Unipower HPL540 Conveyor Overload Monitor
The Unipower HPL540 is a high-precision conveyor overload monitor designed for intelligent load protection in conveyance and motor-driven systems. Equipped with a patented universal power supply (Patent No. PR177225), the HPL540 operates from 100V to 575V - both single-phase and three-phase - covering all global mains voltages with one compact.
Capable of measuring currents up to 40A internally without external transformers, the HPL540 also supports higher current ranges when paired with an external N/5A current transformer. Its advanced measurement system uses a four-quadrant multiplication of current and voltage to deliver exact power readings, even when connected to frequency inverters.
Automatic Reversal for Conveyor Protection
Purpose-built for conveyors and similar mechanical transport systems, the Unipower HPL540 detects overloads or blockages and automatically reverses the motor to clear the obstruction. The number of reversal attempts and reverse duration are both programmable — giving maintenance teams flexibility to recover faults without manual intervention.
This feature significantly reduces downtime and mechanical damage, ensuring efficient and continuous operation. The built-in pause timer prevents rapid switching between forward and reverse modes, protecting motors and drive components from excessive stress.
Simple Setup and Advanced Measurement
Setup is handled through three front-panel keys with a clear LED display. The HPL540 incorporates peak detectors that automatically identify load thresholds for easy calibration and tuning. Parameters such as start delay, reaction time, reverse count, and damping filter can be adjusted to match your application.
Measurement accuracy is based on the formula:
P = √3 × U × I × Cos Φ
This makes the HPL540 suitable for direct shaft power calculations (P₂) as well as motor input power (P₁), enabling process engineers to track performance in real time.
Key Technical Specifications
- Dimensions: 110 × 56 × 75 mm
- Universal Supply Voltage: 100V–575V AC, single or three-phase
- Internal Current Range: 0.5–40A (600A with external CT)
- Reverse Time: Programmable 0.5–25 seconds
- Reversal Attempts: Up to 25 (programmable or continuous)
- Analog Output: 0(4)–20 mA, isolated
- Accuracy: Class 2
- Mounting: DIN-rail or wall-mount, IP40 enclosure
- Approvals: CE, cUL (File E194022), GOST-R certified
Typical Applications
- Conveyor systems in manufacturing or packaging
- Automated bulk handling and feed lines
- Mixers, crushers, and screw conveyors
- Elevators and lifting machinery requiring overload detection
Global Compatibility
The HPL540’s patented power supply eliminates the need for multiple models by covering all standard global voltages in one design. Whether installed in the UK, EU, or international markets, the same unit provides reliable load protection and easy setup.
Product Highlights
- ✅ Universal voltage range — 100–575V single or three-phase
- ✅ Automatic reversal — clears blockages automatically
- ✅ Internal current measurement — up to 40A without external CT, up to 600A with external CT
- ✅ Patented technology — global voltage coverage
- ✅ CE, UL, and GOST-R certifications for industrial compliance
Order or Enquire
For more information, visit the Unipower HPL540 product page or contact our technical sales team at enquiries@charter-controls.com.
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Unipower (UK) Ltd trading as Charter Controls — Simplifying Industrial Automation for the UK and Ireland.