Asco 8300 User manual
8000 SERIES Load Banks
User Manual
Power
Technologies
© NJ Froment & Co. Ltd. This document may not be copied
or disclosed in whole or part without p rior written aut hority.
© 2000-2018, N J Froment and Co Ltd (‘The Company’).
N J Froment and Co Ltd is part of the ASCO Power Technologies business platform.
Froment and the Froment logo are trademarks or registered trademarks of N J Froment and Co Ltd . All other names and logos referred to are trade names, trademarks or registered trademarks
of their respective owners.
While every precaution has been taken to ensure accuracy and completeness herein, N J Froment and Co Ltd assumes no responsibility, and disclaims all liability, for damages resulting from use
of this information or for any errors or omissions. Specifications are subject to change without notice.
The Company retains exclusive rights to the intellectual property in any designs, specifications, publications and software described or included herein. The property shall not be used in whole
or part for any purpose other than in connection with the Company’s particular products that this document is intended to accompany. The Company’s identification marks on its products and
documents must not be intentionally removed, concealed or defaced. This document may not be copied or disclosed, in whole or part, without prior written authority; any such authority will
include the condition that this copyright statement remains attached.
Froment 8000 SERIES load banks are manufactured in the UK by:
N J FROMENT & COMPANY LIMITED,
Easton-on-the-Hill,
STAMFORD,
PE9 3NP,
United Kingdom
Tel: +44 (0)1780 480033
Fax: +44 (0)1780 480044
Web: www.ascopower.com
8000 SERIES Load Bank User Manual
Version 1.3 February 2018
Table of Contents
Introduction
An important note on safety 0 - 2
Chapter One - Introducing Froment Load Banks
Why is Power Supply Testing Required? 1 - 2
• How can a generator be tested eectively?
• The load bank
How do load banks work? 1 - 3
Introducing Froment Load Banks 1 - 4
Froment Load Bank Control Options 1 - 5
• User control interfaces
Non-unity Power Factor Testing 1 - 8
• When is non unity power factor testing required?
• Multiple generator testing
• What equipment is required?
Movable Load Banks 1 - 10
Load Bank Applications 1 - 12
• Generating set testing
Testing UPS systems and batteries 1 - 13
• Site load correction
Using Multiple load banks 1 - 15
Introducing Froment 8000 SERIES Load Banks 1 - 16
8000 SERIES Load Bank Specifications 1 - 17
Chapter Two - Load Bank Installation and Setup
Using a Froment Load Bank Safely 2 - 2
ii
Table of Contents
Transporting Froment 8000 SERIES Load Banks 2 - 4
• Lifting by fork lift truck
• Lifting by crane or hoist
• Transport
• Storage
• Packaging
Installing Froment Load Banks 2 - 6
• Location
• Sound attenuators
• Avoiding hot air re-circulation
Electrical Installation 2 - 8
• Voltage and frequency ratings
• External supply wiring - the fan and controls power source
• Anti-condensation heaters and lighting supply
• Connecting the Supply-on-Test
• Making connections for single-phase operation
Control System Connections 2 - 15
• Remote panels for static load banks
Commissioning 2 - 16
• Troubleshooting
Chapter Three - Load Bank Operation
Before operating the load bank 3 - 2
• Safety warning
Controlling the load bank 3 - 3
• The control room
• Main control panel
• System monitor
• Operating the optional air circuit breakers (ACB’s)
• Status indicator lamp operation
• Fault indicators
Emergency Shutdown Procedures 3 - 11
Load Function Test 3 - 12
Load Bank Emergency Operation 3 - 14
iii
Table of Contents
iv
Table of Contents
Load Bank Operation using a Remote Control 3 - 15
Chapter Four - Hand-held Reference Guide
The Sigma Hand-held 4 - 2
Firmware Updates 4 - 3
Connecting the Hand-held to the Load Bank 4 - 3
The Hand-held Keypad 4 - 4
The Hand-held Menu Display System 4 - 5
Using the Sigma Hand-held 4 - 8
Hand-held Quick Start 4 - 9
Using the Settings Pages 4 - 10
The Options Page 4 - 15
The Test Pages 4 - 19
Manual Test Mode 4 - 23
Auto Test Mode 4 - 27
Chapter Five - Maintenance & Troubleshooting
Safety Warning 5 - 2
Routine Maintenance Procedures 5 - 3
• Air Circuit Breaker (option) Maintenance
• Annually
Fault Finding 5 - 5
Sigma 2 Load Bank Status Display 5 - 6
• Sigma 2 normal operation
• Warnings
• Errors
v
Froment Load Bank System Monitor 5 - 11
• Startup Screen
• Navigation
• The Meters Screen
• I/O Screen
• Status Screen
• Load Screen
• Operating the Load/Control screen
Appendicies
8300 - Installation Diagrams A - 2
8400 - Installation Diagrams A - 5
Certificate of Conformity A - 7
Electromagnetic Compatibility A - 8
Useful Equations A - 9
Introduction
This manual should provide you with all the information that you need to safely install and operate
Froment 8000 SERIES load banks.
The manual is divided into five chapters:
In addition to these five chapters there are a number of Appendices containing information that did
not fit easily within the main body of the text. These include installation drawings, a certificate of
conformity, and some information about electromagnetic compatibility.
Chapter One provides an introduction to the general principles of power supply testing
and explains how a Froment Load Bank makes the process easier, safer and more
reliable. It then provides an introduction to the 8000 SERIES load banks and their main
features.
Chapter Two covers all of the procedures that need to be carried out before a load
bank can be put into operation. It explains how to install the unit safely and how to
commission it to check that it will operate correctly.
Chapter Three explains the basics of how to operate the load bank. It describes the
load bank controls and explains how they are used in an emergency. This chapter also
explains how the load bank can be operated when an Hand-held or other control unit
is not available.
Chapter Four provides a detailed reference to the Sigma Hand-held, including details
of its more advanced features.
Chapter Five covers the maintenance procedures you will need to follow to keep a
8000 SERIES load bank operating correctly. It also explains how to troubleshoot should
a problem occur.
Chapter One
An Important Note on Safety
All Froment load banks are designed with safety as a very high priority, but their operation does
present some risks. In common with other test equipment, the safety of all concerned is dependent
on the way that the unit is operated. Do not use this equipment unless you have read and understood
this manual, and are familiar with the accepted practice for the industry. The equipment should not
be used by unskilled personnel. Misuse could result in serious injury and damage to the equipment.
Be sure to follow all of the safety warnings in this manual. In particular, pay careful attention to the
following points:
• Keep all personnel who are not directly involved with tests well away from the load bank and the
equipment under test.
• The discharge air can be very hot and could cause serious flesh burns. Do not touch the outlet
grille while the load bank is running, or for a few minutes afterwards.
• Ensure that there is no risk of the hot discharge air re-circulating back to the air inlet of the load
bank, extensive damage is possible due to short-circuiting the cooling air.
• Ensure the air inlet and outlets are completely unobstructed and that there is no loose paper,
plastic bags, or other debris that may be drawn on to the air inlet grille, obstructing the airflow.
• Combustible material left near the air discharge should be removed.
• Only operate the load bank with all the guards in place, with doors closed and with all of the
covers and protective screens securely in position.
• Always route cables into the terminal compartment through the gland plate or strain relief
system provided. The terminal compartment door must be closed during the test.
• Make sure that all equipment is adequately grounded; this applies equally to the Supply-on-Test,
and the load bank.
• Ensure all cables are in good condition and adequately rated for the planned load, and that all
connections are securely made.
• Ensure all cables are long enough to lay in smooth curves, and are unstressed, undamaged, and
protected from mechanical damage. Lay the cables to minimise the risk of personnel tripping or
accidentally tugging on the cables.
• Do not switch o the cooling fan immediately after a test. Allow the fan to run for 5 minutes after
removing the load.
• Store the equipment in a clean, dry place when not in use. Only install and operate the load bank
in environmental conditions suited to the enclosure classification of the load bank.
Chapter One
Introducing Froment Load Banks
If you are not familiar with the use of Froment Load Banks then you should start with this chapter. It
provides an introduction to the general principles of power supply testing and then it explains how a
Froment load bank makes the process easier, safer and more reliable.
If you are an experienced load bank user you may want to skip the earlier sections, but you should
certainly read the introduction to Froment 8000 SERIES load banks which appears at the end of the
chapter.
Chapter One
1 - 2
Introducing Froment Load Banks
1 - 3
Why is Power Supply Testing Required?
There are many dierent ways of generating electrical power and many reasons why
generating equipment may be required. All of them have at least one thing in common: it
is essential that the generator be capable of operating eectively at its maximum rated
output when it is required.
Unfortunately, it is not so easy to be absolutely sure that this will be the case. Many
generating sets operate at a fraction of their rated output for a large proportion of the
time, and many others are intended to run in an emergency situation which may occur only
occasionally.
In both cases the only way to ensure that generating equipment is capable of providing
the performance required is to regularly test it whilst it is operating at its full rated output.
The various regulatory authorities and other concerned parties such as insurance
companies are aware of this, and the testing of new installations is mandatory. In many
cases there is also a requirement for regular testing for existing equipment, particularly
those that provide emergency or standby power supplies.
How can a generator be tested eectively?
The answer to this is very straightforward: apply a load that is equivalent to the generator’s
maximum output and then run the generator and observe how it performs.
The careful measurement of the generator’s output will reveal any problems with its ability
to meet the specification. Then, after repairs or modifications have been made, the test
can be repeated to verify that the fault has been rectified.
The load bank
For reliable testing it is important to provide a load that is a precise match for the generator’s
output. It must provide a consistent and repeatable load so that the test can be accurately
measured and recorded and it must also be capable of dissipating the large amount of heat
that is generated during the test. And, it is critically important that the test does not put
the site load at risk.
To achieve all this requires a specialist item of equipment: the load bank. These consist
of an array of load elements combined with a control system designed to ensure that a
precise load can be applied in safety.
+
+
_
_
AV
How Do Load Banks Work?
Load banks are complex precision engineered machines, but to explain the general
principal we can provide a very simple model of how they work:
Figure 1-1 Basic DIY generator output test system.
Figure 1-1 shows the general arrangement of a very basic DIY generator testing system.
It’s simple, but it contains the four basic items necessary to test a generating set safely:
1. The fan heater’s heating elements provide an electrical load that is large enough to
ensure that the generator runs at full capacity.
2. The fan heater’s switch gear provides a control system that will ensure that the load
can be applied safely, and in a way that will not cause damage to the generator and its
control circuits, or injury to the personnel running the test.
3. The fan in the fan heater provides a method of safely dissipating the considerable
amount of heat generated by the test.
4. The voltmeter and ammeter provide instrumentation that will allow the results of the
test to be monitored.
Of course, this kind of arrangement can provide only a crude test for a low powered
generator and its ability to match the generator’s output accurately is very limited. As the
output of the generator increases, the cabling, switchgear and control equipment required
for this becomes increasingly heavier and more sophisticated. In addition, because of the
large amount of heat generated during testing, the issue of how to conduct the test safely
becomes increasingly significant.
Chapter One
1 - 4
Introducing Froment Load Banks
1 - 5
Introducing Froment Load Banks
Froment load banks are purpose designed to provide all of the facilities needed to quickly,
safely and reliably test generating equipment with outputs up to several megawatts.
Figure 1-2 Froment load bank core components
There are many variations between dierent Froment load bank models, but Figure 1-2
shows a simplified schematic of the core components to be found in most units.
The diagram contains:
• An array of load elements grouped in small steps that are individually activated by
switchgear to allow the load applied to the generator to be precisely controlled.
• A fan and duct forced air system which ensures that the heat generated during testing
is vented safely to atmosphere.
• Fuses and safety interlocks that ensure that the test can be shut down in a controlled
fashion if any problems occur.
• A microprocessor based control and three phase instrumentation system connected to
a number of highly accurate voltage and current transformers. This provides automatic
precision control of the test and allow the results to be displayed with better than 0.5%
accuracy.
Cold air
inlet
Fan
motor
Air duct
Fan
contactor
Step 1Step 1Step n
Load Elements
Hot air
outlet
Supply-on-test
Remote control
unit
External supply for
fan and controls
Sigma II
load bank
controller
Front panel controls
Load
contactors
Fuses
Phase
rotation
sensor
Current/Voltage
Transformers
Froment Load Bank Control Options
Reliable testing requires precise control of the load applied to the generator and accurate
real-time measurement of the generator’s output.
To achieve this, most Froment load banks are fitted with a Sigma 2 load control system.
Sigma 2 is a microprocessor-based control and instrumentation system specifically
developed for load bank applications.
Sigma 2 provides precise control over the operation of each load element during the test
whilst simultaneously measuring the results. The unit also provides safety monitoring and
interlocks which shut down the load bank safely should a problem occur.
Figure 1-3 Sigma 2 load bank control unit.
User control interfaces
The wide variety of dierent applications for load banks require a wide variety of user
control interfaces. These range from a very basic switch controlled system through to
sophisticated computerised control, instrumentation and data logging systems.
All Froment load banks are supplied with a built-in switch plate which contains a Fan and
Controls Supply Isolator, Start and Stop switches and (for Sigma2 controller equipped
units) Sigma control cable connectors.
The switch plate may contain other controls, depending on the specific load bank variant.
Depending on the application, the Sigma controller unit can be operated by a number of
dierent control interfaces. These include:
© NJ Froment & Co. Ltd. This document may not be copied
or disclosed in whole or part without prior written authority.
Chapter One
1 - 6
Introducing Froment Load Banks
1 - 7
Decade switch local control panel. The simplest form of control is via a series of decade
switches mounted on the unit’s switchplate or on a remote control panel. These provide
basic manual control and are only available on units fitted with purely resistive load
elements.
Figure 1-4 Decade switch local control panel
Sigma Hand-held. The Hand-held unit provides load control and instrumentation on
Sigma controlled load banks.
Figure 1-5 Sigma Hand-held
The Hand-held contains a membrane keyboard and built in display unit and is connected
to the load bank by a control cable. The Hand-held’s simple user interface provides a way
for generator tests to be conducted in an intuitive way with minimum of calculation.
Sigma PC Load Control Software. As an alternative to the Hand-held the load bank can
be connected to a PC running Froment Sigma PC Load Control software.
This Windows™ application provides all of the facilities of the Hand-held with an enhanced
user interface, improved instrumentation and facilities for response analysis, data
acquisition, and reporting. Test data can be exported for use by other applications such as
Microsoft™ Excel.
Fan and controls
supply isolator (Emergency Stop)
Fan and controls
supply source
selector
Manual stop/start
buttons
Apply/Remove
load pushbuttons
Decade switch
load selectors
Supply on test
status indicator
Figure 1-6 Sigma PC Load Control Software
Sigma Modbus Interface. Every Sigma controlled load bank has the capability to be
remotely controlled using the industry standard Modbus serial communications protocol.
This will allow the load bank to be integrated with a wide range of test, automation,
supervisory and monitoring systems. Modbus control is beyond the scope of this manual.
If you need more information please contact the Froment technical support department.
Note: Both the Hand-
held and the PC soft-
ware can control up to
14 Sigma controlled load
banks simultaneously.
Tests can be run manu-
ally or automatically us-
ing a pre-programmed
test sequence.
© NJ Froment & Co. Ltd. This document may not be copied
or disclosed in who le or part without prior w ritten authority.
Chapter One
1 - 8
Introducing Froment Load Banks
1 - 9
Non-unity Power Factor Testing
It is unusual for a generator to be presented with a purely resistive load. In real-world
applications it is much more likely that the load is made up of a combination of resistive,
inductive and capacitive elements (electric motors, lamp ballasts, etc.) which may be
continuously changing as various items of equipment are switched on and o.
The inductive and capacitive (reactive) parts of the load tend to store and then return
energy, and some proportion of the power supplied to the circuit is returned to the
generator. Consequently, more current has to flow to provide the required amount of
power to the circuit and the circuit is said to have a low (or non-unity) power factor. For
instance, to get 1kW of real power, a load with a power factor of 0.8 will require 1.25 kVA
apparent power to be supplied.
Figure 1-7 Typical power curve for power factor of 0.8
A low power factor puts additional stresses on alternators, voltage regulators, and switch
gear without necessarily putting additional load on the engine. Many generating sets are
designed to reach their maximum output when connected to a non-unity power factor
load.
To provide a realistic test, it is necessary for the load bank to simulate this situation. To
achieve this, the load bank elements need to consist of a mixture of resistive heating
elements and inductors. In some applications, capacitors are also used.
Voltage
Current
Power
0
Proportion of power
returned to the source
When is non unity power factor testing required?
This depends on the type of test that is required.
Sometimes, for smaller generators where a standardised alternator design is in use, the
electrical performance of the alternator and control gear can be assumed to be adequate.
In this case the only requirement during testing is to prove that the motive source of
the generating set is capable of operating at full power without overheating and a purely
resistive load is all that is required. This is sometimes referred to as active load (power
factor 1.0) or unity power factor.
However, in many situations the electrical performance of a generating set is of critical
importance. In these cases it is necessary to put the motive source, alternator and its
associated control gear all under stress during testing. To do this a combined load made
up of resistive and reactive elements is required.
Combined loads are also required to set up systems where multiple generating sets are
running in parallel or where it is necessary to simulate the start up of a large motor.
Multiple generator testing
Multiple generating sets running in parallel can present a problem for installers when it
comes to setting up load sharing and voltage regulation on a new system. A purely resistive
load will not provide the required load characteristics and a combined load is required for
initial calibration and testing.
What equipment is required?
Combined load testing can be accomplished by using a combined load bank (a load bank
consisting of a mixture of resistive and reactive load elements) or by running two or more
dierent type load banks in parallel.
The exact combination of equipment required will depend on the specific application.
Typically power factors from 1.0 to 0.7 are used but motor start simulation may require
a power factor as low as 0.4. See the appendices of this manual for more details of the
calculations involved.
Note: Froment com-
bined, inductive and
capacitive load banks
are in the 6000 SERIES
range. Froment purely
resistive load banks
are in the 3000 SERIES
range and Froment con-
tainerised units are in
the 8000 SERIES range.
Chapter One
1 - 10
Introducing Froment Load Banks
1 - 11
Movable Load Banks
Many Froment load banks are supplied for applications where they will be permanently
installed at a particular site location. However, in some applications the load bank is as a
temporary measure that is only required whilst generator tests are carried out.
This is quite common, for instance, with a new generator installation where the load bank
is used during commissioning and acceptance testing.
Figure 1-8 Additional components required for a movable load bank
Because of the temporary nature of the installation there are some specific design
dierences between a load bank intended for permanent installation and one intended to
be “movable”.
These include:
External power supply inlet. The load bank’s fans and control electronics can be powered
by the generator under test or (as recommended by Froment) a completely separate,
external power source. To make providing external power simple on a movable load bank,
a suitably rated IEC60309 connector is mounted on the unit either externally or behind a
lockable door with cable access.
Hot air
outlet
Cold air
inlet
Fan
motor
Air duct
Sigma II
Load bank
controller
Front panel controls
Load elements
Load
contactors
Fan
contactor
Current/Voltage
Transformers
Supply-on-test
External supply for
fan and controls
Remote control
unit
Step 1 Step 2 Step n
Fuses
Phase
rotation sensors
Supply
selector
Power supply selector switch. The load bank switch panel is fitted with a selector switch,
allowing easy selection between O, Internal supply (generator under test) or external
(Auxiliary) supply. The switch is not fitted where the load system is designed for a supply
that is incompatible with the fan supply, for example, on low voltage AC, DC, or 400Hz load
banks.
Phase rotation sensor and reversing contactors. These ensure that the fans on load
banks with three phase fans automatically rotate in the correct direction, irrespective of
how the phases are connected.
Control cable socket. The switchplate is fitted with a socket which allows Sigma 2 control
cables to be quickly attached and removed.
Multiple power cable entry options. Froment load banks designed for permanent
installations are provided with a non-ferrous gland plate that allows a fully compliant IP54
installation. The movable load banks are provided with a choice of cable entry options:
• Through a pre-punched, non-metallic plate fitted with protecting shutters or grommets.
• Through a protected slot.
• Through a nonferrous gland plate.
• Via optional externally mounted multipole (IEC60309) or single pole plug and socket
connectors.
Figure 1-9 Typical movable load bank control panel.
OUT IN
Sigma 2
Control
∑
Fan and controls
supply isolator (Emergency Stop)
Fan and controls
supply source
selector
Manual stop/start
buttons
Sigma control
interface cable
sockets (in/out)
Load bank
number selector
Supply on test
status indicator
LB00060
LOAD BANK NUMBER
When controlling more
than one load bank, each
must have a different
number set on this switch.
Sigma 2
Control
∑
All doors must be shut
and guards fitted before
running this equipment.
Remove load and allow
elements to cool before
stopping the fan.
START
STOP/
RESET
Warning! Isolator for fan
and controls supply only.
Other supplies may enter this load
bank. Isolate all before working on
this equipment.
Select “Internal” only when the
Fan & Controls Supply Selector
supply-on-test equals the control circuit
rated voltage and frequency.
OFF ExternalInternal
Supply-on-Test
Status
Off: No Voltage
On: Normal
Operation
Flashing: Out of
Limits
© NJ Froment & Co. Ltd. This document may not be copied
or disclosed in whole or part without prior written authority.
Chapter One
1 - 12
Introducing Froment Load Banks
1 - 13
Load Bank Applications
The main application for a load bank is for use during generator testing. However, load
banks are versatile devices and they have a number of useful applications that can be
applicable during the installation, commissioning and ongoing operation of a generator.
Generating set testing
The specific tests that need to be carried out for a particular installation depend on local
regulations, the application, the type of equipment involved and the requirements of
insurance companies, local authorities and other interested parties.
The requirements for the testing of engine driven generators are described in ISO 8528
part 6. This document explains the general test requirements and describes both a
functional test and an acceptance test. Functional tests must always be done and usually
occur at the manufacturer’s factory. Acceptance tests are optional and are often done on
site, witnessed by the customer or his representative.
ISO 8528 part 5 defines three performance classes - G1, G2 and G3, each with dierent
criteria:
• G1 is the least stringent and applies to small generating sets intended to supply simple
loads.
• G2 is broadly equivalent to commercially available power.
• G3 is intended for sets which are powering loads which particularly require a stable
and accurate power supply.
A further class, G4, allows for performance criteria agreed between the supplier and the
buyer.
In addition to the testing that is carried out immediately after installation, it is important
to carry out regular tests as part of an ongoing maintenance program. This is particularly
important for emergency power supplies that may have long periods of non-operation.
The type of tests carried out include:
• Load duration tests (also known as a “heat run”), designed to record steady-state
voltages, frequency, and also to calibrate instrumentation and measure emissions and
fuel consumption.
• Load acceptance tests, which check changes in frequency and voltage regulation due
to sudden load changes. These tests ensure that the rise and fall of the generator’s
output voltage and frequency remain within limits as load is applied and removed.
Testing UPS systems and batteries
Uninterruptable power supply systems consisting of a generating set combined with a set
of batteries are a common feature of data centres and other installations where maintaining
a constant power supply is critical. In the event of a power failure the batteries provide an
immediate source of power whilst the generator is automatically started, synchronised to
the correct frequency and put online.
Regular testing of the batteries, generator and its automatic control gear is extremely
important, but testing using the site load could put critical systems at risk and may not
provide suicient load for a complete test. Load banks provide an ideal solution because
they will allow the operation of the UPS to be fully tested without posing any risk to the
site load.
Site load correction
In many applications a generator may be required to run for extended periods with little or
no load applied. For a diesel generator this may mean that the engine does not reach its
optimum operating temperature and this can cause a problem sometimes known as “wet
stacking” – so called because unburnt fuel can make its way through to the exhaust stack.
This can lead to serious maintenance problems, including high levels of cylinder wear,
excessive fuel consumption and high levels of emissions.
Froment load banks provide a function known as Site Load Correction (SLC) which provides
an automated solution to this problem. This is where the load bank automatically adds and
removes load to keep the generator running at an optimal temperature.
There are many applications for Site Load Correction. Figure 1-10 shows an example
scenario where a site that is usually supplied by the public utility supply makes use of a
backup generator. The system is designed so that, if the utility supply fails, the generator
will start up and supply power to the site until the utility supply is restored.
Note: The specific
details regarding the
frequency and type of
test required may also
be specified by local
regulations or other
interested parties.
Chapter One
1 - 14
Introducing Froment Load Banks
1 - 15
Figure 1-10 Example layout for a typical Site Load Correction system.
The load bank starts up when the generator begins to operate and its control circuits
begin to monitor the output current. If this is below a certain set point then the load bank
will slowly apply additional load to bring the generator within the optimum range. If the
current increases in response to an increase in site load the load bank will remove load
accordingly. The load bank can do this very quickly in response to sudden changes of site
load such as a lift or pump motor starting up.
SLC is a specialist application for a load bank and it requires careful configuration. Please
contact Froment for more information and advice if you are thinking of configuring your
load bank for SLC.
Using Multiple Load Banks
Froment’s Sigma control system allows up to fourteen load banks to be interconnected and
controlled from a single terminal as if they were a single unit. This means that multiple load
banks can be combined to match particularly large generating sets, or that a combination
of resistive, capacitive or inductive loads can be mixed for special purpose or one-o tests.
Figure 1-11 Connecting multiple load banks
One example of the use of multiple load banks might be where a purely resistive load bank
is to be permanently installed for ongoing routine maintenance engine tests. A load bank
with inductive elements could be added for a short period so that commissioning and
acceptance tests can be carried out.
Note: When multiple
load banks of dierent
capacities are used the
load applied is shared
proportionally depend-
ing on the ratio of the
load banks’ capacity.
The cable sizes for the
Supply-on-Test must
take this into account.
Control Signal
Load Bank
Generator
Current
Transformer
Site Load
Utility Supply
Total control cable length = 1km
Sigma interface cable Load Bank
1
Load Bank
2
Load Bank
n
Remote
control
unit
Supply
under
test
In OutIn OutIn
© NJ Froment & Co. Ltd. This document may not be copied
or disclosed in whole or part without prior writ ten authority.
Chapter One
1 - 16
Introducing Froment Load Banks
1 - 17
8000 SERIES Load Bank SpecificationsIntroducing Froment 8000 SERIES Load Banks
The 8000 SERIES load banks are currently the largest capacity self-contained load banks
supplied by Froment. In standard form they are Sigma controlled, combined (resistive/
reactive) load banks with capacity ranging from 3300 kVA (8300) to a maximum of around
6000 kVA (8400).
Both units are housed within custom-made ISO standard intermodal shipping containers.
The 8300 is contained within a 10ft container, and the 8400 within a 20 ft container. Both
sizes are fitted with standard ISO twistlock lifting and fixing points and are supplied with
CSC certification for top-loading shipping. The 8400 is also fitted with pad eyes to provide
a conventional four-point lift.
The units are of all steel construction and are insulated to minimise condensation. The
internal cabinets are manufactured from corrosion resistant, zinc-plated mild steel using
the Froment standard construction method.
The 8300 load section consists of a single, horizontal input, vertical output air duct for the
resistive load elements with the reactive load elements mounted in separate cabinets to
the side.
The resistive elements are mounted in the top half of the duct and forced-air cooling for
them is provided by a pair of axial fans mounted in the lower section. The load section is
combined with a control room containing all of the switchgear and operating controls for
the load bank. A side entry door allows personnel to enter the control room.
The 8400 has a similar configuration to the 8300, but has a second, identical, load section
on the far side of the control room. The Supply-on-Test connection bus bars are connected
together for normal operation, but can be separated for use with unmatched transformers.
Optional power air circuit breakers providing short circuit, overload and earth fault
protection can be fitted to both units.
The air inlet louvres are fitted with steel mesh grills and the outlet ducts are fitted with
stainless steel mesh screens, both of which provide protection to IP1X. Optional air inlet
louvre covers can be fitted to provide environmental protection during transport.
In the control room all of the electrical and electronic components are housed behind
recessed doors, which are fitted with seals that provide protection up to IP54.
8300 8400
Nominal capacity @ 0.8pf 480V 60Hz (kVA) 3300 6000
Nominal capacity @ 0.8pf 400V 50Hz (kVA) 2275 5000
Terminal quantity/phase & size(mm) 6 x M12 12 x M12
Containerised ISO style (10ft) (20ft)
Length (mm) 2991 6058
Width (mm) 2438 2438
Height (mm) 2591 2591
Weight, approximate (kg) 9000 16000
Fan(s) - No. x diameter (mm) 2 x 900 4 x 900
Fan poles 4 4
Fan motor (kW/Ph) 10.5/3 10.5/3
Fan & Control current max (A) 38.4 76.8
Total current max - Starting (A) 124 163
Fan start - Staggered starting for multiple units DOL DOL
Noise level, dB(A) 60Hz @ 90° (@ 3m) 90 93
Airflow 60Hz (m³/sec) 17.5 35
Fan static pressure 60Hz (Pa) 645 645
Average air temp Rise 60Hz (°C) 138 138
Air outlet velocity 60Hz (m/s) 7.5 7.5
Noise level, dB(A) 50Hz @ 90° (@ 3m) 85 88
Airflow 50Hz (m³/sec) 14 28
Fan static pressure 50Hz (Pa) 415 415
Average air temp Rise 50Hz (°C) 146 146
Air outlet velocity 50Hz (m/s) 6 6
Airflow direction Vertical Vertical
Froment load banks are constructed to suit customers specifications for a particular application. The following
table describes standard equipment for the 8300 and 8400, but there are many custom options and configurations
available. Please contact Froment sales oice for more details.
The data shown is for standard build equipment. Other capacities & voltages are available and the fan details may
also change dependant on specific requirement.
Chapter One
1 - 18
Reactive
load elements
Resistive load elements
Axial fan
Louvered air
intake grill
Optional air
intake cover
Hot air exhaust
Switchgear cabinet
Control room
access door Control room power
supply cable inlet
Figure 1-12 Froment 8400 load bank - cutaway view showing
major components
Chapter Two
Load Bank Installation and Setup
This chapter covers all of the procedures that need to be carried out before a Froment load bank can
be put into operation. It explains how to install the unit safely and how to commission it to check that it
will operate correctly.
Important!
The chapter contains a number of important safety instructions. Do not attempt to install or operate
your Froment Load bank until you have read and understood this chapter. Misuse could result in serious
injury and damage to the equipment.
Chapter Two
2 - 2
Using a Froment Load Bank Safely
Your safety, and the safety of those around you, is dependent on your knowledge of this
equipment’s safe operating procedures. Load banks can be dangerous and must not be
used by unskilled personnel, or by those who have not familiarized themselves with these
instructions.
You should remain alert to potential danger during transport and installation, when the
unit is in operation, and when maintenance operations are performed.
There are four main sources of danger:
Handling hazards. Load banks are large, heavy devices and they often have to be
manoeuvred in to tight, diicult spaces before they can be installed.
Contact with high voltage electricity. Serious injury or death could result from contact
with electrically live parts. Even though the connections to the load bank may be temporary,
they must always be made to the same standards as if they were permanent.
Contact with fast moving parts. The fan, in particular, can cause serious injury if you
come into contact with it when it is in operation.
Heat hazards. When a test is in progress the resistive elements can glow cherry red. The
heat they produce is removed by the air that the fan forces past them, but that air in turn
can become very hot.
To avoid these hazards, pay particular attention to the following points:
• Make use of the correct handling equipment and ensure that all personnel involved in
transportation and installation have the appropriate training and experience needed
to carry out the operation safely.
• Only operate the load bank with the doors, covers and protective screens securely in
position.
• Always route cables into the terminal compartment through the gland plate or strain
relief system provided. Do not route cables through the terminal compartment door.
The door must not be open during the test.
• Make sure that both the Supply-on-Test and the load bank are adequately grounded.
• Ensure all cables are in good condition and adequately rated for the planned load, and
that all connections are securely made.
• Ensure all cables are long enough to lay in smooth curves, and are unstressed,
undamaged, and protected from mechanical damage.
• Lay the cables to minimise the risk of personnel tripping or accidentally tugging on
the cables.
• Keep all personnel who are not directly involved with tests well away from the load
bank and the equipment under test.
• The discharge air from the load bank can cause serious burns. Keep away from the
outlet grille while the load bank is running, and do not touch it for at least 10 minutes
after the test is completed.
• Do not switch o the cooling fans immediately on concluding a test. After removing
the load allow the fans to run for a further 5 minutes to dissipate the residual heat. This
will reduce any fire risk and prevent possible damage to the equipment.
• Make sure that the air inlet and outlets are completely unobstructed and that there is
no loose material that could be drawn in to the air inlet grille.
• Ensure that there are no combustible material near the air discharge.
• Keep an approved electrical fire extinguisher present at all times when the load bank
is in operation.
Noise Hazard. The load bank’s operating noise level is above 85dB and ear protection
must be worn when it is in use. Please refer to the local regulations regarding noise levels
and ear protection.
Load Bank Installation and Setup
2 - 3
Chapter Two
2 - 4
Transporting Froment 8000 SERIES Load Banks
The 8300 load bank weighs approximately 9000kg and the 8400 approximately 16000kg
(see the rating plate for the exact weight). They require a hoist, forklift or other lifting
equipment to move them.
Both sizes are fitted with standard ISO twistlock lifting points and are supplied with CSC
certification for top-loading shipping. The 8400 is also fitted with pad eyes to provide
a conventional four-point lift if required. The 8300 is fitted with purpose made forklift
pockets in the base of the container as standard, and the 8400 may have these fitted as
an option.
If you need to move the load bank it is important to pay attention to the following
points:
Lifting by forklift truck
If forklift pockets are installed, they must be used when the unit is lifted by forklift
truck. Check the specifications to ensure that the forklift truck has suicient capacity to
safely lift the weight. Add 5% to the specified weight for packaging materials.
Lifting by crane or hoist
Any equipment designed for moving a shipping container should be suitable for the
purpose. The crane and any lifting chains or straps used must have suicient capacity to
safely lift the weight of the load bank. All of the available lifting points must be used.
Transport
All doors and louvre covers should be closed and locked before moving the unit.
When originally shipped, 8000 SERIES load banks are provided with removable shipping
covers. These should be retained and re-fitted before the unit is moved - this is particularly
important if the unit is to be shipped by sea.
• The container should only be transported on a flat-bed or flat-rack type open vehicle
fitted with the appropriate twistlocks to allow the container to be secured to the
vehicle.
• If the 8300 is to be shipped by sea it will require a 20ft cradle to allow it to be handled
by dockside cranes at the shipping port.
• 8000 SERIES load banks are not suitable for over stowing on the deck of the ship. They
require a top loading slot, under the deck for insurance purposes (refer to the CSC
certification plate attached to the unit for details).
Storage
The original transport packaging should be left in place on the load bank and it should be
stored under cover, in a heated warehouse, until it is ready to be installed and commissioned.
This recommendation applies, even if the load bank is intended for installation outdoors.
Usually such equipment will be fitted with an anti-condensation heater, which will not be
operational until the load bank is finally installed and commissioned.
Packaging
Before installing a load bank remove all packaging. Dispose of it in the appropriate way for
the material type.
8000 SERIES load banks are provided with removable metal covers for the hot air exhaust
and blanking plates for the cable inlet socks. These must be removed before the unit is
put in to operation.
The exhaust covers are secured in place by metal cable ties. These must be cut to remove
them. When removing them take extreme care not to drop pieces of cable tie into the duct.
Load Bank Installation and Setup
2 - 5
Warning! Avoid walking
on the roof of the unit.
As far as possible, use
a ladder to access each
of the top corner lift
points, and use a pre-at-
tached hauling line
to pull the sling-hook
within reach. If walking
on the roof is unavoid-
able use appropriate
anti-fall protection
equipment attached to
the fall-arrest anchorag-
es provided.
Chapter Two
2 - 6
Installing Froment Load Banks
There are a number of factors that need to be considered before you select a load bank
for a particular installation. Obviously it is important to ensure that the load bank has
suicient electrical capacity to test the supply, but you also need to ensure that it can
operate correctly and safely in the position you have chosen.
Refer to the Appendices for details of the installation requirements.
Location
The first thing to decide when installing a load bank is where the unit is to be located. You
need to consider the following to ensure that the unit can be operated safely:
Environment. The load bank should be located only where the environmental conditions
will not exceed the IP classification of the load bank, bearing in mind the required cable
runs and safety procedures. Note that load banks equipped with a cable entry slot, or a
plate with grommets, have a reduced enclosure classification (terminal box to IP21, control
gear compartment to IP23).
A standard 8000 SERIES load bank can be used in ambient temperature between -10°C and
+50°C, at 90% relative humidity (non condensing), and at altitudes up to 1000m above sea
level.
Loading. The load bank is heavy and must be installed on a level surface that is capable of
supporting its weight (see nameplate).
Space. There must be suicient space to provide access for maintenance to all of the
doors and the protective inlet and outlet grilles.
There must be at least one metre of clear space on the air intake side of the load bank
(the fan side) and clear space above the air outlet. See the appendices for the specific
requirements of individual units.
Airflow requirements. When it is operating an 8000 SERIES load bank can require up to
35 m3of cooling air per second. As it passes through the unit, the air becomes hot enough
to provide a risk of fire or personal injury.
When installing the unit you need to make sure that there is adequate air available, that it
can be discharged safely, and that there is no risk that the hot air will recirculate to the air
intake of the unit.
Note: If necessary,
a barrier should be
erected around the hot
air outlet to prevent any
possibility of personal
injury.
Sound attenuators
Please contact our sales department for advice if you intend to fit a sound attenuator to
the duct work.
Avoiding hot air re-circulation
Careful consideration should be given to the likely eect of nearby buildings, walls or even
parked vehicles, which could seriously disrupt the free escape of hot air, and result in hot
air re-circulation.
Other nearby air handling plant can also interfere with the airflow to, or from, the load
bank. Equipment should be spaced well apart and positioned so that their airflows tend to
complement each other rather than compete.
When multiple load banks are being used it is important to ensure that the hot air from one
load bank does not exhaust directly or indirectly on to any other load bank.
Load Bank Installation and Setup
2 - 7
Chapter Two
2 - 8
Load Bank Installation and Setup
2 - 9
Electrical Installation
The electrical installation for a 8000 SERIES load bank consists of making connections for
the Supply-on-Test, an external supply used to power the load bank’s fans and control
system and, finally, a single phase supply that provides power for the control room lights
and cabinet heaters.
Figure 2-1 An 8000 SERIES load bank can have up to three separate power sources.
The requirements for these three supplies are described separately here, but the following
general points apply in all cases:
• The work must be carried out by a person with the appropriate training, qualifications
and experience.
• All cables should be appropriately rated and installed in accordance with current
standards and accepted practice.
• The connections to the load bank may be intended to be temporary, but it is essential
to apply the same standards to the cable glands and terminations as if the installation
were permanent.
Note: The Load Bank
supply cables must be
protected by a Short
Circuit Protective
Device (SCPD), which
is suitably rated to the
capacity of the supply
cables.
Supply-on-Test
Power
Terminations
Main Circuit
Breaker
Load Fuses Load Contactors
Load Elements
Fan & Controls
+
Socket Outlets
External Supply
for Fan
and Controls
Supply for
Anti-Condensation
Heaters and
Lighting
Control Circuit Emergency
Stop / Disconnect Switch Supply For
Fan & Controls
Changeover Switch
Lighting
Changeover
Switch
Control Room &
Terminal
Compartment
Lighting
Anti-Condensation
Heaters
External
EXT
Internal
INT
OFF
OFF
3Φ
3Φ
1Φ
1Φ
Air
Voltage and frequency ratings
It is important to realise that the external supply required for the fans and controls may be
of a dierent voltage or frequency from the Supply-on-Test. The voltage and frequency
ratings are specific to the equipment supplied and are shown on the rating plate.
Exceeding the voltage ratings or supplying the wrong frequency can cause damage to the
load bank so please check the plate carefully before starting the installation.
Figure 2-2 Consult the load bank’s rating plate for voltage and current ratings
before making connections
External supply wiring - the fan and controls power source
We recommend that you use an external power supply that is independent of the Supply-
on-Test. This ensures that the load bank will continue to operate without interruption if the
Supply-on-Test becomes unstable or fails.
Refer to the load bank’s rating plate for the external power supply requirements. The
supply must be capable of supplying the fan motor starting current, and must be fused
accordingly.
Connecting the external supply
The 8400 load bank is fitted with an external power input socket inside the control room.
The external supply socket for the 8300 is mounted externally (see appendix drawings for
the exact location).
Both types of load bank are fitted with a 3-position supply selection switch, which is located
in the control room. This switch is used to switch between the Internal and External power
supplies.
2 - 10
Chapter Two
2 - 11
Load Bank Installation and Setup
If you are making use of this external supply socket, switch the 3-position supply selection
switch to the “External” position.
Figure 2-3 The supply for fan and controls supply selector switch.
If there is no independent power supply available (and the Supply-on-Test is the correct
voltage and frequency rating) then you can power the load bank from the Supply-on-Test
by setting the supply selection switch to the “Internal” position.
8000 SERIES load banks are fitted with an automatic phase rotation detection system to
ensure that the fan rotates in the correct direction irrespective of how the phases are
connected.
Anti-condensation heaters and lighting supply
The control room is fitted with lighting, single-phase socket outlets and anti-condensation
heaters for the switchgear cabinets. It may be necessary to have these powered
continuously, even when the normal fan and controls supply is not available. Because of
this the control room is fitted with a single phase AC line input connector which can be
used to provide power for this equipment.
To connect the AC line connector to the control room equipment set the lighting changeover
switch to the External position.
Notice that when the lighting changeover switch is in the Internal position the control room
equipment is powered by the fan and controls supply. This can be the external supply or
the Supply-on-Test — depending on the fan and controls supply selector switch position.
Supply for Fan and Controls
Change-over Switch
Internal OFF External
1 2
Connecting the Supply-on-Test
The cables for the Supply-on-Test can be fed into the load bank through cable sock
openings in front of the power terminal compartment, or through the bottom of the
container (suitably sized glands must be fitted to the aluminium gland plate provided).
The cables are connected to the ears hanging down from the terminal bars as shown in
Figure 2-4.
For the 8400, where there are two sets of terminal bars, multiple supply cables should be
used to ensure that the supply is distributed evenly between the terminals.
Figure 2-4 8400 power terminal compartment
Instrumentation neutral. 8000 SERIES load banks are provided with an instrumentation
neutral only. The terminal is not connected to any of the load elements and is provided for
connection to instrumentation only. If the Supply-on-Test has a neutral terminal it should
be connected to the load bank neutral terminal to achieve maximum instrumentation
accuracy.
Note: The terminal bars
can accept both copper
or aluminium cables. Re-
fer to local regulations
and size them accord-
ingly.
Optional Air
Circuit Breaker (ACB)
remote trip terminal
Instrumentation
neutral terminal
Circuit breaker #2 terminals
Circuit breaker #1 terminals
L1 (U)L1 (U)L2 (V) L2 (V)L3 (W)L3 (W)
Link bars
EE
Protective earth
terminals
Protectiv
e
earth
terminals
This manual suits for next models
2
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