1. Start from apparent power, not kW
Generators are rated in kVA together with a power factor: 1000 kVA at 0.8 PF is 800 kW. A full-load test at 0.8 PF therefore needs 800 kW of resistive capacity plus roughly 600 kvar of inductive capacity, whose phasor sum is the 1000 kVA rating. Specifying only 800 kW of resistive load leaves the excitation system untested.
2. Allow for overload and growth
Standards commonly require verification at 110% or more, so the bank should cover at least 110% of the rating. If the same equipment will later test larger sets, choose a design that parallels for more capacity rather than buying the maximum up front.
3. Confirm voltage class and connection
Low-voltage banks at 400 or 480 V and medium-voltage banks from 3.3 to 13.8 kV are different products. A medium-voltage set should not be tested through a step-down transformer into a low-voltage bank: the transformer alters the transient response and masks the real voltage dip and recovery behaviour.
4. Work out heat rejection and the site
Everything the bank absorbs becomes heat. A 1000 kW load indoors means 1000 kW of heat to remove, which usually exceeds the room's cooling margin. Indoors, check the airflow path and the risk of hot-air recirculation, or use liquid-cooled rack loads to carry heat out of the room; outdoors, containerised units are the practical choice at high power.
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