Load Bank

Resistive load banks or Dummy Loads

Load banks have an important role in stand by power generation equipment which are a cost effective way of keeping things running.

The necessity and dependence on power at mining sites, oil and gas refining, in hospitals, transport and many other essential services has meant a rapid growth of back up generators and UPS systems for back up power. The increase of computers and telecommunications equipment demands faultless performance in the event of power down conditions. This can only be fully achieved by resistive load testing the stand by systems on installation at regular intervals.

The life and efficiency of diesel generators can be greatly reduced when running under-loaded, causing damage to the engine or fouling of valves and exhaust ports. It could also cause extensive cylinder bore glazing to a point where engines could stall or completely fail to start when they are needed the most – during a mains power failure.

Only resistive load banks can guarantee the ultimate operating conditions and efficiencies of stand by generators. The importance and necessity to test batteries and UPS systems can only be achieved with resistive load banks. Batteries quite often require a full discharge test to monitor cell condition.

Auxiliary equipment such as resistive load banks ensure regular and reliable load testing can be performed without interruption to mains power supply and leaving you confident that your emergency power system will function during any mains power failure.

Design Features

Available in manually switched to fully auto-controlled units. Ranging in sizes from 0.2KW to 2MW with safety interlocks such as high temperature overloads, low air pressure/flow switch, and fan motor overloads.
A load cooling timer which allows the cooling fan to continue operation for an additional five minutes after load shut down is optional.
A range of meters are available which include volts, amps, hertz and kW.

Download our Load Banks brochure.

What are Load Banks?

The necessity and dependence on power at mining sites, oil and gas refining, in hospitals, transport and many other essential services has meant a rapid growth of back up generators and UPS systems for back up power.The increase of computers and telecommunications equipment demands faultless performance in the event of power down conditions. This can only be fully achieved by resistive load testing the stand by systems on installation and at regular intervals.

The life and efficiency of diesel generators can be greatly reduced when running under-loaded, causing damage to the engine, fouling of valves and exhaust ports. Also causing extensive cylinder bore glazing to a point where engines could stall or completely fail to start when they are needed the most – during a mains power failure.

  • Standard Load Banks
  • Touch Screen Control
  • Portable Load Banks
  • Water Cooled Load Banks
  • Braking Resistors
  • Experience List

Standard Load Banks

Only resistive load banks can guarantee the ultimate operating conditions and efficiencies of stand by generators. The importance and necessity to test batteries and UPS systems can only be achieved with resistive load banks. Batteries quite often require a full discharge test to monitor cell condition.

Auxiliary equipment such as resistive load banks ensure regular and reliable load testing can be performed without interruption to mains power supply and leaving you confident that your emergency power system will function during any mains power failure.

Design Features
Vulcanic TEE’s load banks are available in manually switched to fully automatic-controlled units. Ranging in sizes from 0.2kW to 2MW with safety interlocks such as high temperature overloads, low air flow switches, phase sequence control and fan motor overloads.

Other features include

  • Low temp Stainless Steel finned air resistors
  • Powder coated rigid housing
  • High air flow axial fan(s) with safeties
  • Auto and manual load switching⁄shedding
  • LCD multifunction metering
  • Data extraction and fault log capability
  • Auxiliary power outlet for cooling fan operation
  • Emergency stop
  • Power on – Resistors on – Fan on – Fault indication
  • Manual reset over temperature safety thermostat
  • IP55 rated
  • Lockable castors
  • Power-loc connectors and 6m cables
  • Real time graphic display
  • Provision for forklift tynes
  • Overhead lifting access

A load cooling timer which allows the cooling fan to continue operation for an additional 5 minutes after load shut down is optional.

Vulcanic TEE can also provide individual load bank elements, for more information download our specs sheets.

Touch Screen Control

Vulcanic TEE can supply resistive load banks with a touch screen controller for fully automatic operation.

Control Management Setup

  • Manual Override = Yes⁄No
  • Load Dump = Yes⁄No

Monitor Button

This will present the user with real time data of the system in operation, either in auto or manual.
Values presented graphically can be scrolled

  • Generator Load kW
  • Load Bank Engaged kW
  • Volts, Amps, Hz, Cos
  • Load Bank Temperature
  • Fan Status
  • Cool down Time Elapsed
  • Cool down Time Remaining

Auto⁄Manual Button

When Auto is selected the unit will automatically select the required resistor steps based on the setup criteria. In the event mains power is selected, the system will dump the load and initiate the system cool down function.
When Manual is selected, the unit will present the user with a window to enter a kW value as a number. The system will engage the required steps to reach the desired value. There will also be an UP⁄DOWN button to allow the user to increase or decrease the kW value incrementally.

Load Dump Button

At any time while the system is operating in Auto or Manual mode, the user can press the Load Dump Button on the screen to cancel all load steps immediately.

Remote Connection

The ability to connect remotely through the Schneider app.

Data Logging

Optional data logging of testing reports into Excel format

Portable Load Banks

Portable load banks offer a simple and compact solution for load testing.
While all ThermaLoad load banks feature castors, our portable range provide a more compact and portable unit for ease of maneuverability.
ThermaLoad portable load banks make it easy to access out of the way testing locations or roof top generators only accessible by elevators.

Features:

  • Single and Three phase power
  • Centrifugal fan
  • Manual or Auto operation
  • Available with main leads or surface socket
  • Light weight but still rigid
  • Compact size
  • Lockable castors for transport
  • Weatherproof for site operation
  • Optional metering
  • Powder coated housing
  • Simple operation
  • Emergency stop

Water Cooled Load Banks

Vulcanic TEE can design and manufacture water cooled load banks for a wide range of applications, including yachts, ships, high-rise buildings or applications where a fan cooled unit would be too large, bulky or noisy.

Water cooled load banks can use all types of water (including recycled water from chiller systems or sea water pumped directly into a ship) offering a flexible, quiet and efficient design for load testing.

Features:

  • Vertical or Horizontal mount
  • High grade 316L stainless steel resistive elements
  • Full 316 stainless steel construction
  • Power ratings from 10kW up to 1MW
  • Incorporates the digital touch screen control seen on our standard range of ThermaLoad load banks
  • Supplied complete with circulation pump and control cabinet ready for installation
  • Quiet operation
  • Ideal for use in super yachts, naval ships, ferries, cargo vessels, indoor installations, offshore platforms, HVAC, city buildings and more.

Braking Resistors

Braking Resistors are used in motion systems to convert excess electrical energy when decelerating into thermal energy through electric heater elements inside the unit. This is known as dynamic braking.
Vulcanic TEE design and manufacture custom braking resistors to suit the load and spatial requirements of your application. Our braking resistor units can be air cooled or water cooled, based on your needs.

Vulcanic TEE can supply a complete braking resistor unit or individual replacement parts, from controls and accessories, to the finned heater elements used inside the unit.

Braking resistors can be used in a range of applications, including conveyors, engines, cranes, trains and more…

Features:

  • Painted, Galvanised or Stainless Steel finish
  • Aluminium grilles
  • Air Pressure switch
  • IP Rated
  • Lockable castors
  • Isolation switch
  • Axial fan
  • Turret punched grill⁄assembly
  • High temperature overload

Experience List

DateProject NameProductQuantityCountry
2017Load Bank10kW 415V 3 ST Load Bank1Australia
2017Resistive Load Bank240VAC 5280W Resistive Load Bank1Australia
2017Solar Station Automatic Load Bank415V 30kW Automatic Intelligent Load Bank1Australia
2017Resistive Load Bank240VAC 5280W Resistive Load Bank1Australia
2016Free Standing Resistive Load BankResistive Load Bank 250kW 5 Stage1Australia
2016Resistive Load BankResistive Load Bank 240VAC 5280W 22A1Australia
2016Duct Monuted Loadbank415V 40.5kW Resistive Loadbank – Gasfire Generator1Australia
2016Resistive Load Bank29.5VDC 5kW Max. 24VDC Resistive Load Bank6Australia
2016Resistive Load Bank415V 3 Phase 15kW Multi stage Resistive Load Bank2Australia
2016Resistive Load Bank for Military use32Vdc 200A Resistive Load Banks2Australia
2016Resistive Load Bank24VDC 17405 Ohm 5000w max12Australia
2015Fan Cooled Resistive Load bank415V 10kW Load Bank1Australia
2015Isolation Transformers240V 5280W Resistive Loadbank6Australia
2015240V 9kW 12.5A Resistive Load Bank240V 9kW multi-staged manual Load banks1Australia
2015Dummy Load 415v 1 stage 2A415V 1500W load banks2Australia
2015Generator Testing240V 10.75kW manual air cooled resistive load bank1Australia
2015Generator Testing240V 9kW Multi staged manual load banks2Australia
2015APLNG Spring Gully Operations415V 10kW Resistive Load Banks30Australia
2015DSTO Facility -Load Cell testing120 – 1000V DC 11 stage 370kW Resistive Load Bank1Australia
2015Generator Testing415V 3kW Resistive Load Banks30Australia
2015Airport Generator testing415V 3 phase 400kW – Resistive Load Bank1Australia
2015Generator testing Brunei440V 80kW 5 stage Resistive Load Banks2Brunei
201580kW Resistive Loadbank415V 3ph 80kW -multi stage Resistive Load Bank1Australia
2015150kW Resistive Load Bank – Jemena Projects400V 3ph 50Hz 150kW multi stage resistive load bank2Australia
2015Rooftop Generator testing415V 3 phase 100kW – multi stage resistive load bank4Australia
2014Thermaload Load Banks400kW of Resistive Load4Australia
2014150kW Resistive Load Bank – Jemena150kW Resistive Load Bank2Australia
2014Load Testing785V 75kW Braking Resistors2Australia
2014Load Testing240V Load Bank1Australia
2014Site Load Testing415V 15kW Load Bank1Australia
2014Crane400V Braking Resistor1Australia
2014Power Grid SA240V 10.8kW Load Bank1Australia
2014UPS Testing240V 10kW Load bank1Australia
2014Site Load Testing415V 45kW Load Banks5Australia
2014Commonwealth of Australia550V 1.9MW Load Banks2Australia
2014Refurbishment240V Load Banks66Australia
2014GLNG Battery Testing230V 80kW Load Banks2Australia
2014Crane330V Braking Resistor1Australia
2014Refurbishment240V Load Banks80Australia
2014Load Testing415V 20kW Portable Auto Load Bank1Australia
2014Refurbishment240V Load Banks12Australia
2014Refurbishment208V Load Banks48New Zealand
2013Airport Generator Testing415V 33.75kW Portable Load Bank1Australia
2013Chevron Gorgon Project – Barrow Island415V 300kW Resistive Load Bank1Australia
2013Load Testing1000V DC 75kW Fixed Braking Resistor1Australia
2013LongreachVarious size Resistive Load Banks5Australia
2013Solar Power Grid415V 500kW Resistive Load Bank1Tonga
2013NBN Rollout – NSW415V Resistive Load Banks12Australia
2013NBN Rollout – VIC415V Resistive Load Banks18Australia
2013NBN Rollout – TAS415V Resistive Load Banks32Australia
2013SA Power Project415V 15kW Resistive Load Banks2Australia
2012Gen Set Testing – NSW415V 25kW Resistive Load Bank1Australia
2012Gen Set Testing – NSW415V 20kW Resistive Load Bank1Australia
2012Water Plant Project – QLD415V 30kW Resistive Load Banks2Australia
2012Gen Set Testing – QLD415V 30kW Resistive Load Bank1Australia
2011Naval NSW Gen Set Testing450V 64kW Resistive Load Banks8Australia
2011Naval NSW Gen Set Testing450V 60kW Resistive Load Banks8Australia

For more information, download our Load Banks PDF Brochure or contact us.
View the terms of our product warranty.