EPC 60
Service Engineer Training
Printed
Book No.
Mar 2008
EPS006 V 1
ight to make changes at any time without
possible errors and omissions or
this publication would be
be ordered from your local
a Laval Tumba AB
rts & Service
47 80 Tumba
eden
umba AB 2006.
Alfa Laval reserves the r
prior notice.
Any comments regarding
suggestions for improvement of
gratefully appreciated.
Copies of this publication can
Alfa Laval company.
Published by: Alf
Pa
SE - 1
Sw
? Copyright Alfa Laval T
Contents
1 The new marine control
system....................................... 1
2 Control cabinets...................................3
2.1 Introduction .......................................3
2.2 Cabinet with starter ........................4
2.2.1 Cabinet with starters...............................5
2.2.2 Contactor................................................6
2.2.3 AC/DC converter ....................................7
2.3 Heater cabinet ..................................9
2.3.1 Inside the cabinet.................................10
3 CPU and I/O...........................................13
3.1 Inside the cabinets........................13
3.1.1 I/O A3; digital input. .............................15
3.1.2 I/O A4; relay output...............................16
3.1.3 I/O A5; 6 relay output............................17
3.1.4 I/O A6; 4 relay output............................18
3.1.5 I/O A7; 4 Analogue input ......................19
3.1.6 I/O A8; 2 Analogue input ......................20
3.1.7 I/O A9; 2 relay output ...........................21
3.1.8 I/O A10; 4 input namur .........................22
3.1.9 I/O A11; 1 analogue input ....................23
3.1.10 I/O A14; 6 digital output .......................24
3.1.11 I/O A15; 2 digital input..........................25
3.1.12 I/O A12; 6 relay output .........................26
3.1.13 I/O A13; 6 digital input..........................27
3.2 CPU .....................................................28
3.2.1 Bus holder ............................................28
3.2.2 Terminal blocks.....................................29
3.3 The I/O boards .................................30
3.3.1 Change the I/O .....................................30
3.4 Programmable Inputs and
Outputs ..............................................31
3.4.1 Inputs ( I/O A13) ...................................31
3.4.2 Outputs (I/O A12) .................................31
3.5 I/O Test Function............................32
4 Operator Panel ...................................37
4.0.1 Buttons .................................................38
4.1 EPC 60 Menus..................................40
EPS006
4.2 Operation page ...............................41
4.3 Settings page ..................................41
4.3.1 Parameters ...........................................42
4.3.2 Time setting ......................................... 42
4.3.3 Operation info ...................................... 43
4.3.4 I/O Test ................................................ 45
4.3.5 Alarm history........................................ 46
4.3.6 System info .......................................... 48
4.3.7 IP settings ............................................ 48
4.3.8 Password/ Log in ................................. 49
4.4 Alarms List ...................................... 50
4.4.1 Alarm denomination............................. 51
4.4.2 Alarms on the EPC 60.......................... 52
5 Parameters............................................61
5.1 Setting List ..................................... 61
5.2 Additional parameter info........... 69
5.2.1 P & I setting P123 and 124 .................. 69
5.2.2 Calculating Operating Pressure .......... 70
5.2.3 Remote control/ monitoring ................. 71
5.2.4 Programmable in- and outputs............ 72
5.2.5 Cross connection/serial operation....... 72
5.3 ALCAP ............................................... 73
5.3.1 Testing the MT60 ................................. 74
6 Computer connection ....................75
6.1 Computer settup............................ 75
6.2 Download of application
software ........................................... 77
7 Servcom ..................................................79
7.0.1 Process view........................................ 80
7.0.2 Initial settup ......................................... 80
7.0.3 Connect to EPC60 ............................... 81
7.0.4 Parameter view .................................... 81
7.0.5 Managing parameters ......................... 82
7.0.6 Reports ................................................ 84
7.0.7 Logging ............................................... 88
8 Operating instructions..................91
8.1 Before First Startup...................... 91
8.2 Manual Start from Standstill ..... 93
8.3 Automatic Start from
Standstill ........................................ 100
8.4 During separation........................ 101
8.5 Stop.................................................. 103
8.5.1 CIP Start ............................................ 105
8.6 Heater Control (optional).......... 110
8.6.1 Control of the electric heater
(optional)............................................ 111
EPS006
8.6.2 Control of the CBM heater
(optional) ............................................113
8.6.3 If heater not controlled or external .....113
8.6.4 Heater shut down ...............................114
8.7 Operation without all sensors
(Emergency operation)...............115
8.7.1 System Without Speed Sensor ...........115
8.7.2 System Without Vibration Sensor........115
8.7.3 System Without Cover Switch.............115
8.7.4 System With PT1 Disabled .................116
8.7.5 System With PT4 Disabled .................116
8.7.6 System With PT5 Disabled
(S-separator only)...............................116
8.7.7 Control of Sludge Pump,
Level in Sludge Tank,
and Butterfly Valve..............................117
8.7.8 System Without Feed Pump ...............118
8.7.9 System Without Water Transducer
(S-separator only)...............................118
EPS006
EPS006
EPC 60 SERVICE ENGINEER TRAINING 1 THE NEW MARINE CONTROL SYSTEM
ol system1 The new marine contr
In 2003 it was decided that the EPC50 needs to
be replaced by another system.
The arguments for this decision were:
? High product care costs, as the EPC50 is an
Alfa Laval owned product
? Problems with component supply, EPC50 is
an old design, and so are many of its
components
? High product cost
? Too many claims
? Low flexibility
After an initial benchmark of many systems, one
supplier was chosen, B&R Automation, which is
a company located in Austria.
B&R Automation only work with OEM-
customers, which makes their product strategy
suitable for Alfa Laval.
In 2007 B&R Automation where selected to be
Alfa Laval’s preferred supplier for Automation
systems.
The development of EPC60 then began, and from
2004 the system has been developed and tested.
The first product to use the EPC60 will be the
Flex Range, with the first deliveries in June
2008.
Other marine systems will soon follow; projects
for new versions of Ecostream and FCM are
already started.
Also other, non-marine product will use the
EPC60 as a base for their automation.
EPS006 1
1 THE NEW MARINE CONTROL SYSTEM EPC 60 SERVICE ENGINEER TRAINING
2 EPS006
EPC 60 SERVICE ENGINEER TRAINING 2 CONTROL CABINETS
2 Control cabinets
2.1 Introduction
We have two types of cabinets; one with starters,
the large cabinet and one without starters, the
small cabinet. The small cabinet is intended for
customers that uses their own starters. Both
options are available for modules and lose
components.
The new cabinets are not integrated in the
module as on the S units. In the Flex modules we
are using standard cabinets mounted on the
module frames.
There are some new components in the cabinets
and we will go through them in this chapter.
Fig 2.1 Starter cabinet w/contactors and without
EPS006 3
2 CONTROL CABINETS EPC 60 SERVICE ENGINEER TRAINING
Q5 Q7 Q4
Q3/K3
Q1
T A 1
Q2/K2
X3 X4
X5-X20
Q1
X
0
24
90
1A
M
o
tor
s
t
ar
ter
Amm
e
ter
k
i
t
Ex
tr
a I/O
bo
ar
d
ter
m
i
nal
(
o
ptio
nal
)
Vi
br
atio
n tr
an
smi
tter
ter
m
inal
(
o
ptio
nal
)
Sp
eed t
r
a
n
sm
itte
r
t
e
r
m
in
al
(
opti
onal
)
S
t
eam
hea
ter
ter
m
i
nal
(
o
pt
i
o
na
l
)
Heat
tr
aci
ng t
e
r
m
in
al
(
opti
onal
)
E
l
e
c
tr
i
c
al
he
ater
ter
m
i
nal
(
o
pt
i
o
na
l
)
Em
er
g
enc
y s
t
op
Ci
r
c
ui
t br
eak
e
r
Ci
r
c
ui
t br
eak
e
r
Ci
r
c
uit
br
eak
er
2.2 Cabinet with starter
K 2 0
K 1 1 2
TR1
X401 X400 X501 X500
X1 X2
A9-A15
K 6
K 7
Q 6
OP1
P1
G A 1
Fr
on
t view
Inter
nal
vi
ew
Co
v
e
r
i
n
ter
l
oc
k
k
i
t
(
o
ptio
nal
)
ES
D
ki
t
(
o
pti
onal
)
PL
C
A1
-A
8
Sl
ot
s
Fa n
H
e
at
t
r
a
c
i
n
g k
i
t
(
opti
ona
l)
E
l
e
c
tr
i
c
a
l
he
ater
boa
r
d
(
o
pt
i
o
na
l
)
Ex
tr
a I/
O
b
oar
d
(
opti
onal
)
V
i
br
at
ion tr
ans
mitt
er
boar
d
(
opti
ona
l)
Sp
eed t
r
a
n
sm
itte
r
b
oar
d
(
opti
onal
)
S
t
eam
hea
ter
boar
d
(
o
pt
i
o
na
l
)
Te rm i n a l s
T
r
ans
f
o
r
m
er
P
L
C s
t
anda
r
d
ki
t
4 EPS006
EPC 60 SERVICE ENGINEER TRAINING 2 CONTROL CABINETS
ig 2.2 inside a EPC 60 cabinet with starters
2.2.1 Cabinet with starters
This is a picture of the inside of a cabinet with
starters. Most of what we find inside is familiar
parts but some are new. We have a new AC/DC
converter, new terminals and new contactors
with built in overcurrent protection. We will
explain about the new parts in this chapter.
Emergency stop button:
At delivery, the emergency stop button will be
placed loose inside the control cabinet.
Note that an emergency stop button must
always be installed/connected and within
visible range of the separator.
N
O
T
E
Only in small cabinets without contactors
24VAC to 24VAC transformer;
This is an isolation transformer, needed to
isolate the 24VAC used in the cabinet from the
supplied 24VAC.
This because of legal requirements and to
minimize earth potential related problems.
F
EPS006 5
2 CONTROL CABINETS EPC 60 SERVICE ENGINEER TRAINING
ig 2.3 Contactor w/ over current protection
ig 2.4 With the over current protection removed
2.2.2 Contactor
We have a new supplier for the contactor,
Telemecanique and new design.
The big advantage with the new design is that
the over current protection is built into the
contactor and is detachable. This means if there
has been an error during mounting, you don’t
have to remove the whole part anymore you just
remove the over current protection and mount
the right one in its place. You still have to set
the over current protection correctly as before.
F
Changing the over current protection.
To remove the over current protection you first
have to make sure that the power in the cabinet
is off. Then you have to lift the safety handle on
the unit to unlock it. Grab the handle and pull
the unit out horizontally, take care not to
damage the unit. When fitting the protection
unit on the contactor make sure it is well
pushed into place before locking the safety
handle.
When you change the setting on the protection
unit, you first lift the safety handle and then
the plastic protection lid. Set the correct amp
and then fit the lid and handle.
Make sure the safety handle is fitted correctly
to make sure the protection unit is not vibrating
and coming lose from the contactor; which can
be a fire hazard.
F
6 EPS006
EPC 60 SERVICE ENGINEER TRAINING 2 CONTROL CABINETS
g 2.5 AC/DC converter
erminals w/ level connectors
2.2.3 AC/DC converter
This device converts the 24VAC supplied by the
transformer to 24VDC.
Note that this component has a fuse( 5A)
mounted, protecting the 24VDC output.
The 24VDC is used to supply the EPC60 and all
the analogue sensors and digital inputs.
Note that solenoid valves and contactors are
supplied with 24VAC.
Fi
Terminals:
3 level clamp connection terminals are used.
Note that on some terminals an orange “level
connector” is installed, this is used to connect
the different levels to the same potential.
There are also yellow horizontal connectors
used to connect the same potential to more than
one terminal.
This is snap on terminals, fit a screw driver in
the rectangular hole and push. Fit the cable and
remove the screw driver again.
Pic 2.6 T
EPS006 7
2 CONTROL CABINETS EPC 60 SERVICE ENGINEER TRAINING
Pic 2.7 Innside a small cabinet without contactors.
8 EPS006
EPC 60 SERVICE ENGINEER TRAINING 2 CONTROL CABINETS
2.3 Heater cabinet
There is a new heater cabinet to the new EPC
60. It looks almost the same as the old type, but
some parts are new and there are some changes
in the electrical connections.
The heater cabinet is optional and will only be
delivered when electrical heater controlled by
EPC 60 is ordered.
The size of the cabinet will vary with the size of
the heater. Today we have heaters from 7 to
130kW and 380 to 690V. All systems below 380V
are treated as off spec system and can be ordered
specially.
The new flex system allows easy upgrading to el
heater due to the modular system.
Fig 2.7 Double module w/ heater cabinets
EPS006 9
2 CONTROL CABINETS EPC 60 SERVICE ENGINEER TRAINING
F14
K14K12 K13K11
F13
KA1
1-14
2.3.1 Inside the cabinet
F11 to F14;
Overcurrent protection fuses
K11 to K14;
Contactors
V1 and V2;
Triac solide state relay
S2;
Termo switch
KA11 and KA12;
Interface relays
S1;
Main switch
X;
Terminals
Fig 2.9 Parts in the heater cabinet
V1 V2
X
F12F11
S1
S2
10 EPS006
EPC 60 SERVICE ENGINEER TRAINING 2 CONTROL CABINETS
ig 2.10 The new Triac
Electric heater conections,
From the EPC60 there are 5 signals to the
electric heater cabinet.1 output for variable load,
activating the 2 triacs, 3 outputs to the fixed load
steps. The number used depends on heater size.
There is 1 output for “heater on”, this activates
the K11 inside the electric heater cabinet.
There is also one signal going back to the EPC60,
and this is “Heater fault”.
This signal is expected to be high (active) when
the “heater on” signal is high (active), if not, the
“heater fault” alarm will be activated.
This is normally caused by the over temperature
device, “S2”.
Triacs,
A new type of triac is used, and it is equipped
with a led-indicator, which illuminates when
the triac is active.
The function of the triac itself is the same as the
old type of triacs.
F
EPS006 11
2 CONTROL CABINETS EPC 60 SERVICE ENGINEER TRAINING
12 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
0
8
4 C
0
8
4 C
(2)(3)
odule
nel
l input
t
t
t
input
input
t (optional)
(optional)
tput (optional)
(optional)
t (optional)
2 x Digital input (optional)
RJ 45 exter
nal
c
onne
ctor
o
n
th
e
doo
r
(female
)
input (optional)
3 CPU and I/O
3.1 Inside the cabinets
24VDC
(IN)
24VDC
(IN)
24VDC
401
400
1
6
5
9
1
6
5
9
401
400
(1)
Txd
Rxd
GND
1
2
3
123
Note:
(1) Bridge
(2) Node switch = 0
(3) Node switch = 6
Bus supply m
24 V DC
Operator pa
CPU
6 x Digita
2 x Relay outpu
6 x Relay outpu
4 x Relay outpu
4 x Analogue
2 x Analogue
2 x Relay outpu
1 x Namur input
6 x Relay ou
6 x Digital input
6 x Digital outpu
RJ 45
Plug-in
conn
ector (ma
l
e)
Dsub plug
(ma
le)
C
o
nnect
o
r ca
b
l
e
(f
emale)
2 x Analouge
EPS006 13
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
? A3; 6 digital input
X20 DI 6371
Input from the digital inputs
? A4; 2 relay output
X20 DO 2649
Output ot separator and pump contactor
? A5; 6 relay output
X20 DO 6529
signal to sludge pump, common alarm, SV1,
SV4, cooling fan and steam shut off valve.
? A6; 4 relay output
X20 DO 4529
SV5, SV10, SV15 and SV16
? A7; 4 analogue input
X20 AI 4622
PT5, MT, PT1 and PT4
? A8; 2 analouge input
X20 AT 2222
TT1 and TT2
? A9; 2 relay output (optional)
X20 DO 2649
Steam regulating valve decrease and
increase
? A10; 4 input namur
X20 DI 4760
speed transmitter
? A11; 1 analogue input (optional)
X20 AI 2632
Vibration sensor
? A12; 6 relay output (optional)
X20 DO 6529
Programmable outputs
? A13; 6 Digital input (optional)
X20 DI 6371
Programmable innput
? A14; 6 Digital output (optional)
X20 DO 6322
Electrical heater board
? A15; 2 Digital input (optional)
X20 DI 2371
Heater fault signal.
14 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
A3
501400 401
(1)
X
0
24
68
0
A
Separator em
erg
e
nc
y s
t
o
p
Fee
dback pu
mp
con
ta
ctor
(optio
nal
)
Le
ve
l switch
sludge tank (opti
onal
)
Separator cover
limit swi
t
c
h
(o
ption
a
l)
Slu
d
g
e
valve
interlo
c
k
(o
ption
a
l)
Separator interlock switch Aux. r
e
lay
(optio
nal)
F
eedba
ck
separator
c
ontactor
3.1.1 I/O A3; digital input.
500
N.C.
N.O.
b
Ref. 580879 Sheet 4, Rev. 2
Note:
1. Remove jumper
when used.
EPS006 15
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
A4
501
(1)
(1)
a
X
0
24
68
1
A
C
o
nt
ac
t
o
r
separator
C
o
nt
ac
to
r
feed pump(opti
onal
)
Separator contr
o
l
em
er
ge
nc
y
op
e
r
at
i
o
n
Feed pump contr
o
l emerge
ncy
ope
r
ati
o
n
2
r
e
lay
outpu
t
Co
v
e
r limit
s
witch
(op
t
io
nal)
3.1.2 I/O A4; relay output
500
N.C.
N.O.
N.C.
N.O.
(4)
036
(3)
(2)
Ref. 580879 Sheet 5, Rev. 2
Slu
dge v
a
lv
e
inter
l
oc
k
(op
t
io
nal)
Se
par
ato
r
st
ar
t
e
r o
v
er
32
A
1
)
A
v
ai
lab
l
e
f
o
r emerg
ency
op
er
at
ion
.
2
)
C
o
nnect
i
on when
Co
v
e
r Limit
Swit
ch
is with
on
e co
nta
c
t
.
3
)
C
o
nnect
i
on when
Co
v
e
r Limit
Swit
ch
is not
mo
unt
ed.
4
)
R
e
mo
v
e
ju
m
p
er when used
.
16 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
501
A5
401
X
0
24
68
2
A
Pn
eumatic sludge
pu
mp so
leno
id val
v
e
SV6 (optio
nal)
Co
mmon
a
l
ar
m
Fe
ed sole
noi
d valve
SV
1
PLC co
olin
g fa
n
S
tea
m
shu
t
-of
f
valve
(opti
ona
l)
Oi
l outlet so
len
o
id
valve SV4
6 r
e
lay outpu
t
3.1.3 I/O A5; 6 relay output
400
500
Ref. 580879 Sheet 6, Rev. 2
Shut-of
f
(opti
onal
)
(optiona
l)
EPS006 17
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
A6
501
X
0
24
683
A
Drai
n
va
lve SV5
Displac
ement water
SV
10
Disch
arge val
v
e
SV
1
5
Closi
ng water
SV
16
4 r
e
l
a
y outpu
t
3.1.4 I/O A6; 4 relay output
500
Ref. 580879 Sheet 7, Rev. 2
18 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
A7
401
X
0
24
684
A
W
a
ter outlet p
r
ess
u
r
e
PT
5
W
a
te
r transduce
r
MT
Fe
ed pr
essur
e
PT
1
Oil
o
u
tl
et
p
r
essur
e
PT
4
4 an
a
l
og
ue
in
pu
t
3.1.5 I/O A7; 4 Analogue input
400
Ref. 580879 Sheet 8, Rev. 2
(p
ass
i
v
e
)
(pa
s
siv
e
)
(
pa
ssiv
e)
(a
c
t
iv
e)
EPS006 19
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
A8
X
0
24
68
5
A
T
e
mpe
r
a
t
u
r
e sensor
TT
1
T
e
mperatur
e
se
nsor
TT2
2 Ana
l
ogue input
Se
nso
r
+1
S
ens
or
-
1
S
enso
r
-1
Sen
s
or
+
2
Se
nso
r
-
2
S
enso
r
-
2
3.1.6 I/O A8; 2 Analogue input
Ref. 580879 Sheet 9, Rev. 2
20 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
A9
501
X
0
24
90
4
A
Stea
m r
e
gu
lating valve
co
ntr
o
l
Dec
r
ease
Ste
a
m r
e
gu
lating
valve
co
ntr
o
l
Incr
e
a
se
2 Relay
Outp
ut
3.1.7 I/O A9; 2 relay output
500
M
Ref. 580885 Rev. 2
DecGND
In
c
EPS006 21
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
X
0
24
899
A
4 Input Namur
Sp
ee
d tra
n
smitt
e
r
ST
3.1.8 I/O A10; 4 input namur
Ref. 580887 Rev. 2
22 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
gue input
X
0
24
903
A
3.1.9 I/O A11; 1 analogue input
A11
401
400
Vibration sensor
1 Analo
(active)
From drawing
580879
Ref. 580889 Rev. 2
EPS006 23
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
A14
X
0
24
90
5
A
Electric powerHea
t
e
r
vari
abl
e
load
Electric powerHe
ate
r
step 1
Elect
r
ic power
He
ater step 2
El
ectric po
wer
Heater ste
p
3
Spa
r
e
H
ea
te
r on
6 Digital output
3.1.10 I/O A14; 6 digital output
Ref. 580895 Sheet 1 Rev. 2
24 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
Spare
put
X
0
24
906
A
3.1.11 I/O A15; 2 digital input
A15
Electric heater
Fault feedback signal
2 Digital in
Ref. 580895 Sheet 2 Rev. 2
EPS006 25
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
A12
X
0
24
90
7
A
H
e
a
t
er on
I
n
d
i
cation for
separator
St
and
s
till heating
in
di
cation
Alar
m
High oil te
mperatur
e
Alar
m
Lo
w
o
i
l
temperatur
e
Pr
ogrammable
spa
r
e ou
t
p
u
t
6 Relay ou
tput
3.1.12 I/O A12; 6 relay output
Ref. 580893 Sheet 1 Rev. 1
26 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
A13
400 401
X
0
24
90
8
A
System r
e
mote
star
t
System
r
e
mote
stop
Feed pump
r
e
mote
star
t
Pr
ogrammable
r
e
mote s
p
ar
e
inp
u
t
P
r
og
ra
mm
a
b
le
r
e
mo
te spar
e input
Pr
ogrammable
r
e
mote spar
e input
6 Digital input
3.1.13 I/O A13; 6 digital input
Ref. 580893 Sheet 2 Rev. 1
P
u
lse si
gnal
Pul
s
e
sign
al
Pulse signa
l
EPS006 27
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
ig 3.2 CPU with power supply
ig 3.3 Bus holder for I/O
3.2 CPU
3.2.1 Bus holder
The CPU is the brain in the system. This is the
unit to which all the signals in the system are
sent. All the I/O is connected to the CPU.
There is an Ethernet connection on the CPU
and we use this to communicate with the
Servcom program. We also use Ethernet
connection to download new program versions,
covered in chapter 6.2.
There are two node number switches on the
front of the CPU, called x16 and x1.
The arrow on the x16 should be pointing at 0
while the arrow on the x1 should be pointed at
6.
F
This is the backbone in the I/O system, holding
all the cards together. The holder is common for
all the I/Os and has a snapon function to DIN
rail.
It can be difficult to change one of the holders if
the whole setup is connected to the DIN rail. If
it is necessary to change a holder, remove the
whole setup and change the one damaged and
then connect all holders back on to the DIN rail.
To remove the holder from the DIN rail; lift the
orange handle on top of the holder. To fasten
again, move the orange handle down. Make
sure that all the holders are fastened securely
to the DIN rail; shake the holders to make sure
lock is fastened to the DIN rail.
F
28 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
ig 3.4 Terminal block
3.2.2 Terminal blocks
The terminal blocks are where we connect the
internal cables. This is a standard component
used on all the I/O’s. The connections can vary
from I/O to I/O depending on the function.
To connect a cable; push the black button on top
of the right connection, enter the cable and let
go of the button again.
To remove the terminal block; push down the
handle on top of the block and tilt the top of the
block outwards. There is a guide on the bottom
of the terminal block; make sure the terminal
block is in a horizontal position before removal.
The terminal blocks will not be connected in the
factory due to the possibility of damage to the
I/Os from power surges during ship building.
The conection of the terminals must be done
during commissioning.
F
EPS006 29
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
ig 3.5 I/O DI 6371
3.3 The I/O boards
3.3.1 Change the I/O
The I/O boards gather information and act as
the link between the monitors (i.e. temp and
pressure sensors) and the CPU.
There are ten different I/O boards used for,
digital input, digital output, analogue input and
temperature module.
The picture to the right, Fig 3.3 is an example
on a I/O board . All the different
I/Os are listed in chapter 3.1.
F
To change the I/O board you first have to
remove the terminal block, see info in 3.2.2.
The I/O board is locked to the bus holder and
when removing the I/O push the triangle on top
to unlock. To make sure that the I/O card isn’t
damaged during removal, hold the card in a
horizontal position while removing.
When a new card is fitted this also has to be in a
horizontal position. Make sure that the I/O card
is in final resting position before fitting the
terminal block.
It is important that the right I/O board is fitted
in the correct position. See chapter 3.1 for more
information about the I/O boards. All the boards
have their specific task. Fitting the wrong board
can result in damage to the board(s).
30 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
REMOTE selected on
th REMOTE button in any
ual start, see 1.3 Manual
l switch in a tank.
ion is expected
splay
active
ve
3.4 Programmable Inputs
and Outputs
An extra I/O kit is available as an option. This
kit contains two boards, one with six
programmable digital inputs and one with six
progammable relay outputs. The customer can
select an optional function for each of these
inputs and outputs from a list of alternatives
(see below).
3.4.1 Inputs ( I/O A13)
See parameters 139 to 144.
3.4.2 Outputs (I/O A12)
See parameters P133 to P138.
Alternative Comments
Remote start Enter automatic start, only if
operator panel.
Remote stop Enter stop sequence, works wi
position.
Remote start feed pump The same as first push on man
Start from Standstill, page 9.
External alarm For example, used for a leve
See Alarm 123.
Alternative Comments
Indication heater on/ start
external heater
Activated when heating funct
Indication separator motor on
Indication feed pump on
Standstill indication When ‘Standstill’ shown on di
Indication alarm A20 If alarm ’Oil feed temp. high’
Indication alarm A21 If alarm ’Oil feed temp. low’ acti
EPS006 31
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
ence/Limits
to IB(s)
to IB(s)
lid for:
and P types
nal
lid for:
and P types
lid for:
and P types
lid for:
and P types
lid for:
and P types
3.5 I/O Test Function
This is used during commissioning to test all the
functions and also during fault finding to check
functions on one or more I/O.
Activity Refer
If system has active alarms, check and take actions before
starting the I/O test.
Access the I/O test under settings in the panel, see chapter
4.4.4.
Acc.
Follow the list of I/O‘s (item 25-72) to check status of all el.
connections of the system including the operating function of
individual components.
Acc.
OUTPUTS
K2 - Separator motor
Check the operation and rotation of the separator motor.
The output will only be activated for a short time.
Also check that the correct led is activated on the operating
panel.
Va
All S
If no operation, check jumpers according to electrical
diagram.
K3 – Feed pump
Check the operation and rotation of the feed pump.
Also check that the correct led is activated on the operating
panel.
Optio
Va
All S
If no operation, check jumpers according to electrical
diagram.
V1 – 3 way valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
Va
All S
V4 – Oil outlet valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
Va
All S
Cabinet fan
Verify the operation of the fan mounted inside the electrical
cabinet.
W
A
R
N
IN
G
!
Electrocution Hazard
This operation requires tests to be made with
cabinet door open and with power on.
Beware of live parts.
Va
All S
32 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
tional
alid for:
and P types
alid for:
and P types
tional
alid for:
/615
alid for:
and P types
alid for:
and P types
alid for:
and P types
tional
alid for:
and P types
tional
alid for:
and P types
ference/Limits
Steam shutoff valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
Op
V
All S
V5 - Drain valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
V
All S
Hold/reset vibration switch
Ensure that the vibration switch is reset when this output is
activated
Op
V
P605
SV10 – Displacement water valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
V
All S
SV15 Discharge valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
V
All S
SV16 – Closing water valve
Verify the operation of the valve, see also that the green
diode on the valve connector is lit.
V
All S
Steam decrease – Closing of steam valve
Verify that the valve is moving towards closing position. Note
that if the valve is already closed, an opening operation (see
below) needs to be done prior to this test.
Op
V
All S
Steam increase – Opening of steam valve
Verify that the valve is moving towards opening position.
Op
V
All S
Programmable output 1
Not to be tested
Programmable output 2
Not to be tested
Programmable output 3
Not to be tested
Programmable output 4
Not to be tested
Programmable output 5
Not to be tested
Programmable output 6
Not to be tested
Electric heater test Optional
Before the electric heater i/o-test, please ensure that the
electric power to the electric heater cabinet is turned
OFF!
The operating voltage for the relays is supplied from control
cabinet.
Activity Re
EPS006 33
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
nal
lid for:
and P types
nal
lid for:
and P types
nal
lid for:
and P types
nal
lid for:
and P types
nal
lid for:
and P types
nal
lid for:
and P types
lid for:
and P types
nal
lid for:
and P types
nal
lid for:
and P types
ence/Limits
Elheatvar – Variable output
Check that the diodes on the 2 triacs inside the electric
heater cabinet are lit.
Optio
Va
All S
Heater on signal
Check that the relay KA11 (diode) and K11 (mechanical
indication) in the electric heater cabinet is activated.
Note, leave this output activated (indicating 1 on display)
when proceeding with the tests of the fixed power steps
below!
Optio
Va
All S
ElheatPS1 – Power step 1
Check that the relay KA12 (diode) and K12 (mechanical
indication) in the electric heater cabinet is activated.
Optio
Va
All S
ElheatPS2 – Power step 2
Check that the relay KA13 (diode) and K13 (mechanical
indication) in the electric heater cabinet is activated.
Optio
Va
All S
ElheatPS3 Power step 3
Check that the relay KA14 (diode) and K14 (mechanical
indication) in the electric heater cabinet is activated.
Optio
Va
All S
INPUTS
Heater fault signal
Check that this input is 1 as long as the output “Heater on” is
activated. If not ok, check settings of over temperature
device
Go back to “Heater on” Item no. 47 and deactivate (0 on
display), then go back to this section and verify that “Heater
fault” is 0.
Optio
Va
All S
Estop – Emergency stop
This input should be 1 when emergency stop button is not
pushed.
Press emergency stop button and check that it goes to 0.
Va
All S
Feedback feedpump –
Not to be tested
Feedback separator - Contactor feedback
Not to be tested
Sludge tank level switch
If not installed, check that the input is 1, if not? check if
jumper is installed according to electrical diagram.
If installed, manually operate the level switch, the input
should be 0 when high level.
Optio
Va
All S
Cover switch on separator frame
Manually operate the cover switch, the input should be 1
when switch (and cover) is closed
Optio
Va
All S
Activity Refer
34 EPS006
EPC 60 SERVICE ENGINEER TRAINING 3 CPU AND I/O
tional
alid for:
and P types
mA Input
alid for:
types
mA Input
alid for:
types
mA Input
alid for:
and P types
mA Input
alid for:
and P types
00 input
alid for:
and P types
00 input
alid for:
and P types
ference/Limits
Sludge valve interlock
Manually operate the sludge valve, the input should be 1
when the valve is closed.
Op
V
All S
Programmable input 1
Not to be tested
Programmable input 2
Not to be tested
Programmable input 3
Not to be tested
Programmable input 4
Not to be tested
Programmable input 5
Not to be tested
Programmable input 6
Not to be tested
ANALOGUE INPUTS
PT5 – Water outlet pressure transmitter
Check that the indication shows approx 0 bar.
Note that if pipes are connected to the system, pressure
might not be 0 bar.
4-20
V
All S
MT – Water transducer, MT60
Check that the indication shows 30 pF ±5.
Note that this value is only correct when sensor is in air (no
media in pipes).
4-20
V
All S
PT1 – Oil inlet pressure transmitter
Check that the indication shows approx 0 bar.
Note that if pipes are connected to the system, pressure
might not be 0 bar.
4-20
V
All S
PT4 – Oil outlet pressure transmitter
Check that the indication shows approx 0 bar.
Note that if pipes are connected to the system, pressure
might not be 0 bar.
4-20
V
All S
TT1 – Oil inlet temperature sensor 1
Check that the indication shows a relevant temperature.
PT1
V
All S
TT2 – Oil inlet temperature sensor 2
Check that the indication shows a relevant temperature.
Note that the temperature should not deviate from TT1 with
more than 2 °C
PT1
V
All S
Activity Re
EPS006 35
3 CPU AND I/O EPC 60 SERVICE ENGINEER TRAINING
ur input
nal
lid for:
and P625/635 types
nal
lid for:
5 types
put
nal
lid for:
and P625/635 types
ence/Limits
Speed sensor
In order to test this input, use the “Separator motor”, K2, sect
1, I/O-test to start the separator (for a few seconds), then go
back to this input and check the value, it shall be higher then
0 rpm.
Nam
Optio
Va
All S
Vibration switch
Check that this input goes to 0 when the switch is in tripped
position
Optio
Va
P605/61
Vibration sensor
Check that the indication shows approx 3.5 mm.
(Sensor should be installed with 3.5 mm from the axel)
4-20mA In
Optio
Va
All S
Activity Refer
36 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
546
123
.0
987
i
L
Fig 4.1 EPC 60 Operator panel
4 Operator Panel
The aim of this lession is to present all the
features of the new operator panel; the user
interface, method for parameter adjustment and
program layout.
The operator panel used for EPC60 is based on a
standard panel.
The panel has a 420 signs backlit display.
Some adjustments have been made to suit the
FlexRange;
- Some buttons have been removed and used for
indicators instead (feed pump, heater and
separator).
- The front Mylar (graphics) is adapted for Alfa
Laval, where our symbols and colours are used.
O
I REMOTE
CONTRO
CIP
CLEANING
IN PLACE
SLUDGE
PUMP
DISCHARGE
FEED
PUMP
SEPARATORHEATER
EPS006 37
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
he separator system. When this
quence is initiated. Stepwise or
rameter settings and installed
When this button is pushed the
quence and the separator shuts down
uence, heater, feed pump and separator
on only. The LED will light up with a
lication is started, feed pump,
.
charge controlled by the program.
mote control when activated.
is pushed the system allows the
ogram. Se CIP chapter in service manual
, pump activated when button
owledge and reset alarms.
4.0.1 Buttons
Start button for the operation of t
button is pushed the start se
automatic start depending on pa
equipment
Stop button for the separator system.
system initiates the stop se
step by step; production seq
motor.
Indication; this for informati
green light when the different app
heater and separator motor
Manual discharge; initiates a dis
Remote control; allows for re
See chapter 5.2.3 for more information.
CIP button; when this button
operator to start the CIP pr
for more information.
Manual operation of the sludge pump
pushed.
Alarm button; used to ackn
I
O
FEED
PUMP
SEPARATORHEATER
DISCHARGE
REMOTE
CONTROL
CIP
CLEANING
IN PLACE
SLUDGE
PUMP
38 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
values in the program and for
he menus.
step up and down in the menus and in
information about parameters and
ameters directly, and to load new
Enter button; used to store new
navigation in the menus.
Return button; used to navigate in t
Up and down buttons; used to
the different lists.
Information button; to access
alarms.
Numeric button; to access par
values into parameters.
i
3
EPS006 39
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
Alarm page
1/4 Alarm A21
Oil feed temperature LOW
2/4 Alarm A120
Start blocking
Sludge tank
Level high
4.1 EPC 60 Menus
We will in this chapter go through the menus,
how to navigate in the menus and the menu
structure.
In the new EPC 60 there is a whole new way of
thinking when it comes to menus. The PLC gives
us more flexibility in navigation which in turn
gives a better overview.
Another major change from the older EPC
systems is the operator interface. The new EPC
is much more userfriendly and it is easy to get a
good overview over the menus and parameters.
Navigation in the menus
There are three main pages; Operaing page,
Setting page and Alarmpage.
The operation page is the default page and will
always be visible during operation. To be able to
navigate through the different pages, use the
return button. If the arrows up and down are
used we navigate up or down the same page. See
chapter 4.1.1 for more info regarding buttons.
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
2. Time settings
3. Operation info
TT1 = 98°C
TT2 = 98°C
VIB = 3,49 +- 0,00mm
Discharge = 43m 52s
Speed = 9300rpm
PT 1 = 1,2 bar
PT 4 = 2,2 bar
PT 5 = 2,1 bar
40 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
ere we can check or change the parameters
here we set the time on internal clock
, pump etc
here to read all the alarms
. type and oil type
e to set the right IP address for the sep
assword handling side
Operation page
___Separation___
Flow = 2.8m3/h
Temp= 98°C
Discharge= 43m 52s
SS = 9300rpm
PT1 = 2.10bar
PT4 = 2.30bar
PT5 = 2.20bar
TT1 = 98°C
TT2 = 97°C
Vib = 3.49 +- 0.00mm
MT = 15% 82pF
4.2 Operation page
4.3 Settings page
In the setting page will we find the following sub
menues:
We will go through the sub menus in the
following pages.
In the operation page can we find info regarding
the operation, temperatures, pressures, rpm
and vibration sensor (if mounted). There are 3
parts to this page with 4 lines of information.
We navigate between the different parts with
the up and down buttons.
1 Parameters H
2 Time settings W
3 Operation info Timers on separator
4 I/O test I/O test page
5 Alarm history W
6 System info Info regarding sep
7 IP settings Wher
8 Password/login P
9 Simulator§ Not used
EPS006 41
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
__SET TIME_______
4.3.1 Parameters
We will look at the parameters and parameter
settings in the chapter 5.
4.3.2 Time setting
We use this parameter to set the time during
commissioning. We set the right date and time;
this is used in the alarm lists. We are using GMT
time to have the same time in all our separators
To be able to set the time you have to be logged
in. To set the time; when you are in the set time
menue start with the year and then push the
enter button to save the new value, if not pushed
the new values are not stored.
If you load the wrong value push the back button
and start over. If you only need to change the
date, use the enter button to go to the next value.
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
2. Time settings
3. Operation info
42 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
al time the power has been switched
total running time
running time
otal time in production
otal time in recirculation
otal time temperature exceeds 55°C
otal number of sludge pump activations
otal number of alarm activations
otal volume of separated oil
U temperaure
all the time counters in the PLC
eset all the parameters in the PLC to
ory settings. See parameter list for factory
.
4.3.3 Operation info
We have the following sub menues under
operation info;
1 Timers, counters
2 Reset op info
3 Reset parameters
When we open the sub menue “Timers,
counters”, we find the following info
1 Timers, counters
1.1 Power time The tot
on.
1.2 Sep time Separator motor
1.3 Feed pump time Pump total
1.4 Production time T
1.5 Recirc time T
1.6 Temp >65°C T
1.7 Sludge pump T
1.8 Alarm T
1.9 SepOilVolume T
1.10 CPU temp Actual CP
2 Reset op info
2.1 Reset operation No
information? Yes
Reset
3 Reset parameters
3.1 Reset parameters
to factory No
settings? Yes
Used to r
fact
settings
EPS006 43
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
fo___
2. Sep time
3. Feedpump time
4Production time.
2. Sep time
3. Feedpump time
4Production time.
Menue flow for the Operation info:
When you are in the operation page push the
return button. In the setting page use the up and
down arrows and manoeuvre down to operation
info. Push the enter button.
In the operation page push the enter button on
the menu you want to enter, in this case timers,
counters.
Here you will find all the counters for the
equipment on the unit, like Sep timer, pump
timer etc. push the enter button on the timer you
want to check.
When you are looking at a timer you can
manoeuvre up and down between the timers
with the up and down arrows.
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
2. Time settings
3. Operation info
__Operation in
2. Reset op info
3. Reset parameters
44 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
__I/O_TEST_______ __I/O_TEST_______
__I/O_TEST_______ __I/O_TEST_______
4.3.4 I/O Test
Manoeuvre into the I/O test sub menu.
To start the test; find the object you want to test
and hold the enter buttons pushed. The test is
active as long as the button is pushed. After the
action is confirmd, release the button.
See chapter 3.6 for more information.
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
3. Operation info
4. I/O test
EPS006 45
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
i
4.3.5 Alarm history
To access the Alarm History List at any time
during the operation process press the ‘Return
button’ repeatedly until the Alarm History List
is reached.
Press the arrow buttons to go up or down in the
list. The list consists of the following:
Alarm history – List of alarms which have been
rectified. The latest alarm shows at the top of the
list.
Manoeuvre the > sign in front of the alarm of
interest and then you can press the ‘Information’
button for help and information.If you now use
the down button you get some more info
regarding this alarm.
Press the ‘Information’ button again to return to
your previous position.
46 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
01/50_ALARM_HISTORY_
01/50_ALARM_HISTORY_ A072
Water pressure
sensor Pt5 error
08.02.21 22:10
-Check connections
and cables
Mode: Standstill
Sensor or cable
damaged
Menu flow for the Alarm history:
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
4. I/O test
5. Alarm History
EPS006 47
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
e
__System Info_______
Curretn subnet mask:
255.255.0.0
New subnet mask:
-----------------------
___IP Settings_______
2. Change IP adress
3. Change subnet mask
4.3.6 System info
In system info you only get info regarding type of
separator, what type of oil you are separating
and current program version.
4.3.7 IP settings
IP settings are used when you have more than
one separator in a system with remote control.
Each separator must have a designated IP
address to be able to communicate with the
remote. Se more info in chapter 5.2.3. Remote
control/ monitoring.
Operation page Setting pag
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
5. Alarm History
6. System info
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
6. System info
7. IP settings
48 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
ling_ __PASWORD ______
Enter new password
__PASWORD ______
Confirm new password
__PASWORD ______
Password changed
4.3.8 Password/ Log in
There are three password levels in the new EPC
60.
Level 0 – No password needed.
Level 1 – Possible to protect with password.
Level 2 – Alfa Laval password protected.
Depending on which level you log in; you get
access to different parameters
Level 0;
you get access to language, temperature,
pressure and flow denomination.
Level 1;
the chief engineer can set this password
preventing others on the ship to access level 1
parameters.
Level 2;
gives access to all parameters. This level is
protected by a standard Alfa Laval password,
must not be given to the customer. This
password overrides the level 1 password.
The standard Alfa Laval password is 1361, but
we have three more passwords availalbe if the
password is compromised, 1362, 1363 and 1364.
To change the level one password; manoeuvre to
the password page and choose change user
password. Enter the new password and then
confirm it. The system will confirm that the
password have been changed.
Operation page Setting page
___Separation___
Flow = 2,8m3/h
Temp = 98°C
Discharge = 43m 52s
___Settings___
1. Parameters
2. Time settings
3. Operation info
___Settings___
7. IP settings
8. Password/LogIn
__Password hand
2. Logout
3. Change user pw
EPS006 49
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
i
4.4 Alarms List
If the system has a fault, the alarm LED blinks.
Press the ‘Alarm’ button once. The alarm shows
on the display.
Press the ‘Alarm’ button again to acknowledge
the alarm.
N
O
T
E
The latest 50 alarms are stored in the Alarm History
List. See below.
Press the arrow buttons to go up or down in the
list.
When a list item is blinking, you can press the
‘Information’ button for help and information.
Press the ‘Information’ button again to return to
your previous position.
You can also acknowledge and/or reset this
alarm.
If after all alarms have been acknowledged
fault(s) remain in the system, the alarm LED
stops blinking and remains on. An ‘A’ appears at
the end of an alarm which has not been rectified.
The alarms disappear automatically when the
fault is rectified.
When all the alarms have been rectified, the
alarm LED goes out.
For safety reasons, certain alarms must not only
be acknowledged, but also rectified before the
system can continue in operation, for example
alarm A122 ‘Butterfly valve in sludge outlet
closed’.
Also for safety reasons, some alarms will set the
system into recirculation or stop. These alarms
must be rectified before the operator can put the
system into operation.
Press the ‘Return’ button to leave the list.
50 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
V1
PT4
A50-A59
SS
A110-A111
YT
A100-A103
ST
A90-A97
LS
A120-A121
A122
GS
MT
A80-A85
V4
PT5
V5
A70-A74
X
0
2
4
96
8A
4.4.1 Alarm denomination
T2T P1T
A05
A30-A32
T1T
A20-A25
V10
V15
V16
A40-A43
A01 A15
A130 - A139
EPS006 51
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
Why? What to do
? Feedback signal from
contactor K3 missing.
Check the contactor
function.
Check input terminal in the
PLC.
? Power to heater
interrupted.
Check the power supply to
the heater.
? High temp. switch
released
Check temp. setpoint in
the control unit.
Check the heater and
clean if necessary.
When the temperature
decreases, the switch is
automatically reset.
? Feedback signal from
contactor missing.
Check the contactor
function. Check input
terminal in the PLC.
4.4.2 Alarms on the EPC 60
Alarm
code
Alarm text Conditions
Feed pump (if P127 = yes)
A01 Pump starter
failure
Delayed by P168.
A05 Heater fault
(electric)
Delayed 2 s.
Heater, electric (if P119 = electric)
A15 Separator starter
failure
Delayed 2s.
52 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
? Steam supply valve
faulty
Investigate cause and
remedy.
? Faulty triac module(s) in
the power unit or faulty
controller in the control
unit. (electric heater).
? Broken wiring or
defective heater
resistance, or faulty
controller in the control
unit.
? Heater clogged Investigate cause and
remedy.
? Steam supply
insufficient
Investigate cause and
remedy.
? Steam trap faulty Investigate cause and
remedy.
? Steam supply valve
faulty
Investigate cause and
remedy.
? Faulty fuses or burned
contactors (electric
heater)
Check and renew broken
fuses.
Reset overcurrent
protection (applicable for
8/7 - 24/22 kW power unit).
Check wiring and
contactor coils.
? Broken wiring or
defective heater
resistance (electric
heater)
Check wiring and heater
resistance of each block
or heater element.
? Short circuit / broken
sensor or cable.
Disconnect cable at
sensor. Measure
resistance between 1-3.
Resistance shall be within
100-142 ohms = 0-110 C/
32-230 F.
Replace sensor if broken.
If no spare sensor
available, set parameter
P146 = TT1 to be able to
run the system.
? Insufficient heating
during start.
Check heater function.
Why? What to do
Temperatur transmitter feed inlet TT1
A20 Oil feed
temperature high
Delayed by P150. Limit in
P183.
A21 Oil feed
temperature low
Delayed by P150. Limit in
P184.
A22 Temperature alarm
sensor error (TT1)
Delayed by P150.
A23 Temperature alarm
sensor disabled
Reminder only, if P146 =
TT1
A24 Temperature
increase too slow
Delayed by P169. Limit in
P184.
Alarm
code
Alarm text Conditions
EPS006 53
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
? Heating on during stop
sequence.
Check heater function.
? Recirculating oil not
cooling.
Reset alarm to continue.
? Short circuit / broken
sensor or cable.
Disconnect cable at
sensor. Measure
resistance between 1-3.
Resistance shall be within
100-142 ohms = 0-110 C/
32-230 F.
Replace sensor if broken.
If no spare sensor
available, set parameter
P146 = TT2 to be able to
run the system.
? Pipe restricted. Check recirculation for
restriction.
? Pump not working Check pump.
? Pressure in feed line too
low
Check feed line and flow
regulation.
Check heater for fouling.
? Sensor or cable
damaged.
Check cable connections.
Replace sensor. If no
spare sensor available, set
parameter P157 = 0.
? Increased throughput Check. Reduce
backpressure.
? Regulating valve too
restricted
Adjust valve
Why? What to do
A25 Temperature not
decreasing
Delayed by P173. Limit in
P184. Stop sequence
continues after alarm
reset. Disabled if P173 =
0.
Temperatur transmitter heater control TT2
A30 Temperature
control sensor
error (TT2)
Delayed by P150.
A31 Temperature
control sensor
disabled
Reminder only, if P146 =
TT2
A32 Difference TT1/
TT2 too large
Delayed by P176. Alarm
limit in P177. Blocked if
A22, A23, A30, or A31
Pressure transmitter feed inlet PT1
A40 Feed pressure
PT1 high
Delayed by P150. Limit in
P157.
A41 Feed pressure
PT1 low
Delayed by P150. Limit in
P158.
A42 Feed pressure
sensor PT1 error
Delayed by P150.
A43 PT1 disabled Reminder only, if P157 =
0.
Pressure transmitter oil outlet PT4
A50 Oil backpressure
PT4 high
Delayed by P150. Alarm
limit in P153.
Alarm
code
Alarm text Conditions
54 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
? Decreased throughput Check feed pump and
adjust flow.
? Regulating valve open
too much
Adjust back pressure
valve
? Change over valve V1 in
recirculation position
Check air pressure,
solenoid valve SV1 and
output from EPC 50.
Bowl opens unintentionally
during operation because:
? Strainer and piping in
the operating water
supply is clogged.
Clean the strainer and
check the whole system
fore limestone deposits.
? Too little or no water in
the operating water
system.
Measure the water flow in
the three hoses from the
water block and compare
with correct values.
? Hoses between the
supply valves and
separator are incorrectly
fitted.
Fit hoses correctly.
? Nozzle in bowl body
clogged
Clean the nozzle.
? Rectangular ring in
discharge slide is
defective.
Renew the rectangular
ring.
? Valve plugs are
defective.
Renew all plugs.
? Supply valves SV15 and
SV 16 are leaking.
Rectify the leak.
? Sensor or cable
damaged.
Check cable connections.
Replace sensor. If no
spare sensor available, set
parameter P153 = 0.
? No decrease in oil
pressure at discharge.
Check function of change-
over valve V1.
? No increase in oil
pressure at calibration.
Check supply of
displacement water
(SV10).
? No increase in oil
pressure at
displacement.
Check supply of
displacement water
(SV10).
Why? What to do
A51 Oil backpressure
PT4 low
Delayed by P150. Alarm
limit in P154.
A52 Oil pressure
sensor PT4 error
Delayed by P150.
A53 PT4 disabled Reminder only, if P153 =
0.
A54 Oil pressure PT4
high at discharge
Delayed by P171. Alarm
limit in P221.
A55 No PT4 pressure
feedback at
conditioning water
calibration
Delayed by P170. Alarm
limit in P221.
A56 No PT4 pressure
feedback at
displacement
Delayed by P172. Alarm
limit in P221.
Alarm
code
Alarm text Conditions
EPS006 55
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
? Bowl periphery sealing
damaged
Change seal ring in bowl
hood. Check/change
rubber rings and valve
plugs.
? Leakage somewhere in
oil outlet
Check for leakage.
? Closing water leaking Check/change sealings
and plugs.
? Paring tube not moving
correctly.
Check that movement is
not impeded by friction.
? Paring tube not moving
correctly.
Check that movement is
not impeded by friction.
? Sensor or cable
damaged.
Check cable connections.
Replace sensor. If no
spare sensor available, set
parameter P155 = 0.
? V5 not opening or line
restricted.
Check V5 function.
Clean the outlet pipe.
? Extremely high water
content.
Check where the water is
comimg from.
? Fouling in the MT50. Dismantle and clean with
detergent.
? Too much air in oil
outlet.
Check oil backpressure.
? MT50 test failure. Check water supply.
Check SV10.
? Too much water in oil
outlet.
Investigate cause and
remedy.
? Much water in the feed. Check where the water is
comimg from.
? Paring tube not moving
properly.
Check that movement is
not impeded by friction.
? Sensor or cable
damaged.
Check cable connections.
Replace sensor. If no
spare sensor available, set
parameter P128 = standby.
Why? What to do
A57 Oil leaking from
bowl
Delayed by P245. Alarm
limit in P163.
A58 Leak test failure Limit in P164. No. of
attempts in P166.
A59 PT4 pressure high
during Transition
Delayed by P175. Alarm
limit in P154.
Pressure transmitter water drain PT5
A70 Pressure in water
outlet PT5 high
Delayed by P150. Limit in
P155.
A71 Pressure in water
outlet PT5 low
Delayed by P150. Limit in
P156.
A72 Water pressure
sensor PT5 error
Delayed by P150.
A73 PT5 disabled Reminder only, if P155 =
0.
A74 Water outlet
restricted
Delayed 3s.
Water transducer MT60 (if P117 = yes)
A80 Transducer value
high
Delayed by P150. Limit in
P189.
A81 Transducer value
low
Delayed by P150. Limit in
P162.
A82 MT60 in standby
more than 24
hours
Reminder only, if P128 =
standby more than 24h.
A83 Transducer no
response
Limit in P226.
A84 High water content Number of drainings in
P187. Limit in P224.
A85 MT60 fault Delayed by P150.
Alarm
code
Alarm text Conditions
56 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
? High power (net)
frequency.
Check power supply
before restart.
? Incorrect transmission
parts (50 Hz belt pulley
and belt for 60 Hz power
supply).
W
A
R
N
IN
G
!
Disintegration
hazard
Stop and change the
belt transmission to
suit the power supply
frequency.
? Slipping belt Change belt.
? Worn coupling pads Check / change pads.
? Bowl not properly
closed
Check closing water
supply (valve SV 16).
Check bowl operating
system for leakage.
Check nozzle.
? Bowl not properly
assembled
Check that the lock ring is
in place.
? Low power net
frequency
Check power.
? Motor failure. Repair the motor.
? Bearing(s) damaged. Renew all bearings.
? Incorrect transmission
parts (60 Hz belt pulley
and belt for 50 Hz power
supply).
W
A
R
N
IN
G
!
Disintegration
hazard
Stop and change the
belt transmission to
suit the power supply
frequency.
? Sensor or cable
damaged.
Replace sensor. If no
spare sensor available, set
parameter P179 = 0 to be
able to run the system.
? Power still on to the
motor
Check reason and remedy.
Why? What to do
Speed sensor separator (if P113 = yes)
A90 Bowl speed high Delayed 5 s. Limit in
P179.
A91 Bowl speed low Delayed 5 s. Limit in
P180.
A92 Bowl speed sensor
error
Delay 4s. Timer stop.
A93 Speed sensor
disabled
Reminder only, if P148 =
yes.
A94 Bowl speed high
during STOP
Delayed by P174. Alarm
limit in P180.
Alarm
code
Alarm text Conditions
EPS006 57
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
? Separator friction blocks
slipping
Check the friction blocks.
? Belt slipping Check the belt.
? Height position of paring
disc is incorrect.
Stop. Check and adjust the
height.
? Motor failure Repair the motor.
? Bearing(s) damaged or
worn in coupling or
spindle drive.
Renew all bearings.
? Strainer in the operating
water supply is clogged.
Clean the strainer.
? Water flow too low. Check opening water flow
(SV 15) into the bowl.
? Hoses between the
supply valves and
separator are incorrectly
fitted.
Fit hoses correctly.
? Rectangular ring in the
operating slide is
defective.
Replace the rectangular
ring.
? Sludge remaining in
part of the bowl.
Dismantle, clean and
check the bowl before
restart.
W
A
R
N
IN
G
!
Disintegration
hazard
The separator bowl
must be manually
cleaned before
starting up again.
? Bowl wrongly mounted. Check assembly.
? Disc stack compression
incorrect.
Check assembly.
? Bowl assembled with
parts from other
separators.
Check assembly.
? Height position of paring
disc is incorrect
Stop the separator,
measure and if necessary
adjust the height.
? Bowl spindle bent. Renew the bowl spindle.
Why? What to do
A95 Separator motor
run-up time too
long
Delayed by P230. Limit in
P180.
A96 Slow start
acceleration
Speed < 90 rpm 10s after
response from motor
contactor.
A97 Discharge
feedback error
Alarm limit in P161. Test
during P232, one extra
discharge before alarm.
Vibration sensor separator (if P114 = yes)
A100 High vibration
warning
Delayed by P150. Alarm
limit in P182.
Alarm
code
Alarm text Conditions
58 EPS006
EPC 60 SERVICE ENGINEER TRAINING 4 OPERATOR PANEL
? Bearing(s) damaged or
worn.
Renew all bearings.
? The frame feet are worn
out.
Renew the frame feet.
? Spindle top bearing
spring broken.
Renew all springs.
? Sludge remaining in
part of the bowl
Dismantle, clean and
check the bowl before
restart. See Service
Manual.
W
A
R
N
IN
G
!
Disintegration
hazard
The separator bowl
must be manually
cleaned before
starting up again.
? Bowl wrongly mounted Check assembly.
? Disc stack compression
incorrect
Check assembly.
? Bowl assembled with
parts from other
separators
Check assembly.
? Height position of paring
disc is incorrect.
Stop the separator,
measure and if necessary
adjust the height.
? Bowl spindle bent. Renew the bowl spindle.
? Bearing(s) damaged or
worn.
Renew all bearings.
? The frame feet are worn
out.
Renew the frame feet.
? Spindle top bearing
spring broken.
Renew all springs.
? Sensor or cable
damaged.
Replace sensor. If no
spare sensor available, set
parameter P132 = yes to
be able to run the system.
Why? What to do
A101 High vibration
shutdown
Delay 1s. Alarm limit in
P181.
W
A
R
N
IN
G
!
Disintegration
hazard
If 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.
A102 Vibration sensor
error
Delayed by P150.
A103 Vibration sensor
disabled
Reminder only. If P132 =
yes.
Alarm
code
Alarm text Conditions
EPS006 59
4 OPERATOR PANEL EPC 60 SERVICE ENGINEER TRAINING
? Separator not properly
assembled
Assemble the separator
according to instructions.
? Faulty frame cover
switch
Replace cover switch. If no
spare switch available, set
parameter P116 = yes to
be able to run the system.
? Pump has not drained
the tank
Check the pump function.
? Valve closed. Open manual valve.
?
? Emergency stop button
pushed
Check for the cause.
Reset pushbutton.
? Too much sludge in
bowl
This alarm is given if the
bowl is extremely dirty and
cannot be acknowledged.
The separator will be
stopped. Wait until STAND
STILL is indicated.
Investigate cause and
remedy.
? Black-out has occurred
during operation.
Check plant conditions
and restart.
? Time in
RECIRCULATION
expired.
Contactor activated 5 times
within last 60 minutes.
Why? What to do
Frame cover switch separator (if P115 = yes)
A110 Frame cover open Delay 1s.
Start not possible.
A111 Cover switch
disabled
Reminder only, if P116 =
yes.
Sludge handling
A120 Sludge tank level
high
At high level: Start not
possible. Sludge pump
running until level signal
normal + 10s. Alarm delay
and max pump running
time 60s in all modes
without feed flow, P159 in
Separation. Discharge
blocked.
A121 Level switch
disabled
Reminder only, if P149 =
yes.
A122 Valve in sludge
outlet closed
Discharge not possible.
Start not possible.
A123 External alarm. Delay 2 s
System
A130 Emergency stop
button pushed
Delay 1s. No restart.
A131 Sludge in bowl Alarm limit in P160.
A132 Power failure Disabled with P152 = no.
A133 Too long time in
RECIRCULATION
Delayed by P178. System
goes to STOP.
A136 Communication
error
A137 Cabinet over
temperature
Reminder only
A138 Too many start
attempts
Alarm
code
Alarm text Conditions
60 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
i
5 Parameters
5.1 Setting List
Parameters are divided into three password
levels:
Level 0 – No password needed.
Level 1 – Possible to protect with password.
Level 2 – Alfa Laval password protected.
To access the Setting List at any time during the
operation process press the ‘Return button’
repeatedly until the Setting List is reached.
When in the setting list; activate the parameter
list. Parameter is flashing. Push the enter button
to enter into the parameter list.
The parameter list is password protected. To be
able to access all the parameters, log in on level 2
with the Alfa Laval password. If not logged
inonly the setting parameters are accessible, i.e.
parameters P100 to P103.
When in the Parameter Menu a list item is
blinking, you can press the ‘Information’ button
for help and information.
Press the ‘Information’ button again to return to
your previous position.
When a list item is blinking, it’s value can be
changed. Push the enter button to activate the
parameter. Changes can be made either by using
the number buttons to write in a value, or by
choosing a value from the list. Save any change
by pressing the ‘Enter’ button.
To leave the changed parameter, push the return
button and go to next parameter.
N
O
T
E
Certain parameters can only be changed by the
factory, the chief engineer, or an Alfa Laval service
engineer.
EPS006 61
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
Additional information
ated!
Flex system (old SA)/ Flex module(old SU)
This parameter is used to determine which oil-
block that is used.
Because Flex system and module have different
oil-block, there is a difference in the flow-
calculation and in order to get as accurate value
as possible, be sure to set this parameter correct
according to the system configuration.
.If this parameter is changed some other
parameter will change, see tabel in the end.
If changed some other parameter will change see
tabel in the end.
It is possible to run the system without vibration
sensor (P114 = no).
In this case alarms A100 – A103 are not
supervised.
Remote start is not allowed.
This also applies if the vibration sensor is disabled
(P132 = yes) or on alarm ‘A102, Vibration sensor
error’.
It is possible to run the system without cover
switch (P115 = no).
In this case alarms A110 – A111 are not
supervised.
Remote start is not allowed.
This also applies if the cover switch is disabled
(P116 = yes).
This parameter is used to soft uninstall the sensor.
When using this parameter a reminder will be
posted in the alarm list until the parameter is set
to NO again. See also P115.
Parameter Denomination
P100 0 Display language: English/German/
Spanish/French/Italian/Portuguese/
Finnish/ Swedish
P101 0 Selection of temp. presentation Celsius/
Fahrenheit
P102 0 Selection of feed flow rate presentation
m
3
/h or USG/h
P103 0 Selection of pressure presentation kPa,
bar, psi
User password required for all following parameters if activ
System configuration
P110 1 Flex configuration
P111 1 Separator size
P112 1 Oil type
P114 1 Vibration sensor installed yes/no
P115 1 Frame cover switch installed yes/no
P116 1 Frame cover switch disabled yes/no
(if P115 = yes)
62 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
It is possible to run the system without water
transducer (P117 = no).
In this case alarms A80 – A85 and A74 are not
supervised.
There is no calibration of the water flow. In
separation, automatic discharges are initiated
every 15 minutes (overrides P220). SV10 is never
activated (this means no displacement before
discharge and no conditioning water). Water
draining from the bowl is not allowed
This also applies if the water transducer is
disabled (P128 = standby) or on alarm ‘A85,
MT60 fault’.
See also "Control of Heater" in the Operating
instructions manual.
Size of the electric heater in the system
The time it take the valve form fully open to fully
closed.
This is the temp difference between the set point
and actual temperature before the system starts
regulating on the heater. Only applicable for
steam heater.
Decreasing the value of this parameter
(proportional band width) will result in a slower
and more stable control action.
See chapter 5.2.1 for more info
Increasing the value of this parameter (integral
time) results in slower response from the EPC-60
See chapter 5.2.1 for more info
The temperature up to which gain facor is active.
Above this temperature normal gain (P-band) is
active.
This factor is used to dcrease the normal P-band
when temperature is below the temperature
defined in P 125. Meaning that when the oil
temperature is low the response from the heater is
quicker.
Standby = MT60 disabled. Discharge every 15
min. (overrides P220). SV10 not activated. No
drain sequence.
When remote control is installed, this parameter
defines the communication method. See chapter
5.2.3 for more information.
Additional information
P117 1 MT60 (water transducer) installed yes/no
P118 1 Sludge pump installed yes/no
P119 1 Heater installed no/electric/steam/
external
P120 1 If P119 = electric: heater size
P121 1 If P119 = steam: steam valve transition
time
P122 1 Deadband heater
P123 1 P-constant heater (if heater controlled)
see also P125/P126 (cold start)
P124 1 I-constant heater (if heater controlled)
P125 1 Breakpoint cold start (if heater controlled)
P126 1 Gain factor cold start (if heater
controlled)
P127 1 Feed pump controlled yes/no
P128 1 MT60 on/standby.
P129 1 Selection of remote control method
digital inputs
Modbus
Parameter Denomination
EPS006 63
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
When stepwise is active the program askes for
confirmation before starting next sequence.
When automatic is active the program start all the
sequences without asking for cinfirmation.
Automatic require some additional installment like
interlock switch, heater conrtol and pump control.
If valve with interloc switch is installed the EPC
monitores the signal and block start if not open.
This parameter is used to soft uninstall the sensor.
When using this parameter a reminder will be
posted in the alarm list until the parameter is set
to NO again. See also P114.
See also “Programmable in- and outputs” in
chapter 5.2.4
see also “Cross connection/serial operation”
in chapter 5.2.5
If the one temp sensor is broken, first try to
replace it and if not possible we can chose to read
the other sensor, remaider is given in the
alarmlist.
It is possible to run the system if the speed sensor
is damaged or broken, set this parameter to YES.
In this case system control and supervision are
much more basic.
Alarms A90 – A97 are not supervised.
Remote start is not allowed.
The start and stop of the separator will be
controlled by time, not sensors.
Additional information
P130 1 Selection of automatic or stepwise start
automatic, stepwise
P131 1 Valve in sludge outlet installed
no, yes
P132 1 Vibration sensor disabled yes/no
P133 1 Optional output 1 (Relay)
P134 1 Optional output 2 (Relay)
P135 1 Optional output 3 (Relay)
P136 1 Optional output 4 (Relay)
P137 1 Optional output 5 (Relay)
P138 1 Optional output 6 (Relay)
P139 1 Optional input 1
P140 1 Optional input 2
P141 1 Optional input 3
P142 1 Optional input 4
P143 1 Optional input 5
P144 1 Optional input 6
P145 1 Cross connection/serial operation
P146 1 Temperature sensor disabled
no, TT1, TT2
P148 1 Speed sensor disabled
P149 1 Level switch disabled. Run sludge pump
30 s at discharge (overrides P234).
Parameter Denomination
64 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
It is possible to run the system with PT4 disabled
(P153 = 0).
In this case alarms A50 – A52 and A54 – A59 are
not supervised.
As a result, calibration of the water flow is not
possible. The old values are used for
displacement and conditioning water. Cold start
function is disabled. Bowl leakage test is disabled.
This also applies on alarm ‘A52, Oil pressure
sensor PT4 error’.
Remeber to set the operational pressure. See
chapter 5.2.2 for more info
It is possible to run the system with PT5 disabled
(P155 = 0).
In this case alarms A70 – A72 and A74 are not
supervised.
This also applies on alarm ‘A72, Water pressure
sensor PT5 error’.
0.0
It is possible to run the system with PT1 disabled
(P157 = 0).
In this case alarms A40 – A42 and A44 are not
supervised.
This also applies on alarm ‘A42, Feed pressure
sensor PT1 error’.
This is the limit used to control the sludge level in
the bowl. if during calibration test the filling time
has decresed with P 160 an alarm is given.
If bowl speed not decreacing P 161 during
discarge, the alarm A97 is given
The accepteble maximum pressure decreace
during bowl leaking test (P245)
The pressure in PT4 has to be under this level
during leakage test.
The pressure in PT4 has to be above this level
during leakage test.
Used to supervise the temperature for instance if
the operator is using a heater not controlled by the
EPC.
Used to supervise the temperature for instance if
the operator is using a heater not controlled by the
EPC.
Additional information
Alarm related parameters: delays, limits etc.
P152 1 Power failure alarm used yes/no
P153 1 High oil pressure limit (PT4), 0.0 =
pressure sensor disabled
P154 1 Low oil pressure limit (PT4)
P155 1 High water pressure limit (PT5), 0.0 =
water pressure sensor disabled
P156 1 Low water pressure limit (PT5)
P157 1 Alarm limit high feed pressure (PT1), 0.0
= feed pressure sensor disabled
P158 1 Alarm limit low feed pressure (PT1)
P160 1 Alarm limit “A131 Sludge in bowl”
P161 1 Alarm limit "A97 Discharge feedback
error"
P162 2 Alarm limit "A81 Transducer value low"
P163 2 Alarm limit "A57 Oil leaking from bowl"
P164 2 High oil pressure limit (PT4) during
leakage test
P165 2 Low oil pressure limit (PT4) during
leakage test
P169 1 Alarm delay "A24 Temperature increase
too slow"
P173 1 Alarm delay “A25 Temperature not
decreasing”
0 = no temperature supervision
Parameter Denomination
EPS006 65
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
If there is pressure in PT4 during start of
separation sequence, i.e. cold oil in the outlet
pipes, the V1 valve will open/ close repetatly
several times. If no presure drop is registered the
alarm A59 is given at P175.
The temperature deviation between TT1 and TT2
before the alarm is activated. If alarm, find the
reason and if sensor is broken, go to P146 to
disable the damaged sensor.
This is not the same function as in EPC 50. This is
the maximum time in recirkulation, when elapsed
separator shuts down.
See Alfa Lavals reccomndations regarding
discharge intervals.
The time V5 is open during draining, timer is
interrupted when transducer value is below P224.
The procentage value where V5 stop draning.
How often we are checking the tarnsducer signal
The value that the trigger limit must excide in the
test.
How often the paring tube is flushed.
SV16 is opened for one sec with the P228
interval.
The time the SV15 is open for discherge
0
Used to prolong the pumping of the sludge tank if
nessesary
V5 and SV10 is opened in order flush out oil from
the paring tube and water outlet.
V5 is open in P237 sec between deplacement
water and discharge to clean the paring tube
The MT 60 signal is tested.
After P239 the new transducer value is taken.
How often we test the calibrated time for
displacement water.
0
Additional information
P175 2 Alarm delay “A59 PT4 pressure high
after cold start"
P177 1 Alarm limit "A32 Difference TT1/TT2 too
large"
P178 1 Time limit in RECIRCULATION
Setpoints
P220 1 Discharge interval
P222 1 V5 open time at drain sequence
P224 1 MT60 limit stop draining
P225 2 Test of MT60 signal (every xxx
discharge), 0 = test disabled
P226 2 MT60 low trigger limit at transducer test
P227 1 Flush of drain outlet after displacement
(every xx discharge)
P228 1 SV16 pulse interval in SEPARATION
P231 1 SV15 opening time
P232 1 Draining of operating water
P233 1 Filling time conditioning water (calculated
during calibration)
P234 1 Sludge pump additional/manual running
time
P236 2 Water drain time during STOP
P237 1 Sludge pump running and V5 opening
time before discharge
P238 2 Feed on after discharge and test of water
content in oil outlet
P239 2 Time for stabilization of the transducer
signal
P242 2 Test of calibration value, interval (no. of
discharges)
P256 1 Feed pump stop delay at normal STOP
Parameter Denomination
66 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
, default 0)
S500
S850
S851
S855
S856
S600
S860
S861
S865
S866
S700
S870
S871
S875
S876
S800
S880
S881
S885
S886
min.
value
max.
value
Unit
89 82 82 81 0 100 % of
P179
(max
speed)
0.5 0.5 0.5 0.5 0.0 2.5 mm
0.3 0.3 0.3 0.3 0.0 2.5 mm
48 80 61 72 0 150
s
5.5 5.5 11.0 15.0 l/min
s 15 s 25 s 35 s 60 s 0 120
s
5 s 5 s 15 s 25 s 25 s 0.1 30.0
s
20 25 30 30 0 30 s
4 6 8 10 10 0 15
s
10 10 10 10 0 15 s
Parameters depending on the setting of P111
Separator size (P111
S811
S816
S200
S821
S826
S820
S825
S300
S830
S831
S835
S836
S400
S840
S841
S845
S846
Parameter Password
level
Description
P180 2 Alarm limit bowl
speed low
83 90 90
P181 2 Alarm limit high
vibration
shutdown
0.3 0.3 0.5
P182 1 Alarm limit high
vibration
warning
0.2 0.2 0.3
P240 1
Filling time
displacement
water, initial
value (calcu-
lated during
calibration,
see also
P254)
77 63 108
SV10, constant
flow orifice
0.9 1.6 1.6
P243 1
SV16 open
after dis-
charge
15 s 15 s 15
P244 1
SV15 open for
priming water
during start-up
5 s 5 s
P245 2 V4 closed
during bowl
leakage test
10 10 20
P247 1 V4 closing delay
at bowl leakage
test
2 2
P248 2 Delay of PT4
pressure
reference value
registration at
bowl leakage
test
5 5 5
EPS006 67
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
with P112)
HF180
HF380
HF460
HF600
HF700
LO TP
Trunk
LO CH
Cross
head
min.
value
max.
value
Unit
105 100 100 0 115
°C
(P101)
85 90 85 0 115
°C
(P101)
98 95 90 0 110
°C
(P101)
2 0 20
0.6 0.1 10.0
pF
100 100 0 250
%
85 78 0 320
pF
0.0 1.0
Parameters depending on the setting of P112
N
O
T
E
If P111 = 0 (default value), the operator is automatically
forced to go through a system configuration procedure to
setup the system.
Oil type (selected
Parameter Pass
word
level
Description GO MDO IF30
IF40
IF60
IF100
P183 1 High
temperature limit
40
P184 1 Low temperature
limit
20
P249 1 Temperature
setpoint
30
P187 2 Number of
drainings before
alarm “A84 High
water content”
5
P251 MT60 trigger
factor
(corresponds to
100% increase
of the transducer
signal)
3.0
P252 1 MT60 trigger
limit
100
P189 2 Alarm limit “A80
Transducer value
high"
110
P254 2 Reduction of
P240 if DO
Calculated as
P240 P254
1.0
68 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
P
0000
41A
Constant amplitude
P00
0051
A
5.2 Additional parameter
info
5.2.1 P & I setting P123 and 124
If the temperature varies with regularly
repeated oscillation, setting of the proportional
band and integral time is necessary.
We recommend you to follow these guidelines:
Set P123 = 10 minutes.
Decrease P-band (P124) in steps until the
process reaches the point where it starts to
oscillate with a constant amplitude. Test the
stability after each step by introducing a step-
change of load or set point.
When you have discovered the point where the
process oscillates with a constant amplitude note
the following figures:
Calculation of optimal parameter settings.
The settings above give a good result but may be
adjusted according to individual characteristics
in different loops.
A = The value of P-band (P123).
B = The time for one full period
in seconds.
P-band I-time
P123 = 2.2 × A P124 = 0.8 × B
EPS006 69
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
5.2.2 Calculating Operating Pressure
Calculate the normal back pressure level during
operation as follows:
Calculate the value for low pressure alarm
setting (Pr 11) as follows:
Calculate the value for high pressure alarm
setting (Pr 10) as follows:
Adjust the back pressure to P
normal
Set Pr 11 to give alarm at pressure decreasing
below the P
low press.
value.
Set Pr 10 to give alarm at pressure increasing
above the P
high press.
value.
P
min
+ P
max
= P
normal
2
P
min
+ P
normal
= P
low press.
2
P
normal
+ P
max
= P
high press.
2
70 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
5.2.3 Remote control/ monitoring
As earlier, remote monitoring is possible on all
the marine separators, but remote control only
on the S-type and P625/635 separators.
Remote control also requires the speed sensor,
vibration sensor and cover interlock switch to be
installed.
There are two ways to use the remote control/
monitoring:
1, Modbus TCP
The customer connects to the EPC60 Ethernet
port (directly to the CPU inside the cabinet, not
using the service Ethernet port on the cabinet
door) and configures his computer to read and
write the data to/from the EPC60.
An instruction on how to connect and where to
read/write these data will be available on
Alround.
2, Digital inputs/outputs,
The programmable digital inputs and outputs,
available on the extra I/O-boards can be used for
remote control/monitoring.
Configure these inputs and outputs with the
parameters P133-144 and connect the remote
control buttons accordingly.
EPS006 71
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
5.2.4 Programmable in- and outputs
As an option, two extra I/O-boards can be
delivered with the EPC60.
The boards are to be used as extra signals.
The function of these inputs and outputs can be
configured with parameters (P133-P144).
If for instance the parameter P136 is set “Heater
on”, the number 4 relay output will be active
(closed) when the EPC60 expects a heater before
the separator to be active.
If P140 is set to “Remote start”, this number 2
input will be possible to connect to a remote start
button, which will activate the remote start
function in the EPC60 when pressed.
This flexibility to choose different functions on
these extra inputs and outputs gives us a
possibility to add extra “special” functions very
easy.
It is only for us to add the software function, and
the new function is directly available as an
output/input when the corresponding parameter
is set.
If you have suggestions on any new function, let
us know, and we will add it.
It could for instance be “remote sludge tank level
switch” or “high PT1 pressure alarm output”.
5.2.5 Cross connection/serial
operation
The cross connection is intended used if there is
a multiple module. Id one heater is broken the
heater on the other system can be used
controlled by the first EPC.
Serial operation is used with Purifiers.
72 EPS006
EPC 60 SERVICE ENGINEER TRAINING 5 PARAMETERS
20mA
320pF0pF
igger
3pF
HFO
100%
0%
83pF
5.3 ALCAP
After P239 (stabilizing period) the new
transducer reference value is taken. This value
will reflect the water content in the oil and vary
from oil to oil since the HFO is different in every
delivery.
The value we take here will be considered “0” on
the trigger range. The 100% on the trigger range
is an increase by 3pF if HFO is chosen in P112
and 0, 6 if LO is chosen in P112. This means that
if we measure the oil to 85pF the 100% trigger
range will be 88pF when handling HFO.
This values for HFO and LO is set in P251 and is
automatically changed when you change the
value in P112. It is possible to adjust the
sensitivity on the trigger range by P252.
If the value in P252 is changed to 200% for
instance, the actual trigger value will be 200% of
the P251 value,
HFO; 3pF 200% = 6pF
LO; 0,6pF 200% = 1,2pF
4mA
0pF 70pF8
Trigger
range
Tr
range
0,6pF
Lube oil
100%
0%
70,6pF
EPS006 73
5 PARAMETERS EPC 60 SERVICE ENGINEER TRAINING
5.3.1 Testing the MT60
The new MT60 uses 4 to 20mA signal and can be
tested in the following way:
? Hold the sensor in air and the value should
be between 30 to 50pF on the panel. The mA
should be 5,5-6,5mA.
? Put the transducer in water and the value
will go above 320pF. You will see 320pF on
the panel and the mA will be 19mA (max
value allowed in the I/O cards).
? Normally the value we measure in oil is
varies between 80 and 90pF.
74 EPS006
EPC 60 SERVICE ENGINEER TRAINING 6 COMPUTER CONNECTION
6 Computer connection
6.1 Computer settup
IP-address setup
This is a general description and for more
information or assistance contact your local IT
department.
In order to download a new application program
or to use Servcom you need to setup your
computer for the Ethernet connection that are
used.
The EPC60 CPU (central processing unit) has a
fixed IP-address which by default is set to
192.168.0.1 and the sub-network is set to
255.255.0.0
These addresses can be changed using the
EPC60 operating panel.
To setup your computer for this connection you
need to change the settings of you network
connection to the same range as the EPC60.
Open the properties for your computers
Ethernet connection, select “Internet protocol
(TCP/IP)” and press properties.
If available, choose the tab “Alternate
Configuration” and configure the settings as
shown to the right.
EPS006 75
6 COMPUTER CONNECTION EPC 60 SERVICE ENGINEER TRAINING
If this tab is not available (depending on version
of windows installed) the configuration should
be according to the picture below.
N
O
T
E
If the tab “Alternate Configuration” was used, it
is possible to leave this setting, because the
connection to the office network will use the
general setting.
If not available, you will need to change back to
the old settings when finished with the EPC60
work in order to get a connection with the office
network.
N
O
T
E
The IP-address in your computer can not be the
same as the CPU.
When these settings are finished, you should
have a connection with the EPC60.
However, settings in the firewall installed by
Alfa Laval, can block the communication
betwenn the EPC 60 and the computer.
If you have problems with the connection, check
with you local it-department that traffic are
allowed to the specified ip-address/subnet and
the port 11159.
76 EPS006
EPC 60 SERVICE ENGINEER TRAINING 6 COMPUTER CONNECTION
6.2 Download of
application software
The latest application software will be found on
Alround (as with the EPC50).
After downloading the zip-file, you need to
extract all the files to a folder.
The zip-file is password protected, and the
password is “Alfa Laval”.
For more info regarding handling of zip-files
contact your local IT-department.
In the EPC 60 we have separate program for
each application, S, P and all the others
comming in the future. There are not longer
necessary to move a jumper to download a new
program. It is not possible to download a new
program when the program is running, the
system have to be in standstill.
To download the software to the EPC60, make
sure that you have your computer setup for the
connection (see chapter 6.1) connect the
Ethernet cable, and then double-click on the
“start. bat” file.
A status-window will appear, and you will see
the progress of the download.
When you see “finished” and “success” in this
window, the download is completed and you can
disconnect the Ethernet cable.
EPS006 77
6 COMPUTER CONNECTION EPC 60 SERVICE ENGINEER TRAINING
78 EPS006
EPC 60 SERVICE ENGINEER TRAINING 7 SERVCOM
7 Servcom
The aim of this lesson is to present all the
features of the new ServCom system; the user
interface, method work and all the new features
of the program.
Servcom is the tool we use to communicate with
the EPC. We had a Servcom for the EPC 50 and
we used that as a template for the new EPC 60
Servcom.
We noticed that the old Servcom had some
drawbacks and decided to make a completely
new Servcom rather than build on the old
design.
The new Servcom thas a lot of new features, such
as new report templates, and a lot of new logging
features. We will go through all the new features
and how to use the program optimally.
Our intention is to develop the Servcom program
further and we need feedback from the users on
what’s good and what’s not. If you have any
suggestions please contact us.
EPS006 79
7 SERVCOM EPC 60 SERVICE ENGINEER TRAINING
7.0.1 Process view
7.0.2 Initial settup
This is the default page in the Servcom. Here
you can see the process, pressures,
temperatures, flow, valve positions, heater load
etc.
There is also a window containing active
alarms. If there is an active alarm the alarm
will be visible in the alarm window and the
actual sensor will be marked red.
Open the “Connection and settings” menu, then
choose “Settings” and check that the “Current
IP setting for EPC60” is in accordance with the
IP-address in the EPC60.
Current ip-setting
Set the IP-address of the CPU, can be read from
the EPC60 panel.
Default IP-address for the CPU is: 192.168.0.1
Ping EPC60
Use this tool to test the communication to the
EPC60.
A successful ping means that the IP-settings in
the computer and EPC60 is correct.
However, connection can still be blocked by i.e.
firewall, check firewall settings with local IT-
department.
Firewall must allow traffic through the selected
IP-address and port 11159.
Debug
Use for advanced faultfinding, will not be
further explained.
80 EPS006
EPC 60 SERVICE ENGINEER TRAINING 7 SERVCOM
7.0.3 Connect to EPC60
7.0.4 Parameter view
To be able to connect to the EPC60 you have to
have the Ethernet cable connected to the CPU
in the cabinet and to the computer.
Open the “Connection and setting” menu and
push the “connect to EPC”. Servcom will now
try to connect and upload all the parameters,
alarm lists and all information stored in the
memory.
To access the parameter list open views in the
top menue and push “Parameters” or push the
parameter quick button.
This is the page where we manage the
parameters. When we are using the Servcom we
have access to all the parameters, no matter the
password level.
The list on the right side is values currently in
EPC 60, and the list to the left is the
parameters in your computer.
The reason for this is safety, you have the
possibility to go through the parameters before
downloading new values into the EPC.
There are some parameters that are dynamic; if
these parameters are changed some other
parameters are changed automatically. The
parameters marked with a green colour (P 111
and P112) are dynamic parameters and will
change several parameters if changed. It is
important that these parameters are changed
first.
Some fields in the parameter list is coloured
gray and not accessible. These parameters (like
P 121 “Steam valve transition time”) are
dependent on the installation. When electrical
heater is installed the P121 will be gray but
when steam heater is chosen it will be opened
for changes..
EPS006 81
7 SERVCOM EPC 60 SERVICE ENGINEER TRAINING
Search for a parameter:
7.0.5 Managing parameters
Click the upper "Find"-button to search for a
certain parameter. This will open a "search
ruler" on top of the parameter list across the
columns.
Enter for instance "low pres" into the Find
textbox, press Enter or click the Find button to
the right of the box.
A list of all parameters with both the text "low"
and the text "pres" in its description appears on
the line to the right.
? Make sure you are connected to the EPC 60
and use the arrow pointing left to upload
the parameters stored in the CPU.
? Change the necessary parameters according to
the installation and download them into the
CPU using the arrow pointing right..
82 EPS006
EPC 60 SERVICE ENGINEER TRAINING 7 SERVCOM
Save parameter
It is possible to save parameters in your
computer for later installations. If you have
more than one separator installed with the
same set up you can save the setup from the
first machine and load it into all the others.
? Open Servcom and change the parameters
according to earlier instruction.
? When the parameters are downloaded to
the CPU, push the “Save to file” button on
the right side. The file will now be stored in
the default file “customerdata”. If you want
the files to be stored somewhere else, make
a new file. Save the file with a name so you
remember what it’s for.
? To download the saved files; connect to the
EPC and upload the parameters from the
CPU with the left pointed arrow. Push the
“Read from file” on the left side and mark
the correct file to download. The saved
values will be imported in the left column.
If there are some parameters that need
changed do it in the left column before
downloading it to the CPU.
To download these values into the CPU,
push the arrow pointing right.
EPS006 83
7 SERVCOM EPC 60 SERVICE ENGINEER TRAINING
7.0.6 Reports
In the new Servcom we have more report
templates. The reason for this is to make it
possible to make uniformed reports that in the
end are made into PDF documents. There can
be attached to any other form of reporting such
sd the SMS.
Another advantage is that all the reports
created can be delivered to the customer on a
memory stick, CD or be sent by e-mail.
To access the different reports open “Reports” in
the top menu and open the report you need. We
will now look into the different reports and how
to use them.’
All the reports created in Servcom will also
contain all serial nos, parameter lists and alarm
history. This is an automatic process but is only
available when Servcom is connected to the
EPC 60.
84 EPS006
EPC 60 SERVICE ENGINEER TRAINING 7 SERVCOM
Claim report
Commissioning report
The claim report is used whenever there are
suspicions that the fault found during service is
a claim situation or when the customer
demands it. A claim is filed into the CSS
system.
In the field “information from customer” note
all the information from the customer. Try to
talk to the customer and make them describe
the fault as detailed as possible. All information
will help in the further investigation.
In the next field “Information about the
installation” fill in all possible information
about the installation. Depending on the
problem, go around, look at everything that can
have any effect on the separation process and
explain the problem in detail.
Under “Problem description” write down the
how you as an engineer find the problem. Be as
specific and detailed as you can, the more
information we gather the better for the further
handling of the claim.
If you find a solution to the problem or have
some thoughts to how to solve the problem,
write it down under “Recommended solution.
The commissioning report is off course used
during commissioning .
The advantage of using this is that when you
create the report in PDF all the parameters,
alarms and serials will be included in the
report. Make one report for every separator.
This report Can be used instead of the
Commissioning check list since they are identical.
EPS006 85
7 SERVCOM EPC 60 SERVICE ENGINEER TRAINING
Summary service report
The summary service report is used during a
normal service, as a normal service report.
In the field “job order” you fill in the reason for
the service and what you are suppose to do.
Under “comments on the service” your write
down all the findings during the service, what
you did and recommendations to the customer.
This can be used as a service report to the
customer if SMS isn’t implemented yet.
On top of all the report templates you will find
five buttons; get last header, clear all, open
draft and create final report as PDF file.
When you fill inn the report and push eider
“save report as draft” or “create final report as
PDF file, the Servcom will store the information
regarding customer, service site and who. Next
time you open a report you can push the “get
last holder” and the Servcom fill in the fields
with the last stored information.
The “clear all” is self explaining.
The “open draft” and “save report as draft”
buttons are a new feature in the Servcom. This
means that you can start a report on the service
sight and save it as draft and then open it again
when you are back in the hotel or in the office
and finish the report there.
When the report is finished you use the “create
final report in PDF format” and the report is
ready for printing or to be used as an
attachment in a mail or in SMS.
86 EPS006
EPC 60 SERVICE ENGINEER TRAINING 7 SERVCOM
EPC 60 alarm history
Serial numbers in EPC60
In the alarm history list we can find the last 50
alarms in the EPC. In the alarm list we can
see alarm code, date and time (real time),
alarm description, mode, timer and timer
name.
Just by looking at the alarm list you can get
lots of information regarding the operation
of the separator.
This list will be a part of all reports and can also
be stored separately as a pdf file.
In this report we get information from the EPC
60 about all serial numbers stored in the
memory. The serial numbers will be entered
into the EPC 60 in the factory, but if a serial
number is missing we can correct this and store
it in the EPC.
? When the page is open push the “Read
serial numbers from EPC60”. All the
parameters stored will now be visible. If
some numbers are missing, they are not
stored in the EPC.
? Write in the missing numbers and push
“Copy serial numbers into EPC60”, this
stores the numbers in the EPC. Thise will
be available for the next engineer uploading
the serial number.
There are also a field here where we can enter
the commissioning date. This can be important
during claim investigation and is something we
must enter.
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7.0.7 Logging
In the new Servcom 60, the logging function is
vastly improved compared to the older version.
We have a lot more possibilities and many new
features.
When you see the logging for the first time it
can look a little confusing and chaotic, but after
using it a while the new features and
possibilities get clearer.
We will go through the logging functions in this
chapter and try to explain how to use them in
the most effective way.
You have to be connected to the EPC 60 to be
able to log. You can look at a stored log file off
line, we will describe this later.
When you will start logging, push the start
logging button or go to the Logging menu and
use the “Start or Continue logging”. The
program will now open the logging page. The
program has some default variables to log but it
is possible to change these variables.
The default variables are pressure,
temperature, valves, bowl speed and heater
function. The total list is much longer and other
variables can be logged if needed. Push the “set
variables to log” button and choose the ones
that you need to log.
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Scaling
It is possible to change the scaling on analogue
curves if you want to look closet at the values.
Right click on the text and the “set vertical (y)
scale” will open. To set your own scale, tic the
“plot curve according to your range settings”
and set your preferred scale in the Max X-axis
and Min Y axis. There will appear a new green
curve working in your settings. If you tic off the
“Plot automatically scaled curve” box the blue
line will disappear or else you will see both lines
and the blue will work on default settings. It is
also possible to increase the curve height by
using the “relative curve height” scale, making
the value even more fine tuned.
This function is also available if you are looking
at a saved file.
Magnifier
During logging the time line will compress
according to logged time. If you want to change
the time line, use the magnifier to extend the
timeline to preferred size. To go back to normal
view again push the “Fit to screen” button.
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Vertical line
There is a vertical line function in the logging
program. Click on the curve at some interesting
point and a vertical red line will appear. This
line will give you the actual values at this time;
the time is shown beside the line, in reed in the
process value boxes. You can set more than one
vertical line and only the latest is reed showing
the actual process values. If you want to remove
a line click on it again and it will disappear or if
you want to remove all lines push the “reset
curves” button.
There is also possible to left click on an alarm
and a vertical line will appear where the alarm
is initiated in the timeline.
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8 Operating instructions
8.1 Before First Startup
The Control Panel must be configured to suit
the system components.Control Panel
To start the Control Panel, switch on the main
power switch on the control cabinet.
General
The Control Panel has three main lists.
? Operation
? Alarms
? Setting
Operation List
To access the Operation List at any time during
the operation process press the ‘Return button’
repeatedly until the Operation List is reached.
The list gives information on the following where
installed:
? Feed Flow
? Time to discharge, min
? Speed (SS), rpm
? Pressure (PT1, PT4, PT5)
? Temperature (TT1, TT2)
? Vibration (VIB)
? Transducer value
Press the arrow buttons to go up or down in the
list.
N
O
T
E
During operation, the ‘Operation’ list is active on the
display. The present stage of operation, for example
‘SEPARATION’, shows on display together with operating
information such as present temperature.
Press the downward ‘Arrow’ button to go down the list.
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For further information regarding alarms, see
the Alarms and Fault Finding booklet.
For further information regarding parameters,
see the Parameter List booklet.
At any time during operation, the operator can
initiate a STOP sequence by pressing the ‘Stop’
button.
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8.2 Manual Start from
Standstill
Press the ‘Start’ button. The operator can select
to start the system manually by setting
parameter P130 to ‘stepwise’.
N
O
T
E
First start-up is always manual and not dependant on
P130 setting.
A rotation test must be carried out using the I/O test
function prior to first start-up.
N
O
T
E
First start-up after power off should always be
carried out manually!
N
O
T
E
If a butterfly valve is installed, it must be opened
manually before that the system can start.
C
A
U
T
IO
N
!
If power cable polarity has been reversed, the separator
will rotate in reverse, and vital rotating parts can loosen.
If speed sensor, vibration sensor, and frame cover
switch are installed (P113, P114, and P115 =
yes), the operator can select to start the system
automatically by setting parameter P130 to
‘automatic’.
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If the power has been off and/or the separator
bowl cover has been removed a number of
questions which have to be answered before the
system can be started are shown on the display:
‘Has the bowl been dismantled? YES, NO’
Use the ‘arrow’ buttons to move to the
alternative you want.
When the alternative you want is blinking, press
the ‘Enter’ button.
1 If the bowl has been dismantled choose ‘YES’
Manual start only is possible.
If no work has been carried out on the bowl,
choose ‘NO’. ‘Proceed without calibration’
appears on the display. Stepwise/automatic
start is possible (set using parameter P 130).
N
O
T
E
If this is the first start, answer ‘YES’.
‘Assembled according to manual? YES, NO’
2 If the bowl has been dismantled and
assembled according to the instructions in the
Service Manual, choose ‘YES’.
(If ‘NO’ is chosen, the system goes to
‘STANDSTILL’).
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‘Bowl cleaned? YES, NO’
3 If the bowl has been cleaned choose ‘YES’.
‘Proceed with calibration’ appears on the
display. Local manual start only possible.
If the bowl has not been cleaned, choose
‘NO’. ‘Proceed without calibration’ appears on
the display. Stepwise/automatic start is
possible (set using parameter P 130).
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Start
1 The feed pump (if installed) starts.
The LED on the start button flashes, the LED
for the feed pump lights, and text ‘Starting
feed pump’ shows on the display.
The start button LED shines steadily and the
display shows either ‘To start heater, press
start button’, or ‘To start separator, press start
button’.
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2 Press the start button a second time.
The heater (if installed) starts.
The LED on the start button flashes, the LED
for the heater lights, and text “Starting heater”
shows on the display.
Wait for increasing temperature.
Cold Start Function
If the viscosity of the oil is high (low
temperature), a smooth heater start-up is
preferred. The temperature up to which the
cold-start gain factor P126 is active is set in
parameter P125. Above this temperature the
normal P-constant P123 is used.
If the temperature has not reached the value
in parameters P184 (HFO/LO low temperature
limit) within the time specified in parameter
P169 (alarm delay), alarm ‘A24 Temperature
increase too slow’ will show on the display.
If the temperature feedback is correct
(reading on temperature sensor TT1 above
value in parameter P184), the start button LED
shines steadily and the display shows ‘To start
separator, press start button’.
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3 Press the start button a third time.
The separator motor starts.
The LED on the start button flashes, the LED
for the separator lights, and text ‘Starting
separator’ shows on the display.
Wait for speed feedback (if speed sensor
installed), or until the separator max. start time
(4 minutes) has elapsed.
If the speed has not increased to over 90 rpm
within 10 seconds after contactor K2
response, alarm ‘A96 Slow start acceleration’
shows on the display.
If the low speed limit value in parameter P180
has not been reached before the separator
max. start time has elapsed, alarm ‘A95
Separator motor run-up time too long’ shows
on the display.
If the separator is running above the low
speed limit, the start button LED shines
steadily, and the display shows the heading
‘RECIRCULATION’ and text ‘To start
separation, press start button’.
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4 Press the start button a fourth time.
If the feed temperature is below the value in
P184, the controller stays in RECIRCULATION
mode. The LED on the start button flashes,
and text ‘Waiting in RECIRCULATION for
separation temperature’ shows on the display.
If the correct feed temperature is reached, the
controller changes automatically to
SEPARATION mode via a transition sequence
which is shown on the display. The start button
LED shines steadily, and the display shows
the heading ‘TRANSITION’.
If speed sensor not installed (P113 = no) or
disabled (P148 = 0), change over to
RECIRCULATION/SEPARATION takes place
when the separator max. start time has
elapsed.
N
O
T
E
The time in ‘RECIRCULATION’ is limited by timer
P178 to avoid overheating of the separator.
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8 OPERATING INSTRUCTIONS EPC 60 SERVICE ENGINEER TRAINING
8.3 Automatic Start from
Standstill
The operator can select to start the system
automatically by setting parameter P130 to
‘automatic’.
The control panel automatically goes through
the same procedure as described under 1.3
Manual Start from Standstill.
If the bowl has not been dismantled or cleaned,
the previously calculated filling time (parameter
P233) is used, a discharge sequence and a bowl
leakage/water transducer test are run, and the
system goes into SEPARATION mode.
The following equipment must be installed for
automatic start:
? Vibration monitor
? Speed sensor
? Frame cover switch
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8.4 During separation
Observe information on the control panel
display. The times in each sequence are shown in
the bottom left-hand corner of the displa
Discharge sequences run automatically at pre-
set intervals (timer P220).
Discharge sequence can also be run manually by
pressing the ‘Discharge’ button.
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The Sludge Pump runs during discharge or when
there is high level in the sludge tank, or can be
started manually by pressing the ‘Sludge Pump’
button on the control panel.
N
O
T
E
Do not run the sludge pump longer than necessary. If
the pump is run while dry it can be damaged.
In SEPARATION mode, the feed pump is
running, the feed has reached separation
temperature (the heater is working) and the
separator is running at full speed.
Feed valve V1 is open to the separator inlet.
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8.5 Stop
C
A
U
T
IO
N
!
Breakdown hazard
Stop the separator by means of the control unit, and
not by turning off the power.
C
A
U
T
IO
N
!
Never attempt to clean the bowl by manual discharge
in connection with stop.
To stop the system
The operator can stop the system when in the
‘START’, RECIRCULATION’, or ‘SEPARATION’
modes.
1 Stop the system by pushing the ‘Stop’ button
on the control panel. The following sequence
takes place:
? A stop discharge and flushing sequence are
initiated (does not apply to stop from ‘START’).
N
O
T
E
Filling and flushing are not performed if the
discharge feedback has not been received.
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8 OPERATING INSTRUCTIONS EPC 60 SERVICE ENGINEER TRAINING
N
O
T
E
If the system is switched off, it can in most cases
be switched on again without waiting for the
separator to slow down. See 8.2 Manual Start
from Standstill, page 99, and the Alarms and
Fault Finding booklet.
? The separator motor is turned off and the stop-
timer starts running. At the same time, the
heater is turned off (see 8.6.4 Heater shut
down, page 120). The system waits for the
feed temperature and speed to decrease.
? If the speed limit in P180 (low speed limit) is
not reached within 3 minutes, alarm ‘A94 Bowl
speed high during STOP’ is given.
? When the bowl speed has reached 4000 rpm,
closing water valve SV16 is activated for 1
second in order to keep the bowl closed.
? If speed sensor not installed (P113 = no) or
disabled (P148 = 0), SV16 opens for 1 second
5 minutes after the separator motor has been
turned off.
? When 3 minutes has elapsed, the feed pump
is turned off.
? The system waits for the speed sensor (if
installed) to indicate zero speed. When the
bowl has been still for 60 seconds, ‘STAND
STILL’ shows on the display.
? If speed sensor not installed (P113 = no) or
disabled (P148 = 0), ‘STAND STILL’ is shown
when the stop timer has elapsed.
? The sludge pump runs for 10 seconds after
STAND STILL is reached if stopped from
SEPARATION mode or RECIRCULATION
mode.
? All equipment except the sludge pump (which
can still be run manually) is now deactivated.
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8.5.1 CIP Start
CIP can be selected from STAND STILL only,
and only from a local control panel.
Press the CIP button to select CIP.
N
O
T
E
During CIP the separator is running at full speed, but feed
pump, heater, process valves, temperature and pressure
supervision and water transducer MT60 are neither
controlled nor supervised.
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With CIP selected from STAND STILL, press the
‘START’ button to start the separator motor. The
motor starts unless the system prevents start, or
alarms are active.
Wait for speed feedback.
? Speed has to increase to above 90 rpm within
10 seconds after contactor K2 response,
otherwise alarm ‘A96 Slow start acceleration’
will be shown on the display.
? Speed limit in parameter P180 has to be
reached within 4 minutes, otherwise alarm
‘A95 Separator motor run-up time too long’ will
be shown on the display.
? When the separator is running above low
speed limit (P180), or 4 minutes has elapsed if
speed sensor not installed (P113 = no) or
disabled (P148 = 0), a message to start the
cleaning liquid supply is given to the operator.
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CIP Running
N
O
T
E
When the bowl has reached normal speed, a bowl
closing procedure will be performed.
While the CIP system is running, closing water
valve SV16 opens for 2 seconds and closes for the
time set in parameter P228 (pulse interval)
repeatedly. The sludge pump runs when there is
high level in the sludge tank or when activated
by pressing the ‘SLUDGE PUMP’ button on the
control panel.
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A discharge can be activated manually during
the CIP process by pressing the ‘DISCHARGE’
button on the control panel.
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A
CIP Stop
Stop the CIP process by pressing the ‘Stop’
button on the control panel. The CIP process can
be restarted.
? The separator motor is turned off. Alarm delay
(3 minutes) starts, and stop timer starts. If the
speed limit in parameter P180 (alarm limit
bowl speed low) is not reached within 3
minutes, alarm ‘A9 Bowl speed high during
STOP’ is given.
? When the bowl speed has reached 4000 rpm,
closing water valve SV16 is activated for 1
second in order to keep the bowl closed.
? If there is no speed sensor installed
(parameter P113 = no) or disabled (parameter
P148 = 0), SV16 opens for 1 second 5 minutes
after the separator motor has been turned off.
? The system waits for the speed sensor (if
installed) to indicate zero speed. When the
bowl has been still for 60 seconds, ‘STAND
STILL’ shows on the display.
? If there is no speed sensor installed
(parameter P113 = no) or if speed sensor
disabled (parameter P148 = 0), ‘STAND STILL’
is shown when stop timer has elapsed.
? If the bowl speed has been above P180, or
the start timer has elapsed, the sludge pump
runs for 10 seconds after ‘STANDSTILL’.
? Hold the ‘CIP’ button pressed for 5 seconds to
leave CIP mode.
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8.6 Heater Control
(optional)
The temperature in the feed inlet is normally
supervised via TT1, and can be controlled by a
heater via TT2. Supervision and control are
active even if one of the sensors is disabled.
The heater is controlled according to
temperature setpoint P249 using a PI-regulator:
Out = ((I + E) 100) / (200 P123) where
Out = output signal to the heater
E = difference between reading on TT2 and P249
I= I+ E/P124
P123 = P-constant
P124 = I-constant. Every second a new output
value is calculated.
With P119 it is possible to select heater control
mode:
no (no heater controlled)
electric (electric heater controlled, P120 active)
steam (steam heater controlled via three
outputs, P121 active)
external (start/stop request via programmable
output, heater not controlled)
If the viscosity of the oil is high (low
temperature), a smooth start-up of the heater
might be favourable. The temperature, up to
which the cold-start gain factor P126 is active, is
set in P125. Above this temperature the normal
P-constant P123 is used.
Example: P123 = 30, P126 = 40 results in gain
below P125 of 0.40 x 30 = 12
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8.6.1 Control of the electric heater
(optional)
P119 = electric.
Six outputs and one input are used to control the
electric heater:
? Four relay outputs to up to four fixed power
steps depending on the heater size (P120)
? one variable load output
? one output "heater on"
? one input "heater fault" (see A05)
The total heater capacity (100%) is the sum of
the power available at the four fixed steps, plus
the power available via the variable load output
(always 16 kW nominal).
This means, if the output signal to the heater is
100%, all available power steps and the variable
load output have to be activated continuously.
Output signal 0% means that all outputs are
deactivated.
If the output signal is a value between 0 and
100%, the activation pattern of the outputs has
to be calculated using the table below.For each
value of P120 the contribution of each power step
to the total available heater capacity is given in
percent. First use the fixed power steps to fill the
power requirement as far as possible, then use
the variable load output to fine adjust the
output.
As a new output signal is calculated every
second, the variable load output is activated for
parts (0.1) of a second.
0.1 s activates 1/10 of the available power on the
output = 1.6 kW.
0.5 s means 8 kW and so on.
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ower step 3 Variable load output
%
10 x 10
10 x 10
10 x 6.6
10 x 4
.5 10 x 2.9
10 x 2.2
.5 10 x 2.9
10 x 2.2
Example 1: Heater size 72 kW and output signal
to the heater 50%. Activate step 3 (for 1s) and
activate var. output for 0.2s.
Example 2: Heater size 16 kW and output signal
to the heater 88%. Activate var. output for 0.9s.
Example 3: Heater size 144 kW and output
signal to heater 88%. Activate steps 1, 2, 3 and 4
(for 1s).
To prevent problems with too heavy momentary
load at start of the heater, only one output can be
activated per second during the first 6 seconds.
After that time all outputs can be used
simultaneously.
Output power (in % of the total available power)
Heater size (kW nominal,
selected with P120)
Power step 1
%
Power step 2
%
P
%
7, 8 0 0 0
14, 16 0 0 0
22, 24 33.5 0 0
36, 40 20 40 0
50, 56 14.3 28.5 28
65, 72 11 22 45
100 14.3 28.5 28
130 11 22 45
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8.6.2 Control of the CBM heater
(optional)
P119 = steam. In this case alarm A05 is not
supervised.
The steam heater is controlled using three relay
outputs:
? increment steam valve
? decrement steam valve
? steam shut-off valve (hold signal)
The position of the valve is not supervised.
The transition time of the steam valve is set in
P121 (time from fully open to fully closed
position and vice versa). The controller function
defines if the valve should be opened
(incremented) or closed(decremented) in relation
to its actual position.
The signal to the steam valve is pulsed with an
on-time corresponding to the temperature
controller output. Example: output = +50%
means the increment steam valve output is
activated for 0.50 s/s.
When the heater is stopped, the decrement
steam valve signal is on for the time set in P121.
The hold signal is off if the start of the heater is
interlocked (e.g. on alarms A01, A20).
8.6.3 If heater not controlled or
external
It is possible to run the system without heater
control (P119 = no).
In this case alarms A05, A24 and A25 are not
supervised.
It is also possible to run the system with
external heater (P119 = external). The ‘heater
on’ signal is given via a programmable output.
In this case alarm A05 is not supervised.
The description for the system with external
heater is also valid if one of the temperature
sensors is disabled or on sensor error (A22/A30).
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8.6.4 Heater shut down
The system waits for the feed temperature to
decrease (5 degrees or below P184). If the time in
P173 has elapsed and the temperature feedback
was not received, alarm ‘A25 Temperature not
decreasing’ is given.
When the temperature feedback has been
received, or P173 has elapsed, P256 is started.
When P256 has elapsed, the feed pump (if
running) is turned off. If the feedback signal
from the pump contactor is not received within 5
seconds, alarm ‘A01 Pump starter failure’ is
given.
N
O
T
E
Heater shutdown is also initiated at STOP request
during START if feed pump and heater are on but the
separator is not running.
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8.7 Operation without all
sensors
(Emergency operation)
8.7.1 System Without Speed Sensor
It is possible to run the system without speed
sensor (P113 = no).
In this case system control and supervision are
much more basic.
Alarms A90 – A97 are not supervised.
Remote start is not allowed.
The separator is started within 4 minutes and
stopped with stop timer.
This also applies if the speed sensor is disabled
(P148 = 0) or on alarm ‘A92, Bowl speed sensor
error’.
8.7.2 System Without Vibration
Sensor
It is possible to run the system without vibration
sensor (P114 = no).
In this case alarms A100 – A103 are not
supervised.
Remote start is not allowed.
This also applies if the vibration sensor is
disabled (P132 = yes) or on alarm ‘A102,
Vibration sensor error’.
8.7.3 System Without Cover Switch
It is possible to run the system without cover
switch (P115 = no).
In this case alarms A110 – A111 are not
supervised.
Remote start is not allowed.
This also applies if the cover switch is disabled
(P116 = yes).
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8.7.4 System With PT1 Disabled
It is possible to run the system with PT1
disabled (P157 = 0).
In this case alarms A40 – A42 and A44 are not
supervised.
This also applies on alarm ‘A42, Feed pressure
sensor PT1 error’.
8.7.5 System With PT4 Disabled
It is possible to run the system with PT4
disabled (P153 = 0).
In this case alarms A50 – A52 and A54 – A59 are
not supervised.
As a result, calibration of the water flow is not
possible. The old values are used for
displacement and conditioning water. Cold start
function is disabled. Bowl leakage test is
disabled.
This also applies on alarm ‘A52, Oil pressure
sensor PT4 error’.
8.7.6 System With PT5 Disabled (S-
separator only)
It is possible to run the system with PT5
disabled (P155 = 0).
In this case alarms A70 – A72 and A74 are not
supervised.
This also applies on alarm ‘A72, Water pressure
sensor PT5 error’.
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8.7.7 Control of Sludge Pump, Level
in Sludge Tank, and Butterfly
Valve
The sludge accumulated in the bowl can be
discharged into an optional small sludge tank
with level switch. At high level signal a sludge
pump (P118 = yes) is running until the signal is
normal + 10 seconds . Otherwise see alarm A120.
The level switch can be disabled (P159 = 0). In
this case A120 is blocked and the sludge pump is
running for 30 seconds at discharge (instead of
P234, see below).
The sludge pump is also activated during certain
timers. These running times are always
terminated by an extra pump running time (e.g.
during P234, or 5 seconds as in the drain
sequence). Note that this extra time is
independent of the other timers which may be
running simultaneously.
See also the Sequence diagram for other
occasions when the sludge pump is activated, if
selected (Parameter List chapter ‘2.2 Discharge’)
.
The separator sludge outlet can contain a
manual butterfly valve which is used to close the
outlet when the separator is standing still.
Select with P131 (no, manual).
If P131 = no, alarm A122 is blocked.
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8.7.8 System Without Feed Pump
It is possible to run the system without feed
pump (P127 = no).
In this case alarms A01 and A44 are not
supervised.
Remote start is not allowed.
8.7.9 System Without Water
Transducer (S-separator only)
It is possible to run the system without water
transducer (P117 = no).
In this case alarms A80 – A85 and A74 are not
supervised.
There is no calibration of the water flow. In
separation, automatic discharges are initiated
every 15 minutes (overrides P220). SV10 is never
activated (this means no displacement before
discharge and no conditioning water). Water
draining from the bowl is not allowed
This also applies if the water transducer is
disabled (P128 = standby) or on alarm ‘A85,
MT60 fault’.
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