Load Banks

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Load Banks 6255 Halle Drive Cleveland, Ohio 44125 U.S.A. Tel: 216.573.7600 Fax: 216.573.5953 www.EmersonNetworkPower.com/loadbank [email protected] 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 [email protected] 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