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Troubleshooting
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Summary of Contents for Simplex Microstar
- Page 1 Document Number: DOC-01124 MICROSTAR 17.5KW PRECISION AIR HEATER (LOAD BANK)
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Page 3: Table Of Contents
Diagnostics and Troubleshooting ..............21 1. Introduction ........................21 2. General Maintenance ...................... 21 3. Troubleshooting ....................... 22 Ordering Information ..................25 1. Microstar ........................... 25 APPENDIX A — ABBREVIATIONS IN THIS MANUAL ..............27 APPENDIX B — IMPORTANT FORMULA ..................28... - Page 4 VIII. Supplemental Equipment ................20 Diagnostics and Troubleshooting ..............21 1. Troubleshooting Table ..................... 22 2. Side Diagram ........................23 3. Front Parts of Microstar ....................23 4. Front Diagram ........................23 5. Back Parts of Microstar ....................24 6. Exhaust Diagram ......................24...
- Page 5 Last Revision Date: May 20, 2013 For the most up-to-date information for this product and others, please contact Simplex, Inc. at 1-217-483-1600 (Springfield, Il.) or 1-678-214-6575 (Atlanta, Ga.) or visit us on the web at http://www.simplexdirect.com.
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Page 6: Warnings And Cautions
1.0 WARNINGS AND CAUTIONS The following images are four of the most commonly used safety symbols accompany the DANGER, WARNING, and CAUTION blocks. These blocks of text should be adhered to entirely. The type of information each indicates is as follows: This General warning symbol points out important safety information that, if not followed, could endanger personal safety and/or the property of others. -
Page 7: Fire Hazard
• Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are completely turned off 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. -
Page 8: Nameplates And Placards
2.0 NAMEPLATES AND PLACARDS 2.1 Introduction This section will provide copies of the nameplates and placards for the Microstar Load Bank in the event that the current nameplates and placards become unreadable. 2.2 Instruction Placards... -
Page 9: Description And Specification
3.0 DESCRIPTION AND SPECIFICATION 3.1 Introduction This section will provide a brief synopsis of the use of the Microstar Load Bank. Simplex, Inc. reserves the right to change this synopsis, and this section should only serve as a brief concept of the device. -
Page 10: Control System
The Load System consists of independently controlled resistive load elements specifically designed for the unit. 200,000 AIC, 600VAC fuses protect each load step. Simplex, Inc. conservatively selects resistive load elements to provide long life. See “Table 4 Parts of Load Bank” on page 24 for specific elements used. -
Page 11: Microstar Temperature Rise
10.9 14.5 114.8 30.1 105.5 27.7 86.3 22.7 13.8 11.3 15.0 118.8 31.2 109.1 28.6 89.5 23.5 14.7 12.0 16.0 126.7 33.3 116.3 30.5 95.0 24.9 16.1 17.5 13.1 138.6 36.4 127.3 33.4 103.7 27.2 Table 2 Microstar Temperature Rise... - Page 12 Did You Know? Quality Simplex Load Banks and accessories are now available as rental units from Simplex Onsite (SOS), our load bank rental and technical services affiliate, with Simplex Factory-Trained technicians available for system set-up, start- up, training and operation.
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Page 13: Unpacking
4.0 UNPACKING 4.1 Introduction This section will detail the procedures during unpacking the Microstar Precision Air Heater. This guide will include a parts list and an inspection guide. In this section, you will find: — A list of included components and parts. -
Page 14: Installation
5.0 INSTALLATION 5.1 Introduction Proper setup of the Microstar Precision Air Heater is important for long-term use. It is imperative to properly setup the load bank to avoid permanent damage to the unit. In this section, you will find: — How to determine the proper location of the load bank. - Page 15 WARNING REVERSE AIR-FLOW WILL DAMAGE LOAD BANK Note: Load Bank warranty is void if incorrectly cooled. 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: Ensure that the fan has stopped before opening this compartment.
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Page 16: Setup
phasing of power cable and external control power connection to assure proper fan rotation. 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 unattended for long periods of time. 8. - Page 17 This is a permissive/energize-to-run circuit in which all safety sensors must energize their control relays on normal operation before load can be applied. This system will include a thermo switch, set at 175˚ F, tied to a relay that will open all magnetic load contactors if over temperature is achieved.
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Page 18: Operating Instructions
6.0 OPERATING INSTRUCTIONS 6.1 Introduction The Microstar Precision Air Heater was designed with simplicity in mind. The hardware is simple to use and easy to maintain. The load bank allows increases to the applied load on-the-fly. In this section, you will find: —... - Page 19 6.3.3 Adjusting the Fan Speed 1. Once the load has been applied, use the “Fan Speed” knob to precisely set the fan speed as desired. Please refer to “Microstar Faceplate” on page 6 for a desired temperature rises table. 6.3.4 Shutdown 1.
- Page 20 Did You Know? Load banks are not inherently dangerous but there are dangers that exist with operation of load banks. This is a technical, industrial product and should only be set-up and operated by trained, technical personnel who are specifically authorized by the renter.
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Page 21: Alarms And Warnings
7.0 ALARMS AND WARNINGS 7.1 Introduction With the Microstar Precision Air Heaters, alarms and warnings are the same thing. Because of its simple design, the device has very few points for error. In this section, you will learn: — Common issues and how to resolve them. -
Page 22: Supplemental Equipment
8.0 SUPPLEMENTAL EQUIPMENT 8.1 Introduction The Microstar Precision Air Heater are built to be a single-source testing unit without requiring additional parts. Additional cables can be purchased as desired. In this section, you will: — Descriptions of extraneous equipment for the load bank. -
Page 23: Diagnostics And Troubleshooting
Through good practice, cumulative issues can be prevented through basic maintenance. In the unlikely event that something goes wrong with the Microstar Precision Air Heater, we will cover how to solve some of the more common problems. Finally, if the need arises, we will cover how to replace various parts for the load bank. -
Page 24: Troubleshooting
9.3 Troubleshooting This section is designed to aid the electrical technician in basic load bank system troubleshooting. All of the problems listed can be verified with a basic test meter and/ or continuity tester. For safety reason, when troubleshooting load banks systems, always remove power, fan/control power, etc. -
Page 25: Side Diagram
Figure 2 Front Diagram Figure 3 Side Diagram Reference Part Number Description Number 15369075 Handle, Nylon 15453053 Key Cam-Lok Latch 25118505 Potentiometer Knob 25297625 Toggle Switch 13850025 208-240V Fan Table 4 Front Parts of Microstar... -
Page 26: Back Parts Of Microstar
Figure 4 Exhaust Diagram Reference Part Number Description Number 25594500 Binding Post - Black 25594550 Binding Post - White 25618250 IEC C20 Plug Table 5 Back Parts of Microstar... -
Page 27: Ordering Information
This section will serve as a guide to assist in the proper component selection for your Microstar Precision Air Heater (Load Bank). The options below are for the standard models. For any custom orders or for any clarification or questions on the items, please contact your Simplex Inc. - Page 28 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,...
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Page 29: Appendix A - Abbreviations In This Manual
APPENDIX A — ABBREVIATIONS IN THIS MANUAL Listed below are abbreviations of terms found for the Microstar Load Bank. When following a 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 of these terms. -
Page 30: Appendix B - Important Formula
APPENDIX B — IMPORTANT FORMULA OHMS LAW: OHMS = VOLTS / AMPS ( R = E / I) AMPS = VOLTS / OHMS (I = E / R) VOLTS = AMPS / OHMS (E = IR) 3 Phase Resistance = (V² X 2) / W Amperage = W / (V X 1.732) 208V RES 86.5 17.3 8.6... - Page 31 Did You Know? Some other items offered by Simplex, Inc. include: FUEL SYSTEMS LOAD BANKS — Mission Critical Systems — Watt-Muncher — Joe Filter — Swift-E and Swift-E + — Filter Tank — Powerstar — SmartFilter — Northstar — Reliant Series Fuel Tanks —...
- Page 32 Simplex, Inc. 270 Riverside Parkway, Suite G 5300 Rising Moon Road Austell, GA 30168 Springfield, IL 62711 (678) 214-6575 (217) 483-1600 http://www.simplexdirect.com...
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