Generator Load Bank Testing: The Basics

Generator load bank testing is a preventative maintenance process that checks that a generator is operating properly and running in optimal condition.
Annual load bank tests can help prevent any potential damage or sudden breakdowns of your generator due to component fail or items that could be prevented by proper generator service.
If you're wondering more about load bank testing, why it's done, how it's done, items to look out for when conducting a load bank test, then check out our video and learn some of the basics!
If you're looking for more information about load bank testing, check out our blog that covers this topic more in-depth: woodstockpower...
Looking for a backup generator for your business or facility? Check out our website for the latest inventory updates and availability:
www.woodstockpower.com

[@jeanrichelieu4784]

Good advice! Also, always make sure to remove all jewelries for safety purposes when you are working on generators, especially with the power interruptor switch on.

[@woodstockpowercompany1621]

This is correct! Safety should always be first.

[@nomon95]

Load bank are a group of huge resistors connected in series,paralell activated them by contactors or other devices.these banks need fans to extract the Huge heat generated by the resistors.the enclosures are big,With holes or doors which are opened when the bank work ay full power.

[@jamessherwood2374]

Best job I ever had

[@Sportsman134]

you love measuring generators?

[@montagusappling3076]

Load banking is easy it's clean work. Once you do a few it's like riding a bicycle. Generator teardown is where the real work is at.

[@woodstockpowercompany1621]

Right?!? But when your breaking down a generator in the heat? It ain't no joke.

[@montagusappling3076]

@woodstockpowercompany1621 True that especially in this Htown heat. I plan my days around 5am that way around 12 it's all down hill.

[@garbo8962]

Not sure if you mentioned that any time you run a generator under load you must have a 5 minute cool down All of our 500 to 2,000 KW generators had a 5 minute cool down timer.

[@arcanemelvz]

Thank you

[@123ABC-Machine-Basics]

If you ramp up the load too quickly on a unit that has quite a bit of carbon in the muffler you can get a fire in the muffler and burn that generator to the ground real fast. You want to take your time getting the unit heat soaked and I usually only do 25% steps at least 30 minutes apart before pulling 100% or more then after the test step down easily to relieve the exhaust gas pressure then cool down with no load at least 15-30 minutes. I will Never do a full load dump on or off unless the customer absolutely requires it and I have it in writing that customer is completely responsible for any damage to the unit . I have seen a guy do a full load dump on a 500kw Onan and blow a piston through the block.

[@mkhaled23]

How did you come up with 125A at 120/240V single-phase for a 30kW generator? At 0.8 pf, its 37500VA => 37500VA/240V = 156.25A

[@Rustlaser]

You are correct, that it is the amperage rating at 100% rating. However, unless the breaker is rated as a 100% breaker, most breakers are rated at 80% especially on these older cell site machines. In general, we never load bank a generator at 100% other than special cases or requests.

[@mkhaled23]

@@Rustlaser Thank you for your reply.

[@vickiebey8711]

His load bank is non reactive; so the calculations would be done for 1pf. 30kw unit. Single phase formula; I=kw • 1000/E or, 30000/240=125a

[@mudmovers]

Accidentally replied from my wife’s account, LOL. Same info applies though

[@mkhaled23]

@@vickiebey8711 You are correct in that the load bank is a resistive load, so pf=1. However, it was confusing to me because he mentions that he has a 30kW generator which gives 125A at 120/240V.
Anyways, this was a good video showing how its done on the field and its much appreciated.

[@homlethomes]

Nice job.... Do you have a single load for 2.5mva gen

[@woodstockpowercompany1621]

Unfortunately at the moment, we do not have a single load for 2.5 MVA. We did before, as we ran load tests on a 2 mW diesel genset, but one of our company partners asked to borrow it for a project.

[@Bonnechance123]

Would you be interested importing from China. solutions will be given if any issues.

[@marcoscarazo5345]

Cool

[@woodstockpowercompany1621]

Glad you enjoyed it!

[@oussamayahyaoui7103]

Thanks, you reminds me of Gerard Piqué :D

[@woodstockpowercompany1621]

😆Funny thing is football (soccer) is his favorite sport!

[@kennedyquirante208]

How long ?

[@mgmg-zj5jo]

Good😂