Asco 4820, User Manual

Page 1: ...P N D29650 14 3 17 4820 Load Bank User Manual ...

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Page 3: ...ASCO MODEL K875A OUTDOOR LOAD BANK 2016 ASCO Power Technologies Inc January 6 2000 Cleveland Ohio Rev July 7 2016 ...

Page 4: ... 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 limi...

Page 5: ...ad Bank Troubleshooting Guide DRAWINGS See tables on the following two pages See column 1 for the part number purchased Drawings are provided at the end of this manual based on the specific Load Bank purchased OPTION DRAWING S AND INSTRUCTIONS Option drawings are provided for options purchased A list of option drawings begins after page iii Instruction Manual Part Number D29421 X Manual is provide...

Page 6: ...2646 K875AD29461 1 750 240 480 5 10 10 25 50 50 100 100 200 200 SB2793 2 D29826 D29827 K875AD29461 2 1000 240 480 50 50 100 100 200 500 SB2793 2 D29828 D29829 K875AD29461 3 750 240 480 50 100 200 200 200 SB2793 2 D29822 D29823 K875AD29461 4 1000 240 480 5 10 10 25 50 100 100 200 500 SB2793 2 D29824 D29825 K875AD29461 5 1000 700 480 240 5 10 10 25 50 100 200 200 400 5 10 10 25 50 100 100 200 200 SB...

Page 7: ... K875AD29461 2 One D29743 10 SB2950 D27553 2 D27555 2 D29589 1 K875AD29461 3 One D29743 3 SB2950 D27553 2 D27555 2 D29645 D29851 K875AD29461 4 One D29743 4 SB2950 D27552 2 D27553 2 D27555 2 K875AD29461 5 One D29743 22 SB2950 D27552 2 D27553 2 D27555 2 D27555 4 K875AD29650 3 Two D29743 12 SB2950 D27552 1 D27553 1 D27554 1 D27555 1 K875AD29650 4 Two D29743 11 SB2950 D27553 1 D27555 1 K875AD29650 5 T...

Page 8: ...ion 208 115V D37723 3 64 Digital Power Metering Option DW Style V A F KW KVAR PF KVA CT Ratio 1500 5 D37723 4 65 Digital Power Metering Option DW Style V A F KW KVAR PF KVA CT Ratio 2000 5 A32404 71 Control Unit Mounted Front A32573 1 73 Gravity Hood Replacement Single Stack A32573 2 74 Gravity Hood Replacement Two Stack A33333 1 76 Hinged Access Panel Single Stack A34920 1 80 Aluminum Hood Replac...

Page 9: ...uilt into your ASCO equipment The Model K875A Load Bank is an industrial test unit designed to be used outdoors safely with an exhaust hood The unit should not be installed indoors However because the function of the Load Bank is to dissipate electrical energy there are inherent dangers to operators and equipment These dangers are outlined in this section Electrical energy is transformed into heat...

Page 10: ...rd The Load Banks should be used in a cool well ventilated area This Load Bank is specifically designed for outdoor use with an exhaust hood Load Banks are not intended for indoor operation 9 After running a load test residual heat may be removed from the Load Bank by allowing the fans to operate for a few minutes after load is removed This procedure is not required for maintaining Load Bank integ...

Page 11: ...ectrical fire extinguisher should be on hand at all times 15 It is the responsibility of the customer to take diligent care in installing the Load Bank The National Electrical Code NEC sound local electrical and safety codes and the Occupational Safety and Health Act OSHA should be followed when installing the equipment to reduce hazards to persons and property 16 Read and heed all WARNING and CAU...

Page 12: ... motor is controlled by a motor starter contactor Overcurrent protection is provided for the motor by three fuses and an overload relay The overload relay assembly does not have an automatic reset provision and must be reset manually When required the Load Bank may be furnished with blower motor s sized to operate at voltages different from standard The fan free air delivery is nominally 20 000 CF...

Page 13: ...n It can be supplied mounted directly to the Load Bank or loose for mounting in a remote location The K875A Load Bank is fabricated using heavy gauge aluminized sheet steel making a rigid structure Mounted within the structure are the load element resistor assemblies load contactors and the cooling fan s blower s The resistive elements are porcupine type fully supported along their length Mounted ...

Page 14: ...pply W A R N I N G THE FOLLOWING TESTS ARE TO BE ACCOMPLISHED BY A QUALIFIED ELECTRICIAN OR TECHNICIAN 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 1 Verify the Load Bank placement meets...

Page 15: ...ck the mechanical integrity of all customer supplied interconnection wiring A Ensure lugs are properly crimped B Ensure terminations are properly torqued C Verify proper phase to phase clearance on main bus bars load wiring and mounting hardware 3 Utilize system schematics to ohm out customer supplied interconnection control wiring and safety circuits A If control wiring is all the same color ohm ...

Page 16: ...itation is observed locate the cause of the voltage drop causing the problem 6 While the load relays are energized remove the jumper across the air switch All the load contactors should drop Leave the jumper off the air switch es 7 Apply the rated fan voltage Start fans blowers and verify that air is exiting the resistor assembly end top of exhaust hood The air switches must be checked and or fiel...

Page 17: ...ce factory wiring Replace access panel This checkout procedure is intended to be a guide to Load Bank installations in general Special installation considerations not addressed herein may be necessary due to installation site or environment Any questions or concerns regarding Load Bank installation should be directed to field service at 216 573 7600 W A R N I N G It is vitally important to install...

Page 18: ...e exhaust air may exceed 400 F above ambient 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 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 ...

Page 19: ...ull 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 2 Locations which have full or partial perimeter fence necessitate a review The fencing material should have at least 75 open area The minimum clearances still apply Overhead fencing or grating is not recommended 3 Do not install Lo...

Page 20: ...bus using the appropriate control transformer assembly ENCLOSURE HEATERS A 100 watt strip heater is located inside the Load Bank enclosure one per stack on the control blower panel It is controlled by a temperature switch and is factory calibrated to 50 F The heater is used to control condensation problems This heater should also be energized if the Load Bank is stored outdoors prior to installati...

Page 21: ...n 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 For three stack designs all three stacks have a sheet metal cover at base Remove this cover and punch machine cut clearance holes a...

Page 22: ... transformers when servicing the Load Bank Primary current flowing through an unshunted current transformer will destroy the transformer with possible harm to personnel THEORY OF OPERATION The automatic operation circuitry of the Load Bank allows the generator to maintain a minimum percentage of its rated output for efficient generator operation The control range is generally between 60 and 80 of ...

Page 23: ...l DO NOT allow objects to enter or block screens C A U T I O N 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 PROCEDURE 1 Place all switches on the control panel to the OFF position 2 Connect the power source to be tested to the Load Bank as described in the INSTALLATION section 3 Place the VOLT...

Page 24: ...nnected to Load Bank resistance elements unless the airflow switch es is closed and the load dump relay K99 has been interlocked Check for correct exhaust airflow direction C A U T I O N The operation of all of the blowers is vital to the safe operation of this Load Bank When the BLOWER START switch is pressed the AIR FAILURE light will come on momentarily until the blowers accelerate up to their ...

Page 25: ...the Load Bank by allowing the blower to operate for a few minutes after loads are removed This procedure is not required for maintaining Load Bank integrity but it may guard operating personnel from possible burn injuries 2 Place the control power ON OFF switch to the OFF position and other switches on the control panel should be turned OFF 3 Shut down the power source sources 4 Disconnect the Loa...

Page 26: ...he maximum setpoint When the Auto Transfer Contact is opened the Auto Load Shedder will be inactive and the blower will be stopped automatically OPTIONAL CONTROLLER OPERATION AND ADJUSTMENTS NOTE The current setpoints for the Load Shedder option have been preset by the factory Adjustments can be made as follows W A R N I N G Always put a short or shunt across the current transformer when servicing...

Page 27: ...a preset time delayed ramp up period As the building load increases and the actual generator output approaches 1600 kW 80 the controller disables one load step in this example the last 500 kW load step sheds This load shed control continues as the building load continues to increase If the building load decreases causing the actual generator load to fall below 60 the controller will add the approp...

Page 28: ...se 1863 600 or 3 11 amps 1550 kW Adjustments can be made to the PC board controller s via the adjustable resistor potentiometers found on the PC board s Reference resistors labeled R73 R60 R47 R34 and R21 NOTE If more than five load steps are required there will be one additional PC board A102 The resistor potentiometers are labeled identically to the first PC board A101 NOTE R73 controls the last...

Page 29: ...the Automatic Load Shed Controller Control voltage and current sense input W A R N I N G When disconnecting the current transformer the secondary terminals must be shorted The secondary of an unshorted current transformer can exceed several thousand volts 2 Apply 120 VAC 60 Hz control power J1 10 12 see schematic W A R N I N G There is lethal high voltage within the control enclosure 3 Using a con...

Page 30: ... 5 amp input 5 amp 10 Dial Setting 1 25 amp 25 Dial Setting 2 5 amp 50 Dial Setting 3 75 amp 75 Dial Setting 5 0 amp 100 Dial Setting With all power removed from the Load Bank calculate each desired Trip Point and adjust the potentiometers R21 R34 R47 R60 R73 in order to achieve a rough adjustment controller setting NOTE The current sense relay settings must be set sequentially It is extremely imp...

Page 31: ...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 ...

Page 32: ... SAFETY CONSIDERATIONS section of this manual Eye protection should be worn when cleaning the unit with compressed air DAILY 1 Remove any restrictions to the airflow through the Load Bank 2 Check the screens to make sure that no objects have blocked or entered the openings If freezing conditions exist below 32 F or 0 C and freezing rain sleet or snow block the exhaust hood duct louver the followin...

Page 33: ...d 4 Inspect all connections for oxidation or corrosion Clean the connection or replace the hardware where required 5 Verify that the airflow switch works properly 6 Inspect all magnetic contactors to make sure that the contacts are not severely pitted or corroded The contacts must move freely and be properly seated 7 Clean all dirt and debris out of the Load Bank This can be accomplished by blowin...

Page 34: ... 1192769 B27730 36 Remote Monitoring Contacts D27683 9 51 Control Transformer Option 208 115V for 500 to 2000 kW Load Banks D37723 3 64 Digital Power Metering Option DW Style V A F KW KVAR PF KVA CT Ratio 1500 5 D37723 4 65 Digital Power Metering Option DW Style V A F KW KVAR PF KVA CT Ratio 2000 5 A32404 71 Control Unit Mounted Front A32573 1 73 Gravity Hood Replacement Single Stack A32573 2 74 G...

Page 35: ...ASCO Model 4800 Load Bank 6 2 Option Drawing No Option Description A37255 86 Bus Bar Customer Connection Replacement A37594 87 Local Control Metering Unit Mounted Right Side B33795 1 88 Elevating Stand One Bay ...

Page 36: ...ecessary and revisions to the parts list may be made at any time without notice REFERENCE DESIGNATORS Service personnel may use this parts list along with the system schematics to identify and order replaceable parts The reference designators were carefully selected and matched to those on the schematic diagrams and equipment to simplify the troubleshooting and repair process NOTE When ordering re...

Page 37: ...101 SWITCH PUSHBUTTON RED 361661 1 S102 SWITCH TOGGLE 125 VAC 28 VDC 360785 1 K100 240 RELAY 3P 25A 600 VAC IND 35A 350833 2 600 VAC RES 110 120V 50 60 HZ K481 RELAY VOLTAGE SENSING 180 276V PICKUP 350740 1 XK481 RELAY SOCKET DIN RAIL MOUNT 358280 1 XK481 CLIP RETAINER 467522 2 K480 RELAY 3P 25A 208 240V 60 HZ 351924 1 2 SPDT AUX DIN RAIL MT T2 TRANSF CONT 50 VA 440 460 480V PRI 370528 1 220 230 2...

Page 38: ...ON 51 CONTROL TRANSFORMER D27683 9 XF210 212 FUSEBLOCK 3 POLE 324496 1 F212 FUSE CARTRIDGE 15 AMP 600V 324346 1 TIME DELAY CLASS RK 5 F210 211 FUSE 20 AMP 600V TIME DELAY CLASS RK 5 324143 2 T1 TRANSFORMER 1500 VA 1 PH 50 60 HZ 371319 1 OPTION 64 DIGITAL METERING UNIT D37723 3 DW Style CT Ratio 1500 5 RS485 CT1 CT2 Transformer Current 1500 5 370159 2 F100 102 Fuse 1 Amp 600V Time Delay 324449 3 XF...

Page 39: ...ometimes necessary and revisions to the parts list may be made at any time without notice REFERENCE DESIGNATORS Service personnel may use this parts list along with the ASCO system schematics to identify and order replaceable parts The reference designators were carefully selected and matched to those on the schematic diagrams and equipment to simplify the troubleshooting and repair process NOTE W...

Page 40: ...orp Aerospace Commercial Controls Div Milwaukee WI 53200 3N065 Telemecanique Inc 2525 S Clearbrook Dr Arlington Hts IL 60005 4623 30487 Huntington Electric Inc 550 Condit St P O Box 366 Huntington IN 46750 2506 54407 Power One DC Power Supplies 740 Calle Plano Dr Camarillo CA 93010 8555 59270 Selco Products Inc 7580 Stage Rd Buena Park CA 90621 1224 6P125 Potter and Brumfield Div of AMF Inc Prince...

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Page 44: ... is not connected according to the Schematic Interconnection Diagram c Terminals were damaged during shipment d Fuses are blown Check and replace as required e Fuse is blown in Load Bank control circuit Check and replace as required f Dirty or loose connection at Main Power Switch When checking fuses for continuity be sure to remove all fuses from clips in fuseblock or Disconnect Switch Test each ...

Page 45: ...ry 3 BLOWER FAILURE indicator lights yet blower is operating a Airflow restrictions present at Load Bank intake or exhaust b Improper fan blade rotation or phase reversal Check fan motor power connections for proper phase sequence c Air Differential Pressure Switch is malfunctioning d Blower Fail Relay is malfunctioning 4 Fan blade is broken or not turning a Fan blade motion is obstructed b Fan bl...

Page 46: ...ad step resistor is open 6 Contactor chattering exists a Contacts and or core are dirty or corroded b Connections to contactor coil are loose c Control circuit line voltage is too low 7 Load Bank or load step does not give rated load a Applied load voltage is either derated or inadequate b Contactor does not close properly c Load step resistor element is open d One of the individual load branch ci...

Page 47: ...zed 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 Test each fuse individually out of circuit If tested in circuit there is the possibility of feedback which causes false readings A blown fuse may still check out OK ...

Page 48: ...nologies 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 ...

Page 49: ...he Avtron product specified herein is originally deployed for use the User in the fifty United States or Canada This Warranty is not transferable or assignable without the prior written permission of ASCO Assignment of Warranties ASCO assigns to User any warranties which are made by manufacturers and suppliers of components of or accessories to the Avtron product and which are assignable but ASCO ...

Page 50: ...Y APPLICATIONS OR WITHIN THE CONTAINMENT AREA OF A NUCLEAR FACILITY OR FOR INTEGRATION INTO MEDICAL DEVICES Limitations THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE USER S SOLE AND EXCLUSIVE REMEDY IS REPAIR OR REPLACEMENT OF THE AVTRON PRODUCT AS SET FORTH HEREIN IF USER S REMEDY IS DEEMED TO FAIL O...

Page 51: ...eveland Ohio U S A 44125 Tel 216 573 7600 www ascopower com ASCO Innovative Solutions 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 ...