Simplex Trident User manual

150KW1250KW
TRAILERMOUNTED LOAD BANK
TRIDENT

Last Revision Date: March 15, 2016
For the most up-to-date information for this product and others, please
contact Simplex, Inc. at [phone] or visit us on the web at
http://www.simplexdirect.com.
Many of the illustrations and instructions in this manual refer to the stan-
dard conguration for this product. If you have requested customizations,
the drawings provided with your order take precedence; please refer to
them for details specic to your order.

Table of Contents
1 Warnings and Cautions ........................................................ 1
Safety information symbols 1
Cautions 1
2 Nameplates and Placards..................................................... 4
3 Description and Specication.............................................. 8
Overview of Use 8
Control System 8
Cooling System 8
Load System 8
Safety 8
4 Unpacking ...........................................................................11
Included Components and Parts 11
Primary Inspection 11
5 Installation ..........................................................................12
Load Bank Placement 12
6 Operating Instructions .......................................................13
Conducting a test 13
Metering Line Trends screen 14
Single-unit monitoring 15
Shutdown 15
Maintenance mode 15
Diagnostics screen 16
7 Alarms and Warnings..........................................................17
Alarms 17
Warnings 18
8 Maintenance/Troubleshooting..........................................19
General maintenance 19
Each Operation 19
Troubleshooting 19
Appendix A Product Warranty ...............................................21

Table of Figures
Specications.....................................................................................................9
Trident Dimensions....................................................................................... 10
Airow Diagram............................................................................................. 12
Fan/Control Power inlet .............................................................................. 13
Network ports................................................................................................. 13
Load connections.......................................................................................... 13
Main screen ..................................................................................................... 14
Single-unit monitoring screen.................................................................. 14
Numeric keypad............................................................................................. 14
Metering Lines Trend screen ..................................................................... 15
Maintenance mode....................................................................................... 15
Diagnostics screen ........................................................................................ 16
Failure indicator ............................................................................................. 17
Alarm indicators............................................................................................. 17
Troubleshooting ............................................................................................ 20

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Warnings and Cauons — 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 poten-
tial explosion hazards.
is Fire warning symbol points out potential re
hazards.
is Electrical warning symbol points out poten-
tial electrical shock hazards.
is load bank is high-powered, technical, industrial equip-
ment 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 man-
ual is supplied with each load bank and available online at www.
simplexdirect.com. e operator must be familiar with its con-
tents 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 be-
fore 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 frequent-
ly. is check should be established as part of routine mainte-
nance.
e following cautions should be observed before and during
operation:
• Check intake and exhaust screens as well as fan and load ele-
ments for foreign objects.
• Position and install the load bank with consideration given
Safety
information
SymbolS
!
!
CautionS

®
2 — Warnings and Cauons
to large cubic airow requirements, exhaust temperature, and
velocity. Do not point exhaust at any nearby surface or object
that may be adversely aected by high temperature. is in-
cludes but is not limited to painted surfaces, tar paper and
asphalt roofs, water sprinkler heads, re alarms, and volatile
material.
• Do not use in conned spaces. e load bank may have to
compete with cooling air requirements of a nearby running
engine generator set where cooling air intake to a conned
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 sucient 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.
• 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 elec-
trical 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 insu-
lative mats over a dry wooden platform. Work on the equip-
ment 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 condi-
tion or by static electricity. Never disconnect the ground wire

®
Warnings and Cauons — 3
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 noncon-
ducting 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. Jewel-
ry 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 insula-
tion. Keep the extinguisher properly charged and be familiar
with its use. If there are any questions pertaining to re extin-
guishers, please consult the local re department.
• e illustrations in this manual are examples only and may
dier from your load bank.
• Load Bank warranty is void if incorrectly cooled.
• Main Disconnect to be provided by installer, rated 600V
maximum, sized 150% maximum of rated current.
!

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4 — Nameplates and Placards
2 NAMEPLATES AND PLACARDS

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Nameplates and Placards — 5

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6 — Nameplates and Placards

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Nameplates and Placards — 7

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8 — Descripon and Specicaon
3 DESCRIPTION AND SPECIFICATION
Simplex Trident load banks are precision test instruments de-
signed 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 detrimen-
tal eects of unloaded operation of diesel engine generators as
well as prevent damage from reverse power generation.
Trident load banks are available in models ranging from 150
kilowatts up to 1250 kilowatts. All standard Trident models have
a step resolution of 50 kilowatts.
Trident 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.
Trident load banks are cooled by forced air, delivered by an
aluminum fan blade directly driven by a TEFC motor. e air is
brought in through the front of the load bank and expelled through
the rear.
e load system comprises independently controlled Simplex
Powr-Web resistors, which have been designed specically 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 Trident is protected by sensors to ensure that the load
bank is suciently 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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Descripon and Specicaon — 9
Table 1 Specications
Capacity 150-1250 Kilowatts
Power Factor 1.0
Load Step Resolution 50 Kilowatts
Load Type Resistive
Cooling System Forced air
Voltages 208V, 220V, 240V, 416V, 440V, 450V, 460V,
480V, 575V, 600V
Frequency 50, 60Hz standard
Connection Cam-Lock
Time Rating Continuous
Ambient Air Temperature 120°F
Fault Rating 5KAIC
Dimensions 126”W x 48.7”H x 47”D
Weight 3,000 lbs.

®
10 — Descripon and Specicaon
199.687±2.500
131.000±.250
85.500±.500
INTAKE
AIR
EXHAUST
AIR
A
A
DECK STORAGE
REEL CONTROL PANEL
LOCATED UNDER CENTER REEL
CABLE REEL
COMPARTMENT
AUTOTRANSFORMER
36" SAFETY
CHAIN W/HOOK
(4 PER PHASE)
APPROXIMATELY
54.000
EXHAUST
AIR
120.000
INTAKE
AIR
YELLOW CLEARANCE
LIGHT & REFLECTOR
(1 PER GROUND)
19.000" MIN
23.000" MAX
DOOR NOT SHOWN
ELECTRIC BREAK-AWAY
BATTERY & SWITCH
36" CABLE WITH 7 PIN
RV CONNECTOR
CAMLOK CONNECTION
2 5/16" BALL HITCH
PARKING BRAKE
48.750
29.000
LOCAL CONTROL
PANEL
Figure 1 Trident Dimensions
2.500
81.000
2" CONDUIT

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Unpacking — 11
4 UNPACKING
e following items are included with your load bank. If any
of the following are not included, please contact Simplex Direct,
Inc., at 800-637-8603, ext. 4.
1. Load bank
2. Manual
3. Human-Machine Interface (HMI)
4. Electrical drawings package
Preventative visual inspection of the load bank is advised.
Physical or electrical problems due to handling and vibration
may occur. Never apply power to a load bank before perform-
ing this procedure. e following ve-point inspection is rec-
ommended before installation and as part of a 6-month mainte-
nance schedule or as a load bank is relocated:
1. Examine the load bank 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. Inspect all relays and control modules. Make sure all compo-
nents are secure in their bases and safety bails are in place.
Spot check electrical connections for tightness. If any loose
connections are found, inspect and tighten all remaining
connections.
4. Examine all accessible internal electrical components such
as fuses, contactors, and relays. Check lugged wires at these
components.
5. Visually inspect the element chamber for foreign objects,
broken ceramic insulators, and mechanical damage.
inCluded
ComponentS
and partS
primary
inSpeCtion
If any
problems
are observed
during
Primary
Inspection,
call Simplex
24 hours a
day at
800-637-8603

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12 — Installaon
5 INSTALLATION
Trident load banks are intended for outdoor installation. A
forced air system, which discharges out of the rear of the unit,
cools the load elements (See Figure 2.) Load banks require large
quantities of air circulation, so it is essential to place the unit in
an area that provides adequate airow. Before conducting load
tests, a review of site conditions by trained personnel is recom-
mended.
e load bank requires at least 50 feet of clearance on the rear
side and 10 feet on the front side. .
e load bank should be placed in a secure area accessible by
trained personnel only.
Because the unit generates a lot of heat, never operate near
sprinkler systems.
Operating the load bank in a conned space will recycle hot
exhaust air through the cooling system, which can cause severe
damage.
e load bank may compete with nearby generators for cool-
ing air.
load bank
plaCement
Improperly
placing this
unit may
result in
damage or
destruction
of the load
bank, and
adjacent
equipment.
Figure 2 Airow Diagram
EXHAUST
AIR INTAKE
AIR

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Operang Instrucons — 13
6 OPERATING INSTRUCTIONS
1. If you wish to enable
data logging, insert a
USB thumb drive into
the port located either
underneath the HMI
screen or on a sepa-
rate panel.
2. If you will be using
external control/
fan power, connect
the load bank to a
240/480 volt, 3-phase
power source with a
30 amp maximum breaker (see Figure 3).
3. If you will be connecting multiple load banks, use custom-
er-supplied CAT-5,
CAT-5E or CAT-6
ethernet cables to
create a network by
connecting the out-
put of the master load
bank to the input of
the rst slave load
bank (see Figure 4).
Connect as many
load banks as desired
by daisy-chaining
load banks in the same manner.
4. Connect the load bank to the generator or power source with
the included cables.
e connections on
the load bank are lo-
cated on the right side
of the trailer, near the
front (see Figure 5).
5. Start up the generator
set or otherwise bring
the test source on line.
6. Press the “Control
Power” to switch it to
the “On” position on
ConduCting a
teSt
Figure 3 Fan/Control
Power inlet
Figure 4 Network ports
Figure 5 Load
connections

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14 — Operang Instrucons
the Main Screen (see
Figure 6). If multiple
units are networked,
the Main Screen is
only available via the
Master Load Bank.
Slave units will only
display the single-unit
monitoring screen
(see Figure 7).
7. Make sure the fan is
spinning, check the
air intake for obstruc-
tions, conrm air ow and investigate any unusual noises.
8. Make sure no errors are registered in the “System” area in the
bottom le of the screen. If any errors are indicated, consult
the troubleshooting
table on page 20
for information on to
resolve them.
9. Adjust the voltage
and frequency of the
generator.
10. Press the “KW to Ap-
ply” button and enter
the desired load (see
“Figure 8 Numer-
ic keypad” on page
14).
11. Press the “Apply”
button.
12. Monitor and adjust load steps as needed.
While the load bank
is operating, press-
ing the Metering Line
Trends button in the
bottom right corner of
the screen will bring
up the Metering Line
Trends screen. is
screen provides a graph
displaying voltage, cur-
rent, frequency, and
metering line
trendS SCreen
Figure 6 Main screen
Figure 7 Single-unit
monitoring screen
Figure 8 Numeric keypad

®
Operang Instrucons — 15
kilowatts detected by the
load bank.
If you want to re-
cord this data, insert a
USB drive into the port
below the screen and
press the “Data Logging
Disabled” button. When
you are done, press the
button again and the
load bank will write the
data in a tab-delimited
format to the thumb drive.
If you have networked multiple load banks together, you can
monitor just the master load bank by pressing the “Load Bank
Monitoring” button. is will bring up the single-unit monitor-
ing screen (Figure 8).
1. Remove all load by pressing the Remove button on the main
screen.
2. Allow the cooling fan to run for approximately ve minutes
to provide a thorough cooldown for the entire system.
3. Press the “Control Power” button to switch it to the “O ”
position.
4. Turn o the test source.
5. Disconnect the cables and store them in the cable compart-
ment.
6. Disconnect the controller(s) and ethernet cable(s) and store
them appropriately.
While the load bank’s
control power is turned
o, pressing the “Main-
tenance Mode” button
in the bottom right
corner of the screen
will make the unit en-
ter maintenance mode
(Figure 10).
On this screen you
can see the values
Single-unit
monitoring
Shutdown
maintenanCe
mode
Figure 10 Maintenance
mode
Figure 9 Metering Lines
Trend screen

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16 — Operang Instrucons
the temperature sensors are reading, the voltages of the three
phases, and check the operation of the unit’s load steps by acti-
vating them individually.
Any load that you activate on the maintenance screen will be
dumped when you leave the screen.
e Factory Setup screen can be accessed from maintenance
mode, but it is intended for Simplex service representatives only
and is password protected.
From the mainte-
nance mode screen, you
can enter the Diagnos-
tics screen (Figure 11),
which displays the status
of the load bank’s pro-
grammable logic con-
troller. is screen can
be useful when working
with the Simplex Service
Department should a
problem arise with your
load bank.
diagnoStiCS
SCreen
Figure 11 Diagnostics
screen