026 System Manual

PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System

-
System Manual PureBallast 3.2 Ex PB-03626
System Manual
English
EN
1 PureBallast 3.2 System manual

The PureBallast 3.2 is available in several sizes, defined by the system’s max
treatment rated capacity (TRC). The TRC is included in the system name and
the title of each system manual.
The basic document describing the system is the connection list, and the
therein stated flow chart. Those documents are included in the system
manual, chapter 6, Installation description and drawings.
The tables in this document lists the PureBallast systems with reference to the
system manual describing them.
PureBallast system Manual no. Connection list Flow chart
PureBallast 3.2 250 Ex 200000859 9034715 9034859
PureBallast 3.2 300 Ex 200000861 9034716 9034859
PureBallast 3.2 500 Ex 200000863 9034717 9034859
PureBallast 3.2 600 Ex 200000865 9034718 9034859
PureBallast 3.2 750 Ex 200000867 9034719 9034859
PureBallast 3.2 1000 Ex 200000869 9034720 9034859
PureBallast 3.2 1200 Ex 200000871 9034721 9034860
PureBallast 3.2 1500 Ex 200000872 9034722 9034859
PureBallast 3.2 2000 Ex 200000874 9034723 9034860
PureBallast 3.2 3000 Ex 200000875 9034724 9034860

PureBallast 3.2 250 Ex HP 200000860 9034725 9034859

PureBallast 3.2 300/600 Ex 200001586 9048238 9034859
PureBallast 3.2 500/1000 Ex 200001496 9046734 9034859
PureBallast 3.2 750/1500 Ex 200001484 9046735 9034859
PureBallast 3.2 1000/2000 Ex 200001494 9046736 9034860
PureBallast 3.2 1500/3000 Ex 200001502 9046737 9034860
200000921-2-EN-GB 5
EN 1 PureBallast 3.2 System manual
Main component makers

Reference is made to the flow charts 9034859, 9034860 and 9034862.
Flow chart Component Manufacturer Model
legend Size according to Connection list
Filter:
Automatic self- Filtrex ACB-xx-yy, 20 µm mesh
cleaning filter
(xx=935 – 9200
yy= DN200 - DN600)
PT201–71 &
—72 Pressure sensor Barksdale 425X
UV reactor:
UV reactor AlfaWall UV reactor 300 Ex or,
UV reactor 600 Ex or,
UV reactor 1000 Ex or,
UV reactor 1500 Ex
UV lamp Alfa Laval Medium pressure UV lamp, 3 kW for UV reactor 170,
300 and 600
Medium pressure UV lamp, 6 kW for UV reactor 1000
and 1500
Lamp sleeve Alfa Laval Synthetic Quartz
QT201-50 UV sensor UV-TECHNIK, IL SUV 20.2 Y2 C 40° 1000 W/m² or,
Metronic Sensor-
technik GmbH SUV 20.2 Y2 C 40° 3000 W/m² for UV reactor 1000
and 1500
TS201-60 Temperature, JUMO Bimetal Temp. Switch 60.8301
switch
TT201-33 Thermometer, JUMO Dtrans T100 Screw-in RTD temperature probewithout
resistance transmitter 90.2815
LS201-29 & Vibration limit Endress+Hauser Liquiphant M FTL50
—30 switch
PEPPERL+FUCHS NCN3…, Inductive pos. sensor
Air Torque Spa or, AT range, Actuator
V201–19 & – VTORK VT range, Actuator
Valve
20 ARI Armaturen or, ARI –GESA, Lugged valve
Wouter Witzel or, EVTLS, Lugged valve
LK Valves 710701, 2, Lugged valve
Valves:
V201-8 Flow control Siemens SIPART PS2, Positioner
valve
Rotech ALB ACR1.., Pos. switch box
Air Torque Spa or, AT range, Actuator
VTORK VT range, Actuator
ARI Armaturen or, ARI –GESA, Lugged valve
6 200000921-2-EN-GB
PureBallast 3.2 System manual 1 EN

V201-3,-9, Filter inlet, out- - Rotech ALB ACR1.., Pos. switch box
-32 & let, by-pass, &
V403-35 Start up cooling
valve -Air Torque Spa or, AT range, Actuator
- VTORK VT range, Actuator
-ARI Armaturen or, ARI –GESA, Lugged valve
- Wouter Witzel or, EVTLS, Lugged valve
- LK Valves 710701, 2, Lugged valve

V309-1 Filter backflush Air Torque Spa or, AT range, Actuator
valve
ARI Armaturen ARI –GESA, Lugged valve
LK Valves 710701, 710702 Lugged valve
Flow meter:
FT201-1 Flow transmitter Endress+Hauser Promag 300W or,
Promag 300P
System pressure Transmitter:
PT201-16 Pressure trans- Barksdale 425X
mitter
Cleaning in Place (CIP) unit:
CIP cleaning Alfa Laval CIP Ex
module
CIP cleaning liq- Alfa Laval Alpacon Descalant Offshore
uid
Lamp Drive Cabinet:
Lamp Drive Alfa Laval LDC 3.2 Ex
Cabinet
Lamp Drive
Cabinet, secon- Alfa Laval LDCS 3.2 Ex
dary
Control Cabinet:
Control Cabinet Alfa Laval CC 3.2 Ex
Optional system components (Alfa Laval supply)

Booster pump:
Pump: Alfa Laval /
Ballast Water BBP-1 – BBP-5
P201-1 Framo
Booster Pump ACS880-01
VFD: ABB
Connectivity
Hardware for in- Alfa Laval
ternet of things
solution
200000921-2-EN-GB 7
EN 1 PureBallast 3.2 System manual

Log Box:
Connection box
to monitor addi-
tional valves Alfa Laval
and pumps
Optional system components (Other supply possible. Alfa Laval supply

is listed)
Booster pumps:
Centrifugal pump
Filter backflush Pump: Grundfos
P309-1 NB 40-125 – NB 65-125
pump Motor: ABB
M3JP 100LA 2 – 160MLA 2
LDC cooling Centrifugal pump

P401-1 Grundfos
pump CR 5-2
Centrifugal pump
Start-up cooling Pump: Grundfos
P403-1 NBG 50-32 – NBG 80-65
pump Motor: ABB
M3JP 90SLC 2 – 132SMD 2
Vaccum relief valves:
VB201 A.R.I K-060, DN80 – DN100
VB309 A.R.I K-060, DN50
BWTS bypass valve:
Rotech ALB ACR1.., Pos. switch box
Ar Torque Spa or, AT range, Actuator
V212-31 By-pass valve Rotork ILG-D series, Handwheel
ARI Armaturen ARI –GESA, Lugged valve
8 200000921-2-EN-GB
PureBallast 3.2 2000 Ex
System manual
Lit. Code 200000874-5-EN-GB
Published by
Alfa Laval Tumba AB
Hans Stahles väg 7
SE-147 80 Tumba, Sweden
+46 8 530 650 00
The original instructions are in English
© Alfa Laval Corporate AB 2020-05
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.
Contents
1 Safety............................................................................................................................... 9
1.1 Introduction..............................................................................................................10
1.2 Safety information....................................................................................................10
1.2.1 General safety information.........................................................................10
1.2.2 Specific safety information ........................................................................ 10
1.2.3 Personnel requirements.............................................................................13
1.2.4 Warning signs used in the manual............................................................. 13
1.3 Environmental issues ............................................................................................. 13
1.3.1 Unpacking.................................................................................................. 14
1.3.2 Other materials.......................................................................................... 14
2 System description................................................................................................ 15
2.1 Introduction..............................................................................................................16
2.1.1 Components overview............................................................................... 17
2.1.2 Item numbers............................................................................................. 19
2.1.3 Abbreviations............................................................................................. 19
2.2 Process overview.................................................................................................... 20
2.2.1 IMO and USCG mode................................................................................20
2.2.2 Flow control and power optimization..........................................................20
2.2.3 Start-up...................................................................................................... 23
2.2.4 Ballasting................................................................................................... 23
2.2.5 Deballasting............................................................................................... 25
2.2.6 Tank stripping.............................................................................................26
2.2.7 Ballast water handling in the event of malfunction.....................................27
2.3 System components description..............................................................................27
2.3.1 UV reactor..................................................................................................27
2.3.2 Filter .......................................................................................................... 29
2.3.3 CIP (cleaning-in-place) module..................................................................34
2.3.4 Cabinets and control system......................................................................35
2.3.5 Main valves................................................................................................ 40
2.3.6 Flow meter................................................................................................. 41
2.3.7 Pressure monitoring...................................................................................42
2.3.8 Sampling devices.......................................................................................42
2.3.9 Booster pumps (optional)...........................................................................42
2.3.10 Vacuum relief valves (optional).................................................................. 43
3 Operating instructions and control system description................. 45

3.1 Introduction..............................................................................................................46
3.1.1 Operational conditions............................................................................... 46
3.2 Introduction to the control system............................................................................50
3.2.1 Login levels................................................................................................ 50
3.2.2 Control of PureBallast................................................................................ 50
3.2.3 Overview of the screen.............................................................................. 52
3.3 Detailed page descriptions...................................................................................... 57
3.3.1 Page 1.1 – Overview..................................................................................57
3.3.2 Page 1.2 - UVR and flow selection............................................................ 61
3.3.3 Page 1.3 – CIP status................................................................................ 63
3.3.4 Page 1.4 – Power request......................................................................... 65
3.3.5 Page 2.1 – Alarm list..................................................................................68
3.3.6 Page 2.2 – Alarm history............................................................................70
3.3.7 Page 3.1 – Trend (15 min)......................................................................... 71
3.3.8 Page 3.2 - Trend (1 h)................................................................................73
3.3.9 Page 3.3 – Trend (1 h) - TT201-33............................................................ 73
3.3.10 Page 3.4 – Trend (1 h) - TT401-2.............................................................. 73
3.3.11 Page 3.5 – Trend (1 h) - Power optimization............................................. 73
3.3.12 Page 3.7 – Trend (15 min) - External feed control..................................... 74
3.3.13 Page 3.8 – UV optimization....................................................................... 75
3.3.14 Page 4.1 – System info..............................................................................76
3.3.15 Page 4.2 – PLC controller I/O.................................................................... 78
3.3.16 Page 4.3 – Operation timers...................................................................... 79
3.3.17 Page 4.4 – Operation timers UVR............................................................. 80
3.3.18 Page 4.5 – Remote interface 1.................................................................. 81
3.3.19 Page 4.6 – Remote interface 2.................................................................. 81
3.3.20 Page 4.7 – Log box....................................................................................83
3.3.21 Page 4.9 – LPS overview...........................................................................84
3.3.22 Page 5.1–5.7 – Parameter pages.............................................................. 86
3.4 Popup windows....................................................................................................... 87
3.4.1 UVR popup ............................................................................................... 87
3.4.2 Filter popup ............................................................................................... 92
3.5 Operating instructions..............................................................................................93
3.5.1 Log in......................................................................................................... 94
3.5.2 Prepare operation...................................................................................... 95
3.5.3 Perform ballast...........................................................................................96
3.5.4 Perform deballast.......................................................................................97
3.5.5 Perform tank stripping................................................................................98
3.5.6 Pause ballast / deballast / stripping........................................................... 99
3.5.7 Heeling (internal transfer)........................................................................ 100
3.5.8 Change ballast / deballast / stripping flow................................................101
3.5.9 Start ballast / deballast / stripping with specified UV reactor................... 102
3.5.10 Backflush filter manually.......................................................................... 102
3.5.11 CIP clean UV reactor after ballast / deballast / stripping..........................104
3.5.12 Drain UV reactor...................................................................................... 104
3.5.13 Attend to alarms.......................................................................................105
3.5.14 Shut down and deactivate system........................................................... 106
3.5.15 Operate components manually................................................................ 108
3.5.16 Operate UV lamps manually.................................................................... 110
3.5.17 Set ship specific component ID................................................................112
3.5.18 Export control system event log files........................................................112
3.5.19 Backup control system settings................................................................114
3.5.20 Restore control system settings............................................................... 115
3.5.21 Set control panel IP address.................................................................... 115
3.5.22 Set remote control panel communication.................................................116
3.5.23 Set remote interface communication........................................................118
3.5.24 Test remote interface communication...................................................... 118
3.5.25 Simulate power request........................................................................... 120
3.5.26 Update control system softwares.............................................................121
3.5.27 Calibrate the control panel’s touch screen sensibility.............................. 121
3.5.28 Fine tune flow and pressure control ........................................................121
3.6 List of logged information...................................................................................... 126
3.6.1 Event log.................................................................................................. 126
3.7 Detailed process description................................................................................. 129
3.7.1 Standby mode..........................................................................................130
3.7.2 Ballast process.........................................................................................131
3.7.3 Deballast process.................................................................................... 139
3.7.4 Stripping process..................................................................................... 146
3.7.5 CIP process............................................................................................. 152
3.7.6 Manual mode........................................................................................... 157
3.8 Quick guide............................................................................................................158
3.8.1 Introduction.............................................................................................. 158
3.8.2 Ballast, deballast or strip..........................................................................158
3.8.3 Alarm handling......................................................................................... 159
3.8.4 CIP clean UVR.........................................................................................159
3.8.5 Export control system log files................................................................. 159
4 Parameters............................................................................................................... 161
4.1 Introduction............................................................................................................162
4.2 Control system parameters................................................................................... 162
4.2.1 Introduction to parameters and parameter settings................................. 162
4.2.2 Page 5.1 — Main parameters 1............................................................... 164
4.2.3 Page 5.2 — Main parameters 2............................................................... 167
4.2.4 Page 5.3 — UVR parameters.................................................................. 171
4.2.5 Page 5.4 — Filter parameters..................................................................173
4.2.6 Page 5.5 — CIP parameters....................................................................176
4.2.7 Page 5.7 — Remote interface..................................................................177
4.2.8 Page 5.6 — Installation parameters.........................................................179
4.3 Lamp power supply (LPS) parameters.................................................................. 182
4.3.1 DIP switch settings...................................................................................182
4.4 Fuse settings for filter motor and installed (optional) pump motors.......................184
4.5 Conductivity sensor parameters............................................................................ 184
4.6 Flow transmitter parameters..................................................................................184
5 Alarms and faultfinding..................................................................................... 185

5.1 Introduction............................................................................................................186
5.2 List of alarms and warnings...................................................................................186
5.2.1 Control system......................................................................................... 186
5.2.2 Lamp power supply (LPS)........................................................................217
5.2.3 Flow meter............................................................................................... 217
5.2.4 Level switch............................................................................................. 220
5.2.5 I/O system and X20 modules...................................................................221
5.3 List of problems and solutions...............................................................................227
5.3.1 General problems.................................................................................... 227
5.3.2 Filter......................................................................................................... 229
5.3.3 CIP........................................................................................................... 230
5.3.4 Valve V201–8...........................................................................................231
5.3.5 P201–1 (optional).....................................................................................232
6 Technical data and drawings........................................................................ 233

6.1 Introduction............................................................................................................234
6.1.1 Ship specific information.......................................................................... 234
6.2 Technical data........................................................................................................234
6.2.1 Flow requirements................................................................................... 234
6.2.2 Water requirements..................................................................................235
6.2.3 Power requirements.................................................................................236
6.2.4 System pressure...................................................................................... 236
6.2.5 Pressure requirements for filter backflush............................................... 237
6.3 Ex protection..........................................................................................................237
6.3.1 Ex components........................................................................................ 238
6.3.2 Safety control system...............................................................................240
6.4 Control system integration.....................................................................................242
6.5 Drawings................................................................................................................242
6.5.1 Graphic symbols used in drawings.......................................................... 243
6.5.2 General drawings.....................................................................................244
6.5.3 Dimension drawings.................................................................................270
6.5.4 Electrical drawings................................................................................... 308
6.5.5 Intrinsically safe circuits........................................................................... 389
6.5.6 Saftey Data Sheets.................................................................................. 400
7 Service manual .....................................................................................................421

7.1 Introduction............................................................................................................422
7.1.1 Preparations and conditions.................................................................... 422
7.1.2 Welding requirements.............................................................................. 423
7.1.3 Tightening torques................................................................................... 423
7.2 Maintenance schedule.......................................................................................... 425
7.2.1 Calibration schedule................................................................................ 427
7.2.2 Recommended spare parts on board...................................................... 432
7.2.3 Serial number information........................................................................433
7.3 UV reactor............................................................................................................. 437
7.3.1 Safety information.................................................................................... 438
7.3.2 Replace UV lamp..................................................................................... 440
7.3.3 Replace quartz sleeve............................................................................. 443
7.3.4 Replace lamp power supply (LPS)...........................................................445
7.3.5 Test lamp power supply (LPS) installation............................................... 447
7.3.6 Level switch............................................................................................. 447
7.3.7 Replace UV sensor.................................................................................. 449
7.3.8 Temperature switch and temperature transmitter.................................... 449
7.4 Filter.......................................................................................................................451
7.4.1 Remove filter cover and filter element..................................................... 452
7.4.2 Mount filter element and filter cover.........................................................455
7.4.3 Clean filter element and pre-filter.............................................................455
7.5 CIP ........................................................................................................................458
7.5.1 Change and refill CIP liquid..................................................................... 458
7.5.2 Pump........................................................................................................460
7.5.3 Valve block and junction box....................................................................463
7.6 Ballast water booster pump P201–1 (optional)..................................................... 465
7.7 Valves.................................................................................................................... 466
7.7.1 Preparations and conditions.................................................................... 467
7.7.2 Operate valves manually......................................................................... 468
7.7.3 Open and close valves manually (CIP valves).........................................468
7.7.4 Open and close valves manually............................................................. 468
7.7.5 Lock valve in closed position................................................................... 469
7.7.6 Unlock valve.............................................................................................470
7.7.7 Dismount actuator....................................................................................471
7.7.8 Mount actuator......................................................................................... 471
7.7.9 Adjust valve end position ........................................................................ 473
7.7.10 Calibrate positioner on V201-8................................................................ 474
7.7.11 Adjust cam position on V201-8................................................................ 476
7.7.12 Change direction of actuator – without position sensor (V404–36,
V320–4 and V321–2)............................................................................... 477
7.7.13 Change direction of actuator – with position sensor (201-19 and 201–
20)............................................................................................................478
7.7.14 Change direction of actuator – with switch box (V201–3, V201–9,
V201–32, V212–31 and V403–35)...........................................................480
7.7.15 Change direction of actuator – with positioner (201–8)........................... 481
7.7.16 Mount pilot valve on actuator .................................................................. 481
7.7.17 Adjust valve traveling speed ................................................................... 482
7.8 Flow meter.............................................................................................................484
7.8.1 Backing up the data ................................................................................ 484
7.8.2 Replace display module...........................................................................484
7.8.3 Replace the memory card (T-DAT).......................................................... 486
7.8.4 Replace module carrier............................................................................486
7.9 Control panel......................................................................................................... 488
7.9.1 Clean control panel.................................................................................. 488
7.9.2 Replace control panel.............................................................................. 488
7.10 Remote control panel (optional)............................................................................ 489
7.10.1 Mount and connect remote control panel ................................................489
7.11 Control cabinet and lamp drive cabinet (LDC)...................................................... 490
7.11.1 Disassemble and assemble I/O system...................................................490
7.11.2 Cable gland installation – General cables................................................491
7.11.3 Cable gland installation – Power cable to LDC........................................493
7.11.4 Power cable check...................................................................................494
7.11.5 Install IFS confstick in safety relay KS1 in LDC....................................... 494
8 Revision history..................................................................................................... 497
9 SPC............................................................................................................................... 499
EN
1 Safety
Safety
200000874-5-EN-GB 9
EN 1 Safety
1.1 Introduction
This chapter contains general safety and environmental information, personnel
requirements and explanations of symbols used for the PureBallast system.
1.2 Safety information

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

The following general safety information apply:
• Use the equipment only for the purpose and parameter range specified by
Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Always read and follow the documentation that is included in shipment of
components and spare parts regarding handling, safety and disposal.
• Mobile cell phones must not be switched on within an area of 1 meter from
an open cabinet door.
• Before installation, read applicable sections Technical data and drawings
on page 233 and in the Design and installation guidelines.
• Before operation, read the section Operational conditions for applicable
Safety
instructions in Operating instructions and control system description on
page 45.
1.2.2 Specific safety information

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

• Before maintenance, read the Preparations and conditions section for
applicable instructions in Service manual on page 421. Essential safety
information is stated before instruction to routines that might involve any
danger.
• Before maintaining the PureBallast system, the following valves must be
locked in closed position: V201-3 and V201-8.
• Components must be lifted using correct lifting tools (such as a fork-lift
truck, a crane) and tackle with a load capacity greater than the weight of
the component. See the section PureBallast components in Introduction on
page 234 for information about approximate weight. Complementary lifting
instructions in the Design and installation guidelines must be followed.
• Always disconnect the PureBallast system from the power supply before
disassembling, and secure it from being switched on.
10 200000874-5-EN-GB
Safety 1 EN
UV reactor safety items

• 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. See Material data sheet / UV lamp in chapter 6.
• UV lamps are stored according to local regulations.
• Before installation, check that the UV lamps and quartz sleeves are not
broken.
• Depressurize reactors and allow equipment to cool down completely before
disassembling.
• Never handle UV lamps before they are completely cooled down. A hot UV
lamp is under high internal pressure, and the risk of bursting exists. A hot
lamp could also cause a burn if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp
when correctly installed inside the reactor with end caps properly closed.
• UV lamps contain a small amount of mercury (less than 0.2 grams per
lamp) and must be handled and disposed of with care. Used UV lamps 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,
Safety
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.
• Operation and/or manual start of the UV lamps is only allowed when there
is water in the reactor (indicated by level switch LS201-29 and LS201-30),
and the water temperature is below 60 °C.
Improper operation could seriously damage the equipment and injure
personnel.
• Manual operation of LPS, may only be performed after cable connection. If
not hazardous situation may arise which, if not avoided, will result in death
or serious injury.
• Before maintenance of the LDC: Switch off the PureBallast system and
disconnect it from the power supply. See section Shut down and deactivate
system on page 106. The cabinet contain a fan, which can cause injury if in
operation.
200000874-5-EN-GB 11
EN 1 Safety
Filter safety items

• CIP liquid agent; Alpacon descalant offshore, may be used as cleaning
agent. Follow rules when handling CIP liquid agent, regarding ventilation,
personal protection etc. See Safety data sheet / CIP liquid on page 400.
CIP safety items

• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear
protective gloves and goggles. Follow rules when handling CIP liquid agent,
regarding ventilation, personal protection etc.
• If CIP liquid; Alpacon descalant offshore, comes in contact with eyes or
skin, rinse thoroughly with cold water.
• See Safety data sheet / CIP liquid on page 400
• Always wear protective eye glasses and gloves while working on the pump.
Pump
• CIP pump: Always wear protective eye glasses and gloves while working
on the pump.
Flow meter safety items

• Make sure that the power supply is switched off, before the cover of the
electronics compartment are removed. Risk of electric shock! Exposed
components carry dangerous voltages .
Safety
Valve safety items
• Lock valve in closed position before maintenance.
• Actuators must not be pressurized at any time during installation as it may
result in injury.
• Do not remove end caps or disassemble the actuator while the actuator is
pressurized.
• Do not disassemble individual spring elements. Disassembly may result in
personal injury.
• Valve block: Always disconnect the PureBallast system from the power and
air supply before disassembling, and secure it from being switched on.
Ancillary component safety items

• Control panels may only be cleaned when set in wipe mode. This is to
prevent unintended functions from being triggered by buttons pressed
during cleaning.
• Temperature switch, temperature transmitter and level switch: The external
surface may be hot. Care must be taken to avoid possible burns.
Protective earth
• Components e.g. UVR, filter, CIP module, flow meter, cabinets and remote
control panel (optional) must be earthed. The earth nut is indicated as “791”
or “PE bolt” in the dimension drawings.
12 200000874-5-EN-GB
Safety 1 EN
1.2.3 Personnel requirements

The PureBallast system must be installed, operated, maintained and repaired
by persons trained and authorized for their respective type of work.
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.
The person must have knowledge or sufficient experience to perform the tasks
at hand. The person must be able to perceive risks and to avoid hazards
which electricity/mechanics can create. The person must have knowledge
about the specific Ex standard used to eliminate the risk of explosion, for
example IEC 60079 series.
In some cases special skilled personnel may need to be appointed for the job,
e.g. 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.
The person must have sufficient knowledge about the specific Ex standard
used to eliminate the risk of explosion, for example IEC 60079 series.
1.2.4 Warning signs used in the manual
DANGER
DANGER: indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Safety
WARNING
WARNING: indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
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.
1.3 Environmental issues

This section contains general rules regarding environmental issues. However,
local rules and regulations should be consulted for detailed handling of each
material.
200000874-5-EN-GB 13
EN 1 Safety
1.3.1 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.
1.3.2 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
Safety
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.
14 200000874-5-EN-GB
EN
2 System description
200000874-5-EN-GB 15
EN 2 System description
2.1 Introduction
This contains general information about the PureBallast system and its
components.
16 200000874-5-EN-GB
System description 2 EN
2.1.1 Components overview

The key components in PureBallast are shown below.
Example of layout with 1 UV reactor.

1. Control cabinet
2. Lamp drive cabinet (LDC)
3. CIP (cleaning-in-place) module
4. UV reactor
5. Ballast water outlet
6. Control valve
7. Flow meter with conductivity sensor
8. Sampling point
9. Filter
10. Ballast water inlet
Not in illustration:
• System bypass valve
• Pressure monitoring device
• Check valve before UV reactor
System overview
The PureBallast system is an integral part of the vessel’s ballast water system,
on the discharge side of the vessel’s ballast water pumps. During ballast
operation, the water is led through the filter, which removes larger particles
and organisms, and then to the UV reactor, where the water is treated with UV
light. During deballast, the water is led the same way, but the filter is
bypassed.
The UV lamps are powered by the LDC (via LPSs, lamp power supplies).
Every UV reactor has one dedicated LDC.
200000874-5-EN-GB 17
Flow is monitored by the flow meter and regulated by the control valve. Note
that full treatment requires treatment both during ballast and deballast.
The UV reactors are cleaned using the CIP (cleaning-in-place) module, which
first rinse the UV reactor with technical water / potable water, and then
circulates CIP liquid through the UV reactor. At the end of the process the UV
reactor and the filter (filter preservation) is filled with technical water / potable
water from the CIP.
The complete system and ongoing processes is controlled and monitored from
the control cabinet.
Control can also be performed from remote control panels and the ship’s
ISCS, via the remote interface if connected.
The bypass valve* makes it possible to bypass the entire system, for example
to secure ballast operation if the system is not functioning. The valve is
controlled from the ISCS (integrated ship control system).
* Optional as part of scope of supply.
Ex
PureBallast Ex is an explosion-proof version of the PureBallast water
treatment system. The version use Ex certified equipment and a redundant
safety control system to allow installation on board most types of vessels that
carry potentially flammable or explosive substances.
PureBallast Ex is approved for use in hazardous areas defined as zone 1,
explosion group IIC and temperature class T4 (135°) according to the IEC
60079 series of standards. It fulfills the European Directive ATEX 2014/34/EU,
recommended by the IMO for use in marine applications and on the
international market.
PureBallast Ex requires the following:
• The PureBallast Ex version must be installed. This version is equipped with
components certified according to the Atex regulations to be used in
potentially explosive atmospheres.
• The system must be installed, operated and maintained according to a
selected standard used to eliminate the risk of explosion. There are several
standards to be used, for example the European standard IEC 60079-14.
The main features of PureBallasts Ex version are:
• Ex specific components are used in zone 1. See chapter 6. Installation
description and drawings, section Ex protection.
• An Ex specific version of the control system is used to operate and monitor
the system.
• A safety control system supplements the control system. It is designed for
the specific task of securing that the UV reactor is not overheated. All
functions in the safety control system uses redundancy to ensure one fault
tolerance. See chapter 6. Installation description and drawings, section Ex
protection.
18 200000874-5-EN-GB
Marking plate
2.1.2 Item numbers

System components are identified by unique item numbers, for example
“FIT201-1” for the flow transmitter installed before the UV reactor.
2.1.3 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
Previous name for UV reactor. AOT stands for Advanced oxidation
AOT reactor technology.
EU directive “Appareils destinés à être utilisés en ATmosphères
Atex EXplosivles”
CIP Cleaning in place
CIP module Cleaning in place module. Performs the CIP process.
DIN Deutche Institut für Normung
Standard according to CEN (European Committee for Standardiza-
EN tion).
Ex Explosion-proof
I/O Input/output (Describes a program or device handling data)
IACS International Association of Classification Societies
IECEx International Electrotechnical Commission Explosive
ISCS Integrated ship control system
IMO International Maritime Organization
JIS Japanese Industrial Standard
LED Light emitting diode
LDC Lamp drive cabinet.
LPS Lamp power supply
MCB Motor circuit breaker
PLC Programmable logical controller (PureBallast control system)
PSU Practical Salinity Unit
USCG United states coast guard
UV Ultra violet
UV reactor The main component, where the water is treated using UV light.
UVR UV reactor
200000874-5-EN-GB 19
2.2 Process overview

This section gives an overview of the main processes performed by
PureBallast. In the flow chart illustrations, involved pipes are marked in bold.
2.2.1 IMO and USCG mode

The PureBallast has two process modes: IMO mode and USCG mode. These
different modes set the system to run to be compliant with regulations in USA
(USCG mode) or the rest of the world (IMO mode).
USCG mode can be run with a 3 days or 0 day hold-time.
Fore more information about conditions, see section Operational conditions on
page 46.
2.2.2 Flow control and power optimization

To ensure full treatment of the water, allowed flow and power to the lamps are
controlled depending on how clean the water is. Clean water (high UV
intensity) allows high flow and low lamp power, and dirty water requires lower
flow and higher lamp power to treat the water according to requirements.
During ballast the flow is also limited by the maximum capacity of the used
filter and the actual allowed flow is determined by whichever is smaller; filter
capacity or UV reactor capacity as described in following paragraphs.
IMO mode
Treating fresh water (salinity ≤1 PSU) requires a different power optimization
and flow control to be efficient. Therefore, the power optimization and flow
control differs when fresh water is treated compared to brackish and marine
water. When fresh water is treated, this is indicated by an “FW” in the
subprocess field in page Page 1.1 – Overview on page 57.
Salinity is calculated by the control system based on input from the
conductivity sensor (QIT201-51) and temperature transmitter (TT201-33).
The illustration below show flow control and power optimization depending on
the UV intensity and salinity, together with the compliant limit.
Fresh water
20 200000874-5-EN-GB
Brackish and marine water
200000874-5-EN-GB 21
USCG mode
Compliant limit: When UVI falls below compliant limit, the operation
continues but does not fulfill the type approval certificate. A warning and a
common alarm is issued and a log is written to the event log. The operator
must take action according to the ballast water plan to stop the operation or to
continue operation and not comply with type approval certificate.
2.2.2.1 Flow control

When treating fresh water, the flow is regulated to be as high as possible to
fully treat the water. Between UVI value a and b, the flow is regulated be
between 50 % and 100 % of full flow capacity. The higher UVI value (cleaner
water) the higher flow.
When treating brackish and marine water above complaint limit, the flow is
always 100 % of full flow capacity. But when UVI falls below the compliant
limit, the flow is decreased to maximum 50 %.
2.2.2.2 Power optimization

The purpose is to save power by dimming the lamps to minimum power
required to fully treat the water. Power is regulated when the UVI in the water
is over c (see graph above). The power output is regulated between 50 % and
100 % of full power.
2.2.2.3 Power optimization during special conditions

• Start-up and the first two minutes of ballast/deballast: The UV lamps are lit
to 100 % to ensure treatment before values from the UV sensor are stable.
• Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for two
minutes when process is resumed.
• Stop: UV lamps are lit to 100 % for 10 seconds before they are stopped.
This will prolong the life of the lamps
22 200000874-5-EN-GB
• Stripping: The lamps are lit to 100 % during the complete stripping process.
This to have an efficient treatment of the deballast water when it is mixed
with the driving water, which has not been treated at ballast.
• Low UV intensity: See Flow control above.
• Broken UV lamp: See Operation with broken UV lamp below.
2.2.2.4 Operation with broken UV lamp

If a UV lamp breaks during operation, the ongoing process continues but is not
compliant. A warning and an additional common alarm is issued and a log is
written to the event log. The operator should act according to the ballast water
management plan. After process is finished, it will not be possible to start a
new process until the broken lamp has been changed.
The flow is decreased to 80 % in IMO mode or 50 % in USCG mode of max

flow and the UV lamps are lit to 100 %. This is done so that the treatment shall
correspond to the type approval requirements.
If a lamp breaks in standby mode, it is not possible to start a process.
2.2.3 Start-up
Ballasting and deballasting begins with a start-up phase. There must be
available power for the system. If power management is integrated, this will be
confirmed automatically. If power management is not integrated, this is
confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is
pumped through the UV reactor to secure that the UV lamps are not
overheated. The temperature transmitter and level switch secure that there is
water in the UV reactor and that the UV lamps are sufficiently cooled. If not, an
alarm is issued and the system is shut down.
Ballast and deballast start-up
2.2.4 Ballasting
After the start-up, when the lamps are ready, the operator is requested to start
the ballast pump. The ballast water is pumped from the sea chest to the filter,
that removes larger particles and organisms. This also reduces the amount of
200000874-5-EN-GB 23
sediment build-up in the ballast water tanks. The organisms and sediments
caught in the filter are flushed overboard via regular filter backflush operations.
The water is finally led to the UV reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.
Ballasting
2.2.4.1 Backflush
To keep the filter clean, it is automatically backflushed. The backflush is
performed during ongoing process without interrupting the ballasting process.
When a ballast operation is stopped, a backflush is performed before the
system comes to a full stop. The ballast water used for backflushing is
returned to the sea directly at the ballasting site.
Filter backflush
2.2.4.2 Ballast after-treatment (CIP process)

After a ballast operation, a CIP (cleaning-in-place) process is performed to
clean the UV reactor. This process can either be performed immediately after
a ballast operation or started within 30 hours counted from when the process
was started. Note, that it is possible to perform new processes during these 30
hours.
24 200000874-5-EN-GB
We recommend that a CIP process is performed in the same location as the

ballast operation was done. If not possible, in international waters (200
nautical miles from the baseline). This due to risk of untreated or not fully
treated water remaining in reactor/filter.
The UV reactors are cleaned one at a time. The first UV reactor is rinsed with
technical water / potable water. Then the cleaning-in-place (CIP) module
circulates a biodegradable solution through the UV reactor to remove
seawater scaling. After the cleaning is finished, the UV reactor is filled with
technical water / potable water to preserve the UV reactor and prevent scaling,
algae growth etc. Then the system continues with the same procedure for the
next UV reactor. Finally, the filter is filled with technical water / potable water to
prevent scaling and algea growth. The cleaning liquid is reused between the
cleaning operations.
CIP circulation during CIP process
2.2.5 Deballasting
the ballast pump. The water passes through the UV reactor, but the filter is
bypassed since the water has already been filtered during ballasting. The
reason for treating the water a second time during deballasting is to secure
that the treatment is fully effective. The minor part of the organisms, which
were only injured during ballast, will be rendered totally harmless during the
deballast.
The flow control and power optimization functions in the same way as during
ballasting.
200000874-5-EN-GB 25
Deballasting
2.2.5.1 Deballast after-treatment (CIP process)

After deballast operation, a cleaning cycle is performed to clean the UV
reactor. It is performed in the same way as described for the ballasting
process. If only deballast operations has been performed since the last CIP
process, the filter does not need to befilled with technical water / potable water
at the end of the CIP cycle, since the filter has not been used.
2.2.6 Tank stripping

Stripping can be performed to empty the ballast tanks. A stripping process is
similar to a deballast process; in both processes the filter is bypassed.
a stripping pump. Pump used can either be a dedicated stripping pump or a
ballast water pump. Power optimization is not active. Minimum flow includes
the driving water.Number of UV reactors used during stripping is set in a
parameter, to adapt to lower flow during stripping.
Stripping
2.2.6.1 Stripping after-treatment (CIP process)
26 200000874-5-EN-GB
After stripping operation, a cleaning cycle is performed to clean the UV

reactor. It is performed in the same way as described for the ballasting
process. If only stripping operations has been performed since the last CIP
process, the filter does not need to be be filled with technical water / potable
water at the end of the CIP cycle, since the filter has not been used.
2.2.7 Ballast water handling in the event of malfunction

PureBallast is equipped with a bypass valve. The valve can be used in case of
emergency to secure the ship, by allowing ballast water operations (ballast,
deballast and heeling) without involving the ballast water treatment system.
The valve is controlled by the ISCS, not PureBallast’s control system, but all
bypass 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.
The procedures concerning emergency and malfunction of the ballast water
treatment system should be implemented in the ships Ballast water
management plan.
2.3 System components description

This section gives an introduction to the most important PureBallast system
components and their functions in the system.
2.3.1 UV reactor
The main part of PureBallast is the UV reactor in combination with a lamp
drive cabinet (LDC) giving power to the UV lamps in the UV reactor. The LDC
does not need to be placed in close relation to the UV reactor.
2.3.1.1 UV reactor working principle

The main treatment process take place inside the UV reactor, where the
micoro organisms in the water is exposed to UV light, which renders them
completely harmless.
The UV light breaks the DNA chain resulting in an internal connection (T+T)
making it impossible for the micro organisms to reproduce.
Destruction of DNA
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
200000874-5-EN-GB 27
environmental impact and the process does not influence corrosion in any
way.
2.3.1.2 UV reactor description

The UV reactor consist of the reactor, sensors and valves for water and CIP
liquid, as shown in the illustration below. The UV reactor accommodates 16
medium-pressure UV lamps (6 kW each).
The lamps are powered from the lamp drive cabinet (LDC).
The UV lamps are enclosed in individual quartz-glass sleeves.
To secure that there is water in the UV reactor when the lamps are lit, the
system is equipped with a check valve before the inlet valve, and each UV
reactor is equipped with double water level switches. The level switches also
secures that enough CIP liquid is pumped to the UV reactor during the CIP
cleaning process. To secure that the lamps are adequately cooled by the
ballast water, each UV reactor has a threefold heat protection:
Level 1: The temperature transmitter sends information to the control system.
The UV reactor is shut down at 60 °C.
Level 2: The temperature transmitter sends information to a safety relay in the
LDC. The UV reactor is shut down at 62.5 °C.
Level 3: The temperature switch automatically shuts down the UV reactor at
65 °C.
A UV sensor monitors the UV lamp efficiency in relation to the water
transmittance inside the UV reactor. Based on this input, the power to the UV
lamps are regulated between 50 and 100 % of full capacity. To save power, the
UV lamps will be dimmed to lowest possible level, where they are still
effective.
Note:The lamps are always lit with full effect during start-up and the first two
minutes of full ballast to secure full efficiency independent of transmittance.
The lamps are also turned up to full effect for 10 seconds before stop and
normal shut down. This method will prolong the UV lamp life time
The illustration below show the main components for the UV reactor.
28 200000874-5-EN-GB
UV reactor
1. Ballast water outlet valve
2. CIP liquid outlet valve (actuator indicated)
3. Temperature transmitter (Temperature switch not visible)
4. Junction box (signal cables)
5. UV lamp cap (UV lamp and quartz sleeve inside)
6. Inlet valve from CIP module and reactor drain valve (actuator indicated)
7. Ballast water inlet valve
8. UV sensor
9. Level switch
10. Cooling water outlet valve
11. Level switch
2.3.2 Filter
2.3.2.1 Filter working principle
The filter is a fully automatic self-rinsing component, equipped with a filter
element to remove particles and organisms from the ballast water flow. The
ballast water is lead through the filter, and filtered particles are trapped in the
filter.
An optional backflush pump can be mounted to secure correct flow in the
backflush pipe 309.
The filter is entirely controlled from the PureBallast control system.
200000874-5-EN-GB 29
2.3.2.2 Filter description
1. Geared motor
2. Relief valve
3. Backlflush outlet
4. Backflush pump
5. Drain plug
6. Ballast water inlet
7. Adaptor plate to change flange standard and/or diameter (in some systems)
8. Junction box (Not included in the skid version of PureBallast)
9. Ballast water outlet
To secure efficient filtration, the filter performs a self-rinsing backflush
operation at time set intervals or when triggered by indication of dirt in the
filter. Pressure drop over the filter is monitored by pressure transmitters on the
filter inlet and outlet. Dirt is detected by an increased differential pressure drop
caused by particles in the filter. When the differential pressure reaches a
parameter set value, an automatic backflush operation starts.
The backflushing does not interrupt the filtration process, since only a part of
the filter element area is cleaned. The areas that are not cleaned at a specific
time continues the filtration of the ballast water. It is also possible to start
backflush manually from the control system.
30 200000874-5-EN-GB
Step 1: Filtration
The water enters from the inlet flange (A)

and flows through a pre-filter and then
through the filter element (1) from the in-
side to the outside. The filtered dirt is
trapped on the inside of the filter element.
The filtered water passes the chamber
(D) and out from the filter through the out-
let flange (B) and is lead to the UV reac-
tor.
During filtration, the filter operates as a
static filter, there are no moving parts and
the motor (2) is not running and the noz-
zle (3) is standing still.
A. Inlet
B. Outlet
D. Chamber
1. Filter element
2. Motor
3. Nozzle (standing still during filtration)
200000874-5-EN-GB 31
Step 2: Backflush
At backflush, the motor (2) starts to
drives the nozzle (3). At the same time,
the backflush valve (6) opens.
The nozzle rotates inside the filter ele-
ment. The dirt on the inside of the filter el-
ement (1) is cleaned by a high-efficacy
backflush flow in front of the nozzle. The
backflush flow uses filtered water from
the chamber (D) to clean the filter from
the outside to the inside. The water, to-
gether with the dirt, is lead via the nozzle
through the duct (5) and out via the back-
flush valve (6).
All areas of the filter element that is not in
front of the nozzle are filtering the water
as in step 1: The water flows from the in-
let (A) through the filter element and out
through the outlet (B).
When the backflush is done (after ap-
proxemately 20 seconds), the motor
stops and the backflush valve is closed.
The filter then goes back filtration with full
flow to the ballast tank (no flow used for
backflushing.
If a new backflush is triggered within 2
minutes (parameter p302), the filter will
perform a continuous backflush for 20 mi-
nutes (parameter p303).
A. Inlet
B. Outlet
D. Chamber
1. Filter element
2. Motor
3. Nozzle seen from the side (rotating
during backflush)
6. Backflush valve
2.3.2.3 Backflushing for different dirt loads

Below, the filter pressure drop over time (pfilter) is illustrated for different dirt
load situations in the filter. Different dirt load depends on the water condition,
which means that “normal” condition regarding how often the filter needs to
backflush can be very different.
2.3.2.3.1 Low dirt load

In water with low dirt load, the backflush cycle is started by the time trigger
(default: every 30 minutes). As long as the pressure is below the differential
pressure trigger (0.50 bar), there is no need for the pressure triggered
backflush. See examples below.
32 200000874-5-EN-GB
2.3.2.3.2 Medium dirt load

In more dirty waters the backflush cycle will be triggered when pfilter reaches
0.50 bar, which indicates dirt in the filter.
After each backflush, the backflush timer is reset. The filter will be backflushed
again after 30 minutes or when ∆pfilter reaches 0.50 bar, whichever comes first.
In the example below, three backflushes are triggered due to high differential
pressure over the filter. After that, there is not so much dirt build up, so the
next backflush is performed after 30 minutes.
2.3.2.3.3 Heavy dirt load

In conditions with heavy dirt load, the system can perform continuous
backflushes to keep the filter clean. If the filter preforms one backflush, and
the differential pressure trigger a new backflush within a parameter set time,
the filter will perform continuous backflushes for a parameter set time to clean
the filter thoroughly. After the continuous backflush time, a check is made to
make sure that the differential pressure is below 80 % of the backflush trigger
pressure. If not, the backflush continues until this is true.
Also, the 0.50 bar 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 0.50 bar. It is OK that the flow momentarily fluctuates in an irregular
curve, but it is important that the curve stabilizes.
200000874-5-EN-GB 33
In the example below, a series of backflushes are performed (approx. every 4

minute). After that the pressure rises above 0.50 bar where the filter is
backflushed constantly. After that, the normal control is resumed, where the
filter backflush is triggered by pressure (2 times) or by time (last backflush in
the example.
2.3.2.3.4 Long term dirt build-up

Over time, the filter element will undergo a long term build-up of particles that
are not removed by backflushing. One effect of this is that “normal” pressure
will increase over time. Therefore, the maintenance schedule state that the
element 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 element more often. If the
pressure triggered backflushing is performed with short intervals, we suggest
that the filter element is manually cleaned more often than once year.
2.3.3 CIP (cleaning-in-place) module

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

The CIP module consists of a tank where the CIP liquid is stored between
usage. The pumps and valves integrated in the CIP module are controlled by
the valve block.
34 200000874-5-EN-GB
To secure that there is enough CIP liquid for the process, the level switch in
the reactor indicates when it is filled with CIP liquid. To prevent intrusion of
water in the technical water / potable water system, a backflow preventer is
used in the CIP module.
The CIP module is equipped with two membrane pumps:
• Pump P320-1 circulates the CIP liquid in the UV reactor and fills it with
technical water / potable water.
• Pump P321-5 drains water (sea and technical water / potable water)
overboard from the reactor, via the drain line.
1. Deaeration valve
2. Junction box
3. Valve blocks
4. Regulator
5. Pump (CIP liquid)
6. Backflow preventer
7. Pump (reactor drain)
8. Tank for CIP liquid
2.3.4 Cabinets and control system

2.3.4.1 Control cabinet
The control cabinet is used to control and monitor the entire system, via the
built in main control panel. It is also used to communicate with the the vessel’s
systems and components, if integrated. The cabinet is equipped with an
emergency stop button, an audible and visible alarm indication and USB ports
for software upload and log file export.
200000874-5-EN-GB 35
The control cabinet functions as a single point of contact for signal cables to
and from the vessel. Examples of integration: Remote interface integration
and power management system (PMS). Remote interface will allow control of
PureBallast from the vessel’s ISCS and PMS integration will allow automatic
verification that there is enough power to run an operation. If not integrated,
the operator must verify this manually. Also integration with other external
components (not part of Alfa Laval’s scope of supply), such as GPS or booster
pumps, are done to the control cabinet.
Control cabinet
2.3.4.2 Control system

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

The safety control system is an Ex addition to the control system, with the
main purpose to secure that the UV reactor is not overheated. If the normal
control system fails to shut down an reactor when overheated, or when there
is a risk for overheating, it will be shut down by the safety control system.
The safety control system will disconnect the power to the LDC, if some faults
are detected.
36 200000874-5-EN-GB
The safety control system is separate from the control system, and therefore
redundant to strengthen the protection. It is based on safety relays, is
hardwired and is using redundancy to ensure one fault tolerance. See chapter
6. Installation description and drawings, section Ex protection.
2.3.4.2.1 Main control panel

The main control panel in mounted in the control cabinet, and it is included in
the standard installation of PureBallast. It is installed in a safe zone. 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.
Control cabinet with main control panel.
2.3.4.2.2 Remote control panel (optional)

As an option, it is possible to install one or two additional panels to be placed
in locations from where ballast operations are performed. The remote control
panel functions in the same way as the main control panel, and it allows the
same operations. The remote control panel is delivered as an IP protective
cabinet, for installation on bulkhead or on a stand. It is possible to remove the
back cover to use the front as a mounting plate for installations in wall,
worktop etc.
200000874-5-EN-GB 37
Main control panel with integrated remote control panels.
2.3.4.2.3 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.
PureBallast control system´s main control panel integrated with the ISCS. The
interface is only an example.
2.3.4.2.4 Connectivity (optional)

The PureBallast Connectivity solution enables data transfer for Alfa Laval
systems onboard vessels to Alfa Laval IoT web platform, referred to as ALIoT
38 200000874-5-EN-GB
PureBallast Connectivity is a connectivity platform that helps the user to

monitor the PureBallast system. It establishes secure communication between
the PureBallast system onboard and the Alfa Laval data cloud. The user can
see the system performance via an online portal. To get an account, contact
your Alfa Laval contact person.
Overview of the connectivity communication
2.3.4.2.5 Log box (optional)

If one or several valves can be used as both bypass and heeling, a log box
can be used to define different combinations of valves and pumps, that
constitutes bypass or heeling operation. For more information, see Log box
installation guide.
2.3.4.3 Lamp drive cabinet (LDC)

The lamp drive cabinet gives power to the UV reactor.
2.3.4.3.1 LDC working principle

Each UV reactor is connected to a lamp drive cabinet (LDC) containing 16
lamp power supplies (LPS), each feeding with power. The LPS also monitors
the function of each UV lamp and takes action if a fault occurs. Lamps on the
cabinet indicates if power is on, UV lamps are lit and if the cabinet needs to be
reset after a shutdown or power off.
200000874-5-EN-GB 39
2.3.4.3.2 LDC description

The LDC is equipped with a cooling system to maintain correct operating
temperature in the LDC, using low-temperature cooling water. The cooling
water flow is constant, but the fan is regulated based on heat inside the
cabinet. When lamps are lit, the fan starts at 30 % of full effect. When the
temperature reaches 40°, the fan starts to regulated between 30 % and 100
%, according to parameter settings based on input from the temperature
transmitter in the LDC.
The humidity in the cabinet is monitored by a liquid sensor. If a leakage from
the heat exchanger is detected, a warning is issued, the reactor is shut down
and the cooling water inlet valve to the LDC is shut.
The LDC must be placed in a safe zone. The LDC can be placed up to 150
meters (cable length) from the UV reactor. The main breaker cut the power to
the LDC and the UV reactor.
Lamp drive cabinet (LDC)
LDC with one door removed.

1. Fan
2. Heat exchanger
3. 16 Lamp power supplies (LPS)
4. Fuses
5. Ex components including barriers
6. Cooling water inlet and outlet
7. Main breaker
8. Status lights and reset button
2.3.5 Main valves

The main valves in the system are:
40 200000874-5-EN-GB
• Inlet valves: The inlet valves directs the water flow from the vessel's ballast
water system into the PureBallast system. Different valves are used during
ballast and deballast.
• System and filter inlet valve (V201–3): Inlet valve to PureBallast during
ballast. The valve directs the water flow through the PureBallast filter.
• Filter outlet valve (V201–32): The valve directs the water flow from the
filter to the UV reactor during ballast.
• Inlet valve (V201–9): Inlet valve to PureBallast during deballast. The
valve directs the water to PureBallast, but bypass the filter, since the
water was filtered during ballasting.
• Control valve (V201–8): The valve have the following functions:
• Automatic regulation to maintain flow during operation so it does not
exceed selected certified maximum flow. Regulation is based on input
from the flow meter.
• Automatic regulation to maintain pressure needed to perform backflush
of the filter. Regulation is based on input from the pressure transmitter.
• Outlet valve from the PureBallast system to the vessel’s ballast water
system after treatment.
• Cooling water inlet valve (V403-35): Supplies cooling water to the reactor
to secure cooling of the lamps and prevent overheating during start-up. The
valve is common for all installed reactors.
• Check valve (CV201): Ensures that there is water in the reactor at all
times.
• PureBallast bypass valve (V212–31): Makes it possible to completely
bypass the PureBallast system. The valve is solely operated from the ISCS,
but the valve positioning is (and must be) indicated in the PureBallast
control system. When PureBallast is bypassed, an event is written to the
event log. The valve is equipped with a handwheel for manual operation.
The component is optional to be included in Alfa Laval’s scope of supply.
2.3.6 Flow meter

The flow meter (FIT201–1) have two functions:
• Monitor flow
• Monitor conductivity.
The flow meter consists of three parts:
• Flow sensor monitor the flow in the system. Functions together with the
flow transmitter.
• Flow transmitter send flow information to the control system. It is mounted
on the flow sensor.
• The conductivity sensor measure conductivity in the water.
200000874-5-EN-GB 41
Monitor flow
The flow meter monitor the flow within the PureBallast system, to secure that
certified flow is not exceeded. If so, a warning is issued. The flow meter send
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.
Monitor conductivity
The flow meter measure conductivity in the water. This information is used
together with temperature to calculate salinity in the water.
Treating fresh water (salinity ≤1 PSU) requires a different power optimization
and flow control to be efficient. Therefore, the power optimization and flow
control differs when fresh water is treated compared to brackish and marine
water.
2.3.7 Pressure monitoring

The pressure monitoring device is a manifold that includes the following
components to monitor and handle pressure in the system:
• Pressure transmitter (PT201-16): Send current pressure information to
the control system. The control system use the information to take actions
accordingly, for example issue warnings, shut down the system or adjusting
the control valve to obtain optimal pressure during filter backflush.
• Pressure gauge (PI201-18): Analogue displayed of current pressure.
• Needle valve (V201-15): Enables connection of external instruments for
calibration.
• Relief valve (RV201): Safety valve for relief of over pressure.
2.3.8 Sampling devices

The two sampling devices (Q201.1 and Q201.2) make it possible to take water
samples to test the water.
One sampling device is installed before the water is treated and one after the
water is treated. This enables comparative tests of treated and untreated
water. The component is optional to be included in Alfa Laval’s scope of
supply.
2.3.9 Booster pumps (optional)

Booster pumps can be installed to achieve sufficient flow. Start and stop of
optional booster pumps are handled by signals sent from the control system.
See Control system integration on page 242 .
Filter backflush pump (P309-1)

Booster pump to secure enough flow in pipe 309 for enough filter backflush.
The pump is started and stopped from the control cabinet by giving power to
the pump.
42 200000874-5-EN-GB
LDC cooling water pump (P401-1)

Booster pump to secure enough cooling water flow to LDC and LDCS (if
installed). The pump is started and stopped from the control cabinet by giving
power to the pump.
UV reactor cooling water pump (P403-1)

Booster pump to secure minimum cooling water flow to UV reactor during
startup and pause. The pump is started and stopped from the control cabinet
by giving power to the pump.
Ballast water booster pump P201–1

Booster pump to secure minimum pressure in pipe 201 to enable efficient
backflush cleaning of the filter. The pump is controlled by the variable
frequency drive (VFD) and has a separate junction box (VFD JB).
The pump speed is depending on the system pressure: At low pressure
indicated by pressure transmitter PT201-16 the pump speed increases to
increase the pressure, and at high pressure the speed is reduced.
The pump and its pressure monitoring device are installed in zone 1.
Variable frequency drive (VFD) and VFD junction box (JB)

The VFD continuously monitors the pressure during operation. The signals are
transferred from PureBallast control system to the VFD, via Modbus.
The VFD has its own electricity supply and can be switched off via its control
panel.
The variable-frequency drive and its VFD junction box are installed in safe
zone.
2.3.10 Vacuum relief valves (optional)

If the PureBallast system is placed high up in ship’s pump rooms or even on
deck in a deckhouse the fall height in the downward going pipes between the
PureBallast system and the tanks/overboard can be considerable. Whenever
the water in the pipes free fall in downward going pipes the pressure upstream
will be affected and low pressure will appear. Depending of the geometry of
200000874-5-EN-GB 43
the system the low pressure can be considerable and can potentially cause
cavitation and pressure waves which is harmful to the PureBallast installation.
To solve the problems with cavitation and vacuum, the system should be
equipped with vacuum relief valves:
In pipe 201. Float operated vacuum relief valve providing both air re-
VB201 lease upon startup of the system and vacuum relief during operation.
In pipe 309. Only vacuum relief, without air venting function. The valve
VB309 is spring loaded (normally closed) to avoid water spillage during initia-
tion of backflush.
44 200000874-5-EN-GB
EN
3 Operating instructions and control

system description
200000874-5-EN-GB 45
EN 3 Operating instructions and control system description
3.1 Introduction
The control system is used to operate and monitor the PureBallast system. It
also contains functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of
the control system pages, step-by-step instructions and a process description
with detailed information about the components (valves, motors, pumps etc)
involved in each step of respective process.
3.1.1 Operational conditions

This section contains information about operational conditions and modes.
IMO and USCG mode

The PureBallast has two process modes: IMO mode and USCG mode. These
different modes set the system to run to be compliant with regulations in USA
(USCG mode) or the rest of the world (IMO mode).
Before starting a process, the operator must choose if the operation shall be
run in IMO or USCG mode, depending on location and destination. Mode is
set using a function button in the control system.
When to use the different modes
IMO mode
IMO mode is used for:
• Ballast, when the destination is outside US waters.
• Deballast, outside US waters.
IMO mode can also be used if the vessel has an AMS and is operating under
an extended compliance date authorized by USCG.
USCG mode
USCG mode is used for:
• Ballast, when the destination port is within US waters, regardless of starting
point.
• Deballast, within US waters.
USCG hold-time
USCG mode can be run with a 3 days hold-time or 0 day hold-time. Hold time
is set in parameter p182 USCG hold-time.
The time between a completed ballast and the start of deballast
3 days hold-time or stripping must be at least 72 hours.
The time between a completed ballast and the start of deballast
0 day hold-time or stripping must be at least 2.5 hours.
0 day or 3 days hold-time
46 200000874-5-EN-GB
Operating instructions and control system description 3 EN
• Before starting ballast, select 0 day or 3 days hold-time.

• Use the same hold-time setting for deballast and stripping that was used for
ballast.
Example: If you intend to deballast water using 0 day mode, 0 day mode
must be used during ballast.
• Do not mix waters treated with different modes in the same tank. Empty the
tank completely first, preferably using stripping mode.
• Keep track of which treatment mode is used for the water in each individual
tank. Use the ballast water record book for this purpose. How this should
be done is described in the ballast water management plan.
Overboard valves
• The PureBallast control system requests that overboard valves are opened/
closed during process. This means the following:
• When a ballast, deballast or stripping process is started, all valves
leading the flow from the PureBallast via pipes 201, 309, 403 and 404,
must be opened/closed.
• When a CIP process is started, the pipes 309 and 460.1 must be
opened.
• The PureBallast control system needs feedback (opened/closed) since the
valves are outside the system control.
This status can be confirmed in two ways:
• Manually, in a popup.
• Automatically, if feedback signals are integrated via the remote interface
option or via hard drive.
3.1.1.1 Compliant / non-compliant operation

All ballast, deballast and stripping operations should be done using
PureBallast according to system manual.
However, in some cases there is a risk that ballast water is not treated
according to requirements, or contaminated by untreated water.
A process is not compliant in the following cases:
• Water was ballasted with IMO mode, when the destination port is within US
waters.
• PureBallast was bypassed (warnings W33, W66, W67, W68, W69 and
W502).
• Operation with higher flow rate than certified (warning W12).
• System not CIP cleaned within time (warning W140).
• Operation with one or more non-functioning lamp (warnings W130, W131).
200000874-5-EN-GB 47
• UV intensity lower than limit stated in the type approval certificate (warnings
W151, W152, W154).
• The ballast water is contaminated by untreated water from other pipes, i.e.
there are living organisms in the water. Even a very small amount of water,
a few hundred liters, can contaminate a ballast tank and cause non-
compliance during a compliance test. It is therefore important that
PureBallast is always used for operation. The reason for this can be:
• Leaking valves, if there is untreated water present in the piping.
• Internal transfer between tanks can contaminate tanks, if untreated
water is present in the piping.
• Sediment in tanks is a breeding ground for organisms. Therefore it is
important to review the vessel’s ballast water management plan
regarding frequency of sediment removal.
Solution to non-compliant operation

If the ballast water is not fully treated or contaminated by untreated water, a
ballast water exchange must be performed, making sure that the tanks and
pipes (including dead ends) are flushed and replaced with treated water.
Ballast water exchange
The ballast water exchange must be done
• using Pureballast in USCG mode, both at deballast and ballast.
• before entering US territorial water.
• at a location where ballast water exchange is accepted.
• minimum 200 NM from the US coast. Note that mid ocean is most
favourable, since UV transmittance is very high and the biological activity is
low.
It is also possible to contact the captain of the port zone, both at origin and at
destination. They will inform of what measures to be taken.
3.1.1.2 Stripping
Stripping can be performed to empty the ballast tanks. The first time a ballast
tank is stripped, PureBallast must be bypassed.
The stripping process is basically the same as a ballast process with the
following difference: A stripping eductor (or a stripping pump) should be used
to secure enough flow in the system.
Also, the number of UV reactors used is parameter set to normally one, to
make sure that the flow from the stripping pump/eductor is enough to cool the
UV reactor.
We recommend that the driving water alone (without the ballast water flow
from the tank) fulfils the minimum flow requirement for deballast operation.
This will minimize the risk of shut down due to low flow when flow of ballast
water is uneven.
3.1.1.3 Heeling (internal transfer)

Internal transfer of ballast water between tanks, for example during heeling
procedures, does not require the use of the PureBallast system.
48 200000874-5-EN-GB
If a signal for heeling mode is integrated between PureBallast and the vessel's
ISCS (via hard wire, remote interface and the log box), an ongoing process
(ballast, deballast or stripping) will be paused. Cooling water is flushed
through the UV reactor to cool the UV lamps during the pause. During internal
transfer the ballast pump should be stopped.
If no signal is integrated, ongoing process must be paused or stopped
manually. After completed heeling, the operator must start the paused
process. If a bypass valve is opened for internal transfer, an event is written to
the event log. It is necessary to write an explanation in the ballast water record
book to explain why the bypass valve was opened.
3.1.1.4 Gravity operation

Gravity operation (not using the ballast water pump) can only be allowed if the
following prerequisites are fulfilled:
• The requirements for flow and backflush pressure is fulfilled.
• The vessel’s flag state and classification society allow gravity operation.
• It is stated in the vessels’s approved ballast water management plan.
3.1.1.5 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.
200000874-5-EN-GB 49
3.2 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.
3.2.1 Login levels

Different login levels controls which information that is displayed and
changeable. As an example, pages used for commissioning purposes are
hidden for normal operators.
Login level Password Authority
Default mode of control system. This level is not password
protected.
0 Guest N/A
• View all pages.
• As Guest.
• Operate the system to perform daily routines, for example
1 Operator aot ballast and acknowledge alarms.
• Full access to page 1.4 Power request.
• Download files and backup to a USB memory.
• As level Operator.
• Operate equipment in manual mode.
Advanced opera- 2007 • Access to set parameters, with exception from critical pa-
2 tor rameters. See chapter 4. Parameters for information
• Full access to page 4.3 Operation timers and 4.4 Opera-
tion timers UVR.
Full access. Password only available for Alfa Laval person-

nel.
• Full access to all parameter pages.
3 AlfaLaval N/A • Full access to force I/O in page 4.2 PLC controller I/O.
• Full access to make settings for remote control panels and
remote interface in page 4.1 System info and 4.5/4.6 Re-
mote interfaces 1 and 2.
3.2.2 Control of PureBallast

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

PureBallast can only be controlled from one control panel at a time.
To switch command from one panel to another, you log in to the new panel.
This is only possible by using the same or higher login level as used in the
active control panel. When control is about to be changed from one panel to
another, the following will happen:
50 200000874-5-EN-GB
• The inactive control panel will display a message informing that another
control panel is active (some one else is logged in). The popup gives the
alternative to cancel or to continue. If continue is chosen, control is
switched from the first panel to the new panel.
• The active panel will display a popup message informing that another the
panel is inactive and that control is taken by another panel.
On each control panel it is possible to see which panel that is active and which
login level that is used. A panel alias can be entered to clarify where the panel
is installed, for example pump room, bridge etc. See instruction Set control
panel IP address. This information is visible in the upper right corner of the
system according to syntax: login level@control panel.
“Login level” can be: Guest, Operator, Advanced operator or AlfaLaval.
“Control panel” can be:
• 192.168.0.10 (Master) = Main control panel
• 192.168.0.11 = Remote control panel 1
• 192.168.0.12 = Remote control panel 2
Example: Operator logged in at remote control panel with alias “Bridge”.
3.2.2.2 Remote interface (option)

If the remote interface option is used, PureBallast can be controlled from the
vessel's ISCS.
It is only possible to switch command between control panel and ISCS from a
PureBallast control panel. This is done by using the Local (local) and Remote
(remote) buttons, when logged in as Operator or higher. Control status (local
or remote) is indicated by a green frame that corresponds to the system
currently in command. In the ISCS, control status can be indicated by using
the status signal dedicated to this. It is recommended that this signal is
implemented in the ISCS.
When remote interface is activated, PureBallast can only be controlled from
the ISCS. It possible to access the same pages and perform the same
operations from the ISCS as for login level Operator (to the extent that the
systems are integrated. However, the following two tasks can only be
performed from a (any) control panel: Set parameters and switch control
between control panel(s) and ISCS.
When remote interface is activated, the panel(s) can only be used to monitor
the system, export log files and switch control between PureBallast control
panel(s) and ISCS.
The PureBallast system manual does not give any information about how to
run PureBallast from the remote interface. This is due to the fact that the
remote interface is custom-made. Please refer to the vessel specific manual.
Conditions for remote interface control of PureBallast

PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings
200000874-5-EN-GB 51
• The remote interface must be correctly installed, according to Remote

interface implementation guide.
• Remote interface must be activated (parameter p132) and communication
settings must be correct (parameter p700 – p704).
• The Test mode button must be deactivated (no checkmark on the button)
in control system page 4.5 Remote interface 1.
• Remote control must be activated. Check that there is a green frame round
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 06 and 77 are updating in control
system page 4.5 Remote interface 1.
• There must be no active alarms for the UV reactors to be used during
operation. Always check the alarm list (page 2.1 Alarm list in the control
system) before operation.
• The UV reactor/reactors must be in standby mode.
3.2.3 Overview of the screen

This section describes the PureBallast control system screen layout and
navigation.
The control system use a touch screen, where you tap the screen to “click” or
drag objects. Do not use sharp objects to touch the screen. When the screen
is left idle it will go to screen saving mode. Time is set in page 4.1 System info.
The screen is activated again by touching it once. That first 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.
52 200000874-5-EN-GB
Control system screen showing the main overview page.

Tabs: The top and side tabs are used to choose which page to display in the
screen. Pages are referred to as a number and a name, for example 2.1 Alarm
list. The first number refers to selected top tab, counted from left to right. The
second number refers to selected side tab. Selected tabs are indicated by a
white color.
Top tabs: Contain the main function areas of the control system: Overview,
alarm lists, trend curves, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab.
Popup windows: Are used to display or enter detailed information. It is
possible to move a popup by touching the name bar and drag it. A popup is
closed either by touching confirming entered information by touching a
function button (OK, Confirm, etc.) or the X icon in the top right corner (data is
not saved).
Data entry fields: A white field indicates that it is possible to enter data. When
the field is touched, a keyboard is displayed, which is used to enter
information. Enter data is confirmed by touching the Enter button. To close the
keyboard without saving data, touch the Esc button.
Function buttons: Function buttons are used for main processes and control
of the system. They are placed at the bottom of the screen and are always
visible. Some buttons only show if a function is activated. For example, the
Remote and Local buttons are only visible if remote interface is activated.
200000874-5-EN-GB 53
Status indication – Button colour: The buttons appear in different colours, indicat-
ing status:
Blue The function is enabled.
Blue with check- The function is activated.
mark
The function is not possible to activate, for example if higher login
Grey level is required for the function.
Status indication – Button light: After a function button is pressed, a frame is lit to
indicate status:
Green Command is active.
Green, blinking Command will be processed when possible in the data work flow.
Function button description

The illustration below shows the main areas and function buttons on the
screen.
Button Description
Start ballast process.
Resumes paused process.
Start deballast process.

Stop current process.
Start tank stripping process.

Pause ballast, deballast or stripping process. This is only possible dur-

ing full ballast or full deballast. The button can be hidden, using pa-
rameter p137. Allowed length of a pause is parameter set (p138). After
defined time, the paused process is stopped.
To resume a paused process, press the function button Ballast, De-
ballast or Strip depending on which process that was paused.
Start CIP process.
Activate operation from control panels, instead of remote interface (if

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

control panels. The button is only enabled in standby mode.
Sets the control system in manual mode, which enables manual oper-
ation of the system and its components. When activated, the light
flashes yellow. Requires login level Advanced operator or higher. For
detailed information see .
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.
54 200000874-5-EN-GB
Button Description
Activate night light for the panel. Night light makes the panel less
bright. Toggles between night light and day light.
Degree of brightness, is set in the Night light level field in page 4.1
System info.
Contains a print function. To print a screen image to USB: Insert a

USB memory in USB panel port on the cabinet door. Press Utilities,
and then Print to save a screen image to USB.
Login: Expanding menu with login fields. See section Login levels in
Operating instructions and control system description on page 45.
Button Description
Sets the control system in IMO mode, which activate operation in ac-
cordance with IMO requirements.
Sets the control system in USCG mode, which activate operation in

accordance with USCG requirements.
The text under the button indicates if the system is run as USCG 0
days holdtime or USCG 3 days holdtime according to parameter p182.
Status indication – Alarms and warnings

Alarms and warnings for components are displayed directly on the component
they regard:
Active alarm.
Active warning.
200000874-5-EN-GB 55
56 200000874-5-EN-GB
3.3 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.
3.3.1 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.
Control system screen showing the main overview page.
Status box
The status box display current status for the PureBallast system. The
information is updated continuously. To see accumulated operation runtime for
the components, see page 4.3 – Operation timers.
The following status information is displayed:
Status information (unit) Description
Process: Ongoing process.
Subprocess: Sub steps of ongoing process, for
example Start-up during Ballast process.
Process and subprocess
If fresh water is processed in IMO mode “FW” is
stated after the subprocess. See section Flow
control and power optimization in chapter 2.
Remaining time for the ongoing subprocess in
Time the upper right corner.
200000874-5-EN-GB 57
Status information (unit) Description

Amount of water processed during ongoing
Processed volume (m3/h) process. Value remain until next process is star-
ted.
Power consumption (kW) Power consumption for ongoing process.
Certified flow (m3/h) selected for operation. The
information is updated after the warm up time
Certified flow (m3/h) has passed and a UV reactor is used for proc-
ess. This is also the flow the system is aiming to
keep.
Water flow in the system, indicated by flow
transmitter FIT201-1. The system aims for the
Current flow (m3/h) selected flow minus parameter p111 Undershoot
certified flow, which can be set as a safety mar-
gin.
Flow (m3/h) selected for operation.
Flow can be selected manually or automatically:
• Automatically: Activate the Auto button
(checkmark). Maximum flow will always be
selected(equal to all installed and ready UV
reactors).
It is only possible to decrease flow during op-
eration.
Flow selection
• Manually: Deactivate the Auto button (no
checkmark). Flow is selected using the + and
- buttons.
Flow from last operation is selected as de-
fault. It is possible to change flow both in
standby and during operation.
Note: Before first operation after power off or
shutdown, flow must be selected using the +
button.
Status indication for ballast water pump (not part

of Alfa Laval’s scope of supply).
Ballast pump Status indication
Green, blinking = Request sent. Popup message
“Confirm ballast pump started” is displayed.
Green = Pump running. Feedback from popup,
via hard wire or remote interface.
Grey = No request sent (not running).
Status indication for overboard valve(s), and
other relevant valves for the process (not part of
Alfa Laval’s scope of supply).
Status indication
Overboard valve(s) Green, blinking = Request sent. Popup message
“Confirm overboard valve open” is displayed.
(The popup is not displayed if the component
feedback is integrated with the control system.)
Green = Feed back that valve is open, either via
hard wired feedback, remote interface or the
confirmation popup.
Grey = Closed.
Indicates differential pressure over the ilter

(PT201–71 minus PT201–72). When the pres-
Filter diff. pressure sure reach the value set in parameter p305, a
backflush is triggered.
58 200000874-5-EN-GB
Flow chart
The flow chart display a schematic overview of the PureBallast system and its
components.
Relevant information regarding ongoing process and component status can be
monitored directly in the flow chart. Flow in pipes is indicated by coloring of the
pipes and component status are displayed by color indications. Pressure, flow
and control valve opening percentage are displayed directly on component.
Detailed information about the UV reactor, filter and CIP components can be
monitored in their respective pages. The popup contain status for sub
components, for example valves, motors and UV lamps in the UV reactor.
UVR cooling water pump (P403–1) is only displayed if it is used and activated
in the parameter pages.
In manual mode (login level Advanced operator or higher) it is also possible to
operate components manually: If a component is pressed, a popup window is
displayed from which the component can be operated.
Status indication – Component colour
Component status is indicated by a coloured frame:
The symbol indicates that you can change the compo-

nents symbol name (ID). A popup window will appear
when you press the component symbol.
To find out how you enter data, see section Overview
of the screen in section Operating instructions and
control system description on page 45.
The chain symbol indicates that you cannot control the

component by pressing the component symbol.
You can only control the components in manual mode.
Read about manual mode in section Overiew of the
screen in section Operating instructions and control
system description on page 45.
Status indication
Pipes A pipe filled with colour indicates that there is flow in
the pipe.
Status indication
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Valves and pumps
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a compo-
nent. The ID will be visible in page 1.1 Overview and
popups for the components. See instruction Set ship
specific component ID.
Status information for bypass valve(s) V212–31 and

external bypass valves (not part of Alfa Laval’s scope
of supply). These valves are operated from the ISCS,
due to safety reasons.
External bypass is only visible if parameters (p163–
p165) for external bypass valves are activated.
200000874-5-EN-GB 59
Status indication – Component colour

Component status is indicated by a coloured frame:
The component is operated manually in manual mode.
Status information for the backflush pump P309–1 (op-

tional). Only visible if parameter p318 is activated.
60 200000874-5-EN-GB
3.3.2 Page 1.2 - UVR and flow selection

The page is used to select UV reactors or flow for ballast and deballast and to
increase (only possible in ballast) or decrease flow during ongoing operation.
It is also possible to select specific UV reactors to be used during process, or
to change UV reactor during an ongoing process.
This page is only relevant if more than one UV reactor is installed.
Note: If the Auto button is activated in page 1.1 Overview, it is only possible to
change flow during operation, not in standby.
Normally, flow is handled from page 1.1 Overview, and this page is used
during commissioning and faultfinding when it is necessary to start individual
UV reactors.
The main areas of the page are the Flow selection, UVR selection and Status.
Flow selection
Function in the same way as flow selection in page 1.1 Overview.
UVR selection
The area displays a table with installed UV reactors with status information. If
more than one UV reactor is installed, it is possible to choose individual UV
reactor for process in standby (if the Auto button is deactivated) or during
process (regardless of Auto button mode).
The following information is displayed:
200000874-5-EN-GB 61
Elements Description
Enables active selection of individual UV reactors.
Modify button When pressed, the buttons for respective UV reactor
turns blue and are possible to use.
One row for respective installed UV reactor with current
status indicated in the columns.
UVR button: Press the button to select or deselect. A
checkmark on the button indicates selected. The flow
setpoint for the number of UV reactors selected are up-
dated in the Flow selection area.
UVR 1, 2, 3 button
Status indication:
Selected: Grey = Not selected. Green = Selected.
Ready: Grey = Not ready. Green = Ready for process.
Alarm: Grey = No alarm. Red = Active alarm.
Apply the new setpoint to be used for process.
Apply button Note: If ballast flow is lower than deballast flow (param-
eter p315), the higher value is displayed until the Bal-
last button is pressed.
Status
The area displays current status for the flow:
Elements Description
Ballast water flow in the system, indicated by flow
Current flow transmitter FIT201-1.
Maximum allowed flow as set in Flow setpoint or limited
by the number of UV reactors selected in UVR selec-
tion popup. If a smaller filter is installed, the ballast flow
can be lower than the UV reactor capacity.
Certified flow
The information is updated after the warm up time has
elapsed and a UV reactor is used for process. (Before
that it is not used for treatment, and therefore not part
of the certified flow.)
62 200000874-5-EN-GB
3.3.3 Page 1.3 – CIP status

The page is used to display CIP status for all UV reactors and status for the
valves and motors in the CIP unit. The page can either be opened by selecting
the tab or by tapping the CIP module in page 1.1 Overview
CIP status
Row Content
Process: Ongoing process. Can be standby, ballast,
deballast and CIP.
Process and sub process
Sub process: Sub steps of ongoing process, for exam-
ple “Start-up” during Ballast process.
CIP UV reactor information

The area displays CIP status for respective installed UV reactor:
Row Content
UVR 1
Each row display CIP status for every installed UV re-
UVR 2 actor.
UVR 3
This row indicate status and time for the filter preserva-
tion process, that starts after completed CIP. During fil-
Filter preservation ter preservation, the CIP fills the filter with technical wa-
ter / potable water for preservation purpose.
Total estimated time for a complete CIP process includ-
Total time ing filter preservation.
200000874-5-EN-GB 63
Column Content
White = No active alarms regarding the CIP.
CIP error Red = There is an active alarm regarding the CIP.
Check alarms on page 2.1 – Alarm list.
Yellow = CIP required. During ongoing CIP process,

yellow indicates that the UV reactor is waiting for CIP
process to start.
CIP Yellow, blinking = CIP process ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to
an active alarm on the UV reactor.
Displays the status of the UV reactors and the filter.

Status Required
Completed
Estimated time to complete CIP cleaning of the UV re-
actors or the filter. If CIP process has not been started,
total time is displayed. During CIP process, the time is
Estimated time counting down continuously.
The CIP process takes about 25 minutes per UV reac-
tor, if default parameters are used.
Time before a CIP process must be performed after a
process. The time disappears when the CIP cleaning is
CIP req. ready. Time is displayed for the UVR with shortest time
left to required CIP cleaning.
CIP module flow chart

The flow chart on the screen displays a schematic illustration of the CIP
module, with status for for the valves and motors. For status indications, see
Status indication – Component color in section Flow chart, see Page 1.1 –
Overview on page 57.
64 200000874-5-EN-GB
3.3.4 Page 1.4 – Power request

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

If the control system is set in normal mode, the page is used to display power
management status.
Column Content
Process: Ongoing process. Can be standby, ballast,
deballast and CIP.
Process and sub process
Sub process: Sub steps of ongoing process, for exam-
ple “Start-up” during Ballast process.
Maximum power consumption for the number of selec-

Max power consumption ted UV reactors. The value is updated when a process
is started.
Current power consump- Power consumption during process. Value calculated

tion based on number of used UV reactors.
200000874-5-EN-GB 65
Power status
Column Content
Each row represent a number of UV reactors to be
used in a process. Requests can be combined to send
request for 3 UV reactors.
1 UVR: Request power for 1 UV reactor.
2 UVRs: Request power for 2 UV reactors.
Power
The requested power is calculated as the number of
UV reactor times defined power consumption for one
UV reactor.
Common power: Request maximum power, enough to
run all UV reactors installed, even if all UV reactors are
not used.
Indication alternatives: “Requested” or “Not requested”.

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

Indicates if power request has been granted from the
ISCS. Pure Ballast will not consume significant power
until the requested power is granted.
Granted If there is not enough power available for the amount of
(Input signal to PureBallast) UV reactors, a lower power value might be granted.
This means that less UV reactors 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.
Indication alternatives: “Running” or “Not running”.

Status Indicates if power running signal is sent to the ISCS for
respective number of UV reactors. This means that the
(Output signal from Pure- UV reactor is started and is consuming power.
Ballast)
Manual mode: Indicates if a simulated running signal
is sent.
Power consumption for ongoing process.

If individual rows have been selected, the value is the
sum of the number of UV reactor for the request times
Power consumption the set power consumption per UV reactor.
If Common power has been selected, the value is 100
kW per UVR / LDC.
Power management simulation and faultfinding

If the control system is set in manual mode, the page is used to simulate
output from PureBallast to the power management system during
commissioning preparation.
The page can also be used to troubleshoot the power management system
integration by sending and checking each signal.
66 200000874-5-EN-GB
Function buttons
The following function buttons are available and displayed when manual mode
is activated:
Buttons Content
If manual mode is activated, a hand icons are dis-
played on the page. Press the hand icon to make it
possible to send simulated request or granted signal
manually.
Press to manually simulate request for a power step.

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

Set run The button is displayed for login level Advanced opera-
tor or higher.
200000874-5-EN-GB 67
3.3.5 Page 2.1 – Alarm list

The page display active alarms and warnings. When an alarm/warning is
inactive and acknowledged, it is moved to page 2.2 History.
Alarm type can be of two types:
• A= Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
• W= Warnings are notification of a status change, request for action or a
problem that must be attended to. Warnings allow the process to continue.
For detailed information about alarms and warnings see chapter 5. Alarms and
faultfinding.
The main areas of the page are the Alarm list and the Function buttons:
Alarm list
The following information is displayed for each alarm (row):
Column Content
Descriptive alarm text written as: Area-Alarm type Alar-
Text mID Alarm text.
Example: UVR2 A138 Error in LDC cabinet.
Active time The time alarm was activated.
The time the alarm/warning was acknowledged. The
alarm/warning remains in the alarm list until the causing
Acknow-ledged time condition is resolved. For example a high temperature
alarm will remain visible, until the temperature is below
the limit value for the alarm/warning.
68 200000874-5-EN-GB
Status indication – Alarm color

The table below shows status indication for alarms and warnings in the alarm list.
Red Alarm = active
Pink Alarm = acknowledged, but still active
Orange Warning = active
Yellow Warning = acknowledged, but still active
Function buttons
The following function buttons are available:
Button Function
Acknowledge selected alarm (row). Press
Ack selected a row to indicate it, and press the button
to acknowledge it.
Ack all Acknowledge all active alarms.
200000874-5-EN-GB 69
3.3.6 Page 2.2 – Alarm history

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

Column Content
Text Same as in Page 2.1 Alarm list.
Active time Same as in Page 2.1 Alarm list.
Acknowledged time Same as in Page 2.1 Alarm list.
The time the value that caused the alarm
Normal time returned to normal.
70 200000874-5-EN-GB
3.3.7 Page 3.1 – Trend (15 min)

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

Component / Key val- Unit Description
ue
Differential pressure over filter, indicated by
Filter diff. pressure bar pressure transmitter PT201–71 and PT201–
72.
V201–8 Control valve % Control valve V201–8 open, percent.
pos.
PT201-16 System pres- bar System pressure, indicated by the pressure
sure transmitter.
Filter backflush valve V309-1 opened or
Filter backflush valve Status closed.
FIT201–1 System flow m3/h System flow, indicated by the flow meter.
External feed signal, to request increased/
External feed setpoint % decreased flow from external ballast water
pump/valve.
Diagram area
In the diagram area, trend curves are displayed for one or more components.
Components available for plotting is displayed at the bottom of the screen.
Trend curves can be activated or inactivated for respective component.
The scale of the diagram:
X axis: The time interval is 15 minutes.
200000874-5-EN-GB 71
Y axis: The scale and unit used for the Y axis is set in the Settings popup for
respective component. For details, see the Component area section below.
Component area
The following fields and buttons are available for each component in the
component area:
Column Content / Function
Press the button to make settings for the component’s
curve. Settings are done in a popup.
Settings button
1. Press (not slide) the top right button to display or
hide trend curve in the diagram. A green I indicate
displayed, and a grey O indicates not displayed.
2. Press the entry field to change start and stop value
for the components Y axis scale (when this compo-
nent’s scale setting is used).
3. Press this button to use this component’s scale set-
ting in the diagram.
4. Press the entry field to enter number of decimals in
the component area, or use the -- or
++ buttons to increase or decrease.
Filled = Selected. Component values is

plotted in the diagram, in the same col-
or as the icon.
Empty = Not selected. Component val-
ues is not plotted in the diagram.
Status indication
Scale icon = The component scale set-
ting is used in the diagram’s Y axis. If
several components have the same
scale setting, this icon is displayed for
all these items.
Component Item number or name.
Current value for the component is displayed in the gray
Value field. (This corresponds to the diagram.)
If history mode is selected, historic value is displayed.
Function buttons
The following function buttons are available.
72 200000874-5-EN-GB
Column Content / Function

Export trend curve history as a csv file. The file can be
sent to Alfa Laval for advanced trouble shooting.
Export long-term trend Insert a USB memory in USB panel port on the cabinet
data to USB door. Press Export long-term data to USB button.
Wait for the message “Exporting database table …” to
disappear. The file has been downloaded to the USB
memory, in a folder named DatabaseExport.
Only available for page 3.1. Press the button to display

this popup:
History mode
Press one time unit (year, moth, day etc) and then press
- or + to set time.
Real time Press the button to display current trend curve.
3.3.8 Page 3.2 - Trend (1 h)

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

The page is used to display trend curves for water temperature in the UV
reactor, indicated by temperature transmitter TT201–33. This page display
trends with a update frequency (sample time) of 15 seconds and the time span
for trends displayed on the screen is 1 hour. Trend curves are saved in the
trend history for 24 hours, and are then deleted.
See page 3.1 Trend (15 min) for information about function, fields and buttons.
3.3.10 Page 3.4 – Trend (1 h) - TT401-2

The page is used to display trend curves for air temperature in LDC, indicated
by temperature transmitter TT401–2. This page display trends with a update
frequency (sample time) of 15 seconds and the time span for trends displayed
on the screen is 1 hour. Trend curves are saved in the trend history for 24
hours, and are then deleted.
3.3.11 Page 3.5 – Trend (1 h) - Power optimization

The page is used to display trend curves for data valid for the power
optimization. This page display trends with a update frequency (sample time)
200000874-5-EN-GB 73
of 15 seconds and the time span for trends displayed on the screen is 1 hour.
Trend curves are saved in the trend history for 24 hours, and are then deleted.
See chapter 2. System description, section Power optimization for details.
• UVR UV setpoint: The UV intensity the system is aiming to attain by
increasing or decreasing power effect to the LPS controlling the dimming of
the UV lamps. The setpoint is based on actual transmittance and is
updated every 15 seconds.
• UV measurement: Actual UV intensity (W/m2) measured by UV sensor
QT201–50. If intensity is lower or higher than needed, the power to LPS will
increase or decrease to attain setpoint for UV intensity.
• Power output: Actual LPS power to UV lamps. The power is adjusted to
attain the setpoint for UV intensity based on measured water transmittance.
Output is adjusted based on input from UV sensor QT201–50. Power can
be 50–100 %.
3.3.12 Page 3.7 – Trend (15 min) - External feed control

The page is used to display the trend curves for detailed data valid for the
external feed.
We recommend that page 3.1 is used to monitor external feed trend curves.
This page is mainly used for advanced trouble shooting.
The external feed is used to fine tune the control of the flow that comes to
PureBallast. It works as an addition to the flow controlled by the control valve
(V201-8).
74 200000874-5-EN-GB
3.3.13 Page 3.8 – UV optimization

The page is used to display the trend curves for detailed data valid for UV
optimization.
200000874-5-EN-GB 75
3.3.14 Page 4.1 – System info

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

Section Description
on page
HMI info CPU: Control panel’s usage of the central processor unit (CPU) in percent
of total capacity and temperature (°C). The control panel will shut down
when the CPU reaches 100 °C.
Used RAM: Control panel’s used random access memory (RAM) in per-
cent of total capacity and in kB.
Used storage: PLC, used storage in percent and MB. Storage used for
the event and alarm log.
iX version: N/A.
Panel firmware: Version of internal firmware for the control panel.
CAT control version: N/A.
PureBallast HMI software version: Version of HMI software.
IP settings: Display current IP address for the panel.
Setup button: Opens popup to set IP address for the main panel and the
remote control panels (optional). Requires login level AlfaLaval.
HMI Date and time: Set and synchronize date and time. (If parameter p160 is
date and activated, date and time is is retrieved from GPS with RMC protocoll in-
time stead. Requires login level Advanced operator.
UTC
Set button: Set time and date for the main control panel. Remote control
panels are updated with this time within 15 minutes after syncronization.
Regional settings button: Set time zone. Only possible to use if the GPS
is activated.
Synchronize button: PLC is synchronized to use same date and time as
set in the control panel.
76 200000874-5-EN-GB
Section Description
on page
HMI Screen saver timeout: Defines time before the panel is set to screen
Back- save mode. This is set individually per control panel.
light
Night light level: Defines percent of full light for the night light mode.
Night light is activated by the Night function button.
PLC info CPU temperature (°C): Temperature of the central processor unit (CPU)
in the PLC.
PureBallast PLC software version: Version of the PureBallast PLC pro-
gram.
GPS position: Shows current GPS position. The position is used in the
event log.
Select the degrees check box to display symbols for degrees, hours and
minutes.
Control cabinet configuration: Indicates if control of booster pumps can
be controlled from PureBallast control cabinet.
1. Pump started by signal from PureBallast control cabinet: Power sup-
ply with over current protection relay and contactors and are handled
externally.
2. Pump completely controlled from PureBallast control cabinet: Start
signal and power supply with over current protection relays and con-
tactors from control cabinet. It is still possible to connect pumps ac-
cording to configuration 1.
Control cabinet configuration affect parameter p129, p130 and p310.
Backup Settings to/from USB panel: Export and import information to the USB
and re- panel port on the cabinet door.
store
Backup button: The following information is saved in a folder named
“PureBallast Backup”:
• Parameter settings. File: Parameters.csv.
• Operating timers for UVR, UV lamps etc. File: operatingtimers.csv.
• Settings for components in the trend curve pages. File: Value-
Saved.xml and ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different compo-
nents. File: ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
Restore button: Restore all information from a USB backup to the control
system. See Backup above. This shall not be used to restore parameter
settings after software update. Requires login level Advanced operator.
Parameters: Parameter restore.
Set default button: Set all parameter values to the default values. Re-
quires login level Advanced operator.
Export Export button: Opens the Export log files popup to export (copy) event
log files log files and alarm list.
For specific information about logged events, see section List of logged
information, Event log on page 126.
Remote Remote control panels button: Open a popup used for setting IP ad-
control dresses for remote control panels (optional). See instruction Set control
panels panel IP address on page 115. Requires login level AlfaLaval.
Debug Cpy2USB button: Only press this button if asked for by the Tumba Tech-
log nical Support team. It’s for Alfa Laval’s internal fault tracing of the screen.
Enable button: Only press this button if asked for by the Tumba Technical
Support team.Disable button: The default mode of the function is disa-
bled.
200000874-5-EN-GB 77
3.3.15 Page 4.2 – PLC controller I/O

The page is used to display status for the PLC I/O modules and to control
them manually.
Note that this page is only intended for Alfa Laval's personnel and only visible
and available for login level AlfaLaval. This page can only be opened from the
main control panel in the control cabinet.
78 200000874-5-EN-GB
3.3.16 Page 4.3 – Operation timers

The page is used to display operation counters for the components indicted in
the illustration.

Row Unit
Accumulated ballast volume m3 processed
Accumulated deballast volume m3 processed
Control valve V201-8 total runtime Time opened in hours
LDC cooling booster pump total runtime (P401–1) Runtime in hours
Reactor cooling booster pump total runtime (P403–1) Runtime in hours
Filter backflush cycles Number of backflushes
Filter motor total runtime Runtime in hours
Filter backflush motor total runtime (P309) Runtime in hours
CIP pump P320–1 Runtime in hours
CIP pump P321–5 Runtime in hours
CIP: Number cleaned UVRs.

Reset button: Reset to 0. If this is done each time the
CIP liquid is changed, it is possible to build up experi- Number of performed CIP
ence on how many CIP processes it is possible to processes.
perform before it is time to change CIP liquid contain-
er. Requires login level Advanced operator or higher.
200000874-5-EN-GB 79
3.3.17 Page 4.4 – Operation timers UVR

The page is used to display operation runtime for UV reactors:
UVR operation timers Total Lap time

Lap time for installed UV lamps,
since the counter was reset after
Total runtime for the previous reset at UV lamp change.
UVR 1–3: Lamps on UV lamps in respec- Reset button: Reset the value.
tive UV reactor. Shall be done after UV lamp
change. Requires login level Ad-
vanced operator or higher.
Total runtime for the
UVR 1–3: LDC power LDC for respective UV
on reactor.
80 200000874-5-EN-GB
3.3.18 Page 4.5 – Remote interface 1

This page is used to monitor data sent between PureBallast's PLC and the
vessel's ISCS.
For detailed information about addresses, information and format, see chapter
6. Installation description and drawings, section Remote interface integration
(optional).
Function buttons Description

Activates test mode. Communication can
be sent between the ISCS and PureBal-
last’s PLC without actually affecting the
control system (start process etc). To
send information, enter desired digits in
the entry field.
Test mode
Requires login level Advanced operator
or higher.
Active: Check mark on the button.
Deactivated: No check mark on the but-
ton.
3.3.19 Page 4.6 – Remote interface 2

This page is used to monitor UV reactor and LDC specific data sent from
PureBallast's PLC to the vessel's ISCS.
For detailed information about addresses, information and format, see chapter
6. Installation description and drawings, section Remote interface integration
(optional).
200000874-5-EN-GB 81
82 200000874-5-EN-GB
3.3.20 Page 4.7 – Log box

This page is used to administer and monitor the feedback from external
components connected via the log box (optional). The page is used for
defining all individual combinations of signals that result in a bypass or
heeling. PureBallast use the input to write events to the event log and to
trigger correct actions based on if the vessel’s components constitute a
bypass or heeling.
For detailed information, see the Log box installation guide.

Column Content
Top fields for administration
Choose to define/view bypass or heeling con-
Configuration type figurations.
Select configuration number by entering a
number or using the arrow buttons. Signal sta-
Configuration number tus and Configuration are displayed for selec-
ted configuration number.
Saves configuration information after a
Save configuration button change.
Column Content
Signal settings
Signal input Number of the input signals (1 – 32).
Indication of the current status for signal 1 –
32.
Status Green light = Active signal.
No light = No signal.
Marked checkboxes inverts the signal chosen
in the configuration row. In that way you can
Signal invert chose to have the active signal as 0 V. If the
signal invert checkbox is not marked, the ac-
tive signal is 24 V.
200000874-5-EN-GB 83
Column Content
Signal settings
This is the definition of which signal that
should be active to constitute a bypass/heel-
ing. Tap the checkbox to select or unselect it.
Configuration Selected = All selected signals, must be active
for the modes bypass or heeling to occur.
Not selected = Not part of configuration for By-
pass or Heeling.
If a bypass or heeling configuration is active,
Active configuration numbers the numbers of the active configuration is indi-
cated here.
3.3.21 Page 4.9 – LPS overview

This page is used to monitor detailed data for the lamp power supplies in the
lamp drive cabinet. It is intended for Alfa Laval’s personnel during advanced
faultfinding. The number of LPSs displayed corresponds to the number of
LPSs installed per LDC.
Column Content
LPS number Each row indicate status for each LPS.
Measured power output for UV lamp
Power (kW) powered by the LPS.
Lamp on Status: Green = On. Grey = Off.
Ignition Status: Red = Failure to ignite UV lamp.
Status: Green = OK. Red = LPS in fault
LPS OK state.
Status: Green = UV lamp lit and LPS is
Lamp OK OK. Red = LPS in fault state.
Lamp open Status: Rec = No lamp, circuit open.
84 200000874-5-EN-GB
Column Content
Status: Red = Too low incoming power to
Voltage fault the LPS.
Short circuit Status: Red = Short circuit alarm.
Status: Red = Temperature in LPS is too
Air temp fault high.
Heatsink fault LPS internal heat protection tripped.
Fan fault LPS fan broken.
If a sum alarm is issued for an LPS, an
alarm icon is shown for the last LPS with
an alarm. The icon disappears when the
alarm is acknowledged.
200000874-5-EN-GB 85
3.3.22 Page 5.1–5.7 – Parameter pages

These pages are used to set parameters. See chapter 4. Parameters for
detailed information.
86 200000874-5-EN-GB
3.4 Popup windows

This section describes the popup windows for the UV reactor, filter and CIP
opened from page Overview.
It is possible to lock a popup, so it remains open, even if you change page.
Press the pin icon to lock and unlock the popup.
Grey = Unlocked. Blue = Locked.
3.4.1 UVR popup

Information is displayed for the UV reactor selected in the UVR number field.
Press the field to enter an UV reactor number, or press the arrows to step up
or down.
operate components manually. If the component is pressed, a popup window
is displayed from which the sub components can be operated. Operation of
UV lamps in LPS control popup requires login level Advanced operator. LDC
cooling water pump (P401–1) is only displayed if it is used and activated in the
parameter pages.
UVR status: Status indication for the UV reactor: ”Stopped” or “Started”.
UVR illustration
Table 1: UVR popup: UVR illustration
200000874-5-EN-GB 87
Component Description
Status indication:
Grey = Off.
UV lamps
Yellow = Starting.
Green = Started.
Status indication for UV reactor sensors:

LS201–29/LS201–30: Level switch indi-
cates if the UV reactor is filled with water
or not.
Status indication: Green = Filled. Red =
Not filled.
TS201–60/TS201–33: Temperature
switch automatically shuts down the UV
reactor when the temperature reaches 65
Sensor indications °C.
Status indication: Green = OK. Red = Not
OK.
QT201–50: UV sensor QT201–50 indi-
cates UV intensity from the UV lamps in
the UV reactor.
TT201–33: Temperature transmitter
TT201-33 indicates current temperature
in the UV reactor.
For status indications, see Status indica-

tion – Component color in section Flow
Valves chart. See Page 1.1 – Overview on page
57.
Flow in pipes is indicated by coloring of

Water flow the pipes.
LDC status
Table 2: UVR popup: LDC status illustration
Open the LPS control popup, which ena-
bles manual operation of individual UV
lamps. Requires login level Advanced op-
erator to see the button and manual
mode open the popup. See LPS control
popup and instruction Operate UV lamps
manually on page 110.
Open the LPS status popup, which gives

an overview of status for UV lamps and
LPSs.
Fan rotation in percent of full effect. Fan

Fan setpoint effect is based on need for cooling.
Air temperature in the LDC cabinet indi-

Air temperature cated by TT401–2.
Temperature of incoming cooling water to

Water temperature the LDC cabinet indicated by TT401–1.
88 200000874-5-EN-GB
Indicates if the valve for LDC cooling wa-
ter (SV401–51) is open.
Heat exchanger valve
Status indication: Green = Open. No indi-
cation = Closed.
Indicates if the LDC cooling water pump

is running or not. The pump is running if
the cabinet needs cooling, based on tem-
P401–1 Cooling water pump perature.
Status indication: Green = Running. No
indication = Not running.
Indicates if the leakage sensor LS1 is in-

dicating wet condition in the cabinet.
Status indication: Grey = Dry. Red = Wet.
LPS control popup

The popup is used for to manually start the UV lamps in the UV reactor. See
instruction Operate UV lamps manually on page 110. The popup is displayed
when the LPS control button is pressed in the UVR popup. Requires login
level Advanced operator to see the button and that manual mode is activated
to open the popup.
The UV reactor is equipped with 16 UV lamps. In each lamp drive cabinet
(LDC) is 16 lamp power supplies (LPS) that supplies power to one UV lamp
each. The lamps can be operated individually in manual mode.
DANGER
Manual start of the UV lamps is only allowed (and possible) when there is
water in the UV reactor (indicated by level switch LS201-29 and
LS201-30), 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.
200000874-5-EN-GB 89

Table 3: LPS control popup
Information is displayed for the UV reactor selected in
the UV reactor number field. Press the field to enter
UV reactor number an UV reactor number, or press the arrows to step up
or down.
Enables manual operation of the LPSs to light the UV

lamps. The button is displayed for login level Ad-
vanced operator or higher. The button enables manual
control of UV lamps.
Press one button (1–16) to start or stop UV lamp 1–16

manually, controlled by the LPS.
Status indication
LPS 1–16 Blue with checkmark = Lit
Blue without checkmark = Off
Grey = Not selectable.
Start all LPS, and thereby all lamps for the UV reactor.
Requires that the Manual mode button is pressed.
Stops all LPS, and thereby all lamps for the UV reac-
tor.
LPS status popup

The popup gives detailed information about UV intensity for UV reactors and
power for LPSs. The information is mainly used for advanced trouble shooting
by Alfa Laval’s personnel.
90 200000874-5-EN-GB

Table 4: LPS status popup: LPS status
Information is displayed for the UV reac-
tor selected in the UVR field. Press the
UVR field to enter an UV reactor number, or
press the arrows to step up or down.
Displays if LPSs is active and powered

on. UV lamps can only be lit if an LPS is
LPS fail safe active. When a critical alarm (e.g. no wa-
ter in the UV reactor) is issued, the fail
safe function inactivates the LPSs and
cut the power.
Status indication: Green = Active. Grey =
Not active.
Actual effect from each LPS to respective

LPS 1–16 UV lamp. Green = LPS/Lamp on. Gray =
LPS/Lamp off.
Table 5: LPS status popup: Power optimization
200000874-5-EN-GB 91
The UV intensity the system is aiming to
attain by increasing or decreasing power
Setpoint effect to the LPS controlling the dimming
of the UV lamps.
Actual UV intensity (W/m2) measured by

UV sensor QT201–50. If intensity is lower
Measurement or higher than needed, the effect to LPS
will increase or decrease to attain set-
point for UV intensity.
Setpoint for LPS power output (50-100

%). This is how much power the system
is set to maintain.
The power is adjusted so that the UV
Power output lamps are lit to the effect needed to attain
the setpoint for UV intensity (based on
measured transmittance in the water).
Output is adjusted based on input from
UV sensor QT201–50. Effect can be 50–
100 %.
Displays current control mode. Status in-

dication:
• Automatic: Normal mode. Power opti-
mization is activated.
Control mode • Manual: If function button Manual is
pressed, it is possible to enter a value
in the Manual power output field.
• Not used: Power optimization is disa-
bled in parameter p237. UV lamps are
always lit to 100 %.
Manually set effect to LPS. Requires that

Manual power output the system is set in manual mode.
3.4.2 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.
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.
92 200000874-5-EN-GB

Table 6: Filter popup
Filter status:
• Idle (No backflush or preservation)
• Backflush preparation
Mode
• Backflush ongoing
• Continuous backflush
• Filter preservation
Indicates differential pressure over the il-

ter (PT201–71 minus PT201–72). When
Diff. pressure the pressure reach the value set in pa-
rameter p305, a backflush is triggered.
Current pressure:
Pressure • PT201–71: Inlet pressure.
• PT201–72: Outlet pressure.
Press the button to start a manual back-

flush. See instruction Backflush filter
manually on page 102.
For status indications, see Status indica-

tion – Component color in section Flow
Pipes, valves, motor and pump chart. See Page 1.1 – Overview on page
57.
3.5 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.
200000874-5-EN-GB 93
Preparations and conditions

For reference information, see the following sections in this chapter:
• Control system pages used in the instructions: See section Introduction to
the control system on page 50 and Detailed page descriptions on page 57.
• Login levels required for different procedures: See section Login levels on
page 50.
• Detailed information about components (valves, motors, pumps etc)
involved in each step the process. See section Detailed process description
on page 129.
3.5.1 Log in
Follow the steps below
1. Press the Login function button.
Result: A login popup is displayed.
2. Press the dropdown menu at the top of the popup. Press desired user.
Result: A keyboard is displayed.
3. Enter password and press Enter. (See section Login levels on page 50.)
94 200000874-5-EN-GB
3.5.2 Prepare operation

Before ballast operation, check the following:
• The flow must be within defined flow range during operation:
• Ballast: 326 – 2000 m3/h
Note: If you have filter ACB-9120–500 the data is correct. The system
may be supplied with a filter of larger size. If so, consult the Filter size
addendum for correct data.
• Deballast: 200 – 2000 m3/h
• Stripping: 200 – 2000 m3/h
• The input flow to the PureBallast system must be as close as possible to

the flow selected for an operation. This will reduce the stress and wear of
the control valve.
Preparations
Before ballast operation, do the following:
• Select IMO or USCG mode by using IMO or USCG function buttons, based
on which legislation that must be followed.
• For USCG: Select 3days or 0 day hold-time in parameter p182. If ballast
water is stored in tank shorter than 72 hours, the water must be treated
using 0 days mode at ballast.
• Make sure that all valves that lead the flow to and from PureBallast are
opened. They are not operated by PureBallast.
• Check the Alarm list (page 2.1) to verify that no alarms need attention.
• Select the flow before starting a process, either manually or automatically.
See Page 1.1 – Overview on page 57.
• Power for the system must be available. This is handled automatically if
power management is integrated. If power management is not integrated,
confirm the availability of the power manually.
Priming
To reduce the stress and wear of the complete ballast water system, follow the
steps below:
• Prime the system before starting operation:
1. Open sea chest valve to prime pipes upstream PureBallast.
2. Open valves to ballast water tank(s) to prime the pipes between
PureBallast and the tanks to be filled. Any tank(s) can be used to prime.
Note! Do not mix waters treated with different modes.
3. Close valves to tank(s) when system is primed.
• Select the high or the low sea chest depending on water conditions:
• If the water is muddy (for example in port), select high sea chest.
• If the water is icy waters, select low sea chest.
• Deaerate the piping, especially at high points.
200000874-5-EN-GB 95
3.5.3 Perform ballast

Follow this instruction to ballast.
• See information in section Prepare operation on page 95.
Follow the steps below:
1. Press the function button Ballast.
Comment: If the button is not blue, check that flow or UV reactors have
been selected
2. Wait for the message “Open valves ...” and act accordingly. See section
Operational conditions on page 46.
Result: Ballast start-up starts, with cooling water cooling the lamps during
warm-up.
3. Wait for the message “Confirm ballast pump started” and act accordingly.
Result: Cooling stops and ballasting starts.
4. When desired amount of water has been processed, press the function
button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but
not more than 50 %
Result: Ongoing process is stopped and the lamps are switched off. An
automatic filter backflush is performed.
5. Wait for the message “Close valves ...” and act accordingly.
6. Wait for the message “Stop ballast water pump” and act accordingly.
7. Wait for the ”Start CIP” popup.
Yes: A CIP process will be started after the UV lamp cooling time (5
minutes ).
If No: is chosen, CIP must be started within time indicated in the popup. A
ballast/deballast process can be started after the UV lamp cooling time (5
minutes ).
96 200000874-5-EN-GB
NOTE
A CIP cleaning process must be finished within the time stated in the
popup (30 hours from the first operation after the previous CIP process).
Therefore consider the time for CIP process. A CIP process takes about
25 minutes per UV reactor. if default parameters are used. If no CIP
process is performed within the time limit an entry is made in the control
system log file. Operations after the warning does not fulfill the type
approval certificate.
Note that it is possible to run operations during the 30 hours. Complete
status information regarding CIP is displayed in page 1.3 CIP status. A
CIP process is started manually according to instruction CIP clean UV
reactor after ballast / deballast / stripping on page 104.
3.5.4 Perform deballast

Follow this instruction to ballast.
1. Press the function button Deballast.
Comment: If the button is not blue, check that flow or UV reactors have
been selected
2. Wait for the message “Open valves ...” and act accordingly. See section
Operational conditions on page 46.
Result: Deballast start-up starts, with cooling water cooling the lamps
during warm-up.
3. Wait for the message “Confirm ballast pump started” and act accordingly.
Result: Cooling stops and deballasting starts.
4. When desired amount of water has been processed, press the function
button Stop
To get a smooth stop, the flow from the ballast pump can be reduced, but
not more than 50 %
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message “Stop ballast water pump” and act accordingly.
200000874-5-EN-GB 97
minutes ).
minutes ).
NOTE
25 minutes per UV reactor. if default parameters are used. If no CIP
process is performed within the time limit an entry is made in the control
system log file. Operations after the warning does not fulfill the type
approval certificate.
3.5.5 Perform tank stripping

Follow this instruction to strip .
• Stripping function must be activated in parameter p170. Number of UV
reactors used during stripping must be set in p171.
1. Press the function button Strip.
Comment: If the button is not blue, check that flow or UV reactor have
been selected.
2. Wait for the message “Open valves ...”. and act accordingly. . Open
relevant valves and then press the button in the popup to confirm the
action. See section Operational conditions on page 46
Result: Deballast start-up starts, with cooling water cooling the lamps
during warm-up.
98 200000874-5-EN-GB
3. Wait for the message “Confirm strip pump started” and act accordingly.
Result: Cooling stops and stripping starts.
4. When desired amount of water has been stripped, press the function
button Stop.
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message “Stop stripping water pump” and act accordingly.
minutes ).
minutes ).
NOTE
25 minutes per UV reactor. Operations after the warning does not fulfill the
type approval certificate.
3.5.6 Pause ballast / deballast / stripping

Follow this instruction to pause an ongoing process. Preparations and conditions
• This is only possible in sub process full ballast or full deballast. This is indicated by the lit Pause
button.
• Allowed in sub process full stripping if activated in parameter (p170). After defined time, the
paused process is stopped.
• Allowed length of a pause is parameter set (p138). After defined time, the paused process is
stopped.
200000874-5-EN-GB 99
1 Press the function button Pause.
2 Wait for the message “Stop ballast water

pump”. Stop the pump and then press the
button in the popup to confirm the action.
Note! This component is outside the
PureBallast system control. (The popup is not
displayed if the component feedback is
integrated with the control system.)
Result: Ongoing process is paused. The UV
lamps remains on at reduced power and
cooling water is run through the UV reactor to
cool the lamps. Pause mode is indicated by
yellow light under the Pause button and
blinking yellow under the function button
Ballast, Deballast or Strip.
3 To resume the process. Press the Ballast/

Deballast/Stripping button.
Result: PureBallast resumes paused process.
4 Wait for the message “Confirm ballast pump

started”. Start the pump and press the button
in the popup to confirm the action. Note! This
component is outside the PureBallast system
control. (The popup is not displayed if the
component feedback is integrated with the
control system.)
Result: The process is resumed.
3.5.7 Heeling (internal transfer)

• This is only possible in sub process standby, full ballast, full deballast and full stripping.
• Allowed length of heeling is parameter set (p138). After defined time, the process is stopped.
• The remote mode must be activated, by pressing the Remote function button.
If heeling is activated in the sub process standby, the PureBallast system will remain in standby. If
heeling is activated in the sub process full ballast, full deballast or full stripping, the ongoing process
will be paused. In both cases, an alarm will be issued and saved to the event log. To activate heeling
during a process, follow the steps below.
1 Activate heeling from ISCS, if implemented.

An alarm is issued and saved to the event
log.
100 200000874-5-EN-GB
2 Wait for the message “Stop ballast water

pump” to appear on the PureBallast control
panel.
Note:This component is outside the
PureBallast system control. (The popup is not
displayed if the component feedback is
integrated with the control system.)
Note: If you need the ballast pump for
heeling, confirm the request without stopping
the ballast water pump.
The system is now in heeling mode. The UV
lamps remains at reduced power and cooling
water is run through the UVR to avoid
overheating of the lamps. The Pause button
is yellow and the Ballast, Deballast and
Strip buttons are blinking.
3 To resume the process, deactivate the

heeling from ISCS.
4 Wait for the message “Confirm ballast pump

started”. Start the pump and press the button
in the popup to confirm the action. (The
popup is not displayed if the component
feedback is integrated with the control
system.)
Result: The process is resumed.
5 If heeling signal from ISCS is not

implemented, make an entry in the ballast
water record book that heeling was
performed. This is necessary to explain to
any inspector why the bypass valve was
opened.
3.5.8 Change ballast / deballast / stripping flow

Follow this instruction to increase (only possible in ballast) or decrease flow during an ongoing
operation.
• During process, flow can only be changed in the sub process full ballast, full deballast and full
stripping. Current status is indicated in the Status box
.
• It is only possible to increase flow in full ballast mode.
1 Go to page 1.1 Overview or or 1.2 UVR and

flow selection.
200000874-5-EN-GB 101
2 Press the + or - button to change flow.

Result: New flow is updated in the Flow
selection.
3 Press the Apply button to activate the

selection.
Result: The flow is updated in the Certified
flow field when the lamps fully started (after
90 seconds). The change of flow is executed
and can be monitored in the Flow field in this
page and page 1.1 Overview.
3.5.9 Start ballast / deballast / stripping with specified UV reactor

Follow this instruction to ballast with a specified number of UV reactors to be used during ballasting.
• The Auto button on page 1.1 Overview must be deactivated.
.
1 Go to page 1.2 UVR and flow selection.
2 Press the Modify button in the UVR

selection area.
Result: UVR buttons turns blue for UV reactor
that are indicated to be ready and free from
alarm.
3 Press the button for desired UV reactors.

Result: The UV reactor is selected, indicated
by a checkmark on the button.
4 Press the Apply selected UVRs to activate

the selection.
Result: The Selected indication is lit for
selected UV reactors.
5 Continue with ballast or deballast according

to instructions.
3.5.10 Backflush filter manually

Follow this instruction to backflush rinse the filter manually.
• The system must be in full ballast mode.
• The system can be in standby to test the backflush motor, but the filter will
not be cleaned.
102 200000874-5-EN-GB
1. Go to page 1.1 Overview.

2. Press the Filter in the flow chart.
Result: The Filter popup is displayed.
3. Press the Start backflush button.
Result: A backflush is performed. The default backflush process time is 20
seconds.
200000874-5-EN-GB 103
3.5.11 CIP clean UV reactor after ballast / deballast /

stripping
Follow this instruction to clean the UV reactor(s) using the cleaning in place
(CIP) process.
• The system must be in standby mode. This means that this operation
cannot be executed during ballast or deballast.
• We recommend that a CIP process is performed in the same location as
the ballast operation was done. If not possible, in international waters (200
nautical miles from the baseline). This due to risk of untreated or not fully
treated water remaining in reactor/filter.
• 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 UV reactors are required to be CIP:ed etc.
• If a ballast operation has been performed since the last CIP process, the
process is completed with a filter preservation, where the filter is filled up
with technical water / potable water.

1. Press the function button CIP.
Result: The CIP process starts. The CIP process takes approximately 25
minutes per UV reactor.
2. Wait for the message “Open valves ...”. Open overboard valves for the
backflush pipe, 309 and the CIP drain pipe, 460. Also make sure that
valves leading technical or potable water to pipe 310 are opened. Press
the Confirm button to confirm the action. Note! These valves are outside
the PureBallast system control. (The popup is not displayed if the
component feedback is integrated with the control system.)
Result: The CIP process starts. The CIP process takes about 25 minutes
per UV reactor, if default parameters are used.
Note: If CIP process is started after a process the CIP process will start
after 5 minutes, when the UV lamps have been cooled.
3. Wait for the message “Close valves ...”. Close overboard valves for the
backflush pipe, 309 and the drain pipe, 460. Press the Confirm button to
confirm the action. See section Operational conditions on page 46. Note!
These valves are outside the PureBallast system control. (The popup is not
displayed if the component feedback is integrated with the control system.)
3.5.12 Drain UV reactor

Make sure that the following valves are closed: UV reactor inlet (V201-19.n) and outlet (V201-20.n).
1 Open the overboard valve for pipe 460.1.

The valve is outside PureBallast’s system
control.
2 Log in as Advanced operator or higher.
104 200000874-5-EN-GB
3 Set the system in manual mode.
4 Open the following valves: V571-1, V321-2,

V321-3 and 460-2.
5 Start pump P321–5.

The UV reactor is drained of water.
6 Let the pump run for the time entered in

parameter p200 UV reactor draining.
7 Stop pump P321–5.
8 Exit manual mode to close the valves.
3.5.13 Attend to alarms

Follow this instruction to attend to alarms and warnings. For descriptions of
alarms and trouble shooting, see chapter 5. Alarms and faultfinding.

• Alarms will shut down ongoing process and disable start of process.
• Warnings are information to the operator and will not shut down ongoing or
disable start of process.
• An alarm or warning will activate the alarm buzzer (sound and light) on the
cabinet. The sound is silenced by touching the buzzer, but note that the
alarm is not acknowledged by this.
WARNING
Never reset an alarm without first finding and attending to the problem.
Requires login level Operator or higher.
For color indication of alarms. See Page 2.1 – Alarm list on page 68.
200000874-5-EN-GB 105
1. Go to page 2.1 Alarm list to view active alarms.

• In case of alarm with shutdown, go to step 2.
• In case of warning, go to step 3.
2. If the process have stopped: Take action to eliminate what has caused the
alarm.
3. If the process continues: Consider if the process shall be terminated. Take
action to eliminate what has caused the alarm.
4. After the problem has been dealt with Press the Ack all button to
acknowledge all alarms, or press the alarm row and press Ack selected
button to acknowledge only this alarm.
Result: The alarm will change color to indicate change of status. See
section Page 2.1 Alarm list in this chapter.
The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.
3.5.14 Shut down and deactivate system

Follow this instruction to quickly stop any ongoing operation in the PureBallast
system, for example, when a critical fault has been detected, or to make the
system deactivated (powered off/isolated).
PureBallast will shut down if the system loose power (intentionally or
unintentionally) or if an alarm is issued. Alarm has alarm ID beginning with an
“A”.
Events at shutdown
• Any ongoing process will stop.
• Valves will return to closed position. Valves are opened at high signal from
the control system, and when this signal is lost, the valves are closed
pneumatically.
• The following signals to ISCS are lost, which means that PureBallast no
longer require overboard valve open, ballast pump running and request for
dedicated power if power management (optional) is used.
• An event is written to the event log.
• The VFD and booster pump P201–1 will stop. The VFD will go into “pre-
heating mode” to keep the pump motor warm.
106 200000874-5-EN-GB
Control cabinet Lamp drive cabinet
1. Main breaker
2. Emergency stop button
3. Reset button
4. Alarm (light and sound)
A. Main breaker
B. Reset button

One of the following methods can be used to abort any ongoing operation and
stop the system:
Action Method
Stop ongoing process Press the Stop button in the control pan-
el.
Result: Ongoing process is stopped in a
controlled way. Valves are returned to
starting position.
If an external system stop button has
been installed and integrated.
Result: Ongoing process is stopped and
System stop (External button) valves are returned to starting position as
fast as possible.
Note: The power is still on.
The VFD has its own electricity supply
Deactivate VFD and can be switched off using the ship’s
switch board.
Press the Emergency stop button (2) on
the control cabinet.
Emergency stop Result: Ongoing process is stopped im-
mediately, without controlled closing of
any valves, UV lamps etc.
200000874-5-EN-GB 107
Action Method
The VFD has its own electricity supply
Deactivate VFD and can be switched off using the ship’s
switch board.
Complete deactivation is performed in
two steps:
1. 1. Turn off the main breaker (1) at
the side of the control cabinet.
2. Turn off the main breaker (A) on
the lamp drive cabinet (LDC)
doors.
Deactivate PureBallast to make it com- The system is then powered off/isola-
pletely deactivated (powered off/isolated on the PureBallast side of the
ted). main breaker in the control cabinet
and in the lamp drive cabinets.
2. To make the complete system pow-
ered off/isolated, power to PureBal-
last must be switched off using the
ship’s switch board.
Note: Both breakers can be locked in off
position using a padlock.
Reset system after shut down

Follow this instruction to reset the system if deactivated. Numbers refer to the
illustration above.
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.
The system is reset on the control cabinet, depending on reason for shut
down:
Emergency
stop button
(pressed Release the emergency stop button on the control cabinet (2).
down posi-
tion)
Reset button The system has been shut off by the emergency stop button (2) on
on control the control cabinet, external system stop button or power failure.
cabinet
(blue light lit) Press the Reset button (3) on the control cabinet.
Reset button The system has been shut off by power off or by too high tempera-
on LDC ture.
(blue light lit) Press the Reset button (B) on the LDC.
3.5.15 Operate components manually

Follow this instruction to operate components manually. This shall only be
done during commissioning, advanced faultfinding or service.
This is the recommended way to operate components manually. Valves can
also be operated manually according to instruction in chapter 7. Service
manual, section Valves.
The following components can be operated manually:
108 200000874-5-EN-GB
• Filter motor (M709-43)

• Ballast water booster pump (P201–1)*, if installed
• CIP pump for CIP liquid (P320-1)
• CIP pump for draining (P321-5)
• LDC cooling water pump (P401–1), if installed
• UVR cooling water pump (P403–1), if installed
• UV lamps in the UV reactor
• UV lamp power.
* Note: Not from HMI. Only operated manually from local keypad on VFD.
• This operation requires login level Advanced operator or higher.
• It is not possible to run a processes in manual mode. Only individual
components can be operated.
• When operating valves, the screw on the pilot valve block must be in
position 0: Closed (default position).
1. Go to page 1.1 Overview or 1.4 CIP status.
2. Press the button Manual function button.
Result: The control system is set in manual mode.
3. Press desired component.
Result: A popup is opened. Current status is indicated. If an existing alarm
exist, it is indicated with an alarm icon. If the UV reactor or filter was
pressed, a popup is opened with sub components. If the CIP was pressed,
page 1.4 CIP status is opened.
Example popup for a valve.
200000874-5-EN-GB 109
4. Press (not slide) the Hand button icon to enable manual operation of the
component.
Result: The open and closed buttons turn blue for operation. A hand icon is
also displayed on the component in the popup and the page to indicate
that it is manually operated.
5. Operate the component using the open/run (left) and closed/not running
(right) buttons in the popup.
6. Press Hand button to stop manual mode for the component and the X
button to close the popup.
or
Press the X button to close the popup and let the component remain in
manually set status. The popup is closed, and a hand icon is displayed by
the component to indicate it is manually operated.
7. Press the Manual function button to exit manual mode.
Result: All manually operated components are restored to their default
status.
3.5.16 Operate UV lamps manually

Follow this instruction to start and stop UV lamps in the UV reactor and to dim
the UV lamps. This can, for example, be done to check that a changed lamp is
working.
• The control system must be in manual mode.
DANGER
Manual start of the UV lamps is only allowed (and possible) when there is
water in the UV reactor (indicated by level switch LS201-29 and
LS201-30), 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.

1. Go to page 1.1 Overview. Press the Manual function button to activate
manual mode.
2. Press the UVR image.
Result: The UVR popup opens. (See description Popup windows in section
Detailed page descriptions on page 57.
3. Select which UV reactor to operate in the UVR number entry field.
110 200000874-5-EN-GB
4. Open, in stated order, the following valves to fill the UV reactor with water:
201-19, 404-36 and 403-35.
Result: The UV reactor is now filled with water through the cooling water
line 403.
5. Wait until the UV reactor is filled with water, indicated by the level switch
(LS201–29) turning green.
6. Press the LPS control button.
Result: The LPS control popup is displayed for selected UV reactor. Press
the field to enter an UV reactor number, or press the arrows to step up or
down.
7. Press the Manual mode button to enable manual operation of the UV

lamps.
8. Operate the lamps by pressing one of the following buttons:
• Start all LPS units
• Stop all LPS units
• LPS 1–16
Start / stop lamps. Each LPS supply powers to . The buttons toggles
between started and stopped. Place the UVR and the LPS control popups
side to side to see that the lams are started.
UV lamp stauts: Grey = Stopped; Green = Started; Yellow = Starting.
9. If desired, the UV lamps can be dimmed manually: Press the LPS status
button in the UV reactor popup. Press the Manual output field, and enter
desired percentage between 50 and 100 %. The LPS will give the entered
percentage of full effect to the UV lamps. This is indicated in the Power
output field.
10. Press the Stop all LPS units button.
Result: Any lit UV lamps are stopped and the popup is closed.
11. Press the Close button to close the popup.
12. Press the Manual function button exit manual mode.
Result: All manually operated components are restored to standby status.
200000874-5-EN-GB 111
3.5.17 Set ship specific component ID

Follow this instruction to enter ship specific IDs for valves and pumps. If the
ship have own IDs for the components, it is possible to make a note in
respective component popup.
• If remote control panels (option) are used, entered IDs will be displayed on
all panels.
• Requires login level Advanced operator.
2. Press desired component.
Result: A popup is opened.
Example: Popup with ship specific ID. Entered ID is displayed on the component
to the left.
3. Press the input field at the bottom.

4. Use the keyboard to enter an ID. Press Enter to finish.
Result: The name is saved and visible in page 1.1 Overview and in the
popup.
3.5.18 Export control system event log files

Follow this instruction to copy event log files and alarm lists from the control
system. The information (copied as text files to a USB memory).
The following information can be exported:
112 200000874-5-EN-GB
Information to be ex- Description

ported
The event log includes all events in the PureBallast sys-
Event log tem. Also additional information is stored, for example
processed volume, UV intensity and power consumption.
A list of all alarms and warnings that has been issued
Alarms and warnings from the control system. Intended to be used mainly by
service technicians.
Only used when PLC soft ware is updated. The system
export events and parameter settings to a USB, where
Update export the information is stored temporarily during the update.
After update, the system retrieves the information back to
the PLC.
For specific information about logged events, see section List of logged
information on page 126.
• Events are only copied, hence they will remain in the control system.
• The log and alarm files are stamped with the system name and serial
number entered in page 5.6 Installation parameters.
• The easiest way of reading the log file is to use the program Visualog, a
tool designed to present and analyze the information from the PureBallast
log files. Log files may also be read in Excel.
1. Go to page 4.1 System info.
2. Press the Export button in page section Export log files.
Result: A popup is displayed.
Note: The Update export button is only used when updating softwares.
3. Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC
port on the cabinet door.
200000874-5-EN-GB 113
4. Chose one of the following alternatives to decide time interval for the
information to be copied:
• Recommended: Accept suggested default time interval in the Start and
End filelds. Default start date is the oldest file in the system, and default
end date is today's date.
• Optional: Press the Specify time interval box, and enter desired
interval in the Start and End filelds.
5. Press the function buttons Events.
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. Press the function buttons
Alarms.
7. Wait for the message "Export OK" to appear.
Result: A folder named PureBallast has been downloaded. It contains two
sub folders: Alarm and Event. The folder corresponding to your export
choice contains a CSV file.
8. Press Close and remove the USB memory.
3.5.19 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:
• Parameter settings. File: Parameters.csv.
• Operating timers for UVR, UV lamps etc. File: operatingtimers.csv.
• Settings for components in the trend curve pages. File: ValueSaved.xml
and ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different components.
File: ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Backup button in page section Backup and restore.
Result: A popup is displayed and the process is started. Read the final line
of list before closing the popup: Important information might be displayed.
4. Wait for the OK / Close button to turn blue again. If the backup was
successful, the last line shall state "Backup done".
Result: A folder named PureBallast backup has been saved containing the
backup files.
5. Remove the USB memory.
114 200000874-5-EN-GB
3.5.20 Restore control system settings

Follow this instruction to restore all control system settings, previously saved
to a USB memory. This includes parameters and settings for the page 3.1
Trend.
• 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 Page 4.1 – System info on page 76.
• This method shall not be used to restore parameter settings after software
update.
• If you do not wish to update a certain type of setting, remove the specific
file from the USB memory before inserting the USB memory in the USB
panel port on the cabinet door.
• Remove the file Parameters.csv from the USB before following this
instruction.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Restore button in page section Backup and restore, Settings
to/from HMI USB.
Result: A popup is displayed and the process is started.
4. Wait for the OK / Close button to turn blue.
5. Read the second last line in popup: If the restore was successful, it shall
state "Restore done".
6. Press the OK / Close button on the popup.
7. Remove the USB memory.
8. The control panel must be rebooted. At the rear side of the control panel:
Pull out the power cable from the 24V DC port, and insert it again.
3.5.21 Set control panel IP address

Follow this instruction to set IP address for the main panel and the remote
control panels (optional).
• This setting shall be done for all panels installed.
• These instructions require login level AlfaLaval.
• Port LAN 1 must be used for the Ethernet cable at the backside of the
panel.
200000874-5-EN-GB 115

2. Press the Setup button in the IP settings box.
Result: The IP settings popup is displayed.
3. Press the IP settings button.
4. In the Port 1 tab select the radio button Specify an IP address.

Enter the IP address according to the list below. Also check that correct
setting is done for Port 2 in the Port 2 tab.
NOTE
Only the IP address shall be changed.
5. Press OK.
6. Reboot the panel to update communication with the new IP address. Make
sure that the new IP address is displayed on page 4.1 System info.
7. Repeat this instruction for all installed control panels, both main and
remote control panels, if installed.
8. Follow the instruction Set remote control panel communication to activate
remote control panel.
3.5.22 Set remote control panel communication

Follow this instruction to connect remote control panels (optional) to the PLC.
• These instructions require login level AlfaLava.
• The same setting shall be done for all panels installed.
• IP addresses must have been set according to instruction Set control panel
IP address.
116 200000874-5-EN-GB
• Main control panel and remote control panel 1 (192.168.0.11) are added as
default . If no remote control panels is used, address 192.168.0.11 shall be
removed.
• All remote control panels must be on and connected with an Ethernet
cable.
1. On the main panel in the control cabinet : Go to page 4.1 System info.
2. In the Remote control panels box, press the Set button.
3. Select an available remote control panel in the left hand side.

4. Press the >> button.
Result: The panel is connected and moved to the right hand side.
NOTE
Server port shall always be “1001”.
5. Press the Panel alias field for the new control panel. Use the keyboard to
enter a name, for example the location it is placed.
NOTE
Panel alias for all control panels shall be entered (with the same wording)
in all panels to be displayed in a correct way.
6. Press the save (USB symbol) button.
Result: The information is saved and the popup is closed.
7. Repeat step 4–7 to connect more remote control panels.
8. Repeat this entire instruction for all installed panels.
200000874-5-EN-GB 117
Delete a remote control panel

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

Follow this instruction to make settings for the remote interface (optional)
communication between the ISCS and PureBallast.
• These instructions require login level AlfaLaval.
1. Go to page 4.5 Remote interface 1 and 4.6 Remote interface 2 and .
2. Set parameters to match ISCS’s RTU server data according to the
information in chapter 4. Parameters, section 5.7 Remote interface.
3.5.24 Test remote interface communication

Follow this instruction to test that the remote interface (optional)
communication between PureBallast's PLC and the ISCS is correct and
functioning.
Test communication
The first test is to see that the two systems communicate.
1. Go to page 4.5 Remote interface 1 . Make sure that the system is not in
test mode (no checkmark on the button). If not, press the Test mode
button to deactivate it. Make sure that Local operation is activated. If not,
press the Local function button.
2. Check that the heartbeat signal is updated in both systems (06 and 77).
Also check that values are read from the PureBallast system, for example
temperature (address 116 and 117).
This will confirm that the systems communicate.
Test values sent from PureBallast to ISCS
Values are entered and displayed in the control system as actual values, but
are sent to ISCS using the binary numeral system. This information is found in
group Data to ISCS and Cmd/status to ISCS on page 4.5 Remote interface 1,
and is indicated by a unit (m3, hour, second, kW etc).
Addresses with special conditions
The following addresses does not display correct values in page 4.5:
• 50 Process volume
• 52 System pressure
• 63 Differential pressure over filter
• 64 Temperature in electric cabinet (TT401)
• 65 Filter outlet pressure V201–72
118 200000874-5-EN-GB
• 66 Power consumption
• 57/58 Current time
• 114 UV reactor temperature (TT201–33)
For detailed information, see the directory of addresses.
1. Press the Remote function button.
Result: Test mode is activated enabling that communication is sent
between the systems without actually affecting the control system (start
processes etc). This also result in alarm A93 Heartbeat signal missing.
This alarm shall be ignored during this test.
2. Enter actual values in the in the entry field for the address to send
simulated information to the ISCS. Information in decimal form, for
example processed volume, is written as actual values. Information in
binary form, for example command status, is written as a bit pattern. The
key for the bit pattern is found in chapter 6. Installation description and
drawings, section
System interfaces.
3. Make sure that values and status information is displayed correspondingly
in the ISCS.
4. Repeat the simulation for the information you which to test.
NOTE
Only implemented signals needs to be tested.
Test commands from ISCS to PureBallast
In the ISCS, activate input commands corresponding to the addresses
displayed in page 4.5. (Note that address 06 does not need to be tested; it
was tested at the beginning of this procedure.)
1. Activate a command from ISCS, according to the HMI implementation.
2. Make sure that the command is received in page 4.5. Use the directory of
addresses to see that the bit pattern is updated correctly.
3. In the control panel, restore all changed values after the communication
test. If not, commands might be executed involuntarily, when the system is
set to online again. Most important is that address 001
displays ”00000000”.
Test alarms and warnings
Alarms and warnings are tested by simulation in control page 4.5 Remote
interface 1 and 4.6 Remote interface 2 and . Use the alarm list to identify
addresses and bit patterns for the alarms.
You want to simulate alarm W40 (Process pressure too low). When you find
W40 in the table, you use the column heading to see which address the alarm
shall be sent to and the row heading to see which bit in the bit pattern that
shall be high. For W40 the signal shall be sent to address 902, and bit 12 shall
be high.
200000874-5-EN-GB 119
Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first
digit from right is counted as zero, second digit counted as 1 etc). This gives
the following bit pattern: 0010000000000000.
1. Enter the desired bit pattern in the entry field for the address.
2. Make sure that the alarm/warning is indicated in ISCS.
3. If common alarm and warnings are used, make sure that address 70:7 and
70:8 are updated. It is only necessary to check this for the first alarm.
4. Clear the bit pattern in the entry field.
5. Repeat the simulation for those alarms/warnings you which to test.
6. Press the Test mode button to set the system in online mode (no check
mark on the button).
Press the Remote function button if you want to activate remote control.
3.5.25 Simulate power request

Follow this instruction to test the power management signals if PureBallast is integrated with the
vessel's power management system. This instruction can also be used in manual mode during
faultfinding.
This instruction requires login level Advanced operator or higher.
1 Go to page 1.4 Power request. Press the

Manual function button.
Result: The control system is set in manual
mode, indicated by a green checkmark on the
button.
2 Press the hand button in the Request column

for a row with power step for desired number
of UV reactors. For details, see description of
page 1.4 Power request.
3 Press the Request button for the row to

simulate power request signal.
Result: Status is updated to “Requested” in
the Request column.
4 Wait until the status is updated to “Yes” in the

Granted column.
5 Press the hand button in the Status column.
6 Press the Set run button to simulate running

signal.
Result: Status is updated to “Running” in the
Status column.
120 200000874-5-EN-GB
7 Press the Set run button to deactivate the

simulate running signal.
8 Press the Manual function button to exit

manual mode.
3.5.26 Update control system softwares

Control system softwares must be updated according the Release note for the
specific version of the softwares. The release note contains instructions for
updating the softwares and information about new features, changes in the
software etc.
The following is needed:
• A flash card with correct version of the PLC software.
• A USB memory with HMI software. Note that the same version must be
used for the HMI and PLC software (same version number).
• A USB memory with the T15BR firmware.
3.5.27 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 bottom side of the
control panel. And then reconnect the power cable.
For remote control panels: Use the Power button to turn off, and then turn
on the power.
2. Wait for a sandglass to appear and disappear. When it appears again,
press a finger on the screen and hold it there for approximately 20
seconds.
Note: Keep holding the finger on the screen even when the panel turns
white with a red message “Welcome to ...”.
3. Wait for the screen to turn completely white with a message “Tap anywhere
on the screen within 10 seconds”. Release the finger and tap once on the
screen.
4. Follow the instructions on the screen.
3.5.28 Fine tune flow and pressure control

Calibration of flow and pressure regulation (also called PID calibration) is
performed to fine tune the system so it runs with a steady and even flow and
pressure.
3.5.28.1 Calibrate pressure controlled regulation

During ballast and deballast operation, the control valve is regulated based on
input from the flow transmitter FIT201–1 to maintain stable flow. Desired flow
200000874-5-EN-GB 121
is defined as selected certified flow for the operation minus the Undershoot
percentage set in parameter p111.
During backflush, the control valve is regulated based on input from the
pressure transmitter PT201-16 to maintain stable pressure for efficient
backflush. Desired pressure is defined in parameter p304.
The purpose is to adjust the movement of V201-8 when it changes from flow
controlled regulation to pressure controlled regulation which it does during
backflushing of the filter. The first goal is that the valve travels as fast as
possible to a steady position where it creates required pressure (as defined in
parameter p304).
The second goal is to shorten the time from backflush trigger to start of actual
backflush. This is done by shortening the time in p310 (Backflush initial delay)
that is done after the movement of V201-8 has been calibrated.
• This operation requires login level AlfaLaval.
• All components on page 3.1 Trend (15 min) shall be selected for plotting,
and Flow FIT201–1 shall be used for Y axis selection.
This instruction shall be read together with the example after the instruction.
1. Perform a backflush.
2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8.
Before the backflush, the valve shall move as fast as possible to a steady
position where it creates required pressure. If not, parameter p166 shall be
adjusted.
3. Adjust parameters, and perform a new backflush.
4. See if the curve has improved. Repeat until satisfactory result has been
achieved.
5. See if the time between backflush initiation and backflush can be
shortened . If possible, adjust parameter p310. See parameter p310 in the
example below.
Example
In this example, five backflushes are performed. After the first four
backflushes, the PID parameters where changed for pressure regulation to
adjust the movement of the control valve V201-8 before the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated
by the movement of the backflush valve V309–1 (pink line) and the movement
of control valve V201-8 is indicated by the blue line.
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
1st backflush curve slops downwards in a long bend, which means that it
takes time for V201-8 to find correct position.
Parameter p166 was adjusted to 0.6. This made the valve
movement much faster in the beginning, shown by the steep
2nd backflush 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.
122 200000874-5-EN-GB
Parameter p166 was increased to 1.2 which resulted in a satis-

factory valve movement (3): A fast movement, followed by a mi-
3rd backflush nor adjustment. A small overcompensation can be noted (curve
goes too low), that might be adjusted by decreasing the value to
1.1.
During the first backflushes, parameter p310 was set to 60 sec-
onds. The parameter defines time between a backflush is trig-
gered and it actually starts. But now, when V201-8 is calibrated,
4th backflush this time can be shortened. Before the fourth backflush parame-
ter p310 is set to 15 seconds. The shortened time span is indi-
cated by the braces in the illustration.
No parameter was changed. This backflush is only showed to
confirm that the parameter setting is OK and that the curve (5)
5th backflush for V201-8 is basically the same as for backflush three and four
(3 and 4).
3.5.28.2 External feed

External feed control is mandatory for PureBallast system configurations
where the permissible ballast flow differs from the permissible deballast flow
(the control valve V201–8 itself cannot control such large flow interval).
The external feed is used to fine tune the control of the flow that comes to
PureBallast. It works as an addition to the flow controlled by the control valve
(V201-8).
External feed and ballast water booster pump (P201–1) VFD

An internal pressure controller (PI-controller) in the ballast water booster pump
(P201–1) VFD, controls the speed of P201–1 to maintain the system pressure
(PT201-16) at the set point.
3.5.28.2.1 Fine tune external feed control (optional)

External feed control allows PureBallast to control the flow delivered from the
vessel’s ballast water system by regulating either the ballast water pump via a
variable frequency driver (VFD) or a valve installed before PureBallast.
If this optional signal is used to control flow to PureBallast, the regulation can
be finetuned to function as smooth as possible.
200000874-5-EN-GB 123
When the flow in the system is too high, PureBallast’s control valve V201-8 will
close to reduce flow. If the V201-8 closes more than a parameter set degree,
the control system sends a signal requesting the ballast pump to reduce the
speed (and so the flow). When the flow is reduced, V201-8 can open.
Valve V201-8 operates (open/closes) in a range between a parameter set
value (p157) and 100 %, where default is 70 %. Within this range, flow is
regulated by V201-8 without cavitation.
• This operation requires login level AlfaLaval.
This instruction shall be read together with the example after the instruction
1. Start a ballast process. Wait until the system is in mode Full ballast. Listen
for cavitation noises at V201-8.
If cavitation, go to step 2. It not, go to step 5.
2. Go to page 5.2 Main parameters 2.
3. Increase parameter p157 in steps of 5 % at a time. After each change, wait
until the parameter change take effect (a couple of minutes). Listen for
cavitation noises at V201-8.
Note: The effect can not be observed during backflush, since the external
feed function is disabled.
4. Stop raising when the noises from cavitation stops.
5. Look at the movement of V201-8. If the movement is continuously
changing and the curve is unstable, parameter p156 must be adjusted.
The goal is to get a smooth regulation with long and steady curves.
6. Increase parameter p156 in steps of 1 second per % at a time. After each
change, wait until the parameter change take effect (a couple of minutes).
7. Stop when the regulation curve flattens out and the trend curve is long and
smooth. See exemple below.
8. Stop the process.
9. Start another ballast operation. Verify settings during startup and process.
10. Perform a manual backflush. Verify settings during and after backflush.
Note: When the backflush is done, V201-8 is closed under 70 % (defined in
parameter p157). The external feed control signal is lowered to request
less flow from the pump, so that V201-8 can open. Less flow is needed
after the backflush, since the the filter is clean.
11. Stop the process.
12. Start a deballast. Verify settings during startup and process.
Example
In this example, parameter p156 External feed change rate is adjusted to get a
stable regulation.
The illustration is taken from page 3.1 Trend (15 min).
124 200000874-5-EN-GB
Parameter p156 was set to 2 s / % when process was started.

The curves for V201-8 (blue) and external feed (black) signal
Area 1 are chasing each other. The reason is that the request signal
changes too fast which makes V201-8 compensate, which af-
fects the signal in return.
Parameter p156 is raised to 6 seconds which makes the request
Area 2 signal change more slowly, which results in a smooth movement
of V201-8 when regulating the external flow.
200000874-5-EN-GB 125
3.6 List of logged information

Important events and alarm history are logged in the control system and
stored in the PLC for at least 24 months.
The control system store all alarms and relevant events for at least 24 months.
The memory has a vast safety margin, but when it is full, data will be deleted
starting with the oldest data. Logged information can be exported to a USB
memory stick. See Export control system event log files on page 112.
UVR is stated as ”UVR X”, where “X” indicates which UVR number the event
is valid for. This is not applicable for one UVR installations.
3.6.1 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). All events relevant to the IMO certificate are GPS stamped.
Event code Description GPS stamp
E70 Operator command, set certified flow to [x] m3/h N
E80 Operator command, start stripping is issued N
E100 Manual mode set by operator N
E110 Heeling mode set by ISCS. N
E120 Heeling mode cancelled by ISCS. N
E150 Overboard valve opened. Feedback from ISCS. Y
E155 Ballast water pump started. Feedback from ISCS. Y
E160 Overboard valve closed. Feedback from ISCS. Y
E165 Ballast water pump stopped. Feedback from ISCS. Y
External shutdown issued. (System stop button on N
E170 control cabinet or external system stop button)
System stopped by emergency button on control
E175 N
cabinet.
E190 Standby mode N
E210 Ballast Start-up mode N
E220 Full ballast mode Y
E230 Pause Ballast N
E240 Filter backflush mode N
E250 Stop ballast mode N
E260 Deballast start-up mode N
E270 Full deballast mode Y
E280 Pause Deballast mode N
E290 Stop deballast mode N
CIP process started, UVR [x, y, z ...]
E300 N
x, y, z ...= units that has been subjected to CIP.
E310 E-stop N
Power turned on. PureBallast has been powered
E320 off for XX days YY hrs ZZ min. Time of how long N
the power has been switched off
E330 X m3 of ballast intake treated Y
126 200000874-5-EN-GB
E331 Amount (m3) of ballast intake treated. Time interval Y

1 minute.
E340 X m3 of ballast discharge treated Y
E341 [X] m3 of ballast discharge treated. Time interval 1 Y

minute.
E350 PureBallast is bypassed. Valve V212-31 open. Y
PureBallast bypass discontinued. Valve V212-31
E360 closed. Y
E370 Request sent to ISCS: Open overboard valve. N

E380 Request sent to ISCS: Close overboard valve. N
E390 Request sent to ISCS: Start ballast water pump. N
E400 Request sent to ISCS: Stop ballast water pump. N
E410 Power requested from ISCS. N
E420 Power granted by ISCS. N
E430 Power used for process. N
PureBallast shut down and/or start blocked due to
E450 Y
alarm(s).
PureBallast is bypassed. Additional (external) by-
E460 Y
pass valve 1 open.
PureBallast bypass discontinued. Additional (ex-
E470 Y
ternal) bypass valve 1 closed.
E480 Y
pass valve 2 open.
E490 Y
E500 Y
pass valve 3 open.
E510 Y
E515 Y
pass valve opened from ISCS (remote interface).
System heeling via ISCS (remote interface) detec- Y
E517 ted.
E520 Low UV intensity in UVR 1. Y
E640 UV intensity in UVR 1: [X] W/m2 Y
E701 UVR 1 UV lamp time reset Y
200000874-5-EN-GB 127

E60 Power setpoint (%) for UVR 1: Y
E800 Flow higher than certified flow. Y
E801 Flow restored to certified flow Y
E805 System started in IMO mode Y
E806 System started in USCG 3d mode Y
E807 System started in USCG 0d mode Y
E810 UVR 1 was not CIP cleaned within required time. Y
E811 CIP cleaning completedfor UVR 1. Y
E813 CIP cleaning completed for UVR 2. Y
E817 CIP cleaning completed for UVR 4 Y
E5500 Bypass detected by Log box. Y
E5501 Heeling detected by Log box. Y
128 200000874-5-EN-GB
3.7 Detailed process description

This section gives a detailed description of the PureBallast processes. The
processes are divided into three main processes, with subprocesses, with
indications of automatic and manually initiated steps.
All steps are not valid for all installations.
200000874-5-EN-GB 129
3.7.1 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
• Manual mode
130 200000874-5-EN-GB
3.7.2 Ballast process

The ballast process and sub processes are illustrated and described below.
Note that the process can be stopped at any time.
3.7.2.1 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 valve (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 (LDC cooling water pump)
(if used)
- Open V403-35 (cooling water inlet)

- Open V401-51 (LDC cooling water inlet)
- Open V201-32 (filter outlet)
200000874-5-EN-GB 131
4 Power management
Automatic power request from PureBallast to
vessel’s power management system (if
integrated).
• Start P403-1 (UVR cooling water pump) (if
used).
5 UV lamp warming
• Open V404-36 (UV reactor outlet, cooling
water)
• Open V201-19 (reactor inlet).
6 Cooling water fills the UV reactors. When

filled, indicated by LS201-29 and LS201-30:
• Start UV lamps (100 %). If all lamps are
not lit within 70 seconds, process is
stopped.
• Start counter: UV lamp runtime.
• Start LDC fan.
• Set V201-8 (control valve) to 50 %.
7 Time p210 after all lamps are lit: Request

from control system to start ballast water
pump (outside PureBallast system). (Handled
enabled.)
8 Ballast water pump started by operator and

confirmed in control system. If not confirmed
within 20 seconds, lamp power is reduced to
50 %. If not confirmed within p141 (including
the 20 seconds), process is stopped.
9 Open V201-3 (filter inlet).
3.7.2.2 Full ballast

Purpose: To treat ballast water.
132 200000874-5-EN-GB
1 Component activities:
• - Open V201-20 (reactor outlet)
- Start counter: Accumulated water and
CIP required.
- Wait for flow p116 to be established. If
not established, process is stopped.
- Stop P403-1 (UVR cooling water pump)
(if used)
• - Close 403-35 (cooling water inlet)
- Close V404-36 (UV reactor outlet,

cooling water)
• Start P201–1 (if used), when minimum
flow is >10%.
• When flow is established: Start automatic
control of control valve V201-8 based on
input from the flow meter, and input from
UV sensor (QT201–50) and salinity
(conductivity sensor QIT201–1 and
temperature sensor TT201–33).
• USCG mode: Start flow control based on
input from UV sensor (QT201–50).
• After 2 minutes in full ballast: Start power
optimization based on input from UV
sensor (QT201–50).
3.7.2.3 Filter backflush

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

pressure over the filter.
• Start automatic control of control valve
(V201-8) based on input from the pressure
transmitter
• After p310 seconds; start filter motor
M709-43.
• Start backflush pump P309–1 (optional)
• Open V309–1.
2 Filter backflush is performed for p308

seconds
200000874-5-EN-GB 133
3 Filter backflush stop.

• Stop M709-43
• Close V309-1
• Stop backflush pump P309–1 (optional)
(V201-8) based on input from the flow
meter.
4 Differential pressure check. If necessary, the

process is repeated.
3.7.2.4 Change flow - Increase flow

Purpose: To increase flow during operation.
1 Operator adjusts the certified flow from the

control system.
2 Automatic power request from PureBallast to

integrated).
3 Component activities when power has been

granted. (Eventual ongoing backflush will
finish before the activities are effectuated):
water)
• Start counter: CIP required for new UV
reactor.
134 200000874-5-EN-GB
4 Component activities when added UV

reactors are filled, indicated by LS201-29 and
LS201-30. During warm-up, the lamps are
cooled with ballast water, sea-to-sea.
• - Start UV lamps (100 %).
- Start counter: UV lamp runtime

- Start LDC fan.
• Open V201-20 (reactor outlet)
• Close V404-36 (UV reactor outlet, cooling
water)
meter.
• After 2 minutes in full ballast: Start power
sensor QT201–50.
3.7.2.5 Change flow - Decrease flow

Purpose: To decrease flow during operation.
1 Operator adjusts the certified flow manually

from the control system.
• Automatic pressure and flow adjustment
(V201–8).
• One or more UV reactors are switched off.
• Component activities for switched off UV
reactors:
- UV lamps are lit at 100 % for 10

seconds, then switched off.
- Start counter UV lamp cooling time. A
new process can only be started after UV
lamps have been cooled down for 5
minutes.
- Stop counter: UV lamp runtime
- Close V201-19 (reactor inlet)
- Close V201-20 (reactor outlet)
- Automatic power request adjustment (if
integrated).
3.7.2.6 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).
200000874-5-EN-GB 135
1 Operator pause the ballast process manually.

Pause can also be initiated by an external
signal, for example when heeling is initiated
from the ISCS. In this case, the process is
resumed automatically when the heeling
signal is deactivated.
2 Set V201-8 (control valve) to parameter

(p113) set opening percent.
3 Request from control system to stop ballast

water pump (outside PureBallast system).
(Handled automatic, if external component
signal is enabled.)
4 BW pump stopped by operator and confirmed

in control system.
• - Open V404-36 (UV reactor outlet, cooling
water) on running UV reactors
- Stop counter: Accumulated water

• - Start P403-1 (UVR cooling water pump)
(if used)
- Close V201-3 (filter inlet)

- Close V201-20 (reactor outlet) on
running UV reactors
- UV lamps dimmed to 50 %
• Close V201-8 (control valve).
5 System in pause mode
6 Resume ballasting
Operator resumes the ballast process
manually.
• Set V201-8 (control valve) to 50 %
• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running
UV reactors.
7 Request from control system to start ballast

water pump” (outside PureBallast system).
signal is enabled.)
136 200000874-5-EN-GB
8 BW pump started by operator and confirmed

in control system. (Handled automatic, if
external component signal is enabled.)
• Open 201-3 (filter inlet)
9 Component activities when minimum process

flow established, indicated by FIT201-1:
• - Start counter: Accumulated water.

(if used)
cooling water) on running UV reactors
- Start automatic control of control valve
meter.
- After 2 minutes in full ballast: Start power
sensor QT201–50.
3.7.2.7 Stop ballast

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

• Stop P403-1 (UVR cooling water pump) (if
used), only needed if stop from pause
mode.
• Close V403-35 (cooling water inlet), only
needed if stop from pause mode.
• Run backflush process. (See section Filter
backflush in Ballast process.)
2 Request from control system stop ballast

signal is enabled.)
200000874-5-EN-GB 137
3 Set valves and stop UVRs

• Set V201-8 (control valve) to parameter
set opening percent [p113] and wait for
10s or BWP pump stopped or low flow
[p116].
• Close V201-3 (main inlet valve) and wait
for feedback “closed” or timeout feedback
[p115].
• Close V201-8 (control valve) completely.
• Close V201–32.
• UV lamps are lit at 100 % for 10 seconds,
then switched off.
• Start counter UV lamp cooling time. A new
process can only be started after UV
lamps have been cooled down for [p211]
minutes.
• Stop counter: UV lamp runtime.
• Automatic withdrawal of power allocation
(if integrated).
• Stop P201.1 (if used)
• Close V201-19 (reactor inlet).
• Close V201-20 (reactor outlet).
• Stop P401-1 LDC (LDC cooling water
pump) (if used).
• Close V401-51 LDC (LDC cooling water
inlet).
4 Feedback received in control system that BW

pump stopped.
5 Request from control system to close

overboard. (Handled automatic, if external
6 Popup reminder “Start CIP”. Option to start

CIP or delay.
138 200000874-5-EN-GB
3.7.3 Deballast process

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

1 Operator starts the deballast process

manually.


confirmed in control system.
(if used)

200000874-5-EN-GB 139
4 Power management
integrated).
used).
5 UV lamp warming
Component activities when power has been
granted:
water)
6 Water fills the UV reactors.

Component activities, when UV reactors are
stopped.
• Start LDC fan.

enabled.)
8 Ballast water pump started by operator and

9 Open V201–9 (main inlet valve)
3.7.3.2 Full deballast

Purpose: To treat ballast water.
140 200000874-5-EN-GB

• - Open V201-20 (reactor outlet)
- Start counter: Accumulated water and

CIP required.
(if used)

cooling water)
flow is >10%.
control of control valve (V201-8) based on
input from the flow meterand input from
UV sensor (QT201–50) and salinity
(conductivity sensor QIT201–1 and
temperature sensor TT201–33).
• USCG mode: Start flow control based on
input from UV sensor (QT201–50).
• After 2 minutes in full deballast: Start
power optimization based on input from
UV sensor (QT201–50).

200000874-5-EN-GB 141

(V201–8).
reactors:

minutes.
integrated).
3.7.3.4 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.
set opening percent.
• Open V403-35 (cooling water inlet)
(if used)
- Open V404-36 (UV reactor outlet, cooling

water) on running UV reactors.
142 200000874-5-EN-GB

signal is enabled.)
• - Stop counter: Accumulated water
- Close V201-9 (main inlet valve)

- Close V201-8 (control valve)
running UV reactors
- UV lamps dimmed to 50 %.
4 Resume deballasting
Operator resumes the deballast process
manually.
UV reactors.
5 Request from control system to start ballast

water pump” (outside PureBallast system).
signal is enabled.)
6 BW pump started by operator and confirmed

in control system.
• Open V201-9 (main inlet valve)
200000874-5-EN-GB 143


(if used)

cooling water).
meter.
- After 2 minutes in full deballast: Start
UV sensor QT201–50.
3.7.3.5 Stop deballast

Purpose: To stop the deballast process.
1 Operator stops the deballast process

manually.
mode.
needed if stop from pause mode.
2 Request from control system stop ballast

signal is enabled.)
144 200000874-5-EN-GB

[p116].
[p115].
then switched off.
minutes.
(if integrated).
• Stop P201–1 (if used).
pump) (if used).
inlet).
4 Feedback received in control system that BW

pump stopped.


CIP or delay.
200000874-5-EN-GB 145
3.7.4 Stripping process

The stripping process and sub processes are illustrated and described below.
Number of UV reactors used during stripping is defined in p171. Pump used
can either be a dedicated stripping pump or the ballast water pump. Note that
the process can be stopped at any time.
3.7.4.1 Stripping start-up

1 Operator starts the stripping process

manually.

146 200000874-5-EN-GB

(if used)

4 Power management
integrated).
used).
5 UV lamp warming
Component activities when power has been
granted:
water)
6 Water fills the UV reactors.

Component activities, when UV reactors are
stopped.
• Start LDC fan.
• Open V201-20 (reactor outlet)

enabled.)
8 Stripping water pump started by operator and

9 Open V201–9 (main inlet valve)
200000874-5-EN-GB 147
3.7.4.2 Full stripping

Purpose: To treat stripping water.

flow established (p172), indicated by
FIT201-1:
• - Start counter: Accumulated water and
CIP required.

(if used).

cooling water) on running UV reactors
flow is >10%.
control of control valve (V201-8) based on
input from the flow meter.


(V201–8).
reactors:

minutes.
integrated).
148 200000874-5-EN-GB
3.7.4.4 Pause stripping

Purpose: To pause the stripping process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea.
1 Operator pause the stripping process

manually.
set opening percent.
• Open V403-35 (cooling water inlet)
• Close V401–51 LDC (LDC cooling water
inlet)
(if used)
- Open V404-36 (UV reactor outlet, cooling

water) on running UV reactors.

signal is enabled.)
• - Stop counter: Accumulated water
- Close V201-9 (main inlet valve)

- Close V201-8 (control valve)
running UV reactors
- UV lamps dimmed to 50 %.
4 Resume stripping
Operator resumes the stripping process
manually.
UV reactors.
5 Request from control system to start stripping

pump” (outside PureBallast system).
signal is enabled.)
200000874-5-EN-GB 149
6 Stripping pump started by operator and

• Open V201-9 (main inlet valve)


(if used)
cooling water).
meter.
- After 2 minutes in full stripping: Start
UV sensor QT201–50.
3.7.4.5 Stop stripping

Purpose: To stop the stripping process.
1 Operator stops the stripping process

manually.
mode
needed if stop from pause mode
2 Request from control system stop stripping

enabled.)
150 200000874-5-EN-GB

[p116].
[p115].
then switched off.
minutes.
(if integrated).
• Stop P201.1 (if used)
pump) (if used).
inlet).
4 Feedback received in control system that

Stripping pump stopped.


CIP or delay.
200000874-5-EN-GB 151
3.7.5 CIP process

The CIP process is run to remove seawater scaling from the UV reactor after
ballast and deballast. The process is performed for used UV reactor in
sequence. The process can start directly after ballast or deballast process, or
be delayed. A CIP process is started manually according to instruction CIP
clean UV reactor after ballast / deballast / stripping on page 104. Note that the
process can be stopped at any time.
3.7.5.1 Start CIP
1 Operator starts the CIP process manually.


Note: If CIP process is started after a process
the CIP process will start after 2 minutes,
when the UV lamps have been cooled.
152 200000874-5-EN-GB
3.7.5.2 Drain ballast water
1 Component activities (in no specific order):

• - Open V460-2 (CIP, drain valve)
- Open V321–2 (UV reactor, upper CIP
return valve)
- Open V320–4 (UV reactor, lower CIP
return valve)
- Open V571-1 (CIP, deaeration valve)
- Start P321-5 (CIP, water pump).
2 Component activities, when UV reactors are

empty, indicated by LS201-29 and LS201-30:
• - Stop P321-5
- Close V571-1 (CIP, deaeration valve)

- Close V460-2 (CIP, drain valve)
- Close V321–2 (UV reactor, upper CIP
return valve)
- Close V320–4 (UV reactor, lower CIP
return valve).
3.7.5.3 Fresh water filling

Purpose: to fill UV reactor with technical water / potable water.
• - Open V571-1 (CIP, deaeration valve)
- Open V310-6 (CIP, UV reactor fresh
water filling)
return valve)
return valve).

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

return valve)
return valve).
3.7.5.4 Fresh water draining

Purpose: to drain UV reactor with technical water / potable water.
200000874-5-EN-GB 153
• -Open V460-2 (CIP, drain valve)
-Open V571-1 (CIP, deaeration valve)
-Open V321–2 (UV reactor, upper CIP
return valve)
-Open V320–4 (UV reactor, lower CIP
return valve)
-Start P321-5 (CIP, water pump).
2 Component activities when UV reactor is

empty, indicated by LS201-29 and LS201-30
+ drain time (p200):
• -Stop P321-5 (CIP, water pump)
-Close V571-1 (CIP, deaeration valve)

-Close V460-2 (CIP, drain valve)
-Close V321–2 (UV reactor, upper CIP
return valve)
-Close V320–4 (UV reactor, lower CIP
return valve)
3.7.5.5 CIP cleaning
• - Open V320–2 (CIP outlet to UV reactor)
- Open V320-4 (UV reactor, lower CIP
return valve)
- Open V321-2 (UV reactor, upper CIP
return valve)
- Open 321–4
- Start P320-1 (CIP, liquid pump).
2 When UV reactors are filled, indicated by

LS201-29 and LS201-30, CIP liquid is
circulated for 15 minutes.
3 Component activities after finished CIP

process:
• - Stop P320-1 (CIP, liquid pump)
- Close V320-2 (CIP outlet to UV reactor)

- Close V320-4 (UV reactor, lower CIP
return valve)
- Status update for the UV reactor: CIP
completed.
154 200000874-5-EN-GB
3.7.5.6 CIP draining
• - Open V321-4 (CIP, return valve)
- Open V321–1 (CIP, outlet valve)
- Open V321-2 (UV reactor, upper CIP
return valve)
- Open V320-4 (UV reactor, lower CIP
return valve)
- Start P321-5 (CIP, water pump).
2 Component activities, when UV reactor is

empty, indicated by LS201-29 and LS201-30,
+ drain time (p200):
• - Stop P321-5 (CIP, water pump)
- Close V321-2 (UV reactor, upper CIP

return valve)
- Close V 321-4 (CIP, return valve)
- Close V321-1 (CIP, outlet valve).
3.7.5.7 Fresh water filling

Purpose: to fill UV reactor with technical water / potable water.
• - Open V571-1 (CIP, deaeration valve)
- Open V310-6 (CIP, UV reactor fresh
water filling)
return valve)
return valve).

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

return valve)
return valve).
3.7.5.8 Repeat
When CIP process is done for the first UV reactor, the remaining UV reactors with status CIP required
are processed in the same way.
200000874-5-EN-GB 155
3.7.5.9 Filter preservation

Only performed if ballast has been performed since last filter preservation.
1 Component activities when all required UV

reactors are processed:
• - Open V310-1
- Open V309-1
- Start M709-43.
- Pressure measured on PT201-71.
2 Component activities after the filter is filled:

• - Stop M709-43
- Close V309-1
- Close V310-1.

4 Overboard valve closed by operator and

156 200000874-5-EN-GB
3.7.6 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 control panel.
• Operate and simulate power management.
The following limitations exist for manual mode:
• Requires login level; Advanced operator or higher. The Manual button is
only displayed for login level Advanced operator.
• Flow in pipes is not indicated in flow chart.
• Can only be activated from standby mode.
• No automatic processes can be run.
If another operator take over command by logging in on another control panel,
manual mode is deactivated, and the system returns to standby.
See instructions Operate components manually on page 108 and Operate UV
lamps manually on page 110.
200000874-5-EN-GB 157
3.8 Quick guide

3.8.1 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 UV reactor (UVR)
• Basic alarm handling
• Save log files to USB memory
• The Alarm list page 2.1 must be controlled to verify that there are no alarms
needing attention.
3.8.2 Ballast, deballast or strip

The following instructions are applicable for Ballast, Deballast and Strip
procedure.
1.
Press to login as operator with password aot.
2.
Press to check that there are no active alarms needing attention.
3.
Select the applicable flow setting. Press and to
change flow setting.
4.
Press the Ballast, Deballast, or Strip function button to
start.
a. If the popup windows are displayed, follow the instructions in them.
5.
Press Stop button after processing desired amount of water.
a. If the popup windows are displayed, follow the instructions in them.
6. A CIP reminder is displayed. Chose to CIP the system or to wait.
158 200000874-5-EN-GB
3.8.3 Alarm handling

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

icon in the control panel.
1. Go to page 2.1 Alarm list.
2. Press the Ack all button to see if the alarm is still applicable.
3. If the process have stopped: Take action to eliminate what has caused the
alarm.
4. If the process continues: Consider if the process shall be terminated. Take
action to eliminate what has caused the alarm.
5. Press the Ack selected or Ack all button after the problem has been dealt
with.
3.8.4 CIP clean UVR

• The system must be in stand by mode.
• 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 UVRs are required to be CIP:ed etc.
2.
Press the CIP button.
3. If popup windows are displayed, follow the instructions in them.
4. Close the overboard valve after the process is finished.
3.8.5 Export control system log files

Follow this instruction to copy control system information as text files to a USB
memory.
• Required USB memory.
1. Insert a USB memory in USB PLC port on the cabinet door.
3. Press the Export button in page section Export log files.
200000874-5-EN-GB 159
4. Popup Export PLC events is displayed.
5. Do not specify time interval.

6. Press Events to copy the information to the USB memory.
7. After export is completed, press Alarm.
8. Press Close and remove the USB memory.
160 200000874-5-EN-GB
EN
4 Parameters
200000874-5-EN-GB 161
EN 4 Parameters
4.1 Introduction
This chapter contains information about parameters in the control system and
parameter controlled components. It covers:
• Parameter page descriptions.
• Parameter lists including information about setting range, default values
etc.
4.2 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. The PureBallast equipment or connected equipment can be
irreparably damaged if set or handled incorrectly.
• The parameter settings can be exported to a USB memory for safety
backup, and be restored from a backup. See chapter 3. Operating
instructions and control system description for instructions.
• Parameters are valid for PLC software version 3.2.3.
• Parameters are roughly sorted by area, for example UV reactor, filter and
remote interface, but the sorting is not strict.
4.2.1 Introduction to parameters and parameter settings

All parameters are checked and adjusted at first start up during
commissioning.
NOTE Parameters shall normally be set by Alfa Laval.

Login level 2 or 3 is required to change parameters. Login level 2 gives
access to set parameters, with exception from crucial parameters, which
requires level 3.
Parameters are divided into four categories according to table below:

Parameter must be considered during commissioning. The
parameter should match the conditions of the installed sys-
tem. After that, the parameter should normally not be
changed.
Parameter should never be changed. Parameter only exist
to allow advanced faultfinding by Alfa Laval.
Parameter should normally be left alone. If there are specific
No icon reasons, the parameter may be changed.
Parameters in bold can only be changed by login level Alfa
p000 Laval. Parameters in normal text can be changed by login
level Advanced operator.
162 200000874-5-EN-GB
Parameters 4 EN
Follow this instruction to set parameters

1. Go to desired parameter page 5.1–5.7.
Result: The page is displayed with all parameters listed with current setting
and unit.
2. To see allowed range (maximum and minimum values) and change setting,
press the blue button (with the parameter ID). A button pair is displayed.
Press the ≤ ≥ sign to display range. Entered parameter value must be

within defined setting range.
3. To set parameter, press the 123 button.

Result: A keyboard is displayed.
4. Enter the setting and confirm by touching the Enter button. To close the
keyboard without saving data, touch the Esc button.
If the parameter is set with a drop down menu, select desired choice by
touching the value.
Result: The setting is saved directly, it is now safe to leave the page.
200000874-5-EN-GB 163
EN 4 Parameters
4.2.2 Page 5.1 — Main parameters 1

This section describes the main system parameters.
ID Parameter Default Min-Max Unit Description

value
Setpoint for shut down due to high pressure
at PT201–16. Default value shall be used for
p100 High pressure, shut- standard system.
down trigger 7.00 1–10 bar Max working pressure for standard system: 6
(PT201–16) bar.
Max working pressure for high pressure sys-
tem: 9 bar.
p101 Setpoint for warning due to high pressure at

High pressure, warn- PT201-16. Default value shall be used for
ing trigger 6.00 0–10 bar standard system.
(PT201-16)
Max. working pressure: See parameter p100.
Low pressure, warn-

p103 ing trigger 0.1 –1 to 2 bar Setpoint for warning due to low pressure.
(PT201-16)
Defines range for pressure transmitter

PT201–16. Set according to range printed on
p104 the transmitter.
Pressure range for 0 to 10 N/A bar Alternatives:
(PT201-16)
0 to 10
-1 to 15
Safety margin between defined max flow and

actual max flow to avoid unnecessary shut
Undershoot certified down.
p111 5 0–80 %
flow If flow meter FIT 201–1 is installed with a
bend before and after the parameter should
be set to at least 2 %.
164 200000874-5-EN-GB
Parameters 4 EN

value
During ballast and deballast, valve V201–8
handles the automatic pressure and flow con-
p113 Min opening for 20 10–100 % trol.
V201–8
This parameter defines minimum opening, to
secure an even flow without interruptions.
p116
Low flow shut down Set point for shut down due to low flow, de-
10 10–90 %
limit (FIT201-1) fined as percent of UVR capacity.
p117 Define max delay, in hours, before a CIP

Max delay of CIP cy- 6 0–24 hrs process must be performed after ballast or
cle, hours deballast.
p118 Define max delay, in days, before a CIP proc-

Max delay of CIP cy- 1 0–30 day ess must be performed after ballast or debal-
cle, days last.
Defines proportional gain (Pf) value used for

PID regulation of V201–8 during ballast and
p120 deballast.
0.00– Normal value: 0.1 – 1.5.
PID proportional gain 0.30 N/A
10.00
The PID regulation during ballast and debal-
last is based on input from flow meter FT201–
1.
Defines integral time (If) value used for PID
p121 regulation of V201–8 during ballast and de-
ballast.
PID integral time 5.00 0–100 sec
Normal value: 5 – 12.
For details, see p120.
Timeout: Time in Defines maximum time a ballast and debal-

p138 Pause before going 5 1–30 min last process can be manually paused. After
to Stop defined time the process is stopped.
Time the control system will wait for confirma-

Timeout: Request tion (hard wired from ISCS or manually in
p140 "Open overboard 5 1–30 min popup). After defined time, the process is
valve" stopped.

tion (hard wired from ISCS or manually in
popup). After defined time, the process is
Timeout: Request stopped.
p141 3 1–3 min
“Start BW pump”
The parameter is used for both BW pump
during ballast/deballast and for stripping
pump during stripping.
200000874-5-EN-GB 165
EN 4 Parameters

value
Timeout: Power tion signal from ISCS that the operation was
p143 granted signal not re- 60 1-300 sec performed.
ceived Only used if parameter p127 is set to Activa-
ted (Hardwire ranged or fixed).
Defines the pressure (the setpoint) that the

booster pump will try to maintain.
p186 The variable-frequency drive (VFD) gets infor-
Booster pump P201– mation about the PureBallast water pressure
1 setpoint (PT201– 0.5 0.1–2 Bar from the pressure sensor PT201–16. The
16) VFD then controls the speed on the booster
pump and increases or decreases it, so that
the pressure is always according to the value
set in p186.
166 200000874-5-EN-GB
Parameters 4 EN
4.2.3 Page 5.2 — Main parameters 2

value
Defines if power management is used.
Alternatives:
p127
• Not used
Power management Not used N/A Drop list
• Hardwired
• Remote interface (requires that p132 is
activated)
Defines if an LDC cooling water pump or

closed cooling unit is used to create sufficient
cooling water flow to the LDC.
Alternatives:
• Not used.
• External: Pump started by signal from
PureBallast control cabinet: Power supply
with over current protection relay and con-
tactors and are handled externally.
p129 Booster pump • Internal: Pump completely controlled from
(P401-1) for LDC Not used N/A Drop list PureBallast control cabinet: Start signal
cooling water and power supply with over current pro-
tection relays and contactors from control
cabinet. It is still possible to connect
pumps according to configuration 1.
•
Note: In internal mode, external signal will al-
so be activated.
Note: Internal is only displayed for control
cabinets of configuration 2. See control sys-
tem page 4.1, field Control cabinet configura-
tion.
200000874-5-EN-GB 167
EN 4 Parameters

value
Defines if an UVR cooling water pump or
closed cooling unit is used to create sufficient
cooling water flow to the UV reactor.
Alternatives:
• Not used.
• External: Pump started by signal from
PureBallast control cabinet: Power supply
with over current protection relay and con-
tactors and are handled externally.
p130 Booster pump • Internal: Pump completely controlled from
(P403-1) for reactor Not used N/A Drop list PureBallast control cabinet: Start signal
cooling water and power supply with over current pro-
tection relays and contactors from control
cabinet. It is still possible to connect
pumps according to configuration 1.
•
Note: In internal mode, external signal will al-
so be activated.
Note: Internal is only displayed for control
cabinets of configuration 2. See control sys-
tem page 4.1, field Control cabinet configura-
tion.
Defines if remote interface (optional) is used

and connected via modbus.
p132 If connected, the Local and Remote buttons
Remote interface via Not used N/A Drop list are visible in the control panel. They are used
modbus to choose if operation shall be done from the
remote interface or a control panel.
Alternatives: Activated or Not used.
Defines if an external system stop button (or

p135 signal) is installed.
External system stop Not used N/A Drop list Purpose: Ongoing process is stopped and
the system goes to standby.
p137 Defines if the Pause button is visible or hid-

Activa- den in the control system. If activated, the
Hide Pause button N/A Drop list button is hidden.
ted
Defines lowest value PureBallast can request

from external feed. Only valid if PureBallast is
contolling ballast water flow by sending sig-
nals to vessels ballast water pump or throttle
valve before PureBallast.
If external feed controls a ballast water pump,
PureBallast will never request it to run on a
External feed min lower speed than the percentage set in this
p155 50 50–100 %
setpoint parameter. If a valve is controlled, the param-
eter defines percent open.
The parameter also defines starting point for
flow regulation when a process is started, to
ensure a smooth start with a gradually in-
creased flow until desired value is reached.
Default value should normally be used.
168 200000874-5-EN-GB
Parameters 4 EN

value
Defines how many seconds it takes to
p156 change the external feed signal 1%.
External feed change 5 2–30 s/%
rate Note: It might take a little longer for the actual
change of the pump or the valve to adjust the
flow.
Defines when external feed control is activa-
p157 ted, based on V201-8.
External feed V201– 70 50–90 %
8 low trigger limit PureBallast will start to request reduced flow
when V201-8 closes to reach this degree of
percent open.
Only valid if RMC protocol is used for GPS in-

tegration.
If activated, time and date in the control sys-
GPS time synchroni- tem is retrieved from vessel’s GPS.
p160 zation via RMC-pro- Not used N/A Drop list
tocol If no GPS is connected, time and date must
be set in control system page 4.1 System in-
fo.
Defines if an additional bypass valve is used.

p163 The signal gives information if the valve is
Additional bypass opened during process, so that PureBallast is
Not used N/A Drop list
signal 1 bypassed.

signal 1 bypassed.

signal 1 bypassed.
Defines proportional gain (Pf) value used for

PID regulation of V201–8 during backflush.
Pressure PID propor- 0.6 0.00– N/A The PID regulation during backflush is based
tional gain 10.00
p166 on input from pressure transmitter PT201-16.
Normal value: 0.1 – 1.5.
Defines integral time (If) value used for PID

p167 regulation of V201–8 during backflush.
Pressure PID integral 7.0 0.0– sec This parameter shall normally not be
time 100.0 changed.
Normal value: 5 – 12.
Defines if stripping is used.

p170 Purpose: Enables stripping to be used with
stripping events written to event log. Possible
Stripping enabled Not used N/A Drop list to connect a stripping pump via hard wire or
remote interface to be used.
200000874-5-EN-GB 169
EN 4 Parameters

value
p171 Min: 1
No. UV reactors to Defines how many UV reactors to be used for
1 Max: No
use when stripping stripping process.
p106
p172
Minimum flow when Set point for shut down due to low flow, de-
10 7-90 %
stripping (FIT201–1) fined as percent of certified flow.
Defines how long time the water must remain

in ballast tank before it can be discharged
over board in US waters. If 0 days mode is
chosen, more power will be used to treat the
water according to legislation and hold-time.
This parameter can only be changed if pa-
rameter p180 is set to option “USCG 3d+0d”.
Note: This parameter is only relevant for
USCG systems.
Alternatives:
p182
The time between a completed
USCG hold time 3 days N/A Drop list 3 days ballast and the start of deballast
hold- or stripping must be at least 72
time hours.
The time between a completed
0 day ballast and the start of deballast
hold- or stripping must be at least 2.5
time hours.
Note! If ballast water will be stored in tank

shorter than 72 hours, the water must be
treated using 0 days mode (p182 = 0 days) at
ballast.
170 200000874-5-EN-GB
Parameters 4 EN
4.2.4 Page 5.3 — UVR parameters

This section describes parameters controlling the UV reactor.
ID Parameter Default Min- Unit Description

value Max
p200 tion that an UV reactor is drained before an
alarm is issued. Approximate value: 9 min.
Timeout: Draining 2 1-30 min Recommended setting: Approximately 1 mi-
nute more than actual drain time. Set during
commissioning.
p201 Timeout: Reactor tion that technical water / potable water has
cooling water 2 1-30 min filled the UV reactor before an alarm is is-
(LS201–29) sued.
Set during commissioning.
p202 Setpoint for high water temperature alarm, in-
High reactor temp 60 10–100 ºC dicated by temperature transmitter in UV re-
(TT201–33) actor.
p204 Setpoint for low water temperature alarm, in-

Low temp, alarm trig- -2 -5 to 40 ºC dicated by temperature transmitter in the UV
ger (TT201-33) reactor.
Setpoint for max time to fill an UV reactor with

Timeout: CIP fluid fill- 5
p208 0-15 min CIP liquid during CIP process before an alarm
up time UV reactor is issued.
p210
UV lamp warm-up Warm-up time for UV lamps before full ballast,
90 0–130 sec
time deballast or stripping starts.
p211
Cooling time for UV lamps after ballast or de-
UV lamp cooling time 300 180–600 sec ballast.
200000874-5-EN-GB 171
EN 4 Parameters

value Max
p214 High temp, warning Incoming cooling water temperature warning,
trigger in LDC 45 20-100 ºC indicated by temperature transmitter in LDC.
(TT401-1)
Setpoint for max time to fill an UV reactor with

Timeout: Fluid fill-up
p216 time UV reactor 5 2-30 min technical water / potable water during CIP
process before an alarm is issued.
p230
Cabinet temperature 2 Accepted temperature change without effect
0,5-5.0 ºC
hysteresis (TT401-2) on the fan.
Setpoint for LDC cooling fan regulation. When

p231 the temperature is below setpoint, the fan is
Cabinet temperature 20.0-60. ºC running at 30 % of full effect.
low threshold 40.0 0 At setpoint the fan effect is increased propor-
(TT401-2)
tional to temperature from 30 % up to 100 %
at temperature set in p232.
p232 Cabinet temperature 20.0-60. ºC Setpoint for running the LDC cooling fan at
high threshold 45.0 0 100 %.
(TT401-2)
p234 Defines proportional gain (Pf) value used for

UV control propor- 0.00-100 N/A PID regulation of UV lamp power.
0.10
tional gain .00 The PID regulation is based on input from UV
sensor QT201–50.
p235
UV control integral Defines integral time (If) value used for PID
15 0-100 sec
time regulation of UV lamp power.
Activates UV optimization to regulate the UV

lamp power based on actual transmittance in
the UV reactor. This means that the lamps are
p237 lit to the degree needed for full treatment, but
Activa- not more.
Power optimization N/A Drop list
ted If disabled, UV lamps are lit at 100 % all the
time. Disable if the UV optimization malfunc-
tions, to avoid alarms.
p238 High temperature, 20.0-100 ºC Air temperature warning, indicated by temper-

warning trigger in 50.0 .0 ature transmitter in LDC.
LDC (TT401-2)
172 200000874-5-EN-GB
Parameters 4 EN
4.2.5 Page 5.4 — Filter parameters

This section describes parameters controlling the filter module.

value Max
p300 High filter differential Setpoint for shutdown due to high differential
pressure shutdown 3.0 0.0–3.0 bar pressure between by pressure transmitter
trigger PT201–71 and PT201–16.
p301 High filter differential Setpoint for high pressure warning, indicated
pressure, warning 1.5 0.0-2.0 bar by pressure transmitter in the filter.
trigger
If two backflushes are triggered by differential

Extended backflush
p302 2 1–30 min pressure within this time, the filter will run an
time trigger extended backflush for p303 minutes.
Extended backflush Defines the duration for the extended back-
p303 20 1–30 min
duration flush , after triggered by p302.
Defines desired pressure for efficient back-
flushing.
When a backflush is triggered, control valve
V201–8 will regulate to reach this pressure. Af-
ter time set in parameter p310 the backflush
p304 will start, regardless of if the pressure has
Pressure setpoint been reached.
2.0 1.0–5.0 bar
during backflush During backflush pressure is maintained by
PID regulation of control valve V201-8, based
on input from pressure transmitter PT201-16.
Parameter is set according to the formula:
p304 ≥ 1.0 bar + calculated pressure drop for
pipe 309.
200000874-5-EN-GB 173
EN 4 Parameters

value Max
Setpoint for automatic start of filter backflush
due to dirt in the filter, indicated by high differ-
Backflush trigger: ential pressure over filter (PT201-71 and
p305 0.5 0.0–2.0 bar PT201-72).
Differential pressure
Note: This parameter can be adjusted, but on-
ly by Alfa Laval during commissioning.
Defines duration of filter preservation (filling
Filter preservation
p306 time 5 1-30 min with technical water / potable water) after bal-
lasting.
p307 Time the control system will wait for confirma-
Timeout filter filling 3 1–15 min tion that water has filled the filter. Default value
shall be used. Set during commissioning.
p308
Backflush cycle time 20 1–100 sec Defines duration of one filter backflush.
Defines time between automatic backflush of

Time controlled the filter. Automatic backflushes are performed
p309 30 1–120 min
backflush interval with this set interval to secure performance, re-
gardless of current differential pressure.
Defines how long time that should pass from a
p310 backflush is triggered until is actually started.
Backflush initial de- 5 0–60 During this time, the control valve is PID regu-
lay
lated to create the required pressure defined in
parameter p304.
Time constant for low pass filter used for the

differential pressure over the filter. The low
pass filter is used to smoothen the effect of
sudden changes in differential pressure (pri-
marily pressure peaks after completed back-
flush).
Value for low pass filtered differential pressure
Differential pressure is indicated as “dp” on the filter in the filter pop-
p313 5 0-30 sec
measurement filter up, when logged in as login level Operator or
higher.
Actual differential pressure (PT201-71 and
PT201-72) is indicated in the filter popup.
This parameter shall normally not be changed,
but time can be increased to flatten the differ-
ential pressure curves.
Defines type of filter installed.

p314 Filter Type 3 N/A Drop list
Alternatives: Type 3 (Filtrex).
Parameter p314 should be set before this pa-

rameter. Available alternatives depend on se-
lection in p314.
Defines filter type and capacity.
p315
100 – The parameter shall be set to ACB-9120–500.
Filter type 500 6000 m3/h
Note: Do not set the parameter according to
actual filter size according to the marking plate
on the filter. The setting should correspond to
maximum ballast flow. See item 201 in in the
Connection list in chapter 6. Installation de-
scription and drawings.
174 200000874-5-EN-GB
Parameters 4 EN

value Max
Defines range for pressure transmitter PT201–
16. Set according to range printed on the
p316 transmitter.
Pressure range for -1 to 9 N/A bar Alternatives:
filter transmitters
-1 to 9
-1 to 15
Defines if an backflush cooling water pump

(optional) is used to create sufficient backflush
flow in pipe 309.
Alternatives:
• Not used.
• External: Pump started by signal from Pure-
Ballast control cabinet: Power supply with
over current protection relay and contactors
and are handled externally.
p318
Backflush pump Not • Internal: Pump completely controlled from
N/A Drop list PureBallast control cabinet: Start signal and
(P309–1) used
power supply with over current protection
relays and contactors from control cabinet.
It is still possible to connect pumps accord-
ing to configuration 1.
•
Note: In internal mode, external signal will also
be activated.
Note: Internal is only displayed for control cabi-
nets of configuration 2. See control system
page 4.1, field Control cabinet configuration.
p319 Delay from backflush pump P309–1 (optional)

Backflush pump start to opening of backflush valve V309–1.
5 1-30 sec
(P309) lead time
Only used if parameter p318 is activated.
After pressure 1 bar is reached, the system will

wait for defined number of seconds to secure
stable pressure in filter. If pressure falls below
p322 Filter filled timer 20 0–180 sec 1 bar during this time, filling starts again to
reach 1 bar. If pressure is over 1 bar, filter
preservation is completely stopped.
Defines if the backflush pump is used during

filter preservation (when the water is drained
Backflush pump dur- Not from the filter via pipe 309 and filled with new
p323 N/A Drop list water via pipe 310.2. The backflush pump
ing filter preservation used
should not be used if the filter is emptied.
200000874-5-EN-GB 175
EN 4 Parameters
4.2.6 Page 5.5 — CIP parameters

This section describes parameters controlling the CIP module.
ID Parameter Default value Min-Max Unit Description
p400 Duration of circula-

CIP cycle time tion of CIP liquid dur-
15 1–30 min ing a CIP process,
per reactor.
176 200000874-5-EN-GB
Parameters 4 EN
4.2.7 Page 5.7 — Remote interface

This section describes the installation specific system parameters set in page
5.6 Installation parameters. Further information about RTU server data is
found in chapter 6. Installation description and drawings section
Communication between PureBallast PLC and remote interface.
This page is only relevant if remote control interface (optional) is used.
Parameters for the ISCS modbus RTU server data shall be set according to
the information below.
value
Defines communication (cable) type used for
communication between the ISCS and Pure-
p700 Interface type RS485 N/A Drop list Ballast.
Alternatives: RS485 and RS422.
Defines baud rate in bits per second.
The parameter can be changed, but it is not
recommended. Note, that the information
p701 Baud rate 9600 N/A Drop list must be the same in ISCS and PureBallast
control system.
Alternatives: 300, 600, 1200, 2400, 4800,
9600, 19200, 38400, 57600, 115200.
Defines parity.
The parameter can be changed, but it is not
p702 Parity No parity N/A Drop list recommended. Note, that the information
must be the same in ISCS and PureBallast
control system.
p703 Defines data bits per character. Default value

Data bits 8 N/A Drop list shall be used.
Alternatives: 7 or 8.
200000874-5-EN-GB 177
EN 4 Parameters

value
p704 Defines number of stop bits. Default value
Stop bit 1 N/A Drop list shall be used.
Alternatives: 1 or 2.
p705 Defines the PureBallast modbus station ad-

Modbus station num- 10 dress. The address must be unique for each
1–247 Drop list
ber PureBallast system communicating with com-
mon ISCS (ship system).
178 200000874-5-EN-GB
Parameters 4 EN
4.2.8 Page 5.6 — Installation parameters

This section describes the installation specific system parameters.
ID Parameter Default Description

value
Possibility to enter a system name for the system, for example
System name Vessel name. If two systems is installed information about star-
N/A board and port side.
The text is entered in the event log file and alarm lists exported
from the control system for easy identification.
Serial number
PureBallast serial number (starting with PB-0xxxx ) found on the
N/A system plate on the control cabinet.
p106 Defines number of installed UV reactors.

Number of UV reac- 1 Min-Max: 1–6
tors installed
Unit: No.
The parameter shall be set according to pipe dimension for the

flow meter pipe.
Min-Max: 0–3300
Unit: m3/h
Alternatives: Pipe — Max flow for FIT201–1 (m3/h):
p112 80 – 150
Maximum flow 100 – 250
1200
(FIT201-1) 150 – 500
200 – 700
250 – 1200
300 – 1200
350 – 1700
400 – 2200
450 – 3300
500 – 3300
600 – 3300
200000874-5-EN-GB 179
EN 4 Parameters

value
Defines if UV reactors shall be automatically selected for process.
It is possible to toggle the parameter with the Auto button in page
1.1 Overview.
If activated: All UV reactors (without alarms) will be automatically
p131 selected, to enable operation in full capacity. Activation disables
Automatic UV reactor Not used the possibility to select a lower flow before starting a process (dur-
selection ing standby mode). However flow can be changed during process.
If deactivated: Flow must be selected manually at first start-up and
after shutdown.
Min-Max: 0–1
Unit: No
If more lamps than set in this parameter are broken, it is not al-
lowed to start a new operation. This parameter should only be
used by Alfa Laval for service purposes.
p213 Allowed number of
failed UV lamps per 0 Note: Operation with faulty LPS or lamps does not fulfill the type
UV reactor approval certificate.
Min–Max: 0–1
Unit: No.
Defines size of the UV reactor, defined as max capacity (m3/h).

p217 Used to determine certified flow and if one or two LDC´s is used in
UV reactor size the system.
1000
(m3/h)
Alternatives: 170, 300, 600, 1000 and 1500
Set parameter to: 1000
Defines if a ballast water booster pump (P201–1) is used to in-

crease the system pressure.
p185 Alternatives:
Booster pump Not used
(P201–1) • Not used.
• Activated: Pump started and speed controlled via a Modbus sig-
nal to the VFD from the PureBallast control cabinet.
p150 Defines if the Ex proof version of PureBallast is installed. This af-

Ex proof system Not used fects both installation and control system.
Defines if alarm for barrier box is activated.

p151
Mandatory for IECEx installations. Only used for Ex US flag instal-
Ex-I barrier fault Not used lations.
Defines if the system is an USCG system according to the system

plate on the control cabinet. If activated, it is possible to run the
system in USCG mode and IMO mode. This is changed by the
IMO and USCG function buttons.
Note: This parameter can only be activated for a USCG system.
p180 USCG system (Re-
quires USCG ap- Not used Alternatives:
proved installation) • Not used.
• USCG 3 days: It is only allowed to treat water with 3 days hold-
time.
• USCG 3d+0d: It is possible to choose to run process in 3 days
or 0 day hold-time mode. This is set in parameter p182.
180 200000874-5-EN-GB
Parameters 4 EN

value
Defines if the high performance version of PureBallast is activated.
Defines if the system is an USCG HP system according to the sys-
p181 tem plate on the control cabinet. If activated, it is possible to run
USCG high perform- Not used the system in USCG mode and IMO mode. This is changed by the
ance (HP) IMO and USCG function buttons.
Note: This parameter can only be activated for a USCG system.
p500 Defines if the log box (optional) is installed to monitor and log ex-
ternal valves and pumps, that are not part of Alfa Laval’s scope of
Log box Not used supply.
200000874-5-EN-GB 181
EN 4 Parameters
4.3 Lamp power supply (LPS) parameters

This section describes the parameters settings for the LPSs installed in the
lamp drive cabinet (LDC).
DIP switch settings are made for each LPS for individual identification.
4.3.1 DIP switch settings

The DIP switches should be set according to the table below.
Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the
individual LPS according to the table below. Only position ON is indicated. For
empty cells in the table, the switch shall be in position OFF.
Note:
LPSs are installed in the lamp drive cabinet.
SW SW SW SW SW
SW SW SW SW 4 5 6 7 8
1 2 3 3
(16) (8) (4) (2) (1)
LPS 1 ON
LPS 2 ON
LPS 3 ON ON
LPS 4 ON
LPS 5 ON ON
LPS 6 ON ON
LPS 7 ON ON ON
LPS 8 ON
LPS 9 ON ON
LPS ON ON
10
LPS ON ON ON
11
LPS ON ON
12
LPS ON ON ON
13
LPS ON ON ON
14
LPS ON ON ON ON
15
LPS ON
16
Example
In the illustration, the DIP switches is set for LPS no. 5.
182 200000874-5-EN-GB
Parameters 4 EN
200000874-5-EN-GB 183
EN 4 Parameters
4.4 Fuse settings for filter motor and installed

(optional) pump motors
Follow this instruction to change the fuse settings for filter motor M709–43
(F2) and installed (optional) pump motors P401-1 (F3), P309-1 (F4) and
P403-1 (F5) in the control cabinet.
1. On the filter motor and installed (optional) pump motors: Find area on the
mark plate where information is displayed for the frequency used for the
system (50 or 60 Hz).
2. Look at voltage (V), stated as an interval.
3. Look at interval for Imax amp setting (A), also stated as an interval.
4. Make an estimation for Imax amp setting, so that it “match” the voltage in
the range from min to max.
5. On the fuse: Press Reset button until LEDs flash (6 seconds).
6. Turn the potentiometer to estimated amp setting according to mark plate.
7. Check that the setting is correct according to the LEDs. Compare to the
table below.
8. Press Reset button to save the value.
4.5 Conductivity sensor parameters

The parameters are pre-set in the conductivity sensor.
4.6 Flow transmitter parameters

The parameters are pre-set in the flow meter transmitter.
184 200000874-5-EN-GB
EN
5 Alarms and faultfinding
200000874-5-EN-GB 185
EN 5 Alarms and faultfinding
5.1 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 Operating instructions and control system description on page 45
to find information about the alarm pages and how to attend to alarms.
5.2 List of alarms and warnings

This section lists all alarms and warnings.
5.2.1 Control system

This section lists all alarms and warnings in the PureBallast control system.
The alarms are sorted in a strict numerical order.
Alarm Indication
An alarm or warning will activate the alarm buzzer (sound and light) on the
cabinet. The sound is silenced by touching the buzzer, but note that the alarm
is not acknowledged by this. Alarms will shut down ongoing process and
disable the start of the process.
Warnings are information to the operator and will not shut down ongoing or
disable start of process.
Alarms and warnings are indicated in the following ways in the control panel.
Alarms
• The icon in the alarm tab starts to blink.
• The icon is also displayed by the faulty component in the screen.
• A red light in the exclamation mark on the alarm panel frame is lit.
• A sound is issued.
• A blinking light indicates a new alarm
• An acknowledged alarm is indicated by a steady light.
Warnings
Warnings is indicated in the same way as alarms, but with the yellow sym-
bol to the left. No sound is issued for warnings, except for W12, W152 and
W154.
All alarms are displayed in the control panel's page 2.1 Alarm list and are
sorted in order of occurrence; most recent alarm at the top of the list.
186 200000874-5-EN-GB
Alarms and faultfinding 5 EN
Key to the table of alarms and warnings

The following information is available in the List of alarms and warnings. Note
that all of the below is not applicable for all alarms/warnings.
ID number of the alarm. First letter indicate if 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.
Alarm/warning name
Trigger: Source of the alarm or warning, identified by the input sensor's item
number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.
Detailed information sorted on the following headings, when applicable:
Delay: Time before the alarm is activated after the condition of the alarm is
met.
Comments: Additional information or explanations.
Possible cause: Possible causes that might have triggered the alarm.
What to do? Suggested action to solve the problem.
List of alarms and warnings

The table explains alarms triggered by and displayed in the control system.
Note: When alarm list is exported and viewed in Excel, the first digit in the
thousand (1XXX) indicate the number of the affected UVR (UVR1).
Example: Code 2140 is W140 for UVR2.

See section Export control
system event log files on page 112.
Table 7: Supplement for ballast water booster pump (P201–1):
Alarm details Possible cause What to do?

W62
Ballast water booster pump VFD Check fault on VFD. See manufac-
fault. turers instruction manual for details.
Trigger: VFD to ballast water boos-
ter pump (P201–1) (optional).
W63
Ballast water booster pump low in-
let pressure. The inlet pressure is below the 0.2 Increase ballast water pump.
Trigger: Pressure transmitter bar setpoint.
(PT201–1) (optional).
Delay: 30 sec.
200000874-5-EN-GB 187

A01 Check pressure and flow from bal-
last pump(s). If the pressure ex-
Process pressure too high ceeds set value: Adjust incoming
(PT201-16). pressure to PureBallast.
Trigger: PT201–16. Ballast water pump gives too high Control that correct valves are func-
Parameter: p100. pressure. tioning and opened for current
process. See Detailed process de-
Delay: 30 sec. scription on page 129.
Comment: Pressure transmitter Valves in the system after pressure Control that correct valves are func-
PT201-16 indicates pressure higher transmitter are closed. tioning and opened for current
than set in parameter p100. process. See Detailed process de-
scription on page 129.
Material is stocked after pressure Check the entire system for block-
transmitter PT201-16. ing material.
Pressure transmitter PT201-16 is 1. Check cables to pressure trans-
faulty. mitter PT201-16. See circuit di-
agram for control cabinet , in
section Electrical drawings on
page 308.
2. Replace pressure transmitter
PT201-16.
A03 Signal missing or pressure trans- 1. Check fuse F45 in control cabi-
mitter PT201-16 malfunction. net to see what circuit caused
Process pressure signal missing the fuse trip.
(PT201-16).
2. Use the circuit diagram, for con-
Trigger: PT201-16. trol cabinet , in section Electri-
Delay: 30 sec. cal drawings on page 308 to
check the fuse setting, adjust
Comment: Error in system pres- according to figures in circuit di-
sure sensor. Indication of pressure agram if necessary and reset
-1.0 bar is not an error. fuse.
3. Use the circuit diagram to lo-
cate the component or find the
reason that caused the fuse trip
and attend to it.
4. Check that all electrical connec-
tions are OK and that the elec-
trical wiring is not damaged.
5. Replace transmitter PT201-16.
W04 See possible cause for A01. See A01.

Process pressure too high
(PT201-16).
Trigger: PT201-16.
Parameter: p101
Delay: 30 sec.
Comment: Pressure higher than
parameter set limit.
188 200000874-5-EN-GB

A10 Signal missing or flow meter 1. Check fuse F45 in control cabi-
FIT201-1 malfunction. net to see what circuit caused
Process flow signal missing the fuse trip.
(FIT201-1).
Trigger: Flow meter FIT201-1. 2. Use the circuit diagram for con-
trol cabinet , in section Electri-
Delay: 5 sec. cal drawings on page 308, to lo-
Comment: Error in system flow reason that caused the fuse trip
sensor. and attend to it.
4. Check that system flow has not
been significantly over maxi-
mum flow for the system.
5. Replace memory card or mod-
ule carrier. See instruction in
chapter 7. Service manual.
6. Replace flow meter.
W11 Signal missing. 1. Check fuse F45 in control cabi-

net to see which circuit that
Conductivity signal missing caused the fuse trip.
(QIT201–1).
2. Use the circuit diagram to
Trigger: Conductivity sensor check the fuse setting, adjust
(QIT201–1) in flow meter FIT201-1. according to figures in circuit di-
Delay: 20 sec. agram if necessary and reset
fuse.
and attend to it.
4. Check cables to FIT201-1. See
circuit diagram for control cabi-
net in section Electrical draw-
ings on page 308.
5. If the above is OK, the conduc-
tivity sensor is probably broke
and needs to be replaced. Re-
place the component.
W12 Flow rate higher than selected cer- Reduce the incoming ballast water
tified flow. See field certified flow in flow to the PureBallast system.
Process flow higher than certified Page 1.1 – Overview on page 57.
(FIT201-1). Reduce flow!
Wrong setting in FIT201-1. See chapter Parameters on page
Trigger: FIT201-1. 161.
Delay: 30 sec.
Flow sensor malfunctions. See section Flow meter in List of
Comment: An additional common alarms and warnings on page 186.
alarm signal is issued.
Note: Operation continues but is
not compliant and does not fullfil re-
quirements for treatment of ballast
water. Act according to ballast wa-
ter management plan.
200000874-5-EN-GB 189

A13 Flow is too low. 1. Increase flow.
Process flow too low FIT201-1. 2. Make sure the ballast water
from the ballast pump is direc-
Trigger: FIT201-1. ted to PureBallast. When OK
Parameter: p116. the process will continue auto-
matically.
Delay: 20 sec.
3. Check pressure and flow from
Comment: If flow is less than set in ballast pump(s). Adjust incom-
parameter p116, the system is shut ing pressure to PureBallast, if
down. necessary.
Wrong setting in FIT201-1. See chapter Parameters on page

161.
Flow sensor malfunctions. See section Flow meter in List of

alarms and warnings on page 186.
Valves in ballast system closed. 1. Control that correct valves are
opened for current process.
See Detailed process descrip-
tion on page 129
2. Check mechanical function of
the valve and check that the ca-
bles to the component is ac-
cording with the circuit diagram
for control cabinet in section
Electrical drawings on page
308.
Ballast water pump stopped or mal- Attend to. Note: This component is
functions. outside the PureBallast system
control.
A14 See possible cause for A13.
Process flow too low during start-up Control valve V201–8 malfunctions. See A29.
(FIT201-1). Automatic stop.
Trigger: FIT201-1.
Parameter: p116.
Comment: Triggered if flow defined
in p116 is not established within 60
seconds after ballast water pump is
started.
190 200000874-5-EN-GB

A17 Fuse tripped. 1. Check fuse F43 in control cabi-
net to see what circuit caused
Valve error (V201-3). the fuse trip.
Trigger: Limit switch GS201-3. 2. Check relay K1 and K2 on mod-
Delay: 25 sec. ule X10 in control cabinet.
Comment: Error on valve V201–3. 3. Use the circuit diagram for con-
trol cabinet , in section Electri-
cal drawings on page 308, to
according to figures in circuit di-
agram if necessary and reset
fuse.
4. Use the Circuit diagram to lo-
and attend to it.
tions to actuator and sensors
on the valve are OK and that
the electrical wiring is not dam-
aged.
Position sensor can not detect the Adjust sensor or puck.

metal on the puck on the actuator,
or the metal is in wrong position. Hint: Valves can be manually oper-
ated. See instruction Operate com-
Position sensor mounted upside ponents manually on page 108 and
down. Open and close valves manually in
section Valves on page 466.
Position sensor or cables to posi- 1. Check cables.
tion sensor malfunction.
2. Replace position sensor if faul-
ty.
Too long opening/closing time 1. Follow the instruction Adjust

(valve travel time). valve traveling speed on page
482.
2. Adjust exhaust valves on actua-
tor.
3. Check that instrument air pres-
sure is according to require-
ments in Connection list on
page 249.
Valve cannot open/close due to ob- • Clean. If required dismount

struction. valve. See Service manual on
page 421 for instructions.
200000874-5-EN-GB 191

A19
Valve error (V201-32).
Specific for this alarm compared to
Trigger: Limit switch GS201-32. See possible cause for A17. A17: Check relay K7 and K8 on
module X10.
Delay: 25 sec.
Comment: Error on valve V201-32.
A23
Valve error (V201-9).
Trigger: Limit switch GS201-9. See possible cause for A17. A17: Check relay K5 and K6 on
module X10.
Delay: 25 sec.
Comment: Error on valve V201–9.
A25
Valve error (V403-35)
Trigger: Limit switch GS403-35. See possible cause for A17.
Delay: 25 sec.
Comment: Error on valve V403–
35.
See possible cause for A17.
1. Check open indication in the
pneumatic positioner.
2. Check fuse F43 in control cabi-
the fuse trip.
3. Check relay K3 on module X10.
4. Use the Control cabinet / Circuit
diagram to check the fuse set-
• Sensor error. Shows open all ting, adjust according to figures
A29 the time. in circuit diagram if necessary
and reset fuse.
Valve error (V201-8). • Signal error 4–20 mA.
Trigger: Limit switch GS201-8 cate the component or find the
Delay: 25 sec. reason that caused the fuse trip
and attend to it.
Comment: Error on control valve
V201–8 6. Check that all electrical connec-
tions to actuator and sensors
on the valve are OK and that
the electrical wiring is not dam-
aged.
Positioner is not correctly set or Calibrate according to Calibrate po-

calibrated. sitioner on V201-8 on page 474.
Cam wheel not correctly set in posi- Adjust according to Adjust cam po-
tioner, which results in wrong feed sition on V201-8 on page 476.
back to control cabinet.
The air filter on the positioner is Clean the filter.
clogged.
192 200000874-5-EN-GB

W33 Bypass valve has been opened If not opened intentionally, close
manually or via the ISCS. opened bypass valve.
Bypass valve is open (V212-31).
Trigger: Limit switch GS212-31.
Delay: 10 sec. A17:
Comment: If the valve (not control- If not opened: See possible cause • Check relay K3 and K4 on mod-
led by PureBallast) is opened dur- for A17. ule X11.
ing operation, the operation will
continue. A visual and audible • Check barrier TI6.
alarm will be triggered.
A35
Valve error (V212–31).
Trigger: Limit switch GS212-31.
Delay: 25 sec. See possible cause for A17.
Comment: Shutdown of all steps
except CIP. The alarm does not
prevent completion or start of CIP
process.
Check that pressure and flow from
Ballast water pump gives too low ballast pump(s) is according to re-
pressure. quirements in chapter Technical da-
W40 ta and drawings on page 233.
Process pressure too low Pressure safety valve V201 is faul- Check the valve, and repair or
(PT201-16). ty. change.
Trigger: Pressure transmitter:
PT201-16. 1. Check cables to pressure trans-
mitter PT201-16. See control
Parameter: p103 cabinet , in section Electrical
Pressure transmitter PT201-16 is
Delay: 2 sec. faulty. drawings on page 308.
2. Replace pressure transmitter
PT201-16.
A48
System stop activated (Stop but- Note: Find out the reason why the
ton). process has been stopped before
Process has been stopped.
Trigger: Stop button on control releasing the button and starting
cabinet. another process.
Delay: None.
A49
System stop activated during CIP
(Stop button).
See A48.
Trigger: Stop button on control
cabinet.
Delay: None.
A50
System stop activated (External
stop button). Process has been stopped by ex- Note: Find out the reason why the
ternal stop button or signal from the process has been stopped before
Trigger: External stop button on ISCS (integrated ship control sys- releasing the button and starting
control cabinet (or signal). tem). another process.
Parameter: p135
Delay: None.
200000874-5-EN-GB 193

A51
System stop activated during CIP
(External stop button).
Trigger: External stop button on See A50.
control cabinet (or signal).
Parameter: p135
Delay: None.
1. Check fuse F43–F45 in control

cabinet to see what circuit
caused the fuse trip.
W58 Possible reasons: 2. Use the circuit diagram to lo-
Fuse tripped in control cabinet. • overload reason that caused the fuse trip
Trigger: Control cabinet. • short circuit and attend to it.
Delay: None. • overheated fuse 3. Use the circuit diagram for con-
trol cabinet to check the fuse
setting, adjust according to fig-
ures in circuit diagram if neces-
sary and reset fuse.
Possible reasons:
• A motor circuit breaker (Q2, Q3 Reset or turn on the motor circuit
or Q4) in the control cabinet has breakers.
tripped or has been switched off.
1. Motor circuit breaker Q2: Check

that the cables W3091 and
W4031 are connected to the
control cabinet.
W59 2. Motor circuit breaker Q3: Check
that the cables W301 and
A signal is missing from a motor cir- W4011 are connected to the
cuit breaker.. control cabinet.
Trigger: Fuse. • Motor load/problem. 3. Start the motor(s) and check
Delay: None. that the operation is normal.
4. Motor circuit breaker Q4: Check
that the 24VDC rectifier —T1 is
operational.
5. Verify that there is no loose wire
to the —A2–D13 digital input on
the PLC.
Check the mechanical parts of

• Mechanical obstacles. P309–1, M403–1, M709–43,
M309–1 and —T1.
Fuse F3 in the control cabinet has Reset fuse F3.
tripped.
1. Check that cable W4011 is con-
W60 nected to the control cabinet.
A signal is missing from the booster 2. Start the motor and check that
pump fuse. Motor/load problem. the operation is normal.
Trigger: Fuse. 3. Verify that there is no loose wire
Delay: None. to the —A2–DI6 digital input on
the PLC.

Mechanical obstacles. M401–1.
194 200000874-5-EN-GB

Fuse F5 in the control cabinet has Reset fuse F5.
tripped.
W61 1. Check that cable W4031 is con-

nected to the control cabinet.
A signal is missing from the booster
pump fuse for reactor cooling wa- 2. Start the motor and check that
ter. Motor/load problem. the operation is normal.
to the —A2–DI7 digital input on
Delay: None. the PLC.

W62
Booster pump VFD fault. Check fault on VFD. Action accord-
ing to VFD manual.
Trigger: VFD to ballast water boos-
ter pump (P201–1) (optional).
W63
Booster pump low inlet pressure.
Trigger: Ballast water booster The inlet pressure is below the 0.2 Decrease booster pump setpoint.
pump (P201–1) (optional). bar setpoint. Increase ballast water pump.
Parameter: p186
Delay: 30 sec.
W66
Additional bypass valve 1 is open.
Trigger: External system.
Parameter: p163
The valve has been opened man- If not opened intentionally, close the
Delay: 10 sec. ually or via the ISCS. valve.
Comment: If the valve (not control-
led by PureBallast) is opened dur-
ing operation, the operation will
continue. A visual and audible
alarm will be triggered..
W67
Trigger: External system. See W66.
Parameter: p164
Delay: 10 sec.
W68
Trigger: External system. See W66.
Parameter: p165
Delay: 10 sec.
W69
Remote system reports system is
bypassed. Bypass valve opened by ISCS via If not opened intentionally, close
remote interface. opened bypass valve.
Trigger: External bypass valve.
Delay: 10 sec.
200000874-5-EN-GB 195

Check that all electrical connec-
A71 tions are OK. Check that the signal
Faulty connection of signal cable. wiring is according to information in
Ballast water pump is not running. Control cabinet / Interconnection di-
Trigger: Control system timer. agram, in section Electrical draw-
ings on page 308.
Parameter: p141.
If remote interface (optional) is Test relevant addresses. See Test
Delay: Set in parameter p141. used: Communication between remote interface communication on
PureBallast and ISCS is wrong. page 118.
Comment: Feed back signal “BW
pump is running” is not activated af-
Time set in parameter is lower than Check/change parameter in control
ter request. system page 5.1 – Main parame-
needed. ters 1.
A72
Stripping pump is not running
Trigger: Control system timer.
Parameter: p141. See possible cause for A71.
Delay: Set in parameter p141.
Comment: Feed back signal “BW
pump is running” is not activated af-
ter request.
A75
Overboard valve is not open. Auto-
matic stop.
Parameter: p140.
Comment: Feedback “overboard
valve is OPEN”.
A77
Error on all operating UVR:s. Auto-
matic stop. An active alarm exist on all installed Check control system page 2.1
UV reactors. It can be the same er- Alarm list in control panel for rela-
Trigger: UV reactors ror for all UV reactors, or different ted alarms.
Delay: None. errors.
Comment: All UV reactors are de-
activated.
Power management master system Investigate if the reasons for not
not granting power to UV reac- granting power is outside the Pure-
tor(s). Ballast system.
A79 See A71.

Power is not granted. Check signal transmission to/from
PureBallast corresponds to the
Trigger: Control system timer. specifications in Control cabinet /
Delay: Set in parameter p127. Interconnection diagram, in section
Feedback signal from power man- Electrical drawings on page 308.
Comment: No power steps have agement master is faulty.
been granted within parameter set Hint: If problem persists, see con-
time. trol system page 1.4 – PureBallast
power request to find which GRAN-
TED signal that was interrupted
during the ballast/deballast proc-
ess.
196 200000874-5-EN-GB

W80 See possible cause for A79.
Power is not fully granted. Flow ca-
pacity reduced.
Trigger: Power management sys-
tem.
Parameter: p127.
Not enough power has been gran- Continue process with lower flow
Delay: None. ted. capacity or try later.
Comment: Not all requested power
steps are granted. Triggered if
number or requested power steps
does not match number of granted
power steps.
W82
Heeling mode .
Trigger: ISCS.
Delay: 10 sec. If heeling mode has not been re-
quested: See first two possible cau-
Comment: It is not possible to start ses for A71.
a process when the system is in
heeling mode. This warning is auto-
matically acknowledged when the
heeling mode is redrawn from
ISCS.
W83
Heeling mode cancelled by opera-
tor. Process resumed.
Trigger: Heeling (internal transfer)
not requested in control system. See possible cause for W82.
Parameter: N/A
Delay: None.
Comment: Process is resumed af-
ter being paused during heeling.
W84
Heeling mode requested. Only bal-
last and deballast processes are
paused.
Trigger: Heeling mode requested
by remote interface. See possible cause for W82.
Parameter: N/A
Delay: 10 sec.
Comment: Process is resumed af-
ter being paused during heeling.
200000874-5-EN-GB 197

1. Switch on the panel.
2. Restart the panel. See problem
A91 Panel is switched off or faulty. 1 B in General problems on
page 227.
PLC lost communication with all
control panels. 3. Replace if faulty.
Trigger: Control system PLC. Check that the HMI and PLC soft-
Delay: 60 sec. ware have the save program ver-
Wrong software version. sion. This is visible in control sys-
Comment: After 60 seconds of lost tem page 4.1 System 1.
communication, ongoing process is
stopped in a controlled way and the Check settings for each panel ac-
system is shut down. This message Wrong network setting. cording to Set control panel IP ad-
is visible in the control panels and dress on page 115
saved in the log after the communi- Check cables to the component.
cation is restored. But, W92 will be For reference, see Control cabinet /
visible in the main control panel. Interconnection diagram, in section
Faulty cable connection. Electrical drawings on page 308
and Remote control panel / Circuit
diagram (optional) on page 385.
W92 Master panel is switched off or faul- See A91.
ty.
Master control panel lost communi-
cation with the PLC
Trigger: Control system PLC.
Delay: 30 sec.
Comment: After communication is Faulty cable connection. See A91.
lost, ongoing process is stopped in
a controlled way and the system is
shut down. This message is visible
in the main control panel.
198 200000874-5-EN-GB

To operate PureBallast when
communication is down, follow
the steps below:
1. Set the system to Local mode:
Press the local button on the
control panel.
2. Run the system from the control
panel. Note that you will need
to confirm the messages from
the control panel during opera-
tion: "Confirm ballast pump
started".
3. Restore these settings when
the communication is working.
4. Make sure that the system is
not in test mode in page 4.4
Remote 1 (no check mark on
the Test mode button)
.
If you deliberately set the system to

test mode (for example to test re-
A93 mote interface integration, you can
System is set to Test mode.
Heartbeat signal from remote inter- disregard this alarm. If not deacti-
face is not updating. vate the test mode again in page
4.4 Remote 1.
Trigger: Control system PLC.
1. Check that parameter p700 is
Parameter: p132. set to match the modbus cable
Delay: 60 sec. type used (RS422 or RS485).
Comment: After communication is 2. Check if remote operation is de-
lost between ISCS and PLC, ongo- activated in the control panel
ing process is stopped in a control- (The Remote button at the bot-
led way and the system is shut tom of the screen is gray). If so,
down. press the Remote button.
The Heartbeat field in page 4.4 Re- Faulty settings. 3. Check if test mode is activated
mote 1, indicates communication. in page 4.4 Remote 1 (check
mark on button). If so, press the
Test mode button. Requires
login level Advanced operator.
4. Check that the communication
settings is OK according to in-
struction Set remote interface
communication on page 118
Check cable between the ISCS and

the main control panel and the ca-
ble between the PLC and the main
control panel. For reference, see
Control cabinet / Interconnection di-
Faulty cable connection agram, in section Electrical draw-
ings on page 308.
Tips: Make sure that the modbus
cables in terminal X15are correct
(not switched).
Communication between PLC and See W92.
main control panel is lost
Investigate problem in ISCS, and
ISCS is faulty attend to found problems.
200000874-5-EN-GB 199

A94 Specific for this alarm compared to
Fault in barrier box. A17: Check if barrier TA, TI or TO
Barrier fault in barrier box are faulty.
Trigger: Barrier in LDC cabinet
Parameter: p151 Check that all electrical connec-
tions are OK. Check that the signal
Delay: N/A. wiring is according to information in
Faulty wire connection.
Comment: This alarm is specific Control cabinet / Interconnection di-
for the Ex proof version of PureBal- agram, in section Electrical draw-
last for US flag. ings on page 308
W95
PLC battery low.
The voltage in the battery in the Replace PLC battery in the control
Trigger: Control system PLC. control system PLC is too low. cabinet.
Parameter: N/A
Delay: 10 sec.
W96
GPS signal not valid. Check that the signal wiring is ac-
cording to Control cabinet / Inter-
Trigger: Control system PLC. Faulty electrical connection. connection diagram. See section
Parameter: p160. Electrical drawings on page 308.
Delay: 5 sec.
Check the LED error indication for
the electronic modules in the cabi-
Error in module. net. See I/O system and X20 mod-
A97 ules on page 221.
PLC error in control cabinet. 1. Check that the signal wiring is
according to electrical drawings
Trigger: N/A in Technical data and drawings
Parameter: N/A on page 233.
Faulty electrical connection.
Delay: 2 sec. 2. Check that all electrical connec-
tions are OK on bus modules
and that the electrical wiring is
not damaged.
A98 Note: Find out the reason why the

process has been stopped. Then:
Emergency stop Emergency stop button pressed Release the Emergency button and
(control cabinet or external).
Trigger: press the Reset button on the con-
trol cabinet .
• Emergency stop button on con-
trol cabinet (safety relay KS01).
• Temp switch TS201–60.
• Temp switch TS201–33. Check that all electrical connec-
Parameter: p150. tions are OK on bus modules and
Faulty connection of signal cable. that the electrical wiring is not dam-
Delay: 2 sec. aged.
Comment: This alarm is specific
for the Ex proof version of PureBal-
last.
200 200000874-5-EN-GB

W100 • Check that the inlet valves
(V201-19.x, V403-35) and outlet
UVR [x]: UVR temp too high valves (V201-20.x, 404-36.x)
(TT201-33). UVR shutdown. open properly by operating them
High temperature due to obstacles
Trigger: UVR temperature trans- or error in one or more components manually. See Operate compo-
mitter TT201-33. involved. nents manually on page 108
Parameter: p202 • Check that cooling water supply
(403) is within specification in
Delay: 5 sec. Connection list on page 249
Comment: If temperature rises
above parameter set value, the UV Check pump, valves and other
Low flow of cooling water during components involved in the sea
reactor will shutdown. start-up water cooling system.
If the alarm trips during operation
with a flow through the UV reactor, Check/change parameter in control
Parameter p202 not correctly set. system 5.3 – UVR parameters.
the valves V201-19.x and
V201-20.x will close
Replace transmitter TT201–33 ac-
If the alarm trips during ballast TT201-33.x malfunction. cording to instruction in Service
start-up, valve V404-36.x will close. manual on page 421.
W101 See possible cause for W100.

UVR [x]: UVR temp too low Ballast water too cold; temperature See to that incoming water is
(TT201-33). UVR shutdown. below 0 C°. warmer than 0 C°.
Trigger: UVR temperature trans-
mitter TT201-33.
Engine room too cold; temperature
Delay: 5 sec. Increase temperature.
below 0 C°.
Parameter: p204.
1. Check fuse F42 in LDC to see

what circuit caused the fuse
trip.
fuse.
W102 3. Use the circuit diagram to lo-

UVR [x]: UVR temp signal missing reason that caused the fuse trip
(TT201-33). UVR shutdown. Signal missing or transmitter and attend to it.
Trigger: UVR temperature trans- TT201-33.x malfunction. 4. Check cables to the compo-
mitter TT201-33 error. nent. See UV reactor / Circuit
Delay: 5 sec. diagram and Lamp drive cabi-
net / Circuit diagram in Electri-
cal drawings on page 308.
6. Replace transmitter TT201-33.
7. Restart the process from the
beginning.
W105
UVR temp below 0 °C.
Warning cold ballast water.
Trigger: Water temperature in the
UVR temperature transmitter See possible cause W101.
TT201-33.
Delay: 5 sec.
200000874-5-EN-GB 201

Check that cooling water supply
No cooling water to the heat ex-
W107 (401) is within specification in Con-
changer. nection list on page 249.
UVR [x]: LDC cooling water temp
too high (TT401–1). Feel the water pipe, if it is too
Incoming cooling water too warm. warm. If so, investigate and attend
Trigger: LDC temperature transmit- to problem.
ter TT401.
Cooling water valve SV401–51
Parameter: p214 and/or CV402 blocked or closed. Check and attend to.
Delay: 15 sec. Parameter p214 not correctly set in Check/change parameter in control
control system. system 5.3 – UVR parameters.
what circuit caused the fuse
trip.
2. Use the circuit diagram for the
LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary and
reset fuse.
3. Use the circuit diagrams for the
LDC and UV reactor to locate
the component or find the rea-
Signal missing or transmitter TT401 son that caused the fuse trip
malfunction. and attend to it.
W109 4. Check cables to the compo-
UVR [x]: LDC cabinet temp missing nent. See Lamp drive cabinet /
(TT401–1). Circuit diagram in Electrical
drawings on page 308.
Trigger: LDC temperature transmit-
ter TT401–1. 5. Check that all electrical connec-
Delay: 5 sec. trical wiring is not damaged.
6. Replace transmitter TT401.
beginning.
Check that all electrical connec-

tions are OK on X20 module and
Faulty connection to X20 module. that the electrical wiring is not dam-
aged.
Check component. See section I/O
system and X20 modules on page
Faulty X20 module. 221. Change according to instruc-
tion in Service manual on page
421.
W111 Check 2. Alarm list in control panel
LDC faulty. for related alarms.
LDC air temperature too high
(TT401–2).
Trigger: Temperature transmitter
TT401–2. Check electrical and mechanical
Faulty fan. problems, and attend to.
Parameter: p238.
Delay: 15 sec.
Check electrical and mechanical
Faulty fan. problems, and attend to.
202 200000874-5-EN-GB

1. Check fuse F42 in lamp drive
fuse.
W113 3. Use the circuit diagram to lo-
LDC cabinet temperature missing cate the component or find the
(TT401–2) reason that caused the fuse trip
Signal missing or temperature and attend to it.
Trigger: Temperature transmitter transmitter TT401-2 malfunction.
TT401–2. 4. Check cables to the compo-
nent. See Lamp drive cabinet /
Delay: 5 sec. Circuit diagram in Electrical
drawings on page 308.
6. Replace transmitter TT401-2.
beginning.
1. Check fuse F42 in lamp drive

cabinet to see which circuit that
2. Check relay KS02.
adjust according to figures in
circuit diagram if necessary and
reset fuse.
LDC and UV reactor to locate
W116 son that caused the fuse trip
UVR [x]: UVR fluid level signal and attend to it.
missing (LS201-29). Signal missing or sensor
LS201-29.x malfunction. 5. Check cables to the level switch
Trigger: Level sensor LS201-29. LS201-29.x. See drawing UV
reactor/ Circuit diagram and
Delay: 5 sec. Lamp drive cabinet / Circuit dia-
gram in Electrical drawings on
page 308.
6. Check that the level switch is
working correctly. See Level
switch on page 220. Hint: Dis-
mount level switch and put the
forks into a cup of water to
check dry/wet function.
7. Replace LS201-29.x. (Turn the
level switch so the forks are in
the right position. See chapter
Service manual on page 421.
200000874-5-EN-GB 203

1. Check that valves V320-2,
V320-4.x, V321-4 and 321-2.x
open and close correctly.
2. Check that pump P320-1 is
functioning correctly. See prob-
lem 6D-6I in General problems
on page 227.
3. Hint: Valves can be manually
operated. See Valves on page
466. Note that the manual oper-
ations are password-protected
No fluid in UV reactor “x”. and must only be performed by
LS201-29.x is indicating dry condi- authorized trained personnel.
tion. The PureBallast equipment or
W118 connected equipment can be ir-
UVR [x]: CIP flow missing reparably damaged if handled
(LS201-29). incorrectly.
Trigger: Level sensor LS201-29. 4. Examine the pipes related to
the CIP circuit. Make sure that
Parameter: p208. no material is clogging the
Delay: Set in parameter p208. pipes.
5. Check that the level switch is
working correctly. See Level
switch on page 220.
Time set in parameter is lower than Change parameter.

needed.
Level switch at UV reactor See W116 to troubleshoot the level
LS201-29.x malfunction. switch electrically.
Refill the tank with CIP liquid. See
Too low level in CIP tank. instruction Change and refill CIP
liquid on page 458.
Air in fluid. The level switch indi- Deaerate the CIP, using the deaer-
cates this as no fluid in UV reactor. ation valve on the CIP.
1. Check that pressure flushing
water in pipe 310 is according
to requirements in Connection
list on page 249.
W119 No liquid in UV reactor “x”. 2. Check that valves (V310-6,
LS201-29.x is indicating dry condi- V320-4.x, V321-2.x and
UVR [x]: No freshwater filling in tion.
UVR (LS201-29). V571-1) are operating correctly.
Also check that valve V310-3 is
Trigger: Level sensor LS201-29. OK and that V310–8 is opened.
Parameter: p216. Operate the components man-
ually.
Time set in parameter is lower than Change parameter.
needed.
Level switch at UV reactor See W116 to troubleshoot the level
LS201-29.x malfunction. switch electrically.
204 200000874-5-EN-GB

Fluid in UV reactor “x”. LS201-29.x Restart the process from the begin-
is indicating wet condition. ning.
W120 Time set in parameter is lower than Change parameter.

needed.
UVR [x]: UVR was not drained
(LS201-29). Level switch at UV reactor
LS201-29.x malfunction. See W116.
Trigger: Level sensor LS201-29.
Control that correct valves (V320–
Parameter: p200. 4, V460–2, V231–2, V571–1, over-
Faulty valves in the CIP unit. board valve) are opened for current
process. Also control that pump
P321–5 is functioning.
Check fuse F42–43 in LDC cabinet
to see what circuit caused the fuse
trip. Check according to bullets.
• Use the circuit diagram for the
adjust according to figures in cir-
W122 cuit diagram if necessary and
UVR [x]: Fuse tripped in LDC cabi- reset fuse.
net. Fuse in LDC has tripped or has
been switched off. • Use the circuit diagrams for the
Trigger: LDC cabinet for UVR LDC and UV reactor to locate
Delay: 1 sec. son that caused the fuse trip
and attend to it.
• Check cables to the component.
See UV reactor / Circuit diagram
and Lamp drive cabinet / Circuit
diagram.
1. See LPS alarms in section

Lamp power supply (LPS).
W126
2. Check Q101–Q108 in LDC and
UVR [x]: MCB tripped in LDC cabi- Motor circuit breaker (MCB) for an respective cables and LPS unit.
net. LPS in UVR.x has tripped or has
been switched off. 3. Use the circuit diagram to
Trigger: LCD x-1 check the Ampere setting for
Delay: 1 sec. the MCB, adjust according to
figures in circuit diagram if nec-
Comment: MCB=Motor circuit essary and reset MCB.
breaker. UV reactor is deactivated.
Breaker on LDC has tripped or has Reset the breaker by turning the
been switched off. handle.
Motor circuit breaker (MCB) F1 in
control cabinet has tripped or has Check F2 in LDC.
W128 been switched off.
UVR [x]: LDC cabinet fan alarm. Check electrical and mechanical
Faulty fan.
Trigger: F2 problems, and attend to.
Delay: 5 sec. Check that all electrical connec-
Faulty electrical connection. tions are OK and that the electrical
wiring is not damaged.
W129 Repair.
UVR [x]: LDC cabinet water alarm. Leakage in cooling water piping. Dry wet areas in the cabinet. Re-
move the sensor and dry it with pa-
Trigger: Water sensor LS below per.
heat exchanger in LDC.
Delay: 5 sec. Condensation in the cabinet. See above.
200000874-5-EN-GB 205

Check LED indication on the LPS
that triggered the alarm. See LPS
• LPS malfunction. alarms in section Lamp power sup-
• Number of broken UV lamps ex- ply (LPS).
W130 eeds number set in parameter Check which lamps that are broken
p213. in column Lamp OK
UVR [x]: LPS sum alarm.
Trigger: Lamp power supply in UV in page 4.9 LPS overview.
reactors LDC. Check that the signal wiring is ac-
Delay: 5 sec. cording to electrical drawings.
UV lamp OK signal malfunction. Check that all electrical connec-
tions are OK on bus modules and
that the electrical wiring is not dam-
aged.
W131
UVR [x]: Lamp failure. Eventual on-
going process not compliant.
Trigger: Lamp power supply 1–16.
Parameter: p213. Check which lamps that are broken
in column Lamp OK in page 4.9
Delay: 5 sec. LPS overview.
One or more UV lamp is broken.
Comment: UV reactor is deactiva- Change according to instruction in
ted. Service manual on page 421.
not compliant and does not fullfil
the requirements for treatment of
ballast water. Act according to bal-
last water management plan.
W132
Estimated UV lamp lifetime excee-
ded.
Trigger: UV reactor lap time. Estimated lifetime for UV lamps Change according to instruction in
(3000 hours) is exceeded. Service manual on page 421.
Delay: 1 sec.
Comment: Recommended to
change all lamps after 3000 hours
of operation.
206 200000874-5-EN-GB

See W100.
After problem has been attended
to, the LDC needs to be reset. Fol-
low the instruction below:
1. Turn on the power to the cabi-
net/system.
No flow in UV reactor or too low
flow. 2. Push the reset button on the
LDC. The button is placed at
A137 the side facing the UV reactor.
All LDCs must be reset individ-
UVR [x]: To high temperature ually.
(TS201-60 tripped) and/or LDC
powered off. 3. Acknowledge alarm A137 in the
control system.
Trigger: TS201-60
Delay: 1 sec. Check components.
Faulty pump (ballast or UVR cool-
Comment: UV reactor is deactiva- ing water pump) or valve. Control that valves and pumps are
ted. functioning.
The LDC needs to be reset, see
LDC has been powered off. above in this alarm description.
• Check that the signal wiring is
according to electrical drawings.
Faulty electrical connection. • Check that all electrical connec-
tions are OK and that the electri-
cal wiring is not damaged.
A138
UVR [x]: PLC error in LDC cabinet.
Trigger: UV reactor x. the electronic modules in the LDC.
Error in module. See I/O system and X20 modules
Delay: 2 sec. on page 221
Comment: UV reactor is deactiva-
ted.
W140
CIP required. Start CIP! Risk for not
compliant operation.
Delay: Set in parameter p117 and
p118.
Comment: CIP process must be CIP not performed after operation. Start CIP process.
started within 30 hours counted
from when a ballast or deballast
process was started.
not compliant and does not fullfil
the requirements for treatment of
last water management plan.
200000874-5-EN-GB 207

1. Check F42 in LDC to see which
circuit that caused the fuse trip.
fuse.
Signal missing. reason that caused the fuse trip
W151 and attend to it.
UVR [x]: UV sensor signal missing. 4. Check cables to QT201-50.
Ongoing process not compliant. See the drawing Control cabi-
net / Circuit diagram in chapter
Trigger: UV sensor QT201-50. 6. Technical data and drawings.
Delay: 20 sec. 5. If the above is OK, the UV sen-
Note: Operation continues but is sor is probably broke and
not compliant and does not fullfil needs to be replaced. Replace
the requirements for treatment of the component.
last water management plan. Test the UV sensor:
1. Stop the process and restart
the process again.
2. In the control system's UV reac-
Transmitter QT201-50 malfunction tor popup, see if the UV values
are OK during the start-up
phase. UV values shall be OK,
since clean cooling water is
used.
See W152.
208 200000874-5-EN-GB

Note: Operation continues, but
does not fulfill the type approval
certificate. Act according to ballast
water plan.
W152 See Power optimization on page
UVR [x]: UV intensity low. System 22.
flow reduced. Process not compli-
ant. Check water.
Trigger: UV sensor QT201-50. Water is dirty or have low UV trans- It is also possible to fill the reactor
mittance. with technical water / potable water
Delay: 30 sec. to rule out muddy water as reason
Comment: The flow is reduced for the warning.
when UV intensity (W/m3) is below
492 for fresh water and 252 for Run CIP process, and try again.
brackish and marine water, accord- If problem remains, check and
ing to IMO legislation. Power is set Quartz sleeves dirty. clean quarts sleeves according to
to 100% and the flow is reduced to instruction Service manual on page
50 % 421.
Note: See Compliant / non-compli-
ant operation on page 47. Check runtime on page 4.3 Timers
in control system. Change if old.
Note: Operation continues but is Old UV lamps. Lamps loose effect when maximum
not compliant and does not fulfil the runtime has been exceeded.
requirements for treatment of bal-
last water. Act according to ballast Sediments in the tank. If the tank
water management plan. has not been thoroughly cleaned,
sediment in the tank might obstruct
Comment: An additional common the light in the UVR proventing the Clean all ballast water tanks.
alarm signal is issued. light from treating the water and
reaching the UV sensor.
Dirty UV sensor or not installed cor- Check UV sensor and install ac-
cording to instructionReplace UV
rectly. sensor on page 449.
W153
UVR [x]: UV lamp broken. System
flow reduced. Process not compli-
ant.
Trigger: UV reactor.
Parameter: p213
Delay: 30 sec.
Comment: Process is allowed to
finish.
Note: Operation continues, but
If a UV lamp fails during ongoing does not fulfill the type approval
operation, the flow is set to 80 % is certificate. Act according to ballast
set 80 % in IMO mode and 50 % in water plan.
USCG mode of max flow.
See Operation with broken UV
The UV lamps are lit to 100 % for lamp on page 23
the UV reactor with the broken
lamp, but dimming function will con-
tinue for fully functioning UV reac-
tors.
This is done so that the treatment
shall correspond to the type appro-
val requirements. After the process,
it is not possible to start a new
process.
Note: See Compliant / non-compli-
ant operation on page 47.
200000874-5-EN-GB 209

W154
Low UV intensity (USCG). Flow =
50%. Process not compliant.
Trigger: UV sensor QT201-50.
Parameter: p182
Delay: 20 sec.
Comment: Warning issued when
UV intensity falls below compliance
limit (W/m2): 772 in USCG 3 day
and 1220 in USCG 0 day mode. At See W152.
this stage power is 100% and flow
is reduced to 50 %.
not compliant and does not fulfill re-
quirements for treatment of ballast
ter management plan. A new proc-
ess is not allowed to start.
Only relevant for PureBallast
USCG systems.
W160
UVR [x]: No response from LDC.
UVR shutdown.
Trigger: N/A
Delay: 1 sec.
Faulty connection of electricity or Check the three cable connectors
signal cable. on the LPS.
W161 Check that the DIP switches are
UVR [x]: LPS communication error. correctly set for every LPS. See
UVR shutdown. Wrong LPS setting. chapter 4. Parameters, section
Lamp power supply (LPS) parame-
Trigger: LPS ters.
Delay: 1 sec. Change LPS. See instruction in
Faulty LPS. chapter Service manual on page
421.
W163 Change according to instruction in
Broken UV lamp(s). chapter Service manual on page
UVR [x]: Lamp error feedback from 421.
LPS.
Trigger: LPS in UV reactor’s LDC.
Delay: 20 sec.
Faulty connection of UV lamp cable Check UV lamp power cable.
Comment: No lamp feedback
when it is requested to be started
by the LPS.
W164
UVR [x]: LPS error feedback from Check 4.9 LPS power overview and
LPS. LED indication on the LPS that trig-
gered the alarm. See LPS alarms in
Trigger: LPS in UV reactor’s LDC. Faulty LPS. section Lamp power supply (LPS).
Delay: 20 sec. If the power is on but there are no
indication, the LPS is probably bro-
Comment: No LPS feedback when ken.
it is requested to start its lamp(s).
UV reactor is deactivated.
210 200000874-5-EN-GB

Check page 4.9 LPS power over-
view and LED indication on the
W165 LPS that triggered the alarm. See
LPS alarms in Lamp power supply
UVR [x]: LPS in fault state. Process One or more of the below: (LPS) on page 217.
not compliant.
• Air intake temp fault. During commissioning: Alfa Laval
Trigger: LPS in electrical cabinet. can run a process with one faulty
LPS in UV reactor’s LDC. • Fan fault. LPS, to be able to fulfill commis-
• Heat sink fault. sioning. Parameter p213 (Allowed
Delay: 5 sec. nr. of failed UV lamps) is set to 1.
Comment: UV reactor is deactiva- • UV lamp open (broken). Parameter must be reset to 0. Op-
ted. eration with faulty LPS or lamps
• Driver fault does not fulfill the type approval
Note: Operation continues but is certificate.
not compliant and does not fulfil re- • System fault
quirements for treatment of ballast • Fan fault and temperature faults
Voltage fault can be caused by something that is
ter management plan. preventing the fan from rotate.
Change LPS. See instruction in
Service manual on page 421.
W170
Valve error (V201–19)
Trigger: Limit switch GS201–19. See possible cause for A17.
Delay: 25 sec.
ted.
W171
Valve error (V201–20)
Trigger: Limit switch GS201–20.
Delay: 25 sec.
W180
LDC ring redundancy error Check that the power link (LAN) ca-
Faulty connection of signal cable. ble from the control cabinet (in a
Trigger: LDC loop to all LDCs) and back is OK.
Delay: 1 sec.
W181 Faulty connection of electrical or Check cabling in LDC.

signal cable.
UVR [x]: Barrier fault
Trigger: Barrier in LDC for
V201-19, V201-20, LS201-29,
LS201-30, QT201-50 and Check fuse F42 in LDC to see
TS201-60. Fuse tripped. which cricuit that caused the fuse to
trip.
Comment: No barrier for
TT201-33.
W182
UVR [x]: UVR fluid level signal
missing (LS201-30)
Trigger: Level switch LS201-30 See W116.
Delay: 5 sec.
Comment: The UV reactor is shut
down.
200000874-5-EN-GB 211

W183
UVR [x]: UVR fluid level missing
(LS201-30)
Trigger: Level switch LS201-30 See W116.
Delay: 5 sec.
Comment: The UV reactor is shut
down. Prevents start of LPS (UV
lamps) in manual mode.
W184
UVR [x]: CIP flow missing
(LS201-30) See W118
Trigger: Level switch LS201-30
W185
UVR [x]: No freshwater filling in
UVR(LS201-30)
See W119.
Parameter: p216.
Delay: set in parameter p 215.
W186
UVR [x]: UVR was not drained
(LS201-30)
See W120.
Parameter: p200.
Delay: 5 sec.
W187
UVR [x]: High temperature
(TS201-60 tripped) and/or LDC
powered off.
See A137.
Trigger: TS201-60
Delay: 1 sec.
ted..
W188
UVR [x]: No feedback from contac-
tor.
Check control system page 2.1
Trigger: N/A Result of other UVR alarm. Alarm list in control panel for rela-
Delay: 10 sec. ted alarms.
Comment: Internal warning as a
result of other alarm/warning for the
UVR.
212 200000874-5-EN-GB

Motor circuit breaker (MCB) F1 in
control cabinet has tripped or has Reset or turn on.
been switched off.
1. Check that the cable W301 is
connected to the control cabi-
net.
2. Check that the motor is not
W300 Motor problem. overloaded and can rotate easi-
Filter sum alarm. ly.
Trigger: -K4Filter. 3. Start the motor and check that
the operation is normal. See
Delay: 1 sec. Service manual on page 421.
Parameter: p318.
Check that mechanical parts in the
Comment: The feedback signal Mechanical obstacles. filter can rotate freely. See Service
“Filter SUM alarm” is not detected. manual on page 421.
Loosen the pipe connections to the
Filter flanges misaligned, and filter and try to rotate the filter man-
forced together causing stress and ually. If the nozzle can rotate, the
deformation of the filter body. pre- pipe connections must be renewed.
venting the nozzle to rotate freely Cut pipe 201 shorter and insert a
inside the filter. tailor made spool piece with perfect
fitting.
W303
Filter 3 sum alarm
Trigger: Filter.
See W300
Delay: 1 sec.
Comment: Only valid for systems
with three Filtrex filter and flow
3000.
200000874-5-EN-GB 213

Backflush manually from control
system. If not sufficient, clean the
Filter is clogged. filter element according to instruc-
tion in chapter Service manual on
page 421.
Make sure that the two valves con-
Valves connected to filter pressure nected to the filter differential trans-
transmitter closed. mitter are open.
Hint: Pressure signals are dis-
played on in the Filter popup
opened from 1.1 Overview
1. Check fuse F45 in Control cabi-
the fuse trip.
W306
Filter differential pressure too high 2. Use the circuit diagram to
Trigger: Pressure transmitter according to figures in circuit di-
PT201-71 and PT201-72. agram if necessary and reset
fuse.
Parameter: p301, p314.
Delay: 2 sec. Pressure transmitters does not cate the component or find the
work correctly. reason that caused the fuse trip
and attend to it.
4. Check cables to the compo-
nent. See Control cabinet / Cir-
cuit diagram in chapter 6. Tech-
nical data and drawings.
6. Replace faulty transmitter.
beginning.

which circuit that caused the
fuse trip.
W308 according to figures in circuit di-
Filter pressure signal missing agram if necessary and reset
(PT201-71) fuse.
Trigger: Pressure transmitter 3. Use the circuit diagram to lo-
PT201-71. Signal missing or component mal- cate the component or find the
function. reason that caused the fuse trip
Parameter: p314. and attend to it.
Delay: 30 sec. 4. Check cables to PT201-71. See
Comment: Alarm deactivated in the drawing Control cabinet /
Standby. Circuit diagram in chapter 6.
Technical data and drawings.
5. If the above is OK, the UV sen-
sor is probably broke and
needs to be replaced. Replace
the component.
214 200000874-5-EN-GB

W310
Filter pressure signal missing
(PT201-72).
Trigger: Pressure transmitter
PT201-72. See W308.
Parameter: p314.
Delay: 30 sec.
Comment: Alarm deactivated in
Standby.
Fuse F4 in the control cabinet has
tripped. Reset fuse F4.
1. Check that cable W3091 is con-

W313 nected to the control cabinet.
A signal is missing from the fuse for 2. Start the motor and check that
the filter buckflush pump. Motor/load problem. the operation is normal.
Delay: None. to the —A2–DI5 digital input on
the PLC.

Backflush manually from control
system. If not sufficient, clean the
Filter is clogged. filter element according to instruc-
tion in Service manual on page
421.
Make sure that the valve connected
Valves connected to pressure to each pressure transmitter is
transmitters closed. open.
A315
1. Check F45 in control cabinet to
Diff. pressure too high. Automatic see what circuit caused the
shutdown. fuse trip.
Trigger: Pressure transmitter 2. Use the circuit diagram to
PT201-71 and PT201-72. check the fuse setting, adjust
Parameter: p300. agram if necessary and reset
Delay: 5 sec. fuse.
Comment: Diff. pressure higher 3. Use the circuit diagram to lo-
than set in parameter p300. cate the component or find the
Diff. pressure is displayed in page Pressure transmitters does not and attend to it.
1.3 Filter. work correctly.
4. Check cables to the compo-
Diff. pressure is displayed on in the nent. See Control cabinet / Cir-
Filter popup opened from 1.1 Over- cuit diagram in section Electri-
view. cal drawings on page 308.
6. Replace faulty transmitter.
beginning.
200000874-5-EN-GB 215

No log box is installed. Parameter Change parameter to Not used.
activated by mistake.
• 1. heck that there is power to

the A40A and A40B mod-
ules. Power is on if any LED
on the modules have stable
or flickering light.
2. Check power cable (W10) to
the Log box.
• 1. If there is no connection be-
tween control system and
log box (warning W501 still
present in the alarm list.
Move the LAN cable from
Faulty cable connection. the used port to the not used
port on the A40A module.
2. Check LAN cable connec-
tion in the LDC.
A501
3. Verify that the cable is not
Log box error longer that maximum al-
Trigger: Log box (optional). lowed cable length of 100
meters.
Delay: 10 sec.
4. Replace the LAN cable with
Comment: Only valid if Log box a new one. (Try with a tem-
have been activated. porary before installing it
Parameter: p500 through the cable gland.)
Fuse in the log box has tripped or Check fuse F02 and F03 in the log
has been switched off. box.
• Check that the switches on the

A40A module is as below:
X16=0, X1=1
• 1. Check that parameter p500
is activated in the control
Faulty setting. system.
2. Acknowledge the alarm in
the control system, to be
able to see when it disap-
pears.

the electronic modules in the log
Error in module. box. See I/O system and X20 mod-
ules on page 221.
216 200000874-5-EN-GB

W502
Log box: External bypass is open
Trigger: Log box (optional).
Delay: 10 See W33.
Comment: If detected by bypass
configuration in 4.7 Log box.
Parameter: p500
W503
Heeling mode requested by log
box.
Trigger: ISCS.
See W82 and W33.
Delay: 10 sec.
Comment: If detected by bypass
configuration in 4.7 Log box.
Parameter: p500
5.2.2 Lamp power supply (LPS)

The table explains alarms triggered by and displayed in the LPS. The LPS is
equipped with four light indications.
LPS on and communication is functioning.
Flickering during communication with PureBallast system.
Internal fault. The cause can be seen on page 4:9 of the LPS overview in
the HMI. Possible causes:
• Broken UV lamp.
• Loose cables to UV lamp.
• LPS temperature too high.
• LPS fan faulty.
Lamp error. Possible causes:

• Ignition failures due to broken UV lamp or loose cable to UV lamp.
• One phase missing on input to LPS.
• Short circuit detected (implemented from LPS version 3, se revision
number on sticker). To reset the LPS, turn off the power to the LPS and
turn it on again by turning the main breaker on the outside of the LDC.
UV Lamp on. Flickering during UV lamp ignition.
Possible causes:
All
LEDs • Voltage for the fail-safe signal (24V) is missing. It can be caused, for ex-
on. ample, by various alarms, wrong DIP switch settings on one ore several
LPS, safety relay tripped.
Possible causes:
All
LEDs • No power to the LPS.
off. • Power to the LPS, but the LPS is broken (needs to be replaced).
5.2.3 Flow meter
200000874-5-EN-GB 217
This section explains faults and alarms triggered by and displayed in the flow
transmitter, mounted on the flow meter (FIT201-1).
During normal conditions, all relevant alarms are displayed in the PureBallast
control panel. See Control system on page 186.
Messages on the display

Faults detected are displayed as a diagnostic message in alteration with the
operational display. If two or more diagnostics events are pending
simultaneously, only the message of the diagnostic event with the highest
priority is shown.
Operational display in alarm con- Diagnostic message
dition
1. Status signal
2. Diagnostic behaviour
3. Diagnostic behaviour with diag-
nostic code
4. Short text (provide information
about the fault)
5. Operating elements
Status signal Meaning

Failure: A device error ha occurred. The measured value is no longer
F valid.
Function check: The device is in service mode (e.g. during a simula-
C tion).
Out of specification : The device is operate outside its technical
S specification limits (e.g. outside the process temperature range).
Maintenance required: Maintenance is required. The measured val-
M ue remains valid.
Diagnostic Meaning
symbol
Alarm:
• Measurement is interrupted.
• Signal outputs and totalizers assume the defined alarm condition.
• A diagnostic message is generated.
Warning : Measurement is resumed. The signal outputs and totaliz-

ers are not affected. A diagnostic message is generated.
218 200000874-5-EN-GB
Operating Meaning
key
Plus key:
+ In a menu, submenu
Opens the message about remedy information.
Enter key:
E In a menu, submenu
Opens the operating menu.
5.2.3.1 Fault finding instruction
Always start troubleshooting with the checklist below if faults occur after start-up or during operation.
1 Check the diagnostic message on the display.

If the display is dark, proceed to step 3.
• Display texts are in a foreign language:
Correct by press - and + for 2 seconds.
Press E and set the desired language in
the Display language parameter.
• Communication error or Check
Electronics: Check the cable and
connector between the main electronics
module and the display module.
• Backlighting of display is red: Take
remedial measures. See step 2. A
diagnostic event with alarm behaviour has
occurred.
2 Call up remedial measures.
a) Press +, when in the diagnostic message.

The Diagnostic list submenu opens.
1. Diagnostic message
b) Select the desired diagnostic event with +

or - and press E.
The message about the remedial
measures opens.
2. Short text
3. Service ID
4. Diagnostic behaviour with diagnostic
code
5. Operation time of occurrence
6. Remedial measures
200000874-5-EN-GB 219
c) Press + and - simultaneously.

The message about the remedial
measures closes.
3 Check a dark display.

• No display visible and no output
signals present:
• Check the supply voltage.
• Check the connection of the cables and
correct if necessary.
• Check that terminals are plugged in
correctly,
• Replace main electronics module. It
might be defective. See step 5.
• No display visible, but output signals
present:
• Adjust brightness of display. Press +
and E or - and E simultaneously.
• Check the connection of cable of the
display module. Insert the plug correctly
into the main electronics module and
display module.
• Replace display module. It might be
defective. See step 5.
4 Restart by turning off/on the power supply by

using the main breaker on the control cabinet.
5 Replace the flow meter, display module, main

electronics module or module carrier if the
problem cannot be detected or corrected.
See instructions in Flow meter on page 484.
5.2.4 Level switch

This section explains the different status indications on the level switch
LS201-29 in the UV reactor. Alarms and status are indicated by LEDs on the
module.
Color State Description What to do?
Green Steady Power on and in operation.
Check plug, cable and power
Green Off No power supply. supply.
Yellow Steady Wet condition.
220 200000874-5-EN-GB
Color State Description What to do?

Error: Internal sensor error or Replace the component.
Red Blinking sensor corroded.
Rectify the short-circuit.
Error: Overload or short-cir-
Red Steady Reduce maximum load current
cuit in load circuit.
to below 250 mA.
5.2.5 I/O system and X20 modules

This section explains the different status indications on the X20 modules.
Alarms and status are indicated by LEDs on the module.
All modules are identified on the front, for example “X20 AT 2222” in the
illustration below. To the right, the stat indication LEDs are visible, for example
“r, e, X, I” in the illustration below.
The following modules are installed in the LDC or control cabinet :

Identification Function Installed in cabinet
AI4622 Analogue input Control cabinet
AO2622 Analogue output Lamp drive cabinet
AO4622 Analogue output Control cabinet
PLC module (System mod-
CP3585 Control cabinet
ule CPU)
IF1082-2 Interface module, power link Control cabinet
PS2100 Power feed, 24V Control cabinet
DI9371 Digital input Control cabinet
Control cabinet
DO6529 Digital output
Lamp drive cabinet
Control cabinet
DO9322 Digital output, 12 outputs
Lamp drive cabinet
Control cabinet
AI2622 Analogue input
Lamp drive cabinet
AT4222 Temperature input module Lamp drive cabinet
BC0083 Bus controller, power link Lamp drive cabinet
CS1030 Interface module Lamp drive cabinet
DI8371 Digital input Lamp drive cabinet
Interface module, RS422/
IF1030 Control cabinet
RS485
PS9400 24V power feed, bus supply Lamp drive cabinet
200000874-5-EN-GB 221
List of alarms and status indications
NOTE
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 BC0083, CP3585 and IF1082-2 are described in separate tables
below the generic table.
Light Lights on the module.

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

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

• X2X bus power supply is overloaded.
Double flashes
• I/O supply too low.
• For PS9400: Input voltage for the X2X bus supply too low.
On Error or reset state.

Red - steady /
r+e Red/Green Green - single Invalid firmware.
flashes
Off No communication at the X2X bus.
X Orange
On X2X bus communication in progress.
Off Bus controller / X2X link supply in acceptable range.
I Red
On Bus controller / X2X link supply overloaded.
Off No data traffic over service interface; no activity.
S Yellow
On Data is transferred over the service interface.
1–6 Orange In/output status of the corresponding digital in/output.
1–8 Green Output status of the corresponding digital output.
1–12 Orange On In/output status of the corresponding digital in/output.
1–12 Green In/output status of the corresponding digital in/output.
1–16 Green Input status of the corresponding digital input.
222 200000874-5-EN-GB
Light Color State Description

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

Green
L/A IF2 Blinking On and Ethernet activity present on the bus.
200000874-5-EN-GB 223

Bus controller error: Failed Ethernet frames, increased num-
On ber of collisions on the network etc.
Red
Blinking Only during startup. This is not an error.
Bus controller is either powered of or not active. Communica-

tion is not possible with the bus controller. After 5 seconds in
this state, the bus controller restarts.
If POWERLINK communication is detected during the 5 sec-
Green Off onds, the bus controller goes to status PRE_OPERATION-
AL_1 (single flash).
If no powerlink communication is detected, the bus controller
goes to BASIC_ETHERNET state (flickering).
Green On Bus controler in operation.
No Powerlink communication detected by bus controller. In

this state you can communicate directly with the bus controller
Flickering (ap- using UDP.
Green prox. 10 Hz) If POWERLINK communication is detected in this state, the
bus controller goes to state PRE_OPERATIONAL_1 (single
flash).
Bus controller in PRE_OPERATIONAL_1.

S/E
With operation on a POWERLINK V1 master, the bus control-
Single flash (ap- ler goes directly into PRE_OPERATIONAL_2.
Green prox. 1 Hz)
With operation on a POWERLINK V2 manager, the CN (Con-
trolled Node) waits for the reception of a SoC frame and then
switches over to PRE_OPERATIONAL_2 (double flash).
Bus controller in PRE_OPERATIONAL_2.

Double flash (ap- In this state the bus controller is normally configured by the
Green manager. A command (POWERLINK V2) or setting the data
prox. 1 Hz)
valid flag in the output data (POWERLINK V1) then switches
the state to READY_TO_OPERATE (triple flash).
Bus controller in READY_TO_OPERATE.

In a POWERLINK V2 network, the manager then switches via
Triple flash (ap- command to OPERATIONAL.
Green prox. 1 Hz)
In a POWERLINK V1 network, the bus controller then
switches automatically to OPERATIONAL as soon as input
data are present.
Bus controller is in STOPPED.

Blinking (approx. No output data is produced and no input data is received. On-
Green 2.5 Hz) ly the appropriate command from the manager can enter or
leave this state.
Module CP3585
Green On Application is running.

R/E
Red On Service mode.
Yellow On Service or boot mode.

RD/F
Red On Over-temperature.
224 200000874-5-EN-GB
Green on Red off Powerlink OK.
Fatal and irreparable system error. See control system for

Green off Red on alarm or warning. This status can only be changed by reset-
ting the module.
S/E The powerlink managing node failed. This error code can only
Blinking alternately occur in controlled node operation. This means that the set
station number lies within the range $01 - $FD.
System failure according to blinking pattern:

Green off Red blinking ●●●—Pause●●●—Pause: RAM error.
—●●—Pause: Hardware error.
On Link to powerlink remote station is established.

EPL Green
Blinking On and Ethernet activity present on the bus.
On Link to Ethernet remote station is established.

ETH Green
Blinking On and Ethernet activity present on the bus.
Yellow On Flash card OK.

CF
Green On Flash card active.
DC Yellow On CPU power supply OK.

OK Red On Backup battery is empty.
Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated
in two moedes: Either in Powerlink V mode or as an Ethernet TCP/IP
interface. Status light depends on mode. For TCP/IP mode, only SE green is
valid.
Green Red
L/A X1 On Link to the remote station is established.
Green
L/A X2 Blinking On and Ethernet activity present on the bus.
TCP/IP mode: Powerlink interface is operated purely as an

On Off Ethernet TCP/EP interface.
Powerlink mode: Powerlinkt station is running, no errors.
Fatal and irreparable system error. See control system for
Off On alarm or warning. This status can only be changed by reset-
ting the module.
S/E
The powerlink managing node failed. This error code can on-
Blinking alternately ly occur in controlled node operation. This means that the set
station number lies within the range $01 - $FD.
System failure according to blinking pattern:
Off Red blinking ●●● — Pause ●●● — Pause: RAM error
— ●● — Pause — ●● — Pause: Hardware error.
200000874-5-EN-GB 225
Module DI9371
Light Green Red Description
Off Off Module not supplied, check fuse.
Single flash Off Reset mode.
Blinking Off Preoperational mode.
S
On Off Run mode.
Off Module not supplied or everything is OK.
Single flash On Invalid firmware
226 200000874-5-EN-GB
5.3 List of problems and solutions

This section contains problems that can occur, but is not indicated by an
alarm.
5.3.1 General problems

Prob- Description Possible cause What to do?
lem
ID
1A The system does not start. The Main breaker on control cabinet Turn on the breaker and meas-
control panel does not light up. and/or LDC turned off, or power ure that incoming 24 V DC to the
Control panel is not displaying a not connected to the control pan- control panel is present.
normal page. PureBallast can el.
not be controlled or monitored
from the ISCS' graphical user in- Power turned off at main switch Turn on the power.
terface via the remote interface board.
(optional). Fuse F42tripped. 1. Check fuse F42 in control
according to figures in circuit
diagram if necessary and re-
set fuse.
cate the component or find
the reason that caused the
fuse trip and attend to it.
Fuse F41 in control cabinet trip- 1. Check fuse F41 in control

ped. cabinet to see what circuit
according to figures in circuit
diagram if necessary and re-
set fuse.
cate the component or find
the reason that caused the
fuse trip and attend to it.
Control panel error. Can be Replace control panel.

caused by overheating etc.
Control panel error due to damp Let the panel dry and try again.
200000874-5-EN-GB 227

lem
ID
1B Control panel is not displaying a Abnormal operating condition. 1. Restart the control panel:
normal page. Cut the power by removing
the power cable at the back
of the control panel. Wait 30
seconds, and reconnect the
cable again.
2. Restart the entire PureBal-
last system: Cut the power
by switching of the main
breaker on the control cabi-
net . Wait 30 seconds, and
switch on the main breaker
again
3. If panel is not OK, it is proba-
bly broke and needs to be
replaced. Replace the com-
ponent
Wrong software version. Check that the HMI and PLC

software have the save program
version. This is visible in control
system page Page 4.1 – System
info on page 76.
HMI software problem. Re-load the HMI software ac-
cording to the software Release
note.
1C PureBallast can not be controlled Communication is broken be- See the What to do column for
or monitored from the ISCS' tween ISCS and PLC. alarm A93.
graphical user interface via the
remote interface (optional).
228 200000874-5-EN-GB

lem
ID
1D Error message on the screen.
These messages can appear alone or in combination. The message does not appear in remote control
panels (option).
“PureBallast: Comm Error ...”: Check the following:

Communication is broken between remote control panel and PLC. • See the What to do column
for alarm A91.
• If the electrical and signal ca-
bles are disconnected or bro-
ken. See Remote control
panel / Circuit diagram.
• If the control cabinet is turned
off.
• If the PLC is broken.
If control panels are not used:
Remove IP address for Remote
control panel 1 according to in-
struction is set for the remote
control panel. See Set remote
control panel communication on
page 116.
“Disconnected from ...”: Check the following:

Communication is broken between remote control panel and main • If the electrical and signal ca-
panel. bles are disconnected or bro-
ken.
• If the control cabinet is turned
off.
• If the main panel is turned off
or broken.
If control panels are not used:
See 1 D.
5.3.2 Filter
Problem Description Possible cause What to do?
ID
Pressure transmitter PT201–71 Dismantle the component and
and PT201–72 may be faulty. inspect/rinse.
Backflush sequence starting er- Error with the pressure gauge Dismantle the component and
5A ror (general). electric switches. inspect/attend to.
Valves for air pressure to valve Open the valve (ball cock) con-
V309-1 are closed. nected to V309-1.
200000874-5-EN-GB 229

ID
The filter house is not properly Deaerate using deaeration
deaerated. valve V571- on the filter lid.
Check filter element for dam-
Damaged filter element. age. Replace if necessary.
Excessive backflushing or long Open the filter and remove the
5B backflushing sequences (gener- Large obstructions have en- obstructions. See Filter on page
tered the filter.
al). 451.
See Backflushing for different
Dirty water. dirt loads on page 32.
Dirt build-up in the filter ele-
ment. Clean the filter element.
5.3.3 CIP
ID
6A Insufficient pump capacity (gen- Leakage in air hoses or seal- Locate leakage and attend to.
eral). ings.
Air pressure too low due to in- Adjust setting with the manual
correct setting on valve block. valve under the valve block.
Examine the pump and attend
Pump is clogged. to problem. See Test CIP pump
on page 463.
The diaphragm in the CIP pump Examine the pump. See chapter
is broken. 7. Service manual, section Re-
pair CIP pump.
6B Too high consumption of CIP Leakage in the CIP tank, CIP Locate leakage and attend to.
liquid. pump, pipes or UV reactor.
6C CIP pump does not run. • The air pressure is to low. Examine the pump and attend
to problem. See Test CIP pump
• The air connection is on page 463.
blocked.
• Muffler is blocked.
• Dirt in the pump chamber.
• Diaphragm breakdown.
6D CIP pump runs irregularly. • Valve blocked. Examine the pump and attend
to problem.
• Sealings are defect in air
valve or center block.
• Diaphragm breakdown.
6E Insufficient CIP pump suction. • Suction connection blocked Examine the pump and attend
or not tight. to problem.
• Valve blocked or damaged.
230 200000874-5-EN-GB

ID
6F Bad flow or pressure in CIP • Pressure fall in incoming air. Examine the pump and attend
pump. to problem.
• Suction or air connection
blocked.
• Valve balls worn out/broken.
• Diaphragm breakdown, due
to air in liquid.
6G CIP pump leakage. Screws on the housing not Tighten the screws.
properly fastened
6H CIP pump muffler leakage. Diaphragm breakdown Change diaphragm.
1. Increase airflow to the pump
to increase pump capacity
with the manual valve under
the valve block on the CIP
Insufficient pump capacity module.
(P321-5).
2. Check that pump P321-5 is
CIP liquid is not returned to CIP functioning correctly. See
6I problem 6D−6I in this chap-
tank.
ter.
Examine the following valves:

Broken valve. V571-1, V321-2.x, V320-4.x and
V321-1.
Investigate if there is a pipe
Pipe blockage. blockage.
Clean valve block. Open the
6J CIP valves do not operate Dirt in valve block. valve throttle and blow out the
dust. close valve throttle again.
This is not a problem.
The function of the backflow
preventer is to secure that no
Water spilling from the backflow CIP liquid is transferred from
Water on the tray at the bottom
6K preventer, due to pressure lev- the CIP side to the incoming
of the CIP. technical water / potable water
elling.
side. To secure this, the back-
flow preventer is levelling the
pressure. Some water can es-
cape at that point.
Water leaking from back flow Leakages due to defect seals or Dismantle and check for defect
6L preventer. mechanical obstacles. seals or mechanical obstacles.
5.3.4 Valve V201–8

Problem Description Possible cause What do to?
ID
8A Signal change has no effect on Faulty air supply. Check that the air supply is cor-
the actuator position. rectly mounted on the valve.
Faulty signal. • Check input signal to propor-
tional valve.
• Check I/P output.
200000874-5-EN-GB 231
Problem Description Possible cause What do to?

ID
8B Signal change results in actua- Connection or signal problem. • Check coupling between
tor running to end positions. proportional valve and actua-
tor.
• Check input signal.
8C Signal and positioning prob- • Inaccurate positioning. Adjust position sensor. See Cal-
lems. ibrate positioner on V201-8 on
• Input signal fluctuates. page 474.
Check electric connection.
5.3.5 P201–1 (optional)
Fault finding instruction

Always start troubleshooting with the checklist below if faults occur after start-
up or during operation.
Problem ID Symptom Possible cause What to do?
Check for free rotation. Rotate motor/
coupling by hand. If the shaft is stuck,
Propeller is stuck.
The pump fails remove spool piece and inspect the
9A propeller.
to start.
Check fuses, electric protection and
Electric supply failure. starting device.
Abnormal vi- Rotating parts out of balance (foreign Check the propeller.
9B brations from object stuck in the propeller).
pump.
Abnormal Change gear / bearings. See Ballast
9C noise from Worn out gear, or bearings. water booster pump P201–1 installa-
pump. tion guide.
Abnormal Replace the bearings. See Ballast
9D noise from mo- Worn out bearings. water booster pump P201–1 installa-
tor. tion guide.
The capacity is A rag (cloth) in the propeller.
9E Check the propeller.
too low.
Gear oil in Replace shaft seal. See Ballast water
leakage detec- Worn out lip-seal. (Cofferdam-gear-
9F booster pump P201–1 installation
house)
tion chamber. guide.
Excessive wa- Replace shaft seal. See Ballast water
ter in leakage Worn out mechanical seal. (Coffer-
9G booster pump P201–1 installation
detection dam-waterside). guide.
chamber.
Insufficient ventilation. Monitor the environment.
Low voltage. Check.
Abnormally hot Loose terminal connection. Check.
9H motor.
Check that the valve is open (partial
Overload. open) prior to start. Check current
consumption.
232 200000874-5-EN-GB
EN
6 Technical data and drawings
200000874-5-EN-GB 233
EN 6 Technical data and drawings
6.1 Introduction
This chapter contains technical information about PureBallast together with
mechanical and electrical drawings.
6.1.1 Ship specific information

Enter vessel specific information in the table below. This will facilitate reading
information and drawings in this document, since some drawings include
information for all system sizes / dimensions, and the document contains
information for options only used by on some vessels. In PDF, either edit the
document or add a text box.
Data Value
Number of UV reactors 2
Flange standard (EN or JIS) ___________

Main valve and piping Dimension: ________________
Control valve (V201-8) Dimension: ________________
Bypass valve (V212–31)

Dimension: ___________
Alfa Laval’s or other
Cooling water valve (V403-35) Dimension: ________________
Sampling device Location Q201.1: ___________
Alfa Laval’s or other Location Q201.2: ___________
Power consumption, max (kW) ___________
Location:
Remote control panel 1: ___________
Remote operation (optional) Remote control panel 2: ___________
Remote interface integration (yes/no):
___________
6.2 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.
For detailed information about weight and volume for major component in the
PureBallast system, see dimension drawings in section Dimension drawings
on page 270
6.2.1 Flow requirements

BW pump and other pumps must give min and max flow according to the table
below:
234 200000874-5-EN-GB
Technical data and drawings 6 EN
Media Flow / consump-

tion
Flow range – Pipe 201, ballast
Note: Inspect the filter marking plate. If you have filter
ACB-9120–500 the data is correct. The system may be sup- 326 – 2000 m3/h
plied with a filter of larger size. If so, consult the Filter size ad-
dendum for correct data.
Flow range – Pipe 201, deballast 200 – 2000 m3/h

100 – 1000 per
Flow range – Pipe 201, stripping
UVR m3/h
Minimum flow – Pipe 403, startup cooling water to UV reactor
(water sea to sea) 40 m3/h
Minimum flow – Pipe 401, cooling water to LDC (Treated cool-

ing water / technical water) 3.0 m3/h
Minimum flow – Pipe 309, filter backflush 126 m3/h
Maximum consumption – Pipe 310.1 and 310.2, technical wa- 1205 l

ter / potable water during CIP process
6.2.2 Water requirements

Ballast water Used for cooling UV lamps in the UV reactor during start-
up. Pipe 403 is recommended to be connected to the ves-
sel’s sea water cooling system or cooling water pump
P403-1 (optional).
Temperature: -2 to 40 °C (liquid form)
Salinity: PureBallast can treat the following types of water:
• Fresh water (salinity ≤ 1 PSU)
• Brackish water
• Marine water
UV intensity limit: The system have been tested and

found to give full treatment according to below:
IMO mode–fresh water: >492 w/m2
Ballast water
IMO mode–brackish and marine water: >252 w/m2
USCG mode: > 772 w/m2 in USCG 3 day mode and 1220
w/m2 in USCG 0 day mode.
Technical water / pota- UVR and filter preservation
ble water
Temperature: 0–38 °C.
For details, see Quality specification / Technical and pota-
ble water on page 267
Treated cooling wa- Cooling water to LDC
ter / technical water
Temperature: 0–38 °C.
200000874-5-EN-GB 235
6.2.3 Power requirements

General power requirements
• 400–440 VAC, 50/60 Hz 3 phase. If voltage does not meet
the requirements, a transformer can be used. The trans-
former is recommended to give voltage in the higher range,
as close as possible to 440 VAC.
Nominal voltage
and frequency • Max Icu 50 KA.
• Power factor: 0.95.
• 24VDC - Remote control panel (optional).
Control cabinet: IP44

Lamp drive cabinet: IP44
IP rating
VFD: IP55
VFD JB: IP66
Heat dissipation Note: VFD Heat dissipation is pump (P201-1) dependent:

(transfer) – VFD 4.2 kW
Heat dissipation Note: Heat dissipation is pump (P201-1) dependent:

(transfer) – P201–1 7 kW
Component Power consumption

(kW)
Control cabinet
1
Control cabinet including filter motor.
Lamp drive cabinet

Power to UV reactor.
200.0
Note: PureBallast only use power needed for treatment.
PureBallast automatically regulates the lamp power be-
tween 50 and 100 % to secure the treatment efficiency.
Pump P309–1 (optional)

For filter backflush water.
Note: Inspect the filter marking plate. If you have filter 11.0
ACB-9120–500 the data is correct. The system may be
supplied with a filter of larger size. If so, consult the Filter
size addendum for correct data.

0.55
For LDC cooling water.

5.50
For UVR cooling water.
Pump P201-1 (optional) incl. VFD

0–126
For ballast water.
6.2.4 System pressure

The table gives a description of system pressure range for piping and
instrument air.
236 200000874-5-EN-GB
Pressure (bar) Comment

Max pressure for standard system: 6 bar.
PureBallast
Max pressure for high pressure system: 9 bar.
Instrument air Range: 5.5 – 8.0 bar to operate valves and CIP pumps.
6.2.5 Pressure requirements for filter backflush

This is section presents how to calculate pressure necessary to overcome
pressure drop for PureBallast components to ensure filter backflush.
Normal minimum required pressure at filter inlet is 1.7 bar. However, this
pressure is affected by other components installed in the system. This is
presented in this section together with necessary calculations for system
pressure.
NOTE
Pressure requirement only includes PureBallast’s components. Piping is
not included.
If a backflush pump P309–1 is not used, pressure drop in pipe 309
(Δp309) must be calculated and added according to the table below.
Bar Comment
Pressure drop for UV reactors and PureBallast’s
0.2 valves.
Pressure drop during Max differential pressure over the filter during bal-
ballast last operation. When the differential pressure rea-
0.5 ches 0.5 bar due to dirt in the filter, a backflush is
started automatically.
1.0 Required pressure to clean the filter.
Pressure needed for If a backflush pump P309–1 is not used, pressure
backflush drop in pipe 309 must be calculated and added.
Δp309 This is vessel specific and must be calculated us-
ing required flow in pipe 309: 126 m3/h.
Pressure reduction if ballast water booster pump
-1,3 P201–1 (Optional) is used.
The ballast pump must deliver pressure at filter
Total inlet, covering total pressure drop over PureBal-
last system.
6.3 Ex protection
This section describes the Ex protection of PureBallast. It covers the
components that are part of the Ex protection, sorted on UV reactor, filter, CIP
module and pipe net.
Requirements for Ex proof installation:
• The person installing PureBallast must have knowledge about applicable
Ex standard.
• The party responsible for the installation shall carry out an inspection to
verify that the installation is correct regarding the Ex protection.
200000874-5-EN-GB 237
Summary
PureBallast is designed and certified in accordance with the IEC 60079 series
of standards. PureBallast fulfills the European Directive ATEX 2014/34/EU
recommended by the IMO for use in marine applications and the IECEx
certified equipment scheme. All components in the zone are certified. The
installation must be done according to applicable rules and standards
regarding installations in potentially explosive environments.
To secure that the UV lamp quartz sleeves are cooled, there must always be
water in the UV reactor when the lamps are lit. This is secured by the use of a
check valve and monitored by double sensors for fluid level and temperature.
If any value deviates, or if signal is missing, the control system (or safety
control system) will shut down the UV reactor immediately. The UV reactor
(Exd) is hermetic sealed from outer atmosphere and is made flameproof
(Exd). The LDC is separated from the UV reactor and placed in safe zone.
During normal operation, the control system monitors PureBallast
automatically, based on input from sensors, to secure safe function. In addition
to the control system, a safety control system (Exi) is used. It is separate from
the control system, and therefore redundant to strengthen the protection
allowing one fault tolerance. If the normal control system fails, the safety
control system will shut down the system. The safe control system is based on
safety relays and is hardwired.
6.3.1 Ex components
All components in zone 1 have been chosen to be compliant with the Ex
requirements. The tables below list all components that are part of the Ex
protection, sorted on UV reactor, CIP module, filter and interconnecting piping.
UV reactor
All components on the UV reactor are connected to the lamp drive cabinet
(LDC). All LDCs are interconnected, and jointly connected to the control
cabinet via a switch in LDC 1.
Component and ID Sub components
UV reactor
2 junction boxes
Level switches:
Barrier (isolating amplifier) installed in LDC
(LS201-29)(LS201-30)
Temperature transmitter (TT201-33) Barrier (isolating amplifier) installed in LDC
Temperature switch (TS201-60) Barrier (isolating amplifier) installed in LDC
UV sensor (QT201-50) Barrier (smart repeater) installed in LDC
Valves:
Solenoid coil
(V320-4) (V321-2) (V404-36)
Solenoid coil
UVR inlet and outlet valve:
Sensor, inductive
(V201-19) (V201-20)
Barrier (isolating amplifier) installed in LDC
238 200000874-5-EN-GB
CIP module
All components on the CIP module are connected to the control cabinet via
the junction box.
Junction box with fuses
Valve block for
Drain pump (P320-1) CIP pump
(P321-5)
Valve block for:
(V310-1) (V310-6) (V320-2)
(V321-1) (V321-4) (V460-2)
(V571-1)
Filter
All components on the filter are connected to the control cabinet via the
junction box.
Filter motor (M709-43)
Junction box
Pressure transmitters:
(PT201-71) (PT201-72)
Backflush valve (V309-1) Solenoid coil
Backflush pump (optional) (P309–1)
Interconnecting piping
All components in the pipe net are connected to the control cabinet via
components own connection or junction box.
Flow transmitter (FIT201-1)
Pressure transmitter (PT201-16) Junction box
Switch box
Positioner
Control valve (V201–8)
Barrier for positioner installed in control cabi-
net
Valves:
(V201-3)
(V201-9) Solenoid coil
(V201-32) Switch box
(V212-31)
(V403-35)
200000874-5-EN-GB 239

UVR cooling water pump (optional)
(P403–1)
Ballast water booster pump (option-
al) (P201–1), including level switch Barrier for level switch installed in VFD JB
(LS662–1)
Junction box
Pressure transmitter (PT201-1)
6.3.2 Safety control system

To control the system, three different circuits working as different layers are
incorporated. As a first layer the standard operation circuit. Second a safety
control circuit, ensuring that the UV reactors do not overheat. A global
emergency stop function is incorporated as a third layer to handle
unpredictable situations.
This system is based on safety relays and is hardwired to avoid the need of a
separate validation of the software. All function in the safety system is using
redundancy to ensure one fault tolerance.
6.3.2.1 Control circuit for UV reactor

Each UV reactor has its own control circuit. The control circuit can be divided
into three separate sub-circuits as described in the following sections.
Normal operation of UV reactor

Normal operation includes thermal protection through a PT1000 element
connected to the PLC via distributed I/O. This circuit will shut down the LPSs
by breaking the 24V DC control voltage feeding them via relay K1 if the UV
reactor reach a temperature of 60°C.
Safety control circuit for UV reactor

The safe control circuit for the UV reactor will only affect the UV reactor and
not the other parts of the system (e.g. other reactors, filter and CIP unit) since
their safety are not depending on it.
This circuit works as a separate system outside the normal control system
deploying two different functions to control the overheating. It is based on a
certified safety controller.
• Temperature limiting circuit – controls that the UV reactor does not
overheat.
• Level control circuit – controls that the UV reactor does not run dry.
Temperature limiting circuit
240 200000874-5-EN-GB
A redundant temperature limiting circuit consisting of one temperature switch

(TS) and one temperature transmitter PT1000 element (TT) connected to
KS01 via intrinsically safe barriers (IS). This interlocks the LPSs, and if the
temperature rises above either of the sensors limits (TT level 1 = 60°C, TT
level 2 = 62.5 °C and TS = 65°C) the UV reactor is shut down.
The output is redundant by breaking contactor group Q1, Q2 and Q3 together
with interrupting the 24V DC feed to the LPSs.
If the circuit is tripped, the blue Reset button S01 on the LDC door is lit. When
the temperature falls below the safety level (57.5), the circuit is reinstalled and
the cabinet can be reset by pushing the Reset button.
Level control circuit
A redundant level control circuit consisting of two level switches (LS201-29
and LS201-30) connected to KS01 via intrinsically safe barriers (IS). These
will shut down the LPS if one of the level switches does not indicate water for
more than 9 seconds. This time is long enough to allow air pockets in the
water, but not so long that any heat is produced.
After the circuit is tripped due to dry condition in the UV reactor, an automatic
reset will be performed when both level switches are activated again (due to
water in the UV reactor). The UV lamps will not be lit automatically, but it is
possible to start a new process.
The output uses the same redundant structure as the temperature limit circuit.
Below, the circuit is highlighted red.
6.3.2.2 Global emergency stop from control cabinet

The global emergency stop button (S10) on the control cabinet door is a
hardwired circuit that cut off power to all LPS inside the LDC when pressed.
If global emergency stop is triggered, the PLC gets a low signal. This will in
return execute appropriate measures with all other actuators (e.g. filter and
valves) in the system which does not need to be safely disconnected by the
emergency stop since their safety are not depending on it.
System reset: The system is reset by releasing the stop button on the control
cabinet door, pressing the reset button on the LDC door and acknowledge all
alarms in the control system.
Diagnostics of power contactors in LDC

Since the power contactors in LDC (Q1, Q2 and Q3) are not monitored by the
safety controller, the feedback from them is connected to an input of the
distributed I/O. This will indicate if one or more contactors are erroneous, and
the PLC will prohibit use of the system.
6.3.2.3 Priming of the system before start

Since the piping of the ballast water system is classified as zone 1, at start up
no ignition source are allowed to be present. Therefore, the pipes are primed
with seawater before the UV lamps can be lit.
The safety control system of the UV reactor secures that there is water in the
UV reactor before power on.
200000874-5-EN-GB 241
6.3.2.4 Normal stop of the system

When the system is stopped after process, there must be water in the UV
reactor at the time the UV lamps are powered off. This is controlled by the
normal operation system, since this is not considered as an unexpected event.
It does not need to be controlled by the safety control system.
6.4 Control system integration

To facilitate monitoring and control of PureBallast, it is possible to integrate the
system to communicate with other components on board the vessel, for
example GPS.
The following optional integrations are possible:
• Remote control panels
• Remote interface
• Power management
• Component signals (hardwired connection of individual components and
features)
• GPS
• Connectivity
• Log box
For component integration, please refer to the following documents:
• Design and installation guide
• Remote interface implementation guide
• Connectivity installation guide
• Ballast water booster pump P201-1 installation guide
• Log box installation guide.
Mandatory and optional integration

All bypass valves status must be integrated to be logged by PureBallast event
log. All other integrations are optional.
6.5 Drawings
This section contains drawings for the PureBallast system. It is divided into
three main parts:
• General drawings – overall and principle information for system layout
(pipes, components, electricity, air and water).
• Dimension drawing – detailed component information (dimensions, sizes
etc).
• Electrical drawings – detailed electric information (circuit diagrams, cable
lists etc).
See the Contents section at the table of contents to get an overview of
included drawings.
242 200000874-5-EN-GB
6.5.1 Graphic symbols used in drawings
200000874-5-EN-GB 243
6.5.2 General drawings

This section contains the general drawings.
244 200000874-5-EN-GB
6.5.2.1 Flow chart
Note: If closed cooling unit (optional) is used, see flow chart for Closed
cooling unit, regarding item 401 and 402.
200000874-5-EN-GB 245
6.5.2.2 Flow chart — P201–1 (optional)
Supplement regarding ballast water booster pump (P201–1).
246 200000874-5-EN-GB
6.5.2.3 Flow chart — Vacuum relief valve, VB201 and VB309 (optional)
200000874-5-EN-GB 247
6.5.2.4 Flow chart — Closed cooling unit, LDC (optional)
248 200000874-5-EN-GB
6.5.2.5 Connection list

Note: If closed cooling unit (optional) is used, see specific connection list.
Note: Note: Inspect the filter marking plate. If you have filter ACB-9120–500
the drawing is correct. The system may be supplied with a filter of larger size.
If so, consult the Filter size addendum for correct data.
200000874-5-EN-GB 249
250 200000874-5-EN-GB
200000874-5-EN-GB 251
252 200000874-5-EN-GB
6.5.2.6 Connection list — Closed cooling unit, LDC (optional)
200000874-5-EN-GB 253
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
++SHIPSYSTEM
Vessel control system Electrical power
1) -W110 Note: -W211A-D. AlfaLaval cable must be used.
distribution central
2) -W116
A 3) -W116.1 Remote GPS 400-440VAC, LDC.n -W211.A - D are system size dependent. Power per LDC cabinet and recomended -W201.n cable size
4) -W117 Interface Interface 50/60Hz, 3 phase UVR size 300 = -W211A (10x1,5) 32kW / 3x35mm²
5) -W118 (Option) (Option) UVR size 600 = -W211A, -W211B (10x1,5) 62kW / 3x50mm²
24VDC±3V(2A) 24VDC±3V(2A)
UVR size 1000 = -W211A, -W211B, -W211C, -W211D (8x1,5) 100kW / 3x95mm²
-W502.1
-W502.2
1 2 3 4 5
-W2 -W3
+RCP.1 +RCP.2
Remote Control Remote Control
B Panel Panel -W1
(Option) (Option) (1-20kW)
Pump UVR UVR
dependent LOCATED IN LOCATED IN
Safe zone ZONE 1 ZONE 1
-W501.1F
+UVR.1 +LDC.1 +UVR.2 +LDC.2

-W501.1
-W501.2
This document constitutes a contractual obligation on our
-W602
-W601
-W210A Lamp drive -W210A Lamp drive
1 2 3 4 5 -W210B cabinet -W210B cabinet
part only to the extent expressly agreed upon.
-W210C (LDC) -W210C (LDC)
Reactor
Reactor
+CC -W211A -W211A
-W211B -W211B
C -W211C -W211C
-W211D -W211D
ES IN OUT ES ES IN OUT ES
GND GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3
-W401.1
3 -W701
-W702.1
3+PE -W102.1
D -W101
2 Note: If 1 LDC, connect:
M -W103 to LDC.1 OUT
3~ 1 -W103 -W102.1 not needed
-M401-1
Pumps (optional)
Safe zone
6.5.2.7 Electrical system layout
Zone 1
and may not be copied, reproduced, transmitted or communicated to a third party,
E
This document and it's contents are the exclusive property of Alfa Laval AB,
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-W201.16
-W201.8A
-W201.1A
-W201.1B
-W212.31
-W201.32
-W403.35
-W201.8B
-W201.3
-W110.1
-W201.9
-W309.1
-W403.1
-W401
-W301
-W303
nor used for any pupose without written permission.
GS 3+PE 3+PE GS GS GS GS GS
M M FT PT
CIP unit Filter
3~ 3~
F
-V212-31 -M309-1 -M403-1 -V201-3 -V201-9 -V201-32 -V201-8 -V403-35 -FIT201-1 -PT201-16
Bypass valve
Pumps (optional)
Date 2020-03-16 Document No. = PB3.2
Ed. SETUGNH PureBallast Ex 9037266_ver7 +
Appr SETURWAA Customer description
Page 1/4
254
Modification Date Name Original Replacement of Replaced by Electrical system layout
255
0 1 2 3 4 5 6 7 8 9
AlfaWall_2019_ESL
Cable list
A Conductors Cables used should be shipboard cables
Cable no Source (from) Target (to) Cable type Min cross-section Function text Remark
[mm] designed according to IEC 60092
Flame retardent: IEC 60332-1-2
W1 ++SHIPSYSTEM +CC Power cable armoured 3x1,5-10 (1-20kW) Pump dependent Safe zone x5
Fire retardent: IEC 60332-3-22
W2 ++SHIPSYSTEM +LDC.1 Power cable armoured 3x35-95 Safe zone x5 Halogen free: IEC 60754-1 & IEC 60754-2
Flexible insulating sleeving: IEC 60684-2
W3 ++SHIPSYSTEM +LDC.2 Power cable armoured 3x35-95 Safe zone x5
W101 +CC +LDC.1-IN LAN CAT5e Shielded or better Max:100m x Other equivalent and approved cables
B
may be used.
W102.1 +LDC.1-OUT +LDC.2-IN LAN CAT5e Shielded or better Max:100m x
Cable areas are calculated with
W103 +CC +LDC.2-OUT LAN CAT5e Shielded or better Max:100m x correction factor 0,8
Code designations for cables obtainable
W110 ++SHIPSYSTEM +CC Signal cable 6x0,75 Feedback & open/close signal for bypass valve. x
through cable producers Nexans, Sweden
W110.1 +CC -V212-31 Signal cable shielded 6x0,75 Feedback & open/close signal for bypass valve. Safe zone x
Recommendation of voltage class
W116 ++SHIPSYSTEM +CC Signal cable shielded 16x0,75 x
Rated voltage
W116.1 ++SHIPSYSTEM +CC Signal cable shielded 12x0,75 x - Power cables 0,6/1kV
C
- Instrumentation cables min 150V
W117 ++SHIPSYSTEM +CC Signal cable shielded 16x0,75 x3
W118 ++SHIPSYSTEM +CC Signal cable shielded 16x0,75 x
x Cable not included in Alfa Laval delivery
W201.1A +CC -FIT201-1 Signal cable shielded 2x2x0,75 Ex d x
W201.1B +CC -FIT201-1 Signal cable shielded 1x2x0,75 Ex d x
W201.3 +CC -V201-3 Signal cable shielded 6x0,75 Ex e x
W201.8A +CC -V201-8 Signal cable shielded 1x2x0,75 Ex i x
D
W201.8B +CC -V201-8 Signal cable shielded 1x2x0,75 Ex e x
W201.16 +CC -PT201-16 Signal cable shielded 1x2x0,75 Ex e x
W210A +LDC.1 +UVR.1 Signal cable shielded 12x0,75 Ex i x
E
W210A +LDC.2 +UVR.2 Signal cable shielded 12x0,75 Ex i x
W210B +LDC.1 +UVR.1 Signal cable shielded 12x0,75 Ex i x

W210B +LDC.2 +UVR.2 Signal cable shielded 12x0,75 Ex i x
W210C +LDC.1 +UVR.1 Signal cable shielded 12x0,75 Ex e x
REMARK
200000874-5-EN-GB
x1 Feedback & open/close signal for bypass valve. x1, x2, x3 can be integrated in same cable.
x2 System size dependant (min 5x0,75 max 16x0,75) x1, x2, x3 can be integrated in same cable.
F
x3 System size dependant (min common alarm) x1, x2, x3 can be integrated in same cable.
x4 Shielded CAT5e or better, multimode fiber 62.5/125um RJ45 contact (W501.n) or fiber LC contact (W501.nF)
x5 Cable cross section depend on length and class society regulations.
x6 Shielded Bus Cable RS485 with impedance 100-120 ohm.
Modification Date Name Original Replacement of Replaced by Cable list Page 2/4
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
AlfaWall_2019_ESL
Cable list
W210C +LDC.2 +UVR.2 Signal cable shielded 12x0,75 Ex e x
W211A +LDC.1 +UVR.1 Power cable armoured, ALFA LAVAL 8/10x1,5 Max:150M ALFA LAVAL Halogen free: IEC 60754-1 & IEC 60754-2
W211A +LDC.2 +UVR.2 Power cable armoured, ALFA LAVAL 8/10x1,5 Max:150M ALFA LAVAL
W211B +LDC.1 +UVR.1 Power cable armoured, ALFA LAVAL 8/10x1,5 Max:150M ALFA LAVAL Other equivalent and approved cables
B
may be used.
W211B +LDC.2 +UVR.2 Power cable armoured, ALFA LAVAL 8/10x1,5 Max:150M ALFA LAVAL
W211C +LDC.1 +UVR.1 Power cable armoured, ALFA LAVAL 8x1,5 Max:150M ALFA LAVAL correction factor 0,8
W211C +LDC.2 +UVR.2 Power cable armoured, ALFA LAVAL 8x1,5 Max:150M ALFA LAVAL
W211D +LDC.1 +UVR.1 Power cable armoured, ALFA LAVAL 8x1,5 Max:150M ALFA LAVAL
W211D +LDC.2 +UVR.2 Power cable armoured, ALFA LAVAL 8x1,5 Max:150M ALFA LAVAL
Rated voltage
W212.31 +CC -V212-31 Signal cable shielded 4x0,75 Ex e x - Power cables 0,6/1kV
C
W301 +CC +Filter Power cable armoured 4G1,5 Ex d x
W303 +Filter +CC Signal cable shielded 4x2x0,75 Ex e x
W309.1 +CC -M309-1 Power cable armoured 4G2,5-4 Ex d x
W401 +CC +CIP Signal cable shielded 12x0,75 Ex e x
W401.1 +CC -M401-1 Power cable armoured 4G1,5 Safe zone x
W403.1 +CC -M403-1 Power cable armoured 4G2,5-4 Ex d x
D
W501.1 +RCP.1 +CC LAN CAT5e Shielded or better Max:100m x4
W501.1F +RCP.1 +CC Multimode fiber 62.5/125um If more than 100m use fiber cable x4
W501.2 +RCP.1 +RCP.2 LAN CAT5e Shielded or better Max:100m x4
W502.1 ++SHIPSYSTEM +RCP.1 Power Supply 2x 24VDC±3V(2Amp) x5
E
W502.2 ++SHIPSYSTEM +RCP.2 Power Supply 2x 24VDC±3V(2Amp) x5
W601 +CC ++SHIPSYSTEM+GPS Signal cable shielded 2x2x0,75 Safe zone x

W602 +CC ++SHIPSYSTEM+RI Signal cable shielded 2x2x0,75 Safe zone x
W701 +CC +LDC.1-ES Signal cable shielded 2x0,75 Safe zone x
REMARK
F
Page 3/4
256
Modification Date Name Original Replacement of Replaced by Cable list
257
0 1 2 3 4 5 6 7 8 9
AlfaWall_2019_ESL
Cable list
W702.1 +LDC.1-ES +LDC.2-ES Signal cable shielded 2x0,75 Safe zone x
Halogen free: IEC 60754-1 & IEC 60754-2
Other equivalent and approved cables
B
may be used.
correction factor 0,8

Rated voltage
- Power cables 0,6/1kV
C
D
E
REMARK
200000874-5-EN-GB
F
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
++SHIPSYSTEM +CC Booster pump
Capacity Power Recommended cable
Electrical power Control Cabinet
250 - 300 26kW W11, W12 = (3x35)
A 500 - 600 40kW W11, W12 = (3x50)
400-440VAC, 50/60Hz, 3-phase
750 - 1000 63kW W11, W12 = (3x70)
1200 - 1500 91kW W11, W12 = (3x120)
W11, W11.1 = (3x95)
2000 126kW
W12, W12.1 = (3x95)
-W11.1
-W11
-W52
-W54
B
+VFD +VFD.JB
Supplement regarding ballast water booster pump (P201–1).
Variable Frequency Drive

C
6.5.2.8 Electrical system layout — P201–1 (optional)
-W12.1
-W56
-W12
-W53
-W51
-W55
D
Safe zone
Zone 1
E
+P201-1
3+PE
M
3~
-M201-1
PT !
LS
2
-PT201-1 -LS662-1
F
Pressure Booster Pump Leak
Monitor with Thermistor Sensor
Date 2020-04-20 Document No. = PB3.x
Appr SETURAH Customer description
Page 1/2
258
Modification Date Name Original Replacement of Replaced by Electrical system layout
259
0 1 2 3 4 5 6 7 8 9
AlfaWall_2019_ESL
Cable list
W11 ++SHIPSYSTEM +VFD Power cable armoured 3x35/50/70/95/120 Pump dependent, Safe Zone x5
W11.1 ++SHIPSYSTEM +VFD Power cable armoured 3x95 126kW Pump dependent, Safe Zone (Capacity 2x1000) x5 Halogen free: IEC 60754-1 & IEC 60754-2
W12 +VFD +P201-1-M201-1 Power cable armoured 3x35/50/70/95/120 Pump dependent, Max: 150m, Ex d x5
W12.1 +VFD +P201-1-M201-1 Power cable armoured 3x95 126kW Pump dependent, Max: 150m, Ex d (Capacity 2x1000) x5 Other equivalent and approved cables
B
may be used.
W51 +VFD.JB +VFD Signal cable shielded 10x0,75 Safe zone x
W52 +CC +VFD Signal cable shielded 2x2x0,75 Safe zone x correction factor 0,8
W53 +VFD +P201-1-M201-1 Signal cable shielded 2x0,75 Ex d x
W54 +CC +VFD.JB Signal cable shielded 2x0,75 Safe zone x

W55 +VFD.JB +P201-1-LS662-1 Signal cable shielded 2x0,75 Ex i x
Rated voltage
W56 +VFD -PT201-1 Signal cable shielded 1x2x0,75 Ex e x - Power cables 0,6/1kV
C
D
E
REMARK
200000874-5-EN-GB
F
6.5.2.9 Electrical system layout – log box (optional)

and may not be copied, reproduced, transmitted or communicated to a third party, This document constitutes a contractual obligation on our
nor used for any pupose without written permission. part only to the extent expressly agreed upon.
A
B
E
F
Modification
0
+Log Box
++SHIPSYSTEM
400-440VAC, 50/60Hz, 3-phase
Electrical power
Date
Max Fuse 10A

-W10
Name
1
Original
Appr
Ed.
Date
Vessel control system

SETURWAA
SETUGNH
2020-03-13
-W201
-W202
-W203
-W204
2
-W205
-W206
-W207
-W208
Replacement of
PureBallast
-W209
-W210
-W211
-W212
-W213
-W214
3
-W215
-W216
-W217
-W218
Replaced by
-W219
-W220
-W221
-W222
-W223
4
-W224
Log Box Interface
-W225
-W226
-W227
-W228
-W229
-W230
-W231
-W232
5
Electrical system layout
-W321
-W322
-W323
-W324
-W325
-W326
-W327
-W328
-W329
-W330
6
-W331
-W332
9049242_ver1
Document No.
+CC/EC
7
Customer description
Control Cabinet/ Electrical Cabinet

-W104
8
Page
+
= PB3.x
1/3
260 200000874-5-EN-GB
261
0 1 2 3 4 5 6 7 8 9
Cable overview AlfaWall_2018 (FEN)
A
Min cross-section
Cable no Source (from) Target (to) Cable type Conductors Function text
[mm]
-W10 ++SHIPSYSTEM +Log Box Power cable armoured 3 1,5 Mains Supply
-W104 +Log Box +CC/EC LAN CAT5e Shielded or better Max:100m
-W201 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Digital Input
B -W203 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Digital Input
C
D
E
200000874-5-EN-GB
F
Ed. SETUGNH PureBallast 9049242_ver1 +
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
A
Min cross-section
[mm]
B -W230 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Digital Input
-W321 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Analog Input
C
D
E
F
Page 3/3
262
263
0 1 2 3 4 5 6 7 8 9
++SHIPSYSTEM
Electrical power Vessel control system
A
110-230VAC, 50/60Hz
-W11 -W10.LAN
B
+Connectivity
Connectivity Cabinet
6.5.2.10 Electrical system layout – Connectivity (optional)
C
D
-W1.LAN -W2.LAN -W3.LAN -W4.LAN -W5.LAN -W6.LAN -W7.LAN
E
Machine 1 Machine 2 Machine 3 Machine 4 Machine 5 Machine 6 Machine 7

200000874-5-EN-GB
F
Modification Date Name Original Replacement of Replaced by Electrical system layout Page 1/2
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
A
Min cross-section
[mm]
-W1.LAN +Connectivity +Machine 1 LAN CAT5e Shielded or better Max:100m
B -W5.LAN +Connectivity +Machine 5 LAN CAT5e Shielded or better Max:100m
-W10.LAN +Connectivity ++SHIPSYSTEM LAN CAT5e Shielded or better Max:100m, Customer

-W11 ++SHIPSYSTEM +Connectivity Power cable armoured 3G 1,5 Mains Supply
C
D
E
F
Page 2/2
264
6.5.2.11 Instrument air distribution
200000874-5-EN-GB 265
6.5.2.12 Quality specification / Instrument air
266 200000874-5-EN-GB
6.5.2.13 Quality specification / Technical and potable water
200000874-5-EN-GB 267
6.5.2.14 Quality specification / CIP liquid

Note that the information below regarding dilution is not valid for compact or
compact flex systems.
268 200000874-5-EN-GB
200000874-5-EN-GB 269
6.5.3 Dimension drawings

This section contains the dimension drawings.
270 200000874-5-EN-GB
6.5.3.1 UV reactor
200000874-5-EN-GB 271
6.5.3.2 Power cable for lamp drive cabinet and UV reactor
272 200000874-5-EN-GB
6.5.3.3 Filter
Note: Inspect the filter marking plate. If you have filter ACB-9120–500 the
drawing is correct. The system may be supplied with a filter of larger size. If
so, consult the Filter size addendum for correct data.
200000874-5-EN-GB 273
274 200000874-5-EN-GB
6.5.3.4 CIP module
200000874-5-EN-GB 275
276 200000874-5-EN-GB
6.5.3.5 Flow transmitter FIT201-1
200000874-5-EN-GB 277
6.5.3.6 Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and

V201-15)
6 bar system
278 200000874-5-EN-GB
High pressure system
200000874-5-EN-GB 279
6.5.3.7 Control valve V201-8
280 200000874-5-EN-GB
6.5.3.8 Valve V201-3 and V201-9
200000874-5-EN-GB 281
6.5.3.9 Valve V201-32 and V403-35
282 200000874-5-EN-GB
6.5.3.10 Check valve CV201
200000874-5-EN-GB 283
6.5.3.11 Valve V212-31 (optional)
284 200000874-5-EN-GB
6.5.3.12 Backflush valve V309-1
If backflush pump P309–1 (optional) is installed, this valve is delivered

mounted on the pump. If backflush pump is not used, the valve is
mounted on the filter.
200000874-5-EN-GB 285
6.5.3.13 Vacuum relief valve VB201 (optional)
286 200000874-5-EN-GB
6.5.3.14 Vacuum relief valve VB309 (optional)
200000874-5-EN-GB 287
6.5.3.15 Sampling device Q201.1 and Q201.2 (optional)
288 200000874-5-EN-GB
200000874-5-EN-GB 289
290 200000874-5-EN-GB
6.5.3.16 Air filter regulator
200000874-5-EN-GB 291
6.5.3.17 Air preparation unit (optional)
292 200000874-5-EN-GB
6.5.3.18 Lamp drive cabinet (LDC)
200000874-5-EN-GB 293
6.5.3.19 Control cabinet
294 200000874-5-EN-GB
6.5.3.20 Remote control panel (optional)
200000874-5-EN-GB 295
6.5.3.21 Log box (optional)
296 200000874-5-EN-GB
297 200000874-5-EN-GB
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related rights. Without This document may constitute a
limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, contractual obligation on the
mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval. Alfa Laval will enforce its rights part of Alfa Laval AB only
related to this document to the fullest extent of the law, including the seeking of criminal prosecution to the extent expressly agreed upon.
600 50
0
Revision No.
701
Date
799 -Signals
2019-11-14
701 -Power supply
Revised
RNE
380
Approved
Legend: (ref. to electrical system layout)
JoEn
799
-signal cables, 10xM16, cable n4,5-10mm

-110-230V 50/60Hz, M20, cable n6-13,6mm
3
15
210
226
29
4x n10,2
54
A
27
15
A
Specification:
Tolerances, `5mm
Enclosure, min IP44
Weight approx, 15kg
410
Powder painted, RAL 7035

Title
ISO E
Method
542
projection
First angle
Creator
RNE
BALLAST
Responsible Department
Date
NB Review Article Data report for additional demands
Approved
Connectivity cabinet dim. dwg.
JoEn
Aerial view
507
2019-11-14
No.
110°
Sheet
1
Document No.
No. of
sheets
127
1 No.
9046270
Revision
0
584
A2
6.5.3.22 Connectivity cabinet (optional)
6.5.3.23 Transformer (optional)
298 200000874-5-EN-GB
6.5.3.24 LDC cooling water pump P401–1 (optional)
200000874-5-EN-GB 299
6.5.3.25 Closed cooling unit, LDC (optional)
300 200000874-5-EN-GB
6.5.3.26 UVR cooling water pump P403–1 (optional)
200000874-5-EN-GB 301
6.5.3.27 Backflush pump P309–1 (Optional)

Note: Inspect the filter marking plate. If you have filter ACB-9120–500 the
drawing is correct. The system may be supplied with a filter of larger size. If
so, consult the Filter size addendum for correct drawing.
302 200000874-5-EN-GB
200000874-5-EN-GB 303
6.5.3.28 Ballast water booster pump P201–1 (optional)
304 200000874-5-EN-GB
6.5.3.29 Pressure monitoring device (Incl. PT201-1, PI201-1, RV201–1

and V201-1) (optional)
To be used with ballast water booster pump P201–1 (optional).
200000874-5-EN-GB 305
6.5.3.30 VFD JB (optional)
306 200000874-5-EN-GB
6.5.3.31 Variable Frequency Drive (VFD) (optional)
200000874-5-EN-GB 307
6.5.4 Electrical drawings
308 200000874-5-EN-GB
6.5.4.1 Control cabinet / Interconnection diagram

A
B
E
F
Target (to) Source (from)
Modification
0
Date
+CC / 1 +EXT / 1
Supply 400-440 VAC
L1 L1
2 3x1,5 - 10 L1
Max fuse 63A
L2 L2
Q1 4 -W1 L2
Name
L3 L3
6 L3
+CC / 1
1
PE PE
PE PE PE
Original
Appr
Ed.
Date
SETURWAA
SETUGNH
2020-03-11
+EXT.VFD / 22 +CC / 22
1A 1A
2 108
2x2x0,75
2
Modbus Interface
1B 1B
Booster Pump
1 109
X2D2
3
2A -W52 2A
110
X2
Replacement of
PureBallast
VFD
2B x6 2B
3 110
+EXT.VFD / 22 +CC / 22
SH SH
PE Clamp PE PE
3
+EXT.VFD JB / 22 +CC / 22
Replaced by
2x0,75
Safe Torque Off
1 1
Booster Pump
1 111
X1
2
2 -W54 2
112
X2
VFD
x
+EXT.VFD JB / 22 +CC / 22
4
SH SH
PE Gland PE PE
+LDC / 7 +CC / 7
OG/WH OG/WH
1 1
5
Interconnection diagram
OG OG
2 2
CC
GN/WH GN/WH
3 CAT5e SF/UTP 3
BU BU
Connection
4 -W101.LAN 4
Interface
First LDC
BU/WH BU/WH
X6 5 5 X6
GN GN
6 6
BN/WH BN/WH
Ex
7 7 6
BN BN
8 8
SH SH
SH SH
9034560_ver6
Document No.
7
8
Page 25 / 34
+ CC
= PB3
200000874-5-EN-GB 309
A
B
E
F
Modification
0
Date
+LDC / 7 +CC / 7
OG/WH OG/WH
1 1
OG OG
2 2
Name
GN/WH GN/WH
3 CAT5e SF/UTP 3
BU BU
Connection
4 -W103.LAN 4
Interface
Last LDC
1
BU/WH BU/WH
X7 5 5 X7
Original
Appr
Ed.
Date
GN GN
6 6
BN/WH BN/WH
7 7
SETURWAA
SETUGNH
2020-03-11
BN BN
8 8
SH SH
SH SH
2
CAT5e SF/UTP
Replacement of
PureBallast
+Log Box / 5 -W104 +CC / 6

Interface
(Option)
Log Box
cable cable
X6 RJ45
x4
IF3:1 A1
3
+SHIPSYSTEM / 24 +CC / 24
1 1
100
Replaced by
2 2
101
3 6x0,75 3
Control Cabinet
Feedback from
102
U3 -W110 X2
V212-31
4 4
103
4
5 x 5
104
6 6
105
SH SH
PE PE PE PE
5
CC
+EXT / 24 +CC / 24
1 1
1 100
2 2
2 101
3 6x0,75 3
Control Cabinet
3 102
Feedback to
-W110.1 X2
V212-31
4 4
Ex
4 103
V212-31 6
5 x 5
5 104
6 6
6 105
9034560_ver6
Document No.
+CC / 24
SH SH
PE PE PE
7
8
Page 26 / 34
+ CC
= PB3
310 200000874-5-EN-GB
A
B
E
F
Modification
0
Date
1 1
41
2 2
42
Name
3 3
43
4 4
44
1
5 5
45
Original
Appr
Ed.
Date
6 6
46
7 7
47
SETURWAA
SETUGNH
2020-03-11
8 16x0,75 8
48
U1 9 -W116 9
49
X2
PMS
10 10
50
2
11 11
51
12 12
52
Replacement of
PureBallast
13 13
53
14 14
54
15 15
55
16 16
56
3
SH SH
SH Insulated PE PE
Replaced by
4
1 1
BB
2 2 X12-K5
A1
+CC / 12
3 3
BB
4 4 X12-K6
A1
U4 +CC / 12
5
5 5
PMS / External Signals
BB
6 12x0,75 6 X12-K7
CC
A1
-W116.1 +CC / 12
7 x 7
BB
8 8 X12-K8
A1
Ex
6
9 9
75
10 10
76
U2 11 11 X2
106
9034560_ver6
Document No.
12 12
107
SH SH
SH Insulated PE PE
7
8
Page 27 / 34
+ CC
= PB3
200000874-5-EN-GB 311
A
B
E
F
Modification
0
Date
1 1
57
2 2
58
Name
3 3
59
4 4
60
1
5 5
61
Original
Appr
Ed.
Date
6 6
62
7 7
63
SETURWAA
SETUGNH
2020-03-11
8 16x0,75 8
64
U2 9 -W117 9 X2
External
Signals
65
10 x3 10
66
2
11 11
67
12 12
68
Replacement of
PureBallast
13 13
69
14 14
70
15 15
73
16 16
74
3
SH SH
SH Insulated PE PE
Replaced by
4
1 1
BB
2 2 X11-K5
A1
+CC / 12
3 3
BB
4 4 X11-K6
A1
+CC / 12
5
5 5
BB
6 6 X11-K7
CC
A1
+CC / 12
7 7
BB
8 8 X11-K8
16x0,75 A1
U4 -W118 +CC / 12
External
Ex
Signals
9 9 6
BB
x
10 10 X12-K1
A1
+CC / 12
9034560_ver6
Document No.
11 11
BB
12 12 X12-K2
A1
+CC / 12
7
13 13
BB
14 14 X12-K3
A1
+CC / 12
15 15
BB
16 16 X12-K4
A1
8
SH SH
SH Insulated PE PE
Page 28 / 34
+ CC
= PB3
312 200000874-5-EN-GB
A
B
E
F
Modification
0
Date
+EXT / 13 +CC / 13
1A 1A
24 17
2x2x0,75
Flow/Conductivity
1B 1B
System Water
25 18
FIT201-1 -W201.1A X2
FIT201-1
Name
2A 2A
26 13
2B x 2B
27 14
1
+EXT / 13 +CC / 13
Original
Appr
Ed.
Date
SH SH
FIT201-1-SH Insulated PE PE
SETURWAA
SETUGNH
2020-03-11
+EXT / 13 +CC / 13
1x2x0,75
2
Flow/Conductivity
1A 1A
System Water
1 11
FIT201-1 -W201.1B X2
FIT201-1
1B 1B
2 12
Replacement of
PureBallast
x
+EXT / 13 +CC / 13
SH SH
FIT201-1-SH Insulated PE PE
3
+EXT / 11 +CC / 18
1 1
1 33
Replaced by
2 2 X2
2 34
+CC / 11
3
3 6x0,75 3
BB
Close / Open
4
4 -W201.3 4 X10-K1
V201-3
4 A1
V201-3 x
+CC / 11
5 5
5 BB
6 6 X10-K2
6 A1
+CC / 11
SH SH
PE PE PE
5
CC
+EXT / 14 +CC / 14
6+
1A 1x2x0,75 1A
4.1
V201-8 1B -W201.8A 1B T2018
V201-8
Ex
7- 4.2
6
Exi
x
+EXT / 14 +CC / 14
SH SH
V201-8-SH Insulated Clamp PE
9034560_ver6
Document No.
+EXT / 14 +CC / 11
1A 1x2x0,75 1A
3 BB
1B -W201.8B 1B X10-K3
V201-8
4 A1
Close
V201-8 x
+CC / 11
SH SH
PE PE PE
8
Page 29 / 34
+ CC
= PB3
200000874-5-EN-GB 313
A
B
E
F
Modification
0
Date
+EXT / 11 +CC / 18
1 1
1 35
2 2 X2
2 36
Name
+CC / 11
3
3 6x0,75 3
BB
Close / Open
-W201.9 X10-K5
1
4 4
V201-9
4 A1
V201-9
Original
Appr
Ed.
Date
x
+CC / 11
5 5
5 BB
SETURWAA
SETUGNH
2020-03-11
6 6 X10-K6
6 A1
+CC / 11
SH SH
PE PE PE
2
Replacement of
PureBallast
+Press.JB / 13 +CC / 13
1x2x0,75
System Pressure
1A 1A
1 15
-W201.16 X2
PT201-16
1B 1B
2 16
3
X1 x
+CC / 13
SH SH
PE PE PE
Replaced by
+EXT / 11 +CC / 18
4
1 1
1 37
2 2 X2
2 38
+CC / 11
3
3 6x0,75 3
BB
Close / Open
-W201.32 X10-K7
V201-32
4 4
4 A1
V201-32 x
+CC / 11
5
5 5
5 BB
6 6 X10-K8
CC
6 A1
+CC / 11
SH SH
PE PE PE
Ex
+EXT / 24 +CC / 11
1 1
9034560_ver6
Document No.
7 BB
2 2 X11-K3
8 4x0,75 A1
Close / Open
-W212.31 +CC / 11
V212-31
3 3
V212-31 9 BB
7
x
4 4 X11-K4
10 A1
+CC / 11
SH SH
PE PE PE
8
Page 30 / 34
+ CC
= PB3
314 200000874-5-EN-GB
A
B
E
F
Modification
0
Date
+FILTER / 1 +CC / 1
Filter Motor
L1
1 4G1,5 1
1
-W301
M709-43
2 2
L2 2
M709-43 X1
Name
3 x 3
L3 3
GNYE GNYE
PE PE
1
SH SH
Original
Appr
Ed.
Date
SETURWAA
SETUGNH
2020-03-11
+FILTER.JB / 13 +CC / 13
1A 1A
1 1
2
1B 1B
2 2
2A 2A
3 3
Replacement of
PureBallast
4
2B 4x2x0,75 2B
4
Filter Signals
X1
5
3A -W303 3A
5
X2
3B x 3B
6 6
4A 4A
Insulated Insulated
3
4B 4B
Insulated Insulated
+FILTER.JB / 19 +CC / 19
SH SH
SH Insulated PE PE
Replaced by
4
Cross-section depends
+EXT / 2 +CC / 2
4G2,5-4
on Pump Power
1 1
M309-1 Supply
L1 4
L2
2 -W309.1 2
5
M309-1 3 x 3 X1
L3 6
GNYE GNYE
PE PE
SH SH
5
CC
+CIP / 16 +CC / 16
1 1
F1 23
2 2
Ex
F2 24
6
3 3
F3 25
4 4
F4 26
5 5
9034560_ver6
Document No.
F5 27
6 12x0,75 6 X2
CIP Connection
F6 28
F7
7 -W401 7
29
8 x 8
F8 30
7
9 9
F9 31
10 10
400 32
+CIP / 16 +CC / 16
11 11
PE PE
12 12
PE PE PE PE
SH SH
PE PE
8
Page 31 / 34
+ CC
= PB3
200000874-5-EN-GB 315
A
B
E
F
Modification
0
Date
+EXT / 2 +CC / 2
L1
1 4G1,5 1
7
2 -W401.1 2
M401-1
Supply
L2 8
M401-1 X1
Name
3 x 3
L3 9
GNYE GNYE
PE PE
1
SH SH
Original
Appr
Ed.
Date
SETURWAA
SETUGNH
2020-03-11
Cross-section depends
+EXT / 2 +CC / 2
4G2,5-4
On Pump Power
1 1
M403-1 Supply
L1 10
2
L2
2 -W403.1 2
11
M403-1 3 x 3 X1
L3 12
Replacement of
PureBallast
GNYE GNYE
PE PE
SH SH
3
+EXT / 11 +CC / 18
1 1
1 39
Replaced by
2 2 X2
2 40
+CC / 11
3 6x0,75 3
CLOSE / OPEN
3 BB
4
-W403.35 X11-K1
V403-35
4 4
4 A1
V403-35 x
+CC / 11
5 5
5 BB
6 6 X11-K2
6 A1
+CC / 11
SH SH
PE PE PE
5
CC
+RCP / 5 +CC / 5
OG/WH OG/WH
1 1
OG OG
Ex
2 2
6
GN/WH GN/WH
3 CAT5e SF/UTP 3
Control Panel
BU BU
4 -W501.1 4
(Option)
Remote
BU/WH BU/WH
9034560_ver6
Document No.
X2 5
x4
5 X13
GN GN
6 6
BN/WH BN/WH
7 7
BN BN
8 8
7
SH SH
SH SH
8
Page 32 / 34
+ CC
= PB3
316 200000874-5-EN-GB
A
B
E
F
Modification
0
2x62,5/125um
Date
+RCP / 5 +CC / 5
Control Panel
Optical Fiber
-W501.1F
(Option)
RX- RX-
Remote
OUT IN
SW1 TX- x4 TX- SW1
IN OUT
Name
1
2x
Original
Appr
Ed.
Date
+RCP / 5 +SHIPSYSTEM / 5
Control Panel
-W502.1
(Option)
1 1
Remote
Supply
+ +
SETURWAA
SETUGNH
2020-03-11
X1 2 x5 2 PS
- -
2
Replacement of
PureBallast
1A 1A
a 2x2x0,75 3
GPS Interface
1B 1B
b -W601 8
(Option)
2A 2A
GPS x X14
2B 2B
3
SH SH
SH SH
Replaced by
1A 1A
3
4
1B 1B
2x2x0,75
Remote Interface
8 X15
2A 2A
-W602 5
(Option)
RS485
RI x +CC / 9
2B 2B
+CC / 9
SH SH
SH X15
5
CC
+LDC / 15 +CC / 15
2x0,75
Emergency Stop
1 1
1 1
X8 2 -W701 2 X5
Ex
6
2 2
LDC
x
+LDC / 15 +CC / 15
SH SH
PE Clamp PE PE
9034560_ver6
Document No.
CAT5e SF/UTP
Connectivity
+Connectivity / 5 -W801 +CC / 5

(Option)
cable cable
A3 RJ45
x4
X4 SW1
8
Page 33 / 34
+ CC
= PB3
200000874-5-EN-GB 317
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
Power conductors shall be black
Insulated end ferrules shall be used up to 16 mm².
25 mm² and up use pin or ring cable lug.
L1 L1 L1 Standard: IPC/WHMA-A-620A Class 2
A L2 L2 L2
L3 L3 L3 Signal conductors shall be blue 0,75 mm²
1 3 5 13 21 1 3 5 13 21 1 3 5 13 21
-Q2 -Q3 -Q4
32A 14 22 10A 14 22 2,5A 14 22
I> I> I> I> I> I> I> I> I>
/10.2:C
/10.2:C
/10.2:D
2 4 6 2 4 6 2 4 6
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
10 mm²
10 mm²
10 mm²
010 BK
011 BK
012 BK
6 mm²
6 mm²
6 mm²
B
01 BK
02 BK
03 BK
04 BK
05 BK
06 BK
07 BK
08 BK
09 BK
1 3 5
1,5 mm²
1,5 mm²
1,5 mm²
013 BK
014 BK
015 BK
-K2
1 3 5 /2.6:D 2 4 6
C
-Q1
63A 2 4 6
013
014
015
04
05
06
07
08
09
2
3
1 3 5 97 95
-F2
-K4
-K4
-K4
-K3
-K3
-K3
-T1
-T1
-T1
0,8-2,7A 2 4 6 98 96
/10.3:C
/2.6:C
1,5 mm²
1,5 mm²
1,5 mm²
2,5 mm²
GNYE
1 BK
2 BK
3 BK
D
6.5.4.2 Control cabinet / Circuit diagram
-X1 1 2 3
PE
(R) (S) (T)
-W1 L1 L2 L3 PE
3x1,5 - 10
-W301
1 2 3 GNYE
E 4G1,5
+FILTER
+EXT L1 L2 L3 PE
400-440VAC, 50/60Hz
L1 L2 L3 PE
3 Phase
-M709-43
M
Max:20kA 3
Power consumption is pump option dependent
Recomended fuse 10-40A Zone 1
Max fuse 63A
F
Filter Motor Supply Supply
Supply M709-43 Booster Pump 24VDC
M401-1
Date 2020-03-11 Document No. = PB3
Ed. SETUGNH PureBallast CC Ex 9034560_ver6 + CC
Page 1 / 34
318
Modification Date Name Original Replacement of Replaced by Control cabinet
319
0 1 2 3 4 5 6 7 8 9
04
-Q2
-A13
-A13
-A13
-A8
-K2
-K2
-K2
1
05
-Q2
1
013
014
015
027
045
046
047
1
16
21
21
21
A 06
-Q2
1
027
045
046
047
1,5 mm²
1,5 mm²
1,5 mm²
013 BK
014 BK
015 BK
6 mm²
6 mm²
6 mm²
6 mm²
6 mm²
6 mm²
04 BK
05 BK
06 BK
04 BK
05 BK
06 BK
33
-KS1
/15.8:B 34
B 1 3 5 1 3 5 1 3 5
-K4 -K5 -K3
/2.8:D 2 4 6 /2.9:D 2 4 6 /2.7:D 2 4 6
048
1 3 5 97 95 1 3 5 97 95 1 3 5 97 95 95 95 95 95
-F4 -F5 -F3 -F2 -F3 -F4 -F5

2 4 6 98 96 2 4 6 98 96 0,8-2,7A 2 4 6 98 96 /1.4:C 96 /2.5:C 96 /2.1:C 96 /2.3:C 96
/10.3:C
/2.8:C
/10.5:C
/2.9:C
/10.4:C
/2.7:C
C Alt. Current (A) Alt. Current (A)
1 5,7-18,9 1 1,9-6,3
2 9-30 2 5,7-18,9
054
055
056
057
3 9-30
1,5 mm²
1,5 mm²
1,5 mm²
4 mm²
4 mm²
4 mm²
4 mm²
4 mm²
4 mm²
10 BK
11 BK
12 BK
4 BK
5 BK
6 BK
7 BK
8 BK
9 BK
A1 A1 A1 A1
-K2 -K3 -K4 -K5
A2 A2 A2 A2
400.5
400.5
400.5
400.5
D
-X1 4 5 6 10 11 12 7 8 9
PE PE PE
400.5
3
1 2 3 1 2 3 1 2 3
-X3
-W309.1 BN BK GY GNYE -W403.1 BN BK GY GNYE -W401.1 BN BK GY GNYE
4G2,5-4 4G2,5-4 4G1,5
E
+EXT
+EXT
+EXT
L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE
-M309-1
M -M403-1
M -M401-1
M
3 3 3 1 2 /1.4:C 1 2 /2.5:B 1 2 /2.1:B 1 2 /2.3:B
3 4 /1.4:C 3 4 /2.5:B 3 4 /2.1:B 3 4 /2.3:B
200000874-5-EN-GB
Zone 1 Zone 1 5 6 /1.4:C 5 6 /2.5:B 5 6 /2.1:B 5 6 /2.3:B
21 22 /15.6:D 21 22 /15.6:C 21 22 /15.6:C 21 22 /15.6:B
F Included if Booster Pump 309-1 (Option) Included if Booster Pump 403-1 (Option) Included if Booster Pump 401-1 (Option)
Booster Pump Booster Pump Booster Pump Control Circ. Control Circ. Control Circ. Control Circ.
M309-1 M403-1 M401-1 M709-43 M401-1 M309-1 M403-1
Modification Date Name Original Replacement of Replaced by Control cabinet Page 2 / 34
A
B
E
F
Modification
Power supply
-Q4
-Q4
-Q4
07
08
09
0
24V/5A
1
unit
-T1
-F42
Date
PLC, HMI, SWITCH
Electronic
+6 1,5 mm² 1,5 mm²
1 LOAD
AC
+
401 BU 401 BU
Supply
+7
L1
I:3 / fuse
2 SET/RESET
3 STATUS
AC
3
1,5 mm²
Name
+'
GND 5
L2
C:3
4 NC
400 BU
AC
-
-
L3
1,5 mm²
-X3
1
402.1
-'
400.1 BU
Busbar
Busbar
402.1 + 2,5 mm²
Original
Appr
Ed.
Date
402.2 402.2
-''
GNYE
PE
-A1
6 402.2 +
PE
402.3
SETURWAA
SETUGNH
2020-03-11
-OP1 402.3
5 +
13
402.3
402.4
+
14
402.5
DCOK
+
I<IN
2
-SW1 402.6 402.6
5 402.6 +
Replacement of
PureBallast
-F43
Electronic
Digital I/O
+6
SupplyY
1 LOAD
+7
I:2 / fuse
2 SET/RESET
3 STATUS
GND 5
C:2
3
4 NC
-X3
Busbar
403.1
403.1 +
Replaced by
-A1 403.2 403.2

6 403.2 +
-X3
-X10.1 403.3 403.3 400.1
11 403.3 + 400.1 -
-Q2 403.4 403.4 -A1 400.2 400.2
4
10 403.4 + 6 400.2 -
-A10 403.5 403.5 -OP1 400.3 400.3
18 403.5 + 5 400.3 -
-X2 403.6 403.6 -T2018 400.4 400.4
13 403.6 + 14 400.4 -
-K5 400.5 400.5
2 400.5 -
-A7 400.6 400.6
15 400.6 -
-F44
Busbar
E-Stop, Ex Barrier
400.7 400.7
5
-X10.1
24VDC power
Electronic
Digital I/O,
+6 11 400.7 -
1 LOAD
Supply
+7 -X2 400.8 400.8

I:2 / fuse
2 SET/RESET 19 -
CC
400.8
3 STATUS
GND 5 400.9 400.9
C:2
4 NC -A5
13 400.9 -
-KS1 400.10 400.10
15 400.10 -
-X3
404.1 -M01 400.11 400.11

404.1 + 16 400.11 -
-A7 404.2 404.2 -S2 400.12 400.12
Ex
6
15 404.2 + 15 400.12 -
-KS1 404.3 404.3
15 404.3 + 400.13 400.13
-H1
404.4 404.4 16 400.13 -
-F2
10 404.4 + 400.14 400.14
-X5
9034560_ver6
Document No.
404.5 404.5 15 400.14 -

-KS1
15 404.5 + 400.15 400.15
-X2
404.6 404.6 13 400.15 -
-KS1
21 404.6 + 400.16 400.16
-X2
16 400.16 -
400.17 400.17
7
-SW1
5 400.17 -
-F45
400.18
400.18 -
Electronic
+6
1 LOAD
+7
Analog I/O
I:3 / fuse
2 SET/RESET
Ex Barrier
Supply
3 STATUS
GND 5
C:3
4 NC
-X4
400
-X3
405.1 -X2 400.19

405.1 + 22 400.19
-X2 405.2 405.2
13 405.2 +
-T2018 405.3 405.3
EXTERNAL
14 +
SUPPLY
405.3
405.4
Page
+ CC
= PB3
+
025
10
405.5
+
-A2
-X4
405
405.6
3 / 34
405.6 +
320 200000874-5-EN-GB
A
B
E
F
Modification
0
Date
-A1
B&R.X20CP3585
/6.0:E
CPU
Name
-A1.1
-IF2
-IF1
B&R.X20IF1082-2
/7.1:E
1
Powerlink LDC
Original
Appr
Ed.
Date
-A1.2
B&R.X20IF1030
/8.0:E
SETURWAA
SETUGNH
2020-03-11
GPS
-A1.3
B&R.X20IF1030
/9.0:E
2
-A2
B&R.X20DI9371
Replacement of
PureBallast
/10.0:F
-A3
B&R.X20DI9371
/11.0:F
3
-A4
B&R.X20DI9371
/12.0:F
Replaced by
-A5
B&R.X20AI4622
/13.0:F
4
-A6
B&R.X20AO2622
/14.0:A
-A7
B&R.X20PS2100
/15.0:A
5
PLC layout
-A8
B&R.X20DO9322
/16.0:A
CC
-A9
B&R.X20DO6529
/17.0:A
Ex
-A10
6
B&R.X20DO6529
/18.0:A
9034560_ver6
Document No.
-A11
B&R.X20DO6529
/19.0:A
-A12
7
B&R.X20DO6529
/20.0:A
-A13
B&R.X20DO6529
/21.0:A
-A14
B&R.X20CS1030
8
/22.1:A
-A15
B&R.X20AI2622
/23.0:F
Page
+ CC
= PB3
4 / 34
200000874-5-EN-GB 321
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
Cabinet frame Terminal layout for
PE
Ethernet cables
Door Door
A PE PE
6 mm²
6 mm²
GNYE
GNYE
-X3
-X3
-X3
-X3
402.3
400.3
400.17
402.6
3
PE PE
Mounting Door
Plate
400.17
402.3
400.3
402.6
B
1,5 mm²
2,5 mm²
GNYE
GNYE
-OP1 -SW1
Control panel PE COM +VA +VB

+ - PE 1 2 3
Lan A Lan B USB

X1 X2 X3 X4
-A1
IN OUT
C TD RD
LAN104
USB1
6
-W2.LAN
CAT5e SF/UTP
-W501.1F RX- TX-
-USB1 2x62,5/125um
Door Optic fiber cable
-W3.LAN -W801 cable -W104 cable
D CAT5e SF/UTP CAT5e SF/UTP CAT5e SF/UTP
+SHIPSYSTEM -X13
+ - RJ45
PS
24VDC 1 2 3 4 5 6 7 8 SH
OG/WH
GN/WH
BN/WH
BU/WH
OG
GN
-W1.LAN
BN
BU
SH
-W502.1 1 2 -W501.1
CAT5e SF/UTP
2x CAT5e SF/UTP
E
LAN01
+RCP +Connectivity +Log Box

6
-A1
OG/WH
OG
GN/WH
BU
BU/WH
GN
BN/WH
BN
SH
TX- RX-
-X1 -X2 -SW1 -A3 -X6

+ - 1 2 3 4 5 6 7 8 SH TD RD
RJ45 RJ45
24VDC ±3V (2A) RJ45 IN OUT
F
(Optional)
Remote Control Panel Connectivity Log Box Interface
(Option) (Option) (Option)
Page 5 / 34
322
Modification Date Name Original Replacement of Replaced by HMI Panel
A
B
E
F
Modification
/4.0:C
-A1
0
X1
X1
Date
VDC
TXD
11
14
X20CP3585
RS232
IF1
X1
RXD
Name
X1
21
402.2
VDC
-X3
402.2 3
X1
15
GND
1
X20
22
Original
Appr
Ed.
Date
X1
GND
400.2
-X3
3
SETURWAA
SETUGNH
2020-03-11
400.2
16
-USB2
Door
IF4
X1
VDC
USB
2
USB2
1
24
IF4+IF5
USB
IF5
Replacement of
PureBallast
USB
X1
1
403.2
VDC
-X3
403.2 3
25
X1
3
GND
26
Replaced by
IF2
Ethernet
LAN01
IF2
IF2
-SW1
5
1
4
X0
SHLD
1
IF3
LAN104
X0
IF3
EPL
IF3
-X6
SHLD
5
1
2
5
PLC 1 CPU
V2.91
CC
Ex
6
9034560_ver6
Document No.
7
8
Page
+ CC
= PB3
6 / 34
200000874-5-EN-GB 323
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
+LDC
-X6 -X7 Terminal layout for
RJ45 RJ45 Ethernet cables
1 2 3 4 5 6 7 8 SH 1 2 3 4 5 6 7 8 SH
A
OG/WH
OG/WH
GN/WH
GN/WH
BN/WH
BN/WH
BU/WH
BU/WH
OG
OG
GN
GN
BN
BN
BU
BU
SH
SH
B
OG/WH
OG/WH
C
GN/WH
GN/WH
BN/WH
BN/WH
BU/WH
BU/WH
OG
OG
GN
GN
BN
BN
BU
BU
-W101.LAN -W103.LAN
CAT5e SF/UTP CAT5e SF/UTP
-X6 -X7
1 2 3 4 5 6 7 8 SH 1 2 3 4 5 6 7 8 SH
RJ45 RJ45
D
-W6.LAN cable -W7.LAN cable
E
-A1.1
/4.1:C
EPL EPL
IF1 IF2
F
X20IF1082-2
First LDC Last LDC
Interface Interface
Connection Connection
Page 7 / 34
324
Modification Date Name Original Replacement of Replaced by PLC 1,1 Interface
325
0 1 2 3 4 5 6 7 8 9
+SHIPSYSTEM
A
-GPS Interface
a b SH
B
-W601 1A 1B SH
2x2x0,75
Signal
cable
shielded
C
-X14
VIP-2/SC/D 9SUB/M 1 2 3 4 5 6 7 8 9 SH
1 2 3 4 5 6 7 8 9
SH
-W14 1 2 3 4 5 6 7 8 9
CABLE-D 9SUB
D
E 1 2 3 4 5 6 7 8 9
-A1.2 1 2 3 4 5 6 7 8 9
/4.1:C SHLD TXD RXD Res GND 5V/50mA TXD RXD Res.
Res. DATA \Res. \DATA
200000874-5-EN-GB
RS422/RS485
F
X20IF1030
Modification Date Name Original Replacement of Replaced by PLC 1,2 GPS interface Page 8 / 34
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
+SHIPSYSTEM
A
-RI Remote Interface
B
-W602 1A 2A 2B 1B SH
2x2x0,75
Signal
cable
shielded
C
-X15
VIP-2/SC/D 9SUB/M 1 2 3 4 5 6 7 8 9 SH
1 2 3 4 5 6 7 8 9
SH
RI connection 485 (*)
-W15 1 2 3 4 5 6 7 8 9 Term. 3 DATA
CABLE-D 9SUB Term. 5 Signal gnd
D
Term. 8 DATA\
RI connection 422
Term. 2 TxD
Term. 3 RxD
Term. 5 Signal gnd
Term. 7 TxD\
Term. 8 RxD\
E 1 2 3 4 5 6 7 8 9
-A1.3 1 2 3 4 5 6 7 8 9 (*) Default connection

/4.2:C SHLD TXD RXD Res GND 5V/50mA TXD RXD Res.
Res. DATA \Res. \DATA
RS485/RS422
F
X20IF1030
Page 9 / 34
326
Modification Date Name Original Replacement of Replaced by PLC 1,3 RI interface
327
0 1 2 3 4 5 6 7 8 9
-KS1
-F45
-X3
-X3
A
024
025
403.4
404.4
15
3
403.4
404.4
B
13 97 97 97 97
-Q2 -F2 -F4 -F3 -F5

/1.2:A 14 /1.4:C 98 /2.1:C 98 /2.5:C 98 /2.3:C 98
051
C
13
-Q3
/1.4:A 14
052
D
13
-Q4
/1.6:A 14
024
025
053
026
030
031
032
E
-A2 11 21 12 22 13 23 14 24 15 25 16 26
/4.2:C DI-1 DI-2 DI-3 DI-4 DI-5 DI-6 DI-7 DI-8 DI-9 DI-10 DI-11 DI-12
200000874-5-EN-GB
F
X20DI9371
System Stop from DC Fuse MS132 Common M709-43 M309-1 M401-1 .
M403-1 . . . . Stop
Emergency .
Safety Relay KS1 Alarm Fuse Alarm Alarm Alarm Alarm Alarm Released
Modification Date Name Original Replacement of Replaced by PLC 2 Digital input Page 10 / 34
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
+EXT
-V201-8
-V201-3 /14.0:F -V201-9 -V201-32 -V403-35
7
8
9
10
7
8
9
10
7
8
9
10
7
8
9
10
-V212-31
-V212-31
-V212-31
-V212-31
-V212-31
A
Close
Open
Close
Open
Close
Open
Close
Open
212-31.1
212-31.2
212-31.3
212-31.4
21231.SH
24
24
24
24
24
2 2 2 2
Close
Open
Close
Open
Close
Open
Close
Open
Close
Open
1 1 1 1
PE
PE
PE
PE
PE
1
2
3
4
5
6
4
5
2
3
4
5
6
2
3
4
5
6
2
3
4
5
6
Zone 1
B
-W201.3 1 2 3 4 5 6 -W201.8B 1A 1B -W201.9 1 2 3 4 5 6 -W201.32 1 2 3 4 5 6 -W403.35 1 2 3 4 5 6 -W212.31 1 2 3 4
Signal Signal Signal Signal Signal Signal
cable cable cable cable cable cable
18
18
18
18
33
34
18
35
36
18
37
38
18
39
40
18
shielded shielded shielded shielded shielded shielded
6x0,75 1x2x0,75 6x0,75 6x0,75 6x0,75 4x0,75

-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
3 4 5 6 1A 1B 3 4 5 6 3 4 5 6 3 4 5 6 1 2 3 4
C X12:+ -X12
/12.1:C 12
-X10 -X11
BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1
+ 24 + 24 BB+ -K5
+ + 12
-X10.1
403.3 4 403.3
-X3 -K1
3 BB 12
-K1 -K2 -K3 -K4 -K5 -K6 -K7 -K8 -K1 -K2 -K3 -K4
D 400.7 3
-X3 BB- -K5
3 BB 12
24 24
- - -- --
1 2 3 4 5 6 7 8 1 2 3 4
X12:- -X12
12
-W10 BK BN RD OG YE GN BU VT -W11 BK BN RD OG
8x0,14 mm 8x0,14 mm
E
BK BN RD OG YE GN BU VT BK BN RD OG
-A3 11 21 12 22 13 23 14 24 15 25 16 26
F
X20DI9371
V201-3 V201-8 V201-9 V201-32 V403-35 V212-31
Close Open Close Close Open Close Open Close Open Close Open
Page 11 / 34
328
Modification Date Name Original Replacement of Replaced by PLC 3 Digital input
329
0 1 2 3 4 5 6 7 8 9
+SHIPSYSTEM
EXAMPLE CONNECTION
A
Insulated
Insulated
B
-W118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 -W116.1
Signal Signal
cable cable
shielded shielded
16x0,75 12x0,75
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
C X12:+
-X11
11
-X11 -X12
BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1 BB A1
/11.6:C
BB+ + 24
-X11-K4
11 +
403.3
-K1
11
-K5 -K6 -K7 -K8 -K1 -K2 -K3 -K4 -K5 -K6 -K7 -K8
D BB-
-K4
11
24
- -
X12:- 5 6 7 8 1 2 3 4 5 6 7 8
-X11
11
-W11 YE GN BU VT -W12 BK BN RD OG YE GN BU VT
8x0,14 mm 8x0,14 mm
E
YE GN BU VT BK BN RD OG YE GN BU VT
-A4 11 21 12 22 13 23 14 24 15 25 16 26
200000874-5-EN-GB
F
X20DI9371
External External External External External External Heeling Mode External PMS PMS PMS PMS
System Stop Bypass 1 Open Bypass 2 Open Bypass 3 Open Feedback Feedback Feedback Granted:1 Granted:2 Granted:3 Granted:4
BW-Pump Run Overboard Valve Stripping Pump Run Common
Open 404,460.1,309
Modification Date Name Original Replacement of Replaced by PLC 4 Digital input Page 12 / 34
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
+EXT +Press.JB +EXT
-FIT201-1 -PT201-16 -PT201-71 -PT201-72
Output 1 Supply /23.1:A
Insulated
Insulated
A
26 27 1 2 2- 1+ PE
AO+
DC+
+ - PE + - PE
AO-
DC-
RD
SH
BK
X1 2 1 PE
Zone 1 Zone 1 Zone 1
B
SH
1
2
-W201.71 SH -W201.72
Signal Signal
cable cable
2x0,75 2x0,75
+FILTER.JB
Insulated
Insulated
-X1 3 4 5 6 PE
PE
C Zone 1
D
-W201.1A 2A 2B -W201.1B 1A 1B -W201.16 1B 1A -W303 2A 2B 3A 3B 4A 4B
Signal Signal Signal Signal
cable cable cable cable
shielded shielded shielded shielded
2x2x0,75 1x2x0,75 1x2x0,75 4x2x0,75
Insulated
Insulated
+ -
-X2 13 14 11 12 16 15 -X2 3 4 5 6
Busbar Busbar Busbar 405.2 -X2
23
405.2
-X3
3 403.6
-X3
400.15 3
E
-X3
3
14
16
6
400.9
-X3
3
-A5 11 12 13 21 22 23 14 15 16 24 25 26
/4.4:C AI+1I AI+1U AI-1U/I AI+2I AI+2U AI-2U/I AI+3I AI+3U AI-3U/I AI+4I AI+4U AI-4U/I
F
X20AI2622
FIT201-1 PT201-16 PT201-71 PT201-72
System Water System Pressure Pressure Sensor Pressure Sensor
Flow . Filter Filter
Page 13 / 34
330
Modification Date Name Original Replacement of Replaced by PLC 5 Analog input
331
0 1 2 3 4 5 6 7 8 9
-A6 X20AO2622
/4.4:C
A
AO+1I AO+1U AO-1U/I AO+2I AO+2U AO-2U/I
11 12 13 21 22 23
0106
0107
021
022
B
-X3
-X3
405.3
400.4
3
3
-T2018
T1 + - IN +24V GND T1'
3.1 3.2 1.1 1.2
T2 0/4...20 mA T2'
T3 T3' Current 4-20mA (Max load 600!)

0/4...20 mA
T4 T4' -X2:1=Load +
4.1 4.2
T5 + - OUT T5' -X2:3=Load -
C
-X2 106 107
-W201.8A 1A 1B SH -W116.1 11 12
Signal 12x0,75
cable Signal
shielded cable
1x2x0,75 shielded
D
E
+EXT
-V201-8
+SHIPSYSTEM
/11.2:A
Insulated
200000874-5-EN-GB
6+ 7-
F
V201-8 Ext Feed
Control Valve Analog Out
Zone 1
Modification Date Name Original Replacement of Replaced by PLC 6 Analog output Page 14 / 34
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-A7 X20PS2100
/4.5:C
A
+24V I/O +24V I/O GND
24 25 26
042
21
-K5
B /2.9:D 22
-KS1
404.5
404.5
S33 S34 13 23 33 41
13 41 22
14 24 34 42
/15.3:C
/21.5:C
/2.6:B
/15.5:C
-KS1 -KS1 -K4
/15.8:B 14 /15.8:B 42 /2.8:D 21
041
404.5
A1 A2 S10 S11 S21 S22 S12
-X3
3
400.14
x1 21
-X3
3
-S2 -K3
/15.6:D x2 /2.7:D 22
035
036
039
040
400.14
400.12
043
024
22
400.12
-K2 1 11
024
/2.6:D 21 -ES1
10
3
-X5 1 2 2 12
034
033
-A2
-X3
D
037
038
14
-S2
400.10
/15.5:C
404.3
13
-W701 1 2 SH
-XES 1 3 4 2
2x0,75
Signal
cable
400.10
404.3
shielded
404.2
400.6
3
3
E Remove Jumpers
-X3
-X3
If External E-Stop
is connected
+LDC
1 2 SH
404.2 -X8 1 2
400.6
3
3
-X3
-X3
F
Power Emergency Stop Signal Indication Emergency Stop Power Emergency Stop
Supply LDC Cabinet to PLC E-Stop Tripped Reset Supply Circuit
Page 15 / 34
332
Modification Date Name Original Replacement of Replaced by PLC 7 Power supply
333
0 1 2 3 4 5 6 7 8 9
-A8 X20DO9322
/4.5:C
A
DO-1 DO-2 DO-3 DO-4 DO-5 DO-6 DO-7 DO-8 DO-9 DO-10 DO-11 DO-12
11 21 12 22 13 23 14 24 15 25 16 26
min 0,34 mm²

-X3
027
028
029
23
24
25
26
27
28
29
30
31
B
400.16
3
400.16 -X2
18
-X2 23 24 25 26 27 28 29 30 31 32
C
RD
-H1
1
x2 x1
-W401 1 2 3 4 5 6 7 8 9 10 11 12 M
-M01
Signal
x3 Fan
cable
shielded 2
12x0,75 BL
min 0,34 mm²

400.13
D
400.13
400.11
027
3
2
-KS1
-X3
-X3
E
1 2 3 4 5 6 7 8 9 10 11 12 SH
+CIP F1 F2 F3 F4 F5 F6 F7 F8 F9
PE PE PE
200000874-5-EN-GB
400 400 400 400 400 400 400 400 400
F
Zone 1
P320-1 P321-5 V310-1 V571-1 V321-1 V320-2 V321-4 V460-2 V310-6 Filter Motor Alarm / Buzzer Ventilation
M709-43 Fan
Start
Modification Date Name Original Replacement of Replaced by PLC 8 Digital output Page 16 / 34
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-A9 X20DO6529
/4.6:C
A
NO-1 COM-1 NO-2 COM-2 NO-3 COM-3 NO-4 COM-4 NO-5 COM-5 NO-6 COM-6
11 12 21 22 13 14 23 24 15 16 25 26
41
42
43
44
45
46
47
48
49
50
51
52
B
-X2 41 42 43 44 45 46 47 48 49 50 51 52
C
-W116 1 2 3 4 5 6 7 8 9 10 11 12
16x0,75
Signal
cable
shielded
D
E
1 2 3 4 5 6 7 8 9 10 11 12
Insulated
+SHIPSYSTEM
F
PMS PMS PMS PMS PMS PMS
Request 1 Request 2 Request 3 Request 4 Run 1 Run 2
Common
Page 17 / 34
334
Modification Date Name Original Replacement of Replaced by PLC 9 Digital output
A
B
E
F
Modification
/4.6:C
-A10
0
+SHIPSYSTEM
-W116
X20DO6529
Date
-X2 53
NO-1
13
13
53
11
PMS 3
Name
Run
1
COM-1
14
14
Original
Appr
Ed.
Date
54
54
12
SETURWAA
SETUGNH
2020-03-11
NO-2
15
15
55
55
21
2
Common
PMS 4
Run
Replacement of
PureBallast
COM-2
16
16
56
56
22
-X2
-X3
3
400.16
403.5
16
NO-3
-V201-3 34
11
34
13
Replaced by
V201-3
Busbar
4
COM-3
-V201-3 33
11 33
33
14
NO-4
-V201-9 36
11
36
5
23
PLC 10 Digital output
V201-9
CC
35 COM-4
-V201-9
11 35
35
24
Ex
6
NO-5
-V201-32 38
9034560_ver6
Document No.
11
38
15
V201-32
7
COM-5
-V201-32 37
11 37
37
16
NO-6
-V403-35 40
8
11
40
25
403.5
19
V403-35
-A11
Page 18 / 34
+ CC
= PB3
COM-6
-V403-35 39
11 39
39
26
200000874-5-EN-GB 335
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-A11 X20DO6529
/4.6:C
A
11 12 21 22 13 14 23 24 15 16 25 26
403.5
-A10
18
10
7
57
58
59
60
61
62
1
B
400.8
-X3
3
-X2 2 1 7 8 9 10 -X2 57 58 59 60 61 62
C
-W117 1 2 3 4 5 6
Signal
cable
shielded
16x0,75
-W303 1B 1A
4x2x0,75
Signal
D cable
shielded
Insulated
+FILTER.JB
-X1 2 1
Zone 1
E
1 2 3 4 5 6
Insulated
-V309-1
+SHIPSYSTEM
- +
+EXT
F
Zone 1
Filter Common Common Request LDC
Backflush Warning Alarm Booster Pump
Valve P401-1
Page 19 / 34
336
Modification Date Name Original Replacement of Replaced by PLC 11 Digital output
337
0 1 2 3 4 5 6 7 8 9
-A12 X20DO6529
/4.7:C
A
11 12 21 22 13 14 23 24 15 16 25 26
63
64
65
66
67
68
69
70
71
72
73
74
B
-X2 63 64 65 66 67 68 69 70 71 72 73 74
C
-W117 7 8 9 10 11 12 13 14 15 16
Signal
cable
shielded
16x0,75
D
E
7 8 9 10 11 12 13 14 15 16
+SHIPSYSTEM
200000874-5-EN-GB
F
Request UVR Request Start Request Open PureBallast Request Start
Booster Pump BW Pump Overboard Running Stripping Pump
P403-1 Valve
Modification Date Name Original Replacement of Replaced by PLC 12 Digital output Page 20 / 34
A
B
E
F
Modification
/4.7:C
-A13
0
-W116.1
shielded
12x0,75
Signal
cable
+SHIPSYSTEM
X20DO6529
Date
-X2 75
A0.1
9
75
11
Request Filter
Backflush
P309-1
Name
1
COM-1
10
Original
Appr
Ed.
Date
76
76
12
SETURWAA
SETUGNH
2020-03-11
A0.2
21
2
Replacement of
PureBallast
COM-2
22
3
A0.3
Replaced by
13
4
COM-3
14
/15.8:B
-KS1
A0.4
-X3 404.6
3
23
24
044
5
PLC 13 Digital output
23
-X2 111
22
CC
111
P309-1
COM-4
-F4 046
2 046
24
Ex
6
A0.5
9034560_ver6
Document No.
15
7
P401-1
COM-5
-F3 045
2 045
16
A0.6
8
25
Page 21 / 34
+ CC
= PB3
P403-1
COM-6
-F5 047
2 047
26
338 200000874-5-EN-GB
339
0 1 2 3 4 5 6 7 8 9
Twisted Wires
max. 30 mm / turn
A -A14
X20CS1030
/4.8:C
TxD+ TxD- GND RxD+ RxD- GND
X1 11 X1 21 X1 13 X1 12 X1 22 X1 23
108
109
110
-KS1
-X4
B
111
400.19
21
3
Twisted wires
400.19
111
C
-X2 108 109 110 111 112
-W52 1A 1B 2A 2B SH
Signal -W54 1 2 SH
cable Signal
shielded cable
2x2x0,75 shielded
2x0,75
D
1A 1B 2A 2B SH
1 2 SH
+EXT
E
+VFD +VFD JB
A B BGND
-X2D2
2 1 3 -X1 1 2
RS485
200000874-5-EN-GB
F
P201-1 P201-1
Modbus Interface Emergency Stop
VFD Safe Torque Off
VFD.JB
Modification Date Name Original Replacement of Replaced by PLC 14 Booster Pump Interface Page 22 / 34
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
+EXT
-FIT201-1
Output 2 /13.1:A
A
24 25
AO+
AO-
Zone 1
B
C
D
-W201.1A 1A 1B
Signal
cable
shielded
2x2x0,75
-X2 17 18
405.2 Busbar
-X2
13
18
E
400.9
-A15 11 12 13 21 22 23 14 15 16 24 25 26
/4.8:C AI+1I AI+1U AI-1U/I AI+2I AI+2U AI-2U/I n.c. n.c. n.c. n.c. n.c. n.c.
F
X20AI2622
QIT201-1 Spare
Conductivity
Page 23 / 34
340
Modification Date Name Original Replacement of Replaced by PLC 15 Analog input
A
B
E
F
Zone 1
+EXT
Modification
0
Date
+SHIPSYSTEM
Name
-W110.1
shielded
shielded
6x0,75
6x0,75
-W110
Signal
Signal
cable
cable
-V212-31
-X2 100 101 102 103 104 105
1
+24V
1
1
2
Original
Appr
Ed.
Date
0V
2
2
SETURWAA
SETUGNH
2020-03-11
212-31.1
+24V 3 -X11-K3
3
3 7 11
212-31.2
V212-31
Close Close
Close -X11-K3
4
4
4 8 11
212-31.3
+24V -X11-K4
5
5
5 9 11
2
Open Open 212-31.4
Open -X11-K4
6
6
6 10 11
21231.SH
PE -W212.31
11
Replacement of
PureBallast
PE
3
Control Cabinet
Feedback from
Control Cabinet
Feedback to
V212-31
Replaced by
V212-31
4
5
Bypass control, Bypass valve connection
CC
Ex
6
9034560_ver6
Document No.
7
8
Page 24 / 34
+ CC
= PB3
200000874-5-EN-GB 341
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
A Cables used should be shipboard cables designed
NO TYPE Source (from) INSTRUCTION Target (to) REMARK
according to IEC 60092.
-W1 3x1,5 - 10 +EXT +CC -Q1 x5 Flame retardent according to IEC 60332-1-2.
-W52 2x2x0,75 +CC -X2 SSC +EXT.VFD -X2D2 x6 Fire retardent according to IEC 60332-3-22.
-W54 2x0,75 +CC -X2 SSC +EXT.VFD JB -X1 x Halogen free according to IEC 60754-1 & IEC 60754-2.
-W101.LAN CAT5e SF/UTP +CC -X6 Max:100m +LDC -X6 x4
Flexible insulating sleeving according to IEC 60684-2.
-W103.LAN CAT5e SF/UTP +CC -X7 Max:100m +LDC -X7 x4
-W104 CAT5e SF/UTP +CC -A1 Max:100m +Log Box -X6 x4 Other equivalent and approved cables may be used.
-W110 6x0,75 +CC -X2 SSC +SHIPSYSTEM -U3 x Cable areas are calculated with correction factor 0,8.
B -W110.1 6x0,75 +CC -X2 SSC +EXT -V212-31 x Code designations for cables obtainable through cable
-W116 16x0,75 +CC -X2 +SHIPSYSTEM -U1 x producers Nexans, Sweden.
-W116.1 12x0,75 +CC -X2 SSC +SHIPSYSTEM -U2 x
-W117 16x0,75 +CC -X2 +SHIPSYSTEM -U2 x3 Where SSC is indicated it should be a signal shielded cable
-W118 16x0,75 +CC -X11-K5 +SHIPSYSTEM -U4 x with the shield properly connected to earth as shown in the
-W201.1A 2x2x0,75 +CC -X2 SSC +EXT -FIT201-1 x electrical drawings.

-W201.1B 1x2x0,75 +CC -X2 SSC +EXT -FIT201-1 x
-W201.3 6x0,75 +CC -X2 SSC +EXT -V201-3 x Recomendation of voltage class
-W201.8A 1x2x0,75 +CC -T2018 SSC +EXT -V201-8 x Rated voltage of power cables 0,6/1kV
C -W201.8B 1x2x0,75 +CC -X10-K3 SSC +EXT -V201-8 x Rated voltage of instrumentation cables min 150V
-W201.9 6x0,75 +CC -X2 SSC +EXT -V201-9 x
-W201.16 1x2x0,75 +CC -X2 SSC +Press.JB -X1 x
-W201.32 6x0,75 +CC -X2 SSC +EXT -V201-32 x
x Cable not included in Alfa Laval delivery.
-W212.31 4x0,75 +CC -X11-K3 SSC +EXT -V212-31 x
-W301 4G1,5 +CC -X1 +FILTER -M709-43 x
-W303 4x2x0,75 +CC -X2 SSC +FILTER.JB -X1 x
-W309.1 4G2,5-4 +CC -X1 +EXT -M309-1 x
-W401 12x0,75 +CC -X2 SSC +CIP x
-W401.1 4G1,5 +CC -X1 +EXT -M401-1 x
D
-W403.1 4G2,5-4 +CC -X1 +EXT -M403-1 x
-W403.35 6x0,75 +CC -X2 SSC +EXT -V403-35 x
-W501.1 CAT5e SF/UTP +CC -X13 Max:100m +RCP -X2 x4
-W501.1F 2x62,5/125um +CC -SW1 +RCP -SW1 x4
-W502.1 2x +SHIPSYSTEM -PS +RCP -X1 x5
6.5.4.3 Control cabinet / Cable list
-W601 2x2x0,75 +CC -X14 SSC +SHIPSYSTEM -GPS x

-W602 2x2x0,75 +CC -X15 SSC +SHIPSYSTEM -RI x
-W701 2x0,75 +CC -X5 SSC +LDC -X8 x
-W801 CAT5e SF/UTP +CC -SW1 Max:100m +Connectivity -A3 x4

E
REMARKS
x4 Shielded CAT5e or better, multimode fiber 62.5/125um RJ45 contact or fiber LC contact (W501.nF)

F
Page 34 / 34
342
6.5.4.4 Lamp drive cabinet / Interconnection diagram
A
B
E
F
Modification
0
Date
+LDC / 1 +EXT / 1
L1(R) L1(R)
L1 3x95 L1
POWER SUPPLY
L2(S) L2(S)
-Q0 L2 -W201.1 L2
Name
L3(T) L3(T)
L3 L3
+LDC / 1
1
PE PE
PE PE
Original
Appr
Ed.
Date
SETUJAD
SETURWAA
2020-01-31
+UVR.JB.A / 8 +LDC / 8
1 1
1 1
2
2 2
2 2
3 3
3 3
Replacement of
PureBallast Ex
4 4
4 4
5 5
5 5
6
6 12x0,75 6
6
Signal cable
-X20.Exi
7
7 -W210.A 7
7
X1
3
8 8
8 8
9 9
9 9
10 10
10 10
Replaced by
11 11
PE PE
12 12
PE PE
4
SH SH
-SH Insulated Clamp PE
1 1
11 11
5
2 2
12 12
LDC
3 3
13 13
4 4
14 14
5 5
15 15
16
6 12x0,75 6
16
Signal cable
-X20.Exi
17
7 -W210.B 7
17
X1
Ex
6
8 8
18 18
9 9
19 19
10 10
9015565_ver9
Document No.
20 20
11 11
PE PE
12 12
PE PE
7
SH SH
-SH Insulated Clamp PE
8
Page 21 / 24
+ LDC
= PB3
200000874-5-EN-GB 343
A
B
E
F
Modification
0
Date
1 1
31 31
2 2
32 32
Name
3 3
33 33
4 4
34 34
1
5 5
35 35
12x0,75
Original
Appr
Ed.
Date
6 6
36 36
Signal cable
-X20.Exe
37
7 -W210.C 7
37
X2
SETUJAD
SETURWAA
2020-01-31
8 8
38 38
9 9
39 39
10 10
40 40
2
11 11
41 41
12 12
42 42
Replacement of
PureBallast Ex
SH SH
-PE Gland Clamp PE
3
+UVR.JB.B / 6 +LDC / 3
1 1
1 1
Replaced by
2 2
2 2
3 3
3 3
Lamp power cable
4
4 8x1,5 4
4
-W211.A
4
-X20.B 5 5 X3
5 5
6 6
6 6
7 7
7 7
8 8
8 8
SH SH
-PE Gland Clamp PE
5
LDC
Ex
6
9015565_ver9
Document No.
7
8
Page 22 / 24
+ LDC
= PB3
344 200000874-5-EN-GB
A
B
E
F
Modification
0
Date
1 1
9 9
2 2
10 10
Name
3 3
11 11
8x1,5
Lamp power cable
4 4
12 12
X20.B -W211.B X3
1
5 5
13 13
Original
Appr
Ed.
Date
6 6
14 14
7 7
15 15
SETUJAD
SETURWAA
2020-01-31
8 8
16 16
SH SH
PE Gland Clamp PE
2
Replacement of
PureBallast Ex
1 1
17 17
2 2
18 18
3
3 3
19 19
8x1,5
Lamp power cable
4 4
20 20
X20.B
21
5 -W211.C 5
21
X3
Replaced by
6 6
22 22
7 7
23 23
8 8
24 24
4
SH SH
PE Gland Clamp PE
5
1 1
25 25
LDC
2 2
26 26
3 3
27 27
8x1,5
Lamp power cable
4 4
28 28
X20.B
29
5 -W211.D 5
29
X3
6 6
30 30
Ex
6
7 7
31 31
8 8
32 32
9015565_ver9
Document No.
SH SH
PE Gland Clamp PE
7
+LDC.2 / 19 2x0,75 +LDC / 19

Emergency stop
1 1
1 -W702.1 1
2 2
X8 2 2 X8
SH SH
PE PE
8
Page 23 / 24
+ LDC
= PB3
200000874-5-EN-GB 345
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
Power conductors shall be black
Insulated end ferrules shall be used up to 16 mm².
-X01 L1 L1 L1 L1 25 mm² and up use pin or ring cable lug.
Supply block L2 L2 L2 L2 Standard: IPC/WHMA-A-620A Class 2
L3 L3 L3 L3
A
Signal conductors shall be blue 0,75 mm²
2 4 6 2 4 6 2 4 6
-Q1 -Q2 -Q3
70 mm²
70 mm²
70 mm²
100A 100A 100A

04 BK
05 BK
06 BK
I>> I>> I>> I>> I>> I>> I>> I>> I>>

1 3 5 1 3 5 1 3 5
B
-Z1
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
019 BK
020 BK
021 BK
022 BK
023 BK
024 BK
L1' L2' L3'
07 BK
08 BK
09 BK
EMC filter
LOAD
LINE
L1 L2 L3
C
70 mm²
70 mm²
70 mm²
01 BK
02 BK
03 BK
2 4 6 2 4 6 2 4 6
-K1 -K2 -K3
/2.3:D 1 3 5 /2.4:D 1 3 5 /2.4:D 1 3 5
-Q0
XT4 250 L1 L2 L3
6.5.4.5 Lamp drive cabinet / Circuit diagram
L: I1=1
t1=12s
35 mm²
35 mm²
35 mm²
10 mm²
10 mm²
10 mm²
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
35 mm²
D
025 BK
026 BK
027 BK
010 BK
011 BK
012 BK
028 BK
029 BK
030 BK
031 BK
032 BK
033 BK
S:I2=0
t2=0.2s
I:I3=6
LOC
L1 L2 L3
X101.1
X101.3
X101.5
X102.1
X102.3
X102.5
X103.1
X103.3
X103.5
010
011
012
3
5
E -W201.1
EXT POWER SUPPLY
-Q102
-Q102
-Q102
L1
L2
L3
-Q104
-Q104
-Q104
-Q107
-Q107
-Q107
3x95
POWER SUPPLY L1(R) L2(S) L3(T) PE
+EXT
L1 L2 L3 PE
400-440VAC,
50/60Hz, 3 phase
Electrical power
distribution, central
F
SUPPLY 440 VAC SUPPLY SUPPLY SUPPLY SUPPLY
Q101-Q103 F1-F2 Q104-Q105 Q106-Q108
Ed. SETURWAA PureBallast Ex LDC Ex 9015565_ver9 + LDC
Appr SETUJAD Customer description
Page 1 / 24
346
Modification Date Name Original Replacement of Replaced by Power supply, lamp drive cabinet
347
0 1 2 3 4 5 6 7 8 9
-K1
-K1
-K1
010
011
012
1
A
L1 L1
L2 L2
L3 L3
2 4 6 2 4 6
-F1 -F2
6A 6A
1 3 5 1 3 5
B
PE
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
1,5 mm²
2,5 mm²
013 BK
014 BK
015 BK
034 BK
035 BK
016 BK
017 BK
018 BK
GNYE
11 41
-K12 -K12 -X5 U V W PE
/19.4:F /19.4:F
GNYE
12 14 42 44
013
014
015
C
7
3
-T1
-T1
-T1
-M1 KL1
1 2 3 PE
Fan
3 phase
-M1 M
3~
1,5 mm²
1,5 mm²
1,5 mm²
036 BK
038 BK
040 BK
D
A1 A1 A1 KL2 KL3
-K1 -K2 -K3 1 2 2 3
A2 A2 A2
NC COM GND 0-10V
1,5 mm²
1,5 mm²
1,5 mm²
037 BK
039 BK
041 BK
BU
YE
4
5
-X5 1 2 3 4
E
402.7
054
060
059
2 1 /1.3:C 2 1 /1.5:C 2 1 /1.6:C
402.7
4 3 /1.3:C 4 3 /1.5:C 4 3 /1.6:C
054
060
059
17
17
200000874-5-EN-GB
13
7
6 5 /1.3:C 6 5 /1.5:C 6 5 /1.6:C
12 11 /14.3:D 11 12 /14.3:D 12 11 /14.3:E
-A4
-X4
-A8
-A8
F
FAN CIRCUIT
Modification Date Name Original Replacement of Replaced by Power supply, lamp drive cabinet Page 2 / 24
200000874-5-EN-GB

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354 200000874-5-EN-GB
355
0 1 2 3 4 5 6 7 8 9
+CC
-X6 -X7 Terminal layout for
RJ45 RJ45 Ethernet cables
1 2 3 4 5 6 7 8 SH 1 2 3 4 5 6 7 8 SH
A
1 2 3 4 5 6 7 8 SH 1 2 3 4 5 6 7 8 SH
B
1 2 3 4 5 6 7 8 SH 1 2 3 4 5 6 7 8 SH
C
OG/WH
OG/WH
GN/WH
GN/WH
BN/WH
BN/WH
BU/WH
BU/WH
-W101.LAN -W103.LAN
OG
OG
GN
GN
BN
BN
BU
BU
-X6 -X7
1 2 3 4 5 6 7 8 SH 1 2 3 4 5 6 7 8 SH
D RJ45 RJ45
-W6.LAN -W7.LAN
E
-A1
/9.2:C RJ45 RJ45
EPL EPL
IF1 IF2
200000874-5-EN-GB
F X20BC0083
Modification Date Name Original Replacement of Replaced by PLC Bus Page 10 / 24
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-A2 X20PS9400
/9.3:C
A
+24V BC X2X L. +24V BC X2X L. GND +24V I/O +24V I/O GND
14 15 16 24 25 26
401.2
402.2
400.2
B
C
D
E
401.2
402.2
400.2
7
7
-X4
-X4
-X4
F
PLC POWER PLC
SUPPLY COMMON
Page 11 / 24
356
Modification Date Name Original Replacement of Replaced by PLC Power supply
357
0 1 2 3 4 5 6 7 8 9
WH/BN Twisted Wires
-LPS1 -LPS2 -LPS3 -LPS4 -LPS5 -LPS6 -LPS7 -LPS8 max. 30 mm / turn
/3.0:D /3.2:D /3.4:D /3.5:D /3.7:D /3.8:D /4.0:D /4.2:D
1 WH BN BN BN BN BN BN BN
0,5 0,5 0,5 0,5 0,5 0,5 0,5
A 1 1 1 1 1 1 1 1
2 BN WH WH WH WH WH WH WH
0,5 0,5 0,5 0,5 0,5 0,5 0,5
2 2 2 2 2 2 2 2
3 BU BU BU BU BU BU BU BU
0,5 0,5 0,5 0,5 0,5 0,5 0,5
3 3 3 3 3 3 3 3
4 GN GN GN GN GN GN GN GN
0,5 0,5 0,5 0,5 0,5 0,5 0,5
4+ 4+ 4+ 4+ 4+ 4+ 4+ 4+
5 YE YE YE YE YE YE YE YE
0,5 0,5 0,5 0,5 0,5 0,5 0,5
5- 5- 5- 5- 5- 5- 5- 5-
5x0,5
B
-LPS16 -LPS15 -LPS14 -LPS13 -LPS12 -LPS11 -LPS10 -LPS9
/5.8:D /5.7:D /5.5:D /5.4:D /5.2:D /5.0:D /4.5:D /4.4:D
1 WH BN BN BN BN BN BN BN 1
0,5 0,5 0,5 0,5 0,5 0,5 0,5
1 1 1 1 1 1 1 1
2 BN WH WH WH WH WH WH WH 2
0,5 0,5 0,5 0,5 0,5 0,5 0,5
2 2 2 2 2 2 2 2
3 BU BU BU BU BU BU BU BU 3
0,5 0,5 0,5 0,5 0,5 0,5 0,5
3 3 3 3 3 3 3 3
C 4 GN GN GN GN GN GN GN GN 4
0,5 0,5 0,5 0,5 0,5 0,5 0,5
4+ 4+ 4+ 4+ 4+ 4+ 4+ 4+
5 YE YE YE YE YE YE YE YE 5
-W20 0,5 0,5 0,5 0,5 0,5 0,5 0,5
5- 5- 5- 5- 5- 5- 5- 5-
5x0,5
1 3 2 4 5
D
11
-K13
/19.8:D 14
400.10
077
11
-K11
/15.0:E 14
076
E
11
-K10
/19.4:F 14
-A3 11 12 13 21 22 23
/9.3:C TxD+ RxD+ GND TxD- RxD- GND
401.4
200000874-5-EN-GB
400.10
401.4
X20CS1030 RS485
7
F
7
-X4
-X4
MODBUS
CONNECTION
LPS
Modification Date Name Original Replacement of Replaced by LPS Modbus Interface Page 12 / 24
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-X4
-X4
-X4
402.3
402.4
400.4
7
A
13
-Q101
+8
-1
B
-W27
/3.1:B 14 -LS1
4
13 I
-Q102 II
2
/3.4:B 14 Liquid Leakage DIP

Point Sensor SWITCH
13
SETTING:
-Q103
NC
5+
/3.7:B
6-
14 0-50M!
402.4
13
C -Q104
/4.1:B 14
13
-Q105
/4.4:B 14
13
-Q106
/5.1:B 14
13
D
-Q107
/5.4:B 14
13
-Q108
/5.7:B 14
-KS1
-KS1
-F42
-X5
050
051
052
054
19
19
2
E
050
051
052
053
054
055
-A4 X1 11 21 12 22 13 23 14 24
/9.4:C E1.1 E1.2 E1.3 E1.4 E1.5 E1.6 E1.7 E2.0
DI-1 DI-2 DI-3 DI-4 DI-5 DI-6 DI-7 DI-8
F X20DI8371
TS201-60 LPS MS132
LS201-29 TEMP HIGH FUSE ALARM ALARM CIRCUIT FAN ALARM WATER ALARM
Page 13 / 24
358
Modification Date Name Original Replacement of Replaced by PLC Digital input
359
0 1 2 3 4 5 6 7 8 9
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
113
116
114
115
117
120
118
119
8
A
-T19 + - + - +24V GND -T20 + - + - +24V GND
4.1 4.2 5.1 5.2 1.1 1.2 4.1 4.2 5.1 5.2 1.1 1.2
CH 1 IN CH 2 IN CH 1 IN CH 2 IN
II II
I I
1 2 3 4 1 2 3 4
CH1 OUT CH2 OUT CH1 OUT CH2 OUT
T1 T2 T3 T4 T5 T1 T2 T3 T4 T5
3.1 3.2 2.1 2.2 3.1 3.2 2.1 2.2
B 14 13 14 13 14 13 14 13
402.9 402.9
-X4 -T33.1
7 20
-KS1
-KS1
-T10
-X4
C
402.10
074
075
090
7
19
19
16
402.10
12
-K1
/2.3:D 11
D
085
11
-K2
/2.4:D 12
086
12
E
-K3
/2.4:D 11
081
082
083
084
087
074
075
090
-A5 X1 11 21 12 22 13 23 14 24
/9.5:C E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7 E1.0
DI-1 DI-2 DI-3 DI-4 DI-5 DI-6 DI-7 DI-8
200000874-5-EN-GB
F X20DI8371
FEEDBACK BARRIER
V201-19 OPEN V201-19 CLOSE V201-20 OPEN V201-20 CLOSE CONTACTORS LS201-30 TS201-33 FAULT
Modification Date Name Original Replacement of Replaced by PLC Digital input Page 14 / 24
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-A6 X20DO9322
/9.5:C
A
DO-1 DO-2 DO-3 DO-4 DO-5 DO-6 DO-7 DO-8 DO-9 DO-10 DO-11 DO-12
11 21 12 22 13 23 14 24 15 25 16 26
B
056
057
058
136
C
31
32
33
34
35
8
-X2
D
-W401 BU/3 BN/4
M12
-K401 3
A1 x1 Heat
exchange
-K11 -H2.1
valve
/12.5:E A2 Green x2
LAMP ON
Door 4
E
400.11
400.6
400.3
400.3
131
132
133
134
135
19
7
8
-X4
-H1.1
-S1
-X4
-X2
-X2
-X2
-X2
-X2
F
ACTIVATE LPS UV LAMP ON SOLENOID VALVE V201-19 V201-20 V320-4 V321-2 V404-36
Page 15 / 24
360
Modification Date Name Original Replacement of Replaced by PLC Digital output
361
0 1 2 3 4 5 6 7 8 9
-X1
-X1
107
108
8
A
107
108
-T10 -T50
Fault out T1' T1 + - IN + - T1'
4.1 4.2 5.1 5.2
T2' T2 active passive T2'
I T3' T3 T3'
PWR 2 PWR 1 active passive
II T4' T4 T4'
3.3 3.2 3.1 2.2 2.1 1.2 1.1 3.1 3.2 2.1 2.2 1.1 1.2
14 12 11 1 2 GND +24V GND +24V T5' T5 + - OUT - +24V GND T5'
B
400.12
400.12
402.8
090
14
20
7
7
-A5
-X4
-T33.1
-X4
C
088
089
D
E
-A7 11 12 13 21 22 23 14 15 16 24 25 26
/9.6:C AI+1I AI+1U AI-1U/I AI+2I AI+2U AI-2U/I AI+3I AI+3U AI-3U/I AI+4I AI+4U AI-4U/I
200000874-5-EN-GB
F X20AI2622
UV SENSOR
INPUT
Modification Date Name Original Replacement of Replaced by PLC Analog input Page 16 / 24
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-A8
/9.6:C
A
AO+1I AO+1U AO-1U/I AO+2I AO+2U AO-2U/I AO+3I AO+3U AO-3U/I AO+4I AO+4U AO-4U/I
X20AO2622
11 12 13 21 22 23 14 15 16 24 25 26
B
C
059
060
D
E
059
060
2
2
-X5
-X5
F
FAN CONTROL
Page 17 / 24
362
Modification Date Name Original Replacement of Replaced by PLC Analog output
363
0 1 2 3 4 5 6 7 8 9
A
B
C
-T33.2
-T33.2
-TT401.2 -TT401.1
x2 x1 x2 x1
061
062
20
20
D
-X5 A B PE
-W25
092
093
061
062
2x0,75 WH RD
E
-A9 11 12 13 21 22 23 14 15 16 24 25 26
/9.7:C Sensor+1 Sense-1 Sensor-1 Sensor+2 Sense-2 Sensor-2 Sensor+3 Sense-3 Sensor-3 Sensor+4 Sense-4 Sensor-4
200000874-5-EN-GB
F X20AT4222
LDC AIR LDC HEAT EXCHANGE UVR
TEMPERATURE WATER TEMP TEMPERATURE INPUT
Modification Date Name Original Replacement of Replaced by PLC Temp. input Page 18 / 24
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
-X1
-X1
-X1
-X1
-X1
-X1
109
110
111
112
105
106
8
8
A
111
105
106
10
12
9
-T29 -T30 -T60

T1 + - IN +24V GND T1' T1 + - IN +24V GND T1' T1 + - IN +24V GND T1'
4.1 4.2 1.1 1.2 4.1 4.2 1.1 1.2 4.1 4.2 1.1 1.2
T2 NAMUR T2' T2 NAMUR T2' T2 NAMUR T2'
T3 OUT1 OUT2 I T3' T3 OUT1 OUT2 I T3' T3 OUT1 OUT2 I T3'
T4 II T4' T4 II T4' T4 II T4'
3.1 3.2 2.1 2.2 3.1 3.2 2.1 2.2 3.1 3.2 2.1 2.2
T5 14 13 OUT 14 13 OUT 1 2 3 4 T5' T5 14 13 OUT 14 13 OUT 1 2 3 4 T5' T5 14 13 OUT 14 13 OUT 1 2 3 4 T5'
B
067
068
069
070
071
072
-K33
-K33
-X4
-X4
C
400.9
401.3
065
066
400.9 7
401.3 7
20
20
065
067
069
071
066
072
068
070
-KS1 TT201-33 TS201-60 LS201-29 LS201-30
A1 A1 A2 A2 24V 0V O0- O1- T0 T0 T1 T1 I0 I1 I2 I3
A2
-K13
D
/12.5:D A1
I4 I5 I6 I7 M0 M1 M2 M3 O0 O1 O2 O3
TS201-33 TS201-60 LS201-29 LS201-30
094
095
-X8 1 2 PE
078
073
075
051
050
074
091
080
21
E
-K13
/19.8:D 24
-W701 1 2 SH -W702.1 1 2 SH
Signal Signal
079
cable cable
shielded 1 2 SH shielded 1 2 SH
13 A1 A1 x1
2x0,75 2x0,75
-S1 -K10 -K12 -S1
/19.5:F 14 /12.5:E A2 /2.3:C A2 /19.0:F x2
RESET
400.5
400.7
400.2
Door
1 2 SH 1 2 SH
401.6
400.5
400.7
400.3
F
+CC +.2
15
7
075
051
050
074
14 -A5
13 -A4
13 -A4
14 -A5
7
-X5 1 2 PE -X8
1 2 PE
-H1.1
-X4
-X4
-H2.1
Page 19 / 24
364
Modification Date Name Original Replacement of Replaced by Safety relay circuit
365
0 1 2 3 4 5 6 7 8 9
Alternative 1 Alternative 2
-X1
-X1
-X1
-X1
104.
103.
102.
101.
102
101
104
103
8
8
A
4
3
-T33
24V DC
15 14 13 12 11 10 -T33.1 -T33.2
- +
24 V LF
!C 2- 1- 3+ 4+ 2- 1- 3+ 4+
Input I Input I
B
LF Power supply Power supply
9- 8 7+ 6 5+ 4 3 2 1+ 5- 7- 8+ 6+ 9+ 10- 5- 7- 8+ 6+ 9+ 10-
400.12
400.12
402.9
402.9
061
062
064
063
064
063
062
061
C
400.12.
400.12
402.9.
402.9
061.
062.
062
061
14
16
18
18
-T20
-T10
-A9
-A9
T33 T33.1 T33.2
7 8 9
4 5 6
D 1 2 3
STAHL
-K33 -K33
PWR 13 14 12 13 14 12
OUT1 OUT1
LF1
PWR PWR
KCD2-RR-Ex1
KCD2-RR-Ex1
24V DC 24V DC
E
1+ 2- 5 6 1+ 2- 5 6
402.5
400.8
402.5
400.8
LF2
065
066
065
066
402.5.
400.8.
402.5
400.8
065.
066.
9180
065
066
19
200000874-5-EN-GB
19
7
7
-X4
-X4
-KS1
-KS1
/20-77-11
F
10 11 12
13 14 15
Ex
Modification Date Name Original Replacement of Replaced by UVR Temperature barrier Page 20 / 24
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
to the extent expressly agreed upon.
This document may constitute a
contractual obligation on the
Cables used should be shipboard cables designed

part of Alfa Laval AB only
A
-W201.1 3x95 +EXT Power cable armoured +LDC -Q0 x5 Flame retardent according to IEC 60332-1-2.
-W210.A 12x0,75 +LDC -X1 SSC +UVR.JB.A -X20.Exi x Fire retardent according to IEC 60332-3-22.
-W210.B 12x0,75 +LDC -X1 SSC +UVR.JB.A -X20.Exi x Halogen free according to IEC 60754-1 & IEC 60754-2.
-W210.C 12x0,75 +LDC -X2 SSC +UVR.JB.A -X20.Exe x
-W211.A 8x1,5 +LDC -X3 INFORM LENGTH +UVR.JB.B -X20.B
-W211.B 8x1,5 +LDC -X3 INFORM LENGTH +UVR.JB.B -X20.B Other equivalent and approved cables may be used.
-W211.C 8x1,5 +LDC -X3 INFORM LENGTH +UVR.JB.B -X20.B Cable areas are calculated with correction factor 0,8.
-W211.D 8x1,5 +LDC -X3 INFORM LENGTH +UVR.JB.B -X20.B Code designations for cables obtainable through cable
otherwise), or for any purpose, without the expressed permission of Alfa Laval. Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including
B
-W702.1 2x0,75 +LDC -X8 SSC +LDC.2 -X8 x producers Nexans, Sweden.
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related rights. Without limiting any rights
related to this document, no part of this may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or
Where SSC is indicated it should be a signal shielded cable

with the shield properly connected to earth as shown in the
electrical drawings.
Recomendation of voltage class
Rated voltage of power cables 0,6/1kV
C Rated voltage of instrumentation cables min 150V
D
6.5.4.6 Lamp drive cabinet / Cable list
E
REMARKS
the seeking of criminal prosecution.
F
Page 24 / 24
366
367
0 1 2 3 4 5 6 7 8 9
to the extent expressly agreed upon.
This document may constitute a
contractual obligation on the
Cables used should be shipboard cables designed

part of Alfa Laval AB only
A
-W11 3x35-120 +SHIPSYSTEM Power cable armoured +EXT.VFD x Flame retardent according to IEC 60332-1-2.
-W11.1 3x95 +SHIPSYSTEM Power cable armoured +EXT.VFD x Fire retardent according to IEC 60332-3-22.
-W12 3x35-120 +EXT.VFD Power cable armoured +EXT.P201-1 x Halogen free according to IEC 60754-1 & IEC 60754-2.
-W12.1 3x95 +EXT.P201-1 Power cable armoured +EXT.VFD x
-W51 10x0,75 +VFD JB -X1 SSC +EXT.VFD -XSTO x
-W52 2x2x0,75 +CC -X2 SSC +EXT.VFD -XD2D x Other equivalent and approved cables may be used.
-W53 2x0,75 +EXT.VFD SSC +EXT.P201-1 x Cable areas are calculated with correction factor 0,8.
B -W54 2x0,75 +CC -X2 SSC +VFD JB -X1 x Code designations for cables obtainable through cable
otherwise), or for any purpose, without the expressed permission of Alfa Laval. Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including
-W55 2x0,75 +VFD JB -T6621 SSC +EXT.P201-1 -LS662-1 x producers Nexans, Sweden.
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related rights. Without limiting any rights
-W56 1x2x0,75 +EXT.JB -X1 SSC +EXT.VFD -XD24 x

related to this document, no part of this may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or
Where SSC is indicated it should be a signal shielded cable

with the shield properly connected to earth as shown in the
electrical drawings.
Recomendation of voltage class

Rated voltage of power cables 0,6/1kV
C Rated voltage of instrumentation cables min 150V
Supplement for ballast water booster pump (P201–1).

D
E
REMARKS
the seeking of criminal prosecution.
6.5.4.7 VFD JB / Cable list
200000874-5-EN-GB
F
Ed. SETUGNH PureBallast Ex VFD JB 9038497_ver10 + VFD JB
200000874-5-EN-GB
0 1 2 3 4 5 6 7 8 9
+SHIPSYSTEM
400-440VAC W11, W11.1, W12, W12.1 = Pump dependent. (*) PE
50/60Hz
A Max: 65kA L1 L2 L3 PE UVR size 300 26kW W11, W12 = (3x35) 16
Power consumption UVR size 600 40kW W11, W12 = (3x50) 25
is pump dependent UVR size 1000 63kW W11, W12 = (3x70) 50
UVR size 1500 91kW W11, W12 = (3x120) 70
UVR size 2000 126kW W11, W11.1, W12, W12.1 = (3x95) 70
(R) (S) (T) (R) (S) (T)
-W11 L1 L2 L3 SH -W11.1 L1 L2 L3 SH
Pump dependent Pump dependent
3x35-120 ONLY FOR 126kW
3x95
B
L1 L2 L3 SH L1 L2 L3 SH
+EXT
+VFD
L1 L2 L3 PE L1 L2 L3 PE SLOT1
C Power Power Thermistor protection
module
Motor
T1/U T2/V T3/W PE' T1 T2 PE PE

XLFT
(*)
-W53 1 2 SH
Signal
PE
(R) (S) (T) (R) (S) (T) cable
D L1 L2 L3 SH L1 L2 L3 shielded
-W12 -W12.1 SH
Pump dependent Pump dependent 2x0,75
3x35-120 ONLY FOR 126kW
3x95
1 2 SH
L1 L2 L3 SH L1 L2 L3 SH
6.5.4.8 VFD JB / Circuit diagram
E
+EXT
+P201-1
PE
U1 V1 W1 PE
M
3~
!
T1 T2
F
Zone 1
P201-1
Booster Pump
with Thermistor
Page 1/8
368
Modification Date Name Original Replacement of Replaced by P201-1, VFD Power Supply
369
0 1 2 3 4 5 6 7 8 9
+EXT
-PT201.1
-T6621
-T6621
-T6621
A
1+ 2- GND
13 23
-KS1 -KS1
10
11
12
RD
/3.4:D
4
SH
BK
14 24 +CC
+JB
-X1 1 2 PE -X2 108 109 110
Zone 1
-X1 4 6 5 7 3 8 9 10 11 12 PE
B
-W51 2 4 3 5 1 6 7 8 9 10 SH -W56 1A 1B SH -W52 1A 1B 2A 2B SH
Signal Signal Signal
cable cable cable
shielded shielded shielded
10x0,75 1x2x0,75 2x2x0,75
2 4 3 5 1 6 7 8 9 10 SH 1A 1B SH 1A 1B 2A 2B SH
C +EXT
+VFD
OUT IN1 IN2 +24V DICOM DI6 +24V DIOGND AI2+ AI2- A B BGND
XSTO1 XSTO2 XSTO XD24 XDI XD24 XAI XD2D
11 12 21 22 1 3 4 2 3 6 4 5 6 7 2 1 3
Thermistor protection Safe torque off Digital interlock Digital input Digital interlock Analog input Drive-to-drive link
module Analogue input Drive-to-drive link
SLOT2 signal selector (U/I) TERMINATION
Bus terminated
AI2 J3
I U Bus not terminated
D
E
200000874-5-EN-GB
F
Emergency stop LS662-1 PT201-1 Modbus
Safe Torque off Leak sensor Pressure Monitor communication
Modification Date Name Original Replacement of Replaced by P201-1, VFD Control Signals Page 2/8
A
B
E
F
Modification
0
Date
Name
1
-KS1
shielded
Original
Appr
Ed.
Date
2x0,75
Signal
-W54
cable
+CC
Emergency stop
Safe Torque Off
SETURAH
SETUGNH
2020-02-18
-X1 1
-X2 111 112

P201-1
VFD
A1
1
A2
2
2
2
SH
PE
SH
Replacement of
PureBallast Ex
S11
S12
S34
3
S21
S22
Replaced by
/2.2:A
4
14
13
/2.2:A
24
23
34
33
42
41
5
Emergency stop, safe torque off
VFD JB
6
9038497_ver10
Document No.
7
8
Page
+ VFD JB
= PB3
3/8
370 200000874-5-EN-GB
371
0 1 2 3 4 5 6 7 8 9
A
+EXT
+P201-1
1
-LS662-1
2
B
Zone 1
-X1
-X1
-W55 1 2 SH
10
11
2
2
Signal
cable
shielded
2x0,75
C
-T6621
T1 + - IN +24V GND T1'
4.1 4.2 1.1 1.2
T2 NAMUR T2'
T3 OUT1 OUT2 I T3'
T4 II T4'
3.1 3.2 OUT 2.1 2.2 OUT
T5 14 13 14 13 1 2 3 4 T5'
D 12
2
-X1
E
200000874-5-EN-GB
F
LS662-1
Leak sensor
Modification Date Name Original Replacement of Replaced by Barrier, Leak sensor Page 4/8
6.5.4.9 VFD JB / Interconnection diagram

A
B
E
F

Modification
0
Date
+EXT.VFD / 1 +SHIPSYSTEM / 1
3x35-120
Pump dependent
L1 L1
L1 L1
L2 -W11 L2
P201-1
L2 L2
VFD
Name
L3 x L3
L3 L3
SH SH
PE PE
1
Original
Appr
Ed.
Date
SETURAH
SETUGNH
2020-02-18
+EXT.VFD / 1 +SHIPSYSTEM / 1
ONLY FOR 126kW
3x95
Pump dependent
L1 L1
L1 L1
L2 -W11.1 L2
P201-1
L2 L2
VFD
2
L3 x L3
L3 L3
SH SH
PE PE
Replacement of
PureBallast Ex
+EXT.P201-1 / 1 +EXT.VFD / 1
3
L1 3x35-120 L1
Booster pump
U1 T1/U
L2 -W12 L2
P201-1
V1 T2/V
L3 x L3
W1 T3/W
Replaced by
SH SH
PE PE'
4
+EXT.VFD / 1 +EXT.P201-1 / 1
ONLY FOR 126kW
L1 3x95 L1
Booster pump
T1/U U1
L2 -W12.1 L2
P201-1
T2/V V1
L3 x L3
T3/W W1
SH SH
PE' PE
5
VFD JB
6
9038497_ver10
Document No.
7
8
Page
+ VFD JB
= PB3
5/8
372 200000874-5-EN-GB
A
B
E
F
Modification
0
Date
+EXT.VFD / 2 +VFD JB / 2
1 1
XSTO 1 3
+EXT.VFD / 2
Name
2 2
XSTO1 11 4
+EXT.VFD / 2
1
3 3
XSTO2 21 5
Original
Appr
Ed.
Date
+EXT.VFD / 2
4 4
XSTO1 12 6
SETURAH
SETUGNH
2020-02-18
+EXT.VFD / 2 10x0,75
5 5
VFD signals
XSTO2 22 -W51 7
P201-1
+EXT.VFD / 2 x X1
2
6 6
3 8
XSTO 7 7
4 9
Replacement of
PureBallast Ex
+EXT.VFD / 2
8 8
2 10
XD24 9 9
3 11
+EXT.VFD / 2
3
10 10
XDI 6 12
+EXT.VFD / 2
SH SH
PE Clamp PE
Replaced by
4
+EXT.VFD / 2 +CC / 2
1A 1A
2 108
1
1B 2x2x0,75 1B
109
VFD Modbus
XD2D 2A -W52 2A X2
P201-1
3 110
2B x 2B
3 110
+EXT.VFD / 2 +CC / 2
5
SH SH
VFD JB
PE Clamp Clamp PE
+EXT.P201-1 / 1 2x0,75 +EXT.VFD / 1

with Thermistor
Booster Pump
1 1
T1 -W53 XLFT:T1
6
P201-1
2 2
T2 XLFT:T2
SH SH
PE XLFT:PE
9038497_ver10
Document No.
+VFD JB / 3 +CC / 3
7
2x0,75
Emergency stop
Safe Torque Off
1 1
1 111
2
2 -W54 2
112
X2
VFD
X1 x
+CC / 3
SH SH
PE Clamp PE
8
Page
+ VFD JB
= PB3
6/8
200000874-5-EN-GB 373
A
B
E
F
Modification
0
Date
+EXT.P201-1 / 4 +VFD JB / 4
2
1 2x0,75 1
4.1
Leak sensor
LS662-1 2 -W55 2 T6621

LS662-1
1 4.2
Ex e
Name
x
+EXT.P201-1 / 4 +VFD JB / 4
SH SH
SH Insulated PE PE
1
Original
Appr
Ed.
Date
SETURAH
SETUGNH
2020-02-18
+EXT.VFD / 2 +EXT.JB / 2
SEE PAGE 1
XD24:5 - XAI:7
BETWEEN VFD TERMINALS
CONNECT WIRE JUMPER
NOTE
1A 1A
XD24 1x2x0,75
Pressure Monitor
4 1
+EXT.VFD / 2 -W56
PT201-1
2
1B 1B
XAI 6
x
2 X1
+EXT.VFD / 2
Replacement of
PureBallast Ex
SH SH
PE Clamp PE
3
Replaced by
4
5
VFD JB
6
9038497_ver10
Document No.
7
8
Page
+ VFD JB
= PB3
7/8
374 200000874-5-EN-GB
6.5.4.10 UV reactor / Interconnection diagram
200000874-5-EN-GB 375
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200000874-5-EN-GB 383
200000874-5-EN-GB

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Signal conductors shall be blue if not otherwise stated.
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Date 2020-03-12 Document No. = RCP
Ed. SETUGNH RCP 9015558_ver5 + RCP
Modification Date Name Original Replacement of Replaced by RCP Page 1/1
200000874-5-EN-GB

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6.5.5 Intrinsically safe circuits

Signals from intrinsically safe apparatus’ to the safe zone are handled as
intrinsically safe (IS) circuits. This section gives necessary information about
how to verify selected cables for the intrinsically safe circuits.
Cable selection
The cables for the IS circuits are not delivered by Alfa Laval, and must
therefore be selected by the party responsible for designing PureBallast. The
cables must be correct for installation in the hazardous zone, and they must
match the requirements for the intrinsically safe circuits.
Requirements for each cable (and underlying apparatuses) are described in
the documents below. These documents should be filled out.
• Ex i max cable length calulation - P201–1, in Booster pump P201-1
installation guide,
• Ex i max multicore cable length calculation - V201-8 in the System manual
and
• Ex i maximal multicore cable length calculation - UVR components in
theSystem manual.
The table below is an overview of cables to be verified. After the table, the
documents are available. Both documents contains:
• Example calculation: First page gives an example of standard cables and
how to calculate cable specifics to verify that the cable can be used.
• Verification for selected cable: Following page(s) describes the basic
data for the underlaying apparatuses. This section shall be filled out
according to the instruction. They can also be used if a cable needs to be
changed after installation.
Component
Cable ID's to be Reference documents
verified Intrinsically safe appa-
ratus ID
Leakage sensor P201–1 (sim-

W55 LS662-1 ple apparatus)
Valve positioner (simple appa-
W2018A V201-8 ratus)
Temperature transmitter (simple
TT201-33 apparatus)
Temperature switch (simple ap-
W210A TS201-60 paratus)
QT201-50 UV sensor
LS201-29 Level switch
LS201-30 Level switch
Inductive sensors, valve posi-
V201-19GS
W210B tion
Inductive sensors, valve posi-
V201-20GS tion
200000874-5-EN-GB 389
Instruction for updating verification documents

Follow the instruction for each of the verification documents for the IS circuit
cables.
1. Read the example in respective document.
2. Verify that the intended cable complies with stated parameters in the
document according to section Verification of selected/installed cable.
3. Send the completed documents to ship yard / owner for storage on board
the vessel.
390 200000874-5-EN-GB
6.5.5.1 Ex i max cable length calulation – V201–8
200000874-5-EN-GB 391
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6.5.6 Saftey Data Sheets

6.5.6.1 Safety data sheet / CIP liquid
400 200000874-5-EN-GB
200000874-5-EN-GB 401
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200000874-5-EN-GB 409
410 200000874-5-EN-GB
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412 200000874-5-EN-GB
200000874-5-EN-GB 413
414 200000874-5-EN-GB
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7 Service manual
200000874-5-EN-GB 421
EN 7 Service manual
7.1 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.
7.1.1 Preparations and conditions
DANGER
Before maintaining the PureBallast system, the power supply must be
switched off from the vessel’s main switch board.
DANGER Ex protection
Before opening any closed, current carrying components (such as flow
transmitter, junction boxes etc.) or maintaining the PureBallast system:
Make sure that the there is no explosive gas present.
No components that are part of the Ex protection (in zone 1) may be
modified in such a way that the Ex protection is affected in any way. When
replacing or maintaining a component, the work must be performed as
described in the user documentation, and in such a way that the Ex
protection is not affected in any way.
Before replacing a component that is a part of the Ex protection, it is
important to first see if there exist any special conditions for the
component. If the certificate number for the component contains an “X”,
the specific conditions must be read on the EC type-examination
certificate delivered with the component.
Signal cables for the components below are intrinsically safe circuits. If the
cables are damaged, they must be replaced with the exact same type of
cable, and the Intrinsically safe system descriptive document must be
updated. These components may not be repaired. When faulty, they must
be replaced with components that maintain the Ex protection.
• Position sensor signal cables between the control cabinet and valve
V201-3, V201-8, V201-9 and V212-31.
• Analogue output signal cable between V201-8 and control cabinet.
• Signal cable between the ICC switch in LDC 1 and control cabinet.
• Signal cables between the LDC and the following components on the UV
reactor: TT201-33, TS201-60, LS201-29 and LS201-30.
An Ex proof (Ex i) multimeter must be used to measure safe circuits (see
bullit list above). A normal multimeter might damage the component.
Cable glands in zone 1 may not be repaired. When faulty, they must be
replaced with components that maintain the Ex protection.
422 200000874-5-EN-GB
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WARNING
Read Safety on page 9.
Installation must be done by a fully trained professional installer.
When maintaining the UV reactor always follow safety instructions. See
Safety information on page 438.
Follow rules when handling CIP liquid, regarding ventilation, personal
protection etc.
• This chapter is a summary of service information. For full details, see

manufacturers instruction manuals for respective component. Certificates
for Ex components can be ordered from your local Alfa Laval sales
company.
• 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 and V201-8. See instruction Lock valve in
closed position on page 469
• Point of contact: To order service or spare parts, contact your local Alfa
Laval office. For more information, see www.alfalaval.com.
7.1.2 Welding requirements

Earth connection must be done according to the below. If not, the equipment
can be seriously damaged:
• Ensure that all solenoid valve connectors on the reactor valves (V201-19,
V201-20, V320-4, V321-2, V404-36) are disconnected prior to any welding
on- or nearby components of the PureBallast system.
• Earth connection must be made before any welding is done.
• Electrical welding: Connect the welding unit’s negative lead (work lead) to
the component you will weld close to the welding area.
• Follow local regulations for electrical installation and earthing (grounding).
• Installation must be done by a fully trained professional installer.
7.1.3 Tightening torques

Use tightening torques according to the tables below for each respective
component. If no specific torques are specified for a component, see table
General tightening torques below.
UV reactor
Glass socket screws – maximum 7 Nm.
CIP module
Flange bolts – maximum 20 Nm.
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Filter
Thread Maximum tightening torque, Nm
M4 3
M6 7
M8 12
M10 18
M12 25
M14 35
M16 45
M18 60
M20 75
M22 90
M24 105
Actuator
Thread Tightening torque, Nm
M5 5-6
M6 10-11
M8 23-25
M10 48-52
M12 82-86
M14 132-138
M16 200-210
M20 390-410
General Tightening Torques

Thread Stainless steel Carbon steel
Maximum tightening torque, Maximum tightening torque, Nm
Nm
M6 7 10
M8 17 25
M10 33 48
M12 57 83
M16 140 204
M20 270 408
M24 470 696
M30 - -
M36 - 2500
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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
Testrun the sys-
tem: Run a bal-
last and/or de-
ballast process.
Follow up with If the system, for some
a CIP process. See Operating reason, is not operated
instructions and by normal ballast oper-
Note: If system control system ations, it needs to be
is used, but cer- description on run to verify that it is in
tain valves are page 45 good condition.
not used, for Once a month.
example V212– Manual opera- This will also exercise
31, those tion of valves: the valves, actuators
should be See Valves on and other components
General opened and page 466. to keep them in good
closed manual- condition.
ly. For relief
valves, see Cal-
ibration sched-
ule.
Inspect for cor-
rosion and ero- Once a year.
sion damage.
According to See Calibration
Calibration of Calibration schedule on
sensors schedule on page 427.
page 427.
Outer inspec- See Spare parts cata-
tion of seals for Once a year. logue for service kit.
leakage.
See Disassem-
Check UV ble quartz See Spare parts cata-
lamps for leak- Once a year. sleeve on page logue for service kit.
age. 443.
Recommended
Replacement of to change all See Replace See Recommended
lamps after UV lamp on spare parts on board
UV lamps. 3000 hours of page 440. for spare part number.
operation
UV reactor
IMO require-
ment: Every
Replacement of second year.
UV sensor 9008373 02
(QT201–50) EPA require-
ment: Every
year.
Dismount the
valve and make
Check relief sure you can
valve RV201– Once a year. blow air
23. through it from
the inside out.
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See the filter
cleaning in-
struction in this
document.
Cleaning once
a year normally
is enough. But
in exceptional
cases (vessels
trading very
muddy waters) Replace filter basket, if
Inspect and it might be nec- damaged.
clean the filter essary to clean
insert, including Once a year. the more often.
See Spare parts cata-
the filter basket. logue for maintenance
If the pressure kit.
triggered back-
flushing is per-
formed with
short intervals,
we suggest that
the filter ele-
Filter ment manually
cleaned more
often than once
year.
If necessary, change
Outer inspec- faulty seals.
tion of seals for Once a year. See Spare parts cata-
leakage. logue for maintenance
kit.
Dismount the
valve and make
Check relief sure you can
valve RV201– Once a year. blow air
50. through it from
the inside out.
Every 3rd
pH value check. months, which- See Change and refill
ever comes CIP liquid on page 458
first.
If the CIP liquid level is
Rule of thumb: low but the pH value is
Once every 3 below 3, CIP liquid and
months. De- water can be added to
pending on bal- See Change fill up the liquid level in
CIP liquid lev- lasting frequen- and refill CIP the tank.
el check. cy, the liquid liquid on page
check might 458 Note: pH value must
have to be per- be checked after-
CIP liquid formed more wards to secure cor-
regularly. rect pH value.
See Prepara-
tions and con-
Control of Visual inspec- ditions under
stored CIP liq- tion after three Change and re-
uid. years. fill CIP liquid on
page 458
Control that the
Junction box cables are firm-
on CIP mod- ly attached to Once a year.
ule the junction
box.
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Control that the
component, ca-
Valves and See Valves on
bles and hoses Once a year.
actuators page 466.
are firmly at-
tached.
Remove and
disassemble
the valve. Re-
move debris
Vacuum re- and clean the Once a year.
lief valves interior parts if
needed. Inspect
the seal and re-
place if broken.
See instruction
Power cable
check in sec-
Check power
Power cation Control
cables screw Once a year.
bles cabinet and
connections lamp drive cab-
inet (LDC) on
page 490.
When alarm
PLC battery
low is indicated
in the control
system. Automatic check when
Control sys- Replace battery the control cabinet is
tem in PLC module. or: turned on and every 24
After 5 years. hours.
Before stor-
age for longer
periods.
7.2.1 Calibration schedule

Follow this calibration schedule to secure performance of the system and its components. The
schedule is sorted per component.
Interval: Once a year, if nothing else is stated.
7.2.1.1 Calibrate flow meter

This section contains step-by-step instructions on how to calibrate the flow meter FIT201–1 .
There are two alternative methods to calibrate the flow, and a separate method to calibrate the
conductivity measurement:
• Calibrate flow in flow meter:
• Calibration using the vessels tank sounding systems calculating the flow.
• Calibration using an ultrasonic device.
• Calibrate conductivity measurement in flow meter.
7.2.1.1.1 Calibration using the vessels tank sounding systems calculating the flow
Calibration frequency: IMO: Every second year. USCG: Every year.
1 Decide which tank to use for measuring.
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2 Note the start level in tank.
3 Establish stable flow in the system.
4 Note the flow according to PureBallast flow

meter FIT201–1 in control system page Page
1.1 – Overview on page 57, (value A below).
5 Pump for 10-20 minutes.
6 Stop pump and note exact time used.
7 Note finish level in tank and use vessel tank

table to establish the exact volume difference
(m3) between start and finish.
8 Calculate the flow (C) according to vessel

sounding system calculation by dividing the
volume pumped (m3) with the time used
(hours).
9 Compare the figures and calculate the

variance.
a)
Reading Actual var- Allowed
iance variance
A FIT201–1 val- Min: 0.95
A/ C
ue (m3/h) Max: 1.05
C Calculated val-
ue (m3/h)
7.2.1.1.2 Calibration using an ultrasonic device

Calibration frequency: IMO: Every second year. USCG: Every year.
1 Connect a calibrated portable ultrasonic flow

meter close to the PureBallast flow meter.
2 Establish stable flow in the system.
3 Note the PureBallast flow meter reading

(value A below).
4 Note the ultrasonic flow meter reading (value

C).
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variance.
a)
iance variance
A FIT201–1 val- Min: 0.95
A/C
ue (m3/h) Max: 1.05
C value (m3/h)
7.2.1.1.3 Calibrate conductivity measurement in flow meter
1 Note the conductivity measurement QIT201-1

according to PureBallast flow meter FIT201–1
in control system page Page 1.1 – Overview
on page 57, (value A below).
2 Take a ballast water sample.
3 Measure the conductivity in the ballast water

sample with a separate conductivity sensor
C25 sample.
The separate conductivity sensor should
measure the conductivity with a temperature
compensated at 25 Celsius measurement in
μS/cm.
If not, calculate C25 sample:
C25 sample = C / (1 + α * (T – T25))

C = Uncompensated conductivity measurement
is the μS/cm value from the ballast water
sample.
T = Temperature of ballast water sample.
α=2%
T25 = 25

variance.
a)
iance variance
A QIT201-1 val- A/ C25 sam- Min: 0.95
ue (μS/cm) ple Max: 1.05
C25 sample
(μS/cm)
7.2.1.2 Calibrate pressure transmitters

This section contains step-by-step instructions on how to calibrate the pressure transmitters
PT201-71, PT201-72, PT201-16 and PI201-18.
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Calibration frequency: Every year.
1 Connect calibrated portable measure

equipment to the measure point (screw to the
side, under the handle).
2 Open V201-32 from the control system.
3 Pressure transmitters on filter PT201-71

and PT201-72:
a) Compare values indicated for the three
transmitters, in control system and
measure equipment.
iance variance
A PT201-71 val- Min: 0.95
A/C
ue (bar) Max: 1.05
B PT201-72 val- Min: 0.95
B/C
ue (bar) Max: 1.05
C Calibration de-
vice value (bar)
b) Open 403-35 from the control system, and

compare again.
iance variance
A PT201-71 val- Min: 0.95
A /C
ue (bar) Max: 1.05
B PT201-72 val- Min: 0.95
B /C
ue (bar) Max: 1.05
C Calibration de-
vice value (bar)
4 Pressure transmitter PT201-16:

a) Open V403-35 to apply pressure to the
system.
b) Adjust handle on PT201-16 to establish
pressure to measure point.
c) Compare value indicated in control
system and measure equipment.
iance variance
A PT201-16 val- Min: 0.95
A/C
ue (bar) Max: 1.05
C Calibration de-
vice value (bar)
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5 Pressure gauge PI201-18:

a) Compare value indicated in pressure
gauge and measure equipment.
iance variance
A PI201-18 value A / C Min: 0.95
(bar) Max: 1.05
C Calibration de-
vice value (bar)
6 Pressure service valve V201-15:

a) If above tests are OK, valve V201–15 is
OK.
7.2.1.3 Calibrate UV reactor components, transmitters and switches

This section contains step-by-step instructions on how to calibrate the UV reactor components
TT201-33, TS201-60 and LS201-29.
1 Depressurize and drain the reactor: Remove

the drain plug at the bottom of the UV reactor.
2 Temperature transmitter TT201–33:

a) Dismount the transmitter and place in
water with known temperature (calibrated
measure instrument).
b) Compare value indicated in the control
system and measure equipment.
iance variance
A TT201-33 val- Min: 0.95
A /C
ue (C°) Max: 1.05
C Calibration de-
vice value (C°)
3 Temperature switch TS201-60 (and

TS201-33 for Ex installation):
a) Dismount the switch and place in device
with slowly raising temperature starting at
appr 50 going to appr 70 C°.
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b) Check that alarm A137 is displayed in the

control system at 65 ˚C.
iance variance
A TS201-60 val-
ue (C°)
Yes +/- 5 %
A TS201-33
value (C°)
C Calibration de-
vice value (C°)
4 Level switch LS201–29 (and LS201–30 for

Ex installation):
a) Dismount the sensor and lace it in a glass
of water.
b) Check that you get a signal for the UV
reactor in the control system.
c) Fill the UV reactor with water.
7.2.1.4 Calibrate UV reactor components, UV sensor

The UV sensor QT201–50, is not calibrated. The component is replaced. See Maintenance schedule
on page 425.
7.2.1.5 Calibrate temperature transmitter in lamp drive cabinet

This section contains step-by-step instructions on how to calibrate the temperature transmitter TT401,
in the lamp drive cabinet.
1 Place a calibrated thermometer inside the

cabinet.
2 Wait 30 minutes.
3 Compare the TT401 value, with the

thermometer value.
Reading Actual var- Allowed var-
iance iance
A TT401 value Min: 0.95
A/C
(LDC) (C°) Max: 1.05
C Calibration de-
vice value (C°)
7.2.2 Recommended spare parts on board

One of each spare part or spare part kit is recommended to be stored on
board.
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Spare part Spare part number

UV reactor
UV lamp set
• 1 UV lamp 9009521 80
• 2 O rings
Quartz sleeve set

• 1 quartz sleeve 594645 82
• 2 O rings
Temperature transmitter 9006325 02

Temperature switch 9006324 02
Lamp power supply (LPS) 9012146 01
UV sensor 9008373 02
Filter
Filter sealing kit
Note: Inspect the filter
marking plate. If you have
filter ACB-9120–500 the
data is correct. The sys- 9011963 92
tem may be supplied with
a filter of larger size. If so,
consult the Filter size ad-
dendum for correct data.
CIP module
CIP liquid 9012167 01 Recommendation to order 2 cans at a time.
7.2.3 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.
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 controlcabinet.
• 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) or P (pump). A complete list
of abbreviations is found in Connection list on page 249.
Example
If the level switch is faulty, the following information shall be stated:
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• PureBallast serial number.

• Level switch serial number and the serial number for the UV reactor on
which the level switch is installed.
• Item number for the component (LS00000).
7.2.3.1 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: At the right side of the control cabinet.
Lamp drive cabinet

Placing: Inside the cabinet, at the left or right side.
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UV reactor
Placing: At the side of the UV reactor, as indicated in
the illustration.
Filter
Placing: At the side of the filter, as indicated in the il-
lustration.
Lamp power supply

LPSs are installed in the lamp drive cabinet.
Note: Version must be stated together with the serial
number. Version is stated on the serial number plate.
Placing: At the front of each LPS.
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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.
Flow meter
Including flow transmitter and flow sensor
Placing: At the side of the transmitter housing, as in-
dicated in the illustration.
Note: The serial number for the flow transmitter is also
valid for the flow sensor.
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7.3 UV reactor
This section covers instruction for service of the UV reactor.
UV reactor, glass components exploded.

1. Cap
2. PE screw
3. Lamp bush
4. Cable connector
5. UV lamp
6. Screw
7. Glass socket
8. O-ring for quartz sleeves
9. Quartz sleeve
10. Adaptor
11. O-ring (between adaptor and reactor house)
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7.3.1 Safety information
DANGER
Always disconnect the PureBallast system from the power supply before
Always lock valve V201–9, V201–3 and V201–8 if you open the UV
reactor in some way. See Lock valve in closed position.
Before installation, check that the UV lamps and quartz sleeves are not
broken.
DANGER Mercury
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.
• UV lamps radiate ultraviolet light when lit. Only operate the UV lamp when
correctly installed inside the UVR with end caps properly closed and UV
sensor fitted.
• 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.
• It is not allowed to cover any part of the lamp fittings. There must be free
flow of air surrounding the lamp caps to ensure sufficient cooling.
• 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.
• See Safety data sheet / UV lamp on page 409 for detailed safety
information.
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CAUTION Ex protection
The person must have knowledge or sufficient experience to perform the
tasks at hand. The person must be able to perceive risks and to avoid
hazards which electricity/mechanics can create. The person must have
knowledge about the specific Ex standard used to eliminate the risk of
explosion, for example IEC 60079 series.
Maintenance must be done according to the information found in this
manual.
The yield stress of the fasterners for each part of the flame proof
encloserue must be minumum 450 MPa.
If screws cap, adaptor or glass socket need to be replaced, new screws
must meet the following specification: hexagon socket head cap screw,
ISO 4762, screw size M6x25, Material: A4-70.
If one of the components with a signal cable on the UV reactor (TT201-33,
TS201-60, LS201-29 and LS201-30) 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.
The UV lamp sockets have been designed to eliminate potential flame
channels around the fittings and cable connections. These components,
illustrated below, constitute the Ex protection. The components or flame
paths must not be damaged in any way. The components must not be
repaired. When faulty, they must be replaced. If the cap, glass socket or
adaptor is damaged, both must be changed.
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Ex components and flame paths (illustration show a reactor fro 300 m3/h, but the
components are the same for a 1000 m3/h reactor)
1. Cable gland (Ex protection)
2. Cap (Ex protection)
3. Lamp bush
4. Glass socket (Ex protection)
5. O-ring
6. Adaptor (Ex protection)
7.3.2 Replace UV lamp

7.3.2.1 Disassemble UV lamp
Follow this instruction to dismount the UV lamp.
NOTE If the UV lamps are hot they are under internal positive
pressure and may burst if broken.
Wait at least 10 minutes after completed ballast or deballast process, to
allow the UV reactor to cool down to ambient temperature.
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CAUTION
Protect the flame path of the cap and the screws from being damaged. If
the surface is scratched, dented or damaged in any way, the component
must be replaced. See Caution – Ex protection at the beginning of this
section.
Protect the cable gland from being damaged. If bent or damaged in any
way, the component, including cable, must be replaced. See Safety
information for Ex components at the beginning of this section.
• Wait at least 10 minutes after completed ballast or deballast process, to

allow the UV reactor to cool down to ambient temperature. If the UV lamps
are hot they are under internal positive pressure and may burst if broken.
• The PureBallast system must be turned off, and the power disconnected.
1. Unscrew the three Allen screws holding the cap and remove it.
2. Disconnect the cable connector that is attached to the UV lamp.
3. Remove the lamp bush.
4. Repeat step 1–3 on the other side of the UV reactor.
5. Unscrew the three screws holding the glass socket and remove it.
6. Carefully pull out the UV lamp. Do not touch the glass. Only hold the UV
lamp by the ceramic ends. (If required, use a screwdriver to press on the
ceramic end of the lamp through the hole in the lamp bush while carefully
pulling the electric cable at the other end.
7. Carefully draw out the UV lamp. Do not touch the glass. Only hold the UV
lamp by the ceramic ends.(If required, use a screwdriver to press on the
ceramic end of the lamp through the hole in the lamp bush while carefully
pulling the electric cable at the other end.
8. Check that the quartz sleeve is not broken inside the UV reactor, and that
there is no leakage around the glass socket and adaptor.
9. Place the old lamp in the new lamp’s box.
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10. If the quartz sleeves is not broken, mount the new UV lamp according to
the instruction Assemble UV lamp.
11. Dispose of the old lamp according to the safety data sheet, see Safety data
sheet / UV lamp on page 409.
7.3.2.2 Assemble UV lamp

Follow the instruction below to assemble the UV lamp.
• A leakage check must have been performed according to the instruction
Check for leaks after quartz sleeve assembly on page 445.
• Use waxed screws to avoid seizing.
• If needed, replace the heat resistant O-rings in the lamp bushes.
• 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 ends. If needed, use the
cleaning wipes in the UV lamp box to clean the UV lamp.
• Glass sockets and bushes must be dry and clean before mounting.
• It is recommended to replace all UV lamps after 3000 hours of operation.
The timers should then be reset in the control system on page 4.4
Operation timers UVRs.
1. Remove the glass socket on one side.
2. Carefully insert the UV lamp and the lamp bush into the UV reactor. Be
careful with the glass bump! It can easily break the UV lamp if it clashes
into the quartz sleeve.
3. Mount the glass socket onto the adaptor.
4. Check the condition of the three Allen screws that attaches the glass
socket. They must be waxed to avoid seizing.
5. Fasten the glass sockets with the three Allen screws. Cross tighten to a
torque of 7 Nm.
CAUTION
Protect the flame path of the glass socket, the adaptor and the screws
from being damaged. If the surface is scratched, dented or damaged
in any way, the component must be replaced. See Caution – Ex
protection at the beginning of this section.
No lubrication may be used for the flame path.
6. Check the condition of the O-rings in the lamp bushes. Replace the O-rings
if necessary.
7. Insert the lamp bush into the glass socket.
8. Check the condition of the cable connectors for the UV lamp. Look for rust,
burning or fading. Replace the UV lamp if needed.
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9. Reconnect the cable connector.
10. Clean the flame path of the cap with a clean, soft cloth. The surface must
be totally clean and free from scratches. See Safety information for Ex
components at the beginning of this section.
CAUTION
Protect the flame path of the glass socket, the adaptor and screws
from being damaged. If the surface is scratched, dented or damaged
in any way, the component must be replaced. See Safety information
for Ex components at the beginning of this section.
11. Connect the cable's shield to the to the PE screw (grounding) at the bottom
of the cap.
12. Mount the cap and cross tighten the three Allen screws to a torque of 7
Nm. Make sure the electric cable is free when mounting.
CAUTION
When mounting the caps, protect the cable gland from being
damaged. If bent or damaged in any way, the component, including
cable, must be replaced.
13. Repeat step 9–12 on the other side of the UV reactor.

14. Power on the PureBallast system and check the alarm list on page 3.1
Alarm list, to make sure there is no active alarms.
7.3.3 Replace quartz sleeve

7.3.3.1 Disassemble quartz sleeve
Follow this instruction to disassemble the quartz sleeve.
• Lock valve V201–3, V201–9, V201–8, V201–19.x and V201–20.x in closed
position.
• Drain the UV reactor.
• Disconnect the instrument air.
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• Shut down the PureBallast system and secure it from being switched on.
• Remove the UV lamp and the lamp sockets according to instruction
Disassemble UV lamp on page 440.
1. Wet the O-ring in the adaptor with soapy water.
2. Use an angled or hooked O-ring tool to remove the O-ring. The O-ring are
firmly stuck in their seat, and will be damaged during removal, but shall be
replaced at assembly. Be careful not to break the glass. If the O-ring is
hard to remove, try the following:
• Perforate the O-ring to get a good grip.
• Moisten the O-ring with acetone or denatured alcohol.
• Loose the O-ring in a couple of places before removing it.
CAUTION
Protect the flame path of the glass socket, the adaptor including
screws from being damaged. If the surface is scratched, dented or
damaged in any way, the component must be replaced. See Caution –
Ex protection at the beginning of this section.
Do not jerk the glass sockets when removing them. Otherwise the
quartz sleeves may break.
3. Unscrew the screws holding the adaptor and remove it.

4. On the other side of the UV reactor, unscrew the screws holding the
adaptor. Remove the adaptor and the quartz sleeve.
5. Use an O-ring tool to remove the O-ring in the adaptor. The O-ring will be
damaged during removal, but shall be replaced at assembly.
6. Use a soft cloth to clean the surface between the UV reactor and the glass
socket. Remove any small parts, for example glass or rubber.
7. Assemble the new quartz glass according to the instruction Assemble
quartz sleeve on page 444.
7.3.3.2 Assemble quartz sleeve

Follow this instruction to assemble the quartz sleeve.
• Two new O-rings for each quartz sleeve . Included in quartz sleeve set.
• Wax for the screws. They must be waxed to avoid seizing.
• Soapy water to lubricate the O-rings.
• Glass sockets and lamp bushes must be dry and clean before mounting.
Use a soft cloth to clean the surface between the UV reactor and the glass
socket. Remove any small parts, for example glass or rubber.
• Before installation, check that the quartz sleeves are not broken.
• Check the condition of the inner and outer O-ring in the glass sockets and
on the adaptor. If needed, replace them with new O-rings.
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CAUTION
Protect the flame path of the glass socket, the adaptor and screws from
being damaged. If the surface is scratched, dented or damaged in any
way, the component must be replaced. See Caution – Ex protection at the
beginning of this section.

1. Lubricate a new set of O-rings in soapy water. Do not use Vaseline, oil or
similar.
2. Insert the O-ring in the adaptor.
3. Wet the edge of the quartz sleeve and attach the adaptor. Make sure that
the O-ring is pushed into place. It should be sitting at the edge of the
quartz sleeve.
4. Insert the adaptor and the quartz sleeve into the UV reactor. Make sure
that the quartz sleeve is centred in the UV reactor.
5. Attach the screws to the adaptor and tighten them.
6. On the other side of the UV reactor, attach the adaptor and tighten the
screws.
7. Wet the edge of the quartz sleeve and a new O-ring with soapy water.
Push the O-ring over the edge of the quartz sleeve.
8. To push the O-ring into place, attach the glass socket and tighten one of
the screws.
9. Unscrew the screw and remove the glass socket. Check so that the O-ring
is over the edge of the quartz sleeve.
10. Follow the instruction Check for leaks after quartz sleeve assembly on
page 445.
11. To assemble the UV lamp, follow the instruction Assemble UV lamp on
page 442
7.3.3.3 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 UV reactor with water to between 2 and 4 bar.
2. Visually check for leaks.
7.3.4 Replace lamp power supply (LPS)

Follow this instruction to replace a lamp power supply (LPS).
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WARNING
Shut down the PureBallast system according to Shut down and deactivate
system on page 106. The LPS has a voltage of 600 V inside and on the
lamp power connector, even when UV lamps are not lit.
The cabinet contains a fan, which can cause injury if in operation.
1. Open the doors to the lamp drive cabinet.

2. The LPS is connected with three connectors. On the green connector,
press in the two latches and pull up the connector.
3. On the black connector, press in the red latch and pull down the connector.
4. On the green connector, press up the two orange latches and pull down
the connector.
5. Loosen, but do not remove the nuts under the LPS.
NOTE Risk of short circuit.

Be careful not to drop the nut or washer into the LPS.
6. Pull the handle to remove the LPS.

7. On the new LPS, set the DIP switches according to Lamp power supply
(LPS) parameters on page 182.
8. Mount the LPS in the cabinet.
9. Tighten the nuts under the LPS to attach it. Be careful not to tighten the
nuts too much, since that can cause the LPS to deform.
10. Reconnect the three connectors. Make sure the connectors sit tight.
11. Make sure that the motor circuit breakers are on. Turn on if necessary.
12. Power on the PureBallast system and check that LPS:s function correctly
according to instruction Test lamp power supply (LPS) installation on page
447.
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7.3.5 Test lamp power supply (LPS) installation

Follow this instruction to make sure that the installation is correct and safe to
use.
Preparation and conditions
• The PureBallast system should be powered on.
DANGER
Risk of overheating. There must be water in the UV reactor. Check status
of level switch (LS201–29).
WARNING
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.

1. Set the control system in manual mode (requires login level Advanced
operator).
2. Start the UV lamps one by one. Make sure that the UV lamps are lit. This is
checked in the UV reactor popup and on the LPS. Note: It can take up to
90 seconds for the lamp to start.
3. Open the lamp drive cabinet and check the error status lamps on the LPS.
4. Go to 2.1 Alarm list in the control system and make sure that no alarms
have been triggered by the LPS.
5. Turn off all the lamps.
6. Exit manual mode.
7.3.6 Level switch

This section contains information about the level switch LS201-29 installed in
the UV reactor. For information about status indications, see Alarms and
faultfinding on page 185, section Level switch.
Level switch
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• If the signal cable for this component is damaged during the installation or
7.3.6.1 Mount level switch

NOTE
Disconnect power supply before mounting or dismounting the component.
• Do not alter the forks in any way.

• Be careful not to damage the fork in any way.
1. Seal the threads on the level switch with thread tape or thread sealant.
2. Mount the sensor until the joint is finger-tight.
3. Mount the level switch and tighten with a spanner. Identify the sensor align
mark. The marking appears either as a material specification (e. g. 316L)
or a thread designation (e. g. G1). Make sure it is positioned on the upper
or lower side of the level switch.
4. Connect the cable connector.
7.3.6.2 Dismount level switch

The external surface may be hot. Care must be taken to avoid possible burns.
1. Disconnect the cable connector.
2. Use a spanner to remove the level switch.
7.3.6.3 Test level switch

Follow the instruction below to test that a level switch functions OK.
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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.
3. Make sure the level switch reacts to the magnet. The component is OK if
the green and yellow LED is lit.
7.3.7 Replace UV sensor
NOTE
1 Unscrew the nut and pull out the UV sensor.
2 Disconnect the cable connector.
3 Look for rust, burning or fading on the

connectors. Replace if necessary.
4 Thread the cable through the nut first and

spacer after.
5 Connect the cable connector to the new UV

sensor.
Note: Do not touch the glass on the sensor. If
you touch the glass, it will ruin the UV
measurement.
Note: Make sure that the spacer is closest to
the nut, pushing the UV sensor into the UV
reactor.
6 Insert the UV sensor and spacer into the UV

reactor.
7 Tighten the nut by hand.
Power on the PureBallast system.
7.3.8 Temperature switch and temperature transmitter

This section contains information about the temperature switch TS201-60 and
the temperature transmitter TT201–33 installed in the UV reactor. The two
components are similar in design, so the same instructions can be used.
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Temperature switch and temperature transmitter looks similar

NOTE
7.3.8.1 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.
7.3.8.2 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 temperature switch and remove the old seal from the threads.
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7.4 Filter
This section covers the instructions for filter service.
These preparations and conditions are valid for all instructions.
• Lifting device is needed for this instruction. See complementary lifting
instructions in the Design and installation guidelines.
• Filter cover and element weight (kg): 1 780Note: If you have filter
ACB-9120–500 the data is correct. The system may be supplied with a filter
of larger size. If so, consult the Filter size addendum for correct data.
• Only perform maintenance and servicing work when the filter is cooled,
depressurized and drained.
• Disconnect the power to the filter, using the main breaker on the control
cabinet.
• Always lock valve V201–3, V201–9, V201–8 and V201–32 if you open the
filter in some way. See Lock valve in closed position on page 469.
• Shut off the air supply to the filter.
• Visually inspect gasket during maintenance. Replace if necessary.
Tightening torques for filter

See section Preparations and conditions on page 422.
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Filter – Exploded view
1. Gear reducer
2. Gear shaft
3. Gear motor
4. Thrust bearing flange fixing bolt
5. Gear reducer flange / cover fixing bolt
6. Thrust bearing
7. Backflush shaft bushing gasket
7a. Backflush shaft bushing gasket
8. Filter vent plug
9. Filter cover
10. Cover bolt
11. Backflush shaft bushing
12. Filter element fixing bolt
13. Filter cover gasket
14. Filter body
15. Filter element
16. Backflush nozzle
17. Filter element gasket
18. Backflush shaft bushing
19. Filter drain plug
20. Backflush line gasket
22. Pressure transmitter
29. Junction box
30. Backflush nozzle support
31. Backflush nozzle fixing bolt
32. Backflush nozzle support gasket
33. Base frame
34. Base frame fixing bolt
40. Ring spear 44. Cover lifting lug
41. Thrust bearing upper flange 45. Rotation indicator
42. Thrust bearing lower flange 70. Nameplate
43. Circlip 80. Prefilter
7.4.1 Remove filter cover and filter element

Follow this instruction to remove filter cover and filter element.
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1. Unscrew the bolts (5) holding the gear motor (1).If the electrical cable is
short, it might be necessary to disconnect it before removing the motor.
2. Remove the motor (using a lifting device, if necessary). Be careful not to
harm the motor fitting when lifting it from it’s seat.
3. Remove the cover bolts (10) and the lifting lugs (44).
4. Screw two filter cover bolts in the lifting lugs holes until the cover raises
slightly from the filter house.
5. Remove the cover bolts and fasten the lifting lugs in their holes again.
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6. Fasten a lifting device in the lifting lugs and lift the filter cover (9) with the
filter element carefully out of the filter.
NOTE
Be careful not to harm the filter element.
The filter should be lifted in one continuous movement, without sudden
jerks – even if the filter element is slightly stuck in the filter housing.
7. Place the filter element on its side.

8. Remove bolts to the bottom shaft support that holds the shaft inside the
filter element (15). Remove it carefully.
9. Remove the circlip (43) from the backflush shaft bushing (11).
10. Pull out the backflush shaft bushing. If it is stuck, give a couple of light
blows with a soft mallet on the top of the shaft to release it.
11. Place the filter element upside-down.
12. Unscrew the four Allen screws inside the element to loosen the filter cover.
13. Lift the filter element from the cover.

14. Lift the pre-filter (80) from the bottom of the filter house.
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7.4.2 Mount filter element and filter cover

Filter element and cover is mounted in reverse order as described in
instruction Remove filter cover and filter element on page 452.
NOTE
No force should be used to fit the filter element in the filter body or to fit
the motor in its seat.
• Clean the upper inside of the filter body. The area where the O rings
(gaskets) meet the sealing surface of the housing should be clean.
• Check the O rings (gaskets). Replace if necessary.
• Fill up the filter body with technical / potable water after it is mounted.
• There is no need to deaerate the filter when it is filled up.
7.4.3 Clean filter element and pre-filter

Follow this instruction to clean the filter element. At the same time, check that
the filter element is in good condition.
WARNING
Risk for eye and skin irritation.
Follow rules when handling CIP liquid agent; Alpacon descalant offshore,
regarding ventilation, personal protection etc. Avoid contact with eyes and
wear protective gloves and goggles.
If Alpacon descalant offshore comes in contact with eyes or skin, rinse
thoroughly with cold water.
• Alpacon descalant offshore may be used as cleaning agent. See Safety

data sheet / CIP liquid on page 400.
• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon
descalant to 20 parts technical / potable water. Follow this mixing ratio,
regardless of recommendation on label so that the pH value is
approximately 2.0–3.0.
• The used CIP liquid can be drained by using the drain plug (460 Drain) on
the filter.
• Used CIP liquid is drained to one of the following: drain, waste or sludge
tank. Do not drain to bilge. Handle according to local regulations.
• Be careful when transporting, assembling, disassembling and cleaning the
filter element.
• There are two ways to soak the filter element: In a loose soaking tub, or
inside the filter body. See respective instruction below.
• If you choose to soak the filter element inside the filter body, check the
volume of the filter body in the filter’s dimension drawing. See section
Dimension drawings on page 270or on the marking plate. This is necessary
in order to create correct mixing ratio.
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Loose soaking tub — Follow the steps below:

1. Remove the filter cover with the filter element. See the instruction Remove
filter cover and filter element on page 452.
2. Rinse the pre-filter with water and a brush.
3. Remove the filter element gasket (17).
4. Soak the filter element in CIP liquid (1 part of Alpacon descalant liquid with
20 parts of technical water / potable water) for 1-4 hours.
5. Spray the filter element with water (60–80 °C) from the outside, using a flat
nozzle. Note: To avoid damage of the filter mesh: the high-pressure
cleaner must not exceed a maximum of 15 bar. If a cleaner with higher
capacity is used, compensate by increasing the distance, minimum 30 cm.
6. Blow through the filter element with instrument air (with 10 micron filter or
finer), from the outside.
7. Inspect the filter element from the outside with a magnifier to make sure
that it is clean.
8. Clean the inside of the filter body.
9. Put the filter element gasket back. Reassemble the rest of the filter.
Inside filter body — Follow the steps below:
1. Remove the filter cover with the filter element. See the instruction Remove
filter cover and filter element on page 452, but do not separate the filter
cover from the nozzle and the filter element.
2. Remove the filter element gasket (17).
3. Rinse the pre-filter (80) with water and a brush.
4. Rinse inside of the filter body and the filter element from larger debris using
a brush.
5. Insert the filter element back to the filter body and fasten it with 4 bolts.
6. Remove the relief valve RV201-50 and deaeration valve V571-4 from the
filter cover.
7. Fill the filter body with water through the hole using a hose to
approximately 50%.
8. Pour in the CIP liquid to correct mixing ratio.
9. Top up with water.
10. Let the filter element soak for 4 hours.
11. Drain the filter body from CIP liquid.
12. Lift the filter element out of the filter body.
13. Spray the filter element with water (60–80 °C) from the outside, using a flat
nozzle. Note: To avoid damage of the filter mesh, the high-pressure
cleaner must not exceed a maximum of 15 bar. If a cleaner with higher
capacity is used, compensate by increasing the distance, minimum 30 cm.
14. Blow through the filter element with instrument air (with 10 micron filter or
finer), from the outside.
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15. Inspect the filter element from the outside with a magnifier to make sure
that it is clean.
16. Put the filter element gasket back.
17. Reassemble the rest of the filter.
18. Run a ballast operation sea to sea for 5 minutes to remove any residual
CIP liquid from the filter.
19. Do a manual backflush to ensure good function of the filter.
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7.5 CIP
This section covers instruction for service of the CIP module.
7.5.1 Change and refill CIP liquid

The CIP liquid is an acidic solution that is used to clean the UV reactor after
ballast and deballast operations. It contains no solvents or no inorganic acids
and it is non-flammable. For more information, see Safety data sheet / CIP
liquid on page 400. The CIP liquid must be replaced when the pH is above
3.0. Use a pH meter or indication paper to measure. Check the pH regularly
according to the maintenance schedule.
WARNING
Risk for eye and skin irritation. Avoid contact with eyes and wear
protective gloves and goggles. Follow rules when handling CIP liquid
agent, regarding ventilation, personal protection etc.
If Alpacon descalant offshore comes in contact with eyes or skin, rinse
thoroughly with cold water.
• Max tightening torque for bolts on flanges: 20 Nm.

• 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 technical / potable 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.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.
• Used CIP liquid contains chemical residues from the cleaning process.
Handle according to local regulations. Drain the CIP liquid to either drain,
waste or sludge tank. Do not drain to bilge tank.
• Unused CIP liquid should be handled according to the safety data sheet.
• When performing these routines, consider the need for service kits. See
Spare parts catalogue.
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CIP module
1. CIP liquid tank cap
2. Valve block
3. Pump P321–5 (UVR reactor drain)
4. Pump P320–1 (CIP liquid)
5. Drain line 460.2 with manual valve
Change CIP liquid

Follow this instruction to change CIP liquid, when necessary due to high pH
value.
1. If the drain pipe 460.2 (5) is connected to tank (drain, waste or sludge),
follow the sub steps below. This is the preferred way. Otherwise, go to step
2.
a. Open the manual drain valve V460-3 under the CIP tank.
b. Wait for the tank to be totally drained. Then close the drain valve.
2. If the drain valve is not connected to the tank, the steps below can be
followed to drain overboard. This is not the preferred way. It must be
verified that it is accepted by local regulations. This operation requires
login level Advanced operator or higher.
a. Open valve V230–11 manually. Open V320-2 and V460-2. from the
control panel. Start pump P321-5 (3) and P320-1 (2). V321-3 will be
opened automatically when the pump is started.
b. Wait for the CIP tank to be totally drained. Then stop the pumps and
close the valves in reversed order.
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3. Open the cap (1) on top of the CIP tank.

4. Fill the tank with technical / potable water as described below:
a. Open valves V310–6 and V321–1. Start pump P321–5. V321-3 will be
opened automatically when the pump is started.
b. Wait for the tank to be filled with approximately 240 liters of technical /
potable water. That is almost up to the Max indication on the tank.
5. Pour 15 litres of Alpacon descalant offshore liquid into the tank.
6. Measure the pH value. The pH should be around 2.0. If the pH is too high,
add more descant liquid to the tank until the correct pH value is reached.
7. Go to control system page 4.3 – Operation timers. The CIP timer indicates
the number of CIP processes that have been run since the last time the
CIP liquid was changed. The timer helps to predict how often it is
necessary to change the CIP liquid. After the CIP liquid has been changed,
press the Reset button. Requires login level Advanced operator.
Refill CIP liquid

The level of the CIP liquid should be checked regularly according to the
maintenance schedule. If the level is below the minimum indication, you
should fill up the tank with more CIP liquid. Follow this instruction to refill CIP
the CIP tank.
1. Measure the pH in the tank. If the pH is above 3, empty the tank and
change the CIP liquid, see Change CIP liquid on page 459. If the pH is
around 2.0, continue with step 2.
2. Mix 1 part of Alpacon descalant offshore liquid with 20 parts of water in a
separate container.
3. Pour the mixed CIP liquid into the tank. Do not fill over the Max indication
on the tank.
4. Measure the pH value. The pH should be around 2.0. If the pH is too high,
you should add more Alpacon descalant offshore liquid until the correct pH
value is reached. If the pH is too low, add more water.
7.5.2 Pump
This section contain instructions for the CIP pump.
7.5.2.1 Repair CIP pump

Follow this instruction to repair the CIP pump.
WARNING
Always disconnect the PureBallast system from the power supply before
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CAUTION
Always wear protective eye glasses and gloves while working on the
pump.
• 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.
CIP pump, exploded view
7.5.2.1.1 Clean CIP pump

1. Remove the pump from the CIP tank.
2. Rinse the pump with water.
7.5.2.1.2 Disassemble CIP pump

Follow this instruction to disassemble the CIP pump.
Disassemble the main parts

1. Remove the drain pump from the skid 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).
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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).
Disassemble the housing

Follow this instruction to disassemble the housing.
1. Put the house wall with the flat side down on a plane surface.
2. Remove the spacer sleeve (19), by turning it 180°. To do that:
• Put a piece of plastic towards one side of the spacer sleeve.
• Knock on it so that the spacer sleeve is turning.
• Put one of the pin screws in the hole on the spacer sleeve and turn it
until it lays upside down (180°) compared to the starting position. Pull
the spacer sleeve carefully against the lower valve seat (21) until it is
free and can be put out.
3. Stick a something not pointed into the hole for the discharge connection
and gently press out the upper valve seat (20).
4. Place one of the pin screws on the inside (behind) the valve ball stopper on
the lower valve seat (21). Carefully pull out the valve seat in the housing.
5. Remove the valve ball (23) from the valve seat, buy using a pin screw:
Press out the valve ball stopper (22), which will release the valve ball.
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.
7.5.2.1.3 Assemble CIP pump

Follow the instructions below to assemble the CIP pump.
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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.
Assemble the main parts

1. Make sure that the O-rings (18) are placed on the in/outlet (13) before
assembling of pump.
2. Turn the housing (11) with the flat side up.
3. Make sure all pin screws (14) have one nut (37) and one washer (38)
each. Nut should only be put on one or two threads.
4. Put all the pin screws through the housing and then turn the housing so it
rests on the nuts.
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.
7.5.2.2 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.
7.5.3 Valve block and junction box

Read the conditions below before repairing the junction box or valve blocks.
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Valve block
• The junction box and valve blocks, including cabel glands and electrical
components (valve coils, fuses and terminals), are part of the Ex protection.
These components may not be repaired. When faulty, they must be
replaced with components that maintain the Ex protection. Install according
to the Control cabinet / Circuit diagram.
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7.6 Ballast water booster pump P201–1 (optional)

For service instructions, please refer to the Ballast water booster pump P201–
1 installation guide.
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7.7 Valves
This section contain instructions for the valve actuator.
Valve actuator with puck for position sensor

1. Safety cover
2. Padlock
3. Lower position for indicator screw
4. Upper position for indicator screw — with screw
5. Position indicator
6. Center screw
8. Puck
9. Locking bolt
10. End stop bolt
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Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilot valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves with dimension 400
7. DIN connector
7.7.1 Preparations and conditions
CAUTION
Lock valve in closed position before maintenance.
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.
• Do not operate the actuator over pressure limits. It will damage internal
parts as well as cause damage to the housing.
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• The actuator must not be lubricated. It is factory lubricated for the life of the
actuator during normal working conditions. The standard lubricant is
suitable for use from −20 °C (−4 °F) to +80 °C (+176 °F).
• If a valve actuator is removed, check for loose spindle-bushing. Then make
sure the loose bushing is refitted to avoid play between the actuator and
the valve spindle.
• Actuator are mounted together with the valve body and pilot valve at
delivery. Valve and actuator mounting are sealed to guarantee correct
position indication in relation to throttle position.
Tightening torques for actuators

See section Preparations and conditions on page 422.
7.7.2 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 Operating instructions
and control system description on page 45 for instruction.
7.7.3 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.
1 Identify which pilot valve that is controlling the

valve. All pilot valves are marked with a
sticker with the item numbers.
2 Place a screw driver in the maneuvering

screw. Turn the screw to operate the valve.
3 Restore the screw to original position.
7.7.4 Open and close valves manually

Follow this instruction to manually operate valves using the position screw on the pilot valve.
Closed (default position). If the position screw is in position 0 and the valve is
Position 0 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.
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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. Note: Some pilote valves have a
spring supported plastic screw that is pressed
down before the screw is turned.
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.
7.7.5 Lock valve in closed position

Follow this instruction to lock valves 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
should normally not be readjusted.
1. Set the valve to closed position from the control system. Control the
position indicator, to make sure. The yellow position indicator is in line with
the valve throttle (indicating open when the position indicator is in line with
the pipe).
2. Disconnect power and instrument 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).
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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.
9. Repeat the above procedure for all valves concerned.
7.7.6 Unlock valve

Follow this instruction to unlock valves from closed position.

• Note that the end positions of the end stop bolts are factory adjusted and
should normally not be readjusted.
1. Disconnect all power and instrument 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).
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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.
7.7.7 Dismount actuator

Follow this instruction to dismount an actuator.
• The valve must be in closed position.
• The valve position must not be adjusted during the routine.
1. Remove the connector to disconnect the power. Let the air connection
remain.
Verify that the valve is in closed position.
Result: Valve goes to closed position due to air connection. The yellow
indicators on the puck shows position of valve: closed. The yellow position
indicators are in line with the valve throttle (indicating closed when the
position indicators are in opposite line with the pipe).
2. Close air supply: Remove air hose to the pilot valve, and attend to their
position (connection points on the air hoses). Verify that the actuator is not
pressurized. Always use caution and double-check that ports 2 and 4 are
vented and are free from any accessory and/or device.
3. If the actuator have a switch box at the top: Loosen the four screws holding
the switch box to the actuator. Remove the switch box together with its
bracket.
4. Loosen the four hexagonal screws holding the actuator to the valve.
5. If the actuator is mounted on the valve with a bracket and coupling
(dimension 400): Loosen the screws holding the bracket to the valve. Make
sure not to loose the coupling between the valve and actuator when lifting
the actuator.
6. Lift the actuator from the valve.
7.7.8 Mount actuator

Follow this instruction to mount an actuator on a valve.
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1. Allowed travel sector

2. Valve stem groove
3. Valve stem
4. Lock pin opening (covered by rubber plug)
CAUTION
The actuator must not be pressurized at any time during installation as it
may result in injury.

• The utmost cleanliness is required during air supply connection to the
actuator, that is, the connecting pipe thread, fittings and seals must be
clean and dirt-free.
• Before fitting onto the valve, make sure the actuator/valve is correctly
orientated, depending on which direction of rotation is required.
1. Note the position of the groove (2) of the valve stem (3). It indicates the
position of the valve throttle. The illustration shows a square variant, but
octagonal versions exist.
2. Make sure that the lock pin (inside the valve stem) only travels in the
allowed sector (1) and that it does not pass the opening (5).
3. If the actuator is mounted on the valve with a bracket and coupling
(dimension 400): First fit the coupling on the valve stem. Make sure that
the red position indicator on the coupling is in line with the pipe when the
valve is open.
4. Fit the actuator onto the valve stem (or the coupling). The actuator may
only be positioned in even 90° intervals in relation to the valve. It is not
allowed to adjust the position by turning the actuator by hand after it is
fitted on the valve stem.
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5. Mount the actuator on the valve with the four hexagonal screws. For each
screw, one washer and one spring washer shall be used. Tighten with
torque according to the table Tightening torques for actuators in
Preparations and conditions on page 467.
6. If the actuator have a switch box at the top: Make sure that the yellow
position indicator under the switch box is in line with the throttle (according
to the groove in the valve stem). The yellow position indicator shall be in
line with the valve throttle (indicating open when the position indicator is in
line with the pipe). If not, remove the position indicator, turn it 90° and refit
it.
Mount the switch box with the bracket on the actuator, using the four bolts.
7. Reconnect the air hose to the pilot valve.
8. Operate the valve to make sure it operates in the desired direction of
rotation.
7.7.9 Adjust valve end position

Follow this instruction to tune the open and closed end positions for a valve.
This is done if the valve tends to get stuck in the end position or not close
completely.

• 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).
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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).
7.7.10 Calibrate positioner on V201-8

Follow this instruction to calibrate the positioner at installation or when
needed.
1. Arrestor device (screw driver adjusting)

2. Unlock the wheel
3. Locking wheel (screw driver adjusting)
4. Direction to lock the wheel
5. Adjustment wheel
6. Transmission ratio selector
• The valve must be installed and connected to air and power.
• The valve must be closed.
• The cover must be removed.
• The positioner must have power. If the positioner display is empty (no
power): Open V201-8 manually (approximately 1-5 %) from control system
to supply power to the positioner.
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• Do not adjust the cam wheels: 2 grey wheels above the adjustment wheel
(5).
• Buttons on the positioner:
Software settings - Alfa Laval values:

Parameter Settings in menu
1 turn
2 90° (is automatically 90° when turn is used)
34 0.7

1. Make sure that the transmission ratio selector (6) is set to 90° according to
sticker on the component. If not: Adjust by pressing the bar with a screw
driver.
2. Make sure that the Arrestor device wheel (1) is set to 90°. If not: Adjust by
turning.
3. Press HAND button for 5 seconds to enter the parameter list.
4. Make sure that Menu 1 is displayed. If not: Press HAND button repeatedly
until it is.
Make sure that “turn” is displayed in the menu. If not: press + or -
repeatedly until it is.
5. Press the hand button repeatedly until Menu 4 is displayed.
(To go backward, press HAND button and - button.)
6. Press + button for 5 seconds to start automatic calibration.
7. If calibration stops (as displayed below), follow these steps:
- Use a screw driver to loosen the yellow locking wheel (counter

clockwise).
- Turn the adjustment wheel (5) by hand until a 0 is displayed between the
“d” and the “U” as shown in the illustration. Normally this is when the value
in the screen is close to 0.
- Lock the locking wheel (3) with a screw driver (clockwise).

- Press the + button to continue the calibration.
8. Wait until “FINISH” is displayed on the screen.
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9. Press the hand button once.

Result: Menu 4 “INITA” is displayed.
10. Press the hand button for 5 seconds until a number or “VER” is displayed,
then let go of the button.
Result: “MAN” is displayed”.
11. Press the hand button once.
Result: A final adjustment is started, and then “AUT” is displayed.
Trouble shooting
If any problem occurs, do the following:
1. Check the mechanical installation and air supply.
2. Reset factory settings and restart calibration:
- Reset to factory settings: Press HAND button repeatedly until menu 50 is

displayed.
- Press + button until “oCAY” is displayed.
- Restart instruction Calibrate positioner on V201-8 from step 4.
- Set the parameters according to Alfa Laval software settings. See table
above.
7.7.11 Adjust cam position on V201-8

Follow this instruction to adjust cam setting for the pneumatic positioner
feedback on valve V201-8, so that the operating indication is correct in the
control system.
Hint: A multimeter can be used to indicate position of the cam wheels, if it is
hard to hear the click from the micro switch, or if it is inconvenient to see valve
position in control panel. Connect a multimeter to connection point 41 and 42
in the positioner.
- Closed circuit = 0 ohm.

- Open circuit = ∞.
Instruction for multimeter indicated in italic.

1. In control panel: Set system in manual mode.
2. Open V201-8 manually to approximately 50 % in the panel.
3. Close it to approximately 10 %.
4. On the positioner: Adjust both cam wheels to same position. Cam wheels
are above the adjustment wheel (5). See illustration in Calibrate positioner
on V201-8 on page 474.
5. Turn the cam wheels in any direction until it valve indicates steady green in
the control panel. Multimeter indicate circuit closed.
6. Turn the cam wheel slowly counter clock wise until you hear a click from
the micro switch in the positioner. Stop directly after the click. Stop directly
after the multimeter changes to indicate circuit open.
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7. Check that the valve is indicated as open (steady green) in the control
panel.
8. Close the valve to 0 %.
Result 1: Valve closed, indicated with no color. Circuit closed. Setting is
OK. You are done.
Result 2: Valve indicated as red. Cam wheels are in wrong position, for
example due to the wheels been turned too much after the click).
Multimeter indicate circuit open. Repeat from step 2 until setting is OK.
7.7.12 Change direction of actuator – without position sensor (V404–36, V320–

4 and V321–2)
Follow this instruction to turn an actuator without position sensors on the UV reactor.
1 Loosen the four screws holding the actuator

to the valve.
2 Lift the actuator from the valve.
3 Note the position of the groove of the valve

stem. It indicates the position of the valve
throttle.
4 Fit the actuator onto the valve stem.
5 Unscrew the center screw (4) holding the

puck (6) and a bracket (5).
6 Lift the puck (6), rotate it 90° and fasten it

with the center screw (4) and bracket (5).
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7 Make sure that the yellow position indicators

(3) is in line with the throttle (according to the
groove in the valve stem). The yellow position
indicators shall be in line with the valve
throttle (indicating open when the position
indicator is in line with the pipe). If not,
remove the position indicators, turn them 90°
and refit.
8 Connect power and air.
7.7.13 Change direction of actuator – with position sensor (201-19 and 201–
20)
Follow this instruction to turn an actuator with a position sensor, if necessary due to lack of space.
Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-19 and V201-20 on the UV reactor.
• The valve must be mounted and connected to air and power before adjustment.
• Ex connections in the junction box: Intrinsically safe (feedback) and non-intrinsically (open/close)
circuits fitted with the same enclosure shall be separated as required by EN 60079–14.
1 Dismount the actuator from the valve

according to instruction Dismount actuator on
page 471. Put the actuator on a work bench.
2 Disconnect the DIN connector (2) from the

coil: First loosen the screw (1), and then pull
up the connector.
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3 Unscrew the center screw (6) holding the

puck (8) and a bracket (7).
4 Lift the puck (8), rotate it 90° so that one

position indicator (5) with a screw is in
contact with the position sensor. Fasten the
puck with the center screw (6) and bracket
(7).
5 Move the screw on yellow position indicator

to the top position and move the screw on
black position indicator to the bottom position.
6 Make sure that the position sensor have a

maximum distance of 1 mm from the puck
(7). The position sensor and the position
indicator screws must be close to give a
signal. If not, loosen the screws and adjust
the position. Tighten the screws to fixate the
position.
7 Fit the actuator onto the valve stem in its new

position according to instruction Mount
actuator on page 471
8 Make sure that the yellow indicator (5) in line

with the valve throttle according to the groove
in the valve stem.
9 Reconnect the DIN connector.
10 Connect power.
11 Check that the installation is OK, by making

sure that the A1 LED is lit on the position
sensor (visible from the side).
12 Connect air.
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7.7.14 Change direction of actuator – with switch box (V201–

3, V201–9, V201–32, V212–31 and V403–35)
Follow this instruction to turn an actuator with switch box.
Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilot valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves with dimension 400
7. DIN connector
• The valve must be mounted and connected to air and power before
adjustment.
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1. Dismount the actuator according to Dismount actuator on page 471.

2. Remount the actuator according to Mount actuator on page 471
3. Before mounting the switch box, change the position of the yellow position
indicator, so it is in line with the throttle.
4. Remount the switch box according to Mount actuator.
7.7.15 Change direction of actuator – with positioner (201–8)

Follow this instruction to turn the actuator on control valve 201–8, if necessary due to lack of space.
Note that the actuator normally should not be altered.
• Ex connections in the junction box: Intrinsically safe (feedback) and non-intrinsically (open/close)
circuits fitted with the same enclosure shall be separated as required by EN 60079–14.
1 Dismount the actuator from the valve

according to instruction Dismount actuator on
page 471.
2 Fit the actuator onto the valve stem in its new

position and mount it on the valve with the
four hexagonal screws. For each screw, one
washer and one spring washer shall be used.
Tighten with torque according to the table
Tightening torques for actuators. See
Preparations and conditions on page 467.
3 The position indicator scale shall be correct,

but make sure that the scale still indicates
correct opening percent according to the
valve throttle position. If not, loosen the four
bolts to the bracket holding the switch box.
Lift it and turn the scale so it is correct.
4 Refit the switch box. Make sure that the peg

on the scale fits to the carrier on the puck
mounted on the actuator.
7.7.16 Mount pilot valve on actuator

Follow this instruction to mount a pilot valve on actuator and connect it.
• Air and power must be disconnected. The valve position must not be
adjusted during the routine.
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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).
7.7.17 Adjust valve traveling speed

Follow this instruction to adjust valve traveling speed.
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1. Operate the valve manually to check travelling speed according to the

instruction Operate valves manually in section Valves on page 466.
2. To adjust opening speed:
Faster: Screw the throttle (1) valve port 3 counterclockwise.

Slower: Screw the throttle valve (1) port 3 clockwise.
3. To adjust closing speed:
Faster: Screw the throttle valve (2) port 5 counterclockwise.

Slower: Screw the throttle valve (2) port 5 clockwise.
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7.8 Flow meter

CAUTION
Do not make any modifications on Ex-certified devices. If a component
needs to be replaced, it must be replaced with an identical Ex classified
part.
The flow sensor and flow transmitter are pre-assembled from factory, and the
parameters are pre-set.
7.8.1 Backing up the data

A) Read and note the parameters on the display and save them on the new electronics module
following replacement, or
B) Read out the parameters from the memory card (T-DAT) via the web browser (Data management/
Device configuration/Upload settings from device), using the parameter download function.
Save the .xml file to the PC and by using the Download settings to device function.
Save the parameters to the new electronics module.
7.8.2 Replace display module
WARNING
Risk of electric shock! Exposed components carry dangerous voltages.
Make sure that the power supply is switched off before you remove the cover of the electronics
compartment.
Only open the device in a de-energized state (once a delay of 10 minutes has elapsed after
switching off the power supply) or in environments which do not have a potentially explosive
atmosphere.

To open cover without display: See step 1–2.
To open cover with display: See step 1–3 b.
To replace display module: See step 1–5.
1 Turn off power supply, using the main breaker

on the control cabinet
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2 Open the cover of the electronics

compartment.
Opening the cover with display (upper
image), without display (lower image).
a) Loosen the securing clamp.
b) Unscrew the cover.
c) Remove the cover.
3 Remove the display module as follows:

a) Squeeze the tabs of the display module
holder together.
b) Remove the display module holder.
c) Disconnect the cable of the display
module from the main electronics module.
4 Remove the display module from its holder.
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5 Installation is the reverse of the removal

procedure.
7.8.3 Replace the memory card (T-DAT)

If the transmitter or measuring device is replaced: Remove the T-DAT from the old unit and insert it
into the new unit. Once the T-DAT containing the previous data has been exchanged, the new
measuring device is ready for operation.

compartment as described in instruction
Replace display module above.
2 Remove the T-DAT.

procedure.
7.8.4 Replace module carrier

The module carrier contain power supply module and I/O modules.
1 Switch off power supply, using the main

breaker on the control cabinet
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compartment.
a) Loosen the securing clamp.
b) Unscrew the cover.
c) Remove the cover.
3 a) Disconnect the cable of the module

carrier.
b) Loosen the securing clamp.
c) Remove the module carrier.
4 Remove the module carrier from the

transmitter housing.

procedure.
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7.9 Control panel

This section covers instructions for service of the control system.
7.9.1 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.
7.9.2 Replace control panel

Follow this instruction to replace the control panel
• The system must be shut down.
• Connect cables as in the old control panel. Port LAN A must be used for
the Ethernet cable at the backside of the panel.
• After the panel is mounted: Load new software to the panel according to
the release note for the software. Also set communication according to Set
control panel IP address on page 115 and Set remote control panel
communication on page 116.
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7.10 Remote control panel (optional)

This section covers information on how to mount and connect the remote
control panel. The remote control panel is either ordered with a mounting plate
(for installations in wall, worktop etc) or an IP protective back cover (for
installation on stand etc).
7.10.1 Mount and connect remote control panel

• Remote control panel is mounted according to according to drawing
Remote control panel (optional) on page 295. Note the clearance area.
• Use a 24 VDCpower cable with minimum cross section of 0.75 mm2,
preferably halogen free and flexible. Connect power cable to terminal X1 in
• Communication cable (W501) between the remote control panel and
control cabinet can be either Ethernet or optical fiber. Cable requirements
and connection points below:
• Communication cable (W501) between the remote control panel and
control cabinet can be either Ethernet or optical fiber. Cable requirements
and connection points below:
- Ethernet cable – Type: Cat 5e (or better), shielded. Max length: 100
meters.
One remote control panel: From terminal X2 in remote control panels to
terminal X13 in the control cabinet.
Two remote control panels: From terminal X2 in second remote control
panel to either switch SW1 in control cabinet or to switch SW1 in the first
- Optical fiber cable – Type: Multi-mode optical fiber cable with LC
connector. Max length: 500 meters. From remote control panel’s switch
SW1 to switch SW1 in control cabinet. See Remote control panel / Circuit
diagram (optional) on page 385.
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7.11 Control cabinet and lamp drive cabinet (LDC)

This section covers maintenance information for the control cabinet.
7.11.1 Disassemble and assemble I/O system

This section covers maintenance information about the I/O system (X20
electronic modules). For information about status and error indications, please
see Alarms and faultfinding on page 185.
1. Hold down the plastic clip on the top of the terminal block and pivot the
block towards you.
2. Pull away the terminal block.

3. Hold down the triangle on the top of the I/O board and loosen the board.
4. Pull the board straight out (otherwise it can fasten in one of its guides).
5. Compare the part number of the new I/O board to the old board, to make
sure it is correct.
6. If changing more than one board at a time, check with the electrical
diagram to ensure that the boards are mounted in the right places.
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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.
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.
9. Pivot the terminal block on the axel until the clip on the terminal block top
fastens into place in the I/O board.
7.11.2 Cable gland installation – General cables

This section covers information about how to install the cables into the control cabinet and LDC using
the cable glands. Power cables to the LDC are installed according to instruction Cable gland
installation – Power cable to LDC.
Follow this instruction to mount cables into the cabinets.
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1 Lubricate the inside surfaces of the frame

with Roxtec Assembly Gel or equivalent,
specially in the corners.
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.
5 Lubricate all modules thoroughly, both on the

inside and the outside surfaces.
6 Insert the modules from the back of the frame

opening. If possible, start with the largest
modules.
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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.
7.11.3 Cable gland installation – Power cable to LDC

Follow this instruction to install the power cable to the LDC using the cable gland.
1 Adapt the seal to the cable by removing

layers from the halves. The halves may not
differ by more than one layer.
2 Achieve an approximate 0.1–1 mm gap

between the halves when testing against the
cable. There shall be a visual gap.
3 Lubricate thoroughly on the inside surfaces

and sparsely on the outside of the seal.
4 Insert the halves one by one into the sleeve.
5 Tighten the Allen screws crosswise. The seal

will compress and seal the transit.
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7.11.4 Power cable check

Check power cables screw connections, to eliminate potential risk of fire due to loose cables. This
check should be performed in LDC, control cabinet, UVR junction box
1 Switch off the PureBallast system from the

vessel’s main switch board. Where
applicable, turn off power to the individual
cabinet.
2 Make a random check of approximately 10 %

the cables in different areas of the cabinet.
• Make sure that the cables are fastened
with sufficiently tightened screws.
• If one cable is loose, check all cables
connected to this component / component
of the same type.
• Note: Be careful not to tighten the screws
so that the cables are damaged.
7.11.5 Install IFS confstick in safety relay KS1 in LDC

Follow this instruction to install a IFS confstick in the safety relay. This is done when a broken IFS
confstick is replaced or when a new safety relay is installed.
The confstick must be programmed for the specific system it is about to be installed in.
1 Switch off the power to the lamp drive cabinet

(LDC).
494 200000874-5-EN-GB
Service manual 7 EN
2 If the safety relay is broken, follow the sub-

steps below. If the IFS confstick is broken,
continue with step 3. a) Replace the old
safety relay with a new. b) Remove the IFS
confstick from the old safety relay and use it
in the steps below.
3 Insert the IFS confstick in the safety module.

The IFS confstick can only be inserted in one
way.
4 Switch on the power to the LDC. Wait until

the safety relay has initialized (all four status
LEDs light up once during initialization).
5 The safety relay now detects that a IFS

confstick has been inserted. The LED
"CONF" is flashing.
6 Remove the IFS confstick again.
7 Press the Confirm button on and hold it

pressed down.
8 Reinsert the IFS confstick while holding down

the Confirm button.
9 Release the Confirm button once the IFS

confstick is inserted properly. The safety
module now initializes with the new
configuration.
200000874-5-EN-GB 495
EN 7 Service manual
496 200000874-5-EN-GB
EN
8 Revision history
The revision history shows changes since the last release.
Ex
Date Description
2020–05–25 New section Prepare operation in SM chp 3 to contain all preparations such as
choose IMO/USCG, open relevant valves, priming etc.
Section “Operational conditions” now collects conditions and modes for an operation
(IMO, USCG, heeling, gravity filling etc.)
Heeling instruction clarified in chapter 3.
Events corrected, now containing”E” before the number.
Updated according to latest SW release.
Section Flow meter parameters added to chapter 4.
Parameter p111: Setting details added for FIT201-1.
Parameter p111: Setting details added for FIT201-1.
New/updated dimension drawings:
• UVR 1000 and 1500
• Filter 1000
• Filter 3000
• Press. mon. device
• V201-3 and -9
• Connectivity cabinet
New/updated electrical drawings:
• P201-1, Electric system layout
• Electrical system layout all flow
• LDC all flow
• CC
• RCP
2020-03-27 New method for filter cleaning is introduced in chapter 7.

Lifting instructions: All capacities deleted.
Flexible filter size information added.
Section PureBallast components (with weights) deleted.
New drawings:
Electrical system layout – Connectivity
Electrical system layout – Log box
New revisions of drawings:

Electrical drawings – Control cabinet
Electrical drawings – Remote control panel
Electrical system layouts
Added Connectivity, booster pumps, relief valves and log box to section Components
overview.
Added information about booster pump P201–1 in system descriptions and operating
instructions.
200000874-5-EN-GB 497
EN 8 Revision history
498 200000874-5-EN-GB
.
Spare parts catalogue

PureBallast 3.2 2000 Ex - Deckhouse
Specification No. 9006977-05/4

Book No. 9051945 02 Rev. 1
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB 2020-09-02

Original instructions
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1 Important information 7
2 Control Cabinet, Ex 8
2.1 Cabinet 12
2.2 I/O module 14
2.3 Terminal block 16
2.4 Relay module 18
3 Lamp drive cabinet Ex 20

3.1 Lamp drive cabinet, subas 22
4 Remote control panel (optional) 44

4.1 Cover 46
5 Log box (optional) 48
6 UV Reactor EN 50
6.1 Reactor module EN 54
6.2 Junction box Ex 56
6.3 Junction box Ex 58
6.4 Valve, EN DN350 60
6.5 Valve V320-4, V321-2, V404-36 62
7 Filter, ACB-9120-500 EX 64
7.1 Filter, ACB-9120-500 68
7.2 Junction box, Ex 70
7.3 Release valve automatic, Ex 72
8 Backflush pump Ex (optional) 74
9 Valve V201-3, V201-9 76
3
10 Valve V201-32 and V403-35 78
11 Control valve V201-8 80
12 Flow transmitter Ex, EN500 82
13 CIP module, Ex 84
13.1Pump, Ex 88
13.2Valve, Ex 90
13.3Valve block 92
13.4Filter regulator 94
13.5Valve block, Ex 96
14 Booster pump, P401-1 (optional) 98
15 Booster pump Start-up flow

P403-1 (optional) 100
16 Air filter regulator 102
17 Booster pump P201-1, Ex

(optional) 104
17.1Booster pump, Ex 106
17.2VFD 108
17.3Junction box 110
17.4Press. mon. device Ex 112
18 Vacuum relief valve (VB201),

DN80 (optional) 114
19 Vacuum relief valve (VB309),

DN50 (optional) 116
20 Agent X9, single 118
21 Closed cooling unit, LDC 120
4
22 Transformer (optional) 122
23 Cross reference list 124
5
6
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. 9051945 02 Rev. 1 7

2 Control Cabinet, Ex
Machine unit number or
Subassembly description
9034554-
Ref Part No Description -82 Notes
Quantity
1 9012086 84 Cabinet 1 See page 12
2 9006851 01 Software, PLC, PB3.0 1
3 9006852 01 Software, panel 1
4 9017691 03 HMI Panel 15" 1
8 221891 04 Lock nut 12
9 223101 47 Washer 12
10 582212 148 End stop (clip fix) 13
11 582212 122 Terminal block 3
12 582212 13 End plate 3
13 9019135 03 Contactor AF09Z 1 K2
13.1 9019138 01 Over current prot. Relay Ex 1 F2
14 9019135 03 Contactor AF09Z 1 K3
15 9014707 01 Power supply unit 1 T1
16 9004299 04 Fuse 4
17 582212 67 Terminal, PT 2,5-3PV 7
17.1 582212 71 Plug In Bridge, FBS 3-5BU 1 According to electrical document
18 582212 63 Terminal D-PIT 2,5-3L 1
19.2 591103 84 Aux block 1nc 1 K4
20.2 591103 84 Aux block 1nc 1 K5
21 9034945 80 I/O module 1 See page 14
22 582212 147 Patch panel 3
23 582212 91 VIP-2, D 9SUB 2
24 9036909 80 Terminal block 1 See page 16
31 582212 168 Separating plate 2
32 582212 123 Power terminal block, 1
33 9002362 80 Relay module 3 See page 18
35 582221 90 PE Connection bar 1 245mm
37 582212 206 Bar holder 3
38 582212 15 PE/SC Bar 1 500mm
50 591103 71 Pushbutton, ill. Blue 1
50.1 591103 87 Blue LED 1
50.2 591103 88 Holder for 3 pos 1
50.3 591103 89 Contact block 1 NO 1
52 591103 67 Emergency stop 1
52.1 591103 93 Shroud Ye 1
54 9011552 01 Buzzer 1
56 582212 155 Socket with USB 2
59 9025837 01 Switch OT63FT3 1
59.1 591103 37 Breaker handles 1
59.2 9025837 02 Shroud OTS63T3 2
61 9006853 01 Fan 1
62 9006854 01 Air outlet 1
63 595361 02 Cable seal 2
66 9012150 91 Wire set 1
67 582221 101 Splicing connector 2
74 1270001 Lifting instruction 1
76 591103 86 Over current prot. 1 Q2
76.2 591103 64 Connection 1
76.3 591103 10 Auxiliary contact 3
77 591103 54 Over current prot. Relay 1 Q3
78 591103 60 Over current prot. Relay 1 Q4
80 595728 02 Switch 1 SW1
82 595673 03 Ethernet cable 1
82.1 595673 04 Ethernet cable 1
86 582212 90 Cable-D 9SUB 1
100 582212 94 Safety relay 1 KS1
8 Book No. 9051945 02 Rev. 1

3185A
Book No. 9051945 02 Rev. 1 9


9034554-
Quantity
106 582212 102 Terminal PITTB 2,5 PE 4
108 582212 176 IS Analog mA Out, Ex 1 T2018
Z 597330 01 Cable seal
Z0.1 597331 01 Cable seal
10 Book No. 9051945 02 Rev. 1

3185A
Book No. 9051945 02 Rev. 1 11

2.1 Cabinet
9012086-
Quantity
1 9012088 80 Cabinet 1
2 9012091 80 Door 1
4 26556 Spring washer 6
10 593778 01 Latch, housing 1
11 593779 01 Latch, insert 1
12 593991 01 Latch 1
13 9003013 01 Rod Guide 2
14 9003024 02 Rod for latching 2
15 593780 01 Key 1
17 223107 34 Spring washer 4
20 593254 01 Retaining ring 1
34 9014753 01 Piano hinge 1
35 9014815 01 Cover panel 1
36 598571 01 Torx head pan screw M4 8
39 9015118 01 Mounting spacer hole thro 2
40 9015117 01 Mounting spacer single ta 2
41 9012093 01 Magnet 4
12 Book No. 9051945 02 Rev. 1

2.1 Cabinet 2 Control Cabinet, Ex
2900A
Book No. 9051945 02 Rev. 1 13

2.2 I/O module

9034945-
Quantity
1 597033 22 PLC 1 Incl. locking plate.
1.1 597033 18 Interface module 1
1.2 580986 76 Communication module 2
2 580986 17 Bus module 13
3 580986 30 Supply Bus Module 1
4 580986 51 12 Digital Input 3
5 580986 08 4 Analogue input 1
6 580986 53 2 Analogue Output 1
7 580986 32 Supply Module 1
8 580986 59 12 Digital Output 1
9 580986 06 6 Relay output 5
10 580986 40 Input Module 1
11 580986 16 Terminal block 12-pin 14
12 580986 20 Locking Plate right 0 Included in pos:1
13 580986 55 Compact flash card 1
14 580986 72 Communication module 1
14 Book No. 9051945 02 Rev. 1

2.2 I/O module 2 Control Cabinet, Ex
3201A
Book No. 9051945 02 Rev. 1 15

2.3 Terminal block

9036909-
Quantity
1 582212 148 End stop (clip fix) 5
2 9019186 06 End cover, D-PT 4-PE/3L 1
3 9019186 05 Terminal, PT 4-PE/3L 4
6 582212 104 Terminal PITTB 2,5 40
6.1 582212 03 Plug In Bridge 1 According to electrical document
6.2 582212 02 Plug In Bridge 1 According to electrical document
7 582212 63 Terminal D-PIT 2,5-3L 2
8 582212 67 Terminal, PT 2,5-3PV 2
10 582212 104 Terminal PITTB 2,5 1
12 582212 104 Terminal PITTB 2,5 2
13 582212 65 Terminal PIT 2,5-3L 2
16 Book No. 9051945 02 Rev. 1

2.3 Terminal block 2 Control Cabinet, Ex
3202A
Book No. 9051945 02 Rev. 1 17

2.4 Relay module

9002362-
Quantity
1 582212 119 Interface relay, 24V 8
2 582212 120 Input adapter 1
3 582212 121 System cable 1
Z 582212 172 Relay, mini
18 Book No. 9051945 02 Rev. 1

2.4 Relay module 2 Control Cabinet, Ex
2724A
Book No. 9051945 02 Rev. 1 19

3 Lamp drive cabinet Ex

9011941-
Quantity
1 9011953 80 Lamp drive cabinet, subas 1 See page 22
2 9012146 01 Lamp Power supply 16
20 Book No. 9051945 02 Rev. 1

3 Lamp drive cabinet Ex
2906A
Book No. 9051945 02 Rev. 1 21

3.1 Lamp drive cabinet, subas

9011953-
Quantity
2 9004211 01 Centrifugal fan 1
3 221030 10 Screw 5
3.1 223101 47 Washer 5
5 594009 04 Screw 2
6 223101 03 Washer 4
7 221891 01 Lock nut 2
8 594728 01 Temperature sensor 1
9 9004214 01 Heat exchanger 1
10 221030 10 Screw 12
11 223101 47 Washer 6
11.1 223101 04 Washer 11
12 221803 02 Nut 5
13 590624 03 Temperature sensor 1
14 9004303 02 Sensor, liquid 1
15 221803 03 Nut 1
16 223101 17 Washer 1
17 9008401 01 Solenoid valve 1
17 9008403 80 Solenoid valve 1
18 9004254 01 Check valve 1
18 9008407 01 Check valve 1
18.2 595558 01 Wire 1
19 523127 04 Hexagon nipple 2
20 9004426 01 Hose 2
21 591103 69 Pilot light Green 1
24 591103 70 Pilot light White 1
26 591103 71 Pushbutton, ill. Blue 1
26.1 591103 87 Blue LED 1
26.2 591103 88 Holder for 3 pos 1
26.3 591103 89 Contact block 1 NO 1
27 9004442 03 Marking, Reset 1
28 582212 164 Phoenix Contact 16
29 581803 43 Plug M 3p 16
30 582212 165 Phoenix Contact 16
32 593724 03 Distance screw 4
33 594009 03 Screw 2
34 582212 148 End stop (clip fix) 12
35 591103 86 Over current prot. 8
35.1 591103 10 Auxiliary contact 8
37 591103 64 Connection 3
38 9014707 01 Power supply unit 1
39 9004299 04 Fuse 2
40 9012135 80 I/O module 1 See page 32
42 582212 13 End plate 1
43 591103 32 Fuse 2
44 591103 91 Bus bar 1
45 582212 182 Safety module 1
46 582212 146 Interface relay, 24V 2
47 9014546 01 Temperature relay 1
49 9004329 80 Liquid leakage amplifier 1
50 9006677 01 Filter 1
51 223101 47 Washer 4
52 221891 04 Lock nut 4
53 9004313 82 Breaker 1
54 9005494 04 Transmitted handle kit 1
22 Book No. 9051945 02 Rev. 1

3.1 Lamp drive cabinet, subas 3 Lamp drive cabinet Ex
3083A
Book No. 9051945 02 Rev. 1 23


9011953-
Quantity
55 591103 46 Breaker door seal 1
56 591103 61 Self-res. short-circ. lim 3
57 591103 40 Supply block 1
58 591103 03 Bus bar 250A 1 12 terminal lugs
59 591103 41 End cap 2
60 9014833 01 DIN-rail, 35x15 1
61 223101 47 Washer 4
62 221891 04 Lock nut 4
66 587276 02 Washer 12
67 70560 Washer 12
68 221891 05 Hexagon lock nut 12
86 9015197 92 Wire set 1 See page 40
200 591103 82 Contactor 3
200.1 591103 84 Aux block 1nc 3
201 594009 06 Screw 12
202 582212 184 Relay 2pol 1
203 582212 183 Relay 2pol 1
204A 582212 148 End stop (clip fix) 2
204B 582212 179 Power supply 1
204C 582212 180 T-bus 6
204D 582212 178 IS 2ch input, Ex 2
204E 582212 177 IS 1ch input, Ex 3
204F 582212 175 IS Analog mA IN, Ex 1
204G 596019 07 Barrier, Ex-i RTD 2
208 9014582 01 Cable channel blue, 25x80 1
Z 591103 62 RHE handle
Z0.1 9003114 02 Cable gland
24 Book No. 9051945 02 Rev. 1

3083A
Book No. 9051945 02 Rev. 1 25

3.1.1 Cabinet
9011952-
Quantity
2 9012193 01 Mounting plate 1
3 587276 02 Washer 18
5 221716 01 Screw 8
6 9015611 01 Sheet 1
7 223101 47 Washer 4
8 221891 04 Lock nut 4
10 223101 47 Washer 6
11 221891 04 Lock nut 6
13 592005 15 DIN-rail, 35x15 1
14 9003565 03 DIN-rail, 35x15 1
15 9003565 02 DIN-rail, 35x15 1
16 223101 47 Washer 17
17 221891 04 Lock nut 14
18 583556 20 Cable channel 40x80 1
19 583556 19 Cable channel 40x80 1
20 583556 21 Cable channel 40x80 1
21 583556 04 Cable channel 1
22 586056 07 Cable channel 60x80 1
34 223101 47 Washer 13
35 221851 05 Cap nut 13
37 9004212 01 Inlet duct 1
38 9004213 01 Protection 1
39 221891 02 Nut 4
40 223101 16 Washer 4
41 594009 02 Screw 4
42 9003390 01 Bracket, fan 1
43 9006316 01 Cover, fan 1
44 223101 47 Washer 9
45 221030 10 Screw 9
46 591889 01 Cable tie mount 3
50 9003030 01 Drawing Pocket 1
51 223101 47 Washer 2
52 221803 02 Nut 2
53 9014585 01 Sheet, LPS 1
54 9014554 01 Sheet, LPS 1
55 594009 05 Screw 8
56 9002947 01 Yoke 18
57 9002942 01 Stud bolt 36
61 9006322 01 Sheet 1
62 221030 02 Screw 36
63 223101 47 Washer 72
64 221891 04 Lock nut 36
65 9015616 01 Sheet 1
66 70560 Washer 2
68 221716 01 Screw 1
26 Book No. 9051945 02 Rev. 1

2881A
Book No. 9051945 02 Rev. 1 27

3.1.2 Cabinet
9011951-
Quantity
3 9008903 05 Washer 12
4 221035 51 Screw 12
5 9014640 01 Door, RH 1
6 9014642 01 Door, LH 1
9 223101 47 Washer 12
10 221803 02 Nut 12
15 9003075 01 Sheet 2
17 9003410 01 Sheet, heat exchanger 1
18 221030 10 Screw 9
19 223101 47 Washer 2
20 9003401 01 Sheet, heat exchanger 1
21 221030 10 Screw 3
22 223101 47 Washer 3
23 9003186 01 Plug 1
29 591874 04 Seal 1 Upper LPS rack, left
30 591874 06 Seal 1 Upper LPS rack, right
34 9014759 01 Sheet, EMC 1
49 9014762 01 Handle 1
50.1 9016270 01 Rod adapter 4
51 9016268 01 Rod guide 8
52 9014732 01 Three point lock 1
53 9014735 01 Handle 1
54A 9003024 01 Rod for latching 1
55 593780 01 Key 1
56 9003114 02 Cable gland 1
57 9003113 01 Cable seal 1
58 223101 41 Washer, 4,3x9x0,8 10
59 221891 02 Nut 10
64 9003031 01 Condensation outlet 2 Cabinet floor and heat exchanger floor
65 9003186 02 Plug 3
66 9008424 01 Protection 9
67 9003089 02 Vibration damper 2
68 223101 49 Washer 13x24x2,5 2
69 221726 10 Screw 2
28 Book No. 9051945 02 Rev. 1

2882A
Book No. 9051945 02 Rev. 1 29

3.1.3 Terminal block

9012058-
Quantity
1 598323 02 DIN rail TS 15 1
2 582212 202 Terminal MPT1,5 11
3 582212 203 Terminal MPT1,5 PE 2
4 582212 204 Terminal D-MPT1,5 1
5 582212 205 Clip fix 15 2
30 Book No. 9051945 02 Rev. 1

2880A
Book No. 9051945 02 Rev. 1 31

3.1.4 I/O module

9012135-
Quantity
1 580986 64 Bus Module 1
2 580986 17 Bus module 7
3 580986 62 Interface Module 1
4 580986 63 Bus Supply 1
5 580986 72 Communication module 1
6 597033 10 8 Digital input Module 2
7 580986 59 12 Digital Output 1
8 580986 40 Input Module 1
9 580986 53 2 Analogue Output 1
10 580986 61 4 Analog Input (PT100) 1
11 580986 16 Terminal block 12-pin 8
12 580986 19 Locking Plate left 1
13 580986 20 Locking Plate right 1
32 Book No. 9051945 02 Rev. 1

2870A
Book No. 9051945 02 Rev. 1 33


9014704-
Quantity
1 582212 67 Terminal, PT 2,5-3PV 6
2 582212 64 Terminal PT 2,5-3PE 1
3 582212 63 Terminal D-PIT 2,5-3L 1
4 582212 71 Plug In Bridge, FBS 3-5BU 1
5 582212 03 Plug In Bridge 1
34 Book No. 9051945 02 Rev. 1

2871A
Book No. 9051945 02 Rev. 1 35


9012186-
Quantity
2 582212 130 Support, L=95,5 2
3 582212 15 PE/SC Bar 1 148mm
4 582212 147 Patch panel 2
6 582212 04 End plate 1
7 582212 95 Terminal, PIT 2,5 TWIN 2
8 582212 96 Terminal, PIT 2,5 TWIN-PE 1
11 582212 104 Terminal PITTB 2,5 6
13 582212 136 Sc clamp SK 14 2
36 Book No. 9051945 02 Rev. 1

2904A
Book No. 9051945 02 Rev. 1 37


9012198-
Quantity
4 582212 13 End plate 1
5 582212 132 Sealable cover profile 2
6 582212 130 Support, L=95,5 2
7 582212 156 Terminal, PT 6 32
8 582212 15 PE/SC Bar 1 285mm
9 582212 137 Sc clamp SK 20 4
10 582212 157 End cover, D-PT 6 1
11 582212 133 Cover profile (AP-3) L=1m 1 292mm
38 Book No. 9051945 02 Rev. 1

2873A
Book No. 9051945 02 Rev. 1 39

3.1.8 Wire set

9015197-
Quantity
1 9008383 01 Cable, 70mm² 2
2 9008383 02 Cable, 35mm² 15
3 9015704 01 Cable, 4mm² 25
4 9015704 02 Cable, 4mm² 25
5 9015704 03 Cable, 4mm² 25
6 9008383 06 Cable, 2,5mm² PE 5
7 9008383 12 Cable, 25mm² PE 1
8 9008383 13 Cable, 6mm² PE 2
9 9008383 08 Cable, 1,5mm² 6
11 9008387 01 Cable 150
12 9008693 01 Cable, 2x2x0,5mm² 6
15 9004439 01 Cable 1
16 9015692 01 Cable, 1,5mm² 65
17 9015704 04 Cable, 4mm² PE 25
18 9008383 16 Cable, 16mm² 3
40 Book No. 9051945 02 Rev. 1

2377A
Book No. 9051945 02 Rev. 1 41


9012185-
Quantity
3 582212 130 Support, L=95,5 2
4 582212 132 Sealable cover profile 2
7 582212 185 Terminal 10
8 582212 15 PE/SC Bar 1 96mm
9 582212 133 Cover profile (AP-3) L=1m 1 87mm
10 582212 137 Sc clamp SK 20 1
11 582212 136 Sc clamp SK 14 1
42 Book No. 9051945 02 Rev. 1

2907A
Book No. 9051945 02 Rev. 1 43

4 Remote control panel (optional)

9012055-
Quantity
1 9014979 01 Top plate 1
3 221711 16 Screw 8
3.1 9016593 01 Spacer 8
4 9017691 03 HMI Panel 15" 1
6 223101 47 Washer 3
7 221851 05 Cap nut 3
8 592005 14 DIN-rail, 35x15 1
9 223101 47 Washer 2
10 221891 04 Lock nut 2
12 582212 95 Terminal, PIT 2,5 TWIN 4
12.1 582212 03 Plug In Bridge 1
13 582212 96 Terminal, PIT 2,5 TWIN-PE 1
14 582212 04 End plate 1
15 582212 147 Patch panel 1
16 582212 155 Socket with USB 1
18 9011552 01 Buzzer 1
20 591103 72 Pushbutton Black 1
20.1 591103 92 Cover 1
22 9009760 01 Relay, D-sub 1
22.1 582212 214 D-SUB gender changer 1
24 9011960 01 Bracket 1
25 223101 47 Washer 2
26 221891 04 Lock nut 2
28 594009 06 Screw 2
29 223101 47 Washer 2
30 221891 04 Lock nut 2
32 595728 02 Switch 1
34 587276 02 Washer 2
35 70560 Washer 2
37 9015557 80 Wire set 1
38 9011943 80 Cover 1 See page 46
39 582212 215 Connector 1
44 Book No. 9051945 02 Rev. 1

4 Remote control panel (optional)
2875A
Book No. 9051945 02 Rev. 1 45

4.1 Cover
9011943-
Quantity
1 9011944 01 Cover 1
2 594488 01 Washer 4
3 581688 01 Bracket 4
4 221711 16 Screw 8
5 223101 47 Washer 8
6 221891 04 Lock nut 8
7 589569 79 Cable Gland - M25 2
8 589569 35 Counter nut M25 2
9 589569 48 Cable Gland - M16 2
10 589569 33 Counter nut M16 2
11 587276 02 Washer 2
12 70560 Washer 2
46 Book No. 9051945 02 Rev. 1

4.1 Cover 4 Remote control panel (optional)
2883A
Book No. 9051945 02 Rev. 1 47

5 Log box (optional)

9002245-
Quantity
1 582212 05 End stop 9
3 582212 123 Power terminal block, 1
4 582212 124 Circuit breaker 2
5 582212 125 Power supply unit 1
9 582212 88 PIT 2,5 3
10 582212 89 D-ST2,5 1
12 591103 56 Over current prot. Relay 1
15 594781 01 Distance 2
18 9002305 03 Cable seal 1
19 9002362 80 Relay module 4 See page 18
24 594009 03 Screw 8
29 9003490 01 Bracket set 1
30 9038504 02 Limit value switch 12
31 582212 147 Patch panel 1
33 593950 20 Marking, Log box 1
48 Book No. 9051945 02 Rev. 1

5 Log box (optional)
3021A
Book No. 9051945 02 Rev. 1 49

6 UV Reactor EN
9006979-
Quantity
1 9006978 81 Reactor module EN 1 See page 54
2 9011093 80 Junction box Ex 1 Valves, signals & feed back
See page 56
3 9011097 80 Junction box Ex 1 Lamp cables
See page 58
7 9008373 02 Sensor Ex 1
8 9014967 69 Valve, EN DN350 1 V201-19
See page 60
8.1 9014967 69 Valve, EN DN350 1 V201-20
See page 60
12 9006325 02 Thermometer, resistance 1 TT201-33
13 9006324 02 Temperature, switch 1 TS201-60
14 558663 04 Gasket washer 2
15 595592 02 Vibration limit switch 1 LS201-29
15.2 595592 02 Vibration limit switch 1 LS201-30
16 9010648 92 Cable set EX 1 Valves, sensors & feed back
16A 9009120 02 Cable 1 marked: GS201-19
16B 9009120 02 Cable 1 marked: GS201-20
16C 9009120 02 Cable 1 marked: LS201-29
16D 595989 07 Cable, valves
16E 9009120 04 Cable, sensors
20 595936 80 Valve V320-4, V321-2, V404-36 1 V320-4
See page 62
20.1 595936 80 Valve V320-4, V321-2, V404-36 1 V321-2
See page 62
20.2 595936 80 Valve V320-4, V321-2, V404-36 1 V404-36
See page 62
23 9006822 01 Relief valve, 6 bar 1 RV201-23
24 597049 01 Coupling, elbow 90 1
25 594707 02 Pipe 1
26 581534 01 Distributor 1
30 552801 50 Push-on connector 5
37 595272 01 Tube, 6x1 mm 4
42 221711 23 Screw 16
45 221041 02 Screw 16
46 223101 61 Washer 24
47 221036 01 Screw 4
48 223101 33 Washer 16
50 221803 27 Nut 1
51 2210296 02 Screw 2
52 223101 31 Washer 4
53 9003662 01 Plate 1
54 9004638 01 Clamp 1
55 2210296 02 Screw 2
56 223101 31 Washer 4
60 9003672 01 Upper bracket 2
61 67141 Screw 12
63 596103 01 Screw 4
64 526336 04 Nipple 1
65A 9004889 01 Lifting bracket 1
65B 556465 01 Label 1
66 221041 03 Screw 4
67 221803 29 Nut 4
68 67141 Screw 8
70 597044 03 Cable 2
71 597044 04 Cable 1
72 9009416 01 Cable rail 2
73 221031 21 Screw 8
74 223101 32 Washer 12
50 Book No. 9051945 02 Rev. 1

6 UV Reactor EN
2720A
Book No. 9051945 02 Rev. 1 51


9006979-
Quantity
75 221803 28 Nut 4
78 9010633 01 Screw, hexagon socket 2
Z 9009521 80 Lamp, spare set Includes lamp and O rings
Z0.1 594645 82 Quartz sleeve set Includes quartz sleeve and O rings
52 Book No. 9051945 02 Rev. 1

6 UV Reactor EN
2720A
Book No. 9051945 02 Rev. 1 53

6.1 Reactor module EN

9006978-
Quantity
2 9007889 01 Adaptor 32 EX Scheduled
3 9004958 01 O-ring, 40,94x2,62 32
4 221711 09 Screw 288 Vaxed
5 9007938 01 Glass socket 32 EX Scheduled
6 9032600 01 O-ring 32
7 595981 01 O-ring, 35,7x3,5 32
8 9004528 01 O-ring, 39,4x3,1 32
9 9006848 02 Bush 32
10 579380 01 O-ring, 15,1x2,7 32
11 9007943 01 Cap 32 EX Scheduled
12 221706 30 Hexagon socket head screw 32
12 594648 01 Screw, M5x6 32
13 9000738 02 Quartz sleeve 16
15 66169 Drive screw 8
54 Book No. 9051945 02 Rev. 1

6.1 Reactor module EN 6 UV Reactor EN
2781A
Book No. 9051945 02 Rev. 1 55

6.2 Junction box Ex

9011093-
Quantity
1 9011093 01 Junction box Ex 1
3 582212 217 Terminal UT4-BU 20
4 582212 128 Terminal block PE 12
6 582212 140 End cover 3
7 582212 220 Plug in bridge FBS 20-6 R 2 Cut 12+3
8 595928 28 Cable gland, Ex i M16x1,5 7
9 595928 27 Cable gland, Ex e M16x1,5 5
10 589569 33 Counter nut M16 12
11 595928 21 Cable gland, Ex i, M32x1,5 2
12 595928 20 Cable gland, Ex e, M32x1,5 1
13 589569 66 Counter nut EMC Brush M32 1
14 9011099 01 Condensation outlet Ex 1
15 589569 35 Counter nut M25 1
18 9016071 01 Signal lamp, Ex e 2
19 223101 47 Washer 4
20 221851 05 Cap nut 4
21 589569 13 Counter nut M32 2
22 9042921 01 Gasket 3
22.1 9042921 02 Gasket 12
56 Book No. 9051945 02 Rev. 1

6.2 Junction box Ex 6 UV Reactor EN
2863A
Book No. 9051945 02 Rev. 1 57

6.3 Junction box Ex

9011097-
Quantity
1 9011097 01 Junction box Ex 1
4 582212 140 End cover 2
5 582212 128 Terminal block PE 4
6 582212 218 Plug in bridge FBS 4-6 RD 1
12 589569 66 Counter nut EMC Brush M32 10
13 9011099 01 Condensation outlet Ex 1
14 589569 35 Counter nut M25 1
15 9042921 01 Gasket 10
58 Book No. 9051945 02 Rev. 1

6.3 Junction box Ex 6 UV Reactor EN
2914A
Book No. 9051945 02 Rev. 1 59

6.4 Valve, EN DN350

9014967-
Quantity
1 9039016 11 Valve, DN350 1 Vulcanized Liner
1 9040965 70 Valve, DN350 1 Loose Liner
1A 9007167 10 Valve, DN350 1
1B 9007197 01 Gasket
2 9040972 85 Air actuator, AT 451U 1
2 9040973 85 Air actuator, VT 160 1
2A 9007166 06 Air actuator, AT 451U 1
2A 9040493 06 Air actuator, VT 160 1
2B 9041119 06 Maintenance kit,VT 160
2B 9041128 06 Maintenance kit, AT 451U
3 595704 01 Pilot valve 1
4 595706 02 Coil, Ex 1
5 9009153 01 Throttle valve, 1/4 2
8 9015180 01 Inductive sensor, Ex 1
26 595710 01 Air filter 1
27 9015525 03 Indicator cap 1
60 Book No. 9051945 02 Rev. 1

6.4 Valve, EN DN350 6 UV Reactor EN
2909A
Book No. 9051945 02 Rev. 1 61

6.5 Valve V320-4, V321-2, V404-36

595936-
Quantity
1 590037 01 Valve, DN32 1
2 9040972 89 Air actuator, AT 101U 1
2 9040973 89 Air actuator, VT 065 S08 1
2A 9040708 04 Air actuator, VT065 S08 1
2B 9041119 10 Maintenance kit, VT065 S08
4 595706 02 Coil, Ex 1
5 595710 01 Air filter 1
6 9009153 01 Throttle valve, 1/4 2
62 Book No. 9051945 02 Rev. 1

6.5 Valve V320-4, V321-2, V404-36 6 UV Reactor EN
2491A
Book No. 9051945 02 Rev. 1 63

7 Filter, ACB-9120-500 EX
9025132-
Quantity
1 9023662 60 Filter, ACB-9120-500 1 See page 68
2 591090 04 Flange 1 1/4" 1
3 526337 08 Reducing hexagon nipple 1
5 221711 07 Screw 2
6 9024168 01 Elbow union 2
8 9047526 01 Needle valve 1/4" 2
9 595781 02 Press. transmitter Ex 2
13 526336 04 Nipple 5
14 9006822 03 Relief valve, 10 bar 1
15 561094 06 Straight coupling 1
16 9019487 02 Tube 1
18 590667 44 V571-2 1
19 9041765 83 Gear motor 1
19AA 9041782 02 Motor, Ex 1
19B 9041791 04 Gear 1
19C 9041792 04 Shaft key, 8x7x45 1
19D 9041792 01 Shaft key, 10x8x50 1
19E 9041793 04 Shaft 1
19F 9041794 02 Washer 1
19G 221036 01 Screw 4
19H 221046 02 Screw 1
20.1 221803 22 Nut 4
22 9024155 01 Bracket 1
23 7007238 01 Screw 4
24 9011979 80 Junction box, Ex 1 See page 70
24.1 595928 20 Cable gland, Ex e, M32x1,5 1
24.2 595928 06 Cable gland, Ex e, M16x1,5 3
25 221711 25 Screw 4
25.1 223101 32 Washer 4
25.2 221803 28 Nut 4
26 9026076 01 Cable bracket 1
27 221711 07 Screw 2
28 223101 32 Washer 2
29 9026073 01 Bracket 1
30 221711 07 Screw 2
31 221711 13 Screw 1
32 223101 32 Washer 3
33 587276 01 Washer 1
34 9025165 03 Cable 1
42 9039248 80 Release valve automatic, Ex 1 V571-2
See page 72
43 552801 40 Push-in connector 1
44 1779813 03 Valve, 1/2" AISI 316 1 V571-4
45 9029394 01 Union, conical sealing 1
46 569035 05 Flexible pipe, PA12, 8/6 1 4m
47 544465 06 Locking liquid 1 50 ml
48 526345 04 Elbow 2
49 526344 04 T-piece 1
50 590667 49 V571-4 1
Z 9039364 80 Filter deaeration kit Ex
ZA 526336 04 Nipple 4
ZB 526344 04 T-piece 1
ZC 526345 04 Elbow 2
ZD 9029394 01 Union, conical sealing 1
ZE 590667 44 V571-2 1
ZF 595558 01 Wire 2
ZG 9039248 80 Release valve automatic, Ex 1 V571-2
See page 72
64 Book No. 9051945 02 Rev. 1

3032A
Book No. 9051945 02 Rev. 1 65


9025132-
Quantity
ZH 552801 40 Push-in connector 1
ZI 569035 05 Flexible pipe, PA12, 8/6 1 2m
ZJ 544465 06 Locking liquid 1 50ml
ZK 1779813 03 Valve, 1/2" AISI 316 1 V571-4
ZL 590667 49 V571-4 1
66 Book No. 9051945 02 Rev. 1

3032A
Book No. 9051945 02 Rev. 1 67

7.1 Filter, ACB-9120-500

9023662-
Quantity
4 9024205 42 Bolt 4
6 9011970 35 Bearing 1
7 9011972 54 Gasket 2
7.1 9011973 37 Bushing 1
8 9024206 26 Plug 2
9 9011974 53 Filter cover 1
10 9024205 45 Bolt 24
11 9011973 40 Bushing 1
12 9024205 48 Bolt 4
13 9011972 57 Gasket 1
15 9011975 11 Filter element 1
16 9011972 60 Nozzle 1
17 9011972 63 Gasket 1
18 9011973 43 Bushing 1
19 9024206 29 Plug 3
20 9011972 66 Gasket 1
30 9024207 10 Nozzle support 1
31 9024205 51 Bolt 4
32 9011972 69 Gasket 1
33 9011974 56 Base frame 1
34 9024205 54 Bolt 4
36 9011970 38 Grease fitting 1
40 9024208 10 Ring spear 1
41 9011970 41 Bearing flange 1
42 9011970 44 Bearing flange 1
44 9024210 10 Lifting lug 2
70 9011912 15 Identification plate 1
77 9011973 46 Bushing 1
80 9011978 11 Prefilter 1
87 9024206 32 Plug 6
91 9011974 59 Upper filter body 1
92 9011974 62 Bottom filter body 1
93 9024205 57 Bolt 24
94 9011972 72 Gasket 1
Z 9011963 92 Maintenance kit Yearly maintenance
68 Book No. 9051945 02 Rev. 1

7.1 Filter, ACB-9120-500 7 Filter, ACB-9120-500 EX
3045A
Book No. 9051945 02 Rev. 1 69

7.2 Junction box, Ex

9011979-
Quantity
2 581803 46 End plate EW 35 2
3 581803 11 Terminal WDU 2,5mm² 13
4 581803 08 Terminal PE 2,5mm2 3
5 581803 34 Terminal Endplate WAP 2,5 1
70 Book No. 9051945 02 Rev. 1

7.2 Junction box, Ex 7 Filter, ACB-9120-500 EX
3113A
Book No. 9051945 02 Rev. 1 71

7.3 Release valve automatic, Ex

9039248-
Quantity
1 9039248 01 Check valve 1
2 9039248 02 O-ring, small 1
3 9039248 03 Clamping stem 1
4 9039248 04 Rolling seal 1
5 9039248 05 Float 1
6 9039248 06 Body 1
7 9039248 07 Casing 1
8 9039248 08 O-ring 1
9 9039248 09 Base 1
10 9039248 10 Strainer 1
72 Book No. 9051945 02 Rev. 1

7.3 Release valve automatic, Ex 7 Filter, ACB-9120-500 EX
3284A
Book No. 9051945 02 Rev. 1 73

8 Backflush pump Ex (optional)

9029081-
Quantity
1 9029083 83 Centrifugal pump EX 1
1A 9029082 04 Centrifugal pump Ex 1
1B 9019944 01 Centrifugal pump spare pa
2 9023099 63 Valve EX, EN DN65 1
5 595558 01 Wire 2
6 2210463 09 Screw 8
7 223101 37 Washer 16
8 221803 40 Nut 8
9 2210463 03 Screw 4
10 223101 37 Washer 4
11 1765908 08 Gasket 1
12 9029467 01 Elbow adaptor, 65 1
13 2210463 03 Screw 4
14 223101 37 Washer 4
74 Book No. 9051945 02 Rev. 1

8 Backflush pump Ex (optional)
3076A
Book No. 9051945 02 Rev. 1 75

9 Valve V201-3, V201-9

9007171-
Quantity
1 9039016 14 Valve, DN/A500 1 Vulcanized Liner
1A 9007167 13 Valve, DN500 1
1B 9007197 02 Gasket
2 9040931 87 Air actuator, AT 601U 1
2 9040970 87 air actuator, VT 210 1
2A 9040973 87 Air actuator, VT 210 1
2AA 9007166 08 Air actuator, AT 601U 1
2AA 9040493 08 Air actuator, VT 210 1
2AB 9041119 08 Maintenance kit,VT 210
2AB 9041128 08 Maintenance kit, AT 601U
2B 587927 10 Locking device, AL79 601 1
2B 9040703 04 Locking device 1
4 595706 02 Coil, Ex 1
5 9009153 01 Throttle valve, 1/4 2
7 9007196 03 Bracket 1
8 9007189 01 Switch box, Ex 1
26 595710 01 Air filter 1
76 Book No. 9051945 02 Rev. 1

9 Valve V201-3, V201-9
2732A
Book No. 9051945 02 Rev. 1 77

10 Valve V201-32 and V403-35

9007173-
Ref Part No Description -72 -62 Notes
Quantity
1 9039016 14 Valve, DN/A500 1 Vulcanized Liner
1A 9007167 03 Valve, DN80 1
1A 9007167 13 Valve, DN500 1
1B 9007184 02 Insulate plate
1B 9007197 02 Gasket
2 9040972 80 Air actuator, AT 101U 1
2 9040972 87 Air actuator, AT 601U 1
2 9040973 80 Air actuator, VT 065 1
2 9040973 87 Air actuator, VT 210 1
2A 9040493 01 Air actuator, VT 065 1
2A 9040493 08 Air actuator, VT 210 1
3 595704 01 Pilot valve 1 1
4 595706 02 Coil, Ex 1 1
5 9009153 01 Throttle valve, 1/4 2 2
7 9007196 01 Bracket 1
7 9007196 03 Bracket 1
8 9007189 01 Switch box, Ex 1 1
26 595710 01 Air filter 1 1
78 Book No. 9051945 02 Rev. 1

10 Valve V201-32 and V403-35
2736A
Book No. 9051945 02 Rev. 1 79

11 Control valve V201-8

9007175-
Quantity
1A 9007167 11 Valve, DN400 1
1B 9007194 01 Bracket 1
1C 9007199 01 Coupling 1
1D 9007197 02 Gasket
2 9040931 86 Air actuator complete 1
2 9040970 86 Air actuator, VT190 1
2A 9040972 86 Air actuator, AT501U 1
2A 9040973 86 Air actuator, VT 190 1
2AA 9007166 07 Air actuator, AT 501U 1
2AA 9040493 07 Air actuator, VT 190 1
2AB 9041119 07 Maintenance kit,VT 190
2AB 9041128 07 Maintenance kit, AT 501U
2B 587927 08 Locking device, AL79 501 1
2B 9040703 03 Locking device 1
7 9007196 02 Bracket 1
8 9007189 01 Switch box, Ex 1
9 9034058 80 Driver 1
10 9007195 01 Positioner, Ex 1
11 9007188 01 Doppler 1
16 569035 05 Flexible pipe, PA12, 8/6 1
25 9007196 01 Bracket 2
27 9007200 01 Manifold 1
28 9007201 01 Filter 1
29 571697 01 O-ring, small 1
30 523127 01 Hexagon nipple 1
31 592304 02 Plug, 1/4 1
80 Book No. 9051945 02 Rev. 1

11 Control valve V201-8
2734A
Book No. 9051945 02 Rev. 1 81

12 Flow transmitter Ex, EN500

9037342-
Quantity
1 9040729 23 Flow transmitter, Ex, 500 1
Z 9041015 01 Transmitter + display, Ex
Z0.1 9041015 02 Display, Ex
Z0.2 9041015 03 Memory card T-DAT, Ex
Z0.3 9041015 04 Module carrier, Ex
82 Book No. 9051945 02 Rev. 1

12 Flow transmitter Ex, EN500
3195A
Book No. 9051945 02 Rev. 1 83

13 CIP module, Ex
*=On request only, contact your local Alfa Laval representative

9012480-
Ref Part No Description -80* Notes
Quantity
1 9003450 51 Frame complete, EX 1
2 596313 01 Tank, Ex 1
3 9012420 80 Pump, Ex 2 See page 88
4 9002825 81 Valve, Ex 7 See page 90
5 9003730 02 Valve housing, EX 3
6 9002915 81 Check valve, EX 2 Piping extensions and flanges are not
included.
7 9003732 01 O-ring 6
8 590313 01 Valve, angle seat 1
9 590476 01 Nipple, ISO-R 3/4-1/2 1
10 9005046 01 Backflow preventer 1
11 589526 07 U-bolt clamp, c-c 56,5 1
12 526350 06 Plug 1
13 569035 01 Flexible pipe, PA12, 6/4 1
14 569035 05 Flexible pipe, PA12, 8/6 1
15 596143 80 Valve block 1 See page 92
16 9004479 81 Filter regulator 1 See page 94
18 9003514 01 Speed controller 2
19 9004517 01 Reducer 1
20 9002962 02 Pipe #1, EX 1
21 9002963 02 Pipe #2, EX 1
22 9004237 02 Pipe #3, EX 1
23 9003935 02 Pipe #4, EX 2
24 9014747 02 Pipe #5, EX 1
25 9014748 02 Pipe #6, EX 1
26 9002586 02 Pipe #7, EX 2
27 9003570 02 Pipe #8, EX 4
28 9003949 02 Pipe #9, EX 1
29 9002589 02 Pipe #10, EX 1
30 9003792 02 Pipe #11, EX 2
31 9002591 02 Pipe #12, EX 1
32 9003837 02 Pipe #13, EX 2
33 9004247 02 Pipe #14, EX 1
34 9002592 02 Pipe #15, EX 1
35 9003851 02 Pipe #16, EX 1
36 9003853 02 Pipe #17, EX 1
37 9003854 02 Pipe #18, EX 2
38 9003863 02 Pipe #19, EX 1
39 9003886 02 Pipe #20 EX 1
40 9003888 02 Pipe #21, EX 1
42 9015312 01 Hose 1
43 9015221 80 PE cable kit 1
44 592665 01 Hose, 25 1
45 9003574 01 O-ring 6
46 9005743 01 Pipe clamp 5
47 599223 03 Hose clamp 38-50 10
48 599223 02 Hose clamp 32-44 3
49 592676 05 Insulation sheet, 10mm 4
50 592676 07 Insulation sheet, 5mm 7
51 592790 01 Insulation sheet 1
52 558710 01 Air Hose Nipple 1
84 Book No. 9051945 02 Rev. 1

13 CIP module, Ex
2924A
Book No. 9051945 02 Rev. 1 85

*=On request only, contact your local Alfa Laval representative

9012480-
Ref Part No Description -80* Notes
Quantity
53 221803 02 Nut 12
54 221711 17 Screw 6
55 221701 01 Screw 8
56 587276 01 Washer 12
57 221711 16 Screw 18
58 223101 47 Washer 30
59 587276 02 Washer 5
60 27345 Nut, M8 16
61 70560 Washer 14
62 9005147 02 Pipe #22 1
63 552801 50 Push-on connector 7
64 221040 53 Screw 5
65 590539 03 Clip list 1
66 548152 03 Washer 5
67 9014736 02 Coupling 1
68 580758 06 Push-In Fittings 2
69 597118 01 Mounting strip 1
70 221716 02 Screw 1 EX
72 9012412 01 Clamp 31
73 9012412 02 Clamp 13
74 9015231 80 Junction box, EX 1
75 221706 06 Screw 4
76 596140 81 Valve block, Ex 2 See page 96
77 596287 01 Sheet 1
78 221701 26 Screw 2
Z 596313 02 Tank screw cap
86 Book No. 9051945 02 Rev. 1

13 CIP module, Ex
2924A
Book No. 9051945 02 Rev. 1 87

13.1 Pump, Ex
9012420-
Quantity
1 9012420 01 Pump, EX 1
Z 9004587 80 Spare part set Incl. O-rings, diaphragm, ball, muffler
indicated in dwg.
ZA 9004576 01 O-ring set 4
ZB 9004579 01 Diaphragm 2
ZC 9004580 01 Ball 4
ZD 1766702 05 Muffler 1
ZE 9004581 01 O-ring, valve seat 4
Z0.1 9004588 80 Spare part set Incl. air valve, sealings and O-rings,
indicated in dwg.
88 Book No. 9051945 02 Rev. 1

13.1 Pump, Ex 13 CIP module, Ex
2925A
Book No. 9051945 02 Rev. 1 89

13.2 Valve, Ex
9002825-
Quantity
1 9002825 02 Valve, EX 1
Z 9003574 01 O-ring
90 Book No. 9051945 02 Rev. 1

13.2 Valve, Ex 13 CIP module, Ex
2609A
Book No. 9051945 02 Rev. 1 91

13.3 Valve block

596143-
Quantity
1 596144 01 Block 1
3 596142 01 Coil, Ex 7
4 583011 01 Filter 7
5 596145 01 Blind plate 1
6 596465 02 Push-on connector, 8-1/8 1
8 583012 04 Throttle valve, 1/8 1
92 Book No. 9051945 02 Rev. 1

13.3 Valve block 13 CIP module, Ex
2765A
Book No. 9051945 02 Rev. 1 93

13.4 Filter regulator

9004479-
Quantity
1 9004479 01 Valve, shutoff 1
2 9004479 02 Filter regulator 1
3 9004479 03 Bracket 1
6 9004479 06 Rear plate 1
8 9014877 01 Manifold 1
Z 9004479 08 Filter element Replace every 2 years
94 Book No. 9051945 02 Rev. 1

13.4 Filter regulator 13 CIP module, Ex
2766A
Book No. 9051945 02 Rev. 1 95

13.5 Valve block, Ex

596140-
Quantity
2 596142 01 Coil, Ex 1
5 592304 01 Plug 1
96 Book No. 9051945 02 Rev. 1

13.5 Valve block, Ex 13 CIP module, Ex
2742A
Book No. 9051945 02 Rev. 1 97

14 Booster pump, P401-1 (optional)

9037496-
Quantity
1A 9037499 01 Centrifugal pump 1
1BA 9019944 02 Shaft seal 1
1BB 9038536 02 O-Ring Kit 1
1CA 9039236 02 Pump stack 1
1CB 9038538 06 Motor Bearings 1
3 595558 01 Wire 1
4 589569 78 Cable Gland - M20 1
98 Book No. 9051945 02 Rev. 1

14 Booster pump, P401-1 (optional)
3199A
Book No. 9051945 02 Rev. 1 99

15 Booster pump Start-up flow P403-1 (optional)

9029086-
Quantity
1A 9029087 03 Centrifugal pump Ex 1
1B 9019944 01 Centrifugal pump spare pa
3 595558 01 Wire 1
4 2210463 23 Screw 4
5 223101 37 Washer 4
6 1765908 07 Gasket 1
7 9019322 01 Adaptor plate, A65-DN65 1
8 2210463 23 Screw 4
9 223101 37 Washer 4
10 1765908 03 Gasket 1
11 9019321 01 Adaptor plate, A50-DN50 1
100 Book No. 9051945 02 Rev. 1

15 Booster pump Start-up flow P403-1 (optional)
3079A
Book No. 9051945 02 Rev. 1 101

16 Air filter regulator

9018092-
Quantity
1 9018092 01 Filter regulator 1
2 9018092 02 Pressure relief valve 1
3 9018092 03 Bracket 1
Z 9018092 99 Filter element Replace every 2 years
102 Book No. 9051945 02 Rev. 1

16 Air filter regulator
3039A
Book No. 9051945 02 Rev. 1 103

17 Booster pump P201-1, Ex (optional)

9039791-
Quantity
1 9038438 85 Booster pump, Ex 1 See page 106
2 9038554 86 VFD 1 See page 108
3 9038756 80 Junction box 1 See page 110
4 9008007 84 Press. mon. device Ex 1 See page 112
104 Book No. 9051945 02 Rev. 1

17 Booster pump P201-1, Ex (optional)
3197A
Book No. 9051945 02 Rev. 1 105

17.1 Booster pump, Ex

9038438-
Quantity
1 9039957 80 Booster pump, Ex 1 2000m³/h, DN
1A 9039958 01 Booster pump, Ex, 2000m³/h EN 1 2000m³/h, DN
1B 9038873 05 O-ring
1C 9038873 12 O-ring
1D 9038873 13 Mechanical seal
1E 9038873 17 Anode
1F 9038873 20 O-ring
1G 9038873 21 O-ring
1H 9038873 22 O-ring
1I 9038873 25 Tool kit
2 9018672 40 P201-1 1
3 9018672 41 M201-1 1
4 9018672 42 LS662-1 1
5 595558 01 Wire 3
106 Book No. 9051945 02 Rev. 1

17.1 Booster pump, Ex 17 Booster pump P201-1, Ex (optional)
3180A
Book No. 9051945 02 Rev. 1 107

17.2 VFD
9038554-
Quantity
1 9042446 01 VFD, R9 1
3 593950 18 Marking, VFD 1
Z0.1 9038547 02 Fan Internal fan
Z0.2 9038547 09 Fan Main cooling fan kit
Z0.3 9040657 01 Control panel
Z0.4 9040658 01 Options kit
Z0.5 9040659 04 Memory Unit kit
Z0.6 9038547 04 Fan Additional internal fan
Z0.7 9040673 01 Battery Remote control
108 Book No. 9051945 02 Rev. 1

17.2 VFD 17 Booster pump P201-1, Ex (optional)
3181A
Book No. 9051945 02 Rev. 1 109

17.3 Junction box

9038756-
Quantity
1 9038757 01 Enclosure 1
2 589569 05 Cable Gland M40 1
2.1 589569 73 Cable gland sealing M32 1
4 595928 04 Cable gland, Ex i, M20x1,5 1
8 582212 104 Terminal PITTB 2,5 6
9 9019186 07 Safety relays, PSR-MC30 1
10 582212 177 IS 1ch input, Ex 1
11 582212 03 Plug In Bridge 2
12 9038855 01 Bracket set 1
15 593950 19 Marking, VFD Junction box 1
110 Book No. 9051945 02 Rev. 1

17.3 Junction box 17 Booster pump P201-1, Ex (optional)
3182A
Book No. 9051945 02 Rev. 1 111

17.4 Press. mon. device Ex

9008007-
Quantity
1 9047526 02 Needle valve 1/2" 1
2 526336 04 Nipple 3
3 9006075 01 Manifold 1
4 595781 02 Press. transmitter Ex 1
5 543054 09 Pressure gauge 1
6 9006822 02 Relief valve, 8 bar 1
7 546600 02 Pipe union 1
8 544465 06 Locking liquid 1
9 595558 01 Wire 4
14 594431 01 Bracket 1
15 595712 80 Junction box 1
112 Book No. 9051945 02 Rev. 1

17.4 Press. mon. device Ex 17 Booster pump P201-1, Ex (optional)
2760A
Book No. 9051945 02 Rev. 1 113

18 Vacuum relief valve (VB201), DN80 (optional)

9041133-
Quantity
1 9040974 01 Vacuum relief valve, DN80 1
2 9018672 43 VB201 1
3 595558 01 Wire 1
Z 9041961 01 Cover assembly
Z0.1 9041965 01 O-ring
Z0.2 9041966 01 Float
114 Book No. 9051945 02 Rev. 1

3205A2
Book No. 9051945 02 Rev. 1 115


9041153-
Quantity
1 9040843 01 Vacuum relief valve, DN50 1
2 9018672 44 VB309 1
3 595558 01 Wire 1
Z 9041963 01 Cover assembly
Z0.1 9041965 03 O-ring
Z0.2 9041967 01 Float
Z0.3 9041968 01 Spring
116 Book No. 9051945 02 Rev. 1

3212A2
Book No. 9051945 02 Rev. 1 117

20 Agent X9, single

9041379-
Quantity
1 9045930 01 Enclosure 1
1A 9005699 53 Enclosure 380x600x210 1
2 9005699 55 Wall bracket 4pcs 1
3 9005699 06 Door stay 1
4 9006853 01 Fan 1
5 9005699 56 Filter 1
6 592001 01 Thermostat 1 (U1)
7 9037152 03 Gateway 1 (A1)
8 9036476 07 WLAN antenna 1 (A5)
9 9036476 04 Omni-directional antenna 1 (A4)
10 9036476 06 Network switch 8-port 1 (A3)
11 581803 45 Patch cable 0.5m 90° angl 1 (A3)
12 9037158 01 antenna cable 500mm 1 (A4)
13 9037158 01 antenna cable 500mm 1 (A5)
14 9036476 10 RJ45 Plug angled 7
16 583556 31 Cable channel 40x80 1
17 589945 44 Circuit breaker 6A/2P 1 (F1)
18 581803 56 Power supply 5A 1 (T1)
19 1764728 01 Label 1 (Warning electric shock)
20 582212 148 End stop (clip fix) 10
22 582212 13 End plate 2
23 582212 88 PIT 2,5 1
24 582212 97 Terminal, PIT 2,5, QUA 2
25 582212 32 End plate 1
26 589569 78 Cable Gland - M20 1
27 589569 34 Counter nut M20 1
29 589569 48 Cable Gland - M16 10
30 589569 33 Counter nut M16 10
32 593950 24 Marking, Connectivity cabinet 1
118 Book No. 9051945 02 Rev. 1

20 Agent X9, single
3226A2
Book No. 9051945 02 Rev. 1 119

21 Closed cooling unit, LDC

9033605-
Quantity
1 9033623 01 Frame plate 1
2A 9033604 01 Heat exchanger 1
2B 9033929 01 End plate gasket II
2C 9033929 02 Channel/end plate 1 gasket
2D 9033929 03 Foot
3 9037499 01 Centrifugal pump 1
3.1 589569 78 Cable Gland - M20 1
4 9022377 01 Expansion tank 1
5 9022378 01 Relief valve 1
6 1779813 04 Valve 1
7 9024168 03 Elbow union 2
11 9019586 08 Reduc. nipple, R-212 1 1/4x3/4 1
12 526336 05 Nipple 2
13 9022296 02 Hose 1
15 526338 05 Bushing 1
17 591090 03 Flange 2
18 1765908 01 Gasket 2
19 526336 06 Nipple 1
20 2245102 09 Hose clip 1
22 9033629 01 Sheet 1
23 589526 05 U-bolt clamp, c-c 35 1
24 589526 02 U-bolt clamp, c-c 56,5 1
25 221041 20 Screw 4
26 223101 61 Washer 8
27 221803 29 Nut 4
28 221046 07 Screw 4
29 223101 35 Washer 24
30 221803 22 Nut 12
31 221046 09 Screw 8
35 223101 33 Washer 2
36 221803 21 Nut 2
37 223101 61 Washer 2
38 221803 29 Nut 2
40 595558 01 Wire 4
Z 9019944 02 Shaft seal
120 Book No. 9051945 02 Rev. 1

21 Closed cooling unit, LDC
3140A
Book No. 9051945 02 Rev. 1 121

22 Transformer (optional)
9028515-
Quantity
1 9028514 01 Transformer 1
122 Book No. 9051945 02 Rev. 1

22 Transformer (optional)
3096A
Book No. 9051945 02 Rev. 1 123

23 Cross reference list
+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
1270001 23 84 221711 25 64 25 223101 32 64 28
1270001 8 74 221716 01 26 5 223101 32 64 32
1270001 64 40 221716 01 26 68 223101 33 120 35
1764728 01 118 19 221716 02 86 70 223101 33 50 48
1765908 01 120 18 221726 10 28 69 223101 35 120 29
1765908 03 100 10 221803 02 22 12 223101 37 74 7
1765908 07 100 6 221803 02 26 52 223101 37 74 10
1765908 08 74 11 221803 02 28 10 223101 37 74 14
1766702 05 88 ZD 221803 02 86 53 223101 37 100 5
1779813 03 64 44 221803 03 22 15 223101 37 100 9
1779813 03 65 ZK 221803 21 120 36 223101 41 28 58
1779813 04 120 6 221803 22 120 30 223101 47 22 3.1
2210296 02 50 51 221803 22 64 20.1 223101 47 22 11
2210296 02 50 55 221803 27 50 50 223101 47 22 51
221030 02 26 62 221803 28 51 75 223101 47 23 61
221030 10 22 3 221803 28 64 25.2 223101 47 26 7
221030 10 22 10 221803 29 120 27 223101 47 26 10
221030 10 26 45 221803 29 120 38 223101 47 26 16
221030 10 28 18 221803 29 50 67 223101 47 26 34
221030 10 28 21 221803 40 74 8 223101 47 26 44
221031 21 50 73 221851 05 26 35 223101 47 26 51
221035 51 28 4 221851 05 44 7 223101 47 26 63
221036 01 50 47 221851 05 56 20 223101 47 28 9
221036 01 64 19G 221891 01 22 7 223101 47 28 19
221040 53 86 64 221891 02 26 39 223101 47 28 22
221041 02 50 45 221891 02 28 59 223101 47 44 6
221041 03 50 66 221891 04 22 52 223101 47 44 9
221041 20 120 25 221891 04 23 62 223101 47 44 25
221046 02 64 19H 221891 04 26 8 223101 47 44 29
221046 07 120 28 221891 04 26 11 223101 47 46 5
221046 09 120 31 221891 04 26 17 223101 47 56 19
2210463 03 74 9 221891 04 26 64 223101 47 8 9
2210463 03 74 13 221891 04 44 10 223101 47 86 58
2210463 09 74 6 221891 04 44 26 223101 49 28 68
2210463 23 100 4 221891 04 44 30 223101 61 120 26
2210463 23 100 8 221891 04 46 6 223101 61 120 37
221701 01 86 55 221891 04 8 8 223101 61 50 46
221701 26 86 78 221891 05 23 68 223107 34 12 17
221706 06 86 75 221891 05 26 4 2245102 09 120 20
221706 30 54 12 221891 05 26 67 26556 12 4
221711 07 64 5 221891 05 44 36 27345 86 60
221711 07 64 27 221891 05 46 13 523127 01 80 30
221711 07 64 30 223101 03 22 6 523127 04 22 19
221711 09 54 4 223101 04 22 11.1 526336 04 50 64
221711 13 64 31 223101 16 26 40 526336 04 64 13
221711 16 44 3 223101 17 22 16 526336 04 64 ZA
221711 16 46 4 223101 31 50 52 526336 04 112 2
221711 16 86 57 223101 31 50 56 526336 05 120 12
221711 17 86 54 223101 32 50 74 526336 06 120 19
221711 23 50 42 223101 32 64 25.1 526337 02 64 7
124 Book No. 9051945 02 Rev. 1

Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
526337 07 120 16 580986 59 32 7 582212 129 56 5

526337 08 120 10 580986 59 14 8 582212 129 58 3
526337 08 64 3 580986 61 32 10 582212 130 36 2
526338 05 120 15 580986 62 32 3 582212 130 38 6
526344 04 64 49 580986 63 32 4 582212 130 42 3
526344 04 64 ZB 580986 64 32 1 582212 132 38 5
526345 04 64 48 580986 72 32 5 582212 132 42 4
526345 04 64 ZC 580986 72 14 14 582212 133 38 11
526350 06 84 12 580986 76 14 1.2 582212 133 42 9
543054 09 112 5 581534 01 50 26 582212 136 36 13
544465 06 64 47 581688 01 46 3 582212 136 42 11
544465 06 65 ZJ 581803 08 70 4 582212 137 38 9
544465 06 112 8 581803 11 70 3 582212 137 42 10
546600 02 112 7 581803 34 70 5 582212 13 22 42
548152 03 86 66 581803 43 22 29 582212 13 38 4
552801 02 80 13 581803 45 118 11 582212 13 8 12
552801 02 80 24 581803 46 70 2 582212 13 118 22
552801 40 64 43 581803 56 118 18 582212 140 56 6
552801 40 65 ZH 582212 02 16 6.2 582212 140 58 4
552801 50 50 30 582212 03 16 6.1 582212 146 22 46
552801 50 86 63 582212 03 34 5 582212 147 8 22
556465 01 50 65B 582212 03 44 12.1 582212 147 36 4
558663 04 50 14 582212 03 110 11 582212 147 44 15
558710 01 84 52 582212 04 36 6 582212 147 48 31
561094 06 64 15 582212 04 44 14 582212 148 22 34
569035 01 84 13 582212 05 48 1 582212 148 23 204A
569035 05 64 46 582212 102 16 5 582212 148 34 6
569035 05 65 ZI 582212 102 36 10 582212 148 36 1
569035 05 80 16 582212 102 42 6 582212 148 38 1
569035 05 84 14 582212 102 9 106 582212 148 42 1
571697 01 80 29 582212 102 110 7 582212 148 44 11
579380 01 54 10 582212 104 16 6 582212 148 44 31
580758 06 86 68 582212 104 16 10 582212 148 56 2
580986 06 14 9 582212 104 16 12 582212 148 58 2
580986 08 14 5 582212 104 36 11 582212 148 8 10
580986 16 32 11 582212 104 110 8 582212 148 110 5
580986 16 14 11 582212 119 18 1 582212 148 16 1
580986 17 32 2 582212 120 18 2 582212 148 118 20
580986 17 14 2 582212 121 18 3 582212 155 44 16
580986 19 32 12 582212 122 22 41 582212 155 8 56
580986 20 32 13 582212 122 38 3 582212 156 38 7
580986 20 14 12 582212 122 48 2 582212 157 38 10
580986 30 14 3 582212 122 8 11 582212 15 36 3
580986 32 14 7 582212 122 118 21 582212 15 8 38
580986 40 32 8 582212 123 8 32 582212 15 38 8
580986 40 14 10 582212 123 48 3 582212 15 42 8
580986 51 14 4 582212 124 48 4 582212 164 22 28
580986 53 32 9 582212 125 48 5 582212 165 22 30
580986 53 14 6 582212 128 56 4 582212 168 8 31
580986 55 14 13 582212 128 58 5 582212 172 18 Z
Book No. 9051945 02 Rev. 1 125

582212 175 23 204F 583556 19 26 19 591103 32 22 43

582212 176 9 108 583556 20 26 18 591103 37 8 59.1
582212 177 23 204E 583556 21 26 20 591103 40 23 57
582212 177 110 10 583556 31 118 16 591103 41 23 59
582212 178 23 204D 586056 07 26 22 591103 46 23 55
582212 179 23 204B 587276 01 64 33 591103 54 8 77
582212 180 23 204C 587276 01 86 56 591103 56 48 12
582212 182 22 45 587276 02 23 66 591103 60 8 78
582212 183 23 203 587276 02 26 3 591103 61 23 56
582212 184 23 202 587276 02 44 34 591103 62 23 Z
582212 185 42 7 587276 02 46 11 591103 64 22 37
582212 202 30 2 587276 02 86 59 591103 64 8 76.2
582212 203 30 3 587927 08 80 2B 591103 67 8 52
582212 204 30 4 587927 10 76 2B 591103 69 22 21
582212 205 30 5 589526 02 120 24 591103 70 22 24
582212 206 8 37 589526 05 120 23 591103 71 22 26
582212 214 44 22.1 589526 07 84 11 591103 71 8 50
582212 215 44 39 589569 05 110 2 591103 72 44 20
582212 217 56 3 589569 13 56 21 591103 82 23 200
582212 218 58 6 589569 33 46 10 591103 84 23 200.1
582212 220 56 7 589569 33 56 10 591103 84 8 19.2
582212 32 118 25 589569 33 118 30 591103 84 8 20.2
582212 63 16 7 589569 34 118 27 591103 86 22 35
582212 63 8 18 589569 35 46 8 591103 86 8 76
582212 63 34 3 589569 35 56 15 591103 87 22 26.1
582212 64 34 2 589569 35 58 14 591103 87 8 50.1
582212 65 16 13 589569 48 46 9 591103 88 22 26.2
582212 67 16 8 589569 48 118 29 591103 88 8 50.2
582212 67 8 17 589569 66 56 13 591103 89 22 26.3
582212 67 34 1 589569 66 58 12 591103 89 8 50.3
582212 71 8 17.1 589569 73 110 2.1 591103 91 22 44
582212 71 34 4 589569 78 120 3.1 591103 92 44 20.1
582212 88 48 9 589569 78 98 4 591103 93 8 52.1
582212 88 118 23 589569 78 118 26 591874 04 28 29
582212 89 48 10 589569 79 46 7 591874 06 28 30
582212 90 8 86 589945 44 118 17 591889 01 26 46
582212 91 8 23 590037 01 62 1 592001 01 118 6
582212 94 8 100 590313 01 84 8 592005 14 44 8
582212 95 36 7 590476 01 84 9 592005 15 26 13
582212 95 44 12 590539 03 86 65 592304 01 96 5
582212 96 36 8 590624 03 22 13 592304 02 80 31
582212 96 44 13 590667 44 64 18 592665 01 84 44
582212 97 118 24 590667 44 64 ZE 592676 05 84 49
582221 101 8 67 590667 49 64 50 592676 07 84 50
582221 90 22 31 590667 49 65 ZL 592790 01 84 51
582221 90 8 35 591090 03 120 17 593254 01 28 16
582221 90 48 11 591090 04 64 2 593254 01 12 20
583011 01 92 4 591103 03 23 58 593724 01 48 26
583012 04 92 8 591103 10 22 35.1 593724 02 48 25
583556 04 26 21 591103 10 8 76.3 593724 03 22 32
126 Book No. 9051945 02 Rev. 1

593778 01 12 10 595706 02 78 4 597330 01 9 Z

593779 01 12 11 595710 01 60 26 597331 01 23 Z0.3
593780 01 28 55 595710 01 62 5 597331 01 9 Z0.1
593780 01 12 15 595710 01 76 26 598323 02 30 1
593950 18 108 3 595710 01 78 26 598571 01 12 36
593950 19 110 15 595712 80 112 15 599223 02 84 48
593950 20 48 33 595728 02 44 32 599223 03 84 47
593950 24 118 32 595728 02 8 80 66169 54 15
593991 01 12 12 595781 02 64 9 67141 50 61
594009 02 26 41 595781 02 112 4 67141 50 68
594009 03 22 33 595928 04 110 4 7007238 01 64 23
594009 03 48 24 595928 06 64 24.2 70560 23 67
594009 04 22 5 595928 20 56 12 70560 26 66
594009 05 26 55 595928 20 58 7 70560 44 35
594009 06 23 201 595928 20 64 24.1 70560 46 12
594009 06 44 28 595928 21 56 11 70560 86 61
594431 01 112 14 595928 22 58 8 9000738 02 54 13
594488 01 46 2 595928 23 58 9 9002305 03 48 18
594645 82 51 Z0.1 595928 27 56 9 9002362 80 8 33
594648 01 54 12 595928 28 56 8 9002362 80 48 19
594707 02 50 25 595936 80 50 20 9002586 02 84 26
594728 01 22 8 595936 80 50 20.1 9002589 02 84 29
594781 01 48 15 595936 80 50 20.2 9002591 02 84 31
595272 01 50 37 595981 01 54 7 9002592 02 84 34
595361 02 8 63 595989 07 50 16D 9002825 02 90 1
595558 01 120 40 596019 07 23 204G 9002825 81 84 4
595558 01 22 18.2 596103 01 50 63 9002915 81 84 6
595558 01 64 ZF 596140 81 86 76 9002942 01 26 57
595558 01 74 5 596141 01 96 1 9002947 01 26 56
595558 01 98 3 596142 01 92 3 9002962 02 84 20
595558 01 100 3 596142 01 96 2 9002963 02 84 21
595558 01 106 5 596143 80 84 15 9003013 01 12 13
595558 01 112 9 596144 01 92 1 9003024 01 28 54A
595558 01 114 3 596145 01 92 5 9003024 02 12 14
595558 01 116 3 596146 01 92 2 9003030 01 26 50
595592 02 50 15 596287 01 86 77 9003031 01 28 64
595592 02 50 15.2 596313 01 84 2 9003075 01 28 15
595673 03 40 14 596313 02 86 Z 9003089 02 28 67
595673 03 8 82 596465 01 92 7 9003113 01 28 57
595673 04 44 23 596465 02 92 6 9003114 02 23 Z0.1
595673 04 44 33 596465 02 96 3 9003114 02 28 56
595673 04 48 32 596465 02 96 4 9003186 01 28 23
595673 04 8 82.1 597033 10 32 6 9003186 02 28 65
595704 01 60 3 597033 18 14 1.1 9003390 01 26 42
595704 01 62 3 597033 22 14 1 9003401 01 28 20
595704 01 76 3 597044 03 50 70 9003410 01 28 17
595704 01 78 3 597044 04 50 71 9003450 51 84 1
595706 02 60 4 597049 01 50 24 9003450 52 84 1
595706 02 62 4 597118 01 86 69 9003450 53 84 1
595706 02 76 4 597330 01 23 Z0.2 9003450 54 84 1
Book No. 9051945 02 Rev. 1 127

9003450 55 84 1 9004576 01 88 ZA 9007196 01 78 7

9003450 56 84 1 9004579 01 88 ZB 9007196 01 80 25
9004580 01 88 ZC 9007196 02 80 7
9003450 57 84 1
9003450 58 84 1 9004581 01 88 ZE 9007196 03 76 7
9003450 59 84 1 9004587 80 88 Z 9007196 03 78 7
9003450 60 84 1 9004588 80 88 Z0.1 9007197 01 60 1B
9003490 01 48 29 9004638 01 50 54 9007197 02 76 1B
9003514 01 84 18 9004889 01 50 65A 9007197 02 78 1B
9003565 02 26 15 9004958 01 54 3 9007197 02 80 1D
9003565 03 26 14 9005046 01 84 10 9007199 01 80 1C
9003570 02 84 27 9005147 02 86 62 9007200 01 80 27
9003574 01 84 45 9005494 04 22 54 9007201 01 80 28
9003574 01 90 Z 9005699 06 118 3 9007889 01 54 2
9003662 01 50 53 9005699 53 118 1A 9007938 01 54 5
9003672 01 50 60 9005699 55 118 2 9007943 01 54 11
9003730 02 84 5 9005699 56 118 5 9008007 84 104 4
9003732 01 84 7 9005743 01 84 46 9008373 02 50 7
9003792 02 84 30 9006075 01 112 3 9008383 01 40 1
9003837 02 84 32 9006316 01 26 43 9008383 02 40 2
9003851 02 84 35 9006322 01 26 61 9008383 06 40 6
9003853 02 84 36 9006324 02 50 13 9008383 08 40 9
9003854 02 84 37 9006325 02 50 12 9008383 12 40 7
9003863 02 84 38 9006677 01 22 50 9008383 13 40 8
9003886 02 84 39 9006822 01 50 23 9008383 16 40 18
9003888 02 84 40 9006822 02 112 6 9008387 01 40 11
9003935 02 84 23 9006822 03 64 14 9008401 01 22 17
9003949 02 84 28 9006848 02 54 9 9008403 80 22 17
9004211 01 22 2 9006851 01 8 2 9008407 01 22 18
9004212 01 26 37 9006852 01 8 3 9008424 01 28 66
9004213 01 26 38 9006853 01 8 61 9008693 01 40 12
9004214 01 22 9 9006853 01 118 4 9008903 05 28 3
9004237 02 84 22 9006854 01 8 62 9009120 02 50 16A
9004247 02 84 33 9006978 81 50 1 9009120 02 50 16B
9004254 01 22 18 9007166 01 78 2A 9009120 02 50 16C
9004299 04 8 16 9007166 06 60 2A 9009120 04 50 16E
9004299 04 22 39 9007166 07 80 2AA 9009153 01 60 5
9004303 02 22 14 9007166 08 76 2AA 9009153 01 62 6
9004313 82 22 53 9007166 08 78 2A 9009153 01 76 5
9004329 80 22 49 9007167 03 78 1A 9009153 01 78 5
9004426 01 22 20 9007167 10 60 1A 9009416 01 50 72
9004439 01 40 15 9007167 11 80 1A 9009521 80 51 Z
9004442 03 22 27 9007167 13 76 1A 9009760 01 44 22
9004479 01 94 1 9007167 13 78 1A 9010633 01 51 78
9004479 02 94 2 9007184 02 78 1B 9010648 92 50 16
9004479 03 94 3 9007188 01 80 11 9011093 01 56 1
9004479 06 94 6 9007189 01 76 8 9011093 80 50 2
9004479 08 94 Z 9007189 01 78 8 9011097 01 58 1
9004479 81 84 16 9007189 01 80 8 9011097 80 50 3
9004517 01 84 19 9007194 01 80 1B 9011099 01 56 14
9004528 01 54 8 9007195 01 80 10 9011099 01 58 13
128 Book No. 9051945 02 Rev. 1

9011552 01 44 18 9014582 01 23 208 9018672 41 106 3

9011552 01 8 54 9014585 01 26 53 9018672 42 106 4
9011912 15 68 70 9014640 01 28 5 9018672 43 114 2
9011943 80 44 38 9014642 01 28 6 9018672 44 116 2
9011944 01 46 1 9014704 80 22 48 9019135 03 8 13
9011951 80 26 1 9014707 01 8 15 9019135 03 8 14
9011952 80 22 1 9014707 01 22 38 9019138 01 8 13.1
9011953 80 20 1 9014732 01 28 52 9019138 01 8 14.1
9011960 01 44 24 9014735 01 28 53 9019138 04 8 19.1
9011963 92 68 Z 9014736 02 86 67 9019138 04 8 20.1
9011970 35 68 6 9014747 02 84 24 9019186 05 16 3
9011970 38 68 36 9014748 02 84 25 9019186 06 16 2
9011970 41 68 41 9014753 01 12 34 9019186 07 110 9
9011970 44 68 42 9014759 01 28 34 9019321 01 100 11
9011972 54 68 7 9014762 01 28 49 9019322 01 100 7
9011972 57 68 13 9014815 01 12 35 9019487 02 64 16
9011972 60 68 16 9014833 01 23 60 9019586 08 120 11
9011972 63 68 17 9014877 01 94 8 9019944 01 74 1B
9011972 66 68 20 9014967 69 50 8 9019944 01 100 1B
9011972 69 68 32 9014967 69 50 8.1 9019944 02 120 Z
9011972 72 68 94 9014979 01 44 1 9019944 02 98 1BA
9011973 37 68 7.1 9015117 01 12 40 9020930 04 62 2A
9011973 40 68 11 9015118 01 12 39 9022296 02 120 13
9011973 43 68 18 9015180 01 60 8 9022377 01 120 4
9011973 46 68 77 9015197 92 23 86 9022378 01 120 5
9011974 53 68 9 9015221 80 84 43 9023099 63 74 2
9011974 56 68 33 9015231 80 86 74 9023662 60 64 1
9011974 59 68 91 9015312 01 84 42 9024155 01 64 22
9011974 62 68 92 9015525 03 60 27 9024168 01 64 6
9011975 11 68 15 9015557 80 44 37 9024168 03 120 7
9011978 11 68 80 9015611 01 26 6 9024205 42 68 4
9011979 80 64 24 9015616 01 26 65 9024205 45 68 10
9012058 80 22 4 9015692 01 40 16 9024205 48 68 12
9012086 84 8 1 9015704 01 40 3 9024205 51 68 31
9012088 80 12 1 9015704 02 40 4 9024205 54 68 34
9012091 80 12 2 9015704 03 40 5 9024205 57 68 93
9012093 01 12 41 9015704 04 40 17 9024206 26 68 8
9012135 80 22 40 9016071 01 56 18 9024206 29 68 19
9012146 01 20 2 9016266 01 28 50 9024206 32 68 87
9012150 91 8 66 9016266 02 28 54 9024207 10 68 30
9012185 80 23 207 9016268 01 28 51 9024208 10 68 40
9012186 80 23 64 9016270 01 28 50.1 9024209 10 68 43
9012193 01 26 2 9016593 01 44 3.1 9024210 10 68 44
9012198 80 23 65 9017691 03 44 4 9025165 03 64 34
9012412 01 86 72 9017691 03 8 4 9025837 01 8 59
9012412 02 86 73 9018092 01 102 1 9025837 02 8 59.2
9012420 01 88 1 9018092 02 102 2 9026073 01 64 29
9012420 80 84 3 9018092 03 102 3 9026076 01 64 26
9014546 01 22 47 9018092 99 102 Z 9028514 01 122 1
9014554 01 26 54 9018672 40 106 2 9029082 04 74 1A
Book No. 9051945 02 Rev. 1 129

9029083 83 74 1 9039248 02 72 2 9041015 01 82 Z

9029087 03 100 1A 9039248 03 72 3 9041015 02 82 Z0.1
9029394 01 64 45 9039248 04 72 4 9041015 03 82 Z0.2
9029394 01 64 ZD 9039248 05 72 5 9041015 04 82 Z0.3
9029467 01 74 12 9039248 06 72 6 9041119 01 78 2B
9032600 01 54 6 9039248 07 72 7 9041119 06 60 2B
9033604 01 120 2A 9039248 08 72 8 9041119 07 80 2AB
9033623 01 120 1 9039248 09 72 9 9041119 08 76 2AB
9033629 01 120 22 9039248 10 72 10 9041119 08 78 2B
9033929 01 120 2B 9039248 80 64 42 9041119 10 62 2B
9033929 02 120 2C 9039248 80 64 ZG 9041128 01 62 2B
9033929 03 120 2D 9039364 80 64 Z 9041128 01 78 2B
9034058 80 80 9 9039957 80 106 1 9041128 06 60 2B
9034945 80 8 21 9039958 01 106 1A 9041128 07 80 2AB
9036476 04 118 9 9040493 01 78 2A 9041128 08 76 2AB
9036476 06 118 10 9040493 06 60 2A 9041128 08 78 2B
9036476 07 118 8 9040493 07 80 2AA 9041765 83 64 19
9036476 10 118 14 9040493 08 76 2AA 9041782 02 64 19AA
9036909 80 8 24 9040493 08 78 2A 9041791 04 64 19B
9037152 03 118 7 9040657 01 108 Z0.3 9041792 01 64 19D
9037158 01 118 12 9040658 01 108 Z0.4 9041792 04 64 19C
9037158 01 118 13 9040659 04 108 Z0.5 9041793 04 64 19E
9037499 01 120 3 9040673 01 108 Z0.7 9041794 02 64 19F
9037499 01 98 1A 9040703 03 80 2B 9041961 01 114 Z
9038438 85 104 1 9040703 04 76 2B 9041963 01 116 Z
9038504 02 48 30 9040708 04 62 2A 9041965 01 114 Z0.1
9038536 02 98 1BB 9040729 23 82 1 9041965 03 116 Z0.1
9038538 06 98 1CB 9040843 01 116 1 9041966 01 114 Z0.2
9038547 02 108 Z0.1 9040931 86 80 2 9041967 01 116 Z0.2
9038547 04 108 Z0.6 9040931 87 76 2 9041968 01 116 Z0.3
9038547 09 108 Z0.2 9040965 63 78 1 9042446 01 108 1
9038554 86 104 2 9040965 70 60 1 9042921 01 56 22
9038756 80 104 3 9040965 71 80 1 9042921 01 58 15
9038757 01 110 1 9040965 73 76 1 9042921 02 56 22.1
9038855 01 110 12 9040965 73 78 1 9045930 01 118 1
9038873 05 106 1B 9040970 86 80 2 9047526 01 64 8
9038873 12 106 1C 9040970 87 76 2 9047526 02 112 1
9038873 13 106 1D 9040972 80 78 2
9038873 17 106 1E 9040972 85 60 2
9038873 20 106 1F 9040972 86 80 2A
9038873 21 106 1G 9040972 87 76 2A
9038873 22 106 1H 9040972 87 78 2
9038873 25 106 1I 9040972 89 62 2
9039016 04 78 1 9040973 80 78 2
9039016 11 60 1 9040973 85 60 2
9039016 12 80 1 9040973 86 80 2A
9039016 14 76 1 9040973 87 76 2A
9039016 14 78 1 9040973 87 78 2
9039236 02 98 1CA 9040973 89 62 2
9039248 01 72 1 9040974 01 114 1
130 Book No. 9051945 02 Rev. 1

026 System Manual

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026 System Manual

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PureBallast Ballast Water Treatment System

PureBallast Ballast Water Treatment System

1 PureBallast 3.2 System manual

PureBallast system Manual no. Connection list Flow chart

PureBallast system Manual no. Connection list Flow chart

Main component makers

ARI Armaturen or, ARI –GESA, Lugged valve

Wouter Witzel or, EVTLS, Lugged valve

LK Valves 710701, 2, Lugged valve

Flow chart Component Manufacturer Model

- VTORK VT range, Actuator

-ARI Armaturen or, ARI –GESA, Lugged valve

- Wouter Witzel or, EVTLS, Lugged valve

- LK Valves 710701, 2, Lugged valve

Optional system components (Alfa Laval supply)

Flow chart Component Manufacturer Model

Optional system components (Other supply possible. Alfa Laval supply

LDC cooling Centrifugal pump

The original instructions are in English

© Alfa Laval Corporate AB 2020-05

3 Operating instructions and control system description................. 45

5 Alarms and faultfinding..................................................................................... 185

6 Technical data and drawings........................................................................ 233

7 Service manual .....................................................................................................421

8 Revision history..................................................................................................... 497

1.2 Safety information

1.2.1 General safety information

1.2.2 Specific safety information

Maintenance safety items

UV reactor safety items

Filter safety items

CIP safety items

Flow meter safety items

Ancillary component safety items

1.2.3 Personnel requirements

1.2.4 Warning signs used in the manual

1.3 Environmental issues

1.3.2 Other materials

2.1.1 Components overview

Example of layout with 1 UV reactor.

2.1.2 Item numbers

2.2 Process overview

2.2.1 IMO and USCG mode

2.2.2 Flow control and power optimization

Brackish and marine water

2.2.2.1 Flow control

2.2.2.2 Power optimization

2.2.2.3 Power optimization during special conditions

2.2.2.4 Operation with broken UV lamp

The flow is decreased to 80 % in IMO mode or 50 % in USCG mode of max

Ballast and deballast start-up

2.2.4.2 Ballast after-treatment (CIP process)

We recommend that a CIP process is performed in the same location as the

CIP circulation during CIP process

2.2.5.1 Deballast after-treatment (CIP process)

2.2.6 Tank stripping

2.2.6.1 Stripping after-treatment (CIP process)

After stripping operation, a cleaning cycle is performed to clean the UV

2.2.7 Ballast water handling in the event of malfunction

2.3 System components description

2.3.1.1 UV reactor working principle

2.3.1.2 UV reactor description

2.3.2.2 Filter description

The water enters from the inlet flange (A)