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Final Acceptance
of Instruction Manual
Customer: Austin Generator Service
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:
1 Manual Received by:
W.O. #: 63798-07-43/2
Date:
Date:
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Summary of Contents for Simplex Saturn 3000 DV
- Page 1 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...
- Page 2 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.
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Page 3: Table Of Contents
® 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 ................ -
Page 4: Description
® 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. - Page 5 ® 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...
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Page 6: Control System
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 4 of 20 CONTROL SYSTEM These elements are rigidly supported by high-temperature, ceramic-clad, The Control System allows the operator stainless-steel supports. Element-to- to apply a desired load to the test source... -
Page 7: Installation
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 5 of 20 • Load Banks installed indoors must If any problems are observed be equipped with an exhaust air duct during Primary Inspection call of minimum back pressure (supplied... -
Page 8: Procedure
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 6 of 20 PROCEDURE OPERATION 1. Confirm the test source is properly grounded and ground the Load Bank LOCAL in compliance with NEC. 1. Place the “Load Voltage Selector”... -
Page 9: Remote
® 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”... -
Page 10: Load Dump
® 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). -
Page 11: Maintenance
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 9 of 20 For continued safety and for Overgreasing is a major cause maximum equipment protec- of bearing and/or motor failure. tion, always replace fuses with The amount of grease added one of equal rating only. -
Page 12: Every 50 Hours Or 6 Months
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 10 of 20 EVERY 50 RELUBRICATION TIME INTERVAL HOURS for motors with regreasing provisions. OR 6 MONTHS NEMA Frame Size Check the tightness of 140 – 180 210 –... -
Page 13: Troubleshooting
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 11 of 20 7. Motor is ready for operation. RELUBRICATION AMOUNTS Warning: If motor is nameplated for for motors with regreasing provisions. hazardous locations, do not run mo-... -
Page 14: Cooling Failure Indicated
® 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. -
Page 15: Appendix A - Abbreviations Used In This Manual
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. -
Page 16: Appendix B - Calculations & Formulas
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 14 of 20 APPENDIX B - EXAMPLES CALCULATIONS & FORMULAS Using line voltages and currents: 3 Phase The following calculations are used to Current Readings Voltage Readings... - Page 17 ® 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 EXAMPLES the desired amount of kilowatts is ap- When desired amount of kilowatts is applied at 1.0 PF: plied at 1.0 power factor.
- Page 18 ® 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.
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Page 19: Appendix C - Torque Values
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 17 of 20 APPENDIX C - TORQUE VALUES FAN BLADES CONTACTORS TORQUE See torque values on the front of the contactor. PART NO. BOLT SIZE FT LBS // IN LBS... - Page 20 ® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 18 of 20 APPENDIX C - TORQUE VALUES CONT’D TAPER-LOCK BUSHINGS FUSEBLOCKS BUSHING NUMBER TORQUE MANUF. WIRE TORQUE PART NO. SIZE INCH LBS 1008, 1108 55 IN LBS...
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Page 21: Appendix D - Pillow Block Bearings Lube Interval
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 19 of 20 APPENDIX D - PILLOW BLOCK BEARINGS LUBE INTERVAL The Pillow Block Bearings (PN 22691040), which are used on Saturn Load Banks, are pre-lubricated at the time of manufacture. -
Page 22: Appendix E - Drawings
® LOAD BANK MANUAL • Saturn 3000 DV • W.O. 63798/2 • page 20 of 20 APPENDIX E - DRAWINGS Title Drawing Pictorial ..........47BD164460C Control Section......... 47B164461C Fan/Control ........47B164462B Local Manual Control ....... 47B164463B PLC Control ........47B164464C PLC Communications Control ..
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