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The Simplex Merlin is a dual voltage (240/480V - 100KW-400KW; 416/480V - 500KW), fine load step resolution, fully instrumented portable Load Bank intended for shop or field use by engine generator dealers and service shops for maintenance, testing and performance proving of engine generator sets, UPS and other power systems in the 100KW-500KW range.
The Merlin is a totally self-contained testing system. It includes all resistive load elements, load control devices, load element circuit protective devices, connection cable set (100KW-400KW) or cam-type connectors (500KW), cooling system, malfunction detection system, control power supply and test instrumentation.
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Load Elements
| • | Simplex Powr-Web chromium alloy, open wire, continuously supported, power resistor. |
System Controls
| • | Digital Meter (100KW-400KW). |
| • | Fan Reversal, Load Voltage Selector, and Control Voltage Selector switches. |
| • | Operator indicator lights: normal operation, over-voltage, fan failure / over-temperature. |
| • | Master load toggle switch and load step toggle switches. |
Cooling
| • | 3-phase, direct drive fan, 6,000-8,000CFM (depending on load configuration). |
| • | Casts aluminum air foil type, shrouder propeller fan. |
| • | Horizontal airflow - cold air intake from front, hot air exhaust out the rear. |
System Protections
| • | Sensors, alarms (alarm message on remote operator interface terminal), lock-outs as appropriate, for the following: fan failure, high exhaust temperature, high intake temperature, high interior temperature (sensed at three points). |
| • | Load Circuit Protection: branch circuit fuses. One set of fuses each 50KW branch. Fuses are current limiting type, 200,000 AIC, 600V, enabling safe use on large generating or UPS system. |
Load Control
| • | Master load toggle switch and load step toggle switches. |
| • | 3-pole magnetic contactors. |
Power
| • | Operator selectable fan/control power-source:
Internal Power: fan and control circuits powered internally, does not require external power.
External Power: fan and control circuits powered from external 3-phase outlet or other external source. |
Connections
| • | Control Wiring: 105°C, color coded. |
| • | Power Wiring: 150°C XLP color-coded. |
Load Connection
| • | 100KW-400KW: 12' connection cable set including 3-phase power cables, ground cable and external control power cord. |
| • | 500KW: cam-type connectors and external control power cord. |
Enclosure
| • | Exceptionally rugged, all welded, formed steel chassis. |
| • | Portability features: lifting eyes, forklift channels, casters and moving handle. |
Capacity Detail
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Capacity (KW, 1ø) |
Cooling Fan |
Load Steps |
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240/480V,
3-phase |
208/416V,
3-phase |
190/380V,
3-phase |
240,
1-phase |
HP |
Voltage |
CFM |
KW @ 240/480V, 3-phase |
| 100KW |
100 |
75 |
63 |
67 |
.75 |
120V/240V, 1ø |
6000 |
5, 10, 10, 25, 50 |
| 150KW |
150 |
112 |
94 |
100 |
.75 |
120V/240V, 1ø |
6000 |
5, 10, 10, 25, 50, 50 |
| 200KW |
200 |
150 |
125 |
134 |
1.5 |
120V/240V, 1ø |
6700 |
5, 10, 10, 25, 50, 100 |
250KW |
250 |
188 |
157 |
167 |
1.5 |
120V/240V, 1ø |
6700 |
5, 10, 10, 25, 50, 50, 100 |
300KW |
300 |
225 |
188 |
200 |
1.5 |
120V/240V, 1ø |
6700 |
5, 10, 10, 25, 50, 100, 100 |
350KW |
350 |
262 |
219 |
233 |
3.0 |
240V/480V, 3ø |
8000 |
5, 10, 10, 25, 50, 50, 100, 100 |
400KW |
400 |
300 |
250 |
267 |
3.0 |
240V/480V, 3ø |
8000 |
5, 10, 10, 25, 50, 100, 100, 100 |
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Capacity (KW, 1ø) |
Cooling Fan |
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Load Steps |
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416/480V,
3-phase |
HP |
Voltage |
CFM |
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KW @ 416/480V, 3-phase |
| 500KW |
500 |
3.0 |
240V/480V, 3ø |
8000 |
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5, 10, 10, 25, 50, 100, 100, 100, 100 |
General Specifications
| General |
Merlin 100-150 |
Merlin 200-300 |
Merlin 350-400 |
| Load Type |
Resistive |
Resistive |
Resistive |
| Fan/Control Power |
Operator selectable, internal/external |
Operator selectable, internal/external |
Operator selectable, internal/external |
| Internal Fan/Control Power |
120V, 1ø, 2W, 60Hz
240V, 1ø, 3W, 60Hz
208-240V, 3ø, 4W, 60Hz |
120V, 1ø, 2W, 60Hz
240V, 1ø, 3W, 60Hz
208-240V, 3ø, 4W, 60Hz
416-480V, 3ø, 3W, 60Hz |
190 - 205V, 3ø, 3W, 50Hz
208V - 240V, 3ø, 3W, 60Hz
308-416V, 3ø, 3W, 50Hz
416-480V, 3ø, 3W, 60Hz |
| External Fan/Control Power |
115V, 1ø;, 60Hz, 15A service
15' cord with plug provided |
115V, 1ø;, 60Hz, 20A service
15' cord with plug provided |
230/460V, 3ø60Hz, 15A service
15' cord with plug provided |
| Frequency |
50, 60 and 400 Hz |
50, 60 and 400 Hz |
50, 60 and 400 Hz |
| Duty Cycle |
Continuous |
Continuous |
Continuous |
| Temperature Rating |
125°F max. intake air temp
Nominal 110° F rise |
125°F max. intake air temp
Nominal 110° F rise |
125°F max. intake air temp
Nominal 110° F rise |
| Airflow |
6000 CFM |
6700 CFM |
8000 CFM |
| External Power |
115V, 1ø, 60Hz, 15A service,
15' cord with plug provided |
115V, 1ø, 60Hz, 20A service,
15' cord with plug provided |
230/460V, 3ø, 50/60Hz, 20A service, 15' cord with plug provided |
| Dimensions |
31"W x 47"H x 43"D |
31"W x 56"H x 50"D |
31"W x 69"H x 50"D |
| Weight |
616 lbs |
865 lbs |
1,053 lbs |
| General |
Merlin 500 |
| Load Type |
Resistive |
| Fan/Control Power |
Operator selectable, internal/external | >
| Internal Fan/Control Power |
416-480V, 3ø, 3W, 60Hz |
| External Fan/Control Power |
230V, 3ø;, 50/60Hz, 20A service, 15' cord with plug provided |
| Power Connection |
Cam-Type connector, Qty 3 400A rated 4/0 per phase, Qty 1 4/0 ground |
| Frequency |
60 Hz |
| Duty Cycle |
Continuous |
| Temperature Rating |
125°F max. intake air temp
Nominal 110° F rise |
| Airflow |
8000 CFM |
| External Power |
230/460V, 3ø, 50/60Hz, 20A service, 15' cord with plug provided |
| Dimensions |
37.5"W x 53.25"H x 72"D |
| Weight |
1,050 lbs |
- Cam-type power connections (standard for 500KW)
- Vinyl cover
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