Application reports
Applications of transformers in industrial and commercial control circuits
ktc transformers are used in a wide range of industrial and technical applications. They provide defined secondary voltages, ensure a stable supply for control and logic circuits and offer reliable galvanic isolation between mains and device circuits. In areas such as mechanical engineering, automation technology, control cabinet construction, robotics, railroad technology, laboratory environments, medical technology, combustion systems, internationally operated installations or transformers with special approvals, the individual
Medical technology
Medical technology
Devices in medical technology require stable, electrically isolated supply voltages. The solutions from ktc GmbH meet these requirements with defined insulation values and high operational reliability.
Precise supply of small control circuits
Medical control circuits require a constant secondary voltage with minimal fluctuations. The device versions from ktc provide this stability even for sensitive components such as pump units or diagnostic systems. The decisive factor is the clean separation between the mains and device circuits, which minimizes interference currents and enables a reliable supply of voltage.
Galvanic isolation in accordance with medical safety requirements
Isolation plays a central role in medical applications. The transformer technology from ktc ensures defined isolating distances and prevents unwanted couplings. This fulfills safety-related requirements that are necessary for devices used in close proximity to patients or in sensitive applications. IEC 60601-1, for example, is a relevant guideline here.
Supply of medical devices with varying input conditions
Mobile medical devices often face changing input conditions. Ktc series are designed for these environments and generate reliable output voltages regardless of regional grid differences. This supports stable device operation in both stationary and mobile applications.
Systems with international mains voltages
Systems with international mains voltages
Machines and systems are operated worldwide and require defined voltage levels for power and control. The designs from ktc GmbH address these requirements both in the control cabinet and in housings provided with application-specific equipment.
Voltage adjustment in the control cabinet with combined power and control supply
In many industrial machines, international mains voltages have to be converted to a defined system level. The transformer solutions from ktc handle both the adaptation of three-phase input voltages in the control cabinet, for example from 480 V to 400 V, and the provision of single-phase control voltages. The combination of power and control circuit supply within one system reduces interfaces and enables a consistent voltage architecture for machines that are used worldwide in different network environments.
Use in separate enclosures for transforming standard local networks to machine voltages
For applications outside the control cabinet, housing solutions are available that transform standard local power supplies – for example 400 V – into the voltage levels required for the machine, such as 200 V. In these systems, additional peripheral devices are often supplied, for example via integrated 230 V sockets. The design allows different loads to be operated in parallel without affecting the stability of the primary machine supply.
Expandable systems with circuit breakers, meters and function-specific modules
ktc’s enclosure variants offer space for additional technical components such as circuit breakers, electricity meters or modules for special applications, including extinguishing systems in environments with oil-based lubrication. The integration of these elements supports a uniform electrical infrastructure and enables compact complete solutions for systems that use international mains voltages and also require supplementary functions.
Railroad technology
Railroad technology
Railroad systems require transformers that provide defined voltage values, work reliably under extreme environmental conditions and meet safety requirements. The technical designs from ktc GmbH take these requirements into account in outdoor areas, on the rail, in adjacent infrastructures and in accordance with DIN EN 50125.
Use on switch and signal systems with special environmental requirements
Outdoor railroad applications require robust transformers that are used in switching and monitoring devices on switch systems or in signaling systems. The devices from ktc meet increased requirements in terms of temperature range, humidity and weather conditions. The design ensures stable secondary voltages despite changing climatic conditions and mechanical loads, which are common in track systems.
Isolating transformers for voltage stabilization and grid decoupling on the rail
Switch cabinets in which isolating transformers for voltage stabilization and grid decoupling are integrated are located directly on the rail. These designs from ktc GmbH support the safe operation of railroad infrastructure by providing defined isolation distances and reducing disruptive network feedback. The technology addresses the requirements of safety-critical railroad control and auxiliary circuits.
Compliance with Deutsche Bahn specifications including shock, vibration and climate tests
For use in railroad applications, transformers must meet specific Deutsche Bahn requirements. These include defined tests for shock, vibration and climate, which ensure that the devices work reliably even under mechanical and thermal stress. The designs from ktc are designed to meet these requirements and thus support the resilient and standard-compliant operation of railroad equipment.
Robotics
Robotics
Stable supply voltages, defined insulation and resilient transformer designs are required in industrial robotics. The technical solutions from ktc GmbH support precise motion sequences, safe control circuits and reliable power supply in dynamic robot systems.
Supply of control and drive components in robot systems
Robotic modules require defined and low-interference voltages in order to execute motion sequences precisely. The transformer solutions from ktc provide stable secondary voltages for control circuits, sensors and drive interfaces, thereby supporting the functional reliability of robot-supported production processes.
Isolation between power level and sensitive control electronics
In robot systems, power components and sensor units are often located close together. The designs from ktc work with defined insulation properties that reduce interference from the drive area and protect sensitive control and measurement circuits. This contributes to the repeat accuracy of the robot movements.
Resistance to dynamic loads and varying operating conditions
Robotics applications generate changing load conditions, cyclical stresses and sometimes increased ambient temperatures. Transformers from ktc are designed for these operating profiles and deliver constant voltage values even with fast clock cycles, pulse-like control and changing operating conditions. This supports the trouble-free and predictable use of robotics in industrial production environments.
Automation technology
Automation technology
Automated systems require stable voltage levels and robust insulation between the power and control levels. The series from ktc precisely address these technical requirements.
Supply of sensors and actuators
Sensor and actuator modules require a constant supply voltage to ensure reproducible switching and measuring processes. The technology from ktc delivers these values even under continuous thermal stress and changing loads.
Isolation between energy and control circuits
Automation systems benefit from clearly separated voltage levels. Designs from ktc offer defined isolation distances and reduce electromagnetic interference. This increases the stability of sensitive control logic.
Integration in modular control stations
Modular control concepts require compact and compatible components. The transformer versions from ktc fit easily into modular control stand architectures and support international operating conditions thanks to variable input ranges.
Switch cabinet construction
Switch cabinet construction
Defined control and logic voltages are required in control cabinet construction. Products from ktc ensure a clean voltage supply and standard-compliant separation between the power and control circuits.
Power supplies for control and logic levels
Control cabinet control systems require constant voltages for relays, contactors and PLC modules. The transformer series from ktc withstand load fluctuations and provide stable values for control circuits in industrial systems. As a result, the operation of the cabinet logic remains reliable and trouble-free.
Separation between mains and control circuit
The versions from ktc meet common requirements for galvanic isolation in the control cabinet. They limit interference from the mains and prevent faults from being passed on to sensitive control circuits. The defined insulation contributes to operational safety.
Adaptation of international input voltages
Flexible input ranges are required for control cabinets delivered worldwide. The variants from ktc cover international network values and generate standardized control circuit voltages. This enables a standardized enclosure design for different target markets.
Mechanical engineering
Mechanical engineering
In mechanical engineering – especially in special machine construction – transformers are required that cover both stable control circuit voltages and application-specific power profiles. The designs from ktc GmbH take these technical requirements into account from construction to operation.
Supply of industrial control circuits and customer-specific application modules
Machine control systems require constant output voltages for relays, contactors and automation modules. In special machine construction, components that do not work with standardized power profiles are also used. The transformer solutions from ktc cover both areas and provide defined voltage values that are required for different control logics and function-specific modules.
Customizable design for individual performance requirements in special machine construction
Special designs require transformers whose properties are specifically tailored to their subsequent use. The technical design of ktc special transformers takes into account individual parameters such as starting currents, continuous power, thermal load capacity or specific output characteristics. This design adaptability supports safe integration into machines whose functional profiles deviate from standard solutions.
Short-term power provision and robust continuous operation capability
Many machine processes require transformers that can safely absorb short-term load peaks and at the same time are designed for continuous duty cycles. The devices from ktc meet these requirements with stable thermal reserves and defined load capacity in continuous operation. As a result, the power supply remains constant even with recurring peak loads, which supports trouble-free machine operation.
Ignition of oil and gas burners
Ignition of gas burners and oil burners
The ignition transformers from ktc GmbH are designed for long-lasting use in industrial firing and high-temperature processes. They deliver defined high voltages and withstand thermal and mechanical loads over the long term
Continuous load and temperature resistance at 100 % duty cycle
Industrial burner systems place high demands on the thermal load capacity of ignition transformers. The versions from ktc are designed for up to 100 % duty cycle and work reliably in areas with high ambient temperatures near the combustion chamber. The design prevents a drop in performance during continuous operation and maintains the stability of the ignition process over longer periods of use.
Influence on flame stability and energy efficiency in the high-temperature process
The quality of the ignition transformer has a direct influence on flame formation and the energy consumption of industrial ovens. Uniform high-voltage pulses support clean ignition, minimize misfires and contribute to process stability. This is particularly relevant in ceramic kilns, steel industry plants and kiln lines where precise thermal processes are required.
Technical design for defined high voltage and application-dependent current values
Ignition transformers from ktc are designed for defined high voltages, typically 5 kV or 7.5 kV. The current and voltage characteristics are adapted to the respective burner architecture. This application-specific design enables reliable ignition energy even under peak loads. The designs are used in industrial heating systems, thermal process plants, biogas plants and other large-scale combustion environments.
Transformers with special approvals
Transformers with special approvals
For regulated areas of application, transformers from ktc GmbH are available in versions with combined international approvals and complete technical documentation. The design is based on UL, CE, TÜV and VDA specifications as well as industry-specific test protocols.
UL-certified versions for the North American market
Transformers from ktc GmbH are available in UL-compliant versions. The design takes into account defined requirements for electrical safety, thermal behavior and insulation classes. These variants support the use in machines and systems that are operated in UL-relevant markets and require a traceable technical qualification.
CE and TÜV-compliant documentation for European mechanical engineering
In the European environment, the focus is on complete technical documentation. The designs from ktc meet the requirements from CE and TÜV-relevant standard areas and are provided with the necessary documentation. The structured documentation facilitates the approval of machines and systems within the EU, as electrical parameters, test reports and safety-related evidence are clearly assigned.
Combined approvals, VDA requirements and supplementary test protocols
For applications with multiple regulatory requirements, transformers from ktc GmbH are available in versions that cover UL and CE requirements together and are provided with complete verification documentation. In addition, there are variants that meet the VDA quality standards and can therefore also be used in medical technology environments. Test sequences such as shock, vibration and climate tests are available in documented form and form the basis for use in regulated industries.
The areas of application described show the range of electrical and mechanical requirements covered by transformers from ktc GmbH in industrial and technical environments. The various series support defined voltage levels, safe isolating distances and application-specific power profiles. This creates a technically consistent basis for machines, plants and systems that are operated in different industries and international grid environments.