Atec Merlin User Manual
Description
Simplex Merlin Load Banks are the
new standard for advanced design in
Portable Load Banks spanning the
capacity range of 100–400KW. The
Merlin is a dual voltage (240/480v), fi ne
load step resolution, fully instrumented
Portable Load Bank intended for
small-medium capacity shop or fi eld
use by engine generator dealers and
service shops for maintenance, testing
and performance proving of engine
generator sets, UPS and other power
systems in the 50–400KW range. The
Merlin is available in discrete model
sizes of 100KW, 150KW, 200KW,
250KW, 300KW, 350KW and 400KW.
The Merlin control panel includes
test instrumentation, load application
switches, operation indicator lights and
fan/control power switch. The Load
Bank includes rugged “Powr-Web”
load elements, load control contactors,
branch circuit fuse protection of the
load elements, high temperature power
wiring, cooling fan with circuit breaker,
control power fuses. The Load Bank
is protected against fan failure, high
intake air temperature, high exhaust air
temperature, and overvoltage. The unit
includes a 12’ connection cable set.
MERLIN
100KW - 400KW Load Bank
Merlin Load Banks are built on a formed
and welded steel chassis that is both
rugged and lightweight. For fl exible
portability, the Merlin includes casters,
lifting eyes and forklift channels. Airfl ow
through the unit is horizontal with
cooling provided by a cast aluminum
airfoil type shrouded propeller fan.
Features
• Exceptionally rugged, all welded,
formed steel chassis
• Hinge-open control section door
• Lifting eyes, forklift channels and
casters
• Moving handle
• “PowrWeb” Load Elements
• Branch circuit fuse protection
Insight
Onsite
®
MERLIN
100KW - 400KW Load Bank • Page 2
Powr-Web Resistive Load
Element
Description
Simplex Load Banks utilize the “PowrWeb” Load Element (a UL Recognized
Component). The “Powr-Web” is an
advanced design, air-cooled power
resistor specifi cally designed for
application to load bank systems. The
“Powr-Web” is conservatively operated
at half the maximum temperature rating
of the alloy and features a short-circuitsafe design based on continuous
mechanical support of the resistor by
high temperature, ceramic clad stainless
steel rods.
Construction
®
• Precision calibrated to specifi c ohmic
value
• All load elements are continuously
supported by vibration resistant,
ceramic clad, stainless steel throughrods.
Specifi cations
• Alloy: FeCrAl
• Maximum continuous temperature
rating: 1920°F
• Maximum operating temperature as
applied in Load Bank: 1080° F
• Cool down time from operating to
ambient temperature is 10 seconds.
Branch Circuit Fuse
Protection
The load of a resistive load bank
consists of a dense array of open,
uninsulated power resistors mounted
within a cooling air stream. Since
the elements are electrically live, it is
possible for a foreign object to penetrate
the element array and create a short
circuit of adjacent elements or a short to
ground. Since the elements are densely
packed, it is possible for a short circuit,
once started, to rapidly propagate
through the entire element array. As
a load bank represents a relatively
large amount of power concentrated
within a relatively small volume, a selfpropagating, cascading short circuit
would have catastrophic results.
Simplex virtually eliminates the
dangers of short circuit through the
use of branch circuit fuse protection of
the load elements. Per NEC 110-10,
protective devices shall clear a fault
without “extensive damage” to the circuit
components. A Simplex Load Bank is
divided into branch circuits of not more
than 50 KW each.
Simplex, Inc.
5300 Rising Moon Road
Springfi eld, IL 62711-6228
217-483-1600
Fax 217-483-1616
www.simplexdirect.com
© 2012 Simplex, Inc. All Rights Reserved.
Printed in the USA • 1103-03.01
Design subject to change without notice.
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