Simplex Microstar Operating instructions

17.5KW PRECISION AIR HEATER

(LOAD BANK)

MICROSTAR

Document Number: DOC-01124

Page

Table of Contents

I. Warnings and Cautions ..................................................................................... 4

II. Nameplates and Placards .................................................................................. 6

1. Introduction ......................................................................................................................... 6

2. Instruction Placards ........................................................................................................... 6

III. Description and Specication ........................................................................... 7

1. Introduction ......................................................................................................................... 7

2. Overview of Use .................................................................................................................. 7

3. Control System ................................................................................................................... 8

4. Cooling System .................................................................................................................. 8

5. Specications ..................................................................................................................... 8

IV. Unpacking ..........................................................................................................11

1. Introduction ....................................................................................................................... 11

2. Included Components and Parts .................................................................................... 11

3. Primary Inspection ........................................................................................................... 11

V. Installation ......................................................................................................... 12

1. Introduction ....................................................................................................................... 12

2. Load Bank Placement ...................................................................................................... 12

3. Setup .................................................................................................................................. 14

4. Local Control .................................................................................................................... 14

5. Failure Detection .............................................................................................................. 14

VI. Operating Instructions ..................................................................................... 16

1. Introduction ....................................................................................................................... 16

2. Equipment Handling ........................................................................................................ 16

3. Basic Operations .............................................................................................................. 16

VII. Alarms and Warnings ....................................................................................... 19

1. Introduction ....................................................................................................................... 19

2. Over Temperature ............................................................................................................. 19

VIII. Supplemental Equipment ................................................................................ 20

1. Introduction ....................................................................................................................... 20

2. Power Cords ..................................................................................................................... 20

IX. Diagnostics and Troubleshooting ................................................................... 21

1. Introduction ....................................................................................................................... 21

2. General Maintenance ...................................................................................................... 21

3. Troubleshooting ............................................................................................................... 22

X. Ordering Information ........................................................................................ 25

1. Microstar ........................................................................................................................... 25

APPENDIX A — ABBREVIATIONS IN THIS MANUAL .................................................................. 27

APPENDIX B — IMPORTANT FORMULA ...................................................................................... 28

Page

Table of Figures

I. Warnings and Cautions ..................................................................................... 4

II. Nameplates and Placards .................................................................................. 6

III. Description and Specication ........................................................................... 7

1. Specications ..................................................................................................................... 8

2. Microstar Temperature Rise .............................................................................................. 9

IV. Unpacking ..........................................................................................................11

V. Installation ......................................................................................................... 12

1. Airow View ...................................................................................................................... 12

VI. Operating Instructions ..................................................................................... 16

VII. Alarms and Warnings ....................................................................................... 19

VIII. Supplemental Equipment ................................................................................ 20

IX. 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

X. Ordering Information ........................................................................................ 25

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Last Revision Date: May 20, 2013









Page

1.0 WARNINGS AND CAUTIONS







This General warning symbol points out important safety

informaon that, if not followed, could endanger personal safety

and/or the property of others.

This Explosion warning symbol points out potenal explosion

hazard.

This Fire warning symbol points out potenal re hazard.

This Electrical warning symbol points out potenal electrical

shock hazard.

 







 





ELECTRICAL WARNING

• 









• 



• 





• 







• 



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• 





• 









• 



FIRE HAZARD

• 









GENERAL WARNING

• 



Page

2.0 NAMEPLATES AND PLACARDS

2.1 Introducon





2.2 Instrucon Placards

Page

3.0 DESCRIPTION AND SPECIFICATION

3.1 Introducon









— 

— 

— 

3.2 Overview of Use





































• 

• 

• 

• 

• 















Page







3.3 Control System



















3.4 Cooling System







3.4.1 Load System

















3.5 Specicaons

Capacity

Max Amps

at 208V

Max Amps

at 230V

Max Amps

at 240v

Model 208vAC, 1-ph 230vAC, 1-ph 240vAC, 1-ph

      

Max Amps

Per Secon

Secon 1:

 Secon 2 -4: 

Secon 5-6:



Table 1 Specications

Page







@240V Rangs @230V Rangs @208V Rangs

Load

Bank

CFM

Low Fan

Speed -

399

High Fan

Speed -

1520

Load

Bank

CFM

Low Fan

Speed -

399

High Fan

Speed -

1520

Load

Bank

CFM

Low Fan

Speed -

399

High Fan

Speed -

1520

1.5

 

1.4

 

1.1

 

2.5

 

2.3

 

1.9

 

3.0

 

2.8

 

2.3

 

4.0

 

3.7

 

3.0

 

5.0

 

4.6

 

3.8

 

5.5

 

5.1

 

4.1

 

6.5

 

6.0

 

4.9

 

7.0

 

6.4

 

5.3

 

7.5

 

6.9

 

5.6

 

8.0

 

7.4

 

6.0

 

8.5

 

7.8

 

6.4

 

9.0

 

8.3

 

6.8

 

9.5

 

8.7

 

7.1

 

10.0

 

9.2

 

7.5

 

10.5

 

9.6

 

7.9

 

11.0

 

10.1

 

8.3

 

11.5

 

10.6

 

8.6

 

12.0

 

11.0

 

9.0

 

12.5

 

11.5

 

9.4

 

13.0

 

11.9

 

9.8

 

13.5

 

12.4

 

10.1

 

14.0

 

12.9

 

10.5

 

14.5

 

13.3

 

10.9

 

15.0

 

13.8

 

11.3

 

16.0

 

14.7

 

12.0

 

17.5

 

16.1

 

13.1

 

Table 2 Microstar Temperature Rise

Page

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 afliate, with Simplex

Factory-Trained technicians available for system set-up, start-

up, training and operation.

All SOS Rental Load Banks are portable units suitable for eld

use. Rental load banks are differentiated by capacity, voltage

and frequency rating, and relative portability.

Page

4.0 UNPACKING

4.1 Introducon







— 

— 

4.2 Included Components and Parts



— 

— 

4.3 Primary Inspecon











 



 



 

 

 



 







 



 



 











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5.0 INSTALLATION

5.1 Introducon







— 

5.2 Load Bank Placement





feet on the inlet and outlet















250V, 16A-rated

C13/C14 cables





Figure 1 Airow View











WARNING













Page

WARNING



Note: Load Bank warranty is void if incorrectly cooled.

High Voltage

High Temperature



Rotang Equipment

For Operator Safety

























 



 



















-





 



 





 

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



 



 

 



 







5.3 Setup





 



 

 

 

Note: Load is disengaged when 24VDC is applied.

 

5.4 Local Control



















5.5 Failure Detecon











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







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6.0 OPERATING INSTRUCTIONS

6.1 Introducon









— 

— 

— 

6.2 Equipment Handling

6.2.1 General Handling Informaon













6.2.2 Aer-Operaon Handling Informaon









6.3 Basic Operaons







6.3.1 Startup

 



 





6.3.2 Applying a Load

 





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6.3.3 Adjusng the Fan Speed

 





6.3.4 Shutdown

 







 

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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 specically

authorized by the renter.

Be certain that all equipment is properly grounded. Carefully

check cables for wear and tear, insulation damage. Check all

CAM-lock connectors that connections are made sound and

tight including both connector mating (the connector twist-

tightens) and the cable within the connector.

Be certain that cables are phased correctly. A circuit breaker

or fuse set is required at the power source sized appropriately

for the conductor run.

Be sure to run adequate ampacity of cables. Check that

generator voltage corresponds to load bank voltage. Check

correct airow direction and if it is necessary to reverse cooling

fan direction, allow fan to fully stop before reversing. Provide

the CFM required at an ambient not to exceed 125°F.

Simplex Microstar Operating instructions

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