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current Newsletter of E-T-A ElectroTechnical Applications Pty Ltd Power times three: Economy – Compact – High Power Smokin’ hot Power distribution system SVS09 Sailing with Mustang Marine E-T-A October 2009 Content Introduction by Andrew Skaltsounis Managing Director, E-T-A ElectroTechnical Applications Pty Ltd 4/5 Smokin’ hot – power distribution system SVS09 2 Smokin’ hot – power distribution system SVS09 4/5 Power times three: Economy – Compact – High 6/7 URBAN Maschinenbau relies on selective protection 8 Personnel 9 FAQ – Frequently Asked Questions 10 6/7 Power times three: Economy – Compact – High 10 Examples of practical expertise BonsaiCabinet - the optimised control cabinet concept made in Japan 11 E-T-A solutions for a wealth of products 12/13 Australian Made, World‘s Best 14 E-T-A sailing with Mustang Marine 15 Photo Frontpage: The -series features high availability, cost-effective termination and serviceability. See pages 6/7 FAQ – Frequently Asked Questions All you ever wanted to know about E-T-A products Current: Newsletter of E-T-A ElectroTechnical Applications Pty Ltd 14 Australian Made, World‘s Best 2 Editor: E-T-A ElectroTechnical Applications Pty Ltd Unit 14/4 Birmingham Ave Villawood NSW 2163 Phone (02) 9726 3011 . Fax (02) 9726 3021 E-Mail: [email protected] www.e-t-a.com.au Layout: E-T-A Communication Department Editorial You know E-T-A as a supplier of high-quality components, as “the circuit breaker supplier” par excellence, as the world market leader and sole manufacturer of circuit breakers who is able to supply all working principles from a single source. But do you also know E-T-A as a competent supplier of complex system solutions? System solutions in the sense of sophisticated combinations of protective components, termination technology, power distribution and mounting technology? These solutions will be made specifically for you. The result is a powerful comprehensive solution, tailored to the needs of your application, featuring the usual superior E-T-A quality. Systematic Solutions We are prepared to plan and design the entire system for you. This will help you to save valuable internal resources. At the same time you will be able to benefit by our expert know-how with regard to professional design of mounting, termination, installation and cable management of power distribution systems. You can count on that. E-T-A system solutions are conceived by experts working in a flexible and experienced team, designing tailor-made solutions for individual items as well as for higher volumes. The systems are built up, monitored and 100 % tested in our in-house production. Our application specialists can assure you that our systems are optimally suited to practical requirements and at the same time offer maximum reliability. If you are interested in realising a complex protection solution together with E-T-A, please do not hesitate to contact us. We are looking forward to co-operating with you. Andrew Skaltsounis Managing Director E-T-A ElectroTechnical Applications Pty Lts 3 Products “ Smokin’ hot – power distribution system SVS09 Power distribution to your taste: the hot type SVS09 offers overcurrent protection and failure signalisation all in one unit! ” Highly automated and all-time availability – these are properties by means of which modern control technology in power plants ensures our energy supply. Reliably protected connection of thousands of sensors/actuators is the firm basis of a consistent failure communication system reaching the control room. The power distribution system SVS09 combines both overcurrent protection and failure signalling with cost-effective and time-saving mounting and wiring. “Masters” and “slaves” – peacefully united The complex and manifold requirements of measuring and controlling in a power plant with its thousands of transducers and valves request a systematic and reliable integration of the field level into the overall control system of the entire plant. The SVS09 allows cascading several 10way distributors to the master-slaveprinciple and is therefore ideally suited to comprehensive protection concepts where a great number of I/O units and transducers can be involved and protected against overcurrent. The cascadable type SVS09 offers distribution, protection and signalling – optimally suited to control technologies in power plants. 4 The master-slave-principle offers the possibility - in addition to single alarms to combine group signalling for logical functional groups on the field level. At a glance – E-T-A power distribution system SVS09 G cascadable 10-way distribution system for DC 24 V levels with 1 master and up to 5 slaves: up to 60 protection slots in one cascade G track-mountable base module, space-saving design G reduced wiring time for a huge number of circuit breakers for sensors/actuators G selective load disconnection of individual ways in the event of short circuit or overcurrent G single signalisation for individual failures with manual reset in the control cabinet G group signalisation for the entire circuit breaker cascade with external acknowledgment and re-activation directly from the control room Cascaded alarm – the third factor The integral signalling concept generates a single signal for each circuit which was interrupted due to short circuit or overload. At the same time a group signal is generated for the entire SVS09 cascade which is indicated locally in the control cabinet or externally in the control room where it can be acknowledged. The group signalling function will immediately be again ready for use. The single signal, however, has to be reset manually in the field after remedy of the failure and resetting the circuit breaker in the control cabinet. The compact SVS09 is track-mountable and with a width of only 140mm it accommodates ten circuit breakers of the thermal-magnetic series 3600/3900 and 2210-S2 as well as the electronic series ESS20 and ESX10 with integral current limitation. These ideally supplement DC24V circuits with switch-mode power supplies. 5 Coverstory Power times three: Economy – Compact – High The E-T-A family is a product series for power distribution systems featuring a cost-effective, easy-to-mount design, high serviceability and availability (redundancies). The Economy is a highly modular system for redundant or non-redundant system configurations. Therefore industrialised standard products can be combined individually, customerspecifically and cost-effectively. For this purpose E-T-A has adopted an extra platform (19” racks which can also be mounted in ETSI format) into their product range. On this platform you can choose a number of power distribution systems or rails following various criteria such as protection against brush contact, cable management (bending radii of cables, plugand-play cable mounting, cable mounting with spring-loaded cage clamps), total current load or single current load. Customer-specific High Power-D-Box The Compact has particularly been designed for applications where height is an issue. Minimum space requirement with 1U (44 mm) helps to fulfil many a desire with regard to footprint. User friendliness is still a benefit of this power distribution system. Customerspecific system solutions for front or rear-side termination allow technically impeccable cable routing even in extremely limited space. The High meets any customer requirement regarding the requested current ratings. It provides you with a versatile power distribution solution which can be realised and implemented on site without causing downtimes or stoppages. All three models have a stable front plate with a high-value attractive appearance as well as captive mounting screws for ease of installation and de-installation. The use of printed-circuit-board technology allows high currents (2 x 120 A or 240 A total current in redundant version) and the E-T-A high performance circuit breakers or “Mini-E-T-As” work a real space miracle. Customer-specific Economy Power-D-Box The various Power-D-Boxes offer suitable power distribution and protection solutions for almost every application in telecommunications. 6 At a glance – Economy G Installation height (2U) only 88 mm, made of aluminium G stable aluminium front plate, attractive anodised surface G hot-swappable, temperature-independent circuit breakers G suitable for E-T-A power distributions rails type X8340-S Compact G maximum power distribution – minimum space G full range of circuit breaker functionalities, latest-state-of-the-art G customer-specific adjustment to harsh conditions of fixed network or mobile radio operation High G total current max. 600 A in non-redundant or 2 x 600 A in redundant systems at only 88 mm height (2U) G single current max. 125 A – min. 0.05 A Interview URBAN Maschinenbau relies on selective protection Alfred Steiner is responsible forthe development of the electronics hardware of the vinyl welding machines and corner cleaning machines at URBAN. E-T-A benefits convinced URBAN Maschinenbau so that today all window welding machines are fitted with type ESX10. Current: How did you learn about E-T-A circuit breakers? Alfred Steiner: Protection of DC 24 V components became a topical issue with many of my colleagues when there was a changeover from transformer power supplies to switch-mode power supplies. We realised very quickly that standard blade fuses would no longer do the job. When I was at an exhibition, I got in touch with E-T-A. Current: Why did you change from transformer power supplies to switchmode power supplies? Alfred Steiner: We had a big problem with the considerable voltage fluctuations in some European networks. Transformer power supplies were not able to respond to those fluctuations during the day. This might have affected the reliability of our machines which would have been unacceptable for URBAN. As we are the market leader for window welding machines and the biggest manufacturer of these machines in the 8 world, it has been of paramount importance for us to find the best possible solution. Other benefits regarding design, efficiency and serviceability made change easy for us. Current: What are the advantages of using type ESX10? Alfred Steiner: The automation level of our plants is constantly rising. Therefore we were very interested in finding a solution allowing us to disconnect selectively also on the DC24V level and to signal via our PLC. Combining the switch-mode power supplies with the ESX10 allowed us to set a very high standard. The electronic circuit protector ESX10 provides URBAN Maschinenbau with satisfied customers. Alfred Steiner: We could say we don’t have any: ever since we put them into use for the first time, the electronic circuit protectors have been working without any problems, quite inconspicuously. From the moment when we hand over our system to the customer and check the system, they work according to spec and ensure that URBAN machines are working to the full satisfaction of our customers. Current: Many thanks for talking to us. In addition we were able to change cable cross sections because of the short circuit current limitation featured by the ESX10. Moreover, the slim design of the ESX10 – despite of integral auxiliary contacts – helped us to save space in the control cabinet. Current: What have been your experiences with the ESX10 so far? Alfred Steiner, Design Engineer at URBAN Maschinenbau Personnel Strategic Re-inforcements From left to right: Carl Horst Poensgen, Bernd Ellenberger, Dr. Joachim Scheel, Bernd Härtlein, Manfred Kiefl and Dr. Clifford Sell. In the context of the new company strategy the Executive Committee of the family-owned business E-T-A was increased from three to now six persons. New members of the Executive Committee are Dr Joachim Scheel, Bernd Härtlein and Manfred Kiefl. These three experienced managers will now support the Managing Directors Bernd Ellenberger, Carl Horst Poensgen and Dr Clifford Sell who lead the company in the third generation. Mr Härtlein, Mr Kiefl and Dr Scheel have been working for E-T-A for many years and have made a major contribution to the strategically new orientation of the company. Bernd Härtlein has been the Head of Sales and will soon be Head of Divisions. Manfred Kiefl is Head of the Finance and Accounting Department whereas Dr Joachim Scheel is Head of the Production Facilities. In close co-operation with the Executive Committee they have been responsible for essential functions in the company. Their responsibilities have been shaped internationally and have been focussed on customer orientation. Thus E-T-A, the world market leader in circuit breaker production, will manage to meet the ever increasing demands of the global markets, to meet the challenges of ever faster product cycles and of global competition becoming stiffer every day. 9 FAQ Frequently asked questions – all you ever wanted to know about E-T-A products Disconnection of the circuit is by means of a mechanical contact plus actuation. Disconnection by means of a semiconductor has not been covered yet by the standard. Chapter 9 of our comprehensive catalogue (“Technical Information”) advises which type is best suited to which application. It is our core competence to design and sell devices for the protection of electrical equipment. The relating expert knowledge covers a large part of electrical engineering and physics. Our specialists focus on all topics relating to protection of applications and will be pleased to answer your questions. Our FAQ pages are meant to intensify the dialogue between manufacturer and customers. They will deal with topics arising from practice and answer relevant questions as shortly as possible and as detailed as necessary. Do you have any questions you need answered? Send them to us – we are looking forward to hearing from you. E-T-A Elektrotechnische Apparate GmbH Keyword: Current FAQ Industriestraße 2-8, 90518 Altdorf E-Mail: [email protected] 10 “Terms and Abbreviations” Data sheets and product markings use various expert terms and abbreviations which may lead to problems when interpreted wrongly. Many of the terms are defined in the relevant circuit breaker standard DIN EN / IEC 60934. What different types of circuit breakers are there and what is the pertinent abbreviation? Basically we distinguish five different kinds of circuit breakers for equipment protection (CBEs). Thermal trip (TO) is required for protection of electrical loads against overload. Typical tripping element is a bimetal. Thermal-magnetic trip (TM) also includes a protection against short circuit by magnetic fast trip. Magnetic circuit breakers (MO) and hydraulicmagnetic circuit breakers (HM) provide largely temperature-insensitive trip curves including short circuit protection. If the current is detected and evaluated by means of an electronic control unit, we call this a electronic-hybrid product (EH). What rated values are marked on a circuit breaker and what is their meaning? Electrical applications restrictions of a circuit breaker are determined by characteristic current and voltage values. These are called rated values or nominal values and are maximum values up to which the performance indicated in the data sheet is guaranteed, i.e. the data sheet values are also valid if devices are operated at smaller rated values. Rated voltage of a CBE is the voltage referred to the short circuit rupture capacity ICN. This voltage is indicated on the product both for AC and DC. If circuit breakers are to be operated are very low voltages of only some volts, this has at any rate to be clarified with our specialists as there are also minimum limit values due to physical conditions. The rated current IN (nominal value) of a circuit breaker indicates the max. current value at which the circuit breaker can operate permanently at the ambient conditions given in the data sheet. However, the main contacts are not necessarily suitable for operation at very small currents in the mA range. In this case our experts will be pleased to support you. Examples of practical expertise by Satoshi Esumi, Managing Director of E-T-A Components K.K., Japan BonsaiCabinet the optimised control cabinet concept made in Japan Today design engineers of machinery and plants have to strictly observe the systematic optimisation of installation and wiring concepts to achieve a cost- and space-saving design of control cabinets. our new thermal-magnetic circuit breaker type 4220-T we were able to reduce the space requirements for the double pole circuit breakers by approximately 30 %, as the breakers have a width of only 12.5 mm and therefore require significantly less space than standard MCBs (branch protectors). Result of a downsizing project in Japan; the BonsaiCabinet (left) offers the same performance at 40 % less space requirement. Due to a significant price increase of electrical wiring and other automation components many designers of control cabinets work on an optimisation of their entire working methodology. The goal is to reduce all costs for components and production of the complete system. On the other hand there is also the possibility to minimise the control cabinet itself as smaller cabinets simply are less expensive – also with regard to costly production area. In order to create a new and holistic approach, we, E-T-A’s Japanese subsidiary, have broken new grounds entirely with a “downsizing project”. The co-operation between different manufacturers of automation devices, terminals, wiring technology, enclosures and cabinets allowed optimised electrical design for a consistent complete system. Thus we achieved the goal to increase packing density within the cabinet without affecting the performance of the complete system. This is only possible though if the used track-mountable components such as circuit breakers, power supplies, control units, MCBs, contactors etc. feature a miniaturised design. By using Further space was saved by using the power distribution system SVS04 for protection of the DC 24 V control circuits together with the plug-in type electronic circuit protectors ESX10. Additional installation of specific hinged cable conduits opening to the front with integral symmetrical rails allows running all electrical cables directly behind the devices. This helped to reduce the volume of the control cabinet by a total of 40 %. Instead of using a cabinet with a width of 850 mm and a height of 1400 mm our customer can now use a cabinet of 600 x 1200 mm: the new “BonsaiCabinet”. Satoshi Esumi, Managing Director of the E-T-A subsidiary in Japan 11 Applications Application: Production of solar cells E-T-A type: ESX10-T Application: Coffee grinders E-T-A type: 2-5700 Jonas & Redman Photovoltaics Production Solution GmbH was founded in 1989 and is located in Berlin. They design and produce handling technology for the entire production process of crystalline solar cells – from goods incoming inspection of the wafers to testing and sorting of finalised cells. Their automation solutions are used globally by major manufacturers of crystalline solar cells. In the beginning of 2008 Jonas & Redman have replaced branch protectors (MCBs) in their systems and machinery by the single pole E-T-A electronic circuit protector type ESX10-T. Competitive edge of this product: thanks to its combination of active electronic current limitation in the event of a short circuit and overload disconnection from 1.1 times rated current they ensure selective and reliable protection of all DC 24 V circuits, independently of cable cross sections or cable lengths. For more than 80 years Mahlkönig has been the world market leader in the sector of high-quality coffee grinders for professional users. Mahlkönig GmbH & Co KG is located in Hamburg and their strongest product group is mills for grinding coffee. These are mainly used in coffee roasters, in food retailing and bakeries and pastry shops. by E-T-A. Their coffee mill model Guatemala Lab, a mill with a special breaking and milling disc combination for residue-free grinding, is protected by the robust circuit breaker type 2-5700 which features a positively trip-free snap-action mechanism and an extremely reliable switching behaviour and ensures long endurance of the propulsion engine and thus of the mill. For protection of their propulsion engines Mahlkönig is using thermal overcurrent circuit breakers made E-T-A solutions for a wealth of products Application: Lamp production E-T-A type: ESS20, SVS04 Application DWDM-Backbone E-T-A type: The BBC Business Communication Company GmbH offers tailor-made intelligent customer solutions based on an independent network infrastructure for Managed Network, Managed Voice, Managed Security and Managed IT. Full IP competence covering all topical subjects from hardware distribution to consulting and system integration complete the product range of this Managed Services provider. One of BBC’s success factors is the co-operation with leading technology providers. Together with BBC engineers E-T-A established a protection concept meeting all requirements of the BBC experts. Ever rising packing density and high current consumption require flexible protection solutions: the E-T-A fitted with circuit breakers type 8345 offers high reliability, high response speed in the event of a failure at very low costs for maintenance, changes or enhancements of the system. The E-T-A system solution is compact and space-saving and covers a current rating range of 0.05A through 125 A. E-T-A offers tailor-made solutions for a wide range of industries and products. Here are some interesting examples. OSRAM is one of the world’s major lamp manufacturers. In the business year 2007 the Munich-based company achieved a turnover of EUR 4.7 bn. They have a strongly international orientation and have a globe-spanning network with more than 41,000 people on the payroll. They serve customers in some 150 countries and are producing in more than 48 production facilities in 17 countries. Since the end of 2006 OSRAM has been using E-T-A power distribution systems SVS04 with plug-in type electronic circuit breakers ESS20 in all their production plants. The SVS04 has been designed for rail mounting and distributes current from DC 24 V switch-mode power supplies to several slots. The plugged in E-T-A circuit breakers protect the connected loads selectively and thus ensure maximum availability of the production plants. Applications Australian Made, World’s Best Kenworth develops trucks for the Australian marketplace. In the T3 range of trucks, the E-T-A 1610 series is used for strengthen the reliability of the whole truck. With Australia's unique applications, and some of the harshest conditions in the world for heavy duty trucks, you have a real challenge to succeed in this marketplace. Kenworth's ongoing success as market leader in the heavy duty truck market in Australia is therefore hard earned. Kenworth has led the way, since first opening for business in Australia in 1962. Initially operating as an assembler of imported product, Kenworth developed into a manufacturer of trucks specifically designed for the Australian marketplace, with the first Australian manufactured truck completed at the Bayswater plant in March 1971. E-T-A circuit breakers were chosen for their quality and reliability for Kenworth Trucks and our supplier relationship has been ongoing for over 15 years. The 1610 series is used in the T3 range of trucks, a purpose built truck to take on specific metro and interstate applications. The type 1610 automotive circuit breaker has been designed especially for protection of electrical installations in vehicles. Unlike conventional fuses it can be easily reset and does not have to be replaced after operation, thus reducing the risk of incorrect ratings being used. The danger of inappropriate substitutes such as paper clips is similarly avoided. 14 Kenworth uses the E-T-A 1610 series for strengthening the reliability of their T3 range of trucks. The current rating range of the new type 1610 corresponds to that of automotive blade fuses to facilitate interchangeability. For further convenience the same colour coding system is used thereby ensuring that circuit breakers and fuses of the same rating are identified by the same colour marking. Not only is the 1610 well suited to the protection of fixed installations of vehicles, but it is also ideal for protecting socket outlets such as car cigarette lighters or emergency vehicles power points, where the load conditions may be unpredictable and excessive. Applications E-T-A sailing with Mustang Marine The company has risen and overcome many obstacles' thrown in its direction throughout its history only to become stronger, all thanks to the unsurpassable quality of the Mustang product and proven strength of the Mustang brand. The growth Mustang have enjoyed over the past five years has been enormous. In recent years they have established many export markets, which include New Zealand, North America, China, Hong Kong, Japan, Singapore, UK, Thailand, Spain, South Africa, Denmark and France. From their Head Office on the Gold Coast the team works to develop and expand new and existing markets throughout the world. At present they are producing over 200 boats annually and are at full capacity to meet global market demand. However with the inevitable expansion of the international dealership network there are future plans to expand the production facility in order to meet expected future growth. From the humble beginnings of Australia's oldest and second largest boat builder in 1974, Mustang Marine has grown and developed from strength to strength. Mustang’s engineering team realized the advantages of using the advanced system and finds great value being a multi-functional device that not only provides a whole wealth of new possibilities, both for the control of onboard electrical systems and to provide added functionality for the user but can also be used to perform a wide range of additional functions which otherwise could be achieved only with complex and costly electronic solutions. Examples include the dimming of lights, or the remote control of any load circuit by means of a suitable device. For timer controls, delay times within a wide range can be set and four analogue inputs with switching thresholds are available per module for the connection of sensors. In addition all the necessary control. E-T-A PowerPlex helps Mustang Marine to be ahead of the market. E-T-A’s brilliant space saving touch screen electrical control centre is the latest technology, quality equipment and innovative thinking to be fitted into the new Mustang sports coupes. E-T-A is a comprehensive system which significantly reduces the need for conventional wiring, and combines reliability and user convenience, in easy to install modules purpose designed to meet the special requirements of watercraft – today and in the future. The E-T-A PowerPlex offers a link between the look and feel of conventional technology and modern digital processing offering extensive diagnosis, monitoring and control functions. The main benefit for the boat owner is the highly cost-effective integration of a lot of additional features and systems. 15 Protection in control cabinets: the icing on the cake! Circuit breaker type 4220-T You want to have longer production times and reduced stoppages as a tempting desert in your control cabinet menu? Please order our slim components. With a width of only 12.5 mm and a track-mountable design they’ll be a perfect part of your diet: G Electronic circuit protector ESX10-T G G Selective: electronic circuit protector ESX10-T ensures genuine selectivity in Dc 24 V circuits. Only the faulty path will be disconnected which the rest of the system remains running! Slim: circuit breaker type 4220-T offers reliable overcurrent protection for ratings from 0.1 A through 32 A at DC 60 V, AC 240 V and 3 AC 415 V at a width of only 12.5 mm (single pole including auxiliary contact). Double pole and three pole version now available! Compelling: sophisticated wiring concept – across the entire design from the entry line to the auxiliary contact wiring! In brief: E-T-A products enhance your system’s availability with international approvals on the side. Have we whetted your appetite? We will be pleased to provide you with professional protection. Please do not hesitate to contact us – we shall be glad to be of assistance! www.e-t-a.com.au E-T-A ElectroTechnical Applications Pty Ltd Unit 14/4 Birmingham Ave . Villawood NSW 2163 Phone (02) 9726 3011 . Fax (02) 9726 3021 E-Mail: [email protected] . www.e-t-a.com.au