Simplex NEPTUNE Manual
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Simplex NEPTUNE Manual

Simplex NEPTUNE Manual

150kw-650kw stationary load bank
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NEPTUNE
150KW-650KW
STATIONARY LOAD BANK

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Summary of Contents for Simplex NEPTUNE

  • Page 1 NEPTUNE 150KW-650KW STATIONARY LOAD BANK...
  • Page 2 Last Revision Date: March 14, 2016 For the most up-to-date information for this product and others, please contact Simplex, Inc. at (800) 637-8603 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 configuration for this product.

  • Page 3: Table Of Contents

    Table of Contents Warnings and Cautions ............1 Safety information symbols Cautions Nameplates and Placards ............. 5 Description and Specification ..........9 Overview of Use Control System Cooling System Load System Safety Unpacking ................11 Included Components Primary Inspection Installation ................13 Load Bank Placement Installation Procedure Remote HMI installation...
  • Page 4 Maintenance/Troubleshooting ..........29 General maintenance Every 6 Months Troubleshooting Alarms and Warnings ............31 Alarms Warnings Appendix A Parts listings ............33 Appendix B Modbus controls ..........49 Modbus Control Directions Appendix C Product Warranty ..........53...
  • Page 5 Table of Figures Current draw at specified resolutions (in kilowatts) ......10 Clearance requirements ................14 Conduit Opening ................... 15 Ground Bus ...................... 15 Main Load Bus ....................15 HMI TBH......................16 Serial Adapter ....................16 TB-DC ......................... 16 Load Dump Jumper ..................17 Current Transformers ...................
  • Page 6 Option B - Communication (TCP/IP Data Logging) ......35 PLC Component list ..................36 Control Relays ....................38 Terminal Blocks ....................40 Option 010 - Space Heaters ............... 42 Center Subpanel .................... 44 Phase A Detail ....................45 Phase B Detail ....................46 Phase C Detail ....................

  • Page 7: Warnings And Cautions

    1 WARNINGS AND CAUTIONS The following images indicate important safety information: afety information This General warning symbol points out important SymbolS information that, if not followed, could endanger personal safety and/or property. This Explosion warning symbol points out poten- tial explosion hazards. This Fire warning symbol points out potential fire hazards.
  • Page 8 • Position and install the load bank with consideration given to large cubic airflow requirements, exhaust temperature, and velocity. Do not point exhaust at any nearby surface or object that may be adversely affected by high temperature. This in- cludes but is not limited to painted surfaces, tar paper and asphalt roofs, water sprinkler heads, fire alarms, and volatile material.
  • Page 9 tion or by static electricity. Never disconnect the ground wire 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. •...
  • Page 10 Did you know? Simplex products are hand-wired in our factory by skilled technicians. While automation is helpful for many tasks, we’ve found the highest quality is achieved through individual attention to this exacting work.

  • Page 11: Nameplates And Placards

    2 NAMEPLATES AND PLACARDS Nameplates and Placards — 5...
  • Page 12 6 — Nameplates and Placards...
  • Page 13 WARNING - DANGER - WARNING High Voltage: Turn off and disconnect power source before opening this compartment High Temperature: Allow equipment to cool before servicing or opening this compartment Rotating Equipment: Assure that fan has stopped before opening this compartment For Operator Safety: Make sure this equipment is properly grounded when in use...
  • Page 14 Did you know? Load banks simulate the “real world” loads that the power source will experience. Electrical load can be broadly classified as resistive, inductive and capacitive. In the real world, these components are mixed, as they are with a load bank, except with the load bank, full control of the components is possible.

  • Page 15: Description And Specification

    BAS system via standard Modbus RS-485 or optional Modbus TCP/IP, as well as a set of dry contacts for status reporting. Neptune load banks are cooled by forced air, delivered by an ooling aluminum fan blade directly driven by a TEFC motor. The air is...
  • Page 16 a safety hazard to the operator. When a failure occurs, the safety system immediately removes the load to protect the equipment from permanent damage. Table 1 Current draw at specified resolutions (in kilowatts) 208V 721A 240V 625A 208V 416A 555A 694A 240V 361A...

  • Page 17: Unpacking

    4 UNPACKING The following items are included with your load bank. If any nCluded of the following are not included, please contact Simplex Direct omponentS at 800-637-8603. 1. Load bank 2. Controller (remote or local) 3. Manual 4. Drawing package Optional equipment 1.
  • Page 18 Did you know? Simplex was founded in 1938 in Burlington, Iowa, by Michael Debrey, a Hungarian immigrant. A self-taught inventor, Debrey introduced multiple innovations to the electrical engineering field, including the Automatic Voltage Regulator. Simplex was moved to East Moline, Illinois, where it remained until 1951, when the company relocated to Springfield.

  • Page 19: Installation

    5 INSTALLATION Figure 1 Air Flow Normally equipped, Nep- tune load banks are intend- laCement ed for outdoor installation. A forced air system, which discharges out of the top of the unit, cools the load el- Figure 1 Air ements (See Flow.) Load banks require large quantities of air cir- Improperly...
  • Page 20 Figure 2 Clearance requirements 14 — Installation...

  • Page 21: Installation Procedure

    1. To bring in the source’s nStallation power cables, cut holes in roCedure the Conduit Opening, lo- cated in the bottom of the load bank’s control panel Neptune load Figure 5 enclosure (see banks feature Conduit Opening). a power 2. Confirm the test source is outlet in the properly grounded.

  • Page 22: Remote Hmi Installation

    Figure 6 HMI TBH If your HMI is installed emote directly on the load bank, inStallation skip to the next section. 1. Mount the HMI where desired. 2. Connect the HMI to the Load Bank by swinging the HMI’s screen out to expose the TB-H termi- Figure 6 nal block (see...

  • Page 23: Load Dump Installation

    If the Load Dump fea- Figure 9 ture is desired, remove the Load Dump Jumper inStallation factory-installed jump- er at TB-R 1–2 and con- nect customer-supplied Load Dump contacts to Figure 9 TB-R 1–2 (See Load Dump Jumper). To dump the load, open the customer-supplied contact.

  • Page 24: Current Transformer Installation

    Figure 10 If your load bank is urrent Current Transformers equipped with Metering, ranSformer Automatic Mode or Regen- inStallation erative Mode options, you will have to install current transformers on your power cable. • For metering mode, in- stall the current trans- formers on the load bank leg of your power “Figure 13...

  • Page 25: Current Transformer Placement For Metering

    Figure 13 Current Transformer placement for Metering Figure 14 Current Transformer placement for Auto/Regen. Mode The first current transformer must be installed on Phase A, and the second must be installed on Phase C. Installation — 19...

  • Page 26: Modbus Installation

    1. Plug a CAT5e cable into the ethernet jack on the MODBUS Serial Con- Figure 16 verter (see Modbus Serial Converter.) The Neptune Modbus control set is implemented as detailed “Appendix B — Modbus controls” on page 49 20 — Installation...

  • Page 27: Heater Installation

    Figure 17 TB-SH Neptune load banks are eater equipped with space heaters inStallation for cold weather operation and to prevent condensa- tion, which can damage the unit. The heaters require a dedicated power source in- dependent of control power at all times to prevent startup failure due to cold environ- ments.

  • Page 28: Dry Contacts Installation

    Figure 18 TBR The Neptune provides ontaCtS a set of Remote Signal Dry nStallation Contacts, which provide an alarm message to let you know if the load bank has failed. To use the dry contacts, wire three cables to TBR-5-7.

  • Page 29: Setup

    1. General Settings 2. Automatic Mode Settings 3. Test Mode (Intended only for Simplex engineers) 4. Factory Setup (Intended only for Simplex engineers) You can access General Settings and Automatic Mode Set- tings by pressing their respective buttons.
  • Page 30 Did you know? Michael Debrey got the idea for the Automatic Voltage Regulator while working as an electrician at a furniture factory on the night shift. Part of his job was to regulate the output voltage of a steam turbine generator by hand. Being a skilled tinkerer, he developed a device to do it for him.

  • Page 31: Operating Instructions

    Figure 23 HMI - Manual operation source being tested. Mode CHeCkS 2. Ensure the load bank’ s Fan/ Neptune load Control Power Disconnect banks feature Switch, located on the unit’ s a power door, is in the on position outlet in the...

  • Page 32: Setting Up The Test

    If any of three voltage or current values are significantly dif- ferent from the other two, check the load bank for a blown fuse. If no blown fuse is found, contact Simplex service at 800-637- 8603. Pressing “Alarm History” on this screen will bring up a list of registered alarms.

  • Page 33: Automatic Mode

    8 AUTOMATIC MODE Figure 25 Setup Screen The Neptune load bank can be equipped with an optional automatic mode, which will extend your gen- erator’s life by protecting it against wet-stacking and re- verse current. Figure 26 Automatic Automatic Mode adds...

  • Page 34: Setting Up Automatic Mode

    Figure 28 Automatic power draw has increased Mode Running beyond the preset maximum value, it begins removing load until the draw is back within the designated range. Before you activate Auto- etting matic Mode, you must config- utomatiC ure the load bank to interact The values with your generator.
  • Page 35 9 MAINTENANCE/TROUBLESHOOTING Simplex load banks are designed to require minimum main- eneral tenance. All components have been chosen for a long, reliable maintenanCe life. Most problems can be avoided by simply keeping the con- trol panel enclosure clear of any debris or foreign objects and ensuring all electrical connections are tight.
  • Page 36 Although Neptune load banks are designed with trouble-free rouble operation in mind, some problems can arise. Please consult the SHooting following table for solutions to the most common issues before contacting a Simplex service representative. Table 2 Troubleshooting Problem Solution...
  • Page 37 Intake Temp status area will turn yellow. Neptune load banks do not dump load when a warning is triggered, but the problem should be investigated as soon as pos- sible. Alarms and Warnings — 31...

  • Page 38: Troubleshooting Alarms

    Table 3 Troubleshooting alarms Alarm Cause Solution Motor Fan blades blocked Clear obstruction Intake vents blocked Clear intake vents by debris, paper, etc Fan blades have come Tighten fan blade hub. loose from shaft Intake vents blocked Clear intake vents by debris, paper, etc Load bank pulling in Ensure load bank was...

  • Page 39: Option D - Automation/Metering

    APPENDIx A — PARTS LISTINGS Figure 29 Right Subpanel Layout Option D - Automation/ Metering page 34 Option E - Communication (TCP/IP Data Logging) page 35 page 36 Control Relays page 38 Terminal blocks/Service Outlet page 40 Option 010 - Space Heaters page 42 Parts listings - 33...
  • Page 40 Table 4 Option D - Automation/Metering Label Description Part Number Terminal Block, 4 TB-M 1 25678547 Connections, Black Terminal Block, 4 TB-M 2 25678546 Connections, Red Terminal Block, 4 TB-M 3 25678557 Connections, Blue Terminal Block, 4 TB-M 4, 6 25678536 Connections, Grey Terminal Block, 4...
  • Page 41 Table 5 Option B - Communication (TCP/IP Data Logging) Label Description Part Number Modular Controller and Protocol Con- 24955043 verter Ethernet Switch, 5 24955074 Port, Unmanaged Parts listings - 35...

  • Page 42: Tb-Com

    Table 6 PLC Component list Label Description Part Number PLC1 24955113 8PT Relay Output 24955008 Module 4PT Thermocouple 24955023 Input Module DC Power Supply, 25457900 60W, 24VDC RS232/RS485 Con- 24953500 verter, RJ12 Port Terminal Block, Spring Type, 20A, TB-COM1-6 25678532 600Vac, 2 Connec- tions, Grey 36 - Parts listings...
  • Page 43 Parts listings - 37...
  • Page 44 Table 7 Control Relays Label Description Part Number Fuse, 2A, 600V, Instantaneous 14014500 Fuse, 2A, 600V, Time Delay 14012000 Relay, 24VDC Coil, 3PDT 24827045 Relay, 24VDC Coil, 3PDT 24827045 Relay, 24VDC Coil, 3PDT 24827045 Relay, 24VDC Coil, 3PDT 24827045 Relay, 24VDC Coil, 3PDT 24827045 Relay, 24VDC Coil, 3PDT 24827045...
  • Page 45 Parts listings - 39...
  • Page 46 Table 8 Terminal Blocks Label Description Part Number Terminal Block, Spring Type, TB-CP 1-4 20A, 600Vac, 4 Connections, 25678536 Grey Terminal Block, Spring Type, TB-C 14-26 20A, 600Vac, 2 Connections, 25678532 Grey Terminal Block, Spring Type, TB-DC 1-2 20A, 600Vac, 4 Connections, 25678546 Terminal Block, Spring Type, TB-DC 3-4...
  • Page 47 Parts listings - 41...

  • Page 48: Tb-Sh

    Table 9 Option 010 - Space Heaters Label Description Part Number Terminal Block, 2 TB-SH 1-3 25678532 Connections, Grey Fuse, 7A, Time Delay 14039000 Enclosure Heater, HTR1 120Vac, 550W w/ 25309211 Thermostat 42 - Parts listings...
  • Page 49 Phase A page 45 Phase B page 46 Phase C page 47 Load control terminal Subpanel blocks page 48 Parts listings - 43...
  • Page 50 RC 1-6 13011040 sistive Contactor, 65A Re- RC5-15 13011065 sistive Contactor, 40A Re- FMC1 13011040 sistive Overload Relay, 5.7- OLR1 24827710 18.9A Circuit Breaker, 15A 12046615 Trip Transformer, 300VA, 25457650 480/240:240/120Vac Subpanel, Neptune, Subpanel PRT-00025390 Rear 44 - Parts listings...

  • Page 51: Phase A Detail

    Table 11 Phase A Detail Label Description Part Number Bus Bar, Single Pole, Bus Bar (vertical) 60044465G 750A, Phase A Fuse, 35A, Class T, 14074000 Fast Acting Fuse, 70A, Class T, RF7-34 14087000 Fast Acting Bus Bar, Nept/Mars, Bus Bar (horizontal) 60063693 0.250”...

  • Page 52: Phase B Detail

    Table 12 Phase B Detail Label Description Part Number Bus Bar, Single Pole, Bus Bar (vertical) 60044466E 750A, Phase B Fuse, 35A, Class T, 14074000 Fast Acting Fuse, 70A, Class T, RF8-35 14087000 Fast Acting Bus Bar, Nept/Mars, Bus Bar (horizontal) 60063693 0.250”...

  • Page 53: Phase C Detail

    Table 13 Phase C Detail Label Description Part Number Bus Bar, Single Pole, Bus Bar (vertical) 660044467G 750A, Phase C Fuse, 35A, Class T, 14074000 Fast Acting Fuse, 70A, Class T, RF9-36 14087000 Fast Acting Bus Bar, Nept/Mars, Bus Bar (horizontal) 60063693 0.250”...
  • Page 54 Table 14 Load Control Terminal Blocks Label Description Part Number Fuse, 1.5A, Time F1-2 14009500 Delay Fuse, 3.5A, Time 14019775 Delay Terminal Block, 4 TB-L 1 25678547 Connections, Black Terminal Block, 4 TB-L 2 25678546 Connections, Red Terminal Block, 4 TB-L 3 25678557 Connections, Blue...
  • Page 55 APPENDIx B — MODBUS CONTROLS Table 15 Modbus Controls (Read/Write) Function Name Type Address Code Activate Fan Coil 16586 Apply Load Coil 16704 Cancel Coil 16487 Cooldown KW To Apply Floating Point 28911 Modbus controls - 49...
  • Page 56 Table 16 Modbus Indications (Read only) Function Name Type Address Notes Code Exhaust Alarm Coil 16484 Fan Failure Coil 16485 Alarm Load Dump Coil 16486 Activated Fan Overload Coil 16488 Trip Intake Temperature Coil 16489 Alarm Fan Running Coil 8193 Floating Applied Load 29077...
  • Page 57 Function Name Type Address Notes Code Floating 28677 Point Floating 28679 Point Floating 28681 Point Floating 28683 Point Floating 28685 Point Floating 28687 Point Floating 28689 Point Floating Watts 28691 Point Floating 28693 Point Floating 28695 Point (a) Load Banks with Automatic Load Regulation Only (b) Load Banks with Regenerative Power Sensing Only (c) Load Banks with Any Automation Option Only Modbus controls - 51...
  • Page 58 Function Name Type Address Notes Code Floating Power Factor 28697 Point Floating Watt-Hours 28699 Point Floating VAR-Hours 28701 Point Floating 28703 Point (a) Load Banks with Automatic Load Regulation Only (b) Load Banks with Regenerative Power Sensing Only (c) Load Banks with Any Automation Option Only 1.
  • Page 59 SIMPLEX or an authorized SIMPLEX repair station, with transportation costs prepaid, and which its examination shall disclose to its satisfaction to have been thus defective.
  • Page 60 At Simplex, we are experts at building products that meet our customers’ exact requirements. For a complete listing of Simplex products visit www.simplexdirect.com.
  • Page 61 LOAD BANK RENTAL AND SERVICE CENTERS Simplex Onsite can place Load Banks, Cables, Transformers, and Fuel Polish- ers rentals as well as service technicians at your fingertips anywhere in the United States quickly and cost effectively. For information call 855-767-5483 or visit www.simplexonsite.com.
  • Page 62 Simplex, Inc. 5300 Rising Moon Road Springfield, IL 62711-6228 (800) 637-8603 www.simplexdirect.com...

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