TECHNICAL SPECIFICATION



Project:

Quotation #: TBD

Customer:

Date: May 30, 2017

Simplex SATURN-HV Stationary 5000 KW Resistive Generator

Load Bank System designed for permanent outdoor installation and use.

Unit composed of two (2) Saturn-2500KW units on common skid with 4160V transformer.

Line 1, Qty. 1

Operational Ratings and Limitations as follows:

Total Capacity: 5000 kW, 1.0 power factor total

Voltage: 4160V AC:480V AC, 3-phase, 3-wire

Frequency: 60 Hertz

Load Steps: 250 kW load step resolution

Duty cycle: Continuous

Temperature rating: 120°F max air intake temp.

120°F max ambient temp.

100°F nominal max exhaust air temp. (note: as airflow is not laminar, exhaust air temperatures are not equal at all points at the plane of air exhaust. Some parcels of air may reach approximately 575°F before mixing. See additional information in "Warning" block at end below)

Airflow req’d: 70,000 CFM (each resistive cabinet)

Altitude: 5300'

Fan/control power: Internal, from source under test, 4160V:480:120 fan/control power. Fan motor operates at 480-3-60. Control circuits at 120V-1-60. Control circuits fused. Control circuit fuses are 200,000 A.I.C. current limiting type, 600V rated.

General Description:

The load bank is a completely self-contained, freestanding, skidded unit consisting of three (3) principle sections:

1. Environmentally controlled transformer compartment:

a. Main input terminals

b. 4160V:480V, 5000 kVA load transformer(s) (total).

c. Ventilation louvers

d. Anti-condensation interior space heaters and humidistat controller to limit interior condensation during off-line periods

2. Two 480V resistive load sections

a. Tray mounted resistive load elements

b. 70,000CFM, 20HP cooling fans

3. Load bank control unit

a. Type R3 segregated 480V/120V control section including load control branch circuit contactors/fuses, 480V power distribution bus, 480V input terminals from fused circuits, control power transformers, malfunction detection relay panel, cooling fan motor starter, control circuit disconnect, control logic panel, local control panel.

Principle Systems and Components:

Transformer: 5000 kVA, 4160V:480V, delta: 4-W wye with solidly grounded neutral, dry type, convection air cooled transformer. Aluminum windings. 60kV BIL, 220C insulation class, 150°C rise.

Low voltage

output circuit: Low voltage outputs from transformer with overcurrent protection to 480V resistive load.

Load elements: Simplex Pow'r-Web, chromium alloy, open-wire, helically wound, with continuous mechanical support via ceramic-clad stainless steel through-rod. -0%/+5% tolerance, 2% balance. .995 p.f. Element wire to be mechanically supported over entire length such that if a wire should break, the broken wire segments will not short to adjacent conductors or to ground.

Load elements are to be individually serviceable and replaceable in the field without major disassembly of the load bank. An acceptable design to satisfy this requirement is the installation of the load elements in slide-out, removable trays such that any element is easily accessed without disturbing any other elements.

All materials used in the mounting and installation of the load elements shall be suitable for the temperatures both encountered, in normal operation and under fault conditions.

Materials in direct contact with the element wire shall be ceramic, other materials that structurally support the load elements and/or which form the hot air duct within which the elements are mounted shall be steel, stainless steel or aluminum.

Plastics and glass reinforced plastic materials and flammable materials are not acceptable materials of construction for installation, support and mounting of load elements or in the construction of the load bank hot air duct

Load element

branch circuit

fuse protection: Each 50KW branch circuit is protected by a 70A, 200,000AIC, 600V fuse.

Load control: Electrically actuated, electrically held magnetic contactor for each 50 kW branch circuit. Contactors to have enclosed silver surfaced contacts, 120V coils; electrically operated and electrically held.

Power wiring: 150°C insulated, color coded

Cooling: Each load section: One cooling fan consisting of 20HP, 460V, 3-phase, TEFC motor belt drive of cast aluminum, shrouded propeller fan. Airflow is vertical, top hot air exhaust. Motors are controlled by a circuit breaker with combination motor starter. Each fan is 70,000CFM. Control compartment: convection air cooled, insect/bird screens.

Load bank system

protection: Sensors, alarms and safety shutdown/lockout for high intake temperature, high exhaust temperature, fan failure, high transformer winding temperature.

Control power

input: Internally powered

Space heaters: Interior space heaters to control formation of condensation; powered from external 480-3-60 source. External power disconnect switch. Fuses and thermostat provided. Heaters within transformer compartment and within control section, with separate sensors.

Enclosure: Type 3R freestanding, 74”W x 232”D x 140”H (approx).

Consisting of segregated compartments:

- Control

- 480V resistive load

- 4160V transformer

Control and transformer compartments are environmentally controlled. Forced air cooled load compartment is type 3R weatherproof.

All panels for access to serviceable components are to be hinged doors with stainless steel hinges and lockable latches. All exterior fasteners to be stainless steel.

The load bank enclosure shall be of double wall construction for cool exterior and thermal isolation of the load elements.

Cooling airflow through the enclosure shall be vertical with cold air intake at the bottom and hot air exhaust out the top. Intake and exhaust openings shall be screened. Exhaust shall be straight up with no flow to any side. Exhaust flow shall be directed through rain and snow shedding louvers.

**Coastal Environment finish to be applied utilizing custom painted stainless steel.**

Load Bank Control as follows:

This load bank includes unit mounted control circuitry and a remote control panel with PLC-based touch panel HMI controller in an indoor enclosure with hinge-open front consisting of the following:

1. Power supply for load bank control circuits.

2. Malfunction detection/auto disconnect system.

3. Cooling fan automatic start-stop control.

4. Remote load dump circuit to allow use of remote dry contacts (close to run) to trip load bank off line.

5. Remote communications module, MODBUS RTU/TCIP (Ethernet)

6. Input/output devices and control circuits for operation of load bank from remote control panel.

7. Auxiliary dry contacts to indicate "normal operation"/"system failure"

8. Touch panel functions, including:

a. Control Power On – Off buttons (starts/stops cooling fan)

b. Bypass switch to override remote load dump

c. Manual load application button – activates Master Load button and individual load step buttons

d. Numeric load application button – activates numeric keypad for applying or removing desired load value

9. Touch panel message display including:

a. Control Power On/Off

b. Manual mode

c. Load dump – normal/bypass

d. Normal operation

e. High exhaust temp

f. High intake temp.

g. Fan failure

h. Load bank failure

i. Master load on

j. Load step on (one for each load step)

k. V-A-F-KW

Temp rise: the formula for air temp rise is:

RISE = KW X 3000 / CFM

WARNING: The installation site must provide for the free flow of cooling air to the load bank and the free exhaust of hot air (70,000cfm) to the atmosphere without impinging upon buildings, walls, etc and without re-circulating to the load bank air intakes. Load banks installed indoors must be equipped with an exhaust air duct (supplied by others) that will route all load bank hot exhaust air to the outdoors. This load bank will produce 70,000CFM of exhaust air with a calculated temperature rise overall of 100°F, but with possible superheated parcels of air at or near the plane of exhaust of the load bank of approximately 500°F. This air must not be exhausted within an indoor space and must not be allowed to re-circulate to the load bank air intake. Failure to properly install this load bank with a correctly sized and vented exhaust air duct will result in substantial damage to or destruction of the load bank, adjacent equipment and the building in which the load bank is installed. Damage to the load bank due to improper installation is not covered by Simplex warranty. Incidental and consequential damage is not covered by Simplex warranty.

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