Simplex Saturn 3000 DV Technical Manual

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Final Acceptance

of Instruction Manual

Customer: Austin Generator Service

W.O. #: 63798-07-43/2

Load Bank Types: Saturn 3000 DV

1 Manual Shipped for the Load Bank described above.

2550KW/3000KW, 480/600V, 60KW Res,

LCL PLC, INT/EXT CP, Powered Louvers

File: 63798-2.p65, Disk: SDCX155

This instruction manual has been reviewed and is approved

by me as being fully accurate and representative of the

equipment being supplied thereunder and it (the manual)

meets the customer’s specification/order requirements for

manuals.

Approved by: Date:

1 Manual Received by: Date:

LOAD BANK

TECHNICAL MANUAL

(LBD Series)

Customer: Austin Generator Service

Work Order: 63798-07-43/2

Model: Saturn 3000 DV

June 2007

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: 63798-2.p65; Disk: SDCX155)

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 1 of 20

Contents

DESCRIPTION .............................................................................. 2

Control System ...................................................................... 4

Cooling System ..................................................................... 4

Load System .......................................................................... 4

PRIMARY INSPECTION ............................................................... 4

INSTALLATION ............................................................................. 5

Location .................................................................................. 5

Procedure ............................................................................... 6

OPERATION ................................................................................. 6

Local ....................................................................................... 6

Remote ................................................................................... 7

Load Dump ............................................................................. 8

FAILURE DETECTION ................................................................. 8

Thermocouple Temperature Switch ..................................... 8

MAINTENANCE ............................................................................ 9

Each Operation ...................................................................... 9

Every 50 Hours or 6 Months ............................................... 10

Motor Lubrication ................................................................ 10

TROUBLESHOOTING ................................................................ 11

Cooling Fan Motor Will Not Operate .................................. 11

Some Load Steps Cannot Be Energized ........................... 11

Cooling Failure Indicated.................................................... 12

DRAWINGS AND PARTS LIST .................................................. 12

APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL ..... 13

APPENDIX B - CALCULATIONS & FORMULAS ...................... 14

APPENDIX C - TORQUE VALUES ............................................. 17

APPENDIX D - PILLOW BLOCK BEARINGS

LUBE INTERVAL ................................................................. 19

APPENDIX E - DRAWINGS........................................................ 20

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

DESCRIPTION

Simplex Load Banks are precision test instruments specifically designed to apply discrete, selectable electrical load to a power source while measuring the response of the generator to the applied load. They also provide a means for routine maintenance exercise to assure long term reliability and readiness of the standby generator. Exercise Load Banks eliminate the detrimental effects of unloaded operation of diesel engine generators.

The cabinet on this Load Bank is rated NEMA Type 3R outdoor weatherproof.

Power source testing is accomplished by applying resistive load steps at unity (1.0) power factor.

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 2 of 20

Load application is by magnetic contactor. All load branch circuits are protected by 200,000AIC classT fuses.

Operating controls are located on a Local Control Panel and a Remote Control Panel. The Control System is comprised of 120V and 24VDC discrete components. Common serviceable components include Control Fuses (CF1–CF4) and Load Application Fuses (F1–F189). Lamps on the Local Control Panel indicate the Load Bank operating status. Control priority is determined by the “Mode Selector” switch.

Always remove all power from the load bus and all fan/control power before servicing the Load Bank. Never operate or service a Load Bank that is not properly connected to an earthground.

Part of Pictorial Drawing 47BD164460C

SPECIFICATIONS

Capacity: 2560KW/3000KW @ 1.0 PF

Voltage: 480/600VAC

Connection: 3-Phase, 3-Wire

Frequency: 60Hz

Fan Power: Int./Ext. 480/600V, 3ø, 60Hz

Control Power: Int./Ext. 480/600V, 3ø, 60Hz

120V Transformer

Cooling: Forced Air

Airflow: 60,000 CFM

Max. Air Intake Temp.: 120°F

Nominal Air Temp. Rise: 125°F–500°F Max.

Temperature Rise: °F =

Duty Cycle: Continuous

Serial Number: 63798-07-43/2

KW x 3000

CFM

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

The Local Control Panel contains the following components:

1. Louvers Open, Cooling Failure, Over Temperature, Fan Failure, Access Door Ajar, Louvers Closed, Remote Control Active, Control Power On, Normal Operation, and Load Dump Bypassed indicator lamps

2. Fan/Control Power switch

3. Load Bank Mode switch

4. Auto Load Dump switch

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 3 of 20

ALARM

HORN

SILENCE

LOUVERS

OPEN

COOLING FAILURE

OVER

TEMPERATURE

FAN

FAILURE

LOAD DUMP

BYPASSED

5. Load Voltage Selector switch

6. Master Load and load step switches

7. Fan/Control Power Voltage Selector switch

The Remote Control Touch Panel is housed in a suitcase.

This Load Bank is protected against cooling failures (loss of cooling air flow, high intake or exhaust air temperature which could damage the Load Bank or present a safety hazard to the operator). When a cooling failure occurs the automatic safety features in the Control System immediately remove the load from the load source. The malfunction must be corrected and the system must be reset by turning the Load Bank “Off” then “On” before the load can be reapplied.

The Load Bank consists of three principal systems:

LOUVERS

CLOSED

FAN/

CONTROL

POWER

OFF ON REMOTE LOCAL ENABLED BYPASS

RESISTIVE

MASTER

LOAD

OFF ON

42KW

480V

50KW

600V

OFF ON

425KW

480V

500KW

600V

OFF ON

REMOTE

CONTROL

ACTIVE

MODE

SELECT

RESISTIVE LOAD STEP CONTROLS

4.1KW 5KW

OFF ON

85KW

100KW

OFF ON

850KW

1000KW

OFF ON

CONTROL

POWER ON

LOAD DUMP

BYPASS

OFF ON

85KW

100KW

OFF ON

8.5KW 10KW

OFF ON

LOW VOLTAGE

480VAC,3Ø,60HZ

FAN/CONTROL POWER

VOLTAGE SELECTOR

NORMAL

OPERATION

8.5KW 10KW

170KW 200KW

HIGH VOLTAGE

600VAC,3Ø,60HZ

OVER

VOLTAGE

LOAD

VOLTAGE

SELECTOR

480V 600V

21KW 25KW

OFF ON

425KW 500KW

OFF ON

480V 600V

1. Control System

2. Cooling System

3. Load System

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 4 of 20

CONTROL SYSTEM

The Control System allows the operator to apply a desired load to the test source and measure the response of the test source to the load. This system also contains the circuitry utilized to disconnect the load from the test source in the event of cooling failures and/or improperly positioned operating controls.

Fan power is applied to the Fan Motor (MOT) through the Fan Circuit Breaker (FCB 1A or FCB 1B), the Disconnect Switch (DSW), the Fan/Control Voltage Selector swtich (S1), the Auto Transformer, and the Fan Motor Contactor (FMC) contacts. An Overload Relay (OVR) is used to protect the motor.

COOLING SYSTEM

Resistive Load Elements are cooled by a forced air system consisting of a 60" fan blade belt driven by a 30HP, TEFC motor, creating a 50,000 CFM. The fan motor is energized by a 60A, 600V, 3 pole contactor (FMC) and protected by a 100A frame, 60A trip, 3 pole, 600V circuit breaker (FCB).

LOAD SYSTEM

The Load System consists of independently controlled resistive and/or reactive load elements specifically designed for Load Bank systems. They are protected by 200,000AIC, 600VAC fuses.

Simplex Resistive Load Elements conservatively operate at approximately half the maximum temperature rating of the alloy (1080°F vs. 1920°F). For example:

Alloy: FeCrAl

See Parts Legend Drawing for specific elements used.

These elements are rigidly supported by high-temperature, ceramic-clad, stainless-steel supports. Element-toelement short circuits are virtually eliminated. The elements are assembled in discrete trays which are assembled in a vertical “stack”. Each tray is independently serviceable without disturbing adjacent trays.

PRIMARY INSPECTION

Preventative visual inspections of the shipping crate and Load Bank is advised. Physical or electrical problems due to handling and vibration may occur. Never apply power to a Load Bank before performing this procedure. The following Nine Point/30 Minute Inspection is recommended before installation, as part of the 50 hour / 6 month maintenance schedule and whenever the Load Bank is relocated:

1. If crate shows any signs of damage examine the Load Bank in the corresponding areas for signs of initial problems.

2. Check the entire outside of the cabinet for any visual damage which could cause internal electrical or mechanical problems due to reduced clearance.

3. Inspect all hinged panels and doors for smooth and safe operation, try all latches and knobs.

4. Rotate and push all switches through all positions to ensure smooth operation.

5. Check cooling system by inspecting fan motor and blade. Slowly rotate blade by hand and note clearance of blade tip through its rotation near the housing. Observe free rotation of motor shaft.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 5 of 20

If any problems are observed during Primary Inspection call the Simplex Service Manager at 217-483-1600 (24hrs.)

6. Inspect all relays, timers, and control modules by opening all accessible panels. Make sure all components are secure in their bases and safety bails are in place. Spot check electrical connections for tightness. If any loose connections are found inspect and tighten all remaining connections.

7. Examine all accessible internal electrical components such as fuses, contactors and transformers. Check lugged wires at these components.

8. Inspect bottom of crate/enclosure for any components that may have jarred loose during shipment such as indicator light lenses, switch knobs, etc.

9. Visually inspect element chamber for foreign objects, broken ceramic insulators, mechanical damage.

INSTALLATION

LOCATION

Nema-3R Load Banks are intended for outdoor installation. The load elements in this Load Bank are cooled by a forced air system which discharges through the top of the cabinet. This Load Bank will produce a large quantity of exhaust air. Location of the Load Bank is of prime importance and should be done by trained personnel. It is one of the most critical factors involved in safe operation. The Load Bank must be positioned and installed according to large airflow requirements.

• There must be a minimum clearance of 6 feet on all sides of the Load Bank.

• Load Banks installed indoors must be equipped with an exhaust air duct of minimum back pressure (supplied by others) which routes all Load Bank hot exhaust air outdoors.

• Never install any structure or object at any height above the Load Bank.

• Always locate the Load Bank in a secure area accessible by trained personal

only.

• Use the eyehooks and forklift channels provided to position the Load Bank.

• Never move the Load Bank with the exhaust hood attached.

• Never point the exhaust at a nearby surface or object which may be adversely affected by high temperature.

• Never operate the Load Bank in a confined space without regard for adequate intake of air and provision for exit of high temperature exhaust.

• Consider that the Load Bank and a nearby generator set may have to compete for cooling air.

• Never bounce hot exhaust air off nearby objects and allow it to recirculate through the cooling system.

• Never operate the Load Bank in proximity to a sprinkler system.

Failure to properly install this Load Bank may result in substantial damage to or the destruction of the Load Bank, adjacent equipment and the building in which the Load Bank is installed.

Never operate or service a Load Bank that is not properly connected to an earthground.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 6 of 20

PROCEDURE

1. Confirm the test source is properly grounded and ground the Load Bank in compliance with NEC.

2. If Remote Control is desired, using CAT 5 Patch Cable, connect the laptop computer to Receptacle 3 on the Load Bank.

3. Confirm all load command switches are in the “Off” position.

4. Confirm the Disconnect Switch (DSW) is in the “Off” position.

See Fan/Control Power Drawing

47B164462B.

480/600V, 3ø, 60Hz, 60A source to FCB 1A as shown.

Consult NEC for proper wire size.

See Control Drawing 47B164461C.

Using #14 AWG copper wire or greater with a torque of 35 in. lbs., connect customer supplied Load Dump contacts to TB‘LD’ 1–2 or place the “Load Dump Mode” switch in the “Bypass” position.

Load is disengaged when the contact is open.

Load is engaged when the contact is closed.

See Resistive Load Section 1 Drawing 47B164469.

source to the Load Bank as shown.

Consult NEC for proper wire size.

8. Place the Disconnect Switch (DSW) in the “On” position.

9. Place the Fan Circuit Breakers (FCB 1A or FCB 1B) in the “On” position.

Connect and external

Cable the load

OPERATION

LOCAL

1. Place the “Load Voltage Selector” and “Fan/Control Power Voltage Selector” switches in the appropriate positions.

2. Place the “Load Bank Mode” switch in the “Local Manual” or “Remote” position.

3. Start-up generator or bring other test source on line.

If External Fan/Control Power is being used, “Fan/Control Power” switch in the “On” position to energize the cooling fan before starting the generator to assure proper fan operation.

4. Adjust power source voltage and frequency.

5. Place the “Fan/Control Power” switch in the “On” position to energize the cooling fan.

A false “Cooling Failure” lamp indication may be present until the cooling fan creates sufficient airflow to close the Fan Pressure Switch (PS). The “Normal Operation” lamp illuminates and control voltage is supplied to the “Master Load” switch. With voltage supplied to the “Master Load” switch, the operator is now ready to apply load steps.

6. Verify the illumination of the “Normal Operation” lamp before proceeding.

7. Visually observe correct fan operation and investigate any unusual fan related noises.

8. Check air intake for obstructions and confirm positive air flow.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

9. Select the desired load steps by placing them in the “On” position.

10. Place the “Master Load” switch in the “On” position.

This simultaneously applies all of the load steps which are in the “On” position.

Trim is achieved by flipping the load steps “On” and “Off” while the “Master Load” is in the “On” position.

11. Adjust source voltage and load. Monitor as needed.

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 7 of 20

Shutdown

1 De-energize the load.

2. Run the cooling fan for 5 minutes to

assure a thorough cool down of all load elements (optional).

3. Place the “Fan/Control Power” switch

in the “Off” position.

REMOTE

There are three screens on the remote touch panel. They are: Control/Status Screen, Load Screen, and Metering Screen.

1. Press the “Activate Remote” button.

2. Press the “Energize Control Power”

to energize the cooling fan.

A false “Cooling Failure” may be indicated until the cooling fan creates sufficient airflow to close the Fan Pressure Switch (PS).

3. Verify “Normal Operation” via the

status window before proceeding.

4. Visually observe correct fan opera-

tion and investigate any unusual fan related noises.

Control/Status Screen

Load Screen

6. Select the desired load steps by pressing the desired buttons.

7. Press the “Master Load” button.

This simultaneously applies all of the load steps which are in the “On” position.

Trim is achieved by pressing the load steps “On” and “Off” while the “Master Load” is in the “On” position.

5. Check air intake for obstructions and confirm positive air flow.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

8. Adjust source voltage and load. Monitor as needed.

SHUTDOWN

1 De-energize the load.

2. Run the cooling fan for 5 minutes to assure a thorough cool down of all load elements (optional).

3. Press the “De-energize Control Power” button.

4. Press the “Release Remote” button.

LOAD DUMP

This Load Bank contains a Load Dump feature which de-energizes all applied load when customer supplied contacts open. Normally closed to run, they are rated at 2A @ 24VDC and should be wired to TB‘LD’ 1–2. When these contacts open all applied load will be deenergized and the load section will be disabled. If desired, the customer may install automatic transfer switch contacts, a manual pushbutton or circuit breaker for this use.

The operator also has the option of bypassing these contacts and enabling the load section by flipping the “Auto Load Dump” switch to the “Bypass” position. This disables the load dump feature and illuminates the “Load Dump Bypass” lamp.

Do Not allow the Load Bank to operate unattended for extended periods.

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 8 of 20

Metering Screen

FAILURE DETECTION

If a “Failure” occurs the corresponding lamp will illuminate and the load will be de-energized. Before reapplying a load, the failure must be corrected and the system must be reset by turning the Load Bank “Off” then “On”.

This is a permissive/energize-to-run circuit in which all safety sensors must energize their control relays on normal operation before load can be applied. This system includes the following components:

1. Exhaust Temperature Switches (EXTS1–EXTS4)

2. Pressure Switch (PS)

3. Intake Temperature Switch (INTS)

Thermocouple Temperature Switch

The exhaust temperature network consists of a type J thermocouple (TC) and a solid state thermocouple sensor (EXTS). The temperature switch has been factory adjusted for precise Load Bank over temperature protection under normal operating conditions. Unusual operating conditions may require

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 9 of 20

For continued safety and for maximum equipment protection, always replace fuses with one of equal rating only.

field adjustment. The setpoint of the Exhaust Temperature Switch (EXTS) may be changed by rotating the adjustment knob.

Consult the Simplex Service Department (217-483-1600 24hrs) before changing the temperature switch setpoint.

MAINTENANCE

The Load Bank has been designed to require minimum maintenance. All components have been chosen for a long, reliable life. Two basic intervals of maintenance are required: each operation and every 50 hours or 6 months (whichever comes first).

EACH OPERATION

Overgreasing is a major cause of bearing and/or motor failure. The amount of grease added should be carefully controlled. Also make sure dirt and contaminants are not introduced when adding grease.

If lubrication instructions are shown on the motor nameplate, they will supersede this general instruction.

If motor is nameplated for hazardous locations, do not run motor without all of the grease or drain plugs installed.

The air intake screens and louvers, fan and cooling chamber, and exhaust openings must be checked for any obstructions or foreign objects. Due to the high volume of air circulated, paper and other items can be drawn into the air intakes. During Load Bank operation insure that air is exiting from the top exhaust vent.

The Pillow Block Bearings (PN

22691040), which are used on Saturn Load Banks, are pre-lubricated at the time of manufacture. These bearings are lubricated with Mobil Mobilith AW2

The load branches should be checked for blown fuses or opened load resistors. To check the fuses or load resistors, operate the Load Bank from a balanced 3-phase source and check the three line currents. The three cur-

grease (a Lithium based grease). Lubrication using another grease may cause bearing failure.

See Appendix D Pillow Block Bearings Lube Interval for additional information.

rent readings should be essentially the same. If a sizeable difference is noted one or more load fuses or load resistors may have malfunctioned.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 10 of 20

EVERY 50 HOURS OR 6 MONTHS

Check the tightness of the electrical connections. The expansion and contraction caused by Load Bank operation may result in loose connections. The vibrations caused by the cooling

Standard 3 yrs. 8 mo. 2 yrs. 8 mo. 1 yr. 3 mo.

Severe 1 yr. 3 mo. 1 yr. 3 mo. 6 mo. 1 mo.

Seasonal See Note 2.

fan may also loosen electrical connections. If the Load Bank is transported “over the road”, the electrical connections should be checked for tightness at a shorterthan-normal time interval. See “Primary Inspection”.

Standard: Up to 16 hours of operation per day, indoors, 100°F maximum ambient.

Severe: Greater than 16 hours of operation per day. Continuous operation under high

ambient temperatures (100° to 150°F) and/or any of the following: dirty, moist locations, high vibration (above NEMA standards), heavy shock loading, or where shaft extension end is hot.

Seasonal: The motor remains idle for a period of 6 months or more.

Note:

1. For motors nameplated as “belted duty only” divide the above intervals by 3.

2. Lubricate at the beginning of the season. Then follow service schedule above.

MOTOR LUBRICATION

Motors are properly lubricated at the time of manufacture. It is not necessary to lubricate at the time of installation unless the motor has been in storage for a period of 12 months or longer (refer to lubrication procedure that follows).

Inspect the fan motor supplied with your Load Bank for grease fittings. If the motor contains grease fittings you must lubricate the motor. If lubrication instructions are shown on the motor nameplate, they will supersede this general instruction. Belt driven cooling fans have bearings which should be lubricated. Bearings should be lubricated every 50 hours of operation or 6 months whichever comes first.

RELUBRICATION TIME INTERVAL

for motors with regreasing provisions.

NEMA Frame Size

140 – 180 210 – 360 400 – 510

1800 RPM Over 1800 1800 RPM Over 1800 1800 RPM Over 1800

and less RPM and less RPM and less RPM

Lubrication Procedure

1. Stop motor. Disconnect and lock out of service.

2. Remove contaminants from grease inlet area.

3. Remove filler and drain plugs.

4. Check filler and drain holes for blockage and clean as necessary.

5. Add proper type and amount of grease. See the Relubrication Time Intervals table for service schedule and Relubrication Amounts table (see next page) for volume of grease required.

6. Wipe off excess grease and replace filler and drain plugs.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 11 of 20

7. Motor is ready for operation.

Warning: If motor is nameplated for hazardous locations, do not run motor without all of the grease or drain plugs installed.

Grease Type

Unless stated otherwise on the motor nameplate, the motors on this Load Bank are pregreased with a polyurea mineral oil NGLI grade 2 type grease. Some compatible brands of polyurea mineral base type grease are:

• Chevron SRI #2

• Rykon Premium #2

• Exxon Polyrex EM

• Texaco Polystar RB

TROUBLESHOOTING

This section is designed to aid the electrical technician in basic Load Bank system troubleshooting. All of the problems listed can be verified with a basic test meter and/or continuity tester. For safety reasons, when troubleshooting Load Bank systems always remove all test source power, fan/control power, anti-condensation heater power, etc.

RELUBRICATION AMOUNTS

for motors with regreasing provisions.

NEMA Volume

Frame Size cu. in. (fluid oz.)

140 .25 (.14)

180 .50 (.28)

210 .75 (.42)

250 1.00 (.55)

280 1.25 (.69)

320 1.50 (.83)

360 1.75 (.97)

400 2.25 (1.2)

440 2.75 (1.5)

500 3.00 (1.7)

When troubleshooting Load Bank systems always remove all test source power, fan/control power, anti-condensation heater power, etc.

SOME LOAD STEPS CANNOT BE ENERGIZED

COOLING FAN MOTOR WILL NOT OPERATE

1. Inoperative Fan Circuit Breaker (CB)

2. Fan/Control Power not available/ incorrect

3. Inoperative Fan Motor (MOT)

4. Fan Motor Contactor (FMC) deenergized

5. Restriction of air (intake or exhaust)

6. Fan pressure switch inoperative

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

1. Inoperative load step switches

2. Open load step resistor(s)

3. Inoperative load step relays

4. Inoperative load step contactors

5. Open load step fuses

COOLING FAILURE INDICATED

Exhaust temp above EXTS setpoint:

1. Over temperature sensor failure

2. Fan failure

3. Air restriction (intake or exhaust)

4. Overvoltage condition present

Exhaust temp below EXTS setpoint:

1. Restriction of air (intake or exhaust)

2. Fan pressure switch inoperative

3. Overtemperature sensor failure

DRAWINGS AND PARTS LIST

The drawings included in this manual are the most accurate source of part numbers for your Load Bank. When ordering replacement parts for Simplex Load Banks, always consult the Parts Drawing. When contacting the Simplex Service Department always have your work order and drawing number ready for reference. The Work Order Number and the Drawing Numbers are also located on each drawing legend.

drawing legend and parts list is illustrated at right.

A typical

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 12 of 20

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 13 of 20

APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL

Listed below are abbreviations of terms found on Simplex Load Bank Systems. When following a load bank drawing utilize this guide to define abbreviated system and component names. As this is a master list, drawings and text pertaining to your equipment may not contain all these terms.

AC-Alternating current

AIC-Ampere interrupting cur-

rent-maximum short circuit fault current a component can safely interrupt

AM-Ammeter

AMSW- Ammeter selector

switch-selects any phase for current reading

CF-Control fuse

CFM-Cubic feet per minute-

used to rate fan air flow capacity and load bank cooling requirement

CFR-Cooling failure relaynormally energized relay in cooling failure subsystem

CPC-Control power contactor

CPF-Control power fuse

CT-Current transformer- used in

metering circuits

DC-Direct current

EXTS-Exhaust air temperature

switch

FCB-Fan circuit breaker-circuit breaker in series with fan control power

FCVR-Fan control voltage relaynormally energized relay on relay sub-panel

FM-Frequency meter-monitors frequency of test source

FMC-Fan motor contactorcontrols power to fan motor

FMSW-Frequency meter switch

FPS-Fan power switch-used to

energize cooling system

GFB-Ground fault breaker

GBTR-Ground breaker tripped

relay

HVR-High voltage relay

Hz-Hertz-cycles per second,

measurement of frequency

IFCV-Incorrect fan/control voltage

INTS-Intake air temperature switch

K-Relay coil/contact designation

KVA-Kilovolt amperes

KVAR-Kilovolt amperes-reactive

KW-Kilowatts

KWM-Kilowatt meter

KWT-Kilowatt meter transducer

LM-Louver motor

LMC-Louver motor contactor

LR-Load resistive element

LX-Load reactive element

L1-Line 1

L2-Line 2

L3-Line 3

MCB-Main circuit breaker

MDS-Main Disconnect Switch

MF-Meter fuse

MLB-Main Load Bus

MOT-Motor

NEMA-National electrical

manufacturer’s association

ODP-Open, drip-proof-refers to motor enclosure

OVR-Overvoltage relay-relay used in overvoltage failure system, located on relay subpanel

OLR-Overload relay-used for motor protection

OTR-Overtemperature relayused in failure system

PF-Power factor-in resistive only loads expressed as unity (1.0), in inductive loads expressed as lagging, in capacitive loads expressed as leading

PAR-Control power available relay-relay energized when control power is available

PFM-Power factor meter

PS-Pressure switch-switch used

to detect fan failure

RR-Reset relay

RTM-Running time meter-keeps

time log of equipment use.

TB-Terminal block

TDR-Time delay relay-relay

which times out before contacts change state

TEFC-Totally enclosed, fan cooled-refers to motor enclosure

TEAO-Totally enclosed, airover-refers to motor enclosure

UPS-Uninterruptable power source

V-Voltage

VSR-Voltage sensing relay

XCB-Reactive load controlling

circuit breaker

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

APPENDIX B CALCULATIONS & FORMULAS

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 14 of 20

EXAMPLES

Using line voltages and currents:

The following calculations are used to determine the actual kilowatt load being applied by the Load Bank, when line voltages and currents are known (at 1.0 power factor).

3 Phase

1. Read all three line currents and find the average reading.

2. Read all three line-to-line voltages and find the average reading.

3. Multiply the average current times the average voltage.

4. Multiply the answer of step #3 times the square root of 3 (1.732).

5. Divide the answer of step #4 by 1000. The answer is the actual kilowatts of load being applied by the Load Bank.

Single Phase

1. Determine the line current.

2. Determine the line-to-line voltage.

3. Multiply the line current times the line-to-line voltage.

4. Divide the answer of step #3 by 1000.

3 Phase

Current Readings Voltage Readings

A1 = 249A V A2 = 250A V A

= 254A V

A1 + A2 + A

Average Current =

= 481V

1-2

= 479V

2-3

= 483V

3-1

249+250+254

= 251A

+ V

Average Voltage =

1-2

+ V

2-3

3-1

481 + 479 + 483

= 481V

Volts x Amps x 1.732

Kilowatts =

1000

481 x 251 x 1.732

1000

5. The answer of step #4 is the actual kilowatts being applied by the load

= 209.1KW

bank.

Single Phase

Current Reading: 150A Voltage Reading: 240V

Volts x Amps

Kilowatts =

1000

150 x 240

1000

= 36.1KW

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The following calculations are used to determine the amount of current when the desired amount of kilowatts is applied at 1.0 power factor.

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 15 of 20

EXAMPLES

When desired amount of kilowatts is applied at 1.0 PF:

3 Phase

1. Multiply the desired amount of kilowatts to be applied by 1000.

2. Multiply the operating voltage times the square root of 3 (1.732)

3. Divide the answer of step #1 by the answer of step #2.

4. The answer of step #3 is the average line current with the desired kilowatts applied at 1.0 power factor.

Single phase

1. Multiply the desired amount of kilowatts to be applied by 1000.

2. Divide the answer of step #1 by the operating voltage.

3. The answer of step #2 is the average line current with the desired amount of kilowatts applied at 1.0 power factor.

The following calculations are used to determine a step kilowatt rating at other than a rated voltage. This is accomplished by referencing the load step to a KW value at a known voltage.

Applied: 50KW Operating Voltage: 480V

KW x 1000

Amperage =

Volts x 1.732

50 x 1000

480 x 1.732

50,000

831.36

= 60.1

Single Phase

Applied: 25KW Operating Voltage: 240V

KW x 1000

Amperage =

Volts

25 x 1000

240

25,000

240

= 104.2

1. Determine the new unrated operating voltage.

2. Divide the new operating voltage by

Determining step KW at other than rated voltage:

Applied: 80KW Operating Voltage: 450V

Rated Voltage: 480V

the reference voltage.

3. Square the answer of step #2.

4. Multiply the answer of step #3 times the reference kilowatt value of the load step which the new kilowatt rating is desired.

Step KW = (Oper. Volt. ÷ Rated Volt.)2 x Applied KW

= (450

÷ 480)

x 80

= .93752 x 80

= 70.3

5. The answer of step #4 is the kilowatt rating of the load step at the new voltage.

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LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 16 of 20

FORMULAS

Alternating Current Direct Current

Kilowatts 1 phase Volts x Amps x PF* Volts x Amps

1000 1000

3 phase 1.732 x Volts x Amps x PF*

1000

*Power Factor, expressed as decimal.

(Resistive Load Bank PF is 1.0)

Amperes 1 phase KW x 1000 KW x 1000

(KW known)

Volts x PF Volts

3 phase KW x 1000

1.732 x Volts x PF

KVA 1 phase Volts x Amps

1000

3 phase 1.732 x Volts x Amps

1000

Amperes 1 phase KVA x 1000

(KVA known)

Volts

3 phase KVA x 1000

1.732 x Volts

KVAR 1 phase Volts x Amps x 1-PF

1000

3 phase 1.732 x Volts x Amps x 1-PF

1000

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APPENDIX C - TORQUE VALUES

LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 17 of 20

FAN BLADES

FAN TORQUE

PART NO. BOLT SIZE FT LBS // IN LBS

13820000 SET SCREW 11.7 // 140

13820500 SET SCREW 11.7 // 140

13821000 SET SCREW 8.3 // 100

13822000 1/4 — 20 7.5 // 90

13823000 1/4 — 20 7.5 // 90

13824000 1/4 — 20 7.5 // 90

13825100 1/4 — 20 7.5 // 90

13826000 1/4 — 20 7.5 // 90

13827500 5/16” 13 // 156

13827600 5/16” 13 // 156

13828000 3/8” 24 // 288

MOTORS, BRACKETS, BUS BAR CONNECTIONS

BOLT/NUT TORQUE

SIZE GRADE FT LBS // IN LBS

CONTACTORS

See torque values on the front of the contactor.

ELEMENTS/TRAYS

TERM/NUT TORQUE

SIZE INCH LBS

#6 Rod ends 4

#10 Element Conn. 20

1/4-20” High Voltage Contact Simplex

MAIN LOAD BLOCKS- ALL SIZES

WIRE TORQUE

CONNECTION SIZE FT LBS // IN LBS

LOAD SIDE 4-14AWG 2.9 // 35

LINE SIDE 500MCM-4/0 31 // 375

3/0-4/0 20 // 240

2/0-6AWG 10 // 120

8AWG 3.3 // 40

.250 (1/4-20) Grade 5, dry 8 // 96

.250 (1/4-20) Grade 2, dry 5.5 // 66

.312 (5/16) Grade 5, dry 17 // 204

.312 (5/16) Grade 2, dry 11 // 132

.375 (3/8) Grade 5, dry 30 // 360

.375 (3/8) Grade 2, dry 19 // 228

.437 (7/16) Grade 5, dry 50 // 600

.437 (7/16) Grade 2, dry 30 // 360

.500 (1/2) Grade 5, dry 75 // 900

STYLE SIZE INCH LBS

Cutler-Hammer 14-10 AWG 20

1-Phase

Merlin Gerin 14-1/0 50

3-Phase

CIRCUIT BREAKERS

WIRE TORQUE

8 AWG 25

6-4 AWG 27

3-1/0 AWG 45

.500 (1/2) Grade 2, dry 40 // 480

.562 (9/16) & up Grade 5, dry 110 // 1320

.562 (9/16) & up Grade 2, dry 55 // 660

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LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 18 of 20

APPENDIX C - TORQUE VALUES CONT’D

FUSEBLOCKS

MANUF. WIRE TORQUE

PART NO. SIZE INCH LBS

BM6031SQ, 10-18 AWG 20 BM6032SQ, BM6033SQ;

600V, 30A

T60060-2SR 10-18 AWG 20

600V, 60A

T60030-3CR, 10-14 AWG 35

600V, 30A

T60060-3CR,

600V, 60A

60100-3CR,

600V, 100A

8 AWG 40

4-6 AWG 45

2-3 AWG 50

MISCELLANEOUS-TERMINALS, METERS, SWITCHES, COILS, RELAYS, XFORMERS

CONNECTION TORQUE

SIZE INCH LBS

610

819

TAPER-LOCK BUSHINGS

BUSHING NUMBER TORQUE

1008, 1108 55 IN LBS

1210, 1215, 1310, 1610, 1615 15 FT LBS

2012 23 FT LBS

2517, 2525 36 FT LBS

3020, 3030 67 FT LBS

3535 83 FT LBS

4040 142 FT LBS

4545 204 FT LBS

5050 258 FT LBS

6050, 7060, 8065 652 FT LBS

10085, 12010 1142 FT LBS

CAM-LOK STUDS

THREADED MAXIMUM

STUD TORQUE

5/16” – 18 15 FT LBS

1/2” – 13 40 FT LBS

10 31

1/4-20” 66

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LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 19 of 20

APPENDIX D - PILLOW BLOCK BEARINGS LUBE INTERVAL

The Pillow Block Bearings (PN 22691040), which are used on Saturn Load Banks, are pre-lubricated at the time of manufacture. These bearings are lubricated with Mobil Mobilith AW2 grease (a Lithium based grease).

Lubrication using another grease may cause bearing failure.

If the lube interval is

less than a month use the Weekly Relube Quantity at each relube cycle.

If the lube interval is greater than a month and less than a year use the Monthly Relube Quantity.

If the lube interval is greater than a year use the Yearly Relube Quantity.

8 hrs./day 16 hrs./day 24 hrs./day

Minimum Lube Interval 6500 hrs. 116 wks. 58 wks. 38 wks.

Maximum Lube Interval 9100 hrs. 162 wks. 81 wks. 54 wks.

Weekly Relube Quantity 0.14 ozs.

Monthly Relube Quantity 0.21 ozs.

Yearly Relube Quatity 0.28 ozs.

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LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 20 of 20

APPENDIX E - DRAWINGS

Title Drawing

Pictorial ............................................ 47BD164460C

Control Section................................. 47B164461C

Fan/Control ...................................... 47B164462B

Local Manual Control ....................... 47B164463B

PLC Control...................................... 47B164464C

PLC Communications Control .......... 47B164465A

PLC Control Wiring .......................... 47B164466B

Metering ........................................... 47B164467A

Resistive Contactors Coil ................. 47B164468

Load Section 1 of 3 .......................... 47B164469

Load Section 2 of 3 .......................... 47B164470

Load Section 3 of 3 .......................... 47B164471

Load Strapping 1 of 4 ....................... 47B164472

Load Strapping 2 of 4 ....................... 47B164473

Load Strapping 3 of 4 ....................... 47B164474

Load Strapping 4 of 4 ....................... 47B164475

Load Tray Layout ............................. 47BD164476A

Non-Standard Elements ................... 47B164477A

Local Control Panel .......................... 47BD164478B

Remote Control Panel ...................... 47BD164479

Parts Legend 1 of 2 .......................... 47B164480A

Parts Legend 2 of 2 .......................... 47B164481B

Subpanel Layout 1 of 2 .................... 47BD164482C

Subpanel Layout 2 of 2 .................... 47BD164483B

Nameplates ...................................... 47BD164484B

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Simplex Saturn 3000 DV Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual