Servo Voltage Stabilizers
Technology
Advantage
Quality
Manufacturing
Applications
Capacity
Technology
The Technology concept of Differential wound linear regulator with Series Transformer in HIND’S make Automatic Voltage Controller.
We are manufacturing Industrial type Automatic Voltage Regulators (Stabilizers/Rectifiers) using the differential wound Vertical Roller Type Regulators. Manufacturing LINEAR TYPE +/- Heavy Duty Regulators with rollers rolling on both the sides of the coil (as illustrated in the brochure enclosed). The size of conductor used is more than THREE TIMES than used in conventional design regulators. Being + type, the same winding is used for boosting the voltage on one side and bucking the voltage on the other side of the regulator. So, the rating of the regulator required is half of the conventional design regulator.
The losses of differential wound linear regulator should be 1/18th of the conventional type regulator and due to heavy section of copper used in our regulator, overall size is more and practically the losses of our regulator are 1/5th of the conventional type regulator.
The manufacturing material cost of differential wound linear regulator is almost more than THREE TIMES the cost of conventional design Regulator.
As per the Regulator design, the regulator is technically OUT OF CIRCUIT, when the input voltage is LOWEST/HIGHEST as per the voltage range of the stabilizer while in stabilizer with conventional brush type regulators, the regulator is maximum in the circuit and losses are maximum at LOWEST/HIGHEST as per the range of the stabilizer.
The Actual Efficiency of our stabilizer in running conditions at 100% Load for the (360-460 V) model will be 99.5% in comparison to less than approx. 95-96% of conventional type stabilizer for the Automatic Voltage Controller of similar rating.
WINDINGS – linear Coils are manufactured with copper strips of heavy cross sectional area instead of copper wires in conventional design with 4-QPC paper layer cover plus 3 TPC – Polyester film cover for better insulation to resist the high temperatures on continuous duty cycle with Electrolytic grade copper strip while taking the current density of 2 to 2.5 amps/mm2 in oil therefore the maximum temperature rise at full load never goes more than 25 degree centigrade while in conventional design accordingly we use more copper than any other manufacturer to give the highest quality with minimum losses for the entire running life of the equipment. Radiators Cooling is provided to keep the hot spot temp. As low as possible for higher working efficiency for all the years with lowest temperature rise even on full load conditions.
CORE – The core is constructed from low loss, cold rolled, grain oriented, annealed laminations of electrical sheet steel conforming to the latest internationals standards using grade 4 laminations with thickness from 0.23mm to 0.27mm for minimum no load losses.
CARBON ROLLER – We are giving self lubricating carbon roller assemblies with working life of 1 lakh track meters instead of Carbon brush used in conventional technology. Our rollers are point contact with least wear and tear as surface area in contact keeps on changing during the running motion and heat is dissipated through out the body resulting in very high working life on maximum temperature rise with spring tension behind to keep the roller intact with required torque on coil for trouble free operation.
As stabilizers being of Capital equipment, its Life is considered to be 15-20 years. Considering this, we design our equipment accordingly introducing further improvements in the construction of equipment as per feedback received from the customer.
CONTINUOUS DUTY CYCLE – The stabilizers with Roller type Regulators are wound with heavy section of copper strip suitable for continuous duty on 100% load.
Normally, conventional design regulator are designed for temperature rise of 45*C to 55 degree centigrade. We keep temperature rise between 15*C to 20*C, which means that our machine can sustain 15-25% overloading without any harm to the equipment for shorter duration.
LIFE – Life of our stabilizer is more than 20-25 Years as compared to 2-3 years of conventional type stabilizers at FULL LOAD. This is due to the fact that the losses for our differential wound linear regulator model shall be least as against maximum of conventional design regulator and therefore due to these higher losses there shall be more heat generated inside the conventional regulators, which shall ultimately result in the faster deterioration of the paper insulation being used for the winding & thereby resulting in shortening of life of the stabilizer.
In the conventional design regulators, you have to bear the cost of repair & replacement.
Un-Conditional GUARANTEE – Our equipments are guaranteed unconditionally for FIVE YEARS against any defects. During this period, we do not charge anything for spares, services & routine checkups provided to the installation.
SERVICING – We have servicing network all over India for the following reasons:
- To provide prompt/Immediate services to our customers in case of minor problems.
- Regular routine check ups once in two months for checking the performance of our Stabilizer.
- No charges for installation/inspections etc. to be carried out during the visits of service engineer/technician while others will charge AMC after the completion of Warrantee period and for routine visits also.
Advantage
By installing voltage controller, you can save 10% to 20% power consumption of lamps, tube etc. and reduce its failure rate up to 80% if you are having higher voltage problems. It has been observed that the industries usually face the problem of both low as well as high voltage problem. With the installation of AVC and by maintaining 400/230 volts three/single phase – you will certainly achieve the advantages as explained under:
- Reduction in Breakdown of Electrical Equipments: 60-80% depending upon the input voltage ariation and working hours of the plant.
- Energy Saving: 5-10% depending upon the input voltage variation and working hours of the plant.
- Reduction in MDI: There will be definite reduction by 10 -15% after the installation of the equipment.
- Improvement in Power Factor: There will be definite improvement in the power factor by 10-15% after the installation of the equipment.
- Uniform Quality of end product.
- Better Utilization of Existing Transformer and cables.
- Lesser production loss and better efficiency of plant.
- Depreciation allowance @80% as per Income Tax Act.
The table below gives approximate quantitative advantages of Automatic Voltage Controller at various voltage fluctuation levels
| Inputs Voltage Variation | Reduction in breakdown possible | Appx. Power Saving Possible | ||
| Motor Load below 10 hp | Lighting Load | Motor Load below 10 hp | Lighting Load | |
| 380 – 400 Volts | Nill | Nill | Nill | Nill & No Servo Stabilizer Requiredl |
| 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% |
Quality
CORE -
The core will be constructed from low loss, cold rolled, grain oriented, annealled laminations of electrical sheet steel conforming to the latest internationals standards using grade 4 laminations with lamination thickness from 0.24mm to 0.27mm for the minimum no laod and load losses
WINDINGS -
Coils will be wounded with 4- DPC paper layer covered plus 3 polyster film cover for better insulation with Electrolytic grade copper strip and taking current density of 2 to 2.5 amps/mm2 in oil accordingly we use more copper than any other manufacturer to give the highest quality with minimum losses for the entire running life of the equipment. Radiators Cooling is provided to keep the hot spot temp. as low as possible for higher working efficiency for all the years with lowest temperature rise even on full load conditions.
TANKS , PAINTS & OIL -
The acoustic enclosure/tanks will be made of sand blasted M.S. steel plated / sheets of 3 mm thickness with adequate bracing & stiffners. All the external surfaces are given a primary coat of 2 Pack Epoxy primer and finishing two coat of Epoxy paint for better life with chemical treatment inside with seven tank paint procedure for the effective protection of the enclosure while woking in the toughest of the chemical and mositure zones.
OIL – Oil will be tested for resistivity, dielectric and acidic charactristic conforming to IS 335. Before topping up oil is filtered throughly. We use HT grade 11 KV oil even for the LT equipment for better dielectric strength and high flash point.
Protection: We will give tripping to your existing ACB/MCCB in case of single Phasing with single phase preventer. Under voltage cut off and over voltage cut will also be provided.
AVR -
Linear Copper strip wounded regulators in Diiffrential Winding, plus / minus type with negligible losses due to differential winding as regulator part is out of ckt on minimum amd maximum conditions. This regilator is wounded with copper strip wheare as in market the series type regulator are made of copper wire with highest losses due to series winding. The losses of our regulator are 1/18th in comparision to others. Self lubricating carbon roller assemblies.
CARBON ROLLER -
We are giving self lubricating carbon roller assemblies with working life of 1 lakh track meters instead of Carbon brush used by others. Our rollers are point contact with least wear and tear as surface area in contact keeps on changing during the motion and heat is dissipiated through out the body resulting in very high working life on maximum temperature rise with spring tension behind to keep the roller intact with coil for trouble free operation for ages.
Manufacturing
Mass Manufacturing Facility for all products.
Features :
- Plant capacity to produce 50 MVA power transformers per annum.
- Plant is capable to produce and test 66 kV Transformers
- Epoxy coated floor in complete shop
- Built up area 40,000 Sq. feet.
- In-house fabrication facility to manufacture 50 MVA Transformers tanks.
Applications
1, Main Feeder Voltage Controller :
This type of controller is normally required where there are long transmission lines of medium high voltage. They are controlled automatically and are in general, provided with line drop compensation, i.e. the output voltage increases with increase of load. Sizes up to 7500 KVA at 33 KV available.
2, Distribution Controller :
This type of controller varies in size from 60 to 1000 VA through out and are, in general. Used on three – phase 340 to 440 volt system for feeding small towns or sections of fairly densely populated areas. Another use includes the supply system to factories and large buildings. These equipments can be indoor or outdoor substations types, ground or platform mountings.
2, Electrolytic Plating :
Plating applications demand low voltage and high current D.C.. This is Normally obtained from a metal plate or diode rectifier and transformer. Control of the transformer primary voltage by a rolling contact regulator provides steeples on load voltage control giving ideal control of plating current without introducing unnecessary harmonics.
The smooth and steeples On-load control gives an even deposition and Bright finish. Automatic Voltage Controlled plating can also be done with type of controller.
4, Nuclear Power Research and Nuclear Electricity Generating Station :
Stepless On-Load voltage Control without waveform distortion is necessary for nuclear and similar research work. The primary use is in the control of electric power for heat studies and heat transfer research.
Nuclear Electricity Generating stations utilize rolling contact controllers to stabilize the essential power supplies for the operation of the station and for the safety of the station under Emergency conditions.
5, Variable Speed Drives :
Rolling Contact Voltage Controller can be used in four distinctly separate ways to obtain Variable Speed Drives:
- Control of armature voltage of medium and large D.C. Motors.
- Injected phase displacement on A.C. Commutator Motors.
- Slip Power Recovery.
- Controlled frequency drives.
6, Testing Departments and Laboratories :
The rolling contact controllers are extensively employed in testing departments and laboratories both for routine production testing and for research development work. Typical examples include:
Short circuit and over potential testing of power and distribution transformers, current transformers, Potential Transformers etc.
No-load and locked rotor testing of motors.
Normal and over potential testing of capacitors, Reactors, Cables, Heaters, Rectifiers etc.
Routine and development testing of electrical instruments, meters and recorders to ensure the limits of accuracy are maintained for wide variations of voltage current etc.
Testing entails the accurate measurement of voltage, current, power factors etc and the characteristics of the rolling contact controller and such accuracy is unimpaired by Waveform distortion or harmonics.
7, Chemical Electrolytic Process:
With the growing demand for hydrogen, oxygen and chlorine, the chemical industry is increasing it demand for large sources of variable DC Power with Automatic Control by a rolling contact controller and with silicon rectifiers the efficiency and power factor are maintained at very high levels.
8, Electrolytic Refining:
The control of rectifiers for the electrolytic refining of copper etc., is an application generally similar to Chemical Electrolytic Processes. Step less On – Load control by rolling contact controllers provides an ideal control to meet the heavy and arduous conditions.
9, Resistance Furnaces:
Rolling Contact step less On – Load voltage controllers are used extensively to control electric furnaces and heaters. The control can be done by hand, remote or entirely automatic.
10, Glass Melting Furnaces:
In the past, most furnaces of this type have been oil or gas fired, where the thermal efficiency has been as low as 5% even under optimum conditions. Compared with this, an all electric furnace has a thermal efficiency of 50 to 60%.
As glass has a negative resistance characteristic, a very precise and flexible control is needed to vary the voltage feeding the electrodes. The rolling contact voltage controller is ideally suited for this purpose, particularly as it does not introduce any disturbance into the current waveform.
11, Glass Annealing Furnaces :
This type of furnace is of the resistance heating type and is constructed of resistance elements forming zones of heat in the roof and floor as well as the sides. Each zone can be controlled by separate rolling contact Controllers.
12, High Frequency Furnaces :
H.F. Generators are particularly sensitive to poor supply voltage, and stabilization of this voltage is essential if maximum power output is to be obtained.
In many types of H.F. Generators, the frequency is proportional to the input voltage and so the penetration to the input voltage and so the penetration of H.F. heating can be controlled by an adjustable output rolling contact Controller. The lack of waveform distortion is a necessity in this application.
13, Telephone Repeater Stations :
Extensive telephone systems require numbers of repeater stations which have to operate all the year round and are sometimes sited in inaccessible place where maintenance is extremely difficult. Reliability therefore is essential. Rolling contact controllers are installed in very many of these repeater stations.
14, Radio, Radar and Television Transmitters :
Many Transmitting stations in India and abroad use the rolling contact controller to control the input voltage to electronic equipment. Radar Stations AND Micro – wave links also use rolling contact controllers for the same purpose.
15, Electrophoresis : (Electro – deposition of paint) :
As with the electro – deposition of metal the Rolling Contact Voltage Controller can be used in conjunction with rectifier equipment to provide the control D.C. voltage and current for the electro-deposition of priming coats of paint.
16, Cable Voltage Testing :
The A.C. Voltage Testing of cable essentially requires s sine wave voltage If power factor measurement. etc is to be realistic. The rolling contact controller is ideal for energizing the step-up voltage transformer.
17, Capacitor Testing :
Rolling Contact Regulators are used for the control of applied voltage and For adjustable power factor correction in a manner generally similar to that described for cable testing.
18, Control of High Voltage D.C. Test Supplies :
The control and measurement of high voltage D.C. supplies for testing and for research is an application where the characteristics of the Rolling Contact Regulator is ideally suitable. No waveform distortion, linear rate of rise of voltage, sensibly constant reactance through out the regulated range, are some of the features that contribute to the almost universal choice of the Rolling Contact Regulator for this application.
19, Battery Charging and Battery place forming :
The charging of Batteries and the forming of battery plates requires controlled adjustable D.C. Voltages and the rolling contact regulator feeding rectifier equipment can provide. This control within the required degree of accuracy. A.C. Supply Voltage variation can be off-set automatically.
A part from above there are various other applications, e.g. Cinema Rectifiers, etc.
Capacity
We manufacture Automatic Voltage Controllers of 30KVA to 7000 KVA