DC Load Bank Tester

The RST-500A-DC60V-R DC Load Bank Tester is a heavy-duty resistive industrial test device designed to simulate variable DC load conditions. It is widely used for capacity discharge testing of battery packs, EV DC charging pile aging, DC power supply, telecom power, data center HVDC, new energy storage and petrochemical DC system performance verification.

If your team struggles with unreliable load banks that overheat during critical commissioning, or lacks precise data logging for your DC systems, the RST-500A-DC60V-R delivers stable, repeatable testing you can trust.

Core Technical Parameters

Key Product Advantages

1.Corrosion-resistant Alloy Resistance Tube for Long Service Life Nickel-chromium stainless steel resistor with acid & salt spray resistance, excellent insulation & heat dissipation, supports non-stop continuous discharge without rapid aging, cutting your equipment replacement cost.

2.Dual Local & Remote Control System Built-in MCGS touchscreen for on-site manual/automatic loading; RS485 Modbus-RTU communication allows central remote monitoring, perfect for automated production line aging test stations.

3.12-Step Manual Adjustable Load Gear + Auto Constant Current Loading Two operation modes: numeric fixed current loading (one-click target current) & manual independent gear switch (1A~100A multi-range gears). Operators can flexibly simulate light load, medium load & full load working conditions for different test standards.

4.Complete 6-Way Safety Alarm & Auto Unload Mechanism Emergency stop, over-voltage, over-current, over-temperature, fan low wind pressure multi-protection. Once abnormal value exceeds threshold, system instantly cuts all load gears, triggers buzzer alarm & records alarm logs to avoid test sample damage.

5.Intelligent Temperature & Fan Delay Control Auto fan stop logic: fan runs continuously after unloading until outlet temperature drops below 40℃ or 3-minute countdown ends, fully dissipate residual heat to extend resistor service life.

6.Mobile Brake Casters & Compact Cabinet Layout 4 lockable moving wheels for flexible on-site transfer; split independent wiring compartments (control circuit / DC test circuit) separate strong & weak current, convenient wiring & daily inspection.

7.Real-Time Data Monitoring & Alarm Record Storage Touchscreen displays voltage, current, power, outlet temperature, control room temperature simultaneously; all alarm time & fault details saved for later troubleshooting traceability.

Wide Application Scenarios

This 60V 500A DC Load Bank Tester fits multiple industrial verticals:

1.New Energy EV Industry: DC charging pile aging test, on-board power supply discharge test, lithium battery pack capacity detection

2.Telecom & Data Center: 48/60V DC power cabinet discharge maintenance, backup battery capacity verification

3.Power & Energy Storage: DC generator output performance test, off-grid solar storage battery cycle discharge test

4.Industrial Manufacturing: DC switching power supply factory aging test, DC rectifier load simulation

5.Petrochemical & Railway: Station backup DC system regular maintenance inspection

Daily and Periodic Maintenance Guide

1. Daily Pre-Power-On Inspection (Approx. 5 minutes, to prevent thermal runaway and electrical faults)

Inspection Items

● Grounding Wire:Visually and manually confirm that the cabinet grounding wire is securely connected and not loose.

● Air Inlet/Outlet:Ensure there are no obstructions within 3 meters of the air inlet and 5 meters of the air outlet to ensure unobstructed airflow.

● Fan Operation: After starting, listen for any abnormal bearing noise, violent vibration, or jamming.

● Resistor Chamber Interior:Open the access door and check for any fallen foreign objects or severe dust accumulation.

● Panel Buttons and Emergency Stop:Test all physical buttons, emergency stop switch, and touchscreen to ensure sensitive response.

Regular Preventive Maintenance Plan

Every 2-4 weeks (adjust according to workshop dust levels)

Clean the inlet air filter (the filter at the bottom of the equipment is washable).

Operation: Remove the filter → Rinse to remove dust and oil → Dry thoroughly before reinstalling.

Notes:Never operate the machine without a filter.

Every quarter (every 3 months) – Deep Maintenance

Before operation: Disconnect the upstream power supply and lock/tagged the machine (LOTO). Allow internal components to cool completely.

● Insulation resistance test:Standard value ≥ 2MΩ. If below this value, immediately stop the machine and check for moisture-damaged or carbonized insulation components.

● Tighten electrical connections: Open the front and rear doors and tighten all loose terminals and fixing screws one by one.

● Resistor element visual inspection: Check the nickel-chromium alloy resistor tubes for abnormal discoloration (oxidation and reddening), deformation, reduced mesh size, or foreign matter attachment.

● Deep cleaning of resistor elements: Gently remove dust from inside and outside the tubes using a soft brush or low-pressure dry compressed air (≤5 bar).

● Resistance measurement: Measure the actual resistance value for each range using a multimeter, record the readings, and replace any drifting/damaged resistors.

● Alarm parameter verification: Access the HMI settings page and verify each alarm threshold, including temperature and air pressure, to ensure they match factory settings.

Every six months – Connection torque verification

Importance: Long-term thermal cycling can cause busbars and high-current bolts to loosen, leading to increased contact resistance and localized overheating.

Operation: Using a calibrated torque wrench, tighten all busbar and core bolt connections one by one according to the standard torque value specified in the accompanying manual.

Common Fault Troubleshooting

1.Emergency Stop Alarm Cause: Red E-Stop button pressed down;

Solution: Rotate emergency stop clockwise to reset, restart device

2.Over Temperature Alarm Cause: Blocked air duct, fan failure, long-time full load without heat dissipation;

Solution: Clean vents, inspect fan wiring, pause test to cool down

3.Over Voltage / Over Current Alarm Cause: Test DC output exceeds preset threshold;

Solution: Check voltage/current limit value in setting page, adjust sample power supply output

4.Fan Low Wind Pressure Alarm Cause: Fan not started, wiring loose, reversed air outlet direction;

Solution: Restart fan, re-tighten fan terminals, confirm air flows upward from top outlet

FAQ

Q1: Can the RST-500A-DC60V-R test both battery packs and DC power supplies?

Yes, it is purpose-built for this. The DC Load Bank Tester operates in a constant-current mode where the internal resistance dynamically changes to keep the set current (e.g., 500A) fixed, even as the device-under-test's voltage fluctuates. This makes it ideal for both a 48V telecom battery discharge test and a 60V industrial power supply burn-in test.

Q2:How do I integrate this DC Load Bank Tester into my automated test stand?

The rear panel features a Modbus-RTU interface over RS485. You can easily write a simple script in Python, LabVIEW, or a PLC controller to send commands like "Set Current 350A" and read back real-time voltage, current, and status alarms. The Modbus register map is fully documented in the user manual.

Q3: The noise level is listed as 70dB. Is that suitable for a lab environment?

At a 1-meter distance, the full-load noise is ≤70dB, which is comparable to a loud vacuum cleaner. It’s designed for industrial shop floors or dedicated test bays. For extended lab use, users often position the DC Load Bank Tester in an adjacent room with a pass-through busbar connection, as the control is fully remote.

Q4: What does the "R" in the model number signify?

The "R" designates a purely resistive load type. Unlike capacitive or inductive loads, this unit presents a unity power factor (PF=1), creating a true, distortion-free load. This is essential for accurately testing the real-world runtime of batteries and the thermal behavior of power supplies without introducing reactive power variables.

Q5: What happens if the 230VAC auxiliary power fails during a test?

This is a critical safety scenario. Upon loss of auxiliary power, the contactors will immediately disconnect the DC load, bringing the test to a safe, zero-load state. The cooling fans will also stop, so the thermal mass of the resistance elements is designed to absorb the residual heat without damage in this emergency condition.

Why Choose Ruisite RST Series DC Load Banks?

1.Factory direct manufacturer with independent R&D & production, full test report & user manual supplied with each unit

2.Strict factory aging test before delivery, 0.5 class high precision measurement module

3.Global after-sales support, complete operation video & maintenance technical document

4.Customizable voltage/current load bank models available for different test demands

5.Strict quality control: power circuit withstand AC2.5kV insulation test, insulation resistance ≥100MΩ

Real-World Application Cases

Case 1: UAE EV Lab DC Battery & Charger Aging Test (High-Temp Continuous Test Scenario, Dubai New Energy Lab Project)

A third-party new energy testing institute in Dubai, UAE carries out regular certification tests for lithium battery packs and DC EV chargers. It raises high demands on high-temperature resistance, large-current stable discharge and automatic data recording of DC load testers. Core application highlights are as follows:

1.Supports 0–60V wide DC voltage and 0–500A stepless constant current discharge, compatible with 48/60V solar storage batteries and 30kW low-speed EV DC chargers for dual-purpose testing;

2.Reinforced dual large-fan forced air cooling design, stable full-load continuous operation under 40–45℃ long-term high ambient temperature without overheating shutdown;

3.Built-in touch screen data logger with CSV report export function, storing full test curves to meet UAE local energy product certification filing standards;

4.IP23 dust-proof cabinet with complete multi-protection circuits (overvoltage, overcurrent, reverse connection, overtemperature auto cut-off), matched with dry contact alarm output for remote monitoring, adapting to hot and sandy coastal climate;

5.Configured with standard industrial control modules, stable performance after frequent long-hour aging cycles, greatly cutting lab manual recording labor costs.

Case 2: Offshore Drilling Rig Dynamic Braking Load Unit (Heavy-Duty Anti-Corrosion Scenario, Indonesia Oil Platform Project)

1.An Indonesian offshore oil drilling platform requires supporting braking load equipment for VFD electric drive systems, with high standards for salt fog resistance and stable long-cycle braking. Core application highlights are as follows:

2.Nickel-chromium alloy resistance strip with stable resistance value ±5%, equipped with dual axial cooling fans and air pressure differential alarm protection;

3.Anti-salt fog heavy-duty paint cabinet with IP23 protection grade, effectively resisting marine coastal salt corrosion;

4.Dual protection of air volume monitoring and over-temperature sensor, automatically sending stop signal to drilling rig control system under abnormal heat dissipation;

5.Modular detachable resistance components, easy for offshore regular maintenance and quick replacement of damaged parts.

Case 3: Wind Farm Genset Acceptance Load Test (Outdoor Long-Time Test Scenario, Vietnam Wind Power Station Project)

1.A large wind power investor in Vietnam needs full-load acceptance testing for backup generator sets of wind turbine booster stations, putting forward strict requirements on continuous heat dissipation and outdoor safety protection of load banks. Core application highlights are as follows:

2.Double-sided large curved air duct forced air cooling structure, realizing 12-hour uninterrupted full-load operation without overheating;

3.IP23 rainproof and dustproof integrated cabinet, equipped with high-temperature warning light, suitable for open-air wind field complex weather;

4.Reserved Modbus remote communication interface, supporting real-time synchronous upload of test data to wind farm central control platform;

5.Complete multi-layer safety protection including over-temperature, over-current and short-circuit power-off, with lifting lugs and forklift base for convenient field hoisting and transshipment.

Case 3: Data Center UPS FAT Aging Test (Indoor Batch Continuous Test Scenario, Thailand IDC Manufacturer Project)

1.A Thailand data center equipment manufacturer performs batch factory aging tests for UPS standby power supplies, demanding high test efficiency and automatic data recording. Core application highlights are as follows:

2.Stepless adjustable resistance load, supporting segmented loading test of UPS 25%/50%/75%/100% full load;

3.Built-in industrial touch screen, automatically storing voltage, current, power and runtime data, one-click export test reports for factory inspection filing;

4.Independent split electrical control cabinet, isolated high-voltage area with obvious warning signs to avoid accidental electric shock during batch testing;

5.Low-noise optimized fan structure, suitable for indoor long-term workshop continuous operation without excessive noise interference.