Load Test using the Load Bank

For information on troubleshooting, service, replacement parts, see: Load Bank user manual

Safety

Arc Flash safety. Arc Flash rating 15.8 cal/cm^2. Arc Flash PPE; Arc flash suit, Arc rated FR shirt and pants, arc rated gloves with leather protectors, face shield, hearing protection and safety glasses. Insulation blanket and shepherds hook.

Required Tools: Multimeter, 3/8 impact driver bit, keys for the load bank and zip ties.

Connecting and disconnecting cables between Sources and Loads must be done by a qualified DKIST Tech.

Setup to Load test the Generator

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Transfer switch needs to be inhibited from transferring by toggling switch.

Open

Insure feeder breaker from generator is in the off position.

Open

Open Automatic Transfer Switch front door. Select ‘Inhibit’ on the toggle switch mounted on the ATS cabinet door.

Remove lower back cover from ATS to expose connections.

Pull connections out of ATS and install insulation blanket and connect cables.

Locate the Load Test cables. There are two sets of 4 cables. Each cable has a CamLok connector at each end.

Route cables from Automatic Transfer Switch to Load Bank

Connect 6 cables to the matching color at the ATS.

Attach 7 cables at the Load Bank swapping one phase to ensure proper rotation of fan (fan should blow upwards).

Setup to Load test the 300KVA UPS

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Before turning on the load bank

Load Bank requires Key 23 to unlock the control cabinet door and side doors.

Check for any abnormalities , loose wire, blocked vents, foreign objects

Ensure circuit breaker is closed and ready to provide control power to load bank.

Start the Load

Start the load source (generator or UPS).
Ensure the Load Bank Fan/ Control Power Disconnect Switch, located on the door, is in the on position.

Check the Load Bank intake areas, located (bottom of the Load Bank), to ensure that vents are not blocked by paper or other debris that would prevent the cooling fan from pulling in air.

Turn on the Load Bank

On the HMI, turn on the load bank by pressing the Control Power button (upper left corner of the screen)

Verify that the Load Bank fan is operating normally.

Enter Manual Mode

Press the “F1 - Manual Mode” on the screen.

Set the Test Load

In the upper right area of this screen a display indicates the Load to be applied, measured in kilowatts.
To change this value, touch the number and enter the new value on the numeric keypad that appears.

Enter the desired Load Value and press the ↵ button to return to the previous screen, or press “Esc” to return to the main screen without changing the value.
In the lower right quadrant of the screen is the KW Jog value. This indicates by how many kilowatts you will increase or decrease the load by pressing the “-” and “+” buttons, respectively.

To change this Load Value, press the number and enter your choice using the numeric keypad.

Set the Test Load

To begin testing, press the “Master Load” button. This will activate the load bank and begin applying the load displayed in the upper right area of the screen. To quickly decrease or increase the load, press the “-” and “+” buttons.

If ‘Load Dump Active’ appears on the HMI

Press the ‘Settings’ button

Enter security code 4831600

HMI returns to main screen

Press the ‘User Settings’ button

Press the ‘Load Dump Bypass’ button

After testing

Turn off Load Bank

Turn off Generator

Turn off Generator breaker

Disconnect test cables between Source and Load

Inspect Load Bank, close and cap off leads

Turn on generator breaker

Return generator to auto

Return ATS inhibit back to auto