Resistive Load Banks

A resistive load bank is a testing device made up of banks of high-temperature alloy resistor elements. It applies a purely resistive load at unity power factor to a generator, UPS or battery system and converts the energy into heat, which is removed by forced-air cooling. Because the load is applied in controlled steps, the source can be tested at its full rating without connecting the actual plant load.

A resistive load bank loads the source at power factor 1.0 and tests kW output — it exercises the engine, governor, cooling system and alternator. A reactive load bank uses iron-core reactors to draw lagging kVAR and simulates motor loading, testing the excitation system and voltage regulation. Resistive testing is what most generator acceptance and maintenance work calls for; reactive is added when the site load is motor-heavy or when full kVA testing is specified.

Yes. An RLC load bank combines resistive, inductive and capacitive elements in a single unit, so the source can be tested at leading and lagging power factor rather than at unity alone — the closer match where the site load is motor-heavy or carries significant harmonic content. We manufacture RLC load banks in Coimbatore and supply them to generator OEMs, testing agencies and data centre contractors in Chennai, Bangalore and across India. Send us the kW and kVAR split you need to simulate and we will size the unit. Learn more on our RLC Load Banks page.

An AC resistive load bank is connected to the alternator output — typically 415 V three-phase — and tests the generator as a complete machine. A DC resistive load bank is connected across a battery bank or the DC bus of a UPS and applies a controlled discharge current, so battery capacity and autonomy can be measured against the design curve. We build both.

From 10 kW units for small standby sets and UPS work up to 1000 kW for large generator testing, with higher ratings achieved by paralleling units. Step resolution is set at order stage — commonly 1 kW, 5 kW, 10 kW, 25 kW or 50 kW increments depending on how finely you need to control the test.

Two reasons. At commissioning it proves the set genuinely delivers its rated output, and that the governor, AVR and radiator hold up under sudden block loading. In service it prevents wet stacking — the unburnt fuel and carbon that build up in standby sets that only ever run lightly loaded, and that eventually foul the injectors, turbo and exhaust. A periodic full-load run through a load bank clears that deposit.

Yes. Trolley-mounted and skid-built portable units are common for testing agencies and service contractors who move between sites. We also build floor-standing indoor units, weatherproof outdoor enclosures and 19-inch rack-mountable formats for data centre installations.

An airflow proving switch and fan-failure interlock drop the load contactors if airflow is lost, and an over-temperature thermostat trips the bank if element or enclosure temperature exceeds the set limit. Each element bank has its own MCB, and the enclosure carries a door interlock. The unit cannot hold load without cooling.

Yes. Design, fabrication, element mounting, wiring and full-load testing are all carried out at our works in Gandhi Maa Nagar, Peelamedu, Coimbatore. We supply across Tamil Nadu and South India and dispatch regularly to Chennai, Bengaluru, Pune, Hyderabad, the Delhi NCR region and other industrial centres nationwide. Customers are welcome to witness the full-load test before dispatch.

Send the rating of the generator, UPS or battery bank to be tested, the test voltage and frequency, the total kW required, your preferred step resolution, and whether the unit will be indoor, outdoor or portable. Email sales@akshayamcontrols.co.in or call +91 89403 32552, and our engineers will come back with a configuration and price.