50 Kva Power Unit

Technical Description

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 1 of 10

50 Kva Power Unit

Technical Description

50 Kva POWER UNIT

(TEMPERATURE CONTROLLER VERSION)
TECHNICAL DESCRIPTION
This unit provides a 60 Volt supply for powering various types of low voltage heating
elements. It can also serve as a 115 Volt source for use on elements or lights, heating
and power tools.

It consists of an natural air cooled 3 phase transformer contained in a wheeled robust

sheet steel case, it has incorporated the add-on contactorised control module for
control of the secondary output 6 channel control zones.

The output channels are controlled by means of energy regulators and temperature
controllers, but provision is made for external control from any suitable controller or
programmer.

Each channel has its own auto / manual switch so any combination of channels can
be operated either auto or manual.

The unit is protected against over current or over temperature conditions and has
provision for a remote workpiece over-temperature trip.

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 2 of 10

50 Kva Power Unit

Basic Specification

BASIC SPECIFICATION
PRIMARY -

TRANSFORMER

SECONDARY -

60V, 270A per phase

Star connected max load 50 kW

COOLING

Air Natural
Plus 120 cfm Fan for instruments

RATING

100 per cent up to max ambient 35C

INSULATION

Class H

PROTECTION

Over current 3 phase m.c.b.

Over temp. 3 phase m.c.b. with shunt trip
Workpiece over temp. remote to shunt trip

MAINS CONNECTION

The unit is complete with 5 meters of 4 core-armored cables.

LIFTING METHOD

Fork lift under base channels and 2 forged 200 kg lifting eyebolts

MOBILITY

2 fixed 200mm. Dia wheels at rear.

2 swivel castors 125mm dia at front.

ADD ON CONTROL MODULE

(6 Channel)

CONTROLS

6-110V Energy Regulators

1-Multi-pin socket for remote controllers or programmer.

(Standard)
(Remote)

380 / 415 / 480 V/ 525V 3 phase 50/60 Hz.

Delta connected, 50kVA

MODE SELECTION

6-Auto / Manual Switches

SWITCHING

6-200A, 110V coil solenoid switches

6-150A Thyristors

Contactorised
Solid State

INDICATORS

6-110V neon channel indicators

AUX SUPPLY

2 - 115V 5A fused sockets

INCORPORATED CONTROL
MODULE

(6 Channel)

CONTROLS

6 -110V Energy regulators

6 -110V P/D Temperature controllers
1-Multi-pin socket for remote controllers or programmer

(Standard)
(Remote)

MODE SELECTION

6 -Auto / Manual Switches

SWITCHING

6-200A, 110V coil solenoid switches (2 in parallel for each channel)

6-150A Thyristors (2 in parallel for each channel)

Contactorised
Solid State

INDICATORS

6-110V neon channel indicators

AUX SUPPLY

2-115V 5A fused sockets

DIMENSIONS (Complete Unit)

1,160 mm x 700 mm x 700mm

WEIGHT

343 kg

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 3 of 10

50 Kva Power Unit

Troubleshooting

50 kVA POWER UNIT

Operating Instructions: The Unit requires a 3 phase 3-wire supply with a good earth (ground) connection. The primary
armored cable cores are colored red, yellow, blue and green. The green core is earth (ground) and
should be connected on every occasion. As additional protection, the armored sheath should also be
earthed (grounded) by means of suitable cable gland clamps.
The size of the 3 phase supply varies according to the supply voltage and to operate the unit at 100
per cent output the following supplies will be required.
380 Volts 76 Amps : 415 Volts 70 Amps : 440 Volts 66 Amps : 480 Volts 60 Amps
Inspection and Check-out.
1)

On receipt check the unit for physical damage and put aside for an electrical check if the
case shows signs of damage.

2)

Remove the 4 screws and 2 eyebolts and lift the lid. Check for loose connections and
signs of damage. Check that earth (ground) bonding lead is tightly connected externally
between the transformer housing and add-on module.

3)

Remove cover on lower rear of unit and check that primary tapping board is connected for
correct supply voltage. A tapping board diagram is pasted in the cover. Replace cover and
lid.

4)

Connect the 4 core armored cable to a suitable fused supply isolator and switch on. Switch
on the unit by means of the molded case circuit breaker mounted on the front of the
transformer housing. Press the switch toggle downwards and then smartly up into the on
position. If there is an electrical fault the switch will immediately trip. In this case switch off
at the supply isolator and have electrician check the unit.

5)

With unit safety switched in, checked that the auto / manual switches, on the rear of the
unit, are in the manual position.
Set the temperature controller to a temperature well above ambient (approx. 100C will be
OK) and short out the thermocouple input socket on channel 1 by means of a
thermocouple shorting plug.

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 4 of 10

50 Kva Power Unit

Troubleshooting

Turn the energy regulator control knob full-on for channel 1.

Note: Off is 0; Full-on is 10.
The channel indicator light and the lower neon light on the temperature controller will flow
and in a contactorised unit, the contactor will be heard to close. If required a suitable Volt
meter, set for 0-100 volts ac can be used to test the output. It should read approximately
65 volts when connected between the 2 output welding connector sockets on the rear of
the unit.
Turn the energy regulator knob to off and the contactor should be heard to open and the
channel indicator light should turn off.
Turn on the energy regulator again to the full-on position and set the temperature
controller down to a temperature below ambient. The contactor should again be heard to
open and the channel indicator light and the lower neon light on the temperature controller
should be turn off.
Note : The energy regulator and the temperature controller on each channel are in series
on the output signal circuit so both devices need to be calling for heat before and output
signal can be detected.
Repeat the above operations for all the channels.
6)

With the unit switched on and all control knobs fully on. Switch the auto/manual switches
to Auto, the channel indicator neon should go off and on the contactorised unit , the
contactor should be heard to open. Switch back to the manual position and turn the
control knob to off. Switch-off the unit.

Setting Up for Operation

7)

Connect the main supply leads for each channel to be used into the pair of welding
connectors in the rear of the unit.
Note : Channel 1 to 6 run from right to left when viewed from the rear of the unit.
Remember that the transformer can supply a total load of 50 kW, therefore each phase
should be loaded to a maximum of 16 kW.
With a 3 channel unit this means 16kW per channel
With a 6 channel unit this means 8 kW per channel

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 5 of 10

50 Kva Power Unit

Troubleshooting

As a guide, with a 6 channel 60 Volt unit, each channel would normally have connected 3
60 Volt heating elements.
8)

Connect a type K thermocouple compensating or extension cable from the workpiece into
each of the channels required for operation, via a polarized type K thermocouple plug into
one of the pair of thermocouple sockets for each channel located on the rear of the unit.
If a chart record of the heat treatment is required, a signal to the chart recorder can be
provided by means of a compensating cable jumper lead from the second of the
thermocouple sockets for each channel. These sockets are connected in parallel internally.

9)

When the workpiece has been set up with the appropriate number of elements, turn the
relevant channel control knobs to full on and set the temperature controller to the
temperature required. With a clip-on ammeter, check that the correct amount of current is
flowing in the channel circuit. Each heating element takes 45 Amps, so a circuit with 3
elements connected should read 135 Amps on the ammeter. Any large variation from this
indicates a fault of some description. Check all the connections and elements. If the
current reads correctly, turn-off the channel control knob.

10)

When ready to commence the process, remember that you can use the energy regulators
in conjunction with the temperature controllers to obtain a very presentable heat treatment
without the effort and thermocouple chasing that can happened with purely manual heat
treatments. If the job is pre-heat only and there is no restriction on the rate of sire, then,
the energy regulator can be set to full-on and the temperature controller set to the
preheat temperature.
In a normal post weld heat treatment with a restricted rate of rise, set the temperature
controller to the soak temperature and set the energy regulator to a position which will gibe
the desired rate of rise. Choose a setting and then observe the recorder chart trace and
adjust the setting accordingly.
Note : Do not chase the trace. Allow time for the settings to settle down before making an
alteration.
In the case of post weld heat treatments of heavy sections, where a very low rate of
temperature rise is called for, or where the heat input is such that a slow heating rate is
inevitable, then it is often convenient to set the temperature controller in increments of say
25 degrees every so often when all the thermocouples are within specification.

11)

If the process is to be carried out in the auto mode. Connect the load as detailed to in
Paras 7 to 10 then connect the output from the controller or programmer to the Multi Pin
inlet socket on the rear of the unit. Switch the auto / manual switches to auto and initiate
the programme on the programmer or controller.

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 6 of 10

50 Kva Power Unit

Troubleshooting

(See operating instructions for the auto programmer)

Check that the channel indicator lights glow when programmer calls for heat.
Note :
A mixture of auto and manually controlled channels is possible on each unit simply by
switching the auto / manual switches to the desired mode.
If the external programmer or controller develops a fault, the process can still be
completed manually.
12)

On sites where conditions of high humidity lead to condensation inside the unit, it is
advisable to leave the power supply to the unit switched on when not in use. The no load
losses, which amount to approximately 450 Watts, will be sufficient to help to reduce
condensation problems to a minimum.

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 7 of 10

50 Kva Power Unit

Troubleshooting

MAINTENANCE AND FAULT FINDING ON HEAT TREATMENT

TRANSFORMER UNIT
1)

Electrical equipment is used on construction sites is subject to more risk of damage than
similar equipment in a workshop environment, so site equipment should have frequent
visual checks for physical damage, to case, control equipment and supply cable.

2)

Ensure electrical equipment is installed and tested in accordance with the local national
electrical code. A grounding stud is fitted to the unit, this must be bonded to ground by an
adequately sized grounding cable.

3)

All electrical equipment must receive regular maintenance and inspections, the frequency
of inspections will depend on site conditions and amount of time unit is in use, in average
use an internal inspection should be made three times a year to ensure there are no
visible signs of overheating, equipment having moved or cable connections fraying, a
very thorough inspection and test is to be made once a year.

4)

Yearly Check
a)

Electrically isolate the unit by switching off the M.C.B, also disconnect the
supply at the main service switch, the main service switch should be locked.

b)

Disconnected all outgoing cable connections from the units.

c)

Use a clean small brush to clean dust out from internal surfaces especially
insulating material, use a low pressure air line to blow out the interior of the
transformer core and to remove all dust from the unit interior.

d)

Check all electrical connections for tightness and inspect all instrumentation
and control circuits wiring.

e)

If unit is contactorised inspect and if necessary, replace contacts, do not file or

clean contact tips.

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 8 of 10

50 Kva Power Unit

f)

Troubleshooting

If thyristor unit, ensure air ways in heat sink are clear and ensure any
accumulations of dirt and dust are removed from the thyristor device.

g)

Check condition of the panel mounted camlock sockets in the unit, ensure that
connectors are securely fastened; any damaged or burnt connector must be
replaced.

h)

Check all outgoing male connectors, tighten all connections, replace any
damaged or burnt connectors or sleeves, and reconnect all plugs.

i)

Reconnect mains power to unit and carry out commissioning instructions as

the operating procedure.

5)

Fault Finding
Fault finding should be undertaken by a competent electrician who is experienced in
maintenance of electrical machines and transformers.
a. Switch off main M.C.B, disconnect all outgoing connectors
Switch on main M.C.B and check as operating instructions.
b. No output voltage at 65V Camlock Sockets

6)

1)

Faulty mains supply

2)

Faulty contactor could or rectifier (contactorised unit)

3)

Faulty thyristor / trigger / blown thyristor protection fuse Thyristor Unit

4)

Transformer failure

5)

Faulty 110V control circuit

6)

Faulty energy regulator

Transformer M.C.B Trips

1) Transformer failure (shorted or burnt out)
2) Thermostats faulty or tripped due to overheating
3) Shunt trip faulty

7)

No 110 A/C control or auxiliary power

1) Faulty supply
2) Transformer failure
3) Broken connection

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 9 of 10

50 Kva Power Unit

Troubleshooting

4) Blown fuses

8)

Unit checks out satisfactory

If unit checks out it must be assumed fault is in heat treatment set up.

Heat Treatment will not reach set point

1) Test all elements are working correctly be checking with tong test ammeter.
2) Test recorder/ programmer for calibration
3) Check if there are enough heaters on workpiece to raise job to selected temperature,
check heaters and insulation are correctly fitted with no air gaps.

4) Check compensating leads and thermocouples.

Job temperature rising too high
1) Check zoning of thermocouples is correct
2) Contactor stuck in
3) Faulty thyristor or trigger unit
4) Thermocouple connections are not reversed or loose.

50 kva transformer

Primary tapping board

Secondary Tapping board

Lifting bar extension

Folded lid

Eyebolts

Sheet steel case

Nylon Castors

Armored cable

10

Cable Gland

11

Overtemp stat

12

Tapping Access plate

13

Front Wheel

14

Self Tapping Screws

ETL Trade Ltd

8/F Block B Veristrong Industrial Centre, 34-36 Au Pui Wan Street, Fotan, Hong Kong
Tel : (852) 26958318 Fax : (852) 26953944
Email : info@etl-trade.com Web Site : www.etl-trade.com
Page 10 of 10