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This presentation was kindly prepared by the project owner for www.merar.com

POWERBOSS

THE INTELLIGENT CHOICEFOR FIXED SPEED MOTOR

CONTROL

PROBLEMS WITH MOTORS

HIGH STARTING CURRENT PROBLEMS

CurrentDirect On Line

Mot

or C

urr

ent

Speed

In

6-12 x In

100% N

Excess Starting Current

PROBLEMS WITH MOTORS

HIGH STARTING CURRENT PROBLEMSHigh Torque

Torque

Direct On Line

100% N

X N

omin

al M

otor

Tor

qu

e

Speed

2.5

1 Excess Starting Torque

Acceleration Torque

Load Torque

DOL Torque

† Star Delta Current

Speed 100% N

Transition Peakup to 20 x In

Excess StartingCurrent

Mot

or C

urr

ent

6-10 x In

In

3X In

Star Delta Torque

X N

omin

al M

otor

T

orq

ue

Speed 100% N

2.5

1

Excess Acceleration Torque

0.33

Delta Torque

Star Torque

Load Torque

Powerboss vs DOL

Mot

or C

urre

nt

Speed 100% N

6-10 x In

Direct on Line Current

1

Unused Starting Current

Powerboss Start

Powerboss vs DOL

TorqueX

Nom

inal

Mot

or

Tor

que

2.5

0.66

1

Unused Starting Torque

Motor Torque

Speed 100% N

Load Torque

Powerboss Torque

Acceleration Torque

SEE THE DIFFERENCE

Direct on Line Powerboss

PROBLEMS WITH MOTORS

HIGH STARTING CURRENT PROBLEMS High Torque VOLTAGE DIPS HIGH ENERGY COST NUISANCE TRIPPING

"NUISANCE TRIPPING"

A nuisance trip occurs when it mistakes a normal operating condition for a hazardous condition,

Also, it is a nuisance to constantly have to reset a defective circuit breaker. However, it may not be defective, it may be a warning that the wiring and its connections are being overloaded with too much current or too many appliances.

Never try to solve the problem of a nuisance tripping circuit breaker by putting in a higher rated breaker; i.e., a 30 amp breaker in place of a 15 or 20 amp breaker.

PROBLEMS WITH MOTORS

HIGH STARTING CURRENT PROBLEMS High Torque VOLTAGE DIPS HIGH ENERGY COST NUISANCE TRIPPING EXCESSIVE WEAR & TEAR OF EQUIPMENT

Motor Losses

PROBLEMS WITH MOTORS

HIGH STARTING CURRENT PROBLEMS High Torque VOLTAGE DIPS HIGH ENERGY COST NUISANCE TRIPPING EXCESSIVE WEAR & TEAR OF EQUIPMENT FREQUENT CONTACTOR REPLACEMENT CO2 EMISSIONS

Real Power kWCos

Reactive Power kvar

Apparent Power

VA

How Powerboss Works

How Powerboss Works

Torque is proportional to the applied voltage squared: T∞V²

The Powerboss adjusts the output voltage to the motor according to the torque required

This in turn decreases the current.Voltage and current are common to all three

sides of the power triangle

How Powerboss Works

The Power triangle is reduced from all three sides saving energy in three components:

Kva which is the total energy applied which will put less strain on the supply as less current is drawn.

Kw which is paid for.Kvar the reactive component causing heating

and vibration in the motor (all the nastiness).

Powerboss is not designed to increase the PF significantly

If you look at the power triangle the lagging angle is only decreased by a small amount even although there is a significant drop in Kvar. The reason for this is the triangle is affected from all three sides.

Real Power kWCos

Reactive Power kvar

Apparent Power

VA

How Powerboss Works

Recap

If you look at a capacitor it affects Kvar only so it changes the triangle differently see below;

Power Factor correction is designed to counter act the KvarL in the system thus only improves the PF and reduces LPF penalty

Real Power kW

Cos

Apparent Power

VA

Reactive PowerKVAR

USING POWERBOSS AS A SOFT STARTER YOU CAN:

Prevent dips in supply when starting larger motors

Attach more equipment to a single supplySwitch your motors On & Off at any time due

to reduced starting currentSignificantly increase the life of contactors &

drive train componentsReduce the worry of Peak Demand penalties

during starting

EFFICIENT RUNNING withPOWERBOSS INTEGRA

Motors consume only the energy required by the load

Optimisation of Voltage automatically Motors are switched off automatically

when idlingEnergy cost reducedReduced heat and vibrationReduced breakdowns

SMOOTH STARTINGControlled starting currentControlled starting torqueControl on Max Demand

POWERBOSS is in effect an electronic clutch ensuring gradual uptake of power, smooth step-less acceleration and reduced stress on driven equipment

CONTROLLED STOPPINGPowerboss Soft Stop controls decelerationMinimises ‘water hammer’ effectReduces damage to pipe systemsProvides energy efficient plug braking for stored

energy

POWERBOSS-General features

Soft StartOptional DOL startCurrent LimitKick StartSoft StopPlug BrakingEnergy Saving

POWERBOSS- Special Features

Timed Cut offStored EnergyArc-less SwitchingControlled Star-Delta

WHERE SHOULD YOU USE

POWERBOSS ? Injection moulding machines Power Presses & Die Castings Rubber Industry Rock & Aggregate Crushers Water pumps & Compressors Conveyors Fly-Wheel applications Fans & Blowers Ice Plants Agitators , Mixers & Marble Industry

SOME POWERBOSS CLIENTELE

3M Ford Motor Co. Renault Nissan Volvo Penta Aston Martin Proton Cars Honda

Parker Pen Co. Denso Procter & Gamble Coca Cola Cadbury Schweppes Johnson Controls TRW Damage

Powerboss is installed in over 77 countries around the world

CLIENTELE IN PAKISTAN

Samad Rubber Works

Sufi Steel Mills Sazgar Ltd Margla Stone

Crusher Kashif Crushers Awais Flour Mills

Service Industries (Tyre Department)

Al-Qamar Steel Nauras Ltd Pak Chemicals Ltd QadBros Meraj Industries 12 x CNG Stations

Positive Audit for over 85 companies have been

conducted

Energy Readings Logged without Powerboss

Max = 11.826 kWh

Energy readings logged with Powerboss

Max = 8.969 kWh 24% Saving

Max Apparent power without Powerboss

Actual = 32451(VA)

Max Apparent power with Powerboss

Actual = 8487(VA)