Avtron K875A User manual

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K875A 1035409

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

AVTRON LOADBANK
Cleveland, Ohio
AVTRON MODEL K875A
OUTDOOR LOAD BANK
Part Number K875A 1035409
TABLE OF CONTENTS
Page
Section I SAFETY CONSIDERATIONS...............................................................1-1
Section II DESCRIPTION........................................................................................2-1
Section III INSTALLATION ....................................................................................3-1
Section IV OPERATION...........................................................................................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 Enclosure
SB2793 Outline Drawing, Load Bank, Outdoor, Single Bay
1036587 Outline Drawing, Control Panel
1036579 Load Bank Schematic Diagram
1036580 Load Bank/Control Panel Interconnection Diagram
D27553-1 Resistor Assembly
-i-

TABLES OF CONTENTS
VENDOR MANUALS (Provided Separately)
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 Quick Start for SHARK Series Meters, E145703
-ii-

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
OPTIONS - Refer to Section VI (K875A OPTIONS LIST) of this manual. The following
drawings apply to the various options. Only drawings for the options provided have
been included in this manual. Not all options can be installed in the same unit.
Installed options are marked on the identification tag.
Drawing Option Description
* D27683-1 1 Control Transformer Option, 500 to 2000 kW Load Banks,
(240/120V Control Transformer)
* D27683-2 2 Control Transformer Option, 500 to 2000 kW Load Banks,
(380/110V Control 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 Transformer)
* D27683-5 5 Control Transformer Option, 2501 to 3000 kW Load
Banks, (480/120V Control Transformer)
* D27683-6 6 Control Transformer Option, 2501 to 3000 kW Load
Banks, (575/115V Control Transformer)
A24925 7 Remote Control Unit, Mounted (Left Side)
* B26013 8 Overvoltage Protection
* B26019 9 Elapse Time Meter
* D27682-1 10 1 kW Resolution (for 480 Volt Load Banks)
* D27682-2 11 1 kW Resolution (for 240/480 Volt Load Banks)
A25057-1 12 Intake Overtemp Protection
A25057-2 13 Intake Overtemp Protection
*This drawing includes schematic wiring information.
GAH/kv
1/28/99

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
Drawing Option Description
A25057-3 14 Intake Overtemp Protection
* D27684-1 15 Dual Voltage Control Transformer and Blower Circuit
(for Load Banks Using 5 HP Motor @ 240/480V)
* D27684-2 16 Dual Voltage Control Transformer and Blower Circuit
(for Load Banks Using 10 HP Motor @ 240/480V)
A24744 17 Control/Meter Enclosure, Wallmount
A25353 18 Local Control/Metering Unit, Mounted (Left Side)
** D29421-1 19 Digital Power Metering Option (“D” Style)
(Instruction Manual) (V, A, kW, F, kVAR, PF, kVA), CT Ratio 1200:5
* D27683-7 20 Control 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 Option, Single Board Load Shedder
* D27685-2 23 Load Shedder Option, Dual Board Load Shedder
* D27685-3 24 Load Shedder Option, Single Board Load Shedder
(No component Mounting Panel)
* D27685-4 25 Load Shedder Option, Dual Board Load Shedder
(No component Mounting Panel)
** D29785-1 26 Digital Power Metering Option (“DX” Style)
(Instruction Manual) (V, A, F, kW), CT Ratio 1200/5
** D29785-2 27 Digital Power Metering Option (“DX” Style)
(Instruction Manual) (V, A, F, kW), CT Ratio 2500/5
* This drawing includes schematic wiring information.
** This is a Supplemental Instruction Manual.
GAH/kv
1/28/99

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
Drawing Option Description
** D29785-3 28 Digital Power Metering Option (“DX” Style)
(Instruction Manual) (V, A, F, kW), CT Ratio 1500:5
** D29421-2 29 Digital Power Metering Option (“D” Style)
(Instruction Manual) (V, A, F, kW, kVAR, PF, kVA), CT Ratio 3000:5
** D30857-1 30 Digital Power Metering Option (“DZ” Style)
(Instruction Manual) (V, A, F, kW, kVAR, PF, kVA), CT Ratio 3000/5
** D29785-4 31 Digital Power Metering Option (“DX” Style)
(Instruction Manual) (V, A, F, kW), CT Ratio 2000:5
** D30857-2 32 Digital Power Metering Option (“DZ” Style)
(Instruction Manual) (V, A, kW, 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/Meter
** D30857-3 35 Digital Power Metering Option (“DZ” Style)
(Instruction Manual) (V, A, F, kW, kVAR, PF, kVA), CT Ratio 2000:5,
RS485
* B27730 36 Remote Monitoring Contacts
** D29421-4 37 Digital Power Metering Option (“D” Style)
(Instruction Manual) (V, A, kW, kVAR, kVA, PF, F), CT Ratio 1500:5
** D29785-5 38 Digital Power Metering Option (“DX” Style)
(Instruction Manual) (V, A, F, kW), CT Ratio 4000:5
** D30857-4 39 Digital Power Metering Option (“DZ” Style) (V, A, F,
(Instruction Manual) kW, kVAR, PF, kVA), CT Ratio 1200:5
*This drawing includes schematic wiring information.
**This is a Supplemental Instruction Manual.
GAH/kv
9/1/99

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
Drawing Option Description
** D30857-5 40 Digital Power Metering Option (“DZ” Style)
(Instruction Manual) (V, A, F, kW, kVAR, PF, kVA), CT Ratio 2500:5
* D27683-8 41 Control Transformer, 380/115V (for 2001 to 2500 kW
Load Banks)
** D30857-6 42 Digital Power Metering Option (“DZ” Style) (V, A, F,
(Instruction Manual) kW, kVAR, kVA, PF), CT Ratio 1500:5
** D30857-7 43 Digital Power Metering Option (“DZ” Style) (V, A, F,
(Instruction Manual) kW, kVAR, kVA, PF), CT Ratio 2500:5, RS485
** D30857-8 44 Digital Power Metering Option (“DZ” Style) (V, A, F,
(Instruction Manual) kW, kVAR, 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 Shedder Option, Single Board Load Shedder,
Double Stack
* D27685-6 48 Load Shedder Option, Single Board Load Shedder,
Double Stack (No component mounting panel)
* A28623-1 49 Blower and Control Power Disconnect, Single Stack
* A28623-2 50 Blower and Control Power Disconnect, Multiple Stack
* D27683-9 51 Control Transformer, 208/115V (for 500 to 2000 kW
Load Banks)
* D35895-1 52 Control Transformer Option, 500 to 2000 kW Load Banks,
(240/120V Control Transformer), Stainless Steel Panel
*This drawing includes schematic wiring information.
**This is a Supplemental Instruction Manual.
GAH/kv
8/24/00

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
Drawing Option Description
* D35895-2 53 Control Transformer Option, 500 to 2000 kW Load Banks,
(380/110V Control Transformer), Stainless Steel Panel
* D35895-3 54 Control Transformer Option, 500 to 2000 kW Load Banks,
(480/120V Control Transformer), Stainless Steel Panel
* D35895-4 55 Control Transformer Option, 2001 to 2500 kW Load
Banks, (480/120V Control Transformer), Stainless Steel
Panel
* D35895-5 56 Control Transformer Option, 2501 to 3000 kW Load
Banks, (480/120V Control Transformer), Stainless Steel
Panel
* D35895-6 57 Control Transformer Option, 2501 to 3000 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 Control Transformer, 380/115V (for 2001 to 2500 kW
Load Banks), Stainless Steel Panel
* D35895-9 60 Control Transformer, 208/115V (for 500 to 2000 kW
Load Banks), Stainless Steel Panel
* D27683-10 61 Control Transformer 575/115V (for 500 to 2000 kW
Load Banks)
* D37723-1 62 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 800:5
* D37723-2 63 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 2500:5
* D37723-3 64 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 1500:5
*This drawing includes schematic wiring information.
** This is a supplemental instruction manual on CD.

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
Drawing Option Description
* D37723-4 65 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 2000:5
* D37723-5 66 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 4000:5
* D37723-6 67 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio: 3000:5
* D37723-7 68 Digital Power Metering Option (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
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 Hood Replacement, Two Stack
*** A32573-3 75 Gravity Hood Replacement, Three Stack
A33333-1 76 Hinged Access Panel, Single Stack
A33333-2 77 Hinged Access Panel, Two Stack
A33333-3 78 Hinged Access Panel, Three Stack
* This drawing includes schematic wiring information.
** This is a supplemental instruction manual on CD.
***Load Banks equipped with Option 73 should be supplied with special Outline Drawing SB3145.
Load Banks equipped with Option 74 should be supplied with special Outline Drawing SB3146.
Load Banks equipped with Option 75 should be supplied with special Outline Drawing SB3147.

Options Avtron Model K875A Load Bank
TABLE OF CONTENTS (Cont.)
Drawing Option Description
* D37723-9 79 Digital Power Metering Option (DW Style)
** (V, A, F, KW, KVAR, PF, KVA) CT Ratio 5000:5
A34920-1 80 Aluminum Hood Replacement with Stainless Steel
Screen (1 Stack Units)
A34920-2 81 Aluminum Hood Replacement with 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
B32580-3 85 Overhead Lift, Three Stack
A37255 86 Bus Bar, Customer Connection, Replacement
A37594 87 Local Control/Metering Unit, Mounted
B33795-1 88 Elevating Stand (One Bay)
B33795-2 89 Elevating Stand (Two Bay)
* This drawing includes schematic wiring information.
** This is a supplemental instruction manual on CD.

1-1
AVTRON MODEL K875A
OUTDOOR LOAD BANK
Part Number K875A 1035409
SECTION I
SAFETY CONSIDERATIONS
Throughout this manual, you will find WARNING and CAUTION statements. Personal injury to
an operator using or repairing the equipment may occur if a WARNING statement is ignored.
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 proven
reliable as part of the testing procedure of each unit.
As part of your safety program, an initial inspection after receiving the unit(s) and periodic
preventive maintenance and safety inspections should be conducted to ensure the reliability and
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. Because the function of the Load Bank is to
dissipate electrical energy, there are inherent dangers to operators and equipment. Thesedangersare
outlined in this section.
Electrical energy is transformed into heat by the resistors. This heat must be removed fromthe Load
Bank by the cooling fans/blowers. If there is any restriction or stoppage of airflow, the Load Bank
will overheat and may start a fire. It is recommended that:
1. The operator should read the manual before using the Load Bank.
2. Run an approved ground wire from the Load Bank ground bus bar to the generator frame.
Run an approved ground wire from the generator frame to a goodearth ground. Size ground
wire in accordance with National Electrical Code and any local codes.
3. Do not bypass the airflow safety switch or exhaust over-temperature switch to prevent
nuisance tripping.

Safety Considerations Avtron Outdoor Load Bank • Part Number K875A 1035409
1-2
4. 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.
5. Maintenance personnel must always exercise caution when the access panels or intake
screens are 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 only by qualified personnel.
6. The Load Bank must be used in a cool, well ventilated area as described in the
INSTALLATION section of this manual. Do not allow exhaust air to recirculate through the
Load Bank. This causes a constant rise in cooling air temperature and may cause the Load
Bank to overheat.
7. Install the factory-provided exhaust hood(s) as soon as possible. This protects the open
resistor element section from debris and environmental conditions such as freezing rain.
Failure to install hoods in a timely manner may void warranty.
8. Venting the heated air from the exhaust toward overhead cables, sprinkler systems, 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 an exhaust hood. Indoor mounting is not recommended and requires
special attention to exhaust hot air outdoors. Consult Avtron Engineering prior to indoor
mounting.
9. After running a load test, residual heat may be removed fromthe Load Bank by allowing the
fans to operate for a few minutes after load is removed. This procedure is not required for
maintaining Load Bank integrity, but it may guard operating personnel from possible burn
injuries.
10. The operator should avoid coming in contact with the resistor elements or surrounding
covers during and for some time after operation. These portions of the Load Bank become
quite hot and may result in a serious burn should contact be made with them.
11. Do not allow objects to enter or block the air intake or exhaust of the Load Bank. A
blockage can cause Load Bank overheating. If an object enters the screens, it will cause
damage to the resistor elements, possibly shorting them and causing shock and/or fire
hazards.
12. Operators must not operate the Load Bank with the access panels or screens removed. To do
so exposes the operator and other persons to possible personal injury from electrical shock or
from the moving fan blades.

Safety Considerations Avtron Outdoor Load Bank • Part Number K875A 1035409
1-3
13. Emergency Shutdown Procedure
A. In an emergency, turn off the MASTER LOAD switch, then the generator. The
MASTER LOAD switch will allow disconnection of all load steps and still allow for
the motor to run, cooling any heated elements.
B. The power ON/OFF switch will disconnect both load steps and the fan motor. The
Generator Emergency "OFF" switch should be located near the load system.
14. An approved electrical fire extinguisher should be on hand at all times.
15. It 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 Act (OSHA) should be followed when installing the
equipment to reduce hazards to persons and property.
16. Read and heed all WARNING and CAUTION statements in the manual.
17. Do not let the Load Bank sit idle or store outdoors for more than 30 days. If Load Bank is to
be stored, store indoors with exhaust covered. If outdoor, energize heaters. Spin fan motors
monthly to prevent motor bearing issues. Fan motor(s) should be run for 30 minutes
minimum, every month to prevent/limit condensation problems. Consult Avtron Prior to
placing unit in storage.