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LOAD BANK MAINTENANCE
Simplex Load Banks are
designed to require minimum maintenance. All components have
been chosen for a long, reliable life.
Two basic intervals of maintenance are required: each operation
and every 50 hours or 6 months (whichever comes first).
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Each Operation
The air intake screens and louvers, fan and cooling chamber,
and exhaust openings must be checked for any obstructions or
foreign objects. Due to the high volume of air circulated, paper
and other items can be drawn into the air intakes. During Load
Bank operation insure that air is exiting from the top exhaust
vent.
The load branches should be checked for blown fuses or opened
load resistors. To check the fuses or load resistors, operate
the Load Bank from a balanced 3-phase source and check the three
line currents. The three current readings should be essentially
the same. If a sizable difference is noted one or more load fuses
or load resistors may have malfunctioned.
WARNING - For continued safety and for maximum equipment protection,
always replace fuses with one of equal rating only.
Shaft and Grease
Fitting
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Every 50 Hours or 6 Months
Check the tightness of the electrical connections. The expansion
and contraction caused by Load Bank operation may result in loose
connections. The vibrations caused by the cooling fan may also
loosen electrical connections. If the Load Bank is transported
“over the road”, the electrical connections should
be checked for tightness at a shorter-than-normal time interval.
Motor Lubrication
Motors are properly lubricated at the time of manufacture. It
is not necessary to lubricate at the time of installation unless
the motor has been in storage for a period of 12 months or longer
(refer to lubrication procedure that follows).
Inspect the fan motor supplied with your Load Bank for grease
fittings. If the motor contains grease fittings you must lubricate
the motor. If lubrication instructions are shown on the motor
nameplate, they will supersede this general instruction. Belt
driven cooling fans have bearings which should be lubricated.
Bearings should be lubricated every 50 hours of operation or
6 months whichever comes first.
WARNING
The Pillow Block Bearings
(PN 22691042), which are used on Saturn Load Banks, are pre-lubricated
at the time of manufacture. These bearings are lubricated with
Mobil Mobilith AW2 grease (a Lithium based grease). Lubrication
using a non-compatible grease may cause bearing failure. See
Pillow Block Bearings Lube Interval below for additional information. |
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Lubrication Procedure
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1. |
Stop motor. Disconnect and lock
out of service.
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2. |
Remove contaminants from grease
inlet area.
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3. |
Remove filler and drain plugs.
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4. |
Check filler and drain holes for
blockage and clean as necessary.
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5. |
Add proper type and amount of grease.
Below, see the Relubrication Time Intervals table for service
schedule and Relubrication Amounts table for volume of grease
required.
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6. |
Wipe off excess grease and replace
filler and drain plugs.
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7. |
Motor is ready for operation.
WARNING - If motor is nameplated
for hazardous locations, do not run motor without all of the
grease or drain plugs installed.
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Grease Type
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Unless stated otherwise on the
motor nameplate, the motors on this Load Bank are pregreased
with a polyurea mineral oil NGLI grade 2 type grease. Some compatible
brands of polyurea mineral base type grease are:
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1. |
Chevron SRI #2
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2. |
Rykon Premium #2
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3. |
Exxon Polyrex EM
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4. |
Texaco Polystar RB
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RELUBRICATION TIME INTERVAL
for motors with regreasing provisions. |
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NEMA Frame Size |
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140 – 180 |
210 – 360 |
400 – 510 |
1800 RPM
and less |
Over 1800
RPM |
1800 RPM
and less |
Over 1800
RPM |
1800 RPM
and less |
Over 1800
RPM |
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Standard |
3 yrs. |
8 mo. |
2 yrs. |
8 mo. |
1 yr. |
3 mo. |
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Severe |
1 yr. |
3 mo. |
1 yr. |
3 mo. |
6 mo. |
1 mo. |
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Seasonal |
See Note 2. |
STANDARD:
Up to 16 hours of operation per
day, indoors, 100°F maximum ambient.
SEVERE: Greater
than 16 hours of operation per day. Continuous operation under
high ambient temperatures (100° to 150°F) and/or any
of the following: dirty, moist locations, high vibration (above
NEMA standards), heavy shock loading, or where shaft extension
end is hot.
SEASONAL: The
motor remains idle for a period of 6 months or more.
NOTE:
1. For motors nameplated
as “belted duty only” divide the above intervals by
3.
2. Lubricate at the beginning of the season. Then follow service
schedule above.
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RELUBRICATION
AMOUNTS
for motors with regreasing provisions. |
NEMA
Frame Size |
140 |
180 |
210 |
250 |
280 |
320 |
360 |
400 |
440 |
500 |
Volume
(cu. in.) |
.25 |
.50 |
.75 |
1.00 |
1.25 |
1.50 |
1.75 |
2.25 |
2.75 |
3.00 |
Volume
(fluid oz.) |
.14 |
.28 |
.42 |
.55 |
.69 |
.83 |
.97 |
1.2 |
1.5 |
1.7 |
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PILLOW
BLOCK BEARINGS LUBE INTERVAL |
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The Pillow Bearings
(PN 22691042), which are used on Saturn Load Banks, are
pre-lubricated at the time of manufacture. These bearings are
lubricated with Mobil Mobilith AW2 grease (a Lithium based grease).
Lubrication using a non-compatible grease may cause bearing
failure. When re-lubricating slowly add grease until fresh
grease is seen purging past the seal. In the higher speed ranges,
excess grease may cause temporary bearing overheating. The amount
of grease a bearing will take for a specific high speed application
is best determined by experience. When establishing a re-lubrication
schedule, note that a small amount of grease at frequent intervals
is preferred to a large amount of grease at infrequent intervals.
Lubrication recommendations are intended for standard products
applied in general operating conditions. |
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SUGGESTED LUBRICATION
INTERVALS |
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HOURS RUN PER
DAY |
251-500RPM |
501-750RPM |
751-1000RPM |
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8 |
12 WEEKS |
10 WEEKS |
7 WEEKS |
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16 |
7 WEEKS |
5 WEEKS |
4 WEEKS |
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24 |
5 WEEKS |
3 WEEKS |
2 WEEKS |
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TRAILER MAINTENANCE SCHEDULE |
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Trailer
Maintenance
Schedule |
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Item |
Function Required |
Weekly |
3 Months
or 3000 Miles |
6 Months
or 6000 Miles |
12 Months
or 12000 Miles |
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Brakes |
Test that they are operational |
At Every Use |
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Brake Adjustment |
Adjust to proper operating clearance |
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3 Months
or 3000 Miles |
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Brake Magnets |
Inspect for wear and current draw |
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6 Months
or 6000 Miles |
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Brake Linings |
Inspect for wear or contamination |
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12 Months
or 12000 Miles |
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Brake Controller |
Check for correct amperage and modulation |
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6 Months
or 6000 Miles |
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Brake Cylinders |
Check for leaks, sticking |
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12 Months
or 12000 Miles |
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Brake Lines |
Inspect for crakes, leaks, kinks |
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12 Months
or 12000 Miles |
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Trailer Brake Wiring |
Inspect, wiring for bare spots, fray, etc. |
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12 Months
or 12000 Miles |
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Breakaway System |
Check battery charge and switch operation |
At Every Use |
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Hub/Drum |
Inspect for abnormal wear or scoring |
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12 Months
or 12000 Miles |
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Wheel Bearings & Cups |
Inspect for corrosion or wear. Clean and repack. |
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12 Months
or 12000 Miles |
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Seals |
Inspect for leakage. Replace if removed. |
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12 Months
or 12000 Miles |
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Springs |
Inspect for wear, loss of arch. |
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12 Months
or 12000 Miles |
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Suspension Parts |
Inspect for bending, loose fasteners, wear. |
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6 Months
or 6000 Miles |
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Hangers |
Inspect Welds. |
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12 Months
or 12000 Miles |
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Wheel Nuts and Bolts |
Tighten to specified torque values. |
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3 Months
or 3000 Miles |
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Wheels |
Inspect for cracks, dents or distortion. |
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6 Months
or 6000 Miles |
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Tire Inflation Pressure |
Inflate tires to manufacturer's specifications. |
Weekly |
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TROUBLESHOOTING
This section is designed
to aid the electrical technician in basic Load Bank system troubleshooting.
All of the problems listed can be verified with a basic test
meter and/or continuity tester.
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Cooling fan motor will not operate
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1. |
Inoperative fan circuit breaker
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2. |
Fan/control power not available
and/or incorrect
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3. |
Inoperative fan motor
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4. |
Fan motor contactor de-energized
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5. |
Restriction of air (intake or exhaust)
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6. |
Fan pressure switch inoperative
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WARNING
When troubleshooting Load Bank systems remove all test source
power, fan/control power, anti-condensation heater power, etc. |
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Cooling failure indicated
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Exhaust temperature above EXTS setpoint:
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1. |
Over temperature sensor failure
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2. |
Fan failure
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3. |
Air restriction (intake or exhaust)
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4. |
Overvoltage condition present
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Exhaust temperature below EXTS setpoint:
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1. |
Restriction of air (intake or exhaust)
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2. |
Fan pressure switch inoperative
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4. |
Over temperature sensor failure
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Test meters do not operate properly
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1. |
Meter voltage switch failure
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2. |
Meter multiplier resistor inoperative
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3. |
Improper positioning of meter voltage
selector switch
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4. |
Current transformer or current
transformer wiring failure
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5. |
Test meter failure
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6. |
Meter fuses open
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Some load steps cannot be energized
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1. |
Inoperative load step switches
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2. |
Open load step resistor(s)
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3. |
Inoperative load step relays
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4. |
Inoperative load step contactors
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5. |
Open load step fuses
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CALCULATIONS, FORMULAS, TORQUE
VALUES, AND LIFT EYE INSTALLATION |
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Calculations
and Formulas |
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KW Applied
The calculations below are used to determine the actual kilowatt
load being applied by the Load Bank, when line voltages and currents
are known (at 1.0 power factor). |
Current
The calculations below are used to determine the amount of current
when the desired amount of kilowatts is applied at 1.0 power
factor.
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KW Rating
The calculations below are used to determine a step kilowatt
rating at other than a rated voltage. This is accomplished by
referencing the load step to a KW value at a known voltage.
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3 Phase
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1. |
Read all three line currents and
find the average reading.
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2. |
Read all three line-to-line voltages
and find the average reading.
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3. |
Multiply the average current times
the average voltage.
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4. |
Multiply the answer of step #3
times the square root of 3 (1.732).
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5. |
Divide the answer of step #4 by
1000. The answer is the actual kilowatts of load being applied
by the Load Bank.
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Single Phase
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1. |
Determine the line current.
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2. |
Determine the line-to-line voltage.
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3. |
Multiply the line current times
the line-to-line voltage.
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4. |
Divide the answer of step #3 by
1000.
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5. |
The answer of step #4 is the actual
kilowatts being applied by the Load Bank.
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3 Phase
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1. |
Multiply the desired amount of
kilowatts to be applied by 1000.
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2. |
Multiply the operating voltage
times the square root of 3 (1.732).
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3. |
Divide the answer of step #1 by
the answer of step #2.
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4. |
The answer of step #3 is the average
line current with the desired kilowatts applied at 1.0 power
factor.
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Single Phase
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1. |
Multiply the desired amount of
kilowatts to be applied by 1000.
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2. |
Divide the answer of step #1 by
the operating voltage.
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3. |
The answer of step #2 is the average
line current with the desired amount of kilowatts applied at
1.0 power factor.
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1. |
Determine the new unrated operating
voltage.
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2. |
Divide the new operating voltage
by the reference voltage.
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3. |
Square the answer of step #2.
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4. |
Multiply the answer of step #3
times the reference kilowatt value of the load step which the
new kilowatt rating is desired.
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5. |
The answer of step #4 is the kilowatt
rating of the load step at the new voltage.
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Examples of the above Calculations
and Formulas
with additional informational sheets for Torque Values and
Lift Eye Installation,
click here.
Back
to top of page. |
