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AC-00992 - Hull No.: CV22H-JT01 - Name of yard: 24211.
28
Installation and
Instruction Manual
Freshwater Generator AQUA type HW:
AQUA-65-HW, AQUA-80-HW
AQUA-100-HW, AQUA-125-HW
Alfa Laval Copenhagen A/S
– May 6, 2014 1
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 Alfa Laval Company.
Published by: Alfa Laval Copenhagen A/S

Maskinvej 5
DK-2860 S¯borg
Denmark
© Copyright Alfa Laval Copenhagen A/S.
2 Revision number
1 Technical Specifications in overview 11
1.1 Technical data page 11
1.2 Parts included in delivery page 12
2 Safety Instructions and Warnings 13

2.1 Safety Instructions and Warnings page 13
3 System Description – AQUA type HW 17

3.1 Freshwater Quality page 19
3.1.1 Main Components page 20
4 Storage 21
5 Installation 22
5.1 Extent of Delivery page 22
5.1.1 Space Requirements page 22
5.1.2 Ambient Conditions page 22
5.1.3 Vibrations page 22
5.2 General Safety Precautions page 22
5.2.1 Electric Equipment page 23
5.2.2 Transportation page 23
5.3 Installation Instructions page 23
5.3.1 Hot Water System page 24
5.3.2 Sea Water System page 24
5.3.3 Ejector Pump (if supplied) page 25
5.3.4 Brine/Cooling Water Discharge page 25
5.3.5 Freshwater System page 25
5.3.6 Control Panel (if supplied) page 26
5.3.7 Motors (if supplied) page 26
5.3.8 Scale Inhibitor Dosage Equipment for Feed Water page 26
6 Operating Instructions 28
6.0.1 Daily operation page 33
6.1 Adjustment of Hot Water Flow page 33
6.2 Adjustment of Sea Cooling Water page 34
6.3 Stopping the Plant page 34
7 Long Term Standstill 36

7.1 Standstill page 36
Table of Contents – May 6, 2014 3

7.1.1 Preservation Procedure for Freshwater Generator page 36
7.1.2 Restart page 36
7.2 Long Term Standstill page 36
7.2.1 Preservation Procedure for Freshwater Generator page 36
7.2.2 Restart Freshwater Generator page 36
7.2.3 Preservation Procedure for Pumps page 37
7.2.4 Restarting of Pumps page 37
7.2.5 Preservation Procedure for Electric Motors page 37
7.2.6 Restarting of Electric Motors page 38
7.2.7 Preservation Procedure for Electric Panel page 38
7.2.8 Restarting of Electric Panel page 39
7.2.9 Solenoid Valve page 39
8 Maintenance 40
8.1 Overhaul Intervals page 41
8.2 Maintenance of Plate surface page 41
8.3 Renewal of Plate Heat Exchanger Gaskets page 44
8.3.1 Removal of Old Gaskets page 44
8.3.2 Cleaning page 44
8.3.3 Preparation of new Gaskets page 44
8.3.4 Fitting new Gaskets page 44
9 Vacuum test 46
10 Chemical Dosing of Scale Control Chemicals 47

10.1 Feed Water Ratio page 47
10.2 Evaporating Temperature page 48
10.3 Operational Notes page 48
10.3.1 Normal Operation Conditions page 48
10.3.2 Maintaining Distillate Output page 48
10.4 Chemical Dosage page 49
10.4.1 Scale Inhibitor Dosage Equipment for Feed Water page 50
10.4.2 Safety Precautions with the use of Chemicals page 51
10.4.3 Alpacon Altreat 400 page 51
10.5 Preparation of chemical solution page 52
10.5.1 Anti Scalant type Alpacon Altreat 400 page 52
10.5.2 Dosing flow calculation page 52
10.5.3 Calculating Chemical solution page 52
10.6 Dosing Instructions – Anti Scalant page 54
11 Operation and maintenance instructions for Freshwater

Pump type 1525/1532/2040 55
11.1 Product description page 55

11.2 Technical data page 55
11.2.1 Noise level page 56
11.3 Installation / start-up page 56
11.4 Application page 56
11.5 Service page 56
11.5.1 Pump overhaul page 56
11.5.2 Clearance page 58
11.5.3 Dismantling Pump Shaft page 58
11.6 Maintenance page 60
11.7 Transport / storage page 60
11.8 Spare parts page 60
12 Salinometer 61
12.1 Specification of Salinometer type DS-21 page 62
12.2 Installation of Salinometer type DS-21 page 62
12.3 User instruction for Salinometer type DS-21 page 63
12.4 Maintenance of Salinometer type DS-21 page 63
13 Trouble-Shooting 65
13.1 Trouble Shooting Table page 66
14 Spare Parts - 72
14.1 Alfa Laval Service page 72
15 FWG Order Specification - Drawings and Parts lists 73

General description AQUA page 75
Technical data: AQUA 100, 0.5 mm plates page 79
Tech. data - Pumps and motors for FWG type AQUA-100-HW/HWS page 81
Distance Indicator 0.5 mm plates page 83
Flow chart for FWG type AQUA-100-HW 86-126 page 85
Equipment specification - FWG type AQUA-100-HW/HWS page 87
Vertical plant positioning - AQUA page 89
Assembly Scheme AQUA, 0,5 mm plates page 91
Gasket Configuration 0.5 AQUA Plates page 93
Frame plate and parts page 95
Frame Plate DIN 36-200 Plates - parts list page 97
Frame parts page 99
Frame parts - parts list page 101
Seawater system 86-126 page 103
Seawater System 86-126 - parts list page 105
Freshwater outlet system page 107
FW outlet AQUA 86-126 DIN - Parts List page 109
Ejector size 20,8-31,4/36,7 page 111
Ejector DN80 Ø19,9 DIN, 19,9-30,0/35,2 page 113

Fresh water valve DV-20-1.0 page 115
Fresh water valve DV-20-1.0 - Parts list page 117
Feed water valve FVF-40-2.5 page 119
Feed water valve FVF-40-2.5 - Parts list page 121
Solenoid valve - NO/230V page 123
Dimensional drawing - AQUA-100-HW 108 page 125
Adaptors for front connection page 127
Adaptors for front connection - parts list page 129
Root valves for pressure gauges on FWG page 131
Fresh water pump type PVVF-1532 Assembly drawing page 135
Fresh water pump type PVVF-1532 Assembly drawing - parts list page 137
Motor size 80 B, 1.30 kW outline drawing page 139
Feed water treatment unit incl. chemical dosage pump assembly page 141
Feed water treatment unit inc!. chemical dosage pump dimension page 143
Control Panel option A - Technical data page 145
Control Panel option A - Dimensional drawing page 147
Control Panel option A - Electrical diagram page 149
Thermometer, Straight, 0-100°C page 157
Thermometer, Angle, 0-100°C page 159
Instructions manual for CNL pumps size 160 and 200

Alfa Laval Freshwater Generators 161
1 General 163
1.1 Introduction page 163
1.2 Identification page 163
1.3 Directions & warning signs page 164
1.4 Warning symbols page 164
1.5 General safety page 164
1.5.1 Electrical hazards page 165
1.5.2 Temperature hazards page 165
1.5.3 Chemical hazards page 166
1.5.4 Dry running page 166
1.5.5 Noise level page 166
2 Installation 167
2.1 Condition on delivery page 167
2.2 Inspection on delivery page 167
2.3 Storage instructions page 167
2.3.1 Preservation procedure page 168
2.3.2 Restarting of Pumps page 168
2.3.3 Preservation Procedure for Electric Motors page 168
2.3.4 Restarting of Electric Motors page 169
2.4 Foundation page 169
2.5 Environment conditions page 169

2.6 Piping page 170
2.7 Piping connections page 170
2.8 Electrical installation page 171
2.9 Recommended accessories page 171
3 Operation 172
3.1 Start-up procedures page 172
3.2 Starting the pump page 173
3.3 Stand-by page 173
3.4 Pump vibrations page 173
4 Maintenance 174
4.1 Inspections page 174
4.1.1 Three-month inspection page 174
4.1.2 Twelve-month inspection page 174
4.1.3 Lubrication page 175
4.2 Disassembly and assembly page 175
4.2.1 Disassembly page 175
4.2.2 Assembly page 175
4.3 Fitting instructions for mechanical seals page 176
4.3.1 Fitting instructions page 177
4.4 Centrifugal pump wear ring clearance page 178
5 Spare Parts 180

5.1 Ordering page 180
5.2 Alfa Laval Service page 180
5.3 Returning parts page 180
5.4 Decommissioning page 180
5.5 Type CNL - table of materials page 181
5.6 Spare parts drawing for CNL 160 and 200 with flanged coupling page 181
6 Trouble Shooting 182

6.1 Trouble Shooting Table page 182
7 Drawings and Part Lists 186

Ejector pump assembly and spare parts drawing page 187
Ejector pump type CNL 65-65/160, Pump curve page 189
Ejector pump type CNL 65-65/160, Spare Parts list page 191
Outline drawing for motor 132M page 193
Ejector pump type CNL 65-65/160, Tech. data page 195
Ejector pump type CNL 65-65/160, Dim drawing page 197

pH Adjustment and Re-hardening Filter 199
0.1 Description page 201
0.2 Installation - Inline page 203
0.3 Filling procedure page 205
0.4 Operation page 207
0.5 Back flushing page 208
0.6 Safety page 209
Dim drw: pH adjustment filter: Type URF 325/25 1,5 m³/hr page 211
General description - Rehardening filter Type URF page 213
pH adjustment filters - flow chart page 215
pH adjustment filters - PID page 217
pH adjustment filters - equipment specification list page 219
AOT UV Sterilizer - Alfa Laval AOT 3F

Installation- and Operation manual 221
1 Declaration of Conformity 225

General description, Ultraviolet Sterilizer Alfa Laval AOT 3F page 227
Process and Instrument Diagram AoT page 229
Flow Chart - Ultraviolet Sterilizer, AlfaLaval AOT 3F page 231
Equipment Specification UV Sterilizer AOT 3F page 233
2 Alfa Laval AOT 3F General 235

2.1 General safety rules page 235
2.2 Warranty page 236
2.3 Manufacturer page 236
2.4 Service and support page 236
2.5 Validation page 237
2.6 Disposal page 237
2.7.1 Functional description page 237
3 Installation 240
3.1 Before installation page 240
3.2 Unpacking page 241
3.3 Mechanical installation - mounting the Alfa Laval AOT 3F page 241
3.3.1 Tools and materials page 241
3.3.2 Installation example page 242
3.4 Electrical installation - connection instructions page 243
3.4.1 Connections page 243

3.4.2 Mains cable page 243
3.4.3 Ferrite page 243
4 Operation 245
4.1 Important instructions page 245
4.2 Start the Alfa Laval AOT 3F page 246
4.2.1 Check page 246
4.2.2 Starting up page 246
4.3 Alarm function page 247
4.3.1 LPS alarm function details page 247
4.3.2 Fault finding - LPS page 248
4.3.3 UV-monitor alarm function details page 248
4.3.4 Sensitivity adjustment page 249
4.3.5 Fault finding - UV Monitor page 249
5 Service & Maintenance 250

5.1 Before service page 250
5.2 Periodic maintenance and recording of actions page 250
5.3 Quartz sleeve cleaning page 251
5.3.1 Cleaning interval page 251
5.3.3 Cleaning, step by step page 252
5.4 Lamp replacement page 253
5.4.2 Replacing a lamp, step by step page 253
6 Spare parts 254

6.1 Spare parts list page 254
7 Specifications 255
7.1 Technical specifications page 255
7.2 Dimensions & weight page 255
8 Appendix 256
Dimensional and Installation Drawing - AOT page 257
Assembly and Spare Parts Drawing - AOT page 259
AOT 3F Reactor - Part list page 261
985 22987 AOT 3F page 263
Terminal Block Information AOT 3F page 265
Main Electrical Comp. AOT 3F - Electrical Cabinet page 267
Electrical Cabinet AOT 3F - Parts list page 269

9 Maintenance record 271
9.1 Maintenance record (template) page 271

1 Technical Specifications in
overview
Serial No.: AC-00992
1.1 Technical data

Amount: .........................................................1 Pcs
Type: .....................................AQUA-100-HW
Number of plates:..............................24211.28 Pcs
Capacity: ......................................................25 m³/24h
El. Power supply: ...................................3x440 Volt
Frequency.....................................................60 Hz
Control voltage: .........................................230 Volt
Connection standard: ............................... DIN
Hot water flow: .......................................66.54 m³/h
Hot water inlet temp: ...................................80 °C
Hot water outlet temp: ..............................70.7 °C
Heat consumption: .....................................715 kW
Hot water pressure drop: ...........................0.15 bar
Sea water inlet temp.....................................32 °C
Sea water outlet temp................................49.7 °C
Sea water flow.........................................33.18 m³/h
Sea water pressure drop ............................0.13 bar
Technical Specifications in overview 11 May 6, 2014

1.2 Parts included in delivery
AB-HW-108 1 Basic equipment cost - AQUA-100-HW 86-108
39508649-88 1 AQUA Start plate
39508649-03 51 AQUA Process plate
39508650-03 51 AQUA Utility plate
39508650-76 1 AQUA End plate
985 21465-80 1 Frame plate and parts
985 21467-82 1 Frame parts L=1000
985 21479-80 1 Seawater system 86-126
985 21470-22 1 Ejector size 19,9-30,0/35,2
985 21386-51 1 Feed water orifice ø 9,5
985 00091-97 1 Freshwater outlet system
984 23486-00 1 Solenoid valve - NO/230V
985 21510-01 1 Fresh water pump type PVVF-1532
985 63304-04 1 Motor size 80 B, 1.30 kW
985 23179-01 1 Name plate AQUA
985 22956-80 1 Packing for AQUA-100-HW 86-108
AB-TR-100-HW 1 Transport FCA/FOB cost
985 21671-80 1 Ejector pump type CNL 65-65/160
985 63310-04 1 Motor 132M, 11 kW
985 64722-00 1 Control Panel option A
985 21837-82 1 Dosing unit incl. chemical dosage pump - 230 Volt -
loose supply
985 21736-87 1 Parts enlosed with delivery - standard
985 23181-82 1 Distance indicators for tightning bolts
985 21964-80 1 Adaptors - front connection
985 21748-80 1 Root valves for pressure gauges on FWG
985 00089-47 1 Control panel wall mounting brackets
MM-XX-62S 1 Standard certificate
manuals 1 Electronic Installation manual in English in Sen-
seiViewIB
manuals 1 Electronic Instruction manual in English in Sen-
seiViewIB
985 22763-81 1 Alfa Laval AOT 3F (230V - 60 Hz) 3.0 m³/h
985 22580-01 1 pH filter Alfa Laval 1.5 m³/h
1011 1 bolt & nuts
Non Standard
1 CPT FEE
Technical Specifications in overview 12 May 6, 2014

2 Safety Instructions and
Warnings
Should you need further clarification regarding this manual, do not hesitate to contact
your local Alfa Laval representative - or call Alfa Laval Copenhagen A/S directly.
Telephone +45 (for Denmark) 39 53 60 00
Telefax +45 (for Denmark) 39 53 65 66
2.1 Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your atten-
tion is needed and your safety is involved.
WARNING!
This symbol is used to indicate the presence of a hazard, which can or
will cause severe personal injury, if the warning is ignored.
CAUTION!
Certain passages of the text will be marked with a caution mark. This
mark indicates the presence of hazard, which will or can cause prop-
erty damage if the instructions are not observed.
NOTE!
This type of instruction indicates a situation, which, if not avoided,
could result in damage to the equipment.
It is the owner and operator’s responsibility to see that any person involved with the
use or operation of this equipment follow all safety instructions.
Safety Instructions and Warnings 13 985 22146 rev 05 – May 6, 2014

Read all safety instructions carefully and insist that those working with you and for you
will follow them. Not following the instructions may cause severe personal injury or
damage the equipment beyond repair.
Do not allow this equipment to be used if it is faulty or the operator does not understand
the proper use.
WARNING!
Fresh water must not be produced from polluted water, as the
produced water can be unsuitable for human consumption.
Fresh water shall in general only be produced when the vessel is at

least 20 miles from land or remote from any risk of estuarial pollution
which in some sea areas can extend well in excess of 20 miles from
land.
CAUTION!
• Do not adjust spring loaded valves – they are pre adjusted
• Do not run pumps dry – mechanical seals will be damaged
• Do not operate the fresh water generator without recommended

chemicals – else, frequent cleaning will be necessary.
NOTE!
• Maximum ambient temperature for the equipment is 50°C (122°F).
• Minimum ambient temperature for the equipment is 0°C (32°F).

NOTE!
If manuals are translated to local language the unit comply with the
EEC Machinery Directive and EN 292-1/2 standards. For EEC land
installations manuals MUST be available in local language before
installing and operating the unit.
The unit also complies with EN 50081-2 and EN 50082-2 “Industry”
with regards to the EMC directive from EEC.
WARNING!
Read carefully the safety data sheet before using any chemicals.
WARNING!
Noise hazards
• Use ear protection in noisy environments.

Crush hazards:
• Use correct lifting tools.
• Do not work under hanging load.

Burn hazard:
• Wear gloves to avoid burns by hot surfaces.

Cut hazards:
• Wear gloves to avoid cuts by sharp edges when handling machined

parts.
• Wear helmet to avoid cuts by sharp edges during maintenance of the

equipment.

3 System Description – AQUA
type HW
3.0 Working principle
The combined brine/air ejector driven by the cooling water creates the necessary
vacuum in order to lower the evaporation temperature of the feed water.
The feed water is introduced into the evaporator section through an orifice, and is dis-
tributed into every second plate channel (evaporation channels).
System Description – AQUA type HW 17 985 22146 rev 05 – May 6, 2014

The hot water is distributed into the remaining channels, thus transferring its heat to the
feed water in the evaporation channels.
Having reached boiling temperature – which is lower than atmospheric pressure – the
feed water undergoes a partial evaporation and generates a mixture of vapour and
brine. The brine is separated from the vapour and extracted by the combined brine/air
ejector.
Having passed a separation zone the vapour enters every second plate channel in the
condenser section.
The cooling water supplied distributes itself into the remaining channels, thus absorb-
ing the heat being transferred from the condensing vapour.
The produced fresh water is extracted by the freshwater pump and pumped to the fresh-
water storage tank.

3.1 Freshwater Quality
To continuously check the quality of the produced fresh water, a salinity meter is pro-
vided together with an electrode unit fitted on the freshwater pump delivery side.
If the salinity of the produced fresh water exceeds a chosen maximum value, the dump
valve and alarm are activated to automatically dump the produced water back to the
freshwater generator.

3.1.1 Main Components
The freshwater generator consists of the following main components:
1. Production unit
The production unit is build up of Titanium plates encased in a cast iron steel
frame. The plates include the tree main functions. Evaporation, separation and
condensation. Evaporation in the lower part, separation in the middle and conden-
sation in the upper part.
2. Combined brine/air ejector

The ejector extracts brine and non condensable gases from the process.
3. Ejector pump
The ejector pump is a single-stage centrifugal pump. This pump supplies the con-
denser with the necessary seawater and the brine/air ejector with jet water. A part
of the seawater is used as feed water for evaporation.
4. Freshwater pump
The freshwater pump is a single-stage centrifugal pump. The freshwater pump
extracts the produced fresh water after condensing, and pumps the freshwater to
the freshwater tank.
5. Salinometer
The salinometer continuously measures the salinity of the produced freshwater. At
too high salinity the produced freshwater is automatically diverted back to the
freshwater generator. The alarm set point is adjustable (the salinometer is mounted
in the control panel).
6. Control panel
Contains motor starters with thermal overload relays and running lights for each
pump, salinometer and voltage free NC / NO contacts for remote alarm, further the
Control panel is prepared for remote start/stop of the pumps
4 Storage
4.0 Storage
Unless otherwise agreed, Alfa Laval delivers the equipment ready to be put in service
upon arrival and after installation.
However, should it be necessary to store equipment for a longer period (1 month or
more), certain precautions should be made in order to protect and prevent unnecessary
wear of the equipment.
The best solution is often to leave the equipment in the packing until it's time for instal-
lation. In this case Alfa Laval should be informed, in order that proper preparation can
be done prior to packing.
Preferably, the equipment should be stored inside in a vibration free area at a temper-
ature around 15 to 45°C (59 to 113°F) and humidity around 70%.
NOTE!
There should ABSOLUTELY NOT be any OZONE PRODUCING
equipment in the room, like operating electric motors or arc-welding,
since ozone destroys many rubber materials.
Do not store organic solvents or acids in the room.
Avoid heat and ultraviolet radiation.
If the equipment must be stored outdoor, the precautions mentioned above should be
taken as far as practical. The need for protection against the climate etc. is of course
even more important in this case.
Storage 21 985 22146 rev 05 – May 6, 2014

5 Installation
5.0 General Information
5.1 Extent of Delivery

The extent of delivery appears from the installation Flow chart drawing (For order spe-
cific drawing number see attached Order Specification). The freshwater generator is
delivered as a unit that can be either bolted or welded to the flo or plate.
The control panel with salinometer and starters for the electric motors is normally
delivered separately and has to be fitted on site. The salinometer is delivered build into
the control panel while terminals for the salinometer must be connected on site.
Please refer to installation diagram for recommended pipe dimensions.
5.1.1 Space Requirements

The space requirements are indicated on the dimensional drawings of the freshwater
generator, ejector pump, control panel and scale inhibitor unit, see “FWG Order Spec-
ification”.
5.1.2 Ambient Conditions

When determining where to place the freshwater generator in the engine room, due
consideration must be paid to a number of ambient conditions such as vibrations, ser-
vice space, allowable back pressure, and pressure loss.
5.1.3 Vibrations
It is recommended not to place the plant in an area known to be subject to frequent and
very high vibrations.
However, under normal engine room conditions no further precautions are necessary.
5.2 General Safety Precautions

Always handle the equipment with great care. Make sure not to damage the parts
during transportation or installation.
Installation 22 985 22146 rev 05 – May 6, 2014

During erection all inlets and outlets must be covered to be protected from dirt and par-
ticles.
5.2.1 Electric Equipment

All electric installations must be carried out by a professional electrician in full accor-
dance with local regulations.
Before initial start-up
• check all connections and cables to make sure that the frequency and voltage
agrees with the electrical specifications and motors is connected in star or delta
according to the motor name plate (way of connection is stated after the actual
voltage on the motor name plate).
WARNING!
Check that all connections are properly earthened (grounded) in
accordance with local regulations, and properly insulated.
WARNING!
Wrong connection, star or delta, of the motors will occur overheat-
ing and burn out of the motors.
5.2.2 Transportation
All transportation of the equipment must be in accordance with local regulations.
The freshwater generator must be lifted using lifting brackets as illustrated in dimen-
sional drawing (See FWG Order Specification)
Make sure that the straps have the required breaking strength to lift the
unit. See weight in dimensional drawing.
5.3 Installation Instructions

The freshwater generator should be mounted according to diagram “Vertical plant
positioning” drawing (See FWG Order Specification).

5.3.1 Hot Water System
The branches for jacket water inlet and outlet to the evaporator section are marked C3
and C4, respectively. They should be connected to the hot water system according to
the Flow chart drawing, see “FWG Order Specification”.
CAUTION!
A thermometer must be fitted 0.5 m from respectively branch C3 and
branch C4.
WARNING!
Design pressure of the evaporator section is
4.0 Barg (58 Psig), Leakage test pressure 4.0 Barg (58 Psig).
5.3.2 Sea Water System

The seawater supplied to the unit has to pass a filter (Yard supply) in the seawater line
before the ejector pump.
Recommended filter mesh size 2 mm.
The branch for sea water (cooling water) inlet to the condenser is marked C1. This
branch has to be connected to the ejector pump discharge according to the Flow chart
drawing, see “FWG Order Specification”.
CAUTION!
A thermometer must be fitted 0.5 m from branch C1.
CAUTION!
Pipe sizes indicated on the Flow chart drawing, see “FWG Order Spec-
ification are minimum recommended sizes.
Smaller sizes will affect too high-pressure losses in the system with
influence on the distiller performance. Do not install valves etc. with
higher pressure losses than a total of 0.1 bar.

WARNING!
Design pressure of the condenser section is
4,0 Barg (58 Psig), Leakage test pressure 4,0 Barg (58 Psig).
5.3.3 Ejector Pump (if supplied)

The ejector pump/motor shall be mounted vertically.
The ejector pump is not self-priming and must be mounted below lowest water line or
feed from a low pressure raised system.
The inlet and outlet pipes must be fitted according to Flow chart drawing, see “FWG
Order Specification”.
The suction branch B2 and the discharge branch B1 for the ejector pump have to be
fitted with reducers if necessary. Branch dimensions in accordance with pump dimen-
sional drawing, see “FWG Order Specification”.
CAUTION!
Pressure on suction side of ejector pump under working conditions
must be minimum 0.2 Barg (2.8 Psig) including pressure drop over fil-
ter.
5.3.4 Brine/Cooling Water Discharge

Sea cooling water and brine are discharged overboard through the same pipe (branch
B7).
Maximum back pressure at branch B7 to be 0.6 Barg (8.5 Psig).
CAUTION!
A pressure gauge must be fitted 0,5 m from branch B7.
5.3.5 Freshwater System

The discharge branch for produced water to tank is marked D1.
• Max. back pressure according to Technical data, see “FWG Order Specification”.
It is an advantage to establish a drain below the fresh water generator to drain in case
of maintenance.

5.3.6 Control Panel (if supplied)
For document numbers, see “FWG Order Specification”.
The panel contains motor starters with thermal relays, transformer for control voltage,
running lights, salinometer, voltage free NO and NC contacts for running indication
and remote alarm, it is prepared for remote start/stop.
The panel requires a supply voltage as specified in the “FWG Order Specification”.
Cabling from the panel to the ejector pump (PU-SC-01), the freshwater pump (PU-
FR-01), dump valve (VA-FR-06) and the salinity sensor (QT-FR-01) to be done at the
yard and are not Alfa Laval supply.
Cabling and installed power:
Control panel power supply: “See FWG Order Specification”

Ejector pump motor: “See FWG Order Specification”
Freshwater pump motor: “See FWG Order Specification”
Solenoid valve: 1 phase, 0.015 kW
Salinity sensor: 5 core cable with screen
WARNING!
Check that all connections are properly earthened (grounded) in
accordance with local regulations, and properly insulated.
5.3.7 Motors (if supplied)

Check all connections and cables to make sure that the frequency and voltage
agrees with the electrical specifications and the motors are connected in star or delta
according to the motor name plate (way of connection is stated after the actual volt-
age on the motor name plate).
WARNING!
Wrong connection, star or delta, of the motors will occur overheat-
ing and burn out of the motors.
5.3.8 Scale Inhibitor Dosage Equipment for Feed Water

Please refer to Dimensional drawing, see “FWG Order Specification”
The injection shall be connected to the feed water inlet to the evaporator section just
after the orifice OC-FE-01, see “FWG Order Specification”

CAUTION!
In order to avoid malfunctions, we recommend following the pipe
dimensions indicated in the Flow chart drawing.

6 Operating Instructions
WARNING!
Fresh water must not be produced from polluted water, as the produced
water can be unsuitable for human consumption.
WARNING!
Fresh water shall in general only be produced when the vessel is at
least 20 miles from land or remote from any risk of estuarial pollution
which in some sea areas can extend well in excess of 20 miles from
land.
NOTE!
• Maximum ambient temperature for the equipment is 50°C (122°F).
• Minimum ambient temperature for the equipment is 0°C (32°F).
Operating Instructions 28 985 22146 rev 05 – May 6, 2014

6.0 Start up and operating procedure
CAUTION!
Before starting up please observe instructions for feed water treat-
ment, See “10 Chemical Dosing of Scale Control Chemicals”
1. Open valves on the suction and discharge side of the ejector pump PU-SC-01.
2. Open overboard valve for combined brine/air ejector discharge.
3. Switch on power supply.
4. Close air Bleed valve VA-E1-01 on air suction line.
5. Start Ejector Pump PU-SC-01 and create vacuum min 85%.
Adjust the pressure at the ejector inlet to be in the green working area. In cold water
(below 12 °C) it is recommended to keep the inlet pressure at 3.0 barg, as this will
result in a minimum SW flow in the condenser section.
Figure 6-1. Push ejector pump Start button, and switch on salinometer

.
Figure 6-2. Keep inlet SW pressure in the green range.
• Secure that feed water treatment has started with the ejector pump.
• Check feed water treatment and adjust to required dosing rate.
Figure 6-3. Open for feed water treatment and adjust to app. 70 (see table in chapter 10.5.3 for
dosing amount) and keep the other button at 100% as on the picture.
6. Open HW on/off outlet valve 50% and HW on/off inlet valve 100% (Yard supply)
This will secure that the HW by-pass valve adjustment is more optimal. In running
condition, the total pressure loss should be in the range of 0.3 bar (unit alone is
around 0.13 bar).

7. Close partly the HW by-pass valve (Yard supply)
This will send HW to the unit starting it up slowly by only sending a small part of
the HW to the unit.
NOTE!
The maximum freshwater pump discharge pressure can be found in the
attached technical data.
8. Start the freshwater pump PU-FR-01
Distillate production is started when water can be seen in the flow sight glass
check valve, and the differential temperature in the condenser is more than 3-5°C.
When the salinity is below the set point, check the production rate and compare it
with the design production rate.
In cold seawater (below 12 °C), closing the HW by-pass valve too much can result
in a too high production rate and causing too high salinity. In some cases in very
cold seawater, it will also be needed to open the air bleed valve to get the desired
salinity level. This action will increase the boiling temperature and lower the pro-
duction rate.
Figure 6-4. Observe when there is water in the flow sight glass FG-ES-01on the ejector vacuum
suction line

Figure 6-5. Push Freshwater pump start button
9. Adjust the HW by-pass valve until the design production rate is reached
Adjust the HW by-pass valve until the design production rate is reach. The AQUA
type has a very low pressure loss in the HW side. If this gives regulation problems,
this can be improved by partly closing one of the HW on/off valves at the unit
Running the unit at higher production rates than design rate, will result in higher
brine salinities and higher scale rates than normal. The freshwater salinity level
will be higher, and unstable utilities can cause high salinity dumping and alarms.
10. Open air bleed valve VA-E1-01 slowly if salinity is too high
In cold seawater the production rates will increase. It could be needed also to open
the air bleed valve to get the design production and desired salinity level. This
action will increase the boiling temperature and lower the production rate.

Figure 6-6. Air bleed valve. Open this partly in very cold seawater operation.
This operation will send air into the condenser and vacuum system, and secure that the
capacity is not increasing, and the salinity kept low.
6.0.1 Daily operation

• During normal operation it is strongly recommended to make daily logs (by filling
in the test sheet enclosed in the manual).
• If production rates are too high or too low then adjust the HW by-pass valve, and/
or the air bleed valve (VA-E1-01).
• If production rates are below the design and the unit is operated with design utili-
ties (temperature & flow), then clean the unit manually or by CIP.
• Never run the unit without an anti-scale chemical. Secure correct dosing rates by
keeping a log of the chemical consumptions.
6.1 Adjustment of Hot Water Flow

Please refer to “FWG Order Specification”
In order to help adjusting to the specified flow of hot water to the freshwater generator
below calculations can be done.
It is necessary to adjust the bypass valve until desired flow is achieved.
The flow can be calculated as follows:

3
K JW  Cap.m /24h
M JW = ----------------------------------------------  m 3  h 
t JW
Where:
MJW = Hot water flow. [m³/h]
KJW = Constant = 25.6
tJW = Difference in temperature of hot water in and out. [°C]

Cap.m³/24h = Freshwater production in 24 hours,
i.e. production in 5 min. times 288. [m³]
Example: Cap. m³/24h = 15 m³
tJW =18.4°C
25.6  15 3
M JW = ---------------------- = 20.9 m /h
18.4
Alternatively adjust the by-pass valve until the fresh water production is according to
design. If to high production, salinity in the product can be to high.
6.2 Adjustment of Sea Cooling Water

The sea cooling water flow is correct, when the pressure at the inlet side of the com-
bined air/brine ejector (PI-ES-01) is between 3.0 and 4.0 Barg (42.7 and 56.9 Psig).
6.3 Stopping the Plant
1. Close hot water inlet and outlet on/off valves (Yard supply).
2. Close hot water inlet and outlet valves
3. Close valve for feed water treatment and adjust to zero.
4. Stop the freshwater pump PU-FR-01 and close valve to storage tank (Yard sup-
ply).
5. Let the ejector pump PU-SC-01 run for approx. 5 minutes to cool down the unit.
Then stop the pump.
6. Switch off power supply.

7. Open air bleed valve VA-E1-01 on air suction line. It is important to release the
vacuum at standstill.
8. Close valves on the suction and discharge side of the ejector pump PU-SC-01
(Yard supply).
9. Close overboard valve for the combined brine/air ejector discharge (Yard supply).
CAUTION!
If water remains in the flow sight glass (FG-ES-01) in the air suction
pipe, please refer to “Trouble shooting”.
CAUTION!
Close overboard valve for the combined brine/air ejector discharge.
All valves must be shut, while the freshwater generator is out of opera-
tion. Except the air screw VA-E1-01
NOTE!
If the freshwater generator is out of operation for a longer period than
14 days, please refer to part 7.1.0 Standstill and part 7.2.0 Long Term
Standstill.

7 Long Term Standstill
7.1 Standstill
7.1.1 Preservation Procedure for Freshwater Generator

If the freshwater generator is out of operation for a period of 14 to 30 days.
Close all valves in connection with the unit and its pumps.
Open drain valve on the freshwater generator.
Turn the pump/motor shafts once a week to avoid damaging the mechanical shaft seal
and motor bearings.
7.1.2 Restart
Close drain valve on the freshwater generator and visually check outside for defects.
Before restart turn the pump/motor shaft by hand to check for any obstructions, after
starting the pump watch the operation of the pump and electric motor for approx. 10
minutes.
7.2 Long Term Standstill
7.2.1 Preservation Procedure for Freshwater Generator

If the freshwater generator is taken out of operation for a period longer than 30 days.
Close all valves in connection with the unit and its pumps.
Open drain valve on the freshwater generator.
7.2.2 Restart Freshwater Generator

Close drain valve on the freshwater generator and check visually outside for defects.
For other equipment in connection with the freshwater generator follow procedures as
described below.
Long Term Standstill 36 985 22146 rev 05 – May 6, 2014

7.2.3 Preservation Procedure for Pumps
NOTE!
Freshwater pump only to be drained and flushed with fresh water.
Other pumps as following:
1. Drain the pump through the bottom drain.
2. Flush the pump with hot fresh water (maximum 60°C, 140°F), flushing can take
place through the manometer connections.
3. Let the pump dry out.
4. Mount drain plug and manometer connections.
5. Turn the pump shaft once a week to avoid damaging the mechanical shaft seal.
7.2.4 Restarting of Pumps

1. Fill the pump with hot fresh water through the manometer connections.
2. Mount the manometer connections.
3. Turn the pump shaft by hand to check for any obstructions.
4. Open valves and check that the mechanical shaft seal is not leaking (if leaking
start the pump and let it run for 1 to 2 minutes, if still leaking the mechanical seal
must be replaced).
5. Start the pump and watch the operation of the pump and electric motor for approx.
10 minutes.
7.2.5 Preservation Procedure for Electric Motors

Factory fitted bearings use a lithium based grease with a recommended shelf life of two
years. If stored for a longer period, grease may need to be replaced.
Shielded bearings have a storage life of five years and a further two years operational
life following the installation.
To avoid static indentation during long term standstill, the area should be vibration
free.
Where exposure to some vibration is unavoidable, the shaft should be looked. Roller
bearings may be fitted with a shaft locking device, which should be kept in place during
long term standstill.
Shaft should be rotated by hand, one quarter of revolution weekly.

WARNING!
Where anti-condensation heaters have been fitted, it is strongly recom-
mended that they are energized.
In such case, prominent warnings of live terminals inside the termi-
nal box must be posted inside and outside the motor terminal box.
Where anti-condensation heaters are not fitted, the use of desiccant is recommended.
7.2.6 Restarting of Electric Motors

1. Before taking a motor into service, ensure that anti-condensation heaters (if fitted)
have been disconnected and isolate before starting the motor.
2. Check that no foreign matter is present.
3. Remove all surface dust and dirt.
4. Test the stator insulation resistance between phases and also to earth.
5. If an insulation resistance lower than one mega ohm at 20°C (68°F) is measured,
the windings must be dried out until a minimum of one mega ohm is obtained.
6. Start the motor.
7. Watch the operation of the electric motor for approx. 10 minutes.
7.2.7 Preservation Procedure for Electric Panel

The electric panel normally includes motor starters with thermal relays, transformer,
contactors and salinometer.
The panel has to be disconnected from the main supply and kept clean and dry during
the long term standstill period.
The panel is kept dry inside either by an anti-condensation heating element (25 W) or
by use of a desiccant.
WARNING!
If anti-condensation heater is used, prominent warnings of live ter-
minals inside the panel must be posted inside and outside the panel.
Remove the conductivity sensor in the freshwater pipe after the freshwater pump, clean
the sensor and store it in the electric panel or in a dry place.

7.2.8 Restarting of Electric Panel
1. Before taking the panel into service, ensure that anti-condensation heater (if fit-
ted) have been disconnected and removed.
2. Check that no foreign matter is present in the panel.
4. Test the insulation resistance between phases and earth.
5. If an insulation resistance lower than one mega ohm at 20°C (68°F) is measured,
the panel must be dried out until a minimum of one mega ohm is obtained.
6. Clean and mount the salinity sensor in the freshwater pipe.
7.2.9 Solenoid Valve

Solenoid valve is removed, flushed with warm fresh water and stored in a clean dry
ozone free area.
Before replacing, the valve is flushed again with warm fresh water and the function of
the valve is checked by energizing the coil.

8 Maintenance
8.0 Why you need to perform regular maintenance

duties
Regular maintenance of the plant will improve performance and availability.
The maintenance schedule on the following pages will tell you how often service
should be performed on the main components.
As the actual operating conditions of the plant are of major influence on the life time,
the overhaul dates are not obligatory but only recommended intervals.
When the plant has been in operation for a longer period of time and experience has
been established as to the actual performance, it will be possible to adapt the mainte-
nance schedule.
For service on minor components please refer to component instructions.
Maintenance 40 985 22146 rev 05 – May 6, 2014

8.1 Overhaul Intervals
Component Operating Hours Action

Production unit: As required Clean in inhibited acid bath.
Plate stack Scrub with pure freshwater and
brush.
Production unit: As required Clean with pure freshwater and
Complete brush
Combined ejector/ 8000 h Measure seal ring and impeller.
cooling water pump Examine mechanical shaft seal,
with motor cooling water pipe passage. Meg-
ger-test electric motor. Clean
pump thoroughly before reassem-
bly.
Freshwater pump with 8000 h Measure seal ring and impeller.
motor Examine mechanical shaft seal,
cooling water pipe passage. Meg-
ger-test electric motor. Clean
pump thoroughly before reassem-
bly.
Combined air/brine 8000 h Measure nozzles and diffuser and
ejector compare to measurements in
technical specification.
MV-valves 4000 h Disassembly and inspect for dam-
age.
Manometers 8000 h Check with control manometer.
Replace if necessary
Salinometer See separate instruc- See separate instructions
tions
8.2 Maintenance of Plate surface

Clean Plate surface as follows:
NOTE!
Measure and note the tightening measure

1. Remove tightening bolts
2. Open plate stack
3. Remove plate stack
NOTE!
Be careful not to damage the gasket during manual cleaning.
NOTE!
If some of the gaskets come loose on removing plate stack, please see
section 8.3.3
4. Submerge plates completely in a hot, inhibited acid bath at maximum 50ºC

(122°F). For further instructions see “Chemical dosing of scale control chemi-
cals”.
WARNING!
Always follow carefully the supplier’s instructions when using inhib-
ited acids.
Remember to neutralize according to suppliers instructions.
5. Scrub plates with a soft brush and plain hot water at maximum 50°C (122°F).
6. Examine plates and gaskets for possible damage, and remove damaged plates and/
or replace damaged gaskets.
NOTE!
If a defective plate is found, remove the plate together with one of the
adjacent plates.
NOTE!
The assembly measurements must be reduced with 4.9 mm per plate, if
plates are removed from plate stack.

CAUTION!
The end plate and start plate cannot be removed but must always be
replaced, with a corresponding plate.
7. Reassemble the plate stack in accordance with attached assembly scheme.
8. Tighten plate stack to measurements stated in technical specification.
9. Vacuum test the freshwater generator before start up.
10. The evaporator section is pressure tested by letting hot water circulate through the
section with bypass valve for hot water in normal running position.
NOTE!
If a defective plate is found, remove the plate together with one of the
adjacent plates.
NOTE!
The assembly measurements must be reduced with 4.9 mm per plate,
if plates are removed from plate stack.
11. Reassemble the plate stack in accordance with attached assembly scheme.
12. Tighten plate stack to measurements stated in technical specification.
13. Vacuum test the freshwater generator before start up.
14. The condenser section is pressure tested by starting the ejector pump and letting
sea water circulate through the condenser section.
NOTE!
If the gaskets is correct positioned the rubber indicators will be visible
on every second plates on the right respectively left hand side.
If the plates are correctly assembled, the edges form a “honeycomb”
pattern.
CAUTION!
Before starting the combined ejector/cooling water pump, the feed
water must be sealed off.

8.3 Renewal of Plate Heat Exchanger Gaskets
8.3.1 Removal of Old Gaskets

Pull the old gaskets out of groove.
If the gasket cannot come off directly, heat the back of the gasket groove with a hot-air
blower or butane gas burner.
Pay attention not to overheat the plates.
You will obtain a suitable temperature, if the flame is held 10 to 15 cm behind the plate.
WARNING!
DO NOT use acetylene gas
8.3.2 Cleaning
Charred or loose glue and rubber remains must be removed, e.g. using a rotating stain-
less steel brush. The width should be adapted (Ø40-50 mm, width 8-10 mm).
Thin layers of glue, which are difficult to remove, may remain.
Clean the gasket groove with a clean cloth, dipped in a solvent (acetone, methyl ethyl
ketone, trichlorethylene etc.).
WARNING!
Be careful when handling these solvents, as they may be hazardous to
your health. Observe suppliers’ instructions.
Gaskets, that have loosened, can be glued on. Clean gasket groove carefully with a
sharp tool. Then clean the loose part of the gasket with emery cloth or sandpaper.
Finally clean groove and gasket with a solvent, and glue.
8.3.3 Preparation of new Gaskets

Dry new gaskets with a clean cloth that has been slightly moistened with a solvent.
8.3.4 Fitting new Gaskets

1. Apply a thin layer of glue to both gasket and groove.
2. Let the glue dry for 10-15 minutes.
3. Fit new gasket into groove.

4. Gaskets may sometimes be slightly short or long.
5. Short gaskets should be stretched before being fitted into the groove.
6. Long gaskets should be fitted into the grooves at the plate ends first and then grad-
ually be pushed into the groove towards the middle.
7. If necessary, tape gasket into groove.
8. Assemble plate pack according to attached assembly scheme.

9 Vacuum test
9.0 Vacuum testing of unit

If there are leaks in the system, it will be necessary to carry out a vacuum test in order
to identify the leak:
1. Please follow the starting instructions.
2. Stop the ejector pump.
3. The vacuum drop must not be more than 2% within 10min
Vacuum test 46 985 22146 rev 05 – May 6, 2014

10 Chemical Dosing of Scale
Control Chemicals
10.0 Prevention of Scaling

During evaporation of seawater there is always a risk of scaling on the heating surfaces.
Scale will lead to a reduction of the K-values (Heat Transfer Value) on the heating sur-
face and decrease the freshwater production. This will demand extensive cleaning.
Without correct operation of the Freshwater generator as well as chemical treatment of
the feed water before it enters the AQUA unit, solid salts will form scales. The degree
of deposit of scales (solid salts) depends on the concentration of calcium, magnesium,
bicarbonates and sulphate in the seawater. At certain temperatures calcium carbonates,
magnesium hydroxides and calcium sulphate will solidify and deposit on any surface
they are in contact with over a sufficiently long period of time.
Scaling may occur. In order to effectively prevent scaling the operators must be aware
of the various factors influencing scale formations
10.1 Feed Water Ratio

The feed water ratio is an extremely important factor. It is defined by the relationship
between the feed water amount fed into the plant and the produced amount of
freshwater.
Mf
Feed Water Ratio = --------
Md
Mf = total flow of feed water

Md = total flow of freshwater
If the feed water ratio is reduced, the concentration will rise in the plant subsequently
resulting in scale formations.
NOTE!
The AQUA is designed to a feed water ratio at 3.25.
Chemical Dosing of Scale Control Chemicals 47 985 22146 rev 05 – May 6, 2014
Two things may shift the feed water ratio: first of all direct adjustment of the feed
water system, and secondly exceeding the maximum freshwater production laid out for
the plant.
The operators must observe the following rules at all times.
CAUTION!
DO NOT adjust spring loaded valve at the feed water system.
The feed water pressure at PI-ES-01 shall be minimum 3.0 (42.7 Psig)
and maximum 4.0 Barg (56.9 Psig)
10.2 Evaporating Temperature

Another factor influencing scale formation is the evaporating temperature. Tempera-
tures higher than laid out by Alfa Laval Copenhagen will increase the scaling risk.
10.3 Operational Notes
10.3.1 Normal Operation Conditions

It is important that operating personnel become familiar with normal operating condi-
tions so that deviations from the norm can be recognised quickly and dealt with
promptly. The Table in Technical Data lists the approximate readings that should be
obtained during normal operation of the unit. Most of these indications will be found
on the central instrument.
10.3.2 Maintaining Distillate Output

The normal feed water treatment will keep the scale of evaporator to a minimum;
though not prevent it completely, over time scale will accumulate. The length of this
period depends both of the operation of the plant as well as the quality of the seawater.
If the temperature of the incoming feed water is held constant at the normal value, the
production of the unit will gradually decrease as scale accumulates on the plate sur-
faces. Eventually the scale will have to be removed by acid cleaning.
The rate of scale deposition depends on many factors, including:
• Chemical composition of the feed water
• Degree of attention to feed water treatment
It is therefore good practice to shut down the unit periodically for several hours to
inspect the plate surfaces for scale. Experience will dictate the time interval between
inspections. Never depend upon visual inspection alone, but rather, the unit should be
opened and samples of scale taken for measurement of thickness, in accordance with
cleaning the unit.
Scaling on plates leads to an increase of the total plant temperature difference. The
increased temperature difference will lead to a higher evaporation temperature which
will increase the risk of scale formation.
Scaling may occur. In order to effectively prevent scaling the operators must be aware
of the various factors influencing scale formations.
10.4 Chemical Dosage

In order to control scale formations on the heating surfaces and continuously ensure
long operation periods without cleaning the Freshwater generator, it is absolutely nec-
essary to dose scale control chemicals to the feed water.
Calcium carbonate and magnesium hydroxides are soft or alkaline scales and can rel-
atively easy be dissolved with acid solutions. They are primarily formed at tempera-
tures above 45°C. Since the AQUA typically is operated at temperatures above 45°C,
scale becomes a real issue, which needs to be dealt with by adding anti scalant chemi-
cals.
It is also very important that the scale inhibitor used is effective at the evaporation tem-
perature and at the same time effective at a feed water ratio factor 3.25.
The operators must follow the instructions for chemical dosing very carefully.
CAUTION!
If the freshwater generator is operated at boiling temperatures above
45°C (113°F) without chemicals, frequent cleaning of the evaporator
will be necessary.
NOTE!
We recommend that you do not operate the freshwater generator with-
out recommended chemical dosage at boiling temperatures above
45°C (113 °F). Even at lower temperatures it can be recommended.
10.4.1 Scale Inhibitor Dosage Equipment for Feed Water
Mix thoroughly to ensure a homogenous blend when adding chemicals to water.
Use a fully soluble scale inhibitor, e.g. on polymer basis. The following product can be
recommended:
Alpacon Altreat 400
Should other antiscale chemicals be used, the user will be fully responsible concerning
its efficiency in scale control and its compatibility with the plant and equipment.
Should this selection of chemical cause any damage to any part of the plant or result in
insufficient control of the formation of scale in the plant, then such cases will not be
covered under Alfa Laval’s warranty obligations.
Alfa Laval refrains from discussing or commenting on other brands of antiscale chem-
ical, as we find the responsibility for the applicability and use of a certain brand chem-
ical should be the chemical supplier’s.
10.4.2 Safety Precautions with the use of Chemicals
WARNING!
The operators must follow the instructions for chemical dosing given
by the chemical supplier carefully.
USE eye protection and gloves. Avoid direct skin contact, eye contact
or contact with clothes.
CLEAN empty containers before disposal.
If chemicals are spilled on clothes, rinse with water and dispose off
clothes.
If chemicals are spilled on the floor, rinse with water and suck remain-
ing chemicals off with sand. Clean the spot immediately afterwards.
Scale inhibitor is hazardous, if consumed in a concentrated solution. If

consumed by mistake.
IMMEDIATELY SEEK MEDICAL ATTENTION.
If eyes get in contact with the chemicals, rinse for at least 20 minutes.
IMMEDIATELY SEEK MEDICAL ATTENTION.
WARNING!
Read carefully the safety data sheet before using any chemicals.
10.4.3 Alpacon Altreat 400

Alfa Laval recommends Alpacon Altreat 400, which is an Alfa Laval scale inhibitor
product, for dosing to the feed water.
Technical specification
Appearance Light brown liquid

Density at 20°C Approx. 1,25g/cm³
Viscosity at 23°C 600 mm2/s
Flash point >100 °C
pH-value at 20°C Approx 8
Miscibility with water In all proportions
Ordering information
Article number:
985 00056-82 Alpacon Altreat 400 - 25 litre
985 00056-81 Alpacon Altreat 400 – 200 litre
10.5 Preparation of chemical solution
10.5.1 Anti Scalant type Alpacon Altreat 400

The Alpacon Altreat 400 can be used concentrated or as a solution.
It is necessary to use a solution to the AQUA units as the dosing rate shall be at as high
as practical to secure an even distribution.
The solution is prepared in the mixing tank by dissolving the Alpacon Altreat 400 addi-
tive in fresh water or distillate. The maximum effective life of the solution is one week.
Preparation of quantities of solution for longer periods is therefore not recommended.
10.5.2 Dosing flow calculation

Dosing flow [l/day] = Effective volume [litre] / Filling interval [days]
Tank Filling
Volume Effective Interval Dosing l/day Dosing l/hour
litre litre days
60 48 1 48 2,0
60 48 2 24 1,0
60 48 3 16 0,67
Example:
Chemical dosing tank volume = 60 litre
Effective volume (minus spare volume) = 48 litre
Filling interval = 3 days
=> Dosing flow = 16 l/day
10.5.3 Calculating Chemical solution

Feed water [m³/day] = Capacity [m³/day]  Feed water ratio
Chemical dosing [l/day] = Feed water [m³/day]  chemical dosing rate [kg/m³] /
Chemical density [kl/l]
Produc- Feed Chemical Dosing 48 l/day Dosing 24 l/day Dosing 16 l/day

tion water (dosage (density Chemicals Water Chemicals Water Chemicals Water
Capacity Flow 8 g/m³) 1,25 kg/l) litre litre litre litre litre litre
m³/day m³/day kg/day l/day l/day l/day l/day l/day
5 16,3 0,130 0,104 0,104 47,9 0,104 23,9 0,104 15,9
10 32,5 0,260 0,208 0,208 47,8 0,208 23,8 0,208 15,8
15 48,8 0,390 0,312 0,312 47,7 0,312 23,7 0,312 15,7
20 65,0 0,520 0,416 0,416 47,6 0,416 23,6 0,416 15,6
25 81,3 0,650 0,520 0,52 47,5 0,52 23,5 0,52 15,5
30 97,5 0,780 0,624 0,624 47,4 0,624 23,4 0,624 15,4
35 113,8 0,910 0,728 0,728 47,3 0,728 23,3 0,728 15,3
40 130,0 1,040 0,832 0,832 47,2 0,832 23,2 0,832 15,2
45 146,3 1,170 0,936 0,936 47,1 0,936 23,1 0,936 15,1
50 162,5 1,300 1,040 1,04 47,0 1,04 23,0 1,04 15,0
55 178,8 1,430 1,144 1,144 46,9 1,144 22,9 1,144 14,9
60 195,0 1,560 1,248 1,248 46,8 1,248 22,8 1,248 14,8
Example:
Capacity = 20 m³/day
Feed water ratio = 3,25
Chemical dosing rate = 0,008 kg/m³
Chemical density = 1,25 kg/l
=> Chemical dosing = 0,416 l/day
If dosing flow is 16 l/day => Mix is 0,416 litre chemical to (16 - 0,416) litre Water
Obs. Multiply to get the needed Chemical solution volume.
Example:
Dosing flow is 16 l/day

Chemical dosing = 0,416 l/day
Tank volume to be filled = 45 litre
‘=>
Water amount = (16 – 0,416)  45 / 16 = 43,8
Chemical amount = 0,416  45 / 16 = 1,17
10.6 Dosing Instructions – Anti Scalant
The dosing flow shall be adjusted to calculated dosing flow. Use a bucket to determine
the chemical dosing flow.
NOTE!
The dosing pump is started at the same time as the ejector pump.
Stroke rate shall be set to 100%
Use the stroke length knob to adjust flow.
NOTE!
The dosing pump is started at the same time as the ejector pump.
Stroke rate shall be set to 100%
Use the stroke length knob to adjust flow.
Dosing pump
Stroke length knob
11 Operation and maintenance
instructions for Freshwater
Pump type 1525/1532/2040
11.1 Product description

The pump is a single-stage centrifugal pump, direct-coupled to the electric motor shaft
by means of a hollow shaft and hollow point screws. The pump is equipped with
mechanical shaft seal with rubber bellows.
11.2 Technical data
• Pump casing in bronze
• Impeller in bronze
• Shaft in stainless steel
• Pump capacity appears on the nameplate of the pump.
• Motor power and voltage is indicated in the technical specification
• Power consumption is indicated in the technical data sheet for pumps and motors
• Number of revolutions is indicated in the technical data sheet for pumps and motors
The total weight is the sum of pump and motor weight:
Pump Type Weight [kg]

PVVF1525 5.5
PVVF1532 7.5
PVVF2040 9.0
ABB Motor Type Weight [kg] Sound pressure
dB(A) at 3000/1500 rpm

MT 71 5.5 59 / 45
MT 80 10.0 60 / 49
Operation and maintenance instructions for Freshwater Pump type 1525/1532/204055 985 22146 rev 05 – May 6, 2014
11.2.1 Noise level
The noise level of pump without motor is lower than 70 dB (A). The noise level of
pump + motor is about 2 dB (A) higher than the noise level of the motor. The noise
level of the motor is about 1-2 dB (A) higher at 3600 rpm. The above guiding noise
levels are based on a tolerance of ± 3 dB (A). Max. water temperature: +70°C.
11.3 Installation / start-up

Before installation of the pump read these operation and maintenance instructions care-
fully. Installation and running must further be in accordance with local regulations and
common practice. High tensions must not be transferred from piping system to pump.
Make sure that the pump rotates in the direction of the arrow. The pump must be liquid-
filled and bled before start-up as the shaft seal will otherwise be damaged.
11.4 Application
The pump is suitable for the pumping of pure seawater and fresh water.
The pump must not be used in ATEX zones.
11.5 Service
Before service the mains voltage must be disconnected. Make sure that the mains volt-
age cannot unintentionally be cut in. The pump might be so hot that handling may
cause burns.
11.5.1 Pump overhaul

The following instructions must be carefully observed whenever it becomes necessary
to overhaul or repair the freshwater pump.
Please refer to drawing for item references in the text.
Pos. No. Designation
1. Pump casing 2. Impeller 3. Gasket

4. Rear cover 6. Shaft 9. Motor
10. Screw 11. Hollow point screw 14. Screw
17. Sealing ring 18. Pipe plug 19. Sunk key
20. Screw 22. Shaft seal 23. Screw cap
30. Allen screw and disc 31. Guard
1. Remove the bolts pos. 14 in the pump casing pos. 1.
2. Motor with pump cover pos. 4, impeller pos. 2 can now be removed from the
pump casing pos. 1.
3. Remove the screw pos. 20 (right-hand thread).
4. Remove impeller. Normally the impeller can be dismantled without the use of
puller tools.
5. Remove the sunk key pos. 19.
6. The mechanical shaft seal pos. 22 can now be removed.
7. Check the ceramic ring, the carbon ring and the springs in the shaft seal. If neces-
sary, replace the shaft seal.
8. To facilitate the removal of the ceramic seat of the shaft seal it is recommended to
dismantle the pump cover pos. 4 from the motor flange.
9. After replacing the ceramic seat mount the pump cover pos. 4 on the motor flange.
10. Before mounting the remaining part of the shaft seal apply glycerine to the pump
shaft.
11.5.2 Clearance
11. Before assembling the pump, check the clearance between impeller and sealing
ring.
12. Max. clearance impeller/sealing ring 0.5 mm on the diameter
13. Assemble the pump in the reverse order of dismantling.
CAUTION!
Only dismantle the pump shaft if pump shaft or motor bearings are to
be replaced.
In this case carefully observe “Dismantling pump shaft”.
11.5.3 Dismantling Pump Shaft

Dismantle the pump as described above.
Remove the pointed screws pos. 11 and normally the pump shaft can easily be removed
from the motor shaft.
In case the dismantling causes problems, use the puller tools
If the pump shaft does not come loose, use the special dismantling tools shown below.
The tool is not Alfa Laval supply.
.
The tool consists of a pipe (A), a disc (B) with hole for the screw (C) and a nut (D),
washer (E).
Please note that the length L must be longer than the length l.
Place pipe (A) around the shaft. Fasten the screw (C) with nut (D) and washer (E) into
the threaded hole (M 5) on the shaft end.
Loosen shaft by tightening the nut (D) while holding on to the screw (C).
CAUTION!
DO NOT grind the motor shaft.
1. Clean the motor shaft and mount the new pump shaft on the motor shaft.
2. Make sure that the pump shaft fits the motor shaft without any obstructions, before
final shaft fitting as follows:
3. Tighten pointed screws 11 as shown on picture below:
NOTE!
The torque shall be 5 Nm (0.5 kpm) and the maximum wobble 0,06
mm
4. Check the wobble of the pump shaft with a dial indicator.
5. Reassemble the pump as described above in reverse order.
11.6 Maintenance
The motor bearings, which are the only bearings in the pump, are lubricated for life and
must, therefore, not be re-lubricated. Check the shaft seal at regular intervals.
11.7 Transport / storage

The small pumps can be lifted by hand. The big pumps have to be lifted by placing a
rope round the pump so that it is in balance. The rope must not touch sharp edges. Store
the pump in a dry area.
11.8 Spare parts

Spare parts must be ordered on the basis of the freshwater pump assembly drawing and
parts lists attached with this manual.
12 Salinometer
12.0 Salinometer type DS-21
Front view
Salinometer 61 985 22146 rev 05 – May 6, 2014

12.1 Specification of Salinometer type DS-21
Function: The salinometer measures and supervises the salinity (salt
content) of fresh water produced by distillation of sea water
Mains supply: 90-115 or 190-230 V, 50-60 Hz
Mains current: Mains supply must be secured against over current
externally. Max. 100mA
Power consumption: Max. 3.5 W
Range of Salinity: 0 - 20ppm of sea salt ( 0 – 10 ppm 0,1 ppm/step)
(10 – 20 ppm 0,2 ppm/step)
Accuracy: +/- 10% on displayed value
Alarm Level: Adjustable 1 - 20ppm (1 – 10 ppm 1 ppm/step)
(10 – 20 ppm 2 ppm/step)
Alarm: Alarm indicating a bad connection to the electrode
Cable Connections: Terminal 1 - 4: Mains supply
Terminal 5 - 7: Relay contacts for solenoids
Terminal 8 – 10: Relay contacts for ALARM
Terminal 11 – 15: Electrode unit
Terminal 17: 4-20mA Current loop
Terminal 18: Current ref, Ground
Alarms to devices connected to the secondary relay can be cancelled by means of a push button
"ALARM ON/OFF" on the front panel.
Display: LED Bar
Relay contacts: 8A / 24V AC
12.2 Installation of Salinometer type DS-21
1. Make sure, that the mains supply is secured against over current by a fuse (max.100mA). There
are NO fuses in the salinometer.
2. The salinometer is adopted to operate from 90 to 115V AC 50-60 Hz or 200 to 230 V AC 50-60
Hz.

3. Lay the necessary cables and connect them to the female connector.
4. Plug the female connector in the male connector, and test the instrument as described.
12.3 User instruction for Salinometer type DS-21
1. Check that the LED “Electrode Disconnected” not indicates a bad connection to the elec-
trode.
2. Adjust the alarm level to the required level.
3. Be sure that "ALARM ON/OFF" is in the right position.
The salinometer is now ready for use.

If the salinity exceeds the alarm level, the instrument signals alarm:
a) The alarm LEDs are flashing.
b) The externally connected alarm devices (solenoid valve(s), buzzer, external
alarm system(s) etc. are functioning. The externally alarms can be cancelled
by pushing the "ALARM ON/OFF" button, but not the solenoid valve.
When the alarms are operative a green LED appears.
12.4 Maintenance of Salinometer type DS-21

Always keep the salinometer dry and clean. The accuracy of the salinometer is very dependent on
the electrodes are kept clean.
The electrodes should be taken out and cleaned at least once a week. Use only a clean and soft
rag. When cleaning the electrodes it is IMPORTANT that the electrodes are not polluted by oil
or other chemicals.

Any pollution result immediately in an inaccurate measurement of the salinometer.
If the surface of the electrode is damaged it needs to be replaced.

13 Trouble-Shooting
13.0 Test Sheet

Before taking any action, please fill in a test sheet to find possible causes of malfunc-
tions.
Test sheets can be found in the back of this section.
Trouble-Shooting 65 985 22146 rev 05 – May 6, 2014

13.1 Trouble Shooting Table
Problem Cause Action

Drop in production. Partially blocked feed water ori- Dismantle plate stack and clean evap-
fice and/or sludge deposits on orator section and orifice.
hot water side.
Sludge on the heat exchanger Dismantle plate stack and clean con-
plates on the sea water side. denser section.
Inlet channel in evaporator/ Dismantle plate stack, and clean.
condenser plate stack blocked,
e.g. with rust scales, gasket
fragments etc.
Too low ejector pump pressure. See instructions for “Low Sea Cool-
ing water/Ejector pump flow / pres-
sure”, below.
Leakages. Carry out a vacuum test.
Foreign bodies in ejector Inspect nozzles, and clean.Replace
nozzles. nozzles, if damaged.
Too high back pressure on ejec- Check overboard pipe and valves for
tor outlet side. Max 0.6 Barg blocking / function ability.
(8.7 Psig).
Non-return valve in air extrac- Replace non-return valve.
tion pipe defect.
Hot water temperature too low. Increase to specified temperature
Defective water clock. Examine water clock. Let the pro-
duced water flow through water clock
into a 10 l pail, and check production
with a stop watch. Clean strainer if
dirty

Low Sea Cooling Too low ejector pump pressure. Clean, or replace pressure gauge.
water/Ejector pump Impeller / seal ring defective. Check pump maximum clearance See
flow / pressure. “Maintenance of Ejector Pump”.
Minimum pressure Suction strainer blocked. Clean suction strainer.
3.0 Barg (43.5 Psig). Valves on suction or pressure Examine and overhaul defective
At inlet side of ejec-pipe defect. valves.
tor. Leakage from suction pipe to Repair.
pump.
Clocked up condenser. Dismantle plate stack and clean.
Pump rotating in wrong direc- Interchange phases.
tion.
Sight glass overflow. Suction pipe leakage. Check suction pipe especially unions
and connections. Repair.
To high freshwater back pres- Reduce back pressure
sure
Mechanical seal in freshwater Replace mechanical seal.
pump defect.
Impeller / seal ring in fresh- Check pump. Maximum clearance
water extraction pump defect. See “Maintenance of Freshwater-
Pump”.
Pump rotating in wrong direc- Interchange phases.
tion.
Valves to freshwater tank Check all valves.
closed.
Inlet filter for water clock Clean filter.
blocked.
Salinity too high Too high production Reduce production by reducing hot
water flow
Insufficient brine extraction. See separate instructions for insuffi-
cient brine extraction, below.
Very cold seawater • Open air screw (VA-E1-01) in
small steps to increase boiling tem-
perature.
• Reduce hot water flow
• Reduce to min. sea water pressure

3,0 Barg (42,7 Psig) at ejector inlet
(PI-ES-01)
To high hot water flow Reduce hot water flow

To low boiling temperature • Open air screw (VA-E1-01) in
small steps to increase boiling tem-
perature.
• Reduce hot water flow
• Reduce to min. sea water pressure

3,0 Barg (42,7 Psig) at ejector inlet
(PI-ES-01)
Wrong placement or scale in Open clean / reglue
brine separation gaskets
Electrode unit defective or Examine electrode unit for cracks.
dirty. Check that it is fittedcorrectly. Clean,
if necessary.
Leakage in condenser section. Leak test condenser section.
Max. 4.0 Barg (58 Psig). If there is a
defective plate, check gaskets for for-
eign objects, if none remove together
with adjacent plate assemble plate
stack according to new plate number
with reduced assembly measurements.
Check plate gaskets are securely
attached to the plates and replace, if
necessary.
Insufficient brine Ejector pump pressure too low. See special instructions for “Low Sea
extraction. Cooling water/Ejector pump flow /
pressure”, above.
Foreign bodies in ejector noz- Check nozzles, and clean. Replace
zles. damaged nozzles.
Too high back pressure down- Examine overboard pipe and valves.
stream of ejector.
Wrong dimension of feedwater Examine orifice dimension - check
orifice. technical specification.
Non-return flap in brine suction Examine flap and repair, or replace.
pipe of ejector defect.

Frequent refill of Leakage in evaporator section. Leak test evaporator section. Max. 4.0
freshwater expansion Barg (58 Psig). If there is a defective
tank due to loss of hot plate, check gaskets for foreign
water. objects, if none remove together with
adjacent plate assemble plate stack
according to new plate number with
reduced assembly measurements.
Check plate gaskets are securely
attached to the plates and replace, if
necessary.
Abnormal amperage Ejector nozzles defective. Replace nozzles.
consumption of ejec- Wrong dimension of feedwater Check dimensions on spare parts list,
tor pump motor. inlet orifice. and replace if necessary.
Bearings in motor defective. Examine with stethoscope, and
replace bearings, if defective.
Contactor defective. Examine and replace contactor set, if
defective.
Breaking of phases. Max. 5% difference in amperage
between phases.

This page intentionally left blank

Test Sheet for single stage Fresh Water Generator type Aqua HW
Vessel: Date: Location:
Freshwater Generator no.: Type: Capacity:
No. of plates: Date for last cleaning:
TEST
Date:
Time from:
To:
Difference min.
Fresh water
Water clock to: FI-FR-01 m³
From: FI-FR-01 m³
Difference: Calc. m³
Total output: Calc. m³/24h
Evaporator section
Hot water inlet: TI °C
Hot water outlet TI °C
Difference Calc. °C
Hot water flow rate Calc. m³/24h
Feed water temperature TI-ES-01 °C
Process
Boiling temperature TI-E1-01 °C
Vacuum PI-E1-01 °C
Condenser section
Sea water inlet TI °C
Sea water outlet TI-ES-01 °C
Difference Calc. °C
Outlet pressure PI-ES-01 Bar
Brine / Air Ejector
Inlet pressure PI-ES-O1 Bar
Back pressure PI Bar
Ejector pump
Inlet pressure PI Bar
Discharge pressure PI Bar
Freshwater pump
Discharge pressure PI-FR-01 Bar
Salinometer
Salinity QT-FR-01 ppm
Chemical dosage
yes / no
Chemical type / dosage
Comments
*) Hot water flow [m³/h] = 24,6 x Freshwater production [m³/24h] / Hot Water difference temperature [°C]
*) Sea water flow [m³/h] = 23,5 x Freshwater production [m³/24h] / Sea Water difference temperature [°C]
Document number: 985 22699 rev03 _________________________________________

Signature

14 Spare Parts -
14.0 Ordering Spare Parts

When ordering spare parts please always state:
1. Serial number.
2. Spare parts drawing number.
3. Position number.
4. Article number.
In order to identify article numbers, please refer to FWG Order Specification and other
drawings.
When ordering parts for pumps proceed as follows:
1. Find article number in the list of drawings.
2. Check spare part drawing and item list with corresponding article number to iden-
tify the item to be ordered.
14.1 Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world.
DO NOT hesitate to contact your Alfa Laval representative if you have any questions,
problems or require spare parts.
www.alfalaval.com
Spare Parts - 72 985 22146 rev 05 – May 6, 2014

15 FWG Order Specification -
Drawings and Parts lists
FWG Order Specification - Drawings and Parts lists 73 985 22146 rev 05 – May 6, 2014
FWG Order Specification - Drawings and Parts lists 74 985 22146 rev 05 – May 6, 2014
Document: 985 21683
General description AQUA
985 21683 General description AQUA
Application
Conversion of seawater into fresh water by vacuum distillation for the supply of high quality fresh
water for domestic and process utilization. For installation on ships, rigs and remote onshore
locations.
The AQUA is designed for automatic operation with continuous control of fresh water quality.
Heating media is waste heat, jacket water, steam or HWL.
At all time the Alfa Laval AQUA fresh water generator secure pure fresh water onboard and
replacement of bunker water.
Capacity
The AQUA covers a capacity range from 4 to 60 m3/24hr, depending on the heating medium
temperature, flow and seawater temperature. The capacities shown below are at 32ºC seawater
temperature.
Capacity range for AQUA

At different heating medium temperatures and nominal flow
o
for min and max number of plates at 32 °C sea water temperature
11 90 °C
AQUA 125 9
10
80
85
8 75
7 70
11 90 °C
AQUA 100 10 85
9 80
8 75
7 70
11 90 °C
AQUA 80 9
10
80
85
8 75
7 70
90 °C
AQUA 65 11
10 85
9 80
8 75
7 70
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
3
Freshwater capacity in m /24h
985 21683-R00
Illustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part. We reserve 1
the right to change such specification when necessary.
May 6, 2014 75 985 21683

9.2 Production Information
9.2.11 Freshwater Generator AQUA
Working principle
Picture 1
The feed water to be evaporated is taken from the sea cooling water outlet of the condenser. It
enters the evaporator where it evaporates at about 40–60°C as it passes between the plates heated
by the heating medium. The evaporating temperature corresponds to a vacuum of 85–95%,
maintained by the brine/air ejector. The vapours generated pass through a separation section where
any drops of seawater entrained are removed and fall due to gravity to the brine sump at the bottom
of the titanium plate stack. The clean fresh water vapours continue to the condenser section, where
they condense into fresh water as they pass between the cold plates cooled by the sea cooling
water.
Picture 2 Picture 3
Basic equipment
Titanium plate heat exchanger
Sea- and feed water pipes in CuNi and stainless steel.
The freshwater generator is equipped for hot water heating and with a combined condenser and
ejector water system. Furthermore the freshwater generator is equipped with dump valve including
return pipe, water clock, automatic feed water regulator, combined brine/air ejector, instruments,
fresh water pump with electric motor, internal piping and frame parts.
985 21683-R00
May to
the right 6, 2014
change such specification when necessary. 76 985 21683
9.2 Production Information
9.2.11 Freshwater Generator AQUA
Power supply - options

Main power supply: Control voltage:
x 3x220V 50 Hz x 110V
x 3x400V 50 Hz x 230V
x 3x690V 50 Hz
x 3x220V 60 Hz
x 3x440V 60 Hz
x 3x690V 60 Hz
Additional equipment necessary for operation

x Ejector pump including electrical motor
x Electrical motor for fresh water pump
x Control panel with motor starter and salinometer or manual motor starters and salinometer
x Feed water treatment equipment
Optional design
x Flange on fresh water outlet
x Steam heating system type HWS
x Filling line for feed water treatment
x Adaptors for front or side connections
x Control panel build on the unit
x Manometer set for ejector pump
x By-pass on water clock
Optional equipment
x Salinometer type DS21
x Remote control box with lock
x Class test certificates
x Fresh water treatment equipment
Spare parts
x Spare parts kit for one year of operation
x Spare parts kit for two years of operation
x Spare parts kit for five years of operation
x Steel box for spare parts
985 21683-R00
May to
the right 6, 2014
change such specification when necessary. 77 985 21683
May 6, 2014 78 985 21683
Document: 985 23068 R00
Technical data: AQUA 100, 0.5 mm plates
985 23068 Technical data: AQUA 100, 0.5 mm plates
Power consumption
Ejector- and fresh water pump:
Number of plates 50 Hz 60Hz

86 ± 92 6.9 kW 7.8 kW
94 ± 100 8.3 kW 8.3 kW
102 ± 108 8.5 kW 8.5 kW
110 ± 118 8.8 kW 8.7 kW
120 - 126 9.6 kW 9.2 kW
128 ± 134 10.1 kW 9.7 kW
Pressure
bar(g) psi
Max. hot water pressure 5.0 72.5
Max. back pressure to fresh water tank (50 Hz) 1.3 18.9
Max. back pressure to fresh water tank (60 Hz) 2.4 34.8
Max. seawater inlet pressure 4.0 58.0
Min. seawater pressure to ejector 3.0 43.5
Max. back pressure at ejector outlet 0.6 8.7
Max. back pressure for safety valve in steam equipment 1.0 14.5
Max. steam inlet pressure in steam equipment 7.0 101.5
Normal operation pressure for steam equipment (standard) 2±4 29 ± 58
Alternative operation pressure for steam equipment 6±7 87.0 ± 101.5
Min. back pressure to condensate well for steam equipment 0.6 8.7
Max. back pressure to condensate well for steam equipment 0.8 11.6
Materials
Evaporator/condenser plate Titanium

Frame plate Cast iron
Pressure plate Cast iron
Frame parts Aluminum & stainless steel
Stud bolts Steel - galvanized
Pipe for brine discharge Cast iron ± hot dip galvanized
Pipe for feed water Duplex steel
Pipe for seawater CuNi 90/10
Pipe for freshwater Bronze & CuNi 90/10
Combined brine/air ejector housing Bronze
Combined brine/air ejector nozzles Duplex steel & bronze
Steam equipment, type HWS:

Pipes Steel ± hot dip galvanized
Steam injector housing Cast iron ± painted
Steam injector nozzle Bronze
May 6, 2014 79 985 23068 R00.fm

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Illustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part. We reserve
May 6, 2014 80 985 23068 R00.fm

Document no.: 985 21690 R01 Pumps and motors
Technical data AQUA 100
May 6, 2014
50 Hz
No.of plates 86-92 94-100 102-108 110-118 120-126
Pump function Fresh water Ejector Fresh water Ejector Fresh water Ejector Fresh water Ejector Fresh water Ejector
Pump type PVVF-1532 CNL 65-65/160 PVVF-1532 CNL 65-65/200 PVVF-1532 CNL 65-65/200 PVVF-1532 CNL 65-65/200 PVVF-1532 CNL 65-65/200
Motor size 80B 132M 80B 132M 80B 132M 80B 132M 80B 132M
Nom. flow m3/h 1.7 28.9 1.7 31.6 1.7 34.2 1.7 37.4 1.7 40.0
Pressure, min. bar 2.4 3.8 2.4 3.8 2.4 3.8 2.4 3.8 2.4 3.8
Impeller size 50 Hz: mm ø142 ø175 ø142 ø186 ø142 ø186 ø142 ø186 ø142 ø190
Document: 985 21690 R01
Rotating speed 50 Hz: RPM 2730 2880 2730 2920 2730 2920 2730 2920 2730 2920
3 x 380-415 V, 50 Hz
Rated output power kW 1.1 9.5 1.1 9.5 1.1 9.5 1.1 9.5 1.1 9.5
Consumed power kW 0.6 6.3 0.6 7.7 0.6 7.9 0.6 8.2 0.6 8.9
Current (full load) A 2.5 17.3 2.5 17.3 2.5 17.3 2.5 17.3 2.5 17.3
Current (start) A 15.0 129.9 15.0 129.9 15.0 129.9 15.0 129.9 15.0 129.9
3 x 660-720V, 50 Hz
Rated output power kW 1.1 9.5 1.1 9.5 1.1 9.5 1.1 9.5 1.1 9.5
81
Current (start) A 8.7 75.3 8.7 75.3 8.7 75.3 8.7 75.3 8.7 75.3
60 Hz
No.of plates 86-92 94-100 102-108 110-118 120-126
Pump function Fresh water Ejector Fresh water Ejector Fresh water Ejector Fresh water Ejector Fresh water Ejector
Pump type PVVF-1532 CNL 65-65/160 PVVF-1532 CNL 65-65/160 PVVF-1532 CNL 65-65/160 PVVF-1532 CNL 65-65/160 PVVF-1532 CNL 65-65/160
Motor size 80B 132M 80B 132M 80B 132M 80B 132M 80B 132M
Nom. flow m3/h 1.7 28.9 1.7 31.6 1.7 34.2 1.7 37.4 1.7 40.0
Pressure, min. bar 3.7 3.8 3.7 3.8 3.7 3.8 3.7 3.8 3.7 3.8
Tech. data - Pumps and motors for FWG type AQUA-100-HW/HWS
Impeller size 60 Hz: mm ø142 ø152 ø142 ø154 ø142 ø154 ø142 ø154 ø142 ø156
Rotating speed 60 Hz: RPM 3324 3500 3324 3500 3324 3500 3324 3500 3324 3500
3 x 440-480V, 60 Hz
Rated output power kW 1.3 11 1.3 11 1.3 11 1.3 11 1.3 11
Current (start) A 15.5 130.7 15.5 130.7 15.5 130.7 15.5 130.7 15.5 130.7
3 x 660-720V, 60 Hz
Rated output power kW 1.3 11 1.3 11 1.3 11 1.3 11 1.3 11
Current (start) A 10.2 87.0 10.2 87.0 10.2 87.0 10.2 87.0 10.2 87.0
985 21690 R01.fm

Document no.: 985 21690 R01 Pumps and motors
Technical data AQUA 100
May 6, 2014
50 Hz
No.of plates 128-134
Pump function Fresh water Ejector

Pump type PVVF-2040 CNL 65-65/200
Motor size 80B 132M
Nom. flow m3/h 1.7 42.6
Pressure, min. bar 2.4 3.8
Impeller size 50 Hz: mm ø156 ø190
Rotating speed 50 Hz: RPM 2730 2920
3 x 380-415 V, 50 Hz
Rated output power kW 1.1 9.5
Consumed power kW 0.6 9.2
Current (full load) A 2.5 17.3
Current (start) A 15.0 129.9
3 x 660-720V, 50 Hz
Rated output power kW 1.1 9.5
82
60 Hz
No.of plates 128-134
Pump function Fresh water Ejector

Pump type PVVF-2040 CNL 65-65/160
Motor size 80B 132M
Nom. flow m3/h 1.7 42.6
Pressure, min. bar 3.7 3.8
Impeller size 60 Hz: mm ø156 ø156
Rotating speed 60 Hz: RPM 3324 3500
3 x 440-480V, 60 Hz
Rated output power kW 1.3 11
3 x 660-720V, 60 Hz
Rated output power kW 1.3 11
985 21690 R01.fm

6 5 4 3 2 1
A(1:5)
D 2 1 2 D
May 6, 2014
A
Drawing: 985 23331 R01
Distance Indicator 0.5 mm plates
C C
83
B B
LENGTH OF POS. 1:
Ɣ 0.5mm PLATES: (n x 5.0) -25mm
n = No. OF PLATES
01 LENGTH OF POS. 1 CHANGED, WAS 15mm 12-06-2013 AHNA NSR PMH
00 INITIAL DRAWING 27-10-2011 AHNA PLD PMH
Rev
Revision text Date Drawn Checked Approved
No
Title
DISTANCE INDICATOR
0.5mm PLATES
Proj. No Proj. Type Proj. Name
A
AQUA A
Location Size Dimensions without tolerances:
ISO A3
Alfa Laval Copenhagen A/S Method E ISO 2768-M or ISO 13920-B
Scale
Date Drawn 1:10 Drawing No Rev
Sheet
985 23331 R01.fm

27-10-2011 AHNA 1 /1 985 23331 01
6 5 4 3 2
May 6, 2014 84 985 23331 R01.fm
Drawing: 985 21429 ver. 01
Flow chart for FWG type AQUA-100-HW 86-126
May 6, 2014 85 985 21429.fm

May 6, 2014 86 985 21429.fm
Document: 985 21694 ver. 01
Equipment specification - FWG type AQUA-100-HW/HWS
Tag no. Description Article no. Connection

EW-ES-01 Ejector See spec. -
FG-ES-01 Flow sight glass 984 35686-00 1/2" BSP
FI-FR-01 Watermeter 985 42600-09 1/2" BSP
OC-FE-01 Orifice See spec. -
PI-E1-01 Mano / vacuum gauge 985 62601-00 3/8" BSP
PI-ES-01 Pressure gauge 985 62500-02 1/4" BSP
PI-FR-01 Pressure gauge (50 Hz) 985 62501-01 1/4" BSP
PI-FR-01 Pressure gauge (60 Hz) 985 62501-02 1/4" BSP
PU-FR-01 Freshwater pump See spec. -
MO-FR-01 Motor for freshwater pump See spec. -
PU-SC-01 Ejector pump See spec. -
MO-SC-01 Motor for ejector pump See spec. -
QT-FR-01 Electrode sensor 985 21475-01 1/2" BSP
TI-E1-01 Thermometer w. pocket 985 20578-05 1/2" BSP
TI-ES-01 Thermometer w. pocket 985 20577-05 1/2" BSP
VA-E1-01 Air screw 984 40939-03 1/4" BSP
VA-ES-01 Non return valve 985 00036-39 -
VA-ES-02 Non return valve 984 35686-00 1/2" BSP
VA-ES-04 Ball valve 984 35649-00 1/2" BSP
VA-ES-05 Non return valve 984 35671-00 1/2" BSP
VA-FE-02 Spring loaded valve 985 21474-01 DN40 - 3/4"
VA-FE-03 Ball valve 984 35649-00 1/2" BSP
VA-FR-01 Ball valve 984 35649-00 1/2" BSP
VA-FR-03 Spring loaded valve 985 21472-01 3/4"
VA-FR-04 Non return valve 984 35188-00 3/4" BSP
VA-FR-06 Solenoid valve See spec. 1/2" BSP
VA-FR-13 Ball valve (*) 984 35638-00 3/4"
VA-FR-14 Ball valve (*) 984 35638-00 3/4"
VA-FR-15 Ball valve (*) 984 35638-00 3/4"
(*) optional equipment: water clock by-pass
Steam arrangement
IS-SS-01 Steam injector See spec. -
PI-SS-01 Mano / vacuum gauge 985 62600-01 3/8" BSP
TI-SS-01 Thermometer w. pocket 985 20577-05 1/2" BSP
TI-SS-02 Thermometer w. pocket 985 20577-05 1/2" BSP
VA-SS-01 Butterfly valve 985 21325-24 DN 100
VA-SS-02 Safety valve See spec. -
VA-SS-03 Ball valve 984 35649-00 1/2" BSP
VA-SS-04 Seated valve 985 56110-05 1" BSP
VA-SS-05 Butterfly valve 985 21325-24 DN 100
VA-SS-06 Ball valve 984 35649-00 1/2" BSP
May 6, 2014 87 985 21694.fm

May 6, 2014 88 985 21694.fm
Drawing: 98521719 ver. 00
Vertical plant positioning - AQUA
May 6, 2014 89 985 21719.fm

May 6, 2014 90 985 21719.fm
6 5 4 3 2 1
DISTANCE SHEET CRUSH PROTECTION PLATE START PLATE UTILITY PLATE PROCESS PLATE END PLATE CRUSH PROTECTION PLATE, UNHOLED
ARTICLE No.: ARTICLE No.: 985 22455-01 ARTICLE No.: ARTICLE No.: ARTICLE No.: 39508649-03 ARTICLE No.: 39508650-76 ARTICLE No.: 985 22438-04
985 21929-01 39508649-88 39508650-03
D D
May 6, 2014
Document: 985 22505 R04
C C
Assembly Scheme AQUA, 0,5 mm plates
91
B B
L = 5 + (n x 5,0)
DISTANCE SHEET (1mm) + CRUSH PROTECTION PLATE (2mm) +
n x 5,0 + CRUSH PROTECTION PLATE UNHOLED (2mm)
n = TOTAL NUMBER OF PLATES

PLATES: START, UTILITY, PROCESS & END PLATE
04 ARTICLE No. CHANGED FOR START PLATE, WAS 985 22439-90 & END PLATE, WAS 985 22440-90 30-01-2012 AHNA PLD PMH
03 ARTICLE FOR CRUSH PROTECTION PLATE (985 22455-01) UPDATED, WAS 985 22455-04 12-10-2011 AHNA PLD PMH
Rev
CRUSH PROTECTION Revision text Date Drawn Checked Approved
No
PLATE, UNHOLED Title
END PLATE ASSEMBLY SCHEME AQUA
A A
PROCESS PLATE 0.5mm PLATES
UTILITY PLATE AQUA
START PLATE Location Size Dimensions without tolerances:
ISO A2
CRUSH PROTECTION PLATE Alfa Laval Copenhagen A/S Method E ISO 2768-M or ISO 13920-B
Scale
DISTANCE SHEET
985 22505 R04.fm

Sheet
07-04-2010 AHNA 1 /1 985 22505 04
6 5 4 3 2 1
May 6, 2014 92 985 22505 R04.fm
Document: 985 22981 R02
Gasket Configuration 0.5 AQUA Plates
May 6, 2014 93 985 22981 R02.fm

May 6, 2014 94 985 22981 R02.fm
Drawing: 985 21465 R04
Frame plate and parts
May 6, 2014 95 985 21465 R04.fm

May 6, 2014 96 985 21465 R04.fm
Bill Of Material
Parent item no.: Description: Date:
985 21465-80 R: 04 FRAME PLATE DIN 36-200 PLATES 20110204 Page 1 of 1
AQUA
May 6, 2014
Drawing no.: Ini
985 21465 DKSOJBNA
BUBL QTY U/M DESCRIPTION DRAWING NO. ARTICLE NO. MATERIAL REMARKS
1 1.000000 EA FRAME PLATE DIN 36-200 PLATES 3490002530 985 21926-01
AQUA 80, 100 & 125
2 24.000000 EA STUD BOLT M16 X 75 , A4-70 985 00086-98 A4-70
3 7.000000 EA SCREW M12 X 35 DIN 912 985 80011-34 QUALITY 8.8 ; DELTA-MAGNI
4 1.000000 EA RUBBERLINING PORT 1 AND 2 DN80 3490002312 985 21921-80
5 2.000000 EA DISTANCE DN80 FOR AQUA 80+ 3490002441 985 21914-00
Document: 985 21465-80 R04
6 1.000000 EA RUBBER LINING BRINE/FEED WATER 3490002313 985 21872-01

AQUA
7 1.000000 EA RUBBER LINING FEED WATER LEFT 3490002314 985 21873-01
AQUA
8 1.000000 EA FUNNEL FOR BRINE OUTLET PLAST 985 22945 985 22945-01
9 1.000000 EA DISTANCE RING DN20-25 FEEDWATE 3490002440 985 21900-01
Frame Plate DIN 36-200 Plates - parts list
LEFT - AQUA
10 5.000000 EA WASHER Ø 12 MM HFC 1207 984 40901-27 BRASS
97
11 2.000000 EA SET SCREW M12 X 50 HFC 681 984 40912-13 STEEL ; EL. ZINCED KVAL. 8.8
12 2.000000 EA POLYAMID BUSHING FOR FEEDWATER - 985 00089-98 Polyamide PA6
HOLE AQUA
14 2.000000 EA TRIANGULAR INSERT FOR AQUA 985 22941 985 22941-01
FOR FEEDWATER INSERTION

Bank: SEB, Landemarket 10, Copenhagen
BIC/SWIFT ESSEDKKK
Maskinvej 5
DK-2860 Søborg, Denmark Accounts: DKK IBAN Acc. DK5752950010008069
CVR/VAT/EORI No. DK10134285 EUR IBAN Acc. DK4552950013000735
985 21465-80 R04.fm

Phone/Fax: +45 3953 6000 / +45 3953 6568 USD IBAN Acc. DK4252950015000929
May 6, 2014 98 985 21465-80 R04.fm
Drawing: 985 21467 ver. 00
Frame parts
May 6, 2014 99 985 21467.fm

May 6, 2014 100 985 21467.fm
Bill Of Material
985 21467-80 R: 00 FRAME PARTS 600 MM 20090422 Page 1 of 2
May 6, 2014
Drawing no.: AQUA Ini
985 21467 DKSOPLD
1 1.000000 EA PRESSURE PLATE FOR AQUA 3490003511 985 21759-01
WITHOUT FOOT
2 1.000000 EA SUPPORTING COLUMN VERTICAL 3490002363 985 21861-01
Frame parts - parts list
ALL AQUA SIZES

3 8.000000 EA NUT M24 EN ISO 4033 985 00087-73 EN 20898-2/ISO 898-2 - 8
Document: 985 21467-82
4 8.000000 EA SERRATED LOCK WASHER 985 00087-74

5 16.000000 EA GUIDING WASHER M24 1624317 985 21871-01
6 9.000000 EA STUD BOLT M12 X 70 , A4-70 985 00086-97 A4-70
7 2.000000 EA BRACKET FOR AQUA FRAME 3490002339 985 21874-01
8 2.000000 EA CLAMP FOR CARRYING BAR AQUA 3490002340 985 21891-01
9 2.000000 EA CLAMP FOR SUPPORTING COLUMN 3490002419 985 21892-01
AQUA
11 1.000000 EA FOOT FOR SUPPORTING COLUMN 3490003954 985 21760-01
101
AQUA,
12 1.000000 EA GASKET FOR HOT WATER IN/OUT 3490002429 985 21927-01
AQUA - FRAME INTERNAL
13 1.000000 EA PLATE FOR GUIDING BAR AQUA 3490002430 985 21916-01
14 1.000000 EA PLATE FOR CARRYING BARS 3490002431 985 21897-01
AQUA
15 1.000000 EA PROFILE FOR PRESSURE PLATE 3490002432 985 21898-01
AQUA
16 2.000000 EA BEARING FOR PRES PLATE PROFILE 3490002433 985 21899-01
AQUA
17 1.000000 EA DISTANCE RING DN20-25 FEEDWATE 3490002440 985 21900-01
LEFT - AQUA
18 1.000000 EA CRUSH PROTECTION SHEET 3490002443 985 21928-01
19 1.000000 EA DISTANCE SHEET 3490003050 985 21929-01
20 1.000000 EA PLATE FOR PROFILE 3490002685 985 21902-01
AT PRESSURE PLATE
21 2.000000 EA WASHER M12 MORE DETAILS... 985 00087-93
22 5.000000 EA HEXAGON COUNTER SUNK HEAD SCRW 985 00087-75 EN 20898-2/ISO 898-2 - 8
M12 X 30
23 4.000000 EA HEXAGON SCREW M12 X 60 985 00087-76 EN 20898-2/ISO 898-2 - 8
24 10.000000 EA HEXAGON SCREW M12 X 30 985 00087-77 EN 20898-2/ISO 898-2 - 8
Alfa Laval Copenhagen A/S Bank: SEB, Landemarket 10, Copenhagen

BIC/SWIFT ESSEDKKK
Maskinvej 5
CVR/VAT No. 10134285 EUR IBAN Acc. DK4552950013000735
985 21467-82.fm
May 6, 2014 102 985 21467-82.fm
6 5 4 3 2 1
May 6, 2014
D 9 D
8 42
38
42
38 41
Seawater system 86-126
Drawing: 985 21479 R03
39
40
11
1
17
C 16 C
103
29
20
30
21
23
A
22 4
21
22
B B
28
A
31 43 44 10 23
45
A-A
20
40
21
37
22
03 POS. 43, 44 & 45 ADDED 16-11-2010 AHNA PLD PMH
36 02 NON RETURN FLAP POS. 28 CHANGED TO POS. 31 07-07-2010 AHNA PLD PMH
23 Rev
No
35 Title
SW SYSTEM 86 - 126
A 34 A
985 21479 R03.fm

AQUA
ISO A2
Scale
Sheet
27-04-2009 AHNA 1 985 21479 03
6 5 4 3 2 1
May 6, 2014 104 985 21479 R03.fm
Bill Of Material
May 6, 2014
985 21479-80 R: 05 SEAWATER SYSTEM 86-126 20121120 Page 1 of 2
Drawing no.: Ini
985 21479 DKSOPLD
1 1.000000 EA SEA WATER PIPE DN80/DN80 985 21484 985 21484-01 CuNi 90-10
AQUA
4 1.000000 EA GASKET Ø142/75 x 2 984 58094 984 58094-01
8 1.000000 EA PRESSURE GAUGE COCK 1/4" BSP EV 5100-8 984 35533-00 BRASS
BRASS
Document: 985 21479-80 R05
8 1.000000 EA +HEXAGON NIPPLE 1/4" BSP B 3280 985 52721-01 ISO 1338/77 ; CU PB5 SN5 ZN5
8 1.000000 EA PRESSURE GAUGE Ø63 0-6BAR 985 23208 985 23208-02
Seawater System 86-126 - parts list
MULTI SCALE
9 1.000000 EA THERMOMETER STRAIGHT 63MM 985 23188 985 23188-05
NIPPLE & STEM AISI316
10 .000000 EA COMBINED BRINE/AIR EJECTOR SEE SPECIFIC.B
11 1.000000 EA FEED WATER VALVE FVF-40-2,5 985 21474 985 21474-01 Brass (MS-58)
16 .000000 EA ORIFICE FOR FEED WATER SEE SPECIFIC.O
105
17 1.000000 EA GASKET Ø38/24 X 2 984 58333 984 58333-01
20 1.000000 EA FEED WATER PIPE DN25/DN40 985 21491 985 21491-01 EN 1.4462 (duplex)
AQUA
21 1.000000 EA HEXAGON NIPPLE 1/2" 316L 985 52820-04 AISI 316L
MAT 316L
22 1.000000 EA TEE 1/2" BSP L=28 985 00039-96 AISI 316L
MAT 316L
23 2.000000 EA BALL VALVE 1/2" BSP. 984 35649-00 BRASS
TYPE 15420L BUSHING
23 1.000000 EA NIPPLE, RED. 3/4" X 1/2" BSP B 3241 985 52720-06 ISO 1338/77 ; CU PB5 SN5 ZN5
28 1.000000 EA BRINE PIPE AQUA, RG5 - LARGE 985 23311 985 23311-01 RG5 (CuSn5Zn5Pb5)
29 1.000000 EA THERMOMETER L-SHAPE 63MM 985 23189 985 23189-05
STEM & NIPPLE AISI316
30 1.000000 EA COMPOUND GAUGE -100%-2BAR 985 23213 985 23213-00
MULTI SCALE
30 1.000000 EA BUSHING 1/2" X 3/8" BSP B 3241 985 52720-03 ISO 1338/77 ; CU PB5 SN5 ZN5
31 1.000000 EA NON RETURN FLAP Ø 50 984 57281 985 00036-39
STEEL ENHANCED
34 1.000000 EA ELBOW 1/2" BSP B 3092 985 52700-03 ISO 1338/77 ; CU PB5 SN5 ZN5
35 1.000000 EA HEXAGON NIPPLE 1/2" BSP B 3280 985 52721-03 ISO 1338/77 ; CU PB5 SN5 ZN5
36 1.000000 EA NON RETURN VALVE 1/2" BSP 985 13951 984 35686-00 ISO 426/2/83 ; CU ZN39 PB3
BRASS

BIC/SWIFT ESSEDKKK
Maskinvej 5
985 21479-80 R05.fm

Bill Of Material
May 6, 2014
985 21479-80 R: 05 SEAWATER SYSTEM 86-126 20121120 Page 2 of 2
Drawing no.: Ini
985 21479 DKSOPLD
37 1.000000 EA CONNECTION 1/2" BSP X 12 985 00035-84 ISO 426/2/83 ; CU ZN39 PB3
39 1.000000 EA NIPPLE PIPE 1/4" X 80 985 00088-01 AISI316
40 1.000000 EA AIR SUCTION PIPE AQUA 68-126 985 21493 985 21493-80 Copper
41 1.000000 EA TEE 1/4" BSP B 3130 985 52710-01 ISO 1338/77 ; CU PB5 SN5 ZN5
42 1.000000 EA +HEXAGON NIPPLE 1/4" BSP B 3280 985 52721-01 ISO 1338/77 ; CU PB5 SN5 ZN5
42 1.000000 EA NEEDLE VALVE IN-LINE 1/4" F/F 985 00092-34 Brass
FEMALE-FEMALE
43 1.000000 EA GASKET FOR AQUA Ø112/54 X 2 985 23058 985 00091-75
106
NITRIL
44 1.000000 EA SEAL RING LARGE FOR AQUA 985 23026 985 00088-38
Ø112/54 X 3MM STAINLESS STEEL
45 1.000000 EA GASKET Ø56/30 X 2 984 57843 984 57843-01 FJ5004, NBR 65

BIC/SWIFT ESSEDKKK
Maskinvej 5
985 21479-80 R05.fm

6 5 4 3 2 1
42 28 43 44 15 16 41
May 6, 2014
D 29 D
28
27
14
17 1
12
Freshwater outlet system
25 7 19
Drawing: 985 21501 ver. 00
26 11 20
10
9
C C
8
18
2
3 21
107
7 6 5 4 21 22 23 24 40 46 45
B B
41 40 1
may constitute a contractual

obligation on our part.
Rev.
Revision text Date Drawn Cheked Appr.
No.
Title
FW OUTLET AQUA 86 - 126 DIN
A A
Project no. Project type Project name
AQUA
Dimensions Without Tolorances: Location:
Size
985 21501.fm
ISO 2768-M or ISO 13920-B A2 Alfa Laval Copenhagen A/S
Date Drawn ISO
Denmark
Scale
23-04-2009 Method E Drawing No. Rev.
AHNA 1:5
Reviewed Approved Matr:
transmitted or communicated to any other party

or used for purposes not expressly permitted by us.
PLD JNN 985 21501 00
6 5 4 3 2 1
May 6, 2014 108 985 21501.fm
Bill Of Material
985 00091-97 R: 01 FW OUTLET AQUA 86-126 DIN 20121120 Page 1 of 2
Drawing no.: Ini
May 6, 2014
985 21501 DKSOPLD
1 1.000000 EA GASKET Ø84/46 X 2 984 58335 984 58335-01
2 1.000000 EA FRESH WATER PIPE TO PUMP 985 21681 985 21681-01 CuNi 90-10
AQUA 36-126 PLATES
4 2.000000 EA WASHER M10 DIN 125 A 985 32512-14 A4
5 1.000000 EA GASKET Ø75/43 X 2 984 58093 984 58093-01
Document: 985 00091-97 R01
6 .000000 EA FRESHWATER PUMP SEE SPECIFIC.F

7 .000000 EA MOTOR FOR FRESHWATER PUMP SEE SPECIFIC.M
8 1.000000 EA UNION 1/2" BSP B 3341 985 52750-03 ISO 1338/77 ; CU PB5 SN5 ZN5
FW outlet AQUA 86-126 DIN - Parts List
10 1.000000 EA NIPPLE, RED. 3/4" X 1/2" BSP B 3241 985 52720-06 ISO 1338/77 ; CU PB5 SN5 ZN5
109
11 1.000000 EA FRESH WATER MANIFOLD 985 21319 985 21319-01 MS58
13 1.000000 EA BALL VALVE 1/2" BSP. 984 35649-00 BRASS
TYPE 15420L BUSHING
13 1.000000 EA HOSE CONNECTION 1/2" BSP X 15 VVS 74 4700 104 984 40939-01 ISO 426/2/83 ; CU ZN39 PB3
14 1.000000 EA PRESSURE GAUGE Ø63 0-6BAR 985 23209 985 23209-02
MULTI SCALE
15 1.000000 EA ELECTRODE FOR SALINOMETER DS21 985 00086-64
15 1.000000 EA 2.5 M CABLE WITH PLUG 985 00086-65
FOR ELECTRODE FOR DS-21
17 1.000000 EA TEE 3/4" x 1/2" x 3/4" BSP B 3130 985 52710-13 ISO 1338/77 ; CU PB5 SN5 ZN5
18 1.000000 EA NIPPLE PIPE 1/2" BSP X 40 B 3530 984 40943-18 ISO 1338/77 ; CU PB5 SN5 ZN5
19 .000000 EA SOLENOID VALVE SEE SPECIFIC.S
20 1.000000 EA HEXAGON NIPPLE 3/4" X 1/2" BSP B 3245 985 52722-03 ISO 1338/77 ; CU PB5 SN5 ZN5
21 1.000000 EA HOSE 550 MM, 3/4" BSP NIPPLE 985 00083-60 NBR reinforced hydraulic hose
& 3/4" BSP ELBOW W UNION

BIC/SWIFT ESSEDKKK
Maskinvej 5
985 00091-97 R1.fm

Bill Of Material
985 00091-97 R: 01 FW OUTLET AQUA 86-126 DIN 20121120 Page 2 of 2
May 6, 2014
Drawing no.: Ini
985 21501 DKSOPLD
23 1.000000 EA NON RETURN VALVE 3/4". 985 13952 984 35188-00 ISO 426/1/83 ; CUZN15
25 1.000000 EA NIPPLE PIPE 3/4" BSP X 80 B 3530 985 80007-90 ISO 1338/77 ; CU PB5 SN5 ZN5
26 1.000000 EA FRESH WATER VALVE DV-20-1,0 985 21472 985 21472-01 Brass (MS-58)
27 1.000000 EA NIPPLE PIPE 3/4" X 239 985 00088-14 MS58
28 1.000000 EA SOCKET 3/4" BSP B 3270 985 52740-04 ISO 1338/77 ; CU PB5 SN5 ZN5
29 1.000000 EA WATER METER EVW-DK 3/4" 985 42600-04
KENT QN 2,5 M3/H L=130
30 1.000000 EA SOCKET 3/4" BSP B 3270 985 52740-04 ISO 1338/77 ; CU PB5 SN5 ZN5
40 1.000000 EA BRACKET FOR FRESH WATER PUMP 985 21931 985 21931-02 st37-02
PVVF 1532
41 1.000000 EA BRACKET FOR FRESH WATER PIPE 985 21932 985 21932-01 ST37-2
110
OUTLET
41 2.000000 EA SCREW M8 X 16 DIN 916 HFC 1792 984 40908-13 ISO 683/13/86 ; TYPE 20A
42 1.000000 EA CLAMP FOR F.W. PIPE 984 58219 984 58219-01
43 2.000000 EA WASHER M6 ISO 887/83 985 32510-08 A4
44 2.000000 EA NUT M6 ISO 4032/86 985 32010-07 AISI 316 L
45 2.000000 EA WASHER M8 ISO 887/83 985 32512-12 ISO 683/13/86 ; TYPE 20A
46 2.000000 EA SCREW M8 X 20 DIN 933 985 30010-72 ISO 683/13/86 ; TYPE 20A

BIC/SWIFT ESSEDKKK
Maskinvej 5
985 00091-97 R1.fm

6 5 4 3 2 1
HOUSING O-RING NOZZLE ONE NOZZLE TWO DIFFUSOR SCREWS FLANGE
98 1 2 3 4 5 6 7
D D
May 6, 2014
127
61
Ejector size 20,8-31,4/36,7
Drawing: 985 21470 ver. 01
C C
2 4 5
111
B B
1/2" BSP
1 3 6
593
WEIGHT: 17,6 - 18,6 Kg [38,8 - 41 lb]
668
01 DIFFUSER TURNED 90° 18-08-2010 AHNA PLD PMH

00 INITIAL DRAWING 03-02-2009 AHNA JNN PHNA
Rev
No
Title
LIQUID JET LIQUID/AIR PUMP
A A
DN80, ASSEMBLY
AQUA
ISO A2
Scale
985 21470 R01.fm

Sheet
03-02-2009 AHNA 1 985 21470 01
6 5 4 3 2 1
May 6, 2014 112 985 21470 R01.fm
Drawing: 985 21470-22
Ejector DN80 Ø19,9 DIN, 19,9-30,0/35,2
May 6, 2014 113 985 21470-22.fm

May 6, 2014 114 985 21470-22.fm
Drawing: 985 21472
Fresh water valve DV-20-1.0
May 6, 2014 115 985 21472.fm

May 6, 2014 116 985 21472.fm
Bill Of Material
May 6, 2014
985 21472-01 R: 00 FRESH WATER VALVE DV-20-1,0 20090602 Page 1 of 1
Drawing no.: Ini
985 21472 DKSOPLD
1.000000 EA TOP COVER DV-20 985 21472 985 21472-10
Document: 985 21472-01
1.000000 EA SPRING DV-20 985 21472 985 21472-11

1.000000 EA SPRING HOUSING DV-20 985 21472 985 21472-12
1.000000 EA MEMBRANE DISC DV/FV-20, FVF-40 985 21472 985 21472-13
1.000000 EA MEMBRANE DV/FV-20, FVF-40 985 21472 985 21472-14
1.000000 EA VALVE SEAT DV-20 985 21472 985 21472-15
Fresh water valve DV-20-1.0 - Parts list
1.000000 EA VALVE HOUSING DV-20 985 21472 985 21472-16

4.000000 EA SCREW M6 X 16 DIN 912 HFC 1790 984 40906-19 ISO 683/13/86 ; TYPE 20A
117
1.000000 EA SCREW M10 X 50 DIN 933 985 00088-49 AISI 316
ISO 4014/88
1.000000 EA WASHER M10 DIN433 985 00054-93 Varmgalvaniseret
HOT DIP GALVANIZED
1.000000 EA SPRING GUIDE DV/FV-20, FVF-40 985 21472-17

BIC/SWIFT ESSEDKKK
985 21472-01.fm
Maskinvej 5
May 6, 2014 118 985 21472-01.fm
Drawing: 985 21474
Feed water valve FVF-40-2.5
May 6, 2014 119 985 21474.fm

May 6, 2014 120 985 21474.fm
Bill Of Material
985 21474-01 R: 00 FEED WATER VALVE FVF-40-2,5 20090602 Page 1 of 1
Drawing no.: Ini
May 6, 2014
985 21474 DKSOPLD
1.000000 EA TOP COVER DV-20 985 21472 985 21472-10
1.000000 EA MEMBRANE DISC DV/FV-20, FVF-40 985 21472 985 21472-13
1.000000 EA MEMBRANE DV/FV-20, FVF-40 985 21472 985 21472-14
4.000000 EA SCREW M6 X 16 DIN 912 HFC 1790 984 40906-19 ISO 683/13/86 ; TYPE 20A
Document: 985 21474-01
1.000000 EA SCREW M10 X 50 DIN 933 985 00088-49 AISI 316

ISO 4014/88
1.000000 EA WASHER M10 DIN433 985 00054-93 Varmgalvaniseret
HOT DIP GALVANIZED
1.000000 EA SPRING GUIDE DV/FV-20, FVF-40 985 21472-17
1.000000 EA SPRING FV-20 985 21473 985 21473-12
1.000000 EA SPRING HOUSING FV-20 985 21473 985 21473-13
Feed water valve FVF-40-2.5 - Parts list
1.000000 EA VALVE SEAT FVF-40 985 21474 985 21474-10

1.000000 EA VALVE HOUSING FVF-40 985 21474 985 21474-11
121
Alfa Laval Copenhagen A/S SEB, Landemarket 10, Copenhagen
Bank:
BIC/SWIFT ESSEDKKK
Maskinvej 5
985 21474-01.fm
May 6, 2014 122 985 21474-01.fm
6 5 4 3 2 1
May 6, 2014
D D
4
Solenoid valve - NO/230V
1
Drawing: 985 22018 ver. 00
C C
123
B B

Rev.
No.
Title
SOLENOID VALVE

A Size A
Date Drawn ISO
Denmark
Scale
AHNA
985 22018.fm
1:1

PLD JNN 985 22018 00
6 5 4 3 2 1
May 6, 2014 124 985 22018.fm
6 5 4 3 2 1
L1 = 15 [5/8] + (N x 4,9 [1/4])

N = No. of Plates LIFTING EYES B (1:5)
780 [30 3/4] LIFTING EYE
LIFT EYES
A L1 A Q30 [1 1/8] 283 [11 1/8]
107 [4 1/4]
/2]
D1 D1
13 [1
B
May 6, 2014
D D
C1 C C
THIS SPACE
SHOULD BE KEPT
FREE FROM FIXED D C3 D
INSTALLATIONS
C4 E E
1390 [54 3/4]

1188 [46 3/4]
1137 [44 3/4]
942 [37 1/8]
759 [29 7/8]

690 [27 1/8]
B7
122 [4 3/4]
563 [22 1/8]
B B
Drawing: 985 21701 ver. 00
0 0
146 [5 3/4] B7
311 [12 1/4] 850 [33 1/2]
257 [10 1/8]
0 0
C 0 C
383 [15 1/8] 0

A-A
600 [23 5/8]
FREE SPACE
C-C
AND CLOSING
FOR OPENING
RECOMMENDED
367 [14 3/8]
0
110 [4 3/8]
Dimensional drawing - AQUA-100-HW 108
125
30°
423 [16 5/8]

C1
909 [35 3/4]

D-D
478 [18 7/8]
107 [4 1/4]
0
600 [23 5/8]

30 °
B 1599 [63] B
C3
0 50 [2] B-B
E-E
175 [6 7/8]
0 372 [14 5/8]
107 [4 1/4]
0
2 x Q23 [7/8]
340 [13 3/8]

347 [13 5/8]
30°
3 x Q18 [3/4]
C4
170 [6 3/4]
156 [6 1/8]
500 [19 5/8]

2 x Q18 [3/4] x 35 [1 3/8] 0 = ZERO MEASUREMENT POINT
WEIGHT OF UNIT MAX. Kg lbs
78 [3 1/8]
EMPTY 845 1863 TOLERANCES: C5 mm [1/4"]
IN OPERATION 918 2024
FILLED UP 1113 2454 = CENTRE OF GRAVITY
L 209 [8 1/4]

1246 [49] CONNECTIONS FITS IN ACCORDANCE WITH: Rev.
A Revision text Date Drawn Cheked Appr. A
No.
DIN/EN 1092-1, PN10 ANSI B16.5, 150 lbs JIS B2220-1990 - 10K
Title
L = 21,5 [7/8] + (N x 4,9 [1/4]) DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS
N = No. of Plates DESCRIPTION PCD HOLES PCD HOLES PCD HOLES
DIMENSIONAL DRAWING
B7 BRINE & AIR OUTLET 180 8 x ø18 7,5" (190,5) 8 x ø5/8" 175 8 x ø19 AQUA-100-HW 108
C1 SEA WATER INLET 160 8 x M16 6" (152,4) 4 x 5/8-11 UNC 150 8 x M16
C3 HOT WATER INLET 160 8 x M16 6" (152,4) 4 x 5/8-11 UNC 150 8 x M16
C4 HOT WATER OUTLET 160 8 x M16 6" (152,4) 4 x 5/8-11 UNC 150 8 x M16 AQUA
985 21701.fm
D1 FRESH WATER OUTLET 1" BSP FEMALE 1" NPT FEMALE 1" BSP FEMALE Size
Date Drawn ISO
Denmark
Scale
Method E Drawing No. Rev.
17-10-2008 AHNA 1:10

HJNC PHNA 985 21701 00
6 5 4 3 2 1
May 6, 2014 126 985 21701.fm
6 5 4 3 2 1
C1 A A
May 6, 2014
C1
C3 B B
C3
C C
C4
C4
942
690
563
Drawing: 985 21964-R02
0
Adaptors for front connection
A-A C
0
445
218
127
C1
B-B
0
445
632
B
0
C3
C-C
0
445
218 1 INCH = 25,4mm
0 C4 TOLERANCES: C5mm
ADDITIONAL WEIGHT TO UNIT, MAX. 50kg [110 lbs]
02 TABEL UPDATED & INCH DIM. REMOVED 24.05.2009 AHNA PLD PHNA
CONNECTIONS FIT IN ACCORDANCE WITH:
01 ADAPTOR DIMENSIONS CHANGED 11.03.2009 AHNA PLD PHNA
DIN/EN 1092-1, PN10 ANSI B16.5, 150 lbs JIS B2220-1990 - 10K
Rev.
DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS Revision text Date Drawn Cheked Appr. A
No.
DESCRIPTION ND HOLES PCD ND HOLES PCD ND HOLES PCD Title
C1 SEA WATER INLET 80 8 x ø18 160 3" 4 x ø3/4" 6" (152,4) 80 8 x ø19 150 ADAPTORS FRONT CONNEC.
C3 HOT WATER INLET 100 8 x ø18 180 4" 8 x ø3/4" 7 1/2" (190,5) 100 8 x ø19 175 AQUA-100-HW 108
C4 HOT WATER OUTLET 100 8 x ø18 180 4" 8 x ø3/4" 7 1/2" (190,5) 100 8 x ø19 175 Project no. Project type Project name
AQUA
Size
Denmark
985 21964-R02.fm
Date Drawn ISO Scale
Method E Drawing No. Rev.
17-10-2008 AHNA 1:10
HJNC PHNA 985 21964 02
6 5 4 3 2 1
May 6, 2014 128 985 21964-R02.fm
Bill Of Material
985 21964-80 R: 00 ADAPTORS FRONT DIN 86-108 20100420 Page 1 of 1
May 6, 2014
Drawing no.: Ini
985 21964 DKSOASV
1.000000 EA ADAPTOR SW DN80/80 DIN/DIN 985 21865 985 21865-80 CuNi 90/10
SW IN
1.000000 EA ADAPTOR HW DN80/100 DIN/DIN 985 21869 985 21869-80 St 35.8/I (P235GH)
Drawing: 985 21964-80
HW IN/OUT
1.000000 EA ADAPTOR HW DN80/100 DIN/DIN 985 21869 985 21869-80 St 35.8/I (P235GH)
HW IN/OUT
2.000000 EA GASKET DN80 142/90 X 1,5 MM 985 00034-26 FJ 2634
DIN 2690 PN10
Adaptors for front connection - parts list
129
BIC/SWIFT ESSEDKKK
Maskinvej 5
985 21964-80.fm
CVR/VAT No. DK10134285 EUR IBAN Acc. DK4552950013000735
May 6, 2014 130 985 21964-80.fm
6 5 4 3 2 1
ROOT VALVE 1/4"

ROOT VALVE 3/8" 984 35533-00
D 984 35538-00 D
May 6, 2014
HEXAGON NIPPLE 1/4"
984 40941-29
HEXAGON NIPPLE 3/8"
985 52721-02
Drawing: 985 21748 ver. 00
PRESSURE GAUGE 1/4"

VARIES
C C
PRESSURE GAUGE 3/8"
VARIES
Root valves for pressure gauges on FWG
131
ROOT VALVE 1/4"
984 35533-00
HEXAGON NIPPLE 1/4"
984 40941-29
B B
ROOT VALVE 3/8"
984 35538-00
HEXAGON NIPPLE 3/8"
985 52721-02
Rev.
No.
Title
ROOT VALVES - HOOK UP

A Size A
Date Drawn ISO
Denmark
Scale
AHNA 1:2
985 21748 R00.fm

PLD JNN 985 21748 00
6 5 4 3 2 1
May 6, 2014 132 985 21748 R00.fm
984 23486-00
134 984 23486-00 R01.fm
Drawing: 985 21510 ver. 00
Fresh water pump type PVVF-1532 Assembly drawing
May 6, 2014 135 985 21510.fm

May 6, 2014 136 985 21510.fm
Bill Of Material
May 6, 2014
985 21510-01 R: 00 FRESHWATER PUMP PVVF-1532 Ø142 20090511 Page 1 of 1
Drawing no.: PVVF-1525.2X-017 Ini
985 21510 DKSOPLD
1 1.000000 EA PUMP HOUSING 984 10230-01 RG 5
Document: 985 21510-01
2 1.000000 EA IMPELLER Ø 142 FW. PUMP 984 10241-01 RG 9

3 1.000000 EA GASKET 985 13380-R02 984 10230-03 Fj. 2639
PVVF 1532
4 1.000000 EA PUMP COVER PVVF-1532, 80B 985 21510-10 RG 5
6 1.000000 EA SHAFT COMPLETE PVVF-1532, 80B 985 21510-11 AISI 316 (EN 1.4460)
10 4.000000 EA *SCREW M10 X 25 (SET) HFC 473 984 40910-03 HARDENED STEEL ; EL. ZINCED
KVAL. 8.8
11 2.000000 EA SCREW M5 X 8 DIN 916 HFC 710 984 40905-03 STEEL ; KVAL. 45 H
14 4.000000 EA SCREW M8 X 25 DIN 933 984 10740-04 8.8
137
17 1.000000 EA SEAL RING 984 57785 984 10230-06 ISO 1338/77 ; CU PB5 SN5 ZN5 (R
18 2.000000 EA PLUG 1/8". BRONZE 984 10030-87 BRASS
19 1.000000 EA KEY 4 X 4 X 15 984 10230-07 ISO 683/13/86 ; TYPE 20A
20 1.000000 EA SCREW M5 X 12 985 00050-36 ISO 683/13/86 ; TYPE 20A
217560123
22 1.000000 EA MECH. SEAL Ø 16 984 10230-08 AVPGG*
MECHANICAL SEAL
23 1.000000 EA WASHER 984 57763 984 10230-09 ISO 683/13/86 ; TYPE 20A
Fresh water pump type PVVF-1532 Assembly drawing - parts list

Bank:
BIC/SWIFT ESSEDKKK
985 21510-01.fm
Maskinvej 5
May 6, 2014 138 985 21510-01.fm
Drawing: 985 21028 ver. 00
Motor size 80 B, 1.30 kW outline drawing
May 6, 2014 139 985 21028.fm

May 6, 2014 140 985 21028.fm
6 5 4 3 2 1
ITEM QTY TITLE
1 7 8 1 1 DOSING PUMP
2 1 DOSING VALVE
3 1 FOOT VALVE + CERAMIC SINKER
D 4 1 TUBE PVC 4 x 6mm D
May 6, 2014
6 4 5 1 TUBE PE 4 x 6mm
6 1 DOSING TANK 60 LITER
7 2 WASHER M6
8 2 SCREW M6 x 12mm
Drawing: 985 21934
C C
2
141
B A-A B
Feed water treatment unit incl. chemical dosage pump assembly

Rev.
No.
Title
ASSEMBLY FWT WITH PUMP
A A
AQUA
A Size A
Date Drawn ISO
Denmark
Scale
AHNA 1:5
985 21934.fm

PLD JNN 985 21934 00
6 5 4 3 2 1
May 6, 2014 142 985 21934.fm
6 5 4 3 2 1
D D
May 6, 2014
780
Drawing: 985 21837 version 01
C C
577
143
B Q410 B
Feed water treatment unit inc!. chemical dosage pump dimension
01 NEW PUMP ADDED 19.05.2009 AHNA PHNA PLD

OUT Rev.
No.
Title
CHEMICAL DOSING UNIT,
DIMENSIONAL DRAWING
0 AQUA
Q15 Dimensions Without Tolorances: Location:
A Size A
Date Drawn ISO
Denmark
Scale
AHNA 1:5
985 21837 v01.fm

PLD PHNA 985 21837 01
6 5 4 3 2 1
May 6, 2014 144 985 21837 v01.fm
Control Panel option A - Technical data
General
Control panel option A for the AQUA freshwater generator includes start/stop of pumps and
salinity supervision. The panel is internally connected, and needs only to be connected to main
power and to the electrical components on the freshwater generator.
Standard design
Standard design consists of a box with the following build in components:
x Main switch, which locks panel if power is on

x Push button for freshwater, ejector and ejector pump
- Start (green)
- Stop (red)
x Signal lamp for freshwater and ejector pump running (green)
x Signal lamp for source on (white)
x Thermal relay and contractor for:
- Freshwater pump
- Ejector pump
x Operating transformer
x Salinometer
x Ammeter for ejector pump
x Running hour meter for ejector pump
x Mini circuit breaker to protect freshwater pump
x Nameplate (inside panel)
x Painting: RAL 7035
Electrical design
Supply voltage:
3x400V 50Hz
3x690V 50Hz
3x230V 60Hz
3x440V 60Hz
3x690V 60Hz
Control voltage:
110 V or 230 V
Permissible tolerances:
Voltage: +10/-15%
Frequency: ± 2%
Internal wire:
Type flame retardant
Class 70°C
May 6, 2014 145 985 21727.fm

External connections:
Remote alarm, thermal overload freshwater pump – NC
Remote alarm, thermal overload freshwater pump – NO
Remote alarm, thermal overload ejector pump – NC
Remote alarm, thermal overload ejector pump – NO
Remote start/stop freshwater pump
Remote start/stop ejector pump
Contact set, freshwater pump running - NC
Contact set, freshwater pump running – NO
Contact set, ejector pump running – NC
Contact set, ejector pump running – NO
External connections (salinometer):

External meter
Electrode unit
External alarm contact – NC
External alarm contact – NO
Solenoid valve – NC
Solenoid valve – NO
Physical design
Dimensions: 600 x 400 x 210 mm

Weight: App. 27 kg
Max. ambient temperature: 50 ºC
Min. protection degree: IP54
Optional design
Remote control box with lock
May 6, 2014 146 985 21727.fm

Control Panel option A - Dimensional drawing
May 6, 2014 147 985 21732 R01.fm

May 6, 2014 148 985 21732 R01.fm
Control Panel option A - Electrical diagram
May 6, 2014 149 985 21849.fm

May 6, 2014 150 985 21849.fm
May 6, 2014 151 985 21849.fm
May 6, 2014 152 985 21849.fm
May 6, 2014 153 985 21849.fm
May 6, 2014 154 985 21849.fm
May 6, 2014 155 985 21849.fm
May 6, 2014 156 985 21849.fm
Drawing: 985 20578
Thermometer, Straight, 0-100°C
May 6, 2014 157 985 20578.fm

May 6, 2014 158 985 20578.fm
Drawing: 985 20577
Thermometer, Angle, 0-100°C
May 6, 2014 159 985 20577.fm

May 6, 2014 160 985 20577.fm
Instruction Manual
Instructions manual for CNL pumps size 160 and 200
Alfa Laval Freshwater Generators
Instructions for installation,

operation, maintenance and repair of
CNL pumps size 160 and 200.
– May 6, 2014 161 985 22205 rev. 00


Maskinvej 5
DK-2860 S¯borg
Denmark
162 Revision number

1 General
Should you need further clarification regarding this manual, do not hesitate to contact
your local Alfa Laval representative - or call Alfa Laval Copenhagen A/S directly.
Telephone +45 (for Denmark) 39 53 60 00
Telefax +45 (for Denmark) 39 53 65 66
1.1 Introduction
This instruction manual contains relevant information on installing, operating and
maintaining the pump.
The pump is configured for the specific customer requirements. The specific pump
type is described in the enclosed documentation
The personnel in charge of installing, operating and maintaining the pump must be
properly qualified and trained to carry out the operations described in this manual. Alfa
Laval recommends that you read this manual before you install and operate the pump
as this will minimize any risk of incorrect handling. Alfa Laval cannot be held respon-
sible for unauthorized use of the pump.
Alfa Laval does not provide any guarantee if working conditions are inappropriate. If
the working conditions differ from those given in the technical data sheet, please con-
tact Alfa Laval before putting the pump into operation.
1.2 Identification
Details of the pump identification (type, article number ect.) can be found in the tech-
nical data sheet. The Pump no. can also be found on the name plate on the pump.
General – May 6, 2014 163 985 22205 rev. 00

1.3 Directions & warning signs
Comply with all instructions located on the pump or motor, such as direction of rota-
tion, arrows, instruction signs, directions or warning signs and remember to keep this
information in readable condition.
1.4 Warning symbols

Important machine and safety-related instructions in this manual are illustrated with
symbols. It is essential that these instructions are followed to avoid accidents and dam-
ages to machines and/or personnel.
STOP!
This symbol is for all safety instructions which must be followed to
avoid accidental injuries and hazards to life. Observe these safety
instructions carefully and proceed with great care.
ELECTRIC POWER!
This symbol signals possible danger due to presence of electric power.
Only proceed if the operator is experienced with the pump and proce-
dures.
CAUTION!
This symbol is used for instructions of particular importance and sig-
nals a risk of damage to the pump or its components. Proceed only if
the parts or the pump have been assembled according to instructions.
1.5 General safety

The following safety instructions apply for both pumps and motors supplied by Alfa
Laval.
General – May 6, 2014 164 985 22205 rev. 00

Please observe:
• The safety regulations

• Accident prevention regulations
• Country specific safety regulations
• Guide lines and acknowledged technical rules cited in this operating manual.
Non-compliance with safety regulations will result in danger to personnel and damage
to the unit, e.g:
• Danger to personnel through contact with voltages exceeding 42V.

• Failure to observe prescribed methods of transportation, assembly, maintenance
and repair of pump or motor.
CAUTION!
When working on the unit, please observe all valid accident prevention
regulations and generally acknowledged technical rules!
1.5.1 Electrical hazards
ELECTRIC POWER!
Do not carry out any installation or maintenance on the pump or motor
while it is operating or before it has been disconnected. Pumps with
motors must have appropriate connections. Amp ratings are given in
the technical data sheet and the power supply must be adequate.
1.5.2 Temperature hazards
STOP!
Before any maintenance is carried out, be sure to empty the pump of
liquid. If the pump has been pumping hot liquid, the pump should be
cooled to the surrounding temperature.
As a precaution, the hot parts of the machine should always be covered
to avoid accidental contact.
General – May 6, 2014 165 985 22205 rev. 00

1.5.3 Chemical hazards
CAUTION!
The pump should always be cleaned before carrying out any mainte-
nance or repairs. This will prevent chemical reactions if the pump has
been pumping dangerous liquids.
1.5.4 Dry running
CAUTION!
If the pump is not supplied with a priming device, the pump must
never be put into operation before it has been filled with liquid. If the
pump is supplied with a priming device, dry running is permissible for
a short period while the pump is primed.
1.5.5 Noise level
STOP!
Under normal conditions the pump and the motor will produce a noise
level below 80 dB. The exact noise level depends on motor type, foun-
dation and environment.
The operator must wear protective gear if the noise level becomes
harmful.
General – May 6, 2014 166 985 22205 rev. 00

2 Installation
2.1 Condition on delivery

The Pump is tested before delivery to ensure perfect running condition. A test run is
made of the pump using water to check the performance data stated in the technical
specifications.
2.2 Inspection on delivery

Check your shipment immediately upon arrival. Make sure that the parts and accesso-
ries received are in accordance with your order. In the event of damage, defects or defi-
ciency, immediately report the problem to the Transport Company and Alfa Laval.
The packaging must be examined to make sure that it is in good condition to guarantee
protection in storage.
The packaging may only be opened when:
• It is seriously damaged.
• The product is to be stored longer than originally planned.
In all other cases the packaging may only be opened at assembly. When the packaging
has been removed, the product must be examined for any deficiencies or defects.
2.3 Storage instructions
CAUTION!
The standard packaging protects the pump against corrosion during
transport and storage in dry conditions for at least 3 months. If the
pump is not installed immediately after receipt, it must be protected
against corrosion and frost and kept in a dry place.
Installation – May 6, 2014 167 985 22205 rev. 00

2.3.1 Preservation procedure
1. Drain the pump through the bottom drain.
2. Flush the pump with hot fresh water (maximum 60 0C, 140 0F). Flushing can be
done through the manometer connections.
3. Let the pump dry out.
4. Flush the pump with 'Mobil Arama 25' or similar quality.
5. Mount drain plug and manometer connections.
6. Turn the pump shaft once a week to avoid damaging the mechanical shaft seal.
2.3.2 Restarting of Pumps

1. Fill the pump with hot fresh water through the manometer connections.
2. Mount the manometer connections.
3. Turn the pump shaft by hand to check for any obstructions.
4. Open valves and check that the mechanical shaft seal is not leaking (if leaking
starts the pump and let it run for 1 to 2 minutes, if still leaking the mechanical seal
must be replaced).
5. Start the pump and watch the operation of the pump and electric motor for approx.
10 minutes.
2.3.3 Preservation Procedure for Electric Motors

• Factory fitted bearings use a lithium based grease with a recommended shelf life of
two years. If stored for a longer period, grease may need to be replaced.
• Shielded bearings have a storage life of five years and a further two years opera-
tional life following the installation.
• To avoid static indentation during long term standstill, the area should be vibration
free.
• Where exposure to some vibration is unavoidable, the shaft should be looked.
Roller bearings may be fitted with a shaft locking device, which should be kept in
place during long term standstill.
• Shaft should be rotated by hand, one quarter of revolution weekly.
ELECTRIC POWER!
Where anti-condensation heaters have been fitted, it is strongly recom-
mended that they are energized.
In such case, prominent warnings of live terminals inside the terminal
box must be posted inside and outside the motor terminal box.
Where anti-condensation heaters are not fitted, the use of desiccant is recommended.

2.3.4 Restarting of Electric Motors
Before taking a motor into service, ensure that anti-condensation heaters (if fitted) have
been disconnected and isolate before starting the motor.
1. Check that no foreign matter is present.

3. Test the stator insulation resistance between phases and also to earth.
4. If an insulation resistance lower than one mega ohm at 20 oC (68 oF) is measured,
the windings must be dried out until a minimum of one mega ohm is obtained.
5. Start the motor.
6. Watch the operation of the electric motor for approx. 10 minutes.
2.4 Foundation
CAUTION!
The pump must be fixed to a rigid foundation which is substantial
enough to absorb vibrations and to take up stress from the hydraulic
strain and loads from the pipelines.
The pump should be installed with sufficient accessibility for inspec-
tion and maintenance. The surface of the foundation where the pump is
installed must be level and horizontal. Damage due to an inadequate or
faulty foundation is not covered by the guarantee.
2.5 Environment conditions
CAUTION!
The pumps are intended for installing in dry rooms free from aggres-
sive atmosphere in temperatures between + 10 and 50 0C. Installing
the pump in other conditions is only allowed if this is stated in the tech-
nical data sheet.

2.6 Piping
CAUTION!
To keep pressure loss and flow resistance at a minimum, tight bends
and substantial size reductions in the piping system should be avoided.
Loss of pressure in the suction line must be kept at a minimum in order
to avoid cavitations in the pump. Static suction height + loss of pres-
sure in the suction line + NPSH value for the pump + steam pressure
must not exceed 10 mWC at sea level. Long suction pipes that make
air pockets possible should be avoided.
Suction and pressure lines must be connected to the flanges of the
pump, free from strain, as any stresses are taken up at fixed points, and
suitable compensators should therefore be installed in the pipe system.
The flanges between which the pump is installed must be absolutely
parallel.
2.7 Piping connections
CAUTION!
Before installing the pump, the entire piping must be pressure and
leakages tested and flushed clean before it is connected to the suction
and discharge side of the pump. If the pressure test takes place with the
pump installed, the testing pressure must not exceed the testing pres-
sure of the pump, which is stamped into the pump, usually in the suc-
tion flange. The pump’s gaskets or flanges for the mechanical shaft
seal might otherwise be damaged.
Check that all connections to the pump are in working order and that
the various measuring equipment has been correctly connected. Take
care that no parts obstruct easy access to the pump for inspection or
replacement of important parts.

2.8 Electrical installation
ELECTRIC POWER!
Check that there is enough cable to allow the motor to be removed
without disconnecting the wires. A switch (emergency stop) must be
installed close to the pump.
2.9 Recommended accessories

As the pump, especially the mechanical shaft sealing, is designed to run with clean
water without sludge, a suitable filter must be installed in the suction line.

3 Operation
3.1 Start-up procedures
CAUTION!
Ensure that the pump and motor are mounted according to instructions,
all connections are correct and the necessary screens and guards are in
order.
• Check the direction of rotation (marked with an arrow). The motor

must turn in the direction in which the arrow is pointing. If the
direction is wrong, the connections to the terminals of the electric
motor should be changed.
• Check that the pump can be turned by hand.
• Check that the motor has been lubricated with grease. (If applica-
ble)
• Make sure that the piping is clean and free from foreign objects.
Liquid should flow regularly into the pump.
• Check that the pump and suction pipe are filled with liquid. Any air
or gas must be carefully released before start-up.
• Check the pump for noise and vibrations immediately after starting.
At the normal head it should have a very steady motion without
unusual noise and vibrations after one minute.
• Check the seal housing for leakages.
Operation – May 6, 2014 172 985 22205 rev. 00

3.2 Starting the pump
CAUTION!
When the pump is ready, it is started with the discharge valve closed.
After starting, the discharge valve is slowly opened until the working
point is reached. If the pump runs with closed valves for a period, it
should be equipped either with temperature control equipment or recir-
culation. Running with the valves closed for a long period can damage
the pump.
3.3 Stand-by
CAUTION!
If the pump is going to be on stand-by for a long period, it must be
started or rotated at least once a week to avoid damage to the mechani-
cal seals.
3.4 Pump vibrations
CAUTION!
During operation, be aware that significant vibrations have a major
affect on the pump’s performance. If vibrations are significant the
pump should immediately be turned off to be able to locate possible
errors.
Operation – May 6, 2014 173 985 22205 rev. 00

4 Maintenance
4.1 Inspections
STOP!
Before any inspection and maintenance of the pump, the operator must
ensure that the pump cannot be unintentionally started. The pump must
be stopped, and all electronic contacts must be disconnected.
The system must be de-pressurized and the pump must be emptied of
liquid and washed. If the pump has been pumping hazardous liquids,
the liquid must be collected, and the pump should be flushed with
clean water or another suitable liquid. It is important to ensure that the
pump does not contain dangerous amounts of corrosive, toxic or simi-
lar substances when maintenance is taking place.
4.1.1 Three-month inspection

• Check suction and discharge pressure.
• Check for unusual noise, vibrations and leakages.
• Inspect the motor.
• The mechanical seal must be inspected for leaks. The seal must not leak either dur-
ing stand-by or during operation.
If any faults are found during inspection, they must immediately be corrected, since
any defects can be of major importance for the functioning of the pump and its useful
life.
4.1.2 Twelve-month inspection

Take the pump apart - See “Disassembly and assembly instructions”. The rotating parts
are checked and repaired if necessary. Normal clearance between the impeller and
Maintenance – May 6, 2014 174 985 22205 rev. 00

casing wear ring is 0,45-0,50 mm. Maximum clearance is 0,8-1,0 mm. depending on
the size and capacity. See - “Centrifugal pump wear ring clearances”
4.1.3 Lubrication
The pump type CNL is without bearings and needs no lubrication. The motor bearings
are greased in accordance with the motor instructions.
4.2 Disassembly and assembly
4.2.1 Disassembly
1. Ensure that the pump is emptied of liquid
2. Unscrew bolts connecting pump casing and cover. Lift the disconnected part of the
pump comprising motor, bracket and pump cover.
3. The impeller will follow the removed part, enabling direct access.
4. Gentle disconnection is recommended to prevent any damage on the mechanical
seal.
NOTE!
Unless pump shaft and engine shaft are assembled with a flanged cou-
pling, do not remove the pump shaft from the motor shaft unless the
pump shaft or the motor has to be replaced.
4.2.2 Assembly
• Before reassembling clean the inside of the pump casing and paint with appropriate
coating.
• In order to make disconnection of the pump easier at a later stage, lubrication of all
bolts and assembling surfaces with “Never Seez” lubricant is recommended.
• Assemble motor, coupling and pump shaft. Note! Adjustment of the shaft will take
place later.
• Assemble the motor stool item 6 with the motor.
• Pump cover item 2 with the seat ring of the mechanical seal, has to be fitted gently
on the shaft and tightened to the motor stool item 6 by screws.
• The O-ring has to be fitted to the cover
• Adjust the distance (B) between the bottom of the shaft flange and the cover.

IEC size B (mm)
CNL -/160 90-160 4
CNL -/200 90-180 4
CNL -/200 200 14
• The rotating part of the mechanical shaft seal is placed carefully on the shaft.
• The casing wear ring and the impeller have to be fitted and tightened by screws.
• The rotating assembly can be fitted to the pump casing and tightened by screws.
• Before any start-up, the shaft has to be turned by hand in order to check for any
blockages.
• The pump has to be primed in order to prevent any dry running.
4.3 Fitting instructions for mechanical seals

A mechanical seal is a very high-precision product and should be treated with the
utmost care before and during fitting. Do not unpack until ready for use. The rotating
wear ring and the seat have been lapped to a high degree of accuracy.

Mechanical seals used for CNL pumps
Type 1 Type 2
4.3.1 Fitting instructions

1. Remove the protective packaging from the seal, check for damage, and wipe clean.
2. Make sure that the pump is ready and switched off.
3. The shaft should be clean and free of burrs, and the machined place where the seat
fits must be cleaned very carefully. Edges should be rounded so that they are not
sharp or penetrating.
4. Check that the shaft diameter corresponds with the dimension of the seal within a
tolerance of 0.05 mm.
5. The bore in the housing and the seat must be lubricated. Use only liquid soap,
soapy water or glycerine with ethylene-propylene elastomer. The elastomer must
also be lubricated on the inside where it slides on the shaft. Lubricants containing
silicone must never be used.
6. Press the seat into position with your fingers. If the space is tight, use a bush when
pressing the seat into position. Take care not to damage the surface of the seat. For
example, use a piece of plastic for protection between the bush and the seat. After
pressing the seat into position, make sure that it is fully in place by measuring the
depth with a depth calliper.
7. The compressed length after fitting must correspond to the working length of the
size of seal in question given in the table of measurements.
8. Be aware of changes that can occur when bearing arrangements and gaskets etc.
are replaced.
9. Before the pump is started it must be filled with liquid and the air allowed escap-
ing. Air should be bled frequently during the period after starting.

NOTE!
When fitting shaft seals, the instructions should be read carefully,
especially when the medium is dangerous (poisonous, hot, flammable
etc.)
4.4 Centrifugal pump wear ring clearance

In connection with the inspection, the impeller 5 and wear rings 10 are measured in
order to secure that the clearance is not larger than stated in the diagram below.
CAUTION!
The pump shaft may only be dismantled, if pump shaft or bearings, in
the electric motor have to be replaced.
Wear ring Ø Clearance maximum Clearance minimum

100 mm 0.5 mm 0.15 mm
150 mm 0.6 mm 0.2 mm
200 mm 0.7 mm 0.25 mm
250 mm 0.8 mm 0.28 mm
300 mm 0.85 mm 0.3 mm
350 mm 0.9 mm 0.3 mm

If the clearance is too big, replace wear rings as follows:
1. Unscrew countersunk screws 25.

2. Pull out wear (seal) rings.
3. Fit new wear rings and tighten countersunk screws.

5 Spare Parts
5.1 Ordering
When ordering spare parts or requesting our assistance, please advise the following:
• Pump type
• Item numbers and descriptions of parts to be ordered (Check spare part drawing
and corresponding parts list with item numbers to identify the parts to be ordered)
5.2 Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world.
DO NOT hesitate to contact your Alfa Laval representative if you have any ques-
tions, problems or require spare parts.
If you do the repairs yourself, you are requested to follow the instructions regarding
assembly and disassembly or to contact our service department.
5.3 Returning parts

Before returning parts to Alfa Laval, please note that all liquids must be removed and
parts should be cleaned and neutralized.
The sender is liable for damage suffered by the pump or other goods caused by leaking
of liquid during transport.
5.4 Decommissioning
Do not dump old or used parts. Metal parts should be recycled as scrap.
When decommissioning the pump, it should be neutralized and cleaned, and any haz-
ardous liquids, should be removed and sent to a recycling facility.
None of the materials in the pump can be considered hazardous, but we urge you to act
with care and to take the steps needed when decommissioning the pump or its parts.
Spare Parts – May 6, 2014 180 985 22205 rev. 00

5.5 Type CNL - table of materials
Table of materials with the total content calculated as percentage by weight.
Material %
Pump casing See. Parts list 54
Casing cover See. Parts list 10
Base Cast iron 11,5
Shaft AISI 316 2,5
Impeller See. Parts list 7
Motor base Cast iron 10
O-ring Viton 0,2
Mechanical seal Carbon/ceramics 0,3
Casing wear ring See. Parts list 1
Accessories Stainless steel 1
Coupling Cast iron 2,5
5.6 Spare parts drawing for CNL 160 and 200 with
flanged coupling
Spare Parts – May 6, 2014 181 985 22205 rev. 00

6 Trouble Shooting
6.1 Trouble Shooting Table

The diagram below describes the most common faults which can occur during opera-
tion of the pump unit. Should additional information be required, please contact Alfa
Laval.
Pump and motor cannot be actu- • Impeller or shaft blocked.

ated: • Motor fault.
Motor running but no pumping • Motor rotation is not transmitted through cou-
effect: pling.
• Discharge valve closed.
• Non-return valve or other valves are closed.
• Suction line closed.
• Air in pump casing.
• Suction line leaking.
• Shaft seal leaking.
• Bottom valve defective.
• Suction lift too high.
• Priming pump defective.
Trouble Shooting – May 6, 2014 182 985 22205 rev. 00

Insufficient capacity: • Wrong direction of rotation.
• Number of revolutions too low.
• Counter-pressure too high.
• Suction line or impeller partly clogged.
• Air in pump casing.
• Air in pumping medium.
• Suction lift too high (inlet pressure too low).
• Cavitations.
• Suction line leaking.
• Pump worn out.

Pump pressure too high: • Number of revolutions too high.
• Impeller oversized.
• Too many pressure stages.
• Specific gravity of pumping medium too high.
• Viscosity of pumping medium too low.
• Inlet pressure too high.
• Manometer defective.
Capacity too large: • Number of revolutions too high.
• Impeller diameter too big.
• Counter-pressure too low.

Discharge head too low: • Number of revolutions too low.
• Impeller diameter too small.
• Too few pressure stages.
• Specific gravity of pumping medium too low.
• Viscosity of pumping medium to high.
• Manometer defective.

Power consumption too large: • Motor too small.
• Motor fault.
• Capacity too large.
• Counter-pressure too low.
• Stuffing-box tightened too much.
• Shaft ends out of alignment.
• Electricity supply incorrect.

Pump output decreases or stops: • Suction line leaking.
• Increasing suction lift.
• Filter clogged.
• Cavitations.
Irregular running: • Bearings defective.
• Motor fault.
Increasing noise level: • Cavitations beginning.
• Air in pumping medium.
• Capacity too large.
• Clamping to base loosened.
• Base bolts loosened.
• Influences from pipe connections or base.

Leaks: • Cracks in pump casing.
• Faulty assembly of pump.
• Pipe connections leaking.

Bearing temperature too high: • Faulty lubrication or wrong lubricant.
• Defective pump alignment.
• Influences from pipeline.
• Coupling distance wrong.
• Shaft bent.
• Foreign bodies or impurities in bearings.

Pump wears out quickly: • Wrong pump in relation to liquid.
• Cavitations.
• Stuffing-box tightened too much.
• Shaft bent.
• Defective alignment.
• Influences through pipe line.

Strong vibrations: • Impurities in pump.
• Worn or loose bearings.
• Operating the pump at a critical speed.
• Unbalanced motor or rotating components.
• Loose hold-down bolts or loose or damaged

parts.

7 Drawings and Part Lists
Drawings and Part Lists – May 6, 2014 186 985 22205 rev. 00
Drawing: 985 21657 ver. 00
Ejector pump assembly and spare parts drawing
May 6, 2014 187 985 21657.fm

May 6, 2014 188 985 21657.fm
Drawing: 985 21671 ver. 00
Ejector pump type CNL 65-65/160, Pump curve
May 6, 2014 189 985 21671.fm

May 6, 2014 190 985 21671.fm
Bill Of Material
May 6, 2014
985 21671-80 R: 00 PUMP CNL 65-65/160, 132, DIN 20090715 Page 1 of 1
Drawing no.: IMPELLER Ø154, ALBRZ, 60 HZ Ini
985 21657 DKSOPLD
1 1.000000 EA PUMP HOUSING 985 00036-26 RG 10
2 1.000000 EA PUMP COVER FOR CNL SIZE /160 985 00089-26 RG10
210811115
3 1.000000 EA BASE 984 10301-03 ISO 185/61 ; GRADE 250
4 1.000000 EA SHAFT FOR CNL SIZE /160 985 00089-28 AISI329
293520123
Document: 985 21671-80 ver. 00
5 1.000000 EA IMPELLER Ø 154, FOR CNL PUMP 985 00089-10 AL.BRZ

6 1.000000 EA MOTOR BRACKET 985 00037-63 GG-25
7 1.000000 EA GASKET FOR CHAMBER 65-65/160 985 00087-18 Viton
& 80-80/160
8 1.000000 EA MECHANICAL SEAL Ø30 SPECIAL 985 00087-14
EJECTOR PUMP /160 FOR AQUA
9 1.000000 EA WEAR RING - UPPER CNL /160 985 00087-10 Bronze
191
AQUA PUMPS
10 1.000000 EA WEAR RING - LOWER CNL /160 985 00087-11 Bronze
FOR AQUA PUMPS
Ejector pump type CNL 65-65/160, Spare Parts list
11 1.000000 EA WASHER 984 10301-16 AISI 329

16 1.000000 EA HEADLESS SCREW FOR CNL PUMP 985 00089-30
17 1.000000 EA COUPLING CNL/160, 132 985 00089-38 GG-25
293560102
22 1.000000 EA SCREW M12X30 FOR IMPELLER 985 00089-36
217572323

Bank:
BIC/SWIFT ESSEDKKK
Maskinvej 5
985 21671-80.fm
May 6, 2014 192 985 21671-80.fm
Outline drawing for motor 132M
May 6, 2014 193 985 21076 R00.fm

May 6, 2014 194 985 21076 R00.fm
Ejector pump type CNL 65-65/160, Tech. data
985 22032 Technical data CNL 65-65/160
Description
Vertical centrifugal pump with a design in accordance with DIN 24255 and ISO 2858.
Close coupled in-line top pull out version.
As a standard the discharge and suction flanges are drilled alike.
Capacity
The CNL 65-65/160 ejector pump cover a capacity range of 5-50 m3/hr with a minimum lifting
height at 38 MWC. Further details on capacity, pressure and performance can be found at the pump
curves.
Materials and weight
Pump casing Red Brass (RG10)

Impeller NiAlBrz
Shaft Stainless steel
Painting Alfa Blue c310
Weight of pump 56 kg
Connections
Fits to:
DIN DN65, PN10
ANSI 150 lbs, DN65
JIS 10k, DN65
Options
Stainless steel impeller

Manometer set to monitor inlet and outlet pressure
Class test certificate
Warning
The pump is not self-priming and need a positive back pressure.
May 6, 2014 195 985 22032.fm

May 6, 2014 196 985 22032.fm
Drawing: 985 21653 version 02
Ejector pump type CNL 65-65/160, Dim drawing
May 6, 2014 197 985 21653 v02.fm

May 6, 2014 198 985 21653 v02.fm
Installation and
Operation Manual
pH Adjustment and Re-hardening Filter
Alfa Laval 1,5 / Alfa Laval 2,5 /

Alfa Laval 5,0
– May 6, 2014 199 985 22585 Rev. 03


Maskinvej 5
DK-2860 S¯borg
Denmark
200 985 22585 Rev. 03

0.1 Description
The units in this series of re-hardening filters provide carbonate hardness for the distil-
late water generated from the fresh water generator. The series consist of three capacity
sizes as listed below. Drinking water should contain a minimum of carbonate hardness,
if it is to be used for human consumption. Besides this, the carbonate hardness is help-
ing to form a protective layer against corrosion on all wetted surfaces and within the
pipe system.
The Alfa Laval pH reactor generates a constant hardness value in the final product.
The flow capacities of these re-hardeners are accommodated to the evaporator flow
capacities and are usable within a wide flow range. The maximum flow of each hard-
ener must not exceed the following flow capacities:
201 985 22585 Rev. 03 – May 6, 2014

• Type - pH Filter Alfa Laval 1,5 1,5 m³/h
The filter tank is made of stainless steel AISI 304 (W. No. 1.4301), and has highly elec-
tro polished stainless steel surface. The reactor is supplied with pressure gauge and
safety valve. The filter is designed for 4 barg and pressure tested at 6 barg.
The filter material, gravel sand and granulated dolomite, is delivered separately, and is
to be filled into the filter tank after installation.
Water produced from any freshwater generator at the rated capacity, has a pH-value
of 5,0 to 7.0 depending on how much the distillate is cooled below it's boiling point
and how much CO2 the feed water contains. During the sub-cooling process in the con-
denser, the distillate will absorb CO2 and the pH-value will drop depending on the
amount absorbed. Normal sub-cooling of the distillate in a freshwater generator at it's
rated capacity is approx. 15 °C.
At low capacity from any given freshwater generator and with a constant cooling water
flow, the sub-cooling will be higher. This means the distillate will absorb more CO2
whereby the pH-value will drop accordingly and can in cases be as low as 4 or even
lower.
To bring the pH-value back to neutral or to drinking water quality (7 – 8.5 ) a pH-
adjustment filter needs to be installed after the freshwater generator according to the
attached flow chart diagram.
The amount of CO2 in the produced water is one of the decisive factors for how much
Dolomite is being consumed. The consumption of Dolomite will vary according to the
degree of sub-cooling of the produced fresh water and to the amount of CO2 in the feed
water.
The active pH-adjustment material (porous Dolomite) binds the aggressive CO2 con-
tained in the distillate, resulting in formation of calcium bicarbonate and will hereby
raise the pH-value to between
202 985 22585 Rev. 03 – May 6, 2014

7 and 8.5. At the same time the calcium bicarbonate acts as a mineraliser for the pro-
duced distillate..
As a guideline, 1 gram of CO2 will exchange with 1.3 gram of dolomite.

Water with a CO2 content of 6 mg/l will then consume Dolomite
according to following formula:
1.3 x 0.006 = 0.0078 gram Dolomite per produced litre water
20 m³/24h of fresh water will then consume:

0.0078 x 20,000 = 156 gram Dolomite per 24 hours.
The above is only an example and can be used as a guideline only. No exact value of
the content of CO2 can be given, as this will vary as mentioned above.
0.2 Installation - Inline

The filter tank should preferably be installed between the freshwater distiller and the
freshwater storage tank as shown is the attached flow chart diagram. See attached Pro-
cess and instrument diagram and dimensional drawing for terminal points and service
area.
203 985 22585 Rev. 03 – May 6, 2014

The filter reactor is to be installed “inline” where Valve 1 is defined as inlet, and valve
2 as outlet. Terminal points are female thread connections. Size and type is stated on
the installation drawing below.
204 985 22585 Rev. 03 – May 6, 2014

0.3 Filling procedure
Make sure that the valves are placed in closed “filling” position, as shown on below
figure.
Figure 0-1. Valve Settings “Filling”
Remove the cover of filter tank by removing the bolts. Cover the centre pipe to avoid
filter material entering into it. First pour in the quartz gravel and distribute it evenly to
a level of approx. 30 mm over top of inlet nozzles. Then pour in the re-hardening mate-
rial “H06”, and make sure that it the free area “ F” is according to table 2 below.
205 985 22585 Rev. 03 – May 6, 2014

Check position of flat gasket 11 and take care that no gravel or re-hardening material
is under or above the gasket before closing it up. Install the cover and screws and
tighten gently. Do not crush the gasket.
206 985 22585 Rev. 03 – May 6, 2014

0.4 Operation
After installation and filling of the filter, set valves to “operation” position, as shown
in the figure below.
Figure 0-2. Valve Settings “Operation”
During start up, fill up the reactor with water slowly and make sure that the air vent
valve on the top is open to release any air pockets in the vessel.
Initial flow through the filter will always contain granulate powder which will colour
the water white and therefore this water should initially be sent to the drain until it turns
clear.
In case of high pH-value after the filter the flow through the filter is to be adjusted with
the by-pass valve, hereby low pH-value water from the distiller can be mixed with high
207 985 22585 Rev. 03 – May 6, 2014

pH-value water from the filter to obtain a correct pH-value before the distillate is lead
into the storage tank. “By-pass” position of valves is shown in figure below.
Figure 0-3. Valve Settings “Bypass”
The pH-adjusting material (H06) is used up in proportion to the alkalinity of the water
and should be refilled in proportion to the consumption. It is therefore necessary to
check the pH-value regularly or at least once a week. To check the pH value of the
water set the valves in “drain” position.
Figure 0-4. Valve Settings “Drain”
0.5 Back flushing

Back flushing is not necessary for this filter as the flow is always upward and thereby
will remove any excess material.
208 985 22585 Rev. 03 – May 6, 2014

0.6 Safety
For safety reasons, a safety valve is installed on the top of the tank together with a
manual air release valve (normally closed).
The safety valve will open at a pre-set value of 4.0 barg.
209 985 22585 Rev. 03 – May 6, 2014

210 985 22585 Rev. 03 – May 6, 2014
Drawing: 985 22580 R03
Dim drw: pH adjustment filter: Type URF 325/25 1,5 m³/hr
6 5 4 3 2 1
A-A ( 1 : 5 )
D D
225
60
4xØ18
60
225
P325
1114
1066±5
1060±5
C C
689
INLET OUTLET
G 3/4" G 3/4"
280
A
155±5
155±5
A
may constitute a contractual
Only to the extent expressly
agreed by us this document
41±5 224±5
B B
P4
00
100±5
2
03 DIMENSIONS ADDED FOR IN & OUTLETS 30-05-2012 AHNA PLD NSR

3
02 OUTLET TEXT CORRECTED 18-02-2011 DKSONSR DKSOPHNA DKSOANHA

This document and its contents are our exclusive
99±5 34±5
transmitted or communicated to any other party
Rev
property and must not be copied, reproduced,

No
Title
pH ADJ. & REHARDENING FILTER
A A
EMPTY
WEIGHT (Kg)
OPERATING
TYPE: ALFA LAVAL pH 1,5
32 97
URF
= CENTER OF GRAVITY
ISO A3
Scale
09-08-2010 DKSONSR
Sheet
1 985 22580 03
6 5 4 3 2 1
May 6, 2014 211 985 22580 R03.fm

May 6, 2014 212 985 22580 R03.fm
Drawing: 985 22639 R02
General description - Rehardening filter Type URF
Application
The re-hardening filters provide carbonate hardness for the distillate water generated from the fresh
water generator. Drinking water should contain a minimum of carbonate hardness, if it is to be
used for human consumption. Besides this, the carbonate hardness is helping to form a protective
layer against corrosion on all wetted surfaces and within the pipe system.
Capacity
The flow capacities of these hardeners are accommodated to the evaporator flow capacities and
are usable within a wide flow range. The maximum flow of each hardener must not exceed the
following flow capacities:
pH Filter ALFA LAVAL 1,5 1,5 m3/h

pH Filter ALFA LAVAL 2,5 2,5 m3/h
pH Filter ALFA LAVAL 5,0 5,0 m³/h
Working principle
Water produced from any freshwater generator, at it's rated capacity, reaches a pH-value
of 5 to 7.0 depending of how much the distillate is cooled below it's boiling point and how
much CO2 the feed water contain. During sub-cooling, in the condenser, the distillate will absorb CO2
and the pH-value depend of the amount absorbed. The distillate pH-value is brought back to neutral or
to drinking water quality (7 – 8.5 ) after flowing through a pH-adjustment filter.
The active pH-adjustment materials (Granulated Dolomite) bind the aggressive carbon dioxide
contained in the distillate, resulting in formation of calcium bicarbonate and hereby rise the pH-
value to between 7 and 8.5, at the same time the calcium bicarbonate act as a mineraliser for the
produced distillate.
985 22639-R01
May 6, 2014 213 985 22639 R02.fm

The distillate is lead via the intake nozzles, through the dolomite material where the pH adjustment
and rehardening process takes place. The treated water is gathered in the central pipe and lead back
out.
Basic equipment
Filter Tank AISI 304

Pressure Gauge w/ Ball vavle Brass
3-Way Ball Valve ASTM A351-CF8M (AISI 316)
Ball Valve ASTM A351-CF8M (AISI 316)
Pressure Relief Valve CW617N (Brass)
Filter nozzle with gland Polypropylen
985 22639-R01
May 6, 2014 214 985 22639 R02.fm

Drawing: 985 22583 R00
pH adjustment filters - flow chart
May 6, 2014 215 985 22583 R00.fm

May 6, 2014 216 985 22583 R00.fm
Document: 985 23835 R00
pH adjustment filters - PID
May 6, 2014 217 985 23835 R00.fm

May 6, 2014 218 985 23835 R00.fm
Drawing: 985 22586 R00
pH adjustment filters - equipment specification list
DocumentNo.98522586
EquipmentSpecificationpHAdjustmentandRehardeningFilter
Tag No. Description Article No. Connection
PI-WT-01 Pressure Gauge w/ Ball vavle 985 22586-10 1/4" BSP
VA-WT-01 3-Way Ball Valve 985 22586-11 3/4" BSP

VA-WT-04 Ball Valve 985 22586-12 1/4" BSP
VA-WT-05 Pressure Relief Valve 985 22586-13 1/2" BSP
TA-WT-01 Filter Tank URF325-25 985 22586-14

FO-WT-01/06 Filter nozzle with gland 985 22586-17
Recommended qty.
Spare Parts pH Filter ALFA LAVAL 1,5
1 year 2 years 5 years
FF-WT-01 Granulated Rehardening Material 985 22586-30 1 3 9
- Supporting Gravel Sand 985 22586-31 0 0 1
- Flat Cover Gasket 985 22586-32 1 2 5
Recommended qty.
Recommended q y
qty.
0
May 6, 2014 219 985 22586 R00.fm

May 6, 2014 220 985 22586 R00.fm
AOT UV Sterilizer - Alfa Laval AOT 3F
Installation- and Operation manual
– May 6, 2014 Document number:

221 30-03-0035, Ver. 1.6 985 22987 rev 01

Maskinvej 5
DK-2860 S¯borg
Denmark
222 Revision number

1 Declaration of Conformity 3
2 Alfa Laval AOT 3F General 5

2.1 General safety rules page 5
2.2 Warranty page 6
2.3 Manufacturer page 6
2.4 Service and support page 6
2.5 Validation page 7
2.6 Disposal page 7
2.7.1 Functional description page 7
3 Installation 10
3.1 Before installation page 10
3.2 Unpacking page 11
3.3 Mechanical installation - mounting the Alfa Laval AOT 3F page 11
3.3.2 Installation example page 12
3.4 Electrical installation - connection instructions page 13
3.4.1 Connections page 13
3.4.2 Mains cable page 13
3.4.3 Ferrite page 13
4 Operation 15
4.1 Important instructions page 15
4.2 Start the Alfa Laval AOT 3F page 16
4.2.1 Check page 16
4.2.2 Starting up page 16
4.3 Alarm function page 17
4.3.1 LPS alarm function details page 17
4.3.2 Fault finding - LPS page 18
4.3.3 UV-monitor alarm function details page 18
4.3.4 Sensitivity adjustment page 19
4.3.5 Fault finding - UV Monitor page 19
5 Service & Maintenance 20

5.1 Before service page 20
5.2 Periodic maintenance and recording of actions page 20
5.3 Quartz sleeve cleaning page 21
5.3.1 Cleaning interval page 21
5.3.3 Cleaning, step by step page 22

5.4 Lamp replacement page 23
5.4.2 Replacing a lamp, step by step page 23
6 Spare parts 24
6.1 Spare parts list page 24
7 Specifications 25
7.1 Technical specifications page 25
7.2 Dimensions & weight page 25
8 Appendix 26
Dimensional and Installation Drawing - AOT page 27
Assembly and Spare Parts Drawing - AOT page 29
AOT 3F Reactor Part page 31
985 22987 AOT 3F page 33
Terminal Block Information AOT 3F page 35
Main Electrical Comp. AOT 3F - Electrical Cabinet page 37
985 22764 - Electrical Cabinet Parts list page 39
1 Maintenance record 41
1.1 Maintenance record (template) page 41

1 Declaration of Conformity
This appliance is not intended for use by children or persons with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given supervisory or instruction concerning use of the appliance by a
person responsible for their safety. Children shall be supervised to ensure they do not play with the appliance.
Declaration of Conformity 225 985 22187 rev 01 – May 6, 2014

Declaration of Conformity 226 985 22187 rev 01 – May 6, 2014
Drawing: 985 22760 R01
General description, Ultraviolet Sterilizer Alfa Laval AOT 3F
Application
Oxidize and breaking down microorganisms or other organic substances in potable water. This
process is done by the hydroxyl radicals, created in the sterilizer by the UV light. This secure
clean potable water without any chemical or biological pollutants.
Capacity and general specifications

The flow capacities of the AOT 3F Sterilizer is accommodated to the evaporator flow capacities
and are usable within a flow range. The maximum flow of the AOT 3F sterilizer must not exceed
the stated flow capacity.
Technical Data Alfa Laval AOT 3 F

Flow Capacity [m3/h] 3
Maximum Operational Pressure [barg] 10
Maximum Ambient Temperature [oC] 50
Maximum Media Temperature [oC] 60
In- and Outlet Thread Connection [G] 1”
Weight Dry [kg] 10
Material Body Titanium Grade 2
Power Consumption [W] 42 (52)
Power Supply [VAC]/[HZ] 220-240 / 50 or 60 HZ
Protection Class IP 65
Maximum Pressure Drop [bar] 0,2
Working principle
Water flows through the purifier consisting of a light source and a catalytic surface. When the
catalytic surface is exposed to light, free radicals are formed which break down contaminants in the
water. This process occurs only inside the purifier and leaves no harmful residuals behind.
1) A radical formed from a water molecule hits the cell wall of a microorganism in the water.
2) The radical steals a hydrogen atom from the cell wall. Multiple radicals repeat the same process
resulting in the microorganism breaking down.
3) The radical reverts to a water molecule
985 22760-R00
May 6, 2014 227 985 22760 R01.fm

Alfa Laval AOT makes it possible to decompose:
Bacteria such as: Virus such as: Protozoa such as: Fungus such Inorganic substances
as: such as:
Legionella Tobacco Candida
Chryptosporidium Bound chlorine
pneumophila Mosaic Virus Albicans
Tomato Bushy Aspergillus Pharmaceutical
even in amoebas Ghiardia
Stunt Virus fumigatus residues
E. coli Poliovirus Odour
Basic equipment
Description Material
Reactor Pipe Titanium Grade 2
Electrical Panel Painted Carbon Steel (RAL 7035)
Lamp Top Brass
UV Lamp Glass and Ceramic socket
Mounting Plate AISI 316
Solenoid Valve Brass (Body)
Water Quality Requirements
Recommended water specification

Particle size < 50 µm
Suspended solids < 10 mg/l
Turbidity 5 NTU
Transmittance (254 nm) > 80 %
Color None
pH 6,5 – 9,5
Hardness < 12 dH
Iron < 0,5 ppm
Manganese < 0,5 ppm
985 22760-R00
May 6, 2014 228 985 22760 R01.fm

Drawing: 985 22758 R00
Process and Instrument Diagram AoT
May 6, 2014 229 985 22758 R00.fm

May 6, 2014 230 985 22758 R00.fm
Drawing: 985 22757 R00
Flow Chart - Ultraviolet Sterilizer, AlfaLaval AOT 3F
May 6, 2014 231 985 22757 R00.fm

May 6, 2014 232 985 22757 R00.fm
Drawing: 985 22759 R00
Equipment Specification UV Sterilizer AOT 3F
TAG Description Article No. Remarks

Alfa Laval AOT 3F, Complete unit 50 Hz 985 22763-80
Alfa Laval AOT 3F, Complete unit 60 Hz 985 22763-81
Reactor, Ti, 1" 985 22763-01 1" MALE BSP
Quartz Sleeve Holder, Brass 985 22763-02
O-ring, 21x3.0 (3 Pcs.) 985 22763-03
O-ring, IP, 34.65x1.78 985 22763-04
Lamp Cover, Brass 985 22763-05
Lamp Cover Nut, Brass 985 22763-06
Socket, Ceramic 985 22763-07
Quartz Sleeve 985 22763-08
UL 801 UVC Lamp (42W) 985 22763-09
Straight Connector 985 22763-10
Receptacle Connector 985 22763-11
Lamp Cable 985 22763-12
Connector Shield 985 22763-13
QE 801 /QT 801 UV Sensor Assembly incl. Cable 985 22763-14
O-ring, Sensor/Sight pin, 13x1.0 985 22763-15
VA-WT-06 Magnetic Valve 985 22763-16 1" FEMALE BSP
Magnetic Valve Coil, 220-230V, 50/60Hz 985 22763-17
Spare Parts and Spart Part Kits for AOT 3F

Name Description Article No. Remarks
Lamp & quartz sleeve kit 1 UVC-lamp (42W), 1 quartz sleeve incl o-rings 985 22763-20
Lamp 1 UVC-lamp (42W) 985 22763-09
Quartz sleeve kit 1 quartz sleeve incl o-rings 985 22763-30
O-ring kit O-ring, 21x3.0 (3 Pcs.) 985 22763-03
UV sensor kit 1 UV sensor incl cable and o-ring 985 22763-50
LPS 42W 1 Lamp Power Supply (40-60W) 985 22763-60
Contact Socket 1 ceramic contact socket with mounted crimp sockets 985 22763-70
Service kit 1 protective glove, 10 clothes, 1 bottle of cleaning solution 985 22763-90
Spare Parts Operation Packages for AOT 3F
Name Description Article No. Remarks

1 Year Spare parts for 1 year of operation 985 22946-10
2 Year Spare
p parts
p for 2 years
y of operation
p 985 22946-20
5 year Spare parts for 5 years of operation 985 22946-50
Spare Parts Operation Packages for AOT 3F

Qty. Description Article No. Remarks
1 Year Spare parts for 1 year of operation 985 22946-10
1 LAMP & QUARTZ SLEEVEL KIT 985 22763-20
2 Year Spare parts for 2 years of operation 985 22946-20

1 3 PCS. O-RING KIT 21X3 985 22763-03
1 COIL F SOLENOID VALVE 220/230V 985 22763-17
1 SOCKET IN CERAMIC 985 22763-07
5 year Spare parts for 5 years of operation 985 22946-50

1 3 PCS. O-RING KIT 21X3 985 22763-03
1 COIL F SOLENOID VALVE 220/230V 985 22763-17
1 UV SENSOR ASSEMBLY INC. CALBLE 985 22763-14
1 UVC LAMP 985 22763-09
1 LAMP POWER SUPPLY 42W 985 22763-60
1 CONTACT SOCKET 985 22763-70
May 6, 2014 233 985 22759 R00.fm

May 6, 2014 234 985 22759 R00.fm
2 Alfa Laval AOT 3F General
2.1 General safety rules
NOTE!
Please read this manual carefully prior to installation and operating of
the unit.
Save these instructions for future use
• UV-radiation can instantly harm eyes and skin, never look into a burning lamp!
Always use necessary protective equipment (such as protective glasses and gloves)
when working with the UV-lamps.
• The Alfa Laval AOT 3F shall be mounted on a rigid and solid wall or stand.
• Do not operate the Alfa Laval AOT 3F in explosive atmospheres.
• Never use the cords for carrying or pulling the Alfa Laval AOT 3F.
• UV-lamps, quartz sleeves and UV-sensor are fragile components, please take care
when handling these components.
• Never touch the quartz sleeve or lamp with bare hands, always use clean gloves.
• During work with the lamp, make sure the unit is switch off.
• The installation of the unit should only be made by authorized personnel.
• Make sure the installation conditions meets the technical specification described in
this manual (flow rate, working pressure, quality of the water and electrical input).
• Never operate the Alfa Laval AOT 3F without water in the system, except than for
short control sessions (max. 5 minutes)!
• Do not operate the unit when empty. If the water system is shut down for a longer
period of time (due to maintenance or similar), the Alfa Laval AOT 3F must be
switched off to avoid overheating of the system.
Alfa Laval AOT 3F General 235 985 22146 rev 05 – May 6, 2014
2.2 Warranty
We warrant that this product will be free from defects in material and workmanship for
a period of one year from the date of shipment thereof. Within the warranty period we
shall repair or replace such products and component parts which are returned to us with
shipping charges prepaid and which are determined by us to be defective. This war-
ranty will not apply to any product or component part which has been subjected to mis-
use, negligence or accident; or misapplied; or modified or repaired by un-authorised
persons or improperly installed not according to specification given in this manual. Nor
will this warranty apply to UV lamps or quartz sleeves.
Consumable products (UV lamps, quartz sleeves, UV sensor) have a warranty period
of 3 months from delivery date.
Buyer shall inspect the product promptly after receipt and shall notify us at our main
office in writing of claims, including claims of breach or warranty, within thirty days
after the buyer discovers or should have discovered the facts upon which the claim is
based. Failure of the buyer to give written notice of a claim within the time period shall
be deemed to be a waiver of such claim.
2.3 Manufacturer
Wallenius Water AB
Warfvingesväg 32
SE-112 51 Stockholm
SWEDEN
2.4 Service and support

For any support and service enquiries, please contact Alfa Laval:
www.alfalaval.com
Please provide article number and serial number. This information can be found on the
unit.
2.5 Validation
This installation- and operation manual applies to the Alfa Laval AOT 3F.
2.6 Disposal
Always consult local rules and regulations for detailed
handling of each material:
• Used UV lamps can be handled and disposed of in the same way as fluorescent
lamps.
• Used quartz sleeves can be disposed of in the same way as ordinary glass.
2.7 Introduction
AOT UV sterilizer for disinfection of drinking water
Wallenius AOT is an award-winning water purification technology that imitates
nature's own way of purifying water. Wallenius AOT acts as a microbiological barrier
against harmful water-borne microorganisms such as Legionella. The technology is
based on a sustainable and natural solution that efficiently purifies everything from
drinking water to our world's oceans.
The AOT UV sterilizer has been developed specially to decrease highly evasive Legi-
onella bacteria in water systems. The technology is based on Wallenius AOT, a chem-
ical-free technology, which utilises the ability of light, together with photocatalytic
semiconductor surfaces, to produce free radicals, like nature does. In this process the
hydroxyl radical changes back to water before leaving the AOT without creating any
harmful residues.
The products have been tested at the Vitens laboratories in the Netherlands. It meets
the strict new BRL K14010-1/01 guidelines issued by Dutch quality assurance agency
KIWA. The Vitens laboratories' tests prove that the powerful free radicals created by
the AOT UV sterilizer is even effective against Legionella bacteria which live inside
amoebas.
2.7.1 Functional description
The water to be treated enters the unit through the horisontal positioned inlet into the
reactor chamber. In the reactor, the water flows around the axially centered positioned
UVC-lamp.
The AOT UV sterilizer has a safety valve mounted on the outlet to prevent any
untreated water to pass if an alarm is triggered. An alarm is triggered if the UV inten-
sity drops or quartz sleeve fouling. In case of a triggered alarm, the safety valve closes
within one second.
Numbering below is referred to on different places in the manual.
A1. Reactor (titanium)

A2. Quartz sleeve holder (incl. quartz sleeve and o-rings)
A3. Lamp top (incl. UV lamp, ceramic socket, nut and receptacle connector)
A4. Electrical cabinet
(product label with serial number inside) A5. UV-monitor
A6. UV-sensor
A7. Safety valve
A8. Elapsed time counter
A9. Lamp cable connector
A10. ON/OFF switch with LED
A11. Mounting plate
3 Installation
The installation process for the Alfa Laval AOT 3F are divided into these steps:
• Before installation
• Unpacking
• Mechanical installation
• Electrical installation
Below these steps are described step by step.
3.1 Before installation
WARNING!
The installation of the Alfa Laval AOT 3F shall be made by engineers
and electricians certified for this type of work.
UVC lamps and quartz sleeves are easily damaged - handle with care
during installation and service.
Never operate the Alfa Laval AOT 3F without water in the system,
except than for short control sessions (max. 5 min.)!
• Make sure the general safety rules are applied.
• Make sure the application demands is within the technical specifications of the
unit, see related chapter.
• A free space of at least 500 mm above of the Alfa Laval AOT 3F must be kept.
This space is required for service and maintenance of the unit.
• The system in which the Alfa Laval AOT 3F shall be installed should be thor-
oughly decontaminated before the installation is done.
• The Alfa Laval AOT 3F shall only be connected to non-corrosive materials, in

order to avoid galvanic corrosion.
• A particle filter of at least 50 m shall be installed before the Alfa Laval AOT 3F.
The particle filter shall be installed between the pump and the Alfa Laval AOT 3F.

• An inlet valve (pressure relief valve) shall be installed before the Alfa Laval AOT
3F and adjusted to the maximum certified pressure of the unit. An outlet valve
shall be installed after the Alfa Laval AOT 3F. These valves are required to be able
to control the flow through the unit and stop the water flow for service and mainte-
nance activities. Please see illustration on page 242
• Tip: In some cases it can also be useful to have a bypass system for the water, to
use during maintenance of the Alfa Laval AOT 3F.
3.2 Unpacking
• The Alfa Laval AOT 3F is delivered completely assembled (see page 239), ready
to be used when mounted on a wall or stand. In any case, check that the following
items are part of your delivery and check that none of the parts are damaged (tick
off each item below):
 Installations and service manual (this manual)
 One AOT titanium reactor mounted on the mounting plate
 One Electrical Cabinet (control box) mounted on the mounting plate incl. lamp
cable, straight lamp connector, safety valve cable and UV-sensor with cable.
 Following components mounted onto the reactor:
1. UV sensor
2. One magnetic valve and coil
3. One UVC-lamp
4. One quartz sleeve and holder assembled (incl. o-rings)
 Components strapped onto the electrical mains cap screw:
1. One key to the control panel cabinet
2. One ferrite (for the mains)
If any part of the delivery is missing or damaged - contact your retailer
3.3 Mechanical installation - mounting the Alfa Laval

AOT 3F
3.3.1 Tools and materials

All threaded connections (inlet and outlet of Alfa Laval AOT 3F) should be sealed with
PTFE (teflon) tape or other drinking water approved sealant (not included in delivery)

In addition to equipment for pipe connection (wrenches/spanner, etc.) appropriate
screws are required to fixate the Alfa Laval AOT 3F mounting panel to a wall
or stand. See position of the holes in picture below. The holes are dimensioned for M10
size, preferably of the type self-locking nuts and bolts (not included in delivery).
3.3.2 Installation example

• The Alfa Laval AOT 3F can only be installed with the reactor in vertical position
with the lamp top in upper position, see picture below.
• Install valves before and after the Alfa Laval AOT 3F unit to shut down the water
flow during service and maintenance.
• The piping must be supported to a wall or stand in order to avoid stresses on the
Alfa Laval AOT 3F reactor.
• Install a particle filter of at least 50 m between the pump and the inlet valve.

NOTE!
At delivery, all mechanical components within the unit are mounted
3.4 Electrical installation - connection instructions
NOTE!
The electrical installation of the AOT UV Sterilizer shall only be made
by authorized electricians.
3.4.1 Connections
At delivery, the control panel key and a ferrite is temporarily strapped to the mains cap
screw.
3.4.2 Mains cable

Connect the control panel to 220-240 V and 60 Hz with a shielded cable (not included
in delivery). The cap screw (bottom of the control panel) fits mains cable with diame-
ters between 7-12 mm. Correct shielding is done by securing the shield to the cap
screw.
3.4.3 Ferrite
The ferrite (ferrite core) is used to reduce interference acting as a frequency filter. It is
required to mount the ferrite on the mains cable inside the control panel in advance of
terminal connections.

.
More information can be found in the Electrical diagram and Description drawing in
the appendix

4 Operation
WARNING!
• Risk of exposure to UVC rays
• UVC rays are harmful to the eyes and the skin
• Disconnect power before service and use an earth fault breaker
WARNING!
• The unit work with electrical power
• Electrical power can cause electrical chocks
4.1 Important instructions
• Never operate the Alfa Laval AOT 3F without water in it, except than for short
control sessions (max. 5 minutes)!
• If the water system should not be used for a longer period of time due to mainte-
nance of the system or in buildings with shut down periods, the Alfa Laval AOT
3F unit must be switched off in order not to heat up the water.
• On the front of the control panel cabinet is an Elapsed Time Indicator (A8). It
shows the number of hours that the Alfa Laval AOT 3F unit has been in operation.
• After 1 year at continuous operation (approx. 9000 hours) the lamp shall be
replaced.
NOTE!
Switching the unit ON/OFF more than one time per day could reduce
the life time of the lamp or damage the lamp power supply.
• If the Alfa Laval AOT 3F, tanks or other equipment are left unused for long peri-
ods of time (i.e. weeks), sanitation of the entire system might be required.
Operation 245 985 22146 rev 05 – May 6, 2014

• Please note; the AOT unit can't be used as a stand-alone sanitation system. Before
installation, the system in which the Alfa Laval AOT 3F shall be operating must be
thoroughly decontaminated.
• In order to check if the lamp of the Alfa Laval AOT 3F is working, perform a
visual check of the UV monitor (A5). If the green diode is lit (UV monitor), the
lamp is working properly.
• The water in the Alfa Laval AOT 3F must not freeze. Always drain the Alfa Laval
AOT 3F before storage, transportation or when it is not in use.
• The lamp power supplies used in Alfa Laval AOT 3F are specifically validated to
operate with the respective UV-lamps provided with the unit. Using non-original
components can damage the unit and surrounding equipment. Any attempt to
change or modify existing equipment with non-original components invalidates the
totality of the installation.
4.2 Start the Alfa Laval AOT 3F
4.2.1 Check
The first time you start up the Alfa Laval AOT 3F, be extra attentive to any water leak-
age.
For example, check these areas:
• All sealings (inlet, outlet)
• The sealing between the quartz sleeve holder and the Alfa Laval AOT 3F reactor
• The sealing between the sensor and the Alfa Laval AOT 3F reactor.
4.2.2 Starting up
In order to start up the Alfa Laval AOT 3F, follow these steps:
1. Fill up the Alfa Laval AOT 3F with water by opening the inlet and outlet valves.
2. Turn on the power to the Alfa Laval AOT 3F by turning the ON/ OFF switch on
the control panel.
3. Adjust the sensitivity of the UV-measuring by turning the multi potentiometer at

the back of the UV-monitor until the green LED is lit (see description Alarm func-
tion, part 2, page 248).
When the power is on and the Alfa Laval AOT 3F is running, the ON/OFF switch will
shine with a blue light, and the UV monitor on the control panel will indicate the start

up phase with flashing diodes (red, yellow and green) during a couple of seconds.
When the green diode only is lit, the Alfa Laval AOT 3F is ready to operate.
4.3 Alarm function
4.3.1 LPS alarm function details

Onto the lamp power supply (LPS) there are two status LED:s; red and green. The
LED:s follow the fault relay:
• Green LED: UV-lamp is active and lit (relay opened on terminal 4a-5, relay active
- no fault operation).
• Red LED: UV-lamp is not lit (relay closed on terminal 4a-5, relay deactivated -
fault operation).

4.3.2 Fault finding - LPS
• Red LED is on (fault relay tripped), UV-lamp is not on:
1.0 Defective lamp or lamp cable
2.0 Defective LPS
• Green LED is on, UV-lamp is not on:
3.0 Defective LPS
4.0 Wrong wiring (crossed), please switch off immedi ately (this can happen dur-
ing installation). Please check the wiring.
• No LED , no UV-lamp:
5.0 No mains power
6.0 Defective LPS
7.0 Red LED is defective.
4.3.3 UV-monitor alarm function details

The UV-monitor displays the function of the UV-lamp using the relative UV output
from the UV-sensor. The following functions are displayed by the three LED's:
• Green LED: Function and UV output OK.
• Yellow LED: Pre-alarm. UV-lamp is active and lit, UV output is close to alarm
limit. Prepare for lamp replacement.
• Red LED: Main alarm. UV output is too low. The magnetic valve will automati-
cally close to prevent any un-purified water to pass the unit.
The LED function is connected to the connection block, prepared for external alarm
connection, see Terminal table in Appendix.

4.3.4 Sensitivity adjustment
When a new lamp is installed or the first time the unit is used, the sensitivity must be
adjusted using the multi turn potentiometer on the back of the UV-monitor. The correct
level of sensitivity is reached when the green LED beside the potentiometer is lit. A
small screw driver is required to turn the potentiometer.
4.3.5 Fault finding - UV Monitor

• Green LED (beside the adjustment screw) is lit all the time, irrespective of number
of turns or direction (to the end stop): Possible faults:
1. Defective UV monitor
2. Defective UV sensor
Follow these steps in order to find out what the problem might be:
1. Switch off the lamp
2. If green LED still is lit - disconnect the UV sensor from the connection terminal
(UV monitor connections, see Appendix):
3.0 Green LED (front LED)  Defective UV monitor
4.0 Red LED (front LED)  Defective UV sensor
3. If red LED (front LED) is lit - switch ON the lamp (after a few minutes of cool
down period) and observe the three front LED´s:
3.1 Correct function: Red LED  Yellow LED Green LED
3.2 Incorrect function (defective UV monitor): Green LED is lit within less than 1-
2 seconds, yellow LED stays off during lamp start-up time.

5 Service & Maintenance
NOTE!
Wallenius Water only guarantees correct function of the unit with orig-
inal or specified components.
NOTE!
Installation and service are only allowed by authorised personnel.
5.1 Before service

The following steps must be performed before any service take place:
• Shut off the power to the Alfa Laval AOT 3F:
1.0 Turn off the unit with the control panels ON/OFF switch (A10).
2.0 Disconnect the unit from the power line (control cabinet), by removing the
lamp cable connector (A9) from the lamp top (A3).
• Turn off the water supply to the equipment by closing the inlet and outlet valves.
5.2 Periodic maintenance and recording of actions

Set up a periodic maintenance schedule and keep records of all inspections, mainte-
nance, service actions and if there are any problems. A template for a maintenance
record (example) can be found at the end of this manual.
Service & Maintenance 250 985 22146 rev 05 – May 6, 2014

5.3 Quartz sleeve cleaning
NOTE!
Lamps and quartz sleeves are very fragile. Be careful when handling
these parts.
Do not touch the lamp or quartz sleeve with your fingers, because fin-
gerprints may impair the intensity of the light. Wear protective gloves
during all steps involving lamp, quartz sleeve and other connected
parts.
For the Alfa Laval AOT 3F to work properly, the quartz sleeve must be cleaned in reg-
ular intervals, as established in a maintenance record. If the quartz sleeve is not cleaned
regularly iron, calcium and magnesium (which are always present in the water in vary-
ing concentrations) may form a brownish scaling on the outside of the sleeve. This will
reduce the UVC irradiation of the water and impair the function of the Alfa Laval AOT
3F.
5.3.1 Cleaning interval

The cleaning interval of the quartz sleeve depends on the quality of the water and must
be established individually for each installation.
General instructions:
In order to establish a proper cleaning interval, start with a short interval like one week.
Then, if the sleeve is still clean, increase the interval gradually until a level of sufficient
cleaning is reached. Document this cleaning interval in the maintenance record.

The following equipment is needed for cleaning of the quartz sleeve:
• Protective gloves
• Cloth
• Cleaning solution, a weak acid solution (for example: citric acid)

5.3.3 Cleaning, step by step
1. Shut off the power to the Alfa Laval AOT 3F by turning off the unit with the con-
trol panels ON/OFF switch (A10).
2. Disconnect the unit from the power line, by removing the lamp connector plug
(A9) (a) from the lamp top (A3).
3. Turn off the water to the equipment.
4. Quartz sleeve holder (A2): Unscrew the quartz sleeve holder from the reactor
(A1). Gently lift the quartz sleeve and holder assembly from the reactor straight up
until the full length of the quartz sleeve is outside the reactor. Do not touch the
quartz sleeve with bare hands.
5. Hold the lamp and quartz sleeve on the side of the unit, to ensure that no cleaning
solution drips into the unit. Apply a weak acid solution (for example citric acid) on
to a cloth and carefully wipe the quartz sleeve clean.
6. Check the o-ring on outside of the quartz sleeve and replace it if necessary.
7. Reassemble the unit by following the steps above in reverse order.
8. Take care not to turn the quartz sleeve holder to tight into to the reactor, too much
force can cause the quartz sleeve to break. Allow 1 to 1.5 mm distance between
bottom of the quartz sleeve and the reactor.
NOTE!
No tools are necessary!
NOTE!
Make a note in the maintenance record or service log that the quartz
sleeve was cleaned.

5.4 Lamp replacement
NOTE!
Lamps and quartz sleeves are very fragile. Be careful when handling
these parts. Do not touch the lamp or quartz sleeve with your fingers,
because fingerprints may impair the intensity of the light.
Wear the protective gloves during all steps involving lamp, quartz
sleeve and other connected parts.
The lamp of the Alfa Laval AOT 3F must be replaced after an operating time of max-
imum 9000 hours (approx. 1 year). The exact operating life time depends on operating
conditions and number of ON/OFF switches, see The Elapsed Time Indicator on the
front of the control panel will show you the number of hours that the unit has been in
use. Note, the number of hours the lamp has been in use, must be recorded

The following equipment is needed:
• Protective gloves
5.4.2 Replacing a lamp, step by step

1. Shut off the power to the Alfa Laval AOT 3F by turning off the unit with the con-
trol panels ON/OFF switch (A10).
2. Disconnect the unit from the power line, by removing the lamp connector plug
(A9) (a) from the lamp top (A3).
3. Turn off the water supply to the equipment.
4. Disconnect the lamp top from the quartz sleeve holder by unscrewing the nut (b).
5. Carefully pull out the lamp (c) from the holder (A2) using the lamp top (the lamp
base is connected to the socket). Take care not to touch the lamp with bare hands,
the lamp glass and lamp base could be hot.
6. Disconnect the lamp base from the socket and remove the lamp (d). Recycle the parts.
7. To mount a new lamp, follow the instructions in reverse order.
NOTE!
No tools are necessary!
8. Follow the Starting Up routine in chapter Start the Alfa Laval AOT 3F.
6 Spare parts
6.1 Spare parts list

All spare part orders must include the following information:
• the purifiers serial number
• the article number of the spare part
• the spare part designation (name)
• ordered quantity
The spare parts below refers to Drawing No 985 22763-80 "Spare Parts Drawing" in
Appendix.
Designation Includes Art No

Lamp & quartz 1 UVC-lamp (42W), 1 quartz sleeve incl. o-rings 985 22763-20
sleeve kit
Lamp 1 UVC-lamp (42W) 985 22763-09
Quartz sleeve kit 1 quartz sleeve incl. o-rings 985 22763-30
O-ring kit 3 o-rings (21x3,0) 985 22763-03
UV sensor kit 1 UV sensor incl. cable and o-ring 985 22763-50
LPS 42W 1 Lamp Power Supply (40-60W) 985 22763-60
Contact Socket 1 ceramic contact socket with mounted crimp sockets 985 22763-70
Service kit 1 protective glove, 10 clothes, 1 bottle of cleaning solution 985 22763-90
Coil 1 magnetic coil, 230V, 50/60 Hz 985 22763-17
Spare parts 254 985 22146 rev 05 – May 6, 2014

7 Specifications
7.1 Technical specifications
Total lamp power consumption: 42 W

Power supply: 220-240 VAC, 50 or 60 Hz
110 VAC, 60 Hz (Design TBD)
Flow rate: Max. 3 m³/ha
Pressure drop: < 0.2 bar
Operating pressure: PN 10
Ambient temperature: 4-50°C
Water temperature: 6-60°C
IP class: 67 (reactor)
65 (electrical cabinet)
Material (Reactor): Titanium, grade 2
Material (Lamp top): Brass, SS 5170
Material (Electrical Cabinet): Steel plate
Material (Mounting panel): Stainless steel, SS 2348/316L/1.4404
Colour (Reactor): Semi-shiny grey finish (polished)
Colour (Electrical Cabinet): RAL 7035
a. Note that actual water flow depends on the water quality, required decontamination and other for the instal-
lation specific conditions. Contact Alfa Laval to get advice on what is required for your installation, see con-
tact information on page 236
7.2 Dimensions & weight
Alfa Laval AOT 3F

Width: 413 mm
Depth: 165 mm
Height: 607 mm
Total weight (dry/wet): 10 / 10.5 kg
Connections - water (Inlet): G 1" (male)
Connections - water (Outlet): G 1" (female)
See also drawing in appendix.
Specifications 255 985 22146 rev 05 – May 6, 2014

8 Appendix
Appendix 256 985 22146 rev 05 – May 6, 2014

6 5 4 3 2 1
FOR SERVICE AND MAINTENANCE A

OF LAMP AND QUARTZ SLEEVE
D D
165
A
May 6, 2014
20 360
380
MIN. 500mm
Drawing: 985 22763 R00
20
4 x P10,2
C C
INLET
607
Dimensional and Installation Drawing - AOT
400
360
257
B B
TOTAL MASS (DRY): 10 kg
TOTAL MASS (WET): 10.5 kg
AREA FOR SERVICE AND MAINTENANCE OF
THE UNIT: MIN. 500mm (ABOVE)
OUTLET
413 00 INITIAL DRAWING 08-11-2010 AHNA NSR NSR
Rev
No
MAIN CABLE INLET Title
DIMENSIONAL &
INSTALLATION DRAWING
AOT 3F
A Location Size Dimensions without tolerances:
A
ISO A3
Scale
985 22763 R00.fm

Sheet
08-11-2010 AHNA 1 985 22763 00
6 5 4 3 2 1
May 6, 2014 258 985 22763 R00.fm
6 5 4 3 2 1
D D
May 6, 2014
2
Drawing: 985 22946 R01
C C
3
1
Assembly and Spare Parts Drawing - AOT
259
B 5 B
01 POS. 7 VIEW REMOVED 19-11-2010 AHNA NSR NSR

00 INITIAL DRAWING 08-11-2010 AHNA NSR NSR
Rev
No
Title
ASSEMBLY & SPARE PARTS
A A
DRAWING
AOT 3F
ISO A2
Scale
Date Drawn Drawing No Rev
985 22946 R01.fm

1:2
Sheet
08-11-2010 AHNA 1 985 22946 01
6 5 4 3 2 1
May 6, 2014 260 985 22946 R01.fm
Drawing: 985 22946
AOT 3F Reactor - Part list
Part List for 985 22946

AOT 3F Reactor Part
Pos Qty Description Article No. Remarks
1 3 O-ring, 21x3.0 (3 Pcs.) 985 22763-03
2 1 1 ceramic contact socket with mounted crimp sockets 985 22763-70
3 1 1 quartz sleeve incl o-rings 985 22763-30
4 1 UVC Lamp (42W) 985 22763-09
5 1 UV Sensor Assembly incl. Cable 985 22763-50
6 1 Magnetic Valve Coil, 220-230V, 50/60Hz 985 22763-17
May 6, 2014 261 985 22946 parts list.fm

May 6, 2014 262 985 22946 parts list.fm
Drawing: 985 22987 AOT 3F
985 22987 AOT 3F
May 6, 2014 263 985 22987 AOT 3F.fm

May 6, 2014 264 985 22987 AOT 3F.fm
Drawing: Terminal Block Information AOT 3F
Terminal Block Information AOT 3F
Terminal block information: Model type: AOT 3F

Terminal Name/Legend Comment
N Main N N
L1 Main L L
PE Main PE PE
PE PE NC
1 Magnetic safety valve
2 Magnetic safety valve
3 UV-sensor (anod)
4 UV-sensor (cathod)
5 External alarm, M1 Potential free relay alarm.
6 External alarm, M1 6 closed to 7 during UV-sensor
7 External alarm, M1 alarm.
May 6, 2014 265 Terminal Block Information AOT 3F.fm

May 6, 2014 266 Terminal Block Information AOT 3F.fm
6 5 4 3 2 1
May 6, 2014
Drawing: 985 22764 R00
5 9 7 8 4
267
1
Main Electrical Comp. AOT 3F - Electrical Cabinet
6
2
10
3
11
00 INITIAL DRAWING 08-11-2010 AHNA NSR NSR

Rev
No
Title
MAIN ELECTRICAL COMP.
AOT 3F - ELECT. CABINET
AOT 3F
ISO A3
Scale
985 22764 R00.fm

Sheet
08-11-2010 AHNA 1 985 22764 00
6 5 4 3 2 1
May 6, 2014 268 985 22764 R00.fm
Drawing: 985 22764 - parts list
Electrical Cabinet AOT 3F - Parts list
Part List for 985 22764

AOT 3F Electrical Cabinet
Pos Qty Description Article No. Remarks
1 Complete electrical Cabinet 985 22764-80
1 1 UV Monitor 985 22764-01
2 1 Elapsed time counter 50/60 Hz 985 22764-02 / 985 22764-12
3 1 ON/OFF Handle 985 22764-03
4 1 Connection Block 985 22764-04
5 1 Power Line Filter 985 22764-05
6 1 Electronic Ballast 985 22764-06
22764 06
7 1 Relay 985 22764-07
8 1 Line Safety Switch 985 22764-08
9 1 Time Relay 985 22764-09
10 15 Connection block / terminal (incl. End protection) 985 22764-10
11 1 Ferrite 985 22764
22764-11
11 Not mounted at delivery
May 6, 2014 269 985 22764 - parts list.fm

May 6, 2014 270 985 22764 - parts list.fm
9 Maintenance record
9.1 Maintenance record (template)
Date By Action Comments/Notes
Maintenance record 271 985 22146 rev 05 – May 6, 2014

WALLENIUS WATER AB
WARFVINGES VÄG 32 SE-112 51 STOCKHOLM SWEDEN
E-MAIL: INFO@WALLENIUSWATER.COM
Maintenance record
WEB: WWW.WALLENIUSWATER.COM
272 985 22146 rev 05 – May 6, 2014

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AC-00992 - Hull No.: CV22H-JT01 - Name of yard: 24211.

Alfa Laval Copenhagen A/S

Published by: Alfa Laval Copenhagen A/S

2 Safety Instructions and Warnings 13

3 System Description – AQUA type HW 17

7 Long Term Standstill 36

Table of Contents – May 6, 2014 3

10 Chemical Dosing of Scale Control Chemicals 47

11 Operation and maintenance instructions for Freshwater

Table of Contents – May 6, 2014 4

15 FWG Order Specification - Drawings and Parts lists 73

Table of Contents – May 6, 2014 5

Instructions manual for CNL pumps size 160 and 200

Table of Contents – May 6, 2014 6

5 Spare Parts 180

6 Trouble Shooting 182

7 Drawings and Part Lists 186

Table of Contents – May 6, 2014 7

AOT UV Sterilizer - Alfa Laval AOT 3F

1 Declaration of Conformity 225

2 Alfa Laval AOT 3F General 235

Table of Contents – May 6, 2014 8

5 Service & Maintenance 250

6 Spare parts 254

Table of Contents – May 6, 2014 9

Table of Contents – May 6, 2014 10

Serial No.: AC-00992

1.1 Technical data

Technical Specifications in overview 11 May 6, 2014

Technical Specifications in overview 12 May 6, 2014

2.1 Safety Instructions and Warnings

Safety Instructions and Warnings 13 985 22146 rev 05 – May 6, 2014

Fresh water shall in general only be produced when the vessel is at

• Do not run pumps dry – mechanical seals will be damaged

• Do not operate the fresh water generator without recommended

Safety Instructions and Warnings 14 985 22146 rev 05 – May 6, 2014

• Use ear protection in noisy environments.

• Use correct lifting tools.

• Do not work under hanging load.

• Wear gloves to avoid burns by hot surfaces.

• Wear gloves to avoid cuts by sharp edges when handling machined

• Wear helmet to avoid cuts by sharp edges during maintenance of the

Safety Instructions and Warnings 15 985 22146 rev 05 – May 6, 2014

3.0 Working principle

System Description – AQUA type HW 17 985 22146 rev 05 – May 6, 2014

System Description – AQUA type HW 18 985 22146 rev 05 – May 6, 2014

System Description – AQUA type HW 19 985 22146 rev 05 – May 6, 2014

2. Combined brine/air ejector

Do not store organic solvents or acids in the room.

Avoid heat and ultraviolet radiation.

Storage 21 985 22146 rev 05 – May 6, 2014

5.0 General Information

5.1 Extent of Delivery

5.1.1 Space Requirements

5.1.2 Ambient Conditions

5.2 General Safety Precautions

Installation 22 985 22146 rev 05 – May 6, 2014

5.2.1 Electric Equipment

5.3 Installation Instructions

Installation 23 985 22146 rev 05 – May 6, 2014

5.3.2 Sea Water System

Installation 24 985 22146 rev 05 – May 6, 2014

5.3.3 Ejector Pump (if supplied)