Heavy Duty Servo Voltage Stabilizer
100kVA – 2000kVA | 3-Phase | Oil Cooled
Engineered for steel plants, cement factories, chemical plants, and large-scale manufacturing facilities. Built to withstand extreme industrial conditions with 200% overload capacity and ±1% output accuracy.
Steel Plants
Rolling mills, furnaces, continuous casting
Cement Factories
Crushers, conveyors, kilns, grinding mills
Chemical Plants
Reactors, mixers, pumps, compressors
Power Plants
Auxiliary systems, coal handling, pumps
Water Treatment
Large pumps, aeration systems, SCADA
Textile Mills
Spinning, weaving, processing houses
Paper Mills
Pulpers, dryers, winders, calendars
Data Centers
Mainline protection for critical IT load
Built for the Toughest Environments
Oil Cooled Construction
For capacities above 150kVA, oil cooling provides superior heat dissipation, allowing continuous operation in ambient temperatures up to 55°C. The sealed tank protects against dust, moisture, and corrosive atmospheres.
100% Copper Wound
Aluminium windings fail under heavy industrial loads. VoltaPex uses only electrolytic copper for all windings — lower losses, better heat transfer, and 25+ year lifespan.
200% Overload Capacity
Motor starting currents can be 6-8 times full load current. Our heavy duty stabilizers are designed to handle 200% overload for 10 seconds and 150% for 60 seconds — no nuisance tripping.
Complete Protection Suite
Over/under voltage, single phasing, reverse phase, overload, short circuit, and over-temperature protection — all included as standard.
Digital Controller with Modbus
Real-time monitoring of input/output voltage, current, and load percentage. RS485 Modbus RTU for integration with your plant SCADA system.
| Input Voltage Range | 300V – 490V (Line to Line) |
| Output Voltage | 415V ±1% (Adjustable) |
| Frequency | 50Hz ±3% |
| Efficiency | ≥98% at full load |
| Correction Speed | 50V / second |
| Overload | 200% for 10 sec / 150% for 60 sec |
| Cooling Type | Oil Cooled (forced oil circulation for >500kVA) |
| Enclosure Protection | IP54 (standard) / IP65 (optional) |
| Insulation Class | Class H (180°C) |
| Bypass | Automatic + Manual (no-break) |
| Ambient Temperature | -10°C to 55°C |
| Standards | IS 9815, IEC 60076, CE |
Capacity Guide for Industrial Plants
Select the right capacity based on your plant's total connected load and motor starting requirements.
| KVA Rating | Typical Application | Input Range | Cooling | Dimensions (L×W×H mm) |
|---|---|---|---|---|
| 100 kVA | Small factory / Workshop / 2-3 large machines | 300–490V | Oil Cooled | 1200×800×1400 |
| 150 kVA | Textile mill section / Small steel processing unit | 290–490V | Oil Cooled | 1300×900×1500 |
| 200 kVA | Cement plant crusher / Large compressor bank | 280–490V | Oil Cooled | 1400×1000×1600 |
| 250 kVA | Plastic injection moulding plant (10+ machines) | 280–490V | Oil Cooled | 1500×1000×1700 |
| 300 kVA | Steel rolling mill / Large chemical reactor plant | 270–490V | Oil Cooled | 1600×1100×1800 |
| 400 kVA | Mid-size manufacturing plant (50+ HP motor load) | 270–490V | Oil Cooled + Forced | 1700×1200×1900 |
| 500 kVA | Large factory / Mainline for industrial estate | 260–490V | Oil Cooled + Forced | 1800×1300×2000 |
| 600 kVA | Steel plant auxiliary / Large cement mill | 260–490V | Oil Cooled + Forced | 1900×1400×2100 |
| 750 kVA | Large manufacturing facility / Data center mainline | 250–490V | Oil Cooled + Forced | 2000×1500×2200 |
| 1000 kVA | Heavy industrial plant / Steel mill mainline | 250–490V | Oil Cooled + Forced | 2200×1600×2400 |
| 1500 kVA | Large cement factory / Petrochemical plant | 240–490V | Oil Cooled + Forced | 2500×1800×2600 |
| 2000 kVA | Steel melting shop / Entire industrial township | 240–490V | Oil Cooled + Forced | 2800×2000×2800 |
Need a custom capacity?
We manufacture heavy duty stabilizers up to 5000kVA for special applications. Our engineers will visit your plant for a free load assessment.
Oil Cooled vs Air Cooled
For heavy duty applications above 150kVA, oil cooling is the superior choice.
Oil Cooled (Heavy Duty)
- Superior heat dissipation – handles 55°C ambient
- Sealed construction – dust and moisture proof
- Lower operating temperature – longer insulation life
- Suitable for outdoor installation (IP54/IP65)
- Quieter operation (oil dampens magnetic hum)
- Recommended for capacities >150kVA
Air Cooled (Light Duty)
- Limited to 40°C ambient
- Dust accumulation requires regular cleaning
- Louder operation (fans)
- Not suitable for outdoor or dusty environments
- Recommended only up to 150kVA
Heavy Duty Voltage Stabilizer — Industrial Plant Protection
In heavy industrial environments like steel plants, cement factories, and chemical processing units, voltage fluctuations are not just an inconvenience — they are a direct threat to production uptime, equipment longevity, and worker safety. A heavy duty voltage stabilizer from VoltaPex is engineered specifically for these demanding conditions.
Why Standard Stabilizers Fail in Heavy Industries
Standard commercial or light industrial stabilizers are not designed for the punishing conditions found in heavy industries:
- High inrush currents: Large motors (100HP+) draw 6-8x their rated current during starting. Standard stabilizers trip on overload.
- Extreme ambient temperatures: Steel plants often have ambient temperatures exceeding 50°C near furnaces.
- Dust and contaminants: Cement and mining environments clog air-cooled units within weeks.
- Continuous operation: Many heavy industries run 24×7, leaving no downtime for stabilizer maintenance.
- Wide voltage swings: Heavy grid loads in industrial areas cause voltage drops from 440V to 340V in seconds.
VoltaPex Heavy Duty Solution
Our industrial heavy duty stabilizer addresses every one of these challenges:
- Oil cooled design for superior heat dissipation and dust protection
- 200% overload capacity (10 seconds) for motor starting without nuisance tripping
- Wide input window (240V to 490V) for severe grid fluctuations
- Copper wound construction for maximum efficiency and thermal stability
- IP54/IP65 enclosures for dust and water resistance
- Automatic bypass for maintenance without production interruption
Key Applications for Heavy Duty Voltage Stabilizers
Steel Plants & Rolling Mills
Rolling mill motors experience repeated high-current cycles. Voltage drops during the rolling process can cause product rejects and motor damage. Our heavy duty stabilizers maintain ±1% output even during these demanding cycles.
Cement Factories
Crushers, conveyors, and kilns require stable voltage for consistent operation. Voltage sags can cause material blockages and process upsets. A VoltaPex industrial voltage stabilizer ensures smooth operation.
Chemical & Petrochemical Plants
Reactors, mixers, and pumps in chemical plants are sensitive to voltage variations. Process control systems (PLC/DCS) require clean, stable power to maintain setpoints. Our stabilizers provide both voltage regulation and harmonic filtering.
Large Water Treatment Facilities
High-capacity pumps (hundreds of HP) need stable starting and running voltage. Voltage drops can cause pump cavitation and motor overheating. A mainline stabilizer at the plant entrance protects all pumps simultaneously.
Mainline Stabilizer vs. Individual Machine Stabilizers
For heavy industrial plants, you have two options:
- Mainline stabilizer: One large unit at the service entrance protects all downstream equipment. Lower total cost, simpler installation, but single point of failure (mitigated by automatic bypass).
- Distributed stabilizers: Smaller units at each machine. Higher total cost, more complex, but offers redundancy.
VoltaPex engineers recommend mainline voltage stabilizers for plants with 5+ machines above 50HP each. We provide free site assessment to determine the optimal configuration.
Industrial Stabilizer Questions
Answers for plant managers, maintenance engineers, and project consultants.
Protect Your Heavy Industrial Plant Today
Get a free site audit and custom heavy duty stabilizer recommendation from our industrial power quality experts.