Avtron LPV600 User manual

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LPV600 994210

AVTRON MODEL LPV600
RESISTIVE LOAD BANK
Part Number LPV600 994210
©2013 Avtron Loadbank, Inc. November 19, 2013
Cleveland,Ohio

AVTRON LOADBANK, INC.
Cleveland, Ohio
AVTRON MODEL LPV600
RESISTIVE LOAD BANK
Part Number LPV600 994210
TABLE OF CONTENTS
Section Page
I SAFETY CONSIDERATIONS...........................................................................1-1
II DESCRIPTION....................................................................................................2-1
III INSTALLATION ................................................................................................3-1
IV OPERATION.......................................................................................................4-1
V MAINTENANCE................................................................................................5-1
VI REPLACEMENT PARTS LIST.......................................................................... 6-1
APPENDIX - Avtron Load Bank Troubleshooting Guide
DRAWINGS
SB3396 Outline Drawing
995228 Schematic/Interconnection, Load Bank
995221 Resistor Assy
995223 Resistor Assy
SUPPLEMENTAL MANUAL (Provided Separately)
Simpson DC Voltage Indicators, Falcon F35 Series, 3-1/2 Digit
Tenor TOS Series Temp. Ctrlr. Man. NO941017 E141946
-i-

1-1
AVTRON MODEL LPV600
RESISTIVE LOAD BANK
Part Number LPV600 994210
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 potentiallyhazardous 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.
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 LPV600 Load Banks are industrial test units designed for safe use indoors. However,
because the Load Bank’s function is to dissipate electrical energy, there are inherent dangers to the
operators and to the equipment. These dangers shall be outlined in this section.
Electrical energy is transformed into heat by the resistors. This heat must be removed fromthe Load
Bank by the cooling fan. If there is any restriction or stoppage of airflow, the Load Bank may
overheat and may even start a fire. The following events must be conducted if safe operation of the
Load Bank is to take place.
1. Read the manual before operating Load Bank.
2. An approved ground conductor wire from the Load Bank ground point and the generator
frame to a good earth ground must be connected.
3. Do not bypass the airflow switch to prevent nuisance tripping. The switch is designed to
drop out the load if sufficient air is not reaching the load elements.
4. Do not bypass any fuses which have blown. Bypassing fuses can result in damage to the
equipment and potentially hazardous conditions for the operator. If a fuse is blown,
determine the cause of the blown fuse and correct the situation.

Safety Considerations Avtron Resistive Load Bank - Part Number LPV600 994210
1-2
5. 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.
6. Maintenance personnel must always exercise caution when access panels are removed.
Personal injury from electrical shock or from the moving fan blade may result if all sources
of power are not disconnected before servicing. Maintenance work must be conducted only
by qualified personnel.
7. The Load Bank should be operated 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.
8. Venting the heated air from the Load Bank exhaust is a potential hazard. The Load Bank
should be used in a cool, well ventilated area.
9. 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 cooling
air temperature.
10. After running a load test, residual heat should be removed from the Load Bank by allowing
the fan 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.
11. 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.
12. Do not allow objects to enter or block the air intake or exhaust of the Load Bank. A
blockage could 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 fire hazards.
13. Operators must not operate the Load Bank with the access panels, cover, or screens
removed. To do so exposes the operator and other persons to possible personal injury from
electrical shock or from the moving fan blade.
14. Keep all of the hinged access covers closed at all times during testing and while power is on
the load bus. An access port (Load wiring opening) is provided in the bottom (Floor) of
Load Bank for load wiring.
15. Emergency shutdown procedure:
A. 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.

Safety Considerations Avtron Resistive Load Bank - Part Number LPV600 994210
1-3
B. The CONTROL POWER ON/OFF switch will disconnect both load steps and fan
motor. A customer-supplied Generator Emergency OFF switch should be located
near the Load Bank.
16. An approved electrical fire extinguisher should be on hand at all times.
17. 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.
18. Read and heed all WARNING and CAUTION statements in the manual.

Description Avtron Resistive Load Bank - Part Number LPV600 994210
2-1
SECTION II
DESCRIPTION
The Model LPV600 Load Bank is a portable, primarily indoor, self-contained unit for electrically
loading and testing generators. The Load Bank is rated at 600 kW at 600 VDC and 300 kW at 300
VDC. The available load steps are 240 kW, 120 kW, 120 kW, 60 kW, 20 kW, 20 kW, l0 kW, 5 kW,
2 kW, 2 kW, and 1 kWat 600 VDC. Load steps at 300 VDC are 120 kW, 60 kW, 60 kW, 30 kW, 10
kW, 10kW, 5 kW, 2.5 kW, 1 kW, 1 kW, and 0.5 kW. All load steps are selected by toggle switches.
Provisions are included for special operator interface by others. Refer to Schematic Diagram
995228.
The fan motor is a 5 HP, 3-phase motor whichoperates from 240/480 volts, 3-phase, 60 Hz power.
The fan motor obtains power from a remote source (external power source).
Fan failure protection is provided in two ways. A differential pneumatic pressure air switch (S51)
senses the airflow through the Load Bank. An additional slave relay (K30) is activated only if
power is applied to the fan motor terminals. This slave relay will disconnect control power to all
load contactors should the fan power be disconnected, the motor overload trip out, or the air
inlet/exhaust screens become blocked.
*************************************************************
C A U T I O N
This Load Bank should never be used without the fan motor
operating. Inadequate cooling airflow will result in resistor elements
overheating and a definite fire hazard.
Load step contactors are polarity sensitive. Observe proper polarity
when connecting load wiring to the Load Bank. Reverse polarity
connections to the Load Bank will cause contactor damage.
*************************************************************
GENERAL CONSTRUCTION (Refer to Outline Drawing SB3396.)
The Control Panel is mounted on the front face of the Load Bank. 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. Digital Volt and Ammeters are provided on the control panel. The Load Bank is constructed
of aluminized steel, forming a rigid structure. Mounted within this structure are the load element
resistor assemblies, the cooling fan and motor, the load step contactors, motor starter, motor

Description Avtron Resistive Load Bank - Part Number LPV600 994210
2-2
)
RatedVoltage( )
AppliedVoltage(
kW
=
kW 2
2
RatedApplied x
overload relay, fuses and customer connection load bus. The cooling air is drawn in from the bottom
and lower sections of side access panels, forced across the resistor elements and exhausted out the
top of the unit.
The unit is mounted on five-inch casters with one set provided with wheel locks. The customer
connection is located on the front side of the unit. Load connection is made through the lower
hinged access panel.
Lower voltages may be applied to the load circuit. The applied kWwith a lower voltage is computed
with the following formula:
*************************************************************
C A U T I O N
Never exceed the rated voltage, because this will cause the Load
Bank to overheat.
Load step contactors are polarity sensitive. Observe proper polarity
when connecting load wiring to the Load Bank. Reverse polarity
connections to the Load Bank will cause contactor damage.
*************************************************************

Installation Avtron Resistive Load Bank - Part Number LPV600 994210
3-1
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.
LOCATION
The Load Bank is designed primarily for indoor use. The Load Bank must be used in a cool, well
ventilated area. It must be installed where cool air is continually available and where hot exhaust air
will not be recirculated through the Load Bank. If the Load Bank is operated in a closed space,
continuous ventilation of 15,000 CFM or greater is required.
A minimum of four (4) feet of clearance from all sides and twelve (12) feet of clearance on the
exhaust end are required for proper airflow.
*************************************************************
W A R N I N G
The exhaust air will be in excess of 350oF above ambient under full
load conditions. The unit must not be installed near any equipment,
wiring or plumbing which may be damaged by high air temperatures
or which may constitute a fire hazard. Care should also be taken so
as not to set off a sprinkler system by exposing it to hot exhaust air.
*************************************************************
DO NOT STACK LOAD BANKS.
Standard Load Bank design is suitable for operation between sea level and 2,000 ft. maximum
altitude.

Installation Avtron Resistive Load Bank - Part Number LPV600 994210
3-2
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 should 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 elements. Maximum allowable intake air temperature is 110F. A Load
Bank should not be installed so close to any surface which may reflect the exhausted air back
to the air intake. When two or more Load Banks are being used, care must be taken in
positioning the Load Banks so that the exhausted air of one unit does not feed the air intake
of another.
2. RESTRICTION OF COOLING AIR - Any obstruction located within four (4) feet of the
inlet or twelve (12) feet of exhaust screens will restrict the Load Bank's airflow. Airflow is
also restricted when two or more Load Banks have air inlets positioned close to each other.
This competition for cooling air causes a low pressure area, restricting adequate airflow to
either unit.
*************************************************************
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 Airflow switch, a
protective device 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
AIRFLOW SWITCH. This will cause a safety hazard and will void
our warranty. The following installation instructions are critical to
the safe operation of the Load Bank. (Refer to Section I, SAFETY
CONSIDERATIONS, of this manual.)
*************************************************************
3. The heated exhaust air stream can damage any temperature sensitive items if they are
positioned within 30 ft. of exhaust air.
4. 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.

Installation Avtron Resistive Load Bank - Part Number LPV600 994210
3-3
POWER REQUIREMENTS
The Load Bank requires a 120V, single phase, 60 Hz, 20 amp source of power for operation of the
control circuit. An integral 480/120V control power transformeris providedfor poweringthe control
circuit. No external 120V power is required.
FAN MOTOR CONNECTIONS
The fan circuit consists of fuses, motor starters, contactors, overload relays, and the fan motor.
Required power for the fan/blower motor is 240/480V, 3-phase, 60 Hz, 14.4/7.2 Amp per phase. The
fan/blower power connections are made to TB1(11-13). Reference Schematic/Interconnection
Diagram 995228.
LOAD CONNECTION
The Load Bank is designed to load power sources at 600 or 300 VDC. The load connections are
made to the bus bars for 600 VDC labeled POS (+) and 600V NEG (-) and for 300 VDC labeled
POS (+) and 300V NEG (-), located within the Load Bank. Refer to resistor case configuration
labels on the inside of each door located on each side of the Load Bank for configuration setup of
600 VDC or 300 VDC. The Load Bank is configured for 600 VDC. Also refer to Schematic Diagram
995228 for reference. For 600 VDC operation, 300 VDC negative resistor wire must be isolated
from bus bars and each other. Operator must isolate prior to 600 VDC operation. Also, the operator
must ensure that Voltmeter MT1 terminal (2) is connected to the Negative 600 VDC Bus Bar to get
correct voltage reading. Operator must move wire if needed before operation. For 300 VDC
operation, operator must connect 300 VDC negative resistor wires to bus bar. Removal of600 VDC
negative resistor wires is NOT required. Also, operator must ensure that Voltmeter MT1 terminal
(2) is connected to the Negative 300 VDC Bus Bar to get correct voltage reading. Operator must
move wire if needed before operation.
Load connections are made to the bus bars labeled (+) and (–), located within the Load Bank.
(Access via the lower hinged panel on front of the unit.) Run cables through opening in floor (base)
of Load Bank frame up to bus bars. Verify proper phase to phase clearance on cable lugs, mounting
hardware, and wiring. Cables to the Load Bank should be sized to handle the maximum rated load
according to the National Electric Code.
There are two limit switches (LS1 and LS2), one located on each access door of resistor cases
located on the Load Bank. The switches are intended to prevent load from being applied ifdoors are
open. Operator must make sure doors are properly closed prior to operation.

Installation Avtron Resistive Load Bank - Part Number LPV600 994210
3-4
GROUNDING
A permanent ground should be connected to the Load Bank enclosure either by a grounded conduit
or with a separate ground wire to prevent a potential above ground on the enclosure. No internal
ground connections are made to any terminal on the Load Bank.
The ground conductor should be run with the load power conductors to provide the lowest
impedance fault path. The ground stud within the Load Bank (located on floor near cable cutout)
must be connected to both the generator frame and a good earth ground. The ground conductor
should be sized for National Electric Code section 250-95 if not superseded by local codes.
*************************************************************
W A R N I N G
Do not operate the Load Bank with any panel or screen removed or
any doors open. This may expose the operator to dangerous high
voltage and the rotating fan blade, as well as disrupting the airflow.
Keep both of the front hinged covers and both resistor hinged covers
closed and latched.
*************************************************************
STORAGE
The Load Bank should be covered to limit long term effect of moisture and to reduce the
accumulation of dust, dirt, and debris. The unit should be stored in a dry, enclosed area. An
optional waterproof vinyl cover is available for the Load Bank; however, even with this cover, the
Load Bank should not be stored outdoors permanently.

Operation Avtron Resistive Load Bank - Part Number LPV600 994210
4-1
SECTION IV
OPERATION
PURPOSE AND USE OF CONTROLS
1. CONTROL POWER ON/OFF Switch. This switch turns on control power to the control
circuit. Digital meters will illuminate.
2. BLOWER VOLTAGE SELECT Switch. This switch selects the appropriate voltage for the
fan motor. Set to proper position before operation.
3. FAN ROTATION ABC/CBA Switch. This switch is used to reverse the rotation of the
cooling fan if airflow is moving in the wrong direction. Always turn off fan by pressing the
BLOWER STOP switch and allow the fan to coast to a stop before changing the FAN
ROTATION ABC/CBA switch setting.
4. BLOWER START/STOP Pushbuttons. Pushbuttons are used to initiate fan motor start and
stop circuits.
5. BLOWER FAIL Lamp. This lamp should momentarily light when power switch is turned
on. This shows the air safety circuit is working. This lamp's purpose is to warn the operator
of an air failure or improper cooling of load elements.
6. MANUAL/AUTO MODE Switch. This switch is used to select between Manual Mode
(Local Panel) or Auto Mode (PLC Control) supplied by others.
7. MANUAL/AUTO Lamps. These lamps indicate the configuration mode of the Load Bank.
8. MASTER LOAD ON/OFF Switch. This switch connects power to all load steps, thus
allowing all set load steps to be actuated at the same time. It is also a master load
disconnect.
9. KW LOAD Step Switches. The load in kilowatts is marked above each actuating switch. A
load step may be turned on or off before orduring a test, but will load the unit only when the
MASTER LOAD switch is ON.
10. Digital Meters – Displays DC Volts and DC Amps.

Operation Avtron Resistive Load Bank - Part Number LPV600 994210
4-2
NOTE
Operator must ensure that MT1 terminal (2) is wired to either the
Negative 300 VDC or 600 VDC Bus Bar to get correct voltage reading.
Operator must move wire to correct Negative Bus Bar if needed before
operation. Refer to Schematic Diagram 995228 for reference.
OPERATING INSTRUCTIONS – MANUAL OPERATION
1. Connect the Load Bank to 240 or 480 volt, 60 Hz source for fan/blower power.
2. Connect the unit to be tested and configure Load Bank for proper load voltage. Load Bank is
factory set for 600 VDC. Refer to Section III, INSTALLATION, under Load Connection.
3. Place all switches on the control panel in the OFF position and set AUTO/MANUAL switch
(S2) to MANUAL.
4. Place the BLOWER VOLTAGE SELECT switch to the correct voltage.
5. Start the unit to be tested. After unit stabilizes at operating speed, temperature, voltage, and
any other required condition for testing per manufacturer’s instructions, proceed to step 6.
*************************************************************
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.
Load step contactors are polarity sensitive. Observe proper polarity
when connecting load wiring to the Load Bank. Reverse polarity
connections to the Load Bank will cause contactor damage.
*************************************************************
6. Turn the CONTROL POWER switch to the ON position.
7. Depress the BLOWER START pushbutton. Verify air flow is in the correct direction. If
not, shut down fan by depressing the STOP pushbutton. Wait until fan blade stops rotating;
then switch FAN ROTATION switch to the other position. Restart and verify airflow.
Upon energizing the fan, the red BLOWER FAIL lamp will light momentarily until the air
switch detects sufficient cooling air, at which time it will go off, applying power to the load

Operation Avtron Resistive Load Bank - Part Number LPV600 994210
4-3
switches. If at any time, there is insufficient cooling air to the elements, this safety switch
will drop out the load and the red BLOWER FAIL lamp will light.
*************************************************************
C A U T I O N
The operation of the fan is vital to the safe operation of this Load
Bank. When the BLOWER START pushbutton is depressed, the
BLOWER FAIL light will come on momentarily until the blower
accelerates up to its operating speed, at which time the light will go
off. If the air switch prevents the load from being applied, do not
bypass this switch. If the BLOWER FAIL light stays on for more
than a few seconds, shut down the Load Bank and do not operate the
unit until the problem is corrected. (Refer to Section I, SAFETY
CONSIDERATIONS, of this manual.)
*************************************************************
8. The resistive loading is selected by toggle switches, using any one or combination of toggle
switches to make up a given load.
9. By placing the MASTER LOAD switch to the ON position, the preselected load will be
applied to the power source.
10. Any KW LOAD switch can be added or removed as required while the MASTER LOAD
switch is closed (ON).
11. Monitor the unit under test using the digital meters.
12. To remove load, move MASTER LOAD switch to OFF position.
13. Shutdown: Reverse steps 1 through 12. It is good procedure to allow the fan motor to
operate for about 5 minutes after the load is removed. This will exhaust any accumulated
heat and allow exhaust surfaces to cool. Although not required for maintaining Load Bank
integrity, the cooling procedure helps to prevent burn injuries.