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Asco 4820 User Manual

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4820 Load Bank
User Manual
P/N: D29650-14, 3-17

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Summary of Contents for Asco 4820

  • Page 1 4820 Load Bank User Manual P/N: D29650-14, 3-17...
  • Page 3 ASCO MODEL K875A OUTDOOR LOAD BANK © 2016 ASCO Power Technologies, Inc. January 6, 2000 Cleveland, Ohio Rev. July 7, 2016...
  • Page 4 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;...

  • Page 5: Table Of Contents

    ASCO POWER TECHNOLOGIES, INC. Cleveland, Ohio ASCO MODEL K875A OUTDOOR LOAD BANK TABLE OF CONTENTS Page Section I SAFETY CONSIDERATIONS ..............1-1 Section II DESCRIPTION ..................2-1 Section III INSTALLATION ..................3-1 Section IV OPERATION ..................... 4-1 Section V MAINTENANCE ..................5-1 Section VI OPTIONS ....................
  • Page 6 ASCO Model K875A Outdoor Load Bank Table of Contents DRAWINGS Part No. Volts Load Steps O/L Dwg. Schem. Interconn. 2500 50, 50, 100, 100, 200, 500, 500, K875AD28042-4 SB2770 D30049 D30349 500, 500 3000 50, 50, 100, 100, 200, 500, 500,...
  • Page 7 ASCO Model K875A Outdoor Load Bank Table of Contents DRAWINGS Part No. No. of Control Panel O/L Dwg., Resistor Assemblies Stacks Control Panel K875AD28042-4 Three D29743-17 SB2950 D27553-1, D27555-1 K875AD28042-5 Three D29743-18 SB2950 D27555-1, D28438-2 K875AD28042-6 Three D31297 D28438-2, D27555-1...
  • Page 8 ASCO Model 4800 Load Bank Options TABLE OF CONTENTS (Cont.) OPTIONS - Refer to Section VI (K875A OPTIONS LIST) of this manual. The following drawings apply to the various options. Only drawings for the options provided have been included in this manual. Not all options can be installed in the same unit.

  • Page 9: Section I

    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.
  • Page 10 ASCO Model K875A Outdoor Load Bank Safety Considerations 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.
  • Page 11 ASCO Model K875A Outdoor Load Bank Safety Considerations The power ON/OFF switch will disconnect both load steps and the fan motor. The Generator Emergency "OFF" switch should be located near the load system. An approved electrical fire extinguisher should be on hand at all times.

  • Page 12: Description

    SECTION II DESCRIPTION The ASCO Model K875A Resistive Load Bank is a vertical airflow unit designed to provide 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 K875A Load Bank are listed in the Table of Contents.
  • Page 13 ASCO Model K875A Outdoor Load Bank Description The control panel contains a POWER ON-OFF switch with a CONTROL POWER light, a BLOWER POWER light, blower power START and STOP pushbutton switches, an AIR FAILURE light, a Load Bank OVER TEMP light, a MASTER LOAD ON-OFF switch, a VOLTAGE SELECT switch for Load Banks with dual voltage capability, and individual KW LOAD STEP switches.

  • Page 14: Installation

    USING EXTREME CAUTION AS POTENTIALLY LETHAL VOLTAGES AND DANGEROUS ROTATING COMPONENTS ARE PRESENT. IF ASSISTANCE IS REQUIRED, ASCO CAN PROVIDE START UP SERVICE AT A NOMINAL CHARGE. ASCO ALSO WILL PROVIDE TELEPHONE ASSISTANCE IF REQUIRED BY CALLING (216) 573-7600. *******************************************************...
  • Page 15 C A U T I O N Control wiring must be a minimum of 14 AWG for wire runs under 50 feet. Consult ASCO factory for wire sizing when wire run exceeds 50 feet. 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.
  • Page 16 ASCO Model K875A Outdoor Load Bank Installation Energize the source of control power only: A. Check the control voltage and confirm it is within 10% of the required voltage. ****************************************************** W A R N I N G Control power is present on terminal block in steps 4 through 6.
  • Page 17 ASCO Model K875A Outdoor Load Bank Installation Run ohmmeter wiring outside of the unit and temporarily install access panel. Reapply fan/blower voltage and control power. Start fan(s), allowing them to come up to speed, approximately 10 seconds. The normally open contacts should close. If more than one fan/blower, all must be operating before continuing.
  • Page 18 ASCO Model K875A Outdoor Load Bank Installation LOCATION 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.
  • Page 19 Load Banks mounted into a channel, trough, hollow, well, pit, surrounded completely by a parapet wall or backed into a full corner require special considerations even if the other conditions are met. In these cases, provide detailed site layout drawings to ASCO for inspection and comments.
  • Page 20 ASCO Model K875A Outdoor Load Bank Installation SPECIAL NOTE FOR THREE STACK LOAD BANKS (P/N D28042-) These higher capacity three stack (bays/modules) units require special airflow consideration. The center stack must pull in cool intake air from the back and bottom of the stack. Do NOT block or restrict the back or lower (base) screened intake areas.
  • Page 21 The main load bus bar in stack one or three will not carry the high current required to distribute power to resistor sections if more than 20% of load conductors are in these stacks. Contact ASCO if there are special installation requirements or if the above cannot be followed.
  • Page 22 ASCO Model K875A Outdoor Load Bank Installation LOAD SHED CONTROLLER (Optional) Wire the current transformer into the control circuitry as shown on the provided schematic. ******************************************************* W A R N I N G Always put a short or shunt across the current transformers when servicing the Load Bank.

  • Page 23: Operation

    ASCO Model K875A Outdoor Load Bank Operation SECTION IV OPERATION ******************************************************* W A R N I N G DO NOT touch the top exhaust hood/duct or cover panel during operation. The hood will become hot from the exhausted heat and...
  • Page 24 ASCO Model K875A Outdoor Load Bank Operation ******************************************************** C A U T I O N DO NOT operate the Load Bank over the rated voltage as this will cause catastrophic failure in the Load Bank. ******************************************************** Place the AUTO/MANUAL selector switch to the MANUAL position (Load Banks equipped with Load Shed option only).
  • Page 25 ASCO Model K875A Outdoor Load Bank Operation The resistive loading is selected by toggle switches, using any one or combination of the 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.
  • Page 26 ASCO Model K875A Outdoor Load Bank Operation Place AUTO/MANUAL switch to AUTO. Start the generator under test. 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 generator lessens, the Load Shed Controller will automatically apply load steps until the overall generator load exceeds the minimum setpoint.
  • Page 27 ASCO Model K875A Outdoor Load Bank Operation SYSTEM SETPOINT CALCULATION (Example) System Ratings Generator Resistive Rating = 2000 kW @ 480 VAC, 3 PH. Load Bank Shedder Capacity: 1000 kW @ 480 VAC, 3 PH. Load Steps: 50, 50, 100, 100, 200, and 500 kW Actual Generator Output = Load Bank Load + Building Load.
  • Page 28 ASCO Model K875A Outdoor Load Bank Operation Secondary Current Calculation 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: I(sense) = I(line)/ CT Ratio.
  • Page 29 ASCO Model K875A Outdoor Load Bank Operation 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:...
  • Page 30 ASCO Model K875A Outdoor Load Bank Operation Method 2 - Rough Adjustment NOTE Adjustable potentiometers on the controller board have a % scale reference that directly relates to the current, (Isense), delivered from the current transformer used to monitor the building load. Refer to Secondary Current Calculation, in Trip Point Section of this manual.
  • Page 31 ESD PRECAUTIONARY GUIDELINES C A U T I O N 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.

  • Page 32: Maintenance

    ASCO Model K875A Outdoor Load Bank Maintenance 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.
  • Page 33 ASCO Model K875A Outdoor Load Bank Maintenance 10-minute intervals until exhaust is clear. Do not apply continuous full load until both intake and exhaust openings are clear. Verify that the airflow is in the proper direction. Assure that there is no recirculation of the exhaust air through the Load Bank.

  • Page 34: Options

    ASCO Model 4800 Load Bank Options SECTION VI K875A OPTIONS LIST These options are available for ASCO Model K875A Load Banks. Not all options can be installed in the same unit. Installed options are marked on the identification tag. Option Drawing No.
  • Page 35 ASCO Model 4800 Load Bank Options Option Drawing No. Option Description A37255 Bus Bar, Customer Connection, Replacement A37594 Local Control/Metering Unit, Mounted (Right Side) B33795-1 Elevating Stand (One Bay)
  • Page 36 Options Parts List REPLACEMENT PARTS LIST INTRODUCTION The parts list in this section contains the description, quantity required, and ASCO part numbers for each listed part. The list also includes schematic reference designators to facilitate troubleshooting. NOTE Every effort has been made to ensure the accuracy of this information.
  • Page 37 ASCO Model 4800 Load Bank Options Parts List REPLACEMENT PARTS LIST SCHEMATIC ASCO QTY/ DESCRIPTION REFERENCE UNIT OPTION #20: CONTROL TRANSFORMER D27683-7 XF210-212 .FUSEBLOCK 3 POLE 324496 F212 .FUSE, CARTRIDGE, 9 AMP, 600V, 324431 TIME DELAY, CLASS RK-5 F210,211 .FUSE, 5 AMP, 600V, TIME DELAY CLASS RK-5 324394 .TRANSF, CONT: 850 VA, 380/440/550 VAC,...
  • Page 38 ASCO Model 4800 Load Bank Options Parts List SCHEMATIC AVTRON QTY/ DESCRIPTION REFERENCE UNIT OPTION #24: LOAD CONTROLLER D27685-3 K50,51 .RELAY, 3PDT, 120 VAC COIL 351060 XK50,51 .RELAY SOCKET DIN RAIL MOUNT 358280 XK50,51 .HOLDDOWN SPRING 467550 A101 .PRINTED CIRCUIT BOARD ASSY A22829 ..SCHEMATIC...

  • Page 39: Replacement Parts List

    Replacement Parts List SECTION VII REPLACEMENT PARTS LIST INTRODUCTION The parts list in this section contains the description, quantity required, and ASCO part numbers for each listed part. The list also includes schematic reference designators to facilitate parts identification. NOTE Every effort has been made to ensure the accuracy of this information.
  • Page 40 Avtron Model K875A Outdoor Load Bank Replacement Parts List FEDERAL CODE NUMBER LIST 01121 Allen-Bradley Co. 30487 Huntington Electric Inc. 1201 S. Second St. 550 Condit St. Milwaukee, WI 53204 P.O. Box 366 Huntington, IN 46750-2506 02295 General Electric Co. Bloomington, IL 54407 Power-One DC Power Supplies...
  • Page 44 APPENDIX LOAD BANK TROUBLESHOOTING GUIDE NOTE Servicing should always be done only by trained, qualified service technicians. ******************************************************** W A R N I N G Be sure that all sources of power to the Load Bank are disconnected before servicing. ******************************************************** PROBLEM POSSIBLE CAUSES/REMEDIES...
  • Page 45 Appendix Load Bank Troubleshooting Guide PROBLEM POSSIBLE CAUSES/REMEDIES 2. Blower motor does not a. Main switch or circuit breaker is not closed. operate. b. Power is not connected to Load Bank blower circuit. c. External power source is inadequate. d. Motor fuses are blown. (Check and replace as required.) * e.
  • Page 46 Appendix Load Bank Troubleshooting Guide PROBLEM POSSIBLE CAUSES/REMEDIES 5. Load step(s) cannot be a. A blower failure exists. (See problem 2.) energized. b. MASTER LOAD Switch is inoperative. c. Control power is inadequate. d. Fuse is blown in Load Bank control circuit or individual branch circuit load fuse (if so equipped) is blown.

  • Page 47: Appendix Load Bank Troubleshooting Guide

    Appendix Load Bank Troubleshooting Guide PROBLEM POSSIBLE CAUSES/REMEDIES 8. Disconnect Switch a. Fuses are undersized. * fuses are blown. b. A short circuit exists in the blower or control circuit. * *When checking fuses for continuity, be sure to remove all fuses from clips (in fuseblock or Disconnect Switch).
  • Page 48 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;...
  • Page 49 Drawings, Descriptions: ASCO warrants for the period and on the terms of the Warranty set forth herein that the Avtron product will conform to the descriptions contained in the certified drawings, if any, applicable thereto, to ASCO's final invoices, and to applicable Avtron product brochures and manuals current as of the date of product shipment (“Descriptions”).
  • Page 50 Warranty Performance of Component Manufacturers: It is ASCO’s practice, consistent with its desire to remedy Warranty defects in the most prompt and effective manner possible, to cooperate with and utilize the services of component manufacturers and their authorized representatives in the performance of work to correct defects in the product components.
  • Page 51 ASCO Power Technologies — Avtron Load Bank 6255 Halle Drive Cleveland, Ohio, U.S.A. 44125 Tel: 216-573-7600 www.ascopower.com ASCO. Innovative Solutions. ASCO Power Technologies and the ASCO logo are trademarks and service marks of ASCO Power Technologies. ©2016 ASCO Power Technologies. All rights reserved. ASCO. Innovative Solutions.

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K875a

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