UPC-KWH Universal Power Cell

 

Hall Effect technology power cell transducers

Works on OUTPUT of inverter drives

High accuracy (0.5% ) true power sensors

Fast linear response with analogue output

Extremely sensitive at low power factors

Easy to install & no external CT’s or VT’s

Energy Pulse Output (KWH)

KWH Energy Usage

Machine control & process monitoring

Mixture viscosity, motor load, end of process

Pump or fan flow, cavitation, over loads

Dull tools, gap elimination, optimum feed rate

 

Manufactured by Load Controls Inc.

 

The Universal Power Cell (UPC-KWH), the latest addition to an innovative range of high performance “Hall Effect” power sensors for motor load control. The UPC-KWH has been designed specifically for precision process monitoring & control where monitoring energy usage accurately is critical to the production process. The product is designed to cope with the most difficult of motor load sensing tasks when other power sensors and motor load controls are unable to function reliably, such as on the output of variable frequency or inverter drives.

In combination with associated KWH3 energy meter and DM100 load meter, the UPC-KWH is suitable for many applications such as “Batch Mixing”, where the sensor accumulates the total power absorbed in the mixing process for consistent production batches. Examples of this are processes such as the mixing of rubber, dough and clay which all respond to energy control.

Also suitable for “Extruding” applications where accumulated power is indicative of extruder process throughput. Although primarily designed for use with process control applications the UPC is suitable for many other power usage applications such as in power generation and monitoring power accurately in difficult circumstances.

The UPC-KWH Universal Power Cell measures true power ( KW ) and momentarily closes a relay contact every Kilowatt Hour, Kilowatt Minute or Kilowatt Second, which is selectable. The pulse can signal a computer, meter or counter for monitoring of power accumulation. An analogue 0-10V output reflects the instantaneous power and can drive a meter or computer.

The KWH-3 Energy Meter takes the pulsed energy output from the Universal Power Cell model UPC-KWH and displays energy usage. Energy units can be KW hours, KW minutes, or KW seconds for maximum sensitivity. Reset is with the front panel keypad or remote contact.

In addition, the DM-100 Power and Load Meter monitors the analogue output from the Universal Power Cell (UPC) and can be calibrated to read the motor load on its bright LED display in percentage, horsepower or watts (KW). The DM100 meter can read average or peak emphasis, a circuit which displays the peak load long enough to be easily read.

The Universal Power Cell Series includes the original standard UPC with analogue outputs but also the UPC-FR (Fast Response) for machine tool or very fast applications as well as the UPC-E (Ethernet) which has an Ethernet Connection and an analogue output.

All models of the Universal Power Cell are motor load sensors that monitor true power (HP KW) and work with both Fixed and Variable Frequency three phase power as well as single phase, DC, and brushless DC.  The UPC has three balanced Hall Effect sensors and has a fast response but an on board response adjustment slows the output of the Universal Power Cell for applications that require a slower response time.

The control of many process machines such as grinders, mills, mixers, extruders, rollers, pumps, compressors, conveyers, crushers etc may be improved dramatically by sensing true power instead of current. The Universal Power Cell is a unique product that makes this possible under all operating conditions. The UPC accurately measures true electrical power drawn on the input to any industrial electric motor and performs exceptionally well in applications on the “output” of variable frequency or inverter drives.

Wave shape is likely to be poor in these circumstances or power factors may be very low (down to 0.1), but is no problem for the Universal Power Cell.   Conventional CT (current transformer) based power sensors are not suitable for such conditions and will, if used, produce gross power errors (and thus load errors) due to limitations in bandwidth and sensitivity.

The UPC is truly “Universal and is unique, and is suitable for any 3 phase, single phase AC or DC motors all in one model. The UPC also DOES NOT use CT’s (current transformers) or external VT’s (voltage transformers) and its full scale range may be adjusted by the user to accommodate any motor size up to 120KW.

There are many possible industrial applications but the product is particularly suited to mixer “process endpoint detection” where by measuring the power drawn by stirrer or paddle drives, the Universal Power Cell is sensitive enough to detect minute viscosity changes on machines ranging from small laboratory models to large production machines.  Power changes may be used to indicate the start or end of a cycle, viscosity end-point or overload.

Applications include mixture viscosity, tool condition, optimum feed rate, pump or fan flow, beginning or end of processes, detecting obstructions & overloads, loss of load or loss of pump prime. The UPC may be used in a large number of industries, in fact anywhere that electric motors are used such as the food industry, chemical, gas, oil, water treatment, building industries, machine tools and many more.

Installation is simple with no hassle, since you don't need to wrestle with external voltage and current transformers.  This also saves considerably on installation costs.

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