LOAD BANK TECHNICAL MANUAL Customer: XXXXXX Job: XXXXXX-X-X Model: Vector XX August 2017 The information herein is the property of Simplex, Inc. and/or its subsidiaries. Without written permission, any copying, transmitting to others, and other use except that for which it is loaned, is prohibited. (File: Vector-170804.indd) ® LOAD BANK MANUAL • Vector • page 1 of 19 Contents DESCRIPTION .............................................................................. 2 Control System ...................................................................... 3 Load System ........................................................................... 3 PRIMARY INSPECTION ............................................................... 4 INSTALLATION ............................................................................. 4 OPERATION .................................................................................. 5 Manual Loading ...................................................................... 5 Numeric Loading .................................................................... 6 Auto Loading .......................................................................... 6 Active BAck Pressure Monitoring / Soot Control Mode ..... 8 Info Screen ............................................................................. 9 User Setup Screen ................................................................. 9 Genset Cooldown ................................................................ 10 MAINTENANCE .......................................................................... 11 Each Operation .................................................................... 11 Every 50 Hours or 6 Months ............................................... 11 TROUBLESHOOTING ................................................................ 12 Cooling Failure Indicated .................................................... 12 Test Meters Do Not Operate Properly ................................ 12 Some Load Steps Cannot Be Energized ............................ 12 DRAWINGS AND PARTS LIST .................................................. 12 APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL ..... 13 APPENDIX B - C A L C U L A T I O N S & FORMULAS ...................... 15 APPENDIX C - TORQUE VALUES ............................................. 18 Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 800-637-8603 Vector-170804.indd • © 2017 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com ® LOAD BANK MANUAL • Vector • page 2 of 19 39.415 34.340 40.780 19.780 21.138 25.075 6.000 2.000 6.500 4.000 1.500 TYP. 12.318 Part of Typical Pictorial Drawing DESCRIPTION Simplex LBD Series Load Banks are Simplex LBD Series Load Banks are a special form of stationary, resistive, intended for use with water cooled en- forced air-cooled Load Bank which gine generator sets equipped with unit utilizes the air outflow of an engine mounted radiators. These Load Banks radiator for cooling of the load ele- are built per customer specifications ments. They are specifically designed and can be installed in numerous ways, to apply discrete, selectable electrical including direct bolted attachment to the load to a power source while measur- radiator, mounting within an air duct, wall ing the response of the generator to mounting over the air outflow opening, the applied load. They also provide indoors or outdoors. a means for routine maintenance Power source testing is accomplished exercise to assure long term reliability by applying resistive load steps at a and readiness of the standby genera- specific power factor. tor. Exercise Load Banks eliminate the detrimental effects of unloaded Load application is by magnetic contac- operation of diesel engine generators. tor. All load branch circuits are protected by 200KAIC class-T fuses. Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 800-637-8603 Vector-170804.indd • © 2017 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com ® LOAD BANK MANUAL • Vector • page 3 of 19 The Remote Control Panel contains the LOAD SYSTEM following controls and indicator lamps: Simplex Vector Load Banks are built 1. Normal Operation and Over Tem- up in fused branch circuits of not more perature indicator lamps, than 70A each and protected by 600V, 2. 4” Color HMI Controller 200KAIC class-T fuses. All wiring and devices within the branch circuit are This Load Bank is protected against rated in accordance with the fuse rating. cooling failures (high exhaust air tem- Branch circuit fusing of the elements perature which could damage the Load virtually eliminates the danger of short Bank or present a safety hazard to the circuit of the load elements and con- operator). The “Normal Operation” sequent catastrophic damage to the lamp illuminates when Control Power is Load Bank. available and the Cooling System is op- erating properly. When a cooling failure occurs the automatic safety features in Pow'r Rod Load Elements the Control System immediately remove Simlpex Pow'r Rod Load Elements are the load from the test source and illu- UL recognized. These elements are minates the “Over Temperature” lamp. totally enclosed, sealed and weath- The malfunction must be corrected and erproof. Pow'r Rod elements consist the Load Bank must be reset by turning of nickel-chromium resistance wire the Load Bank “Off” then “On” before electrically insulated and sealed within the load can be re-applied. a metallic sheath. The hazard of electric The Load Bank consists of two principal shock to personnel and the danger of systems: short circuit by foreign object penetra- tion are reduced since the elements are 1. Control System electrically dead on the outside. They 2. Load System will not fatigue from engine or air-blast vibrations and will not sag or stretch if overheated. The sheath material is CONTROL SYSTEM "incolloy", a rustproof nickel alloy with a The Control System allows the opera- very high temperature rating (1600°F). tor to apply a desired load to the test These elements do not require a cool source and measure the response of down period. the test source to the load. This system also contains the circuitry utilized to disconnect the Load Bank from the test source in the event of cooling failures and/or improperly positioned operating Never operate or service a Load controls. Common serviceable compo- Bank that is not properly con- nents include Control Fuses (F Series), nected to an earthground. Meter Fuse (MF Series), and Power Fuses (F Series). Control power is supplied to the Load Bank via the test source and a control power transformer. Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 800-637-8603 Vector-170804.indd • © 2017 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com ® LOAD BANK MANUAL • Vector • page 4 of 19 PRIMARY INSPECTION If any problems are observed Preventative visual inspection of the during Primary Inspection call shipping crate and Load Bank must be the Simplex Service Manager at performed before installation. Physical 800-637-8603 (24hrs.) or electrical problems due to handling and vibration may occur during ship- ment. 4. See Control Section Drawing: 1. If crate shows any signs of damage a. Connect customer supplied examine the Load Bank in the cor- 24VDC power source as shown. responding areas for signs of initial b. Connect customer supplied Load problems. Bank Status contacts as shown. 2. Check the entire outside of the c. Connect customer supplied High cabinet for any visual damage which and Low Signal contacts as could cause internal electrical or shown. mechanical problems due to reduced d. If Load Dump control is desired, re- clearance. move the factory installed jumper 3. Rotate and push all switches through and connect customer supplied all positions to ensure smooth opera- Load Dump contact as shown. tion. Close to run. 4. Inspect the bottom of crate/enclosure Open to remove load. for any components that may have 5. See Metering Section Drawing: jarred loose during shipment such as indicator light lenses, switch knobs, a. Place the Current Transformers etc. (CT1, CT2) so as to sense total load and connect them as shown. 5. Visually inspect element chamber b. Cable the Main Load Bus (MLB) for foreign objects and mechanical to the load source as shown. damage. Cables must pass through Cur- rent Transformers (CT1, CT2) as INSTALLATION shown for proper meter operation. Unless stated on drawings consult NEC 6. See Remote Wiring Drawing: for proper wire size on all connections. a. Using RS 485 communications 1. Using the angles provided attach the cable (up to 4000’), connect the Load Bank with bolts per specifica- Load Bank to the Remote Panel tions. Bottom support for the load as shown. element enclosure is recommended. b. Connect the power connection 2. Confirm the test source is properly on the Load Bank to the Remote grounded and ground the Load Bank Panel as shown. to its own independent ground. 3. Mount the Remote Control Box in the desired location. Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 800-637-8603 Vector-170804.indd • © 2017 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com ® LOAD BANK MANUAL • Vector • page 5 of 19 OPERATION The screens in this manual are ex- amples. Your screens may vary. • Load Dump (lower right corner): Drops all load, suspends automatic functions. MANUAL LOADING • Control Power (top left corner) From the Manual