Untitled
Untitled
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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 OPTIONS ............................................................................................................. 6-1
VII REPLACEMENT PARTS LIST.......................................................................... 7-1
DRAWINGS
Electro Industries Quick Start Guide for SHARK Series Meters, E145703, V1.03
(Provided only when Option 20, 21, 22, or 23 is purchased.)
* See the following Table of Contents page for table of applicable numbers.
-i-
Avtron Model LSH • Outdoor Resistive Load Bank
DRAWINGS*
ASSEMBLY STANDARD
DRAWING BLOWER
LOAD BANK VOLTS KW LOAD STEPS (KW) PAGES SCHEMATIC VOLTS
LSH50D34084-1 208 50 5, 10, 10, 25 1, 4 D34089 208V
LSH35D47317-4 208 35 5, 10, 20 1, 3 1045045 208V
LSH40D47317-3 208 40 5, 5, 10, 20 1, 3 1045044 208V
LSH60D47317-1 208 60 5, 5, 10, 20, 20 1, 3 D47318 208V
LSH75D34084-4 208 75 5, 10, 10, 25, 25 1, 2, 4 D34884 208V
LSH100D34084-2 208 100 5, 10, 10, 25, 50 1, 4 D34089 208V
LSH125D34084-5 208 125 5, 10, 10, 25, 25, 50 1, 4 D49097 208V
LSH130D47317-2 208 130 5, 5, 10, 20, 20, 20, 50 1, 3 D48294 208V
LSH150D34084-3 208 150 5, 10, 10, 25, 50, 50 1, 4 D34089 208V
LSH50D34085-1 240/480 50 5, 10, 10, 25 1, 4 D34090 460V
LSH75D34877-1 240/480 75 5, 10, 10, 25, 25 1, 3 D34885 460V
LSH100D34085-2 240/480 100 5, 10, 10, 25, 50 1, 4 D34090 460V
LSH150D34085-3 240/480 150 5, 10, 10, 25, 50, 50 1, 4 D34090 460V
LSH50D34087-1 480 50 5, 10, 10, 25 1, 4 D34092 460V
LSH50D34087-4 480 50 5, 10, 10, 25 1, 4 D34040 460V
LSH75D34879-1 480 75 5, 10, 10, 25, 25 1, 3 D34887 460V
LSH100D34087-2 480 100 5, 10, 10, 25, 50 1, 4 D34092 460V
LSH125D34879-2 480 125 5, 10, 10, 25, 25, 50 1, 3 D34887 460V
LSH150D34087-3 480 150 5, 10, 10, 25, 50, 50 1, 4 D34092 460V
LSH50D34088-1 600 50 5, 10, 10, 25 1, 4 D34093 600V
LSH50D42727-1 600 50 5, 10, 10, 25 1, 4 D42789 600V
LSH75D34880-1 600 75 5, 10, 10, 25, 25 1, 3 D34888 600V
LSH100D34088-2 600 100 5, 10, 10, 25, 50 1, 4 D34093 600V
LSH100D42727-2 600 100 5, 10, 10, 25, 50 1, 4 D42789 600V
LSH150D34088-3 600 150 5, 10, 10, 25, 50, 50 1, 4 D34093 600V
LSH150D42727-3 600 150 5, 10, 10, 25, 50, 50 1, 4 D42789 600V
*Drawings in these columns are provided at the end of the manual based on specific Load Bank(s) purchased.
-ii-
JPH/kv
AVTRON MODEL LSH
OUTDOOR RESISTIVE 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 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 LSH 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
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 from the Load
Bank by the cooling blower. If there is any restriction or stoppage of airflow, the Load Bank may
overheat and may even start a fire. Follow the recommendations below to help prevent injuries,
death, or damage to equipment.
1. The operator should read the manual before using Load Bank.
2. Run an approved ground conductor from the Load Bank ground lug to the generator frame.
Run an approved ground conductor from the generator frame to a good earth ground. Size
ground wire in accordance with National Electrical Code and any local codes.
3. Do not bypass the AIRFLOW safety switch or overtemperature safety switch to prevent
nuisance tripping. The switches drop the load if insufficient air is reaching the load
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 Load Bank and safety of the
operator.
1-1
Safety Considerations Avtron Model LSH • Outdoor Resistive Load Bank
5. Maintenance personnel must always exercise caution when access panels are removed.
Personal injury from electrical shock or from the moving blower blade may result if all
sources of power are not disconnected before servicing. Maintenance work must be done
only by qualified personnel.
6. Do not allow exhaust air to recirculate through the Load Bank. If mounted on a roof, make
sure the hot exhaust will not damage the roofing material.
7. Venting the heated air from the exhaust toward overhead cables, toward sprinkler systems, or
into a room with insufficient volume or "Make-Up" air is a potential hazard.
8. Do not direct the hot exhaust air to other equipment (Load Banks, air conditioners, etc.).
Install the unit where the exhaust will be flowing in the direction of the prevailing winds.
9. 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.
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 will 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.
12. Operators must not operate the Load Bank with the access panels 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 moving fan blade. With portable units, do not leave
the unit unattended during testing or conduct tests with the unit on an inclined surface.
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 for
the motor to run, cooling any heated elements.
B. The POWER ON/OFF switch will disconnect both load steps and fan motor. The
Generator Emergency OFF switch should be located near the load system.
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.
1-2
Safety Considerations Avtron Model LSH • Outdoor Resistive Load Bank
16. Read and heed all WARNING and CAUTION statements in this manual.
1-3
Description Avtron Model LSH • Outdoor Resistive Load Bank
SECTION II
DESCRIPTION
The Avtron Model LSH Load Bank is an outdoor unit designed to absorb a balanced resistive load of
unity power factor, at a specified 3-phase voltage. The total load capability and load steps provided
in a given LSH are listed in the Table of Contents, page ii. Standard Load Bank load step resolution
is 5 kW while 1 kW resolution is available as an option. Using the toggle switches on the control
panel, any combination of the available load steps may be selected to achieve a desired load.
The LSH unit contains a blower with a 3-phase Blower Motor (Table of Contents page ii), which
provides the necessary cooling air for the load elements. The blower motor is controlled by a motor
starter contactor. Overcurrent protection is provided by three fuses and an overload relay, except
LSH50D34097-4, which is protected with a 3-pole circuit breaker and an overload relay. The
overload relay assembly must be reset manually. When required, the unit may be furnished with a
blower motor sized to operate at voltages different from standard. The 1 HP blower air delivery is
approximately 5000 CFM at a three-quarter inch static pressure.
*************************************************************
CAUTION
This Load Bank should never be used without the Fan Blower Motor
operating. Inadequate cooling airflow will result in resistor elements
overheating and a definite fire hazard.
*************************************************************
An AIRFLOW switch is provided to monitor the flow of cooling air. This is a differential pressure
switch which is electrically interlocked with the load application controls to prevent load application
if the blower is not working properly (AIR FAILURE light comes on).
Overtemperature switches are provided to monitor exhaust cooling air. These switches are
electrically interlocked with the load application controls to prevent load application in the event of
an overtemperature condition.
The control panel contains a CONTROL POWER ON-OFF switch with a CONTROL POWER
light, blower power START and STOP pushbutton switches, a BLOWER POWER light, an AIR
FAILURE light, a MASTER LOAD ON-OFF switch, a VOLTAGE SELECT switch for units with
dual voltage capability, and individual KW LOAD STEP switches. The control panel also contains
a fuse for control circuit protection.
2-1
Description Avtron Model LSH • Outdoor Resistive Load Bank
Sized for mounting into a 19-inch rack enclosure, the control panel has a vertical height of
8.75 inches and requires a minimum of 4 inches of clearance behind the panel.
An optional Metering Package can be used to monitor volts, amps, frequency, kW, kVAR, and/or
kVA.
The LSH Load Bank is fabricated using heavy-gauge aluminized sheet steel to make a rigid
structure. Mounted within the structure are the load element resistors and the cooling blower. The
resistive elements are porcupine type, fully supported along their length. Mounted within the
enclosure are the necessary load step contactors, motor starter, motor overload relay, fuses, and
customer connection terminals. The cooling air is drawn in from the sides on one end, forced across
the resistor elements, and exhausted out the opposite end. The control section has a temperature
controlled heater that may be used to prevent condensation on the inside of the contactor enclosure
of the Load Bank.
The units are equipped with screen openings at the inlet and a louver at the outlet opening that
provides protection for the motor and resistor assembly from the weather. Bolt holes are supplied in
the forklift channels to permit permanent mounting to a pad.
Lower voltages and different frequencies may be applied to the load circuit of the Load Bank.
Frequency change causes no derating of the load; however, the applied kW with a lower voltage is
computed with the following formula:
2
( Voltage Applied )
kW Applied = kW Rated
( Voltage Rated )2
*************************************************************
CAUTION
Never exceed the rated voltage as this will cause the Load Bank to
overheat.
*************************************************************
The single voltage designs (i.e., 600V, 480V, and 208V) are available with an automatic load
shedder as an option. The load shedder adds and removes load steps automatically based on preset
controller settings.
2-2
Description Avtron Model LSH • Outdoor Resistive Load Bank
The load control circuitry is factory designed in such a way that remote operation with a customer-
supplied transfer switch may be incorporated into the circuit. The factory control circuitry will be
wired to a terminal board whereas a transfer switch must be enabled and connects at the terminal
board per the schematic.
An Automatic Load Shed Controller (Controller) may be integrated into the control circuitry of the
LSH Load Bank as an option. The Controller is designed to maintain a minimum load on a power
source. A separately supplied current transformer provides the feedback signal required to operate
the Controller. This feedback signal drives the Controller, which has field adjustable current
setpoints. The Controller also incorporates field adjustable time delays to prevent repetitive load
switching or initial overloading of the generator.
The Load Bank manual controls are paralleled by the automatic Controller. Automatic or manual
mode may be chosen when the Load Shed option is provided with the Load Bank.
2-3
Installation Avtron Model LSH • Outdoor Resistive Load Bank
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.
*************************************************************
WARNING
*************************************************************
LOCATION
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, ventilation of 6,000 CFM or greater is required.
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 install the Load Bank in any area where standing water can pool or accumulate. Do not
install near: a drainage basin, surface/ground or roof runoff, sewer collection, or any location where
water can back up or collect. If flooding can occur, we recommend a different location or a raised
platform sufficiently above high water level. Do not operate if any portion of the Load Bank is
submerged. Always install above grade.
The Load Bank should be mounted outdoors in a free field. A prerequisite to approval of site
location is to read the next section titled AIRFLOW CONSIDERATIONS. If the installation
3-1
Installation Avtron Model LSH • Outdoor Resistive Load Bank
dictates mounting in close proximity to any external or adjacent device, transformer, generator set,
building, structure or protuberance, follow these guidelines:
1. Position the Load Bank with a minimum of 6 feet of clearance on both sides. This is in line
with the airflow to allow access for service (Figure 3-1).
2. The inlet requires a free unobstructed hemispherical zone. The radius of this sphere must be
at least 6 feet. Refer to Figure 3-1. If a unit is backed into a corner, the 6 feet is no longer
sufficient. Consult Avtron Engineering to review prior to installation. The intake must not
ingest heated air from another source. The maximum ambient intake air temperature is
120F.
3. Provide a minimum of 4 feet from any obstruction for exhaust clearance to prevent air
restrictions and to limit air recirculation. For thermal considerations, provide a minimum
clearance of 15 feet from any temperature sensitive object. The heated exhaust air stream
may damage temperature sensitive items if they are positioned within the 15 foot clearance
area. Refer to Figure 3-1.
4. Load Banks mounted into a channel, trough, hollow, well, pit, or exhausting into a full wall
or corner require special considerations even if the above conditions are met. In these cases,
provide detailed site layout drawings to Avtron for inspection and comments.
5. Locations which have full or partial perimeter fence necessitate a review. The fencing
material should have at least 75% open area. The 6 foot minimum side clearances shown in
Figure 3-1 still apply. Clearance on intake and exhaust can be adjusted only after approval
by an authorized Avtron representative. Painted or plated metal chain link fence is the
preferred material. All nonmetallic fencing materials are not recommended.
3-2
Installation Avtron Model LSH • Outdoor Resistive Load Bank
1. Do not stack, tier, or layer Load Banks without Avtron approval, as air recirculation will
occur.
2. Indoor installations will always require review. Make up air must be by a supplemental air
moving device. The Load Bank cooling system cannot be used for any purpose other than
cooling the Load Bank.
3. In climates with snow depths exceeding 6 inches, a physical inspection of the Load Bank
intake and exhaust is required prior to operation. Any significant snow drifts or snow depths
must be cleared prior to operation.
4. Standard Load Banks are designed for operation between sea level and 2,000 feet maximum
altitudes. Operation at altitudes over 2,000 feet above sea level requires special
consideration. Contact Avtron for assistance.
5. In general, these guidelines also apply to portable or trailer mounted Load Banks.
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
elements. A Load Bank should not be installed so close to any surface as to 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. If a Load Bank is to be mounted on a raised structure, a shield
must be incorporated in the structure to prevent exhaust air from being drawn back under the
unit.
2. Restriction of Cooling Air - Any obstruction located within the outlined parameters listed in
the previous LOCATION section of the manual will restrict the Load Bank’s airflow. Do
not modify louvers or screens on intake and exhaust. Ducting or diverting of airflow will
increase system airflow resistance and will void the warranty. If ducting is mandatory,
obtain written approval from Avtron prior to installation. 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.
3-3
Installation Avtron Model LSH • Outdoor Resistive Load Bank
When operating a Load Bank outdoors, the wind can work for or against the Load Bank cooling
system. If the Load Bank is positioned with the prevailing wind opposing the airflow from the
blower, inadequate cooling may result and damage to the Load Bank can occur. Improper
positioning may also result in the air switch being deactivated, thus dropping the load.
CONTROL PANEL
The Control Panel is made to be mounted in a 19-inch rack type enclosure. A NEMA 12 enclosure,
option #1, A20712, can be used to house the control panel. Connect terminals of the Control Panel
to terminals of the Load Bank as shown on the Schematic/Interconnection Diagram.
Connect terminals 1 and 2 on the Control Panel to a 120V, 60 Hz, or 110V, 50 Hz, single phase
power source. Recommended minimum wire size is No. 14 AWG. See the Schematic/
Interconnection Diagram.
If 120 VAC is not available for control power, a step-down transformer must be used. An optional
500 VA control step-down transformer may be supplied with the Load Bank. The following
transformer options are available:
The identification plate is marked with the options that are contained in the unit.
ENCLOSURE HEATERS
The Load Bank contains a 100 watt strip heater and a temperature switch. This heater may be used
to prevent problems caused by condensation. If the heater function is desired, 120V control power
must be connected to TB11(3-4) as shown on the schematic.
The blower circuit consists of fuses, motor starter contactor, overload relay, and the blower motor.
The input power connections are directly wired to the main load bus.
Required power for the blower motor in standard LSH units is shown in the Table of Contents on
page ii. Other blower motor voltages are available as options; and if the option is installed in the
Load Bank, the identification plate will indicate the option number.
3-4
Installation Avtron Model LSH • Outdoor Resistive Load Bank
If the blower motor is to be connected to the source under test, make sure that the source voltage is
within the range of the supplied motor. When operating the blower motor from the generator, an
additional load of 750 watts is created.
With any connection, make sure that the correct phase rotation is wired to the blower motor.
Improper phase rotation will cause the blower to run in the reverse direction. The cooling air should
be pushed from the blower, across the resistor elements, and out the exhaust screen. If the blower
rotation is incorrect, shut down the Load Bank and disconnect all power from it. Switch any two of
the three blower input connections at terminals TB11 (28, 29, and 30). Reconnect power and verify
that the blower rotates in the correct direction. This phase rotation check is mandatory every time
the source or blower connections are changed.
If external blower power is provided, safe practice dictates that the blower power should be wired
through a safety disconnect switch that can be locked out.
LOAD CONNECTIONS
A. The Load Bank has three load input bus bar connections marked A, B, and C which are
located in the customer connection area. These connections are accessible by removing the
access panel at the air intake side of the Load Bank. See outline drawing.
B. Terminations
On each of the load bus bars are two pairs of 0.562 diameter holes, spaced 1.75 inches apart,
for attachment of load wiring terminations. (The holes are spaced 1.75 inches, both
directions.) Use 1/2 inch hardware to attach terminal lugs to the bus bars. Two terminals
may be attached to each bus bar, side by side. The load conductors should be sized in
accordance with the National Electrical Code, Article 310, if not superseded by local codes.
When an automatic Load Shed Controller (Option 3, 4, 5, or 6) is included with the Load Bank,
installation of the current transformer on the main power bus as shown in Figure 3-2 is required.
Wire the current transformer into the control circuitry as shown on the provided schematic.
3-5
Installation Avtron Model LSH • Outdoor Resistive Load Bank
Figure 3-2
*************************************************************
WARNING
*************************************************************
Never allow the secondary of the current transformer to remain disconnected when primary current
is passing through the transformer. If the Load Bank must be disconnected, put a short or shunt
across the current transformer.
NOTE
Before placing the system into AUTO, place the Load Bank load step
switch(es) to the OFF position.
3-6
Installation Avtron Model LSH • Outdoor Resistive Load Bank
GROUNDING
A permanent ground conductor must be connected to the Load Bank enclosure by an individual
ground wire to prevent a potential above ground on the enclosure. There is a ground stud in the
Load Bank for this connection. This ground conductor should be run with the load power
conductors to provide the lowest impedance fault path. The ground stud must be connected to both
the generator frame and a good earth ground. The ground conductor should be sized per the
National Electric Code Table 250.122, if not superseded by local codes.
This Installation Checkout Procedure is intended to be used upon initial receipt of equipment and
following any relocation of a permanent mounted Load Bank. These procedures apply to Load
Banks in general and may include steps not relevant to the specific unit being installed. Disregard
those procedures which do not apply.
*************************************************************
WARNING
*************************************************************
1. Verify the Load Bank placement meets the installation requirements found in the
INSTALLATION section of the instruction manual:
A. Check the clearance from both intake and exhaust to any obstruction.
B. If the location has a prevailing wind, make the wind aid in the cooling of the resistor
elements.
C. If the Load Bank is elevated, a plate under the Load Bank will be needed to block hot
exhaust from returning to the intake.
3-7
Installation Avtron Model LSH • Outdoor Resistive Load Bank
3. Utilize system schematics to ohm out customer-supplied interconnection control wiring and
safety circuits:
A. If control wiring is all the same color, ohm out each individual wire to confirm
proper labeling and placement.
CAUTION
B. Confirm the correct wire gauge has been used for interconnection wiring. Control
wiring should be a minimum of 14 AWG for control panel to Load Bank lengths of
50 feet or less. For lengths greater than 50 feet, consult Avtron Loadbank.
CAUTION
3-8
Installation Avtron Model LSH • Outdoor Resistive Load Bank
A. Check the control voltage and confirm it is within 10% of the required voltage.
*************************************************************
WARNING
*************************************************************
B. Operate the safety circuitry with a jumper across the air switch contact at its
termination at the terminal block.
5. Turn on the POWER switch and verify the proper relays energize with each individual load
switch as follows:
A. Turn on the MASTER LOAD switch. Turn on each load step individually and
observe that each relay (or relays) pulls in without chatter or hesitation.
B. Turn off the MASTER LOAD switch. Turn on all the load steps. Turn on the
MASTER LOAD switch and observe the pull in of all the contactors. If chatter or
hesitation is observed, locate the cause of the voltage drop causing the problem.
6. While the load relays are energized, remove the jumper across the air switch. All the load
contactors should drop out as soon as the jumper is removed. Leave the jumper off the air
switch.
7. Apply the rated fan voltage. Start blower and verify that air is exiting the resistor assembly
end.
This checkout procedure is intended to be a guide to Load Bank installations in general. Special
installation considerations not addressed herein may be necessary due to installation site or
environment. Any questions or concerns regarding Load Bank installation should be directed to
Avtron Field Service at (216) 573-7600.
3-9
Operation Avtron Model LSH • Outdoor Resistive Load Bank
SECTION IV
OPERATION
2. Connect the generator or other power sources to be tested to the Load Bank as described in
the INSTALLATION section.
3. Place the VOLTAGE SELECT switch to the correct voltage to test the generator (dual
voltage units only).
*************************************************************
CAUTION
DO NOT operate the Load Bank over the rated voltage as this will
cause catastrophic failure in the Load Bank.
*************************************************************
4. Place the CONTROL POWER switch to the ON position. A pilot light (DS1) will be
energized, indicating control power is present.
5. Press the blower power START switch. The BLOWER POWER light (DS3) will be
energized. Note that the AIR FAILURE indicator (DS2) flashes on momentarily. When the
blower motor has reached proper speed, the AIR FAILURE lamp will be de-energized. Load
voltage will not be connected to Load Bank resistance elements unless the airflow switch has
closed. Also note direction of airflow. If airflow is not “OUT” the exhaust end, shut off the
blower, disconnect power, and reverse any 2-phase connections to the blower.
4-1
Operation Avtron Model LSH • Outdoor Resistive Load Bank
*************************************************************
CAUTION
The operation of the blower is vital to the safe operation of this Load
Bank. When the blower is turned ON, the AIR FAILURE 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 (AIR FAILURE
indicator light on), do not bypass the air switch. This will cause the
Load Bank to burn up. Do not attempt to operate the unit until the
problem is corrected. Refer to the SAFETY CONSIDERATIONS
section of this manual.
*************************************************************
6. With the MASTER LOAD and KW LOAD STEP switches in the OFF position, start the
generator under test. Check for proper phase sequence.
7. The resistive loading is selected by the LOAD STEP toggle switches, using any one or
combination of the toggle switches to make up a given load.
8. By placing the MASTER LOAD switch to the ON position, the preselected load will be
applied to the power source.
9. Any load switch can be added or removed as required while the MASTER LOAD switch is
closed (ON).
a. Turn the MASTER LOAD switch and the LOAD STEP toggle switches to the OFF
position. Allow the blower to run for several minutes to exhaust accumulated heat.
This procedure is not required for maintaining Load Bank integrity, but it may guard
operating personnel from possible burn injuries.
d. Turn all safety switches to which the Load Bank may be connected to the OFF
position. These should include (for operator and personnel safety):
4-2
Operation Avtron Model LSH • Outdoor Resistive Load Bank
*************************************************************
WARNING
DO NOT touch the exhaust screen during operation. The screen will
become hot from the exhausted heat and may cause a serious burn.
Refer to the SAFETY CONSIDERATIONS section of this manual.
*************************************************************
NOTE
2
( Voltage Applied )
kW Applied = kW Rated
( Voltage Rated )2
*************************************************************
CAUTION
Never exceed the rated voltage as this will cause the Load Bank to
overheat.
*************************************************************
4-3
Operation Avtron Model LSH • Outdoor Resistive Load Bank
AUTOMATIC OPERATION (for LSH Load Banks with Load Shedder option)
Complete the Automatic Controller installation by connecting the current transformer on the main
power bus as shown in Figure 4-1. Wire the current transformer into the control circuitry as shown
on the provided schematic.
Figure 4-1
2. Connect the generator or other power source to be tested to the Load Bank as described in
the INSTALLATION section.
3. Place the POWER switch to the ON position. The POWER light (DS1) will be energized,
indicating control power is present.
6. When the Auto/Transfer Contact is closed, the Auto Load Shedder will be active. The Auto
Load Shedder will automatically start the blower and apply load steps. As the load on the
4-4
Operation Avtron Model LSH • Outdoor Resistive Load Bank
generator lessens, the Load Shed Controller will automatically apply load steps until the
overall generator load exceeds the minimum setpoint. The Load Shed Controller
automatically removes load steps when the generator load exceeds the maximum setpoint.
When the Auto/Transfer Contact is opened, the Auto Load Shedder will be inactive and the
blower will be stopped automatically.
NOTE
Before placing the system into AUTO, place the Load Bank load step
switch(es) to the OFF position.
*************************************************************
WARNING
*************************************************************
THEORY OF OPERATION
The automatic operation circuitry of the Load Bank allows for a generator to which it is connected,
to maintain a minimum percentage of its rated output for efficient generator operation. The control
range is generally between 60% and 80% of the output rating of the generator.
4-5
Operation Avtron Model LSH • Outdoor Resistive Load Bank
System Ratings
ACTUAL
LOAD BANK GENERATOR
Trip BUILDING LOAD LOAD OUTPUT % OF GENERATOR
Point 0-<55 kW 145 kW 145-200 kW (58%-80%)
TP.1 >,=55-<105 kW 95 kW 150-200 kW (60%-80%)
TP.2 >,=105-<155 kW 45 kW 150-200 kW (60%-80%)
TP.3 >,=155-<180 kW 20 kW 175-200 kW (70%-80%)
TP.4 >,=180-<190 kW 10 kW 190-200 kW (76%-80%)
TP.5 >,=190 kW 0 kW BUILDING LOAD (>,=76%)
At 0 KW building load, the Load Bank will provide 145 kW worth of load. Actual generator output
will be 145 kW (58%), after a preset time-delayed ramp up period.
As the building load increases and the actual generator output approaches 200 kW (80%), the
controller disables one load step; in this example, the last load step, 50 kW, “sheds”.
This load shed control continues as the building load continues to increase. If the building load
decreases, causing the actual generator load to fall below 58%, the controller will add the
appropriate load step(s) to maintain the desired range of control.
In the system example detailed above, a current transformer having a ratio of 300:5 will be used to
monitor the building load. (Refer to Figure 4-1.) As the actual generator output reached 200 kW,
the controller “shed” a load step. The current flowing to the building load at this point will be called
the current trip point. This “trip point” value can be determined using the following formula:
4-6
Operation Avtron Model LSH • Outdoor Resistive Load Bank
The controller senses the current (Isense), delivered from the current transformer that is monitoring
the building load. This value can be determined using the following formula:
Adjustments can be made to the PC board controller via the adjustable resistor potentiometers found
on the PC board. (Reference resistors labeled R73, R60, R47, R34, and R21.)
NOTE
R73 controls the last load step circuit. (i.e., if the Load Bank has five
load steps, R73 controls the fifth load step.)
The potentiometers should be adjusted such that the last load step is the first step to be “shed”.
The “trip point” value = I(sense) can be applied to the controller terminals J1 and J2, using a
separate current source.
There are two methods of field adjusting the trip point of the current sensing relays:
● Method 1 - Using a separate (0-5 Amp) current source without the current transformer
4-7
Operation Avtron Model LSH • Outdoor Resistive Load Bank
Method 1 - Using a separate (0-5 Amp) Current Source without Current Transformer
1. Disconnect all sources of power to the Automatic Load Shed Controller. (Control voltage
and current sense input)
*************************************************************
WARNING
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WARNING
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3. Using a controlled current source, apply the setpoint current (from secondary current
calculation) to Controller terminals J1(1) and J1(2).
4. Turn the relay knob labeled THRESHOLD past the trip point; then decrease until the relay
trips on, indicated by LED illuminating.
4-8
Operation Avtron Model LSH • Outdoor Resistive Load Bank
NOTE
With all power removed from the Load Bank, calculate each desired Trip Point and adjust the
potentiometers (R21, R34, R47, R60, R73) in order to achieve a rough adjustment controller setting.
NOTE
4-9
ESD PRECAUTIONARY GUIDELINES
CAUTION
The following guidelines are not necessarily all inclusive but rather serve as reminders for good shop
practices for the handling/ repair of ESD sensitive circuit card assemblies and devices.
· Store ESD sensitive items in their original containers. These items are often marked with
the symbol shown at the top of this page.
· Put on a grounded wrist strap before handling any ESD sensitive item.
· Clear work area of Styrofoam®*, plastic, and vinyl items such as coffee cups.
· Handle ESD items by the body, never the open edge connectors.
· Transport ESD sensitive items in a static shielding container to a static-free work station.
· If a static-free work station is not available, ground the transport container before removing
or inserting an ESD item.
· Electric tools used during repair should be grounded. For example, use only anti-static type
solder suckers and grounded tip soldering irons. Discharge non-electric tools before use.
· Pack ESD items in static shielding containers before shipping them to Avtron for repair.
SECTION V
MAINTENANCE
To provide long equipment life and to reduce the chance of electric shock, fires, and personal injury,
good maintenance procedures must be used. Before servicing, review the SAFETY
CONSIDERATIONS section of this manual.
The following are examples of maintenance procedures and a suggested maintenance schedule.
These examples are not intended to be all-inclusive but must be accomplished to maintain the
equipment in a proper, safe condition. All maintenance work must be done by qualified personnel
only.
*************************************************************
WARNING
Personal injury from electrical shock or from the moving fan blade
may result if ALL sources of power are not disconnected. Refer to
the SAFETY CONSIDERATIONS and OPERATION sections of this
manual.
*************************************************************
DAILY
2. Check the screens to make sure that no objects have blocked or entered the openings.
4. Assure that there is no recirculation of the exhaust air through the Load Bank.
5-1
Maintenance Avtron Model LSH • Outdoor Resistive Load Bank
THREE MONTHS
2. Inspect the load resistors for mechanical breakdown which is demonstrated by excessive
sagging of the elements. Replace with new resistor elements as required.
3. Inspect for broken ceramic insulators. Replace with a new ceramic insulator if any cracks
are found.
5. Inspect all connections for oxidation or corrosion. Clean the connection or replace the
hardware where required.
7. Inspect all magnetic contactors to make sure that the contacts are not severely pitted or
corroded. The contacts must move freely and be properly seated.
*************************************************************
WARNING
Eye protection should be worn when cleaning the Load Bank with
compressed air.
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8. Clean all dirt and debris out of the Load Bank. This can be accomplished by blowing the
inside of the unit with clean, dry compressed air (not to exceed 40 PSI). Eye protection
should be worn when cleaning the Load Bank with compressed air.
ANNUALLY
The blower motor should be lubricated per the manufacturer's requirements and specifications on the
motor nameplate, if applicable.
5-2
Options
SECTION VI
OPTIONS
The following options are available for Avtron Model LSH Load Banks. Not all options can be
installed in the same unit.
6-1
Options
6-2
Options
6-3
Options Replacement Parts List Avtron Model LSH Outdoor Resistive Load Bank
6-5
Options Replacement Parts List Avtron Model LSH Outdoor Resistive Load Bank
6-6
Options Replacement Parts List Avtron Model LSH Outdoor Resistive Load Bank
7-2
DRAWINGS
PROPRIETARY NOTE
This document contains information PROPRIETARY TO Avtron
Load Bank branded products and systems by ASCO Power
Technologies, LP. 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 ASCO Power Technologies, LP.
ASCO
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ASCO
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ASCO
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ASCO
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ASCO
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ASCO
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ASCO