Load Bank Maintenance | Simplex Direct

Load Bank Maintenance Schedules

Simplex Load Banks are 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 "Every 50 Hours of Operation or 6 Months" (whichever comes first.)

Each Operation

The air intake screens and louvers, fan and cooling chamber, and exhaust openings must be checked for any obstructions or foreign objects. Check fan blades for stress fractures. Due to the high volume of air circulated, paper and other items can be drawn into the air intakes. During Load Bank operation, we ensure that air is exiting from the top exhaust vent.

The load branches should be checked for blown fuses or opened load resistors. To check the fuses or load resistors, operate the Load Bank from a balanced 3-phase source and check the three-line currents. The three current readings should be essentially the same. If a sizable difference is noted one or more load fuses or load resistors may have malfunctioned.

WARNING - For continued safety and for maximum equipment protection, always replace fuses with one of equal rating only.

50 Hours or 6 Months

Every 50 Hours of Operation or 6 Months (Whichever Comes First)

Check the tightness of the electrical connections. The expansion and contraction caused by Load Bank operation may result in loose connections. The vibrations caused by the cooling fan may also loosen electrical connections. If the Load Bank is transported “over the road”, the electrical connections should be checked for tightness at a shorter-than-normal time interval.

Motor Lubrication

Motors are properly lubricated at the time of manufacture. It is not necessary to lubricate at the time of installation unless the motor has been in storage for a period of 12 months or longer (refer to lubrication procedure below).

Inspect the fan motor supplied with your Load Bank for grease fittings. If the motor contains grease fittings you must lubricate the motor. If lubrication instructions are shown on the motor nameplate, they will supersede this general instruction. Belt driven cooling fans have bearings which should be lubricated. Bearings should be lubricated every 50 hours of operation or 6 months whichever comes first. The bearings which are used on Saturn Stationary Load Banks require special installation and relubrication. See Bearings tab for additional information.

WARNING - Over greasing is a major cause of bearing and/or motor failure. The amount of grease added should be carefully controlled. Also make sure dirt and contaminants are not introduced when adding grease.

Lubrication Procedure

Stop motor. Disconnect and lock out of service.
Remove contaminants from grease inlet area.
Remove filler and drain plugs.
Check filler and drain holes for blockage and clean as necessary.
Add proper type and amount of grease. Below, see the Relubrication Time Intervals table for service schedule and Relubrication Amounts table for volume of grease required.
Wipe off excess grease and replace filler and drain plugs.
Motor is ready for operation.

WARNING - If motor is nameplated for hazardous locations, do not run motor without all of the grease or drain plugs installed.

Grease Type

Unless stated otherwise on the motor nameplate, the motors on this Load Bank are pregreased with a polyurea mineral oil NGLI grade 2 type grease. Some compatible brands of polyurea mineral base type grease are:

Chevron SRI #2
Rykon Premium #2
Exxon Polyrex EM
Texaco Polystar RB

Relubrication Intervals

Relubrication Time Intervals for Motors with Regreasing Provisions

NEMA Frame Size	140 - 180		210 - 360		400 - 510
RPMs	0 to 1800	1,800 +	0 to 1800	1,800 +	to 1800	1,800 +
Standard Use	3 Yrs	8 Mos.	2 Yrs.	8 Mos.	1 Yr.	3 Mos.
Severe Use	1 Yr	3 Mos.	1 Yr.	3 Mos.	6 Mos.	1 Mos.
Seasonal	Lubricate at the beginning of the season. Then follow service schedule above.

STANDARD: Up to 16 hours of operation per day, indoors, 100°F maximum ambient.

SEVERE: Greater than 16 hours of operation per day. Continuous operation under high ambient temperatures (100° to 150°F) and/or any of the following: dirty, moist locations, high vibration (above NEMA standards), heavy shock loading, or where shaft extension end is hot.

SEASONAL: The motor remains idle for a period of 6 months or more.

NOTE:

For motors nameplated as “belted duty only” divide the above intervals by 3.
Lubricate at the beginning of the season. Then follow service schedule above.

Relubrication Amounts


NEMA Frame Size	140	180	210	250	280	320	360	400	440	500
Volume (cu. in.)	.25	.50	.75	1.00	1.25	1.50	1.75	2.25	2.75	3.00
Volume (fluid oz.)	.14	.28	.42	.55	.69	.83	.97	1.2	1.5	1.7

Bearings

Saturn Stationary Load Bank Bearings

These instructions pertain to the bearings used on Saturn Load Banks. See Parts Legend Drawing for the specific bearing used for your unit. It is important that these instructions are read in their entirety before attempting installation and removal. The procedures indicated should be carefully followed. Failure to do so can result in improper installation which could cause bearing performance problems as well as serious personal injury.

Bearings In Bolt-On Housings (Units)

Check Area - Clean and organize bearing installation area, keep well lighted. Be sure mounting surfaces are clean and flat.
Check Shaft - Shaft should be within tolerance range shown in Table #1, clean and free of nicks and burrs. Mount bearing on unused section of shaft or repair/replace shafting as required.
Install Unit - Slide unit onto shaft. If it is difficult to mount bearing on shaft, use a piece of emery cloth to reduce any high spots on the shaft. Do not hammer on any component of the bearing.

Table #1 - Shafting

Shaft Diameter	Shaft Tolerance
2–3 3/16 in. (50–80 mm)	+0 to -0.0010 in. (+0 to -.25 mm)

Fasten Unit In Place - Install housing mounting bolts, check and align bearing and tighten mounting bolts to recommended fastener torques. Exercising extreme caution and safety, rotate shaft slowly to center bearing.
Skwezloc® Inserts: a) Be sure that the Skwezloc® collar is fitted square and snug against the shoulder on the inner ring. b) Torque the Skwezloc® collar cap screw to torque recommended in Table #2.
Monitor Installed Bearing - After bearing has been run for several minutes, and again after several hours, check bearing for excessive noise or vibration. Shutdown machine and check housing temperature: typical applications operate at 100°F – 150°F (38°C –66°C) (Similar feel to household hot tap water temperature). Tighten all locking devices after 500 hours or 3 months, whichever comes first.

Table #2 - Skwezloc® Collar Tightening

English Screw Size	Hex Size	Torque (in-lbs.)	Torque (N-m)
#8-32	T-25	65 – 70	7 – 8
#10-24	T-27	90 – 100	10 – 11
1/4-20	T-30	220 – 240	25 – 27
5/16-18	T-45	450 – 495	51 – 56

Relubrication Instructions

Sealmaster® GoldPlex™-HP has been developed based on the performance characteristics of Sealmaster® brand bearings. Sealmaster® brand bearings are factory fi lled with GoldPlex™-HP and do not need to be greased upon initial installation. GoldPlex™-HP lithium complex base, petroleum oil, NLGI grade 2 consistency. If not using GoldPlex™-HP grease, Table #3 is given as a very general recommendation for typical lithium or lithium complex, petroleum oil, NLGI#2 greases. Contact the grease supplier for a more specific lubrication schedule.

Relubricatable SealMaster® brand bearings are supplied with grease fi ttings or zerks for ease of lubrication with hand or automatic grease guns. Always wipe the fi tting and grease nozzle clean. For safety stop rotating equipment. Add one half the recommended amount shown in Table #4. Start bearing, and run a few minutes. Stop bearing and add the second half of the recommended amount. A temperature rise, sometimes 30°F, after relubrication is normal. Bearing temperatures should not exceed 250°F (121°C). For any applications that are not in the ranges of the table, contact Sealmaster® for suffix modified bearings that can handle temperatures up to 400°F (204°C).

Note: Table #3 and Table #4 state general lubrication recommendations based on our experience and are intended as suggested or starting points only. For best results, specific applications should be monitored regularly and lubrication intervals and amounts adjusted accordingly.

Table #3 - Lubrication Schedule for Sealmate® GoldPlex™-HP

Contamination Level - Clean to Light
Bearing Temperature	500 RPM to 1000 RPM
-50°F to -30°F	12-24 Months
-30°F to 120°F	12-24 Months
120°F to 180°F	6-12 Months
180°F to 250°F	3-6 Months
Contamination Level - Medium
Bearing Temperature	500 RPM to 1000 RPM
-50°F to 120°F	1 Week - 1 Month
120°F to 250°F	Daily - 2 Weeks
Contamination Level - Heavy
Bearing Temperature	500 RPM to 1000 RPM
-50°F to 250°F	Daily - 2 Weeks

Compatibility of grease is critical, therefore, if not using Sealmaster® GoldPlex™-HP, consult your grease supplier to ensure compatibility. GoldPlex™-HP is a lithium complex base grease, petroleum oil, NLGI grade 2 consistency.

Table #4 - Recommended Relubrication Crease Charge

Shaft Size (in.)	Oz.	Shaft Size	Grams
2 to 2 7/16	0.30	55-60	8.51

Application Assistance

Please contact Application Engineering at:
Phone: (219) 465-2211
Fax: (219) 465-2263
Email: sealmaster.engineering@emerson-ept.com

Sealmaster® brand ball bearings now incorporate a unique, color-coding system to help identify the type of grease in the bearings. Each relubricatable Sealmaster® brand bearing features colored fitting cap to help indicate the type of grease used in the individual bearings. Below is a list of the colored fitting caps and the type of grease they represent.

YELLOW - Yellow grease fitting caps indicate that bearings are filled with Sealmaster® GoldPlex™-HP high performance mounted bearing grease.

RED - Red grease fitting caps indicate that bearings are filled with factory standard high-temperature grease. (Lithium complex base with synthetic hydrocarbon oil).

WHITE - White grease fitting caps indicate that bearings are filled with factory standard good grade grease. (Aluminum complex with synthetic oil).

BLACK - Black grease fitting caps indicate that bearings are filled with a non-standard grease.

Trailer Maintenance

Item	Function Required	At Each Use	Weekly	3 Months or 3,000 Miles	6 Months or 6,000 Miles	12 Months or 12,000 Miles
Brakes	Test that they are operational	X
Break Adjustment	Adjust to proper operating clearance			X
Break Magnets	Inspect for wear and current draw				X
Brake Linings	Inspect for wear or contamination					X
Break Controller	Check for correct amperage and modulation				X
Brake Cylinders	Check for leaks, sticking					X
Brake Lines	Inspect for cracks, leaks, kinks					X
Trailer Brake Wiring	Inspect wiring for bare spots, fray, etc.					X
Breakaway System	Check battery charge and switch operation	X

XWheel Bearings & CupsInspect for corrosion or wear. Clean and repackXSealsInspect for leakage. Replace if removed.XSpringsInspect for wear, loss of arch.XSuspension PartsInspect for bending, loose fasteners, wear.XHangersInspect WeldsXWheel Nuts and BoltsTighten to specified torque valuesXWheelsInspect for cracks, dents or distortionXTire Inflation PressureInflate tires to manufacturer's specifications.X