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Three stage filtration pilot plant for hire (03/13)

Pilot plants have long been used as an efficient, cost-effective means to prove the viability of a process or technology before construction of major plant. In the water industry, the use of pilot plants is particularly valuable for those considering investment in large-scale filtration and/or sterilisation.

CAP Industries’ own filtration pilot plant has been used by a range of customers to assess the suitability of filtration options prior to purchase. The plant – affectionately known as Phil – is compact, easy to use and can connect directly to existing systems or pipework. Its simple design ensures it can be easily modified to suit site-specific requirements and/or alternative filter configurations.

The standard configuration of the pilot plant involves 3-stages of filtration:

Stage 1 - coarse filtration. This removes large debris and sediment particles via cartridge filters, typically at 50 micron. Removal of large particles is essential to improve the lifespan and performance of the second stage filtering, as well as to reduce system blockages and ensure optimal performance of the overall system.
Second stage - fine filtration. This is accomplished via bag filters (20 micron and 1 micron). If required, the plant can filter down to 0.5 micron, as was the case in field tests conducted recently in Geelong. Depending on customer requirements, this level of filtration may be sufficient, in which case the final stage (UV sterilisation) can be disabled. If, however, UV sterilisation is required, second stage filtration is essential to ensure that smaller particulate matter does not shield the micro-organisms from the UV light, thereby reducing the effectiveness of the final sterilization process.
Final stage - Ultraviolet (UV) Sterilisation. UV is commonly used by councils, the food industry and in residential applications as a means of controlling harmful microorganisms. Its popularity continues to grow as sterilization occurs without the use of chemicals, it is immediate and there is no change in taste, odor or the general chemistry of the water. However the performance of UV can be greatly affected by issues such as turbidity and high levels of iron or tannins. Depending on the size and operational requirements of the installation, it can also prove to be an expensive option, which is why many are choosing to test the use of UV in-situ prior to investing in it as a solution.

Of course, depending on quality of the incoming water, each filtration option has its own set of advantages and disadvantages. The simple design of the pilot plant ensures alterations can be completed quickly and with minimal fuss – for example the addition of charcoal filters (commonly used to reduce odours).

Contact the team at CAP Industries today to discuss your individual requirements and how we can make Phil work for you!

The importance of adequate ventilation (11/12)

Enclosure ventilation is an important consideration that is often overlooked by operators searching for the smallest or cheapest possible solution for their control system. If you, like many of today’s users, are considering ‘economising’ on this area for your next purchase, don’t. Here’s a few compelling reasons why.

All electric and electronic components lose energy in the form of heat. The amount may be significant – as can be the case for soft starters and variable speed drives – or it may be negligible – for example that of a control relay. The heat is discharged into the surrounding environment. As more and more components are packed into smaller and smaller spaces, the heat produced can rapidly reach a point that is detrimental to the electronic components.

Aside from the obvious safety considerations, the results of equipment overheating range from reduced reliability and a decreased lifespan to complete system failure. To avoid these situations, heat in the enclosure must be removed or minimised.

There are a number of ways to accomplish this and the best solution will depend on a range of factors. A good place to start is to consider your equipment and how much heat it generates; this will then help identify both the enclosure size required (to enable adequate air capacity) and what level of ventilation is required.

In some cases, the addition of air vents will prove sufficient. Generally, this will entail the installation of one vent at the bottom of the enclosure and another at the top where hot air will rise and be expelled. It is good practice to install filters on your vents (and fan units) to help reduce dust, insects and other contaminants entering the enclosure. However, always ensure that you follow manufacturers specifications when fitting a filter as they can also impede the flow of air – particularly once it has collected some dust and a few cobwebs! This is the reason why we strongly recommend that operators inspect their filters regularly.

Often, a vent alone is not sufficient. A common example would be a panel that includes soft starters or variable speed drives. In such cases, a fan may be required to improve air flow and ensure adequate ventilation. A fan helps to dissipate heat by drawing air in or out of the enclosure. Generally external air is drawn in at the bottom of the cabinet and discharged through a ventilation opening at the top. Ideally, the outlet should be placed above the highest mounted drive or starter. While this will undoubtedly increase the price of the panel to some extent, it should definitely not be considered an area of compromise.

For installations where high temperatures are a consistent concern, air conditioning may be recommended for your enclosure. Air conditioned enclosures provide more exact climate control and are more prevalent in panels with extremely high heat output or installations subject to high levels of heat (for example the sun in exposed areas). Air conditioned enclosures are more common in the mining or specialised industries.

Other considerations that will help determine your ventilation requirements include the dimensions of the enclosure, how it is mounted and how much heat can be dissipated through the exposed surfaces. The better the heat conduction of the enclosure the more heat that is dissipated. For this reason metal enclosures tend to be better at dissipating heat than plastic enclosures.

There are a range of calculations and even dedicated software dedicated to this topic. However, it is safe to say that you don’t need to resort to such measures or consider consulting Newton’s Law of Cooling to decide the best solution for your situation. What is advisable is that you make this area a priority when you next invest in any form of panel or pump control system and always ask the following question: What sort of ventilation does the enclosure include?

iCONirrigator joins the iCON controller family (08/12)

July 2012 saw the team at CAP Industries put the finishing touches on the latest product in the iCON controller family - the iCONirrigator. The iCONirrigator is a direct result of some rather specific requests from the agricultural industry. Bou Spithoven, Managing Director of CAP Industries explains “we were demonstrating the iCONpressure controller when one of our customers – who happened to be a big pivot user – highlighted some specific needs he had with his fertigation system. While we could certainly cater for his needs with the iCONpressure controller, there were specific areas that we felt we could address better with a more customised programme. The end result is the iCONirrigator.”

The iCONirrigator was developed to deliver more integrated control for fertigation and/or irrigation pump systems. It is ideal for applications that include a single irrigation method, such as a centre pivot, linear, soft or hard hose irrigator. Like all iCON controllers, it is extremely robust and easy to use and it offers a range of features including:

pump control based on pressure
inbuilt time control for scheduling system operation
remote start
jockey and fertigation pump control
filter control – PD or time based
integrated pump and system protection

Bou Spithoven, Managing Director of CAP Industries explains “we were so fortunate to have someone like David Wright work with us to develop the iCONirrigator. His expertise – particularly with centre pivots and soft and hard hose irrigators – proved to be invaluable throughout the programming phase of the iCONirrigator controller.”

For more information on the iCONirrigator controller, contact us.

Innovative touch-screen controller heralds a new era in pump control (04/12)

From its full colour, touch-screen interface, to its intuitive menus and internet/SMS communication capabilities, the iCONtouch controller from CAP Industries easily ticks all the boxes.

The innovative new controller is the latest release in CAP Industries’ popular iCON series of pump controllers, extending the range to provide operators with a premium touch screen product at a competitive price. Ideal for golf courses, sports turf and municipal irrigators alike, it delivers constant pressure, variable speed control for up to six pumps (5 main plus a jockey).

The iCONtouch controller offers today’s operator a range of unique benefits including:

full colour touch screen interface
uncluttered main screen– only key information is displayed enabling operators to assess system performance “at a glance”
full data-logging of system events, complete with date and time
trending screens for pressure and flow, providing operators with a more in-depth understanding what is happening in the system over a given time period
jockey pump control via independent VSD
in-built SMS and web browsing capabilities – remote system management is not an option but a reality
a wide range of standard features combined with upgradable options to cater for site specific requirements including:
- lead variable speed/lag soft start with automatic rotation of lead VSD;
- incorporation of auxiliary pump units (ie. fertigation/injection units); and
- programmable outputs for additional auxiliary equipment.

The iCONtouch accepts standard inputs from field equipment including emergency stop, remote start/stop, low level float, and analogue signals from flow meters. It can also be further expanded to suit any application or control requirement.

Of course, as it uses MODBUS communication, it is also compatible with a range of BMS and SCADA systems.

While the iCONtouch controller is offered with a 10” touch screen as standard, it can be easily upgraded to accommodate larger screens if desired.

Effective SMS solution suits Next G/3G mobile networks (01/12)

The EDAC SMS315 unit is an effective solution for controlling, monitoring and interrogating your pumping application via SMS messaging.

Designed for use with Next G/3G mobile networks, it features a robust metal enclosure and easy access LED lights for the indication of full system status. The unit includes 8 inputs and 4 outputs which can be programmed to suit remote start/stop and system status notification.

The SMS315 unit is ideally suited to temperature, humidity, level, flow and pressure monitoring applications.

A range of accessories are available to complement the unit including a high gain antennae for areas with low reception, battery backup in case of power failure and surge diverter to protect the unit from lightning and/or power strikes.

Do I need a radio survey? (01/12)

Considering a remote communications solution for your pump or pump system? If so, it is likely that the answer to this question is YES, you do need to conduct a Radio Frequency (RF) survey.

An RF survey, also known as a wireless site survey, is the first and most important step in setting up a wireless network. This is because it is difficult to accurately predict the behaviour and/or propagation of radio waves in a given environment. There are a number of issues which can arise to prevent the RF signal from reaching all access points in your system. The most common example of this is interference. Regardless of the antennae used, interference from buildings, trees, hills and other obstacles can cause the RF radiation pattern to be irregular, unpredictable and inadequate.

An RF survey is used to test for any interference, discover RF coverage areas and identify the optimum number and placement of any wireless devices or access points required to ensure effective remote communications. In situations where RF interference is high, solutions can be identified to overcome this issue (for example the selection of a different radio channel). An RF survey will also define the signal levels needed to support the intended application.

Other potential issues that can be identified by an RF survey include multipath distortion and the presence of RF interference from nearby networks or other sources.

Of course, the need and complexity of an RF survey will vary depending on the location and the environment. However, generally speaking, a RF survey is essential to ensuring your remote monitoring and control solution performs correctly. Without a survey, you run the very real risk of ending up with inadequate coverage, low performance and a system that does not perform as you want it to.

For more information on radio surveys, contact us today.

iCON pump controllers - what's in an upgrade? (10/11)

With revised pricing and a range of optional upgrade items, there has never been a better time to take a look at the iCON pump controller. CAP Industries released the iCON range of controllers earlier this year, and we have been particularly pleased by the interest and feedback received regarding the standard controllers vs the upgraded versions available.

Both the iCON Level controller and the iCON Pressure controller offer two versions – a standard, entry level version and a more advanced version with greater flexibility and customisable options. It is this approach that enables us to provide our customers with the best product to meet their specific needs at the most competitive price possible.

So what is the difference between the two? The following tables summarises some of the key areas:

iCON Pressure Controller	Standard	Advanced
1-3 pumps	√	√
Pressure transducer operation	√	√
IP65 and NEMA4x rating	√	√
System pause	√	√
System alarm	√	√
System fault		√
Individual pump fault	√	√
Individual pump alarm	x1	x2
Start pressure - adjustable for each pump via keypad	√	√
Stop pressure - adjustable for each pump via keypad	√	√
Low pressure fault	√	√
High pressure fault	√	√
Adjustable time delays for: start/stop pressure, system alarm, system fault, low/high pressure, pump alarm	√	√
Adjustable minimum run timers	√	√
Option for automatic reset of faults	√	√
Pump rotation option - Rotate or Fixed	√	√
Auxiliary outputs with on & off timers		x2
Remote reset		√
Output for individual pump fault or alarm		x3
Programmable inputs	x1	x3
System security	√	√

iCON Level Controller	Standard		Advanced
	Switched Operation	Transducer Operation	Switched Operation	Transducer Operation
1-3 pumps	√	√	√	√
Float switch operation	1 per pump		2 per pump
Level transducer operation		√		√
Tank fill or tank empty selection	√	√	√	√
IP65 and NEMA4x rating	√	√	√	√
Caters for single or multiple water sources	√	√	√	√
System pause	√	√	√	√
System alarm	√	√	√	√
System fault		√	√	√
Individual pump fault	√	√	√	√
Individual pump alarm			1 per pump	2 per pump
Start level - adjustable for each pump via keypad		√		√
Stop level - adjustable for each pump via keypad		√		√
Low level fault	via float	√	via float	√
High level alarm	via float	√	via float	√
Adjustable time delays for start/stop levels, system alarm, system fault, low/high level, pump alarm	√	√	√	√
Adjustable minimum run timers	√	√	√	√
Option for automatic resets of faults	√	√	√	√
Pump rotation option - Rotate or Fixed	√	√	√	√
Auxiliary outputs with on & off delay timers			x1	x2
Remote reset			√	√
Output for individual pump fault or alarm			x3	x3
Programmable inputs		x2	x1	x3
System security	√	√	√	√

Should you require further information, don’t hesitate to contact us. In the meantime, keep an eye out for your updated pricing in the mail soon. Alternatively, drop us an email and we can send the updated pricing directly to your inbox for your immediate perusal.

The cheaper alternative for all drive VSD control (07/11)

The Hydro Controller from MAC3 has seen a rapid rise in popularity as customers continue to demand more value from their pumping dollar. Compact and easy to use, this efficient variable speed controller provides a cost effective solution for achieving all drive control in both single and multiple VSD pump systems.

The Hydro controller offers a range of easy-to-use features and is available from CAP Industries with options for single and three phase power supplies. Up to 3 controllers can be easily interconnected (via a communications lead) to achieve a multiple pump system, and the controller can be either pump or cabinet mounted (pictured).

iCON controller meets the challenge in product comparisons (07/11)

The release of our new iCON pump controller earlier this year has been an exciting time for CAP Industries, with systems being dispatched to sites throughout Australia – including Tasmania, country Victoria and South Australia. It has also been a time of evaluation, as customers undertake the inevitable comparisons between the iCON controller and existing pump control products.

As with any purchase decision, there is often more than one element to consider when choosing the right pump controller for your application. In the coming months, our team will address each element separately, with today’s focus being value for money. So, other than the initial purchase price, what should you consider when looking at the value for money equation? The following questions may provide some useful food for thought.

1. Flexibility of your controller. Can your pump controller be easily customised to suit your requirements? For example, can you change the system parameters without ringing the manufactuer? What if your situation changes… how adaptable will the pump controller be if, for example, you want to add another pump?

2. Upgradability. How will my controller keep up with advances in technology? It is important to ask can you simply upgrade software, or will you need to change hardware also?

3. Reliability/physical life-span of the controller. Is the construction of the controller suitable for my environment? Investigate the IP ratings of both your controller and your system - does the controller have its own IP rating or is the panel the only form of environmental protection? Does the accompanying control system use quality electrical components from trusted brands?

4. Useability. Will you (or your personnel) be confident in using the controller? All manufacturers claim their product is “easy to use.” Is this claim a justified one or is it just marketing speak?

5. Maintenance. How much maintenance will the controller require? How can you ensure minimum downtime of your pump system?

CAP Industries

Experts in Pump Control & Packaged Pump Systems