LOAD BANK MANUAL
Model: PLB-330S9
Serial No S107
Date of mfg. November 2009
For service and information contact:
JP Power Technology Inc.
14225-129 Avenue
Edmonton, Alberta, T5L 4N9
Tel: 780-456-9167
Fax: 780-478-7135
www.jppowertechnology.ca
Page 1
General Information
• JP Power Technology Inc. load banks are air-cooled, definite purpose
contactor controlled systems consisting of fused coiled nichrome 60 wire
resistors.
• DC load banks are controlled by solid-state components.
• Load bank enclosures are fabricated out of aluminum for a lightweight,
corrosion free product. Painting of aluminum enclosures is optional, and steel
enclosures are available if a higher strength product is required. Steel
enclosures are powder coated.
• Components have been carefully chosen to provide a reliable and easy to use
product.
• Load banks are designed to allow easy servicing should repair be necessary.
• Load banks are cooled by an electric fan, which requires a separate power
source. As an option, this power source may be contained within the unit.
• Unit electrical ratings are provided in nameplate specifications or drawings.
Warnings
• Load banks emit large quantities of hot air that can reach up to 150˚C
(300˚F). Care must be taken to prevent personal injury or property
damage.
• Improper operation of load banks while connected to a power source can
cause serious damage or personal injury. Follow all applicable rules,
laws, and instructions when connecting and operating load banks.
• Ensure that all power sources are turned off before connecting load
banks.
• Non-weatherproof units must be placed in a dry and well-ventilated area.
Page 2
Setup
•
Connect the power source to be tested to the appropriate terminals on the load
bank. (See attached diagrams).
•
The load bank may or may not be phase sensitive. If a three-phase fan motor
is supplied, airflow direction must be verified.
• Connect a ground cable to the load bank ground connector. A lug marked
“GROUND” is provided on the load bank for one end of the ground cable.
The other end should be firmly connected to a suitable ground, such as a plant
ground bus, a metal water pipe, or a properly buried rod. The ground cable
should be rated for the capacity of the load bank.
• Ensure that cables are placed so that they are safe from being damage and do
not present a hazard.
• Prior to operation, check the load bank’s air intake for foreign objects.
Blockage can cause the unit to overheat and result in load test interruption.
• If the fan is interrupted (by a blow fuse or other means), the load contactors
will open. No damage to the load bank will occur, but the load test will be
interrupted until operation of the fan is regained and the “load on” button is
depressed.
Control Circuit
The following control equipment is provided with this load bank:
a)
b)
c)
d)
Selector switch “ON-OFF”
Illuminated pushbutton “Press to start test” indicator light (green)
Illuminated pushbutton “Press to stop test” indicator light (red)
Load increment switches
Operation
A circuit for sensing voltage is included with multi-voltage load banks and
will automatically select the correct configuration of contactors.
Page 3
• After establishing which load switches will be operated, the equipment can be
loaded by following these steps:
1. Establish output from the equipment being loaded according to the
manufacturer’s instructions.
2. Select “On-Off” to on.
3. Turn off all of the “step switches”.
4. Press “Start Test” (green) button.
5. Turn on the pre-determined “step switches”.
6. The equipment will now be loaded.
7. Increase or decrease the load by turning the appropriate load step
switches on or off as desired.
• The green light indicates that the load is being applied. Exercise caution
around the screen at the air discharge end, as the temperature can become
high enough to cause burns.
• It is also possible to “block load” the equipment by turning on the appropriate
number of step switches before the “Load On” button is pressed, however this
may cause an overload to some systems.
• Never leave the system unattended during load bank operation. Periodic
checks should be made of the load bank, the equipment being loaded, as well
as all cables and connections.
• After test completion, remove the load by pressing the “Load Off” button.
The fan should be left running until the discharge screen and components
have cooled.
• The following steps should be taken following completion of the test:
1.
2.
3.
4.
Turn off the power source
Disconnect the load and ground cables
Restore equipment to operational condition.
Store the load bank and cables in a dry area.
• If a problem occurs during operation (such as overheating or obstruction of
airflow), the load will automatically disconnect. The fan will continue to
operate. The equipment should be checked for any problems and corrected. If
the problem persists, the control circuit will not allow the load to be reapplied.
When conditions return to normal, the load bank will resume normal
operation.
• The following tables and formulas are provided to assist with calculations:
Page 4
a) Known
Rated KVA and Power Factor Rating for equipment
KW=KVA x Power factor
b) Known
Rated Voltage, Amps & Power Factor Rating for equipment
3
Phase
KW=1.732 x Volts x Amps x Power Factor
1000
Note:
The amperage listed on the equipment nameplate may not relate to unity
power factor loads. To use this figure it must be multiplied by the power
factor listed on the equipment nameplate.
Example:
Most AC alternators are rated at a power factor of 0.8. If the rated amperage
is listed as 100 amps on the alternator nameplate, multiply 100 by 0.8 to get
80 amps. 80 amps should be used when calculating the kilowatts.
Page 5
KILOWATTS AT UNITY POWER FACTOR
(1 PHASE AND DC)
AMPERE
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
24VDC
48VDC
0.24
0.48
0.72
0.96
1.20
1.44
1.68
1.92
2.16
2.40
2.64
2.88
3.12
3.36
3.60
3.84
4.08
4.32
4.56
4.80
5.04
5.28
5.52
5.76
6.00
6.24
6.48
6.72
6.96
7.20
7.44
7.68
7.92
8.16
8.40
8.64
8.88
9.12
9.36
9.60
9.84
10.08
10.32
10.56
10.80
11.04
11.28
11.52
11.76
12.00
0.48
0.96
1.44
1.92
2.40
2.88
3.36
3.84
4.32
4.80
5.28
5.76
6.24
6.72
7.20
7.68
8.16
8.64
9.12
9.60
10.08
10.56
11.04
11.52
12.00
12.48
12.96
13.44
13.92
14.40
14.88
15.36
15.84
16.32
16.80
17.28
17.76
18.24
18.72
19.20
19.68
20.16
20.64
21.12
21.60
22.08
22.56
23.04
23.52
24.00
120VAC
1.20
2.40
3.60
4.80
6.00
7.20
8.40
9.60
10.80
12.00
13.20
14.40
15.60
16.80
18.00
19.20
20.40
21.60
22.80
24.00
25.20
26.40
27.60
28.80
30.00
31.20
32.40
33.60
34.80
36.00
37.20
38.40
39.60
40.80
42.00
43.20
44.40
45.60
46.80
48.00
49.20
50.40
51.60
52.80
54.00
55.20
56.40
57.60
58.80
60.00
240VAC
2.40
4.80
7.20
9.60
12.00
14.40
16.80
19.20
21.60
24.00
26.40
28.80
31.20
33.60
36.00
38.40
40.80
43.20
45.60
48.00
50.40
52.80
55.20
57.60
60.00
62.40
64.80
67.20
69.60
72.00
74.40
76.80
79.20
81.60
84.00
86.40
88.80
91.20
93.60
96.00
98.40
100.80
103.20
105.60
108.00
110.40
112.80
115.20
117.60
120.00
480VAC
4.80
9.60
14.40
19.20
24.00
28.80
33.60
38.40
43.20
48.00
52.80
57.60
62.40
67.20
72.00
76.80
81.60
86.40
91.20
96.00
100.80
105.60
110.40
115.20
120.00
124.80
129.60
134.40
139.20
144.00
148.80
153.60
158.40
163.20
168.00
172.80
177.60
182.40
187.20
192.00
196.80
201.60
206.40
211.20
216.00
220.80
255.60
230.40
235.20
240.00
600VAC
6.00
12.00
18.00
24.00
30.00
36.00
42.00
48.00
54.00
60.00
66.00
72.00
78.00
84.00
90.00
96.00
102.00
108.00
114.00
120.00
126.00
132.00
138.00
144.00
150.00
156.00
162.00
168.00
174.00
180.00
186.00
192.00
198.00
204.00
210.00
216.00
222.00
228.00
234.00
240.00
246.00
252.00
258.00
264.00
270.00
276.00
282.00
288.00
294.00
300.00
Page 6
KILOWATTS AT UNITY POWER FACTOR
(3 PHASE)
AMPERE
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
208VAC
3.60
7.21
10.81
14.41
18.01
21.62
25.22
28.82
32.42
36.03
39.63
43.23
46.84
50.44
54.04
57.04
61.25
64.85
68.45
72.06
75.66
79.26
82.86
86.47
90.07
93.67
97.27
100.88
104.48
108.08
111.69
115.29
118.89
122.49
126.10
129.70
133.30
136.91
140.51
144.11
147.71
151.32
154.29
158.52
162.12
165.73
169.33
172.93
176.54
180.14
240VAC
4.16
8.31
12.47
16.63
20.79
24.94
29.10
33.26
37.41
41.57
45.73
49.88
54.04
58.20
62.36
66.51
70.67
74.83
78.98
83.14
87.30
91.45
95.61
99.77
103.93
108.08
112.24
116.04
120.55
124.71
128.87
133.03
137.18
141.34
145.50
149.65
153.81
157.97
162.12
166.28
170.44
174.60
178.75
182.91
187.07
191.22
195.38
199.54
203.69
207.85
440VAC
7.62
15.24
22.86
30.48
38.11
45.73
53.35
60.97
68.59
76.21
83.83
91.45
99.08
106.70
114.32
121.94
129.56
137.18
144.80
152.42
160.05
167.67
175029
182.91
190.53
198.15
205.77
213.39
221.02
228.64
236.26
243.88
251.50
259.12
266.74
274.36
281.99
289.61
297.23
304.85
312.47
320.09
327.71
335.33
342.96
350.58
358.20
365.82
373.44
381.06
460VAC
7.97
15.94
23.90
31.87
39.84
47.81
55.77
63.74
71.71
79.68
87.64
95.61
103.58
111.55
119.51
127.48
135.45
143.42
151.39
159.35
167.32
175.29
183.26
191.22
199.19
207.16
215.13
223.06
231.06
239.03
247.00
254.00
262.93
270.90
278.87
286.84
294.80
302.77
310.74
318.71
326.67
334.64
342.61
350.58
358.54
366.51
374.48
382.45
390.42
398.38
480VAC
8.31
16.63
24.94
33.26
41.57
49.88
58.20
66.51
74.83
83.14
91.45
99.77
108.08
116.40
124.71
133.03
141.34
149.65
157.97
166.28
174.60
182.91
191.22
199.54
207.85
216.17
224.48
232.79
241.11
249.42
257.74
266.05
274.36
282.68
290.99
299.31
307.62
315.94
324.25
332.56
340.88
349.19
357.51
365.82
374.13
382.45
390.76
399.08
407.39
415.70
600VAC
10.39
20.79
31.18
41.57
51.96
62.36
72.75
83.14
93.53
103.93
114.32
124.71
135.10
145.50
155.89
166.28
176.67
187.07
197.46
207.85
218.24
228.64
239.03
249.42
259.82
270.21
280.60
290.99
301.39
311.78
322.17
332.56
342.96
353.35
363.74
374.13
384.53
394.92
405.31
415.70
426.10
436.49
446.88
457.27
467.67
478.06
488.45
498.84
509.24
219.63
Page 7