Polaris Load Bank Manual — Load Marshal Control™

2 Feb 2018 • Simplex Service 800-637-8603 • Page 1 of 50

 Polaris Load Bank Manual — Load Marshal Control™

This manual was last revised:

March 2, 2021
For up-to-date information on this product or others,
please contact Simplex at 800-637-8603 or
on the web at www.simplexdirect.com.

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 Polaris Load Bank Manual — Load Marshal Control™

Table of Contents
I. Polaris Resistive Load Bank ................................................... 5
I-A. OVERVIEW ....................................................................................... 5
I-B. WARNINGS AND CAUTIONS .................................................................... 6
I-C. LOAD BANK STRUCTURE ....................................................................... 8
I-D. SAFETY ........................................................................................... 9
I-E. UNPACKING ...................................................................................... 9
I-F. PRIMARY INSPECTION .......................................................................... 9
I-G. INSTALLATION ................................................................................ 10
I-G-1. INSTALLATION - PLACEMENT ...................................................... 10
I-G-2. INSTALLATION - PROCEDURE ....................................................... 12
I-G-3. INSTALLATION - INPUT SIGNALS ................................................... 13
I-G-4. INSTALLATION - CURRENT TRANSFORMERS ...................................... 13
I-G-5. INSTALLATION - MODBUS COMMUNICATION ..................................... 14
I-G-6. INSTALLATION - ANTI-CONDENSATION HEATERS ................................ 14
I-G-7. INSTALLATION - BMS/BAS SIGNAL CONTACTS ................................... 14

II. SIMPLEX LOAD MARSHAL™ CONTROL SYSTEM ............................ 15

II-A Navigation ..................................................................................... 15
II-B. Specific Unit’s Capabilities................................................................. 16
II-C. User Settings ................................................................................. 16
II-C-1. General Settings .................................................................... 16
II-C-2. Auto Load Leveling Settings ...................................................... 17
II-C-3. Backpressure Monitoring (BPM) Settings ........................................ 18
II-C-4. Miscellaneous Settings ............................................................. 19
II-D. Load Control Modes ......................................................................... 20
II-D-1. Control Screens ..................................................................... 21
II-D-2. Manual Control...................................................................... 22
II-D-3. Numeric Load ....................................................................... 23
II-D-4. Automatic Load Modes ............................................................. 23
II-D-5. Auto Load Leveling ................................................................. 24
II-D-5-a. Auto Load Leveling Operation ............................................ 25
II-D-5-b. Backpressure Monitoring Option ......................................... 25
II-D-5-c. Regen (Reverse Power Prevention) Option ............................. 26
II-D-6. Auto Trigger Input .................................................................. 26
II-D-7. Auto Exercise ....................................................................... 26
II-D-8. Fixed Load ........................................................................... 27
II-D-9. Auto Sequence Load ............................................................... 27
II-D-10. Sequence Loading ................................................................. 28
II-E. Data Logging.................................................................................. 29
II-F. Options Screen ............................................................................... 30

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 Polaris Load Bank Manual — Load Marshal Control™
II-G. Step Quarantine ............................................................................. 30
II-H. Self-Diagnosis ................................................................................ 31
II-I. System Status ................................................................................. 31
II-J. Alarms and Warnings ........................................................................ 32
II-K. Modbus or 2nd Screen Control/Monitoring ............................................... 33

III. Troubleshooting ............................................................... 37

III-A. Cooling Fan Will Not Start/Operate ...................................................... 37
III-B. Fan Failure Indicated....................................................................... 37
III-D. High Exhaust Temp Indicated ............................................................. 38
III-G. HMI/PLC Comm Errors ..................................................................... 38
III-H. Other HMI Issues ............................................................................ 38
III-I. Reduced kW Output or Phase Imbalance ................................................. 39
III-J. Meter Comm Error Indicated .............................................................. 39
III-K. Metering Issues .............................................................................. 39
III-L. Automatic Load Leveling Issues ........................................................... 40

IV.Maintenance .................................................................... 41
IV-A. Each Operation:............................................................................. 41
IV-B. Every 50 Hours or 6 Months, or after transportation: ................................. 41

Appendix A - Simplex Warranty ................................................ 42

Appendix B - Conditions of Sale................................................ 43

Appendix C - Rated Resistance and Current ................................. 45

Appendix D - Single Phase Configuration .................................... 46

Appendix E - Torque Values .................................................... 47

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 Polaris Load Bank Manual — Load Marshal Control™

I. Polaris Resistive Load Bank

Polaris Load Bank with Optional Local Control Box

I-A. OVERVIEW

Simplex Stationary Load Banks are precision test instruments specifically designed to apply discrete,
selectable electrical load to a power source while measuring the source’s response. They also provide a
means for routine maintenance and exercise of standby power systems to assure long term reliability and
readiness of the power system.
Load Banks can also help eliminate the detrimental effects of unloaded operation on diesel engine
generators and are often used to balance load and prevent reverse power generation.
Simplex Stationary Load Banks are available in various cabinet designs and capacities. Standard
cabinets are rated as Type 3R (outdoor weatherproof) but are also available as Type 1 (indoor rated). If
desired, the Load Bank can be mounted on a trailer.
Standard Polaris units are designed to operate in ambient temperatures between 32°and 125°F (0°-
52°C). Units specified and built as Arctic Duty models add features such as cold weather rated wire and
motor grease as well as additional heaters to facilitate use in low temperature environments.
The illustrations in this manual are examples only and may differ from any given load bank. For details
on specific units, see the drawing package provided with the unit.

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 Polaris Load Bank Manual — Load Marshal Control™

I-B. WARNINGS AND CAUTIONS

The GENERAL warning symbol points out important information that, if not followed, could
endanger personal safety and/or property.

The EXPLOSION warning symbol points out potential explosion hazards.

The FIRE warning symbol points out potential fire hazards.

The ELECTRICAL warning symbol points out potential electrical shock hazards.

The load bank is a high-powered, technical, industrial piece of equipment operating at dangerous
voltages and temperatures. It is not a consumer product. It can damage itself, property, and/or personnel
if improperly used.
It must be installed, connected, and operated by personnel properly trained and experienced in its use.
An operator’s manual is supplied with each load bank and available online at www.simplexdirect.com. The
operator must be familiar with its contents and have access to it during operation.

HIGH VOLTAGE: Turn off 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 before opening this unit.
FOR OPERATOR SAFETY: Make sure this equipment is properly grounded when in use.

The following cautions should be observed before and during operation:

Check intake and exhaust screens as well as fan and load elements for foreign objects. Position
and install the load bank with consideration given to large cubic airflow requirements, exhaust
temperature, and velocity. Do not point exhaust at any nearby surface or object that may be
adversely affected by high temperature. This includes but is not limited to painted surfaces, tar
paper, asphalt roofs, water sprinkler heads, fire alarms, and volatile material.
Do not use in confined spaces. The load bank may have to compete with cooling air requirements
of a nearby running engine generator set where cooling air intake to a confined space may not be
adequate for both engine and load bank. Be especially careful not to bounce hot exhaust air off
nearby obstructions for re-circulation through the load bank.
Verify that all control switch positions are set correctly for your intended use before connecting
the load bank to the source to be tested.
The load cables carry high amperage. Be constantly aware of the possibility of inductively
heating adjacent ferrous objects to temperatures sufficient 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.
Do not let the load bank run unattended for long periods of time.
Do not store or operate in rain unless adequate protection is provided.

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 Polaris Load Bank Manual — Load Marshal Control™

I-B. WARNINGS AND CAUTIONS CONT’D

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 has dangerous electrical 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 insulative mats over a dry wooden platform. Work on the equipment only while
standing on such insulative mats.
The National Electrical Code (NEC), Article 250, requires the frame to be connected to an
approved earth ground and/or grounding rods. This grounding will help prevent dangerous
electrical shock that might be caused by a ground fault condition 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 off 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 non-conducting implement, such as a dry rope or board to
free the victim from the live conductor. If the victim is unconscious, render first aid and seek
immediate medical attention.
Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock or may get caught in moving components, causing injury.
Always keep a fire extinguisher near the hardware. DO NOT use any carbon tetra-chloride type
extinguisher as the fumes are toxic and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If there are any questions pertaining
to fire extinguishers, please consult the local fire department.
The illustrations in this manual are examples only and may differ from your load bank.
Main Disconnect to be provided by installer, rated at 600V maximum, and sized 150% maximum
of rated current.
Load Bank warranty is void if incorrectly cooled.

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 Polaris Load Bank Manual — Load Marshal Control™

I-C. LOAD BANK STRUCTURE

The Load Bank comprises three principal systems:

1. Control System
2. Cooling System
3. Load System

Control System
Polaris load banks feature a Human-Machine Interface (HMI) touch screen which, in conjunction with a
Programmable Logic Controller (PLC), controls the load bank operation and displays the unit’s status. With
the HMI, the operator can apply a desired load and measure the response of the test source.
Fan/Control Power is supplied to the load bank in one of two ways. An “Internally” powered unit takes
its control power from the load bus, while an “Externally” powered unit takes its control power from a
separate source. In either case, the voltage is stepped down to 120V control power by a Control Power
Transformer and fused with Control Fuses for protection. See the unit’s drawing package for more details
regarding control power.
The Polaris load bank can be equipped with optional automatic modes, which can extend a power
source’s life. For more information refer to Section II-D, Load Control Modes.
Simplex load banks can also be integrated into a facility’s Building Management/Building Automation
System (BMS/BAS) via standard Modbus RS85 or optional Modbus TCP/IP protocol, as well as by a set of dry
contacts reporting various unit status points. For more information refer to Section II-K, Modbus Controls.

Cooling System
Polaris load banks are cooled by forced air, delivered by an aluminum fan blade driven by a TEFC
motor. The motor is energized through a contactor and protected by a circuit breaker and Motor
Disconnect Switch.
Air flows horizontally through the Load Bank, through screened intake and exhaust vents.
Optional equipment allows the exhaust to be driven through a customer-installed duct, providing for
indoor installation.

Load System
The load system comprises independently
controlled Simplex Powr-Web resistors, which have
been designed specifically for use in load bank
systems. The load elements are supported by high-
temperature, ceramic-clad, stainless steel rods
across their entire length, virtually eliminating
element-to-element short circuits. The elements are
arrayed in discreet, independently serviceable trays.
Groups of resistors comprise discrete Load Steps of
various values. These steps are applied to the load
bus via PLC-controlled contactors and overcurrent
protection is provided by Load Fuses. End view of a Polaris, showing air intake
screen, Motor Disconnect Switch, and
Indicator Lights.

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 Polaris Load Bank Manual — Load Marshal Control™

I-D. SAFETY

The Polaris load bank is protected by various sensors (temperature switches, pressure switches, etc.) to
ensure that the load bank is sufficiently cooled and that the exhaust does not exceed a safe temperature,
which could damage the load bank or present safety hazards to personnel. Any unsafe condition detected
by the Control System and its sensors will result in a drop of all load electrically disconnecting the load
bank elements from the test source. For more details on safety monitoring points, refer to Section II-J,
Alarms and Warnings.

I-E. UNPACKING

The following items are included with a newly shipped load bank. If any of the following are not
included, please contact Simplex at 800-637-8603.
1. Controller (remote or local)
2. Operations manual
3. Drawing package

In addition, depending on the unit’s specifications, certain optional equipment may be included:
1. Additional controllers
2. Current transformers
3. Other optional equipment. see drawing package for
details on specific unit.

I-F. PRIMARY INSPECTION

Before installing a new unit, inspect the shipping crate and load bank. Physical or electrical problems
could arise from handling and vibration. The following six-point inspection is recommended before
installation and as part of a six-month maintenance schedule, or after any load bank relocation. Never
apply power to a load bank before performing this procedure.
1. If the crate shows any signs of damage, examine the load bank in the corresponding areas for signs of
initial problems.
2. Check the entire outside of the cabinet for any visual damage, which could cause internal electrical
or mechanical problems due to reduced clearance. Inspect and operate Motor Disconnect Switch.
3. Open the control panel by removing the load bank’s side (see drawings for details) and inspect all
relays and control modules. Make sure all components are secure in their bases and safety bails are
in place. Spot-check electrical connections for tightness. If any loose connections are found, inspect
and tighten all remaining connections. Refer to Appendix E for torque specifications
4. Examine all accessible internal electrical components such as fuses, contactors, transformers. Spot
check the tightness/torque of lugged wires at these components. If any loose connections are found,
inspect and tighten all remaining connections. Refer to Appendix E for torque specifications.
5. Check cooling system by inspecting the fan motor and blade. Check fan blades for stress fractures.
Slowly rotate blade by hand and note clearance of the blade tip through its rotation near the housing.
Observe free rotation of the motor shaft.
6. Check the load element chamber for foreign objects, broken ceramic insulators, and mechanical
damage.
If any problems are observed during the primary inspection, call Simplex at 800-637-8603, 24 hours a
day.

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 Polaris Load Bank Manual — Load Marshal Control™

I-G-1. INSTALLATION – PLACEMENT

Type 3R load banks are

intended for outdoor
installation. Type 1 load banks
must be installed indoors. The
load elements in a Polaris load
bank are cooled by a forced air
system which discharges
through the top of the cabinet.
The load bank will produce a
large quantity of heated
exhaust air.
Placement of the load bank
is one of the most critical
factors for safe operation of the load bank and should be overseen by trained personnel. The load bank
must be installed and positioned according to its large airflow requirements.
• The load bank requires a minimum of 7.5 feet of clearance around the front and rear, and 3 feet of
clearance on the sides. See clearance diagrams, next page.
• Never install any structure or object at any height above a load bank.
• Load banks installed indoors must be equipped with an exhaust air duct of minimum back pressure
(supplied by others) which routes all load bank hot exhaust air outdoors.
• The load bank should be in a secure area accessible only by trained personnel.
• Never operate the load bank in a confined space without
regard for adequate intake of air and provision for egress of Damage to the load bank
high temperature exhaust. due to improper
• Consider that the load bank and any nearby equipment may
installation is not covered
have to compete for cooling air. by the Simplex Warranty.
• Never allow hot exhaust air to be channeled by nearby
objects in such a way that it recirculates through the cooling system.
• Load banks can exhaust air as hot as 650°F. Never operate the unit in the proximity of a fire suppression
sprinkler system.

Improper installation of the load bank may result in

damage to or destruction of the load bank, adjacent
equipment, and the facility housing the unit.

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 Polaris Load Bank Manual — Load Marshal Control™

I-G-1. INSTALLATION - PLACEMENT CONT’D

Top view of a Polaris, showing clearance requirements.

Polaris load banks are manufactured in

three frame sizes, depending on the
specified capacity.
Small – 27.5 kW
Medium – 50 kW
Large – 75 – 150 kW

Consult unit’s drawing package for

Side View details on capacity and size.

Dimension Small Medium Large

A 64.9” 74.9” 86.9”
B 22.3” 32.3” 44.3”
C 19.9” 29.9” 41.9”
D 11.0” 19.0” 30.0”
E 4.5” 4.0” 4.5”
F 32.8” 38.8” 38.8”
G 31.3” 37.3” 37.3”

Bottom View

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 Polaris Load Bank Manual — Load Marshal Control™

I-G-2. INSTALLATION - PROCEDURE

• Unless specified on the drawing, make all

connections in compliance with the National
Electrical Code (NEC) and all local codes or
ordinances.
• Ground the load bank by connecting the
grounding block to an earth ground or grounding
rod.
• To route and connect the power source cables to
the unit, remove the plate in the bottom of the
control compartment (see diagram above). Cut
holes in the best location, properly install the Bottom view of a Polaris, showing removable
conduit, route appropriately sized cables and plate for cable connections.
reinstall the bottom plate.
• Connect the source’s power output to the load bank via the Main Load
Block.
• Wire the remote contacts for Load Dump, Load Ramp Down and Auto
Trigger (if applicable) as described below and as shown in the unit’s
drawing package.
• If applicable, install the Remote HMI as described below.
• If applicable, wire the sensor contacts for Backpressure Monitoring as
shown in the unit’s drawing package.

Installation - Remote HMI

If the HMI is installed directly on the load bank, and there is no remote
controller, skip to the next section.
• Using holes and slots provided, mount the remote box
where desired.
• Open the remote box to find the terminal block TB-H.
• Connect DC power as shown in the unit’s drawing package. Main Load Block (top) and
• Connect Communication wiring as shown in the unit’s Ground Block
drawing package, using Belkin 9841 or equivalent

Example Remote HMI connection

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 Polaris Load Bank Manual — Load Marshal Control™

I-G-3. INSTALLATION - INPUT SIGNALS

Load Dump: If the Load Dump feature is desired, remove the factory-installed jumper at TB-R 1-2 and
connect customer-supplied Load Dump contacts to TB-R 1-2 (see drawing package). To dump the load,
open the customer-supplied contact. To enable the load, close the contact.
Load Ramp Down: If the Load Ramp Down feature is desired, connect customer-supplied Load Ramp
Down contacts per drawing package. To trigger a Load Ramp Down, close the customer-supplied contact.
To resume normal operation, open the contact.
Auto Trigger: For the Auto Exercise, Fixed Load, and Auto Sequencing features, a customer-supplied
external contact is necessary to start operation in these modes. See unit’s drawing package for connection
details. To trigger the selected Auto function, close the customer supplied contact. To stop the function,
open the contact. See Section II-D, Load Control Modes, for more details.
Back Pressure Monitoring Sensors: Units equipped with the Back-Pressure Monitoring option use inputs
from two customer-supplied pressure sensors. See unit’s drawing package for connection details. For more
details on Back Pressure Monitoring, see Section II-D-5-b.

I-G-4. INSTALLATION - CURRENT TRANSFORMERS

Load banks equipped with digital metering packages must have current transformers (CTs) installed.
Units with only local metering are likely to arrive with CTs factory installed, but units equipped with the
Auto Load Leveling feature will require onsite installation of system CTs either instead of or in addition to
the local metering CTs.
• The CTs must be placed and oriented correctly to ensure that they accurately detect the current. The
first CT must be installed on the phase A cable(s), the second on phase C.
• Orient the CTs so that the H1 on each ring is facing the power source.
• When the CTs are installed, connect them to the load bank per the drawing package.
• Each set of CTs must have its winding ratio entered in the unit’s Settings under the User Settings
section. See Section II-C, User Settings, for more details.
• If the system comprises multiple parallel generators, ensure that the CT placement will capture
totalized power.

Power Load Bank

CTs

Source

Power Unit with local metering only

Load Bank
CTs

Source
Power
Load Bank
CTs

CTs

Source
Facility
Load
Facility
Unit with system/auto metering only Load

Unit with system/auto and local metering.

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 Polaris Load Bank Manual — Load Marshal Control™

I-G-5. INSTALLATION - MODBUS COMMUNICATION

Simplex stationary load banks support monitoring/control by third party systems using the Modbus
protocol, over either RS485 or TCP/IP communication, depending on which was specified for the unit.
To implement Modbus control and monitoring, connect the load bank to the control component per the
unit’s drawing package.
For more detail on Modbus control, see Section II-K, Modbus Controls.

I-G-6. INSTALLATION - ANTI-CONDENSATION HEATERS

Simplex load banks are equipped with space heaters, which require a
dedicated power source independent of Control Power to prevent component
damage from condensation and startup failure in cold environments.
Connect heater power per the unit’s drawing package.
The heaters are thermostatically controlled and are set at the factory to
come on below 50°F. When the load bank is installed, the thermostat should
be set appropriately for the locale.

Heater Connection

I-G-7. INSTALLATION - BMS/BAS SIGNAL CONTACTS

The load bank provides a set of remote signal dry contacts that may be integrated into a facility’s
Building Management System or Building Automation System. The dry contacts provide basic information
about load bank status. See the unit’s drawing package for more details.

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 Polaris Load Bank Manual — Load Marshal Control™

II. SIMPLEX LOAD MARSHAL™ CONTROL SYSTEM

II-A Navigation

From the Main Screen, the user may navigate to all

the major sections of the controls program.

Common Features
The Main Screen introduces two features that are
common to most other screens in the program.
• Help/Information button: The blue question mark
button at the top right of the screen calls the
appropriate section of the onscreen manual. Note
that help screens are available only when there is
no load applied.
• System Status button: This button to the left of
the Help button calls the System Status screen,
which displays all important system parameters.

Navigation and Control Buttons

Load Control Modes: Calls the Control Mode Selection screen, where user selects the load bank’s mode
of operation. See Section II-D, Load Control Modes, for more details.
Other Functions: Calls the Options screen, where user selects other functions such as Step Quarantine,
Self-Diagnosis, and various optional features. See Section II-F, Options Screen, for more details.
User Settings: Calls the User Settings screens, where all user-definable setpoints and parameters are
entered. All setpoints should be entered before the load bank is operated. The User Settings screens are
password protected. When this button is touched, the User Password must be entered before the User
Settings screens will be called. See Section II-C, User Settings, for more details.

The default User Password is 4831600.

For units equipped with a 6” HMI, this may be changed to a user-defined password.
See Section II-F, Options Screen, for more details.

Contact Simplex: Calls a Simplex contact list and important load bank information.
Current Features: Calls a list of all the load bank’s options and capabilities.
Take/Release Control: Allows the load bank to be controlled from an alternate control platform, be it
a 2nd Simplex HMI or a customer-supplied PC communicating via Modbus. See Section II-K, Modbus
Controls, for more details.
Screen Saver: Blanks the control screen.

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 Polaris Load Bank Manual — Load Marshal Control™

II-B. Specific Unit’s Capabilities

The following section contains information on all functions and capabilities available on Simplex
stationary load banks. Not all load banks will be equipped with these functions. For a list of your load
bank’s specific capabilities, select the Current Features screen accessible from the Main Screen - see
Section II-A, Navigation, for more details. Contact Simplex for more information on available features and
the possibility of adding functionality to a load bank.

II-C. User Settings

Before the load bank can be operated properly, the user-defined system settings must be entered.
Access the settings screens from the Main Screen using the User Settings button. A password is required
to call the User Settings screens.
The default User Password is 4831600.
For units equipped with a 6” HMI, a user-defined password is also available.
See Section II-F, Options Screen, for more details.

II-C-1. General Settings

The General Settings screen contains entries

that define the power source and load bank
system.
No. of Sources: Units that are equipped with
Auto Load Leveling and that have been specified
to do so are capable of paralleling with up to 3
sources. See Section II-D-5, Auto Load Leveling,
for more details.
Select the number of sources and for each,
enter its kW capacity.
System Voltage: Enter the system’s rated
voltage. The load bank PLC will compare this with
the load bank’s designed voltage to calculate
derated capacities. A non-zero number must be
entered before the load bank may be operated.
Ramp Down Step: A Load Ramp Down may be
triggered during Auto operations by a user-
supplied input signal (See Input Signals section for more
details) and will also occur upon termination of automatic mode operations. The Ramp Down steps load
down to zero at a set interval. The Ramp Down Step defines the amount of load to be dropped with each
step.
Meter CT Ratios: For units equipped with electrical metering packages, a current transformer (CT) ratio
must be provided for each set of CTs. For Simplex-provided CTs, the ratio will have been entered at the
factory.
Default Settings: Resets all User Settings to factory recommended default values.

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 Polaris Load Bank Manual — Load Marshal Control™

II-C-2. Auto Load Leveling Settings

Connected in parallel with another load, a load bank equipped with Auto Load Leveling will act to
maintain the total system load within a user-specified “Window,” or power level range. If the system
power level is above or below the window, the load bank will add or remove load in steps toward the
window. The steps occur at user-defined intervals. All settings defining the Auto Load Leveling function
are entered on the Auto Settings screen.
Window Low % and High %: These entries
define the desired window, or range, of
operation. Note that the setpoints are entered as
% of total source capacity.
Emergency High %: Should the system power
level reach this setpoint, the load bank will
instantly drop a block of load calculated to return
the power level to within the defined window.
Emergency Low %: This setpoint only comes
into play on units equipped with Regenerative
Power Protection (Regen). When the Emergency
Low setpoint is reached, the load bank will
instantly apply a block of load calculated to
return the power level to within the defined
window. See Section II-D-5-c, Reverse Power
Prevention Operation, for details.
Auto Start Delay: Defines the amount of time
after the load bank starts up before the
Automatic functions begin to regulate the load bank load.
Step Delays: Defines the amount of time between each step up or down as the load bank regulates its
load.
Example Settings — Auto Load Leveling Window shown in green:

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 Polaris Load Bank Manual — Load Marshal Control™

II-C-3. Backpressure Monitoring (BPM) Settings

Monitoring two user-supplied pressure sensors

located in a generator’s exhaust stack, a load
bank equipped with Auto Load Leveling and the
BPM option will react to high pressure conditions
by increasing the load to within a user-defined
elevated “Soot Burn Window” of operation.
Soot Burn Window Low % and High %: These
entries define the desired window of operation
when attempting to clear a backpressure
condition by raising exhaust temperature. Note
that the setpoints are entered as % of total source
capacity.
Active BPM Check Target: Upon startup or
after clearing a fault/alarm, a load bank with the
BPM option enabled will step up to a BPM Check
power level, actively checking for a high-pressure
condition. Note that this setpoint is entered as a
% of total source capacity. Also, the BPM Check
power level is the same as the Auto
Exercise/Fixed Load power level.
Emergency Low %: This setpoint only comes into play on units equipped with Regenerative Power
Protection (Regen). When the Emergency Low setpoint is reached, the load bank will instantly apply a
block of load calculated to return the power level to within the defined window. See Section II-D-5-c,
Regenerative Power Protection Operation, for details on Regen operation.
Soot Burn Duration Minutes: When a high backpressure condition is triggered, the load bank will step
up into the Soot Burn Window of operation. After the condition clears, it will remain in that elevated
window for this user-defined period before returning to the normal Load Leveling window of operation.
Alarm Shutdown Delay Minutes: If the BPM Alarm signal is triggered and does not clear after this user-
defined amount of time, the load bank will step down to zero load and disable all auto functions until the
alarm is reset, if a problem other than soot buildup exists.
Example Settings — Soot Burn Window shown in blue:

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II-C-4. Miscellaneous Settings

Auto Exercise/Fixed Load Target %: When an

Auto Trigger input is received, and the load bank
is equipped with Auto Exercise or Fixed Load
capabilities, the load bank will automatically
apply this amount of load until the trigger is
removed. See Section II-D-7/8 for more details.
Also note that a for a load bank equipped with
the BPM option, this value serves as the target for
the Active BPM Check. See Section II-D-5-b,
Backpressure Monitoring Operation, for more
details.
Step Delay: The rate at which the load bank
will step up/down while in Auto Exercise
operation or in Active BPM Check operation. If the
load bank is equipped with the Auto Load
Leveling function, this level will be entered on
the Auto Load screen, as the Auto Level Step Up
Delay.
Fahrenheit/Celsius Selection: For a load bank
equipped with thermocouples, the temperature readings may be set to display in either system.
Load Dump Bypass: The user-installed Load Dump switch or contact may be bypassed, removing the
necessity of having an input present to operate the load bank.
Single Phase Operation: Load Banks designed as three phase units may be operated at a derated
capacity in single phase mode. The load bank must be connected and configured in a specific way. See
Appendix D, Single Phase Configuration, for more details. Selecting Single Phase operation with this
button will cause the load to apply appropriate derate calculations to the value of each of its load steps.

Genset Overload Protection

The load bank can be configured to detect severe overloading of a genset or source. If such a condition
is detected, the load bank will step down to zero load and reset all automatic functions.
Minimum Frequency: The setpoint at or under which the load bank will detect that the genset’s
output is drooping to a point of concern.
Delay: The amount of time a genset will spend at or below the Minimum Frequency mentioned above
before the load bank begins to step down to zero load.

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II-D. Load Control Modes

This screen displays the various control modes

with which the load bank is equipped, and which
may be selected.
Manual Load: In this mode, the load bank’s load
steps may be individually toggled, and groups of
steps may be toggled using the Master Load switch.
See Section II-D-2, Manual Load, for more details.
Numeric Load: In this mode, the user enters a
desired amount of load to be applied and may toggle
that load with the Apply Load button. The applied
load may be adjusted up or down by a user-defined
amount using the Load Jog function. See Section II-
D- 3, Numeric Load, for more details.
Sequence Load: In this mode, the load bank can
be set up to automatically cycle through a sequence
of user-defined “Stages,” with each Stage applying a
user-defined amount of load for a user-defined
time. The sequences may be set to apply load in blocks or in step increment/decrements. A sequence may
be triggered from the control screen or may be set to run automatically on a user-supplied Auto Trigger
input. See Section II-D-10, Sequence Loading, for more details.
Auto Load Leveling: In this mode, the load bank operates in parallel with another load to maintain the
system total power level within a user-defined “window” of operation. See Section II-D-5, Auto Load
Leveling for more details. There are two optional functions that expand the capability of the Auto Load
Leveling function:
• Regen (Regenerative Power Prevention): With this option enabled, a load bank equipped with Auto
Load Leveling will react to a user-defined “Emergency Low” setpoint to prevent a reverse power
condition. See Section II-D-5-c, Regenerative Power Prevention Operation, for more details.
• Backpressure Monitoring: With this option enabled, a load bank equipped with Auto Load Leveling
accepts input signals from user-supplied pressure sensors and works to automatically clear any
backpressure conditions by raising the power level to burn soot out of a generator’s exhaust stack.
See Section II-D-5-b. Backpressure Monitoring Operation, for more details.

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II-D-1. Control Screens

Common Features
These Manual Control Screen examples
illustrate some features common to all control
screens.
• Low Battery Indicator: The battery symbol will
appear in the upper right corner when the PLCs
memory backup battery is due for replacement.
The PLCs use CR2354 or equivalent batteries.
• System Status Indication: In a field to the right
of the control power button, various system
status messages will be displayed. In the
example to the left, “Ready to Load.” visible.
Other messages will appear here to indicate
various load bank conditions:
• Starting Up: After control power is energized,
there is a five second time delay before load
may be applied, allowing system and fault
checks prior to loading.
• Ready to Load: Indicates that the system has
completed the startup process, that there are no alarm conditions present, and that the system is ready
to apply load.
• Check System: Indicates that an alarm or other condition is present, and that load may not be applied.
Navigate to the System Status screen for more information.
• Load Dump Active: Indicates that the user-supplied remote Load Dump contact is open and not
bypassed. See Load Dump button section on next page for more details.
• Ramp Down Active: Indicates that the user-supplied Ramp Down contact is closed, triggering a step
down to zero load.
• Cooldown Mode: For two minutes after any
load has been applied, load banks with cooling
fans will maintain the fan operation to allow
complete cooldown of the resistive elements. If
Control Power is turned off before this two
minutes elapses, the fan will remain running
for the remainder of the time. This Cooldown
Mode may be canceled with a button that
appears at the bottom of the screen. Our
recommendation is that the cooldown period
be allowed to run its course.
• Specific Alarm/Warning Indications: See
Section II-J, Alarms and Warnings, for details on
other messages displayed in this field.

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II-D-1. Control Screens cont’d

• Auto Shutdown: If a load bank in Manual Load or Numeric Load operation has had no load applied for
one hour, it will shut itself down. For the last 30 minutes of that hour, the countdown will appear at the
bottom center of the screen. In any Automatic mode, the load bank will shut itself down after 2 minutes
of no call for load. See Section II-D-4 through II-D-9 for more details.
• Load Dump: In the lower right corner of each control screen is the local Load Dump button. Toggling the
Load Dump will drop all applied load. The button must be reset before load may be reapplied.
• Metering Band: For load banks equipped with metering, the electrical values are displayed on every
control screen. On units equipped with a 6” or larger touchscreen, touching the Metering Band will call
the Data View/Logging screen. See Section II-E, Data Logging, for more detail.
• Alarm Banner: Any system alarm will cause an
Alarm indication to display in the upper banner
of every screen. Certain alarms and conditions
will display beneath the banner, to the right of
the Control Power button. Press the System
Status button for more details on any alarm.
• Alarm Reset: All alarms latch and must be
reset after the condition has cleared. Note that
latched alarms will persist even through a
Control Power shutdown, so cycling control
power will not clear a latched alarm. The
Alarm Reset button will appear on the screen’s
lower right in the place of the Load Dump
button.
See Section II-J, Alarms and Warnings, for
more details on specific alarms.
• Back Button: Navigates back to the Load
Control Modes screen. Navigation button is
available only when the Control Power is turned
off.

II-D-2. Manual Control

Master Load Button: The Master Load button

toggles to allow individual step buttons to engage
their steps.
Step Toggle Buttons: Each load step toggle
button displays the step number and the kW value
of the step, with voltage and phase derating
considered. When the step button is toggled on,
there will be a blue border around the perimeter
of the button, and when the PLC is commanding
the step relay to energize, the upper half of the
button will turn blue. See Step 7 in the example
screen to the right.

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II-D-3. Numeric Load

KW to Apply Entry: Enter the desired KW.

Apply/Remove Load Button: Toggle this
button to apply or remove the entered load.
Jog KW Amount Entry: Enter the amount by
which to adjust the load up or down with the
Jog buttons.
Jog Up/Jog Down Buttons: These momentary
buttons will adjust the KW to Apply up or down
by the Jog KW Amount.
Steps On: Indicators denote which discrete
load steps are currently energized.

II-D-4. Automatic Load Modes

A load bank with the Load Marshal control system may be equipped with one or more of several
available modes of automated operation.
• Auto Load Leveling: When Auto Load Leveling is enabled, the load bank will react to changes in a
parallel load to maintain the overall system load steady within a user-defined “window” of
operation. When the load bank senses the need to apply load, it will turn itself on if necessary, and
when there is no call for load from the load bank, it will turn itself off. Auto Load Leveling operation
may be enhanced by two optional supplemental functions.
♦ Regen (Reverse Power Prevention): When the Regen option is enabled with Auto Load Leveling,
the load bank will act to prevent a reverse power condition by applying blocks of load if the
power falls to an “Emergency Low” setpoint.
♦ BPM (Active Backpressure Monitoring): When the BPM option is enabled with Auto Load
Leveling, the load bank will act to correct excessive backpressure conditions in a generator’s
exhaust stack by adding load to raise exhaust temperature.
• Auto Exercise: When Auto Exercise is enabled, and a user-supplied Auto Trigger signal is present, the
load bank will turn itself on, step up to a user-defined power level at a user-defined rate, and
maintain that power level until the Auto Trigger is removed, at which point it will step down to zero
load at the same rate, and then turn itself off.
• Fixed Load: When Fixed Load is enabled, and a user-supplied Auto Trigger signal is present, the load
bank will turn itself on, apply a user-defined amount of load in one block load, and maintain that
load level until the Auto Trigger is removed, at which point it will drop to zero load in one block
drop, and then turn itself off.
• Auto Sequencing: When Auto Sequencing is enabled, and a user-supplied Auto Trigger signal is
present, the load bank will turn itself on and execute a user-programmed load sequence (see Section
II-D-10, Sequence Loading, for more details), then turn itself off.
Note that on initial startup, except in the case of the Regen option, all Automatic Load Modes will
begin to operate after a user-defined Auto Start Delay (see Section II-C, User Settings).

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II-D-4. Automatic Load Modes cont’d

Auto Mode Selection: Enable/Disable toggle

buttons for each available auto mode appear on
the Auto Load screen. Note that enabling any
mode locks out all others. Also note that having
any mode enabled will lock out navigation back to
the Mode Selection screen.

The Load Leveling function applies

load seeking a user-defined level
using the metered kW value as
feedback.
If no metered kW is seen, the PLC will
continue adding load and may overload the
power source. Always ensure the meter is
operating properly before enabling Auto
Load Leveling!

II-D-5. Auto Load Leveling

Enable/Disable Auto Level: Toggles the Auto

Load Level function. If the function is enabled
and there is a call for load, meaning that the load
bank needs to apply load to keep the system load
level within the user-defined window of
operation, the load bank will turn on its own
control power and begin to regulate the load.
When there is no call for load (i.e. the parallel
load is within or above the window of operation
with no load bank load applied), the load bank
will turn off its own control power after a two-
minute delay.
Regen/BPM Indicators: Indicate whether these
optional functions are enabled.
Load Bank Activity Indicator: Indicates the status of the load bank as it attempts to maintain system
load within the window of operation. Displays the following conditions:
• Stepping Up (Adding load) • Emergency Down
• Stepping Down (Removing load) • Load Bank No Load
• In Window • Load Bank Full Load
• Emergency Up (Regen Operation)
Genset KW: Displays the total system power. To the left is a numeric display and to the right is a bar
graph showing the current power level as a percentage of the system total capacity. A red line
demarcates window high level setpoint.
KW Target: Displays the Min/Max setpoints of the target window of operations.
KW Applied: Displays the amount of load currently applied by the load bank.

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II-D-5. Auto Load Leveling cont’d

II-D-5-a. Auto Load Leveling Operation

When Auto Load Leveling is enabled, the load bank will monitor total system KW to determine its
actions. If system kW is below the user-defined window of operations, the load bank will add load, and if
the system kW is above the window, the load bank will drop load to maintain total power within that
window.
In normal Load Leveling operation, the load bank will add or drop an amount of load equal to the load
bank’s smallest load step (the load bank resolution) at intervals defined by the user. See Section II-C-2,
Auto Load Leveling Settings, for more details on the Auto Load Leveling time delays.
If the total system kW is greater than the Emergency High setpoint, the load bank will instantly drop a
block of load calculated to bring the system back to within the window of operation.
When Auto Load Leveling is enabled, if the load bank is “off,” meaning that the control power is not
active and the cooling fans (if applicable) are not running, the unit will turn its own control power on and
start its cooling fans any time that the total system kW dips below the window of operations, and begin to
add load.
When there is no call for load bank load (e.g. the total system kW is in the window of operations
without any load bank load applied) for two minutes, the load bank will shut itself down until the call for
load returns.
If Auto Load Leveling is disabled (i.e. turned off) during operation, the load bank will step down to zero
load and shut itself down.

II-D-5-b. Backpressure Monitoring Option

Enabling Auto Load Leveling Options:

Available options are enabled/disabled on the
Other Functions screen accessed from the Main
screen
Backpressure User Inputs: The BPM option
monitors input signals (BPM Warning and BPM
Alarm) from two user-supplied pressure sensors in
the genset’s exhaust stack. See drawings for user
inputs.
Soot Control Mode: When a high-pressure
condition is indicated by either sensor, the load
bank will step up to a higher user-defined window
(Soot Burn Window) of operations to
increase the genset’s exhaust temperature and
burn accumulated soot out of the stack. After the condition has cleared, the load bank will maintain
operation within the Soot Burn Window for a user-defined amount of time before returning to regular Auto
Load Leveling operation.
BPM Alarm Shutdown: If the BPM Alarm signal does not clear after a user-defined amount of time, the
load bank will step load down to zero, shut itself off, and disable all auto functions, under the assumption
that a larger issue exists and must be dealt with before operations may continue.
Active Backpressure Check: Upon startup, the load bank will execute an Active Backpressure Check by
stepping its load up to a user-defined point (ideally very high in the genset’s range) in an active attempt
to trigger a backpressure condition. If either the BPM Warning or Alarm are triggered, the load bank goes
into Soot Burn Mode as described. If no backpressure condition is triggered, the load bank will switch to
normal Auto Load Leveling operation and step down into that window of operations.

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II-D-5. Auto Load Leveling cont’d

II-D-5-c. Regen (Reverse Power Prevention) Option

Emergency Low Setpoint: With the Regen option enabled, the load bank operates as with standard
Auto Load Leveling with an added Emergency Low setpoint. When total system kW drops to the Emergency
Low setpoint, the load bank will instantly add in one block an amount of load calculated to raise the load
level to within the Auto Load Leveling window of operations, to prevent any reverse power conditions.
Emergency Low Setpoint Arming: Upon initial startup or after an alarm reset, the Emergency Low
Setpoint is not armed, meaning that the load bank will not react to the setpoint, until the total system kW
is above the Emergency Low setpoint.
Time Delay Bypass: With the Regen option enabled, the user-defined Auto Startup Delay as well as the
system Startup Time Delay are bypassed, and the load bank will begin to respond to calls for load
instantly.

II-D-6. Auto Trigger Input

The Auto Exercise, Fixed Load, and Auto Sequence functions all use a user-supplied Auto Trigger input.
See drawings for user connections.

II-D-7. Auto Exercise

When Auto Exercise is enabled, and the Auto

Trigger Input signal is present, the load bank will
turn itself on and start its cooling fans if
applicable. After the system Startup Delay and
user-defined Auto Start Delay, it will step up to a
user-defined level and remain there until either
the Auto Trigger signal is removed, or Auto
Exercise is disabled at the screen, at which point
it will step down to zero load and turn itself off.
See Section II-C-4, Miscellaneous Settings, for
details on entering Auto Exercise load level.

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II-D-8. Fixed Load

When Fixed Load is enabled, and the Auto

Trigger Input signal is present, the load bank will
turn itself on and start its cooling fans if
applicable. After the system Startup Delay and
user-defined Auto Start Delay, it will apply in a
single block a user-defined load and remain there
until either the Auto Trigger signal is removed, or
Fixed Load is disabled at the screen, at which
point it will drop all load and turn itself off.
See Section II-C-4, Miscellaneous Settings, for
details on entering Fixed Load level.

II-D-9. Auto Sequence Load

When Auto Sequence is enabled, and the Auto

Trigger Input signal is present, the load bank will
turn itself on and start its cooling fans if
applicable. After the system Startup Delay and
user
-defined Auto Start Delay, it will execute a
previously programmed load sequence. When the
sequence is completed, the Auto Trigger signal is
removed, or Auto Sequencing is disabled at the
screen, the load bank will drop all load and turn
itself off.
See next section, Sequence Loading, for more
details on programming and running load
sequences.
Block/Step Sequence Indicator: under the
Genset kW bar graph, an indication will display when a load sequence is running and will denote
whether the system is in Block or Step Sequence mode. See next section, Sequence Loading, for more
details.
Sequence Screen Navigation: When an Auto Load Sequence is running, it is possible to navigate
between the Auto Load screen and the Sequence Loading screens

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II-D-10. Sequence Loading

A load bank equipped with Sequence Loading

may be programmed to run a sequence of user-
defined “stages.” Each stage is defined with a
load level and a duration. A load bank with a 4”
screen may have up to 10 programmed stages,
while one with a 6” or larger screen can
accommodate up to 16 stages.
Current Stage: Displays the number of the
stage currently being executed, along with the
time remaining in that stage and the
programmed kW.
Next Stage: Displays time and kW information
for the next stage to be executed.
Total Time: Displays the total time remaining
in the full sequence.
Sequence Setup: Navigates to the Sequence
Setup screen. See next page for details.
Step/Block Sequence Indicator: Denotes which sequence mode for which the controls are currently set.
See Sequence Setup section on next page for details on selecting Step or Block mode.
Block Sequence: The desired load for each programmed stage in the sequence will be applied in one
block load for the specified amount of time, then the load bank will apply the next stage’s load in one
block and so on.
Step Sequence: The load bank will step
between stage loads. When the sequence starts,
the load bank will step incrementally to the first
stage’s load level and remain there for the
specified amount of time. It will then step either
up or down to the next stage’s level. Note that
the timer for each step’s programmed duration
does not begin until the level is reached.
Enable/Disable Repeat: The load bank may be
set to repeat the entire programmed sequence. It
will continue to cycle through the sequence until
Repeat is disabled.
Start/Stop Sequence: This button toggles to
run or stop the programmed sequence. Note that
this button will appear in place of the Sequence
Setup button when control power is energized.

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II-D-10. Sequence Loading cont’d

Sequence Setup
# of Stages: Enter the desired number of
Stages to include in the Sequence.
Stage Definition Entries (Hrs., Min., Sec.,
Load KW): Enter desired levels for each
parameter.
Stage Buttons: Pushing a Stage Button will
load the parameters currently in the Stage
Definition Entry fields to that Stage’s definition.
For example, in the definition on the right,
pushing the Stage 5 button will load the values
currently in the entry windows at the top of the
screen into the Stage 5 definition. Stage 5 will
then be defined as 350kW for 2:00:00.
Push for Block Load/Step Load: Select the
sequence mode.
Step Delay: The Step Delay entry in the upper
right corner only applies to, and will only appear
when the sequence is set up for, Step Sequence
Loading. This defines the amount of time between increments as the system steps to the next Stage’s
defined power level.

II-E. Data Logging

Data Logging is an option available on units

equipped with 6” or larger control screens,
accessed by touching the metering display bar on
any load screen. Data is logged from the HMI onto a
flash drive connected through an exterior USB port.
A 1GB flash drive can store 250 million data points,
according to the HMI manufacturer.
Show/Hide Visibility: (Up/Down Arrow button on
the far left of the screen, above the Back Button)
Toggles the visibility controls for parameter graphs.
Visibility Controls (open/closed eye icons): Toggle
the visibility for each parameter’s trace.
Start/Stop Logging: Toggles data logging to the
flash drive. This button, along with the USB
indicator to the right of the kW Applied display, will
be visible only when a flash drive is present and
ready to begin logging.
Clear Graph: Resets the graph, erasing all plotted points. Does not affect data logged to the flash
drive.
Logged Data: Data is logged on the flash drive as a .csv file, with each set of points time and date
stamped. This file may be transferred to a laptop or other computer and opened in a spreadsheet with
software such as Excel.

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II-F. Options Screen

Enable/Disable Capacity Limit: The capacity

limit feature allows the user to enter a maximum
load available. Enable and enter desired limit,
for example to prevent overloading a genset or
another source.
Change User Password: Available only on
units equipped with 6” or larger screens. Allows
a user to set up a custom password to control
access to settings screens.
Run Time Hours: Displays a running total of
time the cooling fan has been running. See
Section IV, Maintenance, for recommended
maintenance intervals.
Enable/Disable Regen & BPM: For units
equipped with Automatic Load Leveling and
these optional features, Regen and BPM are
enabled here. See Section II-D-5, Automatic Load
Leveling, for more details.

II-G. Step Quarantine

A load step may be found to be deficient or in

need of maintenance. Blown fuses, for example,
are a common cause of load steps delivering less
than rated power. Until repairs can be affected,
a deficient step may be taken out of operation
via the Step Quarantine function.
A step in Quarantine will be unavailable for
manual operation and will not be selected by the
system in numeric mode.
Of course, having a step in Quarantine will
reduce the load bank’s total capacity accordingly
and may render certain discrete load levels
unobtainable.
For this reason, having one or more steps in
Quarantine is incompatible with Automatic Load
functions. All Automatic Load functions will be
disabled if any step is under Quarantine.
Step Quarantine is meant to be a short-term
solution to allow operation to continue until the load bank may be repaired.

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II-H. Self-Diagnosis

The Self-Diagnosis feature is a troubleshooting

tool meant to help pinpoint a deficient step.
Dependent upon system configuration certain
small steps may not register correctly and may
indicate a mismatch when one does not exist.
Internal/External Power: This feature
considers a baseline (no steps energized) power
level for internally powered units that have
metering configured such that the power drawn
by the cooling fan and control systems shows up
in the metered power level. This is used to
effectively zero the no load reading.
Start/Stop Self Diagnosis: Starting the Self
Diagnosis sequence will apply the first load step
and cycle through all steps as described below.
Skip Step: Moves the sequence to the next
step.
When the Self-Diagnosis sequence is run, each load step will be applied individually. The system will
then wait a few seconds for the power to reach its operating level, and then compare the metered level
to the expected power output of the step at the current voltage.
If the step measures within 5% of its expected value, the system passes the step and moves on to the
next. If it falls outside of the 5% threshold, a prompt will appear on the screen asking the operator
whether to Quarantine the step.

II-I. System Status

The System Status screen displays indications for

all alarm and warning points, as well as all
measured temperatures.
See Section II-J, Alarms and Warnings, for more
details on all monitored points.

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II-J. Alarms and Warnings

All alarms latch and will remain latched even if control power is turned off. Alarms can be cleared only
with the Alarm Reset button. See Common Features in Section II-D-1 for more details.
Exhaust Temp Failure: The exhaust temperature high limit is calculated by the formula Unit kW
capacity + 150°F (65.6°C), with a maximum of 600°F (315.6°C). An Exhaust Temp Failure will cause the
unit to drop all load.
Fan Failure: Cooling fans’ operation is monitored via a differential pressure sensor. Should the
differential pressure across the fan drop below a threshold indicating a minimum fan speed, the unit will
go into Fan Failure and all load will drop. In case of a Fan Failure, check for:
• Forward fan rotation. Ensure that fan is pulling air from the air intake side of the end of the load
bank (with the Motor Disconnect Switch) and exhausting out the other end.
• Unobstructed airway. Ensure that no debris or foreign material is blocking the intake or exhaust of
the airway.
• Unobstructed, uncrimped vinyl air tube between the differential pressure switch hose fitting and the
fitting in the fan plenum. Caution: the pressure switch is delicate. Do not use compressed air to blow
out any obstruction with tubing connected to pressure switch.
Genset Overload: If the metered frequency drops below a user-defined low frequency setpoint for a
user-defined length of time, the load bank will drop all load and reset all automatic functions. The
automatic functions must be selected again to restart operation.
Hatch Alarm: For units equipped with manual hatches or electrically operated vent louvers, the airway
must be opened to run the cooling fan. If indication of open hatches and/or louvers is lost, the unit will
drop all load and stop the fan. In case of a Hatch Alarm, ensure all hatches and louvers are open, and
check limit switches on manual hatches.
Meter Failure: For units with metering. Indicates that the PLC is failing to communicate with the
digital metering package. In the case of a Meter Failure, the unit may be operated manually, but
automatic functions will be disabled. Check communication connections between the PLC and the meter
per the drawings.
Load Dump Active: A Load Dump may be triggered from either the touchscreen or a remote, user-
supplied contact. The absence of a signal through the contact will trigger a Load Dump. If a Load Dump
Switch or contact has been installed, check that it is closed. If the switch or contact has not been
installed, ensure that a jumper wire is in place between TB-LD 1 & 2. See Drawings for more details. Also
see Section II-C-4, Miscellaneous Settings, for information on the Load Dump Bypass.

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II-J. Alarms and Warnings cont’d

The following indications apply to units equipped with Auto Load Leveling and the BPM option:
BPM Warning: The PLC is receiving a signal from the user-supplied differential pressure warning sensor
in the generator’s exhaust stack. This signal will trigger the load bank to step its load up to the Soot Burn
Window. See Section II-D-5-b, Backpressure Monitoring Operation, for more details.
BPM Alarm: The PLC is receiving a signal from the user-supplied differential pressure alarm sensor in
the generator’s exhaust stack. This signal will trigger the load bank to step its load up to the Soot Burn
Window. See Section II-D-5-b, Backpressure Monitoring Operation, for more details.
BPM Alarm Shutdown: If the BPM Alarm signal is present for a user-defined length of time (See Section
II-C-3 Backpressure Monitoring Settings, for more details), the assumption is that there is some problem
with either the stack or the BPM Alarm sensor beyond a normal soot accumulation. The load bank will ramp
down its load to zero and reset all automatic functions. Automatic functions must be selected again to
continue operation.

II-K. Modbus or 2nd Screen Control/Monitoring

The Simplex Load Marshal control system has Modbus interconnectivity built in. Users may access many
control and status points via the Modbus protocol. See drawings for communication connections. In
addition, units may have a 2nd HMI option enabled where the option has been specified.
When the system is under control over Modbus, or
control is taken by a 2nd HMI, control via the primary
HMI will be locked out and the HMI will act as a
status display for the load bank.
Enable Disable Alternate Control: Allows control
to be taken by the alternate control device/returns
control of the load bank to the HMI.
Modbus Control Bits/Registers:
• Unless otherwise specified, all bits should be
persistent, meaning the bit should be written as
a “1” for as long as the “on” state is desired.
• Modbus maps are shown with Base 1 addresses.
• Floating point values are transmitted in Big
Endian format - most significant bytes in the first
word register.

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II-K. Modbus or 2nd Screen Control/Monitoring cont’d

Modbus Control Sequence of Operations
Starting the Load Bank:
1. Establish communication with Modbus RTU over serial lines or Modbus TCP/IP over a Cat-5 cable,
depending on which type of communication was specified for the unit.
2. Ensure that the “Enable Alternate Control” button is engaged on the HMI.
3. Write a “1” to the “Modbus Take Control” bit.
4. Write a “1” to the “Control Power” bit. The “Startup Mode” bit should be in an on state “1” for
approximately 5 seconds, after which it should toggle to “0,” and the “Normal Operation” bit
should toggle to “1.”
5. Ensure that the load bank is ready for load by reading the “Fan Running” and “Normal Operation”
bits. Both should be “1.” The “Load Bank Failure” bit should be “0,” as should “Load Dump Active”
and “Startup Mode.”
6. To secure the Load Bank after operations, reverse the process. Write a “0” to the “Control Power”
bit and then to the “Modbus Take Control bit.
Reading Meter Values: The metered values (Voltage, Current, Power, Frequency) are transmitted in
Modbus registers 2000 - 2010 as 16-bit Integers and are multiplied by 10 to preserve a decimal point of
precision. Divide the communicated values by 10 to get the actual metered values.
For users who prefer floating point values and can access 5-digit Modbus addresses, the same values are
transmitted in Modbus registers 29471- 29491 as floating-point values with no multiplier.
Numeric Control: Numeric control is the intended mode of operation for Modbus control.
1. Write the desired kW to apply as an integer to the “kW to Apply” register.
2. Write a “1” to the “Numeric Apply Load” bit. This bit will toggle the entered amount of load on and
off.
3. To change load, leave the “Numeric Apply Load” bit as a “1” and write a new value to the “kW to
Apply” register.
Manual Control:
1. Write a “1” to the “Manual Master Load” bit. This bit will toggle the selected load steps on and off.
2. Write a “1” to the individual “Manual Load Step” bits to energize individual steps.
Automatic Control Modes: It is possible to trigger from Modbus control the Auto functions with which
the load bank is equipped. Note that all setpoints, sequence stage definitions, etc. must be set up through
the HMI as described in Section II-D-5 through 10.
1. With the desired Automatic mode completely set up per the appropriate subsections of Section II-C
and II-D-5, write a “1” to the appropriate control bit (i.e. the “Enable Auto Load Level” bit. This bit
acts as the “Enable Auto Level” button on the HMI. Operators should be fully familiarized with the
HMI operation for any Auto function to be controlled via Modbus.
Other Control Bits: The “Alarm Reset” and “Cancel Cooldown” bits function as their HMI button
analogues. See Section II-D-1, Control Screens, for more information on the buttons. To use these bits,
write a “1” to the appropriate register for 1 second and then return to “0.”

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II-K. Modbus or 2nd Screen Control/Monitoring cont’d

Modbus Map - Controls
Base 1

Register Modbus Address Data Type

Modbus Take Control 8353 Bit
Control Power 8354 Bit
Manual Master Load 8355 Bit
Numeric Apply Load 8356 Bit
Cancel Cooldown 8357 Bit
Enable Auto Load Level 8358 Bit
Enable BPM 8359 Bit
Enable AEX 8360 Bit
Enable Regen 8361 Bit
Manual Step 1 8385 Bit
Manual Step 2 8386 Bit
Manual Step 3 8387 Bit
Manual Step 4 8388 Bit
Manual Step 5 8389 Bit
Manual Step 6 8390 Bit
Manual Step 7 8391 Bit
Manual Step 8 8392 Bit
Manual Step 9 8393 Bit
Manual Step 10 8394 Bit
Manual Step 11 8395 Bit
Manual Step 12 8396 Bit
Alarm Reset 8362 Bit
Enable Fixed Load 8363 Bit
Enable Auto Sequence 8364 Bit

Register Modbus Address Data Type

kW to Apply 1001 Int

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II-K. Modbus or 2nd Screen Control/Monitoring cont’d

Modbus Map - Status
Base 1

Register Modbus Address Data Type

Cooldown Mode 8417 Bit
Startup Mode 8418 Bit
Load Dump Active 8419 Bit
Load Bank Failure 8420 Bit
Fan Running 8421 Bit
Normal Operation 8422 Bit
Step 1 On 8423 Bit
Step 2 On 8424 Bit
Step 3 On 8425 Bit
Step 4 On 8426 Bit
Step 5 On 8427 Bit
Step 6 On 8428 Bit
Step 7 On 8429 Bit
Step 8 On 8430 Bit
Step 9 On 8431 Bit
Step 10 On 8432 Bit
Step 11 On 8449 Bit
Step 12 On 8450 Bit
HMI Loss of Comm 8451 Bit

Register Modbus Address Data Type Register Modbus Address Data Type
Vab 2000 Int Vab 29471 Float
Vbc 2001 Int Vbc 29473 Float
Vca 2002 Int Vca 29475 Float
Ia 2003 Int Ia 29477 Float
Ib 2004 Int Ib 29479 Float
Ic 2005 Int Ic 29481 Float
Hz 2007 Int Hz 29485 Float
Vavg 2008 Int Vavg 29487 Float
kW 2009 Int kW 29489 Float
kW Applied 2010 Int kW Applied 29491 Float

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III. Troubleshooting
These recommended checks are meant to guide an experienced technician through investigation of a
few of the most common load bank issues. A certain level of electrical knowledge and familiarity with
electrical drawings is assumed.
If these checks do not pinpoint the problem, or for more information about any of the
recommendations, call the Simplex Service Department at 800-637-8603.

It is sometimes necessary to have control power energized when troubleshooting in a load

bank cabinet. Be aware that load banks may have multiple sources of power (test source
power, fan/control power, anti-condensation heater power, etc.). Remove as much power
as possible before troubleshooting. When control cabinet panels are open, treat every
component and circuit as though it were live and always use all appropriate PPE.

III-A. Cooling Fan Will Not Start/Operate

• Check for presence of correct fan/control power.
• Ensure that the Motor Disconnect Switch is in the “On” Position.
• Reset Motor Disconnect Switch if tripped.
• Check that Fan Motor Contactor (FMC) closes.
• Check that the pilot relay for the FMC closes (See drawings for details).
• Ensure the PLC is in Run mode (generally, Power and Run indicators on
PLC are lit).
Motor Disconnect Switch
III-B. Fan Failure Indicated
• Ensure fan is running (See above if not).
• Ensure fan is turning in the correct direction. Air should be pulled in at the
bottom of the unit and exhausted out the top. If fan is spinning the wrong
direction, check phasing on fan power connection.
• Check for airway obstruction at the intake and exhaust.
• Check the differential pressure switch (Located inside the control
compartment of the load bank). The switch uses a length of nylon tubing to
compare the pressures on each side of the cooling fan. This tube must be
free of any blockage.
Differential
Pressure Switch

Caution: Blowing forcefully into the

differential pressure switch may
damage the switch. Never use
compressed air to clear the tube.

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III-D. High Exhaust Temp Indicated

• Check for obstruction of airway intake and exhaust.
• Ensure that hot air is not being recirculated into the
intake of the load bank.
• Ensure ample airflow. See Placement diagrams in
Installation section for more detail.

III-G. HMI/PLC Comm Errors PLC 001: PLC Communication Timeout

The High Exhaust Temp Alarm pictured above is an
example of a load bank system alarm. This is an alarm
generated by the PLC in response to some abnormal
condition.
The screen to the right is displaying an HMI generated
error code in a banner across its top. This is not a system
alarm, but an indication that the HMI cannot contact the
PLC.
• Check communication cable between HMI and PLC
• Ensure that the PLC is in Run mode. “Power” and “Run”
green LEDs should be lit.

III-H. Other HMI Issues

HMI Communication Error
Other banner error codes—In addition to the PLC
Communication Timeout shown above, the HMI has several different error codes it may display.
♦ Error codes prefaced with “PLC” as the above PLC001 indicate issues between the HMI and the PLC,
either communication or data mismatch errors of some type. Make the checks listed above and call
Simplex Service for assistance.
♦ Error codes prefaced with “RTE” (Run Time Errors) generally indicate issues within the HMI operating
system itself. Two examples:
∗ RTE-002 - Log Failed. (Device) cannot be found.: This error will appear when the system is set up
for data logging, but no USB drive is present on which to log data. This error will not affect load
bank operation but may be a nuisance. Insert a data logging flash drive or ensure that the
Start/Stop Logging button on the data logging screen is set to stop. See Section II-E, Data
Logging, for more information.
∗ RTE-500 - SRAM Check Sum Error: The memory in the HMI has been corrupted, possibly by a power
loss or other external event. The memory will have to be wiped and the program reinstalled.

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III-H. Other HMI Issues cont’d

• Screen is black/dark:
♦ Touch the screen to ensure it is not in sleep or screen saver mode.
♦ Ensure there is power to the HMI.
♦ Check for a bad backlight by shining a flashlight on the screen to see if screen elements appear.

III-I. Reduced kW Output or Phase Imbalance

A power output of more than 5% below the rated or expected output may indicate an issue. Many
factors may contribute to a reduced load bank capacity.
• Check system voltage: A reduced voltage input will result in a derated power output, by the formula
kW output = kW rated * (V input / V rated)2
• Use manual loading or the system self-diagnostic feature to pinpoint a reduced capacity load step. The
most common causes of a reduced load step capacity:
♦ Check for blown load fuses - After pinpointing the affected step(s), refer to the unit’s drawing
package to identify the step’s load fuses.
♦ Check for open resistive elements - See unit’s drawing package to trace element connections back
to their associated Load Contactors. Using an ohmmeter, measure each phase-to-phase resistance
on the load side (output side) of the contactors. The three readings (A-B, B-C, C-A) should be
balanced, meaning that all three resistance readings will be virtually identical or very close to each
other, and none should read open. Note that larger steps will comprise more than one contactor,
so each contactor will control a segment of the step. To find the rated resistance for the segment
under measurement, use the drawings to determine the rated kW value of the segment (rated step
value divided by the number of segments into which the step is divided) and refer to Appendix C,
Rated Resistance and Current, to determine its expected line to line resistance.
♦ Check other components - a chain of control components is associated
with each load step: PLC output - Pilot relay(s) - Load contactor(s)
Refer to the unit’s drawing package to trace the controls. A failure at any of the control components
could result in a missing, reduced capacity, or imbalanced load step.
• Check for accurate metering: See next section for
information on problems with the digital metering
package.

III-J. Meter Comm Error Indicated

The PLC communicates with the unit’s Digital Metering Package (DMP) through a serial communication
connection. If the PLC fails to communicate with the meter, a Meter Comm Failure will indicate.
• Check meter connection wiring per unit’s drawing package.
• Check meter’s power supply connection per unit’s drawing package.

III-K. Metering Issues

Voltage: Displayed voltage zero, imbalanced or does not match system voltage:
• Check Metering Fuses MF 1-3.
• Check voltage connections from the bus to the metering transducer per unit’s drawing package.
Current / kW:
• Current Zero
♦ Check CT connections to meter.
♦ Check ground connections on CTs.

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• Current imbalanced, low, or off, or kW low, negative, or off:

♦ Check CT polarity. All CTs should be installed so that
the X1 / H1 side faces the source.
♦ Check CT connections.
♦ Check phasing. Voltage and Current inputs to the
meter must be connected exactly as shown in the
drawing package.

III-L. Automatic Load Leveling Issues

Automatic Load Leveling works off a kW feedback from the metering package. If the metering is not
reporting kW properly, the PLC may continue adding load, looking for a user-programmed setpoint.
• Check for Metering Issues as above.
• Check Load Leveling setpoints. See Section II-C-2, Auto Load Leveling Settings, for more details.

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IV. Maintenance
The load bank has been designed to require minimum maintenance. All components have been chosen
for a long, reliable life. Two basic intervals of maintenance are required: each operation and Periodically.
Periodic maintenance should be conducted at least every 6 months. Under high use applications (more
than 50 hours of run time in less than 6 months) periodic maintenance should be conducted every 3
months. A periodic maintenance check should be conducted just after installation and any time the load
bank has been relocated. Failure to conduct this maintenance can shorten the usable life of the load bank
and can result in premature component failure.

Always remove all power before doing any work inside the control cabinet or other parts of
the load bank. Be aware that load banks may have multiple sources of power (test source
power, fan/control power, anti-condensation heater power, etc.)

IV-A. Each Operation:

• Check the air intake screens/louvers, fan and cooling chamber, and exhaust openings for any obstruction
or foreign objects. Ensure that air is exiting from the exhaust vent.
• Check the entire outside of the cabinet for any visual damage, which could cause internal electrical or
mechanical problems due to reduced clearance.

IV-B. Every 50 Hours or 6 Months, or after transportation:

• Inspect and operate Motor Disconnect Switch.
• Check fan blades for stress fractures.
• Check the load branches for blown fuses or open load resistors. Operate the load bank from a balanced
3-phase source and check the 3-line currents, which should be essentially the same. If a sizeable
imbalance or reduced capacity is note, see Troubleshooting.
• Remove the side panel to open the control section and inspect all relays and control modules. Make sure
all components are secure in their bases and safety bails are in place.
• Check tightness of all electrical connections. The expansion and contraction caused by load bank
operation may over time result in loosened connections.
• Examine all accessible internal electrical components such as fuses, contactors, transformers, and
relays. Check the tightness/torque of lugged wires at these components. Refer to Appendix E for torque
specifications.
• Check cooling system by inspecting the fan motor and
blades. Check fan blades for stress fractures. Slowly
rotate blade by hand and note clearance of the blade
tip through its rotation near the housing. Observe free
rotation of motor shaft.
• Check the load element chamber for foreign objects,
broken ceramic insulators, and mechanical damage.
The load bank’s HMI will provide notification when 50
hours of operation has elapsed. Acknowledge the message
to return to the previous screen.

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Appendix A - Simplex Warranty

Simplex, Inc., warrants the industrial electrical control, test and accessory equipment and
parts and accessories thereof to be the kind and quality described in Simplex’s specifications
and to be free from defects in material or workmanship under normal service. Simplex’s
obligations under this warranty being limited to repairing or replacing, at its option, any part
or parts which shall, within twelve (12) months from date of shipment from its factory, as
indicated by serial date code on the nameplate or sales orders, be returned to Simplex or an
authorized Simplex repair station.

Simplex will supply and invoice replacement parts at normal prices upon receipt of customer’s
new purchase order including prepaid freight charges. Defective equipment or parts for
warranty credit in exchange for replacement (RMA) parts must be returned freight prepaid
within 10 days of receiving the replacement (RMA) parts. Upon examination of the returned
parts Simplex will determine if the parts are manufacturer defective and if so a credit invoice
will be issued against the replacement parts / equipment invoice.

Defective equipment or parts returned freight prepaid after 10 days may not be eligible for
warranty credit. The invoice for replacement parts will then be due.

The provisions of this warranty shall not apply to any equipment, part or accessory which

(a) has been improperly specified by buyer;

(b) has been improperly stored or handled prior to placing in service;

(c) has been improperly mounted or connected;

(d) has not been operated within specifications stated on its nameplate, label or
placard;

(e) has not been properly maintained;

(f) parts supplied by buyer for inclusion in finished equipment are not covered by this
warranty;

(g) components or assemblies specified by buyer with no substitution permissible that

are not normally used by Simplex.

Simplex reserves the right to reject warranty claims of any kind against assembled
equipment, parts or material for which Simplex has not received payment in full.

This warranty is in lieu of all other warranties, express or implied, and all other obligations
or liabilities on the part of Simplex, and Simplex neither assumes nor authorizes any other
person to assume for it any other liability in connection with any such electrical control,
test or accessory equipment or accessories or parts.

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Appendix B - Conditions of Sale

The following conditions apply without exception unless such exception is made in writing and signed by
an officer of Simplex. Simplex will, at its option, sell or rent technical industrial equipment or parts
thereof or material only on condition that buyer assumes responsibility for correct specification, storage,
installation, field adjustments when normally required, testing and appropriate training of users
technically competent personnel before release to user and that any malfunction or failure of Simplex
supplied material will be reported to Simplex immediately and that no back charges of any nature will
accrue to Simplex, without the express written consent of Simplex.
Quotations: Unless specifically stated otherwise, price quotations are based on standard pricing,
handling, delivery and warranty. Substantial alterations in details or intent of Simplex’s quotations on
buyer’s purchase order will subject buyer to additional charges based on increased cost incurred by
Simplex. Written quotations are firm for 60 days unless otherwise noted. Acceptance of orders based on
oral quotes, published literature or written quotations older than 60 days are subject to approval by an
officer of Simplex. Delivery dates are the best estimated as of date of issue. We reserve the right to
correct and/or reject quotations made on our behalf by our Sales Representatives or Agents. Unless
otherwise advised in writing by seller a minimum 10% down payment on non-standard, special equipment,
quoted to customer specification will be required prior to approval drawings being supplied. In event of
order cancellation this down payment is non-refundable. Progress payments maybe required on high value
special equipment. Such payments would require 10% down payment to cover engineering costs, 25%
payment upon receipt of customer release to production to cover material costs and balance as
determined by Simplex’s Finance Department. These payments are non-refundable in event of order
cancellation or customer default.
Delays in Manufacturing or Delivery: Seller shall not be held liable for delay in manufacturing or
delivery occasioned by causes beyond our control. In no event shall we be liable for any consequential
damages or claims for labor resulting from failure or delay in delivery.
Prices: All prices are f.o.b. Springfield, Illinois, with buyer paying all freight costs, unless allowed in
written quotation. Prices and other published data are for reference purposes only and do not imply
availability of product. Prices are subject to change without notice and prices in effect at the time of
shipment will apply to new orders and unreleased existing orders unless otherwise quoted in writing.
Minimum Billing: A minimum billing of not less than $75 will apply to all orders. Minimal fees to offset
in part extra costs incurred during order entry process, special services as ordered by customer, shipping
processes and collection efforts will be charged where applicable.
Taxes: Published or quoted pricing does not include any federal, state or local taxes. Buyer should
report any federal, state, or local taxes as may be required by local law. Penalty Clauses: Unless
specifically accepted in writing by Simplex, Price quotations do not include participation by Simplex in any
penalties or damages incurred by buyer.
Acceptance of Orders and Contracts: All orders must be bona-fide contracts detailing complete
description of material ordered, included technical specifications as quoted by Simplex, price, terms,
delivery, shipping instructions, etc. Simplex’s failure to object to any provisions contained in buyer’s
order or any other communications shall not constitute a waiver of Simplex’s terms and conditions not
acceptance of such provisions. No order shall be considered accepted unless acknowledged in writing by
Simplex.
Disputes, Judicial Forum: Actionable disputes shall be under the laws of the State of Illinois. Judicial
forum shall be the circuit court of Sangamon County, Illinois or the Federal Court, Central Region, Illinois.
Terms of Payment - Purchase Material: Net cash U.S. funds 30 days from date of invoice, which shall
be the same as date of shipment from our factory, to approved open account customer. All other orders
are cash in advance or COD. Material ordered to ship on a given date and later ordered by buyer to be
held for later shipment will be invoiced on date shipment originally scheduled or on date material
becomes available for shipment, whichever occurs later, and terms of payment will apply from that
invoice date. No cash discounts are allowed. Storage and handling charges will accrue to purchaser.
Terms of Payment - Rental Equipment or Field Service: Payable upon receipt of invoice in U.S. funds
to approved open account customers. In other cases, payment by cash in advance, COD or security
deposit.

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Appendix B - Conditions of Sale cont’d

ACH: When you provide a check as payment, you authorize us either to use information from your
check to make a onetime electronic fund transfer from your account or to process the payment as a check
transaction. When we use information from your check to make an electronic fund transfer, funds may be
withdrawn from your account as soon as the same day we receive your payments, and you will not receive
your check back from your financial institution.
Credit Cards: A processing fee may be added for credit card transactions.
Service Charges: Service charges of 1.5% per month on the unpaid balance apply from 31st day after
invoice date. Failure to pay such charges as billed may result in suspension of open account terms.
Cancellation: Upon acceptance by Simplex your order will be entered for production and will not
thereafter be subject to cancellation or deferment of delivery schedule without written consent from
Simplex. Any expenses already accumulated by Simplex due to cancellation of an order or the extra
expense of deferment of a delivery schedule will be borne by customer.
Packing and Marking: Prices include our standard packing and marking for domestic shipment within
the continental U.S. Additional expenses incurred for special packing and marking as specified by buyer
will be paid by the buyer. No allowance in lieu of packing will be made if buyer accepts material
unpacked at our factory or authorized service station.
Shipping Weights: Published shipping weights are approximate and are provided only for estimating
freight costs.
Shipments: Shipments will be made best way surface unless otherwise specified by buyer.
Responsibility for lowest cost and fastest means shipping method is the buyer’s and details are to be
specified in the buyer’s purchase order. Simplex’s responsibility ceases when the carrier signs for and
accepts shipment and claims for non-delivery of material or damage, should be filed with carrier by buyer.
Returning Material: Written authorization to return material for credit or repair or replacement must
be obtained from Simplex. Such returns are subject to restocking, exchange or repair charges with all
transportation charges paid by buyer and are subject to acceptance by Simplex. Simplex, at its option,
will apply credited amounts to buyers account, current or future balances, or issue cash refund.
Drawings: One copy of standard drawings, wiring diagrams and instruction manual conforming to
Simplex’s standard practices will be furnished per unit purchased at no charge. Prices quoted upon
request for special drawings or additional copies of standard drawings and instruction manuals.
Warranty: Simplex warrants new industrial equipment or parts or material to be the kind and quality
described in Simplex’s specifications and to be free from defects in material or workmanship under proper
conditions of application and use for period of 12 months. SEE WARRANTY FORM.

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Appendix C - Rated Resistance and Current

The following tables show expected current and line to line resistance readings at common power
levels for load banks of various voltage ratings operating at full rated voltage. To find values for other kW
levels, use the following formulas:
3Ø Current: (kW x 100)/(V x 1.732) 1Ø Current: (kW x 1000)/V
2
Resistance: (V x 2)/(kW x 1000) Resistance: V2/(kW x 1000)
Note that these calculations do not take temperature into account. Elements’ resistance will vary with
temperature conditions.
600 V Load Bank 3Ø
kW 1 5 10 20 25 50 100 200 250 500 1000
Ω 720.00 144.00 72.00 36.00 28.80 14.40 7.20 3.60 2.88 1.44 0.72
Amps 0.96 4.81 9.62 19.25 24.06 48.11 96.23 192.46 240.57 481.14 962.28

480 V Load Bank 3Ø

kW 1 5 10 20 25 50 100 200 250 500 1000
Ω 460.80 92.16 46.08 23.04 18.43 9.22 4.61 2.30 1.84 0.92 0.46
Amps 1.20 6.01 12.03 24.06 30.07 60.14 120.28 240.57 300.71 601.42 1202.85

240 V Load Bank 3Ø

kW 1 5 10 20 25 50 100 200 250 500 1000
Ω 115.20 23.04 11.52 5.76 4.61 2.30 1.15 0.58 0.46 0.23 0.12
Amps 2.41 12.03 24.06 48.11 60.14 120.28 240.57 481.14 601.42 1202.85 2405.70

208 V Load Bank 3Ø

kW 1 5 10 20 25 50 100 200 250 500 1000
Ω 86.53 17.31 8.65 4.33 3.46 1.73 0.87 0.43 0.35 0.17 0.09
I 2.78 13.88 27.76 55.52 69.40 138.79 277.58 555.16 693.95 1387.90 2775.80

240 V Load Bank 1Ø

kW 1 5 10 20 25 50 100 200 250 500 1000
Ω 57.60 11.52 5.76 2.88 2.30 1.15 0.58 0.29 0.23 0.12 0.06
Amps 4.17 20.83 41.67 83.33 104.17 208.33 416.67 833.33 1041.67 2083.33 4166.67

208 V Load Bank 1Ø

kW 1 5 10 20 25 50 100 200 250 500 1000
Ω 43.26 8.65 4.33 2.16 1.73 0.87 0.43 0.22 0.17 0.09 0.04
I 4.81 24.04 48.08 96.15 120.19 240.38 480.77 961.54 1201.92 2403.85 4807.69

120 V Load Bank 1Ø

kW 0.25 0.5 1 2 5 10 20 25 50 100 200
Ω 57.60 28.80 14.40 7.20 2.88 1.44 0.72 0.58 0.29 0.14 0.07
I 2.08 4.17 8.33 16.67 41.67 83.33 166.67 208.33 416.67 833.33 1666.67

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 Polaris Load Bank Manual — Load Marshal Control™

Appendix D - Single Phase Configuration

Simplex stationary resistive load banks designed for three phase operation may be used (at a reduced
capacity) for single phase testing when configured properly.
Three phase load banks configured for single phase operation will apply 2/3 of the load bank’s 3 phase
rated load.
Note that units which receive their control power from the test source may not be configured this way.
Only units with a separate source of control power have this option. Also note that the metering of a unit
in single phase operation will be different and therefore Automatic Load functions may not work properly.

Three phase resistive load banks may be configured for single phase according to the
diagram and description in this section, but load banks with inductive or capacitive load
components will not operate the same way. It is hazardous to connect or use any load bank
in a manner not expressly outlined in its dedicated manual.

When operating a three-phase load bank in single phase, Single Phase Operation should be selected on
the unit’s HMI so that the PLC will apply a correction factor to all step values to account for the resulting
capacity derate. See section II-C-4, Miscellaneous Settings for more information.
For single phase operation:
• Connect the source’s L1 to the load bank’s A Phase.
• Connect the source’s L2 to the load bank’s B and C Phase tied together.
• The source’s Neutral does not connect to the load bank.

L1 AØ
BØ
Power Source L2 Load Bank
CØ

March 2, 2021 • Simplex Service 800-637-8603 • Page 46 of 50

 Polaris Load Bank Manual — Load Marshal Control™

Appendix E - Torque Values

Listed in the tables below are the torque requirements for many common connections in Simplex load
banks.
For third-party manufactured components such as contactors, circuit breakers, fuse blocks, etc.,
always adhere to the torque requirements specific to those components.

Fan Blades Elements/Trays

Fan Torque Component Term Nut Torque
Part No. Bolt Size ft-lbs/in-lbs Size in-lbs

13820000 Set Screw 11.7/140 Rod Ends #6 4

13820500 Set Screw 11.7/140 Element Conn. #10 20
High Voltage 1/4 - 20 Call Simplex
13821000 Set Screw 8.3/100
13822000 1/4 - 20 7.5/90
Main Load Blocks - All Sizes
13823000 1/4 - 20 7.5/90
Connection Wire Torque
13824000 1/4 - 20 7.5/90 Size ft-lbs/in-lbs
13825100 1/4 - 20 7.5/90 Load Side 4-14 AWG 2.9/35
13826000 1/4 - 20 7.5/90 500 MCM - 4/0 31/375
13827500 5/16" 13/156 3/0 - 4/0 20/240
Line Side
13827600 5/16" 13/156 2/0 - 6 AWG 10/120
73828000 3/8" 24/288 8 AWG 3.3/40

Miscellaneous - Terminals, Switches, Coils,

Motors, Brackets, Bus Bar Connections Relays, Transformers, Meters
Grade Bolt/Nut Torque
Size ft-lbs /in-lbs Connection Torque
Size in-lbs
Grade 5, dry .250 (1/4 - 20) 8/96
4 5
Grade 2, dry .250 (1/4 - 20) 5.5/66
6 10
Grade 5, dry .312 (5/16) 17/204
8 19
Grade 2, dry .312 (5/16) 11/132
10 31
Grade 5, dry .375 (3/8) 30/360
1/4 - 20 66
Grade 2, dry .375 (3/8) 20/240
Grade 5, dry .437 (7/16) 50/600
Cam-Lock Studs
Grade 2, dry .437 (7/16) 30/360
Grade 5, dry .500 (1/2) 75/900 Connection Max Torque
Grade 2, dry .500 (1/2) 50/600 Size ft-lbs
Grade 5, dry .562 (9/16) & up 110/1320 5/16" - 18 15
Grade 2, dry .562 (9/16) & up 70/840 1/2" - 13 40

March 2, 2021 • Simplex Service 800-637-8603 • Page 47 of 50

 Contact Simplex
for all your Load Bank and Fuel Supply needs.

Simplex, Inc.
5300 Rising Moon Road
Springfield, IL 62711
800-637-8603
www.simplexdirect.com

This manual and all of its contents

Copyright © 2021 Simplex, Inc.
All Rights Reserved.