Rothera Container 81
DSF Dry Lab
British Antarctic Survey
In partnership with
Royal Netherlands Institute for Sea Research
Manufacturer: JM Services
Date: 21-09-2011
Table of Contents
Chapter
1. Container design
2. Heat pump installation
3. Laboratory
4. Ventilation
5. Control cabinet
6. Touch screen display
7. Usable conditions
8. Specifications
9. Maintenance
10. Malfunctions
11. Settings
12. Drawings
Page
2
3-5
6
7
8, 9
10, 11
12
12
13 - 17
18 - 20
21 - 22
23 - 24
1
Container design
Container 81 is part of the project Rothera. This project is located in Antarctica and placed in
a special built station. Because of the ecological aspects and the fuel supply it is
recommended to acclimatize the laboratory by using a heat pump system in combination with
a heat recovery installation. This, in comparison with electric heating, will save a lot of
energy.
There is no air recirculation, because of the fume cupboard, so all the air will be refreshed
continuously. In normal conditions (fume cupboard switched off) the ventilation depends on
the carbon dioxide percentage. If this value increases by people’s breathing or an opened
nitrogen valve, the ventilation system automatically increases the airflow to a maximum of
400m3 per hour till the CO2 percentage will descend below 1000 p.p.m. Below this value the
ventilation automatically decrease to the minimum of 150 m3 per hour.
If the fume cupboard is switched on by switch 14S16, the ventilation will increases to 400m3
per hour. When the laboratory lights are switched off, the ventilation decreases to the
minimum of 150 m3 per hour.
Beside the heat pump, the installation has also been provided with a heat recovery system.
The exhausted warm air flows through a heat exchanger and gives off its energy to the heat
transfer fluid. In the supply airflow another heat exchanger is located. The heat transfer fluid
will preheat the supplied air before the main heat exchanger provides the desired laboratory
temperature. To get and maintain a constant laboratory temperature the container has also
been provided with a floor heating system. If floor heating is used a mass is necessary which
can contain energy, therefore this container is provided with an epoxy-sand floor. Most of the
loss of heat is caused by the steel construction under the floor.
The space in the laboratory is meticulously utilized so that there is maximum room for the
researcher and his research work. In the corner of the container a laminar cross flow unit with
electronically controlled fan is placed.
Three Spectrolab-Plus valves are mounted on the work tables for nitrogen distribution. The
pressure is adjustable by means of the pressure control valve to a maximum of 10 bar.
The sink at the left side of the laboratory is provided with a water tap. The water pipe has
been provided with an insulated tape heating element (tracing) and is controlled by the plant
controller, which gets its information from a pipe probe mounted on the water pipe in the
technical room. A removable splash screen is mounted near the water tap.
The fume cupboard is placed to the left of the sink. It is suitable for research with acid gasses.
The exhaust fan is of a special explosion proof type.
The lighting of the laboratory consists of long-life fluorescent tubes with high-frequency start.
The lifetime of the tubes is up to 60,000 operating hours.
The installation will be explained more detailed in the following chapters.
2
Heat pump installation
Refrigerant system
The working of the heat pump installation is based on the exchange of heat. An air cooler
(evaporator) is mounted in an outdoor niche on the top of the container. Refrigerant liquid
(R507A) evaporate to gas in this air cooler, controlled by an electronic stepper valve (ETS
12.5). The required heat for evaporation comes from the outdoor air. The air is blown through
the evaporator by fans and gives off its energy.
The compressor (Bitzer 2DC-3.F1Y-40S) in the technical room compresses the refrigerant gas
to a high pressure. The high pressurised gas flows into two parallel connected heat exchangers
and gives off its energy to the Ethylene Glycol / water mixture. The high pressurised
refrigerant gas will now condensate to refrigerant fluid and flow to the stock vessel and from
there to the air cooler again. The compressor bearings and pistons are lubricated with an Ester
oil (Emkarate RL 32 H). This oil also circulates through the refrigerant system and decreases
the heat transmission in the copper pipes. To counterbalance this effect an oil separator is
mounted in the discharge pipe. Most of the oil will be separated from the high pressurised gas
and flows back to compressor sump. To prevent the refrigerant from dissolving in the oil
during standstill of the compressor, a crankcase heating element is mounted. This element will
heat the oil to 25 – 28 ºC, controlled by the plant controller. The temperature is measured by a
probe on the crankcase.
To check the refrigerant quantity a sight-glass is mounted in the liquid pipe-line after the
filter/dryer. The sight-glass has to be full during compressor operation. If there are bubbles in
the sight-glass, there could be a refrigerant leakage or the filter/dryer might be saturated. In
this case the indicator on the sight-glass will usually be yellow. Under normal conditions the
indicator will be green, which means that there is no water in the refrigerant.
A solenoid valve is mounted in the pipe-line after the sight-glass. This safety valve prevents
the liquid from flowing into the compressor if the electric power shuts off while the
electronic stepper valve is still open. The solenoid valve is open during compressor operation.
A suction filter is mounted in the suction pipe-line before the compressor. This filter protects
the compressor against dirt and possible refrigerant liquid drops.
In the refrigerant pipes between the compressor and the wall vibration absorbers are mounted
to reduce the vibrations on the wall. Under the compressor feet specially selected vibration
absorbers are mounted to reduce the vibration to a minimum.
Two measuring hoses are connected to the compressor. One is for measuring the low (suction)
pressure (LP). This pressure is controlled by the plant controller, which gets its information
from an electronic pressure transmitter and a mechanical pressure switch. The rotation speed
of the compressor is controlled by a frequency inverter mounted on the compressor,
depending on the required suction pressure. The suction pressure is shown on the low pressure
gauge.
The other hose is for measuring the high (discharge) pressure (HP). This pressure is controlled
in the same way as the low pressure. If the discharge pressure is rising to a critical height, the
rotation speed of the compressor is decreased automatically. The discharge pressure is shown
on the high pressure gauge.
3
Heating system
In the technical room a buffer stock vessel is placed filled with 450 L of glycol/water mixture.
In this vessel the heat will be accumulated. The warm mixture (fluid) leaves the vessel at the
top through 2-way or 3-way valves to several heat exchangers. At the foot of the vessel the
cold mixture returns. The mixture circulates continually. If each 2-way or 3-way valve is
closed, the mixture flows through the overpressure bypass (0.4 bar) so the main pump will not
be blocked.
The pressure in the heating system depends on the temperature of the mixture. When the
container starts up in a cold situation (buffer stock vessel temperature around 0ºC) the
pressure will be around 0.5 bar. When the buffer stock vessel temperature is below zero the
pressure will be 0.0 bar. During the start of a cold installation the malfunction signal “Low
fluid pressure heating system” is blocked. Under these conditions neither pump nor ventilator
will start until the temperature (20-25ºC) and fluid pressure (1.5 – 2.5 bar) of the buffer stock
vessel will be in range. The fluid pressure is measured by a pressure switch (cut out: 0.5 bar /
cut in: 1.1 bar)
The pressure variations are absorbed by an expansion vessel (Flexcon 25 L).
When the laboratory temperature is below the set point, measured by the laboratory probe and
the air sock supply probe, the 3-way valve of the heat exchanger will open proportionally to
reach the required temperature of the supply air. During an installation start-up or air flow
variations the temperature of the supply air can fluctuate a bit.
The floor heating system is controlled by the floor probe and the floor liquid probe. The floor
heating unit controls its floor liquid temperature to the required value by means of a
proportional 2-way valve.
During a compressor operation, moisture will frost the outdoor cooler fins. After three hours
of compressor operation the cooler will be defrosted until it reaches the temperature of 20 ºC,
or for a maximum time of 45 minutes. If the defrost time exceeds this maximum a
malfunction will be generated.
The defrost-interval and final temperature of the cooler, mentioned above, are depend on the
outdoor-humidity percentage and -temperature. These two parameters are adjustable in the
parameter list in consultation with JM Services only!!
When a mixture leakage occurs, the leak has to be closed and the installation refilled.
Refilling is only allowed with a mixture of 40% Ethylene Glycol and 60% water. Other
mixtures are not allowed and will damage the installation.
Refill to a maximum of 1.9 bar by 20 ºC.
The pressure is shown by the pressure gauge of the heating system.
The concentration of 40% Ethylene Glycol guarantees that the mixture will remain liquid till a
temperature of -26ºC. From -26ºC till -37ºC the mixture changes to slush without making the
pipes burst. Below -37ºC the mixture will be solid and cause damage.
If the installation is overfilled, the overpressure valve will open and reduces the pressure to 3
bar. The surplus mixture runs into the drain pipe. It is possible that the overpressure valve
does not close completely after a overpressure situation. So it is important to prevent
overfilling!
Pressure variations of the mixture are absorbed by an expansion vessel.
4
Heat recovery system
In the supply as well as in the exhaust air canal a heat exchanger has been mounted. In this
system the supply air will be preheated by the relative warm mixture (fluid) from the exhaust
air exchanger, circulated by a pump. The relatively cold mixture returns to the exhaust air heat
exchanger.
The heat recovery system is filled with a mixture (40% Ethylene Glycol and 60% water). The
pressure in the system depends on the temperature of the mixture. Because of the small
mixture volume the pressure fluctuates little. The pressure variations are absorbed by an
expansion vessel (Flexcon 12 L). The fluid pressure is measured by a pressure switch (cut out:
0.5 bar / cut in: 1.1 bar). If the fluid pressure descends below 0.5 bar a malfunction signal
“Low fluid pressure heat recovery” will be generated.
When a mixture leakage occurs, the leak has to be closed and the installation refilled.
Refill is only allowed with a mixture of 40% Ethylene Glycol and 60% water. Other
mixtures are not allowed and will damage the installation.
Refill to a maximum of 2.0 bar by 20 ºC.
The pressure is shown by the pressure gauge of the heat recovery system.
The concentration of 40% Ethylene Glycol guarantees that the mixture will remain liquid till a
temperature of -26ºC. From -26ºC till -37ºC the mixture changes to slush without making the
pipes burst. Below -37ºC the mixture will be solid and creates damage.
If the installation is overfilled, the overpressure valve will open and reduces the pressure to 3
bar. The surplus mixture runs into the drain pipe. It is possible that the overpressure valve
does not close completely after a overpressure situation. So it is important to prevent
overfilling!
Pressure variations of the mixture are absorbed by an expansion vessel.
The pump is thermally protected against overload. Overload will generate a malfunction
signal: “Pump heat recovery thermal”. When the malfunction is accepted and solved, restart is
possible by pressing the reset button on the control cabinet.
5
Laboratory
The laboratory is provided with two work tables. On the right a worktable with an control
cabinet and a laminar cross flow cabinet. On the left a fume cupboard and a sink. The laminar
flow cabinet can be switched on by a touch button and controlled by a potentiometer.
The minimum airflow in the container is 150 m3 per hour. The air leaves the laboratory
through the fume cupboard. When the CO2-percentage increases the ventilation will increase
slowly to a maximum of 400 m3 per hour till the CO2-percentage has decreased below the
minimum value (1000 p.p.m.). When the fume cupboard is switched on, the ventilation will
increase rapidly to the maximum of 400 m3 per hour. The fluorescent tube will switch on
automatically. The fume cupboard is suitable for research with acid gasses. Before using the
laboratory, a sheet of glass should be placed in the top of the fume cupboard to create a
laminar airflow.
The sink at the left side of the laboratory has been provided with a water tap. The water
supply should be connected to the coupling in the niche at the front of the container. The
water pipe has been provided with an insulated tape heating element (tracing) and is
controlled by the plant controller, which gets its information from a pipe probe mounted on
the water pipe in the technical room.
The drain should also be connected in the outdoor niche. The swan’s neck under the sink is
provided with a removable cup. Near the drink water tap a removable splash screen is
mounted.
Three Spectrolab-Plus valves are mounted on the work tables for nitrogen distribution. The
pressure is adjustable by means of the pressure control valve to a maximum of 10 bar. The
nitrogen supply should also be connected in the niche at the front of the container.
6
Ventilation
The air in the container is constantly refreshed to ensure a clean atmosphere in the laboratory.
The supply air flows through a G4 air filter before entering the air distribution system (air
sock). After having been filtered the supply air is preheated in the heat recovery exchanger
and flows through the heat exchanger to the air distribution system. The air distribution sock
will spread the air equally throughout the container. The airflow is controlled by an air speed
transmitter which controls the supply fan speed via the controller.
If the G4 air filter gets dirty a pressure difference meter will generate a malfunction signal:
“Air filter dirty”. It is important to replace the dirty air filter in time to guarantee a proper
working.
The air leaves the laboratory through the fume cupboard and the heat recovery exchanger. The
exhaust air flow is measured by an air speed transmitter which controls the exhaust fan speed
via the controller. The exhaust fan is explosion proof and controlled by the inverter in the
technical room.
7
Control cabinet
All the electricity in the container is supplied by the control cabinet. In the wiring diagram
each electric component in the container is encoded. The code has been built up as follows:
Example: 14S16, 15R17
The first number is the page number of the diagram.
The capital letter indicates the type of the component.
S
= Switch, manual
M
= Motor
X
= Universal component
Y
= Electric valve
M
= Motor
E
= Heating element
F
= Fuse
K
= Relay
Z
= Lamp
R
= Resistance (transmitter, temperature probe)
The last number indicates the column where the component can be found.
The plant controller in the control cabinet controls the heat pump installation and the
ventilation. All the values are shown in different tabs of the touch screen display. The
operation of the touch screen is explained in detail in the following chapter. The main
components are fused and monitored separately. Both controllers run on 24VAC and are
double fused. The stepper valve needs a separate power supply, also 24VAC.
The main power 3 x 400Volts is guarded by a phase sequence relay. This relay switches off
the installation release under the following circumstances:
Phase sequence wrong (Phase sequence should turn to the right)
Phase off line (one or two phases are cut off)
If the voltage varies more than 10% for longer than 8 seconds
If the phases are asymmetric more than 10% for longer than 8 seconds
When the power supply is connected to the container it is important to verify that the
voltage between any phase and zero is about 230V, before switching on the reverse main
switch! If the phase sequence is incorrect an alarm will be generated and the main
switch has to be reversed.
When the container starts up at a temperature below 5ºC it is necessary to wait to switch
on the fuse 6F13 (control power) till the control cabinet is heated up to about 20ºC by
the heating element in the cabinet. Below 5 ºC the controller cannot operate reliably!
8
In the top of the control cabinet a patch panel is mounted. From the niche at the front of the
container two data cables are connected to the patch panel (81-1 and 81-2).
Four data outlets are installed in the laboratory, which are also connected to the patch panel
(81-3, 81-4, 81-5, 81-6).
Next the patch panel a router is mounted. In Antarctica this router is unnecessary because the
Plant controller is directly connected to the data switch. But on board a ship or at other
locations this router could be necessary. The router is pre-configured for data communication
with the Plant controller.
The data switch is mounted beside the router. This switch connects the right IP-address to the
right appliance. Ask the local IT-administrator for more information about this connection.
9
Touch screen display
At the front of the control cabinet a touch screen display is mounted. On this touch screen
several values and parameters are shown and sometimes adjustable.
On the main screen, shown above, three values are shown and one parameter is adjustable.
Left half top:
CO2 value in Parts Per Million. If this value increases to over 1000 PPM the ventilation will
increase automatically.
Left half bottom:
Outdoor temperature in ºC. The outdoor temperature is measured in the supply air flow before
the airfilter.
Right half left:
Relative humidity. The relative humidity is measured at the ceiling of the laboratory. This
value cannot be adjusted.
Right half right:
Laboratory temperature set point. The laboratory temperature can be adjusted by the slider.
Because of the slow reaction of the floor heating system it is recommended to keep this set
point steady.
If the lights and fume cupboard have been switched off for more than three days (72 hours),
the laboratory temperature set point will switch to the winter set point (10 ºC). When the
lights or fume cupboard are switched on again, the previous set point will be activated.
By touching the top of the screen the menu will be opened. At the left side of the menu six
tabs are shown. Touch the top again to return to the main screen.
10
Inputs
In this tab the inputs of the controller are shown. The screen is refreshed every five seconds. It
is possible to scroll up and down through the values in each of the tabs.
Outputs
In this tab the outputs of the controller are shown.
State
No data
Parameters
In this tab each parameter can be adjusted. For changing a parameter, contact JM Services.
Alarms
During normal operation conditions the status indicator over the screen is blue. If an alarm is
directed to the display the indicator will flash red and a sounder will be active. Once the alarm
has been accepted the red status indicator remains on permanently until the alarm will be
cleared. The sounder is off .
11
Design demands
The container is designed for the following demands:
Outdoor temperature:
Outdoor relative humidity:
Laboratory temperature:
+ 5ºC
0%
+ 15ºC
/
/
/
-25 ºC
90 %
+25 ºC
Deployment:
Indoor
–
horizontal
The maximum stand still time of the container is one month.
The roof of the container has to be free of ice and snow so that the air can flow through the
cooler easily.
Specifications
Owner:
Manufacturer:
Container number:
Container dimensions (mm):
Container tare weight (kg):
Allowable stacking weight (kg) :
Next container inspection:
NIOZ
JM Services
NIOU 00081-2
6058 x 2438 x 2591
6100
192000
04/2015
Refrigerant:
Required electrical power (front niche):
Data communication connection (front niche):
Fire alarm connection (front niche):
Water pipe connection H2O (front niche):
Nitrogen pipe connection N2 (front niche):
Drain pipe connection (front niche):
Earth connection (front niche):
Cable conduit screw cap internal Ø (front niche):
R507a – 10,0 kg
3 x 400V – 25 A
2 x RJ 45
Direct connection
½” internal thread DIN 2986
½” internal thread DIN 2986
1” external thread DIN 2986
M10 bolt
103.6 mm
12
Maintenance
The installation in the container requires periodic maintenance to minimize malfunctions.
This is shown in the following schedule:
Installation part
Air filter (supply air)
Fluid pressure heating system
Fluid pressure heat recovery system
Oil level compressor
Icing in cooler (outdoor roof niche)
General inspection
Maintenance
interval
Weekly
Weekly
Weekly
Weekly
Daily
Daily
Details
Replace if dirty
About 2 bar (20 ºC)
About 2 bar (20 ºC)
¼ - ¾ of the sight glass
The fins should be free of ice
Visual
Replacing air filter
When the air filter is dirty it has to be replaced. It is not necessary to stop the ventilation.
1.
2.
3.
4.
5.
Unscrew the wing nuts of the supply ventilation door.
Fasten the door in open position by the nylon door fastener.
Pull the air filter out of the slides in a horizontal movement.
Push a new air filter into the slides. Be sure the airflow arrow points at the supply fan!
Close the door and screw on the wing nuts carefully.
13
Refilling heating system
When a low fluid pressure heating system alarm occurs, because of a leak, the installation has
to be refilled after repair.
1. Switch off the installation.
2. Repair the leak.
3. Mix the 100% Ethylene Glycol with drinking water to a mixture of 40% Glycol - 60%
drinking water.
4. Use the hand pump to refill the installation. Be sure that the filling hose is free of air.
5. Pump the mixture into the installation until the system pressure gauge shows a value
of at most 1.9 bar by a buffer stock vessel temperature of 20 ºC. Do not overfill!
6. The installation is provided with bleeding plugs to let the air out of the installation.
Use the bleeding key and hose to led this air out.
7. Restart the installation.
8. Repeat the bleeding procedure a few hours later. It is not necessary to stop the
installation than.
The positions of the bleeding plugs:
Outdoor roof niche: Three plugs at the left side of the container (looking to the
front door).
14
Supply fan niche: (Left door above the laboratory inner door).One plug.
Technical room: Two plugs.
Attention: Do not bleed the refrigerant system, this is a vapour / liquid system.
15
Refilling heat recovery system
When a low fluid pressure heating system alarm occurs, because of a leak, the installation has
to be refilled after repair.
1. Switch off the installation.
2. Repair the leak.
3. Mix the 100% Ethylene Glycol with drinking water to a mixture of 40% Glycol - 60%
drinking water.
4. Use the hand pump to refill the installation. Be sure that the filling hose is free of air.
5. Pump the mixture into the installation until the system pressure gauge shows a value
of at most 1.9 bar by a sytem temperature of 20 ºC. Do not overfill!
6. The installation is provided with bleeding plugs to let the air out of the installation.
Use the bleeding key and hose to led this air out.
7. Restart the installation.
8. Repeat the bleeding procedure a few hours later. It is not necessary to stop the
installation than.
Supply fan niche: (Left door above the laboratory door) Two plugs.
16
Technical room: One plug.
In some cases it might be necessary to bleed the pump. This can be done by removing the
screw at the front of the pump during operation.
Attention: Do not bleed the refrigerant system, this is a vapour / liquid system.
17
Malfunctions
The heat pump installation has a built in auto reset function. When a fault has occurred, the
controller will try to eliminate the interference by a reset procedure. After several attempts the
controller will create a fault message in the touch screen display, shown in the table below:
Fault message:
Description:
1
Reset button
blocked
The reset button has been pressed
for more than 20 seconds .
2
Compressor
inverter
The inverter generates a fault.
3
Compressor
thermistor
Compressor
high/low pressure
Compressor coil overheated
(130ºC).
The pressostat is switched off by a
high or low refrigerant pressure.
5
Compressor low
oil-level
The oil level of the compressor
carter is critically low.
6
Compressor oillevel detector
The oil-level detector at the back of
the compressor is disconnected.
7
Discharge pipe
temperature high
The compressor discharge pipe
temperature is too high (130ºC).
8
Low superheat
The refrigerant superheat of the
outdoor cooler is too low.
9
High superheat
The refrigerant superheat of the
outdoor cooler is too high.
4
Solution:
Reset by touch screen
parameters.
Contact JM Services.
Connect the Danfoss display
LCP 2800 to the inverter.
Reset by compressor main
fuse.
Reset by reset button .
Contacts JM Services.
Reset by fuse control power.
Contact JM Services.
Check the refrigerant liquid
level in the sight glass of the
vessel. (Check for closed
screw/ball valves).
Reset pressostat by a built in
reset button.
Reset by reset button .
Check for oil leakage (or
closed oil ball valve).
Check the temperature
probes.
Reset by reset button .
Screw the detector onto the
compressor carter.
Reset by reset button.
Check the buffer stock vessel
temperature probe.
Reset by reset button.
Check the suction pipe
temperature probe and the
ETS stepper connection.
Reset by reset button .
Check the refrigerant level in
the sight glass of the liquid
line during operation.
The sight glass has to be
filled up completely.
Check the working of the
refrigerant solenoid valve.
Reset by reset button .
Installation
blocked
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
18
Fault name:
Description:
10
Low suction
pressure
The suction pressure of the
compressor is too low.
11
High discharge
pressure
The compressor discharge pressure
is too high (60 ºC).
12
Air filter dirty
13
Supply fan
thermal
The supply air filter is dirty (air
pressure difference 170 Pa)
The supply fan current exceeds the
limit of the fuse (6A).
14
Exhaust fan
thermal
The exhaust fan current exceeds the
limit of the fuse (6A).
15
Cooler fans
thermal
The cooler fans current exceeds the
limit of the fuse (1.3A)
16
Max. defrost time
exceeded
The outdoor cooler defrost exceeds
the maximum defrost time (45min.)
17
Phase (sequence)
incorrect
The phase sequence relay is
switched off.
18
Main pump
heating system
thermal
The main pump current exceeds the
limit of the fuse (6A).
19
Pump cooling
system thermal
The pump current exceeds the limit
of the fuse (6A).
Solution:
Check the refrigerant level in
the sight glass of the liquid
line during operation.
The sight glass has to be
filled completely.
Reset by reset button.
Check the buffer stock vessel
probe (maximum 45 ºC).
(Check for closed screw/ball
valves).
Reset by reset button.
Replace air filter.
Installation
blocked
Yes
Yes
No
Check the fan for mechanical
blockage.
Reset by reset button.
Check the fan for mechanical
blockage.
Check the inverter in the
technical room.
Reset by reset button.
Check the fan for mechanical
blockage by ice.
Reset by reset button.
Check the cooler fins on ice.
Check the defrost probes in
the cooler body.
Check the defrost valve.
Reset by reset button.
Check the electric field
rotation (clockwise).
The electric field rotation is
changeable by the reverse
main switch.
Check the main power
voltage and phases.
Check the fuses before the
phase relay.
No
No
Yes
No
Yes
Check the main pump for
mechanical blockage (by
unscrewing pump lid).
Reset by reset button.
Check the main pump for
mechanical blockage (by
unscrewing pump lid).
Reset by reset button.
No
No
19
Fault name:
Description:
20
Low temp. buffer
stock heating
The buffer stock temperature is
critically low (-25 ºC).
21
Pump heat
recovery thermal
The pump current exceeds the limit
of the fuse (6A).
22
Pump floor
heating thermal
The pump current exceeds the limit
of the fuse (6A).
23
Low fluid
pressure heating
system
The fluid (glycol mixture) pressure
of the heating system is critically
low.
24
Low fluid
pressure heat
recovery system
The fluid (glycol mixture) pressure
of the heating system is critically
low.
25
Tracing water
pipe thermal
The tracing current exceeds the limit
of the fuse (6A).
26
Frost danger
water pipe
High temperature
technical room
The water pipe temperature is
critically low (2 ºC)
The technical room temperature is
critically high (45 ºC).
Comm. fault
expansion:
Restart!
The extension of the controller has
lost communication with the plant
controller.
27
28
Solution:
Check the whole installation
for malfunctions.
Reset by reset button.
Check the main pump for
mechanical blockage (by
unscrewing pump lid).
Reset by reset button.
Check the main pump for
mechanical blockage (by
unscrew pump lid).
Reset by reset button.
Check the installation for
leakage. Refill only with
Ethylene Glycol 40% / 60%
water.
Reset by reset button.
Check the installation for
leakage.
Refill with Ethylene Glycol
40% / 60% water only.
Reset by reset button.
Check the water pipe tracing
for mechanical damage.
(Check the insulated end of
the tracing line).
Reset by reset button.
Check the water pipe tracing.
Reset by reset button.
Check the cause of heating in
the technical room.
Reset by reset button.
Restart the installation by
switching the control power
fuse.
Installation
blocked
No
No
No
No
No
No
No
No
Yes
It is possible that the touch screen shows a fault which has been solved already.
E.g. the fault: Phase (sequence) incorrect. The installation has already restarted, but the fault
has to be accepted in the screen.
20
Settings
The settings of the components in the installation have been adjusted accurately.
Below a table of the component settings.
1
2
3
4
5
Component:
Phase sequence relay
Main fuse outdoor cooler fans
Thermostat heating cabinet
Cooler drain tracing delay
Netgear router
6
7
8
Module ID of controller extension
Plant / Extension controller term
Plant controller direct log in
9
10
11
12
13
14
15
16
17
18
19
LP / HP
Fluid overpressure valve
Heat recovery pump
Main pump heating system
Floor heating pump
Control valve floor heating
Control valve heating
Control valve defrost
Control valve bypass heating
Compressor inverter ramp up speed
Exhaust fan inverter
20 3-way valve heating
21 Filter differential pressure transmitter
22 2-way valve floor heating
23 Air velocity meter
Value(s):
400V / 8 sec. / 10%
1.3A
20 ºC
5 min.
IP-address: 192.168.1.1
Username: admin
Password: password
1
Y
IP-address: 10.255.255.254
Username: install
Password: 1234
LP:1bar / Diff:1bar / HP:30bar
0.4 bar
Speed 1 (slow)
Speed 2 (middle)
Speed 1 (slow)
Position 1.8
Position 2.6
Position 3.0
Position 1.9
5.0 sec.
01: 0 Hz
02: 50 Hz
05: Al.AV
06: 0.43 A
07: 1435 rpm
08: 400 V
16: Volt
22: A
Linear flow C-B
DIP switch 1: ON
DIP switch 2: OFF
DIP switch 4: OFF
DIP switch 6: OFF
100% – 0% <=
0 – 10V
Jumper 15m/s
Details:
7X2
5F3
20S17
12T7
12X3
Resistance 120 Ω
10X3
17X6-2
6M6
6M3
6M8
TA ½
TA ½
TA ¾
TA ½
AKD2800
18Y11
13R18
18Y13
13R13 / 13R15
21
60
4408
1246
600
880
2280
625
1136
560
760
Cable management up to ceiling
Fume
Cupboard
Engine room
flow cytometer
Sink
(FAScanto II 228x76x117 cm ca. 200 Kg)
laminair
cross
flow kast
Electrical box
1226
900
3508
80
5714
Heat
exchanger
Evaporator
500
700
962
Air sock
Filter
Air sock
Connection
Fume Cupboard
Evaporator
Air sock
Heating
Capacitor
+
Buffer-barrel
Capacitor
+
Buffer-barrel
Compressor
Fume
Cupboard
Ventilator
Heat
exchanger
Compressor
Cable housing
extra
Sink
Cable housing
extra
Cable housing
extra
pomp floor
heating.
Effluent
Pomp floor
heating.
Effluent
Client :
Order / Project
Project :
Description
Rothera dry lab container nr. 81
Form
Drawn by
Scale
Checked by
-----
Date
10-3-2011
Drawingnr.
Sht.
Evaporator
Fire connection
box
Evaporator
Internet & VOIP
Cable housing extra
Electric connextion
Water & nitrogen
Sewage
Client :
Order / Project
Project :
Description
Rothera dry lab container nr. 81
Form
Drawn by
Scale
Checked by
-----
Date
10-3-2011
Drawingnr.
Sht.