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Asco 4900 Load Bank User Manual

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4900 Load Bank
User Manual
P/N: 1251794

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  • Page 1 4900 Load Bank User Manual P/N: 1251794...
  • Page 2 ASCO MODEL 4900 OUTDOOR RESISTIVE LOAD BANK Part Number 1251794 2500 kW, 480 VAC, 3 PH, 60 Hz © 2018 ASCO Power Technologies, Inc. April 18, 2018 Cleveland, Ohio...
  • Page 3 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 4: Table Of Contents

    ASCO POWER TECHNOLOGIES, INC. Cleveland, Ohio ASCO MODEL 4900 OUTDOOR RESISTIVE LOAD BANK Part Number 1251794 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 ..................

  • Page 5: 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 6 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 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 7 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Safety Considerations 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...

  • Page 8: Description

    SECTION II DESCRIPTION ASCO Load Bank is an outdoor unit designed to absorb a balanced resistive load of unity power factor, at a specified 3-phase voltage. The total load capability of the K975A Load Bank is 2500 kW at 480 VAC, 3-phase, 60 Hz. The load steps are 50, 50, and (24) at 100 kW.
  • Page 9 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Description ************************************************************* C A U T I O N Voltage must not be connected to the Load Bank resistance elements if the airflow switches have not closed. It is the customer’s responsibility to ensure all load is dropped if an air failure is detected.
  • Page 10 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Description ************************************************************* W A R N I N G Never exceed the rated voltage as this will cause the Load Bank to overheat. Do not apply DC voltages as the contactors do not have arc blowout magnets.

  • Page 11: Installation

    ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Installation SECTION III INSTALLATION BEFORE INSTALLATION Inspect the Load Bank for obvious damage such as broken wires, broken or dented panels, cracked ceramic insulators, or any other component breakage that may have occurred in shipment.
  • Page 12 75% open area. The 36" minimum side clearances shown in Figure 3-1 still apply. Clearance on intake and exhaust can be adjusted only after approval by an authorized ASCO representative. Painted or plated metal chain link fence is the preferred material. All nonmetallic fencing materials are not recommended.
  • Page 13 Figure 3-1. Load Bank Installation Airflow Clearance Requirements ADDITIONAL LOCATION NOTES Do not stack, tier, or layer Load Banks without ASCO approval, as air recirculation will occur. Indoor installations will always require review. Make up air must be by a supplemental air moving device.
  • Page 14 If ducting is mandatory, obtain written approval from ASCO prior to installation. Airflow is also restricted when two or more Load Banks have air inlets positioned close to each other. This competition for cooling air causes a low pressure area, restricting adequate airflow.
  • Page 15 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Installation FAN/BLOWER MOTOR CONNECTION The fan/blower circuit consists of fuses, a motor starter contactor, an overload relay, and the fan motor. The blower input power connections are wired to TB2(1-3) located on the relay panel assembly and are then wired directly to the main Load Bank bus.
  • Page 16 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Installation GROUNDING A permanent ground conductor must be connected to the Load Bank enclosure by an individual ground wire to prevent a potential above ground on the enclosure. There is a ground nut in the Load Bank, located within the control compartment, for this connection.
  • Page 17 14 AWG for control panel to Load Bank lengths of 50 feet or less. For lengths greater than 50 feet, consult ASCO. If a Control Transformer is the source of control power, disconnect the control...
  • Page 18 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Installation C A U T I O N When control power is supplied by a transformer within the Load Bank, it must be disconnected before running this installation checkout procedure. Failure to disconnect the control transformer may damage the Load Bank.
  • Page 19 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Installation This checkout procedure is intended to be a guide to Load Bank installations in general. Special installation considerations not addressed herein may be necessary due to installation site or environment.

  • Page 20: Operation

    ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Operation SECTION IV OPERATION Refer to the Intelligent Handheld Terminal (IHT) Quickstart Guide for operation of the Load Bank. ************************************************************* 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.
  • Page 21 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Operation ************************************************************* W A R N I N G DO NOT touch the exhaust screen during operation. The screen will become hot from the exhausted heat and may cause a serious burn.
  • Page 22 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 23: Maintenance

    ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 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 24 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Maintenance Inspect all cam-lok style connections on both the Load Bank and interconnection cable. Any signs of heat stress dictate a replacement connector. Verify that all cam-lok protective caps are properly secured to unit.
  • Page 25 Maintenance PARTS REPLACEMENT Access to any component is easily made with the removal of the cover panels. Replaceable components are listed in the Replacement Parts List. ASCO maintains an inventory of normally used items. ************************************************************* C A U T I O N When replacing fuses attached to bus bars, tighten wire connection before the fuse is attached to the bus bar.

  • Page 26: Replacement Parts List

    Replacement Parts List SECTION VI 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 27 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Replacement Parts List REPLACEMENT PARTS LIST SCHEMATIC ASCO QTY/ DESCRIPTION REFERENCE UNIT AVTRON MODEL 4900 LOAD BANK, OUTDOOR 4900- 1251794 .SCHEMATIC 1252846 .INSTALLATION, CAMLOK CONNECTORS D41573 J1-9 ..RECEPTACLE, BROWN 315577 J10-18 ..RECEPTACLE, ORANGE...
  • Page 28 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Replacement Parts List SCHEMATIC ASCO QTY/ DESCRIPTION REFERENCE UNIT F16-87 ..FUSE, 150 AMP 324463 CT1,2,3 ..TRANSFORMER, CURRENT, 3200:5 370050 S4,5,6 ..CONTROLLER, TEMP 491017 XS4,5,6 ..SOCKET 358311 ..THERMOCOUPLE A24741 XF210-212 ..FUSEHOLDER...
  • Page 29 ASCO 4900 Outdoor Resistive Load Bank • Part Number 1251794 Replacement Parts List SCHEMATIC ASCO QTY/ DESCRIPTION REFERENCE UNIT .FILTER 432483 .CONTROL PANEL 1252832 DS500,505 ..LAMP, INDICATOR, AMBER AVT-329681 DS501-504 ..LAMP, INDICATOR, RED 329682 S501 ..SWITCH ,KEY-LOCK 362087 K501,502 ..RELAY, 3-POLE, 20A, W/AUX...
  • Page 30 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 31 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 32 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 33: 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 34 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 35 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 36 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 37 6255 Halle Drive Cleveland, Ohio, U.S.A. 44125 Tel: 216-573-7600 loadbanks.ascopower.com The ASCO and ASCO Power Technologies marks are owned by Emerson Electric Co. or its affiliates and utilized herein under license. ©2017 ASCO Power Technologies. All Rights Reserved. ASCO. Innovative Solutions.
  • Page 38 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;...
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  • Page 57 Intelligent Hand-held Terminal (IHT) Technical Reference Manual...
  • Page 59 IHT Technical Reference Manual Version 1.0 - April, 2011 The IHT is manufactured in the UK by: N J FROMENT & COMPANY LIMITED, Easton-on-the-Hill, STAMFORD, PE9 3NP, United Kingdom Tel: +44 (0)1780 480033 Fax: +44 (0)1780 480044 http://www.froment.co.uk/ © 2000-2011, N J Froment and Co Ltd ('The Company'). The Company retains exclusive rights to the intellectual property in any designs, specifications, publications and software described or included herein.
  • Page 60 Table of Contents Introduction An Important Note on Safety IHT Technical Reference The Froment Sigma IHT ................. 2 Connecting the IHT to the Load Bank ............3 Setting the Load Bank Number Sigma Data Cable Testing The IHT Keypad ..................4 The Function Keys The Quadrant Keys The LED Status Lamp...

  • Page 61: Introduction

    Introduction The Froment Intelligent Hand-held Terminal (IHT) provides a very simple to use, direct means of controlling the operation of Froment Sigma controlled load banks whilst simultaneously monitoring the performance of the generator under test. This manual provides a detailed reference to the Froment Intelligent Hand-held Terminal (IHT), including details of its more advanced features.

  • Page 62: An Important Note On Safety

    Introduction An Important Note on Safety All Froment load banks are designed with safety as a high priority, but their operation does present some risks. In common with other test equipment, the safety of all concerned is dependent on the way that the unit is operated.

  • Page 63: Iht Technical Reference

    IHT Technical Reference...

  • Page 64: The Froment Sigma Iht

    IHT Technical Reference The Froment Sigma IHT The Froment Sigma Intelligent Hand-held Terminal (IHT) is one of a number of available user interface options for Sigma controlled Froment load banks. It is a hand-held unit containing a purpose designed microprocessor-based control system for Sigma-equipped load banks.

  • Page 65: Connecting The Iht To The Load Bank

    IHT Technical Reference Connecting the IHT to the Load Bank The IHT connects directly to the load bank's Sigma interface “in” socket using a Sigma data cable which can be up to a kilometre in length. The IHT can connect to and control up to 14 load banks at the same time.

  • Page 66: The Iht Keypad

    IHT Technical Reference The IHT Keypad The IHT keypad contains eight membrane switches and a single LED indicator. The switches provide four function keys (marked F1 to F4) arranged below the LCD screen and a quadrant of four control keys arranged around the LED.

  • Page 67: The Iht Menu Display System

    IHT Technical Reference The IHT Menu Display System The IHT uses a menu display system for initial settings and also during the testing process. The screen provides real-time instrumentation readings, status information and labels for the four function keys (F1 to F4).

  • Page 68: Sigma Status Messages

    IHT Technical Reference Sigma Status Messages A message window is used to display status information and other messages from the load banks. Figure 1-5 Typical Sigma status message Press F2 (HELP) to see further information relating to the specific message. Figure 1-6 Sigma status message help screen The following table lists the messages that may appear: Error Message...
  • Page 69 IHT Technical Reference Error Message Description Possible Causes Fan Tripped On LoadBank nn Fan Overload signal not present • Fan Circuit Breaker or Overload when fan run output energised. Tripped. Check fan is not obstructed and that it is free to rotate. Then reset Trip or Circuit Breaker.

  • Page 70: Using The Sigma Iht

    IHT Technical Reference Using the Sigma IHT The IHT’s on screen menu system is designed to be simple and intuitive, and the best way to learn it is to use it. The quick-start demonstration on the following page shows how you can carry out a full manual generator test with only a few key presses.

  • Page 71: Iht Quick Start

    IHT Technical Reference IHT Quick Start Press the “Start” button on the load bank control panel . Press F1 (CHECK) to go to the Supply on Test Settings Page. CHECK If the Supply on Test settings are correct, press F4 (TEST) to start testing the supply. TEST Settings not correct? Press F2 (NEW).

  • Page 72: Using The Settings Pages

    IHT Technical Reference Using the Settings Pages Before testing begins it is important to set up the IHT so that it is able to control the load bank correctly. The IHT provides two Settings pages for this purpose. The first of Note: You can use the these is used to set the details of the supply on test.

  • Page 73: Settings 1-2 - Supply On Test

    IHT Technical Reference Settings 1-2 - Supply On Test The Settings 1-2 page is used to set up the details of the supply on test and it is important to make sure that these are set correctly before applying any load. The load bank uses the values set here to limit the load that is applied.

  • Page 74: Checking The Rating Values

    IHT Technical Reference Checking the rating values The voltage, frequency and number of phases set are the Sigma controller's best estimate of the supply rating, based on the measurements it makes. However, if the generator is uncalibrated, non- standard, or is underperforming in some way, then these values may need adjustment before testing can begin.
  • Page 75 IHT Technical Reference To edit the supply rating values: 1. On entering the Supply on Test Edit page the kVA value will be highlighted, ready for editing.. kVA value highlighted for editing 2. Press F1 (PRESET) to step through a series of pre-defined Note: The maximum values for kVA.

  • Page 76: Settings 2-2 - Load Bank

    IHT Technical Reference Settings 2-2 - Load Bank The Load Bank settings page shows the number and total maximum capacity of all the load banks under control of the IHT. It also provides access to the Options pages, which allow a number of aspects of the load bank’s operation to be modified.

  • Page 77: The Options Pages

    IHT Technical Reference The Options Pages There are five options pages which will allow you to adjust various aspects of the load bank's operation. To reach the first of the Options pages press F3 (OPTIONS) from the Settings 2-2 - Load Bank page. OPTIONS PAGE PAGE...

  • Page 78: Options 1-5 - Control

    IHT Technical Reference Options 1-5 - Control: Figure 1-14 The Options 1-5 page. The control options change the IHT’s load control behaviour. Ramp Down on Reject. Protects the supply on test from damage by removing the load gradually when the O key is pressed. When this option is selected the load will ramp down in ten equal steps over a period of 12 seconds.

  • Page 79: Options 3-5 - Loading

    IHT Technical Reference Options 3-5 - Loading: Figure 1-16 The Options 3-5 page. The loading options are important for ensuring that the correct load is applied and the automatic stall protection feature can prevent generator damage. Unless you have a good reason for doing otherwise we recommend that these three options are remain selected.

  • Page 80: Options 5-5 - Serial Port

    IHT Technical Reference load bank size and minimum load step. For example it could be in tenths of kW or whole kW or tens of kW. On this page you can select one more or one less resolution then the default selection by setting these to “Fine”...

  • Page 81: The Test Pages

    IHT Technical Reference The Test Pages There are four Test pages which allow you to select and accept load, and to monitor the test as it proceeds. To reach the first of them, press F4 (TEST) from either of the Settings Pages TEST SETTINGS PAGE...

  • Page 82: Test 1-4: Avr And Governor Adjustment Setup

    IHT Technical Reference Test 1-4: AVR and Governor Adjustment Setup Real-time voltage and frequency display Apparent power Power factor Actual power Figure 1-20 IHT Test 1-4 page This first Test page shows the real-time Voltage and Frequency of the supply as it is tested, with the calculated instrumentation powers in the left hand column.

  • Page 83: Test 3-4: Full Load Testing (Phase To Neutral)

    IHT Technical Reference Test 3-4: Full Load Testing (Phase to Neutral) RMS Current Real-time voltage RMS phase to neutral voltages and frequency display Apparent power Power factor Actual power Maximums and minimums since the last load change Figure 1-22 IHT Test 3-4 page Test 3-4 displays true rms three-phase measurements of the phase to neutral voltage (VP), and current (A) in the central column of the display.

  • Page 84: Assessing Supply Performance

    IHT Technical Reference Assessing Supply Performance The voltage and frequency maximum and minimums and transient response graphs can be used to assess the performance of the supply on test. ISO8528 defines three classes of generator performance (G1, G2 and G3) and specifies deviations and recovery times for each class as follows:.

  • Page 85: The Test Screen Status Bar

    IHT Technical Reference The Test Screen Status Bar The status bar provides important information during testing. The information shown varies depending on the test mode (manual or automatic) as shown in Figure 1-24. Current load selected (%, kW, kVA or cos ) θ Page Title Test Mode Auto Test...

  • Page 86: Manual Test Mode

    IHT Technical Reference Manual Test Mode The IHT’s manual test mode provides direct, real time control over the load bank’s operation. The following assumes that: • The supply on test and load bank settings have been made as described earlier in this chapter. •...

  • Page 87: Setting The Load Values

    IHT Technical Reference Setting the Load Values By default, the IHT allows you to set the load as a percentage of the supply on test from 0% up to a maximum of 120%. The actual load applied is based on the supply on test and load bank settings made on the Setting 1-2 and Settings 2-2 Pages.
  • Page 88 IHT Technical Reference To set the load: Begin by setting the value of the load that is to be applied by using the IHT’s + and - keys. The load resolution is set according to the load bank size, and the minimum load step (typically 1kW). The load resolution can be adjusted in the OPTIONS pages if you require finer load steps.

  • Page 89: Applying The Load

    IHT Technical Reference Applying the load 1. Press I to apply the load selected. The IHT will calculate the Note: If load correction is turned on, then the load correct load to apply and distribute this between all the applied will be adjusted connected load banks.

  • Page 90: Rejecting The Load

    IHT Technical Reference Rejecting the load Press O to reject the load and start the fan delay. The load bank should be allowed to run on for a few minutes until the fan delay has completed. This will allow the equipment to cool. If the Ramp Down on Reject function is enabled (see page 1 - 16) the Warning! Ensure the power source under test is fully...

  • Page 91: Automatic Test Mode

    IHT Technical Reference Automatic Test Mode The IHT’s automatic load control function will allow you to set up a pre-programmed sequence of up to 16 different loads of up to 24 hours duration. Once configured the test sequence can then be repeated as often as is required.

  • Page 92: Editing The Automatic Test Sequence

    IHT Technical Reference Editing the Automatic Test Sequence Press F2 (AUTO) from any of the Manual test pages to switch to auto mode. Then press F3 (EDIT TEST) to set up the test sequence stages. Percentage load Power factor Test sequence stage number Duration (hh:mm:ss) Figure 1-27 IHT automatic test sequence edit...
  • Page 93 IHT Technical Reference To edit the Test sequence: 1. Press F1 (NEXT) to choose the sequence stage to be programmed. 2. Press F3 (SELECT) to choose the value to be changed. 3. Use the + and - keys to adjust the value. 4.

  • Page 94: Running The Automatic Sequence

    IHT Technical Reference Running the Automatic Sequence To run the test sequence press the I key. The green LED on the IHT will begin to flash to indicate that the test sequence is running and the status bar will indicate the current stage of the test. Figure 1-29 Automatic test sequence display •...
  • Page 96 www.froment.co.uk...

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