500kW AC400V Liquid-Cooled Resistive Load Bank

Unlike traditional air-cooled load banks, this system utilizes a customer-supplied circulating water system (requiring a flow rate of 100L/min at 500kW) to maintain resistor surface temperatures below 100°C. Integrated with a PLC control system, a local HMI touchscreen, and remote PC communication via Ethernet, 500kW AC400V Liquid cooled Resistive Load Bank offers unparalleled accuracy, safety, and flexibility for factory acceptance tests (FAT), R&D verification, and rigorous industrial power testing.

Technical Parameters

Key Product Advantages

l Superior Heat Dissipation: The stainless steel barrel water-cooling system ensures efficient thermal management, allowing for continuous high-power operation at 400V AC without overheating.

l High Precision & Fine Adjustment: Offers a wide load range with a minimum step resolution of 1kW, ensuring accurate load simulation for sophisticated power supplies and R&D applications.

l Dual-Control System: Equipped with a local touchscreen and remote PC software (Ethernet Modbus-TCP/IP), offering seamless integration into automated test benches.

l Comprehensive Protection Suite: Built-in overvoltage, overcurrent, over-temperature, and low-flow protections safeguard both the load bank and the connected equipment, with automatic load shedding upon fault detection.

l Industrial Mobility & Durability: Features a heavy-duty steel enclosure with RAL7035 powder coating, top lifting rings for crane transport, and bottom casters for easy mobility within the test facility.

l User-Friendly Operation: Designed with a control mode interlocking switch to prevent operation conflicts, alongside clear local electrical parameter displays.

Wide Application Scenarios

l High-Voltage Power Supply Testing: Ideal for testing AC power supplies, battery packs, and high-voltage converters in electric vehicles (EVs) and energy storage systems.

l Generator & Inverter Testing: Provides reliable full-load simulation for industrial generators and inverter systems.

l R&D and Laboratory Testing: Utilized in research and development centers for product characterization, thermal testing, and lifespan validation of high-voltage electrical equipment.

l Factory Acceptance Testing (FAT): Ensures power equipment meets strict quality and performance standards before delivery.

l Data Center & Telecom Power Validation: Tests the reliability of backup power systems and high-capacity AC power infrastructure.

l Aerospace & Marine: Applied in specialized AC power systems testing for harsh environments requiring high voltage and precision.

Daily and Periodic Maintenance Guide

Daily Maintenance:

1. Visual Inspection: Check the cabinet for any signs of leakage (especially at the DN50 inlet/outlet connections), high-voltage warning labels, and general cleanliness.

2. Water Circulation Check: Verify that the external water circulation system is operating normally and that the flow rate meets the 100L/min requirement.

3. Parameter Monitoring: Check the HMI screen for any abnormal temperature, pressure, or flow alarms during operation.

Periodic Maintenance (Monthly / Quarterly):

1. Cleanliness: Clean the cabinet exterior and ensure the air vents (if any) and liquid cooling lines are free of dust and debris. Maintain a minimum 1.2m × 1.2m footprint for indoor installation.

2. Water Quality Management: Check the external cooling water quality. Ensure the liquid contact materials (304 Stainless Steel) are not experiencing corrosion. It is recommended to use deionized water or a suitable coolant to prevent scaling and blockages.

3. Electrical Connections: Inspect the copper busbar connections for tightness and signs of oxidation. Check high-temperature cables for wear.

4. Safety Testing: Perform insulation resistance tests on the electrical components.

5. Protection Function Test: Periodically test the over-temperature, over-flow, and emergency stop functions to ensure they trigger automatic load shedding correctly.

Frequently Asked Questions

Q1: Can this 500kW AC400V Liquid cooled Resistive Load Bank operate continuously at 400V AC?

A: Yes, it is designed for continuous duty. However, to maintain resistor surface temperatures below 100°C, a continuous external water flow of 100L/min must be supplied during operation.

Q2: What are the requirements for the customer-supplied cooling system?

A: The customer must provide a circulating water system with a flow rate of 100L/min at 500kW. The inlet/outlet uses DN50 clamps. We recommend using deionized water to prevent scaling inside the 304 stainless steel barrel.

Q3: Is remote control supported?

A: Yes. The load bank supports both local HMI touchscreen control and remote PC control via Ethernet, allowing for data logging and integration into automated test systems.

Q4: What is the minimum load step?

A: The minimum load resolution is 1kW (from the 1kW step).

Q5: Can the inlet/outlet connection size be customized?

A: Yes, the standard connection is DN50 clamp, but we can customize the inlet/outlet sizes according to your existing cooling system specifications.

Q6: What is the warranty period?

A: We offer a 12-month warranty from the date of final acceptance.

During this period, any non-human-caused faults or component damages will be repaired or replaced free of charge within 7 days.

Real-World Application Cases

Case Study: High-Voltage AC Power Supply Testing for a Renewable Energy Lab

Challenge: A renewable energy R&D facility needed to test the continuous discharge performance and thermal stability of a AC 400V energy storage system. Their existing air-cooled load banks were too bulky, noisy, and could not handle the continuous 500kW load without derating.

Solution: RST Electric provided the 500kW AC400V Liquid-cooled Load Bank. The compact 1.0m × 1.0m footprint perfectly fit their indoor lab. The facility utilized their existing industrial chiller system to supply the required 100L/min water flow.

Result: The load bank successfully simulated 100% full-load conditions for 4 continuous hours. The resistor surface temperature remained stable below 100°C. The remote PC control allowed the engineers to automate 1kW incremental load steps, identifying a minor voltage ripple issue in the inverter before final product launch. The facility reported a 40% reduction in testing noise and zero overheating incidents.