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ASCO Power Technologies | Avtron 6255 Halle Drive
Cleveland, Ohio 44125 U.S.A.Tel: 216.573.7600Fax: 216.573.5953
www.EmersonNetworkPower.com/loadbank [email protected]
ASCO Power Technologies | N.J. Froment & Co. Ltd. Easton-on-the-HillStamford PE9 3NP
United Kingdom Tel: +44 1780 480033Fax: +44 1780 480044
ASCO Innovative Solutions
The global leader in load banks.
Load Banks
Bulletin 608 Rev A
banks to multiple MVA, we can provide a solution for virtually
any application. We revolve around your needs, with the
expertise and technical knowhow to assemble
custom solutions that provide leading
power test solutions.
Technology Innovation is at our core, complemented
by our commitment to build load banks to
the highest standards – ISO9001, UL/CUL, CSA, CE, IEC, NFPA.
Technical leadership includes Sigma control which is sector
leading 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 with the ability to link multiple
load banks of differing capacities or combination
and controlled from one hand-held terminal or PC.
ExperienceNinety years combined experience
in load banks is only matched by the
125 years ASCO has been providing power
solutions. Our team of experts has provided countless standard
and custom load banks to the industry over the years.
Global Reach A dedicated load bank service department is there when
you need them – anywhere in the world.
Our customer-centric approach
guarantees you receive friendly,
knowledgeable advice and support
24/7/365 from a highly trained,
technically proficient team.
Learn more by downloading a load bank
white paper, calling 800-800-ASCO or visiting our webpage
at www.emersonnetworkpower.com/loadbank.
The combination of ASCO, Avtron and Froment. The global leader in load banks.
The proven, market-leading load bank technologies of
Avtron and Froment are a perfect fit with ASCO Power
Technologies. Combining world-class
innovation and more than 200 years
total experience, ASCO is your one-stop
partner that offers complete solutions
that you can rely on to solve any power
testing requirement.
Broadest PortfolioNo company in the world can match the depth and
breadth of our portfolio. From simple 10 kW portable load
We’ve put all the pieces together.
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.
What is a Load Bank?
Why use a load bank?
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
Long term tests - heat runs
Transient response tests - block loading
Test and verification to ISO 8528 - pass or fail
Battery capacity testing
AVR (automatic voltage regulator) and governor set up
New product research and development
Who should use a load
bank?
Anyone involved with insuring the proper operation of gen-sets or UPS systems should be using a load bank for:
System set-up
Periodic maintenance
Continued verification
Prolonged product life
Anyone involved in the design, manufacture, and sale of gen-sets or UPS systems for:
Product development
Final production sign-off
Customer witness testing
Avtron & FromentLoad Banks
Why choose
Enhance reliability of the power source
Help maintain optimum load levels
Prevents low loading on the power source
Reduce downtime
Improves life of generator
Reduces generator maintenance
Proven control systems
Built for rugged and reliable operation
No cool-down period required
Aluminized steel construction
Widest range of voltage and capacity available
Accurate load tolerance
Standard off the shelf components
Continuous duty
What types of Load
Banks are available?
Our Load Banks are
built to the highest standards
ISO9001 UL/CUL
CSA CE IEC
NFPA
AC up to 690V
Resistive
Reactive (Inductive or Capacitive)
Combined (Resistive, Inductive and/or Capacitive)
DC up to 600V
Battery capacitive testing
28VDC ground power unit testing
MV from 3.3 - 15kV
Direct Connect
Step Down Transformer
We have over 125,000 sq. ft.
global production space dedicated
to manufacture of load banks.
We have 90 years combined
experience in the load bank
industry.
Cool Air Intake
Elements
Controls
Power Cables
Generator electrical
power source
Hot Air Exhaust
“ ”“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.” - Christopher Wade, Newmark Grubb Knight Frank
3 4
Broadest Load Bank Portfolio in the WorldAvtron 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.
Our Load Banks Revolve around Your Needs
Power Generation Mission Critical Rental Service Oil, Gas, & Nuclear Wind Farms OEMs Government / Military Maritime / Shipyards
Lightweight & Portable
Serving Every Application in Every Market
Trailer MountedResistive Inductive/Reactive Combined Container Medium VoltageRadiator Direct Current
SIGMA
65
Serving Every Application in Every Market
Our Load Banks Achieve... Commissioning and Validation of Generator
Routine Maintenance
Prevent Wet Stacking
Supplemental Load
Compliance with State & Federal Testing Regulations
24/7 Reliability, Power Outage Prevention
Meet Min. Standards of ASHE
DC Battery Service
Black Start Event
HVAC Verification
Commissioning
Nameplate Testing
Load Data Collection
Ensure Generator Availability when Grid is unavailable
Validate Output
Meet Commissioning Requirements
All Season and All Weather
Performance Testing
Commission Gas Turbines
Supplemental Load
Emission Requirements are within Regulations
Generator Verification
Harmonic Testing
Validate Output
Meet Commissioning Requirements
Inventor Testing
New Product 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
Mission Critical Rental Service Oil, Gas, & Nuclear
Wind Farms OEMs Government/Military Maritime/Shipyards
Power Generation
Applications OurLoad Banks Support...
33
Routine Maintenance
Prevent Wet Stacking
Supplemental Load
“ ”“Prior to building turnover, load bank testing helps insure that electrical genera-tion systems support loads by maintaining voltages and frequencies that meet
design criteria. Generally, if they are going to fail, they will fail quickly.” - Joshua Gepner, Environmental Systems Design, Inc.
7 8
Broadest Load Bank Portfolio in the World
Load Bank Series 1000
Load Bank Series 2000 and 3000
Load Bank Series 3000 and 4000
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
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 trans-portation. 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
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 de-signed 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.
• 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 resis-tive 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
Resistive 5-6000 kW
Trailer Mounted 500-5000 kW
“ ”“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.”
- Stewart Allen, Citizens Property Insurance
109
Load Bank Series 6000 and 7000
Load Bank Series 6000 and 7000
Load Bank Series 8000
Load Bank Series 9000
Load Bank Series 2000 thru 4000
Broadest Load Bank Portfolio in the World “ ”“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. “
- K. Sullivan, Optimum Power Services
• Wide Voltage Range• Sigma Intelligent Control Available • Can link with existing resistive load banks to perform combined load test.
Inductive/Reactive load banks can be used in conjunc-tion 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 induc-tive load are required. The rise of solar energy and wind farms has also led to an increase popularity in inductive/reactive only load testing.
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 com-bined 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
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.
• Bespoke ISO Container Construction• Wide Voltage Range• 50/60 Hertz Frequency• Sigma Intelligent Control Available
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 trans- former 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)
Inductive/Reactive 400-1875* kVAr
Combined 200-6000 kVA
Container 2000 - 6000 kW / 2000 - 6000 kVA
*Additional kVAr available upon request.
Medium Voltage 3500-7000 kW
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
Direct Current 150-3500 Amps
11 12
• Robust Intelligent Hand-held Terminal (IHT) for remote load control operation with full 3-phase instrumentation
• Membrane keyboard and back-lit graphic LCD housed in an Industrial polycarbonate / polyam-ide enclosure providing IP65 protection
• Resistive, combined, inductive and capacitive testing
• Automatic tests
SIGMA IHTCONTROLLER
• Enhanced load control with transient speed instrumentation data acquisition and reporting with graphical displays including real time data such as crest factor, re-covery times and % errors
• Customizable front-panel window layouts
• Supply-on-test properties include ratings, alterna-tor, 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 soft-ware for further analysis
• Certification to ISO8528
SIGMA PCSOFTWARE
• Allows integration with PLC, HMI or SCADA systems and proxy remote controls
• Can be used over TC/IP for remote control
SIGMA MODBUS
• Load control automatically preventing the problems associated with light loading
• Maintain minimum load on gen-set
• Quick response times for unity testing
SITE LOADCORRECTION
SIGMA DECADESWITCHES
SIGMA LT REMOTE CONTROL
SIGMA PC BASIC
SIGMA LT LOCAL CONTROL
PLC/DIGITALCONTROLLER
MANUAL TOGGLESWITCHES
• Load bank mounted decade switches for quick and easy load selection
• Perfect for accepting and rejecting load quickly and simply when at the load bank
• Color touch screen inter-face allows simple load selection
• Allows individual load bank control and monitoring
• USB capability
• Robust enclosure
• Cross platform capability between Sigma LT and Sigma 2
• For Windows tablet and PC
• Daisy chain load banks or control individually
• Multi language
• Link USB interface to link over 50 load banks
• Graphical, chart and indi-vidual load test views
• Electronically controlled push buttons
• Network “Daisy Chain” ability
• Display full metered instrumentation on 3 x 7 seg LEDs
• 480/240V
• 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
• Simple straight forward operation
• Ideal for remote and extreme locations
• Digital metering is often included for indication of applied load in amps and kW
SIGMA 2 Load Bank ControlsSigma 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 LT Load Bank ControlsSigma 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.
• 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
Standard Load Bank ControlsStandard load bank controls are perfect for basic load tests. The toggle switch design ensures reliability.
• 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
Load Bank Control “ ”“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.” - Joe Stonestreet, Comrent International
FEATURES & BENEFITS
1413
Load Bank Quality at Work Load Bank Service & Support
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.
• Applied Voltage(s) or Frequency
• 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
Choice
Design
Build
Knowledge
Service
Avtron & FromentLoad Banks
Resistive, Inductive, Combined, Portable, DC, and Medium Voltage models
Custom builds to specifications
Large range of capacities
Huge selection of option adders
Professional and creative design engineers
The best software for superior results
Innovative problems solving skills
Unrivaled product knowledge
The latest and greatest construction technology
Superior quality materials
Talented and highly skilled engineers
State-of-the-art production techniques
90 years combined experience in manufacture of load banks
Manufactured 1000’s of standard & custom load banks
Worldwide presence in all markets
Dedicated load bank service department
Global presence
Friendly advice and support
24/7 support
Rigorously trained staff
Awareness of customer needs
Global sales teams
Product proficiency
Help Us to Help You
24/7/365 Support
We are there when you
need us
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
Customer centric service puts your needs first
Worldwide Service & Support
“”
“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
15 16
Intr
oduc
ed S
igm
a In
telli
gent
Lo
ad B
ank
Con
trol
Sys
tem
Sigm
a 2
Con
trol
Sy
stem
Rel
ease
d
Firs
t to
offe
r UL
liste
d pe
rman
ent l
oad
bank
s
Firs
t mob
ile lo
ad b
ank
(1
200
kW) d
esig
ned
for
maj
or m
inin
g co
mpa
ny
Intr
oduc
ed th
e
Avt
ron
Hel
idyn
e
resi
stiv
e lo
ad e
lem
ent.
Firs
t loa
d ba
nk (2
50 k
W) d
esig
ned
for 4
00 H
z Je
t Airc
raft
Tes
t Sta
nd
Intr
oduc
ed S
igm
a In
telli
gent
19531947
1967
199319791960
1980 1995 1997 2002 2005 2011
201019991995 2001 2012
Dev
elop
ed fi
rst
mul
ti-v
olta
ge (A
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D
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mul
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requ
ency
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aile
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ad b
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t hig
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paci
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ad b
ank
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ompl
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esis
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MA
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esis
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unch
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tati
on S
yste
m
laun
ched
for d
irect
sup
ply
on te
st
inst
rum
enta
tion
Avt
ron
acqu
ires
From
ent
5MW
, Med
ium
Vol
tage
Loa
d Ba
nk
sold
to S
ocia
l Sec
urit
y A
dmin
-is
trat
ion.
The
load
ban
k us
ed in
co
njun
ctio
n w
ith
a ba
ckup
gen
erat
or
to in
sure
per
sona
l dat
a is
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stiv
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ad
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NA
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oad
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re p
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ng
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ad
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e la
unch
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a In
telli
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and-
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d Te
rmin
al
laun
ched
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er 9
/11,
the
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te H
ouse
cho
se
Avt
ron
load
ban
k fo
r the
ir m
obile
co
mm
unic
atio
ns a
ctiv
itie
s
Mod
bus
conn
ec-
tivi
ty la
unch
ed
for l
oad
bank
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war
ded
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ron
a
cont
ract
for 3
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tabl
e lo
ad b
anks
to h
elp
supp
ort t
heir
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ldw
ide
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oym
ents
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ron
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me
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ds o
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SCO
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itio
nal u
ser b
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ts
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ma
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ks
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rst m
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- vo
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d si
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etw
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aisy
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nk
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elop
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rst t
rue
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ct c
onne
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ansf
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ium
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tage
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ban
k
Avt
ron
foun
ded
by D
wai
n Fr
itz,
P.E
.
From
ent f
ound
ed b
y N
J Fr
omen
t
Avt
ron
begi
ns m
anu-
fact
ure
of lo
ad b
anks
.
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ufac
ture
d fir
st
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ator
mou
nted
lo
ad b
ank
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ent b
egin
s m
anuf
actu
re o
f lo
ad b
anks
Man
ufac
ture
d fir
st h
igh
capa
city
(400
kW
) po
rtab
le lo
ad b
ank
1955
1973
2009 2014
1979 19981994
1999
Add
itio
nal c
ombi
ned
(res
isti
ve/r
eact
ive)
Fro
men
t
2001
1997 20032000 2007
Dev
elop
ed fi
rst m
ulti
-
20082003
1983
From
ent b
egin
s m
anuf
actu
re o
f lo
ad b
anks
1985
Company Timeline
19901980197019601950 20102000
Sigm
a In
stru
men
tati
on S
yste
m
laun
ched
for d
irect
sup
ply
on te
st
2000
1817