3 Phase Voltage Regulators: Industrial Applications Explained

Within industry, 3 phase power is ubiquitous and is used for everything from motors in factory production lines to advanced data centers. Even though it is from the industrial grid, the power may not always be 100% constant; machine failure will occur as there are voltage drops and spikes on the system from other machinery on the grid (when turning on a device on the system or due to the season). Voltage regulators for 3 phase are used here and balance the output power regardless of the input power. There are 4 primary uses for 3 phase regulators found within industry in this article.

Stability is the key component of precision machining. CNCs, laser cutters, and robots have delicate drives/controls, which can malfunction when there are voltage losses or surges. The loss of 10% on the power supply may cause a change in spindle speed which affects the tolerance of the machining operation, or an excess of voltage can damage the electronic control system and result in long, expensive downtime.

The 3-phase voltage regulator plays an essential role in keeping manufacturing machines well connected in terms of electrical power. They maintain the voltage output within 3% of the desired voltage and regardless of the fluctuations in the input voltage of more than 20%. One single large 3-phase voltage regulator can provide protection for all the machines within a manufacturing plant connected to a three phase distribution. Servo motor regulators are the best type of regulator for this use since they continuously accommodate adjustments to the voltage without switching that could disrupt the controls of the machine.

Power stability is extremely important in hospitals, medical laboratories and diagnostic imaging centers. In medical devices such as MRI, CT or X-ray systems, the voltage applied is required to be applied with high precision over time, to achieve good diagnostic image quality. Inconsistent voltage can create image artifacts, necessitate costly rescans and in doing so increase patient radiation exposure and defer treatments. These life-support or surgical machines require non-stop operations.

Three-phase regulators designed for medical use are also usually equipped with additional features such as galvanic isolation to meet patient safety standards, very tight voltage regulation (1-2%) for use with sensitive medical imaging equipment, and output alarms to let the facility manager know that the condition of the power is out of specification. Generally, they are available as relay or SCR regulators. The quiet, no-snap operation of SCR's is preferred when patient care is being rendered.

Three-phase power is used to operate the heating elements of large industrial heating systems such as ovens, dryers, and heat treating furnace or heat treaters as well as injection molding. If the input power varies, a heating element changes in proportion -- the heat output is proportional to the square (P = V(2)/R, of voltage). Hence, a 10% decline in input voltage results in the corresponding reduction of heat output, which reduces the process time, thereby lowering the output. On the other hand a 10% rise in voltage may over heat your product or cause the damage of the heating elements.

In heating applications the variable firing circuit found in SCR regulates, or Thyristor regulators allows an output which is adjustable within a continuous range. Rather than switching the power in segments (as relays would), SCR regulators vary the power output of the heating elements more proportionately. In commercial applications using large HVAC systems, similar large 3-phase regulators can be used to smooth the variations during the peak hours to protect the large motors in the system from voltage sag that may cause the system to fail.

One of the most sensitive devices made today is a huge network of computers, servers and storage arrays that comprise telecommunication and data centers. Voltage sags from the power line will result in unscheduled reboots, corruption of data and excess voltage will cause the internal power supply circuitry of your server or computer system to deteriorate at an accelerated rate and prematurely fail.

A few other 3-phase voltage regulators for data centres add functionality for UPS systems, enabling the regulator to minimise the impact of wide voltage variations, thus ensuring minimal draw on UPS battery run-time during periods of ‘real power’ failure. It also keeps the common large on-demand loads such as the computer room cooling unit (CRAC) from creating severe voltage fluctuations. Depending on applications such as a distributed telecommunication hub or a data center, a smaller rack-mounted three-phase regulator or larger, floor standing regulator is also available.

The three types of three-phase regulators available are simple relay regulators which are a low cost option for equipment with less stringent tolerances or the use of sensitive electronics, and appropriate for light industrial, or general commercial use, applications which have less demands. Servo motor regulators can adjust output voltage quickly and very smoothly; they are generally ideal for manufacturing, medical and any general industrial applications where there may be moderate but relatively rapid fluctuations in voltage. Where silence is a top priority, such as in industrial applications and where need for precision renders this the only effective regulator, the SCR thyristor regulator is the quick, accurate one—appropriate for electronic applications such as telecommunications or heating loads.

The most critical parameters to consider when choosing a regulator include KVA, input voltage range, output voltage tolerance, response speed and environmental requirements like IP ratings. Swallow your humility, plan for future expansion.

It has 20+ years' experience with 50,000 m(2) facility to develop all core component in-house, including sheet metal work and spraying production line. Our three-phase regulators are advanced and controlled by government-approved software, and are officially drafted National Industry Standards and recognised as a Government “Industry Champion” to serve local demands. Whether providing SCR thyristor regulators for heating or relay regulators for cost-effective protection, or servo motor regulators for precision manufacturing, our partners can provide a tailored electrical solution, with complete I.P and expert engineering assistance to hand.

Three-phase voltage regulators are suitable for numerous uses: they protect fragile CNC machines, sensitive medical appliances and big industrial heats. Used in data centers as well, the three-phase voltage regulator always delivers steady balanced voltage, thus avoids any potential damages on equipment, increases the output, and guarantees uninterrupted critical functions despite variations in the input voltage. Contact us to discuss about your requirements regarding the 3-phase voltage regulation of your industrial installation and find the most suitable voltage regulator for your application.