LOAD BANK
PART NUMBER 2004297/2004298
OPERATIONS AND MAINTENANCE MANUAL
Prepared by:
5455 N River RD W
Geneva, OH 44041
Phone: 1-800-969-8527
TechSupport@get-psi.com
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TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 SAFETY CONSIDERATIONS
3.0 CONNECTION PROCEDURE
4.0 OPERATING PROCEDURES
5.0 SPECIFICATION
6.0 MAINTENANCE PROCEDURES
7.0 FAULT FINDING
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1.0 INTRODUCTION
The 2004297/2004298 30kw load bank is designed for applying load for testing or to
prevent wet-stacking on a Diesel Engine Generator Set (DEG). It is designed to operate
on 208VAC at 60Hz. The unit is comprised of pre-set, force air cooled, high powered
resistor elements.
Safety features include internal fuse protection, fan motor overload protection, and
auxiliary circuit protection. The load bank is force air cooled by a three phase powered
fan which is internally connected to the 3 phase load circuit, which represents a
permanent load while the unit is in use. The enclosure is designed for outdoor use.
2.0 SAFETY CONSIDERATIONS
1. The load bank is designed for indoor or outdoor use.
2. The unit should only be operated by competent electrical engineers who are
completely familiar with the operation and specification of the load bank.
3. The equipment is designed for AC operation only.
4. Operators must ensure that interconnecting cables are correctly rated to carry the
required load current and adequately insulated to prevent the possibility of electric
shock when operating at high voltages.
5. When in use the load bank should be isolated using safety barriers.
6. The load bank should only be operated in an area with adequate ventilation.
7. Care should be taken as the exhaust air outlet will be hot during operation.
8. Cables must be positioned away from the air exhaust.
9. During operation the load bank should not be covered or positioned to restrict air
flow.
10. Caution – some metal surfaces will be hot during operation
11. At the end of any test the fans should be kept running for 5 – 10 minutes at no load
to remove the residual heat from the load bank case and elements.
12. There is a Power Distribution Block (PDB) located in the unit to permit the load
cable to be hardwired to the load bank.
3.0 CONNECTION PROCEDURE
1. Ensure the power source to be tested is compatible with the load bank operating
voltage.
2. Ensure the power source is de-engaged.
3. Do not attempt to operate the load bank above the maximum operating voltage.
4. Check that all panel mounted control switches are in the OFF position.
5. Connect phase A, B and C to L1, L2 and L3 respectively and connect the Neutral and
Ground to the corresponding positions on the PDB in the load bank.
6. Connect cable to power source.
4.0 OPERATING INSTRUCTIONS
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Operators should read the SAFETY CONSIDERATIONS and CONNECTION
PROCEDURE before carrying out the following operating instructions.
1. Ensure all panels are in place on the load bank.
2. Ensure all panel mounted switches are in the OFF position.
3. Energize the power source from the generator.
4. Switch on the panel mounted toggle switch.
5. Ensure the fan rotates in correct direction with exhaust air being expelled from the
exhaust grill. If the fan rotates incorrectly the cables have been connected in the
wrong phase rotation and the following procedure should be performed.
a) Disconnect and isolated the power source.
b) Change over any two phase connections
c) Continue the operating procedure from 1 above
6. During running mode the load can be adjusted by moving the toggle switches to on.
There is a 10kw load step and a 20kw load step. There is an indicator light that
illuminates when the load step is activated.
7. Do not exceed the maximum rating of the load bank.
8. At the end of use switch the load bank to fan only (off load) for between 5 and 10
minutes to cool the resistor elements.
9. Isolate the generator power source.
10. DO NOT remove the power circuit with the load circuit energized.
5.0 SPECIFICATION
Part Number:
Max operating voltage:
Max current rating:
Max power rating:
Connection:
Resistor tolerance:
Operating ambient temperature:
Storage ambient temperature:
2004297/2004298
208V three phase 60 Hz
100A per phase
30 KW
1 five point PDB for hardwired connection
+/-5%
-40 to +55 deg C
-40 to +60 deg C
Dimensions
Length...20.75 in
Width….23.37 in
Height…23.13 in
6.0 MAINTENANCE PROCEDURES
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The load bank should not require any special maintenance; however as with any
electrical equipment periodic checks should be carried out to ensure the equipment
is in a safe and satisfactory condition.
The following periodic checks are recommended on the load bank;
1) Check the inlet and outlet grills are free from obstruction or debris.
2) Check that the controls and terminals are undamaged and secure.
3) Check the fan rotates freely without resistance.
4) Check connection cables are undamaged.
7.0 FAULT FINDING PROCEDURES
The following fault finding procedure is intended to identify simple operational errors and
has been categorized into possible problem areas as follows;
Note: Isolate the load bank from any power source before removing any covers.
Testing the load bank with the covers removed is not recommended as high
voltages can be present on power resistors or terminals.
Repair or replacement should be carried out by the manufacturer or trained
personnel at the direction of the manufacturer.
Issue/Symptom
Cause
Solution
Cooling Fan not operational
Fan contactor faulty.
Check to see that control voltage is
coming into the contactor and that all
three phases of power are also available.
If the contactor engages the problem is
elsewhere. If not replace the contactor.
Circuit breaker not closed.
Close the Circuit Breaker. If the breaker
will not close check for continuity to
ground. If continuity exists there is a
short, investigate that. If no continuity
exists replace the breaker.
Power coming to unit is not proper.
Ensure the power coming into the unit is
208 VAC 60Hz three phase with at least
100Amps supply.
Fan is faulty.
Replace the fan motor.
Fuse is blown.
Check and replace the fuse.
Loose Wire.
Inspect the system for a loose wire
connection.
Cause
Solution
Issue/Symptom
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Does not provide sufficient Load Current
Thermal Overload tripped
Check to see if S4 or S5 are open. If
there has been an over temperature
condition the overload may need to cool
before the unit will come back on line. If
no over temperature condition exists the
overload could be faulty. Isolate the
overload and check to see if it is closed at
room temperature (70F).It should be
closed, if not replace the overload.
Resistive element is open (faulty)
Isolate the element and check for
continuity. If there is no continuity the
element is faulty. If there is continuity
connect the wires and check at the top of
the resistive element to see if the proper
voltage is present. Check to see that
amperage is present with an Amp Clamp.
If amperage is present the element is ok.
Either load bank circuit breaker is off.
Contactor faulty.
Switch is faulty.
Indicator light not functional
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Engage the circuit breaker for the 10k or
20k. If the circuit breaker will not engage
check for a short in the system. If the
breaker will not close check for continuity
to ground. If continuity exists there is a
short, investigate that. If no continuity
exists replace the breaker.
Replace the contactor.
Replace the switch.
Loose Wire.
Inspect the system for a loose wire
connection.
The bulb is blown.
Replace the light.
The fuse is blown.
Check and replace the fuse.
Improper input power.
Restore input power to 208VAC 60Hz
three phase.
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