Lex Load Master User manual

TYPE 3R Rainproof TYPE 1 Indoor or
TYPE 3R Rainproof
TYPE 3R Rainproof TYPE 1 Indoor or
TYPE 3R Rainproof
LM-LOADMASTER - Rev.002
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Load Master®
Portable Power Distribution Box
User Manual

Contact Lex Products: 800.643.4460 [email protected]
2
PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
CONTENTS
3 SHIPMENT: UNPACKING AND INSPECTION
4 INTRODUCTION
4 LOAD MASTER® COMPONENTS
5 SETTING UP THE LOAD MASTER® POWER DISTRIBUTION UNIT (PDU)
5 Step 1: Placement and Inspection of the Load Master® PDU
5 Step 2: Making the Input Connections
7 Step 3: Adjusting the Circuit Breakers
9 160-400 Amp Circuit Breaker - DIP Switch Settings
10 100-250 Amp Circuit Breaker - DIP Switch Settings
11 60-150 Amp Circuit Breaker - DIP Switch Settings
12 Step 4: Making the Output Connections
13 Step 5: Powering Up
14 TROUBLESHOOTING GUIDE
14 Circuit Breaker Tripping During Normal Operation
15 Circuit Breaker Tripping When powering Up
15 How to Check a Load Master®for a Short Circuits
15 TECHNICAL SUPPORT

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
SHIPMENT: UNPACKING AND INSPECTION
Check the shipment carefully to confirm it arrived complete and undamaged
1. Unpack the shipment and check the contents against the packing list to ensure the order is complete
2. Check the unit for loose or broken components, which might have resulted from shipping
a. Inspect for signs of damage to wiring devices, device covers or circuit breakers
b. Open and close the lid on the Load Master Box to determine whether it closes and latches properly
3. If there is any damage to the Load Master Box, contact Lex Products Technical Services toll free at 800.643.4460 or email
[email protected]

Contact Lex Products: 800.643.4460 [email protected]
4
PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
INTRODUCTION
This manual details the installation and use of the Lex Products Load Master line of power distribution boxes. This power distribution box
provides a convenient way to adjust the overcurrent protection of the output receptacles. Please review this manual prior to operating the Load
Master® box. Store this manual in a safe location for future reference.
LOAD MASTER® COMPONENTS
(2) Sets of Cam-type Inputs
Hinged Lid
Lid Handles
Locking Latches
Cam-type Outputs
Lifting Handles
Lifting Handles
DIP Switches
Hinged Lid
Adjustable Circuit Breakers
Figure 1.1
Figure 1.2

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
SETTING UP THE LOAD MASTER®POWER DISTRIBUTION UNIT (PDU)
Set up of the Lex Products Load Master power distribution box is to be performed by qualied personnel only
Step 1: Placement and Inspection of the Load Master®PDU
–The Load Master® PDU box is designed for indoor and outdoor use
–The base of the unit is designed to elevate live electrical components above ground level
–The Lex Products Load Master®is UL Listed for use in wet locations, but is not to be operated near standing water or in wet weather
1. The Load Master box is a two man portable unit
a. When moving the Load Master box, use the lifting handles on the sides of the box (Figure 1.2)
2. PlacetheLoadMasterBoxinalevellocationwithadryandrmfoundationwithinproximityofthepowersourceandthelocation
requiring power
3. OpenthelidfortheunittoconrmthattheadjustablecircuitbreakersareintheOFFposition
Step 2: Making the Input Connections
WARNING: Before making connections to the Load Master®PDU, make sure the power source feeding the box is OFF
WARNING: Do not exceed the voltage rating (600 VAC Max.)
1. Locate the (2) sets of feeder cable that will be used to bring power to the Load Master®PDU
a. 4/0 cable must be used to connect the Load Master® PDU to the power source
b. NOTE: If using the feed thru feature on model PH800-N2J-31AV1AX1AZ, connect the feed thru before the input, making the
Cam-type connections in the same manner and order as indicated for the input connection on page 6
WARNING: Both sets of Cam extensions feeding the input must come from the same power source
Locking Latches
Cam-type Outputs
Lifting Handles
DIP Switches
Hinged Lid

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6
PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
Step 2: Making the Input Connections (continued)
2. Connect the bottom input row of Cam cables first, beginning with the ground cable (Green)
3. Push the inline connector (female) into the Cam inlet (male) panel mount receptacle with the screw on the connector facing up
4. Rotate the connector clockwise at least 90 degrees until it stops to make sure it is secured in the locked position
5. Connect the neutral (White) Cam cable second
6. Push the inline connector (female) into the Cam inlet (male) panel mount receptacle with the screw on the connector facing up
7. Rotate the connector clockwise at least 90 degrees until it stops to make sure it is secured in the locked position
8. Repeat steps 3-4 to connect the Blue, Red and then Black phases in the same manner
9. Connect the second (Top) row of the Cam input in the same manner and color order as detailed above.
NOTE: When disconnecting, do so in reverse order starting with the phases (Black, Red and Blue), followed by the neutral (White) and finally
ground (Green)
Align the inline Ground connector with the
corresponding color-coded receptacle
Insert the Cam connector into the receptacle
and rotate Cam connector at least 90 clockwise
degrees to lock
Align the inline Neutral connector with the
corresponding color-coded receptacle
Insert the Cam connector into the receptacle
and rotate Cam connector at least 90 clockwise
degrees to lock

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
Step 3: Adjusting the Circuit Breakers
The current level of the circuit breakers is adjustable to match the load of the output receptacles. The circuit breakers are adjusted
with dip switches located under a clear cover on each circuit breaker.
L
I1 =
In x (0.4+
PR221DS
Test
+-
0.04
0.08 0.16
0.32
)
0
0
0
0
t1
I=6I1
12s
3s
S
I
I2=
In x(Σ
1
1.5 2
5.5
)
0
0
0
0
I3= T2
I=8In
0.25s
0.1s
ON
OFF
N
10050
%
ABCD
Figure 3.1: Circuit Breaker
On (I) / Off (O) Switch
DIP Switch “L” Short/Instant Delay Neutral Sensing
DIP Switches
Figure 3.2: DIP Switches

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
Step 3: Adjusting the Circuit Breakers (continued)
1.1. Determine the load that will be placed on each set of output receptaclesDetermine the load that will be placed on each set of output receptacles
a.a. This is the value that will need to be matched with the circuit breaker settingsThis is the value that will need to be matched with the circuit breaker settings
2.2. Each circuit is labeled with a number that corresponds to a specific output for easy circuit identificationEach circuit is labeled with a number that corresponds to a specific output for easy circuit identification
3.3. Determine which load will be matched with each set of receptacles and circuit breakers based on the available range of the Load MasterDetermine which load will be matched with each set of receptacles and circuit breakers based on the available range of the Load Master
box modelbox model
a.a. For example, a 400 Amp load must be paired with a 160-400 Amp receptacle and circuit breaker; a 60 Amp load must be paired withFor example, a 400 Amp load must be paired with a 160-400 Amp receptacle and circuit breaker; a 60 Amp load must be paired with
a 60-150 Amp receptacle and circuit breakera 60-150 Amp receptacle and circuit breaker
Circuit Label
Corresponding Circuit Label

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
Step 3: Adjusting the Circuit Breakers (continued)
160-400 Amp Circuit Breaker - DIP Switch Settings
1. Set the DIP switches on the circuit breaker to the closest level indicated in the table below with the set level
greater than the actual load
a. Only adjust the DIP switch labeled “L”
b. To adjust the circuit breaker, open the clear cover over the DIP switch using a small flathead screw driver
c. Move each switch (A, B, C, D) into the up or down position based on the table below to achieve the
desired output current rating
d. Close the clear cover over the DIP switch
160-400 Amp Circuit Breaker Adjustment Settings
Amps Dipswitch Conguration Amps Dipswitch Conguration
160 Amps 288 Amps
176 Amps 304 Amps
192 Amps 320 Amps
208 Amps 336 Amps
224 Amps 352 Amps
240 Amps 368 Amps
256 Amps 384 Amps
272 Amps 400 Amps
L
I1 =
In x (0.4+
PR221DS
Test
+-
0.04
0.08 0.16
0.32
)
0
0
0
0
t1
I=6I1
12s
3s
S
I
I2=
In x(Σ
1
1.5 2
5.5
)
0
0
0
0
I3= T2
I=8In
0.25s
0.1s
ON
OFF
N
10050
%
ABCD
ABCD

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10
PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
100-250 Amp Circuit Breaker Adjustment Settings
Amps Dipswitch Conguration Amps Dipswitch Conguration
100 Amps 180 Amps
110 Amps 190 Amps
120 Amps 200 Amps
130 Amps 210 Amps
140 Amps 220 Amps
150 Amps 230 Amps
160 Amps 240 Amps
170 Amps 250 Amps
Step 3: Adjusting the Circuit Breakers (continued)
100-250 Amp Circuit Breaker - DIP Switch Settings
1. Set the DIP switches on the circuit breaker to the closest level indicated in the table below with the set level
greater than the actual load
a. Only adjust the DIP switch labeled “L”
b. To adjust the circuit breaker, open the clear cover over the DIP switch using a small flathead screw driver
c. Move each switch (A, B, C, D) into the up or down position based on the table below to achieve the
desired output current rating
d. Close the clear cover over the DIP switch
L
I1 =
In x (0.4+
PR221DS
Test
+-
0.04
0.08 0.16
0.32
)
0
0
0
0
t1
I=6I1
12s
3s
S
I
I2=
In x(Σ
1
1.5 2
5.5
)
0
0
0
0
I3= T2
I=8In
0.25s
0.1s
ON
OFF
N
10050
%
ABCD
ABCD

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
60-150 Amp Circuit Breaker Adjustment Settings
Amps Dipswitch Conguration Amps Dipswitch Conguration
60 Amps 108 Amps
66 Amps 114 Amps
72 Amps 120 Amps
78 Amps 126 Amps
84 Amps 132 Amps
90 Amps 138 Amps
86 Amps 144 Amps
102 Amps 150 Amps
Step 3: Adjusting the Circuit Breakers (continued)
60-150 Amp Circuit Breaker - DIP Switch Settings
1. Set the DIP switches on the circuit breaker to the closest level indicated in the table below with the set level
greater than the actual load
a. Only adjust the DIP switch labeled “L”
b. To adjust the circuit breaker, open the clear cover over the DIP switch using a small flathead screw driver
c. Move each switch (A, B, C, D) into the up or down position based on the table below to achieve the
desired output current rating
d. Close the clear cover over the DIP switch
L
I1 =
In x (0.4+
PR221DS
Test
+-
0.04
0.08 0.16
0.32
)
0
0
0
0
t1
I=6I1
12s
3s
S
I
I2=
In x(Σ
1
1.5 2
5.5
)
0
0
0
0
I3= T2
I=8In
0.25s
0.1s
ON
OFF
N
10050
%
ABCD
ABCD

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12
PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
Step 4: Making the Output Connections
1. Select the appropriate gauge feeder cable to match the load requirements of each circuit that will be in use
2. Locate the sets of feeder cable that will be used to bring power from the Load Master box further downstream
3. Connect the Cam cables to the output that corresponds to circuit (1) first, beginning with the ground cable (Green)
4. Push the connector into the male (Green) Cam panel mount receptacle with the screw on the connector facing up
5. Rotate the connector clockwise at least 90 degrees until it stops to make sure it is secured in the locked position
6. Connect neutral (White) Cam cable second
7. Push the connector into the male (White) Cam panel mount receptacle with the screw on the connector facing up
8. Rotate the connector clockwise at least 90 degrees until it stops to make sure it is secured in the locked position
9. Repeat steps 3-4 to connect the Blue, Red and then Black phases in the same manner
Align the inline Ground connector with the
corresponding color-coded receptacle
Insert the Cam connector into the receptacle
and rotate Cam connector at least 90 clockwise
degrees to lock
Align the inline Neutral connector with the
corresponding color-coded receptacle
Insert the Cam connector into the receptacle
and rotate Cam connector at least 90 clockwise
degrees to lock

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
Step 4: Making the Output Connections (continued)
10. Connect the Cam set that is connected to circuit (1) to the input of the downstream power distribution box that matches
the load requirements of circuit (1). Connect the Cam set in the same manner and color order as detailed previously.
11. Repeat steps 3-10 for each additional circuit that will be in use on the Load Master Box, connecting the Cam cables in
the same manner and color order as detailed above.
NOTE: When disconnecting the cables, do so in reverse order starting with the phases (Black, Red and Blue), followed by the
neutral (White) and finally ground (Green).
Step 5: Powering Up
– Best practices dictate that loads are applied gradually and systematically the first time the system is set up
– If a circuit breaker cannot be energized or trips, check the system for continuity and short circuits, and make the necessary
corrections before proceeding
1. Turn on the power source
2. Turn the first circuit breaker required on the Load Master box to the ON position
3. After switching on the first circuit on the Load Master box, turn corresponding circuits for the downstream power distribution box to the
ON position
4. Ensure the devices fred by that circuit are ON, tracing the electrical path to the final device fed by that circuit
5. Repeat steps 2 thru 4 for each additional circuit breaker that will be in use on the Load Master power distribution box

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14
PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
TROUBLESHOOTING GUIDE
To help determine what has caused a circuit breaker to trip, it is important to configure the simplest possible power distribution
system set-up under which the problem still occurs. The loads connected to the system might exceed the circuit breaker rating, in
which case a larger power distribution unit would be needed. If a larger power distribution unit is needed, contact Lex Products with
the load information and requirements of the specific application to determine the appropriate power distribution system.
Circuit Breaker Tripping During Normal Operation
1. Verify whether circuit breaker long delay settings are set as needed
a. Ensure the N setting is at 100% and the ON/OFF functionality next to the N is set to OFF
b. These dip switches are intended for specialized single phase applications and do not apply to the Load Master series under
normal operation
2. Retry turning on the circuit after adjustments are made
3. If a large inductive load such as an air conditioner was turned on when the circuit breaker tripped, raise inrush settings or increase
the trip time delay
a. The inrush settings can be adjusted by turning on the dip switches for I3.
b. All dip switches up will result in the maximum inrush tolerance of ten times the circuit breaker rating
L
I1 =
In x (0.4+
PR221DS
Test
+-
0.04
0.08 0.16
0.32
)
0
0
0
0
t1
I=6I1
12s
3s
S
I
I2=
In x(Σ
1
1.5 2
5.5
)
0
0
0
0
I3= T2
I=8In
0.25s
0.1s
ON
OFF
N
10050
%
ABCD
L
I1 =
In x (0.4+
PR221DS
Test
+-
0.04
0.08 0.16
0.32
)
0
0
0
0
t1
I=6I1
12s
3s
S
I
I2=
In x(Σ
1
1.5 2
5.5
)
0
0
0
0
I3= T2
I=8In
0.25s
0.1s
ON
OFF
N
10050
%
ABCD
l3 dip switches: Move all dip switches
UP for maximum inrush tolerance
Set to OFF and 100%

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PowerHOUSE™ Load Master®Power Distribution Unit (PDU)
TROUBLESHOOTING GUIDE (continued)
Circuit Breaker Tripping When Powering Up
1. Follow the steps outlined for circuit breakers tripping during normal operation
2. If the issue persists, disconnect the output connections from the circuit breaker that is tripping
3. Turn on all circuit breakers
a. If the circuit breaker trips, contact Lex Products for technical assistance
b. If the circuit breaker does not trip proceed to the next step
3. Connect the cable to the corresponding circuit breaker outlets and turn off all attached loads
4. Turn on the circuit breaker
a. If the circuit breaker trips, disconnect cabling used and check for short circuits
b. Turn off all circuit breakers, check the cabling connected to the Load Master, and check connected loads for shorts circuits
How to Check a Load Master for Short Circuits
1. Disconnect incoming power from the Load Master box
2. Turn on circuit breaker(s) for the circuit(s) to be tested
3. Using a continuity meter or a multimeter, set to continuity/resistance mode and connect one probe to the input ground (green)
Cam-type connector brass
4. Take the other probe of the meter and check if there is continuity between each Cam-type connector and ground
5. Ifthereiscontinuity(R<1kΩ,orthemeterlightsuporbeeps),thereisshortcircuitpresent
a. Contact Lex Products Technical Services department
6. If there is no continuity, repeat step 3 and 4 checking if there is continuity between the neutral (white) Cam-type connector and
the other Cam-type connectors
7. If continuity is detected, there is a short circuit present
a. Contact Lex Products if a short circuit is detected
TECHNICAL SUPPORT
Lex Products is available to help answer any installation or operation inquiries. For any questions or technical advice, please call
Technical Services 24 hours per day, 7 days per week at 800.643.4460 or email [e-mail].

Lex Products
11 Forest Parkway
Shelton CT 06484
203.363.3738
203.363.3742 Fax
Lex South
15751 SW 41 Street
Davie, FL 33331
954.888.1024
954.888.1026 Fax
www.lexproducts.com
[email protected]
800.643.4460
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Produced in the United States of America
05-30 All Rights Reserved.
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trademarks or registered trademarks of Lex
Products in the United States, other countries,
or both.
WE DELIVER THE POWERTM
PowerGATE™ Load Master®
Portable Power Distribution Box
Operator’s Manual
TYPE 3R Rainproof TYPE 1 Indoor or
TYPE 3R Rainproof
TYPE 3R Rainproof TYPE 1 Indoor or
TYPE 3R Rainproof
PowerGATE®
Switches & Panels
PowerPLUS
Installed Distribution Boxes
TM
PowerRAMP®
Cable Protectors
Power Control Solutions
™
Dimming & Control
™
PowerHOUSE
Portable Distribution Boxes
TM
PowerPARTS
Wiring Devices
TM
PowerRACK
Rolling Distribution Racks
TM
WeldingRACK
WR6
TM
PowerFLEX
Cable Assemblies
TM
LuxCommander®
Portable Work Lights
Smart Power™
Energy Storage
Lex West
12701 Van Nuys Blvd.
Suite Q
Pacoima, CA 91331
818.768.4474
818.768.4040 Fax