#EnergyEfficiency

EMHEATER INTRO

EMHEATER products are manufactured by EM Technologies and are used across the globe in over 100 countries. The Clean Group of Companies (TCGC) has sole distribution rights for all EMHEATER products in southern Africa and sells directly to consumers as well as to other resellers/distributors (various partnership models are available).

Products include the following:

Variable Speed Drives (VSDs) | Soft Starters | Solar Drives (for Water Pumps) | Servo Drives

*Enclosure and remote monitoring and control devices also available on request

Variable Speed Drives (VSDs)

Variable Speed Drives (VSDs) (also referred to as a Variable Frequency Drives (VFDs) or AC Drives) takes fixed-frequency AC supply and converts this to a variable-frequency AC supply. This controls the power use and mechanical power output so that the motor can run at the most efficient speed for the motor and the process. Control of the motor speed can be based on feedback from the process, e.g., flow rate, temperature, or pressure, so that process control is improved. This enables accurate control of the motor speed over a broad range. VSDs thus provide extremely precise electrical motor control so that motor speeds can be ramped up and down and maintained at speeds required (by varying the frequency and voltage supplied to the electric motor). Doing so motors utilise only the energy required rather than running at constant (fixed) speed and utilising an excess of energy.

For a more detailed explanation on this, please see our blog post: What is a Variable Speed Drive?

Distributors and Suppliers of Variable Speed Drives

TCGC offers the following EMHEATER VSD models:

Single-Phase to 3-Phase Converters

EM15-G1 Series
Variable Speed Drive

1-Phase (200-240V) Input

3-Phase (200-240V) Output

EM15-G13 Series
Variable Speed Drive

1-Phase (200-240V) Input

3-Phase (380-440V) Output

3-Phase Input and Output

EM15-G2 Series
Variable Speed Drive

3-Phase (200-240V) Input

3-Phase (200-240V) Output

EM15-G3 Series
Variable Speed Drive

3-Phase (380-440V) Input

3-Phase (380-440V) Output

EM15-G4 Series
Variable Speed Drive

3-Phase (460-480V) Input

3-Phase (460-480V) Output

EM15-G5 Series
Variable Speed Drive

3-Phase (525-575V) Input

3-Phase (525-575V) Output

Advantages of using a Variable Speed Drive

Variable Speed Drives are probably the best method for controlling motor speed in response to varying process demands. These small decreases in the speed of pumps and fans or the pressure of pumps could lead to large decreases in energy use (and thus electricity costs). Since motors consume lots of energy, the importance of the control of motor load demands increases as energy supply becomes more expensive and ever more strained. One of the biggest advantages of using a VSD is the energy cost savings associated with speed control (more efficient operation), with energy savings of 25 - 70% that can be realised by using VSDs.

Motor speeds can be revved up, slowed down, sustained indefinitely, or brought to sudden halts. with speed levels delivered as-needed rather than at uniform, arbitrary rates. By ramping up the motor speed slowly, VSDs also help save energy by reducing the in-rush current and mechanical issues associated with starting motors. A VSD also saves you money by extending the life of your motor. VSDs decrease the fluid flow into an AC motor, which in turn decreases the pressure and friction on the valves and other machinery inside the motor. This will help reduce the wear and tear on your motor, thus extending the life of your equipment. A VSD can therefore save money by increasing the efficiency of AC motors and decreasing electricity use.

When you operate your motors at the most efficient speed for your application, fewer mistakes will occur and production levels will increase, while earning your company higher revenues. The initial cost of a motor or VSD is generally only a fraction of the cost of operating the motor for its lifetime. A VSD usually pays for itself in a matter of months or just a few years. Modern VSD benefits include power-factor correction and low power consumption, along with full-speed control and not just start/stop control. Other benefits include dynamic braking, PID control, built-in I/O and logic, circulatory control mode, multi-motor control, communication interfaces etc. Below is a list of the top 9 benefits of using a VSD:

  • Controlled Starting Current and Acceleration
  • Energy Cost Savings
  • Elimination of Expensive Mechanical Drive Components
  • Increased Motor Longevity
  • Adjustable Operating Speed
  • Limits and Adjusts Torque
  • Controlled Stopping
  • Reverse Operation
  • Reduced Power Line Disturbances

Further to this VSDs allows for an increased number of motor starts per hour and protects motors against possible low/high voltage/current supply, short-circuits, lost phases (in/out) and 3-phase imbalances.

For a more detailed explanation on this, please see our blog post: Advantages of using a Variable Speed Drive (VSD)

 

Soft Starters

Starting of induction motors is accompanied by inrush currents up to 7-10 times higher than running current and starting torque up to 3 times higher than running torque. Torque surges entail high mechanical stress on the machine, which results in higher service costs and increased wear. High currents and current peaks lead to high fixed costs charged by the power supply companies (peak current calculation) and to increased mains and generator loads. A Soft Starter is a device that starts motors with reduced power supplied at start-up. Soft Starter regulate the amount of current fed to the motor to enable the AC induction motor to speed up in smaller increments, resulting in less current drawn than with a traditional motor starter. Due to decreased voltage, torque is also reduced resulting in a soft/easy start. A Soft Starter continuously controls the three-phase motor’s voltage supply during the start-up phase. This reduces the mechanical stress on the motor and shaft, as well as the electrodynamic stresses on the attached power cables and electrical distribution network, extending the lifespan of the system.

For a more detailed explanation on this, please see our blog post: What is a Soft Starter?

Distributors and Suppliers of Soft Starters

TCGC offers the following EMHEATER Soft Starter products:

EM-GW3 Series
Soft Starter

3-Phase (380-440V) Input and Output

Online - Bypass Contactor Optional

EM-GW4 Series
Soft Starter

3-Phase (440-480V) Input and Output

Online - Bypass Contactor Optional

EM-GW6 Series
Soft Starter

3-Phase (525-690V) Input and Output

Online - Bypass Contactor Optional

EM-GB3 Series
Soft Starter

3-Phase (380-440V) Input and Output

Built-in Bypass Contactor - included

EM-GS2 Series
Soft Starter

3-Phase (200-240V) Input and Output

External Bypass Contactor Required - not included

EM-GS3 Series
Soft Starter

3-Phase (380-440V) Input and Output

External Bypass Contactor Required - not included

EM-GS4 Series
Soft Starter

3-Phase (440-480V) Input and Output

External Bypass Contactor Required - not included

EM-GS6 Series
Soft Starter

3-Phase (525-690V) Input and Output

External Bypass Contactor Required - not included

EM-GS3i Series
Soft Starter (in Cabinet)

3-Phase (380-440V) Input and Output

Built-In Air Circuit Breaker (Online - Bypass Contactor Optional)

Advantages of using a Soft Starter

A Soft Starter is used with AC Motors to temporarily reduce the starting current and torque during start-up (avoiding undue mechanical stress and line voltage fluctuation). A Soft Starter provides a linear power slope for smooth acceleration (allows for adjusting the starting voltage and acceleration time to suit specific applications), which reduces in rush currents and excessive wear on mechanical driven components. This method requires less stress on the machine and therefore equipment lasts longer and works better. It may also benefit the electrical distribution network, using a Soft Starter could thus extend the lifespan of the entire system.

Because of the reduced power consumption and maintenance, a Soft Starter will typically pay for itself very quickly. Below is a list of the top 7 benefits of using a Soft Starter:

  • Energy Cost Reduction (Peak Demand Charges)
  • Improved Power Factor
  • Improved Operating Efficiency
  • Reduced Power Surges
  • Reduced Torque Transients
  • Increased life of Contactors
  • Reduced Maintenance

Further to this Soft Starters allows for an increased number of motor starts per hour and protects motors against possible low/high voltage/current supply, short-circuits, lost phases (in/out) and 3-phase imbalances.

For a more detailed explanation on this, please see our blog post: Advantages of using a Soft Starter

 

Solar Drives

A Solar Drive (for water pumps) is a type of electrical converter which converts the variable direct current (DC) output of a photovoltaic (PV) solar panel into alternating current (AC) that can be used by a local electrical water pump motor. These drives are essentially solar-powered Variable Speed Drives (VSDs) providing alternating current (AC) motors with the required energy using standard photovoltaic (PV) panels, but also still allows for an AC input supply if required. In addition to this, the Solar Drive output frequency is adjustable in real time according to flow requirements as well as sunlight intensity. Solar Drives (for water pumps) thus provides an energy efficient, environmentally friendly way to pump water for a variety of purposes. These Solar Drives have a long lifetime with low maintenance costs and allows users to immediately benefit from ‘free’ solar power.

For a more detailed explanation on this, please see our blog post: What is a Solar Drive (for Water Pumps)?

Distributors and Suppliers of Solar Drives

TCGC offers the following EMHEATER Solar Drive products:

Single-Phase In/Out

EM15-SP1S Series
Solar Drive

Solar DC 300-380V Input

Optional Single-Phase (200-240V) AC Input

Single-Phase (200-240V) AC Output

Single-Phase to 3-Phase Converter

EM15-SP1 Series
Solar Drive

Solar DC 300-380V Input

Optional Single-Phase (200-240V) AC Input

3-Phase (200-240V) AC Output

3-Phase In/Out

EM15-SP3 Series
Solar Drive

Solar DC 450-650V Input

Optional 3-Phase (380-440V) AC Input

3-Phase (380-440V) AC Output

Advantages of using a Solar Drive

A Solar Drive serves as fully automated Solar Water Pumping Solution, providing complete protection to the pump and controlling its functions, whilst using the free power from the sun to provide water at an affordable cost in areas with limited or no access to electricity. In addition to this, the Solar Drive also offers a variety of other VSD features for motor protection such as over voltage, under voltage, phase imbalance, phase loss and over current. This solar powered solution also provides the added benefit (compared to using an AC input) of eliminating the potential voltage drop over extended lengths of electrical cable between the AC source and the motor (as well as the cost and possible theft of the cable).

Key benefits of such a Solar Water Pumping Solution include aspects such as:

  • Reliable alternative in regional and remote areas without electricity supply
  • Includes Variable Speed Drive (VSD) features
  • Low operating cost (cost savings)
  • Easy to relocate
  • Low maintenance
  • AC and DC power supply options

For a more detailed explanation on this, please see our blog post: Advantages of using a Solar Drive (for Water Pumps)

 

Servo Drives

A Servo Drive is a special electronic amplifier used to power electric servomechanisms to amplify performance in terms of the desired velocity, torque, and position/angle, as well as stiffness, and damping. The main task of a Servo Drive is to monitor feedback and continually adjust for deviation from expected behaviour (closed loop system). A Servo Drive is thus only one component forming part of a more comprehensive system referred to as a Servo System (servomechanism). Servo Systems include four main components, a Servo Drive, a Servo Motor, a motion Controller, and a Feedback Device(usually referred to as an Encoder). In a Servo System, a Servo Drive is responsible for powering the Servo Motor. Servo Drives can control torque, velocity, or position (torque control being the most common parameter). Controller

For a more detailed explanation on this, please see our blog post: What is a Servo Drive?

Distributors and Suppliers of Servo Drives

TCGC offers the following EMHEATER Servo Drive products (Vector Control Inverter with PG Card for Synchronous Motor):

Single-Phase to 3-Phase Converter

EM15-Z1 Series
Servo Drive

Single-Phase (200-240V) Input

3-Phase (200-240V) Output

3-Phase In/Out

EM15-Z3 Series
Servo Drive

3-Phase (380-440V) Input

3-Phase (380-440V) Output

Advantages of using a Servo Drive

The main advantage of a Servo System, compared to traditional DC or AC motors, is the addition of motor feedback. This feedback can be used to detect unwanted motion, or to ensure the accuracy of the commanded motion. Servo Drives helps to improve overall system performance through faster acceleration rates and more precise speed and position control (rotate parts with high efficiency and great precision). In providing continuous adjustment, they amplify performance in terms of the desired velocity, torque, and position / angle, as well as stiffness, and damping.

Servo Motors, in constant speed changing use, have a better life cycle than typical AC wound motors. Servo Motors can also act as a brake by shunting off generated electricity from the motor itself. Closed loop systems using Servo Drives offer more reliability and precision in motion applications than open loop systems by using the feedback to account for errors and system disturbances (unlike open loop systems). When compared to straight power amplifiers, Servo Drives offer a wide range of advantages for automatic machining systems, including superior positioning, speed, and motion control.

So, whether you are looking for a system with greater torque than a stepper motor or just more precise control, a Servo System is most likely a necessary component of your machining or manufacturing process.

For a more detailed explanation on this, please see our blog post: Advantages of using a Servo Drive

 

Spares

TCGC offers the following EMHEATER standard Spare Parts:

Keypad  |  Control Card  |  Power Card  |  IGBT Model  |  Fan  |  Capacitor  |  Rectifier  |  Fan Board  |  Thyristor  | Control Board  | RS485 Card  |  Keypad Extender

Accessories

TCGC offers the following additional items to be used for EMHEATER products:

Dynamic Braking Systems | Aluminium Housed Braking Resistors | DC Chokes/Reactors | AC Chokes/Reactors | AC EMC/EMI Filters (Noise Filters) | Sine Wave Filters | Enclosures | Custom Built Panels | Remote Monitoring and Control Devices

Industry Applications

Use CasesVSDs and Soft Starters