Simplex Watt-Muncher User Manual

Watt-Muncher Load Bank Manual

6 June 2018 • Simplex Service 800-637-8603 • Page 1 of 13

WATT-MUNCHER

Portable Load Bank

Watt-Muncher Load Bank Manual

6 June 2018 • Simplex Service 800-637-8603 • Page 2 of 13

This manual was last revised:

6 June 2018

For up-to-date information on this product or others,

please contact Simplex at 800-637-8603 or on the web at

www.simplexdirect.com

Watt-Muncher Load Bank Manual

6 June 2018 • Simplex Service 800-637-8603 • Page 3 of 13

Table of Contents

I. Warnings and Cautions .................................................. 4

I-A. Safety information symbols ................................................................. 4

I-B. Cautions ........................................................................................ 4

II. Description and Specification ......................................... 7

II-A. Features ....................................................................................... 7

II-B. Safety .......................................................................................... 7

II-C. Specifications ................................................................................ 8

III. Unpacking ................................................................ 9

III-A. Included Components and Parts .......................................................... 9

III-B. Primary Inspection .......................................................................... 9

IV. Installation ............................................................. 11

IV-A. Load Bank Placement ..................................................................... 11

IV-B. Wiring the load bank ...................................................................... 11

V. Operating Instructions ................................................ 11

V-A. Startup ....................................................................................... 11

V-B. Applying a Load ............................................................................. 11

V-C. Shutdown .................................................................................... 11

VI. Maintenance/Troubleshooting ...................................... 12

VI-A. General maintenance ..................................................................... 12

VI-B. Troubleshooting ............................................................................ 12

Appendix A - Product Warranty .............................. 13

Watt-Muncher Load Bank Manual

6 June 2018 • Simplex Service 800-637-8603 • Page 4 of 13

I. WARNINGS AND CAUTIONS

I-A. Safety Information Symbols:

This General warning symbol points out important information that, if not followed, could
endanger personal safety and/or property.

This Explosion warning symbol points out potential explosion hazards.

This Fire warning symbol points out potential fire hazards.

This Electrical warning symbol points out potential electrical shock hazards.

I-B. Cautions:

This load bank is high-powered, technical, industrial equipment operating at dangerous
voltages and temperatures. It is capable of damaging itself, property or personnel if
improperly used. It is not a consumer product.

It must be installed, connected and operated by personnel properly trained and experienced
in its use. An operator’s manual is supplied with each load bank and available online at
www. simplexdirect.com. The operator must be familiar with its contents and have access to
it during operation.

• High Voltage: Turn off and disconnect power source before opening this equipment

• High Temperature: Allow hardware to cool before servicing or opening this

equipment.

• Rotating Equipment: Ensure that the fans have stopped before opening this unit.

• For Operator Safety: Make sure this equipment is properly grounded when in use.

All compression-type connections on fuse blocks, load blocks, and contactors should be
checked for tightness frequently. This check should be established as part of routine
maintenance.

The following cautions should be observed before and during operation:

• Check intake and exhaust screens as well as fan and load elements for foreign objects.

• Position and install the load bank with consideration given to large cubic airflow

requirements, exhaust temperature, and velocity. Do not point exhaust at any nearby
surface or object that may be adversely affected by high temperature. This includes
but is not limited to painted surfaces, tar paper and asphalt roofs, water sprinkler
heads, fire alarms, and volatile material.

Watt-Muncher Load Bank Manual

6 June 2018 • Simplex Service 800-637-8603 • Page 5 of 13

• Do not use in confined spaces. The load bank may have to compete with cooling air

requirements of a nearby running engine generator set where cooling air intake to a
confined space may not be adequate for both engine and load bank. Be especially
careful not to bounce hot exhaust air off nearby obstructions for re-circulation through
the load bank.

• Verify that all control switch positions are set correctly for your intended usage before

connecting the load bank to the source to be tested.

• The load cables carry high amperage. Be constantly aware of possibility of inductively

heating adjacent ferrous objects to temperatures sufficient to damage cable
insulation.

• Always connect the safety ground cable to a proper ground. Do not rely on a possible

grounded neutral somewhere else in the system.

• Do not let the load bank run unattended for long periods of time.

• Do not store or operate in rain unless adequate protection is provided.

• Routinely inspect all components and electrical connections for tightness and

integrity.

• Repair any damaged or degraded components and wiring without delay.

• If technical assistance, service, or parts are needed, please call 800-837-8603 (24

Hours).

• All hardware covered by this manual have dangerous electrical voltages and can cause

fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc.
Ensure all appropriate covers, guards, grounds, and barriers are in place before
operating the equipment. If work must be done around an operating unit, stand on an
insulated dry surface to reduce the risk of electrocution.

• Do not handle any kind of electrical device while standing in water, while barefoot, or

while your hands or feet are wet.

• If people must stand on metal or concrete while installing, servicing, adjusting, or

repairing this equipment, place insulative mats over a dry wooden platform. Work on
the equipment only while standing on such insulative mats.

• The National Electrical Code (NEC), Article 250 requires the frame to be connected to

an approved earth ground and/or grounding rods. This grounding will help prevent
dangerous electrical shock that might be caused by a ground fault condition or by
static electricity. Never disconnect the ground wire while the load bank is in use.

• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to

handle the maximum electrical current (ampacity) to which they will be subjected.

• Before installing or servicing this (and related) equipment, ensure that all power

voltage supplies are completely turned off at their source. Failure to do so can result
in hazardous and possibly fatal electrical shock.

• In case of accident caused by electric shock, immediately shut down the source of

electrical power. If this is not possible, attempt to free the victim from the live
conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from the live conductor. If
the victim is unconscious, apply first aid and seek immediate medical attention.

• Never wear jewelry when working on this equipment. Jewelry can conduct electricity

resulting in electric shock or may get caught in moving components causing injury.