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Avtron K922A Manual

Outdoor resistive load bank
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January 22, 2008
DATE
V2
VERSION NO.
252050-053-7202
PROJECT NO.
CF104
ECN NO.
DESCRIPTION OF CHANGES: Changed Part #B31105 to B31710.
June 11, 2008
DATE
V3
VERSION NO.
252050-7202
PROJECT NO.
ECN NO.
DESCRIPTION OF CHANGES: Under "Supplemental Vendor Manuals," changed Electro Industries
Version from 5.0 to 5.1; changed date from Aug. 23, 2004, to Oct. 23, 2007. Changed Avtron
Manufacturing, Inc., to Avtron Loadbank, Inc.
23 September 2008
DATE
V4
VERSION NO.
252053
PROJECT NO.
CF402
ECN NO.
DESCRIPTION OF CHANGES: On page 8-5, under D36366 changed schematic from D36367
to D41648.
Sept. 22, 2009
DATE
V5
VERSION NO.
PROJECT NO.
ECN NO.
DESCRIPTION OF CHANGES: Corrected Resistor Assemblies D36383, D36384, D36385, and
D36469 details on Parts List pages 8-3 and 8-4. Customer (Comrent) called Gary Kozel and told him the
info is incorrect.
Part Number K922AD41523
ORIGINAL DATE
ENGINEER
TECH WRITER
TYPIST
PROJECT NO.
ECN NO.
LOG OF CHANGES –
June 21, 2007
Paul Piazza & John Emery
Frank Seruchar
Kathy Van Cise
251855 and 251856
CE868
Page 1
ORIGINATOR
TECH WRITER
TYPIST
ORIGINATOR
TECH WRITER
TYPIST
ORIGINATOR
TECH WRITER
TYPIST
ORIGINATOR
TECH WRITER
TYPIST
John Emery
Frank Seruchar
Kathy Van Cise
John Emery
G. Hollander
G. Hollander
Gary Kozel
George Hollander
Kathy Van Cise

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  • Page 1 TYPIST ECN NO. DESCRIPTION OF CHANGES: Under “Supplemental Vendor Manuals,” changed Electro Industries Version from 5.0 to 5.1; changed date from Aug. 23, 2004, to Oct. 23, 2007. Changed Avtron Manufacturing, Inc., to Avtron Loadbank, Inc. 23 September 2008 John Emery...
  • Page 2 Part Number K922AD41523 LOG OF CHANGES – Page 2 DATE ORIGINATOR VERSION NO. TECH WRITER PROJECT NO. TYPIST ECN NO. DESCRIPTION OF CHANGES: DATE ORIGINATOR VERSION NO. TECH WRITER PROJECT NO. TYPIST ECN NO. DESCRIPTION OF CHANGES: DATE ORIGINATOR VERSION NO. TECH WRITER PROJECT NO.
  • Page 3 Part Number K922AD41523 Special Low Temperature Duty 5 MW at 13,800 Volt, 3-Phase, 60 Hz Load Bank 4 MW at 4160 Volt, 3-Phase, 60 Hz Load Bank © 2008 Avtron Loadbank, Inc. June 21, 2007 Cleveland, Ohio Rev. Sept. 22, 2009...

  • Page 4: Table Of Contents

    AVTRON LOADBANK, INC. Cleveland, Ohio AVTRON MODEL K922A OUTDOOR RESISTIVE LOAD BANK Part Number K922AD41523 TABLE OF CONTENTS Page Section I SAFETY CONSIDERATIONS ............... 1-1 Section II INTRODUCTION AND GENERAL DESCRIPTION ......2-1 Section III INSTALLATION ..................3-1 Section IV PREPARATION FOR USE ..............
  • Page 5 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 TABLE OF CONTENTS (Cont.) SUPPLEMENTAL VENDOR MANUALS (Provided Separately) AMCA Recommended Safety Practices - For Users and Installers of Industrial and Commercial Fans, Publication 410-96, 150M 10/04-TPM Aerovent General Installation, Operation and Maintenance Instructions for...

  • Page 6: 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 safety interlocks and related safety equipment have been proven reliable as part of the testing procedure of each unit.
  • Page 7 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Safety Considerations Maintenance personnel must always exercise caution when access panels and/or screens (guards) are open or removed. Personal injury from electrical shock or from the rotating fan blades may result if all sources of power are not disconnected before servicing. Maintenance work must be done by qualified personnel only.
  • Page 8 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Safety Considerations Always ship unit on air-ride semi-trailers to reduce harmful/destructive over the road vibration and shock. Never operate the Load Bank during heavy rains or high humidity. Always operate heaters before operating the Load Bank.

  • Page 9: Introduction And General Description

    Provisions are included for special operator interface by others. The K922A Load Bank is an outdoor unit designed for portable use to specific test sites. Once on site, Load Bank is to be stationary, pad mounted using the four bolt-on telescoping leg extensions and struts to elevate frame.
  • Page 10 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Introduction and General Description blocks for wiring the safety components, enclosure heater, and the input control and fan power terminal blocks. Located within the medium voltage area are the three main load connection bus bars, CTs, PTs, configuration panel, load step contactors, a ground bus bar, and enclosure heater.
  • Page 11 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Introduction and General Description The Fault Latch Function is incorporated within the Control System of this Load Bank. The Fault Latch Function is used to determine failure, whether intermittent or constant. If a fault is detected for Air Failure or Overtemperature, the load is removed and the proper indicator is illuminated.
  • Page 12 Introduction and General Description Avtron Helidyne load elements are used in the K922A Load Bank. The resistor elements are placed directly in the air stream for cooling purposes. Changes in resistance due to temperature are minimized by maintaining conservative watt densities. The cold ohms are compensated for and the required accuracies are maintained to dissipate the required power.

  • Page 13: Installation

    Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation SECTION III INSTALLATION BEFORE INSTALLATION Inspect the Load Bank for obvious damage such as broken or dented panels, cracked ceramic insulators, broken wires, distorted hatches, or other component damage that may have occurred during shipment.
  • Page 14 No partial or full perimeter fence shall be used within 36 inches of the Load Bank. Consult Avtron Engineering prior to installing if any of these conditions exist.
  • Page 15 Review reference drawing SB3671 while reviewing INSTALLATION section. The following steps outline the recommended sequence for the installation of the K922A Load Bank. The installation procedure defined below describes the handling (rigging) and physical mounting of the Load Bank. All load and control wiring is provided by the installing contractor or site technicians/operator.
  • Page 16 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation The Load Bank must be on a level surface at ground elevation. For overhead lifting, secure the four roof lifting cleats to crane rigging. For base lifting, secure the jacking devices (provided by others) with sockets into ends of 6 x 6 tubing.
  • Page 17 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation A crane with sufficient capacity and lifting height will be required to hoist the Load Bank from the truck trailer and to raise the Load Bank for final positioning. Lifting cables, chain slings, and/or a spreader bar are required and shall be supplied by the rigger.
  • Page 18 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation Hook up either two double leg or one four leg sling to the crane. Hoist above the top of the Load Bank frame. Attach each leg of the sling to the roof lifting cleats on the Load Bank frame. Each leg should be a minimum of 16 ft.
  • Page 19 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation ************************************************************* C A U T I O N Operator/technician must be at roof level of Load Bank to perform this procedure. Verify safety sling is tethered to unit and all safety precautions are taken.
  • Page 20 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation ************************************************************* C A U T I O N Only 460 VAC, 3-phase, 60 Hz power should be connected to the load distribution terminal block (TB2). Other frequencies or voltages will cause severe damage to the Load Bank. Lower frequencies will reduce fan performance and cause overheating.
  • Page 21 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Installation bushings is minimized. Load wiring should have medium voltage stress cones and be properly connected and grounded. ************************************************************* C A U T I O N Never exceed the 13,800 volts as this will cause the Load Bank to overheat.

  • Page 22: Preparation For Use

    Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Preparation for Use SECTION IV PREPARATION FOR USE This procedure is intended to be used upon the initial installation of the Load Bank and following any relocation. ************************************************************* W A R N I N G The following procedures are to be performed only by qualified personnel.
  • Page 23 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Preparation for Use Verify that all Load Bank fan inlets and gravity exhaust hatches are free from any obstruction or debris. Remove any items from the area around the Load Bank that could obstruct airflow or be drawn into the fans.
  • Page 24 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Preparation for Use Energize the external control and fan power sources only. Check the 460 VAC fan voltage and verify the voltage is within 10% of the required voltage. Check the 120 VAC control voltage and verify the voltage is within 10% of the required voltage.
  • Page 25 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Preparation for Use CONSIDERATIONS FOR SEASONAL CONDITIONS Seasons and weather conditions will dictate what steps will be required when preparing the Load Bank for use. Listed below are guidelines to be used by season.
  • Page 26 If build-up is significant, all components must be manually cleaned and wiped dry. ● Any questions or concerns regarding the Load Bank installation should be directed to Avtron Loadbank, Inc., at 216-573-7600.

  • Page 27: Operating Instructions

    Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Operating Instructions SECTION V OPERATING INSTRUCTIONS ************************************************************* C A U T I O N Voltage must not be connected to the Load Bank resistive elements if all airflow switches have not closed. It is the responsibility of the end user to ensure all load is dropped if an air failure is detected.
  • Page 28 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Operating Instructions OPERATING PROCEDURE (Manual Control Panel) Verify the Load Bank gravity exhaust hatches are free to open and all other access doors are closed securely. Place all switches on the Load Bank control panel in the OFF position and set auto manual switch (S14) to MANUAL.
  • Page 29 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Operating Instructions ************************************************************* C A U T I O N The operation of the fans/blowers is vital to the safe operation of this Load Bank. When the FAN/BLOWER switch is turned on, all of the...
  • Page 30 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Operating Instructions SHUTDOWN PROCEDURE Place the MASTER LOAD switch to the OFF position. NOTE After running a load test, it is preferred procedure to remove residual heat from the Load Bank by allowing the fans/blowers to operate for a few minutes after load is removed.

  • Page 31: Maintenance

    Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Maintenance SECTION VI 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 32 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Maintenance Verify all heaters and temperature switches are functional. ************************************************************* W A R N I N G Before performing maintenance or physically disconnecting the generator under test from the Load Bank, ensure that all sources of power to the Load Bank are disconnected.
  • Page 33 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Maintenance Clean all dirt and debris out of the Load Bank. This can be accomplished by blowing the inside of the unit with clean, dry compressed air (not to exceed 40 psi). See above WARNING.
  • Page 34 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Maintenance housing. Lubricate per tag on fan housing after every 2,000-hour interval or every other year for low usage operation. Use special low temperature grease only. Check for build-up of dust, dirt, salt residue, debris, or any heavy film on the inside of the resistor case channels and load wiring.

  • Page 35: Troubleshooting

    Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Troubleshooting SECTION VII TROUBLESHOOTING NOTE Servicing should always be done only by trained, qualified service technicians. ************************************************************* W A R N I N G Be sure that all sources of power to the Load Bank are disconnected before servicing.
  • Page 36 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Troubleshooting PROBLEM POSSIBLE CAUSES/REMEDIES Fan motor does not Main switch or circuit breaker is not closed. operate. Power is not connected to Load Bank fan circuit. External power source is inadequate. (480V, 3-phase, 60 Hz - 120 Amps required) Motor fuses are blown.

  • Page 37: Replacement 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, where appropriate, the manufacturer's name and part number, as well as schematic reference designators to facilitate parts identification.
  • Page 38 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Replacement Parts List REPLACEMENT PARTS LIST SCHEMATIC MANUFACTURER AVTRON QTY/ DESCRIPTION REFERENCE and PART NO. UNIT AVTRON MODEL K922A OUTDOOR RESISTIVE LOAD BANK K922A- D41523 .SCHEMATIC D41648 .LOAD BANK, OUTDOOR (OUTLINE DWG) SB3671 .AIRFAIL/OVERTEMP ASSEMBLY...
  • Page 39 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Replacement Parts List SCHEMATIC MANUFACTURER AVTRON QTY/ DESCRIPTION REFERENCE and PART NO. UNIT F108-110 ..FUSE, 8 AMP BUSSMANN COOPER 324699 FRS-R-8 XF108-110 ..FUSEHOLDER BUSSMANN COOPER 324496 R60030-3SR .TRANSFORMER, CONTROL ACME ELECTRIC CORP 370535...
  • Page 40 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Replacement Parts List SCHEMATIC MANUFACTURER AVTRON QTY/ DESCRIPTION REFERENCE and PART NO. UNIT .RESISTOR ASSEMBLY C,G,H D36385 ..RESISTOR ASSEMBLY C25924 ...RESISTANCE ELEMENT A28814 ...BUSHING, CERAMIC A21179 ...TUBE, INSULATOR: CORDIERITE DU-CO CERAMICS CO 411187 .530"...
  • Page 41 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Replacement Parts List SCHEMATIC MANUFACTURER AVTRON QTY/ DESCRIPTION REFERENCE and PART NO. UNIT .TRANSFORMER, CONTROL ACME ELECTRIC CORP 370825 TA-2-81220 .CONTROL ASSEMBLY D36363 ..SCHEMATIC/INTCON DIAGRAM D41648 XF2,XF3 ..FUSEHOLDER BUSSMANN COOPER 324523 S-8002-1 ..INSULATOR...
  • Page 42 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Replacement Parts List SCHEMATIC MANUFACTURER AVTRON QTY/ DESCRIPTION REFERENCE and PART NO. UNIT CR30 ..RECTIFIER VISHAY 354821 GBPC3506 ..SWITCH, TOGGLE EATON CORP 360747 7992K10 ..SWITCH, PUSHBUTTON OTTO ENGINEERING 360309 P3-32112 .SERVICE PANEL (120 VAC) C27112 ..SCHEMATIC/INTCON DIAGRAM...
  • Page 43 Avtron Outdoor Resistive Load Bank • Part Number K922AD41523 Peak Load Voltage Rating ADDENDUM PEAK LOAD VOLTAGE RATING In the high voltage mode, the Load Bank is rated for 13.8 kV operation. There are several factors which influence the peak voltage rating and need to be reviewed in conjunction with each other. The Load Bank, as designed, can be operated at load voltages to 14,100 VAC with a peak voltage of 14,400 VAC if operation is conducted under specific parameters.
  • Page 44 The air flow to the Load Bank cannot be compromised. Other air handling equipment and/or sources of heat in close proximity can influence the Load Bank cooling. Complete review of Avtron manual is required prior to testing. Power source must be regulated and controlled to assure Load Bank is not subject to transient or voltage spikes during over voltage operation.

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