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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. 
C:\Users\Service-Eng\Desktop\Mx\Manuals\ULB-R110 MANUAL_rev02.docx                                         Page 

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 of 

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INSTRUCTION MANUAL 

110KW PORTABLE 

 RESISTIVE LOAD BANK 

MODEL NO. ULB-R110-480-240-IP

Published by: 

Universal Load Banks, LLC. 

28200 Lakeview Drive 

Wixom, MI  48393

 

Customer Service: 

E-mail:  

[email protected]

Website: 

www.universalloadbanks.com

Phone:  248-

306

-

8011

 

Date of Original:

  2021 SEP 

Summary of Contents for ULB-R110-480-240-IP

Page 1: ...n 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 C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 1 of 42 INSTRUCTION MANUAL 110KW PORTABLE RESISTIVE LOAD BANK MODEL NO ULB R110 480 240 IP Published by Universal Load Banks LLC 28200 Lakeview Drive Wixom MI 48393 Custo...

Page 2: ...ying or disclosure by anyone without express written permission of ULB is not authorized and may result in criminal and or civil liability C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 2 of 42 LIST OF EFFECTIVE PAGES Insert latest changed pages and dispose of superseded pages in accordance with applicable regulations The total number of pages in this manual is approximatel...

Page 3: ...of 42 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 Component Maintenance Manual DC Direct Current Deg Degree DI Digital Input DMM Digital Multi meter DO Digital Output F Fahrenheit F S Full scale Ft lbs Foot pounds GND Ground HMI Human Machine Interface Hz Hert...

Page 4: ...OR ADJUST ALONE 5 SAFETY EARTH GROUND 5 CHEMICAL HAZARD 5 EMERGENCY AID 5 POTENTIALLY HAZARDOUS OPERATOR CONDITIONS 6 EMERGENCY SHUT DOWN 7 SAFETY SYMBOLS 8 INSPECTION AND UNPACKING 10 PRODUCT OVERVIEW 11 OPERATING INSTRUCTIONS 12 GENERAL 12 OPERATION 13 Safeties 14 Load Element status 15 POWER DATA 16 History data for Power Voltage Ampere 17 LOAD PROFILE 18 SINGLE PHASE OPERATION 21 OPERATING MUL...

Page 5: ...om Live Circuits Operating and Maintenance personnel must at all times observe normal safety regulations 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 Disconnect all sources of power to the Load Bank Main input load bus cooling fan circuit and 120 ...

Page 6: ...ld 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 load bank must be positioned to allow for a 4 foot intake clearance as well as a 20 foot exhaust clearance The unit sho...

Page 7: ... Page 7 of 42 Emergency Shut Down In a controlled emergency stop condition click LOAD DROP button on display allowing cooling fan to run while all load steps are disconnected Turn off and disconnect the main power source under test Disconnect all sources of power to the Load Bank Main input load bus and External 120 VAC control power Maintenance should always be done only by qualified personnel an...

Page 8: ... The 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 disassembly or service Main input Load Bus External 120 VAC control power WARNING Do not insert a screwdriver or any thin metal objects through the perforated cooling air grilles while the load bank is...

Page 9: ...Page 9 of 42 CAUTION Air enters through the right side cold air intake of the enclosure and exhausts at the left side hot air exhaust end of the enclosure Blocking these openings will cause overheating and unit failure CAUTION Do not apply more than the rated Voltage or exceed the power rating of the Load Bank Excessive power will damage the internal resistor banks CAUTION Confirm all control volt...

Page 10: ...t carefully for any shipping damage Check for loose broken or otherwise damaged parts due to shipping If damage is noticed do not unpack the unit Immediately notify ULB LLC and report any shipping damage to the freight carrier Be sure to verify that the part number and ratings listed on the nameplate match the order specification The ratings listed on the nameplate are critical installing operatin...

Page 11: ...controller which is connected to load bank by a supplied control cable assembly The load bank is portable unit with casters and handles hence it can be easily moved to the testing place Power connections plug in to Cam Lok Connectors provided on the load bank Use included power cord to connect 120VAC 60Hz power from 10A outlet plug to load bank s Control and cooling fan power circuits Load Circuit...

Page 12: ... Warnings should be strictly enforced CAUTION Operation of the unit with any covers removed will disrupt air flow and allow debris to pass through resistors possibly damaging equipment WARNING Operation of the unit with any covers removed will pose a shock hazard and danger to personnel WARNING Do not look into the exhaust of the enclosure while in operation Exhaust temperatures can reach temperat...

Page 13: ... CAM LOK connectors provided on the load bank using suitable mating CAM LOK plugs and cables sized per the NEC National Electric Code or any local codes The Load Bank is provided with color coded qty 01 CAM LOK connectors 400A Max for each phase L1 L2 L3 and One Connector for Ground Cable connection Load cable conductors from the power source to the load bank and mating CAM LOK cable plugs should ...

Page 14: ...o investigate SAFETY NOT OK status click SAFETY button on Main screen to see following screen see figure 2 Figure 2 Safety Parameters All load steps are disabled and load cannot be applied unless all above parameters are in OK status Green Color Following table show various alarm conditions and their settings See table 1 Sr no Alarm Conditions Settings Note 1 Over voltage at 480VAC 510VAC Settable...

Page 15: ...teps are disabled and load cannot be applied DO NOT attempt to bypass the over temperature switch as this will cause catastrophic damage to the unit Use HMI display touch screen to set require KW Minimum KW resolution that can be selected is 5KW Set desired time duration in Hours HR and Minutes MIN for which selected KW is to be applied Click LOAD APPLY button on Main Screen This action will start...

Page 16: ...nstitutes 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 C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 16 of 42 POWER DATA While load test is running following activities can be done from various screens on HMI 1 Power data display Click POWER DATA ...

Page 17: ... history data screen showing past history of Wattage see figure 5 Figure 5 History data Click Main Screen button to switch back to Main Screen Note If USB stick is inserted on USB port on the HMI display then SCREEN CAPTURE button will appear on various screens Click SCREEN CAPTURE button to copy screen image to USB Stick WARNING While Load bank is running with load applied condition setting Load ...

Page 18: ... civil liability C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 18 of 42 Load Profile Using this feature load bank can be configured to operate at various load condition for predetermined time Following are the steps to configure load profile 1 While load bank is not running click Load Profile button on main screen following screen will appear see figure 6 Figure 6 Load Pro...

Page 19: ...p 1 entry fields b ACTIVATE button will now change to DEACTIVATE meaning load profile run of load bank can be deactivated and hence applied load can be disconnected anytime by click on this button c Click BACK button to display main screen d Flashing LOAD PROFILE button on main screen indicates that load bank is operating with activated load profile Note Following buttons entries on main screen ar...

Page 20: ... 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 C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 20 of 42 WARNING Click Load Drop button any time will cut of all applied load and deactivate LOAD PROFILE Howev...

Page 21: ...of 42 Single phase operation Connect the power source under test to CAM LOK connectors provided on the load bank using suitable mating CAM LOK plugs and cables sized per the NEC National Electric Code or any local codes The Load Bank is provided with color coded qty 01 CAM LOK connectors 400A Max for each phase L1 L2 L3 and One Connector for Ground Cable connection Connect CAM LOK plugs to the Pha...

Page 22: ...te safety NOT OK status click SAFETY button on Main screen to see screen see figure 2 CAUTION DO NOT operate the Load Bank over rated nameplate Voltage as this will cause catastrophic failure The operation of the cooling fans circuit is critical for safe operation If over temp status is NOT OK then all load steps are disabled and load cannot be applied DO NOT attempt to bypass the over temperature...

Page 23: ...duration is over load will automatically disconnect and cooling fan will continue to run for pre set cooling time of 5 minutes OR as set in the Maintenance screen While load test is running following activities can be done from various screens on HMI 1 Power data display Click POWER DATA button on main screen and following power data screen will appear see below figure 10 Figure 10 Power data Sing...

Page 24: ...ool down period of the cooling fans circuit with no load applied should adequately remove any residual heat from the Load Bank and system components WARNING Click Load Drop button any time will cut of all applied load However cooling fan will continue to run until pre set cooling time is over Load Profile Operating Multiple load banks Powering up Master Salve load banks and data logging all these ...

Page 25: ...reen on the display 1 Each Load bank should have unique ID anywhere from 1 16 assigned 2 The First load bank in the network designated as Master load bank should have the lowest ID e g ID 1 if other slave load banks in network have ID 2 3 4 5 i e Slave 1 ID 2 Slave 2 ID 3 Slave 3 ID 4 and Slave 4 ID 5 3 See maintenance section below to know set ID or Master Slave mode for the load bank in the load...

Page 26: ...anuals ULB R110 MANUAL_rev02 docx Page 26 of 42 Slave 2 Next to Slave 1 Load bank should have following settings in above screen THIS LOAD BANK TO OPERATE AS SLAVE THIS LOAD BANK ID 3 Tip Next higher number from Slave 1 Load bank ID ID OF SLAVE 1 LOAD BANK Not applicable Slave 3 Next to Slave 2 Load bank should have following settings in above screen THIS LOAD BANK TO OPERATE AS SLAVE THIS LOAD BA...

Page 27: ...port of next load bank Slave 1 Similarly connect networking cable from out port of Slave 1 load bank to input port of Slave 2 Load bank Connect Slave 3 and Slave 4 in similar way 3 Make sure network resistor E544A located on TB1 inside each load bank are placed in line for Master and last slave in the network e g Slave 4 However this network resistor must be pulled out for any load bank between Ma...

Page 28: ...h 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 C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 28 of 42 Note Click SINGLE button will allow individual load bank operation with an option to operate in multiple load bank mode any time Figure 14 Master Slav...

Page 29: ...E OR MULTIPLE load banks operation choice screen see figure 15 Figure 15 Master Slave Operation WARNING Load bank should never be operated in Master Slave mode if any of the COMM Communication status indicator on above screen is NOT OK Investigation must be done to resolve communication problem 1 Available Capacity Total KW available from all the load banks in network i e for 5 x 110KW Load banks ...

Page 30: ...on will show following screen see figure 16 Figure 16 Data Logging 1 Click START LOGGING will start recording Set KW and ACT KW values for each load bank at every 10 seconds All values are stored in csv format file having following naming convention MultiLoad_MMDDYY_HHMMSS csv e g MultiLoad_052618_150159 csv 2 Click START LOGGING will also start recording following values of load bank in which USB...

Page 31: ...on 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 Bank over rated nameplate Voltage as this will cause catastrophic Failure and danger to personnel DO NOT apply DC voltages to main input load bus Refer to Safety section of this manual Safety and Shut Down Indicators Removing external 120 VAC control power disabl...

Page 32: ... screen Setting should be changed by only qualified person who clearly understands implication of changing each setting A pop up window will ask user to enter password Upon correct password entry following Set up Maintenance screen will appear see figure 17 Figure 17 Maintenance Screen On this screen following settings can be done 1 Fan Run Time after Load Drop Seconds Typically 300 Seconds 5 Minu...

Page 33: ...r disclosure by anyone without express written permission of ULB is not authorized and may result in criminal and or civil liability C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 33 of 42 Voltage Current settings Figure 18 Voltage and Current settings Click Previous Screen button on this screen to go back to Setup Maintenance Screen Click Load Bank Settings button on Setup...

Page 34: ...f power are completely disconnected before servicing Maintenance must always be done by qualified technician Maintenance procedures must be followed to provide longevity of equipment life and to reduce the probability of electric shock hazard fire personal injury or property damage Before servicing this equipment completely review the Safety Points and Potentially Hazardous Operator Conditions sec...

Page 35: ... Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 35 of 42 Daily Maintenance Prior to Operation 1 Inspect and remove any restrictions and or obstructions to cold air intake and hot air exhaust of the Load Bank unit 2 Check screens to make sure objects have not blocked entered openings 3 Verify the direction of the airflow is in the proper direction from cold air intake to hot air exh...

Page 36: ...es of tightness as required 5 Inspect all resistor elements ensuring all hardware is tightened 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 Replace any and all broken or cracked termination ceramics and ceramics on resistor support rods as required 7 I...

Page 37: ...ithout express written permission of ULB is not authorized and may result in criminal and or civil liability C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 37 of 42 CAUTION Do not pressure wash the inside component terminal compartment relay panel as damage may occur to electro mechanical load step relays cooling fan and control circuits safety circuits and terminal strip w...

Page 38: ...ors Ensure all fan and safety component connections are tight If required it is safe to blow any dust from this compartment using 40 PSI or less of clean dry compressed air Replace any broken or failed components Reinstall access panel cover before proceeding with any enclosure maintenance 3 If resistor elements are extremely dirty elements can be pressure washed Pressures up to 400 PSI at a dista...

Page 39: ...rection of airflow Over Temp switch or Over Temp auxiliary relay is malfunctioning or not operating correctly Loose or broken connection at temperature switch terminal blocks 6 Voltage detection fault on HMI Display Wrong 3phase input power 480 240VAC on CAM LOK connectors Input power voltage is higher or lower than allowed tolerances 7 Over voltage fault indication on HMI screen Input power volta...

Page 40: ...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 Power circuit fuses are blown Fuses and or circuit breaker trip settings are undersized ...

Page 41: ...e temperatures should remain 22 F to 122 F 30 C to 50 C Shipping Attach the enclosure to a skid constructed with minimum board thickness of two inches 2 to properly support the unit s weight Secure the load bank to the mounting skid make sure casters not touch to skid surface Secure all loose parts in the bottom of the enclosure and reinstall cover Pack Load bank with VPCI cover seal securely in a...

Page 42: ... 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 C Users Service Eng Desktop Mx Manuals ULB R110 MANUAL_rev02 docx Page 42 of 42 APPENDIX A ELECTRICAL SCHEMATICS See PDF file provided separately APPENDIX B BILL OF MATERIAL Provided upo...

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