Knowledge Base- Self learning software
Energy savings at partial load without reducing the revolutions
Oversized motors + partial load = waste of energy

Save you 20% from your electricity bill guarantee

What is the MotorCon?
The MotorCon is a unique, adaptive control unit, designed and manufactured to improve the energy-efficiency of asynchronous motors at partial load conditions without reducing the revolutions of the motor.

What does the MotorCon do?
It optimizes energy efficiency during start-up as well as during continuous motor operation. The use of the MotorCon reduces
• Energy-consumption
• operating costs and
• CO2-emissions.

How does the MotorCon work?

Problem:
Standardized asynchronous motors are often oversized in relation to the motor driven application and/or they drive a cyclical application. Consequently they run at least temporarily at partial load or idle condition. Only close to full load does a typical asynchronous motor reach its optimum energy-efficiency ratio of 80 % or higher. At partial load or idle condition it draws significantly more current than is necessary and causes avoidable costs.

Solution:
The automatic load-recognition of the MotorCon detects the following motor-parameters at a sample rate of 100μs: current, voltage and Power Factor. Based on these motor-parameters the software-control calculates the actual load of the motor and the optimum voltage for that load. The MotorCon then feeds the motor only this optimum voltage using the long established phase angle control approach, to keep it always at or near its most energy efficient operating point.

Benefits of the MotorCon
The MotorCon offers features which clearly set it apart from currently available energy-saving solutions for asynchronous motors:

Features of the MotorCon	Your benefit
Savings in energy-consumption through reductions of active power P, apparent power S and reactive power Q under partial load without reducing motor-speed and while maintaining the optimum torque required by the application	Reductions of operating costs and CO2-emissions for applications which require constant motor-speed Reductions of downtime, maintenance costs and repair costs of motors through reduced vibrations and heat generation
Self-adaptive software optimizes the motor, based on real-time data and not against a predetermined algorithm	Minimum effort for parameterization Change of tools and/or material does not require new parameter settings
Fully-fledged soft starter functionality	Reduction of peak demand penalties through avoidance of unnecessary current peaks during start-up Reduction of maintenance costs and repair costs of motors through minimization of electrical and mechanical stress during start-up Reduction of operating costs by being able to switch off the motor when idling and to restart with minimal mechanical stress
Harmonics remain within the relevant standards and no steep rises in voltage and current will occur	No additional interference suppression of harmonics necessary No subsequent addition of shielded conductors necessary Can be used with older motors with a weaker insulation
Optimises only the motor	Utilisation is independent of the type of motor driven application
Integrated bypass-functionality	Optimum reliability as even in the unlikely case of a fault and/or failure of the MotorCon your motor will continue to run directly on mains operation
Pre-installed patented Wago® Power Cage Clamps for easy installation	Downtime of the motor related to the installation of the MotorCon  is typically ≤ 60 minutes

Where to use the MotorCon?
The MotorCon is an innovative end-user technology for industrial applications. Substantial reductions in energy-consumption, operating costs and CO2-emissions can be achieved with motors:

• with cyclic load that run temporarily at partial load or idle condition

      OR

•  which are oversized in relation to the powered application

      OR

• Which have a low efficiency factor

Typical applications

• Water Supply Pumps
• Metal Processing factories
• Pulp and Papers facilities
• Pump Manufacturers
• Machinery Manufacturers
• Polymer processing factories
• Moving walkways  and  Elevators
• Lumber Mills
• Mixers

Currently two versions of the MotorCon are available in IP 65 enclosure:

• 22 - 45 kW  mech
• 55 - 75 kW mech
  
  Versions up to 500 kW mech are available on request.
  
  
  Direct mains operation vs. MotorCon operation
  Comparison of active power and energy saving

Comparison Power Factor
MotorCon Improve the Power Factor

Motor data: 5.5 kW, 400 Volt, cos phi 0.84, year 2010.