Pureballast 30 Flow 1000

PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System

System Manual - PureBallast 3.0 Flow 1000 PB-00479
System Manual
English
PureBallast: Ballast Water Table of Contents
Treatment System
Safety 1
System Description 2
Operating Instructions and

Control System 3
Description
Parameters 4
Alarms and Faultfinding 5
Installation and Drawings 6

Only foreseeable conditions have been taken into
consideration. No warnings are given for Service Manual 7
situations arising from unintended usage of the
system components and tools.
Spare Parts Catalogue 8
Marine & Diesel Equipment
Printed 2014
Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement of this
publication would be gratefully appreciated.
Copies of this publication can be ordered from your local AlfaLaval company.
Published by: : Alfa Laval Tumba AB
E-147 80 Tumba, Schweden
Telefon: +46 8 530 650 00
Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB 2014

Chapter: 1. Safety
System manual — PureBallast 3.0 Flow 1000
Book No. 9010183 02, rev. 2

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

Telefax: +46 8 530 310 40
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
Contents
1 Introduction 5
2 Safety information 7
2.1 General safety information 7
2.2 Specif c safety information 7
2.3 Personnel requirements 9
2.4 Warning signs used in the manual 9
3 Environmental issues 11
3.1 Unpacking 11
3.2 Other materials 11
3
1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.
Book No.9010183 02, rev. 2 5

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

The following general safety information apply:
• The PureBallast system is not EX proofed and must not be installed in areas where an
explosive atmosphere may occur.
• Use the equipment only for the purpose and parameter range specified by Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Always read and follow the documentation that is included in shipment of components and
spare parts regarding handling, safety and disposal.
• Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.
• Before installation, read applicable sections in chapter 6. Installation instruction and drawings.
• Before operation, read the Preparations and conditions section for applicable instructions in
chapter 3. Operating instructions and control system description.
2.2 Specif c safety information
The following safety information apply for the areas and components below. This information is also
stated in the Preparations and conditions section for applicable instructions.
Maintenance safety items
• Before maintenance, read the Preparations and conditions section for applicable instructions in
chapter 7. Service manual. Essential safety information is stated before instruction to routines
that might involve any danger.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8.
• Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle
with a load capacity greater than the weight of the component. See the Technical data section
on page for information about weight. Any complementary lifting instructions must be followed.
• Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
Reactor module safety items
• Cut hazards: Sharp edges on broken UV lamps and quartz sleeves can cause cuts. Exercise
great care when handling them.
• Before installation, check that the UV lamps and quartz sleeves are not broken.
Book No.9010183 02, rev. 2 7

2.2 Specific safety information 2 Safety information
• Depressurize reactors and allow equipment to cool down completely before disassembling. Hot
water may escape from the reactor when removing the drain plug.
• Never handle UV lamps before they are completely cooled down. A hot UV lamp is under
high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn
if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the reactor with end caps properly closed.
• UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled with care. Please refer to national regulations regarding disposal of used lamps. If
a UV lamp is broken, mercury could be spilt. Remove mercury with a special tool such as a
syringe (or use pure sulphure to bind the mercury for easy collection).
- Do not allow mercury to come in contact with your eyes or skin.

- Do not inhale mercury fumes. In case of having inhaled mercury fumes, consult a doctor
and follow medical instructions.
- Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
• Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor
(indicated by level switch LS201-29), and the water temperature is below 60 °C. Improper
operation could seriously damage the equipment and injure personnel.
• Manual operation of LPS, may only be performed after cable connection. If not hazardous
situation may arise which, if not avoided, will result in death or serious injury.
• Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the
power supply. The LDC contains a fan, which can cause injury if in operation.
Flow meter safety items
• Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
Valve safety items
• Actuators must not be pressurized at any time during installation as it may result in injury.
• Lock valve in closed position before maintenance.
CIP safety items
• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal
protection etc.
• Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
• Always wear protective eye glasses and gloves while working on the pump.
Ancillary component safety items
• Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
• Temperature switch, temperature transmitter and level switch. The external surface may be hot.
Care must be taken to avoid possible burns.
8 Book No.9010183 02, rev. 2

2 Safety information 2.4 Warning signs used in the manual
2.3 Personnel requirements

The PureBallast system must be operated, installed, maintained and repaired by persons trained for
respective type of work. All persons using and working with the system must know the emergency
stopping procedures.
Personnel installing, maintaining or repairing components must be of one of the following categories:
• Skilled person: A person with technical knowledge or sufficient experience to perform

the tasks at hand and to enable him or her to perceive risks and to avoid hazards which
electricity/mechanics can create.
• Instructed person: A person adequately advised or supervised by a skilled person to enable
him or her to perceive risks and to avoid hazards which electricity/mechanics can create.
• Alfa Laval service engineer: A person with vast knowledge about the PureBallast system.
Alfa Laval service engineer can set parameters and repair intrinsically safe apparatuses. The
person must have experience of similar types of work and be certified in accordance with
local regulations.
In some cases special skilled personnel may need to be hired, like electricians and others. In some
of these cases the personnel has to be certified according to local regulations with experience of
similar types of work.
2.4 Warning signs used in the manual
DANGER
!
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
NG
WARNI
!
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
ON
CAUTI
!
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Book No.9010183 02, rev. 2 9

2.4 Warning signs used in the manual 2 Safety information
3 Environmental issues
This section contains general rules regarding environmental issues. However, local rules and
regulations should be consulted for detailed handling of each material.
3.1 Unpacking
• Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
• Wood and cardboard boxes can be reused, recycled or used for energy recovery.
• Plastics should be recycled or burnt at a licensed waste incineration plant.
• Metal straps should be sent for material recycling.
3.2 Other materials
• Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed to a suitable licensed land fill site.
• Metal parts should be sent to a licensed handler for material recycling.
• Seal rings should be disposed of in a licensed land fill site. Check the local regulations.
• Worn out or defected electronic components should be sent to a licensed handler for material
recycling.
• The operator panel contain the following components with substances that might be hazardous
to health and the environment: lithium battery, electrolytic capacitor and display. They shall
be recycled according to local regulations.
• Used lithium batteries from the control unit are considered hazardous waste and should be
disposed of accordingly.
• Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations.
• Used quarts sleeves should be disposed of as ordinary glass.
Book No.9010183 02, rev. 2 11

Chapter: 2. System description
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

Laval Tumba AB.
Contents
1 Introduction 5
1.1 Components overview 5
1.1.1 Item numbers 6
1.2 System overview 6

1.3 Abbreviations 6
2 Process overview 9
2.1 Start-up 10
2.2 Ballasting 11
2.2.1 Power optimization 11
2.2.2 Backflush 12
2.2.3 Ballast after-treatment (CIP) 14
2.3 Deballasting 15
2.3.1 Deballast after-treatment (CIP) 15
2.4 Stripping with eductor 16

2.5 Ballast water handling in the event of
malfunction 17
3 System components description 19

3.1 AOT reactor 19
3.1.1 AOT reactor working principle 19
3.1.2 AOT reactor description 20
3.2 Lamp drive cabinet (LDC) 21

3.2.1 LDC working principle 22
3.2.2 LDC description 22
3.3 Filter 24
3.3.1 Filter working principle 24
3.3.2 Filter description 24
3.3.3 Backflushing for different dirt loads 27
3.4 CIP (cleaning-in-place) module 29

3.4.1 CIP working principle 29
3.4.2 CIP module description 29
3.5 Control cabinet and control system 30

3.5.1 Control system 31
3.5.2 Main control panel 31
3.5.3 Remote control panel (optional) 32
3.5.4 Remote interface (optional) 33
3
3.6 Main valves 33
3.7 Flow meter 34
3.8 Pressure monitoring device 34
3.9 Sampling devices 34
4
1 Introduction
This contains general information about the PureBallast system and its components.
1.1 Components overview

The key components in PureBallast are shown below. Note that the filter is just an example of
a filter unit; others may be chosen.
2 SystemOverview
Example of layout with 1 AOT reactor.
1. Filter inlet valve

2. Filter
3. Filter bypass valve
4. Lamp drive cabinet (LDC)
5. Control cabinet with main control panel
6. AOT reactor
7. Control valve
8. CIP (cleaning-in-place) module
9. Flow meter
10. Backflush valve
11. Filter outlet valve
Book No.9010183 02, rev. 2 5

1.3 Abbreviations 1 Introduction
Not in illustration:
• System bypass valve

• Sampling devices, before and after treatment
• Pressure monitoring device
1.1.1 Item numbers

System components are identified by unique item numbers, for example “FIT201-1” for the flow
transmitter installed before the AOT reactor.
1.2 System overview

The PureBallast system is an integral part of the vessel’s ballast water system, on the discharge
side of the vessel’s ballast water pumps. During ballast operation, the water is led through the filter,
which removes larger particles and organisms, and then to the AOT reactor, where the water is
treated with UV light and advanced oxidation technology (AOT). During deballast, the water is
led the same way, but the filter is bypassed.
The UV lamps are powered by the LDC (via LPSs, lamp power supplies). The AOT reactor has
one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. The control valve also
regulates pressure during backflushing of the filter.
The AOT reactors are cleaned using the CIP (cleaning-in-place) module, which first rinse the AOT
reactor with fresh water, and then circulates CIP liquid through the AOT. At the end of the process
the AOT reactor and the filter (filter preservation) is filled with fresh water from the CIP.
The complete system and ongoing processes is controlled and monitored from the control cabinet.
Control can also be performed from remote control panels and the ship’s ISCS, via the remote
interface.
The by-pass valve makes it possible to by-pass the entire system, for example to secure ballast
operation if the system is not functioning. The valve is controlled from the ISCS (integrated ship
control system).
1.3 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
AOT Advanced oxidation technology
AOT reactor The main component, where the water is treated using advanced
oxidation technology
6 Book No.9010183 02, rev. 2

1 Introduction 1.3 Abbreviations
Abbreviation Explanation
Atex EU directive “Appareils destinés à être utilisés en ATmosphères

EXplosivles”
CIP Cleaning in place
CIP module Cleaning in place module. Performs the CIP process.
DIN Deutche Institut für Normung
EN Standard according to CEN (European Committee for

Standardization).
EX Explosion-proof
I/O Input/output (Describes a program or device handling data)
IACS International Association of Classification Societies
ISCS Integrated ship control system
IMO International Maritime Organization
JIS Japanese Industrial Standard
LED Light emitting diode
LDC Lamp drive cabinet.
LPS Lamp power supply
MCB Motor circuit breaker
PLC Programmable logical controller (PureBallast control system)
UV Ultra violet
Book No.9010183 02, rev. 2 7

1.3 Abbreviations 1 Introduction
2 Process overview
This section gives an overview of the main processes performed by PureBallast. In the flow chart
illustrations, involved pipes are marked in bold.
Book No.9010183 02, rev. 2 9

2.1 Start-up 2 Process overview
2.1 Start-up
Ballasting and deballasting begins with a start-up phase. There must be available power for
the system. If power management is integrated, this will be confirmed automatically. If power
management is not integrated, this is confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is pumped through the
AOT reactor to secure that the UV lamps are not overheated. The flow is monitored by the flow
meter to secure that there is enough flow to cool the UV lamps. If flow deviates from parameter set
values, an alarm is issued and the system is shut down.
2 Startup
Ballast and deballast start-up
10 Book No.9010183 02, rev. 2

2 Process overview 2.2 Ballasting
2.2 Ballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The ballast water is pumped from the sea chest to the filter, that removes larger particles and
organisms. This also reduces the amount of sediment build-up in the ballast water tanks. The
organisms and sediments caught in the filter are flushed overboard via regular filter backflush
operations. The water is finally led to the AOT reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.
2 FullBallast
Ballasting
2.2.1 Power optimization

It is possible to activate power optimization (parameter p237). During ballast and deballast, the lamp
power is adjusted according to the value from the UV intensity sensor, which constantly measure
the water transmittance. In clear water with good transmittance, the lamps are automatically
dimmed, to lower the power consumption. This means that the lamps are lit to the degree needed
for full treatment, but not more.
The purpose is to save power by dimming the lamps to minimum power required to fully treat the
water. The UV lamps are regulated individual on all AOT reactors between 50 % and 100 % of
full effect.
Power optimization during special conditions.
• During start-up and the first two minutes of ballast/deballast, the UV lamps are lit to 100 % to
ensure treatment before values from the UV sensor are stable.
• Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for 2 minutes when
process is resumed.
Book No.9010183 02, rev. 2 11

2.2 Ballasting 2 Process overview
• Stop: UV lamps are lit to 100 % for 10 seconds before they are stopped. This will prolong
the life of the lamps.
• Low UV intensity: See Actions at low UV intensity below.
• Broken UV lamps: See Operation with broken UV lamp below.
2.2.1.1 Actions at low UV intensity
If the UV intensity falls below minimum (defined in parameter p221) for one AOT reactor, a warning
is issued, but process continues. When UV intensity falls below limit defined in the type certificate,
a new warning is issued and a log is written to the event log. The operation continues but does
not fullfill the type approval certificate. However, the flow is decreased so that the treatment shall
correspond to the type approval requirements. The operator will have do decide to continue or
stop the operation.
2.2.1.2 Operation with broken UV lamp
If a UV lamp breakes a warning is issued and a log is written to the event log. The operation
continues but does not fullfill the type approval certificate. However, the flow is decreased to 80 %
of current flow for all AOT reactors and the UV lamps are lit to 100 %. These actions are taken so
that the treatment shall correspond to the type approval requirements.
The operator will have do choose one alternative:
• Stop the operation.

• Continue operation and not comply with type approval certificate.
2.2.2 Backf ush

To keep the filter clean, it is automatically backflushed. The backflush is performed during ongoing
process without interrupting the ballasting process. When a ballast operation is stopped, a
backflush is performed before the system comes to a full stop. The water used for backflushing is
returned to the sea directly at the ballasting site.
12 Book No.9010183 02, rev. 2

2 Process overview 2.2 Ballasting
2 Back-flush
Filter backflush
Book No.9010183 02, rev. 2 13

2.2 Ballasting 2 Process overview
2.2.3 Ballast after-treatment (CIP)

After a ballast operation, a cleaning-in-place (CIP) process is performed to clean the AOT reactor.
This process can either be performed immediately after a ballast operation or within 30 hours after.
Note, that it is possible to perform new processes during these 30 hours. A CIP process takes
about 25 minutes per AOT reactor, if default parameters are used.
The AOT reactors are cleaned one at a time. First, the AOT reactor is rinsed with fresh water. Then
the cleaning-in-place (CIP) module circulates a biodegradable solution through the AOT reactor to
remove seawater scaling. After the cleaning is finished, the AOT reactor is filled with fresh water to
preserve the filter and prevent scaling, algae growth etc. Then the system continues with the same
procedure for the next AOT reactor. Finally, the filter is filled with fresh water to prevent scaling and
algea growth. The cleaning liquid is reused between the cleaning operations.
2 CIP
CIP process
14 Book No.9010183 02, rev. 2

2 Process overview 2.3 Deballasting
2.3 Deballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The water passes through the AOT reactor, but the the filter is bypassed since the water has
already been filtered during ballasting. The reason for treating the water a second time during
deballasting is to secure that the treatment is fully effective. The minor part of the organisms, which
were only injured during ballast, will be rendered totally harmless during the deballast.
The process flow and power optimization are controlled in the same way as during ballasting.
2 FullDeballast
Deballasting
2.3.1 Deballast after-treatment (CIP)

After deballast operation, a cleaning cycle is performed to clean the AOT reactor. It is performed
in the same way as described for the ballasting process. If only deballast operations has been
performed since the last CIP process, the filter does not need to be filled with fresh water at the end
of the cycle, since the filter has not been used.
Book No.9010183 02, rev. 2 15

2.4 Stripping with eductor 2 Process overview
2.4 Stripping with eductor

Stripping can be performed to achieve total emptying of the ballast tanks via a stripping eductor.
To use PureBallast during a stripping process an eductor must be installed before the PureBallast
system.
The water used in the stripping process, must be filtered from particles larger than approximately 5
mm. The water passes through the PureBallast system as a regular deballasting process (with
the filter by-passed). The water is finally pumped into the sea.
Note the following:
• The eductor is not part of Alfa Laval’s scope of supply.

• Procedures to dispose of sediments from the sieve must be included in the vessel’s ballast
water management plan.
16 Book No.9010183 02, rev. 2

2 Process overview 2.5 Ballast water handling in the event
of malfunction
2.5 Ballast water handling in the event of malfunction

PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallast’s control system, but all by-pass valve activities are logged in the event log. Such valve
is required by the International Convention for the Control and Management of Ship’s Ballast
Water and Sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. In case untreated water is pumped to a ballast tank, this water shall
be discharged on open sea (according to regulations) and exchanged for treated water. Note that
full treatment requires treatment both during ballast and deballast.
The procedures concerning emergency and malfunction of the ballast water treatment system
should be implemented in the ships Ballast water management plan.
Book No.9010183 02, rev. 2 17

2.5 Ballast water handling in the event of 2 Process overview
malfunction
3 System components
description
This section gives an introduction to the most important PureBallast system components and
their functions in the system.
3.1 AOT reactor

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

The main treatment process take place inside the AOT reactor, where the UV light inactivates the
cell DNA to prevent regrowth of organisms. The UV light also generates radicals. The radicals are
extremely reactive and react instantaneously with micro organisms and other organic contaminants
destructing their membranes. The radicals are extremely short-lived and exist only for some
milliseconds. This means that they will only exist inside the AOT reactor. The quantity of radicals
produced in the reactor is sufficient to treat the water as it passes through the reactor.
2 10_2_1_1 Cell
Destruction of cell membranes
1. Radical
2. Cell membrane
Book No.9010183 02, rev. 2 19

3.1 AOT reactor 3 System components description
There are no chemical substances added to the process, and there are no toxic residuals created.
Since the water is not affected chemically there are no environmental impact, and the process does
not influence corrosion in any way.
3.1.2 AOT reactor description

The AOT reactor consist of the reactor, sensors and valves for ballast water, fresh water and CIP
liquid, as shown in the illustration below. The AOT reactor accommodates 16 medium-pressure
UV lamps (6 kW each) powered from the lamp drive cabinet (LDC). The UV lamps are enclosed
in individual quartz-glass sleeves.
The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there is
water in the reactor when the lamps are lit, each reactor is equipped with a level switch. The level
switch also secures that enough CIP liquid is pumped into the reactor during the CIP process. To
secure that the lamps are adequately cooled by the ballast water, each AOT reactor is equipped
with one temperature transmitter that shut down the reactor at 60 °C, completed with a temperature
switch that automatically shuts down the reactor if the temperature reaches 65 °C.
A UV sensor monitors the UV lamp efficiency in relation to the water transmittance inside the AOT
reactor. Based on this input, the power to the UV lamps are regulated between 50 and 100 % of full
capacity. The UV lamps will be dimmed to lowest possible level, where they are still effective.
Note, that the lamps are always lit with full effect during start-up and the first two minutes of full
ballast to secure full efficiency independent of transmittance. The lamps are also turned up to full
effect for 10 seconds before stop and normal shut down. This method will prolong the UV lamp life
time.
The illustration below show the main components for the AOT reactor.
20 Book No.9010183 02, rev. 2

3 System components description 3.2 Lamp drive cabinet (LDC)
2 reactor module Obe
AOT reactor
1. Ballast water outlet valve

2. CIP liquid outlet valve (actuator indicated)
3. Level switch
4. Junction box
5. UV lamp cap (UV lamp and quartz sleeve inside)
6. Access hatch
7. CIP liquid / fresh water inlet valve and reactor
drain valve (actuator indicated)
8. Ballast water inlet valve (actuator indicated)
9. UV sensor
10. Junction box
11. Cooling water outlet valve
12. Ballast water outlet valve actuator (actuator
indicated)
3.2 Lamp drive cabinet (LDC)

The lamp drive cabinet gives power to the AOT.
Book No.9010183 02, rev. 2 21

3.2 Lamp drive cabinet (LDC) 3 System components description
3.2.1 LDC working principle

The AOT reactor is connected to a lamp drive cabinet (LDC) containing 16 lamp power supplies
(LPS), each feeding one lamp with power. The LPS also monitors the function of each UV lamp and
takes action if a fault occurs. Lamps on the cabinet indicates if power is on, UV lamps are lit and
if the cabinet needs to be reset after a shutdown or power off.
3.2.2 LDC description

The LDC is equipped with a cooling system to maintain correct operating temperature in the LDC,
using low-temperature cooling water. The cooling water flow is constant, but the fan is regulated
based on heat inside the cabinet. When lamps are lit, the fan starts at 15 % of full effect. When
the temperature reaches 40°, the fan starts to regulated between 15 % and 100 %, according to
parameter settings based on input from the temperature transmitter in the LDC.
The humidity in the cabinet is monitored by a liquid sensor. If a leakage from the heat exchanger
is detected, a warning is issued, the reactor is shut down and the cooling water inlet valve to
the LDC is shut.
The LDC can be placed up to 150 meters (cable length) from the AOT reactor. The main breaker
cut the power to the LDC and the AOT reactor.
22 Book No.9010183 02, rev. 2

3 System components description 3.2 Lamp drive cabinet (LDC)
2 LDC
LPS with one door removed.
1. Fan
2. Heat exchanger
3. Lamp power supplies (LPS)
4. Fuses
5. Cooling water inlet and outlet
6. Main breaker
7. Status lights and reset button
Book No.9010183 02, rev. 2 23

3.3 Filter 3 System components description
3.3 Filter
3.3.1 Filter working principle

The filter is a fully automatic self-rinsing component, equipped with filter elements to remove
particles and organisms from the ballast water flow. The ballast water is lead through the filter, and
filtered particles are trapped in the filter. The filter control cabinet is is only used for connections.
The filter is entirely controlled from the PureBallast control system.
3.3.2 Filter description
2 FilterHydac
1. Geared motor
2. Water outlet
3. Pressure transmitter, outlet
4. Filter control cabinet.
5. Pressure transmitter, backflush line
6. Backflush outlet
7. Pressure transmitter, inlet
8. Water inlet
To secure efficient filtration, the filter performs a self-rinsing backflush operation at time set intervals
or when triggered by indication of dirt in the filter. Pressure drop over the filter is monitored by
pressure transmitters on the filter inlet and outlet. Dirt is detected by an increased differential
pressure drop caused by particles in the filter. When the differential pressure reaches a parameter
set value, an automatic backflush operation starts.
24 Book No.9010183 02, rev. 2

3 System components description 3.3 Filter
The backflushing does not interrupt the filtration process, since all filter candles are not cleaned
at the same time. The not cleaned filter candles continue the filtration of the ballast water. It is
also possible to start backflush manually from the control system.
Book No.9010183 02, rev. 2 25

The filter candles are backflushed in two steps:
Step 1: The flushing arm is positioned under the first filter candle to be backflushed. The purpose
of the flushing arm is to collect the backflush water and lead it, with the flushed particles, to the
backflush line. From this point, this filter candle is not used for filtering.
A valve on top of the filter candle is opened to
lead water through the filter candle from the top
downwards. The water flow through the filter
candle down to the flushing arm, flushes particles
from the filter candle walls and lead them to the
backflush line.
2 BackFlush1
Step 2: The valve on top of the filter candle is

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

arm change position and the process is repeated
until all filter candles are rinsed.
2 BackFlush2
26 Book No.9010183 02, rev. 2

3 System components description 3.3 Filter
3.3.3 Backf ushing for different dirt loads

Below, the filter pressure drop over time (pfilter) is illustrated for different dirt load situations in the
filter. Different dirtload depends on the water condition, which means that “normal” condition
regarding filter backflush depends on the water conditions.
3.3.3.1 Low dirt load
In water with low dirt load, the backflush cycle is started by the time trigger (default: every 30
minutes). As long as the pressure is below 0.85 (0.085 MPa) bar, there is no need for the pressure
triggered backflush. See examples below.
6 Dirtload1 Hydac
6 Dirtload2 Hydac
3.3.3.2 Medium dirt load
In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.85 bar, which
indicates dirt in the filter candles.
After each backflush, the backflush timer is reset. The filter will be backflushed again after 30
minutes or when ∆pfilterreaches 0.85 bar, whichever comes first.
In the example below, three backflushes are triggered due to high differential pressure over the filter.
After that, there is not so much dirt build up, so the next backflush is performed after 30 minutes.
Book No.9010183 02, rev. 2 27

6 Dirtload3 Hydac
3.3.3.3 Heavy dirt load
In conditions with heavy dirtload, the system will perform more frequent backflushes to keep the
filter clean.
Also, the 0.85 limit might be exceeded. In this case the self rinsing cycle will run continuously
until the problem is solved and the pressure has returned below 0.85 bar. It is OK that the flow
momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes.
In the example below, a series of backflushes are performed (approx. every 4 minute). After that
the pressure rises above 0.85 where the filter is backflushed constantly. After that, the normal
control is resumed, where the filter backflush is triggered by pressure (2 times) or by time (last
backflush in the example.
6 Dirtload4 Hydac
3.3.3.4 Long term dirt build-up
Over time, the filter candles will undergo a long term build-up of particles that are not removed by
backflushing. One effect of this is that “normal” pressure will increase over time. Therefore, the
maintenance schedule state that the candles shall be inspected and manually cleaned once a year.
The extent of the long term dirt build-up is dependent on the water conditions. In the great majority
of cases this will not cause any problems – cleaning once a year is enough. But in exceptional
cases (vessels trading very muddy waters) it might be necessary to clean the filter candles more
often. If the pressure triggered backflushing is performed with short intervals, we suggest that the
filter candles are manually cleaned more often than once year.
28 Book No.9010183 02, rev. 2

3 System components description 3.4 CIP (cleaning-in-place) module
3.4 CIP (cleaning-in-place) module
3.4.1 CIP working principle

To ensure full performance in PureBallast, an automatic cleaning cycle is performed after ballast
and deballast operation. The purpose is to keep the quartz sleeves covering the UV lamps and the
UV sensor clean, to maximize the effect of the UV lamps, and thereby treatment efficiency.
During a cleaning cycle, the CIP module rinse the reactor with fresh water and circulates a CIP
liquid through the AOT reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion
build-up and chemical fouling on the lamps’ quartz glass sleeves. After finished cycle, the liquid
is returned to the CIP module tank; the CIP liquid is reusable for a great number of cycles. The
sequence is finalized by filling the AOT reactor with fresh water. A backflow preventer secures
that no CIP liquid is mixed with the fresh water.
3.4.2 CIP module description

The CIP module consists of a tank where the CIP liquid is stored between usage. The pumps and
valves integrated in the CIP module are controlled by the valve block.
To secure that there is enough CIP liquid for the process, the level switch in the reactor indicates
when it is filled with CIP liquid. To prevent intrusion of water in the fresh water system, a backflow
preventer is used in the CIP module.
The CIP module is equipped with two membrane pumps:
• Pump P320-1 circulates the CIP liquid in the AOT reactor and fills it with fresh water.
• Pump P321-5 drains water (sea and fresh water) overboard from the reactor, via the drain line.
Book No.9010183 02, rev. 2 29

3.5 Control cabinet and control system 3 System components description
2 CIP module
CIP module
1. Deaeration valve
2. Valve block
3. Regulator
4. Pump (CIP liquid)
5. Backflow preventer
6. Pump (reactor drain)
7. Tank for CIP liquid
3.5 Control cabinet and control system

The control cabinet is used to control and monitor the entire system, via the built in main control
panel. It is also used to communicate with the the vessel’s systems and components, if integrated.
The control cabinet functions as a signle point of contact for signal cables to and from the vessel.
Examples of integration: Remote interface integration and power management system (PMS).
Remote interface will allow control of PureBallast from the vessel’s ISCS and PMS integration will
allow automatic verification that there is enough power to run an operation. If not integrated, the
operator must verify this manually. Also integration with other external components (not part of Alfa
Laval’s scope of supply), such as GPS or booster pumps, are done to the control cabinet.
30 Book No.9010183 02, rev. 2

3 System components description 3.5 Control cabinet and control system
2 CC
Control cabint with main control panel.
3.5.1 Control system

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

The main control panel in mounted in the control cabinet, and it is included in the standard
installation of PureBallast. It is installed in the engine room. The main control panel handles
Book No.9010183 02, rev. 2 31

3.5 Control cabinet and control system 3 System components description
every aspect of the control system. It allows the operator to monitor the system, to operate it
manually and automatically, and to set parameters. Please note that some of the operations are
password-protected.
2 MainPanel
Main control panel
3.5.3 Remote control panel (optional)

As an option, it is possible to install one or two additional panels to be placed in locations from
where ballast operations are performed. A remote control panel looks and functions in the same
way as the main control panel, and it allows same operations.
2 RCP
Main control panel with four integrated remote control panels.
32 Book No.9010183 02, rev. 2

3 System components description 3.6 Main valves
3.5.4 Remote interface (optional)

As an option, the control system can be integrated with the vessel’s ISCS via modbus. This allows
monitoring and operation of PureBallast from the ISCS’s graphical user interface.
Note that Alfa Laval does not supply the graphical user interface to handle PureBallast in the
ISCS, only the means to enable the integration.
2 RI
PureBallast control system’s main control panel integrated with the ISCS. The interface is only an example.
3.6 Main valves

The main valves in the system are:
• Inlet valves: The inlet valves directs the water flow from the vessel’s ballast water system into
the PureBallast system. Different valves are used during ballast and deballast.
- System and f lter inlet valve (201–3): Inlet valve to PureBallast during ballast. The valve
directs the water flow through the PureBallast filter.
- Filter outlet valve (V201–32): The valve directs the water flow from the filter to the AOT
reactor during ballast.
- Inlet valve (201–9): Inlet valve to PureBallast during deballast. The valve directs the water
to PureBallast, but bypass the filter, since the water was filtered during ballasting.
• Control valve (V201–8): The valve have the following functions:
- Automatic regulation to maintain flow during operation so it does not exceed selected
certified maximum flow. Regulation is based on input from the flow meter.
- Automatic regulation to maintain pressure needed to perform backflush of the filter.
Regulation is based on input from the pressure transmitter.
- Outlet valve from the PureBallast system to the vessel’s ballast water system after treatment.
Book No.9010183 02, rev. 2 33

3.9 Sampling devices 3 System components description
• PureBallast bypass valve (V212–31): Makes it possible to completely bypass the PureBallast
system. The valve is solely operated from the ISCS, but the valve positioning is (and must be)
indicated in the PureBallast control system. When PureBallast is bypassed, an event is written
to the event log. The component is optional to be included in Alfa Laval’s scope of supply.
• Cooling water inlet valve (V403-35): Supplies cooling water to the reactor to secure cooling of
the lamps and prevent overheating during start-up.
• Check valve (CV201): Ensures that there is water in the reacto at all times.
3.7 Flow meter
The flow meter (FIT201–1) monitors the process-flow during operation. It has two main functions:
• It monitor that the flow within the PureBallast system does not exceed its certified flow. If the
certified flow is exceeded a warning is issued.
• Via the flow transmitter, mounted on the flow meter, it sends valuable data to the PureBallast
control system, where it is displayed. Example of information: Current flow and data about
total amount of treated ballast water.
The flow meter consists of two main parts: A flow sensor, which is a pipe with four electrodes
detecting the flow. On top of the pipe, there is a terminal box, where the flow transmitter is
mounted. The flow transmitter monitors the flow and transmits the information to the PureBallast
control system.
3.8 Pressure monitoring device

The pressure monitoring device is a manifold that includes the following components to monitor
and handle pressure in the system:
• Pressure transmitter(PT201-16): Send current pressure information to the control system. The
control system use the information to take actions accordingly, for example issue warnings, shut
down the system or adjusting the control valve to obtain optimal pressure during filter backflush.
• Pressure gauge (PI201-18): Analogue displayed of current pressure.
• Needle valve (V201-15): Enables connection of external instruments for calibration.
• Safety valve (RV201): Relief of over pressure.
3.9 Sampling devices
The two sampling devices (Q201.1 and Q201.1) make it possible to take water samples to test the
water. One sampling device is installed before the water is treated and one after the water is
treated. This enables comparative tests of treated and untreated water. The component is optional
to be included in Alfa Laval’s scope of supply.
34 Book No.9010183 02, rev. 2

Chapter: 3. Operating instructions and control system description
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 7
1.1 Preparations and conditions 7
1.1.1 Stripping 7
1.1.2 Heeling (internal transfer) 8
1.1.3 Ballast water handling in the event of malfunction 8
1.1.4 Pipe cleaning using PureBallast 9
2 Introduction to the control system 11

2.1 Login levels 11
2.2 Control of PureBallast 12
2.2.1 Remote control panels (option) 12
2.2.2 Remote interface (option) 12
2.3 Overview of the screen 14
3 Detailed page descriptions 19

3.1 Page 1.1 – Overview 19
3.1.1 Status box 20
3.1.2 Flow chart 21
3.2 Page 1.2 – AOT and f ow selection 23

3.2.1 Flow selection 23
3.2.2 AOT selection 24
3.2.3 Status 24
3.3 Page 1.3 – CIP status 25

3.3.1 CIP status 26
3.3.2 AOT information 26
3.3.3 CIP module information 27
3.4 Page 1.4 – Power request 28

3.4.1 Power management status display 28
3.4.2 Power management simulation and faultfinding 29
3.4.3 Function buttons 30
3.5 Page 2.1 – Alarm list 31

3.5.1 Alarm list 32
3.6 Page 2.2 – Alarm history 33

3.7 Page 3.1 – Trend (15 min) 34
3.7.1 Diagram area 35
3.7.2 Component area 35
3
3.8 Page 3.2 – Trend (1 h) 37
3.9 Page 3.3 – Trend (1 h) - TT201-33 37
3.10 Page 3.4 – Trend (1 h) - TT401-2 37
3.11 Page 3.5 – Trend (1 h) - Power
optimization 37
3.12 Page 4.1 – System info 38
3.13 Page 4.2 – PLC controller I/O 41
3.14 Page 4.3 – Operation timers 42
3.15 Page 4.4 Operation timers AOT 44
3.16 Page 4.5 – Remote interface 1 45
3.17 Page 4.6 – Remote interface 2 46
3.18 Page 4.7 – Log box 1 47
3.19 Page 4.8 – Log box 2 48
3.20 Page 4.9 – LPS overview 49
3.21 Page 5.1–5.7 – Parameter pages 51
3.22 Popup windows 51
3.22.1 AOT popup 51
3.22.2 Filter popup 57
4 Operating instructions 59
4.1 Log in 59
4.2 Perform ballast 59
4.2.1 Start ballasting 60
4
4.3 Perform deballast 61
4.4 Pause ballast / deballast 62
4.5 Heel (internal transfer) 62
4.6 Backf ush f lter manually 63
4.7 CIP clean AOT reactor after ballast /
deballast 63
4.8 Stop ballast / deballast 64
4.9 Attend to alarms 65
4.10 Shut down and deactivate system 66
4.11 Reset system after shut down 67
4.12 Operate components manually 67
4.13 Operate UV lamps manually 69
4.14 Set ship specif c component ID 70
4.15 Export control system event log f les 71
4.16 Backup control system settings 73
4.17 Restore control system settings 74
4.18 Set control panel IP address 75
4.19 Set remote control panel
communication 76
4.20 Set remote interface communication 77
4.21 Test remote interface communication 78
4.22 Simulate power request 80
4.23 Set default parameters 80
4.24 Update control system softwares 81
4.25 Calibrate the control panel’s touch
screen sensibility 81
4.26 PID calibrate system 82
4.26.1 Calibrate pressure controlled regulation 82
5
5 List of logged information 85
5.1 Event log 85
6 Detailed process description 91

6.1 Standby mode 91
6.2 Ballast process 92
6.2.1 Ballast start-up 92
6.2.2 Full ballast 93
6.2.3 Filter backflush 93
6.2.4 Pause ballast (Heeling mode) 94
6.2.5 Stop ballast 95
6.3 Deballast process 96

6.3.1 Deballast start-up 96
6.3.2 Full deballast 97
6.3.3 Pause deballast (Heeling) 97
6.3.4 Stop deballast 98
6.4 CIP process 99

6.4.1 Start CIP 100
6.4.2 Drain ballast water 100
6.4.3 Fresh water filling 101
6.4.4 Fresh water draining 101
6.4.5 CIP cleaning 101
6.4.6 CIP draining 102
6.4.7 Fresh water filling 102
6.4.8 Repeat 102
6.4.9 Filter preservation 102
6.5 Manual mode 103
6
1 Introduction
The control system is used to operate and monitor the PureBallast system. It also contains
functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of the control system
pages, step-by-step instructions and a process description with detailed information about the
components (valves, motors, pumps etc) involved in each step of respective process.
The following control system related information is given in other chapters of the manual:
• Parameters are described in chapter 4. Parameters.

• Alarms and warnings including information about faultfinding and how to solve problems is
described in chapter 5. Alarms and faultfinding.
• Information about integrating the control system with the vessel’s ISCS and power management
is described in chapter 6. Installation description and drawings.
1.1 Preparations and conditions
• Make sure all documentation is available, read and understood before start.
• Make sure that the flow is within defined flow range during operation:
Ballast (m3/h): 190 → 1000
Deballast (m3/h): 100 → 1000
• During process, the control system requests that vessel valves are opened/closed. The
valves are outside the PureBallast system control. But the control system needs feedback
(opened/closed) during process. Status can either be confirmed manually in a popup or
automatically, if feedback signals are integrated via the remote interface option or via hard wire.
Please note:
- When overboard valves are requested to be opened/closed, this means that all valves
leading the flow from the PureBallast via one of the following pipes must be opened/closed:
201, 309 and 403 and 404. During CIP process, 460.1 must be opened.
- Such water as described above does not need to be transported overboard. For example,
the flow can be lead to the bilge tank. In such cases, all relevant valves leading the water
from the PureBallast system shall be opened.
• The input flow to the PureBallast system shall be as close as possible to the flow that has been
selected for an operation. This will reduce the stress and wear of the control valve.
1.1.1 Stripping
The first time a ballast tank is stripped, PureBallast must be by-passed.
Min flow during stripping; deballast using one AOT reactor:
Recommended stripping procedure
Book No.9010183 02, rev. 2 7

1.1 Preparations and conditions 1 Introduction
If stripping is performed with a low flow for a long period of time, we recommend that stripping is
performed from the ballast tanks to a “collection tank”. After that it is possible pump the water
from this tank with full flow using the ballast pump, and finally empty it by stripping. Note: The
driving water used for stripping must have been treated once, so that all water that is flushed
overboard has been treated twice.
This will reduce the power consumption and UV lamp runtime. If all tanks are stripped (with a low
flow) the power consumption per treated cubic meter will be unnecessary high, since the power
consumption will be high in relation to the low flow.
Example: If a process is run with a flow of 100 m3/h for 10 hours, it will give a power consumption
of 1000 kwh, not including the ballast water pump. But if the same amount of water is collected
and then processed with a flow of 1000 m3/h using the ballast water pump, the power consumption
will be 100 kWh.
1.1.2 Heeling (internal transfer)

Internal transfer of ballast water between tanks, for example during heeling procedures, does not
require the use of the PureBallast system. It is possible to perform heeling during standby ballast
or deballasting.
If external component signal for heeling mode is integrated between PureBallast and the vessel’s
ISCS, ongoing process will be paused and resumed automatically. The user is notified of started
and stopped heeling via warnings, and the event is logged.
If no external signal is integrated, the ongoing process must be paused manually. During pause,
cooling water is flushed through the AOT to cool the UV lamps. After completed heeling, the
operator must resume the paused process.
1.1.3 Ballast water handling in the event of malfunction

If the ballast water treatment system malfunctions, follow the procedures stated in the ship’s ballast
water management plan. This is valid both if the system malfunctions, for example mechanical
problems, or if full treatment cannot be guaranteed, for example a lamp failure or low UV intensity.
General recommendations are given blow.
PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallast’s control system, but all valve activities are logged in the event log. Such valve is
required by the International convention for the control and management of ship’s ballast water
and sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. Note that the system requires treatment both during ballast and
deballast.
If untreated water is pumped to a ballast tank, this water shall primarily be discharged to a reception
facility. When this is not possible, other discharge possibilities must be agreed with the port state
responsible for the waters where the ship is sailing and most importantly be agreed with the flag
state administration of the ship; the procedures concerning emergency and malfunction of the
ballast water treatment system should be implemented in the ships Ballast Water Management
Plan which must be approved by the flag state administration.
8 Book No.9010183 02, rev. 2

1 Introduction 1.1 Preparations and conditions
1.1.4 Pipe cleaning using PureBallast

In some vessels, the applicable class society may require means and procedure for flushing
ballast pipes with treated water, to clean them from untreated water. This procedure should be
implemented in the ships Ballast water management plan.
In PureBallast, a deballast process is run with the vessel’s ballast valves positioned so that the
• pump takes water from a ballast water tank with treated water and
• the water flow is directed either overboard or to another ballast tank.
Run the process for enough time so all water in the piping is treated. Time for this depends on pipe
size and length on board.
Book No.9010183 02, rev. 2 9

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

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

word
Guest N/A Default mode of control system. This level is not password protected.
• View all pages.
Operator aot • As Guest.

• Operate the system to perform daily routines, for example ballast
and acknowledge alarms.
• Full access to page 1.4 Power request.
• Download files and backup to a USB memory.
Advanced 2007 • As level Operator.

operator
• Operate equipment in manual mode.
• Access to set parameters, with exception from critical parameters.
See chapter 4. Parameters for information.
• Full access to page 4.3 Operation timers and 4.4 Operation timers
AOT.
AlfaLaval N/A Full access. Password only available for Alfa Laval personnel.
• Full access to all parameter pages.

• Full access to force I/O in page 4.2 PLC controller I/O.
• Full access to make settings for remote control panels and remote
interface in page 4.1 System info and 4.5/4.6 Remote interfaces 1
and 2.
Book No.9010183 02, rev. 2 11

2.2 Control of PureBallast 2 Introduction to the control system
2.2 Control of PureBallast

PureBallast can be monitored and controlled in three ways: Main control panel, remote control
panel (optional) and remote interface (optional). The system can only be controlled from one
place at a time.
The information below is only valid if remote control panels and/or remote interface is installed.
2.2.1 Remote control panels (option)

PureBallast can only be controlled from one control panel at a time.
To switch command from one panel to another, you log in to the new panel. This is only possible by
using the same or higher login level as used in the active control panel. When control is about to be
changed from one panel to another, the following will happen:
• The inactive control panel will display a popup message informing that another control panel is
active (some one else is logged in). The popup gives the alternative to cancel or to continue. If
continue is chosen, control is swithced from the first panel to the new panel.
• The active panel will display a popup message informing that another the panel is inactive
and that control is taken by another panel.
On each control panel it is possible to see which panel that is active and which login level that is
used. A panel alias can be entered to clarify where the panel is installed, for example pump room,
bridge etc. See instruction Set remote control panel communication. This information is visible in
the upper right corner of the system according to syntax: login level@control panel.
“Login level” can be: Guest, Operator, Advanced operator or AlfaLaval.
“Control panel” can be:
• 192.168.0.10 (Master) = Main control panel

• 192.168.0.11 = Remote control panel 1
3 ActivePanel
Example: Operator logged in at remote control panel with alias “Bridge”.
2.2.2 Remote interface (option)

If the remote interface option is used, PureBallast can be controlled from the vessel’s ISCS.
It is only possible to switch command between control panel and ISCS from a PureBallast control
panel. This is done by using the Local and Remote buttons, when logged in as Operator or higher.
Control status (local or remote) is indicated by a green light under the button that corresponds to
the system currently in command. In the ISCS, control status can be indicated by using the status
signal dedicated to this. It is recommended that this signal is implemented in the ISCS.
12 Book No.9010183 02, rev. 2

2 Introduction to the control system 2.2 Control of PureBallast
When remote interface is activated, PureBallast can only be controlled from the ISCS. It possible
to access the same pages and perform the same operations from the ISCS as for login level
Operator (to the extent that the systems are integrated. However, the following two tasks can only
be performed from a (any) control panel: Set parameters and switch control between control
panel(s) and ISCS.
When remote interface is activated, the panel(s) can only be used to monitor the system, export log
files and switch control between PureBallast control panel(s) and ISCS.
The PureBallast system manual does not give any information about how to run PureBallast from
the remote interface. This is due to the fact that the remote interface is custom-made. Please
refer to the vessel specific manual.
2.2.2.1 Conditions for remote interface control

of PureBallast
PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings
• The remote interface must be correctly installed, according to Remote interface implementation
guide.
• Remote interface must be activated (parameter p132) and communication settings must be
correct (parameter p700 – p704).
• The Test mode button must be deactivated (no checkmark on the button) in control system
page 4.5 Remote interface 1.
• Remote control must be activated. Check that the green lamp is lit under the Remote button
on the control panel. If not, press the button. The system must be in Standby mode to toggle
between local and remote operation.
Operation
• Heartbeat is updating. See that address +006 +077 are updating in control system page 4.5
Remote interface 1.
• There must be no active alarms for the AOT reactors to be used during operation. Always check
the alarm list (page 2.1 Alarm list in the control system) before operation.
Book No.9010183 02, rev. 2 13

2.3 Overview of the screen 2 Introduction to the control system
2.3 Overview of the screen

This section describes the PureBallast control system screen layout and navigation.
The control system use a touch screen, where you tap the screen to “click” or drag objects. Do not
use sharp objects to touch the screen. When the screen is left idle it will go to screensaving mode.
Time is set in page 4.1 System info. The screen is activated again by touching it once. The touch
will not activate any button that might be placed where you touch.
The illustration below shows the main areas and function buttons on the screen.
3 1.1
Control system screen showing the main overview page.
Login menu: Expanding menu with login fields.
Tabs: The top and side tabs are used to choose which page to display in the screen. Pages are
referred to as a number and a name, for example 2.1 Alarm list. The first number refers to selected
top tab, counted from left to right. The second number refers to selected side tab, counted from top
to bottom. Selected tabs are indicated by a white color.
Top tabs: Contain the main function areas of the control system: Overview, alarm lists, trend
indication, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab. Available side tabs change
depending on which function area that have been selected in the top tab.
14 Book No.9010183 02, rev. 2

2 Introduction to the control system 2.3 Overview of the screen
Popup windows: Are used to display or enter detailed information. It is possible to move a popup
by touching the name bar and drag it. A popup is closed either by touching confirming entered
information by touching a function button (OK, Conf rm, etc.) or the X icon in the top right corner
(data is not saved).
Data entry f elds: A white field indicates that it is possible to enter data. When the field is touched,
a keyboard is displayed, which is used to enter information. Enter data is confirmed by touching the
Enter button. To close the keyboard without saving data, touch the Esc button.
Tables: Individual table rows, for example an alarm, can be selected by pressing them. Column
widths can be adjusted. Press the column border in the head area and hold the finger on the screen.
Function buttons: Function buttons are used for main processes and control of the system. They
are placed att the bottom of the screenare and are always visible, but only available when colored
dark blue. Some buttons are dependent on parameters. For example, the Remote and Local
buttons are only visible if remote interface is activated.
Status indication – Button color: The buttons appear in different colors, indicating status:
Blue The function is enabled.
Blue with The function is activated.

checkmark
Grey The function is disabled, for example if higher login level is required for the
function.
Status indication – Button light: After a function button is pressed, a light under the button is lit
to indicate status for the activated function:
Green Command is active.
Yellow Command will be processed when possible in the data work flow.
Yellow, blinking Command is paused.
Function button description
Button Description
Start ballast process.
Resumes paused process.

3Ballast
Start deballast process.
Resumes paused process.

3Deballast
Book No.9010183 02, rev. 2 15

Button Description
Stop current process.
3StopButtonBlue
Pause ballast or deballast process. This is only possible during full ballast
or full deballast. The button can be hidden, using parameter p137. Allowed
length of a pause is parameter set (p138). After defined time, the paused
3Pause
process is stopped.
To resume a paused process, press the function Ballast or Deballast

depending on which process that was paused.
Start CIP process.
3CIP
Activate operation from control panels, instead of remote interface (if option
is used). The button is only enabled in standby mode.
2 LocalButton
Activate operation from remote interface (if option is used), instead of

control panels. The button is only enabled in standby mode.
2 RIbutton
Sets the control system in manual mode, which enables manual operation
of the system and its components. When activated, the light flashes yellow.
The button is displayed for login level Advanced operator or higher. For
3 EnableManual detailed information see Manual mode on page 103.
Disable the touch screen function for 10 seconds to make it possible to

clean the screen without the risk of starting a process or changing a setting.
3Wipe
Activate night light for the panel. Night light makes the panel less bright.
Toggles between night light and day light.
3 Night Degree of brightness, is set in the Night light level field in page 4.1 System
info.
Contains calculator, Notepad and print function.
To print a screen image to USB: Insert a USB memory in USB panel

port on the cabinet door. Press Utilities, and then Print to save a screen
image to USB.
3 Utilities
Status indication – Alarms and warnings
16 Book No.9010183 02, rev. 2

2 Introduction to the control system 2.3 Overview of the screen
Alarms and warnings for components are displayed in the flow chart and popups:
Active alarm.
3Alarm
Active warning.
2 Warning
Book No.9010183 02, rev. 2 17

3 Detailed page descriptions
This section describes the pages used for operation. Note that this section does not cover the
parameter pages. Please refer to chapter 4. Parameters.
3.1 Page 1.1 – Overview

The page displays an overview of the system, overall status and detailed information regarding
the components.
The main areas are the Status box and the Flow chart.
3 1.1
Book No.9010183 02, rev. 2 19

3.1 Page 1.1 – Overview 3 Detailed page descriptions
3.1.1 Status box

The status box display current status for the PureBallast system. The information is updated
continuously. To see accumulated operation runtime for the components, see page 4.3 – Operation
timers.
The following status information is displayed:
Status information (unit) Description
Process and sub process Process: Ongoing process. Can be standby, ballast, deballast
and CIP.
Sub process: Sub steps of ongoing process, for example

“Start-up” during Ballast process.
Time Remaining time for the ongoing sub process.
Processed volume (m3) Amount of water processed during ongoing process. Value
remain until next process is started.
Power consumption (kW) Calculated power consumption for ongoing process.
Certif ed f ow (m3/h) Certified flow (m3/h) selected for operation. The information is
updated after the warm up time has passed and a AOT reactor
is used for process. This is also the flow the system is aiming
to keep.
Current f ow (m3/h) Ballast water flow in the system, indicated by flow transmitter
FIT201-1. The system aims for the selected flow minus
parameter p111 Undershoot certified flow, which can be set
as a safety margin.
Flow selection Flow (m3/h) selected for operation. Flow is set using the arrow
buttons.
Flow selection depends on parameter p131 Automatic AOT

selection:
• If activated: The AOT is always selected.

• If deactivated: Last used flow is default. Flow must be set
after power off.
Flow can be changed using the + and – arrows.
• + = Increase flow. – = Decrease flow. The Flow selection

field is updated with m3/h when the button is pressed,
but is not changed until the Apply button is pressed.
• Apply = Apply the new setpoint to be used for process.
Note: If ballast flow is lower than deballast flow
(parameter p315), the higher value is displayed until the
Ballast button is pressed.
20 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.1 Page 1.1 – Overview
3.1.2 Flow chart

The flow chart display a schematic overview of the PureBallast system and its components.
Relevant information regarding ongoing process and component status can be monitored directly
in the flow chart. Flow in pipes is indicated by coloring of the pipes and component status are
displayed by color indications. Pressure, flow and control valve opening percentage are displayed
directly on component.
Detailed information about components can be monitored in popups (by tapping the component):
AOT reactor see page 51; filter see page 57. CIP open page 1.3 CIP status, see page 25). The
popup contain status for sub components, for example valves, motors and UV lamps in the AOT
reactor.
Booster pump for AOT reactor (P403–1) and LDC (P401–1) are only displayed if these components
are used and activated in the parameter pages.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually: If a component is pressed, a popup window is displayed from which the component
can be operated.
Status indication – Component color:
Component status is indicated by a colored frame:
Pipes Pipe and flow status. Flow in pipe is indicated as below:
Status indication
Blue = Fresh water or sea water, when flow goes sea-to-sea.
Green = Ballast and deballast flow.
Yellow = CIP liquid.
Mixed colors = Mixed water, for example ballast water and fresh water.
Valves and Status indication

pumps
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a component. The ID will be

visible in page 1.1 Overview and popups for the components. See instruction
Set ship specific component ID on page 70
Book No.9010183 02, rev. 2 21

3.1 Page 1.1 – Overview 3 Detailed page descriptions
Status indication for balast water pump (not part of Alfa Laval’s scope of
supply).
3 PumpReq
Status indication
Green, blinking = Request sent. Popup message message “Confirm ballast

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

valve open” is displayed. (The popup is not displayed if the component
feedback is integrated with the control system.)
Green = Feed back that valve is open, either via hard wired feedback, remote
interface or the confirmation popup.
Grey = Closed.
Status information for bypass valve(s) V212–31 and external bypass valves
(not part of Alfa Laval’s scope of supply). These valves are operated from the
ISCS, due to safety reasons.
External bypass is only visible if parameters (p163–p165) for external bypass

valves are activated.
3 CV and Bypass icon
The component is operated manually in manual mode.
3Manual1
22 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.2 Page 1.2 – AOT and flow selection
3.2 Page 1.2 – AOT and f ow selection

The page is used to select AOT reactors or flow for ballast and deballast and to increase/decrease
flow during ongoing operation. It is also possible to select specific AOT reactors to be used during
process, or to change AOT reactor during an ongoing process.
This page is only relevant if more than one AOT reactor is installed.
Note, that if parameter p131 Automatic AOT selection is activated, it is only possible to change
flow during operation, not in standby mode.
Normally, flow is handled from page 1.1 Overview, and this page is used during commissioning and
faultfinding when it is necessary to start individual AOT reactors.
The main areas of the page are the Flow selection, AOT selection and Status.
3 1.2
3.2.1 Flow selection

Function in the same way as flow selection in page 1.1 Overview.
Book No.9010183 02, rev. 2 23

3.2 Page 1.2 – AOT and flow selection 3 Detailed page descriptions
3.2.2 AOT selection

The area displays a table with installed AOT reactors with status information. It is possible to
choose individual AOT reactor for process in standby (if parameter p131 is disabled) or during
process (regardless of p131 setting).
The following information is displayed:
Elements Description
Modify button Enables active selection of individual AOT reactors. When pressed, the
buttons for respective AOT reactor turns blue and are possible to use.
AOT 1, 2, 3 button One row for respective installed AOT reactor with current status indicated
in the columns.
AOT n button: Press the button to select or deselect. A checkmark on the

button indicates selected. The flow setpoint for the number of AOT reactors
selected are updated in the Flow selection area. The field is updated with
m3/h for the selected AOT reactor.
Status indication:
Selected: Grey = Not selected. Green = Selected.
Ready: Grey = Not ready. Green = Ready for process.
Alarm: Grey = No alarm. Red = Active alarm.
Apply button Apply the new setpoint to be used for process.

Note: If ballast flow is lower than deballast flow (parameter p315), the
higher value is displayed until the Ballast button is pressed.
3.2.3 Status
The area displays current status for the flow:
Elements Description
Current f ow Ballast water flow in the system, indicated by flow transmitter FIT201-1.
Certif ed f ow Maximum allowed flow as set in Flow setpoint or limited by the number of
AOT reactors selected in AOT selection popup. If a smaller filter is installed,
the ballast flow can be lower than the AOT reactor capacity.
The information is updated after the warm up time has elapsed and a AOT
reactor is used for process. (Before that it is not used for treatment, and
therefore not part of the certified flow.)
24 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.3 Page 1.3 – CIP status
3.3 Page 1.3 – CIP status

The page is used to display CIP status for all AOT reactors and status for the valves and motors in
the CIP unit. The page can either be opened by selecting the tab or by tapping the CIP module in
page 1.1 Overview.
The page also display time remaining for ongoing CIP process. If no CIP required process has been
started after a ballast or deballast operation, the time remaining before CIP must be performed is
displayed.
3 1.3
Book No.9010183 02, rev. 2 25

3.3 Page 1.3 – CIP status 3 Detailed page descriptions
3.3.1 CIP status

The area displays status for the following pieces of information:
Row Content
Process and sub Process: Ongoing process. Can be standby, ballast, deballast and CIP.
process
Sub process: Sub steps of ongoing process, for example “Start-up” during
Ballast process.
3.3.2 AOT information

The area displays CIP status for respective installed AOT reactor:
Row Content
AOT Each row display CIP status for every installed AOT reactor
Filter preservation This row indicate status and time for the filter preservation process, that
starts after completed CIP. During filter preservation, the CIP fills the filter
with fresh water for preservation purpose.
Total Total estimated time for a complete CIP process including filter preservation.
Column Content
CIP error Red square: Indicates that there is an active alarm for the component.
Check alarms on page 2.1 – Alarm list.
CIP CIP status for each AOT reactor.
Status indication
Yellow = CIP required. During ongoing CIP process, yellow indicates that
the AOT reactor is waiting for CIP process to start.
Yellow, blinking = CIP process ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to active alarm on

the AOT reactor.
Status Same information as column CIP, but spelled out.
26 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.3 Page 1.3 – CIP status
Column Content
Estimated time Time remaining CIP time. If CIP process has not been started, total time is
displayed. During CIP process, the time is counting down continuously.
The CIP process takes about 25 minutes per AOT reactor, if default
parameters are used.
Required CIP Time before a CIP process must be performed after ballast or deballast.
countdown The time disappears when the CIP process is ready. Time is displayed for
the AOT with shortest time left to required CIP.
3.3.3 CIP module information

The area displays a schematic illustration of the CIP module, with status for for the valves and
motors. For status indications, see Status indication – Component color in section Flow chart
on page 21.
Book No.9010183 02, rev. 2 27

3.4 Page 1.4 – Power request 3 Detailed page descriptions
3.4 Page 1.4 – Power request

The page is used to handle power management. The page have two functions: Display power
status and test power management signals.
3 1.4
3.4.1 Power management status display

If the control system is set in normal mode, the page is used to display power management status.
Column Content
Process and sub Process: Ongoing process. Can be standby, ballast, deballast and CIP.
process
Sub process: Sub steps of ongoing process, for example “Start-up” during
Ballast process.
Max power Maximum power consumption for the number of selected AOT reactors.
consumption The value is updated when a process is started.
Measured power Power consumption during process. Value calculated based on number of
consumption used AOT reactors.
28 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.4 Page 1.4 – Power request
Power status
Column Content
Power Each row represent a number of AOT reactors to be used in a process.

Requests can be combined to send request for 3 AOT reactors.
1 AOT: Request power for 1 AOT reactor.
2 AOTs: Request power for 2 AOT reactors.
The requested power is calculated as the number of AOT reactor times

defined power consumption for one AOT reactor.
Common power: Request maximum power, enough to run all AOT

reactors installed, even if all AOT reactors are not used.
Request Indication alternatives: “Requested” or “Not requested”.

(Output signal from
PureBallast) Indicates if power request has been sent to the ISCS.
Pure Ballast always asks for power before the UV lamps are lit during ballast
or deballast start-up. When a request has been sent, the vessels power
management performs a power check before the generator is started.
Manual mode: Indicates if a simulated request signal is sent.
Granted Indication alternatives: “Yes” or “No”.

(Input signal to
PureBallast) Indicates if power request has been granted from the ISCS. Pure Ballast
will not consume significant power until the requested power is granted.
Manual mode: Indicates if a simulated granted signal is received.
Status Indication alternatives: “Running” or “Not running”.

(Output signal from
PureBallast) Indicates if power running signal is sent to the ISCS for respective number
of AOT reactors. This means that the AOT reactor is started and is
consuming power.
Manual mode: Indicates if a simulated running signal is sent.
Calculated power The field display the calculated power consumption.

consumption
If individual rows have been selected, the value is the sum of the number
of AOT reactor for the request times the set power consumption per AOT
reactor.
If Common power has been selected, the value is 100 kW.
3.4.2 Power management simulation and faultf nding

If the control system is set in manual mode, the page is used to simulate output from PureBallast to
the power management system during commissioning preparation.
Book No.9010183 02, rev. 2 29

3.4 Page 1.4 – Power request 3 Detailed page descriptions
The page can also be used to troubleshoot the power management system integration by sending
and checking each signal.
3.4.3 Function buttons

The following function buttons are available and displayed when manual mode is activated:
Buttons Content
If manual mode is activated, a hand icons are displayed on the page.

Press the hand icon to make it possible to send simulated request or
3Manual1
granted signal manually.
Request Press to manually simulate request for a power step. The button is
displayed for login level Advanced operator or higher.
Set run Press to manually simulate run signal for a power step. The button is
displayed for login level Advanced operator or higher.
30 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.5 Page 2.1 – Alarm list
3.5 Page 2.1 – Alarm list

The page display active alarms and warnings. When an alarm/warning is inactive and
acknowledged, it is moved to page 2.2 Alarm history.
Alarm type can be of two types:
- A = Alarms stop the ongoing process, which can be restarted after the problem has been
attended to.
- W = Warnings are notification of a status change, request for action or a problem that must be
attended to. Warnings allow the process to continue.
For detailed information about alarms and warnings see chapter 5. Alarms and faultfinding.
3 2.1
The main areas of the page are the Alarm list and the Function buttons:
Book No.9010183 02, rev. 2 31

3.5 Page 2.1 – Alarm list 3 Detailed page descriptions
3.5.1 Alarm list

The following information is displayed for each alarm (row):
Column Content
Text Descriptive alarm text written as: Area-Alarm type AlarmID Alarmtext.
Example: AOT2 A138 Error in LDC cabinet.
Active time The time alarm was activated.
Acknow- The time the alarm/warning was acknowledged. The alarm/warning remains
ledged time in the alarm list until the causing condition is resolved. For example a high
temperature alarm will remain visible, until the temperature is below the limit
value for the alarm/warning.
Status indication – Alarm color
The table below shows status indication for alarms and warnings in the alarm list.
Red Alarm = active
Pink Alarm = acknowledged, but still active
Orange Warning = active
Yellow Warning = acknowledged, but still active

The following function buttons are available:
Button Function
Ack selected Acknowledge selected alarm (row). Press a row to indicate it, and press the
button to acknowledge it.
Ack all Acknowledge all active alarms.
32 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.6 Page 2.2 – Alarm history
3.6 Page 2.2 – Alarm history

The page display a list of inactive, previously acknowledged alarms.
3 2.2
Column Content
Text Same as in Page 2.1 Alarm list.
Active time Same as in Page 2.1 Alarm list.
Acknowledged Same as in Page 2.1 Alarm list.

time
Normal time The time the value that caused the alarm returned to normal.
Book No.9010183 02, rev. 2 33

3.7 Page 3.1 – Trend (15 min) 3 Detailed page descriptions
3.7 Page 3.1 – Trend (15 min)

The page is used to display trend curves for basic data in the system. This page display trends
with a update frequency (sample time) of 2 seconds and the time span for trends displayed on the
screen is 15 minutes. Trend curves are saved in the trend history for 2 hours, and are then deleted.
This page is useful for analyzing processes, for example backflushes.
3 3.1
Trends can be plotted for the following components (identified by item number) and key values:
Component / Unit Description

Key value
Filter diff. pressure Bar Differential pressure over filter, indicated by pressure
transmitter 201–71 and 201–72.
V201–8 % Control valve open, percent.
PT201-16 Bar System pressure, indicated by the pressure transmitter.
V309-1 Status Filter backflush valve opened or closed.
FIT 201-1 m3 h System flow, indicated by the flow meter.
34 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.7 Page 3.1 – Trend (15 min)
3.7.1 Diagram area

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

The following fields and buttons are available for each component in the component area:
Column Content / Function
Settings Press the button to make settings for the component’s curve. Settings are
button done in a popup.
3 TrendCurveSet1Nr
1: Press (not slide) the button to display or hide trend curve in the diagram.
An I indicate displayed, and an O indicates inactive.
2: Press the entry field to change start and stop value for the components Y
axis scale (when this component’s scale setting is used).
3: Press this button to use this component’s scale setting in the diagram.
4. Press the entry field and increase or decrease the number of decimals in
the component area.
Book No.9010183 02, rev. 2 35

3.7 Page 3.1 – Trend (15 min) 3 Detailed page descriptions
Status Filled = Selected. Component values is plotted in the diagram,

indication in the same color as the icon.
3 TrendActive
Empty = Not selected. Component values is not plotted in the

diagram.
3 TrendInactive
Scale icon = The component scale setting is used in the

diagram’s Y axis. If several components have the same scale
3 TrendScale
setting, this icon is displayed for all these items.
Component Item number or name.
Value Current value for the component is displayed in the gray field. (This
corresponds to the diagram.)
If history mode is selected, historic value is displayed.

The following function buttons are available.
Buttons Content
Export long- Export trend curve history as a csv file. The file can be sent to Alfa Laval for
term trend advanced trouble shooting.
data to USB
Insert a USB memory in USB panel port on the cabinet door. Press Export
long-term data to USB button. Wait for the message “Exporting database
table …” to disappear. The file has been downloaded to the USB memory,
in a folder named DatabaseExport.
History mode Press the button to display this popup:
3 TrendCurveTime
Press one time unit (year, moth, day etc) and then press – or + to set time.
Real time Press the button to display current trend curve.
36 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.11 Page 3.5 – Trend (1 h) - Power optimization
3.8 Page 3.2 – Trend (1 h)

The page is used to display trend curves for basic data in the system. This page display trends
with a update frequency (sample time) of 15 seconds and the time span for trends displayed on the
screen is 24 hours. Trend curves are saved in the trend history for 2 hours, and are then deleted.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
3.9 Page 3.3 – Trend (1 h) - TT201-33

The page is used to display trend curves for water temperature in the AOT reactor, indicated by
temperature transmitter TT201–33. This page display trends with a update frequency (sample
time) of 30 seconds.
3.10 Page 3.4 – Trend (1 h) - TT401-2

The page is used to display trend curves for air temperature in LDC, indicated by temperature
transmitter TT401–2. This page display trends with a update frequency (sample time) of 30 seconds.
3.11 Page 3.5 – Trend (1 h) - Power optimization

The page is used to display trend curves for data valid for the power optimization. This page display
trends with a update frequency (sample time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons. See chapter 2.
System description, section Power optimization for details.
• AOT UV setpoint: The UV intensity the system is aiming to attain by increasing or decreasing
power effect to the LPS controlling the dimming of the UV lamps. The setpoint is based on
actual transmittance and is updated every 15 seconds.
• UV measurement: Actual UV intensity (W/m2) measured by UV sensor QT201–50. If intensity
is lower or higher than needed, the power to LPS will increase or decrease to attain setpoint
for UV intensity.
• Power output: Actual LPS power to UV lamps. The power is adjusted to attain the setpoint for
UV intensity based on measured water transmittance. Output is adjusted based on input from
UV sensor QT201–50. Power can be 50–100 %.
Book No.9010183 02, rev. 2 37

3.12 Page 4.1 – System info 3 Detailed page descriptions
3.12 Page 4.1 – System info

The page is used to display status information for the control system and the control panel. It is also
used to backup information and restore information from a backup.
3 4.1
Section on page Description
HMI info CPU: Control panel’s usage of the central processor unit (CPU) in
percent of total capacity and temperature (°C). The control panel will
shut down when the CPU reaches 100 °C.
Used RAM: Control panel’s used random access memory (RAM) in

percent of total capacity and in kB.
Used storage: PLC flash card’s used storage in percent and MB.
Storage used for the event and alarm log.
iX version: N/A.
TA150 f rmware: Version of internal firmware for the control panel.
CAT control version: N/A.
38 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.12 Page 4.1 – System info
PureBalalst HMI software version: Version of HMI software.
IP settings: Display current IP address for the panel.
Setup button: Opens popup to set IP address for the main panel and
the remote control panels (optional). Requires login level AlfaLaval.
HMI date and time UTC Date and time: Only used if GPS is not connected to the control
system. If so, time is retrieved from the GPS. Requires login level
Advanced operator.
Set button: Set time and date for the main control panel. Remote
control panels are updated with this time within 15 minutes after
syncronization.
Synchronize button: PLC is synchronized to use same date and

time as set in the control panel.
HMI Backlight Screen saver timeout: Defines time before the panel is set to
screen save mode. This is set individually per control panel.
Night light level: Defines percent of full light for the night light
mode. Night light is activated by the Night function button.
PLC Info CPU temperature (°C): Temperature of the central processor unit
(CPU) in the PLC.
PureBallast PLC sotfware version: Version of the PureBallast

PLC program.
GPS position: Shows current GPS position, if the control system is

connected to a GPS (p160). This position is used in the event log.
Backup and restore Settings to/from USB panel: Export and inport information to the
USB panel port on the cabinet door.
Backup button: The following information is saved in a folder named

“PureBallast Backup”:
• Parameter settings. File: Parameters.csv.

• Operating timers for AOT, UV lamps etc. File:
operatingtimers.csv.
• Settings for components in the trend curve pages. File:
ValueSaved.xml and ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different
components. File: ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
Restore button: Restore all information from a USB backup to
the control system. See Backup above. This shall not be used to
restore parameter settings after software update. Requires login
level Advanced operator.
Book No.9010183 02, rev. 2 39

3.12 Page 4.1 – System info 3 Detailed page descriptions
Parameters: Parameter restore.
Set default button: Set all parameter values to the default values.
Requires login level Advanced operator.
Export log f les Export button: Opens the Export log f les popup to export (copy)
event log files and alarm list.
For specific information about logged events, see section List of

logged information, Event log on page 85.
Remote control panels Remote control panel settings button: Open a popup used for
setting IP addresses for remote control panels (optional). See
instruction Set control panel IP address on page 75.
Requires login level Advanced operator.
40 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.13 Page 4.2 – PLC controller I/O
3.13 Page 4.2 – PLC controller I/O

The page is used to display status for the PLC I/O modules and to control them manually.
Note that this page is only intended for Alfa Laval’s personnel and only visible and available for
login level AlfaLaval.
Book No.9010183 02, rev. 2 41

3.14 Page 4.3 – Operation timers 3 Detailed page descriptions
3.14 Page 4.3 – Operation timers

The page is used to display operation counters for the components indicted in the illustration.
3 4.3
Row Unit
Accumulated ballast volume (FIT 201-1) m3 processed
Accumulated deballast volume (FIT 201-1) m3 processed
Control valve V201-8 total runtime Time opened in hours
Filter backflush via V309-1 Number of times opened
Filter motor M709–42 Runtime in hours
CIP pump P320-1 Runtime in hours
42 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.14 Page 4.3 – Operation timers
Row Unit
CIP pump P321-5 Runtime in hours
CIP: Number of cleaned AOTs. Number of cleaned AOT

reactors
Reset button: Reset to 0. If this is done each time the CIP liquid
is changed, it is possible to build up experience on how many
AOT reactors it is possible to CIP before it is time to change CIP
liquid. Requires login level Advanced operator or higher.
Book No.9010183 02, rev. 2 43

3.15 Page 4.4 Operation timers AOT 3 Detailed page descriptions
3.15 Page 4.4 Operation timers AOT

The page is used to display operation runtime for AOT reactors:
3 4.4
AOT operation Total Lap time

timers
AOT 1–3: Total runtime for the UV lamps in Lap time for installed UV lamps, since
Lamps on respective AOT reactor. the counter was reset after previous
reset at UV lamp change.
Reset button: Reset the value. Shall

be done after UV lamp change.
Requires login level Advanced
operator or higher.
AOT 1–3: LDC Total runtime for the LDC for

power on respective AOT reactor.
44 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.16 Page 4.5 – Remote interface 1
3.16 Page 4.5 – Remote interface 1

This page is used to monitor data sent between PureBallast’s PLC and the vessel’s ISCS.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).
3 4.5
Function buttons Description
Test mode Activates test mode. Communication can be sent between the
ISCS and PureBallast’s PLC without actually affecting the control
system (start process etc). To send information, enter desired
digits in the entry field.
Active: Check mark on the button.

Deactivated: No check mark on the button.
Book No.9010183 02, rev. 2 45

3.17 Page 4.6 – Remote interface 2 3 Detailed page descriptions

This page is used to monitor AOT reactor and LDC specific data sent from PureBallast’s PLC
to the vessel’s ISCS.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).
3 4.6
46 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.18 Page 4.7 – Log box 1
3.18 Page 4.7 – Log box 1

This page is used to administer and monitor the feedback from external components connected
via the log box (optional).
3 4.7
Column Content
Vessel ID Each row represent a component (valve). In the Vessel ID column, it is

possible to enter the actual component ID used on the vessel for easier
identification on the panel. This ID is not used in the Event log. Example: In
the illustration the first valve is named “Valve X45”.
To enter a vessel ID: Press the entry field or the document icon for the
component, and enter the ID using the keyboard displayed on the screen.
Position Each component is identified with a component ID and position.
Component ID: This ID is used in the Event log.
Position: For each valve, it is possible to connect two signals to log feedback
on open, closed or both. If signal “Closed” is used for a valve, the event log
Book No.9010183 02, rev. 2 47

3.19 Page 4.8 – Log box 2 3 Detailed page descriptions
Column Content
will make a record each time the valve is detected closed, and each time it is
detected not closed.
Status Active signal is indicated with a green light on the I/O icon.
Logging Two parameters per valve defines if opened and/or closed signals are
connected for respective position (valve). If parameter is set to Active,
activities for the component is logged in the event log.
Alternatives: Activated or Not used.
3.19 Page 4.8 – Log box 2

This page is used to administer and monitor the feedback from external valves (V) and pumps (P)
connected via the log box (optional).
See page 4.7 Log box 1 for information about function, fields and buttons.
3 4.8
48 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.20 Page 4.9 – LPS overview
3.20 Page 4.9 – LPS overview

This page is used to monitor detailed data for the lamp power supplies in the lamp drive cabinet. It
is intended for Alfa Laval’s personnel during advanced faultfinding.
3 4.9Obe
Column Content
LPS number Each row indicate status for each LPS.
Power Measured power output for UV lamp powered by the LPS.
Lamp on Status: Green = On. Grey = Off.
Reignite Status: Red = Failure to ignite UV lamp.
LPS OK Status: Green = OK. Red = LPS in fault state.
Lamp OK Status: Green = UV lamp lit and LPS is OK. Red = LPS in fault state.
Voltage fault Status: Red = Too low incoming power to the LPS.
System fault General LPS error.
Book No.9010183 02, rev. 2 49

3.20 Page 4.9 – LPS overview 3 Detailed page descriptions
Column Content
Air temp fault Status: Red = Temperature in LPS is higher than 55 °C.
Heatsink fault LPS internal heat protection tripped.
Fan fault LPS fan broken.
50 Book No.9010183 02, rev. 2

3 Detailed page descriptions 3.22 Popup windows
3.21 Page 5.1–5.7 – Parameter pages

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

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

The popup is displayed when the AOT reactor is pressed in the flow chart. The popup displays
status values for the AOT reactor and its related sub components.
manually. If the component is pressed, a popup window is displayed from which the sub
components can be operated. Operation of UV lamps in LPS control popup requires login level
Advanced operator.
AOT status: Status indication for the AOT reactor: ”Stopped” or “Started”.
Book No.9010183 02, rev. 2 51

3.22 Popup windows 3 Detailed page descriptions
3 1.1 AOT popObe
AOT illustration
Component Description
UV lamps Status indication:
Grey = Off.
Yellow = Starting.
Green = Started.
Sensor Status indication for AOT reactor sensors:

indications
LS201–29/: Level switch indicates if the AOT reactor is filled with water or
not.
Status indication: Green = Filled. Red = Not filled.
TS201–60/: Temperature switch automatically shuts down the AOT reactor

when the temperature reaches 65 °C.
Status indication: Green = OK. Red = Not OK.
52 Book No.9010183 02, rev. 2

QT201–50: UV sensor QT201–50 indicates UV intensity from the UV lamps

in the AOT reactor. When transmittance falls below value set in parameter
p221 a warning is issued.
TT201–33: Temperature indicator TT201-33 indicates current temperature

in the AOT reactor.
Valves For status indications, see Status indication – Component color in section
Flow chart on page 21.
Water f ow Flow in pipes is indicated by coloring of the pipes.
LDC status
Open the LPS control popup, which enables manual operation of individual
UV lamps. Requires login level Advanced operator to see the button and
manual mode open the popup. See LPS control popup and instruction
Operate UV lamps manually on page 69.
3 LPSctlrbut
Open the LPS status popup, which gives an overview of status for UV
lamps and LPSs.
3 LPS StatusBut
LDC fan setpoint Fan rotation in percent of full effect. Fan effect is based on need for cooling.
Heat exchanger Indicates if the valve for LDC cooling water (SV401–51) is open.
valve Status indication: Green = Open . No indication = Closed.
Air temp TT401–1 Air temperature in the LDC cabinet.
Water temp Temperature of incoming cooling water to the LDC cabinet.

TT401–2
3.22.1.1 LPS control popup
The popup is used for to manually start the UV lamps in the AOT reactor. See instruction Operate
UV lamps manually on page 69. The popup is displayed when the LPS control button is pressed
in the AOT popup. Requires login level Advanced operator to see the button and that manual
mode is activated to open the popup.
The AOT reactor is equipped with 16 UV lamps. In each lamp drive cabinet (LDC) is 16 lamp
power supplies (LPS) that supplies power to one UV lamp each. The lamps can be operated
individually in manual mode.
Book No.9010183 02, rev. 2 53

NGE R
! DA
• Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. All
necessary items – cooling water flow, water temperature, and power management – must be
supervised and verified by the authorized trained personnel operating the system. Improper
operation of this function could seriously damage the equipment and injure personnel.
3 LPS Manual popObe
AOT number Information is displayed for the AOT reactor selected in the AOT number
field.
Enables manual operation of the LPSs to light the UV lamps. The button is
displayed for login level Advanced operator or higher. The button enables
manual lcontrol of UV lamps.
3 ManModeBut
54 Book No.9010183 02, rev. 2

LPS 1–16 Press one button (1–16) to start or stop UV lamp 1–16 manually, controlled
by the LPS.
Status indication:
Blue with checkmark = Lit
Blue without checkmark = Off
Grey = Not selectable.
Start all LPS, and thereby all lamps for the AOT reactor. Requires that the
Manual mode button is pressed.
3 StartLPSBut
Stops all LPS, and thereby all lamps for the AOT reactor.
3 StopLPSBut
3.22.1.2 LPS status
The popup gives detailed information about UV intensity for AOT reactors and power for LPSs. The
information is mainly used for advanced trouble shooting by Alfa Laval’s personnel.
Book No.9010183 02, rev. 2 55

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

3 1.1 LPS active
56 Book No.9010183 02, rev. 2

LPS 1–16 Actual effect from each LPS to respective UV lamp. Green = LPS/Lamp
on. Gray = LPS/Lamp off.
Power optimization
Setpoint The UV intensity the system is aiming to attain by increasing or decreasing

power effect to the LPS controlling the dimming of the UV lamps.
Measured Actual UV intensity (W/m2) measured by UV sensor QT201–50. If intensity

is lower or higher than needed, the effect to LPS will increase or decrease
to attain setpoint for UV intensity.
Power output Actual LPS power effect to UV lamps.
The effect is adjusted to attain the setpoint for UV intensity based on

measured water transmittance. Output is adjusted based on input from
UV sensor QT201–50. Effect can be 50–100 %.
Control mode Displays current control mode. Status indication:
• Automatic: Normal mode. Power optimization is activated.

• Manual: If function button Manual is pressed, it is possible to enter a
value in the Manual power output field.
• Not used: Power optimization is disabled in parameter p237. UV
lamps are always lit to 100 %.
Manual power Manually set effect to LPS. Requires that the system is set in manual
output mode.
3.22.2 Filter popup

The popup is displayed when the Filter is pressed in the flow chart. The popup displays status
values for the filter and its related components.
manually. If the component is pressed, a popup window is displayed from which the sub component
can be operated. When manual mode is deactivated the system will return to standby mode: All
manually operated components will return to their status prior to the manual operation.
Book No.9010183 02, rev. 2 57

3 1.1 Filter Hydac
Mode Filter status:

- Idle (No backflush or preservation)
- Backflush preparation
- Backflush ongoing
- Filter preservation.
Diff. pressure Indicates differential pressure over the filter (PT201–71 minus PT201–72).
When the pressure reach the value set in parameter p305, a backflush
is triggered.
Pressure Current pressure:
PT201–71: Inlet pressure.

PT201–72: Outlet pressure.
PT309–2: Backflush pressure.
Start backf ush Press the button to start a manual backflush. See instruction Backflush
filter manually on page 63.
Pipes, valves and For status indications, see Status indication – Component color in section
motor Flow chart on page 21.
58 Book No.9010183 02, rev. 2

4 Operating instructions
This section contains step-by-step instructions for operating the PureBallast system. Please read
and follow the preparations and conditions carefully, as well as any danger or warning notes.
Preparations and conditions
For reference information, see the following sections i this chapter:
• Control system pages used in the instructions: See section Control system — Detailed page
descriptions.
• Login levels required for different procedures: See section Login levels on page 11.
• Detailed information about components (valves, motors, pumps etc) involved in each step the
process. See section Detailed process description.
4.1 Log in
Follow the steps below
1. Press the expand button on the Log in tab in the top right corner of the screen.
Result: The log in menu is displayed.
2. Press the expand button on the left drop down menu to display available users. Press desired
user.
Result: A keyboard is displayed.
3. Enter password and press Enter. (See section Login levels on page 11.)
4.2 Perform ballast

Follow this instruction to ballast.
• The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
• All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Laval’s scope
of supply).
Book No.9010183 02, rev. 2 59

4.2 Perform ballast 4 Operating instructions
• Flow must have been selected before a process can be started. If parameter p131 is activated
maximum flow is automatically selected, and flow can only be changed during process
according to instruction Change ballast / deballast flow on page . If parameter p131 is
deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or
1.2 AOT and flow selection.
• There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
4.2.1 Start ballasting

Follow the steps below:
1. Press the function button Ballast.

Comment: If the button is not blue, check that flow or AOT reactors have been selected.
2. Wait for the message “Open valves ...”. Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Ballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and ballasting starts.
4. When desired amount of water has been processed, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off. An automatic filter
backflush is performed.
5. Wait for the message “Close valves ...”. Close relevant valves and then press the button in
the popup to confirm the action. Note! These valves are outside outside the PureBallast
6. Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
NOTE
A CIP cleaning process must be performed after ballasting. It can be done immediately or within 30 hours
from the f rst operation after the previous CIP process. If no CIP process is performed within the time limit,
a warning is issued and an entry is made in the control system log f le. Operations after the warning does
not fullf ll the type approval certif cate.
Note that it is possible to run ballast operations during the 30 hours. Complete status information regarding
CIP is displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP
clean AOT after ballast / deballast on page 63.
60 Book No.9010183 02, rev. 2

4 Operating instructions 4.3 Perform deballast
4.3 Perform deballast

Follow this instruction to deballast.
• All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Laval’s scope
of supply).
• There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
1. Press the function button Deballast.

Comment: If the button is not blue, check that flow or AOT reactor have been selected.
2. Wait for the message “Open valves ...”. Open relevant valves and then press the button in the
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
Result: Cooling stops and deballasting starts.
Result: Ongoing process is stopped and the lamps are switched off.
6. Wait for the message “Close valves ...”. Close relevant valves and then press the button in the
Book No.9010183 02, rev. 2 61

4.5 Heel (internal transfer) 4 Operating instructions
NOTE
A CIP cleaning process must be performed after deballasting. It can be done immediately or within 30 hours
from the f rst operation after the previous CIP process. If no CIP process is performed within the time limit,
a warning is issued and an entry is made in the control system log f le. Operations after the warning does
not fullf ll the type approval certif cate.
Note that it is possible to run deballast operations during the 30 hours. Complete status information regarding
CIP is displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP
clean AOT after ballast / deballast on page 63.
4.4 Pause ballast / deballast

Follow this instruction to pause an ongoing ballast or deballast process.
• This is only possible in sub process full ballast or full deballast. This is indicated by the lit
Pause button.
• Allowed length of a pause is parameter set (p138). After defined time, the paused process
is stopped.
1. Press the function button Pause.
Result: Ongoing process is paused. The UV lamps remains on at reduced power and cooling
water is run through the AOT reactor to cool the lamps. Pause mode is indicated by yellow light
under the Pause button and blinking yellow under the function button Ballast or Deballast.
3. To resume the process. Press the Ballast or Deballast button.

Result: PureBallast goes to Ballast or Deballast mode.
4. Press the Ballast or Deballast button to resume the process.
5. Wait for the message “Confirm ballast pump started”. Start the pump and press the button in the
Result: The process is resumed.
4.5 Heel (internal transfer)

Follow this instruction to pause an ongoing ballast or deballast process to enable heeling (internal
transfer).
62 Book No.9010183 02, rev. 2

4 Operating instructions 4.7 CIP clean AOT reactor after
ballast / deballast
• This requires that a signal for heeling mode is integrated between PureBallast and the vessel’s
ISCS.
• This is only possible in sub process standby, full ballast and full deballast.
• Allowed length of heeling is parameter set (p138). After defined time, the system is stopped.
1. Activate heeling from ISCS, which means that a heeling signal is sent to PureBallast.
2. In PureBallast: Wait for the message “Stop ballast water pump”. Note! This component is
outside the PureBallast system control. (The popup is not displayed if the component feedback
is integrated with the control system.)
Note: If you you need the ballast pump for heeling, confirm the request without stopping the
ballast water pump.
Result: System goes to heeling mode (ongoing process is paused). The UV lamps remains on
at reduced power and cooling water is run through the AOT to avoid overheating of the lamps.
During heeling, the yellow light under the Pause button is lit and the yellow light under the
function button Ballast or Deballast is blinking.
3. To resume the paused process. Deactivate the heeling from ISCS.

Result: PureBallast goes to Pause mode.
4. Press the Ballast or Deballast button to resume the process.
5. Wait for the message “Confirm ballast pump started”. Start the pump and press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
Result: The process is resumed.
4.6 Backf ush f lter manually

Follow this instruction to backflush rinse the filter manually.
• The system must be in full ballast mode.

1. Go to page 1.1 Overview.
2. Press the Filter in the flow chart.

Result: The Filter popup is displayed.
3. Press the Start backf ush button.

Result: A backflush is performed. The default backflush process time is 40 seconds.
4.7 CIP clean AOT reactor after ballast / deballast

Follow this instruction to clean the AOT reactor(s) using the cleaning in place (CIP) process.
Book No.9010183 02, rev. 2 63

4.8 Stop ballast / deballast 4 Operating instructions
If system shut down is activated during the CIP process, the CIP liquid is drained to the CIP tank.
Water in the AOT reactors is drained overboard.
• The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
• Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOT reactors
are required to be CIP:ed etc.
• If a ballast operation has been performed since the last CIP process, the process is completed
with a filter preservation, where the filter is filled up with fresh water.
1. Press the function button CIP.
2. Wait for the message “Open valves ...”. Open relevant valves and then press button in the
Result: The automatic CIP process starts. The CIP process takes about 25 minutes for one
AOT reactor, if default parameters are used.
3. Wait for the message “Close valves ...”. Close relevant valves and then press button in the
4.8 Stop ballast / deballast

Follow this instruction to stop an ongoing ballasting or deballasting operation. Each ballast and
deballast operation must be stopped manually.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off. If ballasting, an automatic
backflush is performed before the system is stopped.
3. Wait for the message “Close valves ...”. Close relevant valves and then press the button in the
64 Book No.9010183 02, rev. 2

4 Operating instructions 4.9 Attend to alarms
NOTE
A CIP cleaning process must be performed after ballasting and deballasting. It can be done immediately or
within a 30 hours. When time is about to elaps, a warning is issued. If no action is taken within the time
limit, an entry is made in the control system’s log as a deviation from a correct handling of the system. Note,
that it is possible to perform processes during these 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status.
4.9 Attend to alarms

Follow this instruction to attend to alarms and warnings. For descriptions of alarms and trouble
shooting, see chapter 5. Alarms and faultfinding.
An alarm or warning is indicated by a audible signal and by a blinking alarm icon:
Alarm and warning: Active but not acknowledged.
4 AlarmActive
Alarm and warning: Acknowledged but still active.
4 AlarmAcknow
• If the alarm is caused by a faulty AOT reactor, the AOT reactor will shut down but the process
will continue with remaining AOT reactors.
NG
WARNI
!
• Never reset an alarm without first finding and attending to the problem.
• Requires login level Operator or higher.
• For color indication of alarms. See page 32.
1. Go to page 2.1 Alarm list to view active alarms.
• If the alarm has caused the system to automatically stop, go to step 2.

• If the alarm allows the ballast process to continue, go to step 3.
2. If the process have stopped: Take action to eliminate what has caused the alarm.
3. If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
Book No.9010183 02, rev. 2 65

4.10 Shut down and deactivate system 4 Operating instructions
4. After the problem has been dealt with Press the Ack all button to acknowledge all alarms, or
press the alarm row and press Ack selected button to acknowledge only this alarm.
Result: The alarm will change color to indicate change of status. See section Page 2.1 Alarm
list in this chapter. The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.
4.10 Shut down and deactivate system

Follow this instruction to quickly stop any ongoing operation in the PureBallast system, for example,
when a critical fault has been detected, or to make the system deactivated (currentless).
Control cabinet Lamp drive cabinet
3 Emergency stop
3 Emergency stop LDC
One of the following methods can be used to abort any ongoing operation and stop the system:
Action Method
Stop ongoing Press the Stop button in the control panel.

process Result: Ongoing process is stopped in a controlled way. Valves are
returned to starting position.
3StopButtonBlue
System stop Press the Stop button (2) on the control cabinet door.
Result: Ongoing process is stopped and valves are returned to starting
position as fast as possible. Note: The power is still on.
66 Book No.9010183 02, rev. 2

4 Operating instructions 4.12 Operate components manually
Action Method
System stop If an external system stop button has been installed and integrated, it
(External button) will function as the system stop above.
Deactivate Complete deactivation is performed in two steps:

PureBallast to
make it completely Stop any ongoing process:
deactivated
(currentless). 1. Turn off the main breaker (1) at the side of the control cabinet.
2. Turn off the main breaker (A) on the LDC door.
The system is then currentless on the PureBallast side of the breaker
(Q1 in control cabinet and Q1 in the LDC.
To make the complete system currentless, power to PureBallast must

be switched off using the ship’s switch board.
Note: Both breakers can be locked in off position using a padlock.
4.11 Reset system after shut down

Follow this instruction to reset the system if deactivated. Numbers refer to the illustration under
instruction Shut down and deactivate system on page 66.
The system may only be reset after the reason for shut down is known. If the reason is not known,
follow the instruction Attend to alarms.
Depending on how the system was shut down:
Manual on control cabinet: Turn the main breaker (1) and acknowledge the alarm in the control
system. Release the button on the control cabinet.
Automatic in LDC: Follow the instruction below if a reactor has been shut down by temperature
switch TS201-60 (alarm A137) or if the cabinet or system has been shut down by a blackout or
electrical faults in the cabinet:
1. Make sure that the main breaker (A) on the LDC door is turned on.
2. Press the blue reset button (B) on the LDC door (when the reactor has cooled down or when
the power is back on).
3. Acknowledge all alarm related to the shut down in the control system.
4.12 Operate components manually

Follow this instruction to operate components manually. This shall only be done during
commissioning, advanced faultfinding or service.
Valves are recommended to be operated via the PureBallast control system. It is also possible to
open/close them manually according to instruction in chapter 7. Service manual, section Operate
valves manually.
The following components can be operated manually:
Book No.9010183 02, rev. 2 67

4.12 Operate components manually 4 Operating instructions
• Filter motor (M709-43) NOTE: Hydac filter motor can only be started from the filter cabinet.
press the F5 button to start a backflush sequence for the motor.
• CIP pump for CIP liquid (P320-1)
• CIP pump for draining (P321-5)
• Booster pump, LDC cooling (401–1), if installed
• Booster pump, AOT reactor cooling (403–1), if installed
• UV lamps in the AOT reactor
• UV lamp effect.
• This operation requires login level Advanced operator or higher.

• It is not possible to run any processes in manual mode. Only individual components can be
operated.
• When operating valves, the positioning screw on the valve must be in position 0: Closed
(default position).
1. Go to page 1.1 Overview or 1.4 CIP status.
2. Press the button Manual function button.

Result: The control system is set in manual mode.
3. Press desired component.

Result: A popup is opened. Current status is indicated. If an existing alarm exist, it is indicated
with an alarm icon. If the AOT reactor or filter was pressed, a popup is opened with sub
components. If the CIP was pressed, page 1.4 CIP status is opened.
3 PopValve
Example popup for a valve.
4. Press (not slide) the Hand button icon to enable manual operation of the component.
Result: The open and closed buttons turn blue for operation. A hand icon is also displayed on
the component in the popup and the flow chart to indicate that it is manually operated.
5. Operate the component using the open/run (left) and closed/not running (right) buttons in
the popup.
68 Book No.9010183 02, rev. 2

4 Operating instructions 4.13 Operate UV lamps manually
6. Press Hand button to stop manual mode for the component and the X button to close the popup.
or
Press the X button to close the popup and let the component remain in manually set status.
The popup is closed, and a hand icon is displayed by the component to indicate it is manually
operated.
7. Press the Manual function button to exit manual mode.

Result: All manually operated components are restored to their previous status.
4.13 Operate UV lamps manually

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

• The control system must be in manual mode.
NGE R
! DA
• Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. All
necessary items – cooling water flow, water temperature, and power management – must be
supervised and verified by the authorized trained personnel operating the system. Inappropriate
operation of this function could seriously damage the equipment and injure personnel.
1. Go to page 1.1 Overview. Press the Manual function button to activate manual mode.
2. Press the AOT image.

Result: The AOT popup opens. (See description on page 51.)
3. Select which AOT reactor to operate in the AOT number entry field.
4. Open, in stated order, the following valves to fill the AOT reactor with water: 201-19, 404-36
and 403-35.
Result: The AOT reactor is now filled with water through the cooling water line 403.
5. Wait until the AOT reactor is filled with water, indicated by the level switch (LS201–29) turning
green.
Book No.9010183 02, rev. 2 69

4.14 Set ship specific component ID 4 Operating instructions
6. Press the LPS control button.

Result: The LPS control popup is displayed for selected AOT reactor.
3 LPS Manual popObe
7. Press the Manual mode button to enable manual operation of the UV lamps.
8. Operate lamps by pressing one of the following buttons:

Start all LPS units.
Stop all LPS units.
LPS1-16: Start / stop individual lamps. Each lamp power supply (LPS) powers to
corresponding UV lamp. The buttons toggles between started and stopped. Place the AOT
and the LPS control popups side to side to see that the lams are started.
UV lamp stauts: Grey = Stopped; Green = Started; Yellow = Starting.
9. If desired, the UV lamps can be dimmed manually: Press the LPS status button in the AOT
reactor popup. Press the Manual output filed, and enter desired percentage between 50
and 100 %. The LPS will give the entered percentage of full effect to the UV lamps. This is
indicated in the Power output field.
10. Press the Stop all LPS units button.

Result: Any lit UV lamps are stopped and the popup is closed.
11. Press the Close button to close the popup.

Result: All manually operated components are restored to standby status.
4.14 Set ship specif c component ID

Follow this instruction to set ship specific IDs for valves and pumps. The ID will be visible in page
1.1 Overview and popups for the components.
70 Book No.9010183 02, rev. 2

4 Operating instructions 4.15 Export control system event log files
• If remote control panels (option) are used, enterd IDs will be displayed on all panels.
• Requires login level Advanced operator.
2. Press desired component.

Result: A popup is opened.
3 ShipIDComp
Example: Popup with ship specific ID. Entered ID is

displayed on the component to the left.
3. Press the input field at the bottom.
4. Use the keyboard to enter an ID. Press Enter to finish.

Result: The name is saved and visible in page 1.1 Overview and the popup. .
4.15 Export control system event log f les

Follow this instruction to copy event log files and alarm lists from the control system. The
information (copied as text files to a USB memory) is recommended to be opened in Visualog, but
can also be opened in Excel or similar tools. Visualog is a tool designed to present and analyze
the information from the PureBallast log files.
The following information can be exported:
Book No.9010183 02, rev. 2 71

4.15 Export control system event log files 4 Operating instructions
Information to be Description
exported
Event log The event log includes all important events in the PureBallast system. The
log also include components connected via the log box. Intended to be
used mainly by service technicians.
Event log - Contains a selection of the complete event log, relevant to comply with
Certif cate the IMO regulations.
Alarms and A list of all alarms and warnings that has been issued from the control
warnings system. Intended to be used mainly by service technicians.
For specific information about logged events, see section List of logged information on page 85.
• Events are only copied, hence they will remain in the control system.
• The log and alarm files are stamped with the system name and serial number entered in page
4.5 Installation parameters.
• The easiest way of reading the log file is to use the program Visualog, but the file can also be
read in Exel. See Read event log in Excel below.
1. Go to page 4.1 System info.
2. Press the Export button in page section Export log f les.

Result: A popup is displayed.
72 Book No.9010183 02, rev. 2

4 Operating instructions 4.16 Backup control system settings
3 ExportLog
Note: The Update export button is only used when

updating softwares.
3. Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.
4. Chose one of the following alternatives to decide time interval for the information to be copied:
• Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is today’s date.
• Select the Specify time interval box, and enter desired interval in the Start and End fields.
5. Press one of the following function buttons: Events, Cert events or Alarms. (The Update
export is only used when updating softwares.)
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
6. Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been saved to the USB. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choices contains a CSV file.
7. Press Close and remove the USB memory
4.16 Backup control system settings

Follow this instruction to export all settings made in the control system to a backup on a USB
memory.
The following information is saved:
Book No.9010183 02, rev. 2 73

4.17 Restore control system settings 4 Operating instructions
• Parameter settings. File: Parameters.csv.

• Operating timers for AOT, UV lamps etc. File: operatingtimers.csv.
• Settings for components in the trend curve pages. File: ValueSaved.xml and
ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different components. File:
ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Backup button in page section Backup and restore.

Result: A popup is displayed and the process is started. Read the final line of list before
closing the popup: Important information might be displayed.
4. Wait for the OK / Close button to turn blue again. If the backup was successful, the last line
shall state "Backup done".
Result: A folder named PureBallast backup has been saved containing the backup files.
5. Remove the USB memory.
4.17 Restore control system settings

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

• A USB memory with backup files. When the files where backuped, the backup files where
saved in a folder named “PureBallast Backup”. For information about backup files, see section
“Backup and restore” in the page description for 4.1 System info, section on page 38.
• This method shall not be used to restore parameter settings after software update.
• If you do not wish to update a certain type of setting, remove the specific file from the USB
memory before inserting the USB memory in the USB panel port on the cabinet door.
• Remove the file Parameters.csv from the USB before following this instruction.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Restore button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started.
4. Wait for the OK / Close button to turn blue.
5. Read the second last line in popup: If the restore was successful, it shall state "Restore done".
74 Book No.9010183 02, rev. 2

4 Operating instructions 4.18 Set control panel IP address
6. Press the OK / Close button on the popup.
7. Remove the USB memory.
8. The control panel must be rebooted. At the rear side of the control panel: Pull out the power
cable from the 24V DC port, and insert it again.
4.18 Set control panel IP address

Follow this instruction to set IP address for the main panel and the remote control panels (optional).
• This setting shall be done for all panels installed.

• These instructions require login level AlfaLaval.
• Port 1 must be used for the Ethernet cable at the backside of the panel. It is marked with the
symbol below.
3 USB
2. Press the Setup button in the IP settings box.

Result: The IP settings popup is displayed.
3. Press the IP Settings button.

3 IPaddress
Book No.9010183 02, rev. 2 75

4.19 Set remote control panel communication 4 Operating instructions
4. In the Port 1 tab select the radio button Specify an IP address.
Enter the IP address according to the list below. Also check that correct setting is done for Port
2 in the Port 2 tab.
3 IPaddress
Note: Only the IP address shall be changed.
5. Press OK.
6. Reboot the panel to update communication with the new IP address. Make sure that the new
IP address is displayed on page 4.1 System info.
7. Repeat this instruction for all installed control panels, both main and remote control panels, if
installed.
8. Follow the instruction Set remote control panel communication to activate remote control panel.
4.19 Set remote control panel communication

Follow this instruction to connect remote control panels (optional) to the PLC.
• These instructions require login level Advanced operator or higher.

• The same setting shall be done for all panels installed.
• IP addresses must have been set according to instruction Set control panel IP address.
• Main control panel and remote control panel 1 (192.168.0.11) are added as default . If no
remote control panelse is used, address 192.168.0.11 shall be removed.
• All remote control panels must be on and connected with an Ethernet cable.
1. On the main panel in the control cabinet: Go to page 4.1 System info.
76 Book No.9010183 02, rev. 2

4 Operating instructions 4.20 Set remote interface communication
2. In the Remote control panels box, press the Set button.

Result: The Remote panels setting popup is displayed.
3 RCP communication
3. Select an available remote control panel in the left hand side.
4. Press the >> button.

Result: The panel is connected and moved to the right hand side.
Note: Server port shall always be “1001”.
5. Press the Panel alias field for the new control panel. Use the keyboard to enter a name, for
example the location it is placed.
Note: Panel alias for all control panels shall be entered (with the same wording) in all panels
to be displayed in a correct way.
6. Press the save (diskette) icon.

Result: The information is saved and the popup is closed.
7. Repeat step 4–7 to connect more remote control panels.
8. Repeat this entire instruction for all installed panels.
Delete a remote control panel
If remote control panels are not used, any added control panels shall be deleted from the list.
To delete a connected panel: Select it a panel in the hand side and press the delete (X) icon. If a
keyboard is displayed, pres Esc to remove it.
4.20 Set remote interface communication

Follow this instruction to make settings for the remote interface (optional) communication between
the ISCS and PureBallast.
Book No.9010183 02, rev. 2 77

4.21 Test remote interface communication 4 Operating instructions
• These instructions require login level AlfaLaval.

1. Go to page 5.7 Remote interface.
2. Set parameters to match ISCS’s RTU server data according to the information in chapter 4.
Parameters, section 5.7 – Remote interface.
4.21 Test remote interface communication

Follow this instruction to test that the remote interface (optional) communication between
PureBallast’s PLC and the ISCS is correct and functioning.
Test communication
The first test is to see that the two systems communicate.
1. Go to page 4.5 Remote interface 1. Make sure that the system is not in test mode (no
checkmark on the button). If not, press the Test mode button to deactivate it. Make sure that
Local operation is activated. If not, press the Local function button.
2. Check that the heartbeat signal is updated in both systems (+006 and +077). Also check
that values are read from the PureBallast system, for example temperature (address +116
and +117).
This will confirm that the systems communicate.
Test values sent from PureBallast to ISCS
Values are entered and displayed in the control system as actual values, but are sent to ISCS using
the binary numeral system. This information is found in group Data to ISCS and Cmd/status to
ISCS on page 4.5 Remote interface 1, and is indicated by a unit (m3, hour, second, kW etc).
Addresses with special conditions
The following addresses does not display correct values in page 4.5:
• +050 Process volume

• +114/124/134 AOT reactor temperature for AOT reactor 1, 2 and 3
• +115/125/135 LDC water temperature for AOT reactor 1, 2 and 3
• +052 System pressure
• +063 Filter differential pressure
• +064 Filter inlet pressure V201–71 (Hydac filter)
• +065 Filter outlet pressure V201–72 (Hydac filter)
• +066 V201-8 setpoint
• +057/+058. Current time
For detailed information, see the directory of addresses.
78 Book No.9010183 02, rev. 2

4 Operating instructions 4.21 Test remote interface communication
1. Press the Remote function button.

Result: Test mode is activated enabling that communication is sent between the systems
without actually affecting the control system (start processes etc). This also result in alarm A93
Heartbeat signal missing. This alarm shall be ignored during this test.
2. Enter actual values in the in the input field for the address to send simulated information to
the ISCS. Information in decimal form, for example processed volume, is written as actual
values. Information in binary form, for example command status, is written as a bit pattern.
The key for the bit pattern is found in chapter 6. Installation description and drawings, section
System interfaces.
3. Make sure that values and status information is displayed correspondingly in the ISCS.
4. Repeat the simulation for the information you which to test.

Note: Only implemented signals needs to be tested.
Test commands from ISCS to PureBallast
In the ISCS, activate input commands corresponding to the addresses displayed in page 4.5. (Note
that address 006 does not need to be tested; it was tested at the beginning of this procedure.)
1. Activate a command from ISCS, according to the HMI implementation.
2. Make sure that the command is received in page 4.5. Use the directory of addresses to see
that the bit pattern is updated correctly.
3. In the control panel, restore all changed values after the communication test. If not, commands
might be executed involuntarily, when the system is set to online again. Most important is that
address 001 displays ”00000000”.
Test alarms and warnings
Alarms and warnings are tested by simulation in control page 4.5 Remote interface 1 and 4.6
Remote interface 2. Use the alarm list to identify addresses and bit patterns for the alarms.
You want to simulate alarm W40 (Process pressure too low). When you find W40 in the table, you
use the column heading to see which address the alarm shall be sent to and the row heading to
see which bit in the bit pattern that shall be high. For W40 the signal shall be sent to address
+902, and bit 12 shall be high.
Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first digit from
right is counted as zero, second digit counted as 1 etc). This gives the following bit pattern:
0010000000000000.
AOT reactor alarms/warnings: Each installed AOT reactor has a unique address:
• AOT reactor 1/ LDC 1: Address +910 – 912

• AOT reactor 2 / LDC 2: Address +913 – 915
1. Enter the desired bit pattern in the input field for the address.
2. Make sure that the alarm/warning is indicated in ISCS.
Book No.9010183 02, rev. 2 79

4.23 Set default parameters 4 Operating instructions
3. If common alarm and warnings are used, make sure that address +070:7 and +070:8 are
updated. It is only necessary to check this for the first alarm.
4. Clear the bit pattern in the input field.
5. Repeat the simulation for those alarms/warnings you which to test.
6. Press the Test mode button to set the system in online mode (no check mark on the button).
Press the Remote function button if you want to activate remote control.
4.22 Simulate power request

Follow this instruction to test the power management signals if PureBallast is integrated with the
vessel’s power management system. This instruction can also be used in manual mode during
faultfinding.
• This instruction requires login level Advanced operator or higher.

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

Result: The control system is set in manual mode, indicated by a green checkmark on the
button.
2. Press the hand button in the Request column for a row with power step for desired number of
AOT reactors. For details, see description of page 1.4 – Power request.
3. Press the Request button for the row to simulate power request signal.
Result: Status is updated to “Requested” in the Request column.
4. Wait until the status is updated to “Yes” in the Granted column.
5. Press the hand button in the Status column.
6. Press the Set run button to simulate running signal.

Result: Status is updated to “Running” in the Status column.
7. Press the Set run button to deactivate the simulate running signal.
4.23 Set default parameters

Follow this instruction to set or reset all parameters in the control system to the factory set default
values.
80 Book No.9010183 02, rev. 2

4 Operating instructions 4.25 Calibrate the control panel’s touch
screen sensibility
2. Press the Default parameters button in page section Parameters.

3. Press Yes in the popup.

Result: All parameters are reset.
4.24 Update control system softwares

Control system softwares must be updated according the Release note for the specific version of
the softwares. The release note contains instructions for updating the softwares and information
about new features, changes in the software etc.
The following is needed:
• A flash card with correct version of the PLC software.

• A USB memory with HMI software. Note that the same version must be used for the HMI
and PLC software (same version number).
• A USB memory with the TA150 firmware.
4.25 Calibrate the control panel’s touch screen
sensibility
Follow this instruction to improve the touch precision on the screen, if it is hard to hit buttons and
icons with precision.
1. Pull out the power cable from the 24V DC port on the rear side of the control panel.
2. Open the small cover on the rear side. Turn DIP switch 1 to position ON.
Book No.9010183 02, rev. 2 81

4.26 PID calibrate system 4 Operating instructions
7BeijerMODE
3. Re-connect the power cable. Wait for a cross is displayed on the screen.
4. Press the cross until it changes position. Repeat until the menu is displayed again.
Result: Calibration is ready.
5. Pull out the power cable from the 24V DC port.
6. Turn DIP switch 1 to position OFF.
7. Re-connect the power cable.
4.26 PID calibrate system

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

The purpose is to adjust the movement of V201-8 when it changes from flow controlled regulation to
pressure controlled regulation which it does during backflushing of the filter. The first goal is that
the valve travels as fast as possible to a steady position where it creates required pressure (as
defined in parameter p304).
The second goal is to shorten the time from backflush trigger to start of actual backflush. This is
done by shortening the time in p310 (Backflush initial delay) that is done after the movement of
V201-8 has been calibrated.
82 Book No.9010183 02, rev. 2

4 Operating instructions 4.26 PID calibrate system
• This operation requires login level AlfaLaval.

• All components on page 3.1 Trend (15 min) shall be selected for plotting, and FIT201-1 shall be
used for Y axis selection.
This instruction shall be read together with the example after the instruction.
1. Perform a backflush.
2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8.
Before the backflush, the valve shall move as fast as possible to a steady position where it
creates required pressure. If not, parameter p166 shall be adjusted.
3. Adjust parameters, and perform a new backflush.
4. See if the curve has improved. Repeat until satisfactory result has been achieved.
5. See if the time between backflush initiation and backflush can be shortened . If possible, adjust
parameter p310. See parameter p310 in the example below.
Example
In this example, five backflushes are performed. After the first four backflushes, the PID parameters
where changed for pressure regulation to adjust the movement of the control valve V201-8 before
the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated by the movement
of the backflush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated
by the blue line.
1st backflush Parameter p166 is set to 0.30. But it takes too long time for V201-8 to get into
position to create desired pressure (1). The curve slops downwards in a long bend,
which means that it takes time for V201-8 to find correct position.
2nd backflush Parameter p166 was adjusted to 0.6. This made the valve movement much faster
in the beginning, shown by the steep curve at the beginning. But then a more slow
regulation starts, shown by the soft slope (2). This was a change for the better, but
3rd backflush Parameter
not enough.p166 was increased to 1.2 which resulted in a satisfactory valve
movement (3): A fast movement, followed by a minor adjustment. A small
overcompensation can be noted (curve goes too low), that might be adjusted by
decreasing the value to 1.1.
4th backflush During the first backflushes, parameter p310 was set to 60 seconds. The parameter
defines time between a backflush is triggered and it actually starts. But now, when
V201-8 is calibrated, this time can be shortened. Before the fourth backflush
parameter p310 is set to 15 seconds. The shortened time span is indicated by
the braces in the illustration.
5th backflush No parameter was changed. This backflush is only showed to confirm that the
parameter setting is OK and that the curve (5) for V201-8 is basically the same as
for backflush three and four (3 and 4).
Book No.9010183 02, rev. 2 83

4.26 PID calibrate system 4 Operating instructions
3 CalibExample
84 Book No.9010183 02, rev. 2

5 List of logged information
Alarm history and important events are logged in the control system. The log also include
components connected via the log box (optional).
The control system store all alarms and relevant events for at least 24 months. The memory has
a vast safety margin but when it is full, data will be deleted starting with the oldest data. Logged
information can be exported to a USB memory stick. See Export control system log files on page 71.
Event log certif cate: Contains events relevant to the IMO certificate. Those events are the
ones that are GPS stamped in the table below, with exception for events regarding the log box
(5010—5220).
5.1 Event log

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

code stamp
10 Operator command, start Ballast is issued Y
20 Operator command, start deballast is issued Y
30 Operator command, start CIP is issued N
40 Operator command, stop process is issued Y
50 Operator command, initiate pause is issued Y
60 Operator command, resume from pause is issued Y
70 Operator command, set certified flow to [x] m3/h N
100 PureBallast is set in mode Manual by operator N
110 Heeling (internal transfer) mode request issued by external Y
120 Heeling (internal transfer) mode request cancelled by external Y
130 Additional (external) bypass of PureBallast is detected open Y
140 Additional (external) bypass of PureBallast is detected closed Y
150 Feedback received, "overboard valve is OPEN" Y
Book No.9010183 02, rev. 2 85

5.1 Event log 5 List of logged information

code stamp
160 Feedback received, "BW-pump is running" N
170 External system stop (System stop button on control cabinet or N

external system stop button)
190 PureBallast is in mode Standby N
210 PureBallast is in mode Start-up Ballast N
220 PureBallast is in mode Full Ballast N
230 PureBallast is in mode Pause Ballast N
240 PureBallast is in mode Backflush N
250 PureBallast is in mode Stop Ballast N
260 PureBallast is in mode Start-up Deballast N
270 PureBallast is in mode Full Deballast N
280 PureBallast is in mode Pause Deballast N
290 PureBallast is in mode Stop Deballast N
300 PureBallast is in mode CIP, AOT [x, y, z ...] N

x, y, z ...= units that has been subjected to CIP
310 PureBallast is in mode E-stop N
320 PureBallast has been powered off for [x]days:[y]hrs:[z]min Y

Time of how long the power has been switched off
330 Amount (m3) of ballast intake treated according to standard Y
331 Amount (m3) of ballast intake treated. Time interval according to Y

parameter p161.
340 [X] m3 of ballast discharge treated according to standard Y
341 [X] m3 of ballast discharge treated. Time interval according to Y

parameter p162.
350 V212-31 bypass valve in open position Y
360 V212-31 bypass valve in closed position Y
370 Request sent to ISCS; open overboard/outlet valve N
380 Request cancelled to ISCS; open overboard/outlet valve N
390 Request sent to ISCS; start BW-pump N
86 Book No.9010183 02, rev. 2

5 List of logged information 5.1 Event log

code stamp
400 Request cancelled to ISCS; start BW-pump N
410 Power requested sent N
420 Power granted received N
430 Power running sent N
450 Pure Ballast is shut down due to failure Y
460 Additional (external) bypass 1 is detected open Y
470 Additional (external) bypass 1 is detected closed Y
515 System bypass via remote interface detected open Y
520 AOT 1 UV sensor low level Y
640 AOT 1 UV sensor value: [X] W/m2 Y
700 AOT 1 LPS power % to UV lamp(s) Y
701 AOT 1 UV lamp lap time reset Y
710 AOT 2 LPS power % to UV lamp
720 AOT 3 LPS power % to UV lamp Y
800 Process flow is higer than certified flow (W12). Y
801 Process flow below certified flow (W12 reset). Y
810 CIP timer exceeded for AOT1 Y
Book No.9010183 02, rev. 2 87


code stamp
811 CIP completed for AOT1 Y
1152 AOT 1 UV intensity low. System flow reduced.
1153 AOT 1 UV lamp fail. System flow reduced.
5010 Log box: Valve V01 position change: [X]. 1=Closed. 0=Not closed. Y
5011 Log box: Valve V01 position change: [X]. 1=Open. 0=Not open. Y
88 Book No.9010183 02, rev. 2

5 List of logged information 5.1 Event log

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

running.

running.

running.

running.
Book No.9010183 02, rev. 2 89

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

Standby mode is the starting point of PureBallast. Standby mode is active at system start-up or
when no other process is active. From Standby mode, the following processes and sub processes
can be started.
• Ballast
• Deballast
• CIP
• Deactivate system
• Change flow (set flow before a ballast or deballast process)
• Manual mode.
Book No.9010183 02, rev. 2 91

6.2 Ballast process 6 Detailed process description
6.2 Ballast process

The ballast process and sub processes are illustrated and described below. Note that the process
can be stopped at any time.
3 BallastProcess
6.2.1 Ballast start-up

Purpose: To warm UV lamps under controlled conditions before water treatment.
1. Operator starts the process from the control system.
2. Request from control system to open overboard (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. Overboard valve opened by operator and confirmed in control system. (Handled automatic, if
external component signal is enabled.)
Component activities:
• - Start P401-1 (booster pump for LDC cooling water) (if used)
- Open V403-35 (cooling water inlet)
- Open V201-32 (filter outlet)
• Start P403-1 (booster pump for reactor cooling water) (if used).
4. Power management
Automatic power request from PureBallast to vessel’s power management system (if
integrated).
92 Book No.9010183 02, rev. 2

6 Detailed process description 6.2 Ballast process
5. UV lamp warming
• Open V404-36 (AOT reactor outlet, cooling water)

• Open V201-19 (reactor inlet).
6. Cooling water fills the AOT reactors. When filled, indicated by LS201-29:
• Start UV lamps (100 %).

• Start counter: UV lamp runtime.
• Start LDC fan.
• Open V201-20 (reactor outlet)
• Set V201-8 (control valve) to 50 %.
7. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8. Ballast water pump started by operator and confirmed in control system.
9. Open V201-3 (filter inlet).
6.2.2 Full ballast

Purpose: To treat ballast water.
1. Component activities:
• - Start counter: Accumulated water and CIP required

- Stop P403-1 (booster pump for reactor cooling water) (if used)
• - Close 403-35 (cooling water inlet)
- Close V404-36 (AOT reactor outlet, cooling water)
- When flow is established: Start automatic control of control valve (V201-8) based on
input from the flow meter.
• After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT201–50.
6.2.3 Filter backf ush

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

• Start automatic control of control valve (V201-8) based on input from the pressure transmitter
• Open V309-1
• Start M709-42.
Book No.9010183 02, rev. 2 93

6.2 Ballast process 6 Detailed process description
2. Filter backflush is performed (1-100 seconds).

• Stop M709-42
• Close V309-1
• Start automatic control of control valve (V201-8) based on input from the flow meter.
3. Differential pressure check. If necessary, the process is repeated.
6.2.4 Pause ballast (Heeling mode)

Purpose: To pause the ballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
1. Operator pause the ballast process manually. Pause can also be initiated by an external signal,
for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
2. Set V201-8 (control valve) to parameter (p113) set opening percent.
3. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
4. BW pump stopped by operator and confirmed in control system. Component activities:
• - Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- Stop counter: Accumulated water
• Start P403-1 (booster pump for reactor cooling water) (if used)
- Close V201-3 (filter inlet)
- Close V201-20 (reactor outlet) on running AOT reactors
- UV lamps dimmed to 50 %
• Close V201-8 (control valve).
5. System in pause mode
6.
Resume ballasting
Operator resumes the ballast process manually.
• Set V201-8 (control valve) to parameter set opening percent

• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running AOT reactors.
7. Request from control system to start ballast water pump” (outside PureBallast system).
8. BW pump started by operator and confirmed in control system. (Handled automatic, if external
component signal is enabled.)
• Open 201-3 (filter inlet)
94 Book No.9010183 02, rev. 2

6 Detailed process description 6.2 Ballast process
9. Component activities when minimum process flow established, indicated by FIT201-1:
• - Start counter: Accumulated water.

- Close V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- Start automatic control of control valve (V201-8) based on input from the flow meter.
- After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT201–50.
6.2.5 Stop ballast

Purpose: To stop the ballast process.
1. Operator stops the ballast process manually.

• Stop P401-1 (booster pump for LDC cooling water) (if used)
• Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from
pause mode
• Stop counter: Accumulated water
• - Close V403-35 (cooling water inlet), only needed if stop from pause mode
- Set V201-8 (control valve) to parameter set opening percent.
- Close V201-32 (filter outlet) Delay: the longes time between of p146 and p119.
• UV lamps are lit at 100 % for 10 seconds, then switched off.
• Stop counter: UV lamp runtime
• - Close V201-19 (reactor inlet)
- Close V201-20 (reactor outlet)
• Automatic withdrawal of power allocation (if integrated).
2. Filter backf ush
Backflushing of filter starts, including the following activities:
• - Start automatic control of control valve (V201-8) based on input from the pressure
transmitter
- Open V309-1
- Start M709-42.
3. Backflush is performed. Approximate duration: 20 seconds.
• - Stop M709-42
- Close V309-1.
4. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
5. BW pump stopped by operator and confirmed in control system.
• - Close V201-8 (control valve)

- Close V201-3 (filter inlet).
6. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)
Book No.9010183 02, rev. 2 95

6.3 Deballast process 6 Detailed process description
6.3 Deballast process

The deballast process and sub processes are illustrated and described below. Note that the
process can be stopped at any time.
3 DeBallastProcess
6.3.1 Deballast start-up

Purpose: To warm UV lamps under controlled conditions before water treatment.
1. Operator start the deballast process manually.

2. Request from control system to open overboard valve (outside PureBallast system). (Handled
3. Overboard valve opened by operator and confirmed in control system.
• - Start P401-1 (booster pump for LDC cooling water) (if used)
• Start P403-1 (booster pump for reactor cooling water) (if used).
4. Power management
Automatic power request from PureBallast to vessel’s power management system (if integrated).
5. UV lamp warming
Component activities when power has been granted:
• Open V404-36 (AOT reactor outlet, cooling water)

• Open V201-19 (reactor inlet).
96 Book No.9010183 02, rev. 2

6 Detailed process description 6.3 Deballast process
6. Water fills the AOT reactors.

7. Component activities, when AOT reactors are filled, indicated by LS201-29:
• Start UV lamps (100 %).

• Start counter: UV lamp runtime.
• Start LDC fan.
• Open V201-20 (reactor outlet)
• Set V201-8 (control valve) to 50 %.
8. Request from control system to start ballast water pump (outside PureBallast system). (Handled
9. BW pump started by operator and confirmed in control system.
• Open V201-9 (main inlet valve).
6.3.2 Full deballast

Purpose: To treat deballast water.
• - Start counter: Accumulated water and CIP required.

- Close V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- When flow is established: Start automatic control of control valve (V201-8) based on
input from the flow meter.
• After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT201–50.
6.3.3 Pause deballast (Heeling)

Purpose: To pause the deballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
1. Operator pause the deballast process manually. Pause can also be initiated by an external
signal, for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.

• Open V403-35 (cooling water inlet)
• - Start P403-1 (booster pump for reactor cooling water) (if used)
- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors.
Book No.9010183 02, rev. 2 97

6.3 Deballast process 6 Detailed process description
2. Request from control system to stop ballast water pump (outside the PureBallast system
control). (Handled automatic, if external component signal is enabled.)
• - Stop counter: Accumulated water

- Close V201-9 (main inlet valve)
- Close V201-8 (control valve)
- Close V201-20 (reactor outlet) on running AOT reactors
- UV lamps dimmed to 50 %.
3. System in pause mode
4. Resume deballasting
Operator resume the deballast process manually.
• Set V201-8 (control valve) to parameter set opening percent.

• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running AOT reactors.
5. Request from control system to start ballast water pump” (outside PureBallast system).
6. BW pump started by operator and confirmed in control system.
• Open V201-9 (main inlet valve)

• - Start counter: Accumulated water.

Stop P403-1 (booster pump for reactor cooling water) (if used)
- Close 404-36 (AOT reactor outlet, cooling water)
- Start automatic control of control valve (V201-8) based on input from the flow meter.
- After 2 minutes in full deballast: Start power optimization based on input from UV sensor
QT201–50.
6.3.4 Stop deballast

Purpose: To stop the deballast process.
98 Book No.9010183 02, rev. 2

6 Detailed process description 6.4 CIP process
1. Operator stops the ballast process manually.

• Stop P401-1 (booster pump for LDC cooling water) (if used)
• Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from
pause mode
• Close V403-35 (cooling water inlet), only needed if stop from pause mode
• Close V201-9 (main inlet valve) Wait for feed back “closed” or delay according to p 115.
• UV lamps are lit at 100 % for 10 seconds, then switched off.
• Stop counter: UV lamp runtime
• - Close V201-19 (reactor inlet)
- Close V201-20 (reactor outlet)
2. Request from control system stop ballast water pump (outside PureBallast system). (Handled
3. BW pump stopped by operator and confirmed in control system.
• Automatic withdrawal of power allocation (if integrated)

• Close V201-8
• Stop counter: Accumulated water.
4. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)
6.4 CIP process
The CIP process is run to remove seawater scaling from the AOT reactor after ballast and deballast.
The process is performed for used AOT reactor in sequence. The process can start directly
after ballast or deballast process, or be delayed. A CIP process is started manually according
to instruction CIP clean AOT after ballast / debalalst on page 63. Note that the process can be
stopped at any time.
Book No.9010183 02, rev. 2 99

6.4 CIP process 6 Detailed process description
3 CIPprocess
6.4.1 Start CIP

1. Operator starts the CIP process manually.
2. Request from control system to open overboard valve (outside PureBallast system). (Handled
3. Overboard valve opened by operator and confirmed in control system.
6.4.2 Drain ballast water

1.
Component activities (in no specific order):
• - Open V460-2 (CIP, drain valve)

- Open V321–2 (AOT reactor, upper CIP return valve)
- Open V320–4 (AOT reactor, lower CIP return valve)
- Open V571-1 (CIP, deaeration valve)
- Start P321-5 (CIP, water pump)
100 Book No.9010183 02, rev. 2

6 Detailed process description 6.4 CIP process
2. Component activities, when AOT reactors are empty, indicated by LS201-29:
• - Stop P321-5
- Close V571-1 (CIP, deaeration valve)
- Close V460-2 (CIP, drain valve)
- Close V321–2 (AOT reactor, upper CIP return valve)
- Close V320–4 (AOT reactor, lower CIP return valve).
6.4.3 Fresh water f lling

1.
• - Open V571-1 (CIP, deaeration valve)

- Open V310-6 (CIP, AOT reactor fresh water filling)
- Open V320–4 (AOT reactor, lower CIP return valve).
2. Component activities, when AOT reactors are filled, indicated by LS201-29:
• - Close V310-6 (CIP, AOT reactor fresh water filling)

- Close V320–4 (AOT reactor, lower CIP return valve).
6.4.4 Fresh water draining

• - Open V460-2 (CIP, drain valve)

- Open V571-1 (CIP, deaeration valve)
- Open V320–4 (AOT reactor, lower CIP return valve)
- Start P321-5 (CIP, water pump).
2. Component activities when AOT reactor is empty, indicated by LS201-29 + drain time (p200):
• - Stop P321-5 (CIP, water pump)

- Close V460-2 (CIP, drain valve)
- Close V320–4 (AOT reactor, lower CIP return valve)
6.4.5 CIP cleaning

• - Open V320–2 (CIP outlet to AOT reactor)

- Open V320-4 (AOT reactor, lower CIP return valve)
- Open V321-2 (AOT reactor, upper CIP return valve)
- Open 321–4
- Start P320-1 (CIP, liquid pump).
2. When AOT reactors are filled, indicated by LS201-29, CIP liquid is circulated for 15 minutes.
Book No.9010183 02, rev. 2 101

6.4 CIP process 6 Detailed process description
3. Component activities after finished CIP process .
• - Stop P320-1 (CIP, liquid pump)

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

• Open V321-4 (CIP, return valve)

Open V321–1 (CIP, outlet valve)
- Open V320-4 (AOT reactor, lower CIP return valve)
- Start P321-5 (CIP, water pump).
2. Component activities, when AOT reactor is empty, indicated by LS201-29 + drain time (p200):
• - Stop P321-5 (CIP, water pump)

- Close V321-2 (AOT reactor, upper CIP return valve)
- Close V 321-4 (CIP, return valve)
- Close V321-1 (CIP, outlet valve).
6.4.7 Fresh water f lling

1.
• - Open V571-1 (CIP, deaeration valve)

- Open V310-6 (CIP, AOT reactor fresh water filling)
- Open V320-4 (AOT reactor, lower CIP return valve).
2. Component activities, when AOT reactor is filled, indicated by LS201-29:
• Close V310-6 (CIP, AOT reactor fresh water filling)

• Close V571-1 (CIP, deaeration valve)
- Close V321-2 (AOT reactor, upper CIP return valve)
- Close V320-4 (AOT reactor, lower CIP return valve).
6.4.8 Repeat
When CIP process is done for the first AOT reactor, the remaining AOT reactors with status CIP
required are processed in the same way.
6.4.9 Filter preservation

Only performed if ballast has been performed since last filter preservation.
102 Book No.9010183 02, rev. 2

6 Detailed process description 6.5 Manual mode
1.
Component activities when all required AOT reactors are processed:
• - Open V310-1
- Open V309-1
- Start M709-42.
2. Component activities after the filter is filled:
• - Stop M709-42
- Close V309-1
- Close V310-1.
3. Request from control system to close overboard valve (outside PureBallast system). (Handled
4. Overboard valve closed by operator and confirmed in control system.
6.5 Manual mode

PureBallast can be set in manual mode, which enables the operator to operate components
manually and to set digital outputs.
The following can be performed in manual mode:
• Operate components from the flow chart. Tap a component to operate it from the displayed
popup window. The following components can be operated: valves, motors, UV lamps etc,
digital output signals.
• Operate and simulate power management.
The following limitations exist for manual mode:
• Requires login level 2. The Manual mode button is only displayed for login level 2.
• Flow in pipes is not indicated in flow chart.
• Can only be activate from standby mode.
• No automatic processes can be run.
To activate: Press the Manual mode button in page 1.1 Flow chart and follow the instructions
Operate UV components manually and Operate UV lamps manually.
To deactivate: Press the Manual mode button again in page 1.1 Flow chart or log out. All forced
outputs and manual changes are reset and the system goes to Standby mode.
Book No.9010183 02, rev. 2 103

1 Quick guide to PureBallast
operations
1.1 Introduction
This is a quick guide to the most common routines performed in the PureBallast control system.
More detailed instructions are found in the PureBallast manual.
This guide covers the following routines:
• Ballast and deballast

• CIP clean AOT
• Basic alarm handling
• Save log file and parameters to USB memory
• There must be available power for the system. If power management is integrated, this will be
done automatically. If power management is not integrated, confirm this manually.
1.2 Ballast and deballast
1. Go to page 1.1 Overview
2. Press the Ballast or Deballast function button.

Comment: If the button is not blue, check that flow or AOT reactors have been selected
3. Wait for the message “Open valves ...”. Open relevant valves and then press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
4. Wait for the message “Confirm ballast pump started”. Start the pump and then press the button
in the popup to confirm the action. (The popup is not displayed if the component feedback is
5. When desired amount of water has been processed, press the function button Stop to end
the process.
1
1.4 CIP clean AOT 1 Quick guide to PureBallast operations
6. Wait for the message “Close valves ...” and “Stop ballast water pump”. Handle accordingly.
(The popups are not displayed if the component feedback is integrated with the control system.)
7. Perform a CIP process if no operation is planned soon. A CIP process must be performed
within 30 hours after operation.
1.3 Alarm handling

Follow this instruction to attend to alarms and to acknowledge them afterwards. For descriptions of
alarms and trouble shooting, see chapter 5. Alarms and fault finding.
An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.
• Never reset an alarm without first finding and attending to the problem.
1. Go to page 2.1 Alarm list.
2. Select an alarm by pressing the alarm row.
3. If the process have stopped: Take action to eliminate what has caused the alarm.
4. If the alarm is caused by a faulty AOT module, the ballast/deballast process has to be restarted
with another AOT according to the Perform ballast instruction.
5. If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
Press the Ack selected or Ack all button after the problem has been dealt with.
1.4 CIP clean AOT

• The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
• Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOTs are
required to be CIP:ed etc.
2. Press the function button CIP.
3. Wait for the message “Open valves ...”. Open relevant valves and then press button in the
popup to confirm the action.
Result: The automatic CIP cycle starts. The CIP cycle takes about 25 minutes per AOT.
2
1 Quick guide to PureBallast operations 1.5 Export control system log files
4. Wait for the message “Confirm overboard valve closed”. Close the valve and then press button
in the popup to confirm the action.
1.5 Export control system log f les

Follow this instruction to copy control system information as text files to a USB memory.
• Required USB memory.

2. Press the Export button in page section Export log f les.

Result: Popup Export PLC events is displayed.
3. Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.
4. Chose one of the following alternatives to decide time interval for the information to be copied:
• Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is today’s date.
• Select the Specify time interval box, and enter desired interval in the Start and End fields.
5. Press one of the following function buttons: Events, Cert events or Alarms.
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
6. Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been downloaded. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choice contains a CSV file.
7. Prtess Close and remove the USB memory
3
Chapter: 4. Parameters
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 5
2 Control system parameters 7

2.1 Setting parameters 7
2.2 Introduction to the parameter pages 8
2.2.1 Key to parameter numbers and indication 8
2.3 Set parameters 8

2.4 Page 5.1 – Main parameters 1 10
2.5 Page 5.2 – Main parameters 2 14
2.6 Page 5.3 – AOT parameters 18
2.7 Page 5.4 – Filter parameters 22
2.8 Page 5.5 – CIP parameters 25
2.9 Page 5.6 – Installation parameters 26
3 Flow transmitter parameters 31

3.1 Check and set parameters 32
4 Lamp power supply (LPS)

parameters 35
4.1 DIP switch settings 35
4.2 Change DIP switch setting 36
3
1 Introduction
This chapter contains information about parameters in the control system and flow transmitter.
It covers:
• Parameter page descriptions.

• Parameter lists including information about setting range, default values etc.
Book No.9010183 02, rev. 2 5

1 Introduction
2 Control system parameters
This section describes all parameters set in the PureBallast control system.
• Parameters shall only be set when the system is in mode Standby.

• Only authorized trained personnel must set parameters in the control system – both manual
operations and parameter settings. The PureBallast equipment or connected equipment can be
irreparably damaged if set or handled incorrectly.
NOTE
• Parameters in bold can only be changed by login level AlfaLaval. Parameters in normal text can
be changed by login level Advanced operator.
• The parameter settings can be exported to a USB memory for safety backup, and be restored
from a backup. See chapter 3. Operating instructions and control system description for
instructions.
Parameters are valid for PLC software version V3.0.7.
2.1 Setting parameters

General (non-installation specific) parameters are preset to function for all systems. They must only
be adjusted, by Alfa Laval (or authorized trained personnel), if required by performance reasons
or similar.
The installation specific parameters are set to reflect the specific installation and shall normally only
be checked and adjusted at first start up, during preparations for commissioning.
The installation specific parameters are found in the pages listed below:
• Page 5.1 Main parameters 1.
- p126: LDC after-cooling.

- p140–p144: Time-out for requests from PureBallast.
• Page 5.2 Main parameters 2.
- All parameters on the page, except p168.

• Page 5.3 AOT parameters:
- p200, p201, p208 and 216: Time-out parameters for draining and filling AOT reactor.
These parameter are evaluated during the commissioning preparation test and adjusted if
necessary.
Book No.9010183 02, rev. 2 7

2.3 Set parameters 2 Control system parameters
• Page 5.4 Filter parameters:
- p304: Required pressure to start backflush (PT201–16). This parameter is calculated to

reflect pressure in the specific installation.
- p306: Filter preservation time. This parameter is evaluated during the commissioning
preparation test and adjusted if necessary.
- p308: Backflush cycle time. Set to match installed filter. See parameter description in
this chapter.
- p314: Filter.
- p315: Filter type. Defines maximum capacity for installed filter.
• Page 5.6 – Installation parameters.
- All parameters on the page, except p218 (Estimated UV lamp time) .

2.2 Introduction to the parameter pages
This section describes the principles for the control system parameters and the parameter pages.
Parameters are roughly sorted by area, for example AOT reactor, filter and remote interface,
but the sorting is not strict.
2.2.1 Key to parameter numbers and indication

Control system parameters are identified by item numbers with the following syntax: pX000.
p stands for parameter

X identifies the area/component the parameter controls. X can be
1 = Main parameters
2 = AOT reactor
3 = Filter
4 = CIP
000 unique number for the parameter.
p118 Parameters in bold can only be changed by login level AlfaLaval.

p101 Parameters in normal text can be changed by login level Advanced operator.
2.3 Set parameters

Follow this instruction to set or change parameters.
NOTE
• Parameters shall only be set by Alfa Laval.
8 Book No.9010183 02, rev. 2

2 Control system parameters 2.3 Set parameters
• These instructions require login level 2 or 3. Level 2 gives access to set parameters, with
exception from crucial parameters, which requires level 3.
1. Go to desired parameter page 5.1–5.7.

Result: The page is displayed with all parameters listed with current setting and unit.
2. To see allowed range (maximum and minimum values) and change setting, press the blue
button (with the parameter ID). A button pair is displayed.
4 ParaIntervalSet
Press the ≥ sign to display range. Entered parameter value must be within defined setting
range.
4 MinMax
3. To set parameter, press 3.14 button.

Result: A keyboard is displayed.
4. Enter the setting and confirm by touching the Enter button. To close the keyboard without
saving data, touch the Esc button.
If the parameter is set with a drop down menu, select desired choice by touching the value.
Result: The setting is saved directly, it is now safe to leave the page.
Book No.9010183 02, rev. 2 9

2.4 Page 5.1 – Main parameters 1 2 Control system parameters
2.4 Page 5.1 – Main parameters 1

This section describes the main system parameters set in page 5.1 Main parameters 1.
4 5.1
The following information is displayed: Parameters in bold can only be changed by login level
AlfaLaval.
ID Parameter De- Min- Unit Description

fault Max
value
p100 High pressure, 7.00 1–10 bar Setpoint for shut down due to high
shutdown trigger pressure at PT201-16. Default value
(PT201-16) shall be used.
(7 bar = 0.7 MPa)
p101 High pressure, 6.00 0–10 bar Setpoint for warning due to high pressure
warning trigger at PT201-16. Default value shall be used.
(PT201-16)
(6 bar = 0.6 MPa)
10 Book No.9010183 02, rev. 2

2 Control system parameters 2.4 Page 5.1 – Main parameters 1

fault Max
value
p103 Low pressure, 0,0 -1–2 bar Setpoint for warning due to low pressure
warning trigger at PT201-16.
(PT201–16)
(1 bar = 0.1 MPa)
p104 Max pressure 6 6/10 bar Defines maximum pressure for the
(PT201–16) system, measured by pressure indicator
PT201-16 for the system.
p105 Transition trigger, 50 10– m3/h Defines which flow that must be
ballast flow 500 established, before the process goes
established from ballast start-up to full ballast.
(FIT201-1)
p111 Undershoot 5 0–80 % Safety margin between defined max

certified flow flow and actual max flow to avoid
unnecessary shut down.
p113 Min % open for 20 10–100 % During ballast and deballast, valve
V201-8 V201–8 handles the automatic pressure
and flow control.
This parameter defines minimum

opening, to secure an even flow without
interruptions.
Min position during backflush is set in

p312.
p115 Maximum travel 10 2–30 sec Maximum time system will wait for filter
time for valves bypass valve to close, when system is
stopped after deballast.
If valve does not close, an alarm is

issued and system is shut down.
Default value shall be used.
p116 Low flow shut 10 10–90 % Set point for shut down due to low flow,
down limit defined as percent of certified flow.
(FIT201-1)
p117 Max delay of CIP 6 0–24 hrs Define max delay, in hours, before a CIP
cycle, hours process must be performed after ballast
or deballast. Default value shall be used.
p118 Max delay of CIP 1 0–30 day Define max delay, in days, before a CIP
cycle, days process must be performed after ballast
or deballast. Default value shall be used.
Book No.9010183 02, rev. 2 11


fault Max
value
p119 Valve travelling 5 1–10 sec Maximum time for V201–8 to go from
time for 201-8 opened to closed, and vice versa, before
a warning is issued.
p120 V201–8 PID 0.30 0.00 – N/A Defines proportional gain (Pf) value used
proportional gain 10.00 for PID regulation of V201–8 during
ballast and deballast.
Normal value: 0.1 – 1.5.
The PID regulation during ballast and

deballast is based on input from flow
transmitter FIT201–1.
p121 V201–8 PID 7.00 0–100 sec Defines integral time (If) value used for
integral time PID regulation of V201–8 during ballast
and deballast.
Normal value: 5 – 12.
For details, see p120.
p122 V201–8 PID 0.0 0.0–100.0N/A Defines derivate gain (Df) value used for
derivative gain PID regulation of V201–8 during ballast
and deballast.
Normal value: 0.
For details, see p120.
p126 LDC after-cooling. 5 0–60 min Defines how long after a ballast or
(Stop delay for deballast process the booster pump shall
401-1, if installed) run to cool the LDC.
Only used if parameter p129 is set to

“Activated”.
p138 Timeout: Time 5 1–30 min Defines maximum time a ballast and
in Pause before deballast process can be manually
going to Stop paused. After defined time, the process
is stopped.
p140 Timeout: 5 1–30 min Time the control system will wait for
Request "Confirm confirmation signal from ISCS, hard
overboard valve wire or manually in popup before
open" displaying message that operation was
not performed.
12 Book No.9010183 02, rev. 2


fault Max
value
p141 Timeout: Request 5 1–30 min Time the control system will wait for
"Confirm ballast confirmation signal from ISCS, hard
pump started" wire or manually in popup before
displaying message that operation was
not performed.
p143 Timeout: Power 60 1–300 sec Time the control system will wait for
granted signal not confirmation signal from ISCS that the
received operation was performed.
Only used if parameter p127 is set to

Activated (Hardwire ranged or fixed).
p144 Timeout: Start-up 60 30–300 sec Time the control system will wait for
ballast flow accepted minimum flow (p105) to be
established established before automatic stop.
p146 Timeout: Main 5 0.1–15.0 sec Maximum time system will wait for filter
valve travel time outlet valve to close, when system is
stopped after ballast.
If valve does not close, an alarm is

issued and system is shut down.
Book No.9010183 02, rev. 2 13

2.5 Page 5.2 – Main parameters 2

This section describes the main system parameters set in page 5.2 Main parameters 2.
4 5.2
The following information is displayed. Parameters in bold can only be changed by login level
AlfaLaval.

fault Max
value
p127 Power Not N/A Drop Defines if power management is used.

management used list
Alternatives:
• Not used
• Hardwire ranged
• Hardwire fixed
• Remote interface (requires that p132
is activated)
p128 Max time 60 15–240 Sec Define max delay before the system
communication shuts down after communication is
14 Book No.9010183 02, rev. 2


fault Max
value
loss PLC/remote lost between the PLC and the remote
interface interface (optional). The value must be
greater than the heartbeat signal interval
defined in the ISCS.
For further information see chapter 6.

Installation description and drawings,
section Remote interface integration
(optional). See address +006 and +047.
p129 Booster pump Not N/A Drop Defines if a booster pump (not part of Alfa
(P401-1) for LDC used list Laval’s scope of suppy) is used to create
cooling water sufficient cooling water flow to the LDC.
p130 Booster pump Not N/A Drop Defines if a booster pump (not part of
(P403-1) for used list Alfa Laval’s scope of suppy) is used to
reactor cooling create sufficient cooling water flow to the
water AOT reactor.
p132 Remote interface Not N/A Drop Defines if remote interface (optional) is
via modubus used list used and connected via modbus.
If connected, the Local and Remote

buttons are visible in the control panel.
They are used to choose if operation
shall be done from the remote interface
or a control panel.
p135 External system Not N/A Drop Defines if an external system stop button
stop used list (or signal) is installed.
Purpose: Ongoing process is stopped

and valves are returned to starting
position as fast as possible.
p137 Hide Pause Not N/A Drop Defines if the Pause button is visible or
button used list hidden in the control system. If activated,
the button is hidden.
Book No.9010183 02, rev. 2 15


fault Max
value
p160 GPS Not N/A Drop Defines if a GPS is connected to the

used list control system. If so, the event log will
be complete with position for the events
defined to include GPS stamp.
If no GPS is connected, time and date

must be set in control system page 4.1.
System info.
p161 Time interval for 1.0 0.1 – Min. Time interval to update the amount (m3)
log event 331 60.0 of ballast water treated in log file.
p162 Time interval for 1.0 0.1 – Min. Time interval to update the amount (m3)
log event 341 60.0 of deballast water treated in log file.
p163 Additional Not N/A Drop Defines if an additional by-pass valve is

by-pass signal used list used. The signal gives information if the
1 valve is opened during process, so that
PureBallast is by-passed.
p164 Additional Not N/A Drop Defines if a second additional by-pass

by-pass signal used list valve is used. The signal gives
2 information if the valve is opened
during process, so that PureBallast is
by-passed.
p165 Additional Not N/A Drop Defines if a third additional by-pass valve
by-pass signal used list is used. The signal gives information if
3 the valve is opened during process, so
that PureBallast is by-passed.
p166 Pressure PID 0.60 0.00 – N/A Defines proportional gain (Pf) value used
proportional gain 10.00 for PID regulation of V201–8 during
backflush.
The PID regulation during backflush is

based on input from pressure transmitter
PT201-27.
Normal value: 0.1 – 1.5.
16 Book No.9010183 02, rev. 2


fault Max
value
p167 Pressure PID 7.0 0.0 – sec Defines integral time (If) value used
integral time 100.0 for PID regulation of V201–8 during
backflush.
This parameter shall normally not be

changed.
Normal value: 5 – 12.
p168 Pressure PID 0.0 0.0 – N/A Defines derivate gain (Df) value used
derivate gain 100.0 for PID regulation of V201–8 during
backflush.
Normal value: 0.
Book No.9010183 02, rev. 2 17

2.6 Page 5.3 – AOT parameters 2 Control system parameters
2.6 Page 5.3 – AOT parameters

This section describes parameters controlling the AOT reactor set in page 5.3 AOT parameters.
4 5.3
AlfaLaval.
ID Parameter De- Min- Unit Comment

fault Max
value
p200 Timeout: AOT 2 1–10 min Time the control system will wait for
draining confirmation that an AOT reactor is
drained before an alarm is issued.
Recommended setting: Approximately 1
minute more than actual drain time.
p201 Timeout: Reactor 2 1–10 min Time the control system will wait for
cooling water confirmation that cooling water has filled
(LS201-29) the AOT reactor before an alarm is
issued.
18 Book No.9010183 02, rev. 2

2 Control system parameters 2.6 Page 5.3 – AOT parameters

fault Max
value
p202 High temp, 60 10–100 ºC Setpoint for high water temperature alarm,
alarm trigger indicated by temperature transmitter in
(TT201-33) AOT reactor. Default value shall be used.
p204 Low temp, 0 0–40 ºC Setpoint for low water temperature alarm,
alarm trigger indicated by temperature transmitter in
(TT201-33) the AOT reactor. Default value shall be
used.
p206 Alarm delay for 5 0–10 sec Delay before alarm is issued after setpoint
sensor TT201-33 temperature (p202 and p204) is reached.
p208 Timeout: CIP fluid 5 1–15 min Setpoint for max time to fill an AOT
fill-up time AOT reactor with CIP liquid during CIP process
before an alarm is issued.
p210 UV lamp warm-up 90 0–90 sec Warm up time for UV lamps before full
time ballast or deballast starts. Default value
shall be used.
p211 UV lamp cooling 120 30–300 sec Cooling time for UV lamps after ballast or
time deballast. Default value shall be used.
p212 Timeout: UV 200 10–200 sec Time the control system will wait for
lamp ignition confirmation signal that UV lamps are
ignited. If no lamps are ignited or if
less lamps than set in parameter p213
are ignited, the AOT reactor will be
automatically stopped. Default value
shall be used.
p214 High temp, 45 20–100 ºC Incoming cooling water temperature

warning trigger warning, indicated by temperature
in LDC (TT401-1) transmitter in LDC.
p215 Alarm delay for 5 0–10 sec Delay before shutdown when there is no
LS201-29 water in an AOT reactor, indicated by
level switch in AOT reactor (LS201-29).
p216 Timeout: Fluid 5 2–10 min Setpoint for max time to fill an AOT
fill-up time AOT reactor with fresh water during CIP
process before an alarm is issued.
Book No.9010183 02, rev. 2 19

2.6 Page 5.3 – AOT parameters 2 Control system parameters

fault Max
value
p220 UV intensity Not N/A Drop Activates measuring of UV intensity in

sensor used list AOT reactor. If activated, UV value will
be logged in the Event log every 60
seconds during ballast and deballast.
Disable if the UV sensor (QT201–50) is

out of order, to avoid alarms.
p221 Low UV intensity 550.0 0.0 – W/m2 Setpoint for warning due to low UV
warning trigger 500.0 intensity indicated by UV sensor
QT201–50 in the AOT reactor. This
warning will be logged in the Event log.
Only used if p220 is set to "Activated".
p230 Cabinet 2.0 0.5–5.0 °C Accepted temperature change without

temperature effect on the fan.
hysteresis
(TT401-2)
p231 Cabinet 40.0 20.0 – °C Setpoint for LDC cooling fan regulation.
temperature 60.0 When the temperature is below setpoint,
low threshold the fan is running at 15 % of full effect.
(TT401-2)
At setpoint the fan effect is increased
proportional to temperature from 15 %
up to 100 % at temperature set in p232.
p232 Cabinet 45.0 20.0 – °C Setpoint for running the LDC cooling fan
temperature 60.0 at 100 %.
high threshold
(TT401-2)
p234 UV control 0.10 0.00 – N/A Defines proportional gain (Pf) value used
proportional gain 100.00 for PID regulation of UV lamp effect.
The PID regulation is based on input from

UV sensor QT201–50.
p235 UV control 15 0–100 sec Defines integral time (If) value used for
integral time PID regulation of UV lamp effect.
20 Book No.9010183 02, rev. 2

2 Control system parameters 2.6 Page 5.3 – AOT parameters

fault Max
value
p236 UV control 0 0–100 sec Defines derivate gain (Df) value used for
derivative time PID regulation of UV lamp effect.
p237 Power Acti- N/A Drop Activates UV optimization to regulate

optimization vated list the UV lamp effect based on actual
transmittance in the AOT reactor. This
means that the lamps are lit to the degree
needed for full treatment, but not more.
Parameter p220 must be activated to

activate this parameter.
If disabled, UV lamps are lit at 100 % all

the time. Disable if the UV optimization
malfunctions, to avoid alarms.
p238 High 50.0 20.0 – °C Air temperature warning, indicated by

temperature, 100.0 temperature transmitter in LDC.
warning trigger
in LDC (TT401-2) Default value shall be used.
Book No.9010183 02, rev. 2 21

2.7 Page 5.4 – Filter parameters 2 Control system parameters
2.7 Page 5.4 – Filter parameters

This section describes parameters controlling the filter module set in page 8.4 Filter parameters.
4 5.4
AlfaLaval.

fault Max
value
p301 High filter 1.5 0.0- bar Setpoint for high pressure warning,
differential 2.0 indicated by pressure transmitter
pressure, PT201-27.
warning trigger
(PT201-27) (1.5 bar = 0.15 MPa)
p304 Required 2.50 1.00– bar Defines pressure needed for efficient
pressure to 5.00 backflushing. This pressure must be
start backflush attained to start backflush.
(PT201-16)
This parameter also defines setpoint for
desired pressure during backflush: To
maintain this pressure, control valve
22 Book No.9010183 02, rev. 2

2 Control system parameters 2.7 Page 5.4 – Filter parameters

fault Max
value
V201-8 is PID regulated, based on input
from pressure transmitter PT201-16.
This parameter shall be set according

the formula in chapter 6. Installation
description and drawings, section Working
pressure for filter during ballast operation.
(2.5 bar = 0.25 MPa)
p305 Backflush trigger, 0.85 0.00– bar Setpoint for automatic start of filter
differential 2.00 backflush due to dirt in the filter, indicated
pressure by differential pressure transmitter on the
(PT201-27) filter.
Note: This parameter can be adjusted, but

only by Alfa Laval during commissioning.
If adjusted, parameter p301 shall be set
to 30 percent higher.
(0.5 bar = 0.05 MPa)
p306 Filter 5 1–30 min Defines duration of filter preservation

preservation time (fresh water filling of filter) after ballasting.
p308 Backflush cycle 20 1– sec Defines duration of one filter backflush.

time 100
This parameter is only relevant to set for
filter type 1 (Boll).
The parameter shall be set to seconds for

a 1000 system.
p309 Time controlled 30 1– min Defines time between automatic backflush

backflush interval 120 of the filter. Automatic backflushes
are performed with this set interval to
secure performance, regardles of current
differential pressure.
p310 Backflush initial 10 0–60 sec Time from backflush trigger until backflush
delay is started. During this delay the control
valve is PID regulated to create the
required pressure defined in parameter
p304.
p311 Backflush delay 2.0 0.0– sec Defines for how many seconds the
(p305 during x 10.0 differential pressure defined in p305 must
sec). last, before automatic backflush starts.
Book No.9010183 02, rev. 2 23

2.7 Page 5.4 – Filter parameters 2 Control system parameters

fault Max
value
p312 V201-8 min 20 15–50 % Minimum allowed opening percentage for

position during V201-8 during backflush.
backflush
Must be higher than value set in p113.
Shall not be lower than 15 %.
p313 Differential 5 0–30 sec Time constant for low pass filter used for
pressure the differential pressure over the filter.
measurement The low pass filter is used to smoothen
filter the effect of sudden changes in differential
pressure (primarily pressure peaks after
completed backflush).
Value for low pass filtered differential

pressure is indicated as “dp” on the filter
in the filter popup, when logged in as login
level Operator or higher.
Actual differential pressure (PT201-27) is

indicated in the filter popup.
This parameter shall normally not be

changed, but time can be increased to
flatten the differential pressure curves.
p314 Filter Type N/A Drop Defines type of filter installed.

2 list
Alternatives: Type 1 (Boll) and Type 2
(Hydac).
p315 Filter type 6000 100 – m3/h Parameter p314 should be set before this
6000 parameter. Available alternatives depend
on selection in p314.
Defines type of filter according to plate

mounted on the filter. Filter type defines
maximum capacity for installed filter.
The parameter shall be set to RF10–35

for system size 1000.
Note: If the parameter is called Filter

size, set the parameter to maximum
capacity for installed filter. This is same
as the maximum ballast flow. See item
201 in in the Connection list in chapter 6.
Installation description and drawings.
p316 Max filter 6 6 – 10 bar Defines maximum pressure for the filter
pressure pressure indicators.
24 Book No.9010183 02, rev. 2

2 Control system parameters 2.8 Page 5.5 – CIP parameters
2.8 Page 5.5 – CIP parameters

This section describes parameters controlling the CIP module set in page 5.5 CIP parameters.
4 5.5
AlfaLaval.

fault Max
value
p400 CIP cycle time 15 1–60 min Duration of circulation of CIP liquid
during a CIP process.
Book No.9010183 02, rev. 2 25

2.9 Page 5.6 – Installation parameters 2 Control system parameters
2.9 Page 5.6 – Installation parameters

This section describes the installation specific system parameters set in page 5.6 Installation
parameters.
4 5.6
AlfaLaval.

fault Max
value
System name N/A N/A N/A Possibility to enter a system name for
the system, for example Vessel name.
If two systems is installed information
about starbord and port side.
The text is entered in the event log

file and alarm lists exported from the
control systen for easy identification.
Serial number N/A N/A N/A Enter the PureBallast serial number.
26 Book No.9010183 02, rev. 2

2 Control system parameters 2.9 Page 5.6 – Installation parameters
p106 No of AOT 1 1–6 # Defines number of installed AOT

reactors installed reactors.
p112 Maximum flow 1200 0– m3/h The parameter shall be set according to
(FIT201-1) 10000 pipe dimension for the flow meter pipe.
Pipe - Qmax (m3/h)

100 – 300
150 – 300
200 – 700
250 – 1200
300 – 1200
350 – 1700
400 – 2200
450 – 3300
500 – 3300
600 – 3300
The parameter shall be set to the same
value as the Qmax value in the flow
meter (FIT201-1).
Qmax setting in the flow meter can be

checked according to instruction Check
and set parameters on page .
p131 Automatic AOT Not N/A Drop Defines if AOT reactors shall be
selection used list automatically selected for process.
If activated: All AOT reactors (without

alarms) will be automatically selected,
to enable operation in full capacity.
Activation disables the possibility
to select a lowr flow before starting
a process (during standby mode).
However flow can be changed during
process.
If deactivated: Flow must be selected

manually at first start-up and after
shutdown.
p213 Allowed no. of 0 0–1 No. If more lamps than set in this parameter
failed UV lamps are broken, operation will be denied.
per AOT reactor
If a UV lamp fails the flow is set to 80
% of current flow. The UV lamps are
lit to 100 %. A warning is issued and a
log is written to the event log, and the
operator will have do decide to continue
or stop the operation.
p217 AOT reactor size 300 N/A Drop Defines size of the AOT reactor, defined
list as max capacity (m3/h).
Alternatives: 300, 600 and 1000.
Book No.9010183 02, rev. 2 27

2.9 Page 5.6 – Installation parameters 2 Control system parameters
p218 Estimated UV 3 000 0 – hrs Setpoint for UV lamp change warning.

lamp lifetime 20000 Counter for UV lamp run time is reset
in page 4.5 Operation timers AOT after
all UV lamps have been changed in an
AOT reactor. Default value shall be
used.
p150 EX proof system Not N/A Drop Defines if the EX proof version of
used list PureBallast is installed. This affects
both installation and control system.
p500 Log box Not N/A Drop Defines if the log box (optional ) is
used list installed to monitor and log external
valves and pumps, that are not part of
Alfa Laval’s scope of supply.
Parameters to activate feedback signals

for components are set in page 4.7 Log
box 1 and 4.8 Log box 2. See chapter
3. Operating instructions and control
system description.
28 Book No.9010183 02, rev. 2

2 Control system parameters 2.10 Page 5.7 – Remote interface
2.10 Page 5.7 – Remote interface

This section describes the installation specific system parameters set in page 5.7 Installation
parameters. Further information about RTU server data is found in chapter 6. Installation
description and drawings section Communication between PureBallast PLC and remote interface.
This page is only relevant if remote interface (optional) is used.
4 5.7
AlfaLaval.
Parameters for the ISCS modbus RTU server data shall be set according to the information below.

fault Max
value
p700 Interface type RS485 N/A Drop Defines communication (cable) type
list used for communication between the
ISCS and PureBallast.
Alternatives: RS485 and RS422.
Book No.9010183 02, rev. 2 29

2.10 Page 5.7 – Remote interface 2 Control system parameters
p701 Baud rate 9600 N/A Drop Defines baud rate in bits per second.
list
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: 300, 600, 1200, 2400,

4800, 9600, 19200, 38400, 57600,
115200.
p702 Parity No N/A Drop Defines parity.

parity list
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: None, Odd, Even, High,

Low.
p703 Data bits 8 N/A Drop Defines data bits per character.
list
Alternatives: 7 or 8.
p704 Stop bits 1 N/A Drop Defines number of stop bits.

list
Alternatives: 1 or 2.
30 Book No.9010183 02, rev. 2

3 Flow transmitter parameters
This section describes the parameters set in the parameter pages in the flow transmitter, installed
on the flow meter.
General (non-installation specific) parameters are preset to function for all systems. They must only
be adjusted, by Alfa Laval, if required by performance reasons or similar. They are checked during
preparations for commissioning and shall normally not be adjusted after start up.
The parameters are set in the flow transmitter panel.
4FTPanel
Buttons used:
4FTLock 4FTChange 4FTBack 4FTFwd 4FTSelect

4FT_Topup
Top up Padlock Change Back Forward Select
Book No.9010183 02, rev. 2 31

3.1 Check and set parameters 3 Flow transmitter parameters
3.1 Check and set parameters

Follow this instruction to check and set parameters in the flow meter.
1. Press Top up for three seconds.

Result: Result: “0000” appears.
2. Press Padlock.
Result: A line appears under the first zero.
3. Press Change to change the first 0 to 1.

c: Result: The “Basic settings” menu appears after two seconds.
4. Press Padlock to set the value.

Result: The “Basic settings” menu appears after two seconds.
Main frequency setting

(Adjusting the flow meter to the vessel’s frequency.)
5. Press Padlock to unlock the menu.
6. Press Forward until “Main frequency” is displayed.
7. Check that the parameter is set to the same frequency as used on the vessel. (Ask the crew
for information):
a: To change: Press Padlock.
b: Press Change to change (toggle) the setting.
c. Press Padlock to set the value.
Flow direction
(Direction of flow measured in the flow meter.)
8. Press Forward until ”Flow” direction is displayed.
Set Qmax
(Measuring range for the flow meter: the analog outputs and the frequency output.)
9. Check that the parameter is set according to the flow direction in the pipe.
c. Press Padlock to set the value.
10. Press Forward until “Qmax” is displayed.
32 Book No.9010183 02, rev. 2

3 Flow transmitter parameters 3.1 Check and set parameters
11. Check that the parameter is set according to pipe dimension for the flow meter pipe:
100 – 300
150 – 300
200 – 700
250 – 1200
300 – 1200
350 – 1700
400 – 2200
450 – 3300
500 – 3300
600 – 3300.
b. Press Select to select digit to change (A line is placed under the changeable digit).
c. Press Change to change (toggle) the digit.
d: Press Padlock to set the value.
Empty pipe setting

(Activates alarm when flow meter is empty.)
12. Press Forward until “Empty pipe” is displayed.
13. Check that the parameter is set to “On”.

c: Press Padlock to set the value.
Current output setting
14. Press Top up until “Basic setting” is displayed.
15. Press Forward until “Output” is displayed.
16. Press Padlock to unlock the menu.

Result: “Current output” is displayed.
17. Press Padlock to display the setting. Check that the parameter is set to “On”.
b: Press Change to change (toggle) setting.
Current output (4-20 mA) setting
18. Press Forward until Current output (mA setting) is displayed. Check that the parameter is
set to “4-20 mA”.
b: Press Change to change (toggle) setting.
19. Press Top up three times to exit.

Result: ”Totalizer 1” is displayed.
Book No.9010183 02, rev. 2 33

3.1 Check and set parameters 3 Flow transmitter parameters
4 Lamp power supply (LPS)
parameters
This section describes the parameters (DIP switch settings) set in the LPS, installed in the lamp
drive cabinet (LDC). Each LPS is set to identify the individual LPS in the installation.
4.1 DIP switch settings

The table below show the correct settings for respective LPS.
Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the individual LPS according
to the table below. Only position ON is indicated. For empty cells in the table, the switch shall be
in position OFF.
LPS 1–16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SW 1
SW 2
SW 3
SW 4 ON
SW 5 ON ON ON ON ON ON ON ON
Example
In the illustration, the DIP switches is set for LPS no. 5.
4 LPSdip
Book No.9010183 02, rev. 2 35

4.2 Change DIP switch setting 4 Lamp power supply (LPS) parameters
4.2 Change DIP switch setting

Follow this instruction to change the DIP switch settings for an LPS. Note that the DIP switch
settings for LPS shall only be changed if faulty, indicated by all LEDs lit in LPS in combination with
alarm A130 in the control system.
NGE R
! DA
• Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside
and on the lamp power connector, even when UV lamps are not lit.
• The LDC contains a fan, which can cause injury if in operatoin.
1. Unscrew the plastic lid (1) over the DIP switches on the fron of the LPS.
7 LPSdip
2. Use a small screw driver to change position of the swithces according to the table under
instruction DIP switch settings.
3. Re-fit the plastic lid of the DIP switches.
4. Turn back the power to the cabintet.
36 Book No.9010183 02, rev. 2

Chapter: 5. Alarms and faultfinding
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 5
2 List of alarms and warnings 7

2.1 Control system 7
2.1.1 Alarm indication 7
2.1.2 Key to the table of alarms and warnings 7
2.1.3 List of alarms and warnings 8
2.2 Lamp power supply (LPS) 48

2.2.1 List of alarms and status indications 48
2.3 Flow meter 49

2.3.1 Fault finding instruction 49
2.3.2 Check flow meter error list 50
2.3.3 List of alarms and problems 50
2.4 Level switch 53

2.5 I/O system and X20 modules 55
2.5.1 List of alarms and status indications 56
3 List of problems and solutions 63

3.1 General problems 63
3.2 Filter 67
3.3 CIP 69
3.4 Valve V201–8 72
3
1 Introduction
This chapter covers information about alarms and warnings, together with information about how
to solve the problems causing the alarms to trip. The chapter also contains a list of solutions for
problems that may occur, but that is not indicated by any system.
The chapter contains lists of alarms indicated by:
• control system
• lamp power supply (LPS)
• flow meter (with fault finding instruction)
• I/O system and X20 modules.
See chapter 3. Operating instructions and control system description to find information about
the alarm pages and how to attend to alarms.
Book No.9010183 02, rev. 2 5

1 Introduction
2 List of alarms and warnings
This section lists all alarms and warnings related to the PureBallast system.
2.1 Control system

This sub section lists all alarms and warnings in the PureBallast control system. The alarms are
sorted in a strict numerical order.
2.1.1 Alarm indication

An alarm is indicated in the following ways in the control panel.
Alarms and warnings
3Alarm
The icon in the alarm tab starts to blink.
The icon is displayed by the faulty component, if applicable.

Warning
2 Warning
The icon is displayed by the faulty component, if applicable.
Alarm and warning: Active but not acknowledged.
The icon is displayed in the screen.

4 AlarmActive
Alarm and warning: Acknowledged but still active.
The icon is displayed in the screen.

4 AlarmAcknow
All alarms are displayed in the control panel’s page 2.1 Alarm list and are sorted in order of
occurrence; most recent alarm at the top of the list.
2.1.2 Key to the table of alarms and warnings

The table below explains the information given in the alarms list table. The table contains the
following columns and information:
Book No.9010183 02, rev. 2 7

2.1 Control system 2 List of alarms and warnings
Column in Description
table
Alarm ID Identification number of the alarm. The number is also indicated in the control
system alarm list.
Alarm ID:s are composed of the following elements: L100
• L: First letter indicate it is an alarm or a warning.
- A = Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
- W = Warnings are notification of a status change or a problem. Warnings
allow the process to continue.
• 1: If the alarm contains three digits, the first digit indicates component
according to: 1=AOT reactor and 2 =Filter. If the alarm contains two digits,
the alarm is general and is not connected to a specific component.
• 00: Unique number for the alarm/warning.
Alarm text / The text displayed in the control system. Note that AOT reactor number is
Problem indicated by “x” in the table, instead of the actual AOT reactor number. In the
control system alarm text, the actual AOT reactor number is stated for the AOT
reactor concerned.
For problems not indicated by an alarm, the text gives a general explanation
of a problem that can occur.
Trigger / Trigger: Source of the alarm or warning, identified by the input sensor’s item
Parameter number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.
Description Detailed information sorted on the following headings, when applicable:
Delay: Time before the alarm is activated after the condition of the alarm is met.
Comments: Additional information or explanations.
Possible Possible causes that might have triggered the alarm.

cause
What to do? Suggested action to solve the problem.
2.1.3 List of alarms and warnings

The table below explains alarms triggered by and displayed in the control system.
See next page.
8 Book No.9010183 02, rev. 2

2
Alarms and warnings — PureBallast control system
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A01 Process Trigger: PT201-16 Delay: 30 sec. Ballast water pump Check pressure and flow from
pressure too Parameter: p100 gives too high ballast pump(s). If the pressure
high (PT201-16). Comment: Pressure pressure. exceeds set value: Adjust incoming
Automatic stop. transmitter PT201-16 pressure to PureBallast.
Book No.9010183 02, rev. 2

indicates pressure
higher than set in Valves in the system Control that correct valves are
parameter p100. after pressure functioning and opened for current
List of alarms and warnings
transmitter are process. See chapter 3. Operating

closed. instructions and control system
description, section Detailed
process description.
Material is stocked Check the entire system for

after pressure blocking material.
transmitter PT201-16
(i.e. in an AOT
reactor).
Pressure transmitter 1. Check cables to pressure

PT201-16 is faulty. transmitter PT201-16. See
Control cabinet / Circuit
diagram in chapter 6.
Installation description and
drawings.
2. Replace pressure transmitter
PT201-16.
2.1
9
Control system
10
2.1
ID
A03 Process Trigger: PT201-16 Delay: 30 sec. Signal missing 1. Check fuse F45 in Control
pressure or pressure cabinet to see what circuit
signal missing Comment: Error transmitter PT201-16 caused the fuse trip.
(PT201-16). in system pressure malfunction.
2. Use the circuit diagram to
Control system
Automatic stop. sensor. Indication of

pressure -1.0 bar (-0.1 check the fuse setting, adjust
MPa) is not an error. according to figures in circuit
diagram if necessary and reset
fuse.
locate the component or find
the reason that caused the fuse
trip and attend to it.
4. Check cables to the
component. See Control
cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.
5. Check that all electrical
connections are OK and that
the electrical wiring is not
damaged.
2
6. Replace transmitter PT201-16.
W04 Process Trigger: PT201-16 Delay: 30 sec. See possible cause See A01.
pressure too Parameter: p101 for A01.
high (PT201-16). Comment: Pressure
higher than parameter
set limit.
Book No.9010183 02, rev. 2

2
ID
A10 Process flow Trigger: FIT201-1. Delay: 5 sec. Signal missing or flow 1. Check fuse F45 in Control
signal missing Parameter: N/A transmitter FIT201-1 cabinet to see what circuit
(FIT201-1). Comment: Error in malfunction. caused the fuse trip.
system flow sensor.
check the fuse setting, adjust
according to figures in circuit
Book No.9010183 02, rev. 2

fuse.

damaged.
6. Replace flow transmitter
FIT201-1.
Flow transmitter Check the flow transmitter. See

FIT201-1 malfunction chapter 7. Service manual.
(no text on the
2.1
transmitter display,
message error)
Flow meter See section Flow meter on page

malfunction. 49.
11
Control system
12
2.1
ID
W12 Process Trigger: FIT201–1 Delay: 30 sec. Flow rate higher than Reduce the incoming ballast water
flow higher Parameter: N/A selected certified flow to the PureBallast system.
than certified flow, for the number
(FIT201-1). of AOT reactors in
Control system
Reduce flow! operation.
Wrong setting in See chapter 4. Parameters, section

FIT201-1. Flow transmitter.
Flow sensor Check that the flow sensor is OK as

malfunctions. described in Problem 7 B and 7 I in
the general problems list on page .
See section Flow meter on page

49.
A13 Process flow too Trigger: FIT201–1 Delay: 20 sec. Flow too low. • Increase flow.
low (FIT201-1). Parameter: p116
• Make sure the ballast water
Automatic stop. Comment: If flow
is less than set in from the ballast pump is
parameter p116, the directed to PureBallast. When
system is shut down. OK the process will continue
automatically.
2
• Check pressure and flow

from ballast pump(s).
Adjust incoming pressure
to PureBallast, if necessary.
Wrong setting in See chapter 4. Parameters, section

FIT201-1. Flow transmitter.
Flow sensor Check that the flow sensor is OK as

malfunctions. described in Problem 7 B and 7 I in
the general problems list on page .
Book No.9010183 02, rev. 2

2
ID
See section Flow meter on page

49.
Valves in ballast Control that correct valves are

system closed. opened for current process.
See chapter 3. Operating
Book No.9010183 02, rev. 2

instructions and control system
description, section Detailed
process description.
If not, check mechanical function of

the valve and check that the cables
to the component is according
with the Control cabinet / Circuit
diagram.
Ballast water Attend to. Note: This component

pump stopped or is outside the PureBallast system
malfunctions control.
A14 Process Trigger: FIT201-1 Delay: Set in Control valve V201–8 See alarm A17.
flow too low Parameter: p105 parameter p144. malfunctions.
during start-up
(FIT201-1). Flow too low. See alarm A13.
Automatic stop.
2.1
13
Control system
14
2.1
ID
A17 Valve error Trigger: Limit switch Delay: 15 sec. Fuse tripped. 1. Check fuses F43 in control
(V201-3). GS201-3. cabinet to see what circuit
Parameter: N/A. Comment: Error on caused the fuse trip.
valve V201–3.
2. Check relay K1 and K2 on
Control system
module X10 in control cabinet.

3. Use the Control cabinet /
Circuit diagram to check the
fuse setting, adjust according
to figures in circuit diagram if
necessary and reset fuse.
connections to actuator and
sensors on the valve are OK
and that the electrical wiring is
not damaged.
Position sensor is Adjust sensor. See chapter 7.

not in correct position Service manual, section Adjust
2
to sense indicator position sensor.

screws. Position
screws are in wrong Hint: Valves can be manually
position. operated. See instruction Operate
components manually in chapter 3.
Position sensor Operating instructions and control
mounted upside system description and Operate
down. valves manually in chapter 7.
Service manual.
Book No.9010183 02, rev. 2

2
ID
Position sensor or 1. Check cables.

cables to position
2. Replace position sensor if
sensor malfunction.
faulty.
Too long 1. Follow the instruction Adjust

opening/closing time valve traveling speed in chapter
Book No.9010183 02, rev. 2

(valve travel time) 7. Service manual.
2. Adjust exhaust valves on
actuator.
3. Check that compressed air
pressure is according to
requirements in chapter 6.
drawings, section Connection
list.
Pilot valve on actuator The red LED on pilot valve contact

malfunction lights if opening signal comes to
the pilot. If the LED lights although
the valve malfunctions, the pilot
valve is faulty: Replace pilot valve.
Valve cannot Clean. If required dismount valve.

open/close due to See chapter 7. Service manual for
obstruction. instructions.
A23 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause Check relay K5 and K6 on module
(V201-9). GS201-9. for A17. X10.
2.1
Parameter: N/A. Comment: Error on

valve V201–9.
15
Control system
16
2.1
ID
A29 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V201-8). GS201-8. for A17.
Parameter: N/A. Comment: Error on
control valve V201–8. • Sensor error. 1. Check open indication in the
Control system
Shows open all pneumatic positioner.

the time.
2. Check fuses F43 in control
• Signal error 4–20 cabinet to see what circuit
mA. caused the fuse trip.
3. Check relay K3 and K4 on
module X10.
4. Use the Control cabinet /
Circuit diagram to check the
connections to actuator and
2
sensors on the valve are OK

and that the electrical wiring is
not damaged.
Positioner is not Calibrate according to chapter 7.

correcly set or Service manual, section Calibrate
calibrated. positioner on V201-8.
The air filters on Clean the filter on the possitioner.

V201-8 might be
clogged.
Book No.9010183 02, rev. 2

2
ID
A33 Bypass valve is Trigger: Limit switch Delay: 15 sec. The valve has been If not opened intentionally, close
open (V212-31). GS212-31. opened manually or valve V212-31.
Parameter: N/A Comment: If the valve via the ISCS.
(not controlled by
PureBallast) is opened, See possible cause
any ongoing process is for A17.
Book No.9010183 02, rev. 2

stopped.
This alarm is not
issued when the valve
is opened during mode

standby, heeling or
pause.
A35 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V212-31). GS212-31. for A17.
Parameter: N/A Comment: Shutdown
of all steps except CIP.
The alarm does not
prevent completion or
start of CIP process.
W40 Process Trigger: Pressure Delay: 2 sec. Ballast water pump Check that pressure and flow
pressure too low transmitter: gives too low from ballast pump(s) is according
(PT201-16). PT201-16. pressure. to requirements in chapter 6.
Parameter: p103. Installation description and
drawings, section Connection list.
Pressure safety valve Check the valve, and repair or

V201 is faulty. change.
2.1
Pressure transmitter 1. Check cables to pressure

PT201-16 is faulty. transmitter PT201-16. See
Control cabinet / Circuit
diagram in chapter 6.
drawings.
17
Control system
18
2.1
ID
2. Replace pressure transmitter

PT201-16.
A48 System stop Trigger: Stop button Delay: None. Process has been
Control system
activated (Stop on control cabinet stopped. NOTE

button). Parameter: N/A
Find out the reason why the process
has been stopped before releasing the
button and starting another process.
A49 System stop Trigger: Stop button Delay: None See A48.
activated during on control cabinet
CIP (Stop Parameter: N/A
button).
A50 System stop Trigger: External Delay: None. Process has been
activated stop button on control stopped by external NOTE
(External stop cabinet (or signal). stop button or signal
button). Parameter: p135 from the ISCS Find out the reason why the process
(integrated ship has been stopped before releasing the
control system). button and starting another process.
A51 System stop Trigger: External Delay: None. See A50.

activated during stop button on control
2
CIP (External cabinet (or signal).

stop button). Parameter: p135
Book No.9010183 02, rev. 2

2
ID
W58 Fuse tripped in Trigger: Control Delay: None. Possible reasons: 1. Check fuse F43–F45 in control
control cabinet. cabinet. • cabinet to see what circuit
Parameter: N/A caused the fuse trip.
• short circuit
• overheated fuse
Book No.9010183 02, rev. 2

3. Use the circuit diagram for
control cabinet to check the

A66 Additional Trigger: External Delay: 5 sec. The valve has been If not opened intentionally, close
bypass valve system. opened manually or the valve.
1 is open. Parameter: p163 Comment: If the valve via the ISCS.
(not controlled by
PureBallast) is opened,
any ongoing process is
stopped.
This alarm is not
issued when the valve
is opened during mode
standby, heeling or
pause.
A67 Additional Trigger: External Delay: 5 sec. See A66.

bypass valve system.
2.1
2 is open. Parameter: p164
A68 Additional Trigger: External Delay: 5 sec. See A66.

bypass valve system.
3 is open. Parameter: p165
19
Control system
20
2.1
ID
A69 Remote system Trigger: External Delay: 5 sec. PureBallast is If valve is not opened intentionally,
reports system system. bypassed via the close the valve.
is bypassed. Parameter: ISCS.
Control system
A71 Ballast water Trigger: Control Delay: Set in Faulty connection of Check that all electrical connections
pump is system timer. parameter p141. signal cable. are OK. Check that the signal
not running. Parameter: p141. wiring is according to information in
Automatic stop. Comment: Feed back chapter 6. Installation description
signal “BW pump is and drawings, section External
running” is deactivated component signal integration.
If remote interface Simulate power request between

(optinal) is used: the systems. See chapter 3.
Communication Operating instructions and control
between PureBallast system description.
and ISCS is wrong.
Time set in parameter Check/change parameter in

is lower than needed. control system page 5.1 – main
parameters 1.
A75 Overboard valve Trigger: Control Delay: Set in See possible cause
is not open. system timer. parameter p140. for A71.
Automatic stop. Parameter: p140
2
Comment: Feedback
“overboard valve is
OPEN”.
A77 Error on all Trigger: AOT Delay: None An active alarm exist Check page 2. Alarm list to for
operating reactors on all installed AOT related alarms.
AOT:s. Parameter: N/A Comment: All reactors. It can be
Automatic stop. AOT reactors are the same error for
deactivated. all AOT reactors, or
different errors.
Book No.9010183 02, rev. 2

2
ID
A79 Power is Trigger: Control Delay: Set in Power management Investigate if the reasons for not
not granted. system timer. parameter p143. master system not granting power is outside the
Automatic stop. Parameter: p127. granting power. PureBallast system.
Comment: No
power steps have Feedback signal from See A71.
been granted within power management
Book No.9010183 02, rev. 2

parameter set time. master is faulty. Check signal transmission to/from
PureBallast corresponds to
the specifications in chapter
6. Installation description
and drawings, section Power
management system integration.
Hint: If problem persists, see page

1.4 – PureBallast power request
to find which GRANTED signal
that was interrupted during the
ballast/deballast process.
W80 Power is not Trigger: Power Delay: None. See possible cause
fully granted. management system. for A79.
Flow capacity Parameter: p127. Comment: Not all
reduced. requested power steps Not enough power Continue process with lower flow
are granted. Triggered has been granted. capacity or try later.
if number or requested
power steps does
not match number of
granted power steps.
2.1
W82 Heeling mode Trigger: Heeling Delay: 2 sec. Heeling mode has
requested (internal transfer) been activated by
by operator. requested in control Comment: The system external system.
Automatic system. is set in pause mode.
pause. Parameter: N/A If operation has not
been requested: See
A71.
21
Control system
22
2.1
ID
W83 Heeling mode Trigger: Heeling Delay: None. See possible cause
cancelled (internal transfer) not for W82.
by operator. requested in control Comment: Process
Process system. is resumed after being
Control system
resumed. Parameter: N/A phased during heeling.
A91 PLC lost Trigger: Control Delay: 60 sec. Panel is switched off 1. Switch on the panel.
communication system PLC. or faulty.
2. Restart the panel. See problem
with all control Parameter: N/A Comment: After
60 seconds of lost 1 B in the general problems list
panels.
communication, on page .
ongoing process is 3. Replace if faulty.
stopped in a controlled
way and the system Wrong software Check that the HMI and PLC
is shut down. This version software have the save program
message is visible in version. This is visible in control
the control panels and system page 4.1 System info.
saved in the log after
the communication is Wrong network Check settings for each panel
restored. But, W92 will setting according to chapter 3, section Set
be visible in the master control panel IP settings.
control panel.
Check that the remote control
panel is added in the main panel
2
according to Set remote control

panel communication.
Faulty cable Check cables to the component.

connection. For reference, see Control cabinet /
Interconnection diagram in chapter
6. Installation description and
drawings.
Book No.9010183 02, rev. 2

2
ID
W92 Master control Trigger: Control Delay: 30 sec. Master panel is See A91.
panel lost system PLC. switched off or faulty.
communication Parameter: N/A Comment: After
with the PLC. communication is lost, Faulty cable See A91.
ongoing process is connection.
stopped in a controlled
Book No.9010183 02, rev. 2

way and the system
is shut down. This
message is visible
in the master control

panel.
A93 Heart beat signal Trigger: Control Delay: Set in To operate PureBallast when communication is down,
from remote system PLC. parameter p128. follow the steps below:
interface is not Parameter: p128
updating. Comment: After 1. Set the system to Local mode: Press the Local button
communication is on the control panel.
lost between ISCS
2. Run the system from the control panel. Note that you
and PLC, ongoing
will need to confirm two messages from the control
process is stopped in a
panel during operation: "Confirm ballast pump started"
controlled way and the
and "Confirm overboard valve open".
system is shut down.
3. Restore these settings when the communication is
The Heartbeat field working.
in page 4.5 Remote
4. Make sure that the system is not in test mode in page
interface, indicates
4.5 Remote interface (no check mark on the Test
communication.
mode button).
System is set to Test If you deliberately set the system

2.1
mode. to test mode (for example to test

remote interface integration, you
can disregard this alarm. If not
deactivate the test mode again in
page 4.5 Remote interface 1.
23
Control system
24
2.1
ID
Faulty settings. 1. Check that parameter p700 is

set to match the modbus cable
type used (RS422 or RS485).
2. Check if remote operation is
Control system
deactivated in the control panel

(The Remote button at the
bottom of the screen is gray). If
so, press the Remote button.
3. Check if test mode is activated
in page 4.5 Remote interface
(check mark on button). If so,
press the Test mode button.
Requires login level Advanced
operator.
4. Check that the communication
settings is OK according to
instruction Set remote interface
communication in chapter 3.
Operating instructions and
control system description.
Faulty cable Check cable between the ISCS

2
connection. and the master control panel and

the cable between the PLC and
the master control panel. For
reference, see Control cabinet /
Interconnection diagram in chapter
6. Installation description and
drawings.
Tips: Make sure that the modbus

cables in terminal X15 are correct
(not switched).
Book No.9010183 02, rev. 2

2
ID
Communication See W92.

between PLC and
master control panel
is lost.
ISCS is faulty. Investigate problem in ISCS, and
Book No.9010183 02, rev. 2

attend to found problems.
W95 PLC battery low. The voltage in the Replace PLC battery in the control
Trigger: Control Delay: 10 sec.

system PLC. battery in the control cabinet.
Parameter: N/A system PLC is too
low.
W96 GPS signal not Trigger: Control Delay: 5 sec. Faulty electrical Check that the signal wiring
valid. system PLC. connection. is according to in chapter 6.
Parameter: p160 Installation description and
drawings, section GPS signal
integration and Control cabinet /
Interconnection diagram
W97 PLC error in Trigger: N/A Delay: 2 sec. Error in module. Check the LED error indication for
control cabinet. Parameter: N/A the electronic modules in the LDC.
See section I/O system and X20
modules on page 55.
Faulty electrical • Check that the signal wiring is

connection. according to electrical drawings
in Chapter 6. Installation
2.1
• Check that all electrical

connections are OK on bus
modules and that the electrical
wiring is not damaged.
25
Control system
26
2.1
ID
W100 AOT [x]: AOT Trigger: AOT Delay: Set in High temperature • Check that the inlet valves
temp too high temperature parameter p206. due to obstacles or (V201-19.x, V403-35) and
(TT201-33). transmitter TT201-33. error in one or more outlet valves (V201-20.x,
AOT shutdown. Parameter: p202 Comment: If components involved. 404-36.x) open properly by
Control system
temperature rises operating them manually.

above parameter set See the instruction Operate
value, the AOT reactor components manually
will shutdown. in chapter 3. Operating
If the alarm trips description.
during operation
with a flow through • Check that cooling water supply
the AOT reactor, the (403) is within specification
valves V201-19.x and in chapter 6. Installation
V201-20.x will close. description and drawings,
section Connection list.
If the alarm trips during
ballast start-up, valve Low flow of sea water Check pump, valves and other
V404-36.x will close. during start-up. components involved in the sea
water cooling system.
Parameter p202 not Check/change parameter in

correctly set. control system page 5.3 – AOT
parameters.
2
TT201-33.x Replace transmitter TT201–33

malfunction. according to instruction in
chapter 7. Service manual
section Temperature switch and
temperature transmitter.
Book No.9010183 02, rev. 2

2
ID
W101 AOT [x]: AOT Trigger: AOT Delay: Set in See possible cause
temp too low temperature parameter p206. for W100.
(TT201-33). transmitter TT201-33.
AOT shutdown. Parameter: p204. Sea water too cold; See to that incoming water is
temperature below 0 warmer than 0 C°.
C°.
Book No.9010183 02, rev. 2

Engine room too cold; Increase temperature.
temperature below 0
C°.
W102 AOT [x]: Trigger: AOT Delay: Set in parameter Signal missing 1. Check fuse F42 in LDC to see
AOT temp temperature p206. or transmitter what circuit caused the fuse
signal missing transmitter TT201-33 TT201-33.x trip.
(TT201-33). error. malfunction.
AOT shutdown.
Parameter: N/A. check the fuse setting, adjust
fuse.
component. See AOT /
Circuit diagram and Lamp drive
cabinet (LDC) / Circuit diagram
2.1

damaged.
6. Replace transmitter TT201-33.
27
Control system
28
2.1
ID
7. Restart the process from the

beginning.
W107 AOT [x]: LDC Trigger: LDC Delay: 15 sec. No cooling water to Check that cooling water supply
Control system
cooling water temperature the heat exchanger. (401) is within specification in

temp too high transmitter TT401. chapter 6. Installation description
(TT401–1). Parameter: p214 and drawings, section Connection
list in the General drawings section.
Incoming cooling Feel the water pipe, if it is too

water too warm. warm. If so, investigate and attend
to problem.
Incoming cooling Check and attend to.

water valve V401–1
and/or outgoing valve
blocked or closed.
Parameter p214 not Check/change parameter in

correctly set in control control system page 5.3 – AOT
system. parameters.
W109 AOT [x]: Trigger: LDC Delay: 5 sec. Signal missing or 1. Check fuse F42 in LDC to see
LDC cabinet temperature transmitter TT401 what circuit caused the fuse
2
temp missing transmitter TT401–1. malfunction. trip.

(TT401–1). Parameter: N/A
2. Use the circuit diagram for the
LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary
and reset fuse.
3. Use the circuit diagrams for
the LDC and AOT reactor to
Book No.9010183 02, rev. 2

2
ID

component. See Lamp drive
Book No.9010183 02, rev. 2

damaged.
6. Replace transmitter TT401.
beginning.
Faulty connection to Check that all electrical connections

X20 module. are OK on X20 module and that the
electrical wiring is not damaged.
Faulty X20 module. Check component. See section I/O

system and X20 modules on page
55.
Change according to instruction in

chapter 7. Service manual, section
Control cabinet.
W111 LDC air Trigger: Delay: 15 sec. LDC faulty. Check page 2. Alarm list to for
temperature too Temperature related alarms.
high (TT401–2) transmitter TT401–2.
2.1
Parameter: p238 Faulty fan. Check electrical and mechanical

problems, and attend to.
29
Control system
30
2.1
ID
W113 LDC cabinet Trigger: Delay: 5 sec. Signal missing or flow 1. Check fuse F42 in Control
temperature Temperature transmitter TT401-2 cabinet to see what circuit
missing transmitter TT401–2. malfunction. caused the fuse trip.
(TT401–2) Parameter: N/A
Control system

fuse.
damaged.
2
6. Replace transmitter FIT201-27.

beginning.
Book No.9010183 02, rev. 2

2
ID
W116 AOT [x]: AOT Trigger: Level sensor Delay: Set in Signal missing or 1. Check fuse F43 in LDC to see
fluid level LS201-29. parameter p215. sensor LS201-29.x which circuit that caused the
signal missing Parameter: N/A malfunction. fuse trip.
(LS201-29).
2. Check relay KS02.
3. Use the circuit diagrams for the
Book No.9010183 02, rev. 2

and reset fuse.

4. Use the circuit diagrams for
5. Check cables to the level switch
LS201-29.x. See drawing AOT
/ Circuit diagram and Control
6. Check that the level switch is
working correctly. See section
Level switch on page 53.
Hint 2: Dismount level switch
and put the forks into a cup of
water to check dry/wet function.
2.1
7. Replace LS201-29.x. (Turn the

level switch so the forks are in
the right position. See chapter
7. Service manual.
31
Control system
32
2.1
ID
W117 AOT [x]: AOT Trigger: Level sensor Delay: Set in No fluid in AOT 1. Control that correct valves
fluid missing LS201-29. parameter p215. reactor. are opened for current
(LS201–29) in Parameter: N/A process. See Detailed process
manual mode Comment: The AOT description in chapter 3.
Control system
reactor is shut down. Operating instructions and

Prevents start of LPS control system description.
(UV lamps) in manual
mode. 2. Check that the flow is equal
through all AOT reactors and
that the AOT.x is not clogged.
beginning.
W118 AOT [x]: CIP Trigger: Level sensor Delay: Set in No fluid in AOT 1. Check that valves V320-2,
flow missing LS201-29. parameter p215. reactor “x”. V320-4.x, V321-4 and 321-2.x
(LS201-29). Parameter: p208 LS201-29.x is open and close correctly.
indicating dry
2. Check that pump P320-1
condition.
is functioning correctly. See
problem 6D−6I in the general
problems list on page .
3. Hint: Valves can be manually
operated. See the instruction
Operate valves manually
2
in chapter 3. Operating
description.
Note that the manual
operations are password-
protected and must only be
performed by authorized
trained personnel. The
PureBallast equipment or
connected equipment can be
irreparably damaged if handled
incorrectly.
Book No.9010183 02, rev. 2

2
ID
4. Examine the pipes related to

the CIP circuit. Make sure
that no material is clogging the
pipes.
5. Check that the level switch is
working correctly. See section
Book No.9010183 02, rev. 2

Level switch on page 53.
Time set in parameter Change parameter.

is lower than needed.
Level switch at AOT See W116 to troubleshoot the level

reactor LS201-29.x switch electrically.
malfunction.
Too low level in CIP Refill the tank with CIP liquid. See
tank. instruction Change and refill CIP
liquid in chapter 7. Service manual.
Air in fluid. The level Deaerate the CIP, using the

switch indicates this deaeration valve on the CIP.
as no fluid in AOT
reactor.
W119 AOT [x]: No Trigger: Level sensor Delay: Set in No liquid in 1. Check that pressure flushing
freshwater LS201-29. parameter p215. AOT reactor “x”. water in pipe 310 is according
filling in AOT Parameter: p216 LS201-29.x is to requirements in chapter 6.
(LS201-29). indicating dry Installation description and
condition. drawings, section Connection
2.1
list.
33
Control system
34
2.1
ID
2. Check that valves (V310-6,

V320-4.x, V321-2.x and
V571-1) are operating correctly.
Also check that valve V310-3 is
Control system
OK and that V310–8 is opened.

Operate the components
manually.

Level switch at AOT See W116 to troubleshoot the level

reactor LS201-29.x switch electrically.
malfunction.
W120 AOT [x]: AOT Trigger: Level sensor Delay: Set in Fluid in AOT reactor Restart the process from the
was not drained LS201-29. parameter p215. “x”. LS201-29.x beginning.
(LS201-29). Parameter: p200 is indicating wet
condition.

Level switch at AOT See W116.

2
reactor LS201-29.x
malfunction.
Faulty valves in the Control that correct valves

CIP unit. (V320–4, V460–2, V231–2,
V571–1, overboard valve) are
opened for current process. Also
control that pump P321–5 is
functioning.
Book No.9010183 02, rev. 2

2
ID
W122 AOT [x]: Fuse Trigger: LDC cabinet Delay: 1 sec. Fuse in LDC has Check fuse F42–43 in LDC cabinet
tripped in LDC for AOT tripped or has been to see what circuit caused the fuse
cabinet. Parameter: N/A switched off. trip. Check according to bullets.
• Use the circuit diagram for the

Book No.9010183 02, rev. 2

and reset fuse.
• Use the circuit diagrams for

• Check cables to the
component. See AOT /
Circuit diagram and Lamp drive
W126 AOT [x]: MCB Trigger: LCD x-1 Delay: 1 sec. Motor circuit breaker 1. See LPS alarms in section
tripped in LDC Parameter: N/A (MCB) for an LPS in Lamp power supply (LPS) on
cabinet. Comment: AOT.x has tripped or page 48.
MCB=Motor circuit has been switched
breaker. AOT reactor 2. Check Q101–Q116 in LDC and
off.
is deactivated. respective cables and LPS unit.
2.1
check the Ampere setting for

the MCB, adjust according
necessary and reset MCB.
35
Control system
36
2.1
ID
Breaker on LDC has Reset the breaker by turning the

tripped or has been handle.
switched off.
Control system
W128 AOT [x]: LDC Q117. Delay: 5 sec. Motor circuit breaker Check Q117 in LDC.
cabinet fan (MCB) F1 in control
alarm cabinet has tripped
or has been switched
off.
Faulty fan. Check electrical and mechanical

problems, and attend to.
Faulty electrical Check that all electrical connections

connection. are OK and that the electrical wiring
is not damaged.
W129 AOT [x]: LDC Trigger: Water Delay: 5 sec. Leakage in cooling Repair.
cabinet water sensor LS below water piping.
alarm. heat exchanger in Dry wet areas in the cabinet.
LDC. Remove the sensor and dry it with
Parameter: N/A paper.
Condensation in the See above.

2
cabinet.
Book No.9010183 02, rev. 2

2
ID
W130 AOT [x]: LPS Trigger: Lamp Delay: 2 sec. • LPS malfunction. Check LED indication on the LPS
sum alarm. power supply in AOT that triggered the alarm. See LPS
• Number of broken
reactors LDC. alarms in section Lamp power
UV lamps exeeds
Parameter: N/A supply (LPS) on page 48.
number set in
parameter p213. Check which lamps that are broken
Book No.9010183 02, rev. 2

in column Lamp OK in page 4.9
LPS overview.
UV lamp OK signal Check that the signal wiring is

malfunction. according to electrical drawings.
Check that all electrical connections

are OK on bus modules and that
the electrical wiring is not damaged.
W131 AOT [x]: UV Trigger: Lamp power Delay: 1 sec. One or more UV lamp Check which lamps that are broken
system failure. supply. is broken. in column Lamp OK in page 4.9
Too many failed Parameter: p213. Comment: AOT LPS overview.
lamps. reactor is deactivated.
Change according to instruction in
chapter 7. Service manual.
W132 Estimated UV Trigger: AOT reactor Delay: 1 sec. Lifetime for UV Recommended to change all lamps
lamp lifetime lap time. lamps are too after 3000 hours of operation.
exceeded. Parameter: p218. exceed according
to estimated lifetime Change according to instruction
in parameter. Replace UV lamp and quartz
sleeve in chapter 7. Service
2.1
manual.
37
Control system
38
2.1
ID
A137 AOT [x]: High Trigger: TS201-60 Delay: 1 sec. No flow in AOT See W100.
temperature Parameter: N/A reactor or too low
(TS201-60 Comment: AOT flow. After problem has been attended
tripped) and/or reactor is deactivated. to, the LDC needs to be reset.
Control system
LDC powered
off. Reset LDC
1. Turn on the power to the

cabinet/system.
2. Push the reset button on the
LDC. The button is placed
at the side facing the AOT
reactor. All LDCs must be reset
individually.
3. Acknowledge alarm A137 in
the control system.
Faulty pump (ballast Check components.

or booster pump) or Control that valves and pumps are
valve. functioning.
LDC has been The LDC needs to be reset, see

powered off. above in this alarm description.
2
Faulty electrical • Check that the signal wiring

connection. is according to electrical
drawings.
• Check that all electrical
damaged.
Book No.9010183 02, rev. 2

2
ID
A138 AOT [x]: PLC Trigger AOT reactor Delay: 2 sec. Error in module. Check the LED error indication for
error in LDC x. the electronic modules in the LDC.
cabinet. Parameter: N/A Comment: AOT See section I/O system and X20
reactor is deactivated. modules on page 55.
W140 CIP schedule Trigger: Control Delay: Set in CIP not performed Control CIP status on page 1.3 CIP
Book No.9010183 02, rev. 2

timer elapsed system timer. parameter p117 and after operation. status in control system.
Start CIP! Parameter: N/A. p118.
Start CIP process.
Comment: CIP has not

been performed within
parameter set time limit
after (de)ballast.
W150 AOT [x]: Low Trigger: UV sensor Delay: 20 sec. Low UV intensity in Check water.
UV intensity QT201-50. AOT reactor.
(QT201-50) Parameter: p220 and Comment: The It is also possible to fill the reactor
p221. warning is issued if with fresh water to rule out muddy
the UV intensity falls water as reason for the warning.
below value set in
parameter p221. Quartz sleeves dirty. Run CIP process, and try again.
Note: See chapter 3. If problem remains, check and

Operating instructions clean quarts sleeves according to
and control system instruction Replace UV lamp and
description, section quartz sleeves in chapter 7.
Ballast water handling
in the event of Old UV lamps. Check runtime on page 4.4
malfunction. Operation timers AOT in control
2.1
system. Change if old. Lamps

loose effect when maximum
runtime has been exceeded.
39
Control system
40
2.1
ID
Transmitter Test the UV sensor:

QT201-50.x 1. Stop the process and restart
malfunction. the process again.
2. In the control system’s AOT
Control system
popup, see if the UV values are

OK during the start-up phase.
UV values shall be OK, since
clean cooling water is used.
W151 AOT [x]: Trigger: UV sensor Delay: 20 sec. See W150.

UV intensity QT201-50.
signal missing Parameter: p220. Comment: The Signal missing. Disable parameter p220 if the UV
(QT201-50) warning is issued if sensor is out of order, to avoid
the UV intensity falls alarms.
below 484 w/m2. Power
is set to 100% for the 1. Check fuse F42 in LDC to see
AOT reactor and the which circuit that caused the
flow is reduced. fuse trip.
Note: Operation does 2. Use the circuit diagram to

not fulfill the type check the fuse setting, adjust
approval certificate. according to figures in circuit
Act according to ballast diagram if necessary and reset
water plan. fuse.
2

4. Check cables to QT201-50.x.
See the drawing Control
Book No.9010183 02, rev. 2

2
ID
5. If the above is OK, the UV

sensor is probably broke and
needs to be replaced. Replace
the component.
W152 AOT [x]: UV Trigger: UV sensor Delay: None. See chapter 2. System overview,
Book No.9010183 02, rev. 2

intensity low. QT201-50. section Power optimization.
System flow Parameter: p221
reduced. and p237
W153 AOT [x]: UV Trigger: AOT reactor. Delay: None. See chapter 2. System overview,
lamp fail. System Parameter: p213 section Operation with broken UV
flow reduced. lamp.
W160 AOT [x]: No Trigger: N/A. Delay: 1 sec.

response from Parameter: N/A
LDC. AOT
shutdown.
W161 AOT [x]: LPS Trigger: LPS Delay: 1 sec. Faulty connection of Check the three cable connectors
communication Parameter: N/A electricity or signal on the LPS .
error. AOT cable.
shutdown.
Wrong LPS setting. Check that the DIP switches
are correctly set for every LPS.
See chapter 4. Parameters,
section Lamp power supply (LPS)
parameters.
2.1
Faulty LPS. Change LPS. See instruction in

41
Control system
42
2.1
ID
W162 AOT [x]: Trigger: None. Delay: None. Motor circuit breaker Replace.
Circuit breaker Parameter: p239 (MCB) is broken.
communication Warning is active
error. if parameter p239 Faulty modubus Check modubus cable W1 and W2.
Control system
Enable circuit breaker signal cable.

data is activated.
W163 AOT [x]: Lamp Trigger: LPS in AOT Delay: 20 sec. Broken UV lamp. Change according to instruction in
error feedback reactor’s LDC. chapter 7. Service manual.
from LPS. Parameter: N/A Comment: No lamp
feedback when it is Faulty connection of Check UV lamp power cable.
requested to be started UV lamp cable.
by the LPS.
W164 AOT [x]: LPS Trigger: LPS in AOT Delay: 20 sec. Faulty LPS. Check page 4.9 LPS power
error feedback reactor’s LDC. overview and LED indication on the
from LPS. Parameter: N/A Comment: No LPS LPS that triggered the alarm. See
feedback when it is LPS alarms in section Lamp power
requested to star its supply (LPS) on page 48.
lamp. AOT reactor is
deactivated If the power is on but there are
no indication, the LPS is probably
broken.
2
W165 AOT [x]: LPS in Trigger: LPS in AOT Delay: 1 sec. One or more of the Check page 4.9 LPS power
fault state. reactor’s LDC. below: overview and LED indication on the
Parameter: N/A Comment: AOT LPS that triggered the alarm. See
reactor is deactivated. • Air temp fault LPS alarms in section Lamp power
• Driver fault supply (LPS) on page 48.
• Fan fault To continue process with one faulty

LPS, it is possible to set parameter
• Heat sink fault
p213 (Allowed nr. of failed UV
• System fault lamps) to 1. Operation is allowed,
but does not fulfill the type approval
• Voltage fault
certificate.
Book No.9010183 02, rev. 2

2
ID
• Broken UV lamp
Fan fault and temperature faults
can be caused by something that
is preventing the fan from rotate.
Change LPS. See instruction in

Book No.9010183 02, rev. 2

W170 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V201–19) GS201–19. for A17.
Parameter: N/A
W171 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V201–20) GS201–20. for A17.
Parameter: N/A
W180 LDC ring Trigger: LDC. Delay: None. Faulty connection of Check that the power link (LAN)
redundancy signal cable cable from the control cabinet (in a
error Parameter: N/A loop to all LDCs) and back is OK.
Filter: Sum Delay: 1 sec.

W300 alarm. Trigger: Filter.
Parameter: N/A Comment: The
feedback signal “Filter NOTE
SUM alarm” is not
detected. If alarm the alarm does not disappear from the alarm list after the
causing problem has been solved and the alarm acknowledged, the
2.1
alarm must be acknowledged on the f lter cabinet.
1. Press ESC.
2. Make sure that “Processdata” is highlighted and press
ESC. (If not, use the arrow buttons to highlight the row.
43
Control system
44
2.1
ID
3. Make sure that “Display alarms” is highlighted and

press ESC. (If not, use the arrow buttons to highlight
the row.
4. Press F4 to acknowledge the alarm.
Control system
Motor circuit breaker See LPS alarms in section Lamp

(MCB) F1 in control power supply (LPS) on page 48.
cabinet has tripped
or has been switched
off.
Motor problem. 1. Check that breaker on the filter

junction box is on.
2. Check that the motor is not
overloaded and can rotate
easily.
3. Start the motor and check
that the operation is normal.
See chapter 3. Operating
description, section Operate
components manually and
2
chapter 7. Service manual,

section Check filter gear motor
function.
Filter candle is Check that the filter flushing

jammed, preventing arm can rotate freely. See 7.
the flushing arm to Service manual, section Filter for
rotate. instructions.
Book No.9010183 02, rev. 2

2
ID
W306 Filter differential Trigger: Pressure Delay: 2 sec. Filter is clogged. Backflush manually from control
pressure transmitter PT201-27 system. If not sufficient, clean
too high on Boll filter. the filter candles according to
(PT-201–27) Parameter: p301, instruction in chapter 7. Service
p314. manual.
Book No.9010183 02, rev. 2

Valves connected Make sure that the two valves
to filter differential connected to the filter differential
pressure transmitter transmitter are open.
closed.
Pressure transmitter Hint: Pressure signal from

PT201-27 does not PT201-27 is displayed on in the
work correctly. Filter popup opened from page 1.1
Overview.
1. Check fuse F45 in Control

cabinet to see what circuit
caused the fuse trip.
fuse.
2.1

45
Control system
46
2.1
ID

damaged.
Control system
6. Replace transmitter FIT201-27.

beginning.
W308 Filter pressure Trigger: Pressure Delay: 30 sec. Signal missing 1. Check fuse F43 in LDC to see
signal missing transmitter PT201-71 or component which circuit that caused the
(PT201-71) on Hydac filter. Comment: Alarm malfunction. fuse trip.
Parameter: p314. deactivated in Standby.
fuse.
4. Check cables to QT201-50.x.
2
See the drawing Control

5. If the above is OK, the UV
sensor is probably broke and
needs to be replaced. Replace
the component.
Book No.9010183 02, rev. 2

2
ID
W310 Filter pressure Trigger: Pressure Delay: 30 sec. See W308.

signal missing transmitter PT201-72
(PT201-72) on Hydac filter. Comment: Alarm
Parameter: p314. deactivated in Standby.
W312 Filter pressure Trigger: Pressure Delay: 30 sec. See W308.
Book No.9010183 02, rev. 2

signal missing transmitter PT309-2
(PT309-2) on Hydac filter. Comment: Alarm
deactivated in Standby.
Parameter: p314.
W314 Backflush failed Trigger: Hydac filter. Delay: 15 sec. See W308.
to start (timeout). Parameter: p314.
A315 Diff pressure too Trigger: Pressure See W306.

high. Automatic transmitter on filter.
shutdown. Parameter: N/A.
W500 Log box hard Trigger: Log box Delay: 10 sec. Faulty cable Check connections and cable for
ware error. (optional). connection. power cable (W10) and Ehternet
Parameter: p314. cable (W104) between Control
cabinet and Log box.
Fuse in the log box Check fuse F02 and F03 in the log
has tripped or has box.
been switched off.
Error in module. Check the LED error indication for

the electronic modules in the log
box. See section I/O system and
2.1
X20 modules on page 55.
47
Control system
2.2 Lamp power supply (LPS) 2 List of alarms and warnings
2.2 Lamp power supply (LPS)

This section explains alarms triggered by and displayed on the lamp power supply (LPS) in the
lamp drive cabinet (LDC). LPS alarms are indicated in the control system by alarm W130 – Sum
alarm LPS unit.
2.2.1 List of alarms and status indications

The table below explains alarms triggered by and displayed in the LPS.
LED indication key
The LPS is equipped whit four light indications:
LPS on and communication is functioning.
5 LPSledG
Flashes (once per second) when processor is running.
5 LPSledG2 Flickering light during modbus communication.

Internal fault. Possible causes:
5 LPSledY
• LPS temperature too high (> 50° C).
• LPS fan faulty.
Lamp error. Possible causes:
5 LPSledR
• Two lamp ignition failures.
• Broken UV lamp.
• Loose cables to UV lamp.
Lamp on.
5 LPSledB
Flickering during lamp ignition, approx 2 seconds when lamp is started.
5 LPSledB2
All lamps on Possible causes:
• Faulty DIP switch setting on one or more LPS. This fault occur after a 10 seconds
delay after start.
• Voltage on the fail safe is missing.
48 Book No.9010183 02, rev. 2

2 List of alarms and warnings 2.3 Flow meter
2.3 Flow meter

This section explains alarms triggered by and displayed in the flow transmitter, mounted on the flow
meter (FIT201-1). An alarm is indicated by two flashing triangles on the flow transmitter. During
normal conditions, all relevant alarms are displayed in the PureBallast control panel.
4FlowT_Alarm
Alarm time is displayed as time elapsed since the error occurred, and is showed as days, minutes
and hours.
Alarms and status are displayed in two lists, accessible from the Service mode screen in the flow
transmitter:
• Pending error list: A list of the 9 most recent errors.

When an error is removed from the pending error list, it is moved to and stored in the status log.
• Status log list. All errors are stored in the log for 180 days.
2.3.1 Fault f nding instruction

1. Does the light indicate power on?
Yes: Go to step 4.
No: Go to step 2.
2. Check the following:
• Cables and connections

• Connection board
• Pins in transmitter multiplug.
Are they OK?
Yes: Go to step 3.
No: Correct the fault.
3. Is output reading OK?
Yes: The display is defect. Change.

No: The transmitter is defect. Change.
4. Is the error triangle flashing?
Yes: Go to step 5.
No: The tranmsitter is defect. Change.
5. Are the output and display readings OK?
Yes: Go to step 7.
No: Go to step 6.
Book No.9010183 02, rev. 2 49

2.3 Flow meter 2 List of alarms and warnings
6. Check the following:
• Cables and connections

• Connection board
• Pins in transmitter multiplug.
Are they OK?
Yes: Go to step 7.
No: Correct the fault.
7. The transmitter is OK. Check the following: Settings, application, installation, sensor, earthing,
connections etc.
8. The transmitter still not OK? Change settings according to chapter 4. Parameters, section
Flow transmitter parameters.
9. If the problem cannot be detected or corrected, the transmitter must be replaced according to
the instruction Mount flow transmitter. Note that it is not necessary to reset parameters in the
new transmitter. The settings are stored in the Sensorprom unit. When the new transmitter is
replaced, settings are downloaded automatically.
2.3.2 Check f ow meter error list

Follow this instruction to check the error list in the flow meter.
Buttons used:
4FTLock 4FTChange 4FTFwd 4FTBack 4FTSelect

4FT_Topup
Top up Padlock Change Forward Back Select
1. Press Top up for three seconds.
2. To enter password (1000): Press Padlock. (A line appears under th e first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The “Basic settings” menu appears after two seconds.
3. Press Forward until the “Service mode” menu appears.
4. Press Padlock, and then Forward until the “Error pending” menu appears.
5. Press Padlock to display the error list.
6. When done, press Top up three times to exit.

Result: ”Totalizer 1” is displayed.
2.3.3 List of alarms and problems

The table below explains alarms triggered by and displayed in the flow transmitter.
50 Book No.9010183 02, rev. 2

2 List of alarms and warnings 2.3 Flow meter
Prob- Description Output Error Possible cause What to do?

lem ID signals code
(trans-
mit-
ter)
7A Empty Mini- N/A. No power supply Power supply

display mum Check flow transmitter for
bended pins on the connector
Flow transmitter Replace transmitter. See

defective chapter 7. Service manual,
section Flow meter.
7B No flow signal Mini- N/A. Current output Turn on current output

mum disabled
Digital output Turn on digital output

disabled
Reverse flow Change direction

direction
F70 Incorrect or no coil Check cables/connections

current
W31 Flow sensor (pipe) Ensure that the flow sensor

empty (pipe) is full
F60 Internal error Replace transmitter. See

chapter 7. Service manual,
section Flow meter.
Unde- P42 No load on current Check cables/connections

fined output
Transmitter Replace transmitter. See

defective chapter 7. Service manual,
section Flow meter.
P41 Initializing error Switch off transmitter, wait 5

seconds and switch on again
7C Indicates flow Unde- N/A. Measuring flow Select empty pipe cut-off
with no flow fined sensor (pipe)
in pipe empty
Empty flow sensor Ensure that the flow sensor

(pipe) cut-off is (pipe) is full
OFF
Electrode Ensure that electrode cable

connection is connected and sufficiently
missing/electrode screened
cable is
Book No.9010183 02, rev. 2 51

2.3 Flow meter 2 List of alarms and warnings

lem ID signals code
(trans-
mit-
ter)
insufficiently
screened
7D Unstable flow Unstable N/A. Pulsating flow Increase time constant

signal
Conductivity of Use special electrode cable
medium too low
Electrical noise Ensure sufficient potential

potential between equalization
medium and
sensor
Air bubbles in Ensure medium does not

medium contain air bubbles. Deareate
the filter, using valve V201-50.
High concentration Increase time constant

of particles or
fibers
7E Measuring Unde- N/A. Incorrect Check installation

error fined installation
P40 No Sensorprom install Sensorprom unit

unit
P44 CT Sensorprom Replace Sensorprom unit or

unit reset Sensorprom unit with
MAG CT transmitter
F61 Deficient Replace Sensorprom unit

Sensorprom unit
F62 Wrong type of Replace Sensorprom unit

Sensorprom unit
F63 Deficient Replace Sensorprom unit

Sensorprom unit
F71 Loss of internal Replace transmitter

data
Maxi- W30 Flow exceeds Check Qmax. (Basic Settings).

mum 100% of Qmax. See parameters for flow
transmitter in chapter 4.
Parameters, section Flow
transmitter.
W21 Pulse overflow
52 Book No.9010183 02, rev. 2

2 List of alarms and warnings 2.4 Level switch

lem ID signals code
(trans-
mit-
ter)
- Volume/pulse too Change volume/pulse

small
- Pulse width too Change pulse width

large
7F Measuring N/A. Missing one Check cables

approx. 50% electrode
connection
7G Loss of OK W20 Initializing error Reset totalizer manually

totalizer data
7H Signs in OK N/A. Totalizer roll over Reset totalizer or increase

display: totalizer unit
#####
7I Too low flow N/A. Clogged sensor Dismount sensor tube and
signal electrodes in clean 4 sensor electrodes
sensor tube
7J Negative flow N/A. Flow meter is Change parameter setting in

is indicated mounted the flow transmitter. See section
wrong way round. Flow transmitter parameters in
chapter 4. Parameters.
Parameter Flow
direction is
incorrectly set.
2.4 Level switch

This section explains the different status indications on the level switch LS201-29 in the AOT
reactor. Alarms and status are indicated by LED:s on the module.
Color State Description What to do?
Green Steady Power on and in operation.
Green Off No power supply. Check plug, cable and power

supply.
Yellow Steady Wet condition.
Book No.9010183 02, rev. 2 53

2.4 Level switch 2 List of alarms and warnings
Red Blinking Error: Internal sensor error or sensor Replace the component.
corroded.
Red Steady Error: Overload or short-circuit in load Rectify the short-circuit.

circuit.
Reduce maximum load current
to below 250 mA.
54 Book No.9010183 02, rev. 2

2 List of alarms and warnings 2.5 I/O system and X20 modules
2.5 I/O system and X20 modules

This section explains the different status indications on the X20 modules. Alarms and status are
indicated by LED:s on the module.
All modules are identified on the front, for example “X20 DO 6529” in the illustration below. To the
right, the stat indication LEDs are visible, for example “r, e, X, I” in the illustration below.
5X20
Book No.9010183 02, rev. 2 55

2.5 I/O system and X20 modules 2 List of alarms and warnings
The following modules are installed in the LDC or control cabinet:
Identif cation Function Installed in cabinet
CP3485-1 PLC module (System module CPU) Control cabinet
DO6529 DO module, 6 x relay Control cabinet
IF1082-2 Interface module, power link Control cabinet
PS2100 Power feed, 24V Control cabinet
AO4622 Analogue output Control cabinet

Lamp drive cabinet
DIF371 Digital input Control cabinet

Lamp drive cabinet
DO6529 Digital output Control cabinet

Lamp drive cabinet
DO9322 Digital output, 12 outputs Control cabinet

Lamp drive cabinet
AI4622 Analogue input Lamp drive cabinet
AT4222 Temperature input module Lamp drive cabinet
BC0083 Bus controller, power link Lamp drive cabinet
CS1030 Interface module Lamp drive cabinet
IF1030 Interface module, RS422/RS485 Lamp drive cabinet
S9400 24V power feed, bus supply Lamp drive cabinet
2.5.1 List of alarms and status indications

Below, alarm and status indications displayed on the modules are explained.
NOTE
• Note that all status indications are not valid for all modules.
• The meaning of a status indication might vary for some modules. These variations are specified
in the Description column.
• Module BC083, CP3485-1 and IF1082-2 are described in separate tables below the generic
table.
The table contains the following columns and information:
56 Book No.9010183 02, rev. 2

Light Lights on the module.

Color Description of each light’s color and behavior.
State Different status is indicated by various light states.
Description Meaning of the light state.
Light Color State Description

r Green Off 24 V DC supply not connected, check fuse.
Single flashes Reset mode.
Blinking Preoperational mode.
On RUN mode.
e Red Off Module not supplied or everything is OK.
Single flashes Warning / error for an I/O channel. Level
monitoring for digital outputs has responded.
AT4222: Overflow or underflow of the analog

inputs.
Double flashes Indicates one of the following conditions:
• X2X bus power supply is overloaded.
• I/O supply too low.
• For PS9400: Input voltage for the X2X bus
supply too low.
On Error or reset state.
r+e Red/Green Red - steady / Invalid firmware.
Green - single
flashes
X Orange Off No communication at the X2X bus.
On X2X bus communication in progress.
I Red Off Bus controller / X2X link supply in acceptable
range.
On Bus controller / X2X link supply overloaded.
S Yellow Off No data traffic over service interface; no activity.
On Data is transferred over the service interface.
1–6 Orange On In/output status of the corresponding digital
in/output.
1–8 Green
Output status of the corresponding digital output.
1–12 Orange
In/output status of the corresponding digital
1–12 Green in/output.
1–16 Green In/output status of the corresponding digital

in/output.
Input status of the corresponding digital input.
Book No.9010183 02, rev. 2 57

Light Color State Description

1–2 Green Off The input is switched off.
Blinking Overflow / underflow of the signal, or broken
connection.
On The analog/digital converter is running, values
OK.
1–4 Orange Off Value = 0.
On Value ≠ 0.
Status Green On Interface module is active.
Red On CPU starting up.
RxD Yellow On The module is receiving data via RS485 (or
RS422) interface.
TxD Yellow On The module is sending data via RS485 (or RS422)
interface.
Tx Yellow On For CS1030: The module is sending data via
RS485 (or RS422) interface.
Rx Yellow On For CS1030: The module is receiving data via
(RS485 or RS422) interface.
T Yellow On For CS1030: The terminating resistor integrated
in the module is turned on.
Module BC0083
Light Color Description
L/A IF1 Green On Link to the remote station is established.

L/A IF2 Blinking On and Ethernet activity present on the bus.
S/E Red On Bus controller error: Failed Ethernet frames, increased
number of collisions on the network etc.
Blinking Only during startup. This is not an error.
Green Off Bus controller is either powered of or not active.
Communication is not possible with the bus controller. After
5 seconds in this state, the bus controller restarts.
If POWERLINK communication is detected during

the 5 seconds, the bus controller goes to status
PRE_OPERATIONAL_1 (single flash).
If no powerlink communication is detected, the bus controller

goes to BASIC_ETHERNET state (flickering).
Green On Bus controler in operation.
Green Flickering No Powerlink communication detected by bus controller.
(approx. 10 Hz) In this state you can communicate directly with the bus
controller using UDP.
58 Book No.9010183 02, rev. 2

If POWERLINK communication is detected in this state, the

bus controller goes to state PRE_OPERATIONAL_1 (single
flash).
Green Single flash Bus controller in PRE_OPERATIONAL_1.
(approx. 1 Hz)
With operation on a POWERLINK V1 master, the bus
controller goes directly into PRE_OPERATIONAL_2.
With operation on a POWERLINK V2 manager, the CN

(Controlled Node) waits for the reception of a SoC frame
and then switches over to PRE_OPERATIONAL_2 (double
flash).
Green Double flash Bus controller in PRE_OPERATIONAL_2.
(approx. 1 Hz)
In this state the bus controller is normally configured by the
manager. A command (POWERLINK V2) or setting the data
valid flag in the output data (POWERLINK V1) then switches
the state to READY_TO_OPERATE (triple flash).
Green Triple flash Bus controller in READY_TO_OPERATE.
(approx. 1 Hz)
In a POWERLINK V2 network, the manager then switches
via command to OPERATIONAL.
In a POWERLINK V1 network, the bus controller then

switches automatically to OPERATIONAL as soon as input
data are present.
Green Blinking Bus controller is in STOPPED.
(approx. 2.5
Hz) No output data is produced and no input data is received.
Only the appropriate command from the manager can enter
or leave this state.
Module CP3485-1
R/E Green On Application is running.

Red On Service mode.
RD/F Yellow On Service or boot mode.
Red On Over-temperature.
Book No.9010183 02, rev. 2 59

S/E Green Green Red Powerlink OK.

/Red on off
Green Red Fatal and irreparable system error. See control
off on system for alarm or warning. This status can only
be changed by resetting the module.
Blinking The powerlink managing node failed. This error
alternately code can only occur in controlled node operation.
This means that the set station number lies within
the range $01 - $FD.
Green Red System failure according to blinking pattern:
off blink-
ing ●●● — Pause ●●● — Pause: RAM error.
— ●● — Pause — ●● — Pause: Hardware error.

EPL Green On Link to powerlink remote station is established.
Blinking On and Ethernet activity present on the bus.
ETH Green On Link to Ethernet remote station is established.
Blinking On and Ethernet activity present on the bus.
CF Yellow On Flash card OK.
Green On Flash card active.
DC Yellow On CPU power supply OK.
OK Red On Backup battery is empty.
Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated in two moedes: Either
in Powerlink V mode or as an Ethernet TCP/IP interface. Status light depends on mode. For
TCP/IP mode, only SE green is valid.

Green Red
L/A X1 Green On Link to the remote station is established.
L/A X2 Blinking On and Ethernet activity present on the bus.
S/E On Off TCP/IP mode: Powerlink interface is operated purely as
an Ethernet TCP/EP interface.
Powerlink mode: Powerlinkt station is running, no errors.

Off On Fatal and irreparable system error. See control system
for alarm or warning. This status can only be changed by
resetting the module.
Blinking alternately The powerlink managing node failed. This error code can
only occur in controlled node operation. This means that
the set station number lies within the range $01 - $FD.
Off Red blinking System failure according to blinking pattern:
●●● — Pause ●●● — Pause: RAM error.
— ●● — Pause — ●● — Pause: Hardware error.
60 Book No.9010183 02, rev. 2

Module DIF371
Light Green Red Description
S Off Off Module not supplied, check fuse.

Single Off Reset mode.
flash
Blink- Off Prepoerational mode.
ing
On Off Run mode.
Off Module not supplied or everything is OK.
Single On Invalid firmware
flash
Book No.9010183 02, rev. 2 61

3 List of problems and solutions
This section contains problems that can occur, but is not indicated by an alarm.
3.1 General problems
Book No.9010183 02, rev. 2 63

64
3.1
Problem Description Possible cause What to do?
ID
1A The system does not start. Main breaker Q1 on control Turn on the breaker and measure that incoming 24 V DC to
The control panel does and LDC cabinet turned off, the control panel is present.
not light up. or power not connected to the
control panel.
General problems
Power turned off at main switch Turn on the power.

board
Fuse F42 tripped. 1. Check fuse F42 in control cabinet to see what circuit
caused the fuse trip.
2. Use the circuit diagram to check the fuse setting, adjust
according to figures in circuit diagram if necessary and
reset fuse.
3. Use the circuit diagram to locate the component or find the
reason that caused the fuse trip and attend to it.
Fuse F41 in control cabinet 1. Check fuse F41 in control cabinet to see what circuit
tripped. caused the fuse trip.
2. Use the circuit diagram to check the fuse setting, adjust
according to figures in circuit diagram if necessary and
reset fuse.
3
3. Use the circuit diagram to locate the component or find the

reason that caused the fuse trip and attend to it.
Control panel error. Can be Replace control panel.

caused by overheating etc.
Control panel error due to Let the panel dry and try again.
damp.
Book No.9010183 02, rev. 2

List of problems and solutions
3

ID
1B Control panel is not Abnormal operating condition. 1. Restart the control panel: Cut the power by removing the
displaying a normal page. power cable at the back of the control panel. Wait 30
seconds, and reconnect the cable again.
2. Restart the entire PureBallast system: Cut the power by
switching of the main breaker on the control cabinet. Wait
30 seconds, and switch on the main breaker again.
Book No.9010183 02, rev. 2

3. If panel is not OK, it is probably broke and needs to be
replaced. Replace the component.
Wrong software version Check that the HMI and PLC software have the save program
version. This is visible in control system page 4.1 System info .
HMI software problem Re-load the HMI software according to the software Release
note.
1C PureBallast can not be Communication is broken See the What to do column for alarm A93.
controlled or monitored between ISCS and PLC.
from the ISCS’ graphical
user interface via the
remote interface (optional)
1D Error message on the screen.

3.1
5 PanelCommunicationError
These messages can appear alone or in combination. The message does not appear in remote control panels (option).
“PureBallast: Comm Error ...”: Check the following:

• See the What to do column for alarm A91.
Communication is broken between remote control panel
and PLC. • If the electrical and signal cables are disconnected or
broken.
General problems
65
66
3.1
ID
• If the control cabinet is turned off.

• If the PLC is broken.
If control panels are not used: Remove IP address for Remote
control panel 1 according to instruction is set for the remote
General problems
control panel. See chapter 3. Operating instructions and

control system description, section Set remote control panel
communication.
“Disconnected from ...”: Check the following:

• If the electrical and signal cables are disconnected or
Communication is broken between remote control panel broken.
and main panel.
• If the control cabinet is turned off.
• If the main panel is turned off or broken.
If control panels are not used: See 1D.
3
Book No.9010183 02, rev. 2

3 List of problems and solutions 3.2 Filter
3.2 Filter
Book No.9010183 02, rev. 2 67

68
3.2
5A Backflush sequence Differential pressure transmitter Dismantle the component and inspect/rinse.
starting error (general) PT201–27 (Boll) may be faulty.
Filter
Differential pressure Differential pressure

transmitters PT201–71 transmitters PT201–71 and
and PT201–72 (Hydac) PT201–72 (Hydac) may be
may be faulty. faulty.
Error with the differential Dismantle the component and inspect/attend to.
pressure gauge electric
switches.
Valves for differential pressure Open the two valves (ball cocks) connected to PT201-27.
gauge PT201–27 (Boll) are
closed.
Valves for air pressure to valve Open the valve (ball cock) connected to V309-1.
V309-1 are closed.
5B Excessive backflushing The filter house is not properly Deaerate using the deaeration valve V201-50 on the filter lid.
or long backflushing deaerated.
sequences (general)
Damaged filter candle. Check filter candles for damage. Replace if necessary.
Large obstructions have Open the filter and remove the obstructions. See chapter 7.
entered the filter. Service manual, section Filter.
3
Dirty water See chapter 2. System description, section Backflushing for

different dirt loads.
Dirt build-up in the filter candles. Clean the filter candles.
Book No.9010183 02, rev. 2

3 List of problems and solutions 3.3 CIP
3.3 CIP
Book No.9010183 02, rev. 2 69

70
3.3
6A Insufficient pump capacity Leakage in air hoses or Locate leakage and attend to.
(general). sealings.
CIP
Air pressure too low due to Adjust setting with the manual valve under the valve block on
incorrect setting on valve block the CIP module.
on CIP.
The diaphragm in the CIP pump Examine the pump. See chapter 7. Service manual, section
is broken. Repair CIP pump.
Pump is clogged. Examine the pump. See chapter 7. Service manual, section
Repair CIP pump.
6B Too high consumption of Leakage in the CIP tank, CIP Locate leakage and attend to.
CIP liquid (> 1 cm/AOT pump, pipes or AOT reactor.
reactor cycle).
6C CIP liquid is not returned Insufficient pump capacity 1. Increase airflow to the pump to increase pump capacity
to CIP tank. (P321-5). with the manual valve under the valve block on the CIP
module.
2. Check that pump P321-5 is functioning correctly. See
problem 6D−6I in this chapter.
Broken valve. Examine the following valves: V571-1, V321-2.x, V320-4.x

and V321-1.
3
Pipe blockage Investigate if there is a pipe blockage.
6D CIP pump does not run • The air pressure is to low Examine the pump and attend to problem. See chapter 7.
Service manual, section Test CIP pump.
• The air connection is
blocked
• Muffler is blocked
• Air valve is defect
• Dirt in the pump chamber
• Diaphragm breakdown
Book No.9010183 02, rev. 2

3
6E CIP pump runs irregularly • Valve balls are blocked Examine the pump and attend to problem.
• Sealings are defect in air
valve or center block
• Diaphragm breakdown
6F Insufficient CIP pump • Suction connection blocked Examine the pump and attend to problem.
suction or not tight.
Book No.9010183 02, rev. 2

• Valve balls are blocked or
damaged
6G Bad flow or pressure in • Pressure fall in incoming air Examine the pump and attend to problem.
CIP pump
• Suction or air connection
blocked
• Air valve is defect
• Valve balls worn out/broken
• Air in liquid Diaphragm
breakdown
6H CIP pump leakage Screws on the housing not Tighten the screws.
properly fastened
6I CIP pump muffler leakage Diaphragm breakdown Change diaphragm.

3.3
71
CIP
3.4 Valve V201–8 3 List of problems and solutions
3.4 Valve V201–8
72 Book No.9010183 02, rev. 2

3
8A Signal change has no effect on Faulty air supply Check air supply to the valve and tubing to the actuator.
the actuator position See chapter 7. Service manual, section Proportional
valve for instructions regarding the proportional valve.
Faulty signal • Check input signal to proportional valve.

• Check I/P output.
8B Signal change results in actuator Connection or signal problem • Check coupling between proportional valve and
running to end positions actuator.
Book No.9010183 02, rev. 2

• Check input signal.
Signal and positioning problems. • Inaccurate positioning. Adjust position sensor. See chapter 7. Service manual,
8C
section Calibrate positioner on V201-8.
• Input signal fluctuates.
Check electric connection.
3.4
Valve V201–8
73
Chapter: 6. Installation description and drawings
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 7
2 Ship specif c information 9
3 Technical data 11
3.1 PureBallast system 11
3.2 PureBallast components 12
3.3 Working pressure and pressure drop 14
3.3.1 Working pressure during ballast operation and
during backflush 14
3.3.2 Pressure calculation 15
4 Installation guidelines 17
4.1.1 Safety information 17
4.1.2 General installation requirements 17
4.1.3 Installation of components supplied by shipyard 18
4.2 AOT reactor 18

4.3 Filter 19
4.4 CIP module 20
4.5 Cabinets and cables 20
4.6 Flow meter 22
4.7 Pressure monitoring device 22
4.8 Pipes and valves 22
4.9 Air supply 23
5 System interfaces 25
5.1 Remote control panel integration
(optional) 25
5.2 Remote interface integration (optional) 27
5.2.1 Communication between PureBallast PLC and
remote interface 27
5.2.2 Directory of addresses 28
3
5.3 Power management system integration 45
5.3.1 Overall power request process 46
5.3.2 Power steps and power signals 46
5.3.3 Power management installation 47
5.4 External component signal integration 48

5.4.1 External component signal installation 50
5.5 GPS signal installation 50
6 Start-up procedures 53
7 Drawings 55
7.1 Graphic symbols used in drawings 56
7.2 General drawings 57
7.2.1 Flow chart 57
7.2.2 Connection list 58
7.2.3 Electrical system layout (2 pages) 64
7.2.4 Air distribution 66
7.2.5 Quality specification / Compressed air 67
7.2.6 Quality specification / Water 68
7.2.7 Quality specification / CIP liquid 69
7.3 Dimension drawings including technical

data 70
7.3.1 AOT reactor / Dimension drawing 70
7.3.2 Filter / Dimension drawing 71
7.3.3 CIP module / Dimension drawing (2 pages) 72
7.3.4 Flow transmitter FIT201-1 / Dimension drawing 74
7.3.5 Pressure monitoring device (Incl. PT201-16,
PI201-18, RV201 and 201-15) / Dimension drawing 75
7.3.6 Control valve V201-8 / Dimension drawing 76
7.3.7 Valve V201-3 and V201-9 / Dimension drawing 78
7.3.8 Valve V201-32 and V403-35 / Dimension drawing 80
7.3.9 Valve V212-31 / Dimension drawing (Optional in
scope of supply) 82
7.3.10 Sampling device Q201.1 and Q201.2 / Dimension
drawing (3 pages) (Optional in scope of supply) 84
7.3.11 Lamp drive cabinet (LDC) / Dimension drawing 87
7.3.12 Control cabinet / Dimension drawing 88
7.3.13 Control panel / Dimension drawing (2 pages) 90
4
7.4 Electrical drawings 92
7.4.1 Control cabinet / Interconnection diagram (7 pages) 92
7.4.2 Control cabinet / Circuit diagram (20 pages) 99
7.4.3 Control cabinet / Cable list 119
7.4.4 Lamp Drive Cabinet (LDC) / Interconnection
diagram (2 pages) 120
7.4.5 Lamp Drive Cabinet (LDC) / Circuit diagram (14
pages) 122
7.4.6 Lamp Drive Cabinet (LDC) / Cable list 136
7.4.7 AOT reactor / Interconnection diagram (2 pages) 137
7.4.8 AOT reactor / Circuit diagram (3 pages) 139
7.4.9 AOT reactor / Cable list 142
7.4.10 AOT reactor and LDC / Lamp power cable 143
8 Shutdown and storage 145

8.1 Decommissioning 145
8.2 Protection 146
8.3 Storage and long term decommission-
ing 146
8.4 Start-up after shutdown 147
9 Delivery and transport

information 149
9.1 Delivery and transport 149
9.2 Lifting instructions 149
9.2.1 AOT reactor 150
9.2.2 Filter 151
9.2.3 CIP module 153
9.2.4 Cabinets 154
5
1 Introduction
This chapter contains information about how the PureBallast system is to be installed and drawings.
The information is presented as installation guidelines per component, relevant standards and
drawings. The chapter is opened with a summary of the main technical data.
Book No.9010183 02, rev. 2 7

1 Introduction
2 Ship specific information
Enter vessel specific information in the table below. This will facilitate reading information and
drawings in this document, since some drawings include information for all system sizes /
dimensions, and the document contains information for options only used by on some vessels.
Data Value
Flange standard (EN or JIS): _______________
Main valve and piping Dimension: ________________
Control valve (201-8) Dimension: ________________
Bypass valve (V212–31) Dimension: ________________
Alfa Laval’s or other. Location: __________________
Cooling water valve (V403-35) Dimension: ________________
Remote operation (optional) Remote control panel (number): _________
Remote interface integration (yes/no): _____
Book No.9010183 02, rev. 2 9

2 Ship specific information
3 Technical data
This section states technical data for the complete PureBallast system and for individual
components. In some cases references are given to data in drawings included in this chapter.
3.1 PureBallast system

The table below states conditions, limit values etc. for the PureBallast system.
Type of data Value
Water requirements See section Quality specification / Water on page 68 and data for
different components in the Connection list on page 58.
Water temperature — AOT reactor: 0–40 °C.
Water temperature — LDC cooling water: Max: 38 °C (± 2 °C).
Water types used in PureBallast:
• Sea water: Used for cooling UV lamps in the AOT reactor during
start-up.
• LT (low temperature) fresh water: Used for cooling the lamp drive
cabinet (LDC) during operation.
• Fresh water: Used for flushing and filling up of AOT reactors after
treatment.
Ambient air 0–55 °C.

temperature
Relative humidity Max. 90 %.
System f ow Flow range ballast (m3/h): 190 → Flow range deballast (m3/h):
1000 100 → 1000
Power consumption Maximum power consumption (kW): 101
Based on maximum:
• 100
Note: PureBallast only use the power needed for efficient
treatment. During operation, the UV lamps are lit to between
50 and 100 % of their capacity, depending on measured water
transmittance.
• 1 kW (Control system including PLC, 24 V feeding, CIP motor
supply, filter motor supply)
Book No.9010183 02, rev. 2 11

3.2 PureBallast components 3 Technical data
Type of data Value
Power: Nominal 400VAC +/-10% − 50Hz

voltage/Frequency
440VAC +/-10% − 60Hz
24VDC - Remote control panel (optional).
Power to LDC: Max Icu 50 KA.
UV intensity power The water is fully treated at UV intensity > 380 W/m2. UV intensity is
limit measured by UV transmitter QT201–50.
The system have been tested and found to give full treatment of the
ballast water when the measured UV intensity is above the value
380 w/m2.
IP rating Components within range IP44–IP67.
See dimensional drawing for respective component in section

Drawings. Encapsulated components, for example in the control
cabinet, can have lower classification.
Working pressure – Max. 6 bar (PN 6). (0.6 MPa).

PureBallast system
Working pressure – See Connection list on page 58.

compressed air
3.2 PureBallast components

The table below states conditions, limit values etc. for the individual component in the PureBallast
system. Dimensions are given in dimension drawings including technical data in the Drawings
section.
Component Type of data Value
AOT reactor Pressure drop See data for different components in Connection
list on page 58.
Weight (empty) 330kg.
Volume 190 liters
12 Book No.9010183 02, rev. 2

3 Technical data 3.2 PureBallast components
Filter Pressure drop and 0.2–0.85 bar (0.05–0.085 MPA).

working pressure
for filter See Working pressure and pressure drop on
page 14.
Weight, empty 980

with adaptor plates
on flanges (kg)
Volume (dm3) 452
CIP module Weight, empty 155 kg

(kg)
Tank volume 250 liters. Note: Total tank volume is 300, but
shall only be filled to max 250.
Flow transmitter Measures, weight See dimensional drawing on 74.

etc.
Valves Measures, weight See section Dimension drawings including

etc. technical data on page 70.
Type See data for different components in Connection

list on page 58.
Connection type EN or JIS.
Electrical cabinets Measures, weight See section Dimension drawings including

etc. technical data on page 70.
Remote control panel Dimensions See Control panel / Dimension drawing on page
(optional) 90 and on Control panel integration page 25.
Book No.9010183 02, rev. 2 13

3.3 Working pressure and pressure drop 3 Technical data
3.3 Working pressure and pressure drop

This section gives a description of working pressure and pressure drops in the system.
3.3.1 Working pressure during ballast operation and during backf ush
During ballast operation, the ballast water flow goes through the filter and AOT reactor which
gives an approximate maximum pressure drop of 0.70 bar at maximum flow rate. Note that piping
outside the PureBallast system is not included. The pressure drop over the filter fluctuates between
approximately 0.2−0.85 bar depending on dirt load in the filter. The differential pressure over the
filter is monitored by one pressure transmitters on the filter inlet 201 and one on the filter outlet 201.
When the differential pressure reaches a parameter set limit (default is 0.5 bar), a backflush
operation is started automatically. To secure sufficient backflush flow, the pressure at pfilter
inlet must be at least 1.0 . For detailed information about backflush, see chapter 2. System
description, section Filter.
6 Working_Pressure_Hydac
Note: According to default parameter setting.
14 Book No.9010183 02, rev. 2

3 Technical data 3.3 Working pressure and pressure drop
3.3.2 Pressure calculation

The information below is used when the ballast water system is dimensioned.
Pressure during ballasting
During ballast operation, the ballast water flow goes through the AOT reactor which gives a
maximum pressure drop of 0.70 bar (not including vessel’s piping), as described in the table below.
Note that the total pressure drop only includes the PureBallast components, not the vessel’s piping
before the first PureBallast component (Q201.1 ) or after the last (V201–8).
Filter ≤ 0.50 bar pfilter: 0.2−0.85
Note that 0.50 bar is the default limit value for parameter p305
(Backflush trigger), which defines maximum allowed differential
pressure over the filter. Note that this parameter can be adjusted,
but only by Alfa Laval during commissioning.
AOT ≤ 0.20 bar pAOT: 0.20 bar (0.02 MPa) including PureBallast valves. Piping
reactor is not included, since it is installation specific.
Total ≤ 0.70 bar ≤ 0.70 bar (0.07 MPa) if parameter p305 is set to 0.50 bar.
Pressure during backf ush
During backflush, the ballast water flow goes through the filter and AOT reactor, and the backflush
discharge flow goes through the filter and pipe 309.
A pressure calculation must be done to secure sufficient backflush flow in pipe 309 and to secure
that the ballast water pump can overcome the pressure drop (see table below). Note that the
calculated total pressure drop only includes components from the PureBallast inlet valve V201–2
to the backflush over board valve.
Backf ush ≥ 1.0 bar Difference between filter inlet “201” and filter backflush outlet
differential “309”.
pressure
∆P309 Calculated The pressure drop for pipe 309 is installation specific and must
be calculated.
The connection list specifies required flow in pipe 309 to be

60–120 m3/h.
Use this flow to calculate the pressure drop in ∆P309. Note

that ∆P309 includes both static pressure and dynamic pressure
(pipe length, bends, valves etc) for pipe 309.
Total Calculated Calculated pressure drop during backflushing give minimum

pressure BW pump capacity required for PureBallast. If the value is
drop greater than existing pump capacity, steps must be taken, for
example:
• Reduce the total pressure drop by reducing ∆p309. This

can, for example, be done by increasing the pipe diameter
or by reducing the number of bends etc in pipe 309.
Book No.9010183 02, rev. 2 15

3.3 Working pressure and pressure drop 3 Technical data
• Upgrade to a pump with bigger capacity.
Calculate value for parameter Required pressure to start backf ush
To ensure that pfilter inlet is 1.0 bar, the total pressure drop must be calculated according to the
formula below:
• pfilter inlet 201 ≥ 1.0 bar + p309

Enter this value in parameter p304 (Required pressure to start backflush) in the control system page
5.4 – Filter parameters. The parameter defines pressure needed to start a backflush operation.
The parameter is also the setpoint for the pressure that the control valve (V201-8) will maintain
during backflush.
16 Book No.9010183 02, rev. 2

4 Installation guidelines
This section covers requirements for installing different components of the system.

Read this section before the system is installed.
4.1.1 Safety information

• Earth connection must be made before any welding is done. The ground cable must have a
cross-section large enough in relation to the supply cables from the vessel. Otherwise the
equipment might be damaged during welding.
• Follow local regulations for electrical installation and earthing (grounding).
• Instructions on how to mount and install components are given in chapter 7. Service manual.
NG
WARNI
!
• Read chapter 1. Safety.
• Installation must be done by a fully trained professional installer.
• Damages related to transport and installation should be recorded.
4.1.2 General installation requirements

The following requirements are valid for all components.
• The Installation guidelines in this section must be followed.

• Installation requirements given in the dimension drawings must be followed. See section
Drawings in this chapter.
• Components must be properly suspended and supported.
• There must be sufficient access to maintain the components. Access area is defined in the
dimension drawings.
• Installed component must not amplify vibrations to or from the hull.
• All piping connected to the PureBallast components (AOT reactor, filter and CIP module shall
be properly self supported. No load shall be transferred to or from any major components.
Book No.9010183 02, rev. 2 17

4.2 AOT reactor 4 Installation guidelines
• All components must be installed and marked as specified in dimension drawings, flow charts
and other drawings included in this manual.
- General drawings – overall and principle information for system layout (pipes, components,
electricity, air and water).
- Dimension drawing – detailed component information (dimensions, sizes etc).
- Electrical drawings – detailed electric information (circuit diagrams, cable lists etc).
4.1.3 Installation of components supplied by shipyard

Additional equipment, not part of Alfa Laval’s scope of supply (for example cables, pipes) must
be installed according to the following sections of the manual:
• Connection list
• Quality specification for water
• Quality specification for compressed air
• Installation guidelines
• Electrical drawings
4.2 AOT reactor
Follow the guidelines below when installing the reactor module.
18 Book No.9010183 02, rev. 2

4 Installation guidelines 4.3 Filter
• The AOT reactor must be fixated at the bottom and supported at the top to carry the weight
of the component. Use the upper and lower fixing holes (1) in the support structure to fixate
the component to the steel construction of the hull. If this is not enough, completing stays has
to be made. There are four fixing holes on each side at the bottom and four at the top, after
the lifting beam has been removed.
6 AOT installation
• Prepare the inlet piping first. Then mount the AOT reactor onto the inlet flange and secure it.
Finally install the outlet piping onto the top of the AOT reactor.
• We recommend that the installation of the reactor is planned to be supported by its lifting point
until the units lower part is completely secured to the foundation and inlet flange.
• No fixtures should be attached to the reactor housing by welding, since this will damage or
distort the reactor, and potentially affect the biological performance of the component.
• The AOT reactor must be earthed. The earth nut is indicated as “791” in the dimension drawing.
4.3 Filter
Follow the guidelines below when installing the filter.
• The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation.
• Pipe 309 (filter backflush overboard line), with its valve, must be correctly connected.
• The component must be earthed. The earth nut is indicated as “791” in the dimension drawing.
• The filter motor must be mounted, if it is not mounted at delivery. See chapter 7. Service
manual, section Mount filter gear motor for instructions.
Book No.9010183 02, rev. 2 19

4.5 Cabinets and cables 4 Installation guidelines
4.4 CIP module

Follow the guidelines below when installing the CIP module.
• The electrical cable is connected from the control cabinet to the CIP valve block. See chapter 7.
Service manual, section Connect electrical cables to valve block.
• The component must be earthed. The earth nut is indicated as “PE bolt” in the dimension
drawing.
bolted or welded in place on a steady foundation.
• The deaeration pipe after deaeration valve V571-1 must reach approximately 2 meters higher
than valve V321-2 at the AOT reactor to avoid water spillage during CIP process. It is
recommended that the deaeration pipe is led to a scupper to collect eventual (minor) water
spillage.
• Connections to the flanges must be made so that the connection is not exposed to any moment
or load. This is particularly important when connecting the plastic flanges.
4.5 Cabinets and cables

Follow the guidelines below when installing cabinets and cables.
NOTE
• System interfaces (optional) must be integrated according to section System interfaces on page :
- remote control panels

- remote interface
- power management
- external component integration
- GPS integration
Cables – General
• Recommendation: Make notes of the actual connections made to the vessel’s systems with part
number and cable number in the electrical drawings. The drawings are prepared with indicated,
empty squared for this purpose. The electrical diagrams are found in the Drawings section.
These notes can be used to make notes of the exact connections done during installation to
simplify future faultfinding.
• Electrical cables must be properly routed and supported according to applicable regulations.
• Cable entries to cabinets must be sealed, using the built in cable glands. See instruction
Cable glands in chapter 7. Service manual.
• Cabling shall be done according to specification in Electrical system layout on page 64, and
the electrical drawings. This includes cable routing, cable types and cable marking to simplify
identification and fault finding.
20 Book No.9010183 02, rev. 2

4 Installation guidelines 4.5 Cabinets and cables
• Power cables shall be separated from signal and bus cables. Distance between them reduces
electrical noise transfer.
- If placed on a cable rack, place power and signal cables on opposite sides.
- If cables are routed in tubes due to narrow space, the power and signal cables shall be
routed in separate tubes.
• EMC: Cables shall be peeled down to the cable shield. The nut holding the cable must be in
contact with the screen bar.
Cabinets – General
• Cabinets must be firmly attached.

• Cabinets must be earthed. The earth nut is indicated as “791” in the dimension drawing.
LDC cabinet
• The cabinets maximum distance (cable length) to the AOT reactor: 150 meters.
bolted or welded in place on a steady foundation. It is possible to detach the cabinet from the
bottom frame to facilitate installation. The cabinet shall also be attached to the bulkhead using
the attachment bolts on the top of the cabinet.
• Cables can be lead to the cabinet either from the floor or from the side of of the cabinet,
depending on which is most convenient. If needed, the location of the cable gland cassette
and the cover is exchanged.
• Power cable W201.1 to be connected to main switch board: Max Icu 50 KA.
• Signal cables W210A and B to be connected from X1 in LDC to A side junction box on the AOT
reactor. Cables from junction box to components are pre-assembled.
• Lamp power cables W211A-D (included in scope of supply) shall be connected from X2 in
LDC to the (B side) junction box on the AOT reactor. (Cables from junction box to lamps
are pre-assembled.)
• The lamp power cable should not be winded. If it is to long, cut it before it is connected. .
• It is possible to dismount the doors during installation: Slide the red catch on the hinge
backwards and release the locking mechanism.
Control cabinet
• Power cable W1 to be connected to control cabinet (Q1).

• A power link (LAN) cable shall be connected from the control cabinet to the LDC and back. The
first power link cable is connected from X6 in the control cabinet to X5 in LDC1. The second
cable is connected from X6 in LDC1 back to X7 in the control cabinet.
Book No.9010183 02, rev. 2 21

4.8 Pipes and valves 4 Installation guidelines
4.6 Flow meter

Follow the guidelines below.
• The ballast water flow direction must be according to the arrow on the flow sensor.
• The flow transmitter must be mounted on the flow sensor pipe. It is not pre-assembled from
factory. See chapter 7. Service manual for instructions.
4.7 Pressure monitoring device

• A drain solution (not part of Alfa Laval’s scope of supply) must be attached to safety valve
RV201. The valve shall be drained to a scupper, with a solution which always allows water to
be drained from the valve. See Pressure monitoring device / Dimension drawing.
4.8 Pipes and valves

Follow the guidelines below when installing pipes and valves.
• Inlet and outlet pipes must be correctly connected. They must also be pressure approved by a
classification society or equivalent, or be tested under supervision of a classification society
and/or at the ship yards pipe shop etc.
• Pipes shall be designed to carry the weight of the component and media.
• A bypass valve (optional part of Alfa Laval’s scope of supply) must be installed. The bypass
valve (V212-31) shall be connected to the the vessel’s ISCS, to enable control of the valve, and
PureBallast control system to indicate valve position. See Control cabinet / Interconnection
diagram on page 92.
• If PureBallast can be bypassed using other valves (apart from V212-31), status signals from
them must be connected to the control cabinet. All bypass cases must be logged.
Three additional bypass valves can be handled, identified as additional bypass valve 1, 2 and 3.
If more valves are used, they must be connected in series, which means that they are handled
as one regarding alarms and logging in PureBallast.
Signal cables for additional bypass valves are installed according to section External component
signal integration.
• The yellow position indicator on actuators must be in line with the valve throttle. For pipes with
dimension 400, the red position indicator on the actuator coupling (see drawing) must also be in
line with the throttle. The position indicator must be in line with the pipe when the valve is open.
If not correct, change according to instruction in chapter 7. Service manual for instructions.
• Valves shall be opened when installed. This is important to avoid that the rubber gaskets are
squeezed and damaged during installation.
• Valve actuator’s pneumatic lines must be correctly connected and supported. See chapter
7. Service manual for instructions.
• Valve actuators electric connectors must be correctly connected.
22 Book No.9010183 02, rev. 2

4 Installation guidelines 4.9 Air supply
• Sampling device Q201.1 and Q201.2.
- If delivered by Alfa Laval: Must be mounted with the pin pointing in the flow direction (see
drawing on page 84).
- Flanges for connecting the sampling devices must be installed before the pipe is coated.
4.9 Air supply

• Components shall be connected to air supply that meets the requirements or the Quality
specification / Compressed air 67. Air shall always be connected.
Book No.9010183 02, rev. 2 23

4.9 Air supply 4 Installation guidelines
5 System interfaces
This section covers guidelines for how to install and integrate the following, if used:
• remote control panels

• remote interface (Not yet defined)
• power management system (Not yet defined)
• external components
• GPS integration
Note that options are not applicable for all installations.
5.1 Remote control panel integration (optional)

The PureBallast system can, as an option, be equipped with up to four remote control panels.
Remote control panel integration requires the following:
• 1 or 2 remote control panels to be mounted at an optional location.

• Communication cable (W501) between the switch (X13) in the control cabinet and the remote
control panel can be either Ethernet or fiber.
- Ethernet cable – Type: Cat 5e (or better). Max length: 100 meters. One free Ethernet
connection point (X13) in the switch in the control cabinet.
- Fiber cable – Type: Multi-mode fiber cable with LC connector. Max length: 500 meters.
Ports: Two free ports in the switch in the control cabinet.
If fiber is used, a network switch must be used, since the cable to the panel must be of
Ethernet type. One network switch and a 1.5 meter Ethernet cable is delivered with each
remote control panel.
• If more remote control panels are to be installed than there are free fiber ports in the control
cabinet, one of the delivered network switches can be used for connection. From this switch,
it is possible to connect more panels using the free ports. Keep in mind that the cable to the
panel must be of Ethernet type. The extra switch shall be placed close to the first remote
control panel so the 1.5 meter Ethernet cable can be used.
• External network switch including a terminal to handle the communication, placed near the
remote control panel. We recommend to use the external network switch close to the remote
control panel, even if it is not necessary (if there are free ports in the control cabinet).
• Network switch in control cabinet. It is installed if remote control panels have been ordered, but
can also be installed at a later stage.
• A signal device must be installed according information in section Cabinets and cables on page
20. Not part of Alfa Laval’s scope of supply.
Switches and cables are installed according to instructions in chapter 7. Service manual, section
Remote control panel (optional).
Book No.9010183 02, rev. 2 25

5.1 Remote control panel integration (optional) 5 System interfaces
Communication settings must be done according to instruction in chapter 3. Operating instructions

and control system description, section Set control panel IP address and Set remote control panel
communication.
26 Book No.9010183 02, rev. 2

5 System interfaces 5.2 Remote interface integration (optional)
5.2 Remote interface integration (optional)

The PureBallast system can, as an option, be integrated with the ISCS. This will allow operation
and monitoring of the system from the ISCS. This section presents guidelines for how to connect
and implement the integration via the remote interface.
PureBallast’s PLC communicate with the vessel’s ISCS via the remote interface. Data is sent to
and from dedicated addresses via modbus. Data can be commands, values (sum of bits), alarms
and status information. The data is then presented in the ISCS according to the vessel’s graphical
standard. It is possible to present all information (all addresses) or a selection. Data is sent as
binary code, with exception for time, which is sent as hexadecimal code.
Remote interface integration requires the following:
• Cable W602 to be connected from connection terminal (X15) in control cabinet to ISCS.
• Modbus connection from ISCS to PureBallast connection terminal X15 in the control cabinet.
Connection standard: RS485 (or RS422, not described in electrical drawings) according to
Control cabinet / Interconnection diagram. Recommended max length: 500 meters.
• Implementation of remote interface signals in the ISCS according to the guidelines in this section.
• Communication settings must be done according to chapter 3. Operating instructions and
control system description, section Set remote interface communication.
• Parameter p132 and p128 must be set in the control system.
• After installation and integration, the function of the remote interface must be verified according
to chapter 3. Operating instructions and control system description, section Test remote
interface communication.
• A signal device must be installed according to information in section Cabinets and cables on
page 20. Not part of Alfa Laval’s scope of supply.
Reference information about the logical flow of the PureBallast processes can be found in chapter
3. Operating instructions and control system description, section Detailed process description.
5.2.1 Communication between PureBallast PLC and remote interface

This section describes all addresses in the remote interface, to handle the communication. These
addresses are displayed in the control system page 5.5 Remote interface 1 and 5.6 Remote interface
2, described in chapter 3. Operating instructions and control system description. Page 4.5 and 4.6
are used to verify that the integration functions and that correct information is displayed in the ISCS.
Modbus settings
The ISCS modbus RTU server data shall be set according to the table below:
Area Value Parameter option
Interface type Set in parameter p700 –p704 in page

Baud rate 4.7 Remote interface. See chapter 4
Parity Parameters for detailed information.
Databits
Stop bits
Modbus RTU N/A
Book No.9010183 02, rev. 2 27

5.2 Remote interface integration (optional) 5 System interfaces
Communication Serial N/A

method
Slave ID 10 N/A
PureBallast
is slave
and ISCS is
master.
5.2.2 Directory of addresses

This section list all addresses for the information sent between the systems.
The following terms are used to explain the signals in the tables below:
Address:Bit The start address is 40000. Individual address and bit for each signal (data), is
written as “Address:Bit”, for example +073:14. Values for an address is written
as “Address=Value”, for example 015=125.
Bits are the Signal reference number. Bits are right aligned in the table.
Function Name of the function. The name corresponds to the text used in the
PureBallast control system HMI. Parenthesis gives reference to the control
system page where the information is used/displayed. For further information
about respective piece of information, see chapter 3. Operating instructions
and control system description.
Description Additional information, for example specific conditions that must be met before
a command can be sent.
The directory starts on next page.
28 Book No.9010183 02, rev. 2

5.2.2.1 Data from ISCS
The addresses below are used to send commands and status information from ISCS to PureBallast.
Example of data: Command to start a ballast process and feedback that the ballast water pump
is running.
Address: Function Description

40000 +
+001 Commands
Condition: All signals for +001 must be high until PureBallast return an
accept or reject signal (see +140).
Bit 0 Start ballast Command: Start ballast
Bit 1 Start deballast Command: Deballast
Bit 2 Start CIP Command: Start CIP
Prerequisite: Only possible during standby.
Note: CIP will be performed for AOT reactors

that requires CIP, indicated by signal AOT reactor
(100:6, 200:6or 300:6 = 0)
Bit 3 Stop Command: Stop ongoing process. It shall always

be possible to send this command.
Bit 4 Pause Command: Pause ongoing process.
Condition: Only possible during full ballast

(+042=2) and full deballast (+042=9).
Bit 5 Manual backflush Command: Start backflush.

(Filter popup)
(+042=2).
Bit 6 Ack all alarms and Command: Acknowledge all alarms and warnings.
warnings (2.1)
Condition: Signal shall be high so long it can be
assumed that it is received by the PureBallast,
considering the installation specific conditions.
Bit 7 Apply new flow (1.1 Confirm activation of new flow selected using
and 1.2) address +003 (Selected flow).
Condition: Only possible during Standby (+041=1),

full ballast (+042=2) and full deballast (+042=9).
Condition: Signal high to confirm. Signal shall be

high until a response to the selection in +001:7 is
sent. We recommend that the signal is high the
new flow is confirmed (address +018 is updated
with the new flow).
Book No.9010183 02, rev. 2 29


40000 +
+002 Feedback
Bit 0 Ballast water pump Status: 1=Started. 0=Stopped.

status (1.1)
Response to address +040:8.
Bit 1 Overboard valve Status: 1=Open. 0=Closed.

status (1.1)
Response to address +040=9.
+003 Select AOTs) (1.1, If set during standby: Defines which flow to be
1.2) used when ballast or deballast is started. If set
during ballast or deballast: Defines that the flow
shall be increased or decreased to the new flow.
Number of AOT reactors is sent to PureBallast as

a value, which represent the maximum flow for
process (for a 300 respective 1000 reactor):
1=300 / 1000 m3/h
2=600 / 2000 m3/h
3=600 / 3=3000 m3/h.
In some installations the filter capacity is lower than

the total capacity of installed AOT reactors, defined
in parameter p315. In this case current max flow
will be reduced to this flow by PureBallast. The
reduced will be sent to address +056.
The selection can be visualized in ISCS either as

number of AOT reactors (1, 2, 3 etc) or the flow that
corresponds to the number of AOT reactors.
Condition: Only possible during Standby (+041=1),

full ballast (+042=2) and full deballast (+042=9).
Condition: The number of AOT reactors required

for the selected flow must not be greater than the
number of AOT reactors indicated as ready in
address +054 (Numbers of AOT reactor ready).
Condition: The selection must be applied using

+001:7.
Note: This signal shall only be changed when the

operator want to change flow; all other times it shall
be constant. This will simplify operation, since the
selection for last process is set as default for next
process.
30 Book No.9010183 02, rev. 2


40000 +
+004 Bypass (1.1) Status: PureBallast system bypassed.
Condition: If this address is > 0 PureBallast is

bypassed. Ongoing process is stopped and an
event is written to the event log with the value in
this address.
Bit 0–15 The bits can represent integer values between 0

and 32 767.
The value can be used to log a component or a

combination of components that result in a bypass
of PureBallast.
If it is not possible to use value that correspond

to valve ID:s, a key must be kept on board that
state which valve or combination of valves the
value represent. This is necessary to be able to
understand the event log.
+005 Power granted (1.4) Only relevant if PureBallast is integrated with the
vessel’s power management system.
Condition: Response to address +045:0–3. Signal

shall be high until signal +046:0-3 goes high.
Note that it is possible for the vessel’s power

management system to grant lower power than
requested.
Bit 0–4 Power granted 1–4. Bit 1–3: Power granted for the number of AOT
reactors sent.
Bit 4: Power granted for the total number of AOT

reactors installed.
+006 Heartbeat (4.5) Status: Handshaking between PureBallast and

ISCS. ISCS send an arbitrary value to address
+047. PureBallast return same counter to confirm
communication. After defined interval, ISCS send
a new number, in a continuous loop. A counter
can be used as value. Recommended interval: 10
seconds.
Condition: Value must be sent as a signed 16 bit

integer between 0 and 32 767.
5.2.2.2 Data to ISCS
The addresses below are used to send data from PureBallast to ISCS.
Example of data: System flow and pressure.
Book No.9010183 02, rev. 2 31


40000 +
+050 Processed volume (1.1) Value: Processed volume [m3] during current
ballast or deballast process. The value is resets
during next start-up.
+051 Flow measurement (1.1, Value: Current flow indicated by FIT201-1

1.2) (/m3/h).
+052 System pressure Value: System pressure indicated by PT201-16.

PT201–16 (1.1)
Condition: The value sent from PureBallast
must be multiplied by 0.01 before presented in
ISCS.
Example: If value 450 is sent (and displayed

in page 5.5), this means that actual pressure is
4.50 bar.
+053 Selected AOTs (1.2) Value: Number of AOT reactors selected for
operation.
Response to address +003 after applied by

address +001:7. Alternative, response to
parameter p131 (Automatic selection of AOT
reactors) if activated in control panel.
Note that PureBallast can respond with a lower

number of AOT reactors than set in +003, for
example if one AOT reactor is not ready.
It is recommended that this address is compared

to +003. If the number is lower, a message can
be displayed in the ISCS to inform the operator
that process will run with a lower flow than
expected.
If flow is increased during operation, this address

will be updated when the new AOT reactors are
started. If flow is decreased during operation,
this address will be updated immediately.
+054 Number of AOTs ready Number of AOT reactors that are ready for use
(1.2) in process.
+055 Selected f ow (1.2) Flow selected for process in m3/h.

address +001:7.
32 Book No.9010183 02, rev. 2


40000 +
+056 Current max f ow (1.1, 1.2) Maximum flow in m3/h for process, based on
number of selected AOT reactors and filter
capacity.
Max flow is calculated as number of selected

AOT reactors multiplied with AOT reactor
capacity (300 or 1000 depending on size).
In some installations the filter capacity is

lower than the total capacity of installed AOT
reactors, defined in parameter p315. In this case
current max flow will be reduced to this flow by
PureBallast.

address +001:7.
+057 Current time - Low (4.1) Value: Seconds since 1970-01-01 00:00,
in combination with address +058. Sent as
hexadecimal code.

must be calculated from seconds since
1970-01-01 00:00 to actual date and time.
+058 Current time - Hi (1.2) Value: Seconds since 1970-01-01 00:00, in

combination with address +057.
+059 Remaining time for CIP Value: Total estimated remaining time (hours) for
(hours) (1.3) all CIP sequences and filter preservation
+060 Remaining time for CIP Value: Total estimated remaining (minutes) time
(min) (1.3) for all CIP sequences and filter preservation.
+061 Remaining time until CIP Value: Hours before CIP must be performed.
req. (hours) (1.3) Displayed per AOT reactor.
Note: In the control system, the counter is

set to 0 after an AOT reactor has been CIP
cleaned. The countdown starts after next
ballast or deballast operation. However, for
remote interface, the value “30” is sent after CIP
cleaning, but without countdown. The countdown
starts after next operation. Time is displayed for
the AOT with shortest time left to required CIP.
+062 Remaining time until CIP Value: Minutes before CIP must be performed.
req. (min) (1.3)
For details, see +061.
Book No.9010183 02, rev. 2 33


40000 +
+063 Filter differential pressure Value: Filter differential pressure indicated by

(Filter popup: dP inlet/outlet) PT201-71 and PT201-72.

ISCS.
Example: If value 34 is sent (and displayed in

page 5.5), this means that actual pressure is
0.34 bar.
+064 Filter inlet pressure Value: Filter differential pressure indicated by

V201–71 (Filter popup) PT201-71.

ISCS.

0.34 bar.
+065 Filter outlet pressure Value: Filter differential pressure indicated by

V201–72 (Filter popup) PT201-72.

ISCS.

0.34 bar.
+066 V201–8 setpoint (1.1) Control valve output signal (%).
+067 Power consumption (1.1, Only relevant if PureBallast is integrated with the
1.4) vessel’s power management system.
Value: Calculated maximum power consumption

[kW] based on number of selected AOT reactors.
Calculated or measured power consumption

(kW).
5.2.2.3 Commands and status to ISCS
The addresses below are used to send commands and status information from PureBallast to ISCS.
Example of data: Process mode (standby, ballast, CIP), acceptance of command from ISCS, and
request to ISCS to start ballast pump.
34 Book No.9010183 02, rev. 2


40000 +
/ Bit
+070 Command status
Bit 0 Start ballast accepted Status: Confirmation from PureBallast that

requested command is executed.
Response to command from ISCS on address

+001:0.
Bit 1 Start deballast accepted Status: Confirmation from PureBallast that


+001:1.
Bit 2 Start CIP accepted Status: Confirmation from PureBallast that


+001:2.
Bit 3 Stop accepted Status: Confirmation from PureBallast that


+001:3.
Bit 4 Pause accepted Status: Confirmation from PureBallast that


+001:4.
Bit 5 Manual backflush accepted Command: Start backflush.

(filter popup)
+001:5.

(+073:2)
Bit 6 Command rejected Status: Information that requested command

cannot be executed. Reason not specified.

+001:0-7.
Book No.9010183 02, rev. 2 35


40000 +
Bit 7 Sum alarm Common alarm indicating that one (any) alarm is
active. Alternative to implementation of individual
alarm signals and hardwired common alarm.
Functions in the same way as hardwired external
signal “Common alarm”.
Note: If common alarm is issued when there

already is an active alarm (this signal already
high), PureBallast will lower the signal for 3
seconds, and then reactivate it as high.
Bit 8 Sum warning Common warning indicating that one (any)

warning is active. Alternative to implementation
of individual warning signals and hardwired
common warning. Functions in the same way as
hardwired external signal “Common warning”.
Note: If common warnings issued when there

already is an active warning (this signal already
high), PureBallast will lower the signal for 3
seconds, and then reactivate it as high.
Bit 9 New flow in progress (1.3) Status: New flow in progress.
Response to command from ISCS to change

flow during ongoing operation applied by address
+001:7.
Bit 10 Local / Remote (5.5) Request: Address values.

1=Activate operation from remote interface.
0=Activate operation from control panels.
+071 Commands
Bit 0 Start ballast water pump Request to ISCS to start ballast water pump:
(1.1) Address values.
1=Request to start.
0=Request to stop.
Bit 1 Open overboard valve (1.1) Request to ISCS to open overboard valve:
Address values:
1=Request to open.
0=Request to close.
36 Book No.9010183 02, rev. 2


40000 +
+072 Process mode (1.1, 1.3) Status: Address values: Values indicating
system mode.
0=Booting
1=Standby
2=Ballast
3=Deballast
4=CIP
5=Emergency stop
6=Manual mode
+073 Subprocess mode (1.1, 1.3) Status: Address values: Values indicating
system mode.
0=None
1=Start-up ballast
2=Full ballast
3=Backflush
4=Pause
5=Stop with backflush
6=Increasing ballast flow capacity
7=Decreasing ballast flow capacity
8=Start-up deballast
9=Full deballast
10=Pause deballast
11=Stop deballast
12=Increasing deballast flow capacity
13=Decreasing deballast flow capacity
14=AOT reactor drain 1 – Sea water
15=AOT reactor fill 1 – Fresh water
16=AOT reactor drain 2 – Fresh water
17=CIP
18=AOT reactor fill 2 – Fresh water
19=Preservation filter – Fresh water
20=Heeling mode
21=CIP drain
22=Stop (If ballast process is stopped before
mode Full ballast, no backflush is performed.)
+074 Filter mode Status: Address values:

0=Idle (No backflush or preservation).
1=Backflush preparation.
2=Backflush ongoing.
3=Filter preservation.
+075 Power request [1–4] (1.4) Only relevant if PureBallast is integrated with the
Value: Calculated maximum power consumption

[kW] based on number of selected AOT reactors.
Book No.9010183 02, rev. 2 37


40000 +
Bit 0–4 Power request [1–4] (1.4). It is only necessary to use signals (bits) to cover
the need for power request. This is defined by
the number of AOT reactors, alternatively use
of common power.
Bit 1–3: Power request for the number of AOT

reactors to be used in operation.
Bit 4: Power request for the total number of AOT

reactors installed.
+076 Power running [1–4] (1.4) Only relevant if PureBallast is integrated with the
For information about power request, see system

manual chapter 6. Installation description and
drawings, section Power management.
Power request to power management system.
Bit 0–4 Power running [1–4] (1.4). Response to address +005:0–4.
Bit 1–3: Power running for the number of AOT

reactors used in operation.
Bit 4: Power running for the total number of AOT

reactors installed.
+077 Heartbeat echo (4.5) Status: Handshaking between PureBallast and

ISCS. Receive counter from address +006 and
return same counter to confirm communication.
See address +006.
5.2.2.4 I/O status to ISCS
The addresses below are used to send status information for components to ISCS.
Example of data: Status for valves and pumps.

40000+
/ Bit
+080 Main valve status (1.1, 1.3 and popups for AOT reactor and filter)
Bit 0 V403-35 Status: Address value:

1=Open. 0=Closed.

1=Open. 0=Closed.
38 Book No.9010183 02, rev. 2


1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.
+081 Main pump status (AOT reactor popup)
Bit 0 P401-1 Status: Address value:

1=Pump running request. 0=Stopp request.

1=Pump running request. 0=Stopped request.
+082 Main bypass valve status (1.1)

1=Open (PureBallast bypassed). 0=Closed.
Bit 1 External bypass valve 1 Status: Address value:

Bit 2 External bypass nr. 2 Status: Address value:

Bit 3 External bypass nr. 3 Status: Address value:

Bit 4 ISCS bypass via remote Status: Address value:

interface 1=One bypass valve open (PureBallast
bypassed). 0=Closed. See address +004 to see
vessel ID for open valve.
+083 CIP status (1.3)

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.
Book No.9010183 02, rev. 2 39


1=Open. 0=Closed.

1=Pump running. 0=Stopped.

1=Pump running. 0=Stopped.
+084 Filter status (Filter popup) Only valid for Filter type 1 = Boll filter.

1=Open. 0=Closed.
Bit 1 M709-42 Status: Address value:

1=Running. 0=Stopped.
5.2.2.5 Alarms to ISCS
The tables below lists all alarms and warnings sent from PureBallast to the ISCS. Each alarm is
defined as a specific bit. The bit is set to 1 when the alarm is activated. The alarm IDs refer to alarms
described in chapter 5. Alarms and faultfinding, where texts to be displayed in ISCS can be found.
Example: If data at address 40902 is 000010000000100, this means that alarm W04 and warning
A33 are active (bit 2 and 10).
Empty fields are not used.
General alarms and warnings
Common alarms and common warnings (+900 and +901) indicate that there exist a common alarm
for the area or component specified.
Example of alarms and warnings: Process flow too high, valve error, component signals missing.
Ad- Common Common Main 1 Main 2 Main 3 Filter

dress alarms warnings +902 +903 +904 +907
40000 + +900 +901
Bit
0 Sum Sum A01 A51 W96 W300
1 Main Main A03 W58 W97
2 AOT AOT W04 A66 A98 1 W306
3 CIP CIP A10 A67 A99 W308
4 Filter Filter W12 A68 W180 W310
5 Power Power A13 A71 A69 W312
40 Book No.9010183 02, rev. 2

Ad- Common Common Main 1 Main 2 Main 3 Filter

dress alarms warnings +902 +903 +904 +907
40000 + +900 +901
6 Logbox Logbox A14 A75 W314
7 A17 A77 A315
8 A23 A79 W500
9 A29 W80
10 A33 W82
11 A35 W83
12 W40 A91
13 A48 W92
14 A49 A93
15 A50 W95
Note 1: Alarm is only relevant for PureBallast 3.0 EX.
Book No.9010183 02, rev. 2 41

5.2.2.6 AOT reactor status to ISCS
The addresses below are used to send status information, alarms and warning for AOT reactors
and LDC to ISCS.
Status information
Addresses for data regarding AOT reactor and respective LDC are separated in number series to
distinguish information for individual AOT reactor/LDC, if more than one.
• AOT reactor 1 / LDC 1 — Addresses starting with +110

Example of data: Status for AOT reactor and LDC and their components, for example temperature,
UV intensity and valve status.

40000+
/ Bit
+110 / +120 AOT status (AOT reactor popup)

/ +130
Bit 0 AOT: Stopped (AOT popup) Status: AOT reactor stopped.
Bit 1 AOT ready (1.2) Status: AOT reactor is ready, which means that
there exist no critical alarms or warnings for the
AOT reactor (110:5, 120:5 and 130:5 = 0).
0=Not ready.
1=Ready. The AOT reactor can be selected and

used for process.
Bit 2 AOT selected (1.2) Status: AOT reactor selected for process by
operator. In PureBallast, the AOT reactor is
visible in the list AOT reactors selected for
process in 1.3.
Response to address 001:7, apply of flow

selection.
Alternative, response to parameter p131

(Automatic selection of AOT reactors) if activated
in control panel.
Bit 3 AOT starting (1.1, 1.2) Status: AOT reactor starting.
Bit 4 AOT Started (AOT popup) Status: AOT reactor started.
Bit 5 AOT sum alarm (1.2 and Status: Common alarm indication for AOT
AOT popup) reactor. The AOT reactor is not ready.
42 Book No.9010183 02, rev. 2

Bit 6 AOT sum warning (1.2 and Status: Common warning indication for AOT
AOT popup) reactor. If the warning is not critical, the AOT
reactor may have status AOT ready.
Bit 7 AOT CIP required (1.3) Status: CIP status for AOT reactor: 0=Not
required. 1=Required.
Bit 8 AOT CIP ongoing (1.3) Status: CIP status for AOT reactor: 0=CIP not
ongoing. 1=CIP ongoing.
Bit 9 AOT CIP error (1.3) Status: Error for AOT reactor during CIP process.
+111 / AOT I/O status (AOT popup)

+121/
+131
Bit 0 LS201-29 Status: 1=Wet condition. 0=Dry condition.
Bit 1 TS201-60 Status: 1=OK (temp within limit). 0=Not OK

(temp exceeded limit).

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.
Bit 6 V320–4 Status: :

1=Open. 0=Closed.
Bit 7 Heat exchange valve Status: :

(V401–51) 1=Open. 0=Closed.
+112 / +122 AOT LPS status 1 (4.9 and Status: Status per individual LPS in the AOT
/ AOT popup) reactor.
+132
Bit 0–15 In AOT reactor 300 m3/h: Only bit 0–9 is used.
Status: Address value:

1=Lamp on. 0=Lamp off.
+113/ AOT LPS status 2 (4.9 and Status: Status per individual LPS in the AOT
+123/ AOT popup) reactor.
+133
In AOT reactor 300 m3/h: Only bit 0–9 is used.
Status: Address value:
1=LPS error. 0=LPS OK.
Book No.9010183 02, rev. 2 43

Bit 0–15 Status: Address value:

1=Lamp error. 0=Lamp OK.
+114/ AOT temperature (AOT Value: Temperature indicated by TT201-33.

+124/ popup) Value displayed for selected AOT reactor.
+134
ISCS.

page 5.5), this means that actual temperature
is 22.1 °C.
+115/ LDC water temperature Value: LDC cooling water temperature in cabinet
125/ (AOT popup) indicated by TT401-1.
135
Condition: See +114.
+116 / +126 LDC air temperature (AOT Value: LDC air temperature in cabinet indicated
/ +136 popup) by TT401-2.
Condition: See +114.
+117 / +127 UV intensity (AOT popup) UV intensity in AOT reactor indicated by

/ +137 QT201-50.
+118 / +128 Power output (4.9) Current LPS power consumption (50-100 %).
/ +138
Alarms and warnings
Alarms and warnings for individual AOT reactors and LDCs are separated into different number
series according to the list below:
• AOT reactor 1/ LDC 1: Address +910 – 912

Example of alarms and warnings: High temperature, fuse tripped, communication error for LPSs.
Ad- Alarms / Alarms / Alarms /

dress warnings 1 warnings warnings
40000 + +911 / +914 / +912 / +915 /
+910 / +913 / +917 +918
+916
Bit
0 W100 W130 W165
44 Book No.9010183 02, rev. 2

5 System interfaces 5.3 Power management system integration
Ad- Alarms / Alarms / Alarms /

dress warnings 1 warnings warnings
40000 + +911 / +914 / +912 / +915 /
+910 / +913 / +917 +918
+916
1 W101 W131 W170
2 W102 W132 W171
3 W107 A137 W1811
4 W109 A138 W1821
5 W111 W1831
6 W113 W140 W1841
7 W116 W150 W1851
8 W117 W151 W1861
9 W118 W152 W1871
10 W119 W153 W1881
11 W120 W160
12 W122 W161
13 W126 W162
14 W128 W163
15 W129 W164
Note 1: Only relevant for PureBallast 3.0 EX.
5.3 Power management system integration

It is possible to connect the PureBallast control system to the vessel’s power management system
or ISCS. The purpose is to automatically handle power request from PureBallast to secure that
enough power is available for each ballast and deballast process. A process can only start after
acceptance from the ISCS.
The communication is either handled by the remote interface (if the option is integrated) or via
hardwires between the vessel’s ISCS and PureBallast’s control cabinet. It is also possible to use
hardwire, even if remote interface is integrated.
Power management requires the following:
• Parameter setting must be done for parameter p127.
Book No.9010183 02, rev. 2 45

5.3 Power management system integration 5 System interfaces
• Integration and connection of signals must be done according to the guidelines in this section.
5.3.1 Overall power request process

Below, the overall power request process is described. The process is based on three signals
types: Power request, power granted and power running.
1. A ballast or deballast process is started from the PureBallast control system.

2. Before the UV lamps are lit, a power request is sent from the PureBallast control system to
the ISCS.
3. After power check, the power management reserves the requested power for PureBallast and
then send power granted to the control system. If the vessel cannot provide the requested
power, less power might be granted. The exact granted power is always visible in the field
Calculated power consumption in control system page 1.5 Power request or 1.1 Overview.
4. The ballast/deballast continues the start-up process and the UV lamps are lit. The control
system confirms this by sending back a power running signal to confirm that the power is used.
5. When the process is stopped from the control system, the power running signal is deactivated.
5.3.2 Power steps and power signals

The power management system is based on defined power steps, defining the power needed for
1-3 AOT reactors: Step 1 extend to one AOT reactor and step 2 extend to three AOT reactors. .
Signals are defined to handle all combinations of power step (amount of power) and function
(request, grant and run). More than one signal can be sent (or received) at the same time to
achieve, for example step 1 and 2 to request power for 3 AOT reactors.
As an alternative, it is possible to use power step 4 (common) that always will be used, regardless
of the number of AOT reactors used for a specific process. The common power is defined as the
number of installed AOT reactor times the defined power consumption for one AOT reactor.
Function signal No. of Signal to Power

AOT terminal (kW)
reac-
tor:s
Request, step 1 1 Terminal strip X2 101

Terminal 41/42.
Request, step 2 2 Terminal strip X2

Terminal 43/44.
46 Book No.9010183 02, rev. 2

5 System interfaces 5.3 Power management system integration
Function signal No. of Signal to Power

AOT terminal (kW)
reac-
tor:s
Request, step 4 1-3 Terminal strip X2 101

(common) Terminal 47/48.
Granted, step 1 1 Relay module 101

X12. Relay K5.
Connection point
BB and A1.
Granted, step 2 2 Relay module

X12. Relay K6.
Connection point
BB and A1.
Granted, step 4 1-3 Relay module 101

(common) X12. Relay K8.
Connection point
BB and A1.
Running, step 1 1 Terminal strip X3 101

Terminal 49/50.
Running, step 2 2 Terminal strip X3

Terminal 51/52.
Running, step 4 1-3 Terminal strip X3 101

(common) Terminal 55/56.
5.3.3 Power management installation

The signals are hardwired and shall be connected to corresponding terminals (same ID) in the
control cabinet according to Control cabinet / Interconnection diagram on page 92. Note that the
drawing indicate a Step 4, which is not used.
Note that It is only necessary to connect enough signals to cover the number of AOT reactors
installed on the vessel. If one AOT reactor is installed it is only necessary to connect step 1 for
request, granted and running.
After installation, the signals need to be tested. This is done by simulating signals from the control
system, page 1.4 Power request. See chapter 3. Operating instructions and control system
description, instruction Simulate power request.
Book No.9010183 02, rev. 2 47

5.4 External component signal integration 5 System interfaces
5.4 External component signal integration

The following components and functions (not part of Alfa Laval’s scope of supply) can be integrated
with the control system. The communication is either handled by the remote interface (if the option
is integrated) or via hardwires. In some cases, hardwire is the only alternative.
Each signal that is used must be activated in the control system page 5.2 – Main parameters 2.
Output indicates signal from PureBallast and Input indicates signal from ISCS.
Signal Control Explanation

cabinet
Common alarm (strongly Output What: Output signal from PureBallast that there is an
recommended to be (any) active alarm. An alarm stops down ongoing process.
integrated)
How: Active alarm = Open circuit. If an alarm is already
present and a new alarm is issued, the signal will go low
for three seconds, and the be reactivated as high.
Common warning Output What: As common alarm, but for warnings. A warning is
a notification of status change or a problem.
How: See common alarm.
External system stop Input What: Input signal to PureBallast to stop the system.
If extra buttons (not part of AL scope of supply) to stop
PureBallast are desired on board. The power is still on.
How: Open circuit = System stop command. Must be

connected via hardwire (W118).
Heeling mode (internal Input What: Input signal to PureBallast to to enter heeling mode.
transfer) Equal to pushing the Pause button in control system.
If integration of heeling command from ISCS is desired to

automatically pause ongoing ballast/deballast process for
a healing operation.
How: Closed circuit = Heeling mode command. Only

possible in standby, ballast and deballast. Must be
connected via hardwire (W118).
Additional bypass 1 is Input What: Input signal to PureBallast that an external bypass
open valve (not part of Alfa Laval’s scope of supply).
Additional bypass 2 is If PureBallast can be bypassed using other valves

open (apart from V212-31), status signals from them must be
integrated to the control system. All bypass cases must
Additional bypass 3 is be logged. When any bypass valve is opened, ongoing
open process is terminated and the event is logged.
Three additional bypass valves can be handled via

hardwire, identified as additional bypass valve 1, 2 and 3.
If more valves are used, they must be connected in series,
which means that they are handled as one regarding
alarms and logging in PureBallast.
48 Book No.9010183 02, rev. 2

5 System interfaces 5.4 External component signal integration

cabinet
If remote interface is implemented, feedback signals can

be connected via the remote interface, which allows a
great number of components to be connected.
How: Open circuit = Valve open.
Request ’’Start BW Output What: Output signal from PureBallast to request opening
pump’’ of relevant valves (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the valve are closed.
If Request and Feedback signals are integrated, the

operator does not have to confirm that the OB valve
is open/closed in a popup in the control panel during
operation.
How: Request = Closed circuit. No request and request

withdrawal = Open circuit.
Feed back ’’Ballast Input What: Input signal to PureBallast to confirm that the
water pump is running’’ ballast pump is started.
How: Closed circuit = Pump running.
Request “Open Output What: Output signal from PureBallast to request opening
overboard valves” of relevant valves (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the valve are closed.
Relevant valves: 201, 309 and 403 and 404 (and 460.1
during CIP process). Note that the signal is mainly
intended for the valves apart from those leading to and
from pipe 201
If Request and Feedback signals are integrated, the

operator does not have to confirm that the OB valve
is open/closed in a popup in the control panel during
operation.

Feed back ’’Overboard Input What: Input signal to PureBallast to confirm that relevant
valve is open’’ valves are open.
How: Closed circuit = Valve open.
Booster pump (P401-1), Output What: Output signal from PureBallast to request start of
for LDC cooling the LDC cooling pump for line 401. Pump P401-1 is used
during ballast, deballast, pause and heeling mode.

Book No.9010183 02, rev. 2 49

5.5 GPS signal installation 5 System interfaces

cabinet
Booster pump (P403-1), Output What: Output signal from PureBallast to request start of
for AOT reactor reactor the AOT reactor cooling pump for line 403. Pump P403-1
cooling is used during start-up, ballast, deballast, pause and
heeling mode.

PureBallast running Output What: Output signal from PureBallast that a process is
running.
How: Pump running = Closed circuit.
5.4.1 External component signal installation

The input and output signal cables must be connected according to the drawing Control cabinet /
Interconnection diagram on page 92. This section gives additional information to the drawing on
how to connect the cables.
Input signals
Chosen input signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 92.
Output signals
Chosen output signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 92. Output signals are connected via potential free relays.
5.5 GPS signal installation

This section describes the installation of GPS position signal to PureBallast. This installation is
optional. If used, the GPS position is used to stamp events in the event log.
The GPS must be connected to the module X20IF1030 in the control cabinet, using an NMEA
(RS422) serial interface with the following settings:
• Baud rate: 4800 bps

• Parity: None
• Bits/characters: 8
• Stop bits: 1
The position data shall be sent as messages according to RMC, GLL or GGA.
For details, see the illustration below (based on the Control cabinet / Interconnection diagram on
page 92).
50 Book No.9010183 02, rev. 2

5 System interfaces 5.5 GPS signal installation
6 GPS
Book No.9010183 02, rev. 2 51

5.5 GPS signal installation 5 System interfaces
6 Start-up procedures
The actions below must be performed after installation, before system is put into operation. This
is important to avoid that the filter and the AOT reactor is damaged by material from the ballast
tanks or remainders from the installation. These actions shall be performed both for new builds and
retrofit installations.
Before f rst operation
Before the system is operated the first time the actions below must be done.
NOTE
• All pipes leading to PureBallast must be well flushed to avoid that debris harm the filter and
AOT reactor quartz sleeves.
• All ballast water tanks must be well cleaned before PureBallast is tested or put into operation.
This is valid both for new builds and retrofit installations.
First operation
Before f rst operation the actions below must be done:
• During the first operation, the filter shall be bypassed, to avoid that debris harms the filter
elements.
• We recommend that a strainer is used during the first operations, to avoid that debris harms
the system.
• The first time a tank is stripped, PureBallast must be bypassed, to avoid that debris harms
the system.
Book No.9010183 02, rev. 2 53

6 Start-up procedures
7 Drawings
This section contains drawings for the PureBallast system. It is divided into three main parts:
• General drawings – overall and principle information for system layout (pipes, components,
electricity, air and water).
• Dimension drawing – detailed component information (dimensions, sizes etc).
• Electrical drawings – detailed electric information (circuit diagrams, cable lists etc).
See the Contents section at the beginning of this chapter to get an overview of included drawings.
Book No.9010183 02, rev. 2 55

7.1 Graphic symbols used in drawings 7 Drawings
7.1 Graphic symbols used in drawings

Symbols used in drawings are according to ISO 14617. Below, a guiding extract is shown.
573644
56 Book No.9010183 02, rev. 2

7 Drawings 7.2 General drawings
7.2 General drawings
7.2.1 Flow chart
Book No.9010183 02, rev. 2 9007243 57

7.2 General drawings 7 Drawings
7.2.2 Connection list

Connection list for Ballast water treatment system according to flow chart 9007243.
Item / Description Requirements/limits

Connec-
tion
Main components
201 Ballast water • Sea water

Inlet/Outlet
• Max. particle size: 10 mm
• Temperature: → 40 °C (liquid form)
• Flow range ballast (m3/h): 190 → 1000

• Flow range deballast (m3/h): 100 → 1000
• Min flow deballast with one AOT reactor reactor in

operation (m3/h): 100
• Max pressure: 6 bar (0.6 MPa)
Ref: figure Pressure and pressure drop after the table.
Q201.1 Sampling device • Ref. drawing 590066 on page 84

V201-2 Valve
(optional)
Q201.2 As above.
V201-25
V201-3 Main valves • Ref. drawing 9007178 or 9008463
V201-9 • Ref. drawing 9007178 or 9008463

• Ref. drawing 9007178 or 9008464
V201–32
• Ref. drawing 9007176 or 9008461 (Optional)
V212-31
V201-8 Control valve (flow • Ref. drawing 9007182 or 9008467, on page 76

control during normal
• Flow restriction acc. to certified flow rate.
operation and pressure
control during filter • Control of pressure, min 0.15 MPa.
back flushing)
IP201-7 IP converter
S201-7 Strainer
58 Book No.9010183 02, rev. 2


Connec-
tion
403 Cooling water Reactor • Sea water

Inlet
• Max pressure: 6 bar (0.6 MPa)
• Pressure drop: 0,05 bar (0.005 MPa)
• Min. flow: 20 m³/h (during start up, ~ 5 min.)
• Max. particle size: 5 mm
V403-35 Valve • Ref. drawing 9007176 or 9008461 on page
FIT201-1 Flow transmitter • Ref. drawing 586502 on page 74
V201-15 Needle valve • Ref. Pressure monitoring device drawing 9007999

PI201-18 Pressure gauge on page 75
RV201 Safety valve
PT201-16 Pressure transmitter
Filter connections, drawing 9006983
201 Filter inlet / outlet • Ref. filter connections drawing on page 71.
309 Backflush water • Sea water

• Backflush range (m3/h):60 → 120 (Intermittent, approx.
40 sec during backflush). Ref: figure Pressure and
pressure drop after the table.
V309-1 Reject valve • Ref. filter connections drawing, connection 309 on

page 71.
310.2 Flushing • Ref. filter connections drawing, connection 310.2 on

miscellaneous page 71.
• Fresh water preservation volume: 226 L
460 Drain Filter • Flanged, blanked

• Ref. filter dimension drawing, connection 460 on page
71.
AOT reactor connections, drawing 9003516
V201-19 Inlet / outlet • Ref. AOT reactor dimension drawing

V201-20
404 Cooling water • Over board

Reactor outlet
• Flow: ref. to con. 403
Book No.9010183 02, rev. 2 59


Connec-
tion
V320-4 CIP / Drain • Ref. AOT reactor dimension drawing on page 70.
V321-2 Reactor outlet
V404-36 Cooling water
Lamp drive cabinet (LDC), drawing 9005331
401 Cooling water Lamp • Fresh water (existing cooling system)

Drive Cabinet (LDC)
• Max. particle size: 600 µm
Inlet
• Temperature: 0 → 38 ºC
• Cooling capacity: 5.0 kW
• Working pressure: 1 → 10 bar (0.1 → 1.0 MPa)
• Pressure drop: 0.15 bar (15 kPa)
• Min. flow: 1.5 m³/h (1.5 m3/h each LDC) @ 38 °C
SV401-51 Valve • Ref. LDC dimension drawing on page 87.
402 Cooling water LDC • Back to recirculation (suction side)

outlet
CV402 Valve • Ref. LDC dimension drawing on page 87.
CIP unit connections, drawing 9004714
310.1 Flushing • Fresh water (potable)

310.2 miscellaneous
• Quality requirements: see 590773 on page 68
• Volume: 380 L/ rinsing & preservation (2 cycles x 1
reactor x 190 L) .
• Min pressure: 3 bar (0.3 MPa)
60 Book No.9010183 02, rev. 2


Connec-
tion
V310-1 Valve • Ref. CIP module dimension drawing on page on page

72.
V310-3 Backflow preventer
V310-6 Valve
V310-8
CV310-7 Strainer
320 Flushing • Sea water / fresh water

miscellaneous, reactor
• CIP liquid quality requirements, see 594956 on page
module
69
V320-2 Valve • Ref. CIP module dimension drawing on page 72.

V320-11
P320-1 Pump • Diaphragm pump (pneumatic)
321 Flushing • Sea water / fresh water

miscellaneous, reactor
• CIP liquid
modue
P321-5 Pump • Ref. CIP module dimension drawing on page 72.

• Diaphragm pump (pneumatic)
V321-1 Valve
V321-4
460.1 Drain Reactor • Sea water / fresh water

• Normally no flow
• Volume: 380 L (1 reactor x 190 L sea water drained
and 1 reactor x 190 L fresh water drained before CIP
sequence). Flow: 60 L/min.
CV460-4 Check valve
460.2 Drain CIP module • By gravity

• Normally no flow
• Volume: 300 L
571 De-aeration • Air

AOT reactor / CIP
Book No.9010183 02, rev. 2 61


Connec-
tion
Air (total system consumption)
501 Instrument air • Ref. 595208 on page 66

• Required pressure: 5.5 – 8.0 bar
Max consumption:
• During ballast and deballast operation: Max 30 NL/min.

• Consumption: continuous, max 30 NL/min, peak load,
0.6 Nm3/min (during CIP sequence: 25 min, pump
running.
• Quality requirements: see 553407 on page 67
6 Working_Pressure_Hydac
62 Book No.9010183 02, rev. 2

∆pf lter - Filter pressure drop, depending on filter contamination. (dynamic and
static pressure).
0.05 – 0.85 bar — Normal operation.
0.85 bar — Filter backflushing sequence triggered.
∆pAOT - AOT reactor pressure drop (dynamic and static pressure).
∆pf lter inlet - 1.0 bar + p309: Required pressure to establish effective back flushing
of filter.
∆p309 - Pressure drop, (dynamic and static pressure), line 309 (back flush over
board).
Book No.9010183 02, rev. 2 63

7.2.3 Electrical system layout (2 pages)
9005353_Page_1
64 Book No.9010183 02, rev. 2

Book No.9010183 02, rev. 2

9005353_Page_2
65
7.2.4 Air distribution
9010001
66 Book No.9010183 02, rev. 2

7.2.5 Quality specif cation / Compressed air
553407
Book No.9010183 02, rev. 2 67

7.2.6 Quality specif cation / Water
590773
68 Book No.9010183 02, rev. 2

7.2.7 Quality specif cation / CIP liquid
Book No.9010183 02, rev. 2 69
594956
7.3 Dimension drawings including technical 7 Drawings
data
7.3 Dimension drawings including technical data
7.3.1 AOT reactor / Dimension drawing
70 Book No.9010183 02, rev. 2

9003516
7 Drawings 7.3 Dimension drawings including technical data
7.3.2 Filter / Dimension drawing
Book No.9010183 02, rev. 2

9006983 71
data
7.3.3 CIP module / Dimension drawing (2 pages)
72 Book No.9010183 02, rev. 2

9004714_p1
9004714_p2
Book No.9010183 02, rev. 2 73

data
7.3.4 Flow transmitter FIT201-1 / Dimension drawing
74 586502
Book No.9010183 02, rev. 2
7.3.5 Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and

201-15) / Dimension drawing
Book No.9010183 02, rev. 2 75

9007999
data
7.3.6 Control valve V201-8 / Dimension drawing

Two alternative valves exists.
9007182
76 Book No.9010183 02, rev. 2

9008467
Book No.9010183 02, rev. 2 77

data
7.3.7 Valve V201-3 and V201-9 / Dimension drawing

9007178
78 Book No.9010183 02, rev. 2

9008463
Book No.9010183 02, rev. 2 79

data
7.3.8 Valve V201-32 and V403-35 / Dimension drawing

Two alternative valves exists for V201–32.
9007180
80 Book No.9010183 02, rev. 2

9008465
Book No.9010183 02, rev. 2 81

data
7.3.9 Valve V212-31 / Dimension drawing (Optional in scope of supply)

9007176
82 Book No.9010183 02, rev. 2

9008461
Book No.9010183 02, rev. 2 83

data
7.3.10 Sampling device Q201.1 and Q201.2 / Dimension drawing (3

pages) (Optional in scope of supply)
590066 1
84 Book No.9010183 02, rev. 2

590066 2
Book No.9010183 02, rev. 2 85

data
590066 3
86 Book No.9010183 02, rev. 2

7.3.11 Lamp drive cabinet (LDC) / Dimension drawing
9005331
Book No.9010183 02, rev. 2 87

data
7.3.12 Control cabinet / Dimension drawing
88 9005261_p1
Book No.9010183 02, rev. 2
9005261_p2
Book No.9010183 02, rev. 2 89

data
7.3.13 Control panel / Dimension drawing (2 pages)
595261_p1
90 Book No.9010183 02, rev. 2

595261_p2
Book No.9010183 02, rev. 2 91

7.4 Electrical drawings 7 Drawings
7.4 Electrical drawings
7.4.1 Control cabinet / Interconnection diagram (7 pages)
92 Book No.9010183 02, rev. 2

7 Drawings 7.4 Electrical drawings
9005343_Page_23
Book No.9010183 02, rev. 2 93

9005343_Page_24
94 Book No.9010183 02, rev. 2

9005343_Page_25
Book No.9010183 02, rev. 2 95

9005343_Page_26
96 Book No.9010183 02, rev. 2

9005343_Page_27
Book No.9010183 02, rev. 2 97

9005343_Page_28
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7.4.2 Control cabinet / Circuit diagram (20 pages)
Book No.9010183 02, rev. 2 9005343_Page_01

99
9005343_Page_02
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9005343_Page_03
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9005343_Page_04
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9005343_Page_05
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9005343_Page_06
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9005343_Page_07
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9005343_Page_08
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9005343_Page_09
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9005343_Page_10
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9005343_Page_11
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9005343_Page_12
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9005343_Page_13
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9005343_Page_14
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9005343_Page_15
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9005343_Page_16
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9005343_Page_17
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9005343_Page_18
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9005343_Page_19
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9005343_Page_20
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7.4.3 Control cabinet / Cable list
9005343_Page_29
Book No.9010183 02, rev. 2 119

7.4.4 Lamp Drive Cabinet (LDC) / Interconnection diagram (2 pages)
120 9005345_Page_16
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9005345_Page_17
Book No.9010183 02, rev. 2 121

7.4.5 Lamp Drive Cabinet (LDC) / Circuit diagram (14 pages)
122
9005345_Page_01
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9005345_Page_02
Book No.9010183 02, rev. 2 123

9005345_Page_03
124 Book No.9010183 02, rev. 2

9005345_Page_04
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7.4.6 Lamp Drive Cabinet (LDC) / Cable list
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7.4.9 AOT reactor / Cable list
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7.4.10 AOT reactor and LDC / Lamp power cable
143
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Book No.9010183 02, rev. 2
8 Shutdown and storage
This section describes requirements for decommissioning and storage. The rules must be followed
when the system shall be shutdown for a long period.
A copy of the decommissioning report must be placed inside the control cabinet. The report must
include all important information from the decommissioning, for example notes and information
about where to find stored components.
8.1 Decommissioning
Follow the process below to decommission the PureBallast system. Note that if there is a freeze
risk, the system must be completely emptied of water.
1. Run the backflush sequence for the filter three times.

2. Drain all water from the filter. Leave the drain open afterwards.
3. Run the CIP process twice.
4. Drain all liquid from the AOT reactors. Leave the drains open. (Use the drain plug at the
bottom of the AOT reactor.)
5. Shut off the main valves for the start-up cooling system. Drain the system afterwards.
6. Isolate the start-up cooling system: Close installed service valve, or use a blind flange, to
prevent fluid to enter the section. (Pipe connection 403, 404.)
7. Drain all water from the LDC heatexchangers. Leave the drains open afterwards (disconnect
hoses). Shut off the main valves for the cooling system (pipe connection 401).
8. Clean the CIP module with fresh water. Rinse the tank. Drain all water/liquid from the CIP
system and leave the drains open afterwards.
9. Isolate the system: Close installed service valves, or use a blind flange, to prevent fluid to
enter the section. (Pipe connection 310, 460.)
10. Drain water from the pipe systems between the main inlet valve (V201-3, V201-9) and control
valve (V201-8). Leave any open drains open afterwards.
11. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 201.)
12. Drain all water from the filter backflush line. Leave the drain flange in the bottom of the filter
open afterwards.
13. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 309.)
14. Shut off the breakers on the control cabinet and the lamp drive cabinet. Lock them in that
position. Label them to avoid connection by mistake.
Book No.9010183 02, rev. 2 145

8.3 Storage and long term decommissioning 8 Shutdown and storage
8.2 Protection
Perform the actions below to protect the system:
• Protect all electrical cabinets from humidity with Silica gel or similar.
• Protect all metal surfaces from corrosion attacks with anti-rust oil. The oil must have long
lasting effective treatment for external surfaces.
• Disconnect the air supply to the CIP module. Use service valve if possible, otherwise plug
the air supply inlet.
• Disconnect and drain the membrane pumps (P320-1, P321-5 or P460-7). Rinse with fresh
water and reconnect the pump.
• Articles made of rubber or plastics (for example seals) must not be treated with antirust oil.
• Protect pressure monitoring device etc. from mechanical damages. The following components
are recommended to be removed and stored safely: PT201-27, PT201-16, and PI201-18.
• Protect components equipped with circuit boards from condensation. Recommendations:
- Remove IP201-7 and FIT201-1 and store in a non condensing environment.
- Remove and store the display for FIT201-1.
- Protect the flow sensor with silica gel or similar. Protect the sensor with the supplied plastic
cover.
• Change the battery in the control panel. If not, the stored log information can be lost during
storage.
• Put all pneumatic valves in open position.
• Every 3 months, operate each valve by close/open exercise. This will keep the valves and
actuators in best condition.
Note that control valve V201-8 must be exercised manually at the same time as the IP201-7 is
removed. Use a wrench to apply appropriate torque.
8.3 Storage and long term decommissioning

• All system equipment must be stored indoors at 5–55°C, in a non-condensing environment.
• If there is a risk for condensation of water during storage, the equipment must be protected
by ventilation and heating above dew point.
• All articles made of rubber / elastomer has a limited useful life time. Therefore, the following
instructions must be followed:
- If the filter or any filter candles are stored for more than 12 months, we recommend that the
seals are checked, and changed if necessary, before the system is put in service.
- If the system is stored for more than 24 months, all articles made of rubber and elastomer
(gaskets, O-rings etc) must be changed before the system is put in service. Such articles are
found in the following components: UV lamps, quartz sleeves and catalytic candles in the
AOT reactors and the filter candles.
146 Book No.9010183 02, rev. 2

8 Shutdown and storage 8.4 Start-up after shutdown
8.4 Start-up after shutdown

Follow the overhaul process below to star-up the PureBallast system after decommission.
1. Locate the decommissioning report stored inside the control cabinet. Use this report to the
re-commissioning of the PureBallast system.
2. Clean away the anti-rust oil with a solvent, for example, white spirit.
3. Assemble items that have been disassembled.
4. If applicable: Remove the silica gel bags from all units.
5. Before the system can be activated, it must be checked according to the commissioning
checklist.
Book No.9010183 02, rev. 2 147

8.4 Start-up after shutdown 8 Shutdown and storage
9 Delivery and transport
information
This section contains information about how to handle PureBallast components during transport,
delivery and installation.
9.1 Delivery and transport

Preparations and conditions:
• Always read and follow the documentation included in shipment of components and spare
parts regarding handling, safety and disposal.
• Handle the delivery with care in order not to damage the equipment or cause personal injuries.
• If the PureBallast system is stored before installation, make sure to store the components
according to the Shutdown and storage section.
9.2 Lifting instructions

This section describes how to lift PureBallasts components.
NG
WARNI
!
• Components must be lifted using correct lifting tools (such as a forklift truck, a crane) and tackle
with a load capacity greater than the weight of the component stated in the section below.
• Any complementary lifting instructions must be followed.
• Components must be empty when lifted.
• The AOT reactor, filter, CIP and control cabinet must be lifted according to the instructions
in the following sections.
Book No.9010183 02, rev. 2 149

9.2 Lifting instructions 9 Delivery and transport information
9.2.1 AOT reactor

Weight of AOT reactor (empty): 330 kg. L = 75 cm
6 AOT Lift
150 Book No.9010183 02, rev. 2

9 Delivery and transport information 9.2 Lifting instructions
9.2.2 Filter
Weight of filter (empty with adaptor plates on flanges): 980 kg. A=103 cm.
6 FilterLift
9.2.2.1 Raise and lift f lter
Follow the instruction to raise the filter to standing position and to lift it for transportation.
1. When the filter is resting in the bottom of the wooden case: Attach a 2 string-round sling to
the two upper lifting bolts.
Book No.9010183 02, rev. 2 151

6 FilterLift Hydac2
2. Use a lifting gear to raise the filter to upright position. Use the bottom filter legs as turning point.
3. When the filter is in upright position: Attach a 3 string-round sling to all three lifting bolts.
6 FilterLift Hydac
4. Lift and transport the filter.
152 Book No.9010183 02, rev. 2

9 Delivery and transport information 9.2 Lifting instructions
9.2.3 CIP module
6 CIP Lift, new 9004908
Book No.9010183 02, rev. 2 153

9.2.4 Cabinets
Use intended lifting attachment at the top of the cabinet.
6 CabinetLift
Example: Control cabinet
154 Book No.9010183 02, rev. 2

Chapter: 7. Service manual
Book No. 9010183 02, rev. 2

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 7
2 Maintenance schedule 9
2.1 Calibration schedule 11
2.2 Serial number information 12
2.2.1 Indicating serial number 12
2.2.2 Example 13
2.3 Placing of serial numbers 14
3 Operate valves manually 19

3.1 Open and close valves manually (CIP
valves) 19
3.2 Open and close valves manually
(V201-3, V201-9 and V201-8) 19
3.3 Lock valve in closed position 20
3.4 Unlock valve 21
4 AOT reactor 23
4.1 Safety information 23
4.2 Replace UV lamp and quartz sleeve 24
4.2.1 Disassemble UV lamp 24
4.2.2 Disassemble quartz sleeve 27
4.2.3 Assemble quartz sleeve 27
4.2.4 Check for leaks after quartz sleeve assembly 28
4.2.5 Assemble UV lamp 28
3
4.3 Internal inspection of AOT reactor 29
4.4 Dismount and mount lamp power
supply (LPS) 30
4.5 Test LPS installation 32
5 Filter 33
5.1 Remove f lter cover and f lter candles 35
5.2 Mount f lter candles and f lter cover 35
5.3 Replace f lter candles 36
5.4 Clean f lter candles 37
5.5 Change sacrif cial anode 37
6 CIP module 39
6.1 Change and ref ll CIP liquid 39
6.1.1 Change CIP liquid 41
6.1.2 Refill CIP liquid 41
6.2 Repair CIP pump 42

6.2.1 Clean CIP pump 42
6.2.2 Disassemble CIP pump 43
6.2.3 Assemble CIP pump 44
6.3 Test CIP pump 45

6.4 Repair junction box and valve blocks 45
6.5 Repair valve block 45
6.5.1 Change valve body 46
6.5.2 Connect electrical cables to valve block 46
6.5.3 Clean valve block 47
6.5.4 Connect pneumatic hoses to valve block 47
7 Flow meter 49
7.1 Mount f ow transmitter 49
7.2 Change direction of f ow transmitter 51
7.3 Change direction of f ow transmitter
control pad 52
7.4 Clean f ow meter electrodes 54
8 Valve actuator 55
8.1.1 Tightening torques for actuators 56
4
8.2 Dismount actuator 57
8.3 Mount actuator on valve 57
8.4 Change direction of actuator – without
position sensor (V404–36, V320–4 and
V321–2) 59
8.5 Change direction of actuator – with
switch box (V201–3, V201–9, V201–32,
V212–31 and V403–35) 60
position sensor (201-19 and 201–20) 60
positioner (201–8) 62
8.8 Mount pilot valve on actuator 62
8.9 Adjust valve end position 63
8.10 Adjust valve traveling speed 64
8.11 Calibrate positioner on V201-8 66
9 Ball valve 69
9.1 Replace seals in ball valve 69
10 Level switch 71
10.1 Mount level switch 71
10.2 Dismount level switch 72
10.3 Test level switch 72
11 Temperature switch and

temperature transmitter 73
11.1 Mount temperature switch / temperature
transmitter 73
11.2 Dismount temperature switch /
temperature transmitter 74
12 Control panel 75
12.1 Clean control panel 75
12.2 Replace control panel 75
12.2.1 Dismount the panel 75
12.2.2 Mount the panel 76
5
13 Remote control panel (optional) 79
13.1 Mount and connect network switch for
remote control panel 79
13.2 Mount and connect network switch for
remote control panel (retrof t) 81
14 Control cabinet and lamp drive

cabinet (LDC) 83
14.1 Disassemble and assemble I/O system 83
14.2 Cable gland installation – General
cables 85
14.3 Cable gland installation – Power cable
to LDC 87
6
1 Introduction
This chapter contains information and instructions about how to service the PureBallast system.
Instructions are sorted per component. The chapter is opened with a maintenance schedule
covering checks and services that must be performed with specified intervals.
NGE R
! DA
• Before maintaining the PureBallast system, the power supply must be switched off, to avoid
accidental starts. See instruction Abort operation and deactivate the system in chapter 3.
Operating instructions and control system description.
NOTE
• All maintenance and calibration activities must be recorded in the vessel’s maintenance log.
This is required by the ballast water convention. It is therefore recommended that the activities
in the maintenance and callibration schedules below are entered in the vessel’s general
maintenance system.
• Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 20.
• Follow local regulations for electrical installation and grounding (earthing).
• Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.
• Point of contact: To order service or spare parts, contact your local Alfa Laval office. For
more information, see www.alfalaval.com.
Book No.9010183 02, rev. 2 7

2 Maintenance schedule
The maintenance
Follow this maintenance schedule to secure performance, safety and durability of the system and
its components. The schedule is sorted per component. The table refers to instructions usable
when performing the respective action.
Component Action Time interval Instructions Notes
General Inspect for Once a year.

corrosion and
erosion damage.
General Calibration of According to See Calibration

sensors Calibration schedule
schedule
AOT reactor Outer inspection Once a year. If necessary, See Spare parts
of seals for change according catalogue for
leakage. to Open AOT service kit.
reactor.
Check UV lamps Once a year. See Disassemble See Spare parts

for leakage. quartz sleeve. catalogue for
service kit.
Replacement of Recommended to See Replace UV See Spare parts

UV lamps. change all lamps lamp and quartz catalogue for
after 3000 hours of sleeve. service kit.
operation.
Filter Inspection and Once a year. See Remove filter Replace filter
cleaning of filter insert. candles, if
insert, including damaged.
filter candles.
See Spare parts
catalogue for
service kit.
Outer inspection Once a year. If necessary,

of seals for change faulty seals.
leakage.
Check sacrificial Once a year. See Change Change when

anode. sacrificial anode. the zinc body is
so worn that the
steel reinforcement
within the zinc is
visible.
Book No.9010183 02, rev. 2 9

2 Maintenance schedule
CIP liquid pH value check. Before each See Change CIP

filling-up or once liquid or Refill CIP
every 3 months, liquid.
whichever comes
first.
CIP liquid level Rule of thumb: See Change CIP If the CIP liquid
check. Once every 3 liquid or Refill CIP is low but the pH
months. liquid. value is below
Depending 3, CIP liquid and
on number of water can be added
AOT reactor to fill up the liquid
and ballasting level in the tank.
frequency, the liquid Note: pH value
check might have to must be checked
be performed more afterwards to
regularly. secure correct pH
value.
Replacement. When the pH value See Refill CIP

is higher than pH 3 liquid.
or once a year.
or
When the CIP
module has been
inactive for over
one year.
Control of stored Visual inspection See Preparations

CIP liquid. after three years. and conditions
under Change and
refill CIP liquid
instruction.
Valve block on Control that the Once a year. See chapter 7.

CIP module cables are firmly Service manual,
attached to the section Connect
terminal strip in electrical cables to
the valve block. valve block.
Flow meter Clean flow meter Once a year. See Clean flow
electrodes. meter electrodes.
Valves and Control that Once a year. See chapter 7.

actuators the component, Service manual,
cables and section Valve
hoses are firmly actuator for
attached. instructions.
Control opening Once a year. See chapter 7. Open and close the
and closing end Service manual, valves and inspect
stops. section Valve visually.
actuator for
instructions.
10 Book No.9010183 02, rev. 2

2 Maintenance schedule 2.1 Calibration schedule
Control system Replace battery in When alarm PLC Automatic check

PLC module. battery low is when the control
indicated in the cabinet is turned on
control system. and every 24 hours.
or:
After 5 years. The battery is
or: placed in the
Before storage for PLC module in
longer periods. the control cabinet.
2.1 Calibration schedule

Follow this calibration schedule to secure performance of the system and its components. The
schedule is sorted per component.
Interval: Once a year, if nothing else is stated.
Component Informatoin / instruction
Flow meter Every second year.
1. Connect a calibrated portable ultrasonic flow meter close to the flow meter.
2. Establish flow in the system.
3. Compare value indicated in control system and measure equipment.
Pressure 1. Connect calibrated portable measure equipment to the measure point

transmitters (screw to the side, under the handle).
Filter: (PT201-71, 2. Open V201-32 from the control system.

PT201-72 and PT201-71, PT201-72 and PT309-2
PT309-2)
3. Compare values indicated for the three transmitters in control system
Pressure and measure equipment.
transmitter
(PT201-16) 4. Open 403-35 from the control system, and compare again.
PT201-16
Pressure gauge
(PI201-18) 5. Open V403-35 to apply pressure to the system.
6. Adjust handle on PT201-16 to establish pressure to measure point.
7. Compare value indicated in control system and measure equipment.
PI201-18
8. Compare value indicated in pressure gauge and measure equipment.
Book No.9010183 02, rev. 2 11

2.2 Serial number information 2 Maintenance schedule
AOT reactor 1. Depressurize and drain the reactor: Remove the drain plug at the bottom
components of the AOT reactor.
Temperature TT201–33
transmitter
2. Dismount the transmitter and place in water with known temperature
(TT201-33)
(calibrated measure instrument).
Temperature 3. Compare value indicated in the control system and measure equipment.
switch (TS201-
TS201-60
60)
4. Dismount the switch and place in water with temperature < 65 ˚C.
Level switch
(LS201-29) 5. Check that alarm A137 is displayed in the control system.
LS201-29
6. Dismount the sensor and lace it in a glass of water.

7. Check that you get a signal for the AOT reactor in the control system.
8. Fill the AOT reactor with fresh water.
UV sensor in Every second year

AOT reactor
(QT201–50) Send the UV sensor to you local Alfa Laval office (parts and service). Use a
spare sensor during the time the calibration is performed.
Temperature Place a calibrated thermometer inside the cabinet and compare after 30
transmitter in minutes.
LDC (TT401)
2.2 Serial number information

This section describes where the serial number plate is placed on the PureBallast system
components.
Serial numbers shall be used at error reporting and other contacts where a specific component is
discussed.
2.2.1 Indicating serial number

Serial numbers shall be stated, including the following information:
• Serial number for the complete PureBallast system. See label on the side of the control cabinet.
• Serial number for the component in question. If the component is installed on, or in, another
component, the number for the mother component shall be stated.
• Item number for the component. The item number identifies a unique component in the system.
It begins with a letter abbreviation indicating the component type, for example: LS (level switch),
P (pump) and PI (pressure gauge). A complete list of abbreviations is found in chapter 6.
Installation description and drawings, section Connection list.
12 Book No.9010183 02, rev. 2

2 Maintenance schedule 2.2 Serial number information
2.2.2 Example
If the level switch is faulty, the following information shall be stated:
• PureBallast serial number

• Level switch serial number and the serial number for the AOT reactor on which the level switch
is installed.
• Item number for the component (LS00000)
Book No.9010183 02, rev. 2 13

2.3 Placing of serial numbers 2 Maintenance schedule
2.3 Placing of serial numbers

The table below indicates the position of the serial number plate per component.
PureBallast water treatment system
Serial number for the complete PureBallast

system.
Placing: On the right-hand side gable of the
control cabinet.
7 PB 591098_SerialNo
AOT reactor
At the side of the AOT reactor, as indicated in

the illustration.
7 AOT Snr
14 Book No.9010183 02, rev. 2

2 Maintenance schedule 2.3 Placing of serial numbers
Filter
Placing: At the side of the filter, as indicated

in the illustration.
7 FilterSnr Hydac
Electrical cabinets (Including breakers)
Placing: At the inside of the door (illustration

shows control cabinet).
• Control cabinet
• Lamp drive cabinet (LDC): Inside top left
door.
7 CC Sernr 591773#1
Book No.9010183 02, rev. 2 15

Lamp power supply
LPSs are installed in the lamp drive cabinet.
NOTE
Version must be stated together with the serial number.

Version is stated on the serial number plate.
Placing: At the front of each LPS.
7 LDC sernr
Valves and actuators
Serial number plate for various valves are placed

at the side of the actuator. One example is
illustrated to the right.
NOTE
This number shall be used both for the actuator and

the mechanical valve.
7 Valve Snr 591890
16 Book No.9010183 02, rev. 2

2 Maintenance schedule 2.3 Placing of serial numbers
Flow meter
(Including flow transmitter and flow sensor)

Placing: At the side of the pipe, as indicated
in the illustration.
NOTE
The f ow transmitter and f ow sensor have individual

serial numbers. But it is suff cient to state the f ow
meter serial number.
7 FM snr 576179_manual 2
Book No.9010183 02, rev. 2 17

3 Operate valves manually
This section covers instructions on how to open, close and lock/unlock valves manually.
Avoid operating valves manually. Valves are normally operated from page 1.1 Overview in
the control system (manual mode). See chapter 3. Operating instructions and control system
description for instruction.
3.1 Open and close valves manually (CIP valves)

Follow this instruction to manually operate the valves installed in the CIP module: V571-1, V321-4,
V321-1, V460-2, V320-2 and V310-6. Note that the orange diode on the valve body will not light
during manual operation.
1. Identify which button (illustrated on page 45) on the valve block that controls the valve. The
lower button operates the inner hose under the valve block, and vice versa. Also see the
sticker under the valve block.
2. Press the button on the valve body with a screw driver to operate the valve.
3.2 Open and close valves manually (V201-3, V201-9

and V201-8)
Follow this instruction to manually operate valves V201-3, V201-8 and V201-9.
Valves can be operated using the position screw on the pilot valve.
Position 0 Closed (default position). If the position screw is in position 0 and the valve is
closed, it can be manually opened. But if the position screw is in position 0 and
the valve is opened, it cannot be manually closed.
Position 1 Opened.
• Air must be connected, but power does not have to be connected.

1. If there is limited access to the screw, it is possible to remove the DIN connector.
2. Place a screw driver in the position screw groove.
Book No.9010183 02, rev. 2 19

3.3 Lock valve in closed position 3 Operate valves manually
3. Turn the screw to desired position.

— Position 1 to open.
— Position 0 to close.
4. When done, turn back the screw to position 0. If the DIN connector was removed, connect it
again.
3.3 Lock valve in closed position

Follow this instruction to lock valves V201-3, V201-9, V201-8 and 212-31 in closed position. These
valves are locked mechanically with two bolts on the actuator.
• Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
1. Set the valve to closed position from the control system. Control the position indicator, to make
sure. The yellow position indicator is in line with the valve throttle (indicating open when
the position indicator is in line with the pipe).
2. Disconnect power and compressed air. Verify that the valve is not under pressure.
3. Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
7 576075_lock_manual
4. Measure exactly how far out the end stop bolt (4) is from a reference surface, for example the
actuator house. Make a note of the distance. This information is needed when unlocking
the valve.
5. Open the locking bolt (3) and turn them a couple of turns.
6. Screw the end stop bolt (4) to its bottom position and tighten the locking bolt.
7. Verify that the valve cannot be opened.
20 Book No.9010183 02, rev. 2

3 Operate valves manually 3.4 Unlock valve
8. Slide the safety cover over the end bolts and lock the safety cover with the pad lock.
9. Repeat the above procedure for all valves concerned.
3.4 Unlock valve

Follow this instruction to unlock valves V201-3, V201-9, V201-8 and 212-31 from closed position.
• Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
1. Disconnect all power and compressed air. Verify that the valve is not under pressure.
2. Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
3. Open the locking bolt (3) slightly.
4. Adjust the end stop bolt (4) to the same position (distance from reference surface) as before
locking the valve, according to the notes made during locking.
NOTE
• It is important to adjust the ends stop bolt to the correct position. Otherwise the actuator
may be damaged.
5. Tighten the locking bolt (3).
6. Verify that the valve can open and close.
Book No.9010183 02, rev. 2 21

3.4 Unlock valve 3 Operate valves manually
7. Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.
22 Book No.9010183 02, rev. 2

4 AOT reactor
This section covers instruction for service of the AOT reactor.
4.1 Safety information
NGE R
! DA
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the AOT reactor with end caps properly closed.
• Never dismount or handle UV lamps before they are completely cooled down. A hot UV lamp is
under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a
burn if it is touched.
ON
CAUTI
!
• Before installation, check that the UV lamps and quartz sleeves are not broken.
• UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care
when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage
and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective
eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.
• UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled and disposed of with care. Used lamps UV can be handled and disposed of in the same
way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally
been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe
(or use pure sulphure to bind the mercury for easy collection).
• Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.
• Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
• In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.
• When performing these routines, consider the need for service kits for UV and quartz sleeves,
containing O-rings, lamps, quartz sleeves etc. See Spare parts catalogue.
• Do not touch the glass of the UV lamp. Wear gloves and hold the lamp by the ceramic end
parts only. If a lamp is stained on its surface, wipe off the glass with a clean soft piece of cloth
soaked with alcohol. If not, it could cause breakage and shorten lamp life.
Book No.9010183 02, rev. 2 23

4.2 Replace UV lamp and quartz sleeve 4 AOT reactor
• Keep the UV lamp in its original protective cover and case when transporting, storing and
disposing of the lamp. Otherwise it could cause injury if the lamp breaks. Do not dispose of
original protective cover and case for the UV lamp, as they should be re-used for storage
and disposal. Mark cases with used UV lamps accordingly, so that they will not be mistaken
for new lamps.
4.2 Replace UV lamp and quartz sleeve
7 AOTexploded2
AOT reactor, exploded (principle).
1. Cap
2. Cap nut
3. Bush
4. O-ring (inside bush)
5. Cable connector
6. Allen screw
7. Glass socket
8. O-ring
9. UV lamp
10. Quartz sleeve
4.2.1 Disassemble UV lamp

Follow this instruction to dismount the UV lamps.
• The PureBallast system must be turned off, and the power disconnected.
24 Book No.9010183 02, rev. 2

4 AOT reactor 4.2 Replace UV lamp and quartz sleeve
• After UV lamps have been changed, the runtime must be reset in page control system page 4.4
Operation timers AOT 1–3. Requires login level Advanced operator.
• Wait at least 10 minutes after completed ballast or deballast process, to allow the AOT reactor
to cool down to ambient temperature. If the UV lamps are hot they are under internal positive
pressure and may burst if broken.
NG
WARNI
!
• The AOT reactor must not be under pressure when dismounting the UV lamps.
NG
WARNI
!
• Burn hazard: UV lamps can be hot and cause burns.
1. Unscrew the cap nuts (2) holding the caps (1). There is one nut on each side of the AOT reactor
per UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.
2. Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).
7UVlampConnection
3. Carefully draw out the lamp bushes (3) on both sides.
Carefully draw out the UV lamp (3) with the electric cable, by holding the electric cables in
both ends. When pulled out, only hold the UV lamp by the ceramic ends. Immediately after
removal, place the lamp in its protective cover.
If required, use a screwdriver to press on the ceramic end of the lamp inside the bush on the
other side while carefully pulling the electric cable at the other end.
Book No.9010183 02, rev. 2 25

7UVBushScrewdriver
4. Check that the quartz sleeve (10) is not broken.

To disassemble the quartz sleeves, see the instruction Disassemble the quartz sleeve.
5. If the quartz sleeves is not broken, mount the new UV lamp according to the instruction
Assemble UV lamp on page 28. If broken see the Preparations and conditions section above.
26 Book No.9010183 02, rev. 2

4 AOT reactor 4.2 Replace UV lamp and quartz sleeve
4.2.2 Disassemble quartz sleeve

Follow this instruction to disassemble the quartz sleeve.
NG
WARNI
!
• Hot water may escape from the AOT reactor when removing the drain plug.
1. Close the AOT reactor inlet (V201-19.n) and outlet (V201-20.n) valves from the control system
set in manual mode.
2. Depressurize and drain the AOT reactor: Remove the drain plug at the bottom of the AOT
reactor.
3. Disconnect the compressed air, as a safety precaution.
4. Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 24.
5. Loosen the three Allen screws (6) of the glass socket (7) on both sides; just a few turns to
release them.
6. Unscrew the Allen screws completely at one side. Carefully remove the glass socket, to avoid
breaking the quartz sleeve. Then remove the glass socket on the other side.
7. Remove the O-rings (8) on both sides. The O-rings are firmly stuck in their seat, and will be
damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring
tool to loosen and remove the O-ring. Be careful to avoid to break the glass.
If the O-ring is hard to remove, try the following:
– Moisten the O-ring with acetone or denatured alcohol.
– Loose the O-ring in a couple of places before removing it.
– Perforate the O-ring to get a good grip.
8. Carefully remove the quartz sleeve (10).
9. Carefully clean the surface and remove any small parts, for example glass or rubber.
4.2.3 Assemble quartz sleeve

Follow the instruction below to assemble quartz sleeve and check for leaks.
• Two new O-rings (8) for each quartz sleeve (10).

• Two new O-rings for each glass socket (7) might be needed.
• Use waxed screws.
• Glass sockets and bushes must be dry and clean before mounting.
1. Insert the quartz sleeve (10) in the AOT reactor.
Book No.9010183 02, rev. 2 27

2. Wet the O-rings (8) with water and slip them over respective side of the quartz sleeve.
Check that the O-ring are positioned evenly on both sides. If not, they may be damaged
and cause leaks.
The O-rings shall not be pressed into position, the glass socket will press them into position
when fastened later.
3. Carefully mount the first glass socket on the quartz sleeve with three Allen screws evenly, but
do not tighten the screws. Note that the waxed screws must be used to avoid seizing.
7QuartzSleeve
4. Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.
5. Mount the second glass socket.
6. Connect the compressed air.
7. Follow the instruction Check for leaks after quartz sleeve assembly.
4.2.4 Check for leaks after quartz sleeve assembly

Follow the instruction below to secure that there are no leaks that may damage the UV lamps.
1. Pressurize the AOT reactor with water to between 2 and 4 bar (0.2 and 0.4 MPa).
2. Visually check for leaks.
4.2.5 Assemble UV lamp

Follow the instruction below to mount UV lamps.
• A leakage check must have been performed according to the instruction Check for leaks after
quartz sleeve assembly.
• Use waxed screws.
28 Book No.9010183 02, rev. 2

4 AOT reactor 4.3 Internal inspection of AOT reactor
• New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.
• Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the
lamp; hold the lamp by its ceramic end parts.
• Glass sockets and bushes must be dry and clean before mounting.
• After UV lamps hav e been changed, the runtime must be reset in control system page 4.4
Operation timers AOTs.
1. Mount the new heat resistent O-rings in the two lamp bushes (3).
2. Place one bush on the UV lamp (9).
3. Insert the UV lamp and bush into the AOT reactor.
4. Insert the other bush in the opposite side of the AOT reactor.
5. Make sure that the connection is clean to ensure good electric connection (no rust, burning or
fading on the connectors). Reconnect the two cable connectors for the UV lamp.
7UVlampConnection
6. Mount the UV lamp caps and tighten the cap nut at both ends of the UV lamp, by hand only.
Make sure that the electric cable is is not squeezed between the cap and the bush when the
cap is mounted. Slack can be pushed into the bush.
7. Re-fit the drain plugs at the bottom of the AOT reactor and/or at the flanges under the AOT
reactor.
8. Control the control system page 3.1 Alarm list, to make sure there is no alarm when after
the the lamp power supply is on.
4.3 Internal inspection of AOT reactor

Follow this instruction to open the AOT reactor for internal inspection and cleaning, for example of a
UV lamp or quartz sleeve has been broken.
• The AOT reactor must be depressurized and the AOT reactor must be emptied from water.
Book No.9010183 02, rev. 2 29

4.4 Dismount and mount lamp power supply 4 AOT reactor
(LPS)
7 OpenAOT
1. Access hatch
1. Remove the bolts on the access hatch (1).
2. Inspect the bottom of the AOT reactor to see if there are any dirt or larger particles. If so,
remove.
Note: Be careful not to break the quartz sleeves.
3. Check the sealing. Replace if necessary.
4. Reassemble when done.
4.4 Dismount and mount lamp power supply (LPS)

Follow this instruction to replace a lamp power supply inside a lamp drive cabinet (LDC).
30 Book No.9010183 02, rev. 2

4 AOT reactor 4.4 Dismount and mount lamp power
supply (LPS)
NG
WARNI
!
• Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V)
inside and on the lamp power connector, even when UV lamps are not lit.
• The LDC contains a fan, which can cause injury if in operation.
7 LPSmaint
1. Dismount LPS
Release two power connectors at the bottom of the LPS and the signal cable connector
at the top.
2. Loosen the nuts at the bottom (1) and the top (2) of the two rods holding the LPS. If necessary,
loosen nuts for adjacent LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short circuit.
3. Pull the handle to remove the LPS.
4. Mount LPS
Set the DIP switches on the LPS according to chapter 4. Parameters, section Lamp power
supply (LPS) parameters.
5. Push the new LPS to the wall of the cabinet.
6. Reconnect the three connectors. Make sure the connectors sit tight.
Book No.9010183 02, rev. 2 31

4.5 Test LPS installation 4 AOT reactor
7. Tighten the nuts to attach the LPS.
8. Turn on the fuse to the LPS.
9. Switch on the main breaker on the LDC door and check that both LPS:s function correctly
according to instruction Test LPS installation below.
10. Send the replaced LPS to Alfa Laval for repair.
4.5 Test LPS installation

Follow this instruction to make sure that the installation is OK and safe to use.
NG
WARNI
!
• This instruction must be performed after cable connection. If not hazardous situation may arise
which, if not avoided, will result in death or serious injury.
DANGER
!
• Before operating the AOT reactor, make sure that there is water in the AOT reactor.
1. Make sure that the AOT reactor breaker is switched off.
2. Check that there is water in the AOT reactor(s) (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the AOT reactor.
3. Switch on the main breaker on the LDC door. Switch on the power to the AOT reactor using
the switches on the breaker cabinet(s).
4. Start UV lamps one by one from the control system (set to manual mode). Make sure that the
UV lamps are lit. This is checked in the AOT reactor popup and on the LPS.
Note: It can take up to 150 seconds for the lamp to start.
5. Check LEDs on the LPS and the alarm list in the control system. Make sure that no alarms
have been triggered by the LPS.
6. Turn off the lamp.
32 Book No.9010183 02, rev. 2

5 Filter
This section covers the instructions for service of the filter.
These preparations and conditions are valid for all instructions.
• Galvanic circuits must always be restored after maintenance, if dismounted.

• Disconnect the power to the filter, using the main switch on the filter cabinet.
• Shut off the air supply to the filter.
• Depressurize the filter: f
Alternative 1: Open the valve on the drain pipe.
Alternative 2: Open the valve on the back flush pipe manually and then open the safety valve.
• Note: The motor does not need to be lubricated.
Filter – Exploded view
Book No.9010183 02, rev. 2 33

5 Filter
7 Filter Exploded Hydac
1. Filter cover bolts

2. Filter cover
3. Motor
4. Protective hood
5. Valve connection plate
6. Drive shaft
7. Gasket
8. Retaining plate
9. Locking pin
10. Gasket
11. Filter candle
12. Hole for locking pin
13. Lid for anode
14. Drain pipe
15. Air pipe
16. Safety valve
34 Book No.9010183 02, rev. 2

5 Filter 5.2 Mount filter candles and filter cover
5.1 Remove f lter cover and f lter candles

Follow this instruction to remove the filter cover and filter candles.
• Read the general preparations and conditions.

• Disconnect the power to the filter, using the main switch on the filter cabinet.
• Lifting device is needed for this instruction.
Filter cover weight (kg), per system size:
150.
Retaining plate (kg): 70.
1. Remove the following components:
- Safety valve pipe (16)

- Air pipe, loosened (15)
- Electrical connections to the motor and valves
- Connection plate for valve connections (5)
- Motor (1)
- Protective hood (4) fasten with four of the filter cover bolts (1)
- Galvanic protection between the filter cover, retaining plate and housing.
2. Remove the filter cover (2) by lifting it using the ring bolts.
3. Remove the gasket (7) on the retaining plate (8).
4. Lift the retaining plate. Four threaded holes that can be used to attach lifting devices.
NOTE
• The plate must be level when lifted, to avoid damaging the gasket and filter candle O-rings.
• It is important not to turn the shaft, after the retaining plate has been removed. If the
rotation is changed, this will make the mounting much more complicated.
5. Remove the gasket under the retaining plate.
6. Carefully pull out the filter candles (11).
5.2 Mount f lter candles and f lter cover

Follow the instruction to mount filter candles and filter cover

• Gaskets for the retaining plate and O-rings for the filter candle must be in good condition.
Book No.9010183 02, rev. 2 35

5.3 Replace filter candles 5 Filter
1. Make sure that the filter candle O-rings are in position in their groove.
2. Carefully insert the filter candles (11). Make sure that they are fitted in the hole in the lower
retaining plate and that they they snap into position.
3. Place the gasket (10) on the filter housing. Make sure that the hole (12) for the locking pin
(9) is not covered by the gasket.
4. Before re-fitting the retaining plate (8), note that the locking pin shall fit into the hole in the
retaining plate.
5. Carefully lower the retaining plate onto the housing.
NOTE
• The locking pin shall be fitted into its hole.

• The candles must be guided into the holes in the retaining plate.
6. Place the gasket (7) on the retaining plate. Make sure to fit the gasket to the locking pin.
7. Carefully lower the filter cover (2) onto the retaining plate.
NOTE
• The filter cover must be level when lowered to the housing.

• The drive shaft (6) must fit the shaft in the filter housing. If not: Lift the retaining plate, turn
the shaft in the filter housing and try again.
8. Refit the following components:
- Protective hood (4) fasten with four of the filter cover bolts (1)
- Motor (1)
- Galvanic protection between the filter cover, retaining plate and housing
- Connection plate for valve connections (5)
- Electrical connections to the motor and valves
- Air pipe, loosened (15)
- Safety valve pipe (16).
5.3 Replace f lter candles

Follow the instruction to replace damaged filter candles.
1. To replace filter candles, follow the Remove filter candles instruction on page 35, and simply
replace damaged elements.
36 Book No.9010183 02, rev. 2

5 Filter 5.5 Change sacrificial anode
5.4 Clean f lter candles

Follow the instruction to

1. Follow the instruction Remove filter cover and filter candles on page 0 to remove the filter
candles.
2. If there is scaling on the filter candles: Soak the filter candles in the cleaning agent and leave
them to soak for 1–3 hours. Read the Preparations and conditions section for instruction
Change and refill CIP liquid.
3. Secure the filter candle, to avoid that it rolls away.
4. Spray the filter candles with water from the outside. Start at a distance of 100 cm and reduce
to 50 cm, which is the minimum distance. The water must not be warmer than 60 °C. Note: If a
high-pressure cleaner is used, the pressure must not exceed 100 bar (10.0 MPa). Minimum:
20 bar. If a cleaner with higher capacity than 100 bar is used, compensate by increasing the
distance.
5.5 Change sacrif cial anode

Follow the instruction to check and change the sacrificial anode.

1. Close inlet and outlet valves to the filter.
2. Drain the filter by opening the drain pipe (14).
3. Open the lid (13).
4. Inspect the anode. Change if the anode has lost approximately 80 % of the zinc mass.
5. Remove the old anode and install the new one.
6. Fasten the lid on the filter and restore the valves in their original positions.
Book No.9010183 02, rev. 2 37

5.5 Change sacrificial anode 5 Filter
6 CIP module
This section covers instruction for service of the CIP module.
6.1 Change and ref ll CIP liquid

Alpacon descalant is used as cleaning agent in the CIP module. It contains no solvents and no
inorganic acids. It is non-flammable and non-hazardous.
ON
CAUTI
!
• Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow
rules when handling CIP liquid agent, regarding ventilation, personal protection etc.
ON
CAUTI
!
• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• Before usage, Alpacon descalant offshore must be visually checked. It shall be transparent
light pink in color.
• The instructions requires pH test equipment (paper indicator or pH meter). This is not a part of
Alfa Laval’s scope of supply.
• The pH value should be between 2.0 and 3.0. From the beginning, the pH value is approximately
2.0. When the pH value rises to 3.0 the cleaning liquid must be changed.
• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant offshore to
20 parts fresh water. Follow this mixing ratio, regardless of recommendation on label.
• The CIP tank shall be filled with maximum 250 liters. Min and max filling of CIP liquid can
be read on the CIP tank.
• Store the CIP liquid according to the instructions on the bottle. General guidelines are:
- Storage temperature 0 °C to +55 °C.

- The Alpacon descalant offshore can be frozen and thawed without impairing performance.
• Used CIP liquid may contain residues from the cleaning process that can potentially have an
impact on the environment, although this impact is regarded as very small. There are no
transport restrictions.
• Used CIP liquid is drained to one of the following: bilge tank, drain tank, sludge tank or bilge well.
• When performing these routines, consider the need for service kits. See Spare parts catalogue.
Book No.9010183 02, rev. 2 39

6.1 Change and refill CIP liquid 6 CIP module
7 CIP 589741_description
CIP module
1. CIP liquid tank cap

2. Drain line with manual valve
3. Pump P321–5 (AOT reactor drain)
4. Pump P320–1 (CIP liquid)
40 Book No.9010183 02, rev. 2

6 CIP module 6.1 Change and refill CIP liquid
6.1.1 Change CIP liquid

Follow this instruction to change CIP liquid, when necessary due to high pH value.
1. If the drain valve (3) is connected to bilge (or other) tank, follow the sub steps below.
Otherwise, go to step 2.
a. Open the manual drain valve V460-3 under the CIP tank.
b. Wait for the tank to be totally drained. Then close the drain valve.
2. If the drain valve is not connected to the bilge tank, the steps below can be followed. This
operation requires login level Advanced operator or higher.
a. Open valves V320-2 and V460-2 from the control valve, and V230–11 manually. Start
pump P321-5 (3) and P320-1 (4).
b. Wait for the tank to be totally drained. Then stop the pumps and close the valves in
reversed order. Go to step 3.
3. Open the cap (1) on top of the CIP tank and pour 12 liters of CIP cleaning agent into the tank.
4. Fill the tank with fresh water to the Max indication on the tank, approximately 240 liters.
5. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.
6. Go to control system page 4.3 – Operation timers. Make a note of the number of AOT reactors
that has been CIPed since last time the CIP liquid was changed. Press the Reset button for
“Total number CIP:ed reactors”. Requires login level Advanced operator. If this is done each
time the CIP liquid is changed, it is possible to build up experience on how many AOT reactors
it is possible to CIP before it is time to change CIP liquid.
6.1.2 Ref ll CIP liquid

Follow this instruction to refill CIP the CIP tank when there is low liquid level in the tank.
1. Measure the pH value in the tank. Based on the pH value, estimation must be done regarding
the proportions between Alpacon descalant offshore and water. Note that the mixing ratio is
stated under Preparations and conditions above.
2. Mix the cleaning agent with water separately. The result will get better than if mixed mix in
the tank.
3. Pour the mixed CIP liquid into the tank. Do not fill over Max indication on the tank.
4. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is still too high, the CIP liquid must be changed. See the Change
CIP liquid instruction in this chapter.
Book No.9010183 02, rev. 2 41

6.2 Repair CIP pump 6 CIP module
6.2 Repair CIP pump

Follow this instruction to repair CIP pump.
ON
CAUTI
!
• Always wear protective eye glasses and gloves while working on the pump.
NG
WARNI
!
• Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
• Drain the pump from liquids.
• The pump should be placed horizontally on a work bench.
7 CIP pump
CIP pump, exploded view
6.2.1 Clean CIP pump

42 Book No.9010183 02, rev. 2

6 CIP module 6.2 Repair CIP pump
1. Remove the pump from the CIP tank.
2. Rinse the pump with fresh water.
6.2.2 Disassemble CIP pump

Follow this instruction to disassemble the CIP pump.
6.2.2.1 Disassemble the main parts
1. Remove the CIP pump from the CIP module and place it on a work bench.
2. Unscrew the nuts (37) on one side of the housing (11).
3. Place the pump on the side that still has the nuts (the pump lays on the nuts) on a stable ground.
4. Carefully remove the "loose housing" (11).
5. Carefully lift up the suction and discharge connections (13). You have the centre block (12)
and one of the housings with pin screws (14) left.
6. Upend the pump and carefully pull out the pin screws (14). Be careful not to damage the
diaphragms (15).
6.2.2.2 Disassemble the housing
Follow this instruction to disassemble the housing.
1. Put the house wall with the flat side down on a plane surface.
2. Remove the spacer sleeve (19), by turning it 180°. To do that:
• Put a piece of plastic towards one side of the spacer sleeve.

• Knock on it so that the spacer sleeve is turning.
• Put one of the pin screws in the hole on the spacer sleeve and turn it until it lays upside
down (180°) compared to the starting position. Pull the spacer sleeve carefully against
the lower valve seat (21) until it is free and can be put out.
3. Stick a something not pointed into the hole for the discharge connection and gently press out
the upper valve seat (20).
4. Place one of the pin screws on the inside (behind) the valve ball stopper on the lower valve
seat (21). Carefully pull out the valve seat in the housing.
5. Remove the valve ball (23) from the valve seat, buy using a pin screw: Press out the valve ball
stopper (22), which will release the valve ball.
Book No.9010183 02, rev. 2 43

6.2 Repair CIP pump 6 CIP module
6.2.2.3 Disassemble the center block
Follow this instruction to disassemble the centre block.
• Have backup spares of the sealing (36) and backup O-ring (47). There is a risk that these parts
get damaged during this operation.
1. Press the diaphragms (15) to their neutral position (both have the same distance to the
centre block).
2. Hold one of the diaphragms (15) and unscrew the other. Then pull out the remaining diaphragm
with the diaphragm shaft (16).
3. Disassemble the circlips (27) which keep the air valve (61) on its place.
4. Press out the air valve. A wood shaft of a hammer can be used. Be careful not to damage the
sealing edges towards the diaphragm or the air valve.
5. If the shaft sealings (36) seem to be worn out, carefully remove them with a pointed tool.
6.2.3 Assemble CIP pump

Follow the instructions below to assemble the CIP pump.
6.2.3.1 Assemble center block
1. Mount the circlip (27) on one side.
2. Apply some soft soap solution on the air valve O-rings (30).
3. Push the air valve (61) into the housing. Make sure that the O-rings (30) remain in the right
position. Put the circlip (27) on the other side.
4. Put the diaphragm (15) with shaft (16) into the centre block. Screw the next diaphragm (15)
onto the shaft (16) and fix the holes.
6.2.3.2 Assemble the main parts
1. Make sure that the O-rings (18) are placed on the in/outlet (13) before assembling of pump.
2. Turn the housing (11) with the flat side up.
3. Make sure all pin screws (14) have one nut (37) and one washer (38) each. Nut should only be
put on one or two threads.
4. Put all the pin screws through the housing and then turn the housing so it rests on the nuts.
44 Book No.9010183 02, rev. 2

6 CIP module 6.5 Repair valve block
5. Put the centre block (12) to the housing with screws through the centre block. Be careful not to
damage the diaphragms.
6. Place suction and discharge connections (13) in their positions in the housing. Be careful not
to damage the O-rings (18).
7. Put the second housing (11) onto the pin screws (14). Make sure that suction/discharge
connections are in right direction. Be careful with the O-rings.
8. Fasten the nuts (37) crosswise by hand, with or without washers depending on how much of
the thread comes out. Turn the nuts gently with a tool to close the pump. If some of the nuts
were fastened without washer, unscrew those and put washers underneath. After a few weeks
operation a follow up draft of the nuts is recommended.
6.3 Test CIP pump

Follow the instruction below to verify that the CIP motor is functioning.
1. Open valves V320-2 and V460-2 from the control system, and V230–11 manually. Start
pump P321-5 (4) and P320-1 (4).
2. Observe if the motors sound and functions OK. If not, check installation and connections and
attend to and test again.
3. Stop the pumps and close the valves in reversed order.
6.4 Repair junction box and valve blocks

Read the conditions below before reparing the junction box or valve blocks.
6.5 Repair valve block

Follow this instruction to repair the valve block, mounted on the CIP module.
• The valve bodies does not have individual placing, they can be placed in any order.
DANGER
!
• Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.
Book No.9010183 02, rev. 2 45

6.5 Repair valve block 6 CIP module
7 Valve block
Valve block
1. Cover (Terminal strip inside)

2. Valve body
3. Button to operate valve
4. Signal plate
5. Cable gland
6.5.1 Change valve body

1. Remove the scresw holding the valve bodies (2) and the signal plate (4).
2. Unscrew the screws holding the valve body (2).
3. Lift the valve body.
4. Attach a new sealing on the new valve body and fasten the valve body to the valve block.
6.5.2 Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the control cabinet to the CIP valve block.
46 Book No.9010183 02, rev. 2

6 CIP module 6.5 Repair valve block
1. Open the cover (1) on the front.
2. Attach the cables according to electrical drawing Control cabinet / interconnection diagram in
chapter 6. Installation description and drawings.
3. Fasten the cable to the cable gland (5).
4. Fasten the cover (1).
6.5.3 Clean valve block

Follow this instruction to clean the valve block house from dirt.
1. Disconnect the outgoing air hoses from the valve block.
2. Operate the service air according to instruction Open and close valves manually (CIP valves)
on page 19 to blow out the dust.
3. Connect the air hoses again.
6.5.4 Connect pneumatic hoses to valve block

Follow this instruction to connect pneumatic hoses to the valve block, if they have been
disconnected.
1. Connect the hoses according to the signal plate (4) on the valve block.
Book No.9010183 02, rev. 2 47

6.5 Repair valve block 6 CIP module
7 Flow meter
The flow meter consists of two main parts.
• Flow sensor: A pipe with four electrodes detecting the flow. On top of the pipe, there is a
terminal box, where the flow transmitter is mounted.
• Flow transmitter: Monitors and transmits information to the PureBallast control system. The
flow transmitter is also used to set parameters for the flow meter. A Sensorprom in the flow
transmitter contains the data.
• If the flow meter is replaced, settings must be checked according to chapter 4. Parameters,
section Flow transmitter parameters.
7.1 Mount f ow transmitter

Follow the steps below to mount the flow transmitter on the flow sensor. The flow transmitter is not
factory mounted, to avoid damage during installation of the flow sensor.
Preparation and conditions
• See chapter 6. Installation description and drawings, section Control cabinet / Interconnection
diagram for detailed information.
• It is recommend that a shielded power cable is used.
NG
WARNI
!
• Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
1. Remove and discard the lid from the terminal box on the flow sensor.
Book No.9010183 02, rev. 2 49

7.1 Mount flow transmitter 7 Flow meter
7 FM Lid
2. Fit PG13.5 cable gland for the power and signal cable.
3. Connect power and grounding to the following terminal positions marked on the circuit board:
1=+
2=–
Grounding.
4. Connect current output signals to the following terminal positions marked on the circuit board:
31 = +
32 = –
5. Tighten the cable gland to obtain optimal sealing.
6. Mount the flow transmitter on the terminal box using the two screws. If other direction of the
flow transmitter is desired, please follow the instruction Change direction of flow transmitter on
page 51.
7 FM MountTM
50 Book No.9010183 02, rev. 2

7 Flow meter 7.2 Change direction of flow transmitter
7.2 Change direction of f ow transmitter

The flow transmitter can be mounted in different directions in relation to the flow sensor. It can
be directed in steps of 90º.
1. Remove the flow transmitter from the terminal box.
7 FM MountTM
2. Disconnect the power supply (terminal positions 1, 2 and grounding) and output signal cables
(terminal positions 31 and 32) from the circuit board.
3. Remove the coil plug (1) from terminal positions 85 and 86. Remove the plug (2) from terminal
positions 82, 0 and 83.
4. Unscrew the two screws (indicated below) holding the circuit board to the terminal box and lift
up the circuit board.
Note that the sensorprom is mounted on the underside of circuit board; be careful not to loose
it. Sometimes, the sensorprom remains in its seat on the terminal box.
7 FM ScrewCricuit
Book No.9010183 02, rev. 2 51

7.3 Change direction of flow transmitter control 7 Flow meter
pad
5. Disconnect the grounding wire holding the circuit board to the terminal box.
• If the flow transmitter shall be turned 180°: Move the sensorprom (1 in the illustration
below) to the position on the opposite side of the circuit board and refit in reversed order.
• If the flow transmitter shall be turned 90°: Continue with next step.
6. Unscrew the four screws (2) on the terminal box to loosen it from the flow sensor.
7 FM LooseTB
7. Turn the terminal box to 90° and fasten it with the four screws.
8. Refit in reversed order.
7.3 Change direction of f ow transmitter control pad

The control pad of the flow transmitter can be mounted in different directions in relation to the
transmitter. It can be directed in steps of 90º.
1. Remove the outer frame with the help of a screw driver.
7 FM LoosFrame
52 Book No.9010183 02, rev. 2

7 Flow meter 7.3 Change direction of flow transmitter
control pad
2. Loosen the four screws holding the control pad.
7 FMScrewPad
3. Withdraw the control pad and turn it to the required orientation.
7 FM TurnPad
4. Tighten the four screws until a mechanical stop is felt.
7 FMScrewPad
Book No.9010183 02, rev. 2 53

7.4 Clean flow meter electrodes 7 Flow meter
5. Snap-lock (a click is heard) the outer frame onto the control pad.
7 FM FastCover
7.4 Clean f ow meter electrodes

Follow this instruction to clean the electrodes.
It is important that the electrodes are clean to secure accurate output. If the four electrodes in the
flow sensor get dirty, it may result in inaccurate and varying output.
1. Drain the entire pipe where the flow meter is mounted.
2. Close the main valves connecting the PureBallast pipe net to the vessel’s ballast pipe net and
secure it from being switched on. See instruction Lock valve in closed position on page 20.
3. Remove all the flange bolts on the flow meter, except one on each flange. Note that the
remaining bolts on each side must be in the same position on respective flange.
4. Loosen the nuts on the remaining bolts. Swing the flow meter outside the pipe.
5. Clean the four electrodes with a mild washing detergent.
6. Refit the flow meter in reversed order.
54 Book No.9010183 02, rev. 2

8 Valve actuator
This section contain instructions for the valve actuator.
7 Actuator and switch
Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4.
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves
with dimension 400
7. DIN connector
8. Position indicator
Book No.9010183 02, rev. 2 55

8.1 Preparations and conditions 8 Valve actuator
7 Actuator
Valve actuator with puck for position sensor
1. Safety cover
2. Pad lock
3. Lower position for indicator screw
4. Upper position for indicator screw — with screw
5. Position indicator
6. Center screw
7. Bracket
8. Puck
9. Locking bolt
10. End stop bolt.

• Do not operate the actuator over pressure limits. It will damage internal parts as well as cause
damage to the housing.
• Do not disassemble individual spring elements. Disassembly may result in personal injury.
• Do not remove end caps or disassemble the actuator while the actuator is pressurized.
• The actuator must not be lubricated. It is factory lubricated for the life of the actuator during
normal working conditions. The standard lubricant is suitable for use from −20 °C (−4 °F)
to +80 °C (+176 °F).
• If a valve actuator is removed, check for loose spindle-bushing. Then make sure the loose
bushing is refitted to avoid play between the actuator and the valve spindle.
• Actuator are mounted together with the valve body and pilot valve at delivery. Valve and actuator
mounting are sealed to guarantee correct position indication in relation to throttle position.
8.1.1 Tightening torques for actuators

Torque is stated in Nm.
56 Book No.9010183 02, rev. 2

8 Valve actuator 8.3 Mount actuator on valve
M5 05–06
M6 10–11
M8 23–25
M10 48–52
M12 82–86
M14 132–138
M16 200–210
M20 390–410
8.2 Dismount actuator

Follow this instruction to dismount an actuator.
• The valve must be in closed position.

• The valve position must not be adjusted during the routine.
1. Remove the DIN connector to disconnect the power. Let the air connection remain.
Result: Valve goes to closed position (due to the air connection). The yellow indicators on the
puck shows position of valve: closed. The yellow position indicators are in line with the valve
throttle (indicating closed when the position indicators are in opposite line with the pipe).
2. Disconnect the air hose to the pilot valve. Verify that the actuator is not pressurized. Always
use caution and double-check that ports 2 and 4 are vented and are free from any accessory
and/or device.
3. If the actuator have a switch box at the top: Loosen the four screws holding the switch box to
the actuator. Remove the switch box together with its bracket.
4. Loosen the four hexagonal screws holding the actuator to the valve.
5. If the actuator is mounted on the valve with a bracket and coupling (dimension 400): Loosen
the screws holding the bracket to the valve. Make sure not to loose the coupling between the
valve and actuator when lifting the actuator.
6. Lift the actuator from the valve.
8.3 Mount actuator on valve

Follow this instruction to mount an actuator.
Book No.9010183 02, rev. 2 57

8.3 Mount actuator on valve 8 Valve actuator
ON
CAUTI
!
• The actuator must not be pressurized at any time during installation as it may result in injury.
• The utmost cleanliness is required during air supply connection to the actuator, that is, the
connecting pipe thread, fittings and seals must be clean and dirt-free.
• Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on
which direction of rotation is required.
1. Note the position of the groove (2) of the valve stem (3). It indicates the position of the valve
throttle. The illustration shows a square variant, but octagonal versions exist.
7 ValveStem
1. Allowed travel sector.

2. Valve stem groove
3. Valve stem
5. Lock pin opening (covered by rubber plug).
2. Make sure that the lock pin (inside the valve stem) only travels in the allowed sector (1) and
that it does not pass the opening (5).
3. If the actuator is mounted on the valve with a bracket and coupling (dimension 400): First fit
the coupling on the valve stem. Make sure that the red position indicator on the coupling is in
line with the pipe when the valve is open.
4. Fit the actuator onto the valve stem (or the coupling). The actuator may only be positioned in
even 90° intervals in relation to the valve. It is not allowed to adjust the position by turning the
actuator by hand after it is fitted on the valve stem.
5. Mount the actuator on the valve with the four hexagonal screws. For each screw, one washer
and one spring washer shall be used. Tighten with torque according to the table Tightening
torques for actuators on page 56.
58 Book No.9010183 02, rev. 2

8 Valve actuator 8.4 Change direction of actuator – without
position sensor (V404–36, V320–4 and V321–2)
6. If the actuator have a switch box at the top: Make sure that the yellow position indicator under
the switch box is in line with the throttle (according to the groove in the valve stem). The yellow
position indicator shall be in line with the valve throttle (indicating open when the position
indicator is in line with the pipe). If not, remove the position indicator, turn it 90° and refit it.
Mount the switch box with the bracket on the actuator, using the four bolts.
7. Reconnect the air hose to the pilot valve.
8. Operate the valve to make sure it operates in the desired direction of rotation.
8.4 Change direction of actuator – without position

sensor (V404–36, V320–4 and V321–2)
Follow this instruction to turn an actuator without position sensors on the AOT reactor.

1. Loosen the four screws holding the actuator to the valve.
2. Lift the actuator from the valve.
3. Note the position of the groove of the valve stem. It indicates the position of the valve throttle.
4. Fit the actuator onto the valve stem.
5. Unscrew the center screw (4) holding the puck (6) and a bracket (5).
7 ActDirectWithout
6. Lift the puck (6), rotate it 90° and fasten it with the center screw (4) and bracket (5).
Book No.9010183 02, rev. 2 59

8.6 Change direction of actuator – with 8 Valve actuator
position sensor (201-19 and 201–20)
7. Make sure that the yellow position indicators (3) is in line with the throttle (according to the
groove in the valve stem). The yellow position indicators shall be in line with the valve throttle
(indicating open when the position indicator is in line with the pipe). If not, remove the position
indicators, turn them 90° and refit.
8. Connect power and air.
8.5 Change direction of actuator – with switch box

(V201–3, V201–9, V201–32, V212–31 and V403–35)
Follow this instruction to turn an actuator with switch box.

• The valve must be mounted and connected to air and power before adjustment.
1. Dismount the actuator according to Dismount actuator on page 57.
2. Remount the actuator according to Mount actuator on valve on page 57.
3. Before mounting the switch box, change the position of the yellow position indicator, so it
is in line with the throttle.
4. Remount the switch box according to Mount actuator on valve.
8.6 Change direction of actuator – with position

sensor (201-19 and 201–20)
Follow this instruction to turn an actuator with a position sensor, if necessary due to lack of space.
Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-19 and V201-20 on the AOT reactor.

• The valve must be mounted and connected to air and power before adjustment.
1. Dismount the actuator from the valve according to instruction Dismount actuator on page 57.
Put the actuator on a work bench.
60 Book No.9010183 02, rev. 2

8 Valve actuator 8.6 Change direction of actuator – with position
sensor (201-19 and 201–20)
2. Disconnect the DIN connector (2) from the coil: First loosen the screw (1), and then pull up
the connector.
7 DisconDINcon
3. Unscrew the center screw (6) holding the puck (8) and a bracket (7).
7 DirActPosSnsr
4. Lift the puck (8), rotate it 90° so that one position indicator (5) with a screw is in contact with the
position sensor. Fasten the puck with the center screw (6) and bracket (7).
5. Move the screw on yellow position indicator to the top position and move the screw on black
position indicator to the bottom position.
6. Make sure that the position sensor have a maximum distance of 1 mm from the puck (7). The
position sensor and the position indicator screws must be close to give a signal. If not, loosen
the screws and adjust the position. Tighten the screws to fixate the position.
7. Fit the actuator onto the valve stem in its new position according to instruction Mount actuator
on valve on page 57.
Book No.9010183 02, rev. 2 61

8.8 Mount pilot valve on actuator 8 Valve actuator
8. Make sure that the yellow indicator (5) in line with the valve throttle according to the groove in
the valve stem.
9. Reconnect the DIN connector.
10. Connect power.
11. Check that the installation is OK, by making sure that the A1 LED is lit on the position sensor
(visible from the side).
12. Connect air.
8.7 Change direction of actuator – with positioner

(201–8)
Follow this instruction to turn the actuator on control valve 201–8, if necessary due to lack of space.
Note that the actuator normally should not be altered.

1. Dismount the actuator from the valve according to instruction Dismount actuator on page 57.
2. Fit the actuator onto the valve stem in its new position and mount it on the valve with the four
hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten
with torque according to the table Tightening torques for actuators on page 56.
3. The position indicator scale shall be correct, but make sure that the scale still indicates correct
opening percent according to the valve throttle position. If not, loosen the four bolts to the
bracket holding the switch box. Lift it and turn the scale so it is correct.
4. Refit the switch box. Make sure that the peg on the scale fits to the carrier on the puck
mounted on the actuator.
8.8 Mount pilot valve on actuator

Follow this instruction to mount a pilot valve on actuator and connect them.

• Air and power must be disconnected. The valve position must not be adjusted during the routine.
62 Book No.9010183 02, rev. 2

8 Valve actuator 8.9 Adjust valve end position
7 MountPilote
Pilot valve and actuator
1. Mounting screw holes

2. Throttle valve
3. Port 1 for air connection (under)
4. Throttle valve
5. DIN connector
6. Screw.
1. Check that the O-rings are fitted on the pilot valve, on the side facing the actuator.
2. Fit the pilot valve on in the actuator, so that the pin on the actuator fits the hole on the pilot
valve. The throttle valves (2 and 4) shall be directed downwards.
3. Mount the pilot valve with two Allen screws in the holes (1).
4. Connect air to port 1 (3) on the pilot valve.
5. Fit the DIN connector (5) on the coil, including gasket. Then fasten the connector with the
screw (6).
8.9 Adjust valve end position

Follow this instruction to tune the open and closed end positions for a valve. This is done if the
valve tends to get stuck in the end position or not close completely.
Book No.9010183 02, rev. 2 63

8.10 Adjust valve traveling speed 8 Valve actuator
• The valve shall be closed (0°) position 0.

1. Note the exact position of the position indicator for reference after adjustment.
2. Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing position and the left
set adjusts open position.
3. Loosen the locking bolt (3).
4. Adjust end position by turning the end stop blot (4) with small turns.
– Clockwise decrease the end position.
– Counterclockwise increase the end position.
NOTE
• The total adjustment degree is 10° for each position.

5. Operate the valve. Compare the new position of the position indicator to see the result on the
adjustment. If needed, adjust again.
6. Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).
8.10 Adjust valve traveling speed

Follow this instruction to adjust valve traveling speed.
64 Book No.9010183 02, rev. 2

8 Valve actuator 8.10 Adjust valve traveling speed
7 AdjustTravel
1. Operate the valve manually to check traveling speed according to the instruction in the Operate
valves manually on page 19.
2. To adjust opening speed:

Faster: Screw the throttle (1) valve port 3 counterclockwise.
Slower: Screw the throttle valve (1) port 3 clockwise.
3. To adjust closing speed:

Faster: Screw the throttle valve (2) port 5 counterclockwise.
Slower: Screw the throttle valve (2) port 5 clockwise.
Book No.9010183 02, rev. 2 65

8.11 Calibrate positioner on V201-8 8 Valve actuator
8.11 Calibrate positioner on V201-8

Follow this instruction to calibrate the positioner at installation or when needed.
7 201-8Positioner4
1. Arrestor device (screw driver adjusting)

2. Unlock the wheel
3. Locking wheel (screw driver adjusting)
4. Direction to lock the wheel
5. Adjustment wheel
6. Transmission ratio selector
• The valve must be installed and connected to air and power.

• The valve must be closed.
• The cover must be removed.
• Do not adjust the cam wheel: 2 grey wheels above the adjustment wheel (5).
• Buttons on the positioner:
7 201-8Positioner
1. Make sure that the transmission ratio selector (6) is set to 90° according to sticker on the
component. If not: Adjust by pressing the bar with a screw driver.
2. Make sure that the Arrestor device wheel (1) is set to 90°. If not: Adjust by turning.
3. If the positioner display is empty (no power): Open V201-8 manually (approximately 1-5 %)
from control system to supply power to the positioner. One of two results may occur:
Alt 1: Menu 1 and “turn” should be displayed. If not: Press – button until it is displayed. Go
to step 4.
Alt 2: Menu 4 and “no” is displayed. Go to step 6.
4. Press the hand button.

Result: Menu 2 and “90°” is displayed.
66 Book No.9010183 02, rev. 2

8 Valve actuator 8.11 Calibrate positioner on V201-8

Result: Menu 4 and “no” is displayed.
6. Press the hand button (approx. 5 sec.) until a (any) menus is displayed. Press the hand
button till menu 4 is displayed.
7. Press + button for 5 seconds to start automatic calibration.
8. If calibration stops (as displayed below), follow these steps:
7 201-8Positioner2
- Use a screw driver to loosen the yellow locking wheel (counter clockwise).
- Turn the adjustment wheel (5) by hand until a 0 is displayed between the “d” and the “U” as
shown in the illustration. Normally this is when the value in the screen is close to 0.
7 201-8Positioner3
- Lock the locking wheel (3) with a screw driver (clockwise).

- Press the + button to continue the calibration.
9. Wait until “FINISH” is displayed on the screen.
10. Press the hand button once.

Result: Menu 4 “INITA” is displayed.
11. Press the hand button until “VER” is displayed (approx. 5 sec.)
Result: “MAN” is displayed”.

Result: “AUT” is displayed.
Trouble shooting
If any problem occurs, do the following:
1. Check the mechanical installation and air supply.
2. Rest factory settings and restart calibration:
- Reset to factory settings: Press hand button until menu 50 is displayed.

- Press + button until “oCAY” is displayed.
- Restart instruction from the beginning.
Book No.9010183 02, rev. 2 67

8.11 Calibrate positioner on V201-8 8 Valve actuator
9 Ball valve
This section contains maintenance information for the ball valve.
9.1 Replace seals in ball valve

Follow this instruction to replace the seals in ball valve.
7 BallV
Ball valve, exploded view
Maximum tightening torque
Valve size Max. torque of Max. torque of stem nut (14)

body bolts (8)
25 = 1 inch 13–16 Nm 14.3 Nm
32 = 1¼ 20–25 Nm 14.3 Nm
inches
50 = 2 inches 35–40 Nm 19.4 Nm
Book No.9010183 02, rev. 2 69

9.1 Replace seals in ball valve 9 Ball valve
1. Relieve the line pressure.
2. With the valve in the open position (lever to be parallel to the axis of the pipe), remove all the
body bolts (19) except one.
3. Loosen the nut (20) on the remaining bolt. Swing the body outside the pipe.
4. Dismount the stem (8).
5. Replace seals (5, 6, 7, 9, 10, and 24). They are available in a spare parts kit for the ball valve.
6. Mount in reverse order. The body bolts of the valve should be tightened evenly. Tighten
one-side snugly, then the one diagonally across. Repeat for the other bolts, bringing them all
down tightly in sequence. Make sure the maximum tightening torque is observed according
to the table above:
7. Check that the valve is operating correctly.
8. Check for leaks when the water flow is on.
70 Book No.9010183 02, rev. 2

10 Level switch
This section contains information about the level switch LS201-29 installed in the AOT reactor. For
information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.
7LS Component
Level switch
10.1 Mount level switch

• Do not alter the forks in any way.

• Be careful not to damage the fork in any way.
NOTE
• Disconnect power supply before mounting or dismounting the component.

1. Connect the level switch according to the label on the component.
2. Seal the level switch with lock tight or equivalent pipe seal.
3. Mount the sensor until the joint is finger-tight.
4. Identify the sensor align mark (▼) on the component. Make sure that it is positioned on the
upper side of the level switch.
Book No.9010183 02, rev. 2 71

10.3 Test level switch 10 Level switch
5. Complete the seal carefully by tightening the component with a spanner. Use the spanner on
the hexagon flats, but not on the level switch body.
10.2 Dismount level switch

• The external surface may be hot. Care must be taken to avoid possible burns.
1. Disconnect the level switch according to the label on the device.
2. Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the level switch body.
3. Remove the level switch and remove the old seal from the threads.
10.3 Test level switch

Follow the instruction below to test that a level switch functions OK.
1. Make sure that the component i powered (the green LED shall be lit).
2. Hold a magnet to the test point indicated on the on the level switch, indicated below.
7LS Test
3. Make sure the level switch reacts to the magnet. The component is OK if the green and
yellow LED is lit.
72 Book No.9010183 02, rev. 2

11 Temperature switch and
temperature transmitter
This section contains information about the temperature switch TS201-60 and the temperature
transmitter TT201–33 installed in the AOT reactor. The two components are similar in design, so
the same instructions can be used.
7 TS and TT
Temperature switch and temperature transmitter
NOTE
• Disconnect power supply before mounting or dismounting the component.

11.1 Mount temperature switch / temperature
transmitter
1. Seal the component’s threads using lock tight or equivalent pipe seal.
2. Mount the component until the joint is finger-tight.
3. Tighten the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
4. Connect the component’s screwed-on power cord.
Book No.9010183 02, rev. 2 73

11.2 Dismount temperature switch / 11 Temperature switch and temper-
temperature transmitter ature transmitter
11.2 Dismount temperature switch / temperature

transmitter
• The external surface may be hot. Care must be taken to avoid possible burns.
1. Disconnect the component’s screwed-on power cord.
2. Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
3. Remove the level switch and remove the old seal from the threads.
74 Book No.9010183 02, rev. 2

12 Control panel
This section covers instructions for service of the control system.
12.1 Clean control panel
NOTE
• Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
• Never use aggressive solvents, chemicals, scouring agents, pressurized air or steam jet.
1. Press the Wipe button on the screen.

Result: Disable the touch screen function for 10 seconds to make it possible to clean the
screen without the risk of starting a process or changing a setting.
2. Clean the display and surrounding front cover with a soft cloth and mild detergent. Do not
spray detergent directly on the control panel.
12.2 Replace control panel

Follow this instruction to replace the control panel.
Preparations and conditions:
• The system must be shut down.

• When the panel is mounted, software must be updated and settings performed accroding to
last step of the instruction.
12.2.1 Dismount the panel

Follow this instruction to dismount the control panel.
1. Open the control cabinet.
2. Pull out the power and signal cables.
Book No.9010183 02, rev. 2 75

12.2 Replace control panel 12 Control panel
3. Loosen the screws on the inside of the cabinet door.
7BeijerScrews
4. Hold the panel on the outside so it does not fall out. At the same time: Slide the brackets
and remove them. Then remove the panel.
7BeijerBracket
12.2.2 Mount the panel

Follow this instruction to mount the control panel.
1. Put the panel in place.
2. Hold the panel on the outside so it does not fall out. At the same time: Attach the brackets on
the inside by sliding them into place.
7BeijerBracket
76 Book No.9010183 02, rev. 2

12 Control panel 12.2 Replace control panel
3. Fasten the screws on the inside of the cabinet door.
7BeijerScrews
4. Open the small cover on the rear side. Make sure that all DIP switches are in position OFF.
7BeijerMODE
5. Connect the signal cable in the 10/100 port.
6. Connect the power cable in the 24V DC port.
7. Remove the laminated film, to avoid static electricity that could damage the terminal.
8. Make sure that the control panel is brought to ambient temperature before it is started. If
condensation forms, ensure that the operator panel is dry before connecting it to the power
outlet. Ensure that the voltage and polarity of the power source is correct.
9. Load new software to the panel according to instruction Update PLC software and Install
TA150 firmware in chapter 3. Operating instruction and control system description. Also
set communication according to Set control panel IP address and Set remote control panel
communication.
Book No.9010183 02, rev. 2 77

12.2 Replace control panel 12 Control panel
13 Remote control panel
(optional)
This section covers information on how to mount and connect communication components for the
The information in this instruction is also given in the Control cabinet / Circuit diagram in chapter 6.
Installation description and drawings.
13.1 Mount and connect network switch for remote

control panel
7 594060 RCP
Network switch and terminals
1. Ethernet ports (3 pieces)

2. 24 VDC port (connection to terminals connected
at delivery)
3. Network switch
4. Terminal (+ 24 V power connection)
5. Terminal (– 24 V power connection).
6. Terminal (grounding)
7. Fiber ports (2 pieces)
Book No.9010183 02, rev. 2 79

13.1 Mount and connect network switch for 13 Remote control panel (optional)
remote control panel
7 RemotPanelCon
Back of remote control panel, side view
• If used, a network switch (3) is installed at a location of your choice, near the position of the
• 24 VDC cables are not included in scope of supply. Use a cable with minimum cross section of
0.75 mm2, preferably halogen free and flexible.
• The remote control panel must have been mounted on a location of your choice. See Remote
control panel (optional) / Dimensional drawing in chapter 6. Installation description and drawings.
• Two wires are mounted between terminal and switch power contact (2) no 1=DC–, no 2=DC+,
cables are marked + and –.
• Prerequisites for cable length and cable types are stated in chapter 6. Installation description
and drawings, section Remote control panel integration (optional). Ethernet and fiber cable can
be used. This instruction is written for Ethernet, but if fiber is used use fiber cable and connect
them to the fiber ports instead of Ethernet ports.
• Switch off the PureBallast system and disconnect it from the power supply.
1. At the back of the remote control panel, fasten the Ethernet cable in Ethernet port 1. Fasten
the other end of the cable in the network switch’s Ethernet port number 1 (1).
2. Connect an Ethernet cable from the network switch near the remote control panel to the
network switch in the control cabinet (see position 1 in illustration on page 81). Also see cable
W501 in Control cabinet / Interconnection diagram.
3. If more than one remote control panel is installed, connect an Ethernet cable from Ethernet
port number 2 (1) in the network switch (near the remote control panel) to the second remote
control panel (or via a second network switch, if used).
4. Connect a 3 core cable from network switch terminals 4 (+), 5 (–) and 6 (GND) to the remote
control panel’s 24 VDC port (2).
5. Connect a 24 VDC power supply cable to the terminals 4 and 5 and 6.
80 Book No.9010183 02, rev. 2

13 Remote control panel (optional) 13.2 Mount and connect network switch for
remote control panel (retrofit)
13.2 Mount and connect network switch for remote

control panel (retrof t)
The information is only relevant if this option is added after installation. If remote control panel is
included in the original order, the network switch is already mounted in the control cabinet. .
7 591773 RI
Control cabinet, opened
1. Loosen the right end stop on the DIN rail at position (1).
2. Mount the network switch on the DIN rail at position (1).
3. Fasten the end stop to fixate the network switch at position (1).
4. On the PLC, disconnect the Ethernet cable (coming from the main control panel) from port IF2
and connect it to the network switch port: 1.
5. Connect an Ethernet cable in the IF2 on the PLC and connect the other cable end to the
network switch port: 2.
6. Connect wire 400 (DC–) to terminal 400 (3) and to network switch (1) terminal no: 1.
7. Connect wire 402 (DC+) to PLC terminal 15 (2) and to network switch (1) terminal no: 2.
8. Follow instruction Mount and connect network switch for remote control panel to connect
Book No.9010183 02, rev. 2 81

13.2 Mount and connect network switch for 13 Remote control panel (optional)
remote control panel (retrofit)
14 Control cabinet and lamp
drive cabinet (LDC)
This section covers maintenance information for the control cabinet.
14.1 Disassemble and assemble I/O system

This section covers maintenance information about the I/O system (X20 electronic modules). For
information about status and error indications, pleas see chapter 5. Alarms and fault finding.
1. Hold down the plastic clip on the top of the terminal block and pivot the block towards you.
7IO1_X025002A
2. Pull away the terminal block.
3. Hold down the triangle on the top of the I/O board and loosen the board.
7IO2_X025003A
Book No.9010183 02, rev. 2 83

14.1 Disassemble and assemble I/O system 14 Control cabinet and lamp drive cabinet (LDC)
4. Pull the board straight out (otherwise it can fasten in one of its guides).
7IO3_X025004A
5. Compare the part number of the new I/O board to the old board, to make sure it is correct.
6. If changing more than one board at a time, check with the electrical diagram to ensure that
the boards are mounted in the right places.
7. Mount the new I/O board by pressing it straight into place. Make sure the board is firmly in
place, otherwise it will be impossible to mount the cable terminal.
7IO4_X025005A
8. Remount the terminal block. Make sure the clip on the bottom of the block fastens properly in
place on the axel on the bus holder.
7IO5_X025007A
84 Book No.9010183 02, rev. 2

14 Control cabinet and lamp drive cabinet 14.2 Cable gland installation – General cables
(LDC)
9. Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in
the I/O board.
7IO6_X025006A
14.2 Cable gland installation – General cables

This section covers information about how to install the cables into the control cabinet and LDC
using the cable glands. Power cables to the LDC are installed according to instruction Cable gland
installation – Power cable to LDC.
Follow this instruction to mount cables into the cabinets.
1. Lubricate the inside surfaces of the frame with Roxtec Assembly Gel or equivalent, specially
in the corners.
7 Cable1
2. Insert the cables through the frame.
3. Adapt the modules, which are to hold cables.
4. Peel off layers until you achieve a 0.1-1.0 mm gap between the two module halves when
held against the cable.
Book No.9010183 02, rev. 2 85

14.2 Cable gland installation – General cables 14 Control cabinet and lamp drive cabinet (LDC)
7 Cable2
7 Cable3
5. Lubricate all modules thoroughly, both on the inside and the outside surfaces.
7 Cable4
6. Insert the modules from the back of the frame opening. If possible, start with the largest
modules.
7 Cable5
86 Book No.9010183 02, rev. 2

14 Control cabinet and lamp drive cabinet 14.3 Cable gland installation – Power
(LDC) cable to LDC
7. Tighten the compression unit firmly to seal the frame. Maximum 10 Nm. A good indication is
when the lubrication is squeezed out between the modules.
7 Cable6
14.3 Cable gland installation – Power cable to LDC

Follow this instruction to install the power cable to the LDC using the cable gland.
1. Adapt the seal to the cable by removing layers from the halves. The halves may not differ by
more than one layer.
7 LDC gland1
2. Achieve an approximate 0.1–1 mm gap between the halves when testing against the cable.
There shall be a visual gap.
7 LDC gland2
3. Lubricate thoroughly on the inside surfaces and sparsely on the outside of the seal.
Book No.9010183 02, rev. 2 87

14.3 Cable gland installation – Power cable 14 Control cabinet and lamp drive cabinet (LDC)
to LDC
4. Insert the halves one by one into the sleeve.
7 LDC gland8
5. Tighten the Allen screws crosswise. The seal will compress and seal the transit.
88 Book No.9010183 02, rev. 2

.
Spare parts catalogue

PureBallast 3.0 Flow 1000
Specification No. 9005247-01/3

Book No 9011878 02
Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB 2014-02-07

Original instructions
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1 Important information 5
2 Control Cabinet 6
2.1 Cabinet 10
2.2 I/O module 12
2.3 Relay module 14
3 Lamp Drive Cabinet 16

3.1 Cabinet 18
4 Control panel 34
5 Remote control panel - Network

switch 36
6 AOT reactor 38
6.1 AOT reactor JIS 42
6.2 Junction box 44
6.3 Junction box 46
6.4 Valve V201-19 and V201-20 48
6.5 Valve 50
7 Filter, RF10-35 52
7.1 Valve, V309-1 58
7.2 Electrical cabinet 60
8 Valve V201-3 and V201-9 - JIS

A350 62
9 Valve V201-32 and 403-35 64
10 Valve V212-31 - JIS A350 66
11 Valve, JIS A300 68
3
12 Flow transmitter, A350 70
13 CIP module 72
13.1Pump P320-1 and P321-5 76
13.2Valve 78
13.3Valve block 80
13.4Air distribution 82
14 Sampling device (QT201.1,

QT201.1) 84
15 Pressure monitoring device 86
16 Cross reference list 88
4
1 Important information
1 Important information
• State number of ordered parts. Note that the quantity in the tables do not states number of parts
delivered (only the how many of that parts that are included in the mother component).
• It is only possible to order parts included in the tables.
• Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with
non-original spare parts. We guarantee the quality and reliability of our products.
• This manual refers to unit number printed on the equipment name-plate.
• When ordering, refer to part number listed in this catalogue and serial number, described in
chapter 7. Service manual, section Serial number information.
Book No. 5
2 Control Cabinet
Machine unit number or
Subassembly description
9004429-
Ref Part No Description -80 Notes
Quantity
1 9006237 80 Cabinet 1 See page 10
3 9006852 01 Software, panel 1
4 595670 80 Panel 1
5 9006804 01 DIN-rail 35x15 1
6 9006805 01 DIN-rail 35x15 2
7 9006806 01 DIN-rail 35x15 1
8 221891 04 Lock nut 13
8.1 223101 47 Washer 13
9 582212 148 End stop (clip fix) 13
10 591103 60 Over current prot. Relay 1
10.1 591103 10 Auxiliary contact 1
11 591103 45 Breaker handles 1
12 582212 125 Power supply unit 1
13 9004299 04 Fuse 4
14 582212 67 Terminal, PIT 2,5-3PV 6
14.1 582212 60 Bus bar blue 1
15 582212 63 Terminal D-PIT 2,5-3L 1
16 591103 38 Contactor 1
16.1 591103 81 Relay, over current prot. 1
17 221701 03 Screw 4
18 9005006 80 I/O module 1 See page 12
19 582212 91 VIP-2, D 9SUB 2
20 582212 147 Patch panel 2
21 582212 104 Terminal PITTB 2,5 3
22 582212 102 Terminal PITTB 2,5 PE 1
23 582212 105 End plate D-PITTB 1
24 582212 104 Terminal PITTB 2,5 40
24.1 582212 171 Busbar 1/3/5-5, red 1 Connected: 11,15,19
24.2 582212 167 Busbar 20-5 Blue 1 Short end 15 pin, connected:
12,18,32,34,36,38,40
25 582212 105 End plate D-PITTB 1
26 582212 67 Terminal, PIT 2,5-3PV 4
26.1 582212 60 Bus bar blue 1
26.2 582212 03 Plug In Bridge 1
27 582212 63 Terminal D-PIT 2,5-3L 1
28 582212 168 Separating plate 2
29 582212 123 Power terminal block, 1
29.1 582212 86 Bus bar, blue 500mm 1 155mm
29.2 582212 87 Bus bar, red, 500mm 1 155mm
30 9002362 81 Relay module 3 See page 14
31 582221 90 PE Connection bar 1 245mm
32 582212 15 PE/SC Bar 1 500mm
33 593724 03 Distance screw 7
34 594009 03 Screw 5
36 583556 16 Cable channel 40x80 2
37 583556 17 Cable channel 40x80 1
38 9003522 07 Cable channel, 25x80 2
39 9003522 06 Cable channel, 25x80 1
41 591922 01 Cable seal 1
42 595361 01 Cable seal 1
44 223101 47 Washer 2 BRB 6,4x12x1,6 fzb
45 221803 02 Nut 2 M6M 6 fzb
46 582221 89 Cable fixing spiral 1
47 582356 18 Puschbutton switch 1
48 582212 155 Socket with USB 2
49 591103 36 Main breaker 1
51.1 596894 01 PE cable, 2,5mm² 1 L= approx. 500mm (door)
51.2 596894 01 PE cable, 2,5mm² 1 L= approx. 300mm (PE bar)
52 9009695 80 Fan 1
52A 9006853 01 Fan 1
6 Book No.
2 Control Cabinet
2690A
Book No. 7

9004429-
Quantity
52B 9009688 01 Filter
53 9009696 80 Air outlet 1
55 595673 01 Ethernet cable 1
68 9008672 80 Cable set 1
69 582212 122 Terminal block 3
70 582212 13 End plate 3
Z 597330 01 Cable seal
Z0.1 597331 01 Cable seal
8 Book No.
2 Control Cabinet
2690A
Book No. 9
2.1 Cabinet
9006237-
Quantity
2 9006246 01 Door 1
3 594009 01 Screw 6 MRX-Z5x6 fzb
4 26556 Spring washer 6 FBB 5,1 fzb
5 9006761 80 Mounting plate 1
6 70915 Spring washer 16
7 221891 05 Hexagon lock nut 12 M6M 8 fzb
8 221716 01 Screw 4
10 579385 01 T-handle 1
11 9003013 01 Rod Guide 2
12 593991 01 Latch 1
13 9003024 02 Rod for latching 2
15 223107 34 Spring washer 4 FBB 6,1 fzb
16 221891 04 Lock nut 4 M6M 6 fzb
19 593254 01 Retaining ring 1
22 221711 19 Screw 1 MC6S 6x25 fzb
23 593282 01 Washer 1 BRB 6,4x12x1,6 polyamide
24 221803 02 Nut 2 M6M 6 fzb
25 223101 73 Washer 1 BRB 6,7x16x1,5 fzb
26 593239 01 Nut 1
27 581688 01 Bracket 4
28 594488 01 Washer 4
29 221711 16 Screw 8 MC6S 6x16 fzb
30 223101 47 Washer 8 MRM 6,4x12x1,6 fzb
31 221891 04 Lock nut 8 M6M 6 fzb
32 587276 02 Washer 6
33 70560 Washer 6
34 221891 05 Hexagon lock nut 6 M6M 8 fzb
35 544465 04 Locking liquid 1 Loctite 270
10 Book No.
2.1 Cabinet 2 Control Cabinet
2718A
Book No. 11
2.2 I/O module

9005006-
Quantity
1 580986 67 PLC unit 1 Incl. locking plate.
1.1 597033 18 Interface module 1
1.2 580986 76 Communication module 1
1.3 580986 76 Communication module 1
2 580986 17 Bus module 11
3 580986 30 Supply Bus Module 1
4 580986 51 12 Digital Input 3
5 580986 08 4 Analogue input 2
6 580986 33 Output Module 1
7 580986 32 Supply Module 1
8 580986 59 12 Digital Output 1
9 580986 06 6 Relay output 4
10 580986 16 Terminal block 12-pin 12
12 580986 55 Compact flash card 1
12 Book No.
2.2 I/O module 2 Control Cabinet
2772A
Book No. 13
2.3 Relay module

9002362-
Quantity
1 582212 119 Interface relay, 24V 8
2 582212 120 Input adapter 1
3 582212 186 System cable 1
Z 582212 172 Relay, mini Spare part only
14 Book No.
2.3 Relay module 2 Control Cabinet
2692A
Book No. 15
3 Lamp Drive Cabinet

9004480-
Quantity
19 9005496 01 Lamp Power Supply 16
16 Book No.
3 Lamp Drive Cabinet
2774A
Book No. 17
3.1 Cabinet
9011549-
Quantity
2 9004211 01 Centrifugal fan 1
3 9004212 01 Inlet duct 1
4 9004213 01 Protection 1
6 9004214 01 Heat exchanger 1
7 590624 03 Temperature sensor 1
9 9004254 01 Check valve 1 Fully exchangable with 9008407.
9.2 595558 01 Wire 1
10 523127 04 Hexagon nipple 2
11 9004426 01 Hose 2
12 582356 30 Lamp green, compl. 1
13 582356 26 Signal lamp, White 1
14 582356 28 Button ill. blue, compl. 1
15 582356 27 Sign holder 3
19.1 582212 164 Phoenix Contact 16
20 582221 90 PE Connection bar 1 830mm
21 9006677 01 Filter 1
22 9004313 80 Main breaker 1
23 9005494 01 Transmitted handle kit 1
24 591103 46 Breaker door seal 1
26.1 591103 10 Auxiliary contact 16
27 591103 66 Bus bar 6
28 591103 64 Connection 3
29 591103 61 Self-res. short-circ. lim 3
30 582212 125 Power supply unit 1
31 9004299 04 Fuse 3
32 9004299 01 Relay safety 1
33 9004299 02 Relay safety 1
34 9004299 03 Relay safety 1
35 9006326 01 Temperature relay 1
36 582212 146 Interface relay, 24V 1
37 9004174 80 I/O module 1 See page 26
37.1 594728 01 Temperature sensor 1
38 9004507 80 Terminal block 1 See page 28
39 9004329 80 Liquid leakage amplifier 1
40 9004303 02 Sensor, liquid 1
41 582212 147 Patch panel 2
42 9004508 80 Terminal block 1 See page 30
43 582212 148 End stop (clip fix) 13
46 9004299 07 Terminal 3
47 582212 141 Cable holder 2
48 70560 Washer 3
49 221030 10 Screw 12
50 221803 02 Nut 5
51 221803 03 Nut 1
52 221891 01 Lock nut 2
53 221891 02 Nut 4
54 221891 04 Lock nut 4
55 221891 05 Hexagon lock nut 3
56 223101 03 Washer 2
57 223101 16 Washer 4
58 223101 17 Washer 1
59 223101 47 Washer 21
60 587276 02 Washer 3
18 Book No.
3.1 Cabinet 3 Lamp Drive Cabinet
2775A
Book No. 19

9011549-
Quantity
61 593724 03 Distance screw 6
62 594009 02 Screw 4
63 594009 03 Screw 3
64 594009 04 Screw 2
66 594009 07 Screw 2
67 9005626 01 Self-tapping screw 5
69 582212 181 Sc clamp SK 35 D 2
73 9008374 01 Igniter 2
74 9008382 80 Cable set 1 See page 32
76 582212 13 End plate 1
20 Book No.
2775A
Book No. 21
3.1.1 Cabinet
9003628-
Quantity
1 9005142 80 Cabinet 1
1A 591874 04 Seal 1 Upper LPS rack, left
1B 591874 05 Seal 1 Upper LPS rack, right
1C 9003031 01 Condensation outlet 2 Cabinet floor and heat exchanger floor
2 9005143 80 Door, RH 1
3 9005144 80 Door, LH 1
4 221803 02 Nut 12
5 223101 47 Washer 12
6 9005145 80 Stand 1
7 9008903 05 Washer 12
9 9003089 02 Vibration damper 2
10 223101 49 Washer 13x24x2,5 2
11 221726 10 Screw 2
12 9003394 01 Mounting plate 1
13 587276 02 Washer 15
15 221716 01 Screw 3
16 9003390 01 Bracket, fan 1
17 223101 47 Washer 6
18 221030 10 Screw 6
19 9003401 01 Sheet, heat exchanger 1
20 223101 47 Washer 3
21 221030 10 Screw 3
22 9003186 01 Plug 1
23 9003410 01 Sheet, heat exchanger 1
24 223101 47 Washer 9
25 221030 10 Screw 9
27 593287 01 Pop rivet, multi grip 3
28 9003113 01 Cable seal 1
29 9003114 02 Cable gland 2
30 9002947 01 Yoke 18
31 9002942 01 Stud bolt 36
33 223101 47 Washer 72
34 221030 02 Screw 36
35 221891 04 Lock nut 36
42 221891 04 Lock nut 17
42.1 223101 47 Washer 17
58 587276 01 Washer 8
59 221851 05 Cap nut 8
60 591889 01 Cable tie mount 3
62 593780 01 Key 1
63 9003186 02 Plug 2
64 9006316 01 Cover, fan 1
66 221030 10 Screw 3
67 223101 47 Washer 3
69 9006322 01 Sheet 2
70 9006519 01 Cover 1
72 221891 02 Nut 20
73 223101 41 Washer, 4,3x9x0,8 20
74 9008424 01 Protection 3
76 221851 05 Cap nut 5
77 587276 01 Washer 5
79 221891 04 Lock nut 2
80 223101 47 Washer 2
82 223101 47 Washer 7
83 221891 04 Lock nut 7
88 587276 01 Washer 17
89 221851 05 Cap nut 17
22 Book No.
2700A
Book No. 23

9003628-
Quantity
90 9009714 01 Sheet 1
91 221891 04 Lock nut 1
92 223101 47 Washer 1
Z 597330 01 Cable seal
Z0.1 597331 01 Cable seal
24 Book No.
2700A
Book No. 25
3.1.2 I/O module

9004174-
Quantity
1 580986 64 Bus Module 1
2 580986 17 Bus module 6
3 580986 62 Interface Module 1
4 580986 63 Bus Supply 1
5 580986 72 Communication module 1
6 597033 19 16 Digital input 1
7 580986 59 12 Digital Output 1
8 580986 08 4 Analogue input 1
9 580986 53 2 Analogue Output 1
10 580986 61 4 Analog Input (PT100) 1
11 580986 16 Terminal block 12-pin 6
12 580986 19 Locking Plate left 0 Included in pos:1
13 580986 20 Locking Plate right 0 Included in pos:1
14 597033 20 Terminal Block 16-pin 1
26 Book No.
2702A
Book No. 27
3.1.3 Terminal block

9004507-
Quantity
1 582212 67 Terminal, PIT 2,5-3PV 7
2 582212 64 Terminal PIT 2,5-3PE 1
3 582212 65 Terminal PIT 2,5-3L 2
4 582212 63 Terminal D-PIT 2,5-3L 1
5 582212 71 Plug In Bridge, FBS 3-5BU 1
6 582212 03 Plug In Bridge 1
28 Book No.
2704A
Book No. 29
3.1.4 Terminal block

9004508-
Quantity
3 582212 130 Support, L=95,5 1
5 582212 88 PIT 2,5 22
6 582212 89 D-ST2,5 1
7 582212 132 Sealable cover profile 2
8 582212 131 Support, L=150 2
9 582212 156 Terminal, PT 6 32
10 582212 157 End cover, D-PT 6 1
11 582212 133 Cover profile (AP-3) L=1m 1 Cut to 294 mm
12 582212 15 PE/SC Bar 1 Cut to 289 mm
13 582212 15 PE/SC Bar 1 Cut to 431 mm
15 582212 137 Sc clamp SK 20 9
16 582212 136 Sc clamp SK 14 1
30 Book No.
2705A
Book No. 31
3.1.5 Cable set

9008382-
Quantity
1 9008383 01 Cable, 70mm² 5
2 9008383 02 Cable, 35mm² 15
3 9008383 03 Cable, 2,5mm² 20
4 9008383 04 Cable, 2,5mm² 20
5 9008383 05 Cable, 2,5mm² 20
6 9008383 06 Cable, 2,5mm² PE 25
7 9008383 12 Cable, 25mm² PE 1
8 9008383 13 Cable, 6mm² PE 2
9 9008383 08 Cable, 1,5mm² 6
11 9008387 01 Cable, 0,75mm² 150
12 9008693 01 Cable, 2x2x0,5mm² 6
15 9004439 01 Cable 1
16 9008388 01 Cable, 2x1,5mm² 35
50 582221 99 Ferrite 2 on 595673 04
51 582221 100 Ferrite 2 On incomming LAN cable
32 Book No.
2377A
Book No. 33
4 Control panel
594060-
Quantity
1 595670 80 Panel 1
2 595728 01 Switch 1
5 582212 95 Terminal, PIT 2,5 TWIN 2
6 582212 96 Terminal, PIT 2,5 TWIN-PE 1
7 582212 04 End plate 1
8 582212 24 End stop 2
34 Book No.
4 Control panel
2311B
Book No. 35
5 Remote control panel - Network switch

594100-
Quantity
1 595728 01 Switch 1
3 597035 01 Cable-400 1
4 597035 02 Cable-402 1
36 Book No.
5 Remote control panel - Network switch
2312B
Book No. 37
6 AOT reactor
9002700-
Quantity
1 9002699 82 AOT reactor JIS 1 See page 42
2 9003748 80 Junction box 1 A-side
See page 44
3 9004960 80 Junction box 1 B-side
See page 46
4 221711 08 Screw 8
5 223101 32 Washer 8
7 9001357 03 Sensor 1
8 594412 92 Valve V201-19 and V201-20 1 V201-19
See page 48
8.1 594412 92 Valve V201-19 and V201-20 1 V201-20
See page 48
8.2 590667 01 V201-19 1
9 9011365 01 Hexagon head screw 32
10 223101 64 Washer 32
12 9006325 01 Thermometer, resistance 1 TT201-33
13 9006324 01 Temperature, switch 1 TS201-60
14 558663 04 Gasket washer 2
15 594171 01 Vibration limit switch 1 LS201-29
16 9005051 04 Cable 1 V201-19
16.1 9005051 07 Cable 1 V201-20
16.2 9005051 06 Cable 1 V320-4
16.3 9005051 08 Cable 1 V404-36
16.4 9005051 05 Cable 1 V321-2
17 9005052 01 Cable 1 GS201-19
17.1 9005052 05 Cable 1 GS201-20
17.2 9005052 07 Cable 1 QT201-50
17.3 9005052 10 Cable 1 TS201-60
17.4 9005052 09 Cable 1 TT201-33
17.5 9005052 08 Cable 1 LS201-29
18 526350 05 Plug 1
20 594413 80 Valve 1 V320-4
See page 50
20.1 594413 80 Valve 1 V321-2
See page 50
20.2 594413 80 Valve 1 V404-36
See page 50
21 2210463 03 Screw 12
22 223101 37 Washer 12
23 1761805 01 Safety valve, 6 bar 1 RV201-23
24 597049 01 Coupling, elbow 90 1
25 594707 02 Pipe 1
26 581534 01 Distributor 1
27 260321 25 Hexagon screw 2
28 592304 01 Plug 1
29 592304 02 Plug, 1/4 1
30 552801 50 Push-on connector 5
31 9004638 01 Clamp 1
32 2210296 02 Screw 1
33 223101 33 Washer 3
34 221803 27 Nut 1
35 9006320 80 Lamp cable 16 Marked acc. to circuit diagram. Incl.
cap, collet, gland and nut.
36 9006320 81 Lamp cable 16 Marked acc. to circuit diagram. Incl.
cap, collet, gland and nut.
37 595272 01 Tube, 6x1 mm 4
38 558710 02 Air Hose Nipple 5
39 597044 04 Cable 1
63 596103 01 Screw 4
95 554214 06 Cable tie 30
38 Book No.
6 AOT reactor
2688A
Book No. 39

9002700-
Quantity
96 544465 15 Pipe-Seal 1
Z 9009521 80 Lamp, spare set
ZA 9007810 80 UV lamp with contact 1
ZB 579380 01 O-ring, 15,1x2,7 2
Z0.1 594645 82 Quartz sleeve set
Z0.1A 9000738 02 Quartz sleeve 1
Z0.1B 599555 01 O-ring 2
40 Book No.
6 AOT reactor
2688A
Book No. 41
6.1 AOT reactor JIS

9002699-
Quantity
3 66169 Drive screw 8
6 9003326 01 Glass socket 32
7 221711 13 Screw 96
8 9002009 81 Lamp bush 32
9 9004878 80 Cap 32
10 9002860 01 Nut 32
11 9001098 01 Blind flange 1
12 9001897 01 O-ring 1
13 221036 02 Screw 10
14 223101 33 Washer 10
15 526350 05 Plug 1
19 9001539 01 Cable bracket 8
20 221711 23 Screw 16
21 9003669 01 Bottom bracket 2
22 221040 04 Screw 16
23 41456 Washer 24
24 221035 06 Screw 4
25 70560 Washer 24
26 9003661 01 Stay 2
27 221035 36 Screw 12
28 9003662 01 Plate 1
29 2210295 03 Screw 1
30 223101 17 Washer 2
31 9003672 01 Upper bracket 2
32 221035 03 Screw 8
33 9004889 01 Lifting bracket 1
33A 9004886 80 Bracket 1
34 221040 55 Screw 4
35 35120 Nut 4
36 9007794 01 Cable rail 2
38 9009416 01 Cable rail 2
39 221031 21 Screw 4
40 223101 32 Washer 8
41 221803 28 Nut 4
42 Book No.
6.1 AOT reactor JIS 6 AOT reactor
2685A
Book No. 43
6.2 Junction box

9003748-
Quantity
1 9004825 80 Enclosure 1
3 582212 88 PIT 2,5 28 Marked acc. to interconnection diagram.
5 582212 154 Busbar 5-5 Bu 1 400
6 582212 70 Plug In Bridge, FBS 3-5 1 402
7 582212 89 D-ST2,5 1
11 582212 151 Socket 6
12 582212 150 Socket 5
18 9003031 01 Condensation outlet 1
19 589569 21 Cable Gland EMC M32 2
20 589569 44 Counter nut EMC M32 2
22 582356 26 Signal lamp, White 1
25 582356 30 Lamp green, compl. 1
44 Book No.
6.2 Junction box 6 AOT reactor
2679A
Book No. 45
6.3 Junction box

9004960-
Quantity
1 9004844 80 Enclosure 1
3 582212 156 Terminal, PT 6 32 Marked acc. to interconnection diagram.
4 582212 157 End cover, D-PT 6 1
5 9003031 01 Condensation outlet 1
6 589569 59 Cable gland EMC-brush M40 4
7 9004959 01 Insert, 8x6 mm 4
9 589569 21 Cable Gland EMC M32 4
46 Book No.
6.3 Junction box 6 AOT reactor
2680A
Book No. 47
6.4 Valve V201-19 and V201-20

594412-
Quantity
1 576886 26 Valve, A350 1 Lug type
2 576075 05 Air actuator, DA551 1
3 576071 01 Pilot valve 1
4 585976 01 Coil, 24 V DC 1
5 594410 01 Valve connector 1
6 583012 01 Throttle valve, 1/4 2
8 9009912 01 Sensor 1
9 595215 01 Plate 1
Z 576075 65 Actuator spare part kit, DA/SR 551
48 Book No.
6.4 Valve V201-19 and V201-20 6 AOT reactor
2686A
Book No. 49
6.5 Valve
594413-
Quantity
1 590037 01 Valve, DN32 1
2 576075 21 Air actuator, SR101 1
3 576071 01 Pilot valve 1
4 585976 01 Coil, 24 V DC 1
5 594410 01 Valve connector 1
6 583012 01 Throttle valve, 1/4 2
Z 576075 71 Actuator spare part kit, DA/SR 101 1
50 Book No.
6.5 Valve 6 AOT reactor
2330A
Book No. 51
7 Filter, RF10-35
*=On request only, contact your local Alfa Laval representative

9006973-
Ref Part No Description -80* Notes
Quantity
11 9006822 02 Safety valve, 8 bar 1
11.5 9000396 55 Union nut 1
12 9000396 51 Tube 1 0,5m
13 9006771 02 2/2-way piston valve 11
14 9000396 92 Double nipple 1
15 9000397 06 O-ring 81.2 x 5.33 - NBR 1
17 9000394 04 Protective box RF10-35 RA 1
18 9000394 63 Sacrificial anode 1
18.5 9000396 12 Extension RF10 vent 200 L 1
19 9000398 51 Litz wire VDE0281 H07V-K 1 1,0m
19.1 9000398 50 Cable shoe DIN46235 - 8 - 22
19.2 9000398 33 Washer ISO7089-8 - 200 HV 20
19.3 9000398 21 Hex-screw ISO 4017-M8 x 2 18
19.4 9000398 45 Stud screw DIN939-M 8 x 9 2
19.5 9000398 11 Hex-nut ISO 4032-M8 4
21 9000395 42 Drive shaft RF10-30/35 1
23 9000395 20 Locking ring DIN471 - 35 3
24 9000395 21 Washer RF3-3/4 1
25 9000395 22 Washer RF3-3/4 bearing bu 1
26 9000395 23 DUB-bearing - id =3 5, ad 2
27 9000395 24 Support ring spiral sprin 1
28 9000395 25 Quad-ring - 32.92 x 39.98 1
29 9000395 26 Washer RF3-3/4 upper driv 1
30 9000395 62 Intermediate shaft RF10-3 1
31 9000395 63 Lower drive shaft RF10-30 1
32 9000395 27 Washer RF3-3/4 Lower driv 1
33 9000395 28 Lower bearing bush RF3-3/ 1
34 9000395 29 Nut RF3-3/4 1
34.5 9000395 29 Nut RF3-3/4 1
35 9000395 32 DUB-bearing - id = 50, ad 2
36 9000398 09 Cylinder screw ISO 4762- 2
37 9000395 34 Washer RF3-3/4 lever arm 1
38 9000395 74 Lever arm 1
39 9000398 08 Cylinder screw ISO 4762- 4
39.6 9000394 24 Upper plate RF10-35 compl 1
39.7 9000394 45 Lower plate 1
39.8 9000398 64 Cylinder pin 1
39.9 9000398 65 Cylinder pin 1
40 9000395 84 Sleeve 1
40.5 9000398 72 Hex screw 2
41 9000397 20 O-ring 1
51 9000395 51 Coupling bush RF10-25/30 1
52 9000397 07 O-Ring 113.67 x 5.33 1
53 9000397 07 O-Ring 113.67 x 5.33 1
61 9000398 93 Cylinder pin 1
65 9000396 96 Coupling 2
65.3 9000396 37 Manometer connection 2
65.5 9000396 97 Coupling 2
68 9000396 02 Blind rivet ISO 15983 - 3 3
70 9000396 72 Plate Inlet - English 1
70.5 9000396 77 Plate 1
71 9000396 73 Plate Outlet - English 1
71.5 9000396 74 Plate Draining - English 1
72 9000396 75 Plate Backflushline - Eng 1
72.5 9000396 76 Plate Dilute - English 1
73 9000398 46 Grooved drive stud ISO 87 12
74 9000396 30 Ring bolt DIN580 - M20 3
75 9000396 04 Cable tape Betz -TYB23M n 16
76 9000396 21 Sticker "directional arro 1
52 Book No.
7 Filter, RF10-35
2693A
Book No. 53

9006973-
Quantity
77 9000396 19 Screw cap OBO Thom. u. B 8
81 9000396 13 Hose - PAN - 6 x 1 Bl* 1 3,0m
82 9000396 24 T-connection QST-6 12
83 9000396 63 Fixing plate 1
83.5 9000398 02 Cylinder screw ISO 4762 - 4
83.6 9000398 40 Spring ring DIN127-A 8 4
83.7 9000398 11 Hex-nut ISO 4032-M8 4
83.8 9000398 59 Thread rod 2
84 9000398 01 Cylinder screw ISO 4762 - 8
85 9000396 52 Tube 1 3,0m
85.5 9000398 92 Screw-in connector 3
86 9000396 57 T-connection 1
86.5 9000396 14 Connection ISO8438-1-SWO 1
87 9000396 58 Connection 1
87.5 9000396 59 Clamp 1
88 9000398 20 Hex-screw ISO 4017 M 6 x 8
88.5 9000398 10 Hex-nut ISO 4032-M 6 8
88.6 9000398 42 Spring ring DIN 127-B6 8
89 9000396 91 Cable channel 1
89.1 9000396 50 Fixing bracket piping RF1 1
89.2 9000396 41 Fixing bracket piping 1
89.3 9000396 54 Pipe nut 1
89.6 9000396 53 Pipe 1 2m
89.8 9000396 34 Pipe clamp 25-28 mm M8/M1 2
91 9006769 02 Gear motor 1
92 9000395 39 Paralel key DIN 6885 - A 1
95 9000395 85 Proximity switch 3
112 9000398 03 Cylinder screw ISO 4762 - 4
113 9000398 41 Spring ring DIN127-B 10 4
113.5 9000398 02 Cylinder screw ISO 4762 - 4
114 9000398 40 Spring ring DIN127-A 8 4
114.5 9000398 11 Hex-nut ISO 4032-M8 4
120 9000395 33 Control plate 1
120.5 9000395 81 Washer RF10-30/35 bored 1
121 9000398 32 Washer ISO7089-3 200 HV 2
121.5 9000398 07 Cylinder screw ISO4762-M 2
122 9000395 45 Saftey plate 1
126 9000396 29 Warning sticker Hein 1 pc 1
130 9000394 15 Cover 1
140 9000394 120 Vessel upper part 1
145 9000394 50 Vessel lower part 1
155 9000394 91 Reducer JIS A100-A80 LH 1
155 9000394 92 Reducer JIS A100-A80 RH 1
155.5 9000394 94 Reducer 1
155.6 9000398 38 Lock screw VSTI G 1 1/2-E 1
155.7 9000398 91 Lock screw 1
156.5 9000394 69 Elbow 1
157 9000398 18 Hex-screw 4
157.5 9000398 90 Washer 4
158 9000397 22 Sealing 1
160.5 9000396 89 Blind flange 1
161 9000398 77 Hex-screw 4
161.5 9000398 78 Hex-screw 4
162 9000398 67 Washer 4
162.5 9000397 22 Sealing 1
163 9000396 85 Drain plug 1
167.5 9000396 90 Blind flange 2
168 9000398 97 Hex-screw 8
168.5 9000398 17 Hex-nut 8
169 9000398 90 Washer 8
54 Book No.
7 Filter, RF10-35
2693A
Book No. 55

9006973-
Quantity
169.5 9000397 21 Sealing 2
170 9000398 80 Hex-screw 20
171 9000398 81 Hex-screw 20
172 9000398 89 Washer 80
173 9000398 16 Hex-nut 40
177 9000397 15 Sealing 4
178 9000398 82 Hex-screw 8
178.1 9000398 88 Washer 8
178.2 9000398 94 Hex-nut 8
178.5 9000398 83 Hex-screw 8
179 9000398 95 Hex-nut 8
180 9000398 87 Washer 16
183 9000395 86 Distance piece 1
184 9000398 84 Hex-screw 8
186 9000398 43 Spring ring 8
188 9000396 71 Fixing plate for Control 2
189 9000397 17 Sealing 1
189.5 9000397 19 Sealing 1
190 9007128 80 Valve, V309-1 1 See page 58
191 9000398 85 Hex-screw 4
191.5 9000398 95 Hex-nut 4
192 9000398 87 Washer 8
200 9007005 83 Electrical cabinet 1 See page 60
203 9007007 01 Pressure transmitter 3
301 9000395 83 Filter element 11
302 9000397 08 O-ring 72.62 x 3.53* 11
303 9000397 09 O-ring 110.72 x 3.53* 11
Z 9007098 83 Sealing kit
Z0.1 9007100 83 Filter element kit
Z0.2 9007099 80 Proximity switch kit
56 Book No.
7 Filter, RF10-35
2693A
Book No. 57
7.1 Valve, V309-1

9007128-
Quantity
1 9000394 141 Butterfly valve 1
2 9000394 144 Actuator 1
16 9000396 08 Coupling M12 x 1, 5-pole, 1
85.5 9000398 92 Screw-in connector 1
193 9000396 01 3/2-Way valve MND310701 G 1
193.1 9000396 93 Coil 1
194 9000396 11 Exhaust throttle valve -G 1
196 9000396 07 Control plate RF3-x-EPT R 1
197 9000398 04 Cylinder screw ISO 4762-M 2
58 Book No.
7.1 Valve, V309-1 7 Filter, RF10-35
2698A
Book No. 59
7.2 Electrical cabinet

9007005-
Quantity
1 9000396 95 Cabinet 1 Incl. glands and door
2 9007239 01 Display 1
3 9007239 02 Main switch 1
4 9007239 03 Power supply 1
5 9007239 04 CPU 1
6 9007239 05 Digital output 1
7 9007239 06 Relay 2
8 9007239 07 Prot. switch 1
9 9007239 08 Contactor 1
10 9007239 23 Terminal 19
11 9007239 11 PE terminal 7
12 9007239 10 Terminal 4
13 9007239 12 Fuse 4
15 9007239 13 Sensor box 2
Z 9007239 24 Fuse
Z0.1 9007239 25 Fuse
Z0.2 9007239 26 Fuse
60 Book No.
7.2 Electrical cabinet 7 Filter, RF10-35
2752A
Book No. 61
8 Valve V201-3 and V201-9 - JIS A350

9007170-
Quantity
1 9007167 24 Valve, A350 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1
5 9007192 01 Throttle valve, 1/4 2
6 9007193 01 Actuator cable 1
7 9007196 02 Bracket 1
8 9007186 01 Switch box 1
19 587927 07 Locking device, AL79 451 1
Z 9007197 01 Gasket
62 Book No.
8 Valve V201-3 and V201-9 - JIS A350
2710A
Book No. 63
9 Valve V201-32 and 403-35

9007172-
Ref Part No Description -89 -82 Notes
Quantity
1 9007167 17 Valve, A80 1
1 9007167 24 Valve, A350 1
2 9007166 01 Air actuator, AT 101U 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1 1
5 9007192 01 Throttle valve, 1/4 2 2
6 9007193 01 Actuator cable 1 1
7 9007196 01 Bracket 1
7 9007196 02 Bracket 1
8 9007186 01 Switch box 1 1
22 9007198 01 Serial no. plate 1
23 595558 01 Wire 1
Z 9007184 02 Insulate plate
Z 9007197 01 Gasket
64 Book No.
9 Valve V201-32 and 403-35
2714A
Book No. 65
10 Valve V212-31 - JIS A350

9007168-
Quantity
1 9007167 24 Valve, A350 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1
5 9007192 01 Throttle valve, 1/4 2
6 9007193 01 Actuator cable 1
7 9007196 02 Bracket 1
8 9007186 01 Switch box 1
12 9005789 03 Gearbox 1
13 552801 02 Push-in connector 1
14 1764011 02 Silencer 1
15 592304 02 Plug, 1/4 1
16 569035 05 Flexible pipe, PA12, 8/6 1
17 580758 06 Push-In Fittings 1
18 9005792 02 Handwheel 1
Z 9007197 01 Gasket
66 Book No.
10 Valve V212-31 - JIS A350
2716A
Book No. 67
11 Valve, JIS A300

9007174-
Quantity
1 9007167 23 Valve, A300 1
2 9007166 06 Air actuator, AT 451U 1
7 9007196 02 Bracket 1
9 9007191 01 Mounting kit, Positioner 1
10 9007190 01 Positioner 1
16 569035 05 Flexible pipe, PA12, 8/6 1
27 9007200 01 Manifold 1
28 9007201 01 Filter 1
30 523127 01 Hexagon nipple 1
31 592304 02 Plug, 1/4 1
68 Book No.
11 Valve, JIS A300
2712A
Book No. 69
12 Flow transmitter, A350

576179-
Quantity
1 585345 62 Sensing tube, A350 1
2 586907 01 Transmitter, MAG 5000 1
5 595229 01 Cable gland 1
70 Book No.
12 Flow transmitter, A350
2363A
Book No. 71
13 CIP module
9002547-
Quantity
1 9003450 01 Frame complete 1
2 590414 01 Tank 1
3 9004533 80 Pump P320-1 and P321-5 2 See page 76
4 9002825 80 Valve 6 See page 78
5 9003730 01 Valve housing 3
6 9002915 01 Check valve 2
7 9003732 01 O-ring 6
8 590313 01 Valve, angle seat 1
9 590476 01 Nipple, ISO-R 3/4-1/2 1
10 9005046 01 Backflow preventer 1
11 589526 07 U-bolt clamp, c-c 56,5 1
12 526350 06 Plug 1
15 9003172 80 Valve block 1 See page 80
16 9004479 80 Filter regulator 1
18 9003514 01 Speed controller 2
19 9004517 01 Reducer 2
20 9002962 01 Pipe #1 1
21 9002963 01 Pipe #2 1
22 9004237 01 Pipe #3 1
23 9003935 01 Pipe #4 2
24 9002964 01 Pipe #5 1
25 9002584 01 Pipe #6 1
26 9002586 01 Pipe #7 2
27 9003570 01 Pipe #8 4
28 9003949 01 Pipe #9 1
29 9002589 01 Pipe #10 1
30 9003792 01 Pipe #11 2
31 9002591 01 Pipe #12 1
32 9003837 01 Pipe #13 2
33 9004247 01 Pipe #14 1
34 9002592 01 Pipe #15 1
35 9003851 01 Pipe #16 1
36 9003853 01 Pipe #17 1
37 9003854 01 Pipe #18 1
38 9003863 01 Pipe #19 1
39 9003886 01 Pipe #20 1
40 9003888 01 Pipe #21 1
41 592649 01 Nipple 1
42 591675 01 Hose, 32 1
43 569038 05 Hose, 32 1
44 592665 01 Hose, 25 1
45 9003574 01 O-ring 6
46 9005743 01 Pipe clamp 5
47 599223 03 Hose clamp 38-50 10
48 599223 02 Hose clamp 32-44 3
49 592676 05 Insulation sheet, 10mm 4
50 592676 07 Insulation sheet, 5mm 7
51 592790 01 Insulation sheet 1
53 221716 02 Screw 2
54 221711 17 Screw 2
55 221701 04 Screw 4
56 223101 41 Washer, 4,3x9x0,8 4
57 221711 16 Screw 16
58 223101 47 Washer 16
59 587276 02 Washer 2
60 27345 Nut, M8 12
61 70560 Washer 19
62 9005147 01 Pipe #22 1
63 9005394 80 Air distribution 1 See page 82
72 Book No.
13 CIP module
2605A
Book No. 73

9002547-
Quantity
64 221040 53 Screw 5
65 590539 03 Clip list 1
66 548152 03 Washer 5
Z 590414 02 Tanck screw cap
74 Book No.
13 CIP module
2605A
Book No. 75
13.1 Pump P320-1 and P321-5

9004533-
Quantity
1 9004533 01 Pump 1
Z 9004587 80 Spare part set Incl. O-rings, diaphragm, ball, muffler
indicated in dwg.
Z0.1 9004588 80 Spare part set Incl. air valve, sealings and O-rings,
indicated in dwg.
76 Book No.
13.1 Pump P320-1 and P321-5 13 CIP module
2606A
Book No. 77
13.2 Valve
9002825-
Quantity
Z 9003574 01 O-ring
78 Book No.
13.2 Valve 13 CIP module
2609A
Book No. 79
13.3 Valve block

9003172-
Quantity
1 9003172 01 Valve block side 1
2 9003172 02 Valve block 5
3 9003172 03 Valve block side 1
4 9003172 04 Valve 2x 3/2 5
5 9003172 05 Connection box 1
6 9003172 06 Cable gland NPT3/4 1
7 9003172 07 Plug 1
8 9003172 08 Plug 1
9 9003172 09 O-ring 1
10 9003172 10 Sign bracket 2
11 9003172 11 Sign plate 1
13 9003172 12 Cable gland, M32 1
80 Book No.
13.3 Valve block 13 CIP module
2607A
Book No. 81
13.4 Air distribution

9005394-
Quantity
1 569035 05 Flexible pipe, PA12, 8/6 1
2 569035 01 Flexible pipe, PA12, 6/4 1
3 552801 50 Push-on connector 6
4 558710 01 Air Hose Nipple 1
5 580758 06 Push-In Fittings 2
82 Book No.
13.4 Air distribution 13 CIP module
2608A
Book No. 83
14 Sampling device (QT201.1, QT201.1)

589745-
Ref Part No Description -90 -91 Notes
Quantity
1 591662 80 Adaptor pipe 1 1
2 591667 01 Pitot tube 1 1
3 1765908 07 Gasket 2 2
4 2210462 30 Screw 4 4 M6S 16x70 fzb
5 221803 34 Nut, M16 4 4 M6M 16 fzb
6 70490 Washer 16 16 BRB 17x30x3 fzb
7 591631 01 Blind flange, DN50/A50 1 1
8 591628 81 Valve, manual A50 1 1
9 2210462 28 Screw 8 M6S 16x45 fzb
9 2210462 45 Screw, M16x45 8 M6S 16x45 fzb
10 590667 27 Q201.1 1
10 590667 28 Q201.2 1
11 556563 01 Wire 1 1
14 591666 01 Rod 1 1
84 Book No.
14 Sampling device (QT201.1, QT201.1)
2780A
Book No. 85
15 Pressure monitoring device

9006076-
Quantity
1 9007231 01 Needle valve, DN15 1
2 526336 04 Nipple 3
3 9006075 01 Manifold 1
4 9001406 82 Pressure transmitter kit 1 Incl. pressure transmitter and connector
5 543054 03 Pressure gauge 1
6 9006822 02 Safety valve, 8 bar 1
7 546600 02 Pipe union 1
9 595558 01 Wire 4
86 Book No.
15 Pressure monitoring device
2709A
Book No. 87
16 Cross reference list
+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
1761805 01 38 23 221891 04 18 54 523127 04 18 10

1764011 02 66 14 221891 04 22 35 526336 04 86 2
1765908 07 84 3 221891 04 22 42 526350 05 38 18
2210295 03 42 29 221891 04 22 79 526350 05 42 15
2210296 02 38 32 221891 04 22 83 526350 06 72 12
221030 02 22 34 221891 04 23 91 543054 03 86 5
221030 10 18 49 221891 04 6 8 544465 04 10 35
221030 10 22 18 221891 04 10 16 544465 15 39 96
221030 10 22 21 221891 04 10 31 546600 02 86 7
221030 10 22 25 221891 05 18 55 548152 03 73 66
221030 10 22 66 221891 05 22 8 552801 02 66 13
221031 21 42 39 221891 05 22 14 552801 02 68 13
221035 03 42 32 221891 05 10 7 552801 02 68 24
221035 06 42 24 221891 05 10 34 552801 50 38 30
221035 36 42 27 223101 03 18 56 552801 50 82 3
221036 02 42 13 223101 16 18 57 554214 06 38 95
221040 04 42 22 223101 17 18 58 556563 01 84 11
221040 53 73 64 223101 17 42 30 558663 03 38 19
221040 55 42 34 223101 32 38 5 558663 03 42 16
2210462 28 84 9 223101 32 42 40 558663 04 38 14
2210462 30 84 4 223101 33 38 33 558710 01 82 4
2210462 45 84 9 223101 33 42 14 558710 02 38 38
2210463 03 38 21 223101 37 38 22 569035 01 82 2
221701 03 6 17 223101 41 22 73 569035 05 66 16
221701 04 72 55 223101 41 72 56 569035 05 68 16
221711 08 38 4 223101 47 18 59 569035 05 82 1
221711 13 42 7 223101 47 22 5 569038 05 72 43
221711 16 72 57 223101 47 22 17 576071 01 48 3
221711 16 10 29 223101 47 22 20 576071 01 50 3
221711 17 72 54 223101 47 22 24 576075 05 48 2
221711 19 10 22 223101 47 22 33 576075 21 50 2
221711 23 42 20 223101 47 22 42.1 576075 65 48 Z
221716 01 22 15 223101 47 22 67 576075 71 50 Z
221716 01 10 8 223101 47 22 80 576886 26 48 1
221716 02 72 53 223101 47 22 82 579380 01 39 ZB
221726 10 22 11 223101 47 23 92 579385 01 10 10
221803 02 18 50 223101 47 6 44 580758 06 66 17
221803 02 22 4 223101 47 72 58 580758 06 82 5
221803 02 6 45 223101 47 6 8.1 580986 06 12 9
221803 02 10 24 223101 47 10 30 580986 08 12 5
221803 03 18 51 223101 49 22 10 580986 08 26 8
221803 27 38 34 223101 64 38 10 580986 16 12 10
221803 28 42 41 223101 73 10 25 580986 16 26 11
221803 34 84 5 223107 34 10 15 580986 17 12 2
221851 05 22 59 260321 25 38 27 580986 17 26 2
221851 05 22 76 26556 10 4 580986 19 26 12
221851 05 22 89 27345 72 60 580986 20 26 13
221891 01 18 52 35120 42 35 580986 30 12 3
221891 02 18 53 41456 42 23 580986 32 12 7
221891 02 22 72 523127 01 68 30 580986 33 12 6
88 Book No.
Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
580986 51 12 4 582212 150 44 12 582356 27 18 15

580986 53 26 9 582212 151 44 11 582356 28 18 14
580986 55 12 12 582212 154 44 5 582356 30 18 12
580986 59 12 8 582212 155 6 48 582356 30 44 25
580986 59 26 7 582212 156 30 9 583012 01 48 6
580986 61 26 10 582212 156 46 3 583012 01 50 6
580986 62 26 3 582212 157 30 10 583556 16 6 36
580986 63 26 4 582212 157 46 4 583556 17 6 37
580986 64 26 1 582212 15 30 12 585345 62 70 1
580986 67 12 1 582212 15 30 13 585976 01 48 4
580986 72 26 5 582212 15 6 32 585976 01 50 4
580986 76 12 1.2 582212 163 18 19.2 586907 01 70 2
580986 76 12 1.3 582212 164 18 19.1 587276 01 22 58
581534 01 38 26 582212 165 18 19.3 587276 01 22 77
581688 01 10 27 582212 167 6 24.2 587276 01 22 88
582212 03 28 6 582212 168 6 28 587276 02 18 60
582212 03 6 26.2 582212 171 6 24.1 587276 02 22 13
582212 04 34 7 582212 172 14 Z 587276 02 72 59
582212 102 6 22 582212 181 19 69 587276 02 10 32
582212 104 6 21 582212 186 14 3 587927 07 62 19
582212 104 6 24 582212 24 34 8 587927 07 66 19
582212 105 6 23 582212 60 6 14.1 587927 07 68 19
582212 105 6 25 582212 60 6 26.1 589526 07 72 11
582212 119 14 1 582212 63 6 15 589569 21 44 19
582212 120 14 2 582212 63 28 4 589569 21 46 9
582212 122 19 75 582212 63 6 27 589569 44 44 20
582212 122 30 4 582212 64 28 2 589569 44 46 10
582212 122 44 4 582212 65 28 3 589569 45 46 8
582212 122 7 69 582212 67 6 14 589569 59 46 6
582212 123 6 29 582212 67 28 1 590037 01 50 1
582212 125 6 12 582212 67 6 26 590313 01 72 8
582212 125 18 30 582212 70 44 6 590414 01 72 2
582212 130 30 3 582212 71 28 5 590414 02 73 Z
582212 131 30 8 582212 86 6 29.1 590476 01 72 9
582212 132 30 7 582212 87 6 29.2 590539 03 73 65
582212 133 30 11 582212 88 30 5 590624 03 18 7
582212 136 30 16 582212 88 44 3 590667 01 38 8.2
582212 137 30 15 582212 89 30 6 590667 27 84 10
582212 13 19 76 582212 89 44 7 590667 28 84 10
582212 13 7 70 582212 91 6 19 591103 10 6 10.1
582212 141 18 47 582212 95 34 5 591103 10 18 26.1
582212 146 18 36 582212 96 34 6 591103 36 6 49
582212 147 18 41 582221 100 32 51 591103 38 6 16
582212 147 6 20 582221 89 6 46 591103 45 6 11
582212 148 18 43 582221 90 18 20 591103 46 18 24
582212 148 28 7 582221 90 6 31 591103 54 18 26
582212 148 30 1 582221 99 32 50 591103 60 6 10
582212 148 44 2 582356 18 6 47 591103 60 18 25
582212 148 46 2 582356 26 18 13 591103 61 18 29
582212 148 6 9 582356 26 44 22 591103 64 18 28
Book No. 89
591103 66 18 27 595361 01 6 42 9000395 21 52 24

591103 81 6 16.1 595558 01 18 9.2 9000395 22 52 25
591628 81 84 8 595558 01 64 23 9000395 23 52 26
591631 01 84 7 595558 01 86 9 9000395 24 52 27
591662 80 84 1 595670 80 6 4 9000395 25 52 28
591666 01 84 14 595670 80 34 1 9000395 26 52 29
591667 01 84 2 595673 01 7 55 9000395 27 52 32
591675 01 72 42 595673 02 34 3 9000395 28 52 33
591874 04 22 1A 595673 03 36 2 9000395 29 52 34
591874 05 22 1B 595673 04 32 14 9000395 29 52 34.5
591889 01 22 60 595728 01 34 2 9000395 32 52 35
591922 01 6 41 595728 01 36 1 9000395 33 54 120
592304 01 38 28 596103 01 38 63 9000395 34 52 37
592304 02 38 29 596894 01 6 51.1 9000395 39 54 92
592304 02 66 15 596894 01 6 51.2 9000395 42 52 21
592304 02 68 31 597033 18 12 1.1 9000395 45 54 122
592649 01 72 41 597033 19 26 6 9000395 51 52 51
592665 01 72 44 597033 20 26 14 9000395 62 52 30
592676 05 72 49 597035 01 36 3 9000395 63 52 31
592676 07 72 50 597035 02 36 4 9000395 74 52 38
592790 01 72 51 597044 04 38 39 9000395 81 54 120.5
593239 01 10 26 597049 01 38 24 9000395 83 56 301
593254 01 10 19 597330 01 23 Z 9000395 84 52 40
593282 01 10 23 597330 01 7 Z 9000395 85 54 95
593287 01 22 27 597331 01 23 Z0.1 9000395 86 56 183
593724 03 19 61 597331 01 7 Z0.1 9000396 01 58 193
593724 03 6 33 599223 02 72 48 9000396 02 52 68
593780 01 22 62 599223 03 72 47 9000396 04 52 75
593991 01 10 12 599555 01 39 Z0.1B 9000396 07 58 196
594009 01 10 3 66169 42 3 9000396 08 58 16
594009 02 19 62 70490 84 6 9000396 11 58 194
594009 03 19 63 70560 18 48 9000396 12 52 18.5
594009 03 6 34 70560 42 25 9000396 13 54 81
594009 04 19 64 70560 72 61 9000396 14 54 86.5
594009 07 19 66 70560 10 33 9000396 19 54 77
594171 01 38 15 70915 10 6 9000396 21 52 76
594410 01 48 5 9000394 04 52 17 9000396 24 54 82
594410 01 50 5 9000394 120 54 140 9000396 29 54 126
594412 92 38 8 9000394 141 58 1 9000396 30 52 74
594412 92 38 8.1 9000394 144 58 2 9000396 34 54 89.8
594413 80 38 20 9000394 15 54 130 9000396 37 52 65.3
594413 80 38 20.1 9000394 24 52 39.6 9000396 41 54 89.2
594413 80 38 20.2 9000394 45 52 39.7 9000396 50 54 89.1
594488 01 10 28 9000394 50 54 145 9000396 51 52 12
594645 82 39 Z0.1 9000394 63 52 18 9000396 52 54 85
594707 02 38 25 9000394 69 54 156.5 9000396 53 54 89.6
594728 01 18 37.1 9000394 91 54 155 9000396 54 54 89.3
595215 01 48 9 9000394 92 54 155 9000396 55 52 11.5
595229 01 70 5 9000394 94 54 155.5 9000396 57 54 86
595272 01 38 37 9000395 20 52 23 9000396 58 54 87
90 Book No.
9000396 59 54 87.5 9000398 40 54 83.6 9002825 80 72 4

9000396 63 54 83 9000398 40 54 114 9002860 01 42 10
9000396 71 56 188 9000398 41 54 113 9002915 01 72 6
9000396 72 52 70 9000398 42 54 88.6 9002942 01 22 31
9000396 73 52 71 9000398 43 56 186 9002947 01 22 30
9000396 74 52 71.5 9000398 45 52 19.4 9002962 01 72 20
9000396 75 52 72 9000398 46 52 73 9002963 01 72 21
9000396 76 52 72.5 9000398 50 52 19.1 9002964 01 72 24
9000396 77 52 70.5 9000398 51 52 19 9003013 01 10 11
9000396 85 54 163 9000398 59 54 83.8 9003024 02 10 13
9000396 89 54 160.5 9000398 64 52 39.8 9003031 01 22 1C
9000396 90 54 167.5 9000398 65 52 39.9 9003031 01 44 18
9000396 91 54 89 9000398 67 54 162 9003031 01 46 5
9000396 92 52 14 9000398 72 52 40.5 9003089 02 22 9
9000396 93 58 193.1 9000398 77 54 161 9003113 01 22 28
9000396 95 60 1 9000398 78 54 161.5 9003114 02 22 29
9000396 96 52 65 9000398 80 56 170 9003172 01 80 1
9000396 97 52 65.5 9000398 81 56 171 9003172 02 80 2
9000397 06 52 15 9000398 82 56 178 9003172 03 80 3
9000397 07 52 52 9000398 83 56 178.5 9003172 04 80 4
9000397 07 52 53 9000398 84 56 184 9003172 05 80 5
9000397 08 56 302 9000398 85 56 191 9003172 06 80 6
9000397 09 56 303 9000398 87 56 180 9003172 07 80 7
9000397 15 56 177 9000398 87 56 192 9003172 08 80 8
9000397 17 56 189 9000398 88 56 178.1 9003172 09 80 9
9000397 19 56 189.5 9000398 89 56 172 9003172 10 80 10
9000397 20 52 41 9000398 90 54 157.5 9003172 11 80 11
9000397 21 56 169.5 9000398 90 54 169 9003172 12 80 13
9000397 22 54 158 9000398 91 54 155.7 9003172 80 72 15
9000397 22 54 162.5 9000398 92 54 85.5 9003186 01 22 22
9000398 01 54 84 9000398 92 58 85.5 9003186 02 22 63
9000398 02 54 83.5 9000398 93 52 61 9003326 01 42 6
9000398 02 54 113.5 9000398 94 56 178.2 9003390 01 22 16
9000398 03 54 112 9000398 95 56 179 9003394 01 22 12
9000398 04 58 197 9000398 95 56 191.5 9003401 01 22 19
9000398 07 54 121.5 9000398 97 54 168 9003410 01 22 23
9000398 08 52 39 9000738 02 39 Z0.1A 9003450 01 72 1
9000398 09 52 36 9001098 01 42 11 9003514 01 72 18
9000398 10 54 88.5 9001357 03 38 7 9003522 06 6 39
9000398 11 52 19.5 9001406 82 86 4 9003522 07 6 38
9000398 11 54 83.7 9001539 01 42 19 9003570 01 72 27
9000398 11 54 114.5 9001897 01 42 12 9003574 01 72 45
9000398 16 56 173 9002009 81 42 8 9003574 01 78 Z
9000398 17 54 168.5 9002362 81 6 30 9003628 80 18 1
9000398 18 54 157 9002584 01 72 25 9003661 01 42 26
9000398 20 54 88 9002586 01 72 26 9003662 01 42 28
9000398 21 52 19.3 9002589 01 72 29 9003669 01 42 21
9000398 32 54 121 9002591 01 72 31 9003672 01 42 31
9000398 33 52 19.2 9002592 01 72 34 9003730 01 72 5
9000398 38 54 155.6 9002699 82 38 1 9003732 01 72 7
Book No. 91
9003748 80 38 2 9005051 05 38 16.4 9007166 01 64 2

9003792 01 72 30 9005051 06 38 16.2 9007166 06 62 2
9003837 01 72 32 9005051 07 38 16.1 9007166 06 64 2
9003851 01 72 35 9005051 08 38 16.3 9007166 06 66 2
9003853 01 72 36 9005052 01 38 17 9007166 06 68 2
9003854 01 72 37 9005052 05 38 17.1 9007167 17 64 1
9003863 01 72 38 9005052 07 38 17.2 9007167 23 68 1
9003886 01 72 39 9005052 08 38 17.5 9007167 24 62 1
9003888 01 72 40 9005052 09 38 17.4 9007167 24 64 1
9003935 01 72 23 9005052 10 38 17.3 9007167 24 66 1
9003949 01 72 28 9005142 80 22 1 9007184 02 64 Z
9004174 80 18 37 9005143 80 22 2 9007185 01 62 3
9004211 01 18 2 9005144 80 22 3 9007185 01 64 3
9004212 01 18 3 9005145 80 22 6 9007185 01 66 3
9004213 01 18 4 9005147 01 72 62 9007186 01 62 8
9004214 01 18 6 9005394 80 72 63 9007186 01 64 8
9004237 01 72 22 9005494 01 18 23 9007186 01 66 8
9004247 01 72 33 9005496 01 16 19 9007190 01 68 10
9004254 01 18 9 9005626 01 19 67 9007191 01 68 9
9004299 01 18 32 9005743 01 72 46 9007192 01 62 5
9004299 02 18 33 9005789 03 66 12 9007192 01 64 5
9004299 03 18 34 9005792 02 66 18 9007192 01 66 5
9004299 04 6 13 9006075 01 86 3 9007193 01 62 6
9004299 04 18 31 9006237 80 6 1 9007193 01 64 6
9004299 07 18 46 9006246 01 10 2 9007193 01 66 6
9004303 02 18 40 9006316 01 22 64 9007196 01 64 7
9004313 80 18 22 9006320 80 38 35 9007196 02 62 7
9004329 80 18 39 9006320 81 38 36 9007196 02 64 7
9004426 01 18 11 9006322 01 22 69 9007196 02 66 7
9004439 01 32 15 9006324 01 38 13 9007196 02 68 7
9004479 80 72 16 9006325 01 38 12 9007197 01 62 Z
9004506 80 18 5 9006326 01 18 35 9007197 01 64 Z
9004507 80 18 38 9006519 01 22 70 9007197 01 66 Z
9004508 80 18 42 9006677 01 18 21 9007198 01 64 22
9004517 01 72 19 9006761 80 10 5 9007200 01 68 27
9004533 01 76 1 9006769 02 54 91 9007201 01 68 28
9004533 80 72 3 9006771 02 52 13 9007231 01 86 1
9004587 80 76 Z 9006804 01 6 5 9007239 01 60 2
9004588 80 76 Z0.1 9006805 01 6 6 9007239 02 60 3
9004638 01 38 31 9006806 01 6 7 9007239 03 60 4
9004825 80 44 1 9006822 02 52 11 9007239 04 60 5
9004844 80 46 1 9006822 02 86 6 9007239 05 60 6
9004878 80 42 9 9006852 01 6 3 9007239 06 60 7
9004886 80 42 33A 9006853 01 6 52A 9007239 07 60 8
9004889 01 42 33 9007005 83 56 200 9007239 08 60 9
9004959 01 46 7 9007007 01 56 203 9007239 10 60 12
9004960 80 38 3 9007098 83 56 Z 9007239 11 60 11
9005006 80 6 18 9007099 80 56 Z0.2 9007239 12 60 13
9005046 01 72 10 9007100 83 56 Z0.1 9007239 13 60 15
9005051 04 38 16 9007128 80 56 190 9007239 23 60 10
92 Book No.
Part No. Page Ref.
9007239 24 60 Z
9007239 25 60 Z0.1
9007239 26 60 Z0.2
9007794 01 42 36
9007810 80 39 ZA
9008374 01 19 73
9008382 80 19 74
9008383 01 32 1
9008383 02 32 2
9008383 03 32 3
9008383 04 32 4
9008383 05 32 5
9008383 06 32 6
9008383 08 32 9
9008383 12 32 7
9008383 13 32 8
9008387 01 32 11
9008388 01 32 16
9008424 01 22 74
9008672 80 7 68
9008693 01 32 12
9008903 05 22 7
9009416 01 42 38
9009521 80 39 Z
9009688 01 7 52B
9009695 80 6 52
9009696 80 7 53
9009714 01 23 90
9009912 01 48 8
9011365 01 38 9
9011549 80 16 1
Book No. 93

Pureballast 30 Flow 1000

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Pureballast 30 Flow 1000

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PureBallast Ballast Water Treatment System

PureBallast Ballast Water Treatment System

Operating Instructions and

Alarms and Faultfinding 5

Installation and Drawings 6

Spare Parts Catalogue 8

Marine & Diesel Equipment

© Alfa Laval Tumba AB 2014

Book No. 9010183 02, rev. 2

Telephone: +46 8 530 650 00

Book No.9010183 02, rev. 2 5

2.1 General safety information

Maintenance safety items

Book No.9010183 02, rev. 2 7

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

8 Book No.9010183 02, rev. 2

2.3 Personnel requirements

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

2.4 Warning signs used in the manual

Book No.9010183 02, rev. 2 9

Book No.9010183 02, rev. 2 11

Book No. 9010183 02, rev. 2

Telephone: +46 8 530 650 00

This publication or any part there of may not be

1.2 System overview 6

2.4 Stripping with eductor 16

3 System components description 19

3.2 Lamp drive cabinet (LDC) 21

3.4 CIP (cleaning-in-place) module 29

3.5 Control cabinet and control system 30

1.1 Components overview

Example of layout with 1 AOT reactor.

1. Filter inlet valve

Book No.9010183 02, rev. 2 5

• System bypass valve

1.1.1 Item numbers

1.2 System overview

AOT Advanced oxidation technology

6 Book No.9010183 02, rev. 2

Atex EU directive “Appareils destinés à être utilisés en ATmosphères

CIP Cleaning in place

CIP module Cleaning in place module. Performs the CIP process.

DIN Deutche Institut für Normung

EN Standard according to CEN (European Committee for

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

IACS International Association of Classification Societies

ISCS Integrated ship control system

IMO International Maritime Organization

JIS Japanese Industrial Standard

LED Light emitting diode

LDC Lamp drive cabinet.

LPS Lamp power supply

MCB Motor circuit breaker

PLC Programmable logical controller (PureBallast control system)

Book No.9010183 02, rev. 2 7

Book No.9010183 02, rev. 2 9

Ballast and deballast start-up

10 Book No.9010183 02, rev. 2

2.2.1 Power optimization

Power optimization during special conditions.

Book No.9010183 02, rev. 2 11

2.2.1.1 Actions at low UV intensity

2.2.1.2 Operation with broken UV lamp

The operator will have do choose one alternative: