Eagle Eye LB-60-30 User manual

Eagle Eye Power Solutions, LLC.
LB-60-30
LOAD BANK
MANUAL CONTAINS
OPERATING INSTRUCTIONS
PARTS LIST
WIRING DIAGRAMS
SERVICE INSTRUCTIONS
Eagle Eye Power Solutions, LLC.
4031 W Kiehnau Ave
Milwaukee, WI 53209

Eagle Eye Power Solutions, LLC.
CAUTION
THIS LOAD BANK IS DESIGNED FOR THE TESTING AND SERVICING 120/208V
60HZ POWER UNITS. THESE GENERATORS HAVE THE POTENTIAL OF
DELIVERING A LETHAL SHOCK. THIS LOAD BANK SHOULD BE USED ONLY BY
TRAINED AND QUALIFIED PERSONNEL. THIS LOAD BANK IS DESIGNED FOR
TEMPORARY USE ONLY. THE LOAD RESISTORS ARE ENERGIZED WHEN THE
RATE SWITCH IS OFF; THEREFORE DO NOT INSERT ANY OBJECTS IN THE
GRILL ASSEMBLY. DO NOT BLOCK THE AIR FLOW OR USE IF THE AIR FLOW IS
REVERSED.

Eagle Eye Power Solutions, LLC.
MANUAL FOR LB-60-30 LOAD BANK
TABLE OF CONTENTS
SUBJECT
SECTION
PAGE
DESCRIPTION
PURPOSE OF LOAD BANK
1 - 1
1
RATING OF LOAD BANK
1 - 2
1
LOAD BANK DESCRIPTION
FIGURE 1 - 1
1 - 3
1
CONTROL PANEL LAYOUT
FIGURE 1 - 2
1
2
CONTROL DESCRIPTION
1 - 4
3
OPERATION
TESTING 120VAC SINGLE PHASE
2
1
TESTING 240VAC SINGLE PHASE
2
3
TESTING 208VAC THREE PHASE
2
5
PARTS
PARTS INFORMATION
3
1
CONTROL PANEL PARTS LAYOUT
FIGURE 3 - 1
3
2
CONTROL PANEL PARTS LIST
3
3
INTERIOR PARTS LAYOUT
FIGURE 3 - 2
3
4
INTERIOR PARTS LIST
3
5
FAN PANEL PARTS LAYOUT
FIGURE 3 - 3
3
6
FAN PANEL PARTS LIST
3
7
VENDOR LIST
3
8
SERVICING
GENERAL SERVICING
4 - 1
1
REPLACING FAN
FIGURE 4 - 1
4 - 2
2
WIRING DIAGRAMS
INTERIOR W IRING
FIGURE 5 - 1
5
1
FAN PANEL WIRING
FIGURE 5 - 2
5
3
SCHEMATIC DIAGRAM
FIGURE 5 - 3
5
5

Eagle Eye Power Solutions, LLC.
---------- -----
DESCRIPTION
1-1 PURPOSE OF LOAD BANK: The LB-60-30 is a portable load bank designed to be used for field
servicing and testing 60HZ generators and UPS systems. It can be used for checking cables after they
have been replaced or repaired. The load bank can also be shipped to different locations using the
carrying case.
1-2 RATING OF LOAD BANK: The LB-60-30 is rated at 30 KW full loads with all six load steps turned
on. The load steps are 1KW, 2KW, 2KW, 5KW, 10KW and10KW. This gives a 0-30KW range in 1KW
steps. All steps arecontinuous.
1-3 LOAD BANK DESCRIPTION: The load bank is completely self-contained and needs no power
source to operate other than the power being tested. The different sides of the load bank are shown in
fig. 1-1. The air enters the right side (fan side) and exits the left side.
<<<< AIR FLOW <<<<
LEFT SIDE------------- --------- RIGHT SIDE (FAN SIDE)
FIGURE 1-1
LENGTH 20 IN.
WIDTH 8 IN.
HEIGHT 11 IN.
WEIGH 33 LBS.

Eagle Eye Power Solutions, LLC.
VOLTMETER
CONTROL PANEL LAYOUT
OVER VOLTAGELIGHT
AMMETER
60
90
30
0
120
150
40
60
20
0
80
100
AC VOLTS
AC AMPS
FREQUENCY
METER
METER
SWITCH
60
58
55
HERTZ
A B C
62
65 L1 L2 L3
B
A C ON
MAIN
POWER
INDICATOR
LIGHTS
OFF
METER
RATE
SWITCHES
METER
TEST
JACKS
1KW 2KW 2KW 5KW 10KW 10KW
OFF
A B C N
FIGURE 1 - 2
1-4 CONTROL DESCRIPTION: The following is a description of the controls on the control panel (see
figure 1-2 on page2.

Eagle Eye Power Solutions, LLC.
VOLT METER - A 150 volt meter used to measure the line to neutral voltage on the power cable. A, B,
or C phase can be selected using the meter selector switch. The meter should read approximately 120
volts. A 150 volt or higher reading would indicate a line and neutral cable switched on the power unit or
cable.
AMMETER - A 100 amp ammeter used to measure the load being used by the load bank. It monitors
“A” phase.
FREQUENCY METER - A 55-65 HZ meter used to measure the frequency of the power unit. It should
read approximately 60HZ.
METER SWITCH - Switch used to select A, B, or C phase on the voltmeter.
RATE SWITCHES - Switch used to select the desired rate on the load bank. The rates are as follows:
1. 1 KW balanced load
2. 2 KW balanced load
3. 2 KW balanced load
4. 5 KW balanced load
5. 10 KW balanced load
6. 10 KW balanced load
POWER INDICATOR LIGHTS - These lights will light to indicate power on A, B, and C phase. All three
lights should be on.
METER TEST JACKS - This provides a place to connect an external meter. There is a test jack for
each cable pin.
POWER RECEPTACLE - The power cable from the equipment to be tested is plugged into the load
bank through the receptacle.

Eagle Eye Power Solutions, LLC.
OPERATION
TESTING 120VAC SINGLE PHASE
2-1 SETTING UP THE LOAD BANK - Place the load bank in an area free from fuel, oil, or any other
flammable substance. The load bank should be positioned so that any strong wind or air currents will
flow with the air flow of the loadbank.
2-2 APPLYING POWER - The load bank should be connected to the power unit to be tested with an
output of120 single phase. Make sure that the power unit is off before connecting the cable to the load
bank. Use L1 and N, the blue plug, when testing single phase circuits. Plug the power cable plug in to
the load bank. DO NOT PLUG THE YELLOW PLUG INTO THE LOAD BANK. Turn on the output of the
power unit.
2-3 CHECKING THE POWER - check the following:
A. The amber light, “A” should be on.
B. The voltmeter should read 120VAC on “A” phase.
C. The frequency meter should read approximately60HZ.
D. The ammeter should read 0A.
2-4 APPLYING THE LOAD - If the above steps checked OK, turn on the main switch. The fans should
start up and the airflow should be as indicated by the airflow arrow. Add the load desired with the rate
switch.
A. Step 1 is .33KW - 2.7A
B. Step 2 is .66KW - 5.5A
C. Step 3 is .66KW - 5.5A
D. Step 4 is 1.66KW - 13.8A
E. Step 5 is 3.33KW - 27.7A
F. Step 6 is 3.33KW - 27.7A
Check to see that the voltage and frequency does not drop beyond acceptable limits under load. Return
the rate switch to the off position.
2-5 SHUTTING DOWN - After turning the rate off, allow the load bank to cool down before turning the
power unit off. Turn the power unit off and disconnect the power cable plug.

Eagle Eye Power Solutions, LLC.
OPERATION
TESTING 240VAC SINGLE PHASE
2-1 SETTING UP THE LOAD BANK - Place the load bank in an area free from fuel, oil, or any other
flammable substance. The load bank should be positioned so that any strong wind or air currents will
flow with the air flow of the loadbank.
2-2 APPLYING POWER - The load bank should be connected to the power unit to be tested with an
output of 240VAC single phase. Make sure that the power unit is off before connecting the cable to the
load bank. Use L1, L2 and N, the blue and yellow plug, when testing 240VAC single phase circuits. Plug
the power cable plug in to the load bank. MAKE SURE THE COPPER LUG ON L3 IS INSULATED.
Turn on the output of the powerunit.
2-3 CHECKING THE POWER - check the following:
A. The amber light, “A” and “B” should beon.
B. The voltmeter should read 120VAC on “A” and “B” phase.
C. The frequency meter should read approximately60HZ.
D. The ammeter should read 0A.
2-4 APPLYING THE LOAD - If the above steps checked OK, turn on the main switch. The fans should
start up and the airflow should be as indicated by the airflow arrow. Add the load desired with the rate
switch.
A. Step 1 is .66KW - 5.5A
B. Step 2 is 1.33KW - 11.1A
C. Step 3 is 1.33KW - 11.1A
D. Step 4 is 3.33KW - 27.7A
E. Step 5 is 6.66KW - 55.5A
F. Step 6 is 6.66KW - 55.5A
Check to see that the voltage and frequency does not drop beyond acceptable limits under load. Return
the rate switch to the off position.
2-5 SHUTTING DOWN - After turning the rate off, allow the load bank to cool down before turning the
power unit off. Turn the power unit off and disconnect the power cable plug.

Eagle Eye Power Solutions, LLC.
OPERATION
TESTING 208VAC THREE PHASE
2-1 SETTING UP THE LOAD BANK - Place the load bank in an area free from fuel, oil, or any other
flammable substance. The load bank should be positioned so that any strong wind or air currents will
flow with the air flow of the loadbank.
2-2 APPLYING POWER - The load bank should be connected to the power unit to be tested with an
output of 208VAC 3 phase. Make sure that the power unit is off before connecting the cable to the load
bank. Use L1, L2, L3 and N, the blue and yellow plug, when testing 208VAC 3 phase circuits. Plug the
power cable plug in to the load bank. Turn on the output of the power unit.
2-3 CHECKING THE POWER - check the following:
A. The amber light, “A”, “B”,”C” should be on.
B. The voltmeter should read 120VAC on “A”, “B”, and “C” phase.
C. The frequency meter should read approximately60HZ.
D. The ammeter should read 0A.
2-4 APPLYING THE LOAD - If the above steps checked OK, turn on the main switch. The fans should
start up and the airflow should be as indicated by the airflow arrow. Add the load desired with the rate
switch.
A. Step 1 is 1KW - 8.3A
B. Step 2 is 2KW - 16.6A
C. Step 3 is 2KW - 16.6A
D. Step 4 is 5KW - 41.6A
E. Step 5 is 10KW - 83.3A
F. Step 6 is 10KW - 83.3A
Check to see that the voltage and frequency does not drop beyond acceptable limits under load. Return
the rate switch to the off position.
2-5 SHUTTING DOWN - After turning the rate off, allow the load bank to cool down before turning the
power unit off. Turn the power unit off and disconnect the power cable plug.

Eagle Eye Power Solutions, LLC.
PARTS INFORMATION
CONTROL PANEL PARTS
1 11 2
60 90
30
0
120
150
40 60
20
0
80
100
AC VOLTS
AC AMPS
4 55
3
60
58
HERTZ
A B C
62
65 L1 L2 L3
B10
A C
5,6
7
METER
MAIN
ON
9
OFF
1KW 2KW 2KW 5KW 10KW 10KW
OFF
A B C N
8
FIGURE 3 - 1

Eagle Eye Power Solutions, LLC.
CONTROL PANEL PARTS
FIGURE 3-1
DRAWING
NUMBER
PART
NUMBER
DESCRIPTION
VENDOR NO.
NUMBER
USED
1
MR-61
0 - 150V VOLT METER
1
2
MR-64
0 - 100 A AMMETER
1
3
MR-60
55-65 HERTZ FREQUENCY METER
1
4
HD-25
HANDLE
2
5
KN-10
POINTER KNOB
1
6
SW-13
ROTARY SWITCH 3POSITION 1 POLE
1
7
SW-21
TOGGLE SWITCH SPST
6
8
TP-10
TEST PINS
4
9
SW-22
TOGGLE SWITCH DPST
1
10
LT-10
115V AMBER LIGHT
3
11
LT-15
115V RED LIGHT
1

INTERIOR PARTS LAYOUT
4 3 15
1
2
5
8
23
21
23
22
24,25
19
6
16,17,
18
20 9,10
7
7
11 12 13 14
FIGURE 3 - 2

Eagle Eye Power Solutions, LLC.
INTERIOR PARTS
FIGURE 3-2
DRAWING
NUMBER
PART
NUMBER
DESCRIPTION
VENDOR NO.
NUMBER
USED
1
HD-10
FOLDING HANDLES
1
2
BX-40
20" X 11" X 8" ALUM BOX
1
3
SB-13
SB CONNECTOR-2PIN-BLUE
1
4
SB-12
SB CONNECTOR-2PIN-YELLOW
1
5
FS-17
125A FUSE
3
6
FT-10
GLIDES
4
7
RY-35
RELAY, 120VAC 30A
6
8
RC-25
560Ω RESISTOR 5W
1
9
RC-56
5.6KΩ RESISTOR 5W
1
10
RY-20
RELAY 2PDT 24VDC 3A
1
11
SW-11
AIR FLOW SWITCH
1
12
RS-20
RELAY SOCKET 2P
1
13
LR-08
8.0Ω RESISTOR
15
14
LR-40
40Ω RESISTOR
3
15
LR-18
18.8Ω RESISTOR
6
16
FH-15
SNAP IN FUSE HOLDER
2
17
FS-10
FUSES, 1A GLASS
1
18
FS-12
FUSE, 5A, GLASS
1
19
CT-10
100:5 CURRENT TRANSFORMER
1
20
SR-25
SCR 12 AMPS
1
21
RC-09
RESISTOR 10KΩ 1/2 WATT-ADJ
1
22
RD-12
ZENER DIODE 120V 5W
1
23
RD-10
DIODE 1A
4
*
GL-24
RESISTOR GRILL
1

Eagle Eye Power Solutions, LLC.
FAN PANEL PARTS LAYOUT
10 1 2 3 4 5 6 7 8 9
FIGURE 3 - 3

Eagle Eye Power Solutions, LLC.
FAN PANEL PARTS
DRAWING
PART
FIGURE 3-3
DESCRIPTION
NUMBER
NUMBER
NUMBER
VENDOR NO.
USED
1
RC-05
5Ω RESISTOR 25W
3
2
TM-20
8 POSITION TERMINAL STRIP
V-BEAU PRODUCTS (78008)
1
3
TM-10
TERMINAL STRIP 11 POS
1
4
RD-06
RECTIFIER 6A
1
5
CP-35
CAPICATOR, 350UF, 160VDC
1
6
FP-28
ALUM. FAN PANEL
1
7
GL-10
FAN GRILL CHROME
V-MERRILL (B-22662)
6
8
FN-25
24VDC FAN
V-EBM (W2G110-AK43-31)
6
9
TS-15
THERMAL SWITCH
V-GEMLINE (L-145)
1
10
SW-12
TILT SWITCH
1

Eagle Eye Power Solutions, LLC.
GENERAL SERVICE
There is no regular maintenance required on the load bank. There are no adjustments inside the load
bank. It should however be checked periodically for defective fans, burned out light bulbs, and defective
meters.
To remove the fan panel, remove the screws around the outer edge.
The meters can be removed and replaced from the front panel.
The fan grills should be kept free of any trash.
Do not place any objects in the fan or resistor grill.
FAN REPLACEMENT
The following are steps to take to replace a defective fan.
1.
Remove the screwsholding the fan panel tothe load bank.
2.
Remove the four wires on the terminalstrip comming from the loadbank
3.
Drill out the rivets holding the fan (four on each side).
4.
Lift up the fan and unplugthe wireto the fan. Plugthe newfan into the wire and put the
fan back on the fan panel.
5.
Rivet the newfan back tothefanpanel.
6.
Placethe fan panel back on the load bank. Make sure that the wires are on the proper
terminals.

Eagle Eye Power Solutions, LLC.
WHITE
ORANGE
FAN 1-6
GREEN
BLACK
FIGURE 4 - 1 WIRES TO LOAD
BANK
FAN PANEL WIRING
FIGURE 5 - 2
1- RED
6- BLK
4- G-R ED
F1+
F1-,F2+
F2-,F3+
8- G-B LU
F3-
3,4 G-
RE D F4+
F4-,F5+
9- WHT
10- -
WHT
F5-,F6+
7,8 G-
BL U F6-
F1
F2
F3
C1
9- WH ITE
SW11 12 WHITE 7 11-RED
R5
1R ED
AC +
-
AC RT1
R2
6
BL K
3
G-RED
F4
F5
F6
R1 11
RE D
12-WHT
10 -WHT
FAN 1-6

Eagle Eye Power Solutions, LLC.
INTERIOR WIRING

Eagle Eye Power Solutions, LLC.
LB-60-30 Schematic
RP1
R3 SR1 R6
Ln1 Ln2 Ln3 N K7 R4
L4 D1 D5
CT1
FS3 FS4 FS5
M2
L1 L2 L3
D4 D3 D2
K7
TP4 TP1 TP2 TP3
LR22
K1 LR23
LR24
1KW
F1 F2 F3 F4 F5
F6
C1
LR1
K2 LR2
LR3
2KW
LR4
K3 LR5
LR6
2KW
RT1
R1 R2 R5
5KW
LR7
K4 LR8
LR9
M1 M3
SW2
FS1
SW1
FS2
LR10
10KW 1 3 SW11 SW10 SW9
K5
LR13
LR11
LR14
LR12
LR15
2
K1
SW3 1KW
LEGEND
C1 CAPICATOR 350UF, 160DC
C3 CAPICATOR 100V 15UF
LR16
10KW CT1 CURRENTTRANSFORMER100:5
LR18
K6
LR19
LR17
LR20
LR18
LR21
K2
SW4 2KW
K3
SW5 2KW
K4
SW6 5KW
K5
SW7 10KW
K6
D1-4 DIODE1A
D5 ZENER DIODE 120V5W
FN1-6 FAN 24VDC
FS1 FUSE,5A
FS2 FUSE,1A
FS3-5 FUSE,125A
K1-6 RELAY, 120VAC 3PST 30A
K7 RELAY, 24VDC 2PDT3A
L1-3 LIGHT, NEON 115V
LT4 LIGHT, NEON115V-RED
LR1-6 LOADRESISTOR18.8
LR7-21 LOADRESISTOR8.0
LR22-24 LOAD RESISTOR40.0 OHM
M1 METER,50-65 HERTZ
M2 METER,0-100AMP
M3 METER, 0-150VOLT
R1-2,5 RESISTOR 25W,5
R3 RESISTOR 560 OHM 5WATT
FIGURE 5-3
SW8 10KW R4 RESISTOR 7.5K 5WATT
R6 RESISTOR 5.6K OHM5WATT
RP1 RECEPTACLE,4POLE
RT1 RECTIFIER6A
SR1 SCR12AMPS
SW1 SWITCH, TOGGLEDPST
SW2 SWITCH, ROTARY 3POS1 POLE
SW3-8 SWITCH,TOGGLESPST
SW9 SWITCH,AIR FLOW
SW10 THERMAL SWITCH 155°
SW11 MERCURY SWITCH
TP1-4 TESTPINS

Eagle Eye Power Solutions, LLC.
Contact EEPS
Eagle Eye Power Solutions, LLC.
4031 W Kiehnau Ave. Milwaukee WI, 53209
TEL: [phone] EEPS (3377) FAX: [phone]
www.eepowersolutions.com [email protected]