Operating Instructions Electrical Glycol Heating for Tank Container
Contents
1. 6 pipelegs can be operated using our glycol heating system Using a suitable arrangement of stop valves either steam or glycol operation is possible Continous maintenance is essentially important for proper and safe operation Considering this advise can decrease running costs and improve durableness 2 Design The electrical glycol heating is a closed practically non pressurised heating system The heat transfer medium is a water glycol mixture 100 glycol Heater pump and monitoring equipment are accommodated in a stainless steel housing mounted at the side on the container The electrical control and regulating units are mounted in a supplementary robust splash proof insulating housing The transparent plastic expansion tanks should be placed as high as possible but at least above the highest steam pocket Tank brackets and retaining straps are supplied separately The mains connection is effected via a cable TPR F 4G4 mm or H07 RN F 4G4 for heavy duty with a CEE connector 5x32A 6h 4x32A 3h container version Feed and return flow have 32mm hose connections The circuit diagram consists of a durable self adhesive plastic foil which is mounted in the housing lid page 2 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 EMAIL loebbeGfwloebbe de heating fwloebbe de GT FRIEDRICH VY IOBBE GMBH ROSI2. sensor FSL Boundary alarm Temperature low look at parameter P30 P31 P32 actual value P30 A30 A31 F3H Boundary alarm Temperature look at parameter P30 P31 P32 high actual value gt P31 A30 A31 F3 Range alarm Temperature in look at parameter P30 P31 P32 between boundaries A30 A31 P30 Istwert P31 Keyboard lock active look at parameter P19 bzw A19 EP lost of data in EE Prom If by switching the line voltage Kontakt K1 and K2 are off off on the error is still present gt repair of controller If an error is located in EEprom Display EP and in that case the stored parameters could not be used the controler contacts are switched off L BBE DA page 8 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 EMAIL loebbeGfwloebbe de heating fwloebbe de GT FRIEDRICH VV IOBBE GMBH POSTFACH 10 1032 e 52010 AACHEN S3 Overheating thermostats Electronic temperature limiter with PT100 The sensor is attached inside the heater element the thermostat is mounted below the transparent covering of the terminal box in the heater housing set at 105 C 140 C and must not be readjusted If the temperature is reached the heating incl the pump shuts off After elemination of the fault witch causes the overheating the heating unit can be restarted by pushing the reset button
3. 241 174528 EMAIL loebbe fwloebbe de heating fwloebbe de GT Second control level P Parameters Simultaneously pressing the UP and DOWN key for at least 4 seconds opens a parameter list containing control parameters starting at parameter P2 With the UP and DOWN keys the list can be scrolled in both directions Pressing the SET key will give you the value of the respective parameter Pressing also the UP or DOWN key at the same time the value can be adjusted Release the UP or DOWN button before releasing the SET button and the new value is saved into the non volatile memory Return to the initial position takes place automatically if no key is pressed for 60 seconds or by simultaneously pressing the UP and DOWN key for approx 4 seconds Parameter Function adjustable Standard Customer Range setting setting P2 Hysteresys K1 0 1 99 9K 1 0K 1K S1 3K S2 P4 Control range limitation 99 C P5 99 C 0 C minimum setpoint PS Control range limitation P4 999 C 999 C 50 C maximum setpoint P6 Actual Value Correction 20 0K 20 0K 0 0K 6 0K S1 0 5K S2 page 6 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 EMAIL loebbeGfwloebbe de heating fwloebbe de GT FRIEDRICH VY IOBBE GMBH ROSTRACH 10 1032 e 52010 AACHEN Third control level A
4. GT 4 Service and Adjustment The controler for pre flow and product temperature are in normal operation mode for the user The displays and control elements are shown below 24V Description UP key By pressing this key the parameter or parameter value is increased SET key The display normally shows the actual value When the SET key is pressed the display changes to show the control setpoint DOWN Key By pressing this key the parameter or parameter value is decreased page 4 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 FRIEDRICH W ORBE GMBH e ROSTPACH 10 1032 e 52010 AACHEN EMAIL loebbe hwloebbe de heating fwloebbe de GT Menue level First control level After doing a short self test the thermostats show the actual value Pushing the SET button the display switches from current value to setpoint To adjust setpoint keep SET button pressed and change setpoint with up and down button After reaching new setpoint release buttons and new setpoint will be stored in non fluctuating memory The up down button have to be realesed always first This so called two finger operation will avoid the user from changing setpoint uncontroled page 5 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0
5. LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 FREDRICH VV IORBE GMBH e POSIPACH 10 1032 e 52010 AACHE EMAIL le yebbe fwloebbe de heating fwloebbe de GT Operating Instructions Electrical Glycol Heating for Tank Container Content 1 General Description 2 Design 3 Mode of Operation 4 Service and Adjustment 5 Fault Diagnosis 6 Diagrammatic Section 7 Circuit Diagram 8 Parts List 9 Technical Data page 1 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 M yebbeGlwloebbe de FREDRICH WW IOBBE GMBH POSTFACH 10 10 32 52010 AACHEN EMAIL loebbe fwloebbe d heating fwloebbe de GT 1 General Description 1 1 Field of Application The glycol heating which we have developed covers the requirements of approx 90 of all container tank heating systems since the temperature range of most heating media is 20 C to 90 C 120 C The maximum contact temperature of tank wall to the product can never be higher than that of the flow temperature which can be adjusted to 105 C 140 C maximum The standard heating medium 60 40 water glycol has an temperature operating range of 20 95 C 10096 glycol max operating range 5 125 C The largest part of all container tanks which have more than
6. OSIPACH 10 10 32 e 52010 AACHEN heating fwloebbe de GT 5 Fault Diagnosis Warning Remove mains plug prior to opening the electrical switch box 5 1 Control light H1 POWER ON does not illuminate Test whether CEE connector plug is correctly plugged in Test whether mains voltage is available Test whether control fuses F2 F4 are switched on 5 2 Illuminated push button S5 H2 bertemperatur OVERTEMPERATURE illuminates Limiter has switched Proof heating fluid level in the expansion vessel If necessary fill up with glycol Loose possibly blocked pump 5 3 Control light H3 St rung Pumpe PUMP FAULT illuminates Motor protective switch F5 has triggered Loose possibly locked pump Reconnect motor protective switch F5 in on position 5 4 Control light H4 St rung Heizung HEATER FAULT illuminates Power switch F1 has triggered Check heating element and reset power switch F1 5 5 Control light H5 Heizung Ein HEATER ON does not light up although the product temperature is set lower than at the product thermostat S1 Flow thermostat S2 is set too low Flow thermostat S2 should be set approximately 10 C higher than product thermostat S1 page 11 13 FREDRICH VV IORBE GMBH POSTFACH 10 1032 e 5201 heatin 6 Diagrammatic Section 1 Product thermostat S1 2 Expansion tank 3 3 way valve 4 Limiter S3 5 Flow thermostat S2 6 Heater 7 Pump 8 Electr
7. Operation devices and messages H1 Signal light white Netz Ein POWER ON PRODUCT TEMPERATURE PREELOW TEMPERATURE H3 Signal light red St rung Pumpe PUMP FAULT H4 Signal light red St rung Heizstab HEATER FAULT H5 Signal light white Heizung Ein HEATER ON b oO H7 h b 000000 h H6 Signal light white HEAT U Pumpe Ein PUMP ON OVERTEMPERATURE PUMP HEATER POWER PUMP HEATER RESET FAULT FAULT ON ON ON H7 Hours counter x Pumpzeit PUMP TIME E H3 H4 5 AS 15 H8 Hours counter FI FZNES FA UR HEATER TRANSF CONTROL PUMP HEATING Heizzeit HEATING TIME o o o g OFESON A S1 Temperature controller o 13 GGA Produkt Product Thermostat o vo oo e S2 Temperature controller L BBE HEATING SYSTEMS Vorlauf Preflow Thermostat S4 Selector switch Heizung AUS EIN Heating OFF ON S5 H2 Illuminated push button red bertemp Reset OVERTEMP RESET page 9 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 ES RT TIE Sox SEIT ACTES EMAIL loebbeGfwloebbe de heating fwloebbe de GT 4 1 Initial Operation Prior to the initial operation the system must be filled with glycol mono or 1 2 polypropylene glycol This is achieved by removing the blanking plug at the expansion tank and by filling the system using a 3 way ball valve u
8. PACH 10 1032 e 52010 AACHEN 3 Mode of Operation After starting up of the heating system a stainless steel circulating pump maintains the glycol circulation Three thermostats provide safe temperature control 1 Product thermostat S1 Electronic industrial controler with digital display Measuring input resistant thermometer PT 100 Input range 0 90 C 120 C Output relay The resistant thermometer could be mounted on the tank wall or put into a diving tube witch is placed in the product 2 Flow thermostat S2 Electronic industrial controler with digital display Measuring input resistant thermometer PT 100 Input range 0 95 C 125 C Output relay 3 Overheating thermostat S3 Electronic temperature limiter 0 200 C set to 105 C 140 C If the product temperature falls below the temperature set at the product thermostat the heating switches on and off again when the flow or product temperature is exceeded The continuous delivery by the recirculating pump prevents an accumulation of hot spots and ensures even heat distribution The overheating thermostat protects the system from overheating at 105 C 140 C and is released via a reset key page 3 13 LOBBE cw SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 FRIEDRICH W L BBE GMBH POSTFACH 10 1032 e 52010 AACHEN EMAIL loebbe fwloebbe de heating fwloebbe de
9. ical control unit 9 Mains supply Tankcontainer fwloebbe de LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 1 TELEFAX 0241 EMAIL loebbe hwloebbe de GT page 12 13 FRIEDRICH VV IOBBE GMBH POSTFACH 10 1032 e 9 Technical Data Dimensions Weight Connecting voltage Heating output Recirculating pump Current consumption Glycol feed and return flow ca LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 EMAIL loebba fwloebbe de fwloebbe de GT 52010 AACHEN heatin Lx WxH 1500 x 285 x 200 mm heater box Lx W x H 300 x 600 x 140 mm control box ap 75 kg 3 x 440 V 60Hz 5 10 3x400V 50Hz 10 10 via CEE connector 5 x 32 A 6h 4 x 32 A 3h 12000 W at 440 V 60 Hz 9900 W at 400 V 50 Hz 195 W ap 0 9 A 15 8 A at 440 V 60 Hz 14 5A at 400 V 50 Hz 32mm hose connection page 13 13
10. level Access to the third control level is granted when selecting the last P parameter on the second control level Continue to press the UP key for approximately 10 seconds until PA appears Continue to press the UP key and additionally press the DOWN key for about 4 seconds and the first A parameter of the third control level is indicated With the keys UP and DOWN you can scroll the list in both directions Pressing the SET key will give you the value of the respective parameter By pressing the UP or DOWN key at the same time the value can be adjusted Return to the initial position takes place automatically if no key is pressed for 60 seconds or by simultaneously pressing the UP and DOWN key for approx 4 seconds Parameter Function adjustable Range Standard Customer setting setting A1 Switch mode K1 0 heating contact at Pt100 0 0 1 cooling contact 2 function alarm K1 3 function alarm K1 inverted A8 Display mode 0 integrals 1 decimals in 0 5 C 1 0 2 decimals in 0 1 C page 7 13 FRIEDRICH VV IOBBE GMBH POSTFACH 10 1032 e 52010 AACHEN LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 EMAIL loebbe fwloebbe de heating fwloebbe de GT Status display error codes Display Error What to do F1L sensor short circuit new sensor F1H sensor failure new
11. ntil the fluid becomes visible in the expansion tank Prior to switching the heating on the product thermostat S1 should be set to its minimum value and then the heater off on switch S4 switched on so that the recirculating pump vents the system without switching on the heating element and so avoid overheating If necessary top up with fluid during venting Lift container at least 3 to 4 times at the front and back by about 30 cm so that the air can escape from the steam halves of the tubes Refit the blanking plug 4 2 Heating Operation 4 2 1 Check heating fluid in expansion vessel must be visible 4 2 2 Set product thermostat S1 to required product temperature 4 2 3 Set flow thermostat S2 at least 10 C higher than product thermostat 4 2 4 Plugin CEE connector plug The control light H1 power on must illuminate 4 2 5 Switch on switch S4 Heizung Aus Halbe Volle Leistung heating off half fullpower The control light H6 Pumpe Ein PUMP ON illuminate the recirculating pump run 4 2 6 If the product temperature is lower than the temperature set at the product thermostat S1 the heating switches on the control light H5 Heizung Ein HEATER ON must illuminate page 10 13 co LOBBE SCHALTANLAGEN UND INDUSTRIEELEKTRONIK URSFELD 16 e 52072 AACHEN POSTFACH 101032 e 52010 AACHEN TELEFON 0241 171011 TELEFAX 0241 174528 EMAIL loebbeGfwloebbe de FRIEDRICH VY IOBBE GMBH R
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