Alarms and Warnings List
In this section of the BioDryer manual, we provide a comprehensive guide to understanding the various alarms and warnings that the BioDryer system may issue. This list is designed to assist operators in quickly identifying the nature of each alarm, understanding its potential causes, and implementing effective resolutions. By familiarizing yourself with this list, you will be better equipped to respond promptly and effectively to any issues, ensuring the smooth operation of the BioDryer. Each entry includes a brief description of the alarm, its likely causes, and suggested actions to resolve the issue.
To access more details on triggered alarms, ensure to click on the info messages button located at the top right corner of the HMI. Often, when an alarm or warning is active, additional useful information is displayed in the info messages tab. Always consult this section before commencing any troubleshooting and fixing procedures.
ALARMS
GENERAL_SAFETY
The safety module has been activated, preventing the operation of all motors and valves due to safety locks.
| Cause | Possible Resolution |
|---|---|
| Manual activation of an emergency button | Reset the triggered emergency button and reset the control cabinet safety. |
| Manual activation of an emergency rope | Reset the triggered emergency rope and reset the control cabinet safety. |
| Control cabinet just powered on | When power is just supplied to the control cabinet, the emergency system is activated. Manually reset the control cabinet safety. |
| Tripping of an essential circuit breaker | Ensure all circuit breakers in the control cabinet and air-skid junction box are ON, then reset the control cabinet safety. |
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_POD_PANEL
One or multiple Plexus PODs (IO Modules) inside the control cabinet are not responding.
| Cause | Possible Resolution |
|---|---|
| The 24VDC circuit breaker that provides power to the Plexus PODs inside the control panel has tripped | Re-engage the circuit breaker. If it trips again, ensure there is no short circuit happening before or after the Plexus POD. |
| The Ethernet cable to the Plexus POD is not connected correctly or is damaged | Inspect the Ethernet cable. If damaged, replace it; otherwise, reconnect the Ethernet cable from the Plexus POD to the switch. |
| The Ethernet switch is not working properly, is damaged, or is off | Ensure 24VDC is supplied to the Ethernet switch. If power is present but no LEDs are blinking, replace the damaged switch with a new one. |
| Firmware temporary blockage | In rare cases, the firmware inside the Plexus POD might freeze. Remove power, wait 10 seconds, and reapply power to the Plexus POD to reboot the system. |
| One of the Plexus PODs is damaged or broken (No blue light blinking on the IO Module) | Contact Bioforcetech |
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_POD_AIR
One or multiple Plexus PODs (IO Modules) inside the Airskid junction box are not responding.
| Cause | Possible Resolution |
|---|---|
| The 24VDC circuit breaker that provides power to the Plexus PODs inside the Airskid junction box has tripped | Re-engage the circuit breaker. If it trips again, ensure there is no short circuit happening before or after the Plexus POD. |
| The Ethernet cable to the Plexus POD is not connected correctly or is damaged | Inspect the Ethernet cable. If damaged, replace it; otherwise, reconnect the Ethernet cable from the Plexus POD to the switch. |
| The Ethernet switch is not working properly, is damaged, or is off | Ensure 24VDC is supplied to the Ethernet switch. If power is present but no LEDs are blinking, replace the damaged switch with a new one. |
| Firmware temporary blockage | In rare cases, the firmware inside the Plexus POD might freeze. Remove power, wait 10 seconds, and reapply power to the Plexus POD to reboot the system. |
| One of the Plexus PODs is damaged or broken (No blue light blinking on the IO Module) | Contact Bioforcetech |
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_POD_BIODRYER
One or multiple Plexus PODs (IO Modules) on the BioDryer rotating body are not responding.
| Cause | Possible Resolution |
|---|---|
| The 24VDC circuit breaker that provides power to the Plexus PODs has tripped | Re-engage the circuit breaker. If it trips again, ensure there is no short circuit happening before or after the Plexus POD. |
| The Ethernet cable to the Plexus POD or the rotaing electrical slip ring is not connected correctly or is damaged | Inspect the Ethernet cable and rotating slip ring. If damaged, replace it; otherwise, reconnect the Ethernet cable from the Plexus POD to the switch. |
| The Ethernet switch is not working properly, is damaged, or is off | Ensure 24VDC is supplied to the Ethernet switch. If power is present but no LEDs are blinking, replace the damaged switch with a new one. |
| Firmware temporary blockage | In rare cases, the firmware inside the Plexus POD might freeze. Remove power, wait 10 seconds, and reapply power to the Plexus POD to reboot the system. |
| One of the Plexus PODs is damaged or broken (No blue light blinking on the IO Module) | Contact Bioforcetech |
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_ROTATION or ERR_AUTO_ROTATION
The BioDryer attempted to rotate, but something prevented this operation. Be sure to check the info messages list on the HMI panel before proceeding with problem resolution.
| Cause | Possible Resolution |
|---|---|
| One of the circuit breakers responsible for rotation (rotation motors or brakes) has tripped or is not engaged | Re-engage the circuit breaker. If it trips again, contact Bioforcetech. |
| The brakes are not disengaging when attempting rotation | Contact Bioforcetech. |
| Airlock is not in the correct position or an airlock proximity sensor is not working properly | Check the section on how to troubleshoot the airlock system to resolve this issue. |
| The butterfly valve on the body is not closing, or the proximity sensor is not reading the closed position | Check the section on how to troubleshoot the butterfly valves to resolve the issue. |
| One of the sludge gates is not fully closed | Check the section on how to troubleshoot the sludge gates to resolve the issue. |
| One of the air gates is not fully closed | Check the section on how to troubleshoot the air gates to resolve the issue. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ALARM_BREAKERS
One or multiple circuit breakers inside the control cabinet or in the airskid juctiuon box has tripped or it off. Be sure to check the info messages list on the HMI panel before proceeding with problem resolution as it will indicate which circuit breaker has the issue.
| Cause | Possible Resolution |
|---|---|
| One of the circuit breakers has tripped or it's off | Re-engage the circuit breaker. If it trips again, contact Bioforcetech. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
ERR_COMPR_AIR
Pneumatic air pressure is too low to operate the BioDryer.
| Cause | Possible Resolution |
|---|---|
| Pneumatic air is not supplied to the BioDryer | Check the pneumatic air inlet valve and pressure reducers. Ensure the valve is open and pressures are set to 100 psi and 60 psi. |
| A pressure sensor is indicating 0 even if pneumatic air is supplied | Replace the sensor. |
| Major pneumatic air leakage | Inspect the pneumatic air tubing and connectors for leakage and repair if necessary by replacing broken tubing or tightening leaking connectors. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_AUTO_AIR
The BioDryer attempted to start the airflow, but something prevented this operation. Be sure to check the info messages list on the HMI panel before proceeding with problem resolution.
| Cause | Possible Resolution |
|---|---|
| One of the circuit breakers responsible for airflow (blowers or condensate pump) has tripped or is not engaged | Re-engage the circuit breaker. If it trips again, contact Bioforcetech. |
| One of the VFDs responsible for airflow (blowers VFD) has an alarm or it's off | Reset the VFD by powering off the panel for 10 seconds and then repowering on. |
| Airlock is not in the correct position (pushed against the BioDryer inlet flange) | Check the section on how to troubleshoot the airlock system to resolve this issue. |
| The butterfly valve on the body or the one on the air skid is not opening, or the proximity sensor is not reading the open position | Check the section on how to troubleshoot the butterfly valves to resolve the issue. |
| One of the sludge gates is not fully closed | Check the section on how to troubleshoot the sludge gates to resolve the issue. |
| At least 2 air gates are not fully opened | Check the section on how to troubleshoot the air gates to resolve the issue. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_UNLOAD
The BioDryer unloading cycle has been suddenly interrupted.
| Cause | Possible Resolution |
|---|---|
| The Manual mode switch has been engaged during the unloading cycle | Switch the BioDryer to Auto mode. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
ERR_AUTO_UNLOAD
The BioDryer attempted to start the unload cycle or is unloading, and it was interrupted.
| Cause | Possible Resolution |
|---|---|
| The chain conveyor is not running | Check the status of the chain conveyor in the main panel to identify any issues. |
| Communication with the main panel, which controls the chain conveyor, is lost | Ensure the main panel is powered on and responsive. Contact Bioforcetech if the issue persists once the main panel is activated. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
Please note that an alarm may have multiple causes. If one resolution does not solve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
POSITION_BIODRYER_ALARM
The BioDryer attempted to find one of the predetermined positions (air, load, or unload) and failed. The system will try to correct this issue three times. If the correct position cannot be found after three attempts, the alarm is triggered.
| Cause | Possible Resolution |
|---|---|
| The encoder has moved from its original position or is returning a value of 0 | Contact Bioforcetech. |
| The rotation proximity sensors are too far from the detecting plates | Check the section on positioning the rotation proximity sensors. |
| One of the rotation proximity sensors is broken | Replace the rotation proximity sensor. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
Please note that an alarm may have multiple causes. If one resolution does not resolve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ERR_POSITION_LOAD
The BioDryer loading cycle has been activated, but the BioDryer is not in the loading position and is not moving into the load position.
| Cause | Possible Resolution |
|---|---|
| The BioDryer is not in the loading position | Remove the loading request, manually position the BioDryer into the loading position, and then reactivate the loading request. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
ERR_TIMEOUT_LOAD
The BioDryer loading request has been active for more than the timeout time set (usually 10 minutes), but no biosolids loading confirmation has been received.
| Cause | Possible Resolution |
|---|---|
| Loading confirmation not received within the allotted time (usually 10 minutes) | Ensure biosolids are available and attempt the loading procedure again. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
ERR_BIODRYER_LOAD
The BioDryer is attempting to load biosolids, but one of the sludge gates is not completely opened.
| Cause | Possible Resolution |
|---|---|
| One of the biosolids gates is not fully opened during the loading cycle | Initiate the automated sludge cleaning cycles from the HMI panel and ensure that all gates are fully opening. If the issue persists, refer to the section on troubleshooting the sludge gates. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
ALARM_WATER_LEVEL
The condensate tank has been full for too long.
| Cause | Possible Resolution |
|---|---|
| The condensate tank is full for more than the accepted timeframe (usually 10 minutes) | Check that the condensate pump is operating correctly and ensure there is no blockage in the condensate discharge piping. |
| The condensate tank level sensor is stuck in the high-level position | Remove the condensate tank level sensor to ensure it is clean and the floating modules are moving freely. Then, remount the sensor. |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
Please note that an alarm may have multiple causes. If one resolution does not solve the issue, review the list above again to check for any other potential causes. If the problem persists, please contact Bioforcetech for assistance.
ALARM_VFD
One or multiple VFDs (Variable Frequency Drives) for rotation or blowers present a fault status.
| Cause | Possible Resolution |
|---|---|
| A VFD is in fault status | Reset the VFD fault status by powering off the control panel for 30 seconds and powering it back on. If the problem persists, there might be an issue with the VFD or the motors (Contact Bioforcetech). |
After resolving the issue, you may need to manually reset the alarm by clicking on the "reset alarm" button in the alarm list of the HMI.
WARNINGS
In the WARNINGS section of the BioDryer manual, we address alerts that, while not critical enough to halt operations, provide crucial information to the operator. These warnings signify that certain aspects of the BioDryer require attention. Understanding these alerts helps in maintaining optimal performance and preventing potential issues from escalating. It's important for operators to regularly monitor these warnings and take appropriate action to ensure the BioDryer continues to operate efficiently. This section outlines the various warnings the system may issue, their implications, and recommended steps for addressing them.
WARN_TANK_FULL
This warning serves as a preventive measure, indicating that the condensate tank has remained full for a few minutes without the pump running. It's essential to verify that there is no blockage in the discharge piping system. Addressing this promptly can prevent overflow issues and ensure the smooth operation of the condensate removal process.
WARN_DELTA_PRESSURE
This warning indicates that the delta pressure between the inlet and outlet of the air-to-air heat exchanger is exceeding preferred values. This situation could signal an accumulation of biosolids residue on the heat exchanger, obstructing airflow. To address this, please check and clean the heat exchanger. For detailed instructions on performing this maintenance, refer to the relevant section.
WARN_STARTUP_VALUES
This warning indicates that the BioDryer settings are currently set to factory defaults. While this may not immediately present a problem, it's likely that these values need adjustment to meet the specific requirements of your plant. Please verify these settings and make any necessary changes to optimize the BioDryer's performance for your operational needs.
WARN_AIRFLOW_UNDETECTED
This warning signals that, although the blowers are operational, no airflow is being detected by the airspeed sensor. The BioDryer will continue its operation under this condition; however, it is crucial to ensure that the sensor is correctly positioned and functioning properly. Additionally, assess whether the sensor is damaged or malfunctioning. Another potential issue could be related to the IO card (Plexus POD). If the problem persists, please contact Bioforcetech for further assistance.
WARN_SELECTOR_OFF
This warning indicates that the auto/manual switch on the BioDryer has been set to OFF. While this may have been done intentionally, it's important to note that the BioDryer cannot perform any operations when the switch is in the OFF position. This warning serves as a reminder that the switch is currently selected to OFF, potentially affecting the BioDryer's functionality.