RCD Load Bank Manufacturer in Coimbatore, Tamil Nadu
Akshayam Controls & Automation designs and manufactures RCD load banks — non-linear load banks that present a rectifier load rather than a resistive one. The name comes from the circuit: a diode bridge feeding a DC capacitor and resistor, the same front end found in every server power supply, variable speed drive and telecom rectifier. Instead of drawing current smoothly across the whole cycle, the load draws it in short peaks around the voltage crest, and that is what stresses a UPS inverter, distorts the supply waveform and reveals whether a system will hold up in service.
The reason this matters is that a UPS is almost always feeding electronic equipment. IEC 62040-3 recognises this and defines a reference non-linear load for UPS performance testing, built from exactly this resistor, capacitor and rectifier arrangement. Testing only with a resistive bank leaves the hardest part of the duty unproven. Our RCD units reproduce the reference load, hold a nominal three-to-one current crest factor, and let the operator switch between fully linear, fully non-linear and mixed loading from the panel front so both halves of the test run on one machine.
We build these at our works in Peelamedu, Coimbatore, for UPS manufacturers, data centre commissioning teams, inverter and energy storage developers, and testing laboratories. Power quality instrumentation is fitted as standard, so crest factor and current distortion are read at the load bank itself rather than inferred. Customers commonly pair an RCD unit with a Resistive Load Bank for straightforward kW work, or with an RLC Load Bank where reactive loading is also specified.
What is an RCD Load Bank?
An RCD load bank is a test load built around a rectifier rather than a plain resistor. Incoming AC passes through a diode bridge into a DC capacitor, which is discharged through a resistor, with a further resistor in series on the line side. Because the capacitor only draws current when the supply voltage exceeds the charge already stored on it, current flows in narrow pulses near the peak of each half cycle. That pulsed waveform is what a non-linear load looks like, and reproducing it is the only way to test a UPS or inverter against the equipment it will really supply.
Resistive Element (R)
Alloy resistors dissipate the real power, split between a line-side series resistor and a resistor across the DC capacitor.
Capacitive Element (C)
A DC-link capacitor bank charges near the voltage peak and discharges between peaks, producing the pulsed current draw.
Diode Rectifier (D)
A heatsink-mounted diode bridge converts AC to DC, forming the rectifier front end that makes the load non-linear.
Reference Non-Linear Load
The combination reproduces the reference non-linear load defined in IEC 62040-3, the standard basis for UPS performance testing.
Key Features of Our RCD Load Banks
IEC 62040-3 Reference Load
Resistor, capacitor and rectifier values set to reproduce the reference non-linear load the standard specifies for UPS testing.
3:1 Crest Factor
Nominal three-to-one current crest factor, the figure UPS ratings are declared against, held across the load range.
Linear / Non-Linear Selection
Switch between fully resistive, fully non-linear and mixed loading from the panel front, so one unit covers both test regimes.
Power Quality Metering
Built-in analyser reading crest factor, current THD, kW, kVA, power factor and frequency, so distortion is measured at the load itself.
Rectifier Section on Heatsinks
Power diode bridges mounted on forced-air heatsinks with fuse protection, sized for continuous rather than intermittent duty.
Capacitor Discharge Protection
DC-link capacitor bank fitted with bleed resistors and a door interlock, so the bank cannot be opened while charged.
Alloy Resistive Section
Fe-Cr-Al alloy elements on ceramic insulators for the linear and rectifier-fed resistive branches.
Step Control and PLC Option
Front-panel step switches and indication as standard, with PLC and HMI touchscreen control for automated test sequences.
Rack or Floor Configuration
19-inch rack-mountable formats for data centre and UPS production use, plus floor-standing and trolley-mounted portable builds.
RCD Load Bank Applications
Why Choose Akshayam Controls for RCD Load Banks?
Built to the Reference Load
Circuit values set against IEC 62040-3, not approximated with a capacitor bolted onto a resistive bank.
Crest Factor Verified
Every unit tested for crest factor and current distortion before dispatch, with the readings on the test report.
Linear and Non-Linear in One
Both halves of a UPS test regime run on a single machine rather than two.
Built by Panel Engineers
Control and switching by our LT panel team, on ABB, Siemens, Schneider, C&S and L&T switchgear.
Coimbatore Works
Designed, assembled and load tested at Peelamedu, Coimbatore, with works inspection welcome.
Test Procedure Support
Guidance on load staging, crest factor settings and interpreting power quality results.
Our RCD Load Bank Manufacturing Process
Requirement Study
UPS or inverter kVA, test voltage and frequency, crest factor target, linear and non-linear split, step resolution and installation type.
Electrical Design
Rectifier, capacitor and resistor sizing, step scheme, heatsink and airflow design, general arrangement drawing for approval.
Component Selection
Alloy elements, power diodes, DC capacitors, contactors, fans and power quality metering to the approved make list.
Fabrication & Assembly
Enclosure fabrication, powder coating, element and rectifier assembly, capacitor bank build, control panel wiring.
Inspection & Load Test
Insulation resistance, HV withstand, crest factor and THD verification, discharge and interlock checks, full-load thermal run.
Delivery & Support
Dispatched with drawings, test report and operating manual, with commissioning guidance where required.
Benefits of RCD Non-Linear Load Testing
- Tests a UPS against the electronic load it will actually supply
- Exposes inverter regulation problems a resistive load never reveals
- Verifies output voltage distortion under pulsed current draw
- Confirms the UPS meets its declared rating at 3:1 crest factor
- Provides documented power quality results for handover
- Proves neutral conductor and busbar sizing under harmonic current
- Validates harmonic filter and PFC equipment performance
- Tests generator and UPS behaviour together before go-live
- Supports IEC 62040-3 based acceptance procedures
- Suits UPS production line testing as well as site commissioning
Note: Results reflect performance at the time of test. Continued reliability depends on battery condition, cooling and routine maintenance.
RCD Load Bank Specifications
| Parameter | Specification Details |
|---|---|
| Product Type | RCD Load Bank — non-linear (resistive, capacitive, diode rectifier) |
| Load Characteristic | Rectifier-fed non-linear load, switchable to fully linear resistive or mixed |
| Reference Load | Reproduces the reference non-linear load defined in IEC 62040-3 for UPS testing |
| Current Crest Factor | 3:1 nominal |
| Current THD | Approximately 30% at rated non-linear load |
| Power Factor Range | 0.7 to 1.0 |
| Capacity Range | 5 kVA to 500 kVA per unit; higher ratings by paralleling multiple units |
| Test Voltage | 415 V, 3-phase, 4-wire, 50 Hz standard; 230 V single-phase and 60 Hz builds available |
| Load Steps | 1 kVA, 5 kVA, 10 kVA and 25 kVA increments |
| Resistive Elements | Fe-Cr-Al alloy elements on ceramic insulators, line-side series and rectifier-fed branches |
| Rectifier Section | Power diode bridge on forced-air heatsinks with semiconductor fuse protection |
| Capacitor Section | DC-link capacitor bank with bleed discharge resistors |
| Cooling | Forced air — axial fan array with ducted airflow and top or side hot-air discharge |
| Control | Front-panel step switches with linear / non-linear selector; PLC and HMI touchscreen with automated test sequencing |
| Metering | Power quality analyser — voltage, current, kW, kVA, power factor, crest factor, current THD, frequency and kWh |
| Protection | Over-temperature thermostat, airflow proving and fan-fail interlock, capacitor discharge circuit, DC-link overvoltage trip, MCB per bank, door interlock |
| Switchgear Make | ABB, Siemens, Schneider Electric, C&S Electric, L&T |
| Enclosure | CRCA sheet steel, seven-tank pre-treatment and powder coated — IP42 indoor, IP54 weatherproof outdoor |
| Configuration | Floor-standing indoor, 19-inch rack-mountable, or trolley-mounted portable |
| Cable Entry | Bottom entry with brass gland plate; camlock connectors or busbar terminals |
| Testing | Insulation resistance, HV withstand at 2.5 kV, crest factor and THD verification, discharge and interlock checks, full-load thermal run |
| Reference Standards | IEC 62040-3 UPS performance and test methods; control section built to IEC 61439 |
RCD Load Bank Supply from Coimbatore to India’s Data Centre Corridors
Non-linear load testing follows the electronics, not the heavy industry, so the buyer map for RCD units is different again from our panel work. Coimbatore itself is the strongest source of UPS and non-linear enquiries we receive, with Bengaluru close behind and steady interest from Ernakulam and Kochi, Chennai, Mumbai, Hyderabad and the Gujarat belt through Ahmedabad and Vadodara. The buyers are UPS manufacturers, data centre commissioning teams, inverter and energy storage developers and test laboratories rather than plant maintenance departments. Units are designed, built and load tested at Peelamedu, Coimbatore, and dispatched with drawings, test report and operating manual.
Frequently Asked Questions About RCD Load Banks
What is an RCD load bank?
An RCD load bank is a non-linear load bank. RCD stands for resistive, capacitive and diode — a rectifier bridge feeding a DC capacitor and resistor, which is the same circuit found at the input of servers, drives and telecom rectifiers. It draws current in short peaks rather than a smooth sine wave, reproducing the load a UPS or inverter actually has to supply.
What is the difference between an RCD load bank and a resistive load bank?
A resistive load bank draws a clean sinusoidal current at unity power factor and tests real power output. An RCD load bank draws a distorted, pulsed current with a high crest factor. A UPS can hold voltage perfectly under resistive load and still fail to regulate under non-linear load, which is why the two are not interchangeable for UPS testing.
What is the difference between an RCD load bank and an RLC load bank?
Both go beyond pure resistance, but in different directions. An RLC unit adds inductive and capacitive reactance to test at a lagging or leading power factor — the load stays linear and sinusoidal, and the purpose is to load a generator to its full kVA rating. An RCD unit keeps the load non-linear and distorted, and the purpose is to test how a UPS or inverter handles harmonic current. Generator acceptance work usually calls for RLC; UPS and data centre work calls for RCD.
Why does IEC 62040-3 specify a non-linear load?
Because almost everything a UPS supplies has a rectifier at its input, so a resistive test does not represent real service. The standard defines a reference non-linear load built from a rectifier, capacitor and resistors, so UPS performance can be declared and compared on a consistent basis rather than each manufacturer choosing its own test load.
What is crest factor and why is 3:1 used?
Crest factor is the ratio of peak current to RMS current. A clean sine wave gives about 1.41. Rectifier loads concentrate their current draw into narrow peaks, pushing the ratio far higher, and 3:1 is the value the reference non-linear load is built around. UPS output ratings are commonly declared at that figure, so testing at it is what confirms the rating.
Can one unit do both linear and non-linear testing?
Yes. Our RCD units carry a linear / non-linear selector on the panel front, so the operator can run a fully resistive test, a fully non-linear test, or a mixed load, without changing machines. This is usually the more economical route when both regimes are in the test procedure.
What capacity RCD load banks do you manufacture?
From 5 kVA units for small UPS and production line testing up to 500 kVA for data centre and large UPS work, with higher ratings by paralleling. Step resolution is 1 kVA, 5 kVA, 10 kVA or 25 kVA depending on how finely the test needs to be controlled.
Do you supply RCD load banks in Coimbatore and elsewhere in India?
Yes. Design, fabrication, assembly and load testing all happen at our works in Gandhi Maa Nagar, Peelamedu, Coimbatore, and Coimbatore is our strongest local market for UPS and non-linear testing equipment. We also supply Bengaluru, Chennai, Kochi, Mumbai, Hyderabad, Ahmedabad and the Delhi NCR region. Customers are welcome to witness the load test before dispatch.
How can I request an RCD load bank quotation?
Send the kVA rating of the UPS or inverter to be tested, the test voltage and frequency, the crest factor you need to test at, whether you also need linear resistive loading, and your preferred step resolution. Email sales@akshayamcontrols.co.in or call +91 89403 32552 and our engineers will size the unit and quote.
Need an RCD Load Bank for UPS or Inverter Testing?
Tell us the kVA rating, the crest factor you need to test at and whether linear loading is also required, and our engineers will size the non-linear load, share the drawing for approval, and build a unit that is load tested before it leaves our works.
Phone: +91 89403 32552
Email: sales@akshayamcontrols.co.in