Automatic Servo Stablizer Manufacturer - Ghaziabad

automatic-voltageInspire 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 upto 7.5 H.P.) in three ways

  1. Higher current produces higher losses in electrical motors which cause premature failure of winding.
  2. These higher losses of electric motors also increase the losses of cables, switches, transformers and other associated equipment.
  3. For smooth continuous operation of motors, over load relays are usually set at 20% higher setting.

With the installation of the stabilizer and maintaining 390/400 volts, the motor will operate smoothly drawing 15 - 20% lesser current and correspondingly the relay setting can be reduced by 15 - 20%. In case single phasing occurs, the relay will trip in 40 - 50 seconds. The motors can withstand the high current for this period and will be safe. Also, the relays, contactors, switchgears, etc. incorporated with the motor will be safe.

 
  • Description
  • Compares
  • Types
  • Special Features
  • Specifications

Description of POWER Make Automatic Voltage Controller

Servo Stabilizer / Servo Voltage Controller primarily consists of the following

  1. LINEAR, PLUS / MINUS TYPE VERTICAL ROLLING CONTACT VOLTAGE REGULATOR
    In our voltage regulator we are using 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 offer more reliability and trouble free performance of the equipment.

  2. DOUBLE WOUND BUCK / BOOST TYPE SERIES TRANSFORMER
    In our Buck / Boost transformer we are using CRGO lamination to minimize iron losses. 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.

  3. ELECTRONIC CONTROL CIRCUIT AND METER PANEL
    Automatic Servo Voltage Controller consists of very simple electronic control voltage circuit for monitoring and controlling voltage, repair & maintenance of which is very easy. 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.


Effect of Unbalanced Input Voltage between Phase to Phase
Industrial units situated in residential / commercial areas and not having their own distribution transformer, have the problem of unbalance input voltage between phase to phase and many have the problem of frequent failure of three phase motors. Normally unbalanced input voltage problem persists for few hours a day and will have the following effects on the three phase motors:

  1. With 5% Unbalanced Input Voltage between phase to phase - the LOAD will be unbalanced and the capacity of the motor reduces by 40%.

  2. Consumption of the three phase motor will increase by 20 - 25%.

To avoid frequent tripping of the overload relays and to continue production, setting of motor relay is kept higher than actual required. The motor (particularly smaller motors upto 7.5 H.P.) cannot withstand this high current for long time and in most cases the motor burns out and this high current flows through the relays, contactors, cables etc. resulting in failure of the same and in some of the cases may cause fire also.

The table below compares the behaviour of 5 H.P. motor at different voltages:
INPUT VOLTAGE CURRENT KVA PF
400 7.5 A 5.2 0.8
425 11% More 18% More 0.7
435 19% More 28% More 0.60
445 265 more 38% More 0.57
The table below compares the behaviour 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

Types of Automatic Voltage Controller

Balanced Type Automatic Voltage Controller Automatic Voltage Controller
Balanced Type Automatic Voltage Controller Automatic Voltage Controller with Bypass arrangement
Automatic Voltage Controller Automatic Voltage Controller
Unbalanced Type Automatic Voltage Controller Automatic Voltage Controller with Isolation

Special Features Of Power's Make Automatic Voltage Stabilizers :
  1. EFFICIENCY
    The efficiency of power make stabilizers is more than 98-99% in comparison to 93-97% of conventional make available in the market depending upon the input voltage range.
  2. BETTER LIFE
    The life of make servo voltage stabilizers is more than 10/15 years at full load in comparison to 2/3 years of conventional make.
  3. DUTY CYCLE
    Conventional type stabilizers are suitable for 30-40% load on continuous duty cycle. Our automatic voltage stabilizers are Heavy Duty & Industrial type and are suitable for 100% load continuous duty cycle. For running load of 200 KVA, generally 400 KVA / 500 KVA conventional type stabilizer is installed while make 200 / 250 KVA is suitable.
  4. GUARANTEE
    Our automatic voltage stabilizers are guaranteed unconditionally for 5 years as compared to 1 year of conventional make.
  5. 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.
  6. SERVICING
    We have all India servicing network to provide immediate service to our customers. The Service Engineers also visit monthly in their respective areas for routine check-ups. Also, servo controlled voltage stabilizers are categorized under ENERGY SAVING. The servo controlled voltage stabilizers should be such that its own consumption is minimum otherwise the basic concept of Energy conservation will be lost.
  7. TEMPERATURE RISE
    Automatic Voltage Controllers and Automatic Servo Voltage Controllers are designed for max. 35-40 degree temperature rise at top of oil whereas allowed limit is 50' C.
  8. 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.
  9. 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.
  10. INSULATION
    Pre-compressed board PARMALI board and JAPANEESE insulation paper of best quality is used.
  11. OIL
    Oil tested for resistivity, dielectric and acidic characteristic conforming to IS 335. Before topping up oil is filtered throughly.
  12. TANKS AND PAINT
    The tanks are made of M.S. steel plated / sheets with adequate bracing & stiffness. All the external surfaces are given a primary coat of Epoxy and finishing coat of Epoxy paint for better life.
  13. METERS & CONTROL SYSTEMS
    AE meters and quality products for controls are used.

APPROXIMATE QUANTITATIVE ADVANTAGES OF AUTOMATIC VOLTAGE CONTROLLER AT VARIOUS FLUCTUATION LEVELS

INPUT VOLTAGE VARIATION % REDUCTION IN BREAKDOWN POSSIBLE APPROX. POWER SAVING POSSIBLE
Motor load below 10 Hp Lighting load Motor load below 10 Hp Lighting load
380 - 400 volts Nil Nil Nil Nil
380 - 420 volts 5% 10% 3% 5%
380 - 440 volts 10% 20% 5% 10%
380 - 460 volts 40% 40% 7% 20%
380 - 480 volts 60% 60% 10 30%

TECHNICAL SPECIFICATIONS

Servo Voltage Stabilizers are available in a wide range and various models. The standard three phase models are suitable for balanced & unbalanced supply and loads. The standard models confirm to the following specifications:

VOLTAGE CURRENT WATTS LUMINOUS INTENSITY LIFE IN HOURS
380 - 400 volts Nil Nil Nil Nil
380 - 420 volts 5% 10% 3% 5%
380 - 440 volts 10% 20% 5% 10%
380 - 460 volts 40% 40% 7% 20%
380 - 480 volts 60% 60% 10 30%

Comparison Of Power Make Regulator With Conventional Regulator

The efficiency and life of power make Automatic Servo Voltage Stabilizers is much better as compared to the Conventional Servo Voltage Stabilizers manufactured by other manufacturer as per the details given below :-
  1. In the Conventional Dimmerstat of 100 Amps. current, winding is done by 10 mm2 approx. copper wire, while in our voltage regulators of 100 Amps. use copper strip of cross section area 20 mm2 copper. That means our copper area for the same voltage input regulators is double than that of dimmerstat used by other manufacturers.
  2. In the voltage regulators manufactured by us, the roller moves on both sides of the coils i.e. in one direction, it increases the voltage and in the other directions it decreases the voltage.
  3. Since the power losses of electrical equipment are directly proportional to the square of the current drawn by it. For above case the losses in conventional dimmerstat are four times because of lesser copper size and with double the sizes of dimmerstat, the losses become eight times more than the losses of our voltage regulators.