P-type Separation System Alarms and Fault Findingmaytau.ut.edu.vn/userfiles/files/Alarms and Fault Finding...1810898-02 3 P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 1 ALARMS

P-type Separation System

Alarms and Fault FindingPrintedBook No.

Sep 20081810898-02 V 4

Alfa Laval reserves 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 Tumba AB Marine & Diesel Equipment SE - 147 80 Tumba Sweden

© Copyright Alfa Laval Tumba AB 2008.

Contents

1810898-02

1 Alarms .........................................................21.1 Alarm Functions ...............................21.2 Reading Alarm History List ...........21.2.1 Alarm message explanation: ..................3

1.3 Alarm Reset .......................................31.4 Abnormalities not displayed.........4

2 Display Alarms and Actions .........5

3 Alarm Tests ..........................................18

1 ALARMS P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

1 Alarms

1.1 Alarm FunctionsThe alarm system is designed to ensure a safe separation system.

All alarms are shown on the operator panel display, and most of them are complemented by light emitting diodes (LEDs).

The alarms are displayed in order of occurrence.

1.2 Reading Alarm History List

To read the stored list of alarms, proceed as follows:

• Push ‘Enter’.

• Push ‘+’ until ‘End’ is displayed.

• Push ‘Enter’ and ‘+’ at the same time.

• Push ‘+’ repeatedly until ‘AL list’ is displayed.


• Go through the list using the ‘+’ pushbutton until ‘End’ is displayed.


• Push ‘+’ repeatedly until ‘Exit’ is displayed.

• Push ‘Enter’ to return to normal display.

2 1810898-02

P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 1 ALARMS

d 13 minutes ago.

s set to 60 minutes.

t after 2 minutes 13 seconds.

ALARM

G0

01

64

8A

ALARM

G0

01

64

9A

1.2.1 Alarm message explanation:

1.3 Alarm Reset

WARNING!

Breakdown hazardNever reset an alarm without first finding and remedying the cause.

It is possible to reset the system without remedying the cause, but the alarm signal will be repeated.

CAUTION!

Risk of injuryNever return to the operator panel to acknowledge or reset an alarm if doing so is by any means hazardous.

The display shows:

Alarm no. 5 Alarm number

0:13 This alarm occurre

Feed pressure low Type of alarm

P1 60 Parameter Pr 1 wa

00:02:13 The alarm was rese

1 Acknowledge the alarm signal by pressing the alarm push button. The flashing LED then changes to steady shine.

2 Remedy the cause.

3 Reset the alarm function by pressing the alarm push button a second time.

The LED will go out.

1810898-02 3

1 ALARMS P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

rrence during start ion blocks are

None.

sump too low. Check oil level and add oil if necessary.

n of paring disc is Stop the separator, measure and adjust the height.

maged or worn. Renew all bearings.

l assembly Check and reassemble.

aration Adjust.

oo high. Adjust.

clogged. Clean disc stack.

in bowl is filled. Clean and reduce the time between sludge discharges.

oo low. Examine the motor and power transmission for correct frequency parts.

Check belt and coupling pads.

in wrong direction Check the electrical connections to the motor.

hy? What to do

1.4 Abnormalities not displayed

There are some abnormalities not shown on the display. Below are listed the most common:

Smell • Normal occuwhile the frictslipping.

• Oil level in oil

Noise • Height positioincorrect.

• Bearing(s) da

• Improper bow

Unsatisfactory separation result • Incorrect septemperature.

• Throughput t

• Disc stack is

• Sludge space

• Bowl speed t

• Bowl rotates

W

4 1810898-02

P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

2 Display Alarms and Actions

10

9

9

17

17

17

13

11

13

15

15

15

16

17

7

8

7

17

15

17

The display shows

on page

Bowl speed sensor - ERROR

Bowl speed - HIGH

Bowl speed - LOW

xxxxx board - ERROR

Communication - ERROR xxxxx

Computer board - ERROR

Discharge feedback - ERROR

Emergency stop - BUTTON PUSHED

Feed flow PT1 - ERROR DURING Tixx

Feed pressure PT1 - HIGH

Feed pressure PT1 - LOW

Feed pressure sensor PT1 - ERROR

Heater - FAULT

Heater board - ERROR

High frequency xxxx Hz

High vibration - WARNING

High vibration - SHUTDOWN

IO expansion board - ERROR

IP address - FAULT

Level switch - DISABLED

16

16

14

14

11

12

15

14

17

15

16

15

13

10

13

17

10

17

17

12

The display shows

on page

Local OP in control

NO SIGNAL FROM EXTRA INPUT X6:8

Oil backpressure PT4 - HIGH

Oil backpressure PT4 - LOW

Oil feed temperature - HIGHxxxxx

Oil feed temperature - LOWxxxxx

OIL PRESSURE PT4 HIGH DURING Ti70

Oil pressure sensor PT4 - ERROR

Parameter xx:xx - ILLEGAL

Parameters changes - LOCKED

POWER FAILURE

Pump starter - FAILURE

Separator motor - FAILURE

Separator run-up - TO LONG

Series communication - ERROR

Service alarm

Sludge tank level - HIGH

Switch power off/on

Temperature increase - TOO SLOW

Temperature alarm sensor - ERROR

1810898-02 5

2 DISPLAY ALARMS AND ACTIONS P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

13

17

8

The display shows

on page

Temperature control sensor - ERROR

Vibration board - ERROR

Vibration sensor - ERROR

6 1810898-02


ining in part of the Dismantle, clean and check the bowl before restart. See Service Manual.

WARNING!

Disintegration hazardThe separator bowl must be manually cleaned before starting up again.

mounted

mpression incorrect

led with parts from tors

Check assembly. See Service Manual.

n of paring disc is Stop the separator, measure and if necessary adjust the height.

bent. Renew the bowl spindle.


et are worn out. Renew the frame feet.

earing spring Renew all springs.

eviation more than Check power supply

y? What to do

WARNING!

Disintegration hazardsIf excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

The cause of the vibration must be identified and corrected before the separator is restarted.

• Sludge remabowl

• Bowl wrongly

• Disc stack co

• Bowl assembother separa

• Height positioincorrect.

• Bowl spindle

• Bearing(s) da

• The frame fe

• Spindle top bbroken.

• Frequency d+ 5%

The display shows

Wh

High vibration - SHUTDOWN

High frequency xxxx Hz

1810898-02 7


ining in part of the Dismantle, clean and check the bowl before restart.

WARNING!

Disintegration hazardThe separator bowl must be manually cleaned before starting up again.

mounted

mpression incorrect

led with parts from ors

Check assembly. See Service Manual.

n of paring disc is Stop the separator, measure and if necessary adjust the height.

bent. Renew the bowl spindle.


et are worn out. Renew the frame feet.

earing spring Renew all springs.

ble damaged Replace sensor. If no spare sensor available, set parameter Fa 16 = 0.0 to be able to run the system.

y? What to do

• Sludge remabowl

• Bowl wrongly

• Disc stack co

• Bowl assembother separat


• Bowl spindle

• Bearing(s) da

• The frame fe

• Spindle top bbroken.

• Sensor or ca

The display shows

Wh

High vibration - WARNING

Vibration sensor - ERROR

8 1810898-02


net) frequency Check power supply before restart.

smission parts ulley and belt for supply). WARNING

!

Disintegration hazardStop and change the belt transmission to suit the power supply frequency.

Change belt.

g pads Check / change pads.

r faulty Check speed sensor

erly closed Check closing water supply (valve SV 16).

Check bowl operating system for leakage.

Check nozzle.

erly assembled Check that the lock ring is in place.

et frequency Check power.

Repair the motor.

maged. Renew all bearings.

smission parts (60 and belt for 50 Hz ). WARNING

!

Disintegration hazardStop and change the belt transmission to suit the power supply frequency.

y? What to do

• High power (

• Incorrect tran(50 Hz belt p60 Hz power

• Slipping belt

• Worn couplin

• Speed senso

• Bowl not prop

• Bowl not prop

• Low power n

• Motor failure.

• Bearing(s) da

• Incorrect tranHz belt pulleypower supply

The display shows

Wh

Bowl speed - HIGH

Bowl speed - LOW

1810898-02 9


ble damaged Replace sensor. If no spare sensor available set parameter In 6 = No to be able to run the system.

t drained the tank Check the pump function.

upling slipping Check the coupling.

Check the belt.

n of paring disc is Stop. Check and adjust the height.

Repair the motor.


rt button not Push start button.

y? What to do

• Sensor or ca

• Pump has no

• Separator co

• Belt slipping


• Motor failure

• Bearing(s) da

• Separator stapushed.

The display shows

Wh

Bowl speed sensor - ERROR

Sludge tank level - HIGH

Separator run-up - TO LONG

10 1810898-02


utton pushed Remedy cause for pushing button.

Reset push button.

ly valve faulty Investigate cause and remedy.

odule(s) in the faulty controller in it. (electric heater)

If relay K11 is on:

Disconnect X12:10.

If the temperature is falling, replace the control module in the control unit.

If the temperature is not falling, replace the triac module(s).

If relay K11 is off, but contactor K12, K16, or K17 is on, and the temperature is not falling:

Check if power is supplied from the control unit to the contactor which is on (X12:6 - X12:12, X12:7 - X12:12 , X12:9 - X12:12). If it is, replace the control module in the control unit.

or defective heater r faulty controller in it.

Check adjustment of P and I functions in the control unit.

If contactor sequence correct:

Check wiring and heater resistance of each block or heater element. See EHM heater component booklet.

If contactor sequence not correct:

Replace the control module in the control unit.

y? What to do

• Emergency b

• Steam supp

• Faulty triac mpower unit orthe control un

• Broken wiringresistance, othe control un

The display shows

Wh


Oil feed temperature - HIGHxxxxx

1810898-02 11


ed

insufficient

ulty

valve faulty

Investigate cause and remedy.

r burned

er)

Check and renew broken fuses. Reset overcurrent protection (applicable for 8/7 - 24/22 kW power unit).

Check wiring and contactor coils.

or defective heater

er)

Check wiring and heater resistance of each block or heater element. See the Service Manual booklet.

broken sensor or Disconnect cable at sensor. Measure resistance between 1-3. Resistance shall be within 100-142 ohms = 0-110 C / 32-230 F.

Test of EPC 50 input:

• Disconnect cables from sensor, (terminal X 5:1-2-3).

• Move jumpers Xj1 and Xj2 upwards - from Normal to Test. (The jumpers can be found in the upper left corner of the I/O Board)

• Indication within 50-60 C when OK.

• If no spare sensor available set parameter Pr 16 = 0, or if control sensor free, move connection to that one.

y? What to do

• Heater clogg

• Steam supply

• Steam trap fa

• Steam supply

• Faulty fuses ocontactors (electric heat

• Broken wiringresistance (electric heat

• Short circuit /cable.

The display shows

Wh

Oil feed temperature - LOWxxxxx


12 1810898-02


broken sensor or Disconnect cable at sensor. Measure resistance between 1-3. Resistance shall be within 100-142 ohms = 0-110 C / 32-230 F. If no spare sensor available set parameter Pr 18 = 0. Heater is then out of function.

rking

ed line too low

Check pump.

Check feed line.

gnal from contactor Check the contactor function. Input terminal X 6:5 in EPC 50.

on between series interrupted

Check the Sattbus connection.

sed (Fa12) as ck.

decreased (Pr 31) back.

on Fa 12 or Pr 31

e operating water ged.

Clean the strainer.

o low. Check opening water. Valve SV 15

en the supply parator are

ted.

Fit hoses correctly.

y? What to do

• Short circuit /cable.

• Pump not wo

• Pressure in fe

• Feedback siK 2 missing

• Communicatiseparators in

If In 6 = yes

Speed not decreadischarge feedba

If In 6 = no

PT1 pressure notas discharge feed

• Check setting

• Strainer in thsupply is clog

• Water flow to

• Hoses betwevalves and seincorrectly fit

The display shows

Wh


Feed flow PT1 - ERROR DURING Tixx

Separator motor - FAILURE

Series communication - ERROR

Discharge feedback - ERROR

1810898-02 13


l due to:

erating water high clogged, or water low.

Clean strainer. Make sure that the water pressure is 200 - 600 kPa (2 - 6 bar).

bowl defective. Install new seal rings.

ening. Examine the electrical system and correct the fault (open circuit, low or high voltage or dirt).

roughput Check feed pump and adjust flow.

lve open too much Adjust back pressure valve

valve V1 in position

Check air pressure, solenoid valve SV1 and output from EPC 50 terminal X 8:1-X 41.

entionally during e:

e operating water ged.

Clean the strainer.

e operating water Check the operating water system and make sure any supply valves are open.

en the supply parator are ed.

Fit hoses correctly.

l body clogged Clean the nozzle.

ring in discharge tive.

Renew the rectangular ring.

re defective. Renew all plugs.

SV15 for opening ng.

Rectify the leak.

roughput Check. Reduce backpressure.

lve too restricted Adjust valve

ble damaged Replace sensor. If no spare sensor available set parameter Pr 10=0.0 to be able to run the system.

y? What to do

Broken water sea

• Strainer in oppressure sidepressure too

• Seal rings in

• MV 10 not op

• Decreased th

• Regulating va

• Change overrecirculation

Bowl opens unintoperation becaus

• Strainer in thsupply is clog

• No water in thsystem.

• Hoses betwevalves and seincorrectly fitt

• Nozzle in bow

• Rectangular slide is defec

• Valve plugs a

• Supply valve water is leaki

• Increased th

• Regulating va

• Sensor or ca

The display shows

Wh

Oil backpressure PT4 - LOW

Oil backpressure PT4 - HIGH


14 1810898-02


in oil pressure er

Check function of change over valve V1.

d Check recirculation for restriction

Check pump and flow regulation.

Check heater for fouling.

ble damaged Check cable connections

Replace sensor. If no spare sensor available set parameter Pr 14=0.0 to be able to run the system.

nal from contactor Check the contactor function.

Check input terminal X 9:1 in the EPC.

een set to make anges not possible

Unlock the code.

ress used in Check the setting.

y? What to do

• No decreaseduring this tim

• Pipe restricte

• Low flow

• Sensor or ca

• Feedback sigK 3 missing

• A code has bparameter ch

• Wrong IP addIn 27-30

The display shows

Wh

OIL PRESSURE PT4 HIGH DURING Ti70

Feed pressure PT1 - HIGH

Feed pressure PT1 - LOW


Pump starter - FAILURE

Parameters changes - LOCKED

IP address - FAULT

1810898-02 15


use of the input Depends on use of the input

eater X 12:3 to EPC

er)

Check the power supply to the heater.

itch released er)

Check temp. setpoint in the control unit.

Check the heater and clean if necessary.

When the alarm is reset, the temp. switch is also reset.

erate remote OP Not legal when local OP is active.

occurred with EPC Check plant conditions and restart.

y? What to do

• Depends on

• 0V in cable h50 X 51:4 (electric heat

• High temp. sw(electric heat

• Attempt to op

• Black-out hasin operation

The display shows

Wh

NO SIGNAL FROM EXTRA INPUT X6:8

Heater - FAULT

Local OP in control

POWER FAILURE

16 1810898-02


s are changed by "thunderstorm" e, alarm is given to f range.

Switch EPC50 power off. Move X J4 on I/O board to position right. Switch power on. Parameters are now all set to default values. Move X J4 back to original position. Adjust all parameter settings to correct value.

r Panel board), Pr (Operator Panel ) in EPC not

Check cables to board or replace the board (see Change of Circuit Board in the Service Manual booklet).

on Check connection

Replace the board

Check cables to board or replace the board (see Change of Circuit Board in the Service Manual booklet).

er board in EPC not Check cables to board or replace the board (see Change of Circuit Board in the Service Manual booklet).

1:3 are both set to to 1

Set one switch to 0, and the other to 1.

tion board in EPC Check cables to board or replace the board (see Change of Circuit Board in the Service Manual booklet).

eating during start Check heater function.

layed at standstill cy or vibration shut

Investigate the cause for the stop and switch the power off and then on to the EPC 50.

high level alarm is Warning to operator only.

, the text in Pr 6 is Take action according to what the text means (plant dependant).

y? What to do

• If parameterautomaticallytype influencindicate out o

• OP (OperatoI/O board or Oremote boardworking

• Bad connecti

• Board faulty

• Cable errors

• Optional heatworking

• X71:2 and X70 or both set

• Optional vibranot working

• Insufficient h(Ti 53)

• Alarm is dispafter emergendown

• If Pr 25=0 thedisabled

• If Pr 5 is useddisplayed

The display shows

Wh

Parameter xx:xx - ILLEGAL

xxxxx board - ERROR

Computer board - ERROR

Communication - ERROR xxxxx

Heater board - ERROR

IO expansion board - ERROR

Vibration board - ERROR


Switch power off/on

Level switch - DISABLED

Service alarm

1810898-02 17

3 ALARM TESTS PA PURIFIER SYSTEM ALARMS AND FAULT FINDING

3 Alarm Tests

Method Terminal Reaction

Switch power off / on during operation

Decrease limit (Pr14)

Increase limit (Pr15)

Disconnect sensor X5:4

Switch pump off

Decrease limit (Pr16/Pr19) V1 off.

Heating off.

Increase limit (Pr17/Pr20) or decrease Ti 53

. V1 off

Disconnect sensor X5:2 V1 off

Heating off.

Increase back pressure V1 off

Decrease back pressure V1 off

Disconnect sensor X5:6

Push the button Sep.motor off, heater off, feed on for 3 min, stop.

Disconnect X51:2

Disconnect X51:4

Start separator and EPC but not heater, or start system with Ti 53 set to 1.

NOTE

If any parameter value is changed to activate an alarm, do not forget to reset to the original value before operation.

Alarm message Red diode

Sequence

Standard functions

POWER FAILURE Start

Feed pressure PT1 - HIGH PT1 Start

Feed pressure PT1 - LOW PT1 Start


PT1 Start

Pump starter - FAILURE Pump Start

Oil feed - TEMPERATURE HIGH TT Start

Oil feed - TEMPERATURE LOW TT Start


TT Start

Oil back pressure PT4 - HIGH PT4 Separation

Oil back pressure PT4 - LOW PT4 Separation


PT4 Separation


Separation

Optional functions


TT Start

Heater - FAULT (Heatpac power unit only)

Heater Start


TT Start

18 1810898-02

Documents

P-type Separation System Alarms and Fault Findingmaytau.ut.edu.vn/userfiles/files/Alarms and Fault Finding...1810898-02 3 P-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 1 ALARMS