Simplex Saturn Series Manuel utilisateur
SATURN
1400KW3200KW
STATIONARY LOAD BANK
Last Revision Date: March 15, 2016
For the most up-to-date information for this product and others, please
contact Simplex, Inc. at (800) 637-8603 or visit us on the web at
http://www.simplexdirect.com.
Table of Contents
1 Warnings and Cautions ........................................................ 1
Safety information symbols 1
Cautions 1
2 Description and Specication.............................................. 4
Overview of Use 4
Control System 4
Cooling System 4
Load System 4
Safety 4
3 Unpacking ............................................................................. 6
Included Components 6
Primary Inspection 6
4 Installation ............................................................................ 7
Load Bank Placement 7
Installation Procedure 8
Remote HMI installation 9
Load Dump installation 10
Current Transformer installation 11
MODBUS installation 13
Heater installation 14
BMS/BAS Installation 15
5 Setup....................................................................................16
General Settings 16
Automatic Mode 16
6 Operating Instructions .......................................................17
Pre-operation checks 17
Setting up the test 17
Testing operation 18
Metering (if equipped) 18
Shutdown and cooling 18
7 Automatic Mode ................................................................. 19
Overview 19
Setting Up Automatic Mode 20
Entering Automatic Mode 20
8 Maintenance/Troubleshooting..........................................21
General maintenance 21
Each Operation 21
Every 6 Months 21
Troubleshooting 22
9 Alarms and Warnings..........................................................23
Alarms 23
Warnings 23
APPENDIX A PARTS LISTINGS ...........................................................25
APPENDIX B MODBUS CONTROLS ...................................................41
Modbus Control Directions 44
APPENDIX C PRODUCT WARRANTY .................................................45
Table of Figures
Current draw at specic resolutions (in kilowatts) ...............................5
Air Flow ................................................................................................................7
Ground Bus .........................................................................................................8
Main Load Bus ...................................................................................................8
Conduit Opening..............................................................................................8
HMI TBH................................................................................................................9
Serial Adapter ....................................................................................................9
TB-DC ....................................................................................................................9
Load Dump Jumper...................................................................................... 10
Current Transformers ................................................................................... 11
CT Orientation ................................................................................................ 11
TB-CT.................................................................................................................. 11
Current Transformer placement for Metering..................................... 12
Current Transformer placement for Auto/Regen. Mode ................. 12
TB-COM ............................................................................................................. 13
Modbus Serial Converter............................................................................ 13
TB-SH.................................................................................................................. 14
TBR...................................................................................................................... 15
Setup Screen ................................................................................................... 16
General Settings............................................................................................. 16
HMI Information............................................................................................. 18
Alarm History .................................................................................................. 18
Automatic/Regenerative Mode................................................................ 19
Setup Screen ................................................................................................... 19
Automatic Mode Setup ............................................................................... 19
Automatic Mode Running.......................................................................... 20
Troubleshooting ............................................................................................ 22
Troubleshooting alarms.............................................................................. 24
Right Subpanel Layout................................................................................ 25
Option D - Automation/Metering............................................................ 26
Option B - Communication (TCP/IP Data Logging)........................... 27
PLC Component list ...................................................................................... 28
Control Relays................................................................................................. 30
Terminal Blocks............................................................................................... 32
Option 010 - Space Heaters....................................................................... 34
Center Subpanel ............................................................................................ 36
Phase A Detail................................................................................................. 37
Phase B Detail ................................................................................................. 38
Phase C Detail ................................................................................................. 39
Load Control Terminal Blocks ................................................................... 40
Modbus Controls (Read/Write)................................................................. 41
Modbus Indications (Read only) .............................................................. 42
Warnings and Cauons — 1
1 WARNINGS AND CAUTIONS
e following images indicate important safety information:
is General warning symbol points out important
information that, if not followed, could endanger
personal safety and/or property.
is Explosion warning symbol points out
potential explosion hazards.
is Fire warning symbol points out potential re
hazards.
is Electrical warning symbol points out potential
electrical shock hazards.
is load bank is high-powered, technical, industrial
equipment operating at dangerous voltages and temperatures. It
is capable of damaging itself, property or personnel if improperly
used. It is not a consumer product.
It must be installed, connected and operated by personnel
properly trained and experienced in its use. An operator’s
manual is supplied with each load bank and available online at
www.simplexdirect.com. e operator must be familiar with its
contents and have access to it during operation.
• High Voltage: Turn o and disconnect power source before
opening this equipment
• High Temperature: Allow hardware to cool before servicing
or opening this equipment.
• Rotating Equipment: Ensure that the fans have stopped
before opening this unit.
• For Operator Safety: Make sure this equipment is properly
grounded when in use.
All compression-type connections on fuse blocks, load blocks,
and contactors should be checked for tightness frequently. is
check should be established as part of routine maintenance.
e following cautions should be observed before and during
operation:
• Check intake and exhaust screens as well as fan and load
elements for foreign objects.
• Position and install the load bank with consideration given
Safety
information
SymbolS
!
!
CautionS
2 — Warnings and Cauons
to large cubic airow requirements, exhaust temperature, and
velocity. Do not point exhaust at any nearby surface or object
that may be adversely aected by high temperature. is
includes but is not limited to painted surfaces, tar paper and
asphalt roofs, water sprinkler heads, re alarms, and volatile
material.
• Do not use in conned spaces. Do not allow the load bank’s
feet to sink into so surfaces thereby cutting o bottom air
intake. e load bank may have to compete with cooling air
requirements of a nearby running engine generator set where
cooling air intake to a conned space may not be adequate
for both engine and load bank. Be especially careful not
to bounce hot exhaust air o nearby obstructions for re-
circulation through the load bank.
• Verify that all control switch positions are set correctly for
your intended usage before connecting the load bank to the
source to be tested.
• e load cables carry high amperage. Be constantly aware of
possibility of inductively heating adjacent ferrous objects to
temperatures sucient to damage cable insulation.
• Always connect the safety ground cable to a proper ground.
Do not rely on a possible grounded neutral somewhere else
in the system.
• Do not let the load bank run unattended for long periods of
time.
• Do not store or operate in rain unless adequate protection is
provided.
• Routinely inspect all components and electrical connections
for tightness and integrity.
• Repair any damaged or degraded components and wiring
without delay.
• If technical assistance, service, or parts are needed, please call
800-837-8603 (24 Hours).
• All hardware covered by this manual have dangerous
electrical voltages and can cause fatal electrical shock. Avoid
contact with bare wires, terminals, connections, etc. Ensure
all appropriate covers, guards, grounds, and barriers are in
place before operating the equipment. If work must be done
around an operating unit, stand on an insulated dry surface
to reduce the risk of electrocution.
• Do not handle any kind of electrical device while standing
in water, while barefoot, or while your hands or feet are wet.
• If people must stand on metal or concrete while installing,
servicing, adjusting, or repairing this equipment, place
insulative mats over a dry wooden platform. Work on the
Warnings and Cauons — 3
equipment only while standing on such insulative mats.
• e National Electrical Code (NEC), Article 250 requires
the frame to be connected to an approved earth ground
and/or grounding rods. is grounding will help prevent
dangerous electrical shock that might be caused by a ground
fault condition or by static electricity. Never disconnect the
ground wire while the load bank is in use.
• Wire gauge sizes of electrical wiring, cables, and cord sets
must be adequate to handle the maximum electrical current
(ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment,
ensure that all power voltage supplies are completely turned
o at their source. Failure to do so can result in hazardous
and possibly fatal electrical shock.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not
possible, attempt to free the victim from the live conductor.
AVOID DIRECT CONTACT WITH THE VICTIM. Use
a nonconducting implement, such as a dry rope or board,
to free the victim from the live conductor. If the victim is
unconscious, apply rst aid and seek immediate medical
attention.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock or may get
caught in moving components causing injury.
• Keep a re extinguisher near the hardware at all times.
Do NOT use any carbon tetra-chloride type extinguisher.
Its fumes are toxic, and the liquid can deteriorate wiring
insulation. Keep the extinguisher properly charged and be
familiar with its use. If there are any questions pertaining to
re extinguishers, please consult the local re department.
• e illustrations in this manual are examples only and may
dier from your load bank.
• Load Bank warranty is void if incorrectly cooled.
!
4 — Descripon and Specicaon
2 DESCRIPTION AND SPECIFICATION
Simplex Saturn load banks are precision test instruments
designed to apply a selectable load to a power source and measure
the source’s response. ey are used for routine maintenance
exercise to ensure the long-term reliability and readiness of the
standby generator. Load banks can also eliminate the detrimental
eects of unloaded operation of diesel engine generators as well
as prevent damage from reverse power generation.
Saturn load banks are available in models ranging from 1400
kilowatts up to 3200 kilowatts. All standard Saturn models have
a step resolution of 25 kilowatts.
Saturn load banks feature a Human-Machine Interface
(HMI) touchscreen, which controls load bank operation and
displays the unit’s status. With the HMI, the operator can apply
a desired load and measure the response of the test source.
e load bank can also be integrated into your facility’s BMS/
BAS system via standard Modbus RS-485 or optional Modbus
TCP/IP, as well as a set of dry contacts for status reporting.
Saturn load banks are cooled by forced air, delivered by an
aluminum fan blade directly driven by a TEFC motor. e air is
brought in on the bottom of the load bank and expelled through the
top. Optional equipment allows the exhaust to be driven through a
customer-installed duct, providing for indoor installation.
e load system comprises independently controlled Simplex
Powr-Web resistors, which have been designed specically for
use in load bank systems. e load elements are supported by
high-temperature, ceramic-clad, stainless-steel rods across their
entire length, virtually eliminating element-to-element short
circuits. e elements are arrayed in discrete trays, which are
independently serviceable.
e Saturn is protected by sensors to ensure that the load
bank is suciently cooled and that the exhaust does not exceed a
safe temperature, which could damage the load bank or present
a safety hazard to the operator. When a failure occurs, the safety
system immediately removes the load to protect the equipment
from permanent damage.
overview of
uSe
Control
SyStem
Cooling
SyStem
load SyStem
Safety
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