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160-400 Amp Load Master Manual

1. actual load L TET SS 8 ho A 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 ABCD 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 Configuration Amps Dipswitch Configuration 160 Amps 288 Amps 176 Amps 304 Amps 224 Amps 302 Amps 368 Amps 240 Amps 384 Amps 272 Amps 400 Amps 800 643 4460 www LexProducts com 4 For a load to be paired with the 100 250 Amp circuit breaker and receptacle set the dipswitches on the circuit breaker to the closest level indicated in the table below with the set level FF e su oF Ps i ink 004 o go oc L paT greater than the actual load a Only adjust the dip switch labeled L SEEE b To adjust the circuit breaker open the clear cover over the dip switch using a small flathead screw driver ABCD 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 100 250 Amp Circuit Breaker Adjustment Settings Amps Dipswitch Configuration Amps Dipswitch Configuration 100 Amps 180 Amps 200 Amps 130 Amps 140 Amps 220 Amps 16
2. circuit breakers check the cabling connected to the Load Master and check connected loads for shorts circuits How to check for 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 2 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 lt 1 KQ or the meter lights up or beeps there is short circuit present Contact Lex Products Technical Services department 6 lf 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 If continuity is detected there is a short circuit present 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 855 LEX 1002 or email support lexproducts com 800 643 4460 o www LexProducts com 15 LEX We Deliver the Power
3. 0 Amps 240 Amps Lex Products User Manual Lex Products Load Master Box 5 For a load to be paired with the 60 150 Amp circuit breaker and receptacle set the dipswitches on the circuit breaker to the closest level indicated in the table below with the I E oy ink 064 a of oc L BERG set level greater than the actual load a Only adjust the dip switch labeled L SEEE b To adjust the circuit breaker open the clear cover over the dip switch using a small flathead screw driver ABCD 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 60 150 Amp Circuit Breaker Adjustment Settings Amps Dipswitch Configuration Amps Dipswitch Configuration 60 Amps 108 Amps 84 Amps 144 Amps 300 643 4460 www LexProducts com Lex Products Load Master Box Step 4 Making the Output Connections 1 Select the appropriate guage feeder cable to match the load requirements of each circuit that will be in use Locate the sets of feeder cable that will be used to bring power from the Load Master box further downstream Connect the Cam cables to the output that corresponds to circuit 1 first beginning with the ground cable Green Push the connector into the male Green Cam panel mount receptacle with the screw on the connector facing up Rotate the connector clo
4. Lex Products Corporation 15 Progress Drive Shelton CT 06484 203 363 3738 203 363 3742 Fax We Deliver the Power Load Master Lex West 11847 Sheldon Street Sun Valley CA 91352 818 768 4474 818 768 4040 Fax www lexproducts com info lexproducts com 800 643 4460 Portable Power Distribution Box OPERATOR S MANUAL LM LOADMASTER Table of Contents SpecificatiON S s cessseveetoce cient pctetscnsteecsre enccien eenresue gee cect etyea ye acct Eiaeaen ee Eea AoE EEA AEA AA DEEN EEEa anaE aE Ea aaiae 2 3 HOUR O e E E E E A AEA E 4 Lex Products Load Master Components sce osscecncetarar sess secdesostonpanie depts sscee demneantea duosteaditivonatenad stunactuesdnalbaangadiastiesadumedds 4 onionenn Unpacking and MING TVG iON cassona inasai aina SAETTA Nin EEEE 5 Set Up Step 1 Placement and Inspection of the Load Master BOX uuu cece ccecesceccesceeseseeceseeseseceeseveveesesevaesevevavseveteeervenenen 5 Step 2 Setting Up the Load Master Distribution Box for USE 6 step 2 1 Making Cam Type Connections oo ccc cece cscs escscscsessseseesesseteeessssstetisstetisttiritesisersieseitisinnetess 7 Step 2 2 Connecting the INpUt nce tencesep secemnce ate eacca nas evateno Grae se eave ace ctcturaen cess a cesubbute ea desettenetcr acon etoueroeterdewtereeconauahe nat 8 023 Connecting Me OUMU C esre E E dette 8 Figure 2 1 Maximum Ampacity of Feeder Cable uuu cess ccssessssssessessssssssssssesesesevsvsesssssssssenserseseseveses
5. ckwise at least 90 degrees until it stops to make sure it is secured in the locked position 1 Align the connector with the 2 Insert the Cam connector into the corresponding color coded receptacle receptacle and rotate Cam connector at least 90 clockwise degrees to lock 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 1 Align the connector with the 2 Insert the Cam connector into the corresponding color coded receptacle receptacle and rotate Cam connector at least 90 clockwise degrees to lock 9 Repeat steps 3 4 to connect the Blue Red and then Black phases in the same manner ki fe EF p ty at EN i a J E wooo i EA Lex Products User Manual 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 When disconnecting the cables do so in reverse order starting with the phases Black Red and Blue followed by the neutral White a
6. d Master distribution 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 When moving the Load Master box use the lifting handles on the sides of the box Figure 1 2 Place the Load Master Box in a level location with a dry and firm foundation within proximity of the power source and the location requiring power 3 Open the lid for the unit to confirm that the adjustable circuit breakers are in the OFF position Step 2 Making the Input Connections AN WARNING Before making connections to the Load Master box make sure the power source feeding the box is OFF AN 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 box a 4 0 cable must be used to connect the Load Master distribution box 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 AN WARNING Both sets of Cam extensions feeding the input must come from the same power source 800 643 4460 www LexProducts com 5 Step 2 Making the In
7. he 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 855 539 1002 or email support lexproducts com 4 For any other questions call Lex Products at 800 643 4460 800 643 4460 o www LexProducts com EN Lex Products Load Master Box 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 Figure 1 1 Lex Products Load Master Components Hinged Lid oOo j Lid Handles TOO O ooo aM bd E ae f Locking Lifting Latches Handles Cam type 2 sets of Cam type Output s Inputs Figure 1 2 Top view with lid open Hinged Lid Adjustable e Circuit Breakers re Dip Switches Za Lex Products User Manual SETTING UP THE LOAD MASTER DISTRIBUTION BOX Set up of the Lex Products Load Master power distribution box is to be performed by qualified personnel only Step 1 Placement of the Load Master Box The Loa
8. l 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 Figure 3 1 Circuit Breaker SACE Tmax On Off Switch Dip Switches I2 In x 0 4 In x my L B EEEE l 99900 E l 2999 0ds 15 0 255 a l 8ln PR221DS Dip Switch L short Instant Delay Neutral Sensing 800 643 4460 www LexProducts com 7 1 Determine the load that will be placed on each set of output receptacles This is the value that will need to be matched with the circuit breaker settings 2 Each circuit is labeled with a number that corresponds to a specific output for easy circuit identification Determine which load will be matched with each set of receptacles and circuit breakers based on the available range of the Load Master box model 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 with a 60 150 Amp receptacle and circuit breaker Circuit Label Lex Products Load Master Box Corresponding Output Circuit Label 8 Lex Products User Manual Circuit Breaker Adjustment Settings 3 For a load to be paired with the 160 400 Amp circuit breaker and receptacle set the dipswitches on the circuit breaker to the closest level indicated in the table below with the set level greater than sa FP ink dd a Foe the
9. nd finally ground Green Step 5 Powering Up Best practices dictate that loads are applied gradually 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 Repeat these steps for each additional circuit breaker that will be in use on the Load Master power distribution box 800 643 4460 o www LexProducts com 13 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 Ensure the N setting is at 100 and the ON OFF functionalit
10. put Connections Continued 2 Connect the bottom input row of Cam cables first beginning with the ground cable Green 3 Push the connector into the male Green Cam 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 1 Align the connector with the 2 Insert the Cam connector into the corresponding color coded receptacle receptacle and rotate Cam connector at least 90 clockwise degrees to lock 5 Connect neutral White Cam cable second 6 Push the connector into the male White Cam 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 1 Align the connector with the 2 Insert the Cam connector into the corresponding color coded receptacle receptacle and rotate Cam connector at least 90 clockwise degrees to lock 8 Repeat steps 3 4 to connect the Blue Red and then Black phases in the same manner Lex Products Load Master Box a 9 Connect the second Top row of the Cam input in the same manner and color order as detailed above When disconnecting do so in reverse order starting with the phases Black Red and Blue followed by the neutral White and finally ground Green 6 Lex Products User Manual Step 3 Adjusting the Circuit Breakers The current leve
11. ssseenesensnss 9 Figure 2 2 Temperature Rating of Feeder Cable occ ccesscscscscsssscsessscsssssseesesessssseesssesessseneesesesssenneesasennenen 9 Step 3 Adjusting the Circuit Breakers cece ccecescesesescececesvevsseeceveceesevaceesevaceesevavsusevaveesevaveueevavaesevavneevecseeevanenen 10 step 3 1 Standard Circuit Breaker Adjustment Settings 0 cccc ccc csesseecscsceseseecscsesseeeecssstssesseestetsssrsrsetinenetes 10 Figure 3 1 Circuit Breaker Diagram ce aes asic est arn Assist ace tinsastitadasdactaatadscaducsiendesodacvitadeanieeleatnanieeteen va voistuncuolewind 11 Figure 3 2 160 400 Amp Circuit Breaker Standard Adjustment Settings Diagram uu ccc cece 11 Figure 3 3 100 250 Amp Circuit Breaker Standard Adjustment Settings Diagram 0 cece cscs 11 Figure 3 4 60 150 Amp Circuit Breaker Standard Adjustment Settings Diagram uo cece teeter 11 Step 3 2 Custom Circuit Breaker Adjustment Instructions eieiirrsirisirirrerrnnn 12 13 O PON U a E S pionetin aes detae teeta inrienineend 13 MTOM OVS SIN OMNI CA tacit ct a a EE E E 14 15 Technical Service Contact Information oo ccc cece ccs ccceecscscscseeesecscscscsececseesscseeeseseseveneeesevetetesseteveveversrsetitinrereetesenenes 15 20 Lex Products User Manual 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 t
12. y next to the N is set to OFF 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 TETTE E A L A Set to OFF and 100 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 The inrush settings can be adjusted by turning on the dip switches for I3 All dip switches up will result in the maximum inrush tolerance of ten times the circuit breaker rating ot oD a ina jod o o gq L EENE fo fa 3 dip switches Move all dip switches UP for maximum inrush tolerance Lex Products Load Master Box 14 Lex Products User Manual 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 If the circuit breaker trips contact Lex Products for technical assistance If the circuit breaker does not trip proceed to the next step 4 Connect the cable to the corresponding circuit breaker outlets and turn off all attached loads a Turn on the circuit breaker a If the circuit breaker trips disconnect cabling used and check for short circuits D Turn off all

160-400 Amp Load Master Manual

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