Background and Basic Principle
I.Industrial Demand
In the petrochemical, metallurgical, and other large-scale industrial sectors, production processes are highly dependent on stable power supply.
Petrochemical production
In petrochemical production, chemical reaction processes require precise control of parameters such as temperature and pressure. Even a brief power interruption of just a few seconds can lead to a runaway reaction, triggering safety incidents and causing significant economic losses.
For example, in a critical reactor vessel at a large petrochemical plant, complex polymerization reactions take place. During the reaction, the temperature must be maintained within a specific range, with deviations not exceeding ±2°C—a condition entirely dependent on a stable power supply to drive the cooling system and agitator. If power is interrupted, the reactor temperature rises rapidly, leading to an uncontrolled reaction. This not only results in the loss of an entire batch of product but may also cause an explosion, posing a severe threat to nearby facilities and personnel safety.
Metallurgical Industry
In the metallurgical industry, particularly in blast furnace iron making, any power supply abnormality can lead to the solidification of molten iron, causing severe equipment damage and incurring extremely high repair costs. As a result, these industries demand the highest levels of power supply continuity and reliability.
II.Limitations of automatic power transfer systems
Traditional Automatic Transfer Switching (ATS) Systems Have Multiple Limitations in Industrial Applications
1. Long Switching Time
The switching process is slow, typically requiring 1-2 seconds from power loss to complete transfer. In petrochemical and metallurgical industries, where motor loads dominate, back-emf from motors causes a gradual decline in bus voltage. The ATS must wait until the bus voltage drops to 20%-35% of rated voltage before activating. By this time, motors have already been affected, with reduced rotational speed, compromising production continuity.
2. Inrush Current Prevention Settings
To avoid high inrush currents caused by phase opposition or phase difference during backup power closure, traditional ATS systems often employ longer delays and lower voltage thresholds, further prolonging the switching time and failing to meet production demands.
Case Example:
During a grid failure at a metallurgical plant, interference from motor back-emf caused the traditional ATS to take 1.5 seconds to complete the transfer. This delay led to:
- Temperature drop in the blast furnace molten iron
- Altered chemical composition
- Severely non-compliant steel quality
- Near-total loss of the entire batch of molten steel
- Direct economic losses exceeding millions of RMB
III. Advantages of ASKVQC Solution
The ASKVQ HVATS series is specifically designed to address the aforementioned challenges.
Integrated Design & Advantages Featuring a unique integrated design combined with advanced hardware/software platforms, it delivers safety, flexibility, rapid response accuracy, and high reliability. During power transfer, it supports multiple switching modes to ensure fast and secure backup power engagement with minimal impact on motors. | ||
| Modular Design Featuring a unique integrated design combined with advanced hardware/software platforms, it delivers safety, flexibility, rapid response accuracy, and high reliability. During power transfer, it supports multiple switching modes to ensure fast and secure backup power engagement with minimal impact on motors. | ||
| Hardware & Control Superiority | ||
Equipped with a high-performance ARM processor and precision AD sampling chips for ultrafast switching (<400ms) and precise | Incorporates anti-interference design in both hardware and software, validated by third-party highest-grade EMC tests for stable operation in harsh industrial environments | 400ms switching time (vs.traditional ATS systems) dramatically reduces production disruptions |
System Assembly & Structure
I. Structure of HVATS
For 12kV and lower voltage power switching, the ASKVQ HVATS provides seamless automatic transfer capability.
Fixed Sealed Insulation Pole Column The hermetically sealed insulated pole assembly utilizes a proprietary embedded casting process, integrating the vacuum arc-extinguishing chamber and current-carrying parts into epoxy resin for solid dielectric insulation, demonstrating 42kV power-frequency voltage endurance. |  | 1：Fixed seal insulation pole column 2：Mechanical interlock 3：Energy storage handle interface 4：Energy storage and split and closing status display 5：Manual switch button 6：Chassis car |
Mechanical Interlocking The mechanism employs positive mechanical interdiction to enforce single-source operation, with structural constraints that make electrically parallel connections physically impossible. |  |
Other Parts Manual charging handle for emergency or maintenance use. LED status display shows charging/switch position via color codes. Emergency manual button and dual-mode chassis trolley: -Manual: Hand-crank operation -Electric: Remote-controlled |  |
Application Scenario
Connected to the central power monitoring center via Ethernet • Real-time data transmission & instant fault logging • Enables rapid fault diagnosis & minimizes downtime |
III.Specifications on Cabinet body Structure
The purpose-built ASKVQ CABINET delivers mechanical mounting and power circuit connectivity for integrated HV switching systems.
Design of Cabinet Body
The size of the cabinet is precise, and its internal layout is reasonable. It is equipped with a main power supply inlet terminal, a backup power supply inlet terminal, and a load output terminal. |  |
Electric Power Transmission
Reliable power transmission is achieved through a voltage-current converter and copper busbars. Installation space is reserved for the installation of HVATS switches and controllers to ensure the compact integration of the system. |  |
Material & Performance of Cabinet Body
The cabinet body is made of high-quality steel, which has good mechanical strength and electromagnetic shielding performance. The internal copper busbars are made of copper materials with high electrical conductivity. The cross-sectional area has been strictly calculated to meet the transmission requirements of the rated current. Moreover, under the condition of large current, the temperature rise of the copper busbars is controlled within a reasonable range, ensuring the stability of power transmission. |
Core Technology
I. Vacuum Circuit Breaker
The vacuum arc - extinguishing chamber is a key component of the ASKVQ HVATS switch.
Arc - Extinguishing Principle
It utilizes the high - insulation strength and rapid arc - extinguishing ability of the vacuum environment. During the opening process, the contact blocks inside the vacuum arc - extinguishing chamber separate, and the electric arc is quickly extinguished in the vacuum environment, effectively cutting off the circuit.
Design and Service Life Advantages
Special design and manufacturing processes ensure the high reliability and long service life of the vacuum arc - extinguishing chamber, which can withstand multiple closing and opening operations. The arc - extinguishing time of the vacuum arc - extinguishing chamber is extremely short, usually completing the arc - extinguishing process within a few milliseconds, greatly improving the switch's ability to interrupt fault currents. Its internal special contact material and structural design can effectively reduce the erosion degree of the contacts, extending the service life of the arc - extinguishing chamber. Under the rated short - circuit breaking current, more than 30 opening operations can be achieved.
II.Busbar System
The busbar system is responsible for the distribution and transmission of electric power.
Material Performance: High-quality material is applied, featuring low resistance and high-current carrying capacity.
Design Consideration: In the design, factors such as current distribution, heat dissipation, and mechanical strength are fully considered to ensure stable operation under high - load conditions. At the same time, the bus-bar system closely cooperates with switches, cabinets, and other components to achieve efficient power transmission.
III. Mechanical Interlock
The mechanical interlock device is an important part of ensuring the safe operation of the system.
Interlock Principle
The operation of the switch is restricted through a mechanical structure to ensure that the two - way power supplies will not be closed simultaneously under any circumstances.
Reliability and Safety
This interlock design is simple and reliable, preventing misoperation from the physical layer and improving the safety and stability of the system. The mechanical interlock adopts multiple sets of mechanical linkages and locking structures. When one - way power supply switch is in the closed state, the mechanical interlock will lock the operating mechanism of the other - way switch, preventing it from performing closing operations. Only when the closed switch is opened will the interlock device release the lock, allowing the other - way switch to perform closing operations, fundamentally eliminating the possibility of the two - way power supplies being closed simultaneously.
In the dual - incoming - line mode, when the voltage of #1 line fails and the voltage of #2 line is normal, and the #2 switch is in the open position, the controller automatically delays tripping the #1 switch and then delays closing the #2 switch; when the voltage of #1 line recovers and the #1 switch is in the open position, it automatically performs the reverse transfer to ensure the continuity of power supply.
In the practical application of a certain factory, when the #1 power supply failed due to a fault, after detecting that the #2 power supply was normal, the controller quickly completed the transfer from the #1 power supply to the #2 power supply within 400ms according to the preset logic, ensuring the normal operation of the factory's production equipment and avoiding production interruptions caused by power outages.
Installation & Commissioning
I. Preparation for Installation
Before installing the ASKVQ SERIES HVATS CABINET, a series of preparatory work needs to be carried out. First of all, it is necessary to ensure that the installation site meets the requirements of the equipment. The site should be dry, well - ventilated, and free of corrosive gases and flammable and explosive substances. At the same time, the flatness and bearing capacity of the installation foundation should be checked. The deviation of the foundation's levelness should not exceed the specified value, and the bearing capacity should meet the weight requirements of the equipment. In addition, tools and materials required for installation, such as wrenches, screwdrivers, and spirit levels, as well as materials like connecting cables and grounding flat steel, need to be prepared.
II. Cabinet Installation
When installing the cabinets, they should be positioned and fixed according to the requirements of the design drawings. First, move the cabinets to the installation location and use a spirit level to adjust the levelness of the cabinets to ensure they are in a horizontal state. Then, fix the cabinets to the installation foundation with bolts. The tightening torque of the bolts should meet the specified requirements. During the cabinet installation process, pay attention to the tightness of the connections between the cabinets to ensure good electrical connections between them.
III. Electrical Connection
Electrical connection is a crucial step in the installation process. When making electrical connections, you must strictly follow the electrical schematic diagram and wiring diagram.
First, connect the incoming lines of the main power supply and the standby power supply, ensuring that the connections are firm and well - insulated. Then, connect the load output terminals, paying attention to the phase sequence and polarity of the load. In addition, connect the control circuit, signal circuit, etc., to ensure that all circuit connections are correct.
When connecting cables, pay attention to the bending radius and fixing method of the cables to avoid damage to the cables.
IV. Commissioning Steps
After the installation is completed, commissioning work is required. Before commissioning, conduct a comprehensive inspection of the equipment. Check whether the electrical connections are secure, the insulation is in good condition, and all components are working properly.
During commissioning, first perform an insulation resistance test. Use an insulation resistance tester to measure the insulation resistance values of each circuit. The insulation resistance values should meet the specified requirements. Then, carry out a withstand voltage test to test the insulation performance of the equipment by applying a test voltage. Next, conduct a control circuit commissioning to check whether all functions of the controller are normal, such as manual switching, automatic switching, protection functions, etc. Finally, perform a load test. Under simulated load conditions, check the operation of the equipment to ensure that it can work properly.
Operation & Maintenance
I.Precautions during Operation
During the operation of the equipment, the following precautions need to be taken. First, pay close attention to the operating status of the equipment. Observe the display screen of the controller to check information such as the electrical parameters and switching status of the equipment. If any abnormal situation is detected, timely measures should be taken for handling. Secondly, regularly inspect the appearance of the equipment. Check whether the cabinet is deformed or damaged, and whether the connections of all components are secure. In addition, pay attention to the operating environment of the equipment. Keep the environment around the equipment clean and dry to avoid the influence of factors such as dust and moisture on the equipment.
II.Routine Maintenance Content
Routine maintenance work includes cleaning the equipment, checking electrical connections, and checking the working status of each component. Regularly clean the surface and interior of the equipment to remove dust and debris and keep the equipment clean. Check whether the electrical connections are loose, and if so, tighten them in a timely manner. Check the working status of each component, such as the opening and closing status of switches and the action of relays. If any abnormality is found, replace the component in a timely manner. In addition, regularly lubricate the equipment to ensure the normal operation of its moving parts.
III.Periodic Maintenance Items
In addition to routine maintenance, periodic maintenance is also required. Periodic maintenance items include checking insulation performance, checking protection functions, and checking communication functions. Regularly use an insulation resistance tester to measure the insulation resistance values of each circuit to check whether the insulation performance of the equipment is good. Check whether the protection functions are normal by simulating fault conditions to see if the protection device can act in a timely manner. Check whether the communication functions are normal by communicating with the host computer through the communication interface to check if the data transmission is normal. In addition, regularly calibrate the equipment to ensure its measurement accuracy and control accuracy.
Technical Parameters
FAQs
FAQ 1: Is your high-voltage dual-power transfer switch compatible with 60Hz power grids?
Answer:
Our ASKVQ controller features wide-frequency design (50/60Hz auto-adaptation) with these key specifications:
Transfer time: <12ms (meets IEEE 446 standards)
Automatic sampling frequency adjustment
12/17.5kV dual insulation design
FAQ 2: How do you prevent false transfers caused by DC-side arcing in PV applications?
Answer:
The AISIKAI protection system provides:
UV arc detection (<2ms response)
Transfer lockout logic during arc faults
Dual-CPU redundancy
Field tests show reduction from 18 false operations/year to zero at 200MW plants.
FAQ 3: What protection is provided for humid environments?
Answer:
Key protective features include:
IP55 aluminum enclosure (salt fog tested)
Silver-plated contacts (95% RH tolerance)
15mm minimum creepage distance
Maintenance requires biannual cleaning with anhydrous ethanol (document P41).
The Electronic MCCB with Built-in Electric Motorized Operating Mechanism solves the long-term reliability problems of traditional external motorized mechanisms, providing a more stable transmission.
The Load Isolation Switches (load disconnector) in this project provide visible isolation for maintenance, ensuring safe disconnection of the 5kV circuits during inspections and repairs to protect personnel and equipment.
Project Background:Vietnam's coastal ports and industrial parks are rapidly expanding. Due to frequent typhoons and rainy seasons, power interruptions are common. Many ports and cold chain warehouses require backup diesel generators and Automatic Transfer Switches (ATS) to ensure continuous operatio
