Alarms
Alarms
Alarms
Product No.
Alfa Laval reserve the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Separation AB Marine & Power Oil Treatment Division S - 147 80 Tumba Sweden
Contents
1 2 3
3.1 3.2 3.3 3.4
1 3 5 5 6 7
4 5
5.1 5.2 5.3 5.4
25 27
27 28
28
8 8 9 10 11 12 13 14
29
3.5
3.6
17 17 18 19 20 21 22 23
1 Scope
The alarms, alarm tests and the test program are valid for the following separation systems: FOPX 605 FOPX 609 FOPX 610 FOPX 613
1 Scope
2 EPC Signs
The signs to the control unit for the FOPX separation systems are shown in this chapter.
Monitoring functions
P000891A
P000881A
2 EPC Signs
Output signals
Operating symbols
P000641A
P000991A
Alarms
If there is more than one alarm at the same time, the EPC-400 will display the alarm with the highest priority first and then the next alarm, and so on in priority order.
An activated alarm condition is identified either by an alarm LED (to the left in the picture) or an alarm code on the display together with the main alarm LED (to the right in the picture).
G0442011
3 Alarms
NOTE
Never return to the EPC-400 control unit to acknowledge or reset an alarm if it by any means can be hazardous.
G001647A
G001645A
3 Alarms
10
11
"Emergency Stop"
12
Vibrations (Option)
13
"Heater Fault"
14
High or Low Oil Temperature (Option) Temperature Sensor Error (Option) "Communication Error"
15
16
17
"Processor Fault"
18
"Programming Error"
19
"Power Failure"
20
"Temperature Deviation"
21
"ALCAP Alarms"
22
Other Alarms
23
3 Alarms
Corrective action Open or regulate RV4, or other valves, to correct back pressure, normally about 1.5 bar (150 kPa).
Automatic actions at alarm Main alarm flashes. Alarm diode (PS41) flashes. Change over valve (V1) is set for oil recirculation.
Automatic actions after alarm reset Main alarm off. Alarm diode off. V1 is set for oil feed to separator.
3 Alarms
Causes Too low oil feed. Strainer before the oil feed pump is clogged. Oil feed pump has stopped. Change over valve (V1) is in recirculation position.
Corrective actions Check the oil feed pump. Adjust the oil flow. Clean the strainer. Check the oil feed pump. 1. 2. 3. Check the air supply to the solenoid valve block air (MV1). Check MV1. Check V1.
Increase the back pressure with regulating valve RV4. The correct back pressure is normally about 1.5 bar (150 kPa). Check the opening water valve (MV15) for leakage. See Separator Manual. See Separator Manual.
Automatic actions at alarm Main alarm flashes. Alarm diode (PS42) flashes. V1 is set for oil recirculation.
Automatic actions after alarm reset Main alarm off. Alarm diode off. V1 is set for oil feed to separator.
3 Alarms
Causes No or very low opening water supply. Opening water valve (MV15) broken. No signal from low oil pressure switch (PS42) at discharge. Separator operating water system not working.
Corrective actions Check the water supply system. Check MV15. Check PS42. 1. 2. Check the separator by manually open MV15. Dismantle and check the operating water system. See Separator Manual.
N.B.
This alarm is activated after two attempts to discharge, within the same discharge cycle, have failed.
Automatic actions at alarm Main alarm flashes. Alarm diode flashes. The stop sequence is initiated.
Automatic actions after alarm reset Main alarm off. Alarm diode off. 1. If the power has been off during more than approximately 10 minutes the separator bowl must be stopped and manually cleaned before restart. The separator and the EPC program has to be restarted.
2.
10
3 Alarms
Causes Loose connection between transducer test circuit board and oscillator. Faulty oscillator unit or faulty EPC control module.
Corrective actions Check connections. Check supply voltage in the MT4 on terminal 3 - 4 (20 V DC). About every 5:th second the voltage at terminal 4 - 5 (20 VDC) will drop for approx. 0.5 second: If voltage drop: replace the oscillator unit.
If no voltage drop: replace the EPC control module. For more information about the interconnections, see System Reference.
Automatic actions at alarm Main alarm flashes. Alarm diode flashes. Change over valve (V1) is set for oil recirculation.
Automatic actions after alarm reset Main alarm off. Alarm diode off. V1 is set for oil feed to separator.
11
3 Alarms
Corrective actions 1. Remedy the cause why the emergency stop button was pushed and then reset it.
Automatic actions at alarm Main alarm flashes. Alarm diode flashes. The separator is stopped and the heater is off. Oil feed is on for further 3 minutes through the heater and separator. Bowl closing water supplied for 3 minutes.
Automatic action after alarm reset The alarm function can not be reset by pushing the alarm reset button. 1. 2. 3. Reset the alarm by switching the power off and on. Restart the separator. Restart the EPC program.
NOTE
The separator bowl must be manually cleaned before starting up again.
12
3 Alarms
Corrective actions Remedy the cause. See Separator Manual. Check the vibration switch setting.
Automatic actions at alarm Main alarm flashes. Alarm diode flashes. Separator is stopped. Oil feed is on for a further 3 minutes through the heater and separator. Bowl closing water supplied for 3 minutes.
Automatic action after alarm reset The alarm function can not be reset by pushing the alarm reset button. 1. 2. 3. Reset the alarm by switching the power off and on. Restart the separator. Restart the EPC program.
NOTE
The separator bowl must be manually cleaned before starting up again.
13
3 Alarms
N.B. Cause
Heater fault is only activated if the heater is controlled by the EPC-400. Corrective action If oil flow stopped, investigate the cause. See corrective actions for PS42. Check the flow switch on the Heatpac heater. If temperature switch tripped, investigate the temperature switch setting. If OK check the heater for cleanliness. Clean heater.
Clogged heater.
Automatic actions at alarm Main alarm flashes. Alarm diode flashes. Change over valve (V1) is set for oil recirculation. Heater switched off.
Automatic actions after alarm reset Main alarm off. Alarm diode off. V1 is set for oil feed to separator. Heater switched on.
14
3 Alarms
N.B. Causes
Also applicable to TT2 temperature sensor, if fitted. Corrective actions Investigate the reason and remedy it.
Low temperature alarm when: - clogged heater - insufficient steam supply - faulty steam trap - faulty steam supply valve - electric fault (tripped fuse) High temperature alarm when: - faulty steam supply valve - electrical control system out of function Set point (P7) changed or the alarm limits are too close to the set point.
1.
Adjust the parameters. P5 = max. temp P6 = min. temp P7 = set point. See Parameter List. Check the temperature control loop. Check and adjust the SRV1 function. Check the EPC output functions.
2. Steam control valve (SRV1) too far open or closed. 1. 2. Low temperature alarm when the temperature increases too slowly, during the start. Pt 100 temperature signal faulty. N.B.
Check the heater and parameter P41, See Parameter List. Check the Pt 100 temperature sensor.
The current temperature is indicated when the alarm is acknowledged. To find the appropriate temperature sensor reading, push the alarm reset button twice 1C (1F) = TT1, 2C (2F) = TT2. For more information, see Operating Instructions.
Automatic actions at alarm Main alarm flashes. Alarm diode and displayed value flashes. Change over valve (V1) is set for oil recirculation.
Automatic actions after alarm reset Main alarm off. Alarm diode off and display returned to normal. V1 is set for oil feed to separator.
Heater is switched off at high temperature (if heater is Heater is switched on (if heater is controlled by EPCcontrolled by EPC-400). 400).
15
3 Alarms
N.B. Causes
Also applicable to TT2 temperature sensor, if fitted. Corrective actions Check the temperature sensor by the test program, see Analog inputs on page 32 in the chapter "Test Program". Check the connections.
Temperature sensor cables are too close to power ca- Check the cables between the temperature sensor bles. and EPC-400. N.B. Push the alarm reset button to find appropriate process value reading. 1C (1F) = TT1, 2C (2F) = TT2. If both temperature sensors are fitted, alarm A6 is also activated.
Automatic actions at alarm Main alarm flashes. Alarm diode and displayed value flashes. Change over valve (V1) is set for oil recirculation.
Automatic actions after alarm reset Main alarm off. Alarm diode off and display returned to normal. V1 is set for oil feed to separator.
16
3 Alarms
Alarm code
I001105A
Cause
Corrective actions Check by measurement the fuses A1:F2 (front board), A2:F2 and A2:F3 (rear board). (See Component Description, EPC-400 Control Unit). Replace the control module.
2.
Automatic actions after alarm reset Main alarm off. Display normal.
17
3 Alarms
Alarm codes
I001091A
I001106A
I001092A
E2 RAM error.
I001093A
Program error.
I001096A
Check that the mode selector is in the correct position. Check the fuse A1:F2 (front board) If the fuse is correct, replace the control module. Ask for service or replace the control module.
I001094A
I001095A
Automatic actions after alarm reset Main alarm off. Display normal.
18
3 Alarms
Alarm code
I001108A
Cause Programming mode too long (more than 30 minutes without programming during this time).
Corrective action Change the mode selector to the L (Local) position and when appropriate, return to the P (Programming) position and continue with programming.
Automatic actions after alarm reset Main alarm off. Display normal.
19
3 Alarms
Alarm codes
I001103A
Corrective actions 1. 2. Check the power supply. If the power has been off during more than approximately 10 minutes the separator bowl must be stopped and manually cleaned before restart. Restart the heater, separator and EPC program. Check the power supply. If the power has been off during more than approximately 10 minutes the separator bowl must be stopped and manually cleaned before restart. Restart the heater, separator and EPC program.
I001104A
1. 2.
3.
Automatic actions at alarm All outputs are off. Only valid for alarm A4-1: Main alarm diode and display start to flash when power returns. Only valid for alarm A4-2: Main alarm flashes. Display flashes. 1.
Only valid for alarm A4-1: Main alarm off. Display indicates OFF. Only valid for alarm A4-2: Main alarm off. Display normal.
The frequency deviation must be repeated or be continuous during the alarm delay time before an alarm is activated.
20
3 Alarms
Alarm code
I001109A
Cause Temperature deviation alarm (difference between TT1 and TT2 is more than 30 C/54 F).
Corrective actions At commissioning Check if the distance between sensors is too great. System in operation Check the temperature sensors.
Automatic actions after alarm reset Main alarm off. Display normal.
Push the alarm reset button to find the appropriate process value reading 1C (1F) = TT1, 2C (2F) = TT2. For more information, see Operating Instructions.
21
3 Alarms
Alarm codes
I001111A
Causes High water transducer (MT4) value (above 400): High water content in oil. Water transducer dirty inside.
Corrective actions
Check the oil system for water leakage. Clean the liquid-wetted surfaces of water transducer. See Component Description, Water Transducer.
I001112A
Low water transducer (MT4) value (below 100): Open circuit in the MT4. 1. 2. Bad connection between oscillator unit and electrode. 1. 2. Check connections in control unit and transducer. Check cables for damage. Check the cable connection. Tighten oscillator unit to the electrode.
I001113A
The reason for stand-by mode must be checked! Try then to operate the system normally. Replace control module.
I001115A
Check the displacement water supply, including parts in separator. Check for bowl leakage.
I001181A
Automatic actions after alarm reset Main alarm off. Display normal.
22
3 Alarms
Alarm codes
I001121A
Corrective actions 1. 2. Check the connected external function. Check the jumper at terminal XC-X7:1 (when extra alarm not used).
I001122A
Low pressure signal (PS42) faulty at Check the pressure switch. start. Circuit should be open.
Automatic actions at alarm Main alarm flashes. Display flashes. The start of the timer sequences is blocked (is only valid for alarm A9-2).
Automatic actions after alarm reset Main alarm off. Display normal.
23
3 Alarms
24
Alarm Tests
Use the following guide for testing alarm functions by activating them. Alarms are provoked by one or more actions (A, B and so on) as shown in the right column, however, certain alarm functions can not be tested without being disconnected. N.B. If the alarm functions are to be disconnected in the control unit, be careful to avoid a short-circuit. The recommendation is to test the alarms every 3 months.
LED alarm Display alarm Function High oil pressure Sensor PS41 Actions to provoke an alarm Increase back pressure.
PS42
A. B. C.
Stop oil feed pump. Change V1 position by reducing air pressure. Reduce the back pressure. Disconnect hose for opening water (MV15). Initiate a sludge discharge.
1. 2.
MT4
Emergency stop
XS2
Vibrations (option)
XS1
Heater fault
1. 2.
25
4 Alarm Tests
LED alarm
Display alarm
Function
Sensor
Actions to provoke an alarm A. B. Remove sensor from pipe and put into hot/cool liquid. Change alarm limit parameters (P5 = max temp., P6 = min. temp.) in relation to actual temperature. For more information see Parameter List. Reset the parameter values after test.
A / D conversion error
Programming error
Leave the mode selector switch in position P for 30 minutes. Switch the power to the EPC off and on when it is in operation. Remove one sensor from pipe to cool off or be heated up (temp. diff. more than 30 C/54 F). Touch the central screw in the MT4 connection box. Disconnect cable to XE:3 in EPC.
Power failure
Temperature deviation
TT1 - TT2
High water transducer (MT4) value (above 400). Low water transducer (MT4) value (below 100). Insufficient amount of displacement water
MT4
MT4
MT4
A.
Change parameter 70 to a low value (e.g. 5 seconds) and initiate discharge cycle twice.
B.
Close displacement water supply and wait 2 discharge cycles. The amount of displacement water supply is checked every 2nd discharge. Extra alarm A. B. PS42 faulty at start PS42 (Circuit should be open) Activate appropriate sensor. Disconnect cable X7:1.
With the EPC in off mode put a jumper between XC- X7:4 and push the start button.
26
Test Program
The EPC-400 control unit has a test program, for testing of input and output functions, memory etc. This test program should be run when the installation is made and whenever there is a need for it, for instance, during fault finding.
27
P000191A
5 Test Program
TT1
MT4
FS4
XT1
XS1
Each LED and display segment individually lit (see the picture).
MV15
MV16
V1
MV10
V5
Push the button 2 (see the figures in the picture below) to switch between the two modes.
28
P000181A
G001142A
FOPX
EPC-400
5 Test Program
Memory correct
I000951A
1.4
Memory fault
2. Digital inputs
Function 2.1
I000941A
Correct value 0 1
Low flow High pressure Not in use Not in use Emergency stop or Vibration switch Not in use Start or stop EPC Start or stop heater
Circuit open
I000961A
Circuit closed
0 0
29
5 Test Program
3. Digital inputs
Function 3.1
I000941A
Correct value 0 1
3.2 3.3
Circuit open
I000961A
Remote switch
Circuit closed
4. Mode selector
Function 4.1
I000971A
4.2 4.3
Remote position
I000981A
Local position
I000991A
Program position
30
5 Test Program
5. Digital outputs Use push-button 3 to activate or deactivate each output (see How to Activate Different Parts of the Test Program on page 28). N.B. Corresponding green LED is not lit.
Function 5.1
I000941A
Oil feed Water drain Displacement or sealing water supply Opening water Closing water Steam shut-off valve or Heatpac fixed load
Circuit deactive
I000961A
Circuit active
Steam valve decrease or Heatpac X6:2-XD fixed load Steam valve increase or Heatpac fixed load X6:3-XD
6. Digital outputs Use button 3 to activate or deactivate each output. (See How to Activate Different Parts of the Test Program on page 28.) N.B. Corresponding green LED is not lit.
Function 6.1
I000941A
Unit
Heatpac variable load Heatpac alarm blocking during start Not in use Separator stop Not in use Remote/common alarm Blocking vibration switch
6.2
Circuit deactive
6.3
I000961A
X1:1-2
Circuit active
7. Not in use
31
5 Test Program
8. Analog inputs To simulate the temperature sensor elements (Pt 100) in 8.1 and 8.2, a resistor can be used. Separate plug connectors with appropriate resistors are included in the test module kit. Resistor 110 140 Display reading 25 C/77 F 60 104 C/219 F 215 Ref.temp
The normal value on the display for function 8.1 and 8.2 should be 60 215. Outside the range 42 233 indicates a fault. Value 000 (or a very low value) or 255 indicates a serious fault. A normal value for function 8.3, Reference 4 V should be 195 215. The table below shows how to find the fault.
Causes to the alarm Temperature sensor error (the display shows the alarm code EEE) Function 8.1 8.2 8.3 8.4 Temperature sensor for control Temperature sensor for alarm Reference 4 V Not in use Terminal X10:1-2-3 X11:1-2-3 Unit Fuse A1:F2 A/D conver- Input open blown sion faulty TT2 TT1 000 000 000 000 000 000 255 255 195 215 Input short circuit 000 000 195 215
For instance, if the display shows 000 for function 8.1, 8.2 and 8.3, it must be either a blown fuse or A/D converter fault. Check it in this order: 1. If the fuse is blown, replace it. 2. If the fuse is correct, replace the control module.
32
P000111A
5 Test Program
9. Serial communication
Function
I000941A
Unit
9.1 9.2
Not applicable (The display will show an E). RS 232 C Measure -10 to -12V DC on X14:1-3 (Circuit correct).
Circuit correct
Circuit fault
N.B. Disconnect the communication cable and put a jumper between X14:3-4 before the test is carried out.
I000951A
N.B. After the test, remove the terminal jumpers and connect communication cables.
33
P000121A
5 Test Program
10. Test of EPROM (rear circuit board) 11. Test of internal RAM in CPU (rear circuit board 12. Test of external RAM in CPU (rear circuit board) 13. Test of IC 8255 I/O port (rear circuit board) 14. Low reference analog input (internal) A value between 42 and 66 is displayed, when it is correct. 15. High reference analog input (internal) A value between 220 and 310 is displayed, when it is correct. 16. Transducer signal (internal) The display shows 100 50 with oil in WT 200 and 55 10 with air, when it is correct. 17. Not in use 18. Not in use
Circuit fault
I000951A I000941A
Circuit correct
34