800KVA Industrial Voltage Stabilizer Integrated with Schneider BlokSeT LV Switchgear
Introduction
Jiangsu Shengbang New Material Co., Ltd. is a high-performance new material manufacturer in China, and its 5000 TPA para-aramid project is one of the company’s key production base projects. For this project, Winzele, as an industrial voltage stabilizer manufacturer, supplied eight 800KVA industrial voltage stabilizer cabinets for integration with Schneider BlokSeT LV switchgear, working with Schneider Electric as the project’s electrical contractor.
Para-aramid production is a continuous industrial process with high requirements for a stable electrical environment; power supply quality directly affects whether production can keep running steadily at design parameters.
Winzele designed and supplied eight 800KVA industrial voltage stabilizer cabinets to Schneider Electric, the electrical contractor of the project, for integration with Schneider BlokSeT LV switchgear in the factory low-voltage distribution system. The selection and procurement of the Winzele stabilizer cabinets by Schneider Electric reflects recognition of the product quality and manufacturing capability through the project’s engineering review and acceptance.
The system provides stable voltage support for continuous industrial production, helping this high-performance new material manufacturer maintain stable production operation.
Project Overview
| Item | Description |
|---|---|
| Project | 5000 TPA para-aramid production project of Jiangsu Shengbang New Material Co., Ltd. |
| Industry | Advanced Material Manufacturing |
| Electrical Contractor | Schneider Electric (stabilizer cabinet purchaser) |
| Installed Equipment | 8 × 800KVA Industrial Voltage Stabilizers (designed and manufactured by Winzele) |
| Total Capacity | 6.4MVA equivalent stabilization capacity |
| Voltage System | 400V |
| Installation Date | December 2024 |
| Application | Dedicated power stabilization for eight aramid spinning production lines |
| Integration | Schneider BlokSeT LV Switchgear integration via busbar connection |
Project Background
The aramid fiber production process relies on continuous spinning, heating control and automated equipment operation. With eight production lines running simultaneously, the facility required a stable low-voltage environment to maintain consistent process operation. Winzele developed a factory-level voltage stabilization solution rather than a single equipment protection system.
Power Challenge
After production expansion, the facility operated eight aramid spinning lines with multiple heating systems, motor-driven equipment and automation controls running simultaneously. This created higher requirements for voltage stability and power continuity.
Voltage variation could affect equipment operation and process control stability — heating power, motor speed and automation control logic all rely on a stable voltage foundation. The production system required voltage stability within 400V ±2%. In addition, a continuous production process cannot afford interruption during stabilizer maintenance, so the solution needed bypass capability to maintain power supply during servicing.
Voltage fluctuation may change the input power of heating equipment, alter motor operating conditions and disturb the supply environment of automation control systems. Voltage stabilization measures were therefore required to provide a stable power supply for production equipment, supporting continuous production and industrial power stability.
Winzele Solution
To support eight independent spinning lines, Winzele configured eight individual 800KVA industrial voltage stabilizer units, allowing each production line to operate with dedicated voltage regulation.
The solution was designed and implemented around production-line-level stabilization:
- Each stabilizer was installed in the distribution circuit of its corresponding spinning line, delivering stabilized voltage directly to that production line without affecting other units;
- Winzele configured each unit with bypass capability, so a single stabilizer could be taken offline for maintenance while its production line continued on the original utility supply;
- The stabilizers were integrated into the factory low-voltage distribution system through Schneider BlokSeT LV switchgear, forming part of the facility’s main power distribution architecture;
- With independent operation and easier maintenance, the eight-unit configuration avoided single-point failure across the production facility.
The stabilized voltage covers spinning, drying, heating and roller motor production loads. This is a factory voltage stabilization system rather than single-machine protection. The solution objective is to support consistent production quality and process stability.
Industrial Voltage Stabilizer Manufacturing Capability
Winzele is an industrial voltage stabilizer manufacturer. For this project, Winzele designed and manufactured the 800KVA industrial voltage stabilizer units, including cabinet structure, high-current busbar interface, electrical configuration and system integration details according to the customer’s low-voltage distribution requirements. The factory voltage stabilization system covers eight production lines through dedicated 800KVA stabilizer units.
- Cabinet structure design: The cabinet was designed for the 800KVA large-capacity unit, meeting the arrangement and layout requirements of the factory LV distribution room;
- High-current busbar interface: The busbar connection design was customized according to the Schneider BlokSeT LV switchgear interface structure, supporting 800KVA rated current capacity;
- Electrical configuration design: Voltage regulation, protection and control parameters were set according to the on-site 400V distribution system;
- System integration: The stabilizers are part of the factory low-voltage distribution architecture, integrated with Schneider BlokSeT LV switchgear via busbar connection.
As a custom voltage stabilizer manufacturer, Winzele designed, manufactured and delivered the equipment according to the project’s power distribution conditions for large capacity industrial loads, rather than installing a standard cabinet directly.
The eight 800KVA stabilizer cabinets were procured by Schneider Electric as the project’s electrical contractor and accepted after engineering review for integration into the factory low-voltage distribution system. Through the engineering review, procurement process and on-site integration requirements of Schneider Electric as the electrical contractor, this project verifies Winzele’s engineering capability in the manufacturing and delivery of large-scale industrial voltage stabilization systems.
Why This Project Is Different
- Factory-level power stability experience: The project covers the power stability requirements of the main power distribution of an entire aramid production base, reflecting Winzele’s practical project experience in delivering large-scale industrial voltage stabilization systems;
- Integration capability with industrial LV distribution systems: The integration of the stabilization system with industrial LV distribution architectures such as Schneider BlokSeT LV switchgear is a direct reflection of Winzele’s delivery capability in large industrial projects;
- Production-line-level customized voltage stabilization approach: Tailoring the stabilization solution to production distribution requirements is Winzele’s differentiated engineering approach for continuous industrial production.
System Configuration
Factory LV Distribution System
↓
Schneider BlokSeT LV Switchgear
↓
Winzele 800KVA Industrial Voltage Stabilizer
↓
Factory Continuous Production Loads
Configuration Parameters
| Configuration Item | Value |
|---|---|
| Transformer | The stabilizers are fed from eight 800KVA LV distribution cabinets assigned from the transformer; they do not connect directly to the transformer |
| Incoming Voltage | 400V±20% |
| Frequency | 50Hz |
| Stabilizer Capacity | 8 × 800KVA (total configuration 6.4MVA) |
| Output Voltage | 400V±2% |
| Connection Type | Busbar connection with Schneider BlokSeT LV switchgear; cable entry and exit directions were customized according to the site switchgear layout, including four left entry/right exit units and four right entry/left exit units |
| Installation Location | Factory low-voltage distribution system / front of each spinning line distribution |
Production Load Characteristics
Based on the project load list, the typical load structure of a single aramid spinning production line is as follows:
| Load System | Typical Power | Function |
|---|---|---|
| Heating System | 360kW | Drying and thermal process control |
| Roller Motor System | 132kW | Spinning line mechanical drive |
| Automation System | — | Process control and monitoring |
| Total Typical Process Load | Approx. 500kW class | Continuous production line |
Based on the project load list, each aramid spinning production line includes approximately 360kW heating loads and 132kW motor-driven loads. The combined production load is around 500kW class per line, requiring appropriate kVA capacity considering motor characteristics, power factor, harmonic influence and future operating conditions.
Key Technical Highlights
| Highlight | Description |
|---|---|
| Multi-unit 6.4MVA stabilization system | 8 × 800KVA multi-unit configuration, total configuration capacity 6.4MVA |
| Eight independent production line stabilization units | Each unit corresponds to the distribution system of one aramid spinning production line |
| Schneider BlokSeT integration | Integrated with Schneider BlokSeT LV switchgear as part of the factory low-voltage distribution system |
| Busbar connection | Stabilizers connect to switchgear via busbar, supporting 800KVA rated current capacity and avoiding cable bottlenecks |
| Customized left/right entry arrangement | 4 units left entry/right exit and 4 units right entry/left exit, compact switchgear integration |
| Continuous process power stability | 400V ±2% stable output, supporting stable operation of continuous production processes |
Installation & System Integration
- Schneider BlokSeT LV Switchgear Integration: The stabilization system is integrated into the factory low-voltage distribution system as part of the factory’s LV distribution architecture;
- Busbar Connection: The stabilizers connect to the switchgear via busbar, supporting 800KVA rated current capacity and avoiding cable bottlenecks;
- Customized Busbar Manufacturing and System Integration: The stabilizer was not installed as a standard cabinet; Winzele designed the busbar interface according to the Schneider BlokSeT switchgear structure, with customized entry and exit arrangements, to meet the reliable connection requirements of large capacity industrial continuous loads;
- Customized Cable Entry Arrangement: According to the LV distribution room layout and switchgear requirements, 4 stabilizers use left entry/right exit and 4 use right entry/left exit, achieving compact integration with Schneider BlokSeT LV switchgear;
- Independent Bypass Maintenance: Each stabilizer can be independently switched to bypass for maintenance, maintaining power continuity for the corresponding production line through the bypass design.
Schneider BlokSeT LV Switchgear Integration Drawing
The integration design drawing shows the 800KVA stabilizer cabinet position, the LV distribution structure and the busbar connection method with Schneider BlokSeT LV switchgear.
Electrical Single Line Diagram of 800KVA Voltage Stabilizer System
Customized Busbar Interface Design for 800KVA Voltage Stabilizer
Based on the Schneider BlokSeT LV switchgear layout, Winzele customized the cabinet structure and busbar interface of the 800KVA voltage stabilizer to achieve reliable high-current connection with the factory low voltage distribution system.
Project Photos
Eight 800KVA Voltage Stabilizer Units Installation
Eight 800KVA industrial voltage stabilizer units installed in the factory low voltage distribution room.
Factory Low Voltage Distribution Room Installation
Schneider BlokSeT LV Switchgear Integration
Busbar Connection Between Voltage Stabilizer and LV Switchgear
Busbar connection details between 800KVA voltage stabilizer cabinet and low voltage switchgear system.
FAQ
Q: Why use eight 800KVA voltage stabilizers instead of one large unit? A: The project includes eight independent aramid spinning production lines. Eight 800KVA stabilizers are used to correspond to the distribution system of each production line, enabling independent stabilization and maintenance line by line and avoiding single-point failure affecting the whole production base. The total configuration capacity is 6.4MVA.
Q: Why was 800KVA selected for each production line? A: Each production line includes high-power heating loads, motor-driven equipment and automation systems. The voltage stabilizer capacity was selected based on complete electrical design conditions, including kVA requirements, power factor, motor operation characteristics and future operating margin.
Q: How was the system integrated with Schneider BlokSeT LV switchgear? A: The stabilizers are integrated with Schneider BlokSeT LV switchgear via busbar connection, with each stabilizer corresponding to an independent spinning line distribution. Schneider Electric is the electrical contractor of the project; the stabilizer cabinets were manufactured by Winzele and procured and accepted by Schneider Electric. Integration feasibility depends on switchgear configuration, busbar rated current and available space; incoming and outgoing units were coordinated during design.
Q: What voltage systems can Winzele support? A: The equipment in this case is configured for the 400V level. Winzele industrial voltage stabilizers can also be customized for other common industrial voltages, including special voltage systems such as 690V.
Related Cases
Related Solutions
| Factory Voltage Stabilizer Solution |
| More Solutions |
| Related Products |
Engineering Guidance
To evaluate a voltage stabilization solution for a large new material production base or other industrial facility, please provide:
- Transformer capacity
- Incoming voltage and frequency
- Stabilizer capacity requirements (capacity per line and number of units)
- Number of production lines and load characteristics (including heating and motor loads)
- Process requirements for voltage stability
- Installation conditions
The Winzele engineering team will evaluate the power supply conditions based on the actual project conditions and recommend a suitable voltage stabilization solution.
