Simplex POWERSTAR 110 KW User manual

110 KW POWERSTAR
DIGITAL LOAD BANK
125 KW NORTHSTAR
150 KW NORTHSTAR
Document Number: DOC-00668

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Table of Contents
I. Warnings and Cautions ..................................................................................... 4
II. Nameplates and Placards.................................................................................. 6
1. Introduction......................................................................................................................... 6
2. Instruction Placards ........................................................................................................... 6
III. Description and Specication..........................................................................11
1. Introduction....................................................................................................................... 11
2. Overview of Use................................................................................................................ 11
3. Capabilities ....................................................................................................................... 11
4. Safety ................................................................................................................................ 12
5. Specications ................................................................................................................... 12
IV. Unpacking ......................................................................................................... 13
1. Introduction....................................................................................................................... 13
2. Included Components and Parts .................................................................................... 13
3. Primary Inspection ........................................................................................................... 13
V. Installation......................................................................................................... 14
1. Introduction....................................................................................................................... 14
2. Load Bank Location ......................................................................................................... 14
VI. Operating Instructions..................................................................................... 16
1. Introduction....................................................................................................................... 16
2. Overview of Load Bank HMI Software ............................................................................ 16
3. Handling ............................................................................................................................ 18
4. Basic Operations .............................................................................................................. 18
5. Shutdown .......................................................................................................................... 20
6. Additional Screens and Programming Information ...................................................... 20
VII. Alarms and Warnings....................................................................................... 23
1. Introduction....................................................................................................................... 23
2. Over-temperature Alarm .................................................................................................. 23
VIII. Supplemental Equipment ................................................................................ 24
1. Introduction....................................................................................................................... 24
2. Cam-Lok Cables ............................................................................................................... 24
IX. Diagnostics and Troubleshooting................................................................... 25
1. Introduction....................................................................................................................... 25
2. General Maintenance ...................................................................................................... 25
3. Failure Subsystem............................................................................................................ 26
4. Parts Breakdown .............................................................................................................. 27
X. Ordering Information........................................................................................ 29
1. Powerstar or NorthStar ................................................................................................... 29
2. Covering ............................................................................................................................ 29
APPENDIX A — ABBREVIATIONS IN THIS MANUAL.................................................................. 31
APPENDIX B — IMPORTANT FORMULA......................................................................................32

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Table of Figures
I. Warnings and Cautions ..................................................................................... 4
II. Nameplates and Placards.................................................................................. 6
III. Description and Specication..........................................................................11
IV. Unpacking ......................................................................................................... 13
V. Installation......................................................................................................... 14
1. Airow Diagram ................................................................................................................ 14
VI. Operating Instructions..................................................................................... 16
1. Screen Explanation .......................................................................................................... 16
2. Screen Explanation 2 ....................................................................................................... 16
3. Home Screen; No Power.................................................................................................. 18
4. Power On........................................................................................................................... 19
5. Press Enter for Entry........................................................................................................ 19
6. Entry Pad........................................................................................................................... 19
7. Metering Screen................................................................................................................ 19
8. Setup Explanations .......................................................................................................... 20
9. Error Menu ........................................................................................................................ 21
10.Auto Jog Chart.................................................................................................................. 22
11. Auto Jog Selection ........................................................................................................... 22
12.Setting Auto Jog ............................................................................................................... 22
VII. Alarms and Warnings....................................................................................... 23
VIII. Supplemental Equipment ................................................................................ 24
1. Load Bank Female Cam-Lok Plugs for Input ................................................................. 24
IX. Diagnostics and Troubleshooting................................................................... 25
1. Fan View ............................................................................................................................ 27
2. Side View........................................................................................................................... 27
3. Exhaust View .................................................................................................................... 27
X. Ordering Information........................................................................................ 29

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Last Revision Date: March 15, 2016
For the most up-to-date information for this product and
others, please contact Simplex, Inc. at 1-800-637-8603 or visit
us on the web at http://www.simplexdirect.com.

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1.0 WARNINGS AND CAUTIONS
Four commonly used safety symbols accompany the DANGER, WARNING, and CAUTION
blocks. The type of informaon each indicates is as follows:
This General warning symbol points out important safety
informaon that, if not followed, could endanger personal safety
and/or property of others.
This Explosion warning symbol points out potenal explosion
hazard(s).
This Fire warning symbol points out potenal re hazard(s).
This Electrical warning symbol points out potenal electrical
shock hazard(s).
Improper operaon of this equipment such as neglecng its maintenance or
being careless can cause possible injury or death. Permit only responsible and
capable persons to install, operate, and/or maintain this equipment.
Potenally lethal voltages and amperages are present in these machines. Ensure
all steps are taken to render the machine safe before aempng to work on the
equipment.
ELECTRICAL WARNING
•All hardware covered by this manual have dangerous electrical voltages and can
cause fatal electrical shock. Avoid contact with bare wires, terminals, connecons,
etc., on the hardware, if applicable. Ensure all appropriate covers, guards, grounds,
and barriers are in place before operang the equipment. If work must be done
around an operang unit, stand on an insulated dry surface to reduce shock hazard.
•Do not handle any kind of electrical device while standing in water, while barefoot, or
while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.
•If trained personnel must stand on metal or concrete while installing, servicing,
adjusng, or repairing this equipment, place insulave mats over a dry wooden
plaorm. Work on the equipment only while standing on such insulave mats.
•The Naonal Electrical Code (NEC), Arcle 250 requires the frame of the equipment
to be connected to an approved earth ground and/or grounding rods. This grounding
will help prevent dangerous electrical shock that might be caused by a ground fault
condion or by stac electricity. Never disconnect the ground wire.
•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.

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•Before installing or servicing this (and related) equipment, make sure that all power
voltage supplies are completely turned o at their source. Failure to do so will 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, aempt to free the vicm from the
live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducng
implement, such as a dry rope or board, to free the vicm from the live conductor. If
the vicm is unconscious, apply rst aid and seek immediate medical aenon.
•Never wear jewelry when working on this equipment. Jewelry can conduct electricity
resulng in electric shock or may get caught in moving components causing injury.
FIRE WARNING
•Keep a re exnguisher near the hardware at all mes. Do NOT use any carbon tetra-
chloride type exnguisher. Its fumes are toxic, and the liquid can deteriorate wiring
insulaon. Keep the exnguisher properly charged and be familiar with its use. If
there are any quesons pertaining to re exnguishers, please consult the local re
department.
GENERAL WARNING
•The illustraons in this manual are examples only and may dier from your load
bank.

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2.0 NAMEPLATES AND PLACARDS
2.1 Introducon
This secon will provide copies of the nameplates and placards for this Load Bank in the
event that the current nameplates and placards become unreadable.
2.2 Instrucon Placards

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