Dual-Source Load Bank

Rack-Mount Dual Source Load Bank for Data Centre
Purpose-built for dual power system commissioning with true A+B channel isolation and partial load transfer capability.
What Is a Dual-Source Load Bank?
A dual-source load bank is a resistive AC load testing device equipped with two independent power input channels — Source A and Source B — that are mechanically and electrically interlocked to prevent simultaneous closure. It is designed to simulate real-world IT or industrial loads while validating the seamless transfer between primary and backup power paths, making it essential for commissioning dual-fed critical power infrastructure.Important: Dual-Source is a power architecture, not a cooling method. A load bank can be: • Dual-Source + Air-Cooled (e.g., MS-R-7kW-D) • Dual-Source + Liquid-Cooled (e.g., MS-RL-42kW-D) • Single-Source + Air-Cooled or Single-Source + Liquid-Cooled"Dual-Source" defines how power enters; "Air-Cooled / Liquid-Cooled" defines how heat exits.

Dual-source load banks operate through four sequential stages: independent power connection, precision load configuration, automated source transfer, and real-time data logging. Every step is monitored and validated for commissioning documentation.
Batterlution dual-source load banks are engineered to order across four configurations: rack-mounted air-cooled, rack-mounted liquid-cooled, standalone liquid-cooled, and containerized. Standard configurations cover 7 kW to 500 kW, with extended ratings available on request.
Every unit is built to your exact power, form factor, and integration requirements — no compromise on fit or function.

Power Rating
Standard: 7 kW, 10.5 kW, 42 kW, 500 kW Extended: Custom ratings from 1 kW to 20+ MW Voltage: 400/230 VAC 50/60 Hz (standard); 480V, 690V, 10.5 kV (custom)

Form Factor
Rack-Mounted: 19" standard, 6U / 10U / 23U heights Standalone: Floor-standing or skid-mounted Containerized: 20 ft / 40 ft enclosure for outdoor deployment Custom: Project-specific dimensions and connector types

Communication Protocol
Standard: Modbus RTU RS-485 Optional: PROFINET, CANopen Custom: OEM proprietary protocols, custom register maps, SCADA/BMS middleware integration Remote: PLC-based control with front-panel HMI and data logging

Power Architecture
Dual-Source: A+B channels with mechanical + electrical interlock Single-Source: Operable on one channel if dual-feed not yet deployed IGBT Option: ±1% precision load control for step-load and ramp testing Protection: Over-temp, over-current, phase-loss, fuse-protected fans
13+ years of load bank manufacturing with in-house R&D, ISO-certified quality systems, and full commissioning lifecycle support. Every unit is factory-tested before dispatch.

In-House R&D & Engineering
25+ engineers specializing in thermal management, power electronics, and control system integration. Every dual-source load bank is engineered to order starting from your single-line diagram.

ISO-Certified Quality Systems
ISO 9001 (Quality Management), ISO 14001 (Environmental Management), ISO 17025 (Calibration Laboratory). Every unit delivered with Factory Test Certificate (FAT / Red Tag) and Calibration Certificate.

Full T&C Levels 1–5 Documentation
Red Tag (FAT) → Yellow Tag (Installation) → Green Tag (Start-up) → Blue Tag (Functional) → White Tag (IST). Complete traceability from factory to final commissioning.

Global Delivery & 24-Month Warranty
FOB Shenzhen, CIF, DDP options. Plywood crate with vacuum packing. 24-month standard warranty on all components; extended warranty available for load elements and control systems.
Dual Source Load Bank | Intelligent Control Software
PLC-based control system with independent channel management, real-time data logging, and seamless SCADA integration. All data exportable for FAT and commissioning documentation.

Separate load control for each channel via PLC.
Front-panel mode selector (Auto/Manual), load step buttons per channel, Source A/B indicators (green), fault/over-temp indicator (red). PLC remote via Modbus RTU RS-485. Optional: PROFINET, CANopen.Protection logic: over-temperature (hardware + software), over-current MCB per step, phase-loss detection, fuse-protected fans, mechanical + electrical interlock.Auto data logging & one-click professional report export
Auto timestamped records: voltage per phase, current per load step, power (kW), power factor, temperature, fan/coolant status, event log. One-click PDF/Excel export for FAT report generation. Full data traceability for commissioning records.Applications of Rack-Mount Liquid Cooled Load Bank
Dual-source load banks are deployed across critical power infrastructure worldwide — from Tier III data centers to marine vessels, hospitals, and microgrids.
CDU Acceptance Testing
Validate CDU thermal performance under controlled load conditions. Simulate real server heat load to verify cooling capacity, flow rate and temperature differential before deploying actual IT equipment.
Data Center Commissioning (Tier III)
MS-R-10.5kW-D with dual A+B channels for IST/TCCF Levels 1-5. Validates N+1 and 2N redundancy, ATS transfer < 100 ms, and UPS ride-through under step-load changes.
Tier III Blackout Testing (IST)
Integrated System Testing with controlled blackout simulation: utility failure → generator auto-start → ATS transfer → UPS battery operation → return-to-utility. Full White Tag documentation.
Generator & ATS Acceptance (NFPA 110)
NFPA 110 and ISO 8528-5 compliance testing: 4-hour continuous rated-load runs, ATS transfer time measurement, and emergency power system validation with full FAT documentation.
Dual UPS Redundancy Testing
N+1 and 2N UPS architecture validation: load both channels at 50% each, transfer 50% from A to B, validate system can operate at 150% of single-unit capacity during maintenance or failure.
Microgrid & Critical Infrastructure
Dual-source load banks for microgrid power stability testing, hospital EPSS validation, and substation commissioning. Validates seamless transfer between utility and renewable/backup sources.
From initial inquiry to final commissioning documentation, every dual-source load bank project follows a structured lifecycle with full traceability and FAT/IST certification.
- Level 1: Inquiry & Engineering Review Share your single-line diagram, load requirements, and commissioning timeline. Our engineering team reviews power architecture, voltage, cooling constraints, and protocol needs. Custom proposal delivered within 48 hours.
- Level 2: Design & Production Engineered-to-order: resistor bank design, contactor selection (Schneider/ABB), control logic programming, and enclosure fabrication. Production lead time: 6–8 weeks standard; 8–12 weeks custom.
- Level 3: Factory Acceptance Test (FAT / Red Tag) Every unit tested at rated load: per-channel validation, interlock verification, step-load accuracy, contactor cycle testing, insulation resistance, and dielectric test. Factory Test Certificate (Red Tag) issued. Optional: customer witness at Batterlution facility.
- Level 4: Installation & Functional Testing On-site installation verification (Yellow Tag), start-up & initial load test (Green Tag), and full functional testing (Blue Tag): load profile validation, source transfer test, protection function check, and data logging verification.
- Level 5: Integrated System Testing (IST / White Tag) Blackout simulation, full system integration with BMS/SCADA, redundancy fail-over under realistic load conditions, and final acceptance documentation. Senior commissioning engineer on-site; 24/7 phone support during test window.
Common Question
What is a dual-source load bank?
A dual-source load bank is a resistive AC load testing device with two independent power input channels (Source A and Source B) that are mechanically and electrically interlocked to prevent simultaneous closure. It is used to validate redundant power architectures, test ATS/STS transfer times, and simulate real-world IT loads during data center commissioning.
What is the difference between dual-source and single-source load banks?
A single-source load bank has one power input and tests one circuit at a time. A dual-source load bank has two independent inputs with interlocked switching, enabling A-to-B failover testing, dual UPS redundancy validation, and ATS/STS transfer time measurement. A dual-source unit can also operate as single-source if only one channel is connected, making it versatile for sites that may upgrade to dual-feed architecture later.
How many load banks are needed for Tier III data center commissioning?
A single MS-R-10.5kW-D unit with dual A+B channels is sufficient for basic dual-source failover testing. For larger facilities requiring higher total load capacity, multiple units can be paralleled, or a single MS-RL-42kW-D can provide higher density in a single rack. The exact number depends on total load capacity, redundancy architecture (N+1 or 2N), and commissioning timeline.
What is the difference between T&C Level 1 (FAT) and Level 5 (IST)?
FAT (Factory Acceptance Test / Level 1 Red Tag) is conducted at the Batterlution factory before dispatch, verifying electrical and functional specifications at rated load. IST (Integrated System Testing / Level 5 White Tag) is conducted at the customer’s site, validating that the load bank integrates with the entire critical power infrastructure under simulated blackout and failover conditions.
Can a dual-source load bank be used for NFPA 110 generator testing?
Yes. The dual-source configuration directly supports NFPA 110 emergency power system acceptance testing by providing both normal power load (Source A) and emergency power load (Source B) with interlocked switching. All units are factory-tested to ISO 8528-5 standards with full FAT documentation.
What is partial load transfer testing, and why is it important?
Partial load transfer testing validates that a redundant power system can handle a load shift from one source to another without exceeding the remaining source’s capacity. For example, in a 2N UPS system, each UPS is rated for 100% of the load. A dual-source load bank can transfer 50% from UPS A to UPS B, validating that the system can operate at 150% of single-unit capacity during maintenance or failure.
What is the difference between air-cooled and liquid-cooled dual-source load banks?
Air-cooled dual-source load banks (MS-R series) use axial fans to dissipate heat and are suitable for standard data halls with adequate HVAC. They are lighter, simpler to install, and cost-effective for capacities up to 10.5 kW. Liquid-cooled dual-source load banks (MS-RL and MS-L series) use a closed-loop liquid cooling system connected to the facility’s CDU or external chiller. They are silent, enable higher power density (42 kW in a single rack, 500 kW in a standalone unit), and are essential for noise-sensitive or high-ambient-temperature environments.
Can I customize the power rating, voltage, or communication protocol?
Yes. Every Batterlution dual-source load bank is built to order. Standard configurations cover 400/230 VAC 50/60 Hz, but custom voltages include 480V, 690V, and 10.5 kV. Standard communication is Modbus RTU RS-485, with optional PROFINET, CANopen, or custom OEM protocols. Power ratings, form factors, connector types, and color (RAL) are all customizable.
How long is the delivery time for a custom dual-source load bank?
Standard rack-mounted air-cooled units (MS-R-7kW-D, MS-R-10.5kW-D) are typically delivered in 6–8 weeks. Custom configurations require 8–12 weeks. Large liquid-cooled or containerized units (MS-L-500kW-D) may require 10–14 weeks. All lead times include factory testing and FAT documentation preparation.
What documentation comes with the load bank?
Every unit includes: Factory Test Certificate (FAT / Level 1 Red Tag), Calibration Certificate (ISO 17025 accredited), Operation Manual, Data Sheet, and Commissioning Procedure Manual. Optional T&C Levels 2–5 commissioning support packages include Installation Verification Report (Yellow Tag), Start-up Certificate (Green Tag), Functional Test Report (Blue Tag), and Integrated System Test Report (White Tag / TCCF).







