Utility Solutions XFMR-3BUSHING User manual

Phone (828)323-8914

Fax (828)323-8410

Email [email protected]

Web www.utilitysolutionsinc.com

101 33rd Street Drive SE · Hickory, NC 28602

Load-Trainer

Transformer Simulator

XFMR-3BUSHING Three Bushing Transformer Simulator

C-00879 XFMR-3BUSHING

(11-11-15)

Operation Manual

Product Description 2

Components 3

Set-Up 4

Simulator Description 4

Front Panel Description 5

Toggle Switches 6

Operation 8

Examples 8

Vector Application 19

Transformer Backfeed 19

Parallel Phases 19

Polarity 19

Polarity Example 20

Warranty 20

CONTENTS

C-00879 XFMR-3BUSHING

(11-11-15)

Product Description

The LOAD-TRAINER Transformer Simulator is a fully functional electrical trainer allowing simulation

of most distribution transformer connection schemes. This device contains actual transformers that

completely duplicate in-eld situations.

The power unit’s components are not rated for continuous duty and may heat up during prolonged

use.

The power unit should not be on for extended periods of time and should only be on when

taking voltage readings.

In addition to reduce the risk of electrical shocks, re, etc.:

• Do not remove screws, covers or cabinet. Refer servicing to qualied

personnel.

• Do not expose this device to rain, moisture or combustible materials.

• Select a place that is level, dry and between 41°F and 95°F. Do not place either

unit on a heat generating object.

• Avoid a dusty place or a place subject to vibrations.

• The power cord supplied is congured and rated for standard 120 Volt,

10 Amp receptacles. It is to be used as a disconnect for this device by

unplugging the power cord from the receptacle.

! !

WARNING

Carefully read and fully understand this manual prior to

operating, maintaining or testing this device. Improper

operation, handling or maintenance of this device can result

in death, grievous personal injury and or equipment damage.

! !

WARNING

is unit can exceed 400 volts in certain congurations. Use caution

and treat ALL components and jumpers as if handling live conductors.

! !

WARNING

e unit should NOT be running during hook-up or conguration.

C-00879 XFMR-3BUSHING

(11-11-15)

Components

Product Line

XFMR-3BUSHING LOAD-TRAINER THREE BUSHING TRANSFORMER SIMULATOR

XFMR-4BUSHING LOAD-TRAINER FOUR BUSHING TRANSFORMER SIMULATOR

XFMR-PRM PHASE ROTATION METER

XFMR-LEADS ASSORTMENT OF EXTRA BANANA LEADS

XFMR-3BUSHING-PRL ADDITIONAL THREE BUSHING FRONT PANEL

XFMR-4BUSHING-PRL ADDITIONAL FOUR BUSHING FRONT PANEL

Front PanelPower Supply

Multiple-conductor

Cord

Shipping Cases

Power Cord

Patch Cords

Qty Description

1 Front Panel (Large Shipping Case)

1 Power Supply (Small Shipping Case)

1 Multiple-conductor cord with polarized plug (Green)

1 120 Volt, AC Power Cord (Black)

812” red ‘pin’ patch cords

312” black ‘pin’ patch cords

44” black ‘banana’ patch cords

512” red ‘banana’ patch cords

512” black ‘banana’ patch cords

C-00879 XFMR-3BUSHING

(11-11-15)

Simulator Description

Simulation of Three-Phase power is created by an electric motor and a 120-to-20 Volt transformer.

The motor is coupled to an alternator that provides a three-phase, four-wire output. The 20 Volt output

of the transformer is rectied and used to excite the rotor of the alternator. A rheostat on the Front

Panel provides ne tuning over the output of the alternator. When the rheostat knob is pointed toward

the word ‘DELTA’ the output voltage of the alternator is approximately seven (7) Volts phase-to-phase

(VPP). When the knob points to ‘WYE’ the output voltage is approximately seven (7) Volts phase-to-

neutral (VPN). See Equation below.

WYE = VPP = √3 • VPN = DELTA

Hence: WYE = VPP = √3 • 7 Volts

WYE = VPP ≈ 12 Volts

It is for this reason that a Delta connected primary wired to a WYE system voltage can produce

secondary voltages much higher than expected. In addition it may be necessary to ne-tune the

rheostat occasionally to obtain the desired voltage output from the transformers.

Set-Up

The Load-Trainer requires two components to operate; the Front Panel (located in

the large shipping case) and the Power Supply (located in the small shipping case).

The Front Panel may be removed from its shipping case and set on a desk or table

using the built-in easel. The Power Supply remains in its shipping case and will be

connected both to the Front Panel and to an electrical wall outlet.

Check that the protective panel on the power supply is in place and the screws are

securely fastened. This Power Supply case should be clear of all other items and

lying at on a level surface with the lid off for adequate ventilation.

PLEASE NOTE - The 120 volts are REAL and NOT simulated. You must use

caution whenever the unit is on. Never leave the unit on while unattended!

The unit should be on when measuring voltages and NEVER while removing

or installing patch cords. Components could OVERHEAT if left on for

extended periods a time!

1. Verify the “ON-OFF” switch on the Front Panel is in the “OFF” position.

1. Connect the green Multiple-conductor Cord to the Front Panel on the lower left hand corner. Turn

the threaded collar on the plug clockwise a single turn to secure it to the polarized receptacle.

2. Attach the black Power Cord to the Power Supply using the female end. Plug in the Power Cord to

a grounded AC outlet.

! !

WARNING

Never leave the unit unattended while plugged in.

Always remove the black power cord when not in use.

C-00879 XFMR-3BUSHING

(11-11-15)

Front Panel Description

Three Phase Power System

The four lines at the top of the Front Panel represent a three-phase four-wire power system (A, B, C, N).

The tip jacks located on the lines are connected to buss bars within the panel and are protected by fast

acting thermal circuit breakers and disconnecting switches. The tip jacks are used to make connections

from the three-phase four-wire power system supply to the primaries of single-phase transformers.

Indicator Lights

An indicator light is to the right of each three-phase power line at the top of the Front Panel. This light

will indicate when the line is energized.

Disconnecting Switches

Each three-phase power line has a toggle switch to the right of the indicator light on the Front Panel.

Power can be controlled to each line separately.

Circuit Breakers

Fast acting thermal circuit breakers are included on each of the three-phase power lines at the top of

the Front Panel and function as fuses for accurate simulations. Simply press the circuit breaker to reset.

Transformer Inputs

Three transformer outlines in the middle of the Front Panel use red input terminals (H1 and H2) which

connect to actual transformers located behind the panel. These connections are made using the Pin

Patch Cords (small metal ends). The plugs can be stacked, if desired.

Transformer Outputs

Each transformer has three black unlabeled output terminals. They can be thought of as X1, X2 and X3

from right to left respectively, where X2 is neutral in a 120/240 Volt transformer.

Load Lines

The lines at the bottom of the Front Panel represent load lines (N, L1, L2, L3). Connections between the

transformer output terminals and the load lines are made using the Banana Patch Cords (large metal

ends). These can be stacked if desired.

AC Meter

An AC meter is on the lower right of the Front Panel and is used to measure the transformer’s output.

Tip jacks utilize Banana Patch Cords connected through the load lines or directly to a transformer.

Delta - Wye Rheostat Knob

A rheostat on the Front Panel provides ne tuning over the output of the alternator. It may be necessary

to ne-tune the rheostat to obtain the desired voltage output from the transformers. During Delta

conguration, the knob should be pointed to the left; while in Wye congurations the knob should be

pointing to the right. See Simulator Description for more information.

C-00879 XFMR-3BUSHING

(11-11-15)

The eight (8) Toggle Switches located on the left side of the Front Panel can be used by instructors to

simulate real-world scenarios that a student would have to diagnose.

The switches are labeled S1 through S8. The normal position of all switches is UP, toward the top of the unit.

Toggle Switches

Switch Description Transformer TOGGLE POSITION

UP MIDDLE DOWN

S1 Phase

Paralleling

Switch

A-B-C B-B-C*

S2 A-B-C A-B-B*

S3 Transformer

Ouput 1120 v (X3↔X2)

No Output (X2↔X1)

Open

(secondary)

120 v (X3↔X2, X2↔X1)

240 v (X3↔X1)

S4 Polarity

Switch 1Additive Subtractive

S5 Transformer

Ouput 2120 v (X3↔X2)

No Output (X2↔X1)

Open

(secondary)

120 v (X3↔X2, X2↔X1)

240 v (X3↔X1)

S6 Polarity

Switch 2Additive Subtractive

S7 Transformer

Ouput 3120 v (X3↔X2)

No Output (X2↔X1)

Open

(secondary)

120 v (X3↔X2, X2↔X1)

240 v (X3↔X1)

S8 Polarity

Switch 3 Additive Subtractive

*when both S1 & S2 are down phasing is B-B-B

H1H2

(additive)

DOWN

(subtractive)

Polarity Switches

(S4/S6/S8)

H1H2

MIDDLE

H1H2

Output Switches

(S3/S5/S7)

DOWN

H1H2

X1X2X3

X3X2X1

H1H2

X3X2X1X3X2X1X3X2X1

C-00879 XFMR-3BUSHING

(11-11-15)

Front Panel

Top of Unit

UP - ABC

DN - BBC

Transformer #1

UP – 120 X1-X2

CTR - 0

DN – 240 X1-X3

Transformer #2

UP – 120 X1-X2

CTR - 0

DN – 240 X1-X3

Transformer #3

UP – 120 X1-X2

CTR - 0

DN – 240 X1-X3

UP - ABC

DN - ABB

(S1 & S2 Both DN - BBB)

Transformer #1

UP - Additive Polarity

DN - Subtractive Polarity

Transformer #2

UP - Additive Polarity

DN - Subtractive Polarity

Transformer #3

UP - Additive Polarity

DN - Subtractive Polarity

Normal position of all switches is UP, toward the top of the unit.

Left Side of Front Panel

FIGURE 1: Toggle Switches

S2 S4 S6 S8

S1 S3 S5 S7

C-00879 XFMR-3BUSHING

(11-11-15)

Operation

The Load-Trainer Transformer Simulator has the capability to connect single-phase and the following

types of three-phase transformers:

Simple Single-Phase Transformer Connections

1. The system should be OFF and remain OFF except for observing voltage measurements on the AC

meter for short periods of time.

2. Be sure all 8 Toggle Switches are in the UP position for normal operation. Be sure all 3 Disconnecting

Switches are ‘ON’ and reset any tripped Circuit Breakers.

3. Using the red ‘pin’ tip patch cords connect a single-phase transformer to a DELTA system primary

as shown in Example 1.

4. Set rheostat pointer to ‘DELTA’.

5. Make output connections with the red and black banana patch cords bringing leads down to load

lines to a 120 Volt WYE secondary as shown in Example 1.

6. Turn the unit ON. The Power Supply will start and deliver the proper voltage to the transformer.

NOTE: The power unit should not be operated for extended periods of time. Run only when

taking voltage readings.

7. If connections have been properly made voltage should appear on the AC Meter. These readings

should be near normal for the transformer bank being made. Use the rheostat to make minor

adjustments.

8. Problems can be introduced after the installation has been shown to operate correctly. This is

done by the toggle switches on the left side of the Front Panel (see Figure 1) and at the instructors

discretion to simulate real world scenarios.

NOTE:

In certain congurations the actual measured device output voltage is greater than or less than the

expected voltage for a given simulation. The AC Meter has been scaled at the factory to compensate for

the differing output voltages. An independent meter device may display voltages that are not expected.

Delta-Delta

Delta-Wye

Open Delta-Open Delta

Wye-Delta

Wye-Wye

Wye (one leg out)-Open Delta

Examples

The following table summarizes the Connection Diagrams provided on the following pages:

Example Simulation

1 Single Phase Transformer w/ Delta Primary & 120 Volt Wye Secondary

2 Single Phase Transformer w/ Delta Primary & 120 Volt Delta Secondary

3 Single Phase Transformer w/ Delta Primary & 120/ 240 Volt Delta Secondary

4 Three Phase Transformer w/ Delta Primary & 120 / 208 Volt Wye Secondary

5 Three Phase Transformer w/ Delta Primary & 120 Volt Delta Secondary

6 Three Phase Transformer w/ Delta Primary & 120 / 240 Volt High Leg B Delta Secondary

7 Three Phase Transformer w/ Open Delta Primary & 120 Volt Open Delta Secondary

8 Three Phase Transformer w/ Wye Primary & 120 Volt Delta Secondary

9 Three Phase Transformer w/ Wye Primary & 120 / 208 Volt Wye Secondary

10 Three Phase Transformer w/ Wye (One Leg Out) & 120 Volt Open Delta Secondary

C-00879

(7-15-14)

Single Phase Transformer with Delta Primary

and 120 Volt Wye Secondary

Example 1

Toggle Switches: All in the UP Position

Rheostat Knob: Delta

Expected Meter Reading

Phase to Ground: 120 volts

Phase to Phase: 0 volts (not shown)

S2 S4 S6 S8

S1 S3 S5 S7

C-00879

(7-15-14)

Single Phase Transformer with Delta Primary

and 120 Volt Delta Secondary

Example 2

Toggle Switches: All in the UP Position

Rheostat Knob: Delta

Expected Meter Reading

Phase to Ground: 0 volts (not shown)

Phase to Phase: 120 volts

S2 S4 S6 S8

S1 S3 S5 S7

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