In the world of critical power testing, “off-the-shelf” solutions often fall short. Standard load banks are built for the average use case-typically standard grid voltages and broad load steps. However, complex infrastructure projects, specialized industrial applications, and international export requirements rarely fit into the “average” box. Whether you are commissioning a data center with high power density, testing aviation ground power units at 400Hz, or validating a generator in a high-ambient desert environment, standard equipment can lead to compromised testing and inaccurate data.
This is where Customised Load Banks become essential. Engineered to match your exact specifications, these bespoke units bridge the gap between standard testing capabilities and your project’s unique reality. Here is how customization ensures your power systems are tested with absolute precision.
1. Precision Voltage and Frequency Engineering
The most common limitation of standard load banks is their fixed voltage and frequency ratings (typically 400V/50Hz or 480V/60Hz). If you are manufacturing generators for export to the US or testing marine equipment, these standard units require cumbersome external transformers, adding cost and complexity.
Customised Load Banks are engineered to match your specific electrical parameters directly.
Multi-Voltage Capabilities: We can design units with internal switchgear that allows you to toggle between voltages (e.g., 240V, 400V, 480V, 690V) using a single unit.
Specialized Frequencies: For niche industries like aviation or military defense, load banks can be built to handle 400Hz power systems, ensuring accurate simulation of ground power units (GPUs) and aircraft systems.
Direct MV/HV Testing: Instead of stepping down voltage, custom units can be engineered for direct connection to Medium Voltage (up to 33kV) systems, eliminating the need for step-down transformers and simplifying the testing setup.
2. Granular Load Steps and Advanced Control Logic
Standard load banks often apply load in large blocks (e.g., 50kW or 100kW steps). While sufficient for general exercising, this lacks the resolution needed for precision commissioning or validating sensitive electronic governing systems.
Customization allows for fine-resolution load stepping. You can specify load steps as small as 1kW or even 0.5kW. This granularity enables:
Exact Load Profiling: You can mimic the precise ramp-up curve of your facility’s specific equipment.
Transient Response Analysis: By applying small, controlled load increments, you can accurately measure how the governor and AVR respond to minor fluctuations, ensuring stability for sensitive IT loads.
Automated Testing Sequences: Custom controllers can be programmed with automatic load profiles (e.g., 25% -> 50% -> 75% -> 100% -> cool down) that run without manual intervention, ensuring consistent, repeatable tests for factory acceptance testing (FAT).
3. Form Factor and Environmental Hardening
Physical constraints and environmental conditions are often the deciding factors in equipment selection. A standard load bank designed for a cool warehouse will fail rapidly in a scorching desert or a corrosive marine environment.
Customised Load Banks are built to survive and fit where you need them:
Space Constraints: For naval vessels or crowded data centers, we design low-profile or vertically oriented units to fit into tight designated spaces or tunnels.
Extreme Environments: Units can be customized with stainless steel enclosures (IP65) for offshore use, sand traps and high-temperature insulation for desert deployment, or sound-attenuated containers for use in noise-sensitive urban areas.
Portability: From trailer-mounted units for rental fleets to containerized solutions with dedicated cable storage, the physical design is tailored to your logistics needs.
4. Dual-Purpose Resistive and Reactive Testing
While standard units are often purely resistive (1.0 Power Factor), real-world loads are rarely that simple. Motors, transformers, and UPS systems create reactive power demands.
Customization allows for the integration of inductive (lagging) or capacitive (leading) elements within the same enclosure. This enables you to test at a specific power factor (e.g., 0.8 lagging) to simulate the true operational stress on your generator’s alternator, not just the engine. This “all-in-one” custom solution provides a comprehensive validation of your power system’s thermal and electrical limits.
By investing in Customised Load Banks, you move beyond the compromises of standard equipment. You gain a testing tool that is accurate, safe, and specifically engineered to validate your project’s success.
Frequently Asked Questions
What features can be customized on a load bank?
Almost every aspect can be tailored, including voltage inputs (low/medium/high), frequency (50/60/400Hz), load step resolution (e.g., 1kW steps), control systems (manual/automatic/remote), and the physical enclosure (trailer-mounted, containerized, sound-proof).
Can I get a load bank that handles multiple voltages?
Yes. Customised Load Banks can be designed with internal switchgear or dual-wound elements, allowing you to switch between different voltages (e.g., 240V, 400V, 480V) using a simple selector switch or control panel setting.
Why would I need a custom load step resolution?
Standard banks apply load in large chunks. If you are testing sensitive equipment or need to verify a specific governor response curve, you may need very small load increments (e.g., 1kW) to achieve precise data points that large steps would miss.
Are custom load banks suitable for extreme environments?
Absolutely. Custom units can be engineered with upgraded ingress protection (IP65/NEMA 4), stainless steel casing for corrosion resistance, and high-temperature cooling systems, making them ideal for deserts, offshore rigs, or arctic conditions.
Can a customized load bank test at a 0.8 power factor?
Yes. While standard units are often resistive (1.0 PF), custom units can combine resistive elements with inductive reactors to test at 0.8 PF (or other specific power factors), simulating real-world motor and transformer loads.
What is the lead time for a customised load bank?
Because they require specific engineering and manufacturing, custom units typically have a longer lead time than off-the-shelf models. However, this ensures the unit meets your exact requirements, preventing costly workarounds later.
Can you integrate the load bank controls with my building management system (BMS)?
Yes. Custom controllers can be engineered with communication protocols like Modbus or TCP/IP to integrate seamlessly with your existing SCADA or Building Management System for centralized monitoring and control.
Is a customized load bank more expensive than a standard one?
Initial costs may be higher due to engineering and specialized components. However, a custom unit often lowers the total cost of ownership by eliminating the need for external transformers, reducing testing time, and preventing equipment damage due to improper testing.
