IntegraPower Features and
Models
Basic Connections
L1
L2
L3
Indicator
LEDs
Line Side
RS-232 cable
to PC
TB1 connections:
Remote ON/OFF
Remote indicator light
Y- Control
Bypass contactor control
TB2 connections:
Remote power supply
Escalator safety chain
T1
35A IntegraPower-E
T2
T3
Load Side (to motor)
Operator Interface Software
MAIN
CONTROL
SAVINGS
CONTROL
SAFETY
CONTROL
SOFT
START
SOFT
STOP
WYE-DELTA
CONTROL
DATA FEEDBACK
Two Energy Saving Methods
Combined in One Controller
1. Power Attenuation using SCRs
2. Intelligent Y- Switching
Energy-Saving Method 1:
Power Attenuation Using SCR Switches
Basic Architecture
a
b
c
3-Phase
Power
V
V
V
Voltage
Sensors
Digital Signal Processor
Voltage Zero
Crossing
A/D
Calculate
Phase Angle
SCR
Control
Signal
Current Zero
Crossing
SCR
Switches
A/D
A
A
A
Current
Sensors
1
voltage
current
V, I
0.5
Motor
0
Phase angle
between current
& voltage
-0.5
Light Motor Load: large phase angle
-1
0
90
180
270
360
450
degrees
540
630
720
Heavy Motor Load: small phase angle
Energy Saving Method Explained Further…
No Savings
With Savings
Voltage AC Waveform
Voltage AC Waveform
Current AC Waveform
Current AC Waveform
Escalator Example: Nevada Casino (up escalator)
Average kW Consumption
2.5
Power (kW)
2
1.5
1
No IntegraPower
With IntegraPower
0.5
0
0
24
48
72
96
120
144
Time (hours)
kW without IntegraPower controller
kW with IntegraPower controller
2.05
1.43
kW reduction
29.5%
168
Energy-Saving Method 2:
Intelligent Wye/Delta Switching
(if Y- starter present)
Typical Y- Control Components
Timer Relay Y-Contactor -Contactor
Up / Down
Contactors
Circuit Breaker
Overload
Protection
Energy Saving In Wye Mode
Delta Configuration*
WYE Configuration*
10A
*balanced load
30A
L1
L1
I phase  I line
480VAC
10A
V phase 
Vline
3
I phase 
480VAC
277VAC
L2
L2
L3
L3
Power Consumption = 1/3 of Delta
Line Current =
1/3 of Delta
Motor Torque =
1/3 of Delta
Winding Voltage =
58% of Delta
Line Impedance =
3 times Delta
L1
L2
L3
I line
3
17.3A60o
17.3A
R
T1
S
R
S
R
Vphase  Vline
T6
T2
T4
T3
T5
Motor
Added Savings with Y- Switching
kW Savings % Relative to Normal Delta Operation
70%
Delta % Savings Voltage
Reduciton
Y % Savings
60%
Y % Savings Voltage
Reduction
% Savings
50%
40%
30%
20%
10%
Sterling Electric
0%
0.00
Model EMOLO4FFA
0.10
0.20
0.30
0.40
0.50
0.60
Delta Mode Power Factor
0.70
0.80
0.90
Y- Motor 10HP
3-phase
230/460 VAC
25.2/12.6 A
Digital Signal Processor
L2
L3
3-Phase
Power
V
V
V
Voltage
Sensors
Reduced-Voltage
Control
Voltage Zero
Crossing
Calculate Phase
Angle
A/D
SCR
Control
Signal
Current Zero
Crossing
SCR
Switches
A/D
I
I
I
Current
Sensors




Y-
contactors
Y
Y
IntegraPower-E
Y
Motor
Power reduction
by Y- switching
Y- Control
Electronic power
reduction
L1
Y- and Voltage Reduction Savings
AZ Center Down Escalator
Montgomery EC-24B
3-phase 460VAC
3
2.5
Savings = 35%
kW
2
1.5
1
0.5
Baseline
Baseline To = 7:35AM, 9/14/2007
Savings To = 7:39AM, 9/12/2007
With IntegraPower-E
0
0
2
4
6
Hours
8
10
12
Example Wiring Diagrams
Basic Connection
With 2 button On/Off Control
PLC Remote Control
Indicator Light Control
GREEN – Control board has power
Self test passed
YELLOW – Start signal received
(controller will output power to
motor)
AMBER – Controller is in savings
mode (Y – Delta)
RED –
Fault condition detected
Switch S1 - setting selects when
1 to 2 shorts
Like most Soft Starters
Bypass & Disconnect
WYE – Delta
The Logic for Y - Delta
115
VAC
The Timer Relay is normally powered at the
same time as the “L” Line contactor
T
1
2
PPL
S
T
R
3
4
R
T
PPL
S
Escalator
Typical Industrial Application
Mounting on Unistrut
Power Quality Capacitors
Data taken on GE 4 pole motor for 2
different loads (PF = .87 and PF = .64
before the capacitors.
 Based upon this limited data, it is
observed that the % KW savings is slightly
higher with the capacitors than without
the capacitors. The % KVA savings is
slightly lower with the capacitors than
without the capacitors.

PPL Controller
From
Source
Motor
Capacitors
PPL Controller
Motor
From
Source
No
Capacitors
No Capacitor
Capacitors
PPL Controller
Motor
From
Source
Before
Capacitors
After
Capacitors
Before Capacitors
After Capacitors
No Capacitors
Before Capacitors
After Capacitors
Power Factor with no Controller
0.35
0.64
0.35
Power Factor with Controller
0.44
0.72
0.43
% KW Savings
25.70%
26.30%
24.70%
% KVA Savings
39.90%
35.00%
38.80%
0.6
0.87
0.6
0.64
0.94
0.65
% KW Savings
4.60%
5.10%
4.90%
% KVA Savings
11.40%
8.40%
11.10%
LOAD 1
LOAD 2
Power Factor with no Controller
Power Factor with Controller
The User Interface
S2 GUI mode & cable
PrecisionPower software interface
Soft Start
 Soft Stop
 Main Control
 Savings
 Safety
 WYE – Delta
 Data Feedback

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Further Information:
Precision Power Labs, Inc.
14201 N Hayden Rd
Suite C-4
Scottsdale, AZ 85260
(480) 268-2393
www.precisionpowerlabs.com
mikeh@precisionpowerlabs.com