Avtron 2000 Series User manual

2000 Series Load Bank
User’s Guide
Part Number: Manual Toggle Switch
Revision Date: November 2022 V3

AVTRON 2000 SERIES USER MANUAL
MANUAL TOGGLE SWITCH
© 2022 Avtron Power Solutions, LLC October 8, 2018
Cleveland, Ohio Rev. November 2022

Form 831B-LB Rev 10-2022
PROPRIETARY NOTE
This document contains information PROPRIETARY TO
Load Bank products and systems by Avtron Power
Solutions, LLC. It is furnished solely to provide
information sufficient for instruction, operation,
maintenance, evaluation, and testing of the equipment
herein disclosed; is not to be used for manufacturing or
procurement; and is not to be disclosed to anyone other
than persons in the Division, or the Company, or the
Government, as the case may be, responsible for action
relating to this document without the express written
permission of Avtron Power Solutions, LLC.
WARRANTY
The last page of this document contains an express
limited warranty. The provisions of this warranty cover
any and all rights extended to holders of Load Bank
products and systems by Avtron Power Solutions, LLC.
6255 Halle Drive, Cleveland, Ohio 44125
Tel: [phone]

AVTRON POWER SOLUTIONS, LLC
Cleveland, Ohio
AVTRON 2000 SERIES
LOAD BANK
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
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1-1
AVTRON 2000 SERIES
LOAD BANK
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 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 reli-
ability and safety built into your equipment.
The Load Bank is an industrial test unit designed to be used indoors. However, because
the function of the Load Bank is to dissipate electrical energy, there are inherent dangers to
the operator and to the equipment. These dangers shall be outlined in this section.
Electrical energy is transformed into heat by the resistor elements. The heat may be
removed from the Load Bank by airflow through the resistor elements. If there are any
restrictions or stoppage of airflow, the Load Bank may overheat and may even start a fire.
The following recommendations are made:
1. Read the manual before operating the Load Bank.
2. Run an approved ground wire from the Load Bank ground lug located on the
customer connection panel to the frame of the power source. Run an approved
ground wire from the power source frame to a good earth ground. Size ground wire
in accordance with National Electrical Code and any local codes.
3. Do not bypass the temperature sensing switches to prevent nuisance tripping. The
switches will drop out the load if insufficient cooling air is reaching the elements.
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 unit and
safety of the operator.

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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.
5. Maintenance should be performed with no power on the unit. The majority of
troubleshooting can be performed with an ohmmeter. There are multiple sources of
power input to the Load Bank. Ensure each is disconnected.
6. 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 potential hazard.
The Load Bank should be used in a cool, well- ventilated area.
7. Allow cool room 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.
8. After running a load test, residual heat may be removed from the Load Bank by
allowing the blower 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.
9. 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.
10. Do not allow objects to enter or block the air intake or exhaust of the Load Bank. A
blockage would 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.
11. Emergency Shutdown Procedure
A. In an emergency, shut down the MASTER LOAD switch, then the power
source. The MASTER LOAD switch will allow disconnection of all load steps
and still allow for motor to run, cooling any heated elements.
B. The POWER ON/OFF switch will disconnect both load steps and fan motor.
The power source EMERGENCY OFF switch should be located near the
load system.
12. An approved electrical fire extinguisher should be on hand at all times.

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13. 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.
14. Read and heed all WARNING and CAUTION statements in the manual.

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SECTION II
DESCRIPTION
The Series 2000 Load Banks are designed for electrically loading and testing power
sources. The Load Bank is designed for production line and job site use.
Refer to the schematic for the load bank KW (Current), voltage, phase and frequency
rating. Using the toggle switches on the control panel, any combination of the available
load steps may be selected to achieve a desired load.
The control panel is integrally mounted on the Load Bank. The controls/metering on the
control panel will vary depending on the model and available accessories. Refer to the
schematic for specific controls associated with the load bank provided. The general
arrangement for the control is:
MODELS 2100/2200
1. MASTER LOAD ON/OFF switch – Applies power to the Load Bank fans and allows
the instantaneous connection and disconnection of all switched ON load steps.
2. OVER TEMP/VOLT indicator – Indicates an air failure/insufficient cooling airflow or
an over voltage condition.
3. VOLTAGE SELECT switch – Configures load resistor circuit for dual voltage
applications if applicable.
4. LOAD STEP switches – Connect and disconnect load steps. Load values are shown
above each switch.
5. ANALOG/DIGITAL METERS – Displays Volts and Amps of Load Bank.
MODEL 2400
1. POWER ON/OFF switch – Applies power to the Load Bank and fan. The POWER
indicator lights when power is applied.
2. BLOWER FAILURE indicator – Indicates an air failure or insufficient cooling airflow.
3. MASTER LOAD ON/OFF switch - Allows instantaneous connection and
disconnection of all switched ON load steps.
4. LOAD STEP switches – Connect and disconnect load steps. Load values are shown
above each switch.

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MODEL 2500
1. POWER ON/OFF switch – Applies power to the Load Bank and fans.
2. VOLTAGE SELECT switch – Configures load resistor circuit for dual voltage
applications if applicable.
3. MASTER LOAD ON/OFF switch - Allows instantaneous connection and
disconnection of all switched ON load steps.
4. LOAD STEP switches – Connect and disconnect load steps. Load values are shown
above each switch.
MODELS 2600/2700
1. POWER ON/OFF switch – Applies power to the Load Bank and fans. The POWER
indicator lights when power is applied.
2. OVER TEMP indicator – Indicates an air failure/insufficient cooling airflow.
3. VOLTAGE SELECT switch – Configures load resistor circuit for dual voltage
applications if applicable.
4. MASTER LOAD ON/OFF switch - Allows instantaneous connection and
disconnection of all switched ON load steps.
5. LOAD STEP switches – Connect and disconnect load steps. Load values are shown
above each switch.
MODELS 2800/2900
1. CONTROL POWER INTEGRAL TRANSFORMER SELECT switch – Configures the
internal control transformer to the voltage selected and that matches the UUT
voltage.
2. CONTROL POWER INTEGRAL TRANSFORMER ON/OFF pushbuttons –
Energizes the configuration relays for the control transformer to the voltage selected
above.
3. BLOWER VOLTAGE SELECT INT/EXT switch – Used to select the correct voltage
and either from the internal bus or from an external voltage source. If internal, this
switch must match the voltage selected with load voltage select switch.
4. LOAD VOLTAGE SELECT switch – Selects the voltage of the UUT.
5. BLOWER START/STOP pushbuttons – Energizes the fan start/stop circuit.
6. FAN ROTATION ABC/CBA – Used to reverse the rotation of the cooling air fan.
Turn fan off by depressing the BLOWER STOP pushbutton and allow the fan to
come to a complete stop before reversing the fan rotation.

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7. BLOWER FAIL indicator - Indicates an air failure or insufficient cooling airflow.
8. MASTER LOAD ON/OFF switch - Allows instantaneous connection and
disconnection of all switched ON load steps.
9. LOAD STEP switches - Connect and disconnect load steps. Load values are shown
above each switch.
A single phase, 60 Hz power source is required for the control circuit. This power is derived
either from an external source or from an internal control power transformer connected to
the load bus.
There are some Models that will require a DC source which is provided from the load bus.
Refer to schematic diagram.
Fan power is obtained from either the power source under test (connected to Load Bank
main load bus) or from a remote source (external power source).
ENCLOSURE
The outside dimensions of the Load Bank are shown on the Outline Drawing. The Load
Bank is fabricated of aluminized steel, assembled with SST hardware, and mounted either
with feet or casters. Handles may be provided for lifting and transporting the Load Bank.
C A U T I O N
Do not allow the Load Bank to be placed where hot exhaust
air can recirculate back through the unit causing a constant
rise in cooling air temperature.
The Load Bank contains fans which provide the necessary cooling air for the load
elements. Sensors are provided to monitor the flow of cooling air. These sensors are
electrically interlocked with the load application controls and if the fans are not working
properly the load steps are disabled.
Air to cool the load elements enters the screened intakes located on one end of the Load
Bank. The air passes over the resistive elements and is then discharged through the
screened opening at the opposite end of the Load Bank.
The Load Bank contains a control fuse and depending on the model the load circuit will be
protected with either branch circuit or main line fusing for short circuit protection.