Simplex Saturn 3000 DV User manual

Final Acceptance
of Instruction Manual
Customer: Austin Generator Service
W.O. #: 63798-07-43/2
Load Bank Types: Saturn 3000 DV
1 Manual Shipped for the Load Bank described above.
2550KW/3000KW, 480/600V, 60KW Res,
LCL PLC, INT/EXT CP, Powered Louvers
File: 63798-2.p65, Disk: SDCX155
This instruction manual has been reviewed and is approved
by me as being fully accurate and representative of the
equipment being supplied thereunder and it (the manual)
meets the customer’s specification/order requirements for
manuals.
Approved by: Date:
1 Manual Received by: Date:

LOAD BANK
TECHNICAL MANUAL
(LBD Series)
Customer: Austin Generator Service
Work Order: 63798-07-43/2
Model: Saturn 3000 DV
June 2007
The information herein is the property of Simplex, Inc. and/or its subsidiaries.
Without written permission, any copying, transmitting to others, and other use
except that for which it is loaned, is prohibited.
(File: 63798-2.p65; Disk: SDCX155)

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 1 of 20
Contents
DESCRIPTION .............................................................................. 2
Control System ...................................................................... 4
Cooling System ..................................................................... 4
Load System .......................................................................... 4
PRIMARY INSPECTION ............................................................... 4
INSTALLATION ............................................................................. 5
Location .................................................................................. 5
Procedure ............................................................................... 6
OPERATION ................................................................................. 6
Local ....................................................................................... 6
Remote ................................................................................... 7
Load Dump ............................................................................. 8
FAILURE DETECTION ................................................................. 8
Thermocouple Temperature Switch ..................................... 8
MAINTENANCE ............................................................................ 9
Each Operation ...................................................................... 9
Every 50 Hours or 6 Months ............................................... 10
Motor Lubrication ................................................................ 10
TROUBLESHOOTING ................................................................ 11
Cooling Fan Motor Will Not Operate .................................. 11
Some Load Steps Cannot Be Energized ........................... 11
Cooling Failure Indicated.................................................... 12
DRAWINGS AND PARTS LIST .................................................. 12
APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL ..... 13
APPENDIX B - CALCULATIONS & FORMULAS ...................... 14
APPENDIX C - TORQUE VALUES ............................................. 17
APPENDIX D - PILLOW BLOCK BEARINGS
LUBE INTERVAL ................................................................. 19
APPENDIX E - DRAWINGS ........................................................ 20

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 2 of 20
DESCRIPTION
Simplex Load Banks are precision
test instruments specifically de-
signed to apply discrete, selectable
electrical load to a power source
while measuring the response of
the generator to the applied load.
They also provide a means for rou-
tine maintenance exercise to as-
sure long term reliability and readi-
ness of the standby generator. Ex-
ercise Load Banks eliminate the
detrimental effects of unloaded op-
eration of diesel engine generators.
The cabinet on this Load Bank is
rated NEMA Type 3R outdoor
weatherproof.
Power source testing is accom-
plished by applying resistive load
steps at unity (1.0) power factor.
Load application is by magnetic
contactor. All load branch circuits
are protected by 200,000AIC class-
T fuses.
Operating controls are located on a
Local Control Panel and a Remote Con-
trol Panel. The Control System is com-
prised of 120V and 24VDC discrete
components. Common serviceable
components include Control Fuses
(CF1–CF4) and Load Application Fuses
(F1–F189). Lamps on the Local Control
Panel indicate the Load Bank operating
status. Control priority is determined by
the “Mode Selector” switch.
SPECIFICATIONS
Capacity: 2560KW/3000KW @ 1.0 PF
Voltage: 480/600VAC
Connection: 3-Phase, 3-Wire
Frequency: 60Hz
Fan Power: Int./Ext. 480/600V, 3ø, 60Hz
Control Power: Int./Ext. 480/600V, 3ø, 60Hz
120V Transformer
Cooling: Forced Air
Airflow: 60,000 CFM
Max. Air Intake Temp.: 120°F
Nominal Air Temp. Rise: 125°F–500°F Max.
Temperature Rise: °F = KW x 3000
CFM
Duty Cycle: Continuous
Serial Number: 63798-07-43/2
Part of Pictorial Drawing 47BD164460C
Always remove all power from
the load bus and all fan/control
power before servicing the Load
Bank. Never operate or service a
Load Bank that is not properly
connected to an earthground.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 3 of 20
The Local Control Panel contains the
following components:
1. Louvers Open, Cooling Failure,
Over Temperature, Fan Failure,
Access Door Ajar, Louvers Closed,
Remote Control Active, Control
Power On, Normal Operation, and
Load Dump Bypassed indicator
lamps
2. Fan/Control Power switch
3. Load Bank Mode switch
4. Auto Load Dump switch
5. Load Voltage Selector switch
6. Master Load and load step
switches
7. Fan/Control Power Voltage Selec-
tor switch
The Remote Control Touch Panel is
housed in a suitcase.
This Load Bank is protected against
cooling failures (loss of cooling air flow,
high intake or exhaust air temperature
which could damage the Load Bank or
present a safety hazard to the opera-
tor). When a cooling failure occurs the
automatic safety features in the Control
System immediately remove the load
from the load source. The malfunction
must be corrected and the system must
be reset by turning the Load Bank “Off”
then “On” before the load can be re-
applied.
The Load Bank consists of three princi-
pal systems:
1. Control System
2. Cooling System
3. Load System
480V
600V
RESISTIVE
LOAD
MASTER 4.1KW
5KW 8.5KW 10KW 8.5KW 10KW 21KW 25KW
42KW
50KW 85KW 100KW 85KW 100KW 170KW 200KW
HIGH VOLTAGE
600VAC,3Ø,60HZ
FAN/CONTROL POWER
VOLTAGE SELECTOR
480VAC,3Ø,60HZ
LOW VOLTAGE
480V 600V
SELECTOR
VOLTAGE
LOAD
500KW
425KW
ALARM
OFF ON REMOTE LOCAL ENABLED BYPASS
RESISTIVE LOAD STEP CONTROLS
SELECT
MODE
CONTROL
POWER
FAN/
LOAD DUMP
BYPASSED
OVER
TEMPERATURE FAN
FAILURE
COOLING
FAILURE
NORMAL
OPERATION
CONTROL
POWER ON
DUMP
BYPASS
LOAD
VOLTAGE
LOUVERS
OPEN
LOUVERS
CLOSED OVER
CONTROL
ACTIVE
REMOTE
500KW
1000KW
425KW
850KW
480V
600V OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
480V
600V
480V
600V
SILENCE
HORN

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 4 of 20
CONTROL SYSTEM
The Control System allows the operator
to apply a desired load to the test source
and measure the response of the test
source to the load. This system also
contains the circuitry utilized to discon-
nect the load from the test source in the
event of cooling failures and/or improp-
erly positioned operating controls.
Fan power is applied to the Fan Motor
(MOT) through the Fan Circuit Breaker
(FCB 1A or FCB 1B), the Disconnect
Switch (DSW), the Fan/Control Voltage
Selector swtich (S1), the Auto Trans-
former, and the Fan Motor Contactor
(FMC) contacts. An Overload Relay
(OVR) is used to protect the motor.
COOLING SYSTEM
Resistive Load Elements are cooled by
a forced air system consisting of a 60"
fan blade belt driven by a 30HP, TEFC
motor, creating a 50,000 CFM. The fan
motor is energized by a 60A, 600V, 3
pole contactor (FMC) and protected by
a 100A frame, 60A trip, 3 pole, 600V
circuit breaker (FCB).
LOAD SYSTEM
The Load System consists of indepen-
dently controlled resistive and/or reac-
tive load elements specifically designed
for Load Bank systems. They are pro-
tected by 200,000AIC, 600VAC fuses.
Simplex Resistive Load Elements con-
servatively operate at approximately half
the maximum temperature rating of the
alloy (1080°F vs. 1920°F). For example:
Alloy: FeCrAl
See Parts Legend Drawing for specific
elements used.
These elements are rigidly supported
by high-temperature, ceramic-clad,
stainless-steel supports. Element-to-
element short circuits are virtually elimi-
nated. The elements are assembled in
discrete trays which are assembled in a
vertical “stack”. Each tray is independ-
ently serviceable without disturbing ad-
jacent trays.
PRIMARY INSPECTION
Preventative visual inspections of the
shipping crate and Load Bank is ad-
vised. Physical or electrical problems
due to handling and vibration may oc-
cur. Never apply power to a Load Bank
before performing this procedure. The
following Nine Point/30 Minute Inspec-
tion is recommended before installa-
tion, as part of the 50 hour / 6 month
maintenance schedule and whenever
the Load Bank is relocated:
1. If crate shows any signs of damage
examine the Load Bank in the corre-
sponding areas for signs of initial
problems.
2. Check the entire outside of the cabi-
net for any visual damage which could
cause internal electrical or mechani-
cal problems due to reduced clear-
ance.
3. Inspect all hinged panels and doors
for smooth and safe operation, try all
latches and knobs.
4. Rotate and push all switches through
all positions to ensure smooth opera-
tion.
5. Check cooling system by inspecting
fan motor and blade. Slowly rotate
blade by hand and note clearance of
blade tip through its rotation near the
housing. Observe free rotation of mo-
tor shaft.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 5 of 20
6. Inspect all relays, timers, and control
modules by opening all accessible
panels. Make sure all components
are secure in their bases and safety
bails are in place. Spot check electri-
cal connections for tightness. If any
loose connections are found inspect
and tighten all remaining connec-
tions.
7. Examine all accessible internal elec-
trical components such as fuses,
contactors and transformers. Check
lugged wires at these components.
8. Inspect bottom of crate/enclosure for
any components that may have jarred
loose during shipment such as indi-
cator light lenses, switch knobs, etc.
9. Visually inspect element chamber for
foreign objects, broken ceramic in-
sulators, mechanical damage.
INSTALLATION
LOCATION
Nema-3R Load Banks are intended for
outdoor installation. The load elements
in this Load Bank are cooled by a forced
air system which discharges through
the top of the cabinet. This Load Bank
will produce a large quantity of exhaust
air. Location of the Load Bank is of
prime importance and should be done
by trained personnel. It is one of the
most critical factors involved in safe
operation. The Load Bank must be po-
sitioned and installed according to large
airflow requirements.
• There must be a minimum clearance
of 6 feet on all sides of the Load Bank.
• Load Banks installed indoors must
be equipped with an exhaust air duct
of minimum back pressure (supplied
by others) which routes all Load Bank
hot exhaust air outdoors.
• Never install any structure or object
at any height above the Load Bank.
• Always locate the Load Bank in a
secure area accessible by trained
personal only.
• Use the eyehooks and forklift chan-
nels provided to position the Load
Bank.
• Never move the Load Bank with the
exhaust hood attached.
• Never point the exhaust at a nearby
surface or object which may be ad-
versely affected by high tempera-
ture.
• Never operate the Load Bank in a
confined 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 off
nearby objects and allow it to recircu-
late through the cooling system.
• Never operate the Load Bank in prox-
imity to a sprinkler system.
Failure to properly install this Load Bank
may result in substantial damage to or
the destruction of the Load Bank, adja-
cent equipment and the building in which
the Load Bank is installed.
If any problems are observed
during Primary Inspection call
the Simplex Service Manager at
217-483-1600 (24hrs.)
Never operate or service a Load
Bank that is not properly con-
nected to an earthground.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 6 of 20
PROCEDURE
1. Confirm the test source is properly
grounded and ground the Load Bank
in compliance with NEC.
2. If Remote Control is desired, using
CAT 5 Patch Cable, connect the
laptop computer to Receptacle 3 on
the Load Bank.
3. Confirm all load command switches
are in the “Off” position.
4. Confirm the Disconnect Switch
(DSW) is in the “Off” position.
5. See Fan/Control Power Drawing
47B164462B. Connect and external
480/600V, 3ø, 60Hz, 60A source to
FCB 1A as shown.
Consult NEC for proper wire size.
6. See Control Drawing 47B164461C.
Using #14 AWG copper wire or
greater with a torque of 35 in. lbs.,
connect customer supplied Load
Dump contacts to TB‘LD’ 1–2 or place
the “Load Dump Mode” switch in the
“Bypass” position.
Load is disengaged when the con-
tact is open.
Load is engaged when the contact is
closed.
7. See Resistive Load Section 1 Draw-
ing 47B164469. Cable the load
source to the Load Bank as shown.
Consult NEC for proper wire size.
8. Place the Disconnect Switch (DSW)
in the “On” position.
9. Place the Fan Circuit Breakers (FCB
1A or FCB 1B) in the “On” position.
OPERATION
LOCAL
1. Place the “Load Voltage Selector”
and “Fan/Control Power Voltage Se-
lector” switches in the appropriate
positions.
2. Place the “Load Bank Mode” switch
in the “Local Manual” or “Remote”
position.
3. Start-up generator or bring other test
source on line.
If External Fan/Control Power is be-
ing used, “Fan/Control Power” switch
in the “On” position to energize the
cooling fan before starting the gen-
erator to assure proper fan opera-
tion.
4. Adjust power source voltage and fre-
quency.
5. Place the “Fan/Control Power” switch
in the “On” position to energize the
cooling fan.
A false “Cooling Failure” lamp indica-
tion may be present until the cooling
fan creates sufficient airflow to close
the Fan Pressure Switch (PS). The
“Normal Operation” lamp illuminates
and control voltage is supplied to the
“Master Load” switch. With voltage
supplied to the “Master Load” switch,
the operator is now ready to apply
load steps.
6. Verify the illumination of the “Normal
Operation” lamp before proceeding.
7. Visually observe correct fan opera-
tion and investigate any unusual fan
related noises.
8. Check air intake for obstructions and
confirm positive air flow.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 7 of 20
9. Select the desired load steps by
placing them in the “On” position.
10. Place the “Master Load” switch in
the “On” position.
This simultaneously applies all of
the load steps which are in the “On”
position.
Trim is achieved by flipping the load
steps “On” and “Off” while the “Mas-
ter Load” is in the “On” position.
11. Adjust source voltage and load.
Monitor as needed.
Shutdown
1 De-energize the load.
2. Run the cooling fan for 5 minutes to
assure a thorough cool down of all
load elements (optional).
3. Place the “Fan/Control Power” switch
in the “Off” position.
REMOTE
There are three screens on the remote
touch panel. They are: Control/Status
Screen, Load Screen, and Metering
Screen.
1. Press the “Activate Remote” button.
2. Press the “Energize Control Power”
to energize the cooling fan.
A false “Cooling Failure” may be indi-
cated until the cooling fan creates
sufficient airflow to close the Fan
Pressure Switch (PS).
3. Verify “Normal Operation” via the
status window before proceeding.
4. Visually observe correct fan opera-
tion and investigate any unusual fan
related noises.
5. Check air intake for obstructions and
confirm positive air flow.
Control/Status Screen
6. Select the desired load steps by
pressing the desired buttons.
7. Press the “Master Load” button.
This simultaneously applies all of
the load steps which are in the “On”
position.
Trim is achieved by pressing the
load steps “On” and “Off” while the
“Master Load” is in the “On” posi-
tion.
8. Adjust source voltage and load.
Monitor as needed.
Load Screen

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 8 of 20
SHUTDOWN
1 De-energize the load.
2. Run the cooling fan for 5 minutes to
assure a thorough cool down of all
load elements (optional).
3. Press the “De-energize Control
Power” button.
4. Press the “Release Remote” button.
LOAD DUMP
This Load Bank contains a Load Dump
feature which de-energizes all applied
load when customer supplied contacts
open. Normally closed to run, they are
rated at 2A @ 24VDC and should be
wired to TB‘LD’ 1–2. When these con-
tacts open all applied load will be de-
energized and the load section will be
disabled. If desired, the customer may
install automatic transfer switch con-
tacts, a manual pushbutton or circuit
breaker for this use.
The operator also has the option of
bypassing these contacts and enabling
the load section by flipping the “Auto
Load Dump” switch to the “Bypass”
position. This disables the load dump
feature and illuminates the “Load Dump
Bypass” lamp.
Metering Screen
Do Not allow the Load Bank to
operateunattendedforextended
periods.
FAILURE DETECTION
If a “Failure” occurs the corresponding
lamp will illuminate and the load will be
de-energized. Before reapplying a load,
the failure must be corrected and the
system must be reset by turning the
Load Bank “Off” then “On”.
This is a permissive/energize-to-run cir-
cuit in which all safety sensors must
energize their control relays on normal
operation before load can be applied.
This system includes the following com-
ponents:
1. Exhaust Temperature Switches
(EXTS1–EXTS4)
2. Pressure Switch (PS)
3. Intake Temperature Switch (INTS)
Thermocouple
Temperature Switch
The exhaust temperature network con-
sists of a type J thermocouple (TC) and
a solid state thermocouple sensor
(EXTS). The temperature switch has
been factory adjusted for precise Load
Bank over temperature protection un-
der normal operating conditions. Un-
usual operating conditions may require

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 9 of 20
field adjustment. The setpoint of the
Exhaust Temperature Switch (EXTS)
may be changed by rotating the adjust-
ment knob. Consult the Simplex Ser-
vice Department (217-483-1600 24hrs)
before changing the temperature switch
setpoint.
MAINTENANCE
The Load Bank has been designed to
require minimum maintenance. All com-
ponents have been chosen for a long,
reliable life. Two basic intervals of main-
tenance are required: each operation
and every 50 hours or 6 months (which-
ever comes first).
EACH OPERATION
The air intake screens and louvers, fan
and cooling chamber, and exhaust open-
ings must be checked for any obstruc-
tions or foreign objects. Due to the high
volume of air circulated, paper and other
items can be drawn into the air intakes.
During Load Bank operation insure that
air is exiting from the top exhaust vent.
The load branches should be checked
for blown fuses or opened load resis-
tors. To check the fuses or load resis-
tors, operate the Load Bank from a
balanced 3-phase source and check
the three line currents. The three cur-
rent readings should be essentially the
same. If a sizeable difference is noted
one or more load fuses or load resistors
may have malfunctioned.
Overgreasing is a major cause
of bearing and/or motor failure.
The amount of grease added
should be carefully controlled.
Also make sure dirt and con-
taminants are not introduced
when adding grease.
If lubrication instructions are
shown on the motor nameplate,
they will supersede this gen-
eral instruction.
If motor is nameplated for haz-
ardous locations, do not run
motor without all of the grease
or drain plugs installed.
The Pillow Block Bearings (PN
22691040), which are used on
Saturn Load Banks, are pre-lu-
bricated at the time of manufac-
ture. These bearings are lubri-
cated with Mobil Mobilith AW2
grease (a Lithium based
grease). Lubrication using an-
other grease may cause bear-
ing failure. See Appendix D -
Pillow Block Bearings Lube In-
terval for additional information.
For continued safety and for
maximum equipment protec-
tion, always replace fuses with
one of equal rating only.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 10 of 20
RELUBRICATION TIME INTERVAL
for motors with regreasing provisions.
NEMA Frame Size
140 – 180 210 – 360 400 – 510
1800 RPM Over 1800 1800 RPM Over 1800 1800 RPM Over 1800
and less RPM and less RPM and less RPM
Standard 3 yrs. 8 mo. 2 yrs. 8 mo. 1 yr. 3 mo.
Severe 1 yr. 3 mo. 1 yr. 3 mo. 6 mo. 1 mo.
Seasonal See Note 2.
Standard: Up to 16 hours of operation per day, indoors, 100°F maximum ambient.
Severe: Greater than 16 hours of operation per day. Continuous operation under high
ambient temperatures (100° to 150°F) and/or any of the following: dirty, moist locations,
high vibration (above NEMA standards), heavy shock loading, or where shaft extension
end is hot.
Seasonal: The motor remains idle for a period of 6 months or more.
Note:
1. For motors nameplated as “belted duty only” divide the above intervals by 3.
2. Lubricate at the beginning of the season. Then follow service schedule above.
EVERY 50
HOURS
OR 6 MONTHS
Check the tightness of
the electrical connec-
tions. The expansion
and contraction caused
by Load Bank operation
may result in loose con-
nections. The vibrations
caused by the cooling
fan may also loosen
electrical connections. If
the Load Bank is trans-
ported “over the road”,
the electrical connec-
tions should be checked
for tightness at a shorter-
than-normal time inter-
val. See “Primary In-
spection”.
MOTOR
LUBRICATION
Motors are properly lubricated at the
time of manufacture. It is not necessary
to lubricate at the time of installation
unless the motor has been in storage for
a period of 12 months or longer (refer to
lubrication procedure that follows).
Inspect the fan motor supplied with your
Load Bank for grease fittings. If the
motor contains grease fittings you must
lubricate the motor. If lubrication in-
structions are shown on the motor name-
plate, they will supersede this general
instruction. Belt driven cooling fans have
bearings which should be lubricated.
Bearings should be lubricated every 50
hours of operation or 6 months which-
ever comes first.
Lubrication Procedure
1. Stop motor. Disconnect and lock out
of service.
2. Remove contaminants from grease
inlet area.
3. Remove filler and drain plugs.
4. Check filler and drain holes for block-
age and clean as necessary.
5. Add proper type and amount of
grease. See the Relubrication Time
Intervals table for service schedule
and Relubrication Amounts table
(see next page) for volume of grease
required.
6. Wipe off excess grease and replace
filler and drain plugs.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 11 of 20
When troubleshooting Load
Banksystemsalwaysremoveall
test source power, fan/control
power,anti-condensationheater
power, etc.
7. Motor is ready for operation.
Warning: If motor is nameplated for
hazardous locations, do not run mo-
tor without all of the grease or drain
plugs installed.
Grease Type
Unless stated otherwise on the motor
nameplate, the motors on this Load
Bank are pregreased with a polyurea
mineral oil NGLI grade 2 type grease.
Some compatible brands of polyurea
mineral base type grease are:
• Chevron SRI #2
• Rykon Premium #2
• Exxon Polyrex EM
• Texaco Polystar RB
TROUBLESHOOTING
This section is designed to aid the elec-
trical technician in basic Load Bank
system troubleshooting. All of the prob-
lems listed can be verified with a basic
test meter and/or continuity tester. For
safety reasons, when troubleshooting
Load Bank systems always remove all
test source power, fan/control power,
anti-condensation heater power, etc.
COOLING FAN MOTOR WILL
NOT OPERATE
1. Inoperative Fan Circuit Breaker
(CB)
2. Fan/Control Power not available/
incorrect
3. Inoperative Fan Motor (MOT)
4. Fan Motor Contactor (FMC) de-
energized
5. Restriction of air (intake or ex-
haust)
6. Fan pressure switch inoperative
RELUBRICATION AMOUNTS
for motors with regreasing provisions.
NEMA Volume
Frame Size cu. in. (fluid oz.)
140 .25 (.14)
180 .50 (.28)
210 .75 (.42)
250 1.00 (.55)
280 1.25 (.69)
320 1.50 (.83)
360 1.75 (.97)
400 2.25 (1.2)
440 2.75 (1.5)
500 3.00 (1.7)
SOME LOAD STEPS
CANNOT BE ENERGIZED
1. Inoperative load step switches
2. Open load step resistor(s)
3. Inoperative load step relays
4. Inoperative load step contactors
5. Open load step fuses

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
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LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 12 of 20
COOLING FAILURE
INDICATED
Exhaust temp above EXTS setpoint:
1. Over temperature sensor failure
2. Fan failure
3. Air restriction (intake or exhaust)
4. Overvoltage condition present
Exhaust temp below EXTS setpoint:
1. Restriction of air
(intake or exhaust)
2. Fan pressure switch inoperative
3. Overtemperature sensor failure
DRAWINGS AND
PARTS LIST
The drawings included in this manual
are the most accurate source of part
numbers for your Load Bank. When
ordering replacement parts for Simplex
Load Banks, always consult the Parts
Drawing. When contacting the Simplex
Service Department always have your
work order and drawing number ready
for reference. The Work Order Number
and the Drawing Numbers are also lo-
cated on each drawing legend. A typical
drawing legend and parts list is illus-
trated at right.

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 13 of 20
APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL
Listed below are abbreviations of terms found on Simplex Load Bank Systems. When following a load bank
drawing utilize this guide to define abbreviated system and component names. As this is a master list, drawings
and text pertaining to your equipment may not contain all these terms.
AC-Alternating current
AIC-Ampere interrupting cur-
rent-maximum short circuit fault
current a component can safely
interrupt
AM-Ammeter
AMSW- Ammeter selector
switch-selects any phase for
current reading
CF-Control fuse
CFM-Cubic feet per minute-
used to rate fan air flow capacity
and load bank cooling require-
ment
CFR-Cooling failure relay-
normally energized relay in
cooling failure subsystem
CPC-Control power contactor
CPF-Control power fuse
CT-Current transformer- used in
metering circuits
DC-Direct current
EXTS-Exhaust air temperature
switch
FCB-Fan circuit breaker-circuit
breaker in series with fan control
power
FCVR-Fan control voltage relay-
normally energized relay on
relay sub-panel
FM-Frequency meter-monitors
frequency of test source
FMC-Fan motor contactor-
controls power to fan motor
FMSW-Frequency meter switch
FPS-Fan power switch-used to
energize cooling system
GFB-Ground fault breaker
GBTR-Ground breaker tripped
relay
HVR-High voltage relay
Hz-Hertz-cycles per second,
measurement of frequency
IFCV-Incorrect fan/control
voltage
INTS-Intake air temperature
switch
K-Relay coil/contact designation
KVA-Kilovolt amperes
KVAR-Kilovolt amperes-reactive
KW-Kilowatts
KWM-Kilowatt meter
KWT-Kilowatt meter transducer
LM-Louver motor
LMC-Louver motor contactor
LR-Load resistive element
LX-Load reactive element
L1-Line 1
L2-Line 2
L3-Line 3
MCB-Main circuit breaker
MDS-Main Disconnect Switch
MF-Meter fuse
MLB-Main Load Bus
MOT-Motor
NEMA-National electrical
manufacturer’s association
ODP-Open, drip-proof-refers to
motor enclosure
OVR-Overvoltage relay-relay
used in overvoltage failure
system, located on relay sub-
panel
OLR-Overload relay-used for
motor protection
OTR-Overtemperature relay-
used in failure system
PF-Power factor-in resistive only
loads expressed as unity (1.0),
in inductive loads expressed as
lagging, in capacitive loads
expressed as leading
PAR-Control power available
relay-relay energized when
control power is available
PFM-Power factor meter
PS-Pressure switch-switch used
to detect fan failure
RR-Reset relay
RTM-Running time meter-keeps
time log of equipment use.
TB-Terminal block
TDR-Time delay relay-relay
which times out before contacts
change state
TEFC-Totally enclosed, fan
cooled-refers to motor enclosure
TEAO-Totally enclosed, air-
over-refers to motor enclosure
UPS-Uninterruptable power
source
V-Voltage
VSR-Voltage sensing relay
XCB-Reactive load controlling
circuit breaker

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 14 of 20
APPENDIX B -
CALCULATIONS
& FORMULAS
The following calculations are used to
determine the actual kilowatt load being
applied by the Load Bank, when line
voltages and currents are known (at 1.0
power factor).
3 Phase
1. Read all three line currents and find
the average reading.
2. Read all three line-to-line voltages
and find the average reading.
3. Multiply the average current times
the average voltage.
4. Multiply the answer of step #3 times
the square root of 3 (1.732).
5. Divide the answer of step #4 by 1000.
The answer is the actual kilowatts of
load being applied by the Load Bank.
Single Phase
1. Determine the line current.
2. Determine the line-to-line voltage.
3. Multiply the line current times the
line-to-line voltage.
4. Divide the answer of step #3 by 1000.
5. The answer of step #4 is the actual
kilowatts being applied by the load
bank.
EXAMPLES
Using line voltages and currents:
3 Phase
Current Readings Voltage Readings
A1= 249A V1-2 = 481V
A2= 250A V2-3 = 479V
A3= 254A V3-1 = 483V
Average Current = A1+ A2+ A3
3
=249+250+254
3
= 251A
Average Voltage = V1-2 + V2-3 + V3-1
3
=481 + 479 + 483
3
= 481V
Kilowatts = Volts x Amps x 1.732
1000
=481 x 251 x 1.732
1000
= 209.1KW
Single Phase
Current Reading: 150A Voltage Reading: 240V
Kilowatts = Volts x Amps
1000
=150 x 240
1000
= 36.1KW

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
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®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 15 of 20
The following calculations are used to
determine the amount of current when
the desired amount of kilowatts is ap-
plied at 1.0 power factor.
3 Phase
1. Multiply the desired amount of kilo-
watts to be applied by 1000.
2. Multiply the operating voltage times
the square root of 3 (1.732)
3. Divide the answer of step #1 by the
answer of step #2.
4. The answer of step #3 is the average
line current with the desired kilowatts
applied at 1.0 power factor.
Single phase
1. Multiply the desired amount of kilo-
watts to be applied by 1000.
2. Divide the answer of step #1 by the
operating voltage.
3. The answer of step #2 is the average
line current with the desired amount
of kilowatts applied at 1.0 power fac-
tor.
The following calculations are used to
determine a step kilowatt rating at other
than a rated voltage. This is accom-
plished by referencing the load step to a
KW value at a known voltage.
1. Determine the new unrated operat-
ing voltage.
2. Divide the new operating voltage by
the reference voltage.
3. Square the answer of step #2.
4. Multiply the answer of step #3 times
the reference kilowatt value of the
load step which the new kilowatt rat-
ing is desired.
5. The answer of step #4 is the kilowatt
rating of the load step at the new
voltage.
EXAMPLES
When desired amount of kilowatts is applied at 1.0 PF:
3 Phase
Applied: 50KW Operating Voltage: 480V
Amperage = KW x 1000
Volts x 1.732
=50 x 1000
480 x 1.732
=50,000
831.36
= 60.1
Single Phase
Applied: 25KW Operating Voltage: 240V
Amperage = KW x 1000
Volts
=25 x 1000
240
=25,000
240
= 104.2
Determining step KW at other than rated voltage:
Applied: 80KW Operating Voltage: 450V
Rated Voltage: 480V
Step KW = (Oper. Volt. ÷ Rated Volt.)2x Applied KW
= (450 ÷480)2x 80
= .93752x 80
= 70.3

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 16 of 20
FORMULAS
Alternating Current Direct Current
Kilowatts 1 phase Volts x Amps x PF* Volts x Amps
1000 1000
3 phase 1.732 x Volts x Amps x PF*
1000
*Power Factor, expressed as decimal.
(Resistive Load Bank PF is 1.0)
Amperes 1 phase KW x 1000 KW x 1000
(KW known) Volts x PF Volts
3 phase KW x 1000
1.732 x Volts x PF
KVA 1 phase Volts x Amps
1000
3 phase 1.732 x Volts x Amps
1000
Amperes 1 phase KVA x 1000
(KVA known) Volts
3 phase KVA x 1000
1.732 x Volts
KVAR 1 phase Volts x Amps x 1-PF2
1000
3 phase 1.732 x Volts x Amps x 1-PF2
1000

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
© 2007 Simplex, Inc. All Rights Reserved. • Printed in the USA. • www.simplexdirect.com
®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 17 of 20
APPENDIX C - TORQUE VALUES
FAN BLADES
FAN TORQUE
PART NO. BOLT SIZE FT LBS // IN LBS
13820000 SET SCREW 11.7 // 140
13820500 SET SCREW 11.7 // 140
13821000 SET SCREW 8.3 // 100
13822000 1/4 — 20 7.5 // 90
13823000 1/4 — 20 7.5 // 90
13824000 1/4 — 20 7.5 // 90
13825100 1/4 — 20 7.5 // 90
13826000 1/4 — 20 7.5 // 90
13827500 5/16” 13 // 156
13827600 5/16” 13 // 156
13828000 3/8” 24 // 288
MOTORS, BRACKETS, BUS BAR CONNECTIONS
BOLT/NUT TORQUE
SIZE GRADE FT LBS // IN LBS
.250 (1/4-20) Grade 5, dry 8 // 96
.250 (1/4-20) Grade 2, dry 5.5 // 66
.312 (5/16) Grade 5, dry 17 // 204
.312 (5/16) Grade 2, dry 11 // 132
.375 (3/8) Grade 5, dry 30 // 360
.375 (3/8) Grade 2, dry 19 // 228
.437 (7/16) Grade 5, dry 50 // 600
.437 (7/16) Grade 2, dry 30 // 360
.500 (1/2) Grade 5, dry 75 // 900
.500 (1/2) Grade 2, dry 40 // 480
.562 (9/16) & up Grade 5, dry 110 // 1320
.562 (9/16) & up Grade 2, dry 55 // 660
CONTACTORS
See torque values on the front of the contactor.
ELEMENTS/TRAYS
TERM/NUT TORQUE
SIZE INCH LBS
#6 Rod ends 4
#10 Element Conn. 20
1/4-20” High Voltage Contact Simplex
MAIN LOAD BLOCKS- ALL SIZES
WIRE TORQUE
CONNECTION SIZE FT LBS // IN LBS
LOAD SIDE 4-14AWG 2.9 // 35
LINE SIDE 500MCM-4/0 31 // 375
3/0-4/0 20 // 240
2/0-6AWG 10 // 120
8AWG 3.3 // 40
CIRCUIT BREAKERS
WIRE TORQUE
STYLE SIZE INCH LBS
Cutler-Hammer 14-10 AWG 20
1-Phase 8 AWG 25
6-4 AWG 27
3-1/0 AWG 45
Merlin Gerin 14-1/0 50
3-Phase

Simplex, Inc., 5300 Rising Moon Road, Springfield, IL 62711-6228 • 217-483-1600 • Fax [phone]
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®
LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 18 of 20
FUSEBLOCKS
MANUF. WIRE TORQUE
PART NO. SIZE INCH LBS
BM6031SQ, 10-18 AWG 20
BM6032SQ,
BM6033SQ;
600V, 30A
T60060-2SR 10-18 AWG 20
600V, 60A
T60030-3CR, 10-14 AWG 35
600V, 30A 8 AWG 40
T60060-3CR,
4-6 AWG 45
600V, 60A
2-3 AWG 50
60100-3CR,
600V, 100A
MISCELLANEOUS-TERMINALS, METERS,
SWITCHES, COILS, RELAYS, XFORMERS
CONNECTION TORQUE
SIZE INCH LBS
45
610
819
10 31
1/4-20” 66
TAPER-LOCK BUSHINGS
BUSHING NUMBER TORQUE
1008, 1108 55 IN LBS
1210, 1215, 1310, 1610, 1615 15 FT LBS
2012 23 FT LBS
2517, 2525 36 FT LBS
3020, 3030 67 FT LBS
3535 83 FT LBS
4040 142 FT LBS
4545 204 FT LBS
5050 258 FT LBS
6050, 7060, 8065 652 FT LBS
10085, 12010 1142 FT LBS
CAM-LOK STUDS
THREADED MAXIMUM
STUD TORQUE
5/16” – 18 15 FT LBS
1/2” – 13 40 FT LBS
APPENDIX C - TORQUE VALUES CONT’D