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AVTRON LOAD BANKS
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Outl ine
History of Avtron
What is a load bank?
Typical load bank applications
Opportunities in the Industry
Types of Avtron Load Banks Avtron Sales Process & Coverage
Avtron Main Competitor
Avtron Competitive Advantages
Avtron website and contact information
Questions
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History of Avt ron
1953 - Avtron founded by Dwayne Fritz, PE
1955 - Developed first military grade 400 Hz load bank
1967 - First multi-voltage (AC & DC), multi-frequency (50/60/400 Hz) trailermounted load bank sold to United States Air Force
1973 - Developed first true radiator mounted load bank
1979 - Developed first high capacity (400 KW) portable load bank
1980 - Developed first high capacity (750 KW) permanent installed load bank
1985 - Introduced the legendary Avtron Helidyne resistive load element
1993 - First to offer UL listed permanent load banks
1994 - Developed first true direct connect medium voltage load bank
Family owned until 2007
2010 - Purchased Froment Loadbanks (UK)
Acquired by ASCO in 2012
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What is a Load Bank?
A load bank provides an electrical load on a power source
Load banks typically use resistive load elements
Common examples of load banks are toasters, hair dryers andlight bulbs.
Toaster resistive heating elements
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What real ly is a Load Bank?
Industrial grade load banks used in our market are characterized by:
Accurate load tolerance
Fine load step resolution
Fully supported Helidyneresistive elements
Continuous duty cycle
No cool down period requirement
Nema 3R type construction
Integral blower motor for cooling
Corrosion resistant frame construction
Load dump circuitry for interface with switchgear
Third party certification
Avtron Helidyne Element
2000 KW outdoor
load bank
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What real ly is a Load Bank?
A Load Bank is a device which develops an electrical load, applies the load toan electrical power source and converts or dissipates the resultant poweroutput of the source.
A Load Bank is intended to accurately mimic the operational or real loadwhich a power source will see in actual application.
However, unlike the real load, which is likely to be dispersed, unpredictable
and random in value, a Load Bank provides a contained, organized and fullycontrollable load.
Consequently, a Load Bank can be further defined as a self-contained, unitized,systematic device which includes both load elements with control andaccessory devices required for operation.
Where the real load is served by the power source and uses the energy output
of the source for some productive purpose, the Load Bank serves the powersource, using its energy output to test, support or protect the power source.
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What real ly is a Load Bank?
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Load Bank Load
Facility Load
Engine
GeneratorDesired
Loading
50% to
70%
Autom at ic Load Contro l ler
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What does a Load Bank do?
All major engine manufacturers specify a minimumload when the engine is running
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What does a Load Bank do?
*National Emiss ions Standards for Hazardous Air Pollutants
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Typical Load Bank App l icat ions
Design Research and Development
Manufacturing... Quality Control
Installation... Acceptance Testing
Maintenance Testing
Solving Lightly Loaded Problems (wet stacking)
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Typical Load Bank App l icat ions
Design
Research and DevelopmentLoad Banks are used to prove out power source during the R & D phase.
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Typical Load Bank App l icat ions
Generator Test Cells
Manufacturers of standby power generators commonly use load banks to test and tune newly
assembled units.
When the generator has been set up in a test cell within the factory, a test engineer uses the load
bank to apply a discrete, selectable electrical load to the generator and measure the response
stability and endurance.
During this process, the test engineer calibrates and adjusts the generator performance to ensure it
meets the intended product specifications and tolerances.
Engine Test Cells
Manufacturers of small gas engines also use load banks to test newly manufactured engines under
various mechanical loads.
This is accomplished by connecting the engine to the load bank via a device called a dynamometer.
Again, engine performance is monitored and, if necessary, adjustments are made to ensure the
product performs within intended specifications.
Manufacturing... Quality Control
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Typical Load Bank App l icat ions
Installation... Acceptance Testing Load banks are often used as tool for demonstrating to buyers and users of
a new generator set that the unit meets the performance specifications
outlined in the purchase contract.
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Typical Load Bank App l icat ions
Maintenance Testing
Generators installed in the field must be periodically tested and
exercised to ensure that it will operate as intended when a power outage
actually occurs.
Service groups use load banks to apply a load that mimics the load of
the facility the generator is protecting. Any problems with the generatorcan then be identified and rectified in a non-critical environment.
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Typ ical Load Bank App l ications(Wet Stack ing )
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What does a Load Bank do?
Why Avoid Wet Stacking
Expense: Excessive Wet Stacking will shorten engine life by many years
and before planned replacement.
Pollution: Many urban areas are restricting the level of smoke emissions
Wet Stacking produces.
Power: Even before an engine is damaged deposits will reduce maximum
power. A prematurely worn engine will have a lower maximum power than
it was designed to develop.
Maintenance: An engine experiencing the effects of Wet Stacking will
require considerable more maintenance than an engine that is adequatelyloaded.
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Typical Load Bank App l icat ions
Solving Lightly Loaded Problems (wet stacking)
Load banks may be installed in a diesel powered generator set to
apply the additional load required to ensure the engine fully
consumes the fuel in the combustion process.
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Oppo rtuni t ies in the Industry
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Oppo rtuni t ies in the Industry
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Oppo rtuni t ies in the Industry
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Types of Load Banks
Resistive: Most common type. Uses resistors to load the AC powersource. Resistors have a unity (1.0 Power Factor)
Reactive: Used anytime an AC power source requires testing at a laggingpower factor (OEM Factory Testing, Military)
DC: Used to test DC power sources such as batteries, invertors.
Capacitive:Used anytime an AC power source requires testing at aleading power factor. (UPS OEMS, Crest Factor Loads)
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Types of Load Banks
Portable:Defined by dual voltage capability (240/480V), digital
metering, casters and proper dimensions required to fit thru mandoors and freight elevators.
Permanent: Defined by single voltage capability (480V), remotecontrol panel, NEMA 3R construction and load dump circuitry.
Radiator Mounted: Defined by single voltage capability(480V), remote control panel, NEMA 3R construction, load dumpcircuitry. Load bank dimensions are based on genset radiator core
opening.
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Avtron Offers the Widest Variety
and can solve any of your Load Bank requirements.
Types o f Load Banks
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Portable Load Banks from
200-400 KW
25-55 KW
10 KW
100 KW
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All Avtron PortableLoad Banks
feature true dual
voltage design
with no capacityde-rate at 240 or
480V
Up to 700 KW
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Real Time Data Logging
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Trai ler Mounted Load Banks from 500 KW . . .
to1250 KW
to2500 KW
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6000 KVA in an ISO Con tainer
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Permanent Outdoor Load Banks
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Permanently Mounted Free-Stand ing
Load Banks from 25 KW
Permanent Outdoor Load Banks
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up to 4000 KW!!!
Permanent Outdoor Load Banks
200-500 KW
500-2000 KW
2500-4000 KW
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Permanent Outdoo r Load Banks
Au tomat ic Load
Contro l ler
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Real Time Data Logging
Sigma Intelligent Hand Held Controller
Provide full load control and 3 phase instrumentation with a
resolution down to 1KW.
Operate multiple Loadbanks by a single controller.
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For Medium Vol tage App l ications
The Conventional Method is to Use a Low VoltageLoad Bank and Step Down Transformer
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Up to 7 MW at 13.8kV in a single load bank
For Medium Voltage App l icat ions
Only Avtron can offer a truedi rect con nect medium vol tage
load bank. Advantages of A vtron
direct connect are:
BENEFITS:
Lower Installation Costs
Smaller Footprint
Less maintenance
No low voltage/high current
cabling required
8 MW at 12.47 kV in 40 container
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Radiator Mounted Load Banks
Designed to f i t ov er genset radiator core
Designed as s upplemental load 50-70% o f
genset
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Roof Moun ted Load Banks
From 25 - 500 KW
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Are designed to l imi t the ground faul t
current in Medium Voltage Systems
Neutral Ground ing Resisto rs
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5-15 KV
10 or 60 Second s
100-1000 Amps
UL Listed up to 1000 Amps
Neutral Ground ing Resisto rs
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Avtro n Sales Process-Genset Dealers
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Avtron Sales Process
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Avtron Main Competi tor
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SIMPLEX-Sprin g field Il l ino is
Lower Cost/Price DiverEstablished Designs.
U.L. Listed Units.
Extensive Product Line.
Some Portable units in Stock.
Good reps in selected areas
Digital ControllerWebsite: simplexdirect.com
STRENGTHS: WEAKNESS:
Suspect Quality.Some units not load tested.
Galvanized Steel Construction.
+/- 5% Load Tolerance.
Undersize blowers for cooling.
Quotes ref. high exhaust temp.
Sales/Service Support.Quotes take a couple of days.
Very hard to get drawings.
Long lead times.
2011 Simplex on Sight (SOS)opened in Atlanta, GA.
SOS is Simplex Rental Arm
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Avtron Competi tive Advantages
Avtron Load Banks are rated -0, +5% Overall Load Tolerance.
Competitors rate Load Bank +/- 5%.
This means that with Avtron your load bank is guaranteed to
deliver full load.
A Competitive 1000 KW Load Bank will deliver between 950-
1050 KW. Avtron load bank will deliver 1000-1050 KW
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Avtron Competi t ive AdvantagesHeavy Gauge Aluminized Steel
Galvanized:
- rated to 500 F
- corrodes easily
Aluminized:- rated to 1250 F
- resists corrosion
2.5X over galvanized
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Polyester Powder Paint Finish.virtually scratch proof
Helidyne Resistor Elements - No cool down period requiredshut down load bank under full load with no damage
Fully Supported Stainless Steel Element Support Rods designed
for rugged transport conditions
Quick floor to door shipment and portable units in stock
Avtron Competi t ive Advantages
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Bu i l t to the Highest Standards
Avtron Competi t ive Advantages
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Contact ing Av t ron
Av tron Loadbank, Inc.
6255 Halle Drive, Cleveland, Ohio 44125
(P) 216-573-7600
(F) 216-573-5953
www.avt ron loadbank.com
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And res Ab reu Perera Latin America & Caribbean
(P) 216-573-7600 ext. 2260
(C) 216-280-6966
(F) 216-573-5953
aabreu@avtron.com
Contact ing Av t ron
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Offer ing the Widest Var iety of Load B anks
59 Years o f Design Experience
Repu tat ion for Qual ity & Rel iabi l i ty
Know ledgeable Sales and Service Personnel
Quick Del ivery and Portable Uni ts in Stock
Summary
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