PLB-LRW Programmable AC Liquid-Cooled Load

Series:

The PLB-SRW series converts three-phase AC electrical energy into controllable heat and removes it from the test area via a circulating coolant. The product is designed to simulate the real-world power consumption and liquid‑cooling thermal loads of servers, storage systems, and network equipment.

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Product Introduction

The PLB-SRW series converts three-phase AC electrical energy into controllable heat and removes this heat from the test area via a circulating coolant. The product is designed to simulate the real-world power consumption and liquid-cooling thermal loads of servers, storage systems, and network equipment.
Prior to the deployment of actual IT equipment, load‑testing, dynamic‑condition assessments, and continuous‑operation validations can be conducted on UPS systems, diesel generators, ATSs, busbars, PDUs, distribution cabinets, CDUs, and cooling‑water systems.

Key item	Series Description
Standard electrical system	AC 380V, 3P4W (A/B/C/N), with an additional PE conductor.
Power range	20–400 kW per unit; 400/800 kW and 1 MW configurations may utilize a 200 kW base cabinet configuration.
Load characteristics	Energy-consuming, purely resistive; rated steady-state power factor ≈ 1.
Reference rated current	30–304 A/unit (calculated based on 380 V, three-phase, PF = 1)
Cooling method	External CDU liquid supply; the majority of heat is removed by the liquid circuit.
Local Control	Front-mounted HMI, hardware emergency stop, and three indicator lights for RUN/ALARM/FAULT.
Rear interface	A/B/C/N/PE, IN/OUT, LAN/RS485, and project‑optional interfaces

Product Features

Water-cooling with high power density: Heat from the load is efficiently transferred to the coolant circuit, reducing hot-air emissions and ventilation pressure in the test area.
Simulate real-world IT power consumption and heat generation: Before deploying actual servers, concurrently validate the UPS, generator, ATS, busbar, PDU, and CDU.
Programmable constant‑power loading: Supports manual, step, ramp, cyclic, hold, and continuous full‑load modes, with power steps configurable per project.
Comprehensive three-phase status monitoring: displays voltage, current, frequency, active power, power factor, load rate, and phase‑by‑phase operating conditions.
Local–Remote Collaboration: Touchscreen-based local control, PC‑based remote control, and multi‑unit master–slave group control; test data can be recorded and exported.
Multi-cabinet modular expansion: The 200 kW base cabinet can be combined to form 400 kW, 800 kW, and 1 MW systems, facilitating scalability, transportation, and maintenance.
All hydraulic, electrical, and communication components are relocated to the rear: the A/B/C/N/PE terminals, inlet and outlet ports, and communication interfaces are all consolidated at the back, while the front panel is reserved solely for operation controls and status indicators.
Complete safety interlocks: emergency stop, overcurrent, short circuit, overtemperature, low flow, leakage, phase loss, and phase sequence protection are all implemented via the safety chain.

Typical Applications

Data center integrated commissioning, IST testing, and project acceptance
UPS, diesel generator, ATS, busbar, and PDU capacity verification
CDU, secondary-side piping, and heat exchange system integrated commissioning
Joint Verification of Data Center Power Supply and Distribution with Liquid Cooling Monitoring System
R&D, factory acceptance testing, and aging tests of AC power equipment
Centralized load control and data logging across multiple data centers and regions

Working principle

The AC power supply under test enters the isolation, protection, and measurement unit via the rear-mounted A/B/C/N/PE terminals. The controller then activates the water-cooled resistive load module 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. If any safety condition—such as low flow rate, overtemperature, overcurrent, or an emergency stop—is triggered, the system will unload and lock out until reloaded.
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.

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	Purely resistive; under rated operating conditions, PF ≈ 1.
Standard rated voltage	AC 380V, three-phase four-wire, 50 Hz; 400 V/415 V, 60 Hz available upon request.
Rated power range	Single-unit capacity: 20 kW to 400 kW; 800 kW and 1 MW systems employ multi‑cabinet parallel operation.
Loading method	Programmable from 0% to 100% under rated voltage and specified cooling conditions; supports manual, step, ramp, cycle, 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 touchscreen + PLC; local operation, PC remote control, and multi‑machine master–slave group control.
Display and Recording	Voltage, current, frequency, power, power factor, 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 are optional.
Measurement capability	42 kW baseline project: electrical accuracy class 0.5, temperature ≤ 0.5°C, pressure ≤ 1%, flow rate ≤ 3%; the entire product range is subject to confirmation based on sensor selection.
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 A/B/C/N/PE; rear IN/OUT and drainage; rear communication interface
Protection function	Emergency stop, overload, overcurrent, short circuit, phase loss, phase sequence error, overtemperature, low flow, fluid leakage, and communication failure; after unloading, maintain necessary cooling.
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 lines and apply corrosion protection 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-SRW-20kW	380 V	20 kW	30 A	4U rack-mountable	178×482×800
PLB-SRW-42kW	380 V	42 kW	64 A	8U rack-mountable	356×482×870
PLB-SRW-60kW	380 V	60 kW	91 A	12U half-height cabinet	534×600×1000
PLB-SRW-80kW	380 V	80 kW	122 A	16U half-height cabinet	712×600×1100
PLB-SRW-100kW	380 V	100 kW	152 A	20U Half-Height Cabinet	889×600×1100
PLB-SRW-120kW	380 V	120 kW	182 A	24U Half-Height Cabinet	1067×600×1200
PLB-SRW-200kW	380 V	200 kW	304 A	42U floor-standing cabinet	2000×600×1200
PLB-SRW-400kW	380 V	400 kW	608 A	2 × 200 kW parallel operation	2×(2000×600×1200)
PLB-SRW-800kW	380 V	800 kW	1216 A	4×200kW parallel operation	4×(2000×600×1200)
PLB-SRW-1MW	380 V	1 MW	1519 A	5 × 200 kW parallel operation	5×(2000×600×1200)

Series Combination Recommendations The recommended main models are 42, 80, 100, 200, and 400 kW, with 20, 60, and 120 kW serving as supplementary options. A 400 kW system is configured using two 200 kW base cabinets; an 800 kW system uses four such cabinets; and a 1 MW system employs five.

Ordering and Selection Guidelines
1. Rated voltage, frequency, connection type, and whether an N conductor is required
2. Rated power, power step size, and requirements for step/ramp/cycle programs
3. Cooling medium, design inlet and outlet water temperatures, target flow rate, allowable pressure drop, and interface specifications
4. Requirements for local control, host computer, Modbus TCP/RTU, CAN, and dry contacts
5. Single-unit or multi-cabinet parallel operation, installation space, transportation access, and continuous operating time
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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