Avtron K922A User manual

Part Number K922AD41523
ORIGINAL DATE June 21, 2007
ENGINEER Paul Piazza & John Emery
TECH WRITER Frank Seruchar
TYPIST Kathy Van Cise
PROJECT NO. 251855 and 251856
ECN NO. CE868
LOG OF CHANGES – Page 1
DATE January 22, 2008 ORIGINATOR John Emery
VERSION NO. V2 TECH WRITER Frank Seruchar
PROJECT NO. 252050-053-7202 TYPIST
ECN NO. CF104
DESCRIPTION OF CHANGES: Changed Part #B31105 to B31710.
DATE June 11, 2008 ORIGINATOR
VERSION NO. V3 TECH WRITER
PROJECT NO. 252050-7202 TYPIST Kathy Van Cise
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.
DATE 23 September 2008 ORIGINATOR John Emery
VERSION NO. V4 TECH WRITER G. Hollander
PROJECT NO. 252053 TYPIST G. Hollander
ECN NO. CF402
DESCRIPTION OF CHANGES: On page 8-5, under D36366 changed schematic from D36367
to D41648.
DATE Sept. 22, 2009 ORIGINATOR Gary Kozel
VERSION NO. V5 TECH WRITER George Hollander
PROJECT NO. TYPIST Kathy Van Cise
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
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. TYPIST
ECN NO.
DESCRIPTION OF CHANGES:

AVTRON MODEL K922A
OUTDOOR RESISTIVE 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
Cleveland, Ohio Rev. Sept. 22, 2009

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-

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
Aerovent Products, IM-100, May 2000
Aerovent General Installation, Operation and Maintenance Instructions for
Aerovent Products, IM-115, June 1997
Electro Industries DMMS300+, DMMS350, DMMS425 3-Phase Multifunction Power
Monitors, Installation, Operation, 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, SUP0259-03
Horner-APG Color-Touch OCS Products Specifications and Installation Data,
MAN0543-04, 28 JUL 2004
Hubbell Installing and Testing a GFCI Receptacle, PD1913
Pepperl+Fuchs Visolux Reflection Light Beam Switch with Polarization Filter
RLK39-54/31/40a/116, 45-0844A
TPI Corporation Taskmaster 5100 Series Horizontal or Vertical Mounting
Industrial/Commercial Unit Heater, Form 9632
Tenor Temperature Controller, TOS Series, E141946
Toshiba Instruction Manual, High-Voltage Vacuum Contactors,
Type: CV-10HA, 12/15kV-320A-5/4kA; CV-10HAL,
12/15kV-320A-5/4kA, 6F9G0133 Rev. 3, May 2001
-ii-

1-1
AVTRON MODEL K922A
OUTDOOR RESISTIVE LOAD BANK
Part Number K922AD41523
SECTION I
SAFETY CONSIDERATIONS
Throughout this manual, you will find WARNING and CAUTION statements. Personal injury or
death may occur to an operator using or repairing the equipment 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 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 Avtron Model 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 and equipment. These dangers are outlined in this section.
In the K922A, electrical energy is transformed into heat by the resistors. This heat must be removed
from the Load Bank by the cooling fans. If there is any restriction or stoppage of airflow, the Load
Bank may overheat and may even start a fire. It is recommended that:
1. The operator should read and understand the manual before operating the Load Bank.
2. Run approved ground wires from the Load Bank ground bus bars located in the medium
voltage enclosure, low voltage enclosure, and ground pad on the Load Bank frame to the
system grounding network. Size ground wire in accordance with the National Electric Code
and any local codes.
3. Do not bypass the airflow safety switches or overtemperature switches to prevent nuisance
tripping. The switches are designed to drop out the load if insufficient/overtemperature
exhaust air is reaching the load elements.

Safety Considerations Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
1-2
4. 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.
5. The Load Bank must be installed outdoors in a well ventilated area as described in the
INSTALLATION section of this instruction manual. DO NOT allow exhaust air to
recirculate through the Load Bank.
6. Allow cool air to pass into the unit to cool the elements. Do not allow the unit to be placed
where hot exhaust air can recirculate back through the unit causing a constant rise in the
cooling air temperature.
7. After running a load test, remove residual heat from the Load Bank by allowing the
fans/blowers to operate for a few minutes after load is removed. This procedure may guard
operating personnel from possible burn injuries and is preferred practice.
8. Personnel should avoid coming in contact with the frame, exhaust hoods and access doors
during and for some time after operation. These external portions of the 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 the Load Bank. A
blockage causes Load Bank overheating. If an object enters the screens, it can cause damage
to the resistor elements, possibly shorting them and causing shock and/or fire hazards.
10. Operators must not operate the Load Bank or apply power to load connections with the
access doors or screens removed and doors open. To do so would expose the operator and
other persons to possible personal injury from electrical shock or from the rotating fan
blades. Operation with access doors removed will upset the designed air movement system.
11. Emergency Shutdown Procedure
Operators or other personnel must be able to quickly disconnect all sources of power from
the Load Bank in an emergency.
12. An approved electrical fire extinguisher should be on hand at all times.
13. It is the responsibility of the installing contractor/test technician to take diligent care in
installing the wiring from the Load Bank to the unit under test. The National Electric Code,
sound local electrical and safety codes, and the Occupational Safety and Health Act (OSHA)
should be followed to reduce hazards to persons and property.
14. Never apply more than 4570 volts to main load input bus when the configuration jumpers
(J1-J48) are installed.

Safety Considerations Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
1-3
15. Always ship unit on air-ride semi-trailers to reduce harmful/destructive over the road
vibration and shock.
16. Never operate the Load Bank during heavy rains or high humidity. Always operate heaters
before operating the Load Bank.
17. Read and heed all WARNING and CAUTION statements in the instruction manual.
This unit is designed specifically 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 the enclosure heaters.
To prevent icing and condensation problems, switch S13 must be turned ON to energize the medium
voltage enclosure heater and switch S12 must be turned ON to energize the motor heaters.
In addition, heaters must be energized before operation in temperatures below 20°F (-6°C). The
main vacuum contactors require ambient temperatures above 20°F (-6°C) before operation. Refer to
schematic/interconnection diagram D41648.

Introduction and General Description Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
2-1
SECTION II
INTRODUCTION AND
GENERAL DESCRIPTION
The Avtron Model K922AD41523 is a custom engineered Load Bank designed to meet the testing
requirements of medium voltage generators at a power factor of 1.0. The Load Bank is rated as
follows:
Maximum Total Primary
Voltage Megawatt Current
13,800V 5.0 209A/Phase
4160V 4.0 555A/Phase
LOAD BANK DESCRIPTION
The Avtron Model K922AD41523 Load Bank is designed to absorb a balanced resistive load of
unity power factor at a specified 3-phase voltage. The total load capacity of the Load Bank is
5 MW, 13,800V, 3-phase, 60 Hz and 4 MW, 4160V, 3-phase, 60 Hz. The Load Bank has been
designed with load steps of 500, 1000, 1500, and 2000 kW at 13,800 volt. Load steps at 4160V are
400, 800, 1200, and 1600 kW. The Load Bank is controlled manually by the local control panel
mounted within the low voltage control compartment. 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. The Load Bank frame is fabricated using heavy-gauge hot-rolled steel,
welded together, making a rigid drip-proof structure. The frame has been cleaned, treated, and
primed. The frame is also painted with two coats of ANSI-61 grey polyurethane top coat with a
spatter finish (with white doors). (Two doors have a smooth finish.) Cooling air for the resistive
load elements is drawn in from the bottom (intake) and exhausted out the top through vertical
gravity exhaust hatches/ hoods. Connections are made in a NEMA 3-R style cabinet that is divided
into a medium voltage cabinet and a low voltage cabinet. The medium voltage cabinet is integral to
the frame section that houses eight independent resistor element stacks. See outline drawing
SB3671. Each resistive stack is provided with its own integral cooling fan. Mounted within the low
voltage cabinet are the control components, fan fuses/motor starters, airflow switches, terminal

Introduction and General Description Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
2-2
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.
Load connections are made through center access door on side of unit. Configuration panel is on the
other side.
The Load Bank is equipped with vertical gravity exhaust hatches fabricated from unpainted stainless
steel. These are mounted to the top of the frame above each resistor stack. The hatches are designed
to open when fans are energized and close by gravity to minimize the effects of rain and snow, and
to prevent foreign objects from entering the Load Bank.
NOTE
Prior to operation, the hatch retaining clip must be unbolted from
each set. Replace retaining clip prior to transport and during storage.
The Load Bank is designed to be lifted from overhead using the four roof cleats welded to the frame
and an appropriate 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 should provide minimum 30 inches clearance from bottom of fan intake
to any surface. The dimensions of the Load Bank including the exhaust hatches are 310.00 inches
long x 102 inches wide x 119.00 inches high (less extension legs), and weight is approximately
18,000 lb. (Ref. SB3671.)
The K922AD41523 Load Bank contains eight tube axial fans with eight 3-phase, 460 VAC, 60 Hz,
10 H.P., 1725 RPM fan motors, which provide the necessary cooling air for the load elements. Each
fan assembly has been designed to provide approximately 16,000 scfm at 1.7 inches of static
pressure. These motors have special bearing lubrication and embedded heaters within the motors for
special low temperature service. The fan motors are controlled by motor starter relays K1-K8. Short
circuit protection is provided by fuses F1-F24, which are dual-element, time delay, Class J, 20 amp
fuses. Overcurrent protection is provided by these fuses and overload relays.
*************************************************************
C A U T I O N
The Load Bank should never be used without all of the fan motors
operating. Inadequate cooling airflow will result in resistor elements
overheating and a fire hazard.
*************************************************************

Introduction and General Description Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
2-3
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. The
fault is not cleared until the fault is corrected and the FAULT RESET pushbutton is pressed to
unlatch the fault. After resetting, the load will be applied.
Airflow switches S1-S8 are used to monitor the flow of cooling air and are located on
Airfail/Overtemp Assembly panel D36358. These differential pressure switches are electrically
interlocked with the load application controls to prevent load application if a fan is not working
properly. When air failure is detected on any stack, it will de-energize relay K99, disconnecting all
load. Load cannot be reapplied unless the fault is corrected and the FAULT RESET pushbutton is
pressed.
Overtemperature switches S10-S17 are used to monitor the temperature of the exhaust air of each
resistor stack and are located on Airfail/Overtemp Assembly Panel D36358. These switches are
electrically interlocked with the load application controls 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 unless the fault is corrected and the
FAULT RESET pushbutton is pressed.
Motor overload relays are provided in the motor circuits to shut down the load if an overload
condition exists in the motor circuits. All load circuits will be shut down by an overload condition if
any motor overload relay is tripped. The motor overload relays must be manually reset. The motors
that did not overload will continue to run. Shut down the Load Bank and correct the problem before
restarting the Load Bank.
Two 500 watt heater strips with a temperature switch and one main 5000 watt heater with a
temperature switch are mounted within the medium voltage enclosure. One 500 watt heater strip is
mounted within the low voltage enclosure. An additional 500 watt heater strip is mounted in the
configuration area. These enclosure heaters should be used to prevent problems associated with
condensation. These heaters are required to warm the enclosure and components when the ambient
temperature falls below 20°F (-6°C). The main 5000 watt heater is powered directly from a 480
VAC, 3-phase, 60 Hz source. The 500 watt heaters are powered from the 120 VAC, single phase, 60
Hz, from a 480/120 volt control transformer. The temperature switch is factory-set at 50°F. Refer to
schematic D41648.
RESISTIVE ELEMENTS

Introduction and General Description Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
2-4
Avtron HelidyneTM 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. The resistive load elements have
been designed to a KW tolerance of -0 to +5% with a normal at +2.5%.
The 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 loaded, segmented ceramic insulators on a stainless steel support rod. This rod is
machined on both ends for stainless steel hitch pins and is securely held at each end. The load
elements are supported such that, should a wire break, the broken wire segments will not short to
adjacent conductors or to ground. Each load element is terminated with a stainless steel lug. All
materials used in mounting and installation of the resistive load elements are suitable for the
temperatures encountered in both normal operations and under short term fault conditions.

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-1
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.
*************************************************************
W A R N I N G
It is vitally important to install the Load Bank properly. Installation
errors may result in a catastrophic failure. The air pressure switches
and overtemperature switches in the Load Bank will guard against
some of these problems. 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 our warranty.
The following installation instructions are critical to the safe
operation of the Load Bank. Refer to the SAFETY
CONSIDERATIONS section of this manual.
*************************************************************
AIRFLOW CONSIDERATIONS
Even with an ample supply of cooling air, the Load Bank may overheat if it is not properly installed.
There are two types of airflow problems that must be avoided:
1. Recirculating Airflow - If the hot, exhausted air is permitted to recirculate through the Load
Bank, it will reach such a high temperature and low density that it will no longer cool the
resistance load elements.

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-2
2. Restriction of Cooling Air - Any obstruction located within 50 inches of any of the sides of
the Load Bank will restrict the airflow. Airflow is also restricted when two or more Load
Banks or other air handling devices have air inlets positioned close to each other. This
competition for cooling air causes a low pressure area, restricting airflow. The 50 inches is
no longer valid if unit is mounted in a corner, well, pit, trough, or channel way. 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.
LOCATION
The Load Bank must be used outdoors with extension legs fully set up in a well ventilated area. It
must be installed where cool unrestricted ambient air is continuously available and where hot
exhaust air will not be recirculated through the Load Bank.
The Load Bank should be positioned so that there is a minimum of 36 inches of clearance on all
sides to provide enough room for 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 air flow, clearances of 72 inches minimum are required.
Consult factory for specific site details.
Localized parcels of exhaust air may be in excess of 350°F under full load conditions. The unit must
not be installed near any structures, equipment, wiring, or plumbing which may be damaged by hot
exhaust air. Installation near natural gas fumes, generator/turbine exhaust fumes, or any combustible
vapors may constitute a fire or explosion hazard and must be avoided. The continuous monitoring of
the ambient air for any of these is recommended.
The intake must not ingest heated air from another source. The maximum ambient intake air
temperature is 110°F.
For cold climate operation, it will be necessary to energize all heaters to warm controls and vacuum
contactors.
Provide a minimum of 16 feet free from any obstruction for exhaust air. For thermal considerations,
provide a minimum clearance of 50 feet from any temperature sensitive objects. The heated exhaust
air will damage any temperature sensitive items in exhaust air wake.
Maximum altitude is 2,000 feet above sea level.
*************************************************************

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-3
W A R N I N G
Personal injury from electrical shock may result if all sources of
power are not disconnected before servicing. Maintenance work
must be done only by qualified personnel.
Failure to follow these guidelines will void the warranty.
*************************************************************
INSTALLATION
NOTE
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. No special hand tools are required for installation. It is the responsibility
of the installing contractor or site technicians/operator to ensure all local laws, rules and regulations
are followed for the installation procedure. All laws, rules, and regulations take precedent over this
procedure.
*************************************************************
W A R N I N G
To prevent injury or death to personnel, never place any portion of
body under the Load Bank while rigging. These procedures are
guidelines only and do not fully detail the scope of work required for
complete installation. The rigger (installing contractor, site
technician, operator) and his equipment must meet all safety and code
regulations.
*************************************************************
PREREQUISITES TO HANDLING

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-4
1. The Load Bank must be on a level surface at ground elevation.
2. 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.
3. Verify that all access door quarter turn latches are fully secured.
4. Verify the low and medium voltage enclosure doors are fully secured.
5. There are two methods to overhead lift/hoist and one base jacking method for positioning the
Load Bank and installing of extension legs. The installation/rigging contractor should obtain
equipment for these 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 leg rated at
40,000 lbs. at 45°. Each leg to be minimum 16 ft. long.
c. BASE LIFTING JACKS: Use four geared jack screws at corners. Each jack rated
8,000 lbs.
6. Obtain and organize extension legs, struts, and all mounting hardware. End user to provide
anchor bolts if unit is to be secured to ground for final mounting.
POSITIONING THE LOAD BANK
*************************************************************
C A U T I O N
The structural supports, concrete pad, platform or pedestal mounting
pads used to position/locate the Load Bank must be designed with
sufficient safety factors to not yield under static and dynamic loading.
These dynamic loads include but are not limited to wind loads,
seismic qualification, snow and fan thrust loads.
*************************************************************
NOTE

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-5
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.
A. Spreader Bar
1. Note the orientation of the spreader bar lifting points relative to the Load Bank.
2. Hook up spreader bar to crane and hoist to about five feet above the top of the Load
Bank frame. Center between the lifting cleats.
3. Using the spreader bar, attach one end of the spreader bar with double leg slings or
two cables or chains, each a minimum 10 feet long, to the appropriate two lifting
cleats on 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 Load Bank. Raise unit up no
more than 6 inches off the trailer or the ground. Lower and adjust if required to
obtain a level lift (level within 6 inches).
6. The rigger should now attach guide wires to at least two legs of the Load Bank for
stabilization. Connect an upper guide wire near final mounting position as well.
7. Keep the Load Bank close to ground and position near final lift point.
8. After verification of all rigging, hoist Load Bank vertically and locate in desired
position.
9. Install the extension legs on the four corners. Use clevis pin hardware provided.
Install extension leg struts (braces from legs to frame mounting location).
10. Lower unit, remove rigging, and verify Load Bank is on solid mounting surface.
B. Heavy Duty Chain/Cable Slings

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-6
1. Hook up either two double leg or one four leg sling to the crane. Hoist above the top
of the Load Bank frame.
2. 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. long.
3. Follow steps 5 through 10 in section “A. Spreader Bar” to complete installation.
C. Base Lifting Jacks
1. Confirm base jacks (provided by 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.
Pin welded jack sockets (5 x 5 tubing) into main 6 inch tube.
4. Follow steps 5, 7, 8, 9, and 10 in Section A to complete installation.
*************************************************************
W A R N I N G
This Load Bank should never be used without the fan motors
operating. Inadequate cooling airflow will result in overheating of
the resistor elements, causing a definite fire hazard. Also, if one or
more fans are not running, these resistor stacks will recirculate air.
*************************************************************
PREPARING GRAVITY EXHAUST HATCHES/HOODS

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-7
*************************************************************
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.
*************************************************************
1. Each hatch must have the retainer clip unfastened from between the hatch lids.
2. Release quarter turn clip or remove hardware and clip completely from Load Bank roof.
Save all hardware and clips.
3. Repeat for all eight hatches.
4. Verify lids open freely. Each side must pivot up approximately 75°and close fully. (Refer
to drawing SB3671.)
CONTROL POWER CONNECTIONS
The control circuit operates on 120 VAC, single phase, 60 Hz, 30 amp power. This power is derived
from the 480 to 120V control transformer. An external 480V, 3-phase, 60 Hz power source is
required. A conduit entry area is located on the bottom of the low voltage enclosure. The installing
contractor is required to punch a hole in the enclosure or make 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
provides 120 VAC, single phase, 60 Hz, 25 amp service. The outlet is located on the service panel
behind the right control door on the low voltage enclosure. The control transformer also powers the
blower heaters and medium voltage contact area heaters.
FAN/BLOWER POWER CONNECTIONS
The fan/blower circuit operates from a 460 VAC, 3-phase, 60 Hz, 150 amps/phase, 3-wire external
power source. This is also the source for internal heaters. The voltage required is supplied externally
and the input connections are made to the distribution block TB2 located on assembly P/N D36369
in the low voltage enclosure. The customer-supplied power source must be sized for the eight (8)
10 HP fan/blower motors and the heaters. The fan blower motors are set up on a staggered start
circuit. Upon initiating start sequence for the Load Bank, two fans will start, followed by a 5-second
delay until the second set of fans start. Then remaining fans start after additional timed delay.

Installation Avtron Outdoor Resistive Load Bank • Part Number K922AD41523
3-8
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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.
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A conduit entry area is located on the bottom of the low voltage enclosure. The installing contractor
is required to adapt or punch a hole in the enclosure for the incoming fan conduit. Reference outline
drawing SB3671 for conduit entry area.
With any connection, ensure that the correct phase rotation is observed. Improper phase rotation
will cause the fans/blowers to run in the reverse direction. The cooling air for the resistive section
should be pulled in from the bottom of the Load Bank 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.
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W A R N I N G
Disconnect all sources of voltage to the Load Bank before opening
any of the access doors or panels. Personal injury from electrical
shock can result if all sources of power are not disconnected. Never
operate the Load Bank with any of the access panels/doors open.
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LOAD CONNECTIONS
The Load Bank has a load design voltage of 13,800 or 4160 VAC, 3-phase, 60 Hz, 3 wire. The load
connections to the Load Bank are made to the three main load bus bars located inside the side
(center) access door in the medium voltage enclosure. The installing contractor is required to install
insulation bushings on the bottom entry aluminum panel.
Load cables should be of adequate size to handle the maximum rated load current according to
applicable codes. Load cables should be supported such that excessive tension on the load bus bar