background image

ULB PROPRIETARY RIGHTS NOTICE

 - This document contains the confidential and proprietary information of ULB. You may not possess, 

use, copy or disclose this document or any information in it for any purpose without express written permission. Neither receipt from any source, 
nor possession of this document, constitutes such 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-R1000-480-OS_NO ALL\TLB-R1000_480_MANUAL_Rev03.docx 

  

Page 

6

 of 

35

 

  Do not operate the unit unattended. Access to an approved electrical fire extinguisher should 

be on hand at all times. 

  Do  not  operate  the  Load  Bank  with  access  panels  removed  or  doors  open.  Doing  so  would 

expose personnel to potential injury from electrical shock or from a moving fan blade. 

  Careful  consideration  needs  to  be  taken  during  installation  and  equipment  location  during 

operation. -Hot exhaust air can cause damage to other installed equipment. 

  Do not direct hot exhaust air in the direction of other installed equipment? 

  Do not allow hot-air exhaust to recirculate through the cold-air intake. 

  Do not allow objects to enter or block the cold-air intake or hot-air exhaust. 

  Do  not  install  any  external  cold-air  intake  or  hot-air  exhaust  duct  work  to  the  Load  Bank  for 

ventilation.  

  The  Load  Bank must  be  installed  and  operated  in  a  cool,  well  ventilated  area  with  adequate 

clearance for both intake and  exhaust air. Do not allow hot air exhaust to recirculate into the 
cold-air intake. 

  The unit should always be operated outdoors in a clean, cool, well-ventilated area free of dust 

and debris. 

  Operating  personnel should  avoid  and  never  come in  contact  with  the  hot-air  exhaust  and/or 

surrounding  covers  during  operation  and  for  some-time  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  indicator  is 

important to the protection of the unit and safety of the operator, and is an indication of proper 
system operation or failure. 

  Do  not  bypass  any  safety  circuit  including  but  not  limited  to;  air-safety  switch,  fan  motor 

overload, exhaust over-temperature switch. 

  Always short/shunt current transformer secondary circuits when troubleshooting metering and 

instrumentation circuits. 

  Operating personnel should not come in contact with hot air exhaust opening, outside panels, 

system components, and load resistors for some time after operation.  

  A recommended 5 minute cool down period of the blower motor circuit, with no load applied is 

recommended as best practice and will protect operating personnel from possible burn injuries. 
A  5  minute  cool  down  should  adequately  remove  any  residual  heat from  the  Load  Bank  and 
system components.  

 
Emergency Shut-Down  
The Emergency STOP pushbutton will immediately turn off control power to the load step application 
circuits, blower motor circuits.  
In a controlled emergency stop condition, click <LOAD DROP> button on display allowing fan motor to 
run  while  all  load  steps  are  disconnected.  Turning  the  “Power  On”  switch  to  the  “OFF”  position  will 
then turn off all control and blower circuits. Turn off and disconnect the main-power source under test. 
Disconnect all sources of power to the Load Bank (Main input load bus), blower motor circuit, and 120 
VAC control circuits).  

  Maintenance should always be done only by qualified personnel and with all sources of power 

disconnected  from  the  unit  (main  input  load  bus  power,  power  to  all  blower  fan  and  control 
circuits). Always follow The National Electric Code (NEC), local electrical safety codes, and the 
Occupational  Safety  and  Health  Act  (OSHA)  when  handling,  installing,  and  operating 
equipment to reduce hazards, personal injury and property damage. 

 

 

 

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...

Reviews: