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Simplex, Inc., 5300 Rising Moon Road, Spring

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 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 4 of 16

Powr-Web Load Elements

Simplex “Powr-Web” load elements are 
UL recognized. These elements conser-
vatively operate at approximately half 
the maximum temperature rating of the 
alloy (1080°F vs. 1920°F). For example:

Alloy: FeCrAl

Ratings: 3333W@120V
 4170W@139V

Connections: 120V wye (208V), 
 

139V wye (240V, 3ø), 

 

277V wye (480V, 3ø),

 

240 delta (240V, 3ø), or

 

480 delta (480V, 3ø).

These elements are rigidly supported 
by high-temperature, ceramic-clad, 
stainless-steel supports. Element-
to-element short circuits are virtually 
eliminated.

PRIMARY INSPECTION

Preventative visual inspection of the 
shipping crate and Load Bank must be 
performed before installation. Physical 
or electrical problems due to handling 
and vibration may occur during ship-
ment.

1. If crate shows any signs of damage 

examine the Load Bank in the cor-
responding areas for signs of initial 
problems.

2. Check the entire outside of the 

cabinet for any visual damage which 
could cause internal electrical or 
mechanical problems due to reduced 
clearance.

3.  Rotate and push all switches 

through all positions to en-
sure smooth operation.

4. Inspect the bottom of crate/

enclosure for any compo-
nents that may have jarred 
loose during shipment such 
as indicator light lenses, 
switch knobs, etc.

5. Visually inspect element 

chamber for foreign objects 
and mechanical damage.

INSTALLATION

1.

 

Using the 

fl

 anges  provided 

attach the Load Bank with 
bolts per specifications. 
Bottom support for the load 
element enclosure is recommended.

2. Con

fi

 rm the test source is properly 

grounded and ground the Load Bank 
to its own independent ground.

3. Con

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 rm all load command switches 

are in the “Off” position.

4. Per load connection drawings cable 

the load source to the Load Bank. 
Consult NEC for proper wire size.

 

When cabling the Load Bank to the 

test source pull Load Bank access 
holes, install conduit connectors and 
conduits as needed.

5.  Connect customer supplied contacts 

to load dump terminals shown on 
electrical drawing or jumper if not 
used.

6. Per drawings connect customer 

supplied alarm contacts.

If any problems are observed 
during Primary Inspection call 
the Simplex Service Manager at 
217-483-1600 (24hrs.)

References to Remote Control 
in this manual should be ig-
nored if the Load Bank you are 
using is equipped with a Local 
Control Panel only.

Part of Typical 

Pictorial Drawing

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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