Rothera Container 82 DSF Clean Lab British Antarctic Survey In partnership with Royal Netherlands Institute for Sea Research Manufacturer: JM Services Date: 21-12-2011
Table of Contents Chapter Page 1. Container design 2 2. Heat pump installation 3-5 3. Laboratory 6 4. Ventilation 7 5. Control cabinet 8, 9 6. Touch screen display 10, 11 7. Usable conditions 12 8. Specifications 12 9. Maintenance 13-18 10. Malfunctions 19-21 11. Settings 22 12. Drawings 24-26 1
Container design Container 82 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. This container is a special clean laboratory and free of untreated metals to shut out measurement imperfections. The container has been provided with an air recirculation system. The recirculating air flows through the bag filters (F7) via the recirculation fan laminar through the HEPA filters (H14). When the laboratory lighting is switched on the air recirculation is 800 m 3 per hour. When the laboratory lights are off the air recirculation is 400 m 3 per hour. Besides the air recirculation there is a continuously air refreshing, because of the fume cupboard. 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 400m 3 per hour till the CO 2 percentage will descend below 1000 p.p.m. Below this value the ventilation automatically decrease to the minimum of 150 m 3 per hour. If the fume cupboard is switched on by switch 14S16, the refreshing ventilation will increases to 400m 3 per hour. When the laboratory lights are switched off, the ventilation decreases to the minimum of 150 m 3 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. Two Spectrolab-Plus valves are mounted on the wall 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. 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 m 3 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 m 3 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 m 3 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. 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 clean room filters. The acclimated supply air flows through the bag filters (F7) via the recirculation fan laminar through the HEPA filters (H14). The air (800 m 3 per hour) circulates via the coves besides the control cabinet and the fume cupboard to the filters again. The airflows are controlled by air speed transmitters which controls the fans 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 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: + 5ºC / -25 ºC Outdoor relative humidity: 0 % / 90 % Laboratory temperature: + 15ºC / +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: NIOZ Manufacturer: JM Services Container number: NIOU 000082-8 Clean Lab Container dimensions (mm): 6058 x 2438 x 2591 Container tare weight (kg): 6200 Allowable stacking weight (kg) : 192000 Next container inspection: 01/2016 Refrigerant: R507a 10.0 kg Required electrical power (front niche): 3 x 400V 25 A Data communication connection (front niche): 2 x RJ 45 Fire alarm connection (front niche): Direct connection Water pipe connection H2O (front niche): ½ internal thread DIN 2986 Nitrogen pipe connection N2 (front niche): ½ internal thread DIN 2986 Drain pipe connection (front niche): 1½ external thread DIN 2986 Earth connection (front niche): M10 bolt Cable conduit screw cap internal Ø (front niche): 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 Maintenance Details interval / Visual check Air filter G4 (supply air) 1x Half-yearly Replace if it is dirty (max. life time is a half year) Air bag filter F7 (supply air / Half-yearly Replace by opening the shaft doors recirculation air) 3x Air filter H14 (clean room) 5x Yearly Replace with a 10 mm screwdriver/ring spanner Air pre-filter F4 (laminar cabinet) 2x Yearly At the top of the laminar flow cabinet Air filter H14 (laminar cabinet) 1x After 30 Replace in combination with seal months Fluid pressure heating system Weekly About 2 bar (20 ºC) Fluid pressure heat recovery system Weekly About 2 bar (20 ºC) Oil level compressor Weekly ¼ - ¾ of the compressor sight glass Icing in cooler (outdoor roof niche) Daily The cooler fins should be free of ice General inspection Daily Visual Replacing air filter When the air filter is dirty it has to be replaced. It is not necessary to stop the ventilation. The air filter has to be replaced each half year. 1. Unscrew the nuts of the supply ventilation door by the ring spanner (10 mm). 2. Fasten the door in open position by the nylon door fastener. 3. Pull the air filter out of the slides in a horizontal movement. 4. Push a new air filter into the slides. Be sure the airflow arrow points at the supply fan! 5. Close the door and screw on the nuts carefully. 13
Replacing laboratory clean room filters The lifetime of the filters depends on the measure of pollution. To ensure a clean laboratory air an exchange interval is advised. Pre-filter F7 The three pre-filters should be replaced every six months. Open the shaft doors and replace the bag filters. Place the filter bags in a vertical position. Clean room filter H14 The five clean room absolute filters has to be replaced yearly. To exchange the absolute filters remove the plastic nut covers and unfasten the stainless steel nuts with a 10 mm screwdriver or ring spanner. Replace a new filter in the centre of the shaft and fasten the nuts carefully. Replace the plastic covers. 14
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). 15
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. 16
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 system 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. 17
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. 18
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: Solution: Installation blocked 1 Reset button blocked The reset button has been pressed for more than 20 seconds. Reset by touch screen parameters. 2 Compressor inverter 3 Compressor thermistor 4 Compressor high/low pressure 5 Compressor low oil-level 6 Compressor oillevel detector 7 Discharge pipe temperature high The inverter generates a fault. Compressor coil overheated (130ºC). The pressostat is switched off by a high or low refrigerant pressure. The oil level of the compressor carter is critically low. The oil-level detector at the back of the compressor is disconnected. 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. Contact JM Services. The Danfoss display LCP 2800 shows a fault. Reset by reset button on the Danfoss display. 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. Check the buffer stock vessel temperature probe. 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. 19
Fault name: Description: Solution: Installation blocked The suction pressure of the compressor is too low. 10 Low suction pressure 11 High discharge pressure The compressor discharge pressure is too high (60 ºC). 12 Air filter dirty The supply air filter is dirty (air pressure difference 170 Pa) 13 Supply fan The supply fan current exceeds the thermal limit of the fuse (6A). 14 Exhaust fan thermal 15 Cooler fans thermal 16 Max. defrost time exceeded 17 Phase (sequence) incorrect The exhaust fan current exceeds the limit of the fuse (6A). The cooler fans current exceeds the limit of the fuse (1.3A) The outdoor cooler defrost exceeds the maximum defrost time (45min.) The phase sequence relay is switched off. Check the refrigerant level in the sight glass of the liquid line during operation. The sight glass has to be filled completely. Check the buffer stock vessel probe (maximum 45 ºC). (Check for closed screw/ball valves). Replace air filter. Check the fan for mechanical blockage. Check the fan for mechanical blockage. Check the inverter in the technical room. Check the fan for mechanical blockage by ice. Check the cooler fins on ice. Check the defrost probes in the cooler body. Check the defrost valve. 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. 18 Main pump heating system thermal 19 Recirculation fan thermal The main pump current exceeds the limit of the fuse (6A). The recirculation fan generates a malfunction. Check the main pump for mechanical blockage (by unscrewing pump lid). Reset by fuse 5F15. 20
Fault name: Description: Solution: Installation blocked 20 Low temp. buffer stock heating The buffer stock temperature is critically low (-25 ºC). Check the whole installation for malfunctions. 21 Pump heat recovery thermal 22 Pump floor heating thermal 23 Low fluid pressure heating system 24 Low fluid pressure heat recovery system 25 Tracing water pipe thermal 26 Frost danger water pipe 27 High temperature technical room 28 Comm. fault expansion: Restart! The pump current exceeds the limit of the fuse (6A). The pump current exceeds the limit of the fuse (6A). The fluid (glycol mixture) pressure of the heating system is critically low. The fluid (glycol mixture) pressure of the heating system is critically low. The tracing current exceeds the limit of the fuse (6A). The water pipe temperature is critically low (2 ºC) The technical room temperature is critically high (45 ºC). The extension of the controller has lost communication with the plant controller. Check the main pump for mechanical blockage (by unscrewing pump lid). Check the main pump for mechanical blockage (by unscrew pump lid). Check the installation for leakage. Refill only with Ethylene Glycol 40% / 60% water. Check the installation for leakage. Refill with Ethylene Glycol 40% / 60% water only. Check the water pipe tracing for mechanical damage. (Check the insulated end of the tracing line). Check the water pipe tracing. Check the cause of heating in the technical room. Restart the installation by switching the control power fuse. 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. 21
Settings The settings of the components in the installation have been adjusted accurately. Below a table of the component settings. Component: Value(s): Details: 1 Phase sequence relay 400V / 8 sec. / 10% 7X2 2 Main fuse outdoor cooler fans 1.3A 5F3 3 Thermostat heating cabinet 20 ºC 21S17 4 Cooler drain tracing delay 5 min. 12K7 5 Netgear router IP-address: 192.168.1.1 Username: admin Password: password 6 Module ID of controller extension 1 15X3 7 Plant / Extension controller term Y Resistance 120 Ω 8 Plant controller direct log in IP-address: 10.255.255.254 12X3 (10X3) Username: install Password: 1234 9 LP / HP LP:1bar / Diff:1bar / HP:30bar 18X6-2 10 Fluid overpressure valve 0.4 bar 11 Heat recovery pump Speed 1 (slow) 6M6 12 Main pump heating system Speed 2 (middle) 6M3 13 Floor heating pump Speed 2 (middle) 6M8 14 Control valve floor heating Position 1.8 TA ½ 15 Control valve heating Position 2.6 TA ½ 16 Control valve defrost Position 3.0 TA ¾ 17 Control valve bypass heating Position 1.9 TA ½ 18 Compressor inverter ramp up speed 5.0 sec. AKD2800 19 Exhaust fan inverter 01: 0 Hz 02: 50 Hz 05: Al.AV 06: 0.43 A 07: 1435 rpm 08: 400 V 16: Volt 22: A 20 3-way valve heating Linear flow C-B 19Y11 21 Filter differential pressure transmitter DIP switch 1: ON 13R18 DIP switch 2: OFF DIP switch 4: OFF DIP switch 6: OFF 22 2-way valve floor heating 100% 0% <= 19Y13 0 10V 23 Air velocity meters Jumper 15m/s 13R13 / 13R15 22