TNS-U 3 Phase Stabilizer: Heat Dissipation and Cooling Solutions

The backbone of industrial power protection, three-phase voltage stabilizers still face one constant threat: heat. All electrical and electronic components, by nature of their function, generate heat. In a lack of controlled management, this heat will degrade performance, diminish life span and cause complete equipment failure. This is a problem that the TNS-U three-phase voltage stabilizer series addresses directly through both design for heat dissipation and active cooling. Knowledge of its thermal management systems is imperative when selecting a stabilizer to meet critical application and longevity requirements.

Heat is detrimental to any electrical equipment. The major components responsible for generating heat within a three-phase voltage stabilizer are the transformer, the servo motor (if applicable) and the control electronics. Higher temperatures accelerate the rate of chemical reactions occurring within the insulator materials, weakening them and causing failure. Electrical components will often lose 50% of their rated shelf life for every 10°C rise above optimal temperatures in the power electronics. An extreme example-a stabilizer rated to work at 60°C but used at 40°C, for instance, will experience a life span reduction of three-quarters. Therefore, heat dissipation has been incorporated into the design of the TNS-U series, rather than treated as an afterthought.

Passive thermal management components are incorporated into the TNS-U series in an effort to minimize the heat generated in the first place and remove it naturally before the use of active cooling.

Efficient transformer design is the first layer of defence. Through the use of high grade silicon steel laminations and winding optimization, the TNS-U's transformer provides minimal core loss and copper loss (IR heating). Reduced internal losses also mean less heat generation at the source, improving overall thermal control.

Generous material sizing are used in the components to provide thermal mass and surface area. Components are also conservatively rated and operated well below their maximum thermal capacities. The unit's enclosure provides a heat sink effect due to large surface area and exhaust vents, allowing for natural convection airflow. The TNS-U's enclosure features a chimney effect that allows cool air to circulate around the internal components without the need for a fan; this is achieved through perforated panels and louvered vents positioned at the top and bottom.

Thermal separation between heat-sensitive components such as control boards and capacitors and heat-generating components such as transformers and rectifiers keeps critical areas cool. Internal baffles also serve to prevent recirculation of hot air.

The TNS-U series also includes active cooling, to complement passive cooling whenever active cooling isn't enough, such as during high ambient temperatures, in confined spaces, or when operating at the maximum continuous load for the appliance.

Thermostatically controlled fans will not activate until the system requires active cooling, saving energy, reducing fan noise and minimizing the entry of dust into the system compared to constant fan operation. Temperature sensitive components within the enclosure trigger both the startup and shut-down of the fans based on an approximate activation temperature of 45-50°C.

Intelligent derating and alarms features. If temperatures continue to rise after active cooling, the TNS-U control software will provide both audible alarms and/or a remote signal to building control systems to warn of potentially damaging heat build-up and will also reduce the output power to avoid unexpected shutdown and give the operators time to address the cause of the overheating.

Optional forced-air plenum configurations. In the harshest environments where installation simply can't be avoided, the option to add a plenum with forced air should be used. These units will have increased fan capacity, redundant fan, and screened air intakes to prevent the influx of dusty air.

No design-even the best-can make up for poor installation. To ensure the TNS-U's stabilizer doesn't exceed thermal limits, these installation guidelines must be followed:

Provide adequate clearance-at least 200 mm (8") of space is needed around the stabilizer, particularly above and below areas that require adequate airflow. Ensure that ventilation ports are not blocked by cables, panels, or any stored items.

Maintain ambient temperatures-keep the stabilizer away from heat sources such as ovens, furnaces or steam pipes. If installing outdoors, plan for additional shade and/or ventilation to mitigate the effects of solar heat.

Monitor filter condition-if the TNS-U's fan intakes have filters, inspect and clean/replace these filters at least every four weeks.

Consider room ventilation-the stabilizer generates heat into the ambient room environment. In tightly confined or poorly ventilated rooms with other heat-producing electrical equipment, the overall room temperature can rise significantly, impacting the stabilizer's overall efficiency in its own cooling process.

With 20 years of experience, our 50,000 m² manufacturing and production facility develops all core components in-house instead of outsourcing them. The TNS-U three-phase stabilizer series are official 'writers' of the national industry standards, and are a government recognized "Industry Champion" for our Thermal Excellence. Advanced Software Control automatically logs internal temperatures and adjusts fan cooling as needed for optimal performance.

This implies that a three phase voltage stabilizer can not be trusted without the inclusion of heat dissipation as a basic part of its design. The TNS-U will remain cool during its highest load due to effective transformer design and by the inclusion of its multi-stage cooling design (passive convection/ thermostatically forced air) so as to ensure it completes its tasks and lasts for years in its industrial surrounding. Please contact us for details on your power protection and cooling requirements.