ENERGY SAVING SOFT STARTER
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FOR A.C. SQUIRREL CAGE INDUCTION
MOTORS
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SYNOPSIS:
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WATT - WIZARD Energy
Saver Soft Starters belong to the latest generation of motor starters,
incorporating state-of-the-art technology. They are far superior to any
of the conventional electro-magnetic modes of starting as they can
provide a smooth start, reducing the in rush currents considerably,
besides offering several other advantages. Further, the built-in energy
saving facility helps in reducing power consumption when the motor is
partially or cyclically loaded.
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SOFT START:
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The starting
current drawn by an induction motor is directly proportional to the
applied voltage. The Soft Starter is designed to make it possible to
choose the lowest voltage possible(pedestal voltage) at which the motor
can be started - the lowest voltage being dependent on the load on the
motor.
The voltage is ramped up from this pedestal level to full voltage in
the set time (selectable- 0 to 10 seconds). Pedestal voltage and ramp
time can be set at site. It is also possible to provide controlled
torque soft start with current limit option. Soft start feature can
also be provided, as optional.
ENERGY SAVING:
A majority of
induction motors in industries are under utilized due to a combination
of design/selection/safety considerations. This results in substantial
energy loss, by way of wasted power and consequent rise in the
temperature of the motor, which is harmful to the motor in the long run.
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WATT - WIZARD ENERGY
SAVER SOFT STARTERS are ideal for saving Energy when used with
induction motors which are operating at partial or on cyclic loads.
They automatically control the voltage applied to the motor, to that
required to meet the varying load conditions without sacrificing torque
or speed, resulting in reduced power consumption and consequent saving
in KWH and improved power factor.
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ENERGY
SAVER SOFT STARTERS are
ideally suited:
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where a smooth start
is desirable to avoid shocks to the drive system or where a gradual
start is required to avoid damage to the product/process/drive system
and accessories.
where system voltage drop is to be eliminated or undue loading of
generators is to be avoided.
where in-rush current is to be limited to avoid heavy line voltage drop
while starting high capacity motors or high inertia loads.
for reduction of maximum demand when motors are started frequently.
where energy saving is desired under partial or cyclic load conditions
and to improve power factor
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ADVANTAGES:
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Smooth start and
Stepless Gradual acceleration of motor and consequent elimination of
shocks during starting.
Reduction in peak motor current during starting.
Reduction in maximum demand.
Reduction in motor temperature, increased motor life and decreased
maintenance.
Comfortable Inching without ant damage.
Power factor improvement.
Reduced power consumption and hence reduced energy bills.
No moving parts that can be affected by dust, dirt or other such
environmental factors.
Easy installation and Retrofit capability (3 wires in, 3 wires out) -
Solid state - low maintenance.
Replaces electro-magnetic starters as well as fluid couplings.
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HOW
WATT WIZARD ENERGY SAVER STARTER
WORKS : PRINCIPLE:
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WATT - WIZARD ENERGY
SAVER SOFT STARTER consists of Silicon Controlled Rectifiers (SCRs),
sensing and control circuits to control the firing of SCRs.
Soft Start is achieved by progressive phasing back of the firing of
SCRs in the present time. To achieve energy saving the phase angle
between the voltage and current is monitored continuously to obtain a
signal proportional to the phase angle, based on which the firing of
the SCRs is controlled. When the phase angle increases, (which is
indicative of low power factor), the control circuit adjusts the firing
angle to decrease the average voltage applied to the motor and vice
versa.
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FEATURES:
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All the above models
have the following features :
Soft Start facility, with initial torque pot. for setting pedestal
voltage, Ramp time pot. for setting ramping time; adjustable from 0 to
5 secs.
Longer ramping time can be provided. (Please refer to us with full
details of application.
Energy Saving.
Indication for Mains ON and Motor ON.
Push buttons for start and stop.
Starting overload trip with indication.
Running overload trip with indication.
Current based single phasing trip with indication.
Anti-stall facility with indication.
Energy saver by-pass switch.
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TECHNICAL SPECIFICATIONS:
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Power input
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415/440
volts AC -+ 10% 3 phase 50 hz. |
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Recommended load
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A.C.
motor, three phase, Multiple Motors
or other loads are not recommended except under specific circumstances.
(Consult us for further details). |
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Maximum
Overload capacity
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115%
continuous, 150% for 10 seconds and 200% for 5 seconds. |
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Altitude of
Installation
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1000
meters. (Above 1000 meters derating has to be done). |
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Voltage rating
of Thyristors
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1400
PIV. |
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Type Of Cooling
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Air-cooled
upto 75 HP. Force-cooled above 75 HP. |
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SCR Protection
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MOV
transient voltage suppressors to
absorb high energy voltage transients provided across the input supplu
points. RC Snubber circuit is porvided across SCR to prevent misfiring
due to rapid rise of voltage. (dv/dt). |
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ENERGY SAVING CASE STUDIES:
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Equipment to which motor is
coupled, HP & No. of working hours/year
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Power Consumption
in units/hour |
Savings
Per Year
(in units)
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Payback Period
(in months)
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Without
"Watt Wizard" ESSS
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With
"Watt Wizard" ESSS
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| 1.
Blower Fan 20 HP (5000) |
7.24 |
6.25
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5110
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20
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| 2.
Pallet Conveyor 10 HP (6000) |
2.00 |
1.20
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5958 |
13 |
| 3.
Vertical Turret Lathe 20 HP (5400) |
4.90 |
4.10
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4320
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23 |
| 4.
Air Compressor 40 HP (6000) |
21.00 |
18.95 |
12300 |
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APPLICATION INDUSTRIES:
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| Textile
mills and textile machinery manufacturing |
Mines/General
Engineering |
| Oil
& Natural gas |
Food/Beverage/Hotels/Entertainment
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| Steel/Rerolling
mills |
Air
- conditioning Equipment Manufacturers |
| Rubber/paper/Plastic |
Cable
Manufacturing
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| Pulp/Rayon |
Railways/Power
Generation |
| Cement/Sugar |
Defence/Ordnance
Factories |
| Chemical/Petro-Chemical/Fertiliser |
And
wherever motors are used and also by Panel |
| Breweries/Distilleries |
Builders
& Energy Consultants.
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TYPICAL APPLICATIONS:
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| Speed/Draw/Ring/spinning/twisting
frames in cotton |
Planning
and Shaping Machines |
| Textile/jute mills |
Machine tools/Punch Presses |
| Chemical
Process Equipments / Centrifuges |
Centreless
Grinding and Polishing Machines
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| Motor
Generator Welding Sets |
Precision
Machines tools |
| Centrifugal
Blowers/Fans/Pumps |
Unloading
type Aircompressors
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| Ball
Mills/Crushers/Mixers |
Extruders/Coilers |
| Bottling
Plants/Packing Machines |
Conveyors |
| Injection
moulding machines |
Cranes
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