Simplex NEPTUNE Manual de usuario
NEPTUNE
150KW650KW
STATIONARY LOAD BANK
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 conguration for this product. If you have requested customizations,
the drawings provided with your order take precedence; please refer to
them for details specic to your order.
Table of Contents
1 Warnings and Cautions ........................................................ 1
Safety information symbols 1
Cautions 1
2 Nameplates and Placards..................................................... 5
3 Description and Specication.............................................. 9
Overview of Use 9
Control System 9
Cooling System 9
Load System 9
Safety 9
4 Unpacking ...........................................................................11
Included Components 11
Primary Inspection 11
5 Installation ..........................................................................13
Load Bank Placement 13
Installation Procedure 15
Remote HMI installation 16
Load Dump installation 17
Current Transformer installation 18
MODBUS installation 20
Heater installation 21
Dry Contacts Installation 22
6 Setup....................................................................................23
General Settings 23
Automatic Mode 23
7 Operating Instructions .......................................................25
Initial start-up inspection 25
Pre-operation checks 25
Setting up the test 26
Testing operation 26
Metering (if equipped) 26
Shutdown and cooling 26
8 Automatic Mode .................................................................27
Overview 27
Setting Up Automatic Mode 28
Entering Automatic Mode 28
9 Maintenance/Troubleshooting..........................................29
General maintenance 29
Every 6 Months 29
Troubleshooting 30
10 Alarms and Warnings..........................................................31
Alarms 31
Warnings 31
Appendix A Parts listings ....................................................... 33
Appendix B Modbus controls ................................................49
Modbus Control Directions 52
Appendix C Product Warranty................................................53
Table of Figures
Current draw at specied 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 ................................................................................... 18
CT Orientation ................................................................................................ 18
TB-CT.................................................................................................................. 18
Current Transformer placement for Metering..................................... 19
Current Transformer placement for Auto/Regen. Mode ................. 19
TB-COM ............................................................................................................. 20
Modbus Serial Converter............................................................................ 20
TB-SH.................................................................................................................. 21
TBR...................................................................................................................... 22
Setup Screen ................................................................................................... 23
General Settings............................................................................................. 23
Metering screen ............................................................................................. 26
Automatic/Regenerative Mode................................................................ 27
Setup Screen ................................................................................................... 27
Automatic Mode Setup ............................................................................... 27
Automatic Mode Running.......................................................................... 28
Troubleshooting ............................................................................................ 30
Troubleshooting alarms.............................................................................. 32
Right Subpanel Layout................................................................................ 33
Option D - Automation/Metering............................................................ 34
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 ................................................................................................. 47
Load Control Terminal Blocks ................................................................... 48
Modbus Controls (Read/Write)................................................................. 49
Modbus Indications (Read only) .............................................................. 50
Warnings and Cauons — 1
1 WARNINGS AND CAUTIONS
e following images indicate important safety information:
is General warning symbol points out important
information that, if not followed, could endanger
personal safety and/or property.
is Explosion warning symbol points out poten-
tial explosion hazards.
is Fire warning symbol points out potential re
hazards.
is Electrical warning symbol points out poten-
tial electrical shock hazards.
is load bank is high-powered, technical, industrial equip-
ment operating at dangerous voltages and temperatures. It is
capable of damaging itself, 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 man-
ual is supplied with each load bank and available online at www.
simplexdirect.com. e operator must be familiar with its con-
tents and have access to it during operation.
• High Voltage: Turn o and disconnect power source before
opening this equipment
• High Temperature: Allow hardware to cool before servicing
or opening this equipment.
• Rotating Equipment: Ensure that the fans have stopped be-
fore opening this unit.
• For Operator Safety: Make sure this equipment is properly
grounded when in use.
All compression-type connections on fuse blocks, load
blocks, and contactors should be checked for tightness frequent-
ly. is check should be established as part of routine mainte-
nance.
e following cautions should be observed before and during
operation:
• Check intake and exhaust screens as well as fan and load ele-
ments for foreign objects.
Safety
information
SymbolS
!
!
CautionS
2 — Warnings and Cauons
• Position and install the load bank with consideration given
to large cubic airow requirements, exhaust temperature, and
velocity. Do not point exhaust at any nearby surface or object
that may be adversely aected by high temperature. is in-
cludes but is not limited to painted surfaces, tar paper and
asphalt roofs, water sprinkler heads, re alarms, and volatile
material.
• Do not use in conned spaces. e load bank may have to
compete with cooling air requirements of a nearby running
engine generator set where cooling air intake to a conned
space may not be adequate for both engine and load bank.
Be especially careful not to bounce hot exhaust air o nearby
obstructions for re-circulation through the load bank.
• Verify that all control switch positions are set correctly for
your intended usage before connecting the load bank to the
source to be tested.
• e load cables carry high amperage. Be constantly aware of
possibility of inductively heating adjacent ferrous objects to
temperatures sucient to damage cable insulation.
• Always connect the safety ground cable to a proper ground.
Do not rely on a possible grounded neutral somewhere else
in the system.
• Routinely inspect all components and electrical connections
for tightness and integrity.
• 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).
• All hardware covered by this manual have dangerous elec-
trical voltages and can cause fatal electrical shock. Avoid
contact with bare wires, terminals, connections, etc. Ensure
all appropriate covers, guards, grounds, and barriers are in
place before operating the equipment. If work must be done
around an operating unit, stand on an insulated dry surface
to reduce the risk of electrocution.
• Do not handle any kind of electrical device while standing
in water, while barefoot, or while your hands or feet are wet.
• If people must stand on metal or concrete while installing,
servicing, adjusting, or repairing this equipment, place insu-
lative mats over a dry wooden platform. Work on the equip-
ment only while standing on such insulative mats.
• e National Electrical Code (NEC), Article 250 requires the
frame to be connected to an approved earth ground and/or
grounding rods. is grounding will help prevent dangerous
electrical shock that might be caused by a ground fault condi-
Warnings and Cauons — 3
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.
• Before installing or servicing this (and related) equipment,
ensure that all power voltage supplies are completely turned
o at their source. Failure to do so can 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,
attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a noncon-
ducting implement, such as a dry rope or board, to free the
victim from the live conductor. If the victim is unconscious,
apply rst aid and seek immediate medical attention.
• Never wear jewelry when working on this equipment. Jewel-
ry can conduct electricity resulting in electric shock or may
get caught in moving components causing injury.
• Keep a re extinguisher near the hardware at all times. Do
NOT use any carbon tetra-chloride type extinguisher. Its
fumes are toxic, and the liquid can deteriorate wiring insula-
tion. Keep the extinguisher properly charged and be familiar
with its use. If there are any questions pertaining to re extin-
guishers, please consult the local re department.
• e illustrations in this manual are examples only and may
dier from your load bank.
• Main Disconnect to be provided by installer, rated 600V
maximum, sized 150% maximum of rated current.
• Load Bank warranty is void if incorrectly cooled.
!
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.
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