Simplex Stationary Load Bank Applications and General Specifications

Stationary	Stationary Load Bank Applications
	Manual Generator exercise and testing via local or remote manual control Minimum loading of generators	Automatic Generator exercise, control from remote control contacts Automatic exercise/test via programmable microprocessor control Automatic load leveling/load regulation to maintain preset load on generator by sensing of total load and automatic addition or subtraction of Load Bank component Reverse power/regenerative power protection of generator by sensing power direction and magnitude and automatic addition of Load Bank component to act as a power sink	NFPA Testing Simplex Stationary Load Banks can be used to satisfy the requirements of the National Fire Protection Association (NFPA) for emergency stand-by power systems. These requirements concern acceptance testing and periodic on-site testing and maintenance of emergency and stand-by power systems. The essence of the requirements is that emergency and stand-by power systems are to be tested under load. NFPA 110 - Emergency and Standby Power Systems, Sections 5-13, 6-3, 6-4 NFPA 99 - Health Care Facilities, Section 3-4.4.1.1 (b) NFPA 70 - National Electric Code, Section 700-4 (b)

Stationary Load Bank General Specifications

Ambient Temperature
Max. Air Intake Temp.: 120°F

Air Temp. Rise:

Temp. Rise (°F) =	KW x 3000
	CFM

Note: Air temperatures at plane of exhaust can vary greatly from point to point. Contact Simplex for temperature gradient date and maximum exhaust air temperatures for specific Load Bank.

Altitude
Above 3500', contact Simplex

Enclosures
Standard: NEMA-3R, outdoor weatherproof
Optional: NEMA-1, indoor

Connection
Copper plated bus bar terminals

Control/Fan Power Source
Standard design—derived internally, from load bus. Cooling fan operates at line voltage. Control circuits operate 120V, either from transformer power supply of from 120V line-neutral connection. As an option, the Load Bank can be designed to obtain control/fan power from an external source, supplied by user.

Voltage and Load Steps

Integral load steps are the basic branch circuits of the Load Bank. The Load Bank is designed in building block multiples of the integral load step. Each integral load step represents a discrete load circuit with branch circuit fuse protection.

Integral load steps are “course:” relatively large in value. To obtain “fine” load step resolution, add fractional load steps. If multiples of the integral load step do not equal the total capacity desired, add fractional load steps to fill-in the difference.

Simplex Load Banks can be used to satisfy the requirements of the National Fire Protection Association (NFPA) for emergency stand-by power systems.

MODEL	LOAD CAPACITY	AIRFLOW REQUIREMENTS	APPROX. WEIGHT
Polaris	5-75KW	2,500 CFM	300 lbs.
Polaris	100-150KW	3,500 CFM	400 lbs.
Mercury	50-250KW	10,000 CFM	800 lbs.
Neptune	250-400KW	10,000 CFM	1,900 lbs.
Neptune	450-650KW	12,500 CFM	1,900 lbs.
Mars	700-1400KW	26,000 CFM	3,000 lbs.
Saturn	1400-1800KW	40,000 CFM	6,000 lbs.
	1800-2250KW	55,000 CFM
	2500-3000KW	70,000 CFM
Triton	150-400KW	10,000 CFM	1,850 lbs.
Trident	450-750KW	18,000 CFM
Trident	800-1250KW	26,000 CFM

		LOAD STEPS (KW)
FREQUENCY	VOLTAGE	INTEGRAL	FRACTIONAL
60 Hz	120V, 1-ph.	5	1
	240V, 1-ph.	10	1, 5
	208V, 3-ph.	20	1, 5, 10
	240V, 3-ph.	20, 25
	416V, 3-ph.	40
	440V, 3-ph.	40	1, 5, 10, 20
	450V, 3-ph.	40, 50	1, 5, 10, 20, 25
	460V, 3-ph.
	480V, 3-ph.
	600V, 3-ph.
50 Hz	240V, 1-ph.	10	1, 5
	200V, 3-ph.	20	1, 5, 10
	240V, 3-ph.	20, 25	1, 5, 10
	380V, 3-ph.	40	1, 5, 10, 20
	400V, 3-ph.
	416V, 3-ph.
	600V, 3-ph.	40, 50	1, 5, 10, 20, 25
400 Hz	200V, 3-ph.	20	1, 5, 10
	208V, 3-ph.	20	1, 5, 10
	416V, 3-ph.	40	1, 5, 10, 20
DC	125V	6.25	1, 5
DC	250V	12.5	1,5,10

Stationary

Stationary Load Bank Features

Features

Options

General

Utilizes the UL Recognized “Powr-Web” load element

Branch circuit fuse protection of load elements

Magnetic contactor control of load

Multiple step load configurations

150°C insulated power wiring, color coded

Copper plated bus bar

Integral cooling fan

120V control circuits

Fused control circuits

Automatic over temperature and fan failure protection

Continuous duty

NEMA-3R outdoor or NEMA-1 indoor

Malfunction Detection

Malfunction detection system provides automatic load disconnect and alarm on sensing of an abnormal operating condition. The systems consists of:

Cooling air intake temperature switch, set at 120°F, to sense recirculation of load bank hot exhaust air or an ambient temperature above the rating of the load bank

Cooling air exhaust temperature switch, set 75°F above maximum rise at maximum ambient, to sense restricted cooling airflow, recirculating air, loss of airflow.

Air pressure switch to sense for positive cooling airflow

Automatic load disconnect/lockout circuit

Remote alarm contacts

Integral Forced Air Cooling System

Motor drive propeller fan

Fan blade, shrouded for high efficiency

Motor control contactor

Motor circuit breaker

Fan motors normally operate at load bank line voltage

Motors for outdoor load banks are totally enclosed

Motors for indoor load banks are open-drip-proof

Powr-Web Load Element

Simplex Load Banks utilize the UL Recognized, “Powr-Web” load element. The “Powr-Web” is an advanced design, air-cooled power resistor specifically 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-circuit-safe design based on continuous mechanical support of the resistor by high temperature, ceramic clad stainless steel rods. The “Power Webs” are assembled into discrete trays which are assembled in a vertical “stack.” Each tray in the “stack” is independently serviceable without disturbing adjacent trays.

Ratings
3333W at 120V
4170W at 139V
8333 watt 240/480V
16,777 watt at 480V

Specifications
Alloy: FeCrAl
Max. continuous temp. rating: 1920°F
Maximum operating temperature as applied in Load Bank: 1080° F
Cool down time from operating to ambient temperature: 10 seconds

Powr-Web Load Element Tray

Construction
Calibrated to specific ohm value
Welded lugs on each end
All load elements are continuously supported by vibration resistant, ceramic clad, stainless steel throughrods

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 self-propagating, 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.

	Stationary Load Bank Options
	Instrumentation 2% or 1% analog type; 2% digital type: AC voltmeter with 3-phase switch AC ammeter with 3-phase switch Frequency meter Kilowatt meter Kilovar meter Power factor meter Kilowatt-hour meter Recording instruments DC voltmeter DC ammeter Enclosure Options Indoor version, NEMA-1, with exhaust duct adaptor flange Optional hot air exhaust hoods/deflectors, including exhaust to one side only, straight-up vertical exhaust Marine environment	System Options Overvoltage protection Ground fault protection Anti-condensation internal space heaters with humidistat control Fan/control power supplied from an external source instead of from the Load Bank main bus Load Options Variable load steps (0-1KW) Inductive load to obtain lagging power factor Capacitive load to obtain leading power factor Main Disconnect Switch Installed on Load Bank Supplied installed in separate enclosure for remote mounting	Highway Trailer Conforms to applicable Federal and DOT standards Load Options Variable load steps (0-1KW) Inductive load to obtain lagging power factor Capacitive load to obtain leading power factor

Mercury page, Neptune page, Mars page, Mars-HV page, Megatron page,
Saturn page, Saturn-HV page, Triton and Trident page

Request Quote.

Stationary Load Bank Features and Options and Engineer’s Specifications.

Simplex Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228
800-637-8603 • 217-483-1600 (24 Hr.) • FAX 217-483-1616

Stationary Load Bank Applications

Stationary Load Bank General Specifications

Stationary Load Bank Features

Powr-Web Load Element

Branch Circuit Fuse Protection

Stationary Load Bank Options