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SOMAR
Motorboss.
Somar Motorboss®
(Powerboss outside the U.S.)
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Powerboss
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Dynamic
Motor Optimiser |
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Leading edge
technology – providing practical solutions to meet some of the demands of this
decade.
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Powerboss - the result of over a decade of
research and continued development - is at the forefront of intelligent
motor control and energy optimisation, offering a unique, energy savings
opportunity. |
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Increased energy cost is undoubtedly one of the major problems facing
industry today. Since almost every product is manufactured with the
utilisation of motors – it is not surprising that the AC induction motor is
the world’s single biggest consumer of energy. Collectively as a world
resource, motors consume over $300 billion in energy each year! In reality,
the cost of running motors is a significant cost element of every product we
purchase. |
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Motors typically work at only 50/60% of rated
capacity.
ENERGY EFFICIENCY OFFICE
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Wasted Energy
Typically, most AC induction motors are under full load for
only limited periods, and at other times, huge amounts of energy is wasted
as heat and vibration. Unfortunately motors have no way of intelligently
adjusting the amount of electricity they draw in relation to the job of work
they do.
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In practical applications, many motors are working
significantly below their design capacity resulting in high levels of
inefficiency. It is clear, if you could intelligently monitor and reduce the
power drawn by a motor to match its actual need under variable load
conditions, you would open up an enormous energy savings opportunity. |
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Intelligent Energy Savings
Utilising a powerful
micro computer, Powerboss provides a simple and effective solution to the
problem by constantly monitoring the ‘efficiency’ of the motor and ensuring
the input power to the motor is matched exactly to the load as it changes.
Even the slightest variations in demand will be sensed and Powerboss will
respond – supplying full power to the motor if required in 100th
of a second. Motor speed is not adversely effected in any way. |
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Powerboss will
produce a more efficient, smoother and quieter motor with increased life and
reduced maintenance costs. Power factor will be improved. |
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Powerboss is suitable for a wide variety of applications.
In some exceptional instances savings have been as high as 30-40%.
However, results will vary depending on several factors, but even a much
smaller saving of say 5-10% will still provide a 100% guaranteed return on
investment. A blend of significantly reduced electricity costs and increased
efficiency can provide a very attractive payback proposition – often within
two years.
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Powerboss
– Soft Start, Soft
Stop |
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Powerboss Plus adds a new
dimension to 3 Phase AC Induction motor applications, by providing
controlled starting and stopping of motors, with variable ramp times and
current limit settings. A simple maintenance free installation with remote
control and current free switching - plus the additional benefit of an
unrivalled potential for optimisation ensure total effective control. |
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This dramatic level of increased motor efficiency can
provide further valuable benefits of: A reduction in electricity and
maintenance costs, improved power factor, lower maximum demand, improved
reliability and increased production. |
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Soft start –
Soft stop
Remote
control/switching
Lower
maintenance costs
Energy savings |
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The
Problem
When
starting, an AC induction motor develops substantially more torque than is
required at full speed. This stress is transferred to the mechanical
transmission systems resulting in excessive wear and premature failure of
gears, chains, belts etc.
Damage
can be inflicted on the machinery under control, which apart from production
losses, can be dangerous, and expensive to correct.In some instances
products under manufacture are destroyed due to motors stopping abruptly.
This is especially the case with pumping fluids where torque transients
often cause water hammer effects, and in some instances, failure to
gradually slow the fluid down before stopping can cause the kinetic energy
to rupture pipes and couplings.
Rapid acceleration also
has a massive impact on the electricity supply charges with high inrush
currents drawing up to 6-9 times the normal run current. Voltage dips,
brownouts, overheating, contactor wear and failure can result. The use of
Star-Delta provides only a partial solution to the problem. Furthermore, in
this configuration, should the motor slow down during the transition period,
high peaks can be repeated and even exceed direct online current. |
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The Solution
Powerboss Plus provides a reliable and economical solution
to these problems by delivering a controlled release of power to the motor,
thereby providing smooth stepless acceleration and deceleration – also
enabling more frequent starting and stopping.
Powerboss will give increased protection to the motor and
peripherals also reducing high shock load, backlash, Vee belt stress etc.
Noise and vibration will decrease and motor life can be extended as damage
to windings and bearings, is reduced. |
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Once the motor has reached full speed, the Powerboss
optimising mode will search for the minimum power required to ensure the
maximum continuous rating of the motor is matched exactly to the load as it
varies. Thus improving power factor and ensuring minimum running costs.
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For a full
technical explanation and specification of the full range of Powerboss units
please refer to the document; Powerboss… technically speaking,
available from Somar. |
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Powerboss
- a proven product!
Satisfied Powerboss customers from thousands of
installations around the world can attest to its ability to save industry
literally millions of pounds in energy and maintenance costs. Independent
reports from a variety of sources have endorsed both the quality of
engineering and economic viability of Powerboss. The following are just a
selection of the results from specific applications where careful monitoring
has taken place. |
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In May 1998, a test was carried out by the giant French
company - Aerospatiale.
A 150 kW Powerboss Plus was installed in the compressor room of the
industrial plant on a Siemens motor of nominal output 132KW. The
installation, carried out by a technician of Aerospatiale, provided a
substantial annualised saving of
30,572 kWh. In addition to the benefits of soft start.
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At a
Local Authority site in
Norway
a 75kW Powerboss Plus has been installed on a Heat Pump used to transfer
heat from an Ice Rink to a nearby school. This efficient heat transfer
process, already saving the Authorities £100K per annum,
has been further enhanced by the installation of Powerboss. The calculated
payback for Powerboss is well within two years. |
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At Volvo
in Sweden
a 22KW Powerboss was installed in a line where the engine blocks are
treated. The motor operates under load 36% of the time and off load 64% of
the time. The metered energy savings of active power were 9% under load and
28% when idling. Reactive power
savings were 25% and 45% respectively. Payback was calculated at 298 days.
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Dillons, a well respected retailer in the
UK has over 700 shops
throughout the group. In 1992 they carried out an evaluation test in
conjunction with an accredited group of independent energy consultants, into
the use and efficacy of the single phase Powerboss on their refrigeration
equipment. Initially one shop was installed and after attractive energy
savings were metered on each unit, a pilot was carried out on a further ten
shops enabling electricity bills to be compared with previous periods.
Following a successful installation a roll-out programme was agreed
resulting in over 4,000 units having
now been installed on equipment throughout the group. |
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The much coveted
Det Norske Veritas
approval has been awarded to
Powerboss
(with limitations as to size and application) for installation on Ships and
other offshore installations. The evaluation also confirmed that the
reduction in electricity, which Powerboss undoubtedly makes, is translated
into a reduction in the amount of fuel consumed by the vessel, thereby
extending the time before refuelling.
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At one
of the largest British Rail
maintenance depots in the South of England a 37kW Powerboss was installed on
a motor used to drive an air compressor. The site engineer metered the
installation both before and after the installation and reported a
21% saving in electricity. |
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In Norway, a
large Municipal pump was
causing considerable electrical problems for a nearby factory. Despite
having been fitted with a variable Speed Drive, there was still very high
starting currents causing transient spikes and a drop in power in the
immediate area – which resulted in computers and electronic control
equipment tripping out. All previous attempts had failed to rectify the
problem. However, following the installation of Powerboss, the problem was
eliminated and a permanent solution was provided. |
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An
aircraft manufacturing plant,
employing over 4000 motors in its factories, ran extensive tests on
Powerboss. A wide variety of applications, including vacuum pumps, sheet
bending and cutting machines, lathes, horizontal boring machines, and
universal milling machines, were installed with Powerboss and carefully
monitored with excellent results. Savings, in kW hour, on a wide range of
motors averaged a staggering 38.4%.
Following these successful results an installation programme was agreed
resulting in almost 1000 Powerboss
having now been employed on one site. |
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The large American Company
Contico
installed and monitored a Powerboss at a site in the UK. The unit was
installed on a Granulator used for re-cycling waste from the injection
moulding machines. The installation was monitored via an energy analyser and
the results confirmed by the local Electricity Supply Company. The motor ran
throughout the day and kW savings of over 50% were achieved for most of this
period.
A laboratory test was
carried out by Edwards High
Vacuum Ltd. (Part of the British Oxygen Group) into the
suitability of installing Powerboss on their vacuum pumps. In summary this
eleven page comprehensive report stated:
"the tests clearly indicate that the Powerboss single phase energy
controller reduces the energy consumption of a typical single phase vacuum
pump by between thirty and forty percent". |
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Curver Limberg,
one of the largest companies in the
Benelux countries, have a Powerboss installation on on of
their Injection Moulding Machines. During the production cycle, which varies
dependant on the products under manufacture, the equipment spends a
proportion of time either off or under low load. Following the Powerboss
installation the energy consumption was metered carefully and
a cost saving of circa 20-25% was being
achieved. |
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In Norway a
400kW ‘Rockmill’
capable of crushing 65 tonnes of granite in circa 5 minutes was suffering
from excessive starting currents even when unloaded. A Powerboss PSO 400
provided an effective soft start solution with complete motor and system
husbandry. It was further noticed that the motor spent over 40 minutes in
each hour of operation in either a low or unloaded condition. During these
periods Powerboss reduced the power consumption from 181kW to 153kW. |
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A manufacturing company,
with the UK
as 40% of its market for their top of the range wood burning stoves, has 102
Powerboss 3phase units controlling motors in its foundry. With a very hot
and dusty environment, and some
motors starting up to 400 times per day, the company
experienced a very high incidence of breakdown and consequent long periods
of down-time on its production lines. Although there has been an average
saving of 22% in energy, they also claim that the greatest benefit is the
dramatic improvement in equipment reliability and an almost
80% reduction in maintenance costs due to
improved motor control. |
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For many people massive
increases in energy costs have become an unpleasant fact of life. Powerboss
is cutting through all the expensive ways to save energy by providing a
brilliant new answer to conquer those big energy bills. |
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Tests & Certification
Summary of Declaration of Conformity
EMC Directive - 89/336/EEC
Low Voltage Directive - 73/23/ECC
Harmonised Standards - BS EN-61010-1-1993, BS
EN-60204-1:1992, EN 50082-2, EN55022
Class A and EN60555 - 2/3.
All Powerboss units carry a CE certification mark
UL & CSA approvals pending |
Powerboss has undergone and
passed the most stringent tests, and an EC Certificate of Conformity
proscribed by the EU has been issued. Further numerous tests have been
carried out by: Equipment Manufacturers, Universities, Engineering Test
Houses and private companies to verify savings and equipment performance.
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All Somar products are designed to the highest possible standards and
the manufacturing process is stringently controlled for quality assurance |
Key Benefits
 | Reduced energy consumption |
| Extended motor life |
| Decreased heat, noise, and vibration |
| Soft starting and stopping
 | Reduced wear and tear |
| Reduced start-up demand |
| Reduced hydraulic hammer effect on motor stop |
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