benlong 
ATS aging test bench
Benlong ATS aging test bench for automatic transfer switches (16A–3200A, PC/CB class). Programmable load/no‑load cycles up to 10,000+, multi‑station parallel test, IEC 60947‑6‑1 compliant. Real‑time monitoring of transfer delay, contact resistance, temperature. Ideal for certification labs and QC.
Automatic Transfer Switch Aging & Lifecycle Test Bench
The ATS aging bench is an automated industrial testing facility that is designed to perform tests of the mechanical and electrical endurance of dual powered Automatic Transfer Switches (ATS). The ATS aging test bench is controlled by a highly stable PLC (Programmable Logic Controller), using an HMI (Human Machine Interface). The ATS aging test bench conducts continuous load and no load operation to simulate grid transfer operations in the real world environment. The ATS aging test bench can be used to validate PC (Power Supply Class) and CB (Current Interruption) classes of transfer switches that have isolation protection and provide over current protection for ATS operation in the event of an emergency power failure or transfer of ATS sources.
The system is able to offer all programmed test parameters such as the total number of switching cycles (up to 10,000+ cycles) and Transfer Interval Times, as well as set Load Currents. It continuously monitors the Voltage, Current, Temperature, and Delay of the Switch across Multiple Test Stations, and will initiate an alarm and halt the Station due to any fault event (Transfer Missed, Contact Weld, Over Temperature). The modularity of the system allows for the use of ATS frames with a rating range from 16A through 3200A, and the test report is exportable to a Manufacturing Execution System (MES), which conforms with full IEC60947-6-1 standards.
Standard delivery: 45-60 days | Test cycles programmable | Multi-station parallel testing
What is an ATS Aging Test Bench?
An Aging Test Bench for ATS is an automated testing system used to perform mechanical and electrical endurance testing on Automatic Transfer Switches (ATS). ATS are used to support emergency power systems in transferring loads electrically from a generator or other back-up system to a primary power source (e.g. utility) and back to a primary power source. The test bench is designed to operate the ATS multiple times in an un-laden (empty) and full-laden (loaded) configuration in order to see how many years of service they would provide and therefore have a shorter total time for testing. Key measurements are made to establish the above, including key performance parameters such as transfer delay time. (Usually
Simulates real-world grid transfers with programmable load currents.
Test up to 8 ATS units simultaneously, independent monitoring per station.
Automatic stop on missed transfer, contact welding, or over-temperature.
Full audit trail and MES export for certification labs.
Machine Features & Testing Process
Technical Specifications
| Supported ATS classes | PC class (isolating) and CB class (overcurrent protected) |
|---|---|
| Current rating range | 16A – 3200A (configurable per station) |
| Test cycles (endurance) | Programmable up to 10,000+ cycles (typical IEC requirement: 1,000-6,000) |
| Test modes | No-load endurance, full-load endurance, mixed sequence |
| Switching delay measurement | Accuracy ±1ms, records I-II, II-I, and off-position times |
| Load bank (optional) | Resistive or inductive load, programmable power factor (0.7-1.0) |
| Monitoring parameters | Contact voltage drop, coil current, temperature (thermocouple), cycle count |
| Control system | PLC (Siemens/Mitsubishi) with HMI, recipe storage for 50+ ATS models |
| Number of test stations | 1 to 8 independent stations (modular expansion) |
| Power supply | 380V ±10% 50Hz | Control power 24V DC |
Core Technical Advantages
True aging simulation
Unlike simple go/no-go testers, this bench performs thousands of continuous switching cycles under controlled load, replicating 10+ years of field use in weeks.
Parallel testing efficiency
Up to 8 ATS units tested simultaneously with independent parameter sets. Ideal for high-volume QC labs and production line sampling.
Comprehensive safety interlock
Enclosed test chambers, emergency stop, and automatic station shutdown on failure (missed transfer, welded contacts, or over-temperature).
MES & certification ready
Full test reports (cycle counts, failure logs, delay times) exported as CSV or SQL. Compliant with ISO 17025 and IEC 60947-6-1 documentation requirements.
Customer Success Story
A major world-wide supplier of emergency power equipment has completed testing and approved for certification an entirely new 630A Automatic Transfer Switch (ATS) per the requirements of IEC 60947-6-1 (safety standards for electrical installations).
After completing 6000 load cycles (100A resistive load), in only 18 days, it was discovered within the tests using the ATS Aging Test Bench that there was an issue with contact bounce at cycle 4200 and redesign efforts took place before mass production began. Upon completing endurance testing on the ATS, the ATS received certification and no field returns occurred during the first year of operation.
In addition, the ATS Aging Test Bench reduced test labor by 85% when compared to carrying out the same testing using a manual operation.
The customer has since installed two additional benches for 1600A and 3200A product lines.
Applications and Test Environments
Standard Delivery and Commissioning
Request a Custom ATS Aging Test Bench Quote
Provide us with your current specifications (rating, class, test cycles) as well as your laboratory requirements. We will provide you with a custom solution crafted to comply with IEC 60947-6-1 and conduct a ROI analysis.
WhatsApp: +86 150 5837 0007 | Email: xsb@benlongkj.cn | English & Chinese support
Why Choose Benlong for ATS Testing Solutions?
- 15+ years designing power switchgear test benches for ATS and transfer switches
- Proven multi-station architecture – up to 8 parallel tests
- Seamless integration with load banks (resistive/inductive)
- IEC 60947-6-1 compliant data logging and reporting
- Global installations in certification labs and manufacturing plants
Standard System Includes
A PLC Control Cabinet with HMI, a Series of Multi-Station Test Fixtures with Custom “ATS” Configurations, Programmable Load Bank Interfaces, Real-Time Monitoring Sensor (Voltage, Current, and Temperature), a Safety Enclosure with an Emergency Stop, Data Logging Software (Exportable in both CSV and SQL formats), 1 Set of Test Wires, Certificate of Calibration, and 1-Year Warranty are included.
Frequently Asked Questions
Only a mechanical endurance and contact/resistance test is performed on the PC Class Removing Switch (ATS) (isolating switches). PC Class ATS protection (overcurrent) is not included. Circuit breakers are used in CB Class ATSs, and additional short-circuit withstand and overload tests are required. Both classes can be tested using our test bench with the appropriate parameter set.
According to IEC Standard 60947-6-1, for different ATS categories (Automatic Transfer Switch) and for various rated current levels, an installation must have between 1,000 – 6,000 mechanical/electrical cycles during operation. We can program our bench for 10,000 + cycles in order to exceed any published requirements.
It is possible to set the PLC to transitional behaviours. There are three options for the transitional sequence: open transition (break before make), closed transition (make before break), and delayed transfer. All timing parameters are programmable from an HMI.
A load bank can be added if needed. We can connect resistor, inductor or R-L (Inductive-Resistive) load banks with Power Factor Control. In addition to providing LAB’s with their own separate LB; we will also provide a TURN KEY solution to supply all the loads for you.
This system will stop at the failed station, log the reason for failure (missed transfer, contact weld, over temperature), record the failing cycle number of that station and sound an alarm. The other stations will keep testing independently of the failed ATS, which may be removed for further examination.
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