500KW 380V AC Load Bank

The 500kW AC Resistive Load Bank from RST Electric represents the forefront of high-power testing technology. Operating at 380V AC (50/60Hz), this 500kW 380V AC Load Bank employs a modular resistor bank architecture with a minimum step load of 5kW, enabling granular simulation of real-world electrical loads. The unit is equipped with a high-precision CET PMC series power meter that displays voltage (L-N/L-L), current, active/reactive/apparent power, power factor, frequency, and cumulative energy - all on a vibrant 7-inch HMI touchscreen. Built to withstand harsh environments, the chassis is fabricated from heavy-gauge cold-rolled steel with a multi-stage anti-corrosion coating. The forced-air cooling system utilizes variable-speed fans with independent thermal sensors, automatically adjusting airflow based on real-time load demands to maximize efficiency and minimize acoustic noise. For automated testing, the load bank supports remote operation via RS485/Modbus-RTU, Ethernet/IP, or PC-based software, allowing seamless integration into existing SCADA systems or custom test protocols. With over 15 years of specialized manufacturing experience, RST Electric ensures every unit undergoes exhaustive factory acceptance testing (FAT) before shipment, complete with calibrated test reports.

1.Ultra-Fine Load Resolution - 5kW step increments allow precise simulation of load variations, critical for governor and AVR testing.

2.Intelligent Thermal Management - PID-controlled fans maintain optimal resistor temperatures, extending service life and reducing acoustic noise.

3.Comprehensive Safety Architecture - Dual-stage over-temperature protection with independent sensors; phase loss and voltage unbalance detection.

4.Industry 4.0 Ready - Standard Ethernet/Modbus TCP interface enables remote monitoring and integration with plant automation systems.

5.User-Centric HMI - Intuitive 7-inch touchscreen with graphical load profiles, real-time trends, and one-touch test presets.

6.Parallel Operation Capability - Master-slave mode allows combining multiple units for multi-megawatt testing without complex external controls.

7.Heavy-Duty Mobility - Reinforced chassis with four-way forklift pockets and lifting lugs designed for easy site relocation.

Technical Specification

Application Scenario Of 500KW 380V AC Load Bank

● Thermal & Gas Power Plants - Commissioning and routine load testing of steam turbines, gas turbines, and diesel generators up to 500kW.

● Hyperscale Data Centers - Validating multi-MW UPS systems, backup generators, and power distribution units (PDUs) under peak load conditions.

● Renewable Energy Parks - Testing utility-scale solar inverters, wind turbine converters, and battery energy storage systems (BESS) at full rated power.

● Heavy Industry - Load testing of large induction motors, variable frequency drives (VFDs), and plant power infrastructure.

● Offshore & Marine - Suitable for platform generator testing, shipboard power system validation, and drilling rig electrical equipment.

● Research & Certification Labs - Providing precise resistive loads for product development, type testing, and grid code compliance verification.

Drawing and dimensions

Package and Shipment

RST Electric employs a stringent packaging protocol for all 500kW 380V AC Load Bank exports. Each unit is first wrapped in VCI (Vapor Corrosion Inhibitor) film to protect against moisture, then encased in multiple layers of industrial stretch wrap. Heavy-duty steel strapping secures the load to a reinforced export pallet, and the entire assembly is enclosed in a custom-built, fumigation-free plywood crate compliant with ISPM 15 standards. For air freight, we provide shock- and tilt-indicators to monitor handling conditions. All shipments include comprehensive documentation: packing lists, commercial invoices, certificates of origin, and factory test reports. We collaborate with global freight forwarders to offer flexible shipping options - FCL, LCL, air freight, or door-to-door express - ensuring your equipment arrives on time and in perfect condition.

When reliability meets power, RST Electric leads the way.

When reliability and high power demand collide, RST Electric is always at the forefront of the industry, offering you high-quality 500KW 380V AC Load Bank. We are a legitimate Chinese manufacturer. From product design, component procurement, to production manufacturing and quality control, every step is strictly managed by us. This ensures stable product quality and saves you the middle links, allowing you to enjoy factory direct supply prices without any hidden charges, achieving a higher procurement cost performance.

Development History

Since 2008, we have been dedicated to the research and manufacturing of high-power load boxes. We have an ISO 9001-certified factory with a total area of over 7,000 square meters, equipped with an automated assembly line. Our production efficiency and quality control capabilities are consistently at the forefront of the industry. We have a professional in-house R&D team that is always focused on the innovation and upgrading of thermal management technology and control software, continuously optimizing product performance to meet the high-end testing requirements of various industries. Before each load box leaves the factory, a calibration instrument is used to complete 100% full-load aging tests to ensure that the product can operate stably after delivery and eliminate any quality risks.

Product Market

Over the years, we have become a trusted supplier for customers in over 50 countries worldwide, with clients located in regions such as the United States, Germany, the United Arab Emirates, Singapore, Australia, and others. We have accumulated extensive industry experience in fields such as power generation, data centers, renewable energy, and heavy industry. If you need customer case studies and reference materials for similar high-power projects, we can provide them at any time. We offer comprehensive customized services. The voltage options include 380V, 400V, 415V, 480V, and 690V. We can also achieve a 11kV voltage requirement by combining with a step-down transformer. The enclosure protection grades include IP23 indoor type, IP54 outdoor type, and IP56 marine grade. The control methods can be upgraded to advanced PLC, wireless remote control, mobile APP control, and can also be customized with SCADA integration. The metering methods can be selected as basic type, power quality analyzer, or multi-point temperature monitoring according to the requirements.

Regarding After-sales Service

In terms of delivery and after-sales, the standard delivery period for the customized 500KW 380V AC Load Bank is 20-25 working days. We provide complete technical materials in multiple languages such as English, Spanish, French, and Arabic. At the same time, we can arrange professional on-site engineers to provide on-site commissioning and training services according to customer needs, ensuring the entire process of your procurement and use is protected.

Project Cases

1. Project Background

Danish customer’s power engineering project involves local thermal power station, data center and new energy storage facility acceptance inspection. During regular commissioning and factory testing of 400V diesel generators, UPS and BESS equipment, conventional load equipment features rough load adjustment steps, low measuring precision and no remote centralized control function, unable to complete long-duration full-load continuous aging test, bringing hidden risks to power product delivery and onsite grid operation. RST Electric customized standard 500kW 400V PF=1.0 AC resistive load bank in strict accordance with EU local power testing standards to solve customer’s full-load verification demands for multiple types of power equipment.

2. Core Technical Specifications & Design Advantages 

Electrical Ratingl 

Total Rated Power: 500kW, three-phase AC400V star connection, PF=1 pure resistive load, rated operating current 722A

Load adjustment: 11 power gears, minimum single-step load 25kW, resistance tolerance ±5%

Withstand voltage: AC2500V/50Hz for 1min without breakdown or spark; high-precision power meter, display accuracy:0.1V/0.1A/0.1kW/1Hz

Ambient Condition: Working Temp: -10℃~+55℃, Max RH≤95% daily average without condensation, Installation altitude ≤2000m, indoor working environment.

Material & Structural Features

(1) Resistor Core: Low TCR alloy resistance elements with low temperature rise and excellent heat dissipation performance, stable performance under long continuous full-load operation.

(2) Forced Cooling System: Bottom-in top-out forced variable-speed air cooling structure equipped with PID speed regulating fans, automatically adjust airflow based on real-time load to reduce operating noise and prolong equipment service life.

(3) Multi-layer Safety Protection System: Overload, overvoltage, emergency stop and overtemperature four major protections, plus phase loss & three-phase unbalance voltage monitoring; independent temperature sensing component to trigger alarm when abnormal overheating occurs.

(4) Cabinet Construction: Heavy-duty cold rolled steel cabinet with multi-layer anti-corrosion coating, IP20/IP23 indoor protection, dimension L1150×D1300×H1900mm, net weight 540kg, F-class insulation; split wiring layout for power busbar, fan circuit and remote signal terminal, convenient for field wiring and connection with customer control cabinet.

(5) Dual Control Mode: Local 7-inch HMI touch screen operation; remote RS485 Modbus RTU communication, supporting PC and SCADA centralized automatic testing; master-slave parallel function to combine multiple units for MW-level combined load testing.

3. Onsite Installation & Commissioning Standard

1). Installation construction follows EU power equipment installation specification; separate wiring for power loop, fan control line and measuring signal line; cabinet fixed via reserved lifting lugs and forklift holes, reliable PE grounding.

2). Pre-commissioning test includes fan steering inspection, air duct smoothness check and insulation resistance test; formal access to customer power equipment only after all debugging items pass FAT factory inspection.

3). Operation rule: Regularly clean air inlet and outlet filters to prevent air blockage and abnormal temperature rise; no flammable articles stacked around load cabinet during long-time continuous load test.

4.Troubleshooting & After-sale Maintenance Service

Common onsite faults including abnormal overheating, resistance short circuit, remote communication failure and false overtemperature alarm are listed in official maintenance manual;

Periodic Inspection Standard: Regular cabinet internal dust cleaning and fan maintenance every 3~6 months; adopt 1000V megohmmeter for periodic insulation inspection and corresponding withstand voltage test.

Warranty Term: 12 months after onsite commissioning or 18 months from shipment date (whichever comes first). Free repair & component replacement for factory manufacturing defects; lifelong spare parts supply and global remote technical guidance for post-warranty customers, optional onsite commissioning service in Europe. 

5. Project Outcome

1). Accurate graded loading fully consumes test redundant power, realizes full-cycle full-load verification of customer’s generator, UPS and energy storage equipment, eliminates incomplete test data risk.

2). Intelligent dual-control and multi-protection design ensures stable long-hour running, zero overheat and safety fault during customer’s long-term actual usage.

3). Modular standard structure greatly reduces daily maintenance workload, cutting customer’s later operation & maintenance cost obviously.

Contact RST Electric for customized high-power 500KW 380V AC Load Bank for European generator, data center and new energy projects, get free technical proposal & quotation.