AVTRON MODEL K696/K696A. RESISTIVE LOAD BANK Part Number D16133/D16423 Serial Numbers 595 Through 649 © 1983 Avtron Manufacturing, Inc. April 13, 1983 Cleveland, Ohio Rev. Mar. 24, 1995 Rev. Apr. 6, 1995This document contains drawings and information that, due to design changes or customer modifications, may not reflect the hardware in its present state. Avtron Manufacturing, Inc. cannot assume responsibility for damage to equipment, or personal injury resulting from the use of this manual when installing, operating, or servicing the unit. Avtron has made every attempt to provide documentation which reflects the original hardware configuration.AVTRON MANUFACTURING, INC. Cleveland, Ohio AVTRON MODEL K696/K696A RESISTIVE LOAD BANK Part Number D16133/D16423 TABLE OF CONTENTS Section I SAFETY CONSIDERATIONS ........... IL K696 DESCRIPTION ........ sees III K696A DESCRIPTION ........0-.2eeeeeeeeeeeeee sees Bed Iv INSTALLATION ..........++ sees 41 v OPERATION Gases ee VI K696A AUXILIARY OPERATION ........--- 2 6-1 VII OPTIONS FOR MODEL K696/K696A ............ Te. OPTION 17, AUTOMATIC LOAD SHED SYSTEM ... 7-1. (Drawings for options are listed at the end of the Table of Contents.) VIII MAINTENANCE .....--200---+005 8-1 Ix K696 REPLACEMENT PARTS LIST . 9-1 bg K696A REPLACEMENT PARTS LIST .. 10-1 APPENDIX - Avtron Load Bank Troubleshooting Guide DRAWINGS FOR K696 SB1360 Outline Drawing D16146 = Schematic Diagram D16136 = Wiring Diagram, Load Bank D16152 Wiring Diagram, Control Panel D17049 ©=«-« Schematic, PC Board DRAWINGS FOR K696A $B1360 Outline Drawing D16464 Schematic Diagram D16463 Wiring Diagram, Load Bank 16222 Wiring Diagram, Control Panel LKG/cr Rev. 7/6/88 Rev. 1/20/97‘Avion Mode! K6S6/K596A Losd Bank TABLE OF CONTENTS (Cont.) OPTIONS - Refer to Section VII (OPTIONS FOR MODEL K696/K696A) of this manual. The following drawings apply to the various options. Only the appropriate drawings have been included in this manual as required by options delivered. Not all options can be installed in the same unit at the same Drawings B16250 16723 16724 B19078 17604, Sheet 3 B19575, Sheets 2 & 3 18523 18701 20523, Sheet 3 A21230 Sheet 3 23382 23974 BMPikv 2888 Rev. 1/8/98 time. Installation of Option 6 Schematic, Remote Control Unit (option 7) Wiring Diagram, Remote Control Unit (Option 7) Schematic, Automatic Load Shed Control (Option 17) Wiring Diagram, Test Jacks Kit (Option 19) - K696 Only Schematics, Fan Reversal Switch (Option 20) Sheet 2 - K696 Sheet 3 - K696a Installation Instructions, Control Transformer (Option 22) Schematic, Control Transformer (Option 23) Wiring Diagram, 600/120V, 50/60 Hz Control ‘Transformer (Option 30) Schematic, Control Transformer 500 VA, 220/110V, 50/60 Hz (Option 32) Installation of Option 35 (for Load Banks S/N 743 and above) Installation of Option 36AVTRON NODEL K696/K696A RESISTIVE LOAD BANK Part Number D16133/D16423 SECTION I SAPETY CONSIDERATIONS Throughout this manual, you will find WARNING and CAUTION statements. Personal injury to an operator using or repairing the equipment may occur if a WARNING statement is ignored. Damage to the equipment and potentially hazardous conditions for personnel may occur if a CAUTION statement is ignored. Each Avtron unit is safety checked for opens and shorts, and the insulation is high potential tested to insure 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 insure the reliability and safety built into your Avtron equipment. The Model K696/K696A Load Banks are industrial test units designed to be used indoors safely. However, because of the nature of the Load Bank function (the dissipation of electrical energy), there is inherent danger 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. 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 lug and the generator frame to a good earth ground must be connected. (Refer to the following table.) 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. LKG/er q-1 Rev. 7/1/87 Rev. 4/28/88Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 70-116 NATIONAL ELECTRICAL CODE Table 250-95. Minimum Size Equipment Grounding Conductors for Grounding Raceway and Equipment Rating or Setting of Size ‘Automatic Overcurrent Device in Circuit Ahoad ‘Aluminum or of Equipment, Condi Copper-Clad ‘tc., Not E> Copper ‘Aluminum, (amperes) Wire No. * 15 4 12 20 12 10 30 10 8 40 10 8 60 10 8 100 8 6 200 6 4 300 4 2 400 3 1 500 2 1/0 600 1 2/0 800 0 3/0 1000 2/0 4/0 1200 3/0 250 MCM 1600 40 350” 2000 250 MC 400” 2500 350” 600” 3000 400” 600” 4000 500” 300” 5000 700” 1200” 6000 800” 1200” NOTE: This information is provided only for reference. For complete information, refer to applicable sections of the NEC. * See installation restrictions in Section 250-92(a). Taken from National Electrical Code ® 1987 MP/kv 1-2 4/28/8810. Le LKG/cr Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 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. 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. 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. This is especially important since the blower motor has an automatic reset overload relay that can restart the blower. Maintenance work must be conducted only by qualified personnel. 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. 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. 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. After running a load test, leave the cooling blower on for two minutes to allow the air to remove accumulated heat from exhaust surfaces. 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. Rev. 7/1/87 Rev. 4/28/8812. 1. 14, 15. 16. le 18. LKG/cr Avtron Model K696/K696A, Resistive Load Bank Part Number D16133/D16423 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. Operators must not operate the Load Bank with the access panels or screens removed or doors open. To do 80 exposes the operator and other persons to possible personal injury from electrical shock or from the moving fan biade. Always put a short or shunt across the current transformers (C.T.) when working on metering. Powering up an unshunted C.m, will destroy the C.T. with possible harm to personnel and metering. 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 fan motor to run, cooling any heated elements. B. The 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. An approved electrical fire extinguisher should be on hand at all times. 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. (Refer to the following tables for additional information.) Read and heed all WARNING and CAUTION statements in the manual. Rev. 7/1/87 Rev. 4/28/88NOTE: MP/kv 4/28/88 Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 ARTICLE 310 — CONDUCTORS FOR GENERAL WIRING _ 70-153 ‘Table 310-16. _Ampacitios of Not More than Three Single Insulated ‘Conductors, Rated 0 through 2000 Veli, n Raceway in Free Air ‘and Ampacities of Gable Types AC, NM, NMG ond SE. Based on Ambiont Air Tomperaturo of 30°C (86°F) ‘ls tea slay femited cess ys Cole jig rcavet Tee ites ea ca hy acd sate ae {er 2AWG tnd anges or 10 AWG santas stoner ci tee sf y ‘Spe, i fo" alent tempore ed ramer of codutan ve ew apad ‘Far ry ted damp leno oly. Ser 15°C couma for welicaieas This information is provided only for reference. For complete information, refer to applicable sections of the NEC. Taken from National Electrical Code® 1987 1-5Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 8. Ampacity Adjustment Factors. (a) More than Three Conductors in a Raceway or Cable. Where the number of conductors in a raceway or cable exceeds three, the ampacities given in Tables 310-16, 310-18, 310-22, 310-26, 310-27, 310-28, 310-29, 310-30, and 310-31 shall be reduced as shown in the following table: 70-168 NATIONAL ELECTRICAL CODE Percent of Values in Tables 310-16, 310-18, 310-22, 310-26, 310-27, 310-28, 310-29, 310-30, Number of and 310-31, as Adjusted for Conductors Ambient Temperature if Necessary 4 thru 6 80 7 thru 9 70 10 thru 24* 10 25 thru 42* 60 43 and above* 50 * These factors include the effects of a load diversity of 50 percent. NOTE: This information is provided only for reference. Por complete information, refer to appli sections of the NEC. ae Taken from National Electrical Code (®) 1987 MP/kv a 4/28/88Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 SECTION II K696 DESCRIPTION The K696/D16133 is a portable, indoor, self-contained unit for electrically loading and testing generators. ‘The Load Bank is rated at 250 KW at 240/480 volts. The available load steps are 100 KW, 50 KW, 50 KW, 20 KW, 10 KW, 10 KW, 5 KW, 5 KW, 4 KW, 3 KW, 2 KW, and 1 KW. The first seven load steps are selected by toggle switches. The last five load steps are selected by a rotary selector switch. The Load Bank provides a balanced load for three phase generators within the range listed above. Single phase loads are 2/3 the normal three phase load. The blower motor is a 2 HP, three phase motor which operates from 230/460 volts, 30, 60 Hz power. The blower motor obtains power from either the power source under test or from a remote source, depending upon the positioning of fanning strip (FS4) on terminal board 1B4. When operating from the power source under test, the motor circuit automatically connects the motor for high or low voltage. The K696 will test 240/480 volt, 36, 60 Hz generators without any wiring changes. It can be used to test 60, 50 Hz, or 400 Hz generators; however, the blower motor and control circuit power must be separate 60 Hz sources. For separate 60 Hz blower motor power connection, see Section IV. Control power is 115 VAC, 60 Hz. A line cord is provided for control power. Blower failure protection is provided in two ways. A differential pneumatic pressure air switch (S17) senses the airflow through the Load Bank. An additional slave relay (K30) is activated only if power is applied to the blower motor terminals. This slave relay will disconnect control power to all load contactors should the blower power be disconnected, the motor overload trip out, or the air inlet/exhaust screens become blocked. TESS IIIS SI IIS IIIS ECS OBI IGE IG 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. TESS I SSIS I III III III AAI LKG/er 2-1 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 General Construction (Refer to Outline Drawing $B1360.) The Control Panel is mounted on the Load Bank, but is also sized for mounting into a 19-inch rack enclosure. The control panel contains all the switches required to operate the Load Bank. Voltage and current measurements are displayed on separate 3-1/2 digit LCD meters with a character height of 0.8 inch. The K696 Load Bank is constructed of aluminized steel and fiberglass, forming a rigid structure. Mounted within this structure is the load element resistor assembly, the cooling blower, the load step contactors, motor starter, motor overload relay, fuses and customer connection terminals. ‘The cooling air is drawn in from both sides, forced across the resistor elements and exhausted out the end. The unit is mounted on five-inch casters with one set provided with wheel locks. ‘The customer connection panel is located at the rear of the unit. Ahandle located above the customer connection panel is provided for cable storage. The Load Bank can operate at either 480 or 240 volts. A switch on the control panel (S2) will automatically switch the load from the high voltage configuration to the low voltage configuration The blower motor configuration also changes if powered from generator under test. The blower motor has separate overload Protection for high and low voltage operation. The voltage protection circuit will select the high voltage mode if 480 volts is applied to the bus and S2 is in the 240 volt position. 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: KWapplied RWRated x (Voltage Applied)? (Voltage Rated)2 TASES IHS O SSH E ES SE rir CAUTION Never exceed the rated voltage, because this will cause the Load Bank to overheat. Do not apply DC voltages, because the contactors do not have arc blowout magnets. JESS SSSI ISOS ISOS IIIS SESS IOI IIA II LKG/cr 2-2 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 JESSIE IID III II TIE CAUTION External blower power is required if a voltage different than 240/480 is being applied or a frequency other than 60 Hz. (See Section IV for further details.) JHE HESS SSIS OT I III IIIS IO III System Description - Option 17, Automatic Load Shed System The Model K696 is offered with an optional Automatic Load Shed Control. It is comprised of a Load Shed Controller Part Number 18495 and a Current Transformer Part Number 370390 interfacing with the K696 Load Bank manual controls. Option 17 maintains a minimum load on a power source. ‘The separately supplied multi- tap current transformer provides the feedback signal required to operate the system. This feedback signal drives two (2) field adjustable current sensing relays which detect the load level. The system limits the resolution of the K696 Load Bank to 10 KW while the Load Shed Controller is operating the Load Bank, whereas operating the Load Bank manually maintains the 1 KW resolution. The Load Shed Controller can be expanded to accommodate a K696A auxiliary Load Bank by adding a jumper wire on the automatic Load Shed Controller Part Number C18495. Automatic Load Shed Controller Description (Option 17) The optional Avtron Automatic Load Shed Controller Part Number C18495 contains all of the control devices of the system. The controller has field adjustable setpoints which sense single phase current from a current transformer. The setpoints (high/low) are adjusted for the required operation range of the generator. The setpoints inform the controller to increment, hold, or delete load. The phase current is detected through the current transformer Part Number 370390, The current transformer is inserted on the generator side of the actual load and the Load Bank. (See Figure 7-1.) To start the controller, a customer-supplied contact (N.0.) must be closed. (See Load Bank Schematic/Interconnection Diagram B19078.) This contact activates a 5-second time delay and enables the controller. Avtron recommends that the generator overload LKG/er 2-3 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 protection circuit open the customer-supplied contacts to immediately shut down the auto load system if an excessive overload is detected. Once the customer contacts close, the Load Bank will remain idle for five (5) seconds, allowing the system to stabilize. The controller adds load steps in 0.8-second intervals and deletes load steps at 0.2-second intervals. If the system experiences many overshoot conditions during the course of normal operation, there can be conditions where the controller may repeat operations. A repeated operation would be viewed as a delay while the controller steps up to its previous status. If an overload is detected, the controller will only attempt to remove load steps for 1.0 second or four load steps. Once the 1.0 second is reached, the unit will drop out all remaining energized load steps. Enclosure ‘The optional Automatic Load Shed Controller is enclosed within a 20 inch x 20 inch x 6 inch deep NEMA 12 wall-mount enclosure. JES ESSE SSIS SISSIES ISIS ISHII TIT IE WARNING Disconnect all power from the Load Bank and the Load Shed Controller before servicing. JHE USS S EIS E SSSI S SEIT IIIT The enclosure protects the internal electronics from direct dust, dirt, oil, and water. The enclosure access door must remain closed. The operating temperature for the controller is from 00°C to 450C with a non-condensing humidity from 5% to 95%. LKG/cr 2-4 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 SECTION ITI K696A DESCRIPTION ‘The K696A is a variant of the K696. It has the versatility of a self-contained Load Bank, or it may be used as a companion to the K696. The K696A has three load steps of 50 KW, 100 KW and 100 KW for a total of 250 KW. The K696 has the capability to control two K696A's and itself for a total energy-absorbing capacity of 750 KW, To use the K696A as an auxiliary companion Load Bank to the K696, see Section VI. The blower motor is a 2 HP, three phase motor which operates from 240/480 volts, 30, 60 Hz power. The blower motor obtains power from either the power source under test or from a remote source depending upon the positioning of fanning strip (PS4) on terminal board (1B4). When operating from the power source under test, the motor circuit automatically connects the motor for high or low voltage. The K696A will test 240/480 volt, 30, 60 Hz generators without any wiring changes. It can be used to test 60, 50 Hz, or 400 Hz generators; however, the blower motor and control circuit power must be separate 60 Hz sources. For separate 60 Hz blower motor power connection, see Section IV. Control power is 115 VAC, 60Hz. A line cord is provided for control power. Blower failure protection is provided in two ways. A differential pneumatic pressure air switch (S17) senses the airflow through the Load Bank. An additional slave relay (K30) is activated only if power is applied to the blower motor terminals. This slave relay will disconnect control power to all load contactors should blower power be disconnected, the motor overload trip out of the air intake or exhaust screens become blocked. JHE ESHEETS III III III Ir 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. JESSIE SE TEES III III IIE LKG/cr 3-1 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 General Construction (Refer to Outline Drawing SB1360.) The control panel is mounted on the Load Bank, but is also sized for mounting into a 19-inch rack enclosure. ‘The control panel contains all the switches required to operate the Load Bank. ‘The K696A Load Bank is constructed of aluminized steel and fiberglass, forming a rigid structure. Mounted within this structure is the load element resistor assembly, the cooling blower, the load step contactors, motor starter, motor overload relay, fuses, and customer connection terminals. The cooling air is drawn in from both sides, forced across the resistor elements, and exhausted out the end. The unit is mounted on five-inch casters with one set provided with wheel locks. The customer connection panel is located at the rear of the unit. A handle located above the customer connection panel is provided for cable storage. The Load Bank can operate at either 480 volts or 240 volts. A switch on the control panel (S2) will automatically switch the load from the high voltage configuration to the low voltage configuration. The blower motor configuration also changes if powered from generator under test. The blower motor has separate overload protection for high and low voltage operation. The voltage protection circuit will select the high voltage mode if 480 volts is applied to the bus and S2 is in the 240 volt position. 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 KW oied = KM 5 Applied ae (Voltage Rated) 2 FEES IU III II III III I III ITI III CAUTION Never exceed the rated voltage because this will cause the Load Bank to overheat. Do not apply DC voltages because the contactors do not have arc blowout magnets. JESSE IORI IIE TI III III III III AE LKG/cr 3-2 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 JOSHI OE EE EE IIE IESE CAUTION External blower power is required if a voltage different than 240/480 is being applied or a frequency other than 60 Hz. (See Section Iv, INSTALLATION, for further details.) TEES S SSSI IIS SEIS OEE IIS ISIE System Description ~ Option 17, Automatic Load Shed System See Section II. LKG/cr 3-3 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 SECTION IV 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 K696 & K696A Load Banks are designed 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, ventilation of 6,000 CFM or greater is required. A minimum of eight feet of clearance from the inlet and exhaust is required for proper airflow. JHE ESSE ESSE SSIES IE ISIE WARNING The exhaust air may be in excess of 2500P 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. TEE HEISEI ES III EIS S IOI III I III 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: LKG/cr 4-1 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 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. 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. RESTRICTION OF COOLING AIR - Any obstruction located within eight (8) feet of the inlet or 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. JESSE ESSE IIS EES II IEE II IIE II WARNING 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.) FEES S SESH SESS O SSUES IOC Un OEE Ee Power Requirements The Load Bank requires a 115V, 10, 60 Hz, 10 amp source of power for operation of the control circuit. A power cord for control power is provided with the Load Bank. Connect unit to a grounded 115 volt source. LKG/cr 4-2 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 An optional control transformer may be installed in the K696/D16133 and K696A/D16423 Load Banks. This option (Option 6 in the Replacement Parts List) enables the operator to use the generator output for control power. When the operator applies either 240 V or 480 V to the primary, the control transformer automatically supplies 120 VAC for control power. As an assurance that proper voltage and frequency are applied to the transformer, Option 6 is connected in parallel with the blower motor. An external power source must be provided (as described in section B of Blower Motor Connections) if internal power for motor and control power is not desired. During startup, be sure the load switch on the generator under test is not "ON" until the prime mover has the generator up to speed. This avoids blowout of fuses Fil and F12. Also, be sure the load switch is OFF before generator shutdown procedures are started. JESSE SIS ISI SSH SISIISIS SII I IEE CAUTION When the Load Bank includes this option, never connect a control power line cord to TB4 (12) and TB4 (13). This would permanently damage the control transformer. JESSE IIIS SIS SIISSIII IO Blower Motor Connections The blower circuit consists of fuses, motor starters, contactors, overload relays, and the blower motor. A. INTERNAL BLOWER POWER OPERATION: The blower is connected on FS4 which is between terminals 1-5 on TB4. When operating the blower motor from the generator source, an additional load of 2400 watts will be applied. This additional load will be reflected in the meter readings and should be noted on load readings to prevent errors. REMOTE FAN POWER OPERATION: When testing single phase system or systems or a frequency other than 60 Hz, the fan motor must be run from a separate source. To do this, locate TB4 on the customer connection panel at the front of the Load Bank. LKG/or Rev. 7/1/87 Rev. 3/24/95 4-3Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Remove fanning strip FS4 from terminals 1 through 5 on TB4 and reconnect it to terminals 6 through 10. Next, connect the jumper wire from terminal 11 to either terminal 10 (for 480V fan power), or to terminal 9 (for 240V fan power). Connect the external fan power source to terminals 6 through & of 1B4, Be sure the fan rotates in the proper direction before operating the Load Bank. If the blower rotation is reversed, interchange any two leads supplying power to the motor. NON-STANDARD BLOWER MOTOR FREQUENCY: Blower motor will operate between 208 and 250 volts and between 416 and 500 volts at 3-phase, 60 Hz. Connection at 50 Hz is the same as 60 Hz, shown on the following page, with motor voltage range of 180 to 220 volts and 360 to 440 volts. JESSE SISSIES CSS ISOS IIS III I IE WARNING When operating at 50 Hz, the motor speed (RPM) is reduced, which also reduces cooling of Load Bank. Do not exceed 400 volts in the 480 mode or 200 volts in the 240 mode, to input bus when running the fan at 50 Hz. TEESE HUIS ISIS IIIS IIIT IIIS II III CAUTION Do not attempt to operate any blower motor at 400 Hz. When loading unit with power other than 50/60 Hz, the blower motor must be wired to external power source supplying any of the above proper voltages and frequencies. JESS OSI ISIS SAI IIIT IIIS LKG/er Rev. Rev. 7/1/87 3/24/95 4-4Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Connection when the Load Source is used to run the fan motor 230V or 460V. LKG/cr Rev. 7/1/87 Connections when the fan motor is run on a 460V external power source. fw] | | Fanning rs | 7 ol w [=| Strip = wa} S22 a o m D 5 =| { tion = 3 = = = 5 sp,asov (To = 2 S 60" 39,2304 Fanning ~ I= | Line ({“ S 60H | |~ "| | strip = fe 2 a tine | [> =| \eonnee- e = Fanning ion © |) strip 7 7 z S a S| | conse = = a = = ‘ion Jumpet 7 = = = Jumper, = opp a a 2 a] Connections when the fan motor is run on a 230V external power source.Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 NOTE The fanning strip is prewired in the factory and is designed to be easily connected to and disconnected from TB4 when the blower motor power source changes. Load Connection Connect a 240/480 volt, three phase source to the three fused bars labeled A, B and C, located on the customer connection panel. Cables to the Load Bank should be sized to handle the maximum rated load according to the National Electric Code. ‘The current can be determined by the following formula: KW_x 577 VOLTAGE (LINE TO LINE) Line Current 696 TYPICAL LOAD WIRING 10 39 ond capactty GENER 00s 7018 oN capacity GeweravoR oot FEES SSSI SEUSS SE IS EEI IOSD WARNING "B" Bus and any attached wiring are electrically hot when operating Load Bank in single phase. JEU OSE ESSE ISIS ISSO ISITE IS IIE LKG/cr 4-6 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 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 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. JOSIE SISOS I IO III I IIT I I III WARNING Do not operate the Load Bank with any panel or screen removed. This may expose the operator to dangerous high voltage and the rotating fan blade, as well as disrupting the airflow. TEE ESS III IIIS III III III I I III Optional Load Capacity Optional auxiliary load capacity may be added to the K696 by purchasing a K696A. (See Section VI, K696A AUXILIARY OPERATION of this manual.) Storage The Load Bank should be covered to protect against moisture, and the accumulation of dust and dirt. ‘The unit should be stored in a dry, enclosed area. An optional waterproof vinyl cover (option 1) is available for the Load Bank; however, even with this cover, the Load Bank should not be stored outdoors. Install £ Option 17 ; a a Option 17, Automatic Load Shed Controller, has two (2) parts: the Load Shed Controller Part Number C18495 and the separately supplied Current Transformer Part Number 370390. LKG/cr 47 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 The current transformer must be installed at the main power bus of the power source to be loaded. The current transformer must be installed before any branching to other loads so that the controller monitors total generator load. (See Figure 7-1.) The Load Shed Controller is contained within the 20 x 20 x 6-inch deep NEMA 12 enclosure. The controller should be located between the Load Bank and the source or at the Load Bank itself. All current transformer interconnecting wire lengths should be minimized. Control Co: ions for Option 17 All interconnections from the Load Bank to the optional controller are shown on the Schematic/Interconnection Diagram Part Number B19078. The controller derives 120 VAC control power from the K696 control power although the Load Shed Controller power can also be derived from any 120 VAC, 60 Hz source Select the next higher C.T. ratio than the full current output of the power source. Amp(Line) = The current transformer taps are defined below: REQUIRED C.T. RATIO TAP 300:5 XB-K4 500 X4-K5 800 X3-K5 1001 x1-x2 1201 X2-K3 1501 X2-K4 2001 X2-K5 2201 X1-K3 2501 x1-K4 3001 x1-K5 LKG/cr 4-8 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 FEES SII IOI III II III IIIT I ITI I III WARNING Disconnect all sources of power before interconnecting the controller. The control power circuit is protected by fuses Fl, F2, F3, and F10. Use only the fuses listed in the spare parts list. Do not bypass the fuses if they blow. Bypassing the fuses can result in damage to the equipment and potentially hazardous conditions for the operator. TOES IESE III III II III IE Disconnect power from the Load Shed Controller unit when the unit is not in use. Never allow the secondary of the current transformer to remain disconnected when primary current is passing through the transformer. If the Load Shed Controller unit must be disconnected, put a short or shunt across the current transformer. A_Au: An additional jumper is required when the Automatic Load Shed Controller interconnects with a K696 and a K696A Load Bank. A jumper is required in Controller C18495 from TB11 (25) to TB11 (26). The incremental steps of the Load Shed Controller are based on the K696 Load Bank. The K696A Load Bank must be preset to 250 KW bulk load when interconnected or the system will not increment correctly. JX HE EIS S OI SISSOSISIOSE SO ETS IAT IA CAUTION When drilling or tapping holes in the enclosure, do not allow metal shavings to enter any device within the Load Shed Controller. Take care in connecting the Load Bank and controller. The controller could be permanently damaged if incorrectly connected. JEU UES ESSE HGS ISS IST II LKG/cr 4-9 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 The Auto Load Shed Controller (P/N C18495) can be a free-standing or wall-mount unit. Control power and interconnections are made by punching a hole into the enclosure. If the unit is wall mounted, conduit can be used to carry wiring. Always protect wiring from sharp edges created by the hole punch. NOTE Before placing the system into automatic, place all K696 load step switches to the OFF position, and, if required, verify that the auxiliary jumper is placed correctly. LKG/er 4-10 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 SECTION V OPERATION Purpose And Use of Controls 1, VOLTS 240/480 Select Switch. ‘This switch selects the 240 or 480 volt mode for the Load Bank. POWER ON/OFF Switch. This switch turns on both the control circuit and the blower circuit. Digital meters will illuminate. (K696A - Power ON lamp will light.) 3. 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. 4. VOLTS AB/BC/CA Phase Select Switch. The function of each switch position is as follows: (NOTE: 696 only) Function cA Measures Phase C to Phase A voltage Be Measures Phase B to Phase C voltage AB Measures Phase A to Phase B voltage 5. AMPS A/B/C Current Phase Select Switch. The function of each switch position is as follows: (NOTE: 696 only) Function A Measures Phase A Current B Measures Phase B Current c Measures Phase C Current 6. METER READ/HOLD Switch. This switch holds all readings on the digital meters at the same time. To update the information on the meters, place the switch back to the read position. (NOTE: K696 only) 7. 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. LKG/cr, Rev. 7/1/87 Rev. 8/29/90 5-1Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 KW LOAD Step Switches. The load in kilowatts is marked above each actuating switch. A load step may be turned on or off before or during a test, but will load the unit only when the MASTER LOAD Switch is ON. A six-position rotary KW LOADS Switch is also provided to enable loading resolution down to 1 KW. 9. Aux Load Switch. Used to control a load outside of the K696. (NOTE: K696 only) Operating Instructions 1. Connect the Load Bank to a 120 volt, 60 Hz source for control power. Line cord provided. 2. Connect the unit to be tested as described in Section Iv, INSTALLATION, under Power Requirements. Use all three terminals on the input terminal board for 3-phase generators, or connect the power cables to the Phase A and Phase C terminals for single phase generators. (See Section IV, INSTALLATION, for details.) JESS SEES SSS IES IS III CAUTION The cooling blower motor is rated at 240/480 volts, 3-phase, 60 Hz, with corresponding overload heaters for protection. The motor must be connected to a separate power source if: 1. Using the unit to test a single phase unit. 2. Operating at any frequencies other than 50/60 Hz. 3. Operating at any voltage other than 240/480 volts + 10 @ 60 Hz and 240/480 volts @ 50 Hz. (Refer to Non-Standard Blower Motor Frequency in Section Iv.) Urtttrercrceterccetteccccetercrttlttretcrrrrrrrssy LKG/cr Rev. 7/1/87 5-23. 4. Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Place all switches on the control panel in the OFF position Place the VOLTS Select Switch to the correct voltage to test the generator. JESUS SISOS HHS III ISITE IIE I IIE CAUTION DO_NOT operate the Load Bank over the rated voltage as this will cause catastrophic failure in the Load Bank. DQ make sure that the VOLTS Select Switch is in the proper position before applying load. EEE OO EEE OEE EEE SOE EERE EE REE EEEEE Place the POWER Switch to the ON position. Digital meters will illuminate. Blower will turn on. Upon energizing the unit, the red BLOWER FAIL lamp will light momentarily until the air switch detects sufficient cooling air, at which time it will go out, applying power load 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. TESS ESD SS EOI SS ESSE EIU DIG RAE EERE EER CAUTION The operation of the blower is vital to the safe operation of this Load Bank. When the POWER Switch is turned ON, the BLOWER FAIL light will come on momentarily until the blower accelerates up to its operating speed, at which time the light will go out. If the air switch prevents the load from being applied, do not bypass this switch. If the BLOWER FAILURE 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 CON- SIDERATIONS, of this manual.) JESUS SEIU IIE SESS ISSO SETI ISIE LKG/cr 5-3 Rev. 7/1/8710. 1. 12. Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 With the MASTER LOAD Switch in the OFF position, start the generator to be tested. Verify that the voltage displayed by the voltmeter matches the position of the VOLTS Select Switch. The resistive loading is selected by toggle switches, using any one or combination of toggle switches to make up a given load. By placing the MASTER LOAD Switch to the ON position, the preselected load will be applied to the power source. Any KW LOAD switch can be added or removed as required with the NASTER LOAD Switch closed (ON). Monitor the unit under test using the digital volts and current display. To remove load, move MASTER LOAD Switch to OFF position. Shutdown: Reverse steps 1 through 11. It is good procedure to allow the fan blower motor to operate for about 2 minutes after the load is removed. This will exhaust any accumulated heat and allow exhaust surfaces to cool. TEESE ISSO SS III IIS ISTO II WARNING DO NOT touch the exhaust screen during operation. The screen will become hot from the exhaust heat and may cause a serious burn. (Refer to Section I, SAFETY CONSIDERATIONS, of this manual.) DO NOT allow objects to enter or block screens. JESSIE SSSI III III II II III III IIIS LKG/er 5-4 Rev. 1/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 NOTE Lower voltages and different frequencies may be applied to the load circuit of the Load Bank. Frequency change causes no derating of the load. The Applied KW with a lower voltage is computed using the following formula: KWapplied = KWRated x (Voltage Applied}: (Voltage Rated) peettetttttttttrtrtrttrtrrttcrrtetterer ttt crrrresy CAUTION Never exceed the rated voltage. This will cause the Load Bank to overheat. Do not apply DC voltages, because the contactors do not have arc blowout magnets. JE SESS EES SHEE IIS SSSI ESS IIEE IS EE LKG/cr 5-5 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 SECTION VI K696A AUXILIARY OPERATION The K696 Load Bank has the capability of using one or two K696A Load Banks for a total of 500 KW or 750 KW. ‘The K696A, when interconnected, can be operated from the main K696 control panel. Installation ie Location of Load Bank should meet all conditions set forth in the INSTALLATION section of this manual. 2. load Connections: (See Figure 6-1, Wiring for K696A Auxiliary Operation.) 3. Control Power: Each Load Bank requires its own 120V, 60 Hz control power source. (See the Power Requirements paragraph of Section IV, INSTALLATION, of this manual.) 4, Blower: Each Load Bank requires 240 or 480 VAC, 3, 60 Hz for the blower motor. See the Blower Motor Connections paragraph of Section Iv, INSTALLATION, of this manual. 5. Control Interface: The K696 can be interconnected to the K696A as follows: On the K696A, connect TB4 (15)-TB4(20) to its counterpart on the K696. Wire point to point. POSSIBLE KW STEPS TOTAL MAX. MODEL (S) AT_240/480 VOLTAGE KW_CAPACITY K696 1 KW thru 250 KW 250 KW K696 PLUS 1 KW thru 250 KW 500 KW K696A PLUS up to 250 KW (AUX) K696 PLUS 1 KW thru 250 KW 750 KW 2xK696A. PLUS up to 500 KW (AUX: Even with this arrangement, the K696A can be used as a self-contained Load Bank with its own control panel. (See Section III, K696A DESCRIPTION, of this manual.) LKG/cr 6-1 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Operation The K696A Load Bank operating instructions are almost identical to that of the K696. If operating a K696A Load Bank independent of a K696, refer to Section V, OPERATION. If more than one Load Bank is interconnected, follow the instructions below; then refer to Section V, OPERATION. Connect the Load Bank to a 120 volt, 60 Hz source for control power. Line cord provided. 2. Place the VOLTS Select Switch to the correct voltage to test the generator. 3. Place the POWER Switch to the ON position. Blower motor will turn ON. Be sure the MASTER LOAD Switch is in the OFF position. Select desired load. The AUX Switch on the K696 can be used to apply and remove the K696A load. Refer to Section V. Option 17 Preset the K696A Load Bank to 250 KW. ‘The incremental steps are based on a 250 KW auxiliary load. Operation Using the Remote Control Panel A Remote Control Panel (OPTION 7, Part Number C16721) allows remote operation of the load step toggle switches. The switches are mounted in a small enclosure which can be connected to the Load Bank with the 90 feet of cable provided. The part number of the Remote Control Unit is D16983. JESSIE IOS IIIT SIITI ETII TIIIE WARNING DISCONNECT ALL POWER FROM THE Load Bank BEFORE INSTALLING THIS OPTION. JAE HE I IS SI E I SSIS IIIS E IIIT I EIIII III LKG/cr 6-2 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Installation of this option is accomplished by connecting the fanning strips at the end of the cable to the terminal blocks (TB5 and TB6) located on the customer connection panel. Wiring Diagrams and Schematics have been included at the back of this manual. Operation of the Load Bank is the same with the Remote Control Panel as it is using the toggle switches on the Load Bank Control Panel. NOTE When using the Remote Control Panel, make sure all load step switches on the Load Bank Control Panel are OFF. These switches will add load if turned ON. Before using the Remote Control Panel switches, set up the Load Bank Control Panel switches as described in this manual with the exception of the load step toggle switches. The indicator light on the Remote Control Panel will illuminate when the MASTER LOAD switch on the Remote Control Panel is turned ON and the Load Bank controls are ON and properly set. LKG/cr 6-3 Rev. 7/1/87Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 K696A/D16423 LOAD BANK TB4 15 | 16 | 17] 18}19 | 20 K696/D16133 LOAD BANK A GENERATOR as [16 | 17 18, TB4 igl20 K696A/D16123, LOAD BANK FIGURE 6-1. WIRING FOR K696A AUXILIARY OPERATION LKG/er 6-4 Rev. 7/1/87‘Aviron Mods! K696IKE96A {oe Bank SECTION VII AVTRON MODEL K696/K696A OPTION LIST These options are available on the Model K696/K696A Load Banks. Not all options can be installed in the same unit Part Number 15941, B16110 B16111 B16112 B16113 B16250 16721, 16722 15583 A14702 B16791, B16792 B16793 A16560 16667 BMPav $2888, Rev. 313197 Option a 2 10 a 12 13 14 Description Storage cover LED Digital Watt Meter (S/N 84 and Below] 45-99 Hz LED Digital Frequency Meter (S/N 84 and Below! 45-450 Hz LCD Digital Frequency Meter (S/N 84 and Below) Air Fail Warning Horn Dual Voltage Control Transformer Control Unit, Remote (with cable) (For K696D16133 Load Bank) Control Unit, Remote (with cable) (For K696D16158 Load Bank: Silkscreen for Load Steps Derated per 208 VAC 10 Feet of Load Cables Lep Digital Watt Meter (S/N 85 to S/N 742) 45-65 Hz LCD Frequency Meter (S/N 85 to S/N 742) 45-450 Hz LCD Digital Frequency Meter (S/N 85 to S/N 742) Elapsed Time Meter Single Overhead Lift Point 7-1‘K696/K696A Option List ‘Avon Model KS96/K5964 Loe Bank Part Number 16770 17543 17603 A17604 B19575 18100 18523 A18647 19135 i972 19173 19174 19175 19176 420523 B22436 21083 21230 BMPrkv 028/88, Rev. 25183, Option 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Description Weather Resistance Kit (Cannot be used with option 18) Auto Load Shed Controller with Current Transformer (for K696D16133 Load Bank Lift Support with Two Handles (Cannot be used with option 16) Instrument Test Jacks Kit with Shorting Links Installation of Fan Reversal Switch Paint Exterior of Load Bank Ford Blue Installation of a 380/120V, 50 Hz, 2 KVA Control Transformer Installation of Universal Control Transformer wired for 380/110V, 400/115V, 208/110V, or 415/120V, 50/60 Hz per customer requirements 200/400V Derated Silkscreen 200/400V Derated Silkscreen 190/380V Derated Silkscreen 190/380V Derated Silkscreen 208/415V Derated Silkscreen 208/415V Derated Silkscreen Installation of 500 VA, 600/120V, 50/60 Hz Control Transformer Installation of Overtemperature Protection Installation of Tie Down Rings Installation of 500 VA, 220/110Vv, 50/60 Hz Control TransformerK696/K696A Option List ‘Aviron Model K696/K696A ‘Load Bank Part. er = Option Description A21735 34 10 ft. power cable, 4 conductor, terminated with 200A Crouse-Hinds connector (for 480V operation only) A23382 35 Installation of Option 35 (replaces original meter with meter P/N A22821 on Load Banks S/N 743 and above) 23974 36 Installation of option 36 rik 7-3 11783, Rev. 11898Avtron Model K696/K696A Load Bank REPLACEMENT PARTS LIST OPTIONS ‘SCHEMATIC MANUFACTURER | AVTRON | OTY/ REFERENCE DESCRIPTION and PART NO. Py | UNIT OPTION 2: LED Digital watt B16110 Meter (S/N 84 and Below: ma -Display ais217 | 1 -Bezel RMF Products | 358954 | 1 Model 140-2 MT3 -Watt Transducer Scientific 372513 | 4 Columbus CTS 10A2 RA -Resistor, 806 Ohm, 1/2 W, 18 123108 | 2 OPTION 3: 45-99 Hz LED B16111 Digital Frequency Meter (S/N 84 and Below, ma Meter Non-Linear 337828 | 1 systems FM-37B Bezel Assembly RMF Products | 358954 | 1 Model 140-2 73 - Transformer B16025 | 1 + Transformer Square "D" co. | 370894 | 1 9070-E0-17 .+Kit, Fuseblock Square "D" co. | 324964 | 1 9070-AP-3 -+Fuse, ¥A, 250V Bussmann 324005 | 2 AGC | OPTION 4: 45-450 Hz LeD B16112 Digital Frequency Meter (S/N 84 and Below] ma -Meter a15225 | 1 :Bezel Assembly RMF Products | 358954 | 1 Model 140-2 13 - Transformer Bie025 | 1 : + Transformer Square "D" co. | 370894 | 1 9070-E0 .+Kit, Fuseblock Square "D" co. | 324964 | 1 9070-AP-3 .+Fuse, ¥A, 250V Bussmann 324005 a AGC-&, BMP/kv 7-4 4/28/88, Rev. 11/3/93Avtron Model K696/K696A options Load Bank SCHEMATIC MANUFACTURER | AVIRON | QTY/ REFERENCE DESCRIPTION and PART NO. eae | UNIT OPTION 5: Air Fail Warning B16133, Horn Audible Warning Device P. R. Mallory | 303006 | 1 H4-1 Code #37942 OPTION 6: Dual Voltage B16250| 1 Control Transformer w/Schematic 4 - Transformer, 500 VA Acme Elect. 370654 | 2 TA-2-81215 K101 -Relay, Volt Sense Magnecraft 350740 | 1 W236ACK~2 T40 - Transformer Square D 370528 | 1 F440 -Fuse, 0.5 Amp, 250V 324005 | 2 XF440 -Fuseblock Square D 324964 | 1 9070-AP-3 XK101 - Socket, Potter & Brum. | 358215 | 1 27121 100 Switch, P.B. Black Switchcraft 360017 | 1 913 s101 Switch, P.B. Red Switchcraft 360019 | 1 903 K100,K240 | .Relay B14795 | 2 K480 :Relay Bie143 | 1 cBL :Circuit Breaker Asea Brown 310330 | 1 Boveri $272-K10 w/ S500-MEL s102 -Switch Cutler Hammer | 360785 | 1 7991K10 TBS -Terminal Board cinch 364054 | 1 6-141 - Insulator cinch 450098 | 1 MS-6-141 FS5 -Fanning strip cinch 365076 | 1 6-161L, BMP/kv 1-5 4/28/88, Rev. 7/23/96Avtron Model K696/K696A options Load Bank SCHEMATIC MANUFACTURER | AVIRON | OTY/ REFERENCE DESCRIPTION and PART NO. p/w | UNIT | OPTION 7: Remote Control unit 16721 | TBS -Terminal Board Kulka 364103 1 | 601-20 BG -Terminal Board Kulka 364063 | 1 601-8 -Control Unit, Remote pi6983 | 1 $10 ++Switch, Rotary 620288 | 1 S81 ++Switch, Toggle Arrow-Hart 360677 | 1 82612 $2-S9 -.Switch, Toggle Westinghouse | 361599 | 8 PB1AAHAB psi ..Indicator, Light Dialight 329137 | 1 502-3228-0112- 302 XDS1 - «Lamp General Elec. | 333011 | 1 686-125V TB1 .-Terminal Board Kulka 364063 | 1 601-8 TB2 ..Terminal Board Kulka 364103 | 1 601-20 FS6 -/Fanning strip Cinch 365073 | a 5-161R FSS +/Fanning strip Cinch 365095 | 2 20-161R +-Wiring Diagram 16724 | REF + +Schematic 16723 | REF OPTION 8: Remote Control 16722 Unit (K696D16158 only, -Control Unit, Remote pissaa | 1 si +.Switch, Toggle Arrow-Hart, 360677 | 1. 82612 s2-S19 + .Switch, Toggle Westinghouse | 361599 | 18 PB1AAHAB psi -.Indicator Light Dialight 329137 | 1 502-3228-0112- 302 XDS1 - «Lamp General Elec. | 333011 | 1 686-125V TBL .-Terminal Board Cinch 364103 | 1 20-141 FS4 ++Fanning strip Cinch 365095 | 1 20-161R + Wiring Diagram c16726 | 2 + «Schematic 16725 | REF TB4 :Terminal Board Cinch 364103 | 2 20-141 BMP/kv 1-6 4/28/88, Rev. 11/3/93Avtron Model K696/K696A options Load Bank ‘SCHEMATIC MANUFACTURER | AVIRON | QTY/ REFERENCE DESCRIPTION and PART NO. py | UNIT OPTION 11: LCD Digital B16792 Wattmeter -Watt Transducer Scientific 372513 | 1 Columbus CTS 10A2 Cable Assembly Augat 390849 | 2 7P14-3912-2 -Display A15327 | 2 QPTION 12: LCD Digital B16792 Frequency Meter, 45-65 Hz «Integrated Circuit U3 Motorola Semi. | 376868 | 1 MC14536BCPDS -Standoff, .38 LG H. H. Smith aii6s4 | 2 2101 Standoff, .25 LG H. H. Smith 411700 | 2 2100 Cable Assembly Augat, 390849 | 1 7P14~3712-2 -Meter Datel-Intersil | 337762 | 1 DM-LX3 Display # SD991M400 COFG OPTION 13: LCD Digital B16793 Frequency Meter, 45-450 Hz -Integrated Circuit U3 Motorola 376868 | 1 MC14536BCPDS Cable Assembly Augat, 390847 | 1 7P14-3736-1 -Standoff, .25 LG H. H. Smith 411700 | 1 2100 Connector Datel-Intersil | 314049 | 1 58-2073083 -Meter ais328 | 1 :-Meter, Frequency Datel-Intersil | 337830 | 1 DM-4105, Display # SD458M400 COFC| OPTION 14: Elapsed Time Metei 16560 Meter, Elapsed Time Engler Instmt. | 369222 | 1 200-10N-L7 BMP/kv 1-7 4/28/88, Rev. 11/3/93Avtron Model K696/K696A options Load Bank SCHEMATIC MANUFACTURER | AVTRON | OT¥/ REFERENCE DESCRIPTION and PART NO. pyu | UNrr OPTION 17: Auto Load Shed 17543 Controller Insulator, Term. Block Cinch Mfg. 450136 | 2 MS-18-140 -Insulator, Term. Block Cinch Mfg. 450092 | 1 MS-6-140 | vais -Terminal Block Cinch Mfg. 364130 | 1 18-140 ‘B17 -Terminal Block Kulka 364180 | 2 600-6 | -Schematic/Interconnection B19078 | REF Diagram T10 -Transformer, Current Instrument 370390 | 2 Transformers 135-302 AL -Load Shed Controller cisao5 | 2 :-Retainer Relay Rundel-IDEC 467522 | 18 1492-N2 -.Socket, Relay Rundel-IDEC 358215 | 9 SL711 . Relay syrelec 351590 | 2 DIRT-110 V . Relay Potter & Brum. | 351060 | 9 KUP14A15 .+Fuseblock, 2 Pole Littelfuse 324521 | 2 357002 -+Fuse, 6 A Littelfuse 324086 | 1 314006 -+Fuse, 0.5 A Littelfuse 324005 | 3 312.500 - .Schematic/Interconnection B19078 | REF Diagram ++Terminal Block Assembly ai7572 | 1 ++sMarker Strip Weidmuller 364410 | 2 4687.6 (1-50) +++Terminal Block Weidmuller 364408 | 30 2796.6 . Programmable Controller ai7s70 | 1 eeI.C. Programmer 680184 | 1 ++ .Controller General Elec. | 395011 | 1 1€609SIR100 OPTION 19: Instrument Test 17604 Jacks Kit w/Shorting Links +Link, Shorting H. H. Smith 410002 | 2 1828 Connector, Fem., Red H. H. Smith 366852 | 3 (Bind’g Post) 257-102 «Connector, Fem., Yel. He H. Smith 366870 | 4 (Bind’g Post) 257-107 BMP/kv 7-8 4/28/88, Rev. 11/3/93Avtron Model K696/K696A options Load Bank SCHEMATIC MANUFACTURER | AVIRON | gTY/ REFERENCE DESCRIPTION and PART NO. pya | UNIT ~ OPTION 20: Installation of Fan Reversal Switch K35,36 -Relay B14795 | 2 $100 :Switch, Toggle, 2 PDT Cutler-Hammer | 360747 | 1 7992K10 OPTION 22: Installation of 18523 380/120 V, 50 Hz, 2 KVA Control Transformer v4 . Transformer General Elec. | 370943 | 2 9951B172 Ful -Fuse Bussmann 324106 | 2 ‘Tron FNQ XFLL -Fuseholder Bussmann 32aeaa | 2 4515 B10 .Terminal Board cinch 364033 | 1 2-140 OPTION 23: Installation of 18647 380/115 V, 50 Hz Control Transformer 120 . Transformer Acme Electric | 370709| 1 TA-1-54524 B20 Terminal Board cinch 364121 | 2 4-140 Fa. -Fuse Bussmann 324101 | 2 KTK-10 F20,22 -Fuse Bussmann 3eaii9 | 2 KTK-6 -Fuseblock Bussmann 32aeis | 2 2809 OPTION 30: 500 VA, 600/120 Vv) 420523, 50/60 Hz Control Transformer 120 . Transformer Acme Elec. 371032 | 2 TA-2-81005 1TB20 .Terminal Board Cinch 364033 | 1 12-140 -Marker Strip Cinch 450042 | 1 MS-12-140 F21,22 «Fuse, 8 A, 600 V Bussmann 32aiso | 2 FNO-8 F19,20 -Fuse, 2.5 A, 600 V Bussmann 324203 | 2 FNQ-R-2% -Fuseblock Bussmann 324615 | 2 BM6033SQ BMP/kv 7-9 4/28/88, Rev. 11/3/93Avtron Model K696/K696A options Load Bank ‘SCHEMATIC manuracturer | AaVERON | gTY/ REFERENCE DESCRIPTION and PART NO. p/w | unrT OPTION 31: Installation of B22436 Overtemperature Protection $100 -Thermoswitch Selco agi012| 2 0-300: OPTION 33: Installation of 21230 220/110 V, 50 Hz Control Transformer 720 - Transformer Hevi Duty 370242| 1 E550 TB20 Terminal Board Cinch 364033 1 2-140 «Marker Strip cinch 450042 | 1 MS-2-140 P46,47 «Fuse, 5A, 600V Bussmann 324475 | 2 FNQ-R-5 F48,49 Fuse, 7.5A, 600V Littelfuse 324493 | 2 KLDR-7.5 .Fuseblock Littelfuse 324615] 2 LM60030-38 OPTION 34: 10 ft. Power 21735 Cable, 4 Conductor, with 200A Crouse-Hinds Connector (480 V operation only) =Connector crouse-Hinds | 313212] 1 AP20468 OPTION 35: Installation of Option #35 ma sMeter aaze2i| 2 | BCM/kv 7-10 6/16/92, Rev. 11/2/96Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 SECTION VII (Cont.) OPTION 17, AUTOMATIC LOAD YSTEM THEORY OF OPERATION AND ADJUSTMENTS Option 17 - Theory of Operation The Load Shed Controller parallels the normal K696 Load Bank manual controls. Thus the Load Bank manual controls can override the automatic control. (Reference Section V, OPERATION, of this instruction manual.) JHE SUSE SHEE SIS SSSI ISIS III ISS Ie CAUTION Always put a short or shunt across the current transformer when servicing the Load Shed Controller. Primary current flowing through an unshunted current transformer will destroy the transformer with possible harm to personnel. JE EEUU ISIS ISOS IIIS III II I IIe A. Automatic Operation of optional Load Shedder 1. Place all K696 KW LOADS step switches on the control panel to the OFF position. Place the 1 to 5 KW rotary KW LOADS switch to the 0 position. 2. Start the Load Bank. (Reference the K696 and K696A OPERATION section.) 3. Place the K696 MASTER LOAD Switch to the oN position. 4. Close the customer-supplied transfer control contacts. (Refer to Automatic Load Shed Controller Description on page 2-3 of this manual.) LKG/cr Rev. 7/1/87 Rev. 12/2/93 7-11Avtron Model K696/K696A. Resistive Load Bank Part Number D16133/D16423 NOTE Load step power is derived from the K696 Load Bank. The Load Bank blower must be energized to energize the Load Shed Controller. The Transfer Control contacts should energize if automatic control is necessary and the generator is prepared to accept loading. 5. Operation with K696A as auxiliary: A. Place all K696A KW LOAD step switches to the ON position. B, Start the Load Bank. C. Open the K696A MASTER LOAD Switch. 6. Shutdown. Open the MASTER LOAD Switch, thus allowing the blower to operate to exhaust any accumulated heat. B. Controller Operation of Optional Load Shed system JESSE SISSIES SSSI III I IIIA CAUTION Keep the enclosure access door closed at all times. JE EEE SSIES SISO IIS SII IIIS III ITI To operate the Automatic Load Control system, first follow the Load Bank operation instructions to start the Load Bank. Verify that all load step switches are open (in the OFF position). Automatic control is engaged by closing the Transfer Control Contacts. The load step power is energized by closing the MASTER LOAD Switch. Once engaged, the controller will automatically maintain a load on the generator. LKG/cr Rev. 7/1/87 Rev. 12/2/93 7-12LKG/or Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 An example of the operation of the unit is illustrated in Figure 7-2, The generator load is shown from zero load and zero time. The curve shows the typical operation of the load controller during normal operation and during small overload conditions. The Load Shed Controller increments load every 0.8 second and will decrement load every 0.2 second. If the system decrements four consecutive load steps, the unit will drop out all additional load steps that are active. NOTE The system is protected from a low current control relay fault. If setpoint 1 fails (remains closed) and setpoint 2 energizes (closes), the controller will recognize this situation as a fault condition. While in this condition, the controller will completely shut down in 1.0 second. The low current relay fault condition can be detected by opening the NEMA enclosure and observing indicator 27 on the face of the programmable controller. If indicator 27 is lit, then the low setpoint has failed to operate. To reset the system, the 120 V, 60 Hz control power must be momentarily interrupted. The programmable controller requires a lithium battery to maintain the controller operation status. The lithium battery is behind a snap-in, rectangular cover plate (located on the left side of the programmable controller). The operation program is stored within PROM memory; thus the program cannot be lost, although the controller requires the lithium battery for internal operation. Therefore, the lithium battery status indicator must be routinely checked. The status indicator (when lit) indicates low battery voltage. Rev. 7/1/87 Rev. 12/2/93 7-13Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 LOAD avrowrte OAD SHED conraoutr Log} oxy curs69 FIGURE 7-1. a8 Lop KW) oun Loan fou oo i TIME (SEC) FIGURE 7-2. LKG/or Rev. 7/1/87 Rev. 6/22/92 Rev: 12/2/93 7-14Avtron Model K696/K696A, Resistive Load Bank Part Number D16133/D16423 Option 17 Setpoint Adjustments Before the setpoint relays can be adjusted, the operator must determine the maximum load the controller should maintain (generally 60% to 70% of the total generator KVA). The maximum value is the high setpoint (K11), and the minimum is the low setpoint (K10). The difference between the high and low setpoints is the operation window. To determine the "operation window," two points must be understood. (See Figure 7-2.) A. There is a 5% hysteresis of the total current transformer ratio; thus the operation window must be greater than 5% of the current transformer ratio. Example: C.T. Tap = 2,000 to 5 Minimum operation window = 2,000 X 0.05 = 100 Amps B. The minimum operation window must be at least two times greater than the minimum resolution of the Load Bank. Example: Load Bank minimum resolution 10 KW Minimum system resolution = 2X 10 KW = 20 Kw Once the high and low setpoints are determined, calculate the line current. LINE CURRENT CALCULATION: y = amp (Li = Amp (Line) Volts (,1) SECONDARY CURRENT CALCULATION: 2) Choose the next higher appropriate current tap on the current transformer. Calculate the SECONDARY transformer current. LKG/cr Rev. 7/1/87 Rev. 12/2/93 7-15Avtron Model K696/K696A, Resistive Load Bank Part Number D16133/D16423 ‘The current transformer taps available are defined below: REQUIRED ¢.T. RATIO TAP 300:5 x3-K4 500:5 X4-X5 800:5 X3-X5 1000:5 x1-x2 1200:5 X2-x3 1500:5 x2-K4 2000:5 X2-X5 2200:5 x1-x3 2500:5 x1-x4 3000:5 X1-X5 Amps (Secondary) = (AMPS X 5)/C.T. (Tap: ‘The setpoint relays are now ready to be set. Example 1: Calculate high and low setpoint. 1) Generator Rating: 800 KVA @ 480 VAC, 962 Amps 2) ¢.T. Ratio = 1,000 to 5 3) “Operating Window" = 2 Min. Load steps (20 KW} 4) Setpoint Values (upper approx. 70% of F.L.) a) High setpoint = 800 x 0.7 = 560 KW 560 KW @ 480 V = 673 Amps b) Low Setpoint = High Setpoint - operating Window Low setpoint = 560 - 20 540 KW current at low setpoint = 540 x 577/480 = 649 Amps (Line) LKG/cr Rev. 7/1/87 Rev. 12/2/93 7-16Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Check for a 5% space between the upper and lower setpoints. Hysteresis = 1,000 X 0.05 50 Amps (Line) = High Setpoint current = Low Setpoint current Operating Window = 673 - 649 = 24 Amps (The operating window must be larger than the hysteresis.) 24 < 50 The operating window is less than the 5% hysteresis. A wider window must be selected. “operating window" = 60 KW Recalculate the low setpoint. Low Setpoint = 560 - 60 = 500 KW current at Low Setpoint = 500 x 577/480 = 601 Amps (Line) Check for the 5% space. “Operating window" = 673 - 601 72 Amps 72 > 50 The “operating window" is indeed greater than the 5% hysteresis. The operating window is also greater than the 2X minimum resolution (20 KW). There are three methods of field adjusting the trip point of the current sensing relays (K10 and K11) Part Number 351590: Method 1 - Using generator load power Method 2 - Using a separate (0-5 Amp) current source without the current transformer Method 3 - Rough adjustment LKG/cr Rev. 7/1/87 Rev. 12/2/93Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 A. METHOD 1. Using the Actual Generator Load Power ‘This method uses the load current to set the setpoint relays. 1. Apply 120 VAC, 60 Hz control power to terminals TB11(22) (high line), TB11(23) (neutral), and TB11(24) (ground). JESSIE EHS SSE SSS ISIS III III WARNING There is lethal high voltage present within the controller enclosure; care must be taken when proceeding from this point. JESSE SESS SSSI ISS SEI ISTE ISS IIIS 2. Turn the low setpoint sensing relay (K10) adjustment knob, labeled THRESHOLD, down to 0.01%. 3. Energize the system while on line. Refer to the OPERATION instructions in Section Vv. NOTE Always monitor the generator load with external metering so as not to overload the generator. 4, Adjust the generator load until the load equals the desired lower setpoint. The K696 Load Bank can be used manually to achieve the desired load current. NOTE If the Load Bank is used as part of the load, it may be necessary to disconnect TB17 (4, 5, and 6) to disable the controller output power. LKG/er Rev. 7/1/87 Rev. 12/2/93 7-18Avtron Model K696/K696A, Resistive Load Bank Part Number D16133/D16423 NOTE On each setpoint relay, there is an LED indicator. When lit, the relay is energized. Turn the low setpoint relay (K10) knob, labeled THRESHOLD, past the trip point (completely clockwise; LED is off); ‘then turn slowly counterclockwise until the relay trips on (LED is on). 5. Adjust the generator load until the load equals the desired high setpoint. Turn the high setpoint relay (K11) knob, labeled THRESHOLD, past the trip point (completely clockwise; LED ‘is off); then turn counterclockwise until the relay trips on (LED is on). B. METHOD 2. Using a Separate (0-5 Amp) Current Source Without the Current Transformer 1. Disconnect all sources of power to the Control Unit Part Number ¢18495. TEE ODES ISIS ISI ISIS ISI IIIS IAAI WARNING When disconnecting the current transformer, the secondary terminals must be shorted. The secondary of an unshorted current transformer can penetrate several thousand volts. JOISTS IIIT IIIT TAI ITI I II IIA 2. Set relays. a. Apply 120 VAC, 60 Hz control power to terminals TB11(22) (high line), 1B11(23) (neutral), and 1B11(24) (ground). LKG/cr Rev. 7/1/87 Rev. 12/2/93 7-19Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 JESSE ESS SSSI SISSIES IOC IIIT II II IAI III WARNING There is lethal high voltage within the control enclosure. JESS SESE SSE ISSO ISIS ISSO III ISI A I b. Using a controlled current source, apply the lower setpoint current (from secondary —_ current calculation) to controller terminals 29 and 30. ©. Turn the relay knob labeled THRESHOLD past the trip point; then decrease until the relay trips on. a. Repeat steps b. and c. above for the high setpoint relay Kil. From Example 1: 1) Generator Rating: 800 KVA @ 480 VAC, 962 Amps 2) ¢.T. Ratio Selected = 1,000 to 5 3) peration Window" = 60 KW 4) Setpoint Values (upper approx. 70% of F.L.) a) High Setpoint = 673 Amps (Line) b) Low Setpoint = 601 Amps (Line) c) Calculate the current transformer secondary current: Isec. HIGH = 673 X 5/1,000 = 3.37 Amps (Secondary) Isec. LOW = 601 X 5/1,000 = 3.00 Amps (Secondary) a) Inject the controlled current as described above in 2-b, c, and d. LKG/cr Rev. 7/1/87 Rev. 12/2/93 7-20c. METHOD 3 Avtron Model K696/K696A Resistive Load Bank Part Number D16133/D16423 Rough Adjustment. Use the following formula to calculate the percentage c.T. Tap chosen to operate the relays: % Dial Setting = Setpoint/c.T. Tap From Example 1. 1) 2) 3) 4) 5) 6) LKG/er Rev. 7/1/87 Rev. 12/2/93 Generator Rating: 800 KVA @ 480 VAC, 962 Amps ©... Ratio Selected = 1,000 to 5 "operation Window’ 60 KW Setpoint Values a. High setpoint = 560 KW 560 KW @ 480 V = 673 Amps b. Low setpoint = 560 - 60 = 500 KW 500 KW @ 480 V = 601 Amps Calculate % of full load. a. High setpoint = 673/1,000 = .67 b. Low setpoint = 601/1,000 = .60 Set relays. a. Set relay K10 to .67 setting. b. Set relay K11 to .60 setting.1] ESD PRECAUTIONARY GUIDELINES CAUTION Certain circuit card assemblies and their components, typically integrated circuits, may be damaged by seemingly undetectable electrostatic discharge (ESD). Care must be exercised during handling/repair of these items Use electrostatic discharge precautionary procedures. 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. Never slide ESD sensitive items over any surface. 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. “styrofoam is a registered trademark of Dow Chemical.