Project Details
Client: Confidential
Location: Munich, Germany
Solution provided: 500kW Liquid-Cooled Load Bank & In-Rack Hybrid Load Bank Module
Project type: Data Centre Retrofit
Case Study: Advanced Load Bank Solutions for Retrofit Data Centre – Munich, Germany
Overview
Our client, a major global technology company (identity confidential), embarked on a major retrofit project at their data centre facility in Munich, Germany. The objective was to transition from traditional air-cooled data halls to cutting-edge on-chip liquid cooling. This upgrade required equally advanced infrastructure testing tools that could match the new cooling strategy’s demands.
We were engaged to supply tailored load testing solutions that would support and validate the chilled water infrastructure, simulate real-world IT load profiles, and ensure the upgraded facility could operate reliably at full design capacity.
Case Study Details
Our Solution
To meet the project’s complex requirements, we provided:
- A 500kW Liquid-Cooled Load Bank
Designed specifically to integrate with chilled water systems, this high-capacity unit enabled precise thermal load emulation under varying conditions. It allowed the chilled loop to be tested at full design capacity, ensuring optimal performance and system reliability under realistic thermal stress. - In-Rack Hybrid Load Bank Module
Installed directly into the designed position of final racks, the hybrid module was engineered to replicate the actual heat and airflow profile of modern servers. It was capable of mimicking real-world rack-level output, combining both air and liquid-cooled heat rejection modes to validate the effectiveness of chip-level cooling.
Project Highlights
- Realistic Load Emulation:
Our equipment replicated dynamic IT workloads, offering a close approximation of power and thermal profiles expected during live operation. - Seamless Integration:
Both the liquid-cooled and hybrid modules were fully compatible with the facility’s upgraded chilled infrastructure, offering plug-and-play integration with minimal disruption. - Validated Performance:
The testing process confirmed the data centre’s chilled water systems could handle full load operation, with measured thermal rejection and coolant flow performance aligned with the design specifications.
Outcome
The successful deployment and operation of our load banks enabled the client to confidently commission their next-generation cooling infrastructure. The system’s performance under emulated full-load conditions validated the effectiveness of the on-chip cooling strategy and helped de-risk the transition from air-cooled systems.
This project highlights our capability to engineer and deliver high-performance load bank solutions tailored for modern, energy-efficient data centre environments
