Wanting to build electrical test bench

[gk351]

Hello all,

I'm wanting to build an electrical test bench for our shop. We primarily test substation relays, circuit breakers (molded case- MV voltage), motors. Just about anything really. My co workers were thinking we would need voltage "ports" where we could use test leads for 120, 208, 240, 277, and 480V. We didnt know if we should mount this on phenolic board, etc. Im not sure we could make this portable, but we have the space to build one, and the power to facilitate all voltages. Does anyone have any photos of one they made and would be willing to share. Thanks again.

 

[big john]

Depending on what equipment you've got to test and how much money you're willing to spend, you might just want to nix the portability idea right up front, it will free you to focus on capability and cost-cutting.

I'll get some pictures of our permanently mounted test panels when I go into work. They're just built in big NEMA 1 boxes. They need to be able to supply about 7kVA because of the size of some of the starters we work on, and the weight of the autotransformers and contactors for such a system adds up fast.

For small 125VDC/120VAC stuff we just carry little switched rectifier boxes that plug into the wall, and honestly, those work for at least half of all our testing.

 

[mgookin]

Hello all,

I'm wanting to build an electrical test bench for our shop. We primarily test substation relays, circuit breakers (molded case- MV voltage), motors. Just about anything really. My co workers were thinking we would need voltage "ports" where we could use test leads for 120, 208, 240, 277, and 480V. We didnt know if we should mount this on phenolic board, etc. Im not sure we could make this portable, but we have the space to build one, and the power to facilitate all voltages. Does anyone have any photos of one they made and would be willing to share. Thanks again.

I think the motors is going to be your controlling factor. We use an AC power source to replicate any grid on earth; any voltage and any frequency but limited power (1.5kw). You may need a few sources. I'm thinking a variac, a power source and a 3 phase supply if you're doing substation equipment testing.

 

[gk351]

Thanks for some ideas. I believe we have decided that we will not go for a portable option. My idea so far is to buy some sheet phenolic board (4'x8') and go from there. I was thinking about taking wire duct and wrapping around the board (kind of like an upside down U) and that can be the surround that can house my wires, and then feed my all my test ports (whatever they may be, still deciding) If you have photos, that would be great!