You are on page 1of 53



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

History of Avtron

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) trailer mounted 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

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 and light bulbs.

Toaster resistive heating elements

What really is a Load Bank?

Industrial grade load banks used in our market are characterized by: Accurate load tolerance Fine load step resolution Fully supported Helidyne resistive 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

What really is a Load Bank?

A Load Bank is a device which develops an electrical load, applies the load to an electrical power source and converts or dissipates the resultant power output of the source. A Load Bank is intended to accurately mimic the operational or real load which 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 fully controllable load. Consequently, a Load Bank can be further defined as a self-contained, unitized, systematic device which includes both load elements with control and accessory 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 power source, using its energy output to test, support or protect the power source.

What really is a Load Bank?

Automatic Load Controller

Engine Generator Desired Loading 50% to 70%

Load Bank Load

Facility Load

What does a Load Bank do?

All major engine manufacturers specify a minimum load when the engine is running

What does a Load Bank do?

*National Emissions Standards for Hazardous Air Pollutants

Typical Load Bank Applications

Design Research and Development Manufacturing... Quality Control

Installation... Acceptance Testing

Maintenance Testing

Solving Lightly Loaded Problems (wet stacking)

Typical Load Bank Applications

Design Research and Development
Load Banks are used to prove out power source during the R & D phase.

Typical Load Bank Applications

Manufacturing... Quality Control
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.

Typical Load Bank Applications

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.

Typical Load Bank Applications

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 generator can then be identified and rectified in a non-critical environment.

Typical Load Bank Applications (Wet Stacking)

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 adequately loaded.

Typical Load Bank Applications

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.

Opportunities in the Industry

Opportunities in the Industry

Opportunities in the Industry

Types of Load Banks


Most common type. Uses resistors to load the AC power source. Resistors have a unity (1.0 Power Factor)


Used anytime an AC power source requires testing at a lagging power 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 a

leading power factor. (UPS OEMS, Crest Factor Loads)

Types of Load Banks


Defined by dual voltage capability (240/480V), digital metering, casters and proper dimensions required to fit thru man doors and freight elevators.

Permanent: Defined by single voltage capability (480V), remote

control panel, NEMA 3R construction and load dump circuitry.

Radiator Mounted:

Defined by single voltage capability (480V), remote control panel, NEMA 3R construction, load dump circuitry. Load bank dimensions are based on genset radiator core opening.

Types of Load Banks

Avtron Offers the Widest Variety

and can solve any of your Load Bank requirements.

Portable Load Banks from

100 KW 10 KW

25-55 KW
200-400 KW

Up to 700 KW
All Avtron Portable Load Banks feature true dual voltage design with no capacity de-rate at 240 or 480V

Real Time Data Logging

Trailer Mounted Load Banks from 500 KW . . .

to1250 KW

to2500 KW

6000 KVA in an ISO Container

Permanent Outdoor Load Banks

Permanent Outdoor Load Banks

Permanently Mounted Free-Standing Load Banks from 25 KW

Permanent Outdoor Load Banks

500-2000 KW

2500-4000 KW
200-500 KW

up to 4000 KW!!!

Permanent Outdoor Load Banks

Automatic Load Controller

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.

For Medium Voltage Applications

The Conventional Method is to Use a Low Voltage Load Bank and Step Down Transformer

For Medium Voltage Applications

Up to 7 MW at 13.8kV in a single load bank

Only Avtron can offer a true direct connect medium voltage load bank. Advantages of Avtron 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

Radiator Mounted Load Banks

Designed to fit over genset radiator core Designed as supplemental load 50-70% of genset

Radiator Mounted Load Banks

From 15 KW to 1000 KW

Roof Mounted Load Banks

From 25 - 500 KW

Neutral Grounding Resistors

Are designed to limit the ground fault current in Medium Voltage Systems

Neutral Grounding Resistors

5-15 KV 10 or 60 Seconds 100-1000 Amps UL Listed up to 1000 Amps

Avtron Sales Process

Consulting Engineers / Third Party Engineering Auditors / Codes & Standards
Specifications Influence to Purchase Avtron Load banks


Facility Managers (Emcor, Jones Lang, Cushman)

Construction Managers (Turner, Holder, Tishman)

Genset Dealers

Genset OEMs

Real Estate

Electrical Contractors Systems Integrators

Turner Logistics


Electrical Distributors

Rental Co

Avtron Sales Process-Genset Dealers

Avtron Sales Process

Avtron Main Competitor

SIMPLEX-Springfield Illinois
STRENGTHS: Lower Cost/Price Diver Established Designs. U.L. Listed Units. Extensive Product Line. Some Portable units in Stock. Good reps in selected areas Digital Controller Website: 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

Avtron Competitive 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 9501050 KW. Avtron load bank will deliver 1000-1050 KW

Avtron Competitive Advantages

Heavy Gauge Aluminized Steel
Galvanized: - rated to 500 F - corrodes easily Aluminized: - rated to 1250 F - resists corrosion 2.5X over galvanized

Avtron Competitive Advantages

Polyester Powder Paint Finish.virtually scratch proof Helidyne Resistor Elements - No cool down period required shut 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 Competitive Advantages

Built to the Highest Standards

Contacting Avtron
Avtron Loadbank, Inc.

6255 Halle Drive, Cleveland, Ohio 44125

(P) 216-573-7600 (F) 216-573-5953

Contacting Avtron
Andres Abreu Perera Latin America & Caribbean

(P) 216-573-7600 ext. 2260

(C) 216-280-6966 (F) 216-573-5953


Offering the Widest Variety of Load Banks 59 Years of Design Experience Reputation for Quality & Reliability Knowledgeable Sales and Service Personnel Quick Delivery and Portable Units in Stock