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use, copy or disclose this document or any information in it for any purpose without express written permission. Neither receipt from any source, 
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permission of ULB is not authorized and may result in criminal and/or civil liability. 

U:\ILB\5_Technical Manual\TLB-R1000-480-OS_NO ALL\TLB-R1000_480_MANUAL_Rev03.docx 

  

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  Over-Temp switch or Over-Temp auxiliary relay is malfunctioning or not operating correctly. 

  Air  switch  high  pressure  intake  tubing  obstruction.  Remove,  clean  and  replace  tubing  as 

necessary. 

 
6) Wrong Voltage Lamp Illuminated (dual voltage units). 

  Over  voltage  fault  indication  on  HMI  screen:    Input  power  voltage  is  higher  than  allowed 

tolerances. 

  Under  Voltage  /  Phase  Loss  /  Phase  reversal  fault  indication  on  HMI  display:  Input  power 

voltage is lower than allowed tolerances or one phase is missing or input phase is reversed. 

 
7) Load Dump On indication on HMI screen. 

  Indicates that all load steps are removed because load dump toggle switch is operated.  

 
8) Resistor Open or Phase Imbalance. 

  Blown load step fuse in branch load circuit (check and replace as necessary). 

  Loose  bus  bar  or  loose  connection  at  resistor  terminal  or  fuse  (tighten  all  bus  bar  and 

connection points as required). 

  Resistor element failure and burned open (replace as necessary).

 

 

9) Load Step or Load step application circuit cannot be energized. 

  Blower Failure, Air failure, Over-Temp, Wrong Voltage, Motor Overload, Load Dump, (see item 

2 thru 8 above). 

  Load Dump switch is operated. One or more of the branch circuit load step fuses for the load 

step in question is blown (check and replace as necessary). 

  One or more of the load step resistor for the load step in question has failed or burned open 

(check and replace as necessary). 

  Load step contactor has failed or is inoperative due to loose connection or failed-open coil. 

 
10) Load Step energized without rated load, or un-balanced load. 

  Applied main input bus voltage from power source under test is de-rated, low, imbalanced or 

inadequate. 

            Contactor failure or not closing properly. Loose connection. 

  One or more of the branch circuit load step fuses for the load step in question is blown (check 

and replace as necessary). 

  One or more of the load step resistor for the load step in question has failed or burned open 

(check and replace as necessary). 

 

11) Load Step contactor or relay chattering. 

  Contacts are pitted or oxidized. 

  Magnetic core and coil are dirty or corroded. 

  Coil connections to the contactor are loose. 

  120 VAC control circuit line voltage is low and/or inadequate. 

 

12) Switchgear Circuit Breaker trips or Main Disconnect fuses are blown. 

  Fuses and/or circuit breaker trip settings are undersized. 

  A short circuit exists at the Load Bank Resistor (main input load bus or blower circuit). 

  A short exists in the power conductors feeding the Load Bank Resistor. Note: When checking 

fuses for continuity, remove all fuses from fuse blocks, bus bars, fuse holders, and disconnect 
switch. Test each fuse individually and out of circuit. A blown fuse left in the circuit may check 
out OK with false reading of continuity due to feedback and return paths within the 

 

Summary of Contents for TLB-R1000-480-OS

Page 1: ...ession use copying or disclosure by anyone without express written permission of ULB is not authorized and may result in criminal and or civil liability U ILB 5_Technical Manual TLB R1000 480 OS_NO AL...

Page 2: ...sclosure by anyone without express written permission of ULB is not authorized and may result in criminal and or civil liability U ILB 5_Technical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_R...

Page 3: ...Page 3 of 35 ABBREVIATIONS AND ACRONYMS The following is a list of abbreviations and acronyms used throughout this manual A Amperes Amps AC Alternating current AI Analog Input AO Analog Output CMM Com...

Page 4: ...AY FROM LIVE CIRCUITS 5 SHOCK HAZARD 5 DO NOT SERVICE OR ADJUST ALONE 5 SAFETY EARTH GROUND 5 CHEMICAL HAZARD 5 EMERGENCY AID 5 POTENTIALLY HAZARDOUS OPERATOR CONDITIONS 5 EMERGENCY SHUT DOWN 6 SAFETY...

Page 5: ...Do not replace components or make adjustments to equipment with power turned on To avoid casualties always remove power to the entire system Turn off and disconnect the main power source under test D...

Page 6: ...ime after operation as these surfaces become hot and may result in a serious burn injury Never bypass any blown fuse Replace any indicator lamps on the operator control panel as required Each indicato...

Page 7: ...he following safety warnings appear in the text where there is danger to operating personnel They are noted and repeated here for emphasis WARNING Disconnect unit from all power sources before any dis...

Page 8: ...should occur after receiving the unit Periodic preventative maintenance and inspections should be performed to ensure system reliability Upon receipt of your Load Bank be sure to carefully unpack the...

Page 9: ...be used without the Fan Blower Motor operating Inadequate cooling airflow will result in resistor load elements overheating fire hazard and danger to personnel Operating Instructions General All insta...

Page 10: ...e NEC National Electric Code or any local codes Correctly sized copper compression lugs are recommended The Load Bank has three main input load bus bars marked L1 L2 and L3 Load cable connections are...

Page 11: ...L TLB R1000_480_MANUAL_Rev03 docx Page 11 of 35 Use HMI display touch screen to set require KW Minimum KW resolution that can be selected is 25KW Set desired time duration in Hours HR and Minutes MIN...

Page 12: ...ocx Page 12 of 35 Safeties Any alarm condition existing in the load bank is indicated by LOAD BANK SAFETY NOT OK indication on the top right corner of the main screen on HMI To investigate safety NOT...

Page 13: ...wer E stop Loss of control power or E stop is operated Table 1 All load steps are disabled and load cannot be applied unless all above parameters in OK status Green Color Note Ensure and check for pro...

Page 14: ...riminal and or civil liability U ILB 5_Technical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 14 of 35 Power data 1 Power data display Click POWER DATA button on main screen and...

Page 15: ...inal and or civil liability U ILB 5_Technical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 15 of 35 WARNING While Load bank is running with load applied condition setting Load D...

Page 16: ...l liability U ILB 5_Technical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 16 of 35 Load Profile Using this feature load bank can be configured to operate at various load condit...

Page 17: ...Fig 5 Load Profile 3 Enter require Hr Min and KW values for each step and click ACTIVATE button a Now Load bank will start operating with Hr Min and KW values selected for step 1 This will be indicate...

Page 18: ...hnical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 18 of 35 e Load bank will continue to operate at KW values Hr and Min selected for step 1 then after step 2 will be activated...

Page 19: ...al and or civil liability U ILB 5_Technical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 19 of 35 Operating Multiple Load banks Multiple load banks Max 5 can be operated in Mast...

Page 20: ...screen shown below Refer maintenance section below to know how to access this screen on the display 1 Each Load bank should have unique ID anywhere from 1 16 assigned 2 The First load bank in the net...

Page 21: ...bank should have following settings in above screen THIS LOAD BANK TO OPERATE AS SLAVE THIS LOAD BANK ID 4 Tip Next higher number from Slave 2 Load bank ID ID OF SLAVE 1 LOAD BANK Not applicable Slav...

Page 22: ...03 docx Page 22 of 35 Powering up Master Slave Load banks Note For master to identify all salves load banks master load bank should be powered up last i e power up all slave load banks first or all lo...

Page 23: ...permission Possession use copying or disclosure by anyone without express written permission of ULB is not authorized and may result in criminal and or civil liability U ILB 5_Technical Manual TLB R10...

Page 24: ...l TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 24 of 35 WARNING Load bank should never be operated in Master Slave mode if any of the COMM Communication status indicator on above scree...

Page 25: ...Page 25 of 35 Data Logging 1 Insert USB stick in USB port on the back of HMI display 2 Click DATA LOGGING button will show following screen See Fig 11 Fig 11 Data Logging 1 Click START LOGGING will s...

Page 26: ...closure by anyone without express written permission of ULB is not authorized and may result in criminal and or civil liability U ILB 5_Technical Manual TLB R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Re...

Page 27: ...circuits WARNING DO NOT touch the exhaust louver during operation Hot Air exhaust will cause serious burns DO NOT allow objects to enter or block air intake or exhaust louvers DO NOT operate the Load...

Page 28: ...his load bank WARNING Stop Load Test before entering in to this set up screen Setting should be changed by only qualified person who clearly understands implication of changing each setting A pop up w...

Page 29: ...injury from electrical shock or from moving fan blades could result unless all sources of power are completely disconnected before servicing Maintenance must always be done by qualified technician Ma...

Page 30: ...ened and elements are clear and free of debris 6 Inspect all resistors for mechanical and structural integrity and location Replace any excessive sagging resistor elements ceramics and support rods Re...

Page 31: ...jumper are tightened to 15 in lb and ceramic tubes spring bushings are tightened to 9 in lb Inspect all ceramic bushings and insulators for cracks Replace all broken or cracked ceramic insulators Ensu...

Page 32: ...ng coil or on operator control unit main power blower start stop pushbuttons Blower Motor fuse is blown check and replace as required Motor Over Load relay is tripped Motor starting relay failed Fan b...

Page 33: ...nnot be energized Blower Failure Air failure Over Temp Wrong Voltage Motor Overload Load Dump see item 2 thru 8 above Load Dump switch is operated One or more of the branch circuit load step fuses for...

Page 34: ...f time indoors cover the unit to prevent any accumulation or buildup of dust or dirt If stored outdoors do not cover with plastic that may create condensation and enclosure corrosion or staining keep...

Page 35: ...R1000 480 OS_NO ALL TLB R1000_480_MANUAL_Rev03 docx Page 35 of 35 Customer Service Any maintenance or service procedure beyond scope of those provided in this manual should be referred to a factory en...

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