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Maintenance

Avtron Outdoor Load Bank • Part Number K875A 1035409

5-3

ANNUALLY

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.

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Summary of Contents for 1035409

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...

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Page 6: ...ERATION 4 1 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...

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Page 8: ...arately 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 Q...

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Page 10: ...rol Transformer D27683 3 3 Control Transformer Option 500 to 2000 kW Load Banks 480 120V Control Transformer D27683 4 4 Control Transformer Option 2001 to 2500 kW Load Banks 480 120V Control Transform...

Page 11: ...ntrol Transformer Option 500 to 2000 kW Load Banks 440 115V Control Transformer D29476 1 21 Dual Voltage Control Transformer 500 2000 kW Load Banks 240 480 Control Transformer D27685 1 22 Load Shedder...

Page 12: ...kVAR kVA PF F CT Ratio 4000 5 D29421 3 33 Digital Power Metering Option D Style Instruction Manual V A F kW kVAR PF kVA C T Ratio 2500 5 400 Hz B27647 34 Wallmount Enclosure Large Remote Control Mete...

Page 13: ...AR kVA PF CT Ratio 3000 5 D32051 1 45 1 kW Load Step Resolution 240 480 D30857 9 46 Digital Power Metering Option DZ Style Instruction Manual V A F kW kVAR kVA PF CT Ratio 2000 5 D27685 5 47 Load Shed...

Page 14: ...0 kW Load Banks 575 115V Control Transformer Stainless Steel Panel D35895 7 58 Control Transformer Option 500 to 2000 kW Load Banks 440 115V Control Transformer Stainless Steel Panel D35895 8 59 Contr...

Page 15: ...500 to 2000 kW Load Banks A32404 71 Control Unit Mounted Front D38803 72 Dual Voltage Blower Control Transformer 2 Stack 10 HP A32573 1 73 Gravity Hood Replacement Single Stack A32573 2 74 Gravity Hoo...

Page 16: ...Stainless Steel Screen 2 Stack Units A34920 3 82 Aluminum Hood Replacement with Stainless Steel Screen 3 Stack Units B32580 1 83 Overhead Lift Single Stack B32580 2 84 Overhead Lift Two Stack B32580...

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Page 18: ...nd safety built into your 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 Becaus...

Page 19: ...or into a room with insufficient volume or Make Up air is a definite hazard The Load Banks should be used in a cool well ventilated area This Load Bank is specifically designed for outdoor use with a...

Page 20: ...is the responsibility of the customer to take diligent care in installing the Load Bank The National Electrical Code NEC sound local electrical and safety codes and the Occupational Safety and Health...

Page 21: ......

Page 22: ...VAC 60 Hz 10 H P 1800 RPM fan motor which provides the necessary cooling air for the load elements The fan motor is controlled by a motor starter contactor Overcurrent protection is provided for the m...

Page 23: ...N Voltage must not be connected to the Load Bank resistance elements if the airflow switches have not closed It is the customer s responsibility to ensure all load is dropped if an air failure is det...

Page 24: ...dling by a forklift truck Bolt holes are also supplied in the base to permit permanent mounting to a concrete pad or metal foundation C A U T I O N Never exceed the rated voltage as this will cause th...

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Page 26: ...not apply W A R N I N G THE FOLLOWING TESTS ARE TO BE ACCOMPLISHED BY A QUALIFIED ELECTRICIAN OR TECHNICIAN USING EXTREME CAUTION AS POTENTIALLY LETHAL VOLTAGES AND DANGEROUS ROTATING COMPONENTS ARE...

Page 27: ...rity of all customer supplied interconnection wiring A Ensure lugs are properly crimped B Ensure terminations are properly torqued C Verify proper phase to phase clearance on main bus bars load wiring...

Page 28: ...l the contactors If chatter or hesitation is observed locate the cause of the voltage drop causing the problem 6 While the load relays are energized remove the jumper across the air switch All the loa...

Page 29: ...of power from the Load Bank K Remove access panel remove ohmmeter wiring and replace factory wiring Replace access panel This checkout procedure is intended to be a guide to Load Bank installations in...

Page 30: ...ng or plumbing which may be damaged by high air temperatures or which may constitute a fire hazard AIRFLOW CONSIDERATIONS Even with an ample supply of cooling air the Load Bank may overheat if it is n...

Page 31: ...inspection and comments 2 Locations which have full or partial perimeter fence necessitate a review The fencing material should have at least 75 open area The minimum clearances still apply Overhead...

Page 32: ...lower panel It is controlled by a temperature switch The heater is used to control condensation problems The switch is factory calibrated to 50 F FAN BLOWER MOTOR CONNECTION The fan blower circuit con...

Page 33: ...n Load Bank Schematic Diagram 1036579 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 enclos...

Page 34: ...er to the SAFETY CONSIDERATIONS section of this manual DO NOT allow objects to enter or block screens C A U T I O N Never exceed the rated voltage as this will cause the Load Bank to overheat Do not a...

Page 35: ...elements unless the airflow switch closes and the load dump relay K99 interlocks C A U T I O N The operation of the blower is vital to the safe operation of this Load Bank When the BLOWER START switc...

Page 36: ...ing personnel from possible burn injuries 2 Place the control POWER ON OFF switch to the OFF position Other switches on the control panel should be OFF 3 Shut down the power source s 4 Disconnect the...

Page 37: ...EP INPUTS 120 VAC HI A contact closure to the respective terminal on TB300 will turn on the load step TB300 3 6 Reference Interconnection Diagram 1036580 D AIR FAILURE A set of contacts is brought out...

Page 38: ...409 4 5 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 ensu...

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Page 40: ...t the top of this page Put on a grounded wrist strap before handling any ESD sensitive item Clear work area of Styrofoam plastic and vinyl items such as coffee cups Handle ESD items by the body never...

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Page 42: ...urces of power are not disconnected Refer to the SAFETY CONSIDERATIONS section of this manual Eye protection should be worn when cleaning the unit with compressed air DAILY 1 Remove any restrictions t...

Page 43: ...required 5 Verify that the airflow switch works properly 6 Inspect all magnetic contactors to make sure that the contacts are not severely pitted or corroded The contacts must move freely and be prope...

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 tha...

Page 45: ......

Page 46: ...nsformer Option 500 to 2000 kW Load Banks 480 120V Control Transformer D27683 4 4 Control Transformer Option 2001 to 2500 kW Load Banks 480 120V Control Transformer D27683 5 5 Control Transformer Opti...

Page 47: ...ual Voltage Control Transformer 500 2000 kW Load Banks 240 480 Control Transformer D27685 1 22 Load Shedder Option Single Board Load Shedder D27685 2 23 Load Shedder Option Dual Board Load Shedder D27...

Page 48: ...D Style V A F kW kVAR PF kVA CT Ratio 1500 5 D29785 5 38 Digital Power Metering Option DX Style V A F kW CT Ratio 4000 5 D30857 4 39 Digital Power Metering Option DZ Style V A F kW kVAR PF kVA CT Rati...

Page 49: ...ontrol Transformer 380 110V Load Banks 500 2000 kW SST Panel D35895 3 54 Control Transformer 480 120V Load Banks 500 2000 kW SST Panel D35895 4 55 Control Transformer 480 120V Load Banks 2001 2500 kW...

Page 50: ...ion DW Style V A F KW KVAR PF KVA CT Ratio 1200 5 D37723 8 69 Digital Power Metering Option DW Style V A F KW KVAR PF KVA CT Ratio 1000 5 D27683 11 70 Control Transformer 220 110V for 500 to 2000 kW L...

Page 51: ...34920 3 82 Aluminum Hood Replacement with Stainless Steel Screen 3 Stack Units B32580 1 83 Overhead Lift Single Stack B32580 2 84 Overhead Lift Two Stack B32580 3 85 Overhead Lift Three Stack A37255 8...

Page 52: ...ry and revisions to the parts list may be made at any time without notice REFERENCE DESIGNATORS Service personnel may use this parts list along with the Avtron system schematics to identify and order...

Page 53: ...96 1 F212 FUSE CARTRIDGE 9 AMP 600V 324431 1 TIME DELAY CLASS RK 5 F210 211 FUSE CARTRIDGE 4 AMP 600V 324424 2 TIME DELAY CLASS RK 5 T1 TRANSF CONT 750 VA 371148 1 OPTION 4 CONTROL TRANSFORMER D27683...

Page 54: ...ON 11 1 KW RESOLUTION D27682 2 K10 11 12A RELAY 3P N O 600 VAC 9A 351889 6 12B 0 05PF 110 VAC 60 HZ COIL XF13 18 FUSEBLOCK 30 AMP 3 POLE CLASS T 324977 2 F13 18 FUSE CARTRIDGE 10 AMP 600V 324480 6 VER...

Page 55: ...351925 1 1 SPDT AUX DIN RAIL MT K480 RELAY 3P 25A 208 240V 60 HZ 351924 1 2 SPDT AUX DIN RAIL MT T2 TRANSF CONT 50 VA 440 460 480V PRI 370528 1 220 230 240V SEC 50 60 HZ T1 TRANSF CONT 850 VA 240 480...

Page 56: ...361874 1 S101 SWITCH PUSHBUTTON RED 361873 1 OPTION 19 DIGITAL METERING UNIT D29421 1 CT1 2 TRANSFORMER CURRENT 1200 5 50 400 HZ 370323 2 T100 TRANSF POTENTIAL 480V PRI 120V SEC 371046 1 1 ACC 1 0 95...

Page 57: ...MT T2 TRANSF CONT 50 VA 440 460 480V PRI 370528 1 220 230 240V SEC 50 60 HZ T1 TRANSF CONT 850 VA 240 480 VAC PRI 371148 1 120 VAC SEC 50 60 HZ OPTION 22 LOAD SHEDDER D27685 1 K50 51 RELAY 3PDT 120 VA...

Page 58: ...REF DS30 LAMP INDICATOR NEON PANEL MNT 329681 1 110 125 VAC AMBER 375 MTG HOLE S30 SWITCH TOGGLE DPDT 6 TERM ON NONE ON 360747 1 K71 AUX2 CONTACT AUX SPDT 312361 2 R30 RESISTOR 12K OHM 2W 5 119311 1 O...

Page 59: ...SEC 371046 1 1 ACC 1 0 95 PF 50 60 HZ F100 102 FUSE CARTRIDGE 1 AMP 600 VAC 324449 3 TIME DELAY CLASS CC XF100 102 FUSEBLOCK CLASS CC 600V REJ TYPE 324998 1 M1 DIGITAL POWER METER 338272 1 CR30 BRIDG...

Page 60: ...49 3 TIME DELAY CLASS CC XF100 102 FUSEBLOCK CLASS CC 600V REJ TYPE 324998 1 M1 DIGITAL POWER METER 338288 1 CR30 BRIDGE RECTIFIER 35A 600V 354821 1 C30 CAPACITOR ELECTROLYTIC 250V 100 MFD 222097 1 OP...

Page 61: ...ACC 1 0 95 PF 50 60 HZ F100 102 FUSE CARTRIDGE 1 AMP 600 VAC 324449 3 TIME DELAY CLASS CC XF100 102 FUSEBLOCK CLASS CC 600V REJ TYPE 324998 1 M1 DIGITAL POWER METER 338272 1 CR30 BRIDGE RECTIFIER 35A...

Page 62: ...60 HZ F100 102 FUSE CARTRIDGE 1 AMP 600 VAC 324449 3 TIME DELAY CLASS CC XF100 102 FUSEBLOCK CLASS CC 600V REJ TYPE 324998 1 M1 DIGITAL POWER METER 338272 1 CR30 BRIDGE RECTIFIER 35A 600V 354821 1 C30...

Page 63: ...Y A22829 1 SCHEMATIC D26034 REF DS30 LAMP INDICATOR NEON PANEL MNT 329681 1 110 125 VAC AMBER 375 MTG HOLE S30 SWITCH TOGGLE DPDT 6 TERM ON NONE ON 360591 1 K71 AUX2 CONTACT AUX SPDT 312361 2 R30 RESI...

Page 64: ...68 1 TIME DELAY CLASS RK 5 F210 211 FUSE 5 AMP 600V TIME DELAY CLASS RK 5 324394 2 T1 TRANSFORMER CONTROL 1100 VA 370258 1 240 480V PRI 120V SEC 50 60 HZ OPTION 56 CONTROL TRANSFORMER D35895 5 XF210 2...

Page 65: ...mp 600V Time Delay 324424 2 T1 Transformer 371088 1 OPTION 62 DIGITAL METERING UNIT D37723 1 DW Style CT Ratio 800 5 RS485 CT1 CT2 Transformer Current 800 5 371200 2 F100 102 Fuse 1 Amp 600V Time Dela...

Page 66: ...102 Fuse 1 Amp 600V Time Delay 324449 3 XF100 102 Fuseblock 324998 1 M1 Meter Digital 338344 1 OPTION 69 DIGITAL METERING UNIT D37723 8 DW Style CT Ratio 1000 5 RS485 CT1 CT2 Transformer Current 1000...

Page 67: ...l Machining Top D32672 1 Hinge B28406 1 Latch Spring Flush Head 442595 3 Handle B27422 1 Label Warning B15868 1 Panel Machining Bottom D33312 1 OPTION 77 HINGED ACCESS PANEL TWO STACK A33333 2 2 Panel...

Page 68: ...are sometimes necessary and revisions to the parts list may be made at any time without notice REFERENCE DESIGNATORS Service personnel may use this parts list along with the Avtron system schematics...

Page 69: ...TROL BLOWER ASSEMBLY D27681 3 1 F203 205 FUSE 324283 3 XF203 205 FUSEHOLDER 324997 1 K71 RELAY B14711 1 K72 RELAY OVERLOAD 350980 1 XK72 BRACKET RELAY MOUNTING 408304 1 K73 RELAY B17839 1 R1 HEATER 35...

Page 70: ...LAMP INDICATOR AMBER AVT 329681 4 DS2 4 LAMP INDICATOR RED 329682 2 F1 FUSE 20 AMP 324754 1 XF1 FUSEHOLDER 324985 1 KA KM RELAY 351060 2 XKA XKM SOCKET RELAY 358280 2 XKA XKM SPRING HOLD DOWN 467550 2...

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Page 78: ...the first person firm association or corporation for whom the Avtron product specified herein is originally deployed for use the User in the fifty United States or Canada This Warranty is not transfe...

Page 79: ...t 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...

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