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The standard powerPerfector has been designed with no moving parts or electronics: voltage optimisation and power quality improvement is achieved through the interaction of magnetic fields only, and the unit is as reliable as the incoming power supply itself.
Since 1993, tens of thousands of VPO® units have been installed worldwide, without a single failure. The unit requires little or no maintenance and the anticipated life-time expectancy is 50 years.
The insulation used is class H and if over current protective devices fail to operate, the powerPerfector technology can withstand a 50% overload for one hour or 10% for up to 3 hours. Both points further demonstrate the resilience of the technology.
The high efficiency of the design means there is negligible heat loss with no requirement for temperature sensing or forced cooling. As a result the unit sustains very little degradation over the lifetime and performance is not affected.
The efficiency of the powerPerfector is supported through the purity and processing of the copper windings. The primary winding is constructed from wide, cold rolled copper sheet rather than wire and the space around the coils is reduced as far as possible to minimise wasteful induced currents. Also essential to efficiency is the response of the core to an alternating magnetic field - the powerPerfector core is constructed from low inertia flaked silicon steel with a hysteresis loop close to 90°.
These factors ensure that the powerPerfector unit achieves a peak efficiency of 99.94%.
Innovations in the design and manufacturing processes have allowed the powerPerfector unit to achieve these very high levels of efficiency and performance.
Cast Resin Insulation (Class H)
powerPerfector units use Insulation Class H (180 °C), which is above the UK standard class F (155 °C) for cast resin devices. This is in recognition of the critical point in the circuit that powerPerfector technology sits. A breakdown of the insulation on a device would lead to short circuits, which would mean operational failure and the possibility of a fire, and hence the quality of the materials and manufacturing are key.
Flaked Silicon Steel
The use of flaked silicon steel allows the magnetic core to have low inertia which is crucial to the efficient operation of the device, and ensures that the powerPerfector unit achieves a peak efficiency of 99.94%
High Conductivity Copper Sheet
A major innovation in the fabrication of powerPerfector units is the use of high purity cold-rolled copper sheet, rather than lower grade copper wire or strips used in normal transformers. This significantly reduces wasteful induced currents, improving efficiency.
In the manufacture of dry type inductive devices, efficiency comes from having a very ‘tight’ construction. Any gaps between windings, or between windings and core, can cause a build-up of heat in ‘hot spots’ that can become dangerous. As the powerPerfector is designed for maximum efficiency and total reliability, minimisation of gaps is central to its design and manufacture throughout. Innovative winding techniques and unique cold-rolled copper sheeting are used in the manufacturing process, with each unit being hand-wound by a specialist winding engineer. Quality control is subject to exacting UK standards.
The low number of turns required in the design of the powerPerfector primary winding ensures that the amount of copper presented to the circuit is minimal, keeping the efficiency high and the impedance negligibly low.