500kW AC liquid-cooled resistive load bank manufacturer Rata
The Rata Hydro-500L is a 500kW AC liquid-cooled resistive load bank designed for Data Center, providing controlled load testing for three-phase AC power supplies. Its core advantage lies in its innovative liquid cooling system, which enables stable operation at full rated power while minimizing heat dissipation and noise in the test environment, making it ideal for indoor test facilities where traditional air-cooled solutions are impractical.
5.0
Schneider Eletric Authorise:
Prisma E Standardized low-voltage sub switchboard Technology and Business Partner
Warranty time:
3 years
Delivery time:
4 weeks
ISO Certification:
ISO9001/ISO14001
Brand:
RATA
Factory Price:
Negotiate
Supply Ability:
200,000 Piece/Pieces per Month
Port:
Shanghai and Guangzhou are both available
Payment Terms:
L/C,Cash,Western Union,T/T, Paypal
Min.Order Quantity:
1 pcs
ODM & OEM:
Available
Certification:
CE 60204 Standard
design customization
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Product Introduction
Bank(Hydro-500L) is designed for controlled load testing of three-phase AC power sources under Data Center.
By utilizing a liquid-based cooling system, the load bank enables stable operation at full rated power while minimizing heat emission and noise within the test environment. The equipment is suitable for both continuous and step load testing of generators, UPS systems and power supply equipment, particularly in indoor test facilities where air-cooled solutions are impractical.
Engineering drawing
Front view
Top view
Side view
Key Features and Advantages
High-Efficiency Liquid Cooling
Achieves stable operation at high power density through a liquid cooling system, significantly reducing noise and heat emissions, making it particularly suitable for indoor testing environments with stringent requirements.
Precise Control
Provides fine load resolution of 1kW and high load accuracy of ≤±2%, ensuring data reliability during continuous and step load testing of generators, UPS systems, and power supply equipment.
Intelligent Monitoring and Communication
Equipped with a local HMI touchscreen and PC-based remote control and monitoring software, supporting Modbus TCP protocol communication via RJ45 Ethernet port, and supporting parallel control for collaborative operation of multiple devices.
Robust and Durable
Constructs a cold-rolled steel shell and a stainless steel 304 load resistor tank, with an IP34 protection rating (for indoor use), and features forklift mounting holes for easy transport and deployment.
Comprehensive Safety Protection
Integrating multiple safety mechanisms including over-temperature alarm/shutdown, over-voltage alarm/shutdown, low airflow alarm/shutdown, electrical load branch fuse protection, and main circuit breaker protection for the control circuit, ensuring safe and reliable testing.
With its superior performance and liquid cooling advantages, the Hydro-500L is an ideal tool for verifying the performance of critical power equipment under various operating conditions, especially excelling in applications with special environmental requirements such as data centers.
Key details
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Main Parameters
| Model | Hydro-500L |
| Rated power | 500 kW. |
| Rated test voltage | 400Vac 3Phase 4Wires |
| Frequency | 50/60Hz. |
| Load connection | IP 67 Power-fit quick connector 400Amps |
| Load resolution | 1kW |
| Load accuracy | ≤+2% |
| Auxiliary voltage | 230Vac 50/60Hz. Single phase |
| Frequency | 50/60Hz. |
| Liquid flow in& out connection | Flange DN 100 |
| Air vent connection | Flange DN 15 |
| IP ingress grade | Enclosure IP34(using indoor) |
| Portability | Forklift pockets*2. |
| Housing material | Cold rolled steel |
| Resistors tank material | Stainless steel grade 304 |
| Operation temp. | -25°C to +50°C |
| Altitude | ≤2000 m.a.s.l |
| Dimension(W*D*H) | 1549.5*1204*1591.5mm |
| Weight(KGS) without liquid | 1100 |
| Communication | Modbus TCP via RJ45 Ethernet port |
| Parallel connection control | Available |
| Control | Local built-in HMI touch screen |
| PC based remote control& monitoring software | |
| Transducers | Liquid in& out temperature sensor |
| Liquid flow volume sensor | |
| Liquid pressure sensor | |
| Protection | Over temp. Alarm&cut out |
| Over pressure Alarm&cut out | |
| Low air volume Alarm& cut out | |
| Electrical LOAD branches fuse protection | |
| Control circuit mains breaker | |
| Air vent valve |
FAQ
1
How to interface with the data center cooling system (CDU/cold plate circulation)?
Liquid-cooled load banks are typically connected to the data center chilled water system or CDU (Coolant Distribution Unit) via piping. Matching hot and cold loop connectors are required; standard ISO or custom flanges are commonly used. Ensure the liquid-cooled load bank's outlet loop can be connected to the server room cooling tower or chiller unit.
2
What type of coolant is used? How to maintain it?
Generally, deionized water or a water-glycol mixture is used.The liquid should be kept clean and corrosion-resistant; hard water is strictly prohibited to prevent scaling. During maintenance, regularly check the conductivity, pH value, and coolant quality, and replace it every 1-2 years; clean the filter regularly to ensure the circulation pump and cold plates are not clogged.
3
Does the liquid-cooled load bank require an external cooling system?
Whether external cooling is needed depends on the power rating. For low-power systems (below several hundred kilowatts), a built-in closed-loop system is usually sufficient for self-heating. For high-power systems (MW level and above), it is recommended to connect external cooling equipment (such as cooling towers, chillers, or plate heat exchangers) to ensure stable coolant temperature and support continuous full-load operation.
4
Can heat be recovered and reused?
Yes. The liquid-cooled load bank concentrates the test heat to the coolant, facilitating heat recovery. Heat can be returned to building heating, domestic hot water preheating, or other process systems via plate heat exchangers, improving overall energy efficiency.
5
What are the control and communication methods?
Supports local HMI touchscreen control and remote PLC/SPS control. Typical interfaces are Modbus TCP or other industrial protocols for real-time monitoring and recording of parameters such as test voltage, current, temperature, and flow rate.
6
How to configure the three-phase wiring? Is grounding required?
Load banks generally use a three-phase four-wire (3P4W) connection, meaning three live wires (L1, L2, L3) plus a neutral wire (N) input, where the neutral wire is used for the load circuit. The control power supply is typically 120VAC single-phase. The equipment's metal casing must be reliably grounded (PE) and comply with safety regulations.
7
What safety protection functions does the equipment have?
It has multiple protections, such as over-temperature protection (disconnecting the load and triggering an alarm if the temperature exceeds a preset upper limit), coolant flow detection, coolant over pressure protection, and an emergency stop button. In addition, there are often over current fuses and leakage protection at the circuit level.
8
What are the temperature rise and flow rate requirements during continuous operation?
Under rated load, the liquid cooling system can maintain a low temperature rise: for models under 40kW, the full-load temperature rise is ≤15°C.Generally, the inlet coolant temperature should be within 80°C from ambient temperature. During design, it should be ensured that the circulating pump provides sufficient flow to match the cold plate requirements.
9
What are the considerations regarding operating noise and size?
The liquid-cooled load bank eliminates the need for a high-power fan, and operating noise is typically controlled below 60dB. The equipment adopts a modular rack-mount or compact cabinet structure, which can be directly placed in a computer room or cabinet.
10
What precautions should be taken when using it in coastal or high-humidity environments?
In coastal high-humidity environments, corrosion-resistant chassis and piping should be selected to avoid salt spray corrosion. Generally, an IP54 or higher protection rating is required. The sealing of the equipment wiring harness and connections should be checked, and the fans/cooling pipes should be cleaned regularly to prevent mold or salt scale.
11
What are the procedures for generator load testing?
Generator testing is generally divided into two parts: no-load and load testing. It is recommended to perform a step-by-step loading test according to the standard: Start the generator → No-load commissioning → 25%, 50%, 75%, 100% load tests → 110% overload test.
After running at each load point for a period of time (e.g., 20-30 minutes), record stability data such as voltage, current, and frequency.
12
What are the key points of UPS system testing?
UPS testing includes verifying full-load capacity under mains power and testing backup time under power outage conditions. Typically, a dummy load is connected first to simulate the actual load, and the output stability of the UPS is measured at different load levels; then, the system is switched to battery mode, and the duration of full load is measured. Sudden power increase/decrease response also needs to be tested: quickly change the load and observe the UPS voltage regulation and switching speed.
13
How to monitor temperature and flow? How is the data recorded and exported?
The system is equipped with temperature (inlet/outlet), flow sensors, and other instruments, which can be displayed in real time on a local touch screen.
The testing software usually supports real-time sampling and curve recording, and can export reports in Excel or CSV format.
14
What are the spare parts and maintenance cycles?
Common spare parts include coolant circulation pumps, sensors, filters, and electrical contactors. Due to the compact liquid-cooled structure, pumps and sensors require regular inspection. A complete maintenance check is recommended annually: replace filters, calibrate sensors, and tighten wiring. Core resistive components generally do not require replacement unless a fault occurs.
15
What needs to be checked before system integration?
Before installation, check the power supply capacity (voltage, current, phase sequence), hot and cold fluid connection interfaces, ventilation system, rack space, and grounding connections. Verify that the UPS or generator output matches the load bank's rating. Confirm that the cooling circuit is pre-charged with coolant and there are no leaks.
16
Does it support compatibility with rack-mount liquid-cooled servers?
Yes. The liquid-cooled load bank can simulate the thermal load of rack-mount liquid-cooled servers and can be tested in parallel with data center rack-mount liquid-cooled systems. Through the cold plate interface, it can simulate the resistance characteristics of server water-cooled plates.
17
How to verify reliable equipment operation?
Conduct continuous full-load operation tests. Observe temperature, flow rate, and alarm status during prolonged operation under full load (e.g., 8 hours or longer); also, observe for minor leaks or electrical overheating.
18
What are the requirements for on-site venting or pipe filling?
Perform flushing and venting of the liquid cooling circuit: Before injecting coolant, flush the pipes with deionized water and remove air; after installation, slowly add coolant until the system is full to avoid air resistance affecting heat dissipation.
19
Safety precautions for long-term system operation?
During long-term operation, regularly check the tightness of coolant pipes and electrical wiring, ensuring there is no dust accumulation or oil leakage. Avoid coolant freezing or overheating; it is recommended to monitor coolant temperature, setting the trigger threshold higher than ambient temperature but lower than the device's safe operating temperature.
20
Precautions for data center liquid cooling load testing?
During testing, consider the server room's PUE and cooling capacity; avoid prolonged high heat loads that could overload the air conditioning. Also, avoid extreme testing during peak hours. Confirm that the load bank matches the harmonic and short-circuit protection capacity of the UPS/generator to prevent interference with the operation of other equipment.
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