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Gontents
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
8 I I 10 11 12 13 14
3.5
o
3.6
17 17 18 19 20 21 22 23
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2 EPCSigns
The signsto the controlunit for the FOPX are systems shownin this chapter. separation
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Monitoringfunctions
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Monitoringfunctions(Oqtions)
2 EPCSigns
rOPX
Outputsignals
_ EPC 4OO
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Operatingsymbols
Alarms
3.1 AlarmFunctions
that is to Tite aiarmsystem designed ensure in alwaysremains a safe system dr separaion are sane,TberE two differenttypesof alarm :;mrions: Sasor-related alarm functions are irxricared light emittingdiodes(LEDs) by on *re EPC-400. alarm functions are Displa.r--related irraicaed theEPC-4OO When display. on alarmfunctionsare any oi the displayed the activated left digits startflashingand tre right digits aresteadilylit. F Serc is morethanone alarmat the same will :=e- 6e EPC-4O0 displaythe alarmwith 3e hig[est priority first andthenthe next 3.*m- and so on in priority order.
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An activatedalarm conditionis i&ntified eitherby an alarm LED (to the left in the picture)or an alarm u& on the disflay togetherwith the main alarm LED (to the right in the picture).
3 Alarms
3.2 AlarmReset
1. Acknowledgethe alarm signalby pressing the alarm push-button. The flashing light then changesto steady. 2. Remedythe cause. 3. Resetthe alarm function by pressingthe a alarm push-button secondtime. The LED will turn off. )t is possib)e to resettbe systemwitltout remedying the cause,but the alarm signal will be repeated.
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NOTE
llnsrom ffie Iilfqru m the EPC-4OO control or resetan alarm rrn ls hazardous.
3 Alarms
3.3 AlarmSuruey
LED alarms Display alarms Alarmfunction "High Pressure" Oil "LowOil Pressure (LowFlow)" "Sludge Failure" Discharge "Water Fault" Transducer "Emergency Stop" "Vibrationd' (Option) Page
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10
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11
12
13
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14
15
16
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E ErW E E W
"Communication Error" "Processor Fault" "Programming Error" "Power Failure" "Temperature Deviation" "ALCAP Alarms" "Other Alarms"
17
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18
19
21
7
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3 Alarms
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Cause action Corrective
RV4, other valves, correct to back or valve,RV4,or othervalves, downstream Openor regulate Regulating pressure, normally about1.5bar(150kPa). throttled closed. or
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3 Alarms
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Causes
Toolowoilfeed. the before oilfeedpumpis clogged. Strainer Oilfeedpumphasstoppecl. position. overvalve(V1)is in recirculation Change Correctiveactions the Gheck oilfeedpump. the Adjust oil flow. Cleanthe strainer. the Check oilfeedpump. valveblock to 1. Checkthe air supply the solenoid a i r( M V 1 ) . MV1. 2. Check V1. 3. Check
pressure. Toolowback
valve with the Increase backpressure regulating is about1.5 backpressure normally RV4.Thecorrect bar (150kPa). for watervalve(MV15) leakage. Checkthe opening Manual". See"Separator Manual". See"Separator
Automatic actions after alarm reset Mainalarmotf, Alarmdiodeotf. V1 is setfor oil feedto separator.
3 Alarms
b*E
Causes watersupply. Noor verylowopgning
watervalve(MV15) broken. Opening Correctiveactions Checkthe watersupply system.
CheckMV15.
No signalfrom oil pressure low switch(PS42) dis- Check PS42. at charge. watersystemnot working. Separator operating 1. Check separator manually the openMV15. by water 2. Dismantle checkthe operating and Manual". system. See"Separator N.B. the Thisalarmis activated aftertwo attempts discharge, to within samedischarge cycle,havefailed.
Automatic actions after alarm reset Mainalarmoff. Alarmdiodeoff. 1. lf the powerhasbeenoff duringmorethan 10 the bowl approximately minutes separator before mustbe stopped manually and cleaned restart. has 2. The separator the EPCprogram to be and restarted.
Alarm dio@sho0.
is The stopsequence initiated.
10
3 Alarms
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Causes
test transducer circuit between Loose@nnection boardandoscillator. module. unit oscillator or faultyEPCcontrol Faulty Correctiveactions Checkconnections. 3in voltage the MT4on terminal 4 (20 supply Check 4 at the AbouteveryS:thsecond voltage terminal - 5 0.5 (20VDC)will dropfor approx. second: unit. o lf voltage the drop:replace oscillator the drop:replace EPCcontrol lf no voltage module. see interconnections, aboutthe Formoreinformation "System Reference". .
v Dc).
Automatic actions after alarm reset Mainalarmoff. Alarmdiodeoff. V1 is setfor oil feedto separator. .s.
3 Alarms
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Gause
Emergency stopbuttonhas beenpushed. Correctiveactions 1. Remedy cause the why theemergency stop was pushed thenresetit. button and
Automatic actionafteralarmreset
the Thealarmfunction notbe resetby pushing can alarmresetbutton. 1. Resetthe alarmby switching poweroff and the on. 2. Restart separator. the 3. Restart EPCprogram. the
NOTE
The separator bowl mustbe manually cleaned beforestartingup again.
12
3 Alarms
3.4.6 Vibrations(OPtion)
@;
Cause activated. switch Vibration bowlout of balance. Separator Correctiveactions Manual. the See"Separator Remedy cause. switchsetting. Checkthe vibration Automaticactionsat alann Automaticaction afteralarm reset
the can Thealarmfunction not be resetby pushing Mainalarmflashes. alarmresetbutton. Alarmdiodeflashes. is Separator stopPed. the poweroff and the the through heat- 1. Reset alarmby switching 3 is on for a further minutes Oilfeed on. er and separator. the for 2. Restart seParator. watersupplied 3 minutes. Bowlclosing the 3. Restart EPCprogram.
NOTE
The separatorbowl must be manually cleanedbefore starting up again.
3 Alarms
Ns
N.B. Heater faultis onlyactivated the heateris controlled the EPC-400. if by Correctiveaction lf oil flowstopped, investigate cause. the Seecorrectiveactions PS42. for heater. Checkthe flowswitch the Heatpac on lf temperature tripped, investigate temperthe switch lf for atureswitch setting. OK checkthe heater cleanliness. Cleanheater.
Cause
Oil flow stoppedor temperature switchtrippedin an installed Heatpac heater.
\_-
heater. Clogged
Automatic actionsafteralarmreset
Mainalarmoff. Alarmdiodeoff. V1 is setfor oil feedto separator. Heater switched on.
Rtarrtrt|ode flashes.
valve(V1)is set for oil recirculation. Change:ov$ Heaterswitched off.
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14
3 Alarms
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to if Alsoapplicable TT2temperature sensor, fitted. Correctiveactions the it. Investigate reason and remedy
Gauses
Lowtemperature alarmwhen: - doggedheater - insufficient steamsupply - faultysteamtrap - faultysteamsupplyvalve - electricfault(tripped fuse) 'High temperature alarmwhen: - faultysteamsupplyvalve - electrical controlsystemout of function or Set point(P7)changed the alarmlimitsaretoo to the set point. close
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1. Adjust parameters. the temp P5 = rnax. P6 = min.tmp P7 = set point. List'. See"Parameter loop. the 2. Check temperature control
(SRVI)too far openor closed. 1. Checkandadjust SRVI function. the Steamcontrolvalve the functions. 2. Gheck EPCoutput inLowtemperature alarmwhenthe temperature creasestoo slowly,duringthe start. Pt 100temperature signalfaulty. N.B. P41,See"Parameand parameter Checkthe heater ter List'. sensor. Checkthe Pt 100temperature 1
To temperature indicated is whenthe alarmis acknowledged. findthe appropriate Thecurrent pushthe alarmresetbutton twice1C (1F) = TT1,2C (2F)= TT2.For reading, temperature sensor g rnoreinformation, "Operatin Instructions'. see
Automaticactions at alarm Mainalarmflashes. valueflashes. Alarmdiodeanddisplayed overvalve(V1)is setfor oil recirculation. Change
Automaticactionsafter alarm reset Mainalarmoff. to returned normal. Alarmdiodeoff anddisplay V1 is setfor oil feedto separator.
(if is by is on Heater switched at hightemperature heateris Heater switched (if heater controlled EPCis ofi 400). by controlled EPC-400).
15
3 Alarms
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N.B.
E EEE
Correctiveactions
Check temperature the sensor thetestprogram, by "Analog "Test page in thechapter 32 inputs" see on Program".
Checkthe connections.
to the Temperature cabetween temperature sensor sensor cables tooclose power Checkthe cables are and EPC-400. bles.
N.B. process Pushthe alarmresetbutton findappropriate to valuereading. 1C (1F)= TT1,2C (2Fl =TT2.lf bothtemperature are alarmA6 is alsoactivated. sensors fitted,
Automaticactionsat alarm Mainalarmflashes. Alarmdiodeanddisplayed valueflashes. Change overvalve(V1)is set for oil recirculation.
Automatic actions after alarm reset Mainalarmotf. Alarmdiodeoff anddisplay returned normal. to V1 is set for oil feedto separator.
16
3 Alarms
W-H
Alarm code
Cause
actions Corrective
the front 1 . Checkby measurement error Communication between board), A1:F2(front fuses board. and rearcircuit A2:F2 M:F3 (rearboard). and (See"Component DescriPtion, Unit'). Control EPC-400 the 2 . Replace contol module.
3 Alarms
E H
Alarm codes s
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6
Causes
Internal RAMerror.
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External RAMerror.
E2 RAMerror.
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Program error.
Modeswitcherror.
: 6
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error.
Calibration error.
18
3 Alarms
E-;
Alarmcode Cause modetoo long Programming without (morethan30 minutes programming this during time). Correctiveaction to the Change modeselector the "L" (Local) position when and to return the appropriate, "P" (Programming) and Position withprogramming. continue
19
3 Alarms
Eg
Alarmcodes
Causes
Power failure.
Correctiveactions 1. Check powersupply. the 2. lf the powerhasbeenofi duringmorethan 10 the approximately minutes separator bowlmustbe stopped manually and cleaned beforerestart. 3. Restart heater, the separator and EPCprogram. \ i
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1. Check powersupply. the 2. lf the powerhasbeenoff morethan during 10 the approximately minutes separator bowlmustbe stopped manually cleaned and beforerestart. 3. Restart heater, the separator and EPCprogram.
Automaticactionsat alarm
Thefrequency deviation mustbe repeated be continuous or during alarmdelay the timebefore alarmis an activated.
20
3 Alarms
E_g
Alarm code
I
Cause
=
6
Correctiveactions
alarm deviation Temperature (difference TT1 and TT2 between is morethan30 'C/54 "F).
At commissioning senbetween if Check thedistance sorsis toogreat. Systemin operation sensors. the Check temperature
Automaticactions after alarm reset Mainalarmoff. normal. Display
1C process valuereading (1F)= TT1, to Pushthe alarmresetbutton findthe appropriate Insfuctions". (2F)=TT2. Formoreinformation, "Operating see 2C
3 Alarms
3.6.6 ALCAPAlarms
EIg
Alarm codes
e
Causes
(MT4) Highwatertransducer value(above 400): . o Highwatercontent oil. in
Corrective actions
at
(MT4) Lowwatertransducer value(below 100): . in Opencircuit the MT4. 1. Checkconnections control in unitandtransducer. 2. Checkcables damage. for . Badconnection between oscillator and electrode. unit
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1. Check cableconnection. the 2. Tighten oscillator to the unit electrode. Thbleason stand-by for modemust be checked! Try thento operate systemnorthe mally. Replace contdi module.
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PROMand/orRAMfault.
5
water Nofriggering water tansducer 1. Checkthe displacement by partsin in including signal twosludge at dischargesa supply, row. separator. 2. Check bnwlleakage. for
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22
3.6.7 OtherAlarms
Eg
Alarm codes
Causes
Extraalarm.
Correctiveactions n."&.,:
Automaticactions at alarm Mainalarmflashes. flashes. Display is The startof the timersequences (is onlyvalidfor alarm blocked A9-2). Mainalarmotf. normal. :;,rj, Display
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AlarmTests
Usethe following guidefor testingalarm functionsby activatingthem.Alarmsare (A, provoked oneor moreactions B andso by however, on) as shownin the right columno certainalarmfunctionscannot be tested withoutbeingdisconnected. N.B. If the alarmfunctionsareto be in disconnected the controlunit, be carefulto avoida short-circuit. is The recommendation to testthe alarms every3 months.
LEDalarm Displayalarm Function Highoil pressure
'+ffi
Sensor
PS41
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L-
PS42
hosefor oPening 1. Disconnect water(MV15). discharge. a 2. Initiate sludge Disconnect cableto XE:4 (thetest MT4). signalto
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stop Emergency
X52
(option) Vibrations
XS1
three switch Tapon the vibration second. timeswithinone 1. Startthe heater. cableto X9:3. 2. Disconnect
Heater fault
Tests 4 Alarm
LEDalarm
Displayalarm
Function
Sensor
Actionsto provokean alarm frompipeand A. Remove sensor put intohoVcool liquid. B. Change alarmlimitparameters = m?xtemp., = min. (P5 P6 temp.)in relation actual to temperature. more For information "Parameter see List'. N.B. Resetthe parameter values aftertest.
Communication error
Remove fuse42:F3(rearboard).
A/Dconversionerror
Remove fuseA1:F2(frontboard).
Programming error
.
!"
Leavethe modeselector switchin position for 30 minutes. P the to Switch power the EPCoff and on whenit is in operation.
Power failure
tui',:
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Temperature frompipeto cool deviation TT1 . TT2 Remove sensor one diff. off or be heated (temp. more up than 30'C/54'F). Highwatertransducer MT4 (MT4) value(above 400). Lowwatertransducer MT4 (MT4) value(below 100). Insufficient amount of water displacement
MT4
Touchthe central screwin the MT4 cpnnection box. Disconnect cableto XE:3in EPC.
parameter to a low 70 A. Ghange value(e.9.5seconds) and initiate cycletwice. discharge :,'. water B. Closedisplacement supply andwait2 discharge cycles. water Theamount displacement of is every2nd dissupply checked charge. A. Activate sensor. appropriate X7:1. B. Disconnect cable
Extraalarm
Withthe EPCin off modeputa jump XCer between X7:4and pushthe startbutton.
26
AlarmTests
Usethe following guidefor testingalarm functionsby activatingthem.Alarmsare (A, provoked oneor moreactions B andso by however, on) as shownin the right columno certainalarmfunctionscannot be tested withoutbeingdisconnected. N.B. If the alarmfunctionsareto be in disconnected the controlunit, be carefulto avoida short-circuit. is The recommendation to testthe alarms
every3 months.
LEDalarm Displayalarm
'"Fw
Sensor
PS41 Actions to provokean alarm Increase backpressure. .:*i
Function
Highoil pressure
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PS42
A. Stopoilfeedpump. by V1 B. Ghange position reducing air pressure the C. Reduce backpressure.-:' hosefor opening 1. Disepnnect water(MV15). discharge. 2. Initiate sludge a Disconnect cableto XE:4(thetest MT4). signalto
L-
@ @ @
fault Watertransducer
MT4
Emergency stop
X52
(option) Vibrations
XS1
switchthree Tap on the vibration timeswithinone second. 1. Startthe heater. cableto X9:3. 2. Disconnect
fault Heater
Tests 4 Alarm
LEDalarm
Display alarm
Function
Sensor
Actionsto provokean alarm frompipeand A. Remove sensor put intohoVcool liquid. B. Change alarmlimitparameters (P5= mdxtemp., = min. P6 to temp.)in relation actual temperature. more For information "Parameter see List'. N.B. Resetthe parameter values aftertest.
Communication error
Remove fuse42:F3(rearboard).
A/Dconversionerror
fuseA1:F2(frontboard). Remove
Programming error
Leavethe modeselector switchin position for 30 minutes. P the Switch powerto the EPCoff and on whenit is in operation. Remove sensor frompipeto cool one off or be heatedup (temp.diff. more than30'C/54'F). Touchthe centralscrewin the MT4 connection box. Disconnect cableto XE:3in EPC.
\ MT4 -
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Power failure
bS":,',1'
t-: t' hr. Fi,-
F-* "
Fi".. ',d:... ,
ry
Highwaterfansducer (MT4) value(above 400). Lowwatertransducer (MT4)value (below 100). Insufficient amount of displacement water
MT4
MT4
parameter to a low 70 A. Change value(e.9.5 seconds) and initiate discharge cycletwice. water B. Closedispldcement supply andwait2 discharge cycles. water Theamount displacement of is dissupply checked every2nd charge.
Extraalarm
Withthe EPCin otf modeputa jump XC- X7:4and pushthe er between startbutton.
26
TestProgram
controlunit hasa testprogram, The EPC-400 for testingof input andoutputfunctions, memoryetc. This testprogramshouldbe run whenthe thereis a is installation madeandwhenever duringfault finding. needfor it, for instance,
f-
fr3:
27
5 TestProgram
5.2 LampTest
The testprogramstartswith a lamptest. 1. The displaylit with poweron. 2. Therearetwo waysto checkthe lamps: . EachLED anddisplaysegment lit individually (see picture). the . Eachgroupof LED:s anddisplay lit. segments Pushthe button2 (seethe figuresin the picturebelow)to switchbetween two the modes.
/n\ v
A v
/Ar
1nr v
v
1nl v
ic
28
5 TestProgram
a
Memory correct
U
Memorytault
I
E
2. Digitalinputs
1.4 EEPROM
Function
Unit PS42
PS41
Gorrect value
0
1
a
Circuitopen
{ { {
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Ciruit closed
X8:4-XC
XS2or XS1
1
..t'
X8:2-XC
Remote switch
0 0
L-
29
5 TestProgram
3. Digitalinputs
Function 3.1 9.2 Circuitopen 3.3 Alarmacknowledge Reset or fault Heater Sludge discharge Terminal Unit X9:4-XC X9:3-XC X9:2-XC Remote switch Remote switch Correct value 0
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Circuitclosed
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4. Modeselector
Function
F'
ll.C o.
Remoteposition t L
4.1 4.2
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t
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Localposition
Pr o
position Program
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30
l
FOPXAlarms and FaultFinding
5 TestProgram
outputs 5. Digital
or 3 Usepush-button to activate deactivate "How to ActivateDifferent eachoutput(see Partsof theTestProgram"on page28). greenLED is not lit. N.B. Corresponding
Function Terminal X4:4-XD Unit MV1/V1 5.1 5.2 5.3 Oilfeed Waterdrain water Displacement sealing or suPPIY water Opening water Closing
n u
Circuitdeactive
I
Circuitactive
MV15
MV16
valveor Heatpac X 6 : 1 - X D Steamshut-off fixedload valvedecrease Heatpac X6:2-XD or Steam fixedload valveincrease Heatpac X6:3-XD or Steam fixedload
outputs 6. Digital
each or Usebutton3 to activate deactivate "How to ActivateDifferentParts output.(See of theTestProgram"on page28.) L-,, greenLED is not lit. N.B. Corresponding
Function
Terminal X6:4-XD X4:2-XD i K15n power unit
Unit
n u
Circuitdeactive
6.1 6.2
variable load Heatpac Heatpac during alarmblocking start Notin use stop Separator Notin use Remote/commonalarm vibration Blocking switch
I
Ciranitactive
X1:1-2
7. Notin use
31 I
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I
5 TestProgram
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inputs 8. Analog
To simulate temperature the sensor elements (Pt 100)in 8.1and8.2,a resistor beused. can plug connectors Separate with appropriate resistors included thetestmodule are in kit. Resistor Ref.temp Display reading
110 c) 140 c)
25"ct77"F 60 104'ct2t9.F215
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The normalvalueon the displayfor function 8.1and8.2 should 60 - 215.Outside be the - 233indicates fault. Value000 (or range42 a a very low value)or 255 indicates serious a fault. A normalvaluefor function8.3"Reference 4 V shouldbe 195- ?lln
t - 1, '
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Terminal Unit Fuse A1:F2 A/Dconver- Inputopen Input short blown sionfaulty circuit X 1 0 : 1 - 2 - 3TT2 X11:1-2-3 TT1 000 000 000 000 000 000 255 255
1 9 5- 2 1 5
000 000
1 9 5- 2 1 5
"000" for For instance, thedisplayshows if function8.1,8.2and8.3,it mustbe eithera blown fuseor A/D converter fault. Checkit in this order: l. If thefuseis blowno replace it. 2. If the fuseis correct,replace control the module.
32
i
5 TestProgram
communication 9. Serial
Function Terminal X14:1-3
X14:1-3
Unit
B
Circuit@rrect
9.1 9.2
Notapplicable (Thedisplay showan E). will RS232C -10 Measure to -12VDC (Circuit correct). on X14:1-3
E
Circuitfault
t
the cable N.B. Disconnect communication Xl4:3-4 andput a jumperbetween beforethe testis carriedout.
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F
33
? f! t
5 TestProgram
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(rearcircuitboard) 10;-Test EPROM of 11.Test internal RAMin GPU(rear of circuitboard 12.Test RAMin GPU(rear of"exftllnal circuitboard) , 13.Test lC 8255l/Oport (rearcircuit of board) 14.Lowreference input analog (internal)
42 when A valuebetween and66is displayed, it is correct.
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B
Circuit correct
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F
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Ciraitfault
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>xul
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F. l6.Transducer signal(internal)
i ' 100 fne display shows + -50 withoil in WT + 10withair,when is correct. 200and55 it ( i orr
34
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