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Hanjin Heavy Ind. Co.

Subic Bay Shipyard - Philippines


Hulls:
NCP 0104/05/06/07/08/09/10/11/18/19

PureBallast Ballast Water Treatment System

System Manual
English

Hanjin Heavy Ind. Co. Subic Bay Shipyard Philippines


Hulls:
NCP 0104/05/06/07/08/09/10/11/18/19
PureBallast Ballast Water Treatment System
System Manual - PureBallast 3.0 Flow 750

PureBallast: Ballast Water


Treatment System

Table of Contents
Safety

System Description

Operating Instructions and


Control System
3
Description

Only foreseeable conditions have been taken into


consideration. No warnings are given for
situations arising from unintended usage of the
system components and tools.

Marine & Diesel Equipment

Printed 2013

Parameters

Alarms and Faultfinding

Installation and Drawings

Service Manual

Spare Parts Catalogue

Alfa Laval reserves 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 AlfaLaval company.
Published by: :

Alfa Laval Tumba AB


E-147 80 Tumba, Schweden
Telefon: +46 8 530 650 00
Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 2013

Chapter: 1. Safety
System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1

Introduction

Safety information

2.1

General safety information

2.2

Specific safety information

2.3

Personnel requirements

2.4

Warning signs used in the manual

Environmental issues

11

3.1

Unpacking

11

3.2

Other materials

11

1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.

Book No.9010182 02, rev. 0

Introduction

2 Safety information
This section contains safety information. This information must be read and understood before the
system is installed, operated and maintained.

2.1

General safety information

The following general safety information apply:

The PureBallast system is not EX proofed and must not be installed in areas where an
explosive atmosphere may occur.

Use the equipment only for the purpose and parameter range specified by Alfa Laval.

Use only Alfa Laval genuine spare parts.

Always read and follow the documentation that is included in shipment of components and
spare parts regarding handling, safety and disposal.

Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.

Before installation, read applicable sections in chapter 6. Installation instruction and drawings.

Before operation, read the Preparations and conditions section for applicable instructions in
chapter 3. Operating instructions and control system description.

2.2

Specific safety information

The following safety information apply for the areas and components below. This information is also
stated in the Preparations and conditions section for applicable instructions.
Maintenance safety items

Before maintenance, read the Preparations and conditions section for applicable instructions in
chapter 7. Service manual. Essential safety information is stated before instruction to routines
that might involve any danger.

Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8.

Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle
with a load capacity greater than the weight of the component. See the Technical data section
on page for information about weight. Any complementary lifting instructions must be followed.

Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.

Reactor module safety items

Cut hazards: Sharp edges on broken UV lamps and quartz sleeves can cause cuts. Exercise
great care when handling them.

Before installation, check that the UV lamps and quartz sleeves are not broken.

Book No.9010182 02, rev. 0

2.2

Specific safety information

Safety information

Depressurize reactors and allow equipment to cool down completely before disassembling. Hot
water may escape from the reactor when removing the drain plug.

Never handle UV lamps before they are completely cooled down. A hot UV lamp is under
high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn
if it is touched.

The reactor must not be under pressure when dismounting the UV lamps.

UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the reactor with end caps properly closed.

UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled with care. Please refer to national regulations regarding disposal of used lamps. If
a UV lamp is broken, mercury could be spilt. Remove mercury with a special tool such as a
syringe (or use pure sulphure to bind the mercury for easy collection).
-

Do not allow mercury to come in contact with your eyes or skin.

Do not inhale mercury fumes. In case of having inhaled mercury fumes, consult a doctor
and follow medical instructions.

Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.

Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor
(indicated by level switch LS201-29), and the water temperature is below 60 C. Improper
operation could seriously damage the equipment and injure personnel.

Manual operation of LPS, may only be performed after cable connection. If not hazardous
situation may arise which, if not avoided, will result in death or serious injury.

Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the
power supply. The LDC contains a fan, which can cause injury if in operation.

Flow meter safety items

Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).

Valve safety items

Actuators must not be pressurized at any time during installation as it may result in injury.

Lock valve in closed position before maintenance.

CIP safety items

CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal
protection etc.

Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.

Always wear protective eye glasses and gloves while working on the pump.

Ancillary component safety items

Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.

Temperature switch, temperature transmitter and level switch. The external surface may be hot.
Care must be taken to avoid possible burns.

Book No.9010182 02, rev. 0

Safety information

2.3

2.4

Warning signs used in the manual

Personnel requirements

The PureBallast system must be operated, installed, maintained and repaired by persons trained for
respective type of work. All persons using and working with the system must know the emergency
stopping procedures.
Personnel installing, maintaining or repairing components must be of one of the following categories:

Skilled person: A person with technical knowledge or sufficient experience to perform


the tasks at hand and to enable him or her to perceive risks and to avoid hazards which
electricity/mechanics can create.

Instructed person: A person adequately advised or supervised by a skilled person to enable


him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

Alfa Laval service engineer: A person with vast knowledge about the PureBallast system.
Alfa Laval service engineer can set parameters and repair intrinsically safe apparatuses. The
person must have experience of similar types of work and be certified in accordance with
local regulations.

In some cases special skilled personnel may need to be hired, like electricians and others. In some
of these cases the personnel has to be certified according to local regulations with experience of
similar types of work.

2.4

Warning signs used in the manual

ANGER
D
!
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

NG
WARNI

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

ON
CAUTI

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTE
NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Book No.9010182 02, rev. 0

2.4

Warning signs used in the manual

Safety information

3 Environmental issues
This section contains general rules regarding environmental issues. However, local rules and
regulations should be consulted for detailed handling of each material.

3.1

Unpacking

Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.

Wood and cardboard boxes can be reused, recycled or used for energy recovery.

Plastics should be recycled or burnt at a licensed waste incineration plant.

Metal straps should be sent for material recycling.

3.2

Other materials

Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed to a suitable licensed land fill site.

Metal parts should be sent to a licensed handler for material recycling.

Seal rings should be disposed of in a licensed land fill site. Check the local regulations.

Worn out or defected electronic components should be sent to a licensed handler for material
recycling.

The operator panel contain the following components with substances that might be hazardous
to health and the environment: lithium battery, electrolytic capacitor and display. They shall
be recycled according to local regulations.

Used lithium batteries from the control unit are considered hazardous waste and should be
disposed of accordingly.

Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations.

Used quarts sleeves should be disposed of as ordinary glass.

Book No.9010182 02, rev. 0

11

Chapter: 2. System description


System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1

Introduction

1.1

Abbreviations

1.2

System overview

1.3

Components overview

1.3.1

Item numbers

Process overview

2.1

Start-up

10

2.2

Ballasting

11

2.2.1
2.2.2
2.2.3

Power optimization
Backflush
Ballast after-treatment (CIP)

11
12
14

2.3

Deballasting

15

2.3.1

Deballast after-treatment (CIP)

15

2.4

Stripping with eductor

16

2.5

Ballast water handling in the event of


malfunction

17

System components description

19

3.1

AOT reactor

19

3.1.1
3.1.2

AOT reactor working principle


AOT reactor description

19
20

3.2

Lamp drive cabinet (LDC)

21

3.2.1
3.2.2

LDC working principle


LDC description

21
22

3.3

Filter

23

3.3.1
3.3.2
3.3.3

Filter working principle


Filter description
Backflushing for different dirt loads

23
24
26

3.4

CIP (cleaning-in-place) module

28

3.4.1
3.4.2

CIP working principle


CIP module description

28
28

3.5

Control cabinet and control system

29

3.5.1
3.5.2
3.5.3
3.5.4

Control system
Main control panel
Remote control panel (optional)
Remote interface (optional)

30
30
30
32

3.6

Main valves

32

3.7

Flow meter

33

3.8

Pressure monitoring device

33

3.9

Sampling devices

33

1 Introduction
This contains general information about the PureBallast system and its components.

1.1

Abbreviations

The table below is a list of abbreviations used in this manual.


Abbreviation

Explanation

AOT

Advanced oxidation technology

AOT reactor

The main component, where the water is treated using advanced


oxidation technology

Atex

EU directive Appareils destins tre utiliss en ATmosphres


EXplosivles

CIP

Cleaning in place

CIP module

Cleaning in place module. Performs the CIP process.

DIN

Deutche Institut fr Normung

EN

Standard according to CEN (European Committee for


Standardization).

EX

Explosion-proof

I/O

Input/output (Describes a program or device handling data)

IACS

International Association of Classification Societies

ISCS

Integrated ship control system

IMO

International Maritime Organization

JIS

Japanese Industrial Standard

LED

Light emitting diode

LDC

Lamp drive cabinet.

LPS

Lamp power supply

MCB

Motor circuit breaker

Book No.9010182 02, rev. 0

1.2

System overview

Introduction

Abbreviation

Explanation

PLC

Programmable logical controller (PureBallast control system)

UV

Ultra violet

1.2

System overview

The PureBallast system is an integral part of the vessels ballast water system, on the discharge
side of the vessels ballast water pumps. During ballast operation, the water is led through the filter,
which removes larger particles and organisms, and then to the AOT reactor, where the water is
treated with UV light and advanced oxidation technology (AOT). During deballast, the water is
led the same way, but the filter is bypassed.
The UV lamps are powered by the LDC (via LPSs, lamp power supplies). The AOT reactor has
one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. The control valve also
regulates pressure during back-flushing of the filter.
The AOT reactors are cleaned using the CIP (cleaning-in-place) module, which first rinse the AOT
reactor with fresh water, and then circulates CIP liquid through the AOT. At the end of the process
the AOT reactor and the filter (filter preservation) is filled with fresh water from the CIP.
The complete system and ongoing processes is controlled and monitored from the control cabinet.
Control can also be performed from remote control panels and the ships ISCS, via the remote
interface.
The by-pass valve makes it possible to by-pass the entire system, for example to secure ballast
operation if the system is not functioning. The valve is controlled from the ISCS (integrated ship
control system).

Book No.9010182 02, rev. 0

Introduction

1.3

1.3

Components overview

Components overview

The key components in PureBallast are shown below. Note that the filter is just an example of
a filter unit; others may be chosen.

2 SystemOverview

Example of layout with 1 AOT reactor.


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Filter inlet valve


Filter
Filter bypass valve
Lamp drive cabinet (LDC)
Control cabinet with main control panel
AOT reactor
Control valve
CIP (cleaning-in-place) module
Flow meter
Backflush valve
Filter outlet valve

Not in illustration:

System bypass valve

Sampling devices, before and after treatment

Pressure monitoring device

1.3.1

Item numbers

System components are identified by unique item numbers, for example FIT201-1 for the flow
transmitter installed before the AOT reactor.
Book No.9010182 02, rev. 0

1.3

Components overview

Introduction

2 Process overview
This section gives an overview of the main processes performed by PureBallast. In the flow chart
illustrations, involved pipes are marked in bold.

Book No.9010182 02, rev. 0

2.1

2.1

Start-up

Process overview

Start-up

Ballasting and deballasting begins with a start-up phase. There must be available power for
the system. If power management is integrated, this will be confirmed automatically. If power
management is not integrated, this is confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is pumped through the
AOT reactor to secure that the UV lamps are not overheated. The flow is monitored by the flow
meter to secure that there is enough flow to cool the UV lamps. If flow deviates from parameter set
values, an alarm is issued and the system is shut down.

2 Startup

Ballast and deballast start-up

10

Book No.9010182 02, rev. 0

Process overview

2.2

2.2

Ballasting

Ballasting

After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The ballast water is pumped from the sea chest to the filter, that removes larger particles and
organisms. This also reduces the amount of sediment build-up in the ballast water tanks. The
organisms and sediments caught in the filter are flushed overboard via regular filter backflush
operations. The water is finally led to the AOT reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.

2 FullBallast

Ballasting

2.2.1

Power optimization

It is possible to activate power optimization (parameter p237). During ballast and deballast, the lamp
power is adjusted according to the value from the UV intensity sensor, which constantly measure
the water transmittance. In clear water with good transmittance, the lamps are automatically
dimmed, to lower the power consumption. This means that the lamps are lit to the degree needed
for full treatment, but not more.
The purpose is to save power by dimming the lamps to minimum power required to fully treat the
water. The UV lamps are regulated individual on all AOT reactors between 50 % and 100 % of
full effect.
Power optimization during special conditions.

During start-up and the first two minutes of ballast/deballast, the UV lamps are lit to 100 % to
ensure treatment befor values from the UV sensor are stable.

Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for 2 minutes when
process is resumed.

Book No.9010182 02, rev. 0

11

2.2

Ballasting

Process overview

Stop: UV lamps are lit to 100 % for 10 seconds before they are stoped. This will prolong
the life of the lamps.

Low UV intensity: See Actions at low UV intensity below.

Broken UV lamps: See Operation with broken UV lamp below.

2.2.1.1

Actions at low UV intensity

If the UV intensity falls below minimum (defined in parameter p221) for one AOT reactor, a warning
is issued, but process continnues. When UV intensity falls below limit defined in the type certificate,
a new warning is issued and a log is written to the event log. The operation continues but does
not fullfill the type approval certificate. However, the flow is decreased so that the treatment shall
correspond to the type approval requirements. The operator will have do decide to continnue
or stop the operation.

2.2.1.2

Operation with broken UV lamp

If a UV lamp breakes a warning is issued and a log is written to the event log. The operation
continues but does not fullfill the type approval certificate. However, the flow is decreased to 80 %
of current flow for all AOT reactors and the UV lamps are lit to 100 %. These actions are taken so
that the treatment shall correspond to the type approval requirements.
The operator will have do choose one alternative:

Stop the operation.

Continnue operation and not comply with type approval certificate.

2.2.2

Backflush

To keep the filter clean, it is automatically backflushed. The backflush is performed during ongoing
process without interrupting the ballasting process. When a ballast operation is stopped, a
backflush is performed before the system comes to a full stop. The water used for backflushing is
returned to the sea directly at the ballasting site.

12

Book No.9010182 02, rev. 0

Process overview

2.2

Ballasting

2 Back-flush

Filter backflush

Book No.9010182 02, rev. 0

13

2.2

Ballasting

2.2.3

Process overview

Ballast after-treatment (CIP)

After a ballast operation, a cleaning-in-place (CIP) process is performed to clean the AOT reactor.
This process can either be performed immediately after a ballast operation or within 30 hours after.
Note, that it is possible to perform new processes during these 30 hours. A CIP process takes
about 25 minutes per AOT reactor, if default parameters are used.
The AOT reactors are cleaned one at a time. First, the AOT reactor is rinsed with fresh water. Then
the cleaning-in-place (CIP) module circulates a biodegradable solution through the AOT reactor to
remove seawater scaling. After the cleaning is finished, the AOT reactor is filled with fresh water to
preserve the filter and prevent scaling, algae growth etc. Then the system continues with the same
procedure for the next AOT reactor. Finally, the filter is filled with fresh water to prevent scaling and
algea growth. The cleaning liquid is reused between the cleaning operations.

2 CIP

CIP process

14

Book No.9010182 02, rev. 0

Process overview

2.3

2.3

Deballasting

Deballasting

After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The water passes through the AOT reactor, but the the filter is bypassed since the water has
already been filtered during ballasting. The reason for treating the water a second time during
deballasting is to secure that the treatment is fully effective. The minor part of the organisms, which
were only injured during ballast, will be rendered totally harmless during the deballast.
The process flow and power optimization are controlled in the same way as during ballasting.

2 FullDeballast

Deballasting

2.3.1

Deballast after-treatment (CIP)

After deballast operation, a cleaning cycle is performed to clean the AOT reactor. It is performed
in the same way as described for the ballasting process. If only deballast operations has been
performed since the last CIP process, the filter does not need to be filled with fresh water at the end
of the cycle, since the filter has not been used.

Book No.9010182 02, rev. 0

15

2.4

Stripping with eductor

2.4

Process overview

Stripping with eductor

Stripping can be performed to achieve total emptying of the ballast tanks via a stripping eductor.
To use PureBallast during a stripping process an eductor must be installed before the PureBallast
system.
The water used in the stripping process, must be filtered from particles larger than approximately 5
mm. The water passes through the PureBallast system as a regular deballasting process (with
the filter by-passed). The water is finally pumped into the sea.
Note the following:

The eductor is not part of Alfa Lavals scope of supply.

Procedures to dispose of sediments from the sieve must be included in the vessels ballast
water management plan.

16

Book No.9010182 02, rev. 0

Process overview

2.5

2.5

Ballast water handling in the event


of malfunction

Ballast water handling in the event of malfunction

PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallasts control system, but all by-pass valve activities are logged in the event log. Such valve
is required by the International Convention for the Control and Management of Ships Ballast
Water and Sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. In case untreated water is pumped to a ballast tank, this water shall
be discharged on open sea (according to regulations) and exchanged for treated water. Note that
full treatment requires treatment both during ballast and deballast.
The procedures concerning emergency and malfunction of the ballast water treatment system
should be implemented in the ships Ballast water management plan.

Book No.9010182 02, rev. 0

17

2.5 Ballast water handling in the event of


malfunction

Process overview

3 System components
description
This section gives an introduction to the most important PureBallast system components and
their functions in the system.

3.1

AOT reactor

The main part of PureBallast is the AOT reactor in combination with a lamp drive cabinet (LDC)
giving power to the UV lamps in the AOT reactor. The LDC does not need to be placed in close
relation to the AOT reactor.

3.1.1

AOT reactor working principle

The main treatment process take place inside the AOT reactor, where the UV light inactivates the
cell DNA to prevent regrowth of organisms. The UV light also generates radicals. The radicals are
extremely reactive and react instantaneously with micro organisms and other organic contaminants
destructing their membranes. The radicals are extremely short-lived and exist only for some
milliseconds. This means that they will only exist inside the AOT reactor. The quantity of radicals
produced in the reactor is sufficient to treat the water as it passes through the reactor.

2 10_2_1_1 Cell

Destruction of cell membranes


1. Radical
2. Cell membrane

Book No.9010182 02, rev. 0

19

3.1

AOT reactor

System components description

There are no chemical substances added to the process, and there are no toxic residuals created.
Since the water is not affected chemically there are no environmental impact, and the process does
not influence corrosion in any way.

3.1.2

AOT reactor description

The AOT reactor consist of the reactor, sensors and valves for ballast water, fresh water and CIP
liquid, as shown in the illustration below. The AOT reactor accommodates 16 medium-pressure
UV lamps (6 kW each) powered from the lamp drive cabinet (LDC). The UV lamps are enclosed
in individual quartz-glass sleeves.
The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there is
water in the reactor when the lamps are lit, each reactor is equipped with a level switch. The level
switch also secures that enough CIP liquid is pumped into the reactor during the CIP process. To
secure that the lamps are adequately cooled by the ballast water, each reactor is equipped with
a temperature transmitter, monitored by the control system. If the temperature deviates from
parameter set values, the AOT reactor will shut down. The temperature transmitter is completed
with a temperature switch that automatically shuts down the reactor at 65 C.
A UV sensor monitors the UV lamp efficiency in relation to the water transmittance inside the AOT
reactor. Based on this input, the power to the UV lamps are regulated between 50 and 100 % of full
capacity. The UV lamps will be dimmed to lowest possible level, where they are still effective.
Note, that the lamps are always lit with full effect during start-up and the first two minutes of full
ballast to secure full efficiency independent of transmittance. The lamps are also turned up to full
effect for 10 seconds before stop and normal shut down. This method will prolong the UV lamp life
time.
The illustration below show the main components for the AOT reactor.

20

Book No.9010182 02, rev. 0

System components description

3.2

Lamp drive cabinet (LDC)

2 reactor module Obe

AOT reactor
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Ballast water outlet valve


CIP liquid outlet valve (actuator indicated)
Level switch
Junction box
UV lamp cap (UV lamp and quartz sleeve inside)
Access hatch
CIP liquid / fresh water inlet valve and reactor
drain valve (actuator indicated)
Ballast water inlet valve (actuator indicated)
UV sensor
Junction box
Cooling water outlet valve
Ballast water outlet valve actuator (actuator
indicated)

3.2

Lamp drive cabinet (LDC)

The lamp drive cabinet gives power to the AOT.

3.2.1

LDC working principle

Each AOT reactor is connected to a lamp drive cabinet (LDC) containing 16 lamp power supplies
(LPS), each feeding one lamp with power. The LPS also monitors the function of each UV lamp and
Book No.9010182 02, rev. 0

21

3.2

Lamp drive cabinet (LDC)

System components description

takes action if a fault occurs. Lamps on the cabinet indicates if power is on, UV lamps are lit and
if the cabinet needs to be reset after a shutdown or power off.

3.2.2

LDC description

The LDC is equipped with a cooling system to maintain correct operating temperature in the LDC,
using low-temperature cooling water. The cooling water flow is constant, but the fan only runs
when needed. When the temperature reaches 40, the fan starts at 15 % of full effect. After
that, the fan speed is regulated between 15 % and 100 %, based on input from the temperature
transmitter in the LDC.
The humidity in the cabinet is monitored by a liquid sensor. If a leakage from the heat exchanger
is detected, a warning is issued, the reactor is shut down and the cooling water inlet valve to
the LDC is shut.
The LDC can be placed up to 150 meters (cable length) from the AOT reactor. The main breaker
cut the power to the LDC and the AOT reactor.

22

Book No.9010182 02, rev. 0

System components description

3.3

Filter

2 LDC

LPS with one door removed.


1.
2.
3.
4.
5.
6.
7.

Fan
Heat exchanger
16 LPS
Fuses
Cooling water inlet and outlet
Main breaker
Status lights and reset button

3.3

Filter

3.3.1

Filter working principle

The filter is a fully automatic self-rinsing component, equipped with filter elements to remove
particles and organisms from the ballast water flow. The ballast water is lead through the filter, and
filtered particles are trapped in the filter element.

Book No.9010182 02, rev. 0

23

3.3

Filter

3.3.2

System components description

Filter description

2 FilterHydac

1.
2.
3.
4.
5.
6.
7.
8.

Geared motor
Water outlet
Pressure transmitter, outlet
Filter control cabinet. Only used for connections.
The filter is entirely controlled from the
PureBallast control system.
Pressure transmitter, backflush line
Backflush outlet
Pressure transmitter, inlet
Water inlet

To secure efficient filtration, the filter performs a self-rinsing backflush operation at time set intervals
or when triggered by indication of dirt in the filter. Pressure drop over the filter is monitored by
pressure transmitters on the filter inlet and outlet. Dirt is detected by an increased differential
pressure drop caused by particles in the filter candles. When the differential pressure reaches a
parameter set value, an automatic backflush operation starts. The backflushing does not interrupt
the filtration process, since the filter candles are cleaned one by one. The other filter candles
continue the filtration of the ballast water. It is also possible to start backflush manually from the
control system.

24

Book No.9010182 02, rev. 0

System components description

3.3

Filter

The filter candles are backflushed in two steps:


Step 1: The flushing arm is positioned under the first filter candle to be backflushed. The purpose
of the flushing arm is to collect the backflush water and lead it, with the flushed particles, to the
backflush line. From this point, this filter candle is not used for filtering.
A valve on top of the filter candle is opened to
lead water through the filter candle from the top
downwards. The water flow through the filter
candle down to the flushing arm, flushes particles
from the filter candle walls and lead them to the
backflush line.

2 BackFlush1

Step 2: The valve on top of the filter candle is


closed to stop the axial flow to the filter element.
The existing water pillar inside the candle
continues the flow downwards, which creates
an under pressure. This under pressure forces
water to flow radial through the filter candle from
the outside (filtered side) to the inside (unfiltered
side), which pulls remaining particles from the
mesh and downwards to the backflush line.
When the first candle is backflushed, the flushing
arm change position and the process is repeated
until all filter candles are rinsed.

2 BackFlush2

Book No.9010182 02, rev. 0

25

3.3

Filter

3.3.3

System components description

Backflushing for different dirt loads

Below, the filter pressure drop over time (pfilter) is illustrated for different dirt load situations in the
filter. Different dirtload depends on the water condition, which means that normal condition
regarding filter backflush depends on the water conditions.

3.3.3.1

Low dirt load

In water with low dirt load, the backflush cycle is started by the time trigger (default: every 30
minutes). As long as the pressure is below 0.5 bar (0.05 MPa), there is no need for the pressure
triggered backflush. See examples below.

6 Dirtload1 Hydac

6 Dirtload2 Hydac

3.3.3.2

Medium dirt load

In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.5 bar, which indicates
dirt in the filter candles.
After each backflush, the backflush timer is reset. The filter will be backflushed again after 30
minutes or when pfilterreaches 0.5 bar, whichever comes first.
In the example below, three backflushes are triggered due to high differential pressure over the filter.
After that, there is not so much dirt build up, so the next backflush is performed after 30 minutes.

26

Book No.9010182 02, rev. 0

System components description

3.3

Filter

6 Dirtload3 Hydac

3.3.3.3

Heavy dirt load

In conditions with heavy dirtload, the system will perform more frequent backflushes to keep the
filter clean.
Also, the 0.5 limit might be exceeded. In this case the self rinsing cycle will run continuously
until the problem is solved and the pressure has returned below 0.5 bar. It is OK that the flow
momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes.
In the example below, a series of backflushes are performed (approx. every 4 minute). After that
the pressure rises above 0.5 where the filter is backflushed constantly. After that, the normal
control is resumed, where the filter backflush is triggered by pressure (2 times) or by time (last
backflush in the example.

6 Dirtload4 Hydac

3.3.3.4

Long term dirt build-up

Over time, the filter candles will undergo a long term build-up of particles that are not removed by
backflushing. One effect of this is that normal pressure will increase over time. Therefore, the
maintenance schedule state that the candles shall be inspected and manually cleaned once a year.
The extent of the long term dirt build-up is dependent on the water conditions. In the great majority
of cases this will not cause any problems cleaning once a year is enough. But in exceptional
cases (vessels trading very muddy waters) it might be necessary to clean the filter candles more
often. If the pressure triggered backflushing is performed with short intervals, we suggest that the
filter candles are manually cleaned more often than once year.

Book No.9010182 02, rev. 0

27

3.4

CIP (cleaning-in-place) module

3.4

CIP (cleaning-in-place) module

3.4.1

CIP working principle

System components description

To ensure full performance in PureBallast, an automatic cleaning cycle is performed after ballast
and deballast operation. The purpose is to keep the quartz sleeves covering the UV lamps and the
UV sensor clean, to maximize the effect of the UV lamps, and thereby treatment efficiency.
During a cleaning cycle, the CIP module rinse the reactor with fresh water and circulates a CIP
liquid through the AOT reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion
build-up and chemical fouling on the lamps quartz glass sleeves. After finished cycle, the liquid
is returned to the CIP module tank; the CIP liquid is reusable for a great number of cycles. The
sequence is finalized by filling the AOT reactor with fresh water.

3.4.2

CIP module description

The CIP module consists of a tank where the CIP liquid is stored between usage. The pumps and
valves integrated in the CIP module are controlled by the valve block.
To secure that there is enough CIP liquid for the process, the level switch in the reactor indicates
when it is filled with CIP liquid. To prevent intrusion of water in the fresh water system, a backflow
preventer is used in the CIP module.
The CIP module is equipped with two membrane pumps:

Pump P320-1 circulates the CIP liquid in the AOT reactor and fills it with fresh water.

Pump P321-5 drains water (sea and fresh water) overboard from the reactor, via the drain line.

28

Book No.9010182 02, rev. 0

System components description

3.5

Control cabinet and control system

2 CIP module

CIP module
1.
2.
3.
4.
5.
6.
7.

Deaeration valve
Valve block
Regulator
Pump (CIP liquid)
Backflow preventer
Pump (reactor drain)
Tank for CIP liquid

3.5

Control cabinet and control system

The control cabinet is used to control and monitor the entire system, via the built in main control
panel. It is also used to communicate with the the vessels systems and components, if integrated.
The control cabinet functions as a signle point of contact for signal cables to and from the vessel.
Examples of integration: Remote interface integration and power management system (PMS).
Remote interface will allow control of PureBallast from the vessels ISCS and PMS integration will
allow automatic verification that there is enough power to run an operation. If not integrated, the
operator must verify this manually. Also integration with other external components (not part of Alfa
Lavals scope of supply), such as GPS or booster pumps, are done to the control cabinet.

Book No.9010182 02, rev. 0

29

3.5

Control cabinet and control system

3.5.1

System components description

Control system

The control system is used to set parameters, operate and monitor the PureBallast system. The
control system continuously monitor PureBallast (sensors, communication and PLC status), both
during operation and in standby mode. Any deviation is either communicated to the operator or
handled automatically, based on parameter settings. Safety risks are always handled automatically.
The control system store all alarms and relevant events for at least 24 months. The memory has
a vast safety margin but when it is full, data will be deleted starting with the oldest logs. Logged
information can be exported to a USB memory stick.
There are three alternative ways to monitor and control PureBallast: Main panel, remote control
panel (optional) and remote interface (optional).
If two PureBallast systems are installed on a vessel, two control systems are needed.

3.5.2

Main control panel

The main control panel in mounted in the control cabinet, and it is included in the standard
installation of PureBallast. It is installed in the engine room. The main control panel handles
every aspect of the control system. It allows the operator to monitor the system, to operate it
manually and automatically, and to set parameters. Please note that some of the operations are
password-protected.

2ControlPanel

Main control panel

3.5.3

Remote control panel (optional)

As an option, it is possible to install 14 additional panels to be placed in locations from where


ballast operations are performed. A remote control panel looks and functions in the same way as
the main control panel, and it allows same operations.

30

Book No.9010182 02, rev. 0

System components description

3.5

Control cabinet and control system

2RemotePanels

Main control panel with four integrated remote control panels.

Book No.9010182 02, rev. 0

31

3.6

Main valves

3.5.4

System components description

Remote interface (optional)

As an option, the control system can be integrated with the vessels ISCS via modbus. This allows
monitoring and operation of PureBallast from the ISCSs graphical user interface.
Note that Alfa Laval does not supply the graphical user interface to handle PureBallast in the
ISCS, only the means to enable the integration.

2RemoteInterface

PureBallast control systems main control panel integrated with the ISCS. The interface is only an example.

3.6

Main valves

The main valves in the system are:

Inlet valves: The inlet valves directs the water flow from the vessels ballast water system into
the PureBallast system. Different valves are used during ballast and deballast.
-

System and filter inlet valve (2013): Inlet valve to PureBallast during ballast. The valve
directs the water flow through the PureBallast filter.

Filter outlet valve (V20132): The valve directs the water flow from the filter to the AOT
reactor during ballast.

Inlet valve (2019): Inlet valve to PureBallast during deballast. The valve directs the water
to PureBallast, but bypass the filter, since the water was filtered during ballasting.

Control valve (V2018): The valve have the following functions:


-

Automatic regulation to maintain flow during operation so it does not exceed selected
certified maximum flow. Regulation is based on input from the flow meter.

Automatic regulation to maintain pressure needed to perform backflush of the filter.


Regulation is based on input from the pressure transmitter.

Outlet valve from the PureBallast system to the vessels ballast water system after treatment.

PureBallast bypass valve (V21231): Makes it possible to completely bypass the PureBallast
system. The valve is solely operated from the ISCS, but the valve positioning is (and must be)
indicated in the PureBallast control system. When PureBallast is bypassed, an event is written
to the event log. The component is optional to be included in Alfa Lavals scope of supply.

Cooling water inlet valve (V403-35): Supplies cooling water to the reactor to secure cooling of
the lamps and prevent overheating during start-up.

32

Book No.9010182 02, rev. 0

System components description

3.7

3.9

Sampling devices

Flow meter

The flow meter (FIT2011) monitors the process-flow during operation. It has two main functions:

It monitor that the flow within the PureBallast system does not exceed its certified flow. If the
certified flow is exceeded a warning is issued.

Via the flow transmitter, mounted on the flow meter, it sends valuable data to the PureBallast
control system, where it is displayed. Example of information: Current flow and data about
total amount of treated ballast water.

The flow meter consists of two main parts: A flow sensor, which is a pipe with four electrodes
detecting the flow. On top of the pipe, there is a terminal box, where the flow transmitter is
mounted. The flow transmitter monitors the flow and transmits the information to the PureBallast
control system.

3.8

Pressure monitoring device

The pressure monitoring device is a manifold that includes the following components to monitor
and handle pressure in the system:

Pressure transmitter(PT201-16): Send current pressure information to the control system. The
control system use the information to take actions accordingly, for example issue warnings, shut
down the system or adjusting the control valve to obtain optimal pressure during filter backflush.

Pressure gauge (PI201-18): Analogue displayed of current pressure.

Needle valve (V201-15): Enables connection of external instruments for calibration.

Safety valve (RV201): Relief of over pressure.

3.9

Sampling devices

The two sampling devices (Q201.1 and Q201.1) make it possible to take water samples to test the
water. One sampling device is installed before the water is treated and one after the water is
treated. This enables comparative tests of treated and untreated water. The component is optional
to be included in Alfa Lavals scope of supply.

Book No.9010182 02, rev. 0

33

Chapter: 3. Operating instructions and control system description


System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1

Introduction

1.1

Preparations and conditions

1.1.1
1.1.2
1.1.3
1.1.4

Stripping
Heeling (internal transfer)
Ballast water handling in the event of malfunction
Pipe cleaning using PureBallast

7
8
8
9

Introduction to the control system

11

2.1

Login levels

11

2.2

Control of PureBallast

12

2.3

Remote interface (option)

12

2.3.1

Conditions for remote interface control of


PureBallast

13

Overview of the screen

14

Detailed page descriptions

19

3.1

Page 1.1 Overview

19

3.1.1
3.1.2

Status box
Flow chart

20
21

3.2

Page 1.2 AOT and flow selection

23

3.2.1
3.2.2
3.2.3

Flow selection
AOT selection
Status

23
24
24

3.3

Page 1.3 CIP status

25

3.3.1
3.3.2
3.3.3

CIP status
AOT information
CIP module information

26
26
27

3.4

Page 1.4 Power request

28

3.4.1
3.4.2
3.4.3

Power management status display


Power management simulation and faultfinding
Function buttons

28
30
30

3.5

Page 2.1 Alarm list

31

3.5.1
3.5.2

Alarm list
Function buttons

32
32

3.6

Page 2.2 Alarm history

33

3.7

Page 3.1 Trend (15 min)

34

3.7.1
3.7.2
3.7.3

Diagram area
Component area
Function buttons

35
35
36

2.4

3.8

Page 3.2 Trend (1 h)

37

3.9

Page 3.3 Trend (1 h) - TT201-33

37

3.10

Page 3.4 Trend (1 h) - TT401-2

37

3.11

Page 3.5 Trend (1 h) - Power


optimization

37

3.12

Page 4.1 System info

38

3.13

Page 4.2 PLC controller I/O

41

3.14

Page 4.3 Operation timers

42

3.15

Page 4.4 Operation timers AOT

44

3.16

Page 4.5 Remote interface 1

45

3.17

Page 4.6 Remote interface 2

46

3.18

Page 4.7 Log box 1

47

3.19

Page 4.8 Log box 2

48

3.20

Page 4.9 LPS overview

50

3.21

Page 4.10 LDC power

52

3.22

Page 5.15.7 Parameter pages

53

3.23

Popup windows

53

3.23.1 AOT popup


3.23.2 Filter popup

53
59

Operating instructions

61

4.1

Log in

61

4.2

Perform ballast

61

4.2.1

Start ballasting

62

4.3

Perform deballast

62

4.4

Pause ballast / deballast

64

4.5

Backflush filter manually

64

4.6

CIP clean AOT reactor after ballast /


deballast

65

4.7

Stop ballast / deballast

65

4.8

Attend to alarms

66

4.9

Shut down and deactivate system

67

4.10

Reset system after shut down

68

4.11

Operate components manually

68

4.12

Operate UV lamps manually

70

4.13

Set ship specific component ID

71

4.14

Export control system log files

72

4.14.1 Read event log in Excel

74

4.15

Set control panel IP address

74

4.16

Set remote control panel


communication

76

4.17

Set remote interface communication

77

4.18

Test remote interface communication

77

4.19

Simulate power request

79

4.20

Set default parameters

80

4.21

Update PLC software

80

4.22

Install TA150 firmware

81

4.23

Update HMI software

82

4.24

Calibrate the control panels touch


screen sensibility

83

4.25

Backup control system settings

84

4.26

Restore control system settings

84

4.27

Export control system history files

85

4.28

PID calibrate system

86

4.28.1 Calibrate pressure controlled regulation

86

List of logged information

89

5.1

89

Event log

Detailed process description

95

6.1

Standby mode

95

6.2

Ballast process

96

6.2.1
6.2.2
6.2.3
6.2.4
6.2.5

Ballast start-up
Full ballast
Filter backflush
Pause ballast (Heeling mode)
Stop ballast

96
97
97
98
99

6.3

Deballast process

6.3.1
6.3.2
6.3.3
6.3.4

Deballast start-up
Full deballast
Pause deballast (Heeling)
Stop deballast

6.4

CIP process

6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.4.9

Start CIP
Drain ballast water
Fresh water filling
Fresh water draining
CIP cleaning
CIP draining
Fresh water filling
Repeat
Filter preservation

6.5

Manual mode

100
100
101
101
102

103
104
104
105
105
105
106
106
106
106

107

1 Introduction
The control system is used to operate and monitor the PureBallast system. It also contains
functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of the control system
pages, step-by-step instructions and a process description with detailed information about the
components (valves, motors, pumps etc) involved in each step of respective process.
The following control system related information is given in other chapters of the manual:

Parameters are described in chapter 4. Parameters.

Alarms and warnings including information about faultfinding and how to solve problems is
described in chapter 5. Alarms and faultfinding.

Information about integrating the control system with the vessels ISCS and power management
is described in chapter 6. Installation description and drawings.

1.1

Preparations and conditions

Make sure all documentation is available, read and understood before start.

Make sure that the flow is within defined flow range during operation:
Ballast (m3/h): 190 300190 600190 750
Deballast (m3/h): 100 1000

During process, the control system requests that vessel valves are opened/closed. The
valves are outside the PureBallast system control. But the control system needs feedback
(opened/closed) during process. Status can either be confirmed manually in a popup or
automatically, if feedback signals are integrated via the remote interface option or via hard wire.
Please note:

When overboard valves are requested to be opened/closed, this means that all valves
leading the flow from the PureBallast via one of the following pipes must be opened/closed:
201, 309 and 403 and 404. During CIP process, 460.1 must be opened.

Such water as described above does not need to be transported overboard. For example,
the flow can be lead to the bilge tank. In such cases, all relevant valves leading the water
from the PureBallast system shall be opened.

The input flow to the PureBallast system shall be as close as possible to the flow that has been
selected for an operation. This will reduce the stress and wear of the control valve.

1.1.1

Stripping

The first time a ballast tank is stripped, PureBallast must be by-passed.


Recommended stripping procedure

Book No.9010182 02, rev. 0

1.1

Preparations and conditions

Introduction

If stripping is performed with a low flow for a long period of time, we recommend that stripping is
performed from the ballast tanks to a collection tank. After that it is possible pump the water from
this tank with full flow using the ballast pump, and finally empty it by stripping.
This will reduce the power consumption and UV lamp runtime. If all tanks are stripped (with a low
flow) the power consumption per treated cubic meter will be unnecessary high, since the power
consumption will be high in relation to the low flow.
Example: If a process is run with a flow of 100 m3/h for 10 hours, it will give a power consumption
of 1000 kwh, not including the ballast water pump. But if the same amount of water is collected
and then processed with a flow of 1000 m3/h using the ballast water pump, the power consumption
will be 100 kwh.

1.1.2

Heeling (internal transfer)

Internal transfer of ballast water between tanks, for example during heeling procedures, does not
require the use of the PureBallast system. It is possible to perform heeling when PureBallast
is in standby mode.
If external component signal for heeling mode is integrated between PureBallast and the vessels
ISCS, any ongoing process will be paused and resumed automatically. The user is notified of
started and stopped heeling via a message in the control system, and the event is logged.
If no external signal is integrated, the ongoing process must be paused manually. During pause,
cooling water is flushed through the AOT reactor to cool the UV lamps. After completed heeling,
the operator must resume the paused process. Warning W82 will appear in the alarm list. See
instruction Pause ballast / deballast on page 64.

1.1.3

Ballast water handling in the event of malfunction

If the ballast water treatment system malfunctions, follow the procedures stated in the ships ballast
water management plan. This is valid both if the system malfunctions, for example mechanical
problems, or if full treatment cannot be guaranteed, for example a lamp failure or low UV intensity.
General recommendations are given blow.
PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallasts control system, but all valve activities are logged in the event log. Such valve is
required by the International convention for the control and management of ships ballast water
and sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. Note that the system requires treatment both during ballast and
deballast.
If untreated water is pumped to a ballast tank, this water shall primarily be discharged to a reception
facility. When this is not possible, other discharge possibilities must be agreed with the port state
responsible for the waters where the ship is sailing and most importantly be agreed with the flag
state administration of the ship; the procedures concerning emergency and malfunction of the
ballast water treatment system should be implemented in the ships Ballast Water Management
Plan which must be approved by the flag state administration.

Book No.9010182 02, rev. 0

Introduction

1.1.4

1.1

Preparations and conditions

Pipe cleaning using PureBallast

In some vessels, the applicable class society may require means and procedure for flushing
ballast pipes with treated water, to clean them from untreated water. This procedure should be
implemented in the ships Ballast water management plan.
In PureBallast, a deballast process is run with the vessels ballast valves positioned so that the

pump takes water from a ballast water tank with treated water and

the water flow is directed either overboard or to another ballast tank.

Run the process for enough time so all water in the piping is treated. Time for this depends on pipe
size and length on board.

Book No.9010182 02, rev. 0

1.1

Preparations and conditions

Introduction

2 Introduction to the control


system
This section describes different login levels, overview of the system interface and how to navigate
and operate the control system.

2.1

Login levels

Different login level controls which information that is displayed and changeable. As an example,
pages used for commissioning purposes are hidden for normal operators.
Login level

Password

Authority

Guest

N/A

Default mode of control system. This level is not password protected.

Operator

Advanced
operator

AlfaLaval

aot

2007

N/A

Book No.9010182 02, rev. 0

View all pages.

As Guest.

Operate the system to perform daily routines, for example ballast


and acknowledge alarms.

Full access to page 1.4 Power request.

Download files and backup to a USB memory.

As level Operator.

Operate equipment in manual mode.

Access to set parameters, with exception from critical parameters


(which are grey).

Full access to page 4.3 Operation timers and 4.4 Operation timers
AOT.

Full access. Password only available for Alfa Laval personnel.

Full access to all parameter pages.

Full access to force I/O in page 4.2 PLC controller I/O.

Full access to make settings for remote control panels and remote
interface in page 4.1 System info and 4.5/4.6 Remote interfaces 1
and 2.

11

2.3

Remote interface (option)

2.2

Introduction to the control system

Control of PureBallast

PureBallast can be monitored and controlled in three ways: Main control panel, remote control
panel (optional) and remote interface (optional). The system can only be controlled from one
place at a time.
The information below is only valid if remote control panels and/or remote interface is installed.
Remote control panels. It is possible to log in on one panel, even if a user is logged on another
panel. This requires that the new operator log in with the same login level or higher. The new
operator will get a popup message saying that another user is logged in. The popup gives the
alternative to cancel or to continue. If continue is chosen, the first operator will get a popup
message and is then logged out.
On each control panel it is possible to see which panel that is active and which login level that is
used. This is visible in the upper right corner of the system according to syntax: login level@control
panel.
Login level can be: Guest, Operator, Advanced operator or AlfaLaval.
Control panel can be:

192.168.0.10 (Master) = Main control panel

192.168.0.11 = Remote control panel 1

192.168.0.12 = Remote control panel 2

192.168.0.13 = Remote control panel 3

192.168.0.14 = Remote control panel 4

Note: A panel alias can be entered to clarify where the panel is installed, for example pump room,
bridge etc. See instruction Set remote control panel communication.
Remote interface: The buttons Local and Remote are used to select which system that shall
be in command. A green light is lit under the button that corresponds to the system currently in
command. It is only possible to change between local and remote using these buttons.

2.3

Remote interface (option)

If the remote interface option is used, PureBallast can be controlled from the vessels ISCS. It is
possible to access the same pages and perform the same operations from the remote interface as
for login level Operator (if allowed by the ISCS).
When the remote interface is used, the panel(s) cannot be used to operate the system; it is only
possible to monitor the system and to export log files. It is possible to turn of the remote interface,
and thus activate the panels when logged in as Operator or higher.
The PureBallast system manual does not give any information about how to run PureBallast from
the remote interface. This is due to the fact that the remote interface is custom-made. Please
refer to the vessel specific manual.

12

Book No.9010182 02, rev. 0

Introduction to the control system

2.3.1

2.3

Remote interface (option)

Conditions for remote interface control of PureBallast

PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings

The remote interface must be correctly installed, according to received information.

Remote interface must be activated (parameter p132) and communication settings must be
correct (parameter p700 p704).

Remote operation must be in online mode. Check that the Test mode button is deactivated (no
checkmark on the button) in control system page 4.5 Remote interface 1.

Remote mode must be activated. Check that the green lamp is lit under the Remote button
on the control panel. If not, press the button. The system must be in Standby mode to toggle
between local and remote operation.

Operation

Heartbeat is updating. See that address +006 +077 are updating in control system page 4.5
Remote interface 1.

There must be no active alarms for the AOT reactors to be used during operation. Always check
the alarm list (page 2.1 Alarm list in the control system) before operation.

Book No.9010182 02, rev. 0

13

2.4

2.4

Overview of the screen

Introduction to the control system

Overview of the screen

This section describes the PureBallast control system screen layout and navigation.
The control system use a touch screen, where you tap the screen to click or drag objects. Do not
use sharp objects to touch the screen. When the screen is left idle it will go to screensaving mode.
Time is set in page 4.1 System info. The screen is activated again by touching it once. The touch
will not activate any button that might be placed where you touch.
The illustration below shows the main areas and function buttons on the screen.

3 1.1

Control system screen showing the main overview page.

Login menu: Expanding menu with login fields.


Tabs: The top and side tabs are used to choose which page to display in the screen. Pages are
referred to as a number and a name, for example 2.1 Alarm list. The first number refers to selected
top tab, counted from left to right. The second number refers to selected side tab, counted from top
to bottom. Selected tabs are indicated by a white color.
Top tabs: Contain the main function areas of the control system: Overview, alarm lists, trend
indication, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab. Available side tabs change
depending on which function area that have been selected in the top tab.
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Introduction to the control system

2.4

Overview of the screen

Popup windows: Are used to display or enter detailed information. It is possible to move a popup
by touching the name bar and drag it. A popup is closed either by touching confirming entered
information by touching a function button (OK, Confirm, etc.) or the X icon in the top right corner
(data is not saved).
Data entry fields: A white field indicates that it is possible to enter data. When the field is touched,
a keyboard is displayed, which is used to enter information. Enter data is confirmed by touching the
Enter button. To close the keyboard without saving data, touch the Esc button.
Tables: Individual table rows, for example an alarm, can be selected by pressing them. Column
widths can be adjusted. Press the column border in the head area and hold the finger on the screen.
Function buttons: Function buttons are used for main processes and control of the system. They
are placed att the bootom of the screenare and are always visible, but only available when colored
dark blue. Some buttons are dependent on parameters. For example, the Remote and Local
buttons are only visible if remote interface is activated.
Status indication Button color: The buttons appear in different colors, indicating status:
Blue

The function is enabled.

Blue with
checkmark

The function is activated.

Grey

The function is disabled, for example if higher login level is required for the
function.

Status indication Button light: After a function button is pressed, a light under the button is lit
to indicate status for the activated function:
Green

Command is active.

Yellow

Command will be processed when possible in the data work flow.

Yellow, blinking

Command is paused.

Function button description


Button

Description
Start ballast process.
Resumes paused process.
3Ballast

Start deballast process.


Resumes paused process.
3Deballast

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2.4

Overview of the screen

Button

Introduction to the control system

Description
Stop current process.

3StopButtonBlue

3Pause

Pause ballast or deballast process. This is only possible during full ballast
or full deballast. The button can be hidden, using parameter p137. Allowed
length of a pause is parameter set (p138). After defined time, the paused
process is stopped.
To resume a paused process, press the function Ballast or Deballast
depending on which process that was paused.
Start CIP process.

3CIP

Activate operation from control panels, instead of remote interface (if option
is used). The button is only enabled in standby mode.
2 LocalButton

Activate operation from remote interface (if option is used), instead of


control panels. The button is only enabled in standby mode.
2 RIbutton

3 EnableManual

Sets the control system in manual mode, which enables manual operation
of the system and its components. When activated, the light flashes yellow.
The button is displayed for login level Advanced operator or higher. For
detailed information see Manual mode on page 107.
Disable the touch screen function for 10 seconds to make it possible to
clean the screen without the risk of starting a process or changing a setting.

3Wipe

Activate night light for the panel. Night light makes the panel less bright.
Toggles between night light and day light.
3 Night

Degree of brightness, is set in the Night light level field in page 4.1 System
info.
Contains calculator, Notepad and print function.
To print a screen image to USB: Insert a USB memory in USB panel
port on the cabinet door. Press Utilities, and then Print to save a screen
image to USB.

3 Utilities

Status indication Alarms and warnings


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Introduction to the control system

2.4

Overview of the screen

Alarms and warnings for components are displayed in the flow chart and popups:
Active alarm.
3Alarm

Active warning.
2 Warning

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2.4

Overview of the screen

Introduction to the control system

3 Detailed page descriptions


This section describes the pages used for operation. Note that this section does not cover the
parameter pages. Please refer to chapter 4. Parameters.

3.1

Page 1.1 Overview

The page displays an overview of the system, overall status and detailed information regarding
the components.
The main areas are the Status box and the Flow chart.

3 1.1

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3.1

Page 1.1 Overview

3.1.1

Detailed page descriptions

Status box

The status box display current status for the PureBallast system. The information is updated
continuously. To see accumulated operation runtime for the components, see page 4.3 Operation
timers.
The following status information is displayed:
Status information (unit)

Description

Process and sub process

Process: Ongoing process. Can be standby, ballast, deballast


and CIP.
Sub process: Sub steps of ongoing process, for example
Start-up during Ballast process.

Time

Remaining time for the ongoing sub process.

Processed volume (m3)

Amount of water processed during ongoing process. Value


remain until next process is started.

Power consumption (kW)

Power consumption during process. Value is either exact value


for the AOT reactor(including LDC cabinet), or calculated value
including power optimization. This is set in parameter p239.

Certified flow (m3/h)

Certified flow (m3/h) selected for operation. The information is


updated after the warm up time has passed and a AOT reactor
is used for process. This is also the flow the system is aiming
to keep.

Current flow (m3/h)

Ballast water flow in the system, indicated by flow transmitter


FIT201-1.

Flow selection

Flow (m3/h) selected for operation. Flow is set using the arrow
buttons. Flow selection depends on parameter p131 Automatic
AOT selection:

20

If activated: All ready AOT reactors are selected.

If deactivated: Last used flow is default. Flow must be


set after power off. Flow can be changed using the + and
arrows.

+ = Increase flow. = Decrease flow. The Flow selection


field is updated with 1000 m3/h each time the button is
pressed, but is not changed until the Apply button is
pressed.

Apply = Apply the new setpoint to be used for process.


Note: If ballast flow is lower than deballast flow
(parameter p315), the higher value is displayed until the
Ballast button is pressed.

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Detailed page descriptions

3.1.2

3.1

Page 1.1 Overview

Flow chart

The flow chart display a schematic overview of the PureBallast system and its components.
Relevant information regarding ongoing process and component status can be monitored directly
in the flow chart. Flow in pipes is indicated by coloring of the pipes and component status are
displayed by color indications. Pressure, flow and control valve opening percentage are displayed
directly on component.
Detailed information about components can be monitored in popups (by tapping the component):
AOT reactor see page 53; filter see page 59. CIP open page 1.3 CIP status, see page 25). The
popup contain status for sub components, for example valves, motors and UV lamps in the AOT
reactor.
Booster pump for AOT reactor (P4031) and LDC (P4011) are only displayed if these components
are used and activated in the parameter pages.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually: If a component is pressed, a popup window is displayed from which the component
can be operated.
Status indication Component color:
Component status is indicated by a colored frame:
Pipes

Pipe and flow status. Flow in pipe is indicated as below:


Status indication
Blue = Fresh water or sea water, when flow goes sea-to-sea.
Green = Ballast and deballast flow.
Yellow = CIP liquid.
Mixed colors = Mixed water, for example ballast water and fresh water.

Valves and
pumps

Status indication
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a component. The ID will be
visible in page 1.1 Overview and popups for the components. See instruction
Set ship specific component ID on page 71

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3.1

Page 1.1 Overview

Detailed page descriptions

Status indication for balast water pump (not part of Alfa Lavals scope of
supply).
3 PumpReq

Status indication
Green, blinking = Request sent. Popup message message Confirm ballast
pump started is displayed. (The popup is not displayed if the component
feedback is integrated with the control system.)
Green = Feed back that pump is running, either via hard wired feedback,
remote interface or the confirmation popup.
Grey = No request sent (not running).
Status indication for overboard valve(s), and other relevant valves for the
process (not part of Alfa Lavals scope of supply).

3 OBvalveReq

Status indication
Green, blinking = Request sent. Popup message message Confirm overboard
valve open is displayed. (The popup is not displayed if the component
feedback is integrated with the control system.)
Green = Feed back that valve is open, either via hard wired feedback, remote
interface or the confirmation popup.
Grey = Closed.
Status information for bypass valve(s) V21231 and external bypass valves
(not part of Alfa Lavals scope of supply). These valves are operated from the
ISCS, due to safety reasons.
External bypass is only visible if parameters (p163p165) for external bypass
valves are activated.

3 CV and Bypass icon

The component is operated manually in manual mode.


3Manual1

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Detailed page descriptions

3.2

3.2

Page 1.2 AOT and flow selection

Page 1.2 AOT and flow selection

The page is used to select AOT reactors or flow for ballast and deballast and to increase/decrease
flow during ongoing operation. It is also possible to select specific AOT reactors to be used during
process, or to change AOT reactor during an ongoing process.
This page is only relevant if more than one AOT reactor is installed.
Note, that if parameter p131 Automatic AOT selection is activated, it is only possible to change
flow during operation, not in standby mode.
Normally, flow is handled from page 1.1 Overview, and this page is used during commissioning and
faultfinding when it is necessary to start individual AOT reactors.
The main areas of the page are the Flow selection, AOT selection and Status.

3 1.2

3.2.1

Flow selection

Function in the same way as flow selection in page 1.1 Overview.

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3.2

Page 1.2 AOT and flow selection

3.2.2

Detailed page descriptions

AOT selection

The area displays a table with installed AOT reactors with status information. It is possible to
choose individual AOT reactor for process in standby (if parameter p131 is disabled) or during
process (regardless of p131 setting).
The following information is displayed:
Elements

Description

Modify button

Enables active selection of individual AOT reactors. When pressed, the


buttons for respective AOT reactor turns blue and are possible to use.

AOT 1, 2, 3 button

One row for respective installed AOT reactor with current status indicated
in the columns.
AOT n button: Press the button to select or deselect. A checkmark on the
button indicates selected. The flow setpoint for the number of AOT reactors
selected are updated in the Flow selection area. The field is updated with
m3/h for each selected AOT reactor.
Status indication:
Selected: Grey = Not selected. Green = Selected.
Ready: Grey = Not ready. Green = Ready for process.
Alarm: Grey = No alarm. Red = Active alarm.

Apply button

3.2.3

Apply the new setpoint to be used for process.


Note: If ballast flow is lower than deballast flow (parameter p315), the
higher value is displayed until the Ballast button is pressed.

Status

The area displays current status for the flow:


Elements

Description

Current flow

Ballast water flow in the system, indicated by flow transmitter FIT201-1.

Certified flow

Maximum allowed flow as set in Flow setpoint or limited by the number of


AOT reactors selected in AOT selection popup. If a smaller filter is installed,
the ballast flow can be lower than the AOT reactor capacity.
The information is updated after the warm up time has elapsed and a AOT
reactor is used for process. (Before that it is not used for treatment, and
therefore not part of the certified flow.)

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Detailed page descriptions

3.3

3.3

Page 1.3 CIP status

Page 1.3 CIP status

The page is used to display CIP status for all AOT reactors and status for the valves and motors in
the CIP unit. The page can either be opened by selecting the tab or by tapping the CIP module in
page 1.1 Overview.
The page also display time remaining for ongoing CIP process. If no CIP required process has been
started after a ballast or deballast operation, the time remaining before CIP must be performed is
displayed.

3 1.3

The following information is displayed:

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25

3.3

Page 1.3 CIP status

3.3.1

Detailed page descriptions

CIP status

The area displays status for the following pieces of information:


Row

Content

Process and sub


process

Process: Ongoing process. Can be standby, ballast, deballast and CIP.

3.3.2

Sub process: Sub steps of ongoing process, for example Start-up during
Ballast process.

AOT information

The area displays CIP status for respective installed AOT reactor:
Row

Content

AOT

Each row display CIP status for every installed AOT reactor

Filter preservation This row indicate status and time for the filter preservation process, that
starts after completed CIP. During filter preservation, the CIP fills the filter
with fresh water for preservation purpose.
Total

Total estimated time for a complete CIP process including filter preservation.

Column

Content

CIP error

Red square: Indicates that there is an active alarm for the component.
Check alarms on page 2.1 Alarm list.

CIP

CIP status for each AOT reactor.


Status indication
Yellow = CIP required. During ongoing CIP process, yellow indicates that
the AOT reactor is waiting for CIP process to start.
Yellow, blinking = CIP process ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to active alarm on
the AOT reactor.

Status

26

Same information as column CIP, but spelled out.

Book No.9010182 02, rev. 0

Detailed page descriptions

3.3

Page 1.3 CIP status

Column

Content

Estimated time

Time remaining CIP time. If CIP process has not been started, total time is
displayed. During CIP process, the time is counting down continuously.
The CIP process takes about 25 minutes per AOT reactor, if default
parameters are used.

Required CIP
countdown

3.3.3

Time before a CIP process must be performed after ballast or deballast.


The time disappears when the CIP process is ready.

CIP module information

The area displays a schematic illustration of the CIP module, with status for for the valves and
motors. For status indications, see Status indication Component color in section Flow chart
on page 21.

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3.4

Page 1.4 Power request

3.4

Detailed page descriptions

Page 1.4 Power request

The page is used to handle power management. The page have two functions: Display power
status and test power management signals.

3 1.4

3.4.1

Power management status display

If the control system is set in normal mode, the page is used to display power management status.
Column

Content

Process and sub


process

Process: Ongoing process. Can be standby, ballast, deballast and CIP.

Max power
consumption

Maximum power consumption for the number of selected AOT reactors.


The value is updated when a process is started.

28

Sub process: Sub steps of ongoing process, for example Start-up during
Ballast process.

Book No.9010182 02, rev. 0

Detailed page descriptions

3.4

Page 1.4 Power request

Column

Content

Measured power
consumption

Power consumption during process. Value is either exact value for all
AOT reactors in use (including LDC cabinets), or calculated value based
on number of used AOT reactors and UV lamp dimming. This is set in
parameter p239.

Power status
Column

Content

Power

Each row represent a number of AOT reactors to be used in a process.


Requests can be combined to send request for 3 AOT reactors.
1 AOT: Request power for 1 AOT reactor.
2 AOTs: Request power for 2 AOT reactors.
The requested power is calculated as the number of AOT reactor times
defined power consumption for one AOT reactor.
Common power: Request maximum power, enough to run all AOT
reactors installed, even if all AOT reactors are not used.

Request
(Output signal from
PureBallast)

Indication alternatives: Requested or Not requested.


Indicates if power request has been sent to the ISCS.
Pure Ballast always asks for power before the UV lamps are lit during ballast
or deballast start-up. When a request has been sent, the vessels power
management performs a power check before the generator is started.
Manual mode: Indicates if a simulated request signal is sent.

Granted
(Input signal to
PureBallast)

Indication alternatives: Yes or No.


Indicates if power request has been granted from the ISCS. Pure Ballast
will not consume significant power until the requested power is granted.
Manual mode: Indicates if a simulated granted signal is received.

Status
(Output signal from
PureBallast)

Indication alternatives: Running or Not running.


Indicates if power running signal is sent to the ISCS for respective number
of AOT reactors. This means that the AOT reactor is started and is
consuming power.
Manual mode: Indicates if a simulated running signal is sent.

Calculated power
consumption

The field display the calculated power consumption.


If individual rows have been selected, the value is the sum of the number
of AOT reactor for the request times the set power consumption per AOT
reactor.

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3.4

Page 1.4 Power request

Column

Detailed page descriptions

Content
If Common power has been selected, the value is 100 kW.

3.4.2

Power management simulation and faultfinding

If the control system is set in manual mode, the page is used to simulate output from PureBallast to
the power management system during commissioning preparation.
The page can also be used to troubleshoot the power management system integration by sending
and checking each signal.

3.4.3

Function buttons

The following function buttons are available and displayed when manual mode is activated:
Buttons

Content

3Manual1

If manual mode is activated, a hand icons are displayed on the page.


Press the hand icon to make it possible to send simulated request or
granted signal manually.

Request

Press to manually simulate request for a power step. The button is


displayed for login level Advanced operator or higher.

Set run

Press to manually simulate run signal for a power step. The button is
displayed for login level Advanced operator or higher.

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Detailed page descriptions

3.5

3.5

Page 2.1 Alarm list

Page 2.1 Alarm list

The page display active alarms and warnings. When an alarm/warning is inactive and
acknowledged, it is moved to page 2.2 Alarm history.
Alarm type can be of two types:
-

A = Alarms stop the ongoing process, which can be restarted after the problem has been
attended to.

W = Warnings are notification of a status change, request for action or a problem that must be
attended to. Warnings allow the process to continue.

For detailed information about alarms and warnings see chapter 5. Alarms and faultfinding.

3 2.1

The main areas of the page are the Alarm list and the Function buttons:

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31

3.5

Page 2.1 Alarm list

3.5.1

Detailed page descriptions

Alarm list

The following information is displayed for each alarm (row):


Column

Content

Text

Descriptive alarm text written as: Area-Alarm type AlarmID Alarmtext.


Example: AOT2 A138 Error in LDC cabinet.

Active time

The time alarm was activated.

Acknowledged time

The time the alarm/warning was acknowledged. The alarm/warning remains


in the alarm list until the causing condition is resolved. For example a high
temperature alarm will remain visible, until the temperature is below the limit
value for the alarm/warning.

Status indication Alarm color


The table below shows status indication for alarms and warnings in the alarm list.
Red

Alarm = active

Pink

Alarm = acknowledged, but still active

Orange

Warning = active

Yellow

Warning = acknowledged, but still active

3.5.2

Function buttons

The following function buttons are available:


Button

Function

Ack selected

Acknowledge selected alarm (row). Press a row to indicate it, and press the
button to acknowledge it.

Ack all

Acknowledge all active alarms.

32

Book No.9010182 02, rev. 0

Detailed page descriptions

3.6

3.6

Page 2.2 Alarm history

Page 2.2 Alarm history

The page display a list of inactive, previously acknowledged alarms.

3 2.2

The following information is displayed:


Column

Content

Text

Same as in Page 2.1 Alarm list.

Active time

Same as in Page 2.1 Alarm list.

Acknowledged
time

Same as in Page 2.1 Alarm list.

Normal time

The time the value that caused the alarm returned to normal.

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33

3.7

Page 3.1 Trend (15 min)

3.7

Detailed page descriptions

Page 3.1 Trend (15 min)

The page is used to display trend curves for basic data in the system. This page display trends with
a update frequency (sample time) of 1 second. This page is useful for analyzing processes, for
example backflushes.

3 3.1

Trends can be plotted for the following components (identified by item number) and key values:
Component /
Key value

Unit

Description

Filter diff. pressure

Bar

Differential pressure over filter, indicated by pressure


transmitter 20171 and 20172.

V2018

Control valve open, percent.

PT201-16

Bar

System pressure, indicated by the pressure transmitter.

V309-1

Status

Filter backflush valve opened or closed.

FIT 201-1

m3 h

System flow, indicated by the flow meter.

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.7.1

3.7

Page 3.1 Trend (15 min)

Diagram area

In the diagram area, trend curves are displayed for one or more components. Components
available for plotting is displayed at the bottom of the screen. Trend curves can be activated or
inactivated for respective component.
The scale of the diagram:
X axis: The time interval is always 15 minutes.
Y axis: The scale and unit used for the Y axis is set in the Settings popup for respective component.
For details, see the Component area section below.

3.7.2

Component area

The following fields and buttons are available for each component in the component area:
Column

Content / Function

Settings
button

Press the button to make settings for the components curve. Settings is
done in a popup.

3 TrendCurveSet1Nr

1: Press (not slide) the button to display or hide trend curve in the diagram.
An I indicate displayed, and an O indicates inactive.
2: Press the entry field to change start and stop value for the components Y
axis scale (when this components scale setting is used.
3: Press this button to use this components scale setting in the diagram.
4. Press the entry field and increase or decrease the number of decimals in
the component area.

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3.7

Page 3.1 Trend (15 min)

Detailed page descriptions

Filled = Selected. Component values is plotted in the diagram,


in the same color as the icon.

Status
indication
3 TrendActive

Empty = Not selected. Component values is not plotted in the


diagram.
3 TrendInactive

3 TrendScale

Scale icon = The component scale setting is used in the


diagrams Y axis. If several components have the same scale
setting, this icon is displayed for all these items.

Component

Item number or name.

Value

Current value for the component is displayed in the gray field. (This
corresponds to the diagram.)
If history mode is selected, historic value is displayed.

3.7.3

Function buttons

The following function buttons are available.


Buttons

Content

Export data to
USB

Export trend curve history as a csv file. The file can be sent to Alfa Laval for
advanced trouble shooting.
Insert a USB memory in USB panel port on the cabinet door. Press Export
data to USB button. Wait for the message Exporting database table to
disappear. The file has been downloaded to the USB memory, in a folder
named DatabaseExport.

History mode

Press the button to display this popup:

3 TrendCurveTime

Press one time unit (year, moth, day etc) and then press or + to set time.
Real time

36

Press the button to display current trend curve.

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Detailed page descriptions

3.8

3.11

Page 3.5 Trend (1 h) - Power optimization

Page 3.2 Trend (1 h)

The page is used to display trend curves for basic data in the system. This page display trends with
a update frequency (sample time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.

3.9

Page 3.3 Trend (1 h) - TT201-33

The page is used to display trend curves for water temperature in the AOT reactor, indicated by
temperature transmitter TT20133. This page display trends with a update frequency (sample
time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.

3.10 Page 3.4 Trend (1 h) - TT401-2


The page is used to display trend curves for air temperature in LDC, indicated by temperature
transmitter TT4012. This page display trends with a update frequency (sample time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.

3.11 Page 3.5 Trend (1 h) - Power optimization


The page is used to display trend curves for data valid for the power optimization. This page display
trends with a update frequency (sample time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons. See chapter 2.
System description, section Power optimization for details.
The following information is displayed:

AOT UV setpoint: The UV intensity the system is aiming to attain by increasing or decreasing
power effect to the LPS controlling the dimming of the UV lamps. The setpoint is based on
actual transmittance and is updated every 15 seconds.

UV measurement: Actual UV intensity (W/m2) measured by UV sensor QT20150. If intensity


is lower or higher than needed, the power to LPS will increase or decrease to attain setpoint
for UV intensity.

Power output: Actual LPS power to UV lamps. The power is adjusted to attain the setpoint for
UV intensity based on measured water transmittance. Output is adjusted based on input from
UV sensor QT20150. Power can be 50100 %.

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37

3.12

Page 4.1 System info

Detailed page descriptions

3.12 Page 4.1 System info


The page is used to display status information for the control system and the control panel. It is also
used to backup information and restore information from a backup.

3 4.1

The following information is displayed:


Section on page

Description

HMI info

CPU: Control panels usage of the central processor unit (CPU) in


percent of total capacity and temperature (C).
Used RAM: Control panels used random access memory (RAM) in
percent of total capacity and in kB.
Used storage: PLC flash cards used storage in percent and MB.
Storage used for the event and alarm log.
iX version: N/A.
IMG version: Version of TA150 firmware for the control panel.
CAT control version: N/A.

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Book No.9010182 02, rev. 0

Detailed page descriptions

Section on page

3.12

Page 4.1 System info

Description
Program version: Version of HMI software.
IP settings: Display current IP address.
Setup button: Opens popup to set IP address for the main panel and
the remote control panels (optional). Requires login level AlfaLaval

HMI date and time UTC

Date and time: Only used if no GPS is connected to the control


system. If so, time is retrieved from the GPS.
Requires login level Advanced operator.
Set button: Set time and date for the control panel.
Synchronize button: PLC is synchronized to use same date and
time as the control panel.

HMI Backlight

Screen saver timeout: Defines time before the panel is set to


screen save mode. This is set individually per control panel.
Night light level: Defines percent of full light for the night light
mode. Night light is activated by the Night function button.

PLC Info

CPU temperature (C): Temperature of the central processor unit


(CPU) in the PLC.
Program version: Version of the PureBallast PLC program.
GPS position: Shows current GPS position, if the control system is
connected to a GPS (p160). This position is used in the event log.

Backup and restore

Settings to/from USB panel: Export and inport information to the


USB panel port on the cabinet door.
Backup button: The following information is saved in a folder named
PureBallast Backup:

Parameter settings. Saved in file Parameters.csv.

Audit trail (tracking of actions in the control system, e.g. changed


password, acknowledged alarms, changed parameter values).
Saved in file AuditTrail.sdf.

Settings for trend pages, e.g. min and max values for different
components. Saved in file ValueTrendLegend.xml.

Passwords. Saved in file Security.xml.

Notpad.txt. Can be used to make notes for the backup.

Restore button: Restore all information from a USB backup to


the control system. See Backup above. This shall not be used to
restore parameter settings after software update. Requires login
level Advanced operator.

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39

3.12

Page 4.1 System info

Section on page

Detailed page descriptions

Description
Parameters: Restore manually changed parameter to default
values.
Set default button: Set all parameter values to the default values.
Requires login level Advanced operator.
History to USB panel: Export information to the USB panel port
on the cabinet door
Backup button: The following information is saved in a folder named
PureBallast Export:

Export log files

Database including alarm history, trend history etc. Saved in


file Database.sdf.

Audit trail (tracking of actions in the control system, e.g. changed


password, acknowledged alarms, changed parameter values).
Saved in file AuditTrail.sdf.

Settings for trend pages, e.g. min and max values for different
components. Saved in file ValueTrendLegend.xml.

Passwords. Saved in file Security.xml.

Notpad.txt. Can be used to make notes for the backup.

Export: Opens the Export log files popup to export (copy) event
log and alarm list as a set of files in a folder named PureBallast.
For specific information about logged events, see section List of
logged information, Event log on page 89.

Remote control panels

Set: Open a popup used for setting IP addresses for remote control
panels (optional). See instruction Set control panel IP address on
page 74.
Requires login level Advanced operator.

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.13

Page 4.2 PLC controller I/O

3.13 Page 4.2 PLC controller I/O


The page is used to display status for the PLC I/O modules and to control them manually.
Note that this page is only intended for Alfa Lavals personnel and only visible and available for
login level AlfaLaval.

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41

3.14

Page 4.3 Operation timers

Detailed page descriptions

3.14 Page 4.3 Operation timers


The page is used to display operation counters for the components indicted in the illustration.
Note that these timers are reset when the PLC software is updated.

3 4.3

The following information is displayed:


Row

Unit

Accumulated ballast volume (FIT 201-1)

m3 processed

Accumulated deballast volume (FIT 201-1)

m3 processed

Control valve V201-8 total runtime

Time opened in hours

Filter backflush via V309-1

Number of times opened

Filter motor M70942

Runtime in hours

CIP pump P320-1

Runtime in hours

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.14

Page 4.3 Operation timers

Row

Unit

CIP pump P321-5

Runtime in hours

CIP: Number of cleaned AOTs.

Number of cleaned AOT


reactors

Reset button: Reset to 0. If this is done each time the CIP liquid
is changed, it is possible to build up experience on how many
AOT reactors it is possible to CIP before it is time to change CIP
liquid. Requires login level Advanced operator or higher.

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43

3.15

Page 4.4 Operation timers AOT

Detailed page descriptions

3.15 Page 4.4 Operation timers AOT


The page is used to display operation runtime for AOT reactors:

3 4.4

The following information is displayed:


AOT operation
timers

Total

Lap time

AOT 13:
Lamps on

Total runtime for the UV lamps in


respective AOT reactor.

Lap time for installed UV lamps, since


the counter was reset after previous
reset at UV lamp change.
Reset button: Reset the value. Shall
be done after UV lamp change.
Requires login level Advanced
operator or higher.

AOT 13: LDC


power on

44

Total runtime for the LDC for


respective AOT reactor.

Book No.9010182 02, rev. 0

Detailed page descriptions

3.16

Page 4.5 Remote interface 1

3.16 Page 4.5 Remote interface 1


This page is used to monitor data sent between PureBallasts PLC and the vessels ISCS.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).

3 4.5

Function buttons

Description

Test mode

Activates test mode. Communication can be sent between the


ISCS and PureBallasts PLC without actually affecting the control
system (start process etc). To send information, enter desired
digits in the entry field.
Active: Check mark on the button.
Deactivated: No check mark on the button.

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45

3.17

Page 4.6 Remote interface 2

Detailed page descriptions

3.17 Page 4.6 Remote interface 2


This page is used to monitor AOT reactor and LDC specific data sent from PureBallasts PLC
to the vessels ISCS.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).

3 4.6

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.18

Page 4.7 Log box 1

3.18 Page 4.7 Log box 1


This page is used to administer and monitor the feedback from external components connected
via the log box (optional).

3 4.7

The following information is displayed:


Column

Content

Vessel ID

Each row represent a component (valve). In the Vessel ID column, it is


possible to enter the actual component ID used on the vessel for easier
identification on the panel. This ID is not used in the Event log. Example: In
the illustration the first valve is named Valve X45.
To enter a vessel ID: Press the entry field or the document icon for the
component, and enter the ID using the keyboard displayed on the screen.

Position

Each component is identified with a component ID and position.


Component ID: This ID is used in the Event log.

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47

3.19

Page 4.8 Log box 2

Column

Detailed page descriptions

Content

Position: For each valve, it is possible to connect two signals to log feedback
on open, closed or both. If signal Closed is used for a valve, the event log
will make a record each time the valve is detected closed, and each time it is
detected not closed.
Status

Active signal is indicated with a green light on the I/O icon.

Logging

Two parameters per valve defines if opened and/or closed signals are
connected for respective position (valve). If parameter is set to Active,
activities for the component is logged in the event log.
Alternatives: Activated or Not used.

3.19 Page 4.8 Log box 2


This page is used to administer and monitor the feedback from external valves (V) and pumps (P)
connected via the log box (optional).
See page 4.7 Log box 1 for information about function, fields and buttons.

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.19

Page 4.8 Log box 2

3 4.8

Book No.9010182 02, rev. 0

49

3.20

Page 4.9 LPS overview

Detailed page descriptions

3.20 Page 4.9 LPS overview


This page is used to monitor detailed data for the lamp power supplies in the lamp drive cabinet. It
is intended for Alfa Lavals personnel during advanced faultfinding.

3 4.9Obe

Column

Content

LPS number

Each row indicate status for each LDC.

Power

Measured power output for UV lamp powered by the LPS.

Lamp on

Status: Green = On. Grey = Off.

Reignite

Status: Red = Failure to ignite UV lamp.

LPS OK

Status: Green = OK. Red = LPS in fault state.

Lamp OK

Status: Green = UV lamp lit and LPS is OK. Red = LPS in fault state.

Voltage fault

Status: Red = Too low incoming power to the LPS.

System fault

General LPS error.

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.20

Page 4.9 LPS overview

Column

Content

Air temp fault

Status: Red = Temperature in LPS is higher than 55 C.

Heatsink fault

LPS internal heat protection tripped.

Fan fault

LPS fan broken.

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51

3.21

Page 4.10 LDC power

Detailed page descriptions

3.21 Page 4.10 LDC power


This page is used to monitor detailed data for the lamp power cabinet. It is intended for Alfa Lavals
personnel during advanced faultfinding.

3 4.10

Column

Content

AOT

Each row indicate status for the LDC for each AOT reactor.

Current

Power through phase L1 L3.

Voltage

Voltage through phase U12U31.

Power total

Total effect at LDC main breaker Q1. Presented as active, reactive and
apparent values.

Freq.

Frequency of incoming power to LDC.

L, S and I

Trip characteristics of breaker settings for L, S and I.

Read button

Press the button to update data for the row. (The data is not uppdated
continuously.)

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.23

Popup windows

3.22 Page 5.15.7 Parameter pages


These pages are used to set parameters. See chapter 4. Parameters for detailed information.

3.23 Popup windows


This section describes the popup windows for the AOT reactor, filter and CIP opened from page 1.1
Overview.

3.23.1 AOT popup


The popup is displayed when the AOT reactor is pressed in the flow chart. The popup displays
status values for the AOT reactor and its related sub components.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually. If the component is pressed, a popup window is displayed from which the sub
components can be operated. Operation of UV lamps in LPS control popup requires login level
Advanced operator.
AOT status: Status indication for the AOT reactor: Stopped or Started.

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53

3.23

Popup windows

Detailed page descriptions

3 1.1 AOT popObe

The following information is displayed:


AOT illustration
The following information is displayed:
Component

Description

UV lamps

Status indication:
Grey = Off.
Yellow = Starting.
Green = Started.

Sensor
indications

Status indication for AOT reactor sensors:


LS20129: Level switch indicates if the AOT reactor is filled with water or
not.
Status indication: Green = Filled. Red = Not filled.
TS20160: Temperature switch TS20160 automatically shuts down the
AOT reactor when the temperature reaches 65 C.
Status indication: Green = OK. Red = Not OK.

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Book No.9010182 02, rev. 0

Detailed page descriptions

Component

3.23

Popup windows

Description
QT20150: UV sensor QT20150 indicates UV intensity from the UV lamps
in the AOT reactor. When transmittance falls below value set in parameter
p221 a warning is issued.
TT20133: Temperature indicator TT201-33 indicates current temperature
in the AOT reactor.

Valves

For status indications, see Status indication Component color in section


Flow chart on page 21.

Water flow

Flow in pipes is indicated by coloring of the pipes.

LDC status
Component

3 LPSctlrbut

Description
Open the LPS control popup, which enables manual operation of individual
UV lamps. Requires login level Advanced operator to see the button and
manual mode open the popup. See LPS control popup and instruction
Operate UV lamps manually on page 70.
Open the LPS status popup, which gives an overview of status for UV
lamps and LPSs.

3 LPS StatusBut

LDC fan setpoint

Fan rotation in percent of full effect. Fan effect is based on need for cooling.

Heat exchanger
valve

Indicates if the valve for LDC cooling water (SV40151) is open.


Status indication: Green = Open . No indication = Closed.

TT4011

Temperature of incoming cooling water to the LDC cabinet.

TT4012

Air temperature in the LDC cabinet.

Power

Current power consumption for the AOT reactor/LDC.

3.23.1.1 LPS control popup


The popup is used for to manually start the UV lamps in the AOT reactor. See instruction Operate
UV lamps manually on page 70. The popup is displayed when the LPS control button is pressed
in the AOT popup. Requires login level Advanced operator to see the button and that manual
mode is activated to open the popup.
The AOT reactor is equipped with 16 UV lamps. In each lamp drive cabinet (LDC) is 16 lamp
power supplies (LPS) that supplies power to one UV lamp each. The lamps can be operated
individually in manual mode.

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55

3.23

Popup windows

NGE
! DA

Detailed page descriptions

Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 C. All
necessary items cooling water flow, water temperature, and power management must be
supervised and verified by the authorized trained personnel operating the system. Improper
operation of this function could seriously damage the equipment and injure personnel.

3 LPS Manual popObe

The following information is displayed:


Component

Description

AOT number

Information is displayed for the AOT reactor selected in the AOT number
field.
Enables manual operation of the LPSs to light the UV lamps. The button is
displayed for login level Advanced operator or higher. The button enables
manual lcontrol of UV lamps.

3 ManModeBut

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Detailed page descriptions

3.23

Popup windows

Component

Description

LPS 116

Press one button (116) to start or stop UV lamp 116 manually, controlled
by the LPS.
Status indication:
Blue with checkmark = Lit
Blue without checkmark = Off
Grey = Not selectable.
Start all LPS, and thereby all lamps for the AOT reactor. Requires that the
Manual mode button is pressed.

3 StartLPSBut

Stops all LPS, and thereby all lamps for the AOT reactor.

3 StopLPSBut

3.23.1.2 LPS status


The popup gives detailed information about UV intensity for AOT reactors and power for LPSs. The
information is mainly used for advanced trouble shooting by Alfa Lavals personnel.

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57

3.23

Popup windows

Detailed page descriptions

3 LPS popObe

The following information is displayed:


LPS status
Component

Description

AOT

Information is displayed for the AOT reactor selected in the AOT number
field.

Fail safe

Displays if LPSs is active and powered on. UV lamps can only be lit if an
LPS is active. When a critical alarm (e.g. no water in the AOT reactor) is
issued, the fail safe function inactivates the LPSs and cut the power.
Status indication: Green = Active. Grey = Not active.

3 1.1 LPS active

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Book No.9010182 02, rev. 0

Detailed page descriptions

3.23

Popup windows

Component

Description

LPS 116

Actual effect from each LPS to respective UV lamp. Green = LPS/Lamp


on. Gray = LPS/Lamp off.

Power optimization
Component

Description

Setpoint

The UV intensity the system is aiming to attain by increasing or decreasing


power effect to the LPS controlling the dimming of the UV lamps.

Measured

Actual UV intensity (W/m2) measured by UV sensor QT20150. If intensity


is lower or higher than needed, the effect to LPS will increase or decrease
to attain setpoint for UV intensity.

Power output

Actual LPS power effect to UV lamps.


The effect is adjusted to attain the setpoint for UV intensity based on
measured water transmittance. Output is adjusted based on input from
UV sensor QT20150. Effect can be 50100 %.

Control mode

Manual power
output

Displays current control mode. Status indication:

Automatic: Normal mode. Power optimization is activated.

Manual: If function button Manual is pressed, it is possible to enter a


value in the Manual power output field.

Not used: Power optimization is disabled in parameter p237. UV


lamps are always lit to 100 %.

Manually set effect to LPS. Requires that the system is set in manual
mode.

3.23.2 Filter popup


The popup is displayed when the Filter is pressed in the flow chart. The popup displays status
values for the filter and its related components.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually. If the component is pressed, a popup window is displayed from which the sub component
can be operated. When manual mode is deactivated the system will return to standby mode: All
manually operated components will return to their status prior to the manual operation.

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59

3.23

Popup windows

Detailed page descriptions

3 1.1 Filter Hydac

The following information is displayed:


Component

Description

Mode

Filter status:
- Idle (No backflush or preservation)
- Backflush preparation
- Backflush ongoing
- Filter preservation.

Diff. pressure

Indicates differential pressure over the filter (PT20171 minus PT20172).


When the pressure reach the value set in parameter p305, a backflush
is triggered.

Pressure

Current pressure:
PT20171: Inlet pressure.
PT20172: Outlet pressure.
PT3092: Backflush pressure.

Start backflush

Press the button to start a manual backflush. See instruction Backflush


filter manually on page 64.

Pipes, valves and


motor

For status indications, see Status indication Component color in section


Flow chart on page 21.

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Book No.9010182 02, rev. 0

4 Operating instructions
This section contains step-by-step instructions for operating the PureBallast system. Please read
and follow the preparations and conditions carefully, as well as any danger or warning notes.
Preparations and conditions
For reference information, see the following sections i this chapter:

Control system pages used in the instructions: See section Control system Detailed page
descriptions.

Login levels required for different procedures: See section Login levels on page 11.

Detailed information about components (valves, motors, pumps etc) involved in each step the
process. See section Detailed process description.

4.1

Log in

Follow the steps below


1.

Press the expand button on the Log in tab in the top right corner of the screen.
Result: The log in menu is displayed.

2.

Press the expand button on the left drop down menu to display available users. Press desired
user.
Result: A keyboard is displayed.

3.

Enter password and press Enter. (See section Login levels on page 11.)

4.2

Perform ballast

Follow this instruction to ballast.


Preparations and conditions

The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.

All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).

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61

4.3

Perform deballast

Operating instructions

Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.

There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.

4.2.1

Start ballasting

Follow the steps below:


1.

Press the function button Ballast.


Comment: If the button is not blue, check that flow or AOT reactors have been selected.

2.

Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Ballast start-up starts, with cooling water cooling the lamps during warm-up.

3.

Wait for the message Confirm ballast pump started. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and ballasting starts.

4.

When desired amount of water has been processed, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off. An automatic filter
backflush is performed.

5.

Wait for the message Close valves .... Close relevant valves and then press the button in
the popup to confirm the action. Note! These valves are outside outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)

6.

Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
NOTE

A CIP cleaning process must be performed after ballasting. It can be done immediately or within 30 hours. When
time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made in the control
systems log as a deviation from a correct handling of the system. Note, that it is possible to perform processes
during these 30 hours. Complete status information regarding CIP is displayed in page 1.3 CIP status. A CIP
process is started manually according to instruction CIP clean AOT after ballast / deballast on page 65.

4.3

Perform deballast

Follow this instruction to deballast.


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Book No.9010182 02, rev. 0

Operating instructions

4.3

Perform deballast

Preparations and conditions

The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.

All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).

Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.

There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.

Follow the steps below:


1.

Press the function button Deballast.


Comment: If the button is not blue, check that flow or AOT reactor have been selected.

2.

Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.

3.

Wait for the message Confirm ballast pump started. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and deballasting starts.

4.

When desired amount of water has been processed, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off.

5.

Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)

6.

Wait for the message Close valves .... Close relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
NOTE

A CIP cleaning process must be performed after deballasting. It can be done immediately or within 30 hours.
When time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made
in the control systems log as a deviation from a correct handling of the system. Note, that it is possible to
perform processes during these 30 hours. Complete status information regarding CIP is displayed in page 1.3
CIP status. A CIP process is started manually according to instruction CIP clean AOT after ballast /
deballast on page 65.

Book No.9010182 02, rev. 0

63

4.5

Backflush filter manually

4.4

Operating instructions

Pause ballast / deballast

Follow this instruction to pause an ongoing ballast or deballast process. This instruction is also
used before heeling (internal transfer), if no external signal for heeling mode is integrated between
PureBallast and the vessels ISCS.
Preparations and conditions

This is only possible in sub process full ballast or full deballast. This is indicated by the lit
Pause button.

Allowed length of a pause is parameter set (p138). After defined time, the paused process
is stopped.

Follow the steps below:


1.

Press the function button Pause.

2.

Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Note: If you pause to perform heeling (internal transfer) you confirm the request without
stopping the ballast water pump.
Result: Ongoing process is paused. The UV lamps remains on at reduced power and cooling
water is run through the AOT reactor to cool the lamps. Pause mode is indicated by yellow light
under the Pause button and blinking yellow under the function button Ballast or Deballast.

3.

To resume the paused process, press the function button Ballast or Deballast.

4.

Wait for the message Confirm ballast pump started. Start the pump and press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: The process is resumed.

4.5

Backflush filter manually

Follow this instruction to backflush rinse the filter manually.


Preparations and conditions

The system must be in full ballast mode.

Follow the steps below:


1.

Go to page 1.1 Overview.

2.

Press the Filter in the flow chart.


Result: The Filter popup is displayed.

3.

Press the Start backflush button.


Result: A backflush is performed. The default backflush process time is 35 seconds.

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Book No.9010182 02, rev. 0

Operating instructions

4.6

4.7

Stop ballast / deballast

CIP clean AOT reactor after ballast / deballast

Follow this instruction to clean the AOT reactor(s) using the cleaning in place (CIP) process.
If system shut down is activated during the CIP process, the CIP liquid is drained to the CIP tank.
Water in the AOT reactors is drained overboard.
Preparations and conditions

The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.

Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOT reactors
are required to be CIP:ed etc.

If a ballast operation has been performed since the last CIP process, the process is completed
with a filter preservation, where the filter is filled up with fresh water.

Follow the steps below:


1.

Press the function button CIP.

2.

Wait for the message Open valves .... Open relevant valves and then press button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: The automatic CIP process starts. The CIP process takes about 25 minutes per
AOT reactor, if default parameters are used.

3.

Wait for the message Close valves .... Close relevant valves and then press button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)

4.7

Stop ballast / deballast

Follow this instruction to stop an ongoing ballasting or deballasting operation. Each ballast and
deballast operation must be stopped manually.
Follow the steps below:
1.

When desired amount of water has been processed, press the function button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off. If ballasting, an automatic
backflush is performed before the system is stopped.

2.

Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)

3.

Wait for the message Close valves .... Close relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)

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65

4.8

Attend to alarms

Operating instructions

NOTE
A CIP cleaning process must be performed after ballasting and deballasting. It can be done immediately or
within a 30 hours. When time is about to elaps, a warning is issued. If no action is taken within the time
limit, an entry is made in the control systems log as a deviation from a correct handling of the system. Note,
that it is possible to perform processes during these 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status.

4.8

Attend to alarms

Follow this instruction to attend to alarms and warnings. For descriptions of alarms and trouble
shooting, see chapter 5. Alarms and faultfinding.
An alarm or warning is indicated by a audible signal and by a blinking alarm icon:
Warning: Warnings are notification of a status change or a problem. Warnings
allow the process to continue.
2 Warning

Alarm: Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.

3Alarm

Preparations and conditions

If the alarm is caused by a faulty AOT reactor, the AOT reactor will shut down but the process
will continue with remaining AOT reactors.

NG
WARNI

Never reset an alarm without first finding and attending to the problem.

For color indication of alarms. See page 32.

Follow the steps below:


1.

Go to page 2.1 Alarm list to view active alarms.

If the alarm has caused the system to automatically stop, go to step 2.

If the alarm allows the ballast process to continue, go to step 3.

2.

If the process have stopped: Take action to eliminate what has caused the alarm.

3.

If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.

4.

After the problem has been dealt with Press the Ack all button to acknowledge all alarms, or
press the alarm row and press Ack selected button to acknowledge only this alarm.
Result: The alarm will change color to indicate change of status. See section Page 2.1 Alarm
list in this chapter. The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.

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Book No.9010182 02, rev. 0

Operating instructions

4.9

4.9

Shut down and deactivate system

Shut down and deactivate system

Follow this instruction to quickly stop any ongoing operation in the PureBallast system, for example,
when a critical fault has been detected, or to make the system deactivated (currentless).
Lamp drive cabinet

Control cabinet

3 Emergency stop

3 LDC Main breaker

Follow the steps below:


One of the following methods can be used to abort any ongoing operation and stop the system:
Action

Method

Stop ongoing
process

Press the Stop button in the control panel.


Result: Ongoing process is stopped in a controlled way. Valves are
returned to starting position.

3StopButtonBlue

Shut down

Book No.9010182 02, rev. 0

Press the Stop button (2) on the control cabinet door.


Result: Ongoing process is shut down and valves are returned to
starting position as fast as possible. Note: The power is still on.

67

4.11

Operate components manually

Operating instructions

Action

Method

External shut down


button

If an external system stop button has been installed and integrated, it


will function as the shut down above.

Deactivate
PureBallast to
make it completely
deactivated
(currentless).

Complete deactivation is performed in two steps:


Stop any ongoing process:
1. Turn off the main breaker (1) at the side of the control cabinet.
2. Turn off the main breaker on the LDC door.
The system is then currentless on the PureBallast side of the breaker
(Q1 in control cabinet and Q1 in the LDC.
To make the complete system currentless, power to PureBallast must
be switched off using the ships switch board.
Note: Both breakers can be locked in off position using a padlock.

4.10 Reset system after shut down


Follow this instruction to reset the system if deactivated. Numbers refer to the illustration under
instruction Shut down and deactivate system on page 67.
The system may only be reset after the reason for shut down is known. If the reason is not known,
follow the instruction Attend to alarms.
Depending on how the system was shut down:
Manual on control cabinet: Turn the main breaker (1) and acknowledge alarm A48 in the control
system.
Automatic in LDC: Follow the instruction below if a reactor has been shut down by temperature
switch TS201-60 (alarm A137) or if the cabinet or system has been shut down by a blackout or
electrical faults in the cabinet:
1. Make sure that the main breaker on the LDC door is turned on.
2. Press. the blue reset button on the LDC door (when the reactor has cooled down or when the
power is back on). All LDCs must be reset individually.
3. Acknowledge all alarm related to the shut down in the control system.

4.11 Operate components manually


Follow this instruction to operate components manually. This shall only be done during
commissioning, advanced faultfinding or service.
Valves are recommended to be operated via the PureBallast control system. It is also possible to
open/close them manually according to instruction in chapter 7. Service manual, section Operate
valves manually.
The following components can be operated manually:
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Book No.9010182 02, rev. 0

Operating instructions

Filter motor (M709-43)

CIP pump for CIP liquid (P320-1)

CIP pump for draining (P321-5)

Booster pump, LDC cooling (4011), if installed

Booster pump, AOT reactor cooling (4031), if installed

UV lamps in the AOT reactor

UV lamp effect.

4.11

Operate components manually

Preparations and conditions

This operation requires login level Advanced operator or higher.

It is not possible to run any processes in manual mode. Only individual components can be
operated.

When operating valves, the positioning screw on the valve must be in position 0: Closed
(default position).

Follow the steps below:


1.

Go to page 1.1 Overview or 1.4 CIP status.

2.

Press the button Manual function button.


Result: The control system is set in manual mode.

3.

Press desired component.


Result: A popup is opened. Current status is indicated. If an existing alarm exist, it is indicated
with an alarm icon. If the AOT reactor or filter was pressed, a popup is opened with sub
components. If the CIP was pressed, page 1.4 CIP status is opened.

3 PopValve

Example popup for a valve.

4.

Press (not slide) the Hand button icon to enable manual operation of the component.
Result: The open and closed buttons turn blue for operation. A hand icon is also displayed on
the component in the popup and the flow chart to indicate that it is manually operated.

5.

Operate the component using the open/run (left) and closed/not running (right) buttons in
the popup.

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69

4.12

Operate UV lamps manually

Operating instructions

6.

Press Hand button to stop manual mode for the component and the X button to close the popup.
or
Press the X button to close the popup and let the component remain in manually set status.
The popup is closed, and a hand icon is displayed by the component to indicate it is manually
operated.

7.

Press the Manual function button to exit manual mode.


Result: All manually operated components are restored to their previous status.

4.12 Operate UV lamps manually


Follow this instruction to start and stop individual UV lamps in an AOT reactor and to dim the UV
lamps. This can, for example, be done to check that a changed lamp functions OK.
Preparations and conditions

This operation requires login level Advanced operator or higher.

The control system must be in manual mode.

NGE
! DA

Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 C. All
necessary items cooling water flow, water temperature, and power management must be
supervised and verified by the authorized trained personnel operating the system. Inappropriate
operation of this function could seriously damage the equipment and injure personnel.

Follow the steps below:


1.

Go to page 1.1 Overview. Press the Manual function button to activate manual mode.

2.

Press the AOT image.


Result: The AOT popup opens. (See description on page 53.)

3.

Select which AOT reactor to operate in the AOT number entry field.

4.

Open, in stated order, the following valves to fill the AOT reactor with water: 201-19, 404-36
and 403-35.
Result: The AOT reactor is now filled with water through the cooling water line 403.

5.

Wait until the AOT reactor is filled with water, indicated by the level switch (LS20129) turning
green.

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Book No.9010182 02, rev. 0

6.

Operating instructions

4.13

Set ship specific component ID

Press the LPS control button.


Result: The LPS control popup is displayed for selected AOT reactor.

3 LPS Manual popObe

7.

Press the Manual mode button to enable manual operation of the UV lamps.

8.

Operate lamps by pressing one of the following buttons:


Start all LPS units.
Stop all LPS units.
LPS1-16: Start / stop individual lamps. Each lamp power supply (LPS) powers to
corresponding UV lamp. The buttons toggles between started and stopped. Place the AOT
and the LPS control popups side to side to see that the lams are started.
UV lamp stauts: Grey = Stopped; Green = Started; Yellow = Starting.

9.

If desired, the UV lamps can be dimmed manually: Press the LPS status button in the AOT
reactor popup. Press the Manual output filed, and enter desired percentage between 50
and 100 %. The LPS will give the entered percentage of full effect to the UV lamps. This is
indicated in the Power output field.

10. Press the Stop all LPS units button.


Result: Any lit UV lamps are stopped and the popup is closed.
11. Press the Close button to close the popup.
12. Press the Manual function button to exit manual mode.
Result: All manually operated components are restored to standby status.

4.13 Set ship specific component ID


Follow this instruction to set ship specific IDs for valves and pumps. The ID will be visible in page
1.1 Overview and popups for the components.
Book No.9010182 02, rev. 0

71

4.14

Export control system log files

Operating instructions

Preparations and conditions

IDs are only displayed in the control panel it is entered. If desired the settings can be entered in
remote control panels (optional).

IDs are not included in the backup of control system settings.

Follow the steps below:


1.

Go to page 1.1 Overview.

2.

Press desired component.


Result: A popup is opened.

3 ShipIDComp

Example: Popup with ship specific ID. Entered ID is


displayed on the component to the right.

3.

Press the input field at the bottom.

4.

Use the keyboard to enter an ID. Press Enter to finish.


Result: The name is saved and visible in page 1.1 Overview and the popup. .

4.14 Export control system log files


Follow this instruction to copy control system information as a text file to a USB memory. The text
file can then be analyzed either in Excel (or similar tools) or in Visualog. Visualog is a tool designed
to present and analyze the information from the PureBallast log files.
The following information can be exported:

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Book No.9010182 02, rev. 0

Operating instructions

4.14

Export control system log files

Information to be
exported

Description

Event log

The event log includes all important events in the PureBallast system. The
log also include components connected via the log box. Intended to be
used mainly by service technicians.

Event log Certificate

Contains a selection of the complete event log, relevant to comply with


the IMO regulations.

Alarm history

A list of all alarms and warnings that has been issued from the control
system. Intended to be used mainly by service technicians.

For specific information about logged events, see section List of logged information on page 89.
Preparations and conditions

Events are only copied, hence they will remain in the control system.

Required USB memory capacity is indicated in the Export PLC events popup.

The easiest way of reading the log file is to use the program Visualog, but the file can also be
read in Exel. See Read event log in Excel below.

Follow the steps below:


1.

Go to page 4.1 System info.

2.

Press the Export button in page section Export log files.


Result: Popup Export log files is displayed.

3 ExportLog

3.

Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.

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73

4.15

4.

Set control panel IP address

Operating instructions

Chose one of the following alternatives to decide time interval for the information to be copied:

Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is todays date.

Select the Specify time interval box, and enter desired interval in the Start and End fields.

5.

Press one of the following function buttons: Events, Cert events or Alarms.
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.

6.

Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been saved to the USB. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choices contains a CSV file.

7.

Press Close and remove the USB memory

4.14.1 Read event log in Excel


Follow this instruction to read event logs in Excel. Note: In Excel, time and date is expressed as
seconds since 1970-01-01. This instruction will help you to display date and time in clear figures.
Also, events are displayed with their event code. For reference, see section Event log on page 89.
Preparations and conditions

Event log must have been downloaded.

Follow the steps below


1.

Open the event log in Excel.

2.

Add two new columns to the furthers left. (They will become new column A and B.)

3.

Write 1970-01-01 in cell H1. Write =A2 in cell B2.

4.

Copy cell B2 to all lines in column B.

5.

Write =C2/(60*60*24)+$H$1 in cell A2. (It is important that all characters are correct, so it is
better to type the formula rather than copying this text.)

6.

Copy cell A2 to all lines in column A.


Result: Date is displayed in Column A as YYYY-MM-DD. Time is displayed in column B
as HH:MM:SS.
Note: If date and time does not show correct, format the cells as date and time. To do this:
Select the cells, right click on the cells. In tab Number, select date/time and select the format it
shall be displayed in.

4.15 Set control panel IP address


Follow this instruction to set IP address for the main panel and the remote control panels (optional).
Preparations and conditions

74

This setting shall be done for all panels installed.


Book No.9010182 02, rev. 0

Operating instructions

4.15

Set control panel IP address

These instructions require login level AlfaLaval.

Port 1 must be used for the Ethernet cable at the backside of the panel. It is marked with the
symbol below.

3 USB

Follow the steps below:


1.

Go to page 4.1 System info.

2.

Press the Setup button in the IP settings box.


Result: The IP settings popup is displayed.

3.

Press the IP Settings button.


Result: A popup is displayed.

3 IPaddress

4.

In the Port 1 tab select the radio button Specify an IP address.


Enter the IP address according to the list below. Also check that correct setting is done for Port
2 in the Port 2 tab.

3 IPaddress

Note: Only the IP address shall be changed.


5.

Press OK.

6.

Repeat this instruction for all installed control panels, both main and remote control panels, if
installed.

Book No.9010182 02, rev. 0

75

4.16

7.

Set remote control panel communication

Operating instructions

Follow the instruction Set remote control panel communication to activate remote control panel.

4.16 Set remote control panel communication


Follow this instruction to connect remote control panels (optional) to the PLC.
Preparations and conditions

These instructions require login level Advanced operator or higher.

The same setting shall be done for all panels installed.

IP addresses must have been set according to instruction Set control panel IP address.

Main control panel and remote control panel 1 (192.168.0.11) are added as default . If no
remote control panelse is used, address 192.168.0.11 shall be removed.

All remote control panels must be on and connected with an Ethernet cable.

Follow the steps below:


1.

On the main panel in the control cabinet: Go to page 4.1 System info.

2.

In the Remote control panels box, press the Set button.


Result: The Remote panels setting popup is displayed.

3 RCP communication

3.

Select an available remote control panel in the left hand side.

4.

Press the >> button.


Result: The panel is connected and moved to the right hand side.
Note: Server port shall always be 1001.

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Operating instructions

4.18

Test remote interface communication

5.

Press the Panel alias field for the new control panel. Use the keyboard to enter a name, for
example the location it is placed.
Note: Panel alias for all control panels shall be entered (with the same wording) in all panels
to be displayed in a correct way.

6.

Press the save (diskette) icon.


Result: The information is saved and the popup is closed.

7.

Repeat step 47 to connect more remote control panels.

8.

Repeat this entire instruction for all installed panels.

Delete a remote control panel


If remote control panels are not used, any added control panels shall be deleted from the list.
To delete a connected panel: Select it a panel in the hand side and press the delete (X) icon. If a
keyboard is displayed, pres Esc to remove it.

4.17 Set remote interface communication


Follow this instruction to make settings for the remote interface (optional) communication between
the ISCS and PureBallast.
Preparations and conditions

These instructions require login level AlfaLaval.

Follow the steps below:


1.

Go to page 5.7 Remote interface.

2.

Set parameters to match ISCSs RTU server data according to the information in chapter 4.
Parameters, section 5.7 Remote interface.

4.18 Test remote interface communication


Follow this instruction to test that the remote interface (optional) communication between
PureBallasts PLC and the ISCS is correct and functioning.
Test communication
The first test is to see that the two systems communicate.
1.

Go to page 4.5 Remote interface 1. Make sure that the system is not in test mode (no
checkmark on the button). If not, press the Test mode button to deactivate it. Make sure that
Local operation is activated. If not, press the Local function button.

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77

4.18

2.

Test remote interface communication

Operating instructions

Check that the heartbeat signal is updated in both systems (+006 and +077). Also check
that values are read from the PureBallast system, for example temperature (address +116
and +117).
This will confirm that the systems communicate.

Test values sent from PureBallast to ISCS


Values are entered and displayed in the control system as actual values, but are sent to ISCS using
the binary numeral system. This information is found in group Data to ISCS and Cmd/status to
ISCS on page 4.5 Remote interface 1, and is indicated by a unit (m3, hour, second, kW etc).
Addresses with special conditions
The following addresses does not display correct values in page 4.5:

+050 Process volume

+114/124/134 AOT reactor temperature for AOT reactor 1, 2 and 3

+115/125/135 LDC water temperature for AOT reactor 1, 2 and 3

+052 System pressure

+063 Filter differential pressure

+064 Filter inlet pressure V20171 (Hydac filter)

+065 Filter outlet pressure V20172 (Hydac filter)

+066 V201-8 setpoint

+057/+058. Current time

For detailed information, see the directory of addresses.


Follow the steps below:
1.

Press the Remote function button.


Result: Test mode is activated enabling that communication is sent between the systems
without actually affecting the control system (start processes etc). This also result in alarm A93
Heartbeat signal missing. This alarm shall be ignored during this test.

2.

Enter actual values in the in the input field for the address to send simulated information to
the ISCS. Information in decimal form, for example processed volume, is written as actual
values. Information in binary form, for example command status, is written as a bit pattern.
The key for the bit pattern is found in chapter 6. Installation description and drawings, section
System interfaces.

3.

Make sure that values and status information is displayed correspondingly in the ISCS.

4.

Repeat the simulation for the information you which to test.


Note: Only implemented signals needs to be tested.

Test commands from ISCS to PureBallast


In the ISCS, activate input commands corresponding to the addresses displayed in page 4.5. (Note
that address 006 does not need to be tested; it was tested at the beginning of this procedure.)
1.

Activate a command from ISCS, according to the HMI implementation.

2.

Make sure that the command is received in page 4.5. Use the directory of addresses to see
that the bit pattern is updated correctly.

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Book No.9010182 02, rev. 0

3.

Operating instructions

4.19

Simulate power request

In the control panel, restore all changed values after the communication test. If not, commands
might be executed involuntarily, when the system is set to online again. Most important is that
address 001 displays 00000000.

Test alarms and warnings


Alarms and warnings are tested by simulation in control page 4.5 Remote interface 1 and 4.6
Remote interface 2. Use the alarm list to identify addresses and bit patterns for the alarms.
You want to simulate alarm W40 (Process pressure too low). When you find W40 in the table, you
use the column heading to see which address the alarm shall be sent to and the row heading to
see which bit in the bit pattern that shall be high. For W40 the signal shall be sent to address
+902, and bit 12 shall be high.
Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first digit from
right is counted as zero, second digit counted as 1 etc). This gives the following bit pattern:
0010000000000000.
AOT reactor alarms/warnings: Each installed AOT reactor has a unique address:

AOT reactor 1/ LDC 1: Address +910 912

AOT reactor 2 / LDC 2: Address +913 915

AOT reactor 3 / LDC 3: Address +916 918

Follow the steps below:


1.

Enter the desired bit pattern in the input field for the address.

2.

Make sure that the alarm/warning is indicated in ISCS.

3.

If common alarm and warnings are used, make sure that address +070:7 and +070:8 are
updated. It is only necessary to check this for the first alarm.

4.

Clear the bit pattern in the input field.

5.

Repeat the simulation for those alarms/warnings you which to test.

6.

Press the Test mode button to set the system in online mode (no check mark on the button).
Press the Remote function button if you want to activate remote control.

4.19 Simulate power request


Follow this instruction to test the power management signals if PureBallast is integrated with the
vessels power management system. This instruction can also be used in manual mode during
faultfinding.
Preparations and conditions

This instruction requires login level Advanced operator or higher.

Follow the steps below:


1.

Go to page 1.4 Power request. Press the Manual function button.


Result: The control system is set in manual mode, indicated by a green checkmark on the
button.

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79

4.21

Update PLC software

Operating instructions

2.

Press the hand button in the Request column for a row with power step for desired number of
AOT reactors. For details, see description of page 1.4 Power request.

3.

Press the Request button for the row to simulate power request signal.
Result: Status is updated to Requested in the Request column.

4.

Wait until the status is updated to Yes in the Granted column.

5.

Press the hand button in the Status column.

6.

Press the Set run button to simulate running signal.


Result: Status is updated to Running in the Status column.

7.

Press the Set run button to deactivate the simulate running signal.

8.

Press the Manual function button to exit manual mode.

4.20 Set default parameters


Follow this instruction to set or reset all parameters in the control system to the factory set default
values.
Preparations and conditions

This operation requires login level Advanced operator or higher.

Follow the steps below


1.

Go to page 4.1 System info.

2.

Press the Default parameters button in page section Parameters.


Result: A popup is displayed.

3.

Press Yes in the popup.


Result: All parameters are reset.

4.21 Update PLC software


Follow this instruction to update the PLC software for the control system.
Preparations and conditions

Take a backup according to instruction Export control system log files on page 72. The files
are required to be saved for at least 24 months. The log files are erased when the software is
updated.

Take a backup according to instruction Backup control system settings. Note that this backup is
not used to reload settings, it is only a safety backup.

We recommend that a screen dump is taken for all parameter pages. (To do that: Insert a USB
memory in USB panel port on the cabinet door and press function button Utilities, and Print for
all pages.) Alternatively, take a photo. This will facilitate resetting of the parameters.

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Book No.9010182 02, rev. 0

Operating instructions

4.22

The release notes must have been read for the version to be installed.

Flash card with correct version of the PLC software.

Install TA150 firmware

Follow the steps below


1.

Shut off the power to the control cabinet using the main breaker on the side of the cabinet.

2.

Pull out the Ethernet cable from port IF2 ETH in the PLC module.

3.

Turn on the power to the control cabinet and wait for the panel to restart. Let the power to
the control cabinet remain on. Ignore the message Disconnected from remote alarm server,
it is due to the unconnected Ethernet cable. It is reconnected at the end of the Update HMI
software instruction.

4.

Next step is to install TA150 firmware, if needed. If not, next step is to install the HMI software.

4.22 Install TA150 firmware


Follow this instruction to update the TA150 firmware for the control panel.
Preparations and conditions

USB with correct version of the software.

Follow the steps below


1.

At the rear side of the main control panel: Pull out the power cable from the 24V DC port.
Open the small cover on the rear side. Turn DIP switch 1 to position ON.

7BeijerMODE

2.

Insert a USB memory with the TA150 firmware in USB panel port on the cabinet door.
Reconnect the power.

3.

Wait for requests to update and delete project. Answer Yes to both. (If you dont get the
question, set DIP switch to OFF, and try again. Or copy the files to another type of USB
memory.)
Result: The new software is updated to the panel.

4.

Wait for message: Remove USB memory to continue. Remove the USB.

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81

4.23

Update HMI software

Operating instructions

5.

Wait for message: Please reboot panel to complete update. Pull out the power cable and
reconnect it to restart the panel.
(If the reboot request does not appear on the screen (some older panels freeze), pull out the
power cable and reconnect it to restart. When the panel restarts, the reboot request will not
appear, since the panel was already restarted.)

6.

When the panel has restarted, tap the screen within 10 seconds. Press Touch calibrate:
Follow the instructions on screen.

7.

In the menu displayed: Press IP settings, and set according to instruction Set control panel
IP address on page 74. (This must be done, since the older IP setting was deleted during
installation of the new TA150 firmware.) . The firmware is now installed.

8.

Let the panel remain with the menu displayed and the DIP switch in position ON.

9.

Next step is to install the HMI software on the control panel.

4.23 Update HMI software


Follow this instruction to update the HMI software on remote control panels after the PLC software
has been updated, or after the control panel firmware has been updated.
Preparations and conditions

USB with correct version of the software. Note that the same version must be used for the HMI
and PLC software (same version number).

Follow the steps below


If you have installed TA150 firmware on the control panel, go directly to step 4.
1.

At the rear side of the main control panel: Pull out the power cable from the 24V DC port.
Open the small cover on the rear side. Turn DIP switch 1 to position ON.

7BeijerMODE

2.

Re-connect the power cable and wait for the panel to restart. (If the system requests a touch
calibration, perform it.)

3.

Touch the screen to display a menu.

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Book No.9010182 02, rev. 0

Operating instructions

4.24

Calibrate the control panels touch


screen sensibility

4.

Press Erase project in the menu. Answer Yes in the popup. Wait for the popup to close.

5.

At the rear side: Pull out the power cable from the control panel, turn DIP switch 1 to position
OFF.

6.

Insert a USB memory with the HMI software in USB Panel port on the cabinet door. Reconnect
the power.

7.

Wait for the message Copy project from USB. Press Yes.

8.

Wait until the program is started and page 1.1 Overview is displayed. Ignore the message
Disconnected from remote alarm server, it is due to the unconnected Ethernet cable.

9.

Pull out the USB memory.

10. If remote control panels are installed, repeat this instruction for all remote control panels. Do
not forget to update TA150 firmware if needed.
11. Make sure that the CF light on the PLC module is green. (It takes approximately 10 minutes
from the PLC software is loaded.)
12. Insert the Ethernet cable in port IF2 ETH in the PLC module.
13. Restart the system: Shut off the power to the control cabinet using the breaker at the side,
and then turn it on again.

4.24 Calibrate the control panels touch screen


sensibility
Follow this instruction to improve the touch precision on the screen, if it is hard to hit buttons and
icons with precision.
Follow the steps below
1.

Pull out the power cable from the 24V DC port on the rear side of the control panel.

2.

Open the small cover on the rear side. Turn DIP switch 1 to position ON.

7BeijerMODE

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83

4.26

Restore control system settings

Operating instructions

3.

Re-connect the power cable. Wait for a cross is displayed on the screen.

4.

Press the cross until it changes position. Repeat until the menu is displayed again.
Result: Calibration is ready.

5.

Pull out the power cable from the 24V DC port.

6.

Turn DIP switch 1 to position OFF.

7.

Re-connect the power cable.

4.25 Backup control system settings


Follow this instruction to export all settings made in the control system to a backup on a USB
memory. Alsmost the same information is saved as history files, appart from that parameter settings
are saved here and alarms and trend history is saved in the control system history files.
The following information is saved:

Parameter settings. Saved in file Parameters.csv.

Audit trail (tracking of actions in the control system, e.g. acknowledged alarms, changed
parameter values). Saved in file AuditTrail.sdf.

Parameters. It is only possible to restore parameters to the same version of the PLC software
as the back-up was taken from.

Settings for trend pages, e.g. min and max values for different components. Saved in file
ValueTrendLegend.xml.

Notpad.txt. Can be used to make notes for the backup.

Follow the steps below


1.

Go to page 4.1 System info.

2.

Insert a USB memory in USB panel port on the cabinet door.

3.

Press the Backup button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the occur.
Read the final line of list before closing the popup: Important information might be displayed.

4.

Wait for the OK / Close button to turn blue again. If the backup was successful, the last line
shall state "Backup done".
Result: A folder named PureBallast backup has been downloaded containing the backup files.

5.

Remove the USB memory.

4.26 Restore control system settings


Follow this instruction to restore all control system settings, previously saved to a USB memory.
This includes parameters and settings for the trend pages 3.1 3.5.
Preparations and conditions
84

Book No.9010182 02, rev. 0

Operating instructions

4.27

Export control system history files

This operation requires login level Advanced operator or higher.

Parameters can only be restored to the same version of the PLC software.

A USB memory with backup files. When the files where backuped, the backup files where
saved in a folder named PureBallast Backup. For information about backup files, see section
Backup and restore in the page description for 4.1 System info, section on page 38.

This method shall not be used to restore parameter settings after software update. Instead,
follow instruction Update PLC software using a flash card.

If you do not wish to update a certain type of setting, remove the specific file from the USB
memory before inserting the USB memory in the USB panel port on the cabinet door.

Follow the steps below


1.

Go to page 4.1 System info.

2.

Insert a USB memory in USB panel port on the cabinet door.

3.

Press the Restore button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the occur.

4.

Wait for the OK / Close button to turn blue again.

5.

Read the final line of list before closing the popup: Important information might be displayed. If
the restore was successful, the last line shall state "Restore done".

6.

Press the OK button on the popup and remove the USB memory.

7.

The control panel must be rebooted. At the rear side of the control panel: Pull out the power
cable from the 24V DC port, and insert it again.

4.27 Export control system history files


Follow this instruction to export all settings made in the control system to a backup on a USB
memory. Alsmost the same information is saved as history files, appart from that alarms and trend
history is saved here and parameter settings are saved in the control system settings.
The following information is saved:

Database, including alarm history, trend history etc. Saved in file Database.sdf.

Audit trail (tracking of actions in the control system, e.g. acknowledged alarms, changed
parameter values). Saved in file AuditTrail.sdf.

Settings for trend pages, e.g. min and max values for different components. Saved in file
ValueTrendLegend.xml.

Notpad.txt. Can be used to make notes for the backup.

Preparations and conditions

This operation requires login level Operator or higher.

Follow the steps below


1.

Go to page 4.1 System info.

2.

Insert a USB memory in USB panel port on the cabinet door.

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85

4.28

PID calibrate system

Operating instructions

3.

Press the Backup button in page section Backup and restore, History to HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the
occur. Be sure to read the final line of list before closing the popup: Important information
might be displayed.

4.

When the message Export done is displayed, press the OK button on the popup.
Result: A folder called PureBallast Export is created on the USB memory.

5.

Remove the USB memory.

4.28 PID calibrate system


PID calibration is performed to fine tune the system so it runs with a steady and even flow and
pressure.
During ballast and deballast operation, the control valve is PID regulated based on input from the
flow transmitter FIT201-1 to maintain stable flow. Desired flow is defined as selected certified flow
for the operation minus the Undershoot percentage set in parameter p111.
During backflush, the control valve is PID regulated based on input from the pressure transmitter
PT201-16 to maintain stable pressure for efficient backflush. Desired pressure is defined in
parameter p304.

4.28.1 Calibrate pressure controlled regulation


The purpose is to adjust the movement of V201-8 when it changes from flow controlled regulation to
pressure controlled regulation which it does during backflushing of the filter. The first goal is that
the valve travels as fast as possible to a steady position where it creates required pressure (as
defined in parameter p304).
The second goal is to shorten the time from backflush trigger to start of actual backflush. This is
done by shortening the time in p310 (Backflush initial delay) that is done after the movement of
V201-8 has been calibrated.
Preparations and conditions

This operation requires login level AlfaLaval.

All components on page 3.1 Trend (15 min) shall be selected for plotting, and FIT201-1 shall be
used for Y axis selection.

Follow the steps below:


This instruction shall be read together with the example after the instruction.
1. Perform a backflush.
2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8.
Before the backflush, the valve shall move as fast as possible to a steady position where it
creates required pressure. If not, parameter p166 shall be adjusted.
3. Adjust parameters, and perform a new backflush.
4. See if the curve has improved. Repeat until satisfactory result has been achieved.

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Operating instructions

4.28

PID calibrate system

5. See if the time between backflush initiation and backflush can be shortened . If possible, adjust
parameter p310. See parameter p310 in the example below.
Example
In this example, five backflushes are performed. After the first four backflushes, the PID parameters
where changed for pressure regulation to adjust the movement of the control valve V201-8 before
the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated by the movement
of the backflush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated
by the blue line.
1st backflush

Parameter p166 is set to 0.30. But it takes too long time for V201-8 to get into
position to create desired pressure (1). The curve slops downwards in a long bend,
which means that it takes time for V201-8 to find correct position.
2nd backflush Parameter p166 was adjusted to 0.6. This made the valve movement much faster
in the beginning, shown by the steep curve at the beginning. But then a more slow
regulation starts, shown by the soft slope (2). This was a change for the better, but
not enough.
3rd backflush Parameter p166 was increased to 1.2 which resulted in a satisfactory valve
movement (3): A fast movement, followed by a minor adjustment. A small
overcompensation can be noted (curve goes too low), that might be adjusted by
decreasing the value to 1.1.
4th backflush During the first backflushes, parameter p310 was set to 60 seconds. The parameter
defines time between a backflush is triggered and it actually starts. But now, when
V201-8 is calibrated, this time can be shortened. Before the fourth backflush
parameter p310 is set to 15 seconds. The shortened time span is indicated by
the braces in the illustration.
5th backflush No parameter was changed. This backflush is only showed to confirm that the
parameter setting is OK and that the curve (5) for V201-8 is basically the same as
for backflush three and four (3 and 4).

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4.28

PID calibrate system

Operating instructions

3 CalibExample

88

Book No.9010182 02, rev. 0

5 List of logged information


Alarm history and important events are logged in the control system. The log also include
components connected via the log box (optional).
The control system store all alarms and relevant events for at least 24 months. The memory has
a vast safety margin but when it is full, data will be deleted starting with the oldest data. Logged
information can be exported to a USB memory stick. See Export control system log files on page 72.
Event log certificate: Contains events relevant to the IMO certificate. These events are stored
for 24 months. Events included are equal to the events that are GPS stamped in the table below,
with exception for events regarding the log box (50105220).

5.1

Event log

The table below shows which information that is saved in the log file.
The GPS stamp column indicates if the event is stamped with GPS position (Y=yes, N=no).
Event
code

Description

GPS
stamp

10 Operator command, start Ballast is issued

20 Operator command, start deballast is issued

30 Operator command, start CIP is issued

40 Operator command, stop process is issued

50 Operator command, initiate pause is issued

60 Operator command, resume from pause is issued

70 Operator command, set certified flow to [x] m3/h

100 PureBallast is set in mode Manual by operator

110 Heeling (internal transfer) mode request issued by external

120 Heeling (internal transfer) mode request cancelled by external

130 Additional (external) bypass of PureBallast is detected open

140 Additional (external) bypass of PureBallast is detected closed

150 Feedback received, "overboard valve is OPEN"

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5.1

Event log

Event
code

90

List of logged information

Description

GPS
stamp

160 Feedback received, "BW-pump is running"

170 External Shutdown of PureBallast issued

190 PureBallast is in mode Standby

210 PureBallast is in mode Start-up Ballast

220 PureBallast is in mode Full Ballast

230 PureBallast is in mode Pause Ballast

240 PureBallast is in mode Backflush

250 PureBallast is in mode Stop Ballast

260 PureBallast is in mode Start-up Deballast

270 PureBallast is in mode Full Deballast

280 PureBallast is in mode Pause Deballast

290 PureBallast is in mode Stop Deballast

300 PureBallast is in mode CIP, AOT [x, y, z ...]


x, y, z ...= units that has been subjected to CIP

310 PureBallast is in mode E-stop

320 PureBallast has been powered off for [x]days:[y]hrs:[z]min


Time of how long the power has been switched off

330 Amount (m3) of ballast intake treated according to standard

331 Amount (m3) of ballast intake treated. Time interval according to


parameter p161.

340 [X] m3 of ballast discharge treated according to standard

341 [X] m3 of ballast discharge treated. Time interval according to


parameter p162.

350 V212-31 bypass valve in open position

360 V212-31 bypass valve in closed position

370 Request sent to ISCS; open overboard/outlet valve

380 Request cancelled to ISCS; open overboard/outlet valve

390 Request sent to ISCS; start BW-pump

400 Request cancelled to ISCS; start BW-pump

N
Book No.9010182 02, rev. 0

List of logged information

Event
code

Description

5.1

Event log

GPS
stamp

410 Power requested sent

420 Power granted received

430 Power running sent

450 Pure Ballast is shut down due to failure

460 Additional (external) bypass 1 is detected open

470 Additional (external) bypass 1 is detected closed

480 Additional (external) bypass 2 is detected open

490 Additional (external) bypass 2 is detected closed

500 Additional (external) bypass 3 is detected open

510 Additional (external) bypass 3 is detected closed

520 AOT 1 UV sensor low level

530 AOT 2 UV sensor low level

540 AOT 3 UV sensor low level

640 AOT 1 UV sensor value: [X] W/m2

650 AOT 2 UV sensor value: [X] W/m2

660 AOT 3 UV sensor value: [X] W/m2

700 AOT1 LPS power % to UV lamps

710 AOT2 LPS power % to UV lamps


720 AOT3 LPS power % to UV lamp
1152

AOT1 UV intensity low. System flow reduced.

1153

AOT1 UV lamp fail. System flow reduced.

2153 AOT2 UV lamp fail. System flow reduced.


5010 Log box: Valve V01 position change: [X]. 1=Closed. 0=Not closed.

5011 Log box: Valve V01 position change: [X]. 1=Open. 0=Not open.

5020 Log box: Valve V02 position change: [X]. 1=Closed. 0=Not closed.

5021 Log box: Valve V02 position change: [X]. 1=Open. 0=Not open.

5030 Log box: Valve V03 position change: [X]. 1=Closed. 0=Not closed.

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91

5.1

Event log

Event
code

List of logged information

Description

GPS
stamp

5031 Log box: Valve V03 position change: [X]. 1=Open. 0=Not open.

5040 Log box: Valve V04 position change: [X]. 1=Closed. 0=Not closed.

5041 Log box: Valve V04 position change: [X]. 1=Open. 0=Not open.

5050 Log box: Valve V05 position change: [X]. 1=Closed. 0=Not closed.

5051 Log box: Valve V05 position change: [X]. 1=Open. 0=Not open.

5060 Log box: Valve V06 position change: [X]. 1=Closed. 0=Not closed.

5061 Log box: Valve V06 position change: [X]. 1=Open. 0=Not open.

5070 Log box: Valve V07 position change: [X]. 1=Closed. 0=Not closed.

5071 Log box: Valve V071 position change: [X]. 1=Open. 0=Not open.

5080 Log box: Valve V08 position change: [X]. 1=Closed. 0=Not closed.

5081 Log box: Valve V08 position change: [X]. 1=Open. 0=Not open.

5090 Log box: Valve V09 position change: [X]. 1=Closed. 0=Not closed.

5091 Log box: Valve V09 position change: [X]. 1=Open. 0=Not open.

5100 Log box: Valve V10 position change: [X]. 1=Closed. 0=Not closed.

5101 Log box: Valve V10 position change: [X]. 1=Open. 0=Not open.

5110 Log box: Valve V11 position change: [X]. 1=Closed. 0=Not closed.

5111 Log box: Valve V11 position change: [X]. 1=Open. 0=Not open.

5120 Log box: Valve V12 position change: [X]. 1=Closed. 0=Not closed.

5121 Log box: Valve V12 position change: [X]. 1=Open. 0=Not open.

5130 Log box: Valve V13 position change: [X]. 1=Closed. 0=Not closed.

5131 Log box: Valve V13 position change: [X]. 1=Open. 0=Not open.

5140 Log box: Valve V14 position change: [X]. 1=Closed. 0=Not closed.

5141 Log box: Valve V14 position change: [X]. 1=Open. 0=Not open.

5150 Log box: Valve V15 position change: [X]. 1=Closed. 0=Not closed.

5151 Log box: Valve V15 position change: [X]. 1=Open. 0=Not open.

5160 Log box: Valve V16 position change: [X]. 1=Closed. 0=Not closed.

5161 Log box: Valve V16 position change: [X]. 1=Open. 0=Not open.

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List of logged information

Event
code

Description

5.1

GPS
stamp

5170 Log box: Valve V17 position change: [X]. 1=Closed. 0=Not closed.

5171 Log box: Valve V17 position change: [X]. 1=Open. 0=Not open.

5180 Log box: Valve V18 position change: [X]. 1=Closed. 0=Not closed.

5181 Log box: Valve V18 position change: [X]. 1=Open. 0=Not open.

5190 Log box: Pump 01 operation change: [X]. 1=Running. 0=Not


running.

5200 Log box: Pump 02 operation change: [X]. 1=Running. 0=Not


running.

5210 Log box: Pump 03 operation change: [X]. 1=Running. 0=Not


running.

5220 Log box: Pump 03 operation change: [X]. 1=Running. 0=Not


running.

Book No.9010182 02, rev. 0

Event log

93

5.1

Event log

List of logged information

6 Detailed process description


This section gives a detailed description of the PureBallast processes. The processes are divided
into three main processes, with sub processes, with indications of automatic and manually initiated
steps.
All steps are not valid for all installations.

6.1

Standby mode

Standby mode is the starting point of PureBallast. Standby mode is active at system start-up or
when no other process is active. From Standby mode, the following processes and sub processes
can be started.

Ballast

Deballast

CIP

Deactivate system

Change flow (set flow before a ballast or deballast process)

Manual mode.

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95

6.2

Ballast process

6.2

Detailed process description

Ballast process

The ballast process and sub processes are illustrated and described below. Note that the process
can be stopped at any time.

3 BallastProcess

6.2.1

Ballast start-up

Purpose: To warm UV lamps under controlled conditions before water treatment.


1.

Operator starts the process from the control system.

2.

Request from control system to open overboard (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)

3.

Overboard valve opened by operator and confirmed in control system. (Handled automatic, if
external component signal is enabled.)
Component activities:

4.

96

- Start P401-1 (booster pump for LDC cooling water) (if used)
- Open V403-35 (cooling water inlet)
- Open V201-32 (filter outlet)

Start P403-1 (booster pump for reactor cooling water) (if used).

Power management
Automatic power request from PureBallast to vessels power management system (if
integrated).

Book No.9010182 02, rev. 0

Detailed process description

5.

6.2

Ballast process

UV lamp warming
Component activities:

6.

Open V404-36 (AOT reactor outlet, cooling water)

Open V201-19 (reactor inlet).

Start counter: CIP required.

Cooling water fills the AOT reactors. When filled, indicated by LS201-29:

Start UV lamps (100 %).

Start counter: UV lamp runtime.

Start LDC fan.

Open V201-20 (reactor outlet)

Set V201-8 (control valve) to 50 %.

7.

Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)

8.

Ballast water pump started by operator and confirmed in control system.

9.

Open V201-3 (filter inlet).

6.2.2

Full ballast

Purpose: To treat ballast water.


1. Component activities:

- Start counter: Accumulated water


- Stop P403-1 (booster pump for reactor cooling water) (if used)

- Close 403-35 (cooling water inlet)


- Close V404-36 (AOT reactor outlet, cooling water)
- When flow is established: Start automatic control of control valve (V201-8) based on
input from the flow meter.

After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT20150.

6.2.3

Filter backflush

Purpose: To clean the filter when clogged. This sub process is either triggered by too high
differential pressure or by time set interval. It can also be started manually. It is normally repeated
several times during a ballast process.
1. Filter backflush triggered by high differential pressure over filter.
Component activities:

Start automatic control of control valve (V201-8) based on input from the pressure transmitter

Open V309-1

Start M709-42.

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97

6.2

Ballast process

Detailed process description

2. Filter backflush is performed (1-100 seconds).


Component activities:

Stop M709-42

Close V309-1

Start automatic control of control valve (V201-8) based on input from the flow meter.

3. Differential pressure check. If necessary, the process is repeated.

6.2.4

Pause ballast (Heeling mode)

Purpose: To pause the ballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
1. Operator pause the ballast process manually. Pause can also be initiated by an external signal,
for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
2. Set V201-8 (control valve) to parameter (p113) set opening percent.
3. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
4. BW pump stopped by operator and confirmed in control system. Component activities:

- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- Stop counter: Accumulated water
- Open V403-35 (cooling water inlet)

Start P403-1 (booster pump for reactor cooling water) (if used)
- Close V201-3 (filter inlet)
- Close V201-20 (reactor outlet) on running AOT reactors
- UV lamps dimmed to 50 %

Close V201-8 (control valve).

5. System in pause mode


6.

Resume ballasting
Operator resumes the ballast process manually.
Component activities:

Set V201-8 (control valve) to parameter set opening percent

UV lamps are lit at 100 %

Open V201-20 (reactor outlet) on running AOT reactors.

7. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8. BW pump started by operator and confirmed in control system. (Handled automatic, if external
component signal is enabled.)

98

Open 201-3 (filter inlet)

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Detailed process description

6.2

Ballast process

9. Component activities when minimum process flow established, indicated by FIT201-1:

- Start counter: Accumulated water.


- Stop P403-1 (booster pump for reactor cooling water) (if used)

- Close 403-35 (cooling water inlet)


- Close V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- Start automatic control of control valve (V201-8) based on input from the flow meter.
- After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT20150.

6.2.5

Stop ballast

Purpose: To stop the ballast process.


1. Operator stops the ballast process manually.
Component activities:

Stop P401-1 (booster pump for LDC cooling water) (if used)

Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from
pause mode

Stop counter: Accumulated water

- Close V403-35 (cooling water inlet), only needed if stop from pause mode
- Set V201-8 (control valve) to parameter set opening percent.
- Close V201-32 (filter outlet) Delay: the longes time between of p146 and p119.

UV lamps are lit at 100 % for 10 seconds, then switched off.

Stop counter: UV lamp runtime

- Close V201-19 (reactor inlet)


- Close V201-20 (reactor outlet)

Automatic withdrawal of power allocation (if integrated).

2. Filter backflush
Backflushing of filter starts, including the following activities:

- Start automatic control of control valve (V201-8) based on input from the pressure
transmitter
- Open V309-1
- Start M709-42.

3. Backflush is performed. Approximate duration: 20 seconds.

- Stop M709-42
- Close V309-1.

4. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
5. BW pump stopped by operator and confirmed in control system.

- Close V201-8 (control valve)


- Close V201-3 (filter inlet).

6. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)

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6.3

Deballast process

6.3

Detailed process description

Deballast process

The deballast process and sub processes are illustrated and described below. Note that the
process can be stopped at any time.

3 DeBallastProcess

6.3.1

Deballast start-up

Purpose: To warm UV lamps under controlled conditions before water treatment.


1. Operator start the deballast process manually.
2. Request from control system to open overboard valve (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. Overboard valve opened by operator and confirmed in control system.
Component activities:

- Start P401-1 (booster pump for LDC cooling water) (if used)
- Open V403-35 (cooling water inlet)

Start P403-1 (booster pump for reactor cooling water) (if used).

4. Power management
Automatic power request from PureBallast to vessels power management system (if integrated).

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Detailed process description

6.3

Deballast process

5. UV lamp warming
Component activities when power has been granted:

Open V404-36 (AOT reactor outlet, cooling water)

Open V201-19 (reactor inlet).

Start counter: CIP required.

6. Water fills the AOT reactors.


7. Component activities, when AOT reactors are filled, indicated by LS201-29:

Start UV lamps (100 %).

Start counter: UV lamp runtime.

Start LDC fan.

Open V201-20 (reactor outlet)

Set V201-8 (control valve) to 50 %.

8. Request from control system to start ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
9. BW pump started by operator and confirmed in control system.
Component activities:

6.3.2

Open V201-9 (main inlet valve).

Full deballast

Purpose: To treat deballast water.


1. Component activities when minimum process flow established, indicated by FIT201-1:

- Start counter: Accumulated water.


- Stop P403-1 (booster pump for reactor cooling water) (if used)

- Close 403-35 (cooling water inlet)


- Close V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- When flow is established: Start automatic control of control valve (V201-8) based on
input from the flow meter.

After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT20150.

6.3.3

Pause deballast (Heeling)

Purpose: To pause the deballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).

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101

6.3

Deballast process

Detailed process description

1. Operator pause the deballast process manually. Pause can also be initiated by an external
signal, for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
Component activities:

Set V201-8 (control valve) to parameter set opening percent

Open V403-35 (cooling water inlet)

- Start P403-1 (booster pump for reactor cooling water) (if used)
- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors.

2. Request from control system to stop ballast water pump (outside the PureBallast system
control). (Handled automatic, if external component signal is enabled.)
Component activities:

Stop counter: Accumulated water


Close V201-9 (main inlet valve)
Close V201-8 (control valve)
Close V201-20 (reactor outlet) on running AOT reactors
UV lamps dimmed to 50 %.

3. System in pause mode


4. Resume deballasting
Operator resume the deballast process manually.
Component activities:

Set V201-8 (control valve) to parameter set opening percent.

UV lamps are lit at 100 %

Open V201-20 (reactor outlet) on running AOT reactors.

5. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
6. BW pump started by operator and confirmed in control system.
Component activities:

Open V201-9 (main inlet valve)

7. Component activities when minimum process flow established, indicated by FIT201-1:

- Start counter: Accumulated water.


Stop P403-1 (booster pump for reactor cooling water) (if used)

- Close 403-35 (cooling water inlet)


- Close 404-36 (AOT reactor outlet, cooling water)
- Start automatic control of control valve (V201-8) based on input from the flow meter.
- After 2 minutes in full deballast: Start power optimization based on input from UV sensor
QT20150.

6.3.4

Stop deballast

Purpose: To stop the deballast process.

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Detailed process description

6.4

CIP process

1. Operator stops the ballast process manually.


Component activities:

Stop P401-1 (booster pump for LDC cooling water) (if used)

Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from
pause mode

Close V403-35 (cooling water inlet), only needed if stop from pause mode

Set V201-8 (control valve) to parameter set opening percent

Close V201-9 (main inlet valve) Wait for feed back closed or delay according to p 115.

UV lamps are lit at 100 % for 10 seconds, then switched off.

Stop counter: UV lamp runtime

- Close V201-19 (reactor inlet)


- Close V201-20 (reactor outlet)

2. Request from control system stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. BW pump stopped by operator and confirmed in control system.

Automatic withdrawal of power allocation (if integrated)

Close V201-8

Stop counter: Accumulated water.

4. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)

6.4

CIP process

The CIP process is run to remove seawater scaling from the AOT reactor after ballast and deballast.
The process is performed for used AOT reactor in sequence. The process can start directly
after ballast or deballast process, or be delayed. A CIP process is started manually according
to instruction CIP clean AOT after ballast / debalalst on page 65. Note that the process can be
stopped at any time.

Book No.9010182 02, rev. 0

103

6.4

CIP process

Detailed process description

3 CIPprocess

6.4.1

Start CIP

1. Operator starts the CIP process manually.


2. Request from control system to open overboard valve (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. Overboard valve opened by operator and confirmed in control system.

6.4.2
1.

Component activities (in no specific order):

104

Drain ballast water

Open V460-2 (CIP, drain valve)


Open V3212 (AOT reactor, upper CIP return valve)
Open V3204 (AOT reactor, lower CIP return valve)
Open V571-1 (CIP, deaeration valve)
Start P321-5 (CIP, water pump)

Book No.9010182 02, rev. 0

Detailed process description

6.4

CIP process

2. Component activities, when AOT reactors are empty, indicated by LS201-29:

6.4.3
1.

Stop P321-5
Close V571-1 (CIP, deaeration valve)
Close V460-2 (CIP, drain valve)
Close V3212 (AOT reactor, upper CIP return valve)
Close V3204 (AOT reactor, lower CIP return valve).

Fresh water filling

Component activities:

Open V571-1 (CIP, deaeration valve)


Open V310-6 (CIP, AOT reactor fresh water filling)
Open V3212 (AOT reactor, upper CIP return valve)
Open V3204 (AOT reactor, lower CIP return valve).

2. Component activities, when AOT reactors are filled, indicated by LS201-29:

6.4.4

Close V310-6 (CIP, AOT reactor fresh water filling)


Close V571-1 (CIP, deaeration valve)
Close V3212 (AOT reactor, upper CIP return valve)
Close V3204 (AOT reactor, lower CIP return valve).

Fresh water draining

1. Component activities:

Open V460-2 (CIP, drain valve)


Open V571-1 (CIP, deaeration valve)
Open V3212 (AOT reactor, upper CIP return valve)
Open V3204 (AOT reactor, lower CIP return valve)
Start P321-5 (CIP, water pump).

2. Component activities when AOT reactor is empty, indicated by LS201-29 + drain time (p200):

6.4.5

Stop P321-5 (CIP, water pump)


Close V571-1 (CIP, deaeration valve)
Close V460-2 (CIP, drain valve)
Close V3212 (AOT reactor, upper CIP return valve)
Close V3204 (AOT reactor, lower CIP return valve)

CIP cleaning

1. Component activities:

Open V3202 (CIP outlet to AOT reactor)


Open V320-4 (AOT reactor, lower CIP return valve)
Open V321-2 (AOT reactor, upper CIP return valve)
Open 3214
Start P320-1 (CIP, liquid pump).

2. When AOT reactors are filled, indicated by LS201-29, CIP liquid is circulated for 15 minutes.
Book No.9010182 02, rev. 0

105

6.4

CIP process

Detailed process description

3. Component activities after finished CIP process .

6.4.6

Stop P320-1 (CIP, liquid pump)


Close V320-2 (CIP outlet to AOT reactor)
Close V320-4 (AOT reactor, lower CIP return valve)
Status update for the AOT reactor: CIP completed.

CIP draining

1. Component activities:

Open V321-4 (CIP, return valve)


Open V3211 (CIP, outlet valve)
- Open V321-2 (AOT reactor, upper CIP return valve)
- Open V320-4 (AOT reactor, lower CIP return valve)
- Start P321-5 (CIP, water pump).

2. Component activities, when AOT reactor is empty, indicated by LS201-29 + drain time (p200):

6.4.7
1.

Stop P321-5 (CIP, water pump)


Close V321-2 (AOT reactor, upper CIP return valve)
Close V 321-4 (CIP, return valve)
Close V321-1 (CIP, outlet valve).

Fresh water filling

Component activities:

Open V571-1 (CIP, deaeration valve)


Open V310-6 (CIP, AOT reactor fresh water filling)
Open V321-2 (AOT reactor, upper CIP return valve)
Open V320-4 (AOT reactor, lower CIP return valve).

2. Component activities, when AOT reactor is filled, indicated by LS201-29:

Close V310-6 (CIP, AOT reactor fresh water filling)

Close V571-1 (CIP, deaeration valve)


- Close V321-2 (AOT reactor, upper CIP return valve)
- Close V320-4 (AOT reactor, lower CIP return valve).

6.4.8

Repeat

When CIP process is done for the first AOT reactor, the remaining AOT reactors with status CIP
required are processed in the same way.

6.4.9

Filter preservation

Only performed if ballast has been performed since last filter preservation.

106

Book No.9010182 02, rev. 0

1.

Detailed process description

6.5

Manual mode

Component activities when all required AOT reactors are processed:

- Open V310-1
- Open V309-1
- Start M709-42.

2. Component activities after the filter is filled:

- Stop M709-42
- Close V309-1
- Close V310-1.

3. Request from control system to close overboard valve (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
4. Overboard valve closed by operator and confirmed in control system.

6.5

Manual mode

PureBallast can be set in manual mode, which enables the operator to operate components
manually and to set digital outputs.
The following can be performed in manual mode:

Operate components from the flow chart. Tap a component to operate it from the displayed
popup window. The following components can be operated: valves, motors, UV lamps etc,
digital output signals.

Operate and simulate power management.

The following limitations exist for manual mode:

Requires login level 2. The Manual mode button is only displayed for login level 2.

Flow in pipes is not indicated in flow chart.

Can only be activate from standby mode.

No automatic processes can be run.

To activate: Press the Manual mode button in page 1.1 Flow chart and follow the instructions
Operate UV components manually and Operate UV lamps manually.
To deactivate: Press the Manual mode button again in page 1.1 Flow chart or log out. All forced
outputs and manual changes are reset and the system goes to Standby mode.

Book No.9010182 02, rev. 0

107

1 Quick guide to PureBallast


operations
1.1

Introduction

This is a quick guide to the most common routines performed in the PureBallast control system.
More detailed instructions are found in the PureBallast manual.
This guide covers the following routines:

Ballast and deballast

CIP clean AOT

Basic alarm handling

Save log file and parameters to USB memory

Preparations and conditions

The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.

Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.

There must be available power for the system. If power management is integrated, this will be
done automatically. If power management is not integrated, confirm this manually.

1.2

Ballast and deballast

Follow the steps below


1.

Go to page 1.1 Overview

2.

Press the Ballast or Deballast function button.


Comment: If the button is not blue, check that flow or AOT reactors have been selected

3.

Wait for the message Open valves .... Open relevant valves and then press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)

4.

Wait for the message Confirm ballast pump started. Start the pump and then press the button
in the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)

5.

When desired amount of water has been processed, press the function button Stop to end
the process.

Book No.9010182 02,

rev. 0

1.4

CIP clean AOT

Quick guide to PureBallast operations

6.

Wait for the message Close valves ... and Stop ballast water pump. Handle accordingly.
(The popups are not displayed if the component feedback is integrated with the control system.)

7.

Perform a CIP process if no operation is planned soon. A CIP process must be performed
within 30 hours after operation.

1.3

Alarm handling

Follow this instruction to attend to alarms and to acknowledge them afterwards. For descriptions of
alarms and trouble shooting, see chapter 5. Alarms and fault finding.
An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.
Preparations and conditions

Never reset an alarm without first finding and attending to the problem.

Follow the steps below:


1.

Go to page 2.1 Alarm list.

2.

Select an alarm by pressing the alarm row.

3.

If the process have stopped: Take action to eliminate what has caused the alarm.

4.

If the alarm is caused by a faulty AOT module, the ballast/deballast process has to be restarted
with another AOT according to the Perform ballast instruction.

5.

If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
Press the Ack selected or Ack all button after the problem has been dealt with.

1.4

CIP clean AOT

Preparations and conditions

The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.

Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOTs are
required to be CIP:ed etc.

Follow the steps below


1.

Go to page 1.1 Overview.

2.

Press the function button CIP.

3.

Wait for the message Open valves .... Open relevant valves and then press button in the
popup to confirm the action.
Result: The automatic CIP cycle starts. The CIP cycle takes about 25 minutes per AOT.

Book No.9010182 02

, rev. 0

4.

Quick guide to PureBallast operations

1.5

Export control system log files

Wait for the message Confirm overboard valve closed. Close the valve and then press button
in the popup to confirm the action.

1.5

Export control system log files

Follow this instruction to copy control system information as text files to a USB memory.
Preparations and conditions

Required USB memory.

Follow the steps below:


1.

Go to page 4.1 System info.

2.

Press the Export button in page section Export log files.


Result: Popup Export PLC events is displayed.

3.

Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.

4.

Chose one of the following alternatives to decide time interval for the information to be copied:

Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is todays date.

Select the Specify time interval box, and enter desired interval in the Start and End fields.

5.

Press one of the following function buttons: Events, Cert events or Alarms.
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.

6.

Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been downloaded. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choice contains a CSV file.

7.

Prtess Close and remove the USB memory

Book No.9010182 02,

rev. 0

Chapter: 4. Parameters
System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1

Introduction

Control system parameters

2.1

Setting parameters

2.2

Introduction to the parameter pages

2.3

Set parameters

2.4

Page 5.1 Main parameters 1

10

2.5

Page 5.2 Main parameters 2

14

2.6

Page 5.3 AOT parameters

18

2.7

Page 5.4 Filter parameters

22

2.8

Page 5.5 CIP parameters

25

2.9

Page 5.6 Installation parameters

26

2.10

Page 5.7 Remote interface

29

Flow transmitter parameters

31

3.1

32

Check and set parameters

Lamp power supply (LPS)


parameters

35

4.1

DIP switch settings

35

4.2

Change DIP switch setting

36

1 Introduction
This chapter contains information about parameters in the control system and flow transmitter.
It covers:

Parameter page descriptions.

Parameter lists including information about setting range, default values etc.

Book No.9010182 02, rev. 0

Introduction

2 Control system parameters


This section describes all parameters set in the PureBallast control system.
Preparations and conditions

Parameters shall only be set when the system is in mode Standby.

Only authorized trained personnel must set parameters in the control system both manual
operations and parameter settings. The PureBallast equipment or connected equipment can be
irreparably damaged if set or handled incorrectly.
NOTE

To change system parameters, at least login level 2 Advanced operator is required. To get
full access, login level 3 AlfaLava is required.

The parameter settings can be exported to a USB memory for safety backup, and be restored
from a backup. See chapter 3. Operating instructions and control system description for
instructions.
Parameters are valid for PLC software version V3.0.2.

2.1

Setting parameters

General (non-installation specific) parameters are preset to function for all systems. They must only
be adjusted, by Alfa Laval (or authorized trained personnel), if required by performance reasons
or similar.
The installation specific parameters are set to reflect the specific installation and shall normally only
be checked and adjusted at first start up, during preparations for commissioning.
The installation specific parameters are found in the pages listed below:

Page 5.1 Main parameters 1.


-

p126: LDC after-cooling.

p140p144: Time-out for requests from PureBallast.

Page 5.2 Main parameters 2.


-

All parameters on the page, except p168.

Page 5.3 AOT parameters:


-

p200, p201, p208 and p216: Time-out parameters for draining and filling AOT reactor.
These parameter are evaluated during the commissioning preparation test and adjusted if
necessary.

Book No.9010182 02, rev. 0

2.3

Set parameters

Control system parameters

Page 5.4 Filter parameters:

p304: Required pressure to start backflush (PT20116). This parameter is calculated to


reflect pressure in the specific installation.

p314: Filter type.

p306: Filter preservation time. This parameter is evaluated during the commissioning
preparation test and adjusted if necessary.

p315: Filter size. Defines maximum capacity for installed filter.

Page 5.6 Installation parameters.


-

All parameters on the page, except p218 (Estimated UV lamp time) .

2.2

Introduction to the parameter pages

This section describes the principles for the control system parameters and the parameter pages.
Parameters are roughly sorted by area, for example AOT reactor, filter and remote interface,
but the sorting is not strict.
Key to parameter numbers
Control system parameters are identified by item numbers with the following syntax: pX00.
p

stands for parameter

identifies the area/component the parameter controls. X can be


1 = Main parameters
2 = AOT reactor
3 = Filter
4 = CIP

00

unique number for the parameter.

2.3

Set parameters

Follow this instruction to set or change parameters.


Preparations and conditions
NOTE

Parameters shall only be set by Alfa Laval.

These instructions require login level 2 or 3. Level 2 gives access to set parameters, with
exception from crucial parameters, which requires level 3.

Follow the steps below:


1.

Go to desired parameter page 5.15.7.


Result: The page is displayed with all parameters listed with current setting and unit.

Book No.9010182 02, rev. 0

2.

Control system parameters

2.3

Set parameters

To see allowed range (maximum and minimum values) and change setting, press the blue
button (with the parameter ID). A button pair is displayed.

4 ParaIntervalSet

Press the sign to display range. Entered parameter value must be within defined setting
range.

4 MinMax

3.

To set parameter, press 3.14 button.


Result: A keyboard is displayed.

4.

Enter the setting and confirm by touching the Enter button. To close the keyboard without
saving data, touch the Esc button.
If the parameter is set with a drop down menu, select desired choice by touching the value.
Result: The setting is saved directly, it is now safe to leave the page.

Book No.9010182 02, rev. 0

2.4

Page 5.1 Main parameters 1

2.4

Control system parameters

Page 5.1 Main parameters 1

This section describes the main system parameters set in page 5.1 Main parameters 1.

4 5.1

The following information is displayed:


ID

Parameter

p100

High pressure,
shutdown trigger
(PT201-16)

Default
value

MinMax

Unit

Description

7.00

110

bar

Setpoint for shut down due to high


pressure at PT201-16. Default value
shall be used.
(7 bar = 0.7 MPa)

p101

10

High pressure,
warning trigger
(PT201-16)

6.00

010

bar

Setpoint for warning due to high pressure


at PT201-16. Default value shall be used.
(6 bar = 0.6 MPa)

Book No.9010182 02, rev. 0

Control system parameters

2.4

Page 5.1 Main parameters 1

ID

Parameter

Default
value

MinMax

Unit

Description

p103

Low pressure,
warning trigger
(PT20116)

0,0

-12

bar

Setpoint for warning due to low pressure


at PT201-16.

p105

Transition trigger,
ballast flow
established
(FIT201-1)

p111

Undershoot
certified flow

p113

Min % open for


V201-8

(1 bar = 0.1 MPa)


50

10
500

m3/h

Defines which flow that must be


established, before the process goes
from ballast start-up to full ballast.

080

Safety margin between defined max


flow and actual max flow to avoid
unnecessary shut down.

20

10100 %

During ballast and deballast, valve


V2018 handles the automatic pressure
and flow control.
This parameter defines minimum
opening, to secure an even flow without
interruptions.
Min position during backflush is set in
p312.

p115

Maximum travel
time for valves

10

230

sec

Maximum time for V2013 and V2019


to go from opened to closed, and vice
versa, before a warning is issued.
Default value shall be used.

p116

Low flow, warning


trigger (FIT201-1)

10

1090

Set point for low flow warning, defined as


percent of certified flow.
This parameter shall be > 10 % to obtain
efficient cooling.

p117

Max delay of CIP


cycle, hours

024

hrs

Define max delay, in hours, before a CIP


process must be performed after ballast
or deballast. Default value shall be used.

p118

Max delay of CIP


cycle, days

030

day

Define max delay, in days, before a CIP


process must be performed after ballast
or deballast. Default value shall be used.

p119

Valve travelling
time for 201-8

110

sec

Maximum time for V2018 to go from


opened to closed, and vice versa, before
a warning is issued.

Book No.9010182 02, rev. 0

11

2.4

Page 5.1 Main parameters 1

ID

Parameter

p120

V2018 PID
proportional gain

Default
value
0.30

Control system parameters

MinMax

Unit

Description

0.00
10.00

N/A

Defines proportional gain (Pf) value used


for PID regulation of V2018 during
ballast and deballast.
Normal value: 0.1 1.5.
The PID regulation during ballast and
deballast is based on input from flow
transmitter FIT2011.

p121

V2018 PID
integral time

7.00

0100

sec

Defines integral time (If) value used for


PID regulation of V2018 during ballast
and deballast.
Normal value: 5 12.
For details, see p120.

p122

V2018 PID
derivative gain

0.0

0.0100.0N/A

Defines derivate gain (Df) value used for


PID regulation of V2018 during ballast
and deballast.
Normal value: 0.
For details, see p120.

p126

LDC after-cooling.
(Stop delay for
401-1, if installed)

060

min

Defines how long after a ballast or


deballast process the booster pump shall
run to cool the LDC.
Only used if parameter p129 is set to
Activated.

p138

Timeout: Time
in Pause before
going to Stop

130

min

Defines maximum time a ballast and


deballast process can be manually
paused. After defined time, the process
is stopped.

p140

Timeout:
Request "Confirm
overboard valve
open"

130

min

Time the control system will wait for


confirmation signal from ISCS, hard
wire or manually in popup before
displaying message that operation was
not performed.

p141

Timeout: Request
"Confirm ballast
pump started"

130

min

Time the control system will wait for


confirmation signal from ISCS, hard
wire or manually in popup before
displaying message that operation was
not performed.

12

Book No.9010182 02, rev. 0

Control system parameters

ID

Parameter

p143

Timeout: Power
granted signal not
received

2.4

Default
value
60

Page 5.1 Main parameters 1

MinMax

Unit

Description

1300

sec

Time the control system will wait for


confirmation signal from ISCS that the
operation was performed.
Only used if parameter p127 is set to
Activated (Hardwire ranged or fixed).

60

30300 sec

p144

Timeout: Start-up
ballast flow
established

p145

Sequence step
delay

05

sec

Defines delay between each step in the


process.

p146

System valve
close delay

015

sec

Defines delay before AOT reactor is


closed after the filter outlet has been
closed during ballast operation. See
Detailed process description in chapter 3.

p149

Timeout: Time in
Auto pause before
going to stop

10300 sec

Defines maximum time a ballast and


deballast process can be automatically
paused by the system. Example: When
process is paused during heeling.

45

Time the control system will wait for


accepted minimum flow (p105) to be
established before automatic stop.

After defined time, the process is


stopped.

Book No.9010182 02, rev. 0

13

2.5

Page 5.2 Main parameters 2

2.5

Control system parameters

Page 5.2 Main parameters 2

This section describes the main system parameters set in page 5.2 Main parameters 2.

4 5.2

The following information is displayed:


ID

Parameter

Default
value

MinMax

Unit

Description

p127

Power
management

Not
used

N/A

Drop
list

Defines if power management is used.

14

Alternatives:

Not used

Hardwire ranged

Hardwire fixed

Remote interface (requires that p132


is activated)

Book No.9010182 02, rev. 0

Control system parameters

2.5

ID

Parameter

Default
value

MinMax

Unit

p128

Max time
communication
loss PLC/remote
interface

60

15240 Sec

Page 5.2 Main parameters 2

Description

Define max delay before the system


shuts down after communication is
lost between the PLC and the remote
interface (optional). The value must be
greater than the heartbeat signal interval
defined in the ISCS.
For further information see chapter 6.
Installation description and drawings,
section Remote interface integration
(optional). See address +006 and +047.

p129

Booster pump
(P401-1) for LDC
cooling water

Not
used

N/A

Drop
list

Defines if a booster pump (not part of Alfa


Lavals scope of suppy) is used to create
sufficient cooling water flow to the LDC.
Alternatives: Activated or Not used.

p130

Booster pump
(P403-1) for
reactor cooling
water

Not
used

N/A

Drop
list

Defines if a booster pump (not part of


Alfa Lavals scope of suppy) is used to
create sufficient cooling water flow to the
AOT reactor.
Alternatives: Activated or Not used.

p132

Remote interface
via modubus

Not
used

N/A

Drop
list

Defines if remote interface (optional) is


used and connected via modbus.
If connected, the Local and Remote
buttons are visible in the control panel.
They are used to choose if operation
shall be done from the remote interface
or a control panel.

p135

External shut
down signal

Not
used

N/A

Drop
list

Defines if an external shut down button


(or signal) is installed.
Purpose: Ongoing process is shut
down and valves are returned to starting
position as fast as possible.
Alternatives: Activated or Not used.

p137

Hide Pause
button

Not
used

N/A

Drop
list

Defines if the Pause button is visible or


hidden in the control system. If activated,
the button is hidden.
Alternatives: Activated or Not used.

Book No.9010182 02, rev. 0

15

2.5

Page 5.2 Main parameters 2

Control system parameters

ID

Parameter

Default
value

MinMax

Unit

Description

p160

GPS

Not
used

N/A

Drop
list

Defines if a GPS is connected to the


control system. If so, the event log will
be complete with position for the events
defined to include GPS stamp.
If no GPS is connected, time and date
must be set in control system page 4.1.
System info.
Alternatives: Activated or Not used.

p161

Time interval for


log event 331

1.0

0.1
60.0

Min.

Time interval to update the amount (m3)


of ballast water treated in log file.

p162

Time interval for


log event 341

1.0

0.1
60.0

Min.

Time interval to update the amount (m3)


of deballast water treated in log file.

p163

Additional
by-pass signal
1

N/A

Drop
list

Defines if an additional by-pass valve is


used. The signal gives information if the
valve is opened during process, so that
PureBallast is by-passed.

Not
used

Alternatives: Activated or Not used.


p164

Additional
by-pass signal
2

Not
used

N/A

Drop
list

Defines if a second additional by-pass


valve is used. The signal gives
information if the valve is opened
during process, so that PureBallast is
by-passed.
Alternatives: Activated or Not used.

p165

Additional
by-pass signal
3

Not
used

N/A

Drop
list

Defines if a third additional by-pass valve


is used. The signal gives information if
the valve is opened during process, so
that PureBallast is by-passed.
Alternatives: Activated or Not used.

p166

Pressure PID
proportional gain

0.60

0.00
10.00

N/A

Defines proportional gain (Pf) value used


for PID regulation of V2018 during
backflush.
The PID regulation during backflush is
based on input from pressure transmitter
PT201-27.
Normal value: 0.1 1.5.

16

Book No.9010182 02, rev. 0

Control system parameters

2.5

Page 5.2 Main parameters 2

ID

Parameter

Default
value

MinMax

Unit

Description

p167

Pressure PID
integral time

7.0

0.0
100.0

sec

Defines integral time (If) value used


for PID regulation of V2018 during
backflush.
This parameter shall normally not be
changed.
Normal value: 5 12.

p168

Pressure PID
derivate gain

0.0

0.0
100.0

N/A

Defines derivate gain (Df) value used


for PID regulation of V2018 during
backflush.
Default value shall be used.
Normal value: 0.

Book No.9010182 02, rev. 0

17

2.6

Page 5.3 AOT parameters

2.6

Control system parameters

Page 5.3 AOT parameters

This section describes parameters controlling the AOT reactor set in page 5.3 AOT parameters.

4 5.3

The following information is displayed:


ID

Parameter

p200

Timeout: AOT
draining

p201

Timeout: Reactor
cooling water
(LS201-29)

18

Default
value
2

MinMax

Unit

Comment

15

min

Time the control system will wait for


confirmation that an AOT reactor is
drained before an alarm is issued.
Recommended setting: Approximately 1
minute more than actual drain time.

110

min

Time the control system will wait for


confirmation that cooling water has filled
the AOT reactor before an alarm is
issued.

Book No.9010182 02, rev. 0

Control system parameters

2.6

Unit

Page 5.3 AOT parameters

ID

Parameter

Default
value

MinMax

p202

High temp,
alarm trigger
(TT201-33)

60

10100 C

Setpoint for high water temperature alarm,


indicated by temperature transmitter in
AOT reactor. Default value shall be used.

p204

Low temp,
alarm trigger
(TT201-33)

040

Setpoint for low water temperature alarm,


indicated by temperature transmitter in
the AOT reactor. Default value shall be
used.

p206

Alarm delay for


sensor TT201-33

010

sec

Delay before alarm is issued after setpoint


temperature (p202 and p204) is reached.

p208

Timeout: CIP fluid


fill-up time AOT

115

min

Setpoint for max time to fill an AOT


reactor with CIP liquid during CIP process
before an alarm is issued.

p210

UV lamp warm-up
time

90

090

sec

Warm up time for UV lamps before full


ballast or deballast starts. Default value
shall be used.

p211

UV lamp cooling
time

120

30300 sec

Cooling time for UV lamps after ballast or


deballast. Default value shall be used.

p212

Timeout: UV
lamp ignition

200

10200 sec

Time the control system will wait for


confirmation signal that UV lamps are
ignited. If no lamps are ignited or if
less lamps than set in parameter p213
are ignited, the AOT reactor will be
automatically stopped. Default value
shall be used.

p214

High temp,
warning trigger
in LDC (TT401-1)

45

20100 C

Incoming cooling water temperature


warning, indicated by temperature
transmitter in LDC.

Comment

Default value shall be used.


p215

Alarm delay for


LS201-29

010

sec

Delay before shutdown when there is no


water in an AOT reactor, indicated by
level switch in AOT reactor (LS201-29).
Default value shall be used.

p216

Timeout: Fluid
fill-up time AOT

210

min

Setpoint for max time to fill an AOT


reactor with fresh water during CIP
process before an alarm is issued.

Book No.9010182 02, rev. 0

19

2.6

Page 5.3 AOT parameters

Control system parameters

ID

Parameter

Default
value

MinMax

Unit

Comment

p220

UV intensity
sensor

Not
used

N/A

Drop
list

Activates measuring of UV intensity in


AOT reactor. If activated, UV value will
be logged in the Event log every 60
seconds during ballast and deballast.
Disable if the UV sensor (QT20150) is
out of order, to avoid alarms.
Alternatives: Activated or Not used.

p221

Low UV intensity
warning trigger

550.0

0.0
500.0

W/m2 Setpoint for warning due to low UV


intensity indicated by UV sensor
QT20150 in the AOT reactor. This
warning will be logged in the Event log.
Default setting: 550.
Only used if p220 is set to "Activated".

p230

Cabinet
temperature
hysteresis
(TT401-2)

2.0

1.05.0 C

Accepted temperature change without


effect on the fan.

p231

Cabinet
temperature
low threshold
(TT401-2)

40.0

20.0
60.0

Setpoint for starting the LDC cooling fan,


indicated by air temperature transmitter.
The fan will start at 15 % of full effect.
The effect is increase proportional to
temperature up to 100 % at temperature
set in p232. Default value shall be used.

p232

Cabinet
temperature
high threshold
(TT401-2)

45.0

20.0
60.0

Setpoint for running the LDC cooling fan


at 100 %.

p234

UV control
proportional gain

0.10

0.00
100.00

N/A

Defines proportional gain (Pf) value used


for PID regulation of UV lamp effect.
Default value shall be used.
The PID regulation is based on input from
UV sensor QT20150.

p235

UV control
integral time

15

0100

sec

Defines integral time (If) value used for


PID regulation of UV lamp effect.
Default value shall be used.

p236

UV control
derivative time

0100

sec

Defines derivate gain (Df) value used for


PID regulation of UV lamp effect.
Default value shall be used.

20

Book No.9010182 02, rev. 0

Control system parameters

2.6

Page 5.3 AOT parameters

ID

Parameter

Default
value

MinMax

Unit

Comment

p237

Power
optimization

Activated

N/A

Drop
list

Activates UV optimization to regulate


the UV lamp effect based on actual
transmittance in the AOT reactor. This
means that the lamps are lit to the degree
needed for full treatment, but not more.
Parameter p220 must be activated to
activate this parameter.
If disabled, UV lamps are lit at 100 % all
the time. Disable if the UV optimization
malfunctions, to avoid alarms.
Alternatives: Activated or Not used.

p238

p239

High
temperature,
warning trigger
in LDC (TT401-2)

50.0

Enable circuit
breaker data

Not
used

Book No.9010182 02, rev. 0

20.0
100.0

Air temperature warning, indicated by


temperature transmitter in LDC.
Default value shall be used.

N/A

Drop
list

Activates modbus communication with


the LDC breaker. If activated, measured
power consumption is displayed in page
1.1 Overview. If deactivated, calculated
power consumption is displayed instead.
Parameter can be deactivated if
communication with LDC breaker does
not work.

21

2.7

Page 5.4 Filter parameters

2.7

Control system parameters

Page 5.4 Filter parameters

This section describes parameters controlling the filter module set in page 8.4 Filter parameters.

4 5.4

The following information is displayed:


ID

Parameter

p301

p304

22

Default
value

MinMax

Unit Comment

High filter
differential
pressure,
warning trigger
(PT201-27)

0.50

0.00
0.1

bar

Required
pressure to
start backflush
(PT201-16)

2.50

Setpoint for high pressure warning,


indicated by pressure transmitter
PT201-27.
(0,7 bar = 0.07 MPa)

1.00
5.00

bar

Defines pressure needed for efficient


backflushing. This pressure must be
attained to start backflush.
This parameter also defines setpoint for
desired pressure during backflush: To
maintain this pressure, control valve

Book No.9010182 02, rev. 0

Control system parameters

ID

Parameter

2.7

Default
value

MinMax

Page 5.4 Filter parameters

Unit Comment

V201-8 is PID regulated, based on input


from pressure transmitter PT201-16.
This parameter shall be set according
the formula in chapter 6. Installation
description and drawings, section Working
pressure for filter during ballast operation.
(2.5 bar = 0.25 MPa)
p305

Backflush trigger,
differential
pressure
(PT201-27)

0.5

0.00
1.00

bar

Setpoint for automatic start of filter


backflush due to dirt in the filter, indicated
by differential pressure transmitter on the
filter.
Note: This parameter can be adjusted, but
only by Alfa Laval during commissioning.
If adjusted, parameter p301 shall be set
to 30 percent higher.
(0.5 bar = 0.05 MPa)

130

min

Defines duration of filter preservation


(fresh water filling of filter) after ballasting.

Backflush cycle
time

20

1
100

sec

Defines duration of one filter backflush.


This parameter is only relevant for filter
type 1 (Boll). Default value shall be used.

p309

Time controlled
backflush interval

30

1
120

min

Defines time between automatic backflush


of the filter. Automatic backflushes
are performed with this set interval to
secure performance, regardles of current
differential pressure.

p310

Backflush initial
delay

10

060

sec

Time from backflush trigger until backflush


is started. During this delay the control
valve is PID regulated to create the
required pressure defined in parameter
p304.

p311

Backflush delay
(p305 during x
sec).

2.0

0.0
10.0

sec

Defines for how many seconds the


differential pressure defined in p305 must
last, before automatic backflush starts.

p312

V201-8 min
position during
backflush

20

1550

Minimum allowed opening percentage for


V201-8 during backflush.

p306

Filter
preservation time

p308

Book No.9010182 02, rev. 0

Must be higher than value set in p113.


Shall not be lower than 15 %.

23

2.7

Page 5.4 Filter parameters

ID

Parameter

p313

Differential
pressure
measurement
filter

Default
value

MinMax

Unit Comment

030

sec

Control system parameters

Time constant for low pass filter used for


the differential pressure over the filter.
The low pass filter is used to smoothen
the effect of sudden changes in differential
pressure (primarily pressure peaks after
completed backflush).
Value for low pass filtered differential
pressure is indicated as dp on the filter
in the filter popup, when logged in as login
level Operator or higher.
Actual differential pressure (PT201-27) is
indicated in the filter popup.
This parameter shall normally not be
changed, but time can be increased to
flatten the differential pressure curves.

p314

Filter type

Type
1

N/A

Drop Defines type of filter installed.


list
Alternatives: Type 1 (Boll) and Type 2
(Hydac).

p315

Filter size

6000

100
6000

m3/h Defines maximum capacity for installed


filter.
The parameter shall be set to 750 m3/h for
a 300600750 system.

24

Book No.9010182 02, rev. 0

Control system parameters

2.8

2.8

Page 5.5 CIP parameters

Page 5.5 CIP parameters

This section describes parameters controlling the CIP module set in page 5.5 CIP parameters.

4 5.5

The following information is displayed:


ID

Parameter

p400

CIP cycle time

Default
value

MinMax

Unit

Comment

15

160

min

Duration of circulation of CIP liquid


during a CIP process.
Default value shall be used.

Book No.9010182 02, rev. 0

25

2.9

Page 5.6 Installation parameters

2.9

Control system parameters

Page 5.6 Installation parameters

This section describes the installation specific system parameters set in page 5.6 Installation
parameters.

4 5.6

The following information is displayed:


ID

Parameter

p106

No of AOT
reactors installed

26

Default
value
1

MinMax

Unit

Comment

16

Defines number of installed AOT


reactors.

Book No.9010182 02, rev. 0

Control system parameters

p112

Maximum flow
(FIT201-1)

2.9

1200

0
10000

m3/h

Page 5.6 Installation parameters

The parameter shall be set according to


pipe dimension for the flow meter pipe.
Pipe - Qmax (m3/h)
100 300
150 300
200 700
250 1200
300 1200
350 1700
400 2200
150 2200
500 2200
600 2200
The parameter shall be set to the same
value as the Qmax value in the flow
meter (FIT201-1).
Qmax setting in the flow meter can be
checked according to instruction Check
and set parameters on page 32.

p131

Automatic AOT
selection

Not
used

N/A

Drop
list

Defines if AOT reactors shall be


automatically selected for process.
If activated: All AOT reactors (without
alarms) will be automatically selected,
to enable operation in full capacity.
Activation disables the possibility
to select a lowr flow before starting
a process (during standby mode).
However flow can be changed during
process.
If deactivated: Flow must be selected
manually at first start-up and after
shutdown.

p213

p217

Allowed no. of
failed UV lamps
per AOT reactor

AOT reactor size

Book No.9010182 02, rev. 0

01

No.

If more lamps than set in this parameter


are broken, operation will be denied.
If a UV lamp fails the flow is set to 80
% of current flow. The UV lamps are
lit to 100 %. A warning is issued and a
log is written to the event log, and the
operator will have do decide to continue
or stop the operation.

300

N/A

Drop
list

Defines size of the AOT reactor, defined


as max capacity (m3/h).
Alternatives: 300 and 1000.

27

2.9

Page 5.6 Installation parameters

p218

Estimated UV
lamp lifetime

p150

EX proof system

3 000

Not
used

Control system parameters

0
20000

hrs

Setpoint for UV lamp change warning.


Counter for UV lamp run time is reset
in page 4.5 Operation timers AOT after
all UV lamps have been changed in an
AOT reactor. Default value shall be
used.

N/A

Drop
list

Defines if the EX proof version of


PureBallast is installed. This affects
both installation and control system.
Alternatives: Activated or Not used.

p500

Log box

Not
used

N/A

Drop
list

Defines if the log box (optional ) is


installed to monitor and log external
valves and pumps, that are not part of
Alfa Lavals scope of supply.
Parameters to activate feedback signals
for components are set in page 4.7 Log
box 1 and 4.8 Log box 2. See chapter
3. Operating instructions and control
system description.
Alternatives: Activated or Not used.

28

Book No.9010182 02, rev. 0

Control system parameters

2.10

Page 5.7 Remote interface

2.10 Page 5.7 Remote interface


This section describes the installation specific system parameters set in page 5.7 Installation
parameters. Further information about RTU server data is found in chapter 6. Installation
description and drawings section Communication between PureBallast PLC and remote interface.
This page is only relevant if remote interface (optional) is used.

4 5.7

The following information is displayed:


Parameters for the ISCS modbus RTU server data shall be set according to the information below.
ID

Parameter

Default
value

MinMax

Unit

Comment

p700

Interface type

RS485

N/A

Drop
list

Defines communication (cable) type


used for communication between the
ISCS and PureBallast.
Alternatives: RS485 and RS422.

Book No.9010182 02, rev. 0

29

2.10

p701

Page 5.7 Remote interface

Baud rate

9600

N/A

Drop
list

Control system parameters

Defines baud rate in bits per second.


The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: 300, 600, 1200, 2400,
4800, 9600, 19200, 38400, 57600,
115200.

p702

Parity

No
parity

N/A

Drop
list

Defines parity.
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: None, Odd, Even, High,
Low.

p703

p704

30

Data bits

Stop bits

N/A

N/A

Drop
list

Defines data bits per character.

Drop
list

Defines number of stop bits.

Alternatives: 7 or 8.

Alternatives: 1 or 2.

Book No.9010182 02, rev. 0

3 Flow transmitter parameters


This section describes the parameters set in the parameter pages in the flow transmitter, installed
on the flow meter.
General (non-installation specific) parameters are preset to function for all systems. They must only
be adjusted, by Alfa Laval, if required by performance reasons or similar. They are checked during
preparations for commissioning and shall normally not be adjusted after start up.
The parameters are set in the flow transmitter panel.

4FTPanel

Buttons used:

4FTLock

4FTChange

4FTBack

4FTFwd

4FTSelect

Padlock

Change

Back

Forward

Select

4FT_Topup

Top up

Book No.9010182 02, rev. 0

31

3.1

Check and set parameters

3.1

Flow transmitter parameters

Check and set parameters

Follow this instruction to check and set parameters in the flow meter.
1.

Press Top up for three seconds.

2.

To enter password (1000): Press Padlock. (A line appears under the first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The Basic settings menu appears after two seconds.

3.

Press Padlock to unlock the menu.


Set Qmax (Measuring range for the flow meter: the analog outputs and the frequency output.)

4.

Press Forward until Qmax is displayed. Check that the parameter is set according to pipe
dimension for the flow meter pipe:
Pipe - Qmax (m3/h)
100 300
150 300
200 700
250 1200
300 1200
350 1700
400 2200
150 2200
500 2200
600 2200
- To change: Press Padlock.
- Press Select to select digit to change (A line is placed under the changeable digit).
- Press Change to change (toggle) the digit.
- Press Padlock to set the value.
Set Empty pipe

5.

Press Forward until Empty pipe is displayed. Check that the parameter is set to On.
- To change: Press Padlock.
- Press Change to change (toggle) the setting.
- Press Padlock to set the value.
Set Empty pipe (Activates alarm when flow meter is empty.)

6.

Press Forward until Output is displayed.

7.

Press Padlock to unlock the menu.


Result: Current output is displayed.

8.

Press Padlock to display the setting. Check that the parameter is set to On.
- To change: Press Padlock.
- Press Change to change (toggle) setting.
- Press Padlock to set the value.
Set Current output 4-20 mA

32

Book No.9010182 02, rev. 0

9.

Flow transmitter parameters

3.1

Check and set parameters

Press Forward until Current output (mA setting) is displayed. Check that the parameter is
set to 4-20 mA.
- To change: Press Padlock.
- Press Change to change (toggle) setting.
- Press Padlock to set the value.

10. Press Top up three times to exit.


Result: Totalizer 1 is displayed.

Book No.9010182 02, rev. 0

33

3.1

Check and set parameters

Flow transmitter parameters

4 Lamp power supply (LPS)


parameters
This section describes the parameters (DIP switch settings) set in the LPS, installed in the lamp
drive cabinet (LDC). Each LPS is set to identify the individual LPS in the installation.

4.1

DIP switch settings

The table below show the correct settings for respective LPS.
Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the individual LPS according
to the table below. Only position ON is indicated. For empty cells in the table, the switch shall
be in position off.
LPS nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

SW 4

SW 5

SW 6

SW 7
ON
ON

ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON

SW 8
ON
ON
ON

ON
ON

ON
ON

ON
ON
ON
ON
ON
ON

ON
ON

ON
ON

ON

ON

Example
In the illustration, the DIP switches is set for LPS no. 5.

Book No.9010182 02, rev. 0

35

4.2

Change DIP switch setting

Lamp power supply (LPS) parameters

7 LPSdipEx

4.2

Change DIP switch setting

Follow this instruction to change the DIP switch settings for an LPS. Note that the DIP switch
settings for LPS shall only be changed if faulty, indicated by all LEDs lit in LPS in combination with
alarm A130 in the control system.
Preparations and conditions

ANGER
D
!

Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside
and on the lamp power connector, even when UV lamps are not lit.

The LDC contains a fan, which can cause injuryt if in operatoin.

Follow the steps below


1.

Unscrew the plastic lid (1) over the DIP switches on the fron of the LPS.

7 LPSdip

2.

36

Use a small screw driver to change position of the swithces according to the table under
instruction DIP switch settings.

Book No.9010182 02, rev. 0

Lamp power supply (LPS) parameters

3.

Re-fit the plastic lid of the DIP switches.

4.

Turn back the power to the cabintet.

Book No.9010182 02, rev. 0

4.2

Change DIP switch setting

37

Chapter: 5. Alarms and faultfinding


System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1

Introduction

List of alarms and warnings

2.1

Control system

2.1.1
2.1.2
2.1.3

Alarm indication
Key to the table of alarms and warnings
List of alarms and warnings

7
7
8

2.2

Lamp power supply (LPS)

49

2.2.1

List of alarms and status indications

49

2.3

Flow meter

50

2.3.1
2.3.2
2.3.3

Fault finding instruction


Check flow meter error list
List of alarms and problems

50
51
51

2.4

Level switch

54

2.5

I/O system and X20 modules

56

2.5.1

List of alarms and status indications

57

List of problems and solutions

63

3.1

General problems

63

3.2

Filter

66

3.3

CIP

68

3.4

Valve V2018

71

1 Introduction
This chapter covers information about alarms and warnings, together with information about how
to solve the problems causing the alarms to trip. The chapter also contains a list of solutions for
problems that may occur, but that is not indicated by any system.
The chapter contains lists of alarms indicated by:

control system

lamp power supply (LPS)

flow meter (with fault finding instruction)

I/O system and X20 modules.

See chapter 3. Operating instructions and control system description to find information about
the alarm pages and how to attend to alarms.

Book No.9010182 02, rev. 0

Introduction

2 List of alarms and warnings


This section lists all alarms and warnings related to the PureBallast system.

2.1

Control system

This sub section lists all alarms and warnings in the PureBallast control system. The alarms are
sorted in a strict numerical order.

2.1.1

Alarm indication

An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.

3Alarm

2 Warning

All alarms are displayed in the control panels page 2.1 Alarm list and are sorted in order of
occurrence; most recent alarm at the top of the list.

2.1.2

Key to the table of alarms and warnings

The table below explains the information given in the alarms list table. The table contains the
following columns and information:
Column in
table

Description

Alarm ID

Identification number of the alarm. The number is also indicated in the control
system alarm list.
Alarm ID:s are composed of the following elements: L100

L: First letter indicate it is an alarm or a warning.


-

A = Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.

W = Warnings are notification of a status change or a problem. Warnings


allow the process to continue.

Book No.9010182 02, rev. 0

2.1

Control system

Alarm text /
Problem

List of alarms and warnings

1: If the alarm contains three digits, the first digit indicates component
according to: 1=AOT reactor and 2 =Filter. If the alarm contains two digits,
the alarm is general and is not connected to a specific component.

00: Unique number for the alarm/warning.

The text displayed in the control system. Note that AOT reactor number is
indicated by x in the table, instead of the actual AOT reactor number. In the
control system alarm text, the actual AOT reactor number is stated for the AOT
reactor concerned.
For problems not indicated by an alarm, the text gives a general explanation
of a problem that can occur.

Trigger /
Parameter

Trigger: Source of the alarm or warning, identified by the input sensors item
number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.

Description

Detailed information sorted on the following headings, when applicable:


Delay: Time before the alarm is activated after the condition of the alarm is met.
Comments: Additional information or explanations.

Possible
cause

Possible causes that might have triggered the alarm.

What to do?

Suggested action to solve the problem.

2.1.3

List of alarms and warnings

The table below explains alarms triggered by and displayed in the control system.
See next page.

Book No.9010182 02, rev. 0

A01

Trigger / Parameter

Trigger: PT201-16
Process
Parameter: p100
pressure too
high (PT201-16).
Automatic stop.

Alarm Alarm text


ID

Comment: Pressure
transmitter PT201-16
indicates pressure
higher than set in
parameter p100.

Delay: 2 sec.

Description

Alarms and warnings PureBallast control system

Control that correct valves are


functioning and opened for current
process. See chapter 3. Operating
instructions and control system
description, section Detailed
process description.
Check the entire system for
blocking material.

1. Check cables to pressure


transmitter PT201-16. See
Control cabinet / Circuit
diagram in chapter 6.
Installation description and
drawings.

Valves in the system


after pressure
transmitter are
closed.

Material is stocked
after pressure
transmitter PT201-16
(i.e. in an AOT
reactor).
Pressure transmitter
PT201-16 is faulty.

List of alarms and warnings

Book No.9010182 02, rev. 0

2. Replace pressure transmitter


PT201-16.

Check pressure and flow from


ballast pump(s). If the pressure
exceeds set value: Adjust incoming
pressure to PureBallast.

What to do?

Ballast water pump


gives too high
pressure.

Possible cause

2
2.1
Control system

Trigger / Parameter

Trigger: PT201-16

Alarm Alarm text


ID

Process
pressure
signal missing
(PT201-16).
Automatic stop.

Trigger: PT201-16
Process
Parameter: p101
pressure too
high (PT201-16).

A03

10

W04
Comment: Pressure
higher than parameter
set limit.

See A01.

6. Replace transmitter PT201-16.

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

4. Check cables to the


component. See Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

1. Check fuse F45 in Control


cabinet to see what circuit
caused the fuse trip.

What to do?

See possible cause


for A01.

Signal missing
or pressure
transmitter PT201-16
malfunction.

Possible cause

Control system

Delay: 2 sec.

Comment: Error
in system pressure
sensor. Indication of
pressure -1.0 bar (-0.1
MPa) is not an error.

Delay: 2 sec.

Description

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger: FIT201-1.
Parameter: N/A

A10

Process flow
signal missing
(FIT201-1).

Trigger / Parameter

Alarm Alarm text


ID

Comment: Error in
system flow sensor.

Delay: 5 sec.

Description

What to do?

Book No.9010182 02, rev. 0

Check the flow transmitter. See


chapter 7. Service manual.

See section Flow meter on page


50.

Flow meter
malfunction.

List of alarms and warnings

Flow transmitter
FIT201-1 malfunction
(no text on the
transmitter display,
message error)

6. Replace flow transmitter


FIT201-1.

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

4. Check cables to the


component. See Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

Signal missing or flow 1. Check fuse F45 in Control


transmitter FIT201-1
cabinet to see what circuit
malfunction.
caused the fuse trip.

Possible cause

2
2.1
Control system

11

12

Trigger: FIT2011
Parameter: N/A

Process
flow higher
than certified
(FIT201-1).
Reduce flow!

Process flow too


low (FIT201-1).
Automatic
pause.

W12

A13

Trigger: FIT2011
Parameter: p116

Trigger / Parameter

Alarm Alarm text


ID

Comment: If flow
is less than set in
parameter p116, the
system is shut down.

Delay: 20 sec.

Delay: 30 sec.

Description

Check that the flow sensor is OK as


described in Problem 7 B and 7 I in
the general problems list on page .

Flow sensor
malfunctions.

Check that the flow sensor is OK as


described in Problem 7 B and 7 I in
the general problems list on page .

Check pressure and flow


from ballast pump(s).
Adjust incoming pressure
to PureBallast, if necessary.

Flow sensor
malfunctions.

Make sure the ballast water


from the ballast pump is
directed to PureBallast. When
OK the process will continue
automatically.

See chapter 4. Parameters, section


Flow transmitter.

Increase flow.

Control system

Wrong setting in
FIT201-1.

Flow too low.

See chapter 4. Parameters, section


Flow transmitter.

Wrong setting in
FIT201-1.

See section Flow meter on page


50.

Reduce the incoming ballast water


flow to the PureBallast system.

What to do?

Flow rate higher than


selected certified
flow, for the number
of AOT reactors in
operation.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: FIT201-1
Parameter: p105

A14

Process
flow too low
during start-up
(FIT201-1).
Automatic stop.

Trigger / Parameter

Alarm Alarm text


ID

Delay: Set in
parameter p144.

Description

Attend to. Note: This component


is outside the PureBallast system
control.

If not, check mechanical function of


the valve and check that the cables
to the component is according
with the Control cabinet / Circuit
diagram.

Control that correct valves are


opened for current process.
See chapter 3. Operating
instructions and control system
description, section Detailed
process description.

See section Flow meter on page


50.

What to do?

Flow too low.

See alarm A13.

Control valve V2018 See alarm A17.


malfunctions.

Ballast water
pump stopped or
malfunctions

Valves in ballast
system closed.

Possible cause

2
List of alarms and warnings
2.1
Control system

13

14

Trigger: Limit switch


GS201-3.
Parameter: N/A.

A17

Valve error
(V201-3).

Trigger / Parameter

Alarm Alarm text


ID

Comment: Error on
valve V2013.

Delay: 15 sec.

Description

Hint: Valves can be manually


operated. See instruction Operate
components manually in chapter 3.
Operating instructions and control
system description and Operate
valves manually in chapter 7.
Service manual.

Adjust sensor. See chapter 7.


Service manual, section Adjust
position sensor.

5. Check that all electrical


connections to actuator and
sensors on the valve are OK
and that the electrical wiring is
not damaged.

4. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

3. Use the Control cabinet /


Circuit diagram to check the
fuse setting, adjust according
to figures in circuit diagram if
necessary and reset fuse.

2. Check relay K1 and K2 on


module X10 in control cabinet.

1. Check fuses F43 in control


cabinet to see what circuit
caused the fuse trip.

What to do?

Control system

Position sensor
mounted upside
down.

Position sensor is
not in correct position
to sense indicator
screws. Position
screws are in wrong
position.

Fuse tripped.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger: Limit switch


GS201-9.
Parameter: N/A.

A23

Book No.9010182 02, rev. 0

Comment: Error on
valve V2019.

Delay: 15 sec.

Description

3. Check that compressed air


pressure is according to
requirements in chapter 6.
Installation description and
drawings, section Connection
list.

2. Adjust exhaust valves on


actuator.

1. Follow the instruction Adjust


valve traveling speed in chapter
7. Service manual.

See possible cause


for A17.

Valve cannot
open/close due to
obstruction.

Check relay K5 and K6 on module


X10.

Clean. If required dismount valve.


See chapter 7. Service manual for
instructions.

Pilot valve on actuator The red LED on pilot valve contact


malfunction
lights if opening signal comes to
the pilot. If the LED lights although
the valve malfunctions, the pilot
valve is faulty: Replace pilot valve.

Too long
opening/closing time
(valve travel time)

1. Check cables.

Position sensor or
cables to position
sensor malfunction.
2. Replace position sensor if
faulty.

What to do?

Possible cause

List of alarms and warnings

Valve error
(V201-9).

Trigger / Parameter

Alarm Alarm text


ID

2
2.1
Control system

15

16

Trigger: Limit switch


GS201-8.
Parameter: N/A.

A29

Valve error
(V201-8).

Trigger / Parameter

Alarm Alarm text


ID

Comment: Error on
control valve V2018.

Delay: 15 sec.

Description

Clean the filter on the possitioner.

The air filters on


V201-8 might be
clogged.

6. Check that all electrical


connections to actuator and
sensors on the valve are OK
and that the electrical wiring is
not damaged.

5. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

4. Use the Control cabinet /


Circuit diagram to check the
fuse setting, adjust according
to figures in circuit diagram if
necessary and reset fuse.

3. Check relay K3 and K4 on


module X10.

2. Check fuses F43 in control


cabinet to see what circuit
caused the fuse trip.

Calibrate according to chapter 7.


Service manual, section Calibrate
positioner on V201-8.

Signal error 420


mA.

1. Check open indication in the


pneumatic positioner.

What to do?

Control system

Positioner is not
correcly set or
calibrated.

Sensor error.
Shows open all
the time.

See possible cause


for A17.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Limit switch


GS212-31.
Parameter: N/A

Bypass valve is
open (V212-31).

Valve error
(V212-31).

Process
pressure too low
(PT201-16).

A33

A35

W40

Trigger: Pressure
transmitter:
PT201-16.
Parameter: p103.

Trigger: Limit switch


GS212-31.
Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Delay: 2 sec.

Comment: Shutdown
of all steps except CIP.
The alarm does not
prevent completion or
start of CIP process.

Delay: 15 sec.

Comment: If valve
V212-31 is in open
position, ballast or
deballast is cancelled.
The bypass valve is
not controlled by the
PureBallast system.

Delay: 15 sec.

Description

Check that pressure and flow


from ballast pump(s) is according
to requirements in chapter 6.
Installation description and
drawings, section Connection list.

If not opened intentionally, close


valve V212-31.

What to do?

1. Check cables to pressure


transmitter PT201-16. See
Control cabinet / Circuit
diagram in chapter 6.
Installation description and
drawings.

List of alarms and warnings

Pressure transmitter
PT201-16 is faulty.

Pressure safety valve Check the valve, and repair or


V201 is faulty.
change.

Ballast water pump


gives too low
pressure.

See possible cause


for A17.

See possible cause


for A17.

The valve has been


opened manually or
via the ISCS.

Possible cause

2
2.1
Control system

17

18

Trigger: Shutdown
button on control
cabinet
Parameter: N/A

Shutdown
activated
(Shutdown
button).

Shutdown
activated during
CIP (Shutdown
button).

Shutdown
activated
(External
system).

Shutdown
activated during
CIP (External
system).

A48

A49

A50

A51

Trigger: External
shut down signal.
Parameter: p135

Trigger: External
shut down signal.
Parameter: p135

Trigger: Shutdown
button on control
cabinet
Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Delay: None.

Delay: None.

See A50.

Manual shutdown
from the ISCS
(integrated ship
control system).

See A48.

System has been


shutdown by the
shutdown button on
the control cabinet.

Delay: None.

Delay: None

Possible cause

Description

Find out the reason why the system has


been shut down before releasing the
button.

NOTE

Find out the reason why the system has


been shut down before releasing the
button.

NOTE

2. Replace pressure transmitter


PT201-16.

What to do?

2.1
Control system
2
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Control
cabinet.
Parameter: N/A

Fuse tripped in
control cabinet.

Additional
bypass valve
1 is open.

Additional
bypass valve
2 is open.

Additional
bypass valve
3 is open.

W58

A66

A67

A68

Trigger: External
system.
Parameter: p165

Trigger: External
system.
Parameter: p164

Trigger: External
system.
Parameter: p163

Trigger / Parameter

Alarm Alarm text


ID

Delay: 5 sec.

Delay: 5 sec.

Delay: 5 sec.

Delay: None.

Description

overheated fuse

See A66.

See A66.

The valve has been


opened manually or
via the ISCS.

short circuit

Possible reasons:
overload

Possible cause

If not opened intentionally, close


the valve.

3. Use the circuit diagram for


control cabinet to check the
fuse setting, adjust according
to figures in circuit diagram if
necessary and reset fuse.

2. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

1. Check fuse F43F45 in control


cabinet to see what circuit
caused the fuse trip.

What to do?

2
List of alarms and warnings
2.1
Control system

19

20

Trigger: Control
system timer.
Parameter: p141.

Ballast water
pump is
not running.
Automatic stop.

Overboard valve
is not open.
Automatic stop.

Error on all
operating
AOT:s.
Automatic stop.

A71

A75

A77

Simulate power request between


the systems. See chapter 3.
Operating instructions and control
system description.

If remote interface
(optinal) is used:
Communication
between PureBallast
and ISCS is wrong.

An active alarm exist


on all installed AOT
reactors. It can be
the same error for
all AOT reactors, or
different errors.

See possible cause


for A71.

Check page 2. Alarm list to for


related alarms.

Time set in parameter Check/change parameter in


is lower than needed. control system page 5.1 main
parameters 1.

Check that all electrical connections


are OK. Check that the signal
wiring is according to information in
chapter 6. Installation description
and drawings, section External
component signal integration.

What to do?

Faulty connection of
signal cable.

Possible cause

Comment: All
AOT reactors are
deactivated.

Delay: None

Comment: Feedback
overboard valve is
OPEN.

Delay: Set in
parameter p140.

Comment: Feed back


signal BW pump is
running is deactivated

Delay: Set in
parameter p141.

Description

Control system

Trigger: AOT
reactors
Parameter: N/A

Trigger: Control
system timer.
Parameter: p140

Trigger / Parameter

Alarm Alarm text


ID

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Control
system timer.
Parameter: p127.

Power is
not granted.
Automatic stop.

Power is not
fully granted.
Flow capacity
reduced.

W79

W80

Comment: No
power steps have
been granted within
parameter set time.

Delay: Set in
parameter p143.

Description

Trigger: Power
Delay: None.
management system.
Comment: Not all
Parameter: p127.
requested power steps
are granted. Triggered
if number or requested
power steps does
not match number of
granted power steps.

Trigger / Parameter

Alarm Alarm text


ID
Investigate if the reasons for not
granting power is outside the
PureBallast system.

What to do?

Not enough power


has been granted.

See possible cause


for W79.
Continue process with lower flow
capacity or try later.

Hint: If problem persists, see page


1.4 PureBallast power request
to find which GRANTED signal
that was interrupted during the
ballast/deballast process.

Feedback signal from See A71.


power management
Check signal transmission to/from
master is faulty.
PureBallast corresponds to
the specifications in chapter
6. Installation description
and drawings, section Power
management system integration.

Power management
master system not
granting power for
one or more AOT
reactors.

Possible cause

2
List of alarms and warnings
2.1
Control system

21

22

Trigger: Heeling
(internal transfer)
requested in control
system.
Parameter: N/A

Heeling mode
requested
by operator.
Automatic
pause.

Heeling mode
cancelled
by operator.
Process
resumed.

PLC lost
communication
with all control
panels.

W82

W83

A91

Trigger: Control
system PLC.
Parameter: N/A

Trigger: Heeling
(internal transfer) not
requested in control
system.
Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Possible cause

Comment: After
60 seconds of lost
communication,
ongoing process is
stopped in a controlled
way and the system
is shut down. This
message is visible in
the control panels and
saved in the log after
the communication is
restored. But, W92 will
be visible in the master
control panel.

Delay: 60 sec.

Comment: Process
is resumed after being
phased during heeling.

Delay: None.

Check settings for each panel


according to chapter 3, section Set
control panel IP settings.

Wrong network
setting

Control system
2

Check that the remote control


panel is added in the main panel
according to Set remote control
panel communication.

Check that the HMI and PLC


software have the save program
version. This is visible in control
system page 4.1 System info.

3. Replace if faulty.

2. Restart the panel. See problem


1 B in the general problems list
on page .

1. Switch on the panel.

What to do?

Wrong software
version

Panel is switched off


or faulty.

See possible cause


for W82.

Heeling mode has


been activated by
Comment: The system external system.
is set in pause mode.
If operation has not
been requested: See
A71.

Delay: 2 sec.

Description

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger / Parameter

Trigger: Control
system PLC.
Parameter: N/A

Alarm Alarm text


ID

Master control
panel lost
communication
with the PLC.

Heart beat signal Trigger: Control


from remote
system PLC.
Parameter: p128
interface is not
updating.

W92

Book No.9010182 02, rev. 0

A93

See A91.

To operate PureBallast when communication is down,


follow the steps below:

Faulty cable
connection.

See A91.

Check cables to the component.


For reference, see Control cabinet /
Interconnection diagram in chapter
6. Installation description and
drawings.

Faulty cable
connection.

Master panel is
switched off or faulty.

What to do?

Possible cause

2.1

If you deliberately set the system


to test mode (for example to test

List of alarms and warnings

System is set to Test


mode.

Comment: After
1. Set the system to Local mode: Press the Local button
on the control panel.
communication is
lost between ISCS
2. Run the system from the control panel. Note that you
and PLC, ongoing
will need to confirm two messages from the control
process is stopped in a
panel during operation: "Confirm ballast pump started"
controlled way and the
and "Confirm overboard valve open".
system is shut down.
3. Restore these settings when the communication is
The Heartbeat field
working.
in page 4.5 Remote
4. Make sure that the system is not in test mode in page
interface, indicates
4.5 Remote interface (no check mark on the Test
communication.
mode button).

Delay: Set in
parameter p128.

Comment: After
communication is lost,
ongoing process is
stopped in a controlled
way and the system
is shut down. This
message is visible
in the master control
panel.

Delay: 30 sec.

Description

2
Control system

23

Alarm Alarm text


ID

Trigger / Parameter

Description

24

Check cable between the ISCS


and the master control panel and
the cable between the PLC and
the master control panel. For
reference, see Control cabinet /
Interconnection diagram in chapter
6. Installation description and
drawings.

4. Check that the communication


settings is OK according to
instruction Set remote interface
communication in chapter 3.
Operating instructions and
control system description.

3. Check if test mode is activated


in page 4.5 Remote interface
(check mark on button). If so,
press the Test mode button.
Requires login level Advanced
operator.

2. Check if remote operation is


deactivated in the control panel
(The Remote button at the
bottom of the screen is gray). If
so, press the Remote button.

1. Check that parameter p700 is


set to match the modbus cable
type used (RS422 or RS485).

remote interface integration, you


can disregard this alarm. If not
deactivate the test mode again in
page 4.5 Remote interface 1.

What to do?

Control system

Faulty cable
connection.

Faulty settings.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Control
system PLC.
Parameter: N/A

PLC battery low.

GPS signal not


valid.

PLC error in
control cabinet.

W95

W96

W97

Trigger: N/A
Parameter: N/A

Trigger: Control
system PLC.
Parameter: p160

Trigger / Parameter

Alarm Alarm text


ID

Delay: 2 sec.

Delay: 5 sec.

Delay: 10 sec.

Description

Faulty electrical
connection.

List of alarms and warnings


2.1

Check that the signal wiring is


according to electrical drawings
in Chapter 6. Installation
description and drawings.

Check the LED error indication for


the electronic modules in the LDC.
See section I/O system and X20
modules on page 56.

Check that the signal wiring


is according to in chapter 6.
Installation description and
drawings, section GPS signal
integration and Control cabinet /
Interconnection diagram

Error in module.

Faulty electrical
connection.

Replace PLC battery in the control


cabinet.

Investigate problem in ISCS, and


attend to found problems.

ISCS is faulty.
The voltage in the
battery in the control
system PLC is too
low.

See W92.

Tips: Make sure that the modbus


cables in terminal X15 are correct
(not switched).

What to do?

Communication
between PLC and
master control panel
is lost.

Possible cause

2
Control system

25

26

Check that cooling water supply


(403) is within specification
in chapter 6. Installation
description and drawings,
section Connection list.

Check that all electrical


connections are OK on bus
modules and that the electrical
wiring is not damaged.
Check that the inlet valves
(V201-19.x, V403-35) and
outlet valves (V201-20.x,
404-36.x) open properly by
operating them manually.
See the instruction Operate
components manually
in chapter 3. Operating
instructions and control system
description.

What to do?

High temperature

due to obstacles or
error in one or more
components involved.

Possible cause

Check/change parameter in
control system page 5.3 AOT
parameters.
Replace transmitter TT20133
according to instruction in
chapter 7. Service manual
section Temperature switch and
temperature transmitter.

TT201-33.x
malfunction.

Parameter p202 not


correctly set.

Control system

If the alarm trips during


Low flow of sea water Check pump, valves and other
ballast start-up, valve
during start-up.
components involved in the sea
V404-36.x will close.
water cooling system.

If the alarm trips


during operation
with a flow through
the AOT reactor, the
valves V201-19.x and
V201-20.x will close.

Trigger: AOT
Delay: Set in
temperature
parameter p206.
transmitter TT201-33.
Comment: If
Parameter: p202
temperature rises
above parameter set
value, the AOT reactor
will shutdown.

AOT [x]: AOT


temp too high
(TT201-33).
AOT shutdown.

W100

Description

Trigger / Parameter

Alarm Alarm text


ID

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Parameter: N/A.

See to that incoming water is


warmer than 0 C.

What to do?

6. Replace transmitter TT201-33.

2.1

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

List of alarms and warnings

4. Check cables to the


component. See AOT /
Circuit diagram and Lamp drive
cabinet (LDC) / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

1. Check fuse F42 in LDC to see


what circuit caused the fuse
trip.

Engine room too cold; Increase temperature.


temperature below 0
C.

Sea water too cold;


temperature below 0
C.

See possible cause


for W100.

Possible cause

Delay: Set in parameter Signal missing


p206.
or transmitter
TT201-33.x
malfunction.

AOT [x]:
AOT temp
signal missing
(TT201-33).
AOT shutdown.

W102

Trigger: AOT
temperature
transmitter TT201-33
error.

Trigger: AOT
Delay: Set in
temperature
parameter p206.
transmitter TT201-33.
Parameter: p204.

AOT [x]: AOT


temp too low
(TT201-33).
AOT shutdown.

W101

Description

Trigger / Parameter

Alarm Alarm text


ID

2
Control system

27

28

Trigger: LDC
temperature
transmitter TT401.
Parameter: p214

AOT [x]: LDC


cooling water
temp too high
(TT4011).

AOT [x]:
LDC cabinet
temp missing
(TT4011).

W107

W109

Trigger: LDC
temperature
transmitter TT4011.
Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Feel the water pipe, if it is too


warm. If so, investigate and attend
to problem.

Incoming cooling
water too warm.

Delay: 5 sec.

Check that cooling water supply


(401) is within specification in
chapter 6. Installation description
and drawings, section Connection
list in the General drawings section.

No cooling water to
the heat exchanger.

Signal missing or
transmitter TT401
malfunction.

3. Use the circuit diagrams for


the LDC and AOT reactor to
locate the component or find
the reason that caused the fuse
trip and attend to it.

Control system

2. Use the circuit diagram for the


LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary
and reset fuse.

1. Check fuse F42 in LDC to see


what circuit caused the fuse
trip.

Parameter p214 not


Check/change parameter in
correctly set in control control system page 5.3 AOT
system.
parameters.

Incoming cooling
Check and attend to.
water valve V4011
and/or outgoing valve
blocked or closed.

7. Restart the process from the


beginning.
Delay: 15 sec.

What to do?

Possible cause

Description

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger:
Temperature
transmitter TT4012.
Parameter: p238

W111

LDC air
temperature too
high (TT4012)

Trigger / Parameter

Alarm Alarm text


ID

Delay: 15 sec.

Description

Check component. See section I/O


system and X20 modules on page
56.

Faulty X20 module.

Check page 2. Alarm list to for


related alarms.
Check electrical and mechanical
problems, and attend to.

LDC faulty.
Faulty fan.

Change according to instruction in


chapter 7. Service manual, section
Control cabinet.

Check that all electrical connections


are OK on X20 module and that the
electrical wiring is not damaged.

7. Restart the process from the


beginning.

6. Replace transmitter TT401.

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

4. Check cables to the


component. See Lamp drive
cabinet (LDC) / Circuit diagram
in chapter 6. Installation
description and drawings.

What to do?

Faulty connection to
X20 module.

Possible cause

2
List of alarms and warnings
2.1
Control system

29

30

Trigger:
Temperature
transmitter TT4012.
Parameter: N/A

W113

LDC cabinet
temperature
missing
(TT4012)

Trigger / Parameter

Alarm Alarm text


ID
Delay: 5 sec.

Description

What to do?

7. Restart the process from the


beginning.

Control system

6. Replace transmitter FIT201-27.

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

4. Check cables to the


component. See Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

Signal missing or flow 1. Check fuse F42 in Control


transmitter TT401-2
cabinet to see what circuit
malfunction.
caused the fuse trip.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger: Level sensor Delay: Set in


LS201-29.
parameter p215.
Parameter: N/A

AOT [x]: AOT


fluid level
signal missing
(LS201-29).

W116

Description

Trigger / Parameter

Alarm Alarm text


ID
Signal missing or
sensor LS201-29.x
malfunction.

Possible cause

Book No.9010182 02, rev. 0

7. Replace LS201-29.x. (Turn the


level switch so the forks are in
the right position. See chapter
7. Service manual.

List of alarms and warnings

6. Check that the level switch is


working correctly. See section
Level switch on page 54.
Hint 2: Dismount level switch
and put the forks into a cup of
water to check dry/wet function.

5. Check cables to the level switch


LS201-29.x. See drawing AOT
/ Circuit diagram and Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

4. Use the circuit diagrams for


the LDC and AOT reactor to
locate the component or find
the reason that caused the fuse
trip and attend to it.

3. Use the circuit diagrams for the


LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary
and reset fuse.

2. Check relay KS02.

1. Check fuse F43 in LDC to see


which circuit that caused the
fuse trip.

What to do?

2
2.1
Control system

31

32

No fluid in AOT
reactor x.
LS201-29.x is
indicating dry
condition.

AOT [x]: CIP


flow missing
(LS201-29).

W118

Trigger: Level sensor Delay: Set in


LS201-29.
parameter p215.
Parameter: p208

Trigger: Level sensor Delay: Set in


No fluid in AOT
LS201-29.
parameter p215.
reactor.
Parameter: N/A
Comment: Prevents
start of LPS (UV lamps)
in manual mode.

AOT [x]: AOT


fluid missing
(LS20129) in
manual mode

Possible cause

A117

Description

Trigger / Parameter

Alarm Alarm text


ID

Check that pump P320-1


is functioning correctly. See
problem 6D6I in the general
problems list on page .

Control system

3. Hint: Valves can be manually


operated. See the instruction
Operate valves manually
in chapter 3. Operating
instructions and control system
description.
Note that the manual
operations are passwordprotected and must only be
performed by authorized
trained personnel. The
PureBallast equipment or
connected equipment can be
irreparably damaged if handled
incorrectly.

2.

1. Check that valves V320-2,


V320-4.x, V321-4 and 321-2.x
open and close correctly.

3. Restart the process from the


beginning.

2. Check that the flow is equal


through all AOT reactors and
that the AOT.x is not clogged.

1. Control that correct valves


are opened for current
process. See Detailed process
description in chapter 3.
Operating instructions and
control system description.

What to do?

2.1
2
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Level sensor Delay: Set in


LS201-29.
parameter p215.
Parameter: p216

AOT [x]: No
freshwater
filling in AOT
(LS201-29).

A119

Description

Trigger / Parameter

Alarm Alarm text


ID

5. Check that the level switch is


working correctly. See section
Level switch on page 54.

4. Examine the pipes related to


the CIP circuit. Make sure
that no material is clogging the
pipes.

What to do?

Deaerate the CIP, using the


deaeration valve on the CIP.

Air in fluid. The level


switch indicates this
as no fluid in AOT
reactor.

1. Check that pressure flushing


water in pipe 310 is according
to requirements in chapter 6.
Installation description and
drawings, section Connection
list.

Refill the tank with CIP liquid. See


instruction Change and refill CIP
liquid in chapter 7. Service manual.

Too low level in CIP


tank.

No liquid in
AOT reactor x.
LS201-29.x is
indicating dry
condition.

See W116 to troubleshoot the level


switch electrically.

Level switch at AOT


reactor LS201-29.x
malfunction.

Time set in parameter Change parameter.


is lower than needed.

Possible cause

2
List of alarms and warnings
2.1
Control system

33

34

Trigger: Level sensor Delay: Set in


LS201-29.
parameter p215.
Parameter: p200

AOT [x]: AOT


was not drained
(LS201-29).

W120

Description

Trigger / Parameter

Alarm Alarm text


ID
2. Check that valves (V310-6,
V320-4.x, V321-2.x and
V571-1) are operating correctly.
Also check that valve V310-3 is
OK and that V3108 is opened.
Operate the components
manually.

What to do?

Restart the process from the


beginning.

See W116 to troubleshoot the level


switch electrically.

Control that correct valves


(V3204, V4602, V2312,
V5711, overboard valve) are
opened for current process. Also
control that pump P3215 is
functioning.

Faulty valves in the


CIP unit.

See W116.

Control system

Level switch at AOT


reactor LS201-29.x
malfunction.

Time set in parameter Change parameter.


is lower than needed.

Fluid in AOT reactor


x. LS201-29.x
is indicating wet
condition.

Level switch at AOT


reactor LS201-29.x
malfunction.

Time set in parameter Change parameter.


is lower than needed.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: LDC cabinet


for AOT
Parameter: N/A

AOT [x]: Fuse


tripped in LDC
cabinet.

AOT [x]: MCB


tripped in LDC
cabinet.

W122

W126

Trigger: LCD x-1


Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Comment:
MCB=Motor circuit
breaker. AOT reactor
is deactivated.

Delay: 1 sec.

Delay: 1 sec.

Description

Motor circuit breaker


(MCB) for an LPS in
AOT.x has tripped or
has been switched
off.

Fuse in LDC has


tripped or has been
switched off.

Possible cause

Use the circuit diagrams for


the LDC and AOT reactor to
locate the component or find
the reason that caused the fuse
trip and attend to it.
Check cables to the
component. See AOT /
Circuit diagram and Lamp drive
cabinet (LDC) / Circuit diagram
in chapter 6. Installation
description and drawings.

List of alarms and warnings

3. Use the circuit diagram to


check the Ampere setting for
the MCB, adjust according
to figures in circuit diagram if
necessary and reset MCB.

2. Check Q101Q116 in LDC and


respective cables and LPS unit.

1. See LPS alarms in section


Lamp power supply (LPS) on
page 49.

Use the circuit diagram for the


LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary
and reset fuse.

Check fuse F4243 in LDC cabinet


to see what circuit caused the fuse
trip. Check according to bullets.

What to do?

2
2.1
Control system

35

36

Q117.

AOT [x]: LDC


cabinet fan
alarm

AOT [x]: LDC


cabinet water
alarm.

W128

W129

Trigger: Water
sensor LS below
heat exchanger in
LDC.
Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Delay: 5 sec.

Delay: 5 sec.

Description

Check that all electrical connections


are OK and that the electrical wiring
is not damaged.

Faulty electrical
connection.

See above.

Control system

Condensation in the
cabinet.

Dry wet areas in the cabinet.


Remove the sensor and dry it with
paper.

Repair.

Check electrical and mechanical


problems, and attend to.

Faulty fan.

Leakage in cooling
water piping.

Check Q117 in LDC.

Reset the breaker by turning the


handle.

Breaker on LDC has


tripped or has been
switched off.
Motor circuit breaker
(MCB) F1 in control
cabinet has tripped
or has been switched
off.

What to do?

Possible cause

2.1
2
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Lamp
power supply in AOT
reactors LDC.
Parameter: N/A

AOT [x]: LPS


sum alarm.

AOT [x]: UV
system failure.
Too many failed
lamps.

Estimated UV
lamp lifetime
exceeded.

A130

W131

W132

Delay: 2 sec.

Description

Trigger: AOT reactor


lap time.
Parameter: p218.

Delay: 1 sec.

Trigger: Lamp power Delay: 1 sec.


supply.
Comment: AOT
Parameter: p213.
reactor is deactivated.

Trigger / Parameter

Alarm Alarm text


ID

Lifetime for UV
lamps are too
exceed according
to estimated lifetime
in parameter.

Change according to instruction


Replace UV lamp and quartz
sleeve in chapter 7. Service
manual.

Recommended to change all lamps


after 3000 hours of operation.

Change according to instruction in


chapter 7. Service manual.

One or more UV lamp Check which lamps that are broken


is broken.
in column Lamp OK in page 4.9
LPS overview.

Check that all electrical connections


are OK on bus modules and that
the electrical wiring is not damaged.

Check that the signal wiring is


according to electrical drawings.

in column Lamp OK in page 4.9


LPS overview.

What to do?

Check LED indication on the LPS


that triggered the alarm. See LPS
Number of broken
alarms in section Lamp power
UV lamps exeeds
supply (LPS) on page 49.
number set in
parameter p213.
Check which lamps that are broken

LPS malfunction.

UV lamp OK signal
malfunction.

Possible cause

2
List of alarms and warnings
2.1
Control system

37

38

Trigger: TS201-60
Parameter: N/A

A137

AOT [x]: High


temperature
(TS201-60
tripped) and/or
LDC powered
off.

Trigger / Parameter

Alarm Alarm text


ID

Comment: AOT
reactor is deactivated.

Delay: 1 sec.

Description

Check components.
Control that valves and pumps are
functioning.
The LDC needs to be reset, see
above in this alarm description.
Check that the signal wiring
is according to electrical
drawings.
Check that all electrical
connections are OK and that
the electrical wiring is not
damaged.

LDC has been


powered off.
Faulty electrical
connection.

3. Acknowledge alarm A137 in


the control system.

2. Push the reset button on the


LDC. The button is placed
at the side facing the AOT
reactor. All LDCs must be reset
individually.

1. Turn on the power to the


cabinet/system.

Reset LDC

After problem has been attended


to, the LDC needs to be reset.

See W100.

What to do?

Faulty pump (ballast


or booster pump) or
valve.

No flow in AOT
reactor or too low
flow.

Possible cause

2.1
Control system
2
List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger AOT reactor


x.
Parameter: N/A

AOT [x]: PLC


error in LDC
cabinet.

CIP schedule
timer elapsed
Start CIP!

AOT [x]: Low


UV intensity
(QT201-50)

A138

W140

W150

Book No.9010182 02, rev. 0

Comment: CIP has not


been performed within
parameter set time limit
after (de)ballast.

Delay: Set in
parameter p117 and
p118.

Comment: AOT
reactor is deactivated.

Delay: 2 sec.

Description

Note: See chapter 3.


Operating instructions
and control system
description, section
Ballast water handling
in the event of
malfunction.

Trigger: UV sensor
Delay: 20 sec.
QT201-50.
Parameter: p220 and Comment: The
warning is issued if
p221.
the UV intensity falls
below value set in
parameter p221.

Trigger: Control
system timer.
Parameter: N/A.

Trigger / Parameter

Alarm Alarm text


ID

Old UV lamps.

Quartz sleeves dirty.

Low UV intensity in
AOT reactor.

CIP not performed


after operation.

Error in module.

Possible cause

Check runtime on page 4.4


Operation timers AOT in control
system. Change if old. Lamps
loose effect when maximum
runtime has been exceeded.

If problem remains, check and


clean quarts sleeves according to
instruction Replace UV lamp and
quartz sleeves in chapter 7.

Run CIP process, and try again.

It is also possible to fill the reactor


with fresh water to rule out muddy
water as reason for the warning.

Check water.

Start CIP process.

Control CIP status on page 1.3 CIP


status in control system.

Check the LED error indication for


the electronic modules in the LDC.
See section I/O system and X20
modules on page 56.

What to do?

2
List of alarms and warnings
2.1
Control system

39

40

Trigger: UV sensor
QT201-50.
Parameter: p220.

W151

AOT [x]:
UV intensity
signal missing
(QT201-50)

Trigger / Parameter

Alarm Alarm text


ID

See W150.

Test the UV sensor:


1. Stop the process and restart
the process again.

Transmitter
QT201-50.x
malfunction.

4. Check cables to QT201-50.x.


See the drawing Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

Control system

Note: Operation does


not fulfill the type
approval certificate.
Act according to ballast
water plan.

1. Check fuse F42 in LDC to see


which circuit that caused the
fuse trip.

Disable parameter p220 if the UV


sensor is out of order, to avoid
alarms.

2. In the control systems AOT


popup, see if the UV values are
OK during the start-up phase.
UV values shall be OK, since
clean cooling water is used.

What to do?

Possible cause

Comment: The
Signal missing.
warning is issued if
the UV intensity falls
below 484 w/m2. Power
is set to 100% for the
AOT reactor and the
flow is reduced.

Delay: 20 sec.

Description

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

AOT [x]: LPS


communication
error. AOT
shutdown.

W161

Trigger: LPS
Parameter: N/A

Check that the DIP switches


are correctly set for every LPS.
See chapter 4. Parameters,
section Lamp power supply (LPS)
parameters.
Change LPS. See instruction in
chapter 7. Service manual.

Faulty LPS.

Check modubus cable and power


cables.

Check the three LPS cable


connectors.

Wrong LPS setting.

Faulty connection of
electricity or signal
cable.

Delay: 1 sec.

AOT [x]: No
response from
LDC. AOT
shutdown.

W160

Delay: 1 sec.

See chapter 2. System overview,


section Operation with broken UV
lamp.

Trigger: AOT reactor. Delay: None.


AOT [x]: UV
lamp fail. System Parameter: p213
flow reduced.

W153

Trigger: N/A.
Parameter: N/A

See chapter 2. System overview,


section Power optimization.

Delay: None.

5. If the above is OK, the UV


sensor is probably broke and
needs to be replaced. Replace
the component.

Trigger: UV sensor
QT201-50.
Parameter: p221
and p237

What to do?

AOT [x]: UV
intensity low.
System flow
reduced.

Possible cause

W152

Description

Trigger / Parameter

Alarm Alarm text


ID

2
List of alarms and warnings
2.1
Control system

41

42

Trigger: None.
Parameter: p239

AOT [x]:
Circuit breaker
communication
error.

AOT [x]: Lamp


error feedback
from LPS.

AOT [x]: LPS


error feedback
from LPS.

AOT [x]: LPS in


fault state.

W162

W163

W164

W165

Warning is active
if parameter p239
Enable circuit breaker
data is activated.

Delay: None.

Description

Faulty modubus
signal cable.

Motor circuit breaker


(MCB) is broken.

Possible cause

Driver fault
Fan fault
Heat sink fault
System fault
Voltage fault

To continue process with one faulty


LPS, it is possible to set parameter
p213 (Allowed nr. of failed UV
lamps) to 1. Operation is allowed,
but does not fulfill the type approval
certificate.

Air temp fault

Check page 4.9 LPS power


overview and LED indication on the
LPS that triggered the alarm. See
LPS alarms in section Lamp power
supply (LPS) on page 49.

If the power is on but there are


no indication, the LPS is probably
broken.

Check page 4.9 LPS power


overview and LED indication on the
LPS that triggered the alarm. See
LPS alarms in section Lamp power
supply (LPS) on page 49.

One or more of the


below:

Faulty LPS.

Check UV lamp power cable.

Change according to instruction in


chapter 7. Service manual.

Check modubus cable W1 and W2.

Replace.

What to do?

Control system

Trigger: LPS in AOT Delay: 1 sec.


reactors LDC.
Parameter: N/A

Trigger: LPS in AOT Delay: 20 sec.


reactors LDC.
Comment: No LPS
Parameter: N/A
feedback when it is
requested to star its
lamp.

Trigger: LPS in AOT Delay: 20 sec.


Broken UV lamp.
reactors LDC.
Comment: No lamp
Parameter: N/A
feedback when it is
Faulty connection of
requested to be started UV lamp cable.
by the LPS.

Trigger / Parameter

Alarm Alarm text


ID

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Limit switch


GS20119.

Valve error
(V20119)

Valve error
(V20120)

LDC ring
redundancy
error

Filter: Sum
alarm.

W170

W171

W180

W300

Trigger: Filter.
Parameter: N/A

Parameter: N/A

Trigger: Limit switch


GS20120.

Parameter: N/A

Trigger: Limit switch


GS20120.

Parameter: N/A

Trigger / Parameter

Alarm Alarm text


ID

Comment: The
feedback signal Filter
SUM alarm is not
detected.

Delay: 1 sec.

Delay: None.

Delay: 15 sec.

Delay: 15 sec.

Description
Broken UV lamp

1. Check that breaker on the filter


junction box is on.

Motor problem.

List of alarms and warnings


2.1

2. Check that the motor is not


overloaded and can rotate
easily.

See LPS alarms in section Lamp


power supply (LPS) on page 49.

Check that the power link (LAN)


cable from the control cabinet (in a
loop to all LDCs) and back is OK.

Change LPS. See instruction in


chapter 7. Service manual.

Fan fault and temperature faults


can be caused by something that
is preventing the fan from rotate.

What to do?

Motor circuit breaker


(MCB) F1 in control
cabinet has tripped
or has been switched
off.

Faulty connection of
signal cable

See possible cause


for A17.

See possible cause


for A17.

Possible cause

2
Control system

43

44

Trigger: Pressure
transmitter PT201-27
on Boll filter.
Parameter: p314.

W304

Filter pressure
signal missing
(PT201-27).

Trigger / Parameter

Alarm Alarm text


ID

Comment: Error in
pressure transmitter.
Indication of pressure
-1.0 bar (-0.1 MPa) is
not an error.

Delay: 2 sec.

Description

Check that the filter flushing


arm can rotate freely. See 7.
Service manual, section Filter for
instructions.

3. Start the motor and check


that the operation is normal.
See chapter 3. Operating
instructions and control system
description, section Operate
components manually and
chapter 7. Service manual,
section Check filter gear motor
function.

What to do?

4. Check cables to the


component. See Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

Control system

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

Signal missing or flow 1. Check fuse F45 in Control


transmitter PT201-27
cabinet to see what circuit
malfunction.
caused the fuse trip.

Filter candle is
jammed, preventing
the flushing arm to
rotate.

Possible cause

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Pressure
transmitter PT201-27
on Boll filter.
Parameter: p301,
p314.

W306

Filter differential
pressure
too high
(PT-20127)

Trigger / Parameter

Alarm Alarm text


ID

Delay: 2 sec.

Description

Hint: Pressure signal from


PT201-27 is displayed on in the
Filter popup opened from page 1.1
Overview.

Pressure transmitter
PT201-27 does not
work correctly.

List of alarms and warnings


2.1

1. Check fuse F45 in Control


cabinet to see what circuit
caused the fuse trip.

Make sure that the two valves


connected to the filter differential
transmitter are open.

Valves connected
to filter differential
pressure transmitter
closed.

Check that the valve V201-26


in the filter is open.

Backflush manually from control


system. If not sufficient, clean
the filter candles according to
instruction in chapter 7. Service
manual.

Hint: Check pressure signal


from PT201-27 is displayed in
the Filter popup opened from
page 1.1 Overview.

7. Restart the process from the


beginning.

6. Replace transmitter FIT201-27.

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

What to do?

Filter is clogged.

Relative pressure in
filter is below 0 bar.

Possible cause

2
Control system

45

Trigger: Pressure
transmitter PT201-71
on Hydac filter.
Parameter: p314.

W308

46

Signal missing
or component
malfunction.

Possible cause
2. Use the circuit diagram to
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

2. Use the circuit diagram to


check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.

1. Check fuse F43 in LDC to see


which circuit that caused the
fuse trip.

7. Restart the process from the


beginning.

6. Replace transmitter FIT201-27.

5. Check that all electrical


connections are OK and that
the electrical wiring is not
damaged.

4. Check cables to the


component. See Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

What to do?

Delay: 2 sec.

Description

Control system

Filter pressure
signal missing
(PT201-71)

Trigger / Parameter

Alarm Alarm text


ID

2.1
List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Backflush failed Trigger: Hydac filter.


to start (timeout). Parameter: p314.

W314

Diff pressure too


high. Automatic
shutdown.

Filter pressure
signal missing
(PT309-2)

W312

Trigger: Pressure
transmitter on filter.
Parameter: N/A.

Delay: 15 sec.

Delay: 2 sec.

Delay: 2 sec.

Description

See W306.

See W308.

See W308.

See W308.

Possible cause

5. If the above is OK, the UV


sensor is probably broke and
needs to be replaced. Replace
the component.

4. Check cables to QT201-50.x.


See the drawing Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.

3. Use the circuit diagram to


locate the component or find
the reason that caused the fuse
trip and attend to it.

What to do?

List of alarms and warnings

W315

Trigger: Pressure
transmitter PT201-72
on Hydac filter.
Parameter: p314.

Filter pressure
signal missing
(PT201-72)

W310

Trigger: Pressure
transmitter PT309-2
on Hydac filter.
Parameter: p314.

Trigger / Parameter

Alarm Alarm text


ID

2
2.1
Control system

47

48

Trigger: Log box


(optional).
Parameter: p314.

W500

Log box hard


ware error.

Trigger / Parameter

Alarm Alarm text


ID
Delay: 10 sec.

Description
Check connections and cable for
power cable (W10) and Ehternet
cable (W104) between Control
cabinet and Log box.
Check fuse F02 and F03 in the log
box.
Check the LED error indication for
the electronic modules in the log
box. See section I/O system and
X20 modules on page 56.

Fuse in the log box


has tripped or has
been switched off.
Error in module.

What to do?

Faulty cable
connection.

Possible cause

2.1
Control system
2
List of alarms and warnings

Book No.9010182 02, rev. 0

List of alarms and warnings

2.2

2.2

Lamp power supply (LPS)

Lamp power supply (LPS)

This section explains alarms triggered by and displayed on the lamp power supply (LPS) in the
lamp drive cabinet (LDC). LPS alarms are indicated in the control system by alarm A130 Sum
alarm LPS unit.

2.2.1

List of alarms and status indications

The table below explains alarms triggered by and displayed in the LPS.
LED indication key
The LPS is equipped whit four light indications:
LPS on and communication is functioning.
5 LPSledG

5 LPSledG2

5 LPSledY

Flashes (once per second) when processor is running.


Flickering light during modbus communication.
Internal fault. Possible causes:

LPS temperature too high (> 50 C).

LPS fan faulty.


Lamp error. Possible causes:
5 LPSledR

Two lamp ignition failures.

Broken UV lamp.

Loose cables to UV lamp.


Lamp on.
5 LPSledB

Flickering during lamp ignition, approx 2 seconds when lamp is started.

5 LPSledB2

All lamps on Possible causes:

Faulty DIP switch setting on one or more LPS. This fault occur after a 10 seconds
delay after start.

Voltage on the fail safe is missing.

Book No.9010182 02, rev. 0

49

2.3

Flow meter

2.3

List of alarms and warnings

Flow meter

This section explains alarms triggered by and displayed in the flow transmitter, mounted on the flow
meter (FIT201-1). An alarm is indicated by two flashing triangles on the flow transmitter. During
normal conditions, all relevant alarms are displayed in the PureBallast control panel.

4FlowT_Alarm

Alarm time is displayed as time elapsed since the error occurred, and is showed as days, minutes
and hours.
Alarms and status are displayed in two lists, accessible from the Service mode screen in the flow
transmitter:

Pending error list: A list of the 9 most recent errors.


When an error is removed from the pending error list, it is moved to and stored in the status log.

Status log list. All errors are stored in the log for 180 days.

2.3.1

Fault finding instruction

1.

Does the light indicate power on?


Yes: Go to step 4.
No: Go to step 2.

2.

Check the following:

Cables and connections

Connection board

Pins in transmitter multiplug.

Are they OK?


Yes: Go to step 3.
No: Correct the fault.
3.

Is output reading OK?


Yes: The display is defect. Change.
No: The transmitter is defect. Change.

4.

Is the error triangle flashing?


Yes: Go to step 5.
No: The tranmsitter is defect. Change.

5.

Are the output and display readings OK?


Yes: Go to step 7.
No: Go to step 6.

50

Book No.9010182 02, rev. 0

6.

List of alarms and warnings

2.3

Flow meter

Check the following:

Cables and connections

Connection board

Pins in transmitter multiplug.

Are they OK?


Yes: Go to step 7.
No: Correct the fault.
7.

The transmitter is OK. Check the following: Settings, application, installation, sensor, earthing,
connections etc.

8.

The transmitter still not OK? Change settings according to chapter 4. Parameters, section
Flow transmitter parameters.

9.

If the problem cannot be detected or corrected, the transmitter must be replaced according to
the instruction Mount flow transmitter. Note that it is not necessary to reset parameters in the
new transmitter. The settings are stored in the Sensorprom unit. When the new transmitter is
replaced, settings are downloaded automatically.

2.3.2

Check flow meter error list

Follow this instruction to check the error list in the flow meter.
Buttons used:

4FT_Topup

Top up

4FTLock

4FTChange

4FTFwd

4FTBack

Padlock

Change

Forward

Back

1.

Press Top up for three seconds.

2.

To enter password (1000): Press Padlock. (A line appears under the first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The Basic settings menu appears after two seconds.

3.

Press Forward until the Service mode menu appears.

4.

Press Padlock, and then Forward until the Error pending menu appears.

5.

Press Padlock to display the error list.

6.

When done, press Top up three times to exit.


Result: Totalizer 1 is displayed.

2.3.3

List of alarms and problems

The table below explains alarms triggered by and displayed in the flow transmitter.

Book No.9010182 02, rev. 0

51

2.3

Flow meter

Problem ID

Description

Output
signals

Error Possible cause


code
(transmitter)

7A

Empty
display

Minimum

N/A.

7B

No flow signal Minimum

Undefined

7C

52

Indicates flow Undefined


with no flow
in pipe

N/A.

List of alarms and warnings

What to do?

No power supply

Power supply
Check flow transmitter for
bended pins on the connector

Flow transmitter
defective

Replace transmitter. See


chapter 7. Service manual,
section Flow meter.

Current output
disabled

Turn on current output

Digital output
disabled

Turn on digital output

Reverse flow
direction

Change direction

F70

Incorrect or no coil Check cables/connections


current

W31

Flow sensor (pipe) Ensure that the flow sensor


empty
(pipe) is full

F60

Internal error

P42

No load on current Check cables/connections


output

Replace transmitter. See


chapter 7. Service manual,
section Flow meter.

Transmitter
defective

Replace transmitter. See


chapter 7. Service manual,
section Flow meter.

P41

Initializing error

Switch off transmitter, wait 5


seconds and switch on again

N/A.

Measuring flow
sensor (pipe)
empty

Select empty pipe cut-off

Empty flow sensor


(pipe) cut-off is
OFF

Ensure that the flow sensor


(pipe) is full

Electrode
connection
missing/electrode
cable is

Ensure that electrode cable


is connected and sufficiently
screened

Book No.9010182 02, rev. 0

List of alarms and warnings

Problem ID

Description

Output
signals

2.3

Error Possible cause


code
(transmitter)

Flow meter

What to do?

insufficiently
screened
7D

Unstable flow
signal

Unstable N/A.

Pulsating flow

Increase time constant

Conductivity of
medium too low

Use special electrode cable

Electrical noise
potential between
medium and
sensor

Ensure sufficient potential


equalization

Air bubbles in
medium

Ensure medium does not


contain air bubbles. Deareate
the filter, using valve V201-50.

High concentration Increase time constant


of particles or
fibers
7E

Measuring
error

Undefined

Maximum

Book No.9010182 02, rev. 0

N/A.

Incorrect
installation

Check installation

P40

No Sensorprom
unit

install Sensorprom unit

P44

CT Sensorprom
unit

Replace Sensorprom unit or


reset Sensorprom unit with
MAG CT transmitter

F61

Deficient
Sensorprom unit

Replace Sensorprom unit

F62

Wrong type of
Sensorprom unit

Replace Sensorprom unit

F63

Deficient
Sensorprom unit

Replace Sensorprom unit

F71

Loss of internal
data

Replace transmitter

W30

Flow exceeds
100% of Qmax.

Check Qmax. (Basic Settings).


See parameters for flow
transmitter in chapter 4.
Parameters, section Flow
transmitter.

W21

Pulse overflow

53

2.4

Level switch

Problem ID

Description

Output
signals

Error Possible cause


code
(transmitter)

List of alarms and warnings

What to do?

- Volume/pulse too Change volume/pulse


small
- Pulse width too
large

Change pulse width

N/A.

Missing one
electrode
connection

Check cables

7F

Measuring
approx. 50%

7G

Loss of
totalizer data

OK

W20

Initializing error

Reset totalizer manually

7H

Signs in
display:
#####

OK

N/A.

Totalizer roll over

Reset totalizer or increase


totalizer unit

7I

Too low flow


signal

N/A.

Clogged sensor
electrodes in
sensor tube

Dismount sensor tube and


clean 4 sensor electrodes

7J

Negative flow
is indicated

N/A.

Flow meter is
mounted the
wrong way round.

Change parameter setting in


flow transmitter. See section
Flow transmitter parameters in
chapter 4. Parameters.

Parameter Flow
direction is
incorrectly set.

2.4

Level switch

This section explains the different status indications on the level switch LS201-29 in the AOT
reactor. Alarms and status are indicated by LED:s on the module.
Color

State

Description

Green

Steady

Power on and in operation.

Green

Off

No power supply.

Yellow

Steady

Wet condition.

54

What to do?

Check plug, cable and power


supply.

Book No.9010182 02, rev. 0

List of alarms and warnings

2.4

Level switch

Red

Blinking

Error: Internal sensor error or sensor


corroded.

Red

Steady

Error: Overload or short-circuit in load Rectify the short-circuit.


circuit.
Reduce maximum load current
to below 250 mA.

Book No.9010182 02, rev. 0

Replace the component.

55

2.5

2.5

I/O system and X20 modules

List of alarms and warnings

I/O system and X20 modules

This section explains the different status indications on the X20 modules. Alarms and status are
indicated by LED:s on the module.
All modules are identified on the front, for example X20 DO 6529 in the illustration below. To the
right, the stat indication LEDs are visible, for example r, e, X, I in the illustration below.

5X20

56

Book No.9010182 02, rev. 0

List of alarms and warnings

2.5

I/O system and X20 modules

The following modules are installed in the LDC or control cabinet:


Identification

Function

Installed in cabinet

CP3485-1

System module CPU

Control cabinet

DO6529

DO module, 6 x relay

Control cabinet

IF1082-2

Interface module, power link

Control cabinet

PS2100

Power feed, 24V

Control cabinet

AO4622

Analogue output

Control cabinet
Lamp drive cabinet

DIF371

Digital input

Control cabinet
Lamp drive cabinet

DO6529

Digital output

Control cabinet
Lamp drive cabinet

DO9322

Digital output, 12 outputs

Control cabinet
Lamp drive cabinet

AI4622

Analogue input

Lamp drive cabinet

AT4222

Temperature input module

Lamp drive cabinet

BC0083

Bus controller, power link

Lamp drive cabinet

CS1030

Interface module

Lamp drive cabinet

IF1030

Interface module, RS422/RS485

Lamp drive cabinet

S9400

24V power feed, bus supply

Lamp drive cabinet

2.5.1

List of alarms and status indications

Below, alarm and status indications displayed on the modules are explained.
NOTE

Note that all status indications are not valid for all modules.

The meaning of a status indication might vary for some modules. These variations are specified
in the Description column.

Module BC083, CP3485-1 and IF1082-2 are described in separate tables below the generic
table.

The table contains the following columns and information:

Book No.9010182 02, rev. 0

57

2.5

I/O system and X20 modules

List of alarms and warnings

Light
Color

Lights on the module.


Description of each lights color and behavior.

State
Description

Different status is indicated by various light states.


Meaning of the light state.

Light

Color

State

Description

Green

Red

Off
Single flashes
Blinking
On
Off
Single flashes

24 V DC supply not connected, check fuse.


Reset mode.
Preoperational mode.
RUN mode.
Module not supplied or everything is OK.
Warning / error for an I/O channel. Level
monitoring for digital outputs has responded.

Double flashes

AT4222: Overflow or underflow of the analog


inputs.
Indicates one of the following conditions:
X2X bus power supply is overloaded.

I/O supply too low.

r+e

X
I

On
Red/Green Red - steady /
Green - single
flashes
Off
Orange
On
Red
Off

Yellow

16

Orange

18

Green

112

Orange

112

Green

116

Green

On
Off
On
On

For PS9400: Input voltage for the X2X bus


supply too low.
Error or reset state.
Invalid firmware.

No communication at the X2X bus.


X2X bus communication in progress.
Bus controller / X2X link supply in acceptable
range.
Bus controller / X2X link supply overloaded.
No data traffic over service interface; no activity.
Data is transferred over the service interface.
In/output status of the corresponding digital
in/output.
Output status of the corresponding digital output.
In/output status of the corresponding digital
in/output.
In/output status of the corresponding digital
in/output.
Input status of the corresponding digital input.

58

Book No.9010182 02, rev. 0

List of alarms and warnings

2.5

I/O system and X20 modules

Light

Color

State

Description

12

Green

Off
Blinking

The input is switched off.


Overflow / underflow of the signal, or broken
connection.
The analog/digital converter is running, values
OK.
Value = 0.
Value 0.
Interface module is active.
CPU starting up.
The module is receiving data via RS485 (or
RS422) interface.
The module is sending data via RS485 (or RS422)
interface.
For CS1030: The module is sending data via
RS485 (or RS422) interface.
For CS1030: The module is receiving data via
(RS485 or RS422) interface.
For CS1030: The terminating resistor integrated
in the module is turned on.

On
14

Orange

Status
RxD

Green
Red
Yellow

Off
On
On
On
On

TxD

Yellow

On

Tx

Yellow

On

Rx

Yellow

On

Yellow

On

Module BC0083
Light
L/A IF1 Green
L/A IF2
S/E

Red

Color

Description

On
Blinking

Link to the remote station is established.


On and Ethernet activity present on the bus.
Bus controller error: Failed Ethernet frames, increased
number of collisions on the network etc.
Only during startup. This is not an error.
Bus controller is either powered of or not active.
Communication is not possible with the bus controller. After
5 seconds in this state, the bus controller restarts.

On
Blinking

Green

Off

If POWERLINK communication is detected during


the 5 seconds, the bus controller goes to status
PRE_OPERATIONAL_1 (single flash).

Green
Green

If no powerlink communication is detected, the bus controller


goes to BASIC_ETHERNET state (flickering).
Bus controler in operation.
On
Flickering
No Powerlink communication detected by bus controller.
(approx. 10 Hz) In this state you can communicate directly with the bus
controller using UDP.

Book No.9010182 02, rev. 0

59

2.5

I/O system and X20 modules

Light

Color

Green

Green

Green

Green

Single flash
(approx. 1 Hz)

Double flash
(approx. 1 Hz)

Triple flash
(approx. 1 Hz)

Blinking
(approx. 2.5
Hz)

List of alarms and warnings

Description

If POWERLINK communication is detected in this state, the


bus controller goes to state PRE_OPERATIONAL_1 (single
flash).
Bus controller in PRE_OPERATIONAL_1.
With operation on a POWERLINK V1 master, the bus
controller goes directly into PRE_OPERATIONAL_2.
With operation on a POWERLINK V2 manager, the CN
(Controlled Node) waits for the reception of a SoC frame
and then switches over to PRE_OPERATIONAL_2 (double
flash).
Bus controller in PRE_OPERATIONAL_2.
In this state the bus controller is normally configured by the
manager. A command (POWERLINK V2) or setting the data
valid flag in the output data (POWERLINK V1) then switches
the state to READY_TO_OPERATE (triple flash).
Bus controller in READY_TO_OPERATE.
In a POWERLINK V2 network, the manager then switches
via command to OPERATIONAL.
In a POWERLINK V1 network, the bus controller then
switches automatically to OPERATIONAL as soon as input
data are present.
Bus controller is in STOPPED.
No output data is produced and no input data is received.
Only the appropriate command from the manager can enter
or leave this state.

Module CP3485-1
R/E
RD/F

60

Green
Red
Yellow
Red

On
On
On
On

Application is running.
Service mode.
Service or boot mode.
Over-temperature.

Book No.9010182 02, rev. 0

List of alarms and warnings

S/E

Green
/Red

Green
on
Green
off

Red
off
Red
on

Blinking
alternately

Green
off

EPL

Green

ETH

Green

CF

Yellow
Green
Yellow
Red

DC
OK

Red
blinking

On
Blinking
On
Blinking
On
On
On
On

2.5

I/O system and X20 modules

Powerlink OK.
Fatal and irreparable system error. See control
system for alarm or warning. This status can only
be changed by resetting the module.
The powerlink managing node failed. This error
code can only occur in controlled node operation.
This means that the set station number lies within
the range $01 - $FD.
System failure according to blinking pattern:
Pause Pause: RAM error.
Pause Pause: Hardware error.
Link to powerlink remote station is established.
On and Ethernet activity present on the bus.
Link to Ethernet remote station is established.
On and Ethernet activity present on the bus.
Flash card OK.
Flash card active.
CPU power supply OK.
Backup battery is empty.

Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated in two moedes: Either
in Powerlink V mode or as an Ethernet TCP/IP interface. Status light depends on mode. For
TCP/IP mode, only SE green is valid.
Light
L/A X1
L/A X2
S/E

Green
Green
On

Off

Color
Red
On
Blinking
Off

On

Blinking alternately

Off

Red blinking

Description
Link to the remote station is established.
On and Ethernet activity present on the bus.
TCP/IP mode: Powerlink interface is operated purely as
an Ethernet TCP/EP interface.
Powerlink mode: Powerlinkt station is running, no errors.
Fatal and irreparable system error. See control system
for alarm or warning. This status can only be changed by
resetting the module.
The powerlink managing node failed. This error code can
only occur in controlled node operation. This means that
the set station number lies within the range $01 - $FD.
System failure according to blinking pattern:
Pause Pause: RAM error.
Pause Pause: Hardware error.

Book No.9010182 02, rev. 0

61

2.5

I/O system and X20 modules

List of alarms and warnings

Module DIF371
Light
S

Green Red

Description

Off
Single
flash
Blinking
On

Off
Off

Module not supplied, check fuse.


Reset mode.

Off

Prepoerational mode.

Off
Off
On

Run mode.
Module not supplied or everything is OK.
Invalid firmware

Single
flash

62

Book No.9010182 02, rev. 0

3 List of problems and solutions


This section contains problems that can occur, but is not indicated by an alarm.

3.1

General problems

Book No.9010182 02, rev. 0

63

Description

The system does not start. The


control panel does not light up.

Problem
ID

1A

64

1. Check fuse F42 in control cabinet to see what circuit


caused the fuse trip.

Fuse F42 tripped.

Replace control panel.


Let the panel dry and try again.

Control panel error due to


damp.

3. Use the circuit diagram to locate the component or


find the reason that caused the fuse trip and attend
to it.

2. Use the circuit diagram to check the fuse setting,


adjust according to figures in circuit diagram if
necessary and reset fuse.

1. Check fuse F41 in control cabinet to see what circuit


caused the fuse trip.

3. Use the circuit diagram to locate the component or


find the reason that caused the fuse trip and attend
to it.

General problems

Control panel error. Can be


caused by overheating etc.

Fuse F41 in control cabinet


tripped.

Turn on the power.

Power turned off at main


switch board

2. Use the circuit diagram to check the fuse setting,


adjust according to figures in circuit diagram if
necessary and reset fuse.

Turn on the breaker and measure that incoming 24 V DC


to the control panel is present.

What to do?

Main breaker Q1 on control


and LDC cabinet turned off,
or power not connected to
the control panel.

Possible cause

3.1
List of problems and solutions

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Error message on the screen.

1D

Communication is broken
If control panels are used: See the What to do column
between remote control panel for alarm A91.
and PLC.
If control panels are not used: Remove IP address for
Remote control panel 1 according to instruction is set
for the remote control panel. See chapter 3. Operating
instructions and control system description, section Set
remote control panel communication.

See the What to do column for alarm A93.

List of problems and solutions


3.1

5 PanelCommunicationError

PureBallast can not be controlled Communication is broken


or monitored from the ISCS
between ISCS and PLC.
graphical user interface via the
remote interface (optional)

Re-load the HMI software according to instruction Update


HMI software in chapter 3. Operating instructions and
control system description.

HMI software problem

1C

Check that the HMI and PLC software have the save
program version. This is visible in control system page
4.1 System info .

Wrong software version

3. If panel is not OK, it is probably broke and needs to


be replaced. Replace the component.

2. Restart the entire PureBallast system: Cut the power


by switching of the main breaker on the control
cabinet. Wait 30 seconds, and switch on the main
breaker again.

1. Restart the control panel: Cut the power by removing


the power cable at the back of the control panel.
Wait 30 seconds, and reconnect the cable again.

Abnormal operating
condition.

Control panel is not displaying a


normal page.

1B

What to do?

Possible cause

Description

Problem
ID

3
General problems

65

3.2

3.2

66

Filter

List of problems and solutions

Filter

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

5B

5A
Differential pressure
transmitter PT20127 (Boll)
may be faulty.

Excessive back flushing or


long backflushing sequences
(general)

See chapter 2. System description

Dirty water

Dirt build-up in the filter


candles.

Open the filter and remove the obstructions. See chapter


7. Service manual, section Filter.

Large obstructions have


entered the filter.

Clean the filter candles.

, section Backflushing for different dirt loads.

Check filter candles for damage. Replace if necessary.

Damaged filter candle.

Open the valve (ball cock) connected to V309-1.

Valves for air pressure to


valve V309-1 are closed.

Deaerate using the deaeration valve V201-50 on the


filter lid.

Open the two valves (ball cocks) connected to PT201-27.

Valves for differential


pressure gauge PT20127
(Boll) are closed.

The filter house is not


properly deaerated.

Dismantle the component and inspect/attend to.

Dismantle the component and inspect/rinse.

Error with the differential


pressure gauge electric
switches.

Differential pressure transmitters


Differential pressure
PT20171 and PT20172
transmitters PT20171
(Hydac) may be faulty.
and PT20172 (Hydac) may
be faulty.

Back flush sequence starting


error (general)

3
List of problems and solutions
3.2
Filter

67

3.3

3.3

68

CIP

List of problems and solutions

CIP

Book No.9010182 02, rev. 0

Insufficient pump capacity


(general).

Too high consumption of CIP


liquid (> 1 cm/AOT reactor
cycle).

CIP liquid is not returned to CIP


tank.

CIP pump does not run

6A

6B

Book No.9010182 02, rev. 0

6C

6D

Adjust setting with the manual valve under the valve


block on the CIP module.
Examine the pump. See chapter 7. Service manual,
section Repair CIP pump.
Examine the pump. See chapter 7. Service manual,
section Repair CIP pump.

Air pressure too low due to


incorrect setting on valve
block on CIP.
The diaphragm in the CIP
pump is broken.
Pump is clogged.

The air pressure is to low


The air connection is
blocked
Muffler is blocked
Air valve is defect
Dirt in the pump chamber
Diaphragm breakdown

Examine the pump and attend to problem. See chapter


7. Service manual, section Test CIP pump.

Investigate if there is a pipe blockage.

Pipe blockage

Examine the following valves: V571-1, V321-2.x,


V320-4.x and V321-1.

2. Check that pump P321-5 is functioning correctly.


See problem 6D6I in this chapter.

1. Increase airflow to the pump to increase pump


capacity with the manual valve under the valve block
on the CIP module.

Broken valve.

Insufficient pump capacity


(P321-5).

Leakage in the CIP tank, CIP Locate leakage and attend to.
pump, pipes or AOT reactor.

Locate leakage and attend to.

Leakage in air hoses or


sealings.

3
List of problems and solutions
3.3
CIP

69

CIP pump runs irregularly

Insufficient CIP pump suction

Bad flow or pressure in CIP


pump

CIP pump leakage

CIP pump muffler leakage

6E

6F

70

6G

6H

6I

Suction or air connection


blocked
Muffler is blocked
Air valve is defect
Valve balls worn
out/broken
Air in liquid Diaphragm
breakdown

Change diaphragm.

Diaphragm breakdown

Tighten the screws.

Examine the pump and attend to problem.

Examine the pump and attend to problem.

Examine the pump and attend to problem.

CIP

Screws on the housing not


properly fastened

Pressure fall in incoming


air

Valve balls are blocked


or damaged

Muffler is blocked

Diaphragm breakdown

Suction connection
blocked or not tight.

Sealings are defect in air


valve or center block

Valve balls are blocked

3.3
List of problems and solutions

Book No.9010182 02, rev. 0

List of problems and solutions

3.4

3.4

Valve V2018

Valve V2018

Book No.9010182 02, rev. 0

71

72

8C

Inaccurate positioning.
Input signal fluctuates.

Signal and positioning problems.

Check input signal.

Check electric connection.

Adjust position sensor. See chapter 7. Service manual,


section Calibrate positioner on V201-8.

Check coupling between proportional valve and


actuator.

Check I/P output.

Signal change results in actuator Connection or signal problem


running to end positions

Check input signal to proportional valve.

Faulty signal

8B

Check air supply to the valve and tubing to the actuator.


See chapter 7. Service manual, section Proportional
valve for instructions regarding the proportional valve.

Faulty air supply

Signal change has no effect on


the actuator position

8A

3.4
Valve V2018
3
List of problems and solutions

Book No.9010182 02, rev. 0

Chapter: 6. Installation description and drawings


System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1

Introduction

Ship specific information

Technical data

11

3.1

PureBallast system

11

3.2

PureBallast components

12

3.3

Working pressure and pressure drop

14

3.3.1

Working pressure during ballast operation and


during backflush
Pressure calculation

14
14

3.3.2

Installation guidelines

17

4.1

Preparations and conditions

17

4.1.1
4.1.2
4.1.3

Safety information
General installation requirements
Installation of components supplied by shipyard

17
17
18

4.2

AOT reactor

18

4.3

Filter

19

4.4

CIP module

20

4.5

Cabinets and cables

20

4.6

Flow meter

21

4.7

Pressure monitoring device

22

4.8

Pipes and valves

22

4.9

Air supply

23

System interfaces

25

5.1

Remote control panel integration


(optional)

25

5.2

Remote interface integration (optional)

27

5.2.1

Communication between PureBallast PLC and


remote interface
Directory of addresses

27
28

5.2.2

5.3

Power management system integration

45

5.3.1
5.3.2
5.3.3

Overall power request process


Power steps and power signals
Power management installation

46
46
47

5.4

External component signal integration

48

5.4.1

External component signal installation

50

5.5

GPS signal installation

50

Start-up procedures

53

Drawings

55

7.1

Graphic symbols used in drawings

56

7.2

General drawings

57

7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7

Flow chart
Connection list
Electrical system layout
Air distribution
Quality specification / Compressed air
Quality specification / Water
Quality specification / CIP liquid

57
58
64
65
66
67
68

7.3

Dimension drawings including technical


data

69

7.3.1
7.3.2
7.3.3
7.3.4
7.3.5

AOT reactor / Dimension drawing


Filter / Dimension drawing
CIP module / Dimension drawing (2 pages)
Flow transmitter FIT201-1 / Dimension drawing
Pressure monitoring device (Incl. PT201-16,
PI201-18, RV201 and 201-15) / Dimension drawing
Control valve V201-8 / Dimension drawing
Valve V201-3 and V201-9 / Dimension drawing
Valve V201-32 and V403-35 / Dimension drawing
Valve V212-31 / Dimension drawing (Optional in
scope of supply)
Sampling device Q201.1 and Q201.2 / Dimension
drawing (3 pages) (Optional in scope of supply)
Lamp drive cabinet (LDC) / Dimension drawing
Control cabinet / Dimension drawing
Remote control panel / Dimension drawing (2
pages)

7.3.6
7.3.7
7.3.8
7.3.9
7.3.10
7.3.11
7.3.12
7.3.13

69
70
71
73
74
75
76
77
78
79
82
83
85

7.4

Electrical drawings

7.4.1
7.4.2
7.4.3
7.4.4

Control cabinet / Interconnection diagram (7 pages)


Control cabinet / Circuit diagram (20 pages)
Control cabinet / Cable list
Lamp Drive Cabinet (LDC) / Interconnection
diagram (2 pages)
Lamp Drive Cabinet (LDC) / Circuit diagram (14
pages)
Lamp Drive Cabinet (LDC) / Cable list
AOT reactor module / Interconnection diagram (2
pages)
AOT reactor module / Circuit diagram (3 pages)
AOT reactor module / Cable list

7.4.5
7.4.6
7.4.7
7.4.8
7.4.9

87
87
95
115
116
118
132
133
135
138

Shutdown and storage

139

8.1

Decommissioning

139

8.2

Protection

140

8.3

Storage and long term decommissioning

140

8.4

Start-up after shutdown

141

Delivery and transport


information

143

9.1

Delivery and transport

143

9.2

Lifting instructions

143

9.2.1
9.2.2
9.2.3
9.2.4

AOT reactor
Filter
CIP module
Cabinets

144
145
147
147

1 Introduction
This chapter contains information about how the PureBallast system is to be installed and drawings.
The information is presented as installation guidelines per component, relevant standards and
drawings. The chapter is opened with a summary of the main technical data.

Book No.9010182 02, rev. 0

Introduction

2 Ship specific information


Enter vessel specific information in the table below. This will facilitate reading information and
drawings in this document, since some drawings include information for all system sizes /
dimensions, and the document contains information for options only used by on some vessels.
Data

Value

Flange standard

(EN or JIS): _______________

Main valve and piping

Dimension: ________________

Control valve (201-8)

Dimension: ________________

Bypass valve (V21231)

Dimension: ________________

Alfa Lavals or other.

Location: __________________

Cooling water valve (V403-35)

Dimension: ________________

Remote operation (optional)

Remote control panel (number): _________


Remote interface integration (yes/no): _____

Book No.9010182 02, rev. 0

Ship specific information

3 Technical data
This section states technical data for the complete PureBallast system and for individual
components. In some cases references are given to data in drawings included in this chapter.

3.1

PureBallast system

The table below states conditions, limit values etc. for the PureBallast system.
Type of data

Value

Water requirements

See section Quality specification / Water on page 67 and data for


different components in the Connection list on page 58.
Water temperature AOT reactor: 040 C.
Water temperature LDC cooling water: Max: 38 C ( 2 C).
Water types used in PureBallast:

Sea water: Used for cooling UV lamps in the AOT reactor during
start-up.

LT (low temperature) fresh water: Used for cooling the lamp drive
cabinet (LDC) during operation.

Fresh water: Used for flushing and filling up of AOT reactors after
treatment.

Ambient air
temperature

055 C.

Relative humidity

Max. 90 %.

System flow

Flow range ballast (m3/h): 190


750

Power consumption

Maximum power consumption (kW): 101

Flow range deballast (m3/h):


100 1000

Based on maximum:

Compressed air
requirements

Book No.9010182 02, rev. 0

100 kW
1 kW (Control system including PLC, 24 V feeding, CIP motor
supply, filter motor supply)

See data for individual components in Connection list on page 58 and


the Quality specification for compressed air on page 66.

11

3.2

PureBallast components

Technical data

Type of data

Value

Piping connections

See data for different components in Connection list on page 58.

Working pressure
PureBallast system

Max. 6 bar (PN 6). (0.6 MPa).

Working pressure
compressed air

See Connection list on page 58.

Power: Nominal
voltage/Frequency

400VAC +/-10% 50Hz


440VAC +/-10% 60Hz
24VDC - Remote control panel (optional).
Power to LDC: Max Icu 50 KA. (Fixed breaker setting: 200 amp.

IP raiting

Components within range IP44IP67.


See dimensional drawing for respective component in section
Drawings. Encapsulated components, for example in the control
cabinet, can have lower classification.

3.2

PureBallast components

The table below states conditions, limit values etc. for the individual component in the PureBallast
system. Dimensions are given in dimension drawings including technical data in the Drawings
section.
Component

Type of data

Value

AOT reactor

Pressure drop

See data for different components in Connection


list on page 58.

Weight (empty)

330 kg.

Volume
Filter

12

Pressure drop and


working pressure
for filter

0.20.50 bar (0.0050.05 MPA).

Weight, empty
with adaptor plates
on flanges (kg)

825

Volume (dm3)

304

See Working pressure and pressure drop on


page 14.

Book No.9010182 02, rev. 0

Technical data

3.2

PureBallast components

Weight, empty
(kg)

155 kg

Tank volume

250 liters. Note: Total tank volume is 300, but


shall only be filled to max 250.

Flow transmitter

Measures, weight
etc.

See dimensional drawing on 73.

Valves

Measures, weight
etc.

See section Dimension drawings including


technical data on page 69.

Type

See data for different components in Connection


list on page 58.

Connection type

EN or JIS.

Electrical cabinets

Measures, weight
etc.

See section Dimension drawings including


technical data on page 69.

Remote control panel


(optional)

Dimensions

See Remote control panel / Dimension drawing


on page 85 and on Remote control panel
integration page 25.

CIP module

Book No.9010182 02, rev. 0

13

3.3

Working pressure and pressure drop

3.3

Technical data

Working pressure and pressure drop

This section gives a description of working pressure and pressure drops in the system.

3.3.1

Working pressure during ballast operation and during backflush

During ballast operation, the ballast water flow goes through the filter and AOT reactor which
gives an approximate maximum pressure drop of 0.70 bar at maximum flow rate. Note that piping
outside the PureBallast system is not included. The pressure drop over the filter fluctuates between
approximately 0.20.5 bar depending on dirt load in the filter. The differential pressure over the
filter is monitored by one pressure transmitters on the filter inlet 201 and one on the filter outlet 201.
When the differential pressure reaches a parameter set limit (default is 0.5 bar), a backflush
operation is started automatically. To secure sufficient backflush flow, the pressure at Pfilter inlet
p309 (pressure loss in the backflush line). For detailed information
201 must be at least 1.0 bar +
about backflush, see chapter 2. System description, section Filter.

6 Working_Pressure_Hydac

Note: According to default parameter setting.

3.3.2

Pressure calculation

The information below is used when the ballast water system is dimensioned.
14

Book No.9010182 02, rev. 0

Technical data

3.3

Working pressure and pressure drop

Pressure during ballasting


During ballast operation, the ballast water flow goes through the AOT reactor which gives a
maximum pressure drop of 0.70 bar (not including vessels piping), as described in the table below.
Note that the total pressure drop only includes the PureBallast components, not the vessels piping
before the first PureBallast component (Q201.1 ) or after the last (V2018).
Filter

0.50 bar

AOT
reactor

0.20 bar

pAOT: 0.20 bar (0.02 MPa) including PureBallast valves. Piping


is not included, since it is installation specific.

Total

0.70 bar

0.70 bar (0.07 MPa) if parameter p305 is set to 0.50 bar.

Pressure during backflush


During backflush, the ballast water flow goes through the filter and AOT reactor, and the backflush
discharge flow goes through the filter and pipe 309.
A pressure calculation must be done to secure sufficient backflush flow in pipe 309 and to secure
that the ballast water pump can overcome the pressure drop (see table below). Note that the
calculated total pressure drop only includes components from the PureBallast inlet valve V2012
to the backflush over board valve.
Backflush
differential
pressure

1.0 bar

Difference between filter inlet 201 and filter backflush outlet


309.

P309

Calculated

The pressure drop for pipe 309 is installation specific and must
be calculated.
The connection list specifies required flow in pipe 309 to be
in range 60120 m3/h.
Use this flow to calculate the pressure drop in P309. Note
that P309 includes both static pressure and dynamic pressure
(pipe length, bends, valves etc) for pipe 309.

Total
pressure
drop

Calculated

Calculated pressure drop during backflushing give minimum


BW pump capacity required for PureBallast. If the value is
greater than existing pump capacity, steps must be taken, for
example:

Reduce the total pressure drop by reducing p309. This


can, for example, be done by increasing the pipe diameter
or by reducing the number of bends etc in pipe 309.

Upgrade to a pump with bigger capacity.

Calculate value for parameter Required pressure to start backflush


To ensure sufficient pressure at pfilter inlet 201, the total pressure drop during backflush operation
must be calculated according to the formula below:

Book No.9010182 02, rev. 0

15

3.3

Working pressure and pressure drop

Technical data

Pfilter inlet 201 1 bar + p309

Enter this value in parameter p304 (Required pressure to start backflush) in the control system page
5.4 Filter parameters. The parameter defines pressure needed to start a backflush operation.
The parameter is also the setpoint for the pressure that the control valve (V201-8) will maintain
during backflush.

16

Book No.9010182 02, rev. 0

4 Installation guidelines
This section covers requirements for installing different components of the system.

4.1

Preparations and conditions

Read this section before the system is installed.

4.1.1

Safety information

Earth connection must be made before any welding is done. The ground cable must have a
cross-section large enough in relation to the supply cables from the vessel. Otherwise the
equipment might be damaged during welding.

Follow local regulations for electrical installation and earthing (grounding).

Instructions on how to mount and install components are given in chapter 7. Service manual.

NG
WARNI

Read chapter 1. Safety.

Installation must be done by a fully trained professional installer.

Damages related to transport and installation should be recorded.

4.1.2

General installation requirements

The following requirements are valid for all components.

The Installation guidelines in this section must be followed.

Installation requirements given in the dimension drawings must be followed. See section
Drawings in this chapter.

Components must be properly suspended and supported.

There must be sufficient access to maintain the components. Access area is defined in the
dimension drawings.

Installed component must not amplify vibrations to or from the hull.

All piping connected to the PureBallast components (AOT reactor, filter and CiP module shall be
propperly self supported. No load shall be transferred to or from any major components.

Book No.9010182 02, rev. 0

17

4.2

AOT reactor

Installation guidelines

All components must be installed and marked as specified in dimension drawings, flow charts
and other drawings included in this manual.
-

General drawings overall and principle information for system layout (pipes, components,
electricity, air and water).

Dimension drawing detailed component information (dimensions, sizes etc).

Electrical drawings detailed electric information (circuit diagrams, cable lists etc).

4.1.3

Installation of components supplied by shipyard

Additional equipment, not part of Alfa Lavals scope of supply (for example cables, pipes) must
be installed according to the following sections of the manual:

Connection list

Quality specification for water

Quality specification for compressed air

Installation guidelines

Electrical drawings

4.2

AOT reactor

Follow the guidelines below when installing the reactor module.

18

Book No.9010182 02, rev. 0

Installation guidelines

4.3

Filter

The AOT reactor must be fixated at the bottom and supported at the top to carry the weight
of the component. Use the upper and lower fixing holes (1) in the support structure to fixate
the component to the steel construction of the hull. If this is not enough, completing stays has
to be made. There are four fixing holes on each side at the bottom and four at the top, after
the lifting beam has been removed.

6 AOT installation

Prepare the inlet piping first. Then mount the AOT reactor onto the inlet flange and secure it.
Finally install the outlet piping onto the top of the AOT reactor.

We recommend that the installation of the reactor is planned to be supported by its lifting point
until the units lower part is completely secured to the foundation and inlet flange.

No fixtures should be attached to the reactor housing by welding, since this will damage or
distort the reactor, and potentially affect the biological performance of the component.

The AOT reactor must be earthed. The earth nut is indicated as 791 in the dimension drawing.

4.3

Filter

Follow the guidelines below when installing the filter.

The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation.

Pipe 309 (filter back flush overboard line), with its valve, must be correctly connected.

The component must be earthed. The earth nut is indicated as 791 in the dimension drawing.

Book No.9010182 02, rev. 0

19

4.5

Cabinets and cables

4.4

Installation guidelines

CIP module

Follow the guidelines below when installing the CIP module.

The electrical cable is connected from the control cabinet to the CIP valve block. See chapter 7.
Service manual, section Connect electrical cables to valve block.

The component must be earthed. The earth nut is indicated as PE bolt in the dimension
drawing.

The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation.

Connections to the flanges must be made so that the connection is not exposed to any moment
or load. This is particularly important when connecting the plastic flanges.

4.5

Cabinets and cables

Follow the guidelines below when installing cabinets and cables.


NOTE

System interfaces (optional) must be integrated according to section System interfaces on page :
-

remote control panels

remote interface

power management

external component integration

GPS integration

Cabinets General

Cabinets must be firmly attached.

Cabinets must be earthed. The earth nut is indicated as 791 in the dimension drawing.

LDC cabinet

The cabinets maximum distance (cable length) to the AOT reactor: 150 meters.

The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation. It is possible to detach the cabinet from the
bottom frame to facilitate installation. The cabinet shall also be attached to the bulkhead using
the attachment bolts on the top of the cabinet.

It is possible to dismount the doors during installation: Slide the red catch on the hinge
backwards and release the locking mechanism.

Cables can be lead to the cabinet either from the floor or from the side of of the cabinet,
depending on which is most convenient. If needed, the location of the cable gland cassette
and the cover is exchanged. Power cable W201.1 to be connected to LDC: Max Icu 50 KA.
(Fixed breaker setting: 200 amp).

20

Book No.9010182 02, rev. 0

Installation guidelines

4.6

Flow meter

Signal cables W210A and B to be connected from X1 in LDC to junction box on the AOT reactor.
Cables from junction box to components are pre-assembled.

Lamp power cables W211A-D (included in scope of supply) shall be connected from X2 in
LDC to the (B side) junction box on the AOT reactor. Cables from junction box to lamps are
pre-assembled.

Control cabinet

Power cable W1 to be connected to control cabinet (Q1).

One power link cable shall be connected from the control cabinet (X6) to LDC1 (X5). Another
power link cable shall be connected from X6 back to A1.1 in the control cabinet.

Cables General

Recommendation: Make notes of the actual connections made to the vessels systems with part
number and cable number in the electrical drawings. The drawings are prepared with indicated,
empty squared for this purpose. The electrical diagrams are found in the Drawings section.
These notes can be used to make notes of the exact connections done during installation to
simplify future faultfinding.

Electrical cables must be properly routed and supported according to applicable regulations.

Cable entries to cabinets must be sealed, using the built in cable glands. See instruction
Cable glands in chapter 7. Service manual.

Cabling shall be done according to specification in Electrical system layout on page 64, and
the electrical drawings. This includes cable routing, cable types and cable marking to simplify
identification and fault finding.

Power cables shall be separated from signal and bus cables. Distance between them reduces
electrical noise transfer.

If placed on a cable rack, place power and signal cables on opposite sides.

If cables are routed in tubes due to narrow space, the power and signal cables shall be
routed in separate tubes.

EMC: Cables shall be peeled down to the cable shield. The nut holding the cable must be in
contact with the screen bar.

4.6

Flow meter

Follow the guidelines below.

The ballast water flow direction must be according to the arrow on the flow sensor.

The flow transmitter must be mounted on the flow sensor pipe. It is not pre-assembled from
factory. See chapter 7. Service manual for instructions.

Book No.9010182 02, rev. 0

21

4.8

Pipes and valves

4.7

Installation guidelines

Pressure monitoring device

Follow the guidelines below.

A drain solution (not part of Alfa Lavals scope of supply) must be attached to safety valve
RV201. The valve shall be drained to a scupper, with a solution which always allows water to
be drained from the valve. See Pressure monitoring device / Dimension drawing.

4.8

Pipes and valves

Follow the guidelines below when installing pipes and valves.

Inlet and outlet pipes must be correctly connected. They must also be pressure approved by a
classification society or equivalent, or be tested under supervision of a classification society
and/or at the ship yards pipe shop etc.

Pipes shall be designed to carry the weight of the component and media.

A bypass valve (optional part of Alfa Lavals scope of supply) must be installed. The bypass
valve (V212-31) shall be connected to the the vessels ISCS, to enable control of the valve, and
PureBallast control system to indicate valve position. See Control cabinet / Interconnection
diagram on page 87.

If PureBallast can be bypassed using other valves (apart from V212-31), status signals from
them must be connected to the control cabinet. All bypass cases must be logged.
Three additional by-pass valves can be handled, identified as additional bypass valve 1, 2 and
3. If more valves are used, they must be connected in series, which means that they are
handled as one regarding alarms and logging in PureBallast.
Signal cables for additional bypass valves are installed according to section External component
signal integration.

The yellow position indicator on actuators must be in line with the valve throttle. For pipes with
dimension 400, the red position indicator on the actuator coupling (see drawing) must also be in
line with the thottle. The position indicator must be in line with the pipe when the valve is open.
If not correct, change according to instruction in chapter 7. Service manual for instructions.

Valves shall be opened when installed. This is important to avoid that the rubber gaskets are
squeezed and damaged during installation.

Valve actuators pneumatic lines must be correctly connected and supported. See chapter
7. Service manual for instructions.

Valve actuators electric connectors must be correctly connected.

Sampling device Q201.1 and Q201.2.

22

If delivered by Alfa Laval: Must be mounted with the pin pointing in the flow direction (see
drawing on page 79).

Flanges for connecting the sampling devices must be installed before the pipe is coated.

Book No.9010182 02, rev. 0

Installation guidelines

4.9

4.9

Air supply

Air supply

Follow the guidelines below.

Components shall be connected to air supply that meets the requirements or the Quality
specification / Compressed air 66. Air shall always be connected.

Book No.9010182 02, rev. 0

23

4.9

Air supply

Installation guidelines

5 System interfaces
This section covers guidelines for how to install and integrate the following, if used:

remote control panels

remote interface (Not yet defined)

power management system (Not yet defined)

external components

GPS integration

Note that options are not applicable for all installations.

5.1

Remote control panel integration (optional)

The PureBallast system can, as an option, be equipped with up to four remote control panels.
Remote control panel integration requires the following:

14 remote control panels to be mounted at an optional location.

Communication cable (W501) between the switch (X13) in the control cabinet and the remote
control panel can be either Ethernet or fiber.
-

Ethernet cable Type: Cat 5e (or better). Max length: 100 meters. One free Ethernet
connection point (X13) in the switch in the control cabinet.

Fiber cable Type: Multi-mode fiber cable with LC connector. Max length: 500 meters.
Ports: Two free ports in the switch in the control cabinet.
If fiber is used, a network switch must be used, since the cable to the panel must be of
Ethernet type. One network switch and a 1.5 meter Ethernet cable is delivered with each
remote control panel.

If more remote control panels are to be installed than there are free fiber ports in the control
cabinet, one of the delivered network switches can be used for connection. From this switch,
it is possible to connect more panels using the free ports. Keep in mind that the cable to the
panel must be of Ethernet type. The extra switch shall be placed close to the first remote
control panel so the 1.5 meter Ethernet cable can be used.

External network switch including a terminal to handle the communication, placed near the
remote control panel. We recommend to use the external network switch close to the remote
control panel, even if it is not necessarey (if there are free ports in the control cabinet).

Network switch in control cabinet. It is installed if remote control panels have been ordered, but
can also be installed at a later stage.

A signal device must be installed according information in section Cabinets and cables on page
20. Not part of Alfa Lavals scope of supply.

Switches and cables are installed according to instructions in chapter 7. Service manual, section
Remote control panel (optional).

Book No.9010182 02, rev. 0

25

5.1

Remote control panel integration (optional)

System interfaces

Communication settings must be done according to instruction in chapter 3. Operating instructions


and control system description, section Set control panel IP address and Set remote control panel
communication.

26

Book No.9010182 02, rev. 0

System interfaces

5.2

5.2

Remote interface integration (optional)

Remote interface integration (optional)

The PureBallast system can, as an option, be integrated with the ISCS. This will allow operation
and monitoring of the system from the ISCS. This section presents guidelines for how to connect
and implement the integration via the remote interface.
PureBallasts PLC communicate with the vessels ISCS via the remote interface. Data is sent to
and from dedicated addresses via modbus. Data can be commands, values (sum of bits), alarms
and status information. The data is then presented in the ISCS according to the vessels graphical
standard. It is possible to present all information (all addresses) or a selection. Data is sent as
binary code, with exception for time, which is sent as hexadecimal code.
Remote interface integration requires the following:

Cable W602 to be connected from connection terminal (X15) in control cabinet to ISCS.

Modbus connection from ISCS to PureBallast connection terminal X15 in the control cabinet.
Connection standard: RS485 (or RS422, not described in electrical drawings) according to
Control cabinet / Interconnection diagram. Recommended max length: 500 meters.

Implementation of remote interface signals in the ISCS according to the guidelines in this section.

Communication settings must be done according to chapter 3. Operating instructions and


control system description, section Set remote interface communication.

Parameter p132 and p128 must be set in the control system.

After installation and integration, the function of the remote interface must be verified according
to chapter 3. Operating instructions and control system description, section Test remote
interface communication.

A signal device must be installed according to information in section Cabinets and cables on
page 20. Not part of Alfa Lavals scope of supply.

Reference information about the logical flow of the PureBallast processes can be found in chapter
3. Operating instructions and control system description, section Detailed process description.

5.2.1

Communication between PureBallast PLC and remote interface

This section describes all addresses in the remote interface, to handle the communication. These
addresses are displayed in the control system page 5.5 Remote interface 1 and 5.6 Remote interface
2, described in chapter 3. Operating instructions and control system description. Page 4.5 and 4.6
are used to verify that the integration functions and that correct information is displayed in the ISCS.
Modbus settings
The ISCS modbus RTU server data shall be set according to the table below:
Area

Value

Interface type
Baud rate
Parity
Databits
Stop bits
Modbus

Parameter option
Set in parameter p700 p704 in page
4.7 Remote interface. See chapter 4
Parameters for detailed information.

RTU

Book No.9010182 02, rev. 0

N/A

27

5.2

Remote interface integration (optional)

Communication
meth,od

Serial

N/A

Slave ID

10

N/A

System interfaces

PureBallast
is slave
and ISCS is
master.

5.2.2

Directory of addresses

This section list all addresses for the information sent between the systems.
The following terms are used to explain the signals in the tables below:
Address:Bit

The start address is 40000. Individual address and bit for each signal (data), is
written as Address:Bit, for example +073:14. Values for an address is written
as Address=Value, for example 015=125.
Bits are the Signal reference number. Bits are right aligned in the table.

Function

Name of the function. The name corresponds to the text used in the
PureBallast control system HMI. Parenthesis gives reference to the control
system page where the information is used/displayed. For further information
about respective piece of information, see chapter 3. Operating instructions
and control system description.

Description

Additional information, for example specific conditions that must be met before
a command can be sent.

The directory starts on next page.

28

Book No.9010182 02, rev. 0

System interfaces

5.2.2.1

5.2

Remote interface integration (optional)

Data from ISCS

The addresses below are used to send commands and status information from ISCS to PureBallast.
Example of data: Command to start a ballast process and feedback that the ballast water pump
is running.
Address:
40000 +

Function

Description

+001

Commands
Condition: All signals for +001 must be high until PureBallast return an
accept or reject signal (see +140).
Bit 0

Start ballast

Command: Start ballast

Bit 1

Start deballast

Command: Deballast

Bit 2

Start CIP

Command: Start CIP


Prerequisite: Only possible during standby.
Note: CIP will be performed for AOT reactors
that requires CIP, indicated by signal AOT reactor
(100:6, 200:6or 300:6 = 0)

Bit 3

Stop

Command: Stop ongoing process. It shall always


be possible to send this command.

Bit 4

Pause/Heeling

Command: Pause ongoing process.


Condition: Only possible during full ballast
(+042=2) and full deballast (+042=9).

Bit 5

Bit 6

Bit 7

Manual backflush
(Filter popup)

Command: Start backflush.

Ack all alarms and


warnings (2.1)

Command: Acknowledge all alarms and warnings.

Apply new flow (1.1


and 1.2)

Confirm activation of new flow selected using


address +003 (Selected flow).

Condition: Only possible during full ballast


(+042=2).

Condition: Signal shall be high so long it can be


assumed that it is received by the PureBallast,
considering the installation specific conditions.

Condition: Only possible during Standby (+041=1),


full ballast (+042=2) and full deballast (+042=9).
Condition: Signal high to confirm. Signal shall be
high until a response to the selection in +001:7 is
sent. We recommend that the signal is high the
new flow is confirmed (address +018 is updated
with the new flow).

Book No.9010182 02, rev. 0

29

5.2

Remote interface integration (optional)

Address:
40000 +

Function

+002

Feedback
Bit 0

Bit 1

+003

System interfaces

Description

Ballast water pump


status (1.1)

Status: 1=Started. 0=Stopped.

Overboard valve
status (1.1)

Status: 1=Open. 0=Closed.

Select AOTs) (1.1,


1.2)

If set during standby: Defines which flow to be


used when ballast or deballast is started. If set
during ballast or deballast: Defines that the flow
shall be increased or decreased to the new flow.

Response to address +040:8.

Response to address +040=9.

Number of AOT reactors is sent to PureBallast as


a value, which represent the maximum flow for
process (for a 300 respective 1000 reactor):
1=300 / 1000 m3/h
2=600 / 2000 m3/h
3=600 / 3=3000 m3/h.
In some installations the filter capacity is lower than
the total capacity of installed AOT reactors, defined
in parameter p315. In this case current max flow
will be reduced to this flow by PureBallast. The
reduced will be sent to address +056.
The selection can be visualized in ISCS either as
number of AOT reactors (1, 2, 3 etc) or the flow that
corresponds to the number of AOT reactors.
Condition: Only possible during Standby (+041=1),
full ballast (+042=2) and full deballast (+042=9).
Condition: The number of AOT reactors required
for the selected flow must not be greater than the
number of AOT reactors indicated as ready in
address +054 (Numbers of AOT reactor ready).
Condition: The selection must be applied using
+001:7.
Note: This signal shall only be changed when the
operator want to change flow; all other times it shall
be constant. This will simplify operation, since the
selection for last process is set as default for next
process.

30

Book No.9010182 02, rev. 0

System interfaces

5.2

Remote interface integration (optional)

Address:
40000 +

Function

Description

+004

By-pass (1.1)

Status: PureBallast system bypassed.


Condition: If this address is > 0 PureBallast is
by-passed. Ongoing process is shut down and
an event is written to the event log with the value
in this address.

Bit 015

The bits can represent integer values between 0


and 32 767.
The value can be used to log a component or a
combination of components that result in a by-pass
of PureBallast.
If it is not possible to use value that correspond
to valve ID:s, a key must be kept on board that
state which valve or combination of valves the
value represent. This is necessary to be able to
understand the event log.

+005

Power granted (1.4)

Only relevant if PureBallast is integrated with the


vessels power management system.
Condition: Response to address +045:03. Signal
shall be high until signal +046:0-3 goes high.
Note that it is possible for the vessels power
management system to grant lower power than
requested.

Bit 04

Power granted 14.

Bit 13: Power granted for the number of AOT


reactors sent.
Bit 4: Power granted for the total number of AOT
reactors installed.

+006

Heartbeat (4.5)

Status: Handshaking between PureBallast and


ISCS. ISCS send an arbitrary value to address
+047. PureBallast return same counter to confirm
communication. After defined interval, ISCS send
a new number, in a continuous loop. A counter
can be used as value. Recommended interval: 10
seconds.
Condition: Value must be sent as a signed 16 bit
integer between 0 and 32 767.

5.2.2.2

Data to ISCS

The addresses below are used to send data from PureBallast to ISCS.
Example of data: System flow and pressure.
Book No.9010182 02, rev. 0

31

5.2

Remote interface integration (optional)

System interfaces

Address:
40000 +

Function

Description

+050

Processed volume (1.1)

Value: Processed volume [m3] during current


ballast or deballast process. The value is resets
during next start-up.

+051

Flow measurement (1.1,


1.2)

Value: Current flow indicated by FIT201-1


(/m3/h).

+052

System pressure
PT20116 (1.1)

Value: System pressure indicated by PT201-16.


Condition: The value sent from PureBallast
must be multiplied by 0.01 before presented in
ISCS.
Example: If value 450 is sent (and displayed
in page 5.5), this means that actual pressure is
4.50 bar.

+053

Selected AOTs (1.2)

Value: Number of AOT reactors selected for


operation.
Response to address +003 after applied by
address +001:7. Alternative, response to
parameter p131 (Automatic selection of AOT
reactors) if activated in control panel.
Note that PureBallast can respond with a lower
number of AOT reactors than set in +003, for
example if one AOT reactor is not ready.
It is recommended that this address is compared
to +003. If the number is lower, a message can
be displayed in the ISCS to inform the operator
that process will run with a lower flow than
expected.
If flow is increased during operation, this address
will be updated when the new AOT reactors are
started. If flow is decreased during operation,
this address will be updated immediately.

+054

Number of AOTs ready


(1.2)

Number of AOT reactors that are ready for use


in process.

+055

Selected flow (1.2)

Flow selected for process in m3/h.


Response to address +003 after applied by
address +001:7.

32

Book No.9010182 02, rev. 0

System interfaces

5.2

Remote interface integration (optional)

Address:
40000 +

Function

Description

+056

Current max flow (1.1, 1.2)

Maximum flow in m3/h for process, based on


number of selected AOT reactors and filter
capacity.
Max flow is calculated as number of selected
AOT reactors multiplied with AOT reactor
capacity (300 or 1000 depending on size).
In some installations the filter capacity is
lower than the total capacity of installed AOT
reactors, defined in parameter p315. In this case
current max flow will be reduced to this flow by
PureBallast.
Response to address +003 after applied by
address +001:7.

+057

Current time - Low (4.1)

Value: Seconds since 1970-01-01 00:00,


in combination with address +058. Sent as
hexadecimal code.
Condition: The value sent from PureBallast
must be calculated from seconds since
1970-01-01 00:00 to actual date and time.

+058

Current time - Hi (1.2)

Value: Seconds since 1970-01-01 00:00, in


combination with address +057.

+059

Remaining time for CIP


(hours) (1.3)

Value: Total estimated remaining time (hours) for


all CIP sequences and filter preservation

+060

Remaining time for CIP


(min) (1.3)

Value: Total estimated remaining (minutes) time


for all CIP sequences and filter preservation.

+061

Remaining time until CIP


req. (hours) (1.3)

Value: Hours before CIP must be performed.


Displayed per AOT reactor.
Note: In the control system, the counter is
set to 0 after an AOT reactor has been CIP
cleaned. The countdown starts after next
ballast or deballast operation. However, for
remote interface, the value 30 is sent after CIP
cleaning, but without countdown. The countdown
starts after next operation.

+062

Remaining time until CIP


req. (min) (1.3)

Value: Minutes before CIP must be performed.


Displayed per AOT reactor.
For details, see +062.

Book No.9010182 02, rev. 0

33

5.2

Remote interface integration (optional)

System interfaces

Address:
40000 +

Function

Description

+063

Filter differential pressure


(Filter popup: dP inlet/outlet)

Value: Filter differential pressure indicated by


PT201-71 and PT201-72.
Condition: The value sent from PureBallast
must be multiplied by 0.01 before presented in
ISCS.
Example: If value 34 is sent (and displayed in
page 5.5), this means that actual pressure is
0.34 bar.

+064

Filter inlet pressure


V20171 (Filter popup)

Value: Filter differential pressure indicated by


PT201-71.
Condition: The value sent from PureBallast
must be multiplied by 0.01 before presented in
ISCS.
Example: If value 34 is sent (and displayed in
page 5.5), this means that actual pressure is
0.34 bar.

+065

Filter outlet pressure


V20172 (Filter popup)

Value: Filter differential pressure indicated by


PT201-72.
Condition: The value sent from PureBallast
must be multiplied by 0.01 before presented in
ISCS.
Example: If value 34 is sent (and displayed in
page 5.5), this means that actual pressure is
0.34 bar.

+066

V2018 setpoint (1.1)

Control valve output signal (%).

+067

Power consumption (1.1,


1.4)

Only relevant if PureBallast is integrated with the


vessels power management system.
Value: Calculated maximum power consumption
[kW] based on number of selected AOT reactors.
Calculated or measured power consumption
(kW).

5.2.2.3

Commands and status to ISCS

The addresses below are used to send commands and status information from PureBallast to ISCS.
Example of data: Process mode (standby, ballast, CIP), acceptance of command from ISCS, and
request to ISCS to start ballast pump.

34

Book No.9010182 02, rev. 0

System interfaces

Address:
40000 +

Function

5.2

Remote interface integration (optional)

Description

/ Bit
+070

Command status
Bit 0

Start ballast accepted

Status: Confirmation from PureBallast that


requested command is executed.
Response to command from ISCS on address
+001:0.

Bit 1

Start deballast accepted

Status: Confirmation from PureBallast that


requested command is executed.
Response to command from ISCS on address
+001:1.

Bit 2

Start CIP accepted

Status: Confirmation from PureBallast that


requested command is executed.
Response to command from ISCS on address
+001:2.

Bit 3

Stop accepted

Status: Confirmation from PureBallast that


requested command is executed.
Response to command from ISCS on address
+001:3.

Bit 4

Pause/Heeling accepted

Status: Confirmation from PureBallast that


requested command is executed.
Response to command from ISCS on address
+001:4.

Bit 5

Manual backflush accepted


(filter popup)

Command: Start backflush.


Response to command from ISCS on address
+001:5.
Condition: Only possible during full ballast
(+073:2)

Bit 6

Command rejected

Status: Information that requested command


cannot be executed. Reason not specified.
Response to command from ISCS on address
+001:0-7.

Book No.9010182 02, rev. 0

35

5.2

Remote interface integration (optional)

Address:
40000 +
Bit 7

System interfaces

Function

Description

Sum alarm

Common alarm indicating that one (any) alarm


is active. Alternative to implementation of
individual alarm signals and hard wired common
alarm. Functions in the same way as hard wired
external signal Common alarm.
Note: If common alarm is issued when there
already is an active alarm (this signal already
high), PureBallast will lower the signal for 3
seconds, and then re-activate it as high.

Bit 8

Sum warning

Common warning indicating that one (any)


warning is active. Alternative to implementation
of individual warning signals and hard wired
common warning. Functions in the same way as
hard wired external signal Common warning.
Note: If common warnings issued when there
already is an active warning (this signal already
high), PureBallast will lower the signal for 3
seconds, and then re-activate it as high.

Bit 9

New flow in progress (1.3)

Status: New flow in progress.


Response to command from ISCS to change
flow during ongoing operation applied by address
+001:7.

Bit 10

+071

36

Local / Remote (5.5)

Request: Address values.


1=Activate operation from remote interface.
0=Activate operation from control panels.

Commands
Bit 0

Start ballast water pump


(1.1)

Request to ISCS to start ballast water pump:


Address values.
1=Request to start.
0=Request to stop.

Bit 1

Open overboard valve (1.1)

Request to ISCS to open overboard valve:


Address values:
1=Request to open.
0=Request to close.

Book No.9010182 02, rev. 0

System interfaces

5.2

Remote interface integration (optional)

Address:
40000 +

Function

Description

+072

Process mode (1.1, 1.3)

Status: Address values: Values indicating


system mode.
0=Booting
1=Standby
2=Ballast
3=Deballast
4=CIP
5=Emergency stop
6=Manual mode

+073

Subprocess mode (1.1, 1.3)

Status: Address values: Values indicating


system mode.
0=None
1=Start-up ballast
2=Full ballast
3=Backflush
4=Pause
5=Stop with backflush
6=Increasing ballast flow capacity
7=Decreasing ballast flow capacity
8=Start-up deballast
9=Full deballast
10=Pause deballast
11=Stop deballast
12=Increasing deballast flow capacity
13=Decreasing deballast flow capacity
14=AOT reactor drain 1 Sea water
15=AOT reactor fill 1 Fresh water
16=AOT reactor drain 2 Fresh water
17=CIP
18=AOT reactor fill 2 Fresh water
19=Preservation filter Fresh water
20=Heeling mode
21=CIP drain
22=Stop (If ballast process is stopped before
mode Full ballast, no backflush is performed.)

+074

Filter mode

Status: Address values:


0=Idle (No backflush or preservation).
1=Backflush preparation.
2=Backflush ongoing.
3=Filter preservation.

+075

Power request [14] (1.4)

Only relevant if PureBallast is integrated with the


vessels power management system.
Value: Calculated maximum power consumption
[kW] based on number of selected AOT reactors.

Book No.9010182 02, rev. 0

37

5.2

Remote interface integration (optional)

Address:
40000 +
Bit 04

System interfaces

Function

Description

Power request [14] (1.4).

It is only necessary to use signals (bits) to cover


the need for power request. This is defined by
the number of AOT reactors, alternatively use
of common power.
Bit 13: Power request for the number of AOT
reactors to be used in operation.
Bit 4: Power request for the total number of AOT
reactors installed.

Power running [14] (1.4)

+076

Only relevant if PureBallast is integrated with the


vessels power management system.
For information about power request, see system
manual chapter 6. Installation description and
drawings, section Power management.
Power request to power management system.

Bit 04

Response to address +005:04.

Power running [14] (1.4).

Bit 13: Power running for the number of AOT


reactors used in operation.
Bit 4: Power running for the total number of AOT
reactors installed.
Heartbeat echo (4.5)

+077

5.2.2.4

Status: Handshaking between PureBallast and


ISCS. Receive counter from address +006 and
return same counter to confirm communication.
See address +006.

I/O status to ISCS

The addresses below are used to send status information for components to ISCS.
Example of data: Status for valves and pumps.
Address:
40000+

Function

Description

/ Bit
+080

38

Main valve status (1.1, 1.3 and popups for AOT reactor and filter)
Bit 0

V403-35

Status: Address value:


1=Open. 0=Closed.

Bit 1

V201-9

Status: Address value:


1=Open. 0=Closed.
Book No.9010182 02, rev. 0

System interfaces

5.2

Remote interface integration (optional)

Bit 2

V201-3

Status: Address value:


1=Open. 0=Closed.

Bit 3

V201-8

Status: Address value:


1=Open. 0=Closed.

Bit 4

V201-32

Status: Address value:


1=Open. 0=Closed.

Main pump status (AOT reactor popup)

+081
Bit 0

P401-1

Status: Address value:


1=Pump running request. 0=Stopp request.

Bit 1

P403-1

Status: Address value:


1=Pump running request. 0=Stopped request.

Main bypass valve status (1.1)

+082
Bit 0

V212-31

Status: Address value:


1=Open (PureBallast bypassed). 0=Closed.

Bit 1

External bypass valve 1

Status: Address value:


1=Open (PureBallast bypassed). 0=Closed.

Bit 2

External bypass nr. 2

Status: Address value:


1=Open (PureBallast bypassed). 0=Closed.

Bit 3

External bypass nr. 3

Status: Address value:


1=Open (PureBallast bypassed). 0=Closed.

CIP status (1.3)

+083
Bit 0

V571-1

Status: Address value:


1=Open. 0=Closed.

Bit 1

V321-4

Status: Address value:


1=Open. 0=Closed.

Bit 2

V321-1

Status: Address value:


1=Open. 0=Closed.

Bit 3

V460-2

Status: Address value:


1=Open. 0=Closed.

Bit 4

V320-2

Status: Address value:


1=Open. 0=Closed.

Bit 5

V310-1

Status: Address value:


1=Open. 0=Closed.

Bit 6

V310-6

Status: Address value:


1=Open. 0=Closed.

Bit 7

P320-1

Status: Address value:


1=Pump running. 0=Stopped.

Book No.9010182 02, rev. 0

39

5.2

Remote interface integration (optional)

Bit 8

P321-5

System interfaces

Status: Address value:


1=Pump running. 0=Stopped.

Filter status (Filter popup)

+084
Bit 0

V309-1

Status: Address value:


1=Open. 0=Closed.

Bit 1

M709-42

Status: Address value:


1=Running. 0=Stopped.

5.2.2.5

Alarms to ISCS

The tables below lists all alarms and warnings sent from PureBallast to the ISCS. Each alarm is
defined as a specific bit. The bit is set to 1 when the alarm is activated. The alarm IDs refer to alarms
described in chapter 5. Alarms and faultfinding, where texts to be displayed in ISCS can be found.
Example: If data at address 40902 is 000010000000100, this means that alarm W04 and warning
A33 are active (bit 2 and 10).
Empty fields are not used.
General alarms and warnings
Common alarms and common warnings (+900 and +901) indicate that there exist a common alarm
for the area or component specified.
Example of alarms and warnings: Process flow too high, valve error, component signals missing.
Address
40000 +

Common
alarms
+900

Common
warnings
+901

Main 1
+902

Main 2
+903

Main 3
+904

Filter
+905

Sum

Sum

A01

A51

W96

W300

Main

Main

A03

W58

W97

W304

AOT

AOT

W04

A66

A98 1

W306

CIP

CIP

A10

A67

A99 1

W308

Filter

Filter

W12

A68

W310

Power

Power

A13

A71

W312

Logbox

Logbox

A14

A75

W314

A17

A77

A315

A23

W79

A29

W80

Bit

40

W500

Book No.9010182 02, rev. 0

System interfaces

Address
40000 +

5.2

Remote interface integration (optional)

Main 1
+902

Main 2
+903

10

A33

W82

11

A35

W83

12

W40

A91

13

A48

W92

14

A49

A93

15

A50

W95

Common
alarms
+900

Common
warnings
+901

Main 3
+904

Filter
+905

Note 1: These alarms are only relevant for PureBallast 3.0 EX.

Book No.9010182 02, rev. 0

41

5.2

Remote interface integration (optional)

5.2.2.6

System interfaces

AOT reactor status to ISCS

The addresses below are used to send status information, alarms and warning for AOT reactors
and LDC to ISCS.
Status information
Addresses for data regarding AOT reactor and respective LDC are separated in number series to
distinguish information for individual AOT reactor/LDC, if more than one.

AOT reactor 1 / LDC 1 Addresses starting with +110

AOT reactor 2 / LDC 2 Addresses starting with +120

AOT reactor 3 / LDC 3 Addresses starting with +130

Empty fields are not used.


Example of data: Status for AOT reactor and LDC and their components, for example temperature,
UV intensity and valve status.
Address:
40000+

Function

Description

/ Bit
+110 / +120
/ +130

AOT status (AOT reactor popup)

Bit 0

AOT: Stopped (AOT popup)

Status: AOT reactor stopped.

Bit 1

AOT ready (1.2)

Status: AOT reactor is ready, which means that


there exist no critical alarms or warnings for the
AOT reactor (110:5, 120:5 and 130:5 = 0).
0=Not ready.
1=Ready. The AOT reactor can be selected and
used for process.

Bit 2

AOT selected (1.2)

Status: AOT reactor selected for process by


operator. In PureBallast, the AOT reactor is
visible in the list AOT reactors selected for
process in 1.3.
Response to address 001:7, apply of flow
selection.
Alternative, response to parameter p131
(Automatic selection of AOT reactors) if activated
in control panel.

42

Bit 3

AOT starting (1.1, 1.2)

Status: AOT reactor starting.

Bit 4

AOT Started (AOT popup)

Status: AOT reactor started.

Bit 5

AOT sum alarm (1.2 and


AOT popup)

Status: Common alarm indication for AOT


reactor. The AOT reactor is not ready.
Book No.9010182 02, rev. 0

System interfaces

5.2

Remote interface integration (optional)

Bit 6

AOT sum warning (1.2 and


AOT popup)

Status: Common warning indication for AOT


reactor. If the warning is not critical, the AOT
reactor may have status AOT ready.

Bit 7

AOT CIP required (1.3)

Status: CIP status for AOT reactor: 0=Not


required. 1=Required.

Bit 8

AOT CIP ongoing (1.3)

Status: CIP status for AOT reactor: 0=CIP not


ongoing. 1=CIP ongoing.

Bit 9

AOT CIP error (1.3)

Status: Error for AOT reactor during CIP process.

AOT I/O status (AOT popup)

+111 /
+121/
+131
Bit 0

LS201-29

Status: 1=Wet condition. 0=Dry condition.

Bit 1

TS201-60

Status: 1=OK (temp within limit). 0=Not OK


(temp exceeded limit).

Bit 2

V201-19

Status: Address value:


1=Open. 0=Closed.

Bit 3

V201-20

Status: Address value:


1=Open. 0=Closed.

Bit 4

V404-36

Status: Address value:


1=Open. 0=Closed.

Bit 5

V321-2

Status: Address value:


1=Open. 0=Closed.

Bit 6

Heat exchange valve


(V40151)

Status: :
1=Open. 0=Closed.

AOT LPS status 1 (4.9 and


AOT popup)

Status: Status per individual LPS in the AOT


reactor.

+112 / +122
/
+132
Bit 015
+113/
+123/
+133

Status: Address value:


1=Lamp on. 0=Lamp off.
AOT LPS status 2 (4.9 and
AOT popup)

Bit 015

Book No.9010182 02, rev. 0

Status: Status per individual LPS in the AOT


reactor.
Status: Address value:
1=LPS error. 0=LPS OK.
Status: Address value:
1=Lamp error. 0=Lamp OK.

43

5.2

Remote interface integration (optional)

+114/
+124/
+134

AOT temperature (AOT


popup)

System interfaces

Value: Temperature indicated by TT201-33.


Value displayed for selected AOT reactor.
Condition: The value sent from PureBallast
must be multiplied by 0.1 before presented in
ISCS.
Example: If value 221 is sent (and displayed in
page 5.5), this means that actual temperature
is 22.1 C.

+115/
125/
135
+116 / +126
/ +136

LDC water temperature


(AOT popup)

Value: LDC cooling water temperature in cabinet


indicated by TT401-1.
Condition: See +114.

LDC air temperature (AOT


popup)

Value: LDC air temperature in cabinet indicated


by TT401-2.
Condition: See +114.

+117 / +127
/ +137

UV intensity (AOT popup)

UV intensity in AOT reactor indicated by


QT201-50.

+118 / +128
/ +138

Power output (4.9)

Current LPS power consumption (50-100 %).

Alarms and warnings


Alarms and warnings for individual AOT reactors and LDCs are separated into different number
series according to the list below:

AOT reactor 1/ LDC 1: Address +910 912

AOT reactor 2 / LDC 2: Address +913 915

AOT reactor 3 / LDC 3: Address +916 918

Empty fields are not used.


Example of alarms and warnings: Hight temperature, fuse tripped, communication error for LPSs.
Address
40000 +

Alarms /
warnings 1
+910 / +913 /
+916

Alarms /
warnings
+911 / +914 /
+917

Alarms /
warnings
+912 / +915 /
+918

Bit
0

W100

W130

W170

W101

W131

W171

44

Book No.9010182 02, rev. 0

System interfaces

5.3

Address
40000 +

Alarms /
warnings 1

W102

W132

W107

W137

W109

A138

W111

W113

W140

W116

W150

W117

W151

W118

W160

10

W119

W161

11

A120

W162

12

W122

W163

13

W126

W164

14

W128

W165

15

W129

5.3

+910 / +913 /
+916

Alarms /
warnings
+911 / +914 /
+917

Power management system integration

Alarms /
warnings
+912 / +915 /
+918

Power management system integration

It is possible to connect the PureBallast control system to the vessels power management system
or ISCS. The purpose is to automatically handle power request from PureBallast to secure that
enough power is available for each ballast and deballast process. A process can only start after
acceptance from the ISCS.
The communication is either handled by the remote interface (if the option is integrated) or via hard
wires between the vessels ISCS and PureBallasts control cabinet. It is also possible to use
hard wire, even if remote interface is integrated.
Power management requires the following:

Parameter setting must be done for parameter p127.

Integration and connection of signals must be done according to the guidelines in this section.

Book No.9010182 02, rev. 0

45

5.3

Power management system integration

5.3.1

System interfaces

Overall power request process

Below, the overall power request process is described. The process is based on three signals
types: Power request, power granted and power running.
1. A ballast or deballast process is started from the PureBallast control system.
2. Before the UV lamps are lit, a power request is sent from the PureBallast control system to
the ISCS.
3. After power check, the power management reserves the requested power for PureBallast and
then send power granted to the control system. If the vessel cannot provide the requested
power, less power might be granted. The exact granted power is always visible in the field
Calculated power consumption in control system page 1.5 Power request or 1.1 Overview.
4. The ballast/deballast continues the start-up process and the UV lamps are lit. The control
system confirms this by sending back a power running signal to confirm that the power is used.
5. When the process is stopped from the control system, the power running signal is deactivated.

5.3.2

Power steps and power signals

The power management system is based on defined power steps, defining the power needed for
1-3 AOT reactors: Step 1 extend to one AOT reactor and step 2 extend to three AOT reactors. .
Signals are defined to handle all combinations of power step (amount of power) and function
(request, grant and run). More than one signal can be sent (or received) at the same time to
achieve, for example step 1 and 2 to request power for 3 AOT reactors.
As an alternative, it is possible to use power step 4 (common) that always will be used, regardless
of the number of AOT reactors used for a specific process. The common power is defined as the
number of installed AOT reactor times the defined power consumption for one AOT reactor.
Function signal

No. of
AOT
reactor:s

Signal to
terminal

Power
(kW)

Request, step 1

Terminal strip X2
Terminal 41/42.

33

Terminal strip X2
Terminal 43/44.

65

Terminal strip X2
Terminal 47/48.

33-97

Relay module
X12. Relay K5.
Connection point
BB and A1.

33

Request, step 2

Request, step 4
(common)

1-3

Granted, step 1

46

101

201

101-401

101

Book No.9010182 02, rev. 0

System interfaces

5.3

Power management system integration

Function signal

No. of
AOT
reactor:s

Signal to
terminal

Power
(kW)

Granted, step 2

Relay module
X12. Relay K6.
Connection point
BB and A1.

65

Relay module
X12. Relay K8.
Connection point
BB and A1.

33-97

Terminal strip X3
Terminal 49/50.

33

Terminal strip X3
Terminal 51/52.

65

Terminal strip X3
Terminal 55/56.

33-97

Granted, step 4
(common)

1-3

Running, step 1

Running, step 2

Running, step 4
(common)

5.3.3

1-3

201

101-401

101

201

101-401

Power management installation

The signals are hard wired and shall be connected to corresponding terminals (same ID) in the
control cabinet according to Control cabinet / Interconnection diagram on page 87. Note that the
drawing indicate a Step 4, which is not used.
Note that It is only necessary to connect enough signals to cover the number of AOT reactors
installed on the vessel. If one AOT reactor is installed it is only necessary to connect step 1 for
request, granted and running.
After installation, the signals need to be tested. This is done by simulating signals from the control
system, page 1.4 Power request. See chapter 3. Operating instructions and control system
description, instruction Simulate power request.

Book No.9010182 02, rev. 0

47

5.4

External component signal integration

5.4

System interfaces

External component signal integration

The following components and functions (not part of Alfa Lavals scope of supply) can be integrated
with the control system. The communication is either handled by the remote interface (if the option
is integrated) or via hard wires.
Each signal that is used must be activated in the control system page 5.2 Main parameters 2.
Output indicates signal from PureBallast and Input indicates signal from ISCS.
Signal

Control
cabinet

Explanation

Common alarm (strongly


recommended to be
integrated)

Output

What: Output signal from PureBallast that there is an


(any) active alarm. An alarm shuts down ongoing process.

Common warning

Output

How: Active alarm = Open circuit. If an alarm is already


present and a new alarm is issued, the signal will go low
for three seconds, and the be re-activated as high.
What: As common alarm, but for warnings. A warning is
a notification of status change or a problem.
How: See common alarm.

External system stop

Input

What: Input signal to PureBallast to shut down the


system. If extra button (not part of AL scope of supply) to
shut down PureBallast are desired on board. The power
is still on.
How: Open circuit = System stop command. Must be
connected via hardwire (W117).

Heeling mode (internal


transfer)

Input

What: Input signal to PureBallast to to enter heeling mode.


Equal to pushing the Pause button in control system.
If integration of heeling command from ISCS is desired to
automatically pause ongoing ballast/deballast process for
a healing operation.
How: Closed circuit = Heeling mode command. Only
possible in standby, ballast or deballast.

Additional bypass 1 is
open
Additional bypass 2 is
open
Additional bypass 3 is
open

Input

What: Input signal to PureBallast that an external by-pass


valve (not part of Alfa Lavals scope of supply).
If PureBallast can be bypassed using other valves
(apart from V212-31), status signals from them must be
integrated to the control system. All bypass cases must
be logged. When any bypass valve is opened, ongoing
process is terminated and the event is logged.
Three additional by-pass valves can be handled via hard
wire, identified as additional bypass valve 1, 2 and 3. If
more valves are used, they must be connected in series,
which means that they are handled as one regarding
alarms and logging in PureBallast.

48

Book No.9010182 02, rev. 0

System interfaces

Signal

5.4

Control
cabinet

External component signal integration

Explanation

If remote interface is implemented, feedback signals can


be connected via the remote interface, which allows a
great number of components to be connected.
How: Open circuit = Valve open.
Request Start BW
pump

Output

What: Output signal from PureBallast to request opening


of relevant valves (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the valve are closed.
If Request and Feedback signals are integrated, the
operator does not have to confirm that the OB valve
is open/closed in a popup in the control panel during
operation.
How: Request = Closed circuit. No request and request
withdrawal = Open circuit.

Feed back Ballast


water pump is running

Input

What: Input signal to PureBallast to confirm that the


ballast pump is started.
How: Closed circuit = Pump running.

Request Open
overboard valves

Output

What: Output signal from PureBallast to request opening


of relevant valves (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the valve are closed.
Relevant valves: 201, 309 and 403 and 404 (and 460.1
during CIP process). Note that the signal is mainly
intended for the valves apart from those leading to and
from pipe 201
If Request and Feedback signals are integrated, the
operator does not have to confirm that the OB valve
is open/closed in a popup in the control panel during
operation.
How: Request = Closed circuit. No request and request
withdrawal = Open circuit.

Feed back Overboard


valve is open

Input

What: Input signal to PureBallast to confirm that relevant


valves are open.
How: Closed circuit = Valve open.

Booster pump (P401-1),


for LDC cooling

Output

What: Output signal from PureBallast to request start of


the LDC cooling pump for line 401. Pump P401-1 is used
during ballast, deballast, pause and heeling mode.
How: Request = Closed circuit. No request and request
withdrawal = Open circuit.

Book No.9010182 02, rev. 0

49

5.5

GPS signal installation

System interfaces

Signal

Control
cabinet

Explanation

Booster pump (P403-1),


for AOT reactor reactor
cooling

Output

What: Output signal from PureBallast to request start of


the AOT reactor cooling pump for line 403. Pump P403-1
is used during start-up, ballast, deballast, pause and
heeling mode.
How: Request = Closed circuit. No request and request
withdrawal = Open circuit.

PureBallast running

Output

What: Output signal from PureBallast that a process is


running.
How: Pump running = Closed circuit.

5.4.1

External component signal installation

The input and output signal cables must be connected according to the drawing Control cabinet /
Interconnection diagram on page 87. This section gives additional information to the drawing on
how to connect the cables.
Input signals
Chosen input signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 87.
Output signals
Chosen output signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 87. Output signals are connected via potential free relays.

5.5

GPS signal installation

This section describes the installation of GPS position signal to PureBallast. This installation is
optional. If used, the GPS position is used to stamp events in the event log.
The GPS must be connected to the module X20IF1030 in the control cabinet, using an NMEA
(RS422) serial interface with the following settings:

Baud rate: 4800 bps

Parity: None

Bits/characters: 8

Stop bits: 1

The position data shall be sent as RMC messages.


For details, see the illustration below (based on the Control cabinet / Interconnection diagram on
page 87).

50

Book No.9010182 02, rev. 0

System interfaces

5.5

GPS signal installation

6 GPS

Book No.9010182 02, rev. 0

51

5.5

GPS signal installation

System interfaces

6 Start-up procedures
The actions below must be performed after installation, before system is put into operation. This
is important to avoid that the filter and the AOT reactor is damaged by material from the ballast
tanks or remainders from the installation. These actions shall be performed both for new builds and
retrofit installations.
Before first operation
Before the system is operated the first time the actions below must be done.
NOTE

All pipes leading to PureBallast must be well flushed to avoid that debris harm the filter and
AOT reactor quartz sleeves.

All ballast water tanks must be well cleaned before PureBallast is tested or put into operation.
This is valid both for new builds and retrofit installations.

First operation
Before first operation the actions below must be done:

During the first operation, the filter shall be bypassed, to avoid that debris harms the filter
elements.

We recommend that a strainer is used during the first operations, to avoid that debris harms
the system.

The first time a tank is stripped, PureBallast must be bypassed, to avoid that debris harms
the system.

Book No.9010182 02, rev. 0

53

Start-up procedures

7 Drawings
This section contains drawings for the PureBallast system. It is divided into three main parts:

General drawings overall and principle information for system layout (pipes, components,
electricity, air and water).

Dimension drawing detailed component information (dimensions, sizes etc).

Electrical drawings detailed electric information (circuit diagrams, cable lists etc).

See the Contents section at the beginning of this chapter to get an overview of included drawings.

Book No.9010182 02, rev. 0

55

7.1

7.1

Graphic symbols used in drawings

Drawings

Graphic symbols used in drawings

Symbols used in drawings are according to ISO 14617. Below, a guiding extract is shown.

573644

56

Book No.9010182 02, rev. 0

Drawings

7.2

General drawings

7.2.1

Flow chart

Book No.9010182 02, rev. 0

7.2

9007243

General drawings

57

7.2

General drawings

7.2.2

Drawings

Connection list

Connection list for Ballast water treatment system according to flow chart 9007243.
Item /
Connection

Description

Requirements/limits

Main components
201

Ballast water
Inlet/Outlet

Flow range ballast


(m3/h): 140
300190 750

Flow range
deballast (m3/h):
100 1000

Sea water

Max. particle size: 10 mm

Temperature: 40 C (liquid form)

Min flow deballast with one AOT reactor reactor in


operation (m3/h): 100

Max pressure: 6 bar (0.6 MPa)

Ref: figure Pressure and pressure drop after the table.


Q201.1
V201-2

Sampling device
Valve
(optional)

Ref. drawing 590066 on page 79

As above.

Q201.2
V201-25
V201-3

Main valves

V201-9
V20132

Ref. drawing 9007178 or 9008463

Ref. drawing 9007178 or 9008463

Ref. drawing 9007178 or 9008464

Ref. drawing 9007176 or 9008461 (Optional)

V212-31
V201-8

Control valve (flow


control during normal

operation and pressure

control during filter


back flushing)

IP201-7

IP converter

S201-7

Strainer

58

Ref. drawing 9007182 or 9008467, on page 75


Flow restriction acc. to certified flow rate.
Control of pressure, min 0.15 MPa.

Book No.9010182 02, rev. 0

Drawings

7.2

General drawings

Item /
Connection

Description

Requirements/limits

403

Cooling water Reactor


Inlet

Sea water

Max pressure: 6 bar (0.6 MPa)

Pressure drop: 0,05 bar (0.005 MPa)

Min. flow: 20 m/h (during start up, ~ 5 min.)

Max. particle size: 5 mm

V403-35

Valve

Ref. drawing 9007180 or 9008465 on page

FIT201-1

Flow transmitter

Ref. drawing 586502 on page 73

V201-15
PI201-18
RV201
PT201-16

Needle valve
Pressure gauge
Safety valve
Pressure transmitter

Ref. Pressure monitoring device drawing 9007999


on page 74

Filter connections, drawing 9006982


201

Filter inlet / outlet

Ref. filter connections drawing on page 70.

309

Backflush water

Sea water

Backflush range (m3/h):60 120 (Intermittent, approx.


35 sec during backflush). Ref: figure Pressure and
pressure drop after the table.

V309-1

Reject valve

Ref. filter connections drawing, connection 309 on


page 70.

310.2

Flushing
miscellaneous

Ref. filter connections drawing, connection 310.2 on


page 70.

Fresh water preservation volume: 152 L

Flanged, blanked

Ref. filter dimension drawing, connection 460 on page


70.

460

Drain Filter

AOT reactor connections, drawing 9003516


V201-19
V201-20

Inlet / outlet

Ref. AOT reactor dimension drawing

404

Cooling water
Reactor outlet

Over board

Flow: ref. to con. 403

Book No.9010182 02, rev. 0

59

7.2

General drawings

Item /
Connection

Description

Requirements/limits

V320-4

CIP / Drain

V321-2

Reactor outlet

V404-36

Cooling water

Drawings

Ref. AOT reactor dimension drawing on page 69.

Lamp drive cabinet (LDC), drawing 9005331

401

Cooling water Lamp


Drive Cabinet (LDC)
Inlet

Fresh water (existing cooling system)

Max. particle size: 600 m

Temperature: 0 38 C

Cooling capacity: 5 kW

Working pressure: 1 10 bar (0.1 1.0 MPa)

Pressure drop: 15 bar (0.15 MPa)

Min. flow: 1.5 m/h (1.5 m3/h each LDC) @ 38 C

SV401-51

Valve

Ref. LDC dimension drawing on page 82.

402

Cooling water LDC


outlet

Back to recirculation (suction side)

CV402

Valve

Ref. LDC dimension drawing on page 82.

CIP unit connections, drawing 9004714

60

Book No.9010182 02, rev. 0

Drawings

7.2

General drawings

Item /
Connection

Description

Requirements/limits

310.1
310.2

Flushing
miscellaneous

Fresh water (potable)

Quality requirements: see 590773 on page 67

Volume:
380 L/ rinsing & preservation (2 cycles x 1 reactor x
190 L)
.

Min pressure: 3 bar (0.3 MPa)

Ref. CIP module dimension drawing on page on page


71.

V310-1

Valve

V310-3

Backflow preventer

V310-6
V310-8

Valve

CV310-7

Strainer

320

Flushing
miscellaneous, reactor
module

Sea water / fresh water

CIP liquid quality requirements, see 594956 on page


68

V320-2
V320-11

Valve

Ref. CIP module dimension drawing on page 71.

P320-1

Pump

Diaphragm pump (pneumatic)

321

Flushing
miscellaneous, reactor
modue

Sea water / fresh water

CIP liquid

Pump

Ref. CIP module dimension drawing on page 71.

Diaphragm pump (pneumatic)

Sea water / fresh water

Normally no flow

Volume: 380 L (1 reactor x 190 L sea water drained


and 1 reactors x 190 L fresh water drained before CIP
sequence). Flow: 60 L/min.

Ref. CIP module dimension drawing on page 71.

P321-5

V321-1
V321-4

Valve

460.1

Drain Reactor

V460-2

Valve

CV460-4

Check valve

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61

7.2

General drawings

Item /
Connection

Description

Requirements/limits

460.2

Drain CIP module

By gravity

Normally no flow

Volume: 300 L

Drawings

V460-3

Valve

Ref. CIP module dimension drawing on page 71.

571

De-aeration
AOT reactor / CIP

Air

V571-1

Valve

Ref. CIP module dimension drawing on page 71.

Ref. 595208 on page 65

Required pressure: 5.5 8.0 bar

Air (total system consumption)


501

Instrument air

Max consumption:

62

During ballast and deballast operation: Max 30 NL/min.

Consumption: continuous, max 30 NL/min, peak load,


0.6 Nm3/min (during CIP sequence: 25 min, pump
running.

Quality requirements: see 553407 on page 66

Book No.9010182 02, rev. 0

Drawings

7.2

General drawings

6 Working_Pressure_Hydac

pfilter

pAOT
pfilter inlet
p309

- Filter pressure drop, depending on filter contamination. (dynamic and


static pressure).
0.2 0.5 bar Normal operation.
0.5 bar Filter backflushing sequence triggered.
- AOT reactor pressure drop (dynamic and static pressure).
- 1.0 bar + p309: Required pressure to establish effective back flushing
of filter.
- Pressure drop, (dynamic and static pressure), line 309 (back flush over
board).

Book No.9010182 02, rev. 0

63

7.2

General drawings

7.2.3

Drawings

Electrical system layout

9005353

64

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Drawings

7.2.4

7.2

General drawings

Air distribution

585828

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65

7.2

General drawings

7.2.5

Drawings

Quality specification / Compressed air

553407

66

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Drawings

7.2.6

7.2

General drawings

Quality specification / Water

590773

Book No.9010182 02, rev. 0

67

7.2

General drawings

7.2.7

68
594956

Drawings

Quality specification / CIP liquid

Book No.9010182 02, rev. 0

Drawings

7.3

Dimension drawings including technical data

7.3

Dimension drawings including technical data

7.3.1

AOT reactor / Dimension drawing

Book No.9010182 02, rev. 0


9003516

69

7.3 Dimension drawings including technical


data

7.3.2

70

9006982

Drawings

Filter / Dimension drawing

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Drawings

7.3.3

7.3

Dimension drawings including technical data

CIP module / Dimension drawing (2 pages)

71

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9004714_p1

7.3 Dimension drawings including technical


data

Drawings

9004714_p2

72

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Drawings

7.3.4

7.3

Dimension drawings including technical data

Flow transmitter FIT201-1 / Dimension drawing

Book No.9010182 02, rev. 0

586502

73

7.3 Dimension drawings including technical


data

7.3.5

Drawings

Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and


201-15) / Dimension drawing

74

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9007999

Drawings

7.3.6

7.3

Dimension drawings including technical data

Control valve V201-8 / Dimension drawing

Book No.9010182 02, rev. 0

9007182

75

7.3 Dimension drawings including technical


data

7.3.7

76

Drawings

Valve V201-3 and V201-9 / Dimension drawing

9007178

Book No.9010182 02, rev. 0

Drawings

7.3.8

7.3

Dimension drawings including technical data

Valve V201-32 and V403-35 / Dimension drawing

Book No.9010182 02, rev. 0

9007180

77

7.3 Dimension drawings including technical


data

7.3.9

78

Drawings

Valve V212-31 / Dimension drawing (Optional in scope of supply)

9007176

Book No.9010182 02, rev. 0

Drawings

7.3

Dimension drawings including technical data

7.3.10 Sampling device Q201.1 and Q201.2 / Dimension drawing (3


pages) (Optional in scope of supply)

590066 1

Book No.9010182 02, rev. 0

79

7.3 Dimension drawings including technical


data

Drawings

590066 2

80

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Drawings

7.3

Dimension drawings including technical data

590066 3

Book No.9010182 02, rev. 0

81

7.3 Dimension drawings including technical


data

Drawings

7.3.11 Lamp drive cabinet (LDC) / Dimension drawing

9005331

82

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Drawings

7.3

Dimension drawings including technical data

7.3.12 Control cabinet / Dimension drawing

Book No.9010182 02, rev. 0

9005261_p1

83

7.3 Dimension drawings including technical


data

Drawings

9005261_p2

84

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Drawings

7.3

Dimension drawings including technical data

7.3.13 Remote control panel / Dimension drawing (2 pages)

595261_p1

Book No.9010182 02, rev. 0

85

7.3 Dimension drawings including technical


data

Drawings

595261_p2

86

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Drawings

7.4

Electrical drawings

7.4

Electrical drawings

7.4.1

Control cabinet / Interconnection diagram (7 pages)

Filter type 1 = Boll filter. Filter type 2 = Hydac filter.

Book No.9010182 02, rev. 0

87

7.4

Electrical drawings

Drawings

9005343_Page_22

88

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Drawings

7.4

Electrical drawings

9005343_Page_23

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89

7.4

Electrical drawings

Drawings

9005343_Page_24

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Drawings

7.4

Electrical drawings

9005343_Page_25

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91

7.4

Electrical drawings

Drawings

9005343_Page_26

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Drawings

7.4

Electrical drawings

9005343_Page_27

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93

7.4

Electrical drawings

Drawings

9005343_Page_28

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Drawings

7.4.2

7.4

Electrical drawings

Control cabinet / Circuit diagram (20 pages)

Book No.9010182 02, rev. 0

9005343_Page_01

95

7.4

Electrical drawings

Drawings

9005343_Page_02

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Drawings

7.4

Electrical drawings

9005343_Page_03

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7.4

Electrical drawings

Drawings

9005343_Page_04

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Drawings

7.4

Electrical drawings

9005343_Page_05

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7.4

Electrical drawings

Drawings

9005343_Page_06

100

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Drawings

7.4

Electrical drawings

9005343_Page_07

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101

7.4

Electrical drawings

Drawings

9005343_Page_08

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Drawings

7.4

Electrical drawings

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7.4

Electrical drawings

Drawings

9005343_Page_10

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Drawings

7.4

Electrical drawings

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7.4

Electrical drawings

Drawings

9005343_Page_12

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Drawings

7.4

Electrical drawings

9005343_Page_13

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7.4

Electrical drawings

Drawings

9005343_Page_14

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Drawings

7.4

Electrical drawings

9005343_Page_15

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Electrical drawings

Drawings

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Electrical drawings

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Drawings

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Electrical drawings

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Electrical drawings

Drawings

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Drawings

7.4.3

7.4

Electrical drawings

Control cabinet / Cable list

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115

7.4

Electrical drawings

7.4.4

116

Drawings

Lamp Drive Cabinet (LDC) / Interconnection diagram (2 pages)

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Drawings

7.4

Electrical drawings

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7.4

Electrical drawings

7.4.5

118

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7.4

Electrical drawings

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Drawings

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Electrical drawings

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Drawings

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Drawings

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7.4

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Drawings

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Drawings

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Drawings

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7.4

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7.4

Electrical drawings

7.4.6

Drawings

Lamp Drive Cabinet (LDC) / Cable list

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Drawings

7.4.7

7.4

Electrical drawings

AOT reactor module / Interconnection diagram (2 pages)

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7.4

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Drawings

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7.4

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AOT reactor module / Circuit diagram (3 pages)

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Drawings

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7.4

Electrical drawings

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7.4

Electrical drawings

7.4.9

Drawings

AOT reactor module / Cable list

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8 Shutdown and storage


This section describes requirements for decommissioning and storage. The rules must be followed
when the system shall be shutdown for a long period.
A copy of the decommissioning report must be placed inside the control cabinet. The report must
include all important information from the decommissioning, for example notes and information
about where to find stored components.

8.1

Decommissioning

Follow the process below to decommission the PureBallast system. Note that if there is a freeze
risk, the system must be completely emptied of water.
1. Run the back flush sequence for the filter three times.
2. Drain all water from the filter. Leave the drain open afterwards.
3. Run the CIP process twice.
4. Drain all liquid from the AOT reactors. Leave the drains open. (Use the drain plug at the
bottom of the AOT reactor.)
5. Shut off the main valves for the start-up cooling system. Drain the system afterwards.
6. Isolate the start-up cooling system: Close installed service valve, or use a blind flange, to
prevent fluid to enter the section. (Pipe connection 403, 404.)
7. Drain all water from the LDC heatexchangers. Leave the drains open afterwards (disconnect
hoses). Shut off the main valves for the cooling system (pipe connection 401).
8. Clean the CIP module with fresh water. Rinse the tank. Drain all water/liquid from the CIP
system and leave the drains open afterwards.
9. Isolate the system: Close installed service valves, or use a blind flange, to prevent fluid to
enter the section. (Pipe connection 310, 460.)
10. Drain water from the pipe systems between the main inlet valve (V201-3, V201-9) and control
valve (V201-8). Leave any open drains open afterwards.
11. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 201.)
12. Drain all water from the filter back flush line. Leave the drain flange in the bottom of the filter
open afterwards.
13. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 309.)
14. Shut off the breakers on the control cabinet and the lamp drive cabinet. Lock them in that
position. Label them to avoid connection by mistake.

Book No.9010182 02, rev. 0

139

8.3

Storage and long term decommissioning

8.2

Shutdown and storage

Protection

Perform the actions below to protect the system:

Protect all electrical cabinets from humidity with Silica gel or similar.

Protect all metal surfaces from corrosion attacks with anti-rust oil. The oil must have long
lasting effective treatment for external surfaces.

Disconnect the air supply to the CIP module. Use service valve if possible, otherwise plug
the air supply inlet.

Disconnect and drain the membrane pumps (P320-1, P321-5 or P460-7). Rinse with fresh
water and reconnect the pump.

Articles made of rubber or plastics (for example seals) must not be treated with antirust oil.

Protect pressure monitoring device etc. from mechanical damages. The following components
are recommended to be removed and stored safely: PT201-27, PT201-16, and PI201-18.

Protect components equipped with circuit boards from condensation. Recommendations:

Remove IP201-7 and FIT201-1 and store in a non condensing environment.

Remove and store the display for FIT201-1.

Protect the flow sensor with silica gel or similar. Protect the sensor with the supplied plastic
cover.

Change the battery in the control panel. If not, the stored log information can be lost during
storage.

Put all pneumatic valves in open position.

Every 3 months, operate each valve by close/open exercise. This will keep the valves and
actuators in best condition.
Note that control valve V201-8 must be exercised manually at the same time as the IP201-7 is
removed. Use a wrench to apply appropriate torque.

8.3

Storage and long term decommissioning

All system equipment must be stored indoors at 555C, in a non-condensing environment.

If there is a risk for condensation of water during storage, the equipment must be protected
by ventilation and heating above dew point.

All articles made of rubber / elastomer has a limited useful life time. Therefore, the following
instructions must be followed:

If the filter or any filter candles are stored for more than 12 months, we recommend that the
seals are checked, and changed if necessary, before the system is put in service.

If the system is stored for more than 24 months, all articles made of rubber and elastomer
(gaskets, O-rings etc) must be changed before the system is put in service. Such articles are
found in the following components: UV lamps, quartz sleeves and catalytic candles in the
AOT reactors and the filter candles.

140

Book No.9010182 02, rev. 0

Shutdown and storage

8.4

8.4

Start-up after shutdown

Start-up after shutdown

Follow the overhaul process below to star-up the PureBallast system after decommission.
1. Locate the decommissioning report stored inside the control cabinet. Use this report to the
re-commissioning of the PureBallast system.
2. Clean away the anti-rust oil with a solvent, for example, white spirit.
3. Assemble items that have been disassembled.
4. If applicable: Remove the silica gel bags from all units.
5. Before the system can be activated, it must be checked according to the commissioning
checklist.

Book No.9010182 02, rev. 0

141

8.4

Start-up after shutdown

Shutdown and storage

9 Delivery and transport


information
This section contains information about how to handle PureBallast components during transport,
delivery and installation.

9.1

Delivery and transport

Preparations and conditions:

Always read and follow the documentation included in shipment of components and spare
parts regarding handling, safety and disposal.

Handle the delivery with care in order not to damage the equipment or cause personal injuries.

If the PureBallast system is stored before installation, make sure to store the components
according to the Shutdown and storage section.

9.2

Lifting instructions

This section describes how to lift PureBallasts components.


Preparations and conditions

NG
WARNI

Components must be lifted using correct lifting tools (such as a forklift truck, a crane) and tackle
with a load capacity greater than the weight of the component stated in the section below.

Any complementary lifting instructions must be followed.

Components must be empty when lifted.

The AOT reactor, filter, CIP and control cabinet must be lifted according to the instructions
in the following sections.

Book No.9010182 02, rev. 0

143

9.2

Lifting instructions

9.2.1

Delivery and transport information

AOT reactor

Weight of AOT reactor (empty): 330 kg. L = 75 cm

6 AOT Lift

144

Book No.9010182 02, rev. 0

Delivery and transport information

9.2.2

9.2

Lifting instructions

Filter

Weight of filter (empty with adaptor plates on flanges): 825 kg. A=98 cm.

6 FilterLift

9.2.2.1

Raise and lift filter

Follow the instruction to raise the filter to standing position and to lift it for transportation.
1.

When the filter is resting in the bottom of the wooden case: Attach a 2 string-round sling to
the two upper lifting bolts.

Book No.9010182 02, rev. 0

145

9.2

Lifting instructions

Delivery and transport information

6 FilterLift Hydac2

2.

Use a lifting gear to raise the filter to upright position. Use the bottom filter legs as turning point.

3.

When the filter is in upright position: Attach a 3 string-round sling to all three lifting bolts.

6 FilterLift Hydac

4.

146

Lift and transport the filter.

Book No.9010182 02, rev. 0

Delivery and transport information

9.2.3

9.2

Lifting instructions

CIP module

6 CIP Lift, new 9004908

9.2.4

Cabinets

Use intended lifting attachment at the top of the cabinet.

Book No.9010182 02, rev. 0

147

9.2

Lifting instructions

Delivery and transport information

XXXXX

6 CabinetLift

Example: Control cabinet

148

Book No.9010182 02, rev. 0

Chapter: 7. Service manual


System manual PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:

+46 8 530 310 40

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.

Contents
1
2

Introduction

1.1

Preparations and conditions

Maintenance schedule

2.1

Calibration schedule

11

2.2

Serial number information

12

2.2.1
2.2.2

Indicating serial number


Example

12
13

2.3

Placing of serial numbers

14

Operate valves manually

19

3.1

Open and close valves manually (CIP


valves)

19

3.2

Open and close valves manually


(V201-3, V201-9 and V201-8)

19

3.3

Lock valve in closed position

20

3.4

Unlock valve

21

AOT reactor

23

4.1

Safety information

23

4.2

Replace UV lamp and quartz sleeve

24

4.2.1
4.2.2
4.2.3
4.2.4
4.2.5

Disassemble UV lamp
Disassemble quartz sleeve
Assemble quartz sleeve
Check for leaks after quartz sleeve assembly
Assemble UV lamp

24
27
27
28
28

4.3

Open AOT reactor

29

4.3.1

Disassemble AOT reactor

29

4.4

Dismount and mount lamp power


supply (LPS)

31

4.5

Test LPS installation

32

Filter

35

5.1

Disconnect power to filter

37

5.2

Remove filter cover and filter candles

37

5.3

Mount filter candles and filter cover

38

5.4

Replace filter candles

39

5.5

Clean filter candles

39

5.6

Change sacrificial anode

40

CIP module

41

6.1

Change and refill CIP liquid

41

6.1.1
6.1.2

Change CIP liquid


Refill CIP liquid

43
43

6.2

Repair CIP pump

44

6.2.1
6.2.2
6.2.3

Clean CIP pump


Disassemble CIP pump
Assemble CIP pump

45
45
46

6.3

Test CIP pump

47

6.4

Repair junction box and valve blocks

47

6.5

Repair valve block

47

6.5.1
6.5.2
6.5.3
6.5.4

Change valve body


Connect electrical cables to valve block
Clean valve block
Connect pneumatic hoses to valve block

48
48
49
49

Flow meter

51

7.1

Mount flow transmitter

51

7.2

Change direction of flow transmitter

53

7.3

Change direction of flow transmitter


control pad

54

7.4

Clean flow meter electrodes

56

Valve actuator

57

8.1

Preparations and conditions

58

8.1.1

Tightening torques for actuators

58

8.2

Dismount actuator

59

8.3

Mount actuator on valve

59

8.4

Change direction of actuator without


position sensor (V40436, V3204 and
V3212)

61

Change direction of actuator with


switch box (V2013, V2019, V20132,
V21231 and V40335)

62

8.6

Change direction of actuator with


position sensor (201-19 and 20120)

62

8.7

Change direction of actuator with


positioner (2018)

64

8.8

Mount pilot valve on actuator

64

8.9

Adjust valve end position

65

8.10

Adjust valve traveling speed

66

8.11

Calibrate positioner on V201-8

68

8.5

Ball valve

71

9.1

71

Replace seals in ball valve

10 Level switch

73

10.1

Mount level switch

73

10.2

Dismount level switch

74

10.3

Test level switch

74

11 Temperature switch and


temperature transmitter

75

11.1

Mount temperature switch / temperature


transmitter

75

11.2

Dismount temperature switch /


temperature transmitter

76

12 Control panel

77

12.1

Clean control panel

77

12.2

Replace control panel

77

12.2.1 Dismount the panel


12.2.2 Mount the panel

77
78

13 Remote control panel (optional)


13.1

Mount and connect network switch for


remote control panel

81

13.2

Mount and connect network switch for


remote control panel (retrofit)

83

14 Control cabinet and lamp drive


cabinet (LDC)

81

85

14.1

Disassemble and assemble I/O system

85

14.2

Cable gland installation

87

1 Introduction
This chapter contains information and instructions about how to service the PureBallast system.
Instructions are sorted per component. The chapter is opened with a maintenance schedule
covering checks and services that must be performed with specified intervals.

1.1

Preparations and conditions

NGE
! DA

Before maintaining the PureBallast system, the power supply must be switched off, to avoid
accidental starts. See instruction Abort operation and deactivate the system in chapter 3.
Operating instructions and control system description.
NOTE

All maintenance of the PureBallast system must be logged in the vessels maintenance log.

Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.

Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 20.

Follow local regulations for electrical installation and grounding (earthing).

Follow general rules when handling of Alpacon descalant offshore cleaning agent, regarding
ventilation, personal protection etc.

Point of contact: To order service or spare parts, contact your local Alfa Laval office. For
more information, see www.alfalaval.com.

Book No.9010182 02, rev. 0

1.1

Preparations and conditions

Introduction

2 Maintenance schedule
Follow this maintenance schedule to secure performance, safety and durability of the system and
its components. The schedule is sorted per component. The table refers to instructions usable
when performing the respective action.
Component

Action

Time interval

General

Inspect for
corrosion and
erosion damage.

Once a year.

General

Calibration of
sensors

According to
Calibration
schedule

See Calibration
schedule

AOT reactor

Outer inspection
of seals for
leakage.

Once a year.

If necessary,
change according
to Open AOT
reactor.

See Spare parts


catalogue for
service kit.

Check UV lamps
for leakage.

Once a year.

See Disassemble
quartz sleeve.

See Spare parts


catalogue for
service kit.

Replacement of
UV lamps.

Recommended to
change all lamps
after 3000 hours of
operation.

See Replace UV
lamp and quartz
sleeve.

See Spare parts


catalogue for
service kit.

Inspection and
cleaning of filter
insert, including
filter candles.

Once a year.

See Remove filter


insert.

Replace filter
candles, if
damaged.

Outer inspection
of seals for
leakage.

Once a year.

Check sacrificial
anode.

Once a year.

Filter

Book No.9010182 02, rev. 0

Instructions

Notes

See Spare parts


catalogue for
service kit.

Change if needed
or every five years.

If necessary,
change faulty seals.
See Change
sacrificial anode.

Change if the
anode has lost
approximately 80
% of the zinc mass.

Maintenance schedule

pH value check.

Before each
filling-up or once
every 3 months,
whichever comes
first.

CIP liquid level


check.

Rule of thumb:
See Change CIP
Once every 3
liquid or Refill CIP
months.
liquid.
Depending
on number of
AOT reactor
and ballasting
frequency, the liquid
check might have to
be performed more
regularly.

Replacement.

When the pH value


is higher than pH 3
or once a year.
or
When the CIP
module has been
inactive for over
one year.

See Refill CIP


liquid.

Control of stored
CIP liquid.

Visual inspection
after three years.

See Preparations
and conditions
under Change and
refill CIP liquid
instruction.

Valve block on
CIP module

Control that the


cables are firmly
attached to the
terminal strip in
the valve block.

Once a year.

See chapter 7.
Service manual,
section Connect
electrical cables to
valve block.

Flow meter

Clean flow meter


electrodes.

Once a year.

See Clean flow


meter electrodes.

Control system

Cleaning of
display.

Displays should be
cleaned at regular
intervals or when
dirty.

See Clean control


panel.

Battery check
(PLC module).

Automatically every
when turned on and
every 24 hours.

CIP liquid

Battery
When alarm PLC
replacement (PLC battery low is
module).
indicated in the
control system.
or:
10

See Change CIP


liquid or Refill CIP
liquid.

If the CIP liquid


is low but the pH
value is below
3, CIP liquid and
water can be added
to fill up the liquid
level in the tank.
Note: pH value
must be checked
afterwards to
secure correct pH
value.

Alarm PLC battery


low issued when
battery is low.
The battery is
placed in the
PLC module in
the control cabinet.
Book No.9010182 02, rev. 0

Maintenance schedule

2.1

Calibration schedule

After 5 years.
or:
Before storage for
longer periods.

2.1

Calibration schedule

Follow this calibration schedule to secure performance of the system and its components. The
schedule is sorted per component.
Interval: Once a year, if nothing else is stated.
Component

Informatoin / instruction

Flow meter

Every second year.


1. Connect a calibrated portable ultrasonic flow meter close to the flow meter.
2. Establish flow in the system.
3. Compare value indicated in control system and measure equipment.

Pressure
transmitters

1. Connect calibrated portable measure equipment to the measure point


(screw to the side, under the handle).

Filter: (PT201-71, 2. Open V201-32 from the control system.


PT201-72 and
PT201-71, PT201-72 and PT309-2
PT309-2)
3. Compare values indicated for the three transmitters in control system
Pressure
and measure equipment.
transmitter
4. Open 403-35 from the control system, and compare again.
(PT201-16)
PT201-16
Pressure gauge
(PI201-18)
5. Open V403-35 to apply pressure to the system.
6. Adjust handle on PT201-16 to establish pressure to measure point.
7. Compare value indicated in control system and measure equipment.
PI201-18
8. Compare value indicated in pressure gauge and measure equipment.

Book No.9010182 02, rev. 0

11

2.2

Serial number information

Maintenance schedule

AOT reactor
components

1. Depressurize and drain the reactor: Remove the drain plug at the bottom
of the AOT reactor.

Temperature
transmitter
(TT201-33)

TT20133

Temperature
switch (TS20160)

3. Compare value indicated in the control system and measure equipment.

Level switch
(LS201-29)

2. Dismount the transmitter and place in water with known temperature


(calibrated measure instrument).
TS201-60
4. Dismount the switch and place in water with temperature < 65 C.
5. Check that alarm A137 is displayed in the control system.
LS201-29
6. Dismount the sensor and lace it in a glass of water.
7. Check that you get a signal for the AOT reactor in the control system.
8. Fill the AOT reactor with fresh water.

UV sensor in
AOT reactor
(QT201-50)

Every second year.

Temperature
transmitter in
LDC (TT401)

Place a calibrated thermometer inside the cabinet and compare after 30


minutes.

2.2

Order a exchange sensor from your local Alfa Laval office (parts and service)
to be installed and used during the time the sensor is calibration at factory.

Serial number information

This section describes where the serial number plate is placed on the PureBallast system
components.
Serial numbers shall be used at error reporting and other contacts where a specific component is
discussed.

2.2.1

Indicating serial number

Serial numbers shall be stated, including the following information:

Serial number for the complete PureBallast system. See label on the side of the control cabinet.

Serial number for the component in question. If the component is installed on, or in, another
component, the number for the mother component shall be stated.

Item number for the component. The item number identifies a unique component in the system.
It begins with a letter abbreviation indicating the component type, for example: LS (level switch),
P (pump) and PI (pressure gauge). A complete list of abbreviations is found in chapter 6.
Installation description and drawings, section Connection list.

12

Book No.9010182 02, rev. 0

Maintenance schedule

2.2.2

2.2

Serial number information

Example

If the level switch is faulty, the following information shall be stated:

PureBallast serial number

Level switch serial number and the serial number for the AOT reactor on which the level switch
is installed.

Item number for the component (LS00000)

Book No.9010182 02, rev. 0

13

2.3

2.3

Placing of serial numbers

Maintenance schedule

Placing of serial numbers

The table below indicates the position of the serial number plate per component.
PureBallast water treatment system
Serial number for the complete PureBallast
system.
Placing: On the right-hand side gable of the
control cabinet.

7 PB 591098_SerialNo

AOT reactor
At the side of the AOT reactor, as indicated in
the illustration.

7 AOT Snr

14

Book No.9010182 02, rev. 0

Maintenance schedule

2.3

Placing of serial numbers

Filter
Placing: At the side of the filter, as indicated
in the illustration.

7 FilterSnr Hydac

Electrical cabinets (Including breakers)


Placing: At the inside of the door (illustration
shows control cabinet).

Control cabinet

Lamp drive cabinet (LDC): Inside top left


door.

7 CC Sernr 591773#1

Book No.9010182 02, rev. 0

15

2.3

Placing of serial numbers

Maintenance schedule

Lamp power supply


LPSs are installed in the lamp drive cabinet.
NOTE
Version must be stated together with the serial number.
Version is stated on the serial number plate.

Placing: At the front of each LPS.

7 LDC sernr

Valves and actuators


Serial number plate for various valves are placed
at the side of the actuator. One example is
illustrated to the right.
NOTE
This number shall be used both for the actuator and
the mechanical valve.

7 Valve Snr 591890

16

Book No.9010182 02, rev. 0

Maintenance schedule

2.3

Placing of serial numbers

Flow meter
(Including flow transmitter and flow sensor)
Placing: At the side of the pipe, as indicated
in the illustration.
NOTE
The flow transmitter and flow sensor have individual
serial numbers. But it is sufficient to state the flow
meter serial number.

7 FM snr 576179_manual 2

Book No.9010182 02, rev. 0

17

2.3

Placing of serial numbers

Maintenance schedule

3 Operate valves manually


This section covers instructions on how to open, close and lock/unlock valves manually.
Avoid operating valves manually. Valves are normally operated from page 1.1 Overview in
the control system (manual mode). See chapter 3. Operating instructions and control system
description for instruction.

3.1

Open and close valves manually (CIP valves)

Follow this instruction to manually operate the valves installed in the CIP module: V571-1, V321-4,
V321-1, V460-2, V320-2 and V310-6. Note that the orange diode on the valve body will not light
during manual operation.
Follow the steps below
1.

Identify which button (illustrated on page 47) on the valve block that controls the valve. The
lower button operates the inner hose under the valve block, and vice versa. Also see the
sticker under the valve block.

2.

Press the button on the valve body with a screw driver to operate the valve.

3.2

Open and close valves manually (V201-3, V201-9


and V201-8)

Follow this instruction to manually operate valves V201-3, V201-8 and V201-9.
Valves can be operated using the position screw on the pilot valve.
Position 0
Position 1

Closed (default position). If the position screw is in position 0 and the valve is
closed, it can be manually opened. But if the position screw is in position 0 and
the valve is opened, it cannot be manually closed.
Opened.

Follow the steps below

Air must be connected, but power does not have to be connected.

Follow the steps below


1.

If there is limited access to the screw, it is possible to remove the DIN connector.

2.

Place a screw driver in the position screw groove.

Book No.9010182 02, rev. 0

19

3.3

Lock valve in closed position

Operate valves manually

3.

Turn the screw to desired position.


Position 1 to open.
Position 0 to close.

4.

When done, turn back the screw to position 0. If the DIN connector was removed, connect it
again.

3.3

Lock valve in closed position

Follow this instruction to lock valves V201-3, V201-9, V201-8 and 212-31 in closed position. These
valves are locked mechanically with two bolts on the actuator.
Preparations and conditions

Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.

Follow the steps below


1.

Set the valve to closed position from the control system. Control the position indicator, to make
sure. The yellow position indicator is in line with the valve throttle (indicating open when
the position indicator is in line with the pipe).

2.

Disconnect power and compressed air. Verify that the valve is not under pressure.

3.

Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).

7 576075_lock_manual

4.

Measure exactly how far out the end stop bolt (4) is from a reference surface, for example the
actuator house. Make a note of the distance. This information is needed when unlocking
the valve.

5.

Open the locking bolt (3) and turn them a couple of turns.

6.

Screw the end stop bolt (4) to its bottom position and tighten the locking bolt.

7.

Verify that the valve cannot be opened.

20

Book No.9010182 02, rev. 0

Operate valves manually

3.4

Unlock valve

8.

Slide the safety cover over the end bolts and lock the safety cover with the pad lock.

9.

Repeat the above procedure for all valves concerned.

3.4

Unlock valve

Follow this instruction to unlock valves V201-3, V201-9, V201-8 and 212-31 from closed position.
Preparations and conditions

Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.

Follow the steps below


1.

Disconnect all power and compressed air. Verify that the valve is not under pressure.

2.

Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).

7 576075_lock_manual

3.

Open the locking bolt (3) slightly.

4.

Adjust the end stop bolt (4) to the same position (distance from reference surface) as before
locking the valve, according to the notes made during locking.
NOTE

It is important to adjust the ends stop bolt to the correct position. Otherwise the actuator
may be damaged.

5.

Tighten the locking bolt (3).

6.

Verify that the valve can open and close.

Book No.9010182 02, rev. 0

21

3.4

7.

22

Unlock valve

Operate valves manually

Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.

Book No.9010182 02, rev. 0

4 AOT reactor
This section covers instruction for service of the AOT reactor.

4.1

Safety information

NGE
! DA

Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.

UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the AOT reactor with end caps properly closed.

Never dismount or handle UV lamps before they are completely cooled down. A hot UV lamp is
under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a
burn if it is touched.

ON
CAUTI

Before installation, check that the UV lamps and quartz sleeves are not broken.

UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care
when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage
and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective
eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.

UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled and disposed of with care. Used lamps UV can be handled and disposed of in the same
way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally
been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe
(or use pure sulphure to bind the mercury for easy collection).

Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.

Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.

In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.

When performing these routines, consider the need for service kits for UV and quartz sleeves,
containing O-rings, lamps, quartz sleeves etc. See Spare parts catalogue.

Do not touch the glass of the UV lamp. Wear gloves and hold the lamp by the ceramic end
parts only. If a lamp is stained on its surface, wipe off the glass with a clean soft piece of cloth
soaked with alcohol. If not, it could cause breakage and shorten lamp life.

Book No.9010182 02, rev. 0

23

4.2

Replace UV lamp and quartz sleeve

AOT reactor

Keep the UV lamp in its original protective cover and case when transporting, storing and
disposing of the lamp. Otherwise it could cause injury if the lamp breaks. Do not dispose of
original protective cover and case for the UV lamp, as they should be re-used for storage
and disposal. Mark cases with used UV lamps accordingly, so that they will not be mistaken
for new lamps.

4.2

Replace UV lamp and quartz sleeve

7 AOTexploded2

AOT reactor, exploded (Example shows a 300 AOT reactor).


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Cap
Cap nut
Bush
O-ring (inside bush)
Cable connector
Allen screw
Glass socket
O-ring
UV lamp
Quartz sleeve

4.2.1

Disassemble UV lamp

Follow this instruction to dismount the UV lamps.


Preparations and conditions

24

The PureBallast system must be turned off, and the power disconnected.
Book No.9010182 02, rev. 0

AOT reactor

After UV lamps have been changed, the runtime must be reset in page control system page 4.4
Operation timers AOT 13. Requires login level Advanced operator.

Wait at least 10 minutes after completed ballast or deballast process, to allow the AOT reactor
to cool down to ambient temperature. If the UV lamps are hot they are under internal positive
pressure and may burst if broken.

Replace UV lamp and quartz sleeve

NG
WARNI

The AOT reactor must not be under pressure when dismounting the UV lamps.

4.2

NG
WARNI

Burn hazard: UV lamps can be hot and cause burns.

Follow the steps below


1.

Unscrew the nut (2) holding the caps (1). There is one nut on each side of the AOT reactor per
UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.

2.

Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).

7UVlampConnection

3.

Carefully draw out the UV lamp and one of its bushes (3) with the electric cable, by holding the
electric cables in both ends. If required, use a screwdriver to press on the ceramic end of the
lamp inside the bush on the other side whilst carefully pulling the electric cable at the other end.

Book No.9010182 02, rev. 0

25

4.2

Replace UV lamp and quartz sleeve

AOT reactor

7UVBushScrewdriver

4.

Hold the UV lamp by the ceramic ends after the bushes have been removed. Immediately after
removal, place the lamp in its protective cover.

5.

Check that no quartz sleeves (10) are broken.


To disassemble the quartz sleeves, see the instruction Disassemble the quartz sleeve.

6.

If no quartz sleeves are broken, mount new UV lamps according to the instruction Assemble
UV lamp on page 28. If broken see the Preparations and conditions section above.

26

Book No.9010182 02, rev. 0

AOT reactor

4.2.2

4.2

Replace UV lamp and quartz sleeve

Disassemble quartz sleeve

Follow this instruction to disassemble the quartz sleeve.

NG
WARNI

Hot water may escape from the AOT reactor when removing the drain plug.

Follow the steps below


1.

Close the AOT reactor inlet (V201-19.n) and outlet (V201-20.n) valves from the main panel.

2.

Depressurize and drain the AOT reactor: Remove the drain plug at the bottom of the AOT
reactor.

3.

Disconnect the compressed air, as a safety precaution.

4.

Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 24.

5.

Unscrew the three Allen screws (6) of the glass socket (7), just a few turns to release the
sockets on both sides.

6.

Unscrew the glass sockets on both sides completely.

7.

Carefully remove the glass sockets and the quartz sleeve (10).

8.

Remove the O-rings (8) on both sides. The O-rings are firmly stuck in their seat, and will be
damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring
tool to loosen and remove the O-ring. Be careful to avoid to break the glass.
If the O-ring is hard to remove, try the following:
Moisten the O-ring with acetone or denatured alcohol.
Loose the O-ring in a couple of places before removing it.
Perforate the O-ring to get a good grip.

9.

Carefully remove the quartz sleeve (10).

10. Carefully clean the surface and remove any small parts, for example glass or rubber.

4.2.3

Assemble quartz sleeve

Follow the instruction below to assemble quartz sleeve and check for leaks.
Preparations and conditions

Two new O-rings for each glass socket (7) might be needed.

Two new O-rings (8) for each quartz sleeve (10).

Use waxed screws.

Glass sockets and bushes must be dry and clean before mounting.

Follow the steps below


1.

Insert the quartz sleeve (10) in the AOT reactor.

Book No.9010182 02, rev. 0

27

4.2

Replace UV lamp and quartz sleeve

AOT reactor

2.

Wet the O-rings (8) with water and slip them over respective side of the quartz sleeve. Check
that the O-ring is correctly placed, or they may be damaged and cause leaks.

3.

Check the condition of the glass socket O-rings . If needed, replace them with new O-rings.

4.

Adjust the quartz sleeve, so it is placed in the middle of the AOT reactor.
Adjust the O-rings, so they are placed equally on both sides of the quartz sleeve.

5.

Carefully mount the first glass socket on the quartz sleeve with three Allen screws evenly, but
do not tighten the screws. Note that the waxed screws must be used to avoid seizing.

7QuartzSleeve

6.

Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.

7.

Mount the second glass socket.

8.

Connect the compressed air.

4.2.4

Check for leaks after quartz sleeve assembly

Follow the instruction below to secure that there are no leaks that may damage the UV lamps.
Follow the steps below
1.

Pressurize the AOT reactor with water to between 2 and 4 bar (0.2 and 0.4 MPa).

2.

Visually check for leaks.

4.2.5

Assemble UV lamp

Follow the instruction below to mount UV lamps.


Preparations and conditions

A leakage check must have been performed according to the instruction Check for leaks after
quartz sleeve assembly.

Use waxed screws.

28

Book No.9010182 02, rev. 0

AOT reactor

4.3

Open AOT reactor

New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.

Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the
lamp; hold the lamp by its ceramic end parts.

Glass sockets and bushes must be dry and clean before mounting.

Follow the steps below


1.

Mount the new O-rings (4) in the two bushes (3).

2.

Place one bush on the UV lamp (9).

3.

Insert the UV lamp and bush into the AOT reactor.

4.

Insert the other bush in the opposite side of the AOT reactor.

5.

Make sure that the connection is clean to ensure good electric connection (no rust, burning or
fading on the connectors). Reconnect the two cable connectors for the UV lamp.

7UVlampConnection

6.

Mount the UV lamp caps and tighten three Allen screws at both ends of the UV lamp, by hand
only. Make sure that the electric cable is is not squeezed between the cap and the bush when
the cap is mounted. Slack can be pushed into the bush.

7.

Re-fit the drain plugs at the bottom of the AOT reactor and/or at the flanges under the AOT
reactor.

8.

Make sure there is no UV lamp failure when the lamp power supply is on.

4.3

Open AOT reactor

4.3.1

Disassemble AOT reactor

Follow this instruction to open the AOT reactor for internal inspection and cleaning.

Book No.9010182 02, rev. 0

29

4.3

Open AOT reactor

AOT reactor

7 OpenAOT

1. Access hatch

Preparations and conditions

NGE
! DA

Always disconnect the PureBallast system from the power supply before disassembling, and
make sure it remains switched off during service.

Follow the steps below


1.

Remove the bolts on the access hatch (1).

2.

Inspect the bottom of the AOT reactor to see if there are any dirt or larger particles. If so,
remove.
Note: Be careful not to break the quartz sleeves.

3.

Check the sealing. Replace if necessary.

4.

Reassemble when done.

30

Book No.9010182 02, rev. 0

AOT reactor

4.4

4.4

Dismount and mount lamp power


supply (LPS)

Dismount and mount lamp power supply (LPS)

Follow this instruction to replace a lamp power supply inside a lamp drive cabinet (LDC).
Preparations and conditions

NG
WARNI

Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V)
inside and on the lamp power connector, even when UV lamps are not lit.

The LDC contains a fan, which can cause injury if in operation.

Follow the steps below

7 LPSmaint

1.

Dismount LPS
Release two power connectors at the bottom of the LPS and the signal cable connector
at the top.

2.

Loosen the nuts at the bottom (1) and the top (2) of the two rods holding the LPS. If necessary,
loosen nuts for adjacent LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short circuit.

3.

Pull the handle to remove the LPS.

Book No.9010182 02, rev. 0

31

4.5

Test LPS installation

4.

AOT reactor

Mount LPS
Set the DIP switches on the LPS according to chapter 5. Parameters, section Lamp power
supply (LPS) parameters.

5.

Push the new LPS to the wall of the cabinet.

6.

Reconnect the three connectors. Make sure the connectors sit tight.

7.

Tighten the nuts to attach the LPS.

8.

Turn on the fuse to the LPS.

9.

Switch on the main breaker on the LDC door and check that both LPS:s function correctly
according to instruction Test LPS installation below.

10. Send the replaced LPS to Alfa Laval for repair.

4.5

Test LPS installation

Follow this instruction to make sure that the installation is OK and safe to use.
Preparations and conditions

NG
WARNI

This instruction must be performed after cable connection. If not hazardous situation may arise
which, if not avoided, will result in death or serious injury.

NGE
! DA

Before operating the AOT reactor, make sure that there is water in the AOT reactor.

Follow the steps below


1.

Make sure that the AOT reactor breaker is switched off.

2.

Check that there is water in the AOT reactor(s) (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the AOT reactor.

3.

Switch on the main breaker on the LDC door. Switch on the power to the AOT reactor using
the switches on the breaker cabinet(s).

4.

Start UV lamps one by one from the control system (set to manual mode). Make sure that the
UV lamps are lit. This is checked in the AOT reactor popup and on the LPS.
Note: It can take up to 150 seconds for the lamp to start.

5.

Check LEDs on the LPS and the alarm list in the control system. Make sure that no alarms
have been triggered by the LPS.

32

Book No.9010182 02, rev. 0

6.

AOT reactor

4.5

Test LPS installation

Close the lamp.

Book No.9010182 02, rev. 0

33

4.5

Test LPS installation

AOT reactor

5 Filter
This section covers the instructions for service of the filter.
Preparations and conditions
These preparations and conditions are valid for all instructions.

Galvanic circuits must always be restored after maintenance, if dismounted.

Disconnect the power to the filter, using the main switch on the filter cabinet.

Shut off the air supply to the filter.

Depressurize the filter:


Alternative 1: Open the valve on the drain pipe.
Alternative 2: Open the valve on the back flush pipe manually and then open the safety valve.

Note: The motor does not need to be lubricated.

Filter Exploded view

Book No.9010182 02, rev. 0

35

Filter

7 Filter Exploded Hydac

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

36

Filter cover bolts


Filter cover
Motor
Protective hood
Valve connection plate
Drive shaft
Gasket
Retaining plate
Locking pin
Gasket
Filter candle
Hole for locking pin
Lid for anode
Drain pipe
Air pipe
Safety valve

Book No.9010182 02, rev. 0

Filter

5.1

5.2

Remove filter cover and filter candles

Disconnect power to filter

Follow the instruction below to disconnect the power supply to the filter and to secure it from being
switched on.

7 FilterLock

Safety lock with wire legs pulled out

Follow the steps below


1.

Open the control cabinet.

2.

Turn the filter main switch to cut currency to the filter.

3.

Take the separate safety lock (illustrated above) and slide the plastic part backwards, to
reveal the wire legs.

4.

Put the end of the wire leg into the hole under the switch knob.

5.

Compress the legs and put the other steel wire leg into the slot to the right of the knob.

6.

Slide the plastic part back to cover the wire legs. It is now possible to lock the safety lock with
a padlock, inserted in the loop at the top of the safety lock.

5.2

Remove filter cover and filter candles

Follow this instruction to remove the filter cover and filter candles.
Preparations and conditions

Read the general preparations and conditions.

Disconnect the power to the filter, using the main switch on the filter cabinet.

Lifting device is needed for this instruction.


Filter cover weight (kg), per system size:
120.
Retaining plate (kg): 50.

Follow the steps below

Book No.9010182 02, rev. 0

37

5.3

Mount filter candles and filter cover

1.

Remove the following components:

Safety valve pipe (16)

Air pipe, loosened (15)

Electrical connections to the motor and valves

Connection plate for valve connections (5)

Motor (1)

Protective hood (4) fasten with four of the filter cover bolts (1)

Galvanic protection between the filter cover, retaining plate and housing.

2.

Remove the filter cover (2) by lifting it using the ring bolts.

3.

Remove the gasket (7) on the retaining plate (8).

4.

Lift the retaining plate. Four threaded holes that can be used to attach lifting devices.

Filter

NOTE

The plate must be level when lifted, to avoid damaging the gasket and filter candle O-rings.

It is important not to turn the shaft, after the retaining plate has been removed. If the
rotation is changed, this will make the mounting much more complicated.

5.

Remove the gasket under the retaining plate.

6.

Carefully pull out the filter candles (11).

5.3

Mount filter candles and filter cover

Follow the instruction to mount filter candles and filter cover


Preparations and conditions

Read the general preparations and conditions.

Gaskets for the retaining plate and O-rings for the filter candle must be in good condition.

Follow the steps below


1.

Make sure that the filter candle O-rings are in position in their groove.

2.

Carefully insert the filter candles (11). Make sure that they are fitted in the hole in the lower
retaining plate and that they they snap into position.

3.

Place the gasket (10) on the filter housing. Make sure that the hole (12) for the locking pin
(9) is not covered by the gasket.

4.

Before re-fitting the retaining plate (8), note that the locking pin shall fit into the hole in the
retaining plate.

38

Book No.9010182 02, rev. 0

5.

Filter

5.5

Clean filter candles

Carefully lower the retaining plate onto the housing.


NOTE

The locking pin shall be fitted into its hole.

The candles must be guided into the holes in the retaining plate.

6.

Place the gasket (7) on the retaining plate. Make sure to fit the gasket to the locking pin.

7.

Carefully lower the filter cover (2) onto the retaining plate.
NOTE

8.

The filter cover must be level when lowered to the housing.

The drive shaft (6) must fit the shaft in the filter housing. If not: Lift the retaining plate, turn
the shaft in the filter housing and try again.

Refit the following components:


-

Protective hood (4) fasten with four of the filter cover bolts (1)

Motor (1)

Galvanic protection between the filter cover, retaining plate and housing

Connection plate for valve connections (5)

Electrical connections to the motor and valves

Air pipe, loosened (15)

Safety valve pipe (16).

5.4

Replace filter candles

Follow the instruction to replace damaged filter candles.


Follow the steps below
1.

To replace filter candles, follow the Remove filter candles instruction on page 37, and simply
replace damaged elements.

5.5

Clean filter candles

Follow the instruction to


Preparations and conditions

Read the general preparations and conditions.

Follow the steps below


Book No.9010182 02, rev. 0

39

5.6

Change sacrificial anode

Filter

1.

Follow the instruction Remove filter cover and filter candles on page 0 to remove the filter
candles.

2.

If there is scaling on the filter candles: Soak the filter candles in the cleaning agent and leave
them to soak for 13 hours. Read the Preparations and conditions section for instruction
Change and refill CIP liquid.

3.

Secure the filter candle, to avoid that it rolls away.

4.

Spray the filter candles with water from the outside. Start at a distance of 100 cm and reduce
to 50 cm, which is the minimum distance. The water must not be warmer than 60 C. Note: If a
high-pressure cleaner is used, the pressure must not exceed 100 bar (10.0 MPa). Minimum:
20 bar. If a cleaner with higher capacity than 100 bar is used, compensate by increasing the
distance.

5.6

Change sacrificial anode

Follow the instruction to check and change the sacrificial anode.


Preparations and conditions

Read the general preparations and conditions.

Follow the steps below


1.

Close inlet and outlet valves to the filter.

2.

Drain the filter by opening the drain pipe (14).

3.

Open the lid (13).

4.

Inspect the anode. Change if the anode has lost approximately 80 % of the zinc mass.

5.

Remove the old anode and install the new one.

6.

Fasten the lid on the filter and restore the valves in their original positions.

40

Book No.9010182 02, rev. 0

6 CIP module
This section covers instruction for service of the CIP module.

6.1

Change and refill CIP liquid

Alpacon descalant is used as cleaning agent in the CIP module. Alpacon descalant offshore
contains no solvents and no inorganic acids. It is non-flammable and non-hazardous.
Preparations and conditions

ON
CAUTI

Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow
general rules when handling of cleaning agents regarding ventilation, personal protection etc.

ON
CAUTI

If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.

Before usage, Alpacon descalant offshore must be visually checked. It shall be transparent
light pink in color.

The instructions requires pH test equipment (paper indicator or pH meter). This is not a part of
Alfa Lavals scope of supply.

The pH value should be between 2.0 and 3.0. From the beginning, the pH value is approximately
2.0. When the pH value rises to 3.0 the cleaning liquid must be changed.

Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant offshore to
20 parts fresh water. Follow this mixing ratio, regardless of recommendation on label.

The CIP tank shall be filled with maximum 250 liters. Min and max filling of CIP liquid can
be read on the CIP tank.

Store the CIP liquid according to the instructions on the bottle. General guidelines are:
-

Storage temperature 0 C to +55 C.

The Alpacon descalant offshore can be frozen and thawed without impairing performance.

Used CIP liquid may contain residues from the cleaning process that can potentially have an
impact on the environment, although this impact is regarded as very small. There are no
transport restrictions.

Used CIP liquid is drained to one of the following: bilge tank, drain tank, sludge tank or bilge well.

When performing these routines, consider the need for service kits. See Spare parts catalogue.

Book No.9010182 02, rev. 0

41

6.1

Change and refill CIP liquid

CIP module

7 CIP 589741_description

CIP module
1.
2.
3.
4.

42

CIP liquid tank cap


Drain valve
Pump (AOT reactor drain)
Pump (CIP liquid)

Book No.9010182 02, rev. 0

CIP module

6.1.1

6.1

Change and refill CIP liquid

Change CIP liquid

Follow this instruction to change CIP liquid, when necessary according to the Maintenance schedule.
Follow the steps below
1.

If the drain valve (2) is connected to the bilge tank, follow the sub steps below. Otherwise, go
to step 2.
1. Open the drain valve V460-3 (2) under the CIP tank.
2. Wait for the tank to be totally drained. Then close the drain valve (2).

2.

If the drain valve is not connected to the bilge tank, the steps below can be followed. This
operation requires login level Advanced operator or higher.
1. Open valves V320-2 and V460-2 from the control valve, and V23011 manually. Start
pump P321-5 (4) and P320-1 (4).
2. Wait for the tank to be totally drained. Then stop the pumps and close the valves in
reversed order. Go to step 3.

3.

Open the cap (1) on top of the CIP tank and pour 12 liters of CIP cleaning agent into the tank.

4.

Fill the tank with fresh water to the Max indication on the tank.

5.

Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.

6.

Go to control system page 4.3 Operation timers. Make a note of the number of AOT reactors
that has been CIPed since last time the CIP liquid was changed. Press the Reset button for
Total number CIP:ed reactors. Requires login level Advanced operator. If this is done each
time the CIP liquid is changed, it is possible to build up experience on how many AOT reactors
it is possible to CIP before it is time to change CIP liquid.

6.1.2

Refill CIP liquid

Follow this instruction to refill CIP the CIP tank when there is low liquid level in the tank.
Follow the steps below
1.

Measure the pH value in the tank. Based on the pH value, estimation must be done regarding
the proportions between Alpacon descalant offshore and water. Note that the mixing ratio is
stated under Preparations and conditions above.

2.

Mix the cleaning agent with water separately. The result will get better than if mixed mix in
the tank.

3.

Pour the mixed CIP liquid into the tank. Do not fill over Max indication on the tank.

4.

Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is still too high, the CIP liquid must be changed. See the Change
CIP liquid instruction in this chapter.

Book No.9010182 02, rev. 0

43

6.2

Repair CIP pump

6.2

CIP module

Repair CIP pump

Follow this instruction to repair the CIP pump.


For spare parts ordering, please specify pump model and serial no.
Preparations and conditions

ON
CAUTI

Always wear protective eye glasses and gloves while working on the pump.

NG
WARNI

Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.

Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.

Drain the pump from liquids.

The pump should be placed horizontally on a work bench.

7 CIP pump

CIP pump, exploded view

44

Book No.9010182 02, rev. 0

CIP module

6.2.1

6.2

Repair CIP pump

Clean CIP pump

Follow the steps below


1.

Remove the pump from the CIP tank.

2.

Rinse the pump with fresh water.

6.2.2

Disassemble CIP pump

Follow this instruction to disassemble the CIP pump.

6.2.2.1

Disassemble the main parts

Follow the steps below


1.

Remove the CIP pump from the CIP module and place it on a work bench.

2.

Unscrew the nuts (37) on one side of the housing (11).

3.

Place the pump on the side that still has the nuts (the pump lays on the nuts) on a stable ground.

4.

Carefully remove the "loose housing" (11).

5.

Carefully lift up the suction and discharge connections (13). You have the centre block (12)
and one of the housings with pin screws (14) left.

6.

Upend the pump and carefully pull out the pin screws (14). Be careful not to damage the
diaphragms (15).

6.2.2.2

Disassemble the housing

Follow this instruction to disassemble the housing.


Follow the steps below
1.

Put the house wall with the flat side down on a plane surface.

2.

Remove the spacer sleeve (19), by turning it 180. To do that:

Put a piece of plastic towards one side of the spacer sleeve.

Knock on it so that the spacer sleeve is turning.

Put one of the pin screws in the hole on the spacer sleeve and turn it until it lays upside
down (180) compared to the starting position. Pull the spacer sleeve carefully against
the lower valve seat (21) until it is free and can be put out.

3.

Stick a something not pointed into the hole for the discharge connection and gently press out
the upper valve seat (20).

4.

Place one of the pin screws on the inside (behind) the valve ball stopper on the lower valve
seat (21). Carefully pull out the valve seat in the housing.

Book No.9010182 02, rev. 0

45

6.2

5.

Repair CIP pump

CIP module

Remove the valve ball (23) from the valve seat, buy using a pin screw: Press out the valve ball
stopper (22), which will release the valve ball.

6.2.2.3

Disassemble the center block

Follow this instruction to disassemble the centre block.


Preparations and conditions

Have backup spares of the sealing (36) and backup O-ring (47). There is a risk that these parts
get damaged during this operation.

Follow the steps below


1.

Press the diaphragms (15) to their neutral position (both have the same distance to the
centre block).

2.

Hold one of the diaphragms (15) and unscrew the other. Then pull out the remaining diaphragm
with the diaphragm shaft (16).

3.

Disassemble the circlips (27) which keep the air valve (61) on its place.

4.

Press out the air valve. A wood shaft of a hammer can be used. Be careful not to damage the
sealing edges towards the diaphragm or the air valve.

5.

If the shaft sealings (36) seem to be worn out, carefully remove them with a pointed tool.

6.2.3

Assemble CIP pump

Follow the instructions below to assemble the CIP pump.

6.2.3.1

Assemble center block

Follow the steps below


1.

Mount the circlip (27) on one side.

2.

Apply some soft soap solution on the air valve O-rings (30).

3.

Push the air valve (61) into the housing. Make sure that the O-rings (30) remain in the right
position. Put the circlip (27) on the other side.

4.

Put the diaphragm (15) with shaft (16) into the centre block. Screw the next diaphragm (15)
onto the shaft (16) and fix the holes.

6.2.3.2

Assemble the main parts

Follow the steps below


1.

Make sure that the O-rings (18) are placed on the in/outlet (13) before assembling of pump.

2.

Turn the housing (11) with the flat side up.

46

Book No.9010182 02, rev. 0

CIP module

6.5

Repair valve block

3.

Make sure all pin screws (14) have one nut (37) and one washer (38) each. Nut should only be
put on one or two threads.

4.

Put all the pin screws through the housing and then turn the housing so it rests on the nuts.

5.

Put the centre block (12) to the housing with screws through the centre block. Be careful not to
damage the diaphragms.

6.

Place suction and discharge connections (13) in their positions in the housing. Be careful not
to damage the O-rings (18).

7.

Put the second housing (11) onto the pin screws (14). Make sure that suction/discharge
connections are in right direction. Be careful with the O-rings.

8.

Fasten the nuts (37) crosswise by hand, with or without washers depending on how much of
the thread comes out. Turn the nuts gently with a tool to close the pump. If some of the nuts
were fastened without washer, unscrew those and put washers underneath. After a few weeks
operation a follow up draft of the nuts is recommended.

6.3

Test CIP pump

Follow the instruction below to verify that the CIP motor is functioning.
1.

Open valves V320-2 and V460-2 from the control system, and V23011 manually. Start
pump P321-5 (4) and P320-1 (4).

2.

Observe if the motors sound and functions OK. If not, check installation and connections and
attend to and test again.

3.

Stop the pumps and close the valves in reversed order.

6.4

Repair junction box and valve blocks

Read the conditions below before reparing the junction box or valve blocks.

6.5

Repair valve block

Follow this instruction to repair the valve block, mounted on the CIP module.
Preparations and conditions

The valve bodies does not have individual placing, they can be placed in any order.

NGE
! DA

Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.

Book No.9010182 02, rev. 0

47

6.5

Repair valve block

CIP module

7 Valve block

Valve block
1.
2.
3.
4.
5.

Cover (Terminal strip inside)


Valve body
Button to operate valve
Signal plate
Cable gland

6.5.1

Change valve body

Follow the steps below


1.

Remove the scresw holding the valve bodies (2) and the signal plate (4).

2.

Unscrew the screws holding the valve body (2).

3.

Lift the valve body.

4.

Attach a new sealing on the new valve body and fasten the valve body to the valve block.

6.5.2

Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the control cabinet to the CIP valve block.
Follow the steps below

48

Book No.9010182 02, rev. 0

CIP module

6.5

Repair valve block

1.

Open the cover (1) on the front.

2.

Attach the cables according to electrical drawing Control cabinet / interconnection diagram in
chapter 6. Installation description and drawings.

3.

Fasten the cable to the cable gland (5).

4.

Fasten the cover (1).

6.5.3

Clean valve block

Follow this instruction to clean the valve block house from dirt.
Follow the steps below
1.

Disconnect the outgoing air hoses from the valve block.

2.

Operate the service air according to instruction Open and close valves manually (CIP valves)
on page 19 to blow out the dust.

3.

Connect the air hoses again.

6.5.4

Connect pneumatic hoses to valve block

Follow this instruction to connect pneumatic hoses to the valve block, if they have been
disconnected.
Follow the steps below
1.

Connect the hoses according to the signal plate (4) on the valve block.

Book No.9010182 02, rev. 0

49

6.5

Repair valve block

CIP module

7 Flow meter
The flow meter consists of two main parts.

Flow sensor: A pipe with four electrodes detecting the flow. On top of the pipe, there is a
terminal box, where the flow transmitter is mounted.

Flow transmitter: Monitors and transmits information to the PureBallast control system. The
flow transmitter is also used to set parameters for the flow meter. A Sensorprom in the flow
transmitter contains the data.

If the flow meter is replaced, settings must be checked according to chapter 4. Parameters,
section Flow transmitter parameters.

7.1

Mount flow transmitter

Follow the steps below to mount the flow transmitter on the flow sensor. The flow transmitter is not
factory mounted, to avoid damage during installation of the flow sensor.
Preparation and conditions

See chapter 6. Installation description and drawings, section Control cabinet / Interconnection
diagram for detailed information.

It is recommend that a shielded power cable is used.

NG
WARNI

Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).

Follow the steps below


1.

Remove and discard the lid from the terminal box on the flow sensor.

Book No.9010182 02, rev. 0

51

7.1

Mount flow transmitter

Flow meter

7 FM Lid

2.

Fit PG13.5 cable gland for the power and signal cable.

3.

Connect power and grounding to the following terminal positions marked on the circuit board:
1=+
2=
Grounding.

4.

Connect current output signals to the following terminal positions marked on the circuit board:
31 = +
32 =

5.

Tighten the cable gland to obtain optimal sealing.

6.

Mount the flow transmitter on the terminal box using the two screws. If other direction of the
flow transmitter is desired, please follow the instruction Change direction of flow transmitter on
page 53.

7 FM MountTM

52

Book No.9010182 02, rev. 0

Flow meter

7.2

7.2

Change direction of flow transmitter

Change direction of flow transmitter

The flow transmitter can be mounted in different directions in relation to the flow sensor. It can
be directed in steps of 90.
Follow the steps below
1.

Remove the flow transmitter from the terminal box.

7 FM MountTM

2.

Disconnect the power supply (terminal positions 1, 2 and grounding) and output signal cables
(terminal positions 31 and 32) from the circuit board.

3.

Remove the coil plug (1) from terminal positions 85 and 86. Remove the plug (2) from terminal
positions 82, 0 and 83.

4.

Unscrew the two screws (indicated below) holding the circuit board to the terminal box and lift
up the circuit board.
Note that the sensorprom is mounted on the underside of circuit board; be careful not to loose
it. Sometimes, the sensorprom remains in its seat on the terminal box.

7 FM ScrewCricuit

Book No.9010182 02, rev. 0

53

7.3 Change direction of flow transmitter control


pad
5.

6.

Flow meter

Disconnect the grounding wire holding the circuit board to the terminal box.

If the flow transmitter shall be turned 180: Move the sensorprom (1 in the illustration
below) to the position on the opposite side of the circuit board and refit in reversed order.

If the flow transmitter shall be turned 90: Continue with next step.

Unscrew the four screws (2) on the terminal box to loosen it from the flow sensor.

7 FM LooseTB

7.

Turn the terminal box to 90 and fasten it with the four screws.

8.

Refit in reversed order.

7.3

Change direction of flow transmitter control pad

The control pad of the flow transmitter can be mounted in different directions in relation to the
transmitter. It can be directed in steps of 90.
Follow the steps below
1.

Remove the outer frame with the help of a screw driver.

7 FM LoosFrame

54

Book No.9010182 02, rev. 0

2.

Flow meter

7.3

Change direction of flow transmitter


control pad

Loosen the four screws holding the control pad.

7 FMScrewPad

3.

Withdraw the control pad and turn it to the required orientation.

7 FM TurnPad

4.

Tighten the four screws until a mechanical stop is felt.

7 FMScrewPad

Book No.9010182 02, rev. 0

55

7.4

5.

Clean flow meter electrodes

Flow meter

Snap-lock (a click is heard) the outer frame onto the control pad.

7 FM FastCover

7.4

Clean flow meter electrodes

Follow this instruction to clean the electrodes.


It is important that the electrodes are clean to secure accurate output. If the four electrodes in the
flow sensor get dirty, it may result in inaccurate and varying output.
Follow the steps below
1.

Drain the entire pipe where the flow meter is mounted.

2.

Close the main valves connecting the PureBallast pipe net to the vessels ballast pipe net and
secure it from being switched on. See instruction Lock valve in closed position on page 20.

3.

Remove all the flange bolts on the flow meter, except one on each flange. Note that the
remaining bolts on each side must be in the same position on respective flange.

4.

Loosen the nuts on the remaining bolts. Swing the flow meter outside the pipe.

5.

Clean the four electrodes with a mild washing detergent.

6.

Refit the flow meter in reversed order.

56

Book No.9010182 02, rev. 0

8 Valve actuator
This section contain instructions for the valve actuator.

7 Actuator and switch

Valve actuator with switch box for position feedback to control system
1.
2.
3.
4.
5.
6.

Switch box
Bracket
Actuator

Bracket - Used for valves with dimension 400


Coupling with position indicator - Used for valves
with dimension 400
7. DIN connector
8. Position indicator

Book No.9010182 02, rev. 0

57

8.1

Preparations and conditions

Valve actuator

7 Actuator

Valve actuator with puck for position sensor


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Safety cover
Pad lock
Lower position for indicator screw
Upper position for indicator screw with screw
Position indicator
Center screw
Bracket
Puck
Locking bolt
End stop bolt.

8.1

Preparations and conditions

Do not operate the actuator over pressure limits. It will damage internal parts as well as cause
damage to the housing.

Do not disassemble individual spring elements. Disassembly may result in personal injury.

Do not remove end caps or disassemble the actuator while the actuator is pressurized.

The actuator must not be lubricated. It is factory lubricated for the life of the actuator during
normal working conditions. The standard lubricant is suitable for use from 20 C (4 F)
to +80 C (+176 F).

If a valve actuator is removed, check for loose spindle-bushing. Then make sure the loose
bushing is refitted to avoid play between the actuator and the valve spindle.

Actuator are mounted together with the valve body and pilot valve at delivery. Valve and actuator
mounting are sealed to guarantee correct position indication in relation to throttle position.

8.1.1

Tightening torques for actuators

Torque is stated in Nm.

58

Book No.9010182 02, rev. 0

Valve actuator

M5
M6
M8
M10
M12
M14
M16
M20

8.2

8.3

Mount actuator on valve

0506
1011
2325
4852
8286
132138
200210
390410

Dismount actuator

Follow this instruction to dismount an actuator.


Preparations and conditions

The valve must be in closed position.

The valve position must not be adjusted during the routine.

Follow the steps below


1.

Remove the DIN connector to disconnect the power. Let the air connection remain.
Result: Valve goes to closed position (due to the air connection). The yellow indicators on the
puck shows position of valve: closed. The yellow position indicators are in line with the valve
throttle (indicating closed when the position indicators are in opposite line with the pipe).

2.

Disconnect the air hose to the pilot valve. Verify that the actuator is not pressurized. Always
use caution and double-check that ports 2 and 4 are vented and are free from any accessory
and/or device.

3.

If the actuator have a switch box at the top: Loosen the four screws holding the switch box to
the actuator. Remove the switch box together with its bracket.

4.

Loosen the four hexagonal screws holding the actuator to the valve.

5.

If the actuator is mounted on the valve with a bracket and coupling (dimension 400): Loosen
the screws holding the bracket to the valve. Make sure not to loose the coupling between the
valve and actuator when lifting the actuator.

6.

Lift the actuator from the valve.

8.3

Mount actuator on valve

Follow this instruction to mount an actuator.


Preparations and conditions

Book No.9010182 02, rev. 0

59

8.3

Mount actuator on valve

Valve actuator

ON
CAUTI

The actuator must not be pressurized at any time during installation as it may result in injury.

The valve must be in closed position.

The valve position must not be adjusted during the routine.

The utmost cleanliness is required during air supply connection to the actuator, that is, the
connecting pipe thread, fittings and seals must be clean and dirt-free.

Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on
which direction of rotation is required.

Follow the steps below


1.

Note the position of the groove (2) of the valve stem (3). It indicates the position of the valve
throttle. The illustration shows a square variant, but octagonal versions exist.

7 ValveStem

1.
2.
3.
5.

Allowed travel sector.


Valve stem groove
Valve stem
Lock pin opening (covered by rubber plug).

2.

Make sure that the lock pin (inside the valve stem) only travels in the allowed sector (1) and
that it does not pass the opening (5).

3.

If the actuator is mounted on the valve with a bracket and coupling (dimension 400): First fit
the coupling on the valve stem. Make sure that the red position indicator on the coupling is in
line with the pipe when the valve is open.

4.

Fit the actuator onto the valve stem (or the coupling). The actuator may only be positioned in
even 90 intervals in relation to the valve. It is not allowed to adjust the position by turning the
actuator by hand after it is fitted on the valve stem.

5.

Mount the actuator on the valve with the four hexagonal screws. For each screw, one washer
and one spring washer shall be used. Tighten with torque according to the table Tightening
torques for actuators on page 58.

60

Book No.9010182 02, rev. 0

Valve actuator

8.4 Change direction of actuator without


position sensor (V40436, V3204 and V3212)

6.

If the actuator have a switch box at the top: Make sure that the yellow position indicator under
the switch box is in line with the throttle (according to the groove in the valve stem). The yellow
position indicator shall be in line with the valve throttle (indicating open when the position
indicator is in line with the pipe). If not, remove the position indicator, turn it 90 and refit it.
Mount the switch box with the bracket on the actuator, using the four bolts.

7.

Reconnect the air hose to the pilot valve.

8.

Operate the valve to make sure it operates in the desired direction of rotation.

8.4

Change direction of actuator without position


sensor (V40436, V3204 and V3212)

Follow this instruction to turn an actuator without position sensors on the AOT reactor.
Preparations and conditions

The valve must be in closed position.

The valve position must not be adjusted during the routine.

Follow the steps below


1.

Loosen the four screws holding the actuator to the valve.

2.

Lift the actuator from the valve.

3.

Note the position of the groove of the valve stem. It indicates the position of the valve throttle.

4.

Fit the actuator onto the valve stem.

5.

Unscrew the center screw (4) holding the puck (6) and a bracket (5).

7 ActDirectWithout

6.

Lift the puck (6), rotate it 90 and fasten it with the center screw (4) and bracket (5).

Book No.9010182 02, rev. 0

61

8.6 Change direction of actuator with


position sensor (201-19 and 20120)

Valve actuator

7.

Make sure that the yellow position indicators (3) is in line with the throttle (according to the
groove in the valve stem). The yellow position indicators shall be in line with the valve throttle
(indicating open when the position indicator is in line with the pipe). If not, remove the position
indicators, turn them 90 and refit.

8.

Connect power and air.

8.5

Change direction of actuator with switch box


(V2013, V2019, V20132, V21231 and V40335)

Follow this instruction to turn an actuator with switch box.


Preparations and conditions

The valve must be in closed position.

The valve position must not be adjusted during the routine.

The valve must be mounted and connected to air and power before adjustment.

Follow the steps below


1.

Dismount the actuator according to Dismount actuator on page 59.

2.

Remount the actuator according to Mount actuator on valve on page 59.

3.

Before mounting the switch box, change the position of the yellow position indicator, so it
is in line with the throttle.

4.

Remount the switch box according to Mount actuator on valve.

8.6

Change direction of actuator with position


sensor (201-19 and 20120)

Follow this instruction to turn an actuator with a position sensor, if necessary due to lack of space.
Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-19 and V201-20 on the AOT reactor.
Preparations and conditions

The valve must be in closed position.

The valve position must not be adjusted during the routine.

The valve must be mounted and connected to air and power before adjustment.

Follow the steps below


1.

62

Dismount the actuator from the valve according to instruction Dismount actuator on page 59.
Put the actuator on a work bench.

Book No.9010182 02, rev. 0

2.

Valve actuator

8.6

Change direction of actuator with position


sensor (201-19 and 20120)

Disconnect the DIN connector (2) from the coil: First loosen the screw (1), and then pull up
the connector.

7 DisconDINcon

3.

Unscrew the center screw (6) holding the puck (8) and a bracket (7).

7 DirActPosSnsr

4.

Lift the puck (8), rotate it 90 so that one position indicator (5) with a screw is in contact with the
position sensor. Fasten the puck with the center screw (6) and bracket (7).

5.

Move the screw on yellow position indicator to the top position and move the screw on black
position indicator to the bottom position.

6.

Make sure that the position sensor have a maximum distance of 1 mm from the puck (7). The
position sensor and the position indicator screws must be close to give a signal. If not, loosen
the screws and adjust the position. Tighten the screws to fixate the position.

7.

Fit the actuator onto the valve stem in its new position according to instruction Mount actuator
on valve on page 59.

Book No.9010182 02, rev. 0

63

8.8

Mount pilot valve on actuator

Valve actuator

8.

Make sure that the yellow indicator (5) in line with the valve throttle according to the groove in
the valve stem.

9.

Reconnect the DIN connector.

10. Connect power.


11. Check that the installation is OK, by making sure that the A1 LED is lit on the position sensor
(visible from the side).
12. Connect air.

8.7

Change direction of actuator with positioner


(2018)

Follow this instruction to turn the actuator on control valve 2018, if necessary due to lack of space.
Note that the actuator normally should not be altered.
Preparations and conditions

The valve must be in closed position.

The valve position must not be adjusted during the routine.

Follow the steps below


1.

Dismount the actuator from the valve according to instruction Dismount actuator on page 59.

2.

Fit the actuator onto the valve stem in its new position and mount it on the valve with the four
hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten
with torque according to the table Tightening torques for actuators on page 58.

3.

The position indicator scale shall be correct, but make sure that the scale still indicates correct
opening percent according to the valve throttle position. If not, loosen the four bolts to the
bracket holding the switch box. Lift it and turn the scale so it is correct.

4.

Refit the switch box. Make sure that the peg on the scale fits to the carrier on the puck
mounted on the actuator.

8.8

Mount pilot valve on actuator

Follow this instruction to mount a pilot valve on actuator and connect them.
Preparations and conditions

The valve must be in closed position.

Air and power must be disconnected. The valve position must not be adjusted during the routine.

64

Book No.9010182 02, rev. 0

Valve actuator

8.9

Adjust valve end position

7 MountPilote

Pilot valve and actuator


1.
2.
3.
4.
5.
6.

Mounting screw holes


Throttle valve
Port 1 for air connection (under)
Throttle valve
DIN connector
Screw.

Follow the steps below


1.

Check that the O-rings are fitted on the pilot valve, on the side facing the actuator.

2.

Fit the pilot valve on in the actuator, so that the pin on the actuator fits the hole on the pilot
valve. The throttle valves (2 and 4) shall be directed downwards.

3.

Mount the pilot valve with two Allen screws in the holes (1).

4.

Connect air to port 1 (3) on the pilot valve.

5.

Fit the DIN connector (5) on the coil, including gasket. Then fasten the connector with the
screw (6).

8.9

Adjust valve end position

Follow this instruction to tune the open and closed end positions for a valve. This is done if the
valve tends to get stuck in the end position or not close completely.

Book No.9010182 02, rev. 0

65

8.10

Adjust valve traveling speed

Valve actuator

7 576075_lock_manual

Preparations and conditions

The valve shall be closed (0) position 0.

Follow the steps below


1.

Note the exact position of the position indicator for reference after adjustment.

2.

Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing position and the left
set adjusts open position.

3.

Loosen the locking bolt (3).

4.

Adjust end position by turning the end stop blot (4) with small turns.
Clockwise decrease the end position.
Counterclockwise increase the end position.
NOTE

The total adjustment degree is 10 for each position.

5.

Operate the valve. Compare the new position of the position indicator to see the result on the
adjustment. If needed, adjust again.

6.

Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).

8.10 Adjust valve traveling speed


Follow this instruction to adjust valve traveling speed.

66

Book No.9010182 02, rev. 0

Valve actuator

8.10

Adjust valve traveling speed

7 AdjustTravel

Follow the steps below


1.

Operate the valve manually to check traveling speed according to the instruction in the Operate
valves manually on page 19.

2.

To adjust opening speed:


Faster: Screw the throttle (1) valve port 3 counterclockwise.
Slower: Screw the throttle valve (1) port 3 clockwise.

3.

To adjust closing speed:


Faster: Screw the throttle valve (2) port 5 counterclockwise.
Slower: Screw the throttle valve (2) port 5 clockwise.

Book No.9010182 02, rev. 0

67

8.11

Calibrate positioner on V201-8

Valve actuator

8.11 Calibrate positioner on V201-8


Follow this instruction to calibrate the positioner at installation or when needed.

7 201-8Positioner4

1.
2.
3.
4.
5.
6.

Arrestor device (screw driver adjusting)


Unlock the wheel
Locking wheel (screw driver adjusting)
Direction to lock the wheel
Adjustment wheel
Transmission ratio selector

Preparations and conditions

The valve must be installed and connected to air and power.

The valve must be closed.

The cover must be removed.

Do not adjust the cam wheel: 2 grey wheels above the adjustment wheel (5).

Buttons on the positioner:

7 201-8Positioner

Follow the steps below


1.

Make sure that the transmission ratio selector (6) is set to 90 according to sticker on the
component. If not: Adjust by pressing the bar with a screw driver.

2.

Make sure that the Arrestor device wheel (1) is set to 90. If not: Adjust by turning.

3.

If the positioner display is empty (no power): Open V201-8 manually (approximately 1-5) from
control system to supply power to the positioner.
Result: Menu 1 and turn should be displayed. If not: Press button until it is displayed.

4.

Press the hand button.


Result: Menu 2 and 90 is displayed.

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Book No.9010182 02, rev. 0

Valve actuator

8.11

Calibrate positioner on V201-8

5.

Press the hand button.


Result: Menu 4 and no is displayed

6.

Go to step 8.

7.

(Skip this step if installing a new positioner)


Press the hand button (approx. 5 sec.) until a (any) menus is displayed. Press the hand
button till menu 4 is displayed.

8.

Press + button for 5 seconds to start automatic calibration.

9.

If calibration stops (as displayed below), follow these steps:

7 201-8Positioner2

Use a screw driver to loosen the yellow locking wheel (counter clockwise).

Turn the adjustment wheel (5) by hand until a 0 is displayed between the d and the U as
shown in the illustration. Normally this is when the value in the screen is close to 0.

7 201-8Positioner3

Lock the locking wheel (3) with a screw driver.

Press the + button to continue the calibration.

10. Wait until FINISH is displayed on the screen.


11. Press the hand button once.
Result: Menu 4 INITA is displayed.
12. Press the hand button until VER is displayed (approx. 5 sec.)
Result: MAN is displayed.
13. Press the hand button.
Result: AUT is displayed.
Trouble shooting
If any problem occurs, do the following:
1.

Check the mechanical installation and air supply.

2.

Rest factory settings and restart calibration:


-

Reset to factory settings: Press hand button until menu 50 is displayed.

Press + button until oCAY is displayed.

Restart instruction from the beginning.

Book No.9010182 02, rev. 0

69

8.11

Calibrate positioner on V201-8

Valve actuator

9 Ball valve
This section contains maintenance information for the ball valve.

9.1

Replace seals in ball valve

Follow this instruction to replace the seals in ball valve.

7 BallV

Ball valve, exploded view

Preparations and conditions


Maximum tightening torque
Valve size

Max. torque of
body bolts (8)

Max. torque of stem nut (14)

25 = 1 inch

1316 Nm

14.3 Nm

32 = 1
inches

2025 Nm

14.3 Nm

50 = 2 inches

3540 Nm

19.4 Nm

Book No.9010182 02, rev. 0

71

9.1

Replace seals in ball valve

Ball valve

Follow the steps below


1.

Relieve the line pressure.

2.

With the valve in the open position (lever to be parallel to the axis of the pipe), remove all the
body bolts (19) except one.

3.

Loosen the nut (20) on the remaining bolt. Swing the body outside the pipe.

4.

Dismount the stem (8).

5.

Replace seals (5, 6, 7, 9, 10, and 24). They are available in a spare parts kit for the ball valve.

6.

Mount in reverse order. The body bolts of the valve should be tightened evenly. Tighten
one-side snugly, then the one diagonally across. Repeat for the other bolts, bringing them all
down tightly in sequence. Make sure the maximum tightening torque is observed according
to the table above:

7.

Check that the valve is operating correctly.

8.

Check for leaks when the water flow is on.

72

Book No.9010182 02, rev. 0

10 Level switch
This section contains information about the level switch LS201-29 installed in the AOT reactor. For
information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.

7LS Component

Level switch

10.1 Mount level switch


Preparations and conditions

Do not alter the forks in any way.

Be careful not to damage the fork in any way.


NOTE

Disconnect power supply before mounting or dismounting the component.

Follow the steps below


1.

Connect the level switch according to the label on the component.

2.

Seal the level switch with lock tight or equivalent pipe seal.

3.

Mount the sensor until the joint is finger-tight.

4.

Identify the sensor align mark () on the component. Make sure that it is positioned on the
upper side of the level switch.

Book No.9010182 02, rev. 0

73

10.3

5.

Test level switch

10

Level switch

Complete the seal carefully by tightening the component with a spanner. Use the spanner on
the hexagon flats, but not on the level switch body.

10.2 Dismount level switch


Preparations and conditions

The external surface may be hot. Care must be taken to avoid possible burns.

Follow the steps below


1.

Disconnect the level switch according to the label on the device.

2.

Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the level switch body.

3.

Remove the level switch and remove the old seal from the threads.

10.3 Test level switch


Follow the instruction below to test that a level switch functions OK.
Follow the steps below
1.

Make sure that the component i powered (the green LED shall be lit).

2.

Hold a magnet to the test point indicated on the on the level switch, indicated below.

7LS Test

3.

74

Make sure the level switch reacts to the magnet. The component is OK if the green and
yellow LED is lit.

Book No.9010182 02, rev. 0

11 Temperature switch and


temperature transmitter
This section contains information about the temperature switch TS201-60 and the temperature
transmitter TT20133 installed in the AOT reactor. The two components are similar in design, so
the same instructions can be used.

7 TS and TT

Temperature switch and temperature transmitter

Preparations and conditions


NOTE

Disconnect power supply before mounting or dismounting the component.

11.1 Mount temperature switch / temperature


transmitter
Follow the steps below
1.

Seal the components threads using lock tight or equivalent pipe seal.

2.

Mount the component until the joint is finger-tight.

3.

Tighten the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.

4.

Connect the components screwed-on power cord.

Book No.9010182 02, rev. 0

75

11.2 Dismount temperature switch /


temperature transmitter

11

Temperature switch and temperature transmitter

11.2 Dismount temperature switch / temperature


transmitter
Preparations and conditions

The external surface may be hot. Care must be taken to avoid possible burns.

Follow the steps below


1.

Disconnect the components screwed-on power cord.

2.

Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.

3.

Remove the level switch and remove the old seal from the threads.

76

Book No.9010182 02, rev. 0

12 Control panel
This section covers instructions for service of the control system.

12.1 Clean control panel


NOTE

Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.

Preparations and conditions

Never use aggressive solvents, chemicals, scouring agents, pressurized air or steam jet.

Follow the steps below


1.

Press the Wipe button on the screen.


Result: Disable the touch screen function for 10 seconds to make it possible to clean the
screen without the risk of starting a process or changing a setting.

2.

Clean the display and surrounding front cover with a soft cloth and mild detergent. Do not
spray detergent directly on the control panel.

12.2 Replace control panel


Follow this instruction to replace the control panel.
Preparations and conditions:

The system must be shut down.

When the panel is mounted, software must be updated and settings performed accroding to
last step of the instruction.

12.2.1 Dismount the panel


Follow this instruction to dismount the control panel.
Follow the steps below
1.

Open the control cabinet.

2.

Pull out the power and signal cables.

Book No.9010182 02, rev. 0

77

12.2

3.

Replace control panel

12

Control panel

Loosen the screws on the inside of the cabinet door.

7BeijerScrews

4.

Hold the panel on the outside so it does not fall out. At the same time: Slide the brackets
and remove them. Then remove the panel.

7BeijerBracket

12.2.2 Mount the panel


Follow this instruction to mount the control panel.
1.

Put the panel in place.

2.

Hold the panel on the outside so it does not fall out. At the same time: Attach the brackets on
the inside by sliding them into place.

7BeijerBracket

78

Book No.9010182 02, rev. 0

12

Control panel

3.

Fasten the screws on the inside of the cabinet door.

12.2

Replace control panel

7BeijerScrews

4.

Open the small cover on the rear side. Make sure that all DIP switches are in position OFF.

7BeijerMODE

5.

Connect the signal cable in the 10/100 port.

6.

Connect the power cable in the 24V DC port.

7.

Remove the laminated film, to avoid static electricity that could damage the terminal.

8.

Make sure that the control panel is brought to ambient temperature before it is started. If
condensation forms, ensure that the operator panel is dry before connecting it to the power
outlet. Ensure that the voltage and polarity of the power source is correct.

9.

Load new software to the panel according to instruction Update PLC software and Install
TA150 firmware in chapter 3. Operating instruction and control system description. Also
set communication according to Set control panel IP address and Set remote control panel
communication.

Book No.9010182 02, rev. 0

79

12.2

Replace control panel

12

Control panel

13 Remote control panel


(optional)
This section covers information on how to mount and connect communication components for the
remote control panel.
The information in this instruction is also given in the Control cabinet / Circuit diagram in chapter 6.
Installation description and drawings.

13.1 Mount and connect network switch for remote


control panel

7 594060 RCP

Network switch and terminals


1. Ethernet ports (3 pieces)
2. 24 VDC port (connection to terminals connected
at delivery)
3. Network switch
4. Terminal (+ 24 V power connection)
5. Terminal ( 24 V power connection).
6. Terminal (grounding)
7. Fiber ports (2 pieces)

Book No.9010182 02, rev. 0

81

13.1 Mount and connect network switch for


remote control panel

13

Remote control panel (optional)

7 RemotPanelCon

Back of remote control panel, side view

Preparations and conditions

If used, a network switch (3) is installed at a location of your choice, near the position of the
remote control panel.

24 VDC cables are not included in scope of supply. Use a cable with minimum cross section of
0.75 mm2, preferably halogen free and flexible.

The remote control panel must have been mounted on a location of your choice. See Remote
control panel (optional) / Dimensional drawing in chapter 6. Installation description and drawings.

Two wires are mounted between terminal and switch power contact (2) no 1=DC, no 2=DC+,
cables are marked + and .

Prerequisites for cable length and cable types are stated in chapter 6. Installation description
and drawings, section Remote control panel integration (optional). Ethernet and fiber cable can
be used. This instruction is written for Ethernet, but if fiber is used use fiber cable and connect
them to the fiber ports instead of Ethernet ports.

Switch off the PureBallast system and disconnect it from the power supply.

Follow the steps below


1.

At the back of the remote control panel, fasten the Ethernet cable in Ethernet port 1. Fasten
the other end of the cable in the network switchs Ethernet port number 1 (1).

2.

Connect an Ethernet cable from the network switch near the remote control panel to the
network switch in the control cabinet (see position 1 in illustration on page 83). Also see cable
W501 in Control cabinet / Interconnection diagram.

3.

If more than one remote control panel is installed, connect an Ethernet cable from Ethernet
port number 2 (1) in the network switch (near the remote control panel) to the second remote
control panel (or via a second network switch, if used).

4.

Connect a 3 core cable from network switch terminals 4 (+), 5 () and 6 (GND) to the remote
control panels 24 VDC port (2).

5.

Connect a 24 VDC power supply cable to the terminals 4 and 5 and 6.

82

Book No.9010182 02, rev. 0

13

Remote control panel (optional)

13.2

Mount and connect network switch for


remote control panel (retrofit)

13.2 Mount and connect network switch for remote


control panel (retrofit)
The information is only relevant if this option is added after installation. If remote control panel is
included in the original order, the network switch is already mounted in the control cabinet. .

7 591773 RI

Control cabinet, opened

Follow the steps below


1.

Loosen the right end stop on the DIN rail at position (1).

2.

Mount the network switch on the DIN rail at position (1).

3.

Fasten the end stop to fixate the network switch at position (1).

4.

On the PLC, disconnect the Ethernet cable (coming from the main control panel) from port IF2
and connect it to the network switch port: 1.

5.

Connect an Ethernet cable in the IF2 on the PLC and connect the other cable end to the
network switch port: 2.

6.

Connect wire 400 (DC) to terminal 400 (3) and to network switch (1) terminal no: 1.

7.

Connect wire 402 (DC+) to PLC terminal 15 (2) and to network switch (1) terminal no: 2.

8.

Follow instruction Mount and connect network switch for remote control panel to connect
remote control panel.

Book No.9010182 02, rev. 0

83

13.2 Mount and connect network switch for


remote control panel (retrofit)

13

Remote control panel (optional)

14 Control cabinet and lamp


drive cabinet (LDC)
This section covers maintenance information for the control cabinet.

14.1 Disassemble and assemble I/O system


This section covers maintenance information about the I/O system (X20 electronic modules). For
information about status and error indications, pleas see chapter 5. Alarms and fault finding.
Follow the steps below
1.

Hold down the plastic clip on the top of the terminal block and pivot the block towards you.

7IO1_X025002A

2.

Pull away the terminal block.

3.

Hold down the triangle on the top of the I/O board and loosen the board.

7IO2_X025003A

Book No.9010182 02, rev. 0

85

14.1

4.

Disassemble and assemble I/O system

14

Control cabinet and lamp drive cabinet (LDC)

Pull the board straight out (otherwise it can fasten in one of its guides).

7IO3_X025004A

5.

Compare the part number of the new I/O board to the old board, to make sure it is correct.

6.

If changing more than one board at a time, check with the electrical diagram to ensure that
the boards are mounted in the right places.

7.

Mount the new I/O board by pressing it straight into place. Make sure the board is firmly in
place, otherwise it will be impossible to mount the cable terminal.

7IO4_X025005A

8.

Remount the terminal block. Make sure the clip on the bottom of the block fastens properly in
place on the axel on the bus holder.

7IO5_X025007A

86

Book No.9010182 02, rev. 0

14 Control cabinet and lamp drive cabinet


(LDC)
9.

14.2

Cable gland installation

Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in
the I/O board.

7IO6_X025006A

14.2 Cable gland installation


This section covers information about how to install the cables into the control cabinet and LDC
using the cable glands.
Follow this instruction to mount cables into the cabinets.
Follow the steps below
1.

Lubricate the inside surfaces of the frame with Roxtec Assembly Gel or equivalent, specially
in the corners.

7 Cable1

2.

Insert the cables through the frame.

3.

Adapt the modules, which are to hold cables.

4.

Peel off layers until you achieve a 0.1-1.0 mm gap between the two module halves when
held against the cable.

Book No.9010182 02, rev. 0

87

14.2

Cable gland installation

14

Control cabinet and lamp drive cabinet (LDC)

7 Cable2

7 Cable3

5.

Lubricate all modules thoroughly, both on the inside and the outside surfaces.

7 Cable4

6.

Insert the modules from the back of the frame opening. If possible, start with the largest
modules.

7 Cable5

88

Book No.9010182 02, rev. 0

14 Control cabinet and lamp drive cabinet


(LDC)
7.

14.2

Cable gland installation

Tighten the compression unit firmly to seal the frame. Maximum 10 Nm. A good indication is
when the lubrication is squeezed out between the modules.

7 Cable6

Book No.9010182 02, rev. 0

89

Spare parts catalogue


PureBallast 3.0 Flow 750

Specification No. 9005247-01/2


Book No. 9010670 02

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone:
Telefax:

+46 8 530 650 00


+46 8 530 310 40

Alfa Laval Tumba AB 2014-02-03


Original instructions
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.

Contents
1

Important information

Control Cabinet

2.1 Cabinet

10

2.2 I/O module

12

2.3 Relay module

14

Lamp Drive Cabinet

16

3.1 Cabinet

18

AOT reactor

34

4.1 AOT reactor JIS

38

4.2 Junction box

40

4.3 Junction box

42

4.4 Valve V201-19 and V201-20

44

4.5 Valve

46

Filter, RF10-30

48

5.1 Valve, V309-1

54

Valve, JIS A300

56

Valve, JIS A300

58

Valve, JIS A300

60

Control valve V201-8

62

10 Flow transmitter, A300

64

11 CIP module

66

11.1Pump P320-1 and P321-5

70

11.2Valve

72

11.3Valve block

74

11.4Air distribution

76

12 Sampling device (QT201.1,


QT201.1)

78

13 Pressure monitoring device

80

14 Cross reference list

82

Important information

1 Important information

State number of ordered parts. Note that the quantity in the tables do not states number of parts
delivered (only the how many of that parts that are included in the mother component).
It is only possible to order parts included in the tables.

Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with
non-original spare parts. We guarantee the quality and reliability of our products.

This manual refers to unit number printed on the equipment name-plate.

When ordering, refer to part number listed in this catalogue and serial number, described in
chapter 7. Service manual, section Serial number information.

Book No.

PureBallast 3.0 Flow 750

2 Control Cabinet
Machine unit number or
Subassembly description

Ref

Part No

Description

1
3
4
5
6
7
8
8.1
9
10
10.1
11
12
13
14
14.1
15
16
16.1
17
18
19
20
21
22
23
24
24.1
24.2

9006237 80
9006852 01
595670 80
9006804 01
9006805 01
9006806 01
221891 04
223101 47
582212 148
591103 60
591103 10
591103 45
582212 125
9004299 04
582212 67
582212 60
582212 63
591103 38
591103 81
221701 03
9005006 80
582212 91
582212 147
582212 104
582212 102
582212 105
582212 104
582212 171
582212 167

Cabinet
Software, panel
Panel
DIN-rail 35x15
DIN-rail 35x15
DIN-rail 35x15
Lock nut
Washer
End stop (clip fix)
Over current prot. Relay
Auxiliary contact
Breaker handles
Power supply unit
Fuse
Terminal, PIT 2,5-3PV
Bus bar blue
Terminal D-PIT 2,5-3L
Contactor
Relay, over current prot.
Screw
I/O module
VIP-2, D 9SUB
Patch panel
Terminal PITTB 2,5
Terminal PITTB 2,5 PE
End plate D-PITTB
Terminal PITTB 2,5
Busbar 1/3/5-5, red
Busbar 20-5 Blue

25
26
26.1
26.2
27
28
29
29.1
29.2
30
31
32
33
34
36
37
38
39
41
42
44
45
46
47
48
49
51.1
51.2
52
52A

582212 105
582212 67
582212 60
582212 03
582212 63
582212 168
582212 123
582212 86
582212 87
9002362 81
582221 90
582212 15
593724 03
594009 03
583556 16
583556 17
9003522 07
9003522 06
591922 01
595361 01
223101 47
221803 02
582221 89
582356 18
582212 155
591103 36
596894 01
596894 01
9009695 80
9006853 01

End plate D-PITTB


Terminal, PIT 2,5-3PV
Bus bar blue
Plug In Bridge
Terminal D-PIT 2,5-3L
Separating plate
Power terminal block,
Bus bar, blue 500mm
Bus bar, red, 500mm
Relay module
PE Connection bar
PE/SC Bar
Distance screw
Screw
Cable channel 40x80
Cable channel 40x80
Cable channel, 25x80
Cable channel, 25x80
Cable seal
Cable seal
Washer
Nut
Cable fixing spiral
Puschbutton switch
Socket with USB
Main breaker
PE cable, 2,5mm
PE cable, 2,5mm
Fan
Fan

-80
1
1
1
1
2
1
13
13
13
1
1
1
1
4
6
1
1
1
1
4
1
2
2
3
1
1
40
1
1
1
4
1
1
1
2
1
1
1
3
1
1
7
5
2
1
2
1
1
1
2
2
1
1
2
1
1
1
1
1

9004429Quantity

Notes
See page 10

See page 12

Connected: 11,15,19
Short end 15 pin, connected:
12,18,32,34,36,38,40

155mm
155mm
See page 14
245mm
500mm

BRB 6,4x12x1,6 fzb


M6M 6 fzb

L= approx. 500mm (door)


L= approx. 300mm (PE bar)

Book No.

Control Cabinet

2690A

Book No.

PureBallast 3.0 Flow 750

Machine unit number or


Subassembly description

Ref

Part No

Description

52B
53
55
68
69
70
Z
Z0.1

9009688 01
9009696 80
595673 01
9008672 80
582212 122
582212 13
597330 01
597331 01

Filter
Air outlet
Ethernet cable
Cable set
Terminal block
End plate
Cable seal
Cable seal

-80

9004429Quantity

Notes

1
1
1
3
3

Book No.

Control Cabinet

2690A

Book No.

PureBallast 3.0 Flow 750

2.1 Cabinet
Machine unit number or
Subassembly description

Ref

Part No

2
3
4
5
6
7
8
10
11
12
13
15
16
19
22
23
24
25
26
27
28
29
30
31
32
33
34
35

9006246
594009
26556
9006761
70915
221891
221716
579385
9003013
593991
9003024
223107
221891
593254
221711
593282
221803
223101
593239
581688
594488
221711
223101
221891
587276
70560
221891
544465

10

Description

01 Door
01 Screw
Spring washer
80 Mounting plate
Spring washer
05 Hexagon lock nut
01 Screw
01 T-handle
01 Rod Guide
01 Latch
02 Rod for latching
34 Spring washer
04 Lock nut
01 Retaining ring
19 Screw
01 Washer
02 Nut
73 Washer
01 Nut
01 Bracket
01 Washer
16 Screw
47 Washer
04 Lock nut
02 Washer
Washer
05 Hexagon lock nut
04 Locking liquid

-80
1
6
6
1
16
12
4
1
2
1
2
4
4
1
1
1
2
1
1
4
4
8
8
8
6
6
6
1

9006237Quantity

Notes
MRX-Z5x6 fzb
FBB 5,1 fzb
M6M 8 fzb

FBB 6,1 fzb


M6M 6 fzb
MC6S 6x25 fzb
BRB 6,4x12x1,6 polyamide
M6M 6 fzb
BRB 6,7x16x1,5 fzb

MC6S 6x16 fzb


MRM 6,4x12x1,6 fzb
M6M 6 fzb
M6M 8 fzb
Loctite 270

Book No.

Cabinet

Control Cabinet

2718A

2.1

Book No.

11

PureBallast 3.0 Flow 750

2.2 I/O module


Machine unit number or
Subassembly description

Ref

Part No

1
1.1
1.2
1.3
2
3
4
5
6
7
8
9
10
12

580986
597033
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986

12

67
18
76
76
17
30
51
08
33
32
59
06
16
55

Description
PLC unit
Interface module
Communication module
Communication module
Bus module
Supply Bus Module
12 Digital Input
4 Analogue input
Output Module
Supply Module
12 Digital Output
6 Relay output
Terminal block 12-pin
Compact flash card

-80
1
1
1
1
11
1
3
2
1
1
1
4
12
1

9005006Quantity

Notes
Incl. locking plate.

Book No.

I/O module

Control Cabinet

2772A

2.2

Book No.

13

PureBallast 3.0 Flow 750

2.3 Relay module


Machine unit number or
Subassembly description

Ref
1
2
3
Z

14

Part No

Description

582212
582212
582212
582212

Interface relay, 24V


Input adapter
System cable
Relay, mini

119
120
186
172

-81
8
1
1

9002362Quantity

Notes

Spare part only

Book No.

Relay module

Control Cabinet

2692A

2.3

Book No.

15

PureBallast 3.0 Flow 750

3 Lamp Drive Cabinet


Machine unit number or
Subassembly description

Ref
1
19

16

Part No

Description

9011549 80 Cabinet
9005496 01 Lamp Power Supply

-80
1
16

9004480Quantity

Notes
See page 18

Book No.

Lamp Drive Cabinet

2774A

Book No.

17

PureBallast 3.0 Flow 750

3.1 Cabinet
Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
4
5
6
7
9
9.2
10
11
12
13
14
15
19.1
19.2
19.3
20
21
22
23
24
25
26
26.1
27
28
29
30
31
32
33
34
35
36
37
37.1
38
39
40
41
42
43
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

9003628 80
9004211 01
9004212 01
9004213 01
9004506 80
9004214 01
590624 03
9004254 01
595558 01
523127 04
9004426 01
582356 30
582356 26
582356 28
582356 27
582212 164
582212 163
582212 165
582221 90
9006677 01
9004313 80
9005494 01
591103 46
591103 60
591103 54
591103 10
591103 66
591103 64
591103 61
582212 125
9004299 04
9004299 01
9004299 02
9004299 03
9006326 01
582212 146
9004174 80
594728 01
9004507 80
9004329 80
9004303 02
582212 147
9004508 80
582212 148
9004299 07
582212 141
70560
221030 10
221803 02
221803 03
221891 01
221891 02
221891 04
221891 05
223101 03
223101 16
223101 17
223101 47
587276 02

Cabinet
Centrifugal fan
Inlet duct
Protection
Terminal block
Heat exchanger
Temperature sensor
Check valve
Wire
Hexagon nipple
Hose
Lamp green, compl.
Signal lamp, White
Button ill. blue, compl.
Sign holder
Phoenix Contact
Phoenix Contact
Phoenix Contact
PE Connection bar
Filter
Main breaker
Transmitted handle kit
Breaker door seal
Over current prot. Relay
Over current prot. Relay
Auxiliary contact
Bus bar
Connection
Self-res. short-circ. lim
Power supply unit
Fuse
Relay safety
Relay safety
Relay safety
Temperature relay
Interface relay, 24V
I/O module
Temperature sensor
Terminal block
Liquid leakage amplifier
Sensor, liquid
Patch panel
Terminal block
End stop (clip fix)
Terminal
Cable holder
Washer
Screw
Nut
Nut
Lock nut
Nut
Lock nut
Hexagon lock nut
Washer
Washer
Washer
Washer
Washer

18

-80
1
1
1
1
1
1
1
1
1
2
2
1
1
1
3
16
16
16
1
1
1
1
1
2
16
16
6
3
3
1
3
1
1
1
1
1
1
1
1
1
1
2
1
13
3
2
3
12
5
1
2
4
4
3
2
4
1
21
3

9011549Quantity

Notes
See page 22

Fully exchangable with 9008407.

830mm

See page 26
See page 28

See page 30

Book No.

Cabinet

Lamp Drive Cabinet

2775A

3.1

Book No.

19

PureBallast 3.0 Flow 750

Machine unit number or


Subassembly description

Ref
61
62
63
64
66
67
69
73
74
75
76

20

Part No

Description

593724 03
594009 02
594009 03
594009 04
594009 07
9005626 01
582212 181
9008374 01
9008382 80
582212 122
582212 13

Distance screw
Screw
Screw
Screw
Screw
Self-tapping screw
Sc clamp SK 35 D
Igniter
Cable set
Terminal block
End plate

-80
6
4
3
2
2
5
2
2
1
1
1

9011549Quantity

Notes

See page 32

Book No.

Cabinet

Lamp Drive Cabinet

2775A

3.1

Book No.

21

PureBallast 3.0 Flow 750

3.1.1 Cabinet
Machine unit number or
Subassembly description

Ref

Part No

Description

1
1A
1B
1C
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
27
28
29
30
31
33
34
35
42
42.1
58
59
60
62
63
64
66
67
69
70
72
73
74
76
77
79
80
82
83
88
89

9005142
591874
591874
9003031
9005143
9005144
221803
223101
9005145
9008903
221891
9003089
223101
221726
9003394
587276
221891
221716
9003390
223101
221030
9003401
223101
221030
9003186
9003410
223101
221030
593287
9003113
9003114
9002947
9002942
223101
221030
221891
221891
223101
587276
221851
591889
593780
9003186
9006316
221030
223101
9006322
9006519
221891
223101
9008424
221851
587276
221891
223101
223101
221891
587276
221851

Cabinet
Seal
Seal
Condensation outlet
Door, RH
Door, LH
Nut
Washer
Stand
Washer
Hexagon lock nut
Vibration damper
Washer 13x24x2,5
Screw
Mounting plate
Washer
Hexagon lock nut
Screw
Bracket, fan
Washer
Screw
Sheet, heat exchanger
Washer
Screw
Plug
Sheet, heat exchanger
Washer
Screw
Pop rivet, multi grip
Cable seal
Cable gland
Yoke
Stud bolt
Washer
Screw
Lock nut
Lock nut
Washer
Washer
Cap nut
Cable tie mount
Key
Plug
Cover, fan
Screw
Washer
Sheet
Cover
Nut
Washer, 4,3x9x0,8
Protection
Cap nut
Washer
Lock nut
Washer
Washer
Lock nut
Washer
Cap nut

22

80
04
05
01
80
80
02
47
80
05
05
02
49
10
01
02
05
01
01
47
10
01
47
10
01
01
47
10
01
01
02
01
01
47
02
04
04
47
01
05
01
01
02
01
10
47
01
01
02
41
01
05
01
04
47
47
04
01
05

-80
1
1
1
2
1
1
12
12
1
12
12
2
2
2
1
15
12
3
1
6
6
1
3
3
1
1
9
9
3
1
2
18
36
72
36
36
17
17
8
8
3
1
2
1
3
3
2
1
20
20
3
5
5
2
2
7
7
17
17

9003628Quantity

Notes
Upper LPS rack, left
Upper LPS rack, right
Cabinet floor and heat exchanger floor

Book No.

Cabinet

Lamp Drive Cabinet

2700A

3.1

Book No.

23

PureBallast 3.0 Flow 750

Machine unit number or


Subassembly description

Ref

Part No

Description

90
91
92
Z
Z0.1

9009714
221891
223101
597330
597331

Sheet
Lock nut
Washer
Cable seal
Cable seal

24

01
04
47
01
01

-80
1
1
1

9003628Quantity

Notes

Book No.

Cabinet

Lamp Drive Cabinet

2700A

3.1

Book No.

25

PureBallast 3.0 Flow 750

3.1.2 I/O module


Machine unit number or
Subassembly description

Ref

Part No

1
2
3
4
5
6
7
8
9
10
11
12
13
14

580986
580986
580986
580986
580986
597033
580986
580986
580986
580986
580986
580986
580986
597033

26

64
17
62
63
72
19
59
08
53
61
16
19
20
20

Description
Bus Module
Bus module
Interface Module
Bus Supply
Communication module
16 Digital input
12 Digital Output
4 Analogue input
2 Analogue Output
4 Analog Input (PT100)
Terminal block 12-pin
Locking Plate left
Locking Plate right
Terminal Block 16-pin

-80
1
6
1
1
1
1
1
1
1
1
6
0
0
1

9004174Quantity

Notes

Included in pos:1
Included in pos:1

Book No.

Cabinet

Lamp Drive Cabinet

2702A

3.1

Book No.

27

PureBallast 3.0 Flow 750

3.1.3 Terminal block


Machine unit number or
Subassembly description

Ref
1
2
3
4
5
6
7

28

Part No

Description

582212 67
582212 64
582212 65
582212 63
582212 71
582212 03
582212 148

Terminal, PIT 2,5-3PV


Terminal PIT 2,5-3PE
Terminal PIT 2,5-3L
Terminal D-PIT 2,5-3L
Plug In Bridge, FBS 3-5BU
Plug In Bridge
End stop (clip fix)

-80
7
1
2
1
1
1
1

9004507Quantity

Notes

Book No.

Cabinet

Lamp Drive Cabinet

2704A

3.1

Book No.

29

PureBallast 3.0 Flow 750

3.1.4 Terminal block


Machine unit number or
Subassembly description

Ref
1
3
4
5
6
7
8
9
10
11
12
13
15
16

30

Part No

Description

582212 148
582212 130
582212 122
582212 88
582212 89
582212 132
582212 131
582212 156
582212 157
582212 133
582212 15
582212 15
582212 137
582212 136

End stop (clip fix)


Support, L=95,5
Terminal block
PIT 2,5
D-ST2,5
Sealable cover profile
Support, L=150
Terminal, PT 6
End cover, D-PT 6
Cover profile (AP-3) L=1m
PE/SC Bar
PE/SC Bar
Sc clamp SK 20
Sc clamp SK 14

-80
2
1
2
22
1
2
2
32
1
1
1
1
9
1

9004508Quantity

Notes

Cut to 294 mm
Cut to 289 mm
Cut to 431 mm

Book No.

Cabinet

Lamp Drive Cabinet

2705A

3.1

Book No.

31

PureBallast 3.0 Flow 750

3.1.5 Cable set


Machine unit number or
Subassembly description

Ref
1
2
3
4
5
6
7
8
9
11
12
14
15
16
50
51

32

Part No

Description

-80

9008383 01
9008383 02
9008383 03
9008383 04
9008383 05
9008383 06
9008383 12
9008383 13
9008383 08
9008387 01
9008693 01
595673 04
9004439 01
9008388 01
582221 99
582221 100

Cable, 70mm
Cable, 35mm
Cable, 2,5mm
Cable, 2,5mm
Cable, 2,5mm
Cable, 2,5mm PE
Cable, 25mm PE
Cable, 6mm PE
Cable, 1,5mm
Cable, 0,75mm
Cable, 2x2x0,5mm
Ethernet cable
Cable
Cable, 2x1,5mm
Ferrite
Ferrite

5
15
20
20
20
25
1
2
6
150
6
2
1
35
2
2

9008382Quantity

Notes

on 595673 04
On incomming LAN cable

Book No.

Cabinet

Lamp Drive Cabinet

2377A

3.1

Book No.

33

PureBallast 3.0 Flow 750

4 AOT reactor
Machine unit number or
Subassembly description

Ref

Part No

Description

-82

1
2

9002699 82 AOT reactor JIS


9003748 80 Junction box

1
1

9004960 80 Junction box

4
5
7
8

221711
223101
9001357
594412

Screw
Washer
Sensor
Valve V201-19 and V201-20

8
8
1
1

594412 92 Valve V201-19 and V201-20

8.1
8.2
9
10
12
13
14
15
16
16.1
16.2
16.3
16.4
17
17.1
17.2
17.3
17.4
17.5
18
19
20

590667
9011365
223101
9006325
9006324
558663
594171
9005051
9005051
9005051
9005051
9005051
9005052
9005052
9005052
9005052
9005052
9005052
526350
558663
594413

08
32
03
92

01
01
64
01
01
04
01
04
07
06
08
05
01
05
07
10
09
08
05
03
80

V201-19
Hexagon head screw
Washer
Thermometer, resistance
Temperature, switch
Gasket washer
Vibration limit switch
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Cable
Plug
Gasket washer
Valve

1
32
32
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1

20.1

594413 80 Valve

20.2

594413 80 Valve

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

2210463
223101
1761805
597049
594707
581534
260321
592304
592304
552801
9004638
2210296
223101
221803
9006320

36

9006320 81 Lamp cable

37
38
39
63
95

34

595272
558710
597044
596103
554214

03
37
01
01
02
01
25
01
02
50
01
02
33
27
80

01
02
04
01
06

Screw
Washer
Safety valve, 6 bar
Coupling, elbow 90
Pipe
Distributor
Hexagon screw
Plug
Plug, 1/4
Push-on connector
Clamp
Screw
Washer
Nut
Lamp cable

Tube, 6x1 mm
Air Hose Nipple
Cable
Screw
Cable tie

12
12
1
1
1
1
2
1
1
5
1
1
3
1
16
16
4
5
1
4
30

9002700Quantity

Notes
See page 38
A-side
See page 40
B-side
See page 42

V201-19
See page 44
V201-20
See page 44

TT201-33
TS201-60
LS201-29
V201-19
V201-20
V320-4
V404-36
V321-2
GS201-19
GS201-20
QT201-50
TS201-60
TT201-33
LS201-29
V320-4
See page 46
V321-2
See page 46
V404-36
See page 46
RV201-23

Marked acc. to circuit diagram. Incl.


cap, collet, gland and nut.
Marked acc. to circuit diagram. Incl.
cap, collet, gland and nut.

Book No.

AOT reactor

2688A

Book No.

35

PureBallast 3.0 Flow 750

Machine unit number or


Subassembly description

Ref

Part No

Description

96
Z
ZA
ZB
Z0.1
Z0.1A
Z0.1B

544465
9009521
9007810
579380
594645
9000738
599555

Pipe-Seal
Lamp, spare set
UV lamp with contact
O-ring, 15,1x2,7
Quartz sleeve set
Quartz sleeve
O-ring

36

15
80
80
01
82
02
01

-82
1

9002700Quantity

Notes

1
2
1
2

Book No.

AOT reactor

2688A

Book No.

37

PureBallast 3.0 Flow 750

4.1 AOT reactor JIS


Machine unit number or
Subassembly description

Ref

Part No

Description

-82

3
6
7
8
9
10
11
12
13
14
15
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
33A
34
35
36
38
39
40
41

66169
9003326
221711
9002009
9004878
9002860
9001098
9001897
221036
223101
526350
558663
9001539
221711
9003669
221040
41456
221035
70560
9003661
221035
9003662
2210295
223101
9003672
221035
9004889
9004886
221040
35120
9007794
9009416
221031
223101
221803

Drive screw
Glass socket
Screw
Lamp bush
Cap
Nut
Blind flange
O-ring
Screw
Washer
Plug
Gasket washer
Cable bracket
Screw
Bottom bracket
Screw
Washer
Screw
Washer
Stay
Screw
Plate
Screw
Washer
Upper bracket
Screw
Lifting bracket
Bracket
Screw
Nut
Cable rail
Cable rail
Screw
Washer
Nut

8
32
96
32
32
32
1
1
10
10
1
1
8
16
2
16
24
4
24
2
12
1
1
2
2
8
1
1
4
4
2
2
4
8
4

38

01
13
81
80
01
01
01
02
33
05
03
01
23
01
04
06
01
36
01
03
17
01
03
01
80
55
01
01
21
32
28

9002699Quantity

Notes

Book No.

AOT reactor JIS

AOT reactor

2685A

4.1

Book No.

39

PureBallast 3.0 Flow 750

4.2 Junction box


Machine unit number or
Subassembly description

Ref
1
2
3
4
5
6
7
11
12
18
19
20
22
25

40

Part No

Description

9004825 80
582212 148
582212 88
582212 122
582212 154
582212 70
582212 89
582212 151
582212 150
9003031 01
589569 21
589569 44
582356 26
582356 30

Enclosure
End stop (clip fix)
PIT 2,5
Terminal block
Busbar 5-5 Bu
Plug In Bridge, FBS 3-5
D-ST2,5
Socket
Socket
Condensation outlet
Cable Gland EMC M32
Counter nut EMC M32
Signal lamp, White
Lamp green, compl.

-80
1
2
28
3
1
1
1
6
5
1
2
2
1
1

9003748Quantity

Notes
Marked acc. to interconnection diagram.
400
402

Book No.

Junction box

AOT reactor

2679A

4.2

Book No.

41

PureBallast 3.0 Flow 750

4.3 Junction box


Machine unit number or
Subassembly description

Ref
1
2
3
4
5
6
7
8
9
10

42

Part No

Description

9004844 80
582212 148
582212 156
582212 157
9003031 01
589569 59
9004959 01
589569 45
589569 21
589569 44

Enclosure
End stop (clip fix)
Terminal, PT 6
End cover, D-PT 6
Condensation outlet
Cable gland EMC-brush M40
Insert, 8x6 mm
Counter nut EMC M40
Cable Gland EMC M32
Counter nut EMC M32

-80
1
2
32
1
1
4
4
4
4
4

9004960Quantity

Notes
Marked acc. to interconnection diagram.

Book No.

Junction box

AOT reactor

2680A

4.3

Book No.

43

PureBallast 3.0 Flow 750

4.4 Valve V201-19 and V201-20


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
4
5
6
8
9
Z

576886
576075
576071
585976
594410
583012
9009912
595215
576075

Valve, A350
Air actuator, DA551
Pilot valve
Coil, 24 V DC
Valve connector
Throttle valve, 1/4
Sensor
Plate
Actuator spare part kit, DA/SR 551

44

26
05
01
01
01
01
01
01
65

-92
1
1
1
1
1
2
1
1

594412Quantity

Notes
Lug type

Book No.

Valve V201-19 and V201-20

AOT reactor

2686A

4.4

Book No.

45

PureBallast 3.0 Flow 750

4.5 Valve
Machine unit number or
Subassembly description

Ref

Part No

1
2
3
4
5
6
Z

590037
576075
576071
585976
594410
583012
576075

46

01
21
01
01
01
01
71

Description
Valve, DN32
Air actuator, SR101
Pilot valve
Coil, 24 V DC
Valve connector
Throttle valve, 1/4
Actuator spare part kit, DA/SR 101

-80
1
1
1
1
1
2
1

594413Quantity

Notes

Book No.

Valve

AOT reactor

2330A

4.5

Book No.

47

PureBallast 3.0 Flow 750

5 Filter, RF10-30
*=On request only, contact your local Alfa Laval representative
Machine unit number or
Subassembly description

Ref

Part No

Description

11
11.5
12
13
14
15
17
18
18.5
19
19.1
19.2
19.3
19.4
19.5
21
23
24
25
26
27
28
29
30
31
32
33
34
34.5
35
36
37
38
39
39.6
39.7
39.8
39.9
40
40.5
41
51
52
53
61
65
65.3
65.5
68
70
70.5
71
71.5
72
72.5
73
74
75
76

9006822
9000396
9000396
9006771
9000396
9000397
9000394
9000394
9000396
9000398
9000398
9000398
9000398
9000398
9000398
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000398
9000395
9000395
9000398
9000394
9000394
9000398
9000398
9000395
9000398
9000397
9000395
9000397
9000397
9000398
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000398
9000396
9000396
9000396

Safety valve, 8 bar


Union nut
Tube
2/2-way piston valve
Double nipple
O-ring 81.2 x 5.33 - NBR
Protective box RF10-30 RA
Sacrificial anode RF10-30
Extension RF10 vent 200 L
Litz wire VDE0281 H07V-K
Cable shoe DIN46235 - 8 Washer ISO7089-8 - 200 HV
Hex-screw ISO 4017-M8 x 2
Stud screw DIN939-M 8 x 9
Hex-nut ISO 4032-M8
Drive shaft RF10-30/35
Locking ring DIN471 - 35
Washer RF3-3/4
Washer RF3-3/4 bearing bu
DUB-bearing - id =3 5, ad
Support ring spiral sprin
Quad-ring - 32.92 x 39.98
Washer RF3-3/4 upper driv
Intermediate shaft RF10-3
Lower drive shaft RF10-30
Washer RF3-3/4 Lower driv
Lower bearing bush RF3-3/
Nut RF3-3/4
Nut RF3-3/4
DUB-bearing - id = 50, ad
Cylinder screw ISO 4762Washer RF3-3/4 lever arm
Lever arm
Cylinder screw ISO 4762Upper plate RF10-30 compl
Lower plate RF10-30 compl
Cylinder pin
Cylinder pin
Sleeve
Hex screw
O-ring
Coupling bush RF10-25/30
O-Ring 113.67 x 5.33
O-Ring 113.67 x 5.33
Cylinder pin
Coupling
Manometer connection
Coupling
Blind rivet ISO 15983 - 3
Plate Inlet - English
Plate
Plate Outlet - English
Plate Draining - English
Plate Backflushline - Eng
Plate Dilute - English
Grooved drive stud ISO 87
Ring bolt DIN580 - M20
Cable tape Betz -TYB23M n
Sticker "directional arro

48

02
55
51
02
92
06
03
62
12
51
50
33
21
45
11
42
20
21
22
23
24
25
26
62
63
27
28
29
29
32
09
34
69
08
23
43
64
65
84
72
20
51
07
07
93
96
37
97
02
72
77
73
74
75
76
46
30
04
21

-80*
1
1
1
9
1
1
1
1
1
1
22
20
18
2
4
1
3
1
1
2
1
1
1
1
1
1
1
1
1
2
2
1
1
4
1
1
1
1
1
2
1
1
1
1
1
2
2
2
3
1
1
1
1
1
1
12
3
16
1

9006972Quantity

Notes
0,5m

1,0m

Book No.

Filter, RF10-30

2693A

Book No.

49

PureBallast 3.0 Flow 750

*=On request only, contact your local Alfa Laval representative


Machine unit number or
Subassembly description

Ref

Part No

Description

77
81
82
83
83.5
83.6
83.7
83.8
84
85
85.5
86
86.5
87
87.5
88
88.5
88.6
89
89.1
89.2
89.3
89.6
89.8
91
92
95
112
113
113.5
114
114.5
120
120.5
121
121.5
122
126
130
140
145
155
155
155.5
155.6
155.7
156.5
157
157.5
158
160.5
161
161.5
162
162.5
163
167.5
168
168.5
169

9000396 19
9000396 13
9000396 24
9000396 63
9000398 02
9000398 40
9000398 11
9000398 59
9000398 01
9000396 52
9000398 92
9000396 57
9000396 14
9000396 58
9000396 59
9000398 20
9000398 10
9000398 42
9000396 91
9000396 50
9000396 40
9000396 54
9000396 53
9000396 34
9006769 02
9000395 39
9000395 85
9000398 03
9000398 41
9000398 02
9000398 40
9000398 11
9000395 31
9000395 81
9000398 32
9000398 07
9000395 45
9000396 29
9000394 13
9000394 123
9000394 132
9000394 91
9000394 92
9000394 94
9000398 38
9000398 91
9000394 69
9000398 18
9000398 90
9000397 22
9000396 89
9000398 77
9000398 78
9000398 67
9000397 22
9000396 85
9000396 90
9000398 97
9000398 17
9000398 90

Screw cap OBO Thom. u. B


Hose - PAN - 6 x 1 Bl*
T-connection QST-6
Fixing plate
Cylinder screw ISO 4762 Spring ring DIN127-A 8
Hex-nut ISO 4032-M8
Thread rod
Cylinder screw ISO 4762 Tube
Screw-in connector
T-connection
Connection ISO8438-1-SWO
Connection
Clamp
Hex-screw ISO 4017 M 6 x
Hex-nut ISO 4032-M 6
Spring ring DIN 127-B6
Cable channel
Fixing bracket piping RF1
Fixing bracket piping RF1
Pipe nut
Pipe
Pipe clamp 25-28 mm M8/M1
Gear motor
Paralel key DIN 6885 - A
Proximity switch
Cylinder screw ISO 4762 Spring ring DIN127-B 10
Cylinder screw ISO 4762 Spring ring DIN127-A 8
Hex-nut ISO 4032-M8
Control plate RF10-30
Washer RF10-30/35 bored
Washer ISO7089-3 200 HV
Cylinder screw ISO4762-M
Saftey plate
Warning sticker Hein 1 pc
Cover RF10-30A-x-PF compl
Vessel upper part
Vessel lower part
Reducer JIS A100-A80 LH
Reducer JIS A100-A80 RH
Reducer
Lock screw VSTI G 1 1/2-E
Lock screw
Elbow
Hex-screw
Washer
Sealing
Blind flange
Hex-screw
Hex-screw
Washer
Sealing
Drain plug
Blind flange
Hex-screw
Hex-nut
Washer

50

-80*
8
1
10
1
4
4
4
2
8
1
2
1
1
1
1
8
8
8
1
1
1
1
1
2
1
1
3
4
4
4
4
4
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
4
4
4
1
1
2
8
8
8

9006972Quantity

Notes
3,0m

3,0m

2m

Book No.

Filter, RF10-30

2693A

Book No.

51

PureBallast 3.0 Flow 750

*=On request only, contact your local Alfa Laval representative


Machine unit number or
Subassembly description

Ref

Part No

Description

169.5
170
171
172
173
177
178
178.1
178.2
178.5
179
180
183
184
186
188
189
189.5
190
191
191.5
192
200
200A
200B
200C
200D
200E
200F
200G
200H
200I
200J
200K
200L
200M
200N
200O
200P
200Q
203
301
302
303
Z
Z0.1
Z0.2

9000397 21
9000398 103
9000398 108
9000398 150
9000398 94
9000397 14
9000398 141
9000398 87
9000398 95
9000398 83
9000398 95
9000398 87
9000395 86
9000398 84
9000398 43
9000396 71
9000397 10
9000397 19
9007128 80
9000398 85
9000398 95
9000398 87
9007005 82
9000396 95
9007239 01
9007239 02
9007239 03
9007239 04
9007239 05
9007239 06
9007239 07
9007239 08
9007239 23
9007239 11
9007239 10
9007239 12
9007239 13
9007239 24
9007239 25
9007239 26
9007007 01
9000395 83
9000397 08
9000397 09
9007098 82
9007100 82
9007099 80

Sealing
Hex-screw
Hex-screw
Washer
Hex-nut
Sealing
Hex-screw
Washer
Hex-nut
Hex-screw
Hex-nut
Washer
Distance piece
Hex-screw
Spring ring
Fixing plate for Control
Sealing EN1514-1-IBC-DN 1
Sealing
Valve, V309-1
Hex-screw
Hex-nut
Washer
Electrical cabinet
Cabinet
Display
Main switch
Power supply
CPU
Digital output
Relay
Prot. switch
Contactor
Terminal
PE terminal
Terminal
Fuse
Sensor box
Fuse
Fuse
Fuse
Pressure transmitter
Filter element
O-ring 72.62 x 3.53*
O-ring 110.72 x 3.53*
Sealing kit
Filter element kit
Proximity switch kit

52

-80*
2
20
20
80
40
4
8
8
8
8
8
16
1
8
8
2
1
1
1
4
4
8
1
1
1
1
1
1
1
2
1
1
19
7
4
4
2

9006972Quantity

Notes

See page 54

3
9
9
9

Book No.

Filter, RF10-30

2693A

Book No.

53

PureBallast 3.0 Flow 750

5.1 Valve, V309-1


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
16
85.5
193
193.1
194
196
197

9000394 141
9000394 144
9000396 08
9000398 92
9000396 01
9000396 93
9000396 11
9000396 07
9000398 04

Butterfly valve
Actuator
Coupling M12 x 1, 5-pole,
Screw-in connector
3/2-Way valve MND310701 G
Coil
Exhaust throttle valve -G
Control plate RF3-x-EPT R
Cylinder screw ISO 4762-M

54

-80
1
1
1
1
1
1
1
1
2

9007128Quantity

Notes

Book No.

Valve, V309-1

Filter, RF10-30

2698A

5.1

Book No.

55

PureBallast 3.0 Flow 750

6 Valve, JIS A300


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
5
6
7
8
19

9007167
9007166
9007185
9007192
9007193
9007196
9007186
587927

Valve, A300
Air actuator, AT 451U
Pilot valve
Throttle valve, 1/4
Actuator cable
Bracket
Switch box
Locking device, AL79 451

56

23
06
01
01
01
02
01
07

-88
1
1
1
2
1
1
1
1

9007170Quantity

Notes

Book No.

Valve, JIS A300

2710A

Book No.

57

PureBallast 3.0 Flow 750

7 Valve, JIS A300


Machine unit number or
Subassembly description

Ref

Part No

Description

1
1
2
2
3
5
6
7
7
8
22
23
Z

9007167
9007167
9007166
9007166
9007185
9007192
9007193
9007196
9007196
9007186
9007198
595558
9007184

Valve, A50
Valve, A300
Air actuator, AT 101U
Air actuator, AT 451U
Pilot valve
Throttle valve, 1/4
Actuator cable
Bracket
Bracket
Switch box
Serial no. plate
Wire
Insulate plate

58

15
23
01
06
01
01
01
01
02
01
01
01
01

9007172-88 -80
1
1
1
2
1
1
1

Quantity
1

Notes

1
1
2
1
1
1
1
1

Book No.

Valve, JIS A300

2714A

Book No.

59

PureBallast 3.0 Flow 750

8 Valve, JIS A300


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
5
6
7
8
12
13
14
15
16
17
18
19

9007167
9007166
9007185
9007192
9007193
9007196
9007186
9005789
552801
1764011
592304
569035
580758
9005792
587927

Valve, A300
Air actuator, AT 451U
Pilot valve
Throttle valve, 1/4
Actuator cable
Bracket
Switch box
Gearbox
Push-in connector
Silencer
Plug, 1/4
Flexible pipe, PA12, 8/6
Push-In Fittings
Handwheel
Locking device, AL79 451

60

23
06
01
01
01
02
01
03
02
02
02
05
06
02
07

-88
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1

9007168Quantity

Notes

Book No.

Valve, JIS A300

2716A

Book No.

61

PureBallast 3.0 Flow 750

9 Control valve V201-8


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
7
9
10
13
16
19
24
27
28
30
31
Z

9007167
9007166
9007196
9007191
9007190
552801
569035
587927
552801
9007200
9007201
523127
592304
9007184

Valve, A250
Air actuator, AT 351U
Bracket
Mounting kit, Positioner
Positioner
Push-in connector
Flexible pipe, PA12, 8/6
Locking device, AL79 351
Push-in connector
Manifold
Filter
Hexagon nipple
Plug, 1/4
Insulate plate

62

22
05
02
01
01
02
05
05
02
01
01
01
02
04

-87
1
1
1
1
1
2
1
1
2
1
1
1
1

9007174Quantity

Notes

Book No.

Control valve V201-8

2712A

Book No.

63

PureBallast 3.0 Flow 750

10 Flow transmitter, A300


Machine unit number or
Subassembly description

Ref
1
2
5

64

Part No

Description

585345 61 Sensing tube, A300


586907 01 Transmitter, MAG 5000
595229 01 Cable gland

-93
1
1
1

576179Quantity

Notes

Book No.

Flow transmitter, A300

2363A

10

Book No.

65

PureBallast 3.0 Flow 750

11 CIP module
Machine unit number or
Subassembly description

Ref

Part No

1
2
3
4
5
6
7
8
9
10
11
12
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
53
54
55
56
57
58
59
60
61
62
63

9003450
590414
9004533
9002825
9003730
9002915
9003732
590313
590476
9005046
589526
526350
9003172
9004479
9003514
9004517
9002962
9002963
9004237
9003935
9002964
9002584
9002586
9003570
9003949
9002589
9003792
9002591
9003837
9004247
9002592
9003851
9003853
9003854
9003863
9003886
9003888
592649
591675
569038
592665
9003574
9005743
599223
599223
592676
592676
592790
221716
221711
221701
223101
221711
223101
587276
27345
70560
9005147
9005394

66

01
01
80
80
01
01
01
01
01
01
07
06
80
80
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
05
01
01
01
03
02
05
07
01
02
17
04
41
16
47
02

Description

Frame complete
Tank
Pump P320-1 and P321-5
Valve
Valve housing
Check valve
O-ring
Valve, angle seat
Nipple, ISO-R 3/4-1/2
Backflow preventer
U-bolt clamp, c-c 56,5
Plug
Valve block
Filter regulator
Speed controller
Reducer
Pipe #1
Pipe #2
Pipe #3
Pipe #4
Pipe #5
Pipe #6
Pipe #7
Pipe #8
Pipe #9
Pipe #10
Pipe #11
Pipe #12
Pipe #13
Pipe #14
Pipe #15
Pipe #16
Pipe #17
Pipe #18
Pipe #19
Pipe #20
Pipe #21
Nipple
Hose, 32
Hose, 32
Hose, 25
O-ring
Pipe clamp
Hose clamp 38-50
Hose clamp 32-44
Insulation sheet, 10mm
Insulation sheet, 5mm
Insulation sheet
Screw
Screw
Screw
Washer, 4,3x9x0,8
Screw
Washer
Washer
Nut, M8
Washer
01 Pipe #22
80 Air distribution

-81
1
1
2
6
3
2
6
1
1
1
1
1
1
1
2
2
1
1
1
2
1
1
2
4
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
6
5
10
3
4
7
1
2
2
4
4
16
16
2
12
19
1
1

9002547Quantity

Notes
See page 70
See page 72

See page 74

See page 76

Book No.

CIP module

2605A

11

Book No.

67

PureBallast 3.0 Flow 750

Machine unit number or


Subassembly description

Ref

Part No

64
65
66
Z

221040
590539
548152
590414

68

53
03
03
02

Description
Screw
Clip list
Washer
Tanck screw cap

-81
5
1
5

9002547Quantity

Notes

Book No.

CIP module

2605A

11

Book No.

69

PureBallast 3.0 Flow 750

11.1 Pump P320-1 and P321-5


Machine unit number or
Subassembly description

Ref

Part No

Description

1
Z

9004533 01 Pump
9004587 80 Spare part set

Z0.1

9004588 80 Spare part set

70

-80
1

9004533Quantity

Notes
Incl. O-rings, diaphragm, ball, muffler
indicated in dwg.
Incl. air valve, sealings and O-rings,
indicated in dwg.

Book No.

Pump P320-1 and P321-5

11

CIP module

2606A

11.1

Book No.

71

PureBallast 3.0 Flow 750

11.2 Valve
Machine unit number or
Subassembly description

Ref
Z

72

Part No

Description

9003574 01 O-ring

-80

9002825Quantity

Notes

Book No.

Valve

11

CIP module

2609A

11.2

Book No.

73

PureBallast 3.0 Flow 750

11.3 Valve block


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
4
5
6
7
8
9
10
11
13

9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172

Valve block side


Valve block
Valve block side
Valve 2x 3/2
Connection box
Cable gland NPT3/4
Plug
Plug
O-ring
Sign bracket
Sign plate
Cable gland, M32

74

01
02
03
04
05
06
07
08
09
10
11
12

-80
1
5
1
5
1
1
1
1
1
2
1
1

9003172Quantity

Notes

Book No.

Valve block

11

CIP module

2607A

11.3

Book No.

75

PureBallast 3.0 Flow 750

11.4 Air distribution


Machine unit number or
Subassembly description

Ref

Part No

1
2
3
4
5

569035
569035
552801
558710
580758

76

05
01
50
01
06

Description
Flexible pipe, PA12, 8/6
Flexible pipe, PA12, 6/4
Push-on connector
Air Hose Nipple
Push-In Fittings

-80
1
1
6
1
2

9005394Quantity

Notes

Book No.

Air distribution

11

CIP module

2608A

11.4

Book No.

77

PureBallast 3.0 Flow 750

12 Sampling device (QT201.1, QT201.1)


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
4
5
6
7
8
9
9
10
10
11
14

591662
591667
1765908
2210462
221803
70490
591631
591628
2210462
2210462
590667
590667
556563
591666

Adaptor pipe
Pitot tube
Gasket
Screw
Nut, M16
Washer
Blind flange, DN50/A50
Valve, manual A50
Screw
Screw, M16x45
Q201.1
Q201.2
Wire
Rod

78

80
01
07
30
34
01
81
28
45
27
28
01
01

589745-90 -91
1
1
2
4
4
16
1
1
8
1
1
1

Quantity
1
1
2
4
4
16
1
1
8

Notes

M6S 16x70 fzb


M6M 16 fzb
BRB 17x30x3 fzb
M6S 16x45 fzb
M6S 16x45 fzb

1
1
1

Book No.

Sampling device (QT201.1, QT201.1)

2780A

12

Book No.

79

PureBallast 3.0 Flow 750

13 Pressure monitoring device


Machine unit number or
Subassembly description

Ref

Part No

Description

1
2
3
4
5
6
7
9

9007231
526336
9006075
9001406
543054
9006822
546600
595558

Needle valve, DN15


Nipple
Manifold
Pressure transmitter kit
Pressure gauge
Safety valve, 8 bar
Pipe union
Wire

80

01
04
01
82
03
02
02
01

-80
1
3
1
1
1
1
1
4

9006076Quantity

Notes

Incl. pressure transmitter and connector

Book No.

Pressure monitoring device

2709A

13

Book No.

81

14

Cross reference list

14 Cross reference list


+

Part No.
1761805
1764011
1765908
2210295
2210296
221030
221030
221030
221030
221030
221030
221031
221035
221035
221035
221036
221040
221040
221040
2210462
2210462
2210462
2210463
221701
221701
221711
221711
221711
221711
221711
221711
221711
221716
221716
221716
221726
221803
221803
221803
221803
221803
221803
221803
221803
221851
221851
221851
221891
221891
221891

82

01
02
07
03
02
02
10
10
10
10
10
21
03
06
36
02
04
53
55
28
30
45
03
03
04
08
13
16
16
17
19
23
01
01
02
10
02
02
02
02
03
27
28
34
05
05
05
01
02
02

Page
34
60
78
38
34
22
18
22
22
22
22
38
38
38
38
38
38
67
38
78
78
78
34
6
66
34
38
66
10
66
10
38
22
10
66
22
18
22
6
10
18
34
38
78
22
22
22
18
18
22

Ref.

Part No.
23
14
3
29
32
34
49
18
21
25
66
39
32
24
27
13
22
64
34
9
4
9
21
17
55
4
7
57
29
54
22
20
15
8
53
11
50
4
45
24
51
34
41
5
59
76
89
52
53
72

221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
221891
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223101
223107
260321
26556
27345
35120
41456
523127

04
04
04
04
04
04
04
04
04
05
05
05
05
05
03
16
17
17
32
32
33
33
37
41
41
47
47
47
47
47
47
47
47
47
47
47
47
47
47
47
49
64
73
34
25

01

Page
18
22
22
22
22
23
6
10
10
18
22
22
10
10
18
18
18
38
34
38
34
38
34
22
66
18
22
22
22
22
22
22
22
22
22
23
6
66
6
10
22
34
10
10
34
10
66
38
38
62

Ref.

Part No.
54
35
42
79
83
91
8
16
31
55
8
14
7
34
56
57
58
30
5
40
33
14
22
73
56
59
5
17
20
24
33
42.1
67
80
82
92
44
58
8.1
30
10
10
25
15
27
4
60
35
23
30

523127
526336
526350
526350
526350
543054
544465
544465
546600
548152
552801
552801
552801
552801
552801
554214
556563
558663
558663
558663
558710
558710
569035
569035
569035
569035
569038
576071
576071
576075
576075
576075
576075
576886
579380
579385
580758
580758
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986
580986

04
04
05
05
06
03
04
15
02
03
02
02
02
50
50
06
01
03
03
04
01
02
01
05
05
05
05
01
01
05
21
65
71
26
01
01
06
06
06
08
08
16
16
17
17
19
20
30
32
33

Page
18
80
34
38
66
80
10
35
80
67
60
62
62
34
76
34
78
34
38
34
76
34
76
60
62
76
66
44
46
44
46
44
46
44
35
10
60
76
12
12
26
12
26
12
26
26
26
12
12
12

Ref.
10
2
18
15
12
5
35
96
7
66
13
13
24
30
3
95
11
19
16
14
4
38
2
16
16
1
43
3
3
2
2
Z
Z
1
ZB
10
17
5
9
5
8
10
11
2
2
12
13
3
7
6

Book No.

PureBallast 3.0 Flow 750

Part No.

Page

580986 51
580986 53
580986 55
580986 59
580986 59
580986 61
580986 62
580986 63
580986 64
580986 67
580986 72
580986 76
580986 76
581534 01
581688 01
582212 03
582212 03
582212 102
582212 104
582212 104
582212 105
582212 105
582212 119
582212 120
582212 122
582212 122
582212 122
582212 122
582212 123
582212 125
582212 125
582212 130
582212 131
582212 132
582212 133
582212 136
582212 137
582212 13
582212 13
582212 141
582212 146
582212 147
582212 147
582212 148
582212 148
582212 148
582212 148
582212 148
582212 148
582212 150

12
26
12
12
26
26
26
26
26
12
26
12
12
34
10
28
6
6
6
6
6
6
14
14
19
30
40
7
6
6
18
30
30
30
30
30
30
19
7
18
18
18
6
18
28
30
40
42
6
40

Book No.

Ref.
4
9
12
8
7
10
3
4
1
1
5
1.2
1.3
26
27
6
26.2
22
21
24
23
25
1
2
75
4
4
69
29
12
30
3
8
7
11
16
15
76
70
47
36
41
20
43
7
1
2
2
9
12

Part No.

Page

582212 151
582212 154
582212 155
582212 156
582212 156
582212 157
582212 157
582212 15
582212 15
582212 15
582212 163
582212 164
582212 165
582212 167
582212 168
582212 171
582212 172
582212 181
582212 186
582212 60
582212 60
582212 63
582212 63
582212 63
582212 64
582212 65
582212 67
582212 67
582212 67
582212 70
582212 71
582212 86
582212 87
582212 88
582212 88
582212 89
582212 89
582212 91
582221 100
582221 89
582221 90
582221 90
582221 99
582356 18
582356 26
582356 26
582356 27
582356 28
582356 30
582356 30

40
40
6
30
42
30
42
30
30
6
18
18
18
6
6
6
14
19
14
6
6
6
28
6
28
28
6
28
6
40
28
6
6
30
40
30
40
6
32
6
18
6
32
6
18
40
18
18
18
40

Ref.

Part No.
11
5
48
9
3
10
4
12
13
32
19.2
19.1
19.3
24.2
28
24.1
Z
69
3
14.1
26.1
15
4
27
2
3
14
1
26
6
5
29.1
29.2
5
3
6
7
19
51
46
20
31
50
47
13
22
15
14
12
25

583012
583012
583556
583556
585345
585976
585976
586907
587276
587276
587276
587276
587276
587276
587276
587927
587927
587927
589526
589569
589569
589569
589569
589569
589569
590037
590313
590414
590414
590476
590539
590624
590667
590667
590667
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591103
591628
591631

01
01
16
17
61
01
01
01
01
01
01
02
02
02
02
05
07
07
07
21
21
44
44
45
59
01
01
01
02
01
03
03
01
27
28
10
10
36
38
45
46
54
60
60
61
64
66
81
81
01

Page
44
46
6
6
64
44
46
64
22
22
22
18
22
66
10
62
56
60
66
40
42
40
42
42
42
46
66
66
67
66
67
18
34
78
78
6
18
6
6
6
18
18
6
18
18
18
18
6
78
78

Ref.
6
6
36
37
1
4
4
2
58
77
88
60
13
59
32
19
19
19
11
19
9
20
10
8
6
1
8
2
Z
9
65
7
8.2
10
10
10.1
26.1
49
16
11
24
26
10
25
29
28
27
16.1
8
7

83

14

Part No.
591662
591666
591667
591675
591874
591874
591889
591922
592304
592304
592304
592304
592649
592665
592676
592676
592790
593239
593254
593282
593287
593724
593724
593780
593991
594009
594009
594009
594009
594009
594009
594171
594410
594410
594412
594412
594413
594413
594413
594488
594645
594707
594728
595215
595229
595272
595361
595558
595558
595558

84

80
01
01
01
04
05
01
01
01
02
02
02
01
01
05
07
01
01
01
01
01
03
03
01
01
01
02
03
03
04
07
01
01
01
92
92
80
80
80
01
82
02
01
01
01
01
01
01
01
01

Page
78
78
78
66
22
22
22
6
34
34
60
62
66
66
66
66
66
10
10
10
22
19
6
22
10
10
19
19
6
19
19
34
44
46
34
34
34
34
34
10
35
34
18
44
64
34
6
18
58
80

Ref.
1
14
2
42
1A
1B
60
41
28
29
15
31
41
44
49
50
51
26
19
23
27
61
33
62
12
3
62
63
34
64
66
15
5
5
8
8.1
20
20.1
20.2
28
Z0.1
25
37.1
9
5
37
42
9.2
23
9

Part No.

Page

595670 80
595673 01
595673 04
596103 01
596894 01
596894 01
597033 18
597033 19
597033 20
597044 04
597049 01
597330 01
597330 01
597331 01
597331 01
599223 02
599223 03
599555 01
66169
70490
70560
70560
70560
70560
70915
9000394 03
9000394 123
9000394 132
9000394 13
9000394 141
9000394 144
9000394 23
9000394 43
9000394 62
9000394 69
9000394 91
9000394 92
9000394 94
9000395 20
9000395 21
9000395 22
9000395 23
9000395 24
9000395 25
9000395 26
9000395 27
9000395 28
9000395 29
9000395 29
9000395 31

6
7
32
34
6
6
12
26
26
34
34
23
7
23
7
66
66
35
38
78
18
38
66
10
10
48
50
50
50
54
54
48
48
48
50
50
50
50
48
48
48
48
48
48
48
48
48
48
48
50

Ref.
4
55
14
63
51.1
51.2
1.1
6
14
39
24
Z
Z
Z0.1
Z0.1
48
47
Z0.1B
3
6
48
25
61
33
6
17
140
145
130
1
2
39.6
39.7
18
156.5
155
155
155.5
23
24
25
26
27
28
29
32
33
34
34.5
120

Cross reference list

Part No.
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000395
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396
9000396

32
34
39
42
45
51
62
63
69
81
83
84
85
86
01
02
04
07
08
11
12
13
14
19
21
24
29
30
34
37
40
50
51
52
53
54
55
57
58
59
63
71
72
73
74
75
76
77
85
89

Page
48
48
50
48
50
48
48
48
48
50
52
48
50
52
54
48
48
54
54
54
48
50
50
50
48
50
50
48
50
48
50
50
48
50
50
50
48
50
50
50
50
52
48
48
48
48
48
48
50
50

Ref.
35
37
92
21
122
51
30
31
38
120.5
301
40
95
183
193
68
75
196
16
194
18.5
81
86.5
77
76
82
126
74
89.8
65.3
89.2
89.1
12
85
89.6
89.3
11.5
86
87
87.5
83
188
70
71
71.5
72
72.5
70.5
163
160.5

Book No.

PureBallast 3.0 Flow 750

Part No.

Page

9000396 90
9000396 91
9000396 92
9000396 93
9000396 95
9000396 96
9000396 97
9000397 06
9000397 07
9000397 07
9000397 08
9000397 09
9000397 10
9000397 14
9000397 19
9000397 20
9000397 21
9000397 22
9000397 22
9000398 01
9000398 02
9000398 02
9000398 03
9000398 04
9000398 07
9000398 08
9000398 09
9000398 103
9000398 108
9000398 10
9000398 11
9000398 11
9000398 11
9000398 141
9000398 150
9000398 17
9000398 18
9000398 20
9000398 21
9000398 32
9000398 33
9000398 38
9000398 40
9000398 40
9000398 41
9000398 42
9000398 43
9000398 45
9000398 46
9000398 50

50
50
48
54
52
48
48
48
48
48
52
52
52
52
52
48
52
50
50
50
50
50
50
54
50
48
48
52
52
50
48
50
50
52
52
50
50
50
48
50
48
50
50
50
50
50
52
48
48
48

Book No.

Ref.
167.5
89
14
193.1
200A
65
65.5
15
52
53
302
303
189
177
189.5
41
169.5
158
162.5
84
83.5
113.5
112
197
121.5
39
36
170
171
88.5
19.5
83.7
114.5
178
172
168.5
157
88
19.3
121
19.2
155.6
83.6
114
113
88.6
186
19.4
73
19.1

Part No.
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000398
9000738
9001098
9001357
9001406
9001539
9001897
9002009
9002362
9002584
9002586
9002589
9002591
9002592
9002699
9002825
9002860
9002915
9002942
9002947
9002962
9002963
9002964
9003013
9003024
9003031

51
59
64
65
67
72
77
78
83
84
85
87
87
87
90
90
91
92
92
93
94
95
95
95
97
02
01
03
82
01
01
81
81
01
01
01
01
01
82
80
01
01
01
01
01
01
01
01
02
01

Page
48
50
48
48
50
48
50
50
52
52
52
52
52
52
50
50
50
50
54
48
52
52
52
52
50
35
38
34
80
38
38
38
6
66
66
66
66
66
34
66
38
66
22
22
66
66
66
10
10
22

Ref.
19
83.8
39.8
39.9
162
40.5
161
161.5
178.5
184
191
178.1
180
192
157.5
169
155.7
85.5
85.5
61
173
178.2
179
191.5
168
Z0.1A
11
7
4
19
12
8
30
25
26
29
31
34
1
4
10
6
31
30
20
21
24
11
13
1C

Part No.
9003031
9003031
9003089
9003113
9003114
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003172
9003186
9003186
9003326
9003390
9003394
9003401
9003410
9003450
9003514
9003522
9003522
9003570
9003574
9003574
9003628
9003661
9003662
9003669
9003672
9003730
9003732
9003748
9003792
9003837
9003851
9003853
9003854
9003863
9003886
9003888
9003935
9003949

01
01
02
01
02
01
02
03
04
05
06
07
08
09
10
11
12
80
01
02
01
01
01
01
01
01
01
06
07
01
01
01
80
01
01
01
01
01
01
80
01
01
01
01
01
01
01
01
01
01

Page
40
42
22
22
22
74
74
74
74
74
74
74
74
74
74
74
74
66
22
22
38
22
22
22
22
66
66
6
6
66
66
72
18
38
38
38
38
66
66
34
66
66
66
66
66
66
66
66
66
66

Ref.
18
5
9
28
29
1
2
3
4
5
6
7
8
9
10
11
13
15
22
63
6
16
12
19
23
1
18
39
38
27
45
Z
1
26
28
21
31
5
7
2
30
32
35
36
37
38
39
40
23
28

85

14

Part No.
9004174
9004211
9004212
9004213
9004214
9004237
9004247
9004254
9004299
9004299
9004299
9004299
9004299
9004299
9004303
9004313
9004329
9004426
9004439
9004479
9004506
9004507
9004508
9004517
9004533
9004533
9004587
9004588
9004638
9004825
9004844
9004878
9004886
9004889
9004959
9004960
9005006
9005046
9005051
9005051
9005051
9005051
9005051
9005052
9005052
9005052
9005052
9005052
9005052
9005142

86

80
01
01
01
01
01
01
01
01
02
03
04
04
07
02
80
80
01
01
80
80
80
80
01
01
80
80
80
01
80
80
80
80
01
01
80
80
01
04
05
06
07
08
01
05
07
08
09
10
80

Page
18
18
18
18
18
66
66
18
18
18
18
6
18
18
18
18
18
18
32
66
18
18
18
66
70
66
70
70
34
40
42
38
38
38
42
34
6
66
34
34
34
34
34
34
34
34
34
34
34
22

Ref.

Part No.
37
2
3
4
6
22
33
9
32
33
34
13
31
46
40
22
39
11
15
16
5
38
42
19
1
3
Z
Z0.1
31
1
1
9
33A
33
7
3
18
10
16
16.4
16.2
16.1
16.3
17
17.1
17.2
17.5
17.4
17.3
1

9005143
9005144
9005145
9005147
9005394
9005494
9005496
9005626
9005743
9005789
9005792
9006075
9006237
9006246
9006316
9006320
9006320
9006322
9006324
9006325
9006326
9006519
9006677
9006761
9006769
9006771
9006804
9006805
9006806
9006822
9006822
9006852
9006853
9007005
9007007
9007098
9007099
9007100
9007128
9007166
9007166
9007166
9007166
9007166
9007167
9007167
9007167
9007167
9007167
9007184

80
80
80
01
80
01
01
01
01
03
02
01
80
01
01
80
81
01
01
01
01
01
01
80
02
02
01
01
01
02
02
01
01
82
01
82
80
82
80
01
05
06
06
06
15
22
23
23
23
01

Page
22
22
22
66
66
18
16
19
66
60
60
80
6
10
22
34
34
22
34
34
18
22
18
10
50
48
6
6
6
48
80
6
6
52
52
52
52
52
52
58
62
56
58
60
58
62
56
58
60
58

Ref.

Cross reference list

Part No.
2
3
6
62
63
23
19
67
46
12
18
3
1
2
64
35
36
69
13
12
35
70
21
5
91
13
5
6
7
11
6
3
52A
200
203
Z
Z0.2
Z0.1
190
2
2
2
2
2
1
1
1
1
1
Z

9007184
9007185
9007185
9007185
9007186
9007186
9007186
9007190
9007191
9007192
9007192
9007192
9007193
9007193
9007193
9007196
9007196
9007196
9007196
9007196
9007198
9007200
9007201
9007231
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007239
9007794
9007810
9008374
9008382
9008383
9008383
9008383
9008383
9008383
9008383

04
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
02
02
02
02
01
01
01
01
01
02
03
04
05
06
07
08
10
11
12
13
23
24
25
26
01
80
01
80
01
02
03
04
05
06

Page
62
56
58
60
56
58
60
62
62
56
58
60
56
58
60
58
56
58
60
62
58
62
62
80
52
52
52
52
52
52
52
52
52
52
52
52
52
52
52
52
38
35
19
19
32
32
32
32
32
32

Ref.
Z
3
3
3
8
8
8
10
9
5
5
5
6
6
6
7
7
7
7
7
22
27
28
1
200B
200C
200D
200E
200F
200G
200H
200I
200L
200K
200M
200N
200J
200O
200P
200Q
36
ZA
73
74
1
2
3
4
5
6

Book No.

PureBallast 3.0 Flow 750

Part No.
9008383
9008383
9008383
9008387
9008388
9008424
9008672
9008693
9008903
9009416
9009521
9009688
9009695
9009696
9009714
9009912
9011365
9011549

Book No.

08
12
13
01
01
01
80
01
05
01
80
01
80
80
01
01
01
80

Page
32
32
32
32
32
22
7
32
22
38
35
7
6
7
23
44
34
16

Ref.
9
7
8
11
16
74
68
12
7
38
Z
52B
52
53
90
8
9
1

87