100 kilowatt outdoor resistive load bank
A 100 kilowatt outdoor resistive load bank is a critical test equipment used to simulate real-world electrical loads for evaluating the performance and reliability of power generation systems, such as diesel generators, solar inverters, and battery storage units. Designed for use in field environments—such as construction sites, remote telecom towers, or industrial facilities—it offers robust, weather-resistant housing that ensures safe operation under diverse climatic conditions.
This type of load bank provides pure resistive loading (power factor ≈ 1.0), making it ideal for testing engine mechanical capacity, generator voltage regulation, cooling system efficiency, and fuel consumption at full load. Unlike reactive or capacitive load banks, which simulate inductive or capacitive loads (common in motors or power factor correction), resistive load banks focus on heat dissipation and thermal stress testing—a fundamental requirement for factory acceptance tests (FATs) and commissioning checks.
Typical specifications include a three-phase AC input (380–480 V), current ranges up to 150 A per phase, and air-cooled heat dissipation using high-efficiency fans with automatic speed control. Thermal protection systems prevent overheating by automatically reducing load or shutting down if temperatures exceed safe thresholds (e.g., 85°C). Built-in digital meters measure voltage, current, active power (kW), and power factor, often with Modbus RTU or Ethernet communication interfaces for remote monitoring via SCADA systems or mobile apps.
Safety features include grounding compliance, short-circuit protection, overvoltage/undervoltage alerts, and emergency stop functionality—all essential for meeting IEC 60034-1 and UL 1598 standards. The unit’s rugged chassis (IP54 rating) resists dust and water ingress, while lifting eyes and forklift pockets allow easy transport and installation. Maintenance intervals typically recommend annual calibration of sensors and inspection of resistor blocks, with replacement cycles every 5–7 years depending on usage intensity.
An anonymized case study from a mining site in northern Canada demonstrated that a 100 kW outdoor resistive load bank successfully validated a new 125 kVA diesel generator during winter testing. At -20°C ambient temperature, the unit sustained 100% load for 4 hours without overheating, confirming adequate thermal management and consistent output voltage stability within ±2%. This ensured the generator could safely support critical operations in extreme cold.
For engineers and facility managers seeking reliable, portable, and scalable load testing solutions, a 100 kW outdoor resistive load bank delivers precision, durability, and compliance across industries—from renewable energy integration to backup power validation.
