Alfalaval EPC-400 User manual

Alfa Laval Marine & Power
EPC-400
Control Unit
P000681A
Product No.
Printed
Book No.
31830-6149-1
31830-6149-2
31830-6149-3
31830-6228-1
31830-6228-2
31830-6228-3
Nov 1998
1818053-02 V3
Component
Description

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local Alfa
Laval company.
Published by: Alfa Laval Marine & Power AB
S - 147 80 Tumba
Sweden
© Copyright Alfa Laval Marine & Power AB 1998.

1818053-02
Contents
1 Overview 1
2 Function Description 3
2.1 Application 3
2.2 Working Principle 3
2.3 Design 4
2.3.1 Front Panel 4
2.3.2 Label Inside the Front Panel 5
2.3.3 Control Module 5
2.3.4 Power Supply 6
3 Operation 7
3.1 Process Operation 7
3.2 Parameter Setting 7
3.2.1 Overview 8
3.2.2 Setting Procedure 8
4 Maintenance 11
4.1 Preventive Maintenance 11
4.1.1 Lamp Test 11
4.2 Corrective Maintenance 12
4.2.1 Fuses and Related
Functions 12
4.3 Replacement of
Control Module 13
5 Technical Data 15
5.1 Specification 15
5.2 Dimensions 16
5.3 Circuit Diagram 17
6 Installation 19
6.1 Mounting 19
6.2 Cable Routing 20
6.3 Location of Cable Entries 20
6.4 Terminal Protectors 21
7 Spare Parts 23

1818053-02

1818053-02 1
1 Overview
EPC-400 control unit is used within a
separation system for automatic control of the
separation process.
The unit is microprocessor based and
comprises output functions for control of
ancillary equipment and input functions for
monitoring and alarm. The EPC-400 is
programmable to suit different separator
systems and different operation conditions.
The programming can easily be adjusted to
new conditions or new experience.

1 Overview EPC-400
21818053-02

1818053-02 3
2 Function Description
2.1 Application
The EPC-400 control unit is used in ALCAP
separation systems.
2.2 Working Principle
The EPC-400 is used for monitoring and
control of the separation process. It controls
starting, separation, sludge discharge and
stopping sequences.
The process is monitored via input signals
from sensors, etc., and an alarm is given if
preset values are exceeded.
The unit also contains a PI-controller for
temperature control which can operate an Alfa
Laval Heatpac electric heater or a steam
heater or any other heater with control valve
(for steam / hot water /thermal oil).
The control unit can be programmed for
different separator systems and for different
conditions within the system. The
programming is made by setting parameters,
such as type of equipment, temperature limits,
times, etc. Some parameters are set at
installation whilst process parameters are
easily accessible for adjustment during
operation.

2 Function Description EPC-400
41818053-02
2.3 Design
2.3.1 Front Panel
The front panel of the EPC-400 control unit
provides a display and LEDs (light emitting
diodes) for alarm and process information,
and push-buttons for on/off and manual
process control.
Four push-buttons are located to the right on
the panel. The upper three (1–3) are used for
process functions and the lower (4) is used for
alarm reset. The push-buttons are also used for
parameter selection and setting.
On and off functions corresponding to the
push-buttons are indicated on the LEDs (6–8)
above the display. The LEDs under the
display (9–10) are used for alarm indications.
The five digit display (11) shows process
information during operation and alarm codes
at certain alarms. It is also used for parameter
selection and setting.
The left part of the front panel contains two
rows of LEDs. The upper row (12) indicates
alarms. The alarm source is indicated on the
upper schematic diagram (13).
The LEDs in the lower row (14) indicate when
an output from the control unit is active. The
valve or other unit connected to each output is
indicated on the lower schematic diagram
(15).
The schematic diagrams can be replaced in
case of system changes or updates.
The front panel can be swung open like a door
by opening the lock (16) to the left.
G001145A
G001141A
1. Heater on/off push-button
2. Control program on/off push-button
3. Sludge discharge push-button
4. Alarm reset
5. Function symbols
6. LED for heater (green)
7. LED for control program running (green)
8. LED for stop sequence running (yellow)
9. LED for discharge failure (red)
10. LED for common main alarm (red)
11. Display
12. LEDs for alarm inputs (red)
13. Schematic diagram, alarm inputs
14. LEDs for output functions (green)
15. Schematic diagram, outputs
16. Door lock

EPC-400 2 Function Description
1818053-02 5
An on/off switch combined with a fuse is
located behind the front panel. The power is
intended to be permanently on. When work is
to be carried out in the control unit the mains
supply should be externally switched off.
2.3.2 Label Inside the Front Panel
A label on the inner side of the front panel,
serves as a quick reminder for parameter
setting in the EPC. It shows:
•the positions of the mode switch
•the connection between the display and
the push buttons
•the meaning of some parameters (P)
To make use of the label you must be familiar
with parameter setting, see section
“Operation” in this manual, and parameter
values, see the “Parameter List” manual.
2.3.3 Control Module
All electronic components are grouped on two
circuit boards which are mounted in a hinged
aluminium frame, forming an easily
accessible control module (1) inside the
cabinet. The module is fastened by two
screws, making it easy to remove and service.
Electrical output and input connections to the
module is made by cables terminated with
multi-plugs that fit into sockets on the circuit
board.
The front circuit board controls the operating
sequences. It holds the operating push-buttons
(5, 6), mode switch (3) and display segments
(4).
G001161AP000591A
1. Control module
2. Front circuit board
3. Mode switch
4. Display
5. Push buttons (for parameter setting)
6. Push buttons (for parameter selection)
F1–F3
Fuses
F11.Main switch/main fuse
X-. Terminals

2 Function Description EPC-400
61818053-02
It also contains built-in relays, which are used
e.g. for the output signals to ancillary
components, stop signal to the separator motor
starter and control signals to an optional
heater.
The rear circuit board (2b) monitors the water
transducer and coordinates the monitoring
with the operating sequences for the ALCAP
functions.
2.3.4 Power Supply
Inside the cabinet, behind the control module,
there is a mounting plate with terminals (XA),
power line filter (Z1) and a transformer (T1).
P000612A
1. Control module (folded out)
2b. Rear circuit board
F1, F2 fuses
F11 Main switch/main fuse
T1 Transformer
Z1 Power line filter
XA Terminals

1818053-02 7
3 Operation
3.1 Process Operation
The process operation is described in the
“Operating Instructions” manual.
3.2 Parameter Setting
The parameter setting is performed initially at
installation, and also when required during
operation.
How to set parameters is described below,
while the meaning and values of the
parameters are described separately in the
Parameter List for each system.
The parameters are divided into two groups.
Each group begins with a code; C1 and C2.
•Process parameters (C1): 1 – 19
•Installation, timer sequence and service
mode parameters (C2):
– Installation parameters: 20 –49
– Timer sequence parameters: 50 –89
– Service mode parameter: 90 – 95
The settings of process, installation and timer
sequence parameters are similar and are
described together, while the handling of the
service mode parameter is somewhat
different, and is described separately.

3 Operation EPC-400
81818053-02
3.2.1 Overview
The principle of parameter setting is:
1. Set the mode selector in position P
(programming).
2. Select parameter number or code with the
two upper push buttons (“1” for increasing
and “2”for decreasing the number). The
number or code is shown in the left part of
the display (7).
3. Set the desired value for each parameter
with the two lower push buttons (“3” for
increasing and “4” for decreasing the
value). The value is shown in the right part
of the display (6).
3.2.2 Setting Procedure
Setting of parameters is described below.
The installation parameters must be set before
the process parameters. If the installation
parameters are OK, and you just want to
change process parameters, follow the
sequence:1-3, 9, 6-7, 11-12.
1. Open the front panel.
2. Turn the mode selector to P
(programming) position.
“Pro” flashes on the display.
3. Press the upper selection push button.
The code C1 1 is displayed. This indicates
process parameters.
G001391A
1 Parameter selection - increase number
2. Parameter selection - decrease number
3. Parameter setting - increase value
4. Parameter setting - decrease value
5. Mode selector
6. Parameter value indication
7. Parameter number indication
G001861AG001871AG001881A

EPC-400 3 Operation
1818053-02 9
Installation Parameters
4. Press the same button again and keep it
pressed until code C2 2 appears. This
indicates installation parameters.
5. Change the code to C2 12 using the
parameter value push button. This makes
it possible to change the values of the
installation parameters.
6. Press the upper selection push button
again. The first installation parameter (20)
is displayed. Keep the button pressed until
you reach the desired parameter. To step
down the parameters, press the lower
parameter selection button.
Adjust the value of the selected parameter,
using the parameter value push buttons.
(See the “ Parameter List” manual for an
explanation of parameters and
recommended values.
The display flashes.
7. Confirm the new value by pushing the
upper parameter selection push button.
The display stops flashing.
8. When all installation parameters are
properly set, return to process parameter
code C1 1:
• Switch the the mode selector to L and
back to P, and then press the upper
parameter selection push button.
Process Parameters
9. Set the code to C1 12, using the parameter
value push buttons. This makes it possible
to change process parameter values.
G001921AG044781AG044791AG044801AG001891A

3 Operation EPC-400
10 1818053-02
10. Set the process parameters in the same
way as the installation parameters, see
points 6 and 7.
End of Parameter Setting
11. When all parameters are appropriately
adjusted, switch the mode selector to L
(local).
12. Close the front panel.
G001931AG001941A

1818053-02 11
4 Maintenance
The EPC-400 has a test program for self
testing and separation system testing. For
more information, see the “Alarms and Fault
Finding” manual.
4.1 Preventive
Maintenance
It is recommended to carry out a lamp (LED)
test once a month. No other regular
maintenance is required.
4.1.1 Lamp Test
•Press the alarm reset button for five
seconds. (This can be done during
operation.)
•Check that all LEDs are lit.

4 Maintenance EPC-400
12 1818053-02
4.2 Corrective
Maintenance
4.2.1 Fuses and Related Functions
Fuses are located on the front board, the rear
board and the power terminal.
Front board (A1)
Rear board (A2)
Power terminal
Fuse Functions influenced Alarm
F1 10 V AC supply to the board Remote alarm
Display black (A4 when new fuse installed)
F2 20 V AC supply to the board
Analog/digital conversion
Pt-100 inputs
A1-4
A2-6
C/F EEE
F3 All outputs PS42
Fuse Functions influenced Alarm
F2 10 V AC supply to the board A1-4
F3 20 V AC supply to the board A1-4
At restart with new fuse,
switch power ON-OFF-ON
Fuse Functions influenced Alarm
F12, F13 Power to the EPC-400 Display black
P000104A

EPC-400 4 Maintenance
1818053-02 13
4.3 Replacement of
Control Module
If a persistent fault is found in the control
module it must not be repaired, but must be
replaced and sent to an Alfa Laval
representative for repair.
1. Make a note of all the actual parameter
settings.
2. Switch off the power to the EPC by the
main switch on the starter.
3. Open the panel door.
4. Pull out the wire terminal sockets by hand
Remove terminals XC and XD using a
screwdriver.
Note: both terminal and sockets are marked
with terminal numbers.
5. Remove the two screws holding the
module and fold the module out.
G009293AG009294AG009295A

4 Maintenance EPC-400
14 1818053-02
6. Pull out the wire terminal sockets by hand
on the rear circuit board.
7. Lift off the control module from the
cabinet and replace it with a spare module.
8. Fit the spare module in reverse order.
9. Switch on the power.
10. Set the parameters to the values noted.
11. Fill in the report form on the rear of the
faulty module and send it for repair.
G009296A

1818053-02 15
5 Technical Data
5.1 Specification
Mains voltage 48 V AC +10 %
–15 %
Total power requirement During separation: max. 110 VA
During sludge discharge: max. 200 VA
Power requirement for outputs Inrush: max. 5 x 45 VA
Continuous: max. 5 x 23 VA
Frequency 50/60 Hz ±5%
Max. cable area 1.5 mm2
Outputs for valves Five relays, connected for 48 V AC at delivery
Outputs for oil heater Three potential-free relays: max 0.5 A
One triac: max. 100 mA
(If the steam control valve is applicable, two
relays are used for increase/decrease signals 24
V AC)
Motor stop function One potential-free relay: max. 50 V, 1 A
Alarm inputs Five potential-free contacts
One Pt-100 temperature sensor
One WT 200 water transducer
Temperature control inputs One for Pt-100 temperature sensor
Remote input signals Six potential-free contacts
Remote alarm output One potential-free relay: max. 50 V, 0.5 A
Communication One current loop, 20 mA, one RS232 C
Fuses Built-in automatic fuse 3.0 A for power supply
combined with power switch
Fuse 1.6 A for 24 V AC supply to external
electronic units, max. total load 0.5 A
Glass fuses 250 mA, 500 mA, 2.5 A, 5 A
Weight 21 kg

5 Technical Data EPC-400
16 1818053-02
5.2 Dimensions
Ambient temperature Max. 55 °C
Degree of protection IP 65
Ref. 1762575 Rev.11
Article No. Type Separator type
31830-6149-1
31830-6228-1 EPC-400 FOPX
31830-6149-2
31830-6228-2 EPC-400 LOPX
31830-6149-3
31830-6228-3 EPC-400 MFPX
X001531A
Ref. 1762575 Rev.11