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Summary of Contents for Avtron LPH400
- Page 1 AVTRON MODEL LPH400 RESISTIVE LOAD BANK Part Number LPH400D43233 © 2008 AVTRON • Cleveland, Ohio January 30, 2008 Rev. February 11, 2008...
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Page 2: Table Of Contents
Page SAFETY CONSIDERATIONS ................1-1 DESCRIPTION ....................2-1 INSTALLATION ....................3-1 OPERATION ....................... 4-1 MAINTENANCE ....................5-1 REPLACEMENT PARTS LIST ................6-1 APPENDIX - Avtron Load Bank Troubleshooting Guide DRAWINGS SB2975 Outline Drawing D43234 Schematic, Load Bank D27552 Resistor Assembly... -
Page 3: Safety Considerations
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 tested as part of the testing procedure of each unit. - Page 4 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Safety Considerations equipment and potentially hazardous conditions for the operator. If a fuse is blown, determine the cause of the blown fuse and correct the situation. 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 5 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Safety Considerations personnel and metering. Emergency shutdown procedure: In an emergency, shut down the MASTER LOAD switch, then the generator. The MASTER LOAD switch will allow disconnection of all load steps and still allow the fan motor to run, cooling any heated elements.
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Page 6: Description
SECTION II DESCRIPTION The Model LPH400 Load Bank is a portable, primarily indoor, self-contained unit for electrically loading and testing generators. The Load Bank is rated at 400 kW at 240/480 volts. The available load steps are 100 kW, 100 kW, 100 kW, 50 kW, 25 kW, 10 kW, 10 kW, and 5 kW. - Page 7 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Description The Control Panel is mounted in the Load Bank behind a sliding door. It is also sized for mounting into a 19-inch rack enclosure. The control panel contains all the switches required to operate the Load Bank.
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Page 8: Installation
Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 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 9 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Installation DO NOT STACK LOAD BANKS. Standard Load Bank design is suitable for operation between sea level and 3,000 feet maximum altitude. AIRFLOW CONSIDERATIONS Even with an ample supply of cooling air, the Load Bank may overheat, if it is not properly installed.
- Page 10 Load Banks mounted into a channel, trough, hollow, well, or pit, or exhausting into a full wall or corner, require special considerations even if above conditions are met. In these cases, provide a detailed sketch of site layout for Avtron to inspect and comment. POWER REQUIREMENTS The Load Bank requires a 115V, single phase, 60 Hz, 15 amp source of power for operation of the control circuit which is provided by an integral 240/480 to 115V control transformer.
- Page 11 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Installation REMOTE FAN POWER OPERATION: When testing single phase system or systems or a frequency other than 60 Hz, the fan motor must be run from a separate source. First review schematic, set control panel selector switch to match external voltage applied, and then connect external power.
- Page 12 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Installation LOAD CONNECTION Connect a 240/480 volt, 3-phase source to the three fused bars labeled A, B and C, located in the customer connection access box. Cables to the Load Bank should be sized to handle the maximum rated load according to the National Electric Code.
- Page 13 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Installation The ground conductor should be run with the load power conductors to provide the lowest impedance fault path. The ground stud must be connected to both the generator frame and a good earth ground.
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Page 14: Operation
Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Operation SECTION IV OPERATION PURPOSE AND USE OF CONTROLS BLOWER VOLTAGE SELECT Switch. This switch selects the appropriate voltage and source for the fan motor. Set to proper position BEFORE operation. - Page 15 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Operation A load step may be turned on or off before or during a test, but will load the unit only when the MASTER LOAD switch is ON. OPERATING INSTRUCTIONS Connect the unit to be tested as described in Section III, INSTALLATION, under Power Requirements.
- Page 16 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 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. DO make sure that the VOLTS Select switch is in the proper position before applying load.
- Page 17 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Operation Any kW LOAD switch can be added or removed as required with the MASTER LOAD switch closed (ON). Monitor the unit under test using the digital metering package. Toggle through the phases to review individual phase amps, kW, and volts.
- Page 18 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Operation Never exceed the rated voltage. This will cause the Load Bank to overheat. Do not apply DC voltages, because the contactors do not have arc blowout magnets. *******************************************************...
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Page 19: Maintenance
Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Maintenance SECTION V MAINTENANCE Good maintenance procedures must be followed to provide long equipment life and to reduce the chance of electric shock, fires, and personal injury. Before servicing, review Section I, SAFETY CONSIDERATIONS, of this manual. - Page 20 Avtron Model LPH 400 • Resistive Load Bank Part Number LPH400D43233 Maintenance THREE MONTHS OR 500 HOURS Remove access panels and screens. Inspect the load resistors for mechanical breakdown which is demonstrated by excessive sagging of the elements. Replace with new resistor elements, support rods, and insulators as required.
- Page 21 PARTS REPLACEMENT Access to any component is easily made with the removal of the cover panels. All components in the unit that may need replacement are listed in the Replacement Parts List. Avtron maintains an inventory of normally used items.
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Page 22: Replacement Parts List
REFERENCE DESIGNATORS Service personnel may use this parts list along with the Avtron system schematics to identify and order replaceable parts. The reference designators were carefully selected and matched to those on the schematic diagrams and equipment to simplify the troubleshooting and repair process. - Page 23 Avtron Model LPH 400 Resistive Load Bank • Part Number LPH400D43233 Replacement Parts List REPLACEMENT PARTS LIST SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT AVTRON MODEL LPH LOAD BANK LPH400- D43233 .SCHEMATIC D43234 .CONTROL PANEL D43237-2 ..LAMP, INDICATOR, AMBER 329681 ..LAMP, INDICATOR, RED 329682 ..METER, DIGITAL...
- Page 24 Avtron Model LPH 400 Resistive Load Bank • Part Number LPH400D43233 Replacement Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT ..INSULATOR (2.00 LG) 411187 ..INSULATOR (.50 LG) 411188 ..INSULATOR 411146 ..INSULATOR 411147 K100,240 .RELAY B14795 K480 .RELAY B16148 CT1,2 .TRANSFORMER, CURRENT...
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