What Issues Need Attention When Using a Liquid Cooled Load Bank

30kW liquid cooled load bank
 

I. Before Use: Conduct Basic Inspections and Environmental Adaptation​

Environmental Condition Verification​

Liquid cooled load banks have clear requirements for the operating environment: the temperature should be controlled between 5℃ and 40℃ to avoid reduced coolant heat dissipation efficiency due to high temperatures or pipeline freezing caused by low temperatures; the relative humidity should not exceed 85% to prevent moisture from entering electrical components and causing short circuits; at the same time, the device should be kept away from dust and corrosive gases (such as acid-base mist) to avoid contaminants clogging the liquid cooling channels or corroding metal pipelines.​

Power Supply and Wiring Inspection​

Confirm that the input power voltage and frequency match the rated parameters of the device (e.g., 380V/50Hz or 220V/50Hz), and strictly prohibit overvoltage or wrong-phase connection; check whether the insulation layer of the power cables is damaged and whether the grounding circuit is secure (grounding resistance ≤ 4Ω) to avoid electric shock risks caused by poor grounding; tighten the wiring terminals to prevent poor contact and heat-induced burnout.​

Coolant System Preprocessing​

Use the coolant type specified in the equipment manual (e.g., special antifreeze, a mixture of deionized water and rust inhibitor), and strictly prohibit the use of tap water (which contains impurities and is prone to scaling) or low-quality coolant (which may corrode pipelines); check whether the coolant level is between the "minimum-maximum" scale lines and add more if insufficient; before starting, remove air from the liquid cooling circuit (open the exhaust valve until no air bubbles escape) to avoid local overheating caused by air resistance.​

II. During Operation: Follow Standard Procedures and Monitor Status in Real Time​

Strictly Follow the Startup and Shutdown Sequence​

Startup sequence: First start the coolant circulation pump, and after the pressure gauge shows stable pressure (usually 0.2-0.5MPa) and the coolant flows normally, connect the power supply of the load bank and gradually adjust the load power (each increase should not exceed 20% of the rated power); Shutdown sequence: First gradually reduce the load power to 0, turn off the load output, and after the coolant continues to circulate for 10-15 minutes (to remove residual heat), turn off the circulation pump and main power supply. Avoid instantaneous power failure which may cause heat accumulation and damage components.​

Adjust Load Smoothly and Avoid Overloading​

Strictly prohibit adjusting the load power to the maximum value at one time; instead, gradually increase it according to the equipment's heat dissipation capacity to prevent a sudden temperature rise in a short period; monitor the load current and voltage in real time to ensure they do not exceed the rated range of the device (e.g., for a load bank with a rated current of 100A, the operating current should be controlled within 100A); if the test requires long-term full-load operation (e.g., more than 4 hours), confirm in advance whether the device has the capability for continuous full-load operation, and add heat dissipation auxiliary measures (such as installing fans) if necessary.​

Focus on Monitoring Key Parameters​

During operation, continuously observe: ① Coolant temperature (usually not exceeding 55℃; if it exceeds this value, stop the device and inspect the heat dissipation system); ② Liquid cooling circuit pressure (a sudden drop in pressure may indicate pipeline leakage, while a sudden rise may indicate channel blockage); ③ Equipment surface temperature (cabinet temperature not exceeding 60℃, and temperature of local components such as wiring terminals and power modules not exceeding 85℃); ④ Abnormal alarms (e.g., over-temperature, over-pressure, leakage alarms). Once an alarm is triggered, stop the device immediately to troubleshoot and prohibit operation with faults.