Why is it necessary to maintain a generator set with a load bank?

The purpose of a generator is to rescue an electrical network during a power cut, but who can take over from the generator? Nobody! Hence the importance of regular engine maintenance using a load bank.

Just like a car, the diesel engine of a generator clogs up naturally over time. Maintenance and roadworthiness checks ensure that the vehicle runs smoothly, protecting it from potential problems. Similarly, regular genset maintenance and testing ensure it functions as intended.

The performance of a generator will deteriorate over time, especially if not used in adequate conditions, such as, running empty for less than 30 minutes (similarly to a car used for short journeys) or regularly underloaded for long periods (similarly to a car stuck in a during traffic jam). There is a real danger that when a power cut occurs, the generator will stall and continuity of service won’t be guaranteed.
Don’t take the risk of suffering heavy operational and financial losses. To protect your equipment, installations or production, the generator/load bank pair is essential.

To the question, “Does it matter if my generator runs low and idle or idles in uninterrupted service?” The answer is YES. At less than 30% of its rated capacity, engine performance drops and maintenance requirements increase. Imagine running at low load continuously!

The engine will produce black / or slightly blue smoke and emit a lot of polluting gases and particles, because at low load it doesn’t heat up sufficiently and the diesel only burns partially.

Low-power operation creates a number of problems, including :

• Reduced engine efficiency
• Increased fuel consumption
• Increased oil consumption
• Injector clogging
• Premature wear of multiple components: oil leaks, turbocharger wear, cylinder glazing…

These are all problems that can be avoided by using a load bank as part of a methodical, regular maintenance plan.

Whether for preventive, corrective or emergency maintenance, the load bank is an indispensable tool for ensuring the reliability of your electrical installations.

Thanks to its different load technologies (resistive, inductive or capacitive), it faithfully reproduces the real operating conditions of your equipment, so you can test it in complete safety.

The main advantages of a load bench

Check the performance of your equipment

The load bank allows you to carry out tests at full power in order to validate the real performance of your installations:

• Testing alternators with a combined resistive/inductive load bank.
• Testing emergency generators without disrupting the plant network.
• Simulation of loads on isolated networks or micro-grids.

Keeping your equipment in optimum condition

Prolonged underload operation can degrade performance and shorten the service life of some equipment. The load bank allows you to :

• Maintain the performance of generators used on an occasional or rental basis.
• Check the actual autonomy and capacity of inverters and batteries.
• Identify malfunctions before they become critical.

Preventing failures and securing the installation

The load bank helps to maintain the operating conditions recommended by the manufacturers:

• Maintain the minimum load required on generators (generally between 30% and 50% of rated power).
• Stabilization of cogeneration plants operating in island mode.
• Compensation for the reactive energy produced by certain equipment, such as LED lighting or long cable runs.

A response to your safety and compliance requirements

Operating a power source on a load bank ensures :

• Safety of people and installations.
• Service continuity for your critical equipment.
• The reliability of your power sources.
• Compliance with regulatory requirements and manufacturer recommendations.

Anticipate rather than suffer

Inappropriate use of a generator or emergency power supply can lead to costly breakdowns and even irreversible damage.

Delta-Résistel’s teams will work with you to analyze your needs and technical constraints, and offer you a durable, reliable testing solution tailored to your operation.

Investing in an appropriate maintenance and testing strategy is often far less expensive than a major breakdown or repair.