PROJECT: LAFARGE LHOKNGA

IDEAL LOAD BANK

GRID RESISTOR ASSEMBLY PROCEDURE

AND TESTS(rev.1)

INTERNATIONAL ELECTRONICS, S.A.

13 / JANUARY / 2009

INTERNATIONAL ELECTRONICS, S.A.

C/ LOS PINTORES No. 3
28925 ALCORCÓN (MADRID) ESPAÑA
TEL: 00 34 91 6.41.22.11
FAX: 00 34 91 6.41.23.14
e-mail: ies_sa@teleline.es

Page 1 of 6
 IDEAL LOAD BANK
GRID RESISTOR ASSEMBLY PROCEDURE

1. MECHANICAL ASSEMBLY

The grid resistors are shipped in two sections.

• Section 1 includes the fan and the air inlet mounting frame. This
the bottom section.
• Section 2 includes the Grid Resistor and power connections. This
is the top section.

SECTION 2

(1)

SECTION 1

(2)
Fig. 1 – Complete Unit (one phase)

Assemble Section 2 on top of Section 1 and bolt them together with bolts
(1) as shown in Fig. 1. These bolts are at the front and back of the unit.
Check that bolts (2) between mounting frame and fan cubicle are tight.

Fix resistor to the ground with the appropriate bolts on the mounting
frame.

Page 2 of 6
 IDEAL LOAD BANK
GRID RESISTOR ASSEMBLY PROCEDURE

2. ELECTRICAL CONNECTIONS

Ground connections.
It is very important for safety reasons to connect all the resistor
sections to ground.

B POWER
CONNECTIONS

(3)

Fig. 2 – Ground connections for Grid Resistor Sections

Connect the three lugs (3) shown in Fig. 2 to ground with minimum
50mm2 bare copper cable.

Power connections
Each complete cubicle including resistor section fan section and
mounting frame make up a phase resistor to be connected in star,
together with two more complete cubicles, to make-up a three phase
resistor. See Fig. 3 and Fig. 2.

Page 3 of 6
 IDEAL LOAD BANK
GRID RESISTOR ASSEMBLY PROCEDURE

R S T
A A A

RESISTOR
CUBICLES

POWER
CONNECTIONS
SHOWN IN RED
B B B

NEUTRAL

Fig. 3 – Three Phase Grid Resistor

Connect phase R of feeder to terminal A of the first resistor.

Connect phase S of feeder to terminal A of the second resistor.
Connect phase T of feeder to terminal A of the third resistor.
Connect terminal B of first resistor to terminal B of second resistor.
Connect terminal B of second resistor to terminal B of third resistor.

Fan connections
Connect the three phase supply 400V / 3ph / 50Hz to the fan terminals
shown on Fig. 4 and Fig. 5.
These connections must be done via circuit breakers. The motor rated
current of each fan is 15A and the starting current is approximately 6.5
times rated current.

TERMINAL
BOARD FOR FAN
CONNECTION

Fig. 4 – Location of Terminal board for the fan.

Page 4 of 6
 IDEAL LOAD BANK
GRID RESISTOR ASSEMBLY PROCEDURE

Fig. 5 – Detail of Terminal Board for Fan

Control connections
The motor protection circuit breaker must be equipped with auxiliary
contacts wired in series and connected to the emergency stop circuit of
the 10.5 kV Feeder breaker. The resistor fans must be always running
when the resistors are connected to the 10.5 kV supply, failure to do this
will result in catastrophic failure of the resistor. Note that all these
protections are required only for testing. In operation with the ILB all
these protections are already included.

Possible configurations
Drawings E681.012 and E681.013 are included to show the minimum
requirements to carry out load tests on the power plant. The best
possible configuration is one circuit breaker per 3 phase resistor. This
allows testing with small load steps and high load steps. The
recommended configuration is using two 3 phase resistors per circuit
breaker as shown in E681.013. If this is not possible, initial tests can be
carried out with two 3 phase resistors per breaker and then with four per
breaker as shown in E681.012.

3. TEST TO BE CARRIED OUT BEFORE OPERATION

The following tests must be carried out prior to operation:

a. Measure resistance value between Phases R-S = 92 Ohms.

b. Measure resistance value between Phases S-T = 92 Ohms.
c. Measure resistance value between Phases T-R = 92 Ohms.
d. Megger all the power connections.
e. Check the direction of air flow in the resistor. Air must come in
through the bottom and out through the top.

Page 5 of 6
 IDEAL LOAD BANK
GRID RESISTOR ASSEMBLY PROCEDURE

f. With the 10.5 kV Breaker racked out and in the test position, close
the breaker then simulate a trip of the fan protection circuit
breakers. Check that the 10.5kV breaker opens.

Page 6 of 6