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Avtron K975A Manual

Outdoor resistive load bank
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K975A 994213

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Summary of Contents for Avtron K975A

  • Page 1   K975A 994213...
  • Page 2 AVTRON MODEL K975A OUTDOOR RESISTIVE LOAD BANK Part Number K975A 994213 2500 kW, 480 VAC, 3 PH, 60 Hz © 2013 Avtron Loadbank, Inc. November 20, 2013 Cleveland, Ohio...

  • Page 6: Table Of Contents

    Section III INSTALLATION ..................3-1 Section IV OPERATION ................... 4-1 Section V MAINTENANCE ..................5-1 Section VI REPLACEMENT PARTS LIST .............. 6-1 APPENDIX - Avtron Load Bank Troubleshooting Guide DRAWINGS SB3833 Outline Drawing, Load Bank 997418 Schematic Diagram D24712 Resistor Assembly...

  • Page 8: Section I

    Damage to the equipment and potentially hazardous conditions for personnel may occur if a CAUTION statement is ignored. Each Avtron unit is safety checked for opens and shorts, and the insulation is high potential tested to ensure safe operation. All fuses, safety interlocks, and related safety equipment have been proven reliable as part of the testing procedure of each unit.
  • Page 9 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Safety Considerations Replace any burned out bulbs on the Control Panel. Each lamp is an indication that a system is active or has failed and is important to the operation of the Load Bank and safety of the operator.
  • Page 10 Occupational Safety and Health Act (OSHA) should be followed when installing the equipment to reduce hazards to persons and property. K975A 994213 has special quick connect cam-lok style connectors for load connection. All connectors must be fully engaged and share current before load is applied. Keep connector covers on all locations when not in use, during transit, and during storage.

  • Page 12: Description

    3-phase voltage. The total load capability of the K975A Load Bank is 2500 kW at 480 VAC, 3-phase, 60 Hz. The load steps are 50, 50, and (24) at 100 kW.
  • Page 13 ************************************************************* The K975A Load Bank is fabricated using heavy-gauge aluminized sheet steel to make a rigid structure. Mounted within the structure are the load element resistor assemblies, the blower assemblies, and the necessary load step contactors, motor starters, motor overload relays, fuses, and customer connection bus bars.
  • Page 14 START pushbutton, a STATION SELECT switch, and a STOP/RESET push button. The control panel also includes the connection for the IHT. The K975A 994213 Load Bank utilizes two local, integrally mounted control panels. The first local control panel (997419) is the interface between the Load Bank and the Intelligent Handheld Terminal (IHT), and is used with the unit is operating under Sigma control.
  • Page 15 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Description TOP AND BOTTOM OVERTEMPERATURE, TOP AND BOTTOM AIR-FAIL, and BLOWER POWER.

  • Page 16: Installation

    Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Installation SECTION III INSTALLATION BEFORE INSTALLATION Inspect the Load Bank for obvious damage such as broken wires, broken or dented panels, cracked ceramic insulators, or any other component breakage that may have occurred in shipment.
  • Page 17 75% open area. The 36" minimum side clearances shown in Figure 3-1 still apply. Clearance on intake and exhaust can be adjusted only after approval by an authorized Avtron representative. Painted or plated metal chain link fence is the preferred material. All nonmetallic fencing materials are not recommended.
  • Page 18 Figure 3-1. Load Bank Installation Airflow Clearance Requirements ADDITIONAL LOCATION NOTES Do not stack, tier, or layer Load Banks without Avtron approval, as air recirculation will occur. Indoor installations will always require review. Make up air must be by a supplemental air moving device.
  • Page 19 If ducting is mandatory, obtain written approval from Avtron prior to installation. Airflow is also restricted when two or more Load Banks have air inlets positioned close to each other. This competition for cooling air causes a low pressure area, restricting adequate airflow.
  • Page 20 LOAD CONNECTIONS On K975A 994213 units, quick connect cam-lok style connectors are installed on the outside corner of the Load Bank frame. All nine connections per phase and the three ground connections must be made prior to applying any load.
  • Page 21 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Installation GROUNDING A permanent ground conductor must be connected to the Load Bank enclosure by an individual ground wire to prevent a potential above ground on the enclosure. There is a ground nut in the Load Bank, located within the control compartment, for this connection.
  • Page 22 14 AWG for control panel to Load Bank lengths of 50 feet or less. For lengths greater than 50 feet, consult Avtron Manufacturing, Inc. If a Control Transformer is the source of control power, disconnect the control...
  • Page 23 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Installation C A U T I O N When control power is supplied by a transformer within the Load Bank, it must be disconnected before running this installation checkout procedure. Failure to disconnect the control transformer may damage the Load Bank.
  • Page 24 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Installation This checkout procedure is intended to be a guide to Load Bank installations in general. Special installation considerations not addressed herein may be necessary due to installation site or environment.

  • Page 26: Operation

    Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Operation SECTION IV OPERATION Refer to the Intellight Handheld Terminal (IHT) Quickstart Guide for operation of the Load Bank. ************************************************************* C A U T I O N DO NOT operate the Load Bank over the rated voltage as this will cause catastrophic failure in the Load Bank.
  • Page 27 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Operation ************************************************************* W A R N I N G DO NOT touch the exhaust screen during operation. The screen will become hot from the exhausted heat and may cause a serious burn.
  • Page 28 Electric tools used during repair should be grounded. For example, use only anti-static type solder suckers and grounded tip soldering irons. Discharge non-electric tools before use. · Pack ESD items in static shielding containers before shipping them to Avtron for repair. * Styrofoam® is a registered trademark of Dow Chemical.

  • Page 30: Maintenance

    Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Maintenance SECTION V MAINTENANCE To provide long equipment life and to reduce the chance of electric shock, fires, and personal injury, good maintenance procedures must be used. Before servicing, review the SAFETY CONSIDERATIONS section of this manual.
  • Page 31 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Maintenance On K975A 994213 units, inspect all cam-lok style connections on both the Load Bank and interconnection cable. Any signs of heat stress dictate a replacement connector. Verify that all cam-lok protective caps are properly secured to unit.
  • Page 32 Maintenance PARTS REPLACEMENT Access to any component is easily made with the removal of the cover panels. Replaceable components are listed in the Replacement Parts List. Avtron maintains an inventory of normally used items. ************************************************************* C A U T I O N When replacing fuses attached to bus bars, tighten wire connection before the fuse is attached to the bus bar.

  • Page 34: Replacement Parts List

    Replacement Parts List SECTION VI REPLACEMENT PARTS LIST INTRODUCTION The parts list in this section contains the description, quantity required, and Avtron part numbers for each listed part. The list also includes schematic reference designators to facilitate parts identification. NOTE Every effort has been made to ensure the accuracy of this information.
  • Page 35 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Replacement Parts List REPLACEMENT PARTS LIST SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT AVTRON MODEL K975A LOAD BANK, OUTDOOR K975A- 994213 .SCHEMATIC 997418 .INSTALLATION, CAMLOK CONNECTORS D41573 J1-9 ..RECEPTACLE, BROWN 315577 J10-18 ..RECEPTACLE, ORANGE...
  • Page 36 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Replacement Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT F16-87 ..FUSE, 150 AMP 324463 CT1,2,3 ..TRANSFORMER, CURRENT, 3200:5 370050 S4,5,6 ..CONTROLLER, TEMP 491017 XS4,5,6 ..SOCKET 358311 ..THERMOCOUPLE A24741 XF210-212 ..FUSEHOLDER...
  • Page 37 Avtron Outdoor Resistive Load Bank • Part Number K975A 994213 Replacement Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT PH C ..CONNECTOR, FEMALE, YELLOW 315727 ..CONNECTOR, FEMALE, GREEN 315068 .FILTER 432483 .TERMINAL, HAND HELD OPERATOR PR00517 Form No. 755A...
  • Page 44 User, or fifteen months from the date of shipment, whichever expires first. The product shipment date will be determined only from the Avtron bill of lading. If any part or portion of the Avtron product fails to conform to the Warranty within the Warranty period, Avtron, at its option, will furnish new or factory remanufactured products for repair or replacement of that portion or part.
  • Page 45 User will be issued a credit in an amount equal to the parts prices previously invoiced. Warranty coverage will be provided only after Avtron's inspection discloses the claimed defect and shows no signs of treatment or use which would void the coverage of this Warranty.
  • Page 46 Sigma IHT Version 4 Quickstart Setting Up When in SETTINGS you can press the + and – keys to quickly change the screen This Quickstart guide, along with the in-built help, will help contrast. you get the best out of your Sigma IHT. The Sigma Intelligent Hand-held Terminal (IHT) provides full load control and three-phase instrumentation on any Froment Sigma-equipped load bank.
  • Page 47 Sigma IHT Version 4 Quickstart Testing 5. Apply Load The second and third instrumentation pages provide all the electrical data required when full-load testing. Displayed on the right are the voltage and frequency; below There are four pages; which offer different views of TEST each are the maximum and minimum values for the last load change.
  • Page 50 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON DRAWN DATE 6255 HALLE DRIVE 9/5/13 CLEVELAND, OH 44125 CHECKED .015 9/5/13 SCHEMATIC DIAGRAM, ENG APVD 9/5/13 LOAD BANK APVD PROD 9/27/13 K975A994213 K975A994213 (2500KW, 480V, 3 PH, 60HZ) SCALE NEXT ASSY USED ON MODEL 997418 APPLICATION...
  • Page 51 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 52 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 53 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 54 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 55 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 56 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 57 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 58 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 59 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 60 LA1427 REVISED PER ECN J.FRANK 11/25/13 B.DIXON 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 61 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 62 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
  • Page 63 6255 HALLE DRIVE CLEVELAND, OH 44125 SCHEMATIC DIAGRAM LOAD BANK (2500 KW, 480V, 3 PH, 60 HZ) SCALE MODEL 997418 K975A FORM 832D2-LB, 2/20/2012...
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