C6416

Loadbank Operating
Instructions
Crestchic Ltd.
2nd Avenue
Centrum 100
Burton upon Trent
Staffordshire
United Kingdom
DE14 2WF

Tel. +44 (0) 1283 531645

Fax. +44 (0) 1283 510103

www.crestchicloadbanks.com
sales@crestchic.co.uk
hires@crestchic.co.uk
service@crestchic.co.uk
warranty@crestchic.co.uk
Reproduction of this document, in part or whole, by any means, electrical, mechanical, optical, chemical,
manual or otherwise is prohibited without written permission from Crestchic Limited.

The information contained herein is believed to be accurate as of the date of publication, however, Crestchic
Limited will not be liable for any damages, including indirect or consequential, arising from use of the
hardware or software described within or reliance upon the accuracy of this documentation. The information
contained herein is subject to change without notice.

Revision: 1
Date: 23rd December 2020
 1000kW RESISTIVE LOADBANK

CONTENTS

1. GENERAL LOADBANK INFORMATION

2. SAFETY
3. DESCRIPTION OF A LOADBANK
4. INSTALLATION / OPERATION OF LOADBANK
5. MAINTENANCE
6. TROUBLESHOOTING
7. CONTACTS
8. TERMINOLOGY / CALCULATIONS
9. PARTS LISTS
10. DRAWINGS – GENERAL ARRANGEMENT
11. DRAWINGS – WIRING DIAGRAMS
12. PARTS LISTS/DRAWIGS – SUB-ASSEMBLIES
13. ABB M2M INSTRUMENTATION
14. TEST CERTIFICATE AND RESULTS
15. EC DECLARATION OF CONFORMITY
16. END OF LIFE PRODUCT RECYCLING AND
DISPOSAL

Loadbank Serial No: C6416 Page 2

1. GENERAL LOADBANK INFORMATION

Customer Hawthorne Power Systems

Loadbank Serial No. C6416

Equipment 1000kW Loadbank

Transportable with Fork Base

Test Supply 480V, 60Hz, 3-Phase, 3/4-Wire

Voltage Tolerance +/- 5% for short duration

(+5% Max. 10 minutes not continuous)
Frequency Tolerance +/- 5%
kW Tolerance +/- 2.5%

Step Resolution 1kW @ 480V

Auxiliary Supply 480V, 60Hz, 3-Phase, 3/4-Wire

Control System KCS - Extendable

Controller KCS100H-M

Loadbank Software C6416

PC Software N/A

Dimensions (- Frame) 2186 x 1290 x 1990mm (l, w, h) / 85” x 50” x 67”

(+Frame) 2150 x 1260 x 1690mm (l, w, h) / 86” x 51” x 79”

Gross Weight 1150kg / 2540 lbs

Paint Specification RAL7046 – Telegrey 2

Loadbank Serial No: C6416 Page 3

2. SAFETY
General Safety

1. Injury to the person operating or servicing this equipment is able to occur if any of
these SAFETY and/or WARNING statements are ignored.

2. The user must be fully conversant with this manual and in full understanding of it
before operating the loadbank.

3. Personal injury from electrical shock may occur if the power is not isolated before
any maintenance measures are undertaken.

4. The loadbank must be operated only by personnel adequately experienced in the

operation of the power source(s) being connected to it.

5. The loadbank must only be operated with all of its covers in their correct positions
and secured.

6. Ear defenders are recommended if operator is working constantly in the vicinity of

the loadbank.

Installation
7. For safety purposes upon receiving the loadbank an initial inspection is
recommended. In addition to this periodical preventative maintenance and safety
inspections are required to ensure the continued safe and reliable operation of the
unit.

8. The loadbank must be properly sited, stable and located in a well ventilated area.

9. Connect a ground (Earth) wire from the Loadbank Earth Stud Terminal to the power
supply under test. Size the Earth cable accordingly. The loadbank must not be
operated without an adequate Earth connection.

10. A minimum clearance of 1m / 40” (2m / 80” recommended) must be allowed from
the inlet grille.

11. A minimum clearance of 5m / 197” (7m / 275” recommended) is required from the
outlet grille. It is recommended that the operator cordon off this area prior to
operation of the unit, to prevent accidental contact with the exhaust grilles and the
hot exhaust gas whilst the loadbank is operating.

Warning The loadbank produces a hot exhaust gas approximately 180ºC

(356ºF) above ambient temperature at a distance of 1m from the
outlet grilles.

Loadbank Serial No: C6416 Page 4

13. Do not position the loadbank where hot exhaust air is able to re-circulate back
through the inlet grille, as this will cause the unit to overheat.

14. All safety devices within the loadbank have been proven reliable as part of the test
procedure.

15. Ensure that the load cables are of good condition and suitably rated for the current
they will be required to carry from the power source to the loadbank.

16. Route the load cables through the canvas pouch aperture to the connection
chamber and securely connect them to the correct loadbank terminals – Cam-Loks.
Do not route the cables through the connection chamber door, or leave the door
open during test.

17. Observe the correct 3-Phase & Neutral sequence (if Neutral is used) when
connecting the loadbank to the power source. Connecting a Phase to the Neutral
will damage the loadbank.

18. Do not operate the Loadbank over the rated voltage or frequency as this may cause
failure of the loadbank.

19. Under no circumstances are the Over-Temperature Switches to be bypassed. If the

loadbank is operated with a temperature switch bypassed the elements will be liable
to overheat if any fault condition occurs. In severe cases this will result in the unit
catching fire.

20. Air-flow switches are fitted to the fan(s) to detect the fan(s) are running. If an air-flow
switch as not activated upon start up, or should open during operation the load will
be dropped after a 10 second delay to prevent overheating.

21. Circuit Breakers and/or Fuses are fitted in the loadbank for short circuit and over
current protection.

22. Ensure that all covers, inlet/outlet grilles are fixed and all doors are closed before
applying power to the loadbank.

23. At the end of a test the load must be set to zero and the loadbank fan(s) left running
for a minimum of 5 minutes to cool the resistive elements.

24. Avoid contact with the outlet grille during test and a period of time afterwards as this
becomes very hot during operation and may result in serious burns.

25. Do not permit objects to enter or block the air inlet/outlet grilles of the Loadbank. A
blockage will cause the Loadbank to overheat. If an object enters the loadbank it will
cause damage to the fan(s) and/or resistor elements. If objects enter the loadbank
grilles then the unit must be switched off, removed from all sources of electrical
supply and then inspected physically and electrically to ensure no damage has
occurred.

Loadbank Serial No: C6416 Page 5

3. DESCRIPTION OF A LOADBANK
The loadbank is an outdoor, transportable resistive unit for electrically load testing 480V
A.C. 60Hz 3-Phase power supplies with voltage tolerance of 5%.

The function of the loadbank is the dissipation of electrical energy which is transformed
into heat by the resistive elements. This unit will produce 1000kW of real power
dissipation at 480V full load.

The heat is removed from the loadbank by the fan(s) passing air over the resistive
elements. It is essential the inlet and outlet grilles are free from any obstruction otherwise
the loadbank will overheat.

Circuit Breakers and/or Fuses are fitted inside the loadbank for short circuit and over
current protection.

Do not operate the Loadbank over the rated voltage or frequency as this may cause
failure to the loadbank

Thermal switches are located within the control chamber of the loadbank to protect the
equipment from any overheating that may occur.

External Auxiliary Supply input 380/480V 50/60Hz. If this supply is connected select
‘External’ using the ‘Control Supply’ switch and also select the voltage range on the
‘Control Voltage’ switch of the connected supply. This will supply the cooling fans and the
control of the loadbank. A 32A 3-phase supply is required.

If no External Auxiliary Supply is connected, the ‘Control Supply’ switch must be in the
‘Internal’ position. If the control of the loadbank is derived from the test supply, should the
voltage fall below 340V while under load the cooling fan(s) will stop, resulting in the load
being dropped.

Note: It is recommended that the auxiliary supply is utilised when the voltage is
not at the nominal 480V 60Hz

Loadbank Serial No: C6416 Page 6

4. INSTALLATION / OPERATION OF LOADBANK
Installation

Upon receiving the loadbank an initial inspection is recommended. In addition to this

periodical preventative maintenance and safety inspections are required to ensure the
continued safe and reliable operation of the unit.

The loadbank must be properly sited, stable and located in a well ventilated area.

A minimum clearance of 1m / 40” (2m / 80” recommended) must be allowed from the
inlet grille. Ensure that no loose material is in the vicinity of the inlet grille (e.g. Paper).

A minimum clearance of 5m / 197” (7m / 275” recommended) is required from the outlet
grille. It is recommended that the operator cordon off this area before operation of the
unit.

Warning The loadbank produces a hot exhaust gas approximately 180ºC

(356ºF) above ambient temperature at a distance of 1m from the outlet
grilles.

Do not position the loadbank where hot exhaust air is able to re-circulate back through
the inlet grille, as this will cause the unit to overheat.

When installing two or more loadbanks ensure they are sufficiently spaced from each
other, so the hot exhaust from one unit does not feed the air intake of another.

Failure to observe the above may result in overheating and subsequent activation of the
over temperature protection.

Connect a ground (Earth) wire from the Loadbank Earth Stud Terminal to the power
supply under test. Size the Earth cable accordingly. The loadbank must not be operated
without an adequate Earth connection.

Ensure that the load cables are of good condition and suitably rated for the current they
will be required to carry from the power source to the loadbank.

Route the load cables through the canvas pouch aperture to the connection chamber and
securely connect them to the correct loadbank terminals – Cam-Loks. Do not route the
cables through the connection chamber door or leave the door open during test.

If using slave units, connect the loadbank load cables in parallel with the master unit.

Connect the ‘External’ auxiliary supply if one is to be used. A 32A 3-phase supply is
required. This is the most suitable option to maintain the control / fan(s) supply if the test
supply should fail.

Loadbank Serial No: C6416 Page 7

If using slave units, connect an auxiliary supply to each unit.

Do not leave the connection chamber door open during operation of the loadbank or test
supply.

All safety devices within the loadbank have been proven reliable as part of the test
procedure.

Under no circumstances is the Over Temperature Switch to be bypassed. If the loadbank

is operated with the temperature switch bypassed the elements will be liable to overheat
if any fault condition occurs. In severe cases this will result in fire.

Circuit Breakers and/or Fuses are fitted in the loadbank for short circuit and over current
protection.

Ensure that all covers, inlet/outlet grilles are fixed and all doors are closed before applying
power to the loadbank.

Loadbank Serial No: C6416 Page 8

Operation
1. Select ‘Internal’ or ‘External’ auxiliary supply as required on the control facia.
(Internal – control supply taken from the test supply / External – control supply taken
from the separate auxiliary supply). Also there is a ‘Control Supply’ selector switch
which must be configured to the appropriate supply that is being fed either Internal
or External for the control circuitry.

Eg.1 For 480V test supply – no auxiliary, select the following:-

Internal
440-480V – Control Supply

Eg.2 For 208V test supply – 480V auxiliary supply, select the following:-
External
440V-480V – Control Supply

2. Connect the controller unit to the control-input socket mounted on the load module
facia of the master unit, this is marked ‘Control I/P’. In some cases this may be via
an extension reel. Ensure that the cables are in good condition. A damaged cable
or plug may lead to failure of the loadbank.

3. If slave units are to be used, connect their control cables in cascade i.e. from the
‘Control O/P’ socket on the master unit to the ‘Control I/P’ socket on the first slave
unit and so on until all slave units are connected.

4. If the unit is to be used ‘Stand Alone’, the ‘Control O/P’ socket is not used.

5. Check that the decade switches on the remote controller are all set to zero.

6. Ensure that all covers are fixed and all doors are closed.

7. This equipment has been fitted with an ‘Emergency Stop’, if pressed this will shed
all load and stop the movement of the fan(s). Ensure that the fault / hazard as been
cleared before resetting the Emergency Stop.

Warning: - The Emergency Stop does not isolate the Test or Auxiliary
Supplies; this must be done at source.

8. The equipment is now ready for use.

9. Switch on the Auxiliary Supply if one is to be used.

10. Switch on the test supply.

11. Press the start button to start the cooling fan(s)

Loadbank Serial No: C6416 Page 9

12. The load module is fitted with automatic correction of phase rotation on the fan
supplies. Once the fan(s) have started check that the airflow is normal and in the
direction from the fan(s) and across the elements

13. Select the kW required on the indexing switches and press the ‘Enter’ button to
apply the load. The next load step may be selected but will not be applied until the
‘Enter’ button is pressed again.

Warning: - This equipment will produce a hot exhaust. (Approx. 180°C /

356°F above ambient at 1m from the outlet grille).

14. The load may be removed at any time by pressing the ‘Clear’ button.

15. Avoid contact with the outlet grille during test and a period of time afterwards as this
becomes very hot during operation and may result in serious burns. It is
recommended that the loadbank operator to cordon off the area for a minimum of
5m (7m recommended) to prevent accidental contact with the exhaust grilles and
the hot exhaust gas whilst the loadbank is operating.

16. Do not permit objects to enter or block the air inlet/outlet grilles of the Loadbank. A
blockage will cause the Loadbank to overheat. If an object enters the loadbank it will
cause damage to the fan(s) and/or resistor elements. If objects enter the loadbank
grilles then the unit must be switched off, removed from all sources of electrical
supply, allowed to cool fully, and then inspected both physically and electrically to
ensure no damage has occurred.

17. If a cooling fault condition occurs, by loss of the airflow due to the inlet grilles being
blocked or fan failure, which is detected by airflow switches AF1 – AF2, or if the
temperature sensors inside the load module exceed 90°C (194°F) the load will
automatically lock out. If the fault can be cleared without removing the supply from
the loadbank then to re-initialise the operating system press the ‘Reset’ button,
otherwise isolate Test / Auxiliary supplies to clear the fault.

18. At the end of a test the load must be set to zero and the loadbank fan(s) left running
for a minimum of 5 minutes to cool the resistive elements. At that point the Stop
button can be actuated.

19. The number of starts per hour of the fan(s) should be limited to ten to avoid
overheating.

Loadbank Serial No: C6416 Page 10

5. MAINTENANCE
Crestchic Load Banks are virtually ‘maintenance free’ however we do recommend that
the units are checked once a year for tightness of all electrical and mechanical
connections, and also the load contactors should be checked for wear.

General maintenance must be carried out with the test and auxiliary power isolated from
the loadbank.

Maintenance work should only be done by qualified personnel, fully aware of the danger
involved.

WARNING: - PERSONAL INJURY FROM ELECTRICAL SHOCK MAY RESULT IF THE

POWER IS NOT ISOLATED BEFORE SERVICING. MAINTENANCE
WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNEL.

The resistive elements are long life maintenance free items, if an element was to “blow”
or become damaged for any reason, obviously this would affect the loading of the
electrical supply under test. The element cannot be repaired and a replacement element
would have to be installed, this can be obtained from Crestchic Ltd. (please specify kW
rating and voltage engraved on the element).

Fan units are fitted with ‘sealed for life’ bearings lubricated with wide temperature range
grease and require no maintenance.

All panel/door seals must be inspected every 6-months to ensure they make a good seal
to prevent water or any foreign matter entering the enclosure.

Door hinges and fasteners must be lubricated every 6-months, and also castor mounted
units should have the castors lubricated.

Replacing Elements

Disconnect the cables or coppers connected to the faulty element termination points. The
elements are fitted with two glands at the termination ends which securely hold the
element in position, some Load Banks are fitted with element support hooks and others
fitted with `toast racks' to support the other end. Remove the nuts on the glands to free
the element. Remove one of the grilles in the element chamber (the nearest to the
element) and slide the element out.

Loadbank Serial No: C6416 Page 11

 Insulation Resistance

With regard to insulation readings of the loadbank, the minimum recommended constant
safe level to use is 1Meg.
When taking insulation readings, should any instrumentation/transducers be included
with the loadbank (INS370 or VIP) then these should be isolated before an IR test, as
damage may be caused to the instruments.
Ensure the equipment to be tested and the work area is safe (the equipment is de-
energised and disconnected).
Crestchic Loadbanks are an outdoor piece of equipment and therefore depending on the
time of year and/or climatic conditions with regard to moisture over the exposed parts of
the loadbank, the insulation reading may be measured below the minimum
recommended.
The loadbank should be thoroughly inspected before use, checking resistance levels are
in the region of those stated on the electrical drawing. If resistance values are not in the
region of the stated values, then further investigation will be required to ascertain potential
failed elements.
If resistance values are satisfactory, then it is possible to use the loadbank on load for a
period of time to remove any moisture and apply heat to the equipment. It is then advised
before any further usage, the insulation reading is again checked to ensure the level is
above the recommended minimum acceptable value of 1Meg.
Should the level not be above the recommended minimum value after the period of
operation, then there is the possibility of an element that is leaking to earth and each
element bank will be required to be individually inspected to identify the section and then
removing the copper to identify the specific element.
Note:- The element insulation could potentially degrade over a period time, depending
on usage or extreme climatic conditions.

Loadbank Serial No: C6416 Page 12

Torque Settings

To ensure correct tightness of all electrical POWER connections, the following table of
torque settings must be used.

Steel Fixings Brass Fixings

Location Connections Torque Torque Torque Torque
(N.m) (lbf.in) (N.m) (lbf.in)
M6 Copper 7.2 63.7
M8 Copper 17 150.5
Busbars M10 Copper 28 247.8
M12 Copper 45 398.3 33 292.1
M16 Copper 91 805.4 74 654.9
4BA Elements 1.2 10.6
Elements
2BA Elements 1.75 15.5
Bolt-on fuses 17 150.5
32A Fuse Holder 2 17.7
Fuses 63A Fuse Holder 3 26.6
100A Fuse Holder 3.5 31.0
125A Fuse Holder 4 35.4
Contactor 10231-10261 2.0-2.5 18.0-22.0
Contactor 10341-10361 3.0-4.5 27.0-40.0
Siemens Contactor 10441-10461 4.0-6.0 36.0-53.0
Contactors Contactor 10541-10566 10.0-14.0 90.0-124.0
Contactor 10646-10666 14.0-24.0 124.0-210.0
Contactor 10756-10766 14.0-24.0 124.0-210.0
Contactor D12 1.2 10.6
Contactor D18 1.7 15.0
Contactor D25 1.85 16.4
Contactor D32 2.5 22.1
Contactor D40 5 44.3
Contactor D50 5 44.3
Telemecanique Contactor D65 5 44.3
Contactors Contactor D80 9 79.7
Contactor D95 9 79.7
Contactor D115 14 123.9
Contactor F150 14 123.9
Contactor F185 17 150.5
Contactor F225 to F500 35 309.9

Table 1 – Torque Settings

Loadbank Serial No: C6416 Page 13

ROUTINE CHECKLIST

The below checklist is recommended to be carried out at least once a year or after
prolonged usage to assist in the safe / reliable running of the loadbank.
Any areas of concern must be acted upon, or risk failure or damage to the loadbank.

Mechanical Checks Electrical Checks

Check elements for rusting Measure and record element resistance
and compare with loadbank drawings
Check element clamps for loose Measure and record the insulation
connections resistance between neutral and earth.
Check element coppers for loose Make Live the control circuit and start the
connections fans (Check direction)
Check contactors for loose connections Enable each contactor step

Check crimps and cables for signs of Test the Extend facility if applicable
heating
Check terminals for tightness and wear to Check Emergency Stop
terminal pins
Check Earth Stud Check the Fan Overloads

Check control sockets for bent pins, Check heat sensors

corrosion etc
Check door fasteners Check Air-Flow paddle function

Check and replace rubber seal if required Check Running indication

Check castors if applicable Check Cooling Fault indication

Ensure enclosure is free from rubbish Check Reset Button if applicable

Check fan fixings for loose connections Check Phase Rotation Sensor(s)

Check the continuity and correct value Load Test and check for Balance
fuses are fitted Record (if possible)
Check positioning of reactor sensors in the
outer winding and rubber sleeve fitted
Check the reactor fan filters for blockages

Table 2 – Routine Checklist

Loadbank Serial No: C6416 Page 14

6. TROUBLESHOOTING
Maintenance should be carried out with the main power isolated from the loadbank, and
only done by qualified service engineers/technicians. Auxiliary power supply may be
required to carry out necessary checks. Ensure wiring diagrams are available to assist
with fault finding.

Problem - Loadbank control supply not on

Check Control circuit breaker(s) not closed

Action Check and close circuit breaker(s) – Repeated tripping of the circuit breaker
must be investigated

Check Int-Off-Ext switch is set to the Off or incorrect position

Action Set the switch to the Int or Ext position as required

Check Control Voltage switch is selected to the corresponding Voltage range

deriving the control supply.
Action Set the switch to the correct position as required

Check Emergency Stop actuated

Action Release the emergency stop (pull)

Problem - Fan(s) not running/Fan contactor(s) not energised

Check Fan motor overload tripped

Action Reset fan motor overload. Repeated tripping must be investigated further

Check Check for Relay/Timer failure

Action Check and replace as required

Check Fan(s) failure

Action Check and replace if necessary

Check PSR Supply problem – refer to Table 4 below

Action Refer to Table 4

Check Loose connection(s)

Action Check and tighten as necessary

Loadbank Serial No: C6416 Page 15

Problem – No load applied

Check Load circuit breaker(s) not closed

Action Close circuit breaker(s). Repeated tripping of the circuit breaker must be
investigated

Check Loadbank Over Temperature sensor activated

Action Check loadbank cooling/airflow for any obstructions

Check Air-flow paddle not energised

Action Check air-flow paddle switch(s) operation and/or air-flow

Check Loose connection(s)

Action Check and tighten as necessary

Problem - Load step not energised

Check Fuse(s) blown / Circuit breaker(s) not closed

Action Check and replace fuse(s) / Close circuit breaker. Repeated fuse blowing
or breaker tripping must be investigated further

Check Contactor(s) failure

Action Check and replace if required

Check Driver board relay failure

Action Check and replace as required

Check Loose connection(s)

Action Check and tighten as necessary

Problem - Load step not providing the rated load

Check Applied voltage is de-rated

Action Check and correct if necessary

Check Fuse(s) blown

Action Check and replace. Repeated fuse blowing must be investigated further

Check Contactor not fully energised

Action Check and replace contactor if necessary

Check Load step resistor element(s) are open-circuit.

Action Check and replace as required – check wiring diagram for approximate
resistance values for each associated step.

Loadbank Serial No: C6416 Page 16

Problem - Contactor “chattering”

Check Control circuit voltage too low

Action Check control voltage and auxiliary supply and/or test supply

Check Contacts/core dirty or corroded

Action Check and replace contactor if necessary

Check Connection to the contactor coil loose

Action Check and tighten as necessary

Problem – No communication response

Check Check all control leads

Action Check connection security/lead integrity. If using an extension reel try
plugging the controller directly into the loadbank

Check Check all ribbon cable connections

Action Check connection security/lead integrity

Check Check Systems Board (Fuse/Transformer)

Action Check and replace as required

Table 3 – Troubleshooting

Loadbank Serial No: C6416 Page 17

Supply PSR PSF Action
Condition Green Red Green Red
LED LED LED LED
Normal On Off On Flashing No action required
On Flashing On Off
Under Voltage On On On On Correct supply voltage,
Condition or use auxiliary supply or
phase missing increase cable sizes
PSR Failure Off Off On Off Check and replace PSR
PSF Failure On Off Off Off Check and replace PSF
No Supply Off Off Off Off Check supply at CB13

Table 4 – Phase Failure Relay/Supply Problems

Loadbank Serial No: C6416 Page 18

7. CONTACTS
Crestchic provides rentals and sales of loadbanks, power cables, transformers and
switchgear. With numerous applications and the capability to develop tailor made
testing solutions that fulfil your requirements.

For spare/replacement parts see parts list enclosed and quote the stock reference
number. (service@crestchic.co.uk)

Crestchic Head Office: Crestchic (Middle East):

Crestchic Limited Crestchic (Middle East) FZE

2nd Avenue PO Box 262519
Centrum 100 1 Jebel Ali
Burton upon Trent Dubai
Staffordshire
United Kingdom
DE14 2WF

Tel. +44 (0) 1283 531645 Tel. +97 1488 18655

Fax. +44 (0) 1283 510103 Fax. +97 1488 18573

www.crestchic.co.uk www.crestchic.com
sales@crestchic.co.uk info-me@crestchic.com

Crestchic Germany: USA:

Crestchic Loadbanks Ltd. Crestchic INC USA

ZNL Deutschland 235 Sweet Spring Road
Im Kleinen Loh 25 Glenmore
D-34376 Immenhausen PA 19343
Germany USA

Tel. +49 5673 995 6880 Tel. +1 (610) 458 8182

Fax. +49 5673 995 6882 Fax. +1 (610) 458 8186

www.crestchic.de www.crestchic-usa.com
lager@crestchic.de www.Sales-USA@crestchic.com

Loadbank Serial No: C6416 Page 19

Crestchic Asia: Crestchic France:

Crestchic (Asia-Pacific) Pte Ltd. Crestchic France

No. 5 Tuas Avenue 13 15 Avenue Condorcet
Singapore 91240
638977 Saint-Michel Surorge
France

Tel. +65 6862 5608 Tel. +33 016 925 9434

Fax. +65 6862 5082 Fax. +33 017 044 5333

www.crestchic.com www.crestchic.fr
info@crestchic-ap.com contact@crestchic.fr

Loadbank Serial No: C6416 Page 20

8. TERMINOLOGY / CALCULATIONS
Apparent Power MVA / kVA / VA
Real/Actual Power MW / kW / W
Reactive Power MVAr / kVAr / VAr
Power Factor p.f. = cosφ
Unity Power Factor kW = kVA

Power Relationship

Ohm’s Law I = V / R (A) V = I x R (V) R = V / I (Ω)

Loadbank Capacity at other voltages:-

Rated Power Capacity of loadbank x (Applied Voltage / Design Voltage)² = Actual

Power

e.g. 3600 x (440 / 450)² = 3441kW

Power Calculations:-

e.g. 2.0MVA @ 0.9p.f. 450V

Real Power = kVA x pf = kW 2000 x 0.9 = 1800kW

Reactive Power = √ ((kVA²)-(kW²)) = kVAr √ ((2000²)-(1800²)) = 872kVAr

Apparent Power = √ ((kW²)+(kVAr²)) = kVA √ ((1800²)+(872²)) = 2000kVA

Real Power = √ ((kVA²)-(kVAr²)) = kW √ ((2000²)-(872²)) = 1800kW

3Ø Current = kW / (√3 x V) 1800 / (1.732 x 450) = 2309A (kW)

3Ø Current = kW / (√3 x V x pf) 1800 / (1.732 x 450 x 0.9) = 2566A (kVA)

3Ø Current = √ ((A-kW²)+(A-kVAr²)) = A √ ((2309²)+(1118²)) = 2566A

kVA = √3 x V x I 1.732 x 450 x 2566 = 2000kVA

Loadbank Serial No: C6416 Page 21

Temperature Calculation:-

°C = °F – 32 / 1.8 °F = (1.8 x °C) + 32

Metric Conversions:-

1 inch = 25.4 mm (2.54 cm) 1 cm = 0.3937 inch

1 lb = 0.4536 kg 1 kg = 2.2046 lbs

Loadbank Serial No: C6416 Page 22

9. PARTS LIST

Loadbank Serial No: C6416

 PARTS LIST 1000kW KCS100H C6416

Crestchic Limited Co Reg No: 1772456

Second Avenue, Centrum 100, VAT No: GB880985177
Burton-on-Trent DE14 2WF. U.K sales@crestchic.co.uk
Tel +44 (0) 1283 531645 hires@crestchic.co.uk
Fax +44 (0) 1283 510103 service@crestchic.co.uk
MODEL 1000kW CONTRACT No. C6416
RATING 1000kW ISSUED 1
TEST SUPPLY 480V, 60Hz, 3-Phase, 4-Wire DATED 25/03/2020
CONTROL SYSTEM KCS100HM - Extendable SIGNED GC
ENCLOSURE TYPE Transportable - Fork-Lift Base No. of SHEETS 3
ITEM CIRCUIT REF STOCK No. Unit DESCRIPTION MANUFACTURERS REF ORDER No.
1 CL21217 REF GENERAL ARRANGEMENT
2 CL21218 REF WIRING DIAGRAM
3
4
5 CL15590M ENC656 1 ENCLOSURE 1000kW TRANSPORTABLE HORIZONTAL BL CL15590M p-req
6 SBF004 1 1000kW TRANSPORTABLE HORIZONTAL BLOW LIFTING FCL10202 p-req
7
8 PLT529 1 ELEMENT PLATE (FERROGLASS) - 1000kW TRANS HORI CL10046, Sheet 1. p-req
9 PLT529R 5 ELEMENT RAILS (STAINLESS STEEL) - 1000kW TRANS HOCL10046, Sheet 2. p-req
10
11 COV243 1 CABLE ENTRY, CANVAS POUCH, 1000kW TRANSPORTABCL15786 p-req
12
13
14
15 CT1 - CT3 INS260 3 CT 1500/5A 50/60Hz 10VA Class 0.5 (CTV127M) CTV127M1500/5-10/0.5 p-req
16
17
18 FAC119 1 Fascia - KCS IO, POWER METER, START/STOP CL21219 Sht 1 Issue 1
19
20
21
22 FAN0 - FAN1 FAN330 2 FAN 71JM S/C 380/480V 50/60Hz 3PH 1420RPM 4.8kW / 5.771JM/25/4/6/30 (F2249B)
23
24 INST INS421 1 AC MULTIFUNCTION METER (40-500Hz - 500/866V) ABB M2M 2CSG296992R4052
25 ENC809 1 INSPECTION WINDOW 96x96mm (VIP396) FEC 478-052 / OMRONY92A-96N
26
27 E-STOP SWT169 1 GUARD FOR EMERGENCY STOP ZBZ-1604
28 E-STOP SWT159 1 MUSHROOM HEAD PULL PUSH ZB4-BT84
29 E-STOP, STOP, R SWT138 3 PUSH BUTTON BODY ASSEMBLY 1 N/C ZB4-BZ102
30 RESET SWT158 1 OPERATING HEAD FLUSH BLACK ZB4-BA2
31 START/L3 SWT168 1 ILLUM PUSH BUTTON GREEN (FLUSH) 230V 50/60Hz NO/NXB4-BW33M5
32 STOP SWT157 1 OPERATING HEAD FLUSH RED ZB4-BA4
33
34
35 ELE345ZUL 177 ELEMENT 5555W 277V - (UL Recognised) 1TAK8EN96002
36 ELE265ZUL 3 ELEMENT 3333W 277V - (UL Recognised) 1TAK8FA82004
37 ELE197ZUL 3 ELEMENT 1333W 277V - (UL Recognised) 1TAK8EZ67005
38 ELE167ZUL 3 ELEMENT 1000W 277V - (UL Recognised) 1TAK8EZ67006
39 ELE137ZUL 3 ELEMENT 666W 277V - (UL Recognised) 1TAK8EZ67003
40 ELE107ZUL 3 ELEMENT 333W 277V - (UL Recognised) 1TAK8EZ67002
41
42
43 PCB381 1 PCB KCS LOAD MODULE COMPLETE CL7214 PL1165
44 PCB383 1 PCB KCS EXTEND COMPLETE CL7215 PL1270
45
46
47 ASS148 1 CONTROLLER TYPE KCS100H 4-DECADE MIL PL1222
48 ASS149 1 CONTROL EXTEND LEAD KCS100H (Straight-90 Deg) 10 M PL1224
49
50
51

FORM:CF012.ISS:09: AUTH S.P.P Page 1 ISSUE DATE 21/07/16

 PARTS LIST 1000kW KCS100H C6416

ITEM CIRCUIT REF STOCK No. Unit DESCRIPTION MANUFACTURERS REF ORDER No.
52 BROUGHT FORWARD
53
54 FC0-FC1 CON872 2 CONTACTOR S0 35A 3 POLE (7.5kW) 230V 50/60Hz 3RT20251AL20
55 C0 - C5 CON870 6 CONTACTOR S0 35A 3 POLE (4kW) 230V 50/60Hz 3RT20231AL20
56 C6, C7 CON904 2 CONTACTOR S2 55A 3 POLE 230V 50/60Hz 3RT2035-1AL20
57 C8 CON990 1 CONTACTOR S3 110A 3 POLE 230V 50/60Hz 3RT2047-1AL20
58 C9 - C13 CON902 5 CONTACTOR S6 AC1 250A 3 POLE 230V 50/60Hz No Aux 3RT14566AP36
59
60 SCF/R, AC/MC CON924N1 2 *C/O CONT. S0 3 POLE, AC-3 18kW 38A 400V, 230V 50/60H3RA2328-8XB30-1AL2
61
62 RL0, RLT CON860 2 CONTACTOR RELAY 10A 230V 50/60Hz - 3 NO 1 NC 3RH2131-1AP00
63 RL0, RLT CON861 2 SURGE SUPPRESSOR - 127-240V 3RT2916-1CD00
64 SCF/R, AC/MC
65 C0 - C5, FC0-1 CON953 12 SUPPRESSOR CAPACITOR SIZE 202 - 127-240V 3RT2926-1BD00
66 C6 - C8 CON967 3 SUPPRESSOR CAPACITOR FOR SIZE S2 S3 CONTACTOR3RT2936-1CD00
67 C9 - C13 CON952 5 SUPPRESSOR CAPACITOR SIZE 105-107 - 127-240V 3RT1956-1CD00
68
69 C0 - C4 BUS101 1 3PH BUSBAR INFEED TERMINAL CONNECTION FROM AB 3RV2925-5AB
70 C0 - C4 BUS105 1 3PH BUSBAR FOR 5 S0 CONTACTORS (63A/690V) 3RV1915-1DB
71
72 FC0T CON970 1 TIME DELAY 0.5 - 100 SECONDS 3RA2813-1AW10
73
74 OL0 - OL1 OLR142 2 OVERLOAD RELAY 9.0-12.5A 3RU2126-1KB0
75
76 F1 - F6 FUH542 2 CLASS T 3 POLE FUSE BLOCK 60A 60608T
77 F1 - F6 FUH559 6 CLASS T FUSE LINK 50A 600V - UL/CSA A6T50
78 F7 - F9 FUH543 1 CLASS T 3 POLE FUSE BLOCK 100A 61033T
79 F7 - F9 FUH562 3 CLASS T FUSE LINK 100A 600V - UL/CSA A6T100
80 F10 - F24 FUH568 15 CLASS T FUSE LINK 250A 600V - UL/CSA A6T250
81
82 CB1 CCT441 1 MCB 3 POLE 32 AMP TYPE C - UL 5SJ4 332-7HG42
83 CB2 CCT440 1 MCB 3 POLE 25 AMP TYPE C - UL 5SJ4 325-7HG42
84
85 CB10, CB11 CCT437 2 MCB 3 POLE 32 AMP TYPE D - UL 5SJ4 332-8HG42
86 CB15, 16 CCT413 2 MCB 2 POLE 10 AMP TYPE D - UL 5SJ4 210-8HG42
87 CB17 CCT412 1 MCB 2 POLE 6 AMP TYPE D - UL 5SJ4 206-8HG42
88 CB12, CB13 CCT438 2 MCB 3 POLE 2 AMP TYPE C - UL 5SJ4 302-7HG42
89 CB18 CCT400 1 MCB 1 POLE 1 AMP TYPE C - UL 5SJ4 101-7HG42
90 CB14 CCT420 1 MCB 2 POLE 2 AMP TYPE C - UL 5SJ4 202-7HG42
91 CB19 CCT401 1 MCB 1 POLE 2 AMP TYPE C - UL 5SJ4 102-7HG42
92
93
94 SW1 SWT303 1 SWITCH 4 POLE 3 POSITION CENTRE OFF (20A) CA10-A213-620EF
95 SW2 SWT312 1 SWITCH 1 POLE 2 POSITION (20A) CA10-A220-600EF
96
97 L1, L2 IND122 2 PILOT LIGHT BODY 440-480V 60Hz ZB4-BV8
98 L1, L2 IND144 2 PILOT LIGHT LENS RED ZB4-BV04
99
100 L4 IND134 1 PILOT INDICATOR TYPE ND 16 240V AC RED ND16R240
101
102 PSF, PSR SEN171 2 PHASE ROTATION RELAY 500 VOLTS FEC178-871 / 3UG4513-1BR20
103
104 AF0 - AF2 SEN109 3 AIR FLOW PADDLE COMPLETE ASSEMBLY SEN103-106
105
106 S0, S1
107 TEMP. SEN. SEN153 2 BI-METAL THERMAL SWITCH 90 DEG N/C (75 Reset) RS 331-528 / Farnell 1006844
108
109 RT, LOT TIM243 2 MULTI-FUNCTION TIMER 3RP1505-1BP30
110 RT SET TO MODE B & 10 SECONDS
111 LOT SET TO MODE E & 10 SECONDS
112
113

FORM:CF012.ISS:09: AUTH S.P.P Page 2 ISSUE DATE 21/07/16

 PARTS LIST 1000kW KCS100H C6416

ITEM CIRCUIT REF STOCK No. Unit DESCRIPTION MANUFACTURERS REF ORDER No.
114 BROUGHT FORWARD
115
116 TRX554U 1 TRANSFORMER 1000VA P-380,400,415,440,480V/SEC 220VBWS
117
118
119 AUX I/P TML381 5 TERMINAL 125A/115A UL 600V - M6 Studs ENTRELEC UK - 115.140.23
120
121
122
123
124
125 CONT I/P, O/P CNR640 2 CHASSIS MOUNTED SOCKET SIZE 14 19 WAY (KCS) AB0521001419SN00
126 CONT I/P, O/P CNR641 2 DUST COVER CHASSIS MTD SOCKET 19 WAY (KCS) AB05006514
127 CONT I/P CNR415 1 COVER RED 25 WAY D-TYPE FEC 470-053
128 CONT I/P CNR275 1 PLUG 25 WAY D-TYPE FEC 113-2407
129
130
131 FIX122 15 EMKA LATCH SHORT (GH=18mm) (H=28mm)
132
133 FIX134 9 4-HOLE HINGE C.P. RH 7/04132
134 FIX135 6 4-HOLE HINGE C.P. LH 7/04131
135
136
137 WAC477 8 RUBBER BUFFER A0967
138
139
140 TEST - L1 CNR975 4 CAM-LOK J-SERIES 600V 400A MALE RECEPTACLE 2 HOLE1016-1707BB
141 TEST - L2 CNR976 4 CAM-LOK J-SERIES 600V 400A MALE RECEPTACLE 2 HOLE1016-1703BB
142 TEST - L3 CNR977 4 CAM-LOK J-SERIES 600V 400A MALE RECEPTACLE 2 HOLE1016-1701BB
143
144 TEST - E CNR972 1 CAM-LOK J-SERIES 600V 400A MALE RECEPTACEL 2 HOLE1016-1704BB
145
146 FIX453 26 5/16 UNC X 1 BRASS HEX SET SCREW (SPECIAL FIXING F
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176

FORM:CF012.ISS:09: AUTH S.P.P Page 3 ISSUE DATE 21/07/16

10. DRAWINGS – GENERAL ARRANGEMENT

Loadbank Serial No: C6416

 1 2 3 4 5 6 7 8
NOTES
1. APPROXIMATE WEIGHT: 2540lbs 1 EMERGENCY STOP
86 16"
2. PAINT FINISH: RAL7046 (TELEGREY 2). EMERGENCY STOP
ER
GEN
C POWER METER

EM

Y
392°F
STOP

3. APPROX. AIR TEMPERATURE AT THE GRILLE LOADBANK INSTRUMENTATION

ABB

000 0
000 0
M2M

CONTROL SUPPLY SWITCHES

000 0

4. NO OBSTRUCTION PERMITTED WITHIN 80" ON AIR INLET & 275" FAN START/STOP, RESET BUTTON
A OUTLET GRILLES.
LOADBANK CONTROL SUPPLY

INT
OFF/RESET

FAN START
EXT

RESET
CONTROL VOLTAGE
380V-440V 440V-480V

FAN STOP
AUXILIARY/TEST SUPPLY LIVE / COOLING FAULT A
5. 40" CLEARANCE REQUIRED FOR MAINTENANCE ON CONTROL SIDE. TEST
SUPPLY
COOLING
FAULT
AUXILIARY
SUPPLY
KCS INPUT / OUTPUT
CONTROL I/P CONTROL O/P

A A
B M B M
P N L P N L
C C
V K V K
R U R U
D D
S T J S T J
E E
F H F H
G G

AIR INTAKE AIR OUTLET

ADCOCK
R
DRJAMES
WENTWORTH
TRENTSTRETTON15
ON
BURTON
Aux.
Serial No. Weight kg.

IMPORTANT
BEFORE COMPLETING TEST
RUN FANS FOR 5 MINUTES
WITH ZERO LOAD SELECTED

B B
L1 L2 L3
E
kW
ENTER CLEAR

0 0 0 0

PLAN VIEW TEST SUPPLY - CAM-LOKS (4 PER PHASE)

INLET VIEW
25
50 32" DOOR REMOVED

C C

2540lbs 2540lbs

EMERGENCY STOP
GEN
ER C
EM

STOP
DANGER DANGER
LIVE PARTS LIVE PARTS

ADCOCK
R
DRJAMES
WENTWORTH
TRENTSTRETTON15
ON
BURTON
POWER PLANT PROVING ENGINEERS ACCESS TO THIS APPARATUS BY ACCESS TO THIS APPARATUS BY
2ND. AVENUE CENTRUM 100
BURTON ON TRENT AUTHORISED PERSONS ONLY AUTHORISED PERSONS ONLY
UNITED KINGDOM STAFFORDSHIRE DE14 2WF
TEL:-44(0)1283 531645 FAX:-44(0)1283 510103

ABB M2M

0 00 0
0 00 0 ADCOCK
R
DRJAMES
WENTWORTH
TRENTSTRETTON15
ON
BURTON
0 00 0
Aux.
Serial No. Weight kg.

LOADBANK CONTROL SUPPLY CONTROL VOLTAGE IMPORTANT

OFF/RESET 380V-440V 440V-480V BEFORE COMPLETING TEST
RUN FANS FOR 5 MINUTES
INT EXT WITH ZERO LOAD SELECTED

DANGER
FAN START RESET FAN STOP
LIVE PARTS
ACCESS TO THIS APPARATUS BY
AUTHORISED PERSONS ONLY

TEST COOLING AUXILIARY

SUPPLY FAULT SUPPLY

CONTROL I/P CONTROL O/P

A A
B M B M
P N L P N L
C C
V K V K
D R U D R U
S T J S T J
E E
F H F H
G G

DANGER
Electric
shock risk

D D
ADCOCK
R
DRJAMES
WENTWORTH
TRENTSTRETTON15
ON
BURTON
DANGER OF ELECTROCUTION
Aux.
EXPOSED ELECTRICAL
Serial No. Weight kg. CONDUCTORS WITHIN DANGER DANGER
ACCESS STRICTLY PROHIBITED
IMPORTANT WHILST SUPPLIES ARE Electric Electric
BEFORE COMPLETING TEST CONNECTED
RUN FANS FOR 5 MINUTES
WITH ZERO LOAD SELECTED
shock risk shock risk
32"

DANGER OF ELECTROCUTION DANGER OF ELECTROCUTION

EXPOSED ELECTRICAL EXPOSED ELECTRICAL
CONDUCTORS WITHIN CONDUCTORS WITHIN
11

ACCESS STRICTLY PROHIBITED ACCESS STRICTLY PROHIBITED

WHILST SUPPLIES ARE WHILST SUPPLIES ARE
CONNECTED CONNECTED
78

IMPORTANT
BEFORE COMPLETING TEST
RUN FANS FOR 5 MINUTES
WITH ZERO LOAD SELECTED
DANGER
LIVE PARTS
YB S
ACCESS
UTARAPTO
PATHIS
SIHTAPPARATUS
OT SSECCA BY
YLNAUTHORISED
O SNOSREP DPERSONS
ESIROHTUONLY
A
DANGER
LIVE PARTS
YB S
ACCESS
UTARAP TO
PATHIS
SIHTAPPARATUS
OT SSECCA BY
YLNAUTHORISED
O SNOSREP DPERSONS
ESIROHTUONLY
A

DANGER
Electric DANGER
shock risk Electric
shock risk
DANGER OF ELECTROCUTION
EXPOSED ELECTRICAL
CONDUCTORS WITHIN
ACCESS STRICTLY PROHIBITED
WHILST SUPPLIES ARE
CONNECTED

E E

DRAWING APPROVED FOR

FRONT VIEW SIDE VIEW END VIEW ISSUE BY D.O.
CABLE ENTRY CABLE ACCESS
PANEL Printed On: 23 Dec,2020
4 CAM-LOKS PER PHASE
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
GENERAL ARRANGEMENT 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21217 1 of 5
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
2150

ELEMENT
RAILS

A COOL AIR HOT EXHAUST A

FAN ELEMENT
CHAMBER

CONTROL
B CABLE ENTRY
CHAMBER
B
kW
ENTER CLEAR

0 0 0 0

SECTIONAL PLAN VIEW

C C
EMERGENCY STOP
G EN
ER
EM

CY

STOP

ABB M2M

00 0 0

PSR
00 0 0

PSF
LOT
RT
00 0 0
RL0 RLT MC AC SCF SCR

LOADBANK CONTROL SUPPLY CONTROL VOLTAGE

OFF/RESET 380V-440V 440V-480V

INT EXT

FAN START RESET FAN STOP

TEST COOLING AUXILIARY

SUPPLY FAULT SUPPLY

CONTROL I/P CONTROL O/P

A A
B M B M
P N L P N L
C C
V K V K
R U R U
D D
S T J S T J
E E
F H F H

FCA FCB
G G

CB11
CB17

CB13

CB15
CB16
CB14
CB19
CB18
OLA OLB
ADCOCK
R
DRJAMES
WENTWORTH
TRENTSTRETTON15
ON
BURTON
Aux.
Serial No. Weight kg.

IMPORTANT

TX
BEFORE COMPLETING TEST
RUN FANS FOR 5 MINUTES
WITH ZERO LOAD SELECTED

D L1 L2L3 LNE
D
CAM-LOKS

CABLE POUCH

E E

INLET VIEW SIDE VIEW EXHAUST VIEW

GRILLE's REMOVED DOORS OPEN GRILLE's REMOVED
DRAWING APPROVED FOR
ISSUE BY D.O.
Printed On: 23 Dec,2020
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
GENERAL ARRANGEMENT 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21217 2 of 5
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

REAR VIEW
DOOR OPEN
C C

1140kg / 2500lbs 1100kg / 2415lbs

D D

E E

DRAWING APPROVED FOR

REAR VIEW ISSUE BY D.O.
Printed On: 23 Dec,2020
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
GENERAL ARRANGEMENT 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21217 3 of 5
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

S1 S2
CB12

C0
C1
CB10

PSR
PSF
LOT
RT
RL0 RLT MC AC SCF SCR

C2
KCS PCB CB1

C3
6 5 4 3 2 1 20 12 13 14 15 16 17 18 19 11 10 9 8 7 6 5 4 3 2 1

TBC

CB2
TBB

+
C14

C4
B B
-
- D0 D1 D2 D3 D7 D8 D9 D13 D14 D15
IC12 IC13
FS1 C4

+
C13 P2
C7
HS REG
-
C12

+
S
S
-

C5
REF
1

IC6 IC5 C5
C6

IC9 IC10 IC11

C9 C10

I
C
1
RN5
I
C
2
RN6
I
C
3
RN7
I
C
4
RN8 C11

F1
RN1 RN2 RN3 RN4

CRESTCHIC LTD
CL7214/A TBA
TX1 PL1

C6
F2
110V 240V 110V SER No
1 2 3 4 5 6

F3

FCA FCB

CB17

CB15
CB16
CB14
CB19
CB18
F4

F5

C7
OLA OLB

5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
F6

F7

TX F8

C8
F9

C C
CAM-LOKS

C9 C10
L1 L3 E F10

SIEMENS
L2 LN

L1 L2 L3 CAM-LOKS
F11

F12

F13

SIEMENS
F14

CT F15

C11 C12
F16

SIEMENS
F17
D F18
D
F19

SIEMENS
F20

F21

C13
F22

SIEMENS
F23

F24

E E

SECTIONAL INLET VIEW SECTIONAL SIDE VIEW

DRAWING APPROVED FOR
ISSUE BY D.O.
Printed On: 23 Dec,2020
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
GENERAL ARRANGEMENT 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21217 4 of 5
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

EMERGENCY STOP
EMERGENCY STOP
ER
GEN
POWER METER

EM

CY
STOP

LOADBANK INSTRUMENTATION

CONTROL SUPPLY SWITCHES

ABB M2M

0000
0000
0000

LOADBANK CONTROL SUPPLY

OFF/RESET
CONTROL VOLTAGE
380V-440V 440V-480V
FAN START/STOP, RESET BUTTON
INT EXT

B FAN START RESET FAN STOP

AUXILIARY/TEST SUPPLY LIVE / COOLING FAULT B
TEST
SUPPLY
COOLING
FAULT
AUXILIARY
SUPPLY
KCS INPUT / OUTPUT
CONTROL I/P CONTROL O/P

A A
B M B M
P N P N
C L C L
V V
R U K R U K
D D
S T J S T J
E E
F H F H
G G

ADCOCK
R
DRJAMES
WENTWORTH
TRENTSTRETTON15
ON
BURTON
Aux.
Serial No. Weight kg.

IMPORTANT
BEFORE COMPLETING TEST
RUN FANS FOR 5 MINUTES
WITH ZERO LOAD SELECTED

C C

D D

L1 L2 L3
E

E E

INLET VIEW
DRAWING APPROVED FOR
DOOR REMOVED ISSUE BY D.O.
Printed On: 23 Dec,2020
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
GENERAL ARRANGEMENT 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21217 5 of 5
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
11. DRAWINGS – WIRING DIAGRAMS

Loadbank Serial No: C6416

 1 2 3 4 5 6 7 8

4 PER PHASE
CAM-LOCKS

L1
L1
L1
L1
1500:5A
A CT1 1206A A
(1)
L1
S2 S1
CT2 (2)
S2 S1 TO
CT3 (3) SHEET

L2
L2
L2
L2
S2 S1 2
(4)
L2 LN

TEST SUPPLY
B B

5
1

CB10
CB12
CONNECTION

32A
2A
480V 60Hz
L3
L3
L3
3-PHASE L3

6
4
2

6
4
(310)

(311)

(312)

(313)
L3

(206)

(207)
(205)
S2 S1 S2 S1 S2 S1
(205)
1 CAM-LOCK I1 I2 I3 CONTROL

2
OUT1
EARTH (206)
SUPPLY
TO

1
C C
E

(207)
SHEET
4

2
OUT2
E

1
COLOUR CODING:
3-PHASE (4)

Max 500V LN (850V LL)

ABB M2M METER

N
L1 - BROWN INS421 (301)

L1
D L2 - ORANGE X1
D
R
L1
L3 - YELLOW TEST SUPPLY
(302)
LN - GREY

L2
LIVE LAMP
E - GREEN X2
(303)

L3
1-PHASE 220V CB18
24-240V (269) 2 1 (250)
L - BROWN AC-DC 1A
FROM
N - BLUE (5) SHEET
(5)
12V DC & 24V DC 4
E P - RED E
NOTE:-
N - BLACK WHERE ORANGE SLEEVING
48V DC IS REQUIRED - RED IS
USED (NON AVAIALBLE) DRAWING APPROVED FOR
P - WHITE ISSUE BY D.O.
N - BLACK CURRENT VALUES SHOWN ARE CALCULATED AT 480V 60Hz PHASE-TO-PHASE Printed On: 23 Dec,2020
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 1 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

(1) 1207A 14566 14566 14566 14566 14566 20471 (1)

A L1 A
(2) (2)
L2
FROM
SHEET 1 (3) (3)
L3
(4) 200.5A 200.5A 200.5A 200.5A 200.5A 80.2A
LN

250A

250A

250A

250A

250A

250A

250A

250A

250A

250A

250A

250A

250A

250A

250A

100A

100A

100A
F21

F11
F19

F9
F22

F23

F20

F16

F17

F18

F13

F15

F10

F12

F7

F8
F24

F14
B B

(56)

(57)

(58)
TO
SHEET

5
3

C11
C13

C12

C10

C9

C8
2

6
4

4
(44)

(45)

(46)
C C
70mm² 70mm² 70mm² 70mm² 70mm² 25mm²

4x5.55kW

4x5.55kW

4x5.55kW
10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW

10x5.55kW
(4)
D D
166.65kW 166.65kW 166.65kW 166.65kW 166.65kW 66.66kW
1.38Ω/LEG 1.38Ω/LEG 1.38Ω/LEG 1.38Ω/LEG 1.38Ω/LEG 3.46Ω/LEG

E E

DRAWING APPROVED FOR

ISSUE BY D.O.
Printed On: 23 Dec,2020
UNLESS OTHERWISE STATED ALL VALUES OF CURRENT ARE CALCULATED AT 480V PHASE-TO-PHASE
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 2 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

(1) 20351 20351 20231 (1) 20231 20231 20231 20231 20231

(2) (2)
A A
(3) (3)

24.1A

5
50A

50A

50A

50A

50A

50A

CB1
CB2

25A

32A
F1
F5

F6

F2

F3
F4

6
4

4
10mm²

B B

(17)

(18)

(19)
FROM
SHEET
C 2 C
40.1A 40.1A 20.4A 12.0A 4.81A 3.61A 2.41A 1.20A
(53)

(54)

(55)

(50)

(51)

(52)

(47)

(48)

(49)
1

5
C1
C7

C6

C5

C3

C2

C0
C4
2

6
4

4
(41)

(42)

(43)

(38)

(39)

(40)

(35)

(36)

(37)

(32)

(33)

(34)

(29)

(26)

(27)

(28)

(23)

(24)

(25)

(22)
(30)

(20)
(31)

(21)
D D
10mm² 10mm² 4mm² 2.5mm² 2.5mm² 2.5mm² 2.5mm² 2.5mm²
2x5.55kW

2x5.55kW

2x5.55kW

2x5.55kW

2x5.55kW

2x5.55kW

1x5.55kW

1x5.55kW

1x5.55kW

1x3.33kW

1x3.33kW

1x3.33kW

1x1.33kW

1x1.33kW

1x1.33kW

1x1.00kW

1x1.00kW

1x1.00kW

1x0.66kW

1x0.66kW

1x0.66kW

1x0.33kW

1x0.33kW

1x0.33kW
(4) (4)
E E
33.33kW 33.33kW 16.66kW 10kW 4kW 3kW 2kW 1kW
6.91Ω/LEG 6.91Ω/LEG 13.83Ω/LEG 23.04Ω/LEG 57.6Ω/LEG 76.8Ω/LEG 115.2Ω/LEG 230.4Ω/LEG

DRAWING APPROVED FOR

ISSUE BY D.O.
Printed On: 23 Dec,2020
UNLESS OTHERWISE STATED ALL VALUES OF CURRENT ARE CALCULATED AT 480V PHASE-TO-PHASE
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 3 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

MC
(205) 1 2 (211) (211)

CONTROL TO
SUPPLY (206) 3 4 (212) (212) SHEET 5
A FROM COOLING A
SHEET 1 (207) (213) (213)
5 6 FANS

5
CB13
CB11

2A
(201) 1 2
(208) 1 2
(211)
T1

(217) 2

(219) 6
(218) 4
(202) 3 4
(209) 3 4
(212)
T2
AUXILIARY SUPPLY
CONNECTIONS (203) 5 6
(210) 5 6
(213)
380-480V 50/60Hz T3
B 3-PHASE 3-WIRE
32A AC B

1
CB15

CB16
22 22
T4

10A

10A
24 21 24 21

(221) 2

(223) 2
(220) 4

4
E 12 12
PSF & PSR
(222) L1 L2 L3 L1 L2 L3
3

14 14
CB14

11 11 VOLTAGE - 450V
5C1 PSF PSR 5C2
2A

(262)
PSF PSR DELAY - 2.0s
2
4

(261)
(228)

(229)

OFF

OFF

OFF
C EXT C

EXT

EXT
INT

INT

INT

SW1
1 3 5 7 9 11

2 6 10

(225)
AUXILIARY SUPPLY

SW2 2
LIVE LAMP

VOLTAGE
(224)

X1
R
L2
1 3 (260)
(226)
(227)

X2
440V
415V

D (250) 24 23
(260) D
RL0
TX1 E-STOP START
1.0KVA CB19 STOP
(250) 2 1
(251) 2 1
(252) (253) 4 3
1 2
220V TO
2A

61

61
(230) (231) SHEETS
1 3

MC
AC
CB17 14 13 1 & 5

(263) 62

(264) 62
6A RL0
2 4

(254)
E E
(250)

X1
A1 L3 A1 A1
NOTE:- ALL CONTACTOR COILS HAVE A (250) TO G
RL0 MC AC
SUPPRESSION CAPACITOR WIRED IN PARALLEL SHEET 1 A2 A2 A2
X2 DRAWING APPROVED FOR
(5) (5) ISSUE BY D.O.
Printed On: 23 Dec,2020
Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 4 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
SCF
(211) 1 2 20251 (214) 20251

FROM (212) 3 4 (215)

SHEET
A 4 (213) 5 6 (216) A

5
9.0-12.5A

9.0-12.5A
FC1
FC0
1 2

6
4

4
3 4

OL1
OL0
2

6
4

4
5 6

(600)

(601)

(602)

(603)

(604)

(605)
SCR
B B
4.8/5.76kW 4.8/5.76kW
FAN0 FLC 9.2/10.0A FAN1 FLC 9.2/10.0A
SC 56.9/55.0A SC 56.9/55.0A

(260) (260)

25
13

RT
RLT
BATTLE LINK TO BY-PASS
11

11

AF0
C
13

13
C

26
28
AIR FLOW SWITCHES

14
SCR
SCF
PSR

(291)
PSF

13
14

14

(285)
12

12
14

14

TEMP. SENSOR

FC0
(281)

1
RESET
S0
(270)

14
16
18

16
18
(280)
AF1

53 (292)
2
13

67

LOT
RT
(282)
FROM
FC0T
FC1

15

15
SHEET

FC1
14

68

D 4 D

(280)
(265)

(260)

(287)

(290)
(266)

TEMP. SENSOR
(271)

54
S1

(286)
95

95
61

61

(283)
SCR

OL1
SCF

OL0
(272) 96

(273) 96
(367)62

(368) 62

TIMER B1 A1 A1
X1

MODE B

MODE E
2 SEC. RT LOT R
L4
MAX. 2 1 (295)
A1 A1 A1 A1 A1 A2 (10 SECS) A2 (10 SECS) TO
X2
SCF SCR FC0 FC1 RLT SHEET
E A2 A2 A2 FC0T A2 A2 E
(5) (5) 6
FAN 0 FAN 1 RUN OFF LOCKOUT COOLING
CONTACTOR CONTACTOR DELAY TIMER PULSE TIMER FAULT
DRAWING APPROVED FOR
ISSUE BY D.O.
NOTE:- ALL CONTACTOR COILS HAVE A SUPPRESSION Printed On: 23 Dec,2020
CAPACITOR WIRED IN PARALLEL Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 5 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
19-WAY 'MIL' (CONTROL OUTPUT-EXTEND)
S H G F E D C B A V U P N M L K J

(4000)
(8000)

(2000)
(1000)

(400)
(800)

(200)
(100)
(40)
(0v)

(80)

(20)
(10)

(4)
(8)

(2)
(1)
A A

GRN/RED

RED/BRN
YEL/BLU

YEL/RED
RED/BLK
WHT

GRY
BRN

GRN

TRQ
PNK
ORG
YEL
BLK

BLU
RED
VIO
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I/P
7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8
COIL I/P COIL I/P
TBB
IN LINK ISOLATE PIN 10
0V ON IC1,IC2 FROM
TBA
B CONTROL INPUT 19-WAY 'MIL' SOCKET 12V 0V +12V B
P1
PCB CL7215/A
CONNECT PIN TO PIN AS SHOWN ON SHEET 7 NO RELAYS FITTED

CONTROL INPUT 25-WAY 'D' PLUG

1 2 3 4 5 6
1 13 PCB CL7214/A
C TBA
PL1 C
14 25 OUT
12V
P1 P2 0V
TBB

12V OUT

240V IN
5V OUT

0V OUT

NEU. IN
EARTH
COIL I/P COIL I/P
TBC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6
D (295) D
FROM
SHEET (5)

(104)
(109)

(108)

(107)

(106)

(105)

(103)

(102)

(100)
(113)

(112)

(110)

(101)
(111)

A1 A1 A1 A1 A1 A1 A1
C12 C10 C8 C6 C4 C2 C0
A2 A2 A2 A2 A2 A2 A2

A1 A1 A1 A1 A1 A1 A1

E C13 C11 C9 C7 C5 C3 C1 E
A2 A2 A2 A2 A2 A2 A2

166.65kW 166.65kW 66.66kW 33.33kW 10kW 3kW 1kW

166.65kW 166.65kW 166.65kW 33.33kW 16.66kW 4kW 2kW DRAWING APPROVED FOR
ISSUE BY D.O.
Printed On: 23 Dec,2020
NOTE:- ALL COILS HAVE SUPPRESSION MODULES CONNECTED IN PARALLEL WITHPrinted
THEM By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 6 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

PL1 - 25-WAY 'D' TYPE

SOCKET TO CL7214/A
CONTROLLER PCB

A 19-WAY 'MIL' A
CHASSIS SOCKET
& COVER ON
LOADBANK FACIA

B B

C C

D D

E E

DRAWING APPROVED FOR

ISSUE BY D.O.
Printed On: 23 Dec,2020
CONNECTORS SHOWN FROM SOLDER SIDE Printed By: TONY HIGGINSON
CUSTOMER DRAWN BY DATE
Crestchic Loadbanks
2nd Avenue, Centrum 100, Burton-on-Trent, HAWTHORNE POWER SYSTEMS 24/03/20
Staffordshire, DE14 2WF, United Kingdom.
F TEL. +44 (0)1283 531645 FAX. +44 (0)1283 510103 CHECKED DATE
F
www.crestchicloadbanks.com 1 23/12/20 TH CN6416-01 AS BUILT AND TESTED
TITLE 25/03/20 ISSUE
A Northbridge Industrial Services PLC Company DATE CHK'D CHANGE No. DESCRIPTION
WIRING DIAGRAM 1000kW
This Drawing is the property of Crestchic Ltd and may not be copied, or used for any CONTRACT SCALE ISSUE DRG. No. SHEET No.
purpose other than that for which it is supplied. Contravention will be prosecuted 480V, 60Hz, 3-PHASE, 3/4-WIRE A
KCS100H-M TRANSPORTABLE LOADBANK C6416 DNS 1 CL21218 7 of 7
copyright © 2020 Crestchic Ltd. 3
1 2 3 4 5 6 7 8
12. PARTS LISTS/DRAWINGS – SUB-ASSEMBLIES

Loadbank Serial No: C6416

 CONTROLLER UNIT 4-DECADE PL1222

MODEL CONTRACT No.

RATING ISSUED 2
TEST SUPPLY DATED 10/12/2001
CONTROL SYSTEM SIGNED KH
ENCLOSURE TYPE No. of SHEETS 1
ITEM CIRCUIT REF STOCK DESCRIPTION MANUFACTURERS REF No. ORDER No. REC. ISS.
1 CL8280 GENERAL ARRANGEMENT CL8280 ISSUE 5 REF
2 CL8281 WIRING DIAGRAM CL8281 ISSUE 6 REF
3
4 PCB362 PCB KCS CONTROLLER COMPLETE CL6522 PL1111 1
5 ENC817 VERONEX INSTRUMENT CASE RS 584-738 1
6 ENC818 KCS CONTROLLER FRONT CL6548 1
7 ENC820 KCS CONTROLLER REAR MIL-TYPE CL8275 1
8 SW1-SW4 SWT415 ROCKER SWITCH 4
9 SW1-SW4 SWT418 SWITCH SPACER 1
10 SW1-SW4 SWT413 SWITCH END PLATES 1
11 ENT,CLR SWT481 PUSH BUTTON SPST 3A BLACK RS 336-602 2
12 PCB CNR426 NYLON SPACER 4.6 X 3.2 ADHESIVE RS 220-771 4
13 CNR268 SOCKET 25 WAY STRAIGHT D-TYPE RS 544-3834 1
14 CNR640 CHASSIS MOUNTED SOCKET SIZE 14 19 WAY (KCSAB0521001419SN00 1
15 CNR641 DUST COVER CHASSIS MTD SOCKET 19 WAY (KCSAB05006514 1
16 LABEL SERIAL/PLANT Nos N:\Labels\Dave labels\PLANT.job 1
17
18
19
20 NOTE: THIS PARTS LIST COVERS 2, 3 & 4
21 DECADE CONTROLLERS - ADJUST
22 ITEMS 8 & 9 ACCORDINGLY
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

FORM CF012 CRESTCHIC LIMITED PHONE +44 (0) 1283 531645

ISSUE 08 2ND AVENUE, CENTRUM 100, FAX. +44 (0) 1283 510103
ISSUE DATE 16/11/05 BURTON ON TRENT, STAFFS www.crestchic.co.uk
AUTHORISED M.W.B. UNITED KINGDOM DE14 2WF sales@crestchic.co.uk

Page 1
 KCS EXTEND LEAD MIL-TYPE PL1224

Crestchic Limited Co Reg No: 1772456

Second Avenue, Centrum 100,  VAT No: GB880985177
Burton‐on‐Trent DE14 2WF. U.K sales@crestchic.co.uk
Tel +44 (0) 1283 531645 hires@crestchic.co.uk
Fax +44 (0) 1283 510103 service@crestchic.co.uk
MODEL CONTROL LB TO CONTROL LEAD KCS100H (Straight-90 Deg) 10 METRE M CONTRACT No.
RATING ISSUED 4
TEST SUPPLY DATED 17/08/2018
CONTROL SYSTEM SIGNED TH
ENCLOSURE TYPE No. of SHEETS 1
ITEM CIRCUIT REF STOCK No. Unit DESCRIPTION MANUFACTURERS REF ORDER No. REC. ISS.
1 CL8279 REF GENERAL ARRANGEMENT
2
3
4
5 CAB428 10 m CABLE 20 CORE SCREENED 7/0.2mm (100m) FEC 715-517 / RS 660-0479
6
7
8 CNR621 1 CABLE BOOT SIZE 14 RAYFAST 202K142-100-0 / 155-42-GW24
9 CNR623 1 CABLE BOOT SIZE 14 90 DEGREE 222K142-25/225-0
10
11 CNR690 2 CABLE MTD PLUG COVER 19 WAY SIZE 14 AB05007114
12
13 CNR688 2 CABLE MOUNTED PLUG 19 WAY SIZE 14 AB0562001419PN00.
14
15 CNR617 2 SPINDLE BACK SHELL SIZE 14 RS 241-1323
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

FORM:CF012.ISS:09: AUTH S.P.P Page 1 ISSUE DATE 21/07/16

13. ABB M2M INSTRUMENTATION

Loadbank Serial No: C6416

M2M

2CSG445010D1001
2CSG299883R4052
M2M MODBUS
2CSG299893R4052
M2M ETHERNET
2CSG299903R4052
M2M PROFIBUS
2CSG299913R4052
M2M ALARM
2CSG299923R4052
M2M I/O
2CSG299933R4052
M2M LV
2CSG299943R4052

NETWORK ANALYSER
EN Assembly and use instructions
M2M

ABB
SUMMARY
ABB
1 GENERAL INFORMATION
1.1 Reference regulations and conformity....................................................5
1.2 Use and storage of the manual.................................................................6
1.2.1 Storing .....................................................................................................6

EN
1.2.2 Copyright..................................................................................................6
1.3 General safety warnings............................................................................7
2 PACKAGING CONTENTS
2.1 Removal of packaging...............................................................................8
2.2 Description of the contents.......................................................................9
3 TECHNICAL CHARACTERISTICS
3.1 Description of the device........................................................................10
3.2 Measuring functions................................................................................10
3.3 Models....................................................................................................... 11
3.4 Overall dimensions ................................................................................12
3.5 Technical data...........................................................................................13
4 INSTALLATION
4.1 Assembly..................................................................................................18
4.2 Disassembly.............................................................................................19
4.3 Wiring diagrams.......................................................................................20
4.3.1 Wiring diagrams......................................................................................22
4.3.2 Inputs and outputs connections..............................................................24
4.4 Configurations for first use.....................................................................26
5 OPERATING
5.1 Front panel................................................................................................27
5.2 Use of device............................................................................................29
5.2.1 Access to the page.................................................................................30
5.3 Configuration of the SETUP device........................................................31
5.3.1 Control keys............................................................................................32
5.3.1.1 Data entry......................................................................................................33
5.3.2 Password menu......................................................................................34
5.3.2.1 Password creation.........................................................................................34
5.3.2.2 Password modification...................................................................................35
5.3.2.3 Password entry..............................................................................................35
5.3.3 Reset menu............................................................................................37
5.3.4 Configuration menu................................................................................38
5.3.4.1 Type of entry..................................................................................................38
5.3.4.2 CT ratio..........................................................................................................40
5.3.4.3 VT ratio..........................................................................................................41
5.3.4.4 Average time.................................................................................................42
5.3.4.5 Current threshold for T2 hour counter........................................................... 42
5.3.4.7 Generation.....................................................................................................44
5.3.4.8 Euro/energy factor.........................................................................................45
5.3.4.9 CO2/energy factor.........................................................................................45
5.3.4.10 Back lighting..................................................................................................46
5.3.4.11 Energy saving................................................................................................46

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 ABB SUMMARY

5.3.5 Digital output menu.................................................................................47

5.3.5.1 Digital output mode........................................................................................47
5.3.5.2 Energy value for pulse...................................................................................48
5.3.5.3 Alarm1 or alarm2(*) parameter...................................................................... 49
5.3.5.4 Alarm 1 or 2 threshold...................................................................................50
EN

5.3.5.5 Alarm 1 or 2 activation...................................................................................50

5.3.5.6 Alarms 1 or 2 activation delay....................................................................... 51
5.3.5.7 Alarm 1 or 2 hysteresis..................................................................................51
5.3.6 Alarm output menu.................................................................................52
5.3.6.1 Alarm 3 or 4 parameter (*).............................................................................52
5.3.6.2 Alarm 3 or 4 threshold...................................................................................53
5.3.6.3 Alarm 3 or 4 activation...................................................................................53
5.3.6.4 Alarms 3 or 4 activation delay....................................................................... 54
5.3.6.5 Alarm 3 or 4 hysteresis..................................................................................54
5.3.7 I/O card menu.........................................................................................55
5.3.7.1 Outputs span.................................................................................................55
5.3.7.2 Output 1 parameter.......................................................................................56
5.3.7.3 Output 2 parameter.......................................................................................56
5.3.7.4 Input pulses factors.......................................................................................57
5.3.7.5 External synchronism....................................................................................57
5.3.7.6 Output associated parameter table............................................................... 58
5.3.8 Communication menu.............................................................................59
5.3.8.1 PROFIBUS address (only M2M PROFIBUS)................................................ 59
5.3.8.2 Serial protocol................................................................................................60
5.3.8.3 Address.........................................................................................................60
5.3.8.4 Baud rate.......................................................................................................61
5.3.8.5 Parity type......................................................................................................61
5.3.8.6 Number of stop bits.......................................................................................62
5.3.9 Language menu......................................................................................63
5.3.10 Self-diagnosis menu...............................................................................64
5.3.11 Info menu................................................................................................65
5.3.12 SETUP mode exit...................................................................................65
5.3.13 Setup parameters table and factory settings..........................................66
5.4 Data reading.............................................................................................68
5.4.1 Default page setting................................................................................68
5.4.2 Voltages, Currents and 3-phase powers.................................................69
5.4.3 Energies..................................................................................................70
5.4.4 Voltage, Currents and single phase 3-phase Powers.............................72
5.4.5 THDF, Alarms, Timer and input pulses...................................................73
5.4.6 Maximums..............................................................................................75
5.4.7 Minimums...............................................................................................76
5.4.8 Averages.................................................................................................77
5.4.9 Maximum demand..................................................................................77
6 TROUBLESHOOTING
6.1 Problems, causes, solutions...................................................................78
6.1.1 Error codes ............................................................................................79

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NETWORK ANALYSER Rev. 1.0
CHAPTER 1
GENERAL INFORMATION ABB
1 GENERAL INFORMATION

1.1 Reference regulations and conformity

EN
2006/95/CEE
93/68/CEE (Low-Voltage Directive).
Electrical safety
IEC 61010-1

Electromagnetic compatibility 89/336/CEE

Use of hazardous substances UE 2002-95-CE – RoHS

IEC 60688
IEC 61326-1
Measuring instruments IEC 62053-21
IEC 62053-23
IEC 62053-31

Degree of protection IEC 60529

Standardised dimensions for the panel IEC 61554

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Rev. 1.0 NETWORK ANALYSER
 CHAPTER 1
ABB GENERAL INFORMATION

1.2 Use and storage of the manual

Carefully read this manual and adhere to the indications

EN

described prior to using the device.

This manual contains all of the safety information, the technical aspects and the
operating necessary to ensure the correct use of the device and maintain it in safe
conditions.

1.2.1 Storing
The manual must be stored close to the device; safe from liquids and anything else
which may compromise its leggibility.
The manual and the declaration of conformity are both an integral part of the device
until it is dismantled.
If the manual is lost or illegible please request a copy from the manufacturer.

1.2.2 Copyright
The copyright of this manual is the property of ABB S.p.A.
This manual contains texts, designs and illustrations of a technical nature which must
not be disclosed or transmitted to third parties, even partially, without the written
authorisation of ABB S.p.A.

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CHAPTER 1
GENERAL INFORMATION ABB
1.3 General safety warnings

Non-adherence to the following points can lead to serious

EN
injury or death.

•• Use the suitable personal protection devices and adhere to the current
regulations governing electrical safety.
•• This device must be installed exclusively by qualified personnel who have
read all of the information relative to the installation.
•• Check that the voltage supply and measurement are compatible with the range
permitted by the device.
•• Ensure that all current and voltage supplies are disconnected prior to carrying
out any controls, visual inspections and tests on the device.
•• Always assume that all circuits are under voltage until they are completely
disconnected, subjected to tests and labelled.
•• Disconnect all of the power supply prior to working on the device.
•• Always use a suitable voltage detection device to check that the supply is
interrupted.
•• Pay attention to any dangers and carefully check the work area ensuring that
no instruments or foreign objects have been left inside the compartment in
which the device is housed.
•• The correct use of this device depends on a correct manipulation, installation
and use.
•• Failure to adhere to the basic installation information can lead to injuries as well
as damage to the electric instruments or to any other product.
•• NEVER connect an external fuse in by-pass.
•• Disconnect all of the input and output wires before carrying out a dielectric
rigidity test or an insulation test on an instrument in which the device is installed.
•• The tests carried out at a high voltage can damage the device's electronic
components.

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Rev. 1.0 NETWORK ANALYSER
 CHAPTER 2
ABB PACKAGING CONTENTS

2 PACKAGING CONTENTS

2.1 Removal of packaging

EN

We recommend that the packaging is stored in a suitable

location in compliance with the warranty terms

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NETWORK ANALYSER Rev. 1.0
CHAPTER 2
PACKAGING CONTENTS ABB
2.2 Description of the contents
The packaging includes:
1) network analyser
2) user manual

EN
3) calibration certificate
4) mini CD with technical documentation
5) assembly accessories

Prior to using the product read the documentation attached

and strictly adhere to the indications provided.

3
1 2

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Rev. 1.0 NETWORK ANALYSER
 CHAPTER 3
ABB TECHNICAL CHARACTERISTICS

3 TECHNICAL CHARACTERISTICS

3.1 Description of the device

EN

The M2M network analyser is an instrument that measures of the main electric
quantities on 3-phase and monophase networks designed for the monitoring and
the local or remote analysis of:
•• electrical parameters of systems in low or medium voltage;
•• system energy consumption.
3.2 Measuring functions
All of the M2M series models are able to measure and process the quantities
shown below.

1) Voltages (phase neutral and concatenated) and relative peak values;

2) Currents and relative peak values;
3) Power factors or PF phases and the 3-phase system, with distinction icon
between the inductive and capacitive load;
4) Frequency (measured on L1-N phase);
5) Active, reactive and apparent phase energies and the 3-phase system on 2
quadrants (with automatic recognition function of the AT directions);
6) Active, reactive and apparent power phases and the 3-phase system on 4
quadrants (monitoring of energy aborbed and generated by the system);
7) Average power values on a time period programmed by the user;
8) Maximum calculated demand on active and apparent power;
9) Voltage and current THdF expressed in absolute and percent values;
10) T1 increase total operating hour counter and T2 decrease partial hour counter;
11) Balance of active, reactive and apparent energy of 3-phase system,
balance = absorbed energy - generated energy;
12) Balance of the "partial" active, reactive and apparent energies of the 3-phase
system on 4 quadrants in a period that can be programmed by the user, balance
= energy absorbed - energy generated;

The refresh rate (for each value available on the display) is 2

times/second.

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CHAPTER 3
TECHNICAL CHARACTERISTICS ABB
3.3 Models
Serial
Models Inputs and outputs communication

EN
protocol

2 outputs programmable with pulses or

M2M
threshold alarms

2 outputs programmable with pulses or

M2M MODBUS Modbus RTU
threshold alarms

M2M 2 outputs programmable with pulses or

Modbus TCP/IP
ETHERNET threshold alarms

M2M 2 outputs programmable with pulses or

Profibus DP
PROFIBUS threshold alarms

2 electromechanical relays 16A AC1 - 3A

AC15
M2M ALARM Modbus RTU
2 outputs programmable with pulses or
threshold alarms
2 analog outputs 4 -20 mA
3 inputs for external pulse reading
M2M I/O Modbus RTU
2 outputs programmable as pulses or
threshold alarms
2 outputs programmable with pulses or
M2M LV threshold alarms.
Current input stage with Shunt.

All of the models have the following in common:

•• multivoltage supply voltage;
•• multilanguage display with scrolling text;
•• self-diagnosis function for the installation control;
•• settiing of a safety password;
•• T1 and T2 hour counter.

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 CHAPTER 3
ABB TECHNICAL CHARACTERISTICS

3.4 Overall dimensions

D
A
EN

E F

B C

A 96 mm D 77 mm

B 96 mm E 57 mm

C 92 mm F 20 mm

IEC 61554

X 92 -0+0,8 mm

Y 92 -0+0,8 mm Y

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CHAPTER 3
TECHNICAL CHARACTERISTICS ABB
3.5 Technical data
Auxiliary power supply
from 24 to 240 a.c./d.c.

EN
Voltage range [V] from 48 to 240 a.c../d.c. M2M ETHERNET,
M2M PROFIBUS, M2M I/O
Frequency range [Hz] 45 ÷ 65
T 0,5 A from 24 V to 100 V
Protection fuse
T 0.25 A from 24 V to 100 V

Power consumption [VA] 7 max

Measurement type Sampling TRMS

Accuracy class
Voltage ±0,5% F.S. ±1 digit
Current ±0,5% F.S. ±1 digit
40.0 ÷ 99.9: ±0,2% ±0,1
Frequency [Hz]
100 ÷ 500: ±0,2% ±1
±1% ±1 digit
Power factor (from cosΦ= 0,3 Inductive
to cosΦ= 0,3 Capacitive)
±1% ±0,1% F.S
Active power (from cosΦ= 0,3 Inductive
to cosΦ= 0,3 Capacitive)
Active energy Class 1

Measurement range
from 10 to 500 approx. TRMS VL-N
Voltage [V]
Visualisation with 0 decimals
from 50 mA to 5 A TRMS
Current
Visualisation in A with 2 decimals
from 40 to 500
Visualisation:
Frequency [Hz]
with 1 decimal up to 99.9
with 0 decimals above 100
Power factor Visualisation with 2 decimals

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 CHAPTER 3
ABB TECHNICAL CHARACTERISTICS

Installation
Low and medium voltage
Singlephase insertion
Distribution networks
3-phase with neutral
EN

3-phase without neutral

Always use external CT
Primary from 1 to 10.000 A a.c. approx.
Ammetric inputs [A] Secondary 5 A and 1 A a.c. approx.
N.B.: in case of CT secondary at 1 A the
accuracy class is declassified to 2,5% F.S.
±1 digit, in range 5%-100% F.S.
Direct insertion up to 500 a.c. approx.
Indirect insertion with VT:
Primary from 60 to 60,000 V a.c. approx.
Voltmetric inputs [V] secondary from 60 to 190 V a.c.
N.B.: In case of VT secondary lower than
100V the accuracy class is declassified to
2,5% F.S. ±1 digit, in range 5%-100% F.S.
Protection fuse [A] 0,1

Data referesh rate 2 time/second

Harmonic distortion [Hz] Measurement bandwidth up to 500

Energy measurement
Single phase maximum value
10 GWh / Varh / VAh
counted
3-phase maximum value counted 30 GWh / Varh / VAh
Energy balance maximum value
10 GWh / GVarh / GVAh with sign
counted
Input pulses maximum energy value
40 GWh / Varh
counted

Terminal characteristics
Ammetric inputs Section 6 mm2 - Step 6,35 mm
Volumetric inputs Section 2.5 mm2 - Step 7.62 mm
Pulse outputs Section 2.5 mm2 - Step 5.08 mm
RS485 Serial port Section 2.5 mm2 - Step 5.08 mm
Relay outputs Section 2.5 mm2 - Step 5.08 mm

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CHAPTER 3
TECHNICAL CHARACTERISTICS ABB
Overall dimensions
96 mm x 96 mm x 77 mm (Depth inside switchboard: 57 mm)

EN
Weight [Kg] 0.400 max

Standard normatives
Overall dimensions IEC 61554
Degree of protection IEC 60529
IEC 60688, IEC 61326-1, IEC 62053-21 ,
Accuracy class
IEC 62053-23, IEC 62053-31.
Electrical safety IEC 61010-1

User interface
Scrolling text in several languages user
Display
selectable.
Display type LCD with back light intensity user selectable
Display dimensions [mm] 72x57

Communication interface
RS485
Protocol Modbus RTU
Electric standard RS485 with optical isolation
Baud rate 4.8, 9.6, 19.2 kbps
Parity number Odd, Even, None
Stop bit 1, 2
Address 1-247
4 pole terminal (integrated 120 Ohm terminator on T
Connectors
terminal)
Profibus
Profibus with slave DP-V0 function in compliance with IEC
Protocol
61158 standard
Electric standard RS485 with optical isolation
Baud rate Automatic detection [9.6 - 12 Mbps]
Green for communication status and Red for communication
LED indicators
error
Address 1-126
DB 9 female connector (do not use connectors with 90°
Connectors
cable outlet)

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 CHAPTER 3
ABB TECHNICAL CHARACTERISTICS

Ethernet
Protocol Modbus TCP/IP
Connectors RJ45
EN

Digital output programmed as pulse

Contact supply external voltage [V] 48 max (peak ac/dc)
Maximum current [mA] 100 (peak ac/dc)
Pulse duration [ms] 50 OFF (min) / 50 ON closed contact
Pulse frequency 10 pulses/s (max)

Digital output programmed as alarm

Contact supply external voltage [V] 48 max (peak a.c./d.c.)
Maximum current [mA] 100 (peak a.c./d.c.)
Alarm activation delay [s] 1 - 900 s (programmable)
Alarm return hysteresis 0 - 40% (programmable)

Relay outputs
Nominal current [A] 16 AC1 - 3 AC15
Max. instant current [A] 30
Nominal voltage [V] 250 a.c.
Max instant voltage [V] 400 a.c.
Nominal load [VA] 4000 AC1 - 750 AC15

Analog output
Settable electric parameters Span [0 - 20 mA or 4 - 20 mA]
Load typical 250 Ohm, max 600 Ohm

Digital inputs
Nominal voltage [V] 24 d.c. (absorption = 13 mA)
Max. voltage [V] 32 d.c. (absorption = 22 mA)
Max. voltage for OFF state [V] 8 d.c.
Min. voltage for ON state [V] 18 d.c.

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CHAPTER 3
TECHNICAL CHARACTERISTICS ABB
Hour counters
Count of the system operating time through
the activation of a programmable threshold
Count-down timer on total current. Upon expiry of the

EN
maintenance period set an icon will appear
on the display.
Count-up timer Life time of instrument

Climatic conditions
Storing [°C] from -10 to +60
Operation [°C] from -5 to +55
Relative humidity Max 93% (without condensation) at 40°C

Degree of protection
Frontal IP50
At terminals IP25

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Rev. 1.0 NETWORK ANALYSER
 CHAPTER 4
ABB INSTALLATION

4 INSTALLATION

4.1 Assembly
EN

IEC 61554

A
2

A
A

A x4

A A

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NETWORK ANALYSER Rev. 1.0
CHAPTER 4
INSTALLATION ABB
4.2 Disassembly

EN
A
A A x4

A
A A 1

2
1

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 CHAPTER 4
ABB INSTALLATION

4.3 Wiring diagrams

The operations to carry out for the correct connection of the device, based on the
type of electric line available, are described in this section.
EN

The installation and the cabling of the device must be carried

out by qualified personnel.

Danger of electrocution, burning and electric arc.

Use the personal protection devices suitable to adhere to the
current regulations governing electrical safety.
Prior to carrying out any connections check the sectioning of
the electric supply with the voltage detection device.

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NETWORK ANALYSER Rev. 1.0
CHAPTER 4
INSTALLATION ABB

EN
M2M MODBUS
M2M / M2M LV

S2 S2
I1 I1
S1 S1
B
S2 S2
S I2
I2
A
S1 S1
T
S2 S2
I3 I3
S1 S1
24-240V| Max 500 V OUT2 | OUT1 24-240V| Max 500 V OUT2 | OUT1

AC-DC |L3 L2 L1 N| 1 2|1 2 AC-DC |L3 L2 L1 N| 1 2|1 2

M2M ETHERNET

M2M PROFIBUS

S2 S2
P
I1 I1
S1 r S1
o
LAN S2 f S2
I2 I2
i
S1 b S1
S2 u S2
I3 I3
s
S1 S1
48-240V| Max 500 V OUT2 | OUT1 48-240V| Max 500 V OUT2 | OUT1

AC-DC |L3 L2 L1 N| 1 2|1 2 AC-DC |L3 L2 L1 N| 1 2|1 2

C NO NC | C NO NC + COM + COM + - + - + -

IN1 | IN2 | SYNC

M2M ALARM

OUT4 OUT3 AN-01 AN-02

S2 S2
M2M I/O

I1 I1
S1 S1
B B
S2 S2
S I2 S
A I2
S1 A
T S1
T
S2 S2
I3 I3
S1 S1
24-240V| Max 500 V OUT2 | OUT1 48-240V| Max 500 V OUT2 | OUT1

AC-DC |L3 L2 L1 N| 1 2|1 2 AC-DC |L3 L2 L1 N| 1 2|1 2

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 CHAPTER 4
ABB INSTALLATION

4.3.1 Wiring diagrams

3-phase + neutral with 3 CT and

1 3-phase + neutral with 3 CT 3
3 VT
EN

2 3-phase with 3 CT
 
A Fuse B Load

1
A A

2
A A

3
TV3 TV2 TV1
A

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CHAPTER 4
INSTALLATION ABB
AARON 3-phase with 2 CT and 3
4 6 Balanced 3-phase with 1 CT
VT

5 Monophase with 1 CT

EN
 
Fuse
A B Load

4
A
TV3 TV1

Not suitable for the M2M LV model.

5
A
A

A A

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 CHAPTER 4
ABB INSTALLATION

4.3.2 Inputs and outputs connections

Digital outputs as alarms with Electromechanical relay outputs

7 9
external relay for loads command M2M ALARM
EN

8 Digital outputs as pulses

7 8
A A

B C

D
E

 
A V aux 48 V a.c./d.c. 100 mA D Load 16A AC1 - 3A AC15
 
B External relay E V aux 250 V a.c. MAX

C Pulse acquisition

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NETWORK ANALYSER Rev. 1.0
CHAPTER 4
INSTALLATION ABB
M2M I/O digital inputs (example in
10 11 M2M I/O analog outputs
NPN mode)

EN
10 11 + +

H H
G

 
F G.M.C. + ES card H Typical 250 Ohm load, max 600 Ohm

G V aux 24 V d.c. (32 V d.c. max)

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 CHAPTER 4
ABB INSTALLATION

4.4 Configurations for first use

After having cabled the instrument according to the pre-selected layout, the following
operations must be carried out to start to use the analyser:
EN

1) set the language (see paragraph “5.3.9 Language menu”)

2) set the CT transformation ratio (see “5.3.4.2 CT ratio”)
3) set the VT transformation ratio (see “5.3.4.3 Set VT ratio”)

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CHAPTER 5
OPERATING ABB
5 OPERATING

5.1 Front panel

EN
13

15
14
18

17 16
L12

19
L23 10
8
L31 11

7 Alarm Setup

12
9

1 2 3 4 5

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 CHAPTER 5
ABB OPERATING

Description
1 Control key 1

2 Control key 2
EN

3 Control key 3

4 Control key 4

5 Control key 5

6 Control keys unit

7 Device error or warning indicator

8 Data transmission to external devices indicator

9 Indicator for data acquisition on 4 quadrants-GENERATION

10 Alarm indicators

11 Hours counter indicator

12 SETUP mode indicator

13 Scrolling descriptive text

14 Descriptive or data display text

15 Size reading values

16 Measurement unit

17 Line indicator corresponding to value displayed

18 Indicator of capacitive load (PF and reactive power page)

19 Indicator of inductive load (PF and reactive power page)

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OPERATING ABB
5.2 Use of device
During normal operating or during the reading of the parameters, the device is set
in DATA READING mode.
During the configuration phase of one or more parameters the device will pass on

EN
to the SETUP mode (signalled on display by the 12 icon).
Based on the mode activate, the control keys 6 perform a specific function.

Passing from the DATA READING to SETUP mode and viceversa

occurs by keeping the 5 key pressed down for over 2 seconds.

If the 7 icon is active when switching on, the device is

signalling an installation or internal electronic anomaly.
See paragraphs “5.3.10 Self-diagnosis menu” and “6.1 Problems,
causes, solutions” to check the anomaly and solve the problem.

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 CHAPTER 5
ABB OPERATING

5.2.1 Access to the page

The device page is accessed by pressing, in sequence, the control keys 6 .
The following layout explains how to correctly interpret the symbology used in this
chapter.
EN

A B
XXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXX

x1 x1 x1

>2s
Setup

C D

A Control key sequence

B Number of times to press the control key

C How long to press the control key for

D Page shown after having carried out the sequence in point A

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OPERATING ABB
5.3 Configuration of the SETUP device
To access the SETUP device configuration menu press the 5 key for more than
2 seconds.

EN
The display order of the main page of the menu and the relative configurations are
illustrated in the following table:

Menu Function
Insertion, modification and disabling of device protection
Password
password.
Reset the peak/average, energy, hour counter values and
Reset
reset the factory setting.
Device configurations (electric network, back lighting,
Configurations
conversion factors, alarm thresholds, etc.)

Digital ouput Digital output configurations.

Alarm outputs M2M ALARM alarm output configuration

Analog output configuration and digital inputs for M2M I/O

I/O card
pulses reading.

Communications Communication module configurations

Language Language selection.

Self-diagnosis Insertion control and device status.

Info Display of device identifying data

Exit Return to normal DATA READING navigation.

The device returns to the normal DATA READING

navigation automatically if it remains waiting for over 3
minutes after any of the keys have been pressed.

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 CHAPTER 5
ABB OPERATING

Repeatedly press the 1 key to reach the Exit page, regardless of navigation point.
Press the 5 key to confirm.
EN

To quickly return to the normal DATA READING navigation, keep the 5 key pressed
down for more than 2 seconds.

5.3.1 Control keys

In the SETUP mode, the control keys 6 allow the navigation and/or insertion of
data between the different device configuration pages.

Key Function

Return to an advanced level menu or pass on to the field more on the

left in the data entry phase

Ascending navigation of the page or increase of a data in data entry

phase

Descending navigation of the page or decrease of a data in data entry

phase

Change to field further to the right in data entry phase

Access to an advance menu level or confirmation of a data in data

entry phase

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OPERATING ABB
5.3.1.1 Data entry

Some of the pages require the entry of alphanumerical characters (A-Z, 0-9) in the
SETUP mode.

EN
In these cases the page will have a series of fields where the active field will be
identified by a flashing cursor.

The data entry procedure (password, etc) is as follows:

1) Use the 2 and 3 keys to scroll the alphanumerical characters available in either
ascending or descending order until the required character is obtained;
2) Use the 4 key to move the cursor between the characters:
3) Repeat the operations described in points 1 and 2 up to the completion of all
the fields on the page:
4) Press the 5 key to confirm or the 1 key to cancel the modification...

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5.3.2 Password menu

Password menu
Enter?
EN

x1 x1 x1

>2s
Setup

The entry, convalidation, modification and disabling of the device protection password
operations can be carried out in this menu.

5.3.2.1 Password creation

Password creatio
Password:

x1 x1 x1 x1 x1

>2s
Setup

1) Enter the new password (see paragraph “5.3.1.1 Data entry”).

2) When the entry is completed a page will appear for a few seconds to confirm the
modification which has taken place.

In the session subsequent to the setting of the

password all of the menus will be protected and in
"reading only" mode.

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5.3.2.2 Password modification

Password modifica

EN
Password:

x1 x1 x1 x1

>2s
Setup

1) Modify the password (see paragraph”5.3.1.1 Data entry”).

2) When the entry is completed a page will appear for a few seconds to confirm the
modification which has taken place.

To disable the password set the value 0000.

5.3.2.3 Password entry

Password entry
Password: ----

x1 x1 x1 x1

>2s
Setup

The password entry page does not appear if the password

has not been previously set.

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To avoid unauthorised persons intervening in the device configurations parameters,

the access to a number of pages, in SETUP mode, requires the entry of a password
(if set).
EN

At the password entry request, go to the Password entry page in the Password entry
menu and continue as follows:

1) Press the 5 key

Enter password
Password:

Setup

2) Insert the password (see paragraph “5.3.1.1 Data entry”).

If the password is entered incorrectly the following error will be shown

Password incorre
Password:

Setup

and the device will automatically return to the advanced menu level.

The correct entry of the password enables the

modification of all of the parameters for the duration of
the configuration session.

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5.3.3 Reset menu

Reset menu
Enter?

EN
x1 x2 x1

>2s
Setup

The following operations can be carried out in this menu:

•• Peaks reset, the maximum, minimum and Maximum demand values are zeroed
•• Average values reset
•• Timer reset: T1 is zeroed, T2 starts from the value set
•• Balance reset partial of energy
•• Energy reset, all of the energy counts are zeroed, including the counts from
external impulses for M2M I/O
•• Total reset: resetting of the factory settings for all of the setup parameters
1) With the 2 or 3 keys select the page corresponding to the value you wish
to reset.
2) Press the 5 key to confirm.

Confirm reset
<-esc OK-conf.

Setup

3) Press the 5 key to confirm the selection or the 1 key to cancel and return
to the advanced menu level.

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5.3.4 Configuration menu

Configuration men
Enter?
EN

x1 x3 x1

>2s
Setup

In this menu the settings of the parameters relative to the entry of the electric
network device, the T2 hour counter, the generation functions, the back lighting and
the conversion factors used to calculate the values in euro and CO2 can be made.

5.3.4.1 Type of entry

Type of entry
GENERIC

x1 x3 x1 x1

>2s
Setup

1) Press the 2 or the 3 key to navigate between the following options:

•• GENERIC
•• MONOPHASE
•• BALANCED 3-PHASE
•• 3-PHASE (default)
2) Press the 5 key to confirm.

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Types of entry Description / Effect Note

The pages relative to the Use channel I1 to enter the

MONOPHASE 3-phase size are not shown current and channel L1-N for

EN
in the navigation menu the voltage
The self-diagnosis carries
3-PHASE out controls on the correct
insertion[1]
The value of the I1 current
is assumed to be valid for
BALANCED Use channel I1 to insert the
the two remaining phases
3-PHASE current
(allows you not to connect
I2 and I3)
The self-diagnosis does not
GENERIC carry out controls on the
correct insertion

See paragraph “5.3.10 Self-diagnosis menu” for more information on the tests
[1]

carried out.

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5.3.4.2 CT ratio

Set CT ratio
5/5
EN

x1 x3 x1 x1 x1
A B
>2s
Setup

1) Insert a value between 1 A and 10000 A for the primary value in A (see
paragraph “5.3.1.1 Data entry”).
2) Move the cursor to the figure relative to the secondary current B and select
1 A or 5 A.
3) Press the 5 key to confirm.

If the CT is replaced varying the value of the transformation ratio, before proceeding
we recommend:

1) Noting the value of the energy counts accumulated with the previous ratio.
2) Resetting the energy counts.
3) Insert a new value of the transformation ratio.

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5.3.4.3 VT ratio

Set ratio
VT 100/100

EN
x1 x3 x1 x2 x1
A B
>2s
Setup

1) Insert a value between 60 A and 60000 A for the primary value in A (see
paragraph “5.3.1.1 Data entry”).
2) Move the cursor to the figure relative to the voltage of the secondary B and
insert a value between 60 V and 190 V (see paragraph “5.3.1.1 Data entry”).
3) Press the 5 key to confirm.

In case of direct insertion, up to 500 V phase-neutral,

without voltage transformers set 100/100 (default) as
value.

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5.3.4.4 Average time

Average time
time(min) 15
EN

x1 x3 x1 x3 x1

>2s
Setup

In this page the time intervals used by the device to carry out the calculation of the
average values is set.

1) Insert a value between 1 and 60 minutes (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

5.3.4.5 Current threshold for T2 hour counter

Current threshol
ThrI(A) 0.00

x1 x3 x1 x4 x1

>2s
Setup

The current threshold for the T2 hour counter represents the minimum current value
at which the counter begins the countdown.

1) Insert a value of between 0 and the nominal value of the current transformer
used, KA*5 (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

KA and KV respectively represent the ammetric and

voltmetric transformation ratio.

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5.3.4.6 Hour counter count-down

Hour counter

EN
T2(h) 8760h

x1 x3 x1 x5 x1

>2s
Setup

When the count down hour counter completes the countdown the 11 symbol will
appear on the display.

1) Insert a value between 1 and 26280 hour (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

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5.3.4.7 Generation

Generation
EN

Enabled

x1 x3 x1 x6 x1

>2s
Setup

By activating the GENERATION option, the energy counts will be carried out on 4
quadrants separating energy and absorbed power, shown with the “+” sign, from that
generated shown with the “-” sign.
It is important that the insertion of the CT is carried out correctly adhereing to
the absorption direction of the current.

1) Press the 2 or the 3 key to enable or disable the acquisition mode of the
data in the 4 quadrants.
2) Press the 5 key to confirm.

If the Generation option is not active the instrument will carry out the automatic
inversion of the current direction meaning that the powers active will always be
positive and the energy count will occur on two quadrants. With each switching on
or as soon as the current is different from 0, the analyser will automatically and in an
independent manner for each phase, read the displacement of the current in respect
to the corresponding phase voltage for some periods. If it finds that the current is out
of phase it inverts the direction of the current concerned.

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5.3.4.8 Euro/energy factor

Euro/energy fact

EN
€/KWh 0.18

x1 x3 x1 x7 x1

>2s
c Setup

The active 3-phase energy, both absorbed and generated, is multiplied by the
conversion factor so that the equivalent can be displayed in euro.

1) Insert a value between 0.01 and 9.99 (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

5.3.4.9 CO2/energy factor

The active 3-phase energy, both absorbed and generated, is multiplied by the

CO2/energy facto
Kg/KWh 0.05

x1 x3 x1 x8 x1

>2s
c Setup

conversion factor so that the equivalent can be displayed in Kg CO2.

1) Insert a value between 0.01 and 9.99 (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

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5.3.4.10 Back lighting

Back lighting
EN

interme

x1 x3 x1 x9 x1

>2s
Setup

1) Press the 2 or the 3 key to navigate between the following options:

•• off
•• intermediate
•• maximum
2) Press the 5 key to confirm.

5.3.4.11 Energy saving

Energy saving
Enabled

x1 x3 x1 x10 x1

>2s
Setup

The energy saving foresees the automatic switching off of the back lighting (if not set
at “off”) if the control keys 6 remain inactive for approx. 3 minutes.
The back lighting can be reactivated by pressing any of the 6 control keys.
1) Press the 2 key or the 3 key to enable or to disable the ‘Energy saving’
mode.
2) Press the 5 key to confirm.

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5.3.5 Digital output menu

Digital output m
Enter?

EN
x1 x4 x1

>2s
c Setup

5.3.5.1 Digital output mode

In this menu the parameters associated with the pulses or the alarms of the digital
output available on all models, OUT1 and OUT2 can be set.
Select “pulses” to use OUT1 and OUT2 as pulse output channels associated
respectively with the 3-phase active energy and the 3-phase reactive energy.
Select “Alarms” to use OUT1 and OUT2 as alarm output channels.

Output mode
Alarms

x1 x4 x1 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the two options available (‘Alarms’
or ‘Pulses’).
2) Press the 5 key to confirm.

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5.3.5.2 Energy value for pulse

Energy value
EN

Wh/imp. 10

x1 x4 x1 x1 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the following values expressed
in Wh/imp for OUT1 and VArh/imp for OUT2:
•• 10
•• 100
•• 1000
•• 10000
2) Press the 5 key to confirm.

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5.3.5.3 Alarm1 or alarm2(*) parameter

Alarm parameter

EN
None
x2
x1 x4 x1 x1
x3(*)

>2s Setup

1) Press the 2 key or the 3 key to navigate between the parameters given in
paragraph “5.3.7.6 Output associated parameter table”.

2) Press the 5 key to confirm.

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5.3.5.4 Alarm 1 or 2 threshold

Alarm threshold
EN

th2 1.00

x1 x4 x1 x4 x1

>2s
Setup

1) Insert the values required (see paragraph “5.3.1.1 Data entry”), checking the
parameters and the setting intervals (see paragraph “5.3.7.6 Output associated
parameter table”).
2) Press the 5 key to confirm.

5.3.5.5 Alarm 1 or 2 activation

Activation at
over threshold

x1 x4 x1 x5 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the two options available (‘over
threshold’ or ‘below threshold’).
2) Press the 5 key to confirm.

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5.3.5.6 Alarms 1 or 2 activation delay

Activ. delay

EN
Dly2(s) 10

x1 x4 x1 x6 x1

>2s
Setup

1) Insert a value between 1 and 900 seconds (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

In alarm situations the 10 symbol will flash on the display.

Check which alarm is activated on the screen relative to the alarms status.

5.3.5.7 Alarm 1 or 2 hysteresis

1) Insert a value between 0 and 40% (see paragraph “5.3.1.1 Data entry”).

Alarm hysteresis
Hyst2(%) 0

x1 x4 x1 x7 x1

>2s
Setup

2) Press the 5 key to confirm.

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5.3.6 Alarm output menu

Alarm output men

EN

Enter?

x1 x5 x1

>2s
c Setup

5.3.6.1 Alarm 3 or 4 parameter (*)

Alarm parameter
None
x1
x1 x5 x2(*) x1

>2s Setup

1) Press the 2 key or the 3 key to navigate between the parameters given in
paragraph “5.3.7.6 Output associated parameter table”.

2) Press the 5 key to confirm.

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5.3.6.2 Alarm 3 or 4 threshold

Alarm threshold

EN
th3 1.00

x1 x5 x1 x1 x1

>2s
Setup

Insert the values required (see paragraph “5.3.1.1 Data entry”), checking the
parameters and the setting intervals (see paragraph “5.3.7.6 Output associated
parameter table”).
1) Press the 5 key to confirm.

5.3.6.3 Alarm 3 or 4 activation

Activation at
over threshold

x1 x5 x1 x2 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the two options available
(‘over threshold’ or ‘below threshold’).
2) Press the 5 key to confirm.

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5.3.6.4 Alarms 3 or 4 activation delay

Activ. delay
EN

Dly3(s) 10

x1 x5 x1 x3 x1

>2s
Setup

1) Insert a value between 1 and 900 seconds (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

In alarm situations the 10 symbol will flash on the display.

Check which alarm is activated on the screen relative to the alarms status.

5.3.6.5 Alarm 3 or 4 hysteresis

Alarm hysteresis
Hyst3(%) 0

x1 x4 x1 x4 x1

>2s
Setup

1) Insert a value between 0 and 40% (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

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5.3.7 I/O card menu

I/O card menu

EN
Enter?

x1 x5 x1

>2s
c Setup

From the I/O card menu it is possible to set the parameters associated with the
analog outputs 4-20mA (“AN-O1” and “AN-O2”) and the pulse reading inputs(“IN1”,
“IN2” and “SYNCH”).

5.3.7.1 Outputs span

Outputs span
0-20mA

x1 x5 x1 x1

>2s
Setup

Selecting “0-20mA”, the output current will assume the values from 0 to 20mA
proportional to the parameter associated therewith; when selecting “4-20mA” the
values assumed by the output currents will be between 4 and 20 mA. Values lower
than 4mA indicate a failure along the current loop.

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5.3.7.2 Output 1 parameter

Outputs paramete
V1
EN

x1 x5 x1 x1 x1

>2s
Setup

1) Press the 2 key or the 3 key to navigate between the parameter given in
paragraph “5.3.7.6 Output associated parameter table”.
2) Press the 5 key to confirm.

5.3.7.3 Output 2 parameter

Outputs size
l1

x1 x5 x1 x2 x1

>2s
Setup

1) Press the 2 key or the 3 key to navigate between the parameter given in
paragraph “5.3.7.6 Output associated parameter table”.
2) Press the 5 key to confirm.

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5.3.7.4 Input pulses factors

Input pulses fac

Wh/imp. 10

EN
x1 x4 x1 x3 x1

>2s
Setup

1) Insert the value required between 1 and 10000 Wh/pulses (see paragraph
“5.3.1.1 Data entry”); in case of interface with analysers MTME and DMTME
the same value must be set as in the setup of these instruments.
2) Press the 5 key to confirm.

5.3.7.5 External synchronism

Time synchronism
Disabled

x1 x4 x1 x4 x1

>2s
Setup

For the M2M I/O model the enabling of this parameter, in correspondence with the
arrival of an external synchronism pulse, synchronises the calculation of all of the
average values; any synchronism commands from protocol will not be accepted.

1) Press the 2 key or the 3 key to enable or disable the external synchronism
of the average time.
2) Press the 5 key to confirm.

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5.3.7.6 Output associated parameter table

The following table shows the parameters associated to alarm ouput and/or analog
output in current.
EN

Parameter Measurement unit Max. limit

Frequency Hz 500
V12 concatenated voltage V KV * 866
V23 concatenated voltage V KV * 866
V31 concatenated voltage V KV * 866
L1 voltage V KV * 500
L2 voltage V KV * 500
L3 voltage V KV * 500
Equivalent 3-phase voltage V KV * 866
L1 current A KA * 5
L2 current A KA * 5
L3 current A KA * 5
3-phase current A KA * 5
L1 active power W KA * KV * 2500
L2 active power W KA * KV * 2500
L3 active power W KA * KV * 2500
3-phase active power W KA * KV * 7500
L1 reactive power VAr KA * KV * 2500
L2 reactive power VAr KA * KV * 2500
L3 reactive power VAr KA * KV * 2500
3-phase reactive power VAr KA * KV * 7500
L1 apparent power VA KA * KV * 2500
L2 apparent power VA KA * KV * 2500
L3 apparent power VA KA * KV * 2500
3-phase apparent power VA KA * KV * 7500
PF1 1.00
PF2 1.00
PF3 1.00
3-phase PF 1.00
T2(1) h Activated when 0 is reached
(1)
Parameter not associated to analog output in current.

KA and KV respectively represent the ammetric and

voltmetric transformation ratio.

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5.3.8 Communication menu

Communication me
Enter?

EN
x1 x4 x1

>2s
Setup

When the communication is active or the instrument is

interrogated by a monitoring system and responds, the
flashing communication active 8 symbol appears.

5.3.8.1 PROFIBUS address (only M2M PROFIBUS)

Nod address
Addr 126
x1 x4 x1 x1

>2s
Setup

1) Enter the PROFIBUS node between 1 and 126 (see paragraph “5.3.1.1 Data
entry”) to be associated with the instrument.
2) Press the 5 key to confirm.

This is the only page available in this menu for the M2M
PROFIBUS model.

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5.3.8.2 Serial protocol

Serial protocol
Prot MODBUS
EN

x1 x4 x1 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the two options available
(‘MODBUS’ or ‘ASCII’).
2) Press the 5 key to confirm.

5.3.8.3 Address

Address
Addr 31

x1 x4 x1 x1 x1

>2s
Setup

1) Insert a value between 1 and 247 (see paragraph “5.3.1.1 Data entry”).
2) Press the 5 key to confirm.

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5.3.8.4 Baud rate

Baud rate
BR(bps) 9600

EN
x1 x4 x1 x2 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the following values available:
•• 4800
•• 9600 (default)
•• 19200
2) Press the 5 key to confirm.

5.3.8.5 Parity type

1) Press the 2 key or the 3 key to select one of the following values available:
•• None (default)

Parity type
Pty None

x1 x4 x1 x3 x1

>2s
Setup

•• EVEN
•• ODD
2) Press the 5 key to confirm.

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5.3.8.6 Number of stop bits

N. of bit of sto
Sb 1
EN

x1 x4 x1 x4 x1

>2s
Setup

1) Press the 2 key or the 3 key to select one of the two options available (‘1’ or ‘2’).
2) Press the 5 key to confirm.

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5.3.9 Language menu

Language menu
Enter?

EN
x1 x3 x1

>2s
Setup

In this menu it is possible to specify the display language of the page.

Active language
ITALIAN

Setup

1) Press the 5 key to modify the language.

2) Press the 2 key or the 3 key to select the language required amongst
those available.
3) Press the 5 key to confirm.

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5.3.10 Self-diagnosis menu

Self diagnosis m
Enter?
EN

x1 x2 x1

>2s
Setup

In this menu the device self-diagnosis procedure can be started up.

The instrument is able to carry out a diagnosis on the correctness of the connections
made by the user between the device and the network and various parameters, with
indications of the code referred to the type of error.
Press the 5 key to carry out the self-diagnosis.

The tests carried out are:

•• Internal data memory consistency and integrity control
•• Voltage sequence verification
•• Verification of the coherence between the insertions carried out and the
configurations set
•• Current sequence verification
•• Uniformity verification of the powers in GENERATION mode (see “5.3.4.7
Generation”)

The self-diagnosis procedure is carried out a few

seconds after the device is switched on and displays
the results of the test on the screen for a few seconds
before returning to the default page.

If the self-diagnosis procedure detects non-conformities in the behaviour of the

analyser, the 7 warning/error symbol will appear on the screen.
Consult the list of error codes (paragraph “6.1.1 Error codes”) to trace the cause of
the problem.

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5.3.11 Info menu

Info menu
Enter?

EN
x1 x1 x1

>2s
Setup

In this menu the identifying data of the device can be displayed, such as:
•• Type of configuration
•• Series number
•• Firmware version
Press the 2 key or the 3 key to navigate between the pages and display the
information required.

5.3.12 SETUP mode exit

To quickly exit from the SETUP mode keep the 5 key pressed for more than
seconds.

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5.3.13 Setup parameters table and factory settings

Parameter Settable values Default

EN

Average time (min) [1÷60] 15

CT ratio [1÷10000A] / (1A or 5A) 5/5
direct insertion
VT ratio [1÷60000V] / [60÷190V]
(100/100)
Output pulses factors (Wh/imp) 10, 100, 1000, 10000 10
Alarm parameter 1
See table “5.3.7.6
Alarm parameter 2
Output associated None
Alarm parameter 3
parameter table”
Alarm parameter 4
Alarm threshold 1 Max. limit = high
Alarm threshold 2 See table “5.3.7.6 full scale value
Alarm threshold 3
Output associated of the parameter
parameter table” associated with the
Alarm threshold 4 alarm
Alarm 1 activation mode
Alarm 2 activation mode Above threshold or
Above threshold
Alarm 3 activation mode below threshold
Alarm 4 activation mode
Alarm 1 activation delay (s)
Alarm 2 activation delay (s)
[1÷900] 10
Alarm 3 activation delay (s)
Alarm 4 activation delay (s)
Alarm 1 activation hysteresis (% of the
threshold)
Alarm 2 activation hysteresis (% of the
threshold)
[0÷40] 0
Alarm 3 activation hysteresis (% of the
threshold)
Alarm 4 activation hysteresis (% of the
threshold)
RS-485 communication protocol ASCII or MODBUS MODBUS
MODBUS [1-247] MODBUS 31
Analyser address
PROFIBUS [1-126] PROFIBUS 126
4.8Kbps, 9.6 Kbps, 19.2
Baud rate 9.6 Kbps
Kbps
Analog current output span (mA) 0-20 or 4-20 0-20
Analog 1 output parameter See table “5.3.7.6
Output associated None
Analog 2 output parameter
parameter table”

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Parameter Settable values Default
Input pulses factors (Wh/imp) [1÷10000] 10
Hour counter T2 (h) [1÷26280] 8760 (= 1 year)
Energy saving (automatic switching off

EN
ENABLED/DISABLED ENABLED
of display backlight)
OFF, INTERMEDIATE,
Display back lighting level MAXIMUM
MAXIMUM
MONOPHASE,
Configurations 3-PHASE, BALANCED 3-PHASE
3-PHASE, GENERIC
Generation mode ENABLED/DISABLED DISABLED
Energy cost factor (€/KWh) [0÷9.99] 0.18
Conversion factor in CO2 (KgCO2/KWh) [0÷9.99] 0.05
Password 4 digit alphanumericals 0000 = disabled
ENGLISH, ITALIAN,
FRENCH, SPANISH,
Language ENGLISH
GERMAN,
PORTUGUESE
Threshold in current for T2 timer (A) [0 - KA*5] 0A
Digital output mode Pulses or alarms Pulses
External synchronism for average values Enabled or disabled Disabled

KA and KV respectively represent the ammetric and

voltmetric transformation ratio.

M2M
67
Rev. 1.0 NETWORK ANALYSER
 CHAPTER 5
ABB OPERATING

5.4 Data reading

In DATA READING mode, the control keys 6 allow the navigation between the
various reading pages of the parameter measured by the device.
EN

Each key has a series of pages grouped according to the logic reported in the
following table:

Key Type of reading

Voltage, Currents and 3-phase powers, instant values, peak and
average

Energies

Voltage, Currents and single phase powers

THD, alarms, hour counters and and external pulse counters

Access to peak, average and maximum demand values menus

Press the key corresponding to the data reading which you wish to carry out to
display the start page.
Each subsequent pressing of the same key cause the scrolling (cyclic) of the pages
available up to the return to the start page.

When you move from one key to another the first page to be
displayed is always the start page.

The display duration of a page is a maximum of 3 minutes after which the device will
return to the default page.

5.4.1 Default page setting

To reset the default page:
1) Display the page you wish to set as the default page;
2) Keep the 4 and 5 keys pressed down contemporaneously for more than
3 seconds.

M2M
68
NETWORK ANALYSER Rev. 1.0
CHAPTER 5
OPERATING ABB
5.4.2 Voltages, Currents and 3-phase powers

3-phase value Phase-neutral voltages

EN
3-phase value Phase-neutral vo
PF 3F CAP0.99 Frq 50.0Hz
,3,9,8 V L1
,2,3,0 V
x1
,2.9,3 A x2
L2
,2,3,1 V
,1.9,9KW L3
,2,2,8 V
Concatenated voltages Currents

Concatenated vol Currents

Frq 50Hz 3F 2.93A
L12
,3,9,9 V L1
,3.4,0 A
x3
L23
,3,9,8 V x4
L2
,1.3,0 A
L31
,3,9,7 V L3
,4.1,0 A
Active power Reactive power

Active power Reactive power

3F 2.00KW 3F 240Var
L1
,7,7,4 W L1
,1,0,9 VAr
x5
L2
,3,0,0 W x6
L2
, , ,0 VAr
L3
,9,2,5 W L3
,1,3,1 VAr
Apparent power Power factors

Apparent power Power factors

3F 2.02KVA 3F CAP 0.99
L1
,7,8,2 VA L1
,0.9,9
x7
L2
,3,0,0 VA x8
L2
,1.0,0
L3
,9,3,5 VA L3
,0.9,9

M2M
69
Rev. 1.0 NETWORK ANALYSER
 CHAPTER 5
ABB OPERATING

5.4.3 Energies

Active energies Reactive energies

EN

Active energies Reactive energie

3F 1.11MWh 3F 90.52
L1
3,0,7.1KWh L1
3,0.2,5KVArI
x1
L2
2,7,2.0KWh x2
L2
2,2.5,1KVArI
L3
5,3,0.3KWh L3
3,7.7,6KVArI
Apparent energies Active energies activated

Apparent energie Active energy g

3F 1.11MVAh 3F - 226.39KWh
L1
3,0,8.1KVAH L1
8,0.2,1KWh
x3
L2
2,7,3.5KVAH x4
L2
7,2.3,0KWh
L3
5,3,1.2KVAH L3
7,3.8,8KWh
c

Reactive energies generated Apparent energies generated

Reactive energie Apparent energie

3F .30KVArh 3F - 227.81KVAh
L1
,5,0,2 VArI L1
8,0.9,0KVAH
x5
L2
,7,0,1 VArI x6
L2
7,2.8,5KVAH
L3
,1,0,0 VArI L3
7,4.0,6KVAH
c c

Partial energy balance Total energies balance

Partial balances Total balances

and
, ,1,0KWh 8,8,3.0KWh
x7
, , ,1KVArI x8
8,9.2,2KVArI
, ,1,0KVAH 8,8,5.0KVAH
c c

M2M
70
NETWORK ANALYSER Rev. 1.0
CHAPTER 5
OPERATING ABB
Equivalent active euro energy Equivalent active CO2 energy

EN
Equivalent euro Equivalent C02
€ 199.8 KgC02 55.4

x9 x10

Equivalent active euro energy generated Equivalent active CO2 energy generated

Equivalent euro Equivalent C02

€ 40.7 KgC02 11.3

x11 x12
c c

M2M
71
Rev. 1.0 NETWORK ANALYSER
 CHAPTER 5
ABB OPERATING

5.4.4 Voltage, Currents and single phase 3-phase Powers

Phase 1 values Phase 1 powers

EN

Phase 1 values Phases powers

PF1 CAP0.99 Frq 50.0Hz
L1
,2,3,0 V L1
,7,7,4 W
x1
,3.4,0 A x2
,1,0,9 VAr
,7,7,4 W ,7,8,2 VA
Phase 2 values Phase 2 powers

Phase 2 values Phases powers

PF2 1.00 Frq 50.0Hz
,2,3,1 V ,3,0,0 W
x3
L2
,1.3,0 A x4
L2
, , ,0 VAr
,3,0,0 W ,3,0,0 VA
Phase 3 values Phase 3 powers

Phase 3 values Phases powers

PF3 CAPO.99 Frq 50.0Hz
,2,2,8 V ,9,2,5 W
x5
,4.1,0 A x6
,1,3,1 VAr
L3
,9,2,5 W L3
,9,3,5 VA

M2M
72
NETWORK ANALYSER Rev. 1.0
CHAPTER 5
OPERATING ABB
5.4.5 THDF, Alarms, Timer and input pulses

Total voltage harmonic distortion factor (%) Total voltage harmonic distortion factor

EN
Distortion facto Distortion facto
THDFV% THDFV
L1
, , ,1 L1
,1.0,1
x1
L2
, , ,0 x2
L2
,1.0,0
L3
, , ,1 L3
,1.0,1
Total current harmonic distortion factor (%) Total current harmonic distortion factor

Distortion facto Distortion facto

THDFI% THDFI
L1
, ,1,3 L1
,1.1,3
x3
L2
, , ,2 x4
L2
,0.9,8
L3
, , ,3 L3
,0.9,7
Alarms status Hour counter 1 free-running

Alarms status Hour counter 1 f

4 o f f T1 192.42h
3,on
x5
2,oFF x6
1,oFF , Alarm

Hour counter 2 count-down Pulses input 1

Hour counter 2 c Pulses input 1

T2 8640.17h 320.3KWh
,2.5,0KW
x7 x8

M2M
73
Rev. 1.0 NETWORK ANALYSER
 CHAPTER 5
ABB OPERATING

Pulses input 2 Pulses input status

EN

Pulses input 2 Input 1 status

50.8KVArh CH1-CH2-CH3
, ,1.0KVAr , ,6,8
x9 x10
, ,1,2
, , ,3

M2M
74
NETWORK ANALYSER Rev. 1.0
CHAPTER 5
OPERATING ABB
5.4.6 Maximums

Maximum 3-phase values Phase-neutral voltages maximums

EN
Maximum values Maximum voltages

,4,0,0 V x1 L1
,2,3,3 V
x1
,2.9,9 A L2
,2,3,3 V
,2.1,0KW L3
,2,3,2 V
x1
Maximum concatenated voltages Maximum current

Maximum voltages Maximum current

3F 3.20A
x1 L12
,4,0,3 V x1 L1
,3.8,0 A
L23
,4,0,2 V L2
,2.0,0 A
L31
,4,0,2 V L3
,4.8,0 A
x2 x3
Maximum active power Maximum reactive power

Maximum power Maximum power

3F 1.50KW 3F 290VAr
x1 L1
,8,8,0 W x1 L1
,1,1,0 VAr
L2
,4,6,0 W L2
, ,2,0 VAr
L3
,1.1,0KW L3
,1,4,0 VAr
x4 x5
Maximum apparent power

Maximum power
3F 2.40KVA
x1 L1
,8,8,5 VA
L2
,4,6,5 VA
L3
,1.1,3KVA
x6

M2M
75
Rev. 1.0 NETWORK ANALYSER
15. EC DECLARATION OF CONFORMITY

Loadbank Serial No: C6416

 E.C. DECLARATION OF CONFORMITY
Herewith we declare that the load proving equipment designated below, on the
basis of its design and construction, in the form brought on to the market by us,
is in accordance with the relevant safety and health requirements of the EC
Council Directive on electrical equipment. If modifications are made to the
equipment without prior consultations with us, this declaration becomes invalid.

Designation of Equipment: Loadbanks

Type: Resistive, Reactive, D.C.

Relevant EC Council Directive: Electrical Equipment 2006/95/EC

Applied National Standards: BS EN 61082-2006, IEC 60617-2:1996

BS EN 60529-1992

Basis of self attestation: Quality Assurance to BS EN ISO 9001 2008

NQA-Registration firm – Cert. No. 169

Signature of Manufacturer: Tony Higginson Date: 25/05/18

Position of Signatory: Head of Engineering

File: Crestchic Original

Customers Copy

Form Issue Date Authorised Sheet No. 2nd Avenue, Centrum 100, Burton-on-Trent, Staffs. U.K.
CF091 11 18.02.14 M.W.B 1 of 1 Tel. +44 (0) 1283 531645 Fax. +44 (0) 1283 510103
 E.C. DECLARATION OF CONFORMITY
Herewith we declare that the load proving equipment designated below, on the
basis of its design and construction, in the form brought on to the market by us,
is in accordance with the relevant safety and health requirements of the EC
Council Directive on electrical equipment. If modifications are made to the
equipment without prior consultations with us, this declaration becomes invalid.

Designation of Equipment: Loadbanks

Type: Resistive, Reactive, D.C.

Relevant EC Council Directive: Machinery Directive 2006/42/EC

Applied National Standards: BS EN 60204-1-2006

Basis of self attestation: Quality Assurance BS EN ISO 9001 2008

NQA Registration firm – Cert. No. 169

Signature of Manufacturer: Tony Higginson Date: 25/05/18

Position of Signatory: Head of Engineering

File: Crestchic Original

Customers Copy

Form Issue Date Authorised Sheet No. 2nd Avenue, Centrum 100, Burton-on-Trent, Staffs. U.K.
CF092 10 18.02.14 M.W.B 1 of 1 Tel. +44 (0) 1283 531645 Fax. +44 (0) 1283 510103
16. END OF LIFE PRODUCT RECYCLING AND DISPOSAL

With proper maintenance Crestchic Loadbanks can be used reliably for many years. We
offer a service department who can provide spare parts, maintenance and upgrades for
all our loadbanks.

Please contact service@crestchic.co.uk for further details.

If the loadbank is no longer economical to maintain it can be decommissioned for

disposal. Crestchic can provide this service if the loadbank is returned to our Head Office
in Burton upon Trent and will disassemble the loadbank for correct recycling and disposal.

If you require to dispose of the loadbank locally all the components can be unbolted from
the enclosure and separated for recycling.

The main metalwork components of the loadbank are:

• Enclosure: Mild Steel or Stainless Steel.

• Copper busbar.

The main electrical components of the loadbank are:

• Elements: Stainless Steel finning surrounding stainless steel tubing filled

magnesium oxide and 80/20 nickel chrome resistance wire, and ceramic
bushes.
• Reactors: Copper or aluminium wire wound around an iron core and insulating
material.
• Cables and electrical connectors.
• Electronic control equipment including; Transformers, Fuses, Contactors,
Relays and Switches.
• Printed Circuit Boards.

These devices can be recycled due to their low pollutant content.

It is the responsibility of the loadbank owner to ensure that disposal is carried out in
accordance with local regulations. For environmentally friendly recycling and disposal of
your electronic waste, please contact a local company certified for the disposal of
electronic waste.

Loadbank Serial No: C6416

15. EC DECLARATION OF CONFORMITY

Loadbank Serial No: C6416

 E.C. DECLARATION OF CONFORMITY
Herewith we declare that the load proving equipment designated below, on the
basis of its design and construction, in the form brought on to the market by us,
is in accordance with the relevant safety and health requirements of the EC
Council Directive on electrical equipment. If modifications are made to the
equipment without prior consultations with us, this declaration becomes invalid.

Designation of Equipment: Loadbanks

Type: Resistive, Reactive, D.C.

Relevant EC Council Directive: Electrical Equipment 2006/95/EC

Applied National Standards: BS EN 61082-2006, IEC 60617-2:1996

BS EN 60529-1992

Basis of self attestation: Quality Assurance to BS EN ISO 9001 2008

NQA-Registration firm – Cert. No. 169

Signature of Manufacturer: Tony Higginson Date: 25/05/18

Position of Signatory: Head of Engineering

File: Crestchic Original

Customers Copy

Form Issue Date Authorised Sheet No. 2nd Avenue, Centrum 100, Burton-on-Trent, Staffs. U.K.
CF091 11 18.02.14 M.W.B 1 of 1 Tel. +44 (0) 1283 531645 Fax. +44 (0) 1283 510103
 E.C. DECLARATION OF CONFORMITY
Herewith we declare that the load proving equipment designated below, on the
basis of its design and construction, in the form brought on to the market by us,
is in accordance with the relevant safety and health requirements of the EC
Council Directive on electrical equipment. If modifications are made to the
equipment without prior consultations with us, this declaration becomes invalid.

Designation of Equipment: Loadbanks

Type: Resistive, Reactive, D.C.

Relevant EC Council Directive: Machinery Directive 2006/42/EC

Applied National Standards: BS EN 60204-1-2006

Basis of self attestation: Quality Assurance BS EN ISO 9001 2008

NQA Registration firm – Cert. No. 169

Signature of Manufacturer: Tony Higginson Date: 25/05/18

Position of Signatory: Head of Engineering

File: Crestchic Original

Customers Copy

Form Issue Date Authorised Sheet No. 2nd Avenue, Centrum 100, Burton-on-Trent, Staffs. U.K.
CF092 10 18.02.14 M.W.B 1 of 1 Tel. +44 (0) 1283 531645 Fax. +44 (0) 1283 510103
16. END OF LIFE PRODUCT RECYCLING AND DISPOSAL

With proper maintenance Crestchic Loadbanks can be used reliably for many years. We
offer a service department who can provide spare parts, maintenance and upgrades for
all our loadbanks.

Please contact service@crestchic.co.uk for further details.

If the loadbank is no longer economical to maintain it can be decommissioned for

disposal. Crestchic can provide this service if the loadbank is returned to our Head Office
in Burton upon Trent and will disassemble the loadbank for correct recycling and disposal.

If you require to dispose of the loadbank locally all the components can be unbolted from
the enclosure and separated for recycling.

The main metalwork components of the loadbank are:

• Enclosure: Mild Steel or Stainless Steel.

• Copper busbar.

The main electrical components of the loadbank are:

• Elements: Stainless Steel finning surrounding stainless steel tubing filled

magnesium oxide and 80/20 nickel chrome resistance wire, and ceramic
bushes.
• Reactors: Copper or aluminium wire wound around an iron core and insulating
material.
• Cables and electrical connectors.
• Electronic control equipment including; Transformers, Fuses, Contactors,
Relays and Switches.
• Printed Circuit Boards.

These devices can be recycled due to their low pollutant content.

It is the responsibility of the loadbank owner to ensure that disposal is carried out in
accordance with local regulations. For environmentally friendly recycling and disposal of
your electronic waste, please contact a local company certified for the disposal of
electronic waste.

Loadbank Serial No: C6416