Simplex Microstar User manual
17.5KW PRECISION AIR HEATER
(LOAD BANK)
MICROSTAR
Document Number: DOC-01124
Page1
Table of Contents
I. Warnings and Cautions ..................................................................................... 4
II. Nameplates and Placards.................................................................................. 6
1. Introduction......................................................................................................................... 6
2. Instruction Placards ........................................................................................................... 6
III. Description and Specication........................................................................... 7
1. Introduction......................................................................................................................... 7
2. Overview of Use.................................................................................................................. 7
3. Control System ................................................................................................................... 8
4. Cooling System .................................................................................................................. 8
5. Specications ..................................................................................................................... 8
IV. Unpacking ..........................................................................................................11
1. Introduction....................................................................................................................... 11
2. Included Components and Parts .................................................................................... 11
3. Primary Inspection ........................................................................................................... 11
V. Installation......................................................................................................... 12
1. Introduction....................................................................................................................... 12
2. Load Bank Placement ...................................................................................................... 12
3. Setup.................................................................................................................................. 14
4. Local Control .................................................................................................................... 14
5. Failure Detection .............................................................................................................. 14
VI. Operating Instructions..................................................................................... 16
1. Introduction....................................................................................................................... 16
2. Equipment Handling ........................................................................................................ 16
3. Basic Operations .............................................................................................................. 16
VII. Alarms and Warnings....................................................................................... 19
1. Introduction....................................................................................................................... 19
2. Over Temperature............................................................................................................. 19
VIII. Supplemental Equipment ................................................................................ 20
1. Introduction....................................................................................................................... 20
2. Power Cords ..................................................................................................................... 20
IX. Diagnostics and Troubleshooting................................................................... 21
1. Introduction....................................................................................................................... 21
2. General Maintenance ...................................................................................................... 21
3. Troubleshooting ............................................................................................................... 22
X. Ordering Information........................................................................................ 25
1. Microstar ........................................................................................................................... 25
APPENDIX A — ABBREVIATIONS IN THIS MANUAL.................................................................. 27
APPENDIX B — IMPORTANT FORMULA......................................................................................28
Page2
Table of Figures
I. Warnings and Cautions ..................................................................................... 4
II. Nameplates and Placards.................................................................................. 6
III. Description and Specication........................................................................... 7
1. Specications ..................................................................................................................... 8
2. Microstar Temperature Rise .............................................................................................. 9
IV. Unpacking ..........................................................................................................11
V. Installation......................................................................................................... 12
1. Airow View ...................................................................................................................... 12
VI. Operating Instructions..................................................................................... 16
VII. Alarms and Warnings....................................................................................... 19
VIII. Supplemental Equipment ................................................................................ 20
IX. Diagnostics and Troubleshooting................................................................... 21
1. Troubleshooting Table ..................................................................................................... 22
2. Side Diagram..................................................................................................................... 23
3. Front Parts of Microstar................................................................................................... 23
4. Front Diagram ................................................................................................................... 23
5. Back Parts of Microstar ................................................................................................... 24
6. Exhaust Diagram .............................................................................................................. 24
X. Ordering Information........................................................................................ 25
Page3
Last Revision Date: May 20, 2013
Page4
1.0 WARNINGS AND CAUTIONS
This General warning symbol points out important safety
informaon that, if not followed, could endanger personal safety
and/or the property of others.
This Explosion warning symbol points out potenal explosion
hazard.
This Fire warning symbol points out potenal re hazard.
This Electrical warning symbol points out potenal electrical
shock hazard.
ELECTRICAL WARNING
•
•
•
•
•
Page5
•
•
•
FIRE HAZARD
•
GENERAL WARNING
•
Page6
2.0 NAMEPLATES AND PLACARDS
2.1 Introducon
2.2 Instrucon Placards
Page7
3.0 DESCRIPTION AND SPECIFICATION
3.1 Introducon
—
—
—
3.2 Overview of Use
•
•
•
•
•
Page8
3.3 Control System
3.4 Cooling System
3.4.1 Load System
3.5 Specicaons
Capacity Max Amps
at 208V
Max Amps
at 230V
Max Amps
at 240v
Model 208vAC, 1-ph 230vAC, 1-ph 240vAC, 1-ph
Max Amps
Per Secon Secon 1: Secon 2 -4: Secon 5-6:
Table 1 Specications
Page9
@240V Rangs @230V Rangs @208V Rangs
Load
Bank
CFM
Low Fan
Speed -
399
High Fan
Speed -
1520
Load
Bank
CFM
Low Fan
Speed -
399
High Fan
Speed -
1520
Load
Bank
CFM
Low Fan
Speed -
399
High Fan
Speed -
1520
1.5 1.4 1.1
2.5 2.3 1.9
3.0 2.8 2.3
4.0 3.7 3.0
5.0 4.6 3.8
5.5 5.1 4.1
6.5 6.0 4.9
7.0 6.4 5.3
7.5 6.9 5.6
8.0 7.4 6.0
8.5 7.8 6.4
9.0 8.3 6.8
9.5 8.7 7.1
10.0 9.2 7.5
10.5 9.6 7.9
11.0 10.1 8.3
11.5 10.6 8.6
12.0 11.0 9.0
12.5 11.5 9.4
13.0 11.9 9.8
13.5 12.4 10.1
14.0 12.9 10.5
14.5 13.3 10.9
15.0 13.8 11.3
16.0 14.7 12.0
17.5 16.1 13.1
Table 2 Microstar Temperature Rise
Page10
Did You Know?
Quality Simplex Load Banks and accessories are now
available as rental units from Simplex Onsite (SOS), our
load bank rental and technical services afliate, with Simplex
Factory-Trained technicians available for system set-up, start-
up, training and operation.
All SOS Rental Load Banks are portable units suitable for eld
use. Rental load banks are differentiated by capacity, voltage
and frequency rating, and relative portability.
Page11
4.0 UNPACKING
4.1 Introducon
—
—
4.2 Included Components and Parts
—
—
4.3 Primary Inspecon
Page12
5.0 INSTALLATION
5.1 Introducon
—
5.2 Load Bank Placement
feet on the inlet and outlet
250V, 16A-rated
C13/C14 cables
Figure 1 Airow View
WARNING
Page13
WARNING
Note: Load Bank warranty is void if incorrectly cooled.
High Voltage
High Temperature
Rotang Equipment
For Operator Safety
-
Page14
5.3 Setup
Note: Load is disengaged when 24VDC is applied.
5.4 Local Control
5.5 Failure Detecon
Page15
Page16
6.0 OPERATING INSTRUCTIONS
6.1 Introducon
—
—
—
6.2 Equipment Handling
6.2.1 General Handling Informaon
6.2.2 Aer-Operaon Handling Informaon
6.3 Basic Operaons
6.3.1 Startup
6.3.2 Applying a Load
Page17
6.3.3 Adjusng the Fan Speed
6.3.4 Shutdown
Page18
Did You Know?
Load banks are not inherently dangerous but there are
dangers that exist with operation of load banks. This is a
technical, industrial product and should only be set-up and
operated by trained, technical personnel who are specically
authorized by the renter.
Be certain that all equipment is properly grounded. Carefully
check cables for wear and tear, insulation damage. Check all
CAM-lock connectors that connections are made sound and
tight including both connector mating (the connector twist-
tightens) and the cable within the connector.
Be certain that cables are phased correctly. A circuit breaker
or fuse set is required at the power source sized appropriately
for the conductor run.
Be sure to run adequate ampacity of cables. Check that
generator voltage corresponds to load bank voltage. Check
correct airow direction and if it is necessary to reverse cooling
fan direction, allow fan to fully stop before reversing. Provide
the CFM required at an ambient not to exceed 125°F.
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