No matter where or how much power you need, high performance, reliable and stable output is critical to keep day-to-day operations up and running. Load banks are designed to protect generators and equipment, ensuring they will operate to the best of their ability.

Here’s everything you need to know about load banks and why they are critical to any operation. 

What Is a Load Bank? 

Load banks ensure the correct function of generators used on site during any operation that requires a power supply. Load bank testing not only makes sure the generator is dependable but is also capable of its highest load capacity. It will produce artificial loads on the generator by powering the engine to a designated operating temperature and pressure rating.

In most cases, generators are not frequently running at heavy loads, so if it’s not powering higher than around 30% of its rated kW load, then a load test is recommended.

Two main kind of load banks are available for specific instances:

• Resistive load banks
• Reactive load banks 

How Does a Load Bank Work?

When implemented, an artificial load is put on the generator to gradually increase the kW in specific time-based increments. Each time the kW load rises, the load bank will measure and record the engine parameters and its ability to handle the load increases. It will also test its ability to function at its heaviest load for an extended period of time.

What is the Difference Between a Resistive and a Reactive Load Bank?

Depending on the application of your generator, you may either need a resistive or a reactive load bank. While each are used for different loads, resistive load banks are the most common.

Resistive Load Banks

Resistive load banks draw a designated power load in kW from the generator to check and ensure the safe operation of the cooling system, exhaust and engine. They will mimic the load the generator or equipment will produce in real application.

Reactive Load Banks

Reactive load banks will replicate inductive loads and will test the apparent power in kVA of the generator or equipment.

Why Is Load Bank Testing Important?

It is critical to go through load bank testing to test the generator at its full kW rating to ensure it can actually produce the highest output it may require. This is to ensure the adequate maintenance is performed to safeguard against performance issues and overall functionality. As a result, load bank testing can be done annually or as outlined by your generator supplier to ensure the following:

Prevents Underloading

You can use a load bank to ensure the generator adequately and optimally consumes fuel. When generators are often run on lighter loads over time (also called underloading), it can result in unburnt fuel and soot build up in the exhaust system. When this occurs it can risk doing damaging the generator, become a safety and fire hazard and even cause the generator to fail and shut down.

Because load bank testing allows the generator to run at full capacity and full temperature, it will cause any unused fuel to burn off. Eliminating the risk of causing problems due to underloading. 

Field Testing

Testing the reliability of generators is always recommended to ensure they are able to perform optimally whenever needed. Because load banks work to imitate the load of the facility or operations, operators can easily identify any problems early on before it’s needed in an emergency.

Manufacturing Testing

Regular generator maintenance is essential to identify any weaknesses in the system in controlled conditions. This removes the risk of any potential faults coming to light in situations of power outages that may result in the system failing entirely during operation.

Ensures Full Capacity Operation

The generator must be able to produce power at its full capacity when it’s needed most. Load bank testing allows this test to run to ensure the system can reach and maintain its full load without overheating or shutting down.

Need a Power Solution? Get the Right Advice.

With years of experience servicing the mining, construction industries, Blue Diamond Machinery has the equipment you need and can rely on. We not only offer expert advice and industry-leading warranties, we provide an all-encompassing solution. We will customise and install your power solution to your specific power demand requirements, wherever you are. Get in touch with our team today.