Simplex POWERSTAR 110 KW User manual

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

Page1
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

Page2
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

Page3
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.

Page4
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.

Page5
•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.

Page6
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

Page7

Page8

Page9

Page10

Page11
3.0 DESCRIPTION AND SPECIFICATION
3.1 Introducon
This secon will provide a brief synopsis of the use of the load bank. Simplex, Inc.
reserves the right to change this synopsis, and this secon should only serve as a brief
concept of the device.
In this secon, you will nd:
—An overview of normal usage of the load bank.
—An overview of hardware capabilies.
—An overview of safety funcons.
3.2 Overview of Use
The Simplex Portable Load Bank is an ultra-compact, lightweight, and versale test
instrument specially designed for manufacturers, dealers, and users of AC power
systems. The load bank also provides roune maintenance exercise in order to assure
the long-term reliability and readiness of the standby generator. Exercise load banks
eliminate the detrimental eects of unloaded operaon of diesel engine generators. It
is suitable for tesng engine generators, wind generators, UPS systems, ground power
units, auxiliary power units, stac inverters, or virtually any other AC power source in
the producon line in the service shop or in the eld. The load of the unit can be applied
to all common AC voltages. See Table 1 under “3.5 Specicaons” on page 12 for a list
of specicaons for each type of load bank.
This fully self-contained load bank includes test instrumentaon, cooling system, rugged
load elements, load-applicaon control devices, and automac system protecon
devices. The resisve load elements in the load bank are cooled by a horizontal forced
air system. The load system is connected to the test source via the load cables.
3.3 Capabilies
The load bank is a digitally controlled load bank with network capability. The unit is
controlled via a hand-held touchscreen controller that is connected to the load bank
by a supplied RS-232 network cable. It includes a digital power transducer with meter
displays on the touchscreen. Power load is applied via a screen keypad. Using the RS-232
cables, any number of load banks can be connected in a series. To create a load bank
chain, connect the RS-232 cables from the “out” connector to the “in” connector of the
next unit. Connue this process unl the desired number of units are connected. All
control and metering is provided from a single hand-held controller. All instrumentaon
values for the total network are summed and displayed on the master controller.
The load bank is highly portable and easily transported to the job site. The load bank
includes casters, liing, and moving handles. Power connecons plug in to Cam-Lok
connectors. Control and cooling fan power is obtained from a common 115v, 15A outlet
via the included connecon cord. The load bank is a fully self-contained and portable
tesng system. It includes integral cooling fans and control circuits, which can operate
from a supplied 120V control power cord.

Page12
3.4 Safety
In the interest of safety, the load bank is equipped with an automac system to de-
energize all the load if condions are met that may be dangerous to the operator or
could damage the hardware. If the load elements aren’t cooled properly due to a fan
failure or high exhaust temperature, the load bank will de-energize any applied load.
Aer operaon, the load bank has an auto cool down feature to prevent burns and
injury during transportaon aer use.
3.5 Specicaons
The table below shows the operaon KW at the various voltages across the Powerstar
and the dierent model of Northstar Load Banks.
Model KW Rang 600VAC, 3Ph 480VAC, 3Ph 240VAC, 3Ph 240VAC, 1Ph 230VAC, 1Ph 208VAC, 2Ph 208VAC, 1Ph
PowerStar 110 110 480VAC, 3Ph 110KW/132A 110KW/264A 70.4KW/293A 64.7KW/281A 82.5KW/229A 52.9KW/254A
NorthStar 125 125 208VAC, 3Ph 125KW/345A 80KW/385A
NorthStar 150 150 600VAC, 3Ph 150KW/145A 96KW/115A 24KW/58A
Table 1 Specications of Load Banks

Page13
4.0 UNPACKING
4.1 Introducon
This secon will detail the procedure to unpack the load bank. This guide will include
preparaon for seng up the equipment for proper use.
In this secon, you will nd:
—A list of included components and parts.
—An inspecon list.
4.2 Included Components and Parts
—Powerstar or Northstar Portable Load Bank
—HMI
—Power cord
—Serial cable
—Manual
4.3 Primary Inspecon
Preventave visual inspecons of the shipping crate and the load bank are advised.
Physical or electrical problems due to handling and vibraon may occur. Never apply
power to a load bank before performing this procedure. The following ve-point
inspecon is recommended before installaon and as part of the 50-hour / 6-month
maintenance schedule or as a load bank is relocated:
1. If the crate shows any signs of damage, examine the load bank in the
corresponding areas for signs of inial problems.
2. Check the enre 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 components are secure in
their bases and safety bails are in place. Spot check electrical connecons for
ghtness. If any loose connecons are found, inspect and ghten all remaining
connecons.
4. Examine all accessible internal electrical components such as fuses, contactors,
and relays. Check lugged wires at these components.
5. Visually inspect element chamber for foreign objects, broken ceramic
insulators, and mechanical damage.
If any problems are
observed during Primary
Inspection, call the
Simplex Service Manager
at 1-800-637-8603.

Page14
5.0 INSTALLATION
5.1 Introducon
With a portable load bank, placement is not a permanent thing; however, because of its
mobile nature, extra aenon is required whenever the load bank is moved. Whenever
the load bank is moved, even within the same room, the following warnings must be
observed.
In this secon, you will nd:
—How to choose the load bank’s locaon.
5.2 Load Bank Locaon
The load elements in the load bank are cooled by a horizontal forced air system, which
discharges through the front of the cabinet. The
locaon of the load bank is of prime importance
and is one of the most crical factors involved in
safe operaon. The load bank must be posioned
and installed to allow for a 4-foot intake clearance
as well as a 20-foot exhaust clearance. Never
point the exhaust at nearby surfaces or objects,
which may be adversely aected by high
temperatures. Never operate the load bank in a
conned space without regard for adequate
intake of air and provision for exit of high
temperature exhaust. Consider that the load bank
and a nearby generator set may have to compete
for cooling air. Never bounce hot exhaust air o
nearby objects and allow it to re-circulate through the cooling system. Never operate
the load bank in proximity to a sprinkler system.
See Figure 1 load bank placement image for more specic details when choosing a place
for your load bank.
WARNING
Reverse air-ow will damage load bank. Please observe the above image for how air
travels into and out of the load bank.
Note: Load bank warranty is void if incorrectly cooled.
High Voltage: Because this unit uses dangerous voltage, turn o the equipment and
disconnect power source before opening the load bank.
High Temperature: Due to the amount of heat generated during operaon, allow the
equipment to cool before servicing or opening the load bank.
Rotang Equipment: Before opening the load bank, ensure that the power is removed,
and the fan has stopped completely.
For Operator Safety: Make sure this equipment is properly grounded when in use.
All compression type connecons on fuse blocks, load blocks, and contactors should
be checked for ghtness frequently. This check should be established as part of roune
maintenance.
Figure 1 Airow Diagram

Page15
CAUTION
This load bank is high-powered, technical, industrial equipment operang at dangerous
voltages, and temperatures. It is capable of damage to itself or 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. It is imperave that the operator be familiar
with its contents and has access to it during operaon.
The following cauons should be observed before and during operaon:
1. Check all aspects of the load bank (intake/exhaust screen, louvers, fans, and load
elements) for foreign objects.
2. Posion and install load bank with great consideraon given to large cubic airow
requirements, exhaust temperature and velocity. The exhaust temperature of a
large load bank rapidly diminishes downstream but can easily exceed 300°F within
20 feet of exhaust outlet. Therefore, do not point exhaust at any nearby surface or
object, which may be adversely aected by high temperature. This includes but is
not limited to painted surfaces, tar paper and asphalt roofs, water sprinkler heads,
re alarms, and volale material.
Do not use in conned spaces with less than a 4-foot clearance for intake air and
less than a 20-foot clearance for exit of high temperature exhaust. Do not permit
vercal airow unit with wheels to sink into so surfaces thereby cung o boom
air intake. Be concerned with possibility that the load bank may have to compete
with cooling air requirements of a nearby running engine generator set where cool-
ing 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 obstrucons for
re-circulaon through the load bank.
3. Verify that all control switch posions are correct for intended usage before making
connecon.
4. The load cables carry high amperage. Be constantly aware of possibility of
inducvely heang adjacent ferrous objects to temperatures sucient to damage
cable insulaon.
5. If load bank does not have a fan reversal switch, give extra aenon to proper
phasing of power cable and external control power connecon to assure proper fan
rotaon.
6. Always connect safety ground cable to a proper ground. Do not rely on a possible
grounded neutral somewhere else in the system.
7. Do not let equipment operate unaended for long periods of me.
8. Do not store or operate in rain or spray unless unit is designed for this service or
adequate protecon is provided.
9. Rounely inspect all components and electrical connecons for ghtness and
integrity.
10. 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).

Page16
6.0 OPERATING INSTRUCTIONS
6.1 Introducon
The load bank was designed with simplicity in mind. The hardware is simple to use and
easy to maintain.
Using a hand-held interface, the load bank can apply a desired load to a target device.
In this secon, you will nd:
—An overview of the load bank’s HMI.
—How to properly handle the load bank.
—How to start the load bank, apply a load, and shut down the load bank.
6.2 Overview of Load Bank HMI Soware
In order to apply a load using the load bank, you must use the hand-held HMI
touchscreen. The HMI is loaded with a number of important features to complete your
desired tasks. It is advised to fully understand the screens of the HMI soware fully
before starng using the equipment. See Figure 2 Screen Explanaon and the related
Table 2 for a breakdown of the main screen.
Figure 2 Screen Explanation
Figure 3 Screen Explanation 2

Page17
Reference
Number
Explanaon
1The “Fan” switch will turn the fan and unit on.
2The “Load” switch will apply the set load to the tesng source.
3The “Vavg” is the average voltage of the load.
4This secon will designate the phase in which the load bank is running. It can be in 1Ph
(single phase) or 3Ph (3-phase).
5The “Available” secon is how much KW is available for use.
6The “Running” is the amount of KW load bank has aempted to apply.
7The “Normal Operaon” secon will remain normal unless an error appears. Touch-
ing here, “ERR” (Reference Number 10), or F1 will access the errors and allow you to
address the issues.
8The “Entry” value is the value entered that you desire for the load. When touched, a
number pad will appear for entering values.
9The “Metered” secon is the amount of KW the load bank has applied as read from
the on-board digital meter.
10 The “ERR” selecon will load the error tab for the HMI. If any errors are acve, then
this tab will show what is causing the errors.
11 & 12 The JG+ and JG- values are abbreviaons for “Jog Up” and “Jog Down,” respecvely.
These will increase or decrease the KW entry by a value set in the setup (See Refer-
ence 14).
13 The “MTR” (Meter) buon will display the metering screen.
14 The “SHF” (Shi) buon will reveal newer funcons of “AJG” and “SET” on the boom
of the screen where the funcon buons are.
15 The “AJG” (Auto-Jog) buon will allow you to set the Auto-Jog funcons. By using a
minimum and maximum value as well as seng the steps and duraon to go from the
minimum to the maximum, the auto-jog will run in a loop unl stopped.
16 The “SET” buon will load the setup menu. Please see “6.6.1 Setup Informaon” on
page 20 for more informaon on the setup menu.
Table 2 Screen Denitions

Page18
6.3 Handling
6.3.1 General Handling Informaon
When moving the Load Bank, please keep the device upright and do not transport
on its side. Use the aached rollers for short distances. If the unit needs to be
lied, only li the unit using the handles on the sides or liing the from the
boom of the unit. Avoid liing from the Cam-Lok connecons as it will apply
extra pressure to the BUS connectors. Do not insert any liing tools in the fan
grang. Avoid impact while transporng as well as avoid dropping the unit in
general. While the metal casing is quite strong, avoid dropping anything heavy on
the unit.
6.3.2 Aer-Operaon Handling Informaon
Because of the nature of the Load Bank’s operaon, the unit will be extremely
hot. To prevent burn injury, allow the fans to run for a few minutes without an
applied load at the end of operaon. When the unit has cooled, turn the fans o
and move it as necessary.
6.4 Basic Operaons
6.4.1 Powering the Load Bank
2. Before starng the Load Bank, ensure that the load bank is connected
to an independent ground line.
3. Connect the Control Power Cable to the control power outlet, connect
the HMI(Port 3) to the “In” port (Port 1), and connect the cables from
the load source to the Cam-Lok connectors.
4. Plug in the Control Power Cable into a 120V, 15A maximum external
receptacle.
5. Visually observe for any possible fan obstrucon.
6. The HMI hand-held controller will energize. On the HMI hand-held
controller, press the “On” switch for the “Fan.” (See Figure 4). The
fans will start.
Figure 4 Home Screen; No Power