POWER PROVE AC100-CPT Operating instructions

Operating and Maintenance Manual
AC100-CPT load bank
100kW at 400V AC 3-Phase
Reference No.
162736
Revision
A
Revision ref. (ECN)
N/A
Date
09-MAR-2021
Author
AK
Power Prove
www.powerprove.com
Leicester. LE5 5LZ. United Kingdom
[e-mail]
a division of Cressall Resistors Ltd.
[phone]

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 1 of 11
Operating and maintenance manual
Load bank providing maximum load of 100kW at 400V AC 3-
phase in 2.5kW increments
Figure 1 - Product photo.
1) ! Warnings
Prior to use
Operators of this equipment should be of suitable competency to perform electrical testing.
Prior to use ensure the equipment operator must have read and understood this document.
First use
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 any exterior damage immediately.
During use
When testing for a continuous period of more than 5 minutes the exit grill and adjacent covers will become hazardously
hot to touch and remain hot for approximately 20 minutes after testing is completed. The exiting air will also be hot
(>100°C). Exercise care when touching casework (especially exit grill) even after power supply is disconnected.
The unit should not be connected and used with a DC supply.

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 2 of 11
2) Safety Requirements
General
When using electrical appliances, basic precautions should always be followed to reduce the risk of fire, electrical shock,
and injury to persons, including the following:
1) This product is designed for indoor use, i.e. in dry conditions. Do not store or use outside in wet weather
conditions.
2) Position on flat horizontal surface and remove any combustible materials from the test area.
3) This load bank is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. Keep combustible
materials at least 6 feet (1.8 meters) from the front of the load bank and keep them away from the sides
and rear.
4) Do not operate any load bank with a damaged cord or plug or after the load bank malfunctions or has
been dropped or damaged in any manner. Discard load bank or return to authorized service facility for
examination and/or repair.
5) Always unplug load bank when not in use.
6) Do not run cables under carpeting. Do not cover cord with throw rugs, runners, or similar coverings.
7) Arrange cables away from high foot traffic areas, where they will not present a trip hazard.
8) Connect to properly earthed outlets only.
9) Do not insert or allow foreign objects to enter any ventilation or exhaust opening as this may cause an
electric shock, fire or damage the heater/load bank.
10) To prevent a possible fire, do not block air intakes or exhaust in any manner.
11) Ensure free movement of air at fan inlet. Minimum recommended clearance from the air outlet of 1500mm.
12) Do not use the load bank areas where flammable liquids are used or stored.
13) Always plug load banks directly into a wall receptacle. Never use with a re-locatable power tap
(outlet/power strip).
14) This load bank includes a visual alarm to warn that parts of the load bank are getting excessively hot. If
the alarm light goes on, immediately turn the load bank off and inspect for any objects on or adjacent to
the load bank that may cause high temperatures. Do not operate the load bank with the alarm light on.
Protective earth bonding
Electric shock hazard! The protective earth stud must be connected to an external earth point. Operating without a
grounding connection could lead to injury or death.
When the load bank is in operation, the grounding stud securely, electrically connected to an external earth point. The
earth bonding connection provides a low resistance path to ground. This earth bonding protects the operator from the
possibility of electrical shock.
Power Connections
Electric shock hazard! All power connections must be connected or guarded. Failure to do so will expose operators
to possible shock.
Control power
If using an external source use 230V AC 1-phase C14 type 3-pin cable to a wall connection. Cord and service rated to
10 A minimum. (See Figure 2) Otherwise ensure the unit’s Control Source switch is properly set and the voltage input to
the Powersafe sockets is appropriate to supply the units control circuits as well as the full load.

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 3 of 11
Figure 2 - Powersafe load connections, control power (C14 socket) and Protective Earth stud
Air intakes and exhaust ports
All air intakes and exhaust ports must be clear and fully open. This load bank has one air intake designed for proper
airflow. Reducing or blocking airflow will lead to overheating and load bank failure and risk of fire.
High volumes of cooling air are needed to prevent load elements from overheating. By their very nature, resistors under
load convert electrical energy 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 airflow will allow the load bank to
overheat.
Keep intake at least four feet away from walls and obstructions. Keep exhaust at least 10 feet away 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.
Ductwork must not be attached to either the air intake or exhaust of this load bank. This will cause a backpressure that
may be harmful to the resistors.
Material can be moved by intake air or exhaust air. Failure to secure material could cause injury to bystanders, damage
to the load bank or other nearby equipment.
Exhaust Temperature
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 fumes
or materials. Failure to maintain proper housekeeping and properly securing flammable
material could lead to fire, burns, and/or injury.
Even with sufficient airflow, internal component temperature may 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.
Connecting and disconnecting
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.

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 4 of 11
Connection sockets to be used for both 3-phase and 1-phase operation are shown in Figure 3.
Figure 3 - 3-phase and 1-phase connection diagram

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 5 of 11
3) Specification
Cooling
8 x 24V DC Fans powered by internal supply
Control power
230V AC, single phase, 50 Hz , Int./Ext. supplied
Rating
Continuous duty
Power factor
1.0
Load elements
Each circuit is connected in Star (Y).
The kW of step is subject to a manufacturing tolerance of ±5%.
Enclosure
Electro-statically powder coat, Smooth ASA 70 Gray: PPG PCT70158
Metal screens cover the air inlet and outlet.
Heat is discharged horizontally.
Table 1 - Equipment specifications
Load sections
Table 2 - Load sections and corresponding phase resistances
Input voltage modes
Terminal
Volt.
Mode
Load sections
Total (all
sections)
400V AC, 3Ø
Resistive
2 kW
4kW
4kW
6kW
14kW
14kW
28kW
28kW
100kW
Resistance
when loaded;
Line-Neutral
(Ω)
80.0
40.0
40.0
26.7
11.4
11.4
5.71
5.71
1.60
Resistance;
when cold;
Line-Neutral
(Ω)
76.2
38.1
38.1
25.4
10.9
10.9
5.44
5.44
1.52
Input Voltage
Volt.
Mode
kW
Steps
kW
Steps
kW
Steps
kW
Steps
kW
Steps
kW
Steps
kW
Steps
kW
Steps
Total
Power
Amps
400V AC, 3Ø
Resistive
400
2
4
4
6
14
14
28
28
100
144.3
230V AC, 1Ø
Resistive
230
.67
1.33
1.33
2
4.67
4.67
9.33
9.33
33.33
144.9
Table 3 - Load step and total power levels in both operating modes

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 6 of 11

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 7 of 11
4) Instructions for use
Note. Contact Power Prove if you are planning operations in ambient temperatures above 46 °C. (Ambient plus heat
generated by the resistor can cause electrical components to possibly malfunction.)
Figure 4 –User control panel.
Pre-start-up
1. Check housekeeping in the area in which the load bank is operating, and correct all unsafe conditions.
Failure to do this may result in debris being blown around and may cause a fire hazard
2. Connect the load bank’s protective earth stud to a known external earth point
3. Check the switch panel and move the load switches and main power switch to the OFF position. (see Figure
4)
4. Position the load bank so that air will flow freely into the intakes and out of the exhaust vents
5. All air intakes and exhaust vents must be clear
Start-up
i. Using internal control and fan power
1. Connect the ground stud on the unit directly to a known earth-ground.
2. With the supply source de-energised, connect all main load (Powersafe) plugs to the sockets on
the unit. Ensure cable size is sufficient to carry the expected current. Failure to size conductors
properly will lead to conductor overheating, which will damage conductors and may pose a fire
hazard.
3. Set the “Control Source” to the “Int” (Internal) position. The unit will use the Source voltage
between L1 phase and neutral to power the control circuitry and fans.
4. Energize the load power source with an acceptable voltage.
5. 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 not allow the unit operate if bus voltage exceeds
421VAC L-L (243VAC L-N). The blowers, meter, and green Main Power switch light will turn on
with an acceptable voltage level.
Caution! Make sure air is flowing from the exhaust port. Failure to have proper airflow will cause unit to
overheat and fail.

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 8 of 11
ii. Using external control and fan power
1. Connect the ground stud on the unit directly to a known earth-ground.
2. Connect all de-energized load power Powersafe to the unit Ensure cable size is sufficient to carry
the expected current. Failure to size conductors properly will lead to conductor overheating, which
will damage conductors and may pose a fire hazard.
3. Connect an external 3-pin 230VAC control cable to the 3-pin plug located on the connections
panel.
4. Set the “Control Source”switch to the “Ext” (External) position.
5. Energize the external power source with an acceptable voltage.
6. Energize the load power source with an acceptable voltage.
7. 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 not allow the unit operate if bus voltage exceeds
421VAC L-L (243VAC L-N). The blowers, meter, and green Main Power switch light will turn on
with an acceptable voltage level.
Caution! Make sure air is flowing from the exhaust port. Failure to have proper airflow will cause unit to
overheat and fail.
Applying & disconnecting load
1. Start with the Main Power switch located in the ON position, the Control Source switch in the correct
position, and the Master Load switch in the OFF position.
2. “Shock” Loading
a. Begin with the Master switch in the OFF position
b. Place the desired test step switches in the ON position.
c. Place the Master switch ON to engage all selected load simultaneously.
3. “Step” Loading
a. Begin with the Master switch in the ON position.
b. Place desired step switches in the ON position to apply load systematically.
4. Disconnect individual steps by placing the step switches in the OFF position and/or disconnect all load
simultaneously by placing the Master switch in the OFF position.
5. “Step” and “Shock” loading can be used in conjunction with one another during testing.
6. Repeat tests as needed.
Shutdown
1. Place all load step switches in the OFF position. Put Master Load in the OFF position.
2. Allow fans to operate at least five minutes or until exhaust, air is cool before shutting them off. This cooling
period will extend the life of your load bank.
3. Turn Main Power switch to the OFF Position.
4. Turn off Generator/Power source for the unit.
5. If using external power source remove the 230V control plug.
6. Before removing the main load cables, verify that the source power is off. Once this is verified, disconnect
the load cables from the Powersafe sockets.
7. Remove ground connections.
8. Move the unit to storage.

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 9 of 11
Power meter operation
1. 1. Press the “VA” button on the front of the meter to view and cycle through the line voltage and current
options.
2. Press the “P’ button on the front of the meter to view and cycle through the Power Reading and Power
Factor options.
Software instructions can be found in section 5) of this manual with further details available on the “accuenergy.com”
website.
5) USB communication port
This load bank is equipped with an Acuvim II Power Meter that has a USB communications port
1
. This port enables the
user to connect the meter to a PC and read the test parameters from a remote location. The communications software can
be downloaded at accuenergy.com.
Downloading communications software
Under the Products tab under Power Meters, click Acuvim II Series. Then under Downloads, click Software. Run
Acuview.exe to load the software on your computer. After loading the software, connect the cable between the PC and
the load bank.
Using the Acuview software
Start the Acuview program and take the following steps:
Create a connection Click Settings > Connection Manager > New
Type in a name that you want to use for your connection
Check Serial Port
Select the Com Port that your computer is set up to use for USB
Select the Baud Rate –(default for the meter is 19200)
Set Parity to None 1
Add a device Click Operation > Add Device
Select Acuvim II for the device type
Select the Com Port name that you configured above
Select 1 for the Device Address (should match meter settings)
Enter the description that you want to use for this device.
Connect Click Operation > Connect
You should now be able to view the power meter readings from the load bank. More detailed instructions on the set-up
and use of your software can be found on the “accuenergy.com” website.
1
A USB cable is not provided. A USB type-B male is required to connect to the load bank and usually USB type-A at the
other end of the cable for PC connection. This can be purchased from Power Prove.

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 10 of 11
6) Maintenance
This load bank is designed for a variety 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 the load bank internal
systems shall done by suitably competent persons (trained technicians) and only when power has been disconnected and
cannot be reconnected to the unit.
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
Every use
Insulation Resistance Test
Every 6 months
Cold Resistance Check
Every 6 months
Air Flow Test
Every 6 months
Power Test
Every 6 months
Open Control Panel and Inspect for:
a) Loose wire connections
b) Visually damaged components
Every 6 months
Inspect Fan
Annually
Inspect Resistors for:
a) Damage to coils
b) Delamination of the mica
Annually
Contactors are opening and closing
Annually
Table 4 - Routine maintenance checks table

Document Operating and Maintenance manual, AC100-CPT
Reference No. 162736
Revision A
Date 09-MAR-2021
Author AK
Power Prove www.powerprove.com
Leicester. LE5 5LZ. United Kingdom [e-mail]
a division of Cressall Resistors Ltd. [phone] Page 11 of 11
7) Troubleshooting
Meter/load bank
will not turn on
Make sure main switch is in the ON position with correct voltage.
Make sure 230V control power is connected if using external source, and that the Control
Source switch is set to Ext (External).
If using internal source mode, verify that the Control Source switch is set to Int (Internal)
Ensure L1 phase and neutral load terminals are connected.
Main power switch
not illuminated
Verify that the input power is 230VAC L-N 1-phase, or 400VAC 3-phase L-L
Check if Meter Relay is blown
Check if Switch Light is burnt out.
Load steps will not
turn on.
Check if Over Temp red light is on.
Make sure that test source is on.
Check Voltage/Main Switch.
Over temperature
light.
This is an indication that the internal cabinet temperature has exceeded 75°C.
Make sure the cabinet is ventilated.
Blower will not turn
on.
Check for debris preventing fan from turning.
Table 5 - Troubleshooting guidance table
Should any of the above checks fail to resolve the problem, please return the unit to Power Prove for further
investigation.
8) Waste Electrical & Electronic (WEEE) Disposal Instructions
European directive 2012/19/EU Waste Electrical and Electronic Equipment (WEEE) GB this appliance is marked
according to the European directive 2012/19/EU on Waste Electrical and Electronic Equipment (WEEE). By ensuring that
this product is disposed of correctly. You will help prevent potential negative consequences for the environment and
human health, which could otherwise be caused by inappropriate disposal of this product.
The symbol on the product, or on the documents accompanying the product, indicates that this appliance must
not be treated as municipal waste. Instead it must be handed over to a licensed waste carrier and waste broker
approved by the Environment agency under the Waste (England and Wales) Regulations 2011.
9) Spares
Enquire with reference to resistor product code and serial number, as shown on rating plate.
We offer a full equipment inspection, repair (when necessary) and re-test service for any of our load banks at our
headquarters in Leicester, UK.