PLB-LRW Programmable DC Liquid-Cooled Load

Series:

The PLB-LRW series is a programmable, liquid‑cooled DC load designed for validating high‑voltage DC data centers, energy storage systems, and DC power supply equipment, supporting four voltage platforms: 240 V, 336 V, 400 V, and 800 V. The device can perform step, ramp, cycling, and continuous discharge tests at user‑defined power levels, accurately replicating the power‑consumption conditions of DC servers, DC PDUs, and busbar systems.

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Product Introduction

The PLB-LRW series is a programmable, liquid-cooled DC load designed for validating high-voltage DC data centers, energy storage systems, and DC power supply equipment, supporting four voltage platforms: 240 V, 336 V, 400 V, and 800 V. The device can perform step, ramp, cycling, and continuous discharge tests at user-defined power levels, accurately replicating the power‑consumption conditions of DC servers, DC PDUs, and busbar systems.
The modular water-cooled resistive unit stably converts DC electrical energy into heat and removes it from the test area via an external CDU or a liquid‑cooling loop. The system is equipped with DC isolation, polarity detection, reverse‑connection protection during loading, insulation monitoring interfaces, a hardware emergency stop, and interlocks for both electrical and hydraulic systems. It can be used for single‑unit capacity testing and, when combined with 200 kW base cabinets in parallel, can be expanded to 800 kW or even 1 MW systems.

Key item	Series Description
Voltage platform	DC 240V, 336V, 400V, 800V
Power range	42–400 kW single-unit; 800 kW and 1 MW units employ a multi-cabinet configuration.
Load characteristics	Unidirectional energy-dissipating water-cooled purely resistive load, with no power feedback to the grid.
Reference maximum current	Single unit: up to 500 A; for multi‑cabinet systems, verify each branch circuit separately.
Cooling method	External CDU liquid supply; the majority of heat is removed via the liquid circuit.
Local Control	Front-mounted HMI, hardware emergency stop, and three indicator lights for RUN/ALARM/FAULT.
Rear interface	DC+, DC−, PE, IN/OUT, LAN/RS485, and optionally configured interfaces

Product Features

Four-level DC voltage platform: covers 240 V, 336 V, 400 V, and 800 V, and is compatible with both conventional and next-generation high-voltage DC data centers.
Stable energy‑dissipative loading: The water‑cooled resistive power module converts DC electrical energy into measurable heat, making it suitable for capacity and continuous‑load verification.
Programmable power profiles: Supports power setpoint, step, ramp, cycle, hold, and long-duration constant‑power operation.
High-Voltage DC Condition Monitoring: Displays DC voltage, current, power, load ratio, and insulation/polarity-related status.
Local–Remote Collaboration: On‑board touchscreen control, remote control via a host PC, data logging, and centralized multi‑device management—configured on a per‑project basis.
Multi‑cabinet modular expansion: The 200 kW base cabinet can be configured into 400 kW, 800 kW, and 1 MW systems, supporting master–slave power allocation.
High-voltage and water‑line components are all mounted at the rear: DC+, DC−, PE, inlet and outlet ports, and the communication interface are all centrally located on the back side, facilitating engineering isolation.
DC‑specific safety protections: emergency stop, overcurrent, overvoltage, short circuit, overheating, low flow, fluid leakage, polarity detection and reverse‑connection protection during startup, as well as interlocking for insulation abnormalities.

Application Industries

240V, 336V, 400V, and 800V high-voltage DC data centers and intelligent computing centers
Manufacture of HVDC rectifier cabinets, DC busbars, DC PDUs, and communication power supply equipment.
Research and development of energy storage systems, battery packs, DC switchgear, and high-voltage DC power supplies.
Testing of charging modules, industrial DC power supplies, and power electronic conversion equipment
Manufacture and integration of CDU, liquid cooling pipelines, cold plates, and the secondary-side heat exchange system.
Research institutes, third-party testing, type testing, factory inspection, and aging tests

Applicable Standards and Specifications

This series does not have a single, dedicated national standard that can independently cover all requirements for the entire system. Product design, manufacturing, and verification are conducted in accordance with a combination of standards covering electrical safety, low-voltage switchgear assemblies, insulation coordination, EMC, environmental testing, and liquid‑cooling interface specifications. The following standards apply based on the product configuration and project scope.

Standard/Specification	Applicable Content
GB/T 7251.1-2023, GB/T 7251.2-2023	Low-voltage switchgear and controlgear assemblies: applicable to the structural integrity, temperature rise, dielectric performance, protective circuits, and verification requirements of complete electrical assemblies, as determined by the equipment’s configuration.
GB/T 5226.1-2019	Mechanical and Electrical Safety: General safety design measures for safeguarding connections, wire identification, control circuits, emergency stop devices, and electrical documentation.
GB/T 16935.1-2023	Insulation coordination of equipment in low-voltage power supply systems: used for the design of electrical clearances, creepage distances, overvoltage categories, and pollution degrees.
GB/T 4208-2017	Enclosure Protection Rating (IP Code): The overall protection rating and test requirements shall be determined in accordance with the installation environment and the technical agreement specified in the order.
GB/T 17626.2-2018, GB/T 17626.3-2023, GB/T 17626.4-2018, GB/T 17626.5-2019, GB/T 17626.6-2017	Electromagnetic compatibility immunity testing: covers electrostatic discharge, radio-frequency radiation, electrical fast transients, surges, and radio-frequency conducted disturbances; test levels are determined based on the project’s environmental conditions.
GB/T 2423.1-2008, GB/T 2423.2-2008, GB/T 2423.10-2019	Environmental testing: Low-temperature, high-temperature, and sinusoidal vibration tests shall be conducted in accordance with the environmental conditions of transportation, storage, and operation.
GB/T 40815.4-2021	Water‑cooled heat exchanger cooling performance test for electronic cabinets: serves as a reference for testing liquid‑side heat transfer capacity, temperature rise, and flow rate.
YD/T 3982-2021	Technical Requirements and Test Methods for Cooling Fluids in Data Center Liquid-Cooling Systems: A Reference for Coolant Selection, Compatibility, Application, Maintenance, and Testing.
YD/T 3980-2021, YD/T 4024-2022	Technical Requirements for Cold Plate and Liquid-Cooled Server Systems in Data Centers: A Reference Guide for Liquid-Cooling Interfaces, Deployment, and System Integration Testing.

Conformity Statement The standard version, test levels, IP ratings, scope of certification, and acceptance criteria shall be specified in the order’s technical agreement. Reference to standards indicates the basis for design and testing but does not imply that the complete equipment has obtained third-party certification under those standards; for export projects, IEC/EN requirements may be added as stipulated in the contract.

Working principle

The DC source under test is connected via the rear‑panel DC+ and DC− terminals, along with the PE terminal, to the DC isolation, polarity/insulation protection, and measurement unit. The controller then activates the water‑cooled resistive modules according to the target power setting. Once electrical energy is converted into heat, the majority of this heat is carried away by the coolant to the CDU. Polarity errors, insulation faults, low flow rates, overheating, overcurrent conditions, or an emergency stop will either prevent loading or trigger immediate unloading.
Liquid-side thermal power calculation Q = ρ × cp × F × ΔT. Taking water as an example, the required flow rate is approximately F ≈ 14.3P/ΔT (L/min); for instance, at 42 kW with a design temperature difference of 10°C, the theoretical flow rate is about 60 L/min. For ethylene glycol or propylene glycol solutions, the actual density and specific heat capacity must be used for correction.

Safety Principles Do not initiate loading when the water‑cooling authorization is not established, the emergency stop has not been released, or an electrical fault exists. After a protective trip disconnects the load circuit, the cooling circuit shall remain active for the prescribed hold‑down period. Upon fault reset, the target power shall be maintained at 0 kW, and automatic restoration of the original load is prohibited.

Series Specifications and Parameters

The table below is intended for product lineup display on the official website. Items marked as “Typical” or “Customizable” shall be finalized in the specific order’s technical agreement.

Project	Technical Specifications
Load characteristics	Water-cooled energy-consuming purely resistive load
Standard Voltage Platform	DC 240V, 336V, 400V, 800V; the actual operating voltage range shall be confirmed upon order.
Rated power range	42 kW to 400 kW single-unit; 800 kW and 1 MW units employ multi‑cabinet parallel operation.
Loading method	Programmable from 0% to 100% under rated voltage and specified cooling conditions; supports manual, step, ramp, cyclic, and hold modes.
Power regulation	For the 42 kW baseline model, the minimum step size is 0.1 kW; for other models, configuration is based on power range and technical specifications.
Work style	Continuous duty; the rated full-load capacity must simultaneously meet the specified voltage, flow rate, inlet water temperature, and ambient conditions.
Control method	Front-mounted touch screen + PLC; local operation, PC remote control, and multi-unit master–slave group control.
Display and Recording	DC voltage, current, power, load factor, temperature, pressure, flow rate, differential pressure, and liquid-side thermal power
Communication interface	Ethernet/Modbus TCP, RS485/Modbus RTU; CAN and dry contacts available as options.
Measurement capability	42 kW baseline project: electrical accuracy class 0.5, temperature ≤ 0.5°C, pressure ≤ 1%, flow rate ≤ 3%; full range subject to sensor selection confirmation.
Cooling medium	It is recommended to use deionized water with a corrosion inhibitor; for ethylene glycol or propylene glycol solutions, the concentration, material compatibility, and thermal properties must be verified.
Recommended Inlet Conditions	The standard series recommends a temperature range of 15–35°C, with a minimum margin of 3 K above the ambient dew point; special temperature ranges require dedicated verification.
Waterway pressure	The recommended typical operating pressure range is 0.2 to 0.6 MPa; the maximum working/test pressure shall be based on the lowest-rated hydraulic components and the technical specifications.
Fluid path materials	It is recommended to use 304/316L stainless steel with EPDM; final confirmation shall be based on the coolant, its concentration, temperature, and the supplier’s components.
Interface Layout	Rear-mounted DC+, DC−, PE, and DC isolation; rear-mounted IN/OUT, drain, and communication interfaces.
Protection function	Emergency stop, overvoltage/undervoltage, overcurrent, short circuit, polarity detection and reverse‑connection protection during loading, insulation fault, overtemperature, low flow rate, and fluid leakage; maintains necessary cooling after unloading.
Environment and Protection	42 kW reference configuration: −15 to +40°C, 0–95% RH, altitude 1,500 m, IP21; series‑standard ratings are subject to testing and contractual agreement.
Craftsmanship and Environmental Protection	It is recommended to perform acid pickling and passivation on the water circuit and apply anti-corrosion treatment to the entire unit; insulation class and RoHS compliance shall be confirmed in accordance with the project requirements and certification status.

Product Selection Specifications

The rated current is calculated based on the nominal voltage and rated power and is intended solely for preliminary equipment selection. Cables, circuit breakers, busbars, and terminals shall be verified in accordance with continuous current-carrying capacity, temperature rise, installation method, and local regulations.

Model number	Voltage	Power	Rated current	Structure	Reference dimensions/mm
PLB-LRW-240V-42kW	240 V	42 kW	175 A	8U rack-mountable	356×482×870
PLB-LRW-240V-60kW	240 V	60 kW	250 A	12–16U	H534–712×W600×D1000
PLB-LRW-336V-42kW	336 V	42 kW	125 A	8U rack-mountable	356×482×870
PLB-LRW-336V-80kW	336 V	80 kW	238 A	16–20U	H712～889×W600×D1100
PLB-LRW-336V-100kW	336 V	100 kW	298 A	20–24U	H889～1067×W600×D1100～1200
PLB-LRW-400V-50kW	400 V	50 kW	125 A	8U rack-mountable	356×482×870
PLB-LRW-400V-100kW	400 V	100 kW	250 A	20–24U	H889～1067×W600×D1100～1200
PLB-LRW-400V-200kW	400 V	200 kW	500 A	42U floor-standing cabinet	2000×800×1200
PLB-LRW-800V-100kW	800 V	100 kW	125 A	20–24U	H889～1067×W600×D1100～1200
PLB-LRW-800V-200kW	800 V	200 kW	250 A	42U floor-standing cabinet	2000×600×1200
PLB-LRW-800V-400kW	800 V	400 kW	500 A	2 × 200 kW parallel operation	2×(2000×600×1200)
PLB-LRW-800V-800kW	800 V	800 kW	1000 A	4×200kW parallel operation	4×(2000×600×1200)
PLB-LRW-800V-1MW	800 V	1 MW	1250 A	5 × 200 kW parallel operation	5×(2000×600×1200)

Series Combination Recommendations 240V is primarily used for 42/60 kW; 336V is primarily used for 42/80/100 kW; 400V is primarily used for 50/100/200 kW; and 800V is primarily used for 100/200/400 kW, with the capability to scale up to 800 kW and 1 MW through parallel connection of multiple cabinets.

Ordering and Selection Guidelines
1. Rated voltage, allowable operating voltage range, rated power, and maximum current
2. Power stepping, step/ramp/cycle programming, and continuous discharge time
3. Requirements for DC isolation, pre-charge/discharge, reverse connection, insulation monitoring, and emergency stop circuits
4. Cooling medium, design temperature difference, target flow rate, allowable pressure drop, and interface specifications
5. Communication protocol, single-unit or multi-cabinet parallel operation, installation space, and transportation conditions
Note: The dimensions listed in the table are for product planning reference only and do not include handles, casters, leveling feet, exposed connectors, or external cables. For multi‑cabinet systems, the footprint must also account for inter‑cabinet spacing, power distribution/main control equipment, water manifolds, and maintenance clearances. The actual delivered specifications shall be governed by the equipment nameplate, the order’s technical agreement, and the accompanying controlled drawings.

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