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Simplex, Inc., 5300 Rising Moon Road, Spring

fi

 eld, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616

Lbdman8p.indd (04/11) • © 2011 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com

LOAD BANK MANUAL  •  LBD Series  •  page 2 of 16

DESCRIPTION

Simplex LBD Series Load Banks are 
a special form of stationary, resistive, 
forced air-cooled Load Bank which 
utilizes the air out

fl

 ow of an engine 

radiator for cooling of the load ele-
ments. They are speci

fi

 cally designed 

to apply discrete, selectable electrical 
load to a power source while measur-
ing the response of the generator to 
the applied load. They also provide 
a means for routine maintenance 
exercise to assure long term reliability 
and readiness of the standby genera-
tor. Exercise Load Banks eliminate 
the detrimental effects of unloaded 
operation of diesel engine generators.

Simplex LBD Series Load Banks are 
intended for use with water cooled 
engine generator sets equipped 
with unit mounted radiators. These 
Load Banks are built per customer 
speci

fi

 cations and can be installed 

in numerous ways, including direct 
bolted attachment to the radiator, 
mounting within an air duct, wall 
mounting over the air out

fl

 ow open-

ing, indoors or outdoors.

Power source testing is accom-
plished by applying resistive load 
steps at unity (1.0) power factor. 

See the Load Bank Speci

fi

 cations 

Sheet in the front of this manual for 
the rating of your Load Bank.

Load application is by magnetic 
contactor. All load branch circuits 
are protected by 200,000AIC class-
T fuses.

The Control Panel contains the fol-
lowing controls and indicator lamps:

1. Over Temperature and Normal 

Operation lamps,

2. Control Power switch and/or 

pushbutton and

Part of Typical Pictorial Drawing

3. Master Load and load step switch-

es.

Summary of Contents for LBD Series

Page 1: ...er XXXXX XX XX Model LBD XXX April 2011 The information herein is the property of Simplex Inc and or its subsidiaries Without written permission any copying transmitting to others and other use except...

Page 2: ...rol System 3 Load System 3 PRIMARY INSPECTION 4 INSTALLATION 4 OPERATION 5 Manual 5 Automatic 5 Load Dump 7 COOLING FAILURE SUBSYSTEM 7 MAINTENANCE 7 Each Operation 7 Every 50 Hours or 6 Months 8 TROU...

Page 3: ...s of unloaded operationofdieselenginegenerators Simplex LBD Series Load Banks are intended for use with water cooled engine generator sets equipped with unit mounted radiators These Load Banks are bui...

Page 4: ...Section Control power 120V is supplied to the Load Bank by one of the following methods 1 testsourceviaacontrolpowertrans former 2 test source line to neutral or 3 external source LOAD SYSTEM Simplex...

Page 5: ...nal electrical or mechanicalproblemsduetoreduced clearance 3 Rotateandpushallswitches through all positions to en sure smooth operation 4 Inspect the bottom of crate enclosure for any compo nents that...

Page 6: ...the load steps which are in the On position Trim is achieved by flipping the load steps On and Off whilethe Master Load is in the On position 7 Adjust source voltage and load Monitor as needed AUTOMA...

Page 7: ...eratorloadincreasesabove70kW This establishes a window between 50kW and70kW insideofwhichthePLCtakes no action to change Load Bank Load When total generator load is below 50kW the PLC receives a signa...

Page 8: ...TR contacts 7 4 will close and 7 1 will open Closed OTR contacts 7 4 will illuminate the Over Temperature lamp Open OTR contacts 7 1 will interrupt the power path to the Normal Operation lamp and the...

Page 9: ...ver the road the electrical connections should be checked for tightness at a shorter than normal time interval See Primary Inspection When troubleshooting Load Bank systems always remove all test sour...

Page 10: ...he most accurate source of part numbers for your Load Bank When ordering replacement parts for Simplex Load Banks always consult the Parts Legend drawing When contacting the Simplex Service Department...

Page 11: ...temperature switch FCB Fan circuit breaker Circuit breaker in series with fan control power FCVR Fan control voltage relay Normally energized relay on relay sub panel FM Frequency Meter Monitors freq...

Page 12: ...itch Normally closed switch used to detect fan failure PSI Pounds per square inch PSR Pump Start Relay RML Remote Master Load Relay RR Run relay RS Remote Load Step Relay RTM Running time meter Keeps...

Page 13: ...Multiply the answer of step 3 times the square root of 3 1 732 5 Dividetheanswerofstep 4by1000 The answer is the actual kilowatts of loadbeingappliedbytheLoadBank Single Phase 1 Determine the line cu...

Page 14: ...th the desired amount of kilowatts applied at 1 0 power fac tor The following calculations are used to determine a step kilowatt rating at other than a rated voltage This is accom plished by referenci...

Page 15: ...watts 1 phase Volts x Amps x PF Volts x Amps 1000 1000 3 phase 1 732 x Volts x Amps x PF 1000 Power Factor expressed as decimal Resistive Load Bank PF is 1 0 Amperes 1 phase KW x 1000 KW x 1000 KW kno...

Page 16: ...BS IN LBS 250 1 4 20 Grade 5 dry 8 96 250 1 4 20 Grade 2 dry 5 5 66 312 5 16 Grade 5 dry 17 204 312 5 16 Grade 2 dry 11 132 375 3 8 Grade 5 dry 30 360 375 3 8 Grade 2 dry 20 240 437 7 16 Grade 5 dry 5...

Page 17: ...35 600V 30A 8 AWG 40 T60060 3CR 4 6 AWG 45 600V 60A 2 3 AWG 50 60100 3CR 600V 100A MISCELLANEOUS TERMINALS METERS SWITCHES COILS RELAYS XFORMERS CONNECTION TORQUE SIZE INCH LBS 4 5 6 10 8 19 10 31 1...

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