Large
Portable

Merlin
100KW
150KW
200KW
250KW
300KW
350KW
400KW

Merlin Portable Load Bank

The Simplex Merlin is a dual voltage (240/480V), fine load step resolution, fully instrumented portable Load Bank intended for shop or field use by engine generator dealers and service shops for maintenance, testing and performance proving of engine generator sets, UPS and other power systems in the 50-400KW range.

The Merlin is a totally self-contained testing system. It includes all resistive load elements, load control devices, load element circuit protective devices, connection cable set, cooling system, malfunction detection system, control power supply and test instrumentation.


Control Panel

Voltmeter, Ammeter, and Frequency Meter

Fan Reversal, Volt-Ammeter, Ammeter Range, Load Voltage Selector, and Control Voltage Selector switches

Fan/Control Power pushbutton

Cooling Failure, Load Over Voltage, and Control Over Voltage indicator lamps

Master load toggle switch and load step toggle switches 

Hinged Access Door to Fuses and Contactors



Features

Exceptionally rugged, all welded, formed steel chassis

Utilizes the UL Recognized “Powr-Web” load element

Branch circuit fuse protection of load elements

Lifting eyes, forklift channels and casters

Moving handle

Connection cable set

Powr-Web Load Element

Simplex Load Banks utilize the UL Recognized, “Powr-Web” load element. The “Powr-Web” is an advanced design, air-cooled power resistor specifically designed for application to load bank systems. The “Powr-Web” is conservatively operated at half the maximum temperature rating of the alloy and features a short-circuit-safe design based on continuous mechanical support of the resistor by high temperature, ceramic clad stainless steel rods. The “Power Webs” are assembled into discrete trays which are assembled in a vertical “stack.” Each tray in the “stack” is independently serviceable without disturbing adjacent trays.

Ratings
3333W at 120V
4170W at 139V
8333 watt 240/480V
16,777 watt at 480V

Specifications
Alloy: FeCrAl
Max. continuous temp. rating: 1920°F
Maximum operating temperature as applied in Load Bank: 1080° F
Cool down time from operating to ambient temperature: 10 seconds

Construction
Calibrated to specific ohm value
Welded lugs on each end
All load elements are continuously supported by vibration resistant, ceramic clad, stainless steel throughrods

Branch Circuit Fuse Protection

The load of a Resistive Load Bank consists of a dense array of open, uninsulated power resistors mounted within a cooling air stream. Since the elements are electrically live, it is possible for a foreign object to penetrate the element array and create a short circuit of adjacent elements or a short to ground. Since the elements are densely packed, it is possible for a short circuit, once started, to rapidly propagate through the entire element array. As a Load Bank represents a relatively large amount of power concentrated within a relatively small volume, a self-propagating, cascading short circuit would have catastrophic results.

Simplex virtually eliminates the dangers of short circuit through the use of branch circuit fuse protection of the load elements. Per NEC 110-10, protective devices shall clear a fault without “extensive damage” to the circuit components. A Simplex Load Bank is divided into branch circuits of not more than 50 KW each.