Controls Incorporated, the Ohio-based manufacturer of engine and generator set controls, is set to unveil the prototypes of its newest generator control platform. The NextGen controllers are designed to operate with both CAN-capable electronic engines and Tier 1 mechanical engines.
"This new generator control platform has been redesigned from the ground up," said Bob Cowen, president of the company. "The purpose of a total redesign from scratch was to incorporate years of customer feedback into the new product. Redesigning from scratch required a significant investment of nine and resources, but it was determined to be worth it to come out with a new product line that addressed customer feedback on issues such as functionality, flexibility, value and simplicity.
"The new design allows for a high quality product/platform that is very flexible in terms of functionality and features, very cost-effective and simple to install."
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The NextGen controllers will be available in two version, the 1.01 for standard engines and the 2.01 for electronic J1939 engines. The NextGen 2.01 control is designed to provide digital monitoring and control of a variety of engine and generator functions. Through CAN-bus communications, it is designed to survey the J1939 data link for engine parameters such as temperature, oil pressure, battery voltage, rpm and engine operating hours, etc., which can be output to an LCD panel. Generator conditions, such as voltage, frequency, etc., are also monitored.
A wide range of other conditions, including coolant level, fuel pressure, coolant pressure, oil level, oil and fuel temperature, intercooler temperature, percent throttle, fuel rate, boost pressure, manifold temperature, air filter differential pressure, exhaust gas temperature, ECM battery voltage, air inlet temperature and rejector pressure, can also be monitored and displayed. A four-button key pad provides access to these additional parameters and other engine and control functions. The unit can also provide system protection and alarms for specified conditions.
The NextGen 1.01 incorporates some of the same features, using analog inputs, outputs and features.
The NextGen systems have been in development for more than a year. "We have been upgrading our technology portfolio over the last several years," Cowen said. "As part of the process, we recently received our first patent that covers several of these technologies.
"Much of the technology that has been developed has been implemented in the new generator control platform. The new product platform will be a first step in bringing to market some of these new circuits/technologies. A new engine control will also be forthcoming as part of this process that will utilize much of the same circuitry/ technology and achieve the same positive benefits and cost-effectiveness."
The key to the NextGen system is a single circuit design that is small in size, according to Cowen. "Minimizing size was certainly one of the design goals.
"The overall goal was to create a product platform that can be individualized to specific customer specifications in terms of functionality and capabilities," he added. "We think of it as "mass customization" or the ability to address a wide range of customer specifications from the most basic through very complex based on the same product platform that can be specified accordingly."
There will be a variety of housing solutions based on customer requests/ specifications, Cowen said. "In addition to providing product functionality and capability options, we wanted the new product to be flexible in how it is housed and easy for customers to install and wire," he noted.
The first of the new units is expected to enter regular production in the first quarter of 2005, with the release of the engine controller to follow.
Aside from the development of its new control system, Controls Inc. has also been busy on other fronts, highlighted by a move from its first location in Sharon Center, Ohio, to a purpose-built, 5600 sq.ft. facility in nearby Medina. "We're having success in the marketplace and needed additional space for assembly, office, testing, storage, etc.," said Cowen. "The new facility was built to our design specifications so that it had the necessary amenities and efficiencies that would improve the business and provide the basis for future growth.
"One of the key benefits with reference to the manufacturing/assembly process is that the facility could be laid out to properly accommodate the assembly process. The proper work flow could be implemented, the proper work stations could be set up, the proper delineation between assembly, storage and shipping could be implemented.
Wednesday, April 25, 2007
New gen-sets, switch from cummins power generation
Cummins Power Generation, Minneapolis, Minn., has developed new generator sets on both the small and large end of its gen-set range, along with new switchgear for emergency and standby power applications.
The new 150 kW model GGLB spark-ignited natural gas gen-set is designed to provide full-rated standby power for backup and emergency power applications. The new generator set features a heavy-duty GM 8.1 L four-cycle natural gas engine that is torque matched to a high-capacity Newage ac alternator for handling motor starting loads. An electronic governor provides precise frequency regulation for powering sensitive loads and the unit also accepts 100% of the nameplate standby-rated load in one step in compliance with NFPA 110, Level 1, the company said.
"The new 150 kW model GGLB spark-ignited generator set is both user-friendly and environment-friendly," said Colette Weiser, market manager for Commercial Standby Generator Sets, Cummins Power Generation. "The basic control system is easy to operate and includes system protection features, digital engine speed control and transfer switch compatibility. The industrial, spark-ignited V-8 engine burns clean natural gas for exceptionally low exhaust emissions."
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A wide range of options and accessories is available with the generator set to allow configuration for specific onsite power applications. The optional PowerCommand 2100 generator set control adds microprocessor-based features such as remote start/stop, integrated voltage regulation, alarm and status message display, output metering and auto-shutdown at fault protection for high reliability.
Several alternator sizes offer selectable motor-starting capability with low reactance, the company said. Available permanent magnet generator excitation delivers enhanced motor-starting and precise voltage regulation for nonlinear loads such as variable speed motor controls and UPS systems. The standard cooling system allows full-rated load operation up to 50[degrees]C ambient air temperature. Available weather-protective and sound attenuated enclosures permit installations at outdoor and noise-sensitive sites.
On the larger end, Cummins Power Generation has introduced a new low-BTU generator set series specifically designed to run on the dilute methane gas mixture produced by natural decay in landfills, sewage digesters or methane emitted from coal seams. The new GQ series generator sets produce a continuous 1570 kW (50 Hz) or 1750 kW (50 and 60 Hz) running on landfill or digester gas containing very low thermal energy, while producing low exhaust emissions. Multiple units can be paralleled for higher power production at larger landfill sites.
"Industry studies indicate that, globally, landfills represent an immense untapped energy resource," said Trevor Passmore, general manager for Energy Solutions, Cummins Power Generation. "In North America alone, candidate landfills can produce enough methane gas to support a total generating capacity of approximately 1500 MW. Currently, much of this potential energy is being flared off or vented into the atmosphere. This new generator set will provide landfill operators, utilities and independent power producers with a proven generating solution to make use of this energy resource. In addition, since methane gas released to the atmosphere has about 20 times the greenhouse effect of carbon dioxide and hence global warming potential, burning methane in a generator set can reduce its environmental impact by a factor of about 20."
Minimum pretreatment is required for the landfill gas to remove particulate matter and excess water vapor. Any additional pretreatment is dependent on the quality of the gas at a particular site and project economics.
Powered by modified versions of the model QSV81G 16-cylinder and QSV91G 18-cylinder natural gas reciprocating engines, the new GQ series 1570 kW and 1750 kW low-BTU generator sets feature an enlarged fuel delivery system, double-safety gas shut-off valves, and special coatings and bearing materials to withstand the corrosive contaminants typical in landfill gas.
A Cummins low-BTU generator at a landfill site in Shrewsbury, England, has accumulated more than 5700 hours of operation. Future installations include a wastewater digester site in the Canary Islands and the Viridor Waste Management landfill near Edinburgh, Scotland. At Viridor, Cummins Power Generation is developing a complete turnkey 3.5 MW power plant using two low-BTU generator sets running on methane from the landfill. The electricity produced at the site will be used to run a nearby cement works. An additional pair of low-BTU generators will be installed during the next two years to take advantage of the site's estimated 20-year supply of methane. "Consistent with our goal of providing total energy solutions, Cummins Power Generation can deliver this new product in a number of ways," says Passmore. "For example, we can deliver a Build-Own-Operate (BOO) power plant, or provide application design, installation and project management for a turnkey power plant. Supply of only the generator set, open or containerized, is also available
The new 150 kW model GGLB spark-ignited natural gas gen-set is designed to provide full-rated standby power for backup and emergency power applications. The new generator set features a heavy-duty GM 8.1 L four-cycle natural gas engine that is torque matched to a high-capacity Newage ac alternator for handling motor starting loads. An electronic governor provides precise frequency regulation for powering sensitive loads and the unit also accepts 100% of the nameplate standby-rated load in one step in compliance with NFPA 110, Level 1, the company said.
"The new 150 kW model GGLB spark-ignited generator set is both user-friendly and environment-friendly," said Colette Weiser, market manager for Commercial Standby Generator Sets, Cummins Power Generation. "The basic control system is easy to operate and includes system protection features, digital engine speed control and transfer switch compatibility. The industrial, spark-ignited V-8 engine burns clean natural gas for exceptionally low exhaust emissions."
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A wide range of options and accessories is available with the generator set to allow configuration for specific onsite power applications. The optional PowerCommand 2100 generator set control adds microprocessor-based features such as remote start/stop, integrated voltage regulation, alarm and status message display, output metering and auto-shutdown at fault protection for high reliability.
Several alternator sizes offer selectable motor-starting capability with low reactance, the company said. Available permanent magnet generator excitation delivers enhanced motor-starting and precise voltage regulation for nonlinear loads such as variable speed motor controls and UPS systems. The standard cooling system allows full-rated load operation up to 50[degrees]C ambient air temperature. Available weather-protective and sound attenuated enclosures permit installations at outdoor and noise-sensitive sites.
On the larger end, Cummins Power Generation has introduced a new low-BTU generator set series specifically designed to run on the dilute methane gas mixture produced by natural decay in landfills, sewage digesters or methane emitted from coal seams. The new GQ series generator sets produce a continuous 1570 kW (50 Hz) or 1750 kW (50 and 60 Hz) running on landfill or digester gas containing very low thermal energy, while producing low exhaust emissions. Multiple units can be paralleled for higher power production at larger landfill sites.
"Industry studies indicate that, globally, landfills represent an immense untapped energy resource," said Trevor Passmore, general manager for Energy Solutions, Cummins Power Generation. "In North America alone, candidate landfills can produce enough methane gas to support a total generating capacity of approximately 1500 MW. Currently, much of this potential energy is being flared off or vented into the atmosphere. This new generator set will provide landfill operators, utilities and independent power producers with a proven generating solution to make use of this energy resource. In addition, since methane gas released to the atmosphere has about 20 times the greenhouse effect of carbon dioxide and hence global warming potential, burning methane in a generator set can reduce its environmental impact by a factor of about 20."
Minimum pretreatment is required for the landfill gas to remove particulate matter and excess water vapor. Any additional pretreatment is dependent on the quality of the gas at a particular site and project economics.
Powered by modified versions of the model QSV81G 16-cylinder and QSV91G 18-cylinder natural gas reciprocating engines, the new GQ series 1570 kW and 1750 kW low-BTU generator sets feature an enlarged fuel delivery system, double-safety gas shut-off valves, and special coatings and bearing materials to withstand the corrosive contaminants typical in landfill gas.
A Cummins low-BTU generator at a landfill site in Shrewsbury, England, has accumulated more than 5700 hours of operation. Future installations include a wastewater digester site in the Canary Islands and the Viridor Waste Management landfill near Edinburgh, Scotland. At Viridor, Cummins Power Generation is developing a complete turnkey 3.5 MW power plant using two low-BTU generator sets running on methane from the landfill. The electricity produced at the site will be used to run a nearby cement works. An additional pair of low-BTU generators will be installed during the next two years to take advantage of the site's estimated 20-year supply of methane. "Consistent with our goal of providing total energy solutions, Cummins Power Generation can deliver this new product in a number of ways," says Passmore. "For example, we can deliver a Build-Own-Operate (BOO) power plant, or provide application design, installation and project management for a turnkey power plant. Supply of only the generator set, open or containerized, is also available
* Refer to this month's "HVACR Designer Tips" for the emergency generator system with cogeneration system application design review and startup checklist
* Refer to the 2004 ASHRAE Handbook--HVAC Systems and Equipment, Chapter 1, for an analytical process for determining the optimum system selection. For the next three months, "Back to Basics" will cover a 200kW emergency generator hospital installation supplemented with a 200kW cogeneration unit (August 2004 "Back to Basics"). The emergency power system distribution includes life safety systems, critical systems (e.g., health care systems), and noncritical systems (e.g., heating system).
* Refer to the IEEE Recommended Practice for Electrical Systems in Health Care Facilities (IEEE Std 602-1996) for a comprehensive overview of emergency generator planning and design.
* "Back to Basics" is focused on the HVAC system associated with an emergency generator application. For more specific questions regarding the electrical functional performance associated with these three months worth of tests, contact Tom Cooke, director of construction quality management for Richard D. Kimball Company, Inc. at tcooke@rdkengineers.com.
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Helpful Hints-Design Phase
* Design engineers need to consider both combustion air requirements to the generator engine and ventilation air requirement for limited space heat gain within a generator room.
* If the generator room is located with an exterior wall to accommodate air intake and exhaust louvers, consideration should be given to the short-circuiting of warm-to-hot room. Termination point for engine exhaust is also a short circuit concern when locating air intakes (e.g., operable widows, ventilation louvers, etc.).
* When specifying exterior louvers, consideration should be given to sound attenuator louvers to limit the ambient noise leaving the generator room. For cogeneration equipment, which operates continuously, this type of louver treatment will most likely be mandatory, due to local regulations regarding noise impact on the surrounding neighborhood.
* If the generator room is located within the building and away from any exterior wall, consideration should be given to the air static resistance when sizing the makeup air fan, and it should be determined if the generator manufacturer's standard propeller exhaust fan can overcome exhaust duct air resistance.
* An alternative to large makeup air and exhaust air ducts serving a generator room within a building is to furnish and install a remote radiator to reduce duct sizes.
* For fuel oil/diesel emergency generators, consideration should be given to locating the storage tank indoors to avoid underground storage tank failure later in the life of the tank. Locating the tank indoors can avoid potential hazardous waste material contamination associated with underground fossil fuel tanks.
* Design engineers must comply with codes that dictate the criteria for designing an indoor storage tank as it pertains to rated wall construction, ventilation, and containment/dike wall construction.
Helpful Hints-Commissioning
* The commissioning team for this month's application should include the commissioning engineer, the owner's project manager and facility engineer, facility technicians responsible for operating and maintaining the equipment, the general contractor or construction manager's commissioning coordinator, the electrical trade contractor and HVAC trade contractor, and emergency generator manufacturer's representative(s). It shall be the responsibility of the contractor to demonstrate the emergency generator system performance to the owner and the commissioning engineer.
1 ON-OFF CONTROL IN THE MANUAL 'OFF' POSITION CYCLE
ACTION: When emergency generator system is manually shut off to confirm fail-safe positions, the REACTION shall be:
* Generator EM-1 is (off, on, modulating).
* Cogenerator CG-1 is (off, on, modulating).
* Outdoor air damper D-1 is (open, closed, modulating) for minimum outdoor combustion air.
* Outdoor air damper D-4 is (open, closed, modulating) for maximum outdoor ventilation air.
* Engine air damper D-2 is (open, closed, modulating) for EM-1 exhaust from radiator.
* Engine air damper D-3 is (open, closed, modulating) for CG-1 exhaust from radiator.
* Exhaust air damper D-5 is (open, closed, modulating) for maximum outdoor ventilation air.
* Fuel oil pump P-1 is (off, on, modulating).
2 ON-OFF CONTROL IN THE 'ON-TEST' POSITION CYCLE (HEATING SEASON)
ACTION: When normal electrical power is shutoff to test the engine with no connected load on the engine, the REACTION shall be:
* EM-1 is (off, on, modulating).
* CG-1 is (off, on, modulating).
* D-1 is (open, closed, modulating) for minimum outdoor combustion air.
* D-4 is (open, closed, modulating) for maximum outdoor ventilation air.
* Refer to the 2004 ASHRAE Handbook--HVAC Systems and Equipment, Chapter 1, for an analytical process for determining the optimum system selection. For the next three months, "Back to Basics" will cover a 200kW emergency generator hospital installation supplemented with a 200kW cogeneration unit (August 2004 "Back to Basics"). The emergency power system distribution includes life safety systems, critical systems (e.g., health care systems), and noncritical systems (e.g., heating system).
* Refer to the IEEE Recommended Practice for Electrical Systems in Health Care Facilities (IEEE Std 602-1996) for a comprehensive overview of emergency generator planning and design.
* "Back to Basics" is focused on the HVAC system associated with an emergency generator application. For more specific questions regarding the electrical functional performance associated with these three months worth of tests, contact Tom Cooke, director of construction quality management for Richard D. Kimball Company, Inc. at tcooke@rdkengineers.com.
Advertisement
Helpful Hints-Design Phase
* Design engineers need to consider both combustion air requirements to the generator engine and ventilation air requirement for limited space heat gain within a generator room.
* If the generator room is located with an exterior wall to accommodate air intake and exhaust louvers, consideration should be given to the short-circuiting of warm-to-hot room. Termination point for engine exhaust is also a short circuit concern when locating air intakes (e.g., operable widows, ventilation louvers, etc.).
* When specifying exterior louvers, consideration should be given to sound attenuator louvers to limit the ambient noise leaving the generator room. For cogeneration equipment, which operates continuously, this type of louver treatment will most likely be mandatory, due to local regulations regarding noise impact on the surrounding neighborhood.
* If the generator room is located within the building and away from any exterior wall, consideration should be given to the air static resistance when sizing the makeup air fan, and it should be determined if the generator manufacturer's standard propeller exhaust fan can overcome exhaust duct air resistance.
* An alternative to large makeup air and exhaust air ducts serving a generator room within a building is to furnish and install a remote radiator to reduce duct sizes.
* For fuel oil/diesel emergency generators, consideration should be given to locating the storage tank indoors to avoid underground storage tank failure later in the life of the tank. Locating the tank indoors can avoid potential hazardous waste material contamination associated with underground fossil fuel tanks.
* Design engineers must comply with codes that dictate the criteria for designing an indoor storage tank as it pertains to rated wall construction, ventilation, and containment/dike wall construction.
Helpful Hints-Commissioning
* The commissioning team for this month's application should include the commissioning engineer, the owner's project manager and facility engineer, facility technicians responsible for operating and maintaining the equipment, the general contractor or construction manager's commissioning coordinator, the electrical trade contractor and HVAC trade contractor, and emergency generator manufacturer's representative(s). It shall be the responsibility of the contractor to demonstrate the emergency generator system performance to the owner and the commissioning engineer.
1 ON-OFF CONTROL IN THE MANUAL 'OFF' POSITION CYCLE
ACTION: When emergency generator system is manually shut off to confirm fail-safe positions, the REACTION shall be:
* Generator EM-1 is (off, on, modulating).
* Cogenerator CG-1 is (off, on, modulating).
* Outdoor air damper D-1 is (open, closed, modulating) for minimum outdoor combustion air.
* Outdoor air damper D-4 is (open, closed, modulating) for maximum outdoor ventilation air.
* Engine air damper D-2 is (open, closed, modulating) for EM-1 exhaust from radiator.
* Engine air damper D-3 is (open, closed, modulating) for CG-1 exhaust from radiator.
* Exhaust air damper D-5 is (open, closed, modulating) for maximum outdoor ventilation air.
* Fuel oil pump P-1 is (off, on, modulating).
2 ON-OFF CONTROL IN THE 'ON-TEST' POSITION CYCLE (HEATING SEASON)
ACTION: When normal electrical power is shutoff to test the engine with no connected load on the engine, the REACTION shall be:
* EM-1 is (off, on, modulating).
* CG-1 is (off, on, modulating).
* D-1 is (open, closed, modulating) for minimum outdoor combustion air.
* D-4 is (open, closed, modulating) for maximum outdoor ventilation air.
New Producer Price Index for the Direct Health and Medical Insurance Carriers Industry—NAICS 524114
In July 2004, in its ongoing effort to expand coverage of the service sector in the Producer Price Index (PPI), the Bureau of Labor Statistics (BLS) introduced a new price index for the direct health and medical insurance carriers industry. This index, NAICS 524114--Direct Health and Medical Insurance Carriers, appears in table 5 of this publication and is available online via the BLS homepage: www.bls.gov. Data are available for December 2002 to present; prior to December 2003, the index is published as discontinued series SIC 6325.
The primary output of this industry is the contractual transfer of the risk for payment of medical costs and financial intermediation. The policy underwritten by the insurer represents a unique output. The policy lists the conditions for which restitution would be made to the policyholder to cover medical costs. The amount of risk being transferred to the insurer is clearly stated in terms of covered benefits (and benefits not covered), and it obligates the insurer to pay claims for all such occurrences. The indexes for this industry measure the change in the total premium (employee and employer contribution) paid to the insurer plus the return on the invested portion of the premium.
The services for which price indexes are available include:
5241141 Medical service plans
524114101 Group comprehensive medical service plans
52411410101 Group managed care medical service plans
52411410102 Group fee-for-service medical service plans
524114102 Other group and individual medical service plans
52411410201 Individual comprehensive medical service plans
52411410202 Dental service plans
52411410203 Supplemental Medicare service plans
52411410204 Other medical service plans
5241142 Accident and health insurance
To track price movement for the selected policy, insurance companies participating in the survey are presented with two options. With the first option, companies are asked to estimate a premium for a "frozen" policy. An actual policy is selected, and the price-determining characteristics are held constant when the policy is priced each year on its anniversary or renewal date. The companies estimate the premium using current charges applied to the characteristics of this policy.
With the second option, the insurance companies follow the selected policy over time. They are asked to provide the actual premium charged to the policyholder and to identify any modifications to the policy each year on the anniversary or renewal date. Any changes in benefits over time must be factored out so that index movements reflect only changes in price and not any additional benefits. To maintain constant quality, the companies must be able to provide the value of the risk change associated with any change to the policy characteristics.
The primary output of this industry is the contractual transfer of the risk for payment of medical costs and financial intermediation. The policy underwritten by the insurer represents a unique output. The policy lists the conditions for which restitution would be made to the policyholder to cover medical costs. The amount of risk being transferred to the insurer is clearly stated in terms of covered benefits (and benefits not covered), and it obligates the insurer to pay claims for all such occurrences. The indexes for this industry measure the change in the total premium (employee and employer contribution) paid to the insurer plus the return on the invested portion of the premium.
The services for which price indexes are available include:
5241141 Medical service plans
524114101 Group comprehensive medical service plans
52411410101 Group managed care medical service plans
52411410102 Group fee-for-service medical service plans
524114102 Other group and individual medical service plans
52411410201 Individual comprehensive medical service plans
52411410202 Dental service plans
52411410203 Supplemental Medicare service plans
52411410204 Other medical service plans
5241142 Accident and health insurance
To track price movement for the selected policy, insurance companies participating in the survey are presented with two options. With the first option, companies are asked to estimate a premium for a "frozen" policy. An actual policy is selected, and the price-determining characteristics are held constant when the policy is priced each year on its anniversary or renewal date. The companies estimate the premium using current charges applied to the characteristics of this policy.
With the second option, the insurance companies follow the selected policy over time. They are asked to provide the actual premium charged to the policyholder and to identify any modifications to the policy each year on the anniversary or renewal date. Any changes in benefits over time must be factored out so that index movements reflect only changes in price and not any additional benefits. To maintain constant quality, the companies must be able to provide the value of the risk change associated with any change to the policy characteristics.
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