Load Banks
6255 Halle Drive
Cleveland, Ohio 44125 U.S.A.
Tel: 216.573.7600
Fax: 216.573.5953
www.EmersonNetworkPower.com/loadbank
LBsales@Emerson.com
ASCO Power Technologies | N.J. Froment & Co. Ltd.
Easton-on-the-Hill
Stamford PE9 3NP
United Kingdom
Tel: +44 1780 480033
Fax: +44 1780 480044
www.froment.co.uk
loadbanks@froment.co.uk
Image Area
ASCO Power Technologies | Avtron
The global leader in load banks.
Bulletin 608 Rev A
ASCO Innovative Solutions
The combination of ASCO, Avtron and Froment.
The global leader in load banks.
We’ve put all the pieces together.
The proven, market-leading load bank technologies of
banks to multiple MVA, we can provide a solution for virtually
cost effective solutions to today’s power testing requirements
Global Reach
Avtron and Froment are a perfect fit with ASCO Power
any application. We revolve around your needs, with the
which can require high level instrumentation, data capture
A dedicated load bank service department is there when
Technologies. Combining world-class
expertise and technical knowhow to assemble
and verification with the ability to link multiple
you need them – anywhere in the world.
innovation and more than 200 years
custom solutions that provide leading
load banks of differing capacities or combination
Our customer-centric approach
total experience, ASCO is your one-stop
power test solutions.
and controlled from one hand-held terminal or PC.
guarantees you receive friendly,
partner that offers complete solutions
Technology
Experience
knowledgeable advice and support
that you can rely on to solve any power
Innovation is at our core, complemented
Ninety years combined experience
24/7/365 from a highly trained,
testing requirement.
by our commitment to build load banks to
in load banks is only matched by the
technically proficient team.
Broadest Portfolio
the highest standards – ISO9001, UL/CUL, CSA, CE, IEC, NFPA.
125 years ASCO has been providing power
No company in the world can match the depth and
Technical leadership includes Sigma control which is sector
solutions. Our team of experts has provided countless standard
white paper, calling 800-800-ASCO or visiting our webpage
breadth of our portfolio. From simple 10 kW portable load
leading in simplicity, ease of use, and accuracy. Sigma brings
and custom load banks to the industry over the years.
at www.emersonnetworkpower.com/loadbank.
Learn more by downloading a load bank
What is a Load Bank?
A load bank is a device that develops an electrical
load and applies the load to an electrical power
source. Avtron and Froment Brand load banks
provide consistent, accurate, measurable, and
repeatable electrical loads on a power source.
To help prevent lightly loaded
conditions (wet-stacking) on
your diesel generator set
Meet the testing requirements
of NFPA 110
Power systems commissioning
and acceptance testing
“
“Running an engine with minimal load causes residual fuel buildup, which decreases
the efficiency of the engine and reduces the useful life of critical parts.”
Long term tests - heat runs
Transient response tests block loading
Test and verification to ISO 8528
- pass or fail
AC up to 690V
AVR (automatic voltage
regulator) and governor set up
Resistive
New product research and
development
Reactive (Inductive or Capacitive)
What types
of Load
Banks are
available?
Battery capacity testing
Why use a
load bank?
Combined (Resistive, Inductive
and/or Capacitive)
”
- Christopher Wade, Newmark Grubb Knight Frank
We have 90
years combined
experience in
the load bank
industry.
DC up to 600V
Battery capacitive testing
28VDC ground power unit testing
MV from 3.3 - 15kV
Direct Connect
Step Down Transformer
Generator
electrical
power source
Hot Air Exhaust
Enhance reliability of the power source
Help maintain optimum load levels
Power Cables
Prevents low loading on the power source
Anyone involved with insuring
the proper operation of gen-sets
or UPS systems should be using a
load bank for:
Elements
Who should
use a load
bank?
Controls
Cool Air Intake
Why choose
Avtron & Froment
Load Banks
System set-up
Continued verification
Prolonged product life
Anyone involved in the design,
manufacture, and sale of gen-sets
or UPS systems for:
Product development
Customer witness testing
Improves life of generator
Reduces generator maintenance
Proven control systems
Built for rugged and reliable operation
Periodic maintenance
Final production sign-off
3
Reduce downtime
Our Load
Banks are
built to
the highest
standards
We have over
125,000 sq. ft.
global production
space dedicated
to manufacture of
load banks.
No cool-down period required
Aluminized steel construction
Widest range of voltage and capacity available
ISO9001
UL/CUL
CSA
CE
IEC
NFPA
Accurate load tolerance
Standard off the shelf components
Continuous duty
4
Broadest Load Bank Portfolio in the World
Avtron and Froment brand load banks offer the widest range of load testing solutions available today.
From a simple 10 kW portable load to multiple megawatt units, our experience and support make us
the worldwide leader in the manufacture of rugged and reliable load banks.
Radiator
Lightweight & Portable
Resistive
Trailer Mounted
Our Load Banks Revolve around Your Needs
Inductive/Reactive
Combined
Container
Medium Voltage
Direct Current
SIGMA
Serving Every Application in Every Market
Power Generation
5
Mission Critical
Rental
Service
Oil, Gas, & Nuclear
Wind Farms
OEMs
Government / Military
Maritime / Shipyards
6
Serving Every Application in Every Market
Applications Our
Load Banks Support...
Our Load Banks Achieve...
Power Generation
Commissioning and
Validation of Generator
Routine Maintenance
Prevent Wet Stacking
Supplemental Load
Mission Critical
Compliance with State &
Federal Testing Regulations
24/7 Reliability, Power
Outage Prevention
Meet Min. Standards of ASHE
Rental
Service
Commissioning
Validate Output
Nameplate Testing
Meet Commissioning
Requirements
Load Data Collection
Ensure Generator Availability
when Grid is unavailable
All Season and All Weather
Performance Testing
DC Battery Service
Oil, Gas, & Nuclear
Commission
Gas Turbines
Supplemental Load
Emission Requirements
are within Regulations
Generator Verification
Black Start Event
HVAC Verification
New Product Testing
Harmonic Testing
Validate Output
Meet Commissioning
Requirements
Inventor Testing
“
Quality Control Testing
and Verification
Troubleshooting
Ensure Performance
Specification
Tactical Generator Testing
Supplemental Load for
Deployable Power
Depot Maintenance
Flight Line Testing &
Support (400 Hz)
Test & Verify Primary &
Backup Power
Nameplate Testing
of Generators
Commissioning
Generator Verification
“Prior to building turnover, load bank testing helps insure that electrical generation systems support loads by maintaining voltages and frequencies that meet
design criteria. Generally, if they are going to fail, they will fail quickly.”
3
7
”
- Joshua Gepner, Environmental Systems Design, Inc.
Wind Farms
OEMs
Government/Military
Maritime/Shipyards
3
8
Broadest Load Bank Portfolio in the World
Resistive
5-6000 kW
Load Bank Series 1000
Load Bank Series 3000 and 4000
Indoor or Outdoor Construction
Remote or Local Controls
Roof Mounted Designs are also Available
Automatic Load Controller (Optional)
The most popular load bank requests are for purely resistive models, these apply load in a resistive manner only.
Our resistive load banks are ruggedly constructed and
designed for continuous operation and are available for
all applications including small indoor load test to large
outdoor static load tests. We offer a complete power
range from 5 kW to over 6000 kW. Our resistive load
banks are CE approved for Europe and also UL approved
for use in America.
•
•
•
•
•
•
Wide Voltage Range to Choose From
Various Frequencies Available
Sigma Intelligent Control Available
Remote or Local Controls
Horizontal & Vertical Options Available
Custom Designs Available
Lightweight and Portables
5-700 kW
Trailer Mounted
500-5000 kW
Load Bank Series 2000 and 3000
We offer a complete line of lightweight and portable load
banks. They are designed and constructed to the highest
standards to resist vibration encountered during transportation. Our load banks are lightweight, compact, and
reliable. Smaller models are available with handy carry
cases for protection and most models come with casters
for maneuverability in the tightest spaces. Our lightweight
and portable load banks are perfect for
operators that are testing lower loads
in a variety of places.
• Dual Voltage
• Local Controls
• Standard Data Logging with
Digital Metering
• Designed to Fit through Man
Doors and Freight Elevators
• Sigma Intelligent Control
Available
9
”
- Stewart Allen, Citizens Property Insurance
Radiator
10-1500 kW
Our radiator mounted load banks are designed to be fitted
directly onto diesel generator sets. The load bank utilizes
the engine cooling air from the generator radiator to cool
the load elements. Radiator mounted load banks are designed as supplemental loads rated 50-70% of generator
kW. We can offer models that allow from 10-1500 kW load
and with this unique design, it is perfect for generator
that consistently light load.
•
•
•
•
“
“As per National Fire Protection Association Standard 110 (NFPA 110), if you cannot achieve at least
30% load on a unit, you will build up carbon in the system. When you run the units at the higher
load, it creates greater temperatures and burns off any carbon that may have built up.”
Load Bank Series 3000 and 5000
If you need a load bank that is easily transportable and
maneuverable but can still provide a high enough load for
your needs, than a trailer-mounted load bank is for you.
Typically used by rental companies, our trailer mounted
load banks use the latest load bank technology combined
with its superior versatility.
•
•
•
•
•
•
Various Voltages and Frequencies Available
DOT Certified Trailers
Remote or Local Controls
Sigma Intelligent Control Available
Vertical or Horizontal Airflow
Storage Box, Manual or Electric Cable Reels,
and Quick Disconnect Receptacles Available
10
Broadest Load Bank Portfolio in the World
Medium Voltage
3500-7000 kW
Load Bank Series 6000 and 7000
Load Bank Series 9000
• Wide Voltage Range
• Sigma Intelligent
Control Available
• Can link with existing
resistive load banks
to perform combined
load test.
Combined
200-6000 kVA
Load Bank Series 6000 and 7000
Our combined load banks test both resistive and inductive
loads within a single load bank. Manufactured with the
highest quality resistive elements and inductors the combined load banks will give the precision and longevity you
need. Our combined load bank models are available from
200-6000 kVA, so if you need a combined load bank of any
size then we have you covered.
Rugged Construction
Permanent or Maneuverable
Wide Voltage Available
Sigma Intelligent Control Available
Container
2000 - 6000 kW / 2000 - 6000 kVA
Load Bank Series 8000
For larger load test, the containerized construction of our
load banks is perfect. Not only can they provide a very
large load capacity, but this construction means it is
easily transportable. Our container load banks are
available in both resistive only and combined version.
Typical containers are available in 10 and 20 foot
lengths and specialized control rooms within to keep
the components weatherproof and to provide the
operator with a safe and secure work area.
•
•
•
•
11
”
- K. Sullivan, Optimum Power Services
Inductive/Reactive
400-1875* kVAr
Inductive/Reactive load banks can be used in conjunction with existing resistive load banks for testing AC
supplies at non-unity power factors. Generating sets are
rated at 0.8 power factor so both resistive and inductive load are required. The rise of solar energy and wind
farms has also led to an increase popularity in inductive/
reactive only load testing.
*Additional kVAr available upon request.
•
•
•
•
“
“OPS has been buying Froment products for about 8 years. We have over 8 different types across the
Froment range from 40kW units to 2.5mVA single units. The quality and reliability of the Froment
product has enabled and helped OPS in being the market leader in the UK for load bank testing. “
We are the leading manufacturer of true medium voltage
load banks. Our units operate at the actual output voltage
of medium voltage generators and do not require large
step-down transformers. We also have available the
conventional load bank with step-down transformer designed to mount on common structural
skid. Both resistive and resistive/reactive loads
are available with a wide voltage range to suit
your needs perfectly.
•
•
•
•
•
•
Direct Connect with NO Transformer
Voltages of 5-15 kV
50/60 Hertz Frequency
Remote or Local Controls
Rugged Construction
Automatic Load Controller (Optional)
Direct Current
150-3500 Amps
Load Bank Series 2000 thru 4000
Direct current load banks are the ideal solution for the
customer that need to test DC generating systems,
converters, transformer/rectifier units, battery systems,
and controls. The rugged, aluminized steel construction
ensures a long life and minimal maintenance. We offer
a range of both portable and permanent DC load
banks from 150-3500 amps with a wide range
of voltages available.
• Permanent and Portable
• Aluminized Steel Enclosure for
Superior Corrosion Protection
Bespoke ISO Container Construction
Wide Voltage Range
50/60 Hertz Frequency
Sigma Intelligent Control Available
12
“
“The ability to “daisy chain” load banks is a necessity in the rental industry. It enables the use of
multiple units in order to reach higher capacities without the addition of larger units.”
Load Bank Control
”
- Joe Stonestreet, Comrent International
FEATURES & BENEFITS
MANUAL TOGGLE
SWITCHES
• Simple straight forward
operation
• Ideal for remote and
extreme locations
• Digital metering is often
included for indication
of applied load in amps
and kW
PLC/DIGITAL
CONTROLLER
• Ideal for larger direct
connect medium voltage
systems
• Pre program a load profile
with specific loads and
intervals
• Can interface with existing
building management
system
SIGMA LT
LOCAL CONTROL
• Electronically controlled
push buttons
• Network “Daisy Chain”
ability
• Display full metered
instrumentation on 3 x 7
seg LEDs
SIGMA LT
REMOTE CONTROL
• Cross platform capability
between Sigma LT and
Sigma 2
• Load bank mounted
decade switches for quick
and easy load selection
• Allows individual load
bank control and monitoring
• For Windows tablet and PC
• Perfect for accepting and
rejecting load quickly and
simply when at the load
bank
• USB capability
• Daisy chain load banks or
control individually
• Robust enclosure
• Multi language
• 480/240V
SIGMA LT Load Bank Controls
Standard load bank controls are perfect for basic load
tests. The toggle switch design ensures reliability.
Sigma LT load bank control is the latest product
development from Avtron and Froment. It offers a
simple and sleek touch screen design and provides
consistent and reliable testing for resistive load banks.
13
SIGMA DECADE
SWITCHES
• Color touch screen interface allows simple load
selection
Standard Load Bank Controls
• Simple easy to use design
• For basic, resistive load testing
• Offers automatic load control: allows permanently
installed or radiator mounted load banks to provide
load levelling
SIGMA PC
BASIC
• Resistive load bank control
• Link up to 25 individual load banks for testing
• Transfer data on USB stick for analysis
• Accept and reject load from individual load banks
• Stand alone and daisy chain load tests
• Available with hand-held remote control
• Full 3 phase instrumentation
• Link USB interface to link
over 50 load banks
• Graphical, chart and individual load test views
SITE LOAD
CORRECTION
SIGMA
MODBUS
• Load control automatically
preventing the problems
associated with light
loading
• Allows integration with
PLC, HMI or SCADA
systems and proxy remote
controls
• Maintain minimum load on
gen-set
• Can be used over TC/IP for
remote control
• Quick response times for
unity testing
SIGMA 2 Load Bank Controls
Sigma load control is the leader in simplicity, ease of use and accuracy. Sigma brings
cost effective solutions to today’s power testing requirements which can require high
level instrumentation, data capture and verification.
• No Need for any pre-calculations
• Automatic detection senses the supply-on-test
• Quick start wizard allows easy setup of load via % load, power factor and time
• Load steps down to 0.1kW or 0.1kVAr with adjustable leading and lagging power factor
• Adaptive and Predictive load-correction facility ensures the correct load is applied even
if the voltage drops
• Transient load tests, results analysed and reported
• Automatic load control provides multiple timed load steps including cyclic testing
• Manual control via selection of kW, % load, or kVA and power factor
• Link multiple Sigma load banks and control from one IHT or PC
• Commissioning and verification to ISO8528
SIGMA IHT
CONTROLLER
• Robust Intelligent Handheld Terminal (IHT) for
remote load control
operation with full
3-phase instrumentation
• Membrane keyboard
and back-lit graphic LCD
housed in an Industrial
polycarbonate / polyamide enclosure providing
IP65 protection
• Resistive, combined,
inductive and capacitive
testing
• Automatic tests
SIGMA PC
SOFTWARE
• Enhanced load control
with transient speed
instrumentation data
acquisition and reporting
with graphical displays
including real time data
such as crest factor, recovery times and % errors
• Customizable front-panel
window layouts
• Supply-on-test properties
include ratings, alternator, engine, customer and
additional notes can be
saved with test results
for future reference or
template creation
• Result data can be printed
or exported to other software for further analysis
• Certification to ISO8528
14
Load Bank Quality at Work
Load Bank Service & Support
Resistive, Inductive, Combined, Portable,
DC, and Medium Voltage models
24/7/365
Support
Custom builds to specifications
Large range of capacities
Huge selection of option adders
Choice
Professional and creative design engineers
The best software for superior results
Innovative problems solving skills
Avtron and Froment Services are much more than
a “service department”. We are a self-sufficient
organization offering a broad range of services,
products, and solutions.
•
Commissioning
•
Periodic scheduled maintenance of
equipment
•
Technology upgrades to legacy systems
•
Modifications in system operation
•
On-going customer training
•
Access to the latest development including
parts and equipment
We are there
when you
need us
Customer centric service puts your needs first
Worldwide Service & Support
Unrivaled product knowledge
Design
90 years combined experience in
manufacture of load banks
Please have the following information to supply to your regional sales
manager for us to provide you with a fast turnaround on a
load bank quote.
Manufactured 1000’s of
standard & custom load banks
•
Applied Voltage(s) or Frequency
Worldwide presence in
all markets
•
Resistive, Reactive, or DC
•
Portable or Permanent Installation
•
Capacity
•
Load Step Resolution
•
Blower Voltage Requirements
•
Internal and/or External Control Power
•
Indoor or Outdoor Service
•
Core Dimensions and Air Flow for radiator mounted applications
Experience
Avtron & Froment
Load Banks
Build
The latest and greatest
construction technology
Superior quality materials
Talented and highly skilled engineers
State-of-the-art production techniques
Knowledge
Rigorously trained staff
Awareness of customer needs
Global sales teams
Product proficiency
Service
Dedicated load bank
service department
Global presence
Friendly advice and support
“
Help Us to
Help You
“Routine load bank testing ensures generator set performance during an emergency. Such
testing means facilities executives may uncover system defects that may not be found otherwise
until a power outage. Discovering them during testing allows any necessary repairs to be
made before the facility has a critical need.”
”
- Kurt Summers, Austin Generator Service
24/7 support
15
16
17
1 9 79
1 9 85
1997
1 9 94
1 9 98
2002
2005
2 0 09
2 0 03
2 0 08
USMC awarded Avtron a
contract for 300+ portable load banks to help
support their worldwide
deployments
2010
2012
2011
Introduced Network Capable
(i.e. Daisy Chain) 150 kW
Portable Load Bank
2000
Avtron and Froment
become brands of
ASCO Power Technologies
2001
Avtron acquires Froment
Modbus connectivity launched
for load bank
After 9/11, the White House chose
Avtron load bank for their mobile
communications activities
3MW resistive load
bank used at NASDAQ
as supplemental load to
insure power is constant
for trading
5MW, Medium Voltage Load Bank
sold to Social Security Administration. The load bank used in
conjunction with a backup generator
to insure personal data is secure
Sigma Intelligent
Hand-Held Terminal
launched
2 0 07
Interactive HMI interface launched
for container products
2 0 01
2 0 03
Developed first multivoltage rack server
(10 kW) load simulator
2000
Released PC based diagnostics,
configuration, and
calibration application
1 9 99
Additional user benefits
added to Sigma
Hand-Held Terminal
1999
Additional combined
(resistive/reactive) Froment
models are launched
1990
Sigma Instrumentation System
launched for direct supply on test
instrumentation
Sigma PC Software launched
1995
Began to offer complete line
of neutral grounding and
industrial resistors
First monocoque load
banks are launched
Introduced the
Avtron Helidyne
resistive load element.
First mobile load bank
(1200 kW) designed for
major mining company
1995
2 0 00
Sigma 2 Control
System Released
1980
1993
1 9 97
Introduced line of suitcase-style high capacity
portable load banks
1967
Introduced Sigma Intelligent
Load Bank Control System
1980
First to offer UL listed
permanent load banks
1979
Manufacture SIGMA
Control Resistive/Reactive
Container Load Bank
1 9 55
1970
1 9 83
Developed first true
direct connect (no step
down transformer)
medium voltage load bank
1960
Froment begins
manufacture of
load banks
1950
First high capacity (750 kW)
permanent installed load bank
1960
1 9 73
Manufactured first high
capacity (400 kW)
portable load bank
First load bank (250 kW) designed
for 400 Hz Jet Aircraft Test Stand
1953
Manufactured first
radiator mounted
load bank
Avtron founded by Dwain Fritz, P.E.
1947
Developed first
multi-voltage (AC &
DC), multi-frequency
(50, 60, 400 Hz) trailer
mounted load bank
Avtron begins manufacture of load banks.
Froment founded by N J Froment
Company Timeline
2010
2 0 14
18