smart solutions driving your mission

11/2019

Customer Magazine informative · up-to-date · pioneering

www.benning.de

Improved safety in the diamond city 22– 25

Modularity reduces maintenance costs 3– 7

26– 31Support for space project "Ariane 6"

Smart solutions driving your mission

POWER news 11/2019 Editorial

Publication detailsBENNING Elektrotechnik und ElektronikGmbH & Co. KG’s client magazine

Publisher: BENNING Elektrotechnik undElektronik GmbH & Co. KG,Münsterstrasse 135-137, 46397 Bocholt

Design und Production: Advertising AgencyPaus Design & Medien GmbH & Co. KG,Brinkstegge 13, 46395 Bocholt

Liability and CopyrightAll texts are protected by copyright. Thepublication, adoption or use of texts, pic-tures or other information is subject to thewritten agreement from BENNING GmbH.No liability is accepted for any guidance,references, recommendations or evalua-tions. In spite of making every effort tocarry out a correct presentation andchecking of the subject matter, errors ormistakes in interpretation remain pos sible.

Picture credits© BENNING Elektrotechnik und Elektronik

GmbH & Co. KG© Apple Inc.© ArianeGroup Holding© ARIANESPACE© Bluetooth SIG, Inc.© Cisco© Drägerwerk AG & Co. KGaA, Lübeck© ESA-CNES-ARIANESPACE/Optique

Vidéo du CSG - Service Optique

© Google LLC© alex_black, alswart, Björn Wylezich,

Cristian Andriana, den-belitsky, Fenton,franke182, ftotti1984, greenbelka, Jelena Dautova, jotily, lesikvit, MatyasRehak, Mirko, mode_list, MonikaHuňáčková, newb1, Pavel Losevsky, pechenka_123, phyZick, sakura,vectorfusionart, 昊周 , zhouyilu, zozifoto – stock.adobe.com

Dear Reader,

In November 2018, NASA's InSight spacecraft successfully landedon the red planet in order to conduct various studies on the internalstructure and composition of Mars by 2020. Aerospace projects likethis prove to be particularly demanding and pose enormous, but ex-tremely exciting challenges for everyone involved. The products and services used for this purpose must be perfectlyharmonised to one another and must meet the highest quality, relia-bility and safety standards.

This is also true for the international Ariane 6 project, which BENNING supports by deliveringrobust, highly reliable power supply systems. Read more in this issue of POWER news, whereyou can also find out how BENNING succeeds in contributing to greater safety and reliabilityin other market segments. For example, in the public transport of the city of Antwerp (Bel-gium) or in the medical sector.

As a new member of the Managing Board in charge of the industry and telecommunicationsareas, I am looking forward to the challenges that lie ahead. I believe the fundamental basisfor mastering this, as has always been the case at BENNING, is about working in partnershipwith our customers , ensuring the highest quality, reliability and safety, regardless of the fieldof activity.

I hope you enjoy reading this, and I look forward to receiving your feedback.

Respectfully, Dietmar Papenfort

e-mail: [email protected]

telephone: +49 2871 93 264

2 | BENNING | POWER news | 11/2019

This final article within our 'ility' series focuseson the important subject of system maintain-ability and how the various UPS topologiesinfluence servicing methodology, site opera-tive training needs and spare parts holdings.We will also consider how system maintain-ability affects both system availability andtotal cost of ownership.

Different levels of maintenance

Companies purchase a UPS because theyhave a critical load that requires clean, con-tinuous power; so, regardless of the UPStopology purchased, the UPS must alwaysbe in peak operational condition. However,because all UPS systems contain both elec-trical and mechanical components that havea statistical reliability, and consequently a sta-tistical probability of unexpectedly failing atany time, it is essential that they receive rou-tine preventative maintenance inspections.

Indeed, some components (e.g. capacitors,cooling fans, batteries) have a known finite

Modular power protection and conversion technology, partic-ularly in the form of UPSs, has long been used in commercialapplications but take-up in industrial applications has, to date,been relatively slow.

This relatively slow uptake is due, in part, to a limited under-standing of the “ilities” (“Availability”, “Reliability”, “Scalabil-ity”, “Flexibility” and “Maintainability”) commonly associatedwith modular technology and how the various “ilities” com-plement each other.

useful working life and will definitely requireproactive replacement if the UPS system’savailability and reliability are to be maximised.

In the “Availability v Reliability” article in thisseries (Power News 08/2017), maximisingsystem availability was considered to be theprimary objective of almost all UPS systems.To maximise system availability the reliability(MTBF) must be maximised and the repairtime (MTTR) must be minimised; to achievethis every UPS system must be:

• Properly maintained to minimise the prob-ability of an unexpected failure (i.e. max-imise MTBF);

• Rapidly repaired when an unexpected fail-ure occurs (i.e. minimise MTTR).

With the above in mind we can define a UPSsystem’s maintainability as how easy it is toproperly maintain without risk to the criticalload and how quickly the system can be re-turned to full operation following a systemfailure.

Modular power protection in industrial applications

The principle of modularity provides significant

technical and economic benefits in the design

and operation of UPS systems.

Ideally, day-to-day routine checks should be carried out independently by

the plant operator on site.

BENNING | POWER news | 11/2019 | 3

Contents

3– 7 Modular power protection in industrial applications The principle of modularity provides signifi-cant technical and economic benefits in thedesign and operation of UPS systems.

8– 12 Increasing efficiency and asbestos removal for an Italian hydropower plantBENNING has performed the repair of a generator in an extremely short period oftime. Modern insulation material technologyincreases efficiency and extends the servicelife of the machine.

13– 15 TRUE RMS Digital Power Current ClampMultimeter BENNING CM 12Equipped with a data logger and Bluetooth®

technology for app connectivity it is designedfor sophisticated measuring tasks both in industry and trade.

16– 21 Production solutions at two sites in Germany and Ireland guarantee 100%delivery availability of power supply unitsRisk management – development of parallelpower supply unit production at sites in Bocholt (Germany) and Wexford (Ireland).

22– 25 Improved safety in the diamond cityHigh availability modular UPS systems of the type ENERTRONIC modular SE help to increase safety in the Antwerp underground.

26– 31 Support for the international space project "Ariane 6"Unique modularity and flexibility

32 Fairs, events and exhibitions 2019

Compared to monobloc systems, modular systems allow for faster repairs because

faults can be remedied by replacing a module. For example, 'hot swappable' systems

offer key advantages.


The “hot swap” nature of the modules meansthat a faulty module can be safely removedfrom the UPS system and a new module fitted into the system within minutes. Furthermore, if the UPS system has beencorrectly rightsized with N+1 parallel redun-dancy (see Scalability article) then the systemcould be returned to full operation withoutthe critical load having ever been exposed toraw mains.

Site operative training

It is often desirable, and in some cases es-sential, for a site to have one or more of itsoperatives trained by the manufacturer to un-dertake certain maintenance tasks on thesystem. If the site is remote and/or there area large number of the manufacturer’s sys-tems on a site then the default position maywell be to have manufacturer-trained opera-tives permanently on-site. However, training site operatives on specificUPS and power protection systems presentssome problems:

• Manufacturer product training is expensive; • Trained operatives can change jobs or siteswith little notice;

3 Third line (“open-the-door” systemfault investigation/repair)

Non-modular topologies require the site at-tendance of experienced manufacturer-trained engineers to undertake any fault in-vestigation and repair activities. Theseengineers must use the latest manufacturersupplied service manuals and software,whilst having access to a complete set ofmanufacturer supplied spare parts.

The call-out time and the time needed to di-agnose the problem, to carry out the repairand to return the system to full operationmeans that the system could be offline any-where from many hours up to several days,depending upon the availability of the trainedengineer and the nature of the fault.

Modular topology systems allow a much sim-pler third line fault investigation and repair.System faults can be corrected by simply re-placing the faulty module. “Hot swap” mod-ular systems in particular present third linemaintenance benefits as module exchangescan be performed by trained site operativeswith access to telephone support from man-ufacturer-trained engineers.

• Trained operatives can be absent from site because of shift patterns, holidays orsickness;

• If an operative is not working regularly on asystem then the training is soon forgotten;

• The system documentation, modificationstatus and maintenance procedures willhave been the latest available at the time of training but are unlikely to have been updated over time;

• Site operatives are typically “generalist” innature (i.e. they are expected to have a rea-sonable knowledge of a large number ofdifferent systems);

• UPS/power protection systems requirespecialist knowledge.

There is a very significant difference in thetraining, skill and experience needed to repairsystems using “hot swap” true modulartopology and other topologies. “Hot swap”true modular topology systems can bequickly repaired by the exchange of a faultymodule by a trained site operative with tele-phone support. A non-modular topology system must be repaired by a highly skilled and trained oper-ative who is capable of replacing individualPCBs and components.

There are generally three levels of mainte-nance. These are often referred to as firstline, second line and third line, and for thebenefit of this article we will define thesetypes of maintenance as:

1 First line (“day-to-day” routine checks)

This level of maintenance is typically visualwhere operational conditions such as alarmconditions and cooling fan operation, etc.,are noted and reported. First line mainte-nance can and should be routinely carriedout by site operatives and, depending uponthe site’s maintenance regime, first line main-tenance will typically take place daily, weeklyor monthly. Some systems have their alarms connectedto a building management system (BMS) orsome other form of remote monitoring sys-tem to provide immediate notification of anyalarms. Such remote monitoring enhancesthe effectiveness of first line maintenance.

First line maintenance tasks are the same regardless of the UPS topology in use, how-ever, it is essential for site operatives to haveaccess to expert technical support if a system problem is encountered.

2 Second line (“open-the-door” routinepreventative maintenance)

This level of maintenance is proactive in na-ture and is intended to prevent problems oc-curring (i.e. to maximise MTBF). Regardlessof the UPS topology, all routine preventativemaintenance works must be performed bymanufacturer-trained engineers using the lat-est revision of the maintenance procedures,service software and manuals. Systemfirmware should also be upgraded as part ofpreventative maintenance.

Some routine preventative maintenancetasks will require system modification orcomponent replacement. When this is re-quired, modular UPS topology provides sig-nificant benefits as, regardless of the com-plexity of the modification or componentreplacement works, all works can be quicklyand successfully completed on-site by mod-ule exchange.

Non-modular topologies may require theUPS to be offline for several hours whilstsuch modification/component replacementworks are carried out, which exposes thecritical load to raw mains.

Modular power protection

'Open-the-door' preventive measures should only be performed

by service personnel who have been appropriately trained by the

system manufacturer.

Monobloc systems require the engagement of experienced and factory-

trained engineers to expertly and efficiently perform fault analysis and repair.



If “hot swap” true modular topology is used,emergency (third line) maintenance and re-pair tasks can be performed by trained siteoperatives with access to telephone support,if spare modules are available on-site. Thisminimises repair times (MTTR) and thereforemaximises system availability.

If non-modular UPS topology is used, thirdline maintenance and repair tasks must beperformed by highly skilled manufacturer-trained operatives. Both site operative training and spare partsholding and storage are simplified if “hot swap”true modular topology is used.

contact: Alexander Proemel

telephone: +49 2871 93 238


of ownership are to be achieved. It is falseeconomy to “save money” by not having a power protection system properly main-tained.

First line maintenance tasks, regardless ofthe UPS topology used, should be per-formed by site operatives and can be en-hanced by using remote monitoring to pro-vide early identification of actual and potentialproblems.

Routine (second line) proactive preventativemaintenance maximises system reliability(MTBF) and, regardless of the UPS topologyused, must be carried out by manufactur-ertrained operatives using the latest mainte-nance procedures, technical manuals andservice software.

Spare parts and module rotation

It is not uncommon for industrial sites to pur-chase and hold on-site a set of spare partsfor their UPS and power protection systems.This is good practice as it ensures thatspares are readily available should there everbe a system failure. However, this may not besuitable for all components or for all systems.For example:

• Electrolytic capacitors have a finite shelf lifeand after an extended period of storage(e.g. two years) they might need to be reformed, otherwise they will fail to operateand could cause further system damagewhen operating voltage is applied to them;

• Printed circuit boards and firmware held as spares might no longer comply with thelatest modification status;

• There are no guarantees that spare partsthat have been stored for a number ofyears will still work.

As an alternative to holding spare parts on-site, users of modular topology systems havethe option of holding spare modules on-site.These “spare” modules can be put into service to add redundancy into a system or

can be placed in spare parts stock and rotated into service as part of routine main-tenance. Such routine spare module rotationensures that all modules on-site will receivethe same amount of duty, prevents compo-nent damage caused by the module sittingunused for several years, and all but guaran-tees that the spare modules are known to beworking.

A potential downside to putting “spare” modules into service and supporting the critical load is that system “right-sizing” (see “Scalability” article) could be affectedand the system might no longer be operatingat an optimum point on the efficiency curve,which will impact total cost of ownership.

To overcome this potential problem somemodular systems have inbuilt intelligence (see “Flexibility” article) that places any mod-ules in excess of the number needed to protect the critical load into a “sleep mode”.

Conclusion

All UPS and power protection systems needto be properly maintained if the twin goals of highest availability and lowest total cost

Modular power protection

In particular, when non-modular topologies

are used, it is absolutely necessary that the

personnel employed by the plant operator is

appropriately trained by the manufacturer..

Scan the QR code for

further information


ENERTRONIC modular SE,

40 kW module

Replacement modules can be swapped in

the system as part of routine maintenance.

of modern insulating material technology extends the service life of the machine bydecades. In addition, the nominalpower can be significantly in-creased by means of a newwinding design.

View into the generator with the

180 newly wound high-voltage coils

Hydropower is one of the most impor-tant renewable energy sources in theworld. While in Germany it generatesabout 5 percent of the electricity pro-duced, in Italy, for example, it generates20 percent, in Switzerland 62 percent,and in Austria as much as 76 percent. Akey advantage is that water does notproduce any emissions and thereforehas no negative effects on the climate.It also enables relatively low-cost pro-duction of large quantities of electricity.One could ask, what more could youwant? However, there remains a majorneed for optimisation in this energy sec-tor, above all in terms of efficiency, reli-ability and sustainability.

Many facilities are outdated - having oftenbeen in operation for as long as 50 years oreven more. Modernisation processes canhelp to increase the performance of a facilityin the long term and are also often more effi-cient than a new build. In addition to techni-cal retrofitting, for example by replacing hy-droelectric generators, asbestos removal isalso a subject of great importance. Eventhough this health-damaging, fine-fibre sili-cate mineral was banned throughout Ger-many back in 1993, asbestos issues oftenhave to be resolved when repairing olderelectrical machines.

In addition, every new hydropower facility,irrespective of its design and technical char-acteristics, has an ecological impact on thesurrounding environment or region. It can,for example, result in the disruption of natu-ral river courses or the elimination of floodzones. Another reason to pursue not onlythe construction of new hydropower facili-ties, but also the modernisation and moreefficient use of existing ones - an area in

which BENNING's Electrical Machines (BeM)division has been successfully operating formany decades.

Reduced downtime

We recently completed the repair of a gener-ator with a rated output of 12.3 MW for a hy-dropower facility in northern Italy. In this case,a generator failure had occurred as a resultof a short circuit in the winding. Since a failurecauses huge losses in terms of the feed-intariff, the repair had to be performed asquickly as possible. In no time at all, the fa-cility got in touch with BENNING, with thefirst contact being made at a trade fair in2017.

Within a very short time, BENNINGtook over the drafting and presen-tation of a suitable maintenanceconcept. Compared to theinstallation of a new gener-ator, it reduced the timesubstantially. Other keyadvantages: The use

Increasing efficiency and asbestos removalfor an Italian hydropower plantBENNING has performed the repair of a generator in an extremely short period of time. Modern

insulation material technology increases efficiency and extends the service life of the machine.

BENNING | POWER news | 11/2019 | 98 | BENNING | POWER news | 11/2019

Maximum flexibility

In particular, the dismantling of the winding,which had to be performed very carefullydue to the asbestos removal, turned out tobe extremely time-consuming. Thanks to theflexibility of the electrical machines division,however, there was no risk to the scheduledloading deadlines, nor was there any risk ofthe 180 high-voltage coils required for thenew winding having to be manufactured.

Major client satisfaction

The thermography on the sheet metal pack-age was performed on 18 May in the pres-ence of the client. The tests showed thesheet stack to be in order, so that the

Production of HS full-form coils for stator winding Professional installation of the high-voltage winding

For the operator of the hydropower facility,this means greater efficiency, safety and sus-tainability.But this was not only the advantage of theoffering. The many references to similar pro-jects, as well as the great deadline flexibilityof BENNING is what won the client over.

Efficient maintenance

On 24 January 2018, only six days after theoffer had been submitted, repair work beganon the facility. This included dismantling andcleaning on site using the dry snow process,obtaining transport permission and arrang-ing special transport because of the statorwidth (external diameter: 3.8 m, height: 2 m,weight: over 30 t).

The measurements of the 4 t flat enamelledcopper wire integrated in the generator weretaken directly on site at the facility. This madeit possible to significantly reduce the procure-ment time for the new wire.The loading of the generator in the facilitytook place on 28 February. For the subse-quent transport, the Reschenpass (AT) hadto be temporarily blocked, but this did notcause any major loss of time. As early as 2March, the equipment safely reached the re-pair works in Bocholt. In Bocholt, the removalof asbestos from the stator, the dismantlingof the winding in the so-called black area (as-bestos), the examination of the existing sheetstack for hotspots by thermography as wellas the new design and production of thehigh-voltage winding all took place.

Graun church tower on Lake Reschensee in the South Tyrol -

even the development of hydropower means disruption in the

surrounding region, so it is all the more important to modernise

the existing hydropower facilities and increase their efficiency.


... modernise sustainably and thus increase the efficiency of the existing hydropower facilities


The generator safely packed on 4 July

during the scheduled loading.

... repair period reduced to the minimumAs early as 6 July 2018, the generator was

switched back on in the hydrofacility.

installation of the high-voltage coils began im-mediately afterwards in three-shift operation.Thanks to the additionally optimised windingdesign from BENNING, the nominal power ofthe generator was actually increased by ap-prox. 1 MW.

The loading of the generator in the repairshop took place as scheduled on 4 July.Thus, BENNING avoided the risk that a de-livery could not have taken place until 11 Julydue to road closures. The generator arrivedwithout delay at the northern Italian facility on6 July.

The client was more than satisfied with thefast and professional service, as well as in-creased efficiency achieved, and promisedBENNING several follow-up orders for furthergenerators.

Bottom line

Compared to a new generator build, the re-pair time of a generator is significantly shorter

and so the downtime is also reduced. Theservice life of the machine is extended bydecades, through the use of modern insulat-ing material technology and the nominalpower can be increased significantly in somecases by means of a new winding design.Sustainable factors that are both positive forour environment and in the interest of hydro-electric operators.

author/contact: Matthias Loerwink

telephone: +49 2871 93 318



further information


Enck: Ultimately, it's the combination of nu-merous measuring capabilities, the wide mea-suring ranges and high basic accuracy, aswell as the wide variety of switchable and se-lectable functions. The whole package of thisdata logging current clamp is totally roundedoff, complete, and both functional and practi-cal – designed to meet the highest demands.

PN:

For many years, current clamps have proved to be safe and reliable measuring de-vices for measuring current flows, without needing to disconnect the current-carryingconductors. Precise measurements that were initially only possible for sinusoidal al-ternating currents, but later also for direct current systems, are achievable todayusing modern measuring technology with the TRUE RMS measuring method or aswitchable low-pass filter for high frequency suppression, even in industrial plantswith non-linear loads. POWER News (PN) spoke to Tobias Enck, a sales representa-tive at BENNING's Testing and Measuring Equipment department, about the key fea-tures of today's current clamps, as well as their advantages and capabilities. The dis-cussion focused on the BENNING CM 12 Digital Power Current Clamp Multimeter.

PN: Let's go into detail and talk about themeasuring functions. Which ones can theuser particularly rely on?

Enck: The main functions are the currentmeasurement of 10 mA to 600 A, the voltagemeasurement of 10 mV to 1,000 V and thecombination of these measurements into thepower measurement up to 600 kW. In addition, the power factor shows in thepower measurement whether an inductive orcapacitive load is present.

In electrical systems, e.g. where frequencytransformers or pulsed motor drives are pre-sent, the switchable low-pass filter in the V AC and A AC function for high frequency(or RFI) suppression is a useful feature for fil-tering out high-frequency pulses.

TRUE RMS Digital Power Current Clamp MultimeterBENNING CM 12Equipped with a data logger and Bluetooth® technology for app connectivity it is designed for

sophisticated measuring tasks both in industry and trade.



PN: Mr Enck, thank you for the informativeinterview.

author/contact: Tobias Enck

telephone: +49 2871 93 111


A data logger is a recording and storagemethod in which a sampling rate is set. In thisway, up to 9,999 measured values can bewritten to the internal memory or transferreddirectly to the BENNING app via Bluetooth.The app display stores the measured valuesand presents them as a graph. Once a mea-surement series has been saved in the app,it can be forwarded to colleagues for jointevaluation.

PN: Aren't we now pretty far removed fromthe standard current clamp used by the elec-trical system installer?

Enck: Installation companies are becomingmore specialised and increasingly supportindustrial electricians in the maintenance ofindustrial firms’ systems and equipment. Inthis case, the electrician is optimallyequipped with a current clamp that has ameasuring category of CAT IV 600 V suitedto the industrial environment, with adequatemeasurement ranges, a generous clampopening and the appropriate accessories.

PN: That all sounds very convincing. Is thereanything else that has not been addressedthat may be relevant to many of our readers?

Enck: This fully highlights the main advan-tages of the BENNING CM 12 Power Current

Clamp Multimeter. In addition, there are the re-sistance and capacitance measurement func-tions, the continuity and diode tests, the bipo-lar phase sequence test, as well as the voltsensor located in the clamp head. The openinglever for opening and closing the current clampalso activates the measuring point and displayillumination. The bar graph display is clearly vis-ible in dark surroundings due to the backlight.

PN: The BENNING CM 12 Power CurrentClamp Multimeter and BENNING MM 12Multimeter are the highest quality measuringinstruments in your range. What is your over-all view of BENNING's position in the area oftesting and measuring equipment?

Enck: Over the past ten years we have laidthe groundwork very well and have continu-ously developed our products. We will, ofcourse, continue to work on that. Today, weare represented on the market with a well-rounded and complete range, from the bipo-lar voltage tester to the installation and devicetester.

We’re happy to answer any questions abouttesting and measuring technology, becauseas a matter of course, good customer-ori-ented and competent advice prior to pur-chase and comprehensive after-sales sup-port are among our strengths.

forms into a broad spectrum of harmonic fre-quencies. Harmonics are currents or voltagesthat have a frequency above the 50/60 Hzfundamental frequency and which are an in-teger multiple of this fundamental frequency.The current harmonics do not affect the ac-tive power – they only load the network ther-mally. As harmonic currents flow in additionto the active sine wave, this leads to an over-load, a reduced lifespan and potentially evenearly failures of electrical consumers. Harmonic loads are the cause of invisiblevoltage quality problems, which can lead toenormous costs for repairs and investments.The THD measurement determines the totalharmonic distortion and shows the ratio ofthe actual effective value of all the harmonicsto the actual effective value of the basic os-cillation. This function is particularly useful inindustrial environments.

The BENNING CM 12 is not a network anal-ysis device but gives a first basic impressionso that appropriate measures can be put inplace. Passive components, but also modern'active harmonic filters' help to eliminate har-monics. .PN: The term 'datalogger' forms part of theproduct name for a reason. What exactly arethe memory function and data logger in thiscontext and how do they work?

A particularly useful form of current measure-ment with the BENNING CM 12 Power Cur-rent Clamp Multimeter is that of the inrushcurrent that occurs immediately after switch-ing on an electrical load and is measuredover the first 0.1 seconds. It is often signifi-cantly higher than the rated current and putsa heavy load on the supply network and itscomponents. Inrush currents mainly occur intransformers, motors, heating coils, lightbulbs, DC/DC converters and in power sup-plies generally, where power-related voltagedips can occur. Cables, switches and relaysmust therefore be able to withstand thesehigh currents without becoming damaged.

Probably the most important characteristic of high inrush currents is the accidental nui-sance tripping of fuses and circuit breakers.If these inrush currents are known, due tobeing measured with the BENNING CM 12,the technician can immediately initiate appro-priate countermeasures and install inrushcurrent limits.

PN: A lot of people don't use, or know about,the ability to determine the network qualityusing the THD measurement function. Canyou explain that in more detail to help ourreaders understand it better?

Enck: To assess the power quality, the BENNING CM 12 can be used to identify anddisplay the total harmonic distortion (THD)and the distortion of individual harmonics upto the 25th harmonic wave. I would like tobriefly explain the background to this. Theconstantly rising number of non-linear loadsleads increasingly to 'network contamina-tion'. More and more electrical consumersare taking a non-sinusoidal current from thegrid. The Fast Fourier Transform (FFT) of theTHD function disassembles the frequencycomponents of the ‘contaminated’ current

Enck: Multimeters and current clamps havesome simple, but also transient memoryfunctions such as the display of a minimum,maximum or average effective measuredvalue. The HOLD function 'freezes' the latestmeasurement result so it can be read easily.The PEAK function shows the peak value ofa measurement.

The measurement results that are recordedusing the current clamp multimeter's MEMmemory function are stored in an 'actualmemory'. Here, measurement series of up to1,000 measured values can be stored andread later via the display. These values canalso be sent via Bluetooth to smart phonesand tablets for further processing, using thefree BENNING CM-MM Link app. The sub-function SAVE stores a measured value onkey confirmation.

The A-SAVE variant can be used for voltageand resistance measurements. As soon as astable measured value is detected by themeasuring tips of the safety test leads, thisemits a signal tone and the value is automat-ically transferred to the next free storage lo-cation. This enables successive series mea-surements to be made, e.g. in battery rooms.The significant advantages are immediatedocumentation and the speed at which mea-surement series can be recorded.

“The BENNING CM 12 Power CurrentClamp Multimeter is a precise, handymeasuring instrument for diverse ap-plications, especially in industrial en-vironments.”

Tobias Enck,

Sales

Legal attribution:

Apple and the Apple logo are trademarks of Apple Inc., regis-

tered in the U.S. and other countries. App Store is a service

mark of Apple Inc., registered in the U.S. and other countries.

IOS is a trademark or registered trademark of Cisco in the U.S.

and other countries and is used under license. Android,

Google Play and the Google Play logo are trademarks of

Google LLC. The Bluetooth® word mark and logos are registered

trademarks owned by Bluetooth SIG, Inc. and any use of such

marks by BENNING Elektrotechnik und Elektronik GmbH & Co. KG

is under license. Other trademarks and trade names are those of

their respective owners.


further information

The BENNING CM 12 is ideal for conducting series measurements, e.g. in battery rooms, due

to its practical memory functions. The ability to quickly record and document measurement

series is crucial.

Transmission of measured values to smart-

phones and tablets via Bluetooth wireless

technology (app for iOS and Android TM)


Photo: ©

Drägerwerk AG & Co. KGaA, Lübeck. All rights reserved.

Manufacturing of power supply units for medical technology systems is subject tothe highest safety and quality standards. In addition to this, guaranteeing a capacityfor uninterrupted delivery represents a key demand placed on the supplier. This isbecause uncontrolled fluctuations in, or a complete breakdown of supply, can havea significant impact on the logistical processes of the manufacturing system anddisrupt production of devices for an indeterminate period of time. This could resultin significant economic consequences for the device manufacturer.

As one of the leading producers of synchro-nised OEM power supplies, BENNING hasbeen developing complex power supply unitsfor more than 30 years. Its products are es-pecially designed for the rigorous demandsof medical technology applications. They stand out for two reasons. Firstly, theirhigh quality and excellent reliability, whichmeet both national and international safety(EN 60950, UL/CUL 1950 and IEC 60601-1)and EMC (EN 55022-B) standards. Secondly, their hardware and software,which is tailored to the individual require-ments of each customer, meaning eachpower supply unit has its own specific layout

and software design. According to the tech-nical specifications required by the customer,units are also fitted with the appropriate in-terfaces, AC and DC outputs as well as thecontrol, regulation and monitoring of the soft-ware necessary to enable it to operate effi-ciently.

Tailor-made solutions

Power supply units developed by BENNINGare widely used in the complex field of med-ical technology, for example in heart/lungmachines, MRI, dialysis systems, anaestheticsystems and respiratory devices.

Production solutions at two sites inGermany and Ireland guarantee 100%delivery availability of power supply units

Risk management – development of parallel power supply unit

production at sites in Bocholt (Germany) and Wexford (Ireland).

BENNING | POWER news | 11/2019 | 1716 | BENNING | POWER news | 11/2019

The compact structure of the

M7.3 Plus combines innovative

and reliable hardware and soft-

ware in the smallest of spaces.

It is used in a respiratory device

manufactured by the company

Dräger (see fig. below).

Wexford

Bocholt

Lubeck

cesses; each power supply unit needs to bepackaged, stored, repackaged and inte-grated into the customer's production pro-cesses and logistics. Together, they developed a concept wherebytwo independent sites would each manufac-ture at a workload rate of 50%. This intendedthe set-up of an identical production line inWexford to run in parallel to the BENNINGfactory in Bocholt. Inspection and approvalof the second production site by Dräger tookplace in summer 2018 and is testament tothe fact that production is taking place in ac-cordance with the highest manufacturingstandards at both production facilities.

Designed in Germany

The only difference between the devicesmanufactured in Ireland and Germany is thename plate, which bears the marking "Madein Germany" or "Made in Ireland". In otherwords, "Designed in Germany, made in Ire-land". All inspection and production proce-dures are replicated precisely in Ireland,where the implementation timeframe wasaround twelve months. During this time, var-ious ideas and possibilities were discussedand processes and potential solutions wereanalysed. With a mindset of "Train the Trainer",the Irish production manager underwent

happen at one of the production sites, suchas a flood or fire. The alternative could be sig-nificant economic losses, because develop-ing, verifying and launching a similar produc-tion route with the required capabilities andlevel of output would take a detrimentallength of time to set up.

BENNING entered into intensive discussionswith Dräger in order to work out all of its spe-cific requirements for the production and lo-gistics processes – with the aim of not onlyguaranteeing delivery availability, but alsomaximising economy through the implemen-tation of resource-friendly, sustainable pro-

Constant dialogue

The design and functionality of all power sup-ply units is specifically tailored to individualcustomer requirements, ensuring quality oftreatment and safety for patients. This is theresult of decades of experience working withthe highest standards and requirements ofthe medical sector, as well as a close andtrusting collaboration with producers of med-ical devices.

BENNING maintains a dialogue with its cus-tomers throughout the entire process, fromthe planning phase through to the start ofproduction. This means any special or com-plex requirements can be discussed in greatdetail and appropriate solutions can befound. The development process usually in-volves the creation of an initial prototype,which is then further developed in close co-operation with the customer. When it comesto agreeing IT, logistics and production pro-cesses, regular inspection takes place in ac-cordance with the customer's quality andmanufacturing standards.

Risk management

A special requirement that the companyDräger presented to BENNING, was theguaranteed availability of the M7.3 Pluspower supply unit. The company uses thisunit in a number of different types of devices.The request was for identical production attwo independent sites, both of which wouldbe designed to have the capacity to com-pletely fulfil the required delivery quantities.This would ensure that the delivery of powersupply units would not stop – and thereforeDräger's production of medical deviceswould not be disrupted if something were to

BENNING Factory II in Bocholt, Germany

Assembled PCBs are checked using in-circuit testers. Adapters scan the PCBs, compare

the result with the program and identify improper assembly, interruptions, short-circuits or

deviations in the electrical values straight away.

BENNING Factory in Wexford, Ireland Light beam-controlled assembly of

circuit boards prevents errors and

increases efficiency.

Final assembly of the two-part structure

Final testing (west-test) of all power supply

units is carried out using state-of-the-art test

computers.

18 | BENNING | POWER news | 11/2019 BENNING | POWER news | 11/2019 | 19

Wexford

Bocholt

Lubeck

production and transport systems used atDräger. The total weight of the container,complete with six power supply units, is just15 kg. This means it can easily be lifted andcarried by one person.

The dimensions of the box are optimised foruse with pallets. A total of 192 power supplyunits can be placed on a Euro-pallet, alsomade of ESD plastic – split into four levels,each with eight boxes. The base of one boxforms the lid of the box below to make opti-mum use of pallet height, which is restricted

ment, these units can be gripped quickly andsecurely removed for installation. Speciallymoulded foam cushions with an exceptionaldegree of hardness have also been inte-grated into the packaging unit, to reduce theimpact of knocks during transport. The veri-fication process was carried out on vibratingtables in BENNING's, in-house, environmen-tal laboratory. Each power supply unit is ad-ditionally equipped with a Fairchild bag toprevent moisture from getting in (e.g. duringtransport). There are two inlays in a packag-ing unit, designed especially for the internal

by the size of shelving units. This reusablepackaging system simply calls for a separatelid on the very top. By avoiding the use ofwood or cardboard, significantly less dirt anddust is released – a highly beneficial factor inthe production process.

Bottom line: reliable and sustainable

The new system removes the need for addi-tional goods handling as the individual pack-aging units can now be integrated into pro-duction logistics directly from the pallet. Afterthat, they go back to BENNING’s factories inBocholt and Wexford, where they are stockedwith power supply units once again.

The production solution implemented at thetwo sites has made it possible to maximisedelivery availability. The new multiple-useprinciple has led to more economical logisticsprocesses, with significant savings on pack-aging materials such as wood and card-board, which have made an important con-tribution towards dealing responsibly with ournatural resources.

author/contact: Dirk Petrich

telephone: +49 2871 93 401


intensive training in Bocholt, learning allabout the processes so that they could beapplied in exactly the same way in the Wex-ford factory. For the purposes of quality as-surance and inspection, the production man-ager from Bocholt then visited Ireland tocheck that all processes were indeed beingimplemented in an identical manner.

Secure and efficient logistics

There was particular scope to identify exist-ing potential and optimise processes in thefield of logistics. For example, production atBENNING is to be linked into the VMI (Ven-dor Management Inventory) principle. This isa supplier-managed warehouse, in whichBENNING is responsible for ensuring thatthe current stock is always in line with spec-ifications set out by Dräger. This enables thenecessary production capacity to be organ-ised in an efficient manner, where Drägerprovides access to a special supplier plat-form, which delivers up-to-date forecasts onexpected product demand.

In addition to ensuring maximum deliveryavailability, sustainable solutions were devel-oped for external and internal logistics processes. For instance, a modular ESD(electro-static discharge) plastic returnablepackaging system has been developed, designed precisely for secure and efficientexternal and internal transport of power sup-ply units. The smallest unit is a speciallymoulded inlay, which holds three power sup-ply units. Thanks to the ergonomic arrange-


further information

"Our supplier performance isevaluated byDräger on aweekly basis and has thus faralways been100%."

Dirk Petrich, Chief Sales Officer OEM PSU, Traction, E-Mobility and After Sales Service

Returnable packaging system for

192 power supply units

In the final inspection step before dispatch,

all power supply units are subjected to an

endurance test (run-in test) lasting several

hours (image left).

Each inlay can hold three power supply units. To prevent penetration

of moisture during transport, all power supply units are additionally

equipped with a Fairchild bag.

20 | BENNING | POWER news | 11/2019 BENNING | POWER news | 11/2019 | 21

The main train station "Antwerp-Centraal" is an

architectural gem. The first time you come from

the main train station to Diamant Premetro sta-

tion to continue the journey by metro you will be

surprised to get into a typical tramcar.

The ENERTRONIC modular SE combines robust-

ness, maximum availability and a high degree

of IP protection. Otherwise the penetration with

metal brake dust, which is permanently released

from the rolling stock, could lead to serious

problems.


Premetro Antwerp

Another special feature catches the visitor’seye when coming from the railway station tothe Diamant Premetro station looking for aconnection by underground. There are notypical underground railway carriages here.Instead, you sit in a tram car by which youtravel through a network of several tunnels in

Antwerp – a city with exceptional brilliancy. For more than five centuries it has beenconsidered the most important diamond centre in the world. Around 1600 diamondcompanies, four diamond exchanges and a diamond museum are based here. Alsoimpressive are the magnificent buildings and cultural institutions from different erasin the Belgian port city in the Flanders region. The historic main train station"Antwerp-Centraal" is an architectural gem. It was built between 1899 and 1905 andis striking for its splendid station building, consisting of an elegant station roof madeof steel and a 75 metre high dome.

the Antwerp underground. Hence the desig-nation Antwerp "Premetro", based on theoriginal intention to convert the tramway tun-nel into an underground railway at a laterdate. But this plan was already rejected dur-ing construction in 1974.Only the first four stations Meir, Opera, Dia-mant and Plantin were realised as an under-ground railway concept, equipped with

Improved safety in the diamond cityHigh availability modular UPS systems of the type

ENERTRONIC modular SE help to increase safety in the

Antwerp underground.


tenance windows are only very limited due tothe long operating hours of the rail system.In combination with the very good energy ef-ficiency (efficiency > 96 %), a significant re-duction in the total costs of operation (TCO)also results.

The best conditions, therefore, to generatemore safety in the Antwerp underground andto make railway operations as problem-freeas possible.

author/contact: Kim Corten

telephone: +32 2 582 87 85


BENNING was the only supplier able to offerthe transport company De Lijn a modularUPS system with this degree of IP protection.Thanks to its combination of modularity onthe one hand and maximum robustness andresilience on the other, the ENERTRONICmodular SE proves to be predestined for thisproject. But other product features also con-tribute to ensuring the safest possible oper-ation of the Antwerp Premetro over the longterm.

N + X redundant design

BENNING supplies De Lijn with state-of-the-art three-phase UPS systems. These have anN + X redundant design that does not havea "single point of failure" - combined with aminimal service time, which, among otherthings, is based on the "hot swap" capabilityof the modules. The resulting availability of99.9999 % is a crucial advantage, as main-

The ENERTRONIC modular SE,

40 kW and battery cabinets placed

at "Ghost station" Foorplein BENNING | POWER news | 11/2019 | 25

the eastern track, it could be suitable in thefuture as a transfer station. What is nowcalled a ghost station could become an im-portant connection point in the future.

But to guarantee maximum availability of therailway system here and thus to ensure safetravel for thousands of commuters, reliablesignal technoloigy has top priority. In theevent of evacuation, for example, it is veryimportant that emergency systems for light-ing and control systems function properly.

Critical and very sensitive electrical systemslike these, therefore, need voltage indepen-dent of disturbances in the public network.This can only be assured by robust uninter-ruptible power supplies (UPS) that have beenspecifically designed for tough 24/7 use inrailways - the highest requirements that BEN-NING complies with in its UPS systems of theENERTRONIC modular SE series.

90 metre long platforms. Stations built later,however, had more cost-effective platformlengths of 60 metres . The tram network is operated by the Flemishpublic transport company De Lijn. Of the total13.5 km long tunnel route and 19 stops, only11.2 kilometres and twelve stations are in op-eration.

Another branch was opened in September2017 for tram traffic. Since then, tram line 10enters what is called the Reuzenpijp just be-fore Zegel station. From here it leaves thePremetro tunnel in the direction of Wijnegem,east of Foorplein station, which has not yetbeen put into service.

"Ghost station" Foorplein

Foorplein is still one of what are known as"ghost stations". Due to its location right nextto the former railway station Borgerhout on

High degree of IP protection

The order placed by De Lijn was received byBENNING in 2016 after a planning and eval-uation phase of about five months. Decisivefor convincing the customer was, above all,the resistance of the UPS systems to envi-ronmental influences.

This is because not only moisture and humid-ity, but also the penetration of other foreignbodies such as metal brake dust, which ispermanently released from the rolling stock,could lead to serious problems. If, for exam-ple, a signal malfunction or even a poweroutage occurs, the safety of all passengersand railway staff would be jeopardised. How-ever, due to their high degree of IP protec-tion, BENNING's specially developed UPSsystems are optimally protected against thepenetration of even the finest dust and dirtparticles.


... n + x redundant design andhigh degree of IP protection


further information


Europe's independent access to spacewill continue to be realised by the con-struction of the European rocket, Ariane 6.Thanks to its unique modularity, the newlaunch vehicle family, the first launch ofwhich is scheduled for summer 2020, isdesigned to provide maximum flexibilityand reliability.

There are two different configurations: Ariane 64is equipped with four boosters and cantransport more than 11 tonnes into geosta-tionary transfer orbit (GTO) in a double-start.Ariane 62, on the other hand, has two boost-ers and is designed to carry around 5 tonnesof payload into GTO or 5.5 tonnes in sun-synchronous orbit (SSO).

International cooperation

The European Space Agency (ESA) pro-gramme is an international joint venture. De-velopment and production are driven bymultinational teams of experts. To ensure thebest possible quality, they use state-of-the-artdigital technology and are geared towardsthe most efficient organisational standards -including the construction of the new ELA-4launch pad located at the Kourou SpaceCentre in French Guiana, for example.

Two versions of Ariane 6

Support for the international space project "Ariane 6"

Unique modularity and flexibility


A62: with two solid rocket motors• initial performance to geostationarytransfer orbit: more than 5 metric tons

• initial performance to sun-synchronousorbit: more than 5.5 metric tons

A64: with four solid rocket motors• initial performance to geostationarytransfer orbit: 11 metric tons

Photo: ©

ArianeGroup Holding

Geostationary Transfer Orbit (GTO)

Launch trajectory

Geostationary Orbit

Sun-Synchronous Orbit(800 km)

35786 km

Satellite manoeuvre to orbital orbit


As early as 2009, the CNES (Centre Nationald'Etude Spatiale) decided to undertake thenext generation to Ariane 5, the start of con-struction began in 2015.

Development of the high voltage infras-tructure

The contract for all infrastructure work wasawarded to the Eiffage Group - more pre-cisely, the Space Division of CLEMESSY SA,a subsidiary of Eiffage. An essential part ofthe order was the power distribution for thelaunch pad and all ancillary buildings. Engi-neers from CLEMESSY Space developed thesystem for the power supply to the new plant- based on a centralised high voltage supplyto be built on the site of the old Ariane 5launch platform ELA-3. From here it is a mat-ter of supplying power to and securing thehigh voltage dispatch substation on the newlaunch pad ELA-4.

During a rocket launch all processes such asrocket ignition, the opening of valves or theoperation of various measuring instrumentsmust be continuously powered, a highly reli-able power supply is essential. Failure of theautomatic controls and switchgear in thehigh voltage infrastructure could lead to agrid or power failure that would prevent asafe rocket launch. In order to avoid thisworst-case scenario and to have an experi-enced and reliable partner at its side,CLEMESSY SA decided to co-operate withBENNING as its power systems provider.

Intensive engineering services

The co-ordination and negotiation discus-sions began in March 2016 with the contractawarded to BENNING in October 2017. Asignificant deciding factor in this, in particular,was the high level of technical support evenin the context of preparing the proposal,combined with the excellent reliability andquality which symbolise the modular indus-trial rectifiers of the TEBECHOP 3000 HDIseries. The power supply system for both thehigh voltage central station and for the elec-trical dispatch substation is based on thismodel type.

… during a rocket launch a highly reliable power supply is essential


Photo: ©

2018 ESA-CNES-ARIANESPACE/Optique Vidéo du CSG - Service Optique

Ariane 5 · July 25, 2018• flight VA244 was performed fromSpaceport’s ELA-3 launch zone. Ariane 5 transported four satellites for Europe’s Galileo navigation satellite system.

contact: Bruno Guerytelephone: +33 2 77 68 60 13e-mail: [email protected]. As with the technology used in

the construction of the Ariane 6 and the ELA-4launch pad, the highest level of reliability andoperational safety is combined with the bestpossible efficiency and flexibility and, just asthe entire Ariane 6 project is composed of in-ternational teams of experts, BENNING isalso characterised by a global, customer-ori-ented service and support network. Theseform the best conditions for successful co-operation.

Moreover, BENNING and Eiffage, the parentcompany of CLEMESSY SA, have had verygood business relations for several years. Forexample, in 2014 BENNING supplied EiffageRail Express with power supply systems andbatteries for the new high-speed rail line be-tween Le Mans and Rennes (see PowerNews 07/2016) - a successful co-operationwhich will continue within the framework ofthe "Ariane 6" project and most probably be-yond.

Modularity and flexibility

The modular rectifier systems were suppliedby BENNING in June 2018. They are usedfor the safe and continuous power supply tothe PLC control systems that manage theautomated sequences and switching pro-cesses in the central station and in the sub-station. The modular rectifier systems of theTEBECHOP 3000 HDI series were devel-oped taking into account the special condi-tions of industrial use, for example in thepetrochemical industry, in power generationand distribution, in automation technologyand in traffic engineering.

The central components include power mod-ules with reliable hot plug technology, whichare installed in 19" rectifier modules in thecorresponding number, depending on thepower requirement. There is a parallel systemof power modules, so that both flexible scala-bility of the output power and the provision ofredundant systems (e. g. n + 1 redundancy)are possible.

Low operating costs

The 19" rectifier plug-in units have a compactdesign and require only three u (height units)for installation in corresponding system cab-inets. They are also characterised by high en-ergy efficiency, since they have a very lowpower loss in both partial load and full loadoperation, and thus contribute to lower op-erating costs. This ensures that power supply systems areprovided to CLEMESSY SA that fully meetthe demanding quality and innovation re-


ELA-3 launch pad and electrical central station

ELA-4 launch pad and dispatchsub station, under construction

19” modular rectifier shelf with 5 modules TEBECHOP 3000 HDI

Final Assembly Building

Launcher IntegrationBuilding

Launch Control Center

Photo: ©

2018 ARIANESPACE


Photo: ©ArianeGroup Holding

Scan the QR code for further information.

www.benning.de

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BENNING Elektrotechnik und Elektronik GmbH & Co. KG

Factory IMünsterstr. 135-137

Factory II Robert-Bosch-Str. 20

46397 BOCHOLTGERMANY

Tel.: +49 2871 93 0 Fax: +49 2871 93 297

E-Mail: [email protected]

All details provided without liability

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