Heavy Duty Low Loss Servo Voltage Stabilizer
Automatic Voltage Controllers | 30KVA to 8000KVA
Introduction
Power Engineers and Consultants ( Regd.), E-731, Phase VIII, Focal Point, Ludhiana, Punjab – is a group of qualified engineers led by Mr. P.K. Maheshwary who is a degree holder (Electrical Engineering ) of 1972 batch from REC. THE PEC has been in operation in the field of Servo Controlled Voltage Stabilizers, Automatic Voltage Controllers, Electroplating Rectifiers, Servo Stabilizers, Anodizing Rectifiers, Electro Colouring Transformers, Distribution Transformers, Isolation Transformers, Variable DC or AC Power Supplies, Rectifier Transformers etc.
The systems are designed and supervised by a team of qualified engineers having more than 39 years of experience to provide best quality equipment leading to total customer’s satisfaction. We have more than 10,000 installations around the country and also exported numbers of equipment to U.S.A., U.K., Africa, Middle East Countries up to 4500 KVA
Effects of Voltage Fluctuation
Inspite of best efforts, no state electricity board can ensure constant voltage to the customer because of long and inadequate distribution lines and irregular load pattern on distribution transformers. Generally Voltage is low during day time and high during night hours. Moreover on holidays, peak hours, rainy days and when agricultural and industrial load is switched off, the voltage rises sharply which is more dangerous.
This higher current affects the electrical motors (particularly smaller capacity motors up to 7.5 H.P.) in three ways:
- Higher current produces higher losses in electrical motors which causes premature failure of winding
- These higher losses of electric motors also increase the losses of cables, switches, transformers and other associated equipments.
- For smooth continuous operation of motors, over load relays are usually set at 20% higher setting.
The table below compares the behavior of 5 H.P. motor at different voltages
| INPUT VOLTAGE | CURRENT | KVA | PF |
|---|---|---|---|
400 | 7.5 A | 5.2 | 0.8 |
425 | 11% More | More | 0.7 |
435 | 19% More | 28% More | 0.61 |
445 | 26% more | 38% More | 0.57 |
The table below compares the behavior of 60 watt lamp at different voltages
| VOLTAGE | CURRENT | WATTS | LUMINOUS INTENSITY | LIFE IN HOURS |
|---|---|---|---|---|
230 | 0.26 | 60 W | 710 | 1000 |
240 | 0.27 | 65 W - 8.3% More | 820 | 575 |
250 | 0.28 | 70.6 - 17.6% More | 943 | 338 |
260 | 0.29 | 75.4 - 25.6% More | 1073 | 200 |
270 | 0.31 | 83.4 - 39% More | 1213 | 100 |
Where To Install power industrial servo voltage Stabilizer
If you have your own distribution Transformer, then it can be installed in LT Side of transformer after ACB / MCCB. Output of stabilizer can be connected to common bus bar of MV Panel, so that entire plant will get stabilized voltage. Otherwise, it can be installed in the selective feeders where critical loads have been used. If you get LT (415V) supply from the State Electricity Board then in order to get stabilized voltage for the entire plant, it can be installed immediately after metering.
Advantages of Installing Servo Voltage Stabilizers
Applications of Servo Stabilizer
- Reduction in breakdown of electrical equipments.
- Improvement in power factor.
- Power saving (reduction in power bills).
- Depreciation as per Income Tax Act in India.
- Uniform quality of end products.
- Better efficiency in plant.
- Reduction in MDI.
Technical Specifications of Servo Voltage Stabilizer
| Input Voltage Range | 360-450V | 350-460V | 340-460V | 340-480V | 320-480V | 300-500V |
|---|---|---|---|---|---|---|
Efficiency (as per calculation) | 99.5% | 99.3% | 99.10% | 99% | 98.7% | 98.10% |
| Input Voltage Range | 400V ± 1%, 3Phase, 50Hz . |
|---|---|
Output Voltage Adjustment | ± 5%. |
Output Voltage Regulation | ± 1% (at no load / full load). |
Correction Rate | 10V -15V / second or as per requirement . |
Temperature Rise (Max.) | 35°C-40°C above ambient. |
Cooling | Naturally Oil Cooled. |
Insulation | Class 'A'. |
Type | Indoor. |
Mode of Systems | Fully Automatic / Semi Automatic / Manual. |
Mounting | On Uni-directional wheel. |
Wave form Distortion | Nil. |
Duty Cycle | 100% Continuous. |
*All specifications/calculations are subjected to change due to regular improvements in products without prior notice.
Basic Power Circuit of Servo Stabilizer
Description of POWER Make Servo Voltage Stabilizer
Servo Stabilizer primarily consists of the following
Linear, Plus / Minus type vertical rolling contact voltage regulator
In our regulator we use heavy section of electrolytic grade rectangular copper strip instead of copper wire to minimize the losses & increase the efficiency of equipment. We are also using self lubricating Carbon Roller Assemblies instead of ordinary Carbon Brushes which offers more reliability and trouble free performance of the equipment.
Double wound Buck / Boost type series Transformer
In our Buck / Boost transformer we use CRGO lamination to minimize iron losses and coils of Buck / Boost transformer are wound with heavy section of multi strips electrolytic copper to minimize copper losses for getting better efficiency of the equipment.
Electronic control circuit and meter panel
Automatic Voltage Controller consists of very simple electronic control circuit for monitoring and controlling voltage, repair & maintenance of which is very easy ( ALTHOUGH IT IS NOT REQUIRED EVEN FOR SEVERAL YEARS ). The regulator and Buck / Boost transformer are oil cooled, housed in same or separate sheet steel tanks. Radiators are provided for effective cooling. The coils of voltage regulator & Buck / Boost Transformers are vacuum impregnated and oven dried as per IS.
Salient Features of POWER Servo Controlled Voltage Stabilizer
Vertical Voltage Regulator
Better Llife
The life of POWER make stabilizer is more than 20 TO 25 years at full load.
Double Wound Transformer
Double Wound Transformer is a conventionally designed step down transformer and confirming to IS 2026 as regards the temperature rise and insulations are concerned. These transformers are wound with multiple strips of electrolytic prime grade copper strip to minimize power losses. Servo Voltage Stabilizers are designed liberally as per capacity and are ideally suitable for marginal overloading conditions. Cooling ducts are provided to keep the hot spot temperature as low as possible. Coils are dried in electric oven and rigid connection support and coil clamping are provided to ensure high short circuit strength. We use very high quality 0.27mm to 0.3mm thick CRGO core, so no load losses becomes very less in our Servo Voltage Stabilizers.
Insulation
Precompressed board, PARMALI board and JAPANEESE insulation paper of best quality is used
Core
The core is constructed from low loss, cold rolled, grain oriented, annealed laminations of electrical sheet steel conforming to the latest international standards. Special frame is built in-house for clamping the core to reduce the magnetic noise as well as making the whole structure rigid and robust.
Oil
Oil tested for resistivity, dielectric and acidic characteristic conforming to IS 335. ABSOLUTELY NEW TRF. OIL IS USED BY POWER.
Tanks and Paint
The tanks are made of M.S. steel plated / sheets with adequate bracing & stiffeners. All the external surfaces are given a primary coat of Epoxy primer and finishing coat of Epoxy paint for better life.
Payback Period
Owing to its high efficiency and associated benefits, the payback period for the cost of POWER's Servo Voltage Stabilizers is from 6-12 months depending upon the input voltage variation and number of working hours of the plant. The HIGHER the input voltage the SHORTER will be the payback period.
Onload Voltage Regulator
POWER Sevo Voltage Stabilizers are equipped with Vertical, Copper Strip Wound, Rolling Contact type Voltage Regulator. These voltage regulators are ± type, wound with heavy section of electrolytic grade rectangular copper strip and fitted with Carbon Rollers. POWER Voltage Regulators have higher efficiency of above 99% and are suitable for continuous duty cycle. Self lubricating Carbon Roller Assemblies offer more reliability and trouble free performance of the equipment. In POWER Voltage regulators Carbon Rollers move on both sides of the coil to give ± 440V or ± 230Volts.
Efficiency
The efficiency of POWER make stabilizer is more than 98-99.5% depending upon the input voltage range.
Duty Cycle
POWER MAKE stabilizers are Heavy Duty, Industrial type, suitable for 100% load and continuous duty cycle. For running load of 200 KVA, POWER make 200 / 225 KVA is suitable.
Windings
Coils are wound with paper covered electrolytic grade copper strip or synthetic enameled copper conductors. Cooling ducts are provided to keep the hot spot temperature as low as possible. Coils are dried in electric ovens. Rigid connection support and coil clamping is provided to ensure high short circuit strength.
Metering
Good quality of Voltmeter and Ammeter with selecter switches are provided on a separate panel to indicate the output voltage and current.
Carbon Roller Assembly
Temperature Rise
Automatic Voltage Controllers are designed for max. 40-45 degree temperature rise at top of oil whereas allowed limit is 50°C.
Construction
Voltage Regulator and Buck / Boost Transformer are fitted in a common frame and housed in same sheet steel tanks. Absolutely new radiators are provided for better cooling. Servo Stabilizers are painted with EPOXY paint, which is resistant to acidic environment in the plant. We use new IS 335 grade Transformer Oil from Silvassa which provides better cooling and in turn increases life of Servo Voltage Stabilizer.
Warrantee & Customer support
POWER's Servo Voltage Stabilizers are warranted for 5 years against any manufacturing defect. Inorder to ensure complete customer satisfaction, we provide excellent customer service to our clients. We also offer friendly technical assistance for new installation where highly qualified engineers will attend your quiries.
Effect of Input voltage unbalancing
- With 5% Unbalanced Input Voltage between phase to phase - the LOAD will be unbalanced and the capacity of the motor reduces by 40%.
- Consumption of the three phase motor will increase by 20 - 25%.
Comparison between POWER make
and dimmer type Servo Stabilizers
POWER Servo Stabilizer
- Linear, plus / minus, vertical type rolling contact Voltage Regulator is used.
- POWER Voltage Regulators are wound with heavy section of copper stip (having four times more cross sectional area) to keep lowest current density and thus above 99% efficiency is obtained.
- Due to lesser losses and compact design, oil quantity required become almost half.
- To avoid wear and tear, self lubricating carbon roller assembly is used instead of ordinary carbon brushes. Hence the carbon deposit in the track is Nil, which offers more reliability and trouble free perfomance of the equipment. Life of carbon roller is about 1,00,000 Meter track level.
- POWER stabilizers are of heavy duty type and suitable for 100% loading condition and continuous duty cycle.
- Life of POWER Servo Voltage Stabilizer is 15 to 20 years full load.
- In POWER Voltage Regulator, carbon rollers are sliding in both sides of the coil. At full buck or boost condition, rollers will be in extreme end. In this position primaries of buck-boost transformer get direct supply from top rollers and bottom rollers help to form star connection. Regulator copper losses become zero and get approx. 99.5% efficiency.
- Vertical regulator design in POWER servo stabilizer saves floor area.
- POWER Automatic Voltage Controller or Servo Voltage Stabilizers are warranted for five years in india. No risk for 5 years and no AMC is required.
Servo Stabilizer using Dimmer
- Toroidal wire wound carbon brush type Voltage Regulator is used.
- Conventional manufactures use wire wound voltage regulator popularly known as Dimmer or Varic. Due to lesser cross-sectional area current density is more, hence losses also. Efficiency of conventional stabilizer is 95%.
- More oil quantity is required to maintain the temperature within the limit.
- Carbon brushes slide over the windings and tends to wear off; there by causing carbon deposit in between turns, which naturally shortens the life of the regulator. Frequent track cleaning and replacement of carbon brush is required.
- Conventional Stabilizers can be loaded only up to 70% continuously.
- Maximum life is 3 to 4 years at full load.
- In conventional regulator, carbon brush is sliding only in one side of the coil. At full buck or boost condition, current flow through the regulator winding become maximum and efficiency lowered to less than 94%.
- Space required is almost double.
- Conventional Stabilizer suppliers normally offer one year warrantee. Later, end up in bearing risk for another 4 Years. In order to avoid the risk customer is being compelled to go for expensive AMC for the rest of the years.
Superior Features of POWER Automatic
Servo Voltage Stabilizers
Comparison of Power Make Voltage Controllers with Conventional makes
In the conventional dimmerstat of 100 Amps, winding is done using 10mm2 Copper wire. In our voltage regulator of 100 Amps, we use copper strip of 20mm2. That means cross sectional area used in our regulator is double than that used in dimmerstat by other manufacturers. In the voltage regulators manufactured by us, the roller moves on both sides of the coils. In one direction, it increases the voltage and in the other direction it decreases the voltage. In conventional dimmerstat, carbon brush moves only in one direction, requiring double capacity regulator used by us.
Power losses of electrical equipments are directly proportional to the square of the current drawn by it. Considering the lesser cross sectional area and the need of double capacity regulator, losses of dimmerstat becomes four times compared to losses in our regulators. Because of this fact, efficiency of our voltage stabilizer is approx. 99% compared to less than 95% of conventional makes. This 4% better efficiency can save substantial amount of power in stabilizer losses as explained below:- In case of a 100KVA Voltage Stabilizer, four units of power per hour can be saved and the annual saving can be calculated as follows:-
4units x 24 hours a day x 365 days x Rs. 4/unit = Rs. 1,40,160/-
Long life at full load
Carbon rollers instead of carbon brushes for lesser maintenance and long life
Negligible losses at full buck / boost conditions
100% duty cycle reduces KVA requirement.
5 Years Warrantee
Save 15 to 35% electrical energy by
installing Voltage Stabilizer in Lighting Feeder
| VOLTAGE | CURRENT | WATTS | % OF EXTRA CONSUMPTION | LUMINOUS INTENSITY | LIFE IN HOURS |
|---|---|---|---|---|---|
230 | 0.26 | 60 W | Nil | 710 | 1000 |
240 | 0.27 | 65 W | 8.3% | 820 | 575 |
250 | 0.28 | 706W | 70.6% | 943 | 338 |
260 | 0.29 | 75.4 W | 25.6% | 1073 | 200 |
270 | 0.31 | 83.4W | 39% | 1213 | 100 |
From the above table it is clear at 230Volt, a bulb consumes normal power and deliver its normal luminance with designed life. Even a small increase in voltage will cause tosharp increase in power consumption and its life reduce drastically.
Transformers are designed in India with 11KV/433V ratio and voltage remains 430V or even higher specially during night hours.
Major Energy Auditors including Confederation of Indian Industry recommend Automatic Voltage Stabilizer in lighting feeder with output voltage 360V. (210 V SinglePhase ) . Many Industries have already installed SVS for this purpose and theyhave confirmed the following advantages after installing the same.
- More than 20% -30% Energy can be saved.
- Reduction in break down of Bulbs, Tubes, Control Gears, Chokes, starters etc.
- Life of luminaires increase upto 150% to 200%
- Improvement in Power Factor.
- Uniform Luminous Output.
- Reduction in MDI
Energy Saving Principle
Tube light, Sodium vapor lamp, Mercury vapor lamp, Metal halide lamps, CFL etc. are gas discharge lamps. Above certain power, performance of gas discharge lamp saturates and saving is achieved by cutting excess energy consumed by load. Because of this, life of lighting devices extends, choke burning reduces and thus maintenance and hazards are minimized. This is based on principle that, above saturation region, even if more power is pumped in luminaries, it gets dissipated in form of heat thereby even reducing it’s life. Lamp manufacturer propose lower power usage for increased lamp life at optimum lumen level. Please note that lighting energy saving system is optimization between luminosity and power.
The table below shows the practical readings obtained with the help of MICRO VIPLOAD MANAGER at different voltages in the premises of Textile Mills in Coimbatore.
| VOLTAGE | CURRENT | WATTS | % OF EXTRA CONSUMPTION | LUMINOUS INTENSITY | LIFE IN HOURS |
|---|---|---|---|---|---|
230 | 0.26 | 60 W | Nil | 710 | 1000 |
240 | 0.27 | 65 W | 8.3% | 820 | 575 |
250 | 0.28 | 706W | 70.6% | 943 | 338 |
260 | 0.29 | 75.4 W | 25.6% | 1073 | 200 |
270 | 0.31 | 83.4W | 39% | 1213 | 100 |
| 3 Phase V | Single Phase V | Amps | P.F | K.W | % of saving |
|---|---|---|---|---|---|
360 | 210V | 19.7 | 0.74 | 8.88 | 0% |
371 | 215 | 21.1 | 0.71 | 9.77 | 9.10% |
382 | 220 | 22.4 | 0.70 | 10.5 | 15.4% |
392 | 225 | 23.9 | 0.69 | 11.1 | 20.00% |
401 | 230 | 25.3 | 0.67 | 11.7 | 24.10% |
411 | 237 | 26.8 | 0.65 | 12.5 | 28.96% |
431 | 242 | 29.2 | 0.64 | 14.0 | 36.57% |
441 | 248 | 30.7 | 0.63 | 14.8 | 40.00% |
451 | 260 | 32.5 | 0.62 | 15.4 | 42.33% |
While reducing the voltage to the level of 360Volts, (210V. single phase) percentage of reduction in lumen is negligible compared to the percentage of energy saved.
While selecting an Automatic Voltage Stabilizer for this application, efficiency and durability of the equipment have to be considered. Otherwise, saved energy will be consumed by the stabilizer.
Features of Power Voltage Stabilizer
- POWER Stabilizers are of heavy duty type, wound with heavy section of copper strip, facilitating more current flow suitable for 100% loading conditions and continuous duty cycle.
- POWER regulators are wound with heavy section of copper strip (having 4 times more cross sectional area) to keep lowest current density and ensures 99% efficiency. In conventional type stabilizers, toroidal type wire wound regulator is used. Due to lesser cross sectional area, current density is more hence losses also. Efficiency of such stabilizers is only 94 to 95%.
- In POWER regulators carbon rollers are sliding in both sides of the coil. At full buck and boost condition, regulator copper losses becomes zero. In conventional stabilizers, at full buck and boost condition, regulator losses will be maximum and efficiency lowered to less than 94%
- We use carbon roller assembly instead of brushes to avoid wear and tear.
- Since losses are at the lowest, the life of POWER Stabilizer is more than 20 years.
Payback period of POWER’s enegy saving Voltage Stabilizer.
Considering energy saving, reduction in failure rate, increased life of luminaries and 80% depreciation allowed as per IT Acts, normally payback can be achieved within a period of 6-8 months. Please note that life of POWER Voltage stabilizer is more than 20 years and warranted for 5 years in India.
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