Eagle Eye LB-60-70 User manual

Eagle Eye Power Solutions, LLC.
LB-60-70
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-60-70 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
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-60-70 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-60-70 is rated at 70 KW full load with all four load steps turned
on and the rotary rate switch set to 5KW. The load steps are 5KW, 10KW, 20KW and 30KW plus a
rotary rate switch with loads of 1-5KW. This gives a 0-70KW range in 1KW steps. All steps are
continuous.
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.
LENGTH 22 IN.
WIDTH 8 IN.
HEIGHT 21 IN.
WEIGH 55 LBS.

Eagle Eye Power Solutions, LLC.

Eagle Eye Power Solutions, LLC.
1-4 CONTROL DESCRIPTION: The following is a description of the controls on the control panel (see
figure 1-2 on page2.
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 200 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. 5 KW balanced load
2. 10 KW balanced load
3. 20 KW balanced load
4. 30 KW balanced load
5. 1-5 KW balanced load with rotary rate switch
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 of 120VAC 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. If the HI-VOLTAGE light comes on, push the High Voltage reset button if the meter
shows 120VAC or less. If the voltage is above 120VAC, turn off the power being tested and fix the high
voltage problem, before using the load bank.
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.
E. The HI-VOLTAGE light should be off.
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 1.67KW
B. Step 2 is 3.33KW
C. Step 3 is 6.67KW
D. Step 4 is 10KW
E. Rotary Rate Switch 0-1.67KW
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 power unit. If the HI-VOLTAGE light comes on, push the High Voltage reset
button if the meter shows 120VAC or less. If the voltage is above 120VAC, turn off the power being
tested and fix the high voltage problem, before using the load bank.
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.
E. The HI-VOLTAGE light should be off.
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 3.33KW
B. Step 2 is 6.66KW
C. Step 3 is 13.33KW
D. Step 4 is 20KW
E. Rotary Rate Switch 0-3.33KW
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. If the HI-VOLTAGE light
comes on, push the High Voltage reset button if the meter shows 120VAC or less. If the voltage is
above 120VAC, turn off the power being tested and fix the high voltage problem, before using the load
bank.
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.
E. The HI-VOLTAGE light should be off.
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 5KW
B. Step 2 is 10KW
C. Step 3 is 20KW
D. Step 4 is 30KW
E. Rotary Rate Switch 0-5KW
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
The following pages list the parts used in the load bank. All of the major parts are shown. Wire, screws, bolts, and
small miscellaneous hardware are not listed. Parts that are purchased from a vendor will show a vendor name. These
names refer to the vendor list is on page 8. Parts manufactured for or by EEPS will not show a vendor name.
A part number can be found by first locating the part on a drawing. After finding the part use the number to refer to the
parts list on the opposite page. Each part will have a drawing number, EEPS part number, description and the number
used for each load bank.
Parts should be ordered from the address below giving the machine model
number, part number and the description.
Contact EEPS
Eagle Eye Power Solutions, LLC.
4031 W Kiehnau Ave
Milwaukee WI, 53209
TEL: [phone] EEPS (3377) FAX: [phone]
www.eepowersolutions.com
[e-mail]

Eagle Eye Power Solutions, LLC.

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-25
0 - 250A AMMETER
1
3
MR-60
55-65 HERTZ FREQUENCY METER
1
4
HD-25
HANDLE
2
5
KN-10
POINTER KNOB
2
6
SW-13
ROTARY SWITCH 3 POSITION 1 POLE
1
7
LT-10
115VAC AMBER LIGHT
3
8
SW-31
ROTARY SWITCH 10 POSITION 3 POLE
1
9
SW-22
TOGGLE SWITCH DPST
1
10
SW-21
TOGGLE SWITCH SPST
5
11
12
13
14
TP-10
SB-12
SB-13
LT-25
TEST PIN
SB CONNECTOR 2PIN-YELLOW
SB CONNECTOR 2PIN-BLUE
250VAC RED LIGHT
4
1
1
1

Eagle Eye Power Solutions, LLC.

Eagle Eye Power Solutions, LLC.
INTERIOR PARTS
FIGURE 3-2
DRAWING
NUMBER
PART
NUMBER
DESCRIPTION
VENDOR NO.
NUMBER
USED
1
HD-10
FOLDING HANDLE
1
2
BX-27
20" X 21" X 8" ALUM BOX
1
3
SB-13
SB CONNECTOR-2PIN-BLUE
1
4
SB-12
SB CONNECTOR-2PIN-YELLOW
1
5
FS-25
250A FUSE
3
6
FT-10
GLIDES
8
7
RY-35
RELAY, 120VAC 30A
10
8
RC-30
RESISTOR 100Ω5W
1
9
CP-22
22UF, 150VDC
1
10
RD-10
DIODE 1A
4
11
SW-11
AIR FLOW SWITCH
1
12
LR-08
8.0Ω RESISTOR
39
13
LR-40
40Ω RESISTOR
3
14
LR-18
18.8Ω RESISTOR
6
15
FH-15
SNAP IN FUSE HOLDER
1
16
FS-10
FUSE, 1A GLASS
1
17
CT-25
250:5 CURRENT TRANSFORMER
1
18
SR-25
SCR 25 AMPS
1
19
ZN-10
ZENER DIODE 10V 5W
1
20
RC-56
RESISTOR 5.6KΩ5W
1
21
ZN-12
ZENER DIODE 120V 5W
1
22
RY-20F
RELAY 24VDC, 2PDT 3A FLANGE
1
23
24
25
RC-09
ZN-24
TM-13
RESISTOR 10KΩ.5W ADJ
ZENER DIODE 24V 5W
TERMINAL STRIP
1
1
2
*
GL-20
RESISTOR GRILL
2

Eagle Eye Power Solutions, LLC.

Eagle Eye Power Solutions, LLC.
FAN PANEL PARTS
DRAWING
PART
FIGURE 3-3
DESCRIPTION
NUMBER
NUMBER
NUMBER
VENDOR NO.
USED
1
FP-57
ALUM. FAN PANEL
1
2
TM-20
8 POSITION TERMINAL STRIP
V-BEAU PRODUCTS (78008)
1
3
SW-12
TILT SWITCH
1
4
GL-10
GRILL CHROME
12
5
FN-25
24 VDC FAN
12
6
TS-15
THERMAL SWITCH
1
7
PS-30
POWER SUPPLY 28-
33VDC 400W
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.

Eagle Eye Power Solutions, LLC.
FAN REPLACEMENT
The following are steps to take to replace a defective fan.
1. Remove the screwsholding the fan panel to the load bank.
2. Remove the wires on the terminal strip coming from the load bank
3. Drill out the rivets holding the fan (four on each side).
4. Lift up the fan and unplug the wire to the fan. Connect the plug to the new fan.
5. Rivet the new fan back to the fan panel and install the fan guard.
6. Install the wires back on the terminal strip and place the fan panel back on the load bank. Make sure that the wires
are on the proper terminals.

Eagle Eye Power Solutions, LLC.

Eagle Eye Power Solutions, LLC.