firstcase
//Case · 2023 · Netherlands

New busbar tested with a 1 MW loadbank

First Case positioned and connected a 1 MW loadbank to a newly installed busbar system in a data hall. Both feeds were loaded separately, ramped up in steps with five compact units under a single remote control.

//Netherlands
New busbar tested with a 1 MW loadbank

New busbar system tested with a 1 MW loadbank, both feeds loaded separately and in steps.

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//The brief & what we delivered

Prove a new busbar system under full load, feed by feed.

A freshly installed busbar system must be proven before it carries production. First Case positioned five 200 kW loadbanks under a single remote control and connected them, so both feeds of the data hall could be loaded separately with 1 MW. The manufacturer ran the test itself. The load was ramped up in steps, not all at once, so the behaviour stayed visible at each level. The work took place in an active environment, on weekdays within fixed windows.

The constraints: as few loadbanks and as little cabling as possible, compact units under the 600 kg floor-loading limit and cable sets up to 75 m to reach the setup. The work ran five days with a team of two.

Region
Netherlands
Client
Confidential
Type
Colocation
Load
1 MW per feed
Setup
5× 200 kW, 1 remote
Service
Loadbank Assist
The full work package05 components · one point of contact

Setup

Five 200 kW loadbanks are set up and connected to the feed with cable sets up to 75 m.

Stepped load

The load is ramped up in small steps, so the behaviour stays visible at each level.

Both feeds

Both feeds of the hall are loaded separately up to 1 MW, one at a time.

Control

The five compact units, under the 600 kg floor limit, run under a single remote control.

Teardown

After the test, units and cabling are removed and the hall handed back clean.

FEED5× 200 kW · 1 MW1 REMOTECABLE SETS ≤75 m · UNITS <600 kgFIRST CASEFC-2305-01LOADBANK ASSIST01 · SETUPSCALEISO

Five units set up, one remote, minimal cabling

Five 200 kW loadbanks are set up in the hall, 1 MW combined. With cable sets of 25 and 50 metres, up to a maximum of 75 metres, they are connected to the busbar feed. The setup keeps the number of units and the cabling small, with compact units under the 600 kg floor-loading limit.

01Five 200 kW units, 1 MW together
02Cable sets of 25 and 50 m, up to 75 m
03Compact units under the 600 kg floor limit

Both feeds loaded separately to 1 MW, in steps

The busbar has a feed on both sides of the hall; each side is tested separately, one at a time. The load is ramped up in small steps to 1 MW, not all at once, so the system can be assessed at each level. Five units run in sync under a single remote control.

011 MW per feed, tested one at a time
02Stepped ramp-up, not 300 kW at once
03Five units in sync under a single remote control
1 MWSTEPPED LOADREMOTEBOTH FEEDS · 1 MW PER FEEDFIRST CASEFC-2305-02LOADBANK ASSIST02 · LOADINGSCALEISO
ASSESSED1 MWPER FEED CONFIRMEDHALL HANDED BACKASSESSMENT & TEARDOWNBEHAVIOUR PER LOAD STEP · FULL 1 MWFIRST CASEFC-2305-03LOADBANK ASSIST03 · ASSESSMENTSCALEISO

Behaviour under load assessed, hall handed back

At each load step, the behaviour of the busbar system is assessed, so it is clear that the feed handles the full 1 MW. After the test, the units and cabling are removed. The hall is handed back clean, ready to go into production.

01Behaviour assessed per load step
02Full 1 MW per feed confirmed
03Units and cabling removed, hall handed back
//The lead time

Five days, from setup to handover

A fixed flow: set up, connect, switch over, tear down.

View Load bank assist →
01Setup

Units connected

Five 200 kW loadbanks set up and connected to the feed.

02Feed 1

First side loaded

First feed ramped to 1 MW in steps and assessed.

03Feed 2

Second side loaded

Second feed loaded to 1 MW in the same way.

04Teardown

Hall handed back

Units and cabling removed, hall handed back clean.

055 days

Lead time

Setup, test and teardown within five days. Our crew: two engineers.

//handover

We set up five 200 kW units under one remote control, connected with cable sets up to 75 m: 1 MW per feed. After five days we removed the units and cabling and handed the hall back clean.

//cases

Other cases

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//The brief
Prove a new busbar system under full load, feed by feed.

New busbar system tested with 1 MW per feed, both sides separately and in steps. Five units, one remote control.

Compact units under the 600 kg floor limit, cable sets up to 75 m, five days with two engineers.

Region
Netherlands
Client
Confidential
Type
Colocation
Load
1 MW per feed
Setup
5× 200 kW, 1 remote
Service
Loadbank Assist

The full work package

One team sets up, connects, switches over and clears up.

Setup
5× 200 kW · ≤75 m
+–

Five 200 kW loadbanks are set up and connected to the feed with cable sets up to 75 m.

Stepped load
Not all at once
+–

The load is ramped up in small steps, so the behaviour stays visible at each level.

Both feeds
1 MW per side
+–

Both feeds of the hall are loaded separately up to 1 MW, one at a time.

Control
1 remote · <600 kg
+–

The five compact units, under the 600 kg floor limit, run under a single remote control.

Teardown
Hall handed back
+–

After the test, units and cabling are removed and the hall handed back clean.

Five units set up, one remote, minimal cabling

Five 200 kW loadbanks are set up in the hall, 1 MW combined. With cable sets of 25 and 50 metres, up to a maximum of 75 metres, they are connected to the busbar feed. The setup keeps the number of units and the cabling small, with compact units under the 600 kg floor-loading limit.

FEED5× 200 kW · 1 MW1 REMOTECABLE SETS ≤75 m · UNITS <600 kgFIRST CASEFC-2305-01LOADBANK ASSIST01 · SETUPSCALEISO
01Five 200 kW units, 1 MW together
02Cable sets of 25 and 50 m, up to 75 m
03Compact units under the 600 kg floor limit
Both feeds loaded separately to 1 MW, in steps

The busbar has a feed on both sides of the hall; each side is tested separately, one at a time. The load is ramped up in small steps to 1 MW, not all at once, so the system can be assessed at each level. Five units run in sync under a single remote control.

1 MWSTEPPED LOADREMOTEBOTH FEEDS · 1 MW PER FEEDFIRST CASEFC-2305-02LOADBANK ASSIST02 · LOADINGSCALEISO
011 MW per feed, tested one at a time
02Stepped ramp-up, not 300 kW at once
03Five units in sync under a single remote control
Behaviour under load assessed, hall handed back

At each load step, the behaviour of the busbar system is assessed, so it is clear that the feed handles the full 1 MW. After the test, the units and cabling are removed. The hall is handed back clean, ready to go into production.

ASSESSED1 MWPER FEED CONFIRMEDHALL HANDED BACKASSESSMENT & TEARDOWNBEHAVIOUR PER LOAD STEP · FULL 1 MWFIRST CASEFC-2305-03LOADBANK ASSIST03 · ASSESSMENTSCALEISO
01Behaviour assessed per load step
02Full 1 MW per feed confirmed
03Units and cabling removed, hall handed back
//The lead time
Five days, from setup to handover
Setup
Units connected

Five 200 kW loadbanks set up and connected to the feed.

Feed 1
First side loaded

First feed ramped to 1 MW in steps and assessed.

Feed 2
Second side loaded

Second feed loaded to 1 MW in the same way.

Teardown
Hall handed back

Units and cabling removed, hall handed back clean.

5 days
Lead time

Setup, test and teardown within five days. Our crew: two engineers.

//handover

We set up five 200 kW units under one remote control, connected with cable sets up to 75 m: 1 MW per feed. After five days we removed the units and cabling and handed the hall back clean.

//cases
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