Resistive Load Bank Manufacturer in Coimbatore, Tamil Nadu
Akshayam Controls & Automation designs and builds resistive load banks — alloy element test loads that draw real power at unity power factor — for generator acceptance testing, UPS discharge trials and routine standby maintenance. Testing a generator under real load proves the engine, governor, fuel system and cooling circuit before the machine is depended on in service. Units are built and full-load tested at our works in Peelamedu, Coimbatore, and delivered to power generation plants, healthcare facilities, data centres and testing agencies across India.
Our builds range from compact 10 kW portable units on heavy-duty castors up to 1000 kW floor-standing and containerized frames for large standby sets. Each unit carries stepped load selection from panel-mounted switches or remote PLC control, so the operator can apply load in precise kW increments. Over-temperature thermostats, forced-air cooling airflow proving and fan-failure interlocks are standard across the range. Switchgear comes from Schneider Electric, L&T, Siemens, C&S Electric and ABB.
We also build combined RLC Load Banks for 0.8 power factor testing and RCD Load Banks for non-linear UPS load trials. Customers across Coimbatore, Chennai, Bangalore and Kerala pair our load banks with DG Synchronization Panels or order them alongside AMF / ATS Panels for site handover trials.
What is an Electrical Load Bank?
A load bank is a testing device that creates an artificial electrical load, so a power source can be tested at its rated output without connecting the actual facility load.
Typical Connection Arrangement
The load is applied in steps and held while voltage, current and frequency are watched. That is how generator capacity, UPS battery condition and switchgear behaviour get verified at commissioning and at each periodic test.
Types of Load Banks We Can Design
Resistive Load Banks
High-grade alloy resistor elements apply load at unity power factor to test engine, governor and cooling capacity. Standard choice for kW acceptance testing.
Reactive Load Banks
Iron-core reactors apply a lagging power factor load, simulating motor-heavy plant loads to test excitation and alternator regulation. Learn more about RLC Load Banks.
Resistive / Reactive (RLC)
Combined units applying active (kW) and reactive (kVAR) loads for 0.8 power factor full nameplate testing. Explore our RLC Load Banks.
RCD Non-Linear Load Banks
Non-linear rectifier-capacitor test loads built to IEC 62040-3 for UPS, inverter and data centre testing. Explore our RCD Load Banks.
How Does Load Bank Testing Work?
Connect
Load cables connected to the generator or UPS output terminals through the gland plate and breaker.
Start Up
Source started and run until voltage and frequency are stable at no load.
Apply Load
Load applied in steps from the control panel, typically to 25, 50, 75 and 100 percent of rating.
Monitor
Voltage, current and frequency tracked at each step, along with engine temperature and exhaust behaviour.
Evaluate
Readings compared against the acceptance criteria for the machine and the commissioning specification.
Note: Actual test procedures should be performed by qualified personnel according to safety and manufacturer requirements.
Key Features of Our Load Banks
Controlled Load Stages
Step switches let the operator build load to the test plan rather than dumping full load onto a cold machine.
High-Temperature Resistors
Stainless steel alloy grid elements rated for continuous running at full load.
Forced Air Cooling
Axial fan arrays draw air across the grids and discharge it through louvres, keeping element and enclosure temperatures in range.
Electrical Protection
Over-temperature trips, fan-failure interlocks and fuse protection, so the unit shuts down before elements are damaged.
Integrated Metering
Digital power meter showing voltage, current, active power and frequency live through the test.
Custom Enclosures
Stationary indoor, weatherproof outdoor or wheel-mounted portable frames for testing that moves between sites.
Load Bank Applications Across Industries
Textile Industries
Standby generator testing to confirm backup capacity before a mill relies on it.
Engineering Industries
Switchgear and busduct testing at rated current.
Data Centres
UPS battery and standby distribution verification before live server load is applied.
Hospitals & Healthcare
Periodic load testing of emergency generators, where backup readiness is not optional.
Commercial Buildings
Generator testing for safety approvals and fire department certification.
Power & Utility Systems
Commissioning tests on panels, substations and utility switchgear.
Load Bank Testing Applications
Four situations account for most load bank work:
Diesel Generator Testing
Output capacity, governor response, voltage regulation and radiator performance verified under real load.
UPS & Battery Verification
Controlled discharge load applied to prove battery autonomy and inverter behaviour.
Preventive Maintenance
Periodic testing that confirms the set still starts and accepts load — and clears wet stacking on generators that idle at low load.
Portable Testing
Wheel-mounted or skid frames for testing services moving between sites.
Benefits of Using Load Banks
- Full-capacity testing under controlled, safe conditions
- Generator performance proven at rated output, not assumed
- Supports commissioning and safety approval requirements
- No dependence on the facility's actual load to run a test
- Backup systems can be tested during off-peak hours
- Stepped control supports proper load acceptance testing
- Digital metering records parameters through the test
- Stationary or portable configurations to suit how you test
- Radiator and cooling performance checked under real heat load
- Clears wet stacking on generators that normally run lightly loaded
Our Load Bank Engineering & Manufacturing Process
Requirement Analysis
Generator or UPS rating, test voltage and frequency, step resolution, duty and the space the unit has to fit.
Configuration
Load type — resistive, inductive or combined — step sizes, fan arrangement and protection scheme.
Design Engineering
Resistor bank layout, control circuits, cooling airflow paths and panel schematics, drawn for approval.
Manufacturing
Steel frame fabricated, alloy resistor grids mounted, control switching wired and cooling fans installed.
Inspection & Testing
Connections verified, step switching checked, fan interlocks proved and insulation resistance tested.
Delivery & Support
Delivered with operating manual, test record sheets and technical support.
Generator Load Bank Testing Solutions
Three things a load test tells you about a generator that nothing else will:
- Voltage behaviour: how quickly the AVR recovers as load steps on and off
- Frequency stability: whether the governor holds speed through a load change
- Engine cooling: whether the radiator actually copes at full load, on a hot day, in the space it is installed in
Why Choose Akshayam Controls for Load Banks?
Built to Your Test Plan
Rating, voltage, frequency, load type and step resolution set by what you actually need to prove, not by a catalogue size.
Coimbatore Manufacturer
Built at our Peelamedu works, with design reviews you can attend and support across Tamil Nadu.
Cooling Designed Properly
Fan arrays and airflow paths sized to the heat the grids produce. An under-cooled load bank fails at the moment it is working hardest.
Quality Resistor Elements
High-grade alloy grids, correct wire sizing and insulation checks throughout.
Whole-System Supplier
The same works builds the DG sync panel, the AMF / ATS panel and the acoustic enclosure for the generator you are testing.
Support After Delivery
Operating guidance, test procedure help and service support once the unit is in use.
Load Bank Specifications
| Parameter | Specification Details |
|---|---|
| Product Type | Electrical Load Bank / Resistive Load Bank |
| Load Type | Resistive, inductive or combined RLC, as configured |
| Power Rating | 10 kW to 1000 kW |
| Voltage | 415 V, 3-phase, 4-wire; other voltages |
| Frequency | 50 Hz / 60 Hz |
| Load Steps | Customised resolution — typically 5, 10, 25 and 50 kW steps |
| Control | Front selector switch panel with stepped load switching |
| Cooling | Forced air cooling with axial fan arrays |
| Application | Generator, UPS and battery load testing |
| Protection | Over-temperature trip, fan-failure interlock and fuse protection |
| Metering | Digital multi-function power meter |
| Installation | Stationary indoor, outdoor canopy or portable wheel-mounted frame |
| Enclosure | Powder-coated sheet steel |
| Testing | FAT, insulation resistance test, step switching and functional testing |
Load Bank Manufacturer Serving Coimbatore & Tamil Nadu
Load testing work comes to us from generator suppliers, commissioning contractors, hospitals, data facilities and mills. Coimbatore, Tiruppur, Erode, Salem, Karur, Madurai and Trichy account for most of it, with further units going to Bengaluru and Karnataka, Kochi and Kerala, and across South India. Send the rating, test voltage and step resolution you need and we will configure the unit before quoting.
Frequently Asked Questions About Load Banks
What is a load bank?
An electrical load bank is a testing device that creates an artificial load, so a generator, UPS or battery system can be tested at rated output without connecting the facility's actual load.
What is a resistive load bank?
A resistive load bank uses high-temperature alloy resistor grids to convert electrical energy into heat, applying load at unity power factor. It is also written as a resistance load bank or resistive loadbank, and it is the type most generator testing calls for.
What is the difference between an AC and a DC resistive load bank?
An AC resistive load bank tests alternating current sources — generators, UPS outputs and switchgear. A DC resistive load bank applies load to direct current sources such as battery banks and DC UPS systems. The resistor principle is the same; the switching, protection and control differ.
What is a reactive load bank?
A reactive load bank uses reactors to apply a lagging power factor load, simulating the motor-heavy load a real plant presents. It is used where testing at unity power factor alone would not represent site conditions.
Why is load bank testing performed on diesel generators?
To verify output capacity at commissioning and at each periodic test, and to clear wet stacking — the unburnt fuel and carbon that builds up in generators habitually run at low load.
What size load bank do I need for my generator?
As a rule, a load bank rated at or slightly above the generator's kW output, so the set can be tested to 100 percent. A 500 kVA generator at 0.8 power factor is 400 kW, so a 400 kW load bank tests it fully. Testing only to 50 percent proves far less than most people assume.
Can load banks be customised?
Yes. Power rating, test voltage, step resolution, load type, cooling arrangement and enclosure are all built to your requirement.
Can load banks be used for UPS testing?
Yes. Controlled discharge load is applied to verify UPS batteries, inverter circuits, voltage stabilisers and changeover behaviour under real load.
Can load banks be used during generator commissioning?
Yes, and commissioning is the most common use. Graded step tests verify operation, safety shutdowns and transient behaviour before any building load is connected.
Are portable load banks available?
Yes. Wheel-mounted and skid frames are built for testing that moves between sites — the usual choice for service contractors and multi-site facility teams.
Do you manufacture load banks in Coimbatore?
Yes. Design, resistor mounting, panel wiring, assembly and inspection are all carried out at our works in Gandhi Maa Nagar, Peelamedu, Coimbatore.
How can I request a load bank quotation?
Send your power rating, test voltage, frequency, step sizes and application to sales@akshayamcontrols.co.in, or call our engineering desk on +91 89403 32552.
Need a Customised Load Bank for Generator Testing?
Tell us the rating you need to test, the voltage and frequency, and how fine the load steps have to be. Our engineers will configure the resistor bank and cooling, and quote a load bank built for your testing programme.
Phone: +91 89403 32552
Email: sales@akshayamcontrols.co.in