Load Bank

We offer rental basis air-cooled, indoor resistive load banks.

The load bank is required for periodic exercising and testing of the (standby) emergency power source( like-UPS,GENERATOR and any AC 230v/415v) . The load bank shall be portable with casters, forced air cooled and shall have a local control panel.

Load banks can be used in a wide variety of applications, such as:

• Factory testing of engine generator sets
• To reduce "wet stacking" problems
• Periodic exercising of stand-by engine generator sets
• UPS system testing
• Battery system testing
• Ground power testing
• Load optimization in prime power applications
• Factory testing of turbines

The Loadbank is a continuous duty, portable, lightweight load bank that is easily transported, set up and operated by one technician.

Load Bank Products

Ratings

The total avilable capacity of the load bank is 1000 KW at (_230V/415V) Volts, 3-Phase, 4-Wire/1 Phase,2 wire, 50 Hertz, at unity Power Factor. Modular ranges are 30, 50, 75, 100 & 150 KW. Minimum load step 1KW.

The load bank shall be designed for continuous duty cycle operation with no limitations.

What is Load Bank Testing and how does it work?

A UPS (Uninterruptible Power Supply) sits between an alternative source of power - such as a Standby Diesel Generator - and protected loads. Most UPS are designed to power connected loads continuously via their inverter, which also enables conditioning of mains supply voltage and insurance of a break-free supply of electrical energy in the even of a mains failure. In most applications, UPS are considered critical to business continuity without which loads would not be able to operate during a power outage. For this reason, load bank testing is implemented to ensure UPS can meet the requirements of their intended function when most needed.

Load Bank Testing is a way of validating the correct operational performance and battery autonomy of the UPS system. It tests the UPS and generator under load conditions. It is most often carried out during preventative maintenance. As a UPS battery set is only as strong as its weakest battery cell, load bank testing can also be used to ascertain the condition of UPS batteries and battery sets (or ‘strings’ as they are also known) to indicate if any individual cells are approaching the end of their working life and not holding a charge or about to fail. This enables them to be replaced in advance of critical application.

Load Bank Testing is offered as a service by suppliers of power protection equipment, such as Uninterruptible Power Supplies Limited. Some suppliers offer load bank testing as part of the UPS commissioning process but caution must be exercised:

ideally it should be carried out at least one week after the UPS has been commissioned to permit the voltage across the battery blocks to equalise and batteries to be fully charged. Load bank testing prior to this will not yield accurate results, or give a true picture of how the system is running, and thus be a waste of time and money.

Suppliers of load bank testing normally carry their own small load banks (typically 100kW or less) and will hire in larger dummy sets to test larger UPS systems as required. These load banks are typically resistive (neither inductive nor capacitive and with no initial switch-on surge. Current rises immediately to a steady state). Load banks are available for either ac or dc systems. An ac load bank is used to test entire UPS systems, whereas adc load bank will be used to test batteries.

Load Bank Testing will ensure that the components within the power protection system will work and perform together as intended when called upon to support a critical load.

Engineering Specification

Material And Construction

The load bank shall be suitable for operation indoors/outdoors.

The load bank shall be constructed of heavy gauge steel sheet. Powder coated steel provides superior corrosion protection and extended service life, with a better tolerance to high heat exposure compared to the more common Galvanized steel.

The main parts load bus(resistive coils), load step MCBs, and fan/control fuses shall be located within the load bank enclosure.

Airflow throughout the load bank shall be horizontal. Ambient intake cooling air shall be drawn in at the sides of the unit and heated air exhausted other side .

Resistive Load Elements

Heater Elements/Speg

Finned tubular heating elements are of the type where the surface area is enlarged by a strip in order to heat gases. At high power the surface temperature is small and the heating element is short. Finned Tubular Heaters are manufactured with the same rugged construction as the standard Tubular Heaters except a MILD STEEL ELECTROPLATED or a corrugated 304 STAINLESS STEEL FIN is helically wound on Heater Tube diameter (304 stainless steel) element. To insure a permanent bond, each end of the fin is fully brazed to the Heater sheath, for optimum heat dissipation and efficiency, as Brazed fins transfer heat at about double the efficiency of unbrazed designs. These heaters are ideal for heating air and select gases in forced and natural convection applications.

Elements must be fully supported across the entire length within the air stream by segmented ceramic insulators on stainless steel rods. Element supports shall be designed to prevent a short circuit to adjacent elements or to ground.

The overall tolerance of the load bank shall be –0% to +5% KW at rated voltage. A –5%, +5% rating allows the load bank to deliver less than rated KW and shall not be used. The load bank must deliver full rated KW at rated voltage.

The load bank wirings are made by aluminum bus bars and PTFE (TEFLON) INSULATED SILVER PLATED COPPER WIRES(PTFE insulation is fireproof and flame proof. In case of short circuit or fire PTFE does not damage ) so, in any condition the load bank wiring does not short/fire.

in any extreme condition the load coils get problem the MCB will trip off.

Features:

• Possible Tube & Fin diameters
• Heater OD : 8.2mm 11.2mm
• Fin OD : 28mm 30mm
• Mild Steel (Fin) sheath (Electro plated) models are suitable for operating temperatures to 300 °C.
• Watt density : Max up to 35 w/in²
• High Temperature grade magnesium oxide insulation imbeds the resistance wire coil for optimum heat transfer & Dielectric Strength.

Cooling

The load bank shall be cooled by integral fan which is direct coupled to the cooling. The fan motor must be electrically protected against overload/fault using current limiting fuses

Protective Devices

Any load short-circuit/over load in the load/coil the MCB will trip for fan production fuse provided

Control Panel

The control panel shall be mounted in front of the load bank. The control panel shall contain the following manual controls : input indicationsload on MCBs for ON/OFF application of individual load steps.