P Flex Separation Alarms and Fault Findingmaytau.ut.edu.vn/userfiles/files/Alarm and Fault Finding.pdf1 Alarms For each item in the list you can press the ‘Information’ button

P Flex Separation

Alarms and Fault Finding

Printed 06-2015

Book No. 586660-02, rev. 6

Published By:

Alfa Laval Tumba ABSE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

© Alfa Laval Tumba AB 06-2015The original instructions are in English

This publication or any part there of may not bereproduced or transmitted by any process ormeans without prior written permission of AlfaLaval Tumba AB.

Contents

1 Alarms 5

1.1 Alarms List 5

1.2 Alarm History List 8

2 Display Alarms and Actions 9

3 EPC 60 Control panel 19

3

1 Alarms

1.1 Alarms List

To access the Alarms List press the ‘AlarmButton’.

NOTE

The latest 50 alarms are stored in the Alarm HistoryList. See below.

9

6

3

8

2

0

7

4

1

.

i

5

SLUDGE

PUMP

CLEANING

IN PLACE

REMOTE

CONTROL

CIP

DISCHARGE

FEED

PUMP

HEATERSEPARATOR

X023912B

Press the arrow buttons to go up or down inthe list.

9

6

3

8

2

0

7

4

1

.

i

5

SLUDGE

PUMP

CLEANING

IN PLACE

REMOTE

CONTROL

CIP

DISCHARGE

FEED

PUMP

HEATERSEPARATOR

X023914A

5

1 Alarms

For each item in the list you can press the‘Information’ button for help and information.Press the ‘Information’ button again to return toyour previous position.

You can also acknowledge and/or reset thisalarm.

9

6

3

8

2

0

7

4

1

.

i

5

SLUDGE

PUMP

CLEANING

IN PLACE

REMOTE

CONTROL

CIP

DISCHARGE

FEED

PUMP

HEATERSEPARATOR

X023915A

If the system has a fault, the alarm LED blinks.Press the ‘Alarm’ button once. The alarm showson the display.Press the ‘Alarm’ button again to acknowledgethe alarm.To go through the alarm list, press the ‘Arrow’buttons.

NOTE

After acknowledging an alarm, go through thealarm list to make sure that there are no otherunacknowledged alarms!

If after all alarms have been acknowledgedfault(s) remain in the system, the alarm LEDstops blinking and remains on. An ‘A’ appearsat the end of an alarm which has not beenrectified.The alarms disappear automatically when thefault is rectified.When all the alarms have been rectified, thealarm LED goes out.For safety reasons, certain alarms must not onlybe acknowledged, but also rectified before thesystem can continue in operation, for examplealarm A122 ‘Butterfly valve in sludge outletclosed’.Also for safety reasons, some alarms will set thesystem into recirculation or stop. These alarmsmust be rectified before the operator can put thesystem into operation.

X023919A

6

1 Alarms

Press the ‘Return’ button to leave the list.

9

6

3

8

2

0

7

4

1

.

i

5

SLUDGE

PUMP

CLEANING

IN PLACE

REMOTE

CONTROL

CIP

DISCHARGE

FEED

PUMP

HEATERSEPARATOR

X023912A

7

1 Alarms

1.2 Alarm History List

To access the Alarm History List at any timeduring the operation process press the ‘Returnbutton’ repeatedly until the Alarm History Listis reached.

NOTE

Relevant parameters only are shown on the display

9

6

3

8

2

0

7

4

1

.

i

5

SLUDGE

PUMP

CLEANING

IN PLACE

REMOTE

CONTROL

CIP

DISCHARGE

FEED

PUMP

HEATERSEPARATOR

X023912A

Press the arrow buttons to go up or down in thelist. The list consists of the following:

1. Parameter menu – List of all parameters.Password protected.To go directly to a parameter, enter theparameter number.

2. Time settings – For setting date, time, etc.Password protected.To go directly to a parameter, enter theparameter number.

3. Operation time – Different counters andtimers can be read.

4. I/O Test – Here it is possible to activate alloutputs and to read the status for all inputs,for testing purposes.

5. Alarm history – List of alarms which havebeen rectified. The latest alarm shows atthe top of the list.

6. System info

7. IP settings

8. Password / Login

9. Set contrast

9

6

3

8

2

0

7

4

1

.

i

5

SLUDGE

PUMP

CLEANING

IN PLACE

REMOTE

CONTROL

CIP

DISCHARGE

FEED

PUMP

HEATERSEPARATOR

X023914A

8

2 Display Alarms and Actions

T 2T P 1T

A05 A30-A32

T 1T

A20-A25

V1

V10

V15

V16

A40-A43

PT4

A50-A57

SS

A110-A111

YTA100-A103

ST

A90-A97

LS

A120-A121

A122

GS

A01 A15

A130 - A139

X024967a

Alarmcode

Alarm text Conditions Why? What to do

Feed pump (if P127 = yes)A01 Pump starter failure Delayed by P168. Feedback signal from

contactor K3 missing.Check the contactorfunction.Check input terminalin the PLC.

Power to heaterinterrupted.

Check the powersupply to the heater.

A05 Heater fault (electric) Delayed 2 s.

High temp. switchreleased

Check temp. setpointin the control unit.Check the heater andclean if necessary.When thetemperaturedecreases,the switch isautomatically reset.

9


Alarmcode


Heater, electric (if P119 = electric)A15 Separator starter

failureDelayed 2s. Feedback signal from

contactor missing.Check the contactorfunction. Check inputterminal in the PLC

Temperatur transmitter feed inlet TT1Steam supply valvefaulty

Investigate causeand remedy.

Faulty triac module(s)in the power unit orfaulty controller in thecontrol unit. (electricheater).

A20 Oil feed temperaturehigh

Delayed by 15s. Limitin P183.

Broken wiring ordefective heaterresistance, or faultycontroller in thecontrol unit.Heater clogged Investigate cause

and remedy.Steam supplyinsufficient


Steam trap faulty Investigate causeand remedy.

Steam supply valveinsufficient


Faulty fuses or burnedcontactors (electricheater)

Check and renewbroken fuses.Reset overcurrentprotection(applicable for 8/7- 24/22 kW powerunit).Check wiring andcontactor coils.

A21 Oil feed temperaturelow

Delayed by 15s. Limitin P184

Broken wiring ordefective heaterresistance (electricheater)

Check wiring andheater resistance ofeach block or heaterelement.

A22 Temperature alarmsensor error (TT1)

Delayed by 15s Short circuit / brokensensor or cable.

Disconnect cableat sensor. Measureresistance between1-3. Resistanceshall be within100-142 ohms =0-110 C/32-230 F.Replace sensor ifbroken. If no sparesensor available, setparameter P146 =TT1 to be able to runthe system.

10


Alarmcode


A23 Temperature alarmsensor disabled

Reminder only, if P146= TT1

A24 Temperature increasetoo slow

Delayed by P169.Limit in P184.

Insufficient heatingduring start.

Check heaterfunction.

Heating on duringstop sequence.

Check heaterfunction.

A25 Temperature notdecreasing

Delayed by P173.Limit in P184. Stopsequence continuesafter alarm reset.Disabled if P173 = 0.

Recirculating oil notcooling.

Reset alarm tocontinue.

Temperatur transmitter heater control TT2A30 Temperature control

sensor error (TT2)Delayed by 15s. Short circuit / broken

sensor or cable.Disconnect cableat sensor. Measureresistance between1-3. Resistanceshall be within100-142 ohms =0-110 C/32-230 F.Replace sensor ifbroken. If no sparesensor available, setparameter P146 =TT2 to be able to runthe system

A31 Temperature controlsensor disabled

Reminder only, if P146= TT2

A32 Difference TT1/TT2too large

Delayed by 2s. Alarmlimit in P177. Blockedif A22, A23, A30, orA31

Pressure transmitter feed inlet PT1A40 Feed pressure PT1

highDelayed by 15s. Limitin P157

Pipe restricted. Check recirculationfor restriction.

Pump not working Check pump.A41 Feed pressure PT1low

Delayed by 15s. Limitin P158. Pressure in feed line

too lowCheck feed line andflow regulation.Check heater forfouling.

A42 Feed pressure sensorPT1 error

Delayed by 15s. Sensor or cabledamaged

Check cableconnections.Replace sensor. Ifno spare sensoravailable, setparameter P157 =0.

A43 PT1 disabled Reminder only, if P157= 0.

Pressure transmitter oil outlet PT4A50 Oil backpressure PT4

highDelayed by 15s. Alarmlimit in P153.

Increased throughput Check. Reducebackpressure.

Regulating valve toorestricted

Adjust valve.

11


Alarmcode


A51 Oil backpressure PT4low

Delayed by 15s. Alarmlimit in P154.

Liquid seal broken Check that thegravity disc is correctfor the oil density.

Decreasedthroughput

Check feed pumpand adjust flow.

Regulating valve opentoo much

Adjust back pressurevalve

Change over valveV1 in recirculationposition

Check air pressure,solenoid valve SV1and output from EPC60.

Bowl opensunintentionally duringoperation because:Strainer and piping inthe operating watersupply is clogged.

Clean the strainerand check thewhole system forelimestone deposits.

Too little or no waterin the operating watersystem.

Measure the waterflow in the threehoses from the waterblock and comparewith correct values.

Hoses betweenthe supply valvesand separator areincorrectly fitted.

Fit hoses correctly.

Nozzle in bowl bodyclogged

Clean the nozzle.

Rectangular ring indischarge slide isdefective.

Renew therectangular ring.

Valve plugs aredefective.

Renew all plugs.

Supply valves SV15and SV 16 areleaking.

Rectify the leak.

A52 Oil pressure sensorPT4 error

Delayed by 15s. Sensor or cabledamaged.

Check cableconnections.Replace sensor. Ifno spare sensoravailable, setparameter P153 =0.

A53 PT4 disabled Reminder only, if P153= 0.

A54 Oil pressure PT4 highat discharge

Delayed by 15s. Alarmlimit 0.2bar.

No decrease in oilpressure at discharge.

Check function ofchange-over valveV1.

12


Alarmcode


Speed sensor separator (if P113 = yes)Bowl peripherysealing damaged

Change seal ringin bowl hood.Check/changerubber rings andvalve plugs.

Leakage somewherein oil outlet

Check for leakage.

A57 Oil leaking from bowl Delayed by P245.Alarm limit in P163.

Closing water leaking Check/changesealings and plugs.

High power (net)frequency.

Check power supplybefore restart.

A90 Bowl speed high Delayed 5 s. Limitdepends on separatorsize. Incorrect transmission

parts (50 Hz beltpulley and belt for 60Hz power supply).

! WARNING

DisintegrationhazardStop and change thebelt transmission tosuit the power supplyfrequency.

Slipping belt Change belt.Worn coupling pads Check / change pads.Bowl not properlyclosed

Check closing watersupply (valve SV 16).Check bowloperating systemfor leakage.Check nozzle.

Bowl not properlyassembled

Check that the lockring is in place.

Low power netfrequency

Check power.

Motor failure. Repair the motor.Bearing(s) damaged. Renew all bearings.

A91 Bowl speed low Delayed 5 s. Limit inP180.

Incorrect transmissionparts (60 Hz beltpulley and belt for 50Hz power supply).

! WARNING

DisintegrationhazardStop and change thebelt transmission tosuit the power supplyfrequency.

A92 Bowl speed sensorerror

Delay 4s. Timer stop. Sensor or cabledamaged.

Replace sensor.

Alarmcode


A93 A93 Speed sensordisabled

Reminder only, if P148= yes.

13


A94 Bowl speed highduring STOP

Delayed by 3min.Alarm limit in P180.

Power still on to themotor

Check reason andremedy.

Separator frictionblocks slipping

Check the frictionblocks.

Belt slipping Check the belt.Height positionof paring disc isincorrect.

Stop. Check andadjust the height.

Motor failure Repair the motor.

A95 Separator motorrun-up time too long

Delayed depending onseparator size. Limit inP180.

Bearing(s) damagedor worn in coupling orspindle drive.

Renew all bearings.

A96 Slow startacceleration

Speed < 90 rpm 10safter response frommotor contactor.

A97 Discharge feedbackerror

Alarm limit in P161.Test during P232, oneextra discharge beforealarm.

Strainer in theoperating watersupply is clogged.

Clean the strainer.

Water flow too low. Check opening waterflow (SV 15) into thebowl.

Hoses betweenthe supply valvesand separator areincorrectly fitted.

Fit hoses correctly.

Rectangular ring inthe operating slide isdefective.

Replace therectangular ring.

Vibration sensor separator (if P114 = yes)Sludge remaining inpart of the bowl.

Dismantle, cleanand check the bowlbefore restart.

! WARNING

DisintegrationhazardThe separator bowlmust be manuallycleaned before startingup again.

A100 High vibration warning Delayed by 15s. Alarmlimit in P182.

Bowl wronglymounted.

Check assembly.

Alarmcode


Disc stackcompressionincorrect.

Check assembly.

14


Bowl assembledwith parts from otherseparators.

Check assembly.

Height positionof paring disc isincorrect

Stop the separator,measure and ifnecessary adjustthe height.

Bowl spindle bent. Renew the bowlspindle

Bearing(s) damagedor worn.

Renew all bearings.

The frame feet areworn out.

Renew the frame feet.

Spindle top bearingspring broken.

Renew all springs.

Delay 1s. Alarm limitin P181.

! WARNING

DisintegrationhazardIf excessive vibrationoccurs, stop separatorand keep bowl filledwith liquid duringrundown. The causeof the vibration mustbe identified andcorrected before theseparator is restarted.

Sludge remaining inpart of the bowl

Dismantle, cleanand check the bowlbefore restart. SeeService Manual.

! WARNING

Disintegration hazardThe separator bowlmust be manuallycleaned before startingup again.

Bowl wronglymounted

Check assembly.

Disc stackcompressionincorrect

Check assembly.

Bowl assembledwith parts from otherseparators

Check assembly.

Height positionof paring disc isincorrect.

Stop the separator,measure and ifnecessary adjustthe height.

Bowl spindle bent. Renew the bowlspindle.

A101 High vibrationshutdown

Bearing(s) damagedor worn.

Renew all bearings.

15


Alarmcode


The frame feet areworn out.

Renew the frame feet.

Spindle top bearingspring broken.

Renew all springs.

A102 Vibration sensor error Delayed by 15s. Sensor or cabledamaged.

Replace sensor. Ifno spare sensoravailable, setparameter P132 =yes to be able to runthe system.

A103 Vibration sensordisabled

Reminder only. If P132= yes.

Frame cover switch separator (if P115 = yes)Separator notproperly assembled

Assemble theseparator accordingto instructions.

A110 Frame cover open Delay 1s.Start not possible.

Faulty frame coverswitch

Replace coverswitch. If no spareswitch available, setparameter P116 = yesto be able to run thesystem.

A111 Cover switch disabled Reminder only, if P116= yes.

Sludge handlingA120 Sludge tank level high At high level: Start

not possible. Sludgepump running untillevel signal normal +10s. Alarm delay andmax pump runningtime 60s in all modeswithout feed flow, 2s inSeparation. Dischargeblocked.

Pump has not drainedthe tank

Check the pumpfunction.

A121 Level switch disabled Reminder only, if P149= yes.

A122 Valve in sludge outletclosed Discharge notpossible. Start notpossible.

Delayed by 15s. Valve closed. Open manual valve.

A123 External alarm. Delay2 s

16


SystemA130 Emergency stop

button pushedDelay 1s. No restart. Emergency stop

button pushedCheck for the cause.Reset pushbutton.

A132 Power failure Disabled with P152 =no.

Black-out hasoccurred duringoperation.

Check plantconditions andrestart.

A133 Too long time inRECIRCULATION

Delayed by P178.System goes to STOP.

Time inRECIRCULATIONexpired.

A136 Communication errorA137 Cabinet over

temperatureReminder only

A138 Too many startattempts

Contactor activated5 times within last 60minutes.

A139 EPC60 internal failure Delay 2s IO-card status or PLCstatus not OK

Check IO cards haveno red LEDs

PLC has detected anIO-configuration thatdoes not exist

Check ifIO-configurationis right or verifyelectrical drawings

A140 Too long time out ofoperation

Alarm is created ifthe separator hasbeen out of operationfor one month ormore. It is reset if theseparator has beenrunning for at least 5hours.

Pre-lubricate spindlebearings.After service alwaysrun the separatorcontinuously forat least 5 hoursto ensure properlubrication.

A145 Panel communicationerror

Check wiring

17


3 EPC 60 Control panel

Fault RemedyBlack screen Press and hold Enter button and adjust contrast with

up and down button.This can be done regardless of which page iscurrently displayed.

19

Documents

P Flex Separation Alarms and Fault Findingmaytau.ut.edu.vn/userfiles/files/Alarm and Fault Finding.pdf1 Alarms For each item in the list you can press the ‘Information’ button