ESP Power & Control
A complete range of products for power and control
Our Control and Power Equipment for Electrostatic Precipitators (ESPs) provide a complete range of products designed to filter emissions and control outputs across various industries, including fossil fuel power generation, cement, and glass manufacturing. Trusted by end-users worldwide, our ESP solutions are built on a legacy of over 50 years of innovation and engineering expertise.
Controlled by the industry-leading MCS III Controller Family, our ESP Power and Control Equipment ensures enhanced pollution and particulate control, optimizing plant performance and efficiency. From installation to maintenance and upgrades, our range of ESP Power Control products and services is designed to meet the unique needs of each application, offering tailored solutions to improve reliability, safety, and environmental compliance.
- Design Services
- HV Transformer Rectifiers
- MCS III Controller Family
- HV Control Cubicles
- ESP Controller Retrofits
- Earthing Switches
ESP Sectors
- ENERGY STORAGE
- MILITARY & AEROSPACE
- MINERALS
- POWER GENERATION
- CEMENT & METAL
- WASTE
Design Services for ESP Power and Control
To provide turnkey solutions, Castlet engineers provide a full design service. Our engineers will work closely with you, from pre-order to factory testing. This approach means every customer has a ready to use solution, reducing down time and ensuring efficiency is a priority.
Our bespoke solutions include:
- Additive manufacturing
- Concept studies with our customers at pre-order stage, engineering solutions
- Project engineering and management (including subcontractor management)
- Drawing packages electrical and mechanical (equipment and installation)
- 3D Modelling
- Bills of Materials
- SCADA / PLC programming and verification testing
- Specialist software including AI
- Design standard verification
- Factory Acceptance Testing
HV Transformer Rectifiers
Castlet Single Phase and Three-phase Transformer Rectifier (T/R) units have provided reliable power for Electrostatic Precipitators since 1974. The use of internal silicon rectifiers results in low maintenance costs, increased reliability, and allows higher ambient temperatures and lower cost cooling techniques. Castlet employs internally built integral high reactance technology in the design and manufacture of Transformer Rectifier units, typically with 40% impedance for optimum performance. With the benefit of simplified manufacture, the use of internal reactance technology also reduces the potential risk of equipment failure, unit size and kW losses.
HV Transformer Rectifier Units are used to provide a high negative DC voltage, typically between 45kVpoc to 130kVpoc at DC currents typically between 100mA and 3000mA.
At Castlet we install suitable TR Units for outdoor use. All units are IP65 protection standard, hermetically sealed, ONAN cooled using either mineral oils or synthetic fluids such as Silicone fluid or Midel. Coatings are suitable for outdoor, coastal and aggressive environments.
HV Control Cubicles
Since 1974, Castlet’s Single-Phase and Three-Phase HV Control Cubicles have been delivering reliable power and control for Transformer Rectifier (TR) units in Electrostatic Precipitators. Utilizing a thyristor regulator in the form of an inverse parallel pair and our advanced microprocessor-based Automatic Voltage Controller (AVC), these cubicles ensure precise and efficient Transformer Rectifier control.
Features & Benefits
- Primary Voltage and Frequency to suit
- Ambient Temperature: +40°C
- IP54 Protection
- RAL 7035 paint colour as standard
- Range of indication, control and alarm signals available, with meters, control and indication components fitted as standard
- Built to BS/ EN standards and EMC certified
- Typical dimensions: 800mmW x 400mmD x 2000mmH
MCS III Controller Family
These units incorporate industry-leading technology for superior air and particulate control, built on comprehensive design, prototyping, manufacturing, and testing.
Castlet provides MCS III controls for reliability and scalability giving customers optimal efficiency and adaptability. This ensures we can continue to provide solutions for customers across industries from manufacturing to energy management.
As technology advances, Castlet remains focused on the future with advanced processing power, real-time monitoring and flexible configurations to meet demands.
Controllers for electrostatic precipitator power supplies are what Castlet are known for.
The MCS III automatic voltage controller represents the latest iteration in a long string of controllers for electrostatic precipitator power supplies.
Specifications:
Input Voltage Rating: 110 Vac ±25% @ 25VA, 47 to 63Hz
Operating Temperature: 0 to 70˚C, Storage Temperature: -20 to 85˚C
CPU and Memory: 16 Bit 40MHz Near-RISC
ROM: 64 Kbytes, RAM: 128 Kbytes
Analogue Inputs / Outputs: 4 x Differential inputs,
1 x 4-20mA or 0-20mA input, 2 x 4-20mA or
0-20mA outputs. All inputs and outputs optically isolated
Digital Inputs / Outputs: 16 x Configurable optically isolated inputs, 6 x Volt-free relay outputs with changeover contacts
SCR Drivers: 2 x Mains supply 700V RMS Max
Communication Ports: 2 x CAN bus Network connection Max 500 kbaud, 1 x USB port, 1 x Fibre Optic ports (Rx & Tx), 1 x I/O Expansion port.
ESP Controller Retrofits
With ongoing technological advancements, many older electrical and electronic components have been discontinued by suppliers, making it challenging for ESP controller manufacturers to support outdated products. Castlet offers a retrofit kit designed to upgrade its own MCSI and MCSII controllers, as well as competitor controllers, to the latest MCS version with minimal modifications to the existing control panel while retaining all power components.
Earthing Switches
Our solenoid operated automatic external earth switches have been used in installations across the world, from power stations to glass plants.
They are designed to provide a reliable, safe and cost effective way to earth transformers.
The earth switch is designed to be fail safe with a spring operated return to earth function. The earth position micro switches ensure the transformer rectifier cannot be started with the earth switch in its earth on position. It can be activated by a high CO alarm signal.
Typical specifications:
- Heavy duty solenoid
- Fail safe, spring operated return to earth
- Micro switch operation status
- Can be designed with interlock facility
- Ambient Temperature: –25°C to +40°C
- Housed in a weatherproof enclosure to IP65 – NEMA4 protection
