background image

 
 

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 ..................................................................... 4-1 

 

Section V 

 

OPERATING INSTRUCTIONS ............................................................. 5-1 

 

Section VI 

 

MAINTENANCE .................................................................................... 6-1 

 

Section VII   

TROUBLESHOOTING ........................................................................... 7-1 

 

Section VIII   

REPLACEMENT PARTS LIST .............................................................. 8-1 

 

ADDENDUM  

PEAK LOAD VOLTAGE RATING ...................................................... A-1 

 
 
DRAWINGS 
 
SB3671 

Outline Drawing, Load Bank, Resistive 

C25920 Resistor 

Assembly 

C25921 Resistor 

Assembly 

C25922 Resistor 

Assembly 

C25923 Resistor 

Assembly 

C25924 Resistor 

Assembly 

C25925 Resistor 

Assembly 

C25926 Resistor 

Assembly 

D36358 Airfail/Overtemp 

Assembly 

D36360 

Motor Controller Assembly Drawing 

D36362 

PLC Component Assembly 

D36363 

Control Assembly Drawing 

D36383 Resistor 

Assembly 

D36384 Resistor 

Assembly 

D36385 Resistor 

Assembly 

D36469 Resistor 

Assembly 

D41523 

Load Bank, Resistive Drawing 

D41648 

Schematic Diagram, Load Bank 

 
 -i- 

 

Содержание K922A

Страница 1: ...upplemental 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 DATE 23 September 200...

Страница 2: ...IGINATOR 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 W...

Страница 3: ...ESISTIVE LOAD BANK 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 Clev...

Страница 4: ...CEMENT PARTS LIST 8 1 ADDENDUM PEAK LOAD VOLTAGE RATING A 1 DRAWINGS SB3671 Outline Drawing Load Bank Resistive C25920 Resistor Assembly C25921 Resistor Assembly C25922 Resistor Assembly C25923 Resist...

Страница 5: ...ation and Programming Manual Version 5 1 Oct 23 2007 Hoffman Electric Heaters 87565511 rev C Horner APG AC Input AC Output Module HE800DIQ627 HE DIQ627 MAN0408 05 Horner APG Installation Notice SUP025...

Страница 6: ...K922A Load Bank is an industrial test unit designed to be used outdoors safely However because the function of the Load Bank is to dissipate electrical energy there are inherent dangers to operators a...

Страница 7: ...Load Bank can become quite hot during extended load testing and may result in a serious burn should contact be made with them 9 Do not allow objects to enter or block the air intakes or exhausts of t...

Страница 8: ...for low temperature operation When the unit is in storage and prior to operation an external source of power 460 VAC 3 phase 60 Hz 150 amps must be connected to TB2 1 2 3 and GND This will energize t...

Страница 9: ...or 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 bo...

Страница 10: ...te lifting hoisting device Refer to the INSTALLATION section of this manual Bolt holes are provided in the legs of the unit for permanent pad mounting via elevated frame extension legs Installation sh...

Страница 11: ...ols to prevent load application if a resistor stack temperature exceeds 375 F When temperature exceeds 375 F in any stack it will de energize relay K99 disconnecting all load Load cannot be reapplied...

Страница 12: ...ohmic value of each phase is within 3 of the average ohmic value of the three phases To prevent sagging or adverse movement the load elements are fully supported across their entire length by spring l...

Страница 13: ...ems If protective circuitry prevents application of the load determine the source of the problem DO NOT DISABLE THE AIR PRESSURE OR OVERTEMPERATURE SWITCHES This causes a safety hazard and will void o...

Страница 14: ...or maintenance A minimum of 30 inches of clearance is required below the Load Bank on the intake side for proper airflow When installed next to a similar air handling unit or Load Bank with vertical a...

Страница 15: ...ting of the Load Bank All load and control wiring is provided by the installing contractor or site technicians operator No special hand tools are required for installation It is the responsibility of...

Страница 16: ...options a SPREADER BAR Use a minimum 16 ft long 40 000 lb minimum rated spreader bar with two double leg type slings minimum 10 ft long b HEAVY DUTY CHAIN SLING Use either two double leg or one four l...

Страница 17: ...the Load Bank Spreader bar is to be parallel to longitudinal direction of the Load Bank frame 4 Repeat step 3 for the opposite end of the bar 5 Test and verify that the unit is level by lifting of the...

Страница 18: ...others are rated to at least 8 000 lbs each 2 Semi trailer to position Load Bank at final testing site location 3 Install lifting jacks into the 6 x 6 tubes on both ends of frame Four jacks required P...

Страница 19: ...e necessary modifications for the incoming control feed Reference outline drawing SB3671 for conduit entry A separate control transformer 480V 120VAC is used to power one 1 duplex GFI receptacle that...

Страница 20: ...ank and exhausted out the top Verify all top exhaust gravity hatches open when fans are energized This phase rotation check is mandatory each time the source or fan connections are changed W A R N I N...

Страница 21: ...tage Rating Addendum sheet Never apply more than 4570 volts to the main bus when the configuration jumpers J1 J48 are in place GROUNDING A permanent ground conductor must be connected to the Load Bank...

Страница 22: ...ower to the Load Bank are disconnected before proceeding 1 Open the twelve access doors and inspect the resistor stack area A Ensure no debris is within the resistor stacks or inside resistor area B V...

Страница 23: ...ore operating Load Bank Consult factory if unit is suspect A high potential test and check for excessive leakage current may be required prior to operation 6 Ohm out all interconnection control wiring...

Страница 24: ...erify that airflow switches are functional 11 Verify that overtemperature switches are functional 12 Disconnect all sources of power 13 Ensure that all access doors are closed and all 1 4 turn latches...

Страница 25: ...rgize the fans only to loosen any small debris SUMMER Most maintenance should be performed during the summer such as paint touch up checking gaskets and latches lubrication of the hinges and one quart...

Страница 26: ...nk This will create several layers of ice and snow on both the internal components and the gravity exhaust hatches A visual check must be performed on the resistors fan blades and inside the medium vo...

Страница 27: ...ad and during a switching sequence After energizing contactor wait 2 3 seconds before switching off DO NOT re energize for a minimum of 5 seconds If a remote controller is used the PLC program must ha...

Страница 28: ...to the Load Bank resistive elements if an overtemperature alarm switch opens It is the responsibility of the end user to ensure all load is dropped if an overtemperature alarm is detected 5 Energize...

Страница 29: ...ge mode never exceed 13 800 volts configuration jumpers J1 J48 removed as this will cause the Load Bank to overheat See Peak Load Voltage Rating Addendum sheet In the medium voltage mode when the conf...

Страница 30: ...dure may guard operating personnel from possible burn injuries 2 Press the STOP pushbutton to turn off the fans blowers 3 Place the POWER ON switch to the OFF position and other switches on the contro...

Страница 31: ...e work must be done by qualified personnel only W A R N I N G Personal injury from electrical shock or from the moving fan blade may result if ALL sources of power are not disconnected Refer to the SA...

Страница 32: ...ect the load resistors for mechanical breakdown Replace with new resistor elements as required 2 Inspect for broken ceramic insulators Replace with new ceramic insulators if any cracks are found 3 Ins...

Страница 33: ...e if damaged Clean screen on top of medium voltage area top center of unit on roof 14 For fan motor lubrication follow this procedure If Load Bank runs continuously lubricate after every 2 000 hours 3...

Страница 34: ...an industrial cleaner which does not leave a solvent behind i e acetone alcohol 4 Clean both medium voltage cabinet screens located on both sides of storage box with a mild detergent and dry with com...

Страница 35: ...in power fails to come on or load cannot be energized a Main switch or circuit breaker is not closed b Unit is not connected according to the Schematic Interconnection Diagram c Terminals were damaged...

Страница 36: ...ly 4 Fan failure a Airflow restrictions present at Load Bank intake or exhaust b Improper fan blade rotation or phase reversal Check fan motor power connections for proper phase sequence c Air differe...

Страница 37: ...acy of this information However changes 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 a...

Страница 38: ...TROLS 360772 8 RANGE 0 5 02IN W C 2 0 IN W C AFS 271 PER 2 0 IN W C 300VA 115 277VAC DESCRIPTION INCLUDES LINE NUT FERRULE CONNECTORS MOTOR CONTROLLER ASSEMBLY D36360 1 SCHEMATIC INTCON DIAGRAM D41648...

Страница 39: ...R DU CO CERAMICS CO 411188 24 CORDIERITE 530 006 O D PER DESCRIPTION 340 005 I D 500 010 LONG RESISTOR ASSEMBLY D D36384 1 RESISTOR ASSEMBLY C25920 3 RESISTANCE ELEMENT A26913 12 BUSHING CERAMIC A2117...

Страница 40: ...A21179 40 TUBE INSULATOR DU CO CERAMICS CO 411187 150 CORDIERITE 530 006 O D PER DESCRIPTION 340 005 I D 2 000 030 LONG TUBE INSULATOR DU CO CERAMICS CO 411188 20 CORDIERITE 530 006 O D PER DESCRIPTI...

Страница 41: ...8 1 BC6033SQ K27 RELAY POTTER BRUMFIELD 351060 1 KUP14A15 CONNECTOR ASSY ALTECH CORP 314836 2 225 405 CONNECTOR ASSY ALTECH CORP 314837 1 225 406 PE1 SENSOR PHOTOELECTRIC PEPPERL AND FUCHS 372081 1 RL...

Страница 42: ...C C27112 1 SCHEMATIC INTCON DIAGRAM D41648 REF J10 RECEPTACLE GFCI GRAINGER W W INC 315443 1 3AU51 S12 13 SWITCH TOGGLE CARLINGSWITCH INC 360589 2 2GK51 73 THERMOCOUPLE A24375 8 S10 11 SWITCH THERMOST...

Страница 43: ...on 3 In extremely cold climates follow special instructions in PREPARATION FOR USE section 4 Excess moisture and surface contamination are a primary concern Prior to operation the heaters need to be e...

Страница 44: ...sustained full load operation The over temperature thermocouples are factory set at 375 F These devices monitor a fault condition and will not likely trip at 14 400 VAC testing The temperature contro...

Страница 45: ......

Страница 46: ......

Страница 47: ......

Страница 48: ......

Страница 49: ......

Страница 50: ......

Страница 51: ......

Страница 52: ......

Страница 53: ......

Страница 54: ......

Страница 55: ......

Страница 56: ......

Страница 57: ......

Страница 58: ......

Страница 59: ......

Страница 60: ......

Страница 61: ......

Страница 62: ......

Страница 63: ......

Страница 64: ......

Страница 65: ......

Страница 66: ......

Страница 67: ......

Страница 68: ......

Страница 69: ......

Страница 70: ......

Страница 71: ......

Страница 72: ......

Страница 73: ......

Страница 74: ......

Страница 75: ......

Страница 76: ......

Страница 77: ......

Страница 78: ......

Страница 79: ......

Страница 80: ......

Страница 81: ......

Страница 82: ......

Страница 83: ......

Страница 84: ......

Страница 85: ......

Страница 86: ......

Страница 87: ......

Страница 88: ......

Страница 89: ......

Страница 90: ......

Отзывы: