Free generator load bank test record

What is a generator load bank test record?

A generator load bank test record is a structured form used to document the results of a resistive load bank test on a standby diesel or gas generator. It captures the test set-up (load bank capacity connection method and step increments) the test load profile (typically 25 percent 50 percent 75 percent and 100 percent of rated output) and the readings recorded at each step (voltage frequency current kilowatts coolant temperature oil pressure exhaust temperature and ambient temperature). The record also notes the duration at each load step (commonly 30 to 60 minutes at each increment with a sustained 2-hour run at 100 percent for life safety generators) and the technician sign-off against NFPA 110 and AS/NZS 3010 requirements.\n\nStandby generators that sit idle for most of their life accumulate unburnt fuel and carbon deposits in the exhaust system a condition known as wet stacking. A load bank test exercises the generator at or near its rated capacity which burns off these deposits restores rated output and proves the cooling system can sustain full thermal load. NFPA 110 Level 1 emergency standby power systems require an annual load bank test of at least 2 hours at no less than 30 percent of rated load (or higher per the standard's load profile). AS/NZS 3010 references the same testing principles for generating sets in Australia and AS 2941 imposes additional requirements where the generator backs up a fire pump set. Maintaining a clean load bank test record per generator provides documented evidence that the asset is fit to carry life-safety load during an emergency and supports the compliance certificate renewal cycle.

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Benefits of digitising forms in MapTrack

When you digitise generator records in MapTrack, you get:

• Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
• Automatically get alerts when faults are identified.
• Link every form digitally as a PDF to the relevant asset, location or person.
• Receive a digital PDF copy with every submission to your email.
• Ability to share forms digitally.
• Build conditional logic (show or hide questions based on answers).
• Take pictures or attach photos. Not possible with a paper-based form.
• Electronic signatures.
• Edit forms later without reprinting.
• Restrict permissions (who can view, complete or approve).
• Build forms with AI (describe what you need and MapTrack suggests the form).
• Trigger work orders automatically when a fault is logged during an inspection.
• Track service intervals by hours, kilometres or calendar date in one place.
• Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a generator load bank test record

This generator load bank test record covers 9 key areas:

• Generator details: ID make model serial number rated output (kW and kVA) voltage configuration year of manufacture and engine model
• Test set-up: load bank model capacity (kW) connection point (load bank breaker or generator terminals) cable size and routing and ambient conditions
• Pre-test checks: engine oil coolant fuel level fuel filter water separator battery voltage and block heater operation recorded before start
• Test load profile: load steps applied (typically 25 50 75 100 percent) duration at each step and sustained 100 percent run time (minimum 2 hours for NFPA 110 Level 1)
• Engine readings: oil pressure coolant temperature exhaust temperature fuel pressure crankcase pressure and engine vibration at each load step
• Alternator readings: voltage (each phase) frequency current (each phase) kilowatts power factor and voltage regulator response at each load step
• Ambient conditions: generator room temperature humidity and ventilation airflow recorded at start mid-test and end
• Exceptions and shutdowns: any safety shutdowns warnings or abnormal readings during the test with corrective actions taken
• Sign-off: technician name licence (where applicable) building owner or facility manager witness signature date and next load test due

How often should you complete this record?

NFPA 110 Standard for Emergency and Standby Power Systems requires an annual load test of Level 1 emergency standby power systems with a sustained period at rated capacity. In Australia AS/NZS 3010 and AS 2790 reference equivalent testing principles for generating sets and AS 2941 imposes load testing requirements for fire pump generator backup sets. Most facility managers schedule a full load bank test every 12 months as part of the annual major service.\n\nMonthly operational tests under NFPA 110 and AS 2941 are not a substitute for the annual load bank test because they typically run at building load (often only 10 to 30 percent of rated capacity) which is insufficient to prevent wet stacking. Generators with high run hours in actual emergencies may justify additional load bank testing on a quarterly basis. In MapTrack the load test record can be attached to the generator asset with automated reminders set against calendar intervals and run hours.

Applicable regulatory standards

This template aligns with the following regulations and standards:

• NFPA 110
• AS/NZS 3010
• AS 2790
• AS 2941
• WHS Regulations 2011 Chapter 5

Related resources

More maintenance templates and guides:

• generator inspection checklist
• generator maintenance checklist
• generator pre start checklist
• standby generator annual service
• standby generator monthly test
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• Maintenance management
• /features/compliance
• Compliance tracking
• /features/asset-tracking
• Asset tracking