ENERGY-SAVING MOTOR CONTROLLERS
Energy Optimizer, Motorboss, Power Commander 

SM Service & Technology is a distributor for several brands of Energy-Saving, Soft Starting Motor Controllers (Power Commander, Motorboss, Energy Optimizer) each suited for different types of applications.

What are these controllers, why are they used and how do they work?

Electric motors are estimated to consume over half of all electricity in the United States and over 70% of all electricity in industrial applications.

Simply stated, most AC induction motors waste energy. An AC induction motor can consume more energy than it actually needs to perform its work, particularly when operated at less than full-load conditions.  This excess energy is given off by the motor in the form of heat.  

Studies conducted by the Electric Power Research Institute reveal that over 60% of industrial motors are operating under 60% of their rated load capacity.  Idling, cyclic, lightly loaded or oversized motors consume more power than required even when they aren't working.  These motors waste energy, generating excessive utility costs and unnecessary motor wear.

Fortunately there's good news - Energy-Saving, Soft Starting Motor Controllers that optimize motor drive systems while maintaining constant motor speed.

Energy Savings: The controller saves energy by measuring the work load on the motor by comparing the difference in voltage and current waveforms at the motor.  This information is then used to reduce the current and voltage to match the work load as required by the motor, while maintaining constant speed.  This transaction takes place 120 times per second which prevents the motor from stalling under any and all changes to motor load conditions.

In simple terms, the controller automatically and electronically down-sizes the motor to match its work load. It adjusts power consumption proportional to motor loading conditions without altering motor RPM. This results in reduced electrical consumption (kWh), and demand (kW).  In addition, excess current, which is normally dissipated as heat through the motor is eliminated.  As a result, the motor runs cooler, quieter and with less vibration, thus extending motor life.

Soft Start:  Over time, full voltage hard starts can damage motors as well as equipment.  Soft starts prevent unnecessary high starting current by reducing the peak current by as much as 50%.  A controlled soft-start limits the inrush of current, prevents unnecessary excess torque and reduces power line disturbances.  The soft-start circuit in the motor controller senses the motor load and the power to the motor. It then applies only the exact power required to start the motor without reducing the necessary starting torque or RPM.  Actual kW demand is reduced and the power factor is improved.  Every start is smooth, stepless, and adjustable to the operator's needs.

Enhanced Motor Efficiency - An Energy-Saving motor controller completely controls the AC induction motor so it always functions at optimum efficiency.  This extends motor life and reduces stress and strain on the motor and the drive train, both electrically and mechanically.  

TYPICAL SPECIFICATIONS:

AC line voltage: Available in 208, 230, 460, 480 volts, @ 60Hz, 3 phase
Horsepower:  Available 10-200 HP, larger sizes on special order.
Load Types:  Three phase AC induction motors, motor specific.
Output Stage:  Full-wave in-line control utilizing dual pack SCR's.
Adjustments:  Soft-start ramp voltage to full speed adjustable from 0 to 30 seconds.
Ambient temperature:  Operating range: -30 to +85 degrees centigrade at rated current.  Storage range: -35 to +85 degrees centigrade.
Transient Voltage Suppression:  Metal oxide varistors protect against high potential transient voltage spikes.
Wiring:  Straight through configuration.  Three in, three out with by-pass switch.
Case:   NEMA 1 enclosure.  Other enclosures available on special order.

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