General User Manual V2 6 5-20200117

File No.
: HMT/QW-824-200
Version: 2.6.5
Date: Jan., 2020
OceanGuard® Ballast Water Management System
User Manual
(HMT-50~4000)
Headway Technology Group (Qingdao) Co., Ltd.

Revision History
Rev. No. Reason Issued by Audit/Approval Date
1.0 First Issue LBY, DQH, NSL CXL
2.5 DNVGL Comment Incorporated LBY, DQH, NSL CXL
2.6 DNVGL Comment Incorporated LBY, DQH, NSL CXL 08/29/2017
2.6.2 DNVGL Comment Incorporated LBY, DQH, NSL CXL 01/08/2018
2.6.3 USCG Comment Incorporated LBY, DQH, NSL CXL 07/12/2018
2.6.4 USCG Comment Incorporated LBY, DQH, NSL CXL 10/13/2018

Company Name and Holding
2.6.5 LBY, DQH, NSL CXL 01/17/2020
time Changed
User Manual for OceanGuard○
R BWMS
CONTENT
1. Preface............................................................................................................................................... 1-1
1.1. Objectives............................................................................................................................... 1-1
1.2. Safety ..................................................................................................................................... 1-2
1.2.1. Safety Instructions ....................................................................................................... 1-2
1.2.2. Symbols and Explanatory Notes ................................................................................. 1-3
1.3. Warranty ................................................................................................................................. 1-4
1.4. Abbreviations ......................................................................................................................... 1-4
2. Introduction to System ...................................................................................................................... 2-1
2.1. Background ............................................................................................................................ 2-1
2.2. Application Scope of the System ........................................................................................... 2-2
2.3. Introduction to System Principles .......................................................................................... 2-3
2.4. Chemical Used or produced ................................................................................................... 2-3
3. System Components .......................................................................................................................... 3-1
3.1. System general information ................................................................................................... 3-1
3.1.1. Componts and Specification........................................................................................ 3-1
3.1.2. System Control Sequence............................................................................................ 3-5
3.2. Filter ....................................................................................................................................... 3-7
3.2.1. HMT-F Series .............................................................................................................. 3-7
3.2.2. S-ZF Series ................................................................................................................ 3-17
3.3. EUT Unit .............................................................................................................................. 3-24
3.3.1. Appearance ................................................................................................................ 3-24
3.3.2. Function and Principle .............................................................................................. 3-24
3.3.3. Main Parameters........................................................................................................ 3-25
3.3.4. Main Components ..................................................................................................... 3-26
3.4. EUT Power ........................................................................................................................... 3-27
3.4.1. Appearance and Structure.......................................................................................... 3-27
3.4.2. Function .................................................................................................................... 3-28
I
R BWMS
3.4.3. Main Parameters........................................................................................................ 3-29
3.4.4. Main Components ..................................................................................................... 3-30
3.4.5. Adjustment and Control ............................................................................................ 3-30
3.5. Control Unit ......................................................................................................................... 3-36
3.5.1. Appearance and Structure.......................................................................................... 3-36
3.5.2. Function .................................................................................................................... 3-38
3.5.3. Main Parameters........................................................................................................ 3-38
3.6. Monitoring Unit ................................................................................................................... 3-49
3.6.1. Components............................................................................................................... 3-49
3.6.2. Function .................................................................................................................... 3-50
3.6.3. Main Parameters........................................................................................................ 3-52
3.6.4. Operation ................................................................................................................... 3-53
3.7. Flow Meter ........................................................................................................................... 3-60
3.7.1. Appearance ................................................................................................................ 3-60
3.7.2. Function .................................................................................................................... 3-60
3.7.3. Parameters ................................................................................................................. 3-61
3.7.4. Operation ................................................................................................................... 3-62
3.8. Remote Control Panel .......................................................................................................... 3-68
3.8.1. Appearance ................................................................................................................ 3-68
3.8.2. Function .................................................................................................................... 3-68
3.8.3. Main Parameter ......................................................................................................... 3-69
3.9. Power Distribution Unit ....................................................................................................... 3-70
3.9.1. Appearance ................................................................................................................ 3-70
3.9.2. Function .................................................................................................................... 3-72
3.9.3. Parameters ................................................................................................................. 3-72
3.10. Neutralization Unit ............................................................................................................. 3-73
II
R BWMS
3.10.1. Appearance .............................................................................................................. 3-73
3.10.2. Function and Principle ............................................................................................ 3-74
3.10.3. Main Parts ............................................................................................................... 3-76
3.10.4. Main Parameters...................................................................................................... 3-77
3.10.5. Adjustment and Control .......................................................................................... 3-78
4. Packing, Transportation and Storage................................................................................................. 4-1
4.1. Packing ................................................................................................................................... 4-1
4.1.1. Packing Marks............................................................................................................. 4-1
4.1.2. Packing Method .......................................................................................................... 4-1
4.1.3. Notice for Packing....................................................................................................... 4-2
4.2. Mode of Transportation .......................................................................................................... 4-2
4.3. Storage ................................................................................................................................... 4-2
5. Installation......................................................................................................................................... 5-1
5.1. Unpacking .............................................................................................................................. 5-1
5.2. Installation .............................................................................................................................. 5-2
5.2.1. Installation Requirements ............................................................................................ 5-2
5.2.2. Principles for Installation and Positioning .................................................................. 5-4
5.2.3. Installation Steps ......................................................................................................... 5-9
5.2.4. Notes for Installation ................................................................................................. 5-12
5.3. Acceptance Check ................................................................................................................ 5-35
5.4. Notes for Prolonged Outage ................................................................................................. 5-35
6. Trial Run ........................................................................................................................................... 6-1
6.1. Preparation ............................................................................................................................. 6-1
6.2. Starting Up ............................................................................................................................. 6-1
6.3. Function Test .......................................................................................................................... 6-1
6.4. Settings ................................................................................................................................... 6-1
6.5. Shut Down.............................................................................................................................. 6-2
7. Operation........................................................................................................................................... 7-1
7.1. Preparation ............................................................................................................................. 7-1
III
R BWMS
7.1.1. Check .......................................................................................................................... 7-1
7.1.2. Preparation of Neutralizer ........................................................................................... 7-1
7.2. Routine Operation .................................................................................................................. 7-3
7.2.1. Ballast.......................................................................................................................... 7-4
7.2.2. De-ballast .................................................................................................................... 7-6
7.2.3. Bypass ......................................................................................................................... 7-7
7.2.4. Emergency Switch....................................................................................................... 7-9
7.3. Brine / Sea Water Injection .................................................................................................. 7-10
8. System Maintenance and Routine Check .......................................................................................... 8-1
8.1. Maintenance Mode ................................................................................................................. 8-1
8.2. Maintenance ........................................................................................................................... 8-2
8.2.1. Filter (HMT-F Series) .................................................................................................. 8-2
8.2.2. Filter (S-ZF Series) ..................................................................................................... 8-6
8.2.3. EUT Unit ................................................................................................................... 8-13
8.2.4. EUT Power ................................................................................................................ 8-14
8.2.5. Control Unit and Remote Control Panel ................................................................... 8-15
8.2.6. Monitoring Unit ........................................................................................................ 8-16
8.2.7. Flow Meter ................................................................................................................ 8-20
8.2.8. Power Distribution Unit (PDU)................................................................................. 8-20
8.2.9. Neutralization Unit .................................................................................................... 8-20
8.2.10. Pipes ........................................................................................................................ 8-21
8.3. Routine Check ...................................................................................................................... 8-22
8.3.1. Check before Operation ............................................................................................ 8-22
8.3.2. Check during Operation ............................................................................................ 8-23
8.4. Spare List ............................................................................................................................. 8-24
9. Troubleshooting ................................................................................................................................ 9-1
9.1. Notes ...................................................................................................................................... 9-1
9.2. System Faults ......................................................................................................................... 9-2
9.3. Faults of Filter ........................................................................................................................ 9-8
IV
R BWMS
9.3.1. HMT-F Series .............................................................................................................. 9-8
9.3.2. S-ZF Series .................................................................................................................. 9-9
9.4. Faults of EUT Unit ............................................................................................................... 9-11
9.4.1. Fault Description and Solutions ................................................................................ 9-11
9.4.2. Steps for Changing Parts ........................................................................................... 9-11
9.5. Faults of EUT Power............................................................................................................ 9-13
9.6. Faults of Control Unit .......................................................................................................... 9-14
9.7. Faults of Monitoring Unit .................................................................................................... 9-15
9.7.1. TRO Meter ................................................................................................................ 9-15
9.7.2. Salinity Meter ............................................................................................................ 9-15
9.8. Faults of Power Distribution Unit ........................................................................................ 9-16
9.9. Faults of Flow Meter ............................................................................................................ 9-16
9.10. Faults of Neutralization Unit .............................................................................................. 9-17
9.11. Other faults ......................................................................................................................... 9-17
10. Miscellaneous................................................................................................................................ 10-1
10.1. Calibration.......................................................................................................................... 10-1
10.1.1. TRO Meter Calibration ........................................................................................... 10-1
10.1.2. Salinity Meter Calibration ....................................................................................... 10-4
10.1.3. Temperature Sensor ................................................................................................. 10-6
10.1.4. Flow Meters ............................................................................................................ 10-6
10.2. Disposal of Wastes ............................................................................................................. 10-8
10.2.1. Back-flushing of Filter ............................................................................................ 10-8
10.3. Personal Requirements ....................................................................................................... 10-9
11. Annex ............................................................................................................................ 11-1
V
Chapter 1 Preface
User Manual for OceanGuard○R BWMS
1. Preface
1.1. Objectives
This Manual gives detailed descriptions and introduction to OceanGuard○

R BWMS (Ballast Water
Management System), covering the packaging, delivering, storing, installing, operating, maintaining
and troubleshooting etc. of the system. In addition, information for safe operation and tips for
personnel protection are also covered.
Installation, maintenance and operation personnel of OceanGuard ○

R Ballast Water Management
System shall carefully read and fully understand this manual. For any questions, please contact the
manufacturer in time.
This Manual shall be kept by installation, maintenance and operation personnel in an accessible place.
This Manual follows the following standards:
 International Convention for the Control and Management of Ships’ Ballast Water and
Sediments
 MEPC 300(72)---- Code for Approval of Ballast Water Management System
 MEPC 169(57)---- Procedure for Approval of Ballast Water Management System that Make
Use of Active Substances (G9)
 MEPC 173(58)---- Guideline for Ballast Water Sampling (G2)
 DNV GL Class Programme DNVGL-CP-0209-Type Approval – Ballast Water Managemtent
Systems
 USCG Final Rule Subpart 162.060-Ballast Water Management System-2013
 General Protocol for the Verification of Ballast Water Treatment Technology-ETV 2010
1-1
Chapter 1 Preface
1.2. Safety
1.2.1. Safety Instructions
 All parts provided by the manufacturer are exclusively for OceanGuard○

R
Ballast Water
Management System. Every part can be used only under the required conditions and
environment, being an integral part of the ballast water management system. Please don’t use
the parts for other purposes. This may lead to physical injury of the user.
 The installation and maintenance of OceanGuard○

R
Ballast Water Management System shall
be carried on by technicians authorized by the manufacturer. Otherwise, injuries may happen
to related personnel because of the unfamiliarity with the system.
 The parameters of OceanGuard○

R Ballast Water Management System shall be set in the
factory. User’s modification is not allowed.In case any modification is needed, it shall be
down with the manufacturer’s permission and in the correct way.Parameters set by the user
could cause system failure, or change the safe operation environment of the system; and thus
cause injuries to the personnel.
 The structure of any equipment in the system is not allowed to be changed without the
manufacturer’s permission. Any part that does not run properly shall be replaced
immediately with parts from Headway. For parts from other manufacturers, we cannot
guarantee that they are designed and manufactured according to the design requirements and
the safety standards of the system. This may cause death or injuries of the personnel.
 To prevent safety accidents from happening, this manual uses safety symbols to provide
safety tips. Please read the related sections carefully. Failing to follow the tips and
instructions of this manual may cause equipment malfunctions or personnel injuries.
 Symbolic safety tips are put on OceanGuard○

R Ballast Water Management System. Please
do not tear off or scrawl over them. Please follow the instructions strictly and operate safely.
 Clients have the right to specify the material and detailed specifications of some devices of
OceanGuard○
R Ballast Water Management System. Please make sure your requirements
meet the ship conditions and can ensure the personnel safety.
1-2
Chapter 1 Preface
User Manual for OceanGuard○R
BWMS
1.2.2. Symbols and Explanatory Notes
1.2.2.1. Explanatory Notes in this Manual
Danger
This symbol is a safety note. Ignorance of it may cause severe damage to human
body.
Caution
This symbol is a safety note. Ignorance of it may cause general damage to

human body.
Note
This symbol is a reminding note. Ignorance of it may cause damage to

equipment.
Reading
This symbol is a reading note. Please follow the symbol to look for related
chapters or sections.
Information
This symbol is an information note. Please follow the instructions of this

symbol.
1.2.2.2. Safety notes on BWMS
Electric Shock Warning – Ignorance of this note may cause electrical shock hazard.
1-3
Chapter 1 Preface
1.3. Warranty
Within 12 months after a client signs for acceptance of OceanGuard○

R Ballast Water Management
System, under the condition of normal operation and use, if any part does not work properly, the
manufacturer will replace or repair the part for free.
Within the warranty period, the manufacturer will charge if any of the following occurs:
 Within the warranty period, any system failure or part damage caused by an improper
operation or usage.
 Within the warranty period, damages are caused by parts from other manufacturers.
 Within the warranty period, any system failure or part damage caused by a modification of
the equipment structure.
 Within the warranty period, any system failure or part damage caused by the material or
specifications specified by the client.
1.4. Abbreviations
AEOP: Advanced Electrocatalysis Oxidation Process
BWMS: Ballast Water Management System
EUT: Electrocatalysis Ultra Treatment
FCB: Filter Control Box
IMO: International Maritime Organization
PDU: Power Distribution Unit
PLC: Programmable Logic Controller
TRO: Total Residual Oxidant
USCG: United State Coast Guard
1-4
Chapter 2 Introduction to System
User Manual for OceanGuard○ R BWMS
2. Introduction to System
2.1. Background
The invasive spread of foreign invasive organism is one of the four threats that oceans are facing.
Ships' ballast water is the main route that causes the spread of foreign invasive
organism.OceanGuard○
R
Ballast Water Management System is used to kill the organism in ships'
ballast water, so as to protect the ocean environment, to maintain the diversity of marine organism, and
to prevent marine biological pollution. The ballast water processed by the system can meet the
requirements of the International Convention for the Control and Management of Ships’ Ballast Water
and Sediments issued by the International Maritime Organization (IMO) in 2004.
It is pointed out by IMO that treatment of invasive harmful organism in ships’ ballast water is a
focused concern of the world. The basic requirements are: it shall be treated onboard, with acceptable
costs, small devices, easy operation; it shall not cause new pollution to nearshore waters; and the
treatment equipment shall be safe and reliable to operate.
OceanGuard○
R
Ballast Water Management System has the following features:
 It can kill microorganism in ballast water with fewer active substances;
 Active substances themselves can break down into unharmful substances. At the same time,
active substances can break down dead microorganism and toxins so as to purify the ballast
water;
 Microorganism can be killed quickly.
 No negative influence or new pollution will be created for the marine environment;
 It runs at low costs;
 The equipment is simple and easy to be operated;
 The equipment and the operation are safe and reliable;
 The operation of the system will not cause further corrosion to the ship body.
This system is the technical achievement of Headway Technology Group (Qingdao) Co. Ltd. through
years of development. The system adopts the Electrocatalysis Ultra Treatment technology and can
carry out online treatment to ballast water. The method is an advanced oxidation technology, which
2-1
uses electrocatalysis technology. It can effectively kill the organism in ships’ ballast water in an online
manner.
The whole system is completely closed. It is impossible to cause affects, such as chemical hazard or
noise etc., on the people working around. The system produces active substances online so that there is
no need to add or store harmful chemicals. It is economical and won’t cause threats to crew. Therefore,
the system is safe, reliable, economical and practical. This system produces fewer active substances,
which would reduce quickly. Moreover, the system runs with less energy. This meets the requirement
of “energy saving and environmental protection”.
2.2. Application Scope of the System
The OceanGuard○
R
Ballast Water Management System uses Electro-catalysis, which can kill not only
organism in sea water but also organism in fresh water. The system can be used to treat ballast water of
all conditions. Therefore, this system is applicable for ships sailing in all waters.
The OceanGuard○
R
Ballast Water Management System uses modular design, with small sizes and light
weight. It can be installed on small ships. At the same time, the units can be easily installed. Therefore,
this system can be used on all ships, big or small, new or old.
The OceanGuard ○
R
Ballast Water Management System has an explosion-proof model, which is
designed by Headway. The model has passed the strict explosion-proof certification. Therefore, it can
be installed on ships with explosive environment, such as oil tankers, liquefied gas ships, and chemical
tankers etc. Explosion-proof model of OceanGuard BWMS can be installed on all flag vessels, except
USA.
OceanGuard BWMS will treat ballast water to the D-2 standard if operated within the ranges identified
in the type approval certificate, as follows:
Flow rate: Ballast water flow rate kept between 65 m3/h and 5200 m3/h. TRC of Ballast Pump should
be below the TRC of the BWMS.
Temperature: Ballast water temperature kept above 0 °C.
Salinity: Ballast water salinity is higher than 0.85-0.95 PSU. The brine/sea water injection system
should be used if the salinity is lower than 0.85PSU.
2-2
TRO level after the EUT unit is kept around 2 mg/L. The ballast water must be kept in the ballast tanks
for a period of at least 2 hours. The Maximum TRO can fluctuate between 1.5 and 2.5 when the target
is set to 2. And the Maximum Allowable Discharge Concentration is 0.1 mg/L.
In order to comply with environmental requirements on discharged ballast water, the OceanGuard
BWMS is designed to automatically neutralize ballast water during discharge to be below 0.1 mg/L of
TRO.
2.3. Introduction to System Principles
The OceanGuard○
R Ballast Water Management System uses the dual mechanisms of filtering and
electro-catalysis to filter and kill the organism in water. EUT Unit is the key part of the system. By
producing hydroxyl radicals of high concentration, this unit kills the planktonic creatures, bacteria and
viruses in ballast water.The technology is also called Advanced Electro-Catalysis Oxidation Processes
(AEOP), which is environment-friendly, non-toxic and harmless.
Hydroxyl radicals have strong oxidizing. Their oxidation capacity is next to that of fluorine.Hydroxyl
radicals can survive for a very short period of time. They react instantly with microorganism and other
organism to kill microorganism and remove other organism. Because of their short surviving time, they
won’t cause direct corrosion to pipes and other onboard parts.
2.4. Chemical Used or produced
Plenty of hydroxyl radicals will be produced during operation of the system. Due to the strong activity
of hydroxyl radicals, it will react with chloride ions in the water and produce a small quantity of
disinfection products. Since concentration of these substance is very low, based on the Assessment to
environment and human exposure, there is no potential impact on environment or human exposure.
Table 2.4-1 Chemicals Generated or Stored
Active Substance （TRO） Stored Chemical Substance
Hydroxyl radicals Sodium thiosulfate
Sodium hypochlorite
Hypochloric acid
2-3
Chapter 3 System Components
R BWMS
3. System Components
3.1. System general information
3.1.1. Componts and Specification
OceanGuard○
R
Ballast Water Management System consists of components such as the Filter, EUT
Unit, EUT Power, Control Unit, Monitoring Unit, Flow Meter, Power Distribution Unit, Neutralization
Unit and pipes etc. (see Figure 3.1—1 Components of OceanGuard BWMS( in bulk) ).
○
1 ○
2 ○
3 ○
4 ○
9
○
5 ○
6 ○
7 ○
8 ○
10
Figure 3.1—1 Components of OceanGuard BWMS( in bulk)
○1 — Control Unit
○2 — Power Distribution Unit (PDU)
○3 — Filter Control Box
○4 — Monitoring Unit
○5 — Ballast Pump
○6 — Filter (for example HMT-F )
○7 — EUT Power
○8 — EUT
○9 — Flow meter
○
10 — Neutralization Unit
3-1
R BWMS
Table 3.1-1 General Information of all models
Model Flow Range (m3/h) Footprint (m2)* Weight (kg) Power Demand (kw)**
HMT-50 10 - 65 6.6 1380 12
HMT-100 10 - 130 6.9 1380 13
HMT-200 20 - 260 6.9 1420 14
HMT-300 30 - 390 7.6 1700 17
HMT-450 30 - 585 8.0 1950 19
HMT-600 50 - 780 8.3 2160 28
HMT-800 50 - 1040 9.4 2990 31
HMT-1000 50 - 1300 11.0 3500 35
HMT-1200 50 - 1560 11.1 3580 42
HMT-1500 50 - 1950 11.9 3750 52
HMT-2000 100 - 2600 12.6 5735 62
HMT-2500 100 - 3250 13.7 6160 70
HMT-3000 100 - 3900 14.6 6620 86
HMT-4000 100 - 5200 15.2 7500 108
*Footprint is the total amount of all the componts takes;
**The Power Demand listed above is the total power consumption in common marine water, including
the self-celeaning of filter, sterilization of EUT unit, Control Unit and other components.
Each model is a most suitable combination of some type components. It is advised to configure the
BWMS according to the table 3.1-2.
3-2
R
BWMS
Table 3.1-2 Combination List of OceanGuard BWMS
Power Distribution Neutralization

TRC EUT Unit Filter Control Unit EUT Power Monitoring Unit Flow Meter
Model Unit Unit
m3/h Type Qty. Type Qty. Type Qty. Type Qty. Type Qty. Type Qty. Type Qty. Type Qty.
HMT-100F
HMT-50 65 HMT-50E 1 1 HMT-50PE 1 HMT-50PDU 1 HMT-100FM 1 HMT-60N 1
S-ZF1
HMT-100F
S-ZF1
HMT-200F
S-ZF2
HMT-300F
S-ZF3
HMT-500F
S-ZF4 HMT-CL 1 HMT-MU 1
HMT-600F
S-ZF5
HMT-800F
S-ZF6
HMT-1000F
S-ZF7
HMT-1500F
HMT-1200 1560 HMT-1200E 1 1 HMT-1200PE 1 HMT-1200PDU `1 HMT-400FM 1 HMT-300N 1
S-ZF8
HMT-1500 1950 HMT-1500E 1 HMT-1500F 1 HMT-1500PE 1 HMT-1500PDU 1 HMT-450FM 1 HMT-300N 1
3-3
R
BWMS
S-ZF9
Power Distribution Neutralization

TRC EUT Unit Filter Control Unit EUT Power Monitoring Unit Flow Meter
Model Unit Unit
m3/h Type Qty. Type Qty. Type Qty. Type Qty. Type Qty. Type Qty. Type Qty. Type Qty.
HMT-2000F
S-ZF10
HMT-3000F
HMT-2500 3250 HMT-2500E 1 1 HMT-2500PE 1 HMT-2500PDU 1 HMT-600M 1 HMT-600N 1
S-ZF11
HMT-CL 1 HMT-MU 1
HMT-3000F
S-ZF12
HMT-4000F
S-ZF13
3-4
R BWMS
3.1.2. System Control Sequence
Stand by
No No No
B_ON D_ON E_ON
Yes
Yes Yes
Open valves on deballast pipe.

Open valves on ballast pipe.
Power on Neutralization pump and
Power on Filter, Monitoring Unit and
Monitoring Unit
EUT Power Unit
Open valves on
bypass pipe
Adjust current output to EUT Neutralization to be controled based No

according to flow rate and TRO E_OFF
on the TRO reading before
Neutralizaer injection point .
TRO of discharged water will be real Yes
time monitored
Close valves on
bypass pipe
Note:
No E-ON ： Bypass On
B_OFF
E-OFF： Bypass Off
Yes
Close valves on ballast pipe.

Power off Filter,Monitoring Unit and
EUT Power Unit
No
D_OFF
Yes
Figure3.1-2 Flow Chart of System Control Sequence
OceanGuard® BWMS can achieve “Ballast”, “DeBallast” and “Emergency” operation. When powered
up, the system can initiate any of the operation above by push the button on Control Unit or Remote
Control Panel, the whole process will be automatically controlled without manual operation. All
parameter and status can be find on the screen of Control Unit.
The concentration of TRO during Ballast should remain in the range of 1.5-2.5 mg/L in order to
provide an effective treatment. Control Unit will adjust the output from EUT Power Unit based on the
reading of TRO to keep a steady concentration. The concentration of TRO during DeBallast should not
exceed 0.1 mg/L, the Control Unit will start Neutralization Unit once DeBallast operation was started
3-5
R BWMS
by the operator. The Neutralization Unit will keep working until a reading shows that the TRO
concentration is below 0.1 mg/L.
Emergency operation is only used under the special circumstance that endangered the safety of ship
and/or personnel. In emergency operation, system will open the bypass valve and ballast water will be
directly pumped into ballast tank or overboard without passing the whole system. Please be noted that
Emergency operation will only be allowed under emergency situation and with the authentication of
officer.
For details of operation above, please refer to chapter 3.5 and chapter 7.
3-6
R BWMS
3.2. Filter
3.2.1. HMT-F Series
3.2.1.1. Structure
1
8
9
6
5
（a）（b）
Figure 3.2—1 Appearance
○
1 － Gear motor
○
2 － Top Cover
○
3 － Upper Shell
○
4 － Lower Shell
○
5 － Backflushing Pipe
○
6 － Backflushing Valve
○
7 － Differential Pressure Gauge
○
8 － Vent
○
9 － Draining
3-7
R BWMS
Figure 3.2—2 Inside Structure (Sectional View along D-D in Figure 3.2-1 (b))
○
1 － Coupling
○
2 － Top Flushing Arm
○
3 － Filter Element
○
4 － Connecting Pipe
○
5 － Bottom Flushing Arm
3.2.1.2. Function and Principle
 Function
The Filter mainly handles the impurity particles in the liquid with
low viscosity. The full automatic backflushingFilter from Headway
is a mechatronics product, with features such as compact structure,
high filtering efficiency, and low consumption of water for
backflushing, low operating costs, and continuous filtration during
backflushing etc. Tangent structure is adopted at the filter inlet. It
Figure 3.2-3 Appearance
3-8
R BWMS
can effectively buffer the impact of water at the inlet and reduce the resistance loss of the whole
system at the Filter. The filter element uses special structure, which can speed up the backflushing,
keep the speed equal and remove the dead areas of backflushing, so that the efficiency of filtration and
backflushing in the equipment can be improved.Thiskind of filter is widely used in the areas such as
shipping, metallurgy, chemical, energy, paper making, machine processing, public works and
environmental protection etc., with special advantages in the filtration of ships’ ballast water.
The filter element inside the Filter is a double-way device. Its customized structure optimizes the
backflushing effect of the filter element. Therefore, the pressure lose in the Filter is less and the Filter
is stable.
 Filtration Principle
3
N2
N1
4
Figure 3.2—3 Schematic Drawing of Filtration Principle
○
1 － Gear Motor
○
2 － Middle Path
○
○
N1－ Filter Inlet
N2－ Filter Outlet
3-9
R BWMS
 The ballast water that is to be filtered passes the filter inlet N1 and enters into the Filter.
 Part of the water goes through the middle path and enters into the upper part of the Filter.
 The ballast water that is to be filtered passes the upper and lower joints and enters into the
filter element. Filtered by the strainer of the filter element, purified water gathers together
and flow out of the Filter through the Filter outlet. Impurity particles stay on the interior
surface of the strainer of the filter element.
 During the filtration, the gear motor and the backflushing valve are closed.
 Backflushing Principle
6
2
N2
5
N1
4
N3
Figure 3.2—4 Schematic Drawing of Backflushing
○
1 － Gear Motor
○
○
○
○
5 － Bottom Flushing Arm
○
6 － Top Flushing Arm
N1 － Filter Inlet
3-10
R BWMS
N2 － Filter Outlet
N3 －Backflushing Outlet
 When the Filter is filtering the ballast water, with more and more impurity particles accumulated
inside the filter element, the pressure difference between the filter outlet and inlet becomes greater
and greater.
 When the pressure difference reaches a preset value, the backflushing process starts.
 The Filter Control Box (FCB) controls the backflushing valve to open. The gear motor starts to
work and drives the top and bottom flushing arms, through the connecting pipe, to rotate at a
constant speed.
 To prevent the backflushing arms from being stuck and the filter element from being block, the
control system is set to start the backflushing process when a certain time interval (8 min) is
reached, even without the preset pressure difference being reached.
 During the backflushing, when the joint of the flushing arm, which is connected to the
backflushing pipe, targets at a filter element, the backflushing valves has been opened already.
Under the impact of the pressure difference, the filtered clean fluid is pushed back from the
outside into the inside of the filter element. The impurity particles adhering to the surface of the
filter element is washed back into the flushing arm and then out of the backflushing pipe N3.
 As the backflushing arms rotate at a constant speed, the filter elements are washed one by one.
During this process, other filter elements are still functioning. Therefore, the backflushing is
carried on automatically during the filtration.
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3.2.1.3. Parameters for the Filter
Table 3.2—1 Types of the HMT-F Filter

Flow rate range Max. working
Model Nominal Diameter Rated flow (m3/h)
(m3/h) pressure
HMT-100F 125 130 10-130 10 bars
HMT-200F 150 260 10-260 10 bars
HMT-300F 200 390 50-390 10 bars
HMT-500F 250 650 50-650 6 bars
HMT-600F 250 780 50-780 6 bars
HMT-800F 300 1040 50-1040 6 bars
HMT-1000F 400 1300 50-1300 6 bars
HMT-1500F 400 1950 100-1950 6 bars
HMT-2000F 500 2600 100-2600 6 bars
HMT-3000F 600 3900 100-3900 6 bars
HMT-4000F 700 5200 100-5200 6 bars
Table 3.2—2 Parameters for the Filter

Filtration Grade 50µm
Material of Filter Shell Carbon steel (anticorrosive treatment inside)
Material of Filter Elements Stainless steel (904 L)
Material of Internal Components Stainless steel (904 L)
Protection Degree of Gear motor IP56, B (insulation level)
Protection Degree of FCB IP44
Protection Degree of Backflushing Valve IP65
3-12
R BWMS
3.2.1.4. Main Components
(1) Filter Shell

The filter shell consists of components such as the upper shell, the lower shell, and the top cover, etc.
To prevent from being corroded, the internal surfaces of the upper shell, the lower shell and the top
cover, which would touch the filtration medium, are treated with anticorrosive measures.
(2) Filter Control Box

FCB is used to control the operation of the Filter, including the running of the Filter, the
start-up/shut-down of the gear motor, the open/close of the backflushing valve, warning, and the
communication with the Control Unit etc.
○
1 ○
5
○
2 ○
3 ○
4
Figure 3.2—5 Layout of FCB Panel
Table 3.2—3 Function Listing of FCB panel

NO. Name Function
1 Lock Lock of Box
2 Alarm Audible and visual alarm

3 Backflushing Run Light Backing flushing is ongoing.
Used for testing back flushing function. Press the
4 Manual Button button, the filter will start the backflushing for one time,
can show the back flushing is running well or not.
5 Pressure Differential Display Display pressure differential
3-13
R BWMS
1 4
2 3
5
8
10
9
Figure 3.2—6 Layout of FCB Internal Components
Table 3.2—4Function Listing of FCB Internal Components

NO
Name Function
.
1 Motor starter To protect the motoron Filter
2 Breaker To control the DC24V power-on and power-off
3 AC Contactor Control the motor forward on Filter.
4 Intermediate relay Control the valve is working
5 Terminal Connect the external cables,
6 Control Panel Control the running of filter.
7 Data Indicator Show differential pressure of Filter.
8 Manual Button Backing flushing is ongoing by manual
9 Running Lights Backing flushing is ongoing.
(3) Differential Pressure Gauge

The differential pressure gauge is used to check the pressure difference between the filter inlet and
outlet. It can also be used to set the backflushing pressure difference of the Filter. When the dirt in the
filter elements increases, the pressure difference between the filter inlet and outlet also increases.
When the difference reaches the preset value for backflushing, the Filter Control Box (FCB) detects
3-14
R BWMS
the electrical signal of the differential pressure gauge and starts the backflushing process; after the
backflushing, the pressure difference is lower than the preset value for backflushing, FCB detects the
electrical signal of the differential pressure gauge and stops the backflushing process.If the pressure
difference of the Filter continues to rise after the backflushing and even reaches the preset value for
alarming, the FCB gives an alarm. This indicates that some filter elements shall be taken out for
replacement or cleaning.
Information
The value of differential pressure can be read from the dial of the differential
pressure gauge.
(4) Gear motor

When the backflushing process starts, the gear motor is used to drive the flushing arms, which joint
with the filter element, to rotate at a constant speed until the backflushing process is stopped.
The gear motor is fixed on the top cover, while the backflushing pipe is fixed on the flange on the
underside of the lower shell.

(5) Backflushing Valve
The backflushing valve is pneumatic drive type. The valve opens and closes as the backflushing
process starts and stops.

(6) Components of the Filter Elements
1
2
Figure 3.2—7 Installation Drawing for Filter Elements

○
1 － Top Fixed Plate
○
○
3 － Connecting pipe
○
4 － Bottom Fixed Plate
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R BWMS
The filter elements are the basic components that carry out the filtration function of the Filter. Fluid
flows out of the Filter through the strainer of the filter elements. Impurity particles are separated and
stay on the strainer inside the filter elements. The component has many filter elements of the same size.
They are fixed in parallel in between the top and the bottom fixed plates. These filter elements can
replace each other or be removed separately. The top and the bottom ends of the filter elements are
pressed elastically and thus connected to the rotating flushing arms. The size and the quantity of the
filter elements depend on the rated flow of the Filter.
3.2.1.5. Adjustment and Control
 Switch on the “Breaker” (Fig 3.2-7, No. 2) in the Filter Control Box (FCB), the backflush
process will be started automatically if the preset value of the pressure difference between
the inlet and the outlet of the Filter has been reached.
Note
When the Filter is running, please always keep the “Breaker” switch on. Otherwise,
the filter elements could be blocked easily and the filtration efficiency could be
affected.
Note
The motor starter (Figure 3.2-7, No 1) should keep in “1” point under normal state.
When the filter motor is over current, the motor starter will turn off and rotate to “0”
point automatically, meanwihile an alarm will be initated. If the Filter need to run
again, the starter should be rotate to “1” point by manual.
Note
1.Three ways of initiating filter backflushing are supplied:
(1) Manual: If the "Manual" button on the control box panel is pressed, filter will
automatically start backwash once;
(2) Differential Pressure: When filter differential pressure reaches the setting
value (set in factory), filter will begin to continue backflushing, until differential
pressure drops below the set point;
(3) Timing: The filter will start backflushing once from the last stop of
backflushing after eight minutes (default).
2.The (2) and (3) above is in operation at the same time, no matter which condition is
met firstly, filter will start the backwash immediately.
3-16
R BWMS
3.2.2. S-ZF Series
3.2.2.1. Structure
17 15 16 13 14 12 6 11 10 9 8 7 5 4 3 2 1
Figure 3.2—8 Appearance of Filter (Horizontal)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Figure 3.2—9 Appearance of Filter (Vertical)
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R BWMS
1- Gear motor
2- Transmission connecting sleeve
3- Cleaning water inlet
4- Cleaning inlet chamber
5- Pressure gauge
6- Automatic exhaust valve
7- Gear motorend cover
8- Outlet
9- Body
10- Lifting lug
11- Pressure transmitter
12- Cleaning water outlet
13- Raw water intake
14- Nameplate
15- Discharge port
16- Backflush outlet
17- Cleaning pump (optional)
3.2.2.2. Function and Principle
S-ZF series filter is different from the HMT-F filter. The difference between them is mainly manifested
in the following two aspects: (1) The backwash method; (2) only one filtering screen, not multiple
elements as that in HMT-F Series. Its function is the same as that of HMT-F series, and it has better
performance in backwash, so it is more suitable to be used in bad water quality environment.
The raw water flow into the filter from the inlet, through the filter screen, then flow out from the outlet.
As the accumulation of various contaminants inside the screen, the filtration channel is blocked. And
the differential pressure between inlet and outlet increases gradually. When the pressure reaches to the
pre-set value, the system will start the stroke motor and cleaning pump (optional) automatically.
Meanwhile, the shaft with driving device and suction nozzle will rotate and move back and forth
horizontally inside the screen. And at the same time, thecleaning device and the shaft run
synchronously. And the movements are correspondingly. At the premise without interrupting producing
water, it can run the cleaning function by a small part of the product water. The cleaning water flows
through the filterscreen, together with the impurities from the filter screen. And they are quickly
inhaled into the dirt collector by the nozzle, sent to the shaft, and finally discharged from the drain.
3-18
R BWMS
After one cleaning process, the pressure differential is down. All the parts recover to the initial state.
And the system will go back to the normal operation state again.
3
2
1
5 12
6
7 8
9 11 10
Flow Direction of Water

before Filtering
Flow Direction of Clean

Water
Figure 3.2—10 Schematic Drawing of Filtration Principle
3
2
1
5 12
6
7 8
9 11 10
Flow Direction of Water Flow Direction of Clean Flow Direction of Backflush

before Filtering Water
Figure 3.2—11 Schematic Drawing of Backflushing

1 — Gear motor
2 — Drive shaft
3 — Automatic exhaust valve
4 — Raw water intake
5 — Back flush outlet
6 — Backflushing pump
7 — Flushing water outlet
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R BWMS
8 — Outlet
9 — Cleaning pump inlet
10 — Cleaning pump outlet
11 — Cleaning pump (optional)
12 — Cleaning water inlet
3.2.2.3. Parameters for the Filter
Table 3.2—5 Types of the S-ZF Filter

Nominal Rated flow Flow rate range Max. working
Model
Diameter (m3/h) (m3/h) pressure (bar)
S-ZF1-H
125 130 10-130 6
S-ZF1-V
S-ZF2-H
150 260 10-260 6
S-ZF2-V
S-ZF3-H
200 390 50-390 6
S-ZF3-V
S-ZF4-H
250 650 50-650 6
S-ZF4-V
S-ZF5-H
300 780 50-780 6
S-ZF5-V
S-ZF6-H
300 1040 50-1040 6
S-ZF6-V
S-ZF7-H
400 1300 50-1300 6
S-ZF7-V
S-ZF8-H
400 1560 50-1560 6
S-ZF8-V
S-ZF9-H
400 1950 100-1950 6
S-ZF9-V
S-ZF10-H
500 2600 100-2600 6
S-ZF10-V
S-ZF11-H
500 3250 100-3250 6
S-ZF11-V
S-ZF12-H
600 3900 100-3900 6
S-ZF12-V
S-ZF13-H
700 5200 100-5200 6
S-ZF13-V
3-20
R BWMS
Table 3.2—6 Parameters for the Filter

Filtration grade 50μm
Material of Filter Shell Duplex stainless steel
Material of Filter Screen Duplex stainless steel
Material of Internal Components Duplex stainless steel
Minimum working pressure 0.5bar
Maximum working pressure 6bar
Pressure loss 0.1~0.5bar
Protection Degree of Gear motor IP55
Protection Degree of FCB IP44
Protection Degree of Backflushing Valve IP65
3.2.2.4. Filter Control Box
5
1
2 3 4
Figure 3.2—12 Layout of FCB Panel
Table 3.2—7 Function Listing of FCB Panel

NO. Name Function
1 Lock Lock of Box
3 BackflushingRun Light Backing flushing is ongoing.
Used for testing back flushing function. Press the button, the
4 Manual Button filter will start the backflushing for one time, can show the
back flushing is running well or not.
5 Pressure Differential Display Display pressure differential
3-21
R BWMS
7
1 6
3
4
5
9 11
10
Figure 3.2—13 Layout of FCB Internal Components
Table 3.2—8 Function Listing of the Components in FCB

NO. Name Function
1 Motor starter To protect the motor on Filter
2 Breaker To control the DC24V power-on and power-off
3 AC Contactor Control the motor forward on Filter.
4 AC Contactor Control the motor backward on Filter.
5 Terminal Connect the external cables,
6 Intermediate relay Control the valve is working
7 Control Panel Control the running of filter.
8 Data Indicator Show differential pressure of Filter.
9 Manual Button Backing flushing is ongoing by manual
10 Running Lights Backing flushing is ongoing.
3-22
R BWMS
3.2.2.5. Adjustment and Control
Switch on the “Breaker” (Figure 3.2—13 Layout of FCB Internal Components, No. 2) in the Filter
Control Box (FCB), the backflush process will be started automatically if the preset value of the
pressure difference between the inlet and the outlet of the Filter has been reached.
Note
When the Filter is running, please always keep the “Breaker” switch on. Otherwise,
the filter elements could be blocked easily and the filtration efficiency could be
affected.
Note
The motor starter (Figure 3.2—13 Layout of FCB Internal Components, No 1)
should keep in “1” point under normal state. When the filter motor is over current,
the motor starter will turn off and rotate to “0” point automatically, meanwhile an
alarm will be initiated. If the Filter need to run again, the starter should be rotate to
“1” point by manual.
Note
1.Three ways of initiating filter backflushing are supplied:
(1) Manual: If the "Manual" button on the control box panel is pressed, filter will
automatically start backwash once;
(2) Differential Pressure: When filter differential pressure reaches the setting
value (set in factory), filter will begin to continue backflushing, until differential
pressure drops below the set point;
(3) Timing: The filter will start backflushing once from the last stop of
backflushing after eight minutes (default).
2.The (2) and (3) above is in operation at the same time, no matter which condition is
met firstly, filter will start the backwash immediately.
3-23
R BWMS
3.3. EUT Unit
3.3.1. Appearance
3 4 2
Figure 3.3—1 Appearance of the EUT Unit
○
1 — Shell
○
2 — Temperature Sensor
○
3 — Pressure Switch
○
4 — Cover of Electrode Group
3.3.2. Function and Principle
The EUT Unit produces active substances, which is used to
remove or kill the microorganism in the medium. The
electro-catalysis module uses high-performance semiconductive
catalysis materials. Water molecules are catalysised by special
materials and produce large amount of active substances such as
hydroxyl radicals etc. The module has very high current
efficiency and super long service life. When water passes the
Filter and the EUT Unit, the organism contained are filtered or
Figure 3.3—2 EUT Unit killed.
A temperature sensor was installed in the EUT Unit, and all data monitored will be uploaded to Control
Unit and shown on the screen. Control Unit will treated any temperature high than 45℃ as critical
malfunction and give out an alarm, and the system will automatically shutdown afterwards.
3-24
R BWMS
And a pressure switch is installed on the other side of EUT unit, which will cut off system power if the
EUT internal pressure is over 6 bar. This is also self-protection for the whole system.
3.3.3. Main Parameters
Table 3.3—1 Technical Data for EUT models

Rated Capacity Connection Quantity of Space
Model Weight
3
（m /h） (DN) Electrocatalysis Modules (m3) (kg)
HMT-50E 65 125 1 0.5 210
HMT-100E 130 125 2 0.58 270
HMT-200E 260 150 3 0.76 330
HMT-300E 390 200 3 0.93 420
HMT-450E 585 250 3 1.09 570
HMT-600E 780 250 3 1.23 620
HMT-800E 1040 300 3 1.53 680
HMT-1000E 1300 350 3 1.44 790
HMT-1200E 1560 400 3 1.67 870
HMT-1500E 1950 400 3 1.74 980
HMT-2000E 2600 500 3 2.04 1120
HMT-2500E 3250 500 3 2.34 1270
HMT-3000E 3900 600 3 2.34 1370
HMT-4000E 5200 700 3 2.34 1430
Table 3.3—2 Parameter for EUT
Maximum External Temperature 55℃
Maximum Working Pressure 6 Bar

Carbon steel (painted surface, anticorrosive coating on internal
Material of Shell
surface)
Protection Degree IP44
Working Medium Water
3-25
R BWMS
3.3.4. Main Components
Figure 3.3—3 Main Components of EUT Unit
Where:
○
1 － Shell
○
2 － Cover Plate
○
3 － Electro-catalysis Material
○
4 － External Conductor Post
○
5 － Fixing Plate of Conductor Post
3-26
R BWMS
3.4. EUT Power
3.4.1. Appearance and Structure
Figure 3.4—1 Appearance of EUT Power
Front View Left View
③ ⑤
④
②
⑥
⑦
⑧
⑨
⑩ 11
14
15
Back View 12 13
Right View
Figure 3.4—2 Structure of EUT Power
3-27
R BWMS
○1 － Blank
○2 － Power Switch of EUT Power
○3 － Blank
○4 － EMI
○5 － Control Box
○6 － Reserved Line Bank
○7 － Power Control and Alarm
○8 － Power Output of Module Power
○9 － 485 Communication Port With Instructions
○
10 － Power Input
○
11 － Inverter Components
○
12 － Output Terminal (Terminal A)
○
13 － Output Terminal (Terminal B)
○
14 － The Outlet Flange
○
15 － The Inlet Flange
3.4.2. Function
EUT Power is exclusively used in OceanGuard® Ballast
Water Management System. It is the power supplying
system of the EUT Unit. The power supply for the EUT
power is AC 380/440 V. If the system works normally,
EUT Power is automatically controlled. Instructions are
sent by the Control Unit. The output of the EUT Power
can also be controlled manually from the panel. Working
parameters are directly displayed on the panel. This power
has excellent dynamic and static output characteristics. It
also has advantages including overcurrent protection and
overvoltage protection etc. Protective responses can be
quickly made toward malfunctions.

Figure 3.4—3 EUT POWER
The value of current indicated on EUT power unit is
based on the connection between each electrocatalysis group within EUT unit. Current value for
parallel connection equals the current value for series connection times the amount of electrocatalysis
3-28
R BWMS
group within EUT unit. However, series connection or parallel connection will not affect the total
power consumption.
Table 3.4—1 Technical Data of EUT Power
Maximum Maximum Current

Depth Width Height
Model Current Input Output to Each Catalysis
(mm) (mm) (mm)
(A) Group (A)
HMT-50PE 550 751 800 26 500
HMT-100PE 550 751 800 26 500
HMT-200PE 550 751 800 52 1000
HMT-300PE 550 751 800 52 1000
HMT-450PE 550 751 800 52 1500
HMT-600PE 550 751 800 78 1500
HMT-800PE 650 1001 1200 108 2000
HMT-1000PE 650 1001 1200 144 2500
HMT-1200PE 650 1001 1200 157 3000
HMT-1500PE 750 1100 1600 210 4000
HMT-2000PE 750 1100 1600 287 5000
HMT-2500PE 750 1150 1950 315 6000
HMT-3000PE 750 1150 1950 367 7000
HMT-4000PE 700 1500 1650 472 10000
Table 3.4—2 Main Parameters of EUT Power

Maximum Environment Temperature 60℃
Material of Box Q195
Input Voltage AC 380/440 V
Frequency of Input Power 50/60 Hz
Rated Output Voltage DC 40 V (Max.)
Voltage Adjustment Scope 0～40 V
Insulation Degree B
3-29
R BWMS
Protection Function Short circuit, overcurrent, overheating
Water Cooling Input Water Flow 10-20L/min
Water Cooling Input Water Pressure 0.1-0.3Mpa
Water Cooling Input Water Temperature 28-35℃
Water Cooling PH of Cooling Water PH:6-8
3.4.4. Main Components
Table 3.4—3 Functions of the Main Components of the EUT Power
Output Filtering Capacitance Remove output noise
Output Filtering Inductances Store energy and remove output disturbance
To realize the communication between the Control

485 Communication
Unit and the electrocatalysis module power
Power Input of Electrocatalysis Module
AC 380/440V
Power
Anode and cathode of the electrocatalysis module
Terminal A and Terminal B
power
Inlet (Outlet) for water used to cool the EUT
Inlet (Outlet) for Cooling Water
Power
To switch between anode and cathode of the
Direction Control Module 1#, 2#, 3#, 4#
power for the electrocatalysis module
3.4.5. Adjustment and Control
Note
All parameters of EUT power have been set up during trial run. Please don't change
any setting, it will cause damage to the system.
Caution
Keep the power of EUT Power Unit off when the system stands by.
3-30
R BWMS
3.4.5.1. Display Windows and Lights
Figure 3.4—4 Control Panel of the EUT Power
（A） Value displays on the top left section: various parameters such as forward voltage, forward
current and forward time;
（ B ） Value displays on the lower left section: various parameters such as negative voltage,
negativecurrent and negative time;
（C）Value unit display V A:
【V】lighting denotes（A）、（B）windows display voltage value;
【A】lighting denotes （A）、（B）windows display current value;
（D） Value unit display: to display soft-start time/run time unit;
【H】lighting denotes time unit is “Hour”;
【M】lighting denotes time unit is “minute”;
【S】lighting denotes time unit is “second”;
（E）Value displays on the lower right section: fault information, forward and negative running time
and unit in automatic reverse mode;
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R BWMS
（F）Output control status indication
【CV】lighting denotes output mode is constant voltage(in operation);
【CC】lights denotes output mode is constant current (in operation);
Note
Operational key：press 「CV CC」 button ⑤ to switch operation.
（G）window value indicting
【V/A】lighting denotes the window value displays the running voltage /current (in operation);
【SET/RUN】 lighting denotes （A）（B）windows display the set value and actual value of
voltage /current;
【SLOPE】lighting denotes the set of soft-start time (stop);
【TIME】lights denotes the set value of forward and negative running time in automatic reverse
status:
（A） window displays forward preset running time, （B）window displays negative
preset running time. (E) window displays forward and negative running time unit (“0”
denotes the time unit is second, “1” denotes the time unit is minute, “2”denotes the
time unit is “hour” )
Note
Operational key: Press 【DISP SELECT】 button ○

4 to switch operation.
（H）automatic reverse / manual reverse control mode display:
【AUTO】lighting denotes the power is in automatic reverse control mode;
【MANUAL】lighting denoted the power is in manual reverse control code;
Note
Operational key: press 【REVERSE】 button ○

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R BWMS
（I）positive output/negative output display in manual reverse control mode;
【FORWARD】lighting denotes it is in forward output status (in operation);
【REVERSE】lighting denotes it is in negative output status(in operation)
Note
Operational key: press 【FORWARD/REVERSE】button ○

3.4.5.2. Button Description
○
1 - Blank
○
2 【FORWARD/REVERSE】-forward output/negative output setting button; Press this key to switch
「FORWARD」 and 「REVERSE」output in manual reverse control code (in operation);
○
3 【REVERSE】-control code setting button; Press this key to switch the automatic reverse and
manual reverse control mode;
○
4 【DISP SELECT】-press this key to switch the 「V/A」「SET/RUN」「SLOPE」「TIME」 data
of window (A) (B) (E) ;
○
5 【CV CC】-output control setting button; Press this key to switch 「CV」 and「CC」control;
○
6 【START/STOP】-start/stop setting button; For starting or stopping running;
○
7 【REMOTE / PANEL】-distance control setting button; Press this key to switch panel control and
remote control.
Note
【REMOTE / PANEL】 is not permitted to being pressed by users expect for the
commission technical person of manufacturer.
○
8 【CLEAR】-when Err0 alarms, buzzer beeps; Press the key to reset and unlock buzzer beep; when
the button is pressed, the alarm has not been lifted, close the air switch;
○
9 【SET】-switch the window when setting the value of （A）（B）（E）in the process of
inputtingparameter data;
○
10 【Encoder】knob; to set the parameter of （A）（B）（E）window. When stopped, the digital of
3-33
R BWMS
the window flashesandthe value increase when you rotate the knob clockwise, while the value
decreases when you rotate the knob counterclockwise.
3.4.5.3. The Window Value Switching Description in Automatic Reverse and Manual Reverse
Mode
(1) Press 【AUTO】to switch automatic/ manual control code.
(2) Press 【DISP SELECT】to switch the window value.
(3) When the data flashes, the encoder data changes are displayed.
Table 3.4—4 Displaying contents of EUT Power window
Lighting Window Control Mode：ATUO Control Mode：MANUAL
Average output voltage Average output voltage

(A)
(in operation) (in operation)
Average output current Average output current
(B)
(in operation) (in operation)
【V/A】
Remaining forward action time F
(in operation)
(E) //
Remaining negative action time ｒ
(in operation)
Average output current
(A) To set forward voltage / current F
(in operation)
【SET/RUN】 (B) To set negative voltage/current r To set negative voltage/current r
(E) // //
Set value of slope (soft-start ) time Set value of slope (soft-start ) time
(A)
(0 means lifting) (0 means lifting)
【SLOPE】 (B) // //
(E) // //
(A) Forward running time value F //
(B) Negative running time value r //

【TIME】
(E) Forward running time unit F //
Negative running time unit r //
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3.4.5.4. Software Version Check
(1) When powered on EUT Power Unit will boot into Remote Control. Press the
“REMOTE/PANEL” button on the display panel to enter panel control (the indicator above
Remote/Panel will turn off when EUT Power in panel control).
(2) Press and hold “DISP/SELECT” button until the 7-seg display blink and display “Pr.00”, press
“SET” button and the lower large 7-seg display should blinking. Slowly turn the knob clockwise to
adjust the lower large display to 99.
(3) Press “Set” button and the upper large display should blink, slowly turn the knob clockwise
and adjust the upper large display to “Pr.04”. And the program version (74.AA) will be displayed in
lower small display area.
(4) Press “DISP/SELECT” to quit.
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(5) Press “REMOTE/PANEL” to set the EUT Power Unit back to Remote Control (The indicator
above the button should be light up).
3.5. Control Unit
3.5.1. Appearance and Structure
Figure 3.5—1 Appearance of Control Unit
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⑧
⑤
①
③
②
⑥
⑦ ⑨
Figure 3.5—2 Layout of Internal Components of Control Unit
Table 3.5—1 Functions of Internal Components of Control Unit
NO. Name Function
1 Plate for Serial Interfaces To communicate with external serial devices
2 Three phase socket Debugging personnel use
3 Breaker To control the power-on and –off of the whole Control Unit
4 AD Contactor To control the operation of the whole Control Unit
5 Switch Power To change AC 220 V into DC 24 V
To collect the status information of devices; to control the

6 PLC
devices
7 PLC Expansion Module To expand the IO interface of PLC
8 PLC Analog Module To collect analog signals of 4-20 mA current
9 Communication Module To communicate with the computer
10 Terminals Connectors for external cables
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3.5.2. Function
The Control Unit controls the whole system of BWMS, including collecting and processing all
monitoring sensor signals, processing alarm signals, and automatically controlling the sequence of
starting up and shutting down the components. The Control Unit contains the control program that is
required for the operation of the system. The working status of the BWMS can be displayed on the
panel of the Control Unit, including the working status of each component, and real-time data detected
by the sensors. When the equipment breaks down, the Control Unit can send acousto-optic alarm,
switch off the power, and stop the system. The operation of the equipment can be stored and recorded
in the Control Unit. Data can be displayed as required by formal inspections.
The Control Unit collects various monitoring sensor signals in the whole system, including the
open/close status of the valves, monitoring signals such as current values, voltage values and TRO
values from the Salinity Meter, the Flow Meter and the EUT Power, and voyage data of ships. With
built-in programs, the computer system of the Control Unit can calculate the current values and voltage
values based on parameters collected, so as to adjust the operation of the system until it reaches the
best operation status. In this way, BWMS can keep on working under the best status.
The Control Unit has functions of recording and storing. It can record and store the operation data for
at least 24 months. The Control Unit also has an alarm output interface, which can integrate with other
alarm signals from the engine control room. Therefore, it ensures that the alarm information can be
easily detected anywhere in the engine room.
The Remote Control Panel has the same functions with the Control Unit, including controlling,
displaying and alarming. The two equipments are connected by the remote communication interface on
the Control Unit. They both can control and adjust the system. The Control Unit can start up or shut
down the Remote Control Panel.
Table 3.5—2 Main Parameters of Control Unit

Dimension (L x W x H) 560 x 830 x220 (mm)
Weight 30Kg
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Material Structural Carbon steel (Q195)
Power Supply AC 110/220 V, 50/60 Hz
Output Voltage DC 24 V
Output Signal RS485/422
The control panel can be divided into three sections. Please see (Figure 3.5—3 Sections of Control
Panel) for their layout.
○
1
○
2
○
3
○
4
Figure 3.5—3 Sections of Control Panel

Where:
○
1 Monitoring and Control Area; ○
2 Control Area for Operation;○
3 Function Area; ○
4
Control Area for Power Supply
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a) Monitoring and Control Section
An 9-inch touch screen is used in the monitoring and control section, which can not only display
information such as the status of the BWMS and the data detected by the sensors etc., but also let the
operator know about BWMS' performance at the present and in the past. Moreover, by using the
buttons on the screen and the input mode of soft keyboard etc., parameters can be flexibly modified.
Start Screen
Figure 3.5—4 Start Screen
When the system starts up, the Startscreen will appear. During the appearance of this screen, the
system will run an inspection on the SD card. “Pipe” interface will appear after the self-inspection.
Pipe
Figure 3.5—5 Pipe Screen
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The Pipe screen mainly provides information about the pipes during the operation of the system. In this
screen, the status of each valve can be seen directly; the path and direction of the flow can be judged;
and the operation of the system can be monitored. In addition, in the information box on the upper
right, the instantaneous flow rate, the total flow rate, and the accumulative operation time of the
BWMS are displayed.
The interface contains information from sensors such as GPS, Temperature, TRO, etc.
If there is a failure of BWMS, the alarm will be shown in a block. After acknowledge by pressing the
alarm information once, the alarm will disappear, while it can be found in the“Alarm” Menu.
If you want to enter other function screens, please click on the button under the screen.If you want to
return to the Function Menu screen, please click on the “ ” button on the upper left.
Function Menu
In the Function Menu screen, click different buttons to enter different function screens.
Figure 3.5—6 Function Menu
The function screens are introduced separately below.
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Log
Figure 3.5—7 Log Screen
Figure 3.5—8 Date Record Screen
The Log screen is used to display the system log. The list on the left shows the time and date of the
events. Events include ballast, deballast, bypass and emergency operation.
Log is displayed by scroll bar on the screen. It is saved in the Storage Card MMC by RDB format and
it’s name is “Operation Log”. Please refer to “Setting” on the screen if you want to copy the Log.
On the right, detailed information of logs is provided, such as the operations that have been carried out.
“Time” indicates how long the operation has lasted; “Position” indicates where the ship is located; and
“Total flow” indicates the total flow accounted when the operation is over.
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If you want to enter other function screens, please click on the button under the screen.
Setting
Figure 3.5—9 Setting Screen
Through the Setting screen, User can log in different account IDs and modify the operational
parameters of the EUT Unit. Before entering the Setting Interface, password should be input to access
the setting function. Since part of this would involve the operation status of the BWMS and may
directly influence its processing effect, please follow the instructions of the technical people sent by
the manufacturer.
Information
All parameters have been set in the factory. The password is kept by the
manufacturer.
All parameters in the setting interface are not allowed to be changed, except the valve display
name. If User need to modify the valve display name, please ask the manufacturer for the
password.
All changes will be recorded in Control Unit.
If you want to copy Log, ballast data record and history alarm list, just insert USB equipment.
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If you want to return to the Function Menu screen, please click on the “ ” button on
thelower left.
Alarm
If the system does not work properly, the Alarm screen will give current alarm information, count the
alarms, and show the content and the serial number of the current alarm. Personnel concerned shall
check the fault position immediately and make judgments about the reasons. If the fault may threat the
safety of personnel and equipment, corresponding measures shall be taken.
Figure 3.5—10 Real-Time Alarm Screen
Figure 3.5—11 Historical Alarm Screen
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Alarms include real-time alarm records and historical alarm records, which can be chosen based on
client’s needs. Please press button to switch. The selected type
of alarm will appear at the top of the screen.
If you want to return to the Function Menu screen, please click on the button on the lower left.
User
Through the User screen, clients can set their own log-in account IDs and passwords. With the IDs and
passwords, clients can enter the Setting screen to download the log of the BWMS only. When entering
the screen, there will be a soft keyboard. Operators can use it to input. As the Setting screen is related
to the stability of the system’s operation, clients are prohibited to change the log-in account IDs and the
passwords.
Information
All parameters have been set in the factory. The password is kept by the
manufacturer.
All parameters in the setting interface are not allowed to be changed, except the valve display
name. If User need to modify the valve display name, please ask the manufacturer for the
password. Other parameters can be changed by manufacturer only.
All changes will be recorded in Control Unit.
Figure 3.5—12 User Screen
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Info
On the Info screen, contact information of the manufacturer can be found.
Figure 3.5—13 Info Screen
b) Control Area of Operation
There are three buttons in the Control Area to realize three different functions.
 Ballast : To start ballasting mode. The ballast function is started by pressing this button.
The regular process is: sea chest – water pump – Filter – EUT Unit – ballast tank.(The ballast
process will be stopped when “Ballast” button was pushed during the ballast.）
 Deballast: To start the deballasting process. The deballasting function is started by pressing this
button.
The regular process is: ballast tank – water pump – overboard. (The de-ballast process will be
stopped when “Deballast” button was pushed during the ballast.)
 Bypass: To start emergency mode. When emergency occurs, the by-pass valves can be
emergently opened by using this button.
The water will not run through BWMS, but directly flow into the ballast tank or be discharged
overboard by bypass pipe.
Information
Please carry on the operations in pairs. For example, after using “Ballast”, please
use “Ballast ” to end the operation.
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c) Function Area
There are three function buttons in the Function Area, which are the buttons of Test, Remote/Local,
Mute.
 TEST：This button is used to test whether the Audible and visual alarm is working properly.
Press this button to Audible and visual alarm for 3 Seconds, resume normal operation.
 Remote/Local：Switch of local control and remote control. The Remote Control Panel can be
operated only when this button is pressed.
 Mute：This button is used to mute the alarm when the system alarm is on.
Remote/Local Instruction
After switch “Remote/Local” in the Control Unit and tapping “Sure” on the Remote Control Panel, the
system will be altered into the Remote Control pattern. After the activation of the remote control, local
will be disabled.
In the Pipe screen, the states will be shown. indicates that the BWMS is
under local control. If the BWMS is under remote control, will appear on
the screen.
Figure 3.5—14 Remote Control Request
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d) Control Area for Power Supply
 Alarm: If there is an alarm of the BWMS system, it will make a sound and light alarm.
 Power on: By pressing this button, the control panel of the Control Unit starts to work.
 Power off: By pressing this button, the control panel of the Control Unit stops working.
 Emergency Switch: Pressing this valve, valves on the ballasting line will be closed and valves on
the bypass line will be opened, EUT Power Unit will be at standby mode. The water will go into
ballast tank bypassing BWMS.
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3.6. Monitoring Unit
3.6.1. Components
The Monitoring Unit consists of parts such as TRO Meter, Salinity Meter, electromagnetic valve, pump,
relay, radiator and reagent bottle etc.
Figure 3.6—1 Appearance and Internal Layout of Monitoring Unit

1 — Air outlet
2 — Vortex Cooler
3 — Relay
4 — Cable connecting terminal
5 — TRO Meter
6 — Indicator Cup
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7 — Pump
8 — Salinity Meter
9 — Magnetic valve
10 — Water Outlet
11 — Drain
12 — Grounding
13 — 1# water inlet of Monitoring Unit
16 — Water outlet of Monitoring Unit
17 — PG
18 — Air Vent
19 — Compressed Air Inlet
3.6.2. Function
The Monitoring Unit is used to detect the TRO and salinity of
the ballast water, which are very important information for the
performance of the BWMS. The resulting data can be uploaded
to the Control Unit. Based on the data. The Control Unit can
determine the working status and modes of equipment in the
system. The performance of the Monitoring Unit will directly
influence the working status of the BWMS.
TRO means “Total Residual oxidant”. It is an important
parameter for determining whether the active substance in the
water are sufficient or not. This instrument is the use of cuvettes

Figure 3.6—2 Appearance of
measurement.
Figure 3.6—3 Appearance of MU
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Figure 3.6-3 TRO Meter
The Monitoring Unit is used to detect the TRO of the ballast water, which is very important
information for the performance of the BWMS. The resulting data can be uploaded to the Control
Unit.Based on the data, the Control Unit can determine the working status and modes of equipment in
thesystem. The performance of the Monitoring Unit will directly influence the working status of
theBWMS. The Monitoring Unit includes 1 set of TRO Meter. Inlet 1# is located in front of
theNeutralization Unit injection, inlet 2# is located after the Neutralization Unit, and inlet 3# is located
after EUTunit. According to the practical situation, sample points can be merge into two. Please refer
to Figure 7.2—1 System Operation Flow Chart of OceanGuard® Ballast Water Management System.
Inlet1 # is used to detect the TRO concentration before neutralization during deballasting process. Inlet
2# is used to detect theTRO concentration in the discharged ballast water, which has been neutralized.
TRO concentrations of inlet 1# and 2# are used to check the Neutralization Unit efficiency. Inlet 3 # is
used todetect the TRO concentration generated by the EUT Unit during ballasting process. If
TROconcentration is beyond the scope of requirement, EUT Unit Power will adjust the
currentautomatically. To ensure the TRO value fall into the correct value. Please check the Figure
3.10.2 for control principle.
TRO Meter is used to detect the concentration of the residual oxidant in water, so as to determine
whether the quantity of the active substance in the system has reached established level.The TRO
content in wateris usually expressed in (mg/L), which is equivalent to ppm.
It is actually a simple online detecting control instrument that is easy to operate, can be automatically
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count, display reading. Its detecting ability is highly realizable and accurate. This meter connected to
the Control Unit. The operator can use the main screen of the Control Unit or the backlit screen of the
meter to read values.
This meter has easy-to-operate buttons. The meter can also be easily operated in the dark.
Salinity value in relationship with the output current of EUT Power, can be used for indirect judgment
of system working status.
Table 3.6—1 Main Parameters of Monitoring Unit Box

Dimension (L x W x H) 720 x 245 x800 (mm)
Material Cold plate Q195
Table 3.6—2 Main Parameter of TRO Meter

Detecting Range 0~10 mg/L
Maximum Environment Temperature of Controller 60℃
Power Supply AC 110/220 V，50/60 Hz
Protection Degree IP 66
Maximum of Working Pressure of Probe Holder 10 Bar
Rated Flow of Pump 1.0 L/min
Maximum Working Pressure of Pump 0.85Mpa
Maximum Environment Temperature of Pump 60℃
Power Supply for Pump DC 24 V

Diameter of Connecting Hose 16, 12, 8, 6 (mm)
Diameter of Connecting Copper Pipe 8mm
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Table 3.6—3 Main Parameter of Salinity Meter

Model HMT-SM
Range 0-50PSU
Output Signal 4-20mA (2Wire)
Display LED model: 4 bits LED display
Calibration 2 point calibration
Protection IP65
Resolution 0.1
Accuracy ±1.5%F.S.
Thread 3/4" NPT thread
Power supply 24VDC
3.6.4. Operation
3.6.4.1. TRO Meter
3.6.4.1.1. TRO Meter Screen
Note
Please keep all of the default factory parameters of the TRO Meter. Modification by
unauthorized personal is strictly prohibited. Any unauthorized modification might
cause damage of the system.
Figure 3.6-4 Control Panel of the TRO Meter
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The upper row of the display (1) is used for reporting the chlorine levels and to provide user guidance
in the customer setting routine. The lower row of the display (2) is used to communicate error
messages (message queue) and provide user guidance. The display has two icons (3) that are used to
indicate the use of access code and offset mode. In addition, mode arrows (4) are used to indicate the
current instrument operating mode; AUTO (normal operation), CAL (calibration) and CONFIG
(configuration).
3.6.4.1.2. TRO Meter Button Panel
Figure 3.6.5 illustrates the touch pad. The touch pad has six buttons: PRIME, SERVICE, MODE/EXIT,
, and .
Figure 3.6-5
The MODE/EXIT button is used to cycle between the three operational modes of the instrument: CAL,
CONFIG, and AUTO (Measurement) mode. The button enters the option or mode that is
highlighted or chosen. The and buttons are used to change settings.The PRIME and
SERVICE buttons are dedicated controls. The PRIME will start 75 reagent pump pulses to prime the
tubing after a change or addition of reagent bottles. The SERVICE button will drain the instrument and
hold all operations until either the SERVICE button is pushed again or the power is reset. This button
should be used while changing the tubing, the measurement cuvette or reagent bottles.
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3.6.4.1.3. Principle of TRO Meter Operation
TRO meter consists a sample inlet, a purge drain, and an overflow. A green LED provides the 515 nm
source lamp, a red LED is used for sample level and flow measurement. A replaceable glass cuvette
separates the LEDs from the detector and maintains the measurement path length. Sample water flows
in the inlet at the bottom, through the measurement cuvette and out through an overflow drain. This
flow is used to both fill the cuvette and flush the system.
The reagents are dispensed from two replaceable bottles. One bottle has a buffer to control the pH; the
second has an indicator that contains DPD, which produces color when an oxidant such as chlorine is
present in the sample water. The degree of color depends on the amount of oxidant in the sample water.
3.6.4.1.4. TRO Meter Operation Steps
First of all, before operation two reagents need to be installed on TRO detector, including buffer
reagent and indicator, also it should be verified that all piping and electrical connections have been
completed.
The following steps describe how to measure the value of chlorine of a sample using this instrument:
○
1 Apply power to the instrument. The instrument will perform a water calibration (WCAL).
This automatic calibration is necessary and will only be performed once on power up.
○
2 When the instrument has completed the WCAL it will enter standby mode and is ready to
run a measurement cycle.
○
3 The display will continue measuring and show the reading, the RS-485 mA and alarms will
be representative of this reading.
During normal operation, the instrument will have the arrow beside AUTO highlighted with the current
scale displayed on the lower row of the display and the measured reading on the upper row of the
display (see illustration below).
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Figure 3.6-6
The screen depicted below indicates that the system has just been started or just entered AUTO mode
from Service mode and no readings have been taken yet.
Note
Please note that calibrations will not be allowed until a reading is posted.
Figure 3.6-7
3.6.4.1.5. The White LED
A white LED is used to illuminate the measurement cuvette for easy viewing of the instrument
operations. During the Zeroing portion of the cycle and the Measurement portion of the cycle, when
the green LED is active, the white LED is turned off to lower interference. This normal operation for
the instrument and does not represent an error or problem.
The white LED is also used to draw attention to a problem as described in section 9.8.1TRO Meter
Fault Detection. In these instances, the white LED blinks but is still turned off as described above.
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3.6.4.1.6. Instrument Configuration
○
1 Configuring the RS 485 Port: The instrument is equipped with an RS 485 port, the port the Modbus
to work. Prompts will appear for setting the baud rate, the address and the Modbus transmission
mode.Select the correct baud rate (1200, 2400, 4800, 9600, or 19200) for operation of the I/O port by
pressing the or buttons to change the displayed baud rate.
Figure 3.6-8
Press the button to continue on and select the desired instrument address using the or
buttons. Once the selection is satisfactory, press the button.
Figure 3.6-9
○
2 Relay: control valve switch, TRO meter and TRO pump power on.
3.6.4.1.7. Security Access Feature
The instrument is provided with a built-in security access. When turned on, user is required to input the
access code “333”（Code is not allowed to change）into the instrument to get to any mode other than
AUTO. See below, the security key icon will be visible and flashing on the display whenever the
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access option is selected using the or buttons.
Figure 3.6-10
Note
Please keep the factory password. Password function is used to protect the setting
menu of SETUP from being modified by unauthorized people. There is no
remedial measure for forgetting the password but to reset the meter. However, all
of the setting parameters will be deleted. This may cause the TRO meter work
improperly.
3.6.4.1.8. Setting Flow Rate
The flow rate on the TRO meter as factory adjusted and should not need adjustment. Installation
variances may affect the flow. The optimal flow rate through the TRO meter may be adjusted if needed.
The flow is adjusted by removing regulator vinyl cap. Follow the procedure shown below:
○
1 Press the SERVICE button.
○
2 Wait for the display to read HOLd, then press Mode/ Exit.
○
3 Display will show FLOW with the number 0. Press either the or button.
○
4 The display will show one of three messages HI, LO or Good.
The flow test determines if the flow rate is suitable for proper operation. Loosen the locking nut then
adjust the pressure regulator using a coin or a large flat blade screwdriver. Press either the or
button while in the FLOW routine to display a new flow rate. Please note that only ¼ turn
incremental adjustments should be made to the regulator on each attempt. If the message is LO, turn
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the regulator control clockwise. If the message is HI, turn the regulator counterclockwise. If the
message is good, no adjustment is required. Tighten the locking nut after adjustment and replace the
regulator vinyl cap. To return to normal operation, press the button.
3.6.4.2. Salinity Meter
3.6.4.2.1. Appearance
HMT-SM is a component of OceanGuard® BWMS, which can show the salinity of water correctly.
HMT-SM is suitable to be used in any quality of water without any restriction, including fresh water,
brackish water, sea water and high salinity water.
Figure 3.6—11 Appearance of Salinity Meter
3.6.4.2.2. Operation
After installation, salinity meter will directly display the salinity value, with the “ppt” Unit, which does
not need to be adjusted.
For calibration procedure, please refer to the Chapter 10.
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3.7. Flow Meter
3.7.1. Appearance
BAWAY Flow Meter ABB Flow Meter

Figure 3.7—1 Appearance of Flow Meter
3.7.2. Function
The Flow Meter can be used to detect the instantaneous flow rate in the ballast water pipes and to
measure the total amount of the ballasting and de-ballasting water. These are important input
parameters of the Control Unit.
After being actually calibrated with ordinary water, the Flow Meter can be used to measure the
volumetric flow of any other conductive fluid medium, without any amendment. Since there is no
moveable part or flow-resisting parts in the measuring pipe, there is almost no loss of pressure, and the
reliability is high.
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3.7.3. Parameters
Model DN Dimensions Nominal Weight
BAWAY ABB (mm) L D N φ H Pressure (Kg)
HMT-125FM FEP311 125 250 250 8 18 454 PN16 22
HMT-150FM FEP311 150 300 285 8 22 513.5 PN 16 33
HMT-200FM FEP311 200 350 340 8 22 581 PN 10 41
HMT-250FM FEP311 250 450 395 12 22 623.5 PN 10 61
HMT-300FM FEP311 300 500 445 12 22 671.5 PN 10 74
HMT-350FM FEP311 350 550 505 16 22 716.5 PN 10 95
HMT-400FM FEP311 400 600 565 16 26 788.5 PN 10 103
HMT-500FM FEP311 500 600 670 20 26 849 PN 10 190
HMT-600FM FEP311 600 800 780 24 33 955 PN 10 246
HMT-700FM FEP311 700 910 895 24 30 1051.5 PN 10 303
HMT-800FM FEP311 800 1040 1015 28 33 1161.5 PN 10 406
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General information
Detecting Range Flow velocity: 0.1~15 m/s
Type Magnetic
Maximum Environment Temperature 55 ℃
Maximum Medium Temperature 55 ℃
Maximum Working Pressure 6 Bar
Material PTFE lining
Power Supply DC 24V
Signal Output RS485
Protection Degree IP 65
Connecting Manner Flanged connection
3.7.4. Operation
The LCD display is provided with capacitive control buttons. These enable you to control the device
through the glass of the closed cover. The transmitter automatically calibrates the capacitive control
buttons on a regular basis. If the cover should be opened during operation, the buttons' sensitivity is at
first increased. As aresult, operating errors may occur. The button sensitivity will return to normal
during the next automatic calibration.
Note
The equipment has four security levels, we only open the first level “Display” to
customers. All the parameters have been set up before they are installed. Please keep
all of the default factory parameters of the flow meter. They are not allowed to be
modified. Any modification on your own may cause the instrument break down
easily.
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3.7.4.1. BAWAY Flow Meter
3.7.4.1.1. Display
1— Control buttons for menu navigation
2— Menu name
4— Marker for indicating relative positionwithin the menu
5— Function currently assigned to the right and left control buttons
Table 3.7-2 Meanings of Control Button
You can use the up or down control buttons to browse through the menu or select a number or
character within a parameter value.
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Figure 3.7-3 Process Display (for example)
1— Measuring point identifier
2— Current process values
3— Symbol indicating button function
4 —Symbol indicating "Parameterization protected"
The process display appears on the LC display when the device is switched on. It shows information
about the device and current process values.
Table 3.7-3 Meanings of Symbols
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3.7.4.2. ABB Flow Meter
3.7.4.2.1. Display
Figure 3.7-2 LCD Indicator
1— Control buttons for menu navigation
2— Menu name
3— Menu number
4— Marker for indicating relative positionwithin the menu
5— Function currently assigned to the and control buttons
Table 3.7-4 Meanings of Control Button
You can use the or control buttons to browse through the menu or select a number or
character within a parameter value.
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Figure 3.7-3 Process Display (for example)
1— Measuring point identifier
2— Current process values
3— Symbol indicating button function
4 —Symbol indicating "Parameterization protected"
The process display appears on the LC display when the device is switched on. It shows information
about the device and current process values.
Table 3.7-5 Meanings of Symbols
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3.7.4.2.2. Alarm Message
1. Use to go to the
information level.
2. Use or select
the submenu "Diagnostics".
3. Confirm the selection with
The first line shows the area in

which the error hasoccurred.
The second line shows the

unique error number.
The next lines show a brief

description of the error and
information on how to remedy it.
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3.8. Remote Control Panel
3.8.1. Appearance
Figure 3.8—1 Appearance of Remote Control Panel
3.8.2. Function
The Remote Control Panel is embedded in the engine control room. It carries on related data
communication with the Control Unit.The Remote Control Panel can realize the remote control of the
BWMS and display related system information. Its operation and display are exactly the same with the
Control Unit.
The Remote Control Panel does not have control area or function area as in the Control Unit. However,
the operation of these two areas can be carried out with the interface on the touch screen.
The Remote Control Panel can be used only when the remote control function is activated by the
Control Unit. Steps for activating the remote control function:
(1) Power on the Control Unit;
(2) Press the “Power On” button on the Control Unit screen. Please refer to （Figure 3.8—1
Appearance of Remote Control Panel）for the position of the button;
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(3) Switch “Remote/Local” on the Control Unit screen. Please refer to Figure 3.5-3 for the
position of the button;
(4) Press the “Sure” of the Remote Control Request. The remote control function is activated.
Please refer to the Figure 3.5—14 Remote Control Request.
If you want to check whether the function is activated successfully, please carry on the following steps:
(1) Enter the main screen of the Control Unit;
(2) Enter the Pipe screen;
(3) If the box at the top shows , the operation is successful.
At this time, the Remote Control Panel functions as the Control Unit to operate the system, to monitor
the operation status of the system, and to check the alarm information.
Reading
Please refer to Section 3.5.4 c) Function Area for the steps to activate and check the
remote control function.
3.8.3. Main Parameter
Table 3.8—1 Main Parameters of Remote Control Panel

Dimension(L x W x H) 338 x 443 x 132(mm)
Weight 5 Kg
Material Cold plate Q195
Input Signal RS485
The adjustment and control of the Remote Control Panel is the same with the Control Unit.
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3.9. Power Distribution Unit
3.9.1. Appearance
2 3
4 6
5
9
7 8
Figure 3.9—1 Appearance of Power Distribution Unit
1 － Main switch, to realize door opening and electrical outage;
2 － Amperemeter, to show the electric current of backflushing pump ;
3 － Timer, to show the backflushing time;
4 － The 440 V power light, the 440 v electric has been through;
5 － Lights, to indicate running of backflushing;
6 － The test lamp, to indicate running of backflushing;
7 － The 220 V power light, the 220 v electric has been through;
8 － Lights, to indicate running of backflush pump heater;
9 － Emergency stop button, Power off in emergency situations
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2 3 4 5 24
8 16
9
10 17
11
12 15
13
14
7
18
20
6
19
21
23
22
Figure 3.9—2 Layout of Components of Power Distribution Unit

Table 3.9—1 Function List of Main Parts of Power Distribution Unit
NO. ITEM Name Function
1 QF14 Main switch Shut down the power when door open
2 KA12 Intermediate relay To control back-flushing pump by Filter Control Box
3 KA13 Intermediate relay To control the heater of pump motor by Control Unit
4 KA14 Intermediate relay To control three phase main power by Control Unit
5 KA16 Intermediate relay To control the heater of motor by botten
6 QF52 Motor starter To protect the Cleaning Pump motor
To control the power-on and power-off of the
7 KM52 AC contactor
Cleaning Pump
8 QF15 Breaker To protect the Control Unit (AC220V)
9 QF16 Breaker To protect the Spare (AC220V)
10 QF17 Breaker To protect the Neutralization ( AC220V)
11 QF18 Breaker To protect the Monitor Unit (AC220V)
12 QF19 Breaker To protect the Heater (AC220V)
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13 QF20 Breaker To protect the Spare (AC220V)

14 QF21 Breaker To protect the Transformer
15 KM13 AC contactor To control the AC 220V power-on and power-off
To control the power-on and power-off of heater of
16 KM14 AC contactor
back-flushing pump motor
17 KM15 AC contactor To control the power-on and power-off of the heater
18 SMPS Transformer To change AC440V to DC24V
19 QF12 Motor starter To protect the Backflushing Pump
To control the power-on and power-off of
theBackflushing Pump
To control the power-on and power-off of all the three
phase
22 QF11 Breaker To protect EUT power electric current
23 TA1 Current transformer To detect the working current of Backflushing Pump
24 QF53 Breaker To protect the Neutralization(AC440V)
3.9.2. Function
The Power Distribution Unit is the power supply control equipment of OceanGuard® Ballast Water
Management System.The input for the Power Distribution Unit is AC 380/440V and AC 110/220 V
(from ship), while the output is AC 380/440 V, AC 110/220 V and DC24V. AC 380V/440 V is for the
EUT Unit Power, the Filter, cleaning pump and the Backflushing Pump; AC 110/220 V is for the
Control Unit, Neutralization Unit, cooling system of EUT Power and the TRO Meter; DC 24 V is for
the Flow Meter and FCB.
3.9.3. Parameters
Table 3.9—2 Main Parameters of Power Distribution Unit
HMT-300PDU HMT-450~HM HMT-800~HM HMT-2000~H HMT-4000PD

Parameters
（below） T-600PDU T-1500PDU MT-3000PDU U
Dimension 600x270x1000 630x270x1240 650x350x1720 900x420x1720 1100x450x1750

(L x W x H) (mm) (mm) (mm) (mm) (mm)
Weight 64 Kg 75 Kg 147 Kg 170 Kg 190Kg

Material of Box Structural carbon steel (Q195)
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Under normal conditions, please keep all the “Breakers” on and keep two motor starter (Figure 3.9—2
Layout of Components of Power Distribution Unit) in the “1” points in the PDU. Before operating the
BWMS, please rotate the main switch on the PDU panel to the “On” point, and all components will be
powered on. At the end of BWMS work, please do not forget to rotate the main switch to the
“off”point.
Note
The motor starter (Figure 3.9—2 Layout of Components of Power Distribution Unit)
should keep in “1” point under normal state. When the motor is over current, the
motor starter will turn off and rotate to “0” point automatically. If the BWMS need
to run again, the starter should be rotate to “1” point by manual. Or it will result in
the abnormal work of filter, and make damage to whole system.
3.10. Neutralization Unit
3.10.1. Appearance
Neutralization Unit mainly consists of neutralization barrel, metering pump, control box, fixing
support, blender, injection valve, safety valve, and pressure gauge etc.
Figure 3.10—1 Neutralization unit
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3.10.2. Function and Principle
If the TRO in the tank exceeds 0.1 mg/l when the system discharges ballast water, the Control Unit
automatically starts the Neutralization Unit and automatically add certain amount of neutralizer
(sodium thiosulfate solution) into the pipes. The amount of the neutralizer is automatically controlled
by the Control Unit to keep the TRO in the water from the system lower than 0.1 mg/l. If the
Monitoring Unit detect the water discharged has a TRO that is lower than 0.1 mg/L, the Neutralization
Unit will automatically stop.
2.2g sodium thiosulfate is needed per cubic meter of water when TRO is up to 2.5 mg/L.
Neutralization Unit adds sodium thiosulfate pentahydrate into the pipes in order to remove the TRO in
the water. Please refer to the following equation:

5H2O·Na2S2O3+4Cl2=Na2SO4+H2SO4+8HCl
Sodium thiosulfate pentahydrate is white crystal powder, which is well soluble in water. It is non-toxic
and harmless, with no impact on the environment. Sodium thiosulfate pentahydrate is a water clarifier
that is often used in water-clarifying projects. In textile industry, it is used as the antichlor for bleached
cotton fabrics, the sulfur dye for dyed wool fabrics, the blush preventive agent for indigo dye, and the
antichlor for paper pulp, and so on.
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R BWMS
Figure 3.10—2 Control Principle of Neutralization Unit
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3.10.3. Main Parts
Figure 3.10—3 Components of Liquid-Adding Equipment
Table 3.10—1 Function List of Main Parts of Neutralization Unit
NO. Name Function
1 Dosing port Dosing port of solid neutralizer
The outlet where neutralizer goes into ballast water

2 Neutralizer outlet
pipe line
The outlet where drain waste water and the
3 Overflow& Drain outlet
overflow water go out
4 Running lamp Indicating the neutralizer injection
5 Mixing button Open the agitator
6 alarm system Alarm when Neutralization Unit breaks down
Realease the pressure when the pressure in the

7 Safety valve
neutralization pipe line exceeds rated value
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Fresh water is injected into neutralization unit

8 Freshwater injection port
from this port
9 Solenoid valve To control the inlet water
Drive the agitating of neutralization liquid

10 agitator gear motor
medicine
Detect liquid level in the neutralization water tank
11 level sensor
at any time and alarm timely
Display the pressure value in the pipe line of
12 Pressure gauge
Neutralization Unit
13 Neutralization junction box Electrical wiring box
14 Metering pump Pumping the solution
15 Lifting eye Lifting Neutralization Unit
Table 3.10—2 Technical Data of Neutralization Unit
Depth Width Height Volume Maximum Flow

Model Matched BWMS
(mm) (mm) (mm) (L) Rate of Dosing
Type
Pump (L/h)
HMT-50
HMT-100
HMT-60N 760 750 1165 60 9.5
HMT-200
HMT-300
HMT-450
HMT-100N 760 750 1365 100 26 HMT-600
HMT-800
HMT-1000
HMT-1200
HMT-300N 786 786 1564 300 52
HMT-1500
HMT-2000
HMT-2500
HMT-600N 825 825 1784 600 90 HMT-3000
HMT-4000
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3.10.5.1. Control Process of Neutralization Unit
The Neutralization Unit needs one set of TRO Meters which is installed in the Monitoring UnitInlet 1#
is located in front of the Neutralization Unit, and inlet 2# is located after the Neutralization Unit.
When the value reaches 0.1 mg/L, the system will automatically continue to add neutralizer. Inlet 2# is
used to detect the TRO concentration in the discharged ballast water, which has been neutralized.
When the value is lower than 0.1 mg/L, the system will automatically stop adding neutralizer. By the
way, if de-ballast water’s TRO value is over 0.1 mg/l, an alarm will be shown in the control unit which
remind the crew onboard should check and confirm the neutralizer has been added, or even the outlet
valve not open.
3.10.5.2. Process of Controlling Liquid Level in Neutralization Barrel
Only when sodium thiosulfate dissolves in certain amount of water (solvent), it can produce neutralizer
with proper concentration. Water will be automatically added by the Control Unit. Sodium thiosulfate
will be manually added after the Neutralization Unit alarms.
There are various liquid level switches in the neutralization barrel. They are used to realize different
functions.
(1) There are four liquid levels, which are low low, low, high and high high. They can realize the
following functions:
 Low low level: Shut down;
 Low level: Alarm, prompt to add sodium thiosulfate;
 High level: Stop adding water.
 High High Level: Water over flow.
(2) When the liquid level is at or lower than the low level, the Neutralization Unit sends acoustooptic
alarms to prompt for adding the sodium thiosulfate manually. When the sodium thiosulfate is
added manually, the “Mixing” button shall be pressed manually. The water valve will
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automatically open and the blender starts to work. The blender will automatically shut down after
10 minutes. The system will automatically detect the water level. When it reaches the high level,
the valve will automatically close.
(3) The process of controlling the liquid level and the control of neutralizer belong to two different
systems. The metering pump may be always working during the process of controlling the liquid
level.
3.10.5.3. Function Selection
Figure 3.10—4 Operation Panel of Neutralization Unit
 “Alarm” —Alarm light for liquid level in the neutralization barrel when it reaches the low level
 “Mixing” —Button, used to eliminate the alarm, open the water valve, and start the blender
 “Run” — Button,indicating the neutralizer injection is running.
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Chapter 4 Packing, Transportation and Storage
4. Packing, Transportation and Storage
4.1. Packing
4.1.1. Packing Marks
Keep dry, this mark indicates that the cargo shall be kept dry, be protected from humidity
and rain.
This way up, the package must always be transported and stored in such a way that the
arrows always point upwards. Otherwise, the equipment in the package can be broken
easily.
Fragile, this symbol indicates that fragile goods are contained in the package, which shall
be protected from squeeze and vibration when it is transported, loaded or unloaded.
Recycle, indicating that the packing material can be recycled.
4.1.2. Packing Method
OceanGuard○
R Ballast Water Management System is separately packed by parts. Please follow the
packing list to check the equipment before they are separately packed. The packages shall meet the
requirements for long-distance transportation by sea or by land.
Design basis for packing:
 Means of Transportation
 Weight
 Volume
 Nature of Equipment
4-1
Chapter 4 Packing, Transportation and Storage
4.1.3. Notice for Packing
Caution
1. If any lifting equipment is required (such as forklift, crane), the carrying
capacity of the lifting equipment should be heavier than the net weight of the
equipment that is to be lifted. If there are rings on the equipment, it can only be
lifted with ring bolts.
2. The lifting and hoisting equipment shall be operated by experienced personnel.
3. Please vertically place Filter, EUT Unit, EUT Power and Neutralization Unit.
Note
To prevent equipment from being damaged during transportation, the packing
status prepared by the manufacturer shall be kept before the equipment reaches the
installation site.
4.2. Mode of Transportation
In general, OceanGuard○
R
Ballast Water Management System is transported by trucks in China and by
ocean-going cargo ships to aboard.
During the transportation, the instructions of the packing marks shall be strictly followed so as to avoid
the equipment from being damaged.
Information
When the equipment reaches the client, please check carefully whether the packing
is damaged or not. Check the equipment according to the packing list. If there is any
problem, please contact the manufacturer.
4.3. Storage
All equipment shall be stored together at one place according to the packing list, so as to avoid the
parts from missing.
The equipment shall be stored in rooms which are rain-proof and humidity-proof, with little
mechanical vibration; shocks shall be avoided; the temperature shall be -20～+60 ℃; and the
humidity shall be less than 90%.
4-2
Chapter 5 Installation
5. Installation
5.1. Unpacking
Information
1. Before unpacking, please check the external packing and observe whether there is
any damage.
2. After unpacking, please check to see if the quantity of the parts complies with the
packing list.
3. Unpacking shall be carried on only when it is allowed by the space ad environment.
4. As for some large equipment, such as the EUT Unit and the Filter etc., please use
lifting or hoisting equipment to lift them.
Note
During the process of unpacking, do not use sharp tools so that damages to the
equipment or instruments can be avoided.
If there is any problem, please contact the manufacturer immediately.
Caution
During the process of lifting and hoisting, the operation instructions shall be strictly
followed to ensure the safety of related personnel.
5-1
5.2. Installation
5.2.1. Installation Requirements
5.2.1.1. Environment Requirements
Table 5.2—1 Requirements on Installation Environment of BWMS
Site Indoor
Environment
-20 ℃ ~ +60 ℃
Temperature
Relative Humidity 5~90 % (non-condensing)
Avoid sunlight, dusts, corrosive gas, inflammable gas, fog, steam, and
Environment
water-drop etc.; avoid condensing caused by sudden temperature changes.
Interval Save at least 0.5 meter at the left and the right sides
5.2.1.2. Personnel Requirements
The equipment can only be installed by people with the following qualifications:
 Be familiar with regulations related to working safety and safety protection; be trained.
 Understand how to install and use this system properly
 Have read this manual and fully understood the contents
 If the installation needs to be done by professional personnel, only people with related
qualifications can carry on the installation, including jobs such as electrical connection and
welding etc.
 If safety protection is needed, the installation people shall put on clothes and operate as required
by the safety rules
5.2.1.3. Tools and Instruments
 Equipment installation: chain block, harnesses, adjustable wrench, fork wrench, and crowbar.
 Piping installation: chain block, harnesses, adjustable wrench, crowbar, copper tubing cutter, and
copper tubing bender.
5-2
 Cable installation: wire stripper, crimping pliers, adjustable wrench, slotted screwdriver, Philips
screwdriver etc.
Table 5.2—2 List of Installation Tools

NO. Image Name
1 Chain block
2 Harnesses
3 Adjustable wrench
4 Fork wrench
5 Copper tubing cutter
6 Copper tubing bender
7 Wire stripper
5-3
8 Crimping pliers
9 Slotted screwdriver
10 Philips screwdriver
11 Crowbar
5.2.1.4. Material Requirement
The connection pipe between the compontents of BWMS, i.e. between the filter and EUT Unit,
between filter and backflushing pump, is supplied by shipyard, with material #20 seamless steel.
5.2.2. Principles for Installation and Positioning
Generally, the BWMS is positioned at the bottom of a ship’s engine room, the same floor with ballast
pump. All other parts except the Remote Control Panel are installed here and connected to the Remote
Control Panel in the engine control room through 485 signals.
When installed on ex-proof vessels such as oil tankers or chemical tankers, the Ex-type componts
(Filter, EUT, Monitoring Unit and Flow Meter) should be installed in Pump room, the rest should be
installed in engine room.
In case that there was no enough space in engine room, the system can be installed on a sealed space
on deck with the environmental temperature of 0-55°C.
The layout principle of the equipment is:
5-4
a) Filter
 The Filter shall be close to the ballast pump area. As far as possible, it shall be positioned
above the girder and frame of the ship structure.
 Save enough space above the Filter for carrying on maintenance and replacing the filter
elements.
 To ensure convenient connection to the inlet and outlet of the Filter with the ballast pump
and the pipes of EUT Unit; to avoid excessive circuitous piping and to many elbows.
 To save enough space around the equipment for maintenance.
 To save enough space around the Filter Control Box for maintenance and operation.
 Filter must be installed at the outlet of pump, and a check valve should be installed at the
outlet of the filter, to prevent damage to filter screen which caused by instantaneous negative
pressure and back pressure due to sudden water-stopping.
 Network for installation shall be stable and be controlled in the required range. In order to
protect the filter from damage, measures shall be taken to lower the pressure if the pipeline's
pressure is exceeding the limit.
 Filter shall be vertically or horizontally installed. Sewage outlet shall not upwardly installed
(otherwise, a back-flushing pump is necessary). Minimize elbow during installation to ensure
smooth drainage.
 Pressure gauges shall be equipped for inlet/outlet pipes, for the observation of filter’s
operation pressure and pressure loss.
 Before Installation, there shall be some measures to prevent impurities such as slag, overlap,
and so on from getting into the filter, especially the outlet. If impurities got into the filter due
to mistake, the filter, bypass pipe and cleaning pipe must be cleaned thoroughly with vacuum
cleaner. Make sure these parts are clean to prevent the spray nozzles from blocking.
5-5
b) EUT Unit
 The EUT Unit shall be close to the Filter and the ballast pump area. As far as possible, it
shall be positioned above the girder and frame of the ship structure.
 To save enough space for installing and replacing the electrocatalysis module.
 To ensure convenient connection of the EUT Unit with the Filter’s piping.
 To save enough space around the EUT Unit for maintenance.
c) Electrical equipment such as EUT Power, Control Unit, and Power Distribution Unit etc.
 Electrical equipment such as the EUT Power, Control Unit, and Power Distribution Unit etc.
shall be positioned together and shall be close to the Filter and the EUT Unit for the
convenience of collective control and management.
 The EUT Power and the EUT Unit shall be as close as possible, so as to reduce the energy
loss during transmission.
 To ensure convenient observation of the operation of above mentioned electrical equipment.
There should be no piping flanges above them; and there should be spaces for the installation
of cable.
d) Neutralization Unit
 It should be convenient to operate the Neutralization Unit and to observe the pressure gauge
on the pipes.
 The shorter the liquid-adding pipe (pipe between the Netralization Unit and the liquid-adding
point), the faster and more sensitive of the Neutralization Unit.
 To ensure that the control box of the Neutralization Unit can be operated easily.
5-6
 There should be no flanges above the Neutralization Unit, to prevent water from leaking to
the blending motor.
e) Backflushing Pump
 The Backflushing Pump shall be positioned around the Filter. The suction port of the pump
shall be lower than the backflushing port of the Filter if possible.
 The connection between the Backflushing Pump and the backflushing port of the Filter shall
be simple, to avoid too many elbows in the suction port piping.
f) Cleaning Pump
 The cleaning pump shall be positioned around the Filter.
 Make sure that the rotation direction of motor is right.
 The connection pipe should be as short as possible to avoid too much pressure loss.
 Please keep the pipe clean before installation the cleaning pump.
g) Flow Meter
 The meter can be installed along a straight pipe or on a horizontal or oblique pipe. But the
connecting line between both electrodes has to be horizontal.
 Tight flow of medium is required for the pipe where the installation is carried on. Loose flow
and electrodes with air shall be avoided.
 Vertical installation shall be adopted so that the wear of the sensor’s lining shall be even and
the service life can be extended.
 If the installation place for the Flow Meter does not have tight flow of medium, the second
half of the pipe can be raised to get tight flow. It is prohibited to install the Flow Meter at
tiptop and the water outlet of the pipe
5-7
Figure 5.2—1 Installation Diagram of Flow Meter
 Installation method of modifying pipes:
If the flow speed of medium cannot meet the requirement, an Flow Meter with smaller
diameter shall be chosen. In this case, a reducing pipe shall be used or part of the pipes shall
be modified to make the flowmeter have the same diameter with the sensor. But it is
suggested that the length of the first and second halves of the straight pipe shall be: the first
half ≧3DN, and the second ≧2DN, better if the first half ≧5DN, and the second ≧2DN
(DN is the diameter of pipe).
 To ensure convenient operation of the Flow Meter.
h) Monitoring Unit
 The hole position of the inlet pipe of the Monitoring Unit on the ballast piping shall not be at
the dead corners of the piping, but shall be at places where the medium is flowing.
 The shorter of the inlet pipe of the Monitoring Unit the better, this would improve the
response time of the TRO Meter.
 The position of the sampling pipe shall be after the EUT Unit and shall avoid the position
near the electrical equipment.
 Please inject the effluent back into the main pipeline of ballast water. The injection point
5-8
must be in the upstream position of the Neutralizer injection port.
i) Valve
 The manual valve shall be placed above the checker plate, with no blocking around the
handle.
 The pneumatic valve shall be placed at a position where the open and close of the valve can
be observed.
j) Cables
 Cables shall be laid on cable bracket of flat steel with holes or steel plate with holes, and be
fastened with cable ties.
 Cables shall not be laid below a checker plate. If it has to be below a checker plate, it shall be
protected with a steel pipe.
 Cables shall not be laid in areas with high temperature or high humidity.
 Clear and durable labels or marks shall be put at the both ends of cables for identification.
 Signal cables shall be strictly separated from other power cables to avoid been affected. They
are not allowed to be laid in the same pipe or in parallel. They shall not be stranded together,
but shall be put in separate pipes.
5.2.3. Installation Steps
5.2.3.1. Installation of Base
 Make bases for the equipment according to the drawings, and paint them.
 Lift and move the bases to the installation positions
 Check the consistency between the bases and the structure
 Weld the bases for the equipment
 Check the quality of the welding lines
5-9
5.2.3.2. Installation of Equipment
a) Check before Installation
 Check whether the model, specification and quantity of the products are consistent with the
drawings, and whether the attachments of products are complete
 Check whether there are any scratches, damages or pollutions on the surface of products
 Check the cleanness and anti-rust status of the joint of the equipment
 Check whether any of the internal parts of the equipment is missing
b) Installation of Equipment
 Lift the equipment with a crane and move it into the engine room through the hoist hole; to
move the equipment to the installation area with the engine room crane.
 Move the equipment to the above of the base with a chain block. The foundation of
equipment shall be connected and locked to the base with single nuts and spring washers
(welded gasket is not necessary).If there is any space between the foundation of equipment
and the base, three layers (at the most) steel or copper plates shall be used as gasket.
 Prepare enough fastening bolts, washers, and nuts. Use a wrench to fix the anchor bolt.
When it is done, the head of the bolt shall have 1-2 pitches emerged.The bolts for the Filter
and the EUT Unit shall be of class 8.8.
c) Protection after Installation
 Each of the equipment shall be covered with three-anti cloth. Fragile instruments such as the
differential pressure gauge etc. shall be protected with steel plate.
d) Integration and Connection of System
 Make outboard holes for the backflushing piping
○
1 Weld the overboard pipes (class II) on the ship structure. While the outboard pipes are
welded, both sides need to be welded. The pipes shall be 10-15 mm out of the board and
strengthened with web plates or knee plates (the thickness of an outboard pipe and a web
5-10
plate shall be less than the thickness of the side plate of the ship).
○
2 A flaw detection and a 5-kilogram watertight test shall be carried out after the welding.
 Connection between Equipment
○
1 Based on the layout of equipment such as the ballast pump, the Filter, the EUT Unit etc.
and the accessories of the equipment, with the schematic diagram of the piping system, a
drawing for connecting piping and piping support shall be made.
○
2 Produce pipes and supports, and galvanize them.
○
3 Connect the pipes and equipment with bolts and rubber gaskets; support them with
supports.
○
4 Based on the positions of the Filter, the Backflushing Pump and the outboard outlet,
produce the suction pipe and the discharge outlet pipe of the Backflushing Pump, and
galvanize them; connect the pipes and accessories according to the schematic diagram.
○
5 Make cooling water pipe based on the positions of the EUT Power and the cooling water
pipe for low-temperature fresh water. Connect the pipes and accessories according to the
schematic diagram.
○
6 The Monitoring Unit and ballast water main pipe are connected with an 8mm copper pipe.
The inlet pipe and outlet pipe of the Neutralization Unit are also connected to ballast
water main pipe with an 8mm copper pipe. The copper pipes shall be fixed with
tetrafluoroethylene pipe clamps.
○
7 The pneumatic valve and the gas pipeline shall be connected with an 8mm copper pipe.
The copper pipe shall be fixed with tetrafluoroethylene pipe clamps.
○
8 When the piping system is installed, check the completeness of the pipes, and check
5-11
whether the positions of the accessories are reasonable.
○
9 Carry out a watertight test of the piping system.
 Connection of Cables between Equipment
○
1 Connection of the internal cables of the equipment has been done in the factory. Only the
cables between each equipment and cables between the equipment and the engine control
room shall be connected. The cables shall be arranged according to the electrical
schematic diagram and the arrangement diagram of cables between the electrical devices.
○
2 Connect the cables with the electrical equipment according to the connection diagram.As
for the multi-core cables, the terminals shall be equipped with proper cable pins or joints.
5.2.4. Notes for Installation
5.2.4.1. Filter
PART A: HMT-F Series
Caution
Incorrect installation may cause accidents.

To avoid accidents and damages to equipment caused by installation, please do
follow the following instructions:
1. The Filter has to be installed by professionals.
2. Proper working clothes shall be worn during the installation.
3. Handling tools and devices with sufficient power shall be used when moving or
lifting the Filter.
4. While moving the Filter, its gravity core should be kept in balance to prevent the
Filter from tilting.
5. While moving or lifting the Filter, please do not stand or work under the Filter.
5-12
Reading
Before the installation, please read the installation and positioning principles of the
Filter (section 5.2.2(a)) carefully.
(1) Fix
Figure 5.2—2 Fixing Base for Filter

1. Supporting Channel Steel
2. Fixing Plate
 Please keep the floor even and solid.
 Vertical and horizontal calibrations for the Filter.
 To fix the Filter on the ground with foundation bolts that match the specifications of the
fixing plate. The force applied to the bolts shall be even in order to avoid stress on the Filter.
Information
1. The Filter is design for internal pressure. Please keep its body and the flanges from
external load.
2. Based on the quality of water that is to be filtered, pre-filtration is suggested before

use Headway’s Filter. The filtration accuracy of pre-filtration equipment shall be 5mm.
3. The inlet/outlet of Filter and the backflushing port on the Filter has already been
marked.
(2) Connection off the Inlet and Outlet of Filter with the Ballast Main Pipe
 The connection flange of filter and ballast water main line shall be aligned and calibrated.
 Proper gaskets shall be used.

5-13
 Pipes connected to the inlet and outlet of the Filter may need extra support. This depends on
the installation environment. The inlet and outlet of the Filter shall not be affected by high
load.
(3) Connection of Back-flushing Port

 The back-flushing port and the connection of ballast water pipe shall be aligned and
calibrated.
 Pipes connected to the back-flushing port may need extra support. This depends on the
installation environment. The back-flushing port shall not be affected by high load.
 The diameter of the pipe connected to the back-flushing port shall be bigger than the
diameter of the back-flushing port. Back-flushing pipe with smaller diameter may cause
backpressure and thus influence the back-flushing efficiency. The outlet of the back-flushing
pipe shall be lower than the back-flushing port of the Filter in order to prevent polluted water
from flowing back under the back pressure.
(4) Connection of Back-flushing Pump
 Install the foundation of the Back-flushing Pump on the base and fix it with bolts.
 The inlet and outlet port of Back-flushing Pump and the ballast pipe mouth shall be aligned
and calibrated
 The weight of pipes shall not be applied to the Back-flushing Pump.
(5) Connection of Compressed Air Pipe (only for back-flushing pipes with pneumatic valve)
 Connect the compressed air pipe to the compressed air port of the electromagnetic reversing
valve.
(6) Connection of Hydraulic Pipes (only for back-flushing pipes with hydraulic driven valve)
 Connect the hydraulic pressure source to the hydraulic pressure port of the electromagnetic
reversing valve.
5-14
(7) Fixing filter Control Box (FCB)
155
330
290
O PERATING SPAC E
460
420
370
325
500
Figure 5.2—3 Installation Sketch for FCB
Danger
When the equipment’s power is connected, the voltage of power supplying may
cause electric shock accidents.All of the electrical connections shall be carried out by
professional electricians under the instructions of electrical engineers
Note
1. Be careful of equipment malfunctions or damages
2. Delayed handling of alarms may easily cause malfunctions of or damages to the

filer.
5-15
PART B: S-ZF Series

(1) Installation Arrangement
(a) Horizontal Type
(b) Vertical Type

Figure 5.2—4 Installation Arrangement
(2) Installation Procedure

a) When using safe and appropriate methods to open the packing box, you should check the
number of products, random parts and accessories in the productlist. Checking instrumentation
5-16
equipment whether damage or malfunction in transportation. Without question, the following figure
illustrates a safe method using ropes or special lifting hook for lifting, pay attention to the lifting
process to maintain a balance; any question, please contact Technical Services personnel.
Lifting Position
Lifting Position
吊装位置
吊装位置 Lifting position
Lifting position
(a) Horizontal Type
Lifting Position
Lifting Position 吊装位置
吊装位置 Lifting position
Lifting position
(b) Vertical Type

Figure 5.2—5 Lifting Positions
5-17
b) Lifting the filter to theinstallation position by site construction drawings, you should adjust
the filter to the direction. The filter shall be placed smoothly and slowly in the installation position,
then fastened with bolts.
c) Flushing piping installation, wiring fitted by the shipyard construction drawings based
validation, please read the relevant instructions carefully before pumps, valves and other
componentsfitted flush the pipeline. However, cleaning pump is fixed to the filter housing, skip this
step and continue to refer to the following installation steps.
d) Inlet and outlet piping, back-flushing piping installation, wiring fitted by the shipyard
construction drawings based validation, please read their instructions carefully before pumps, valves
and other components fitted flush the pipeline.
5.2.4.2. EUT Unit
Reading
EUT Unit (section 5.2.2(b)) carefully.
(1) Fixing
 EUT Unit cannot be used as the fixing point along the pipe.
 The EUT Unit has to be fixed under no pressure. No pipe pressure shall be applied to the
equipment.
 The equipment’s shell shall be horizontally or vertically installed on the horizontal surface;
and the bottom corners shall be fixed with bolts.
 We recommend the vertical installation mode. The water will be more stable with the vertical
installation.
5-18
FLANGE TYPE
ONLY FOR
1500-4000
电
缆
进
出
口,
从
此
侧
面
开
PG
孔
FLANGE TYPE
ONLY FOR
1500-4000
Figure 5.2—6 EUT Unit installation size chart

Table 5.2—3The Size list of EUT Unit
Model Inlet and outlet of A B C D E F G H
diameter
HMT-50E DN125 1530 —— 445 381 —— —— —— ——
HMT-100E DN125 1530 —— 445 381 —— —— —— ——
HMT-200E DN150 1530 —— 527 381 —— —— —— ——
HMT-300E DN200 1701 —— 612 426 —— —— —— ——
HMT-450E DN250 1821 —— 707 456 —— —— —— ——
HMT-600E DN250 1957 630 707 505 320 260 φ18 1000
HMT-800E DN300 1957 630 844 505 470 410 φ18 1000
HMT-1000E DN350 2123 730 817 605 320 260 φ22 1100
HMT-1200E DN400 2123 732 892 605 470 410 φ22 1100
HMT-1500E DN400 2208 786 884 663 470 410 φ22 1100
HMT-2000E DN500 2208 866 1022 663 620 560 φ26 1200
5-19
HMT-2500E DM500 2212 898 1187 695 720 660 φ26 1200
HMT-3000E DN600 2222 898 1187 695 720 660 φ26 1200
HMT-4000E DN700 2222 898 1187 695 720 660 φ26 1200
(2) Connection of Water Inlet and Outlet
 The water inlet and outlet of the EUT Unit and the mouth of ballast water pipe shall be
aligned and calibrated.
 Suitable gaskets shall be used.
 Pipes connected to the water inlet and outlet of the EUT Unit may need extra support. This
depends on the installation environment. The water inlet and outlet of the EUT Unit shall not
be affected by too much load.
(3) Connection
Figure 5.2—7 Connection Sketch of EUT Unit (HMT-600 for example)
Note: Those included in the square area are the internal connections of the EUT Unit
1— Conductive Copper Plate
2— Protective Shield for Electrode
3— Connection Terminal for External Cables
Danger
Connections for the electrical part may have voltage that could put life in danger.
Only authorized professionals (electricians) may carry out the connection.
5-20
5.2.4.3. EUT Power
Reading
EUT Power (section 5.2.2(b)) carefully.
(1) Notes
a) The power shall be horizontally installed on a structure that have enough spaces for heat
dissipation and can stand for high temperature. Inversion or tilt is not allowed for the installation.
b) Keep other articles such as fabrics, scraps of paper, wood chips and metal pieces etc. out of the
power.
c) All of the phases of the power cord (three phases) shall be connected. Otherwise, the machine
may not be working or get damaged.
d) Ensure good conductivity of the contact surface (smooth, without burrs); to fix with copper
screws or stainless steel screws.
e) The grounding terminals shall be well grounded so that electrical shocks or fire accidents can be
avoided.
f) The anode and cathode of the output of EUT Power and the anode and cathode of the inlet of EUT
unit shall be connected according to the technical requirements.
(2) Installation of EUT Power
Figure 5.2-8 Installation Dimension of Power Base (Unit: mm)

5-21
Table5.2-5 The Size List of EUT Power

Model A (Unit: mm) B (Unit: mm) C (Unit: mm) D (Unit: mm)
HMT-50PE 200 550 300 751

HMT-100PE 200 550 300 751
HMT-200PE 200 550 300 751
HMT-300PE 200 550 300 751
HMT-450PE 200 550 300 751
HMT-600PE 200 550 300 751
HMT-800PE 200 650 300 1000
HMT-1000PE 200 650 300 1000
HMT-1200PE 200 650 300 1000
HMT-1500PE 200 750 300 1100
HMT-2000PE 200 750 300 1100
HMT-2500PE 300 750 300 1150
HMT-3000PE 300 700 300 1150
HMT-4000PE 300 700 300 1500
5-22
5.2.4.4. Control Unit
The Control Unit is supplied as a whole. Connections inside the unit has already been done.
Reading
electrical equipment (section 5.2.2 (c）) carefully.
(1) Installation of Control Unit
Figure 5.2—8 Installation Dimension of Control Unit

The base for the equipment is installed on a horizontal plane and the bottom corners are fixed with
bolts.
(2) Installation of Control Unit
Figure 5.2—9 Maintenance Space of Control Unit

5-23
5.2.4.5. Monitoring Unit
(1) Fixing Box

 There are two kinds of Monitoring Unit installation: floor and wall-mounted.
Figure 5.2—10 Floor Installation of Monitoring Unit
Figure 5.2—11 Wall-mounted Installation of Monitoring Unit
5-24
5.2.4.6. Remote Control Panel
(1) Installation of Remote Control Panel
(a) Wall Embedded Type
(b) Wall Hanging Type

Figure 5.2—12 Installation Dimension of Remote Control Panel
5-25
5.2.4.7. Flow Meter
Reading
Flow Meter (section 5.2.2(g)) carefully.
(1) Fixing
 The pipe mouth of the Flow Meter and the mouth of ballast water pipe shall be aligned and
calibrated.
(2) Connection
Figure 5.2—13 Definition of Connection Terminals
Table 5.2—4 Meanings of Labels on Connection Terminals
Terminals Function Specification Set Location
L, N Power Line DPYCS-0.75(24V) 1 From PDU to Flow Meter
From Control Unit To Flow

A1, B1 Signal Line DPYCS-0.75 1
Meter
5-26
(3) Grounding
 In order to avoid problems caused by static electricity, a ground wire (with a sectional area
not less than 4mm) shall be connected.
 The ground wire shall be connected to a ground bolt (Figure 5.2—13 Definition of
Connection Terminals).
(4) Check after Installation
After the Flow Meter is connected to the ballast water pipe, the followings shall be checked first:
 To fasten and connect the pipes in front of and behind the sensor with copper wires.
 To well ground the sensor.
 To ensure stable creation of the oxidation film on the electrode of the sensor (48 hours after
the continuous contact between the electrode and water).
5-27
5.2.4.8. Power Distribution Unit (PDU)
Reading
electrical equipment (section 5.2.2 (c)) carefully.
(1) Notes
 During the installation of PDU, it should be kept vertical to the horizontal plane. The four
fixing corner should be fixed reliably. No metal pieces are allowed into PDU.
 When the installation is over, shrink the PG port to ensure that the incoming and outgoing
wires stay tight.
 Before powering on, make sure that the incoming and the outgoing wires are correctly
connected; and the intermediate relay stays tight.
Danger
1. The electrical part may have voltage that could put life in danger. Only
authorized professionals (electricians) may carry out the connection.
2. When carrying on maintenance, make sure that the breaker is disconnected.
3. Under power-on status, PDU should not be opened as far as possible, so as to avoid
the danger of electric shock.
4. Non-professionals are not allowed to work on PDU, so as to avoid unwanted

danger.
5-28
(2) Installation of PDU
Figure 5.2—14 Installation Dimension of PDU
Table 5.2—5 Dimension of Operating Space of PDU
HMT-300PD HMT-450~H HMT-800~HM HMT-2000~H HMT-4000PD

Type
U( below ) MT-600PDU T-1500PDU MT-3000PDU U
A Type 807x522 900x600 874x565 - -
B Type - - - 1500x450 1700x450
5-29
(3) Connection
Information
(1) Be sure there is no tangles or short circuits among lines. The connections are solid,
without losing.
(2) Following the connection instructions of the paster in the box, to connect the power
lines and signal line to the corresponding connection terminals.
Danger
Pay attention to the corresponding relations. The connections should be reliable.

There is no bare wire exposed outside the terminal bar.
Table 5.2—6 Power Voltages of Parts of Ballast Water Management System
Type Power Supply Power Supplying Parts
AC440V/380V Power supplying system for ships
AC220V/110V Power supplying system for ships

Power Input
Power supplying for control signals (Filter), coming
out of the Control Unit
DC24V
Power supplying for control signals (Backflushing
Pump), coming out of the Control Unit
EUT Power
Filter
AC440V/380V
Backflushing Pump
Power Output Cleaning Pump
Control Unit
AC220V/110V
Neutralization Unit
DC24V Pump of Monitoring Unit
5-30
5.2.4.9. Neutralization Unit
Reading
Before the installation, please read the installation and positioning principles of
the Neutralization Unit (section 5.2.2(d)) carefully.
(1) Fixing
Figure 5.2—15 Operating Space for Neutralization Unit
5-31
Figure 5.2—16 Installation Dimension of Base for Neutralization Unit
The base for the Neutralization Unit is installed on a horizontal plane and the bottom corners are fixed
with bolts.
Table 5.2—7 Each Model Parameter Table of Neutralization Unit
Parameters (mm) HMT-60N HMT-100N HMT-300N HMT-600N
h 680 880 1030 1280
H 1165 1365 1589 1809
H1 951 1151 1351 1571
H2 230 230 260 240
L 760 760 1000 1200
W 750 750 1000 1200
A 135 135 165 215
B 130 130 225 275
C 130 130 375 425
D 300 300 300 300
E 400 400 400 400
F 710 710 950 1150
G 450 450 600 800
H (base) 700 700 950 1150
I 6xφ15 6xφ15 6xφ20 6xφ20
5-32
(2) Installation of Water Inlet and Outlet Pipe
Aperemeter Timer
440V Power Source
W10 G12 SB14
220V Power Source
W11 B13 S15
Figure 5.2—17 Installation Sketch of Water Inlet and Outlet Pipe
(3) Connection
Danger
The electrical part may have voltage that could put life in danger.Only authorized
professionals (electricians) may carry out the connection.
5.2.4.10. Valve
The arrangement of the manual valve shall comply with the electrical principle diagram. The valve
shall be place on a checker plate as far as possible. There should be no blocking articles around the
handle. When the valve’s handle is vertical to the pipe, it is closed.
PTFE tape shall be used on the copper air tube at the pneumatic valve to keep close connection with
the electromagnetic valve so as to avoid air leakage. From the installation position, the on/off indicator
of the switch shall be able to observed.
5-33
5.2.4.11. Sampling Point
Please locate the sampling points according to the PID diagram. In general, there are three sampling
points, the first one located in front of the filter, the second one after the EUT unit, and the third one at
the pipe overboard.
45°
Figure 5.2—18 Dimension Drawing of Sampling Port
5.2.4.12. Ballast Water Pipes
Following the diagrams to connect the system pipes, sealing gaskets shall be placed between the
linking flanges. The sealing gaskets shall be silicon gaskets or highland barley paper gaskets.
5-34
5.3. Acceptance Check
After the trial run of the OceanGuard○

R
Ballast Water Management System, personnel from the ship,
installation personnel (equipment provider and other specified people) and the ship surveyor shall
carry on a test and inspection together according to the Checklist for the OceanGuard○
R Ballast Water
Management System. The three parties shall sign and stamp on the Acceptance Report.
5.4. Notes for Prolonged Outage
Note
When the equipment is not used for a long time (15 days), attention should be paid to
the following points:
Cut off the power supply for the BWMS; Keep all devices electrically neutral;
Filter should be full of fresh water to avoid the erosion and corrosion
Close the valve at the water inlet/outlet of the BWMS;
Pay attention to the overall humidity-proof and storage of the BWMS; Prohibit
water or other medium from entering into the equipment that contains electrical
components;
At least once in a year, check the positions with sealing elements in the BWMS,
including the joints of all flanges and the thread mouth, to make sure that the sealing
elements are not aged.
At least once in a year, check all the cables of the BWMS to make sure the cables
are not stripped.
At least once in a year, check to see if all the BWMS devices are still fixed.
5-35
Chapter 6 Trial Run
6. Trial Run
6.1. Preparation
Please check to see if the power supply system for ships is working properly.
Please make sure there is no other article around the BWMS.
Please make sure that there is no conductive material or article around the EUT Power.
Please check to see if the BWMS and the piping is leaking.
Please check to see if there is any water on the BWMS equipment, or it is humid.
Please check the open/close status of the automatic valve.
6.2. Starting Up
 Turn on the switch and all breakers of the PDU
 Open the control unit and turn the breaker
 Open the FCB and turn on the breaker
 Turn on the power switch of the EUT Power
 Press the “Power On” key on the panel of the Control Unit. An interface occurs on the screen
of the Control Unit
6.3. Function Test
Reading
To start up the BWMS, please follow related instructions in Section 7.2.
Please follow the checklist carry on the function test and to fill out the forms
carefully.
6.4. Settings
Reading
All parameters of the system have been set in factory, please do not change any
setting without the instruction of manufacturer. Or it will result in the abnormal
work of the BWMS.
6-1
Chapter 6 Trial Run
6.5. Shut Down
 After the trail run, if the system will start to run formally in a short period of time.
Please follow the following steps to shut down the system:
Option 1: Control Unit Press the “POWER OFF” button on the panel of the Control Unit. The
system will automatically shut down.
Option 2: When Control Unit stand by, please refer to Figure 3.4—2 Structure of EUT Power○
2
to shut down the power of EUT Power Unit
 After the trail run, if the system may stay shutting down for a long time.
Please follow the following steps to shut down the system:
Press the “POWER OFF” button on the panel of the Control Unit. The system will automatically
shut down.
Open the Control Unit, disconnect the breaker in the Control Unit
Open the PDU, disconnect switch on the PDU panel.
Note
When the system is running, all switches are in the correct positions and all
parameters are correctly set. Arbitrary modifications are prohibited.
Modification of parameters may influence the normal work of the system.
Filter needs to be filled with clean fresh water if not planed to be used in 10 days.
Reading
Please observe the notes for prolonged outage in Section 5.4.
6-2
Chapter 7 Operation
User Manual for OceanGuard® BWMS
7. Operation
7.1. Preparation
7.1.1. Check
Please check to see if the power supply system for ships are working properly.
Please make sure there is no other article around the BWMS.
Please make sure that there is no conductive material or article around the EUT Power.
Please check to see if the BWMS and the piping is leaking.
Please check to see if there is any water on the BWMS equipment, or it is humid.
Please check to see if the automatic valve is closed.
Please check to see if the power switch inside the PDU is on.
Please check to see if the power switch inside the Control Unit is on.
Please check to see if the switch on the panel of FCB is on.
Please check to see if the power switch for the EUT power and electrocatalysis module power of
the EUT Power is on.
Please check to see if the devices work properly.
7.1.2. Preparation of Neutralizer
Figure 7.1—1 Sodium Thiosulfate Pentahydrate Figure 7.1—2 Package of Sodium Thiosulfate
Sodium thiosulfate pentahydrate is colorless or half-transparent crystal. It can deliquesce easily. So it
shall be all added to the neutralization barrel after being unpacked. For storage, don’t store it in an
environment with too high humidity.
7-1
Chapter 7 Operation
Information
If the appearance of the sodium thiosulfate pentahydrate changed after it is

unpacked, please do not use it.
Before neutralizer is prepared, please open the dosing port of the Neutralization Unit first. You will
find the device shown below.
Figure 7.1—3 Dosing Port of Neutralization Barrel (red virtual box)
Steps for preparation of neutralizer:
a) The control unit send “low level alarm ” to neutralization unit. Alarm is initiated.
b) Pleas add all neutralizer into the Neutralization barrel according to the label near the dosing
port. Then close the port cover.
c) Press the “MIXING” button on the Neutralization Unit. The alarm stops; the blender starts to
work. At the same time, water is automatically added. When the water reaches the high liquid
level, the system will stop to add water.
7-2
Chapter 7 Operation
7.2. Routine Operation
Symbols
O.B.
V12 Hand Valve

A
V11 O.B. Auto Valve
A
High
BACK-FLUSHING S S Sampling Pipe

V1 PUMP
P Pump
S
V10 F Filter
A
BALLAST V9
A
V5 EUT EUT Unit

A PUMPS A A
P F EUT FM Neutralization
V3
NU Unit
V4 V6
MU Monitoring
MU
Unit
FM Flow Meter
NU A V7
A Backflushing
Pump
V2 V8
Low
B.W.T.
Figure 7.2—1 System Operation Flow Chart of OceanGuard® Ballast Water Management System.
In the chart, the BWMS control automatically the Filter, EUT Unit, Monitoring Unit, Flow Meter,
Neutralization Unit and the automatic valve (V4, V5,V9,V11). Other devices and automatic valves are
automatically controlled by the onboard controlling system based on the demands of ballast and
deballast. Generally, Valves V6 and V12 are always kept open (except for maintenance and
troubleshooting).
The system flowchart for different handing requirements are described in details as below.
Note
Two ballast pump cannot be used at the same time in a set of equipment.
Note
The figures in Chapter 7.2 are for reference only. During the installation on vessels,
the figure(s) approved by the classification society shall prevail.
7-3
Chapter 7 Operation
7.2.1. Ballast
Start Ballasting
 Open valves V1 and V2
 Press the “Power On” key on the panel of the Control Unit. An interface occurs on the screen.
 Press the “Ballast” key on the panel of the Control Unit. Check that the following sequences
occur:
 Step 1: Open valve V4, V5 and V6
 Step 2: Check that valves V5 and V6 are open
 Step 3: Start filter, EUT unit and sensors
 Step 4: Send request to IAS to start the ballast pump
 Step 5: Wait for the stop operation input from the operator by pressing the “Ballast”
key once again
Stop ballasting
 Press the “Ballast” key on the panel of the Control Unit. Check that the following
sequences occur:
 Step 1: Shut down the filter, EUT unit and monitoring unit
 Step 2: Close valve V4 and V6
 Step 3: Check that valves V4 and V6 are closed
 Step 4: System goes into Standby mode
 Close valves V1 and V2
Reading
When the system is shut down, if it has to be shut down for a long time, please
follow the shut-down steps for prolonged outage in section 5.4 and 6.5
7-4
Chapter 7 Operation
O.B.
V12
V11 O.B.
A
High
BACK-FLUSHING S
V1 PUMP
S
V10
A
BALLAST V9
A V5
A PUMPS A A
P F EUT FM
V3 V4 V6
MU
NU A V7
A
V2 V8
Low
B.W.T.
Figure 7.2—2 Flow Chart of Ballast Operation
7-5
Chapter 7 Operation
7.2.2. De-ballast
Start Deballasting
 Press the “Deballast” key on the panel of the Control Unit. Check that the following sequences
occur:
 Step 1: Open valves V9
 Step 2: Start Neutralization Unit and Monitoring Unit
 Step 3: Wait for the stop operation input from the operator by pressing the “Deballast”
key once again
Stop deballasting
 Press the “Deballast” key on the panel of the Control Unit. Check that the following sequences
occur:
 Step 1: Close valve V9
 Step 2: Stop TRO sensors and Neutralization Unit
Reading
When the system is shut down, if it has to be shut down for a long time, please
follow the shut-down steps for prolonged outage in section 6.5.
Note
(1) Before the BWMS is started, make sure all valves are in their positions; then the
ballast pump can be turned on in order to avoid unstable pressure in the system,
which may influence the operation stability of the BWMS.
(2) During the running of the BWMS, if the system pressure is found to be too high
or abnormal, the ballast pump and the power shall be turned off immediately. The
open/close status of the valves shall be checked. After the problem is checked and
determined, the BWMS and the ballast pump can be turned on again.
(3) During the running of the system, it is prohibited to run the Backflushing Pump
without water.
7-6
Chapter 7 Operation
O.B.
V12
V11 O.B.
A
High
BACK-FLUSHING S
V1 PUMP
S
V10
A
BALLAST V9
A
PUMPS V5
A A A
P F EUT FM
V3 V4 V6
MU
NU A V7
A
V2 V8
Low
B.W.T.
Figure 7.2—3 Flow Chart of De-ballast Operation
7.2.3. Bypass
OceanGuard® Ballast Water Management System has prepared bypass keys in case of the Emergency
situation. Based on the needs of navigation safety, when ballasting or deballasting the is badly needed
Start Bypass
 Open the relative hand valves
 Press the “Bypass” key on the panel of the Control Unit. Check that thefollowing sequences
occur:
 Step 1: Open Bypass valve V9
 Step 2: Wait for the stop operation input from the operator by pressing the “Bypass”
key once again

7-7
Chapter 7 Operation
Stop Bypass
 Press the “Bypass” key on the panel of the Control Unit. Check that the following sequences
occur:
 Step 1: close valves V9
 Close the relative hand valves
O.B.
V12
V11 O.B.
A
High
BACK-FLUSHING S
V1 PUMP
S
V10
A
BALLAST V9
A
PUMPS V5
A A A
P F EUT FM
V3 V4 V6
MU
NU A V7
A
V2 V8
Low
B.W.T.
Figure 7.2—4 Flow Chart of Bypass
7-8
Chapter 7 Operation
7.2.4. Emergency Switch
Emergency
Switch
Knob
Figure 7.2—5 Position of Emergent Shut-Down Knob
OceanGuard® Ballast Water Management System has prepared the function of emergent shut-down.
This function is designed to ensure the safety of equipment and personnel. It is prohibited to use this
function except when the safety of equipment and personnel is in danger. The emergency switch knob
is located on the panel of the Control Unit. The rightmost button is the Emergency knob.
Note
The Emergency Switch can be used only under “Ballast” mode, while the “Bypass”
could be pressed under standby mode.
Start Emergency
 If there is an unexpected danger to the ship and may result in the safety of the ship, during the
ballasting process, please press the “Emergency Switch” knob on the panel of the Control Unit.
Check that thefollowing sequences occur:
 Step 1: Open bypass valve V9
 Step 2:Close valves V4 and V6
 Step 3: Shut down the filter and EUT unit
7-9
Chapter 7 Operation
 Step 4: Wait for the stop operation input from the operator by rotate the “Emergency
Switch” knob
Stop Emergency
 Rotate the “Emergency Switch” knob on the panel of the Control Unit.Check that the
following sequences occur:
 Step 1: Close valves V9
7.3. Brine / Sea Water Injection
Under the circumstance that the salinity of intake water was below 0.85PSU, the system should
provide with an Injection functionality. Injection can be controlled automatically.
When salinity is below 0.85PSU, the control system will automatically start the injection and no
manual operation will be required.
The injection flow rate is fixed based on the TRC of the BWMS , which is enough to make sure the
mixed salinity value is high than 1 PSU.
In case the salinity of intake water was 0.0PSU (S1), the salinity of sea water to be injected was 30PSU
(S21), or the purchased brine water was 300PSU (S22), the target salinity should be 1PSU (S3).
Please note that S1~S3 is used as the code for more convenience in calculation, not the salinity
parameter that needs to be monitored.
The amount to injected is calculated as:
∗（）
FM1*（S3-S1）≈FM2*S2；FM2≈
7-10
Chapter 7 Operation
O.B.
V12
APT IP
V11 O.B.
A
High
BACK-FLUSHING S
V1 PUMP
S
V13 V10
A
A
V9
A
V5
A A A
P F EUT FM1
V3 BALLAST V4 V6
PUMPS
MU
NU A V7
A
V2 V8
Low
B.W.T.
Figure 7.3—1 Flow Chart of Brine/ Sea Water Injection Operation
When injection function initiated, injection pump, valve (V13) will start working and stored sea water
will be injected into the main pipe and mixed with intake water before pump. Stired by the ballast
pump, the salinity of intake water should be above 1PSU and system will treat the water as normal
operation.
7-11
Chapter 8 System Maintenance and Routine Check
8. System Maintenance and Routine Check
8.1. Maintenance Mode
The system is provided with repair/maintenance mode, which interface can only be shown and used
inthe standby state (Figure 8.1—1 Interface of repair/maintenance mode). In the repair/maintenance
mode, no ballasting and deballasting operation can be carried out. Press the button of this mode, there
will be audible and visual alarm, prompting that the system is in repair or alarm state.
(a)
(b)
Figure 8.1—1 Interface of repair/maintenance mode
Danger
When the equipment is under maintenance/ repair mode, the voltage of power
supplying may cause electric shock accidents. All of the electrical connections shall
be carried out by professional electricians under the instructions of electrical
engineers
8-1
8.2. Maintenance
8.2.1. Filter (HMT-F Series)
8.2.1.1. Regular Check
Table 8.2—1 Maintenance of Filter
No. Maintenance Method

Maintenance Item
Frequency
When BWMS is not in operation, if the

pressure difference is higher than zero,
please take the following measures:
1. Check if the pressure gauge is

Pressure different between inlet blocked;
1 Monthly
and outlet 2. Check if the relevant lines are
blocked;
3. If the 1 and 2 are not effective,

please contact manufacturer to replace
the differential pressure gauge.
Check the sealing status of the

Fastening the bolts or change the seal
2 threaded connections and the Monthly
if there leaking
flange connections
Check to see if the Filter has been Grind rust and repaint
3 Monthly
corroded or damaged
Check to see if the fixed plate of

4 Every 6 months Fastening the bolts
the Filter is loose
5 Clean the vent Every 3 months Clean the sundries
8.2.1.2. Clean Impurities in Filter
There is a draining at the lower shell of the Filter (see Figure 3.2-1 for its position). It is used to
remove big impurity particles manually. Generally, after the Filter has worked for 300 hours (the time
is specified based on the water quality along the route), the draining shall be opened and the big
impurity particles inside shall be removed manually. When the slag is removed, the vent at the upper
shell of the Filter shall be opened. After the slag is removed, the vent can be closed. The cleaning
process of slag shall be taken after the ballast process is over. Impurities such as sludge etc. are
8-2
discharged. They should be disposed in a pollution-free manner or burned according to the
requirements of the Convention.
Table 8.2—2 Maintenance of Filter
No. Maintenance Item Maintenance Frequency Method
Clean big impurity particles in Accumulatively worked for Open the draining, let the water
1
the lower shell of the Filter 300 hours or 1 year flow out.
8.2.1.3. Maintenance of Gear motor of Filter
The gear motor is an important part of the Filter. Regular maintenance is necessary. The maintenance
shall be carried out according to Table 8.2—3 Maintenance of Gear motor.
Table 8.2—3 Maintenance of Gear motor
No. Maintenance Item Maintenance Frequency Method
Check the noise change of the Change the gear moter if the
1 Monthly
gear motor noise is bigger than nomal
Check the tightness of the gear Change the seal of the gear
2 Monthly
motor motor if there is a leak
Worked for about 2000

3 First oil change after operation hours or 3 years at the Chang the oil
longest
Every 3 years or every

4 Following oil changes Chang the oil
10000 working hours
8.2.1.4. Maintenance of Filter Elements
When the Filter runs properly, if the start-up intervals of the automatic backflushing gets shorter and
shorter, this indicates that the filter elements are blocked by more and more impurities.If the
backflushing intervals suddenly becomes longer, some of the filter elements may have been damaged.
If the filter elements are damaged, the quality of outflow water would be deteriorated. In this case,
please check all the filter elements immediately and change the damaged elements.
8-3
Information
Since the filter elements are under the stress for a long time, it is suggested that a spare
set of filter elements shall be prepared for alternative use.
Steps for cleaning and changing the filter elements:
a) Preparation
Close the valve that is connected to the Filter
Turn off the power of FCB
As for Filters with pneumatic valves, close the compressed air power source
To release the pressure in the Filter, open the vent
Carefully open the draining at the bottom of the Filter; use a proper container to collect the
water discharged from the draining.
When above mentioned steps are finished, the pressure in the Filter is released and the impurities
are removed.
Danger
Please be noted that arbitrary operation on FCB may cause potential safety hazard
during the maintenance of the Filter, please keep FCB away from others so as to
avoid arbitrary operation and prevent danger from happening. You might consider
to lock FCB.
b) Remove Filter Elements

Use proper lifting equipment.
Open the upper shell of the Filter; remove the top flushing arm; slowly take out the pressure
pipe of the seal ring and the upper fixed plate from the upper shell of the Filter; then
vertically lift the filter elements upwards with special attention to prevent the elements from
being bumped or scratched.
Put the filter elements in a proper container.
8-4
Caution
1. When the Filter is running properly, there is no need to wash the filter elements
manually.When liquid is filtered by the Filter, there would be certain pressure loss.
After the backflushing, if the pressure loss (pressure difference) keeps on raising
up to the preset alarm value, some filter elements might have been blocked. Then
the filter elements need to be washed manually.
2. Incorrect cleaning methods may cause damages to the filter elements.
3. When cleaning the filter elements, please be noted of the followings:
① When the filter elements is cleaned with a high pressure water gun, the
pressure shall not exceed 60Bar; and the distance between the nozzle of the
water gun and the filter element shall not be less than 20cm.
② Keep impurity particles away from the external surface of the filter elements.
③Do not pile up the filter elements while cleaning to prevent them from being
crushed.
c) Clean Filter Elements

Put the filter elements in the cleaning basin and soak them in water; add detergent.
While soaking the element in the water, remove the floating impurities first.
Clean the filter elements one by one with a high pressure water gun.
Change the water, add detergent, and wash the elements again.
The filter elements can be dried by air or by compressed air.
d) Installation of Filter Elements

Check the filter elements, especially the filter screen and the seal ring inside the elements, to
see if there is any damage. If there is, please replace immediately.
Before installing the filter elements, other inside parts, such as the pressure pipe and the
upper fixed plate etc., shall be cleaned.
8-5
Install the filter elements, upper fixed plate, pressure pipe, and the top flushing arm one by
one. Pay attention to ensure that the installation planes of all parts are aligned and the seal
rings are in positions.
Put back the top cover.
Close the vent and the draining.
Check the sealing of the connections.
Open the stop valve that is connected to the Filter; close the by-pass filtration pipe.
As for Filter with pneumatic- or hydraulic-driven backflushing valves, close the compressed
air or the hydraulic power source
Turn on the power of FCB, the Filter can run properly.
8.2.2. Filter (S-ZF Series)
8.2.2.1. Regular Maintenance
 The power transmission system: Check the power transmission system for any potential
failure and make sure the whole system can work properly and the drive motor should be
installed tightand have no trace of water and/or oil. Please contact manufacturer to change the
water tight components in case any leakage was spotted. All components such as drive motor,
transmission connection should be kept in well lubricated. Bolts and nuts should be greased
regularly. .
Note
DO NOT collide any part of the power transmission system during

maintenance.
 The self-cleaning mechanism: Please prime the cleaning pump by open the air vent. Pressure
gauge should indicate a reading that within the range of “Rated Pressure (on the plate) +
Pressure in the pipeline”. In any case, if the indication exceed the limit mentioned above,
8-6
please clean the injection nozzle. If the indication is lower than 5bar, please check the sealing
ring in the cleaning chamber. All connections should be checked regularly for any potential
leakage.
Note
When assemble again, the suction nozzle must be align to injection nozzle,
and all sealing rings should be in good condition.
 The drainage pipeline: The drainage pipeline should be checked regularly for potential leakage,
clogging and significant drop of discharge. Please contact the manufacturer if any malfunction
was spotted.
 The filtration mechanism: The filter might not be able to restore to normal operation status
under some extreme water condition. To restore the filter, please shut inlet valve and drainage
valve, manually start the cleaning pump for 3-5 cleaning cycles to clean the element with
filtered water, afterwards, open the drainage valve to drain the filter. In case the filter cannot
be properly cleaned, please take the filter element out and clean manually.
 Control system: Keep all connections between cables and component fasten. Power supply
MUST be cut off during maintenance of control system. To avoid any damage to the system
and/or injury to operator, control system must not expose to any kind of liquid.
 Sealing components: Water tight components are wearable and should be checked during the
maintenance and be replaced when damaged;
Note
In order to keep the quality of the BWMS, if any spare parts needed, please
contact maker to avoid any wrong material or type for damaging the
transmission parts.
8-7
8.2.2.2. Solution for High Differential Pressure
Under any circumstance when a “High Differential Pressure” alarm was triggered and the filter was in
constant back-flush, please follow the procedure below:
a) Stop the ballast water system;
b) Shut outlet valve of filter;
c) Start ballast pump with the drainage vlave of the filter open;
d) Push “Ballast” button start the system;
e) Push the “Manual” button on filter control box for two or three seconds to start manual
back flush for 5 times and drainthe filter;
f) Open sea to sea valve and outlet valve of the filter, start the ballast pump for 2 minutes
after the operation, then the system is good to switched to the ballast tank.
Please refer to 8.2.2.3 to disassemble the filter if the procedure above cannot resolve High
Differential Pressure problem.
8.2.2.3. Disassemble of the Filter
a) Preparation
 Shut all valves that is connected to the Filter; Turn off Filter Control Box;
 For Filters with pneumatic or hydraulic valves, close the compressed air or the hydraulic
power source;
 Open the vent to relies the internal pressue of filter;
 Drain the filter by open the drainage port located at the bottom of filter.
DANGER
Filter Control Box is working under hazardous voltage that can cause serious injury
or death. Keep the Filter Control Box locked during maintenance.
b) Disassembly
 Step 1:Remove screws to disassemble the motor.
8-8
 Step 2: Remove cylinder flange bolts to open maintenance window..
 Step 3: Lift up the head cover by 80mm. .
8-9
 Step 4: Loose 2 sets of screws (part 4) through maintenance window, make check ring (part 5)
fall to shaft sleeve (part 6), then tighten 2 size of M8 set screws (part 4).
 Step 5: Loose down a little bit hoisting rope, it is better to make transmission pin (part 3)
rotate freely, otherwise it is very difficult to extract because transmission pin (part 3) strains.
Pull up retaining nail (part 2) in the end of part 3 with taper chamfer, then rotate and extract
part 3.
8-10
 Step 6: After completing the above steps, raise up the top cover. Remove screws (part 1) when
space is enough, so that the flushing arms can be disassembled. Remove the top cover, and
take out the flushing arms.
 Step 7: Remove bolts around filter top cover to remove top cover and move out intermediate
driving shaft.
Note
In case of no enough space, it is possible to disassemble part 4 and part 5
and leave the driving shaft In the cylinder body.
 Step 8: Remove all six bolts on the flange above filter screen.
Note
DO NOT leave any wastes (bolts, shavings, etc) inside filter.
8-11
c) Clean Filter Element
 Place the filter element into a cleaning basin and soak in water with detegent.
 Clean all contamintations floating on surface of water;
 Clean the filter element with high pressure water cleaner;
 Repeat the steps twice;
 Dry the filter element in shade or by compressed air.
8.2.2.4. A procedure for priming the filter
If the filter was operated in an extraordinarily dirty water last time, it is advised to taka a complete
priming after entrance into a clean water. Please follow the procedure below:
a) Shut outlet valve of filter;
b) Push “Ballast” button start the system;
c) Push the “Manual” button on filter control box for two or three seconds to start manual
back flush for 5 times and drain the filter;
d) Then , the system can be operated according to operator requirements.
8-12
8.2.3. EUT Unit
®
The EUT Unit of OceanGuard Ballast Water Management System is a maintenance free system.
There is no repairable part in the unit. To ensure that the system runs properly, regular maintenance for
the EUT Unit is necessary. The maintenance items are shown in Table 8.2-4.
Table 8.2—4 Maintenance of EUT Unit
No. Maintenance Item Maintenance Method

Frequency
1 Check to see if the fixing screws Every 6 1. Visually inspection on the bolts to check
are loose months whether the bolt is loose or not.
2. Check the anti-loose mark of bolts.
3. Use torque wrench to check whether the

bolt is loose.
If loosening occurs, bolts need to be

tightened.
2 Check the tightness of the EUT Monthly 1. Inspect visually whether there is water
Unit leakage from the sealing area of the cover.
2. Check the torque value of M12 bolts in

the cover with torque wrench, the torque
value should be 100NM.
3 Check the function of the Yearly 1. Connect the compressed air pipe with
pressure switch pressure switch, then install a pressure
regulating valve on the compressed air pipe.
The pressure of compressed air should be
set to 0.6MPa through the pressure
regulating valve. Please observe the contact
points of the pressure switch is closed or
not.
2. Reduce the pressure of compressed air

slowly from 0.6MPa to 0.4MPa, and
observe whether the pressure switch contact
is reset or not.
4 Check the function of the Yearly Dismantle the temperature sensor frome
temperature sensor EUT Unit, and put it into a thermostat to
observe whether the temperature value on
the control unit is same as that of
thermostat.
8-13
8.2.4. EUT Power
To ensure that the system runs properly, regular maintenance for the EUT Power is necessary. The
maintenance items are shown in Table 8.2-5.
Table 8.2—5 Maintenance of EUT Power

No. Maintenance Item Frequency Method
1 Check to see if the fixing Every 6 months 1. Visually inspection on the bolts to check
screws are loose whether the bolt is loose or not.
2 Check the remote control Yearly Please confirm the indicator light of
ability of the EUT Power Remote/Panel is on to make sure the EUT
Power is in a remote state when it is
working
3 Check the insulating Yearly Use a megger to test the ground resistance
property of the EUT Power
4 Check to see if the Every 6 months 1.Visually inspection on the connection to

connection of the inlet and check whether it is loose or not.
outlet of the cooling water
2. Check the anti-loose mark
pipe is loose
5 The heat dissipation Every 3 months Compare the temperature values of more
efficiency of the radiator than three months when the radiator works
properly. If there is little difference, there is
no problem. If there is huge different,
something must be wrong with the radiator.
6 Descaling (if the cooling Every 5 years Remove mainly the salt impurities (such as
water is soft water) calcium carbonate etc.) inside the radiator, s
o as to improve its efficiency. If the scale is
not too big, use ordinary disincrustant to
carry on circulate cleaning for 10-20
minutes; If the scale is too big, use acetic
acid to clean for 10-20 minutes.
7 Descaling (if the cooling Yearly If the scale is not too big, use ordinary
water is natural water) disincrustant to clean for 10-20 minutes; If
the scale is too big, use acetic acid to clean
for 10-20 minutes.
8-14
8.2.5. Control Unit and Remote Control Panel
Table 8.2—6 Maintenance of Control Unit and Remote Control Panel
1. Visually inspection on the bolts to

check whether the bolt is loose or
Check to see if the fixing screws not.
1 Every 6 months
are loose
2. Check the anti-loose mark of
bolts.
Check to see if the connections

2 Every 6 months Fastening the terminal
of the Control Unit is loose
Check the electrical insulating Use a megger to test the ground

3 Every 6 months
property of the Control Unit resistance
8-15
8.2.6. Monitoring Unit
8.2.6.1. TRO Meter
8.2.6.1.1. Maintenance Schedule
The TRO Meter should be calibrated each year to make sure it is working accurately. Please check the
calibration date every 3 months and contact manufacturer to take the calibaration work. The
recommended schedule is shown below. It is important to replace the indicator reagents every three
months and buffer reagent every 12 months to get reliable accurate readings from theTRO meter. The
TRO meter is shipped with one Tubing/Cuvette kit, The kitconsists of the following:Buffer Cap
Assembly, Indicator Cap Assembly, Cuvette.
Figure 8.2—1 Reagent Tubing Set
The drawing above shows one complete reagent tubing set. Two complete sets are used in the TRO
meter; one for the buffer and one for the indicator. Please note that a smaller cap is required for the
indicator. Generally, all pump tubes should be replaced on an annual basis. The cap assemblies and the
cuvette should be replaced as required.
Note
(1) The indicator reagent required for operating this instrument must be changed.
Write the mixing date on the reagent bottle labels in the area provided. Out will
expire reagent.
(2) The external strainer should be checked and cleaned if necessary.
(3) The glass cuvette should be inspected. Check for excessive debris on the
insidesurface of the glass. It is suggested to keep a spare cuvette to replace when
required. The old cuvette may be cleaned, if possible, for future replacement.
8-16
8.2.6.1.2. Flushing the System
It is recommended that the tubing replacements be timed with reagent replacement. Press the
SERVICE button to stop the water flow. Remove old reagents and discard. Place theinlet tubing in a
small container of clean chlorine free water Press SERVICE to return tooperation mode, press PRIME
and then to remove most of the water.
8.2.6.1.3. Cap Assembly Replacement
The cap assemblies should be changed as required. Check the condition of cuvette andchange if it
appears badly soiled or discolored. Follow the steps below:
○
1 Always replace both cap assemblies at the same time. Replace when they become worn or badly
soiled.
○
2 Check the drawing on the following page to ensure correct installation.
Figure 8.2—2 Reagent Tubing Installation
8-17
○
3 Return to operation as described. Press the SERVICE button to return sample flow to the system.
Check for leaks. If a leak occurs press SERVICE again, repair leak and try again. Once the system is
operating correctly, return or replace reagents and press PRIME and then one time to
restartreagent flow. The system will automatically return to normal operation.
Note
Tubes may darken due to contact with the reagent. This condition does not affect the
performance of these parts.
8.2.6.1.4. Replacing or Installing the Reagents
Reagent kits are available from Headway. There are two reagents required, and supplied in each kit;
the buffer and theindicator.The buffer and indicator reagents are provided as dry reagents and require
the addition of deionized water.
○
1 Buffer Reagent Preparation
Add about 400 ml of deionized water into the buffer bottle. Cap tightly and shake vigorously until the
powder is fully dissolved. When fully dissolved add enough deionized water to bring the volume in the
bottle up to the fill line. Under normal use the buffer will last until the last indicator has been used up
to one year.
○
2 Indicator Reagent Preparation
The indicator reagents are packed in a small snap lid case. Open the case and remove onesmall white
bottle indicator bottle and one brown DPD tube. Add about 100ml of deionized water into one of the
125 ml indicator bottle. Cap tightly and shake vigorously until the powder is dissolved. Remove the
cap and add the contents of the DPD powder bottle (small brown tube). Cap and shake to fully dissolve
the powder.When fully dissolved add enough deionized water to bring the volume in the bottle up
tothe knee of the bottle neck.
8-18
8.2.6.1.5. Cuvette Change
As recommended, maintenance schedule the cuvette should be inspected at 3 month intervals and
replaced when needed.
Note
The cuvette is spring loaded to allow for removal. Leave the cuvette retainer (O-ring)
in place while loosening top.
Loosen the knurled top until the cuvette pops out. Pull the cuvette retainer down to allow for cuvette
removal. Remove and replace or clean cuvette. Reverse the procedure toreplace. To avoid damage do
not over tighten the knurled top. Press the SERVICE key toreturn the system to normal sample flow
and check for leaks.
If the TRO meter is relocated or will be inactive for more than 3 months, remove the reagents. Flush
the reagent system as describe in 8.2.6.1.2 Flushing the System. Place the instrument in Service mode
to drain the system then remove power by disconnecting the mains powerplug.
The items shown below are recommended accessories and replacement parts. To order any accessory
or replacement part, please contact manufacturer.
Table 8.2—7 Accessories and replacement parts
No. Accessory Frequency Method
1 Buffer Reagent 12 months Please refer to 8.2.6.1.4
2 Indicator Reagent 3 months Please refer to 8.2.6.1.4
Please refer to 8.2.6.1.1

Monthly inspection once, if there is a
3 Tubing Kit
need to be replaced
4 Replacement Cuvette 3months Please refer to 8.2.6.1.5
8.2.6.2. Salinity Meter
Table 8.2—8 Maintenance of Salinity Meter

1 Check to Salinity Meter Yearly Contact the manufacturer to determine
electrode whether it need to be replaced.
8-19
8.2.7. Flow Meter
Table 8.2—9 Maintenance of Flow Meter

1 Check to see if the connecting Every 6 months 1. Visually inspection on the bolts to
flange bolts are loose check whether the bolt is loose or not.
2 Check to see if the connections Monthly

Fastening the terminal
are loose
3 Check to see if the gaskets Yearly Inspect visually whether there is water
between flanges are aging leakage from the sealing area
4 Check to see if the sensor in Yearly Contact the manufacturer to take the
the pipe are corroded calibration work.
8.2.8. Power Distribution Unit (PDU)
Table 8.2—10 Maintenance of PDU
1. Visually inspection on the bolts to

Check to see if the fixing check whether the bolt is loose or not.
1 Every 6 months
screws are loose
Check to see if the connections

2 Monthly Fastening the terminal
of the PDU are loose
Check the electrical insulating Use a megger to test the ground

3 Every 6 months
property of the PDU resistance
8.2.9. Neutralization Unit
Table 8.2—11 Maintenance of Neutralization Unit
Check to see if the fixing screws of the base 1. Visually inspection on

1 Every 6 months
are loose the bolts to check whether
Check to see if the fixing screws of the the bolt is loose or not.
2 Every 6 months
blender are loose 2. Check the anti-loose
mark of bolts.
Check to see if the fixing screws of the liquid
3 Every 6 months
level sensor are loose
Check to see if the fixing screws of the
4 Every 6 months
electromagnetic pump are loose
8-20
Inspect visually whether
5 Check to see if the joints of pipes are leaking Monthly
there is water leakage from
the sealing area
Check to see if the adding point on the ballast Monthly
6
pipe is leaking
8.2.10. Pipes
To ensure that the system runs properly, regular maintenance is necessary for all the pipes in the
system, including the connecting parts for air pipe, sampling pipe, ballast pipe, and all valves.
Table 8.2—8 Maintenance of Pipes
1 Check to see if the connecting Yearly 1. Visually inspection on the bolts to

bolts of the pipes are loose check whether the bolt is loose or not.
2 Check to see if the sealing Yearly Inspect visually whether there is water
parts of the pipes are aging leakage from the sealing area
3 Check to see if the compressed Three months Prepare soap water, and apply it to the
air connections of valves are connection to see if there is any bubble
damaged to determine whether there is any
leakage.
4 Check to see if the valves is Three months Inspect visually whether there is water
leaking leakage from the sealing area
8-21
8.3. Routine Check
In order to ensure the safety of the ship and the crew while the BWMS is running, routing check on the
equipment is necessary.
8.3.1. Check before Operation
Table 8.3—1 Check Items before Operation of System

No. Position Item for Check
1 Pipes Check to see if there is any leakage on the pipes
Check to see if the connecting wires are fine; if there is any peeling of
the wires
2 Filter
Check to see if there is any leakage in the Filter
the wires
3 EUT Unit
Check to see if there is any leakage in the EUT Unit
Check to see if the connecting wires in the Control Unit are fine; if there
4 Control Unit
is any peeling of the wires
Check to see if there is any accumulative water in the box of the
Monitoring Unit
Check to see if the connecting wires of the TRO Meter are fine; if there
is any peeling of the wires
5 Monitoring Unit
Check to see if the joint between the sampling pipe and the ballast pipe is
leaking
Check the buffer reagents and indication reagent is finished or overdue
(buffer reagent can use a year, indicating reagent can use three months)
Remote Control Check to see if the connecting wires are fine; if there is any peeling of
6
Panel the wires
Check to see if there is any leakage at the flange joints

7 Flow Meter
the wires
Check to see if the power connection is fine; if there is any peeling of the
wires; and if the switches are under correct open/close status
8 EUT Power
Check to see if there is any leakage on the cooling water pipe
Power Distribution Check to see if the connecting wires are fine; if there is any peeling of
9
Unit the wires
Check to see if there is any leakage in the Neutralization Unit

10 Neutralization Unit
the wires
8-22
Check to see if there is any leakage at the valve joints

11 Automatic Valve
the wires
8.3.2. Check during Operation
Table 8.3—2 Check Items during Operation
No. Position Item for Check
1 Pipes Check to see if there is any leakage on the pipes
Check to see it there is any water leakage at the flange joints; if the vent
2 Filter
at the top are closed; and if the air in the Filter is totally evacuated.
Backflushing of Press the “Manual” button of the Filter to see if the backflushing
3
Filter function works; if the backflushing pressure changes stably.
Check to see if the EUT Unit works properly; if there is any strange
4 EUT Unit
sound during the processing procedure.
5 Monitoring Unit Check to see if the sensor connections works properly
6 EUT Power Check to see if the EUT Power works properly
Check to see if the Control Unit works properly; if the data displayed on
7 Control Unit
the screen complies with the data displayed on the sensors.
8 Control Valves Check to see if the valves are correctly opened or closed
8-23
8.4. Spare List
No. Name Type Quantity Remark

Joint of Pressure G1/4 to ￠8 SS
1 2 Filter spare
Differ Gauge Pipe
Hex head galvanized

2 M12x50 4 EUT Unit spare
flange face screw
RIF-0-RPT-24D
3 Relay 2
C/21 Control Unit spare
4 Copper Bolt M3x45 4
G1/2 to G1/4
5 Connections 2
SS304 Monitoring spare
6 Pipe 8mm 0.5m
7 Hinge CL209Z3A001 2 pairs

Electric Cabinet spare
8 Electric Cabinet Key -- 1
9 Na2S2O3 6kg/bag 6 Neutralization Unit spare

10 Mechanical seal -- 1 Backflushing Pump spare
11 O ring -- 1 Backflushing Pump spare
8-24
Chapter 9 Troubleshooting
R BWMS
9. Troubleshooting
9.1. Notes
Danger
(1) Maintenance may cause accidents.
(2) When repairing heavy equipment, please follow the following instructions to
ensure safety:
Maintenance shall be carried out by professionals.
Put on proper working clothes and protective gears.
Choose transport tools and devices with sufficient power.
While transporting the Filter, the EUT Unit and the Control Unit, their
gravity cores should be kept in balance to prevent them from tilting.
While transporting, removing or installing the Filter, the EUT Unit and the
Control Unit, please do not stand or work under the equipment.
Maintenance can be carried on only after the Filter and the EUT Unit are
decompressed and unloaded.
When opening the Filter and the EUT Unit, please keep them very clean. It is
prohibited to leave tools, clothes or other articles in the cavities inside the
equipment.
Check the sealing of the equipment; and change gaskets when necessary.
Before the installation, clean all the sealing surfaces.
Maintenance shall strictly follow the work standards for maintenance of

electrical equipment. All power switches shall be off, including the remote switches
and the power switches on the equipment. In addition, maintenance can be carried
out only when there are two or more people on the site.
In order to ensure the navigation safety of ships, OceanGuard® Ballast Water Management System has
prepared an emergency ballast and deballastsystem.The emergency system can be activated only when
the navigation safety of ships and the personnel safety are in danger. The emergency system shall be
used according to related regulations. Records shall be made appropriately.
9-1
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BWMS
9.2. System Faults
The Control Unit has the function of fault alarm. When any part of the system breaks down, the information of current alarm and the serial number of the alarm will
be displayed on the screen. Relevant personnel shall check the fault position immediately and determine the fault cause. If the fault may threat the personnel safety
and equipment safety, corresponding measures shall be taken immediately.
Table 9.2—1 Alarm Set Points

Locatio
Alarm /
Failure
Type
Arming Delay
Measurement
n
Shutdown
Units
No
(sec)
Non-criti
Alarm
Console
Range Description
Critical
position
Remote
.
cal
1 Ballast TRO High alarm X X X 0.1–10 >2.5 mg/L 4min 1min TRO overdose during ballasting
2 Ballast TRO Low alarm X X X 0.1–10 <1.5 mg/L 4min 1min TRO insufficient during ballasting
Deballast TRO adjust
3 X X X 0.1–10 >0.1 mg/L 4min 1min TRO overdose after neutralization
overtime
4 TRO Communication fail X X X 30S 1min TRO communication failure
Over pressure/Pressure Loss Alarm for Ex type
5 TRO Pressure abnormal X X X <100 or >1500 Pa 0S 1min
MU
6 TRO status: No intake water X X X 1min No TRO sensor: insufficient intake water
7 TRO status: Purge is slow X X X 1min No TRO sensor: purge process slow
8 TRO status: Purge clogged X X X 1min No TRO sensor: purge pipe clogged
Salinity meter
9 X X X 30S 1min Salinity Meter Communication Failure
Communication Fail
10 Salinity meter low alarm X X X <0.05 PSU 30S 1min Low salinity alarm
9-2
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11 Salinity lower than 0.85PSU X X X <0.85 PSU 1min No Salinity detected is lower than 0.85PSU
12 Repair Alarm X X X 0S No System under repair
13 High flow rate X X X Refer to Table 9.2-3 m3/h 2min 1min Flow rate exceed higher limit of TRC
3
14 Low flow rate X X X Refer to Table 9.2-4 m /h 2min 1min Flow rate below lower limit of TRC
Flow meter communication
15 X X X 30S 1min Flow meter communication alarm
fail
16 Bypass mode X X X - - - 0S No System in bypass mode
17 Emergency switch is pressed X X X 0S No Emergency Switch pushed
18 GPS communication fail X X X 2min No GPS communication failure
19 Valve1~Valve6 alarm X X X 30S 1min Status fault of valve
Abnormal shutdown, alarm will be: Attention！
The system is Power Lost! When the Power is
OK, Please press the OK button.
20 Power Lost X X X 0S No
Note: When Power is lost, all valves will be
closed and system will shut down immediately.
21 Local HMI SD card load fail X X X 0S No SD card loading failure of local HMI
Remote HMI SD card load
22 X X X 0S No SD card loading failure of remote HMI
fail
Ballast opertion start without ballast pump
23 Ballast Pump start failure X X X 30S 1min
running
HMI communication error
24 X X X 0S No Communication failure between HMI and PLC
with PLC
EUT Power Unit can not EUT Power unit is not able to control current
25 X X X 0S No
control the output accuratly output according to the command of Control Unit
26 The Current of EUT Power X X X >Max current98% A 0S 1min Current output from EUT Power Unit exceed
9-3
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BWMS
high alarm 98% of maximum allowable current

The Voltage of EUT Power Voltage output from EUT Power Unit exceed
27 X X X >39.2 V 0S 1min
high alarm 98% of maximum allowable voltage
EUT Power powered on in EUT Power Unit powered on under non-ballast
28 X X X 1min No
non-ballast operation operation
Insufficient cooling water inside EUT Power
29 EUT Power cooling alarm X X X 0S No
Unit
EUT Power communication
30 X X X 30S 1min Communication failure of EUT Power Unit
fail
Abnormal alarm of EUT Power Unit (i.e.
31 EUT Power abnormal alarm X X X 0S 1min
overheat)
32 Pressure differ high(Filter) X X X 1.5 bar 0S 1min Differential Pressure of filter exceed set point
33 Back flushing pump error X X X 0S No Back flushing pump failure
34 Filter motor error X X X 0S No Failure of the motor on filter
Filter angle valve Communication failure of the angle valve on
35 X X X 30S 1min
communication fail filter
Filter Control box lost of Filter Control Box power loss during ballast
36 X X X 0S 1min
power alarm operation
37 EUT_Temperature high X X X 45 °C 10S 1min EUT Unit over heat
EUT_Temperature lower
38 X X X 1min No Internal temperature of EUT unit below 0 °C
than 0 degree celsius
EUT_Temperature
39 X X X 10S 1min Communication failure of tempreature sensor
Communication Fail
Neutralization Unit power loss during
40 NU Lost of Power Alarm X X X 0S 1min
deballasting operation
41 NU Pump failure alarm X X X 10S 1min Injection pump start overtime
9-4
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Neutralization liquid level

42 X X X 0S No High liquid level alarm of neutralization unit
high
Low Lever Alarm
43 X X X 0S No Low liquid level alarm of neutralization unit
(Neutralization Unit)
Table 9.2—2 Warning Set Points

Locatio
Alarming Delay
Alarm / Failure
Measurement
Type
Shutdown
n
Range
Units
(sec)
Non-crit
Console
position
No. Alarm Description
Remote
Critical
ical
0.1 -
1 Warning: Ballast TRO high X X X >2.4 and <2.5 mg/L 4min No TRO overdose alarm during ballast
10
0.1 -
2 Warning: Ballast TRO low X X X >1.5 and <1.6 mg/L 4min No TRO insufficient alarm during ballast
10
Refer to Table
3 Warning: high Flow X X X m3/h 2min No Flow rate
9.2-3
<0.1
4 Warning: Salinity meter low X X X PSU 0S No Low Salinity of Source Water
and >0.05
Warning: EUT Power running in EUT Power Unit Running in Panel
5 X X X 0S No
Panel Mode Control
Current output from EUT power unit
Warning: The Current of EUT Power >Max Current Amper
6 X X X 0S No exceed 95% of maximum allowable
high 95% e
current
Warning: The Voltage of EUT Power Voltag Voltage output from EUT power unit
7 X X X >38 0S No
high e exceed 95% of maximum allowable
9-5
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voltage
Warning : BWMS running in Test
8 X X X 0S No System running in Test Mode
Mode
Warning : Please check ballast pump Ballast Pump started while system stand
9 X X X 0S No
signal by
Table 9.2—3 High-flow Warning and Aram Set Point for All Models
Marine/ Brackish Water Fresh Water Marine/ Brackish Water Fresh Water
BWMS (≥0.85PSU) (<0.85PSU) BWMS (≥0.85PSU) (<0.85PSU)
Model Warning Warning Model Warning Warning
Alarm（m3/h） Alarm（m3/h） Alarm（m3/h） Alarm（m3/h）
（m3/h）（m3/h）（m3/h）（m3/h）
HMT-50 65 67.5 50 52.5 HMT-1000 1300 1350 1000 1050
HMT-100 130 135 100 105 HMT-1200 1560 1620 1200 1260
HMT-200 260 270 200 210 HMT-1500 1950 2025 1500 1575
HMT-300 390 405 300 315 HMT-2000 2600 2700 2000 2100
HMT-450 650 675 500 525 HMT-2500 3250 3375 2500 2625
HMT-600 780 810 600 630 HMT-3000 3900 4050 3000 3150
HMT-800 1040 1080 800 840 HMT-4000 5200 5400 4000 4200
9-6
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BWMS
Table 9.2—4 Low-flow Aram Set Point for All Models
Model Alarm（m3/h） Model Alarm（m3/h） Model Alarm（m3/h）
HMT-50 10 HMT-600 50 HMT-2000 100
HMT-100 10 HMT-800 50 HMT-2500 100
HMT-200 20 HMT-1000 50 HMT-3000 100
HMT-300 30 HMT-1200 50 HMT-4000 100
HMT-450 30 HMT-1500 50
9-7
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9.3. Faults of Filter
9.3.1. HMT-F Series
Table 9.3—1 Faults of Filter (HMT-F Series)
NO. Fault Fault Cause Measures

Too much liquid Decrease the flow rate and start the manual
1 impurities in the water to backflushing unit the pressure difference
be filtered drops to the normal value.
(1) Decrease the flow rate and start the
Frequent
manual backflushing unit the pressure
backflushing
difference drops to the normal value.
2 Filter elements blocked
(2) Clean or change the filter elements.
Please see Section 8.2.1.4 Maintenance of
Filter Elements of Filter for details.
3 No power supply Check the power supply
The gear motor Setting problem of filter

4 Check the control system
does not work the control system
The backflushing arm or Open the Filter and solve the problem that
5
connecting pipe is stuck causes the equipment being stuck.
Clean or change the filter elements. Please see
6 Filter elements blocked Section 8.2.1.4 Maintenance of Filter
Elements of Filter for details.
The pressure
The pressure at the
difference
Filter’s outlet is too low Open the backflushing valve on the
7 between the
or the flow rate of the backflushing pipe
inlet and outlet
backflushing is too low.
of the Filter
Check the backflushing valve. If it is
does not reduce
pneumatic- or hydraulic-driven, check to see
8 or exceed the
The backflushing valve if the air source or hydraulic power source is
preset value
is not open closed or if the pressure is too low
9 Check the filter control system
The pressure differential Check the pipe with differential pressure
10 No display of
pipe is blocked gauge, remove the obstructions
pressure
The differential pressure Check, repair or change the differential
11 difference
gauge damaged pressure gauge
The pressure
difference is 0.0
The drain of pressure
12 bar while the Close the drain of pressure gauge.
gauge is open.
flow is
decreasing
The motor of The power is not on or
13 Check and switch on the power
Backflushing short-circuited
Pump does not Phase failure of the
14 Connect or change the line
rotate power line
9-8
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The pump or the pump Remove the sundries; adjust the distance in
15 cover get stuck with the between the impeller and the pump and the
impellers cover; reassemble them.
The motor winding of
16 the Backflushing Pump Please contact the manufacturer
is burnt
There is air in the pump
Cut off the power; add water to evacuate air;
17 or the water supply is
check the tightness of the water inlet pipes
insufficient
The motor rotate
18 Adjust the direction of rotation
The reversely
Backflushing The water inlet pipe is
19 Check the water inlet pipe
Pump is blocked
Rotating, but no The impeller is damaged
20 water flows out. by sundries entered into Please contact the manufacturer
the pump
After long-time use of
21 the pump, the impeller Please contact the manufacturer
or the pump are worn
The Check the water inlet pipe and evacuate the
22 There is air in the pump
Backflushing air in the pump
Pump vibrates
23 Phase loss of the motor Connect or change the line
or makes noises
9.3.2. S-ZF Series
Table 9.3—2 Faults of Filter (S-ZF Series)

NO. Fault Cause Measures
1 The preset value of the Increase the preset value of the pressure
pressure difference is too difference
small.
2 Raw water quality is too Decrease the flow rate and start the
poor, and the choice of manual backflushing unit the pressure
Too much
filter area does not difference drops to the normal value.
frequency of
match, or sudden changes
backflushing
in water quality, beyond
design range.
3 Impurities in the filter Taking out the filter screen, impurities
screen is not washed out. should be removed by appropriate
measures.
9-9
R BWMS
4 External injection nozzle Taking out the high pressure flushing

or internal suction nozzle pipe or discharging pipe, impurities in
clogging, filter is not the blocking position should be
cleaned throughly. removed completely. Please see the
step 4 of Section 8.2.2.3 to take out the
pipes. If the nozzles are damaged,
please contact the manufacturer to
replace them.
5 Sewage valve is not Check the sewage valve, and the FCB
open.
6 Too much Abnormal status of (1) Check to see whether cleaning
frequency of cleaning pump pump work works or not;
backflushing (2) Check whether the current
parameter of the motor starter of
cleaning pump is correct or not;
If there is any problem of the pump,
please contact the manufacturer.
7 The preset value of the Flushing set differential pressure shall be
pressure is too high. reduced appropriately.
8 The FCB is not Checking that the power supply, wiring,
Backflushing is
operational. pressure differential transmitter and FCB are
not operational
normal according to the circuit diagram. If
not operational, please contact with
manufacture in time.
9 The power is off. Checking the power supply wiring.
10 The setting of FCB is Checking the FCB.

Gear motor
abnormal.
does not
11 Discharging pipe or drive Opening the filter to solve the problem caused
operate
shaft is stuck. by the stuck.
normally.
12 The motor is short of oil, The motor should be supply with oil,
or transmission maintained or replaced.
component damaged.
13 The tube of pressure Check the pressure transmitter pipeline,
differential transmitter is clearing blockage
stuck.
14 No pressure The pressure differential Check that the differential pressure
differential transmitter is damaged. transmitter needs to be repaired or replaced
15 display The wiring of pressure Check the wiring of pressure transmitter and
differential transmitter is FCB
16 abnormal.
9-10
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Digital display pressure Repair or replace the digital display

differential transmitter is
abnormal.
9.4. Faults of EUT Unit
9.4.1. Fault Description and Solutions
Table 9.4—1 Faults of EUT Unit
No. Fault Fault Cause Measures
Poor insulation between the

1 Electric leakage electrocatalysis module and the Please contact the manufacturer.
shell
The electrode plate of the same
EUT Unit does Check to see if the resistance
2 polarity inside the EUT is poorly
not work between the electrodes is good
connected or not connected
Check to see if the external
conductor post and the internal
Poor connection between the conductor plateare well welded; if
The conductor
3 internal and external conductor the conductor post and the internal
post gets hot
posts conductor plate are well touched
directly. Check to see if the contact
resistance is good.
Check the leakage positions; change
4 Leakage Sealing parts are aging relevant parts; see Section 9.4.2
Steps for Changing Parts for details.
High organic matter in ballast
Reduce the flow of ballast water,
Ballast TRO water,
5 control the flow rate of inlet of the
Low alarm The system cannot produce
system.
enough TRO.
9.4.2. Steps for Changing Parts
a) Preparation
Close the valve that is connected to the EUT Unit;
Turn off the BWMS power
Open the decompression valve slowly; discharge the water in the shell of the EUT Unit; and
ensure that there is no water in the electro-catalysis module to be changed.
When above steps are finished, the water in the EUT Unit is completely discharged.
9-11
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Danger
1. Please be noted that arbitrary operation on the PDU may cause potential safety
hazard.
2. During the maintenance of the EUT Unit, please keep the EUT Power is power off,
to avoid arbitrary operation and prevent danger from happening. You might
consider to lock the PDU.
b) Remove Cover of Electro-Catalysis Module and Electro-Catalysis Module

Remove the bolts with an internal hexagonal wrench;
Remove the electro-catalysis module cover from the EUT shell.
c) Change Electro-Catalysis Module

Gently pull out the original electro-catalysis module from the shell, without scratching the
lining of the inner cavity.
Put a new electro-catalysis module into the inner cavity of the EUT shell.
Also make sure not to scratch the lining of the inner cavity.
Determine the position of the electrode conductor post based on the relative position of the
electro-catalysis module and the shell, and make a mark;
Based on the marked position of the external conductor post, remove the top electrode plate
of the electro-catalysis module from the electro-catalysis module; weld the external
conductor post of electrode on it. Make sure the welding lines are even. Solder skips and
missing solder shall be avoided.
Polish the welded surface;
Fix the conductive copper plate on the electro-catalysis module;
Put the cover of electro-catalysis module in place, and fix it on the EUT shell with bolts;
Put the PTFE sealing ring on the external conductor post, and tighten it with the fixing plate;
Screw the internal conductor post in the electrode external conductor post, and fix it with a
wrench;
9-12
R BWMS
Use copper strips to connect the electrocatalysis modules. Connect cables to the anode and
cathode using the internal connecting wires;
Put the electrode protection cover in place and fix it with bolts.
9.5. Faults of EUT Power
Table 9.5—1 Faults of EUT Power

The power supply is Check to see if the power supply is
1
open-circuited well connected.
The power switch is The switch is damaged. Please
2
The working indicator of disconnected or damaged contact the manufacturer.
the power of There is indication on the
electro-catalysis module voltmeter and the The indicator is damaged. Please
3
is off ammeter, but the contact the manufacturer.
indicator does not work
4 Other faults Please contact the manufacturer.
The indicator can continue to work
The indicator for The environment
5 after cooling down, but needs to
overheat of the power of temperature is too high
restart the power switch
the electro-catalysis
The cooling water flow is Please see Section 8.2.4 Maintenance
6 module is on
not smooth of EUT Power for details
The working indicator of
the power of the
Fault of the power
electro-catalysis module
7 supplying line for the Please contact the manufacturer.
is on, but there is no
meters
display on the ammeter
and voltmeter
Check to see if the 380V power
8 The alarm indicator of Under voltage
voltage is too low
the power of the
Check when the indicating light is
electro-catalysis module
on. If there is no problem, shut down
is on unexpectedly
the system and restart. If it doesn’t
9 during start-up or Other faults
work, something must be wrong with
operation, and the
the power. Please contact the
operation suddenly stops
manufacturer.
9-13
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9.6. Faults of Control Unit
Table 9.6—1 Faults of Control Unit and Remote Control Panel
Check to see if the breaker is closed; check the

Press the “Power connections of the AC contactor coil and the
The AC contactor contact points, so as to ensure that they are
On” button, but
1 does not work. It correctly connected. If the AC contactor is
the system is not
is disconnected found to be damaged, please change it
powered on
immediately.
The function of The contact point

Emergency of the Emergency
2 Change the Emergency Switch
Switch does not Switch is
work damaged
The system is
3 Carry on the checks described in the first fault
The indicators for powered off
“Power On” and Something wrong
Make sure the indicators are correctly connected
“Power Off” are with the
4 and the indicators are not damaged. Otherwise,
off connections of the
the relevant button shall be changed.
indicators
9-14
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9.7. Faults of Monitoring Unit
9.7.1. TRO Meter

Table 9.7—1 Faults of TRO Meter
Check to see if the power is turned

1 No display on The power is off
on
instruments
2 Fault of meter Please contact the manufacturer
3 No water flowing Pipeline jam Check the flow line

Sample cuvette
4
filling too slowly The factory set up flow has
Set flow rate
Intake water flow changed
5
too fast
Sample cuvette has
6 slow purge Not flow Check drain lines
Or not purging
7 Dirty cuvette With by reagent, long wear Replace or clean cuvette
(1) Install desiccant cartridge
(1)Condensate or leaky
kit
measurement cuvette
(2) Replace or clean cuvette
(2) Measurement cuvette dirty
(3) Replace reagents
Readings are lower (3) Reagents bad or expired
8 (4) Check buffer lines and
than expected (4) Buffer reagent not being
check valves.
Dispensed
(5)Priming several times accoding
(5)Insufficient priming after
to the description of step 3 of
replacement of reagents
section 8.2.6.1.3
Brief spikes in
9 Indicator bad or expired Replace Indicator
readings
Upper display Check sample. Sample may be
10 Sample Over-Range
flashes too high to read.
Upper display shows
none while Wait for TRO meter to post a
11 No current reading displayed
attempting to reading
calibrate
12 Water leakage The joint is leaking Change the joint
9.7.2. Salinity Meter
Table 9.7-2 Faults of Sanlinity Meter

The power is off Check the power supply

No display on
１
instruments
Fault of meter Please contact the manufacturer
9-15
R BWMS
Readings are Fault of meter Please contact the manufacturer

2 lower or higher
than expected No flow Check the sample inlet
9.8. Faults of Power Distribution Unit
Table 9.8—1 Faults of PDU
Fault of the breaker or Please contact the

1 No voltage output when switch on
the AC contactor manufacturer
When a touching button on the panel is
Fault of the touching Please contact the
2 pressed, the corresponding equipment
button manufacturer
does not work
9.9. Faults of Flow Meter
Table 9.9—1 Faults of Flow Meter
1 The power is off Check to see if the power is turned on

No display
2 on The fuse is blown Check to see if the fuse is good
instruments
The power supply Check to see if the power supply voltage
3
voltage is low meets the requirement
Excitation
4 Fault of converter Please contact the manufacturer
alarm
5 Liquid Insufficient liquid
6 Fault of converter Please contact the manufacturer

Alarm for
blank pipe Incorrect connections of Check to see if the signal connections are
7
the signal line correct
The sensor electrode
8 Please contact the manufacturer
cannot be used
Check to see if the measuring pipe of the
9 Liquid
sensor is full of liquid
Inaccurate Check to see if the signal line is properly
10 Signal line
measurement connected
11 Sensor Please contact the manufacturer
9-16
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9.10. Faults of Neutralization Unit

Table 9.10—1 Faults of Neutralization Unit
1 Damage to pipe joints Check to see if the joint are fine

Pipe leakage Wrong status of the valves on When the Neutralization Unit runs,
2
the pipes the valves shall be open
Leakage at the head of
The threads of the pump head Rotate clockwise to tight the pump
3 the electromagnetic
are too loose head
pump
Please check the connections of the
The high liquid level of the
Overflow of the liquid level sensor. If there is no
4 liquid level sensor breaks
neutralization barrel problem, please contact the
down
manufacturer
5 Fault of the liquid level sensor Please contact the manufacturer
Fault of the alarming device in

6 The neutralization Please contact the manufacturer
the control box
barrel is empty
Poor connection between the
without alarm
liquid level sensor and the Check to see if the connection of the
7
communication cables on the cables is correct and reliable
control box
8 Fault of the blender motor Please contact the manufacturer
Check to see if the power is turned

9 The blender is not powered on
on
The blender does not
The AC contactor 1# in the
work Change the AC contactor or the
10 control box or the intermediate
intermediate relay.
relay 1# is damaged
Poor connection of Check to see if the connection of the
11
communication cables cables is correct and reliable
12 The electric valve is damaged Change the electric valve
The water-in electric Poor connection of Check to see if the connection of the
13
valvecannot be communication cables cables is correct and reliable
opened The AC contactor 3# in the
Change the AC contactor or the
14 control box or the intermediate
intermediate relay.
relay 3# is damaged
9.11. Other faults

OceanGuard® Ballast Water Management System is a mechatronics device. Although we’ve tried our
best to consider more about the possible types of faults and the solutions, it is unavoidable that some
faults are not included in the above lists. If you have encountered any fault that is not included in this
manual, please contact our authorized maintenance people or our after-sales service.
9-17
Chapter 10 Miscellaneous
10. Miscellaneous
10.1. Calibration
OceanGuard Ballast Water Management System is equipped with sensors including TRO Meter,
Salinity Meter, Flow Meter, Temperature Sensor (on EUT Unit) and Pressure Switch (on EUT Unit).
Please keep tracking the accuracy of those sensors. In case of abnormal reading, please calibrate the
salinity meter, TRO meter, temperature senor and flow meter according to Chapter 10.1.1~10.1.4. It is
required to contact manufacturer for replacement when there is any potential failure of temperature
sensor and pressure switch. In normal cirstrance, the calibration work will be carried out by
manufacturer one time every year .
10.1.1. TRO Meter Calibration
Note
If the probe exposed to the air, the showing value is invalid.
The testing solution must flow.
TRO Meter was tested prior to leaving the factory. Since it operates from a predetermined calibration
curve, no calibration is required. It is recommended to take calibration operations if the user feels that
the deviation of TRO value is greater than (1mg/L) and determines the it is not caused by other devices.
Calibration can easily be performed if required. The method is by comparison against another
instrument, such as a laboratory or hand held photometer.
There are two points of calibration. The slope (gain) and the zero (offset). To perform the zero the
instrument must be plumbed to a sample of known chlorine free water such as deionized water for a
zero adjustment.
10-1
10.1.1.1. Zero (offset) Calibration Procedure
To perform this calibration, the water supply to the TRO Meter must be changed to chlorine free water
such as de-ionized water. This chlorine free water must be run through the instrument for at least 5
minutes prior to using the following procedure.
 On the TRO Meter, press the MODE/EXIT button once. The screen is shown below.
Figure 10.1-1
 Press either the or buttons to get the following screen.
Figure 10.1-2
 Press to enter the zero calibration screen.
Figure 10.1-3
10-2
 The screen will show the current reading on the TRO Meter. Since there is no chlorine, the
only reading may be a slight offset due to the absorbance of the reagents. There should be no
pink color developed.
 Press to perform a Zero calibration. When the calibration has completed the instrument
will return to AUTO measurement mode automatically.
Note
There is a limit of ±0.20 mg/L total adjustment available. A ZERO Cal. greater
than this will cause a TRO Meter warning and no calibration will have occurred.
Enter SERVICE mode to clear this error.
10.1.1.2. Slope (gain) Calibration Procedure
It is important that the chlorine level be quite stable to use this method. The comparison will be made
against a trusted measurement such as a chlorine photometer,spectrophotometer, or an amperometric
titration.
 Obtain a grab sample of the flow.
 Measure the value of the sample with one of the methods shown above.
 On the TRO Meter, press the MODE/EXIT button once. The screen is shown below.
Figure 10.1-4
10-3
 Press to enter the calibration adjustment.
Figure 10.1-5
 The screen will show the current reading on the TRO Meter. Using the &
buttons adjust the reading to agree with the laboratory method or portable photometer.
 Press to accept the calibration adjustment and return to AUTO measurement mode.
Note
There is a limit to the size of the change that can be made to a current reading. The
upper limit is the current reading times 1.5. The lower limit is the current reading
divided by 1.5.
Ensure a reading is posted to the display before calibrating to avoid a nOnE error.
10.1.2. Salinity Meter Calibration
10.1.2.1. Salinity Ratio Calibration
When using ratio calibration, the salinity of sampling water should be very stable. Calibration
procedure are shown below:
1) Confirm the salinity using contrast analyzer. Salinity should be very stable.
2) Turn the analyzer-to-be-calibrated on, measuring the water sample and operate for 5 to 10
minutes.
3) Press “MODE” to enter CONFIG interface.
Press “ENTER” and select “PSU ADJ”.
10-4
Figure 10.1-6
4) Adjust the reading by press → or ← to make it identical with contrast equipment.
5) Press “ENTER” to save the calibration.
6) Press “MODE” back to display interface to finish ratio calibration.
10.1.2.2. Salinity Zero Calibration
Zero calibration require stable non-salinity water, the procedure should be:
1) Analysis water with 0 salinity for 5 to 10 minutes.
2) Press “MODE” button to enter CONFIG interface.
3) Press “ENTER” button and select “PSU ZERO”
4) Set the reading to 0.00 by → or ←.
Figure 10.1-7
5) Press “ENTER” to confirm.

Press “MODE” to back to display interface and finish Zero Calibration
Note
If the probe exposed to the air, the showing value is invalid.
The testing solution must flow.
10-5
10.1.3. Temperature Sensor
1) Remove the temperature sensor from the EUT unit. Please note that the sensor protector should
be left in the EUT Unit to avoid the water leakage.
Figure 10.1-8 (Left-Temperature Senor, Right-protector)

2) Prepare two cups of water for a temperature difference at least 20 degrees
3) Put the temperature sensor and calibrated Thermometer together into the two cups in turn, and
compare the values. If the difference is within the allowable error range (0.5℃ advised), the
temperature could continue to be used, if the error range is exceeded, please contact the
manufacturer to replace the sensor.
10.1.4. Flow Meters
It is recommended to take calibration operations if the user doubts about the flow meter validity
and determines the it is not caused abnormal operation condition, for example, partially filled
pipes. Calibration can easily be performed when ballast pump works in normal status, if required.
1) Record the total amout of water from flow meter and the total amount of ballast water in ballast
tank by Liquid Level Telemetry System of ballast tank before ballasting operation;
2) Operation BWMS for several hours;
10-6
3) Re-record the total amout of water from flow meter and the total amount of ballast water in
ballast tank after ballasting operation;
4) Caculate the water amount during the ballasting operation;
5) Compare the values of flow meter and that from Liquid Level Telemetry System of ballast tank.
If the difference is within the allowable error range (10% advised), the flow meter could continue
to be used, if the error range is exceeded, please contact the manufacturer to replace the flow
meter.
10-7
10.2. Disposal of Wastes
OceanGuard® Ballast Water Management System has to follow the system instructions to add sodium
thiosulfate into the Neutralization Unit. This substance is non-toxic and harmless. It does not belong to
dangerous chemicals.The reaction between sodium thiosulfate and TRO won’t produce wastes.
Wastes are mainly the concentrated wastes produced by the back-flushing of the Filter and the wastes
produced during repairs.
10.2.1. Back-flushing of Filter
10.2.1.1. Back-flushing Process of Filter
The Filter used by OceanGuard® Ballast Water Management System runs only when the ship is
preloaded with ballast water. While the Filter is working, its back-flushing function also works. The
concentrated wastes produced by the Filter during its operation will be discharged through the
back-flushing pipe into the local water area where the ship gets ballast water.The concentrated wastes
from the Filter will be diluted when they are discharged into the sea. Its concentration is very close to
the concentration in the original seawater. It can be regarded that the concentration did not change.
Therefore, the discharged wastes won’t have any influence on the environment.
10.2.1.2. Sewage Discharge during Repairs
When OceanGuard® Ballast Water Management System is repaired, the sewage and water shall be
discharged firstly.
There is a draining at the lower shell of the Filter. When the system is repaired, the draining should be
opened; the vent on the top of the Filter shall also be opened. The vent shall be closed after the sewage
is discharged. Impurities shall be collected and disposed or burnt in a harmless manner according to
the requirements of the Convention.
There is a water drain outlet at the bottom of the EUT Unit. When the system is repaired, the water
drain outlet should be opened; and the vent outlet on the top shall also be opened. The vent outlet shall
10-8
be closed after the water is discharged.The discharged water shall be collected and disposed or burnt in
a harmless manner according to the requirements of the Convention.
When the Monitoring Unit is repaired, the residual liquid in the probe holder and the filter bowl has to
be discharged. The residual liquid hall be collected and disposed or burnt collectively in a harmless
manner according to the requirements of the Convention
10.3. Personal Requirements
The system is fully automated and can be operated by a trained crew onboard any commercial vessel.
Operation of the system will have no markable effect on the labor burden.There are no health and
safety certification/training requirements for personnel operating the BWMS.
The only crew training required is an 8 hours session covering the following:
 Basic understanding of the system´s technologies
 Basic operation of the system
 Neutralizer handling
 Basic introduction to the system´s control and automation system
10-9
Chapter 11 Annex
11. Annex
Table 11-1 Annex List
Annex A~Q BWMS Drawings
Name Type Page
Series or Parallel Connection of EUT 1
HMT-50~100E 4
HMT-200E 4
HMT-300E 4
HMT-450E 4
HMT-600E 4
Annex A HMT-800E 4
EUT Unit
HMT-1000E 4
HMT-1200E 4
HMT-1500E 4
HMT-2000E 4
HMT-2500E 4
HMT-3000E 4
HMT-4000E 4
HNT-50~300PE 2
HMT-450~600PE 2
HNT-800~1200PE 2
Annex B EUT Power
HMT-1500~2000PE 2
HMT-2500~3000PE 2
HMT-4000PE 2
Annex C Control Unit HMT-CL 1
Annex D Remote Control Panel HMT-CR 3

11-1
Chapter 11 Annex
HMT-F 7
Annex E Filter
S-ZF 8
Annex F Monitoring Unit HMT-MU 4
Annex G Power Distribution Unit HMT-50~4000PDU 47
Annex H Neutralization Unit HMT-60~600N 7
Annex I Flow Meter HMT-FM 2
Annex J Control Valve All models 2
Annex K Main Valve All models 1
Annex L Sampling Device All models 1
Annex M Flow Diagram All models 2
Annex N Assembly Drawings All models 3
Electrical Wiring
Annex O All models 9
Drawing
Annex P Bill of Materials
Annex Q Commissioning Procedure
Annex R Treatment Proposal For Fresh Water
Annex S MSDS
11-2
海德威科技集团（青岛）有限公司
Headway Technology Group (Qingdao)Co., Ltd.
电话(Tel.)：0532-83107817
传真(Fax)：0532-83107816
网址(Website)：www.headwaytech.com
电子邮箱(Email)：sales@headwaytech.com

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OceanGuard® Ballast Water Management System

Headway Technology Group (Qingdao) Co., Ltd.

1.0 First Issue LBY, DQH, NSL CXL

2.5 DNVGL Comment Incorporated LBY, DQH, NSL CXL

2.6 DNVGL Comment Incorporated LBY, DQH, NSL CXL 08/29/2017

2.6.2 DNVGL Comment Incorporated LBY, DQH, NSL CXL 01/08/2018

2.6.3 USCG Comment Incorporated LBY, DQH, NSL CXL 07/12/2018

2.6.4 USCG Comment Incorporated LBY, DQH, NSL CXL 10/13/2018

1.1. Objectives............................................................................................................................... 1-1

1.2. Safety ..................................................................................................................................... 1-2

1.2.1. Safety Instructions ....................................................................................................... 1-2

1.2.2. Symbols and Explanatory Notes ................................................................................. 1-3

1.3. Warranty ................................................................................................................................. 1-4

1.4. Abbreviations ......................................................................................................................... 1-4

2. Introduction to System ...................................................................................................................... 2-1

2.1. Background ............................................................................................................................ 2-1

2.2. Application Scope of the System ........................................................................................... 2-2

2.3. Introduction to System Principles .......................................................................................... 2-3

2.4. Chemical Used or produced ................................................................................................... 2-3

3. System Components .......................................................................................................................... 3-1

3.1. System general information ................................................................................................... 3-1

3.1.1. Componts and Specification........................................................................................ 3-1

3.1.2. System Control Sequence............................................................................................ 3-5

3.2. Filter ....................................................................................................................................... 3-7

3.2.1. HMT-F Series .............................................................................................................. 3-7

3.2.2. S-ZF Series ................................................................................................................ 3-17

3.3. EUT Unit .............................................................................................................................. 3-24

3.3.1. Appearance ................................................................................................................ 3-24

3.3.2. Function and Principle .............................................................................................. 3-24

3.3.3. Main Parameters........................................................................................................ 3-25

3.3.4. Main Components ..................................................................................................... 3-26

3.4. EUT Power ........................................................................................................................... 3-27

3.4.1. Appearance and Structure.......................................................................................... 3-27

3.4.2. Function .................................................................................................................... 3-28

3.4.3. Main Parameters........................................................................................................ 3-29

3.4.4. Main Components ..................................................................................................... 3-30

3.4.5. Adjustment and Control ............................................................................................ 3-30

3.5. Control Unit ......................................................................................................................... 3-36

3.5.1. Appearance and Structure.......................................................................................... 3-36

3.5.2. Function .................................................................................................................... 3-38

3.5.3. Main Parameters........................................................................................................ 3-38

3.5.4. Adjustment and Control ............................................................................................ 3-39

3.6. Monitoring Unit ................................................................................................................... 3-49

3.6.1. Components............................................................................................................... 3-49

3.6.2. Function .................................................................................................................... 3-50

3.6.3. Main Parameters........................................................................................................ 3-52

3.6.4. Operation ................................................................................................................... 3-53

3.7. Flow Meter ........................................................................................................................... 3-60

3.7.1. Appearance ................................................................................................................ 3-60

3.7.2. Function .................................................................................................................... 3-60

3.7.3. Parameters ................................................................................................................. 3-61

3.7.4. Operation ................................................................................................................... 3-62

3.8. Remote Control Panel .......................................................................................................... 3-68

3.8.1. Appearance ................................................................................................................ 3-68

3.8.2. Function .................................................................................................................... 3-68

3.8.3. Main Parameter ......................................................................................................... 3-69

3.8.4. Adjustment and Control ............................................................................................ 3-69

3.9. Power Distribution Unit ....................................................................................................... 3-70

3.9.1. Appearance ................................................................................................................ 3-70

3.9.2. Function .................................................................................................................... 3-72

3.9.3. Parameters ................................................................................................................. 3-72

3.9.4. Adjustment and Control ............................................................................................ 3-73