MARS

700KW-1250KW
STATIONARY LOAD BANK
 Last Revision Date: June 8, 2021
For the most up-to-date information for this product and others,
please contact Simplex, Inc. at (800) 637-8603 or
visit us on the web at http://www.simplexdirect.com.
 Table of Contents
1 Warnings and Cautions......................................................... 1
Safety information symbols 1
Cautions 1
2 Nameplates and Placards...................................................... 5
3 Description and Specification............................................... 9
Overview of Use 9
Control System 9
Cooling System 9
Load System 9
Safety 9
4 Unpacking............................................................................11
Included Components 11
Primary Inspection 11
5 Installation...........................................................................13
Load Bank Placement 13
Installation Procedure 15
Remote HMI installation 16
Load Dump installation 17
Current Transformer installation 18
MODBUS installation 20
Heater installation 21
BMS/BAS Installation 22
6 Setup.....................................................................................23
General Settings 23
Automatic Mode 23
7 Operating Instructions........................................................25
Pre-operation checks 25
Setting up the test 25
Testing operation 26
Metering (if equipped) 26
Shutdown and cooling 26
8 Automatic Mode ..................................................................27
Overview 27
Setting Up Automatic Mode 28
Entering Automatic Mode 28
 9 Maintenance/Troubleshooting...........................................29
General maintenance 29
Each Operation 29
Every 6 Months 29
Troubleshooting 30
10 Alarms and Warnings...........................................................31
Alarms 31
Warnings 31

Appendix A — PARTS LISTINGS............................................................33

Appendix B — MODBUS CONTROLS ....................................................49
Modbus Control Directions 52
 Table of Figures
Current draw at specified resolutions (in kilowatts).......................... 10
Clearance requirements............................................................................... 14
Conduit Opening............................................................................................ 15
Ground Bus....................................................................................................... 15
Main Load Bus................................................................................................. 15
HMI TBH............................................................................................................. 16
Serial Adapter.................................................................................................. 16
TB-DC.................................................................................................................. 16
Load Dump Jumper....................................................................................... 17
Current Transformers.................................................................................... 18
CT Orientation................................................................................................. 18
TB-CT................................................................................................................... 18
Current Transformer placement for Metering...................................... 19
Current Transformer placement for Auto/Regen. Mode.................. 19
TB-COM.............................................................................................................. 20
Modbus Serial Converter............................................................................. 20
TB-SH................................................................................................................... 21
TBR....................................................................................................................... 22
Setup Screen.................................................................................................... 23
General Settings............................................................................................. 23
HMI Information.............................................................................................. 26
Alarm History................................................................................................... 26
Automatic/Regenerative Mode................................................................. 27
Setup Screen.................................................................................................... 27
Automatic Mode Setup................................................................................ 27
Automatic Mode Running........................................................................... 28
Troubleshooting............................................................................................. 30
Troubleshooting alarms............................................................................... 32
Right Subpanel Layout................................................................................. 33
Option D - Automation/Metering............................................................ 34
Option B - Communication (TCP/IP Data Logging)............................ 35
PLC Component list....................................................................................... 36
Control Relays.................................................................................................. 38
Terminal Blocks................................................................................................ 40
Option 010 - Space Heaters........................................................................ 42
Center Subpanel............................................................................................. 44
Phase A Detail.................................................................................................. 45
Phase B Detail.................................................................................................. 46
Phase C Detail.................................................................................................. 47
Load Control Terminal Blocks .................................................................... 48
Modbus Controls (Read/Write).................................................................. 49
Modbus Indications (Read only)............................................................... 50
1 WARNINGS AND CAUTIONS
Safety The following images indicate important safety information:
information
This General warning symbol points out important
symbols
information that, if not followed, could endanger
personal safety and/or property.

This Explosion warning symbol points out

! potential explosion hazards.

!
This Fire warning symbol points out potential fire
hazards.

This Electrical warning symbol points out potential

electrical shock hazards.

Cautions This load bank is high-powered, technical, industrial

equipment operating at dangerous voltages and temperatures. It
is capable of damaging itself, property or personnel if improperly
used. It is not a consumer product.
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.

All compression-type connections on fuse blocks, load blocks,

and contactors should be checked for tightness frequently. This
check should be established as part of routine maintenance.
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
Warnings and Cautions — 1
 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 and
asphalt roofs, water sprinkler heads, fire alarms, and volatile
material.
• Do not use in confined spaces. Do not allow the load bank’s
feet to sink into soft surfaces thereby cutting off bottom air
intake. 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 usage before connecting the load bank to the
source to be tested.
• The load cables carry high amperage. Be constantly aware of
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.
• 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 have 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
2 — Warnings and Cautions
 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 nonconducting implement, such as a dry rope or board,
to free the victim from the live conductor. If the victim is
unconscious, apply 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.
• Keep a fire extinguisher near the hardware at all times.
Do NOT use any carbon tetra-chloride type extinguisher.

! Its 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.
• Load Bank warranty is void if incorrectly cooled.

Warnings and Cautions — 3

2 NAMEPLATES AND PLACARDS

(800) 637-8603
www.simplexdirect.com

Nameplates and Placards — 5

 (800) 637-8603
www.simplexdirect.com

6 — Nameplates and Placards

WARNING - DANGER - WARNING
High Voltage: Turn off and disconnect power source before opening
this compartment

High Temperature: Allow equipment to cool before servicing or

opening this compartment

Rotating Equipment: Assure that fan has stopped before opening

this compartment

For Operator Safety: Make sure this equipment is properly

grounded when in use

All compression type connections on fuse blocks, load blocks, and

contactors where used, should be checked for tightness frequently.
This check should be established as part of routine maintenance.

PN 24055502

Nameplates and Placards — 7

3 DESCRIPTION AND SPECIFICATION
Overview of Simplex Mars load banks are precision test instruments
Use designed to apply a selectable load to a power source and measure
the source’s response. They are used for routine maintenance
exercise to ensure the long-term reliability and readiness of the
standby generator. Load banks can also eliminate the detrimental
effects of unloaded operation of diesel engine generators as well
as prevent damage from reverse power generation.
Mars load banks are available in models ranging from 700
kilowatts up to 1250 kilowatts. All standard Mars models have a
step resolution of 25 kilowatts.
Standard Mars units are designed to operate in ambient
temperatures between 5 and 125 degrees Fahrenheit. For colder
temperatures, an Arctic Duty load bank is required.

Control Mars load banks feature a Human-Machine Interface (HMI)

System touchscreen, which controls 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.
The load bank can also be integrated into your facility’s BMS/
BAS system via standard Modbus RS-485 or optional Modbus
TCP/IP, as well as a set of dry contacts for status reporting.

Cooling Mars load banks are cooled by forced air, delivered by an

System aluminum fan blade directly driven by a TEFC motor. The
air is brought in on the bottom of the load bank and expelled
through the top. 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 discrete trays, which are
independently serviceable.

Safety The Mars is protected by sensors to ensure that the load bank
is sufficiently cooled and that the exhaust does not exceed a safe
Description and Specification — 9
 temperature, which could damage the load bank or present a
safety hazard to the operator. When a failure occurs, the safety
system immediately removes the load to protect the equipment
from permanent damage.
Table 1 Current draw at specified resolutions (in kilowatts)

700 725 750 775 800

416V 972A 1006A 1041A 1076A 1110A
480V 842A 872A 902A 932A 962A
600V 674A 698A 722A 746A 770A

825 850 875 900 925 950

416V 1145A 1180A 1214A 1249A 1284A 1318A
480V 992A 1022A 1052A 1083A 1113A 1143A
600V 794A 818A 842A 866A 890A 914A

975 1000 1025 1050 1075 1100

416V 1353A 1388A 1423A 1457A 1492A N/A
480V 1173A 1203A 1233A 1263A 1293A 1323A
600V 938A 962A 986A 1010A 1034A 1058A

1125 1150 1175 1200 1225 1250

416V N/A N/A N/A N/A N/A N/A
480V 1353A 1383A 1413A 1443A 1473A 1504A
600V 1083A 1107A 1131A 1155A 1179A 1203A

These measurements are based on ideal numbers. They do not take into account
control power draw, power cable resistance, voltage droop, etc.

10 — Description and Specification

 4 UNPACKING
Included The following items are included with your load bank. If any
Components of the following are not included, please contact Simplex Direct
at 800-637-8603.

1. Load bank
2. Controller (remote or local)
3. Manual
4. Drawing package

Optional equipment

1. Additional controllers
2. Exhaust hood
3. Current transformers
4. Other optional equipment

Primary Before installing your Mars, inspect the shipping crate and
Inspection load bank. Physical or electrical problems could arise from
handling and vibration. Never apply power to a load bank before
performing this procedure. The following five-point inspection
is recommended before installation and as part of a 6-month
maintenance schedule or when the load bank is relocated:

If any 1. If the crate shows any signs of damage, examine the load
problems bank in the corresponding areas for signs of initial problems.
are observed 2. Check the entire outside of the cabinet for any visual damage,
during which could cause internal electrical or mechanical problems
Primary due to reduced clearance.
Inspection, 3. Open the control panel door and inspect all relays and
call Simplex control modules. Make sure all components are secure in
24 hours a their bases and safety bails are in place. Spot-check electrical
day at connections for tightness. If any loose connections are found,
800-637-8603 inspect and tighten all remaining connections.
4. Examine all accessible internal electrical components such
as fuses, contactors, and relays. Check lugged wires at these
components.
5. Check the load element chamber for foreign objects, broken
ceramic insulators, and mechanical damage.

Unpacking — 11
 5 INSTALLATION
Load Bank Normally equipped, Mars Figure 1 Air Flow
Placement load banks are intended
for outdoor installation. A
forced air system, which
discharges out of the top
of the unit, cools the load
elements (See Figure 1 Air
Flow.) Load banks require
large quantities of air
Improperly circulation, so it is essential
installing to install the unit in an
this unit may area that provides adequate
result in airflow. Before conducting
damage or load tests, a review of site
destruction conditions by trained
of the personnel is recommended.
load bank,
The load bank requires at
adjacent
least 20 feet of vertical clearance; 6 feet of clearance on the front,
equipment,
left, and right; and 1.5 feet of clearance in the rear (see “Figure 2
and the
Clearance requirements” on page 14).
building
housing the The load bank should be placed in a secure area accessible by
unit. trained personnel only.
Because the unit generates a lot of heat, never operate near
sprinkler systems.
Operating the load bank in a confined space will recycle hot
exhaust air through the cooling system, which can cause severe
damage.
The load bank may compete with nearby generators for
cooling air.

Installation — 13
 Figure 2 Clearance requirements

14 — Installation
 Installation 1. To bring in the source’s Figure 3 Ground Bus
Procedure power cables, pull holes
in the Conduit Opening,
located in the bottom of
the load bank’s control
panel enclosure (see
Mars load Figure 5 Conduit
banks feature Opening).
a power 2. Confirm the test source is
outlet in the properly grounded.
control panel 3. Ground the load bank
for your use. by connecting the
This outlet is Grounding Bus to an earth
limited to 2 ground or grounding rod. Figure 4 Main Load Bus
amps. See Figure 3 Ground Bus
4. Connect the source’s
power output to the load
bank via the Main Load
Bus with appropriately
sized cables (see Figure 4
Main Load Bus).

Figure 5 Conduit Opening

Installation — 15
 Remote HMI If your HMI is installed Figure 6 HMI TBH
installation directly on the load bank,
skip to the next section.

1. Mount the HMI where

desired.
2. Connect the HMI to the
Load Bank by swinging
the HMI’s screen out to
expose the TB-H terminal
block (see Figure 6 HMI
TBH) and wiring it to the
Load Bank.
A. Using a Belden 9841 Figure 7 Serial Adapter
or equivalent cable,
make the following
connections between
the HMI’s TB-H
terminals to the Serial
Adapter (see Figure 7
Serial Adapter).
1. TB-H 4 → TXD+
2. TB-H 5 → TXD-
3. Wire shielding →
COM B
B. Using a copper wire, Figure 8 TB-DC
14AWG or larger,
rated at 60C or
higher, connect the
HMI’s TBH 1 to the
load bank’s TB-DC
1 terminal and the
HMI’s TBH 2 to the
load bank’s TB-DC 3
terminal (see Figure 8
TB-DC).

16 — Installation
 Load Dump If the Load Dump Figure 9
installation feature is desired, remove Load Dump Jumper
the factory-installed
jumper at TB-R 1–2 and
connect customer-supplied
Load Dump contacts to
TB-R 1–2 (See Figure 9
Load Dump Jumper). To
dump the load, open the
customer-supplied contact.
To enable load, close the
customer-supplied contact.

Installation — 17
 Current If your load bank is Figure 10
Transformer equipped with Metering, Current Transformers
installation Automatic Mode or
Regenerative Mode options,
you will have to install
current transformers on
your power cable.

• For metering mode,

install the current
transformers on the load
bank leg of your power
system (see “Figure 13
Current Transformer
placement for Metering” Figure 11
on page 19.) CT Orientation
• For Automatic/
Regenerative Mode,
install the current
transformers on the power
source leg (see “Figure 14
Current Transformer
placement for Auto/
Regen. Mode” on page
19.)
The current Orient the current
transformers transformers so that the XI or
must be HI on each ring is facing the Make sure the XI or HI on the
placed and power source (see Figure 11 ring faces the power source.
oriented CT Orientation.)
correctly to Figure 12 TB-CT
When the current
ensure they
transformers are installed,
accurately
connect them to the load
detect the
bank by connecting the
current. The
white wire of the current
first current
transformer on Phase A to
transformer
TB-CT 1 and the black wire
must be
to TB-CT 2. If a second
installed on
current transformer is
Phase A, and
installed on Phase C, connect
the second
its white wire to TB-CT 3
must be
and its black wire to TB-CT
installed on
4 (see Figure 12 TB-CT.)
Phase C.

18 — Installation
 Figure 13
Current
Transformer
placement for
Metering

Figure 14
Current
Transformer
placement for
Auto/Regen.
Mode

The first current transformer must be installed on Phase A, and the second must be
installed on Phase C.

Installation — 19
 MODBUS The Mars load bank Figure 15 TB-COM
installation supports the Modbus
protocol, implemented
either as RS485 or TCP/
IP (which is an optional
upgrade).
To implement Modbus
control and monitoring,
connect the load bank to
your facility’s systems as
follows:
For RS485:
Figure 16 Modbus Serial
1. Connect the RS485+ line Converter
to TB-COM 1
2. Connect the RS485- line
to TB-COM 2
3. Connect the wire
shielding to TB-COM
Terminal 3

For Optional Modbus

TCP/IP

1. Plug a CAT5e cable

into the ethernet jack
on the MODBUS Serial
Converter (see Figure 16 Modbus Serial Converter.)
The Polaris Modbus control set is implemented as detailed in
“Appendix B — Modbus controls” on page 49

20 — Installation
 Heater Mars load banks are Figure 17 TB-SH
installation equipped with space heaters
for cold weather operation
and to prevent condensation,
which can damage the
unit. The heaters require
a dedicated power source
independent of control
power at all times to prevent
startup failure due to cold
environments.
To run power to the
heaters:

1. Run a 120V, 15A, 1-phase power cable into the control panel.
2. Connect the Line leg of the power cable to SH-1
3. Connect the Neutral leg of the power cable to SH-2
4. Connect the Ground leg of the power cable to SH-3
The heaters are set at 50 degrees Fahrenheit. If a different
temperature is required, adjust the red thermostat on the front
of the heater.

Installation — 21
 BMS/BAS The Polaris provides a Figure 18 TBR
Installation set of Remote Signal Dry
Contacts, which allow you to
integrate the load bank into
your Building Management
System (BMS) or Building
Automation System (BAS)
The dry contacts provide an
alarm message, letting you
know if the load bank has
failed.
To enable BMS/BAS
functionality, wire three
cables to TBR 5-7. Continuity between TBR 5 and TBR 6 indicate
normal load bank operation, and continuity between TBR 5 and
TBR 7 indicate load bank failure.

22 — Installation
 6 SETUP
The Mars load bank offers Figure 19 Setup Screen
a number of configuration
Mars load options through its setup
banks feature screens. You can access the
a power setup screens by pressing “F4
outlet in the - Setup” or the F4 function
control panel key.
for your use.
This outlet is At the main setup screen,
limited to 2 you are presented with four
amps. options:

1. General Settings
2. Automatic Mode Settings
3. Test Mode (Intended only for Simplex engineers)
4. Factory Setup (Intended only for Simplex engineers)

You can access General Settings and Automatic Mode

Settings by pressing their respective buttons.

General General Settings presents Figure 20 General

Settings three fields: Settings
1. Cooldown Delay (sec)
2. Intake Temp Warning (F)
3. Exhaust Temp Alarm (F)
Cooldown Cooldown Delay
Delay should determines how long the
not normally load bank fans will continue
be changed. running after an operation has been concluded. Intake Temp
Warning determines at what temperature the load bank will
present a warning that the air being used for the forced air
cooling system is too hot.
Exhaust Temp Alarm determines how hot the exhaust must
be before the load bank will trigger an Exhaust Temp High alarm
and remove the load. This and Intake Temp Warning may need
to be changed at installation, depending on the climate.

Automatic Automatic Mode Settings specify the operation of Automatic/

Mode Regenerative Mode. For information about how to set them up,
see “Setting Up Automatic Mode” on page 28.
Setup — 23
 7 OPERATING INSTRUCTIONS
Pre-operation 1. Start the generator or Figure 21 Fan/Control
checks source being tested. Power Disconnect Switch
2. Ensure the load bank’s
Fan/Control Power
Mars load
Disconnect Switch,
banks feature
located on the unit’s door,
a power
is in the on position (see
outlet in the
Figure 21 Fan/Control
control panel
Power Disconnect
for your use.
Switch.)
This outlet is
3. Check the load bank’s
limited to 2
intake areas, located on
amps.
the bottom of the unit, to
ensure that the vents are
not blocked by paper or Figure 22 Control Power
other debris that would Button
prevent the cooling fan
from pulling in air.
4. On the HMI, turn on the
load bank by pressing the
Control Power button in
the upper left corner of
the screen (see Figure 22
Control Power Button.) Figure 23 HMI - Manual
5. Listen to the load Mode
bank’s fan to ensure it is
operating normally.

When the fan is running

Setting up the properly, you are ready to
test begin testing.
Press the F1 function
Figure 24 HMI -
key or “F1 - Manual Mode”
Numeric keypad
on the screen to bring up
Manual Mode (See Figure
23 HMI - Manual Mode). In
the upper right area of this
screen is a display indicating
the load to be applied,
measured in kilowatts. To
change this value, touch the
Operating Instructions — 25
 number and enter the new Figure 25 HMI
value on the numeric keypad Information
that appears (see Figure 24
on page 25). Enter the
desired value and press the
↵ button to return to the
previous screen, or press
“Esc” to return to the main
screen without changing the
value.
In the lower right quadrant of the screen is the KW Jog
value. This indicates by how many kilowatts you will increase
or decrease the load by pressing the “-” and “+” buttons,
respectively. To change this value, press the number and enter
your choice using the numeric keypad.

Testing To begin testing, press the “Master Load” button. This will
operation activate the load bank and begin applying the load displayed
in the upper right area of the screen. To quickly decrease or
increase the load, press the “-” and “+” buttons.

Figure 26 Alarm History

Metering (if If you have purchased the
equipped) metering upgrade, pressing
the F3 function key or “F3 -
Information” on the screen
while the test is running will
bring up the metering screen
(see Figure 25). Here you can
monitor the voltage, current,
load applied to the source,
and the frequency of the electricity. This screen also displays the
temperatures registered by the load bank’s three sensors.
If any of three voltage or current values are significantly different
from the other two, check the load bank for a blown fuse. If no
blown fuse is found, contact Simplex service at 800-637-8603.
Pressing “Alarm History” on this screen will bring up a list of
registered alarms (See Figure 26.)

Shutdown and When the test is complete, press the Master Load button then
cooling the Control Power button to remove the load from the test source.
The load bank’s fan will continue running for the duration of the
cooldown delay (see page 23 for more information).

26 — Operating Instructions
8 AUTOMATIC MODE
Figure 27 Setup Screen
The Mars load bank can
be equipped with an optional
automatic mode, which will
extend your generator’s life
by protecting it against wet-
stacking and reverse current.

Overview Automatic Mode adds Figure 28 Automatic

load when the load bank Mode Setup
detects that your generator
isn’t operating in its optimal
range.
When your load bank
is installed, a set of current
transformers will be installed
on your generator’s power
lines to monitor the load on
your system. When the load bank detects that the power draw
has fallen below a preset range, it begins adding load until the
draw on the generator is within the designated range. Should the
load bank determine that the power draw has increased beyond

10%
10%

Figure 29 Automatic/Regenerative Mode

In this illustration, the load bank has been set up for an
800KW generator. The Target Load is set at 560KW, with 10%
Max Deviation. So long as the load remains in the green area,
the load bank will not add or drop load. But if the load moves
into the red area, the load bank will adjust the load to move it
back into the green.
Automatic Mode — 27
 the preset maximum value, Figure 30 Automatic
it begins removing load until Mode Running
the draw is back within the
designated range.

Setting Up Before you activate

Automatic Automatic Mode, you must
Mode configure the load bank to
interact with your generator.
The values Enter the Automatic mode
you will need setup screen by pressing the “F4 Setup” button on the screen or
to set up the F4 function key to reach the Setup Screen, then pressing the
this mode Automatic Mode Settings button (see “Figure 27 Setup Screen” on
are specific page 27.)
to your
On the setup screen will be five options specific to Automatic
generator.
Mode. (See “Figure 28 Automatic Mode Setup” on page 27.)
For example,
if you have an • Target load (KW): Sets the target load you want on your
800 kilowatt generator, measured in whole kilowatts.
generator • Max Deviation (%): Determines how far above and below your
with a 60% to target load is acceptable, measured in whole percentage points.
80% optimal • Step Up Delay (sec): Determines how fast the load bank will
operating add sequential load steps, measured in whole seconds.
range, you • Step Down Delay (sec): Determines how fast the load bank
might set will remove sequential load steps, measured in whole seconds.
Target Load • Startup Delay (sec): Determines how long the load bank will
to 560 (which wait before adding load once the power draw has dropped below
is 70% of its the lower limits established by Target Load and Max Deviation,
capacity) measured in whole seconds.
and Max
To change any of the values, press the value and a numeric
Deviation to
keypad will come up. Use it to enter a new value the same way you
10%.
would enter a load to apply. (See page 25 for more information
about using the numeric keypad.)

Entering When your load bank is configured, return to the main screen
Automatic by pressing the “Back” button. From the Main screen, press the
Mode “F2 - Auto” button or the F2 function key to enter the Automatic
Mode screen (See Figure 30 Automatic Mode Running.)
On the Automatic Mode screen, press the “Auto Mode”
switch. Once this mode is enabled, the load bank will monitor
your generator and step the load up or down as necessary.
Once configured and enabled, your load bank can remain in
Automatic Mode indefinitely.
28 — Automatic Mode
 9 MAINTENANCE/TROUBLESHOOTING
General The load bank has been designed to require minimum
maintenance maintenance. All components have been chosen for a long,
reliable life. Two basic intervals of maintenance are required:
each operation and every 6 months.

Each • Check the air intake screens and louvers, fan and cooling
Operation chamber, and exhaust openings for any obstructions or
foreign objects.
• Check fan blades for stress fractures.
• Check the exhaust vent for obstructions
Remove all • Check the load branches for blown fuses or opened load
power from resistors.
the load bank
before To check the fuses or load resistors, operate the load bank
servicing the from a balanced 3-phase source and check the three line
unit. 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.

Every 6 Check the tightness of the electrical connections. The

Months expansion and contraction caused by load bank operation may
cause loose connections. For a detailed inspection guide, see
“Primary Inspection” on page 11.

Maintenance/Troubleshooting — 29
 Trouble Although Mars load banks are designed with trouble-free
shooting operation in mind, some problems can arise. Please consult the
following table for solutions to the most common issues before
contacting a Simplex service representative.
Table 2 Troubleshooting

Problem Solution
Load bank Ensure load bank is wired to source correctly
wired to
Check for and replace any blown fuses
source but
won’t turn on Tighten any loose relays, contactors, lugged wires, etc.

Clear intake and exhaust vents of any debris

Ensure load bank was not installed too close to generator
or any other source of exhaust
Load bank
overheating Ensure load bank was installed in a location that allows
sufficient cool air intake
Make sure ambient temperature isn’t too high to allow for
cool air flow

HMI not Ensure HMI power connections are wired correctly

displaying data Check HMI serial cable connections

30 — Maintenance/Troubleshooting
10 ALARMS AND WARNINGS
Mars load banks are protected by four types of sensors.

1. Intake temperature, which checks the incoming air to ensure

the load elements can be adequately cooled.
2. Exhaust temperature, which checks the air temperature
coming out the load bank.
3. Fan pressure, when ensures the fan blades are forcing air into
the load element chamber.
4. Fan current, which ensures the fan motor isn’t overloaded or
jammed.

Alarms The Mars load bank’s HMI features five status areas:

• Motor: Indicates the status of the cooling fan motor

• Fan: Indicates whether the fan is blowing air into the element
Unresolved chamber
cooling • Intake Temp: Indicates status of incoming cooling air
issues may • Exhaust Temp: Indicates status of load bank’s exhaust
result in • Load Dump: Indicates whether the load dump feature has
damage to been activated
the load
bank. With the exception of Intake Temp, any failure state will cause
the unit to dump the load until the problem is fixed.
The load bank will alert you to alarms by turning the status
areas for the alarm on the home screen from green to red and
displaying the alarm signal in white text.

Warnings The Mars features one warning: Intake Temp High. When
this warning is triggered, the Intake Temp status area will turn
yellow.
Mars load banks do not dump load when a warning is
triggered, but the problem should be investigated as soon as
possible.

Alarms and Warnings — 31

 Table 3 Troubleshooting alarms

Alarm Cause Solution

Motor Fan blades blocked Clear obstruction

Intake vents blocked

Clear intake vents
by debris, paper, etc
Fan
Fan blades have come
Tighten fan blade hub.
loose from shaft

Intake vents blocked

Clear intake vents
by debris, paper, etc

Load bank pulling Ensure load bank was

in exhaust from not installed too close
generator, etc. source of exhaust

Intake Temp
Ensure load bank has
Insufficient airflow access to sufficient
cool air intake

Ambient temperature Conduct operation on

too high cooler day, if possible

Ensure fan and fan

Air not being forced motor are working
Exhaust Temp
over load elements correctly and rotating
in correct direction

Load dump switch Deactivate load dump

activated switch

Load Dump
Load dump jumper Replace load dump
fell out of TB-LD 1-2 jumper

32 — Alarms and Warnings

Appendix A — PARTS LISTINGS
Figure 31 Right Subpanel Layout

Option D - Automation/
Metering page 34
Option E - Communication
(TCP/IP Data Logging)
page 35

PLC
page 36

Control Relays
page 38

Terminal blocks/Service Outlet

page 40

Option 010 - Space Heaters

page 42

Parts listings - 33
 Table 4 Option D - Automation/Metering

Label Description Part Number

Terminal Block, 4
TB-M 1 25678547
Connections, Black

Terminal Block, 4
TB-M 2 25678546
Connections, Red

Terminal Block, 4
TB-M 3 25678557
Connections, Blue

Terminal Block, 4
TB-M 4, 6 25678536
Connections, Grey

Terminal Block, 4
TB-M 5, 7 25678537
Connections, Green

Digital Metering
DMP1 24345050
Package, RS232

34 - Parts listings
Table 5 Option B - Communication (TCP/IP Data Logging)

Label Description Part Number

Modular Controller
CM1 and Protocol 24955043
Converter

Ethernet Switch, 5
NS1 24955074
Port, Unmanaged

Parts listings - 35
 Table 6 PLC Component list

Label Description Part Number

PLC1 PLC 24955113

8PT Relay Output

EX1 24955008
Module

4PT Thermocouple
EX2 24955023
Input Module

DC Power Supply,
DC1 25457900
60W, 24VDC

RS232/RS485
CM2 24953500
Converter, RJ12 Port

Terminal Block,
Spring Type,
TB-COM1-6 25678532
20A, 600Vac, 2
Connections, Grey

36 - Parts listings
Parts listings - 37
 Table 7 Control Relays

Label Description Part Number

F4 Fuse, 2A, 600V, Instantaneous 14014500

F5 Fuse, 2A, 600V, Time Delay 14012000

SR9 Relay, 24VDC Coil, 3PDT 24827045

SR8 Relay, 24VDC Coil, 3PDT 24827045

SR7 Relay, 24VDC Coil, 3PDT 24827045

SR6 Relay, 24VDC Coil, 3PDT 24827045

SR5 Relay, 24VDC Coil, 3PDT 24827045

SR4 Relay, 24VDC Coil, 3PDT 24827045

SR3 Relay, 24VDC Coil, 3PDT 24827045

SR2 Relay, 24VDC Coil, 3PDT 24827045

SR2 Relay, 24VDC Coil, 3PDT 24827045

NOR1 Relay, 24VDC Coil, 3PDT 24827045

NOR2 Relay, Large, 24VDC Coil 24816000

LBR1 Relay, Large, 24VDC Coil 24816000

38 - Parts listings
2A

Parts listings - 39
 Table 8 Terminal Blocks

Label Description Part Number

Terminal Block, Spring Type,

TB-CP 1-4 20A, 600Vac, 4 Connections, 25678536
Grey

Terminal Block, Spring Type,

TB-C 14-26 20A, 600Vac, 2 Connections, 25678532
Grey

Terminal Block, Spring Type,

TB-DC 1-2 20A, 600Vac, 4 Connections, 25678546
Red

Terminal Block, Spring Type,

TB-DC 3-4 20A, 600Vac, 4 Connections, 25678547
Black

Terminal Block, Spring Type,

TB-C 1-13 20A, 600Vac, 4 Connections, 25678536
Grey

Triple Deck Terminal Block,

TB-R 1-2 25678550
Spring Type, 24A, Blue

Terminal Block, Spring Type,

TB-R 3-6 20A, 600Vac, 4 Connections, 25678536
Grey

Outlet, 120Vac, DIN Rail

CO1 25629900
Mount, 15A

40 - Parts listings
Parts listings - 41
 Table 9 Option 010 - Space Heaters

Label Description Part Number

Terminal Block, 2
TB-SH 1-3 25678532
Connections, Grey

HF1 Fuse, 7A, Time Delay 14039000

Enclosure Heater,
HTR1 120Vac, 550W w/ 25309211
Thermostat

42 - Parts listings
 Phase A
page 45

Phase B
page 46

Phase C
page 47
Load
control
Subpanel terminal
blocks
page 48

Parts listings - 43
 Table 10 Center Subpanel

Label Description Part Number

Contactor, 40A
RC 1-6 13011040
Resistive

Contactor, 65A
RC5-15 13011065
Resistive

Contactor, 40A
FMC1 13011040
Resistive

Overload Relay, 5.7-

OLR1 24827710
18.9A

Circuit Breaker, 15A

CB1 12046615
Trip

Transformer, 300VA,
T1 25457650
480/240:240/120Vac

Subpanel Subpanel, Mars, Rear PRT-00025390

44 - Parts listings
 Table 11 Phase A Detail

Label Description Part Number

Bus Bar, Single Pole,

Bus Bar (vertical) 60044465G
750A, Phase A

Fuse, 35A, Class T,

RF4 14074000
Fast Acting

Fuse, 70A, Class T,

RF7-34 14087000
Fast Acting

Bus Bar, Nept/Mars,

Bus Bar (horizontal) 60063693
0.250” x 4.00” x10.50”

Fuse, 35A, Class T,

RF1 14074000
Fast Acting

Parts listings - 45
 Table 12 Phase B Detail

Label Description Part Number

Bus Bar, Single Pole,

Bus Bar (vertical) 60044466E
750A, Phase B

Fuse, 35A, Class T,

RF5 14074000
Fast Acting

Fuse, 70A, Class T,

RF8-35 14087000
Fast Acting

Bus Bar, Nept/Mars,

Bus Bar (horizontal) 60063693
0.250” x 4.00” x10.50”

Fuse, 35A, Class T,

RF2 14074000
Fast Acting

46 - Parts listings
 Table 13 Phase C Detail

Label Description Part Number

Bus Bar, Single Pole,

Bus Bar (vertical) 660044467G
750A, Phase C

Fuse, 35A, Class T,

RF6 14074000
Fast Acting

Fuse, 70A, Class T,

RF9-36 14087000
Fast Acting

Bus Bar, Nept/Mars,

Bus Bar (horizontal) 60063693
0.250” x 4.00” x10.50”

Fuse, 35A, Class T,

RF3 14074000
Fast Acting

Parts listings - 47
 Table 14 Load Control Terminal Blocks

Label Description Part Number

Fuse, 1.5A, Time

F1-2 14009500
Delay

Fuse, 3.5A, Time

F3 14019775
Delay

Terminal Block, 4
TB-L 1 25678547
Connections, Black

Terminal Block, 4
TB-L 2 25678546
Connections, Red

Terminal Block, 4
TB-L 3 25678557
Connections, Blue

Terminal Block, 2
TB-L 4-19 25678532
Connections, Grey

48 - Parts listings
Appendix B — MODBUS CONTROLS
Table 15 Modbus Controls (Read/Write)

Function
Name Type Address
Code
Activate Coil 01 16586
Fan
Apply Load Coil 01 16704

Cancel Coil 01 16487

Cooldown
KW To Floating Point 03 28911
Apply

Modbus controls - 49
 Table 16 Modbus Indications (Read only)
Function
Name Type Address Notes
Code

Exhaust Alarm Coil 01 16484

Fan Failure
Coil 01 16485
Alarm

Load Dump
Coil 01 16486
Activated

Fan Running Coil 01 8193

Floating
Applied Load 03 29077
Point

Regulate Mode
Coil 01 16705 (a)
Active

Regenerative
Sensing Mode Coil 01 16706 (b)
Active

Floating
Vab 03 28673 (c)
Point

Floating
Vbc 03 28675 (c)
Point

Floating
Vac 03 28677 (c)
Point

(a) Load Banks with Automatic Load Regulation Only

(b) Load Banks with Regenerative Power Sensing Only
(c) Load Banks with Any Automation Option Only

50 - Modbus controls
 Table 15 Modbus Indications (Cont.)
Function
Name Type Address Notes
Code

Va Floating
03 28679 (c)
Point

Vbc Floating Point 03 28681 (c)

Vc Floating Point 03 28683 (c)

Ia Floating Point 03 28685 (c)

(a) Load Banks with Automatic Load Regulation Only

(b) Load Banks with Regenerative Power Sensing Only
(c) Load Banks with Any Automation Option Only

Modbus controls - 51
 Modbus 1. Ensure that “Regulate Mode Active” (16705) and
Control “Regenerative Sensing Mode Active” (16706) are OFF,
Directions indicating that the load bank is ready for Modbus Control
2. Turn “Activate Fan” (16586) ON to energize the cooling fan
3. Verify fan is running by checking that “Fan Running” (8193
is ON
4. Write the desired amount of KW to apply to “KW To Apply”
(28911)
5. Turn “Apply Load” (16704) ON to energize the desired
amount of load
6. Verify applied load by reading value at “Applied Load” 29077.
The load bank will apply as much load as possible to reach the
“KW To Apply” value, without exceeding it.
7. Monitor other values as desired.
8. Turn “Apply Load” off to de-energize the load
9. Turn “Activate Fan” OFF to stop the cooling fan. Load bank
will continue to operate cooling fan for Cooldown Time set
on HMI.
10.Cooldown mode has ended and cooling fan has stopped
when “Fan Running” is OFF
11.Cooldown mode can be stopped by writing ON then OFF to
“Cancel Cooldown” (16487)

52 - Modbus controls
 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 © 20Ϯϭ Simplex, Inc.
All Rights Reserved.