Asco 4820 User manual

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

ASCO MODEL K875A
OUTDOOR LOAD BANK
© 2016 ASCO Power Technologies, Inc. January 6, 2000
Cleveland, Ohio Rev. July 7, 2016

6255 Halle Drive, Cleveland, OH 44125-4615 -216.573.7600 -f: 216.573.5953
www.avtronloadbank.com Form 831B-LB Rev. 11-16
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.

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...................................................................................................6-1
Section VII REPLACEMENT PARTS LIST................................................................7-1
APPENDIX - Load 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 provided if this option is purchased.
Instruction Manual Part Number D29785-X Manual is provided if this option is purchased.
-i-

Table of Contents ASCO Model K875A Outdoor Load Bank
DRAWINGS
Part No. kW Volts Load Steps O/L Dwg. Schem. Interconn.
K875AD28042-4 2500 480 50, 50, 100, 100, 200, 500, 500,
500, 500 SB2770 1D30049 D30349
K875AD28042-5 3000 480 50, 50, 100, 100, 200, 500, 500,
500, 500, 500 SB2770 1D30051 D30350
K875AD28042-6 3000 480 50, 50, 100, 100, 200, 500, 500,
500, 500, 500 SB2770 1D31135 D31136
K875AD28042-7 2500 480 5, 10, 10, 25, 50, 100, 100, 200,
500, 500, 500, 500 SB2770 1D38361 D38362
K875AD28042-8 3000 480 5, 10, 10, 25, 50, 100, 100, 200,
500, 500, 500, 500, 500 SB2770 1D42596 D42595
K875AD29440-2 750 480 50, 100, 200, 200, 200 SB2793 2D29809 D29810
K875AD29440-3 750 480 5, 10, 10, 25, 50, 50, 100, 100,
200, 200 SB2793 2D29811 D29812
K875AD29440-4 1000 480 50, 50, 100, 100, 200, 500 SB2793 2D29813 D29814
K875AD29440-5 1000 480 5, 10, 10, 25, 50, 100, 100,
200, 500 SB2793 2D29815 D29816
K875AD29440-6 1000 480 5, 10, 10, 25, 50, 100, 100, 200,
500 SB2793 2D30417 D30416
K875AD29440-10 750 480 25, 25, 50, 50, 100, 100, 200,
200 SB2793 2D42645 D42646
K875AD29461-1 750 240/480 5, 10, 10, 25, 50, 50, 100, 100,
200, 200 SB2793 2D29826 D29827
K875AD29461-2 1000 240/480 50, 50, 100, 100, 200, 500 SB2793 2D29828 D29829
K875AD29461-3 750 240/480 50, 100, 200, 200, 200 SB2793 2D29822 D29823
K875AD29461-4 1000 240/480 5, 10, 10, 25, 50, 100, 100, 200,
500 SB2793 2D29824 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
SB2793 2D31287 D31288
K875AD29650-3 1500 480 5, 10, 10, 25, 50, 100, 100, 200,
500, 500 SB2827 3D30041 D30278
K875AD29650-4 1500 480 50, 50, 100, 100, 200, 500, 500 SB2827 3D30042 D30125
K875AD29650-5 1500 240/480 5, 10, 10, 25, 50, 100, 100, 200,
500, 500 SB2827 3D30043 D30126
K875AD29650-6 1500 240/480 50, 50, 100, 100, 200, 500, 500 SB2827 3D30044 D30127
K875AD29650-7 2000 480 5, 10, 10, 25, 50, 100, 100, 200,
500, 500, 500 SB2827 3D30088 D30089
K875AD29650-8 2000 480 50, 50, 100, 100, 200, 500, 500,
500 SB2827 3D30047 D30296
K875AD29650-9 2000 480 50, 50, 100, 100, 200, 500, 500,
500 SB2827 3D30047 D30296
K875AD29650-14 1250 480 50, 100, 100, 100, 200, 200,
500 SB2827 3D35454 D35453
K875AD36922-1 1250 480 5, 10, 10, 25, 50, 50, 100, 100,
200, 200, 500 SB2827 3D36923 D36924
See the following page for additional drawings. -ii-

Table of Contents ASCO Model K875A Outdoor Load Bank
DRAWINGS
Part No. No. of
Stacks Control Panel O/L Dwg., Control Panel Resistor Assemblies
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
K875AD28042-7 Three D29743-30 SB2950 D28438-2, D27555-1, D27554-1,
D27552-1
K875AD28042-8 Three D29743-33 SB2950 D27552-1, D27553-1, D27555-1
K875AD29440-2 One D29743-5 SB2950 D27553-1, D27555-1
K875AD29440-3 One D29743-6 SB2950 D27552-1, D27553-1, D27555-1
K875AD29440-4 One D29743-7 SB2950 D27555-1, D28438-2
K875AD29440-5 One D29743-8 SB2950 D27552-1, D27553-1, D27555-1
K875AD29440-6 One D30415 SB2988 D27552-1, D27555-1
K875AD29440-10 One D29743-34 SB2950 D27553-1, D27555-1, D34941
K875AD29461-1 One D29743-9 SB2950 D27552-2, D27553-2, D27555-2,
D29645
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 Two D29743-13 SB2950 D27552-2, D27553-2, D27554-2,
D27555-2, D29645, D29851
K875AD29650-6 Two D29743-14 SB2950 D27553-2, D27555-1, D29645, D29851
K875AD29650-7 Two D29743-15 SB2950 D27552-1, D27553-1, D27555-1
K875AD29650-8 Two D29743-19 SB2950 D27555-1, D28438-2
K875AD29650-9 Two D29743-19 SB2950 D27555-1, D28438-2
K875AD29650-14 Two D29743-26 SB2950 D27553-1, D27554-1, D27555-1
K875AD36922-1 Two D36925-1 SB2950 D27555-1, D28438-2, D27552-1
1For Load Banks equipped with Option 75, use Outline Drawing SB3147.
2For Load Banks equipped with Option 73, use Outline Drawing SB3145.
3For Load Banks equipped with Option 74, use Outline Drawing SB3146.
-iii-

Options ASCO Model 4800 Load Bank
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.
Drawing Option Description
SB2196 17 Control/Meter Enclosure, Wallmount (Outline)
1192769 23 Automatic Load Controller Option (Schematic)
1192769 24 Automatic Load Controller Option (Schematic)
B27730 36 Remote Monitoring Contacts
D27683-9 51 Control Transformer Option, 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 Replacement with Stainless Steel
Screen (1 Stack Units)
B32580-1 83 Overhead Lift, Single Stack
B32580-2 84 Overhead Lift, Two Stack
A37255 86 Bus Bar, Customer Connection, Replacement
A37594 87 Local Control/Metering Unit, Mounted (Right Side)
B33795-1 88 Elevating Stand (One Bay)
*Load Banks equipped with Option 73 should be supplied with special Outline Drawing SB3145.

1-1
ASCO MODEL K875A
OUTDOOR LOAD BANK
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 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 by the resistors. This heat must be removed from the Load
Bank by the cooling fans/blowers. If there is any restriction or stoppage of airflow, the Load Bank
will overheat and may start a fire. It is recommended that:
1. The operator should read the manual before using the Load Bank.
2. Run an approved ground wire from the Load Bank ground lug(s) to the generator frame.
Run an approved ground wire from the generator frame to a goodearth ground. Size ground
wire in accordance with National Electrical Code and any local codes.
3. Do not bypass the airflow safety switch or exhaust over-temperature switch to prevent
nuisance tripping.

Safety Considerations ASCO Model K875A Outdoor Load Bank
1-2
4. 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.
5. Maintenance personnel must always exercise caution when the access panels or intake
screens are removed. Personal injury from electrical shock or from the rotating fan blades
may result if all sources of power are not disconnected before servicing. Maintenance work
must be done only by qualified personnel.
6. The Load Bank must be used 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. This causes a constant rise in cooling air temperature and may cause the Load
Bank to overheat.
7. Install the factory-provided exhaust hood(s) as soon as possible. This protects the open
resistor element section from debris and environmental conditions such as freezing rain.
Failure to install hoods in a timely fashion may void warranty.
8. 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 definite hazard. 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 fromthe 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 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
can 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/or fire hazards.
12. Operators must not operate the Load Bank with the access panels or screens removed. To do
so exposes the operator and other persons to possible personal injury from electrical shock or
from the moving fan blades.
13. Emergency Shutdown Procedure
A. In an emergency, turn off the MASTER LOAD switch, then the generator. The
MASTER LOAD switch will allow disconnection of all load steps and still allow for
the motor to run, cooling any heated elements.