SVIB 53 840605028 PB-00317 v00 PB-750 OP

PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System

System Manual - PureBallast 2.0 Flow 750, DIN 300 0"
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 2012
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 2012

Chapter: 1. Safety
System manual — PureBallast 2.0 Flow 500
Book No. 9000479 02, rev. 0

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

Telefax: +46 8 530 310 40
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
Contents
1 Introduction 5
2 Safety instructions 7
2.1 Personnel requirements 7
2.2 Warning signs used in the manual 8
3 Environmental issues 9
3.1 Unpacking 9
3.2 Other materials 9
3
1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.
Book No.9000479 02, rev. 0 5

1 Introduction
2 Safety instructions
The following basic safety instructions apply:
NGE R
! DA
Before maintaining the PureBallast system, make sure that the atmosphere is non-explosive.
• Use the equipment only for the purpose and parameter range specified by Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Strictly follow the instructions for installation, operation and maintenance specified in this
manual.
• 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.
• Depressurize AOT reactors and allow equipment to cool down completely before disassembling.
• Before maintenance, read the Preparations and conditions section in chapter 7. Service manual.
• Before installation, read applicable sections in chapter 6. Installation instruction and drawings.
2.1 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.
Book No.9000479 02, rev. 0 7

2.2 Warning signs used in the manual 2 Safety instructions
2.2 Warning signs used in the manual
NGE R
! DA
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.
8 Book No.9000479 02, rev. 0

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.9000479 02, rev. 0 9

Chapter: 2. System description
Book No. 9000479 02, rev. 0

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 Abbreviations 5
1.2 System overview 6
1.3 Applicable directives and standards 6
1.4 Components overview 8
1.4.1 Item numbers 9
2 Process overview 11
2.1 Ballast start-up 12
2.2 Ballasting 13
2.2.1 Back-flush 14
2.2.2 Ballast after-treatment 15
2.3 Deballasting 16
2.3.1 Deballast after-treatment 16
2.4 Stripping with eductor 17
3 System components description 19

3.1 AOT module 19
3.1.1 AOT working principle 19
3.1.2 AOT module description 20
3.1.3 AOT reactor 22
3.1.4 Lamp drive cabinet (LDC) 22
3.2 Filter 23
3.2.1 Filter working principle 23
3.2.2 Filter description 23
3.3 CIP (cleaning in place) module 25

3.3.1 CIP working principle 25
3.3.2 CIP module description 25
3.4 Flow meter 26

3.5 Sampling device 27
3.6 Pressure gauge and pressure
transmitter 27
3.7 Main valves 27
3.8 Control system 27
3.8.1 Main control panel 28
3.8.2 Remote control panel (optional) 28
3.8.3 Remote interface (optional) 29
3
1 Introduction
This contains general information about the PureBallast system and its components.
1.1 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
AL Alfa Laval
AOT Advanced oxidation technology
AOT module Complete component handling the purification. Includes AOT

reactor, valves and LDC module
AOT reactor The reactor house with UV lamps purifying the water
Atex EU directive “Appareils destinés à être utilisés en ATmosphères

EXplosivles”
CIP Cleaning in place
CIP module Cleaning in place module. Performs the CIP cycle.
DIN Deutche Institut für Normung
EMC Electromagnetic compatibility
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
IP Integrated proportional (Regulation)
JIS Japanese Industrial Standard
LED Light emitting diode
LDC Lamp drive cabinet.
Book No.9000479 02, rev. 0 5

1.3 Applicable directives and standards 1 Introduction
Abbreviation Explanation
LDC module Complete component including mounting devices
LPS Lamp power supply
MCB Motor circuit breaker
PI Pressure indicator (pressure gauge)
PLC Programmable logical controller (PureBallast control system)
USB Universal serial bus (External data storage device)
UV Ultra violet
VCD Voltage clipping device
1.2 System overview

The main principle of PureBallast treatment is filtration followed by an advanced oxidation
technology (AOT). In the process PureBallast uses a patented AOT component: Wallenius AOT®,
which is the main stage of treatment during ballasting and deballasting.
A PureBallast system consists of one to twelve AOTs, which can be connected in parallel to achieve
a total flow capacity between 250 and 3000 m3/h. The capacity of one AOT module is 250 m3/h.
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. It is equipped with a bypass valve that is controlled
from the ISCS (integrated ship control system). PureBallast is also equipped with two sampling
devices, one before treatment and one after treatment. This makes it possible to take samples of
the ballast water according to IMO requirements.
PureBallast is operated from a control panel, which starts the automated ballast and deballast
processes. If integrated, it is also possible to control PureBallast from the ISCS, including the
vessel’s ballast water pump, overboard valve and power management.
1.3 Applicable directives and standards

PureBallast has received full Ballast Water Type Approval in accordance with the requirements
specified in IMOs International Convention for the Control and Management of Ships’ Ballast Water
and Sediments, adopted in 2004. A copy of the type approval, together with a summary of the
test results, is found in chapter 6. Installation description and drawings. This is an international
convention to prevent the potentially devastating effects of the spread of harmful aquatic organisms
carried by vessel’s ballast water.
PureBallast meets the following directives and standards:
• PureBallast meets the standard as set out in Regulation D-2 of International Convention for the
Control and Management of Ships’ Ballast Water and Sediments.
6 Book No.9000479 02, rev. 0

1 Introduction 1.3 Applicable directives and standards
• PureBallast has been examined, tested and found to comply with the requirements of the
specifications contained in the IMO Resolutions:
- Guidelines for approval of ballast water management systems (G8), Res MEPC.174(58).
- Procedure for approval of ballast water management systems that make of active substance
(G9), MEPC.169(57).
• DNV Rules for Classification of ships, Pt.4 Ch.1, Pt4, Ch.6, Pt4 Ch.9 Sec.5 B.
Book No.9000479 02, rev. 0 7

1.4 Components overview 1 Introduction
1.4 Components overview

The key components in PureBallast are shown below.
2 59999955_ComponentsOverview
Example of layout with 4 AOT modules (flow capacity: 1000 m3/hour).
1. Filter bypass valve

2. PureBallast bypass valve
3. Flow meter
4. Control cabinet including control panel
5. AOT reactor
6. Lamp drive cabinet (LDC)
7. Remote control panel (optional)
8. Control valve
9. Sampling device (before treatment)
10. Filter
11. Sampling device (after treatment)
12. CIP (Cleaning in place) module
8 Book No.9000479 02, rev. 0

1 Introduction 1.4 Components overview
1.4.1 Item numbers

System components are identified by unique item numbers, for example “FIT201-1” for the flow
transmitter installed before the AOT. These item numbers are listed in chapter 6. Installation
description and drawings, section Connection list.
Book No.9000479 02, rev. 0 9

1.4 Components overview 1 Introduction
2 Process overview
This section gives an overview of the main processes performed by PureBallast. A detailed
description of the processes, including operator actions and component activities, is given in section
Detailed process description in chapter 3. Operating instructions and control system description.
In the flow chart illustrations, involved pipes are marked in bold.
Book No.9000479 02, rev. 0 11

2.1 Ballast start-up 2 Process overview
2.1 Ballast start-up

Ballasting begins with a start-up phase. The start-up can start when required power has been
granted, either manually or automatically via the vessel’s power management system.
During the start-up, the UV lamps are warmed up. Cooling water is pumped through the AOTs
to secure that the UV lamps are not overheated. When the lamps are ready, the operator is
requested to start the ballast pump.
The process 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 start-up
12 Book No.9000479 02, rev. 0

2 Process overview 2.2 Ballasting
2.2 Ballasting
When the actual ballasting process starts, water is taken from the sea chest. The water passes the
PureBallast filter that removes particles and organisms larger than 40 µm. This also reduces the
amount of sediment build-up in the ballast water tanks. 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
Book No.9000479 02, rev. 0 13

2.2 Ballasting 2 Process overview
2.2.1 Back-flush
To keep the filter clean, it is automatically back-flushed. The back-flush is performed during ongoing
process without interrupting the ballasting process. The water used for back-flushing is returned to
the sea directly at the ballasting site.
2 Back-flush
Filter back-flush
14 Book No.9000479 02, rev. 0

2 Process overview 2.2 Ballasting
2.2.2 Ballast after-treatment

After every ballast operation, an automatic cleaning cycle is performed to clean the AOT reactor.
This cleaning can either be performed immediately after a ballast operation or within 30 hours
after. A CIP cycle takes about 15 minutes per AOT. Note, that it is possible to perform processes
during these 30 hours.
First, all AOTs are simultaneously rinsed with fresh water. Then the cleaning in place (CIP) module
circulates a biodegradable solution through each AOT in sequence to remove seawater scaling.
The cleaning liquid is reused between the cleaning operations. After the cleaning is finished all
AOTs are filled with fresh water to preserve the filter and prevent scaling, algae growth etc. Also the
filter is filled with water for preservation reasons.
2 CIP
Cleaning in place (CIP)
Book No.9000479 02, rev. 0 15

2.3 Deballasting 2 Process overview
2.3 Deballasting
Deballasting also begins with a ballast start-up to warm the UV lamps. When the actual deballasting
process starts, the water passes through the AOT a second time, thus treating the water one
more time. The reason for treating the water a second time 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. However, the filter is bypassed since the water
has already been filtered.
The process flow is monitored by the flow meter to secure that the flow does not exceed the certified
rate and to secure that there is enough flow to cool the UV lamps.
2 FullDeballast
Deballasting
2.3.1 Deballast after-treatment

After every deballasting operation, an automatic cleaning cycle takes place. It is performed in the
same way as described for the ballasting process, but without the filter preservation step, since
the filter is not used during deballast.
16 Book No.9000479 02, rev. 0

2 Process overview 2.4 Stripping with eductor
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, but
the filter is 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.
Book No.9000479 02, rev. 0 17

2.4 Stripping with eductor 2 Process overview
3 System components
description
This section gives an introduction to the most important PureBallast system components and
their functions in the system.
3.1 AOT module
3.1.1 AOT working principle

The PureBallast system is based on a patented advanced oxidation technology (AOT). The process
is operating within the AOT reactor where the UV light in combination with titanium dioxide catalyst
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
reactor. The quantity of radicals produced in the reactor is sufficient to treat the water as it passes
through the reactor. The UV light in itself inactivates the cell DNA to prevent regrowth of organisms.
The Wallenius AOT process is chemical-free, similar to the technology used in many of today’s
smart products. The self-cleaning windows of skyscrapers and cars, for example, prevent the
growth of organisms through an AOT reaction that occurs when sunlight radiates titanium dioxide.
2 10_2_1_1 Cell
Destruction of cell membranes
1. Radical
2. Cell membrane
Book No.9000479 02, rev. 0 19

3.1 AOT module 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 module description

An AOT module consists of an AOT reactor, a lamp drive cabinet (LDC) and valves at the inlet and
outlet of the unit as shown in the illustration below.
To secure that there is water in the reactor when the lamps are lit, each AOT reactor is equipped a
level switch. The level switche also secures that enough CIP liquid is pumped to the AOT reactor
during the CIP cleaning cycle. To secure that the lamps are adequately cooled by the ballast water,
each AOT reactor is equipped with one temperature transmitter. The control system monitors theses
values and will shut down the AOT if they deviate from parameter set termperature, completed with a
temperature switch that automatically shuts down the AOT reactor if the temperature reaches 70 °C.
20 Book No.9000479 02, rev. 0

3 System components description 3.1 AOT module
2 AOT mod 592830_description
AOT module
1. Ballast water out

2. Outlet valves
3. Temperature switch
4. Level switch
5. AOT reactor
6. Temperature transmitter
7. Lamp drive cabinet (LDC)
8. Inlet valves
9. Ballast water inlet
Book No.9000479 02, rev. 0 21

3.1 AOT module 3 System components description
3.1.3 AOT reactor

The AOT reactor accommodates 12 medium-pressure UV lamps (3000 W each), which are
enclosed in individual quartz-glass sleeves. The reactor also includes a catalyst insert made of
titanium meshes. The picture below shows the principle design of the AOT reactor.
2 AOT react 593915_principle
AOT reactor
1. Reactor housing
2. Catalyst insert
3. Quartz sleeve
4. UV lamp
3.1.4 Lamp drive cabinet (LDC)

The AOT is equipped with a lamp drive cabinet (LDC) containing twelve lamp power supplies (LPS).
Each LPS supplies power to one UV lamp in the reactor. The LPS triggers an alarm if a UV lamp is
broken or if the LPS malfunction. Each LDC is equipped with a main breaker for the AOT.
The LDC is equipped with a cooling system to maintain the correct operating temperature in the
LDC, using low-temperature cooling water.
22 Book No.9000479 02, rev. 0

3 System components description 3.2 Filter
3.2 Filter
3.2.1 Filter working principle

The filter is a fully automatic, self-rinsing component equipped with filter candles designed to
separate particles and organisms larger than 40 µm from the ballast water flow. The filter candles
used are of mesh type made of SuperDuplex.
3.2.2 Filter description
2 Filter 2_2_2
Filter
1. Geared motor (to rotate flushing arms)

2. Differential pressure transmitter
3. Water outlet
4. Pressure before filter
5. Pressure after filter
6. Back-flush outlet
7. Water inlet
To secure efficient filtration, the filter performs a self-rinsing back-flush operation at time set
intervals or when triggered by indication of dirt in the filter. Dirt is detected by the differential
pressure transmitter installed on the filter, which monitors the differential pressure before and
after the filter. When the difference reaches a defined value, caused by particles, the automatic
back-flush operation starts. It is also possible to start back-flush manually from the control system.
Book No.9000479 02, rev. 0 23

3.2 Filter 3 System components description
The flushing arm is turned to flush each individual filter candle in sequence. At the same time, the
back-flushing discharge valve is opened which causes a high axial flow in the filter candle, so that
the dirt particles are flushed off. The water flowing lengthways through the filter candle conveys
the particles out from the filter. The control valve, placed after the AOT, secures the pressure
needed to perform the back-flush. If the differential pressure still is too high after the back-flush,
the sequence is repeated.
The back-flushing does not interrupt the filtration process, since the filter candles are cleaned one
by one by the upper and lower flushing arms alternately. The other filter candles continue the
filtration of the ballast water.
2FilterFiltering
2FilterBackFlush
Water flow inside the filter during filtration. Water flow inside the filter during self-rinsing
back-flush cycle.
1 Gear motor 8 Hydrodynamic element

2 Top flushing arm 9 Connecting pipe
3 Flushing bush 10 Spacer pipe
4 Filter candle N1 Filter inlet
5 Differential pressure transmitter N2 Filter outlet
6 Back-flushing discharge valve N3 Back-flush discharge
7 Bottom flushing arm
24 Book No.9000479 02, rev. 0

3 System components description 3.3 CIP (cleaning in place) module
3.3 CIP (cleaning in place) module
3.3.1 CIP working principle

To ensure full performance in PureBallast, an automatic cleaning cycle is performed after every
ballast or deballast operation. The purpose is to keep the catalyst surface and the quartz sleeves
covering the UV lamps free from scaling, which otherwise would decreases the efficiency of the
AOT.
During a cleaning cycle, the CIP module circulates a CIP liquid through the AOT reactor to remove
seawater scaling. After finished cycle, the liquid is returned to the CIP module; the CIP liquid is
reusable for a great number of cycles.
All ingredients in the CIP liquid are registered under HOCNF for use in the UK offshore fields.
Saltwater data is specified and all ingredients are listed in the PLONOR list (recommended
chemicals from the environment). The product is 100% PLONOR- approved for offshore. The CIP
liquid is classified as Group E in the UK (lowest environmental hazard).
3.3.2 CIP module description

The CIP module consists of a tank where the CIP liquid is stored between usage. Before the
CIP cycle starts, the AOT is drained from sea water and rinsed with fresh water. When the CIP
operation has completed, the CIP module fills the AOT with fresh water. 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 AOT 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 to and from the AOT.
• Pump P321-5 drains water (sea and fresh water) overboard from the AOT, via the drain line.
The pump is used if the vessel itself is unable to perform the drainage.
Book No.9000479 02, rev. 0 25

3.4 Flow meter 3 System components description
2 CIP 589741_3D_description
CIP module
1. Deaeration valve
2. Valve block
3. Regulator
4. Tank for CIP liquid
5. Pump (CIP liquid)
6. Backflow preventer
7. Pump (AOT drain)
3.4 Flow meter

The flow meter monitors the process-flow during operation. It has two main functions:
• It ensures that the flow within the PureBallast system does not exceed its certified flow rate. 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.
26 Book No.9000479 02, rev. 0

3 System components description 3.8 Control system
3.5 Sampling device

The two sampling devices 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.
3.6 Pressure gauge and pressure transmitter

A pressure gauge and a pressure transmitter monitor the pressure in the PureBallast system.
Current pressure is analogously displayed on the pressure gauge and electronically sent to the
PureBallast control system by the pressure transmitter.
3.7 Main valves

The main valves in the system are:
• PureBallast bypass valve: Makes it possible to completely bypass the PureBallast system.
The valve is solely operated from the ISCS, but the valve positioning is however indicated
in the PureBallast control system.
• Main inlet and main outlet valve: Connects the PureBallast system to the vessel’s ballast
system. The inlet valve directs the water flow into the PureBallast system and the outlet valve
returns the water to the vessel’s ballast system after treatment.
• Control valve: The valve have the following functions:
- Regulate the pressure to secure that there is enough pressure to perform a back-flush,
and that it is maintained.
- Regulates the process flow so it does not exceed the flow chosen for a process.
- Main outlet valve.
• Cooling water inlet valve: Supplies cooling water to the AOT to protect the lamps from
overheating. The valve is common for all installed AOTs.
• Filter bypass valve: During deballasting, the water does not pass the filter, since it has
already been filtered during ballasting. The bypass valve is used to direct the water flow so
that the filter is bypassed.
3.8 Control system
The control system is used to operate, monitor and administer the PureBallast system. The
system monitors the system automatically, based on input from sensors. Any deviation is either
communicated to the operator or handled automatically, based on parameter settings.
There are three alternative ways to access the control system: Main panel, remote control panel
(optional) and remote interface (optional). To avoid double command, PureBallast can only be
controlled from one place.
Book No.9000479 02, rev. 0 27

3.8 Control system 3 System components description
3.8.1 Main control panel

The main control panel is included in the standard installation of PureBallast. It is installed in the
engine room. The main control panel handles every aspect of the control system. It allows the
operator to monitor the system, to operate it manually and automatically, and to set parameters.
Please note that some of the operations are password-protected.
2ControlPanel
Main control panel
3.8.2 Remote control panel (optional)

It is possible to install 1–4 additional panels as an option 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 for the same operations.
2RemotePanels
Main control panel with four integrated remote control panels.
28 Book No.9000479 02, rev. 0

3 System components description 3.8 Control system
3.8.3 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.
2RemoteInterface
PureBallast control system’s main control panel integrated with the ISCS. The interface is only an example.
Book No.9000479 02, rev. 0 29

Chapter: 3. Operating instructions and control system description
Book No. 9000479 02, rev. 0

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 8
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 Remote interface (option) 12
2.2.1 Conditions for remote controlling PureBallast 12
2.3 Overview of the screen 13
3 Detailed page descriptions 17

3.1 Page 1.1 – Overview 17
3.1.1 Status box 18
3.1.2 Flow chart 19
3.2 Page 1.3 – AOT and flow selection 20

3.2.1 Status box 20
3.2.2 Flow setpoint 20
3.2.3 Current status 21
3.2.4 AOT selection 22
3.3 Page 1.4 – CIP status 23

3.4 Page 1.5 – Power request 25
3.4.1 Power management simulation and faultfinding 25
3.4.2 Power management status display 25
3.4.3 Function buttons 27
3.5 Page 3.1 – Alarm list 28

3.5.1 Alarm list 29
3.6 Page 3.2 – Alarm history 31

3.7 Page 4.1 – Trend (1 s.) 32
3.7.1 Diagram area 33
3.7.2 Component area 33
3
3.8 Page 4.2 – Trend (30 s.) 34
3.9 Page 4.3 – Trend – AOT 1–6, TT201–33 34
3.10 Page 4.4 – Trend – AOT 7–12, TT201–33 34
3.11 Page 4.5 – Trend – AOT 1–6, TT401 35
3.12 Page 4.6 – Trend – AOT 7–12, TT401 35
3.13 Page 5.1 – System info 36
3.14 Page 5.2 – Main controller I/O 39
3.15 Page 5.3 – Operation timers 40
3.16 Page 5.4 Operation timers: AOT 1–12 42
3.17 Page 5.5 – Remote interface 1 43
3.18 Page 5.6 – Remote interface 2 44
3.19 Page 8.1–8.6 – Parameter pages 45
3.20 Page 5.7 – Log box 1 45
3.21 Page 5.8 – Log box 2 46
3.22 Popup windows 47
3.22.1 AOT popup 47
3.22.2 Filter popup 51
3.22.3 CIP popup 52
4 Operating instructions 53
4.1 Log in 53
4.2 Perform ballast 53
4.2.1 Start ballasting 54
4.2.2 Start ballasting with specified AOTs 54
4
4.3 Perform deballast 55
4.4 Pause ballast / deballast 56
4.5 Change ballast / deballast flow 57
4.6 Back-flush filter manually 57
4.7 CIP clean AOT after ballast / deballast 58
4.8 Stop ballast / deballast 58
4.9 Attend to alarms 59
4.10 Abort operation and deactivate the
system 60
4.11 Reset system after shut down 61
4.12 Operate components manually 61
4.13 Operate UV lamps manually 63
4.14 Set parameters 64
4.15 Restore default parameters 65
4.16 Backup control system settings 65
4.17 Restore control system settings 66
4.18 Export control system log files 67
4.19 Export control system history files 68
4.20 PID calibrate system 68
4.20.1 Calibrate pressure controlled regulation 69
4.20.2 Calibrate flow controlled regulation 70
5
4.21 Simulate power request 72
4.22 Set control panel IP address 73
4.23 Set remote control panel
communication 74
4.24 Set remote interface communication 75
4.25 Test remote interface communication 76
4.26 Update PLC software and HMI software 77
4.27 Update HMI software 79
4.28 Update control panel software 80
4.29 Calibrate the control panel’s touch
screen sensibility 81
5 List of logged information 83

5.1 Event log 83
6 Detailed process description 89

6.1 Standby mode 89
6.2 Ballast process 90
6.2.1 Ballast start-up 90
6.2.2 Full ballast 91
6.2.3 Filter back-flush 91
6.2.4 Pause ballast (Heeling mode) 92
6.2.5 Stop ballast 93
6.3 Deballast process 95

6.3.1 Deballast start-up 95
6.3.2 Full deballast 96
6.3.3 Pause deballast (Heeling) 97
6.3.4 Stop deballast 98
6.4 CIP cycle 99

6.4.1 Start CIP 99
6.4.2 Drain ballast water 100
6.4.3 Fresh water filling 100
6.4.4 Fresh water draining 100
6.4.5 CIP cleaning 101
6.4.6 CIP draining 101
6.4.7 Fresh water filling 101
6.4.8 Repeat step 2-7 102
6.4.9 Filter preservation 102
6.5 Manual mode 102
6
1 Introduction
The control system is used to operate and monitor the PureBallast system. It also contains
functions for setting parameters, monitoring the system, saving log files etc.
This chapter describes the control system. It includes general description of the control system
pages, step-by-step instructions on how to operate PureBallast and a process descriptions 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. Study this information before operating
the PureBallast system.
• Alarms and warnings including information about faultfinding and actions to be taken are
described in chapter 5. Alarms and fault finding.
• 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 not to exceed or fall below the limit values stated in chapter 6. Installation description
and drawings, section Technical data.
• 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 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 404.
- Water 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 flow 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.
• Operation with reduced number of AOTs must be done according to a or b below:
a Reduced number of AOTs according to the table below can be done without any steps
taken. In these cases, control valve V201-8 will adjust the flow.
b Operation with fewer AOTs (than stated in the table) requires that the incoming flow is
reduced to correspond with the capacity of the AOTs in use (250 m3/h per AOT).
Book No.9000479 02, rev. 0 7

1.1 Preparations and conditions 1 Introduction
Number of installed Allowed non-used AOTs

AOTs
2–5 1 AOT not in use
6–9 2 AOTs not in use
10–12 3 AOTs not in use
1.1.1 Stripping
The first time a ballast tank is stripped, PureBallast must be by-passed.
If stripping is performed via PureBallast, select the number of AOTs that match the flow from
the eductor.
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 ballast or deballasting. If it is done, the ongoing process
must be paused. During pause, cooling water is flushed through the AOT to cool the UV lamps.
After completed heeling, the operator must resume the paused process. See instruction Pause
ballast / deballast on page 56.
If external component signal for heeling mode is integrated between PureBallast and the vessel’s
ISCS, the process will be paused and resumed automatically. The user is notified of started and
stopped heeling via a message in the control system, and the event is logged.
1.1.3 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 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 (200 NM) 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.
8 Book No.9000479 02, rev. 0

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.9000479 02, rev. 0 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

The control system is protected by login levels. The login level controls which information that is
displayed and changeable and which operations and activities that are accessible. As an example,
pages used for commissioning purposes are hidden for normal operators.
It is possible to log in if another user is logged in with the same login level, or lower. This person
will then be logged out. In this case a popup message is displayed that another user is logged in
on another panel. It is possible to continue (and logout the other user) or cancel. The logged out
user will receive a popup message that the user will be logged out. It is not possible to log in with
a lower level than a logged in user.
Login Status Password Authority
Level 0 Guest N/A Level 0 is the default mode of control system. This level is
not password protected.
• View status and overview pages, but not parameter pages.
Level 1 Operator aot • As level 0.

• Operate the system to perform daily routines, for example
ballast and acknowledge alarms.
• Download files to a USB memory.
Level 2 Advanced 2007 • As level 1.

operator
• Operate equipment in manual mode and perform PID
calibration.
• Full access to page 1.5 Power request.
• Access to set parameters in page 5.7, 5.8, 8.2—8.6.
• Full access to page 5.3 Operation timers and 5.4
Operation timers AOT.
Level 3 Alfa Laval N/A Password only available for Alfa Laval personnel.
• As level 2.
• Full access to all parameter pages.
Book No.9000479 02, rev. 0 11

2.2 Remote interface (option) 2 Introduction to the control system
Login Status Password Authority
• Full access to force I/O in page 5.2 Main controller I/O.

• Full access to make settings for remote control panels
and interface in page 5.1 System info and 5.5/5.6 Remote
interfaces 1 and 2.
• Change passwords.
2.2 Remote interface (option)

If the remote interface option is used, PureBallast can be controlled from the vessel’s ISCS. It is
possible to access the same pages and perform the same operations from the remote interface as
for login level 1.
When the remote interface is used, the panel(s) cannot be used to operate the system; it is only
possible to monitor the system and to export log files. It is possible to turn of the remote interface,
and thus activate the panels, from a panel when logged in as level 2 or 3.
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.
2.2.1 Conditions for remote controlling PureBallast

PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings
• The remote interface must be correctly installed.

• Remote interface must be activated. Check that parameter p132 is set to Activated.
• Remote operation must be in online mode. Check that the Online button is activated (indicated
by a checkmark on the button) in control system page 5.5 Remote interface 1.
• Remote mode must be activated. Check that the green lamp is lit under the Remote button
on the control panel. If not, press the button. The system must be in Standby mode to toggle
between local and remote operation.
Operation
• Heartbeat is updating. See that address +155 is updated in control system page 5.5 Remote
interface 1.
• There must be no active alarms for the AOTs to be used during operation. Always check the
alarm list (page 3.1 Alarm list in the control system) before operation.
12 Book No.9000479 02, rev. 0

2 Introduction to the control system 2.3 Overview of the screen
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 for a defined amount of time, it
will go to screen saving mode. Time is set in page 5.1 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 fields for logging in and out. Logged in user is always
displayed. If remote control panels (optional) are used, all inactive panels also displays which panel
that is active. The name used, is the on set for respective panel in page 5.1 System info.
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 3.2 Alarm history. 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.
Book No.9000479 02, rev. 0 13

2.3 Overview of the screen 2 Introduction to the control system
Top tabs: Contain the main function areas of the control system: Overview, alarm lists, trend
indication and parameters.
Side tabs: Contain sub pages for the function area selected in the top tab. Available side tabs
change depending on which function area that have been selected in the top tab. Example: If Alarm
lists is active, it is possible to choose between alarm list and alarm history.
Popup windows: Are used to display or enter detailed information. It is possible to move a popup
by touching the name bar and drag it. A popup is closed either by touching confirming entered
information by touching a function button (OK, Confirm, etc.) or the X icon in the top right corner
(data is not saved).
Data entry fields: A white field indicates that it is possible to enter data. When the field is touched,
a keyboard is displayed, which is used to enter information. Use the touch keys to enter data,
and confirm the entry 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. The column border will turn bold, to indicate that it is possible to drag the column border
to desired width.
Function buttons: Function buttons are used during operation. They are always visible, but only
available when colored dark blue.
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.
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
14 Book No.9000479 02, rev. 0

2 Introduction to the control system 2.3 Overview of the screen
Button Description
Start ballast process.
Resumes paused process.

3Ballast
Start deballast process.
Resumes paused process.

3Deballast
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 the
3Pause
paused process is stopped.
To resume a paused process, press the function Ballast or Deballast

depending on which process that was paused.
Start CIP cycle manually.
3CIP
Activate operation from control panels, instead of remote interface (if option
is used). The system can only be operated from either a remote control
panel or the remote interface. The button is only enabled in standby mode.
2 LocalButton
Activate operation from remote interface (if option is used), instead of

control panels. The system can only be operated from either a remote
control panel or the remote interface. The button is only enabled in
2 RIbutton standby mode.
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. If
night light is activated, the button activates day light.
3 Night Degree of brightness, is set in the Night light level field in page 5.1 System
info.
Sets the control system in manual mode, which enables manual operation
of components. The button is displayed for login level 2 and 3. For detailed
3 EnableManual
information see Manual mode on page 102.
Book No.9000479 02, rev. 0 15

2.3 Overview of the screen 2 Introduction to the control system
Button Description
Display PID calibration popup. PID calibration is performed to fine tune the
system so it runs with a steady and even flow. The button is displayed for
3 PIDbutton login level 2 and 3.
The button is displayed beside the control valve 201–8 in the flow chart.
Contains calculator, Notepad and print function.
To print a screen image to the USB port: Insert a USB memory at the back
of the panel. Press Utilities, and then Print to save a screen image to USB.
The USB port can also be connected to a printer.
3 Utilities
Displays help files, if available. This function is not yet implemented.
3 Help
16 Book No.9000479 02, rev. 0

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.9000479 02, rev. 0 17

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 5.3 – 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 AOT

draining during CIP cycle.
See section Detailed process description for detailed information

about the processes and sub processes.
Current flow (m3/h) Ballast water flow in the system, indicated by flow transmitter
FIT201-1.
Selected certified flow (m3/h) Flow (m3/h) selected for the current operation, according to
selection made in page 1.3 AOT and flow selection. Flow can
either be set by selecting a flow or select a number of AOTs. As
default value, last set flow is used.
Processed volume (m3) Amount of water processed during current process.
Calculated power Approximate power consumption for the number of selected

consumption (kW) AOTs.
Ballast pump status. This component is outside the PureBallast

system control.
3 PumpReq
Status indication
Red, blinking = Indicates that the operator is requested to start

the ballast pump during process. At the same time, the popup
message message “Confirm ballast pump started” is displayed.
Green, blinking = Pump is starting.
Green = Operating.
Grey = Not operating
Overboard valve status. This component is outside the

PureBallast system control.
3 OBvalveReq Status indication
Red, blinking = Indicates that the operator is requested to open

the overboard valve. At the same time, the popup message
message “Confirm overboard valve open” is displayed.
Green, blinking = Travelling (opening or closing).
18 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.1 Page 1.1 – Overview
Status information (unit) Description
Green = Open.
Grey = Closed
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. As a complement to the status box, pressure, flow and control valve
opening percent are displayed close to respective component.
Detailed information about the main components can be monitored in popup windows for respective
component (AOT see page 47; filter see page 51; CIP see page 52). These popup are opened
by tapping the component on the screen. They display status for sub components, for example
inlet valve and individual UV lamps in the AOT.
Booster pump for AOT (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 2 and 3) 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:
Green Open (if valve).

Operating (if motor or pump).
Green, flashing Travelling (opening or closing).
No frame Closed (if valve)

Not operating (if motor or pump)
Status can not be displayed: The component is either completely manual or
outside the PureBallast system control, for example the PureBallast bypass
valve (212–31). These components cannot be operated via the control system
due to safety reasons.
Red, flashing Indicates that there is an active alarm for the component.
Blue pipes Fresh water flow. Flow is not indicated in manual mode.
Green pipes Ballast and deballast flow. Flow is not indicated in manual mode.
Grey pipes Air flow during deareation. Flow is not indicated in manual mode.
The component has been modified manually in manual mode.
3Manual1
Book No.9000479 02, rev. 0 19

3.2 Page 1.3 – AOT and flow selection 3 Detailed page descriptions
3.2 Page 1.3 – AOT and flow selection

The page is used to set flow for ballasting and deballasting and to increase/decrease flow during
full ballast or deballast. It is also possible to select specific AOTs to be used during process,
or to change AOT during an ongoing process.
The main areas of the page are the Status box, Current status, Flow setpoint and AOT selection.
3 1.3
The following information is displayed:
3.2.1 Status box

The status box displays operation process status information. The field content is described in
the Status box in page 1.1 Overview.
3.2.2 Flow setpoint

The Flow setpoint area is used to change flow before or during a process.
20 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.2 Page 1.3 – AOT and flow selection
Elements Description
Increase Press the button to increase the flow.
Setpoint is updated in the Flow setpoint field, but the flow is not changed
until the Confirm button is pressed. The field is updated with 250 m3/h
each time the button is pressed.
Flow setpoint Displays current setpoint (not actual flow).
Decrease Press the button to decrease the flow. Functions as the Increase button.
Confirm Press the button to execute selected setpoint. If flow capacity is changed
during ballast or deballast, the flow change will take effect directly. If flow
capacity is set before ballast or deballast has been started, this is the flow
that will be used when process is started.
When the button is pressed, the text “New flow in progress” is displayed
until the new flow is reached. The Certified flow field is updated when
the lamps are started.
3.2.3 Current status

The Current status area displays current status for the following pieces of information:
Current flow Ballast water flow in the system, indicated by flow transmitter FIT201-1.
Selected certified Maximum allowed flow as set in Flow setpoint or limited by the number of
flow AOTs selected in AOT selection popup.
This is also the flow the system is aiming for.
AOTs selected for A list of installed AOT. Current status for respective AOT is indicated by
process colors:
Status indication
Black = Selected
Green = Operating
Green, blinking = Starting.
Grey = Not selected, disabled
Red = Active alarm for the AOT
Book No.9000479 02, rev. 0 21

3.2 Page 1.3 – AOT and flow selection 3 Detailed page descriptions
3.2.4 AOT selection

When the AOT selection button is pressed, a popup is displayed, where specific AOTs can be
selected to be used for process.
3 AOTselect
AOT A list of installed AOTs are represented by one button. Press a button to
activate that AOT for use.
Current status for respective AOT is indicated by colors.
Status indication:
Blue with checkmark = Selected
Blue without checkmark = Not selected
Grey with alarm symbol = Active alarm for the AOT
Indicates that there is an active alarm for the component. Check alarms on
page 3.1 – Alarm list.
3Alarm
Corresponding The field indicates flow setpoint for the number of AOts selected. The field
flow setpoint is updated with 250 m3/h for each selected AOT.
Confirm Press the button to save the AOT selection and close the popup.
22 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.3 Page 1.4 – CIP status
3.3 Page 1.4 – CIP status

The page is used to display CIP status for all AOTs.
The page also display time remaining for ongoing CIP cycle. 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 1.4
Row Content
AOT Each row indicate status and time for each installed AOT.
Filter preservation This row indicate status and time for the filter preservation process, that
starts after completed CIP cycle for all AOTs after ballasting.
Total Total estimated time for a complete CIP cycle including filter preservation.
Book No.9000479 02, rev. 0 23

3.3 Page 1.4 – CIP status 3 Detailed page descriptions
Column Content
CIP error Red square: Indicates that there is an active alarm for the component.
Check alarms on page 3.1 – Alarm list.
CIP CIP status for each AOT.
Status indication
Yellow = CIP required. During ongoing CIP cycle, yellow indicates that the
AOT is waiting for CIP cycle to start.
Yellow, blinking = CIP cycle ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to active alarm on

the AOT.
Status Same information as column CIP, but spelled out.
Estimated Time remaining for each AOT. If CIP cycle has not been started, total time
remaining time is displayed. During CIP cycle, the time is counting down continuously.
Required CIP Time before a CIP cycle must be performed after ballast or deballast. When
countdown CIP cycle starts, the time disappears.
24 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.4 Page 1.5 – Power request
3.4 Page 1.5 – Power request

The page is used to handle power management. The page have two functions: Test power
management signals and display power status.
3 1.5
3.4.1 Power management simulation and faultfinding

If the control system is set in manual mode (login level 2 and 3), the page is used to simulate output
from PureBallast to the power management system during commissioning preparation.
The page can also be used to troubleshoot the power management system integration by sending
and checking each signal.
3.4.2 Power management status display

If the control system is set in normal mode, the page is used to display power management status.
Book No.9000479 02, rev. 0 25

3.4 Page 1.5 – Power request 3 Detailed page descriptions
Page content
Column Content
Power Each row represent a number of AOTs to be used in a process. The rows
can be combined. For example row 1 and 2 equals three AOTs.
As an alternative, it is possible to use row 6 (common), that request enough

for all AOTs installed.
1 AOT Row 1: Request power for 1 AOT.
2 AOT Row 2: Request power for 2 AOTs.
The requested power is calculated as the number of AOTs times defined

power consumption for one AOT.
Common power Request maximum power, enough to run all AOTs installed, even if all AOTs
are not used. This alternative is used if power management is not installed.
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.
If there is not enough power available for the amount of AOTs, a lower
power value might be granted. This means that less AOTs will be used and,
consequently, the process will be run with a less flow capacity.
Manual mode: Indicates if a simulated granted signal is received.
26 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.4 Page 1.5 – Power request
Column Content
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 AOTs. This means that the AOT modules are started and are 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 maximum
number of AOT for the request times the set power consumption per AOT.
If Common power has been selected, the value is the standard total power
according to parameter p107.
3.4.3 Function buttons

The following function buttons are available in manual mode if power management is used:
Buttons Content
Press the hand icon to make it possible to send simulated request or

granted signal manually.
3Manual1
Request Press to manually simulate request for a power step. The button is
displayed for login level 2 and 3.
Set run Press to manually simulate run signal for a power step. The button is
displayed for login level 2 and 3.
Book No.9000479 02, rev. 0 27

3.5 Page 3.1 – Alarm list 3 Detailed page descriptions
3.5 Page 3.1 – Alarm list

The page display active alarms. When an alarm is inactive and acknowledged, it is moved to
page 3.2 Alarm history.
For further information about the specific alarms see chapter 5. Alarms and fault finding.
3 3.1
The main areas of the page are the Alarm list and the Function buttons:
28 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.5 Page 3.1 – Alarm list
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.
Alarm type can be:
- 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.
Active time The time alarm was activated.
Acknow- The time the alarm was acknowledged. The alarm remains in the alarm list
ledged time until the causing condition is resolved. For example a high temperature alarm
will remain visible, until the temperature is below the alarm setpoint.
Status indication – Alarm color
Alarms and warnings can be active after they have been acknowledged. The table below shows
status indication for alarms and warnings in the alarm list.
Red Alarm = active
Red, light Alarm = acknowledged, but still active
Yellow Warning = active
Yellow, light Warning = acknowledged, but still active
Book No.9000479 02, rev. 0 29

3.5 Page 3.1 – Alarm list 3 Detailed page descriptions

The following function buttons are available:
Button Function
Ack selected Acknowledge selected alarm (row).
Ack all Acknowledge all active alarms.
|| Pause the alarm list screen, so that the page is not updated with new alarms.
This is useful when many alarms are issued at the same time, to facilitate
selection and acknowledgement of individual alarms.
Press again to release the pause function, so that all new alarms are displayed
and the list is dynamically updated.
30 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.6 Page 3.2 – Alarm history
3.6 Page 3.2 – Alarm history

The page display a list of inactive, previously acknowledged alarms.
3 3.2
Column Content
Text Same as in Page 3.1 Alarm list.
Active time Same as in Page 3.1 Alarm list.
Acknowledged Same as in Page 3.1 Alarm list.

time
Normal time The time the value that caused the alarm returned to normal.
Book No.9000479 02, rev. 0 31

3.7 Page 4.1 – Trend (1 s.) 3 Detailed page descriptions
3.7 Page 4.1 – Trend (1 s.)

The page is used to display trend curves for basic data in the system. This page display trends
with a update frequency (sample time) of 1 second. This page is useful to monitor an ongoing PID
calculation or analyze it afterwards.
3 4.1
Trends can be plotted for the following components (identified by item number) and key values:
Component / Unit Description Updating

Key value frequency
PT201-27 Bar Differential pressure over filter, indicated by the 1 sec

pressure transmitter.
PT201-16 Bar System pressure after filter, indicated by the 1 sec

FIT 201-1 m 3h Flow, indicated by the flow meter. 1 sec
V201–8 % Valve open, percent. 1 sec
V309-1 Sta- Filter back-flush valve opened or closed. 1 sec

tus
32 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.7 Page 4.1 – Trend (1 s.)
3.7.1 Diagram area

In the diagram area, trend curves are displayed for one or more components.
The diagram plot trend curves for the components selected by the plot checkbox. The color of the
line corresponds with the color of the plot checkbox.
X axis: The time interval is always 15 minutes.
Y axis: The scale and unit used for the Y axis can only be displayed for one selected component
at a time, since different units are used. The component controlling the Y axis is selected by
pressing the Y axis selection button in the component area. Note that interval Y axis scales are
defined individually per component.
3.7.2 Component area

The following fields and buttons are available for each component in the selection area:
Column Content / Function
Plot checkbox Press the colored checkbox to plot trend for the component. It is possible to
plot trend curves for one or more component.
3 PlotBox1
Status indication:
Selected = Component values is plotted in the diagram.

3 PlotBox1
Not selected = Component values is not plotted in the diagram.

3 PlotBox2
Component Item number or name.
Unit Components unit.
Y axis Press the button to let this component control unit and Y axis scale. Only one
selection component can be selected to control the Y axis scale and unit.
Status indication:
3 YAxis1
Selected and used in the diagram.

3 YAxis2
Not selected.
3 YAxis1
Y axis - Low The Y axis low value for the diagram when this component i selected.
Press the entry field to change the value.
Book No.9000479 02, rev. 0 33

3.10 Page 4.4 – Trend – AOT 7–12, TT201–33 3 Detailed page descriptions
Y axis - High The Y axis high value for the diagram when this component i selected.
Press the entry field to change the value.
Actual value Current actual 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
Show history Press the button to display historic trend curve. A popup is opened where it is
mode possible to display trend curve for
• latest hour
• latest day
• a customized time interval set by year, moth, day, hour, minutes and
seconds.
History mode is indicated by the word “History” at the bottom of the screen.
Leave history Press the button to leave history mode and display current trend curve.
mode
3.8 Page 4.2 – Trend (30 s.)

The page is used to display trend curves for basic data in the system. This page display trends with
a update frequency (sample time) of 30 seconds.
See page 4.1 Trend (1 s.) for information about function, fields and buttons.
3.9 Page 4.3 – Trend – AOT 1–6, TT201–33

The page is used to display trend curves for temperature transmitter TT201–33 for AOT 1–6. This
page display trends with a update frequency (sample time) of 30 seconds.
3.10 Page 4.4 – Trend – AOT 7–12, TT201–33

The page is used to display trend curves for temperature transmitter TT201–33 for AOT 7–12. This
page display trends with a update frequency (sample time) of 30 seconds.
34 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.12 Page 4.6 – Trend – AOT 7–12, TT401
3.11 Page 4.5 – Trend – AOT 1–6, TT401

The page is used to display trend curves for temperature transmitter TT401 for LDC for AOT 1–6.
This page display trends with a update frequency (sample time) of 30 seconds.
3.12 Page 4.6 – Trend – AOT 7–12, TT401

The page is used to display trend curves for temperature transmitter TT401 for LDC for AOT 7–12.
This page display trends with a update frequency (sample time) of 30 seconds.
Book No.9000479 02, rev. 0 35

3.13 Page 5.1 – System info 3 Detailed page descriptions
3.13 Page 5.1 – 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 5.1
Section on page Description
HMI info CPU temperature (°C): Temperature of the central processor unit
(CPU) in the control panel.
Free memory (mb): Free memory space in the control system.
CPU load (%): Current CPU usage in percent of total capacity.
IX version; IMG version; CAT control version; Version: N/A.
IP-settings
Setup button: Opens popup to set IP address for the main panel
and the remote control panels (optional).
36 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.13 Page 5.1 – System info
HMI date and time UTC Time and date: Only used if no GPS is connected to the control
system. If so, time is retrieved from the GPS.
Set button: Set time and date for the control panel.
Synchronize button: PLC is synchronized to use same date and

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

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

“PureBallast Backup”:
• Audit trail (tracking of actions in the control system, e.g. changed

password, acknowledged alarms, changed parameter values).
Saved in file AuditTrail.sdf.
• Parameter settings. Saved in file Parameters.csv.
• Settings for trend pages, e.g. min and max values for different
components. Saved in file ValueTrendLegend.xml.
• Passwords. Saved in file Security.xml.
• Notpad.txt. Can be used to make notes for the backup.
Restore button: Restore all information from a USB backup to
the control system. See Backup above. This shall not be used to
restore parameter settings after software update.
Parameters: Restore manually changed parameter to default

values.
Set default button: Set all parameter values to the default values.
History to PLC USB: Export information to the USB port on the

PLC inside the control cabinet.
Backup button: The following information is saved in a folder named

“PureBallast Export”:
Book No.9000479 02, rev. 0 37

3.13 Page 5.1 – System info 3 Detailed page descriptions
• Database including alarm history, trend history etc. Saved in

file Database.sdf.
• Audit trail (tracking of actions in the control system, e.g. changed
password, acknowledged alarms, changed parameter values).
Saved in file AuditTrail.sdf.
• Settings for trend pages, e.g. min and max values for different
components. Saved in file ValueTrendLegend.xml.
Export log files Export: Export (copy) event log and alarm list is saved as a set of
files in a folder named “PureBallast”.
For specific information about logged events, see section List of

logged information, Event log on page 83.
38 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.14 Page 5.2 – Main controller I/O
3.14 Page 5.2 – Main 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 available (displayed) for
login level 3.
Book No.9000479 02, rev. 0 39

3.15 Page 5.3 – Operation timers 3 Detailed page descriptions
3.15 Page 5.3 – Operation timers

The page is used to display operation counters for the components indicted in the illustration.
3 5.3
Row Unit
Accumulated ballast volume (FIT 201-1) m3
Accumulated deballast volume (FIT 201-1) m3
Control valve V201-8 total runtime Time opened
Filter back-flush via V309-1 Number
Filter motor M709–42 Runtime
CIP pump P320-1 Runtime
40 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.15 Page 5.3 – Operation timers
Row Unit
CIP pump runtime P321-5 Time
Total number CIP:ed AOTs. Number
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 AOTs it is possible to CIP before it is time to change CIP
liquid. Requires login level 2.
Book No.9000479 02, rev. 0 41

3.16 Page 5.4 Operation timers: AOT 1–12 3 Detailed page descriptions
3.16 Page 5.4 Operation timers: AOT 1–12

The page is used to display operation runtime for AOTs:
3 5.4
AOT operation Total Lap time

timers
AOT 1: Lamps Total runtime for the UV lamps in Lap time for installed UV lamps, since
on respective AOT. 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 2.
AOT 1: LDC Total runtime for the LDC for

power on respective AOT.
42 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.17 Page 5.5 – Remote interface 1
3.17 Page 5.5 – Remote interface 1

This page is used to monitor data sent between PureBallast’s PLC and the vessel’s ISCS. Data
is displayed in the following forms:
• Binary: Only the number of digits used are displayed.

• Decimal form: Actual values are displayed.
• Hexadecimal: Only used for Time (111 and 112).
For detailed information about respective address: See chapter 6. Installation description and
drawings, section Communication between PureBallast PLC and remote interface.
3 5.5
Function buttons Description
Online Activates the remote interface communication between the

PureBallast’s PLC and the vessel’s ISCS.
Offline Deactivates the remote interface communication between the

PureBallast’s PLC and the vessel’s ISCS.
Controller(s) Opens a popup to make settings for the remote interface

(optional) communication with the PLC. See Set remote interface
communication on page 75.
Book No.9000479 02, rev. 0 43

3.18 Page 5.6 – Remote interface 2 3 Detailed page descriptions
3.18 Page 5.6 – Remote interface 2

This page is used to monitor alarms sent from PureBallast’s PLC to the vessel’s ISCS. The data is
displayed binary form.
For detailed information about respective address: See chapter 6. Installation description and
drawings, section Communication between PureBallast PLC and remote interface.
3 5.6
44 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.20 Page 5.7 – Log box 1
3.19 Page 8.1–8.6 – Parameter pages

These pages are used to set parameters. See chapter 4. Parameters for detailed information
about parameters and the parameter pages.
3.20 Page 5.7 – Log box 1

This page is used to administer and monitor the feedback from external components connected
via the log box (optional).
3 5.7
Book No.9000479 02, rev. 0 45

3.21 Page 5.8 – Log box 2 3 Detailed page descriptions
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 Vessel ID “Valve X45” is entered for position V01.
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
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.
Example: In the illustration V03 is indicated as closed.
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.
3.21 Page 5.8 – 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 5.7 Log box 1 for information about function, fields and buttons.
46 Book No.9000479 02, rev. 0

3 Detailed page descriptions 3.22 Popup windows
3 5.8
3.22 Popup windows

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

The popup is displayed when the AOT is pressed in the flow chart. The popup displays status
values for one AOT and its related sub components. The specific AOT to be monitored, is selected
in the AOT number field.
In manual mode (login level 2 and 3) it is also possible to operate components manually. If the
component is pressed, a popup window is displayed from which the sub components can be
operated.
Book No.9000479 02, rev. 0 47

3.22 Popup windows 3 Detailed page descriptions
3 1.1 AOT pop
Component Description
AOT number Indicates which AOT that is selected and displayed. Press the field to enter
an AOT number, or press the arrows to step up or down.
AOT Status indication: ”Stopped” or “Active” is written beside the AOT.
Indicates that there is an active alarm for the selected AOT. Check alarms
on page 3.1 – Alarm list.
3Alarm
UV lamps Status indication:
Grey = Off.
Green = Started.
Yellow = Starting.
48 Book No.9000479 02, rev. 0

LPS manual Open the Manual LPS operation popup, which enables manual operation
control of individual UV lamps in an AOT. See section Page 1.1 Manual LPS
operation popup and instruction Operate UV lamps manually on page 63.
The button is displayed for login level 2.
LS201–29 Level switch indicates if the AOT is filled with water or not.
Status indication:
Green = Filled.
Red = Not filled.
TT201–33 Temperature indicator TT201-33 indicates current temperature in displayed

TT401 AOT reactor and TT401 in the corresponding LDC.
TS201–60 Temperature switch TS201–60 automatically shuts down the AOT reactor
when the temperature reaches 60 °C.
Status indication:
Green = OK.
Red = Not OK.
UV intensity UV sensor (optional) QT201–50 indicates water transmittance in the AOT

reactor. When transmittance falls below value set in parameter p221 a
warning is issued.
Valves For status indications, see Status indication – Component color in section
Flow chart on page 19.
3.22.1.1 Manual LPS operation popup
Each AOT is equipped with twelve lamp power supplies (LPS), which respectively supplies power to
the one UV lamp in the reactor. The UV lamps can be operated via the LPSs in manual mode. The
LPSs are installed in the lamp drive cabinet (LDC).
The popup is displayed when the LPS manual control button is pressed in the AOT popup. The
popup displays status for all individual UV lamps in a selected AOT.
In manual mode (login level 2 or 3) it is also possible to operate UV lamps manually. See instruction
Operate UV lamps manually on page 63. 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.9000479 02, rev. 0 49

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 LPSpop
Manual LPS Indicates which AOT LPS are to be operated. Press the field to change
operation for AOT.
AOT
LPS 1–12 Press one button (1–12) to start or stop UV lamp 1 – 12 manually,
controlled by the LPS.
Status indication:
Blue with checkmark = Lit
Blue without checkmark = Off
Grey = Not selectable.
Indicates that there is an active alarm for the component. Check alarms
on page 3.1 – Alarm list.
3Alarm
50 Book No.9000479 02, rev. 0

Start all lamps Press the button to start all lamps for the AOT.
Stop all lamps Press the button to stop all lamps for the AOT.
LPS mode A hand icon indicates that the component has been modified manually.
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.
In manual mode (login level 2 or 3) it is also possible to operate components manually. If the
component is pressed, a popup window is displayed from which the sub component can be
operated. When manual mode is deactivated the system will return to standby mode: All manually
operated components will return to their status prior to the manual operation.
3 1.1 Filter
Diff. pressure Indicates differential pressure over the filter.

over filter
Initiate back- Press the button to start a manual back-flush. See instruction Back-flush
flush filter manually on page 57.
Valves and motor See Page 1.1 – Overview section Status indication – Component color
for status indications.
Book No.9000479 02, rev. 0 51

3.22.3 CIP popup

The popup is displayed when the CIP is pressed in the flow chart. The popup displays status
values for the CIP and its related components.
In manual mode (login level 3) it is also possible to operate components manually. If the component
is pressed, a popup window is displayed from which the sub component can be operated. When
manual mode is deactivated the system will return to standby mode: All manually operated
components will return to their status prior to the manual operation.
Valves and motors: See Page 1.1 – Overview section Status indication – Component color for
status indications.
3 1.1 CIP
52 Book No.9000479 02, rev. 0

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

Follow this instruction to ballast. The system automatically selects the number of AOTs required
for the selected flow.
• This operation requires login level 1.

• The Alarm list (page 3.1) 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).
• Selection of specific AOTs to be used can only be done before a process is started (stand
by mode).
• 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.
Book No.9000479 02, rev. 0 53

4.2 Perform ballast 4 Operating instructions
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 AOTs have been selected in page
1.3 AOT and flow selection.
As default, last selected flow is used. If you want to, change flow according to instruction
Change ballast / deballast flow on page 57.
2. Wait for the message “Open valves ...”. Open relevant valves 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: 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
back-flush is performed.
5. Wait for the message “Close valves ...”. Close relevant valves and then press the button in the
6. Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the
NOTE
A CIP cleaning process must be performed after ballasting. It can be done immediately or within 30 hours. When
time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made in the control
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 1.4 CIP status. A CIP
process is started manually according to instruction CIP clean AOT after ballast / deballast on page 58.
4.2.2 Start ballasting with specified AOTs

Follow this instruction to ballast with a specified number of AOTs to be used during ballasting.
• See the list under the Perform ballast on page 53.

by mode).
54 Book No.9000479 02, rev. 0

4 Operating instructions 4.3 Perform deballast
1. Go to page 1.3 AOT and flow selection.
2. Press the AOT selection button on the right hand side of the page.
Result: A popup is displayed. Installed AOT are displayed and previously activated AOTs are
indicated by a green checkmark.
3 AOTselect
3. Press the button for the AOTs you want to activate.

Result: The AOT is selected, indicated by a green checkmark on the button. The field
Corresponding flow setpoint is updated with 250 m3/h for each AOT.
4. Press the Confirm button to activate the selection.

Result: The following information is updated on the page: The AOTs that will be used are
listed under AOTs selected for process. The flow is updated in the field Certified flow
when the lamps are started. If the flow is increased over the capacity of the selected AOTs,
the control system will choose which AOT that will be added, based on which AOT has the
lowest UV lamp usage time.
5. Continue with the Start ballasting instruction above.
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/deballasting. The valve after the ballast pump must be closed.
by mode).
Book No.9000479 02, rev. 0 55

4.4 Pause ballast / deballast 4 Operating instructions
1. Press the function button Deballast.

Comment: If the button is not blue, check that flow or AOTs have been selected in page
1.3 AOT and flow selection.
As default, last selected flow is used. If you want to, change flow according to instruction
Change ballast / deballast flow on page 57.
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
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and deballasting starts.
Result: Ongoing process is stopped and the lamps are switched off.
NOTE
A CIP cleaning process must be performed after deballasting. It can be done immediately or within 30 hours.
When time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made
in the control 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 1.4
CIP status. A CIP process is started manually according to instruction CIP clean AOT after ballast /
deballast on page 58.
4.4 Pause ballast / deballast

Follow this instruction to pause an ongoing ballast or deballast process. This instruction is also
used before heeling (internal transfer), if no external signal for heeling mode is integrated between
PureBallast and the vessel’s ISCS.
• 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 the paused process
is stopped.
56 Book No.9000479 02, rev. 0

4 Operating instructions 4.6 Back-flush filter manually
1. Press the function button Pause.
Note: If you pause to perform heeling (internal transfer) you confirm the request without
stopping the ballast water pump.
Result: Ongoing process is paused. The UV lamps remains on and cooling water is run
through the AOT to avoid overheating of the lamps. Pause mode is indicated by yellow light
under the Pause button and blinking yellow under the function button Ballast or Deballast.
3. To resume the paused process, press the function button Ballast or Deballast.
4. Wait for the message “Confirm ballast pump started”. Start the pump and press the button in the
Result: The process is resumed.
4.5 Change ballast / deballast flow

Follow this instruction to increase or decrease flow during an ongoing ballasting or deballasting.
• Flow can either be set before the operation is started, or during operation. Flow can only be
changed in the sub process full ballast or full deballast. Selected certified flow for operation is
indicated in the Status box.
• There must be available power for the increased flow. If power management is integrated, this
will be done automatically. If power management is not integrated, confirm this manually.
1. Go to page 1.3 AOT and flow selection.
2. Set flow on the left hand side of the page: Press the Increase button to increase or Decrease
arrow button arrow to decrease.
Result: Setpoint for flow is updated in the Flow setpoint field with 250 m3/h for each time
the button is pressed.
3. Press the Confirm button to activate the selection.

Result: The flow is updated in the field Certified flow when the lamps are started. The change
of flow is executed and can be monitored in the Flow field in this page and page 1.1 Overview.
4.6 Back-flush filter manually

Follow this instruction to back-flush rinse the filter manually.
Book No.9000479 02, rev. 0 57

4.8 Stop ballast / deballast 4 Operating instructions
• 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 Initiate back-flush button.

Result: A back-flush is performed. The default back-flush cycle time is 20 seconds.
4.7 CIP clean AOT after ballast / deballast

Follow this instruction to clean the AOT(s) using the cleaning in place (CIP) process. This instruction
applies if the CIP cycle was not activated at the end of a ballast operation.
If System shut down is activated during the CIP cycle, the CIP liquid is drained to the CIP tank and
any water in the AOTs 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 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
Result: The automatic CIP cycle starts. The CIP cycle takes 15 minutes per AOT.
4. 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.
58 Book No.9000479 02, rev. 0

4 Operating instructions 4.9 Attend to alarms
Result: Ongoing process is stopped and the lamps are switched off. If ballasting: The filter is
rinsed by an automatic back-flush process.
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 1.4 CIP status.
4.9 Attend to alarms

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 the blinking alarm icon in the control panel:
3Alarm
NG
WARNI
!
• Never reset an alarm without first finding and attending to the problem.
1. Go to page 3.1 Alarm list to view active alarms.
2. Select an alarm by pressing the alarm row.
• If the alarm has caused the system to automatically stop, go to step 3.

• If the alarm allows the ballast process to continue, go to step 5.
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 or started when the fault has
been corrected.
Book No.9000479 02, rev. 0 59

4.10 Abort operation and deactivate the 4 Operating instructions
system
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 button after the problem has been dealt with. If you want to
acknowledge all alarms, press the Ack all button.
Result: The alarm will change color to indicate change of status. See section Page 3.1 Alarm
list in this chapter. The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.
4.10 Abort operation and deactivate the 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 dead (currentless).
3 Emergency stop
One of the following methods can be used to abort any ongoing operation and stop the system:
Action Method
Abort operation Press the Stop button (2) on the control cabinet.
Result: Ongoing process is stopped in a controlled way. Valves are
returned to starting position. The power is still on.
Safety stop If an external safety stop button dedicated for PureBallast has been
installed, it will function as described above. In the alarm list, it is
referred to as stop by “external system”.
60 Book No.9000479 02, rev. 0

4 Operating instructions 4.12 Operate components manually
Action Method
Deactivate Complete deactivation is performed in two steps:

PureBallast to
make it dead 1. Press the main breaker (1) at the side of the control cabinet.
(currentless).
2. Tilt the main breaker inside the LDC.
Both breakers are marked at respective cabinet.
Turn of power Turn off the main breaker (1) at the side of the control cabinet. The
completely to system is made completely dead (currentless) from the power supply
PureBallast cabinet/main switch board, including the control cabinet.
4.11 Reset system after shut down

Follow this instruction to reset the system if deactivated. Numbers refer to the illustration under
instruction Abort operation and deactivate the system on page 60.
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 done:
Manual on control cabinet: Reset the Stop button (2) or turn the main breaker (1).
Automatic on LDC: If an AOT 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, follow the instruction below:
1. Turn on the power to the cabinet/system.

2. Push the reset button on the LDC for the shut down AOT. 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.
4.12 Operate components manually
Follow this instruction to operate components manually. This shall only be done during
commissioning, advanced faultfinding or service.
The following components can be operated manually:
• 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.
• Filter motor (M709-42)
• CIP pump for CIP liquid (P320-1)
• CIP pump for draining (P321-5)
• Booster pumps (if used)
• UV lamps in the AOT
Book No.9000479 02, rev. 0 61

4.12 Operate components manually 4 Operating instructions

• Current status for components are displayed in the flow chart. See the Components – Status
indication section under heading Page 1.1 Overview.
• 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).
2. Press the button Enable manual mode in the Flow chart.

Result: The control system is set in manual mode, indicated by a green checkmark on the
button.
3. Press the component you want to operate.

Result: A popup is opened. Current status is indicated. If an existing alarm exist, it is indicated
with an alarm icon. If the AOT, filter or CIP was pressed, a new popup is opened, where
integrated components can be opened. See example of a pump popup below:
3 PopValve
4. Press the Hand icon to enable manual operation of the component.

Result: The hand starts to blink.
5. Operate the component using the buttons in the popup.

Result: Status change is effectuated. The popup remains open.
Press the X button to close the popup.

Result: The popup is closed and a hand icon is displayed by the component, indicating that it
has been manually modified.
6. Exit manual mode.

Alternative 1: Press the Enable manual mode button.
Alternative 2: Log out.
Result: All manually operated components are restored to their previous status.
62 Book No.9000479 02, rev. 0

4 Operating instructions 4.13 Operate UV lamps manually
4.13 Operate UV lamps manually

Follow this instruction to start and stop individual UV lamps in an AOT. 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. Improper
operation of this function could seriously damage the equipment and injure personnel.
2. Press the AOT image.

Result: The AOT popup opens. (See description on page 47.)
3. Select which AOT to operate in the AOT number entry field.
4. Open, in stated order, the following valves to fill the AOT with water: 201-19, 404-36 and
403-35.
5. Wait until the AOT is filled with water. This is indicated by the level switch, which turns green.
6. Press the LPS manual control button. (The button is displayed for login level 3.)
Result: The LPS popup is displayed for selected AOT. If an existing alarm exist, it is indicated
with an alarm icon. Each lamp is represented by a button, indicating there status:
Grey = Stopped; Green = Started; Yellow = Starting.
Book No.9000479 02, rev. 0 63

4.14 Set parameters 4 Operating instructions
3 LPSpop
7. Operate the lamps by pressing one of the following buttons:

Start all lamps.
Stop all lamps.
LPS1-12: Start or stop an individual lamp. Each UV lamp is powered by one dedicated lamp
power supplies (LPS). Each individual UV lamp is operated (started and stopped) via its
dedicated LPS. The buttons toggles between started and stopped.
Close: All lamps are stopped. The popup is closed.
8. If you want to operate lamps for another AOT, go to step 3. If you want to end, continue
with step 9.
9. Close the LPS popup and then the AOT popup.
10. Press the Manual mode button.

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

Follow this instruction to set or change parameters.
NOTE
• Parameters shall only be set by Alfa Laval.

• These instructions require login level 3 or 4.
64 Book No.9000479 02, rev. 0

4 Operating instructions 4.16 Backup control system settings
1. Go to desired parameter page 8.1–8.6.

Result: The page is displayed with all parameters listed in rows with three columns displaying
values.
• Left column = Minimum value

• Middle column = Current setting (entry field with white background)
• Right column = Maximum value
2. Press the entry field for the parameter to be changed.
Result: A keyboard is displayed.
If the parameter is set with a drop down menu, the alternatives are displayed.
3. Use the touch keys to enter data, and confirm the entry 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.
4.15 Restore default parameters

Follow this instruction to reset all parameters in the control system to the default values.
• This operation requires login level 2 or 3.

1. Go to page 5.1 System info.
2. Press the Default parameters button in page section Parameters.

Result: A popup is displayed.
3. Press Yes in the popup.

Result: All parameters are reset.
4.16 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:
• Audit trail (tracking of actions in the control system, e.g. changed password, acknowledged
alarms, changed parameter values). Saved in file AuditTrail.sdf.
• Parameter settings. Saved in file Parameters.csv.
• Settings for trend pages, e.g. min and max values for different components. Saved in file
ValueTrendLegend.xml.
Book No.9000479 02, rev. 0 65

4.17 Restore control system settings 4 Operating instructions
• This operation requires login level 1–3.

• This routine is performed in the main panel.
2. Place a USB memory at the back of the panel.
3. Press the Backup button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the occur.
Read the final line of list before closing the popup: Important information might be displayed.
4. Wait for the OK / Close button to turn blue again. If the backup was successful, the last line
shall state "Backup done".
Result: A folder named PureBallast backup has been downloaded containing the backup files.
5. Remove the USB memory.
4.17 Restore control system settings

Follow this instruction to restore all control system settings, previously saved to a USB memory.
This includes parameters, passwords and settings for the trend pages 4.1 — 4.6.

• 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 5.1 System info, section on page 36.
• This method shall not be used to restore parameter settings after software update. Instead,
follow instruction Update PLC software using a flash card.
• If you do not wish to update a certain type of setting, remove the specific file from the USB
memory before inserting it into the control panel.
3. Press the Restore button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the occur.
4. Wait for the OK / Close button to turn blue again.
5. Read the final line of list before closing the popup: Important information might be displayed. If
the restore was successful, the last line shall state "Restore done".
6. Press the OK button on the popup and remove the USB memory.
66 Book No.9000479 02, rev. 0

4 Operating instructions 4.18 Export control system log files
7. The control panel must be rebooted. At the rear side of the control panel: Pull out the power
cable from the 24V DC port, and insert it again.
4.18 Export control system log files

Follow this instruction to copy control system information as a text file to a USB memory. The text
file can then be analyzed either in Excel (or similar tools) or in Visualog. Visualog is a tool designed
to present and analyze the information from the PureBallast log files.
The following information can be exported:
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 IMO.
Certificate
Alarm history A list of all alarms and warnings that has been issued from the control
system. Intended to be used mainly by service technicians.
For specific information about logged events, see section List of logged information on page 83.
• Events are only copied, hence they will remain in the control system.
• Required USB memory capacity is indicated in the Export PLC events popup.
• The program Visualog must be used to open the files saved.
2. Press the Export button in page section Export log files.

Result: Popup Export PLC events is displayed.
3. Wait for message: Insert USB in PLC. Place a USB memory in the Main PLC module (A01) in
the control cabinet.
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.
Book No.9000479 02, rev. 0 67

4.20 PID calibrate system 4 Operating instructions
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 choices contains a CSV file.
7. Press Close and remove the USB memory
4.19 Export control system history files

Follow this instruction to export all settings made in the control system to a backup on a USB
memory.
The following information is saved:
• Database, including alarm history, trend history etc. Saved in file Database.sdf.
• Audit trail (tracking of actions in the control system, e.g. changed password, acknowledged
alarms, changed parameter values). Saved in file AuditTrail.sdf.
• Settings for trend pages, e.g. min and max values for different components. Saved in file
ValueTrendLegend.xml.
• This operation requires login level 1–3.

3. Press the Backup button in page section Backup and restore, History to HMI USB.
Result: A popup is displayed and the process is started. All activities are displayed as the
occur. Be sure to read the final line of list before closing the popup: Important information
might be displayed.
4. When the message “Export done” is displayed, press the OK button on the popup.
Result: A folder called PureBallast Export is created on the USB memory.
5. Remove the USB memory.
4.20 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.
68 Book No.9000479 02, rev. 0

4 Operating instructions 4.20 PID calibrate system
During back-flush, the control valve is PID regulated based on input from the pressure transmitter
PT201-16 to maintain stable pressure for efficient back-flush. Desired pressure is defined in
parameter p304.
4.20.1 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. 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 back-flush trigger to start of actual back-flush. This is
done by shortening the time in p310 (Back-flush initial delay). This is done after the movement of
V201-8 has been calibrated.

• All components on page 4.1 Trend (1 s.) 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 back-flush.
2. Open page 4.1 Trend (1 s.) and analyze the trend curve for V201-8.
Before the back-flush, 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 back-flush.
4. See if the curve has improved. Repeat until satisfactory result has been achieved.
5. See if the time between back-flush initiation and back-flush can be shortened . If possible,
adjust parameter p310. See parameter p310 in the example below.
Example
In this example, five back-flushes are performed. After the first four back-flushes, the PID
parameters where changed for pressure regulation to adjust the movement of the control valve
V201-8 before the back-flush.
The illustration is taken from page 4.1 Trend (1 s). Back-flush is indicated by the movement of the
back-flush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated by the
blue line.
1st back-flush 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 back-flush Parameter p166 was adjusted to 0.6. This made the valve movement much faster
in the beginning, shown by the steep curve at the beginning. But then a more slow
regulation starts, shown by the soft slope (2). This was a change for the better, but
not enough.
3rd back-flush Parameter p166 was increased to 1.2 which resulted in a satisfactory valve
movement (3): A fast movement, followed by a minor adjustment. A small
overcompensation can be noted (curve goes too low), that might be adjusted by
decreasing the value to 1.1.
Book No.9000479 02, rev. 0 69

4.20 PID calibrate system 4 Operating instructions
4th back-flush During the first back-flushes, parameter p310 was set to 60 seconds. The
parameter defines time between a back-flush is triggered and it actually starts. But
now, when V201-8 is calibrated, this time can be shortened. Before the fourth
back-flush parameter p310 is set to 15 seconds. The shortened time span is
indicated by the braces in the illustration.
5th back-flush No parameter was changed. This back-flush 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 back-flush three and four (3 and 4).
3 CalibExample
4.20.2 Calibrate flow controlled regulation

The purpose is to define a default opening percentage for control valve 201-8 based on the actual
condition on the vessel.
The purpose is to update settings below, based on the calibration. These values are saved as
parameters, which can only be set by this process.
• Pf — Proportional
• If — Integral
• Df — Derivative

• The control system must be in standby mode.
• This operation is only performed during commissioning preparation and commissioning.
70 Book No.9000479 02, rev. 0

4 Operating instructions 4.20 PID calibrate system
2. Press the PID button beside the control valve 201-8 in page 1.1 Overview.
Result: PID calibration popup is opened. In the popup, the current parameter (parameter
p120–p122) values are displayed in the Actual column: Pf, If and Df.
3 PopPid
3. If you want to start the PID calibration with a manually set start value, enter the values in
the Calculated entry fields. This can be used if you have approximate values based on
experience. If
4. Press the Open valves button.

Result Popup Confirm “Ballast pump” started. is displayed.
5. Start pump (This component is outside the PureBallast system control.). When done, press the
Confirm “Ballast pump” started button.
6. Press the Start calibration button in the Activate PID calib popup.
Result:
• Calibration starts, indicated by the Calibration in progress light.

• Values for (Pf, If and Df) are displayed in the Calculated column as they are calculated.
7. Wait until the calibration status is updated to Calibration ready.
8. Wait for the popup “Confirm ballast pump stopped”. Stop ballast pump. When done, press
the Confirm ballast pump stopped button.
Book No.9000479 02, rev. 0 71

4.21 Simulate power request 4 Operating instructions
9. Choose one of the following alternatives:
• Press the Save to parameter button to save the calculated calibration values to parameter.
At the same time, the Actual column is updated with these values.
• Adjust the calculated values before you save them. Enter the values in the Calculated
entry fields. Then press the Save to parameter button.
• Press the Read from parameters button to reload current parameter values. The
Calculated column is updated with the current values from the Actual column. This is
useful if you have modified the values and want to reset the values.
• Press the Abort / Exit button to exit the popup without saving any data.
4.21 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 2 or 3.

1. 1. Go to page 1.1 Overview. Press the button Enable manual mode in the Flow chart.
Result: The control system is set in manual mode, indicated by a green checkmark on the
button.
2. Go to page 1.6 Power request.
3. Press the hand button in the Request column for a row with power step for desired number of
AOTs. For details, see description of page 1.5 – Power request.
4. Press the Request button for the row to simulate power request signal.
Result: Status is updated to “Requested” in the Request column.
5. Wait until the status is updated to “Yes” in the Granted column.
6. Press the hand button in the Status column.
7. Press the Set run button to simulate running signal.

Result: Status is updated to “Running” in the Status column.
8. Press the Set run button to deactivate the simulate running signal.
9. Go to page 1.1 Overview and press the Enable manual mode button to exit manual mode.
72 Book No.9000479 02, rev. 0

4 Operating instructions 4.22 Set control panel IP address
4.22 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 only be done by Alfa Laval.

• These instructions require login level 3.
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
4. At the backside of the panel, check which port that is use for the Ethernet cable. The one
marked with the symbol below is port 1 and the other one is port 2.
3 USB
In the popup, select the tab for the port that is used. Then select the radio button Specify
an IP address.
Enter the IP address for the panel according to the list below:
• Main panel: 192.168.0.10.

• Remote control panel 1: 192.168.0.11.
Book No.9000479 02, rev. 0 73

4.23 Set remote control panel communication 4 Operating instructions
Not that only the IP address shall be set.
5. Press OK.
6. Repeat this instruction for all installed remote control panels.
7. Follow the instruction Set remote control panel communication to activate the remote control
panel.
4.23 Set remote control panel communication

Follow this instruction to connect all remote control panels (optional) to the PLC.

• IP addresses must have been set according to instruction Set control panel IP address.
• Remote control panels to be connected must be on and connected with an Ethernet cable.
1. On the main panel, go to page 8.6 Installation parameters.
2. In the Remote panels box, press the Set button.

3. Press the Set button.

3 RCP communication
4. Select an available remote control panel (IP address ending with 11–14 in the left list.
74 Book No.9000479 02, rev. 0

4 Operating instructions 4.24 Set remote interface communication
5. Press the >> button.

Result: The panel is connected and moved to the right list.
6. Press the Panel alias field for the new panel. Use the keyboard to enter a name, for example
the location it is placed.
7. Press the save (diskette) icon.

Result: The information is saved and the popup is closed.
8. Repeat this instruction for all installed remote control panels.
To delete a connected panel: Select it in the right list and press the delete (X) icon.
4.24 Set remote interface communication

Follow this instruction to make settings for the remote interface (optional) communication to the PLC.
NOTE

1. On the main panel, go to page 5.5 Remote interface.
2. Press the Controller(s) button.

3 RI communication1
Book No.9000479 02, rev. 0 75

4.25 Test remote interface communication 4 Operating instructions
3. Press the ModubusSlave line. Make sure that the check box is still selected. Then press
the Settings button.
3 RI communication2
4. Scroll down in the list until you find the Serial section. Change the fields to match the settings
in the illustration above.
4.25 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.
• There must be no active alarms for the AOTs to be used during operation. Always check the
alarm list (page 3.1 Alarm list in the control system) before operation.
• If the system has been shut down, it must be reset:
- Control cabinet: Stop button must be released and the main breaker must be on.
- LDC: Cabinet must be reset. If the reset button at the side of the cabinet lights blue, push
it to release it.
76 Book No.9000479 02, rev. 0

4 Operating instructions 4.26 Update PLC software and HMI software
1. Open page 5.5 Remote interface 1. Make sure that the system is in online mode. If not,
press the Online button. Make sure that Local operation is activated. If not, press the Local
function button.
2. Make sure that values are read from the PureBallast system, for example temperature
(address +116 and +117).
3. Make sure that the heartbeat is updated in address +013 and reflected in address +155.
4. Press the Offline button to set the system in offline mode. Press the Remote function button.
Result: Communication is deactivated between the ISCS and the PLC (to avoid that any
processes is started). This also result in alarm A93 Heartbeat signal missing. This alarm
shall be ignored during this test.
5. To test information from PLC to ISCS: Go to page 5.5 Remote interface 1.
6. Enter information in the output fields (100–156) 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.
Note: Only implemented signals needs to be tested.
7. Make sure that values and status information is displayed correspondingly in the ISCS.
8. Go to page 5.6 Remote interface 2. Enter information in the alarm output fields (170–199)
to send simulated information to the ISCS. Make sure that the alarms are displayed
correspondingly in the ISCS.
9. To test information from ISCS to PLC: In the ISCS, activate input commands corresponding
to address 000–099 in page 5.5. (Note that address 013 does not need to be tested; it was
tested at the beginning of this procedure.)
10. Make sure that the information is updated correspondingly in page 5.5.
11. 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”.
12. Press the Online button to set the system in online mode.
4.26 Update PLC software and HMI software

Follow this instruction to update the PLC software for the control system together with the HMI
software for the main panel in the control cabinet. The two softwares are updated at the same
time, since they must have the same version.
• Take a backup according to instruction Export control system log files on page 67. The files are
required to be saved for at least 24 months.
Book No.9000479 02, rev. 0 77

4.26 Update PLC software and HMI software 4 Operating instructions
• Take a backup according to instruction Backup control system settings. Note that this backup is
not used to reload settings, it is only a safety backup.
• We recommend that a screen dump is taken for all parameter pages. (To do that: Insert a USB
into the panel and press function button Utilities, and Print for all pages.) Alternatively, take a
photo. This will facilitate resetting of the parameters.
• The release notes must have been read for the version to be installed.
• Flash card with correct version of the PLC software.
• USB memory with correct version of the HMI software. If the remote interface option is used,
the signal standard (RS422 or RS485) must match the standard used by the ISCS (ships
integrated control system) for communication with PureBallast.
1. Shut off the power to the control cabinet.
2. Remove the old compact flash card from the PLC in the control cabinet, and insert the compact
flash card with the new software.
3. At the rear side of the control panel: Open the small cover and turn DIP switch 1 to position ON.
7BeijerMODE
4. Turn on the power to the control cabinet and wait for the panel to reboot.
5. Touch the screen to display a menu: Press “Erase project” and then answer Yes. (If the
system requests a touch calibration, perform it and then erase project.) Wait for popup to
confirm that the project is erased.
6. At the rear side: Pull out the power cable from the control panel, turn DIP switch 1 to position
OFF, insert the USB memory and reconnect the power.
7. Wait for the message “Copy project from USB”. Press Yes.
8. Wait until the program is started and page 1.1 Overview is displayed. Pull out the USB memory.
9. Go to page 5.1 System info. Press the Set default button in page section Backup and
restore, Parameters.
10. Set all parameters in Parameter page 8.1–8.6. Use the screen dumps/photos as reference.
Make sure to set new parameters included in the new version, if any. New parameters are
stated in the release notes.
78 Book No.9000479 02, rev. 0

4 Operating instructions 4.27 Update HMI software
11. If remote control panels are installed, update the HMI software for the other panels according
to Update HMI software below.
4.27 Update HMI software

Follow this instruction to update the HMI software on remote control panels after the PLC software
has been updated, or after the control panel firmware has been updated.
• USB with correct version of the software. Note that the same version must be used for the HMI
and PLC software (same version number).
• If the remote interface option is used, the signal standard (RS422 or RS485) must match the
standard used by the ISCS (ships integrated control system) for communication with PureBallast.
1. At the rear side of the control panel: Pull out the power cable from the 24V DC port. Open the
small cover on the rear side. Turn DIP switch 1 to position ON.
7BeijerMODE
2. Re-connect the power cable and wait for the panel to reboot.
3. Touch the screen to display a menu: Press “Erase project” and then answer Yes. (If the
system requests a touch calibration, perform it and then erase project.) Wait for popup to
confirm that the project is erased.
4. At the rear side: Pull out the power cable from the control panel, turn DIP switch 1 to position
OFF, insert the USB memory and reconnect the power.
5. Wait for the message “Copy project from USB”. Press Yes.
6. Wait until the program is started and page 1.1 Overview is displayed. Pull out the USB memory.
7. If remote control panels are installed, repeat this instruction for all remote control panels.
Book No.9000479 02, rev. 0 79

4.28 Update control panel software 4 Operating instructions
4.28 Update control panel software

Follow this instruction to update the software (firmware) for the control panel.
• USB with correct version of the software.

1. At the rear side of the control panel: Pull out the power cable from the 24V DC port. Open the
small cover on the rear side. Turn DIP switch 1 to position ON.
7BeijerMODE
2. Insert the USB memory and reconnect the power.
3. Wait for request to upgrade and delete project. Answer Yes to both. (If you don’t get the
question, set DIP switch to OFF, and try again. Or copy the files to another type of USB
memory.)
4. Wait for the request on screen to update software. Press Yes within ten seconds.
Result: The new software is downloaded to the panel.
5. Wait for request to reboot: Remove the USB and reboot the panel. (Some older panels freeze
at this stage. If so, pull out the power cable and reconnect it to reboot.)
6. When the screen has rebooted: Follow the instructions on screen to perform a touch calibration.
7. In the menu displayed: Press “IP settings”, and set according to instruction Set control panel IP
address on page 73. The firmware is now installed.
8. Next step is to install the HMI software. This must be done after the firmware has been
updated. Go to step 3 in instruction Update HMI software.
9. If remote control panels are installed, repeat this instruction for all remote control panels.
80 Book No.9000479 02, rev. 0

4 Operating instructions 4.29 Calibrate the control panel’s touch
screen sensibility
4.29 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.
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.
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4.29 Calibrate the control panel’s touch screen 4 Operating instructions
sensibility
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.
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. Logged information can be exported to a USB
memory stick. See Export control system log files on page 67.
Event log certificate: Contains events relevant to the IMO certificate. These events are stored
for 24 months. Events included are equal to the events that are GPS stamped in the table below,
with exeption 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 External bypass of PureBallast is detected open Y
140 External bypass of PureBallast is detected closed Y
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5.1 Event log 5 List of logged information

code stamp
150 Feedback received, "overboard is OPEN" Y
160 Feedback received, "BW-pump is running" N
170 External Shutdown of PureBallast issued N
180 External Stop of PureBallast issued N
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 Back-flush 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
84 Book No.9000479 02, rev. 0

5 List of logged information 5.1 Event log

code stamp
390 Request sent to ISCS; start BW-pump N
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 External bypass 1 is detected open Y
470 External bypass 1 is detected closed Y
520 AOT 1 UV sensor low level Y
630 AOT12 UV sensor low level Y
640 AOT 1 UV sensor value: [X] W/m Y
Book No.9000479 02, rev. 0 85


code stamp
670 AOT4 UV sensor value: [X] W/m Y
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
86 Book No.9000479 02, rev. 0

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.9000479 02, rev. 0 87

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

Standby mode is the starting point of PureBallast. Standby mode is active at system start-up or
when no other process is active. From Standby mode, the following processes and sub processes
can be started.
• Ballast
• Deballast
• CIP
• Deactivate system
• Change flow (set flow before a ballast or deballast process)
• Manual mode.
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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).
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6 Detailed process description 6.2 Ballast process
5. UV lamp warming
• Open V404-36 (cooling water outlet)

• Open V201-19 (reactor inlet).
6. Cooling water fills the AOTs. When filled, indicated by LS201-29:
• Start UV lamps. Runtime for ignited UV lamps starts

• Open V201-20 (reactor outlet)
• Set V201-8 (control valve) to parameter set opening percent.
7. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8. Ballast water pump started by operator and confirmed in control system.
9. Open V201-3 (filter inlet).
6.2.2 Full ballast

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

- Stop P403-1 (booster pump for reactor cooling water) (if used)
- Stop P401-1 (booster pump for LDC cooling water) (if used)
• - Close 403-35 (cooling water inlet)
- Close V404-36 (cooling water outlet)
- Start automatic control of control valve (V201-8) based on input from the flow meter.
6.2.3 Filter back-flush

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 back-flush 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.
2. Filter back-flush 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.
Book No.9000479 02, rev. 0 91

3. Differential pressure check. If necessary, the process is repeated.
6.2.3.1 Change flow - Increase flow
Purpose: To increase the ballast water flow during ballasting (full ballast).
1. Operator adjusts the certified flow from the control system.

2. Automatic power request from PureBallast to vessel’s power management system (if integrated).
3. Component activities when power has been granted. (Eventual ongoing back-flush will finish
before the activities are effectuated):

4. Component activities when added AOTs are filled, indicated by LS201-29. During warm-up, the
lamps are cooled with ballast water, sea-to-sea.
• - Start UV lamps
- Start counter: UV lamp runtime
• Close V404-36 (cooling water outlet)
6.2.3.2 Change flow - Decrease flow
Purpose: To decrease the ballast water flow during ballasting.
1. Operator adjusts the certified flow manually from the control system.
• - One or more AOTs are switched of
- Stop counter: UV lamp runtime
- Close V201-19 (reactor inlet)
• Close V201-20 (reactor outlet)
• Automatic power request adjustment (if integrated).
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. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
92 Book No.9000479 02, rev. 0

6 Detailed process description 6.2 Ballast process
3. BW pump stopped by operator and confirmed in control system. Component activities:
• Set V201-8 (control valve) to parameter set opening percent

- Open V404-36 (cooling water outlet) on running AOTs
- 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 AOTs
• Close V201-8 (control valve).
4. System in pause mode
5.
Resume ballasting
Operator resumes the ballast process manually.

• Open V201-20 (reactor outlet) on running AOTs.
6. Request from control system to start ballast water pump” (outside PureBallast system).
7. BW pump started by operator and confirmed in control system. (Handled automatic, if external
component signal is enabled.)
• Open 201-3 (filter inlet)

8. Component activities when minimum process flow established, indicated by FIT201-1:
• - Start counter: Accumulated water.

- Close V404-36 (cooling water outlet) on running AOTs
6.2.5 Stop ballast

Purpose: To stop the ballast process.
Book No.9000479 02, rev. 0 93

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
• Switch off UV lamps
• Stop counter: UV lamp runtime
• - Close V201-19 (reactor inlet)
- Close V201-20 (reactor outlet)
• 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)
• Automatic withdrawal of power allocation (if integrated).
2. Filter back-flush
Back-flushing 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. Back-flush 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.)
94 Book No.9000479 02, rev. 0

6 Detailed process description 6.3 Deballast process
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:

Book No.9000479 02, rev. 0 95

6.3 Deballast process 6 Detailed process description
6. Water fills the AOTs.

7. Component activities, when AOTs are filled, indicated by LS201-29:
• Start UV lamps
• Start counter: UV lamp runtime
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.

- Close V404-36 (cooling water outlet) on running AOTs
6.3.2.1 Change flow - Increase flow
Purpose: To increase the ballast water flow during ballasting (full deballast).
2. Automatic power request from PureBallast to vessel’s power management system (if integrated).
3. AOT filling:
• - Open V310-6 (CIP, AOT fresh water filling)

- Open V320-4 (reactor, CIP drain)
- Open V404-36 (cooling water outlet)
96 Book No.9000479 02, rev. 0

6 Detailed process description 6.3 Deballast process
4. Component activities when added AOTs are filled, indicated by LS201-29. During warm-up, the
lamps are cooled with fresh water.
• Start UV lamps
• Start counter: UV lamp runtime
• Open V201-19 (reactor inlet) on running AOTs
• Close V310-6 (CIP, AOT fresh water filling)
• Close V320-4 (reactor, CIP drain)
• Close V404-36 (cooling water outlet)
5. Start automatic control of control valve (V201-8) based on input from the flow meter.
6.3.2.2 Change flow - Decrease flow
Purpose: To decrease the ballast water flow during deballasting (full deballast).
• Automatic pressure and flow adjustment (V201-8)

• One or more AOTs are switched of
• Close V201-19 (reactor inlet)
• Close V201-20 (reactor outlet).
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 (cooling water outlet) on running AOTs.
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 AOTs.
Book No.9000479 02, rev. 0 97

6.3 Deballast process 6 Detailed process description
3. System in pause mode
4. Resume deballasting
Operator resume the deballast process manually.

• Open V201-20 (reactor outlet) on running AOTs.
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)

• Stop P403-1 (booster pump for reactor cooling water) (if used)
- Close 404-36 (cooling water outlet)
• Start counter: Accumulated water.
6.3.4 Stop deballast

Purpose: To stop the deballast 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
• Switch off UV lamps
• - Close V201-19 (reactor inlet)
- Close V201-20 (reactor outlet)
• Close V403-35 (cooling water inlet), only needed if stop from pause mode
• Close V201-9 (main inlet valve).
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.
98 Book No.9000479 02, rev. 0

6 Detailed process description 6.4 CIP cycle
4. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)
6.4 CIP cycle
The CIP cycle is run to remove seawater scaling from the AOT reactor after ballast and deballast.
The process is performed for used AOT 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 58. Note that the process can be stopped at any time.
3 CIPprocess
6.4.1 Start CIP

1. Operator starts the CIP cycle 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.
Book No.9000479 02, rev. 0 99

6.4 CIP cycle 6 Detailed process description
6.4.2 Drain ballast water

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

- Open V321–2 (AOT, upper CIP return valve)
- Open V320–4 (AOT, lower CIP return valve)
- Open V571-1 (CIP, deaeration valve)
- Start P321-5 (CIP, water pump)
2. Component activities, when AOTs 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, upper CIP return valve)
- Close V320–4 (AOT, lower CIP return valve).
6.4.3 Fresh water filling

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

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

- Close V320–4 (AOT, 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, lower CIP return valve)
- Start P321-5 (CIP, water pump).
2. Component activities when AOT 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, lower CIP return valve)
100 Book No.9000479 02, rev. 0

6 Detailed process description 6.4 CIP cycle
6.4.5 CIP cleaning

• - Open V320–2 (CIP outlet to AOT)

- Open V320-4 (AOT, lower CIP return valve)
- Open V321-2 (AOT, upper CIP return valve)
- Open 321–4
- Start P320-1 (CIP, liquid pump).
2. When AOTs are filled, indicated by LS201-29, CIP liquid is circulated for 15 minutes.
3. Component activities after finished CIP cycle .
• - Stop P320-1 (CIP, liquid pump)

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

• Open V321-4 (CIP, return valve)

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

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

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

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

• Close V571-1 (CIP, deaeration valve)
- Close V321-2 (AOT, upper CIP return valve)
- Close V320-4 (AOT, lower CIP return valve).
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6.5 Manual mode 6 Detailed process description
6.4.8 Repeat step 2-7

When CIP cycle is done for the first AOT, the process continues, by repeating step 2–7 for
remaining AOTs with status CIP required.
6.4.9 Filter preservation

1.
Component activities when all required AOTs 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.
• Only login level 3 can set operate control valve V201–8.
• Flow in pipes is not indicated in flow chart.
• Can only be activate from standby mode. PID calibration can not be activated at the same time.
• 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.
102 Book No.9000479 02, rev. 0

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
1.2 Ballast and deballast
1. Go to page 1.3 AOT setup.
2. Check the Certified flow field to see if it is OK. If not, change flow according to instruction
Change flow.
3. Press the Ballast or Deballast function button.
4. Wait for the message “Confirm overboard valve open”. Open the valve and then press the
button in the popup to confirm the action. (The popup is not displayed if the component
feedback is integrated with the control system.)
5. Wait for the message “Confirm ballast pump started”. Start the pump and then press the button
in the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
6. When desired amount of water has been processed, press the function button Stop to end
the process.
7. Wait for the message “Confirm overboard valve open” and “Confirm ballast pump started”.
Handle accordingly. (The popup is not displayed if the component feedback is integrated
with the control system.)
Book No.9000479 02, rev. 0 5

1.4 CIP clean AOT 1 Quick guide to PureBallast operations
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 3.1 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 button after the problem has been dealt with. If you want to
acknowledge all alarms, press the Ack all button.
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 “Confirm overboard valve open”. Open the valve and then press button
in the popup to confirm the action.
Result: The automatic CIP cycle starts. The CIP cycle takes 15 minutes per AOT.
4. Wait for the message “Confirm overboard valve closed”. Close the valve and then press button
in the popup to confirm the action.
6 Book No.9000479 02, rev. 0

1 Quick guide to PureBallast operations 1.5 Export control system log files
1.5 Export control system log files

Follow this instruction to copy control system information as a text file to a USB memory.
• Required USB memory capacity is indicated in the Export PLC events dialog box.
2. Press the Export button in page section Export log files.

Result: Popup Export PLC events is displayed.
3. Wait for message: Insert USB in PLC. Place a USB memory in the Main PLC module (A01) in
the control cabinet.
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
Book No.9000479 02, rev. 0 7

Chapter: 4. Parameters
Book No. 9000479 02, rev. 0

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
2.3 Page 8.1 – Main parameters 1 10
2.4 Page 8.2 – Main parameters 2 14
2.5 Page 8.3 – AOT parameters 18
2.6 Page 8.4 – Filter parameters 20
2.7 Page 8.5 – CIP parameters 23
2.8 Page 8.6 – Installation parameters 24
3 Flow transmitter parameters 27

3.1 Check and set parameters 28
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.9000479 02, rev. 0 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
• The control system display parameters pages are login dependent according to the following:
– Login level 0: Parameter page 8.2–8.6 are displayed.
– Login level 1: Parameter page 8.2–8.6 are displayed. Full access to pages 5.7 and 5.8.
– Login level 2: Full access to parameter page 8.2–8.6 (but not set remote control settings).
– Login level 3: Full access to all parameter pages.
• 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.
2.1 Setting parameters

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.
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 8.2 Main parameters 2.
- All parameters on the page.

• Page 8.3 AOT parameters:
- p200: Time-out AOT draining. This parameter is evaluated during the commissioning
preparation test and adjusted if necessary.
• Page 8.4 Filter parameters:
- p304: Required pressure to start back-flush (PT201–16). This parameter is calculated to

reflect pressure in the specific installation.
- p314: Filter type.
Book No.9000479 02, rev. 0 7

2.2 Introduction to the parameter pages 2 Control system parameters
• Page 8.6 – Installation parameters.
- p106: No of AOT modules installed.

- p107: Max power consumption of PureBallast
- p112: Pipe diameter for flow meter
- p150: Ex proof system.
- p500: Log box.
For instructions on how to set parameters, see chapter 3. Operating instructions and control
system description.
2.2 Introduction to the parameter pages

This section describes the principles for the control system parameters and the parameter pages.
Key to parameter numbers
Control system parameters are identified by item numbers with the following syntax: pX00.
p stands for parameter
X identifies the area/component the parameter controls. X can be

1 = Main parameters
2 = AOT
3 = Filter
4 = CIP
00 unique number for the parameter.
Parameter pages
Parameters are sorted on the following pages according to the area of applicability:
• Main parameters 1 (Common for the whole system)

• Main parameters 2 (Common for the whole system)
• AOT
• Filter
• CIP
• Installation parameters (Specific for installation)
Parameter description
In the parameter pages, the parameters are displayed with the following information:
8 Book No.9000479 02, rev. 0

2 Control system parameters 2.2 Introduction to the parameter pages
Parameter ID Unique parameter ID.
Description Descriptive text.
Unit The unit the parameter is set in, where applicable.
Parameter setting Parameters are displayed in three columns.
Left column: Display minimum value for the parameter.
Middle column: Current parameter setting is displayed

in the middle column. To change setting, press the field
to display a key board popup. In some cases a parameter
is set in a drop down menu.
Right column: Display maximum value for the parameter.

In some cases a drop down menu is used to set a
parameter choice, instead of the three columns.
The value must be within defined setting range (left and

right column.
Book No.9000479 02, rev. 0 9

2.3 Page 8.1 – Main parameters 1 2 Control system parameters
2.3 Page 8.1 – Main parameters 1

This section describes the main system parameters set in page 8.1 Main parameters 1.
4 8.1
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.
(PT201-16)
(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.
(PT201-16)
(6 bar = 0.6 MPa)
10 Book No.9000479 02, rev. 0

2 Control system parameters 2.3 Page 8.1 – Main parameters 1

fault Max
value
p103 Low pressure, 0 -1–2 bar Setpoint for warning due to low pressure
warning trigger at PT201-16.
(PT201–16)
(1 bar = 0.1 MPa)
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 back-flush is set in

p312.
p114 Maximum rotation 10 1–90 °/s Defines maximum rotation rate to attain
rate for V201-8 a smooth automatic pressure and flow
control.
p115 Maximum travel 10 2–30 sec Maximum time for V201–3 and V201–9
time for valves to go from opened to closed, and vice
versa, before a warning is issued.
This parameter is preset.
p116 Low flow, warning 10 10–90 % Set point for low flow warning, defined as
trigger (FIT201-1) percent of certified flow.
This parameter shall be > 10 % to obtain

efficient cooling.
p117 Max delay of CIP 6 0–24 hrs Define max delay, in hours, before a CIP
cycle, hours cycle must be performed after ballast or
deballast.
p118 Max delay of CIP 1 0–30 day Define max delay, in days, before a CIP
cycle, days cycle must be performed after ballast or
deballast.
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.
Book No.9000479 02, rev. 0 11


fault Max
value
p120 V201–8 PID 0.30 0–10 N/A Defines proportional gain (Pf) value used
proportional gain 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.
The value can either be set manually

or be set after calibration. See PID
calibrate system instruction in chapter
3. Operating instructions and control
system description.
p121 V201–8 PID 7.0 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 detailes, see p120.
p122 V201–8 PID 0 0–100 N/A Defines derivate gain (Df) value used for
derivative gain PID regulation of V201–8 during ballast
and deballast.
Normal value: 0.
For detailes, 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 visible and used if parameter p129

is set to “Activated”.
p138 Timeout: Time 5 1–5 min Defines maximum time a ballast and
in Pause before deballast process can be puased. After
going to Stop defined time, the process is stopped.
p140 Timeout: 5 1–10 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.9000479 02, rev. 0


fault Max
value
p141 Timeout: Request 5 1–10 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 visible and used if power

management is activated (Hardwire
ranged or fixed) in parameter p127.
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.
p145 Sequence step 1.0 0.0–5.0 sec Defines delay between each step in the
delay process.
p149 Timeout: Time in 10–300 45 sec Defines maximum time a ballast and
Auto pause before deballast process can be automatically
going to stop paused by the system. Example: When
process is paused due to low flow.
After defined time, the process is

stopped.
Book No.9000479 02, rev. 0 13

2.4 Page 8.2 – Main parameters 2

This section describes the main system parameters set in page 8.2 Main parameters 2.
4 8.2

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)
14 Book No.9000479 02, rev. 0


fault Max
value
p129 Booster pump Not N/A Drop Defines if a booster pump is used when
(P401-1) for LDC used list pressure for cooling water to LDC is too
cooling water low.
p130 Booster pump Not N/A Drop Defines if booster pump is used when
(P403-1) for used list pressure for cooling water to AOT reactor
reactor cooling is too low.
water
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.
p133 Max time 60 0–300 Sec Define max delay before the system
communication shuts down after communication is
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 40155 and
40013.
p134 External stop Not N/A Drop Defines if an additional stop button for
button used list PureBallast is installed.
p135 External shut Not N/A Drop Defines if an additional signal controlled
down signal used list stop function for PureBallast is installed.
p137 Hide Pause Not N/A Drop Defines if the Pause button is hidden in
button used list the control system.
Book No.9000479 02, rev. 0 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 5.1.
System info.
p161 Time interval for 1 0.1–60 Min. Time interval to update the amount (m3)
log event 331 of ballast water treated in log file.
p162 Time interval for 1 0.1–60 Min. Time interval to update the amount (m3)
log event 341 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 0.6 0–10 N/A Defines proportional gain (Pf) value used
proportional gain for PID regulation of V201–8 during
back-flush.
The PID regulation during back-flush is

based on input from pressure transmitter
PT201-27.
Normal value: 0.1 – 1.5.
16 Book No.9000479 02, rev. 0


fault Max
value
p167 Pressure PID 7 0–100 sec Defines integral time (If) value used
integral time for PID regulation of V201–8 during
back-flush.
This parameter shall normally not be

changed.
Normal value: 5 – 12.
p168 Pressure PID 0 0–100 N/A Defines derivate gain (Df) value used
derivate gain for PID regulation of V201–8 during
back-flush.
This parameter shall not be changed.
Normal value: 0.
Book No.9000479 02, rev. 0 17

2.5 Page 8.3 – AOT parameters 2 Control system parameters
2.5 Page 8.3 – AOT parameters

This section describes parameters controlling the AOT module set in page 8.3 AOT parameters.
4 8.3
ID Parameter De- Min- Unit Comment

fault Max
value
p200 Timeout: AOT 2 0.5–5.0 min Time the control system will wait for
draining confirmation that an AOT is drained
before an alarm is issued. Recommended
setting: Approx 0.5-1.0 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 before an alarm is issued.
p202 High temp, 60 10–100 ºC Setpoint for high water temperature alarm,
alarm trigger indicated by temperature transmitter in
(TT201-33) AOT reactor.
18 Book No.9000479 02, rev. 0

2 Control system parameters 2.5 Page 8.3 – AOT parameters

fault Max
value
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.
p206 Alarm delay for 5 0–10 sec Delay before alarm is issued after setpoint
sensor TT201-33 temperature (p202 and p204) is reached.
p210 UV lamp warm-up 90 0–90 sec Warm up time for UV lamps before full
time ballast or deballast starts.
p211 UV lamp cooling 120 30–300 sec Cooling time for UV lamps after ballast
time or deballast.
p212 Timeout: UV lamp 100 10–100 sec Time the control system will wait for
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 will be automatically
stopped.
p214 High temp, 60 20–100 ºC Setpoint for high temperature warning,

warning trigger indicated by temperature transmitter in
in LDC (TT401) LDC.
Default value shall be used.
p215 Alarm delay for 5 0–10 sec Delay before shutdown when there is no
LS201-29 water in an AOT, indicated by level switch
in AOT (LS201-29).
p216 Timeout: Fluid 5 2–10 min Setpoint for max time to fill an AOT with
fill-up time AOT fresh water before an alarm is issued.
p220 UV intensity Not N/A Drop Defines if a UV sensor (optional) is

sensor used list installed in the AOT. If activated, UV
value will be logged in the Event log every
60 seconds during ballast and deballast.
p221 Low UV intensity 20 0–500 W/m2 Setpoint for warning due to low UV
warning trigger intensity indicated by UV sensor
(optional) QT201–50 in the AOT reactor.
This warning will be logged in the Event
log.
Only used if p220 is set to "Activated".
Book No.9000479 02, rev. 0 19

2.6 Page 8.4 – Filter parameters 2 Control system parameters
2.6 Page 8.4 – Filter parameters

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

fault Max
value
p301 High filter 0.50 0.00– bar Setpoint for high pressure warning,
differential 1.00 indicated by pressure transmitter
pressure, PT201-27.
warning trigger
(PT201-27) (0,5 bar = 0.05 MPa)
p304 Required 2.50 1.00– bar Defines pressure needed for efficient
pressure to 5.00 back-flushing. This pressure must be
start back-flush attained to start back-flush.
(PT201-16)
This parameter also defines setpoint
for desired pressure during back-flush:
To maintain this pressure, control valve
20 Book No.9000479 02, rev. 0

2 Control system parameters 2.6 Page 8.4 – 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 Back-flush 0.38 0.00– bar Setpoint for automatic start of filter
trigger, 1.00 back-flush due to dirt in the filter, indicated
differential by differential pressure transmitter on the
pressure filter.
(PT201-27)
Note: This parameter can be adjusted, but
only by Alfa Laval during commissioning.
If adjusted, parameter p301 shall be set
to 30 percent higher.
(0.38 bar = 0.038 MPa)
p306 Filter 1 1–30 min Defines duration of filter preservation

preservation time (fresh water filling of filter) after ballasting.
p308 Back-flush cycle 20 1– sec Defines duration of one filter back-flush.

time 100
p309 Time controlled 30 1– min Defines time between automatic

back-flush 120 back-flushing of the filter. Automatic
interval back-flushes are performed with this set
interval to secure performance, regardles
of current differential pressure.
p310 Back-flush initial 10 0–60 sec Time from back-flush trigger until
delay back-flush is started. During this delay the
control valve is PID regulated to create the
required pressure defined in parameter
p304.
p311 Back-flush delay 2.0 0.0– sec Defines for how many seconds the
(p305 during x 10.0 pressure defined in p305 must last, before
sec). automatic back-flush starts.
p312 V201-8 min 25 15–50 % Minimum allowed opening percentage for

position during V201-8 during back-flush.
back-flush
Must be higher than value set in p113.
Shall not be lower than 15 %.
Book No.9000479 02, rev. 0 21

2.6 Page 8.4 – Filter parameters 2 Control system parameters

fault Max
value
p313 V201-8 min 5 0–30 sec Time constant for low pass filter used for
position during the differential pressure over the filter.
back-flush The low pass filter is used to smoothen
the effect of sudden changes in differential
pressure; primarily pressure peaks after
completed back-flush.
Value for low pass filtered differential

pressure is indicated as “dp” on the filter
in the filter popup, when logged in as login
level 2 or 3.
Actual differential pressure (PT201-27) is

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

changed, but time can be increased to
flatten the differential pressure curves.
p314 Filter type Type N/A Drop Defines type of filter installed.
1 list
Alternatives: Type 1 (Boll) and Typ 2
(Hydac).
22 Book No.9000479 02, rev. 0

2 Control system parameters 2.7 Page 8.5 – CIP parameters
2.7 Page 8.5 – CIP parameters

This section describes parameters controlling the CIP module set in page 8.5 CIP parameters.
4 8.5

fault Max
value
p400 CIP cycle time 15 1–60 min Flow 500–3000: Duration of a CIP cycle
per AOT.
Book No.9000479 02, rev. 0 23

2.8 Page 8.6 – Installation parameters 2 Control system parameters
2.8 Page 8.6 – Installation parameters

This section describes the installation specific system parameters set in page 8.6 Installation
parameters.
4 8.6

fault Max
value
p106 No of AOT 1 1–12 # Defines number of installed AOT

modules installed modules.
24 Book No.9000479 02, rev. 0

2 Control system parameters 2.8 Page 8.6 – Installation parameters
p107 Max power 36 0– kW Defines amount of power to request if

consumption of (p106) common power request is used. this
PureBallast x means that max power is requested
(p108) regardless of the number of AOT:s to
be used.
This parameter is only used if power

management (optional) is used and
parameter p127 is set to 2=Hardwire
ranged.
p108 Power 36 0–100 kW Defines power consumption for each

consumption per installed AOT during process. Power
AOT request is based on this parameter.
This parameter is preset and shall not

be changed.
p110 Certified flow per 250 10– m3/h Defines the max amount of ballast water
AOT module 1000 that can be treated per hour and AOT.

be changed.
p112 Pipe diameter for 150 150– DN This parameter shall be set to
flow meter 600 correspond to the dimension of the flow
meter (FIT201-1).
Alternatives: 150, 200, 250, 300, 350,

400, 450, 500 and 600.
p213 Allowed no. of 0 0–12 No. If more lamps than set in this parameter
failed UV lamps are broken, operation will be denied.
per AOT
be changed.
p218 Estimated UV 3 000 0 – hrs Setpoint for UV lamp change warning.

lamp lifetime 20000 Time is counted down per AOT. Counter
for UV lamp run time is reset in page
5.5 Operation timers AOT after all UV
lamps have been changed in an AOT.
N/A Remote panels N/A N/A N/A Used to set IP adresses for remote
control panels (optional). See instruction
Set control panel IP address in chapter
system description.
Book No.9000479 02, rev. 0 25

2.8 Page 8.6 – Installation parameters 2 Control system parameters
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 activated 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 5.7 Log
box 1 and 5.8 Log box 2. See chapter
system description.
26 Book No.9000479 02, rev. 0

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

4FT_Topup
Top up Padlock Change Forward Select
Book No.9000479 02, rev. 0 27

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.
2. To enter password (1000): Press Padlock. (A line appears under the first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The “Basic settings” menu appears after two seconds.
3. Press Padlock to unlock the menu.
Set Qmax
4. Press Forward until “Qmax” is displayed. Check that the parameter is set to 1200 m3/h for
pipe size 300 .
- To change: Press Padlock.
- Press Select to select digit to change (A line is placed under the changeable digit).
- Press Change to change (toggle) the digit.
Set Empty pipe
5. Press Forward until “Empty pipe” is displayed. Check that the parameter is set to “On”.
- Press Change to change (toggle) the setting.
6. Press Forward until “Output” is displayed.
7. Press Padlock to unlock the menu.

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

Result: ”Totalizer 1” is displayed.
28 Book No.9000479 02, rev. 0

Chapter: 5. Alarms and faultfinding
Book No. 9000479 02, rev. 0

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) 46

2.2.1 List of alarms and status indications 46
2.3 Flow meter 49

2.3.1 Fault finding instruction 50
2.3.2 Check flow meter error list 50
2.3.3 List of alarms and problems 51
2.4 Level switch 55

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 61

3.1 General, Filter, CIP and valve V201–8 61
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
• instruction Attend to alarms

• description of the pages 3.1 Alarm list and 3.2 Alarm history.
Book No.9000479 02, rev. 0 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 by a audible signal and by a blinking warning icon in the control panel.
3Alarm
If the optional remote interface is installed, the alarm is also indicated on the remote interface
screen. All alarms are displayed in the control panel’s page 3.1 Alarm list and are sorted in order of
occurrence; most recent alarm at the top of the list.
2.1.2 Key to the table of alarms and warnings

The table below explains the information given in the alarms list table. The table contains the
following columns and information:
Column in 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 and 2 =Filter. If the alarm contains two digits, the
alarm is general and is not connected to a specific component.
Book No.9000479 02, rev. 0 7

2.1 Control system 2 List of alarms and warnings
• 00: Unique number for the alarm/warning.
Alarm text / The text displayed in the control system. Note that AOT number is indicated by
Problem “x” in the table, instead of the actual AOT number. In the control system alarm
text, the actual AOT number is stated for the AOT 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.
Active during step: Under which steps in the process the alarm is active.
Additional information in parenthesis, for example if the alarm also stop the
ongoing process step. The steps are described in chapter 3. Operating
instructions and control system description, section Detailed process description.
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.9000479 02, rev. 0

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: 2 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). Active during step: pressure. exceeds set value: Adjust incoming
Automatic stop. pressure to PureBallast.
Book No.9000479 02, rev. 0

• Ballast (stop)
• Back flush (stop) Valves in the system Control that correct valves are
after pressure functioning and opened for current
List of alarms and warnings
• Deballast (stop) transmitter are process. See chapter 3. Operating

• Manual mode closed. instructions and control system
description, section Detailed
Comment: Pressure process description.
transmitter PT201-16
indicates pressure Material is stocked Check the entire system for
higher than set in after pressure blocking material.
parameter p100. 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: 2 sec. Signal missing 1. Check fuse F45 in Control
pressure or pressure cabinet to see what circuit
signal missing Active during step: transmitter PT201-16 caused the fuse trip.
(PT201-16). All steps. malfunction.
2. Use the circuit diagram to
Control system
Automatic stop.
Comment: Error check the fuse setting, adjust
in system pressure according to figures in circuit
sensor. Indication of diagram if necessary and reset
pressure -1.0 bar (-0.1 fuse.
MPa) is not an error. 3. Use the circuit diagram to
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: 2 sec. See possible cause See A01.
pressure too Parameter: p101 for A01.
high (PT201-16). Active during step:
All process steps.
Comment: Pressure
higher than parameter
set limit.
Book No.9000479 02, rev. 0

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). Active during step: malfunction. caused the fuse trip.
All steps.
Comment: Error in check the fuse setting, adjust
according to figures in circuit
Book No.9000479 02, rev. 0

system flow sensor.
diagram if necessary and reset
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: p101 the certified flow for flow to the PureBallast system.
than certified Active during step: the number of AOTs
(FIT201-1). in operation.
Control system
Reduce flow! • Ballast start-up

• Ballast Parameter p101 not Check parameter setting.
correctly set in control
• Ballast pause system. Check settings for flow transmitter.
• Deballast start-up See chapter 4. Parameters, section
Flow transmitter parameters.
• Deballast
• Deballast pause Flow sensor Check that the flow sensor is OK
malfunctions. as described in Problem 7 B and 7
I in the general problems list.
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
Active during step: • Make sure the ballast water
Automatic
from the ballast pump is
pause.
• Ballast (Pause) directed to PureBallast. When
OK the process will continue
• Deballast (Pause)
2
automatically.
Comment: If flow • Check pressure and flow
is less than set in from ballast pump(s).
parameter p116, Adjust incoming pressure
the system is set in to PureBallast, if necessary.
pause mode time set in
parameter p149, where Flow sensor Check that the flow sensor is OK
after it is set to pause malfunctions. as described in Problem 7 B and
mode. 7 I in the general problems list on
page 61.
Book No.9000479 02, rev. 0

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.9000479 02, rev. 0

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). Active during step: Flow too low. See alarm A13.
Automatic stop.
• Ballast start-up
(stop)
• Ballast pause
2.1
(stop)
• Deballast start-up
(stop)
• Deballast pause
(stop)
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. Active during step: caused the fuse trip.
All steps.
2. Use the Control cabinet /
Control system
Comment: Error on Circuit diagram to check the

valve V201–3. 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
to sense indicator position sensor.
screws. Position
2
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.
Position sensor or 1. Check cables.

cables to position
2. Replace position sensor if
sensor malfunction.
faulty.
Book No.9000479 02, rev. 0

2
ID
Too long 1. Follow the instruction Adjust

opening/closing time valve traveling speed in chapter
(valve travel time) 7. Service manual.
2. Adjust exhaust valves on
actuator.
Book No.9000479 02, rev. 0

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
(V201-9). GS201-9. for A17.
Parameter: N/A. Active during step:
All steps.
Comment: Error on
2.1
valve V201–9.
15
Control system
16
2.1
ID
(V201-8). GS201-8. for A17.
Parameter: N/A. Active during step:
All steps. • Sensor error. 1. Check open indication in the
Control system
Shows open all pneumatic positioner.

Comment: Error on the time.
control valve V201–8. 2. Check fuses F43 in control
• Signal error 4–20 cabinet to see what circuit
mA. caused the fuse trip.
3. Use the Control cabinet /
Circuit diagram to check the
fuse setting, adjust according
connections to actuator and
sensors on the valve are OK
and that the electrical wiring is
not damaged.
2
The air filters on Check according to instruction

V201-8 might be Replace filter in proportional valve.
clogged.
Book No.9000479 02, rev. 0

2
ID
A33 Bypass valve is Trigger: Limit switch Delay: 15 sec. The valve has been Close valve V212-31
open (V212-31). GS212-31. opened manually or
Parameter: N/A Active during step: via the ISCS.
• Standby (start See possible cause

unabled) for A17.
Book No.9000479 02, rev. 0

(stop)
• Ballast (stop)
• Back flush (stop)
(stop)
• Deballast (stop)
Comment: If valve
V212-31 is in open
position, ballast or
deballast is cancelled.
The bypass valve is
not controlled by the
PureBallast system.
(V212-31). GS212-31. for A17.
Parameter: N/A Active during step:
All steps.
2.1
Comment: Shutdown
of all steps exept CIP.
The alarm does not
prevent completion or
start of CIP cycle.
17
Control system
18
2.1
ID
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. Active during step: pressure. to requirements in chapter 6.
Parameter: p103. Installation description and
Control system
• Full ballast drawings, section Connection list.

• Full deballast
Pressure transmitter 1. Check cables to pressure
PT201-16 is faulty. transmitter PT201-16. See
Control cabinet / Circuit
drawings.
2. Replace pressure transmitter
PT201-16.
A48 Shutdown Trigger: Shutdown Delay: None. System shutdown Release the button.
activated button on control button on the control
(Shutdown cabinet Active during step: cabinet has been
button). Parameter: N/A All steps. activated (pressed NOTE
down).
Find out the reason why the system has
been shut down before releasing the
button.
2
A49 Shutdown Trigger: Shutdown Delay: None See possible cause

activated during button on control for A48.
CIP (Shutdown cabinet Active during step:
button). Parameter: N/A
• CIP (stop)
Book No.9000479 02, rev. 0

2
ID
A50 Shutdown Trigger: System Delay: None. Manual shutdown Release the button.
activated outside PureBallast. from the ISCS
(External Parameter: p135 Active during step: (integrated ship
system). All steps. control system). NOTE
Find out the reason why the system has
Book No.9000479 02, rev. 0

been shut down before releasing the
button.
A51 Shutdown Trigger: System Delay: None. See possible cause

activated during outside PureBallast. for A50.
CIP (External Parameter: p135 Active during step:
system).
• CIP (stop)
W58 Fuse tripped in Trigger: Control Delay: 2 sec. Possible reasons: 1. Check fuse F42–F45 in control
control cabinet. cabinet. • overload cabinet to see what circuit
Parameter: N/A Active during step: caused the fuse trip.
All process steps. • short circuit
• overheated fuse
3. Use the circuit diagram for
control cabinet to check the
fuse setting, adjust according
2.1
19
Control system
20
2.1
ID
A66 Additional Trigger: External Delay: 2 sec. The valve has been Close the valve and resume the
bypass valve system. opened manually or process by pressing the Pause
1 is open. Parameter: p163 Active during step: via the ISCS. button in the control system.
Control system
• Standby (start If operation has not

unabled) been requested: See
• Ballast start-up possible cause for
(stop ballast) A71.
• Ballast (stop
ballast)
• Back flush (stop
ballast)
(stop deballast)
• Deballast (stop
deballast)
A67 Additional Trigger: External See A66. See A66.

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

2
bypass valve system.

3 is open. Parameter: p165
Book No.9000479 02, rev. 0

2
ID
A71 Ballast water Trigger: Control Delay: Set in Faulty connection of Check that all electrical
pump is system timer. parameter. electricity or signal connections are OK. Check that
not running. Parameter: p141. cable. the signal wiring is according to
Automatic stop. Active during step: information in chapter 6. Installation
description and drawings, section
• Ballast start-up External component signal
Book No.9000479 02, rev. 0

• Deballast start-up integration.
Comment: Feed back

signal “BW pump is

running” is deactivated
A75 Overboard valve Trigger: Control Delay: Set in See possible cause
is not open. system timer. parameter. for A71.
Automatic stop. Parameter: p140
Active during step:
(stop)
• Ballast pause
(stop)
(stop)
• Deballast pause
(stop)
• CIP
Comment: Feedback
2.1
“overboard valve is
OPEN”.
21
Control system
22
2.1
ID
A77 Error on all Trigger: AOT Delay: None An active alarm exist See page 3.1 Alarm list in the
operating modules on all installed AOTs. control system to see which AOT
AOT:s. Parameter: N/A Active during step: It can be the same alarms that preceded this alarm.
Automatic stop. error for all AOTs, or
Control system
• Standby (start different errors.

unabled)
(stop)
• Ballast (stop)
• Back flush (stop)
• Ballast pause
(stop)
(stop)
• Deballast (stop)
• Deballast pause
(stop)
Comment: All AOTs
are deactivated.
2
W79 Power is Trigger: Control Delay: Set in Power management Investigate if the reasons for not
not granted. system timer. parameter. master system not granting power is outside the
Automatic stop. Parameter: p143 granting power for PureBallast system.
Active during step: one or more AOTs.
• Ballast start-up Feedback signal from See W71.

• Deballast start-up power management
master is faulty. Check signal transmission to/from
Comment: No PureBallast corresponds to
power steps have the specifications in chapter
been granted within 6. Installation description
parameter set time. and drawings, section Power
Book No.9000479 02, rev. 0

management interface integration.
2
ID
Hint: If problem persists, see page

1.5 – PureBallast power request
to find which GRANTED signal
that was interrupted during the
ballast/deballast process.
Book No.9000479 02, rev. 0

W80 Power is not Trigger: Power Delay: None. See possible cause
fully granted. management system. for W79.
Flow capacity Parameter: N/A Active during step:

reduced. Not enough power Only activate the number of AOTs
• Ballast start-up has been granted. for which power has been granted.
• Deballast start-up See page 1.5 – Power request
or the status box in page 1.1.
Comment: Not all Overview.
requested power steps
are granted. Triggered
if number or requested
power steps does
not match number of
granted power steps.
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.
2.1
W83 Heeling mode Trigger: Heeling Delay: None. See possible cause
cancelled (internal transfer) not for W82.
by operator. requested in control Comment: During
Process system. heeling, the system is
resumed. Parameter: N/A paused. At this point it
is resumed.
23
Control system
24
2.1
ID
A91 PLC lost Trigger: Control Delay: 60 sec. Panel is switched off 1. Switch on the panel.
communication system PLC. or faulty.
Active during step: 2. Restart the panel. See problem
with all control Parameter: N/A
All process steps. 1 B in the general problems list
panels.
on page 61.
Control system
Comment: After 3. Replace if faulty.

60 seconds of lost
communication, Faulty cable Check cables to the component.
ongoing process is connection. For reference, see Control cabinet /
stopped in a controlled Interconnection diagram in chapter
way and the system 6. Installation description and
is shut down. This drawings.
message is visible in
the control panels and
saved in the log after
the communication is
restored. But, W92 will
be visible in the master
control panel.
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 Active during step:
with the PLC. All process steps. Faulty cable See A91.
2
connection.
Comment: After
communication is lost,
ongoing process is
stopped in a controlled
way and the system
is shut down. This
message is visible
in the master control
panel.
Book No.9000479 02, rev. 0

2
ID
A93 Heart beat signal Trigger: Control Delay: Set in To operate PureBallast when communication is down,
from remote system PLC. parameter p133. follow the steps below:
interface is not Parameter: p133
updating. Active during step: 1. Set the system to Local mode: Press the Local button
All process steps. on the control panel.
2. Run the system from the control panel. Note that you
Book No.9000479 02, rev. 0

Comment: After
will need to confirm two messages from the control
communication is
panel during operation: "Confirm ballast pump started"
lost between ISCS
and "Confirm overboard valve open".

and PLC, ongoing
process is stopped in a 3. Restore these settings when the communication is
controlled way and the working.
system is shut down.
4. Make sure that the system is online in page 5.5 Remote
The Heartbeat field interface (Online button activated).
in page 5.5 Remote
interface, indicates System is set to off If you deliberately set the system
communication. line mode. to offline mode (for example to test
remote interface integration, you
can disregard this alarm. If not set
the system in online mode again in
page 5.5 Remote interface 1.
Faulty settings. 1. Check if remote operation is

deactivated in the control panel
(The Remote button at the
bottom of the screen is gray).
If so, press the Remote button.
2. Check if remote interface
2.1
is deactivated in page 5.5

Remote interface. If so, press
the Online button. Requires
login level 3.
25
Control system
26
2.1
ID
3. Check that the communication

settings is OK according to
instruction Set remote interface
Control system
communication in chapter 3.
Operating instructions and
control system description.
Faulty cable Check cable between the ISCS

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.
Communication See W92.

between PLC and
master control panel
is lost.
ISCS is faulty. Investigate problem in ISCS, and

attend to found problems.
2
A95 PLC battery low. Trigger: Control Delay: 30 sec. The voltage in the Replace PLC battery in the control
system PLC. battery in the control cabinet.
Parameter: N/A Active during step: system PLC is too
All process steps. low.
Book No.9000479 02, rev. 0

2
ID
W96 GPS signal not Trigger: Control Delay: N/A Faulty electrical Check that the signal wiring is
valid. system PLC. connection. according to Control cabinet /
Parameter: N/A Active during step: Interconnection diagram in chapter
All process steps. 6. Installation description and
drawings.
Book No.9000479 02, rev. 0

Faulty GPS This component is not a part of the
equipment. PureBallast system.
Parameter p160 not Check parameter setting.

system.
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.
Active during step: See section I/O system and X20
All steps. modules on page 55.
Faulty electrical • Check that the signal wiring is

connection. according to electrical drawings
in Chapter 6. Installation
• Check that all electrical
connections are OK on bus
modules and that the electrical
wiring is not damaged.
2.1
27
Control system
28
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 Active during step: components involved. 404-36.x) open properly by
Control system
All steps. operating them manually.

See the instruction Operate
Comment: If components manually
temperature rises in chapter 3. Operating
above parameter set instructions and control system
value, the AOT module description.
will shutdown.
• Check that cooling water supply
If the alarm trips during (403) is within specification
operation with a flow in chapter 6. Installation
through the AOT, the description and drawings,
valves V201-19.x and section Connection list.
V201-20.x will close.
Low flow of sea water Check pump, valves and other
If the alarm trips during during start-up. components involved in the sea
ballast start-up, valve water cooling system.
V404-36.x will close.
Parameter p202 not Check parameter setting in control
correctly set. page 8.3 – 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.9000479 02, rev. 0

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. Active during step: Sea water too cold; See to that incoming water is
All steps. temperature below 0 warmer than 0 C°.
C°.
Book No.9000479 02, rev. 0

Engine room too cold; Increase temperature.
temperature below 0
C°.
W102 AOT [x]: Trigger: AOT Delay: Set in parameter Signal missing 1. Check fuse F44 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. Active during step: malfunction.
All steps. 2. Use the circuit diagram to
AOT shutdown.
Parameter: N/A. check the fuse setting, adjust
fuse.
component. See Lamp drive
cabinet (LDC) / Circuit diagram
2.1

damaged.
6. Replace transmitter TT201-33.
29
Control system
30
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
cabinet temp too temperature the heat exchanger. (401) is within specification in
high (TT401). transmitter TT401. Active during step: chapter 6. Installation description
Parameter: p214 All steps. and drawings, section Connection
list in the General drawings section.
LDC fan faulty. Check component. Change if

broken.
Thermostat set too Decrease setting.

high.
Thermostat faulty. Check component. Change if

broken.
Parameter p214 not Check parameter setting.

system.
W109 AOT [x]: LDC Trigger: LDC Delay: 5 sec. Signal missing or 1. Check fuse F44 in LDC to see
cabinet temp temperature transmitter TT401 what circuit caused the fuse
2
missing (TT401). transmitter TT401. Active during step: malfunction. trip.

Parameter: N/A All steps.
check the fuse setting, adjust
fuse.
Book No.9000479 02, rev. 0

2
ID

Book No.9000479 02, rev. 0

damaged.
6. Replace transmitter TT401.
beginning.
Faulty bus module Check that all electrical

connection. connections are OK on bus
modules and that the electrical
wiring is not damaged.
Faulty bus 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.
2.1
31
Control system
32
2.1
ID
W116 AOT [x]: AOT Trigger: Level sensor Delay: Set in No fluid in AOT 1. Control that correct valves
fluid level LS201-29. parameter p215. reactor “x”. are opened for current
signal missing Parameter: p215 LS201-29.x is process. See Detailed process
(LS201-29). Active during step: indicating dry description in chapter 3.
Control system
condition. Operating instructions and

• Ballast start-up control system description.
(deactivate)
2. Check that the flow is equal
• Ballast (deactivate) through all AOT reactors and
• Back flush that the AOT.x is not clogged.
(deactivate) 3. Restart the process from the
• Ballast pause beginning.
(deactivate)
Signal missing or 1. Check fuse F42 in LDC to see
• Ballast stop sensor LS201-29.x which circuit that caused the
(deactivate) malfunction. fuse trip.
• Deballast start-up 2. Use the circuit diagram to
(deactivate) check the fuse setting, adjust
• Deballast according to figures in circuit
(deactivate) diagram if necessary and reset
fuse.
• Deballast pause
(deactivate) 3. Use the circuit diagram to
2
• Deballast stop the reason that caused the fuse

(deactivate) trip and attend to it.
• Manual mode 4. Check cables to the level
(deactivate) switch LS201-29.x. See the
drawing Control cabinet /
Circuit diagram in chapter 6.
drawings.
Book No.9000479 02, rev. 0

2
ID
5. Check that the level switch is

working correctly. See section
Level switch on page 55.
Hint 2: Dismount level switch
and put the forks into a cup of
water to check dry/wet function.
Book No.9000479 02, rev. 0

6. Replace LS201-29.x. (Turn the
level switch so the forks are in
the right position. See chapter

7. Service manual.
Air in fluid. The level Deaerate the filter, using valve

switch indicates this V201-50.
as no fluid in AOT.
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: p216 LS201-29.x is open and close correctly.
Active during step: indicating dry
2. Check that pump P320-1
condition.
• CIP (Stop) is functioning correctly. See
problem 6D−6I in the general
problems list on page 61.
2.1
33
Control system
34
2.1
ID
3. Hint: Valves can be manually

operated. See the instruction
Operate valves manually
in chapter 3. Operating
Control system

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.
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
Level switch on page 55.
2
Level switch at See W116 to troubleshoot the level

AOT 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 filter, using valve

switch indicates this V201-50.
as no fluid in AOT.
Book No.9000479 02, rev. 0

2
ID
W119 AOT [x]: No Trigger: Level sensor Delay: Set in No liquid in 1. Check that pressure flushing
freshwater LS201-29. parameter p216. 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). Active during step: indicating dry Installation description and
condition. drawings, section Connection
• CIP (Stop fresh list.
Book No.9000479 02, rev. 0

water filling)
2. Check that valves (V310-6,
V320-4.x, V321-2.x and
V571-1) are operating correctly.

Also check that valve V310-3 is
OK and that V310–8 is opened.
Operate the components
manually.
Level switch at See W116 to troubleshoot the level

AOT 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 p200. “x”. LS201-29.x beginning.
(LS201-29). Parameter: p215 is indicating wet
Active during step: condition.
• CIP (Stop drain) Level switch at See W116.

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

CIP unit. (V320–4, V460–2, V231–2,
2.1
V571–1, overboard valve) are

opened for current process. Also
control that pump P321–5 is
functioning.
35
Control system
36
2.1
ID
W122 AOT [x]: Fuse Trigger: LDC cabinet Delay: 1 sec. Fuse in LDC has Check LDC cabinet to see what
tripped in LDC for AOT tripped or has been circuit caused the fuse trip. Check
cabinet. Parameter: N/A Active during step: switched off. according to bullets.
All steps.
Control system
1. Check if fuse K233 tripped

(orange LED is lit). Reset by
pressing the reset button on
F231 and F232.
2. Check if fuse F42–45 has
tripped. Reset.
3. Check if V23 is functioning.
Test voltage between – (400)
and cable 058, then cable 053.
If no voltage at 053, the V23
shall be replaced.
• Use the circuit diagram to
fuse.
• Use the circuit diagram to
2

• Check cables to the
Book No.9000479 02, rev. 0

2
ID
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. Active during step: AOT.x has tripped or page 46.
All steps. has been switched
2. Check MCB F12 in LDC and
off.
Comment: respective cables and LPS unit.
Book No.9000479 02, rev. 0

MCB=Miniature circuit 3. Use the circuit diagram to
breaker. AOT is check the Ampere setting for
deactivated. the MCB, adjust according

necessary and reset MCB.
Motor circuit breaker 1. Check MCB F110–F111 in

(MCB) for AOT.x LDC and respective cables.
(LDC cabinet) has
tripped or has been
check the Ampere setting for
switched off.
the MCB, adjust according
necessary and reset MCB.
3. Reset the alarm on the control
panel. Investigate which
component in the circuit that
caused the MCB trip, and
attend to it.
Breaker on LDC has Reset the breaker by turning the

tripped or has been handle.
switched off.
2.1
VCD/varistor failure. Check VCD (V23)/varistor in LDC.

Replace if required. See chapter 7.
Service manual, section Replace
VCD (voltage clipping device) and
varistor.
37
Control system
38
2.1
ID
A130 AOT [x]: LPS Trigger: Lamp power Delay: 2 sec. • LPS malfunction. Check LED indication on the LPS
sum alarm. supply in AOT:s LDC. that triggered the alarm. See LPS
Active during step: • UV lamp
Parameter: N/A alarms in section Lamp power
malfunction.
supply (LPS) on page 46.
Control system
• Ballast UV lamp OK signal Check that the signal wiring is
malfunction. according to electrical drawings.
• Back flush
• Ballast pause Check that all electrical
connections are OK on bus
• Ballast stop modules and that the electrical
• Deballast start-up wiring is not damaged.
• Deballast
• Deballast pause
• Deballast stop
W131 AOT [x]: UV Trigger: Lamp power Delay: 1 sec. One or more UV Change according to instruction in
system failure. supply. lamps is broken. chapter 7. Service manual.
Too many failed Parameter: p213. Active during step:
lamps. All steps
Comment: AOT is
2
deactivated.
W132 Estimated UV Trigger: AOT lap Delay: 1 sec. Lifetime for UV Recommended to change all lamps
lamp lifetime time. lamps are too after 3000 hours of operation.
exceeded. Parameter: p218. Active during step: exceed according
All steps to estimated lifetime Change according to instruction
in parameter. Replace UV lamp and quartz
Comment: This alarm sleeve in chapter 7. Service
is only displayed in the manual.
control panel(s); not in
the remote interface
(option), if installed.
Book No.9000479 02, rev. 0

2
ID
A137 AOT [x]: High Trigger: TS201-60 Delay: 1 sec. No water in the AOT See W100.
temperature Parameter: N/A reactor or too low
(TS201-60 Active during step: flow. After problem has been attended
tripped) and/or All steps. to, the LDC needs to be reset.
LDC powered
off. Comment: AOT is 1. Turn on the power to the
Book No.9000479 02, rev. 0

deactivated. 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
valve. Control that valves and pumps are
functioning.
LDC has been The LDC needs to be reset, see

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

connection. is according to electrical
drawings.
• Check that all electrical
2.1

damaged.
39
Control system
40
2.1
ID
A138 AOT [x]: PLC Trigger AOT module 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 Active during step: See section I/O system and X20
All steps modules on page 55.
Control system
Comment: AOT is
deactivated.
W140 CIP schedule Trigger: Control Delay: Set in CIP not performed Control CIP status on page 1.4 CIP
timer elapsed system timer. parameter. after operation. status in control system.
Start CIP! Parameter: p117 and
p118. Active during step: Start CIP cycle.
All process steps.
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 transmittance in N/A.
UV intensity QT201-50. water.
(QT201-50) Parameter: p221. Active during step:
Quartz sleeves dirty. Clean the quartz sleeves. See
• Full ballast instruction Replace UV lamp and
2
• Full deballast quartz sleeve in chapter 7. Service

manual.
Comment: The
warning is issued if Transmitter Test the UV sensor:
the UV intensity falls QT201-50.x 1. Stop the process and restart
below the parameter malfunction. the process again.
set value.
2. In the control system’s AOT
popup, see if the UV values are
OK during the start-up phase.
UV values shall be OK, since
clean cooling water is used.
Book No.9000479 02, rev. 0

2
ID
W151 AOT [x]: Trigger: UV sensor Delay: None. Signal missing. 1. Check fuse F45 in LDC to see
UV intensity QT201-50. which circuit that caused the
signal missing Parameter: N/A Active during step: fuse trip.
(QT201-50)
• Full ballast 2. Use the circuit diagram to
• Full deballast according to figures in circuit
Book No.9000479 02, rev. 0

fuse.

4. Check cables to QT201-50.x.
See the drawing Control
5. If the above is OK, the UV
sensor is probably broke and
needs to be replaced. Replace
the component.
W300 Filter: Motor sum Trigger: Filter. Delay: 1 sec. Motor circuit breaker See LPS alarms in section Lamp
alarm. Parameter: N/A (MCB) F1 in control power supply (LPS) on page 46.
Active during step: cabinet has tripped
All steps. or has been switched
off.
2.1
Comment: The
feedback signal “Filter Motor problem. 1. Check that breaker on the filter
SUM alarm” is not junction box is on.
detected.
2. Check that the motor is not
overloaded and can rotate
easily.
41
Control system
42
2.1
ID
3. Start the motor and check

that the operation is normal.
See chapter 3. Operating
Control system
description, section Operate

components manually and
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.
W304 Filter pressure Trigger: Pressure Delay: 2 sec. Signal missing 1. Check fuse F45 in Control
signal missing transmitter PT201-27 or pressure cabinet to see what circuit
(PT201-27). on Boll filter. Active during step: transmitter PT201-27 caused the fuse trip.
Parameter: N/A malfunction.
• Ballast 2. Use the circuit diagram to
• Back flush according to figures in circuit
• Ballast pause diagram if necessary and reset
fuse.
• Ballast stop
2

• Deballast start-up locate the component or find
• Deballast the reason that caused the fuse
• Deballast pause
• Deballast stop component. See Control
• CIP cabinet / Circuit diagram
• E-stop description and drawings.
Book No.9000479 02, rev. 0

2
ID
• Manual mode 5. Check that all electrical

Comment: Error in
damaged.
Indication of pressure
-1.0 bar (-0.1 MPa) is 6. Replace transmitter FIT201-27.
not an error.
Book No.9000479 02, rev. 0

beginning.
Relative pressure in • Hint: Check pressure signal

filter is below 0 bar. from PT201-27 is displayed in
the Filter popup opened from
page 1.1 Overview.
• Check that the valve V201-26
in the filter is open.
W306 Filter differential Trigger: Pressure Delay: 2 sec. Filter is clogged. Back-flush manually from control
pressure transmitter PT201-27 system. If not sufficient, clean
too high on Boll filter. Active during step: the filter candles according to
(PT-201–27) Parameter: p301. instruction in chapter 7. Service
• Ballast manual.
• Back flush
Valves connected Make sure that the two valves
• Ballast pause to filter differential connected to the filter differential
• Ballast stop pressure transmitter transmitter are open.
closed.
• Deballast Pressure transmitter Hint: Pressure signal from
PT201-27 does not PT201-27 is displayed on in the
2.1
• Deballast pause work correctly. Filter popup opened from page 1.1
• Deballast stop Overview.
• CIP 1. Check fuse F45 in Control

• E-stop cabinet to see what circuit
caused the fuse trip.
43
Control system
44
2.1
ID
• Manual mode 2. Use the circuit diagram to

Control system
fuse.
damaged.
6. Replace transmitter FIT201-27.
beginning.
2
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: N/A Active during step: cable (W104) between Control
cabinet and Log box.
• Ballast
• Back flush Fuse in the log box Check fuse F02 and F03 in the log
has tripped or has box.
• Ballast pause been switched off.
• Ballast stop
Error in module. Check the LED error indication for
the electronic modules in the log
Book No.9000479 02, rev. 0

2
ID
box. See section I/O system and
• Deballast
X20 modules on page 55.
• Deballast pause
• Deballast stop
• CIP
Book No.9000479 02, rev. 0

• E-stop
• Manual mode
2.1
45
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 A130 – Sum
alarm LPS unit.
Please note that the LPS is mounted upside-down in some LDCs.
2.2.1 List of alarms and status indications

The table below explains alarms triggered by and displayed in the LPS.
LED indication key
In the table, the LED behavior is indicated by the symbols below:
LED is off.
5_2_3_03 EmpCirc
LED is on with a steady light.

5_2_3_01 FilledCirc
LED is blinking.
5_2_3_02 CemiCirc
Alarm LED indication Possible cause What to do?

ID
3.1 No error. UV lamp OFF. N/A
5_2_3_1
3.2 No error. UV lamp ON. N/A
5_2_3_2
3.3 UV lamp is igniting. N/A

Max 10 ignition
attempts during max
100 seconds.
Note: Normal condition

during UV lamp ignition.
5_2_3_3
46 Book No.9000479 02, rev. 0

2 List of alarms and warnings 2.2 Lamp power supply (LPS)

ID
3.4 The UV lamp is not • If the lamp is used for the first
successfully ignited. time: Put it on a soft bedding.
(The alarm is activated Flash twice with a normal
101 seconds after first camera on the UV lamp
ignition attempt). (functions as a ionization).
Check again.
5_2_3_4 • Check lamp cable isolation
and connection between
lamp contact and LPS
output.
• Replace UV lamp if broken.
See chapter 7. Service
manual, section Replace UV
lamp and quartz sleeve.
• Reset LED by switching
AOT breaker OFF. Wait 5
seconds and switch it ON
and reignite the lamp.
3.5 Internal temperature in • Check the LDC cooling

LPS > 80 °C whilst the system.
UV lamp is OFF.
• Check that no LPS cooling
fans are broken.
• The LPS automatically
makes the LED go out when
5_2_3_5
the temperature goes below
80 °C.
3.6 LED Temp warning > 80 • Check the LDC cooling

°C whilst the UV lamp is system.
ON.
• Check that the LPS cooling
fans are rotating.
• The LPS automatically
makes the LED go out when
5_2_3_6
the temperature goes below
80 °C.
3.7 LED Temp alarm > 100 • Check the LDC cooling
°C. system.
fans are broken.
• The temperature warning
LED will automatically go
5_2_3_7
off when temperature goes
below 80 °C.
Book No.9000479 02, rev. 0 47

2.2 Lamp power supply (LPS) 2 List of alarms and warnings

ID
• Reset the alarm by switching

the AOT breaker OFF and
ON.
This will cut 24 V DC power
to the LPS units.
• Wait until the two temp alarm
LEDs are switched off, then
the system is ready for a
restart.
• If the problem persists, check
that the cooling fans on the
LPS are rotating whilst the
UV lamps are switched on.
3.8 LED Temp alarm > 100 • Check the LDC cooling
°C. system.
fans are broken.
• Reset the alarm by switching
the AOT breaker OFF and
5_2_3_8
ON.
• Wait until the temp alarm
LEDs are switched off, which
indicates that the system is
ready for a restart.
• If the problem persists, check
that the cooling fans on the
LPS are rotating whilst the
UV lamps are switched on.
3.9 Mains voltage failure. • Check mains voltage supply

to LPS and that the MCB
Broken LPS unit. for that LPS has not tripped
(F01 to F20.
See drawing Lamp Drive
Cabinet (LDC) / Circuit
5_2_3_9
drawings.
• If the Mains fail LED is still
lit and voltage is supplied:
Replace the LPS. See
section Dismount and mount
lamp power supply (LPS).
48 Book No.9000479 02, rev. 0

2 List of alarms and warnings 2.3 Flow meter

ID
3.10 No 24 V DC feeding to Check 24 V DC on LPS terminals

LPS. (The LPS requires "24 V/30 mA Ext", or replace
4 mA input current @ LPS. See chapter 7. Service
24 V DC.) manual, section Dismount and
mount lamp power supply (LPS).
5_2_3_10
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.
Book No.9000479 02, rev. 0 49

2.3 Flow meter 2 List of alarms and warnings
2.3.1 Fault finding instruction

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

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

No: The transmitter is defect. Change.
4. Is the error triangle flashing?
Yes: Go to step 5.
No: The tranmsitter is defect. Change.
5. Are the output and display readings OK?
Yes: Go to step 7.
No: Go to step 6.
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 flow meter error list

Follow this instruction to check the error list in the flow meter.
50 Book No.9000479 02, rev. 0

Buttons used:
4FTLock 4FTChange 4FTFwd

4FT_Topup
Top up Padlock Change Forward
1. Press Top up for three seconds.
2. To enter password (1000): Press Padlock. (A line appears under the first zero.)
- Press Change to change the first 0 to 1.
- 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.
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
Book No.9000479 02, rev. 0 51


lem ID signals code
(trans-
mit-
ter)
W31 Flow sensor (pipe) Ensure that the flow sensor

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

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
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
52 Book No.9000479 02, rev. 0


lem ID signals code
(trans-
mit-
ter)
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
- 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
#####
Book No.9000479 02, rev. 0 53


lem ID signals code
(trans-
mit-
ter)
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.
54 Book No.9000479 02, rev. 0

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

This section explains the different status indications on the level switch LS201-29 in the AOT
module. 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.
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.
2.5 I/O system and X20 modules

This section explains the different status indications on the X20 electronic modules. Alarms and
status are indicated by LED:s on the module.
All modules are clearly identified on the front, for example “X20 BR 9300” in the illustration below.
To the right, the state indication LEDs are visible, for example “r, e, X, I” in the illustration below.
5X20
Book No.9000479 02, rev. 0 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:
Identification Function Installed in cabinet
AI 2622 Analog input, 2 inputs Control cabinet
AI 4622 Analog input module, 4 inputs Control cabinet
AO 4622 Analog output module, 4 outputs Control cabinet
AT 2222 Temperature input module, 2 temp. inputs Control cabinet
CP 3485 System module CPU Control cabinet
IF 1030 Interface module Control cabinet
IF 1082 Bus controller Control cabinet
PS 2100 Supply module Control cabinet
BC 0083 Bus controller Control cabinet

Log box
DI 8371 Digital input module Log box
PS 9400 Supply module for bus controller Log box

Lamp drive cabinet
DI 6371 Digital input module, 6 inputs Lamp drive cabinet

Control cabinet
DO 6322 Digital output module, 6 outputs Lamp drive cabinet

Control 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 IF 1082 is described in a separate table below the generic table.
The table contains the following columns and information:
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.
56 Book No.9000479 02, rev. 0

Light Color State Description

r Green Light off 24 V DC supply not connected, check fuse.
Single flashes Reset mode.
Blinking Preoperational mode.
Steady light RUN mode.
e Red Light off Module not supplied or everything is OK.
Single flashes Warning / error for an I/O channel. Level monitoring for
digital outputs has responded.
AT 2222: 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.
• Input voltage for the X2X bus supply too low.
Light on Error or reset state.
e+r Steady red/single green flashes Invalid firmware.
X Orange Light off No communication at the X2X bus.
Steady light X2X bus communication in progress.
I Red Light off X2X bus supply in the acceptable range.
Steady light X2X bus power supply is overloaded.
For BC 0083: Solution: Use an additional feed module

PS 3300.
S Yellow Off No data traffic over service interface; no activity.
On Data is transferred over the service interface.
1–6 Orange Light off Output status of the corresponding digital output.
For AI For AI 4622: Off - Value = 0. On > 0.

2622:
Green For AI 2622: Open connection or sensor is disconnected.
For AT 2222: The input is switched off.
Blinking Overflow or underflow of the input signal.
AT 2222: As above, or broken connection.
Light on The analog/digital converter is running, values OK.
Book No.9000479 02, rev. 0 57

Light Color State Description

1–8 Green On For DI 8371.
Input status of the corresponding digital input.
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.
Module IF 1082
The status/error light is a green/red dual LED. The status lights can have different meanings
depending on operating mode.
Light Color Description
Green Red
L/A Green On A link to the remote station has been established.

X1/X2
Blinking A link to the remote station has been established. The
light blinks when Ethernet activity is present on the bus.
S/E Green/ Various Status/error light. The status indication varies depending
Red on mode. See the two subsections in below in this table.
Ethernet TCP/IP mode
Starting with Automation Studio Version V 2.5.3 and with Automation Runtime V 2.90, the
interface can be operated purely as an Ethernet TCP/IP interface.
S/E On Off The POWERLINK interface is operated purely as an

light Ethernet TCP/IP interface.
POWERLINK V1 mode
S/E On Off The POWERLINK station is running with no errors.

light
S/E Off On A fatal system error has occurred. The error type can be
light read using the PLC logbook. It concerns an irreparable
problem. The system cannot properly carry out its
tasks. This status can only be changed by resetting
the module.
58 Book No.9000479 02, rev. 0

Light Color Description
Green Red
S/E The POWERLINK managing node failed. This error

light code can only occur in controlled node operation. This
Blinking alternately
means that the set station number lies within the range
$01 - $FD.
S/E Off Blinking System failure. The red blinking light signals an error
light code. See blow.
3 short and 1 long Ram error.
1 long, 2 short, 1 Hardware error – Blinking.

long
Book No.9000479 02, rev. 0 59

3 List of problems and solutions
This section contains problems that can occur, but is not indicated by an alarm.
3.1 General, Filter, CIP and valve V201–8

The list is sorted by the following areas and components: general system problems, filter, CIP and
valve V201–8.
Book No.9000479 02, rev. 0 61

62
3.1
Area Problem Description Possible cause What to do?
ID
General 1A The system does not start. Power not connected to Measure that incoming 24 V DC to the control
The control panel does not the control panel. panel is present.
light up.
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 F4.1 in control 1. Check fuse F4.1 in control cabinet to see what
General, Filter, CIP and valve V201–8
cabinet tripped. 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.
3
Overheated CPU due to Check that the fan mounted on the control panel
control panel cooling fan is running and rotating in the correct direction. If
error. not, change fan rotation. If out of function, replace
the fan.
Control panel error. Replace control panel.

List of problems and solutions
Book No.9000479 02, rev. 0

3

ID
General 1B Control panel is not displaying Abnormal operating 1. Restart the control panel: Cut the power by
a normal page. condition. removing the 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
Book No.9000479 02, rev. 0

control cabinet. Wait 30 seconds, and switch
on the main breaker again.
3. If panel is not OK, it is probably broke and
needs to be replaced. Replace the component.
General 1C PureBallast can not be Communication is broken See the What to do column for alarm A93.
controlled or monitored from between ISCS and PLC.
the ISCS’ graphical user
interface via the remote
interface (optional)
Filter 5A Back flush sequence starting Differential pressure Dismantle the component and inspect/rinse.
error (general) transmitter PT201–27
3.1
(Boll) may be faulty.

Differential pressure
transmitters PT201–71 Differential pressure
and PT201–72 (Hydac) may transmitters PT201–71
be faulty. and PT201–72 (Hydac)
may be faulty.
Error with the differential Dismantle the component and inspect/attend to.
pressure gauge electric
switches.
Valves for differential Open the two valves (ball cocks) connected to
pressure gauge PT201-27.
PT201–27 (Boll) are
closed.
63
64
3.1
ID
Valves for air pressure to Open the valve (ball cock) connected to V309-1.
valve V309-1 are closed.
Filter 5B Excessive back flushing The filter house is not Deaerate using the deaeration valve V201-50 on
or long back-flushing properly deaerated. the filter lid.
sequences (general)
Damaged filter candle. Check filter candles for damage. Replace if
necessary.
Large obstructions have Open the filter and remove the obstructions. See
entered the filter. chapter 7. Service manual, section Filter.
Dirt build-up in the filter Clean the filter candles.

candles.
CIP 6A Insufficient pump capacity Leakage in air hoses or Locate leakage and attend to.
(general). sealings.
Air pressure too low due to Adjust setting with the manual valve under the
incorrect setting on valve valve block on the CIP module.
block on CIP.
The diaphragm in the CIP Examine the pump. See chapter 7. Service
3
pump is broken. manual, section Repair CIP pump.
Pump is clogged. Examine the pump. See chapter 7. Service

manual, section Repair CIP pump.
CIP 6B Too high consumption of CIP Leakage in the CIP tank, Locate leakage and attend to.
liquid (> 1 cm/AOT cycle). CIP pump, pipes or AOT
reactor.
Book No.9000479 02, rev. 0

3

ID
CIP 6C CIP liquid is not returned to Insufficient pump capacity 1. Increase airflow to the pump to increase pump
CIP tank. (P321-5). capacity 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.
Book No.9000479 02, rev. 0

Broken valve. Examine the following valves: V571-1, V321-2.x,
V320-4.x and V321-1.
Pipe blockage Investigate if there is a pipe blockage.
CIP 6D CIP pump does not run • The air pressure is to Examine the pump and attend to problem. See
low chapter 7. Service manual, section Test CIP pump.
• The air connection is
blocked
• Muffler is blocked
• Air valve is defect
3.1
• Dirt in the pump

chamber
• Diaphragm
breakdown
CIP 6E CIP pump runs irregularly • Valve balls are Examine the pump and attend to problem.
blocked
• Sealings are defect
in air valve or center
block
• Diaphragm
breakdown
65
66
3.1
ID
CIP 6F Insufficient CIP pump suction • Suction connection Examine the pump and attend to problem.
blocked or not tight.
• Valve balls are
blocked or damaged
CIP 6G Bad flow or pressure in CIP • Pressure fall in Examine the pump and attend to problem.
pump incoming air
• Suction or air
connection blocked
• Air valve is defect

• Valve balls worn
out/broken
• Air in liquid Diaphragm
breakdown
CIP 6H CIP pump leakage Screws on the housing not Tighten the screws.
properly fastened
3
CIP 6I CIP pump muffler leakage Diaphragm breakdown Change diaphragm.
Valve 8A Signal change has no effect Faulty air supply Check air supply to the valve and tubing to the
V201–8 on the actuator position actuator.
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.
Book No.9000479 02, rev. 0

3

ID
Valve 8B Signal change results in Connection or signal • Check coupling between proportional valve
V201–8 actuator running to end problem and actuator.
positions
• Check input signal.
Valve 8C Signal and positioning • Inaccurate positioning. Adjust position sensor. See chapter 7. Service
V201–8 problems. manual, section Valve actuator.
Book No.9000479 02, rev. 0

• Input signal fluctuates.
Check electric connection.
3.1
67
Chapter: 6. Installation description and drawings
Book No. 9000479 02, rev. 0

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 Technical data 9
2.1 PureBallast system 9
2.2 PureBallast components 10
2.3 Working pressure and pressure drop 12
2.3.1 Pressure drop for a PureBallast system 12
2.3.2 Working pressure for filter during ballast operation 12
2.3.3 Pressure calculation 13
2.3.4 Pressure during different dirt loads 14
3 Delivery and transport

information 17
3.1 Delivery and transport 17
3.2 Lifting instructions 17
3.2.1 AOT module 18
3.2.2 Filter 20
3.2.3 CIP module 21
3.2.4 Control cabinet 22
4 Installation guidelines 23
4.1.1 Safety information 23
4.1.2 Correct installation 23
4.1.3 After installation, before system is put into operation 24
4.2 Planning the installation — Main

considerations 24
4.3 Scope of supply 25
4.4 AOT module 30
4.4.1 Placing guidelines 30
4.4.2 Installation guidelines 30
4.5 Filter 34
4.6 CIP module 35

3
4.7 Cabinets and cables 36
4.7.3 EMC cable installation 38
4.8 Flow meter 38

4.9 Pipes and valves 40

4.10 Air supply 40

4.11 Ancillary equipment 41

5 System interfaces 43
5.1 Remote control panel integration
(optional) 43
5.2 Remote interface integration (optional) 44
5.2.1 Communication between PureBallast PLC and
remote interface 44
5.2.2 Directory of addresses 45
5.2.3 Sequence example 61
5.3 Power management interface

integration 65
5.3.1 Overall power request process 65
5.3.2 Power steps and power signals 65
5.3.3 Power signal sequence 67
5.3.4 Power management installation 68
5.4 External component signal integration 69

5.4.1 External component signal installation 70
5.5 Log box integration (optional) 72

4
5.6 GPS signal installation 75
6 Shutdown and storage 77

6.1 Decommissioning 77
6.2 Protection 78
6.3 Storage and long term decommission-
ing 78
6.4 Disassembling before transportation 79
6.5 Start-up after shutdown 79
7 Drawings 81
7.1 Graphic symbols used in drawings 82
7.2 General drawings 83
7.2.1 Flow chart 83
7.2.2 Connection list 84
7.2.3 Electrical system layout 89
7.2.4 Air distribution 90
7.2.5 Quality specification / Compressed air 91
7.2.6 Quality specification / Water 92
7.2.7 Quality specification / CIP liquid 93
7.3 Dimension drawings including technical

data 94
7.3.1 AOT module / Dimension drawing (2 pages) 94
7.3.2 AOT reactor / Dimension drawing 96
7.3.3 Filter / Dimension drawing 97
7.3.4 CIP module / Dimension drawing (2 pages) 98
7.3.5 Sampling device Q201.1, Q201.2 / Dimension
drawing (2 pages) 100
7.3.6 Flow transmitter FIT201-1 / Dimension drawing 102
7.3.7 Pressure transmitter PT201-16 / Dimension drawing 103
7.3.8 Pressure gauge PI201-18 / Dimension drawing 104
7.3.9 Valve V201-3 and V201-9 / Dimension drawing 105
7.3.10 Control valve V201-8 / Dimension drawing 106
7.3.11 Valve V212-31 / Dimension drawing 107
7.3.14 Valve V310–1 and 310–6 / Dimension drawing 110
7.3.15 Control cabinet / Dimension drawing 111
7.3.16 Remote control panel / Dimension drawing (2
pages) 112
5
7.4 Log box / dimension drawing 114
7.5 Electrical drawings 115
7.5.1 Control cabinet / Assembly drawing 115
7.5.2 Control cabinet / Circuit diagram (19 pages) 116
7.5.3 Control cabinet / Interconnection diagram (9 pages) 135
7.5.4 Control cabinet / Cable list 144
7.5.5 Remote control panel (optional) / Assembly drawing 145
7.5.6 Lamp Drive Cabinet (LDC) / Assembly drawing 146
7.5.7 Lamp Drive Cabinet (LDC) / Circuit diagram (20
pages) 147
7.5.8 Lamp Drive Cabinet (LDC) / Interconnection
diagram (5 pages) 167
7.5.9 Lamp Drive Cabinet (LDC) / Cable list 172
8 Type approval and test result

summary 173
8.1 Type approval (5 pages) 174
8.2 Test result summary (4 pages) 179
6
1 Introduction
This chapter contains information about how the PureBallast system is installed and stored.
The information is presented as installation guidelines per component, relevant standards and
drawings. The chapter is opened with a summary of technical data relevant for planning and
installing PureBallast.
Book No.9000479 02, rev. 0 7

1 Introduction
2 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.
2.1 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 92 and data for
different components in the Connection list on page 84.
Water temperature — AOT: 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 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 modules after
treatment.
Ambient air 0–55 °C.

temperature
Relative humidity Max. 90 %.
System flow Recommended min flow (m3/h): Max flow (m3/h):

200. 750.
Power consumption Total power consumption (kW):

109
Based on:
36 kW per AOT module. Power factor: 0.95.
1.0 kW (Control system including PLC, 24 V feeding, CIP motor

supply, filter motor supply)
Book No.9000479 02, rev. 0 9

2.2 PureBallast components 2 Technical data
Type of data Value
Compressed air See data for individual components in Connection list on page 84 and
requirements the Quality specification for compressed air on page 91.
Piping connections See data for different components in Connection list on page 84.
Working pressure – Max. 6 bar (PN 6). (0.6 MPa).

PureBallast system
Working pressure – See Connection list on page 84.

compressed air
Power: Nominal 400VAC +/-10% − 50Hz

voltage/Frequency
440VAC +/-10% − 60Hz
24VDC - Remote control panel (optional).
Power to LDC: Max Icu 70 KA. (Fixed breaker setting: 125 amp).
IP raiting 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.
2.2 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 module (per AOT) Pressure drop See data for different components in Connection
list on page 84.
Weight 600 kg (Empty AOT reactor, including lamp

drive cabinet).
Volume 55 liters
LDC, pressurizing unit Air requirements See Quality specification / Purge air on page .
10 Book No.9000479 02, rev. 0

2 Technical data 2.2 PureBallast components
Component Type of data Value
Filter Pressure drop 0.05–0.38 bar (0.005–0.038 MPA). Also see

data for different compondnts in the General
drawings section.
Working pressure See Working pressure and pressure drop on

for filter during page 12.
ballast operation
Weight, empty (kg) 900
Volume (dm3) 500
CIP module Weight (empty) 195 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 102.

etc.
Valves Measures, weight See section Dimension drawings including

etc. technical data on page 94.
Type See data for different components in Connection

list on page 84.
Connection type DIN
Electrical cabinets Measures, weight See section Dimension drawings including

etc. technical data on page 94.
Remote control panel Dimensions See Remote control panel / Dimension drawing
(Optional) on page 112 and on Remote control panel
integration page 43.
Log box Dimensions See Log box / Dimension drawing on page 114.
Book No.9000479 02, rev. 0 11

2.3 Working pressure and pressure drop 2 Technical data
2.3 Working pressure and pressure drop

This section gives a description of working pressure and pressure drops in the system. This
information is necessary to be able to dimension the ballast water system. The values in the text
and formulas below refer to the illustration in the Connection list on page 84.
2.3.1 Pressure drop for a PureBallast system

During ballasting, the ballast water flow goes through the filter and AOT which gives a pressure
drop of 0.80 bar at maximum flow rate. Note that piping is not included.
2.3.2 Working pressure for filter during ballast operation

This section describes the principles of the filter back-flush. (A back-flush can be started manually
or automatically, but this section only deals with the automatically initiated back-flush.)
During ballast, the filter is rinsed by an automatic back-flush operation. A differential pressure
indicator monitors the pressure drop over the filter, which fluctuates between 0.05−0.38 bar
depending on dirt load in the filter.
When the differential pressure over the filter, ∆pfilter, reaches 0.38 bar, a back-flush operation is
started automatically. To ensure sufficient back-flush flow, ∆pback-flush must be at least 1.50 bar.
6 WorkPressure
12 Book No.9000479 02, rev. 0

2 Technical data 2.3 Working pressure and pressure drop
2.3.3 Pressure calculation

Consider the following when the ballast water system is dimensioned.
Pressure during ballasting
During ballasting, the ballast water flow goes through the filter and AOT which gives a pressure
drop of 0.80 bar (not including piping), as described in the table below.
Filter ≤ 0.40 bar pfilter: 0.05−0.38 bar (0.005–0.038 MPa).
0.40 bar is used as an approximate value. Actual pressure drop

over the filter fluctuates between 0.05−0.38 bar during ballast
operation.
AOT ≤ 0.40 bar pAOT: 0.40 bar (0.04 MPa) including PureBallast valves. Piping
is not included, since it is installation specific.
As the AOTs are connected in parallel the pressure drop over

AOT is 0.4 bar (0.04 MPa) regardless of the number of AOTs.
Total ≈ 0.80 bar ≈ 0.80 bar (0.08 MPa) not including piping.
Pressure during back-flush
During back-flush, the ballast water flow goes through the filter and AOT, and the back-flush
discharge flow goes through filter and pipe 309.
A pressure calculation must be done to secure sufficient back-flush flow in pipe 309 and to secure
that the ballast water pump can overcome pressure drop according to the table below:
∆pfilter ≤ 0.40 bar (approximate value).
∆pback-flush ≥ 1.50 bar Required for efficient back-flushing.
∆P309 Calculated Pressure drop for pipe 309 is installation specific and must
be calculated.
The required ∆Pback-flush (1.5 bar ) gives the following flow,

stated in the Connection list: 129 m3/h. Use this flow to
calculate the pressure loss in ∆P309.
Note that ∆P309 includes both static pressure and dynamic

pressure (pipe length, bends, valves etc) for pipe 309.
Total Calculated Calculated value give

pressure
drop • total pressure drop during back-flush
• minimum BW pump capacity required for PureBallast.
If the value is greater than existing pump capacity, steps must
be taken, for example:
Book No.9000479 02, rev. 0 13

• Reduce the total pressure drop by reducing ∆p309. This

can, for example, be done by increasing the pipe diameter
or by reducing the number of bends etc in pipe 309.
• Upgrade to a pump with bigger capacity.
Calculate value for parameter Pressure trigger for V201-8 during back-flush
To ensure that pback-flush is 1.5 bar, the pressure at the filter outlet must be calculated according
to the formula below:
• pfilter outlet ≥ ∆pback-flush + ∆p309

Enter this value in parameter p304 (Pressure trigger for V201-8 during back-flush) in the control
system page 8.4 – Filter parameters. This parameter will trigger the control valve V201-8 to create
the remaining pressure, if the pressure at pfilter outlet falls below entered value.
2.3.4 Pressure during 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 the filter back-flush depends on trade.
2.3.4.1 Low dirt load
In clear water, where the dirt load is low, the back-flush cycle is started by the time trigger (default:
every 30 minutes). As long as the pressure is below 0.38 bar (0.038 MPa), there is no need for the
pressure triggered back-flush. See examples below.
6 Dirtload1
6 Dirtload2
14 Book No.9000479 02, rev. 0

2 Technical data 2.3 Working pressure and pressure drop
2.3.4.2 Medium dirt load
In more dirty waters the back-flush cycle will be triggered when pfilterreaches 0.38 bar, which
indicates dirt in the filter candles.
After each back-flush, the back-flush counter is reset. The filter will be back-flushed again after 30
minutes or when ∆pfilterreaches 0.38 bar, whichever comes first.
In the example below, three back-flushes are triggered due to high differential pressure over the
filter. After that, there is not so much dirt build up, so the next back-flush is performed after
30 minutes.
6 Dirtload3
2.3.4.3 Heavy dirt load
In conditions with heavy dirtload the system will perform more frequent back-flushes to keep the
filter clean.
Also, the 0.38 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 0.38 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 back-flushes are performed (approx. every 4 minute). After that
the pressure rises above 0.38 where the filter is back-flushed constantly. After that, the normal
control is resumed, where the filter is back-flushed triggered pressure (2 times) or by time (last
back-flush in the example.
6 Dirtload4
Book No.9000479 02, rev. 0 15

2.3.4.4 Long term dirt build-up
Over time, the filter candles will undergo a long term build-up of particles that are not removed by
back-flushing. 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 back-flushing is performed with short intervals, we suggest that the
filter candles are manually cleaned more often than once year.
16 Book No.9000479 02, rev. 0

3 Delivery and transport
information
This section contains information about how to handle PureBallast components during transport,
delivery and installation.
3.1 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.
• Each AOT module is delivered with an extra set of loose components to secure that installation
and commissioning can be performed without any crucial parts missing. The AOT module is
delivered with the following surplus consumables, compared to the amount needed.
- O-ring, 10 pieces. Part number: 579380 01

- O-ring, 10 pieces. Part number: 589774 01
- UV lamp set, 1 piece. Part number: 579367 98
- Quarts sleeve set, 1 piece. Part number: 594645 80.
3.2 Lifting instructions

This section describes how to lift PureBallasts components.
NG
WARNI
!
• 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.
Book No.9000479 02, rev. 0 17

3.2 Lifting instructions 3 Delivery and transport information
• Components must be empty when lifted.

• The AOT module, filter and CIP module must be lifted according to the instructions in the
following sections.
3.2.1 AOT module
NOTE
• The AOT is delivered lying down in a wooden box. It must not be turned to vertical position.
• The AOT is delivered with a wooden bearer attached at the bottom of protect the components
around the lower flange. The bearer must remain attached to the AOT if the AOT is to be
placed standing up prior to mounting.
• Weight and center of gravity according to illustration below:
6 595570_manual
Ref. 595570
18 Book No.9000479 02, rev. 0

3 Delivery and transport information 3.2 Lifting instructions
3.2.1.1 Lift AOT module
Follow the instruction to raise the AOT module to standing position. Note that two lifting devices are
needed for this operation.
1. At the bottom (left in the illustration): Attach a soft sling or webbing sling to the uppermost
fixing hole of the flange.
2. At the top (right in the illustration): Attach a soft sling to the lifting eye bolt on the girder.
3. Direct the sling from the lifting eye bolt via the valve to the lifting device. Stretch the sling in an
angle which allows approximately 100 mm safety margin from the actuator.
4. Lift the AOT module. Make sure that the slings do not damage any equipment, for example an
actuator.
5. When AOT is in the air it can be turned to vertical position by lower of the sling attached to
the bottom flange. Make sure that the slings do not damage any equipment, for example an
actuator.
6. Lower the AOT module to its mounting position.
Book No.9000479 02, rev. 0 19

3.2.2 Filter
Weight of filter (empty): 900 kg.
6 FilterLift 594949#0
Ref 594949
20 Book No.9000479 02, rev. 0

3 Delivery and transport information 3.2 Lifting instructions
3.2.3 CIP module

Use intended lifting attachment according to the illustration below.
6 CIP Lift 590857_manual
Ref 590857
Book No.9000479 02, rev. 0 21

3.2.4 Control cabinet

Use intended lifting attachment according to the illustration below. Protect the panel during lifting.
6 CCLift 597309
Ref 597309
22 Book No.9000479 02, rev. 0

4 Installation guidelines
This section covers requirements for planning, locating and installing different components of
the system.

Read this section before the system is installed.
4.1.1 Safety information

• Ground 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.
• Read the section Personnel requirements in chapter 1. Safety.
• Follow local regulations for electrical installation and grounding (earthing).
NG
WARNI
!
• The PureBallast system must be installed in an engine room on the vessel. The remote control
panel (optional) can also be installed in all other locations, for example cargo control room, back
office or the bridge, provided the area is not hazardous.
• The PureBallast system is not EX proofed and must not be installed in areas where an
explosive atmosphere may occur.
• Damages related to transport and installation should be recorded.
• All components must be installed and marked as specified in dimension drawings, flow charts
and other drawings included in this manual.
• Installation must be done by a fully trained professional installer.
4.1.2 Correct installation

In the installation guidelines, the word “correctly” is used. This means that installation must be
performed according to the following:
• The Installation guidelines for each component in this section.

• Sizes and installation requirements are given in the dimension drawing for respective
component. See section Drawings in this chapter.
• Instructions on how to mount and install components are given in chapter 7. Service manual.
Book No.9000479 02, rev. 0 23

4.2 Planning the installation — Main 4 Installation guidelines
considerations
• The drawings included in this chapter:
- 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 (circuit diagrams, cablings etc).
4.1.3 After installation, before system is put into operation

After installation, the following actions must be performed to avoid that the filter and the AOT reactor
is damaged by material from the ballast water tanks or from mounting pipes and valves.
NOTE
• All ballast water tanks must be well cleaned before PureBallast is put into operation. This is
valid both for new builds and retrofit installations.
• All pipes to PureBallast must be well flushed, before water is run through the filter.
4.2 Planning the installation — Main considerations

The table below summarize the most important factors to be considered when planning the
installation of a PureBallast system.
Main considerations – System
System requirements The system must be designed according to the basic layout
requirements specified in the Flow chart on page 83.
Study this drawing to secure a functioning system, for example

correct placing of component and access to fresh water etc.
Pressure and pressure The system must be designed and installed to secure required flow
drop and pressure, and the ballast water pump must be dimensioned to
handle the filter back-flush according to reference below. Pressure
calculations must be performed to secure this.
See the following sections in this chapter:
• Installation requirements for even flow distribution on page 31

• Working pressure and pressure drop on page 12.
General function Note that the function and performance of PureBallast are dependent
of the installation. It is the shipyard’s responsibility to plan and
perform the installation according to the specifications given in this
manual.
24 Book No.9000479 02, rev. 0

4 Installation guidelines 4.3 Scope of supply
Main considerations – Components
Components within Alfa Information about installation requirements for individual components
Laval’s scope of supply according to section Correct installation on page 23.
Components supplied by Additional equipment is needed to install the PureBallast system,

shipyard apart from them included in Alfa Laval’s scope of supply. Note that
the shipyard is responsible to choose material and purchase the
equipment.
Examples on not included equipment:
• Support for mounting heavy components, for example AOT

module and filter.
• Electrical and signal cables.
• Pipes for liquids, for example water and CIP liquid.
• Pipes for air, for example deareation pipe and pipes for
compressed air.
• Ancillary equipment, for example sieve for stripping.
• Device for visual and audible alarm signal. See Cabinets and
cables on page 36.
This equipment must be according to specifications in the following
sections of the manual:
• Connection list
• Quality specification for water
• Quality specification for compressed air
• Installation guidelines
• Electrical drawings
4.3 Scope of supply

The table below is a list of all PureBallast components and consumables delivered by Alfa Laval.
The list is compiled on the top level so that integrated components are not described, because they
are already mounted at delivery. For example, the lamp drive cabinet is not described individually in
the list, since it is already mounted as a part of the AOT module.
Book No.9000479 02, rev. 0 25

4.3 Scope of supply 4 Installation guidelines
Component ID Function Main considerations
Main components
AOT module, AOT n, The main water treatment It is crucial that the AOT:s are installed
pieces where component in the system, so that the water flow as well as
according to “n” including reactor, lamp static and dynamic pressure is equally
order. indicate drive cabinet, valves, distributed between all AOTs.
unique temperature sensor, limit
AOT switch and temperature
number. switch.
Control Control Contains the main As described below in this section.

cabinet, 1 cabinet control panel, from which
piece PureBallast is controlled. It
also contains a breaker
and communication
components such as PLC,
switches for communication
with remote interface,
remote control panels etc.
Filter, 1 Filter Mechanical filtration of the The cover and insert are heavy.
piece water before treatment. When planning the location of the
filter, consider the need for a lifting
device to be used for installation and
maintenance.
The installation must also consider

the defined installation height for the
filter. See the dimension drawing in the
Drawings section.
CIP module, CIP Automatic cleaning of the The CIP module must be placed so the
1 piece AOT after treatment. pipes from the AOT have a downward
gradient towards the CIP module.
Remote Extra panel to control and Can be installed in locations from where
control panel monitor the PureBallast ballast operations are performed, for
(optional), 1 system. example on the bridge.
piece
Log box Log box Connection box to connect Max distance to the control cabinet: 100
(optional), 1 feedback signals for valves meters.
piece and pumps that are not
included in the PureBallast
system. This makes it
possible to monitor and
log the components in the
control system.
Main valves
26 Book No.9000479 02, rev. 0

Valve, V201-8 • Main outlet valve from The valve must be placed as last
1 piece the PureBallast system component on the ballast water outlet
including to the vessel’s ballast pipe.
junction box system after treatment.
• Control valve to
maintain pressure
needed to perform back
flush.
• Automatic flow
regulation during
operation.
The junction box function
as cable connection point
for the component.
Valve V201-3 Function as As described below in this section.

including
junction box • Main inlet valve to the
PureBallast system
during ballast, in
combination with
V201-32. The valve
directs the water flow
through the PureBallast
filter. (Closed during
deballast)
The junction box function
as cable connection point
for the component.
Valve, 1 V201-32 • Inlet valve to the As described below in this section.

piece PureBallast system
during ballast, in
combination with
V201-3. The valve
directs the water flow
from the PureBallast
filter to the AOT
reactor. (Closed during
deballast)
Valve, V201-9 • Main inlet valve As described below in this section.

1 piece (bypass valve) to the
including PureBallast system
junction box during deballast, when
the filter is bypassed.
(Closed during ballast)
• The junction box
function as cable
connection point for
the component.
Book No.9000479 02, rev. 0 27

4.3 Scope of supply 4 Installation guidelines
Valve, V212-31 • Functions as bypass The valve must be connected to

1 piece valve to bypass the • the vessels pneumatics
including complete PureBallast
• the vessel’s ISCS, to enable control
junction box system. The valve is
of the valve position
solely operated from
the ISCS. • PureBallast control system to
indicate valve position.
• The junction box
function as cable
connection point for
the component.
Flow sensor FIT201-1 Flow sensor monitor As described below in this section.
the flow in the system.
Flow FIT201-1 Functions together with the
transmitter flow transmitter.
Flow transmitter send flow

information to the control
system. It is mounted on
the flow sensor.
Ancillary equipment
Sampling Q201-1 Sampling points to tap The sampling devices must be

device, 2 Q201-2 water for test of water accessible for taking samples.
pieces before and after treatment.
Valve, 1 V403-35 • Cooling water inlet As described below in this section.

piece valve.
• Supplies cooling water
to the AOT(s) to
protect the lamps from
overheating during
start-up. The valve is
common for all installed
AOT(s).
Pressure PI201-18 • Display analogue As described below in this section.

gauge set, pressure information.
1 piece
Pressure PT201-16 • To send pressure As described below in this section.

transmitter information to the
set, 1 piece control system.
Consumables
28 Book No.9000479 02, rev. 0

CIP liquid, 1 The liquid is used for the See chapter 7. Service manual,
can first filling of CIP liquid. instruction Change and refill CIP liquid.
Loose com- Each AOT module is Included items are listed in section
ponents for delivered with an extra Delivery and transport on page 17.
commission- set of lose components
ing, 1 set. to secure that installation
and commissioning can
be performed without any
crucial parts missing.
Book No.9000479 02, rev. 0 29

4.4 AOT module 4 Installation guidelines
4.4 AOT module

Follow the guidelines below when installing the AOT module.
4.4.1 Placing guidelines

• The size and the required access area around the component are given in the dimension
drawing for the AOT module.
• There must be free space available to open the lamp drive cabinet (LDC) door.
4.4.2 Installation guidelines

• Prepare the inlet piping first. Then mount the AOT onto the inlet flange and secure it. Finally
install the outlet piping onto the top of the AOT.
• We recommend that the installation of the AOT module is planned to be supported by its lifting
point until the unit is completely secured between the inlet and outlet flanges.
• The AOT reactor must be mounted vertically with the water flow going upwards. Also see
lifting instructions for the AOT on page 18.
• The installation must not amplify vibrations to or from the hull.
• No fixtures should be attached to the AOT reactor by welding, since this will damage or distort
the AOT reactor, and potentially affect the biological performance of the component.
• The component must be earthed. The earth nut is placed at the underside of the component, .
• The cooling water supply to the LDC must be connected to meet the requirements in the
Connection list on page 84 under item 401. Correct temperature and flow are crucial to secure
that the LDC is cooled in a sufficient way. The cooling water installation must be verified after a
couple of hours, to make sure that there is no leakage in the cabinet.
30 Book No.9000479 02, rev. 0

4 Installation guidelines 4.4 AOT module
4.4.2.1 Installation requirements for even flow

distribution
The installation of the AOTs and piping for ballast water must be designed so that the water is
distributed evenly through all AOTs. There is no standard solution for how to organize the AOTs.
Requirements and recommendations are given below.
Requirements
• The flow must not exceed certified flow: 750 m3/h in total for the system.
• The flow must be evenly distributed through the AOTs. A small fluctuation is allowed, but the
flow must not exceed 255 m3/h for one AOT.
• Chosen solution must be verified by a flow and pressure calculation (by installing party) to verify
that the flow is evenly distributed.
Recommendations
The principles below are recommended to attain even flow:
• Install AOTs on the same level.

• Design the manifold so that the outlet flow goes in opposite direction, compared to the inlet
flow. See examples below.
6 Even flow 1
Book No.9000479 02, rev. 0 31

4.4 AOT module 4 Installation guidelines
• Increase the diameter for the inlet and outlet manifold with one standard pipe size (or more).
This will result in a lower velocity, and thereby a more even distribution of the flow. This is
strongly recommended for system sizes 1250–3000. See example below.
6 Even flow 2
• Strive to use as few bends and other components as possible before and after the manifolds.
This will result in smaller pressure drops and a more even distribution of the flow.
• A mechanical device can be installed to secure even flow through the AOTs, for example an
orifice or a balancing valve (not part of Alfa Laval’s scope of supply). Note that any chosen
solution must be verified.
4.4.2.2 Support for AOT and LDC cabinet
Fixate the AOT module according to the guidelines below:
• The LDC cabinet must be secured with a stay at the top. Use the Ø15 mm support hole at the
top of the LDC module. See A in the illustration below.
• The LDC cabinet must be secured with stays at the bottom. Use the support plate. See B in
the illustration below.
• The AOT reactor must be supported to carry the weight of the component. Stays has to be
made at site, and can be done according to of the examples below.
- The AOT reactor rests on a stay. See C in the illustration below.

- The AOT reactor rests on the pipe, which is firmly supported to carry the weight of the AOT.
• If recommended installation (inlet piping installed before AOT), it is possible to install the AOT
module before the piping using the combination of B and C in the two illustrations below.
32 Book No.9000479 02, rev. 0

4 Installation guidelines 4.4 AOT module
6 592830_support2
6 592830_support1
Fixating the AOT module.
Book No.9000479 02, rev. 0 33

4.5 Filter 4 Installation guidelines
• The AOT module must be mounted vertically between the inlet and outlet flanges as shown in
the illustration below (flange A is the inlet and flange B is the outlet). The AOT can be mounted
in any rotational position about the center line of the inlet and outlet flanges.
• The AOT module (including the LDC) module must be secured to withstand forces of loads
according to the table and illustration below. The table indicates the calculated load applied
by a full AOT when the vessel is heeling 50°. The direction of load is shown in the illustration
below the table.
Cartesian load Flange A (inlet) Flange B (outlet)
direction
Fx ± 3200 N ± 3200 N
Fy ± 2600 N ± 2600 N
Fz + 11400 N + 5700 N
Fz support + 5000 N + 1200 N
6 592830_force diagram
AOT loads. Ref: 587359
4.5 Filter
Follow the guidelines below when installing the filter.
34 Book No.9000479 02, rev. 0

4 Installation guidelines 4.6 CIP module

• The size and the required access area around the filter are given in the dimension drawing for
the filter.
• The filter must be placed on a firm level surface. The legs of the component can be bolted
or welded in place on a steady foundation.

• Pipe 309 (filter back flush overboard line), with its valve, must be correctly connected.
• Pipe 309: It is recommended that the pipe diameter for pipe 309 is increased with one standard
pipe size directly after the filter flange.
• 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.
• If desired, valves V201-3 and V201-32 can be mounted directly on the filter flanges.
4.6 CIP module

Follow the guidelines below when installing the CIP module.

• The size and the required access area around the component are given in the dimension
drawing for the CIP module.
• The CIP module must be placed on a firm level surface. The legs of the component can be
bolted or welded in place.
• The CIP module is recommended to be installed below the AOT or on the same level to
minimize dilution or loss of CIP liquid.

• The installation must not amplify vibrations to or from the hull.
• 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 CIP is recommended to be earthed, using the PE bolt on the front side of the frame,
marked “PE bolt” in the drawing.
• Rotation of the CIP pump must be verified according to Test CIP pump in chapter 7. Service
manual.
• The deaeration pipe after deaeration valve V571-1 must reach approximately 2 meters higher
than valve V321-2 at the AOT to avoid leakage.
• 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.
Book No.9000479 02, rev. 0 35

4.7 Cabinets and cables 4 Installation guidelines
• It is recommended that the drain valve (V460–3) is connected to one of the following tanks:
bilge tank, drain tank, sludge tank or bilge wel. This will facilitate drainage of the CIP tank.
• Follow the recommended installation of pipes to and from the AOT, to minimize dilution or loss
of CIP liquid and to secure good pump efficiency (as illustrated below):
- Pipe 321: Downward gradient towards both the CIP module and the AOT reactor. There
must be no risk for water or air pockets in the pipe.
- Pipe 320: Downward gradient from the AOT towards the CIP module. Create a water lock
close to the CIP module, before the vertical pipe to the CIP module. There must be no risk
for water or air pockets in the pipe, which can effect efficiency in a negative way.
6 AOT-CIP 6_4_5_2
CIP under AOT CIP in level with AOT
4.7 Cabinets and cables

Follow the guidelines below when installing cabinets and cables.

• Cables must be braced and placed so that they are protected from friction and wear.
36 Book No.9000479 02, rev. 0

4 Installation guidelines 4.7 Cabinets and cables
NOTE
• Alarms from PureBallast must be distributed as a visual and audible signal to all stations from
which ballast water operations are controlled. To achieve this, a signal device (not part of Alfa
Laval’s scope of supply) is connected to the control system alarm relay indicated as “common
alarm” in drawing Control cabinet / Interconnection diagram on page 135.
• 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
- log box
Cabinets
• Cabinets must be firmly attached and must not amplify vibrations to or from the hull.
• Control cabinet: The component must be earthed. The earth nut is placed at the underside of
the component, marked “PE” in the drawing.
Cables
• Electrical cables must be properly suspended and supported according to applicable regulations.
• Cabling shall be done according to specification in Electrical system layout on page 89, and
the electrical drawings. This includes cable routing, cable types and cable marking to simplify
identification and fault finding.
• Power cables shall be separated from signal and bus cables. Distance between them reduces
electrical noise transfer.
- If placed on a cable rack, place power and signal cables on opposite sides.
- If cables are routed in tubes due to narrow space, the power and signal cables shall be
routed in separate tubes.
• Power cable to LDC: Max Icu 70 KA. (Fixed breaker setting: 125 amp).
• Power cable (4 cords) to V201-8 must be done according to the Control cabinet / Interconnection
diagram on page 135.
Please note the following:
- Two cords are connected to the terminal in 201-8GS.

- Two cords are lead in the cable pipe from 201-8GS to IP 201-7.
• 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.
Book No.9000479 02, rev. 0 37

4.8 Flow meter 4 Installation guidelines
4.7.3 EMC cable installation

• Cables shall be peeled down to the cable shield. The nut holding the cable must be in contact
with the screen bar.
4.8 Flow meter

Follow the guidelines below when installing the flow meter. See chapter 7. Service manual, section
Flow meter for instructions.
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: Monitor flow and transmits the 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.

• The flow direction must be according to the arrow on the flow sensor.
• The flow transmitter must be mounted on the flow sensor. It is not pre-assembled from factory.
See chapter 7. Service manual for instructions.
• We recommend that a straight pipe is installed before and after the flow sensor, with length
(L) proportional to the pipe diameter (⌀) according to the illustration below. This will secure
accurate measure (less than 0.5 % divergence).
6 FM install
Flow meter — Plan (Flow according to arrow)
38 Book No.9000479 02, rev. 0

4 Installation guidelines 4.8 Flow meter
• If there is a lack of space, it is possible to shorten the straight pipes. Note that the accuracy
is affected negatively by shorter straight pipes. It is also possible to place the flow meter in a
bend without straight pipes. In this case we recommend that the radius (R) is proportional to
the pipe diameter (⌀) according to the illustration below. Installation without straight pipes will
result in a divergence of approximately 2 %.
6 FM bend
Flow meter in bend — Plan (Flow according to arrow)

• The flow meter must always be completely filled during operation to ensure optimum flow
measurement. To achieve this, it is recommended that the flow meter is installed in a pipe with
an upward flow direction (vertical or slanting). This minimizes the risk for gas and bubbles
effecting the measurement negatively. See illustration below for example.
6 FM Pipe
Flow meter in pipe — Section (Flow according to arrow)
• Do not install the flow meter at the highest point in the pipe: This results in partially filled pipes.
Do not install in a pipe with a downward flow direction: The water shall not stream by gravity.
If there is a risk for pour measuring conditions (e.g. partially filled pipes), the flow sensor should
be located in a U tube to ensure that it is completely filled. See illustration below.
6 FM Upipe
Flow meter on pipe — Section (Flow left to right)
Book No.9000479 02, rev. 0 39

4.10 Air supply 4 Installation guidelines
4.9 Pipes and valves

Follow the guidelines below when installing pipes and valves.

• Pipes must be installed to minimize vibrations to or from the hull.
• 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.
• Marking of pipes that indicate media and flow directions must be followed. These shall be
corresponding to the flow chart on page 83.
• Bypass valve V212-31 for the PureBallast system must be correctly connected. Note that the
valve is only operated by the ISCS (integrated ship control system).
Bypass valve shall be installed according to the following: There are two sets of sensors. One
pair shall be connected to the ISCS and the other pair shall be connected to the PureBallast
control system according to the Control cabinet / Interconnection diagram on page 135.
• Valve actuators must be mounted correctly, if not mounted at delivery. See chapter 7. Service
manual for instructions.
• Valves can be installed on vertical, horizontal and sloping pipes.
• 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.
• Cooling valve V403-35 must be installed between valve V201-19 and V201-9. Valve
characteristics for V403–35: ⌀ 50, flange standard DIN.
• Non-return valves are recommended to be installed, as a safety precaution, at the end of the
following pipes: 309, 402 and 404. Note that these valves are not delivered as a part of the
PureBallast system.
• Sampling device Q201.1 and Q201.2 must be mounted with the pin pointing in the flow direction
(see drawing on page 100).
• Sampling devices must be accessible for taking samples.
4.10 Air supply

Follow the guidelines below when installing air supply.

• There must be sufficient access to maintain the components.
40 Book No.9000479 02, rev. 0

4 Installation guidelines 4.11 Ancillary equipment

• Compressed air supplies must be installed to meet with the requirements specified in the Quality
specification for compressed air on page 91 and drawing Air distribution on page 90.
• Pipes must be properly suspended and supported. The pipes must not amplify vibrations to
or from the hull.
4.11 Ancillary equipment

• Prepare and install the following components according to the flow chart and dimension
drawings.
- Pressure gauge set
- Pressure transmitter set
- Sampling devices
• If an eductor (not part of Alfa Laval’s scope of supply) is installed for stripping, it shall be
installed before the PureBallast system and the water involved in stripping must be filtered
from particles larger than approximately 5 mm.
Book No.9000479 02, rev. 0 41

4.11 Ancillary equipment 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
• power management
• external component integration
• GPS integration
• log box
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:
• 1–4 remote control panels to be mounted at an optional location. Note:
- If Cat 5e (or better) is used as communication cable (W501), the maximum distance
between control cabinet and the remote control panel is 100 meters.
- If the distance is longer, a multi-mode fiber cable with LC connector must be used.
• A signal device must be installed according information in section Cabinets and cables on page
36. Not part of Alfa Laval’s scope of supply.
• Ethernet switch connecting set in control cabinet.
• External switch including a terminal to handle the communication.
Switches and cables are installed according to instructions in chapter 7. Service manual, section
Remote control panel (optional).
IP addresses are set according to instruction in chapter 3. Operating instructions and control system
description, section Set control panel IP address and Set remote control panel communication.
Book No.9000479 02, rev. 0 43

5.2 Remote interface integration (optional) 5 System interfaces
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 exeption for time, which is sent as hexadecimal code.
Remote interface integration requires the following:
• A signal device must be installed according to information in section Cabinets and cables on
page 36. Not part of Alfa Laval’s scope of supply.
• Connection terminal (X4) must be installed in control cabinet. (Installed at delivery if remote
interface is included in original order. If remote interface is added after installation, the terminal
and wiring must be installed according to instructions in chapter 7. Service manual, section
Remote interface (optional).
• Modbus connection from ISCS to PureBallast connection terminal X4 in the control cabinet.
Connection can be either RS422 or RS485, and is connected 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 setting must be done for parameter p132 and p133 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.
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 5.5 and 5.6
are used to verify that the integration functions and that correct information is displayed in the ISCS.
Modbus settings
ISCS modbus RTU server data shall be set according to the table below:
• Modbus: RTU
• Communication: Serial
• Baud rate: 300–187500 bps (default: 9600)
• Parity: None
• Bits per character: 8
44 Book No.9000479 02, rev. 0

5 System interfaces 5.2 Remote interface integration (optional)
• Stop bits: 1
• Slave ID: 10 (PureBallast is slave and ISCS is master)
• Port in master control panel: Com 1.
The following values may be changed, but it is not recommended. Note, that the information must
be the same in ISCS and PureBallast control system.
• Baud rate
• Parity
• Slave ID
• Port in master control panel.
5.2.2 Directory of addresses

The start address is 40000. Individual addresses are separated in two number series:
• Address for data from ISCS to PLC are written as “+001”, “+002” etc, which means 40001,
40002 etc.
• Address for data from PLC to ISCS are written as “+101”, “+102” etc, which means 40101,
40102 etc.
The following terms are used to explain the signals in the tables below:
Address:Bit Individual address and bit for each signal (data), written as Address:bit, for
example +140:3. Values for an address is written as address=value, for
example 142=9.
Bits are the Signal reference number. Bits are right aligned, where applicable.
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.
Book No.9000479 02, rev. 0 45

5.2.2.1 Data to ISCS
The addresses below are used to send data from PureBallast to ISCS.
Address: Function Description

40000 +
+101 Processed volume (1.1) Value: Processed volume [m3] during current
ballast or deballast process. The value is resets
during next start-up.
+102 Accumulated ballast Value: Total treated volume during all ballast
volume (5.3) operations.
Actual volume = sent value x 100.
Example: If value 351.25 is sent (and displayed

in page 5.5), this means that actual volume is
35 125 m3.
Condition: The value sent from PureBallast

must be multiplied by 100 before presented in
ISCS.
+103 Accumulated deballast Value: Total treated volume during all deballast
volume (5.3) operations.
For details, see +102.
+104 Current flow (1.1, 1.3) Value: Current flow indicated by FIT201-1 [m3/h]
+105 System pressure (1.1) Value: System pressure indicated by PT201-16.
Actual pressure = sent value x 0.1
Example: If value 5 is sent (and displayed in

page 5.5), this means that actual pressure is 0.5
bar.

must be multiplied by 0.1 before presented in
ISCS.
+106 Certified flow (1.1, 1.3) Value: Selected certified flow [m3/h], which is
max flow for operation.
Response to address +003 or +011 after

confirmed by address +002:3. If flow is increased
during operation, this address will be updated
when the new AOTs are started. If flow is
decreased during operation, this address will be
updated immediately.
46 Book No.9000479 02, rev. 0


40000 +
+107 Flow setpoint (1.3) Value: Selection for new flow [m3/h].
Response from address +003 or +011 before

confirmed by address +002:3.
+108 Remaining time (hours) Value: Estimated remaining time for the ongoing
sub process. [Hrs] (Not displayed in PureBallast
control system.)
+109 Remaining time (minutes) Value: Estimated remaining time for the ongoing
sub process. (Not displayed in PureBallast
control system.)
+110 Remaining time (seconds) Value: Estimated remaining time for the ongoing
sub process. (Not displayed in PureBallast
control system.)
+111 Current time - Lo word Value: Seconds since 1970-01-01 00:00,

in combination with address +112. Sent as
hexadecimal code.

must be calculated from seconds since
1970-01-01 00:00 to actual date and time.
+112 Current time - Hi word Value: Seconds since 1970-01-01 00:00, in

combination with address +111.
+113 Remaining preservation Value: Filter preservation – Estimated remaining

time (1.4) time for [min]
+114 Total CIP remaining time Value: Total estimated remaining time for all CIP
(hours) (1.4) sequences and filter preservation [hrs]
+115 Total CIP remaining time Value: Total estimated remaining time for all CIP
(minutes) (1.4) sequences and filter preservation [min]
+116 AOT [index] temperature Value: Temperature indicated by TT201-33.

(AOT popup) Value displayed for selected AOT [index].
Actual temperature = sent value x 0.1.

page 5.5), this means that actual temperature
is 22.1 ˚C.

ISCS.
Book No.9000479 02, rev. 0 47


40000 +
+117 AOT [index] LDC Value: Temperature in LDC cabinet indicated

temperature (AOT popup) by TT401. Value displayed for selected AOT
[index].
+118 Required CIP count down Value: Time before CIP must be performed per
(1.4) AOT [hour]. Displayed per AOT [index].
Note: In the control system, the counter is set

to 0 after an AOT 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.
+119 Required CIP count down Value: Time before CIP must be performed per
(1.4) AOT [min]. Displayed per AOT [index].
+120 Diff. pressure over filter Value: Filter differential pressure indicated by
(Filter popup) PT201-27.
Actual pressure = sent value x 0.1.

page 5.5), this means that actual pressure is 0.5
bar.

ISCS.
+121 AOT [index] UV intensity UV intensity indicated by QT201-50. Value

(AOT popup) displayed for selected AOT [index]. Only relevant
if UV sensor is used.
5.2.2.2 Commands and status to ISCS
The addresses below are used to send commands and status information from PureBallast to ISCS.

40000 +
/ Bit
+140 Command status
48 Book No.9000479 02, rev. 0


40000 +
Bit 0 Start ballast accepted Status: Confirmation from PLC that requested
command is executed.
Response to address +001:0.
Bit 1 Start deballast accepted Status: Confirmation from PLC that requested
Bit 2 Start CIP accepted Status: Confirmation from PLC that requested
Bit 3 Stop accepted Status: Confirmation from PLC that requested

Bit 4 Pause accepted Status: Confirmation from PLC that requested

Bit 5 Command rejected Status: Information that requested command

cannot be executed. Reason not specified.
Response to address +001:0-6.
Bit 6 Sum alarm Common alarm indicating that one (any) alarm
is active. Alternative to implementation of
individual alarm signals and hard wired common
alarm. Functions in the same way as hard wired
external signal “Common alarm”.
Note: If common alarm is issued when there

already is an active alarm (this signal already
high), PureBallast will lower the signal for 3
seconds, and then re-activate it as high.
Bit 7 New flow in progress (1.3) Status: New flow in progress.
Bit 8 Start ballast water pump Request to ISCS to start ballast water pump:
(1.1, 1.3 and popup) Address values.
1=Request to start.
0=Request to stop.
Book No.9000479 02, rev. 0 49


40000 +
Bit 9 Open overboard valve (1.1, Request to ISCS to open overboard valve:
1.3 and popup) Address values:
1=Request to open.
0=Request to close.
Bit 10 Local / Remote (5.5) Request: Address values.

1=Activate operation from remote interface.
0=Activate operation from control panels.
Bit 11 Back-flush accepted Status: Confirmation from PLC that requested

+141 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
7=PID calibration
+142 Subprocess mode (1.1, Status: Address values: Values indicating

1.3) system mode.
0=None
1=Start-up ballast
2=Full ballast
3=Back-flush
4=Puase
5=Stop with back-flush
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 drain 1 – Sea water
15=AOT fill 1 – Fresh water
16=AOT drain 2 – Fresh water
17=CIP
18=AOT 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 back-flush is performed.)
50 Book No.9000479 02, rev. 0


40000 +
+143 Filter preservation (1.4) Status: Address values:

0=Completed.
1=Required.
2= Preserving.
+144 AOT flow selection mode
Bit 0 AOT selection enabled (1.3) Status: Address values:

1=Enabled: Flow can be selected using +003.
0=Disabled: Flow can not be selected using
+003.
Bit 1 Flow selection enabled (1.3) Status: Address values:

1=Enabled: Flow can be selected using +011.
0=Disabled: Flow can not be selected using
+011.
+145 AOT index (AOT popup) Confirmation of the AOT [index].
+146 AOT [index] status
Bit 0 AOT [index]: Started (AOT Status: AOT [index] started.

popup)
Bit 1 AOT [index]: Stopped (AOT Status: AOT [index] stopped

popup)
Bit 2 AOT [index]: Sum alarm Status: Sum alarm for AOT [index]. The AOT is
(AOT popup) not ready.
Bit 3 AOT [index]: CIP error Status: Error for AOT [index] during CIP process
Bit 4 AOT [index]: CIP required Status: CIP status for AOT [index]: 0=Not
required. 1=Required.
Bit 5 AOT [index]: CIP ongoing Status: CIP status for AOT [index]: 0=CIP not
ongoing. 1=CIP ongoing.
+147 AOT ready [1–12] (1.3) Status: Respective AOT is ready, which means
that there exist no active alarm for the AOT
(146:2 = 0).
0=Not ready.
1=Ready. The AOT can be selected and used

for process.
Bit 0–11 Bits represent AOT 1–12.
Book No.9000479 02, rev. 0 51


40000 +
+148 AOT selected [1–12] (1.3) Status: AOT selected for process by operator. In
PureBallast, the AOT is visible in the list AOT:s
selected for process in 1.3.
Response to address 002:3, confirmation of flow

selection. How this address is updated, depends
on if flow was set using address +003 or +011:
• +011: This address will be updated with the

exact AOT individuals selected in +011.
• +003: This address will be updated with the
number of AOTs to match the selection in
+003.
Bit 0–11 Bits represent AOT 1–12. 0=Not selected. 1=Selected.
+149 AOT sum alarm [1–12] Status: Sum alarm indication for AOT. The AOT
(1.3, AOT popup) is not ready.
Note: This address can be used to indicate

which AOTs that are
Bit 0–11 AOT 1–12.
+150 AOT started [1–12] (1.1, Status: AOT module started

1.3)
Bit 0–11 AOT 1–12.
+151 AOT starting [1–12] (1.1, Status: AOT module starting

1.3)
Bit 0–11 AOT 1–12.
+152 Calculated power Only relevant if PureBallast is integrated with the

consumption (1.1, 1.5) vessel’s power management system.
Value: Calculated power consumption [kW]

based on number of selected AOTs.
+153 Power request [1–6] (1.5) Only relevant if PureBallast is integrated with the
vessel’s power management system.
For information about power request, see system

manual chapter 6. Installation description and
drawings, section Power management.
Power request to power management system.
Bit 0–5 Power request 1–6. It is only necessary to use signals (bits) to cover
the need for power request. This is defined
by the number of AOTs, alternatively use of
common power.
52 Book No.9000479 02, rev. 0


40000 +
+154 Power running [1–6] (1.5) Power running to power management system.
Bit 0–5 Power running 1–6. Response to address +012:0–5.
+155 Heartbeat echo Status: Handshaking between PLC and ISCS.

Receive counter from address +013 and return
same counter to confirm communication. See
address +155.
+156 GPS position Value: GPS position.
Book No.9000479 02, rev. 0 53

5.2.2.3 I/O status to ISCS
The addresses below are used to send status information for components to ISCS.

40000+
/ Bit
+160 Main status (1.1 and popups for AOT, filter and CIP)
Bit 0 V212-31 Status: Address value:

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.
Bit 5 V201-32 Address value (Status):

1=Open. 0=Closed.
Bit 6 P401-1 Status: Address value:

1=Running request. 0=Stopp request.

1=Running request. 0=Stopped request.
+161 AOT [index] status (AOT popup)

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.
Bit 5 LS201-29 Status: 1=Wet condition. 0=Dry condition.
Bit 6 TS201-60 Status: 1=OK (temp within limit). 0=Not OK

(temp exceeded limit).
54 Book No.9000479 02, rev. 0

+162 CIP status (CIP popup)

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Open. 0=Closed.

1=Running. 0=Stopped.

+163 Filter status (Filter popup)

1=Open. 0=Closed.
Bit 1 M709-42 Status: Address value:

5.2.2.4 Data from ISCS
The addresses below are used to send commands and status information from ISCS to PureBallast.

40000 +
/ Bit
+001 Commands
Condition: All signals for +001 must be high until PLC return an accept
or reject signal (see +140).
Bit 0 Start ballast Command: Start ballast
Bit 1 Start deballast Command: Deballast
Book No.9000479 02, rev. 0 55


40000 +
Bit 2 Start CIP Command: Start CIP
Prerequisite: Only possible during standby.
Note: CIP will be performed for AOTs that requires

CIP, indicated by signal +146:4.
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

(+142=2) and full deballast (+142=9).
Bit 5 Manual back-flush Command: Start back-flush.

(Filter popup)
Condition: Only possible during full ballast
(+142=9).
Bit 6 Ack all alarms (3.1) Command: Acknowledge all alarms
Condition: Signal shall be high so long it can be

assumed that it is received by the PLC, considering
the installation specific conditions.
+002 Feedback
Bit 0 Ballast water pump Status: 1=Started. 0=Stopped.

status
Bit 1 Overboard valve Status: 1=Open. 0=Closed.

status
Response to address +140=9.
Bit 2 Flow controlled Status: Defines if flow capacity for process is set
selection (1.3, AOT using address +003 or +011.
selection popup)
1 = Number of AOTs to be used for process, set
using address +003.
0 = Individual AOTs to be used for process, set

using address +011.
56 Book No.9000479 02, rev. 0


40000 +
Bit 3 Confirm (1.3) Confirm activation of new flow selected using

address +003 (Selected flow) or +011 (Selected
AOT).
Condition: Only possible during Standby (+141=1),

full ballast (+142=2) and full deballast (+142=9).
Condition: Signal shall be high until a response

to the selection in +003 or +011 is sent. We
recommend that the signal is high until address
+148 is updated with the new flow.
+003 Selected flow (1.1, If set during standby: Defines which flow to be
1.3) used when ballast or deballast is started. If set
during ballast or deballast: Defines that flow shall
be increased or decreased to the new flow set.
Selected flow is sent to PureBallast as a value,

which represent the total number of AOTs to be
used in process. Each AOT represent 250 m3/hour:
1=250 m3/h, 2=500 m3/h, 3=750 m3/h etc.
The selection can be visualized in ISCS either as

number of AOTs (1, 2, 3 etc) or flow (250, 500,
750 etc).

Condition: Signal +002:2 = 1.
Condition: The number of AOTs required for the

selected flow must not be greater than the number
of AOTs indicated as ready in address +147:0-11
(AOT ready).
Condition: The selection must be confirmed using

+002:3.
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.
Book No.9000479 02, rev. 0 57


40000 +
+010 AOT index (1.3, 1.4, Only relevant if more than one AOT is installed and
1.5, AOT popup, signals for AOT status are used.
alarms etc)
PureBallast only send status and feedback
information for one AOT at the time. This address
defines for which AOT data shall be sent from PLC.
PLC will send status and feedback for the AOT

selected in this address. Addresses affected by this
is indicated with [index]. It is therefore important
that information affected by AOT index is visualized
in the ISCS, in such way that the user knows for
which AOT the information is valid.
Value 1–12 = AOT 1–12.
+011 Selected AOT (1.3, Defines flow for process. Flow is sent to PureBallast
AOT popup) as a bit pattern, where bits are high for each
selected individual AOT to be used in process.
Each selected AOT represent 250 m3/hour.

Condition: Signal +002:2 = 0.
Condition: An AOT can only be selected if it

is ready. Ready AOTs are indicated in address
+147:0–11.
Condition: The selection must be confirmed using

+002:3.
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.
Bit 0–11 AOT 1–12.
+012 Power granted (1.5) Only relevant if PureBallast is integrated with the
vessel’s power management system.
Address values:
1=Power granted.
0=Not granted.
Condition: Response to address +153:0–5. Signal

shall be high until signal +154:0-5 goes high.
58 Book No.9000479 02, rev. 0


40000 +
Bit 0–5 Power granted 1–6. Note that it is possible for the vessel’s power
management system to grant lower power than
requested.
+013 Heartbeat Status: Handshaking between PLC and ISCS.

ISCS send an arbitrary value to address +155. PLC
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.
Book No.9000479 02, rev. 0 59

5.2.2.5 Alarms and warnings to ISCS
The table below lists all alarms 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.
Alarm can be connected and indicated in three ways. Note that alarms must be indicated in ISCS
on one of these ways:
• Individual alarm integration via remote interface (address +171 – +199 described in the table
below). This is the recommended alternative.
• Common alarm integration via remote interface, indicating that there is an (any) active
alarm/warning in PureBallast. (Address +140:6)
• Common alarm connected via hard wire, indicating that there is an (any) active alarm/warning in
PureBallast. It is recommended that this alternative is integrated a redundant safety precaution.
Example: If data at address 40172 is 000010000000100, this means that alarm A66 and warning
W83 are active (bit 2 and 10).
Note: Address +187 is not used. A66 exist two times in the table: only one (optional which)
shall be used. N/A=Not applicable.
Ad- Main Main AOT Filter Main AOT

dress alarm alarms alarms alarms alarms alarms
40000 + +171 +172 +173–184 +185 +186 +188–199
(1) (2)
Bit
0 A01 A51 W100 W300 A91 W150
1 A03 W58 W101 W304 W92 W151
2 W04 A66 W102 N/A A93 W132
3 A10 N/A W107 W306 A66 N/A
4 W12 A71 W109 N/A A67 N/A
5 A13 A75 W116 N/A A68 N/A
6 A14 A77 W118 N/A N/A N/A
7 A17 W79 W119 N/A N/A N/A
8 A23 W80 W120 N/A N/A N/A
9 A29 W82 W122 N/A N/A N/A
10 A33 W83 W126 N/A N/A N/A
11 A35 A95 A130 N/A N/A N/A
12 W40 A96 W131 N/A N/A N/A
60 Book No.9000479 02, rev. 0

Ad- Main Main AOT Filter Main AOT

dress alarm alarms alarms alarms alarms alarms
40000 + +171 +172 +173–184 +185 +186 +188–199
(1) (2)
13 A48 W97 A137 N/A N/A N/A
14 A49 N/A A138 N/A N/A N/A
15 A50 N/A W140 N/A N/A N/A
Note 1: Individual alarms for installed AOTs 1–12: 173=AOT 1, 174=AOT 2 etc to 184=AOT 12.
The actual alarm states the AOT concerned.
Note 2: Individual alarms for installed AOTs 1–12: 188=AOT 1, 189=AOT 2 etc to 189=AOT 12.
The actual alarm states the AOT concerned.
5.2.3 Sequence example

The example shows how commands and status signals are sent between PureBallast and ISCS.
For detailed information about power management signals, see Power signal sequence on page 67.
Conditions for the example:
• The system consists of at least 2 AOTs. During this example, the flow is increased.
• To start a process, a flow must have been selected. This can either be done by selecting a flow
(m3/h) or by selecting AOTs (AOT nr. 1–12). How flow is set is controlled by address +002, bit
2. Then, flow is set via address +003, or individual AOTs via address +011. In both cases,
selection must be confirmed via address +002, bit 3. Selections for these addresses are stored
in the memory, and will be used as default for next operation, if not changed. In the example
below the following selections are used as default from memory: Address +003=1, address
+002+, bit 2=1 and address +010=1 (AOT index display information for AOT nr. 1.)
• Remote control is activated (Address +140, bit 10 is 1).
• Power management (optional) is integrated.
• No alarms are active: address +171 through +199.
Book No.9000479 02, rev. 0 61

Ballast
6 SignalExampleBal
62 Book No.9000479 02, rev. 0

Deballast
The following addresses differs from a ballast process: +140, +141, +142, and +001.
6 SignalExampleDeb
Book No.9000479 02, rev. 0 63

CIP
6 SignalExampleCip
Note 1: Status signals for subprocess mode +142 (14–19 and 21) alters during the CIP process
depending on sub process and which AOT that is processed.
64 Book No.9000479 02, rev. 0

5 System interfaces 5.3 Power management interface integration
5.3 Power management interface integration

It is possible to connect the PureBallast control system to the vessel’s ISCS. The purpose is to
automatically handle power request from PureBallast to secure that enough power is available for
each ballast and deballast process. A process can only start after acceptance from the ISCS.
The communication is either handled by the remote interface (if the option is integrated) or via hard
wires between the vessel’s ISCS and PureBallast’s control cabinet. It is also possible to use
hard wire, even if remote interface is integrated.
Power management requires the following:
• Parameter setting must be done for parameter p127.

• Integration and connection of signals must be done according to the guidelines in this section.
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 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
1-16 AOTs. For example, step 1 extend to one AOT and step 3 extend to four AOTs. The steps can
be combined: Power step 1 in combination with power step 3 equals five AOT:s. See table below.
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, a request for 3 AOTs.
As an alternative, it is possible to use power step 6 (common) that always will be used, regardless
of the number of AOT:s used for a specific process. The common power is defined as the number
of installed AOT:s times the defined power consumption for one AOT.
Book No.9000479 02, rev. 0 65

5.3 Power management interface integration 5 System interfaces
Function signal No. of Signal ID / Power (kW)

AOT:s Terminal
Request, step 1 1 229 36
Request, step 6 (common) 1-16 234 36-432
Granted, step 1 1 223 36
Granted, step 6 (common) 1-16 228 36-432
Running, step 1 1 235 36
Running, step 6 (common) 1-16 240 36-432
5.3.2.1 Detailed power request process
Below, the signals sent and received are described in detail, including examples.
Power request
Power request is sent to ISCS as one or more signals, identified with a unique ID. Note that the
signals must be handled and interpreted as one package by the ISCS.
Example: A 750 m3/h process shall start, requiring 3 AOT:s. This requires power step 1 and 2 in
combination add up to 108 kW (1×36 + 2x36 = 108). Therefore signal 229 and 230 are sent to
the ISCS.
66 Book No.9000479 02, rev. 0

5 System interfaces 5.3 Power management interface integration
Power granted
After an availability check, power granted must be sent back to PureBallast control system. Power
granted must correspond to the request signal(s) sent from the PureBallast control system. If
not, less or more power will be available for operation. If less power than requested is available,
signals for available power must be sent. If no signals are sent within parameter set time interval
(p143), the operation will be canceled.
Example 1: Power for the 750 m3/h process (108 kW) was required by signal 229 and 230. It is
granted. Requested power is available and shall be granted. This requires that power step 1 and 2
in combination are granted. Therefore power granted signal 223 and 224 are sent to the control
system at the same time to the control system.
Example 2: Power for a 750 m3/h process (108 kW) was required by signal 229 and 230. But only
72 kW is available. Therefore power granted signal 224 is sent to the control system. The control
system will automatically reduce the number of AOTs used for the process to 2.
Power running
To confirm that the power is used, Power running is sent to ISCS using signals that corresponds
exactly with the received power granted. In example 1 above, power running signals 235 and 236
are sent. In example 2 above, power running signal 236 is sent.
5.3.3 Power signal sequence

The signals in the power request process shall be defined so they overlap the next signal with
approximately 2 seconds. The power running signal is active as long as the ballast/deballast
process is running.
Request when starting new ballast/deballast process.
6 PowerSignals
1. Power request
2. Power granted
3. Power running
4. Signal overlap (≈ 2 seconds)
t. Time
Request when starting increasing flow during ballast/deballast process
It is possible to increase flow during ongoing operation. In this case, the power request process
must be repeated, with some modifications.
Book No.9000479 02, rev. 0 67

5.3 Power management interface integration 5 System interfaces
Example: A 750 m3h process is ongoing (power step 1+2). In this case the power running signals
235 and 236 are active.
The flow is increased by one AOT to 1000 m3h from the control system. To handle an additional
AOT power request signal 229 (request for power step 1) is sent. The process continues and
the running signals are still active.
During the time overlap of the power granted signal, the power running signals 235 and 236 are
inactivated, and signal 237 is activated. The new power running signal is active as long as the
ballast/deballast process is running.
6 PowerSignals2
1. Power request
2. Power granted
3. Power running
4. Signal overlap
5. Partial signal overlap
t. Time
5.3.4 Power management installation

The signals (223–240) are hard wired and shall be connected to corresponding terminals (same ID)
in the control cabinet according to Control cabinet / Interconnection diagram on page 135.
Note that It is only necessary to connect enough signals to cover the number of AOT:s installed on
the vessel. If four AOTs are installed it is only necessary to connect the following signals: request
229–231, granted 223–225 and running 235–237.
After installation, the signals need to be tested. This is done by simulating signals from the control
system, page 1.5 Power request. See chapter 3. Operating instructions and control system
description, instruction Simulate power request.
68 Book No.9000479 02, rev. 0

5 System interfaces 5.4 External component signal integration
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 hard wires.
The following components cannot be connected via remote interface. If used, they must be
connected via hard wire: External stop, External system stop and External bypass 1-3.
Each signal that is used must be activated in the control system page 8.2 – Main parameters 2.
Output indicates signal from PLC and Input indicates signal from ISCS.
Signal Control Explanation

cabinet
Common alarm (strongly Output Send an alarm/warning signal from control cabinet.
recommended to be
integrated) If an alarm is already present and a new alarm is issued,
the signal will go low for three seconds, and the be
re-activated as high.
External stop Input Send a stop signal to control cabinet. Equal to pushing
the Stop button in control system panel.
Result: Control cabinet is shut down.
Note: This signal must be connected via hard wire.
External system stop Input Send a system stop signal to control cabinet.
Result: System processes are stopped as fast as

possible. All valves are closed, but the control cabinet
power remains on.
Note: This signal must be connected via hard wire.
Heeling mode (internal Input Send a pause signal to control cabinet (to enter heeling
transfer) mode). Equal to pushing the Pause button in control
system.
Result: System is paused.
External bypass 1 is Input Used to detect when an external bypass valve is open,
open used in addition to V212-31. Signals for up to three
bypass valves can be handled.
External bypass 2 is
open Active signal to control cabinet = Valve closed =
PureBallast is used for ballast and deballast processes.
External bypass 3 is Inactive signal = Valve open = PureBallast is bypassed.
open
Result: If PureBallast is bypassed, it is shut down and
the event is logged.
Book No.9000479 02, rev. 0 69

5.4 External component signal integration 5 System interfaces
Signal Control Explanation

cabinet
Feed back ’’Ballast Input Send a ballast water pump running signal to control
water pump is running’’ cabinet.
Result: System continues automatically. No popup shown
in control system.
Feed back ’’Overboard Input Send an overboard valve open signal to control cabinet.
valve is open’’ Result: System continues automatically. No popup shown
in control system.
Booster pump (P401-1), Output Send a signal from control cabinet to start/stop LDC
for LDC cooling cooling pump for line 401. P401-1 is used during ballast,
deballast and pause mode.
Booster pump (P403-1), Output Send a signal from control cabinet to start/stop reactor
for AOT reactor cooling cooling pump for line 403. P401-3 is used during start
ballast, ballast, start deballast, ballast and pause mode.
Request ’’Start BW Output Send a signal from control cabinet to start/stop ballast
pump’’ water pump.
Request ’’Open Output Send a signal from control cabinet to open/close

overboard valve’’ overboard valve.
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 135. This section gives additional information to the drawing on
how to connect the cables.
Input signals
Input signals must be connected from the control cabinet via – W117 to the ISCS. In the ISCS,
cables must be connected to one common terminal (common DC + for all input signals) and one
terminal dedicated to respective signal used. Make notes about cable part number for the control
cabinet and the ISCS in the Control cabinet / Interconnection diagram (indicated in the illustration
below) to facilitate fault finding. In the illustration, cable part numbers 1 and 2 noted as an example.
70 Book No.9000479 02, rev. 0

5 System interfaces 5.4 External component signal integration
7 ExtSignalIN
Input signals: Cable connections (bold lines) in the ISCS. Excerpt from Control cabinet / Interconnection
diagram with cable part number 1 and 2 noted.
Output signals
Output signals must be connected from the control cabinet via – W117 to the ISCS. Output signals
are connected via potential free relays. It is possible to choose either a normally opened connection
or a normally closed connection. See illustration below. Make notes about cable part number for
the control cabinet and the ISCS in the Control cabinet / Interconnection diagram (indicated in the
illustration below) to facilitate fault finding. In the illustration, cable part numbers 3 and 4 noted
as an example.
Book No.9000479 02, rev. 0 71

5.5 Log box integration (optional) 5 System interfaces
7 ExtSignalOUT
Output signals: Potential free output. Excerpt from Control cabinet / Interconnection diagram with cable part
number 3 and 4 noted.
5.5 Log box integration (optional)

This section describes the installation of the log box, used to integrate signals from external
components (valves and pumps) that are not part of Alfa Laval’s scope of supply. The purpose is to
monitor component activities in the control system and to log them in the Event log. See chapter 3.
Operating instructions and control system description, section Event log.
The following components can be integrated to be integrated:
• Valves: Max 18 valves can be integrated. Two feedback signals can be connected per valve:
Open and closed.
• Pumps: Max 4 pumps can be integrated. One feedback signal per pump: Running.
Remote interface integration requires the following additions:
• Log box is installed and signal cables for components to be logged must be connected.
• Parameter p500 Log box must be activated.
• Signals for components to be integrated and logged must be activated in parameter p501–540.

• Max distance from control cabinet is 100 meters, due to the signal cable limitations.
72 Book No.9000479 02, rev. 0

5 System interfaces 5.5 Log box integration (optional)

Cables and connectors are not part of Alfa Laval’s scope of supply.
The following cables shall be installed:
6 LogBoxCP
1. Signal cable (W104) is connected between control cabinet (connection point IF3/IPL) and log box
(connection point A40A/IF1). Cable properties: Ethernet cable, > CAT 5e with RI45 connector.
Note: This cable is not indicated in the control cabinet drawings (interconnection diagram,
circuit diagram and cable list).
2. Power cable (W10) is connected to log box (connection point -X01). Cable properties: 440
VAC, Three-phase, 1 amp.
3. Signal and power cables are connected between the log box (connection point, relay module
X1–X5) and respective component. Cable properties: Suitable, marine approved cables.
Signal and power cables are connected to the relays in the log box according to the
diagrammatic illustration below:
6 LogBoxCab
Book No.9000479 02, rev. 0 73

5.5 Log box integration (optional) 5 System interfaces
Connection Function Use

point on relay
A1 Feedback signal Always connected for the components to be logged.
BB DC+ Always connected for the components to be logged.
A2 DC– Only connected if DC- is needed for the sensor.
Signal cables are connected according to the table below. Relay module and Relay refers to
connection point in the log box. Position refers to ID in control system page 5.7 and 5.8.
Relay Relay Description Position

module V=Valve
P=Pump
K1 -X1 Closed signal for valve V01. V01
K2 Open signal for valve V01. V01
K3 Closed signal for valve V02. V02
74 Book No.9000479 02, rev. 0

5 System interfaces 5.6 GPS signal installation

K5 Running signal for pump P1. P1
5.6 GPS signal installation

This section describes the installation of GPS position signal to PureBallast. This installation is
optional. If used, the GPS position is used to stamp events in the event log.
The GPS must be connected to the module X20IF1030 in the control cabinet, using an NMEA
(RS422) serial interface with the following settings:
• Baud rate: 4800 bps

• Parity: None
• Bits/characters: 8
• Stop bits: 1
The position data shall be sent as RMC messages.
For details, see the illustration below (based on the Control cabinet / Interconnection diagram on
page 135).
Book No.9000479 02, rev. 0 75

5.6 GPS signal installation 5 System interfaces
6 GPS
76 Book No.9000479 02, rev. 0

6 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.
6.1 Decommissioning
Follow the process below to decommission the PureBallast system. Note that if there is a freeze
risk, the system must be completely emptied of water.
1. Run the back flush sequence for the filter three times.
2. Drain all water from the filter. Leave the drain open afterwards.
3. Run the CIP process twice.
4. Drain all liquid from the AOT reactors. Leave the drains open. (Use the drain plug at the
bottom of the AOT.)
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 heat-exchangers. Leave the drains open afterwards (disconnect
hoses). Shut off the main valves for the cooling system (pipe connection 401).
8. Clean the CIP module with fresh water. Rinse the tank. Drain all water/liquid from the CIP
system and leave the drains open afterwards.
9. Isolate the system: Close installed service valves, or use a blind flange, to prevent fluid to
enter the section. (Pipe connection 310, 460.)
10. Drain water from the pipe systems between the main inlet valve (V201-3, V201-9) and control
valve (V201-8). Leave any open drains open afterwards.
11. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 201.)
12. Drain all water from the filter back flush line. Leave the drain flange in the bottom of the filter
open afterwards.
13. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter
the section. (Pipe connection 309.)
14. Shut off the breakers on the control cabinet and the lamp drive cabinet. Lock them in that
position. Label them to avoid connection by mistake.
Book No.9000479 02, rev. 0 77

6.3 Storage and long term decommissioning 6 Shutdown and storage
6.2 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 gauges 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.
6.3 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.
78 Book No.9000479 02, rev. 0

6 Shutdown and storage 6.5 Start-up after shutdown
6.4 Disassembling before transportation

• If the equipment is to be disassembled and transported, the quartz sleeve and UV lamps must
be removed from the AOT and transported in protective packaging material.
6.5 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.9000479 02, rev. 0 79

6.5 Start-up after shutdown 6 Shutdown and storage
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 (circuit diagrams, cablings etc).
See the Contents section at the beginning of this chapter to get an overview of included drawings.
Book No.9000479 02, rev. 0 81

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
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7 Drawings 7.2 General drawings
7.2 General drawings
7.2.1 Flow chart
Book No.9000479 02, rev. 0 83

592013
7.2 General drawings 7 Drawings
7.2.2 Connection list

Connection list for Ballast water treatment system according to flow chart 591696, 592013 .
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 (m3/h): 200 → 750
• Max pressure: 6 bar (0.6 MPa)

Ref: figure Pressure and pressure drop after the table.
Q201.1 Sampling device Valve • Ref. drawing 590066 on page 100

V201-2
Q201.2
V201-25
V201-3 Main valves • Ref. drawing 594793 on page 105

V201-9
• Ref. drawing 594793 on page 105
V201-32
V212-31 • Ref. drawing 594796 on page 108
• Ref. drawing 594794 on page 107
V201-8 Control valve (flow • Ref. drawing 594797, on page 106

control and back
• Flow restriction acc. to certified flow rate.
flushing of filter)
• Control of pressure, min 0.15 MPa.
IP201-7 IP converter
S201-7 Strainer
403 Cooling water Reactor • Sea water

Inlet
• Max pressure: 6 bar (0.6 MPa)
• Pressure drop: 0,05 bar (0.005 MPa)
• Min. flow: 15 m³/h (during start up, max 10 min.)
• Max. particle size: 5 mm
V403-35 Valve • Ref. drawing 594795 on page 109
FIT201-1 Flow transmitter • Ref. drawing 586502 on page 102
V201-15 Needle valve • Ref. drawing 590419 on page 103

PT201-16 Pressure transmitter
84 Book No.9000479 02, rev. 0


Connec-
tion
V201-17 Ball valve • Ref. drawing 590420 on page 104

PI201-18 Pressure gauge
Filter connections, drawing 593802
201 Filter inlet / outlet • Ref. filter connections drawing on page 97.
309 Back-flush water • Sea water

• Back-flush flow: 129 m3/h (Intermittent, approx. 20
sec during back-flush). Ref: figure Pressure and
pressure drop after the table.
V309-1 Reject valve • Ref. filter connections drawing, connection 309 on

page 97.
310.2 Flushing • Ref. filter connections drawing, connection 310.2 on

miscellaneous page 97.
• Fresh water preservation volume: 250 L
460 Drain Filter • Flanged, blanked

• Ref. filter dimension drawing, connection 460 on page
97.
AOT module connections, drawing 594657
V201-19 Inlet / outlet • Ref. AOT module dimension drawing

V201-20
401 Cooling water Lamp • Fresh water (existing cooling system)

Drive Cabinet (LDC)
• Max. particle size: 600 μm
Inlet
• Temperature: 0 → 38 ºC
• Working pressure: 1 → 10 bar (0.1 → 1 MPa)
• Pressure drop: 0.15 bar (15.0 MPa)
• Min. flow: 3.6 m³/h (1.2 m3/h each LDC) @ 38 °C
V401-51 Valve Ref. AOT module dimension drawing on page 94.
402 Cooling water LDC • Back to recirculation (suction side)

outlet
V402-52 Valve • Ref. AOT module dimension drawing on page 94.
404 Cooling water • Over board

Reactor outlet
• Flow: ref. to conn. 403
Book No.9000479 02, rev. 0 85


Connec-
tion
V320-4 CIP / Drain • Ref. AOT module dimension drawing on page 94.
V321-2 Reactor outlet
V404-36 Cooling water
CIP unit connections, drawing 590527
310.1 Flushing • Fresh water (potable)

310.2 miscellaneous
• Quality requirements: see 590773 on page 92
• Volume: 360 L/ rinsing & preservation (2 cycles x 3
reactors x 60 L) .
• Min pressure: 3 bar (0.3 MPa)
V310-1 Valve • Ref. CIP module dimension drawing on page on page

98.
V310-3 Backflow preventer
V310-6 Valve
V310-8
S310-7 Strainer
320 Flushing • Sea water / fresh water

miscellaneous AOT
• CIP liquid quality requirements, see 594956 on page
93
V320-2 Valve • Ref. CIP module dimension drawing on page 98.

V320-11
P320-1 Pump • Diaphragm pump (pneumatic)
321 Flushing • Sea water / fresh water

miscellaneous AOT
• CIP liquid
P321-5 Pump • Ref. CIP module dimension drawing on page 98.

• Diaphragm pump (pneumatic)
V321-1 Valve
V321-4
460.1 Drain Reactor • Sea water / fresh water

• Normally no flow
• Volume: 360 L (3 reactors x 60 L sea water drained
and 3 reactors x 60 L fresh water drained before CIP
sequence). Flow: 60 L/min.
86 Book No.9000479 02, rev. 0


Connec-
tion
CV460-4 Check valve
460.2 Drain CIP module • By gravity

• Normally no flow
• Volume: 300 L
571 De-aeration • Air

Reactor / CIP
Air (total system consumption)
501 Instrument air • Ref. 595208 on page 90

• Required pressure: 5.5 – 8.0 bar
Max consumption:
• During ballast and deballast operation: Max 25 NL/min.

• Consumption: continuous, max 25 NL/min, peak load,
0.6 Nm3/min (during CIP sequence, : 45 min, pump
running.
• Quality requirements: see 553407 on page 91
Book No.9000479 02, rev. 0 87

6 ConListFig
∆pfilter -Filter pressure drop, depending on filter contamination. (dynamic and

static pressure).
0.05 – 0.38 bar — Normal operation.
0.38 bar — Filter back-flushing sequence triggered.
0.5 bar — Alarm.
∆pAOT - AOT module pressure drop (dynamic and static pressure).
∆pfilter outlet - Required pressure to establish effective back flushing of filter (acc. to
formula).
∆p309 - Pressure drop, (dynamic and static pressure), line 309 (back flush over
board).
88 Book No.9000479 02, rev. 0

7.2.3 Electrical system layout
581726
Book No.9000479 02, rev. 0 89

7.2.4 Air distribution
585828
90 Book No.9000479 02, rev. 0

7.2.5 Quality specification / Compressed air
553407
Book No.9000479 02, rev. 0 91

7.2.6 Quality specification / Water
590773
92 Book No.9000479 02, rev. 0

7.2.7 Quality specification / CIP liquid
Book No.9000479 02, rev. 0 93
594956
7.3 Dimension drawings including technical 7 Drawings
data
7.3 Dimension drawings including technical data
7.3.1 AOT module / Dimension drawing (2 pages)
594657_p1
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7 Drawings 7.3 Dimension drawings including technical data
594657_p2
Book No.9000479 02, rev. 0 95

data
7.3.2 AOT reactor / Dimension drawing
96
593915
Book No.9000479 02, rev. 0
7.3.3 Filter / Dimension drawing
Book No.9000479 02, rev. 0 97

593812
data
7.3.4 CIP module / Dimension drawing (2 pages)
98 Book No.9000479 02, rev. 0

590527_p1
590527_p2
Book No.9000479 02, rev. 0 99

data
7.3.5 Sampling device Q201.1, Q201.2 / Dimension drawing (2 pages)

Note. Only 2 of the 3 drawing pages are used depending on if DIS or JIN is used.
590066 1
100 Book No.9000479 02, rev. 0

590066 2
Book No.9000479 02, rev. 0 101

data
7.3.6 Flow transmitter FIT201-1 / Dimension drawing
102 586502
Book No.9000479 02, rev. 0
7.3.7 Pressure transmitter PT201-16 / Dimension drawing
103
590419
Book No.9000479 02, rev. 0
data
7.3.8 Pressure gauge PI201-18 / Dimension drawing
104 Book No.9000479 02, rev. 0

590420
7.3.9 Valve V201-3 and V201-9 / Dimension drawing
Book No.9000479 02, rev. 0 594793 105

data
7.3.10 Control valve V201-8 / Dimension drawing
106 594797 Book No.9000479 02, rev. 0

7.3.11 Valve V212-31 / Dimension drawing
Book No.9000479 02, rev. 0 594794#3 107

data
108 594796 Book No.9000479 02, rev. 0

594795
Book No.9000479 02, rev. 0 109

data
7.3.14 Valve V310–1 and 310–6 / Dimension drawing
110 Book No.9000479 02, rev. 0

576953
7.3.15 Control cabinet / Dimension drawing
Book No.9000479 02, rev. 0 111

591962
data
7.3.16 Remote control panel / Dimension drawing (2 pages)
595261_p1
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595261_p2
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7.4 Log box / dimension drawing 7 Drawings
7.4 Log box / dimension drawing
9002906
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7 Drawings 7.5 Electrical drawings
7.5 Electrical drawings
7.5.1 Control cabinet / Assembly drawing
591773
Book No.9000479 02, rev. 0 115
7.5 Electrical drawings 7 Drawings
7.5.2 Control cabinet / Circuit diagram (19 pages)
581701_p01
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581701_p02
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581701_p03
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581701_p04
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581701_p13
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581701_p15
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581701_p18
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581701_p19
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7.5.3 Control cabinet / Interconnection diagram (9 pages)
581702_p01
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581702_p02
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581702_p03
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581702_p04
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581702_p05
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581702_p06
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581702_p07
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581702_p08
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581702_p09
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7.5.4 Control cabinet / Cable list
581703
144 Book No.9000479 02, rev. 0

7.5.5 Remote control panel (optional) / Assembly drawing
594060
Book No.9000479 02, rev. 0 145

7.5.6 Lamp Drive Cabinet (LDC) / Assembly drawing
146 591097
Book No.9000479 02, rev. 0
7.5.7 Lamp Drive Cabinet (LDC) / Circuit diagram (20 pages)
581704_p01
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581704_p02
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581704_p03
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7.5.8 Lamp Drive Cabinet (LDC) / Interconnection diagram (5 pages)
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581705_p2
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581705_p5
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7.5.9 Lamp Drive Cabinet (LDC) / Cable list
581706
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8 Type approval and test result
summary
This section contains the type approval for PureBallast together with a summary of the test result
from the land based and ship board testings.
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8.1 Type approval (5 pages) 8 Type approval and test result summary
8.1 Type approval (5 pages)
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6 TypeApproval 1
8 Type approval and test result summary 8.1 Type approval (5 pages)
6 TypeApproval 2
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6 TypeApproval 3
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8 Type approval and test result summary 8.1 Type approval (5 pages)
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6 TypeApproval 5
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8 Type approval and test result summary 8.2 Test result summary (4 pages)
8.2 Test result summary (4 pages)
Book No.9000479 02, rev. 0 179

8.2 Test result summary (4 pages) 8 Type approval and test result summary
180 Book No.9000479 02, rev. 0

8 Type approval and test result summary 8.2 Test result summary (4 pages)
Book No.9000479 02, rev. 0 181

8.2 Test result summary (4 pages) 8 Type approval and test result summary
182 Book No.9000479 02, rev. 0

Chapter: 7. Service manual
Book No. 9000479 02, rev. 0

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 Serial number information 11
2.1.1 Indicating serial number 11
2.1.2 Example 11
2.2 Placing of serial numbers 12
3 AOT module 17
3.1 Safety information 17
3.2 Replace UV lamp and quartz sleeve 19
3.2.1 Disassemble UV lamp 20
3.2.2 Disassemble quartz sleeve 22
3.2.3 Assemble quartz sleeve 22
3.2.4 Check for leaks after quartz sleeve assembly 24
3.2.5 Assemble UV lamp 24
3.3 Disassemble and assemble AOT reactor 25

3.3.1 Disassemble AOT reactor 25
3.3.2 Assemble AOT reactor 26
3.4 Dismount and mount lamp power

supply (LPS) 27
3.5 Test LPS installation 29
3.6 Replace VCD (voltage clipping device)
and varistor 29
4 Filter 31
4.1 Disconnect power to filter 33
4.2 Remove filter insert 33
4.3 Remove filter candles 34
4.4 Clean filter candles 37
4.5 Replace filter candle 38
4.6 Mount filter candle and filter insert 38
4.7 Mount filter gear motor 39
4.7.1 Check filter gear motor function 40
3
4.8 Change sacrificial anode 40
5 CIP module 43
5.1 Change and refill CIP liquid 43
5.1.1 Change CIP liquid 45
5.1.2 Refill CIP liquid 45
5.2 Repair CIP pump 46

5.2.1 Clean CIP pump 47
5.2.2 Disassemble CIP pump 47
5.2.3 Assemble CIP pump 48
5.3 Test CIP pump 49

5.4 Repair junction box and valve blocks 49
5.5 Repair valve block 49
5.5.1 Change valve body 50
5.5.2 Connect electrical cables to valve block 50
5.5.3 Clean valve block 51
5.5.4 Connect pneumatic hoses to valve block 51
6 Flow meter 53
6.1 Mount flow transmitter 53
6.2 Change direction of flow transmitter 55
6.3 Change direction of flow transmitter
control pad 56
6.4 Clean flow meter electrodes 58
7 Operate valves manually 59

7.1 Open and close valves manually (CIP
valves) 59
7.2 Open and close valves manually
(V201-3, V201-9 and V201-8) 59
7.3 Lock valve in closed position 60
7.4 Unlock valve 61
8 Valve actuator 63
8.1.1 Tightening torques for actuators 64
4
8.2 Mount actuator on valve 64
8.3 Dismount actuator 65
8.4 Change direction of actuator – without
position sensor 66
8.5 Mount pilot valve on actuator 67
8.6 Change direction of actuator – with
position sensor 68
8.7 Change direction of actuator – with
proportional valve 71
8.8 Adjust valve end position 72
8.9 Adjust position sensor 73
8.10 Adjust valve traveling speed 73
9 Proportional valve 75
9.1 Replace proportional valve 75
9.2 Replace filter in proportional valve 76
10 Ball valve 79
10.1 Replace seals in ball valve 79
11 Level switch 81
11.1 Mount level switch 81
11.2 Dismount level switch 82
11.3 Test level switch 82
12 Temperature switch and

temperature transmitter 83
12.1 Mount temperature switch / temperature
transmitter 83
12.2 Dismount temperature switch /
temperature transmitter 84
13 Control panel 85
13.1 Clean control panel 85
13.2 Replace control panel 85
13.2.1 Dismount the panel 85
13.2.2 Mount the panel 86
5
14 Remote control panel (optional) 89
14.1 Mount and connect switch for remote
control panel 89
14.2 Mount and connect Ethernet switch for
remote control panel 91
15 Remote interface (optional) 93

15.1 Mount connection terminal for remote
interface 93
16 Control cabinet 95
16.1 Cable glands 95
16.2 I/O system 97
16.2.1 Disassemble I/O system 97
16.2.2 Assemble I/O system 99
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.
NGE R
! DA
NOTE
• All maintenance of the PureBallast system must be logged in the vessel’s maintenance log.
• Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 60.
• Follow local regulations for electrical installation and grounding (earthing).
• Follow general rules when handling of Alpacon descalant offshore cleaning agent, regarding
ventilation, personal protection etc.
• Cut hazards: Sharp edges on the catalyst cassettes, threads, broken UV lamps and quartz
sleeves can cause cuts.
Book No.9000479 02, rev. 0 7

2 Maintenance schedule
Follow this maintenance schedule to secure performance, safety and durability of the system and
its components. The schedule is sorted per component. The table refers to instructions usable
when performing the respective action.
Component Action Time interval Instructions Notes
General Inspect for Once a year.

corrosion and
erosion damage.
AOT reactor Outer inspection Once a year. If necessary, See Spare parts
of seals for change according catalogue for
leakage. to Disassemble service kit.
UV lamp and
Disassemble AOT
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 if the

anode. sacrificial anode. anode has lost
Change if needed approximately 80
or every five years. % of the zinc mass.
Book No.9000479 02, rev. 0 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 modules 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 Connect

CIP module cables are firmly electrical cables
attached to the to valve block.
terminal strip in
the valve block.
Flow meter Clean flow meter Once a year. See Clean flow
electrodes. meter electrodes.
Control system Cleaning of Displays should be See Clean control

display. cleaned at regular panel.
intervals or when
dirty.
Battery check Every time the The check

(PLC module). device is turned on is performed
and every 24 hours. automatically for
PLC.
Battery When alarm PLC The battery is

replacement (PLC battery low is placed in the
module). indicated in the PLC module in
control system. the control cabinet.
10 Book No.9000479 02, rev. 0

2 Maintenance schedule 2.1 Serial number information
or:
After 5 years.
or:
Before storage for
longer periods.
2.1 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.
2.1.1 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.
2.1.2 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 module on which the level switch
is installed.
• Item number for the component (LS00000)
Book No.9000479 02, rev. 0 11

2.2 Placing of serial numbers 2 Maintenance schedule
2.2 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 module
At the side of the reactor, as indicated in the

illustration.
7 AOT Snr 592830
12 Book No.9000479 02, rev. 0

2 Maintenance schedule 2.2 Placing of serial numbers
Filter
Placing: At the side of the filter, as indicated

in the illustration.
7 FilterSnr
Electrical cabinets
(Including breakers)
Placing: At the inside of the door (illustration

shows control cabinet).
• Control cabinet
• Lamp drive cabinet (LDC)
7 CC Sernr 591773#1
Book No.9000479 02, rev. 0 13

Lamp power supply
The LPS is 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: Over the edge between top and front

as indicated in the illustration. 7 LPS Sernr 7_2_3_6
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
14 Book No.9000479 02, rev. 0

2 Maintenance schedule 2.2 Placing of serial numbers
Flow meter
(Including flow transmitter and flow sensor)

Placing: At the side of the pipe, as indicated
in the illustration.
NOTE
The flow transmitter and flow sensor have individual

serial numbers. But it is sufficient to state the flow
meter serial number.
7 FM snr 576179_manual 2
Book No.9000479 02, rev. 0 15

3 AOT module
This section covers instruction for service of the AOT reactor.
3.1 Safety information
NGE R
! DA
• 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.
• Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the AOT 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.
• 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.
• 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.
• 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.
Book No.9000479 02, rev. 0 17

3.1 Safety information 3 AOT module
• 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.
ON
CAUTI
!
• Before installation, check that the UV lamps and quartz sleeves are not broken.
18 Book No.9000479 02, rev. 0

3 AOT module 3.2 Replace UV lamp and quartz sleeve
3.2 Replace UV lamp and quartz sleeve
7 593915_replace lamp
AOT reactor, exploded.
1. Electric cable
2. UV lamp
3. Quartz sleeve
4. Hub
5. Bush
6. Cap
7. Cap nut
8. Cable connector
9. Bush
10. O-ring (inside bush)
11. Allen screw
12. Glass socket
13. O-ring
Book No.9000479 02, rev. 0 19
3.2 Replace UV lamp and quartz sleeve 3 AOT module
3.2.1 Disassemble UV lamp

Follow this instruction to dismount the UV lamp. Note that there are 12 UV lamps.
• The PureBallast system must be turned off, and the power disconnected.
• After UV lamps have been changed, the runtime must be reset in page control system page 5.4
Operation timers: AOT 1–12. Requires login level 2.
• Wait at least 10 minutes after completed ballast or deballast process, to allow the 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 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 nut (7) holding the caps (6). There is one nut on each side of the AOT 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 (8) in both ends of the UV lamp (2).
7UVlampConnection
3. Carefully draw out the UV lamp and one of its bushes (5) with the electric cable (1), by holding
the electric cables in both ends. If required, use a screwdriver to press on the ceramic end of the
lamp inside the bush on the other side whilst carefully pulling the electric cable at the other end.
20 Book No.9000479 02, rev. 0

7UVBushScrewdriver
4. Hold the UV lamp by the ceramic ends after the bushes have been removed. Immediately after
removal, place the lamp in its protective cover.
5. Check that no quartz sleeves (3) are broken.

To disassemble the quartz sleeves, see the instruction Disassemble the quartz sleeve.
6. If no quartz sleeves are broken, mount new UV lamps according to the instruction Assemble
UV lamp on page 24. If broken see the Preparations and conditions section above.
Book No.9000479 02, rev. 0 21

3.2.2 Disassemble quartz sleeve

Follow this instruction to disassemble the quartz sleeve. Note that there are 12 quartz sleeves.
NG
WARNI
!
• Hot water may escape from the reactor when removing the drain plug.
1. Close the AOT inlet (V201-19.n) and outlet (V201-20.n) valves from the main panel.
2. Depressurize and drain the 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 20.
5. Unscrew the three Allen screws (11) of the glass socket (12), just a few turns to release the
sockets on both sides.
6. Unscrew the glass sockets on both sides completely.
7. Carefully remove the glass sockets and the quartz sleeve (3).
8. Remove the O-rings (13) on both sides. The O-rings are firmly stuck in their seat, and will be
damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring
tool to loosen and remove the O-ring. Be careful to avoid to break the glass.
If the O-ring is hard to remove, try the following:
– Moisten the O-ring with acetone or denatured alcohol.
– Loose the O-ring in a couple of places before removing it.
– Perforate the O-ring to get a good grip.
9. Carefully remove the quartz sleeve (3).
10. Carefully clean the surface and remove any small parts, for example glass or rubber.
3.2.3 Assemble quartz sleeve

Follow the instruction below to assemble quartz sleeve and check for leaks.
• Two new O-rings for each glass socket (12) might be needed.
• Two new O-rings (13) for each quartz sleeve (3).
• Use waxed screws.
• Glass sockets and bushes must be dry and clean before mounting.
1. Insert the quartz sleeve (3) in the reactor.
22 Book No.9000479 02, rev. 0

2. Wet the O-rings (13) with water and slip them over respective side of the quartz sleeve. Check
that the O-ring is correctly placed, or they may be damaged and cause leaks.
3. Check the condition of the glass socket O-rings . If needed, replace them with new O-rings.
4. Adjust the quartz sleeve so that the it is approximately 2.5 mm off-center in the AOT reactor,
towards the side you will attach the first glass sockets (12).
5. Check that the quartz sleeve (3 below) is correctly placed. The end (2 below) shall not protrude
passed the planar face (1 below) on the glass socket. The bush must be able to meet this
surface. If the glass sleeve protrudes it might get crush when the bushes are mounted.
7 GlassSocket
6. On the side with the quartz sleeve off-centered, 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. Check again, that the quartz sleeve does not
protrude passed the planar face.
7QuartzSleeve
7. Once the Allen screws (11) are evenly entered, carefully tighten them evenly to a torque
of 7 Nm.
8. Mount the second glass socket. Check again, that the quartz sleeve does not protrude passed
the planar face.
Book No.9000479 02, rev. 0 23

9. Connect the compressed air.
3.2.4 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.
3.2.5 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.
• 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.
1. Mount the new O-rings (10) in the two bushes (9).
2. Place one bush on the UV lamp (2).
3. Insert the UV lamp and bush into the reactor.
4. Insert the other bush in the opposite side of the 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
24 Book No.9000479 02, rev. 0

3 AOT module 3.3 Disassemble and assemble AOT reactor
6. Mount the UV lamp caps and tighten three Allen screws at both ends of the UV lamp, by hand
only. Make sure that the electric cable is is not squeezed between the cap and the bush when
the cap is mounted. Slack can be pushed into the bush.
7. Re-fit the drain plugs at the bottom of the reactor and/or at the flanges under the reactor.
8. Make sure there is no UV lamp failure when the lamp power supply is on.
3.3 Disassemble and assemble AOT reactor

AOT reactor, exploded view.
3.3.1 Disassemble AOT reactor

Follow this instruction to disassemble the reactor for internal inspection and cleaning.
NGE R
! DA
make sure it remains switched off during service.
NG
WARNI
!
• It is recommended that two persons handle the top plate and catalyst insert, to avoid personal
injuries and damages to threads and catalyst insert.
• The top plate weighs approximately 30 kg. Wear protective footwear.
• Avoid disassembling the catalyst insert. Send it to Alfa Laval for exchange or repair if damaged.
• Wear protective gloves. Sharp edges on catalyst inserts can cause cuts.
• Note that pins and nuts in the catalyst insert are made from titanium. They must never be
replaced with components made from other materials.
1. Disassemble all UV lamps and quartz sleeves according to the instructions Disassemble
UV lamp and Disassemble quartz sleeve.
2. Remove one top plate on the reactors in question. All reactor top plates and reactor sides must
be marked to make sure that they are remounted in the same position as before.
3. Unscrew all nuts at the top plate only a few turns.
4. Remove all nuts and washers except one at the top and one at the bottom of the top plate (to
prevent the top plate from falling).
Book No.9000479 02, rev. 0 25

3.3 Disassemble and assemble AOT reactor 3 AOT module
5. Release the top plate from the housing:

If required: Carefully tap the plate sideways with a soft hammer, or prize with a screwdriver in
recesses.
6. When the top plate is released, remove remaining nuts and washers and carefully lift out
the plate.
NOTE
The plate is heavy (approximately 30 kg).
7. Carefully pull out the catalyst insert by alternately pulling it at the top and bottom. The side
reflector plates are not fixed to the reactor housing, so they might fall to the center of the
reactor housing when the catalyst insert is removed.
8. Push and pull out the two side reflector plates.
9. Clean the side reflector plates.
10. Replace the reflector plates if there are discolorations.
11. Inspect the catalyst insert.
• If it is damaged, replace the complete catalyst insert.

• If the catalyst insert has become clogged it must be taken out and flushed with fresh water
(max overpressure 8 bar (0.8 MPa)).
12. Inspect the reactor housing and the side reflector plates. Clean if necessary.
3.3.2 Assemble AOT reactor

Follow this instruction to assemble the reactor.
• Silicon grease is needed.

• Molykote P40 or similar lubricant is needed.
1. Verify that the catalyst insert has no transport or handling damages.
2. Place the two side reflector plates into the reactor housing.
3. Carefully insert the catalyst insert. Make sure the fine meshes do not get damaged. Also make
sure the catalyst insert does not protrude outside the reactor housing.
4. Place the new O-ring in its recess in the housing. Hint: Apply some O-ring grease in the recess
to make the O-ring stick.
5. Lubricate all stud threads with Molykote P40 or similar lubricant to prevent seizing.
26 Book No.9000479 02, rev. 0

3 AOT module 3.4 Dismount and mount lamp power
supply (LPS)
6. Place the top plate on the reactor housing.

Make sure the correct top plate is placed on the correct reactor side and screw a nut just a few
turns on a top stud to prevent the top plate from falling off.
7. Mount all washers and nuts and tighten evenly by hand, checking that the O-ring enters its
recess correctly.
If the O-ring is not correctly mounted it may be damaged and a leak may occur.
8. Tighten all nuts evenly and crosswise to a torque of 47 Nm.
9. Proceed by mounting the quartz sleeves and UV lamps according to instructions Assemble UV
lamp on page 24 and Assemble quartz sleeve on page 22.
3.4 Dismount and mount lamp power supply (LPS)

Follow this instruction to replace a lamp power supply inside a lamp drive cabinet (LDC).
7 LPSreplace 7_3_4_1
LDC with LPS inside
1. Bracket
2. LPS’s in pair
3. Mounting screw (two per LPS)
4. Cable strap holder
5. Securing nut
• Switch off the PureBallast system and disconnect it from the power supply.
• If the signal cable for this component is damaged during the installation or maintenance, it must
be replaced with the exact same type of cable, and the Intrinsically safe system descriptive
document must be updated. If the signal cable is affected in any way it must restored.
Book No.9000479 02, rev. 0 27

3.4 Dismount and mount lamp power supply 3 AOT module
(LPS)
NG
WARNI
!
• Burn hazard: The LPS can be hot and cause burns.
1. Dismount LPS
Disconnect all cable straps and cables from the two LPS:s.
NOTE
Since the LPS:s are mounted in pairs, it is necessary to disconnect both LPS:s. Carefully write down
how all cables are connected to the two LPS:s (2).
2. Dismount the bracket (1) on both sides by unscrewing the two securing nuts (5) on the brackets.
3. Release the LPS to be replaced by removing it from the brackets by the mounting screws (3).
4. Mount LPS
Place the cable strap holder (4) under the screw head and mount the LPS to the brackets by
the mounting screws (3).
NOTE
The mounting screws (3) must never be replaced by longer screws. If a screw is longer it will damage the
electronics in the LPS.
5. Remount the two LPS:s (2) mounted at the brackets (1) with the securing nuts (5).
Make sure both LPS:s in pairs are horizontal and in good contact with the rear wall while
mounting the frames and nuts.
6. Tighten the nuts to a torque of maximum 10 Nm.
7. Connect the cables and replace the cable straps and holders (4) to the LPS according to
marking on the LPS and the Control cabinet / Interconnection diagram in chapter 6. Installation
NG
WARNI
!
• The installation must be done correctly according to the information above.
• Be careful not to let any cable strands from different cables get in contact.
8. Switch on the power and check that both LPS:s function correctly according to instruction
Test LPS installation below.
9. Send the replaced LPS to Alfa Laval for repair.
28 Book No.9000479 02, rev. 0

3 AOT module 3.6 Replace VCD (voltage clipping
device) and varistor
3.5 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.
NGE R
! DA
• Before operating the AOT, make sure that there is water in the reactor.
1. Make sure that the AOT breaker is switched off.
2. Make sure that the motor circuit breaker is switched off for each LPS in the LDC cabinet(s).
3. Check that there is water in the reactor(s) (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the reactor.
4. Switch on the power to the AOT unit using the switches on the AOT breaker cabinet(s).
5. Switch on the motor circuit breaker for each LPS in the LDC cabinet(s). Only the Power on
LED shall be lit with a green light on the LPS. No other events shall be triggered.
6. Start UV lamps one by one from the control system (set to manual mode). Make sure that the
UV lamps are lit: The Power on and UV lamp on LEDs are lit with a green light on the LPS.
7. Close each group and make sure that the UV lamp on LEDs is turned off on the LPS.
8. Check all cabinets visually and make sure that the equipment inside the cabinets is behaving
OK. If necessary recheck and switch on any electric fuse that is switched off.
3.6 Replace VCD (voltage clipping device) and varistor

One VCD and one varistor protect the LPS:s from excessive voltage. If a VCD or varistor stops
functioning, it could cause failure of all LPS:s in that AOT.
The VCD (V23) is placed on the ceiling inside LDC cabinet, and the varistor (V1) is placed on a
mounting plate in the upper part of LDC cabinet.
Book No.9000479 02, rev. 0 29

3.6 Replace VCD (voltage clipping device) 3 AOT module
and varistor
7 V1 581804#1
7 VCD 581805
Varistor (V1)
VCD (V23)
1. Remove the power and signal cables from the VCD and varistor.
2. Unscrew and remove the VCD and varistor.
3. Position the new VCD and new varistor and mount them.
4. Reconnect the power and signal cables to the VCD and varistor.
5. Switch on the power and check that the VCD and varistor function correctly.
30 Book No.9000479 02, rev. 0

4 Filter
This section covers the instructions for service of the filter.
These preparations and conditions are valid for all instructions.
• Disconnect the power to the filter according to the Disconnect power to filter instruction on page
. Secure it from being switched on.
• Lock valves. See instruction Lock valve in closed position on page 60.
• Only perform maintenance and servicing work when the filter is cooled, depressurized and
drained.
• Visually inspect seals during maintenance. Replace if necessary
ON
CAUTI
!
Filter – Exploded view
Book No.9000479 02, rev. 0 31

4 Filter
7 Filter Exploded 7_4_1
Filter, exploded view.
32 Book No.9000479 02, rev. 0

4 Filter 4.2 Remove filter insert
1. Gear motor
2. Shaft nut
3. Lock washer
4. Bearing support
5. Cover
6. Carrier screw
7. Top flushing arm
8. Eyelets
9. Flushing device
10. Bottom flushing arm
11. Ball valve
12. Lid (sacrificial anode inside)
4.1 Disconnect power to filter

Follow the instruction below to disconnect the power supply to the filter and to secure it from being
switched on.
7 FilterLock
Safety lock with wire legs pulled out
1. Open the control cabinet.
2. Turn the filter main switch to cut currency to the filter.
3. Take the separate safety lock (illustrated above) and slide the plastic part backwards, to
reveal the wire legs.
4. Put the end of the wire leg into the hole under the switch knob.
5. Compress the legs and put the other steel wire leg into the slot to the right of the knob.
6. Slide the plastic part back to cover the wire legs. It is now possible to lock the safety lock with
a padlock, inserted in the loop at the top of the safety lock.
4.2 Remove filter insert

Follow this instruction to remove the filter insert.
• Read the general preparations and conditions on page .
Book No.9000479 02, rev. 0 33

4.3 Remove filter candles 4 Filter
• The filter cover and insert are heavy! Handle with care to avoid personal injuries and damages
to the equipment. Wear protective footwear.
ON
CAUTI
!
• Lifting device is needed for this instruction. Filter cover weight (kg): 72
Filter insert weight (kg) / height (mm): 110 / 800.
1. Close the following valves: V201-3, V201-32, and V310-2 according to the instruction in
the Operate valves manually on page 59.
2. Close the compressed air supply for V309-1 by closing the ball valve (11) on the filter.
3. Disconnect the power to the filter according to the Disconnect power to filter instruction on
page .
4. Open the deaeration valve (V201-50) at the top of the filter lid.
5. Disconnect all connection lines from the gear motor (1). Unscrew the screws which fasten
the gear motor.
6. Remove the motor. Approximate weight: 20 kg.
7. Release the shaft nut (2) and the lock washer (3) and remove them.
8. Unscrew the Allen screws holding the bearing support (4) and remove the bearing support.
9. Loosen the cover nuts and lift the cover (5).
10. Loosen the carrier screw (6) holding the top flushing arm (7) to the shaft.
11. Remove the top flushing arm and the filter candle retaining plate.
12. Lift the filter insert vertically out of the filter using the welded-on eyelets (8). Note that the
bottom flushing arm (10) and the shaft must be left in position in the tank. If lifted, there is a
risk that a bearing for the bottom flushing arm will fall out of position.
13. Check that the O-rings on the top flushing arm and on top and bottom of the filter insert are in
good condition. Replace if necessary.
NOTE
Note that only filter specific O-rings can be used.
4.3 Remove filter candles

Follow this instruction to remove the filter candles.
34 Book No.9000479 02, rev. 0

4 Filter 4.3 Remove filter candles
• During assembly and disassembly of the filter candles, avoid touching other filter parts with
the filter candles.
• Please proceed with the utmost caution when transporting, assembling, disassembling and
cleaning the filter candles.
• For this operation, the following tool may be required: Drift tool for demounting filter candles.
Note that the drift tool is not part of Alfa Laval’s scope of supply, but can be manufactured
with the following diameter: 57 .
7DriftTool
Drift tool for demounting the filter candles (not included)
Book No.9000479 02, rev. 0 35

4.3 Remove filter candles 4 Filter
7 Filter Exploded 7_4_2_3
Filter insert with filter candle.
1. Carrier screw
2. Carrier screw hole
3. Top flushing arm
4. Filter candle
5. Bottom flushing arm
6. Drift tool
7. Direction of filtration through filter candle
1. Follow the instruction Remove filter insert on page 33.

Note: If you only want to remove filter candles, without removing the filter insert: Stop following
the instruction after the flushing arm is removed, and continue below.
2. Fold the filter candle tool so that the gripping ends are tight together.
3. Insert the gripping ends into the filter candle (4).
4. Pull the handles and make sure that the ends grip the inside of the filter candle (4).
5. Pull out the filter candle vertically upwards.

If necessary, release the filter candles with the drift tool (6), applied from below with light
strokes.
36 Book No.9000479 02, rev. 0

4 Filter 4.4 Clean filter candles
6. Check that the O-rings on top and bottom of the filter candles are in good condition. Replace if
necessary.
NOTE
Note that only filter specific O-rings can be used.
4.4 Clean filter candles

Follow this instruction to clean the filter candles. At the same time, check that the filter candles
are in good condition. A damaged filter candle can lead to bypass flow in the filter and decreased
filter efficiency.
• Alpacon descalant offshore shall be used as cleaning agent.

• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant to 20 parts
fresh water. Follow this mixing ratio, regardless of recommendation on label.
• Before usage, Alpacon descalant offshore must be visually checked. It shall be transparent
light pink in color.
NG
WARNI
!
• Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves.
NG
WARNI
!
• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• The pH value should be approximately 2.0.
• Please proceed with the utmost caution when transporting, assembling, disassembling and
cleaning the filter candles.
1. Follow the instructions Remove filter insert (page 33) and Remove filter candles (page 34) to
remove the filter candles.
2. Soak the filter candles in the cleaning agent and leave them to soak for 1–3 hours.
3. Remove loose particles which float on the top of the cleaning agent during the soaking stage.
4. Spray the filter candles with water from both directions. The water must not be warmer than
60 °C. Note: If a high-pressure cleaner is used, the pressure must not exceed a maximum
of 60 bar (6.0 MPa). If a cleaner with higher capacity than 60 bar is used, compensate
by increasing the distance.
5. Finish by spraying counter to filtration direction (from outside to inside).
Book No.9000479 02, rev. 0 37

4.6 Mount filter candle and filter insert 4 Filter
6. Rinse the filter candle carefully in water and allow draining.
7. Check all filter candles and seals for damage. If needed, replace any damaged filter candles
or seals.
4.5 Replace filter candle

To replace filter candles, follow the Remove filter candles instruction on page 34, and simply
replace damaged candles.
Replace the filter candle O-rings when a candle is replaced. These must be ordered separately.
4.6 Mount filter candle and filter insert

Follow this instruction to mount the filter candles into the filter insert and the filter insert into the filter
housing after inspection, cleaning and replacement of filter candles.
See illustrations in instructions Remove filter insert on page 33 and Remove filter candles on
page 34.
• When performing this routine, use the service kit for the filter, containing O-rings. New O-rings
for the filter candles are also recommended.
• During assembly and disassembly of the filter candles, avoid touching other filter parts with
the filter candles.
1. Carefully insert the cleaned filter candles into the filter insert from above, with the chamfered
end first. Push the filter candles all the way into the filter insert.
2. Make sure that the seals are properly in place, and fit the filter cover plate.
3. Insert the filter insert vertically into the housing from above.
4. Make sure that the seals are properly in place and put the filter candle retaining plate in place.
5. Insert the upper flushing arm into the connecting pipe.
6. Fasten the upper flushing arm in place with the screws.
7. Check that the back-flushing device moves easily.
8. Fit the cover. Check the seal for damage. Replace any damaged seals as necessary. Tighten
the screw connection evenly, gradually tightening opposite screws step-by-step.
9. Attach the bearing support and the bearing to the coupling. Check the seal for damage.
Replace if necessary.
38 Book No.9000479 02, rev. 0

4 Filter 4.7 Mount filter gear motor
10. Fasten the bearing support in place with the respective screws. Tighten the screw connection
evenly, gradually tightening opposite screws step-by-step.
11. Place the lock washer on the coupling and screw the shaft nut onto the coupling.
12. Firmly tighten the shaft nut and secure it with the securing plate.
13. Fasten the motor flange in place with the respective screws. Tighten the screw connection
evenly, gradually tightening opposite screws step-by-step.
14. Place the gear motor on the bearing support. Fasten the gear motor in place with the
respective screws. Tighten the screw connection evenly, gradually tightening opposite screws
step-by-step. Re-connect all connection lines as necessary.
15. Close the drain hole and the vent.
4.7 Mount filter gear motor

Follow this instruction to mount the gear motor on the filter.
7 Filter motor 7_4_5
Filter cover and gear motor.
1. Filter crank
2. Gear motor
3. Shaft nut
4. Lock washer
5. Filter fitting
6. Bearing support
7. Axel
Book No.9000479 02, rev. 0 39

4.8 Change sacrificial anode 4 Filter
• When performing this routine, use the service kit for the filter, containing O-rings.
1. Put down the lock washer (4) and the shaft nut (3) in the filter fitting (5).
2. Fasten the nut, but not completely.
3. Bend one of the lock washer leafs upwards so it fits the bevel in the nut. Fasten the shaft
nut completely.
4. Lower the motor (2) into the filter fitting (5) with the electrical box directed to facilitate electrical
connection. Make sure that the wedge on the motor shaft fit into the groove in the axel (7).
Result: The motor now rests on the bearing support (6), but the bolt holes are not aligned.
5. Fasten the motor with the bolts.
6. Check the motor according to the instruction Check filter gear motor function.
4.7.1 Check filter gear motor function

Follow this instruction to see to that there are no mechanical obstacles in the motor on connected
parts.
1. Use the filter crank (1 in illustration on page 39) to turn the bolt on top of the motor maximum
three turns.
2. Let go of the crank.
3. Observe the crank: If it remains steady, the motor is OK. If it reverses back, there might be a
mechanical problem that needs to be attended to.
4.8 Change sacrificial anode

Follow this instruction to change the sacrificial anode on the filter.
• Read the general preparations and conditions on page .

1. Open the deaeration valve and drain valve to drain all water from the filter.
2. Open the lid (12 in the filter exploded view in the introduction of this section on).
3. Inspect the anode. Change if the anode has lost approximately 80 % of the zinc mass.
4. Remove the old anode and install the new one.
40 Book No.9000479 02, rev. 0

4 Filter 4.8 Change sacrificial anode
5. Fasten the lid on the filter and restore the valves in their original positions.
Book No.9000479 02, rev. 0 41

4.8 Change sacrificial anode 4 Filter
5 CIP module
This section covers instruction for service of the CIP module.
5.1 Change and refill CIP liquid

Alpacon descalant is used as cleaning agent in the CIP module. Alpacon descalant offshore
contains no solvents and no inorganic acids. It is non-flammable and non-hazardous.
ON
CAUTI
!
• Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow
general rules when handling of cleaning agents regarding ventilation, personal protection etc.
ON
CAUTI
!
• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• Before usage, Alpacon descalant offshore must be visually checked. It shall be transparent
light pink in color.
• The instructions requires pH test equipment (paper indicator or ph meter). This is not a part of
Alfa 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.9000479 02, rev. 0 43

5.1 Change and refill CIP liquid 5 CIP module
7 CIP 589741_description
CIP module
1. CIP liquid tank cap

2. Drain valve
3. Pump (AOT drain)
4. Pump (CIP liquid)
44 Book No.9000479 02, rev. 0

5 CIP module 5.1 Change and refill CIP liquid
5.1.1 Change CIP liquid

Follow this instruction to change CIP liquid, when necessary according to the Maintenance schedule.
1. If the drain valve (2) is connected to the bilge tank, follow the sub steps below. Otherwise, go
to step 2.
1. Open the drain valve V460-3 (2) under the CIP tank.
2. Wait for the tank to be totally drained. Then close the drain valve (2).
2. If the drain valve is not connected to the bilge tank, the steps below can be followed. This
subroutine requires login level 2 or 3 in the control system. .
1. Open valves V320-2 and V460-2 from the control valve, and V230–11 manually. Start
pump P321-5 (4) and P320-1 (4).
2. Wait for the tank to be totally drained. Then stop the pumps and close the valves in
reversed order. Go to step 3.
3. Open the cap (1) on top of the CIP tank and pour 12 liters of CIP cleaning agent into the tank.
4. Fill the tank with fresh water to the Max indication on the tank.
5. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.
6. Go to control system page 5.3 – Operation timers. Make a note of the number of AOTs that
has been CIPed since last time the CIP liquid was changed. Press the Reset button for “Total
number CIP:ed AOTs”. Requires login level 2. If this is done each time the CIP liquid is
changed, it is possible to build up experience on how many AOTs it is possible to CIP before it
is time to change CIP liquid.
5.1.2 Refill 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.9000479 02, rev. 0 45

5.2 Repair CIP pump 5 CIP module
5.2 Repair CIP pump

Follow this instruction to repair the CIP pump.
For spare parts ordering, please specify pump model and serial no.
ON
CAUTI
!
• Always wear protective eye glasses and gloves while working on the pump.
NG
WARNI
!
secure it from being switched on.
• Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
• Drain the pump from liquids.
• The pump should be placed horizontally on a work bench.
7 CIP pump
CIP pump, exploded view
46 Book No.9000479 02, rev. 0

5 CIP module 5.2 Repair CIP pump
5.2.1 Clean CIP pump

1. Remove the pump from the CIP tank.
2. Rinse the pump with fresh water.
5.2.2 Disassemble CIP pump

Follow this instruction to disassemble the CIP pump.
5.2.2.1 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).
5.2.2.2 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.
Book No.9000479 02, rev. 0 47

5.2 Repair CIP pump 5 CIP module
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.
5.2.2.3 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.
5.2.3 Assemble CIP pump

Follow the instructions below to assemble the CIP pump.
5.2.3.1 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.
5.2.3.2 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.
48 Book No.9000479 02, rev. 0

5 CIP module 5.5 Repair valve block
3. Make sure all pin screws (14) have one nut (37) and one washer (38) each. Nut should only be
put on one or two threads.
4. Put all the pin screws through the housing and then turn the housing so it rests on the nuts.
5. Put the centre block (12) to the housing with screws through the centre block. Be careful not to
damage the diaphragms.
6. Place suction and discharge connections (13) in their positions in the housing. Be careful not
to damage the O-rings (18).
7. Put the second housing (11) onto the pin screws (14). Make sure that suction/discharge
connections are in right direction. Be careful with the O-rings.
8. Fasten the nuts (37) crosswise by hand, with or without washers depending on how much of
the thread comes out. Turn the nuts gently with a tool to close the pump. If some of the nuts
were fastened without washer, unscrew those and put washers underneath. After a few weeks
operation a follow up draft of the nuts is recommended.
5.3 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.
5.4 Repair junction box and valve blocks

Read the conditions below before reparing the junction box or valve blocks.
5.5 Repair valve block

Follow this instruction to repair the valve block, mounted on the CIP module.
NGE R
! DA
• Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.
Book No.9000479 02, rev. 0 49

5.5 Repair valve block 5 CIP module
NGE R
! DA
• The valve bodies does not have individual placing, they can be placed in any order.
7_3_3_1 VBlock
Valve block
1. Cover (Terminal strip inside)

2. Button to operate valve
3. Valve body
4. Cable gland
5.5.1 Change valve body

1. Unscrew the Allen bolts holding the valve body (3).
2. Lift the valve body: Note: It is easy to drop the sealing when the valve body is lifted. Be
careful not to loose it.
3. Attach a new sealing on the new valve body and fasten the valve body to the valve block.
5.5.2 Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the control cabinet to the CIP valve block.
1. Open the cover (1) on the front.
2. Lift the terminal strip from its position to facilitate cable connection.
3. Attach the cables according to electrical drawing Control cabinet / interconnection diagram in
chapter 6. Installation description and drawings.
50 Book No.9000479 02, rev. 0

5 CIP module 5.5 Repair valve block
4. Fasten the cable to the cable gland (4).
5. Place the terminal strip in the slot to the right. Make sure it is pushed to the bottom so it
connects.
6. Fasten the cover (1).
5.5.3 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 59 to blow out the dust.
3. Connect the air hoses again.
5.5.4 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 sticker on the CIP module, under the valve block.
Book No.9000479 02, rev. 0 51

5.5 Repair valve block 5 CIP module
6 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.
6.1 Mount flow transmitter

Follow the steps below to mount the flow transmitter on the flow sensor. The flow transmitter is not
factory mounted, to avoid damage during installation of the flow sensor.
Preparation and conditions
• See chapter 6. Installation description and drawings, section Control cabinet / Interconnection
diagram for detailed information.
• It is recommend that a shielded power cable is used.
NG
WARNI
!
• Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
1. Remove and discard the lid from the terminal box on the flow sensor.
Book No.9000479 02, rev. 0 53

6.1 Mount flow transmitter 6 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 55.
7 FM MountTM
54 Book No.9000479 02, rev. 0

6 Flow meter 6.2 Change direction of flow transmitter
6.2 Change direction of flow transmitter

The flow transmitter can be mounted in different directions in relation to the flow sensor. It can
be directed in steps of 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.9000479 02, rev. 0 55

6.3 Change direction of flow transmitter control 6 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.
6.3 Change direction of flow transmitter control pad

The control pad of the flow transmitter can be mounted in different directions in relation to the
transmitter. It can be directed in steps of 90º.
1. Remove the outer frame with the help of a screw driver.
7 FM LoosFrame
56 Book No.9000479 02, rev. 0

6 Flow meter 6.3 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.9000479 02, rev. 0 57

6.4 Clean flow meter electrodes 6 Flow meter
5. Snap-lock (a click is heard) the outer frame onto the control pad.
7 FM FastCover
6.4 Clean flow meter electrodes

Follow this instruction to clean the electrodes.
It is important that the electrodes are clean to secure accurate output. If the four electrodes in the
flow sensor get dirty, it may result in inaccurate and varying output.
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 60.
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.
58 Book No.9000479 02, rev. 0

7 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.
7.1 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 49) 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.
7.2 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.9000479 02, rev. 0 59

7.3 Lock valve in closed position 7 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.
7.3 Lock valve in closed position

Follow this instruction to lock valves V201-3, V201-8 and V201-9 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 indicators, to
make sure.
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.
8. Slide the safety cover over the end bolts and lock the safety cover with the pad lock.
60 Book No.9000479 02, rev. 0

7 Operate valves manually 7.4 Unlock valve
9. Repeat the above procedure for all valves concerned.
7.4 Unlock valve

Follow this instruction to unlock valves V201-3, V201-8 and V201-9 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.
7. Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.
Book No.9000479 02, rev. 0 61

7.4 Unlock valve 7 Operate valves manually
8 Valve actuator
This section contain instructions for the valve actuator.
7 Actuator
Valve actuator
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.
Book No.9000479 02, rev. 0 63

8.2 Mount actuator on valve 8 Valve actuator
8.1.1 Tightening torques for actuators

Torque is stated in Nm.
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 Mount actuator on valve

The actuator is mounted together with the valve body and pilot valve at delivery. Follow the
instructions below if the actuator has been dismounted.
ON
CAUTI
!
• The actuator must not be pressurized at any time during installation as it may result in injury.
• The valve must be in closed position.
• The valve position must not be adjusted during the routine.
• The utmost cleanliness is required during air supply connection to the actuator, that is, the
connecting pipe thread, fittings and seals must be clean and dirt-free.
• Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on
which direction of rotation is required.
• When using a spring return actuator for a fail safe operation, ensure that when air or power
failure occurs, the direction of rotation is correct for your application.
1. Make sure that the groove (2) at the top of the stem (3) is in line with the throttle. In some cases
the valve stem is fitted with one or two spindle-bushings (4) to prevent play. If so, make sure
that the bushing is in place. The illustration shows a square variant, but octagoal versions exist.
64 Book No.9000479 02, rev. 0

8 Valve actuator 8.3 Dismount actuator
7 ValveStem
1. Allowed travel sector.

2. Valve stem groove
3. Valve stem
4. Spindel-bushing
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. Fit the actuator onto the valve stem. 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.
4. 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 64.
5. Operate the valve to make sure it operates in the desired direction of rotation. Control the
position indicators, to make sure that the valve is in correct position.
6. Next step is to mount the pilot valve on the actuator, if not already mounted.
8.3 Dismount actuator

Follow this instruction to disassemble the actuator for maintenance.
• 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.
• If the actuator is a spring return unit, make sure the actuator is in the failed position before
disassembling.
Book No.9000479 02, rev. 0 65

8.4 Change direction of actuator – without 8 Valve actuator
position sensor
1. Disconnect the power to the proportional valve. 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.
2. Disconnect the air supply to the proportional valve.
3. Unscrew the four hexagonal screws holding the actuator to the valve. Some valve stems are
equipped with one or two sockets. Make sure not to lose them.
4. Lift the actuator from the valve.
8.4 Change direction of actuator – without position

sensor
Follow this instruction to turn an actuator without position sensors.

• 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 65.
Put the actuator on a work bench.
2. If the actuator is equipped with a bracket and junction box: Disconnect the DIN connector
from the coil: First loosen the screw (1), and then pull up the connector (2). Make sure not
to loose the screw or the gasket.
7 DisconDINcon
3. If the actuator is equipped with a bracket and junction box: Unscrew the four hexagonal screws
holding the junction box bracket on the actuator, and remove the bracket.
66 Book No.9000479 02, rev. 0

8 Valve actuator 8.5 Mount pilot valve on actuator
4. Unscrew the center screw (4) holding the puck (6) and a bracket (5).
7 ActDirectWithout
5. Lift the puck (6), rotate it 90° and fasten it with the center screw (4) and bracket (5).
6. Make sure that the yellow position indicator (3) in line with the valve throttle.
7. Mount the junction box bracket on the actuator with the four hexagonal screws.
8. Fit the actuator onto the valve stem in its new position according to instruction Mount actuator
on valve on page 64.
9. Reconnect the DIN connector (2), including the gasket.
10. Connect power and air.
8.5 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.
Book No.9000479 02, rev. 0 67

8.6 Change direction of actuator – with 8 Valve actuator
position sensor
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).
8.6 Change direction of actuator – with position

sensor
Follow this instruction to turn an actuator with one or two position sensors, if necessary due to lack
of space. Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-3, V201-9, and V212-31.
68 Book No.9000479 02, rev. 0

8 Valve actuator 8.6 Change direction of actuator – with
position sensor

Put the actuator on a work bench.
2. Disconnect the DIN connector (1) from the coil: First loosen the screw (1), and then pull up
the connector.
7 DisconDINcon
3. Unscrew the four screws holding the junction box cover, and remove the cover.
4. Unscrew the four Allen screws holding the junction box to the bracket, and remove the junction
box bracket.
5. Loosen the junction box bracket by unscrewing the two Allen screws holding each position
sensor. The screws are reached through the hole in the junction box bracket.
For actuators with one sensor: Unscrew the two hexagonal screws holding the junction box
bracket to the actuator on the side without sensor.
6. Unscrew the center screw (6) holding the puck (8) and a bracket (7).
Book No.9000479 02, rev. 0 69

8.6 Change direction of actuator – with 8 Valve actuator
position sensor
7 DirActPosSnsr
7. Lift the puck (8), rotate it 90° and fasten it with the center screw (6) and bracket (7).
8. Move the indicator screws vertically on the position sensor (5): Screws on upper position (4)
shall be moved to the lower position (3), and vice versa.
For actuators with one sensor: Screw on yellow indicator is moved to the top position. Screw
on black indicator is moved to the lower position on the black indicator on the opposite side of
the puck.
9. Mount the junction box bracket, distance and position sensor on the actuator with the four
hexagonal screws. The position sensor must be in upright position. Tighten loosely.
10. Adjust the sensor to a maximum distance of 1 mm from the puck (7). The position sensor and
the position indicator must be close to give a signal. Tighten the screws to fixate the position.
11. Remount the junction box and the cover.
on valve on page 64.
13. Make sure that the yellow indicator (5) in line with the valve throttle.
14. Reconnect the DIN connector.
15. Connect power.
16. Check that the installation is OK, by making sure that the A1 LED is lit on the position sensor
(visible from the side).
17. Connect air.
70 Book No.9000479 02, rev. 0

8 Valve actuator 8.7 Change direction of actuator – with
proportional valve
8.7 Change direction of actuator – with proportional

valve
Follow this instruction to turn the actuator direction 90° if necessary due to lack of space. Note that
the actuator normally should not be altered.
This instruction is valid for valve V201–8.

on valve on page 64. 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.
Result: The position indicators (1) are now in the wrong positions and must be changed.
7 DirectProp
3. Change place of the 2 yellow and 2 black position indicators (1). The indicators can be pushed
upwards from the puck (4) with a screw driver. When they are pushed back, make sure that
they snap into position. The yellow indicators shall now show valve position: closed.
4. Connect air and power.
5. Operate the valve manually to check the function of the component.
Book No.9000479 02, rev. 0 71

8.8 Adjust valve end position 8 Valve actuator
8.8 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.
• 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).
72 Book No.9000479 02, rev. 0

8 Valve actuator 8.10 Adjust valve traveling speed
8.9 Adjust position sensor

Follow the instruction below to adjust the valve end position for the position sensor. Note that the
sensor is factory set. It must only be adjusted if it is out of position.
This instruction is valid for the following valves: V201-3, V201-9 and V212-31.
1. Follow the instruction Change direction of actuator – with position sensor on page 68, but
ignore all steps concerning change of orientation of the actuator and puck.
2. When the position sensor are described, be careful to mount the position sensors close to the
puck. The position sensor must be in upright position.
3. Refit in reversed order. Do not forget to perform the check at the end of the instruction Change
direction of actuator – with position sensor.
8.10 Adjust valve traveling speed

Follow this instruction to adjust valve traveling speed.
7 AdjustTravel
1. Operate the valve manually to check traveling speed according to the instruction in the Operate
valves manuallyon page 59.
2. To adjust opening speed:

Faster: Screw the throttle (1) valve port 3 clockwise.
Slower: Screw the throttle valve (1) port 3 counterclockwise.
3. To adjust closing speed:

Faster: Screw the throttle valve (2) port 5 clockwise.
Slower: Screw the throttle valve (2) port 5 counterclockwise.
Book No.9000479 02, rev. 0 73

8.10 Adjust valve traveling speed 8 Valve actuator
9 Proportional valve
This section contains mounting and maintenance information for the proportional valve installed on
the actuator for control valve V201-8. The proportional valve is mounted together with actuator
and valve body at delivery.
Proportional valve maintenance
Follow these general rules:
NOTE
• In case of malfunction, the proportional valve should be replaced. Do not try to disassemble
or adjust the component!
• After a proportional valve has been replaced, it must be checked for correct function. Normally,
no adjustment of settings is required.
9.1 Replace proportional valve

Follow this instruction to replace a proportional valve.
Proportional valve is mounted on a bracket sitting on actuator.
1. Disconnect the power cable from the proportional valve. Note how the cable is connected,
to be able to reconnect correctly.
2. Disconnect the air supply to the proportional valve and the air connections between the
actuator and the proportional valve. Note how the air supply is connected, to be able to
reconnect correctly.
3. Loosen the four hexagonal screws between the proportional valve and the bracket.
4. Remove the proportional valve.
5. Mount a new proportional valve with the four hexagonal screws.
6. Connect air according to the notes made in step 2.
7. Connect the power cable according to the notes made in step 1.
Book No.9000479 02, rev. 0 75

9.2 Replace filter in proportional valve 9 Proportional valve
9.2 Replace filter in proportional valve

Follow this instruction to check and change filter in the proportional valve.
• Do not operate the proportional valve without the filter installed.

• Do not attempt to unscrew the filter plug while the proportional valve is pressurized. The internal
filter normally requires no attention if an external inlet filter is installed.
• When performing this routine, use the service kit for the filter, containing filter, O-ring and baffle.
1. Separate the two hexagonal bolts on the hose gland (1). The filter is fitted inside.
7 CVfilter591890#0
2. Check the filter (2) and replace it, if it is discolored. At the same time, replace the O-ring (1)
and baffle (3).
76 Book No.9000479 02, rev. 0

9 Proportional valve 9.2 Replace filter in proportional valve
7 PropFilter 595541#1
Book No.9000479 02, rev. 0 77

9.2 Replace filter in proportional valve 9 Proportional valve
10 Ball valve
This section contains maintenance information for the ball valve.
10.1 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.9000479 02, rev. 0 79

10.1 Replace seals in ball valve 10 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.
80 Book No.9000479 02, rev. 0

11 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
11.1 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.9000479 02, rev. 0 81

11.3 Test level switch 11 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.
11.2 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.
11.3 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.
82 Book No.9000479 02, rev. 0

12 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.

12.1 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.9000479 02, rev. 0 83

12.2 Dismount temperature switch / 12 Temperature switch and temper-
temperature transmitter ature transmitter
12.2 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.
84 Book No.9000479 02, rev. 0

13 Control panel
This section covers instructions for service of the control system.
13.1 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.
13.2 Replace control panel

Follow this instruction to replace the control panel.
Preparations and conditions:
• The system must be shut down.
13.2.1 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.9000479 02, rev. 0 85

13.2 Replace control panel 13 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
13.2.2 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
86 Book No.9000479 02, rev. 0

13 Control panel 13.2 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.
Book No.9000479 02, rev. 0 87

13.2 Replace control panel 13 Control panel
14 Remote control panel
(optional)
This section covers information on how to mount and connect communication components for the
remote control panel.
The information in this instruction is also given in the Control cabinet / Circuit diagram in chapter 6.
Installation description and drawings.
14.1 Mount and connect switch for remote control panel
7 594060 RCP
Connect switch and terminals
1. Ethernet ports (3 pieces)

2. 24 VDC port (connection to terminals connected
at delivery)
3. Connect switch
4. Terminal (+ 24 V power connection)
5. Terminal (– 24 V power connection).
6. Terminal (grounding)
7. Fiber ports (2 pieces)
Book No.9000479 02, rev. 0 89

14.1 Mount and connect switch for remote 14 Remote control panel (optional)
control panel
7 RemotPanelCon
Back of remote control panel, side view
• 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.
• Note that the terminals are marked with 4 (+), 5 (–) and 6 (GND).
• Two wires are mounted between terminal and switch power contact (2) no 1=DC–, no 2=DC+,
cables are marked + and –.
1. Mount the switch (3) at a location of your choice. Note that the delivered Ethernet cable to be
used between the switch and the control panel is 1.5 meters.
2. At the back of the remote control panel, fasten the Ethernet cable in one the Ethernet ports.
Fasten the other end of the cable in the connect switch’s Ethernet port number 1 (1).
3. Connect an Ethernet cable from the connect switch to the switch in the control cabinet. See
position 1 in illustration on page 91. Also see cable W501 in Control cabinet / Interconnection
diagram.
If the distance between the two switches are more than 100 meter, a fiber cable must be used
instead of an Ethernet cable. Fiber cables are connect to the fiber ports (7) on the connect
switches.
4. If more than one remote control panel is installed, connect an Ethernet cable from Ethernet port
number 2 (1) on the connect switch to the connect switch for the second remote control panel.
If the distance between the two switches are more than 100 meter, a fiber cable must be used
instead of an Ethernet cable. See step 3 above.
5. Connect a 3 core cable from connection switch terminals 4, 5 and 6 to the remote control
panel’s 24 VDC port (2).
6. Connect a 24 VDC power supply cable to the terminals 4 and 5 and 6.
90 Book No.9000479 02, rev. 0

14 Remote control panel (optional) 14.2 Mount and connect Ethernet switch
for remote control panel
14.2 Mount and connect Ethernet switch for remote

control panel
The information is only relevant if this option is added after installation. If remote control panel is
included in the original order and installation, the Ethernet switch is already mounted.
7 591773 RI
Control cabinet, opened
1. Loosen the right end stop on the DIN rail at position (1).
2. Mount the Ethernet switch on the DIN rail at position (1).
3. Fasten the end stop to fixate the Ethernet 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 Ethernet switch port: 1.
5. Connect an Ethernet cable in the IF2 on the PLC and connect the other cable end to the
Ethernet switch port: 2.
6. Connect wire 400 (DC–) to terminal 400 (3) and to Ethernet switch (1) terminal no: 1.
7. Connect wire 402 (DC+) to PLC terminal 15 (2) and to Ethernet switch (1) terminal no: 2.
Book No.9000479 02, rev. 0 91

14.2 Mount and connect Ethernet switch for 14 Remote control panel (optional)
remote control panel
15 Remote interface (optional)
This section covers information on how to mount and connect communication components in the
control cabinet. The information is only relevant if this option is added after installation.
15.1 Mount connection terminal for remote interface

Follow this instruction to mount and connect the remote interface communication components
in the control cabinet.
The information in this instruction is also given in the Control cabinet / Circuit diagram in chapter 6.
Installation description and drawings.
• Delivered cable shall be used.
1. Loosen the right end stop on the lowest DIN rail in the control cabinet at position (1).
2. Mount the connection terminal (X4) on the DIN rail at position (1).
Book No.9000479 02, rev. 0 93

15.1 Mount connection terminal for remote 15 Remote interface (optional)
interface
7 RIintegr 591773-82
3. Fasten the end stop to fixate the connection terminal.
4. Fasten the cable (D-SUB) to the connection terminal.
5. Lead the cable in the cable ducts in the cabinet the door to the backside of the control panel.
6. Fasten the cable (D-SUB) to the COM1 port at the backside of the control panel.
7 RemotPanelCon
Remote control panel, side view
7. Connect the signal cables (RS422 or RS485) from the connection terminal to the ISCS
according to drawing Interconnection diagram / Control cabinet.
94 Book No.9000479 02, rev. 0

16 Control cabinet
This section covers maintenance information for the control cabinet and LDC.
16.1 Cable glands

Follow this instruction to mount cables into the cabinet.
7 Cable0
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.
7 Cable2
Book No.9000479 02, rev. 0 95

16.1 Cable glands 16 Control cabinet
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
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
96 Book No.9000479 02, rev. 0

16 Control cabinet 16.2 I/O system
16.2 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.
16.2.1 Disassemble I/O system

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
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.
Book No.9000479 02, rev. 0 97

16.2 I/O system 16 Control cabinet
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
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
98 Book No.9000479 02, rev. 0

16 Control cabinet 16.2 I/O system
16.2.2 Assemble I/O system

1. Assemble components in reverse order compared to instruction Disassemble I/O system on

page 97.
2. Put back all additional locking clips by pushing them into their holes. The additional clips are
required to safely attach the electronic module to the bus module.
Book No.9000479 02, rev. 0 99

.
Spare parts catalogue

PureBallast 2.0 Flow 750 DIN 300 CV250 RCP
Specification No. 59999955/2

Book No.
Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB 2012-10-10

Original instructions
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1 Important information 5
2 Control cabinet 6
2.1 Cabinet 8
2.2 Terminal block 10
3 Remote control panel 12
4 Switch connecting set - Remote

ctrl panel (option) 14
5 AOT module 16
5.1 Reactor 18
5.2 Lamp drive cabinet 20
5.3 Valve 44
5.4 Valve 46
6 Filter DIN DN300 48

6.1 Filter DIN 300 50
7 Valve V201-3 and V201-9, DN300

PN10 56
8 Valve V201-32, DN300 PN10 58
9 Valve V212-31, DN300 PN10 60
10 Valve 201-8, DN250 62
11 Flow transmitter, DN300 64
12 CIP module 66
12.1Fresh water piping 70
12.2Pipe #5 76
3
12.3Pipe #6 78
12.4Pump 80
12.5Valve block 82
12.6Air distribution, CIP 84
13 CIP liquid, 15 L 86
14 Ancillary equipment 88
14.1Sampling device 90
14.2Pressure transmitter set 92
14.3Pressure gauge set 94
14.4Valve V403-35 96
15 Actuator spare part kit, DA/SR

301 98
16 Cross reference list 100
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
591773-
Ref Part No Description -80 Notes
Quantity
1 594447 80 Cabinet 1 See page 8
4 595670 80 Panel 1
4A 595670 01 Panel 1
4B 595670 02 Backlight -1
7 223101 47 Washer 12 BRB 6,4x12x1,6 fzb
8 221891 04 Lock nut 12 M6M 6 fzb
10 591102 01 Power supply 1
11 591103 12 Over current prot. Relay 1
12 591103 10 Auxiliary contact 2
13 591103 29 Fuse 1
14 591103 16 Fuse 4
16 582212 24 End stop 9
17 591103 38 Contactor 1
18A 580986 17 Bus module 14
18B 580986 30 Supply Bus Module 1
18C 580986 58 Interface Module 1
18D 580986 76 Communication module 1
18E 580986 04 6 Digital input 5
18F 580986 32 Supply Module 1
18G 580986 11 6 Digital Output 6
18H 580986 08 4 Analogue input 1
18I 580986 33 Output Module 1
18J 580986 16 Terminal block 12-pin 15
18K 580986 44 Additional locking clip 15
18L 580986 55 Compact Flash 1
18M 580986 08 4 Analogue input 1
18N 580986 79 Battery, 3V 950mAh -1
19 582212 72 Connector 2
20 591103 36 Main breaker 1
20.1 591103 37 Breaker handles 1
21 582212 88 PIT 2,5 6
22 582212 89 D-ST2,5 1
23 582212 91 VIP-2, D 9SUB 1
24 582212 90 Cable-D 9SUB 1
25 594774 80 Terminal block 1 See page 10
27 583556 08 Cable channel 40x80 3
31 593724 02 Distance screw 8
36 594009 02 Screw 4 MRX-Z 4x15 fzb
37 582221 90 PE Connection bar 1 L=450mm
38 582212 15 PE/SC Bar 1 L=500mm
39 582212 19 Sc Clamp 18
40 582212 93 Sc clamp 2
41 594781 01 Distance 5
42 594009 02 Screw 5 MRX-Z 4x15 fzb
43 591922 01 Cable seal 1
44 595361 01 Cable seal 1
46 223101 47 Washer 3 BRB 6,4x12x1,6 fzb
47 221803 02 Nut 3 M6M 6 fzb
48 582221 89 Cable fixing spiral 1
51 591103 31 Locking device 1
52 595673 01 Ethernet cable 1
65 260137 04 Pop rivet 4
Z 597330 01 Cable seal -1
Z0.1 597331 01 Cable seal -1
6 Book No.
2 Control cabinet
2307
Book No. 7
2.1 Cabinet
594447-
Quantity
2 593710 01 Door 1
3 594009 01 Screw 6 MRX-Z5x6 fzb
4 26556 Spring washer 6 FBB 5,1 fzb
6 587276 02 Washer 12
7 221891 05 Hexagon lock nut 12 M6M 8 fzb
9 579385 01 T-handle 1
11 593991 01 Latch 1
12 593781 01 Rod 2
15 223107 34 Spring washer 4 FBB 6,1 fzb
16 221891 04 Lock nut 4 M6M 6 fzb
17 593240 01 Bracket 1
19 593254 01 Retaining ring 1
21 221891 04 Lock nut 2 M6M 6 fzb
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 593239 01 Nut 1
26 260154 08 Lifting eye bolt 2
27 70560 Washer, 8,4x16x1,6 2 BRB 8,4x16x1,6 fzb
29 581688 01 Bracket 4
30 221711 16 Screw 8 MC6S 6x16 fzb
31 223101 47 Washer 8 MRM 6,4x12x1,6 fzb
32 221891 04 Lock nut 8 M6M 6 fzb
33 587276 02 Washer 3
35 544465 04 Locking liquid 1 Loctite 270
36 593282 02 Washer 2 BRB 8,4x25x2 polyamide
37 594488 01 Washer 4
38 70560 Washer, 8,4x16x1,6 3
39 223101 73 Washer 1 BRB 6,7x16x1,5 fzb
8 Book No.
2.1 Cabinet 2 Control cabinet
2308
Book No. 9
2.2 Terminal block

594774-
Quantity
1 582212 67 Terminal, PIT 2,5-3PV 11
2 582212 63 Terminal D-PIT 2,5-3L 4
3 582212 65 Terminal PIT 2,5-3L 24
4 582212 60 Bus bar blue 2
5 582212 50 Plug In Bridge red 1 Cut to length
6 582212 03 Plug In Bridge 1
7 582212 85 Interface ralay, 24V 7
10 Book No.
2.2 Terminal block 2 Control cabinet
2310
Book No. 11

594060-
Quantity
1 595670 80 Panel 1
1A 595670 01 Panel 1
1B 595670 02 Backlight -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
12 Book No.
2311B
Book No. 13
4 Switch connecting set - Remote ctrl panel (option)

594100-
Quantity
1 595728 01 Switch 1
3 597035 01 Cable-400 1
4 597035 02 Cable-402 1
14 Book No.
4 Switch connecting set - Remote ctrl
panel (option)
2312B
Book No. 15
5 AOT module
592830-
Quantity
1 593915 80 Reactor 1 See page 18
2 591097 80 Lamp drive cabinet 1 See page 20
3 221803 22 Nut 8 M6M 12 A4-70
4 223101 35 Washer 8 BRB 13x24x2,5 A4
5 594412 80 Valve 1 V201-19
See page 44
6 594412 80 Valve 1 V201-20
See page 44
7 260001 40 Screw 16 M6S 20x50 fzb
8 223101 39 Washer 16 BRB 21x37x3 A4
9 594413 80 Valve 1 V320-4
See page 46
10 594413 80 Valve 1 V321-2
See page 46
11 594413 80 Valve 1 V404-36
See page 46
12 2210462 10 Screw 12 M6S 16x40 fzb
13 223101 37 Washer 12 BRB 17x30x3 A4
14 594171 01 Vibration limit switch 1 LS201-29
15 594169 01 Thermometer, resistance 1 TT201-33
16 594157 01 Temperature switch 1 TS201-60
17 1761805 05 Safety valve, 8 bar 1 RV201-23
18 597049 01 Coupling, elbow 90 1
19 594707 01 Pipe 1
20 592827 01 Bracket 2
21 27345 Nut, M8 4 M6M 8 fzb
23 592823 01 Tee, 3/4 2
24 595302 01 Valve, 3/4 DN20 2 V401-51 and V401-52
25 540006 01 U-bolt 4
26 221803 02 Nut 8 M6M 6 fzb
27 223101 47 Washer 8 BRB 6,4x12x1,6 fzb
28 594785 01 Hose, R3/4 - Rp1/2 2
29 594785 02 Hose, R3/4 - Rp1/2 2
30 591076 01 Plate 3
31 221711 08 Screw 6 MC6S 6x16 A4-70
32 583488 01 Pipe clip 3
33 591092 01 Pozidrive Countersink 6
34 581534 01 Distributor 1
36 558710 01 Nipple 5
37 592304 01 Plug 1
38 592304 02 Plug, 1/4 1
39 580759 04 Push-In Fittings 5
40 544465 06 Locking liquid 0 Or eqvivalent
41 1270001 Lifting instruction 1
42 554214 01 Cable tie 21
43 595272 01 Tube, 6x1 mm 7.5
44 956264 17 Name sign 2 Alfa Laval Logo
45 588835 01 Brand label 2 Wallenius Water Logo
48 595390 01 Lamp label A 1
49 595390 02 Lamp label B 1
53 221803 22 Nut 1 M6M 12 A4-70
54 223101 35 Washer 1 BRB 13x24x2,5 A4
55 27345 Nut, M8 1
56 587276 02 Washer 1
57 70560 Washer, 8,4x16x1,6 1
16 Book No.
5 AOT module
2314
Book No. 17
5.1 Reactor
593915-
Quantity
1 592280 80 Reactor housing 1
2 593913 80 Top plate 2
4 579376 01 O-ring, 750x5,7 2
5 589076 01 Stud bolt 56
6 221803 29 Nut 56 M6M 10 A4-70, vaxed
7 592532 01 Distance 56
8 592685 01 Reflector 1
9 592684 01 Catalyst insert 1
10 596346 01 Plug, ISO-G 1 1
12 589774 01 O-ring 24
13 526350 05 Plug 2 R-236, DN20
14 587587 01 Glass socket 24
15 221711 09 Screw 72
16 588228 01 Lamp bush 24
17 579380 01 O-ring, 15,1x2,7 24
18 590703 80 Cap 24
19 579379 01 Nut 24
21 66169 Drive screw 4
24 537086 02 Molybdenum disulfide past 0
24A 594306 02 Solid lubricant paste 1
Z 579367 98 UV Lamp set -1 1 pcs of UV lamp and 2 pcs of Ref 17.
Z0.1 579367 95 UV Lamp kit -1 12 pcs of Ref Z
Z0.2 594645 80 Quartz sleeve set -1 1 pcs of Quarts sleeve and 2 pcs of Ref
12.
Z0.3 594646 80 Sealing kit -1 2 pcs of Ref 4 and 24 pcs of Ref 12.
18 Book No.
5.1 Reactor 5 AOT module
2315
Book No. 19
5.2 Lamp drive cabinet

591097-
Quantity
1 592048 80 Lamp drive cabinet 1 See page 24
2 591795 80 Power supply assembly 1 See page 28
3 591798 80 LPS A and B side 1 See page 34
4 591797 80 PLC assembly 1 See page 36
7 221891 05 Hexagon lock nut 40
8 581805 01 Varistor 1
9 223101 17 Washer 4 BRB 5,3x10x1 fzb
10 221891 03 Lock nut 4 M6M 5 fzb
11 591792 80 Over current prot. A and B side 1 See page 42
17 223101 47 Washer 28 BRB 6,1 fzb
18 221803 02 Nut 28 M6M 6 fzb
19 593263 01 Cable gland 1
22 596905 02 Cable gland EMC, M16x1,5 9
24 596905 03 Cable gland EMC, M20x1,5 2
26 592003 01 Sheet 1
27 592002 01 Sheet 1
28 221711 17 Screw 5
29 223101 47 Washer 5 BRB 6,1 fzb
30 221803 02 Nut 5
31 592926 04 Grommet, M40 1
32 582356 08 Push button, illuminated 1
32.1 582356 09 Button socket 1
36 594770 01 Pipe 3
37 27345 Nut, M8 6
38 587276 02 Washer 6
39 595433 80 Lamp cable set 1
39A 596600 80 Lamp cable 3
39AA 597361 01 Cable 1.2
39AB 597428 02 Cable gland EMC, M16x1,5 1
39AC 596905 01 Cable gland EMC, M12x1,5 1
39AD 585457 02 Cap, female 1
39AE 585457 04 Collet 1
39BA 597361 01 Cable 1.1
39BB 597428 02 Cable gland EMC, M16x1,5 1
39BC 596905 01 Cable gland EMC, M12x1,5 1
39BD 585457 02 Cap, female 1
39BE 585457 04 Collet 1
39CA 597361 01 Cable 1.5
39CB 597428 02 Cable gland EMC, M16x1,5 1
39CC 596905 01 Cable gland EMC, M12x1,5 1
39CD 585457 02 Cap, female 1
39CE 585457 04 Collet 1
39DA 597361 01 Cable 1.4
39DB 597428 02 Cable gland EMC, M16x1,5 1
39DC 596905 01 Cable gland EMC, M12x1,5 1
39DD 585457 02 Cap, female 1
39DE 585457 04 Collet 1
39EA 597361 01 Cable 1.7
39EB 597428 02 Cable gland EMC, M16x1,5 1
39EC 596905 01 Cable gland EMC, M12x1,5 1
39ED 585457 02 Cap, female 1
39EE 585457 04 Collet 1
39FA 597361 01 Cable 1.6
39FB 597428 02 Cable gland EMC, M16x1,5 1
39FC 596905 01 Cable gland EMC, M12x1,5 1
39FD 585457 02 Cap, female 1
20 Book No.
5.2 Lamp drive cabinet 5 AOT module
2318B
Book No. 21

591097-
Quantity
39FE 585457 04 Collet 1
39GA 597361 01 Cable 1
39GB 597428 02 Cable gland EMC, M16x1,5 1
39GC 596905 01 Cable gland EMC, M12x1,5 1
39GD 585457 02 Cap, female 1
39GE 585457 04 Collet 1
39HA 597361 01 Cable 0.9
39HB 597428 02 Cable gland EMC, M16x1,5 1
39HC 596905 01 Cable gland EMC, M12x1,5 1
39HD 585457 02 Cap, female 1
39HE 585457 04 Collet 1
39I 596594 01 Cable 5
39J 596594 02 Cable 1
39K 596594 03 Cable 1
39L 596594 04 Cable 1
42 596904 01 Cable channel 30x30 1
43 70560 Washer, 8,4x16x1,6 6
22 Book No.
2318B
Book No. 23
5.2.1 Lamp drive cabinet

592048-
Quantity
5 593714 01 Door, RH 1
6 593715 01 Door, LH 1
7 593233 01 Hinge 6
8 592824 01 Screw, countersunk 24 MFX-Z6x12 4.8fzb
9 582632 01 Eccentric lock 6
10 582633 01 Lock plate 6
11 583609 01 Screw, countersunk 18 MFX-Z 5x12 fzb
12 221803 03 Nut 18 M6M 5 fzb
13 223101 17 Washer 18 BRB 5,3x10x1 fzb
14 583608 01 Tapping screw, ST4,2x9,5 12
15 591852 80 Heat exchanger 2 See page 26
16 221706 01 Screw 20 MC6S 5x12 fzb
17 583602 01 Seal 10
19 593245 01 Seal 2
20 593244 01 Flange 2
21 593243 01 Cable gland, M40x1,5 4
22 223101 47 Washer 8 BRB 6,4x12x1,6 fzb
23 221803 02 Nut 8 M6M 6 fzb
24 595477 01 Clamp 2
26 223101 47 Washer 4 BRB 6,4x12x1,6 fzb
30 593239 01 Nut 2
31 221803 02 Nut 2 M6M 6 fzb
32 221030 10 Screw 2 M6S 6x14 fzb
33 593282 01 Washer 2 BRB 6,4x12x1,6 polyamide
34 221711 18 Screw 4 MC6S 6x12 fzb
36 221891 13 Hexagon lock nut 6 M6M A4
38 223101 73 Washer 2 BRB 6,7x16x1,5 fzb
39 221030 10 Screw 2 M6S 6x14 fzb
40 223101 47 Washer 2 BRB 6,4x12x1,6 fzb
41 596804 04 Lock nut, M6 2 M6M 6 fzb
24 Book No.
2376B
Book No. 25
5.2.2 Heat exchanger

591852-
Quantity
3 591856 80 Heat exchanger 1
4 221030 43 Screw 26 M6S 6x10 fzb
5 223107 34 Spring washer 26 FBB 6,1x11,8x1,3 fzb
6 591862 01 Sheet 1
7 223101 17 Washer 2 BRB 5,3x10x1
8 221803 03 Nut 2 M6M 5 fzb
9 586207 02 Tapping screw 2 ST 2,9x9,5 fzb DIN 7981
10 591873 01 Protection 1
11 593573 01 Inlet duct 1
12 221701 02 Screw 4 MC6S 4x12 fzb
13 223101 41 Washer, 4,3x9x0,8 4 BRB 4,3x9x0,8 fzb
14 221891 02 Nut 4 M6M 4 fzb
15 593580 80 Bracket 1
16 591872 01 Centrifugal fan 1
18 223107 34 Spring washer 8 FBB 6,1x11,8x1,3 fzb
19 221711 17 Screw 4 MC6S 6x10 fzb
20 221711 16 Screw 4 MC6S 6x16 fzb
21 221803 02 Nut 8 M6M 6 fzb
22 591889 01 Cable tie mount 7
23 586207 02 Tapping screw 9 ST2,9x9,5 fzb DIN 7981
24 591877 01 Terminal 1
25 592926 02 Grommet, M16 1
26 591874 01 Seal 1
26 Book No.
2319
Book No. 27
5.2.3 Power supply assembly

591795-
Quantity
2 592004 01 Filter 1
3 581804 01 Varistor 1
4 223101 47 Washer 8 BRB 6,4x12x1,6 fzb
5 221803 02 Nut 8 M6M 6 fzb
8 223101 47 Washer 5 BRB 6,1 fzb
9 221803 02 Nut 5 M6M 6 fzb
10 582212 24 End stop 3
11 591136 80 Main breaker 1 See page 30
12 591099 80 Internal AC supply A 1 See page 32
28 Book No.
2320C
Book No. 29
5.2.4 Main breaker

591136-
Quantity
1 591103 01 Breaker 1
2 591103 23 Fuse 1
30 Book No.
2321
Book No. 31
5.2.5 Internal AC supply A

591099-
Quantity
1 582212 83 ST-16 TWIN 6
2 582212 82 bus bar, red 3
3 582212 84 End plate -16 1
4 591103 06 Fuse 1
32 Book No.
2322
Book No. 33
5.2.6 LPS A and B side

591798-
Quantity
2 579445 80 Lamp power supply (LPS) 6
3 591892 01 Tie rod 6
4 593888 01 Guide rod 3
5 223101 47 Washer 15 BRB 6,4x12x1,6 fzb
7 591319 01 Yoke 6
9 554515 05 Cross recessed screw MRX 12 M5x12 MRX 4.8 fzb
10 544465 02 Locking liquid 1 Loctite 242
34 Book No.
2323
Book No. 35
5.2.7 PLC assembly

591797-
Quantity
3 221803 02 Nut 6 M6M 6 fzb
4 223101 47 Washer 6 BRB 6,1 fzb
5 582212 24 End stop 6
6 591102 01 Power supply 1
7 582212 94 Safety relay 1
8 591131 80 24V DC supply 1 See page 38
9 591103 38 Contactor 2
10 582212 64 Terminal PIT 2,5-3PE 1
11 582212 63 Terminal D-PIT 2,5-3L 1
13 591132 80 I/O module 1 See page 40
14 591134 80 Terminal block 1 Valve sensor distribution
15 582212 72 Connector 2 VS-08-RJ45-5-Q
16 594728 01 Temperature sensor 1
20 223101 47 Washer 8 BRB 6,1 fzb
21 221803 02 Nut 8 M6M 6 fzb
22 582212 97 Terminal, PIT 2,5, QUA 3
23 582212 32 End plate 1
24 582212 98 PLC relay 1
25 582212 109 Time Relay 1
29 221120 03 Screw 2
36 Book No.
2324C
Book No. 37
5.2.8 24V DC supply

591131-
Quantity
1 591103 16 Fuse 1 F42
2 591103 16 Fuse 1 F43
2.1 591103 17 Auxiliary contact 1
3 591103 16 Fuse 1 F44
3.1 591103 17 Auxiliary contact 1
4 591103 16 Fuse 1 F45
38 Book No.
2325
Book No. 39
5.2.9 I/O module

591132-
Quantity
1 580986 64 Bus Module 1
2 580986 17 Bus module 9
3 580986 62 Interface Module 1
4 580986 63 Bus Supply 1
5 580986 04 6 Digital input 3
6 580986 11 6 Digital Output 4
7 580986 09 2 Analogue input 1
8 580986 40 Input Module 1
9 580986 16 Terminal block 12-pin 10
10 580986 44 Additional locking clip 10
40 Book No.
2327B
Book No. 41
5.2.10 Over current prot. A and B side

591792-
Quantity
2 591103 28 Bus bar 2
3 591103 08 Terminal block 2
6 582212 64 Terminal PIT 2,5-3PE 4
7 582212 63 Terminal D-PIT 2,5-3L 5
8 582212 24 End stop 6
10 582212 65 Terminal PIT 2,5-3L 6
13 582212 58 Bus bar blue 1
14 582212 50 Plug In Bridge red 1
42 Book No.
2328
Book No. 43
5.3 Valve
594412-
Quantity
1 576886 02 Valve, DN150 1 Lug type
2 576075 11 Air actuator, DA301 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 75 Actuator spare part kit, DA/SR 301 -1 See page 98
44 Book No.
5.3 Valve 5 AOT module
2329
Book No. 45
5.4 Valve
594413-
Quantity
1 590037 01 Valve, DN32 1
2 576075 21 Air actuator, SR101 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 See page 98
46 Book No.
5.4 Valve 5 AOT module
2330
Book No. 47
6 Filter DIN DN300

597274-
Quantity
593802 81 Filter DIN 300 1 See page 50
48 Book No.
6 Filter DIN DN300
2377
Book No. 49
6.1 Filter DIN 300

593802-
Quantity
2 597262 53 Cover, 350 1
3 597263 03 Flushing arm bottom 1
4 597263 10 Coupling 1
4.1 597263 24 Connecting shaft 1
5 597263 32 Flange 1
6 597263 36 Motor flange 1
7 597263 48 Sieve plate top 1
8 597263 60 Sieve plate bottom 1
9 597263 66 Distance tube 1
10 597263 73 Filter candle 16
11 585357 11 Bearing bush 1
12 597263 86 Bushing 2
12.1 585357 15 Bush 2
13 597263 93 Flushing arm top 1
14 597264 38 Covering plate 1
15 585357 69 Shaft spring 2
16 597264 02 Anchor bolt 8
17 585357 21 Deep groove ball bearing 1
18 597547 01 Shaft nut 1
19 597547 02 Tab washer 1
22 585357 23 O-ring 1
23 585357 26 O-ring 1
24 585357 29 O-ring 1
25 585357 31 O-ring 1
26 585357 35 O-ring 16
27 585357 38 O-ring 16
29 585357 40 Truarc inverted ring 1
35 597547 03 Screwing 1
36 597547 04 Gasket 1
38 597547 05 Hexagon nut 20
39 597547 38 Stud bolt 20
40 597547 07 Hexagon socket cap screw 4
41 597547 08 Countersunk screw hexagon 8
48 597264 11 Mounting sheet 1
50 597547 16 Stud bolt 8
51 597547 39 Hexagon socket head cap s 16
53 597547 18 Slotted cheese head screw 2
54 597547 19 Hexagon nut 2
57 597547 20 Hexagon nut 8
64 585357 43 Gear motor 1
65 595799 01 Pressure transmitter 1
66 585357 46 Solenoid valve 1
66.1 585357 47 Coil 24V, dc 1
67 582089 81 Valve, DN80 PN10 1 See page 54
68 597264 61 Angle ball valve 1
69 597264 66 Ball cock 2
71 597547 21 Screwing 5
73 597264 12 Tube, seamless 3 mm 1
74 597264 23 Injector tubing 1
75 597264 13 Bushing 1
76 597547 23 Precision exhaust silence 1
50 Book No.
6.1 Filter DIN 300 6 Filter DIN DN300
2472
Book No. 51

593802-
Quantity
77 597547 24 Screwing 3
78 597264 14 Bushing 1
84 597547 25 Threaded pipe fitting 1
85 1779813 03 Valve, 1/2" AISI 316 1
91 597264 31 Blind flange 2
95 597547 26 Hexagon nut 12
96 597547 27 Hexagon screw 12
98 597547 29 Hexagon nut 4
100 594405 80 Junction box 1
101 597264 15 Sacrificial anode 1
103 597547 31 Hexagon nut 8
104 597547 32 Screwed sealing plug 1
105 597547 33 Gasket 1
106 577803 01 Name sign 1
108 597547 34 Blind rivet 8
109 1270001 Lifting instruction 1
Z 597298 83 Service kit filter, 350 -1
ZA 585357 23 O-ring 1
ZB 585357 26 O-ring 1
ZC 585357 29 O-ring 1
ZD 585357 31 O-ring 1
ZE 585357 40 Truarc inverted ring 1
52 Book No.
2472
Book No. 53
6.1.1 Valve, DN80 PN10

582089-
Quantity
1 587040 02 Valve, DN80 1
2 587041 02 Air actuator, 004 1
54 Book No.
2379
Book No. 55
7 Valve V201-3 and V201-9, DN300 PN10

594420-
Quantity
1 576886 05 Valve, DN300 1
2 576075 03 Air actuator, DA451 1
4 576091 01 Sensor 1
5 585976 01 Coil, 24 V DC 1
6 594426 01 Actuator cable 1
7 583012 01 Throttle valve, 1/4 2
8 594431 01 Bracket 1
9 594471 81 Junction box 1
10 595232 01 Grommet 1
11 595215 01 Plate 1
14 587927 07 Locking device, AL79 451 1
Z0.1 576075 63 Actuator spare part kit, DA/SR 451 -1 See page 98
56 Book No.
7 Valve V201-3 and V201-9, DN300 PN10
2360
Book No. 57
8 Valve V201-32, DN300 PN10

594422-
Quantity
1 576886 05 Valve, DN300 1
2 576075 03 Air actuator, DA451 1
4 585976 01 Coil, 24 V DC 1
6 583012 01 Throttle valve, 1/4 2
7 594431 01 Bracket 1
58 Book No.
8 Valve V201-32, DN300 PN10
2361
Book No. 59
9 Valve V212-31, DN300 PN10

594421-
Quantity
1 576886 05 Valve, DN300 1
2 576075 03 Air actuator, DA451 1
4 576091 01 Sensor 2
5 585976 01 Coil, 24 V DC 1
7 583012 01 Throttle valve, 1/4 2
8 594431 01 Bracket 1
10 595232 01 Grommet 2
11 595215 01 Plate 2
Z0.1 576075 63 Actuator spare part kit, DA/SR 451 -1 See page 98
60 Book No.
9 Valve V212-31, DN300 PN10
2362
Book No. 61
10 Valve 201-8, DN250

591890-
Quantity
1 576886 04 Valve, DN250 1 Lug type
2 576075 03 Air actuator, DA451 1
3 577113 01 Proportional valve 1 IP201-7
4 594939 01 Pneumatic positioner 1
5 595229 01 Cable gland 1
6 595219 01 Hose 1
8 595541 01 Filter 1 S201-7
12 587927 07 Locking device, AL79 451 1
13 552801 02 Push-in connector 2
14 569035 05 Flexible pipe, PA12, 8/6 1
Z0.1 583011 01 Filter -1
Z0.2 595541 02 Filter, spare part set -1
62 Book No.
10 Valve 201-8, DN250
2317
Book No. 63
11 Flow transmitter, DN300

576179-
Quantity
1 585345 11 Sensing tube, DN300 1
2 586907 01 Transmitter, MAG 5000 1
64 Book No.
11 Flow transmitter, DN300
2363
Book No. 65
12 CIP module
589741-
Quantity
1 590207 80 Frame 1
3 592677 01 Beam 2
4 592760 01 Beam 1
5 221035 06 Screw 14 M6S 8x20 fzb
7 27345 Nut, M8 14 M6M 8 fzb
8 592653 01 Pipe support 1
13 26853 Screw 8 M6S 6x20 fzb
14 221803 02 Nut 8 M6M 6 fzb
15 223101 47 Washer 20 BRB 6,4x12x1,6 fzb
16 590238 80 Fresh water piping 1 See page 70
17 589526 07 U-bolt clamp, c-c 56,5 2
18 589526 06 U-bolt clamp, c-c 50,5 4
20 27345 Nut, M8 12 M6M 8 fzb
21 590414 01 Tank 1
22 590260 80 Pipe #2 1
23 590255 80 Pipe #3 1
24 590253 80 Pipe #4 2
25 590252 80 Pipe #5 1 See page 76
26 590258 80 Pipe #6 1 See page 78
27 591410 80 Pipe #7 1
28 590256 80 Pipe #8 1
29 590355 80 Pipe #9 1
30 590259 80 Pipe #10 1
30A 592649 01 Nipple 1
31 590261 80 Pipe #11 1
32 221035 36 Screw 4 M6S 8x12 fzb
33 2210295 32 Screw 8 M6S 5x10 fzb
34 586773 80 Pump 1 See page 80
35 586773 80 Pump 1 See page 80
37 27345 Nut, M8 8 M6M 8 fzb
38 591411 80 Valve block 1 See page 82
39 221711 18 Screw 4 MC6S 6x12 fzb
40 590544 01 Filter regulator 1
41 591585 01 Bracket 1
42 591406 01 Mounting ring 1
43 221711 17 Screw 2 MC6S 6x10 fzb
44 1779813 01 Valve, 1/4" 1
45 589526 05 U-bolt clamp, c-c 35 2
47 27345 Nut, M8 4 M6M 8 fzb
48 591693 01 Valve, needle type 2
49 590476 01 Nipple, ISO-R 3/4-1/2 1 ISO-R 3/4 - 1/2
50 590313 01 Valve, angle seat 1
51 591688 80 Air distribution, CIP 1 See page 84
52 590539 01 Clip list 1
53 27497 Plug 1 ISO-R 1, square
54 569038 05 Hose, 32 1
55 591675 01 Hose, 32 1
56 599223 02 Hose clamp 32-44 1
57 599223 03 Hose clamp 38-50 10
59 592649 01 Nipple 1
60 592665 01 Hose, 25 1
66 Book No.
12 CIP module
2364
Book No. 67

589741-
Quantity
61 599223 01 Hose clamp 26-38 2
62 590539 02 Clip list 1
64 223101 97 Washer 2 BRB 8,4x25x2 fzb DIN 9021B
65 223101 17 Washer 8 BRB 5,3x10x1 fzb
66 592790 01 Insulation sheet 1
67 592676 01 Insulation sheet, 2mm 6 Fitted at assembly
71 221716 02 Screw 1
72 70560 Washer, 8,4x16x1,6 4
73 587276 02 Washer 1
74 27345 Nut, M8 1
68 Book No.
12 CIP module
2364
Book No. 69
12.1 Fresh water piping

590238-
Quantity
1 590251 80 Pipe #12 1 See page 72
2 591424 01 Backflow preventer 1
3 591425 01 strainer 1
4 523127 08 Nipple 1
5 590241 80 Pipe #1 1
70 Book No.
12.1 Fresh water piping 12 CIP module
2365
Book No. 71
12.1.1 Pipe #12

590251-
Quantity
1 578074 03 Flange, DN32 PN10 2
3 576953 82 Valve 2 See page 74
7 579082 04 Equal tee, 42,4x2 2
72 Book No.
2366
Book No. 73
12.1.2 Valve
576953-
Quantity
1 576438 06 Valve, DN32 1
2 576075 22 Air actuator, SR201 1
74 Book No.
2367
Book No. 75
12.2 Pipe #5
590252-
Quantity
5 591659 01 Check valve, DN 25 1
7 588996 80 2
76 Book No.
12.2 Pipe #5 12 CIP module
2368
Book No. 77
12.3 Pipe #6
590258-
Quantity
6 588996 80 1
78 Book No.
12.3 Pipe #6 12 CIP module
2369
Book No. 79
12.4 Pump
586773-
Quantity
1 586773 01 Pump 1
Z 586773 02 Spare part set -1 Diaphragm, O-ring set (in/outlet), Valve
ball, Muffler, O-ring (valve seat)
Z0.1 586773 03 Diaphragm -1 Contains: O-ring set (in/outlet), Valve
ball, Muffler, O-ring (valve seat)
80 Book No.
12.4 Pump 12 CIP module
2370
Book No. 81
12.5 Valve block

591411-
Quantity
1 591411 01 Valve block 1 Complete valve block
Z 591411 02 Valve, incl. gasket -1
Z0.1 591411 03 Terminal PCB -1 Placed under the cover, indicated in the
illustration.
Z0.2 591411 04 Gasket -1
82 Book No.
12.5 Valve block 12 CIP module
2316
Book No. 83
12.6 Air distribution, CIP

591688-
Quantity
1 569035 02 Flexible pipe, PA12, 10/7 1
2 569035 05 Flexible pipe, PA12, 8/6 1
3 569035 01 Flexible pipe, PA12, 6/4 1
5 558710 03 Nipple 1
6 558710 01 Nipple 1
7 552801 50 Push-on connector 6
9 583012 04 Throttle valve, 1/8 6
84 Book No.
12.6 Air distribution, CIP 12 CIP module
2375
Book No. 85
13 CIP liquid, 15 L
596250-
Quantity
A 596250 01 CIP liquid, 15 L 1
86 Book No.
13 CIP liquid, 15 L
2377
Book No. 87
14 Ancillary equipment
589744-
Quantity
1 589745 80 Sampling device 1 See page 90
2 589745 81 Sampling device 1 See page 90
3 590436 80 Pressure transmitter set 1 See page 92
4 590437 80 Pressure gauge set 1 See page 94
5 594536 80 Valve V403-35 1 DN50 PN10
See page 96
88 Book No.
14 Ancillary equipment
2377
Book No. 89
14.1 Sampling device

589745-
Ref Part No Description -80 -81 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, 17x30x3 16 16 BRB 17x30x3 fzb
7 591631 01 Blind flange, DN50/A50 1 1
8 591628 80 Valve, manual DN50 1 1
9 2210462 45 Screw, M16x45 8 8 M6S 16x45 fzb
14 591666 01 Rod 1 1
90 Book No.
14.1 Sampling device 14 Ancillary equipment
2371
Book No. 91
14.2 Pressure transmitter set

590436-
Quantity
1A 581006 04 Connector 1
4 1767267 01 Needle valve 1
7 1761834 05 Washer 1
92 Book No.
14.2 Pressure transmitter set 14 Ancillary equipment
2372
Book No. 93
14.3 Pressure gauge set

590437-
Quantity
1 543054 03 Pressure gauge 1
4 1779813 01 Valve, 1/4" 1
94 Book No.
14.3 Pressure gauge set 14 Ancillary equipment
2373
Book No. 95
14.4 Valve V403-35

594536-
Quantity
1 576886 13 Valve, DN50 1
2 576075 22 Air actuator, SR201 1
4 585976 01 Coil, 24 V DC 1
6 583012 01 Throttle valve, 1/4 2
7 594431 01 Bracket 1
96 Book No.
14.4 Valve V403-35 14 Ancillary equipment
2374
Book No. 97
15 Actuator spare part kit, DA/SR 301

576075-
Ref Part No Description -75 -71 -63 -61 Notes
Quantity
A 576075 61 Actuator spare part kit, DA/SR 201 -1
A 576075 71 Actuator spare part kit, DA/SR 101 1
98 Book No.
15 Actuator spare part kit, DA/SR 301
2443
Book No. 99
16 Cross reference list
+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
1270001 16 41 221803 34 90 5 26853 66 13

1270001 51 109 221891 02 26 14 27345 16 21
1761805 05 16 17 221891 03 20 10 27345 16 55
1761834 05 92 7 221891 04 6 8 27345 20 37
1765908 07 90 3 221891 04 8 16 27345 66 7
1767267 01 92 4 221891 04 8 21 27345 66 20
1779813 01 66 44 221891 04 8 32 27345 66 37
1779813 01 94 4 221891 05 20 7 27345 66 47
1779813 03 51 85 221891 05 20 21 27345 67 74
2210295 32 66 33 221891 05 8 7 27497 66 53
221030 10 24 32 221891 05 8 28 523127 08 70 4
221030 10 24 39 221891 05 8 34 526350 05 18 13
221030 43 26 4 221891 13 24 36 537086 02 18 24
221035 06 66 5 221891 13 34 6 540006 01 16 25
221035 36 66 32 223101 17 20 9 543054 03 94 1
2210462 10 16 12 223101 17 24 13 544465 02 34 10
2210462 30 90 4 223101 17 26 7 544465 04 8 35
2210462 45 90 9 223101 17 67 65 544465 06 16 40
221120 03 36 29 223101 35 16 4 552801 02 62 13
221701 02 26 12 223101 35 16 54 552801 02 62 15
221706 01 24 16 223101 37 16 13 552801 03 84 4
221711 08 16 31 223101 39 16 8 552801 50 84 7
221711 09 18 15 223101 41 26 13 554214 01 16 42
221711 16 26 20 223101 47 16 27 554515 05 34 9
221711 16 8 30 223101 47 20 17 558710 01 16 36
221711 17 20 28 223101 47 20 29 558710 01 84 6
221711 17 26 19 223101 47 24 22 558710 03 84 5
221711 17 66 43 223101 47 24 26 569035 01 84 3
221711 18 24 34 223101 47 24 40 569035 02 84 1
221711 18 66 39 223101 47 28 4 569035 05 62 14
221711 19 8 22 223101 47 28 8 569035 05 84 2
221716 02 67 71 223101 47 34 5 569038 05 66 54
221803 02 16 26 223101 47 36 4 576071 01 44 3
221803 02 20 18 223101 47 36 20 576071 01 46 3
221803 02 20 30 223101 47 6 46 576071 01 56 3
221803 02 24 23 223101 47 6 7 576071 01 58 3
221803 02 24 31 223101 47 66 15 576071 01 60 3
221803 02 26 21 223101 47 8 31 576071 01 96 3
221803 02 28 5 223101 73 24 38 576075 03 56 2
221803 02 28 9 223101 73 8 39 576075 03 58 2
221803 02 36 3 223101 97 67 64 576075 03 60 2
221803 02 36 21 223107 34 24 35 576075 03 62 2
221803 02 6 47 223107 34 26 5 576075 11 44 2
221803 02 66 14 223107 34 26 18 576075 21 46 2
221803 02 8 24 223107 34 8 15 576075 22 74 2
221803 03 24 12 223107 34 8 20 576075 22 96 2
221803 03 26 8 260001 40 16 7 576075 61 74 Z
221803 22 16 3 260137 04 6 65 576075 61 96 Z
221803 22 16 53 260154 08 8 26 576075 61 98 A
221803 29 18 6 26556 8 4 576075 63 56 Z0.1
100 Book No.

Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
576075 63 58 Z 580986 63 40 4 582212 98 36 24

576075 63 60 Z0.1 580986 64 40 1 582221 89 6 48
576075 63 62 Z 580986 76 6 18D 582221 90 6 37
576075 63 98 A 580986 79 6 18N 582356 08 20 32
576075 71 46 Z 581006 04 92 1A 582356 09 20 32.1
576075 71 98 A 581534 01 16 34 582632 01 24 9
576075 75 44 Z 581688 01 8 29 582633 01 24 10
576075 75 98 A 581804 01 28 3 583011 01 62 Z0.1
576091 01 56 4 581805 01 20 8 583012 01 44 6
576091 01 60 4 582089 81 50 67 583012 01 46 6
576438 06 74 1 582212 03 10 6 583012 01 56 7
576886 02 44 1 582212 04 12 7 583012 01 58 6
576886 04 62 1 582212 109 36 25 583012 01 60 7
576886 05 56 1 582212 15 6 38 583012 01 96 6
576886 05 58 1 582212 19 6 39 583012 04 84 9
576886 05 60 1 582212 24 12 8 583488 01 16 32
576886 13 96 1 582212 24 6 16 583556 08 6 27
576953 82 72 3 582212 24 28 10 583602 01 24 17
577113 01 62 3 582212 24 36 5 583608 01 24 14
577803 01 51 106 582212 24 42 8 583609 01 24 11
578074 03 72 1 582212 32 36 23 585345 11 64 1
579082 04 72 7 582212 50 42 14 585357 11 50 11
579367 95 18 Z0.1 582212 50 10 5 585357 15 50 12.1
579367 98 18 Z 582212 58 42 13 585357 21 50 17
579376 01 18 4 582212 60 10 4 585357 23 50 22
579379 01 18 19 582212 63 36 11 585357 23 51 ZA
579380 01 18 17 582212 63 42 7 585357 26 50 23
579385 01 8 9 582212 63 10 2 585357 26 51 ZB
579445 80 34 2 582212 64 36 10 585357 29 50 24
580759 04 16 39 582212 64 42 6 585357 29 51 ZC
580986 04 6 18E 582212 65 42 10 585357 31 50 25
580986 04 40 5 582212 65 10 3 585357 31 51 ZD
580986 08 6 18H 582212 67 10 1 585357 35 50 26
580986 08 6 18M 582212 72 6 19 585357 38 50 27
580986 09 40 7 582212 72 36 15 585357 40 50 29
580986 11 6 18G 582212 82 32 2 585357 40 51 ZE
580986 11 40 6 582212 83 32 1 585357 43 50 64
580986 16 6 18J 582212 84 32 3 585357 46 50 66
580986 16 40 9 582212 85 36 12 585357 47 50 66.1
580986 17 6 18A 582212 85 42 9 585357 69 50 15
580986 17 40 2 582212 85 10 7 585457 02 20 39AD
580986 30 6 18B 582212 88 6 21 585457 02 20 39BD
580986 32 6 18F 582212 89 6 22 585457 02 20 39CD
580986 33 6 18I 582212 90 6 24 585457 02 20 39DD
580986 40 40 8 582212 91 6 23 585457 02 20 39ED
580986 44 6 18K 582212 93 6 40 585457 02 20 39FD
580986 44 40 10 582212 94 36 7 585457 02 21 39GD
580986 55 6 18L 582212 95 12 5 585457 02 21 39HD
580986 58 6 18C 582212 96 12 6 585457 04 20 39AE
580986 62 40 3 582212 97 36 22 585457 04 20 39BE
Book No. 101

585457 04 20 39CE 590258 80 66 26 591134 80 36 14

585457 04 20 39DE 590259 80 66 30 591136 80 28 11
585457 04 20 39EE 590260 80 66 22 591319 01 34 7
585457 04 21 39FE 590261 80 66 31 591406 01 66 42
585457 04 21 39GE 590270 01 66 12 591410 80 66 27
585457 04 21 39HE 590313 01 66 50 591411 01 82 1
585976 01 44 4 590355 80 66 29 591411 02 82 Z
585976 01 46 4 590414 01 66 21 591411 03 82 Z0.1
585976 01 56 5 590424 01 66 11 591411 04 82 Z0.2
585976 01 58 4 590425 01 66 9 591411 80 66 38
585976 01 60 5 590436 80 88 3 591424 01 70 2
585976 01 96 4 590437 80 88 4 591425 01 70 3
586207 02 26 9 590476 01 66 49 591585 01 66 41
586207 02 26 23 590539 01 66 52 591628 80 90 8
586773 01 80 1 590539 02 67 62 591631 01 90 7
586773 02 80 Z 590544 01 66 40 591659 01 76 5
586773 03 80 Z0.1 590703 80 18 18 591662 80 90 1
586773 80 66 34 591076 01 16 30 591666 01 90 14
586773 80 66 35 591092 01 16 33 591667 01 90 2
586907 01 64 2 591097 80 16 2 591675 01 66 55
587040 02 54 1 591099 80 28 12 591688 80 66 51
587041 02 54 2 591102 01 36 6 591693 01 66 48
587276 02 16 56 591102 01 6 10 591792 80 20 11
587276 02 20 38 591103 01 30 1 591795 80 20 2
587276 02 8 6 591103 06 32 4 591797 80 20 4
587276 02 67 73 591103 08 42 3 591798 80 20 3
587276 02 8 33 591103 09 42 4 591852 80 24 15
587587 01 18 14 591103 10 42 5 591856 80 26 3
587927 07 56 14 591103 10 6 12 591862 01 26 6
587927 07 62 12 591103 12 6 11 591872 01 26 16
588228 01 18 16 591103 16 6 14 591873 01 26 10
588835 01 16 45 591103 16 38 1 591874 01 26 26
588996 80 76 7 591103 16 38 2 591877 01 26 24
588996 80 78 6 591103 16 38 3 591889 01 26 22
589076 01 18 5 591103 16 38 4 591892 01 34 3
589526 05 66 45 591103 17 6 15 591922 01 6 43
589526 06 66 18 591103 17 38 2.1 592002 01 20 27
589526 07 66 17 591103 17 38 3.1 592003 01 20 26
589745 80 88 1 591103 23 30 2 592004 01 28 2
589745 81 88 2 591103 28 42 2 592048 80 20 1
589774 01 18 12 591103 29 6 13 592280 80 18 1
590037 01 46 1 591103 31 6 51 592304 01 16 37
590207 80 66 1 591103 36 6 20 592304 02 16 38
590238 80 66 16 591103 37 6 20.1 592467 01 66 10
590241 80 70 5 591103 38 6 17 592532 01 18 7
590251 80 70 1 591103 38 36 9 592649 01 66 30A
590252 80 66 25 591103 39 6 67 592649 01 66 59
590253 80 66 24 591103 50 36 31 592653 01 66 8
590255 80 66 23 591131 80 36 8 592665 01 66 60
590256 80 66 28 591132 80 36 13 592676 01 67 67
102 Book No.

592676 02 67 68 594412 80 16 6 595670 80 6 4

592676 05 67 69 594413 80 16 9 595670 80 12 1
592676 06 67 70 594413 80 16 10 595673 01 6 52
592677 01 66 3 594413 80 16 11 595673 02 12 3
592684 01 18 9 594426 01 56 6 595673 03 14 2
592685 01 18 8 594426 01 58 5 595728 01 12 2
592760 01 66 4 594426 01 60 6 595728 01 14 1
592790 01 67 66 594426 01 96 5 595799 01 50 65
592823 01 16 23 594431 01 56 8 596250 01 86 A
592824 01 24 8 594431 01 58 7 596346 01 18 10
592827 01 16 20 594431 01 60 8 596594 01 21 39I
592926 02 26 25 594431 01 96 7 596594 02 21 39J
592926 04 20 31 594447 80 6 1 596594 03 21 39K
593233 01 24 7 594471 80 58 8 596594 04 21 39L
593239 01 24 30 594471 80 96 8 596600 80 20 39A
593239 01 8 25 594471 81 56 9 596804 04 24 41
593240 01 8 17 594471 82 60 9 596904 01 21 42
593243 01 24 21 594488 01 8 37 596905 01 20 39AC
593244 01 24 20 594536 80 88 5 596905 01 20 39BC
593245 01 24 19 594645 80 18 Z0.2 596905 01 20 39CC
593254 01 8 19 594646 80 18 Z0.3 596905 01 20 39DC
593263 01 20 19 594707 01 16 19 596905 01 20 39EC
593282 01 24 33 594728 01 36 16 596905 01 20 39FC
593282 01 8 23 594770 01 20 36 596905 01 21 39GC
593282 02 8 36 594774 80 6 25 596905 01 21 39HC
593573 01 26 11 594781 01 6 41 596905 02 20 22
593580 80 26 15 594785 01 16 28 596905 03 20 24
593710 01 8 2 594785 02 16 29 597035 01 14 3
593714 01 24 5 594939 01 62 4 597035 02 14 4
593715 01 24 6 595215 01 56 11 597049 01 16 18
593724 01 6 32 595215 01 60 11 597262 53 50 2
593724 02 36 28 595218 01 62 7 597263 03 50 3
593724 02 6 31 595219 01 62 6 597263 10 50 4
593781 01 8 12 595229 01 62 5 597263 24 50 4.1
593802 81 48 595229 01 64 5 597263 32 50 5
593888 01 34 4 595232 01 56 10 597263 36 50 6
593913 80 18 2 595232 01 60 10 597263 48 50 7
593915 80 16 1 595272 01 16 43 597263 60 50 8
593991 01 8 11 595302 01 16 24 597263 66 50 9
594009 01 8 3 595361 01 6 44 597263 73 50 10
594009 02 6 36 595390 01 16 48 597263 86 50 12
594009 02 6 42 595390 02 16 49 597263 93 50 13
594157 01 16 16 595433 80 20 39 597264 02 50 16
594169 01 16 15 595477 01 24 24 597264 11 50 48
594171 01 16 14 595541 01 62 8 597264 12 50 73
594306 02 18 24A 595541 02 62 Z0.2 597264 13 50 75
594405 80 51 100 595670 01 6 4A 597264 14 51 78
594410 01 44 5 595670 01 12 1A 597264 15 51 101
594410 01 46 5 595670 02 6 4B 597264 23 50 74
594412 80 16 5 595670 02 12 1B 597264 31 51 91
Book No. 103

Part No. Page Ref. Part No. Page Ref.
597264 32 51 93 597547 29 51 98
597264 33 51 94 597547 31 51 103
597264 38 50 14 597547 32 51 104
597264 61 50 68 597547 33 51 105
597264 66 50 69 597547 34 51 108
597298 83 51 Z 597547 38 50 39
597330 01 6 Z 597547 39 50 51
597331 01 6 Z0.1 597547 55 51 102
597361 01 20 39AA 599223 01 67 61
597361 01 20 39BA 599223 02 66 56
597361 01 20 39CA 599223 03 66 57
597361 01 20 39DA 66169 18 21
597361 01 20 39EA 70490 90 6
597361 01 20 39FA 70560 16 22
597361 01 21 39GA 70560 16 57
597361 01 21 39HA 70560 20 6
597428 02 20 39AB 70560 20 20
597428 02 20 39BB 70560 21 43
597428 02 20 39CB 70560 66 6
597428 02 20 39DB 70560 66 19
597428 02 20 39EB 70560 66 36
597428 02 20 39FB 70560 66 46
597428 02 21 39GB 70560 67 63
597428 02 21 39HB 70560 67 72
597547 01 50 18 70560 8 27
597547 02 50 19 70560 8 38
597547 03 50 35 956264 17 16 44
597547 04 50 36
597547 05 50 38
597547 07 50 40
597547 08 50 41
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104 Book No.

SVIB 53 840605028 PB-00317 v00 PB-750 OP

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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 2012

Book No. 9000479 02, rev. 0

Telephone: +46 8 530 650 00

Book No.9000479 02, rev. 0 5

The following basic safety instructions apply:

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

Book No.9000479 02, rev. 0 7

2.2 Warning signs used in the manual

8 Book No.9000479 02, rev. 0

Book No.9000479 02, rev. 0 9

Book No. 9000479 02, rev. 0

Telephone: +46 8 530 650 00

2.4 Stripping with eductor 17

3 System components description 19

3.3 CIP (cleaning in place) module 25

3.4 Flow meter 26

AOT Advanced oxidation technology

AOT module Complete component handling the purification. Includes AOT

Atex EU directive “Appareils destinés à être utilisés en ATmosphères

CIP Cleaning in place

CIP module Cleaning in place module. Performs the CIP cycle.

DIN Deutche Institut für Normung

EMC Electromagnetic compatibility

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

IP Integrated proportional (Regulation)

JIS Japanese Industrial Standard

LED Light emitting diode

LDC Lamp drive cabinet.

Book No.9000479 02, rev. 0 5

LDC module Complete component including mounting devices

LPS Lamp power supply

MCB Motor circuit breaker

PI Pressure indicator (pressure gauge)

PLC Programmable logical controller (PureBallast control system)

USB Universal serial bus (External data storage device)

VCD Voltage clipping device

1.2 System overview

1.3 Applicable directives and standards

PureBallast meets the following directives and standards:

6 Book No.9000479 02, rev. 0

Book No.9000479 02, rev. 0 7

1.4 Components overview

Example of layout with 4 AOT modules (flow capacity: 1000 m3/hour).

1. Filter bypass valve

8 Book No.9000479 02, rev. 0

1.4.1 Item numbers

Book No.9000479 02, rev. 0 9

In the flow chart illustrations, involved pipes are marked in bold.

Book No.9000479 02, rev. 0 11