LOAD BANK TECHNICAL MANUAL (LBD Series) Customer: XXXXX Work Order: XXXXX-XX-XX Model: Merlin 150KW-300KW March 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 that for which it is loaned, is prohibited. (File: Merlin-150-300c.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 1 of 15 Contents DESCRIPTION .............................................................................. 2 PRIMARY INSPECTION ............................................................... 4 LOAD BANK LOCATION.............................................................. 4 OPERATION.................................................................................. 5 Shutdown ...............................................................................
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 2 of 15 Part of Typical Pictorial Drawing DESCRIPTION Simplex Load Banks are precision test instruments specifically designed to apply a discrete, selectable resistive electrical load to a power source while measuring 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 generator.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 3 of 15 Part of Typical Local Control Detail Drawing The Local Control Panel is comprised of the following components: 1. Voltmeter, Ammeter, and Frequency Meter 2. Control Power, Volt-Ammeter, Ammeter Range Selector, Control Power Selector, and Voltage Selector switches 3. Cooling Failure and Load Over Voltage lamps 4. Ammeter Range Selector Switch 5. Alarm Reset pushbutton 6.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 4 of 15 PRIMARY INSPECTION Preventative visual inspections of the shipping crate and Load Bank is advised. Physical or electrical problems due to handling and vibration may occur. Never apply power to a Load Bank before performing this procedure. The following Nine Point/30 Minute Inspection is recommended before installation, as part of the 50 hour / 6 month maintenance schedule and whenever a Load Bank is relocated: 1.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 5 of 15 OPERATION 1. Confirm the test source is properly grounded and ground the Load Bank to its own independent ground. 2. Confirm the “Control Power” circuit breaker (FCB) is in the “Off” position. 3. See Control Section Drawing: a. Using the cables provided, connect the load source to the Load Bank as shown. b. If external control power is desired, place the External Fan Control Power Plug into a 120V, 1ø, 60Hz, 15A receptacle. 4.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 6 of 15 SHUTDOWN 1. De-energize the load. 2. Run the cooling fan for 5 minutes to assure a thorough cool down of all load elements (optional). 3. Place the “Control Power” circuit breaker (FCB) in the “Off” position. COOLING FAILURE SUBSYSTEM Excessive intake or exhaust temperatures or any reduction in cooling air flow for any reason is indicated by the illumination of the “Cooling Failure” lamp.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 7 of 15 LOAD OVER VOLTAGE DETECTION SUBSYSTEM The over voltage detection network is activated only when a high (greater than 380V) voltage test source is applied and the “Voltage Selector” switch (S1) is incorrectly placed in the “Low Voltage” position. When the switch is in the “Low Voltage” position load bus voltage is supplied to the Over Voltage Relay (OVR) via Transformer T1.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 8 of 15 MAINTENANCE The Load Bank has been designed to require minimum maintenance. All components have been chosen for a long, reliable life. Two basic intervals of maintenance are required: each operation and every 50 hours or 6 months (whichever comes first). For continued safety and for maximum equipment protection, always replace fuses with one of equal rating only.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 9 of 15 LOAD OVER VOLTAGE INDICATED DRAWINGS AND PARTS LIST 1. Load Voltage Selector switch incorrectly positioned The drawings included in this manual are the 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 always have your work order and drawing number ready for reference.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 10 of 15 APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL Listed below are abbreviations of terms found on Simplex Load Bank Systems. When following a load bank drawing utilize this guide to define abbreviated system and component names. As this is a master list, drawings and text pertaining to your equipment may not contain all these terms.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 11 of 15 APPENDIX B CALCULATIONS & FORMULAS The following calculations are used to determine the actual kilowatt load being applied by the Load Bank, when line voltages and currents are known (at 1.0 power factor). 3 Phase EXAMPLES Using line voltages and currents: 3 Phase Current Readings A1 = 249A A2 = 250A A3 = 254A Voltage Readings V1-2 = 481V V2-3 = 479V V3-1 = 483V Average Current = 1. Read all three line currents and find the average reading.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 12 of 15 The following calculations are used to determine the amount of current when the desired amount of kilowatts is applied at 1.0 power factor. EXAMPLES When desired amount of kilowatts is applied at 1.0 PF: 3 Phase 3 Phase Applied: 50KW 1. Multiply the desired amount of kilowatts to be applied by 1000. Amperage 2. Multiply the operating voltage times the square root of 3 (1.732) 3. Divide the answer of step #1 by the answer of step #2. 4.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 13 of 15 FORMULAS Kilowatts 1 phase 3 phase Alternating Current Direct Current Volts x Amps x PF* Volts x Amps 1000 1000 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 known) 3 phase KW x 1000 KW x 1000 Volts x PF Volts KW x 1000 1.732 x Volts x PF KVA 1 phase Volts x Amps 1000 3 phase 1.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 14 of 15 APPENDIX C - TORQUE VALUES CONTACTORS FAN BLADES See torque values on the front of the contactor. FAN PART NO. BOLT SIZE TORQUE FT LBS // IN LBS 13820000 SET SCREW 11.7 // 140 13820500 SET SCREW 11.7 // 140 13821000 SET SCREW 8.3 // 100 TERM/NUT SIZE 13822000 1/4 — 20 7.5 // 90 #6 Rod ends 4 13823000 1/4 — 20 7.5 // 90 #10 Element Conn. 20 13824000 1/4 — 20 7.
LOAD BANK MANUAL • Merlin 150-300 Load Bank • page 15 of 15 APPENDIX C - TORQUE VALUES CONT’D TAPER-LOCK BUSHINGS FUSEBLOCKS MANUF. PART NO.
