How will installing a Powerdown220 Voltage Optimiser affect my current electrical equipment and appliances?

We are often asked by potential customers. “What impact will VO have on our equipment?”. The simple answer is, none, because we are simply suggesting that you supply your electrical equipment with the correct voltage level. European standard IEC 60038 specifies all supply voltage limits, it stipulates that the voltage provided to a customer must be within the range of 230V (398V 3ph) +/-10%. Therefore, to comply with current CE legislation all electrical equipment intended for use within the EU must be designed to operate within this range. Our proposal assumes that the equipment used across your site is from reputable manufacturers, and the products supplied are fully compliant with current CE legislation.

Whilst IEC 60038 ensures that health and safety standards can be maintained, operating equipment at the upper or lower end of the voltage range is at the detriment of the equipment’s efficiency and life expectancy which under the regulations can be sacrificial. In fact, the UK’s Wiring Regulations (BS7671) state that any linear

appliance with a design voltage of 230V, when required to work at a constant voltage of 240V and above, will consume more energy and suffer a shortened working life of up to 46%!

Most motors manufactured outside the Americas are designed to comply with the requirements of IEC 60034 standards which include strict voltage tolerances to

ensure reliable and predictable operation without overheating under normal operating conditions.

IEC 60034 states that all designs must be capable of operating with a voltage range of 230V +/-5%, (378V – 418V 3ph). The standard states that the motor must develop its rated output, as stamped on the rating plate on the motor, without exceeding the maximum permissible design temperature, 230V -5% (378V 3ph) the lower limit of Zone A in the following graph. Designs must also be capable of operating

intermittently and infrequently within the extended range of 230V +/-10%, (359V – 438V 3ph) Zone B, but the maximum permissible design temperature can be exceeded by 10˚C within this range.

C 60034 Voltage Range Graph

X axis – Frequency (Hz) % deviation from rating point

Y axis – Voltage (V) % deviation from rating point

1. Zone A is the combination of voltage deviation of +/-5% and frequency deviation of +/-2%. Full rated output produced; temperature rises may be higher than at the rated Voltage and Frequency.

2. Zone B is the combination of voltage deviation of +/-10% and frequency deviation of +3/-5%. Full rated output produced; temperature rises may be higher than those in Zone A.

Extended operations at the limits of Zone B may shorten the life of the equipment.

3. Rating point.

The effects of thermal stress on electrical equipment are easily calculated and widely understood. It is considered to be the dominant stress in relation to premature failure of equipment. Additionally, experience and analysis have shown that the insulation aging process is completely dependent on the operating temperature and hours run. To compound matters, whilst older equipment tended to use large robust designs which offered some protection to thermal stress. Newer more modern equipment is designed close to optimum for reductions in size, better utilisation of lighter materials and to meet more stringent efficiency criteria.

When operating at the maximum design temperature allowed, the expected lifetime for modern electrical insulation is 20,000 hours, 2.3 years if operated 24/7. For every 10°C increase in

temperature above this, the expected thermal life is reduced by half. Conversely reducing the

operating temperature by 10°C doubles the life expectanc

Assume supply voltage across your site is in the region of the UK average of 242V (421V 3ph) which is above the upper limit of IEC 60034 Zone A detailed earlier. We propose to reduce this voltage by 9% to provide a supply voltage of 383V which is nearer to the lower limit of IEC 60034 Zone A. Because the proposed supply voltage remains within the criteria of IEC 60038 and IEC 60034-1 the performance of the machinery can be assured, whilst delivering a welcome energy saving. We

C 60034 Voltage Range Graph

X axis – Frequency (Hz) % deviation from rating point

Y axis – Voltage (V) % deviation from rating point

1. Zone A is the combination of voltage deviation of +/-5% and frequency deviation of +/-2%. Full rated output produced; temperature rises may be higher than at the rated Voltage and Frequency.

2. Zone B is the combination of voltage deviation of +/-10% and frequency deviation of +3/-5%. Full rated output produced; temperature rises may be higher than those in Zone A.

Extended operations at the limits of Zone B may shorten the life of the equipment.

3. Rating point.

The effects of thermal stress on electrical equipment are easily calculated and widely understood. It is considered to be the dominant stress in relation to premature failure of equipment. Additionally, experience and analysis have shown that the insulation aging process is completely dependent on the operating temperature and hours run. To compound matters, whilst older equipment tended to use large robust designs which offered some protection to thermal stress. Newer more modern equipment is designed close to optimum for reductions in size, better utilisation of lighter materials and to meet more stringent efficiency criteria.

 

When operating at the maximum design temperature allowed, the expected lifetime for modern electrical insulation is 20,000 hours, 2.3 years if operated 24/7. For every 10°C increase in temperature above this, the expected thermal life is reduced by half. Conversely reducing the operating temperature by 10°C doubles the life expectancy. Assume supply voltage across your site is in the region of the UK average of 242V (421V 3ph) which is above the upper limit of IEC 60034 Zone A detailed earlier. We propose to reduce this voltage by 9% to provide a supply voltage of 383V which is nearer to the lower limit of IEC 60034 Zone A. Because the proposed supply voltage remains within the criteria of IEC 60038 and IEC 60034-1 the performance of the machinery can be assured, whilst delivering a welcome energy saving. 

So, the question customers ought to be asking is. “What is the impact of constantly supplying our equipment with an unnecessarily high voltage level?”

Powerdown220 are delighted to be exhibiting at EMEX 2021

Powerdown220 are delighted to be exhibiting at EMEX 2021. Come and meet the team at stand b62 to discuss how we are using technology to help UK Businesses improve their energy efficiency, reduce energy costs, and reduce carbon emissions against a backdrop of rising energy prices. We deliver guaranteed savings via Voltage Optimisation (VO) or Coolnomix technology.

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Looking back now, it feels as though I was educated in a bygone era. Unlike today, (where I grew up at least) kids left school at 16 and didn’t think they had an automatic right to stay on for A levels and progress to Uni. No, we accepted that only the really, really, clever kids went to Uni. Despite having access to a computer, a Sinclair ZX81 (this was 1981, Google it kids) there was no internet, no YouTube, blogging or vlogging, so my chances of becoming an ‘influencer’ were remote, to say the least. TV was limited to three channels, reality TV didn’t exist, so becoming a celebrity nobody wasn’t an option. For me, like the many millions of other average kids leaving school that year, the only option was to get a job!

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Voltage Optimisation – what exactly is it

Quite simply, the basic principle of Voltage Optimisation (VO) is to it is to reduce the voltage level from that of the incoming grid supply to match the needs of your electrical equipment. Unfortunately, electrical equipment can consume more energy at higher voltages, so the higher your supply voltage is, the more likely you are needlessly wasting energy. High supply voltages are also a major contributor to the premature failure of electrical equipment, so you are also ‘burning out’ your equipment.

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Powerdown220 Managing Operational Risks During COVID-19

Powerdown220 Technicians perform daily health screenings, including daily regular
temperature tests, to ensure they are safe to enter your site. The technician will be
wearing Personal Protective Equipment (PPE) for the entirety of the install, which includes a mask, gloves and boot covers.

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