Eagle Eye Power Solutions LB-AC Series User manual

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LB-AC Series Automatic Load Banks
User Manual
1 Important Safety Instructions
●Please read the manual before and reference during use of the product
●The load bank should be kept and used in a clean, safe environment. This entails that
the product should be AWAY from environments such as high corrosive, acidic alkaline,
combustible, and explosive objects
● Make sure the area is clean and well-ventilated INDOORS. No obstructions are
allowed within 3-5 meters of the device. If outdoor operation is necessary, avoid having
the unit in sunlight, rain, wind, and any other adverse conditions
●Connect all cables correctly. This includes properly installing the ground terminal.
Power on the system only when all cables are properly secured
●Risk of electric shock, do not touch the elements inside the machine when powered on.
● In order to avoid overheating damage, electrical fan is required to continue running for
3-5 more minutes after load testing.
2 Product Overview
2.1 Introduction
Thank you for purchasing the LB-AC Automatic Load Bank from Eagle Eye Power
Solutions! Our systems will accurately test output power and load capacity with all kinds
of generators and generator sets, for each main electrical parameter including the
dynamic parameters tested. The following manual will describe the operation and
performance features of the LB-AC Series. If you have any questions or comment,
please contact us.

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2.2 Supply List
The following table lists the accessories provided with standard purchase.
Items
Quantity
Remarks
LB- AC Automatic Load Bank
1
Power Cord
2
3 meters (1 set 110V,
1set 220V)
RS485 Cable
1
10 meters
RS485/RS232/USB Converter
1
2.3 Technical Parameters
System Parameters
Load Voltage
208, 240, 380, 400, 415, 440, or 480 V
Load Power
10, 30, 40, 50, 100, 200, 300, 500, 800, or 1000 kW
Frequency
50/60 or 400 Hz
Wiring Options
Single Phase / 3 Phase 3 Wire / 3 Phase 4 Wire
Power Factor
1
Load Tolerance
(each step)
±5%
Load Tolerance
(overall)
±3%
Control Power
110/220 VAC single phase, 50/ 60 Hz
Wire Connection
Load bank input——busbar or terminal block
Control power input——3-pin plug or terminal block
Communication
Interface
RS232/ RS485
Insulation
F
Working Mode
Continuous Working
Cooling
Forced air, horizontal air intake and cooling
Transportation
Has lifting eyes and wheel castors
Operating Environment Parameters
Ambient
Temperature
-10℃ ～ +50℃
Relative Humidity
≤ 95%
Atmospheric
Pressure
86 ～ 106kPa
Brands of Main Components
Contactor
Schneider
Fuse
MIRO
PLC
Siemens
Multi-function Meter
QINGZHI (Model 3432B)

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2.4 Available Load Steps (Model Specific)
Available Load Steps (at rated voltage)
LB-10kW
4 Steps – 1, 2, 2, and 5 kW
LB-30kW
6 Steps – 1, 2, 2, 5, 10, and 10 kW
LB-40kW
6 Steps – 1, 2, 2, 5, 10, and 20 kW
LB-50kW
7 Steps – 1, 2, 2, 5, 10, 10, and 20 kW
LB-100kW
8 Steps – 1, 2, 2, 5, 10, 10, 20, and 50 kW
LB-200kW
7 Steps – 5, 5, 10, 10, 20, 50, and 100 kW
LB-300kW
8 Steps – 5, 5, 10, 10, 20, 50, 100, and 100 kW
LB-500kW
9 Steps – 5, 5, 10, 10, 20, 50, 100, 100, and 200 kW
LB-800kW
10 Steps – 5, 5, 10, 10, 20, 50, 100, 200, 200, and 200 kW
LB-1000kW
11 Steps – 5, 5, 10, 10, 20, 50, 100, 200, 200, 200, and 200 kW
2.5 Measuring Control Function
Load testing: Can provide load power up to the model’s rated power, test and display
stable state 3 phase voltage, current, active power, frequency, and working time of
generator sets.
Load/unload with one key: Whether manual control or software control, user can preset
the power, then press load master button. Loading is according to preset power to avoid
load fluctuation during the power changing.
Control Pattern: User can choose between local control and intelligent control.
Local control: There is a local control panel with several power steps available; user can
load/unload as necessary by these buttons.
Intelligent control: Through PC software, user can set automatic loads and display,
record, and manage testing data. User can also form curves, tables, and print reports.
Local meter display data: Displays 3 phase voltage, current, active power, frequency, etc.
2.6 Software Function
Communication pattern: The intelligent control uses a photoelectric isolated RS485
interface connected to PC with anti-interference technology to make system control
stable. Users can also use USB or RS232 through a converter.
Load pattern: Manual Load or Automatic Load.
Manual Load: System will load according to preset power.

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Automatic load: User can preset power and length of operation time for several load
periods.
Parallel testing: When load banks are used in parallel users can control the parallel test
using the software. User can display and record parameters of each load bank and
system parameters.
Real-time parameter: Through the software you can display voltage, current, power,
power factor, frequency, and time.
Security monitoring and control: Monitor working state of the load bank by watching
software light. When there is abnormal occurrence, the load will stop and protect from
damage. Stop reason will be shown.
Data collection interval: The minimum data storage interval is two seconds.
Data save and query: Test data is saved in the software which can be accessed in the
testing data history.
Graphical display: View and print real-time or historical testing data curves and graphs
as follows:
1) Graphs of real-time voltage, current, frequency and power
2) Voltage graph
3) Current graph
4) Power graph
5) Frequency graph
6) Power factor graph
Data format: All curves and graphs can be outputted as ‘.doc’ format. Testing data can be
outputted as ‘.xls’ format and can be printed.
2.7 Protection
Emergency stop: User can press the Emergency Stop switch in the panel and the load
bank will stop supplying current. When locked in this state the load/unload button cannot
be used.
Overvoltage protection: When input voltage is over the safe value, the load automatically
stops and gives an alarm.
Short circuit protection: When short circuit occurs, fuses in the load bank insure load
stops automatically.

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Overheating protection: When temperature is over the safe value, it can unload
automatically and give an alarm.
Fan interlock protection: When the fan is powered off, the load bank will not supply load.
Protection Buttons: There are buttons for some protection, when misinformation occurs
or user has special needs, user can temporarily turn off the corresponding protection
function to continue working.
When the control power cable is connected in incorrect phase sequence, the 3-phase fan
can still work in good condition.
3 Appearance
3.1 Overall Appearance*
*Load Bank size and appearance varies based on specific model.
3.2 Inspection
(1) Ventilation system: Verify all vents are operating without any obstructions.
(2) Switch interface: Check all switches and interfaces to ensure that the protection
switches are turned on and that there are no visible dangers with powering on.

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(3) Working conditions: Verify power supply, environment, and equipment is ready to
handle the load bank current.
3.3 Wiring Installation
(1) Ground: Connect one end of Earth grounding wire to ground terminal of load bank
and the other end to the work site grounding system.
(2) Test Cable: Connect the load cabinet wiring compartment load power input terminal
to output terminals of generator under test. Connect the end marked with a yellow sign to
input terminal phase L1, the other end to the output terminal of the device under test
phase L1. Connect phase L2 to green cable, L3 to red, and blue (or black) cable to N
phase.
(3) Power Lines: Connect one end of power line to power terminal of load bank, the other
end to power supply of 3 phase 50/60Hz at the rated voltage. The blue (or black) color
cable should be connected to null line (N) of power supply and load bank. And the yellow
color cable is connected to phase L1 of power supply and load bank; green cable to
phase L2, red cable to phase L3. Please make sure all the connections are correct and
tight before operating the system.
(4)Data Transmission Lines: Connect one end of the data transmission line to the
RS485 or RS232 interface on the LB-AC load bank. Connect the other end to a PC to
allow for communication through the software.
4 Local Control
4.1 Control Panel
(1) Measuring meter: Displays testing data.
(2)Fault indicator: In an alarm event, the red fault indicator lights up and the load bank
protection is active.
(3) Control mode selector: [Local] switch on for manual operation or switch to
[Intelligent] to operate via PC software. Two methods are mutually exclusive modes of
operation; please make sure the current operation mode is in accordance with the
corresponding mode.
(4) Fan power supply: Push to power on the fans (light will turn on).

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(5) Load/Unload: Master load switch, press to power on (light will turn on) and load bank
will load/unload according to preset power loading.
(6)Emergency Stop: In case of an emergency, press this switch to immediately stop all
loading. After resolving the issue, user may rotate the rotary switch clockwise to unlock
and resume loading.
(7) Power setting switches: Rating specific switches used to increase the load at
various increments, press the desired combination of switches to reach the total load
power needed, and press the < Load/Unload > to confirm and turn on.
4.2 Start
(1) Start the device to be tested: After all cables are properly connected turn on power
to the device ready for testing.
(2) Start the machine: Flip power switch on to turn on the machine. The unit can be
operated by either the control panel or PC.
(3) Start PC: For intelligent control, connect to PC and open the supporting data
management software on your computer.
4.3 Select Control
(1) Local control: The unit can switch between 2 kinds of operation by the < Control
Mode > in the control panel. When the switch is set to [Local], please use the control
panel to operate the machine.
(2) Intelligent Control: When the switch is set to [Intelligent] use the software to
control the machine.
(3) Control interlock: If the unit is not responding, it may be due to two interlocking
control settings, check whether the control mode is set correctly on both the unit and the
software. The rest of this chapter focuses on the local control method.
4.4 Load
(1) Start: Select local control mode and press < Fan Power Supply > on the panel to
start the fans. Please ensure the fan is working normally before proceeding.

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Attention: before starting fan, please make sure the dust cover on top of enclosure is
removed.
(2) Load: Calculate the total power which needs to be loaded, then press and combine
the power values needed (they will light up when pressed). Then push the
<Load/Unload > switch. The yellow indicator lights up and the machine loads in
accordance with the appropriate power level.
Example: Suppose you want to load 15 kW total. Press the control panel on the 5 kW &
10 kW switches to get to 15kW. Then press the <Load/Unload> switch.
If you need to change the loading power, please press the power setting switches
accordingly. You may re-combine load profile and press < Load/Unload > to begin
again.
Attention: To protect the system, please make sure any new load is not less than 70% of
the existing load.
(3) Stop: If you need to end the test, press < Load/Unload > and remove the entire load
via the power setting switches.
4.5 Data Display
(1) Meter Symbol Description: In the loading process, the machine can display real-
time parameters by measuring instruments. Display instrument operating diagram is
shown as follows:

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Instrument has the upper, middle, and lower three display windows. Each value and unit
symbol form the data. For example, the upper window shows 100.0V, it is to say phase A
voltage is 100V.
F1, F2 and on the bottom are to switch three windows and recycling display parameters.
Symbols meaning:
V: phase voltage symbol; Unit: V combined with K or M = kV MeV
V LL two symbols denote a line voltage; Unit: V, and combined with K, M to kV MV;
A: Current Symbol; Unit: A, and combined with K, M to kA, MA;
W: active power symbol; Unit: W, and combined with K, M to kW, MW;
Var: reactive power symbol; unit: Var, and combined with K, M to kVar, MVar;
VA: Apparent power symbol; Unit: VA, and K, M combination kVA, MVA;
Hz: Frequency Symbol; Unit: Hertz;
PF: Power Factor symbol;
E: energy symbols; Unit: Ep (active power) kWh, Eq (reactive energy) kVAh, Es
(apparent power) kVA;
3P3L: 3-phase 3-wire two components;
3V3A: 3-phase 3-wire three elements;
3P4L: three-phase four-wire;
(2) Display the voltage & current: In the non-setting state press F2. Current and voltage
will be displayed. For example, in the 01 interface (see the following pictures), press the
F2 key to switch to 02 interface. When in 03 interface press the F2 key to return to 01
interface. Switch the display process shown below:

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01: Displays three phase voltages, from top to bottom is A, B, C phase voltage wiring in
only 3P4L;
02: Display of three-phase line voltage, from top to bottom as AB, BC, CA line voltage.
03: Display of three-phase current, from top to bottom as A, B, C-phase current.
(3). Display the power, frequency, power factor, and electric energy: in the non-set
state, by pressing F1 and > button, you can view the following parameters. For example,
in the corresponding interface 04, such as by > key to display 05 interfaces; such as
pressing the F1 key, the display screens 08. The display switch process is shown below:

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04: From top to bottom display the total active power, total reactive power, total apparent
power, display units are watts, var, VA, and with k combined into kw, kvar, kVA, and with
M combined into MW, Mvar, MVA;
05: Three-phase active power display, from top to bottom as A, B, C-phase power,
display units in watts, and with k, M combined into kilowatts, megawatts;
06: Three-phase reactive power display, from top to bottom as A, B, C phase reactive,
lack of display units, and with k, M combination into kvar, Mvar;
07: Display of three-phase apparent power, from top to bottom as A, B, C phase
apparent power, display units VA and with k, M combined into KVA, MVA;
08: From top to bottom display voltage and frequency, the total power factor, frequency
is displayed in Hertz;
09: Display of three-phase power factor, from top to bottom as A, B, C-phase power
factor;
10: Shows the total active energy, the first line shows the symbol Ep, second and third
lines are combined into 8 data show power, display unit’s kWh;
11: Shows the total reactive energy, the first line shows the symbol Eq, second and third
lines are combined into eight data show power when the unit kvar display;

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12: Shows the total apparent energy, the first line shows the symbol ES, second, a
combination of three lines into eight data show power when the unit kVA displayed.
Note: In addition to the above features, do not perform other operations on the
measuring meter. Incorrect settings can result with inaccurate data. If the meter does not
work properly or shows inaccurate data, please contact Eagle Eye Power Solutions
4.6 Protection
(1) Emergency Manual: If an emergency happens, please immediately press the red
[EMERGENCY STOP] switch. The machine will remove the load. Emergency indicator
lights up and beeps alarm. In this state the load function is locked out and only the fan
continues to run. After an emergency is corrected, the emergency stop switch can be
rotated clockwise to unlock for testing to resume.
(2) Automatic protection: This machine has an automatic protection function. When the
following circumstances occur the fault and the corresponding alarm indicator lights and
alarm engage. Protection status loading function is locked. Identify the reasons for
troubleshooting and once resolved release and re-test the alarm.
Overheating: The internal temperature exceeds a preset warning level;
Overvoltage: The machine input voltage exceeds a preset warning level;
Some of the protective functions have a switch, and when the protection switches point
downward, it can safely give alarm. When the protective functions give false alarms, or
require temporary removal of some protection functions, then pull up on the appropriate
protection switch to turn off protection. Then under the same condition, unit will not give
the corresponding alarm and instead continues load testing.
Attention: If there are no special needs for testing, be sure to keep the protection
switches in downward position so that protection is active.
4.7 Shutdown
Let fans continue running for about 3 - 5 minutes to disperse the heat inside the chassis.
Then turn off the power switch on the control panel to stop the fan. Finally, turn off the

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machine by switching the chassis power switch (located on the side) downward. Once
the machine is shutdown, remove power supply, testing cables, and any other cables.
5 Data Management Software
5.1 System Configuration
In this chapter description, [ ] contents quote menu item or option; “” contents quote the
screen prompts.
Intelligent control with data management software is accomplished by flipping the
selector switch to intelligent. The recommended configuration to run data management
software is:
◆Microsoft Windows 98/2000/ XP/Vista/7/8/10 Operating system
◆Display Resolution of 1280 × 960 or more
◆CPU clocked at 300MHz or more
◆64M RAM or above
◆50M or higher hard drive
◆Keyboard, mouse or compatible input device
◆ Color or black and white printer
Installation files of the data management software are found on the Eagle Eye USB flash
drive.

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5.2 Main Interface
Title Bar: Displays the host name and test information tips.
Menu bar: Contains the main operations. Click the drop-down menus to see sub menu
options.
Toolbar: Contains the shortcut keys. Using the mouse, hover over the icon to display the
function description.
When the "alarm indicator" is under normal load conditions the light will be green. If the
light becomes red, this would indicate an abnormal load down, and in a protected state.
Hover your mouse over the lights to view the protection reasons.
Comment Field: Used for information tips of shortcut keys, task detail tips, and other
information.
5.3 Communication Settings
After the PC is connected to the unit by data transmission line, the first step is selecting
communication settings. Click the [Settings] menu, and then click the drop-down menu
in the [Communication Settings] options or click icon on the toolbar. After selecting the
appropriate communication interface (COM1-COM20) in the dialog box, click OK. Match
the COM ports assigned by the PC. You can look for available port on your PC in the
Device Manager (My Computer > Properties > Hardware > Device Manager > Ports).

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5.4 Loading
(1) To start the fan: Click the [Shift Control] on [Control] menu, or click the icon on the
toolbar into sub-file control interface, power setting and loading. Before loading, first click
[start fan].
(2) Loading: The software has two loading modes: manual loading and automatic
loading.
(3) Manual load: Can load a single power value, do not select load period in left side,
and directly select the power value on the right side, then click [Load] or [Unload]. If you
want to change the power value, just re-select the power and click [Load] or [Unload].
(4) Automatic loading: You can set the power and duration of each stage sequentially
for continuous loading. After clicking [Power Distribution], < Active Power > column to
set load power, < Power Factor > to set power factor, please then click [OK] and the
machine will automatically assign load power values. It’s also OK to input load power in
25% and other periods.
Then click [Interval], set the duration of each stage, click [Auto load] and it is
automatically loaded. The system will automatically load 25%, 50%, 75%, 100% or 110%,
100%, 75%, 50%, 25% of the sequence, and the power change is completed.
(5) Unload: Click [Unload] to remove the full load. Please keep the fans running 3-5
minutes after unloading so that standby heat dissipates, then click [End Task] to stop
the fan.

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5.5 Real-time data
(1) Real-time interface: In the loading process, click [Online] menu option immediately
or click directly on the icon on the toolbar. You can use this window to view real-time
information during a test. Click the middle of the label; you can switch the display to voltage,
current, power, frequency, or power factor curve.
(2) Save Data: Before starting loading, the user can set up to save the forthcoming test.
Choose the appropriate "interval", then press [Save Real Data] to the right of the Real
Data window shown, the button changes to [Stop Save], and the program will start
saving this real-time data of the test. After the test is complete, click [Stop Save] to stop
and save the test data stored within this period. Then from the [File] menu select [Open
Test Data] in the test record to view previously saved historical data.
5.6 Test records
(1) Open Test Data: Click the [File] menu, then click the drop-down menu and select
[Open Test Data] or click the icon on the toolbar, the following window appears. Test
data is stored in this interface; you can open any one existing test record and view a
variety of graphs and reports for the test.

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Open: Double-click the test records or choose test records and click [Open] button to
open them. The following analysis of the data, print and other operations are based on
saved data records from the test.
Delete: To delete the selected record, click the [Delete] button and confirm. To avoid
accidental deletion, please back up important data files.
Import Records: Click [Import] button, then select the recording which you want to
import in the dialog box and click OK.
Export Records: Select the record which you want to export, click [Export], confirm the
message, and in the "Save As" dialog box, click the subsequent [Save].
(2) View charts: Click the [Data] menu, and then click the drop-down menu for each
option, you can choose to view voltage, current, frequency, power, power factor graphs
and tabular/form data. In the Form Data window, click [Export to Excel] to save the data
as an Excel document.

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(3) Report Epitomize: Click [File], then click the [Report epitomize], fill the test
information as desired, then fill in any comments in the test result window, as reference.
This page will be printed in the report.
(4) Parameter List: Click [Set] in the toolbar and select [Modify Parameters], enter the
correct data, then click [OK], This page will be printed in the report.
(5) Print Report: Click [File] then select the option [Print Report], fill in the test
information, then fill in any comments in the test result window, as reference. This page
will be printed in the report.

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5.7 Exit the System
Click the [File] menu, select the drop-down menu [Exit] option, or click the icon on the
toolbar in the confirmation dialog box, then click [Yes] to close the software.
6 Equipment maintenance
6.1 Routine maintenance
(1) Dehumidification: Before use you must confirm there is no water or moisture on
joint interface of cables. If there is moisture, it should be dried before use to avoid a short
circuit after powering on.
(2) Cover: After testing, safely put away all the parts (do not store cables in the sunlight).
The plug should be covered. Using a dust cover for the machine is recommended. If
used outdoors, the load bank should be covered up by a rainproof cloth to avoid
corrosion and dampness.
(3) Storage: The machine and accessories should ideally be stored in a cool, dry indoor
environment, away from high temperature and damp environments.
6.2 Regular maintenance
(1) Maintenance time: It is recommended that the machine gets system maintenance
checks after one year (according to the unit’s actual condition). If left idle for a long time,
it is recommended to perform system maintenance before using. Reasonable regular

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maintenance can prolong the service life of the machine and maintain good
performance.
(2) Cleaning: Operators should do thorough cleaning, especially the dust and debris that
adhere to the vents which can be sweep out by brush or compressed air. Operators
should be careful when cleaning to not open the enclosure.
(3) Check: After cleaning, check carefully whether the equipment is in good condition.
Turn on the power and check measuring instrument and that the fan is in good condition.
If no abnormal issues then start the testing.
(4) Ventilation: Operator should turn on the power to check the performance of the fan.
If the cooling fan is abnormal or there is air duct blockage, it could cause the machine to
overheat.
(5) No-load running: If the machine is stored for a long time, it is recommended to first
let the machine run without load, while not connected to the device under test.
Components heat will disperse moisture to ensure that the device performance is stable
and reliable. In areas where the air humidity is high, no-load running on a regular basis is
an effective measure to reduce equipment failure.
6.3 Troubleshooting
Please see the below table for common issues and their possible solutions. If the
problem you encountered is not listed here, please contact Eagle Eye Power Solutions,
LLC for support.
Problem
Possible reasons
Solutions
The machine does not
start
Power supply is not
connected
Check the device wiring is correct, and check
whether the local power supply is powered.
Automatic shutdown after
starting
Power anomalies
Check if the voltages of input working power supply
is correct
Abnormal fan rotation
Power supply not steady
Provide the steady power supply
Lack of fan flow, poor
heat
dissipation
Vents or fan blockage
Check the vents and fan if there is debris, sweep
out.
Operation no response
Control mode selection
error
Check that the control mode selection is in
accordance with the current operation mode.