Load Bank Control Systems
Our loadbank control systems are designed to deliver precise, reliable, and scalable control across every testing environment. Whether managing a single loadbank or coordinating large, multi-unit installations, our systems combine intuitive operation with high-performance data handling, real-time monitoring, and seamless integration.
VCS 2.0.0 is a powerful, future-ready control system for the LC80 controller and Windows PC/laptop. It provides flexible control of individual, multiple or clustered loadbanks, with up to 240 loadbanks on a single network. A custom UDP interface gives sub-millisecond data exchange for real-time management, with live graphical updates every 250 ms.
VCS supports resistive, reactive, resistive-reactive, capacitive and liquid-cooled loadbanks. Air-cooled and liquid-cooled units can be clustered into a single test. For liquid-cooled loadbanks, VCS provides full Delta-T control with:
- flow monitoring
- coolant quality indication
- pressure sensing
- redundant inlet/outlet temperature
- full thermal efficiency reporting via the Crestchic Portal
Loads can be controlled in kW, kVA, kVAR, Amps, Percentage or Delta T. Leading and lagging power factor are adjustable, and star, delta and single-phase topologies are supported. Load is spread across units using proportional, follow or overflow distribution. Automatic ramp and block sequences, preset load blocks, gradual ramping and shed/dump functions let operators run complex tests at the touch of a button.
Built-in diagnostics include:
- automatic fault detection
- configurable fault tolerance
- system statistics and a service internal advisor
- a manual relay test screen
- automatic firmware upgrades
- an automatic network configuration wizard
Test results can be exported as CSV or accessed via Modbus/TCP, and configurations can be imported and exported. Automated compliance reports are available via the Crestchic Portal against:
- NEMA MG1
- EN 50160
- ISO 22514
- ISO 8528-5
- IEEE 141
- ASHRAE G22
- e-NTU method
A compact load-distribution controller that handles resistive, reactive, resistive-reactive, capacitive and liquid-cooled loadbank testing without the complexity of a full desktop system. It networks up to 50 loadbanks with daisy chaining at up to 100 m between units.
Loads can be controlled in kW, kVA, kVAR, Amps, Percentage or Delta T, with adjustable leading and lagging power factor and star, delta and single-phase topologies. Load is spread across units using proportional, follow or overflow distribution. Gradual load ramping, dump load, staggered start-up and overload protection are built in.
For liquid-cooled loadbanks, the LC10 provides:
- Delta-T setpoint control
- flow monitoring
- coolant quality indication
- pressure sensing
- redundant inlet/outlet temperature
The 4.3-inch capacitive touchscreen shows all test parameters, with live data updated every 500 ms from INS550/ACI500 instrumentation (0.1% accuracy). Automatic fault detection flags issues immediately. The enclosure is sealed against moisture and dust, protected against shock, vibration and EMI, and rated for operation from −35 °C to +85 °C.
For advanced sequencing, compliance reporting, unlimited load presets or networks of up to 240 loadbanks, the LC80 running VCS 2.0.0 is the ideal upgrade.
Available on the LC80/A controllers or via dedicated PC software, NOVA AC is a bespoke industrial high-performance electronic control module housed within the load bank enclosure. Paired with Orion software, the system provides manual control of AC loadbanks with a detailed instrumentation display, pre-set load programmes, automatic load sequencing, transient data capture, motor start facility and real-time data capture. Allows control of up to 15 load banks from a single controller with proportional load-sharing and long-distance fibre optic communication. Delivers clean load switching, high-resolution control (1kW/1kVAr), and accurate 3-phase measurements with better than 1% precision.
Available on the LC80/A controllers or via dedicated PC software, NOVA DC is carefully designed to provide top-tier performance, easy scalability, and a user-friendly experience for our full range of DC loadbanks. A control module based inside the loadbank is paired with Crestchic’s powerful NOVA DC software to offer easy manual controls, clear instrument readings, pre-set programs for efficient automated tests, a motor start function, and live data recording. The system supports everything from testing single units to the synchronised control of numerous loadbanks, and is ideal for large-scale operations such as data centre commissioning and large industrial tests.
Modbus over industrial ethernet using TCP-IP protocol interface is available on all new microprocessor based loadbanks for easy integration into the client’s own system.
Load Tracking Controls:
Load Trakker II: For oversized or lightly loaded generators running below minimum load level, our Trakker II System can add load in 1kW steps. This can help to avoid a reduction in engine performance and efficiency due to incomplete combustion.
Regen: To cater for the regenerative load experienced by crane, lift and cable car operators. The damaging effects of regenerative load can easily be avoided with the highly responsive regen loadbank.
Feature Comparison:
| Loadbank Control Hardware | Loadbank Control Software | LC80 | LC80A | PC/Laptop | LC10 |
|---|---|---|---|---|---|
| NOVA AC | Orion | ✔ | ✔ | ✔ | |
| NOVA DC | NOVA DC | ✔ | ✔ | ✔ | |
| VCS | VCS | ✔ | ✔ | ✔ | ✔ |
| Feature | Nova AC (Orion) | Nova DC (Enabling) | VCS |
|---|---|---|---|
| Fault Detection | ✔ | ✔ | ✔ |
| Loadbank Daisy Chain | ✔ | ✔ | ✔ |
| Fault Tolerance | ✔ | ✔ | ✔ |
| Instrumentation Integration | ✔ | ✔ | ✔ |
| Modular Hardware Support | ✔ | ✔ | ✔ |
| Instrumentation Frequency | 1000ms | 500ms | 500ms |
| Data Capture | ✔ | ✔ | ✔ |
| Customized Reports | CSV/TXT | CSV | CSV |
| Instrumentation Accuracy | 0.5 | 0.5 | 0.5 |
| 20% Full Load Safety | ✔ | ✔ | ✔ |
| Gradual Load Ramping | ✔ | ✔ | ✔ |
| Manual Load Test | ✔ | ✔ | ✔ |
| Auto Load Adjustment | ✔ | ✔ | ✔ |
| Learned Loads | ✔ | ✔ | ✔ |
| Automatic Load Test (Test Profiles) | ✔ | ✔ | ✔ |
| Transience Reporting | ✔ | ✔ | |
| Motor Load Simulator | ✔ | ||
| Overload Protection | ✔ | ✔ | ✔ |
| Real Time Graphical Updates | 1000ms | 1000ms | 500ms |
| Documentation / Guides | ✔ | ✔ | ✔ |
| Resistive Loads | ✔ | ✔ | ✔ |
| Inductive Loads | ✔ | ✔ | |
| Capacitive Loads | ✔ | ||
| Hybrid Loads | ✔ | ✔ | |
| Percentage load Support | ✔ | ✔ | ✔ |
| Amps Load Support | ✔ | ✔ | ✔ |
| kW Load Support | ✔ | ✔ | ✔ |
| kVA Load Support | ✔ | ✔ | |
| KVAr Load Support | ✔ | ✔ | |
| Star Topology (3P) | ✔ | ✔ | ✔ |
| Delta Topology (3P) | ✔ | ✔ | ✔ |
| Single Phase Topology (1P) | ✔ | ✔ | |
| Adjustable Leading Power Factors | ✔ | ✔ | |
| Adjustable Lagging Power Factors | ✔ | ✔ | |
| Multi-Loadbank Network | 16 | 3 | 200+ |
| Load Distribution | F-O-P | F-O-P | F-O-P |
| Loadank Clusters | ✔ | ||
| AC | ✔ | ✔ | |
| DC | ✔ | ||
| Battery | ✔ | ||
| Modbus Integration | ✔ | ✔ | ✔ |
| Software Configuration Protection | ✔ | ✔ | ✔ |
| Import / Export Configurations | ✔ | ✔ | ✔ |
| Service Mode IO Test | ✔ | ✔ | ✔ |
| Firmware Flashing | ✔ | ✔ | ✔ |
| System Statistics | ✔ | ✔ | |
| Auto Discover Loadbanks | ✔ | ||
| Load Re-Application | ✔ | ✔ | |
| Tolerance Indicator | ✔ | ✔ | |
| Block Load Sequencing | ✔ | ✔ | |
| Ramp Load Sequencing | ✔ | ||
| Adopt Failed Loadbanks Mid-Test | ✔ | ||
| Load Preset (Sequence) Limit | 20 | Infinite |
Download our latest literature:
Frequent Questions
What Load Bank Packages Do You Have?
We provide load bank packages ranging from 20kW to 7000kW and Multi-MVA solutions for turnkey projects, Have a look at our product range page on this site for more details
What Experience Do You Have?
Crestchic was formed in 1983 and has steadily grown to our position today as the industry leading manufacturer and supplier of loadbank solutions. We work for major players in all sectors ranging from Oil and Gas, Marine and Shipbuilding to Healthcare, Building Managers and Datacentres. We understand the complexities faced by businesses and have solutions tailored to suit the needs.
Where Do You Operate?
Our operations are spread across the globe, covering all seven continents. With our HQ in Burton-on-Trent in the UK, we have bases in Europe, the Middle East, Asia Pacific and the United States of America.
Do You Have Any Certification?
Crestchic Limited, the world leader in load bank technology for the testing and commissioning of power generation systems, now hold not only the highest Quality Assurance ISO type (9001-2015), but additionally has now been accredited with the current environmental standard (ISO14001) and current health &safety accreditation (ISO45001).
New appointment continues Crestchic’s year of growth
Crestchic Loadbanks is pleased to announce the appointment of Alex McFie-Hyland as Business Development Manager for the UK Midlands and North Rental Division, the latest step in a period of significant growth for the business. This year has seen Crestchic continue to...
WHY USE A LOAD BANK?
Load banks are primarily used for testing electrical power output on diesel generators, gas turbines and UPS systems whilst carrying out commissioning and maintenance work.
The load banks are used for simulating real electrical loads enabling essential setup and commissioning which ensures that all electrical and control parameters are met prior to power generation/back up equipment being energized on line.
