Press release

High current testing with AC source by ETS

When it comes to the new development of products in the field of switchgear, ABB STOTZ-KONTAKT
use an AC power source by ET System electronic that can deliver very high currents in the frequency
range from 50 Hz to 400 Hz.

Auditing the laboratory also requires appropriate power sources for the standards-compliant testing of such products as line safety
switches and overcurrent cut-outs. The efficiency
and accuracy of the current sources play an important role here because high currents are required in part to check the behaviour of
overcurrent relays, line safety and motor proAltluheim, May 2014

tection switches, thermal and electronic overload

The company ABB STOTZ-KONTAKT GmbH from

relays or small contactors at different loads.

Heidelberg develop, manufacture and sell products for electrical equipment and automation

Special device with flexible frequency range

of buildings, machinery and equipment. The spe-

Since 2013, ABB STOTZ-KONTAKT have been

cialist for switching and control technology of-

using a single-phase AC power source type EAC-

fers customers from industry and trade in

S 9000 by ET System electronic for these safety-

addition to installation equipment and building

related testing tasks. The power supply specialist

systems also primarily encapsulated and non-en-

develops and manufactures AC and DC sources,

capsulated switches, circuit breakers/power swit-

laboratory power supplies, inverters, and elect-

ches and NH fuse load disconnectors. Twelve

ronic loads - and in addition to their standard

inspectors working in the company's own deve-

product range, also mainly offers customer-spe-

lopment laboratory prepare new products for

cific modifications used to fulfil some very spe-

the start of production and demonstrate to re-

cial requirements.

gulatory authorities compliance with statutory

provisions as well as product compliance with va-

ABB STOTZ-KONTAKT had such requirements

rious international standards such as IEC, CSA, UL

when searching for a suitable AC source. The de-

and CCC.

vice was to have not only an accuracy of 0.2%

but should emit currents up to 2000 amps and

"Our development laboratory is allowed to per-

also mainly cover the frequency range between

form these tests themselves, because we are UL-

50 Hz and 400 Hz.

accredited and thus meet the requisites for

checking and certifying compliance with other
standards", explains Simon Stephan from the laboratory for switching technology. "To this purpose, our laboratory is re-audited annually,
which involves examining and checking testing
services and processes as well as the technical
equipment".

Hauptstrae 119 - 121

D-68804 Altluheim

phone
fax

+49-6205-3948-0
+49-6205-37560

e-mail
web

info@et-system.de
www.et-system.de

Press release
The 400 Hz technology is becoming increasingly

experiments. These experiments, however, revealed

important, because compared to the established

that such an E-I transformer was unsuitable for

50 Hz variant, the same current can be transferred

the ABB requirements.

with smaller converters or transformers and cable

cross-sections can be smaller while maintaining

The developers thus decided to commission a

the same power transmission. The thereby

second transformer based on a toroidal core

achievable saving in weight and space plays

because toroidal cores are generally less prone

a role primarily in aircraft construction. The

to saturation problems at higher frequencies

advantages of higher-frequency energy trans-

than E-I cores. ET System electronic was able to

mission are, however, also increasingly recognised

find a transformer manufacturer daring enough

in other areas, mainly in the rail technology and

to build a toroidal transformer for the frequency

the shipbuilding industry.

range of 50 Hz to 400 Hz. This was also a completely

new challenge for this manufacturer because

This is why overcurrent relays or line safety and

transformers are built for a fixed frequency of 50

motor protection switches in 400 Hz technology

Hz or 400 Hz, and the commonly used calculation

will be increasingly in demand - a clear reason for

software is tailored to one of these two frequencies

ABB STOTZ-KONTAKT to expand their product

as well. Overcoming the problems associated

range in this segment further and to acquire a

with the calculations and manufacturing of the

suitable AC power source for the corresponding

variable frequency transformer was a tour de

tests and inspections.

force in itself but six months later, the new toroidal

transformer, a colossus with a weight of about

Special transformer enables high currents

112 kilogrammes, was delivered to ET System

The EAC-S 9000 offers a current adjustable over

electronic.

a wide range, from minimal power with 5 A at

160 V up to the full 2000 A at 9 V. These high

Detailed tests confirmed that the new transformer

currents, however, are not generated directly in

fulfilled the requirements, although only within

the EAC-S 9000, because its maximum power is

the boundaries set by physics: For example, only

60 amps. The emitted currents are fed to a special

800 A can be drawn with a frequency of 400 Hz

transformer first, which then converts the current

because here too the toroidal core is limited by

to a different voltage and power level and in a

the boundaries of magnetic saturation and cannot

second step then allows drawing the desired

transfer any higher currents.

high currents with corresponding low voltages

via different tappings.

Universal options for the test bench

The new AC source is used mainly in the context

And it is with this special transformer that ET

of new developments, but also serves to carry out

System electronic have ventured into uncharted

tests for the production and other departments.

technical terrain because hands-on experience

Numerous tests can be carried out with the test

with variable frequencies was really not available.

bench of the development laboratory. For example,

Gripped by pure engineering ambition, the

various currents are applied to the overcurrent

company here took the initiative even before the

relays or line safety and motor protection switches

order was placed and commissioned a specialised

during thermal tests lasting hours, while thermal

transformer manufacturer to produce a traditional

sensor measuring systems log the temperature

E-I transformer, which they used for initial

progression on the housing.

Hauptstrae 119 - 121

D-68804 Altluheim

phone
fax

+49-6205-3948-0
+49-6205-37560

e-mail
web

info@et-system.de
www.et-system.de

Press release
Duration tests, however, consist of applying the

device is very accurate and reliable, and the entire

rated power to switches for several days to observe

technology including transformer and high-quality

their behaviour at the trigger threshold. After

transducer are fitted in a compact enclosure".

applying the rated current, the test current is

usually also increased to the trigger current at

Since collaboration with ET System electronic

which the device depending on model or design

also leaves no wish unfulfilled, Simon Stephan

must trip within a defined period of time.

and his colleagues have recommended ET System

electronic not only for other locations within the

The AC source by ET System electronic by now

group, but already have also ordered a second

has been in constant use for a year and the testers

power supply: A three-phase AC power source

are more than satisfied with the device.

with 50 Hz, which can emit currents from 90 mA

to 1000 A with an accuracy of 0.2%. New technical

"Previously, we were able to experiment only up

challenges are associated with this tremendous

to maximal 100 A when using 400 Hz and the

bandwidth - but all those involved have little

appropriate transmission ratios for the transformers

doubt that the developers of ET System electronic

had to be determined through testing", summarises

will overcome these problems as well and present

Simon Stephan enthusiastically. "With our power

another masterpiece of engineering in due time.

supply by ET System electronic, we now have an

altogether perfect solution for these tasks". The

Image above: The test bench with motor overload switches and
miniature circuit breakers
Image on the left: Up to 2000 amperes: The special version of the
EAC-S9000

Hauptstrae 119 - 121

D-68804 Altluheim

phone
fax

+49-6205-3948-0
+49-6205-37560

e-mail
web

info@et-system.de
www.et-system.de

Press release
About the company
ET System electronic develop and manufacture power supplies, AC and DC sources, laboratory power
supplies, inverters and electronic loads, which are used in numerous industrial applications worldwide. In
addition to their broad standard program, ET System also mainly offer customer-specific modifications
of their devices and can meet virtually any requirement no matter how unusual with very small
quantities and even individual units.
ET System electronic primarily offers its devices in versions individually modified according to customer
specifications, enabling us to fulfill even the most unusual requirements in extremely small order
quantities, even as one-off items.

Hauptstrae 119 - 121

D-68804 Altluheim

phone
fax

+49-6205-3948-0
+49-6205-37560

e-mail
web

info@et-system.de
www.et-system.de