The RST-600kW AC resistive load bank simulates real-world electrical loads to help you test, validate, and maintain your power equipment with confidence. Whether you're commissioning a new diesel generator, qualifying a UPS system for a data center, or performing routine maintenance on industrial power supplies, this load bank gives you the data you need to ensure stable, reliable operation.
This all-in-one resistive load cabinet integrates sheet metal cabinet, anti-corrosion alloy finned resistance tubes, forced air cooling fan system, Siemens PLC control system and touch screen HMI. It supports 4 universal industrial voltage grades (480V/440V/380V three-phase four-wire star connection, 220V three-phase three-wire delta connection), with manual star-delta wiring switching function, maximum test power up to 600kW, 10kW minimal adjustable load step, loading accuracy ±3%, meeting most industrial power testing demands.
- Generator set performance testing — full-load and partial-load validation
- UPS system commissioning & aging tests
- Power supply quality assessment for industrial facilities
- R&D laboratories requiring precise load simulation
- Electrical equipment troubleshooting and fault diagnosis
1.Multi-voltage compatible design Supports 4 mainstream AC industrial voltages, one machine covers 220V~480V test scenarios; star/delta wiring can be manually switched on copper busbars, no need to replace internal components.
2.Durable alloy resistance core Finned alloy resistance tubes, acid & alkali & salt spray resistant, strong corrosion resistance, high insulation, stable heat dissipation, support long-term continuous operation.
3.World-class electrical components
Contactors: ABB brand stable AC contactors
Controller: Siemens S7-200Smart PLC
Operation terminal: Industrial touch screen HMI
1.Dual control modes Local touch screen manual/automatic loading; remote control via PC software, Modbus-RTU (RS485) / Modbus-TCP (RJ45 Ethernet) communication, convenient for automatic test workshop docking.
2.Full-range safety protection system Equipped with emergency stop, short circuit, overcurrent, overvoltage, over-temperature, fan low air pressure, fan overload, smoke detection multi-layer interlock protection; all loads auto-unload once alarm triggered, buzzer alarm and record full alarm logs.
3.High-precision measurement & display 0.5-level measuring instrument, real-time display 3-phase voltage, current, active power P, reactive power Q, apparent power S, power factor PF, frequency, inlet/outlet temperature, control room & busbar chamber temperature, all data visualized on touch screen.
A high-quality Generator Load Bank is the key to ensuring the reliability of your power system, and proper maintenance is the foundation for ensuring its long-term stable operation. The RST-600kW load bank is designed to balance high performance and ease of maintenance.
Daily Inspection (Before/After Use):
Appearance and Cleaning: Check for any damage, deformation or corrosion on the cabinet, and wipe the surface dust with a dry soft cloth. Ensure that there are no obstructions within 3 meters (for air intake) and 5 meters (for air exhaust) around the equipment, and that the ventilation ports are unobstructed.
Connection Inspection: Check if the power cord, signal cable, etc. are securely connected, and if the connection terminals are loose, oxidized or have burn marks.
Function Pre-Check: After starting, observe if the fan is running normally and if there are any abnormal sounds. Check through the human-machine interface (HMI) if the voltage, current and other parameter displays are normal.
Internal Cleaning: Clean the equipment inside monthly using dry compressed air or soft brushes, especially the dust on the heat sinks and fans.
Core Component Inspection: Every quarter, in a power-off state, check if there is any burnout, odor or looseness in the internal power resistors, contactors (such as ABB), relays, etc. Use a multi-meter to measure the resistance value. If the deviation exceeds ±5%, replace it promptly.
Cooling System Maintenance: Clean the fan filter screen to ensure smooth air intake.
Protection Function Verification: Regularly simulate fault conditions such as over-current and overheating to test if the protection devices of the equipment are sensitive and reliable.
1.After heavy load test, resistance tubes retain high residual temperature; must wait fan delayed stop and full cooling before opening cabinet door to avoid scald injury.
2.Storage environment requirement: Storage temperature -30℃ ~ +60℃, dry environment, cover dust-proof cloth if long-term idle, regularly power on for 30min monthly to dehumidify internal components.
3.Prohibited operation: Do not block air inlet/outlet for long time high-power loading, which will trigger over-temperature alarm and burn resistance tubes; do not disassemble internal busbar copper bars without professional training.
Every RST-600kW load bank is built with industry-leading components: ABB contactors ensure reliable switching, while the Siemens 200Smart PLC provides intelligent, user-friendly control. The alloy resistance tubes feature exceptional corrosion resistance, high insulation performance, and efficient heat dissipation — enabling continuous operation without performance degradation.
One unit supports four voltage configurations — AC480V, AC440V, AC380V, and AC220V — with manual star-to-delta switching for maximum application flexibility. This means you can use the same Generator Load Bank across different test setups, reducing equipment costs and simplifying inventory.
Operate the load bank locally via the 7-inch HMI touchscreen with real-time display of voltage, current, power, power factor, and frequency.Or switch to remote control via PC software, Modbus-RTU, or Modbus-TCP for automated testing, data logging, and report generation.
Your equipment and personnel are protected by multiple safety layers: over-voltage and over-current shutdown, over-temperature protection with automatic load unloading, fan airflow monitoring, smoke detection, and a prominent emergency stop button. The system also features one-key loading/unloading — simply set the target power and press "Load" — the unit handles the rest.
Q1: Can this load bank test 220V, 380V, 440V and 480V equipment at the same time?
A: It cannot test multiple voltages simultaneously, but supports switching different voltage working conditions.
480V/440V/380V: Star connection wiring on busbar, connect neutral wire N;
220V: Adjust busbar jumper to delta connection, remove neutral wire; Switching only needs to adjust the copper bar connecting plate inside test compartment, simple operation without component replacement.
Q2: How do I select the appropriate load bank power for my generator or UPS?
A: Generally, the power of the load bank used for testing should be no less than 30% of the rated power of the tested power supply to ensure regular maintenance. For comprehensive performance tests (such as factory acceptance tests), a Generator Load Bank capable of simulating 100% full load or even 110% overload is required. The power of RST-600kW is adjustable continuously within the range of 1-600kW, enabling flexible satisfaction of various testing requirements from light load to full load.
Q3: The equipment triggers over-temperature alarm frequently during long-time loading, how to solve it?
A: Classify 4 root causes and solutions:
1.Air duct blocked: Dust accumulated on fan and resistance tubes, clean all ventilation channels, remove debris;
2.Fan failure: Fan stall, low rotating speed or overload, replace faulty fan, check fan power supply voltage (allow range 400V±10%);
3.Exceed rated test power: Long-term running over 600kW overload, reduce load power to within rated range;
4.Temperature threshold setting too low: Enter setting page to adjust over-temperature upper limit (factory default 300℃ outlet temperature, do not adjust upward without authorization).
Q4: Why can’t the load bank reach the set power level?
A: This is typically caused by one of the following issues:
1.Contactor issues: The contacts of a frequently operated contactor may be worn, resulting in poor contact;
2.Control or wiring issues: Check whether the control circuit wiring is loose, or whether the PLC (this unit uses a Siemens S200 Smart) control parameters are set correctly;
3.Power supply issues: Verify that the output voltage and frequency of the power supply under test are stable.
Q1: Touch screen shows fan low air pressure alarm after starting fan
A: Troubleshoot step by step:
1.Confirm fan is normally started without stall;
2.Check fan rotation direction must be upward air exhaust, reverse wiring will cause air pressure insufficient;
3.Inspect fan wiring terminals loose or poor contact, re-tighten wiring;
4.Air inlet blocked by sundries, clean surrounding barriers.
Q2: No remote control communication via Modbus-RTU/TCP
A: 1. Confirm only one communication interface used at a time, cannot connect RS485 and RJ45 simultaneously;
2. Check communication address (1~247) and baud rate (9600/19200/38400) consistent with upper computer; 3. Reconnect communication wiring, check cable breakage or shielding interference.
Q3: Emergency stop alarm pops up suddenly during test
A: Check the emergency stop button on the front panel first; if pressed down, rotate the red button clockwise to reset, alarm will disappear automatically. If alarm still exists, check emergency stop wiring loop open circuit.
Q4: Smoke alarm triggered automatically during operation
A: This is a high-risk fault, equipment will unload all loads immediately. Cut off power supply at once, open cabinet door to check resistance tube burning, short-circuit of internal wiring, clear combustible sundries, replace damaged components before reuse.
Q5: Can Generator Load Bank be installed outdoors?
A: Standard model IP20 protection grade, only suitable for indoor dry workshop. Outdoor use needs customized rainproof & dustproof cabinet, and increase cleaning frequency of fan and resistance compartment to prevent rainwater and sediment causing short circuit.
Q6: What’s included in the delivery package?
A: 1 set RST-600kW AC load bank, factory test report, original English instruction manual, standard connecting busbar accessories.
Project Background
This project serves a local generator manufacturer in Brazil. The Brazilian market adopts 60Hz industrial frequency with diversified regional voltages (220V/380V/440V/480V), and all generators need to pass strict INMETRO certification with long-time full-load testing. Besides, local power grids feature frequent voltage fluctuations.
Previously, the customer used scattered split small load cabinets for generator testing. The old equipment was hard to move, required frequent manual wiring switching for different voltage tests, had low testing efficiency, and could not well adapt to unstable local grid conditions, failing to meet local certification testing demands.
Solutions & On-site Application Effects
After adopting our RST-600kW integrated AC load bank customized for Brazil 60Hz grid standard, the customer solved all testing pain points effectively:
1.Multi-voltage integrated design: One single device covers 220~480V four mainstream voltage grades matching Brazil’s local power standard, supporting fast star-delta switching without repeated wiring. It eliminates multiple sets of redundant load equipment and saves 40% workshop space.
2.Professional safety protection for unstable grid: Built-in multi-protection interlock system. It will automatically unload in real time once encountering unstable generator output voltage or overcurrent caused by poor local grid conditions, protecting test generators from damage during long-hour full-load tests.
3.Intelligent automatic test system: Equipped with touch screen one-click automatic loading function. It can automatically record voltage, current, power factor and other test data, and support one-click test report export, perfectly meeting INMETRO certification data traceability requirements. The overall labor cost is cut by half.
4.Convenient mobile structure: Designed with lifting rings and forklift holes, the integrated load bank can be easily transferred between different test stations in the workshop.
A new energy enterprise’s UPS production line needs long-time cyclic aging test of 380V/440V UPS products, old load equipment has large loading error, frequent over-temperature false alarm, and no remote communication function, unable to connect workshop MES system. Advantages after replacing with our Generator Load Bank:
1.Loading accuracy ±3%, stable power output during cyclic aging, consistent test standard for each batch of products;
2.Modbus-TCP Ethernet communication, real-time upload test data to factory central control system, realize unattended automatic aging workshop;
3.Fan delayed stop function, continue heat dissipation after unloading, effectively extend resistance tube service life.
4.Distinguish real over-temperature fault and temperature switch false alarm, false alarm rate reduced over 90%;
A coastal port power department in Penang, Malaysia needs regular on-site load tests for backup generator sets, which puts forward strict requirements on mobile performance and fast wiring efficiency of test equipment. Core application highlights are as follows:
1.Adopts integrated walking wheels and forklift structure, enabling flexible transportation to dispersed generator rooms in different areas of the port;
2.Equipped with alarm log storage function, which records all abnormal operating data during on-site tests, helping technical staff quickly check and eliminate potential faults of generators afterward;
3.IP20 indoor protection cabinet matched with independent smoke detection protection device, adapting to humid and complicated working environment of coastal port power stations;
4.Configured with premium ABB contactors and Siemens PLC control system, ensuring ultra-low failure rate even under frequent handling, moving and vibration working conditions.
1.Production Test Engineer: The most practical point is four voltages integrated, star-delta manual switch saves a lot of wiring time; touch screen operation is intuitive, manual segmented loading is convenient for small power step-by-step test.
2.After-sales Maintenance Technician: Fault classification is clear, each alarm corresponds to independent troubleshooting guide; components are all international mainstream brands, spare parts easy to purchase, quarterly maintenance workload is small.
3.Equipment Procurement Manager: Single set replaces multiple single-voltage load cabinets, one-stop procurement, reduce equipment investment cost; unified size standard, workshop layout planning is simpler.
4.Automation Project Designer: Dual remote communication modes (RS485/TCP) are highly compatible with various PLC and upper computer test systems, no extra signal conversion module needed, simple docking programming.
1.Multi-voltage universal design: 220V/380V/440V/480V four voltage grades, star-delta manual switching, wide application range.
2.Stable high-power load core: Anti-corrosion alloy finned resistance tubes, support long-term continuous operation, ±3% high loading accuracy.
3.Dual local & remote control: Touch screen local operation + Modbus dual protocol remote communication, realize automatic unattended testing.
4.All-round safety protection: Emergency stop, over-voltage, over-current, over-temperature, fan fault, smoke detection multi-layer interlock, auto-unload for all faults.
5.Easy transfer & maintenance: Integrated mobile design with casters, independent control/test compartments, convenient regular cleaning and component inspection.
6.World-class standard components: Siemens PLC, ABB contactors, 0.5-level high-precision measuring instrument, stable performance and long service life.
1. Project Background
1.1 Customer Profile
Business Type: Standard industrial park enterprise.
Power Consumption Characteristics: Daily power consumption is stable, with strict requirements for emergency power supply.
Core Equipment: Equipped with one 550kW inline 6-cylinder diesel generator, serving as the primary emergency backup power source in the event of a mains power outage.
Equipment Advantages: This model performs exceptionally well in 400–550 kW standby power applications, featuring stable torque output, low vibration, and reliable continuous operation, making it perfectly suited for the load demands of industrial facilities and small-scale data infrastructure.
1.2 On-Site Operation and Maintenance Challenges
1. Severe Carbon Deposits: Prolonged operation in a no-load or light-load standby state leads to incomplete combustion, causing carbon deposits to build up in the cylinders, which results in black smoke emissions and reduced engine responsiveness.
2. “Fictitious Power” Risk: Without regular full-load testing, generators face the risk of being “unable to supply power when needed,” potentially failing to support the rated load during an actual mains power outage.
3. Outdated Testing Methods: Existing manual load equipment only supports low-load simulation and cannot perform 100% full-load verification.
4. Non-Compliant Data: Traditional testing methods cannot record complete voltage, frequency, and power curve data, making it difficult to meet the regulatory requirements for annual maintenance audits and safety filings.
1.3 Project Requirements
Specification Requirements: In accordance with industrial generator maintenance and inspection standards, a full-load performance test must be conducted every 6–12 months to verify actual output power, voltage stability, frequency transient response, and overall load-carrying capacity.
Core Objectives: To eliminate the risk of carbon buildup in inline 6-cylinder engines, restore their true power performance, and obtain standardized, traceable test reports for annual inspections.
Final Decision: The customer decided to introduce one 550kW smart resistive load set for periodic full-load testing and routine maintenance of the generators.
2. On-site Equipment Technical ParametersThe 550kW intelligent AC load bank is specially customized for inline 6-cylinder 500–550kW diesel generators, with practical and stable parameters, fully matching daily maintenance and factory acceptance standards:
Rated Working Voltage: 380V/400V three-phase four-wire
Max Test Power: 550kW resistive load
Adjustment Range: 0–550kW continuous adjustable
Load Step: 10kW/20kW/50kW/100kW precision stepping combination
Test Accuracy: ±2% (on-site actual test data)
Sampling Frequency: 1000Hz real-time data collection
Protection Level: IP33 indoor and outdoor universal
Working Temperature: -15℃ to +45℃
Load bank testing is widely used during generator commissioning because it simulates actual electrical loads without interrupting production systems. It also helps identify cooling, fuel, or control issues before the generator is placed into service.
3. Core Advantages for Inline 6-Cylinder Generator Testing
3.1 Eliminate Carbon Deposition of Inline Six-Cylinder EngineInline 6-cylinder diesel engines are more prone to carbon accumulation under long-term light load compared with V-type engines. The 550kW full-load test can fully burn carbon deposits in cylinders, restore engine combustion efficiency, eliminate black smoke during startup, and effectively extend the service life of the generator set.
3.2 Simulate Real Full Load Working ConditionsThe load bank supports stable operation at 25%, 50%, 75%, 100% and even 110% overload. It truly simulates the peak power demand of industrial sudden load increase, verifies the transient response capability of the inline six-cylinder generator, and avoids the problem of "nominal power inflation" of standby units.
3.3 Automatic Step Loading Protects Engine StabilityTraditional manual loading causes sudden load impact, easily leading to speed drop, frequency fluctuation and jitter of inline six-cylinder engines. The intelligent load bank adopts automatic step-up loading to ensure smooth power rise and protect the diesel engine and alternator from impact damage.
3.4 Complete Test Data for Audit FilingThe system automatically records voltage, current, frequency, active power, operating temperature and full-process curve data, and generates standard test reports. The data is traceable and meets factory acceptance, annual maintenance inspection and safety supervision filing standards.
4. On-site Installation and Test ProcessThe project adopts conventional low-voltage quick deployment without transformer transformation and complex construction:
Place the load bank flat on site, reserve heat dissipation space, and complete reliable grounding;
Directly connect the 400V cable to the output end of the inline six-cylinder generator;
Power on the system and self-check the fan, protection system and sampling module.
Standard test procedure for 550kW inline 6-cylinder generator:
No-load preheating: 15 minutes no-load operation to check unit stability;
Step load test: 0%→25%→50%→75%→100%, each stage runs stably for 20 minutes;
Full-load durability test: Continuous 550kW full-load operation for 30 minutes to verify continuous power performance;
Sudden load increase and drop test: Verify transient frequency and voltage recovery capability;
Step unloading and cooling down: Complete data storage and report export.
5. Project Operation Results
After 6 months of actual operation and 2 complete full-load tests, the project achieved obvious and reliable improvement effects:
5.1 Effectively improve engine carbon deposition problem
After full-load combustion test, the exhaust smoke of the inline six-cylinder generator is significantly reduced, the idle speed is more stable, the combustion efficiency is improved, and the engine oil carbon deposition degree is significantly reduced, reducing the frequency of engine maintenance.
5.2 Verify real full-load power performance
The test successfully verified that the 550kW inline six-cylinder unit can maintain stable output under 100% full load, with voltage fluctuation less than ±2% and frequency fluctuation controlled within ±0.5Hz. The unit has no overload alarm or shutdown, proving reliable standby power capacity.
5.3 Greatly improve testing efficiency
The traditional manual load test takes 4–6 hours with unstable data. The intelligent 550kW load bank realizes one-click automatic test, and the whole process is completed within 2 hours, which saves a lot of manual operation time and reduces human error.
5.4 Standard test report meets inspection requirements
All test data and operation curves are automatically saved, which can be exported as PDF/Excel reports at any time, solving the pain points of difficult filing and unqualified acceptance in factory and park power maintenance.
6. Application Scope
The 550kW intelligent load bank is the most matched testing equipment for inline 6-cylinder diesel generators. It is widely used in industrial park standby power, factory generator daily maintenance, commercial building emergency power inspection, generator factory delivery testing, and off-grid power supply system verification. It is an essential professional testing device to solve carbon deposition, insufficient power and unqualified test data of inline six-cylinder diesel generators.
7. Why a 550kW Load Bank?
For medium-size diesel generators powered by inline 6-cylinder engines, a 550kW resistive load bank provides sufficient capacity for factory testing, commissioning, preventive maintenance, and periodic inspection.
Typical applications include:
Generator manufacturers
Rental power companies
Industrial plants
Hospitals
Commercial buildings
Data centers
EPC contractors
Routine load bank testing also helps prevent problems associated with prolonged low-load operation, such as incomplete fuel combustion ("wet stacking"), improving long-term engine reliability.
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