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How to generator load bank testing?

How to generator load bank testing?  This test is a performance check that puts the generator under full load to verify its overall health and operation.

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In the world of power generation, it is vital to ensure the reliability and efficiency of your equipment. One way to accomplish this is through generator load bank testing, a process that sounds specialized but is actually quite simple.

How to generator load bank testing?  This test is a performance check that puts the generator under full load to verify its overall health and operation.

In today’s blog, BISON generator suppliers going to dive into the specifics of how to perform a generator load bank test. So if you’ve ever wondered about specific ways to ensure optimal generator performance, buckle up – you’re in for a treat!

What is load bank testing?

Load bank testing is a critical process that tests the generator’s ability to produce maximum output in terms of amps and voltage. It reveals potential problems within the generator system that may not be noticeable during light loads or no-load conditions. Load bank testing ensures that our generator will work as expected when the power goes out.

The Load Bank Testing Process

Understanding the Load Bank Testing process is crucial to ensure the reliability and longevity of your generator. The process can be broken down into three main stages: Preparation, Testing, and Post-test Inspection.


Before you dive into testing, proper preparation is essential:

  1. Select the Correct Load Bank Type and Size: Based on the type and capacity of your generator, select an appropriate load bank. The load bank should be capable of loading the generator to its full kilowatt or kilovolt-ampere rating.

  2. Disconnect the Generator from the Load: To prevent any unforeseen issues or power interruptions, disconnect the generator from the load it normally serves.

  3. Connect the Load Bank to the Generator: Ensure that the load bank is correctly connected to the generator as per the manufacturer’s instructions.

  4. Warm-up the Generator: Start the generator and allow it to reach its normal operating temperature before applying any load.

what are the steps of load bank testing?

Properly performed load bank testing procedure can confirm the generator’s ability to deliver the required power and help to preemptively pinpoint any issues that could lead to costly damage to the generator set.

With this goal in mind, here are the steps our dealers should follow during load group testing for their customers.

# 1 – fuel & coolant inspection

The first thing we should do is check the fluid levels. Make sure the tank is filled and confirm that the generator has enough oil and coolant.

# 2 –startup and temperature assessment

Next start the generator and visually inspect its operation to bring it up to standard operating temperatures. During the process listen for unusual sounds that may indicate potential problems.

If any problems occur, the test is stopped until the problem is resolved.

# 3 – load connection

In this phase of the load bank test, our technician applies the heaviest loads first, gradually adding smaller ones until reaching 50% of the generator’s maximum continuous rated load.

# 4 – amperage verification

Using an ammeter, we check voltage in each leg to ensure neutrality and that it remains above 105 volts under full load.

# 5 – load monitoring

The technician continues to listen for unusual noises and watch for signs of overheating. This phase usually lasts 4-24 hours for most generators, but can extend to a week for large industrial generators.

# 6 – shutdown and results recording

The test is performed slowly and the loads are gradually removed to allow the generator to cool down. After switching off all loads, switch off the unit and record the results. Recommendations for necessary corrective action are also provided.

Generator load test in progress


We are unwavering in our commitment to providing comprehensive resources to our dealers. With this blog on generator load bank testing, we aim to provide our partners with the knowledge and insights they need to provide quality service to their customers. Ensures BISON generator dealers are equipped to handle the complexities of generator testing, ultimately increasing the reliability and efficiency of our products.

We unswervingly pursue excellence and customer satisfaction and forge ahead together!

How to generator load bank testing FAQ

A generator should typically undergo load bank testing once a year. However, if your generator doesn’t often run at full capacity, or if it’s primarily used as a backup power source, you might want to consider testing it more frequently.

To size a load bank for generator testing, you should match or exceed the generator’s maximum output capacity. This means if your generator’s rated output is 100kW, your load bank should also be able to handle at least 100kW. This allows you to fully test the generator at 100% of its rated capacity.

Performing a generator load bank test is an important procedure to ensure that your generator performs optimally when it is needed most.

The process involves applying a simulated load to the generator, which is gradually increased until full load operation is reached. This helps to identify potential problems that may not be apparent under normal or no-load conditions.

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