Crestchic, the world’s leading provider of load bank solutions, today announced the launch of its innovative 600kW Liquid Cooled Loadbank at Data Centre World, London. The product marks a significant advancement in commissioning technology for the rapidly expanding liquid-cooled data centre market. 

As rack power densities continue to rise, operators are increasingly deploying liquid cooling technologies to manage thermal loads more efficiently. The need for precision commissioning tools has never been greater. Crestchic’s new 600kW Liquid Cooled Loadbank has been purpose-built to meet this challenge, delivering accurate thermal validation and precision electrical testing of liquid-cooled infrastructure at scale. 

Purpose-built for the modern data centre 

The 600kW Loadbank delivers up to 648kW at 415V and has been engineered for the rigours of real-world data centre commissioning.  

At the heart of the new platform is stable ΔT thermal control to ±0.5°C, enabling highly repeatable validation and precision electrical testing of liquid-cooled infrastructure. The unit maintains temperature accuracy to ±0.5°C regardless of flow variation, giving engineers the repeatability and confidence they need during critical testing activities. Comprehensive system protection covers flow, pressure, overload/underload, and thermal shock, safeguarding both the load bank and the infrastructure it is connected to. 

The 600kW platform features a single-vessel architecture, eliminating the need for multi-vessel configurations typically used at this power level. The result is a significantly smaller footprint, making the unit easier to position in space-constrained plant rooms. The compact design also simplifies transport, storage, and on-site handling. With a stackable structure, flush-mounted connections, heavy-duty castors and dual-side forklift pockets, the unit has been engineered for practical deployment on live project sites and can transported double stacked within a standard height ISO shipping container.  

Advanced control and reporting with VCS 

The 600kW platform integrates with Crestchic’s state-of-the-art VCS software, providing a comprehensive digital dashboard with live supply and hydraulic instrumentation data. The software supports real-time monitoring, automatic load profiling and clustering of up to 240 load banks for hybrid air-cooled and liquid-cooled test configurations. Automated compliance reporting via the Crestchic Portal provides audit-ready documentation aligned with key industry standards including ISO 8528-5/22514, NEMA MG1, EN60150, IEEE 141 and ASHRAE G22 standards. 

“The move toward liquid cooling is accelerating as rack densities increase, particularly with AI and high-performance computing workloads,” explains Paul Brickman, Commercial Director at Crestchic. “Our new 600kW Liquid Cooled Loadbank has been designed from the ground up to serve this market, giving commissioning engineers the precision, reliability and control they need to bring critical infrastructure online with confidence.” 

The 600kW Liquid Cooled Loadbank is available for both sale and rental through Crestchic’s global network of offices across the UK, Ireland, Singapore, Germany, Belgium, France, China, and UAE. 

About Crestchic 

Crestchic is a world-leading manufacturer and provider of load bank solutions, with decades of experience supporting the power generation, data centre, marine and defence industries. For more information, visit www.crestchicloadbanks.com 

Media Enquiries: Laura Wilks |  l.wilks@crestchic.com | 07828953758 

Ends 

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Meticulously designed, data centres must be able to store, process, and distribute vast amounts of data, 24 hours a day, 7 days a week. To meet this relentless demand for uninterrupted service data centres combine advanced engineering, architecture, and cutting-edge technology. 

Using comprehensive testing and evaluation, IST ensures that all critical systems work seamlessly together. These tests are conducted after individual systems (like power, cooling, network, and security) have been installed and tested independently. 

Why are Integrated Systems Tests important? 

Tests integrate all critical equipment and systems, conducting rigorous assessments to evaluate and verify functionality, interoperability, and response to simulated failure scenarios. By testing power distribution systems and cooling systems, commissioning managers can verify that systems and components meet specified performance criteria. 

This includes: 

• Verify interoperability: Ensure that systems like power distribution systems, Uninterruptible Power Supplies (UPS), generators, cooling systems, and fire suppression systems work in harmony.
• Assess resilience and reduce risk: Testing allows operators to simulate events such as power outages, equipment failures, and cooling loss to verify that the data centre can continue to operate under these conditions. The tests can also check if backup power systems activate as intended to prevent downtime.
• Safety and compliance: Testing can help to validate that emergency protocols are effective and meet industry regulations, standards and best practices. 
• Performance of electrical systems: Testing allows operators to confirm that the data centre can handle maximum load requirements and ensure that systems like power and cooling can support this load.

What do IST tests cover? 

The Uptime Institute states: “Rigorous, comprehensive commissioning reduces initial failure rates, ensures that the data centre functions as designed, and verifies facility operations capabilities—setting up Operations for success.”

Generally, five levels of testing form the overall process of commissioning a data centre: 

• Level 1: Factory Testing,
• Level 2: Site acceptance inspection 
• Level 3: Pre-functional testing 
• Level 4: Functional Testing,
• Level 5: Integrated System Testing

The below table, from the Uptime Institute, outlines what is covered in each step: 

Level five testing, or integrated systems testing, covers several key areas to ensure reliable and resilient operations. Power systems, including backup generators, UPS systems, power distribution units, and batteries, are tested to confirm they can maintain uninterrupted power.

Cooling systems are verified to ensure they keep temperatures stable even under heavy loads – a vital step for server rooms that exude huge amounts of heat under normal operation. Tests also cover networking infrastructure and fire suppression and security systems. Together, these tests provide a comprehensive view of the data centre’s readiness to handle real-world demands and potential emergencies.

What are the benefits of running an IST?

Prevent unplanned downtime: Modern data centres must operate 24/7.  ISTs can identify weaknesses that might lead to failures during normal operation.

Operational readiness: Ensures the data centre can meet strict Service Level Agreements (SLAs) with minimal risk of failure.

Improved efficiency: Helps to identify areas for operational optimisation, like load balancing in power or cooling systems.

In summary, ISTs are critical because they validate that systems have been designed and commissioned correctly to keep the environment stable, safe, and online—even under stress. This holistic testing approach is critical to minimising risk and maximising reliability in a setting where uptime is everything.

Find out how our 200kW data centre loadbank can help make IST tests more efficient and accurate. Speak to our team now.

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Paul Brickman, Commercial Director at Crestchic Loadbanks, commented: “As the demand for reliable data centre infrastructure continues to grow, Crestchic is dedicated to delivering advanced load-testing solutions that ensure the uninterrupted performance of critical power systems. The Data Centre World Event offers the perfect platform for Crestchic to showcase its latest innovations and engage with professionals from the data centre industry.”

Visitors to the Crestchic stand (R65) can gain insights from the company’s team of experts who will be available to answer questions, provide product information, and offer recommendations tailored to specific data centre requirements.

• Crestchic Loadbanks will showcase its comprehensive range of loadbank solutions designed to meet the diverse needs of data centres, from small-scale testing to large, complex installations.
• The team will be available for discussions on power resilience strategies and how load testing can play a pivotal role in safeguarding data centre operations during power outages or emergencies.
• Crestchic Loadbanks experts will be on hand to provide insights into best practices for generator testing, ensuring data centre operators have complete confidence in their backup power systems.
• Learn about Crestchic Loadbanks’ bespoke solutions, including trailerised loadbanks for multi-generator sites and loadbanks for heat load testing. 

Founded in 1983, Crestchic is one of the world’s leading specialist manufacturers of loadbanks which are used in the testing of power supplies in the most demanding climactic and environmental conditions across seven continents. Operating from locations in the UK, North America, Singapore, France, Germany, and the Middle East, the company is at the forefront of innovation and design, with thriving sales and rental operations and a loyal and growing customer base worldwide.

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The importance of heat load testing 

Data Centre servers exude enormous amounts of heat; making it vital that air conditioning systems can cope with the heat output of the servers. Data centre heat load testing is a process of assessing the performance and capacity of a data centre’s cooling infrastructure by using a load bank to simulate the heat generated by IT equipment.

End-to-end load bank rental

Steven Bacon, Business Development Manager at Crestchic USA, explains, “Heat load testing is a critical step in the design and commissioning of any data center. Failing to heat load test the server hall can result in inadequate cooling, which can impact the performance and reliability of the IT equipment. Higher temperatures can lead to thermal throttling, reduced processing speeds, increased error rates, and overall degradation in system performance. By using a load bank to simulate the heat output of the servers, we are able to subject the cooling systems to different heat loads to ensure they can effectively dissipate the generated heat and maintain optimal operating temperatures.”

Load-testing solutions for maximum uptime

To fulfill this need, the Crestchic team conducted a survey of the data centre site and specified a 255KW load bank. The agreed rental package included a full Risk Assessment and Method Statement, dedicated transport for delivery, as well as fully trained installers and engineers to set up the load banks, perform final electrical connections in line with local regulations, and offer customer training and support. 

Using the load banks, the customer was able to validate the capacity of the cooling infrastructure, helping to prevent overheating issues that could lead to equipment failures and service disruptions. To find out more about Crestchic’s load testing solutions for the data center sector, including heat load testing, bus bar testing, generator testing and more, please download our data centre guide. 

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Efficiency is key: During the two-day conference, there was a lot of talk about efficiency in the data center sector. Many of our customers and prospects want to do testing promptly, making rental turnaround a key driver in selecting a provider. 

Labour shortages are an ongoing issue: Many data centres do not have the right labour pool to execute daily operations, let alone testing. This means that having access to trained technicians is an important factor when selecting a solution provider. 

Heat load testing is as important as genset testing: Most facilities managers and data center operators are aware of the need to test generators to keep backup power running efficiently. Speaking to customers and prospects, it would seem that there is an increased interest in using load bank solutions to heat load test server halls at the commissioning phase. 

Backup power lead times are long: In some cases, lead times for generators are up to two years. This means that data centers must invest in backup power solutions early in the planning and commissioning phase. To avoid this, some data centers rent generators. While this is a temporary solution, rental generators are often older, making it vital that load testing is completed frequently. 

De-risking data centers is high on the agenda: From my many conversations with customers, I heard them speak about de-risking their data center. Some load banked their data centers monthly; others only did it when their generator services company scheduled it. The overwhelming sentiment was that they want to test more often and efficiently to avoid the risk of outages. 

To find out more about how Crestchic can help to address these issues, speak to our rental team here. 

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Due to advancements in microprocessor technology, components for the site’s Eclipse 3.1 load bank control system were becoming obsolete, leaving the campus vulnerable to power testing failures. To prevent this, and to improve overall testing performance, Crestchic upgraded the control system to its latest NOVA hardware, alongside the installation of a new emergency stop system, fibre connectivity, and a rugged LC80 tablet control.

Steven Jewell, Service Engineer for Crestchic, comments on the essential upgrades:

“This data centre offers 11,700 m² of server space and has a maximum IT load of 17.1 MW. That amount of power needs a substantial and well-tested backup solution to prevent financially crippling downtime.

“The loadbank at this site is used to test the backup power system in a way that is robust and proactive to mitigate the risk of failure. When the customer learned that their control system was becoming harder to maintain and repair due to legacy components, they scheduled an upgrade to the latest controller technology without hesitation.”

Installing the NOVA controller technology

Not only does the NOVA controller technology meet the latest microprocessor technology standards, it also enables additional operational and performance benefits such as the installation of fibre connectivity and the introduction of the LC80 tablet.

A large operating interface display

As part of this data centre’s NOVA upgrade, the team opted for a rugged IP65, LC80 tablet that offers a large operating interface display. From here, data and frequency response curves can be clearly observed and engineers can access a range of advanced features such as a graphical display of transient performance at load change, recording of instrumentation data, and storage of multi-user-defined load-profiles.

Fast, interference-free fibre-optic communications

During these upgrades, the Crestchic team installed high-speed fibre optic cables back to the data centre’s building management system (BMS), delivering far faster data transfer capabilities.

With long distances of up to 500m possible without the need for signal boosting, and total immunity to electrical noise interference, Crestchic’s fibre control is a natural choice for demanding data centre environments.

Steven concludes: “With the upgrade works to the load bank control system complete, the data centre operator can now continue with its regular generator testing, safe in the knowledge that they have state-of-the-art technology at their fingertips.

“Crestchic is proactive in recommending system upgrades to its customers whenever technology becomes obsolete, or components become hard to source. This way, we can prevent downtime and help keep our customer’s sites working smoothly.”

Backup power testing best practice for data centres

A robust and proactive approach to the maintenance and testing of the power system is crucial to alleviate the chance of failure. However – it is vital that this doesn’t become a tick-box exercise – implementing a testing regime which validates the reliability and performance of backup power must be done under the types of loads found in real operational conditions. With this in mind, what would be considered best practice for testing a backup power system?

Ideally, all generators should be tested annually for real-world emergency conditions using a resistive-reactive 0.8pf load bank. Best practice dictates that all gensets (where there are multiple) should be run in a synchronised state, ideally for 8 hours but for a minimum of 3.

Where a reactive-only load bank is used, testing should be increased to 2-4 times per year at 3 hours per test. In carrying out this testing and maintenance, fuel, exhaust and cooling systems and alternator insulation resistance are effectively tested and system issues can be uncovered in a safe, controlled manner without the cost of major failure or unplanned downtime.

For more information, contact Crestchic on +44 (0)1283 531 645 or complete the online contact form.

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Taking place on May 10 and 11, 2023, the event will provide an opportunity for Crestchic to showcase their latest range of products, including the following:

• Resistive-only load banks typically up to 300kW for heat load testing
• Rack mounted server emulators for heat load- testing
• Capacitive load banks to test with the leading power factor often associated with servers
• Large multi-megawatt, medium voltage load bank packages to test and synchronise multigenset systems on a common bus with a lagging power factor
• DC load banks to test UPS systems for close battery analysis and discharge performance
• Resistive-reactive load banks for testing the whole system operation in an emergency change-over scenario

With over 30 years of experience in the load testing industry, Crestchic has built a strong reputation for providing high-quality and reliable load testing solutions across the world. Their range of load testing equipment has been used across various industries, including data centres, telecommunications, and military sectors.

Speaking on the upcoming event, Heiko Thoene-Schaub, Sales Manager at Crestchic Loadbanks’ GmbH, said, “We are delighted to participate in the Data Centre World Frankfurt 2023 event. This is an excellent opportunity for us to showcase our latest range of load testing solutions to industry professionals and highlight how load bank testing can help to guarantee uptime in the event of a power outage.”

With over 10,000 attendees expected to attend the event, Crestchic aims to connect with industry leaders and showcase their commitment to providing reliable load testing solutions for businesses across the world. Representatives from Crestchic will be available to answer questions on stand E070. 

More information about Data Centre World Frankfurt can be found at https://www.datacentreworld.de/ 

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Generator testing specialists

Despite being a relatively new business, the owner of Veteran Power Solutions, John Hill, has amassed more than 20 years of experience in generator maintenance. The company offers generator and transfer switch maintenance across a range of makes and models, including Generac, Cat, Cummins, Kohler, Taylor, and Briggs and Stratton. A key part of the servicing offered by the company is generator testing, which uses a load bank to apply a dummy load in order to fully test the integrity of the generator and ensure it will work in the event of a power failure. The company also offers regular load testing regimes to ensure that backup power systems meet NFPA-110 standards.

Why load banks are key to success

John explains, “Load bank testing is a key part of any generator maintenance strategy – it is the only way to fully test how a generator will respond under a full load, including testing the fuel, engine, cooling and switchgear are working as they should. It is critical to my business that I have a supplier that can provide the load bank technology I need to test gensets quickly, reliably, and at a reasonable cost.”

To fulfill this need, Veteran Power Solutions turned to Crestchic. With over 40 years of experience in the supply of load banks and power testing equipment, Crestchic is a global business that has facilities across the US. The company has the expertise and capability to develop tailor-made testing solutions, from standard-size resistive and reactive load banks or custom-designed and built load banks of any size at any voltage and frequency.

Good customer service for all

Crucially, Crestchic offers the same level of service whether the company is a small first-time customer, or a major player in the data centre industry looking for a whole fleet.

John continues, “I went with Crestchic because they were easy to do business with. I’m a small, veteran-owned business, and I know that Crestchic deals with some of the big players, including hyperscale datacentres that require multiple units. I first reached out for a proposal to rent a 100KW load bank for a few months and was really impressed with their response time, cost savings, and the level of support they provided.”

Based out of Texas, the Crestchic team prides itself on providing excellent customer service and a fast turnaround. As load bank rental specialists, the team knows that the equipment is used to run mission-critical testing, often at short notice. The team has a fleet of load banks available for hire. Each unit undergoes full testing, maintenance, and cleaning when it is returned to the depot, ensuring that it is ready for quick shipping if the need arises.

John concludes, “As well as saving me money versus my previous supplier, the Crestchic team made sure my load bank was delivered quickly so I did not lose any business. I’ll be returning to Crestchic for any future load bank requirements and will recommend that others give them a call.”

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What is the LINDA project? 

Funded by the Federal Ministry for Economic Affairs and Energy, the project looks at how renewable energy plants could supply power to a local “island” grid in a decentralised way in the event of a power failure. The project – Local Island Grid Supply and Accelerated Grid Reconstruction with Decentralised Generation Plants in the Event of Large-scale Power Outages (or the more simple “LINDA” to those in the know) – seeks to explore, test and implement ways of making power generation systems use renewable energy sources for emergency power supplies. 

In 2018, phase one of the project – which involved partners from across academia and industry, including the Augsburg University of Applied Sciences, the Technical University of Munich, LEW Verteilnetz and LEW Wasserkraft, and KIMA automation – won the ISGAN Award (International Smart Grid Action Network) and the Bavarian Energy Prize.

The project included the development of a new emergency generator that successfully integrated renewable decentralised power generation systems, including photovoltaic systems, hydroelectric power plants and a biogas plant, into an independent island grid. In the event of a power failure, the system was designed to supply a local grid with electricity power from existing renewable energy sources. 

Emergency power – limitations of the current approach 

Historically, emergency power generators have been operated in such a way that power failures can result in a temporary lapse in supply while the generator kicks in. As well as causing momentary outages and fluctuations in supply, these backups are usually supplied by diesel generators. With the new approach, the system is designed to provide a continuous supply in the event of a power failure – using power from multiple decentralised systems and, crucially, favouring renewables as a backup power source. 

In pilots of the system, LINDA was able to guarantee the uninterrupted power supply of households in the test communities. This was done without costly retrofitting of the current systems, providing an important building block for the energy transition and improved security of supply.

LINDA 2.0 – automating backup power 

In the second phase of the project – LINDA 2.0 – the research team is developing a supply concept with battery storage and a diesel generator to provide an additional backup power supply. As well as providing a backup, the system is being designed to automatically balance the fluctuating power generation from decentralised systems and the energy load itself. As well as ensuring a stable and secure power supply without interruptions, the automation will enable the system to shift into emergency mode remotely, without the need for staff to be on site. 

Bespoke load bank solution helps to balance frequency 

In order to automate the system, AVS – a German blackout management specialist that provides generators and grid stabilisation systems to a range of industries – worked with the team at Crestchic Loadbanks to create a fully automatic hybrid frequency-controlled power control for generators up to 1300 kVA. 

Dubbed AVS Greenomic, the solution allows the system to prioritise drawing on renewable energy (e.g. CHP, wind power or photovoltaic systems) in order to provide backup power in a blackout scenario – allowing Diesel fuel consumption to be reduced by up to 80%. The load bank itself provides a stability of voltage and frequency when switching between different power sources, and maintains a constant 20% load on the Generator. Any oversupply of energy is also consumed in a controlled manner, helping to balance the power generation system and smooth out any frequency inbalances.

Mike Derbyshire, European Area Sales Manager at Crestchic, explains, “We’ve worked with AVS for a number of years, so were delighted to collaborate with them on a bespoke solution that would meet the requirements of the LINDA project. Our standard load banks and controllers were adapted to allow AVS to add their own control system, and we added additional fuse protection, an interface between the load bank and the Greenomic assembly and the power connections themselves – all of which enables the system to balance the frequency and ensure and reliable and stable supply. It’s a high-profile project and we’re pleased to have been able to use our technical experience to support and enable the project goals.” 

To find out more about the role of load banks in backup power systems, get in touch here: Contact Us.

For our German office, visit: Crestchic Germany.

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The global energy crisis is affecting the profitability and operational efficiency of businesses from all sectors, but for data centres and their inherently higher power consumption levels, the impacts are polarised.

For the data centre market to achieve its projected growth trajectory, it must continue to adopt power-intensive next-generation IT technologies. And, it must do that in the face of an unstable grid, potential planned blackouts and suggested power rationing. That means rigorous investment in backup power and generator maintenance, at a time when energy bills are consuming investable profit.

Paul Brickman, Commercial Director, for Crestchic Loadbanks, explores the often-overlooked necessity of load bank testing in securing data centre power in an energy crisis.

Hiked power prices as a result of Russia’s fuel sanctions, and the threat of planned blackouts or power rationing to better manage an unstable grid, are forcing data centres to redistribute investment away from key business functions like training and recruitment, and towards improving energy efficiency and securing power resilience.

The current geopolitical challenges and their far-reaching implications are recognised in the 2023 Uptime Institute Report – Five Data Center Predictions for 2023 – in which the authors acknowledge that the Russian fuel sanctions, along with technological challenges “will make the planning of data centre development and operation more difficult.”

Powering next-generation data centres

According to the Uptime Institute, IT hardware has been fairly standard in terms of its draw on mainstream server capacity for a few decades now, creating technical stability and relatively constant power and cooling requirement.

This has enabled data centre designers to accommodate several IT refreshes without major upgrades to server technology and the associated hike in power consumption that would come with it. Essentially offering the latest technologies, without an increase in energy requirement.

This grace period is now over. Power requirements for next-generation IT hardware are far higher, rack power density is increasing, and “hotter” processors are putting pressure on the performance parameters of existing infrastructure.

This rapid rise in IT power density means server power consumption is on a steep climb, creating a need for more power, at a time when the grid is unstable, and energy prices are at their highest in decades.

Extreme-density racks are now commonplace in technical computing too, as well as high-performance analytics and artificial intelligence training. If data centre operators want to successfully penetrate these niche markets, they will need to foot the heightened energy bill and maintain a robust power resilience regime until the situation stabilises.

Data centres take action

Demand for next-generation IT technologies will not slow. As a result, data centres are forging ahead with the essential upgrades required to UPS, batteries, switchgear and generators to accommodate increased power density.

This is a risk. With an unstable grid and planned blackouts still on the agenda for many governments, upgrades will need to be bolstered with a watertight energy resilience plan to protect against power fluctuations and total outages.

The importance of a power resilience strategy in an energy crisis

According to research from the Ponemon Institute, in its third “Cost of Data Center Outages” report, the total cost of downtime has continued to rise over the last six years – rising a staggering 38% to $740,357 per incident. That equates to nearly $9,000 per minute – a figure that many data centres will have to swallow if the grid becomes too unstable to sustain their increasing power consumption.

Many data centres will already have a robust generator testing and maintenance regime in place, but the use of load banks is often overlooked, especially when budgets are stretched. At a time when power outages are more likely, load bank testing should play an integral role in a data centre’s energy resilience strategy and it would be prudent to evaluate your strategy in line with the current landscape to ensure it is robust enough. With this in mind, what would be considered best practice for testing a backup power system?

Best practice load bank testing in times of crisis

Ideally, as a minimum all generators should be tested annually for real-world emergency conditions using a resistive-reactive 0.8pf load bank. Best practice dictates that all gensets (where there are multiple) should be run in a synchronised state, ideally for 8 hours but for a minimum of 3.

Where a resistive-only load bank is used, testing should be increased to 2-4 times per year at 3 hours per test. In carrying out this testing and maintenance, fuel, exhaust and cooling systems are effectively tested and system issues can be uncovered in a safe, controlled manner without the cost of major failure or unplanned downtime. The alternator is not thoroughly tested though, with a resistive-only test and therefore a resistive-reactive test would always be recommended.

It may be advisable to test more frequently during times of crisis for added peace of mind.

Why is resistive-reactive the best approach? 

Capable of testing both resistive and reactive loads, this type of load bank provides a much clearer picture of how well an entire system will withstand changes in load patterns while experiencing the level of power that would typically be encountered under real operational conditions.

Furthermore, the inductive loads used in resistive/reactive testing will show how a system will cope with a voltage drop in its regulator. This is particularly important in any application which requires generators to be operated in parallel (prevalent in larger business infrastructures such as hyperscale data centres) where a problem with one generator could prevent other system generators from working properly or even failing to operate entirely. This is something which is simply not achievable with resistive-only testing.

Navigating growth when power is scarce

No matter the geopolitical challenges and the effect it is having on power availability, data centres have no choice but to grow.

Demand will not cease, and power-intensive next-generation technologies are unavoidable. Ensuring power resilience via a watertight backup power supply and a robust testing and maintenance regime will enable data centre designers and operators to grow, safe in the knowledge that, should planned blackouts, power rationing or grid fluctuations happen, the power will always remain on.

For support with improving your load bank testing regime, search Crestchic Load Banks online.

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