Bidirvolt Custom Rack Load Bank
Bidirvolt Rack-Mounted Liquid-Cooled Load Bank Specs and Custom Options
This page summarises the standard configuration and common engineering customisation options for rack-mounted liquid-cooled load banks used in CDU testing, AI rack commissioning, server heat load simulation, and data center acceptance testing.
A standard rack-mounted liquid-cooled load bank is usually enough for 19-inch rack commissioning. Large AI data center projects often need deeper customisation because rack power, cold plate resistance, UQD connectors, coolant, and control software vary from site to site.
Standard Rack-Mounted Load Bank Configuration
For normal data center acceptance testing, the standard configuration should first match the rack, the PDU, and the CDU secondary loop. Bidirvolt can configure units around the project voltage, rack U height, connector type, coolant, and commissioning records.
| Category | Parameter | Typical Standard Range |
|---|---|---|
| Physical | Form factor and weight | 19-inch rack-mounted, 2U / 3U / 4U, usually around 25-45 kg depending on configuration |
| Power | Rated power and voltage | 10kW, 20kW, 30kW, or 40kW per unit; AC 380V / 400V / 415V / 480V, 50/60Hz |
| Load control | Step control and accuracy | 0.5kW or 1kW step control, with project-specific accuracy requirement |
| Cooling loop | Coolant, pressure, delta-T, and pressure drop | Deionised water, pure water, PG25/PG50 glycol mixture; 1.0 MPa working pressure; 10-15 degrees C design delta-T; adjustable pressure drop where required |
| Interface | Quick connectors and sensors | UQD02 / UQD04 or project-specific non-drip connectors; inlet/outlet temperature, pressure, differential pressure, and flow monitoring |
| Communication | Control protocol and reporting | RS485 Modbus RTU, Ethernet Modbus TCP, SNMP, trend curves, and report export |
When Do You Need a Custom Rack-Mounted Unit?
Customisation becomes important when the load bank must represent a specific AI rack instead of a generic server rack. Projects based on very high rack density, OCP-style frames, non-standard manifolds, or special coolant may require a custom rack-mounted liquid-cooled load bank rather than a standard model.
Typical triggers include 21-inch rack requirements, unusual rear clearance, special mounting ears or sliding rails, 50kW+ power in a compact module, or rack-level heat loads above 100kW. These are good reasons to send drawings and CDU data before requesting a quote.
Hydraulic Customisation for CDU and Manifold Testing
The most important custom option is often water-side behaviour. A load bank for serious CDU validation should not only generate heat; it should also simulate the pressure-flow behaviour of server cold plates.
- Adjustable hydraulic resistance: manual or motorised needle valves can help simulate different cold plate P-Q curves.
- Connector adaptation: Parker, Staubli, Danfoss, UQD, DN10, DN15, or other project-specific quick connectors can be considered.
- Coolant compatibility: sealing and wetted materials can be selected for glycol mixtures, deionised water, pure water, or special liquid cooling media.
- Manifold balance testing: adjustable flow resistance helps reveal branch bias, low-flow paths, and pump head limitations.
Electrical, Transient Load, and Control Customisation
Electrical customisation may include North American 480V input, project-specific three-phase layouts, HVDC input, solid-state switching, or faster transient load response. A transient load module can help simulate sudden AI training load changes and observe CDU pump and valve response.
For larger deployments, control software is often as important as hardware. Bidirvolt can discuss group control, Modbus point mapping, central PC software, test scripts, trend curves, and report export. For broader engineering scope, see the custom load bank engineering page and custom load bank software options.
RFQ Information to Send Bidirvolt
To quote a custom rack-mounted liquid-cooled load bank accurately, prepare the main site parameters first. A short but complete RFQ saves several rounds of technical clarification.
- Target power per unit and total rack heat load.
- Rack type, U height, depth, rear clearance, mounting rail, and any lifting or caster requirements.
- Site voltage, phase, frequency, PDU capacity, and breaker rating.
- Coolant type, flow rate, pressure rating, design delta-T, and target pressure drop.
- UQD or quick connector model, hose direction, and manifold drawing if available.
- Communication protocol, BMS/DCIM interface, group control requirement, and report export format.
Request a Custom Rack-Mounted Liquid-Cooled Load Bank Quote
Bidirvolt can configure rack-mounted liquid-cooled load banks around your CDU, rack manifold, UQD connectors, voltage, coolant, pressure rating, control protocol, and data center commissioning workflow.
Send your rack drawings, CDU flow data, connector model, site voltage, and test report requirements through the Bidirvolt contact page.
Request a Custom Quote