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Avtron K711 Manual

Load bank, resistive, duct mount
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AVTRON MODEL K711
LOAD BANK, RESISTIVE, DUCT MOUNT
Serial Number 3118 and Above
© 2004 Avtron Manufacturing, Inc.
December 29, 2004
Cleveland, Ohio
Rev. October 4, 2005

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Summary of Contents for Avtron K711

  • Page 1 AVTRON MODEL K711 LOAD BANK, RESISTIVE, DUCT MOUNT Serial Number 3118 and Above © 2004 Avtron Manufacturing, Inc. December 29, 2004 Cleveland, Ohio Rev. October 4, 2005...
  • Page 2 AVTRON MODEL K711 LOAD BANK, RESISTIVE, DUCT MOUNT PROJECT NO. K711 - - - TABLE OF CONTENTS Section Page SAFETY CONSIDERATIONS ......
  • Page 3 Table of Contents • Serial Number 3118 and Above K711 Options List These options are available for Avtron Model K711 Load Banks. Not all options can be installed in the same Load Bank. Installed options are marked on the identification tag. OPTION DWG.
  • Page 4 • Serial Number 3118 and Above K711 Options List (Cont.) These options are available for Avtron Model K711 Load Banks. Not all options can be installed in the same Load Bank. Installed options are marked on the identification tag. OPTION DWG.
  • Page 5 These dangers are outlined in this section. The Model K711 Load Bank is designed to be mounted on a duct or on the exhaust side of the radiator of an engine-driven generator set. The Load Bank resistors rely on the exhaust air from the radiator fan for cooling.
  • Page 6 Avtron Model K711 Load Bank, Resistive, Duct Mount Safety Considerations • Serial Number 3118 and Above Electrical energy is transformed into heat by the resistors. This heat must be removed from the Load Bank by the cooling blower (not part of Load Bank). If there is any restriction or stoppage of airflow, the Load Bank may overheat and may even start a fire.
  • Page 7 The Load Bank is designed for maximum 120ºF ambient at 3,000 ft. maximum elevation. Consult factory if either of these conditions is not met. Standard K711 units which do not include the outdoor (louver) option must have field installed provisions to protect personnel from coming into contact with load resistor elements.
  • Page 8 ****************************************************** CONTROL PANEL The K711 Load Bank may be provided with a Control Panel as an option or the Control Panel may be customer supplied. The Control Panel may be supplied by Avtron in one of the following ways: Factory installed on the side of the Load Bank without an enclosure.
  • Page 9 Avtron Model K711 Load Bank, Resistive, Duct Mount Description and Specifications • Serial Number 3118 and Above When the Control Panel is not factory supplied, load application and safety circuitry are the responsibility of the customer. Each Load Bank is designed with a relay compartment which contains load contactors, safety circuit components, optional load step fusing, optional control transformer with fuses, and a customer connection bus.
  • Page 10 An Automatic Load Shed Controller (Controller) may be integrated into the control circuitry of the K711 Load Bank as an option. The Controller is designed to maintain a minimum load on a power source. A separately supplied current transformer provides the feedback signal required to operate the Controller.
  • Page 11 The outline drawing needs to be available while reviewing the INSTALLATION section. The following steps outline general guidelines for the handling and installation of the Model K711 Load Bank. The first portion of Section III describes the handling (rigging) and physical mounting of the Load Bank.
  • Page 12 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above Verify that all access panels (bolt on panels) are fully secured. There are two methods to handle the Load Bank: Overhead lift using a spreader bar for hoisting the Load Bank into position or base lifting with a forklift.
  • Page 13 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above Test and verify that the unit is level by lifting the Load Bank. Raise unit up no more than 6 inches off the ground. Lower and adjust if required to obtain a level lift (level within 6 inches).
  • Page 14 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above MOUNTING THE LOAD BANK ****************************************************** C A U T I O N The radiator frame or structural supports and mounting hardware used to permanently mount and anchor the Load Bank must be designed with sufficient safety factors to not yield under static and dynamic loading.
  • Page 15 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above ****************************************************** C A U T I O N To prevent load element burnout, adequate airflow must be maintained over the entire load element area at all times voltage is applied.
  • Page 16 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above A ground connection must be made to the Load Bank (GND terminal) to prevent injury to personnel. This may be accomplished by a ground wire connected directly to the Load Bank ground stud provided in the control box.
  • Page 17 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above ****************************************************** W A R N I N G Always put a short or shunt across the current transformer when servicing the Load Bank. Primary current flowing through an unshunted current transformer will destroy the transformer with possible harm to personnel.
  • Page 18 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above THEORY OF OPERATION The automatic operation circuitry of the Load Bank allows for a generator to which it is connected to maintain a minimum percentage of its rated output for efficient generator operation. The control range is generally between 60% and 80% of the output rating of the generator.
  • Page 19 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above In this example I(line) = (75 * 577)/480, = 90.1 amps NOTE: FOR SINGLE PHASE SYSTEMS: I(LINE) = WATTS/VOLTAGE(LINE-to-LINE). Secondary Current Calculation The controller senses the current (Isense) delivered from the current transformer that is monitoring the building load.
  • Page 20 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above There are two methods of field adjusting the trip point of the current sensing relays: Method 1 - Using a separate (0-5 amp) current source without the current transformer...
  • Page 21 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above Method 2 - Rough Adjustment NOTE Adjustable potentiometers on the controller board have a % scale reference that directly relates to the current, (Isense), delivered from the current transformer used to monitor the building load.
  • Page 22 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above 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.
  • Page 23 C A U T I O N Control wiring must be a minimum of 14 AWG for wire runs under 50 feet. Consult Avtron factory for wire sizing when wire run exceeds 50 feet. Confirm the correct wire gauge has been used for interconnection wiring. Control wiring should be a minimum of 14 AWG for control panel to Load Bank lengths of 50 feet or less.
  • Page 24 Avtron Model K711 Load Bank, Resistive, Duct Mount Installation • Serial Number 3118 and Above 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 25 Load Bank are disconnected. ****************************************************** The K711 Load Bank may be operated in a manual mode or, if the Load Shedder option is provided, in an automatic mode. Operation instructions for the different modes are as follows: Manual Operation - K711 units without a Control Panel.
  • Page 26 This procedure is not required for Load Bank integrity, but it may guard operating personnel from possible burn injuries. MANUAL OPERATION (for K711 units with a Control Panel included as an option) After mounting the K711, connecting 120V control power, and running interconnecting control wires per the schematic: Place all switches on the Control Panel to the OFF position.
  • Page 27 Bank integrity, but it may guard operating personnel from possible burn injuries. AUTOMATIC OPERATION (for K711 Load Banks with Load Shedder option) After mounting the K711 and connecting 120V control power per the schematic: Place all switches on the Control Panel to the OFF position.
  • Page 28 Avtron Model K711 Load Bank, Resistive, Duct Mount • Serial Number 3118 and Above SECTION V REPLACEMENT PARTS LIST SCHEMAT MANUFACTURER AVTRON QTY/ DESCRIPTION REFEREN and PART NO. UNIT F101 FUSE, 10A, 600V LITTELFUSE 324128 KLKR-10 XF101 FUSEHOLDER BUSSMANN 325022...