The JTP-4002 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 and the enclosure is fitted with lockable castors and forklift channels to allow it to be moved around.
The load bank is built as 10 x 20kW modules, each with its own water temperature, flow rate, and water pressure sensors, providing a complete picture of the cooling liquid profile along with protection in the case of disruption to the flow of cooling liquid. Each module is supplied with an IEC 60309 32A 3P+N+E socket inlet to avoid the need for inter-connection boxes.
Each individual module displays the module’s voltage, current, frequency and power of the load to an accuracy class of 0.5, flow rate, and both the inlet and outlet water temperature and pressure. The water temperature accuracy is ±0.5 ℃.
A HMI screen installed above the local control panel can display all of the measured values for each module, and additionally the total current and power of the load, and the total flow rate and average inlet and outlet water temperatures, along with average water temperature rise.
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.
Option stainless steel manifolds can be provided to allow other types of connections including quick disconnect connectors.
All piping is corrosion resistant GR304 stainless steel, picked and passivated after welding to prevent contamination of the cooling liquid. All internal pipes are insulated. The resistor and piping can withstand a maximum pressure of 1MPa (10bar).
A flow control valve is fitted to the main outlet 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 -15℃ to +100℃.
The minimum flow rate is 20.25 m3/h (337.5 lpm). The cooling liquid temperature rise will vary with the flow rate.
The IP23 enclosure is robust with a welded steel frame and steel panels. It is powder coated RAL 7035. The earth terminal of each socket inlet is bonded to the enclosure for protection.
The modular design allows easy maintenance or replacement of each of the 10 resistor modules.
The resistors are a stainless-steel alloy with a low temperature coefficient, limiting the change in resistance (±2%), and 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 240V 1 Phase 50Hz 10A auxiliary supply for the control and protection systems is derived from an IEC 60320 C14 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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