Loading up a 36kW transformer

[Yzordderrex]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run.. I looked at having some inductors wound, but that was about $4k. I've looked at custom load bank, also about $4k. I can run three electric water heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The eagle glo-coils are not manufactured anymore - what a shame. I've lookedat immersion heaters and also stuffing a 50 gallon drum with elements froma stove.

So far I like the electric water heaters the best. I can load to about 27kW and make up the rest with some big wirewounds I have kicking around. but looking for any alternate methods before I go to boss with the water heateridea.

Any ideas?

Bob

 

[Cydrome Leader]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run. I looked at having some inductors wound, but that was about $4k. I've looked at custom load bank, also about $4k. I can run three electric water heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The eagle glo-coils are not manufactured anymore - what a shame. I've looked at immersion heaters and also stuffing a 50 gallon drum with elements from a stove.

So far I like the electric water heaters the best. I can load to about 27kW and make up the rest with some big wirewounds I have kicking around. but looking for any alternate methods before I go to boss with the water heater idea.

Any ideas?

rent a load bank from a generator rental/testing company.

 

[Lasse Langwadt Christensen]

Den mandag den 7. oktober 2013 17.22.29 UTC+2 skrev Yzordderrex:

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run. I looked at having some inductors wound, but that was about $4k. I'velooked at custom load bank, also about $4k. I can run three electric water heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The eagle glo-coils are not manufactured anymore - what a shame. I've looked at immersion heaters and also stuffing a 50 gallon drum with elements from a stove.



So far I like the electric water heaters the best. I can load to about 27kW and make up the rest with some big wirewounds I have kicking around. but looking for any alternate methods before I go to boss with the water heater idea.



Any ideas?



Bob

a few of something like this?

http://www.harald-nyborg.dk/p7988/9kw-industrivarmeblaeser

-Lasse

 

[amdx]

rent a load bank from a generator rental/testing company.

I like the idea of buying three water heaters and doing a little
plumbing. Spend about $1200 and at the end of the job sell them for
$250 and it only cost you $450.
You might want to get 4 water heaters, reduce the amount of wire
wounds heating the room. I would put a valve on the input of each so you
can equalize the water flow, just to make sure one doesn't get starved.
Mikek

 

[Adrian Tuddenham]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat
run. I looked at having some inductors wound, but that was about $4k.
I've looked at custom load bank, also about $4k. I can run three electric
water heaters ($250.00 each)and discharge about 90 gals an hour of hot
water. The eagle glo-coils are not manufactured anymore - what a shame.
I've looked at immersion heaters and also stuffing a 50 gallon drum with
elements from a stove.

So far I like the electric water heaters the best. I can load to about
27kW and make up the rest with some big wirewounds I have kicking around.
but looking for any alternate methods before I go to boss with the water
heater idea.

With the secondary O/C, measure the temperature rise due to iron losses
with full primary volts and no secondary load

Then short the secondary and apply reduced primary volts from another
transformer to measure the temperature rise due to copper losses at full
current.

Then calculate the effect of both together.

 

[Artemus]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run. I looked at having
some inductors wound, but that was about $4k. I've looked at custom load bank, also about $4k. I
can run three electric water heaters ($250.00 each)and discharge about 90 gals an hour of hot water.
The eagle glo-coils are not manufactured anymore - what a shame. I've looked at immersion heaters
and also stuffing a 50 gallon drum with elements from a stove.

So far I like the electric water heaters the best. I can load to about 27kW and make up the rest
with some big wirewounds I have kicking around. but looking for any alternate methods before I go to
boss with the water heater idea.

Any ideas?

Bob

*********************
Clothes dryer elements are 240V and air cooled which may be
less work than plumbing the water heaters. They're certainly less
expensive.
Art

 

[tm]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run.
I looked at having some inductors wound, but that was about $4k. I've
looked at custom load bank, also about $4k. I can run three electric water
heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The
eagle glo-coils are not manufactured anymore - what a shame. I've looked at
immersion heaters and also stuffing a 50 gallon drum with elements from a
stove.

So far I like the electric water heaters the best. I can load to about 27kW
and make up the rest with some big wirewounds I have kicking around. but
looking for any alternate methods before I go to boss with the water heater
idea.

Any ideas?

Bob
++++++++++++++++++++++++++++++++++++++++==

How about using one 55 gal drum (open) with several 4.5 kW water heater
elements installed near the bottom. Just let it boil off the water and add
more if necessary. You could wrap insulation around it for safety and pipe
the steam outside.

tm

 

[Neon John]

So far I like the electric water heaters the best. I can load to about 27kW and make up the rest with some big wirewounds I have kicking around. but looking for any alternate methods before I go to boss with the water heater idea.

I'm currently working on the PFC controller for our next generation
induction heater. I load it at 20kW using stove eyes that I purchased
from Amazon. Each one is worth about 1.5kW and cost (if memory
doesn't fail me) less than $5.

I have them suspended on a wire strung between two poles right outside
my lab window. I hung them so the connectors were facing down to keep
the heat off the Teflon insulated wire that I used. In free air like
that and running just a little bit under-voltaged (two in series for a
400 VDC output), they get a dull red.

Other than a salt water bath, this was the cheapest thing I could come
up with.

John
John DeArmond
http://www.neon-john.com
http://www.fluxeon.com
Tellico Plains, Occupied TN
See website for email address

 

[tm]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run.
I looked at having some inductors wound, but that was about $4k. I've
looked at custom load bank, also about $4k. I can run three electric water
heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The
eagle glo-coils are not manufactured anymore - what a shame. I've looked at
immersion heaters and also stuffing a 50 gallon drum with elements from a
stove.

So far I like the electric water heaters the best. I can load to about 27kW
and make up the rest with some big wirewounds I have kicking around. but
looking for any alternate methods before I go to boss with the water heater
idea.

Any ideas?

Bob

++++++++++++++++++++++++++++++++++++++


Another way would be to use a duct heater and fan assembly. I thing any HVAC
supplier can supply what you need. I think they come in 15 kW steps.

 

[Martin Riddle]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run. I looked at having some inductors wound, but that was about $4k. I've looked at custom load bank, also about $4k. I can run three electric water heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The eagle glo-coils are not manufactured anymore - what a shame. I've looked at immersion heaters and also stuffing a 50 gallon drum with elements from a stove.

So far I like the electric water heaters the best. I can load to about 27kW and make up the rest with some big wirewounds I have kicking around. but looking for any alternate methods before I go to boss with the water heater idea.

Any ideas?

Bob

Too bad about the Eagle heaters, have used them in the past.

Toaster oven elements?
Electric stove elements?

I hate water and loads, but have seen water loads used.
The water heater may work as long as the thermal energy is extracted
from the tank. Which brings up the thought of on-demand heaters.
(might be what your thinking)

Cheers

 

[Joerg]

I need to load up a 36kW 3 phase 240v (output) transformer to do a
heat run. I looked at having some inductors wound, but that was
about $4k. I've looked at custom load bank, also about $4k. I can
run three electric water heaters ($250.00 each)and discharge about 90
gals an hour of hot water. The eagle glo-coils are not manufactured
anymore - what a shame. I've looked at immersion heaters and also
stuffing a 50 gallon drum with elements from a stove.

So far I like the electric water heaters the best. I can load to
about 27kW and make up the rest with some big wirewounds I have
kicking around. but looking for any alternate methods before I go to
boss with the water heater idea.

Any ideas?

If you luck out you may be able to find some 240V/10A stadium lamps on
an auction site. From a closed-down stadium they are often sold in bulk
for cheap.

Then you could really light up the place.

 

[legg]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run.
I looked at having some inductors wound, but that was about $4k. I've
looked at custom load bank, also about $4k. I can run three electric water
heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The
eagle glo-coils are not manufactured anymore - what a shame. I've looked at
immersion heaters and also stuffing a 50 gallon drum with elements from a
stove.

So far I like the electric water heaters the best. I can load to about 27kW
and make up the rest with some big wirewounds I have kicking around. but
looking for any alternate methods before I go to boss with the water heater
idea.

Any ideas?

Bob

++++++++++++++++++++++++++++++++++++++


Another way would be to use a duct heater and fan assembly. I thing any HVAC
supplier can supply what you need. I think they come in 15 kW steps.

Nichrome heating coil wire (.25in ID preformed) is also available at
about $6 a foot. Should be > double original length for heat transfer.
Coming up with a safe form that doesn't bankrupt you for ceramic
insulators will take some thought.

RL

 

[Phil Allison]

"Adrian Tuddenham"

With the secondary O/C, measure the temperature rise due to iron losses
with full primary volts and no secondary load

Then short the secondary and apply reduced primary volts from another
transformer to measure the temperature rise due to copper losses at full
current.

Then calculate the effect of both together.

** Cleary the smart way to do it - the temp rise in both cases should be
nearly the same.

The way to measure it is to note the fractional rise in primary resistance
and use the tempco of copper.

IOW: Internal temp rise = 256 times the fractional increase in primary R.

However, temp rise and power loss are not linearly related - the combined
effect will raise the temp less than the sum of the two rises.


.... Phil

 

[Glen Walpert]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat
run. I looked at having some inductors wound, but that was about $4k.
I've looked at custom load bank, also about $4k. I can run three
electric water heaters ($250.00 each)and discharge about 90 gals an hour
of hot water. The eagle glo-coils are not manufactured anymore - what a
shame. I've looked at immersion heaters and also stuffing a 50 gallon
drum with elements from a stove.

So far I like the electric water heaters the best. I can load to about
27kW and make up the rest with some big wirewounds I have kicking
around. but looking for any alternate methods before I go to boss with
the water heater idea.

Any ideas?

Bob

The water heaters are not a bad idea. You could do the same thing in a
much smaller space by skipping the big storage tanks and installing water
heater elements in pipe sections with tees on the ends, arranged to self
vent with a 90 GPH flow switch and contactor for low flow protection. 3
smaller elements on a 3-phase variac could be used for trim, and the
whole thing could be stuffed under a bench or on a shelf when done in
case you need it again.

 

[John S]

"Adrian Tuddenham"



** Cleary the smart way to do it - the temp rise in both cases should be
nearly the same.

The way to measure it is to note the fractional rise in primary resistance
and use the tempco of copper.

IOW: Internal temp rise = 256 times the fractional increase in primary R.

However, temp rise and power loss are not linearly related - the combined
effect will raise the temp less than the sum of the two rises.


... Phil

Even better! It provides some safety margin. I like it.

John S

 

[[email protected]]

I need to load up a 36kW 3 phase 240v (output) transformer to do a
heat run.

My electric kitchen stove says it is 11.8 kW at full load. As a bonus,
you wouldn't have to do any plumbing. Hit up the used appliance store?

Every HVAC shop will have some used electric furnaces kicking around.
If you swear that you aren't going to install it in a house again, they
might sell one to you for cheap. You do probably need to hook up the
blower motor so the elements don't melt. It will also probably have
time delay relays on some of the elements so the whole thing won't come
on at once; this may or may not be what you want.

If you have way more time than money, hit up the local junkyard and get
every sealed-beam headlight you can. The high beams are usually about
65 W, so a string of 20 gets you a whopping 1.3 kW. (Tip: Don't try to
wire it so both the high beam and low beam are on; this will burn out
the lamp very quickly. I found this out when building a load bank this
way for a much smaller DC supply.) On the other hand, this gives you
control in 1.3 kW increments.

Matt Roberds

 

[Jasen Betts]

The water heaters are not a bad idea. You could do the same thing in a
much smaller space by skipping the big storage tanks and installing water
heater elements in pipe sections with tees on the ends, arranged to self
vent with a 90 GPH flow switch and contactor for low flow protection. 3
smaller elements on a 3-phase variac could be used for trim, and the
whole thing could be stuffed under a bench or on a shelf when done in
case you need it again.

water can absorb a lot more energy if you discharge it as steam.

 

[Syd Rumpo]

I need to load up a 36kW 3 phase 240v (output) transformer to do a heat run. I looked at having some inductors wound, but that was about $4k. I've looked at custom load bank, also about $4k. I can run three electric water heaters ($250.00 each)and discharge about 90 gals an hour of hot water. The eagle glo-coils are not manufactured anymore - what a shame. I've looked at immersion heaters and also stuffing a 50 gallon drum with elements from a stove.

So far I like the electric water heaters the best. I can load to about 27kW and make up the rest with some big wirewounds I have kicking around. but looking for any alternate methods before I go to boss with the water heater idea.

Any ideas?

Bob

Water heaters is good, if you have water flow perhaps you could use
electric showers. They're often around 10kW each and can be bought
(here, at least) for < £100.

http://www.toolstation.com/shop/Taps+Showers/Electric+Showers/d240/sd3196

Cheers