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Load
banks are resistance devices that are used to apply an electrical load to
generators, uninterruptable power supplies (UPS), and other backup power
systems to test their operational capability and reliability. By applying a
controlled electrical load, resistance devices allow operators to verify that
these systems can deliver the power they are designed for under simulated load
conditions. This pre-testing helps ensure backup power sources will operate as
expected in the event of an outage.
Load Bank Testing is Important for Several
Key Reasons:
Testing Generator Capacity
Generators are critical backup power sources that kick in automatically
during a utility power failure. Regular resistance device testing verifies a
generator can produce the rated kilowatts of power it is designed for under
load. Applying different load percentages via a resistance device simulates
real-world loading conditions to test full-load performance and response time.
This confirms the generator has the capacity to handle critical site loads.
Exercising the System
Periodically exercising generator and backup power systems with a resistance
device keeps these assets in working order. Much like exercising muscles, load
testing helps identify any performance issues before an actual outage occurs.
It exercises engine components, fuel systems, controls, and ensures all parts
are functioning optimally and the system is ready for emergency duty.
Checking Fuel Consumption
Applying an electrical load reveals the generator’s true fuel consumption
characteristics under load. This is important information for facilities to
budget operating costs accurately. Load bank
challenges also identifies any fuel delivery or usage issues that may
impact runtime during an outage.
Monitoring Generator Parameters
Advanced resistance devices are equipped with monitoring capabilities that
transmit real-time data on critical generator operating parameters like
voltage, current, speed, and temperature to a control system. This allows
operators to closely observe the generator’s response to varying loads and
identify any abnormal reactions or inefficiencies requiring service.
Types of Load Banks
There are different types of resistance devices used for testing stationary
and mobile generator sets with various Load
Bank capabilities:
Resistive Load Banks
The most common and basic type, resistive resistance devices work by
passing electric current through resistor elements to create loading. They are
compact, inexpensive to operate, and generate heat that needs to be rejected.
Resistive resistance devices provide steady load but lack the ability for
reactive loading.
Reactive Load Banks
These resistance devices have components like inductors and capacitors that
provide both resistive and reactive loading. Reactive loading more accurately
simulates the load characteristics a generator would see from motors and other
non-linear loads in a real application. This type of comprehensive testing
verifies volt-ampere output and power factor.
Low-frequency Resistance Devices
Special low-frequency resistance devices are needed to test very large
generator sets used in utility-scale power plants. Their larger elements can
safely dissipate megawatts of power at frequencies as low as 5-10 Hz.
Trailer-mounted Mobile Resistance Devices
For testing generator sets in the field, trailer-mounted resistance devices
provide a compact, portable solution. Integrated cooling systems allow mobile resistance
devices to apply high loads for exercising large generator sets at remote job
sites or during maintenance outages.
Resistance Device Testing Procedure
Now that the basic types and purposes of resistance devices have been
covered, let’s examine the typical steps involved in properly conducting a resistance
device test:
1. Ensure the generator is in good working condition with a full fuel tank
prior to testing. Inspect all connections and control panels.
2. Position the resistance device a safe distance from the generator with
adequate ventilation for heat rejection. Connect power cables to generator
output leads according to resistance device manufacturer’s instructions.
3. Start the generator set and allow a sufficient warm-up period for engine and
electrical components.
4. Gradually apply incremental load levels from the resistance device control
panel, typically in 25% steps, monitoring generator output parameters.
5. Test at full rated load capacity for 30 minutes or as recommended by
manufacturer to fully exercise the system. Record all parameter data.
6. Vary the load up and down to check the generator can handle load changes
smoothly without stalling or dropping frequency/voltage significantly outside
acceptable ranges.
7. Gradually reduce the load to zero and let the generator run for several more
minutes before shutting it down to cool internal components.
8. Document test results. Schedule required maintenance or repair based on any
issues identified during testing.
9. Regularly repeat resistance device testing to certify the generator can
reliably power critical equipment during outages as designed.
Resistance device testing provides critical assurance that backup power systems
such as emergency generators will operate trouble-free when needed most. By
simulating real-world loading conditions, resistance devices enable operators
to thoroughly exercise these systems, monitor performance, and catch minor
problems before they escalate into major failures during power outages. When
performed routinely according to manufacturer guidelines, resistance device
testing is an essential maintenance task to ensure backup power reliability.
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Author:
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