Manual Delivery Flash PB-03035 v00 PB1000 OP - Alfa Laval BWTS

PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System

System Manual - PureBallast 3.13%
System Manual
English
1 PureBallast 3.1 System
manual
The PureBallast 3.1 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 and the connection list and flow chart defining them.
There are two versions of PureBallast. The USCG version use flow control to be compliant with
USCG legislation. The USCG HP (high performance) have double reactor capacity which allows
treatment at full capacity at all time.
1.1 Manual compilation

PureBallst system Manual no. Connection list Flowchart
PureBallast 3.1 250 USCG 9028181 02 9025976 9025598
PureBallst system Manual no. Connection list Flowchart

PureBallast 3.1 250 USCG HP 9028182 02 9025977 9025598
PureBallast 3.1 300 USCG HP 9028184, 02 9025979 9025598
Book No.9028378 02, rev. 1 1

1.2 Main component makers 1 PureBallast 3.1 System manual
1.2 Main component makers

Reference is made to flow chart 9025598, 9025599, 9025600, 9025601 and 9025602.
Flowchart
Component Manufacturer Model (Size according to connection list)
legend
Filter:
Automatic ACB-xx-yy, 20 µm mesh (xx=935 – 9200, yy=
self-cleaning Filtrex DN200 - DN600)
filter
PT201-71
Pressure sensor Jumo MIDAS S07
& -72
UV reactor
UV reactor, 300 or,
UV reactor Wallenius Water UV reactor, 600 or,
UV reactor, 1000
Medium pressure UV lamp, 3 kW for UV reactor
UV lamp 170, 300 and 600
Wallenius Water
Medium pressure UV lamp, 6 kW for UV reactor
1000
Lamp sleeve Wallenius Water Synthetic Quartz 9000738 02
UV-TECHNIK, SUV 20.2 Y2 C 40° 1000 W/m² or,
QT201-50 UV sensor IL Metronic SUV 20.2 Y2 C 40° 3000 W/m² for UV reactor
Sensortechnik GmbH 1000
Temperature, Bimetal Temp. Switch 60.8301
TS201-60 JUMO
switch
Thermometer, Dtrans Temp. probe 90.2815
TT201-33 JUMO
resistance
Vibration limit
LS201-29 PEPPERL+FUCHS Vibracon LVL-A7
switch
- Ifm IN5225, Inductive pos. sensor
V201-19 & -Air Torque Spa AT range, Actuator
Valve
-20
-ARI Armaturen ARI –GESA, Lugged valve
Valves:
- Siemens SIPART PS2, Positioner
Flow control - Air Torque Spa AT range, Actuator
V201-8
valve
- ARI Armaturen ARI –GESA, Lugged valve
V201-3, Filter inlet, outlet, - Rotech ALB ACR3.., Pos. switch box
-9, -32 & by-pass, & Start - Air Torque Spa AT range, Actuator
V403-35 up cooling valve - ARI Armaturen ARI –GESA, Lugged valve
Filter backflush - Air Torque Spa AT range, Actuator
V309-1
valve - ARI Armaturen ARI –GESA, Lugged valve
- Rotech ALB ACR3.., Pos. switch box
- Air Torque Spa AT range, Actuator
V212-31 By-pass valve
- Rotork ILG-D series, Handwheel
- ARI Armaturen ARI –GESA, Lugged valve
Flow meter:
Endress+Hauser Promag 50W1F,
FIT201-1 Flow transmitter
or Siemens Sitrans F, Magflo MAG 5100W
System pressure Transmitter:
2 Book No.9028378 02, rev 1

1 PureBallast 3.1 System manual 1.2 Main component makers
Flowchart
Component Manufacturer Model (Size according to connection list)
legend
Flowchart
Component Manufacturer Model
legend
Pressure
PT201-16 JUMO MIDAS S07
transmitter
Cleaning in Place (CIP) unit:
CIP cleaning
Alfa Laval 595087
module
CIP cleaning
Alfa Laval Alpacon Descalant Offshore
liquid
Lamp Drive Cabinet (LDC):
Lamp Drive
Alfa Laval LDC 3.1
Cabinet
Control Cabinet:
Control Cabinet Alfa Laval CC 3.1
Book No.9028378 02, rev 1 3

PureBallast 3.1 1000
USCG
System manual
Lit. Code 200000657-1-EN-GB
Manual No. 9028195 02 v. 9
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 2019-06
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 ............................................................................................. 14
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............................................................................................. 18
2.1.3 Abbreviations............................................................................................. 18
2.2 Process overview.................................................................................................... 19
2.2.1 IMO and USCG mode................................................................................19
2.2.2 Flow control and power optimization..........................................................19
2.2.3 Start-up...................................................................................................... 21
2.2.4 Ballasting................................................................................................... 22
2.2.5 Deballasting............................................................................................... 24
2.2.6 Tank stripping.............................................................................................25
2.2.7 Ballast water handling in the event of malfunction.....................................25
2.3 System components description..............................................................................26
2.3.1 UV reactor..................................................................................................26
2.3.2 Filter .......................................................................................................... 28
2.3.3 CIP (cleaning-in-place) module..................................................................32
2.3.4 Cabinets and control system......................................................................33
2.3.5 Main valves................................................................................................ 37
2.3.6 Flow meter................................................................................................. 38
2.3.7 Pressure monitoring...................................................................................38
2.3.8 Sampling devices.......................................................................................39
3 Operating instructions and control system description................. 41

3.1 Introduction..............................................................................................................42
3.1.1 Preparations and conditions...................................................................... 42
3.2 Introduction to the control system............................................................................45
3.2.1 Login levels................................................................................................ 45
3.2.2 Control of PureBallast................................................................................ 45
3.2.3 Overview of the screen.............................................................................. 47
3.3 Detailed page descriptions...................................................................................... 51
3.3.1 Page 1.1 – Overview..................................................................................51
3.3.2 Page 1.2 - UVR and flow selection............................................................ 54
3.3.3 Page 1.3 – CIP status................................................................................ 56
3.3.4 Page 1.4 – Power request......................................................................... 58
3.3.5 Page 2.1 – Alarm list..................................................................................61
3.3.6 Page 2.2 – Alarm history............................................................................63
3.3.7 Page 3.1 – Trend (15 min)......................................................................... 64
3.3.8 Page 3.2 - Trend (1 h)................................................................................66
3.3.9 Page 3.3 – Trend (1 h) - TT201-33............................................................ 66
3.3.10 Page 3.4 – Trend (1 h) - TT401-2.............................................................. 66
3.3.11 Page 3.5 – Trend (1 h) - Power optimization............................................. 66
3.3.12 Page 3.7 – Trend (15 min) - External feed ctrl........................................... 67
3.3.13 Page 3.8 – UV optimization....................................................................... 68
3.3.14 Page 4.1 – System info..............................................................................69
3.3.15 Page 4.2 – PLC controller I/O.................................................................... 71
3.3.16 Page 4.3 – Operation timers...................................................................... 72
3.3.17 Page 4.4 – Operation timers UVR............................................................. 73
3.3.18 Page 4.5 – Remote interface 1.................................................................. 74
3.3.19 Page 4.6 – Remote interface 2.................................................................. 74
3.3.20 Page 4.7 – Log box....................................................................................76
3.3.21 Page 4.9 – LPS overview...........................................................................77
3.3.22 Page 5.1–5.7 – Parameter pages.............................................................. 79
3.4 Popup windows....................................................................................................... 80
3.4.1 UVR popup ............................................................................................... 80
3.4.2 Filter popup ............................................................................................... 85
3.5 Operating instructions..............................................................................................86
3.5.1 Log in......................................................................................................... 86
3.5.2 Perform ballast...........................................................................................87
3.5.3 Perform deballast.......................................................................................88
3.5.4 Perform tank stripping................................................................................90
3.5.5 Pause ballast / deballast / stripping........................................................... 92
3.5.6 Heel (internal transfer)............................................................................... 93
3.5.7 Backflush filter manually............................................................................ 94
3.5.8 CIP clean UV reactor after ballast / deballast / stripping............................95
3.5.9 Attend to alarms.........................................................................................95
3.5.10 Shut down and deactivate system............................................................. 96
3.5.11 Operate components manually.................................................................. 98
3.5.12 Operate UV lamps manually.................................................................... 100
3.5.13 Set ship specific component ID................................................................101
3.5.14 Export control system event log files....................................................... 102
3.5.15 Backup control system settings............................................................... 104
3.5.16 Restore control system settings...............................................................104
3.5.17 Set control panel IP address....................................................................105
3.5.18 Set remote control panel communication.................................................106
3.5.19 Set remote interface communication....................................................... 108
3.5.20 Test remote interface communication...................................................... 108
3.5.21 Simulate power request........................................................................... 110
3.5.22 Update control system softwares............................................................. 111
3.5.23 Calibrate the control panel’s touch screen sensibility...............................111
3.5.24 Fine tune flow and pressure control ........................................................ 111
3.6 List of logged information.......................................................................................116
3.6.1 Event log.................................................................................................. 116
3.7 Detailed process description..................................................................................119
3.7.1 Standby mode..........................................................................................120
3.7.2 Ballast process.........................................................................................121
3.7.3 Deballast process.................................................................................... 128
3.7.4 Stripping process..................................................................................... 135
3.7.5 CIP process............................................................................................. 142
3.7.6 Manual mode........................................................................................... 147
3.8 Quick guide............................................................................................................148
3.8.1 Introduction.............................................................................................. 148
3.8.2 Ballast, deballast or strip..........................................................................148
3.8.3 Alarm handling......................................................................................... 149
3.8.4 CIP clean UVR.........................................................................................149
3.8.5 Export control system log files................................................................. 149
4 Parameters............................................................................................................... 151
4.1 Introduction............................................................................................................152
4.2 Control system parameters................................................................................... 152
4.2.1 Introduction to parameters and parameter settings................................. 152
4.2.2 Page 5.1 — Main parameters 1............................................................... 154
4.2.3 Page 5.2 — Main parameters 2............................................................... 157
4.2.4 Page 5.3 — UVR parameters.................................................................. 161
4.2.5 Page 5.4 — Filter parameters..................................................................163
4.2.6 Page 5.5 — CIP parameters....................................................................166
4.2.7 Page 5.7 — Remote interface..................................................................167
4.2.8 Page 5.6 — Installation parameters.........................................................169
4.3 Lamp power supply (LPS) parameters.................................................................. 172
4.3.1 DIP switch settings...................................................................................172
4.4 Fuse settings for filter motor and installed (optional) pump motors.......................174
4.5 Flow meter parameters..........................................................................................174
5 Alarms and faultfinding..................................................................................... 179

5.1 Introduction............................................................................................................180
5.2 List of alarms and warnings...................................................................................180
5.2.1 Control system......................................................................................... 180
5.2.2 Lamp power supply (LPS)........................................................................208
5.2.3 Flow meter............................................................................................... 209
5.2.4 Level switch..............................................................................................211
5.2.5 I/O system and X20 modules...................................................................212
5.3 List of problems and solutions...............................................................................218
5.3.1 General problems.................................................................................... 218
5.3.2 Filter......................................................................................................... 220
5.3.3 CIP........................................................................................................... 221
5.3.4 Valve V201–8...........................................................................................222
6 Technical data and drawings........................................................................ 225

6.1 Introduction............................................................................................................226
6.1.1 Ship specific information.......................................................................... 226
6.2 Technical data........................................................................................................226
6.2.1 Flow requirements................................................................................... 226
6.2.2 Water requirements..................................................................................227
6.2.3 Power requirements.................................................................................227
6.2.4 System pressure...................................................................................... 228
6.2.5 Pressure requirements for filter backflush............................................... 228
6.2.6 PureBallast components.......................................................................... 229
6.3 Control system integration.....................................................................................229
6.4 Drawings................................................................................................................230
6.4.1 Graphic symbols used in drawings.......................................................... 231
6.4.2 General drawings.....................................................................................232
6.4.3 Dimension drawings.................................................................................248
6.4.4 Electrical drawings................................................................................... 278
6.4.5 Saftey Data Sheets.................................................................................. 344
7 Service manual .....................................................................................................365

7.1 Introduction............................................................................................................366
7.1.1 Preparations and conditions.................................................................... 366
7.1.2 Welding requirements.............................................................................. 366
7.1.3 Tightening torques................................................................................... 367
7.2 Maintenance schedule.......................................................................................... 369
7.2.1 Calibration schedule................................................................................ 371
7.2.2 Recommended spare parts on board...................................................... 375
7.2.3 Serial number information........................................................................376
7.3 UV reactor............................................................................................................. 380
7.3.1 Safety information.................................................................................... 380
7.3.2 Replace UV lamp..................................................................................... 381
7.3.3 Replace quartz sleeve............................................................................. 383
7.3.4 Dismount and mount lamp power supply.................................................385
7.3.5 Test lamp power supply installation......................................................... 386
7.4 Filter.......................................................................................................................388
7.4.1 Remove filter cover and filter element..................................................... 389
7.4.2 Mount filter element and filter cover.........................................................392
7.4.3 Clean filter element and pre-filter.............................................................392
7.5 CIP ........................................................................................................................394
7.5.1 Change and refill CIP liquid..................................................................... 394
7.6 Pump..................................................................................................................... 397
7.6.1 Repair CIP pump..................................................................................... 397
7.6.2 Test CIP pump......................................................................................... 399
7.7 Valve block ........................................................................................................... 401
7.7.1 Change valve body.................................................................................. 401
7.7.2 Connect electrical cables to valve block.................................................. 402
7.7.3 Clean valve block.....................................................................................402
7.7.4 Connect pneumatic hoses to valve block.................................................402
7.8 Valves.................................................................................................................... 403
7.8.1 Preparations and conditions.................................................................... 404
7.8.2 Operate valves manually......................................................................... 405
7.8.3 Open and close valves manually (CIP valves).........................................405
7.8.4 Open and close valves manually............................................................. 405
7.8.5 Lock valve in closed position................................................................... 406
7.8.6 Unlock valve.............................................................................................407
7.8.7 Dismount actuator....................................................................................408
7.8.8 Mount actuator......................................................................................... 408
7.8.9 Adjust valve end position ........................................................................ 410
7.8.10 Calibrate positioner on V201-8.................................................................411
7.8.11 Adjust cam position on V201-8................................................................ 413
7.8.12 Change direction of actuator – without position sensor (V404–36,
V320–4 and V321–2)............................................................................... 414
7.8.13 Change direction of actuator – with position sensor (201-19 and 201–
20)............................................................................................................415
7.8.14 Change direction of actuator – with switch box (V201–3, V201–9,
V201–32, V212–31 and V403–35)...........................................................417
7.8.15 Change direction of actuator – with positioner (201–8)........................... 418
7.8.16 Mount pilot valve on actuator .................................................................. 418
7.8.17 Adjust valve traveling speed ................................................................... 419
7.9 Flow meter.............................................................................................................421
7.9.1 Replace display and fuse.........................................................................421
7.9.2 Replace a circuit board............................................................................ 422
7.10 Level switch...........................................................................................................425
7.10.1 Mount level switch....................................................................................425
7.10.2 Dismount level switch.............................................................................. 425
7.10.3 Test level switch....................................................................................... 426
7.11 Temperature switch and temperature transmitter.................................................. 427
7.11.1 Mount temperature switch / temperature transmitter............................... 427
7.11.2 Dismount temperature switch / temperature transmitter.......................... 427
7.12 Control panel......................................................................................................... 428
7.12.1 Clean control panel.................................................................................. 428
7.12.2 Replace control panel.............................................................................. 428
7.13 Remote control panel (optional)............................................................................ 429
7.13.1 Mount and connect remote control panel ................................................429
7.14 Control cabinet and lamp drive cabinet (LDC)...................................................... 430
7.14.1 Disassemble and assemble I/O system...................................................430
7.14.2 Cable gland installation – General cables................................................431
7.14.3 Cable gland installation – Power cable to LDC........................................433
7.14.4 Power cable check...................................................................................433
7.14.5 Install IFS confstick in safety relay KS1 in LDC....................................... 434
EN
1 Safety
Safety
200000657-1-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:
• The PureBallast system is not Ex proofed and must not be installed in
areas where an explosive atmosphere may occur.
• Use the equipment only for the purpose and parameter range specified by
Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Always read and follow the documentation that is included in shipment of
components and spare parts regarding handling, safety and disposal.
• Mobile cell phones must not be switched on within an area of 1 meter from
an open cabinet door.
• Before installation, read applicable sections Technical data and drawings
Safety
on page 225 and in the Design and installation guidelines.
• Before operation, read the Preparations and conditions section for
applicable instructions in Operating instructions and control system
description on page 41.
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 365. Essential safety
information is stated before instruction to routines that might involve any
danger.
• Before maintaining the PureBallast system, the following valves must be
locked in closed position: V201-3, V201-9 and V201-8.
• Components must be lifted using correct lifting tools (such as a fork-lift
truck, a crane) and tackle with a load capacity greater than the weight of
the component. See the section PureBallast components in Introduction on
page 226 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 200000657-1-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 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 96. The cabinet contains a fan, which can cause injury if
in operation.
200000657-1-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 344
.
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 344
• 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
Safety
components carry dangerous voltages .
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.
12 200000657-1-EN-GB
Safety 1 EN
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.
1.2.3 Personnel requirements

The PureBallast system must be operated, installed, maintained and repaired
by persons trained for respective type of work. All persons using and working
with the system must know the emergency stopping procedures.
Personnel installing, maintaining or repairing components must be of one of
the following categories:
• Skilled person: A person with technical knowledge or sufficient experience
to perform the tasks at hand and to enable him or her to perceive risks and
to avoid hazards which electricity/mechanics can create.
• Instructed person: A person adequately advised or supervised by a skilled
person to enable him or her to perceive risks and to avoid hazards which
electricity/mechanics can create.
• Alfa Laval service engineer: A person with knowledge about the
PureBallast system. Alfa Laval service engineer can set parameters and
repair intrinsically safe apparatuses.
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.
Safety
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.
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.
200000657-1-EN-GB 13
EN 1 Safety
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.
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.
Safety
• The operator panel contain the following components with substances that
might be hazardous to health and the environment: lithium battery,
electrolytic capacitor and display. They shall be recycled according to local
regulations.
• Used lithium batteries from the control unit are considered hazardous waste
and should be disposed of accordingly.
• Used UV lamps can be handled and disposed of in the same way as
fluorescent lamps. Please refer to national regulations.
• Used quarts sleeves should be disposed of as ordinary glass.
14 200000657-1-EN-GB
EN
2 System description
200000657-1-EN-GB 15
EN 2 System description
2.1 Introduction
This contains general information about the PureBallast system and its
components.
16 200000657-1-EN-GB
System description 2 EN
2.1.1 Components overview

The key components in PureBallast 3.1 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
8. Sampling point
9. Filter
10. Ballast water inlet
Not in illustration:
• System bypass valve
• Pressure monitoring device
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). The
UV reactor has one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. Note
that full treatment requires treatment both during ballast and deballast.
200000657-1-EN-GB 17
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.
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
EN Standardization).
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)
USCG United states coast guard
UV Ultra violet
UV reactor The main component, where the water is treated using UV light.
UVR UV reactor
18 200000657-1-EN-GB
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 have 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.
Hold-time
USCG mode can be run with a 3 days hold-time or 0 day hold-time. Choose
0/3 days hold-time in parameter p182.
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.
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.
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.
IMO mode
The illustration below show flow control and power optimization depending on
the UV intensity, together with the compliant limit.
200000657-1-EN-GB 19
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

In USCG mode, 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
20 200000657-1-EN-GB
100 % of full flow capacity. The higher UVI value (cleaner water) the the higher
flow.
In IMO mode, the flow is always 100 % above compliant limit. 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 between c and d (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
• 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.
200000657-1-EN-GB 21
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
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.
22 200000657-1-EN-GB
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.
We recommend that a CIP process is performed within the same ecological
zone or in international waters (200 nautical miles from the base line). This will
avoid untreated water from the UV reactor and the filter to enter a different
ecological zones.
First, the 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. Finally, the filter filled with technical
water / potable water to prevent scaling and algea growth. The cleaning liquid
is reused between the cleaning operations.
200000657-1-EN-GB 23
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.
Deballasting
24 200000657-1-EN-GB
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)
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.
200000657-1-EN-GB 25
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
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.
The UV lamps get very warm, so they must be cooled whenever they are lit.
To secure that there is water in the reactor when the lamps are lit, the reactor
is equipped with a level switch. The level switch also secures that enough CIP
liquid is pumped into the reactor during the CIP process. To secure that the
lamps are adequately cooled by the ballast water,
each UV reactor has a threefold heat protection:
26 200000657-1-EN-GB
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.
UV reactor
1. Ballast water outlet valve
2. CIP liquid outlet valve
3. Temperature switch
4. Temperature transmitter
5. Junction box
6. UV lamp cap (UV lamp and quartz sleeve inside)
7. Inlet valve from CIP module and reactor drain valve
8. Ballast water inlet valve
9. UV sensor
10. Level switch
11. Cooling water outlet valve
200000657-1-EN-GB 27
UV reactor
1. Ballast water outlet valve
2. CIP liquid outlet valve (actuator indicated)
3. Temeperature transmitter
4. Junction box
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
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.
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
28 200000657-1-EN-GB
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.
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
inside 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
outlet flange (B) and is lead to the UV
reactor.
During filtration, the filter operates as a
static filter, there are no moving parts and
the motor (2) is not running and the
nozzle (3) is standing still.
A. Inlet
B. Outlet
D. Chamber
1. Filter element
2. Motor
3. Nozzle (standing still during filtration)
200000657-1-EN-GB 29
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
element. The dirt on the inside of the filter
element (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,
together with the dirt, is lead via the
nozzle through the duct (5) and out via
the backflush 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
inlet (A) through the filter element and out
through the outlet (B).
When the backflush is done (after
approxemately 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
minutes (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.
30 200000657-1-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.
200000657-1-EN-GB 31
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.
32 200000657-1-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.
CIP module
1. Deaeration valve
2. Valve block
3. Regulator
4. Pump (CIP liquid)
5. Backflow preventer
6. Pump (reactor drain)
7. Tank for CIP liquid
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.
200000657-1-EN-GB 33
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.
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 the engine room. The
main control panel handles every aspect of the control system. It allows the
operator to monitor the system, to operate it manually and automatically, and
to set parameters. Please note that some of the operations are password-
protected.
34 200000657-1-EN-GB
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.
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
200000657-1-EN-GB 35
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.
2.3.4.3 Lamp drive cabinet (LDC)

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

The UV reactor is connected to a lamp drive cabinet (LDC) containing 16 lamp
power supplies (LPS), each feeding one lamp with power. The LPS also
monitors the function of each UV lamp and takes action if a fault occurs.
Lamps on the cabinet indicates if power is on, UV lamps are lit and if the
cabinet needs to be reset after a shutdown or power off.
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 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.
36 200000657-1-EN-GB
Lamp drive cabinet (LDC)
LDC with one door removed.

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

The main valves in the system are:
200000657-1-EN-GB 37
• 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.
• 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) monitor flow.
The flow meter consists of two components:
• 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.
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.
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:
38 200000657-1-EN-GB
• 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.
200000657-1-EN-GB 39
40 200000657-1-EN-GB
EN
3 Operating instructions and control

system description
200000657-1-EN-GB 41
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 Preparations and conditions

• Make sure all documentation is available, read and understood before start.
• Both ballast and deballast must be run through PureBallast to fully treat the
water.
• Make sure that the flow is within defined flow range during operation:
• Ballast: 195 – 1000 m3/h
• Deballast: 100 – 1000 m3/h
• Stripping: 100 – 1000 m3/h
• The input flow to the PureBallast system shall be as close as possible to

the flow that has been selected for an operation. This will reduce the stress
and wear of the control valve.
• 0 day or 3 days hold-time: Selection of hold-time should be done before
ballast. The same hold-time setting should then be used for deballast. If
you will deballast in US waters, all water in each tank must be treated using
the same hold-time mode. Hold-time is set in parameter p182 USCG hold-
time.
It is not allowed to mix waters treated using different modes in each tank.
Example: If you intend to deballast using 0 day mode, 0 day mode must be
used during ballast. If a tank will be filled with water treated using a different
mode than the water stored in the tank, the tank should be completely
emptied first (preferably using stripping mode).
Therefore, it is recommended to keep track of which mode the water is
treated for each individual tank. The the ballast water record book should
be used to keep track of treatment mode for the water in the different tanks,
how this should be done shall be stated in the ballast water management
plan.
• During process, the control system requests that vessel valves are opened/
closed. The valves are outside the PureBallast system control. But the
control system needs feedback (opened/closed) during process. Status can
either be confirmed manually in a popup or automatically, if feedback
signals are integrated via the remote interface option or via hard wire.
Please note:
• When overboard valves are requested to be opened/closed, this means
that all valves leading the flow from the PureBallast via one of the
following pipes must be opened/closed: 201, 309 and 403 and 404.
During CIP process, 460.1 must be opened.
42 200000657-1-EN-GB
Operating instructions and control system description 3 EN
3.1.1.1 Compliant / non-compliant operation

To optimize operation, all ballast and deballast operations should be done
using PureBallast according to system manual, and the system should be
maintained.
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 (Alarm A33, 66, 67 and 68)
• 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 (Warning W130, W131)
• UV intensity lower than limit stated in the type approval certificate (Warning
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.
200000657-1-EN-GB 43
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.
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. It is possible
to perform heeling during standby ballast or deballasting.
If external component signal for heeling mode is integrated between
PureBallast and the vessel's ISCS, ongoing process will be paused and
resumed automatically. The user is notified of started and stopped heeling via
warnings, and the event is logged.
If no external signal is integrated, the ongoing process must be paused
manually. During pause, cooling water is flushed through the UV reactor to
cool the UV lamps. After completed heeling, the operator must resume the
paused process.
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.
44 200000657-1-EN-GB
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 • Access to set parameters, with exception from critical
2 2007
operator parameters. See chapter 4. Parameters for information
• Full access to page 4.3 Operation timers and 4.4
Operation timers UVR.
Full access. Password only available for Alfa Laval

personnel.
• 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
Remote 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:
200000657-1-EN-GB 45
• 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
46 200000657-1-EN-GB
• 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 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.
200000657-1-EN-GB 47
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.
48 200000657-1-EN-GB
Status indication – Button colour: The buttons appear in different colours,

indicating status:
Blue The function is enabled.
Blue with The function is activated.
checkmark
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

during full ballast or full deballast. The button can be hidden, using
parameter p137. Allowed length of a pause is parameter set (p138).
After defined time, the paused process is stopped.
To resume a paused process, press the function button Ballast,
Deballast 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

operation 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.
200000657-1-EN-GB 49
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 41.
Button Description
Sets the control system in IMO mode, which activate operation in

accordance 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.
50 200000657-1-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.
Process and subprocess Subprocess: Sub steps of ongoing process, for
example Start-up during Ballast process.
Remaining time for the ongoing subprocess in
Time the upper right corner.
Amount of water processed during ongoing
Processed volume (m3/h) process. Value remain until next process is
started.
Power consumption (kW) Power consumption for ongoing process.
200000657-1-EN-GB 51
Status information (unit) Description

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
process. 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
margin.
Flow (m3/h) selected for operation.
Flow can be selected manually or automatically:
• Automatically: Activate the Auto button
(checkmark). Flow will always be selected.
Flow selection • Manually: Deactivate the Auto button (no
checkmark). Flow is selected using the +
button.
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.
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.
52 200000657-1-EN-GB
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

components 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 41.
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 41.
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
component. 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.
The component is operated manually in manual mode.
Status information for the backflush pump P309–1

(optional). Only visible if parameter p318 is activated.
200000657-1-EN-GB 53
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.
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:
54 200000657-1-EN-GB
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
updated 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
(parameter p315), the higher value is displayed until
the Ballast 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
selection 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.)
200000657-1-EN-GB 55
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
The area displays status for the following pieces of information:
Row Content
Process: Ongoing process. Can be standby, ballast,
deballast and CIP.
Process and sub process
Sub process: Sub steps of ongoing process, for
example “Start-up” during Ballast process.
CIP UV reactor information

The area displays CIP status for respective installed UV reactor:
Row Content
Each row display CIP status for every installed UV
UVR reactor.
This row indicate status and time for the filter
preservation process, that starts after completed CIP.
Filter preservation During filter preservation, the CIP fills the filter with
technical water / potable water for preservation
purpose.
Total estimated time for a complete CIP process
Total time including filter preservation.
56 200000657-1-EN-GB
Column Content
CIP status for each UV reactor.
Status indication
Yellow = CIP required. During ongoing CIP process,
yellow indicates that the UV reactor is waiting for CIP
CIP error process to start.
Yellow, blinking = CIP process ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to
active alarm on the UV reactor.
Red square: Indicates that there is an active alarm for
CIP the component. Check alarms on page 2.1 – Alarm list.
Status Same information as column CIP, but spelled out.
Time remaining CIP time. If CIP process has not been
started, total time is displayed. During CIP process, the
Estimated time time is counting down continuously.
The CIP process takes about 25 minutes, if default
parameters are used.
Time before a CIP process must be performed after
ballast or deballast. The time disappears when the CIP
Required CIP countdown process is ready. Time is displayed for the UVR with
shortest time left to required CIP.
CIP module information

The area displays a schematic illustration of the CIP module, with status for for
the valves and motors. For status indications, see Status indication –
Component color in section Flow chart, see Page 1.1 – Overview on page 51.
200000657-1-EN-GB 57
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
example “Start-up” during Ballast process.
Maximum power consumption for the number of

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

consumption based on number of used UV reactors.
58 200000657-1-EN-GB
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 a request has been sent, the vessels power
PureBallast) management 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
Granted ISCS. Pure Ballast will not consume significant power
(Input signal to PureBallast) until the requested power is granted.
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 UV reactor is started and is consuming power.
PureBallast)
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.
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.
Function buttons
The following function buttons are available and displayed when manual mode
is activated:
200000657-1-EN-GB 59
Buttons Content
If manual mode is activated, a hand icons are
displayed on the page. Press the hand icon to make it
possible to send simulated request or granted signal
manually.
Press to manually simulate request for a power step.

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

Set run The button is displayed for login level Advanced
operator or higher.
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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
Text AlarmID 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.
200000657-1-EN-GB 61
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.
62 200000657-1-EN-GB
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.
200000657-1-EN-GB 63
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 Unit Description
value
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 System pressure, indicated by the pressure
bar
pressure 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.
64 200000657-1-EN-GB
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
component’s scale setting is used).
3. Press this button to use this component’s scale
setting in the diagram.
4. Press the entry field 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
color as the icon.
Empty = Not selected. Component
values is not plotted in the diagram.
Status indication
Scale icon = The component scale
setting 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.
200000657-1-EN-GB 65
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)
66 200000657-1-EN-GB
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 ctrl

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).
200000657-1-EN-GB 67
3.3.13 Page 3.8 – UV optimization

The page is used to display the trend curves for detailed data valid for UV
optimization.
68 200000657-1-EN-GB
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
percent 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
time instead. 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.
200000657-1-EN-GB 69
Section Description
on page
HMI Screen saver timeout: Defines time before the panel is set to screen
Backlig save mode. This is set individually per control panel.
ht
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
program.
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
supply 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
contactors from control cabinet. It is still possible to connect pumps
according 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 panel port on the cabinet door.
restore
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:
ValueSaved.xml and ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different
components. File: ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
Restore button: Restore all information from a USB backup to the control
system. See Backup above. This shall not be used to restore parameter
settings after software update. Requires login level Advanced operator.
Parameters: Parameter restore.
Set default button: Set all parameter values to the default values.
Requires 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 116.
Remote Remote control panels button: Open a popup used for setting IP
control addresses for remote control panels (optional). See instruction Set control
panels panel IP address on page 105. Requires login level AlfaLaval.
Debug Cpy2USB button: Only press this button if asked for by the Tumba
log Technical 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
disabled.
70 200000657-1-EN-GB
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.
200000657-1-EN-GB 71
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 Number of performed CIP
experience on how many CIP processes it is possible processes.
to perform before it is time to change CIP liquid
container. Requires login level Advanced operator or
higher.
72 200000657-1-EN-GB
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 Reset button: Reset the value.
respective UV reactor. Shall be done after UV lamp
change. Requires login level
Advanced operator or higher.
Total runtime for the
UVR 1–3: LDC power LDC for respective UV
on reactor.
200000657-1-EN-GB 73
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
PureBallast’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
button.
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).
74 200000657-1-EN-GB
200000657-1-EN-GB 75
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
Configuration type configurations.
Select configuration number by entering a
number or using the arrow buttons. Signal
Configuration number status and Configuration are displayed for
selected configuration number.
Saves configuration information after a
Save configuration button change.
76 200000657-1-EN-GB
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
active signal is 24 V.
This is the definition of which signal that
should be active to constitute a bypass/
heeling. 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
Bypass or Heeling.
If a bypass or heeling configuration is active,
Active configuration numbers the numbers of the active configuration is
indicated 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.
200000657-1-EN-GB 77
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.
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.
78 200000657-1-EN-GB
3.3.22 Page 5.1–5.7 – Parameter pages

These pages are used to set parameters. See chapter 4. Parameters for
detailed information.
200000657-1-EN-GB 79
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

The popup is displayed when the UV reactor is pressed in the flow chart. The
popup displays status values for the UV reactor and its related sub
components.
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
80 200000657-1-EN-GB
Component Description
Status indication:
Grey = Off.
UV lamps
Yellow = Starting.
Green = Started.
Status indication for UV reactor sensors:

LS201–29: Level switch indicates if the
UV reactor is filled with water or not.
Status indication: Green = Filled. Red =
Not filled.
TS201–60: Temperature switch
automatically shuts down the UV reactor
when the temperature reaches 65 °C.
Sensor indications
Status indication: Green = OK. Red = Not
OK.
QT201–50: UV sensor QT201–50
indicates 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

indication – Component color in section
Valves Flow chart. See Page 1.1 – Overview on
page 51.
Water flow Flow in pipes is indicated by coloring of

the pipes.
LDC status
Table 2: UVR popup: LDC status illustration
Open the LPS control popup, which
enables manual operation of individual
UV lamps. Requires login level Advanced
operator to see the button and manual
mode open the popup. See LPS control
popup and instruction Operate UV lamps
manually on page 100.
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

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

the LDC cabinet indicated by TT401–1.
200000657-1-EN-GB 81
Indicates if the valve for LDC cooling
water (SV401–51) is open.
Heat exchanger valve
Status indication: Green = Open. No
indication = Closed.
Indicates if the LDC cooling water pump

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

indicating 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 100. 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 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.

Table 3: LPS control popup
82 200000657-1-EN-GB
Information is displayed for the UV
UV reactor number reactor selected in the UV reactor
number field.
Enables manual operation of the LPSs to

light the UV lamps. The button is
displayed for login level Advanced
operator or higher. The button enables
manual 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 reactor.
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.
200000657-1-EN-GB 83

Table 4: LPS status popup: LPS status
Information is displayed for the UV
UVR reactor selected in the UVR field.
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
water 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
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
setpoint 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

indication:
• Automatic: Normal mode. Power
optimization 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
disabled 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.
84 200000657-1-EN-GB
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.

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

ilter (PT201–71 minus PT201–72). When
Diff. pressure the pressure reach the value set in
parameter p305, a backflush is triggered.
Current pressure:
Pressure • PT201–71: Inlet pressure.
• PT201–72: Outlet pressure.
200000657-1-EN-GB 85
Press the button to start a manual
backflush. See instruction Backflush filter
manually on page 94.
For status indications, see Status

indication – Component color in section
Pipes, valves, motor and pump Flow chart. See Page 1.1 – Overview on
page 51.
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.
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 45 and Detailed page descriptions on page 51.
• Login levels required for different procedures: See section Login levels on
page 45.
• Detailed information about components (valves, motors, pumps etc)
involved in each step the process. See section Detailed process description
on page 119.
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 45.)
86 200000657-1-EN-GB
3.5.2 Perform ballast

Follow this instruction to ballast.
• IMO or USCG mode must be selected by IMO or USCG function buttons,
based on which legislation that should be followed.
• For USCG: Choose, in parameter p182, if 3 days or 0 day hold-time should
be used. 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.
• All valves leading flow to and from PureBallast must be opened. They are
not operated by PureBallast.
• The Alarm list (page 2.1) must be controlled to verify that there are no
alarms needing attention.
• Flow must have been selected before a process can be started, either
manually or automatically. See Page 1.1 – Overview on page 51.
• There must be available power for the system. If power management is
integrated, this will be handled automatically. If power management is not
integrated, confirm available power manually.
Follow the steps below:
1. Press the function button Ballast.
Comment: If the button is not blue, check that flow or UV reactors have
been selected
2. Wait for the message “Open valves ...”. Open relevant valves and then
press the button in the popup to confirm the action. Ensure that pipe 404 is
opened to overboard. See section Preparations and conditions on page
42. Note! These valves are outside the PureBallast system control. (The
popup is not displayed if the component feedback is integrated with the
control system.)
Result: Ballast start-up starts, with cooling water cooling the lamps during
warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and
then press the button in the popup to confirm the action. Note! This
component is outside the PureBallast system control. (The popup is not
displayed if the component feedback is integrated with the control system.)
Result: Cooling stops and ballasting starts.
4. When desired amount of water has been processed, press the function
button Stop
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 ...”. Close relevant valves and then
press the button in the popup to confirm the action. See section
Preparations and conditions on page 42. Note! These valves are outside
outside the PureBallast system control. (The popup is not displayed if the
component feedback is integrated with the control system.)
200000657-1-EN-GB 87
6. Wait for the message “Stop ballast water pump”. Stop the pump and then
press the button in the popup to confirm the action. Note! This component
is outside the PureBallast system control. (The popup is not displayed if
the component feedback is integrated with the control system.)
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 ).
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 . 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 95.
3.5.3 Perform deballast

Follow this instruction to deballast.
be used at deballast. If ballast water has been stored in tank shorter than
72 hours, the water must be treated during deballast using 0 days mode
(p182 = 0 days). It is important that you chose the right mode (same mode
as for ballast to respective tank).
not operated by PureBallast.
88 200000657-1-EN-GB
• Flow must have been selected before a process can be started, either
manually or automatically. See Page 1.1 – Overview on page 51.
1. Press the function button Deballast.
Comment: If the button is not blue, check that flow or UV reactors have
been selected
control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps
during warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and
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”. Stop the pump and then
200000657-1-EN-GB 89
the PureBallast system control. (The popup is not displayed if the
minutes ).
minutes ).
NOTE
25 minutes . 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.
3.5.4 Perform tank stripping

Follow this instruction to strip .
be used at stripping. If ballast water has been stored in tank shorter than 72
hours, the water must be treated during stripping using 0 days mode (p182
= 0 days). It is important that you chose the right mode (same mode as for
ballast to respective tank).
not operated by PureBallast. See section Preparations and conditions on
page 42.
90 200000657-1-EN-GB
• Stripping function must be activated in parameter p170.

1. Press the function button Strip.
Comment: If the button is not blue, check that flow or UV reactor have
been selected.
control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps
during warm-up.
3. Wait for the message “Confirm strip pump started”. Start the pump and
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”. Stop the pump and then
200000657-1-EN-GB 91
the PureBallast system control. (The popup is not displayed if the
minutes ).
minutes ).
NOTE
25 minutes . Operations after the warning does not fulfill the type approval
certificate.
3.5.5 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.
1 Press the function button Pause.
92 200000657-1-EN-GB
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.
3.5.6 Heel (internal transfer)

Follow this instruction to pause an ongoing ballast or deballast process to enable heeling (internal
transfer).
• This requires that a signal for heeling mode is integrated between PureBallast and the vessel’s
ISCS.
• This is only possible in sub process standby, full ballast and full deballast.
• Allowed length of heeling is parameter set (p138). After defined time, the system is stopped.
Follow the steps below:.
1 Activate heeling from ISCS, which means that

a heeling signal is sent to PureBallast.
200000657-1-EN-GB 93
2 In PureBallast: Wait for the message “Stop

ballast water pump”. Note! This component is
outside the PureBallast system control. (The
popup is not displayed if the component
feedback is integrated with the control
system.)
Note: If you you need the ballast pump for
heeling, confirm the request without stopping
the ballast water pump.
Result: System goes to heeling mode
(ongoing process is paused). The UV lamps
remains on at reduced power and cooling
water is run through the UVR to avoid
overheating of the lamps. During heeling, the
yellow light under the Pause button is lit and
the yellow light under the function button
Ballast or Deballast is blinking.
3 To resume the paused process. Deactivate

the heeling from ISCS.
Result: PureBallast goes to Pause mode.
4 Press the Ballast or Deballast button to

resume the process.
5 Wait for the message “Confirm ballast pump

started”. Start the pump and press the button
in the popup to confirm the action. (The
popup is not displayed if the component
feedback is integrated with the control
system.)
Result: The process is resumed.
3.5.7 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.
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.
94 200000657-1-EN-GB
3.5.8 CIP clean UV reactor after ballast / deballast / stripping

Follow this instruction to clean the UV reactor 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 within the same ecological
zone or in international waters (200 nautical miles from the base line). This
will avoid untreated water from the UVR and the filter to enter a different
ecological zone.
• 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 6
hours.
2. Wait for the message “Open valves ...”. Open valves leading technical
water / potable water to pipe 310 and drain water from pipe 309 to
overboard. Press the Confirm button to confirm the action. Note! These
valves are outside the PureBallast system control. (The popup is not
Result: The CIP process starts. The CIP process takes about 25 minutes ,
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.
press button in the popup to confirm the action. See section Preparations
and conditions on page 42. Note! These valves are outside the PureBallast
system control. (The popup is not displayed if the component feedback is
integrated with the control system.)
3.5.9 Attend to alarms

Follow this instruction to attend to alarms and warnings. For descriptions of
alarms and trouble shooting, see chapter 5. Alarms and faultfinding.
200000657-1-EN-GB 95
• 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 61.

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.
3.5.10 Shut down and deactivate system

Follow this instruction to quickly stop any ongoing operation in the PureBallast
system, for example, when a critical fault has been detected, or to make the
system deactivated (currentless).
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.
96 200000657-1-EN-GB
Control cabinet Lamp drive cabinet
1. Main breaker
2. Emergency stop button
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

panel.
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.
200000657-1-EN-GB 97
Action Method
Press the Emergency stop button (2) on
the control cabinet.
Emergency stop Result: Ongoing process is stopped
immediately, without controlled closing of
any valves, UV lamps etc.
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)
door.
Deactivate PureBallast to make it The system is then currentless on the

completely deactivated (currentless). PureBallast side of the main breaker
in the control cabinet and in the lamp
drive cabinet.
2. To make the complete system
currentless, power to PureBallast
must be switched off using the ship’s
switch board.
Note: Both breakers can be locked in off
position using a padlock.
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.
Depending on how the system was shut down:
Manual on control cabinet: Turn the main breaker (1) and acknowledge the
alarm in the control system. Release the button on the control cabinet.
Automatic in LDC: Follow the instruction below if a reactor has been shut
down by temperature switch TS201-60 (alarm A137) or if the cabinet or
system has been shut down by a blackout or electrical faults in the cabinet:
1. Make sure that the main breaker (A) on the LDC door is turned on.
2. Press the blue reset button (B) on the LDC door (when the reactor has
cooled down or when the power is back on).
3. Acknowledge all alarm related to the shut down in the control system.
3.5.11 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:
98 200000657-1-EN-GB
• Filter motor (M709-43)

• 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.
• 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.

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.
200000657-1-EN-GB 99
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.
3.5.12 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 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 51.
3. Select which UV reactor to operate in the UVR number entry field.
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.
100 200000657-1-EN-GB
6. Press the LPS control button.

Result: The LPS control popup is displayed for selected UV reactor.
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 one UV lamp. 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.
3.5.13 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.
200000657-1-EN-GB 101

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.
3.5.14 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:
Information to be Description
exported
The event log includes all events in the PureBallast
Event log system. 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 116.
102 200000657-1-EN-GB
• 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.
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.
200000657-1-EN-GB 103
7. Wait for the message "Export OK" to appear.

Result: A folder named PureBallast has been downloaded. It contains
three sub folders: Alarm and Event. The folder corresponding to your
export choice contains a CSV file.
8. Press Close and remove the USB memory.
3.5.15 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.
3.5.16 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 69.
• This method shall not be used to restore parameter settings after software
update.
104 200000657-1-EN-GB
• 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.
3.5.17 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.
2. Press the Setup button in the IP settings box.
Result: The IP settings popup is displayed.
200000657-1-EN-GB 105
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.
3.5.18 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.
106 200000657-1-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.
200000657-1-EN-GB 107
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.
3.5.19 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.
3.5.20 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
108 200000657-1-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.
200000657-1-EN-GB 109
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.
3.5.21 Simulate power request

Follow this instruction to test the power management signals if PureBallast is integrated with the
vessel's power management system. This instruction can also be used in manual mode during
faultfinding.
This instruction requires login level 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.
110 200000657-1-EN-GB
7 Press the Set run button to deactivate the

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

manual mode.
3.5.22 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.
3.5.23 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.
3.5.24 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.
3.5.24.1 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
200000657-1-EN-GB 111
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.
112 200000657-1-EN-GB
Parameter p166 was increased to 1.2 which resulted in a

satisfactory valve movement (3): A fast movement, followed by
3rd backflush a minor 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
seconds. The parameter defines time between a backflush is
triggered and it actually starts. But now, when V201-8 is
4th backflush calibrated, this time can be shortened. Before the fourth
backflush parameter p310 is set to 15 seconds. The shortened
time span is indicated by the braces in the illustration.
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).
3.5.24.2 External feed

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).
3.5.24.2.1 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.
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.
200000657-1-EN-GB 113

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).
114 200000657-1-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
affects 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.
200000657-1-EN-GB 115
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 log also include components
connected via the log box (optional).
The control system store all alarms and relevant events for at least 24 months.
The memory has a vast safety margin, but when it is full, data will be deleted
starting with the oldest data. Logged information can be exported to a USB
memory stick. See Export control system event log files on page 102.
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
70 Operator command, set certified flow to [x] m3/h N
80 Operator command, start stripping is issued N
100 Manual mode set by operator N
110 Heeling mode set by ISCS. N
120 Heeling mode canceled by ISCS. N
150 Overboard valve opened. Feedback from ISCS. Y
155 Ballast water pump started. Feedback from ISCS. Y
160 Overboard valve closed. Feedback from ISCS. Y
165 Ballast water pump stopped. Feedback from ISCS. Y
External shutdown issued. (System stop button on N
170 control cabinet or external system stop button)
System stopped by emergency button on control
175 N
cabinet.
190 Standby mode N
210 Ballast Start-up mode N
220 Full ballast mode Y
230 Pause Ballast N
240 Filter backflush mode N
250 Stop ballast mode N
260 Deballast start-up mode N
270 Full deballast mode Y
280 Pause Deballast mode N
290 Stop deballast mode N
CIP process started, UVR [x, y, z ...]
300 N
x, y, z ...= units that has been subjected to CIP.
310 E-stop N
Power turned on. PureBallast has been powered
320 off for XX days YY hrs ZZ min. Time of how long N
the power has been switched off
116 200000657-1-EN-GB
330 X m3 of ballast intake treated Y
331 Amount (m3) of ballast intake treated. Time interval Y

1 minute.
340 X m3 of ballast discharge treated Y
341 [X] m3 of ballast discharge treated. Time interval 1 Y

minute.
350 PureBallast is bypassed. Valve V212-31 open. Y
PureBallast bypass discontinued. Valve V212-31
360 Y
closed.
370 Request sent to ISCS: Open overboard valve. N
380 Request sent to ISCS: Close overboard valve. N
390 Request sent to ISCS: Start ballast water pump. N
400 Request sent to ISCS: Stop ballast water pump. N
410 Power requested from ISCS. N
420 Power granted by ISCS. N
430 Power used for process. N
PureBallast shut down and/or start blocked due to
450 Y
alarm(s).
PureBallast is bypassed. Additional (external)
460 Y
bypass valve 1 open.
PureBallast bypass discontinued. Additional
470 Y
(external) bypass valve 1 closed.
480 Y
490 Y
500 Y
510 Y
515 Y
bypass valve opened from ISCS.
520 Low UV intensity in UVR 1. Y
640 UV intensity in UVR 1: [X] W/m2 Y
701 UVR 1 UV lamp time reset Y
200000657-1-EN-GB 117

760 Power setpoint (%) for UVR 1: Y
800 Flow higher than certified flow. Y
801 Flow restored to certified flow Y
805 System started in IMO mode Y
806 System started in USCG 3d mode Y
807 System started in USCG 0d mode Y
810 UVR 1 was not CIP cleaned within required time. Y
811 CIP cleaning completedfor UVR 1. Y
813 CIP cleaning completed for UVR 2. Y
817 CIP cleaning completed for UVR 4 Y
5500 Bypass detected by Log box. Y
5501 Heeling detected by Log box. Y
118 200000657-1-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.
200000657-1-EN-GB 119
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
120 200000657-1-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)
• Start P403-1 (UVR cooling water pump) (if
used).
200000657-1-EN-GB 121
4 Power management
Automatic power request from PureBallast to
vessel’s power management system (if
integrated).
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:
• 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.
122 200000657-1-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)
• 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).
• 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
200000657-1-EN-GB 123
3 Filter backflush stop.

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

process is repeated.
3.7.2.4 Pause ballast (Heeling mode)

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

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

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

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

in control system.
• - 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).
124 200000657-1-EN-GB
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.)
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
optimization based on input from UV
sensor QT201–50.
3.7.2.5 Stop ballast

Purpose: To stop the ballast process.
200000657-1-EN-GB 125
1 Operator stops the ballast process manually.

• Stop P401-1 (LDC cooling water pump) (if
used)
• 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.)
• Close V401–51 LDC (LDC cooling water
inlet)
• Set V201-8 (control valve) to parameter
set opening percent
• Close V201-3 (main inlet valve) Wait for
feed back “closed” or max time 15
seconds.
• Close V201-8 (control valve) completely.
• 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)
2 Request from control system stop ballast

signal is enabled.)

in control system.
• Automatic withdrawal of power allocation
(if integrated)
• Close V201-32
• Stop counter: Accumulated water.
126 200000657-1-EN-GB
4 Request from control system to close

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

CIP or delay.
200000657-1-EN-GB 127
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)

used).
128 200000657-1-EN-GB
4 Power management
integrated).
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.
200000657-1-EN-GB 129

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

CIP required.
(if used)

cooling water)
control of control valve (V201-8) based on
input from the flow meterand input from
• 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
3.7.3.3 Pause deballast (Heeling)

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

manually. Pause can also be initiated by an
external signal, for example when heeling is
initiated from the ISCS. In this case, the
process is resumed automatically when the
heeling signal is deactivated.
set opening percent.
• Open V403-35 (cooling water inlet)
(if used)
- Open V404-36 (UV reactor outlet, cooling

water) on running UV reactors.
130 200000657-1-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)
200000657-1-EN-GB 131


(if used)

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

Purpose: To stop the deballast process.
132 200000657-1-EN-GB
1 Operator stops the deballast process

manually.
used)
mode
inlet)
set opening percent
seconds.
then switched off.
minutes
2 Request from control system stop ballast

signal is enabled.)

in control system.
(if integrated)

200000657-1-EN-GB 133

CIP or delay.
134 200000657-1-EN-GB
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.

200000657-1-EN-GB 135

(if used)

used).
4 Power management
integrated).
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)
136 200000657-1-EN-GB
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
control of control valve (V201-8) based on
input from the flow meter.
3.7.4.3 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
minutes.
- Stop counter: UV lamp runtime
- Close V201-19 (reactor inlet)
- Automatic power request adjustment (if
integrated).
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.
200000657-1-EN-GB 137
1 Operator pause the stripping process

manually.
set opening percent.
• Open V403-35 (cooling water inlet)
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.)
6 Stripping pump started by operator and

• Open V201-9 (main inlet valve)
138 200000657-1-EN-GB


(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.
200000657-1-EN-GB 139
1 Operator stops the stripping process

manually.
used)
mode
inlet)
set opening percent
seconds.
then switched off.
minutes
2 Request from control system stop stripping

enabled.)
3 Stripping pump stopped by operator and

(if integrated)

140 200000657-1-EN-GB

CIP or delay.
200000657-1-EN-GB 141
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 95. 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.
142 200000657-1-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 :
• - 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.
200000657-1-EN-GB 143
• -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 + 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, 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.
144 200000657-1-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, + 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.
200000657-1-EN-GB 145
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

146 200000657-1-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 98 and Operate UV
lamps manually on page 100.
200000657-1-EN-GB 147
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.
148 200000657-1-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.
200000657-1-EN-GB 149
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.
150 200000657-1-EN-GB
EN
4 Parameters
200000657-1-EN-GB 151
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 3.1.19.
• 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
system. 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.
152 200000657-1-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.
200000657-1-EN-GB 153
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, standard system.
shutdown trigger 7.00 1–10 bar Max working pressure for standard system: 6
(PT201–16) bar.
Max working pressure for high pressure
system: 9 bar.
p101 Setpoint for warning due to high pressure at

High pressure, PT201-16. Default value shall be used for
warning trigger 6.00 0–10 bar standard system.
(PT201-16)
Max. working pressure: See parameter p100.
Low pressure,
p103 warning 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
Undershoot certified
p111 5 0–80 % actual max flow to avoid unnecessary shut
flow down.
154 200000657-1-EN-GB
Parameters 4 EN

value
During ballast and deballast, valve V201–8
handles the automatic pressure and flow
Min opening for control.
p113 20 10–100 %
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,
10 10–90 %
limit (FIT201-1) defined as percent of UVR capacity.
p117 Define max delay, in hours, before a CIP

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

Max delay of CIP 1 0–30 day process must be performed after ballast or
cycle, days deballast.
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
deballast 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
deballast.
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

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

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

confirmation (hard wired from ISCS or
manually in popup). After defined time, the
Timeout: Request process is 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.
200000657-1-EN-GB 155
EN 4 Parameters

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

booster pump will try to maintain.
p186 The variable-frequency drive (VFD) gets
Booster pump P201– information about the PureBallast water
1 setpoint (PT201– 0.5 0.1–2 Bar pressure from the pressure sensor PT201–
16) 16. The 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.
156 200000657-1-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
contactors and are handled externally.
p129 • Internal: Pump completely controlled from

Booster pump PureBallast control cabinet: Start signal
(P401-1) for LDC Not used N/A Drop list and power supply with over current
cooling water protection relays and contactors from
control cabinet. It is still possible to
connect pumps according to configuration
1.
•
Note: In internal mode, external signal will
also be activated.
Note: Internal is only displayed for control
cabinets of configuration 2. See control
system page 4.1, field Control cabinet
configuration.
200000657-1-EN-GB 157
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.
p130 • Internal: Pump completely controlled from

Booster pump PureBallast control cabinet: Start signal
(P403-1) for reactor Not used N/A Drop list and power supply with over current
cooling water protection relays and contactors from
control cabinet. It is still possible to
connect pumps according to configuration
1.
•
Note: In internal mode, external signal will
also be activated.
cabinets of configuration 2. See control
system page 4.1, field Control cabinet
configuration.
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

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

from external feed. Only valid if PureBallast is
contolling ballast water flow by sending
signals 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
parameter 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
increased flow until desired value is reached.
Default value should normally be used.
158 200000657-1-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/% Note: It might take a little longer for the actual
rate
change of the pump or the valve to adjust the
flow.
Defines when external feed control is
p157 activated, based on V201-8.
External feed V201– 70 50–90 % PureBallast will start to request reduced flow
8 low trigger limit
when V201-8 closes to reach this degree of
percent open.
Only valid if RMC protocol is used for GPS

integration.
If activated, time and date in the control
GPS time system is retrieved from vessel’s GPS.
p160 synchronization via Not used N/A Drop list
RMC-protocol If no GPS is connected, time and date must
be set in control system page 4.1 System
info.
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 0.00–
0.6 N/A The PID regulation during backflush is based
proportional 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.
200000657-1-EN-GB 159
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,
10 7-90 %
stripping (FIT201–1) defined 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
parameter p180 is set to option “USCG 3d
+0d”.
Note: This parameter is only relevant for
USCG systems.
Alternatives:
p182
USCG hold time 3 days N/A Drop list The time between a completed
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.
160 200000657-1-EN-GB
Parameters 4 EN
4.2.4 Page 5.3 — UVR parameters

This section describes parameters controlling the UV reactor.

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

Low temp, alarm -2 -5 to 40 ºC indicated by temperature transmitter in the
trigger (TT201-33) UV 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
90 0–130 sec
time ballast, deballast or stripping starts.
p211
Cooling time for UV lamps after ballast or
UV lamp cooling time 300 180–600 sec deballast.
200000657-1-EN-GB 161
EN 4 Parameters

value
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 5 2-10 min technical water / potable water during CIP
time UV reactor 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 running at 30 % of full effect.
20.0-60.
low threshold 40.0 ºC
0 At setpoint the fan effect is increased
(TT401-2)
proportional to temperature from 30 % up to
100 % at temperature set in p232.
p232 Cabinet temperature 20.0-60. Setpoint for running the LDC cooling fan at
high threshold 45.0 ºC
0 100 %.
(TT401-2)
p234 Defines proportional gain (Pf) value used for

UV control 0.00-100 N/A PID regulation of UV lamp power.
0.10
proportional 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
p237 are lit to the degree needed for full treatment,
Activate but not more.
Power optimization N/A Drop list
d If disabled, UV lamps are lit at 100 % all the
time. Disable if the UV optimization
malfunctions, to avoid alarms.
p238 High temperature, 20.0-100 ºC Air temperature warning, indicated by

warning trigger in 50.0 .0 temperature transmitter in LDC.
LDC (TT401-2)
162 200000657-1-EN-GB
Parameters 4 EN
4.2.5 Page 5.4 — Filter parameters

This section describes parameters controlling the filter module.
ID Parameter Default Min- Unit Description

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
p303 20 1–30 min
duration backflush , after triggered by p302.
Defines desired pressure for efficient
backflushing.
When a backflush is triggered, control valve
V201–8 will regulate to reach this pressure.
After 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.
200000657-1-EN-GB 163
EN 4 Parameters

value Max
Setpoint for automatic start of filter backflush
due to dirt in the filter, indicated by high
Backflush trigger: differential 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
only by Alfa Laval during commissioning.
Defines duration of filter preservation (filling
Filter preservation
p306 5 1-30 min with technical water / potable water) after
time ballasting.
p307 Time the control system will wait for
confirmation that water has filled the filter.
Timeout filter filling 3 1–15 min 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,
regardless of current differential pressure.
Defines how long time that should pass from a
p310 backflush is triggered until is actually started.
Backflush initial 5 0–60 During this time, the control valve is PID
delay
regulated 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
(primarily pressure peaks after completed
backflush).
Value for low pass filtered differential pressure
Differential pressure is indicated as “dp” on the filter in the filter
p313 5 0-30 sec
measurement filter popup, 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
differential pressure curves.
Defines type of filter installed.

p314 Filter Type 3 N/A Drop list Alternatives: Type 1 (Boll), Type 2 (Hydac) and
Type 3 (Filtrex).
Parameter p314 should be set before this

parameter. Available alternatives depend on
selection in p314.
Defines filter type and capacity according to
p315 plate mounted on the filter.
100 – The parameter shall be set to ACB-999–350.
Filter type 500 6000 m3/h
Note: If the parameter is called Filter size, set
the parameter to maximum capacity for
installed filter. This is same as the maximum
ballast flow. See item 201 in in the Connection
list in chapter 6. Installation description and
drawings.
164 200000657-1-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.
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
according to configuration 1.
•
Note: In internal mode, external signal will also
be activated.
cabinets 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 0-10 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 from the filter via pipe 309 and filled with new
Not
p323 during filter N/A Drop list water via pipe 310.2. The backflush pump
used
preservation should not be used if the filter is emptied.
200000657-1-EN-GB 165
EN 4 Parameters
4.2.6 Page 5.5 — CIP parameters

This section describes parameters controlling the CIP module.

value
p400 Duration of a CIP cycle.
6.00 hours
CIP cycle time 1–30 Duration of circulation of CIP liquid during a
15 min CIP process.
166 200000657-1-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
p700 Interface type RS485 N/A Drop list PureBallast.
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.
200000657-1-EN-GB 167
EN 4 Parameters

value
p703 Defines data bits per character. Default value
Data bits 8 N/A Drop list shall be used.
Alternatives: 7 or 8.
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

Modbus station station address. The address must be unique
10 1–247 Drop list
number for each PureBallast system communicating
with common ISCS (ship system).
168 200000657-1-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
N/A starboard 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 1 Min-Max: 1–6
reactors 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
200000657-1-EN-GB 169
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
selection (during 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

allowed 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 and 1000
Set parameter to: 1000
p150 Defines if the Ex proof version of PureBallast is installed. This

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

p151
Not used Mandatory for IECEx installations. Only used for Ex US flag
Ex-I barrier fault installations.
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
(Requires USCG Not used Alternatives:
approved 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.
170 200000657-1-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
p181 system plate on the control cabinet. If activated, it is possible to run
USCG high Not used the system in USCG mode and IMO mode. This is changed by the
performance (HP) IMO and USCG function buttons.
Note: This parameter can only be activated for a USCG system.
p185
Defines if the optional booster pump is activated or not.
Booster pump 201–1 Not used
p500 Defines if the log box (optional) is installed to monitor and log
external valves and pumps, that are not part of Alfa Laval’s scope
Log box Not used of supply.
200000657-1-EN-GB 171
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)
1 ON
2 ON
3 ON ON
4 ON
5 ON ON
6 ON ON
7 ON ON ON
8 ON
9 ON ON
10 ON ON
11 ON ON ON
12 ON ON
13 ON ON ON
14 ON ON ON
15 ON ON ON ON
16 ON
Example
In the illustration, the DIP switches is set for LPS no. 5.
172 200000657-1-EN-GB
Parameters 4 EN
200000657-1-EN-GB 173
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 Flow meter parameters

The parameters are preset in the flow meter transmitter.
Follow this instruction to check and set internal parameters in the flow meter
transmitter.
The parameters for CURRENT OUTPUT: VALUE 20 mA and the PROCESS
PARAMETER: ON-VAL.LF-CUTOFF shall be set according to pipe dimension
for the flow meter pipe.
The parameters are set by using the three operating keys; E, +, - on the flow
transmitter panel. Use the keys to navigate between options in the meny on
the display.
174 200000657-1-EN-GB
Parameters 4 EN
1. Press E (Enter).
2. Press + (Plus) or - (Minus) to find function group listed below.
3. Press E to find parameter.
4. Press + or - .
5. Set access code 0050 by pressing + or -, the correct digit and then press E
after each digit.
6. Change value by pressing E .
7. Press + and - simultaneously for minimum 3 sec, to escape the
programming mode.
Meny on the display:
Function group Parameter Factory settings
MEASURING VALUES N/A N/A
UNIT VOLUME FLOW m3/h
UNIT VOLUME m3
SYSTEM UNITS
UNIT LENGTH MILLIMETER
FORMAT DATE/TIME DD.MM.YY 24H
QUICK SETUP QUICK SETUP COMMISSIONING NO
LANGUAGE ENGLISH
ACCESS CODE N/A
OPERATION DEF. PRIVATE CODE 50
STATUS ACCESS N/A
ACCESS CODE COUNTER 0
ASSIGN LINE 1 VOLUME FLOW
ASSIGN LINE 2 TOTALIZER 1
FORMAT X.XXXX
USER INTERFACE DISPLAY DAMPING 3s
CONTRAST LCD 50 %
BACKLIGHT 50 %
TEST DISPLAY OFF
ASSIGN TOTALIZER VOLUME FLOW
SUM N/A
OVERFLOW N/A
TOTALIZER 1 / 2 (both)
UNIT TOTALIZER m3
TOTALIZER MODE Totalizer 1 + 2: FORWARD
RESET TOTAL NO
RESET ALL TOTAL NO
HANDLING TOTAL
FAILSAFE MODE STOP
200000657-1-EN-GB 175
EN 4 Parameters
Function group Parameter Factory settings

ASSIGN CURRENT VOLUME FLOW
CURRENT SPAN 4–20 mA
VALUE 20 mA See table below
CURRENT OUTPUT 1 TIME CONSTANT 5.00 s
FAILSAFE MODE ACTUAL VALUE
ACTUAL CURRENT N/A
SIMULATION CURR. OFF
COMMUNICATION N/A N/A
ASSIGN LF-CUTOFF VOLUME FLOW
ON-VAL. LF-CUTOFF See table below
OFF VAL. LF-CUTOFF 50 %
PROCESS PARAMETER EMPTY PIPE DET. OFF
EPD/OED RESPONSE TIME 1.0 s
ECC N/A
EPD/OED ADJUSTMENT OFF
INSTL. DIR. SENSOR NORMAL (FORWARD)
MEASURING MODE STANDARD
SYSTEM PARAMETER POS. ZERO RETURN OFF
SYSTEM DAMPING 9
INTEGRATION TIME 20 ms at 50 Hz, 16.7 ms at 60 Hz
SENSOR DATA N/A N/A
CURRENT SYSTEM CONDITION N/A
PREV. SYS. COND. N/A
ASSIGN SYS. ERROR CANCEL
ASSIGN PROCESS ERRORS CANCEL
SUPERVISION
ALARM DELAY 0s
SYSTEM RESET NO
OPERATION HOURS N/A
PERMANENT STORAGE ON
SIM. FAILSAFE MODE OFF
SIMULATION SYSTEM
SIM. MEASURAND OFF
SENSOR VERSION N/A N/A
AMP. VERSION N/A N/A
Set parameter “VALUE 20 mA” and “ON-VAL. LF-CUTOFF” (low flow cut off)
as table below:
Flow meter - Pipe dimension specific values:
Pipe dimensions VALUE 20 mA (flow span Low flow cut off (m3/h
corresponding to 4-20 mA)
A/DN 150 0-500 2.5
A/DN 200 0-700 5.0
A/DN 250 0-1200 7.5
A/DN 300 0-1200 10
176 200000657-1-EN-GB
Parameters 4 EN
Pipe dimensions VALUE 20 mA (flow span Low flow cut off (m3/h
corresponding to 4-20 mA)
A/DN 350 0-1700 15
A/DN 400 0-2200 20
A/DN 450 0-3300 25
A/DN 500 0-3300 30
A/DN 600 0-3300 40
Reset of factory settings

1. Press E key.
2. Press + and - key to find function group SUPERVISION.
3. Press E key to find parameter SYSTEM RESET.
4. Set access code 0050 by pressing + or -, the correct digit and then press E
after each digit.
5. Change the setting from NO to YES.
6. Press E key.
7. Press + and - simultaneously for minimum 3 sec to escape the
programming mode.
200000657-1-EN-GB 177
EN 4 Parameters
178 200000657-1-EN-GB
EN
5 Alarms and faultfinding
200000657-1-EN-GB 179
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 41
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
symbol 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.
180 200000657-1-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.
Alarm details Possible cause What to do?
A01 Ballast water pump Check pressure and flow from ballast pump(s). If the
gives too high pressure. pressure exceeds set value: Adjust incoming pressure to
Process pressure too PureBallast.
high (PT201-16).
Valves in the system Control that correct valves are functioning and opened for
Trigger: PT201–16. after pressure current process. See Detailed process description on
Parameter: p100. transmitter are closed. page 119.
Delay: 30 sec. Material is stocked after Check the entire system for blocking material.
pressure transmitter
Comment: Pressure PT201-16.
transmitter PT201-16
indicates pressure Pressure transmitter 1. Check cables to pressure transmitter PT201-16. See
higher than set in PT201-16 is faulty. circuit diagram for control cabinet , in section
parameter p100. Electrical drawings on page 278.
2. Replace pressure transmitter PT201-16.
A03 Signal missing or 1. Check fuse F45 in control cabinet to see what circuit
pressure transmitter caused the fuse trip.
Process pressure signal PT201-16 malfunction.
missing (PT201-16). 2. Use the circuit diagram, for control cabinet , in section
Electrical drawings on page 278 to check the fuse
Trigger: PT201-16. setting, adjust according to figures in circuit diagram if
Delay: 30 sec. necessary and reset fuse.
Comment: Error in 3. Use the circuit diagram to locate the component or
system pressure sensor. find the reason that caused the fuse trip and attend to
Indication of pressure it.
-1.0 bar is not an error.
4. Check that all electrical connections are OK and that
the electrical wiring is not damaged.
5. Replace transmitter PT201-16.
200000657-1-EN-GB 181

W04
Process pressure too
high (PT201-16).
Trigger: PT201-16.
See possible cause for
Parameter: p101 See A01.
A01.
Delay: 30 sec.
Comment: Pressure
higher than parameter
set limit.
A10 Signal missing or flow 1. Check fuse F45 in control cabinet to see what circuit
meter FIT201-1 caused the fuse trip.
Process flow signal malfunction.
missing (FIT201-1). 2. Use the circuit diagram for control cabinet , in section
Electrical drawings on page 278, to locate the
Trigger: Flow meter component or find the reason that caused the fuse
FIT201-1. trip and attend to it.
Delay: 5 sec.
Comment: Error in the electrical wiring is not damaged.
system flow sensor.
4. Check that system flow has not been significantly
over maximum flow for the system.
5. Replace flow meter FIT201-1.
W12 Flow rate higher than Reduce the incoming ballast water flow to the PureBallast
selected certified flow. system.
Process flow higher than See field certified flow in
certified (FIT201-1). Page 1.1 – Overview on
Reduce flow! page 51.
Trigger: FIT201-1. Wrong setting in See chapter Parameters on page 151.
Delay: 30 sec. FIT201-1.
Comment: An additional
common alarm signal is
issued.
Note: Operation
continues but is not Flow sensor See section Flow meter in List of alarms and warnings on
compliant and does not malfunctions. page 180.
fullfil requirements for
treatment of ballast
water. Act according to
ballast water
management plan.
182 200000657-1-EN-GB

A13 Flow is too low. 1. Increase flow.
Process flow too low 2. Make sure the ballast water from the ballast pump is
FIT201-1. directed to PureBallast. When OK the process will
continue automatically.
Trigger: FIT201-1.
Parameter: p116. 3. Check pressure and flow from ballast pump(s). Adjust
incoming pressure to PureBallast, if necessary.
Delay: 20 sec.
Comment: If flow is less Wrong setting in See chapter Parameters on page 151.
than set in parameter FIT201-1.
p116, the system is shut
down. Flow sensor See section Flow meter in List of alarms and warnings on
malfunctions. page 180.
Valves in ballast system 1. Control that correct valves are opened for current
closed. process. See Detailed process description on page
119
2. Check mechanical function of the valve and check
that the cables to the component is according with the
circuit diagram for control cabinet in section Electrical
drawings on page 278.
Ballast water pump Attend to. Note: This component is outside the
stopped or malfunctions. PureBallast system control.
A14 See possible cause for
A13.
Process flow too low
during start-up Control valve V201–8 See A29.
(FIT201-1). Automatic malfunctions.
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.
200000657-1-EN-GB 183

A17 Fuse tripped. 1. Check fuse F43 in control cabinet to see what circuit
caused the fuse trip.
Valve error (V201-3).
2. Check relay K1 and K2 on module X10 in control
Trigger: Limit switch cabinet.
GS201-3.
Delay: 25 sec. 3. Use the circuit diagram for control cabinet , in section
Electrical drawings on page 278, to check the fuse
Comment: Error on setting, adjust according to figures in circuit diagram if
valve V201–3. necessary and reset fuse.
4. Use the Circuit diagram to locate the component or
find the reason that caused the fuse trip and attend to
it.
5. Check that all electrical connections to actuator and
sensors on the valve are OK and that the electrical
wiring is not damaged.
Position sensor can not Adjust sensor or puck.

detect the metal on the
puck on the actuator, or Hint: Valves can be manually operated. See instruction
the metal is in wrong Operate components manually on page 98 and Open and
position. close valves manually in section Valves on page 403.
Position sensor
mounted upside down.
Position sensor or 1. Check cables.
cables to position
sensor malfunction. 2. Replace position sensor if faulty.
Too long opening/ 1. Follow the instruction Adjust valve traveling speed on
closing time (valve page 419.
travel time).
2. Adjust exhaust valves on actuator.
3. Check that instrument air pressure is according to
requirements in Connection list on page 236.
Valve cannot open/close Clean. If required dismount valve. See Service manual on
due to obstruction. page 365 for instructions.
A23 See possible cause for Check relay K5 and K6 on module X10.
A17.
Trigger: Limit switch
GS201-9
Delay: 25 sec.
Comment: Error on
valve V201–9.
A25
Valve error (V403-35)
GS201-35. A17.
Delay: 25 sec.
Comment: Error on
valve V201–35.
184 200000657-1-EN-GB

A17.
• Sensor error. Shows 1. Check open indication in the pneumatic positioner.
Trigger: Limit switch open all the time.
GS201-8 2. Check fuse F43 in control cabinet to see what circuit
Delay: 25 sec. • Signal error 4–20 caused the fuse trip.
mA.
Comment: Error on 3. Check relay K3 on module X10.
control valve V201–8 4. Use the Control cabinet / Circuit diagram to check the
fuse setting, adjust according to figures in circuit
diagram if necessary and reset fuse.
5. Use the circuit diagram to locate the component or
find the reason that caused the fuse trip and attend to
it.
6. Check that all electrical connections to actuator and
sensors on the valve are OK and that the electrical
wiring is not damaged.
Positioner is not Calibrate according to Calibrate positioner on V201-8 on

correctly set or page 411.
calibrated.
Cam wheel not correctly
set in positioner, which Adjust according to Adjust cam position on V201-8 on
results in wrong feed page 413.
back to control cabinet.
The air filter on the Clean the filter.
positioner is clogged.
A33 Bypass valve has been If not opened intentionally, close opened bypass valve.
opened manually or via
Bypass valve is open the ISCS.
(V212-31).
If not opened: See
Trigger: Limit switch possible cause for A17.
GS212-31.
Delay: 15 sec.
Comment: If the valve
(not controlled by
PureBallast) is opened,
any ongoing process is
stopped. A new process
can not be started.
A35
Valve error (V212–31).
GS212-31.
Delay: 25 sec. A17.
Comment: Shutdown of
all steps except CIP. The
alarm does not prevent
completion or start of
CIP process.
200000657-1-EN-GB 185

Check that pressure and flow from ballast pump(s) is
Ballast water pump
W40 according to requirements in chapter Technical data and
gives too low pressure. drawings on page 225.
Process pressure too
low (PT201-16). Pressure safety valve Check the valve, and repair or change.
V201 is faulty.
Trigger: Pressure
transmitter: PT201-16. 1. Check cables to pressure transmitter PT201-16. See
Parameter: p103 Pressure transmitter control cabinet , in section Electrical drawings on
PT201-16 is faulty. page 278.
Delay: 2 sec.
2. Replace pressure transmitter PT201-16.
A48
System stop activated
(Stop button). Note: Find out the reason why the process has been
Process has been stopped before releasing the button and starting another
Trigger: Stop button on stopped. process.
control cabinet.
Delay: None.
A49
during CIP (Stop button).
See A48.
Trigger: Stop button on
control cabinet.
Delay: None.
A50
(External stop button). Process has been
Trigger: External stop stopped by external stop Note: Find out the reason why the process has been
button on control cabinet button or signal from the stopped before releasing the button and starting another
ISCS (integrated ship process.
(or signal). control system).
Parameter: p135
Delay: None.
A51
during CIP (External
stop button).
Trigger: External stop See A50.
button on control cabinet
(or signal).
Parameter: p135
Delay: None.
1. Check fuse F43–F45 in control cabinet to see what

W58 circuit caused the fuse trip.
Fuse tripped in control Possible reasons: 2. Use the circuit diagram to locate the component or
cabinet. • short circuit find the reason that caused the fuse trip and attend to
it.
Trigger: Control cabinet. • overheated fuse
3. Use the circuit diagram for control cabinet to check
Delay: None. the fuse setting, adjust according to figures in circuit
186 200000657-1-EN-GB

Possible reasons:
• A motor circuit
breaker (Q2, Q3 or
Q4) in the control Reset or turn on the motor circuit breakers.
cabinet has tripped
or has been switched
off.
1. Motor circuit breaker Q2: Check that the cables

W59 W3091 and W4031 are connected to the control
A signal is missing from cabinet.
a motor circuit breaker.. 2. Motor circuit breaker Q3: Check that the cables W301
Trigger: Fuse. and W4011 are connected to the control cabinet.
Delay: None. • Motor load/problem. 3. Start the motor(s) and check 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.
• Mechanical Check the mechanical parts of P309–1, M403–1, M709–

obstacles. 43, M309–1 and —T1.
Fuse F3 in the control Reset fuse F3.

cabinet has tripped.
W60 1. Check that cable W4011 is connected to the control
the booster pump fuse. 2. Start the motor and check that the operation is
Motor/load problem. normal.
Trigger: Fuse.
Delay: None. 3. Verify that there is no loose wire to the —A2–DI6
digital input on the PLC.
Mechanical obstacles. Check the mechanical parts of M401–1.

W61
1. Check that cable W4031 is connected to the control
the booster pump fuse
for reactor cooling water. Motor/load problem. 2. Start the motor and check that the operation is
normal.
Trigger: Fuse.
3. Verify that there is no loose wire to the —A2–DI7
Delay: None. digital input on the PLC.

A66
Additional bypass valve
1 is open.
Trigger: External
system.
Parameter: p163 The valve has been
opened manually or via If not opened intentionally, close the valve.
Delay: 2 sec. the ISCS.
Comment: If the valve
(not controlled by
PureBallast) is opened,
any ongoing process is
stopped. A new process
can not be started.
200000657-1-EN-GB 187

A67
2 is open.
Trigger: External See A66.
system.
Parameter: p164
Delay: 2 sec.
A68
3 is open.
Trigger: External See A66.
system.
Parameter: p165
Delay: 2 sec.
A69 Bypass valve opened by If not opened intentionally, close opened bypass valve.
ISCS via remote
Remote system reports interface.
system is bypassed.
Trigger: External bypass
valve.
A71 Faulty connection of Check that all electrical connections are OK. Check that
signal cable. the signal wiring is according to information in Control
Ballast water pump is cabinet / Interconnection diagram, in section Electrical
not running. drawings on page 278.
Trigger: Control system If remote interface Test relevant addresses. See Test remote interface
timer. (optional) is used: communication on page 108.
Parameter: p141. Communication
between PureBallast
Delay: Set in parameter and ISCS is wrong.
p141.
Time set in parameter is Check/change parameter in control system page 5.1 –
Comment: Feed back lower than needed. Main parameters 1.
signal “BW pump is
running” is not activated
after request.

A71.
Strip pump is not
running
Trigger: Control system
timer.
Parameter: p141.
Delay: Set in parameter
p141.
Comment: Feed back
signal “BW pump is
running” is not activated
after request.
188 200000657-1-EN-GB

A75
Overboard valve is not
open. Automatic stop.
timer.
Parameter: p140. A71.
p140.
Comment: Feedback
“overboard valve is
OPEN”.
A77
Error on all operating
UVR:s. Automatic stop. An active alarm exist on
all installed UV reactors. Check control system page 2.1 Alarm list in control panel
Trigger: UV reactors It can be the same error for related alarms.
for all UV reactors, or
Delay: None. different errors.
Comment: All UV
reactors are deactivated.
A79 Power management Investigate if the reasons for not granting power is outside
master system not the PureBallast system.
Power is not granted. granting power to UV
Trigger: Control system reactor(s).
timer. Feedback signal from See A71.
Delay: Set in parameter power management
master is faulty. Check signal transmission to/from PureBallast
p127. corresponds to the specifications in Control cabinet /
Comment: No power Interconnection diagram, in section Electrical drawings on
steps have been granted page 278.
within parameter set Hint: If problem persists, see control system page 1.4 –
time. PureBallast power request to find which GRANTED signal
that was interrupted during the ballast/deballast process.
W80 See possible cause for

A79.
Power is not fully
granted. Flow capacity
reduced.
Trigger: Power
management system.
Parameter: p127.
Delay: None. Not enough power has Continue process with lower flow capacity or try later.
been granted.
Comment: Not all
requested power steps
are granted. Triggered if
number or requested
power steps does not
match number of
granted power steps.
200000657-1-EN-GB 189

W82 If heeling mode has not
been requested: See
Heeling mode . first two possible causes
for A71.
Trigger: ISCS.
Delay: 15 sec.
Comment: It is not
possible to start a
process when the
system is in heeling
mode. This warning is
automatically
acknowledged when the
heeling mode is redrawn
from ISCS.
W83
Heeling mode cancelled
by operator. Process
resumed.
Trigger: Heeling
(internal transfer) not
requested in control See possible cause for
system. W82.
Parameter: N/A
Delay: None.
Comment: Process is
resumed after being
phased during heeling.
A91 Panel is switched off or 1. Switch on the panel.

faulty.
PLC lost communication 2. Restart the panel. See problem 1 B in General
with all control panels. problems on page 218.
Trigger: Control system 3. Replace if faulty.
PLC.
Delay: 60 sec. Wrong software version. Check that the HMI and PLC software have the save
program version. This is visible in control system page
Comment: After 60 4.1 System 1.
seconds of lost
communication, ongoing Wrong network setting. Check settings for each panel according to Set control
process is stopped in a panel IP address on page 105
controlled way and the Faulty cable connection. Check cables to the component. For reference, see
system is shut down. Control cabinet / Interconnection diagram, in section
This message is visible Electrical drawings on page 278 and Remote control
in the control panels and panel / Circuit diagram (optional) on page 340.
saved in the log after the
communication is
restored. But, W92 will
be visible in the main
control panel.
190 200000657-1-EN-GB

W92 Master panel is See A91.
switched off or faulty.
Master control panel lost
communication with the Faulty cable connection. See A91.
PLC
PLC.
Delay: 30 sec.
Comment: After
communication is lost,
ongoing process is
stopped in a controlled
way and the system is
shut down. This
message is visible in the
main control panel.
200000657-1-EN-GB 191

A93 To operate PureBallast when communication is down,
follow the steps below:
Heartbeat signal from
remote interface is not 1. Set the system to Local mode: Press the local button
updating. on the control panel.
Trigger: Control system 2. Run the system from the control panel. Note that you
PLC. will need to confirm the messages from the control
panel during operation: "Confirm ballast pump
Parameter: p132. started".
Delay: 60 sec.
3. Restore these settings when the communication is
Comment: After working.
communication is lost
between ISCS and PLC, 4. Make sure that the system is not in test mode in page
ongoing process is 4.4 Remote 1 (no check mark on the Test mode
stopped in a controlled button)
way and the system is .
shut down.
The Heartbeat field in System is set to Test If you deliberately set the system to test mode (for
page 4.4 Remote 1, mode. example to test remote interface integration, you can
indicates disregard this alarm. If not deactivate the test mode again
communication. in page 4.4 Remote 1.
Faulty settings. 1. Check that parameter p700 is set to match the
modbus cable type used (RS422 or RS485).
2. Check if remote operation is deactivated in the control
panel (The Remote button at the bottom of the screen
is gray). If so, press the Remote button.
3. Check if test mode is activated in page 4.4 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 instruction Set remote interface
communication on page 108
Faulty cable connection Check cable between the ISCS and the main control
panel and the cable between the PLC and the main
control panel. For reference, see Control cabinet /
Interconnection diagram, in section Electrical drawings on
page 278.
Tips: Make sure that the modbus cables in terminal
X15are correct (not switched).
Communication See W92.
between PLC and main
control panel is lost
ISCS is faulty Investigate problem in ISCS, and attend to found
problems.
W95
PLC battery low.
Trigger: Control system The voltage in the
battery in the control Replace PLC battery in the control cabinet.
PLC. system PLC is too low.
Parameter: N/A
Delay: 10 sec.
192 200000657-1-EN-GB

W96 Faulty electrical Check that the signal wiring is according to Control
connection. cabinet / Interconnection diagram. See section Electrical
GPS signal not valid. drawings on page 278.
PLC.
Parameter: p160.
Delay: 5 sec.
W97 Error in module. Check the LED error indication for the electronic modules
in the cabinet. See I/O system and X20 modules on page
PLC error in control 212.
cabinet.
Faulty electrical 1. Check that the signal wiring is according to electrical
Trigger: N/A connection. drawings in Technical data and drawings on page
Parameter: N/A 225.
Delay: 2 sec. 2. Check that all electrical connections are OK on bus
modules and that the electrical wiring is not damaged.
A98 Emergency stop button Note: Find out the reason why the process has been
pressed (control cabinet stopped. Then: Release the Emergency button and press
Emergency stop or external). the Reset button on the control cabinet .
Trigger:
Faulty connection of Check that all electrical connections are OK on bus
• Emergency stop signal cable. modules and that the electrical wiring is not damaged.
button on control
cabinet (safety relay
KS01).
• Temp switch TS201–
60.
• Temp switch TS201–
33.
Parameter: p150.
Delay: 2 sec.
Comment: This alarm is
specific for the Ex proof
version of PureBallast.
W100 • Check that the inlet valves (V201-19.x, V403-35) and

High temperature due to outlet valves (V201-20.x, 404-36.x) open properly by
UVR [x]: UVR temp too operating them manually. See Operate components
high (TT201-33). UVR obstacles or error in one
or more components manually on page 98
shutdown.
involved. • Check that cooling water supply (403) is within
Trigger: UVR specification in Connection list on page 236
temperature transmitter
TT201-33.
Low flow of cooling Check pump, valves and other components involved in
Parameter: p202 water during start-up the sea water cooling system.
Delay: 5 sec. Parameter p202 not Check/change parameter in control system 5.3 – UVR
correctly set. parameters.
Comment: If
temperature rises above
parameter set value, the
UV reactor will
shutdown.
If the alarm trips during
operation with a flow Replace transmitter TT201–33 according to instruction in
through the UV reactor, TT201-33.x malfunction. Service manual on page 365.
the valves V201-19.x
and V201-20.x will close
If the alarm trips during
ballast start-up, valve
V404-36.x will close.
200000657-1-EN-GB 193

W101 See possible cause for
W100.
UVR [x]: UVR temp too
low (TT201-33). UVR Ballast water too cold;
shutdown. temperature below 0 C°. See to that incoming water is warmer than 0 C°.
Trigger: UVR
temperature transmitter Engine room too cold;
TT201-33. temperature below 0 C°. Increase temperature.
Delay: 5 sec.
1. Check fuse F42 in LDC to see what circuit caused the

fuse trip.
2. Use the circuit diagram to check the fuse setting,
adjust according to figures in circuit diagram if
W102 necessary and reset fuse.
UVR [x]: UVR temp
signal missing 3. Use the circuit diagram to locate the component or
(TT201-33). UVR find the reason that caused the fuse trip and attend to
Signal missing or it.
shutdown. transmitter TT201-33.x
Trigger: UVR malfunction. 4. Check cables to the component. See UV reactor /
temperature transmitter Circuit diagram and Lamp drive cabinet / Circuit
TT201-33 error. diagram in Electrical drawings on page 278.
Delay: 5 sec. 5. Check that all electrical connections are OK and that
6. Replace transmitter TT201-33.
7. Restart the process from the beginning.
W105
Temp below 0 °C.
Trigger: LDC
temperature transmitter
TT401.
Delay: 5 sec.
No cooling water to the Check that cooling water supply (401) is within
W107 heat exchanger. specification in Connection list on page 236.
UVR [x]: LDC cooling Incoming cooling water Feel the water pipe, if it is too warm. If so, investigate and
water temp too high too warm. attend to problem.
(TT401–1).
Cooling water valve
Trigger: LDC SV401–51 and/or
temperature transmitter Check and attend to.
CV402 blocked or
TT401. closed.
Parameter: p214 Parameter p214 not Check/change parameter in control system 5.3 – UVR
Delay: 15 sec. correctly set in control parameters.
system.
194 200000657-1-EN-GB

1. Check fuse F42 in LDC to see 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 reason that
W109 Signal missing or caused the fuse trip and attend to it.
UVR [x]: LDC cabinet transmitter TT401
temp missing (TT401– malfunction. 4. Check cables to the component. See Lamp drive
1). cabinet / Circuit diagram in Electrical drawings on
page 278.
Trigger: LDC
temperature transmitter 5. Check that all electrical connections are OK and that
TT401–1. the electrical wiring is not damaged.
Delay: 5 sec. 6. Replace transmitter TT401.
Faulty connection to Check that all electrical connections are OK on X20

X20 module. module and that the electrical wiring is not damaged.
Check component. See section I/O system and X20
Faulty X20 module. modules on page 212. Change according to instruction in
Service manual on page 365.
W111 LDC faulty. Check 2. Alarm list in control panel for related alarms.
LDC air temperature too
high (TT401–2).
Trigger: Temperature
transmitter TT401–2. Faulty fan. Check electrical and mechanical problems, and attend to.
Parameter: p238.
Delay: 15 sec.
Check electrical and
Faulty fan. mechanical problems,
and attend to.
1. Check fuse F42 in lamp drive cabinet to see what
circuit caused the fuse trip.
adjust according to figures in circuit diagram if
W113
LDC cabinet 3. Use the circuit diagram to locate the component or
temperature missing find the reason that caused the fuse trip and attend to
Signal missing or it.
(TT401–2) temperature transmitter
Trigger: Temperature TT401-2 malfunction. 4. Check cables to the component. See Lamp drive
transmitter TT401–2. cabinet / Circuit diagram in Electrical drawings on
page 278.
Delay: 5 sec.
6. Replace transmitter TT401-2.
200000657-1-EN-GB 195

1. Check fuse F42 in lamp drive cabinet to see which
circuit that caused the fuse trip.
2. Check relay KS02.
3. Use the circuit diagrams for the LDC to check the
fuse setting, adjust according to figures in circuit
W116 4. Use the circuit diagrams for the LDC and UV reactor
UVR [x]: UVR fluid level to locate the component or find the reason that
signal missing caused the fuse trip and attend to it.
(LS201-29). Signal missing or sensor
LS201-29.x malfunction. 5. Check cables to the level switch LS201-29.x. See
Trigger: Level sensor drawing UV reactor/ Circuit diagram and Lamp drive
LS201-29. cabinet / Circuit diagram in Electrical drawings on
page 278.
Delay: 5 sec.
6. Check that the level switch is working correctly. See
Level switch on page 211. Hint: Dismount 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 365.
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
problem 6D-6I in General problems on page 218.
3. Hint: Valves can be manually operated. See Valves
on page 403. Note that the manual operations are
No fluid in UV reactor password-protected and must only be performed by
“x”. LS201-29.x is authorized trained personnel. The PureBallast
indicating dry condition. equipment or connected equipment can be
W118
irreparably damaged if handled incorrectly.
UVR [x]: CIP flow
missing (LS201-29). 4. Examine the pipes related to the CIP circuit. Make
sure that no material is clogging the pipes.
Trigger: Level sensor
LS201-29. 5. Check that the level switch is working correctly. See
Level switch on page 211.
Parameter: p208.
Delay: Set in parameter Time set in parameter is Change parameter.
p208. lower than needed.
Level switch at UV
reactor LS201-29.x See W116 to troubleshoot the level switch electrically.
malfunction.
Too low level in CIP Refill the tank with CIP liquid. See instruction Change and
tank. refill CIP liquid on page 394.
Air in fluid. The level
switch indicates this as Deaerate the CIP, using the deaeration valve on the CIP.
no fluid in UV reactor.
196 200000657-1-EN-GB

1. Check that pressure flushing water in pipe 310 is
W119 according to requirements in Connection list on page
No liquid in UV reactor 236.
UVR [x]: No freshwater “x”. LS201-29.x is
filling in UVR 2. Check that valves (V310-6, V320-4.x, V321-2.x and
indicating dry condition. V571-1) are operating correctly. Also check that valve
(LS201-29).
V310-3 is OK and that V310–8 is opened. Operate
Trigger: Level sensor the components manually.
LS201-29.
Parameter: p216. Time set in parameter is Change parameter.
lower than needed.
p208 Level switch at UV
reactor LS201-29.x See W116 to troubleshoot the level switch electrically.
malfunction.
Fluid in UV reactor “x”.
LS201-29.x is indicating Restart the process from the beginning.
wet condition.
W120
Time set in parameter is Change parameter.
UVR [x]: UVR was not lower than needed.
drained (LS201-29).
Trigger: Level sensor Level switch at UV
LS201-29. reactor LS201-29.x See W116.
malfunction.
Parameter: p200.
Control that correct valves (V320–4, V460–2, V231–2,
Faulty valves in the CIP V571–1, overboard valve) are opened for current
unit. 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.
W122 • Use the circuit diagram for the LDC to check the fuse
setting, adjust according to figures in circuit diagram if
UVR [x]: Fuse tripped in necessary and reset fuse.
LDC cabinet. Fuse in LDC has tripped
or has been switched • Use the circuit diagrams for the LDC and UV reactor
Trigger: LDC cabinet for off. to locate the component or find the reason that caused
UVR the fuse trip and attend to it.
Delay: 1 sec.
• Check cables to the component. See UV reactor /
Circuit diagram and Lamp drive cabinet / Circuit
diagram.
W126 1. See LPS alarms in section Lamp power supply (LPS).

UVR [x]: MCB tripped in Motor circuit breaker 2. Check Q101–Q108 in LDC and respective cables and
LDC cabinet. (MCB) for an LPS in LPS unit.
UVR.x has tripped or
Trigger: LCD x-1 has been switched off. 3. Use the circuit diagram to check the Ampere setting
for the MCB, adjust according to figures in circuit
Delay: 1 sec. diagram if necessary and reset MCB.
Comment: MCB=Motor
circuit breaker. UV Breaker on LDC has
reactor is deactivated. tripped or has been Reset the breaker by turning the handle.
switched off.
Motor circuit breaker
W128 (MCB) F1 in control Check F2 in LDC.
UVR [x]: LDC cabinet cabinet has tripped or
fan alarm. has been switched off.
Trigger: F2 Faulty fan. Check electrical and mechanical problems, and attend to.
Delay: 5 sec. Faulty electrical Check that all electrical connections are OK and that the
connection. electrical wiring is not damaged.
200000657-1-EN-GB 197

W129 Repair.
Leakage in cooling
UVR [x]: LDC cabinet water piping. Dry wet areas in the cabinet. Remove the sensor and dry
water alarm. it with paper.
Trigger: Water sensor
LS below heat
exchanger in LDC. Condensation in the See above.
cabinet.
Delay: 5 sec.
• LPS malfunction. Check LED indication on the LPS that triggered the
W130 alarm. See LPS alarms in section Lamp power supply
• Number of broken (LPS).
UVR [x]: LPS sum UV lamps exeeds
alarm. number set in Check which lamps that are broken in column Lamp OK
parameter p213. in page 4.9 LPS overview.
Trigger: Lamp power
supply in UV reactors Check that the signal wiring is according to electrical
LDC. drawings.
UV lamp OK signal
Delay: 5 sec. malfunction. Check that all electrical connections are OK on bus
modules and that the electrical wiring is not damaged.
W131
UVR [x]: Lamp failure.
Eventual ongoing
process not compliant.
Trigger: Lamp power
supply 1–16.
Parameter: p213.
Check which lamps that are broken in column Lamp OK
Delay: 5 sec.
One or more UV lamp is in page 4.9 LPS overview.
Comment: UV reactor is broken. Change according to instruction in Service manual on
deactivated. page 365.
Note: Operation
continues but is not
compliant and does not
fullfil the requirements
for treatment of ballast
ballast water
management plan.
W132 Estimated lifetime for Change according to instruction in Service manual on

UV lamps (3000 hours) page 365.
Estimated UV lamp are exceeded.
lifetime exceeded.
Trigger: UV reactor lap
time.
Delay: 1 sec.
Comment:
Recommended to
change all lamps after
3000 hours of operation.
198 200000657-1-EN-GB

See W100.
After problem has been attended to, the LDC needs to be
reset. Follow the instruction below:
No flow in UV reactor or 1. Turn on the power to the cabinet/system.
too low flow.
A137 2. Push the reset button on the LDC. The button is
placed at the side facing the UV reactor. All LDCs
UVR [x]: To high must be reset individually.
temperature (TS201-60
tripped) and/or LDC 3. Acknowledge alarm A137 in the control system.
powered off.
Trigger: TS201-60 Faulty pump (ballast or Check components.
UVR cooling water
Delay: 1 sec. pump) or valve. Control that valves and pumps are functioning.
Comment: UV reactor is LDC has been powered The LDC needs to be reset, see above in this alarm
deactivated. off. description.
• Check that the signal wiring is according to electrical
Faulty electrical drawings.
connection. • Check that all electrical connections are OK and that
A138
UVR [x]: PLC error in
LDC cabinet.
Check the LED error indication for the electronic modules
Trigger: UV reactor x. Error in module. in the LDC. See I/O system and X20 modules on page
212
Delay: 2 sec.
Comment: UV reactor is
deactivated.
W140 CIP not performed after Start CIP process.

operation.
CIP required. Start CIP!
Risk for not compliant
operation.
timer.
p117 and p118.
Comment: CIP process
must be started within
30 hours counted from
when a ballast or
deballast process was
started.
Note: Operation
fullfil the requirements
for treatment of ballast
ballast water
management plan.
200000657-1-EN-GB 199

W151 Signal missing. 1. Check F42 in LDC to see which circuit that caused
the fuse trip.
UVR [x]: UV sensor
signal missing. Ongoing 2. Use the circuit diagram to check the fuse setting,
process not compliant. adjust according to figures in circuit diagram if
Trigger: UV sensor
QT201-50. 3. Use the circuit diagram to locate the component or
Delay: 20 sec. find the reason that caused the fuse trip and attend to
it.
Note: Operation
continues but is not 4. Check cables to QT201-50. See the drawing Control
compliant and does not cabinet / Circuit diagram in chapter 6. Technical data
fullfil the requirements and drawings.
for treatment of ballast 5. If the above is OK, the UV sensor is probably broke
water. Act according to and needs to be replaced. Replace the component.
ballast water
management plan. Transmitter QT201-50 Test the UV sensor:
malfunction
1. Stop the process and restart the process again.
2. In the control system's UV reactor 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.
W152 Note: Operation continues, but does not fulfill the type
approval certificate. Act according to ballast water plan.
UVR [x]: UV intensity
low. System flow See Power optimization on page 21.
reduced. Process not
compliant. Water is dirty or have Check water.
low UV transmittance.
Trigger: UV sensor It is also possible to fill the reactor with technical water /
QT201-50. potable water to rule out muddy water as reason for the
Delay: 30 sec. warning.
Comment: The flow is Quartz sleeves dirty. Run CIP process, and try again.
reduced when UV
intensity (W/m3) is below If problem remains, check and clean quarts sleeves
252 according to IMO according to instruction Service manual on page 365.
legislation. Power is set
to 100% and the flow is Old UV lamps. Check runtime on page 4.3 Timers in control system.
reduced to 50 % Change if old. Lamps loose effect when maximum
runtime has been exceeded.
Note: See Compliant /
non-compliant operation
on page 43.
Note: Operation
fulfil the requirements for
ballast water
management plan.
Comment: An additional
common alarm signal is
issued.
200 200000657-1-EN-GB

W153 Note: Operation continues, but does not fulfill the type
approval certificate. Act according to ballast water plan.
UVR [x]: UV lamp
broken. System flow See Operation with broken UV lamp on page 21
reduced. Process not
compliant.
Trigger: UV reactor.
Parameter: p213
Delay: 30 sec.
Comment: Process is
allowed to finish.
If a UV lamp fails during
ongoing operation, the
flow is set 80 % in IMO
mode and 50 % in
USCG mode of max
flow.
The UV lamps are lit to
100 % .
This is done so that the
treatment shall
correspond to the type
approval requirements.
After the process, it is
not possible to start a
new process.
Note: See Compliant /
non-compliant operation
on page 43.
W154 See W152.

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 this stage
power is 100% and flow
is reduced to 50 %.
Note: Operation
fulfill requirements for
ballast water
management plan. A
new process is not
allowed to start.
Only relevant for
PureBallast USCG
systems.
200000657-1-EN-GB 201

W160
UVR [x]: No response
from LDC. UVR
shutdown.
Trigger: N/A
Delay: 1 sec.
W161 Faulty connection of Check the three cable connectors on the LPS.
electricity or signal
UVR [x]: LPS cable.
communication error.
UVR shutdown. Check that the DIP switches are correctly set for every
Wrong LPS setting. LPS. See chapter 4. Parameters, section Lamp power
Trigger: LPS supply (LPS) parameters.
Delay: 1 sec. Change LPS. See instruction in chapter Service manual
Faulty LPS. on page 365.
W163 Change according to instruction in chapter Service
Broken UV lamp(s). manual on page 365.
UVR [x]: Lamp error
feedback from LPS.
Trigger: LPS in UV
reactor’s LDC.
Delay: 20 sec. Faulty connection of UV Check UV lamp power cable.
lamp cable
Comment: No lamp
feedback when it is
requested to be started
by the LPS.
W164
UVR [x]: LPS error
feedback from LPS.
Trigger: LPS in UV
Check 4.9 LPS power overview and LED indication on the
reactor’s LDC. LPS that triggered the alarm. See LPS alarms in section
Faulty LPS.
Delay: 20 sec. Lamp power supply (LPS). If the power is on but there are
no indication, the LPS is probably broken.
Comment: No LPS
feedback when it is
requested to start its
lamp(s). UV reactor is
deactivated.
W165 One or more of the Check page 4.9 LPS power overview and LED indication
below: on the LPS that triggered the alarm. See LPS alarms in
UVR [x]: LPS in fault Lamp power supply (LPS) on page 208.
state. Process not • Air intake temp fault.
compliant. During commissioning: Alfa Laval can run a process with
• Fan fault. one faulty LPS, to be able to fulfill commissioning.
Trigger: LPS in UV Parameter p213 (Allowed nr. of failed UV lamps) is set to
reactor’s LDC. • Heat sink fault.
1. Parameter must be reset to 0. Operation with faulty
Delay: 5 sec. • UV lamp open LPS or lamps does not fulfill the type approval certificate.
(broken).
Comment: UV reactor is Fan fault and temperature faults can be caused by
deactivated. • Driver fault something that is preventing the fan from rotate.
Note: Operation • System fault Change LPS. See instruction in Service manual on page
continues but is not 365.
compliant and does not • Voltage fault
fullfil requirements for
ballast water
management plan.
202 200000657-1-EN-GB

W170
Valve error (V201–19)
Trigger: Limit switch See possible cause for
GS201–19. A17.
Delay: 25 sec.
deactivated.
W171
Valve error (V201–20)
Trigger: Limit switch A17.
GS201–20.
Delay: 25 sec.
W180
LDC ring redundancy
error Faulty connection of Check that the power link (LAN) cable from the control
signal cable. cabinet (in a loop to all LDCs) and back is OK.
Trigger: LDC
Delay: 1 sec.
W181
UVR [x]: Barrier fault
Trigger: Barrier in LDC Faulty safety barrier.
for V201-19, V201-20, Replace barrier.
Faulty connection of
LS201-29, LS201-30, electrical or signal Check cabling in LDC.
QT201-50 and cable.
TS201-60.
Comment: No barrier for
TT201-33.
W182
UVR [x]: UVR fluid level
signal missing
(LS201-30)
Trigger: Level switch See W116.
LS201-30
Delay: 5 sec.
Comment: The UV
reactor is shut down.
W183
UVR [x]: UVR fluid level
missing (LS201-30)
Trigger: Level switch
LS201-30
See W117.
Delay: 5 sec.
Comment: The UV
reactor is shut down.
Prevents start of LPS
(UV lamps) in manual
mode.
200000657-1-EN-GB 203

W184
UVR [x]: CIP flow
missing (LS201-30)
Trigger: Level switch See W118
LS201-30
p208.
W185
UVR [x]: No freshwater
filling in UVR(LS201-30)
Trigger: Level sensor See W119.
LS201-30.
Parameter: p216.
Delay: set in parameter
p 215.
W186
UVR [x]: UVR was not
drained (LS201-30)
Trigger: Level sensor See W120.
LS201-30.
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.
deactivated..
W188
UVR [x]: No feedback
from contactor.
Trigger: N/A Result of other UVR Check control system page 2.1 Alarm list in control panel
Delay: 10 sec. alarm. for related alarms.
Comment: Internal
warning as a result of
other alarm/warning for
the UVR.
204 200000657-1-EN-GB

W300 Motor circuit breaker Reset or turn on.
(MCB) F1 in control
Filter sum alarm. cabinet has tripped or
has been switched off.
Trigger: Filter.
Delay: 1 sec. Motor problem. 1. Check that the cable W301 is connected to the
control cabinet.
Comment: The
feedback signal “Filter 2. Check the power cable between the filter junction box
SUM alarm” is not and the filter motor, including the condition of the
detected. connector at the filter motor side.
3. Check that the motor is not overloaded and can rotate
easily.
4. Start the motor and check that the operation is
normal. See Service manual on page 365.
Mechanical obstacles. Check that mechanical parts in the filter can rotate freely.
See Service manual on page 365.
Filter flanges
misaligned, and forced Loosen the pipe connections to the filter and try to rotate
together causing stress the filter manually. If the nozzle can rotate, the pipe
and deformation of the connections must be renewed. Cut pipe 201 shorter and
filter body. preventing insert a tailor made spool piece with perfect fitting.
the nozzle to rotate
freely inside the filter.
W302
Filter 2 sum alarm
Trigger: Filter.
Delay: 1 sec. See W300
Comment: Only valid for
systems with two Filtrex
filter and flow 1200–
2000.
W303
Filter 3 sum alarm
Trigger: Filter.
Delay: 1 sec. See W300
Comment: Only valid for
systems with three
Filtrex filter and flow
3000.
200000657-1-EN-GB 205

Backflush manually from control system. If not sufficient,
Filter is clogged. clean the filter element according to instruction in chapter
Service manual on page 365.
Valves connected to Make sure that the two valves connected to the filter
filter pressure differential transmitter are open.
transmitter closed.
Hint: Pressure signals are displayed on in the Filter popup
opened from 1.1 Overview
W306 1. Check fuse F45 in Control cabinet to see what circuit
Filter differential caused the fuse trip.
pressure too high
Trigger: Pressure adjust according to figures in circuit diagram if
transmitter PT201-71 necessary and reset fuse.
and PT201-72.
Parameter: p301, p314. Pressure transmitters find the reason that caused the fuse trip and attend to
does not work correctly. it.
Delay: 2 sec.
4. Check cables to the component. See Control cabinet /
Circuit diagram in chapter 6. Technical data and
drawings.
6. Replace faulty transmitter.
1. Check fuse F42 in LDC to see which circuit that

W308
Filter pressure signal adjust according to figures in circuit diagram if
missing (PT201-71) necessary and reset fuse.
Trigger: Pressure 3. Use the circuit diagram to locate the component or
transmitter PT201-71. Signal missing or find the reason that caused the fuse trip and attend to
component malfunction. it.
Parameter: p314.
Delay: 30 sec. 4. Check cables to PT201-71. See the drawing Control
cabinet / Circuit diagram in chapter 6. Technical data
Comment: Alarm and drawings.
deactivated in Standby.
5. If the above is OK, the UV sensor is probably broke
and needs to be replaced. Replace the component.
W310
Filter pressure signal
missing (PT201-72).
Trigger: Pressure
transmitter PT201-72. See W308.
Parameter: p314.
Delay: 30 sec.
Comment: Alarm
206 200000657-1-EN-GB

W312
Filter pressure signal
missing (PT309-2)
Trigger: Pressure
transmitter PT309-2 on
Hydac filter. See W308.
Parameter: p314.
Delay: 30 sec
Comment: Alarm
W313
1. Check that cable W3091 is connected to the control
the fuse for the filter
buckflush pump. 2. Start the motor and check that the operation is
Motor/load problem. normal.
Trigger: Fuse.
3. Verify that there is no loose wire to the —A2–DI5
Delay: None. digital input on the PLC.

W314
Backflush failed to start
(timeout).
Trigger: Hydac filter. See W308.
Parameter: p314.
Delay: 15 sec.
A315 Filter is clogged. Backflush manually from control system. If not sufficient,
clean the filter element according to instruction in Service
Diff. pressure too high. manual on page 365.
Automatic shutdown.
Valves connected to Make sure that the valve connected to each pressure
Trigger: Pressure pressure transmitters transmitter is open.
transmitter PT201-71 closed.
and PT201-72.
Pressure transmitters 1. Check F45 in control cabinet to see what circuit
Parameter: p300. does not work correctly. caused the fuse trip.
Delay: 5 sec.
Comment: Diff. adjust according to figures in circuit diagram if
pressure higher than set necessary and reset fuse.
in parameter p300.
Diff. pressure is find the reason that caused the fuse trip and attend to
displayed on in the Filter it.
popup opened from 1.1
Overview. 4. Check cables to the component. See Control cabinet /
Circuit diagram in section Electrical drawings on page
278.
6. Replace faulty transmitter.
200000657-1-EN-GB 207

No log box is installed.
Parameter activated by Change parameter to Not used.
mistake.
• 1. heck that there is power to the A40A and A40B

modules. 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 between control system
and log box (warning W501 still present in the
alarm list. Move the LAN cable from the used port
Faulty cable connection. to the not used port on the A40A module.
A501
2. Check LAN cable connection in the LDC.
Log box error
3. Verify that the cable is not longer that maximum
Trigger: Log box allowed cable length of 100 meters.
(optional).
4. Replace the LAN cable with a new one. (Try with a
Delay: 10 sec. temporary before installing it through the cable
Comment: Only valid if gland.)
Log box have been
activated. Fuse in the log box has
Parameter: p500 tripped or has been Check fuse F02 and F03 in the log box.
switched off.
• Check that the switches on the A40A module is as

below: X16=0, X1=1
• 1. Check that parameter p500 is activated in the
Faulty setting. control system.
2. Acknowledge the alarm in the control system, to
be able to see when it disappears.
Check the LED error indication for the electronic modules

Error in module. in the log box. See I/O system and X20 modules on page
212.
A502
Log box: External
bypass is open
Trigger: Log box
(optional). See A33.
Delay: 10 sec.
Comment: If detected
by bypass configuration
in 4.7 Log box.
W503
Heeling mode requested
by log box.
Trigger: ISCS.
See W82 and A33.
Delay: 10 sec.
Comment: If detected
by bypass configuration
in 4.7 Log box.
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.
208 200000657-1-EN-GB
LPS on and communication is functioning.
Flashes (once per second) when processor is running.

Flickering light during modbus communication
Internal fault. Possible causes:
• LPS temperature too high (> 50° C).
• LPS fan faulty.
Lamp error. Possible causes:

• Two lamp ignition failures.
• Broken UV lamp.
• Loose cables to UV lamp.
Lamp on.
Flickering during lamp ignition, approx 2 seconds when lamp is started.
Possible causes:
All • Faulty DIP switch setting on one or more LPS. This fault occur after a 10
lamps seconds delay after start.
on.
• Voltage on the fail safe is missing.
5.2.3 Flow meter

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.
Display lines on flow transmitter
Display lines/fields
1. Main line for primary measured values.
2. Additional line for additional measured variables/status variables.
3. Current measured values.
4. Engineering units/time units.
Fault finding instruction

Always start troubleshooting with the checklist below if faults occur after start-
up or during operation.
Note: Step 1 and 3, are only valid if the unit has a display.
200000657-1-EN-GB 209
1. Check the display, as described below.

2. Restart.
3. If the problem cannot be detected or corrected, the flow meter, its
transmitter, circuit boards or display must be replaced. Follow the
instruction Replace display and fuse or Replace a circuit board in Flow
meter on page 421.
Error messages on the display

Errors which occur during commissioning or measuring operation are
displayed immediately. If two or more system or process errors occur, the error
with the highest priority is the one shown on the display. The measuring
system distinguishes between two types of errors:
• System errors: This group comprises all device errors, e.g. communication
errors, hardware faults, etc.
• Process errors: This group comprises all application errors, e.g. empty
pipe, etc.
There are two error message types:
• Notice message: Displayed as exclamation mark. The error in question
has no effect on the outputs of the measuring device.
• Fault message: Displayed as a lightning flash. The error in question has a
direct effect on the outputs. Serious system errors are always recognized
by the device as "Fault message", and are shown as a lightning flash on
the display. Fault messages immediately affect the outputs.
Figure 1: Error messages on the display

1. Error type; process error or system error.
2. Error message type; fault message or notice message.
3. Error designation: e.g. EMPTY PIPE = measuring tube is only partly filled or
completely empty.
4. Error number: e.g. #401.
5. Duration of most recent error occurrence (in hours, minutes and seconds).
210 200000657-1-EN-GB
Problem What to do?

1. Check the supply voltage.
2. Check the power line fuse.
No display visible and no output signals 20 to 55 V AC / 16 to 62 V DC: 2 A slow-blow / 250 V
present See Replace display and fuse on page 421 for detailed
information
3. Measuring electronics defective.
1. Check whether the ribbon-cable connector of the display module

is correctly plugged into the amplifier board.
No display visible, but output signals
present 2. Display module defective.
3. Measuring electronics defective.
Switch off power supply. Press and hold down both the OS buttons
Display texts are in a foreign language. and switch on the measuring device. The display text will appear in
English (default) and is displayed at maximum contrast.
Error messages consists of a variety of icons. The meaning of these icons can be
seen in the table below.
Problem ID Description
S System error.
P Process error.
Error message type.
$ Fault message.
! Notice message.
EMPTY PIPE Type of error, eg. measuring tube is only partly filled or completely empty.
03:00:05 Duration of error occurrence (in hour, minutes and secounds).
#401
Error number:
No. 001-399 System error (device error) has occurred.
No. 501-699
Error number: Process error (application error) has occurred.

No. 401-499
1. Change the upper or lower limit

S: CURRENT Current output flow: flow is setting, as applicable.
351 to 354 RANGE out of range.
!: # 351 to 354 2. Increase or reduce flow, as
applicable.
1. Check the process conditions of

401 EMPTY PIPE Measuring tube partially the plant.
$: # 401 filled or empty.
2. Fill the measuring tube.
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.
200000657-1-EN-GB 211
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.
Error: Internal sensor error or Replace the component.
Red Blinking sensor corroded.
Rectify the short-circuit.
Error: Overload or short-
Red Steady Reduce maximum load current
circuit 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
CP3585 Control cabinet
module 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
212 200000657-1-EN-GB
Identification Function Installed in cabinet

Interface module, RS422/
IF1030 Control cabinet
RS485
PS9400 24V power feed, bus supply Lamp drive cabinet
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
Single flashes outputs 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.
200000657-1-EN-GB 213
Light Color State Description

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.
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.
214 200000657-1-EN-GB

Bus controller error: Failed Ethernet frames, increased
On number 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.

Communication is not possible with the bus controller. After 5
seconds in this state, the bus controller restarts.
If POWERLINK communication is detected during the 5
Green Off seconds, the bus controller goes to status
PRE_OPERATIONAL_1 (single flash).
If no powerlink communication is detected, the bus controller
goes to BASIC_ETHERNET state (flickering).
Green On Bus controler in operation.
No Powerlink communication detected by bus controller. In

this state you can communicate directly with the bus controller
Flickering using UDP.
Green (approx. 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
Single flash controller goes directly into PRE_OPERATIONAL_2.
Green (approx. 1 Hz)
With operation on a POWERLINK V2 manager, the CN
(Controlled Node) waits for the reception of a SoC frame and
then switches over to PRE_OPERATIONAL_2 (double flash).
Bus controller in PRE_OPERATIONAL_2.

Double flash In this state the bus controller is normally configured by the
Green manager. A command (POWERLINK V2) or setting the data
(approx. 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 command to OPERATIONAL.
Green (approx. 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.
Green 2.5 Hz) Only 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.
200000657-1-EN-GB 215
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
resetting 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
resetting the module.
S/E
The powerlink managing node failed. This error code can
Blinking alternately only occur in controlled node operation. This means that the
set station number lies within the range $01 - $FD.
System failure according to blinking pattern:
Off Red blinking ●●● — Pause ●●● — Pause: RAM error
— ●● — Pause — ●● — Pause: Hardware error.
216 200000657-1-EN-GB
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
200000657-1-EN-GB 217
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

Probl Description Possible cause What to do?
em ID
1A The system does not start. The Main breaker on control cabinet Turn on the breaker and
control panel does not light up. and/or LDC turned off, or power measure that incoming 24 V DC
Control panel is not displaying a not connected to the control to the control panel is present.
normal page. PureBallast can panel.
not be controlled or monitored
from the ISCS' graphical user Power turned off at main switch Turn on the power.
interface via the remote interface board.
(optional). Fuse F42tripped. 1. Check fuse F42 in control
cabinet to see what circuit
2. Use the circuit diagram to
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and
reset fuse.
locate the component or find
the reason that caused the
fuse trip and attend to it.
Fuse F41 in control cabinet 1. Check fuse F41 in control

tripped. cabinet to see what circuit
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and
reset fuse.
locate the component or find
the reason that caused the
fuse trip and attend to it.
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.
218 200000657-1-EN-GB

em 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
PureBallast system: Cut the
power by switching of the
main breaker on the control
cabinet . Wait 30 seconds,
and switch on the main
breaker again
3. If panel is not OK, it is
probably broke and needs to
be replaced. Replace the
component
Wrong software version. Check that the HMI and PLC

software have the save program
version. This is visible in control
system page Page 4.1 – System
info on page 69.
HMI software problem. Re-load the HMI software
according to the software
Release note.
1C PureBallast can not be controlled Communication is broken See the What to do column for
or monitored from the ISCS' between ISCS and PLC. alarm A93.
graphical user interface via the
remote interface (optional).
200000657-1-EN-GB 219

em 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
cables are disconnected or
broken. 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
instruction is set for the remote
control panel. See Set remote
control panel communication on
page 106.
“Disconnected from ...”: Check the following:

Communication is broken between remote control panel and main • If the electrical and signal
panel. cables are disconnected or
broken.
• 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 Error with the pressure gauge Dismantle the component and
5A error (general). electric switches. inspect/attend to.
Valves for air pressure to valve Open the valve (ball cock)
V309-1 are closed. connected to V309-1.
220 200000657-1-EN-GB

ID
The filter house is not properly Deaerate using deaeration
deaerated. valve V571- on the filter lid.
Check filter element for
Damaged filter element. damage. Replace if necessary.
Excessive backflushing or long Open the filter and remove the
Large obstructions have
5B backflushing sequences obstructions. See Filter on page
entered the filter.
(general). 388.
See Backflushing for different
Dirty water. dirt loads on page 30.
Dirt build-up in the filter Clean the filter element.
element.
5.3.3 CIP
ID
6A Insufficient pump capacity Leakage in air hoses or Locate leakage and attend to.
(general). sealings.
Air pressure too low due to Adjust setting with the manual
incorrect 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 399.
The diaphragm in the CIP pump Examine the pump. See chapter
is broken. 7. Service manual, section
Repair 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 399.
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.
200000657-1-EN-GB 221

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
tank.
chapter.
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 the CIP side to the incoming
6K preventer, due to pressure
of the CIP. technical water / potable water
levelling.
side. To secure this, the
backflow preventer is levelling
the pressure. Some water can
escape 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
the actuator position. correctly mounted on the valve.
Faulty signal. • Check input signal to
proportional valve.
• Check I/P output.
222 200000657-1-EN-GB
Problem Description Possible cause What do to?

ID
8B Signal change results in Connection or signal problem. • Check coupling between
actuator running to end proportional valve and
positions. actuator.
• Check input signal.
8C Signal and positioning • Inaccurate positioning. Adjust position sensor. See

problems. Calibrate positioner on V201-8
• Input signal fluctuates. on page 411.
Check electric connection.
200000657-1-EN-GB 223
224 200000657-1-EN-GB
EN
6 Technical data and drawings
200000657-1-EN-GB 225
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 1
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 248
6.2.1 Flow requirements

BW pump and other pumps must give min and max flow according to the table
below:
Media Flow /
consumption
Flow range – Pipe 201, ballast 195 – 1000 m3/h
Flow range – Pipe 201, deballast 100 – 1000 m3/h
226 200000657-1-EN-GB
Technical data and drawings 6 EN
Media Flow /
consumption
Flow range – Pipe 201, stripping 100 – 1000 m3/h
Minimum flow – Pipe 403, startup cooling water to UV reactor
(water sea to sea) 20 m3/h
Minimum flow – Pipe 401, cooling water to LDC (Treated

cooling water / technical water) 1.5 m3/h
Minimum flow – Pipe 309, filter backflush 95 m3/h
Maximum consumption – Pipe 310.1 and 310.2, technical 565 l

water / 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
vessel’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
• Brackish water
• Marine water
UV intensity limit: The system have been tested and

found to give full treatment of the ballast water at these
conditions:
Ballast water IMO mode: > 252 w/m2
USCG mode: > 772 w/m2 in USCG 3 day mode and 1220
w/m2 in USCG 0 day mode.
Technical water / UVR and filter preservation.
potable water
Temperature: 0–38 °C.
For details, see Quality specification / Technical and
potable water on page 245
Treated cooling Cooling water to LDC.
water / technical water
Max temperature: 38 °C (± 2 °C).
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
transformer 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.

IP rating
Lamp drive cabinet: ≥ IP44.
200000657-1-EN-GB 227
Component Power consumption

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

Power to UV reactor.
100.0
Note: PureBallast only use power needed for treatment.
PureBallast automatically regulates the lamp power
between 50 and 100 % to secure the treatment efficiency.
Pump P309–1 (optional)

7.5
For filter backflush water.

0.55
For LDC cooling water.

3.0
For UVR cooling water.
6.2.4 System pressure

The table gives a description of system pressure range for piping and
instrument air.
Pressure (bar) Comment
Max pressure for standard system: 6 bar.
Piping
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.
228 200000657-1-EN-GB
Bar Comment
Pressure drop for UV reactors and PureBallast’s
0.2 valves.
Pressure drop during Max differential pressure over the filter during
ballast ballast operation. When the differential pressure
0.5 reaches 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
using required flow in pipe 309: 95 m3/h.
The ballast pump must deliver pressure at filter
Total inlet, covering total pressure drop over
PureBallast system.
6.2.6 PureBallast components

The table below states basic information about weight and volume for major
component in the PureBallast system.
For detailed information, see Dimension drawings on page 248.
Component Weight, empty, approx. Volume, approx. (l)
(kg)
UV reactor size (m3/h): 560 190
1000
Filter ACB–999–350 1150 370
250. Note: Total tank
CIP unit 195 volume is 300, but shall
only be filled to max 250.
Remote control panel 15
(optional)
6.3 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
• External component signals (hardwired connection of individual
components and features)
• GPS
• Log box
For remote integration, please refer to the following documents:
200000657-1-EN-GB 229
• Design and installation guide

• Remote interface implementation 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.
6.4 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.
230 200000657-1-EN-GB
6.4.1 Graphic symbols used in drawings
200000657-1-EN-GB 231
6.4.2 General drawings

This section contains the general drawings.
232 200000657-1-EN-GB
6.4.2.1 Flow chart
Note: If closed cooling unit (optional) is used, see flow chart for Closed
cooling unit, regarding item 401 and 402. Note: If vacuum relief valve,
VB201 and VB309 (optional) is used see additional flow chart.
200000657-1-EN-GB 233
6.4.2.2 Flow chart — Vacuum relief valve, VB201 and VB309 (optional)
234 200000657-1-EN-GB
6.4.2.3 Flow chart — Closed cooling unit, LDC (optional)
200000657-1-EN-GB 235
6.4.2.4 Connection list

If closed cooling unit (optional) is used, see specific connection list.
236 200000657-1-EN-GB
200000657-1-EN-GB 237
238 200000657-1-EN-GB
200000657-1-EN-GB 239
6.4.2.5 Connection list — Closed cooling unit, LDC (optional)
240 200000657-1-EN-GB
241

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6.4.2.7 Instrument air distribution
200000657-1-EN-GB 243
6.4.2.8 Quality specification / Instrument air
244 200000657-1-EN-GB
6.4.2.9 Quality specification / Technical and potable water
200000657-1-EN-GB 245
6.4.2.10 Quality specification / CIP liquid

Note that the information below regarding dilution is not valid for compact or
compact flex systems.
246 200000657-1-EN-GB
200000657-1-EN-GB 247
6.4.3 Dimension drawings

This section contains the dimension drawings.
248 200000657-1-EN-GB
6.4.3.1 UV reactor
200000657-1-EN-GB 249
6.4.3.2 UV reactor and control cabinet / Lamp power cable
250 200000657-1-EN-GB
6.4.3.3 Filter
200000657-1-EN-GB 251
6.4.3.4 CIP module
252 200000657-1-EN-GB
200000657-1-EN-GB 253
6.4.3.5 Flow transmitter FIT201-1
254 200000657-1-EN-GB
6.4.3.6 Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and

V201-15)
6 bar system
200000657-1-EN-GB 255
High pressure system
256 200000657-1-EN-GB
6.4.3.7 Valve V201-3 and V201-9
200000657-1-EN-GB 257
6.4.3.8 Valve V201-32 and V403-35
258 200000657-1-EN-GB
6.4.3.9 Valve V212-31 (optional)
200000657-1-EN-GB 259
6.4.3.10 Control valve V201-8
260 200000657-1-EN-GB
6.4.3.11 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.
200000657-1-EN-GB 261
6.4.3.12 Vacuum relief valve VB201 (optional)
262 200000657-1-EN-GB
6.4.3.13 Vacuum relief valve VB309 (optional)
200000657-1-EN-GB 263
6.4.3.14 Sampling device Q201.1 and Q201.2 (optional)
264 200000657-1-EN-GB
200000657-1-EN-GB 265
266 200000657-1-EN-GB
6.4.3.15 Remote control panel (optional)
200000657-1-EN-GB 267
6.4.3.16 Log box (optional)
268 200000657-1-EN-GB
6.4.3.17 Lamp drive cabinet (LDC)
200000657-1-EN-GB 269
6.4.3.18 Control cabinet
270 200000657-1-EN-GB
6.4.3.19 Air filter regulator
200000657-1-EN-GB 271
6.4.3.20 Air preparation unit (optional)
272 200000657-1-EN-GB
6.4.3.21 Backflush pump P309–1 (Optional)
200000657-1-EN-GB 273
6.4.3.22 LDC cooling water pump P401–1 (optional)
274 200000657-1-EN-GB
6.4.3.23 UVR cooling water pump P403–1 (optional)
200000657-1-EN-GB 275
6.4.3.24 Closed cooling unit, LDC (optional)
276 200000657-1-EN-GB
6.4.3.25 Transformer (optional)
200000657-1-EN-GB 277
6.4.4 Electrical drawings

This section contains the electrical drawings.
278 200000657-1-EN-GB
6.4.4.1 Control cabinet / Interconnection diagram
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200000657-1-EN-GB 335
6.4.4.8 UV reactor / Circuit diagram
336 200000657-1-EN-GB
200000657-1-EN-GB 337
338 200000657-1-EN-GB
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200000657-1-EN-GB 339
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6.4.5.1 Safety data sheet / CIP liquid
344 200000657-1-EN-GB
200000657-1-EN-GB 345
346 200000657-1-EN-GB
200000657-1-EN-GB 347
348 200000657-1-EN-GB
200000657-1-EN-GB 349
350 200000657-1-EN-GB
200000657-1-EN-GB 351
352 200000657-1-EN-GB
6.4.5.2 Safety data sheet / UV lamp
200000657-1-EN-GB 353
354 200000657-1-EN-GB
200000657-1-EN-GB 355
356 200000657-1-EN-GB
200000657-1-EN-GB 357
358 200000657-1-EN-GB
200000657-1-EN-GB 359
360 200000657-1-EN-GB
200000657-1-EN-GB 361
362 200000657-1-EN-GB
200000657-1-EN-GB 363
364 200000657-1-EN-GB
EN
7 Service manual
200000657-1-EN-GB 365
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.
DANGER
Before maintaining the PureBallast system, the power supply must be
switched off from the vessel’s main switch board.
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 380.
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.
• 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 406
• 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.
366 200000657-1-EN-GB
Service manual 7 EN
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.
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
200000657-1-EN-GB 367
EN 7 Service manual
M12 57 83
M16 140 204
M20 270 408
M24 470 696
M30 - -
M36 - 2500
368 200000657-1-EN-GB
Service manual 7 EN
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
system: Run a
ballast and/or
deballast
process. Follow If the system, for some
up with a CIP See Operating reason, is not operated
process. instructions and by normal ballast
control system
Note: If system operations, it needs to
description on
is used, but be run to verify that it is
page 41
certain valves Once a month. in good condition.
are not used, Manual This will also exercise
for example operation of the valves, actuators
V212–31, those valves: See and other components
should be Valves on page to keep them in good
General opened and 403. condition.
closed
manually. For
relief valves,
see Calibration
schedule.
Inspect for
corrosion and Once a year.
erosion
damage.
According to See Calibration
Calibration of Calibration
sensors schedule on schedule on
page 371. page 371.
Outer See Spare parts

inspection of Once a year. catalogue for service
seals for kit.
leakage.
See
Check UV See Spare parts
Disassemble
lamps for Once a year. catalogue for service
quartz sleeve
leakage. kit.
on page 383.
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 381. for spare part number.
operation
UV reactor
IMO
requirement:
Replacement of Every second
UV sensor year. 9001357 03
(QT201–50) EPA
requirement:
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.
200000657-1-EN-GB 369
EN 7 Service manual

See the filter
cleaning
instruction in
this document.
Cleaning once
a year normally
is enough. But
in exceptional
cases (vessels
trading very
muddy waters)
it might be Replace filter basket, if
Inspect and necessary to damaged.
clean the filter clean the more
insert, including Once a year. often.
See Spare parts
the filter basket. catalogue for
If the pressure maintenance kit.
triggered
backflushing is
performed with
short intervals,
we suggest that
the filter
Filter element
manually
cleaned more
often than once
year.
If necessary, change
Outer faulty seals.
inspection of Once a year. See Spare parts
seals for
leakage. catalogue for
maintenance kit.
Dismount the
Check relief valve and make
valve RV201– Once a year. sure you can
50. blow air
through it from
the inside out.
Every 3rd
See Change and refill
pH value check. months,
whichever CIP liquid on page 394
comes 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. water can be added to
Depending on See Change fill up the liquid level in
CIP liquid ballasting and refill CIP the tank.
level check. frequency, the liquid on page
liquid check 394 Note: pH value must
might have to be checked
be performed afterwards to secure
CIP liquid more regularly. correct pH value.
See
Preparations
Control of Visual and conditions
stored CIP inspection after under Change
liquid. three years. and refill CIP
liquid on page
394
Control that the
Valve block cables are See Connect electrical
on CIP firmly attached Once a year. cables to valve block
module to the terminal on page 402.
strip in the
370 valve block. 200000657-1-EN-GB
Service manual 7 EN

Control that the
component,
Valves and See Valves on
cables and Once a year.
actuators page 403.
hoses are firmly
attached.
Remove and
disassemble
the valve.
Remove debris
Vacuum and clean the
relief valves interior parts if Once a year.
needed. Inspect
the seal and
replace if
broken.
See instruction
Power cable
check in
Check power
Power section Control
cables screw Once a year.
cables cabinet and
connections lamp drive
cabinet (LDC)
on page 430.
When alarm
PLC battery
low is indicated
in the control
system. Automatic check when
Control Replace battery the control cabinet is
system in PLC module. or: turned on and every 24
After 5 years. hours.
Before
storage 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:
• Calibration using the vessels tank sounding systems calculating the flow.
• Calibration using an ultrasonic device.
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.
2 Note the start level in tank.
3 Establish stable flow in the system.
200000657-1-EN-GB 371
EN 7 Service manual
4 Note the flow according to PureBallast flow

meter FIT201–1 in control system page Page
1.1 – Overview on page 51, (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 Allowed
variance variance
A FIT201–1 Min: 0.95
A/ C
value (m3/h) Max: 1.05
C Calculated
value (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).
5 Compare the figures and calculate the

variance.
a)
variance variance
A FIT201–1 Min: 0.95
A/C
value (m3/h) Max: 1.05
C value (m3/h)
372 200000657-1-EN-GB
Service manual 7 EN
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.
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.
variance variance
A PT201-71 Min: 0.95
A/C
value (bar) Max: 1.05
B PT201-72 Min: 0.95
B/C
C Calibration
device value
(bar)
b) Open 403-35 from the control system, and

compare again.
variance variance
A PT201-71 Min: 0.95
A /C
B PT201-72 Min: 0.95
B /C
C Calibration
device 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.
200000657-1-EN-GB 373
EN 7 Service manual
c) Compare value indicated in control

system and measure equipment.
variance variance
A PT201-16 Min: 0.95
A/C
C Calibration
device value
(bar)
5 Pressure gauge PI201-18:

a) Compare value indicated in pressure
gauge and measure equipment.
variance variance
A PI201-18 value A / C Min: 0.95
(bar) Max: 1.05
C Calibration
device 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.
Calibration frequency: Every year.
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.
variance variance
A TT201-33 Min: 0.95
A /C
value (C°) Max: 1.05
C Calibration
device value (C°)
374 200000657-1-EN-GB
Service manual 7 EN
3 Temperature switch TS201-60 :

a) Dismount the switch and place in device
with slowly raising temperature starting at
appr 50 going to appr 70 C°.
b) Check that alarm A137 is displayed in the
control system at 65 ˚C.
variance variance
A TS201-60 Yes +/- 5 %
value (C°)
C Calibration
device value (C°)
4 Level switch LS201–29 :

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 369.
7.2.2 Recommended spare parts on board

One of each spare part or spare part kit is recommended to be stored on
board.
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 9001357 03
Filter
Filter sealing kit 9011963 85
200000657-1-EN-GB 375
EN 7 Service manual
Spare part Spare part number

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 236.
Example
If the level switch is faulty, the following information shall be stated:
• PureBallast serial number.
• Level switch serial number and the serial number for the 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.
376 200000657-1-EN-GB
Service manual 7 EN
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.
UV reactor
Placing: At the side of the UV reactor, as indicated in
the illustration.
200000657-1-EN-GB 377
EN 7 Service manual
Filter
Placing: At the side of the filter, as indicated in the
illustration.
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.
378 200000657-1-EN-GB
Service manual 7 EN
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
indicated in the illustration.
Note: The serial number for the flow transmitter is also
valid for the flow sensor.
200000657-1-EN-GB 379
EN 7 Service manual
7.3 UV reactor
This section covers instruction for service of the UV reactor.
UV reactor, exploded (principle).

1. Cap
2. Cap nut
3. Bush
4. O-ring (inside bush)
5. Cable connector
6. Allen screw
7. Glass socket
8. O-ring
9. UV lamp
10. Quartz sleeve
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.
380 200000657-1-EN-GB
Service manual 7 EN
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 353 for detailed safety
information.
7.3.2 Replace UV lamp

7.3.2.1 Disassemble UV lamp
Follow this instruction to dismount the UV lamps.
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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• 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 cap nuts holding the caps. There is one nut on each side of
the UV reactor per UV lamp. If required, use a screwdriver on the nut,
gently tapping with a hammer to release.
2. Carefully disconnect the two cable connectors in both ends of the UV lamp.
3. Carefully draw out the lamp bushes on both sides.
4. 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.
After removal, place the old lamp in the new lamp’s protective cover.
5. Check that the quartz sleeve is not broken inside the UV reactor, and that
there is no leakage around the glass socket and adaptor.
6. If the quartz sleeves is not broken, mount the new UV lamp according to
the instruction Assemble UV lamp. If broken, follow the instruction
Disassemble quartz sleeve below.
7.3.2.2 Assemble UV lamp

Follow the instruction below to mount UV lamps.
• A leakage check must have been performed according to the instruction
Check for leaks after quartz sleeve assembly on page 385.
• Use waxed screws.
• New heat resistant O-rings must be used in the two bushes. Always replace
used O-rings.
• Keep the UV lamp in its protective cover as long as possible. Do not touch
the glass of the lamp; hold the lamp by its ceramic end parts.
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• Glass sockets and bushes must be dry and clean before mounting.
• After UV lamps have been changed, the runtime must be reset in control
system page 4.4 Operation timers UVRs.
1. Mount the new heat resistant O-rings in the two lamp bushes.
2. Place one bush on the UV lamp.
3. Insert the UV lamp and bush into the UV reactor.
4. Insert the other bush in the opposite side of the UV reactor.
5. Make sure that the connection is clean to ensure good electric connection
(no rust, burning or fading on the connectors). Reconnect the two cable
connectors for the UV lamp.
6. Mount the UV lamp caps and tighten the cap nut at both ends of the UV
lamp, by hand only. Make sure that the electric cable is is not squeezed
between the cap and the bush when the cap is mounted. Slack can be
pushed into the bush.
7. Control the control system page 3.1 Alarm list, to make sure there is no
alarm when after the lamp power supply is on.
7.3.3 Replace quartz sleeve

7.3.3.1 Disassemble quartz sleeve
Follow this instruction to disassemble the quartz sleeve.

1. Make sure that the following valves are closed: UV reactor inlet
(V201-19.n) and outlet (V201-20.n) valves.
2. Drain the UV reactor:
a. Open the overboard valve for pipe 460.1.
b. Set the system in manual mode.
c. Open the following valves: V571-1, V321-2, V321-3 and 460-2. Start
pump P321-5. Let the pump run for the time entered in parameter p200
UV reactor draining.
3. Disconnect the instrument air, as a safety precaution.
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4. Disassemble the UV lamp according to the instruction Disassemble UV

lamp on page 381.
5. Loosen the three screws holding the glass socket on both sides; just a few
turns to release the glass sockets.
6. Unscrew the screws holding the glass sockets completely on one side.
Carefully remove the glass socket, to avoid breaking the quartz sleeve.
Then remove the glass socket on the other side.
7. Remove the quartz sleeve O-rings in the adaptor on both sides. The O-
rings are firmly stuck in their seat, and will be damaged during removal, but
shall be replaced at assembly. Use an angled or hooked O-ring tool to
loosen and remove the O-ring. Be careful to avoid to break the glass.If the
O-ring is hard to remove, try the following:
• 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.
8. Carefully remove the quartz sleeve.
9. Carefully clean the surface between the UVR and the adaptor and remove
any small parts, for example glass or rubber.
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.
• Glass sockets and lamp bushes must be dry and clean before mounting.
• Before installation, check that the quartz sleeves are not broken.
1. Check the condition of the inner and outer O-ring in the glass sockets. If
needed, replace them with new O-rings.
2. Insert the quartz sleeve in the UV reactor.
3. Wet the O-rings with water and some soap and slip them over respective
side of the quartz sleeve.
Check that the O-rings are positioned evenly on both sides. If not, they
may be damaged and cause leaks.
The O-rings shall not be pressed into position, the glass socket press them
into position when fastened later.
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4. Check the condition of the screws. Wax them if needed.

Carefully mount the glass sockets on both sides on the quartz sleeve.
Fasten the glass sockets with three screws, but do not tighten the screws.
5. Once the screws are evenly entered on both sides, carefully tighten them
evenly to a torque of 7 Nm.
6. Connect the instrument air.
7. Follow the instruction Check for leaks after quartz sleeve assembly on
page 385.
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 Dismount and mount lamp power supply

Follow this instruction to replace a lamp power supply (LPS) inside the lamp
drive cabinet (LDC) .
WARNING
Make the system currentless according to Shut down and deactivate
system on page 96. The LPS has high voltage/power (600 V) inside and
on the lamp power connector, even when UV lamps are not lit.
The LDC contains a fan, which can cause injury if in operation.
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1. Dismount LPS
Release two power connectors at the bottom of the LPS and the signal
cable connector at the top.
2. Loosen the nuts at the bottom (1) of the arc holding the LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short
circuit.
3. Pull the handle to remove the LPS.

4. Mount LPS
Set the DIP switches on the LPS according to Lamp power supply (LPS)
parameters on page 172.
5. Push the new LPS to the wall of the cabinet.
6. Reconnect the three connectors. Make sure the connectors sit tight.
7. Tighten the nuts to attach the LPS with the arc.
8. Turn on the manual motor starter to the LPS. The motor starter is located
inside the cabinet.
9. Switch on the main breaker on the cabinet door and check that LPS:s
function correctly according to instruction Test lamp power supply
installation on page 386.
7.3.5 Test lamp power supply installation

Follow this instruction to make sure that the installation is OK and safe to use.
Preparation and conditions
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DANGER
Before operating the UV reactor, make sure that there is water in the UV
reactor.
Check the LED on the level switch: Steady yellow light indicates that there
is water in the UV reactor.
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. Make sure that the UV reactor breaker is switched off.
2. Check that there is water in the UV reactor(s) (LS201-29). Check the LED
on the level switch: Steady yellow light indicates that there is water in the
UV reactor.
3. Switch on the main breaker on the LDC door. Switch on the power to the
UV reactor using the switches on the breaker cabinet(s).
4. Start UV lamps one by one from the control system (set to manual mode).
Make sure that the UV lamps are lit. This is checked in the UV reactor
popup and on the LPS.
Note: It can take up to 90 seconds for the lamp to start.
5. Check LEDs on the LPS and the alarm list in the control system. Make
sure that no alarms have been triggered by the LPS.
6. Turn off the lamp.
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7.4 Filter
This section covers the instructions for filter service.
These preparations and conditions are valid for all instructions.
• Disconnect the power to the filter, using the main breaker on the control
cabinet.
• Always lock valve V201–3 and V201–32 if you open the filter in some way.
See Lock valve in closed position on page 406.
• Only perform maintenance and servicing work when the filter is cooled,
depressurized and drained.
• Shut off the air supply to the filter.
• Visually inspect gasket during maintenance. Replace if necessary.
• Lifting device is needed for this instruction. See complementary lifting
instructions in the Design and installation guidelines.
Filter cover and element weight (kg):
Filter Weight, empty with adaptor plates on
flanges (kg)
ACB–999–350 1150
Tightening torques for filter

See section Preparations and conditions on page 366.
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Filter – Exploded view
1. Gear reducer
2. Gear shaft
3. Electric 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. Seeger 80. Prefilter
7.4.1 Remove filter cover and filter element

Follow this instruction to remove filter cover and filter element.
1. Log in as Advanced operator or higher.
2. Depressurize and drain the filter by pressing the Drain function button in
the control panel.
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3. Close the following valves: V201-3, V310–2 and V201-32 according to the
instruction in the section Open and close valves manually in chapter
Valves on page 403 and Lock valve in closed position on page 406.
4. 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.
5. Remove the motor (using a lifting device, if necessary). Be careful not to
harm the motor fitting when lifting it from it’s seat.
6. Remove the cover bolts (10) and the lifting lugs (44).
7. Screw two filter cover bolts in the lifting lugs holes until the cover raises
slightly from the filter house.
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8. Remove the cover bolts and fasten the lifting lugs in their holes again.
9. 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 house.
10. Place the filter element on its side.

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

17. Lift the pre-filter (80) from the bottom of the filter house.
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 389.
NOTE
No force should be used to fit the filter element in the filter house or to fit
the motor in its seat.
• Clean the upper inside of the house at the top of the. The area where the O
rings (gaskets) meet the housing should be clean.
• Check the O rings (gaskets). Replace if necessary.
• Fill up the filter with technical / potable water after it is mounted.
• There is not need to de-air 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 344.
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• 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.
• The pH value should be approximately 2.0–3.0.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.
• Proceed with the utmost caution when transporting, assembling,
disassembling and cleaning the filter element.
1. Follow the instructions Remove filter cover and filter element on page 389.
2. Rinse the pre-filter with water and a brush.
3. Remove the filter element gasket (17).
4. Soak the filter element in the cleaning agent with the opening facing
upwards. Leave it to soak for 1–4 hours. Let the element dip dry before
next step.
5. Place the element in so it does not fall over when cleaning it.
6. Spray the filter element with water (60–80 °C) from the outside, using a flat
nozzle. Note: If a high-pressure cleaner is used, the pressure must not
exceed a maximum of 15 bar. If a cleaner with higher capacity is used,
compensate by increasing the distance, minimum 30 cm.
7. Blow the filter element with instrument air (with 10 micron filter or finer),
from the outside.
8. Inspect the filter element from the outside with a magnifier to make sure
that it is clean. If needed, repeat the procedure. This time it is enough to let
the element soak for 5 minutes.
9. Clean the inside of the filter house.
10. Put the filter element gasket back. Reassemble the rest 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

Alpacon descalant is used as cleaning agent in the CIP module. It contains no
solvents and no inorganic acids and it is non-flammable. See Safety data
sheet / CIP liquid on page 344.
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 may contain residues from the cleaning process that can
potentially have an impact on the environment, although this impact is
regarded as very small. There are no transport restrictions.
• Used CIP liquid is drained to one of the following: drain, waste or sludge
tank. Do not drain to bilge. Handle according to local regulations.
• 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, 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, V460-2 and V321–3
from the control panel. Start pump P321-5 (3) and P320-1 (4)
b. Wait for the tank to be totally drained. Then stop the pumps and close
the valves in reversed order. Go to step 3.
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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, V321–3 andV321–1. Start pump P321–5.
b. Wait for the tank to be filled with approximately 240 liters of technical /
potable water, almost up to the Max indication on the tank.
5. Pour the CIP liquid into the tank.
6. Measure the pH value in the tank to secure that it is approximately 2.0. If
not, adjust the proportions: If the pH value is too high, add more CIP
cleaning agent. Measure again.
7. Go to control system page 4.3 – Operation timers. Make a note of the
number of UV reactors that has been CIPed since last time the CIP liquid
was changed. Press the Reset button for “Total number CIP:ed reactors”.
Requires login level Advanced operator. If this is done each time the CIP
liquid is changed, it is possible to build up experience on how many UV
reactors it is possible to CIP before it is time to change CIP liquid.
Refill CIP liquid

Follow this instruction to refill CIP the CIP tank when there is low liquid level in
the tank.
1. Measure the pH value in the tank. Based on the pH value, estimation must
be done regarding the proportions between Alpacon descalant offshore
and water. Note that the mixing ratio is stated under Preparations and
conditions above.
2. Mix the cleaning agent with water separately. The result will get better than
if mixed mix in the tank.
3. Pour the mixed CIP liquid into the tank. Do not fill over Max indication on
the tank.
4. Measure the pH value in the tank to secure that it is approximately 2.0. If
not, adjust the proportions: If the pH value is still too high, the CIP liquid
must be changed. See the Change CIP liquid instruction in this chapter.
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7.6 Pump
This section contain instructions for the CIP pump.
7.6.1 Repair CIP pump

Follow this instruction to repair the CIP pump.
WARNING
Always disconnect the PureBallast system from the power supply before
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
7.6.1.1 Clean CIP pump

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

Follow this instruction to disassemble the CIP pump.
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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).
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.
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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.
7.6.1.3 Assemble CIP pump

Follow the instructions below to assemble the CIP pump.
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.
7.6.2 Test CIP pump

Follow the instruction below to verify that the CIP motor is functioning.
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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.
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7.7 Valve block

Follow this instruction to repair the valve block, mounted on the CIP module.
DANGER
Always disconnect the PureBallast system from the power and air supply
before disassembling, and secure it from being switched on.
The valve bodies does not have individual placing, they can be placed in any
order.
Valve block — general illustration

1. Cover (Terminal strip inside)
2. Valve body
3. Button to operate valve
4. Signal plate
5. Cable gland
7.7.1 Change valve body

1. Remove the screws holding the valve bodies (2) and the signal plate (4).
2. Unscrew the screws holding the valve body (2).
3. Lift the valve body.
4. Attach a new sealing on the new valve body and fasten the valve body to
the valve block.
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7.7.2 Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the control cabinet
to the CIP valve block.
1. Open the cover (1) on the front.
2. Attach the cables according to electrical drawing Control cabinet /
interconnection diagram in chapter 6. Installation description and drawings.
3. Fasten the cable to the cable gland (5).
4. Fasten the cover (1).
7.7.3 Clean valve block

Follow this instruction to clean the valve block house from dirt.
1. Disconnect the outgoing air hoses from the valve block.
2. Operate the service air according to instruction Open and close valves
manually (CIP valves) in section Valves on page 403 to blow out the dust.
3. Connect the air hoses again.
7.7.4 Connect pneumatic hoses to valve block

Follow this instruction to connect pneumatic hoses to the valve block, if they
have been disconnected.
1. Connect the hoses according to the signal plate (4) on the valve block.
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7.8 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
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.
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• Do not operate the actuator over pressure limits. It will damage internal
parts as well as cause damage to the housing.
• 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 366.
7.8.2 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 41 for instruction.
7.8.3 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.Note that the orange diode on the valve body will not light during
manual operation.
1 Identify which button on the valve block that

controls the valve. The lower button operates
the inner hose under the valve block, and
vice versa. Also see the sticker under the
valve block.
2 Press the button on the valve body with a

screw driver to operate the valve.
7.8.4 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.
7.8.5 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.
7.8.6 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.
7.8.7 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.
7.8.8 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 404.
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.
7.8.9 Adjust valve end position

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

• 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).
7.8.10 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.
7.8.11 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 411.
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.
7.8.12 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.
7.8.13 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.
1 Dismount the actuator from the valve

according to instruction Dismount actuator on
page 408. 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 408
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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7.8.14 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 408.

2. Remount the actuator according to Mount actuator on page 408
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.
7.8.15 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.
1 Dismount the actuator from the valve

according to instruction Dismount actuator on
page 408.
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 404.
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.
7.8.16 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).
7.8.17 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 403.
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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7.9 Flow meter

The flow meter consists of two main parts:
• Flow sensor: A pipe with two electrodes detecting the flow.
• Flow transmitter: Monitors and transmits information to the PureBallast
control system.
The flow sensor and flow transmitter are pre-assembled from factory, and the
parameters are pre-set.
7.9.1 Replace display and fuse
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.

To replace display: See step 1–3.
To replace fuse : See step 1–6.
The main fuse is located on the power supply board.
1. Turn off power supply, using the main breaker on the control cabinet.
2. Unscrew cover of the electronics compartment from the transmittor
housing.
3. Remove the local display as follows:
- Press the latches at the side and remove the display module.
- Disconnect the ribbon cable of the display from the amplifier board.
Opening Field housing and replacing display.

4. Remove the screws and remove the cover from the electronics
compartment.
5. Remove the power supply board. Insert a suitable tool into the hole,
provided for the purpose and pull the board clear of its holder.
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6. Remove cap (1) and replace the device fuse (2).

Use only fuses of the following type:
- Power supply 20 to 55 V AC / 16 to 62 V DC use a 2.0 A slow-blow / 250

V; 5.2 × 20 mm
Replacing the device fuse on the power supply board (step 5–6)
1. Protective cap
2. Device fuse
7. Installation is the reverse of the removal procedure.
Re-assembly
7.9.2 Replace a circuit board
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.
NOTE
The circuit boards may break if you yourself or your tools not are grounded at the same
ground point as the component that you will work with. Always use an electrostatic discharge
wrist strap connected to the same earth/ground as the component. Always place your tools on
the same earth/ground as the component you will work with before using them. Follow general
rules on how to avoid electrostatic discharge.
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The circuit boards than can be replaced:

1. The power supply circuit board.
2. The measuring amplifier circuit board.
3. The I/O module circuit board.
1 Turn off the power supply, using the main

breaker on the control cabinet
2 Remove the cover (c) from the electronics

compartment (b). The cover threads are
sensitive so place the cover with its threads
facing upwards.
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3 Remove the 2 screws and remove the display

module (grey in the illustration). It’s not
necessary to separate the display from the
module as seen in the illustration. Just
remove the entire module.
4 Disconnect the ribbon cable from the circuit

board.
5 Grip the circuit board around its edges (the

circuit board may break if you touch its
components) and pull it out carefully.
6 Grip the new circuit board around its edges

and insert it carefully. Then follow the above
steps to put back the ribbon cable, the display
module and the lid.
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7.10 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 179, section Level switch.
Level switch
7.10.1 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. Connect the level switch according to the label on the component.
2. Seal the level switch with lock tight or equivalent pipe seal.
3. Mount the sensor until the joint is finger-tight.
4. Identify the sensor align mark (▼) on the component. Make sure that it is
positioned on the upper side of the level switch.
5. Complete the seal carefully by tightening the component with a spanner.
Use the spanner on the hexagon flats, but not on the level switch body.
7.10.2 Dismount level switch

• The external surface may be hot. Care must be taken to avoid possible
burns.
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1. Disconnect the level switch according to the label on the device.

2. Loosen the component with a spanner. Use the spanner on the hexagon
flats, but not on the level switch body.
3. Remove the level switch and remove the old seal from the threads.
7.10.3 Test level switch

Follow the instruction below to test that a level switch functions OK.
1. Make sure that the component i powered (the green LED shall be lit).
2. Hold a magnet to the test point indicated on the on the level switch,
indicated below.
3. Make sure the level switch reacts to the magnet. The component is OK if
the green and yellow LED is lit.
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7.11 Temperature switch and temperature

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

NOTE
Disconnect power supply before mounting or dismounting the component.
7.11.1 Mount temperature switch / temperature transmitter

1. Seal the component's threads using lock tight or equivalent pipe seal.
2. Mount the component until the joint is finger-tight.
3. Tighten the component with a spanner. Use the spanner on the hexagon
flats, but not on the components body.
4. Connect the component's screwed-on power cord.
7.11.2 Dismount temperature switch / temperature

transmitter
• The external surface may be hot. Care must be taken to avoid possible
burns.
1. Disconnect the component's screwed-on power cord.
2. Loosen the component with a spanner. Use the spanner on the hexagon
flats, but not on the components body.
3. Remove the level switch and remove the old seal from the threads.
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7.12 Control panel

This section covers instructions for service of the control system.
7.12.1 Clean control panel
NOTE
Control panels may only be cleaned when set in wipe mode. This is to
prevent unintended functions from being triggered by buttons pressed
during cleaning.

• Never use aggressive solvents, chemicals, scouring agents, pressurized air
or steam jet.
1. Press the Wipe button on the screen.
Result: Disable the touch screen function for 10 seconds to make it
possible to clean the screen without the risk of starting a process or
changing a setting.
2. Clean the display and surrounding front cover with a soft cloth and mild
detergent. Do not spray detergent directly on the control panel.
7.12.2 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 105 and Set remote control panel
communication on page 106.
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7.13 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).
7.13.1 Mount and connect remote control panel

• Remote control panel is mounted according to according to drawing
Remote control panel (optional) on page 267. 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 340.
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7.14 Control cabinet and lamp drive cabinet (LDC)

This section covers maintenance information for the control cabinet.
7.14.1 Disassemble and assemble I/O system

This section covers maintenance information about the I/O system (X20
electronic modules). For information about status and error indications, please
see Alarms and faultfinding on page 179.
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.
7.14.2 Cable gland installation – General cables

This section covers information about how to install the cables into the control cabinet and LDC using
the cable glands. Power cables to the LDC are installed according to instruction Cable gland
installation – Power cable to LDC.
Follow this instruction to mount cables into the cabinets.
200000657-1-EN-GB 431
EN 7 Service manual
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.
432 200000657-1-EN-GB
Service manual 7 EN
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.
7.14.3 Cable gland installation – Power cable to LDC

Follow this instruction to install the power cable to the LDC using the cable gland.
1 Adapt the seal to the cable by removing

layers from the halves. The halves may not
differ by more than one layer.
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.
7.14.4 Power cable check

Check power cables screw connections, to eliminate potential risk of fire due to loose cables.
200000657-1-EN-GB 433
EN 7 Service manual
This check should be performed in LDC, control cabinet, UVR junction box
1 Turn off power to PureBallast from the

vessel’s switch board, to make it currentless.
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.
7.14.5 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 ist about to be installed in.
1 Switch off the power to the lamp drive cabinet

(LDC).
2 If the safety relay is brkoken, follow the sub-

steps below. If the IFS confstik 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.
434 200000657-1-EN-GB
Service manual 7 EN
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.
200000657-1-EN-GB 435
.
Spare parts catalogue

Specification No. 9005247-03/5

Book No. 9032061 02 Rev. 2
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB 2018-08-09

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 5
2 Control cabinet 6
2.1 Cabinet 10
2.2 I/O module 12
2.3 Relay module 14
2.4 Wire set 16
3 Lamp drive cabinet 18

3.1 Lamp drive cabinet, subas 20
4 Remote control panel (optional) 40

4.1 Cover 42
5 Log box (optional) 44
6 UV Reactor EN 46
6.1 UV reactor EN 48
6.2 Junction box, A side 50
6.3 Junction box 52
6.4 Valve, EN DN350 54
6.5 Valve 56
7 Filter, ACB-999-350 58
7.1 Filter, ACB-999-350 60
7.2 Junction box 62
8 Valve V309-1 64
9 Backflush pump (optional) 66
10 Valve V201-3 and V201-9 68
3
11 Valve V201-32 and 403-35 70
12 Valve V212-31 (optional) 72
13 Control valve V201-8 74
14 Flow transmitter, EN350 76
15 CIP module 78
15.1Pump P320-1 and P321-5 82
15.2Valve 84
15.3Valve block 86
16 Sampling device (QT201.1,

QT201.1) (optional) 88
17 Pressure monitoring device 90
18 Booster pump, P401-1 (optional) 92
19 Booster pump, P403-1, EN

(optional) 94
20 Air filter regulator 96
21 Cross reference list 98
4
1 Important information
1 Important information
• State number of ordered parts. Note that the quantity in the tables do not states number of parts
delivered (only the how many of that parts that are included in the mother component).
• It is only possible to order parts included in the tables.
• Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with
non-original spare parts. We guarantee the quality and reliability of our products.
• This manual refers to unit number printed on the equipment name-plate.
• When ordering, refer to part number listed in this catalogue and serial number, described in
chapter 7. Service manual, section Serial number information.
Book No. 9032061 02 Rev. 2 5

2 Control cabinet
Machine unit number or
Subassembly description
9025738-
Ref Part No Description -80 Notes
Quantity
1 9012086 83 Cabinet 1 See page 10
2 9006851 01 Software, PLC, PB3.0 1
3 9006852 01 Software, panel 1
4 592122 03 HMI Panel wide without co 1
8 221891 04 Lock nut 12
9 223101 47 Washer 12
10 582212 148 End stop (clip fix) 14
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
16 9004299 04 Fuse 4
17 582212 67 Terminal, PIT 2,5-3PV 7
17.1 582212 71 Plug In Bridge, FBS 3-5BU 1
18 582212 63 Terminal D-PIT 2,5-3L 1
19 9019135 04 Contactor AF16Z 1 K4
20 9019135 04 Contactor AF16Z 1 K5
21 9025840 80 I/O module 1 See page 12
22 582212 147 Patch panel 2
23 582212 91 VIP-2, D 9SUB 1
24 9019186 05 Terminal, PT 4-PE/3L 4
25 582212 102 Terminal PITTB 2,5 PE 1
26 9019186 06 End cover, D-PT 4-PE/3L 1
27 582212 104 Terminal PITTB 2,5 42
29 582212 67 Terminal, PIT 2,5-3PV 4
30 582212 63 Terminal D-PIT 2,5-3L 1
31 582212 168 Separating plate 2
32 582212 123 Power terminal block, 1
33 9002362 80 Relay module 3 See page 14
34 593724 03 Distance screw 4
35 582221 90 PE Connection bar 1 245mm
36 594009 03 Screw 2
37 582212 206 Bar holder 3
38 582212 15 PE/SC Bar 1 500mm
39 594009 02 Screw 3
40 582212 207 Cable clamp 10
41 9006814 01 Cable channel 100x80 1
42 583556 17 Cable channel 40x80 1
43 583556 16 Cable channel 40x80 2
44 9003522 06 Cable channel, 25x80 1
45 9003522 07 Cable channel, 25x80 2
48 223101 47 Washer 2
49 221851 05 Cap nut 2
50 9019186 07 Safety relays, PSR-MC30 1
51 221701 03 Screw 16
52 591103 67 Emergency stop 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
6 Book No. 9032061 02 Rev. 2

2 Control cabinet
3029A
Book No. 9032061 02 Rev. 2 7


9025738-
Quantity
66 9012150 81 Wire set 1 See page 16
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
82 595673 03 Ethernet cable 2
83 582212 147 Patch panel 1
84 582212 91 VIP-2, D 9SUB 1
86 582212 90 Cable-D 9SUB 1
87 580986 76 Communication module 1
8 Book No. 9032061 02 Rev. 2

2 Control cabinet
3029A
Book No. 9032061 02 Rev. 2 9

2.1 Cabinet
9012086-
Quantity
2 9012091 81 Door 1
4 26556 Spring washer 6
5 9025887 01 Mounting plate 1
6 587276 02 Washer 16
7 221891 05 Hexagon lock nut 12
8 221716 01 Screw 4
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
18 221891 04 Lock nut 4
20 593254 01 Retaining ring 1
21 221711 19 Screw 1
22 593282 01 Washer 1
23 221803 02 Nut 2
24 223101 73 Washer 1
25 593239 01 Nut 1
26 581688 01 Bracket 4
27 594488 01 Washer 4
28 221711 16 Screw 8
29 223101 47 Washer 8
30 221891 04 Lock nut 8
31 587276 02 Washer 6
32 70560 Washer 6
34 9014753 01 Piano hinge 1
35 9014815 01 Cover panel 1
36 598571 01 Torx head pan screw M4 8
37 221851 18 Cap nut 8
38 223101 31 Washer 4
39 9015118 01 Mounting spacer hole thro 2
40 9015117 01 Mounting spacer single ta 2
41 9012093 01 Magnet 4
44 587276 01 Washer 2
45 223101 47 Washer 2
46 221891 04 Lock nut 2
10 Book No. 9032061 02 Rev. 2

2.1 Cabinet 2 Control cabinet
2878A
Book No. 9032061 02 Rev. 2 11

2.2 I/O module

9025840-
Quantity
1 597033 22 PLC 1 Incl. locking plate.
1.1 597033 18 Interface module 1
1.2 580986 76 Communication module 1
2 580986 17 Bus module 11
3 580986 30 Supply Bus Module 1
4 580986 51 12 Digital Input 3
5 580986 08 4 Analogue input 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 16 Terminal block 12-pin 12
11 580986 20 Locking Plate right 0 Included in pos:1
12 580986 55 Compact flash card 1
12 Book No. 9032061 02 Rev. 2

2.2 I/O module 2 Control cabinet
3030A
Book No. 9032061 02 Rev. 2 13

2.3 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
14 Book No. 9032061 02 Rev. 2

2.3 Relay module 2 Control cabinet
2724A
Book No. 9032061 02 Rev. 2 15

2.4 Wire set

9012150-
Quantity
1 9008383 06 Cable, 2,5mm² PE 5
2 9008383 08 Cable, 1,5mm² 12
3 9008387 01 Cable 100
5 582212 90 Cable-D 9SUB 1
8 9008383 15 Cable, 16mm² 3
16 Book No. 9032061 02 Rev. 2

2.4 Wire set 2 Control cabinet
2377A
Book No. 9032061 02 Rev. 2 17

3 Lamp drive cabinet

9011938-
Quantity
1 9012046 80 Lamp drive cabinet, subas 1 See page 20
2 9012146 01 Lamp Power supply 16
18 Book No. 9032061 02 Rev. 2

3 Lamp drive cabinet
2874A
Book No. 9032061 02 Rev. 2 19

3.1 Lamp drive cabinet, subas

9012046-
Quantity
2 9004211 01 Centrifugal fan 1
3 221030 10 Screw 5
3.1 223101 47 Washer 5
4 9012058 80 Terminal block 1 See page 28
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 9008403 80 Solenoid valve 1
18 9004254 01 Check valve 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
33 594009 03 Screw 2
34 582212 148 End stop (clip fix) 16
35 591103 86 Over current prot. 8
35.1 591103 10 Auxiliary contact 8
37 591103 64 Connection 3
39 9004299 04 Fuse 2
40 9012135 80 I/O module 1 See page 30
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 3
47 9014546 01 Temperature relay 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
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
20 Book No. 9032061 02 Rev. 2

3.1 Lamp drive cabinet, subas 3 Lamp drive cabinet
3009A
Book No. 9032061 02 Rev. 2 21


9012046-
Quantity
59 591103 41 End cap 2
60 9014833 01 DIN-rail, 35x15 1
61 223101 47 Washer 4
62 221891 04 Lock nut 4
63 582212 147 Patch panel 2
66 587276 02 Washer 12
67 70560 Washer 12
70 594009 07 Screw 4
86 9015197 82 Wire set 1 See page 38
Z 591103 62 RHE handle
Z0.1 9003114 02 Cable gland
Z0.2 597330 01 Cable seal
Z0.3 597331 01 Cable seal
22 Book No. 9032061 02 Rev. 2

3009A
Book No. 9032061 02 Rev. 2 23

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
24 Book No. 9032061 02 Rev. 2

2881A
Book No. 9032061 02 Rev. 2 25

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
26 Book No. 9032061 02 Rev. 2

2882A
Book No. 9032061 02 Rev. 2 27

3.1.3 Terminal block

9012058-
Quantity
1 598323 02 DIN rail TS 15 1
2 582212 202 Terminal MPT1,5 9
3 582212 203 Terminal MPT1,5 PE 2
4 582212 204 Terminal D-MPT1,5 1
5 582212 205 Clip fix 15 2
28 Book No. 9032061 02 Rev. 2

2880A
Book No. 9032061 02 Rev. 2 29

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
30 Book No. 9032061 02 Rev. 2

2870A
Book No. 9032061 02 Rev. 2 31


9014704-
Quantity
1 582212 67 Terminal, PIT 2,5-3PV 6
2 582212 64 Terminal PIT 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
6 582212 148 End stop (clip fix) 2
32 Book No. 9032061 02 Rev. 2

2871A
Book No. 9032061 02 Rev. 2 33


9011936-
Quantity
3 582212 130 Support, L=95,5 2
5 582212 88 PIT 2,5 22
6 582212 89 D-ST2,5 1
7 582212 15 PE/SC Bar 1 138mm
8 582212 137 Sc clamp SK 20 1
9 582212 136 Sc clamp SK 14 1
34 Book No. 9032061 02 Rev. 2

2872A
Book No. 9032061 02 Rev. 2 35


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
36 Book No. 9032061 02 Rev. 2

2873A
Book No. 9032061 02 Rev. 2 37

3.1.8 Wire set

9015197-
Quantity
1 9008383 01 Cable, 70mm² 5
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
38 Book No. 9032061 02 Rev. 2

2377A
Book No. 9032061 02 Rev. 2 39

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 592122 03 HMI Panel wide without co 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 42
39 582212 215 Connector 1
40 Book No. 9032061 02 Rev. 2

4 Remote control panel (optional)
2875A
Book No. 9032061 02 Rev. 2 41

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
42 Book No. 9032061 02 Rev. 2

4.1 Cover 4 Remote control panel (optional)
2883A
Book No. 9032061 02 Rev. 2 43

5 Log box (optional)

9002245-
Quantity
1 582212 05 End stop 7
3 582212 123 Power terminal block, 1
4 582212 124 Circuit breaker 2
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
19 9002362 80 Relay module 5 See page 14
24 594009 03 Screw 8
29 9003490 01 Bracket set 1
44 Book No. 9032061 02 Rev. 2

5 Log box (optional)
3021A
Book No. 9032061 02 Rev. 2 45

6 UV Reactor EN
9002700-
Quantity
1 9002699 81 UV reactor EN 1 See page 48
2 9010984 81 Junction box, A side 1 Valves, sensors & feed back
See page 50
3 9010987 80 Junction box 1 Lamp cables
See page 52
4 221803 02 Nut 8
5 223101 32 Washer 8
7 9001357 03 Sensor AT201-50 1
8 9014966 69 Valve, EN DN350 1 V201-19
See page 54
8.1 9014966 69 Valve, EN DN350 1 V201-20
See page 54
9 260192 01 Screw 32
10 223101 39 Washer 32
12 9006325 02 Thermometer, resistance 1 TT201-33
13 9006324 02 Temperature, switch 1 TS201-60
14 558663 04 Gasket washer 2
15 594171 01 Limit switch (vibration) 1 LS201-29
16A 9010631 99 Cable (valves and signals)
18 526350 05 Plug 1
19 558663 03 Gasket washer 2
20 594413 80 Valve 1 V320-4
See page 56
20.1 594413 80 Valve 1 V321-2
See page 56
20.2 594413 80 Valve 1 V404-36
See page 56
21 2210463 23 Screw 12
22 223101 37 Washer 12
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
27 260321 25 Hexagon screw 2
28 592304 01 Plug 1
29 592304 02 Plug, 1/4 1
30 552801 50 Push-on connector 5
31 9004638 01 Clamp 1
32 2210296 02 Screw 1
33 223101 33 Washer 2
34 221803 03 Nut 1
35A 9011226 99 Cable (UV lamp to junction box)
37 595272 01 Tube, 6x1 mm 4
38 558710 02 Air Hose Nipple 5
64 526336 04 Nipple 1
70 597044 03 Cable 2 PE, junction box - reactor
71 597044 04 Cable 1 PE, AOT reactor - hull.
74 223101 32 Washer 3
81 221803 26 Nut 4
82 223101 41 Washer, 4,3x9x0,8 4
83 221031 22 Screw 3
93 593301 02 Insulating washer 32
94 593300 04 Insulating sleeve 32
Z 9009521 80 Lamp, spare set Includes UV lamps and 2 O-rings.
Z0.1 594645 82 Quartz sleeve set Includes Quartz sleeve and 2 O-rings.
46 Book No. 9032061 02 Rev. 2

6 UV Reactor EN
2688A
Book No. 9032061 02 Rev. 2 47

6.1 UV reactor EN
9002699-
Quantity
3 66169 Drive screw 8
6 9003326 01 Glass socket 32
7 221711 13 Screw 96
8 9002009 81 Lamp bush 32
9 9004878 80 Cap 32
10 9002860 01 Nut 32
20 221711 23 Screw 16
22 221041 02 Screw 16
23 223101 61 Washer 24
24 221036 01 Screw 4
25 223101 33 Washer 20
27 67141 Screw 8
28 9003662 01 Plate 1
29 2210296 02 Screw 1
30 223101 31 Washer 2
31 9003672 01 Upper bracket 2
32 221036 19 Screw 8
33A 9004889 01 Lifting bracket 1
33B 556465 01 Label 1
34 221041 03 Screw 4
35 221803 29 Nut 4
38 9009416 01 Cable rail 2
39 221031 21 Screw 8
40 223101 32 Washer 12
41 221803 28 Nut 6
43 9010633 01 Screw, hexagon socket 2
Z 9009521 80 Lamp, spare set
Z0.1 594645 82 Quartz sleeve set
48 Book No. 9032061 02 Rev. 2

6.1 UV reactor EN 6 UV Reactor EN
2685A
Book No. 9032061 02 Rev. 2 49

6.2 Junction box, A side

9010984-
Quantity
1 9010981 01 Enclosure 1
3 582212 88 PIT 2,5 28 Marked acc. to electrical doc.
4 582212 122 Terminal block 3 Marked acc. to electrical doc.
6 582212 70 Plug In Bridge, FBS 3-5 1 402
7 582212 89 D-ST2,5 1
8 582212 151 Socket 6
9 582212 150 Socket 5
10 9003031 01 Condensation outlet 1
11 589569 58 Cable gland EMC-brush M32 2
12 589569 44 Counter nut EMC M32 2
13 591103 70 Pilot light White 1
14 591103 69 Pilot light Green 1
50 Book No. 9032061 02 Rev. 2

6.2 Junction box, A side 6 UV Reactor EN
2800A
Book No. 9032061 02 Rev. 2 51

6.3 Junction box

9010987-
Quantity
1 9010983 01 Enclosure 1
3 582212 156 Terminal, PT 6 32 Marked acc. to electrical doc.
4 582212 157 End cover, D-PT 6 1
5 9003031 01 Condensation outlet 1
7 9004959 01 Insert, 8x6 mm 4
52 Book No. 9032061 02 Rev. 2

6.3 Junction box 6 UV Reactor EN
2888A
Book No. 9032061 02 Rev. 2 53

6.4 Valve, EN DN350

9014966-
Quantity
1 9007167 10 Valve, DN350 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1
5 9007192 01 Throttle valve, 1/4 2
6 594410 01 Valve connector 1
7 595215 01 Plate 1
8 9009912 01 Sensor 1
27 9015525 03 Indicator cap 1
54 Book No. 9032061 02 Rev. 2

6.4 Valve, EN DN350 6 UV Reactor EN
2867A
Book No. 9032061 02 Rev. 2 55

6.5 Valve
594413-
Quantity
1 590037 01 Valve, DN32 1
2 576075 21 Air actuator, SR101 1
3 576071 01 Pilot valve 1
4 585976 01 Coil, 24 V DC 1
5 594410 01 Valve connector 1
6 583012 01 Throttle valve, 1/4 2
Z 576075 71 Actuator spare part kit, DA/SR 101 1
56 Book No. 9032061 02 Rev. 2

6.5 Valve 6 UV Reactor EN
2330A
Book No. 9032061 02 Rev. 2 57

7 Filter, ACB-999-350
9023678-
Quantity
1 9023658 60 Filter, ACB-999-350 1 See page 60
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
7 526337 02 Reducing hexagon nipple 2
8 1767267 01 Needle valve 2
9 9017973 01 Pressure transmitter 2
13 526336 04 Nipple 1
14 9006822 03 Relief valve, 10 bar 1
15 561094 06 Straight coupling 1
16 9019487 02 Tube 1
19 9023647 83 Gear motor 1
20 221046 01 Screw 4
22 9024155 01 Bracket 1
23 7007238 01 Screw 4
24 9012246 80 Junction box 1 See page 62
25 221711 25 Screw 4
25.1 223101 32 Washer 4
25.2 221803 28 Nut 4
26 9026074 01 Cable bracket 1
27 221711 07 Screw 2
28 223101 32 Washer 2
29 9026072 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 02 Cable 1
58 Book No. 9032061 02 Rev. 2

7 Filter, ACB-999-350
3040A
Book No. 9032061 02 Rev. 2 59

7.1 Filter, ACB-999-350

9023658-
Quantity
4 9024205 08 Bolt 4
6 9011970 05 Bearing 1
7 9011972 05 Gasket 2
7.1 9011973 05 Bushing 1
8 9024206 08 Plug 2
9 9011974 51 Filter cover 1
10 9024205 16 Bolt 16
11 9011973 10 Bushing 1
12 9024205 24 Bolt 4
13 9011972 10 Gasket 1
14 9011974 37 Filter body 1
15 9011975 05 Filter element 1
16 9011972 15 Nozzle 1
17 9011972 20 Gasket 1
18 9011973 15 Bushing 1
19 9024206 16 Plug 3
20 9011972 25 Gasket 1
30 9024207 08 Nozzle support 1
31 9024205 32 Bolt 4
32 9011972 30 Gasket 1
33 9011974 25 Base frame 1
34 9024205 40 Bolt 4
36 9011970 33 Grease fitting 1
40 9024208 08 Ring spear 1
41 9011970 17 Bearing flange 1
42 9011970 25 Bearing flange 1
44 9024210 08 Lifting lug 2
77 9011973 35 Bushing 1
80 9011978 05 Prefilter 1
87 9024206 24 Plug 6
Z 9011963 85 Maintenance kit Yearly maintenance
ZA 9011972 05 Gasket 2
ZB 9011973 05 Bushing 1
ZC 9011972 10 Gasket 1
ZD 9011972 20 Gasket 1
ZE 9011972 25 Gasket 1
ZF 9011972 30 Gasket 1
60 Book No. 9032061 02 Rev. 2

7.1 Filter, ACB-999-350 7 Filter, ACB-999-350
3044A
Book No. 9032061 02 Rev. 2 61

7.2 Junction box

9012246-
Quantity
1 9012247 01 Enclosure 1
3 582212 88 PIT 2,5 13
4.1 590640 55 Terminal PT 6-PE 1
5 582212 89 D-ST2,5 1
5.1 582212 157 End cover, D-PT 6 1
6 589569 77 Cable Gland - M12 1
7 589569 48 Cable Gland - M16 3
9 589569 79 Cable Gland - M25 1
10 589569 80 Cable Gland - M32 1
11 589569 32 Counter nut M12 1
12 589569 33 Counter nut M16 3
13 589569 34 Counter nut M20 1
14 589569 35 Counter nut M25 1
15 589569 36 Counter nut M32 1
62 Book No. 9032061 02 Rev. 2

7.2 Junction box 7 Filter, ACB-999-350
2866A
Book No. 9032061 02 Rev. 2 63

8 Valve V309-1
NOT VALID IF BACKFLUSH PUMP IS INSTALLED.

9025644-
Quantity
1 9018543 64 Valve, EN DN80 1
1A 9007167 03 Valve, DN80 1
1B 9007166 01 Air actuator, AT 101U 1
1C 9007185 01 Pilot valve 1
1D 9007192 01 Throttle valve, 1/4 2
1E 9007184 02 Insulate plate
1.1 594410 01 Valve connector 1
4 2210463 03 Screw 8
5 223101 37 Washer 8
64 Book No. 9032061 02 Rev. 2

8 Valve V309-1
3023A
Book No. 9032061 02 Rev. 2 65

9 Backflush pump (optional)

9025646-
Quantity
1 9018653 05 Centrifugal pump 1
1.1 589569 79 Cable Gland - M25 1
1.2 589569 35 Counter nut M25 1
2 9018543 63 Valve, EN DN65 1
2A 9007167 02 Valve, DN65 1
2B 9007166 01 Air actuator, AT 101U 1
2C 9007185 01 Pilot valve 1
2D 9007192 01 Throttle valve, 1/4 2
2.1 594410 01 Valve connector 1
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 9025753 01 Elbow adaptor, 65 1
13 2210463 03 Screw 4
14 223101 37 Washer 4
66 Book No. 9032061 02 Rev. 2

9 Backflush pump (optional)
3034A
Book No. 9032061 02 Rev. 2 67

10 Valve V201-3 and V201-9

9007170-
Quantity
1 9007167 10 Valve, DN350 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1
5 9007192 01 Throttle valve, 1/4 2
6 9007193 01 Actuator cable 1
7 9007196 02 Bracket 1
8 9007186 01 Switch box 1
19 587927 07 Locking device, AL79 451 1
Z 9007197 01 Gasket
68 Book No. 9032061 02 Rev. 2

10 Valve V201-3 and V201-9
2710A
Book No. 9032061 02 Rev. 2 69

11 Valve V201-32 and 403-35

9007172-
Ref Part No Description -69 -60 Notes
Quantity
1 9007167 01 Valve, DN50 1
1 9007167 10 Valve, DN350 1
2 9007166 01 Air actuator, AT 101U 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1 1
5 9007192 01 Throttle valve, 1/4 2 2
6 9007193 01 Actuator cable 1 1
7 9007196 01 Bracket 1
7 9007196 02 Bracket 1
8 9007186 01 Switch box 1 1
Z 9007184 01 Insulate plate
Z 9007197 01 Gasket
70 Book No. 9032061 02 Rev. 2

11 Valve V201-32 and 403-35
2714A
Book No. 9032061 02 Rev. 2 71

12 Valve V212-31 (optional)

9007168-
Quantity
1 9007167 10 Valve, DN350 1
2 9007166 06 Air actuator, AT 451U 1
3 9007185 01 Pilot valve 1
5 9007192 01 Throttle valve, 1/4 2
6 9007193 01 Actuator cable 1
7 9007196 02 Bracket 1
8 9007186 01 Switch box 1
12 9005789 03 Gearbox 1
13 552801 02 Push-in connector 1
14 1764011 02 Silencer 1
15 592304 02 Plug, 1/4 1
16 569035 05 Flexible pipe, PA12, 8/6 1
17 580758 06 Push-In Fittings 1
18 9005792 02 Handwheel 1
Z 9007197 01 Gasket
72 Book No. 9032061 02 Rev. 2

12 Valve V212-31 (optional)
2716A
Book No. 9032061 02 Rev. 2 73

13 Control valve V201-8

9007174-
Quantity
1 9007167 09 Valve, DN300 1
2 9007166 06 Air actuator, AT 451U 1
7 9007196 02 Bracket 1
9 9034058 80 Driver 1
10 9007190 01 Positioner 1
10.2 9029781 01 Insert, M20 1 See comment on assembly drawing.
16 569035 05 Flexible pipe, PA12, 8/6 1
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
Z 9007184 04 Insulate plate
74 Book No. 9032061 02 Rev. 2

13 Control valve V201-8
2712A
Book No. 9032061 02 Rev. 2 75

14 Flow transmitter, EN350

9024585-
Quantity
1 9024593 07 Flow transmitter, EN DN35 1
Z 9025145 01 Transmitter + display
Z0.1 9025145 02 Display
Z0.2 9030002 80 Cable gland kit
76 Book No. 9032061 02 Rev. 2

14 Flow transmitter, EN350
3035A
Book No. 9032061 02 Rev. 2 77

15 CIP module
*=On request only, contact your local Alfa Laval representative

9002547-
Ref Part No Description -80* Notes
Quantity
1 9003450 01 Frame complete 1
2 590414 01 Tank 1
3 9004533 80 Pump P320-1 and P321-5 2 See page 82
4 9002825 80 Valve 7 See page 84
5 9003730 01 Valve housing 3
6 9002915 01 Check valve 2
7 9003732 01 O-ring 6
8 590313 01 Valve, angle seat 1
9 590476 01 Nipple, ISO-R 3/4-1/2 1
10 9005046 01 Backflow preventer 1
11 589526 07 U-bolt clamp, c-c 56,5 1
12 526350 06 Plug 1
13 569035 01 Flexible pipe, PA12, 6/4 1
14 569035 05 Flexible pipe, PA12, 8/6 1
15 9003172 80 Valve block 1 See page 86
16 9004479 80 Filter regulator 1
18 9003514 01 Speed controller 2
19 9004517 01 Reducer 2
20 9002962 01 Pipe #1 1
21 9002963 01 Pipe #2 1
22 9004237 01 Pipe #3 1
23 9003935 01 Pipe #4 2
24 9014747 01 Pipe #5 1
25 9014748 01 Pipe #6 1
26 9002586 01 Pipe #7 2
27 9003570 01 Pipe #8 4
28 9003949 01 Pipe #9 1
29 9002589 01 Pipe #10 1
30 9003792 01 Pipe #11 2
31 9002591 01 Pipe #12 1
32 9003837 01 Pipe #13 2
33 9004247 01 Pipe #14 1
34 9002592 01 Pipe #15 1
35 9003851 01 Pipe #16 1
36 9003853 01 Pipe #17 1
37 9003854 01 Pipe #18 2
38 9003863 01 Pipe #19 1
39 9003886 01 Pipe #20 1
40 9003888 01 Pipe #21 1
42 591675 01 Hose, 32 1
43 569038 05 Hose, 32 1
44 592665 01 Hose, 25 1
45 9003574 01 O-ring 6
46 9005743 01 Pipe clamp 5
47 599223 03 Hose clamp 38-50 10
48 599223 02 Hose clamp 32-44 3
49 592676 05 Insulation sheet, 10mm 4
50 592676 07 Insulation sheet, 5mm 7
51 592790 01 Insulation sheet 1
52 558710 01 Air Hose Nipple 1
78 Book No. 9032061 02 Rev. 2

15 CIP module
2558A
Book No. 9032061 02 Rev. 2 79

*=On request only, contact your local Alfa Laval representative

9002547-
Ref Part No Description -80* Notes
Quantity
53 221716 02 Screw 2
54 221711 17 Screw 2
55 221701 04 Screw 4
56 223101 41 Washer, 4,3x9x0,8 4
57 221711 16 Screw 18
58 223101 47 Washer 18
59 587276 02 Washer 2
60 27345 Nut, M8 12
61 70560 Washer 14
62 9005147 01 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 01 Coupling 1
68 580758 06 Push-In Fittings 2
Z 590414 02 Tanck screw cap
Z0.1 9014527 81 Conversion kit, CIP Only relevant for CIP modules before
2012-11-13
80 Book No. 9032061 02 Rev. 2

15 CIP module
2558A
Book No. 9032061 02 Rev. 2 81

15.1 Pump P320-1 and P321-5

9004533-
Quantity
1 9004533 01 Pump 1
Z 9004587 80 Spare part set Incl. O-rings, diaphragm, ball, muffler
indicated in dwg.
Z0.1 9004588 80 Spare part set Incl. air valve, sealings and O-rings,
indicated in dwg.
82 Book No. 9032061 02 Rev. 2

15.1 Pump P320-1 and P321-5 15 CIP module
2606A
Book No. 9032061 02 Rev. 2 83

15.2 Valve
9002825-
Quantity
1 9002825 01 Valve 1
Z 9003574 01 O-ring
84 Book No. 9032061 02 Rev. 2

15.2 Valve 15 CIP module
2609A
Book No. 9032061 02 Rev. 2 85

15.3 Valve block

9003172-
Quantity
1 9003172 01 Valve block side 1
2 9003172 02 Valve block 5
3 9003172 03 Valve block side 1
4 9003172 04 Valve 2x 3/2 5
5 9003172 05 Connection box 1
6 9003172 06 Cable gland NPT3/4 1
7 9003172 07 Plug 1
8 9003172 08 Plug 1
9 9003172 09 O-ring 1
10 9003172 10 Sign bracket 2
11 9003172 11 Sign plate 1
13 9003172 12 Cable gland, M32 1
86 Book No. 9032061 02 Rev. 2

15.3 Valve block 15 CIP module
2607A
Book No. 9032061 02 Rev. 2 87

16 Sampling device (QT201.1, QT201.1) (optional)

589745-
Ref Part No Description -80 -81 Notes
Quantity
1 591662 80 Adaptor pipe 1 1
2 591667 01 Pitot tube 1 1
3 1765908 07 Gasket 2 2
4 2210462 30 Screw 4 4 M6S 16x70 fzb
5 221803 34 Nut, M16 4 4 M6M 16 fzb
6 70490 Washer 16 16 BRB 17x30x3 fzb
7 591631 01 Blind flange, DN50/A50 1 1
8 591628 80 Valve, manual DN50 1 1
8 591628 82 Valve, manual DN50 1 1
8A 9007167 01 Valve, DN50 1 1 Lug type
8B 9037347 01 Hand lever 1 1
9 2210462 45 Screw, M16x45 8 8 M6S 16x45 fzb
14 591666 01 Rod 1 1
88 Book No. 9032061 02 Rev. 2

16 Sampling device (QT201.1, QT201.1)
(optional)
2780A
Book No. 9032061 02 Rev. 2 89

17 Pressure monitoring device

9006076-
Quantity
1 9007231 01 Needle valve, DN15 1
2 526336 04 Nipple 3
3 9006075 01 Manifold 1
4 9001406 83 Pressure transmitter Kit 1
5 543054 09 Pressure gauge 1 0-16 bar
6 9006822 02 Relief valve, 8 bar 1
7 546600 02 Pipe union 1
8 544465 06 Locking liquid 1
90 Book No. 9032061 02 Rev. 2

17 Pressure monitoring device
2709A
Book No. 9032061 02 Rev. 2 91

18 Booster pump, P401-1 (optional)

9019601-
Quantity
1 9019604 01 Pump 1
5 589569 34 Counter nut M20 1
Z 9019944 02 Shaft seal
92 Book No. 9032061 02 Rev. 2

18 Booster pump, P401-1 (optional)
3036A
Book No. 9032061 02 Rev. 2 93

19 Booster pump, P403-1, EN (optional)

9019605-
Quantity
1 9019609 02 Centrifugal pump 1
1.2 589569 34 Counter nut M20 1
4 2210463 08 Screw 4
5 223101 37 Washer 8
6 221803 40 Nut 4
7 2210463 07 Screw 4
8 223101 37 Washer 8
9 221803 40 Nut 4
10 1765908 03 Gasket 1
11 1765908 06 Gasket 1
Z 9019944 01 Centrifugal pump spare pa
94 Book No. 9032061 02 Rev. 2

19 Booster pump, P403-1, EN (optional)
2981A
Book No. 9032061 02 Rev. 2 95

20 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
96 Book No. 9032061 02 Rev. 2

20 Air filter regulator
3039A
Book No. 9032061 02 Rev. 2 97

21 Cross reference list
+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
1270001 21 84 221716 01 24 5 223101 16 24 40

1270001 58 40 221716 01 24 68 223101 17 20 16
1270001 7 74 221716 01 10 8 223101 31 10 38
1764011 02 72 14 221716 02 80 53 223101 31 48 30
1765908 03 94 10 221726 10 26 69 223101 32 46 5
1765908 06 94 11 221803 02 20 12 223101 32 46 74
1765908 07 88 3 221803 02 24 52 223101 32 48 40
1765908 08 66 11 221803 02 26 10 223101 32 58 25.1
1767267 01 58 8 221803 02 46 4 223101 32 58 28
2210296 02 46 32 221803 02 10 23 223101 32 58 32
2210296 02 48 29 221803 03 20 15 223101 33 46 33
221030 02 24 62 221803 03 46 34 223101 33 48 25
221030 10 20 3 221803 26 46 81 223101 37 46 22
221030 10 20 10 221803 28 48 41 223101 37 64 5
221030 10 24 45 221803 28 58 25.2 223101 37 66 7
221030 10 26 18 221803 29 48 35 223101 37 66 10
221030 10 26 21 221803 34 88 5 223101 37 66 14
221031 21 48 39 221803 40 66 8 223101 37 94 5
221031 22 46 83 221803 40 94 6 223101 37 94 8
221035 51 26 4 221803 40 94 9 223101 39 46 10
221036 01 48 24 221851 05 24 35 223101 41 26 58
221036 19 48 32 221851 05 40 7 223101 41 46 82
221040 53 80 64 221851 05 6 49 223101 41 80 56
221041 02 48 22 221851 18 10 37 223101 47 10 45
221041 03 48 34 221891 01 20 7 223101 47 20 3.1
221046 01 58 20 221891 02 24 39 223101 47 20 11
2210462 30 88 4 221891 02 26 59 223101 47 20 51
2210462 45 88 9 221891 04 10 46 223101 47 21 61
2210463 03 64 4 221891 04 20 52 223101 47 24 7
2210463 03 66 9 221891 04 21 62 223101 47 24 10
2210463 03 66 13 221891 04 24 8 223101 47 24 16
2210463 07 94 7 221891 04 24 11 223101 47 24 34
2210463 08 94 4 221891 04 24 17 223101 47 24 44
2210463 09 66 6 221891 04 24 64 223101 47 24 51
2210463 23 46 21 221891 04 40 10 223101 47 24 63
221701 03 6 51 221891 04 40 26 223101 47 26 9
221701 04 80 55 221891 04 40 30 223101 47 26 19
221711 07 58 5 221891 04 42 6 223101 47 26 22
221711 07 58 27 221891 04 6 8 223101 47 40 6
221711 07 58 30 221891 04 10 18 223101 47 40 9
221711 13 48 7 221891 04 10 30 223101 47 40 25
221711 13 58 31 221891 05 10 33 223101 47 40 29
221711 16 40 3 221891 05 21 68 223101 47 42 5
221711 16 42 4 221891 05 24 4 223101 47 6 48
221711 16 80 57 221891 05 24 67 223101 47 6 9
221711 16 10 28 221891 05 40 36 223101 47 80 58
221711 17 80 54 221891 05 42 13 223101 47 10 29
221711 19 10 21 221891 05 10 7 223101 49 26 68
221711 23 48 20 223101 03 20 6 223101 61 48 23
221711 25 58 25 223101 04 20 11.1 223101 73 10 24
98 Book No. 9032061 02 Rev. 2

Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
223107 34 10 17 580986 32 12 7 582212 147 21 63

260192 01 46 9 580986 40 30 8 582212 147 6 22
260321 25 46 27 580986 51 12 4 582212 147 40 15
26556 10 4 580986 53 12 6 582212 147 7 83
27345 80 60 580986 53 30 9 582212 148 20 34
523127 01 74 30 580986 55 12 12 582212 148 32 6
523127 04 20 19 580986 59 12 8 582212 148 34 1
526336 04 46 64 580986 59 30 7 582212 148 36 1
526336 04 58 13 580986 61 30 10 582212 148 40 11
526336 04 90 2 580986 62 30 3 582212 148 40 31
526337 02 58 7 580986 63 30 4 582212 148 50 2
526337 08 58 3 580986 64 30 1 582212 148 52 2
526350 05 46 18 580986 72 30 5 582212 148 62 2
526350 06 78 12 580986 76 12 1.2 582212 148 6 10
543054 09 90 5 580986 76 7 87 582212 150 50 9
544465 06 90 8 581534 01 46 26 582212 151 50 8
546600 02 90 7 581688 01 42 3 582212 155 40 16
548152 03 80 66 581688 01 10 26 582212 155 6 56
552801 02 72 13 581803 43 20 29 582212 156 36 7
552801 02 74 13 582212 03 32 5 582212 156 52 3
552801 02 74 24 582212 03 40 12.1 582212 157 36 10
552801 50 46 30 582212 04 40 14 582212 157 52 4
552801 50 80 63 582212 05 44 1 582212 157 62 5.1
556465 01 48 33B 582212 102 6 25 582212 15 34 7
558663 03 46 19 582212 104 6 27 582212 15 36 8
558663 04 46 14 582212 119 14 1 582212 15 6 38
558710 01 78 52 582212 120 14 2 582212 164 20 28
558710 02 46 38 582212 121 14 3 582212 165 20 30
561094 06 58 15 582212 122 20 41 582212 168 6 31
569035 01 78 13 582212 122 34 4 582212 172 14 Z
569035 05 72 16 582212 122 36 3 582212 182 20 45
569035 05 74 16 582212 122 44 2 582212 202 28 2
569035 05 78 14 582212 122 50 4 582212 203 28 3
569038 05 78 43 582212 122 62 4 582212 204 28 4
571697 01 74 29 582212 122 6 11 582212 205 28 5
576071 01 56 3 582212 123 6 32 582212 206 6 37
576075 21 56 2 582212 123 44 3 582212 207 6 40
576075 71 56 Z 582212 124 44 4 582212 214 40 22.1
580758 06 72 17 582212 125 44 5 582212 215 40 39
580758 06 80 68 582212 130 34 3 582212 63 6 18
580986 06 12 9 582212 130 36 6 582212 63 6 30
580986 08 12 5 582212 132 36 5 582212 63 32 3
580986 16 12 10 582212 133 36 11 582212 64 32 2
580986 16 30 11 582212 136 34 9 582212 67 6 17
580986 17 12 2 582212 137 34 8 582212 67 6 29
580986 17 30 2 582212 137 36 9 582212 67 32 1
580986 19 30 12 582212 13 20 42 582212 70 50 6
580986 20 12 11 582212 13 36 4 582212 71 6 17.1
580986 20 30 13 582212 13 6 12 582212 71 32 4
580986 30 12 3 582212 146 20 46 582212 88 34 5
Book No. 9032061 02 Rev. 2 99

582212 88 44 9 589569 44 52 8 591628 80 88 8

582212 88 50 3 589569 45 52 10 591628 82 88 8
582212 88 62 3 589569 48 42 9 591631 01 88 7
582212 89 34 6 589569 48 62 7 591662 80 88 1
582212 89 44 10 589569 58 50 11 591666 01 88 14
582212 89 50 7 589569 58 52 6 591667 01 88 2
582212 89 62 5 589569 59 52 9 591675 01 78 42
582212 90 16 5 589569 77 62 6 591874 04 26 29
582212 90 7 86 589569 79 42 7 591874 06 26 30
582212 91 6 23 589569 79 62 9 591889 01 24 46
582212 91 7 84 589569 79 66 1.1 592005 14 40 8
582212 95 40 12 589569 80 62 10 592005 15 24 13
582212 96 40 13 590037 01 56 1 592122 03 40 4
582221 101 7 67 590313 01 78 8 592122 03 6 4
582221 90 20 31 590414 01 78 2 592304 01 46 28
582221 90 6 35 590414 02 80 Z 592304 02 46 29
582221 90 44 11 590476 01 78 9 592304 02 72 15
583012 01 56 6 590539 03 80 65 592304 02 74 31
583556 04 24 21 590624 03 20 13 592665 01 78 44
583556 16 6 43 590640 55 62 4.1 592676 05 78 49
583556 17 6 42 591090 04 58 2 592676 07 78 50
583556 19 24 19 591103 03 20 58 592790 01 78 51
583556 20 24 18 591103 10 20 35.1 593239 01 10 25
583556 21 24 20 591103 10 7 76.3 593254 01 26 16
585976 01 56 4 591103 32 20 43 593254 01 10 20
586056 07 24 22 591103 37 6 59.1 593282 01 10 22
587276 01 10 44 591103 40 20 57 593300 04 46 94
587276 01 58 33 591103 41 21 59 593301 02 46 93
587276 02 21 66 591103 46 20 55 593724 01 44 26
587276 02 24 3 591103 54 7 77 593724 02 44 25
587276 02 40 34 591103 56 44 12 593724 03 20 32
587276 02 42 11 591103 60 7 78 593724 03 6 34
587276 02 10 6 591103 61 20 56 593778 01 10 10
587276 02 80 59 591103 62 21 Z 593779 01 10 11
587276 02 10 31 591103 64 20 37 593780 01 26 55
587927 07 68 19 591103 64 7 76.2 593780 01 10 15
587927 07 72 19 591103 67 6 52 593991 01 10 12
587927 07 74 19 591103 69 20 21 594009 02 24 41
589526 07 78 11 591103 69 50 14 594009 02 6 39
589569 32 62 11 591103 70 20 24 594009 03 20 33
589569 33 42 10 591103 70 50 13 594009 03 6 36
589569 33 62 12 591103 71 20 26 594009 03 44 24
589569 34 62 13 591103 72 40 20 594009 04 20 5
589569 34 92 5 591103 86 20 35 594009 05 24 55
589569 34 94 1.2 591103 86 7 76 594009 06 40 28
589569 35 42 8 591103 87 20 26.1 594009 07 21 70
589569 35 62 14 591103 88 20 26.2 594171 01 46 15
589569 35 66 1.2 591103 89 20 26.3 594410 01 54 6
589569 36 62 15 591103 91 20 44 594410 01 56 5
589569 44 50 12 591103 92 40 20.1 594410 01 64 1.1
100 Book No. 9032061 02 Rev. 2

594410 01 66 2.1 9002586 01 78 26 9003450 07 78 1

594413 80 46 20 9002589 01 78 29 9003450 08 78 1
594413 80 46 20.1 9002591 01 78 31 9003450 09 78 1
594413 80 46 20.2 9002592 01 78 34 9003450 10 78 1
594488 01 42 2 9002699 81 46 1 9003490 01 44 29
594488 01 10 27 9002825 01 84 1 9003514 01 78 18
594645 82 46 Z0.1 9002825 80 78 4 9003522 06 6 44
594645 82 48 Z0.1 9002860 01 48 10 9003522 07 6 45
594707 02 46 25 9002915 01 78 6 9003565 02 24 15
594728 01 20 8 9002942 01 24 57 9003565 03 24 14
594781 01 44 15 9002947 01 24 56 9003570 01 78 27
595215 01 54 7 9002962 01 78 20 9003574 01 78 45
595272 01 46 37 9002963 01 78 21 9003574 01 84 Z
595361 02 6 63 9003013 01 10 13 9003662 01 48 28
595673 02 16 6 9003024 01 26 54A 9003672 01 48 31
595673 03 38 14 9003024 02 10 14 9003730 01 78 5
595673 03 7 82 9003030 01 24 50 9003732 01 78 7
595673 04 16 4 9003031 01 26 64 9003792 01 78 30
595673 04 40 23 9003031 01 50 10 9003837 01 78 32
595673 04 40 33 9003031 01 52 5 9003851 01 78 35
595728 02 40 32 9003075 01 26 15 9003853 01 78 36
595728 02 7 80 9003089 02 26 67 9003854 01 78 37
597033 10 30 6 9003113 01 26 57 9003863 01 78 38
597033 18 12 1.1 9003114 02 21 Z0.1 9003886 01 78 39
597033 22 12 1 9003114 02 26 56 9003888 01 78 40
597044 03 46 70 9003172 01 86 1 9003935 01 78 23
597044 04 46 71 9003172 02 86 2 9003949 01 78 28
597049 01 46 24 9003172 03 86 3 9004211 01 20 2
597330 01 21 Z0.2 9003172 04 86 4 9004212 01 24 37
597331 01 21 Z0.3 9003172 05 86 5 9004213 01 24 38
598323 02 28 1 9003172 06 86 6 9004214 01 20 9
598571 01 10 36 9003172 07 86 7 9004237 01 78 22
598571 02 46 63 9003172 08 86 8 9004247 01 78 33
599223 02 78 48 9003172 09 86 9 9004254 01 20 18
599223 03 78 47 9003172 10 86 10 9004299 04 6 16
66169 48 3 9003172 11 86 11 9004299 04 20 39
67141 48 27 9003172 12 86 13 9004303 02 20 14
7007238 01 58 23 9003172 80 78 15 9004313 82 20 53
70490 88 6 9003186 01 26 23 9004426 01 20 20
70560 10 32 9003186 02 26 65 9004439 01 38 15
70560 21 67 9003326 01 48 6 9004442 03 20 27
70560 24 66 9003390 01 24 42 9004479 80 78 16
70560 40 35 9003401 01 26 20 9004517 01 78 19
70560 42 12 9003410 01 26 17 9004533 01 82 1
70560 80 61 9003450 01 78 1 9004533 80 78 3
9001357 03 46 7 9003450 02 78 1 9004587 80 82 Z
9001406 83 90 4 9003450 03 78 1 9004588 80 82 Z0.1
9002009 81 48 8 9003450 04 78 1 9004638 01 46 31
9002362 80 6 33 9003450 05 78 1 9004878 80 48 9
9002362 80 44 19 9003450 06 78 1 9004889 01 48 33A
Book No. 9032061 02 Rev. 2 101

9004959 01 52 7 9007190 01 74 10 9011936 80 21 64

9005046 01 78 10 9007192 01 54 5 9011943 80 40 38
9005147 01 80 62 9007192 01 64 1D 9011944 01 42 1
9005494 04 20 54 9007192 01 66 2D 9011951 80 24 1
9005743 01 78 46 9007192 01 68 5 9011952 80 20 1
9005789 03 72 12 9007192 01 70 5 9011960 01 40 24
9005792 02 72 18 9007192 01 72 5 9011963 85 60 Z
9006075 01 90 3 9007193 01 68 6 9011970 05 60 6
9006316 01 24 43 9007193 01 70 6 9011970 17 60 41
9006322 01 24 61 9007193 01 72 6 9011970 25 60 42
9006324 02 46 13 9007196 01 70 7 9011970 33 60 36
9006325 02 46 12 9007196 02 68 7 9011972 05 60 7
9006677 01 20 50 9007196 02 70 7 9011972 05 60 ZA
9006814 01 6 41 9007196 02 72 7 9011972 10 60 13
9006822 01 46 23 9007196 02 74 7 9011972 10 60 ZC
9006822 02 90 6 9007197 01 68 Z 9011972 15 60 16
9006822 03 58 14 9007197 01 70 Z 9011972 20 60 17
9006851 01 6 2 9007197 01 72 Z 9011972 20 60 ZD
9006852 01 6 3 9007200 01 74 27 9011972 25 60 20
9006853 01 6 61 9007201 01 74 28 9011972 25 60 ZE
9006854 01 6 62 9007231 01 90 1 9011972 30 60 32
9007166 01 64 1B 9008383 01 38 1 9011972 30 60 ZF
9007166 01 66 2B 9008383 02 38 2 9011973 05 60 7.1
9007166 01 70 2 9008383 06 16 1 9011973 05 60 ZB
9007166 06 54 2 9008383 06 38 6 9011973 10 60 11
9007166 06 68 2 9008383 08 16 2 9011973 15 60 18
9007166 06 70 2 9008383 08 38 9 9011973 35 60 77
9007166 06 72 2 9008383 12 38 7 9011974 25 60 33
9007166 06 74 2 9008383 13 38 8 9011974 37 60 14
9007167 01 70 1 9008383 15 16 8 9011974 51 60 9
9007167 01 88 8A 9008387 01 16 3 9011975 05 60 15
9007167 02 66 2A 9008387 01 38 11 9011978 05 60 80
9007167 03 64 1A 9008403 80 20 17 9012046 80 18 1
9007167 09 74 1 9008424 01 26 66 9012058 80 20 4
9007167 10 54 1 9008693 01 38 12 9012086 83 6 1
9007167 10 68 1 9008903 05 26 3 9012091 81 10 2
9007167 10 70 1 9009416 01 48 38 9012093 01 10 41
9007167 10 72 1 9009521 80 46 Z 9012135 80 20 40
9007184 01 70 Z 9009521 80 48 Z 9012146 01 18 2
9007184 02 64 1E 9009760 01 40 22 9012150 81 7 66
9007184 04 74 Z 9009912 01 54 8 9012193 01 24 2
9007185 01 54 3 9010631 99 46 16A 9012198 80 21 65
9007185 01 64 1C 9010633 01 48 43 9012246 80 58 24
9007185 01 66 2C 9010981 01 50 1 9012247 01 62 1
9007185 01 68 3 9010983 01 52 1 9014527 81 80 Z0.1
9007185 01 70 3 9010984 81 46 2 9014546 01 20 47
9007185 01 72 3 9010987 80 46 3 9014554 01 24 54
9007186 01 68 8 9011226 99 46 35A 9014585 01 24 53
9007186 01 70 8 9011552 01 40 18 9014640 01 26 5
9007186 01 72 8 9011552 01 6 54 9014642 01 26 6
102 Book No. 9032061 02 Rev. 2

Part No. Page Ref. Part No. Page Ref.
9014704 80 20 48 9019186 05 6 24
9014707 01 6 15 9019186 06 6 26
9014707 01 20 38 9019186 07 6 50
9014732 01 26 52 9019487 02 58 16
9014735 01 26 53 9019604 01 92 1
9014736 01 80 67 9019609 02 94 1
9014747 01 78 24 9019944 01 94 Z
9014748 01 78 25 9019944 02 92 Z
9014753 01 10 34 9023647 83 58 19
9014759 01 26 34 9023658 60 58 1
9014762 01 26 49 9024155 01 58 22
9014815 01 10 35 9024168 01 58 6
9014833 01 21 60 9024205 08 60 4
9014966 69 46 8 9024205 16 60 10
9014966 69 46 8.1 9024205 24 60 12
9014979 01 40 1 9024205 32 60 31
9015117 01 10 40 9024205 40 60 34
9015118 01 10 39 9024206 08 60 8
9015123 01 10 42 9024206 16 60 19
9015197 82 21 86 9024206 24 60 87
9015525 03 54 27 9024207 08 60 30
9015557 80 40 37 9024208 08 60 40
9015611 01 24 6 9024209 08 60 43
9015616 01 24 65 9024210 08 60 44
9015692 01 38 16 9024593 07 76 1
9015704 01 38 3 9025145 01 76 Z
9015704 02 38 4 9025145 02 76 Z0.1
9015704 03 38 5 9025165 02 58 34
9015704 04 38 17 9025753 01 66 12
9016266 01 26 50 9025837 01 6 59
9016266 02 26 54 9025837 02 6 59.2
9016268 01 26 51 9025840 80 6 21
9016270 01 26 50.1 9025887 01 10 5
9016593 01 40 3.1 9026072 01 58 29
9017973 01 58 9 9026074 01 58 26
9018092 01 96 1 9029781 01 74 10.2
9018092 02 96 2 9030002 80 76 Z0.2
9018092 03 96 3 9034058 80 74 9
9018092 99 96 Z 9037347 01 88 8B
9018543 63 66 2
9018543 64 64 1
9018653 05 66 1
9019135 03 6 13
9019135 03 6 14
9019135 04 6 19
9019135 04 6 20
9019138 01 6 13.1
9019138 01 6 14.1
9019138 02 6 20.1
9019138 03 6 19.1
Book No. 9032061 02 Rev. 2 103

Manual Delivery Flash PB-03035 v00 PB1000 OP - Alfa Laval BWTS

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Manual Delivery Flash PB-03035 v00 PB1000 OP - Alfa Laval BWTS

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PureBallast Ballast Water Treatment System

PureBallast Ballast Water Treatment System

1.1 Manual compilation

PureBallst system Manual no. Connection list Flowchart

Book No.9028378 02, rev. 1 1

1.2 Main component makers

2 Book No.9028378 02, rev 1

Book No.9028378 02, rev 1 3

The original instructions are in English

© Alfa Laval Corporate AB 2019-06

3 Operating instructions and control system description................. 41

5 Alarms and faultfinding..................................................................................... 179

6 Technical data and drawings........................................................................ 225

7 Service manual .....................................................................................................365

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

Valve safety items

Ancillary component safety items

1.2.3 Personnel requirements

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

When to use the different modes

2.2.2 Flow control and power optimization

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)

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

The procedures concerning emergency and malfunction of the ballast water

2.3 System components description

2.3.1.1 UV reactor working principle

2.3.1.2 UV reactor description

Level 1: The temperature transmitter sends information to the control system.

2.3.2.2 Filter description

The water enters from the inlet flange (A)

2.3.2.3 Backflushing for different dirt loads

2.3.2.3.1 Low dirt load

2.3.2.3.2 Medium dirt load

2.3.2.3.3 Heavy dirt load

In the example below, a series of backflushes are performed (approx. every 4

2.3.2.3.4 Long term dirt build-up

2.3.3 CIP (cleaning-in-place) module

2.3.3.2 CIP module description

2.3.4 Cabinets and control system

2.3.4.2 Control system