1. Why Do Certain Tests Require Extremely High Currents?
Ressources FaithTech associées : alimentations DC programmables.
In advanced engineering fields, some test applications impose demands far beyond conventional standards — continuous output currents reaching tens of thousands of amperes. Industry research points out that for superconducting magnet excitation, large-scale electrochemical process validation, and reliability testing of new energy vehicle drive systems, “traditional power systems are fundamentally incapable of performing the test tasks.” The core reason: if the required current cannot be established within the specified time window, the test condition itself fails, not just a matter of reduced efficiency.
This insight reveals the fundamental challenge of high-current testing: the upper limit of demand is defined not by standard parameters, but by the physical mechanism of the device under test. For superconducting coil magnetic field testing, only by raising the excitation current from zero to the target value within the prescribed time can an effective superconducting state be established. Similarly, the current density of hydrogen electrolysis systems directly determines the validity of experimental data. Such applications demand capabilities beyond single-unit limits and rely on system-level current expansion solutions.
Industry perspective: The true difficulty of high-current systems is not simply scaling up the numbers, but providing a system solution that is stable, controllable, and safe under real operating conditions.
2. Typical High-Current Test Applications
The following applications share common characteristics: low voltage, high current, and long-duration stable output, representing the core market for high-current power systems:
- Hydrogen Electrolyzer System Testing : Electrolyzers require stable high current to sustain continuous electrolysis; current accuracy directly affects hydrogen production efficiency and safety.
- Solid Oxide Fuel Cell (SOFC) Testing : Stack performance validation requires simulating wide load variations, demanding stringent current dynamic response.
- New Energy Vehicle Drive System & Automotive Electronics Reliability Testing : High-current endurance validation of motor drives and inverters under peak conditions.
- Superconducting Equipment Performance Validation : Superconducting coil magnetic field excitation requires current rise within specified time, with strict requirements for ramp rate and stability.
- Industrial Electroplating, Metal Smelting, Special Process Power Verification : Long-duration high-current process simulation, demanding continuous full-load capability.
- Rail Transit & Industrial Power System Simulation : Main circuit load simulation requires high-precision, high-stability high-current output.
- Connector, Fuse, Plug Temperature Rise Testing : According to IEC/ISO standards for current-carrying temperature rise validation, with clear requirements for current accuracy and timing control.
3. Engineering Challenges of High-Current Systems
High-current systems are not simply the superposition of several standard power supplies; they involve a series of system-level engineering challenges. Industry practice shows that the following five dimensions are critical to determining whether a system can be reliably deployed:
| Challenge Dimension | Specific Issue | FTG Series Corresponding Design |
|---|---|---|
| Busbar Voltage Drop Control | Under low voltage, high current conditions, busbar resistance voltage drop is non-negligible and affects output accuracy. | 16-bit high-resolution A/D acquisition, voltage measurement accuracy 0.05% F.S.; remote voltage sense interface for external compensation. |
| Parallel Current Sharing | When multiple units are connected in parallel, uneven output current can cause overload or underload of some units. | Master-slave parallel auto-current sharing: slave units automatically follow the master, each slave independently shares current, total current displayed on the master. |
| Inductive Load Transients | During deceleration or step changes, inductive loads generate reverse energy that may cause overvoltage damage. | CV/CC priority output mode to suppress overshoot; optional energy absorber to sink reverse inductive energy. |
| Long-Term Stability | Long-duration processes require sustained full-load output for many hours or longer. | Constant power output mode maintains set power; sequence function supports complex long-duration waveform programming. |
| Abnormal Condition Protection | In a multi-unit parallel system, any abnormal unit must be quickly isolated without affecting overall output. | Multiple protections: OVP, OCP, OPP, UCP, UVP, OTP and reverse protection; emergency stop control input interface. |
The core of the above challenges is that scaling current specifications is only the starting point; the controllability, consistency, and safety during system deployment are the actual deliverable capabilities customers require.
4. FTG Series High-Power Programmable DC Power Supply: System-Level High-Current Solution
The FaithTech FTG Series high-power programmable DC power supply is designed for applications requiring wide voltage coverage, high-current output, and flexible system expansion. With broad-range parameter specifications and built-in master-slave parallel function, the FTG Series can meet diverse test requirements from medium power to ultra-high-current systems in either single-unit or multi-unit combined configurations.
FTG Series Core Specifications
| Parameter | Specification Range |
|---|---|
| Output Voltage | 0 – 1500 V |
| Single unit max. current | 0 – 20,000 A |
| Output power | 4 – 600 kW |
| Number of parallel units | Up to 10 units master-slave parallel |
| System max. current (10 units) | Up to 200,000 A (depending on model configuration) |
| A/D resolution | 16-bit high resolution |
| Voltage measurement accuracy | 0.05% F.S. |
| Current measurement accuracy | 0.1% + 0.1% F.S. |
| Communication interface | Multi-interface, SCPI and Modbus dual protocol support |
5. Parallel Current Expansion: Engineering Path from 20,000 A to 200,000 A
The FTG Series features a built-in master-slave parallel function, supporting up to 10 same-model power supplies in parallel operation. The operating principle of the parallel system is as follows:
- Unified master control : The master unit sets target voltage, current, and power parameters; slave units automatically follow without separate configuration.
- Auto current sharing : Each slave unit independently performs current distribution, automatically adjusting to ensure consistent output across all units, preventing single-unit overload.
- Output waveform synchronization : Cascading function ensures that output ramp curves or sequence waveforms remain consistent across multiple parallel units, meeting the waveform repeatability requirements of precision processes.
- Unified digital display : The master unit's front panel displays total system voltage, total current, and total power in real time without external summation.
System Current Capability under Parallel Configuration
Using the highest-current model as an example, the system output capability after parallel expansion of the FTG Series is shown in the following table:
| Number of Parallel Units | System Max. Current (Example) | Typical Application Scenario |
|---|---|---|
| 1 unit (single) | 20,000 A | Medium-scale electrolysis processes, automotive electronics high-current testing |
| 2 units parallel | 40,000 A | Large SOFC stack testing, connector batch temperature rise validation |
| 3 units parallel | 60,000 A | Superconducting coil magnetic field excitation, industrial electroplating main circuit |
| 5 units parallel | 100,000 A | Large-scale hydrogen electrolyzer system testing, rail transit main circuit simulation |
| 10 units parallel | 200,000 A | Ultra-large superconducting equipment validation, special metallurgical process power supply |
For example, with 3 FTG Series power supplies (20,000 A per unit) in parallel, the total system output current reaches 60,000 A, fully covering test conditions requiring continuous currents above 50,000 A (such as superconducting system magnetic field excitation), while ensuring consistent current sharing and stable system output under the master-slave architecture.
It should be noted that the actual output capability of a parallel system depends on the voltage/current specifications of the selected models, busbar cross-section, and connection methods. Before system deployment, it is recommended to consult the FaithTech technical team about busbar voltage drop compensation to ensure accuracy specifications meet test standards at the system level.
6. Complete Feature Set of FTG Series
In addition to parallel current expansion, the FTG Series integrates a complete set of functional modules for industrial test and research applications, delivering test flexibility beyond expectations among products with comparable current ratings:
Precision Measurement & Monitoring
Built-in 16-bit high-resolution A/D converter, voltage measurement accuracy 0.05% F.S., current measurement accuracy 0.1% + 0.1% F.S. The front panel displays voltage, current, and power simultaneously. Analog monitoring output ports for voltage and current allow users to observe real-time output waveforms via oscilloscope, suitable for dynamic response analysis and process recording.
Constant Power Output Mode
Users can set a target output power along with voltage/current limits; the power supply automatically coordinates output voltage and current regulation to maintain output power at the set value. Adjustable response speed accommodates loads with varying slew rates, particularly suitable for the stringent power stability requirements of electrochemical processes.
Sequence Output Function
Supports programming complex voltage/current waveforms: provides 10 sequence files, each with up to 100 steps, supports looping and cascading calls, enabling arbitrary custom waveforms such as half-sine, trapezoidal, step, etc., meeting the waveform repeatability requirements of standardized test protocols.
CV/CC Priority Output
To address current/voltage overshoot caused by inductive or capacitive loads during turn-on, the FTG Series offers CV priority (fast voltage establishment, current overshoot suppression) and CC priority (fast current establishment, voltage overshoot suppression) modes, effectively protecting the device under test and avoiding protection triggers or damage due to transient overshoot.
Battery Internal Resistance Simulation
The power supply automatically reduces output voltage as output current increases, based on a preset internal resistance value, accurately simulating the internal resistance characteristics of a real battery — suitable for BMS testing, battery pack charge/discharge simulation, and other applications.
PV Array Simulation
Standard equipped with Faith Power demonstration platform, supporting basic PV simulation for photovoltaic inverter testing; optional Faith Solar PV Matrix simulation software supports 5 mainstream test standards including EN50530, Sandia, etc., can simulate series/parallel module parameter variations, cloud shading conditions, meeting complete MPPT static and dynamic performance test requirements.
Inductive Load Braking Protection (Optional)
During deceleration, motors and other inductive loads feed energy back to the power supply, causing bus overvoltage. The FTG Series offers an optional parallel energy absorber that sinks reverse energy during testing, preventing overvoltage damage while shortening braking distance and improving system dynamic performance. The absorber power is recommended to exceed 20% of the power supply's power, and multiple absorbers can be paralleled for expansion.
Multi-Interface & Multi-Protocol Communication
Standard with multiple communication interfaces, supporting both SCPI and Modbus protocols; can be flexibly integrated into automated test systems (ATS). Users configure interface parameters via the menu without additional hardware adaptation, significantly reducing system integration costs.
PC Graphical Software
Includes virtual instrument PC software supporting real-time test data acquisition, curve generation, data export, and test report printing, facilitating data management needs in laboratories and engineering sites.
7. Comparison with Industry Solutions: Flexibility & Openness Differences
Current high-current system solutions on the market are typically delivered as preconfigured racks, making it difficult for users to expand current specifications or change application scenarios based on existing hardware. The FTG Series adopts a different design philosophy:
- On-demand combination : Users can choose single-unit or multi-unit parallel configuration based on current test needs. If future expansion is required, simply add more same-model power supplies and connect to the master-slave parallel bus, without replacing the entire system.
- Wider voltage range : The FTG Series covers 0–1500 V, offering greater applicability in scenarios requiring medium-to-high voltage with high current (e.g., inverter and drive system testing).
- High functional integration : Sequence output, PV simulation, battery internal resistance simulation, constant power control, and other functions are integrated into the standard platform, eliminating the need for separate specialized instruments and reducing overall laboratory investment.
- Standardized protocol interfaces : SCPI + Modbus dual protocol support, compatible with mainstream ATE frameworks, reducing secondary development effort for automated test systems.
8. Summary
The demand for high-current test systems from cutting-edge applications such as superconducting excitation, hydrogen electrolysis, and new energy drive systems is no longer a niche scenario, but is becoming a mainstream component of industry test capabilities. The core of this demand lies not only in current magnitude, but also in whether the system can deliver stable output, parallel current sharing, complete protection, and smooth integration with automated test platforms.
The FaithTech FTG Series programmable DC power supply, through its built-in master-slave parallel architecture, seamlessly expands single-unit 20,000 A capability to a system-level 200,000 A, while providing complete engineering support in measurement accuracy, functional richness, and communication interface standardization.
For detailed FTG Series model specifications, parallel system proposal guidance, or product demonstration requests, please visit the FaithTech official product page or contact our technical support team.
References
- FaithTech, "FTG Series Combined Large Power Programmable DC Power Source", FaithTech Official Product Page, 2025–2026. https://www.faithtechate.com/products/dc-power-supply/ftg-series-combined-large-power-programmable-dc-power-source