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Avtron K875A Manual

Outdoor load bank
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K875A 1035409

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  • Page 1   K875A 1035409...
  • Page 2 AVTRON MODEL K875A OUTDOOR LOAD BANK Part Number K875A 1035409 600 kW @ 480 VAC, 3-Phase, 60 Hz 150, 150, 150, and 150 kW © 2014 Avtron Loadbank October 9, 2014 Cleveland, Ohio...

  • Page 6: Table Of Contents

    Section V MAINTENANCE ..................5-1 Section VI OPTIONS ....................6-1 Section VII REPLACEMENT PARTS LIST .............. 7-1 APPENDIX - Avtron Load Bank Troubleshooting Guide DRAWINGS SB2196 Outline Drawing, Load Bank, Wall Mount Enclosure SB2793 Outline Drawing, Load Bank, Outdoor, Single Bay...
  • Page 8 TABLES OF CONTENTS VENDOR MANUALS (Provided Separately) The following are provided separately only when Option 62, 63, 64, 65, 66, 68, 69, or 79 is purchased: Electro Industries SHARK 100 Installation and Operation Manual – CD-ROM, E14520 Electro Industries Quick Start for SHARK Series Meters, E145703 -ii-...
  • Page 10 TABLE OF CONTENTS (Cont.) OPTIONS - Refer to Section VI (K875A OPTIONS LIST) of this manual. The following drawings apply to the various options. Only drawings for the options provided have been included in this manual. Not all options can be installed in the same unit.
  • Page 11 Avtron Model K875A Load Bank Options TABLE OF CONTENTS (Cont.) Drawing Option Description A25057-3 Intake Overtemp Protection * D27684-1 Dual Voltage Control Transformer and Blower Circuit (for Load Banks Using 5 HP Motor @ 240/480V) * D27684-2 Dual Voltage Control Transformer and Blower Circuit...
  • Page 12 Avtron Model K875A Load Bank Options TABLE OF CONTENTS (Cont.) Drawing Option Description ** D29785-3 Digital Power Metering Option (“DX” Style) (Instruction Manual) (V, A, F, kW), CT Ratio 1500:5 ** D29421-2 Digital Power Metering Option (“D” Style) (Instruction Manual)
  • Page 13 Avtron Model K875A Load Bank Options TABLE OF CONTENTS (Cont.) Drawing Option Description ** D30857-5 Digital Power Metering Option (“DZ” Style) (Instruction Manual) (V, A, F, kW, kVAR, PF, kVA), CT Ratio 2500:5 * D27683-8 Control Transformer, 380/115V (for 2001 to 2500 kW...
  • Page 14 Avtron Model K875A Load Bank Options TABLE OF CONTENTS (Cont.) Drawing Option Description * D35895-2 Control Transformer Option, 500 to 2000 kW Load Banks, (380/110V Control Transformer), Stainless Steel Panel * D35895-3 Control Transformer Option, 500 to 2000 kW Load Banks,...
  • Page 15 Avtron Model K875A Load Bank Options TABLE OF CONTENTS (Cont.) Drawing Option Description * D37723-4 Digital Power Metering Option (DW Style) (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 2000:5 * D37723-5 Digital Power Metering Option (DW Style) (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 4000:5...
  • Page 16 Avtron Model K875A Load Bank Options TABLE OF CONTENTS (Cont.) Drawing Option Description * D37723-9 Digital Power Metering Option (DW Style) (V, A, F, KW, KVAR, PF, KVA) CT Ratio 5000:5 A34920-1 Aluminum Hood Replacement with Stainless Steel Screen (1 Stack Units)

  • Page 18: Section I

    Avtron equipment. The Model K875A Load Bank is an industrial test unit designed to be used outdoors safely with an exhaust hood. The unit should not be installed indoors. Because the function of the Load Bank is to dissipate electrical energy, there are inherent dangers to operators and equipment.
  • Page 19 This Load Bank is specifically designed for outdoor use with an exhaust hood. Indoor mounting is not recommended and requires special attention to exhaust hot air outdoors. Consult Avtron Engineering prior to indoor mounting.
  • Page 20 If outdoor, energize heaters. Spin fan motors monthly to prevent motor bearing issues. Fan motor(s) should be run for 30 minutes minimum, every month to prevent/limit condensation problems. Consult Avtron Prior to placing unit in storage.

  • Page 22: Description

    3-phase voltage. The total load capability of the K875A Load Bank is 600 kW at 480 VAC, 3-phase, 60 Hz. Load steps are 150, 150, 150, and 150 kW. Using the toggle switches on the control panel, any combination of the available load steps may be selected to achieve a desired load.
  • Page 23 ************************************************************* The K875A Load Bank is fabricated using heavy-gauge aluminized sheet steel, making a rigid structure. Mounted within the structure are the load element resistor assemblies, load contactors, and the cooling fans/blowers. The resistive elements are porcupine type, fully supported along their length.
  • Page 24 Avtron Outdoor Load Bank • Part Number K875A 1035409 Description The Load Bank is equipped with screens mounted at the inlet openings and exhaust hoods. The Load Bank uses a welded base to facilitate handling by a forklift truck. Bolt holes are also supplied in the base to permit permanent mounting to a concrete pad or metal foundation.

  • Page 26: Installation

    Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation SECTION III INSTALLATION INSTALLATION CHECKOUT PROCEDURE - TO BE DONE PRIOR TO OPERATION This Installation Checkout Procedure is intended to be used upon initial receipt of equipment and following any relocation of a permanently mounted Load Bank. These procedures apply to Load Banks in general and may include steps not relevant to the specific unit being installed.
  • Page 27 Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation Follow these steps to mount hoods on exhaust (top) of Load Bank. (If applicable) Hoist hoods by installing two heavy rods (5/8" or 3/4" dia.) completely through unit. Make sure at least 6" projects beyond sides.
  • Page 28 Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation Energize the source of control power only: Check the control voltage and confirm it is within 10% of the required voltage. ************************************************************* W A R N I N G Control power is present on terminal block in steps 4 through 6.
  • Page 29 Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation Connect an ohmmeter across the air switch normally open terminals. Run ohmmeter wiring outside of the unit and temporarily install access panel. Reapply fan/blower voltage and control power. Start fan(s), allowing them to come up to speed, approximately 10 seconds. The normally open contacts should close.
  • Page 30 Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation LOCATION Do not install the Load Bank in any area where standing water can pool or accumulate. Do not install near: a drainage basin, surface/ground or roof runoff, sewer collection, or any location where water can back up or collect.
  • Page 31 Load Banks mounted into a channel, trough, hollow, well, pit, surrounded completely by a parapet wall or backed into a full corner require special considerations even if the other conditions are met. In these cases, provide detailed site layout drawings to Avtron for inspection and comments.
  • Page 32 Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation CONTROL CONNECTIONS The control panel is mounted in a control enclosure. Connect terminals of the control panel to terminals of the Load Bank as shown on Interconnection Diagram 1036580. Control power is obtained from a 480:120 volt, 60 Hz AC, 750 VA transformer mounted on the Load Bank and wired to the main Load Bank bus.
  • Page 33 Avtron Outdoor Load Bank • Part Number K875A 1035409 Installation If external 480 volt power is provided, safe practice dictates that the fan power be wired through a safety disconnect switch that can be locked out. LOAD CONNECTIONS Load connections are made to the 3-phase bus bars located in the Load Bank. (Refer to Outline Drawing SB2793.) The connections are marked A, B, and C.

  • Page 34: Operation

    Avtron Outdoor Load Bank • Part Number K875A 1035409 Operation SECTION IV OPERATION ************************************************************* W A R N I N G DO NOT touch the top exhaust hood/duct or cover panel during operation. The hood will become hot from the exhausted heat and...
  • Page 35 Avtron Outdoor Load Bank • Part Number K875A 1035409 Operation ************************************************************* 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. ************************************************************* Place the AUTO/MANUAL selector switch to the MANUAL position.
  • Page 36 Avtron Outdoor Load Bank • Part Number K875A 1035409 Operation Any load switch can be added or removed as required while the MASTER LOAD switch is closed (ON). To remove the load, open the MASTER LOAD switch by placing it in the OFF position.
  • Page 37 Avtron Outdoor Load Bank • Part Number K875A 1035409 Operation AUTOMATIC OPERATION PROCEDURE Place the AUTO/MANUAL selector switch to the AUTO position. Start the generator under test. Place the control POWER ON/OFF switch to the ON position. The CONTROL POWER light will be energized, indicating control power is present.
  • Page 38 Avtron Outdoor Load Bank • Part Number K875A 1035409 Operation *********************************************************** C A U T I O N Voltage must not be connected to the Load Bank resistive elements if any fault (overtemperature, motor overload, air failure) is indicated. It is the customer’s responsibility to ensure all load is dropped if any...
  • Page 40 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 42: Maintenance

    Avtron Outdoor Load Bank • Part Number K875A 1035409 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 43 Avtron Outdoor Load Bank • Part Number K875A 1035409 Maintenance 10 minutes off). The exhaust heat will slowly melt the blockage. Continue cycling for 10- minute intervals until exhaust is clear. Do not apply full load until both intake and exhaust openings are clear.
  • Page 44 1. The fan blower motor should be lubricated per the motor manufacturer's requirements and specifications on the motor nameplate. 2. Inspect exhaust hood and screens. 3. If Load Bank sits idle for more than two months consult Avtron for special written factory authorized procedure.

  • Page 46: Options

    Avtron Model K875A Load Bank Options SECTION VI K875A OPTIONS LIST These options are available for Avtron Model K875A Load Banks. Not all options can be installed in the same unit. Installed options are marked on the identification tag. Option Drawing No.
  • Page 47 Avtron Model K875A Load Bank Options Option Drawing No. Option Description D27684-1 Dual Voltage Control Transformer and Blower Circuit (for Load Banks Using 5 HP Motor @ 240/480V) D27684-2 Dual Voltage Control Transformer and Blower Circuit (for Load Banks Using 10 HP Motor @ 240/480V)
  • Page 48 Avtron Model K875A Load Bank Options Option Drawing No. Option Description D29785-4 Digital Power Metering Option (“DX” Style) (V, A, F, kW), CT Ratio 2000:5 D30857-2 Digital Power Metering Option (“DZ” Style) (V, A, kW, kVAR, kVA, PF, F), CT Ratio: 4000:5 D29421-3 Digital Power Metering Option (“D”...
  • Page 49 Avtron Model K875A Load Bank Options Option Drawing No. Option Description D27685-5 Load Shedder Option, Single Board Load Shedder, Double Stack D27685-6 Load Shedder Option, Single Board Load Shedder, Double Stack (No component mounting panel) A28623-1 Blower and Control Power Disconnect, Single Stack...
  • Page 50 Avtron Model K875A Load Bank Options Option Drawing No. Option Description D37723-2 Digital Power Metering Option (DW Style) (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 2500:5 D37723-3 Digital Power Metering Option (DW Style) (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 1500:5...
  • Page 51 Avtron Model K875A Load Bank Options Option Drawing No. Option Description A34920-2 Aluminum Hood Replacement with Stainless Steel Screen (2 Stack Units) A34920-3 Aluminum Hood Replacement with Stainless Steel Screen (3 Stack Units) B32580-1 Overhead Lift, Single Stack B32580-2 Overhead Lift, Two Stack...
  • Page 52 Options Parts List 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 troubleshooting. NOTE Every effort has been made to ensure the accuracy of this information.
  • Page 53 Avtron Model K875A Load Bank Options Parts List REPLACEMENT PARTS LIST SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #1: CONTROL TRANSFORMER D27683-1 XF210-212 .FUSEBLOCK 3 POLE 324496 F212 .FUSE, CARTRIDGE, 9 AMP, 600V, 324431 TIME DELAY, CLASS RK-5 F210,211 .FUSE, CARTRIDGE, 8 AMP, 600V,...
  • Page 54 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #8: OVERVOLTAGE PROTECTION B26013 K101 .RELAY, VOLTAGE CONTROL; INPUT POWER 110 VAC 351653 R101 .RESISTOR, CARB COMP 1/2W, 10%, 100 KOHM 110048 OPTION #9: ELAPSE TIME METER...
  • Page 55 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #15: DUAL VOLTAGE CONTROL D27684-1 XFMR & BLOWER CIRCUIT .CIRCUIT BREAKER; 16A, 480V, 2 POLE 310336 XF212 .FUSEBLOCK 3 POLE 324496 F212 .FUSE, CARTRIDGE, 9 AMP, 600V,...
  • Page 56 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #16: DUAL VOLTAGE CONTROL XFMR & BLOWER CIRCUIT (CONT.) K481 .RELAY, UNDER VOLTAGE 220 VAC -30% to +15% 350583 K132 .RELAY; 3P, 25A, 120V, 60 HZ,...
  • Page 57 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #21: DUAL VOLT CONTROL TRANSFORMER D29476-1 .CIRCUIT BREAKER; 16A, 480V, 2 POLE 310336 XF212 .FUSEBLOCK 3 POLE 324496 F212 .FUSE, CARTRIDGE, 9 AMP, 600V, 324431...
  • Page 58 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #24: LOAD SHEDDER D27685-3 K50,51 .RELAY, 3PDT, 120 VAC COIL 351060 XK50,51 .RELAY SOCKET DIN RAIL MOUNT 358280 XK50,51 .HOLDDOWN SPRING 467550 A101 .PRINTED CIRCUIT BOARD ASSY A22829 ..SCHEMATIC...
  • Page 59 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #29: DIGITAL METERING UNIT D29421-2 CT1,2 .TRANSFORMER, CURRENT, 3000:5, 370351 50-400 HZ, WINDOW SIZE 3.75” X 7.45” T100 .TRANSF, POTENTIAL; 480V PRI, 120V SEC, 371046 +/-1% ACC @ 1.0 &...
  • Page 60 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #33: DIGITAL METERING UNIT D29421-3 CT1,2 .TRANSFORMER, CURRENT, 2500:5, 370331 50-400 HZ, WINDOW SIZE 4.75" X 3.75" T100 .TRANSF, POTENTIAL; 480V PRI, 120V SEC, 371046 +/-1% ACC @ 1.0 &...
  • Page 61 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #39: DIGITAL METERING UNIT D30857-4 (DZ STYLE), CT RATIO 1200:5, RS485 CT1-2 .TRANSFORMER, CURRENT, 1200:5 370323 T100 .TRANSF, POTENTIAL; 480V PRI, 120V SEC, 371046 +/-1% ACC @ 1.0 & .95 PF, 50/60 HZ F100-102 .FUSE CARTRIDGE, 1 AMP, 600 VAC...
  • Page 62 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #43: DIGITAL METERING UNIT D30857-7 (DZ STYLE), CT RATIO 2500:5, RS485 CT1-2 .TRANSFORMER, CURRENT, 2500:5 370336 T100 .TRANSF, POTENTIAL; 480V PRI, 120V SEC, 371046 +/-1% ACC @ 1.0 & .95 PF, 50/60 HZ F100-102 .FUSE CARTRIDGE, 1 AMP, 600 VAC...
  • Page 63 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #47: LOAD SHEDDER D27685-5 K50,51 .RELAY, 3PDT, 120 VAC COIL 351060 XK50,51 .RELAY SOCKET DIN RAIL MOUNT 358280 XK50,51 .HOLDDOWN SPRING 467550 A101 .PRINTED CIRCUIT BOARD ASSY A22829 ..SCHEMATIC...
  • Page 64 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #53: CONTROL TRANSFORMER D35895-2 XF210-212 .FUSEBLOCK 3 POLE 324496 F212 .FUSE, CARTRIDGE, 9 AMP, 600V, 324431 TIME DELAY, CLASS RK-5 F210,211 .FUSE, 5 AMP, 600V, TIME DELAY CLASS RK-5 324394 .TRANSF, CONT: 850 VA, 380/440/550/...
  • Page 65 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #59: CONTROL TRANSFORMER D35895-8 XF210-212 .FUSEBLOCK 3 POLE 324496 F212 .FUSE, CARTRIDGE, 12 AMP, 600V, 324468 TIME DELAY, CLASS RK-5 F210,211 .FUSE, 7 AMP, 600V, TIME DELAY CLASS RK-5 324697 .TRANSFORMER, CONTROL...
  • Page 66 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #66: DIGITAL METERING UNIT D37723-5 (DW Style), CT Ratio 4000:5, RS485 CT1,CT2 .Transformer, Current, 4000:5 371053 F100-102 .Fuse, 1 Amp, 600V, Time Delay 324449 XF100-102 .Fuseblock...
  • Page 67 Avtron Model K875A Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #72: DUAL VOLTAGE CONTROL D38803 TRANSFORMER & BLOWER CIRCUIT (2 Stack) (Cont.) K100,130,131, .Relay, 3P, 25A, 600 VAC 350833 133-136, 138,139,240 K481 .Relay, Volt Sensing...

  • Page 68: Replacement Parts List

    Replacement Parts List SECTION VII 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 69 Avtron Outdoor Load Bank • Part Number K875A 1035409 Replacement Parts List REPLACEMENT PARTS LIST SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT AVTRON MODEL K875A LOAD BANK, OUTDOOR K875A 1035409 .SCHEMATIC DIAGRAM 1036579 .INTERCONNECTION DIAGRAM 1036580 RA1-RA4 .RESISTOR ASSEMBLY D27553-1 F1-F3 ..FUSE, 80A...
  • Page 70 Avtron Outdoor Load Bank • Part Number K875A 1035409 Replacement Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT .CONTROL PANEL 1036581 DS1,3,5,6 ..LAMP, INDICATOR, AMBER AVT-329681 DS2,4 ..LAMP, INDICATOR, RED 329682 ..FUSE, 20 AMP 324754 ..FUSEHOLDER 324985 KA,KM ..RELAY 351060 XKA,XKM ..SOCKET, RELAY...
  • Page 78 User, or fifteen months from the date of shipment, whichever expires first. The product shipment date will be determined only from the ASCO bill of lading. If any part or portion of the Avtron product fails to conform to the Warranty within the Warranty period, ASCO, at its option, will furnish new or factory remanufactured products for repair or replacement of that portion or part.
  • Page 79 THIS WARRANTY DOES NOT COVER shipping costs, installation costs, or maintenance or service items and further, except as may be provided herein, does NOT include labor costs or transportation charges arising from the replacement of the Avtron product or any part thereof or charges to remove or reinstall same at any premises of User.

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