
240VAC - L1, L2, L3 Linked
240VAC - L1 only
Channel
Watts
Channel
Current
Channel
Watts
Channel
Current
Channel
Watts
Channel
Current
1
1,000 W
1.4 A
1,000 W
4.17 A
333 W
1.4 A
2
1,000 W
1.4 A
1,000 W
4.17 A
333 W
1.4 A
3
3,000 W
4.2 A
3,000 W
12.5 A
1,000 W
4.2 A
4
3,000 W
4.2 A
3,000 W
12.5 A
1,000 W
4.2 A
5
9,000 W
12.5 A
9,000 W
37.5 A
3,000 W
12.5 A
6
18,000 W
25 A
18,000 W
75 A
6,000 W
25 A
7
36,000 W
50A
36,000 W
150A
12,000 W
50A
8
36,000 W
50A
36,000 W
150A
12,000 W
50A
Total
107 kW
149 A
107 kW
447 A
35,666 W
149 A
10
OMHAC415-100
MAINTENANCE PROCEDURES
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;
Check the inlet and outlet grills are free from obstruction.
Check the controls and connection points are undamaged.
Check connection cables are undamaged.
Check the fan rotates freely without obstruction.
FAULT FINDING PROCEDURES
The following fault finding procedure is intended to identify simple operational errors
and has been categorised into two possible problem areas as follows;
FAN COOLING NOT OPERATIONAL
Check the power source is available.
Check the phase rotation is correct.
Check the interconnecting cable connections.
Check the fan motor operates.
Check for air blockage.
Check fan blades are secured to the motor shaft.
LOAD BANK DOES NOT PROVIDE SUFFICIENT LOAD CURRENT
Check the power source is at the required voltage.
Do not exceed the maximum rating of the load bank.
Any faults not corrected by carrying out the above procedures may require the
internal wiring or components of the load bank to be inspected for damage.
Note: Isolate the load bank from all sources of power before removing any
covers.
Testing the load bank with the covers removed should not be carried out
as it presents a risk of injury or death by electric shock.
Repair or replacement should be carried out by the manufacturer.
11
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