Technovision TVS-S1 User manual

TECHNOVISION ENERGY PVT LTD PUNE
S e r v o
Voltage Stabilizer
User Manual
________________________________________________________________________________________________________________________________

T E CH N O V IS I ON E N E R Y P V T L T D
Servo Voltage Stabilizer User Manual
Technovision Energy Pvt Ltd
"KONARK” Narhe Industrial Area, Pune - 411 041
• Phone- 20 24390 063/093/84

Contents
Sr No.
Descriptions
Page No.
1
Introduction
1
2
InformationforSafety
2
2.1
Usingthis manual
2
3
QualityandStandard Guarantee
4
3.1
Declaration of the management
4
3.2
Standard
4
3.3
Environment
5
3.4
Equipmentrecyclingatthe endof its useful life
5
3.5
Packaging
5
4
Presentation
6
4.1
Views
6
4.1.1
Equipmentviews
6
4.1.1.1
Single phase AircooledStabilizer
6
4.1.1.2
Three phase AirCooled Stabilizer
7
4.1.1.3
Three phase AircooledSeries with IsolationTransformer
7
4.1.1.4
Three phase Oil cooledSeries
7
4.1.1.5
Three phase AircooledPowerConditionerSeries
8
4.2
Presentation
8
4.3
Main qualityperformances
10
4.4
Panel indication &controls
11
4.5
Operating principle
11
4.5.1
Control system
12
4.5.2
Protection
12
4.6
Options
13
4.6.1
Manual bypass
13
4.6.2
Isolationtransformer
13
4.7
Major component
14
4.7.1
Variac
14
4.7.2
Buck boosttransformer
14
4.7.3
Servomotor(synchronizingmotors)
15
4.7.4
Carbon brush
15
4.7.5
Contactor
15
4.7.6
SPD( Surge protection device)
16
4.7.7
MCB/MCCB
16
5
Installation
17
5.1
To considerinthe installation
17
5.2
Equipmentreception
19
5.2.1
Unpacking, inspection and contents checking
19
5.2.2
Storage
19

Sr No.
Descriptions
Page No.
5.2.3
Unpacking
19
5.2.4
Transport till itslocation
21
5.2.5
Connections
21
5.2.6
Inputand outputwire selections
22
5.2.7
Connectionof inputterminals
23
5.2.8
Connectionof outputterminals
24
5.2.9
Connectionof the protective earth
25
6
Operating
26
6.1
Controlsbefore commissioning
26
6.2
Start up and shutdown of the stabilizer
26
6.2.1
Firstcommissioning procedure
26
Shutdown of the stabilizer
27
6.3
Bypass manual, option
27
6.3.1
Load powersupply frommainsthrough the manual Bypass
27
7
Control panel Overview
28
7.1
Board connection
28
7.2
Wiringdiagram
29
7.3
TRIACcard connection
29
7.4
LED indication
30
7.5
Running Mode display
30
7.6
Key function
30
7.7
Advance option
31
7.7.1
General settings
31
7.7.2
Error log
31
7.7.3
Parametersetting
31
7.7.4
Change userpassword
32
7.7.5
Disable userpassword
32
7.7.6
Motor test
33
7.7.7
Calibration
33
7.7.8
Error Indications
35
8
Maintenance
36
8.1
Annual maintenance
36
8.1.1
General
36
8.1.2
Brushes
37
8.1.3
Maintenance of oil cooled stabilizer
37
9
Troubleshooting
38
10
Annexure
41

1
INTRODUCTION
We thank you for purchasing our SERVO VOLTAGE STABILIZER. From “TECHNOVISION ENERGY PVT LTD”
We look forward to a long lasting relationship from hereon.
We are pleased to present the Operating Manual foryour “TECHNOVISION ENERGY PVT LTD” SERVO
VOLTAGE STABILIZER.
This equipment has been manufactured to precise specifications, utilizing the latest state of the art
technology with professional grade electrical & electronic components. All the parameters have been
checked & counter checked adequately to ensure long and trouble free service. All thepointsmentioned
in the operating manual are strictly adhere to. You are requested therefore to thoroughly understand
the contents of this manual and acquaint yourself with the operating data provided. If you still have
certain doubts, kindly refer your problems to us.
This equipment’s carries seal of prompt & efficient after sales besides the one-year warranty.Incaseof
any problem, it would help if you can inform us with serial number of equipment, whenever you senda
service request.
Chapter
1

2
INFORMATION FOR SAFETY
2.1. USING THIS MANUAL
The generic information of the equipment is supplied in soft copy on technovision official website, and it
includes among other documents the own user's manual of the system and the document concerning to
«Safety instructions». Before doing any action over the equipment regarding Operational, installation or
commissioning, change of location, setting or handling, read them carefully. This user's manual is intended
to provide information regarding the safety and to give explanations about the procedures for the
installation and operating of the equipment. Read them carefully and follow the stated steps in the
established order
Compliance as regards to “Safety instructions “is mandatory, being the user the legal responsible
regarding to its observance and application.
Prevent exposure to the elements and do not allow water
. To enter the Stabilizer. Please installed the indoors.
Avoid wearing jewelry during installation.
Power connections must remain tight to avoid excessive heating from a loose connection.
Use properly sized conductors and circuit breakers input and output side refer table no.6.
The grounding terminal is located in the wiring compartment and is identified by the symbol
below.
This Stabilizer is to be connected to AC circuits only. These AC connections are identifiedbythe
. Symbol below: Input and Output side also AC Supply.
If you received any damaged material during transportation on your side please contact
technovision technical support team before installing stabilizer.
If you find any loose connection because transportation please tighten the connection before
. Commissioning.
Chapter
2

3
Disconnect the power source before servicing or repairing electrical equipment.
Inspect portable cord-and-plug connected equipment, extension cords, power bars, and
electrical fittings for damage or wear before each use. Repair or replace damaged equipment
immediately.
Always tape extension cords to walls or floors when necessary. Do not use nails and staples
because they can damage extension cords and cause fire and shocks
Use extension cords or equipment that is rated for the levelof amperage or wattage that you
are using.
Always usethe correct size fuse.Replacing a fusewith one of a largersizecan causeexcessive
currents in the wiring and possibly start a fire.
Be aware that unusually warm or hot outlets orcords may be a sign that unsafe wiring
conditions exists. Unplug any cords orextension cords fromtheseoutlets and do not use until a
qualified electrician has checked the wiring.
Risk of electric shock is greater in areas that are wet or damp. Install Ground Fault Circuit
Breakers (ELCB) as they willinterrupt the electricalcircuit before a current sufficient to cause
death or serious injury occurs.
Knowwhere the panel and circuit breakers are located in case of an emergency.
Do not touch a person or stabilizer live apparatus in the event of an electrical incident. Always
disconnect the power sourcefirst.
The equipment’s are delivered duly labelled for the correct identification of any their parts, which combined
with the
Instructions described in this user's manual, allows the end-user to make any operating of both installation
and commissioning, in an easy and ordered way without doubt. When an equipment differs from the one
shown in figures, additional annexes will be edited if they were deemed appropriate or necessary.
Download on technovision official website.
Finally, once the equipment is installed and operative, for future requests or doubts that could arise, it is
recommended to keep the documentation in a safe place with easy access.

4
QUALITY AND STANDARD GUARANTEE
3.1 DECLARATION OF THE MANAGEMENT
Our target is the client’s satisfaction, therefore this Management has decided to establish a Quality and
Environmental policy, by means of installation a Quality and Environmental Management System that
becomes us capable to comply the requirements demanded by the standard ISO 9001:2001 and ISO
9001:2015 and by our Clients and concerned parts too.
Likewise, the enterprise Management is committed with the development and improvement of the
Quality and Environ- mental Management System, by means of:
The communication to all the company about the importance of satisfaction both in the client’s
requirements and in the legal and regulations.
 The Quality and Environmental Policy diffusion and the fixation of the Quality and Environment
targets.
 To carry out revisions by the Management.
 To provide the needed resources.
3.2 STANDARD
The SERVO VOLTAGE STABILIZER product is designed, manufactured and commercial- sized in accordance
with the standard EN ISO 9001:2001 & ISO 9001:2015 of Quality Management Systems and certified by
SGS body. The marking shows the conformity to the EEC Directive by means of the application of the
following standards:
In case of any modification or intervention over the equipment by the end-user, the manufacturer
is not responsible.
This is an equipment of class A. This equipment, in domestic environment can cause radio
interferences, in such case the end-user must take the appropriate measures.
Chapter
3

5
Declaration of conformity CE of the product is at the client disposal under previous request to our
headquarters offices.
3.3. ENVIRONMENT
This product has been designed to respect the Environment and manufactured in accordance with
the ISO 14001 norm.
3.4 EQUIPMENT RECYCLING AT THE END OF ITS USEFUL LIFE
Our company commits to use the services of authorized societies and according to the regulations,
in order to treat the whole recovered product at the end of its useful life (contact your distributor).
3.5 PACKAGING
To recycle the packaging, follow the legal regulations in force, in accordance with the particular norm
of the country where the equipment is installed .

6
PRESENTATION
4.1 VIEWS
4.1.1 Equipment views
Tables from 1 to 5 show the standardized models with their physical dimensions
All models have a control panel with LCD as an interface be- tween the equipment and the end-user,
which gives information of different nature through its menus structured in categories.
Three phase equipment’s consisting of three single phase cabinets, each one of them will have their
own control panel.
4.1.1.1 Single phase Air cooled Stabilizer
Model Number
KVA Rating
Voltage Rating
Dimensions
(L X W X H)
MM
Input
Output
TVS-S1
1 KVA
170-270 VAC
230 VAC
230 X 305 X 180
TVS-S5
2.5 - 5 KVA
170-270 VAC
230 VAC
310 X 430 X 230
TVS-S10
7.5 - 10 KVA
170 - 270 VAC
230 VAC
300 X 380 X 620
TVS-S15
15 KVA
170 - 270 VAC
230VAC
500 X 400 X 660
TVS-WS10
7.5 - 10 KVA
150 - 300 VAC
230 VAC
500 X 400 X 660
Table 1 Single phase servo voltage stabilizer
Chapter
4

7
4.1.1.2 Three phase Air Cooled Stabilizer
Model Number
KVA Rating
Voltage Rating
Dimensions
(L X W X H)
MM
Input
Output
TVS-T10
7.5 - 10 KVA
340 - 480 VAC
415 VAC
400 X 450 X 840
TVS-T15
10 - 15 KVA
340 - 480 VAC
415 VAC
400 X 450 X 840
TVS-T30
20 - 30 KVA
340 - 480 VAC
415 VAC
400 X 800 X 850
TVS-T60
40 –60 KVA
340 - 480 VAC
415 VAC
400 X 800 X 850
TVS-T80
70 –80 KVA
340 - 480 VAC
415 VAC
500 X 900 X 1000
TVS-WT30
20 –30 KVA
260 –520 VAC
415 VAC
400 X 800 X 850
TVS-WT50
40 –50 KVA
260 –520 VAC
415 VAC
500 X 900 X 1000
Table 2 Three phase Air Cooled Stabilizer
4.1.1.3 Three phase Air cooled Series with Isolation Transformer
Model Number
KVA Rating
Voltage Rating
Dimensions
(L X W X H)
MM
Input
Output
TVS-TISO30
20 - 30 KVA
340 - 480 VAC
200 VAC
800 X 600 X 1200
TVS-TISO60
40 –60 KVA
340 - 480 VAC
200 VAC
800 X 600 X 1200
Table 3 Three phase Air cooled Series with Isolation Transformer
4.1.1.4 Three phase Oil cooled Series
Model Number
KVA
Rating
Voltage Rating
Dimensions
(L X W X H)
MM
Input
Output
TVS-TOC100
80-100 KVA
360 -
460 VAC
415 VAC
Rack = 1000X380X620
Tank=1020X410X640
JB=400X400
TVS-TOC150
125 –150
KVA
360 –
460 VAC
415 VAC
Rack = 1180X435X720
Tank=1200X460X800
JB=500X500
Table 4 Threephase Oil cooled Series

8
4.1.1.5 Three phase Air cooled Power Conditioner Series
Model Number
KVA Rating
Voltage Rating
Dimensions
(L X W X H)
MM
Input
Output
TVS-TPC15
10 - 15 KVA
360 - 460 VAC
415 VAC
400 X 450 X 840
TVS-TPC30
20 - 30 KVA
360 - 460 VAC
415 VAC
400 X 800 X 850
TVS-TPC60
40 –60 KVA
360 - 460 VAC
415 VAC
400 X 800 X 850
TVS-TPC80
70 –80 KVA
360 - 460 VAC
415 VAC
500 X 900 X 1000
Table 5 Three phase Air cooled Power Conditioner Series
.4.2 PRESENTATION
Servo Voltage stabilizer model has been designed to operate in fluctuated mains and to safeguard
the critical loads, in particular, those ones with a complicated nature: high inrush start up currents, high
reactive character, high powers, etc. These equipment’s are very robust against long overloads and they
have a high output accuracy (up to ±1%), they are manufactured in single and three phase structures with
independent phase regulation or average regulation in the three phases depending on the model.
Figure 1 Front View
Figure 2 Back View
Figure 3 LHS & RHS View

9
Any three phase servomotor stabilizer has only one electronic control card for all the phases and one
Display card for its monitoring and complete control, less those ones that consist of three independent
single phase equipment’s duly connected to make a three phase equipment. In these ones, each cabinet
will have its own electronic control card and its display card.
Depending on the total power of the three phase equipment’s, no matter if they include some options or
not, they are supplied assembled in one metallic cabinet, and divided in two cabinets joined together
mechanically at factory or by three separate cabinets, which will be joined after their final location. The
input and output are marked in the terminal strips of the equipment. When installing the device, use the
suitable cross cable section in order to guarantee its correct operating.
Three phase servo motor stabilizer has only one electronic control card for all the phases and one display
card for its monitoring and complete control, less those ones that consist of three independent single
phase equipment’s duly connected to make a three phase equipment. In these ones, each cabinet will
have its own electronic control card with Display card. Depending on the total power of the three phase
equipment’s, no matter if they include some options or not, they are supplied assembled in one metallic
cabinet, and divided in two cabinets joined together mechanically at factory or by three separate cabinets,
which will be joined after their final location. The input and output are marked in the terminal strips of the
equipment. When installing the device, use the suitable cross cable section in order to guarantee its correct
operating.
The LCD display of the control panel of the stabilizer allows checking the input/output voltages and
frequency, whenever you need. Also, the LCD has measurements of Load current per phase. There are LED
indicators to indicate Phase indication. Block diagram of a Servo Voltage Stabilizer is shown in Fig. 4 (the
three phase structure is similar to it but repeating the same block per each phase).
The LCD Display shows the values of the input/output voltages (Phase to Phase & Phase to Neutral) and
frequency. And also measure output current with the output current transformers. Also, the LED indicators
inform about Phase indication. To know in detail the LCD panel information and the meaning of the LEDs go
to the corresponding section of this manual. The input circuit breaker protections, provides protection
against long over currents to both the loads and the stabilizer. Depending on the model and the protection
degree IP, the cooling is natural or forced, in order to keep the internal temperature stable .
Figure 4 Block Diagram of Servo Voltage Stabilizer

10
Although the input voltage range is ±15 % for the standard models, under request, it is possible to
manufacture equipment’s with wide input voltage range up to ±30 % (input voltage window).
The voltage stabilizer protects against sudden changes, irregularities, increasing or decreasing of the voltage
mains by means of an accurate voltage stabilization.
Also, as standard the control electronic unit includes the Maximum and minimum voltage protection signal
(adjustable to input or output, but by default on the last), which is needed to disconnect the output by means
of a contactor. In case of the voltage exceeds the allowed limits or mains fault. In order to keep the protection
against sudden voltage changes, the signal is delayed a few seconds.
It is also possible to include an option that allows disconnecting the output of the stabilizer due to overload.
In this case, the equipment will include the output current sensors to make the overload measurement.
As an option, the stabilizer can be equipped with a manual Bypass, which is not ready to be maneuvered
with load connected. It allows keeping the loads supplied during the maintenances or fixing periods.
4.3 MAIN QUALITY PERFORMANCES
 Wide range of powers for single and three phase installations.
 Toroidal shape autotransformers (Variacs) for all the power range, fast and efficient with Servo
motors.
 Output accuracy, better than 1 % (adjustable).
 Depending on the three phase equipment’s model common and independent regulation per phase,
they are immune to unbalanced loads.
 As standard, input voltage range of ±15 %, being able to manufacture ranges up to ±30 %.
 High efficiency, up to 97,5 %.
 High response time, up to 70 V/sec
 Complete control Circuit with LCD to supervise the stabilizer.
 Output accuracy guaranteed by a control with TRIAC through servo Motor.
 Stable operating against load and/or voltage fluctuations.
 Wide operating temperature ranges (–10 ºC.. +55 ºC).
 Optimized mechanical design, easy maintenance.
 Overload up to 200 % over the nominal for 20 sec..
 High robustness and reliability.

11
4.4 PANEL INDICATION & CONTROLS
 Input on
:
This indicator shows the input availability
 Output on
:
This indicator shows the output availability
 High/low voltage indicator
:
This indicator shows the input high or input low i.e.
beyond or below the range of voltage stabilizer.
 Auto/manual switch
:
This switch facilitates automatic and manual mode of
operation to the stabilizer. In auto mode the output
voltage of the servo is always in conjunction with
increase/decrease switch is used to set output voltage
to the desired level.
 Increase/Decrease switch
:
This switch work only in manual mode to Increase /
decrease the output voltage.
 Output/cutoff
:
If output of servo goes above 260 in each phase ± 2V
Ac or falls below 190/200V cut-off. The indicator
shows cut-off condition of the corresponding phase.
 Voltage Adjust
:
This is potentiometer with which output of the Servo
can be set to the required level between 220V and
240V in each phase in Auto mode.
 Reset-auto/ Manual
:
When the reset switch is in Auto position, the Output
will available automatically. When the Reset switch is
in manual position, the output Will available by using
of 3ph output
 ON/OFF
:
Push button switches
4.5 OPERATING PRINCIPLE
The electronic control manages the output voltage of the stabilizer permanently, providing acorrection
signal the Servo motor, in order to achieve the wanted output voltage with an accuracy of ±1 %
(adjustable from ±0,5 % up to ± 5 %). The motor acts over the toroidal autotransformer (Variac), by
increasing ordecreasingthe voltage, by moving the brush in the variable tap in one way or to the other.
Servo Voltage Stabilizer utilizes an autotransformer (variac) coupled with motor and BUCK BOOST
transformer. The BUCK BOOST transformer has two winding i.e. primary and secondary. Primary connected
to AUTOTRANSFORMER (Variac) and secondary to series with supply line. The primary voltage of BUCK
BOOST transformer controlled by auto transformer moving arm position with the help of motor. Thus adding

12
or subtracting the line voltage is being controlled. A solid state sensor unit continuously monitors the output
voltage and the error voltage is compared with fixed reference voltage. The error is amplified through high
gain Pic micro contoller18F450 which in turn controls the direction of the motor movement. This drives an
Auto Transformer moving arm position till the correct output voltage is restored. The action of this SERVO
system is exceptionally FAST with minimal over shoot. Sensing at the output point automatically
compensates for any load current change. This method of stabilization is free from generation and wave
form distortion.
4.5.1 Control System
The advanced feature of control systemlies in its exceptionally fast response withminimal overshoot.
This is mainly due to the use of low internal mechanical system. PIC 18F4520 continuously monitorthe
output voltage with reference voltage and generate error signal. Any error voltage is amplified, this
amplified error voltage is fed to optocoupler fires the correspondent TRIACS to control the AC motor
direction clock wise or Anti clock wise. The control PCB has three identical circuits for R, Y, B phase
controlling along with protection circuit for low and high voltage cut-off. The PCB has followingpresets
for setting the voltage, regulation and below cut-off voltages for regular stabilizer range.high&lowcut
of range change as per wide range of stabilizer.
4.5.2 Protection
High Voltage Protection
Low Voltage Protection
Over load protection with output Trip
Short circuit protection with MCB
SERVO –bypass provided at input
Surge protection as per customer demand
Phase Reversing
Single phasing
Neutral fail
Phase 2 phase
DESCRIPTION
Range
High Output Voltage Cutoff
:
470V
Low Output Voltage Cutoff
:
350V

13
4.6 OPTIONS
4.6.1 Manual Bypass
Manual bypass option consists in atwo positions camswitch, which allows selecting between positions
MAINS «1», where the output is connected to the input of the stabilizer directly (Bypass) and position
SERVO «2» where the output of equipment is connected to the output of the stabilizer directly.
OFF «0» Output OFF
4.6.2 Isolation Transformer
The isolation transformer is built with separate windings and it has an electrostaticshieldbetween
the primary and secondary windings, which provides a high level of electrical noiseattenuation(>40dB).
This option can be built in either inside the “ TVS-TISO ”series attending to differentoperatingconditioning
or in a separate case. Among other functions a part from the isolation, it can act as:
Input or output voltage adaptor.
Configuration adaptor: delta-star or vice versa...).
And even combining the two above options depending on the case.
As a result of the possible combinations, this document does not consider the power standardizationof
tables 1 to8 in the assembling with isolation transformer, because the physical dimensionsandweight
will vary, but in any case its main feature of galvanic isolation will be not be affected.

14
4.7 MAJOR COMPONENT
4.7.1 VARIAC
Variac is also known as Dimmer, Autotransformer or Variable transformer
It is normally round in the shape. Silicon CRGO toroidal core is used forthebase&copperwire
with specific turn ratio according to the capacity is used. The basic purpose of dimmer is to
increase or decrease the voltage which is fed to the buck boost transformer.50%oftheoutput
voltage is increased or decreased by dimmer only.
Let us take an example: If the input voltage is 160V, the dimmer will increaseitto190V&rest
of the 30V (since 220V is required to run any single phase load) will be done by Buck Boost
Transformer.
4.7.2 BUCK BOOST TRANSFORMER
Contrary to dimmer it is in rectangularshape. Bobbin is fitted with EI CRGO orHRGO core.
When the transformer structure is built, it is dipped in varnish tank for extra protection.
This type of Insulating varnish also called transformer varnish is put on all the windingsused
in buck boost transformers to encapsulate thembefore the servo stabilizerisreadyforregress
testing. Transformer varnish enhances coil life and protects windings in the transformerfrom
environmental exposure that would otherwise get damaged due to vibrations. This varnish
can be used as a great insulator for any coil of wire. Though transformer is there in Isolation
Transformer also, But it different from buck boost transformer

15
4.7.3 SERVOMOTOR (SYNCHRONIZING MOTORS)
Servomotoras the name suggests is the main part of servo stabilizer. The motorrotatesthe
arm connected on the dimmer in clockwise or anti clockwise direction according to input
voltage.
4.7.4 CARBON BRUSH
This is a moving part in servo stabilizer, it is fitted in the shaft to make thecontactwithVariac.
If the input voltage variation is very frequent, this carbon brush will erase earlyandcustomer
has to replace it very frequently. That is why servo stabilizermanufacturers should usebest
quality carbon brush.
4.7.5 CONTACTOR
The function of contactoris to cut the output of any servo stabilizerif it exceeds a prescribed
limit.

16
4.7.6 SPD( Surge protection device)
The Surge ProtectionDevice (SPD)is a component of the electrical installation protection system.
This device is connected in parallel on the stabilizer input power supply circuit this is the most
commonly used and most efficient type of Electrical Spikes, Sudden Voltage fluctuation protection.
4.7.7 MCB/MCCB
The MCB is used to switch on /off the servo stabilizer and gives short circuitprotectionwhereasMCCB
is normally for overload protection.