Load Resistors
Reliable testing, load application, and base load assurance
What is a load resistor?
A load resistor from FRIZLEN is the ideal solution for testing power generators under realistic conditions, applying regular loads, or operating with a base load. Our load resistors cover a wide power range from 5 kW to 500 kW and are suitable for both stationary test setups and mobile applications – such as monthly performance checks or maintenance of backup power systems and emergency generators.
Powerful load resistors for mobile and stationary power generators
Specifically engineered to meet the demands of modern Stage V and newer emission-compliant power generators, our power-matched base load resistors ensure consistently stable operation under load. This effectively prevents critical operating conditions caused by underloading or idle operation.
Our load resistors are available in protection ratings ranging from IP 00 to IP 23, making them suitable for outdoor use under demanding environmental conditions. Whether in construction site power supply, with energy providers, in the military sector, or at events – FRIZLEN provides robust, durable, and precisely tailored solutions.
Typical applications of our load resistors include:
- Regular load testing of power generators
- Simulated consumer loads for power supplies, generators, and UPS systems
- Maintenance and commissioning of mobile units
- Reliable base load provision at low utilization
- Load testing as part of scheduled maintenance and inspections
Thanks to our modular design, in-house enclosure manufacturing, and a wide range of connection and monitoring options – such as temperature switches and overcurrent relays – we configure each solution to meet your exact requirements.
FRIZLEN – Load resistors for maximum operational safety.
![[Translate to English:] Lastwiderstand im Abluftkanal](/fileadmin/_processed_/1/d/csm_Lastwiderstand_FKKFQ3223605_f0a858b560.jpg "[Translate to English:] Lastwiderstand im Abluftkanal")
![[Translate to English:] Notstromaggregat](/fileadmin/_processed_/c/a/csm_Branche_Notstromtechnik_Aggregat_2565964641_bbe883579c.jpg "[Translate to English:] Notstromaggregat")
Load Resistor for monthly test runs
Reliable functional test for power generators without grid-parallel operation
The monthly test run of power generators is a key measure to ensure the operational readiness of emergency power systems. But what if no grid-parallel operation is possible? In such cases, there is no natural consumer load – the generator runs idle or under minimal load. The consequences: insufficient operating temperatures, sooted exhaust systems, increased maintenance requirements, and in the worst case, failure during an actual emergency.
A load resistor from FRIZLEN provides a solution in this situation. It simulates a real electrical load and brings the generator to a defined power level during the test run – exactly as required in case of an emergency. This ensures that the engine, exhaust aftertreatment system, and electrical components are regularly operated under nominal conditions.
Regular thermal loading is essential to prevent soot buildup and technical failures. A load resistor also supports the distribution of lubricants, reaching optimal oil temperature, and full thermal conditioning of the system – all critical for safe startup in an emergency.
FRIZLEN load resistors are available in mobile or stationary versions, optionally with control cabinets, and with protection ratings up to IP 23 for outdoor use. They enable reliable, operationally safe test runs in compliance with norms – even where no external load is available.
Reliable testing, load application, and base load assurance
What happens during low-load operation?
When a power generator – such as a diesel genset – is operated below its optimal load threshold, several issues can arise: Incomplete combustion in the engine → leads to soot buildup
- Contamination of the exhaust system → e.g. diesel particulate filter, turbocharger, exhaust pipe
- Poorer emission values → especially critical for modern Stage V generators
- Reduced service life of the engine and exhaust aftertreatment system
- Increased maintenance and repair costs
How does a load resistor help?
A load resistor is used here as an artificial load to bring the generator up to its rated power or base load level. This prevents low-load operation and ensures:
- Optimal operating temperatures in the engine
- Clean combustion
- Efficient performance of the exhaust aftertreatment system
This is particularly important for emergency power systems, which are often run idle or under low load. Regularly applying a base load using a load resistor is both technically sound and economically wise.
![[Translate to English:] Power generator](/fileadmin/_processed_/d/6/csm_Stromaggregat_Techniker_CGT_e4aa30c5c8.png "[Translate to English:] Power generator")
Load resistors for civil protection and emergency response
A load resistor used in civil protection plays a vital role in the regular testing of emergency generators, mobile power sources, and UPS systems. Especially in critical infrastructures such as disaster response facilities, emergency services, or mobile command centers, it is essential to ensure that the power supply functions reliably under real load conditions. FRIZLEN offers robust, custom-configurable load resistors specifically designed to meet these demanding requirements. The FSKZVR series was developed especially for use in civil protection and has been thoroughly tested in real-world applications. It features a rugged design, with a frame engineered for transport by truck or forklift. Two units, each rated at 100 kW, can be connected via coupling cables to achieve a total load of 200 kW.
![[Translate to English:] Baureihe BWZVR](/fileadmin/_processed_/3/4/csm_Stromaggregat_THW_CGT_adcb5536ed.png "[Translate to English:] Baureihe BWZVR")
Load Resistors for power generators with PV feed-in during station disconnections
For grid operators and energy providers, the controlled disconnection of local substations is becoming increasingly important – especially in combination with photovoltaic systems that feed power back into the grid. In emergency situations, power generators are responsible for supplying critical loads. However, the integration of decentralized energy sources such as PV systems introduces new technical challenges, particularly with regard to overvoltage and grid stability. In these cases, a strategically deployed load resistor ensures reliable relief and operational safety.
FRIZLEN load resistors are used in this application to apply a defined load to power generators and to dissipate excess energy – for example, from PV systems when there is no local consumption. This is especially crucial during substation disconnections: once the grid connection is interrupted, uncontrolled feed-in from PV systems must be prevented. The load resistor enables a clean load shedding and protects both the generator and downstream components from malfunctions.
FRIZLEN offers custom-engineered load resistors optimized for temporary energy absorption in combination with power generators. They can be integrated into both stationary and mobile systems and meet all relevant requirements for safety, protection class, and load capacity.
![[Translate to English:] Baureihe F.VR.3](/fileadmin/_processed_/7/1/csm_T600_FSVM_a_0ad38d2ee0.png "[Translate to English:] Baureihe F.VR.3")
![[Translate to English:] Lastwiderstand](/fileadmin/_processed_/8/2/csm_Stromaggregat_PV_CGT_b7ab43cd44.png "[Translate to English:] Lastwiderstand")
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