In-House Production

Load Banks

Load Banks are used performance tests of generators, UPS, voltage regulators, power transformers, alternators and test laboratories and also ensure to operate the generators safely (dummy load) Aktif manufactures all type of load banks with the required;

  • Characteristics (R, L, C)
  • Electric characteristics (AC, DC, V, A, kW)
  • Stage precision
  • Control (manual, HMI-controlled or automatic)
  • Measuring methods
  • Installation (indoor or outdoor)

Areas of Use:

Load Banks are used in many industrial areas and applications. As energy needs become more and more important day by day, testing, protecting and maintaining the resources that provide this energy temporarily or continuously is becoming more and more important. Major areas of use of Load Banks are listed below.

  • Testing whether the products such as power transformer, generator, alternator, UPS, regulator provide the design values and reporting the electrical values read or recorded during the test.
  • testing the generators, UPS or regulators after maintenance or repair on site or workshop.
  • No-load operation of generators is not requested. In this case, automatically providing artificial load when the load supplied by a generator falls below a certain level (ideally 30%)
  • Automatic damping of the regenerative power which is created when facilities where high-power motors are driven by regenerative drives are supplied by generators
  • Load dispatch test at power plants
  • Testing of alternators used by military or civil air, road or marine vehicles
  • Controlled discharge and capacity testing of batteries
  • Electrical and heat simulation and performance tests of data centers with load banks
  • Invertor performance tests

Electrical Specifications:

Load Banks can be manufactured for AC (50/60/400 Hz) or DC and AG or OG operating voltages.

Load banks based on load characteristics;

  • Resistive (kW-cosø: 1)
  • Inductive (kVAr)
  • Resistive + Inductive (kVA-cosø: requested)

Special designs can be made for different frequency and cosø values.

AC Load Banks are designed in kW, kVAr or kVA and DC Load Banks are designed in Current (A).

Load stage precisions can be 1 kW or 1 kVAr for AC or 1 A for DC standard. lower precision can be provided if requested.

The resistor material for resistive loads is stainless steel wire which has low temperature coeffient. This ensures that voltage and power levels are within tolerances even in case of continuous operation.

Inductive loads are manufactured with aluminum or copperconductor, low losses and iron core.

Resistive load resistors provide a large cooling surface for forced cooling and are resistant to short-term overheating and cooling.

The insulation level of load banks are 3 kV/1 minute for the power circuit and 2 kV/1 minute for the control circuit. Ceramic insulation materials resistant to electric and heat are used for insulators.

Any flammable materials, including the cables, are not used in the load compartment. All serial and/or parallel power connections are made with busbar inside the terminal board.

Automatic load banks which work dummy load principle for generators are manufactured without fans and with natural cooling up to 50 kW.

Single-phase or three-phase fans used on load banks cooled with forced air are designed based on the power and volume of resistors and the flow (m3/h) and pressure (pa) of the fan.

Fan and control supply can be supplied with external source from the network or internal from the load bank supply system with a selector switch. This feature provides convenience for tests on site that is far away from network..

Physical Properties:

Load Banks can manufactured IP 20 protection level for indoor use, IP20 / IP 23 for outdoor use under shelter or IP 55 for outdoor use on open area.

Load banks are manufactured portable and case-type up to 100 kW. Load banks up to 500 kW are manufactured with wheels. Over than 500 kW load banks are usually fixed on the ground. Load banks can be installed on a trailer and transported by a vehicle on demand.

There are two types of load banks according to cooling direction.

  • Horizontal air flow
  • Vertical air flow

Load Bank Control Types:


“N0” Control Model

N0” control model is used if the customer wants to control the load bank themselves. Load bank includes loads, fans, sensors and an empty control panel. The power cables of the loads, the supply of the fans and the contacts of the sensors are drawn into the terminals in the empty control panel.

“N1” Control Model

It is the simplest and cheapest control model. Each load phase is directly switched with miniature circuit breaker or cam switches. A wattmeter is used for measurement.

“N2” Control Model

Loads are protected with miniature circuit breakers or compact circuit breakers and switched with contactors. Load contactors are controlled with buttons and their indicators on the control panel.

The network analyzer on the control panel is used for measurement. This analyzer allows reading of kW, kVAr, kVA, A, V, f, cosø ... etc. Optionally, an analyzer with PC communication (RS212, RS458 or USB port) is used to monitor the measured values on the PC.

The following safety precautions are taken in the load bank;
  • Overcurrent (with miniature circuit breakers or compact circuit breakers)
  • Overtemperature (with thermal contactors)
  • Overvoltage and low voltage if requested
  • Fan blowing error (with airflow sensor if the fan cannot blow)

Loads can be switched on only when there is no safety issue.

“N3” Control Model

Loads are protected with miniature circuit breakers or compact circuit breakers and switched with contactors. Load contactors are controlled through the interface of touchscreen “TFT LCD HMI Panel”. HMI runs with a microprocessor-based electronic control board or in integration with the PLC and with a communicating network analyzer.

Operator can manually switch on all loads individually or all in one go via the HMI interface and can automatically control with many control options and scenario. In addition, kW, kVAr, kVA, A, V, f, cosø, etc. are monitored on the HMI screen. These values can also be stored on the HMI's memory card.

The following safety precautions are taken in the load bank
  • Overcurrent (with miniature circuit breakers or compact circuit breakers)
  • Overtemperature (with thermal contactors)
  • Overvoltage and low voltage if requested
  • Fan blowing error (with airflow sensor if the fan cannot blow)

Loads can be switched on only when there is no safety issue. In addition, all errors are monitored on HMI screen.

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