|
Radiator
Cooled
LBD-Series
1000KW,
800KW, 750KW
600KW, 500KW,
400KW, 300KW,
200KW, 150KW,
100KW, 75KW,
50KW, 40KW,
30KW, 25KW,
20KW, 15KW,
10KW, 5KW
|
|
GENERAL SPECIFICATIONS
Capacity
5KW, 10KW,
15KW, 20KW, 25KW, 30KW, 40KW, 50KW, 75KW, 100KW, 150KW, 200KW,
300KW, 400KW, 500KW, 600KW, 750KW, 800KW, 1000KW
Voltage
All common
50, 60 or 400Hz AC
Load Steps
20KW at 208V
25KW or 50KW at 480V
25KW or 50KW at 240V, 1-ph.
5KW and/or 10KW available
LBD-Series Sample Specifications
click here.
Sales
Bulletin
|
|
|
|
The Simplex LBD-Series is
special form of stationary, resistive, forced air-cooled Load
Banks which utilize the air outflow of an engine radiator for
cooling of the resistive load elements. This application recovers
and uses the volume and velocity of air exiting the radiator.
It may appear incongruous that “hot air” from the radiator
is used for “cooling”. However, “hot” and
“cold” are highly relative in this case. The air exhausting
from the radiator and entering the Load Bank may be as hot (or
cold) as 180°F. However, the load elements are heated to
an average of 700°F, and, most important, the air volume
and velocity is very high relative to the heat energy being dissipated
by the Load Bank. Consequently, the critical value of “air
temperature rise” is limited to a conservative nominal 100°F.
Despite an apparent “hot” environment, LBD-Series
Load Banks actually operate “cooler” than those comparably
rated equipped with integral cooling fans installed in the relative
“cold.”
Simplex LBD-Series Load Banks are intended for use with
water cooled engine generator sets equipped with unit mounted
radiators.
The essential consideration for installation is that it be located
somewhere within the radiator air outflow. Installation is simple
and adaptive to site/system conditions in numerous ways, including
direct bolted attachment to the radiator, mounting within an
air duct, wall mounting over the air outflow opening, indoors
or outdoors.
Since the design is adaptive to varying site conditions, Simplex
LBD-Series Load Banks are ideal for after market retrofit.
Many options are available to suit individual requirements and
simplify installation.
LBD-Series
Load Banks are of a modular-building block design. Simplex builds
them up from stock modular parts to match your radiator or duct
dimensions exactly.
The control section's standard location is on the left side,
but it may be ordered on the right side. A control section may
be required on both sides in some applications.
|
Features
This product has earned the UL Listing Mark
Utilizes the UL Recognized “Pow’r Rod” load element
Branch circuit fuse protection of load elements
Magnetic contactor control of load
Multiple step load configurations
150°C XLP insulated power wiring
Power terminal block with standard size pressure terminals for
common building wire
Local or remote control available
Manual or automatic control available
120V control circuits
Install at any point within radiator air outflow
Install indoors or outdoors (via option modification)
Many installation accessories available
Galvanized steel construction
Automatic over temperature protection
Control components separate and isolated from load elements
Continuous duty
|
Applications
Reliability Exercise and testing of standby generator sets to
assure readiness and eliminate the negative effects of both prolonged
standby and of no-load exercise.
Base load leveling to eliminate the deleterious effects of low
load operation: manual application or fully automatic in response
to dynamic load demand.
Automatic protection against generator reverse power and motoring
of prime mover by power regenerated by inertial loads.
Options
Mounting Angles
Mounting Feet
Nema-3R Modification
Automatic Current Sensing Operation
VM-AM-FM Meters with switches
KW Meter
Cooldown Timer
Auto-Exercise
Anti-Condensation Heaters
|
Simplex Load Banks can
be used to satisfy the requirements of the National Fire Protection
Association (NFPA) for emergency stand-by power systems. |
 |
|
|
Calculating
Load Bank Depth, Dimensions, and Width |
|
|
|
DEPTH |
|
Capacity |
Depth
"A" |
|
less than 50KW |
10" |
|
50-150KW, 480V |
10" |
|
150-350KW, 480V |
20" |
|
50-200KW, 208V |
20" |
|
200-350KW, 208V |
20" |
|
350-800KW |
30" |
Note: Depth "A"
does not include
2" Mounting Adapters (Angle Flanges)
or 3" Louvered Exhaust. |
|
DIMENSIONS |
|
A |
B |
C |
D |
E |
|
10" |
24" |
8.5" |
7.575" |
.855" |
|
20" |
24" |
10.0" |
8.075" |
1.355" |
|
20" |
48" |
12.0" |
10.075" |
1.355" |
|
Dimensions are approximate. Due
to system complexity, actual dimensions may vary. |
|
|
TOTAL WIDTH
Total
Width
= Opening Width + 2" + Control Section(s) Width
10" x 24" Control Section = 19.355" W
20" x 24" Control Section = 11.355" W
20" x 48" Control Section = 13.355" W
Note:
A Control Section may be required on both sides for some applications.
Due to system complexity,
actual
dimensions may vary. |
Remote Control Panel
15" W x 15" H x 10" D
24" W x 24" H x 12" D |
|
|
 Powr-Rod Load Element
Simplex LBD-Series Load
Banks utilize the UL Recognized “Pow’r Rod” Load
Element (totally enclosed, sealed and weatherproof). Considerations
of personnel safety and equipment durability dictate the use
of totally enclosed load elements in a radiator airflow cooled
Load Bank. In this application the Load Bank is installed in
front of the engine radiator where the load elements are visible
and within reach of personnel and exposed to the weather. The
elements will be subject to mechanical stresses and airborne
contamination by the radiator air blast. The “Pow’r
Rod” element consists of a nickel-chromium resistance wire
electrically insulated and sealed within a metallic sheath. Since
the element is electrically dead on the outside, it reduces the
hazard of electric shock to personnel and eliminates the danger
of short circuit of the elements by foreign object penetration.
The element is unaffected by rain and by airborne dirt and oil.
Since the element is essentially a solid metallic tube, it is
extremely rugged and will not fatigue from engine or air-blast
vibrations and will not sag or stretch if overheated. The element
sheath material is "incolloy," a rustproof nickel alloy
with a very high temperature rating (1600°F). The element
does not require a cool-down period.
|
Features
Totally enclosed element, eliminates shock hazard
Sealed, unaffected by weather and airborne oil/dirt
Rugged metallic housing unaffected by vibration
Requires no cool down
Long life, rustproof
UL Recognized Component |
 Branch Circuit Fuse Protection
Load Banks must have branch
circuit fuse protection of the load elements. A Load Bank without
fuse protection as defined in the NEC is a safety and fire hazard.
All Simplex Load Banks are built-up in fused branch circuits
of not more than 70A each. All wiring and devices within the
branch circuit are rated in accordance with the fuse rating.
Simplex virtually eliminates the danger of short circuit of the
load elements and consequent catastrophic damage to the Load
Bank and the installation, through the use of discrete branch
circuit fusing of the load elements
Fuse protection scheme per NEC 110-9, 110-10, 230-98
UL Listed Class-T, CSA HRC-1 Fuses
200,000 A.I.C. current limiting
Single element, very fast acting
Discrete circuit design, 70A maximum per fuse
|
|
|
|
SIMPLEX
“POW’R ROD” vs. OPEN-WIRE ELEMENTS |
|
“POW’R
ROD” |
OPEN-WIRE
ELEMENTS |
|
Totally enclosed conductor, eliminates
shock hazard. |
Exposed conductor, a shock hazard
to bystanders, curious children. |
|
Totally enclosed conductor, eliminates
short circuit hazard. |
Exposed conductor can be short
circuited by foreign objects or by the breakage of an adjacent
element. |
|
Totally enclosed design, elements
unaffected by adjacent elements. |
Open design elements can short
to adjacent elements if proper spacing not maintained. Concerns
with engine vibration, overheating, fatigue. |
|
Sealed design is weatherproof. |
Open design requires external weatherproofing,
should not get wet. |
|
Rugged metallic sheath unaffected
by engine and air blast vibrations. Ideal for portable gensets. |
Delicate design using fragile ceramic
insulators and bushings subject to breakage. |
|
High temperature design with great
over temperature tolerance retains mechanical integrity when
overheated. |
Open wire designs deform and stretch
when subject to overheating. |
|
Enclosed conductor is protected
from airborne oil and crud. |
Any contaminants in the airflow
can accumulate on the open wire coils causing hot spots, corrosion,
short circuits.
|
|
|
|
Mounting
Diagram |
 |
 |
Engineer’s Specifications for LBD-Series
Load Banks
(Engine Radiator Airflow Cooled)
Click here
for a text file of these specifications.
|
Options in the specifications are
italicized within parentheses. Blanks are provided in
section 1.4, Ratings, for the addition of specific rating values.
1. Generator Load Bank
1.1 General: An engine radiator airflow cooled, resistive
Load Bank is required for permanent, on site installation as
a component of a standby engine generator system. The Load Bank
shall be designed for (remote, local), (automatic,
manual) control. The Load Bank shall bear the listing mark
of Underwriters Laboratories (UL Listing).
1.2 Installation: The Load Bank shall be installed
within the air outflow of the engine unit mounted radiator and
shall be cooled by the radiator airflow. The Load Bank may be
installed by one of the following methods:
1.2.1 Bolted attachment to radiator with duct and flex
coupling to air outlet in wall.
1.2.2 Installation within air duct; flex transition to
radiator and solid duct transition to air outlet in wall.
1.2.3 Bolted attachment to interior wall with duct and
flex coupling to radiator.
1.2.4 Bolted attachment to exterior wall over air outlet.
Load Bank should be weatherproof for this installation.
1.3 Electrical Connection: Power source to Load
Bank connection is 3-phase, 3-wire plus ground. Additional control
wire connections for remote control as required.
1.4 Load Bank Rating:
1.4.1 Capacity: _____ KW, 1.0 p.f.
1.4.2 Load Steps (5, 10, 20, 25, 40, 50) KW load
step resolution
1.4.3 Voltage: _____V AC, 3-ph., 3-W
1.4.4 Frequency: (50, 60, 400) Hertz
1.4.5 Air intake temperature: 155°F max (radiator
air outflow)
1.4.6 Airflow requirements: Radiator air outflow
1.4.7 Duty Cycle: Continuous
1.4-8 Air temp. rise: 100°F, nominal
1.4.9 Air back pressure: .25-.50" water column
1.5 Load Bank Design
1.5.1 General: The Load Bank shall be a completely self-contained
unit which includes all resistive load elements, load control
devices, load element branch circuit fuse protection, main load
bus and terminals, control terminals, system protection devices
and NEMA enclosure of required type.
1.5.2 The Load Bank shall be the manufacturer's standard
product that has been investigated, tested and listed by Underwriters
Laboratories as a system for the purpose intended. Simple assemblies
of listed parts that are not system UL listed shall not be acceptable.
|
1.5.3
Enclosure: NEMA type (1, 3R), galvanized steel, unit construction,
consisting of a power section, for installation and wiring of
the load elements and a control section for installation and
wiring of control components. The control section is to be physically
and thermally isolated from both the hot load elements and the
heated airflow. Mounting adaptors suitable for the installation
method selected shall be supplied with the Load Bank. The exhaust
of the Load Bank shall be screened and, if installed outdoors,
louvers shall be provided.
1.5.4 Load elements: Load elements shall be UL listed,
labeled or recognized, totally enclosed, sealed and weatherproof
with an electrically grounded outer sheath such that the element
can not be electrically short-circuited by external foreign objects
and personnel are protected against accidental electrical shock.
Elements shall be individually replaceable. Open wire type elements
in which the electrically live conductors are exposed and which
can be short circuited to each other or to ground by foreign
objects or by the breakage of an element or an element support
shall not be permitted.
1.5.5 Load element short circuit protection: Branch circuit
fuses, per each 50KW load branch circuit. Fuses shall be 200,000
A.I.C current limiting type.
1.5.6 Load control: One magnetic contactor per each fused
branch circuit.
1.5.7 Load Bank power wiring shall be 150°C XLP insulated.
1.5.8 Main terminals: Barrier type power terminal block with
compression type terminal to accept stranded building wire. Provide
chassis ground stud with compression type terminal.
1.5.9 Control wiring shall be 105°C XLP insulated.
1.5.10 Control power shall be derived internally from
the main load bus. Control and protective circuits shall operate
at 120V via control power transformer or line-neutral circuit
and shall be fused.
1.5.11 System protection: The Load Bank shall include
a comprehensive protection system to protect against overheating.
The system shall function to disconnect the load elements from
the power source and activate an alarm upon sensing an exhaust
air temperature greater than 300°F.
1.6 (Local, Remote) Control Panel
1.6.1 A NEMA (1,3R) control panel for (automatic,
manual) operation shall be provided. The panel shall include:
1.6.2 Control power on-off pushbuttons
1.6.3 “Normal operation” indicator lamp
1.6.4 Master load control switch
1.6.5 Load step control switches
1.6.6 “Cooling failure” alarm indicator lamp
1.6.7 Remote control panel shall be UL listed. |
1.7 Warranty: The Load Bank shall be supplied with
a 2-year manufacturer's warranty which covers all materials and
service labor. The manufacturer shall demonstrate the availability
of factory service technicians in support of the Load Bank.
1.8 Start-up Service: The Load Bank manufacturer
is to provide one day start-up service of the Load Bank, on site,
after the Load Bank has been installed and connected.
1.9 Qualifications of Load Bank Manufacturer
1.9.1 The Load Bank shall be a product of a firm regularly
engaged in the design and manufacture of generator Load Banks.
1.9.2 The Load Bank manufacturer shall demonstrate at
least five years experience with at least twenty-five successful
installations of Load Banks similar or equal to the Load Bank
specified herein.
1.9.3 The Load Bank for this application shall be a Simplex
LBD-Series as manufactured by Simplex, Inc. 1139 N. MacArthur
Blvd., Springfield, Illinois 62702, 800-637-8603
Add the following section to provide for Load Bank operation
as an automatic load regulator to maintain a preset load level.
1.10 Automatic Load Bank Controller
1.10.1 The Load Bank is to be equipped with an automatic
controller which will be activated when the Load Bank mode control
selector switch is placed in the “automatic” position.
1.10.2 In automatic mode, the Load Bank is to be on-line
and continuously operative whenever the power source runs. The
Load Bank shall provide a component of the total power source
load and shall be automatically variable in response to dynamic
total load demands upon the power source.
1.10.3 The automatic controller shall include control
logic, solid-state sensors and time delays which shall act to
apply/remove Load Bank component in multiple steps in response
to dynamic output of the power source.
1.10.4 The automatic controller shall function to maintain
total load upon the power source within a preset bandwidth by
adding Load Bank load component as external load component drops
and removing Load Bank component as external load rises.
1.10.5 The automatic controller shall sense load (amperes,
kilowatts).
1.10.6 Full manual control of the Load Bank shall be restored
when the mode selector switch is placed in the “manual”
position.
1.10.7 The automatic controller shall include a solid-state
load sensor with level and time delay adjustment and output contacts
for each load step. A current transformer for external installation
shall be provided.
|
