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Resistive Load Bank

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What is a Load Bank?
Load Banks are devices used to test and commission any electrical power source, providing electrical load to power supplies to simulate service loads. 

Load Banks convert the electrical load coming from power sources such as generators, gas turbines, UPS, alternators and transformers into heat with the help of resistive elements (Cr-Al) in it and ensure that it is removed from the system with strong fans.

In addition, load banks are also used as Dummy Loads to prevent “wet-stacking” problems of diesel generators, apart from testing and verification. When diesel generators operate at values lower than 30% of their rated value, the problem known as wet-stacking occurs and causes the generator to fail over time. Many generator manufacturers do not provide warranty for generators and turbines operating in this way. That's why automatic load banks are used.

 

Applications
Load Banks have wide usage area in different industries. The main areas of use are listed below.
  • OEM: It is used to verify the design nominal values of power supplies such as generators, UPS, alternators, transformers produced in factories.
  • Telecom: It is used for controlled discharge and testing of batteries.
  • Energy: It is used for capacity measurement test in the field or in the service after maintenance and repair services of products such as Gas Turbine, Wind Turbine, Generator, UPS.
  • Data Center:  Electrical and thermal operation simulation and performance testing of data centers.
  • Dummy Load: To prevent low load operation (Wet-Stacking), it is used to automatically activate when the field loads that feed the generator fall below ≤ 30%.

 

Load Bank Types
Load banks have different groups according to the load element they contain.
Resistive Load Bank (kW)
It is the most widely used type of load bank. It contains resistive load elements to load the power supply. They are produced by using Cr-Al resistance wires or high heat resistant sheets. These load banks have a Power Factor of cosø :1.

 

Inductive (Reactive) Load Bank (kVAr)

They contain "inductive" load elements. Also known as reactive. Coil with copper wire wound is used to form inductive elements. Unlike resistive loads, inductive load current follows a sinusoidal pattern, with the voltage peaking after the sine wave, so the maximum, minimum, and zero points for voltage changes are out of phase with the current. As a result, inductive coils produce lagging power factors.
 

 

Combined Type Load Bank (kVA) 
It is a type of load bank that contains both resistors and inductive coils in the same cabinet. The resistive and inductive elements inside can be operated separately or, if desired, the power factor can be adjusted by operating them together (cosø : 0 – 1). It is often used to simulate systems affected by electric motors or electromagnetic devices in a network or system.

 

 

General Features 
Load Banks can be produced with various cabin types and ventilation types in accordance with different needs. In order to get the right result, these issues should be considered when choosing a load bank.
Load Bank Protection Classes
If the Load Bank is to be used in a closed environment that will not be affected by environmental conditions, it can be preferred with the Indoor Type Cabinet with IP20 Protection class.
If it will work under a shelter in an external environment, cabinets between IP20 / IP31 will be suitable.

 

Apart from these, outdoor type load banks with IP31 and IP 56 protection classes can be produced that can operate safely in the outdoor environment without any extra precautions.

Cooling Fans
Each load bank has cooling fans to transfer the heated air. These fans can vary as single-phase or 3-phase high-flow fans. It is ed by analyzing the flow rate (m3/h) and pressure (pa) values of the fan, according to the power and volume of the resistors to be cooled.
In order for these fans to work safely, it is necessary to leave a clean area in the suction and air outlet directions. Therefore, the correct air outlet type should be ed according to the suitability of the area where the equipment will be located.
Load banks are also divided into two in terms of air outlet direction.
  • Horizontal Air Outlet Load Bank
  • Vertical Air Outlet Load Bank
 
Electrical Properties
Load banks with different voltage levels, frequency and current types can be produced.
 
The equipment that consumes direct current are DC Load Banks. The unit of power stages is ampere (A). It is mostly preferred for battery capacity testing and aviation applications.
Equipment that consumes alternating current are AC Load Banks. The stages are kW, kVAr or kVA. They can be produced at frequencies such as 50Hz/60Hz or 400Hz. Devices used in aviation are produced with high frequency in order to have a lighter design.
 
Voltage levels are ed according to the project requirement. DC Load banks usually use voltage levels such as 28VDC / 48VDC / 270VDC. However, according to the project needs, safe design and production can be made up to 1000VDC.
In AC load banks, besides 240AC / 400VAC / 690VAC low voltage options, they are produced in different voltage options from 4kV to 36kV for special applications and high capacity load banks.
 
 
 
 Auxiliary Supply
Fan and control supply can be used externally from the mains or internally with a or switch from the main supply system of the load bank. This provides convenience in field tests performed away from the network.
 
 
Security
All steps of load banks and related contactors are protected against short-circuit with the help of separate fuses for each phase.
Load banks have air flow sensors as they are vital to critical energy security. In this way, if the air flow is interrupted for any reason, the load bank automatically disables the loads and shuts down the system.
Although the flow is not interrupted, there are over-temperature protections against temperature rise. The device temperature is monitored instantaneously and if it exceeds the allowable temperatures, it gives a warning and protects the system.
Power connection terminals and all live parts have finger proof housings to protect them from accidental contact.
Appropriate warning/caution statements are placed on the exterior of the load bank, access panels, hot surfaces. Thus, injuries and accidents are prevented.
 
Most Used Load Bank Types
Portable Load Bank
They are generally devices with a capacity of up to 100kW. Since it is used for service and maintenance purposes, it has easy-to-carry wheeled cabins or carrying bags. 

 

 

Movable Load Bank
It is the type of load bank that is planned to be move to different areas within the facility in the usage scenario. It has durable swivel caster cabins. It is suitable for capacities of 500kW and less for easy move

 

Stationary Load Bank


These load banks are suitable for applications that are intended to serve at a fixed point, which do not move much after installation. 
They generally have capacities of 500kW and more. It is widely used in factories, OEM test benches, power systems, etc. generator load support is used for this purpose.

 

 

 

Container Load Bank

Container type load banks are designed to withstand the rigors of both shipping and weather conditions. And due to its standard dimensions, it is also advantageous in terms of logistics.

 

Trailer Type (Mobile) Load Bank

It is mounted on a trailer designed according to its capacity and transported by a vehicle. Useful for capacities between 200kW and 5MW. In addition, trailer options suitable for traffic are also available.
 

 

Please contact us for a load bank recommendation and detailed information suitable for your project.

 

 

General features

  • Full Resistive Loading 
  • Long Life Cr-Al  Resistances
  •  IP2, IP41, IP55 Cabin Designs 
  • 208V-380V-690V Voltage Options 
  • Lifting Lugs 
  • Forklift Loading Stands 
  • Horizontal - Vertical Air Outlets 
  • Smart Fan protection system 
  • Manual and Digital load control 
  • Corrosion Resistant

Optional Features

  • Remote Controller 
  • User Defined Test Scenario
  • Custom Voltage and Current Values 
  • Aluminized Alloy Steel Cabin 
  • SCADA Connection Interface 
  • MODBUS RTU / CAN Bus / RS 485 Communication
  • Smart Fan protection system 
  • 4-20mA Analog 0-10V Analog Outputs 
  • BMS and SCADA Integration 
  • Data Ce and Reportin

Remote Control

Indoor Load Bank

Container Load Bank

Loadron Device

Portable Load Bank

Control Software