Green energy surge for CPS leads to new electrical control solution

To meet increased demand for green energy from solar panel and wind turbine generators, a Scarborough firm has designed a microprocessor-based control panel for monitoring power transfer to the national grid.

Control & Power Systems Ltd (CPS), a leading manufacturer of power control panels, has designed the new system to provide G59/2 protection, which is a legal requirement for those involved in providing more than 16 amps of solar or wind power. This recent statutory obligation requires those involved in supplying power to the grid to monitor production and to automatically turn-off the flow of power in the event of certain abnormal grid conditions.

The CPS control panel acts as a failsafe system, monitoring voltage, frequency and other parameters as requested by the local Distribution Network Operators (DNO). If any of the power parameters go outside the nominal settings, the control panel will automatically trip an integral protection relay and closedown the transfer of electricity to the national grid, thus avoiding risk to personnel or cabling, both of which could prove fatal.

Specialist manufacturer CPS, who has been producing standard control solutions for diesel engines and water turbines for many years, decided to diversify into solar panel and wind turbine generator monitoring following an approach from a green energy producer earlier this year.

Sales Director Stuart Noble explains: "The decision to move into designing the unit followed an approach from a wind turbine installer to manufacture a suitable unit. With the help of word of mouth, highly competitive pricing and the internet, news seems to have quickly spread and demand for our green control panels has really taken off."

Suitable for three-phase and single phase production, CPS is now manufacturing a range of eight different green control panels ranging from small standard 30kw units which measures 400 x 400mm x 210mm deep to panels capable of handling up to 500kw. Very simple to install, the equipment can be supplied for wall-mounting or freestanding, depending on the power rating.

Optional add-ons include third party monitoring to alert operators to power transfer breakdowns or potential problems. CPS also offers an optional field testing service or simulated factory testing using our own secondary injection testing equipment in order to comply with current DNO regulations.

The biggest buyer of the control panels are electrical contractors, who will typically wire in the cable connections from the invertor (steps the solar or turbine voltage up) into the CPS control panel for onward power transit to the grid.

CPS reputation for the design and manufacture of high quality control panels and switchboards has seen the North Yorkshire company build up an impressive blue chip client base located in the UK and overseas in both the industrial and commercial sectors.

Founded by its current directors, managing director Dave Darrell and Mr Noble, the business has over 25 years experience of designing and manufacturing power equipment. CPS now employs 16 people, which the directors anticipate may increase if demand for its innovative equipment continues to grow.

Control and Power Solutions (CPS) in profile
Operating from its modern manufacturing complex on the edge of Scarborough, CPS manufactures a range of electrical control panels for a wide range of markets that use diesel engines or water turbines. In addition to control panels the business also produces automatic paralleling systems for power load sharing, low voltage switchboards, motor control centres, automatic transfer switch panels and mains paralleling systems.

A full design, build and commissioning service is offered and the equipment can be used in locations ranging from the artic to the desert. Products are designed and manufactured to comply with the latest BSEN and international regulations.

The business has an extensive blue chip user base including AgipKCO, Westac Power, Eastern Contracting, ESB Ireland, DNO Yemen, Gilbert Gilkes & Gordon and numerous other sites located here and overseas. Its equipment is installed in a cross-section of sectors including telephone exchanges, industrial plants, water companies, hotels, financial institutions, pharmaceutical sites and electricity producers worldwide.

For further information,  e-mail: stuart.noble@controlandpower.co.uk or view website: www.controlandpower.co.uk

Arc Machines' revolutionary EPS1500 welding system

Arc Machines' EPS1500 welding system is specifically designed for joining high purity applications used in the manufacture of aerospace systems, biopharmaceutical equipment, semiconductor production, food and dairy cooling distribution systems.

Equipped with a 150 amp power supply, the unit weighs just 23Kg and offers a patented S3 weld schedule. The feature rich Exel EPS1500, offers substantial operational cost savings because it can be used with a wide range of AMI weld heads and those of competing suppliers

The EPS1500's exciting features include intuitive 12" software driven touch screen, which uses just three dashboard screens to control and monitor the entire weld process. Fully microprocessor controlled, weld parameters are set by the power supply which records the weld schedule for each size and wall thickness of tube or pipe in the unit's memory. These can easily be recalled and modified for different materials with any subsequent changes logged by the system.

The Exel EPS1500, offers users a  substantial operational cost saving.

Experienced welders can start programing the unit and setting up multi-level, multi-pass, stepped S3 programmes after only a few minutes training. Less experienced welders can also be trained in a fraction of the time needed to learn comparable systems, significantly reducing the time required for training welding operatives.

Suitable for use on a multitude of different weld applications, the EPS1500 represents the culmination of two years development work to manufacture an easy to operate power supply to directly address an industry wide, skills shortage.

Supplied with a high level of connectability, the EPS1500 has two USB ports that allow for the interfacing of peripherals and storing weld schedules on a memory stick for back-up. In addition, there is a network connection allowing for access to both local networks and the internet, enabling if required long distance real-time weld monitoring.

The complimentary highly engineered Excel weld heads and rotors are all constructed from high temperature materials including high-performance polyimide-based plastics like Vespel, and are capable of welding components from as small as 1/8" in very restricted areas.

A further key advantage of the Exel weld heads is their ability to be set up for many different kinds of components without the need to retool. Other features include a large clamping surface for the electrode to ensure optimum conductivity with precise and stable control, the ability to weld in very close proximity allowing easy access and flexibility in the design and joining of miniature fluid systems.

Arc Machines UK's General Sales Manager, Sean Blandford, comments: "The new EPS1500 is the most competitively priced lightweight power source and weld heads on the market. Designed to address a common problem faced by our customers in the orbital welding industry in securing skilled labour, the EPS1500 directly addresses this problem through its ease of use. The fact that the EPS1500 is compatible with various weld heads means that our customers can reduce the number of power sources needed."

AMI has been setting the standards for automated orbital welding technology since it was first established in 1976 and the EPS1500 represents yet a further milestone. The company now has the largest product range on the market and a reputation for the highest manufacturing standards, technical strength, customer service and quality of materials.

Following a recent move to a new site in Daventry, Northants, the company has now consolidated all UK sales activity, including customer support, operator training, equipment maintenance and repair and spares supply, in a single, purpose built facility, enabling it to provide a consistently high standard of service to both new and existing customers.

Arc Machines Inc (AMI) in profile .
Arc Machines Inc (AMI) has been setting the standards for automated orbital TGAW/TIG welding since it was first established in 1976. The company now has the largest product range on the market and a reputation for the highest manufacturing standards, customer service, workmanship and quality of materials.

AMI has a long history of developing orbital welding applications for industry sectors that include nuclear, oil and gas, offshore, shipbuilding, petrochemicals, power generation, pharmaceuticals, food and beverage, dairy, aerospace and defence. Today AMI provides sales, maintenance, support and training for a wide range of precision power sources, control systems and weld heads suitable for numerous environments and applications.

AMI orbital welding equipment is utilised on a wide variety of pipe diameters, wall thicknesses and materials to produce precision welds, deliver superior performance and achieve consistent higher standards.

The company's success is driven by innovation in automated orbital equipment and controls with constant new product development though continuous evaluation of market needs.

For further information,  e-mail: mike.allman@arcmachines.co.uk or view website: www.arcmachines.com

Rail test rig for axlebox bearings
simulates speeds of up to 500km per hour

Schaeffler Group Industrial's Rail Test Facility in Schweinfurt, Germany is now available for UK customers to assess the performance of axlebox (wheelset) bearings for rail applications.

The special axlebox bearing test rigs are able to simulate travel speeds of up to 500 km/h. All test rigs at Schweinfurt enable independent testing in accordance with the requirements of the latest European Standard DIN EN 12082. The functional tests carried out in accordance with this standard are used as verification of the suitability of axlebox bearings for real operational conditions.

The AN55 bearing test rig at Schweinfurt, for example, is primarily used to test double-row tapered and cylindrical roller bearings in their original housings. This system provides data on bearing behaviour under constant radial load and varying axial loads, as well as data on operating temperatures and grease operating life.

Axlebox housings and bearings are air-cooled, which has a considerable influence on grease operating life. The test rig is therefore equipped with an air stream simulation facility, which is able to generate wind speeds of up to 10m/s.

On another test rig at Schweinfurt, axlebox bearings and their original housings undergo leak-tightness water spray tests. During these tests, axlebox bearings mounted in their housings are sprayed continuously with water, both in their stationary position and under simulated operating conditions. During these tests, no water must penetrate the sealed spaces of the bearings.

The Rail Test Facility in Schweinfurt is now one of only two test labs outside of Russia that are authorised to conduct independent tests on rolling bearings used as a method of transport for the Russian Federation. Under Russian Law, these test labs must be certified. The relevant certification tests can only be carried out by accredited test centres in accordance with application requirements……/Continued on the next page.