MDRS HAB Operations Manual - Version 8.9

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If you have any doubts about ANYTHING to do with the Inverter Battery Pack system, contact Mission Support immediately with a message for ET folks before making any changes to its settings.

2. Dynasty Battery Banks

Description

There are two banks of 12 rechargeable 24volt Dynasty industrial grade batteries on a pallet underneath the centre of the HAB itself. These batteries are the HAB's primary source of electrical energy.

Specifications

These batteries are hooked up in parallel to produce 24volts DC per side at very high amperage. Do NOT Attempt any unauthorized work on these batteries. WARNING: The level of amperage in this part of the system Will Kill you if you do not know precisely what you are doing.

Usage - Battery Banks

WARNING: The Dynasty Battery Banks are designated a Hazardous Operation Location. By their design, there is NO crew need to interact with the battery banks. No work should be attempted on the Battery Banks unless Don Foutz is present to supervise or you are an authorized by Paul Graham or James Harris to do something on them for the Engineering Team. They function under the management of the Xantrex Inverter. Any and all engineering work on the Battery Banks and all operations relating to the Battery Banks are to be conducted “OUT OF SIM”. A Reminder: All out of sim operations are accessed via the rear air lock to keep the EVA Prep Room clean for the next "in-sim" EVA.

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3. Main Generator

Description

"Casper and Wendy" are actually the gigantic 450kg "Onan MEP-002A" military surplus power generators, the first of which, “Casper”, was deployed to MDRS during Crew 37's rotation in March of 2005. The first one on site was promptly christened "Casper" because of its all white colour and the fact it's as quiet as a ghost (when compared to the noisy portables gasoline fueled generators previously used). It's identical twin sister arrive in January of 2006 to take over from "Casper" while he went off site for maintenance. This second Onan was promptly christened "Wendy". Thus the "Onan MEP-002A" generators will be referred to as "Casper or Wendy", depending on which one is currently deployed in ALL communications.

The generator stand is located 55 meters south of the HAB (bearing 180’) in the new Engineering Area behind the south ridge and is capable of being remotely monitored and controlled.

Specifications

"Casper and Wendy" are a diesel generators and uses diesel fuel only. The diesel fuel is stored in bulk in a large 500 US gallon tower tank 5 meters to the east of the generator stand. Fuel is fed directly to Onan's injector system which allows it to run non stop between oil changes if necessary. This eliminates the bane of pre-Crew 33 rotations of having to stop all operations to refuel the Gasoline generators by hand every 6 hours.

Casper and Wendy can continuously produce 5.0k Watts of 120volt 60Hrz AC electricity on demand from the Xantrex Inverter. It is capable of short periods of higher out output to meet peak consumption demands as it was manufactured to military specifications.

Usage of Casper or Wendy – Dip Stick Readings

CAUTION: These units are under the remote control of the Xantrex Inverter Control Module and my start up at ANY TIME without warning. They are in the Engineering Area which is considered a Hazardous Operations Location, and all operations relating to the generators are to be conducted “OUT OF SIM”. As with all out of sim operations, access is the north or rear air lock to keep the EVA Prep Room clean for the next EVA.

Daily Oil Level Reading: As the oil level needs to be checked daily by the Crew Engineer, it is suggested that this reading be taken just after a Battery Bank recharge session has been completed. Before heading out to take this Oil Level reading, the Crew Engineer must Deactivate the "Auto Start" function of the Xantrex Inverter Control Module. While out taking the Oil Level reading the Crew Engineer must also write down the Hobbs meter reading. Upon returning to the HAB the Crew Engineer MUST Reactivate the "Auto Start" function of the Xantrex Inverter Control Module before doing anything else.

The Crew Engineer is required to record the Oil Level and Hobbs meter reading of the on site Onan generator in his Daily Engineering Log for transmission to Mission Support each day when the comm.'s window opens up at 19:00 Mountain Time.

Weekly (or more often if the weather is damp, raining, snowing or the temperature is widely fluctuating.) the fuel system water sumps should be drained. There are five water drains to be bled, found in three locations.

They are located as follows; one on the outlet of the large diesel tower tank filter, three on the triple bank fuel filters, and finally a single underneath the Onan's own white onboard fuel tank.. See images below.

Oil changes are done by Don Foutz, TMS's Local Contact in Hanksville, every 100 hours of operation. It is the Hobbs meter readings you send up to Mission Support every evening that lets the ET calculate when to send Don out to do an oil change.

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4. Secondary Backup Generator – The Gasoline Fueled Generator

Description

THE GASOLINE (PETROL) FUELED GENSET IS ONLY TO BE USED AS A LAST RESORT, IN THE MOST EXTREME DIRE EMERGENCIES, when the inverter battery packs are dead, Casper has blown up, the Yanmar will not start and the HABComm UPS is about to fail. The Gasoline Fuel Back Up Genset has destroyed equipment in the past by being under load during start up attempts and during the post start up warming up period.

Always, always, always isolate this GenSet from the HAB power feed prior to attempting to start it up and until 5 minutes after starting it have passed, to give it time to warm up and stabilize the voltage.

The Back Up Genset is located 55 meters south of the HAB (bearing 180’) in the new Engineering Area behind the south ridge. It is considered a hazardous operations location, and all operations relating to the generators are to be conducted “OUT OF SIM”. All out of sim operations are accessed via the rear air lock to keep the EVA Prep Room clean for the next EVA.

The Back Up Genset is a gasoline (petrol) generator and runs off gasoline (petrol) fuel only. The gasoline fuel is stored in 5 gallon red plastic "Gerry Cans" on the water transport tank trailer.

Specifications

Specifications for the Back Up Genset are not yet available at the time of the Version 8.7 updating.

Usage - Gasoline Fueled Back Up Genset

WARNING: Starting the Back Up GenSet under load WILL destroy the control systems of the inverter battery packs in the HAB leaving you without ANY electricity what so ever. So ALWAYS Isolate this GenSet before starting it up and keep it isolated for five minutes post startup for a warming up period.

Instructions for starting up the gasoline generator are in the MDRS HAB Engineering Procedures Manual Version 2.2 .

Caution: The Back Up Genset burns about 200ml of engine oil every eight (8) hours. You must pull the dip stick and visually check the amount of engine oil in Gasoline Fuel Back Up Genset every time you refuel it. You must top up the Back Up Genset’s engine oil at every refueling or the low oil sensor will shut the engine down automatically about 4 to 6 hours later. The oil is changed by Don Foutz of the Whispering Sands Motel in Hanksville every 4 days of its use.

You must notify Mission Support and the Engineering Team Coordinator (via e-mail and IM from the HABComm computer) every time you start up the Back Up Genset for power generation. Also notify Mission Support of the total number of hours that you did use the Back Up Genset generator for each time it is used. This is so that after 96 total hours of operation (4 days) Don Foutz knows to come and change its oil.

Photos and/or diagrams of operating switches and control locations for the Gasoline generator are not yet available at the time of the Version 8.7 update.

5. Circuit Breakers.

The breaker box is located on the first floor of the HAB, to the left of the tool bench. Breakers are installed in positions 1-20, 22, 27 and 29, for a total of 21. Breakers 27 and 29 are the Master Inputs, and can be used to shut off HAB power without turning off the Xantrex Inverter. All the circuits’ breakers are below, according to their actual positions in the breaker box, reading Top to Bottom:

#	Circuit Description	Amps	Pole	Amps	Circuit Description	#
1	Lab Lights	?	R	?	Upper Deck , Overhead Lights	2
3	Bath Room and EVA Prep Room Lights	?	L	?	SR Light	4
5	Engineering Circuit	?	R	?	U1 - HABComm	6
7	Science 02 Circuit	?	L	?	U2 – Galley (Kitchen)	8
9	Science 01 Circuit	?	R	?	U3 – Computer Command Desk	10
11	EVA Prep Room Circuit	?	L	?	U4 Circuit	12
13	Bathroom Circuit	?	R	?	U5 Circuit	14
15	Mush Observatory Circuit	?	L	?	U6 Circuit	16
17	External A – 240 volts – Paired with CB 19	?	R	?	LP Gas Furnace	18
19	External B – 240 volts - Paired with CB 17	?	L	?	GH – Kitchen ??	20
21	Not in Use, expansion slot	?	R	?	Spare	22
23	Not in Use, expansion slot	?	L	?	Not in Use, expansion slot	24
25	Not in Use, expansion slot	?	R	?	Not in Use, expansion slot	26
27	MAIN INPUT	?	L	?	Not in Use, expansion slot	28
29	MAIN INPUT	?	R	?	Not in Use, expansion slot	30

6. Batteries for Portable For Devices

The Mars Society does not supply batteries for crew member's personal electronic equipment. If you are bringing a laptop, GPS, electronic camera, you must bring along a supply of batteries to meet your own needs for at least 16 days.

For HAB radios and HAB portable electronic devices there are new batteries of all types to be found in a drawer on the first floor of the HAB in the laboratory, and also in the EVA room. Used batteries should not be put in the trash after being used, for environmental reasons. There is a container on the shelf in the EVA room on the first floor to collect dead batteries. Anyone who is driving home after a rotation should take the batteries and dispose of them properly.

III. Operations

1. Switching to the Backup Generator

With the Crew 34 refit it is not longer required to transfer power cables from one generator to the other. All that must be done is to throw the switch on the Change over box located between the two generators. So to move power from Casper or Wendy over to the Back Up Genset:

1. Start the Generator that is about to take over the electricity production duty, BUT DO NOT TURN THE POWER Switch to ON YET! Let it warm up for five minutes as timed by a watch or clock.

2. Notify the HAB that power is ready to be switched over NOW and WAIT until someone reports they are standing by at the Xantrex Inverter ready to report to you with the voltage readout. Now on the GenSet being taken off line, switch its AC output switch to the Off Position.

3. Throw the vertical switch on the power transfer box to the position of the Generator you now want to feed power to the HAB. See Image at right.

4. Turn on the Power Switch of the Generator you now want to feed power to the HAB.

5. Call HAB on radio and confirm power is restored. Now shut down the other Generator.

2. Killing Power

There are two methods to shut off power:

1. QUICKEST! Flip both MAIN INPUT breakers (in the breaker box by the tool bench) to the LEFT. Warning! The Xantrex Inverter and the Dynasty Battery Banks will still be "LIVE" and capable of delivering a killer electric shock at high amperage.

2. No Panic or Rush Shutdown! On Xantrex Inverter Control Module, shut off the Xantrex Inverter. This will cut power to the HAB and stop the charging of the Dynasty Battery Banks. Now the only possible "LIVE" circuit would be the underground feed cables from the generators in the Engineering Area that bring power to the Xantrex Inverter. NOTE: Because the Xantrex Inverter is now the primary power producer for the HAB, moving the AC Power switch in on the generator running to the OFF position WILL NOT necessarily cause the power to go off in the HAB.

Shut Down A Generator

To immediately shut down a generator at the GenSet itself,

1. Throw the power supply switch on the Dessco Box to the OFF position

2. Then depending on the generator you are shutting down either:

   1. depress the STOP lever

   2. turn the "On/Off" switch to the Off position,

   3. or turn the key to the OFF position.

Caution: Unless you have thrown the power switch to the Off position, the GenSet will supply power for a few more seconds from fly wheel momentum as it slows to a stop. The wild voltage and frequency oscillations during this period can destroy the Xantrex Inverter. Remember: If you break it, you will pay for a new one.

3. Daily Maintenance

Oil change operations are performed by Don Foutz, of the Whispering Sands Motel in Hanksville every four days. Do remember that the oil in the Back Up Gasoline fueled Genset must be topped up at every refuel as well as Don doing an oil change every 4 days. This Daily Maintenance is to be done by the Crew Chief Engineer.

Starting Up A GenSet

Precautions To Take Before Starting a GenSet

1. Before you start any GenSet, you need to make sure that the oil, coolant (for Casper and Wendy, the Onan’s) and Fuel are full, and the air filters are clean (enough).

2. CAUTION ! Do NOT Attempt to electrically start any Generator if the onboard Battery Power Gauge is NOT in the Green Arc. You WILL do Serious Damage to it's starter motor if you try starting it with the Battery Gauge's needle indicating in the Yellow or the Red parts of the gauge..

3. You need to make sure that the Dessco Power Supply switch box in Engineering has the correct GenSet selected. (See Image previous page.)

4. Lastly, You need to make sure that HAB is capable of taking power. (all breakers are in the correct positions).

5. Make sure no one might be handling live equipment.

6. Make sure no one might be handling what might become live equipment.

(Note, Casper and Wendy are the only GenSet’s that we have capable of starting under load.)

Starting Up The Casper or Wendy Primary GenSet’s

This should be an automatic process. If for whatever reason you need to start Casper or Wendy manually, follow either of the below procedures.

From Within The HAB, Manually Starting an Onan,

From the Xantrex Inverter panel, after completing the above pre-start checklist,

1. Press the green “GEN” button until ON is selected.

1 a. This starts a sequence where the following happens

1 b. Casper's glow plugs will light for one minute.

1 c. The generator will crank for up to 60 seconds. The Generator will probably start in 5 to 15 seconds, the extra crank time is NOT harmful, and is required to energize the field coils and “activate” the generator proper. See section on Manual Start from the GenSet's manual.

1 d. Once the Xantrex Inverter detects that power is present, it waits for one minute before actually drawing power.

2. During this time you should audibly check to make certain that Casper or Wendy has actually started. If not, go to the STOP procedure wait one minute. Retry the Start. IF it does not start again, you will need to go out and initiate troubleshooting procedures.

2 a. This is Warm up time to help with GenSet longevity, and part of the reason that it can be started under load.

After the above sequence has occurred you should see usable power from the GenSet.

3. Make sure the power is at 117 VAC +- 2 VAC on each leg. (Currently there is only one leg.)

If not, adjust the “VOLTAGE ADJUST” control on Casper's main panel until the correct voltage is displayed in the “A.C. VOLTS” gauge.

From Within The HAB, Manually Stopping an Onan,

A reverse of the above procedure;

1. Press the green “GEN” button until OFF is selected.

1 a. This starts a sequence where the following happens

1 b. The Xantrex Inverter removes it's loads.

1 c. Casper returns to idle for two minutes.

1 d. Power is removed from the fuel pumps and Casper or Wendy dies. (Pun intended;)

You should wait for one minute before a restart is attempted.

From An Onan's Control Panel, Manual Starting

Before you start, tell everyone that you are about to start the GenSet, and they should remove their hands from things like potentially live equipment, blenders, mixers, saws and the like.

After completing the above pre-start checklist.

1. Turn “MASTER SWITCH” to the “PRE-HEAT” position. Hold for one minute. (If the GenSet has been run in the last 15 minutes and is warm, you can skip this step.)

2. Turn “MASTER SWITCH” to the "START” position. Hold for one minute, even after the Onan starts. This is required to energize the field coils. The starter motor will disengage as soon as the GenSet engine reaches 800 RPM, so no starter damage will occur. You should see the voltage climb up to the specified voltage at some point during this time. You may release the switch when this happens. (See Gauges Panel Diagram at right)

3. CAUTION: IF for some reason the Onan GenSet does not start in less than 15-20 seconds, you MUST STOP cranking. Do not continue to run the starter or you will over heat it and Severe damage to the starter motor will result.

4. If the GenSet does not start, you must wait at least two minutes before attempting another start to allow the starter motor to cool down. This is a general guideline, you should use your judgment, senses (Hand on starter, feeling for heat.) and situational awareness to determine run/rest cycles.

5. Turn the Master Switch to the correct run position. Normal run is in the “PRIME & RUN AUX FUEL” position. If for whatever reason the external tank is not available, the “PRIME & RUN” position should be used instead. This will require that you fill the “Day Tank” every eight to twelve hours (Center front with Green Label. See Image next page).

6. Make sure the power is at 117 VAC +- 2 VAC on each leg. (Currently there is only one leg.) If not, adjust the “VOLTAGE ADJUST” control on Casper's main panel until the correct voltage is displayed in the “A.C. VOLTS” gauge. (See Gauges Panel Image above right).

7. Check the oil pressure gauge located the North side of Casper, behind the panel, on the right side if you are standing facing the Control Panel. It is nearly underneath the air intake. (See Image at right). Also make sure the Dip Stick is locked in and not loose.

From An Onan’s Control Panel, Manual Shut Down

1. Remove loads. This can be achieved by either turning off the master breaker on the Genset, or switching the Descco main selector switch on the pole to the other position. Note: Do NOT do this if there is a generator running on the other circuit unless it has had time to warm up and is producing stable power.

2. Now Wait, Let Casper or Wendy idle and cool down for two to five minutes, depending on weather and load.

3. Turn Master switch to the “OFF” position. Internal Fuel Tank location image.

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Starting Up The Gasoline Fueled LAST RESORT Back Up Generator

Please DO NOT use the Gasoline Fuel Back Up Genset, except under the most extreme dire emergencies. (Like Casper or Wendy has blown up, the inverter batteries are dead, and the HABComm UPS is about to fail. We very am serious about this.) A Gasoline Fueled GenSet destroyed some very expensive equipment in 2005. Starting the Gasoline Fuel Back Up GenSet under load WILL destroy the control systems of the battery packs in the HAB leaving you without ANY electricity what so ever.

If you must use it, please follow these instructions very carefully.

1. Make absolutely certain that the Generator Select Switch (The big silver one on the pole between the two generators) is in the MAIN position. This is in the UPward position. If you are not absolutely certain that this is correct, unplug the Gasoline Fueled Genset plug.

2. Check the oil and Fuel on the Gasoline Fuel Back Up Genset. Ensure that both are topped up.

3. Start the Gasoline Fuel Back Up Genset per the manufacturer's instructions.

4. Wait 5 minutes (time it by clock or wrist watch, Do Not Guess) with the Gasoline Fuel Back Up Genset running to let it warm up and stabilize the voltage.

5. If you have a volt meter and know how to use it, check the output voltage. I check it in the switch box. (Currently the Gasoline Fuel Back Up GenSet plug is wired for 117 volts. NEVER put anything greater than 120 into the inverter.)

6. If you had to disconnect the plug, reconnect it now.

7. While someone is in front of the inverter, move the Generator select switch to Backup Generator. Stand by.

8. Have the inside helper check the voltage on the inverter. (It is surge voltage from the Gasoline Fuel Back Up Genset that damaged all of the equipment.)

9. If the voltages are stable and the inverter is charging, you may return to HAB and resume your normal duties.

10. Once the inverter has charged, you should shut down the Gasoline Fuel Back Up Genset.

11. To SHUTDOWN the Gasoline Fuel Back Up Genset, first throw the Dessco Generator Selector Switch from Stand By to Main (the UP position) on the pole between the two GenSets.

12. Then having isolated the Gasoline Fuel Back Up Genset from the HAB power feed, now shut off the Gasoline Fuel Back Up Genset

If you need to restart the Gasoline Fuel Back Up Genset you must follow this procedure completely from the beginning again, and every time this GenSet must be used. It is the start up surging and cold engine instability that caused all of the damage and destruction to some very sensitive electrical equipment.

A better backup power generation plan is being worked on. Paul Graham, ETC, April 9^th, 2005

IV. Troubleshooting

The electric start-up method on Back Up Genset or Onan does not work

1. Is the battery connected to the generator?

The battery should be on the side of the generator opposite the control panel. The two wires running from the generator on that side connect to the positive and negative terminals of the battery. The top wire (with the red stripe along the side) connects to the positive terminal; the bottom wire connects to the negative.

2. Is the battery drained?

A voltmeter may be used to test the charge in the battery. Do not use an ammeter, as the current will be high enough to fry circuitry if charge remains in the battery.

The manual start-up method does not work for gasoline fueled Back Up Genset

1. Are you pulling the starter cord hard enough or long enough?

Keep pulling. This process may be difficult.

If this does not work, and you have followed all the instructions in this manual, something may be wrong with the generator. A qualified engineer may inspect it, or contact Don Foutz.

Power is lost in the HAB

1. Has power been lost in one circuit?

Check the breaker box to see if a circuit breaker has been thrown.

If so, this circuit was overloaded. Unplug appliances until total Amps being pulled on this circuit is less than the Amp rating for the circuit.

2. Has power been lost throughout the HAB?

Check the Xantrex Inverter Control Panel to see why it has kicked off.

Check the DC voltage being put out by the Dynasty Battery Banks. If this has fallen below 22 volts you need to bring a GenSet on line immediately to recharge them.

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Water Maintenance and Control

I. Overview

Water control in the HAB is maintained by two systems: the potable to grey water system, and the black water or septic system. They are linked through the mechanism of the GreenHab.

The Potable Water Tank supplies the HAB with its freshwater for drinking and cleaning.

The External Pump sends water from the potable water tank in the Engineering Area via an underground water pipe to the second floor loft into the Internal Tank.

From there, some of water is directed through the Water Heater, and the cold water and hot water pipes. These both run to the upstairs and downstairs Sinks, and the resulting grey water is collected to a pipe exiting on the north side of the HAB and draining into the Settling Tank, which connects to the Grey Water Tank underground.

The Shower also receives water from the hot and cold water pipes and drains directly into a grey water line beneath the HAB. Any water that flows into the bathroom sink drains into this same line. This line exits from beneath the HAB by the Settling Tank, into which it drains.

The sediment in the grey water settles in the Settling Tank and the actual water flows into the grey water tank. It then travels underground into the GreenHab. The water here is treated and ends up in the Toilet Supply Tank (TST), from which water is pumped automatically into the Toilet Flush Tank when ever the toilet is flushed and the float valve falls into the open position. See “GreenHab Project, Ops and Procedure Guide.”

The normal toilet flushes into the larger pipe beneath the HAB which goes underground, also on the north side of the HAB. This drains into a septic tank, which leaches out into the leach field. The Incinolet toilet is no longer in use.

Diagrams of the Water Systems from two views follow:

View A - An Overhead View.

View B - A Cross Section Side View.

View A - Overhead View

View B - Cross Section Side View

II. Elements

1. Tanks

Descriptions

Water is stored externally in the Potable Water Tank, a permanent plastic storage tank located 70 meters south (bearing 180’) of the Hab in the Engineering area. It is in the same area as the trash cans and diesel fuel tank tower. It is filled by Don Foutz on an as needed basis with a portable tank on a trailer.

Water is stored internally in the Internal Tank, which is found in the loft above the second floor of the Hab above the door way of Stateroom 5.

Usage

The Potable Water Tank has a capacity of approximately 450 gallons or about 8 days of supply given a usage rate of about 6 gallons per person per day. Water is pumped through an insulated hose which is underground and feeds from the Engineering Area to the HAB and passes up the core of the HAB to the Internal Tank.

The Internal Tank has a capacity of approximately 60 gallons, but should not be filled beyond 55 gallons. There is a spillway to the rear of the tank, and so it is difficult to tell if the tank is overflowing. The Internal Tank can be accessed by climbing the vertical ladder fixed to the wall between Staterooms 5 & 6.

Water is gravity-fed from the Internal tank to the Hab Pressure Pump located above Stateroom 6, from which water is distributed to the rest of the Hab water systems.

2. Pumps

Descriptions

The External Pump is an ITT Jabsco Utility Puppy 3000 24V located inside a box on top of the outlet opening from the External Potable Water Tank, and pumps water the distance from the Engineering Area to the HAB’s Internal Tank. It is powered by 24VDC and can draw as much as 12A and can flow as much as 680 gph (2580 lph) at 10ft (3 m) total head.

The Hab Pressure Pump is a Flojet Sensor VSD Water System and is on the floor of the loft between the Internal Tank and the Water Heater. When activated, it pressures water to the right (i.e. the Water Heater side) for use in Hab systems. It is powered by 24VDC and can draw as much as 12A and can flow as much as 4.5 gpm (16.3 lpm) at 40psi (2.8 bar).

Usage

The External Pump is turned on and off by means of a switch located to immediately above and to the left of the kitchen sink right next to the Hot Water Tank Switch next to the Kitchen porthole. Before attempting to use this pump be sure to read the Operating Instructions and the Cautions in Refilling The Internal Tank.

The Hab Pressure Pump is turned on by means of a switch also on the edge of the loft, just past the top of the ladder on the right above stateroom 6. Once turned on the HAB Pressure Pump is hydrostatically activated when ever a water tap is turned on and pressure in the hot or cold water lines falls.

Both pumps are on the same fuse and are powered by the 24VDC Dynasty battery system.