A 3-phase driven resistor load bank, electrically connected to an engine-generator-set is controlled to maintain a minimum generator load by turning ON and OFF load-bank heaters for optimal operation of the engine. An operator selects KW power output that best meets electrical load conditions and the load bank converts surplus electrical energy to heat, then cooled by the exhaust gas. The exhaust-gas-cooled resistive heater load bank, mounted in gas flow path, provides a dummy load to the gen-set which allows gen-set to operate at operator defined load level to enhance engine performance and reduce maintenance costs. The gas flow cools the inline resistive heater elements. The 3-phase AC power to the resistor load bank is only switched ON/OFF at zero-crossing points to eliminate electrical noise.

A 3-phase driven resistor load bank, electrically connected to an engine-generator-set is controlled to maintain a minimum generator load by turning ON and OFF load-bank heaters for optimal operation of the engine. An operator selects KW power output that best meets electrical load conditions and the load bank converts surplus electrical energy to heat, then cooled by the exhaust gas. The exhaust-gas-cooled resistive heater load bank, mounted in gas flow path, provides a dummy load to the gen-set which allows gen-set to operate at operator defined load level to enhance engine performance and reduce maintenance costs. The gas flow cools the inline resistive heater elements. The 3-phase AC power to the resistor load bank is only switched ON/OFF at zero-crossing points to eliminate electrical noise.

A resistor support assembly includes first, second, third, and fourth support members. Each of the first and second support members includes one or more resistor contact regions and apertures extending therethrough. Each third support member is at least partially disposed within one of the apertures of one of the first support members and one of the apertures of one of the second support members. Recesses may be formed in the resistor contact regions of the first and the second support members, and one or more load resistors may be at least partially disposed within the recesses. The resistor support assembly may be used to mount one or more load resistors to a printed circuit board, without obstructing airflow through hollow portions of the load resistors. To reduce parasitic capacitance and inductance, the first support members and the second support members are formed from non-conductive materials.

A resistor includes a first resistor element. The first resistor element is connected to at least a first electrical terminal and a second electrical terminal. The first resistor element is configured to directly contact cooling media on at least two surfaces of the first resistor element in order to transfer heat away from the first resistor element. The resistor may also include a second resistor element connected to at least the first electrical terminal and the second electrical terminal, where the second resistor element is configured to directly contact the cooling media on at least two surfaces of the second resistor element in order to transfer heat away from the second resistor element.

A resistor includes a first resistor element. The first resistor element is connected to at least a first electrical terminal and a second electrical terminal. The first resistor element is configured to directly contact cooling media on at least two surfaces of the first resistor element in order to transfer heat away from the first resistor element. The resistor may also include a second resistor element connected to at least the first electrical terminal and the second electrical terminal, where the second resistor element is configured to directly contact the cooling media on at least two surfaces of the second resistor element in order to transfer heat away from the second resistor element.

An air cooled resistor arrangement, comprising a resistor housing comprising an air inlet, an air outlet, a first inner wall extending in a direction from the air inlet to the air outlet, a second inner wall extending in direction from the air inlet to the air outlet, the first and second inner walls forming a primary air flow passage between the air inlet and the air outlet, a first outer wall extending in direction from the air inlet to the air outlet, and a first intermediate wall extending in direction from the air inlet to the air outlet, the first intermediate wall being arranged between the first inner wall and the first outer wall, and a plurality of elongated resistor elements arranged in the resistor housing, each of the plurality of elongated resistor elements comprises at its end portion an electrical connector element connectable to a source of electric power.

An air cooled resistor arrangement, comprising a resistor housing comprising an air inlet, an air outlet, a first inner wall extending in a direction from the air inlet to the air outlet, a second inner wall extending in direction from the air inlet to the air outlet, the first and second inner walls forming a primary air flow passage between the air inlet and the air outlet, a first outer wall extending in direction from the air inlet to the air outlet, and a first intermediate wall extending in direction from the air inlet to the air outlet, the first intermediate wall being arranged between the first inner wall and the first outer wall, and a plurality of elongated resistor elements arranged in the resistor housing, each of the plurality of elongated resistor elements comprises at its end portion an electrical connector element connectable to a source of electric power.

An air cooled resistor arrangement, comprising a resistor housing comprising an air inlet, an air outlet, a first side wall extending from the air inlet to the air outlet, and a second side wall extending from the air inlet to the air outlet on an opposite side to the first side wall, a plurality of elongated resistor elements arranged in the resistor housing, each one of the elongated resistor elements extending from the first side wall to the second side wall, wherein the plurality of elongated resistor elements is arranged in columns along a direction between the air inlet and the air outlet, wherein each one of the plurality of elongated resistor elements is arranged equidistantly to all its neighboring elongated resistor elements.

An air cooled resistor arrangement, comprising a resistor housing comprising an air inlet, an air outlet, a first side wall extending from the air inlet to the air outlet, and a second side wall extending from the air inlet to the air outlet on an opposite side to the first side wall, a plurality of elongated resistor elements arranged in the resistor housing, each one of the elongated resistor elements extending from the first side wall to the second side wall, wherein the plurality of elongated resistor elements is arranged in columns along a direction between the air inlet and the air outlet, wherein each one of the plurality of elongated resistor elements is arranged equidistantly to all its neighboring elongated resistor elements.

A resistor support assembly includes first, second, third, and fourth support members. Each of the first and second support members includes one or more resistor contact regions and apertures extending therethrough. Each third support member is at least partially disposed within one of the apertures of one of the first support members and one of the apertures of one of the second support members. Recesses may be formed in the resistor contact regions of the first and the second support members, and one or more load resistors may be at least partially disposed within the recesses. The resistor support assembly may be used to mount one or more load resistors to a printed circuit board, without obstructing airflow through hollow portions of the load resistors. To reduce parasitic capacitance and inductance, the first support members and the second support members are formed from non-conductive materials.