PIOVAN SpA

Technical Training

OPTICAL DISC: CD Dryer Alarm List

Service & After Sales Dept

©S&AS Dept L&G (OD-ALARM) rev.01 1

 A_01
• BLOCKING ALARM
• ERROR IN
OPERATION DATA
• REMEDY: Replace the
microprocessor. Ensure that it
has the same original
configuration.
• Consult the Piovan After Sales
Department.

©S&AS Dept L&G (OD-ALARM) rev.01 2

 A_02
• NON BLOCKING ALARM
(INDICATION ONLY)
• HIGH DEVIATION
• CAUSE: High deviation of process
temperature.
• REMEDY:
• Check the efficiency of the operating
heater relays.
• Verify the process temperature trend with
respect to the set point value.
• Check the setting of the “d.Hi” in the
microprocessor. (default value = 50).

©S&AS Dept L&G (OD-ALARM) rev.01 3

 A_03
• NON BLOCKING ALARM
(INDICATION ONLY)
• LOW DEVIATION
• CAUSE: Low deviation of process
temperature.
• REMEDY:
• Check the efficiency of the operating
heater and relays.
• Verify that the process temperature trend
respects the set point value.
• Check the setting of the “d.Lo” in the
microprocessor. (default value = 50).

©S&AS Dept L&G (OD-ALARM) rev.01 4

 A_04
• BLOCKING ALARM
• PROCESS BLOWER
THERMAL RELAY
• CAUSE: Main blower problems :air
flow blocked, blower mechanically
blocked ( eg. impeller seizing).
• REMEDY:
• Check the air flow (piping, filters,
aftercoolers, hoppers).
• Check the blower (bearing, impeller).
• Check the blower contacters and the
thermal relays setting.
• Reset the overload switch and check the
real power absorption.
• Note: the absorption should never exceed
the fixed values which can be found on a
label located on the motor.

©S&AS Dept L&G (OD-ALARM) rev.01 5

 A_05
• BLOCKING ALARM
• OVERHEATING IN THE
PROCESS HEATING
CHAMBER
• CAUSE: Obstacle in the air
flow, thermostat set
incorrectly. Heaters always
on. Machine’s power supply
suddenly cut off while the
heaters are functioning.
• REMEDY:
• Check the air flow circuit.
• Check the safety thermostat
operation. Note: In some models
the reset is automatic while in
others it is manual : in both cases,
wait until the temperature
decreases.

©S&AS Dept L&G (OD-ALARM) rev.01 6

 A_08
• BLOCKING ALARM
• AIR OVERHEATING IN THE HOPPER
• REMEDY:
• Check the efficiency of the operating
heater relays.
• Verify that the process temperature trend
conforms with the set point value.
• Verify the correct positioning of the
probe.
• Check if there are any leaks from the
regeneration circuit.
• Check the safety thermostat operation.
• Check the setting of the safety thermostat
on the control panel. Normally it should
be 10-15°C more than the setting of the
process thermostat.
©S&AS Dept L&G (OD-ALARM) rev.01 7
 A_08
• When the safety thermostat
shows:
– “EEE” (faulty or disconnected
safety process probe).
– “----” (Short circuit of the
safety process probe).
• At the same time, the
microprocessor displays the
A_08 blocking alarm.

©S&AS Dept L&G (OD-ALARM) rev.01 8

 A_09
• BLOCKING ALARM
• PROCESS RETURN AIR
OVERHEATING
• CAUSE: Insufficient cooling due to absent/
insufficient water flow or dirty after cooler.
• REMEDY:
• Verify the water flow and water
temperature.
• Check the aftercooler. If dirty or
clogged, remove and clean it.
• Check the setting of the safety
thermostat operation.
• Note: In some models the reset is
automatic, whilst in others it is manual.
In both cases wait until the temperature
decreases.

©S&AS Dept L&G (OD-ALARM) rev.01 9

 A_10
• BLOCKING ALARM
• REGENERATION BLOWER
THERMAL RELAY
• CAUSE: Regeneration blower
problems: air flow blocked, blower
mechanically blocked ( eg. impeller seizing).

• REMEDY:
• Check the air flow (pipe, filter, aftercooler).
• Check the blower (bearing, impeller).
• Check the blower contacter and the thermal
relay setting.
• Reset the overload switch and check the
real power absorption.
• Note: The absorption should never exceed the
fixed values which can be found on a label
located on the motor.

©S&AS Dept L&G (OD-ALARM) rev.01 10

 A_13 •
•
BLOCKING ALARM
REGENERATION INPUT AIR
OVERHEATING.
Note: ALARM PRESENT ONLY ON
DRYER EQUIPPED WITH CLOSED-
LOOP REGENERATION CIRCUIT.
• CAUSE: Inefficient cooling
system. Excessively high water
temperature.
• REMEDY:
• Check the water flow circulation.
• Verify the temperature of the cooling
water.
• Check the set point value of the safety
thermostat (±70°C).
• Make sure that the regeneration
aftercooler is not clogged - if necessary,
clean it.
Note: When the temperature decreases, the
thermostat will reset itself automatically.

©S&AS Dept L&G (OD-ALARM) rev.01 11

 * A_14
• BLOCKING ALARM
• REVERSE ROTATION OF THE
BLOWER
• CAUSE: The phases of the power supply
are not in correct sequence.
• REMEDY:
• Reverse two wires in switch QS1 terminals.
• * Note: This alarm is only present in CD
Dryers models.

NO

OK
©S&AS Dept L&G (OD-ALARM) rev.01 12
• BLOCKING ALARM
• LACK OF COMPRESSED
A_15
AIR
• CAUSE: Lack of compressed
air, or insufficient air pressure.
Incorrect set point of pressure
switch.

• REMEDY:
• Check the pressure switch and
adjust the setting if necessary.
Replace it if necessary.
• Reset the compressed air, make
sure that the line pressure is that
required by the machine and
that the pressure remains
constant over time.

©S&AS Dept L&G (OD-ALARM) rev.01 13

 A_16
• NON BLOCKING (indication only)
• PROCESS FILTER CLOGGED
• CAUSE: Substantial reduction of air flow.
• REMEDY:
• Check air circuit and remove any obstructions.
• Remove the filter from its housing, clean with dry
compressed air and replace it if necessary.

©S&AS Dept L&G (OD-ALARM) rev.01 14

 A 17
• NON BLOCKING (indication only)
• LACK OF MATERIAL IN THE
HOPPER (optional)

• CAUSE: Lack of material in the

hopper/s. Level sensor out of
operation.
• Note: This alarm is only present if the
drying hopper is equipped with a 50% level
sensor.

Selector
50%-100%

©S&AS Dept L&G (OD-ALARM) rev.01 15

• NON BLOCKING (indication only)
A 17
• LACK OF MATERIAL IN THE
HOPPER (optional)
• REMEDY:
• Check that there is material in the silos, container,
bag, etc..
• Check the exact level of the material in the hopper.
• Make sure that the loading device is working
correctly.
• Make sure that the filter of the hopper loader is
clean.
• Check to see if there are any leaks from the
atmosphere in the piping (vacuum or material line)
or in the receiver.
• Check that the receiver flap is working properly.
• Check that the level sensor on the hopper is
working properly. If necessary, either adjust its
sensitivity or replace it.
• Check that there is the correct mixture of air and
granules in the suction probe. This will ensure the
best transportation of the material.

©S&AS Dept L&G (OD-ALARM) rev.01 16

 A_18
This alarm is only present if the dryer is equipped with a hygrometer.

• Non blocking (indication only) • REMEDY:

• UNSATISFACTORY DEW • Check that the value in the Dew Point Alarm
POINT function is correct.
• Leave the unloaded Dryer running in order to
• CAUSES:
regenerate the molecular sieves. This will
• -The set value of the DEW POINT
eliminate the humidity absorbed during the
ALARM function is not correct.
standstill period.
• -Dryer put in operation after period of
disuse. • Check and eliminate any water leaks from the
• -Moisture infiltration (water or air) into aftercooler. Also check to see if there are any
the process circuit. air leaks into the piping from the atmosphere
• -Very wet material. or from the regeneration circuit.
• -Insufficient regeneration. • Check the regeneration operations.
• -Hygrometer problems. • Note: The dryer can function without the
Hygrometer. When the Hygrometer is disabled,
the Dryer functions as normal, relying either on
the automatic timer or on the temperature
controller.

©S&AS Dept L&G (OD-ALARM) rev.01 17

 A_19
BLOCKING ALARM

FAULTY OR DISCONNECTED
PROCESS PROBE

REMEDY:
• Check the cable.
• Check the connection of the
probe and replace it if
necessary.

©S&AS Dept L&G (OD-ALARM) rev.01 18

 A_20
• BLOCKING ALARM
• FAULTY OR DISCONNECTED
REGENERATION THERMOSTATIC
PROBE.

• CAUSE: Probe for regeneration temperature

control in short circuit or disconnected.
• The probe switch-over board for the regeneration
tower input (A2-A3*) is out of operation.
• REMEDY:
• Ensure that the temperature probe is connected
and check the cable.
• Check the probe switch-over for the regeneration
tower input (A2-A3* ) and replace if necessary.
• *Note: Electronic board A3 is present only in the
dryer equipped with the closed-loop regeneration
circuit.

©S&AS Dept L&G (OD-ALARM) rev.01 19

 A_22
• NON BLOCKING (indication
only)
• Faulty or disconnected
auxiliary probe.
• CAUSE: The auxiliary
temperature control probe is in short
circuit or disconnected.
• REMEDY:
• Check the cable.
• Make sure that the auxiliary
temperature probe is connected.
Replace if necessary.

©S&AS Dept L&G (OD-ALARM) rev.01 20

 A_23
• BLOCKING ALARM
• FAULT IN THE
TEMPERATURE REFERENCE
PROBE.
• REMEDY:
• Replace the microprocessor A1.
Ensure that it has the same original
configuration as set by the
manufacturer.
• Consult the Piovan Service
Department.

©S&AS Dept L&G (OD-ALARM) rev.01 21

 A_24
• NON BLOCKING (indication
only)
• LOSS OF CLOCK
DATA
• CAUSE: The clock is not
functioning correctly.
• REMEDY:
• Check the parameters of the
clock.
• Replace the clock.

©S&AS Dept L&G (OD-ALARM) rev.01 22

 A_25 •
•
NON BLOCKING (indication only)
REGENERATION HEATING
ELEMENTS HAVE FAILED.
• CAUSE: One or more of the heating
elements are broken. Overloading has
caused one or more of the fuse breakers to
be damaged. The parameters of the
microprocessor (set by the manufacturer)
are incorrect.
• REMEDY:
• Check fuses and relays and replace if
necessary.
• Check the real power absorption (Amp)
of the heaters.
• Check and replace any damaged heater
elements.
• Check the regeneration circuit: air flow,
piping, etc...
• Check the regeneration operation cycle.
• Consult the Piovan Service Department
for verification of the microprocessor’s
parameters.

©S&AS Dept L&G (OD-ALARM) rev.01 23

 A_26
NON BLOCKING (Indication only)
(NOT PRESENT IN THE C06 MICROPROCESSOR VERSION)
A SIGNAL WHICH INDICATES THAT THE TIME LIMIT OF THE PROCESS
TOWER HAS BEEN REACHED.
Note: This alarm is only present if the dryer is equipped with a hygrometer and if the
dew point control function is activated
• CAUSE: • REMEDY:
• The dew point changeover value has • Check the Hygrometer operation (set
not been reached within the time value, probe connection, air flow on
limit. (Note that the process time probe).
limit is pre-set by the manufacturer). • If necessary, replace the probe.
• There is no variation of the Dew Usually, all that is necessary is to
Point value with the passing of time. send the probe back to the
• The hygrometer is damaged or manufacturer for recalibration.
incorrectly set. • Disactivate the Dew Point Control
• The moisture content of the resin is function and leave the Dryer running
low. without the hygrometer.
• Note: The alarm is not present in the
microprocessor versions above and
including C06.

©S&AS Dept L&G (OD-ALARM) rev.01 24

 When the dryer does not present any defects.
Checkpoints to consider in the event
of continuing moulding problems.
If humidity problems are suspected due to the drying material:
• Make sure that the temperature set on the Dryer is the temperature recommended by the
resin manufacturer.
• Make sure that the resin to be moulded remains in the hopper for the necessary time for it to
be completely dehumidified.
• Make sure that the dried material has no moisture contamination from the environment.
• Carry out a test with dried virgin material. (Some additives or masterbatches may absorb
moisture).
• Stop production temporarily but leave the dryer functioning so as to increase the
dehumidification of the resin.
• Ensure that the air flow in the hopper is not obstructed in any way, for example the air
diffuser cone may be clogged. Any obstruction will decrease the drying performance.
• If the Dryer is equipped with the Dew Point Control function and is suspected to be
incorrectly operating the Hygrometer for measuring the Dew Point value, Piovan recommends
the following:
– It is best to deactivate the Dew Point Control function and leave the Dryer running as normal, relying
on either the automatic timer or the temperature controller.

©S&AS Dept L&G (OD-ALARM) rev.01 25

The air diffuser cone into the
hopper

©S&AS Dept L&G (OD-ALARM) rev.01 26

 Easy System
Important recommendations
• Procedure for switching
off the receiver:
– 1) Select the “EXCLUDE” mode
using the keypad.
– 2) Switch off at the control box
located on the receiver.
• Important note: If the control box is
switched off before the keypad
operation, an alarm (“THE UNIT NR.#
IS OFF LINE”) will be activated. The
rest of the feeding system will continue
functioning as normal.
• In order to stop the alarm, it is
necessary to:
• Switch on at the control box.
• Select the “INCLUDE” mode using the
keypad.

©S&AS Dept L&G (OD-ALARM) rev.01 27

 Status of the receiver and server
control boxes
Receiver control box
• A flashing red light indicates:
• “Loading alarm”- a blocking alarm
appears on the receiver control box after 3
unsuccessful loading attempts.
• In order to reset the alarm, press the
appropriate button on the keypad. The
loading cycle will restart automatically.
Verify and eliminate the cause of the
problem.
©S&AS Dept L&G (OD-ALARM) rev.01
Receiver control box
• A constant red light indicates that:
• The server is disconnected from the serial line.
• A flashing red light indicates:
• A blocking alarm of the vacuum pump
thermal relay.
• Intervention of the security thermostat (if
present) in order to prevent damage caused by
the overheating of the vacuum pump.
• Intervention of draft differential (if present)
located in the centralised filter.
• A flashing red light, (non blocking alarm),
indicates a “loading alarm” in some receivers.
The remainder of the feeding system will
continue to function as normal.
28
 Control Box (Server)
• A constant red light indicates that:
• The server is disconnected from the serial
line.
• A flashing red light indicates:
• A blocking alarm of the vacuum pump
thermal relay.
• Intervention of the security thermostat (if
present) in order to prevent damage caused
by the overheating of the vacuum pump.
• Intervention of draft differential (if
present) located in the centralised filter.
• A flashing red light, (non blocking alarm),
indicates a “loading alarm” in some
receivers. The remainder of the feeding
system will continue to function as normal.

©S&AS Dept L&G (OD-ALARM) rev.01 29

 Alarms:
OFF LINE
• This alarm occurs in the following
conditions:
• 1. Receiver control box switched off.
• 2. Serial line plug disconnected.
• 3. Serial line wires not connected properly.
• 4. The receiver is not assigned.
• Remedy:
• 1. Switch on the receiver.
• 2-3. Verify the serial line connections plug
and wires in the junction box.
• 4. It is necessary to re-assign the receiver
(see procedure in the instruction manual).

Serial line

©S&AS Dept L&G (OD-ALARM) rev.01 30

 Loading Alarm
Remedy:
• Check that there is material in the silos, container,
bag, etc.
• Check all Filters : suction probe, C5 metal filter,
GR1 mesh filter, blower inlet-outlet paper filters. If
they are clogged, clean or replace if necessary.
• Check the exact level of the material in the
hopper/receiver.
• Make sure that the loading device is working
correctly.
• Check if there are any leaks from the atmosphere in
the piping (vacuum or material line) or in the
receiver.
• Check that the flap of the receiver is working
properly.
• Check that there is compressed air.
• Check that the level indicator on the
receiver/hopper is working properly. If necessary,
adjust its sensitivity or replace it.
• Check that there is the correct mixture of air and
granules in the suction probe. This will ensure the
best transportation of the material.
• Check the correct functioning of the slide gate of
the drying hopper.
©S&AS Dept L&G (OD-ALARM) rev.01 31
THANK YOU FOR YOUR
ATTENTION.

ANY QUESTIONS?

©S&AS Dept L&G (OD-ALARM) rev.01 32