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.

WARRANTY

The last page of this document contains an express limited warranty. The provisions of this warranty cover any and all rights extended to holders of Avtron Load Bank branded products and systems by ASCO Power Technologies, LP.

TABLE OF CONTENTS

1. SAFETY CONSIDERATIONS
2. DESCRIPTION
3. INSTALLATION
4. OPERATION (Individual Unit)
5. NETWORK OPERATION (Using the Hand-Held Controller)
6. MAINTENANCE
7. REPLACEMENT PARTS LIST
8. APPENDIX - Load Bank Troubleshooting Guide

DRAWINGS

• 1098042: Outline Drawing, Load Bank
• 1097996: Schematic
• B28571: Cable Set - 20 Ft. (Option 1)

VENDOR DATA

• Cooper Crouse-Hinds Molded Products: Cam-lok® Assembly Instructions, E-Z1016 & E-Z1018 IM1012

SUPPLEMENTARY DATA

• Sigma Hand-Held Quick Start Guide
• Digital Toggle Switch™ Operation Sigma LT Quick Start Guide

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 ASCO unit is safety checked for opens and shorts, and the insulation is high potential tested to ensure safe operation. All fuses, safety interlocks, and related safety equipment have been proven reliable as part of the testing procedure of each unit.

As part of your safety program, an initial inspection after receiving the unit(s) and periodic preventive maintenance and safety inspections should be conducted to ensure the reliability and safety built into your ASCO equipment.

The Load Bank is an industrial test unit designed to be used indoors. However, because the function of the Load Bank is to dissipate electrical energy, there are inherent dangers to the operator and to the equipment. These dangers shall be outlined in this section.

Electrical energy is transformed into heat by the resistor elements. The heat may be removed from the Load Bank by airflow through the resistor elements. If there are any restrictions or stoppage of airflow, the Load Bank may overheat and may even start a fire. The following recommendations are made:

1. Read the manual before operating the Load Bank.
2. Run an approved ground wire from the Load Bank ground lug located on the customer connection panel to the frame of the power source. Run an approved ground wire from the power source frame to a good earth ground. Size ground wire in accordance with National Electrical Code and any local codes.
3. Do not bypass the temperature sensing switches to prevent nuisance tripping. The switches will drop out the load if insufficient cooling air is reaching the elements.

WARNING

Personal injury from electrical shock may result if all sources of power are not disconnected before servicing. Maintenance work must be done only by qualified personnel.

6. Maintenance should be performed with no power on the unit. The majority of troubleshooting can be performed with an ohmmeter. There are multiple sources of power input to the Load Bank. Ensure each is disconnected.
7. Venting the heated air from the exhaust toward overhead cables, sprinkler systems, or into a room with insufficient volume or "Make-Up" air, is a potential hazard. The Load Bank should be used in a cool, well-ventilated area.
8. Allow cool room air to pass into the unit to cool the elements. Do not allow the unit to be placed where hot exhaust air can recirculate back through the unit causing a constant rise in cooling air temperature.
9. After running a load test, residual heat will be automatically 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 would cause Load Bank overheating. If an object enters the screens, it will cause damage to the resistor elements, possibly shorting them and causing shock and fire hazards.

Emergency Shutdown Procedure

A. In an emergency, shut down the MASTER LOAD switch, then the power source. The MASTER LOAD switch will allow disconnection of all load steps and still allow for motor to run, cooling any heated elements.

B. The POWER ON/OFF switch will disconnect both load steps and fan motor. The power source EMERGENCY OFF switch should be located near the load system.

13. An approved electrical fire extinguisher should be on hand at all times.
14. 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.

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

SECTION II

DESCRIPTION

The ASCO 2705 Load Bank is designed for electrically loading and testing power sources. The Load Bank is designed for production line and job site use.

The loading capability of the Load Bank depends on voltage. At 480 volts, 3-phase, 60 Hz, the total load is 100 kW with load steps of 5, 5, 10, 10, 10, 20, 20 20 kW. At 240 volts, 3-phase, 60 Hz, the total loading capability is 93.75 kW also with load steps of 5, 5, 10, 10, 10, 20, 20 20 kW. Using the Digital Toggle Switches ™ on the control panel, any combination of the available load steps may be selected to achieve a desired load.

A 120V, single phase, 60 Hz, 5 amp power source is required for the fan and control circuits. This power is derived from the control power receptacle located on the side of the unit.

GENERAL OVERVIEW

Diagram Description:

• An array of load elements grouped in small steps that are individually activated by switchgear to allow the load applied to the generator to be precisely controlled.
• A fan and duct forced air system which ensures that the heat generated during testing is vented safely to atmosphere.
• Fuses and safety interlocks that ensure that the test can be shut down in a controlled fashion if any problems occur.
• Automatic precision control of the test and allow the results to be displayed with better than 0.5% accuracy.

CONTROL PANEL

The loads described above are controlled from a single control panel. The Sigma LT Digital Toggle Switches ™ (DTS™) are standard in all Sigma LT load banks. The control panel is for local control only and instrumentation is displayed on the seven segment digital display. The control panel is integrally mounted on the front of the Load Bank. The arrangement of the control panel is shown below:

Control Panel Functions:

• Control Power: The control power switch is used to activate/deactivate the load bank for operation. It does not remove 120 VAC internally within the load bank.
• Voltage Select: The voltage select switch is used to select between 240 and 480V when operating in Local Mode (without a hand held controller connected).
• Load Select: Press any combination of the load select switches to choose the required load in kW. For example, if 30kW is required, press 5kW, 5kW, 10kW and 10kW. Then press master load on. Alternatively if master load is already on there will be a 1 second delay; then load will be applied automatically. The delay permits the pre-selection of a load which is not possible with standard toggle switch load banks.
• Mode: Press mode to cycle through the different instrumentation displays: 3 phase Voltage and Currents or Voltage, Frequency and Power. Press and hold for 10 seconds to select single phase (1ph A-C or 1ph AB-C) and three phase (3ph ABC) connections. Cycle to the required settings and leave for 5 seconds to select.
• Master Load: Master load applies any load selected when turned on and rejects all load when turned off.
• Local/Remote Control Selection: Switch between local and remote control. Remote control mode is only available when a Sigma LT hand-held controller is connected.
• Error Warning Lamp: The LED warning lamp will illuminate if an error occurs, the error type will then appear on the metering display.

ENCLOSURE

The outside dimensions of the Load Bank are shown on the outline drawing. The Load Bank is fabricated

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