The JTP-4005 load bank is designed to test the electrical and liquid-cooling infrastructure in data centre halls continuously, at a power factor of 1pu, without having to utilise the normal operating load. It is intended to be operated indoors.
The load bank is nominally rated at either 400V or 415V 3P 50Hz 500kW but can operate at up to 450V 3P 588kW to accommodate increased voltages during no load startup of a data centre hall.
The tanks and piping are corrosion resistant stainless stee, and the coolant system can be fully drained to prevent contamination between projects.
A HMI screen installed above the local control panel can display the voltage, current, frequency, and power of the load to an accuracy class of 0.5, and the flow rate, coolant pressure and inlet / outlet pressure differential, inlet and outlet coolant temperatures, and the coolant temperature rise. The water temperature accuracy is ±0.5 ℃
The user can select the control mode as local or PC mode with a selector switch on the local control panel. Only one mode can be active at a time.
In local mode the load bank is controlled manually by selecting the required load using the load step selectors on the local control panel and then pressing the master load switch. This allows the load to be changed with a single button press without intermediate steps.
Software is provided for installation on the customer’s PC. The software allows the control of the load bank remotely via a RS485 cable and USB adaptor, along with data logging and reporting.
The software allows two control methods, manual or automatic loading. In manual mode the user selects the required load which is then set continuously. In automatic mode the user sets the power and time profile for a full test cycle which is then run automatically.
Up to 50 load banks can be controlled and monitored either individually or as a single load group from the PC by connecting them in a daisy chain configuration with RS485 cables. Any abnormal operating condition is highlighted on the software control screen.
The software displays all of the measured values in 1s intervals as both absolute values and in graph form. Data is saved in the software and can be queried either during or after testing. Test data can be exported in a spreadsheet, and graphs can be exported as .jpg files.
The inlet and outlet liquid cooling connections are made with a 100NB bolted flange equipment with a high temperature EPDM gasket. Stainless steel blanking plates are included to allow the cooling circuit to be sealed when not in use.
Optional stainless-steel manifolds can be provided to allow other types of connections including quick disconnect connectors.
All piping is corrosion resistant, solution annealed GR304 stainless steel, picked and passivated after welding to prevent contamination of the cooling liquid. All internal pipes are insulated. Hoses are peroxide cured EPDM. The resistor and piping can withstand a maximum operating pressure of 0.9MPa (9bar).
Flow control valves are fitted to the inlet of each tank to allow the flow rate to be reduced. Both automatic and manual air exhaust values are included. A manual drain valve ensures that the cooling liquid can be completely drained from the load bank to avoid contamination between projects. Inlet and outlet filters are included for use during filling and draining of the load bank.
The filters need to be removed during operation of the load bank.
The cooling liquid may be either:
The load bank can operate with cooling liquid temperatures from 0℃ to +65℃.
The minimum flow rate is 43.2 m3/h (720 lpm). The cooling liquid temperature rise will vary with the flow rate but is nominally 10℃.
The pressure drop across the load bank will not exceed 100kPa.
The IP23 enclosure is robust with a welded steel frame and steel panels. It is powder coated RAL 7035. The enclosure is fitted with lockable castors and forklift channels to allow it to be moved around.
The resistors are an immersion type, stainless steel cased, NiChrome alloy element with a low temperature coefficient. The change in resistance is limited to ±2%, therefore maintaining a constant load value across the operating profile. The manufacturing tolerance ensures all loads are within ±5% at rated voltage.
All elements undergo a PFWV test at 1.5kV 50Hz for 1 minute.
The load steps are switched with Schneider Electric contactors protected by MCBs on each module for short circuit protection. Each contactor is fitted with auxiliary contacts to provide status feedback.
The control circuit is protected by an MCB.
The control system utilises a highly reliable Siemens PLC to reduce the number of intermediate relays and timers required and simplify manufacture and maintenance.
An external 230V/240V 1 Phase 50Hz 16A auxiliary supply for the control and protection systems is derived from an IEC 60309 socket inlet.
Protection consists of:
Faults are indicated on the local control panel and in the PC software.
The following accessories are included with the load bank:
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