Best Electronic DC Loads for 6.5kW 400V Applications—Recommendations and Experiences

The discussion addresses the need for a high-power variable resistive load capable of handling approximately 6.5 kW to 10 kW at around 400 V DC for distorted voltage testing and THD adjustment on the rectified side of a bridge. Several solutions are proposed, including using multiple high-wattage resistors such as Ohmite 225 W resistors with forced air cooling, TE Connectivity 2500 W resistors requiring fewer units, and Huntington FSE1000-1.0 1000 W resistors. Commercial HVAC duct heaters and finned strip heaters from Hotwatt are suggested as cost-effective, high-power resistive loads that can be rewired for DC use with adequate forced air cooling. Light bulbs and heating elements in ceramic sockets are also mentioned for low inductance loads, though with caution regarding inrush currents. For more advanced and adjustable electronic loads capable of AC testing with power factor and phase angle control, brands like Chroma and California Instruments are referenced, though these are significantly more expensive. Amrel DC loads are noted for DC applications but may require a bridge for AC testing. WATLOW is mentioned as a manufacturer of air-cooled and water-cooled loads. The discussion highlights considerations such as derating, thermal management, safety features, and cost comparisons between building resistor banks and renting commercial electronic loads.
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