Programmable Load Bank Manufacturers & Exporters

Name: Programmable Load Bank
Brand: Powertron

POWERTRON manufactures programmable load bank and electronic load systems in India from 1.2kW to 40kW, covering 0-150V, 0-600V, 0-800V and 0-1200V input ranges with currents to 1200A. Where a resistive bank offers fixed switched steps, a programmable electronic load holds any loading condition the test requires under digital control — constant voltage, constant current, constant resistance or constant power — and switches between them in firmware rather than hardware. Dynamic mode operates to 10kHz, which is fast enough to reproduce the load transients a switch-mode power supply or converter will actually see in service rather than only the steady states. Measurement resolution reaches 0.1mV and 0.1mA, with remote sense correcting for cable drop at the terminals. Dedicated battery test, OPP, OCP, automatic test and CR-LED functions cover the routine qualification sequences directly. Manufactured in-house at Wagle Estate, Thane, Maharashtra.

Programmable Load Bank

Request A Quote

Key Features of the POWERTRON Programmable Electronic Load :

Four operating modes — CV, CC, CR and CP, switched in firmware rather than hardware, so one instrument covers power supply validation, battery discharge, converter characterisation and LED driver testing without reconfiguration.
Dynamic mode to 10kHz — fast enough to reproduce the real load transients a switch-mode supply sees in service, which is where most designs actually fail rather than under steady-state load.
Measurement resolution to 0.1mV and 0.1mA — fine enough to resolve regulation and ripple behaviour that a coarser instrument would average away entirely.
Remote sense — the load condition is measured and held at the device terminals rather than at the load bank input, removing cable drop from the result.
Dedicated battery test function — discharge capacity testing runs as a defined routine rather than being assembled manually from primitive load steps.
OPP and OCP test functions — over-power and over-current protection thresholds of the device under test are verified automatically, which is a required step in most power supply qualification programmes.
CR-LED function — models the non-linear turn-on characteristic of an LED string, so LED driver testing reflects the real load rather than a plain resistance.
Short circuit function — the DUT response to a genuine short is tested under controlled conditions instead of improvised on the bench.
Power-off memory and 100 group storage — set-ups survive a power cycle and a hundred configurations are recalled directly, which is what makes the instrument practical on a production line.
Optional USB, RS232 and RS485 interfaces — the load integrates into an existing automated test environment.

Telecom & Data Centers

Automotive & EV Industries

Aerospace & Defence

Power Plants & Utility

Automation & Drive Testing

Battery Discharge & Setting Testing

Railway & Metro Syatem

UPS Inverter Testing

Technical Specifications — Programmable Electronic Load

Parameter	Specification	What It Means For You
Power Range	1.2 kW to 40 kW	Bench component testing through to system-level loading
Voltage Ranges	0–150V, 0–600V, 0–800V, 0–1200V	Low-voltage electronics through to 800V EV and 1000V+ DC bus
Current Range	Up to 1200 A depending on model	High-current low-voltage loading as well as high-voltage work
Operating Modes	CV, CC, CR, CP	One instrument covers PSU, battery, converter and LED testing
Dynamic Mode	Up to 10 kHz	Real load transients reproduced, not just static steps
Measurement Resolution	0.1 mV / 0.1 mA	Regulation and ripple behaviour resolved rather than averaged
Remote Sense	Standard	Load condition held at the DUT terminals, not the load input
Test Functions	Battery test, automatic test, OPP, OCP, CR-LED	Standard qualification routines run directly
Short Circuit Function	Standard	Controlled short-circuit response testing
Current Monitoring	Standard	Live current readback for logging and verification
Memory	Power-off memory, 100 group storage	Set-ups survive power cycling; fast recall on a production line
Interfaces	Optional USB / RS232 / RS485	Integration with existing test automation
Model Naming	PIPL-[power]-[voltage]-[current]-PEL	Rating readable directly from the part number

Available Variants

Model	Voltage	Current	Power	Model	Voltage	Current	Power
PIPL-1K2-150-120-PEL	0-150V	120A	1200W	PIPL-1K2-800-120-PEL	0-800V	48A	1200W
PIPL-1K8-150-180-PEL	0-150V	180A	1800W	PIPL-1K8-800-72-PEL	0-800V	72A	1800W
PIPL-2K4-150-2K4-PEL	0-150V	2400A	2400W	PIPL-2K4-800-96-PEL	0-800V	96A	2400W
PIPL-3K-150-300-PEL	0-150V	300A	3000W	PIPL-3K-800-120-PEL	0-800V	120A	3000W
PIPL-6K-150-600-PEL	0-150V	600A	6000W	PIPL-6K-800-240-PEL	0-800V	240A	6000W
PIPL-9K-150-900-PEL	0-150V	900A	9000W	PIPL-9K-800-360-PEL	0-800V	360A	9000W
PIPL-12K-150-1K2-PEL	0-150V	1200A	12KW	PIPL-12K-800-480-PEL	0-800V	480A	12KW
PIPL-15K-150-1K5-PEL	0-150V	1500A	15KW	PIPL-15K-800-800-PEL	0-800V	600A	15KW
PIPL-18K-150-1K2-PEL	0-150V	1200A	18KW	PIPL-18K-800-720-PEL	0-800V	720A	18KW
PIPL-24K-150-1K2-PEL	0-150V	1200A	24KW	PIPL-24K-800-960-PEL	0-800V	960A	24KW
PIPL-30K-150-1K2-PEL	0-150V	1200A	30KW	PIPL-30K-800-1K2-PEL	0-800V	1200A	30KW
PIPL-40K-150-1K2-PEL	0-150V	1200A	40KW	PIPL-40K-800-1K2-PEL	0-800V	1200A	40KW

PIPL-3K-1K2-120-PEL	0-1K2V	120A	3000W	PIPL-1K2-600-120-PEL	0-600V	48A	1200W
PIPL-6K-1K2-240-PEL	0-1K2V	240A	6000W	PIPL-1K8-600-72-PEL	0-600V	72A	1800W
PIPL-9K-1K2-360-PEL	0-1K2V	360A	9000W	PIPL-2K4-600-96-PEL	0-600V	96A	2400W
PIPL-12K-1K2-480-PEL	0-1K2V	480A	12KW	PIPL-3K-600-120-PEL	0-600V	120A	3000W
PIPL-15K-1K2-1K2-PEL	0-1K2V	600A	15KW	PIPL-6K-600-240-PEL	0-600V	240A	6000W
PIPL-18K-1K2-720-PEL	0-1K2V	720A	18KW	PIPL-9K-600-360-PEL	0-600V	360A	9000W
PIPL-24K-1K2-960-PEL	0-1K2V	960A	24KW	PIPL-12K-600-480-PEL	0-600V	480A	12KW
PIPL-30K-1K2-1K2-PEL	0-1K2V	1200A	30KW	PIPL-15K-600-600-PEL	0-600V	600A	15KW
PIPL-40K-1K2-1K2-PEL	0-1K2V	1200A	40KW	PIPL-18K-600-720-PEL	0-600V	720A	18KW
				PIPL-24K-600-960-PEL	0-600V	960A	24KW
				PIPL-30K-600-1K2-PEL	0-600V	1200A	30KW
				PIPL-40K-600-1K2-PEL	0-600V	1200A	40KW

Which Voltage Range Do You Need?

Voltage Range	Power Available	Typical Application
0–150 V	1.2 kW to 40 kW	Low-voltage high-current work — PSU validation, 12V/24V/48V systems, LED drivers, telecom rectifiers
0–600 V	1.2 kW to 40 kW	Industrial DC buses, solar string testing, 400V-class battery modules
0–800 V	1.2 kW to 40 kW	EV 800V architectures, traction converters, high-voltage DC-DC testing
0–1200 V	3 kW to 40 kW	Solar string and inverter input testing, high-voltage DC bus characterisation
Selection rule	—	Choose the lowest voltage range that covers your test — measurement resolution and accuracy are best when the DUT sits in the upper part of the range rather than the bottom few percent.

How a Programmable Electronic Load Works

A programmable electronic load does not use resistors to create a load. It uses power semiconductors — typically MOSFETs — operated in their linear region as controlled current sinks. A digital controller sets how much the devices conduct, and therefore how much current flows from the device under test. The energy still becomes heat, but the amount of current drawn is now a software variable rather than a fixed property of a physical resistance.

That is what makes the four modes possible from one instrument. In constant current mode the controller holds current regardless of what the DUT voltage does. In constant voltage mode it adjusts current to hold the terminal voltage. In constant resistance mode it continuously sets current proportional to measured voltage, so the load behaves as a fixed ohm value. In constant power mode it trades voltage and current to hold the product constant — the behaviour that matters when discharging a battery whose voltage falls through the test.

Dynamic mode is where an electronic load earns its cost over a resistive bank. Because the current set point is a software value, it can be stepped between two levels at up to 10kHz. Real switch-mode power supplies are rarely defeated by a steady load; they are defeated by a load that steps hard and repeatedly. Reproducing that transient on the bench is the only way to find the failure before a customer does. Remote sense closes the loop at the DUT terminals rather than at the load input, so cable drop does not appear in the measurement.

Applications by Industry

Industry	Application	Load / Duty Character	Recommended Configuration
Power Generation & Distribution	Component and busbar plating	Continuous, heavy duty	0–24 to 0–60VDC, high current, multi-module
Oil & Gas Refinery	Corrosion-protection plating on components	Continuous, harsh environment	0–24 to 0–100VDC
Railways & Metro	Component plating for rolling stock parts	Continuous production	0–24 to 0–60VDC
Industrial Automation	In-line plating within automated cells	Continuous, high uptime	Independent V/I control
Defence	Precision plating for defence-grade components	Continuous, high-reliability	Tight tolerance, custom current
Marine	Corrosion-resistant coatings for marine hardware	Continuous / harsh environment	0–24 to 0–60VDC

Applications of Programmable Electronic Loads

The programmable load is the R&D and production-test instrument of the three load bank types — chosen where the requirement is to characterise behaviour precisely rather than to prove bulk output.

Industry	Application	Mode Used	Typical Range
Telecom & Data Centre	Rectifier module and DC plant characterisation	CC / CP	0–150V, 3–15 kW
Automotive & EV	On-board charger, DC-DC and pack module testing	CP / CC	0–800V, 6–40 kW
Aerospace & Defence	Power supply and converter qualification	All four + dynamic	0–600V, 1.2–12 kW
Power Plants & Utility	Substation DC system and charger verification	CR / CC	0–600V, 6–30 kW
Automation & Drive Testing	Drive DC link and control supply loading	CP	0–800V, 6–24 kW
Battery Discharge Testing	Capacity and cycle-life characterisation	CP / battery test	0–150V, 0–600V
Railway & Metro	Auxiliary converter and control supply testing	CC / CP	0–1200V, 12–40 kW
UPS & Inverter Testing	DC input side loading and transient response	Dynamic mode	0–600V, 6–40 kW

Programmable Electronic Load vs Resistive vs Regenerative Load Bank

Publish the same three-way comparison used on the other two load bank pages, oriented to this product.

Criteria	Programmable Electronic Load	Resistive Load Bank	Regenerative Load Bank
Load control	Digital, four modes, any value	Fixed switched resistance steps	Digital, four modes
Dynamic capability	Up to 10 kHz transient stepping	None	Fast but not to 10 kHz
Measurement	Integrated, 0.1 mV / 0.1 mA resolution	External instruments needed	Integrated
Power range	1.2 kW to 40 kW	Built to requirement, very high	60 kW to 250 kW
Energy handling	Dissipated as heat	Dissipated as heat	Returned to the grid
Automation	USB / RS232 / RS485, 100 stored set-ups	Manual or contactor stepping	Touchscreen and interfaces
Test functions	Battery, OPP, OCP, CR-LED, short circuit	None	Programmable profiles
Best fit	R&D characterisation and production test	Site commissioning and acceptance	Long-duration high-power testing

How to Select a Programmable Electronic Load

Maximum DUT voltage — then choose the lowest voltage range that covers it, because accuracy and resolution are best when the test sits in the upper part of the range.
Maximum current at the lowest test voltage — power divided by the minimum voltage gives the current the load must sink, and this often drives the selection more than the power figure does.
Minimum operating voltage of the DUT — an electronic load needs some terminal voltage to sink current, which matters when discharging a battery towards its cut-off.
Which modes the test procedure requires — battery work is CP or the dedicated battery function, PSU validation is CC with dynamic stepping, LED driver testing needs CR-LED.
Dynamic requirement — whether transient response must be tested, and at what frequency and slew rate.
Interface — USB, RS232 or RS485, specified at order so the unit ships configured.
Number of stored set-ups needed — 100 groups is standard, which is usually ample, but confirm against a large production test matrix.
Heat rejection and mounting — the full test power appears as heat in the test cell, and that constrains where a 40kW unit can be installed.

Custom Programmable Electronic Load Builds

The standard matrix already covers four voltage ranges across power ratings from 1.2kW to 40kW, which is more than a hundred combinations. Beyond that, POWERTRON supplies parallel configurations where a single test requires more than 40kW, non-standard voltage and current pairings, extended interface register maps for integration with an existing test-management system, and preloaded test sequences configured at the factory for a customer’s specific qualification programme.

Rack integration, custom front-panel arrangements and application-specific protection thresholds are all available. Where the load forms part of a larger POWERTRON test rig alongside a programmable DC or AC source, the two can be supplied with a matched command set so the whole bench is driven from one sequence. Share the DUT voltage, current, modes and dynamic requirement for a proposal.

Manufacturing, Quality and Export Capability

POWERTRON INDIA PVT. LTD. designs and manufactures its complete power conversion range at Plot No. A-426/427, Road No. 28, Wagle Estate MIDC, Thane West 400604, Maharashtra. Design, magnetics, PCB assembly, enclosure fabrication and full-load testing are all carried out in-house, which is what allows both short lead times and real engineering support after the sale rather than component-level replacement only.

Every unit is tested on load across its full operating envelope before dispatch, with the test record supplied against the serial number. The company holds ISO, CE and BIS certifications, is MSME registered and GeM listed, and manufactures under the Make in India framework — making POWERTRON a practical import substitute for organisations currently sourcing from overseas. Domestic sales and service offices operate in Delhi, Pune, Hyderabad, Bangalore and Tamil Nadu, with international offices in Dubai, Singapore and Malaysia supporting export customers across the Middle East, Southeast Asia, Africa and Europe.

Frequently Asked Questions — Programmable Load Bank

What is the difference between a programmable load bank and an electronic load? +

They are the same product. "Electronic load" is the term most commonly used in R&D and test engineering; "programmable load bank" is more common in industrial and utility procurement. Both describe a semiconductor-based load whose value is set digitally rather than by switching resistors.

What power and voltage ranges are available? +

Power runs from 1.2kW to 40kW. Voltage ranges are 0-150V, 0-600V, 0-800V and 0-1200V, with currents up to 1200A depending on the model. The part number encodes power, voltage range and current directly.

What do CV, CC, CR and CP mode mean? +

Constant voltage holds terminal voltage by adjusting current. Constant current holds current regardless of voltage. Constant resistance behaves as a fixed ohm value. Constant power holds the voltage-current product constant, which is the mode used for battery discharge as terminal voltage falls through the test.

What is dynamic mode used for? +

It steps the load between two levels at up to 10kHz, reproducing the fast load transients a switch-mode supply or converter sees in service. Most power supply designs are not defeated by steady load — they are defeated by repeated hard stepping, and dynamic mode is how that is found on the bench.

Why does remote sense matter? +

Without it, the load measures voltage at its own input terminals, which includes the drop along the connecting cable. Remote sense measures at the device under test instead, so the regulation figure you record is the device’s performance rather than your wiring’s.

What is the CR-LED function for? +

An LED string does not behave as a plain resistance — it has a turn-on threshold and a non-linear characteristic above it. CR-LED mode models that behaviour, so an LED driver is tested against a load resembling what it will actually drive rather than a resistor that misrepresents it.

Can it test battery discharge capacity? +

Yes. A dedicated battery test function runs discharge capacity testing as a defined routine, typically in constant power or constant current mode. For high-power or long-duration battery cycling where energy recovery matters, consider the regenerative load bank range instead.

Can it be controlled from test software? +

Yes, with the optional USB, RS232 or RS485 interface, specified at order so the unit ships configured. 100 groups of stored set-ups and power-off memory also allow substantial test matrices to run from the front panel alone.

Which voltage range should I choose? +

The lowest one that covers your maximum DUT voltage. Measurement resolution and accuracy are best when the test sits in the upper part of the range rather than in the bottom few percent, so a 0-1200V unit is the wrong choice for 48V work even though it technically covers it.

Need a Programmable Load Bank?

Request a quotation for a Programmable Load Bank. Send your maximum DUT voltage, current at minimum test voltage, required operating modes, dynamic requirement and interface to sales@powertrondcps.com, or call +91 8097707496 / +91 7208560460. POWERTRON quotes 1.2kW to 40kW across four voltage ranges.

sales@powertrondcps.com | +91 8097707496 | +91 7208560460

Request a Quote Call Now