Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax 217-483-1616
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 4 of 20
CONTROL SYSTEM
The Control System allows the operator
to apply a desired load to the test source
and measure the response of the test
source to the load. This system also
contains the circuitry utilized to discon-
nect the load from the test source in the
event of cooling failures and/or improp-
erly positioned operating controls.
Fan power is applied to the Fan Motor
(MOT) through the Fan Circuit Breaker
(FCB 1A or FCB 1B), the Disconnect
Switch (DSW), the Fan/Control Voltage
Selector swtich (S1), the Auto Trans-
former, and the Fan Motor Contactor
(FMC) contacts. An Overload Relay
(OVR) is used to protect the motor.
COOLING SYSTEM
Resistive Load Elements are cooled by
a forced air system consisting of a 60"
fan blade belt driven by a 30HP, TEFC
motor, creating a 50,000 CFM. The fan
motor is energized by a 60A, 600V, 3
pole contactor (FMC) and protected by
a 100A frame, 60A trip, 3 pole, 600V
circuit breaker (FCB).
LOAD SYSTEM
The Load System consists of indepen-
dently controlled resistive and/or reac-
tive load elements specifically designed
for Load Bank systems. They are pro-
tected by 200,000AIC, 600VAC fuses.
Simplex Resistive Load Elements con-
servatively operate at approximately half
the maximum temperature rating of the
alloy (1080°F vs. 1920°F). For example:
Alloy: FeCrAl
See Parts Legend Drawing for specific
elements used.
These elements are rigidly supported
by high-temperature, ceramic-clad,
stainless-steel supports. Element-to-
element short circuits are virtually elimi-
nated. The elements are assembled in
discrete trays which are assembled in a
vertical “stack”. Each tray is independ-
ently serviceable without disturbing ad-
jacent trays.
PRIMARY INSPECTION
Preventative visual inspections of the
shipping crate and Load Bank is ad-
vised. Physical or electrical problems
due to handling and vibration may oc-
cur. Never apply power to a Load Bank
before performing this procedure. The
following Nine Point/30 Minute Inspec-
tion is recommended before installa-
tion, as part of the 50 hour / 6 month
maintenance schedule and whenever
the Load Bank is relocated:
1. If crate shows any signs of damage
examine the Load Bank in the corre-
sponding areas for signs of initial
problems.
2. Check the entire outside of the cabi-
net for any visual damage which could
cause internal electrical or mechani-
cal problems due to reduced clear-
ance.
3. Inspect all hinged panels and doors
for smooth and safe operation, try all
latches and knobs.
4. Rotate and push all switches through
all positions to ensure smooth opera-
tion.
5. Check cooling system by inspecting
fan motor and blade. Slowly rotate
blade by hand and note clearance of
blade tip through its rotation near the
housing. Observe free rotation of mo-
tor shaft.
