Stationary
Saturn-HV
1500KW
1800KW
2000KW
2500KW
3000KW
2.5KV
5.0KV
8.7KV
15KV
Saturn-HV
Load Bank
The Saturn-HV is a self-contained
Load Bank to 15KV utilizing the Simplex Mars Load Module with
on-board dry-type power transformer. It is a self-contained,
freestanding, semi-portable skidded unit consisting of three
principle sections:
1. High voltage section consisting of main input power terminals,
high voltage: 480V 3-phase power transformer, low voltage output
terminals, low voltage fuses and outputs to load cell
2. 480V, low voltage resistive load section consisting of one
1400-3000KW forced air-cooled load cell
3. Control Section
All control circuits and control power supplies are powered internally.
The Saturn-HV requires connection of a 3-phase feeder
only.
Load circuits and cooling fan operate at 480V; control circuits
operate at 120V.
Input disconnects, fuses, lightning arrestors and potheads available
as options.
Construction
All panels for access to serviceable components are hinged doors
with stainless steel hinges and lockable latches. All exterior
fasteners are stainless steel.
The Load Bank enclosure is double wall constructed for a cool
exterior and thermal isolation of the load elements. Cooling
airflow through the enclosure is vertical with cold air intake
at the bottom and hot air exhaust out the top. Intake and exhaust
openings are screened. Exhaust is straight up with no flow to
any side. Exhaust flow is directed through rain and snow shedding
louvers.
Features
Master load toggle switch
and load step toggle switches
Self-contained load and control
system
Utilizes the UL Recognized “Powr-Web” load element
Branch circuit fuse protection of load elements
Color coded and numbered wiring; power wiring 150°C
Plated bus bar
Options
Input disconnect switch,
5KV or 15KV class
Input fuses
Lightning arrestors
5KV or 15KV Potheads
Low voltage (480v secondary) disconnect switch
Automatic load regulating features
Automatic regenerative power control features
Instrumentation, analog or digital
Capacity 1500KW, 1800KW, 2000KW, 2500KW, 3000KW; Resistive, 1.0 power factor Voltage to 15KV AC, 3-phase (typical: 2400V, 3300V, 4160V, 13,200V, 13,800V) Load circuits operate at 480V via main power transformer Frequency 50, 60 Hertz Load Steps 50 KW resolution standard 1-5-10-25KW resolution available Fan/Control Internal via high voltage: 480V, 3-phase transformer for fan power, 480:120 transformer for control circuits. Cooling Forced air, vertical airflow, top exhaust. 3-phase, TEFC motor driving cast aluminum fan blade. Circuit breaker combination motor starter. Airflow 1500-1800KW: 40,000 CFM 1800-2000KW: 50,000 CFM 2500-3000KW: 60,000 CFM Duty Cycle Continuous Dimensions 74”W x 140”H x 233”D Shipping Weight Approx. 15,850 lbs. Enclosure NEMA-3R control section; NEMA-3R power section Power Wiring 150°C insulated; color coded Control Wiring 105°C, color coded and/or numbered Power Connection Plated bus bar within an oversize NEMA-3R, terminal junction box Sales Bulletin Dimensions and Key Features Diagram Stationary Load Banks: Applications and General Specifications, Features and Options, and Engineer’s Specifications |
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
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.
Principle Systems and Components
High voltage input terminals:
silver-plated copper bus bar
Transformer
Dry type transformer
700-1200KVA, continuous duty
High voltage delta, 3-wire primary
480V wye, 4-wire secondary with grounded neutral
220°C insulation
150°C rise
Insulation Level, Primary
System Voltage - BIL
2.5KV - 20KV
5.0KV - 30KV
8.7KV - 45KV
15KV - 60KV
Over temperature switch embedded in coils.
Output Circuits
Secondary of transformer connected to output fuse circuit.
Simplex “Powr-Web” open wire, helically wound, chromium alloy, thermally derated to 60%. 5% tolerance, 2% balance, .995 p.f.
UL Recognized.
Load Control
Branch circuit contactors, each 50 KW step. Contactors have enclosed silver surfaced contacts, 120V coils; electrically operated and electrically held.
Element Circuit Protection
Branch circuit fuses, each 50KW branch circuit, 70A, 200kAIC, current limiting type.
Temperature
Maximum air intake: 120°F
Maximum ambient: 120°F
Exhaust rise: 150°F
(Note: As airflow is not laminar, exhaust air temperatures are not equal at all points at the plane of air exhaust. Some parcels of air may reach approximately 575°F before mixing.)
Power transformer and load source connections
System Protection
Fan failure, high exhaust temperature, high intake temperature; lockout and alarm.
