Industrial automation thrives on two pillars: reliable hardware and intelligent data. Voltage surges, harmonic distortion, and disconnected systems silently drain productivity, inflating costs through unplanned downtime, equipment replacements, and reactive maintenance. By integrating MTE RL Line/Load Reactors with ControlByWeb (CBW) edge controllers, facilities can address both challenges in tandem—creating a resilient, data-driven ecosystem that protects investments and unlocks long-term savings. Here’s how.
The Problem: A Costly Gap Between Protection and Insight
Electrical disturbances like voltage spikes or harmonics degrade motors, VFDs, and PLCs, leading to premature failures. Meanwhile, isolated systems force teams to manually diagnose issues, wasting hours on troubleshooting. Together, these gaps create a cycle of costly downtime and missed opportunities for optimization.
The Solution: MTE + CBW = Hardware Resilience + Data Agility
1. MTE RL Reactors: Fortify Your Power Supply
MTE’s RL Line/Load Reactors act as industrial “shock absorbers,” neutralizing threats before they reach critical equipment. Installed on the line or load side of systems, they stabilize voltage, reduce harmonic distortion by up to 75%, and prevent nuisance tripping in VFDs and rectifiers. With a rugged design rated for continuous overloads (150% capacity up to 750A) and extreme temperatures (-40°C to 50°C), they ensure motors, CNC machines, and inverters operate smoothly—even in harsh environments like mining sites or solar farms.
2. ControlByWeb: Transform Data into Action
ControlByWeb’s X-410™ browser-based controller bridges legacy systems and modern automation with no-code simplicity. Monitor critical metrics like motor temperature, vibration, and voltage using its 4 relays, 4 digital inputs, and support for 16+ temperature sensors. Deploy anywhere via Ethernet, Wi-Fi (X-410W), or cellular (X-410CW), and power it effortlessly with PoE or 9-28VDC.
With intuitive drop-down logic, the X-410 automates responses, like triggering email alerts for a voltage dip in an MTE-protected motor or logging vibration data to predict bearing wear. Expand functionality using P2P networking to link sensors, PLCs, or relays across your facility while built-in security and protocols (Modbus, MQTT) ensure seamless integration.
How They Work Together: A Seamless Defense
Imagine a manufacturing plant where MTE reactors protect a VFD-driven conveyor system from grid surges. Simultaneously, CBW controllers monitor motor temperatures and vibration sensors via Modbus. If harmonics from aging power lines cause subtle motor strain, CBW’s Task Builder auto-generates a maintenance ticket and adjusts conveyor speed to prevent overheating. The result? A surge that once caused a 4-hour shutdown now triggers a 10-minute inspection, saving $$$ in lost production.
Tangible Savings, Measurable Results
- Downtime Reduction: Surge protection devices such as MTE cuts downtime and equipment failure by up to 79% (source), while predictive maintenance with IoT devices such as CBW can reduce maintenance costs by 40%, and cut downtime by up to 50% (source).
- Energy Efficiency: Power quality units such as MTE RL reactors absorbs disturbances and therefore reduces motor energy waste. CBW also identify idle machines, enabling smarter scheduling. (source)
- Longer Asset Life: Stable voltage and predictive maintenance extend motor and drive lifespan which then yields a potential return on investment (ROI) of roughly 10X the cost. (source)
Your Roadmap to Integration
- Start with Protection: Install MTE RL reactors on high-risk equipment (VFDs, motors, inverters).
- Layer in Connectivity: Use CBW controllers to link protected assets to your SCADA/cloud platform.
- Automate & Optimize: Set CBW rules to auto-respond to anomalies (e.g., throttle a pump if voltage fluctuates).