Mosebach X100L Operation manual

X100L
Load Bank

X100L Load Bank
2
Read all instructions before using the load bank
Contents
1. Components .............................................................................................................................. 3
Total Assembl ................................................................................................................................. 3
2) Specifications ............................................................................................................................... 4
a) X100L Load Bank ............................................................................................................ 4
3) Receiving ...................................................................................................................................... 5
4) Safet ........................................................................................................................................... 5
a) Grounding ............................................................................................................................. 6
b) Power connections ............................................................................................................... 7
d) Air intakes and exhaust ports ............................................................................................... 7
e) Exhaust temperature ............................................................................................................ 7
f) Connecting and disconnecting ............................................................................................. 8
5) Operation ................................................................................................................................... 8
a) Pre-startup ............................................................................................................................ 8
b) Startup .................................................................................................................................. 9
c) Testing .................................................................................................................................. 9
d) Acuvim II Power Meter.......................................................................................................... 9
e) Shutdown ............................................................................................................................ 10
6) USB Communication Port ....................................................................................................... 10
7) Troubleshooting ....................................................................................................................... 11
8) Replacing Fuses ...................................................................................................................... 12
9) Replacing Resistors ................................................................................................................ 13
10) Preventative Maintenance of the Load Bank ...................................................................... 15
11) Service Parts ...................................................................................................................... 16
Figure list:
1) Total Assembl of X100L Load Bank
2) Grounding Cam
3) Switch Panel
4) Acuvim II Power Meter
5) T pical USB A to USB B male
6) Blower/Control/Main Fuses
7) Thermal Switch
8) Replacing Fuses
9) Switch Panel Support Bolts
10) Replacing Resistors
11) Resistor/Contactor Connections

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3
IMPORTANT INSTRUCTIONS
1. Components
Total Assembly
X100L
Lifting
Handle
Customer
Connections
Figure 1b
Exhaust Panel
Figure 1a
Switch Panel
Fan Panel
120V Control
Connection

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4
2 Specifications
Blower 120V C, single phase, 60Hz powered from control
Control power 120V C, single phase, 60 Hz
Rating Continuous duty
Power factor 1.0
Load elements Each circuit is connected in delta.
The kW at each step is subject to a manufacturing tolerance of ±5%.
Enclosure
E
lectro
-
statically
powder coat, Blue: PPG PC
TZ50108
Touch up paint is Pantone 280-c color. Plastikote custom color universal blend.
ir inlet and outlet are covered by metal screens.
Heat is discharged horizontally.
Environmental 8 x 240V, 420CFM fans to bring outside air into the load bank.
a) X100L Load Bank
3Ø
Customer Input
1Ø
Customer Input
Jumper
B Customer

X100L Load Bank
5
3 Receiving
WARNING! ELECTRIC SHOCK HAZARD. Electric shock can lead to severe injury or death.
If the load bank has been damaged in transit, do not operate until a competent
technician inspects the unit and determines that it can be operated safely.
1. Check the equipment for obvious damage.
2. Document and report an exterior damage to the carrier immediatel .
4 Safety
This Load Bank is designed for a variet of loads. Because of this, it is possible that voltages
higher that those applied can be present inside the load bank and at external connections of the
load bank. Work on load bank internal s stems should onl be attempted b highl trained
technicians and onl when power has been disconnected and cannot be reconnected to the unit.
IMPORTANT INSTRUCTIONS
When using electrical appliances, basic precautions should alwa s be followed to reduce the risk
of fire, electrical shock, and injur to persons, including the following:
1) Read all instructions before using this heater/load bank.
2) This load bank is hot when in use. To avoid burns, do not let bare skin touch hot
surfaces. Use handles when moving this load bank.
Input Voltage Volt.
Mode
kW
Steps
kW
Steps
kW
Steps
kW
Steps
kW
Steps
kW
Steps
Total
Power
mps
480v C, 3Ø
Resistive 480 5 10 10 15 30 30 100 120.3
240v C, 3Ø
Resistive 240 5 10 10 15 30 30 100 240.6
208v C, 3Ø
Resistive 208 3.76 7.51 7.51 11.27 22.53 22.53 75.11 208.5
240v C, 1Ø
Resistive 240 3.33 6.67 6.67 10.00 20.00 20.00 66.67 277.8
120v C, 1Ø
Resistive 120 0.83 1.67 1.67 2.50 5.00 5.00 16.67 138.9

X100L Load Bank
6
3) Extreme caution is necessar when an load bank is used b or near children or
invalids and whenever the load bank is left operating and unattended.
4) Alwa s unplug load bank when not in use.
5) Do not operate an load bank with a damaged cord or plug or after the load bank
malfunctions or has been dropped or damaged in an manner. Discard load bank or
return to authorized service facilit for examination and/or repair.
6) Do not use outdoors.
7) This load bank is not intended for use in wet environments.
8) Do not insert or allow foreign objects to enter an ventilation or exhaust opening as
this ma cause an electric shock or fire, or damage the heater/load bank.
9) To prevent equipment failure or a possible fire, do not block air intakes or exhaust in
an manner.
10) A load bank has hot parts inside. Do not use it in areas where gasoline, paint, or
flammable liquids are used or stored.
11) Use this load bank onl as described in this manual. An other use not recommended
b the manufacturer ma cause fire, electric shock, or injur to persons.
12) “SAVE THESE INSTRUCTIONS”
a Grounding
WARNING! ELECTRIC SHOCK HAZARD. The grounding lug must be connected to earth
ground. Operating without a grounding connection could lead to injury or
death.
When the load bank is in operation the grounding cam must be firml and electricall connected
to earth ground. The grounding connection provides a low resistance path to ground. This
grounding protects the operator from the possibilit of electrical shock.
Figure 2. Ground and
Power Cam-locks,
Control Power
G
round
Power
Control Power

X100L Load Bank
7
b Power connections
WARNING! ELECTRIC SHOCK HAZARD. All power connections must be connected or
guarded. Failure to do so will expose operators to possible shock.
c Control Power
Use 120V t pe S or t pe SJ jacketed cord to a wall connection. Cord and service rated to 10 AMP
minimum. (see figure 2.)
d Air intakes and exhaust ports
Caution! All air intakes and exhaust ports must be clear and fully open. This load bank
has one air intake designed for proper air flow. Reducing or blocking air flow will
lead to overheating and load bank failure.
High volumes of cooling air are needed to prevent load elements from overheating. B their ver
nature, resistors under load convert electrical energ to heat. This heat must be removed from
the unit. The blower, intake, and exhaust ports are sized to provide the proper amount of cooling
air. Preventing or limiting air flow will allow the load bank to overheat.
Keep intake at least four feet awa from walls and obstructions. Keep exhaust at least 10 feet
awa from walls and obstructions.
To increase the life of the load elements, allow the fans to run at least three minutes after the load
is removed or until exhaust air is cool.
No ductwork is permitted on intake or exhaust of this load bank as this will cause a backpressure
which ma be harmful to the resistors.
Caution! Material can be moved by intake air or exhaust air. Failure to secure material
could cause injur to b standers or damage to the load bank.
e Exhaust temperature
WARNING! FIRE AND BURN HAZARD. Keep flammable material at least 40 feet away from
the load bank. A great deal of heat is expelled from the load bank.
Temperatures inside the load bank are sufficient to ignite flammable fumes or
materials. Failure to maintain proper housekeeping and properly securing
flammable material could lead to fire, burns, and/or injury.
Even with sufficient air flow, internal component temperature ma exceed 400 °C. Exhaust
temperatures of 90°C are common. Flammable materials must not be kept around the load bank.
Heat from the load bank could ignite this material.

X100L Load Bank
8
f Connecting and disconnecting
WARNING! BURN HAZARD. Attempting to connect or disconnect leads while load bank is
in operation can lead to severe injury or death. Connecting or disconnecting
plugs and receptacles while current is flowing or voltage is present may cause
arcing. Arcing can generate a great deal of light, heat and possibility of
electrocution.
5 Operation
NOTE: Contact Mosebach Manufacturing if ou are planning operations in ambient temperatures
above 46 °C.
Ambient plus heat generated b the resistor can cause electrical components to possibl
malfunction.
a Pre-startup
1. Check housekeeping in the operational area and correct all unsafe conditions.
Failure to do this ma result in debris being blown around and ma cause a fire hazard.
2. Connect the load bank’s ground cam-lock to a known earth ground.
3. Check the switch panel and move all switches to the OFF position. (see figure 3)
4. Position load bank so that air will flow freel into the intakes and out of the exhaust port.
5. All air intakes and exhaust ports must be clear.
Figure 3. Switch Panel

X100L Load Bank
9
b Startup
1. Connect 120VAC control power plug to the unit.
2. Connect cam-locks to the unit.
Ensure cable size is sufficient to carr the expected current. Failure to size conductors
properl will lead to conductor overheating, which will damage conductors and ma pose
a fire hazard.
3. Turn the MAIN on/off power switch to the ON position with the voltage required. Your unit
is equipped with a voltage sensor, that will allow it to operate with either 208/240V or
480V applied. Check the voltage lights on the switch panel to see that the proper voltage
light comes on. The unit will not run if an acceptable voltage is not supplied. The
blowers, meter and green power light will turn on when an acceptable voltage is supplied.
Caution! Make sure air is flowing from the exhaust port. Failure to have proper
air flow will cause unit to overheat and fail.
c Testing
1. Start with the Main Power located in the ON position with the required voltage and Master
in the OFF position.
2. To load instantaneousl to a specific value: turn Master switch to OFF position, turn
desired load switches to ON position, and then turn Master switch to ON position.
3. To load to individual steps: turn Master switch to ON position, turn desired load switches
to ON position.
4. Repeat tests as needed.
d Acuvim II Power Meter
1. Press the “VA” button on the front of the meter to view and c cle through the line voltage
and current options.
2. Press the “P’ button on the front of the meter to view and c cle through the Power
Reading and Power Factor options.
You will find more detailed instructions on the use of our meter on the CD disk that was
supplied with our load bank manual or b visiting the “accuenerg .com” website.
Figure 4.
Acuvim II Pow
er Meter

X100L Load Bank
10
e Shutdown
1. Place all step switches in the OFF position. Put Master in the OFF position.
2. Allow fans to operate at least three minutes or until exhaust air is cool before shutting
them off.
This cooling period will extend the life of our load bank.
3. Turn Main Power Switch to the OFF Position and remove 120v control power.
4. Turn off source power and customer is to confirm prior to disconnection of power cables.
5. Put cables back into the storage box. (Not supplied b Mosebach)
6. Remove ground connections.
7. Move the unit to storage.
6 USB Communication Port
This load bank is equipped with a USB communications post. This port enables the user to
connect the meter to a PC and read the test parameters from a remote location.
A USB cable is not provided. It should be purchased separatel . See Figure 5 for an example.
Figure 5. Typical USB A to USB B male

X100L Load Bank
11
7 Troubleshooting
Meter/Load Bank Will
Not Turn On
Make sure main switch is in the ON position with correct voltage.
Make sure 120v control power is connected.
Blower will not turn on. Check for debris preventing fan from turning.
Check blower fuse. See Figure 6.
Load steps will not turn
on.
Check if over temp red light is on.
Make sure that test source is on.
Check control fuses. See Figures 6.
Check resistor continuity. See Figure 10 and schematic.
Check resistor step fuses. See figure 6
Check Voltage/Main Switch.
Over temperature light.
This is an indication that the internal cabinet temperature has exceeded 150°F.
Make sure the cabinet is ventilated.
Check over temperature sensor (OTS) see Figure 7.
Voltage Lights
Check that applied voltage is in agreement with selected voltage. Check that applied
voltage is no more than 5% in the particular voltage mode that the unit is set in. If the limit
is exceeded then the unit will not operate. Check the power cord loss if the cable is long.
Figure 6 Blower/Control/Main Fuses in the Switch
Panel
Main Fuses
Meter Fuses
OTS Open @ 150°F
Figure 7. Thermal

X100L Load Bank
12
8 Replacing Fuses
1. Using a #2 Phillips head screwdriver, remove the ten #10 screws from the lid. Carefull
remove the panel from the unit. Fuses are located of the main. Service on fuses can now
be performed. (See Figure 8)
Figure 8a
Figure 8b
#10
-
24 Truss
Head Bolt
Replace
Fuses

X100L Load Bank
13
9 Replacing Resistors
1. Using a #2 Phillips head screwdriver, remove the twent #10 screws from the lid.
Carefull remove the panel from the unit. (See Figure 9a)
2. Using a #2 Phillips head screwdriver, remove the ten #10 screws from the Front
Panel. Carefull remove the panel from the unit. (See Figure 9b)
#10
-
24 Truss
Head Bolt
Front Panel
Figure 9a
Figure 9b
Exhaust
Mesh

X100L Load Bank
14
3. Using a #2 Phillips head screwdriver, remove the six #10 screws from the Exhaust
Mesh. Carefull remove the panel from the unit. Service on resistors can now be
performed. (See Figures 9b and 10)
4. Disconnect the bad resistor wires from the contactors. Do not disconnect the wires
from the resistor side. Each wire is labeled on both ends for eas identification.
5. Pull out the bad resistor cassette.
6. Replace the old resistor cassette with a new one. Run the lead through the
corresponding hole in the control panel. The part number of each resistor cassette is
stamped on the top of them.
7. Connect the lead back into the proper contactor location.
8. Carefull place the Exhaust Mesh back into its proper position. Using a #2 Phillips
head screwdriver, replace the six #10 screws.
9. Carefull place the Front Panel back into its proper position. Using a #2 Phillips head
screwdriver, replace the ten #10 screws.
10. Carefull place the lid back into its proper position. Using a #2 Phillips head
screwdriver, replace the twent #10 screws.
Disconnect Wires
from Contactors
Figure 10
S
lide
Out
R Cassette

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10 Preventative Maintenance of the Load Bank
Do not use a power washer to clean off the exterior of the unit. It is high voltage
electrical equipment.
Action Frequency
Walk around the unit and inspect for:
a) Obvious damage
b) Loose hardware
Ever use
Megger Test Ever 6 months
Cold Resistance Check Ever 6 months
Air Flow Test Ever 6 months
Power Test Ever 6 months
Open Control Panel and Inspect for:
a) Loose wire connections
b) Visuall damaged components
Ever 6 months
Inspect Bearings Annuall
Inspect Fan Annuall
Inspect Resistors for:
a) Damage to coils
b) Delamination of the mica
Annuall
Contactors are opening and closing Annuall
Meter Calibration Annuall

X100L Load Bank
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11 Service Parts
Cop right © 2018 Mosebach Manufacturing Compan
MOSEBACH MANUFACTURING COMPANY
1417 McLaughlin Run Road • Pittsburgh, PA 15241-3103 USA
T: 412.220.0237 Customer Care
F: 412-220-0236
www.mosebachresistors.com
OM-X100L.doc
“SAVE THESE INSTRUCTIONS”
Power Part Number
Fan EC-9500-2177
EC-9500-2178
Resistor
Elements
R -0055-0426-1
R -0055-0426-3
R -0055-0426-3
R -0055-0426-4
R -0055-0426-5
R -0055-0426-6
R -0055-0426-7
R -0055-0426-8
Fuses
1 Type GC = GC-1-R
1 = EC-9500-0247
5 = EC-9500-2017
10 = EC-9500-2017
300 = EC-9500-0849
Meter EC-9500-1690
Contactors EC-9500-2143
EC-9500-2174