Professional Documents
Culture Documents
1 2000 Ex
IMO/USCG
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.
Contents
1 Addendum.....................................................................................................................5
1.1 General drawings...................................................................................................... 5
1.1.1 Flow chart — P201–1 (optional).................................................................. 6
1.1.2 Electrical system layout — P201–1 (optional)............................................. 7
1.2 Dimension drawings.................................................................................................. 9
1.2.1 Ballast water booster pump P201–1 (optional).......................................... 10
1.2.2 Pressure monitoring device (Incl. PT201-1, PI201-1, RV201–1 and
V201-1)...................................................................................................... 11
1.2.3 Variable Frequence Drive (VFD)................................................................12
1.2.4 VFD JB ......................................................................................................13
1.3 Electrical drawings...................................................................................................14
1.3.1 VFD JB / Interconnection diagram............................................................. 15
1.3.2 VFD JB / Circuit diagram .......................................................................... 18
1.3.3 VFD JB / Cable list.....................................................................................22
1.4 Intrinsically safe circuits...........................................................................................23
1.4.1 Ex i max cable length calulation – P201–1................................................ 25
1 Addendum
The drawings in the addendum have either been incorporated from an earlier/
later USCG approved version of the system manual, or describes an external
component (e.g. cooling circuit) which is regarded as a non-essential BWMS
component.
This PureBallast system has been updated in order to be compliant with
USCG type approval.
The system manual (follows after this addendum) must be updated with the
information in this addendum in order to correctly describe the installed
system. Some information in the system manual (grayed out and marked with
blue text) shall be replaced with information in the addendum.
Orginal drawings Addendum drawings
Ballast water booster pump P201–1, N/A 9038844
Flow chart
Ballast water booster pump P201–1, N/A 9040361
Electrical system layout
Ballast water booster pump P201–1, N/A 9039959
Dimension drawing
Pressure monitoring device (Incl.
PT201-1, PI201-1, RV201–1 and N/A 9040206
V201-1), Dimension drawing
VFD, Dimension drawing N/A 9042471
VFD JB, Dimension drawing N/A 9038843
VFD JB, Electrical drawing N/A 9038497
Ballast water booster pump P201–1, N/A 9039212
Ex IS doc
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Cable selection
The cables for the IS circuits are not delivered by Alfa Laval, and must
therefore be selected by the party responsible for designing PureBallast. The
cables must be correct for installation in the hazardous zone, and they must
match the requirements for the intrinsically safe circuits.
Requirements for each cable (and underlying apparatuses) are described in
the documents Ex i max cable length calulation - P201–1, Ex i max multicore
cable length calculation - V201-8 and Ex i maximal multicore cable length
calculation - UVR components documents. These documents should be filled
out.
The table below is an overview of cables to be verified. After the table, the
documents are available. Both documents contains:
• Example calculation: First page gives an example of standard cables and
how to calculate cable specifics to verify that the cable can be used.
• Verification for selected cable: Following page(s) describes the basic
data for the underlaying apparatuses. This section shall be filled out
according to the instruction. They can also be used if a cable needs to be
changed after installation.
Component
Cable ID's to be Reference documents
verified Intrinsically safe
apparatus ID
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28 200001138-1-EN-GB
EN
VFD
The speed of the ballast water booster pump (P201–1) is controlled via a
variable frequency drive (VFD).
If the inlet pressure to PureBallast is higher than required the speed of the
booster pump will decrease.
If the inlet pressure to PureBallast is lower than required the speed of the
booster pump will increase.
The signals are transferred from PureBallast control system to the VFD, via
Modbus.
The VFD will be in continuous operation, monitoring PT201-16 pressure, but
will enter sleep mode when inlet pressure to PureBallast is sufficient. In sleep
mode the VFD will activate the "Space Heater" function.
200001138-1-EN-GB 29
EN 2 Chapter 2: System description
The VFD has its own electricity supply and can be switched off via its control
panel.
The VFD junction box (VFD JB) is for the VFD, and has no switch off button.
30 200001138-1-EN-GB
EN
Status box
The status box display current status for the PureBallast system. The
information is updated continuously. To see accumulated operation runtime for
the components, see page 4.3 – Operation timers.
200001138-1-EN-GB 31
EN 3 Chapter 3: Operating instructions and control system description
32 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
Flow chart
The flow chart display a schematic overview of the PureBallast system and its
components.
Relevant information regarding ongoing process and component status can be
monitored directly in the flow chart. Flow in pipes is indicated by coloring of the
pipes and component status are displayed by color indications. Pressure, flow
and control valve opening percentage are displayed directly on component.
Detailed information about the UV reactor, filter and CIP components can be
monitored in their respective pages. The popup contain status for sub
components, for example valves, motors and UV lamps in the UV reactor.
UVR cooling water pump (P403–1) is only displayed if it is used and activated
in the parameter pages.
In manual mode (login level Advanced operator or higher) it is also possible to
operate components manually: If a component is pressed, a popup window is
displayed from which the component can be operated.
200001138-1-EN-GB 33
EN 3 Chapter 3: Operating instructions and control system description
Status indication
Pipes A pipe filled with colour indicates that there is flow in
the pipe.
Status indication
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Valves and pumps
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a
component. The ID will be visible in page 1.1 Overview
and popups for the components. See instruction Set
ship specific component ID.
34 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
200001138-1-EN-GB 35
EN 3 Chapter 3: Operating instructions and control system description
VFD
1. Main breaker
2. Emergency stop button
3. Reset button
4. Alarm (light and sound)
A. Main breaker
B. Reset button
36 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
Action Method
The VFD has its own electricity supply
Deactivate VFD and can be switched off from the ships
supply.
Complete deactivation is performed in
two steps:
1. 1. Turn off the main breaker (1) at
the side of the control cabinet.
2. Turn off the main breaker (A) on
the lamp drive cabinet (LDC)
door.
200001138-1-EN-GB 37
EN 3 Chapter 3: Operating instructions and control system description
38 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
4. Press (not slide) the Hand button icon to enable manual operation of the
component.
Result: The open and closed buttons turn blue for operation. A hand icon is
also displayed on the component in the popup and the page to indicate
that it is manually operated.
5. Operate the component using the open/run (left) and closed/not running
(right) buttons in the popup.
6. Press Hand button to stop manual mode for the component and the X
button to close the popup.
or
Press the X button to close the popup and let the component remain in
manually set status. The popup is closed, and a hand icon is displayed by
the component to indicate it is manually operated.
7. Press the Manual function button to exit manual mode.
Result: All manually operated components are restored to their default
status.
200001138-1-EN-GB 39
EN 3 Chapter 3: Operating instructions and control system description
1 Component activities:
• - Open V201-20 (reactor outlet)
- Start counter: Accumulated water and
CIP required.
- Wait for flow p116 to be established. If
not established, process is stopped.
- Stop P403-1 (UVR cooling water pump)
(if used)
• - Close 403-35 (cooling water inlet)
40 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
200001138-1-EN-GB 41
EN 3 Chapter 3: Operating instructions and control system description
42 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
200001138-1-EN-GB 43
EN 3 Chapter 3: Operating instructions and control system description
44 200001138-1-EN-GB
Chapter 3: Operating instructions and control system description 3 EN
200001138-1-EN-GB 45
EN 3 Chapter 3: Operating instructions and control system description
46 200001138-1-EN-GB
EN
4 Chapter 4: Parameters
4.1 Page 5.6 — Installation parameters
This section describes the installation specific system parameters.
200001138-1-EN-GB 47
EN 4 Chapter 4: Parameters
48 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
p500 Defines if the log box (optional) is installed to monitor and log
external valves and pumps, that are not part of Alfa Laval’s scope
Log box Not used of supply.
Alternatives: Activated or Not used.
200001138-1-EN-GB 49
EN 4 Chapter 4: Parameters
Low pressure,
p103 warning trigger 0.1 –1 to 2 bar Setpoint for warning due to low pressure.
(PT201-16)
50 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
200001138-1-EN-GB 51
EN 4 Chapter 4: Parameters
52 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
Configuration of VFD
ABB ACS880 frequency converter settings, valid for PureBallast Booster pump.
Note! This document only shows the parameters changed from default settings.
Reset to default settings can be done with parameter 96.6=Restore defaults.
Consult the VFD documentation for detailed information.
Parameters should always be consistent with data on the Motor Rating Plate.
Contents
1 Control panel ....................................................................................................................... 2
1.1 Control panel parts. ......................................................................................................... 2
1.2 Display and Keys ............................................................................................................. 3
1.3 Status LED ....................................................................................................................... 5
1.4 Basic operation ................................................................................................................ 6
1.5 Fault and warnings .......................................................................................................... 6
2 Parameter mode .................................................................................................................. 7
2.1 Parameter view. ............................................................................................................... 8
2.2 Parameter editing. ........................................................................................................... 9
2.3 Numeric parameter editing. .......................................................................................... 10
2.4 How to upload data from a drive to the panel ............................................................. 10
2.5 How to download data from the panel to the drive ..................................................... 12
3 Booster pump .................................................................................................................... 13
3.1 Motor Setup .................................................................................................................... 13
3.2 Additional parameters ................................................................................................... 13
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200001138-1-EN-GB 53
EN 4 Chapter 4: Parameters
1 Control panel
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
54 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
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rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
200001138-1-EN-GB 55
EN 4 Chapter 4: Parameters
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
56 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
200001138-1-EN-GB 57
EN 4 Chapter 4: Parameters
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
58 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
2 Parameter mode
The panel enters the Parameter Mode when the user presses the PAR key.
When configuring multiple drives it can be time saving to copy parameters from one drive
to another by using the control panel of the drive. Section 2.2 and 2.3 describes this
procedure.
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rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
200001138-1-EN-GB 59
EN 4 Chapter 4: Parameters
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
60 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
200001138-1-EN-GB 61
EN 4 Chapter 4: Parameters
Note:
· Upload before downloading
· Ensure the program versions of the destination drive are the same as the versions of
the source drive, see parameters 33.01 and 33.02.
· Before removing the panel from a drive, ensure the panel is in remote operating mode
(change with the LOC/REM key).
Template ID: 9004871 Version 2
62 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
Before upload, do the following in the drive from which the copies are to be taken:
· Set the parameters in group 10 to 97 as preferred.
· Proceed to upload sequence (below).
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rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
200001138-1-EN-GB 63
EN 4 Chapter 4: Parameters
Consider the notes in section How to upload data from a drive to the panel in chapter 2.2.
Template ID: 9004871 Version 2
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rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
64 200001138-1-EN-GB
Chapter 4: Parameters 4 EN
3 Booster pump
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related This document may constitute a contractual
rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
200001138-1-EN-GB 65
EN 4 Chapter 4: Parameters
Parameter 96.3 must be set to 1-End user at the end of the parameterization.
To change 96.3 back to 2-Service, parameter 96.02 Passcode must be set to 358.
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rights. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or obligation on the part of Alfa Laval AB only
by any means (electronic, mechanical, recording or otherwise), or for any purpose, without the expressed permission of Alfa Laval. to the extent expressly agreed upon.
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
66 200001138-1-EN-GB
EN
W63
Booster pump low inlet pressure.
The inlet pressure is below the 0.2
Trigger: Pressure transmitter Increase ballast water pump.
bar setpoint.
(PT201–1) (optional).
Delay: 5 sec.
5.2 P201–1
200001138-1-EN-GB 67
EN 5 Chapter 5: Alarms and faultfinding
68 200001138-1-EN-GB
EN
200001138-1-EN-GB 69
EN 6 Chapter 6: Technical data
NOTE
Pressure requirement only includes PureBallast’s components. Piping is
not included.
If a backflush pump P309–1 is not used, pressure drop in pipe 309
(Δp309) must be calculated and added according to the table below.
Bar Comment
Pressure drop for UV reactors and PureBallast’s
0.2 valves.
Pressure drop during Max differential pressure over the filter during
ballast ballast operation. When the differential pressure
0.5 reaches 0.5 bar due to dirt in the filter, a
backflush is started automatically.
1.0 Required pressure to clean the filter.
Pressure needed for If a backflush pump P309–1 is not used, pressure
backflush drop in pipe 309 must be calculated and added.
Δp309 This is vessel specific and must be calculated
using required flow in pipe 309: 126 m3/h.
Pressure reduction if ballast water booster pump
-1,3 P201–1 is used.
The ballast pump must deliver pressure at filter
Total inlet, covering total pressure drop over
PureBallast system.
6.3 Ex components
All components in zone 1 have been chosen to be compliant with the Ex
requirements. The tables below list all components that are part of the Ex
protection, sorted on UV reactor, CIP module, filter and interconnecting piping.
UV reactor
All components on the UV reactor are connected to the lamp drive cabinet
(LDC). All LDCs are interconnected, and jointly connected to the control
cabinet via a switch in LDC 1.
Component and ID Sub components
UV reactor
2 junction boxes
Level switches:
Barrier (isolating amplifier) installed in LDC
(LS201-29)(LS201-30)
Temperature transmitter (TT201-33) Barrier (isolating amplifier) installed in LDC
Temperature switch (TS201-60) Barrier (isolating amplifier) installed in LDC
UV sensor (QT201-50) Barrier (smart repeater) installed in LDC
Valves:
Solenoid coil
(V320-4) (V321-2) (V404-36)
Solenoid coil
UVR inlet and outlet valve:
Sensor, inductive
(V201-19) (V201-20)
Barrier (isolating amplifier) installed in LDC
70 200001138-1-EN-GB
Chapter 6: Technical data 6 EN
CIP module
All components on the CIP module are connected to the control cabinet via
the junction box.
Component and ID Sub components
Junction box with fuses
Valve block for
Drain pump (P320-1) CIP pump
(P321-5)
Valve block for:
(V310-1) (V310-6) (V320-2)
(V321-1) (V321-4) (V460-2)
(V571-1)
Filter
All components on the filter are connected to the control cabinet via the
junction box.
Component and ID Sub components
Filter motor (M709-43)
Junction box
Pressure transmitters:
(PT201-71) (PT201-72)
Backflush valve (V309-1) Solenoid coil
Interconnecting piping
All components in the pipe net are connected to the control cabinet via
components own connection or junction box.
Component and ID Sub components
Flow transmitter (FIT201-1)
Pressure transmitter (PT201-16) Junction box
Switch box
Positioner
Control valve (V201–8)
Barrier for positioner installed in control
cabinet
Valves:
(V201-3)
(V201-9) Solenoid coil
(V201-32) Switch box
(V212-31)
(V403-35)
UVR cooling water pump (optional)
(P403–1)
Ballast water booster pump
(optional) (P201–1), including level Barrier for level switch installed in VFD JB
switch (LS662–1)
Junction box
Pressure transmitter (PT201-1)
200001138-1-EN-GB 71
EN 6 Chapter 6: Technical data
72 200001138-1-EN-GB
EN
200001138-1-EN-GB 73
EN 7 Chapter 7: Service manual
Zink-anode condition
Close service valves and drain pump / pipe. Remove anode flange and
inspect anode condition. Replace anode as necessary.
74 200001138-1-EN-GB
Chapter 7: Service manual 7 EN
• Good quality grease with lithium complex soap and with mineral- or PAO-
oil.
• Base oil viscosity 70-150 cSt at 40°C.
• Consistency NLGI grade 2 or 3.
• Temperature range -30°C - +140°C continuously.
WARNING
Always disconnect the power supply before disassembling, and secure it from being switched on.
CAUTION
Empty the pipe, and assure that nobody can open valves etc.
Remove the spool piece
Do not make any modifications on Ex-certified devices. If a component needs to be replaced, it
must be replaced with an identical Ex classified part.
200001138-1-EN-GB 75
EN 7 Chapter 7: Service manual
2 Electric motor.
Note: Repair of the motor shall be carried out
by qualified personnel, and prior authorization
from manufacturer is essential for explosion
protected motors grade EExde.
a) Switch off and lock the power supply,
mark the wires and their position before
disconnection.
b) Remove the electric motor. Use an
extractor to remove the flexible coupling.
c) In case of bearing replacement, always
replace both bearings and shaft seals as
well. For details see step 4.
76 200001138-1-EN-GB
Chapter 7: Service manual 7 EN
200001138-1-EN-GB 77
PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System
- - PureBallast 3.1 Ex PB-03028
System Manual
System Manual
English
1 PureBallast 3.1 System
manual
The PureBallast 3.1 is available in several sizes, defined by the system’s max treatment rated
capacity (TRC). The TRC is included in the system name and the title of each system manual.
The basic document describing the system is the connection list, and the therein stated flow chart.
Those documents are included in the system manual, chapter 6, Installation description and
drawings.
The tables in this document lists the PureBallast systems with reference to the system manual
describing them and the connection list and flow chart defining them.
Versions. The USCG version use flow control to be compliant with USCG legislation. The USCG
HP (high performance) have double reactor capacity which allows treatment at full capacity at all
time. The US flag version is for vessels sailing under US flag.
Flowchart
Component Manufacturer Model (Size according to connection list)
legend
Filter:
Automatic ACB-xx-yy Ex, 20 µm mesh
self-cleaning Filtrex (xx=935 – 9200,
filter yy= DN200 - DN600)
Ex: Barksdale Ex: 425X
PT201-71
Pressure sensor
& -72 Ex US flag: Hydac Ex US flag: HDA 4346
UV reactor
UV reactor, 300 Ex or,
UV reactor Wallenius Water UV reactor, 600 Ex or,
UV reactor, 1000 Ex
Medium pressure UV lamp, 3 kW for UV reactor
UV lamp 170, 300 and 600
Wallenius Water
Medium pressure UV lamp, 6 kW for UV reactor
1000
Lamp sleeve Wallenius Water Synthetic Quartz 9000738 02
UV-TECHNIK, SUV 20.2 Y2 C 40° 1000 W/m² or,
QT201-50 UV sensor IL Metronic SUV 20.2 Y2 C 40° 3000 W/m² for UV reactor
Sensortechnik GmbH 1000
Temperature, Bimetal Temperature Switch 60.8301
TS201-60 JUMO
switch
Thermometer, Dtrans T100 Screw-in RTD temperature probe
TT201-33 JUMO
resistance without transmitter 90.2815
LS201-29 Vibration limit Liquiphant M FTL50
Endress+Hauser
& -30 switch
- PEPPERL+FUCHS NCN3…, Inductive pos. sensor
V201-19 & - Air Torque Spa AT range,
Valve
-20
- ARI Armaturen ARI –GESA, Lugged valve
Valves:
- Siemens SIPART PS2, Positioner
Ex: ALB ACR1.., Pos. switch box
Flow control - Rotech
V201-8 Ex US flag: ALB APF2, Pos. switch box
valve
- Air Torque Spa AT range, Actuator
- ARI Armaturen ARI –GESA, Lugged valve
Ex: ALB ACR1.., Pos. switch box
V201-3, Filter inlet, outlet, - Rotech
-9, -32 & by-pass, & Start Ex US flag: ALB APF2, Pos. switch box
V403-35 up cooling valve - Air Torque Spa AT range
- ARI Armaturen ARI –GESA, Lugged valve
Filter backflush - Air Torque Spa AT range,
V309-1
valve - ARI Armaturen ARI –GESA, Lugged valve
Flowchart
Component Manufacturer Model (Size according to connection list)
legend
Ex: ALB ACR1.., Pos. switch box
- Rotech
Ex US flag: ALB APF2, Pos. switch box
V212-31 By-pass valve - Air Torque Spa AT range, Actuator
- Rotork ILG-D series, Handwheel
- ARI Armaturen ARI –GESA, Lugged valve
Flow meter:
Endress+Hauser or Promag 50W1F Sitrans F, Magflo MAG 6000I
FIT201-1 Flow transmitter
Siemens
System pressure transmitter:
Ex: Barksdale Ex: 425X
Pressure
PT201-16
transmitter Ex US flag: Hydac Ex US flag: HDA 4346
Cleaning in Place (CIP) unit:
CIP cleaning
Alfa Laval CIP 3.1 Ex
module
CIP cleaning
Alfa Laval Alpacon Descalant Offshore
liquid
Lamp Drive Cabinet (LDC):
Lamp Drive
Alfa Laval LDC 3.1 Ex
Cabinet
Control Cabinet:
Control Cabinet Alfa Laval CC 3.1 Ex
Barrier box: (in US flag systems only)
Barrier box Alfa Laval BB 3.1 Ex US flag
System manual
Lit. Code 200000691-1-EN-GB
Manual No. 9028245 02 v. 5
Published by
Alfa Laval Tumba AB
Hans Stahles väg 7
SE-147 80 Tumba, Sweden
+46 8 530 650 00
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.
Contents
1 Safety............................................................................................................................... 9
1.1 Introduction..............................................................................................................10
1.2 Safety information....................................................................................................10
1.2.1 General safety information.........................................................................10
1.2.2 Specific safety information ........................................................................ 10
1.2.3 Personnel requirements.............................................................................13
1.2.4 Warning signs used in the manual............................................................. 13
1.3 Environmental issues ............................................................................................. 14
1.3.1 Unpacking.................................................................................................. 14
1.3.2 Other materials.......................................................................................... 14
2 System description................................................................................................ 15
2.1 Introduction..............................................................................................................16
2.1.1 Components overview............................................................................... 17
2.1.2 Item numbers............................................................................................. 19
2.1.3 Abbreviations............................................................................................. 19
2.2 Process overview.................................................................................................... 20
2.2.1 IMO and USCG mode................................................................................20
2.2.2 Flow control and power optimization..........................................................20
2.2.3 Start-up...................................................................................................... 23
2.2.4 Ballasting................................................................................................... 23
2.2.5 Deballasting............................................................................................... 25
2.2.6 Tank stripping.............................................................................................26
2.2.7 Ballast water handling in the event of malfunction.....................................26
2.3 System components description..............................................................................27
2.3.1 UV reactor..................................................................................................27
2.3.2 Filter .......................................................................................................... 29
2.3.3 CIP (cleaning-in-place) module..................................................................34
2.3.4 Cabinets and control system......................................................................35
2.3.5 Main valves................................................................................................ 40
2.3.6 Flow meter................................................................................................. 41
2.3.7 Pressure monitoring...................................................................................42
2.3.8 Sampling devices.......................................................................................42
4 Parameters............................................................................................................... 159
4.1 Introduction............................................................................................................160
4.2 Control system parameters................................................................................... 160
4.2.1 Introduction to parameters and parameter settings................................. 160
4.2.2 Page 5.1 — Main parameters 1............................................................... 162
4.2.3 Page 5.2 — Main parameters 2............................................................... 165
4.2.4 Page 5.3 — UVR parameters.................................................................. 169
4.2.5 Page 5.4 — Filter parameters..................................................................171
4.2.6 Page 5.5 — CIP parameters....................................................................174
4.2.7 Page 5.7 — Remote interface..................................................................175
4.2.8 Page 5.6 — Installation parameters.........................................................177
4.3 Lamp power supply (LPS) parameters.................................................................. 180
4.3.1 DIP switch settings...................................................................................180
4.4 Fuse settings for filter motor and installed (optional) pump motors.......................182
4.5 Flow meter parameters..........................................................................................182
1 Safety
Safety
200000691-1-EN-GB 9
EN 1 Safety
1.1 Introduction
This chapter contains general safety and environmental information, personnel
requirements and explanations of symbols used for the PureBallast system.
Safety
• Always read and follow the documentation that is included in shipment of
components and spare parts regarding handling, safety and disposal.
• Mobile cell phones must not be switched on within an area of 1 meter from
an open cabinet door.
• Before installation, read applicable sections Technical data and drawings
on page 233 and in the Design and installation guidelines.
• Before operation, read the Preparations and conditions section for
applicable instructions in Operating instructions and control system
description on page 43.
10 200000691-1-EN-GB
Safety 1 EN
Safety
• Before installation, check that the UV lamps and quartz sleeves are not
broken.
• Depressurize reactors and allow equipment to cool down completely before
disassembling.
• Never handle UV lamps before they are completely cooled down. A hot UV
lamp is under high internal pressure, and the risk of bursting exists. A hot
lamp could also cause a burn if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp
when correctly installed inside the reactor with end caps properly closed.
• UV lamps contain a small amount of mercury (less than 0.2 grams per
lamp) and must be handled and disposed of with care. Used UV lamps can
be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations. If a UV lamp has accidentally been broken,
mercury could be spilt. Remove mercury with a special tool such as a
syringe (or use pure sulphure to bind the mercury for easy collection).
• Do not allow mercury to come in contact with your eyes or skin. Do not
inhale mercury fumes.
• Free mercury must be kept in an airtight bottle, and must be disposed of
according to national regulations
• In case of having inhaled mercury fumes, consult a doctor and follow
medical instructions.
200000691-1-EN-GB 11
EN 1 Safety
• Operation and/or manual start of the UV lamps is only allowed when there
is water in the reactor (indicated by level switch LS201-29 and LS201-30),
and the water temperature is below 60 °C.
Improper operation could seriously damage the equipment and injure
personnel.
• Manual operation of LPS, may only be performed after cable connection. If
not hazardous situation may arise which, if not avoided, will result in death
or serious injury.
• Before maintenance of the LDC: Switch off the PureBallast system and
disconnect it from the power supply. See section Shut down and deactivate
system on page 101. The cabinet contains a fan, which can cause injury if
in operation.
Safety
• If CIP liquid; Alpacon descalant offshore, comes in contact with eyes or
skin, rinse thoroughly with cold water.
• See Safety data sheet / CIP liquid on page 370
• Always wear protective eye glasses and gloves while working on the pump.
Pump
• CIP pump: Always wear protective eye glasses and gloves while working
on the pump.
12 200000691-1-EN-GB
Safety 1 EN
Protective earth
• Components e.g. UVR, filter, CIP module, flow meter, cabinets and remote
control panel (optional) must be earthed. The earth nut is indicated as “791”
or “PE bolt” in the dimension drawings.
Safety
• Skilled person: A person with technical knowledge or sufficient experience
to perform the tasks at hand and to enable him or her to perceive risks and
to avoid hazards which electricity/mechanics can create.
The person must have knowledge about the specific Ex standard used to
eliminate the risk of explosion, for example IEC 60079 series.
• Instructed person: A person adequately advised or supervised by a skilled
person to enable him or her to perceive risks and to avoid hazards which
electricity/mechanics can create.
• Alfa Laval service engineer: A person with knowledge about the
PureBallast system. Alfa Laval service engineer can set parameters and
repair intrinsically safe apparatuses.
The person must have knowledge about the specific Ex standard used to
eliminate the risk of explosion, for example IEC 60079 series.
In some cases special skilled personnel may need to be hired, like electricians
and others. In some of these cases the personnel has to be certified according
to local regulations with experience of similar types of work.
The person must have vast knowledge about the specific Ex standard used to
eliminate the risk of explosion, for example IEC 60079 series.
DANGER
DANGER: indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
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EN 1 Safety
WARNING
WARNING: indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION: indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTE
Note: indicates a potentially hazardous situation which, if not avoided,
may result in property damage.
1.3.1 Unpacking
• Packing material consists of wood, plastics, cardboard boxes and in some
cases metal straps.
• Wood and cardboard boxes can be reused, recycled or used for energy
Safety
recovery.
• Plastics should be recycled or burnt at a licensed waste incineration plant.
• Metal straps should be sent for material recycling.
14 200000691-1-EN-GB
EN
2 System description
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EN 2 System description
2.1 Introduction
This contains general information about the PureBallast system and its
components.
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System description 2 EN
System overview
The PureBallast system is an integral part of the vessel’s ballast water system,
on the discharge side of the vessel’s ballast water pumps. During ballast
operation, the water is led through the filter, which removes larger particles
and organisms, and then to the UV reactor, where the water is treated with UV
light. During deballast, the water is led the same way, but the filter is
bypassed.
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EN 2 System description
The UV lamps are powered by the LDC (via LPSs, lamp power supplies).
Every UV reactor has one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. Note
that full treatment requires treatment both during ballast and deballast.
The UV reactors are cleaned using the CIP (cleaning-in-place) module, which
first rinse the UV reactor with technical water / potable water, and then
circulates CIP liquid through the UV reactor. At the end of the process the UV
reactor and the filter (filter preservation) is filled with technical water / potable
water from the CIP.
The complete system and ongoing processes is controlled and monitored from
the control cabinet.
Control can also be performed from remote control panels and the ship’s
ISCS, via the remote interface if connected.
The bypass valve* makes it possible to bypass the entire system, for example
to secure ballast operation if the system is not functioning. The valve is
controlled from the ISCS (integrated ship control system).
* Optional as part of scope of supply.
Ex
PureBallast Ex is an explosion-proof version of the PureBallast water
treatment system. The version use Ex certified equipment and a redundant
safety control system to allow installation on board most types of vessels that
carry potentially flammable or explosive substances.
PureBallast Ex is approved for use in hazardous areas defined as zone 1,
explosion group IIC and temperature class T4 (135°) accordin to the IEC
60079 series of standards. It fulfills the European Directive ATEX 2014/34/EU,
recommended by the IMO for use in marine applications and on the
international market.
PureBallast Ex requires the following:
• The PureBallast Ex version must be installed. This version is equipped with
components certified according to the Atex regulations to be used in
potentially explosive atmospheres.
• The system must be installed, operated and maintained according to a
selected standard used to eliminate the risk of explosion. There are several
standards to be used, for example the European standard IEC 60079-14.
The main features of PureBallasts Ex version are:
• Ex specific components are used in zone 1. See chapter 6. Installation
description and drawings, section Ex protection.
• An Ex specific version of the control system is used to operate and monitor
the system.
• A safety control system supplements the control system. It is designed for
the specific task of securing that the UV reactor is not overheated. All
functions in the safety control system uses redundancy to ensure one fault
tolerance. See chapter 6. Installation description and drawings, section Ex
protection.
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Marking plate
2.1.3 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
Previous name for UV reactor. AOT stands for Advanced oxidation
AOT reactor technology.
EU directive “Appareils destinés à être utilisés en ATmosphères
Atex EXplosivles”
CIP Cleaning in place
CIP module Cleaning in place module. Performs the CIP process.
DIN Deutche Institut für Normung
Standard according to CEN (European Committee for
EN Standardization).
Ex Explosion-proof
I/O Input/output (Describes a program or device handling data)
IACS International Association of Classification Societies
IECEx International Electrotechnical Commission Explosive
ISCS Integrated ship control system
IMO International Maritime Organization
JIS Japanese Industrial Standard
LED Light emitting diode
LDC Lamp drive cabinet.
LPS Lamp power supply
MCB Motor circuit breaker
PLC Programmable logical controller (PureBallast control system)
USCG United states coast guard
UV Ultra violet
UV reactor The main component, where the water is treated using UV light.
UVR UV reactor
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EN 2 System description
USCG mode
USCG mode is used for
• ballast when the destination port is within US waters, regardless of starting
point.
• deballast within US waters.
Hold-time
USCG mode can be run with a 3 days hold-time or 0 day hold-time. Choose
0/3 days hold-time in parameter p182.
The time between a completed ballast and the start of deballast
3 days hold-time or stripping must be at least 72 hours.
The time between a completed ballast and the start of deballast
0 day hold-time or stripping must be at least 2.5 hours.
Note! If ballast water will be stored in tank shorter than 72 hours, the water
must be treated using 0 days mode (p182 = 0 days) at ballast.
IMO mode
The illustration below show flow control and power optimization depending on
the UV intensity, together with the compliant limit.
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System description 2 EN
USCG mode
Compliant limit: When UVI falls below compliant limit, the operation
continues but does not fulfill the type approval certificate. A warning and a
common alarm is issued and a log is written to the event log. The operator
must take action according to the ballast water plan to stop the operation or to
continue operation and not comply with type approval certificate.
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EN 2 System description
In USCG mode, the flow is regulated to be as high as possible to fully treat the
water. Between UVI value a and b, the flow is regulated be between 50 % and
100 % of full flow capacity. The higher UVI value (cleaner water) the the higher
flow.
In IMO mode, the flow is always 100 % above compliant limit. But when UVI
falls below the compliant limit, the flow is decreased to maximum 50 %
The flow is decreased to 80% of max flow and the UV lamps are lit to 100 %.
This is done so that the treatment shall correspond to the type approval
requirements.
If a UV lamp breaks during operation, the ongoing process continues but is not
compliant. A warning and an additional common alarm is issued and a log is
written to the event log. The operator should act according to the ballast water
management plan. After process is finished, it will not be possible to start a
new process until the broken lamp has been changed.
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System description 2 EN
2.2.3 Start-up
Ballasting and deballasting begins with a start-up phase. There must be
available power for the system. If power management is integrated, this will be
confirmed automatically. If power management is not integrated, this is
confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is
pumped through the UV reactor to secure that the UV lamps are not
overheated. The temperature transmitter and level switch secure that there is
water in the UV reactor and that the UV lamps are sufficiently cooled. If not, an
alarm is issued and the system is shut down.
2.2.4 Ballasting
After the start-up, when the lamps are ready, the operator is requested to start
the ballast pump. The ballast water is pumped from the sea chest to the filter,
that removes larger particles and organisms. This also reduces the amount of
sediment build-up in the ballast water tanks. The organisms and sediments
caught in the filter are flushed overboard via regular filter backflush operations.
The water is finally led to the UV reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.
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EN 2 System description
Ballasting
2.2.4.1 Backflush
To keep the filter clean, it is automatically backflushed. The backflush is
performed during ongoing process without interrupting the ballasting process.
When a ballast operation is stopped, a backflush is performed before the
system comes to a full stop. The ballast water used for backflushing is
returned to the sea directly at the ballasting site.
Filter backflush
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System description 2 EN
2.2.5 Deballasting
After the start-up, when the lamps are ready, the operator is requested to start
the ballast pump. The water passes through the UV reactor, but the filter is
bypassed since the water has already been filtered during ballasting. The
reason for treating the water a second time during deballasting is to secure
that the treatment is fully effective. The minor part of the organisms, which
were only injured during ballast, will be rendered totally harmless during the
deballast.
The flow control and power optimization functions in the same way as during
ballasting.
Deballasting
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EN 2 System description
Stripping
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2.3.1 UV reactor
The main part of PureBallast is the UV reactor in combination with a lamp
drive cabinet (LDC) giving power to the UV lamps in the UV reactor. The LDC
does not need to be placed in close relation to the UV reactor.
Destruction of DNA
There are no chemical substances added to the process, and there are no
toxic residuals created. Since the water is not affected chemically, there are no
environmental impact and the process does not influence corrosion in any
way.
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System description 2 EN
UV reactor
1. Ballast water outlet valve
2. CIP liquid outlet valve (actuator indicated)
3. Temperature transmitter (Temperature switch not visible)
4. Junction box (signal cables)
5. UV lamp cap (UV lamp and quartz sleeve inside)
6. Inlet valve from CIP module and reactor drain valve (actuator indicated)
7. Ballast water inlet valve
8. UV sensor
9. Level switch
10. Cooling water outlet valve
11. Level switch
2.3.2 Filter
2.3.2.1 Filter working principle
The filter is a fully automatic self-rinsing component, equipped with a filter
element to remove particles and organisms from the ballast water flow. The
ballast water is lead through the filter, and filtered particles are trapped in the
filter.
An optional backflush pump can be mounted to secure correct flow in the
backflush pipe 309.
The filter is entirely controlled from the PureBallast control system.
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EN 2 System description
1. Geared motor
2. Relief valve
3. Backlflush outlet
4. Backflush pump
5. Drain plug
6. Ballast water inlet
7. Adaptor plate to change flange standard and/or diameter (in some systems)
8. Junction box (Not included in the skid version of PureBallast)
9. Ballast water outlet
To secure efficient filtration, the filter performs a self-rinsing backflush
operation at time set intervals or when triggered by indication of dirt in the
filter. Pressure drop over the filter is monitored by pressure transmitters on the
filter inlet and outlet. Dirt is detected by an increased differential pressure drop
caused by particles in the filter. When the differential pressure reaches a
parameter set value, an automatic backflush operation starts.
The backflushing does not interrupt the filtration process, since only a part of
the filter element area is cleaned. The areas that are not cleaned at a specific
time continues the filtration of the ballast water. It is also possible to start
backflush manually from the control system.
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Step 1: Filtration
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EN 2 System description
Step 2: Backflush
At backflush, the motor (2) starts to
drives the nozzle (3). At the same time,
the backflush valve (6) opens.
The nozzle rotates inside the filter
element. The dirt on the inside of the filter
element (1) is cleaned by a high-efficacy
backflush flow in front of the nozzle. The
backflush flow uses filtered water from
the chamber (D) to clean the filter from
the outside to the inside. The water,
together with the dirt, is lead via the
nozzle through the duct (5) and out via
the backflush valve (6).
All areas of the filter element that is not in
front of the nozzle are filtering the water
as in step 1: The water flows from the
inlet (A) through the filter element and out
through the outlet (B).
When the backflush is done (after
approxemately 20 seconds), the motor
stops and the backflush valve is closed.
The filter then goes back filtration with full
flow to the ballast tank (no flow used for
backflushing.
If a new backflush is triggered within 2
minutes (parameter p302), the filter will
perform a continuous backflush for 20
minutes (parameter p303).
A. Inlet
B. Outlet
D. Chamber
1. Filter element
2. Motor
3. Nozzle seen from the side (rotating
during backflush)
6. Backflush valve
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To secure that there is enough CIP liquid for the process, the level switch in
the reactor indicates when it is filled with CIP liquid. To prevent intrusion of
water in the technical water / potable water system, a backflow preventer is
used in the CIP module.
The CIP module is equipped with two membrane pumps:
• Pump P320-1 circulates the CIP liquid in the UV reactor and fills it with
technical water / potable water.
• Pump P321-5 drains water (sea and technical water / potable water)
overboard from the reactor, via the drain line.
1. Deaeration valve
2. Junction box
3. Valve blocks
4. Regulator
5. Pump (CIP liquid)
6. Backflow preventer
7. Pump (reactor drain)
8. Tank for CIP liquid
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EN 2 System description
The control cabinet functions as a single point of contact for signal cables to
and from the vessel. Examples of integration: Remote interface integration
and power management system (PMS). Remote interface will allow control of
PureBallast from the vessel’s ISCS and PMS integration will allow automatic
verification that there is enough power to run an operation. If not integrated,
the operator must verify this manually. Also integration with other external
components (not part of Alfa Laval’s scope of supply), such as GPS or booster
pumps, are done to the control cabinet.
Control cabinet
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The safety control system is separate from the control system, and therefore
redundant to strengthen the protection. It is based on safety relays, is
hardwired and is using redundancy to ensure one fault tolerance. See chapter
6. Installation description and drawings, section Ex protection.
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EN 2 System description
PureBallast control system´s main control panel integrated with the ISCS. The
interface is only an example.
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• Inlet valves: The inlet valves directs the water flow from the vessel's ballast
water system into the PureBallast system. Different valves are used during
ballast and deballast.
• System and filter inlet valve (V201–3): Inlet valve to PureBallast during
ballast. The valve directs the water flow through the PureBallast filter.
• Filter outlet valve (V201–32): The valve directs the water flow from the
filter to the UV reactor during ballast.
• Inlet valve (V201–9): Inlet valve to PureBallast during deballast. The
valve directs the water to PureBallast, but bypass the filter, since the
water was filtered during ballasting.
• Control valve (V201–8): The valve have the following functions:
• Automatic regulation to maintain flow during operation so it does not
exceed selected certified maximum flow. Regulation is based on input
from the flow meter.
• Automatic regulation to maintain pressure needed to perform backflush
of the filter. Regulation is based on input from the pressure transmitter.
• Outlet valve from the PureBallast system to the vessel’s ballast water
system after treatment.
• Cooling water inlet valve (V403-35): Supplies cooling water to the reactor
to secure cooling of the lamps and prevent overheating during start-up. The
valve is common for all installed reactors.
• Check valve (CV201): Ensures that there is water in the reactor at all
times.
• PureBallast bypass valve (V212–31): Makes it possible to completely
bypass the PureBallast system. The valve is solely operated from the ISCS,
but the valve positioning is (and must be) indicated in the PureBallast
control system. When PureBallast is bypassed, an event is written to the
event log. The valve is equipped with a handwheel for manual operation.
The component is optional to be included in Alfa Laval’s scope of supply.
Monitor flow
The flow meter monitor the flow within the PureBallast system, to secure that
certified flow is not exceeded. If so, a warning is issued. The flow meter send
valuable data to the PureBallast control system, where it is displayed.
Example of information: Current flow and data about total amount of treated
ballast water.
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42 200000691-1-EN-GB
EN
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EN 3 Operating instructions and control system description
3.1 Introduction
The control system is used to operate and monitor the PureBallast system. It
also contains functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of
the control system pages, step-by-step instructions and a process description
with detailed information about the components (valves, motors, pumps etc)
involved in each step of respective process.
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3.1.1.2 Stripping
Stripping can be performed to empty the ballast tanks. The first time a ballast
tank is stripped, PureBallast must be bypassed.
The stripping process is basically the same as a ballast process with the
following difference: A stripping eductor (or a stripping pump) should be used
to secure enough flow in the system.
Also, the number of UV reactors used is parameter set to normally one, to
make sure that the flow from the stripping pump/eductor is enough to cool the
UV reactor.
We recommend that the driving water alone (without the ballast water flow
from the tank) fulfils the minimum flow requirement for deballast operation.
This will minimize the risk of shut down due to low flow when flow of ballast
water is uneven.
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• As Guest.
• Operate the system to perform daily routines, for example
1 Operator aot ballast and acknowledge alarms.
• Full access to page 1.4 Power request.
• Download files and backup to a USB memory.
• As level Operator.
• Operate equipment in manual mode.
Advanced • Access to set parameters, with exception from critical
2 2007
operator parameters. See chapter 4. Parameters for information
• Full access to page 4.3 Operation timers and 4.4
Operation timers UVR.
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EN 3 Operating instructions and control system description
• The inactive control panel will display a message informing that another
control panel is active (some one else is logged in). The popup gives the
alternative to cancel or to continue. If continue is chosen, control is
switched from the first panel to the new panel.
• The active panel will display a popup message informing that another the
panel is inactive and that control is taken by another panel.
On each control panel it is possible to see which panel that is active and which
login level that is used. A panel alias can be entered to clarify where the panel
is installed, for example pump room, bridge etc. See instruction Set control
panel IP address. This information is visible in the upper right corner of the
system according to syntax: login level@control panel.
“Login level” can be: Guest, Operator, Advanced operator or AlfaLaval.
“Control panel” can be:
• 192.168.0.10 (Master) = Main control panel
• 192.168.0.11 = Remote control panel 1
• 192.168.0.12 = Remote control panel 2
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Top tabs: Contain the main function areas of the control system: Overview,
alarm lists, trend curves, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab.
Popup windows: Are used to display or enter detailed information. It is
possible to move a popup by touching the name bar and drag it. A popup is
closed either by touching confirming entered information by touching a
function button (OK, Confirm, etc.) or the X icon in the top right corner (data is
not saved).
Data entry fields: A white field indicates that it is possible to enter data. When
the field is touched, a keyboard is displayed, which is used to enter
information. Enter data is confirmed by touching the Enter button. To close the
keyboard without saving data, touch the Esc button.
Function buttons: Function buttons are used for main processes and control
of the system. They are placed at the bottom of the screen and are always
visible. Some buttons only show if a function is activated. For example, the
Remote and Local buttons are only visible if remote interface is activated.
Status indication – Button colour: The buttons appear in different colours,
indicating status:
Blue The function is enabled.
Blue with The function is activated.
checkmark
The function is not possible to activate, for example if higher login
Grey level is required for the function.
Status indication – Button light: After a function button is pressed, a frame is lit to
indicate status:
Green Command is active.
Green, blinking Command will be processed when possible in the data work flow.
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Button Description
Pause ballast, deballast or stripping process. This is only possible
during full ballast or full deballast. The button can be hidden, using
parameter p137. Allowed length of a pause is parameter set (p138).
After defined time, the paused process is stopped.
To resume a paused process, press the function button Ballast,
Deballast or Strip depending on which process that was paused.
Activate night light for the panel. Night light makes the panel less
bright. Toggles between night light and day light.
Degree of brightness, is set in the Night light level field in page 4.1
System info.
Login: Expanding menu with login fields. See section Login levels in
Operating instructions and control system description on page 43.
Button Description
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Alarms and warnings for components are displayed directly on the component
they regard:
Active alarm.
Active warning.
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Status box
The status box display current status for the PureBallast system. The
information is updated continuously. To see accumulated operation runtime for
the components, see page 4.3 – Operation timers.
The following status information is displayed:
Status information (unit) Description
Process: Ongoing process.
Process and subprocess Subprocess: Sub steps of ongoing process, for
example Start-up during Ballast process.
Remaining time for the ongoing subprocess in
Time the upper right corner.
Amount of water processed during ongoing
Processed volume (m3/h) process. Value remain until next process is
started.
Power consumption (kW) Power consumption for ongoing process.
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Flow chart
The flow chart display a schematic overview of the PureBallast system and its
components.
Relevant information regarding ongoing process and component status can be
monitored directly in the flow chart. Flow in pipes is indicated by coloring of the
pipes and component status are displayed by color indications. Pressure, flow
and control valve opening percentage are displayed directly on component.
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Detailed information about the UV reactor, filter and CIP components can be
monitored in their respective pages. The popup contain status for sub
components, for example valves, motors and UV lamps in the UV reactor.
UVR cooling water pump (P403–1) is only displayed if it is used and activated
in the parameter pages.
In manual mode (login level Advanced operator or higher) it is also possible to
operate components manually: If a component is pressed, a popup window is
displayed from which the component can be operated.
Status indication – Component colour
Component status is indicated by a coloured frame:
Status indication
Pipes A pipe filled with colour indicates that there is flow in
the pipe.
Status indication
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Valves and pumps
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a
component. The ID will be visible in page 1.1 Overview
and popups for the components. See instruction Set
ship specific component ID.
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Flow selection
Function in the same way as flow selection in page 1.1 Overview.
UVR selection
The area displays a table with installed UV reactors with status information. If
more than one UV reactor is installed, it is possible to choose individual UV
reactor for process in standby (if the Auto button is deactivated) or during
process (regardless of Auto button mode).
The following information is displayed:
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Elements Description
Enables active selection of individual UV reactors.
Modify button When pressed, the buttons for respective UV reactor
turns blue and are possible to use.
One row for respective installed UV reactor with current
status indicated in the columns.
UVR button: Press the button to select or deselect. A
checkmark on the button indicates selected. The flow
setpoint for the number of UV reactors selected are
updated in the Flow selection area.
UVR 1, 2, 3 button
Status indication:
Selected: Grey = Not selected. Green = Selected.
Ready: Grey = Not ready. Green = Ready for process.
Alarm: Grey = No alarm. Red = Active alarm.
Apply the new setpoint to be used for process.
Apply button Note: If ballast flow is lower than deballast flow
(parameter p315), the higher value is displayed until
the Ballast button is pressed.
Status
The area displays current status for the flow:
Elements Description
Ballast water flow in the system, indicated by flow
Current flow transmitter FIT201-1.
Maximum allowed flow as set in Flow setpoint or limited
by the number of UV reactors selected in UVR
selection popup. If a smaller filter is installed, the
ballast flow can be lower than the UV reactor capacity.
Certified flow
The information is updated after the warm up time has
elapsed and a UV reactor is used for process. (Before
that it is not used for treatment, and therefore not part
of the certified flow.)
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CIP status
The area displays status for the following pieces of information:
Row Content
Process: Ongoing process. Can be standby, ballast,
deballast and CIP.
Process and sub process
Sub process: Sub steps of ongoing process, for
example “Start-up” during Ballast process.
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Column Content
CIP status for each UV reactor.
Status indication
Yellow = CIP required. During ongoing CIP process,
yellow indicates that the UV reactor is waiting for CIP
CIP error process to start.
Yellow, blinking = CIP process ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to
active alarm on the UV reactor.
Red square: Indicates that there is an active alarm for
CIP the component. Check alarms on page 2.1 – Alarm list.
Status Same information as column CIP, but spelled out.
Time remaining CIP time. If CIP process has not been
started, total time is displayed. During CIP process, the
Estimated time time is counting down continuously.
The CIP process takes about 25 minutes per UV
reactor, if default parameters are used.
Time before a CIP process must be performed after
ballast or deballast. The time disappears when the CIP
Required CIP countdown process is ready. Time is displayed for the UVR with
shortest time left to required CIP.
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Power status
Column Content
Each row represent a number of UV reactors to be
used in a process. Requests can be combined to send
request for 3 UV reactors.
1 UVR: Request power for 1 UV reactor.
2 UVRs: Request power for 2 UV reactors.
Power
The requested power is calculated as the number of
UV reactor times defined power consumption for one
UV reactor.
Common power: Request maximum power, enough to
run all UV reactors installed, even if all UV reactors are
not used.
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Function buttons
The following function buttons are available and displayed when manual mode
is activated:
Buttons Content
If manual mode is activated, a hand icons are
displayed on the page. Press the hand icon to make it
possible to send simulated request or granted signal
manually.
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The main areas of the page are the Alarm list and the Function buttons:
Alarm list
The following information is displayed for each alarm (row):
Column Content
Descriptive alarm text written as: Area-Alarm type
Text AlarmID Alarm text.
Example: UVR2 A138 Error in LDC cabinet.
Active time The time alarm was activated.
The time the alarm/warning was acknowledged. The
alarm/warning remains in the alarm list until the causing
Acknow-ledged time condition is resolved. For example a high temperature
alarm will remain visible, until the temperature is below
the limit value for the alarm/warning.
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Function buttons
The following function buttons are available:
Button Function
Acknowledge selected alarm (row). Press
Ack selected a row to indicate it, and press the button
to acknowledge it.
Ack all Acknowledge all active alarms.
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Diagram area
In the diagram area, trend curves are displayed for one or more components.
Components available for plotting is displayed at the bottom of the screen.
Trend curves can be activated or inactivated for respective component.
The scale of the diagram:
X axis: The time interval is 15 minutes.
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Y axis: The scale and unit used for the Y axis is set in the Settings popup for
respective component. For details, see the Component area section below.
Component area
The following fields and buttons are available for each component in the
component area:
Column Content / Function
Press the button to make settings for the component’s
curve. Settings are done in a popup.
Settings button
1. Press (not slide) the top right button to display or
hide trend curve in the diagram. A green I indicate
displayed, and a grey O indicates not displayed.
2. Press the entry field to change start and stop value
for the components Y axis scale (when this
component’s scale setting is used).
3. Press this button to use this component’s scale
setting in the diagram.
4. Press the entry field to enter number of decimals in
the component area, or use the -- or
++ buttons to increase or decrease.
Function buttons
The following function buttons are available.
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History mode
Press one time unit (year, moth, day etc) and then press
- or + to set time.
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of 15 seconds and the time span for trends displayed on the screen is 1 hour.
Trend curves are saved in the trend history for 24 hours, and are then deleted.
See page 3.1 Trend (15 min) for information about function, fields and buttons.
See chapter 2. System description, section Power optimization for details.
The following information is displayed:
• UVR UV setpoint: The UV intensity the system is aiming to attain by
increasing or decreasing power effect to the LPS controlling the dimming of
the UV lamps. The setpoint is based on actual transmittance and is
updated every 15 seconds.
• UV measurement: Actual UV intensity (W/m2) measured by UV sensor
QT201–50. If intensity is lower or higher than needed, the power to LPS will
increase or decrease to attain setpoint for UV intensity.
• Power output: Actual LPS power to UV lamps. The power is adjusted to
attain the setpoint for UV intensity based on measured water transmittance.
Output is adjusted based on input from UV sensor QT201–50. Power can
be 50–100 %.
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Section Description
on page
HMI Screen saver timeout: Defines time before the panel is set to screen
Backlig save mode. This is set individually per control panel.
ht
Night light level: Defines percent of full light for the night light mode.
Night light is activated by the Night function button.
PLC info CPU temperature (°C): Temperature of the central processor unit (CPU)
in the PLC.
PureBallast PLC software version: Version of the PureBallast PLC
program.
GPS position: Shows current GPS position. The position is used in the
event log.
Select the degrees check box to display symbols for degrees, hours and
minutes.
Control cabinet configuration: Indicates if control of booster pumps can
be controlled from PureBallast control cabinet.
1. Pump started by signal from PureBallast control cabinet: Power
supply with over current protection relay and contactors and are
handled externally.
2. Pump completely controlled from PureBallast control cabinet: Start
signal and power supply with over current protection relays and
contactors from control cabinet. It is still possible to connect pumps
according to configuration 1.
Control cabinet configuration affect parameter p129, p130 and p310.
Backup Settings to/from USB panel: Export and import information to the USB
and panel port on the cabinet door.
restore
Backup button: The following information is saved in a folder named
“PureBallast Backup”:
• Parameter settings. File: Parameters.csv.
• Operating timers for UVR, UV lamps etc. File: operatingtimers.csv.
• Settings for components in the trend curve pages. File:
ValueSaved.xml and ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different
components. File: ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
Restore button: Restore all information from a USB backup to the control
system. See Backup above. This shall not be used to restore parameter
settings after software update. Requires login level Advanced operator.
Parameters: Parameter restore.
Set default button: Set all parameter values to the default values.
Requires login level Advanced operator.
Export Export button: Opens the Export log files popup to export (copy) event
log files log files and alarm list.
For specific information about logged events, see section List of logged
information, Event log on page 121.
Remote Remote control panels button: Open a popup used for setting IP
control addresses for remote control panels (optional). See instruction Set control
panels panel IP address on page 110. Requires login level AlfaLaval.
Debug Cpy2USB button: Only press this button if asked for by the Tumba
log Technical Support team. It’s for Alfa Laval’s internal fault tracing of the
screen.
Enable button: Only press this button if asked for by the Tumba Technical
Support team.Disable button: The default mode of the function is
disabled.
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Column Content
Signal settings
Signal input Number of the input signals (1 – 32).
Indication of the current status for signal 1 –
32.
Status Green light = Active signal.
No light = No signal.
Marked checkboxes inverts the signal chosen
in the configuration row. In that way you can
Signal invert chose to have the active signal as 0 V. If the
signal invert checkbox is not marked, the
active signal is 24 V.
This is the definition of which signal that
should be active to constitute a bypass/
heeling. Tap the checkbox to select or unselect
it.
Configuration Selected = All selected signals, must be active
for the modes bypass or heeling to occur.
Not selected = Not part of configuration for
Bypass or Heeling.
If a bypass or heeling configuration is active,
Active configuration numbers the numbers of the active configuration is
indicated here.
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Column Content
LPS number Each row indicate status for each LPS.
Measured power output for UV lamp
Power (kW) powered by the LPS.
Lamp on Status: Green = On. Grey = Off.
Ignition Status: Red = Failure to ignite UV lamp.
Status: Green = OK. Red = LPS in fault
LPS OK state.
Status: Green = UV lamp lit and LPS is
Lamp OK OK. Red = LPS in fault state.
Lamp open Status: Rec = No lamp, circuit open.
Status: Red = Too low incoming power to
Voltage fault the LPS.
Short circuit Status: Red = Short circuit alarm.
Status: Red = Temperature in LPS is too
Air temp fault high.
Heatsink fault LPS internal heat protection tripped.
Fan fault LPS fan broken.
If a sum alarm is issued for an LPS, an
alarm icon is shown for the last LPS with
an alarm. The icon disappears when the
alarm is acknowledged.
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UVR illustration
Table 1: UVR popup: UVR illustration
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Component Description
Status indication:
Grey = Off.
UV lamps
Yellow = Starting.
Green = Started.
LDC status
Table 2: UVR popup: LDC status illustration
Component Description
Open the LPS control popup, which
enables manual operation of individual
UV lamps. Requires login level Advanced
operator to see the button and manual
mode open the popup. See LPS control
popup and instruction Operate UV lamps
manually on page 105.
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Component Description
Indicates if the valve for LDC cooling
water (SV401–51) is open.
Heat exchanger valve
Status indication: Green = Open. No
indication = Closed.
DANGER
Manual start of the UV lamps is only allowed (and possible) when there is
water in the UV reactor (indicated by level switch LS201-29 and
LS201-30), and the water temperature is below 60 °C. All necessary items
– cooling water flow, water temperature, and power management – must
be supervised and verified by the authorized trained personnel operating
the system. Improper operation of this function could seriously damage
the equipment and injure personnel.
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Component Description
Information is displayed for the UV
reactor selected in the UV reactor
UV reactor number number field. Press the field to enter an
UV reactor number, or press the arrows
to step up or down.
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Component Description
Information is displayed for the UV
reactor selected in the UVR field. Press
UVR the field to enter an UV reactor number,
or press the arrows to step up or down.
Component Description
The UV intensity the system is aiming to
attain by increasing or decreasing power
Setpoint effect to the LPS controlling the dimming
of the UV lamps.
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Component Description
Filter status:
• Idle (No backflush or preservation)
• Backflush preparation
Mode
• Backflush ongoing
• Continuous backflush
• Filter preservation
Current pressure:
Pressure • PT201–71: Inlet pressure.
• PT201–72: Outlet pressure.
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Component Description
Press the button to start a manual
backflush. See instruction Backflush filter
manually on page 98.
3.5.1 Log in
Follow the steps below
1. Press the Login function button.
Result: A login popup is displayed.
2. Press the dropdown menu at the top of the popup. Press desired user.
Result: A keyboard is displayed.
3. Enter password and press Enter. (See section Login levels on page 47.)
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6. Wait for the message “Stop ballast water pump”. Stop the pump and then
press the button in the popup to confirm the action. Note! This component
is outside the PureBallast system control. (The popup is not displayed if
the component feedback is integrated with the control system.)
7. Wait for the ”Start CIP” popup.
Yes: A CIP process will be started after the UV lamp cooling time (5
minutes ).
If No: is chosen, CIP must be started within time indicated in the popup. A
ballast/deballast process can be started after the UV lamp cooling time (5
minutes ).
NOTE
A CIP cleaning process must be finished within the time stated in the
popup (30 hours from the first operation after the previous CIP process).
Therefore consider the time for CIP process. A CIP process takes about
25 minutes per UV reactor. if default parameters are used. If no CIP
process is performed within the time limit an entry is made in the control
system log file. Operations after the warning does not fulfill the type
approval certificate.
Note that it is possible to run operations during the 30 hours. Complete
status information regarding CIP is displayed in page 1.3 CIP status. A
CIP process is started manually according to instruction CIP clean UV
reactor after ballast / deballast / stripping on page 100.
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• Flow must have been selected before a process can be started, either
manually or automatically. See Page 1.1 – Overview on page 54.
• There must be available power for the system. If power management is
integrated, this will be handled automatically. If power management is not
integrated, confirm available power manually.
Follow the steps below:
1. Press the function button Deballast.
Comment: If the button is not blue, check that flow or UV reactors have
been selected
2. Wait for the message “Open valves ...”. Open relevant valves and then
press the button in the popup to confirm the action. Ensure that pipe 404 is
opened to overboard. See section Preparations and conditions on page
44. Note! These valves are outside the PureBallast system control. (The
popup is not displayed if the component feedback is integrated with the
control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps
during warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and
then press the button in the popup to confirm the action. Note! This
component is outside the PureBallast system control. (The popup is not
displayed if the component feedback is integrated with the control system.)
Result: Cooling stops and deballasting starts.
4. When desired amount of water has been processed, press the function
button Stop
To get a smooth stop, the flow from the ballast pump can be reduced, but
not more than 50 %
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message “Stop ballast water pump”. Stop the pump and then
press the button in the popup to confirm the action. Note! This component
is outside the PureBallast system control. (The popup is not displayed if
the component feedback is integrated with the control system.)
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6. Wait for the message “Close valves ...”. Close relevant valves and then
press the button in the popup to confirm the action. See section
Preparations and conditions on page 44. Note! These valves are outside
the PureBallast system control. (The popup is not displayed if the
component feedback is integrated with the control system.)
7. Wait for the ”Start CIP” popup.
Yes: A CIP process will be started after the UV lamp cooling time (5
minutes ).
If No: is chosen, CIP must be started within time indicated in the popup. A
ballast/deballast process can be started after the UV lamp cooling time (5
minutes ).
NOTE
A CIP cleaning process must be finished within the time stated in the
popup (30 hours from the first operation after the previous CIP process).
Therefore consider the time for CIP process. A CIP process takes about
25 minutes per UV reactor. if default parameters are used. If no CIP
process is performed within the time limit an entry is made in the control
system log file. Operations after the warning does not fulfill the type
approval certificate.
Note that it is possible to run operations during the 30 hours. Complete
status information regarding CIP is displayed in page 1.3 CIP status. A
CIP process is started manually according to instruction CIP clean UV
reactor after ballast / deballast / stripping on page 100.
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6. Wait for the message “Close valves ...”. Close relevant valves and then
press the button in the popup to confirm the action. See section
Preparations and conditions on page 44. Note! These valves are outside
the PureBallast system control. (The popup is not displayed if the
component feedback is integrated with the control system.)
7. Wait for the ”Start CIP” popup.
Yes: A CIP process will be started after the UV lamp cooling time (5
minutes ).
If No: is chosen, CIP must be started within time indicated in the popup. A
ballast/deballast process can be started after the UV lamp cooling time (5
minutes ).
NOTE
A CIP cleaning process must be finished within the time stated in the
popup (30 hours from the first operation after the previous CIP process).
Therefore consider the time for CIP process. A CIP process takes about
25 minutes per UV reactor. Operations after the warning does not fulfill the
type approval certificate.
Note that it is possible to run operations during the 30 hours. Complete
status information regarding CIP is displayed in page 1.3 CIP status. A
CIP process is started manually according to instruction CIP clean UV
reactor after ballast / deballast / stripping on page 100.
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• Alarms will shut down ongoing process and disable start of process.
• Warnings are information to the operator and will not shut down ongoing or
disable start of process.
• An alarm or warning will activate the alarm buzzer (sound and light) on the
cabinet. The sound is silenced by touching the buzzer, but note that the
alarm is not acknowledged by this.
WARNING
Never reset an alarm without first finding and attending to the problem.
Requires login level Operator or higher.
For color indication of alarms. See Page 2.1 – Alarm list on page 64.
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1. Main breaker
2. Emergency stop button
3. Reset button
4. Alarm (light and sound)
A. Main breaker
B. Reset button
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Action Method
Press the Emergency stop button (2) on
the control cabinet.
Emergency stop Result: Ongoing process is stopped
immediately, without controlled closing of
any valves, UV lamps etc.
Complete deactivation is performed in
two steps:
1. 1. Turn off the main breaker (1) at
the side of the control cabinet.
2. Turn off the main breaker (A) on
the lamp drive cabinet (LDC)
door.
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5. Operate the component using the open/run (left) and closed/not running
(right) buttons in the popup.
6. Press Hand button to stop manual mode for the component and the X
button to close the popup.
or
Press the X button to close the popup and let the component remain in
manually set status. The popup is closed, and a hand icon is displayed by
the component to indicate it is manually operated.
7. Press the Manual function button to exit manual mode.
Result: All manually operated components are restored to their default
status.
DANGER
Manual start of the UV lamps is only allowed (and possible) when there is
water in the UV reactor (indicated by level switch LS201-29 and
LS201-30), and the water temperature is below 60 °C. All necessary items
– cooling water flow, water temperature, and power management – must
be supervised and verified by the authorized trained personnel operating
the system. Improper operation of this function could seriously damage
the equipment and injure personnel.
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• If remote control panels (option) are used, entered IDs will be displayed on
all panels.
• Requires login level Advanced operator.
Follow the steps below:
1. Go to page 1.1 Overview.
2. Press desired component.
Result: A popup is opened.
Example: Popup with ship specific ID. Entered ID is displayed on the component
to the left.
For specific information about logged events, see section List of logged
information on page 121.
Preparations and conditions
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• Events are only copied, hence they will remain in the control system.
• The log and alarm files are stamped with the system name and serial
number entered in page 5.6 Installation parameters.
• The easiest way of reading the log file is to use the program Visualog, a
tool designed to present and analyze the information from the PureBallast
log files. Log files may also be read in Excel.
Follow the steps below:
1. Go to page 4.1 System info.
2. Press the Export button in page section Export log files.
Result: A popup is displayed.
Note: The Update export button is only used when updating softwares.
3. Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC
port on the cabinet door.
4. Chose one of the following alternatives to decide time interval for the
information to be copied:
• Recommended: Accept suggested default time interval in the Start and
End filelds. Default start date is the oldest file in the system, and default
end date is today's date.
• Optional: Press the Specify time interval box, and enter desired
interval in the Start and End filelds.
5. Press the function buttons Events.
Result: The information is copied to the USB memory indicated by a green
checkmark on the button during copying.
6. Wait for the message "Export OK" to appear. Press the function buttons
Alarms.
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• If you do not wish to update a certain type of setting, remove the specific
file from the USB memory before inserting the USB memory in the USB
panel port on the cabinet door.
• Remove the file Parameters.csv from the USB before following this
instruction.
Follow the steps below:
1. Go to page 4.1 System info.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Restore button in page section Backup and restore, Settings
to/from HMI USB.
Result: A popup is displayed and the process is started.
4. Wait for the OK / Close button to turn blue.
5. Read the second last line in popup: If the restore was successful, it shall
state "Restore done".
6. Press the OK / Close button on the popup.
7. Remove the USB memory.
8. The control panel must be rebooted. At the rear side of the control panel:
Pull out the power cable from the 24V DC port, and insert it again.
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NOTE
Only the IP address shall be changed.
5. Press OK.
6. Reboot the panel to update communication with the new IP address. Make
sure that the new IP address is displayed on page 4.1 System info.
7. Repeat this instruction for all installed control panels, both main and
remote control panels, if installed.
8. Follow the instruction Set remote control panel communication to activate
remote control panel.
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• Main control panel and remote control panel 1 (192.168.0.11) are added as
default . If no remote control panels is used, address 192.168.0.11 shall be
removed.
• All remote control panels must be on and connected with an Ethernet
cable.
Follow the steps below:
1. On the main panel in the control cabinet : Go to page 4.1 System info.
2. In the Remote control panels box, press the Set button.
Result: A popup is displayed.
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• 66 Power consumption
• 57/58 Current time
• 114 UV reactor temperature (TT201–33)
For detailed information, see the directory of addresses.
Follow the steps below:
1. Press the Remote function button.
Result: Test mode is activated enabling that communication is sent
between the systems without actually affecting the control system (start
processes etc). This also result in alarm A93 Heartbeat signal missing.
This alarm shall be ignored during this test.
2. Enter actual values in the in the entry field for the address to send
simulated information to the ISCS. Information in decimal form, for
example processed volume, is written as actual values. Information in
binary form, for example command status, is written as a bit pattern. The
key for the bit pattern is found in chapter 6. Installation description and
drawings, section
System interfaces.
3. Make sure that values and status information is displayed correspondingly
in the ISCS.
4. Repeat the simulation for the information you which to test.
NOTE
Only implemented signals needs to be tested.
Test commands from ISCS to PureBallast
In the ISCS, activate input commands corresponding to the addresses
displayed in page 4.5. (Note that address 06 does not need to be tested; it
was tested at the beginning of this procedure.)
1. Activate a command from ISCS, according to the HMI implementation.
2. Make sure that the command is received in page 4.5. Use the directory of
addresses to see that the bit pattern is updated correctly.
3. In the control panel, restore all changed values after the communication
test. If not, commands might be executed involuntarily, when the system is
set to online again. Most important is that address 001
displays ”00000000”.
Test alarms and warnings
Alarms and warnings are tested by simulation in control page 4.5 Remote
interface 1 and 4.6 Remote interface 2 and . Use the alarm list to identify
addresses and bit patterns for the alarms.
You want to simulate alarm W40 (Process pressure too low). When you find
W40 in the table, you use the column heading to see which address the alarm
shall be sent to and the row heading to see which bit in the bit pattern that
shall be high. For W40 the signal shall be sent to address 902, and bit 12 shall
be high.
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Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first
digit from right is counted as zero, second digit counted as 1 etc). This gives
the following bit pattern: 0010000000000000.
Follow the steps below:
1. Enter the desired bit pattern in the entry field for the address.
2. Make sure that the alarm/warning is indicated in ISCS.
3. If common alarm and warnings are used, make sure that address 70:7 and
70:8 are updated. It is only necessary to check this for the first alarm.
4. Clear the bit pattern in the entry field.
5. Repeat the simulation for those alarms/warnings you which to test.
6. Press the Test mode button to set the system in online mode (no check
mark on the button).
Press the Remote function button if you want to activate remote control.
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is defined as selected certified flow for the operation minus the Undershoot
percentage set in parameter p111.
During backflush, the control valve is regulated based on input from the
pressure transmitter PT201-16 to maintain stable pressure for efficient
backflush. Desired pressure is defined in parameter p304.
The purpose is to adjust the movement of V201-8 when it changes from flow
controlled regulation to pressure controlled regulation which it does during
backflushing of the filter. The first goal is that the valve travels as fast as
possible to a steady position where it creates required pressure (as defined in
parameter p304).
The second goal is to shorten the time from backflush trigger to start of actual
backflush. This is done by shortening the time in p310 (Backflush initial delay)
that is done after the movement of V201-8 has been calibrated.
Preparations and conditions
• This operation requires login level AlfaLaval.
• All components on page 3.1 Trend (15 min) shall be selected for plotting,
and Flow FIT201–1 shall be used for Y axis selection.
Follow the steps below:
This instruction shall be read together with the example after the instruction.
1. Perform a backflush.
2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8.
Before the backflush, the valve shall move as fast as possible to a steady
position where it creates required pressure. If not, parameter p166 shall be
adjusted.
3. Adjust parameters, and perform a new backflush.
4. See if the curve has improved. Repeat until satisfactory result has been
achieved.
5. See if the time between backflush initiation and backflush can be
shortened . If possible, adjust parameter p310. See parameter p310 in the
example below.
Example
In this example, five backflushes are performed. After the first four
backflushes, the PID parameters where changed for pressure regulation to
adjust the movement of the control valve V201-8 before the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated
by the movement of the backflush valve V309–1 (pink line) and the movement
of control valve V201-8 is indicated by the blue line.
Parameter p166 is set to 0.30. But it takes too long time for
V201-8 to get into position to create desired pressure (1). The
1st backflush curve slops downwards in a long bend, which means that it
takes time for V201-8 to find correct position.
Parameter p166 was adjusted to 0.6. This made the valve
movement much faster in the beginning, shown by the steep
2nd backflush curve at the beginning. But then a more slow regulation starts,
shown by the soft slope (2). This was a change for the better,
but not enough.
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Example
In this example, parameter p156 External feed change rate is adjusted to get a
stable regulation.
The illustration is taken from page 3.1 Trend (15 min).
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4 Power management
Automatic power request from PureBallast to
vessel’s power management system (if
integrated).
5 UV lamp warming
Component activities:
• Open V404-36 (UV reactor outlet, cooling
water)
• Open V201-19 (reactor inlet).
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1 Component activities:
• - Open V201-20 (reactor outlet)
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6 Resume ballasting
Operator resumes the ballast process
manually.
Component activities:
• Set V201-8 (control valve) to 50 %
• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running
UV reactors.
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4 Power management
Automatic power request from PureBallast to
vessel’s power management system (if
integrated).
5 UV lamp warming
Component activities when power has been
granted:
• Open V404-36 (UV reactor outlet, cooling
water)
• Open V201-19 (reactor inlet).
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4 Resume deballasting
Operator resumes the deballast process
manually.
Component activities:
• Set V201-8 (control valve) to 50 %
• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running
UV reactors.
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4 Power management
Automatic power request from PureBallast to
vessel’s power management system (if
integrated).
5 UV lamp warming
Component activities when power has been
granted:
• Open V404-36 (UV reactor outlet, cooling
water)
• Open V201-19 (reactor inlet).
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4 Resume stripping
Operator resumes the stripping process
manually.
Component activities:
• Set V201-8 (control valve) to 50 %
• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running
UV reactors.
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EN 3 Operating instructions and control system description
1 Component activities:
• - Open V571-1 (CIP, deaeration valve)
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Operating instructions and control system description 3 EN
1 Component activities:
• -Open V460-2 (CIP, drain valve)
1 Component activities:
• - Open V320–2 (CIP outlet to UV reactor)
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1 Component activities:
• - Open V321-4 (CIP, return valve)
1 Component activities:
• - Open V571-1 (CIP, deaeration valve)
3.7.5.8 Repeat
When CIP process is done for the first UV reactor, the remaining UV reactors with status CIP required
are processed in the same way.
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Operating instructions and control system description 3 EN
- Open V309-1
- Start M709-43.
- Pressure measured on PT201-71.
- Close V309-1
- Close V310-1.
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EN
4 Parameters
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EN 4 Parameters
4.1 Introduction
This chapter contains information about parameters in the control system and
parameter controlled components. It covers:
• Parameter page descriptions.
• Parameter lists including information about setting range, default values
etc.
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EN 4 Parameters
Low pressure,
p103 warning trigger 0.1 –1 to 2 bar Setpoint for warning due to low pressure.
(PT201-16)
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p116
Low flow shut down Set point for shut down due to low flow,
10 10–90 %
limit (FIT201-1) defined as percent of UVR capacity.
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p172
Minimum flow when Set point for shut down due to low flow,
10 7-90 %
stripping (FIT201–1) defined as percent of certified flow.
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Parameters 4 EN
p211
Cooling time for UV lamps after ballast or
UV lamp cooling time 300 180–600 sec deballast.
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EN 4 Parameters
p232 Cabinet temperature 20.0-60. Setpoint for running the LDC cooling fan at
high threshold 45.0 ºC
0 100 %.
(TT401-2)
p235
UV control integral Defines integral time (If) value used for PID
15 0-100 sec
time regulation of UV lamp power.
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p301 High filter differential Setpoint for high pressure warning, indicated
pressure, warning 1.5 0.0-2.0 bar by pressure transmitter in the filter.
trigger
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Parameters 4 EN
Parameters for the ISCS modbus RTU server data shall be set according to
the information below.
ID Parameter Default Min-Max Unit Description
value
Defines communication (cable) type used for
communication between the ISCS and
p700 Interface type RS485 N/A Drop list PureBallast.
Alternatives: RS485 and RS422.
Defines baud rate in bits per second.
The parameter can be changed, but it is not
recommended. Note, that the information
p701 Baud rate 9600 N/A Drop list must be the same in ISCS and PureBallast
control system.
Alternatives: 300, 600, 1200, 2400, 4800,
9600, 19200, 38400, 57600, 115200.
Defines parity.
The parameter can be changed, but it is not
p702 Parity No parity N/A Drop list recommended. Note, that the information
must be the same in ISCS and PureBallast
control system.
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Parameters 4 EN
p500 Defines if the log box (optional) is installed to monitor and log
external valves and pumps, that are not part of Alfa Laval’s scope
Log box Not used of supply.
Alternatives: Activated or Not used.
200000691-1-EN-GB 179
EN 4 Parameters
SW SW SW SW SW
SW SW SW SW 4 5 6 7 8
1 2 3 3
(16) (8) (4) (2) (1)
1 ON
2 ON
3 ON ON
4 ON
5 ON ON
6 ON ON
7 ON ON ON
8 ON
9 ON ON
10 ON ON
11 ON ON ON
12 ON ON
13 ON ON ON
14 ON ON ON
15 ON ON ON ON
16 ON
Example
In the illustration, the DIP switches is set for LPS no. 5.
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Parameters 4 EN
1. Press E (Enter).
2. Press + (Plus) or - (Minus) to find function group listed below.
3. Press E to find parameter.
4. Press + or - .
5. Set access code 0050 by pressing + or -, the correct digit and then press E
after each digit.
6. Change value by pressing E .
7. Press + and - simultaneously for minimum 3 sec, to escape the
programming mode.
Meny on the display:
Function group Parameter Factory settings
MEASURING VALUES N/A N/A
UNIT VOLUME FLOW m3/h
UNIT VOLUME m3
SYSTEM UNITS
UNIT LENGTH MILLIMETER
FORMAT DATE/TIME DD.MM.YY 24H
QUICK SETUP QUICK SETUP COMMISSIONING NO
LANGUAGE ENGLISH
ACCESS CODE N/A
OPERATION DEF. PRIVATE CODE 50
STATUS ACCESS N/A
ACCESS CODE COUNTER 0
ASSIGN LINE 1 VOLUME FLOW
ASSIGN LINE 2 TOTALIZER 1
FORMAT X.XXXX
USER INTERFACE DISPLAY DAMPING 3s
CONTRAST LCD 50 %
BACKLIGHT 50 %
TEST DISPLAY OFF
ASSIGN TOTALIZER VOLUME FLOW
SUM N/A
OVERFLOW N/A
TOTALIZER 1 / 2 (both)
UNIT TOTALIZER m3
TOTALIZER MODE Totalizer 1 + 2: FORWARD
RESET TOTAL NO
RESET ALL TOTAL NO
HANDLING TOTAL
FAILSAFE MODE STOP
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EN 4 Parameters
Set parameter “VALUE 20 mA” and “ON-VAL. LF-CUTOFF” (low flow cut off)
as table below:
Flow meter - Pipe dimension specific values:
Pipe dimensions VALUE 20 mA (flow span Low flow cut off (m3/h
corresponding to 4-20 mA)
A/DN 150 0-500 2.5
A/DN 200 0-700 5.0
A/DN 250 0-1200 7.5
A/DN 300 0-1200 10
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Pipe dimensions VALUE 20 mA (flow span Low flow cut off (m3/h
corresponding to 4-20 mA)
A/DN 350 0-1700 15
A/DN 400 0-2200 20
A/DN 450 0-3300 25
A/DN 500 0-3300 30
A/DN 600 0-3300 40
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200000691-1-EN-GB 187
EN 5 Alarms and faultfinding
5.1 Introduction
This chapter covers information about alarms and warnings, together with
information about how to solve the problems causing the alarms to trip. The
chapter also contains a list of solutions for problems that may occur, but that is
not indicated by any system. The chapter contains lists of alarms indicated by:
• Control system.
• Lamp power supply (LPS).
• Flow meter (with fault finding instruction).
• I/O system and X20 modules.
See chapter Operating instructions and control system description on page 43
to find information about the alarm pages and how to attend to alarms.
Alarm Indication
An alarm or warning will activate the alarm buzzer (sound and light) on the
cabinet. The sound is silenced by touching the buzzer, but note that the alarm
is not acknowledged by this. Alarms will shut down ongoing process and
disable the start of the process.
Warnings are information to the operator and will not shut down ongoing or
disable start of process.
Alarms and warnings are indicated in the following ways in the control panel.
Alarms
• The icon in the alarm tab starts to blink.
• The icon is also displayed by the faulty component in the screen.
• A red light in the exclamation mark on the alarm panel frame is lit.
• A sound is issued.
• A blinking light indicates a new alarm
• An acknowledged alarm is indicated by a steady light.
Warnings
Warnings is indicated in the same way as alarms, but with the yellow
symbol to the left. No sound is issued for warnings, except for W12, W152
and W154.
All alarms are displayed in the control panel's page 2.1 Alarm list and are
sorted in order of occurrence; most recent alarm at the top of the list.
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Delay: 30 sec. Material is stocked after Check the entire system for blocking material.
pressure transmitter
Comment: Pressure PT201-16.
transmitter PT201-16
indicates pressure Pressure transmitter 1. Check cables to pressure transmitter PT201-16. See
higher than set in PT201-16 is faulty. circuit diagram for control cabinet , in section
parameter p100. Electrical drawings on page 291.
2. Replace pressure transmitter PT201-16.
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EN 5 Alarms and faultfinding
W04
Process pressure too
high (PT201-16).
Trigger: PT201-16.
See possible cause for
Parameter: p101 See A01.
A01.
Delay: 30 sec.
Comment: Pressure
higher than parameter
set limit.
A10 Signal missing or flow 1. Check fuse F45 in control cabinet to see what circuit
meter FIT201-1 caused the fuse trip.
Process flow signal malfunction.
missing (FIT201-1). 2. Use the circuit diagram for control cabinet , in section
Electrical drawings on page 291, to locate the
Trigger: Flow meter component or find the reason that caused the fuse
FIT201-1. trip and attend to it.
Delay: 5 sec.
3. Check that all electrical connections are OK and that
Comment: Error in the electrical wiring is not damaged.
system flow sensor.
4. Check that system flow has not been significantly
over maximum flow for the system.
5. Replace flow meter FIT201-1.
W12 Flow rate higher than Reduce the incoming ballast water flow to the PureBallast
selected certified flow. system.
Process flow higher than See field certified flow in
certified (FIT201-1). Page 1.1 – Overview on
Reduce flow! page 54.
Trigger: FIT201-1. Wrong setting in See chapter Parameters on page 159.
Delay: 30 sec. FIT201-1.
Comment: An additional
common alarm signal is
issued.
Note: Operation
continues but is not Flow sensor See section Flow meter in List of alarms and warnings on
compliant and does not malfunctions. page 188.
fullfil requirements for
treatment of ballast
water. Act according to
ballast water
management plan.
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Ballast water pump Attend to. Note: This component is outside the
stopped or malfunctions. PureBallast system control.
A14 See possible cause for
A13.
Process flow too low
during start-up Control valve V201–8 See A29.
(FIT201-1). Automatic malfunctions.
stop.
Trigger: FIT201-1.
Parameter: p116.
Comment: Triggered if
flow defined in p116 is
not established within 60
seconds after ballast
water pump is started.
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EN 5 Alarms and faultfinding
Position sensor
mounted upside down.
Position sensor or 1. Check cables.
cables to position
sensor malfunction. 2. Replace position sensor if faulty.
Too long opening/ 1. Follow the instruction Adjust valve traveling speed on
closing time (valve page 447.
travel time).
2. Adjust exhaust valves on actuator.
3. Check that instrument air pressure is according to
requirements in Connection list on page 248.
Valve cannot open/close Clean. If required dismount valve. See Service manual on
due to obstruction. page 391 for instructions.
A23 See possible cause for Check relay K5 and K6 on module X10.
A17.
Valve error (V201-9).
Trigger: Limit switch
GS201-9
Delay: 25 sec.
Comment: Error on
valve V201–9.
A25
Valve error (V403-35)
Trigger: Limit switch See possible cause for
GS201-35. A17.
Delay: 25 sec.
Comment: Error on
valve V201–35.
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A35
Valve error (V212–31).
Trigger: Limit switch
GS212-31.
See possible cause for
Delay: 25 sec. A17.
Comment: Shutdown of
all steps except CIP. The
alarm does not prevent
completion or start of
CIP process.
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EN 5 Alarms and faultfinding
A48
System stop activated
(Stop button). Note: Find out the reason why the process has been
Process has been stopped before releasing the button and starting another
Trigger: Stop button on stopped. process.
control cabinet.
Delay: None.
A49
System stop activated
during CIP (Stop button).
See A48.
Trigger: Stop button on
control cabinet.
Delay: None.
A50
System stop activated
(External stop button). Process has been
Trigger: External stop stopped by external stop Note: Find out the reason why the process has been
button on control cabinet button or signal from the stopped before releasing the button and starting another
ISCS (integrated ship process.
(or signal). control system).
Parameter: p135
Delay: None.
A51
System stop activated
during CIP (External
stop button).
Trigger: External stop See A50.
button on control cabinet
(or signal).
Parameter: p135
Delay: None.
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A68
Additional bypass valve
3 is open.
Trigger: External See A66.
system.
Parameter: p165
Delay: 2 sec.
A69 Bypass valve opened by If not opened intentionally, close opened bypass valve.
ISCS via remote
Remote system reports interface.
system is bypassed.
Trigger: External bypass
valve.
A71 Faulty connection of Check that all electrical connections are OK. Check that
signal cable. the signal wiring is according to information in Control
Ballast water pump is cabinet / Interconnection diagram, in section Electrical
not running. drawings on page 291.
Trigger: Control system If remote interface Test relevant addresses. See Test remote interface
timer. (optional) is used: communication on page 113.
Parameter: p141. Communication
between PureBallast
Delay: Set in parameter and ISCS is wrong.
p141.
Time set in parameter is Check/change parameter in control system page 5.1 –
Comment: Feed back lower than needed. Main parameters 1.
signal “BW pump is
running” is not activated
after request.
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A77
Error on all operating
UVR:s. Automatic stop. An active alarm exist on
all installed UV reactors. Check control system page 2.1 Alarm list in control panel
Trigger: UV reactors It can be the same error for related alarms.
for all UV reactors, or
Delay: None. different errors.
Comment: All UV
reactors are deactivated.
A79 Power management Investigate if the reasons for not granting power is outside
master system not the PureBallast system.
Power is not granted. granting power to UV
Trigger: Control system reactor(s).
timer. Feedback signal from See A71.
Delay: Set in parameter power management
master is faulty. Check signal transmission to/from PureBallast
p127. corresponds to the specifications in Control cabinet /
Comment: No power Interconnection diagram, in section Electrical drawings on
steps have been granted page 291.
within parameter set Hint: If problem persists, see control system page 1.4 –
time. PureBallast power request to find which GRANTED signal
that was interrupted during the ballast/deballast process.
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W83
Heeling mode cancelled
by operator. Process
resumed.
Trigger: Heeling
(internal transfer) not
requested in control See possible cause for
system. W82.
Parameter: N/A
Delay: None.
Comment: Process is
resumed after being
phased during heeling.
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Faulty cable connection Check cable between the ISCS and the main control
panel and the cable between the PLC and the main
control panel. For reference, see Control cabinet /
Interconnection diagram, in section Electrical drawings on
page 291.
Tips: Make sure that the modbus cables in terminal
X15are correct (not switched).
Communication See W92.
between PLC and main
control panel is lost
ISCS is faulty Investigate problem in ISCS, and attend to found
problems.
A94
Barrier fault
Trigger: Barrier in LDC
cabinet
Parameter: p151 To be completed. To be completed.
Delay: N/A.
Comment: This alarm is
specific for the Ex proof
version of PureBallast
for US flag.
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W96 Faulty electrical Check that the signal wiring is according to Control
connection. cabinet / Interconnection diagram. See section Electrical
GPS signal not valid. drawings on page 291.
Trigger: Control system
PLC.
Parameter: p160.
Delay: 5 sec.
W97 Error in module. Check the LED error indication for the electronic modules
in the cabinet. See I/O system and X20 modules on page
PLC error in control 221.
cabinet.
Faulty electrical 1. Check that the signal wiring is according to electrical
Trigger: N/A connection. drawings in Technical data and drawings on page
Parameter: N/A 233.
Delay: 2 sec. 2. Check that all electrical connections are OK on bus
modules and that the electrical wiring is not damaged.
A98 Emergency stop button Note: Find out the reason why the process has been
pressed (control cabinet stopped. Then: Release the Emergency button and press
Emergency stop or external). the Reset button on the control cabinet .
Trigger:
Faulty connection of Check that all electrical connections are OK on bus
• Emergency stop signal cable. modules and that the electrical wiring is not damaged.
button on control
cabinet (safety relay
KS01).
• Temp switch TS201–
60.
• Temp switch TS201–
33.
Parameter: p150.
Delay: 2 sec.
Comment: This alarm is
specific for the Ex proof
version of PureBallast.
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EN 5 Alarms and faultfinding
W105
Temp below 0 °C.
Trigger: LDC
temperature transmitter
TT401.
Delay: 5 sec.
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EN 5 Alarms and faultfinding
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EN 5 Alarms and faultfinding
• LPS malfunction. Check LED indication on the LPS that triggered the
W130 alarm. See LPS alarms in section Lamp power supply
• Number of broken (LPS).
UVR [x]: LPS sum UV lamps exeeds
alarm. number set in Check which lamps that are broken in column Lamp OK
parameter p213. in page 4.9 LPS overview.
Trigger: Lamp power
supply in UV reactors Check that the signal wiring is according to electrical
LDC. drawings.
UV lamp OK signal
Delay: 5 sec. malfunction. Check that all electrical connections are OK on bus
modules and that the electrical wiring is not damaged.
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See W100.
After problem has been attended to, the LDC needs to be
reset. Follow the instruction below:
No flow in UV reactor or 1. Turn on the power to the cabinet/system.
too low flow.
A137 2. Push the reset button on the LDC. The button is
placed at the side facing the UV reactor. All LDCs
UVR [x]: To high must be reset individually.
temperature (TS201-60
tripped) and/or LDC 3. Acknowledge alarm A137 in the control system.
powered off.
Trigger: TS201-60 Faulty pump (ballast or Check components.
UVR cooling water
Delay: 1 sec. pump) or valve. Control that valves and pumps are functioning.
Comment: UV reactor is LDC has been powered The LDC needs to be reset, see above in this alarm
deactivated. off. description.
• Check that the signal wiring is according to electrical
Faulty electrical drawings.
connection. • Check that all electrical connections are OK and that
the electrical wiring is not damaged.
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EN 5 Alarms and faultfinding
W151 Signal missing. 1. Check F42 in LDC to see which circuit that caused
the fuse trip.
UVR [x]: UV sensor
signal missing. Ongoing 2. Use the circuit diagram to check the fuse setting,
process not compliant. adjust according to figures in circuit diagram if
Trigger: UV sensor necessary and reset fuse.
QT201-50. 3. Use the circuit diagram to locate the component or
Delay: 20 sec. find the reason that caused the fuse trip and attend to
it.
Note: Operation
continues but is not 4. Check cables to QT201-50. See the drawing Control
compliant and does not cabinet / Circuit diagram in chapter 6. Technical data
fullfil the requirements and drawings.
for treatment of ballast 5. If the above is OK, the UV sensor is probably broke
water. Act according to and needs to be replaced. Replace the component.
ballast water
management plan. Transmitter QT201-50 Test the UV sensor:
malfunction
1. Stop the process and restart the process again.
2. In the control system's UV reactor popup, see if the
UV values are OK during the start-up phase. UV
values shall be OK, since clean cooling water is used.
See W152.
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W160
UVR [x]: No response
from LDC. UVR
shutdown.
Trigger: N/A
Delay: 1 sec.
W161 Faulty connection of Check the three cable connectors on the LPS.
electricity or signal
UVR [x]: LPS cable.
communication error.
UVR shutdown. Check that the DIP switches are correctly set for every
Wrong LPS setting. LPS. See chapter 4. Parameters, section Lamp power
Trigger: LPS supply (LPS) parameters.
Delay: 1 sec. Change LPS. See instruction in chapter Service manual
Faulty LPS. on page 391.
W163 Change according to instruction in chapter Service
Broken UV lamp(s). manual on page 391.
UVR [x]: Lamp error
feedback from LPS.
Trigger: LPS in UV
reactor’s LDC.
Delay: 20 sec. Faulty connection of UV Check UV lamp power cable.
lamp cable
Comment: No lamp
feedback when it is
requested to be started
by the LPS.
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EN 5 Alarms and faultfinding
W165 One or more of the Check page 4.9 LPS power overview and LED indication
below: on the LPS that triggered the alarm. See LPS alarms in
UVR [x]: LPS in fault Lamp power supply (LPS) on page 218.
state. Process not • Air intake temp fault.
compliant. During commissioning: Alfa Laval can run a process with
• Fan fault. one faulty LPS, to be able to fulfill commissioning.
Trigger: LPS in UV Parameter p213 (Allowed nr. of failed UV lamps) is set to
reactor’s LDC. • Heat sink fault.
1. Parameter must be reset to 0. Operation with faulty
Delay: 5 sec. • UV lamp open LPS or lamps does not fulfill the type approval certificate.
(broken).
Comment: UV reactor is Fan fault and temperature faults can be caused by
deactivated. • Driver fault something that is preventing the fan from rotate.
Note: Operation • System fault Change LPS. See instruction in Service manual on page
continues but is not 391.
compliant and does not • Voltage fault
fullfil requirements for
treatment of ballast
water. Act according to
ballast water
management plan.
W170
Valve error (V201–19)
Trigger: Limit switch See possible cause for
GS201–19. A17.
Delay: 25 sec.
Comment: UV reactor is
deactivated.
W171
Valve error (V201–20)
See possible cause for
Trigger: Limit switch A17.
GS201–20.
Delay: 25 sec.
W180
LDC ring redundancy
error Faulty connection of Check that the power link (LAN) cable from the control
signal cable. cabinet (in a loop to all LDCs) and back is OK.
Trigger: LDC
Delay: 1 sec.
212 200000691-1-EN-GB
Alarms and faultfinding 5 EN
W182
UVR [x]: UVR fluid level
signal missing
(LS201-30)
Trigger: Level switch See W116.
LS201-30
Delay: 5 sec.
Comment: The UV
reactor is shut down.
W183
UVR [x]: UVR fluid level
missing (LS201-30)
Trigger: Level switch
LS201-30
See W117.
Delay: 5 sec.
Comment: The UV
reactor is shut down.
Prevents start of LPS
(UV lamps) in manual
mode.
W184
UVR [x]: CIP flow
missing (LS201-30)
Trigger: Level switch See W118
LS201-30
Delay: Set in parameter
p208.
W185
UVR [x]: No freshwater
filling in UVR(LS201-30)
Trigger: Level sensor See W119.
LS201-30.
Parameter: p216.
Delay: set in parameter
p 215.
200000691-1-EN-GB 213
EN 5 Alarms and faultfinding
W187
UVR [x]: High
temperature (TS201-60
tripped) and/or LDC
powered off.
See A137.
Trigger: TS201-60
Delay: 1 sec.
Comment: UV reactor is
deactivated..
W188
UVR [x]: No feedback
from contactor.
Trigger: N/A Result of other UVR Check control system page 2.1 Alarm list in control panel
Delay: 10 sec. alarm. for related alarms.
Comment: Internal
warning as a result of
other alarm/warning for
the UVR.
Delay: 1 sec. Motor problem. 1. Check that the cable W301 is connected to the
control cabinet.
Comment: The
feedback signal “Filter 2. Check that the motor is not overloaded and can rotate
SUM alarm” is not easily.
detected.
3. Start the motor and check that the operation is
normal. See Service manual on page 391.
Mechanical obstacles. Check that mechanical parts in the filter can rotate freely.
See Service manual on page 391.
Filter flanges
misaligned, and forced
together causing stress Loosen the pipe connections to the filter and try to rotate
and deformation of the the filter manually. If the nozzle can rotate, the pipe
connections must be renewed. Cut pipe 201 shorter and
filter body. preventing insert a tailor made spool piece with perfect fitting.
the nozzle to rotate
freely inside the filter.
214 200000691-1-EN-GB
Alarms and faultfinding 5 EN
W303
Filter 3 sum alarm
Trigger: Filter.
Delay: 1 sec. See W300
Comment: Only valid for
systems with three
Filtrex filter and flow
3000.
Backflush manually from control system. If not sufficient,
Filter is clogged. clean the filter element according to instruction in chapter
Service manual on page 391.
Valves connected to Make sure that the two valves connected to the filter
filter pressure differential transmitter are open.
transmitter closed.
Hint: Pressure signals are displayed on in the Filter popup
opened from 1.1 Overview
W306
1. Check fuse F45 in Control cabinet to see what circuit
Filter differential caused the fuse trip.
pressure too high
2. Use the circuit diagram to check the fuse setting,
Trigger: Pressure adjust according to figures in circuit diagram if
transmitter PT201-71 necessary and reset fuse.
and PT201-72.
3. Use the circuit diagram to locate the component or
Parameter: p301, p314. Pressure transmitters find the reason that caused the fuse trip and attend to
does not work correctly. it.
Delay: 2 sec.
4. Check cables to the component. See Control cabinet /
Circuit diagram in chapter 6. Technical data and
drawings.
5. Check that all electrical connections are OK and that
the electrical wiring is not damaged.
6. Replace faulty transmitter.
7. Restart the process from the beginning.
200000691-1-EN-GB 215
EN 5 Alarms and faultfinding
W312
Filter pressure signal
missing (PT309-2)
Trigger: Pressure
transmitter PT309-2 on
Hydac filter. See W308.
Parameter: p314.
Delay: 30 sec
Comment: Alarm
deactivated in Standby.
Fuse F4 in the control Reset fuse F4.
cabinet has tripped.
W313
1. Check that cable W3091 is connected to the control
A signal is missing from cabinet.
the fuse for the filter
buckflush pump. 2. Start the motor and check that the operation is
Motor/load problem. normal.
Trigger: Fuse.
3. Verify that there is no loose wire to the —A2–DI5
Delay: None. digital input on the PLC.
216 200000691-1-EN-GB
Alarms and faultfinding 5 EN
200000691-1-EN-GB 217
EN 5 Alarms and faultfinding
W503
Heeling mode requested
by log box.
Trigger: ISCS. See W82 and A33.
Delay: 10 sec.
Comment: If detected
by bypass configuration
in 4.7 Log box.
Lamp on.
Possible causes:
All • Faulty DIP switch setting on one or more LPS. This fault occur after a 10
lamps seconds delay after start.
on.
• Voltage on the fail safe is missing.
218 200000691-1-EN-GB
Alarms and faultfinding 5 EN
During normal conditions, all relevant alarms are displayed in the PureBallast
control panel.
Display lines on flow transmitter
Display lines/fields
1. Main line for primary measured values.
2. Additional line for additional measured variables/status variables.
3. Current measured values.
4. Engineering units/time units.
200000691-1-EN-GB 219
EN 5 Alarms and faultfinding
Switch off power supply. Press and hold down both the OS buttons
Display texts are in a foreign language. and switch on the measuring device. The display text will appear in
English (default) and is displayed at maximum contrast.
Error messages consists of a variety of icons. The meaning of these icons can be
seen in the table below.
Problem ID Description
S System error.
P Process error.
$ Fault message.
! Notice message.
EMPTY PIPE Type of error, eg. measuring tube is only partly filled or completely empty.
03:00:05 Duration of error occurrence (in hour, minutes and secounds).
#401
220 200000691-1-EN-GB
Alarms and faultfinding 5 EN
Error number:
No. 001-399 System error (device error) has occurred.
No. 501-699
200000691-1-EN-GB 221
EN 5 Alarms and faultfinding
Control cabinet
DO9322 Digital output, 12 outputs
Lamp drive cabinet
Control cabinet
AI2622 Analogue input
Lamp drive cabinet
AT4222 Temperature input module Lamp drive cabinet
BC0083 Bus controller, power link Lamp drive cabinet
CS1030 Interface module Lamp drive cabinet
DI8371 Digital input Lamp drive cabinet
Interface module, RS422/
IF1030 Control cabinet
RS485
PS9400 24V power feed, bus supply Lamp drive cabinet
NOTE
All status indications are not valid for all modules
The meaning of a status indication might vary for some modules. These
variations are specified in the Description column.
Module BC0083, CP3585 and IF1082-2 are described in separate tables
below the generic table.
222 200000691-1-EN-GB
Alarms and faultfinding 5 EN
Module BC0083
Light Color Description
200000691-1-EN-GB 223
EN 5 Alarms and faultfinding
Module CP3585
224 200000691-1-EN-GB
Alarms and faultfinding 5 EN
S/E The powerlink managing node failed. This error code can only
Blinking alternately occur in controlled node operation. This means that the set
station number lies within the range $01 - $FD.
Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated
in two moedes: Either in Powerlink V mode or as an Ethernet TCP/IP
interface. Status light depends on mode. For TCP/IP mode, only SE green is
valid.
Light Color Description
Green Red
L/A X1 On Link to the remote station is established.
Green
L/A X2 Blinking On and Ethernet activity present on the bus.
200000691-1-EN-GB 225
EN 5 Alarms and faultfinding
Module DI9371
Light Green Red Description
Off Off Module not supplied, check fuse.
Single flash Off Reset mode.
Blinking Off Preoperational mode.
S
On Off Run mode.
Off Module not supplied or everything is OK.
Single flash On Invalid firmware
226 200000691-1-EN-GB
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200000691-1-EN-GB 227
EN 5 Alarms and faultfinding
228 200000691-1-EN-GB
Alarms and faultfinding 5 EN
These messages can appear alone or in combination. The message does not appear in remote control
panels (option).
5.3.2 Filter
Problem Description Possible cause What to do?
ID
Pressure transmitter PT201–71 Dismantle the component and
and PT201–72 may be faulty. inspect/rinse.
Backflush sequence starting Error with the pressure gauge Dismantle the component and
5A error (general). electric switches. inspect/attend to.
Valves for air pressure to valve Open the valve (ball cock)
V309-1 are closed. connected to V309-1.
200000691-1-EN-GB 229
EN 5 Alarms and faultfinding
5.3.3 CIP
Problem Description Possible cause What to do?
ID
6A Insufficient pump capacity Leakage in air hoses or Locate leakage and attend to.
(general). sealings.
Air pressure too low due to Adjust setting with the manual
incorrect setting on valve block. valve under the valve block.
Examine the pump and attend
Pump is clogged. to problem. See Test CIP pump
on page 428.
The diaphragm in the CIP pump Examine the pump. See chapter
is broken. 7. Service manual, section
Repair CIP pump.
6B Too high consumption of CIP Leakage in the CIP tank, CIP Locate leakage and attend to.
liquid. pump, pipes or UV reactor.
6C CIP pump does not run. • The air pressure is to low. Examine the pump and attend
to problem. See Test CIP pump
• The air connection is on page 428.
blocked.
• Muffler is blocked.
• Dirt in the pump chamber.
• Diaphragm breakdown.
6D CIP pump runs irregularly. • Valve blocked. Examine the pump and attend
to problem.
• Sealings are defect in air
valve or center block.
• Diaphragm breakdown.
6E Insufficient CIP pump suction. • Suction connection blocked Examine the pump and attend
or not tight. to problem.
• Muffler is blocked.
• Valve blocked or damaged.
230 200000691-1-EN-GB
Alarms and faultfinding 5 EN
6G CIP pump leakage. Screws on the housing not Tighten the screws.
properly fastened
6H CIP pump muffler leakage. Diaphragm breakdown Change diaphragm.
1. Increase airflow to the pump
to increase pump capacity
with the manual valve under
the valve block on the CIP
Insufficient pump capacity module.
(P321-5).
2. Check that pump P321-5 is
CIP liquid is not returned to CIP functioning correctly. See
6I problem 6D−6I in this
tank.
chapter.
200000691-1-EN-GB 231
EN 5 Alarms and faultfinding
232 200000691-1-EN-GB
EN
200000691-1-EN-GB 233
EN 6 Technical data and drawings
6.1 Introduction
This chapter contains technical information about PureBallast together with
mechanical and electrical drawings.
Location:
Remote control panel 1: ___________
Remote operation (optional) Remote control panel 2: ___________
Remote interface integration (yes/no):
___________
234 200000691-1-EN-GB
Technical data and drawings 6 EN
Media Flow /
consumption
100 – 1000 per
Flow range – Pipe 201, stripping
UVR m3/h
Minimum flow – Pipe 403, startup cooling water to UV reactor
(water sea to sea) 40 m3/h
200000691-1-EN-GB 235
EN 6 Technical data and drawings
Instrument air Range: 5.5 – 8.0 bar to operate valves and CIP pumps.
236 200000691-1-EN-GB
Technical data and drawings 6 EN
NOTE
Pressure requirement only includes PureBallast’s components. Piping is
not included.
If a backflush pump P309–1 is not used, pressure drop in pipe 309
(Δp309) must be calculated and added according to the table below.
Bar Comment
Pressure drop for UV reactors and PureBallast’s
0.2 valves.
Pressure drop during Max differential pressure over the filter during
ballast ballast operation. When the differential pressure
0.5 reaches 0.5 bar due to dirt in the filter, a
backflush is started automatically.
1.0 Required pressure to clean the filter.
Pressure needed for If a backflush pump P309–1 is not used, pressure
backflush drop in pipe 309 must be calculated and added.
Δp309 This is vessel specific and must be calculated
using required flow in pipe 309: 126 m3/h.
The ballast pump must deliver pressure at filter
Total inlet, covering total pressure drop over
PureBallast system.
6.3 Ex protection
This section describes the Ex protection of PureBallast. It covers the
components that are part of the Ex protection, sorted on UV reactor, filter, CIP
module and pipe net.
Requirements for Ex proof installation:
• The person installing PureBallast must have knowledge about applicable
Ex standard.
• The party responsible for the installation shall carry out an inspection to
verify that the installation is correct regarding the Ex protection.
200000691-1-EN-GB 237
EN 6 Technical data and drawings
Summary
PureBallast is designed and certified in accordance with the IEC 60079 series
of standards. PureBallast fulfills the European Directive ATEX 2014/34/EU
recommended by the IMO for use in marine applications and the IECEx
certified equipment scheme. All components in the zone are certified. The
installation must be done according to applicable rules and standards
regarding installations in potentially explosive environments.
To secure that the UV lamp quartz sleeves are cooled, there must always be
water in the UV reactor when the lamps are lit. This is secured by the use of a
check valve and monitored by double sensors for fluid level and temperature.
If any value deviates, or if signal is missing, the control system (or safety
control system) will shut down the UV reactor immediately. The UV reactor
(Exd) is hermetic sealed from outer atmosphere and is made flameproof
(Exd). The LDC is separated from the UV reactor and placed in safe zone.
During normal operation, the control system monitors PureBallast
automatically, based on input from sensors, to secure safe function. In addition
to the control system, a safety control system (Exi) is used. It is separate from
the control system, and therefore redundant to strengthen the protection
allowing one fault tolerance. If the normal control system fails, the safety
control system will shut down the system. The safe control system is based on
safety relays and is hardwired.
6.3.1 Ex components
All components in zone 1 have been chosen to be compliant with the Ex
requirements. The tables below list all components that are part of the Ex
protection, sorted on UV reactor, CIP module, filter and interconnecting piping.
UV reactor
All components on the UV reactor are connected to the lamp drive cabinet
(LDC). All LDCs are interconnected, and jointly connected to the control
cabinet via a switch in LDC 1.
Component and ID Sub components
UV reactor
2 junction boxes
Level switches:
Barrier (isolating amplifier) installed in LDC
(LS201-29)(LS201-30)
Temperature transmitter (TT201-33) Barrier (isolating amplifier) installed in LDC
Temperature switch (TS201-60) Barrier (isolating amplifier) installed in LDC
UV sensor (QT201-50) Barrier (smart repeater) installed in LDC
Valves:
Solenoid coil
(V320-4) (V321-2) (V404-36)
Solenoid coil
UVR inlet and outlet valve:
Sensor, inductive
(V201-19) (V201-20)
Barrier (isolating amplifier) installed in LDC
238 200000691-1-EN-GB
Technical data and drawings 6 EN
CIP module
All components on the CIP module are connected to the control cabinet via
the junction box.
Component and ID Sub components
Junction box with fuses
Valve block for
Drain pump (P320-1) CIP pump
(P321-5)
Valve block for:
(V310-1) (V310-6) (V320-2)
(V321-1) (V321-4) (V460-2)
(V571-1)
Filter
All components on the filter are connected to the control cabinet via the
junction box.
Component and ID Sub components
Filter motor (M709-43)
Junction box
Pressure transmitters:
(PT201-71) (PT201-72)
Backflush valve (V309-1) Solenoid coil
Backflush pump (optional) (P309–1)
Interconnecting piping
All components in the pipe net are connected to the control cabinet via
components own connection or junction box.
Component and ID Sub components
Flow transmitter (FIT201-1)
Pressure transmitter (PT201-16) Junction box
Switch box
Positioner
Control valve (V201–8)
Barrier for positioner installed in control
cabinet
Valves:
(V201-3)
(V201-9) Solenoid coil
(V201-32) Switch box
(V212-31)
(V403-35)
UVR cooling water pump (optional)
(P403–1)
200000691-1-EN-GB 239
EN 6 Technical data and drawings
This system is based on safety relays and is hardwired to avoid the need of a
separate validation of the software. All function in the safety system is using
redundancy to ensure one fault tolerance.
240 200000691-1-EN-GB
Technical data and drawings 6 EN
If the circuit is tripped, the blue Reset button S01 on the LDC door is lit. When
the temperature falls below the safety level (57.5), the circuit is reinstalled and
the cabinet can be reset by pushing the Reset button.
Level control circuit
A redundant level control circuit consisting of two level switches (LS201-29
and LS201-30) connected to KS01 via intrinsically safe barriers (IS). These
will shut down the LPS if one of the level switches does not indicate water for
more than 9 seconds. This time is long enough to allow air pockets in the
water, but not so long that any heat is produced.
After the circuit is tripped due to dry condition in the UV reactor, an automatic
reset will be performed when both level switches are activated again (due to
water in the UV reactor). The UV lamps will not be lit automatically, but it is
possible to start a new process.
The output uses the same redundant structure as the temperature limit circuit.
Below, the circuit is highlighted red.
200000691-1-EN-GB 241
EN 6 Technical data and drawings
6.5 Drawings
This section contains drawings for the PureBallast system. It is divided into
three main parts:
• General drawings – overall and principle information for system layout
(pipes, components, electricity, air and water).
• Dimension drawing – detailed component information (dimensions, sizes
etc).
• Electrical drawings – detailed electric information (circuit diagrams, cable
lists etc).
See the Contents section at the table of contents to get an overview of
included drawings.
242 200000691-1-EN-GB
Technical data and drawings 6 EN
200000691-1-EN-GB 243
EN 6 Technical data and drawings
244 200000691-1-EN-GB
Technical data and drawings 6 EN
Note: If closed cooling unit (optional) is used, see flow chart for Closed
cooling unit, regarding item 401 and 402.
200000691-1-EN-GB 245
EN 6 Technical data and drawings
6.5.2.2 Flow chart — Vacuum relief valve, VB201 and VB309 (optional)
246 200000691-1-EN-GB
Technical data and drawings 6 EN
200000691-1-EN-GB 247
EN 6 Technical data and drawings
248 200000691-1-EN-GB
Technical data and drawings 6 EN
200000691-1-EN-GB 249
EN 6 Technical data and drawings
250 200000691-1-EN-GB
Technical data and drawings 6 EN
200000691-1-EN-GB 251
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Cable selection
The cables for the IS circuits are not delivered by Alfa Laval, and must
therefore be selected by the party responsible for designing PureBallast. The
cables must be correct for installation in the hazardous zone, and they must
match the requirements for the intrinsically safe circuits.
Requirements for each cable (and underlying apparatuses) are described in
the the documents Ex i max multicore cable length calculation - V201-8 and
Ex i maximal multicore cable length calculation - UVR components
documents. These documents should be filled out.
The table below is an overview of cables to be verified. After the table, the
documents are available. Both documents contains:
• Example calculation: First page gives an example of standard cables and
how to calculate cable specifics to verify that the cable can be used.
• Verification for selected cable: Following page(s) describes the basic
data for the underlaying apparatuses. This section shall be filled out
according to the instruction. They can also be used if a cable needs to be
changed after installation.
Component
Cable ID's to be Reference documents
verified Intrinsically safe
apparatus ID
200000691-1-EN-GB 361
EN 6 Technical data and drawings
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Technical data and drawings 6 EN
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EN 6 Technical data and drawings
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EN 6 Technical data and drawings
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Technical data and drawings 6 EN
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EN 6 Technical data and drawings
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EN 6 Technical data and drawings
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7 Service manual
200000691-1-EN-GB 391
EN 7 Service manual
7.1 Introduction
This chapter contains information and instructions about how to service the
PureBallast system. Instructions are sorted per component. The chapter is
opened with a maintenance schedule covering checks and services that must
be performed with specified intervals.
DANGER
Before maintaining the PureBallast system, the power supply must be
switched off from the vessel’s main switch board.
DANGER Ex protection
Before opening any closed, current carrying components (such as flow
transmitter, junction boxes etc.) or maintaining the PureBallast system:
Make sure that the there is no explosive gas present.
No components that are part of the Ex protection (in zone 1) may be
modified in such a way that the Ex protection is affected in any way. When
replacing or maintaining a component, the work must be performed as
described in the user documentation, and in such a way that the Ex
protection is not affected in any way.
Before replacing a component that is a part of the Ex protection, it is
important to first see if there exist any special conditions for the
component. If the certificate number for the component contains an “X”,
the specific conditions must be read on the EC type-examination
certificate delivered with the component.
Signal cables for the components below are intrinsically safe circuits. If the
cables are damaged, they must be replaced with the exact same type of
cable, and the Intrinsically safe system descriptive document must be
updated. These components may not be repaired. When faulty, they must
be replaced with components that maintain the Ex protection.
• Position sensor signal cables between the control cabinet and valve
V201-3, V201-8, V201-9 and V212-31.
• Analogue output signal cable between V201-8 and control cabinet.
• Signal cable between the ICC switch in LDC 1 and control cabinet.
• Signal cables between the LDC and the following components on the UV
reactor: TT201-33, TS201-60, LS201-29 and LS201-30.
An Ex proof (Ex i) multimeter must be used to measure safe circuits (see
bullit list above). A normal multimeter might damage the component.
Cable glands in zone 1 may not be repaired. When faulty, they must be
replaced with components that maintain the Ex protection.
392 200000691-1-EN-GB
Service manual 7 EN
WARNING
Read Safety on page 9.
Installation must be done by a fully trained professional installer.
When maintaining the UV reactor always follow safety instructions. See
Safety information on page 407.
Follow rules when handling CIP liquid, regarding ventilation, personal
protection etc.
UV reactor
Glass socket screws – maximum 7 Nm.
CIP module
Flange bolts – maximum 20 Nm.
200000691-1-EN-GB 393
EN 7 Service manual
Filter
Thread Maximum tightening torque, Nm
M4 3
M6 7
M8 12
M10 18
M12 25
M14 35
M16 45
M18 60
M20 75
M22 90
M24 105
Actuator
Thread Tightening torque, Nm
M5 5-6
M6 10-11
M8 23-25
M10 48-52
M12 82-86
M14 132-138
M16 200-210
M20 390-410
394 200000691-1-EN-GB
Service manual 7 EN
200000691-1-EN-GB 395
EN 7 Service manual
If necessary, change
Outer faulty seals.
inspection of Once a year. See Spare parts
seals for
leakage. catalogue for
maintenance kit.
Dismount the
Check relief valve and make
valve RV201– sure you can
Once a year. blow air
50. through it from
the inside out.
Every 3rd
See Change and refill
pH value check. months,
whichever CIP liquid on page 423
comes first.
If the CIP liquid level is
Rule of thumb: low but the pH value is
Once every 3 below 3, CIP liquid and
months. water can be added to
Depending on See Change fill up the liquid level in
CIP liquid ballasting and refill CIP the tank.
level check. frequency, the liquid on page
liquid check 423 Note: pH value must
might have to be checked
be performed afterwards to secure
CIP liquid more regularly. correct pH value.
See
Preparations
Control of Visual and conditions
stored CIP inspection after under Change
liquid. three years. and refill CIP
liquid on page
423
Control that the
Junction box cables are
on CIP firmly attached Once a year.
module to the junction
box.
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7.2.1.1.1 Calibration using the vessels tank sounding systems calculating the flow
Calibration frequency: IMO: Every second year. USCG: Every year.
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C Calibration
device value (C°)
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Example
If the level switch is faulty, the following information shall be stated:
• PureBallast serial number.
• Level switch serial number and the serial number for the UV reactor on
which the level switch is installed.
• Item number for the component (LS00000).
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UV reactor
Placing: At the side of the UV reactor, as indicated in
the illustration.
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Filter
Placing: At the side of the filter, as indicated in the
illustration.
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Flow meter
Including flow transmitter and flow sensor
Placing: At the side of the transmitter housing, as
indicated in the illustration.
Note: The serial number for the flow transmitter is also
valid for the flow sensor.
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7.3 UV reactor
This section covers instruction for service of the UV reactor.
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DANGER
Always disconnect the PureBallast system from the power supply before
disassembling, and secure it from being switched on.
Always lock valve V201–9, V201–3 and V201–8 if you open the UV
reactor in some way. See Lock valve in closed position.
Before installation, check that the UV lamps and quartz sleeves are not
broken.
DANGER Mercury
UV lamps contain a small amount of mercury (less than 0.2 grams per
lamp) and must be handled and disposed of with care. Used lamps UV
can be handled and disposed of in the same way as fluorescent lamps.
Please refer to national regulations. If a UV lamp has accidentally been
broken, mercury could be spilt. Remove mercury with a special tool such
as a syringe (or use pure sulphure to bind the mercury for easy collection)
Do not allow mercury to come in contact with your eyes or skin. Do not
inhale mercury fumes.
Free mercury must be kept in an airtight bottle, and must be disposed of
according to national regulations.
In case of having inhaled mercury fumes, consult a doctor and follow
medical instructions.
• UV lamps radiate ultraviolet light when lit. Only operate the UV lamp when
correctly installed inside the UVR with end caps properly closed and UV
sensor fitted.
• Never dismount or handle UV lamps before they are completely cooled
down. A hot UV lamp is under high internal pressure, and the risk of
bursting exists. A hot lamp could also cause a burn if it is touched.
• It is not allowed to cover any part of the lamp fittings. There must be free
flow of air surrounding the lamp caps to ensure sufficient cooling.
• UV lamps and quartz sleeves are fragile and can easily become damaged.
Exercise great care when handling them. Do not apply vibrations or shock
to the UV lamp. This can cause breakage and shorten lamp life. Broken
glass/quartz can also cause severe cuts. Always use protective eye
glasses and clean cotton gloves when handling UV lamps and quartz glass
sleeves.
• Do not touch the glass of the UV lamp. Wear gloves and hold the lamp by
the ceramic end parts only. If a lamp is stained on its surface, wipe off the
glass with a clean soft piece of cloth soaked with alcohol. If not, it could
cause breakage and shorten lamp life.
• See Safety data sheet / UV lamp on page 379 for detailed safety
information.
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CAUTION Ex protection
The person must have knowledge or sufficient experience to perform the
tasks at hand. The person must be able to perceive risks and to avoid
hazards which electricity/mechanics can create. The person must have
knowledge about the specific Ex standard used to eliminate the risk of
explosion, for example IEC 60079 series.
Maintenance must be done according to the information found in this
manual.
If one of the components with a signal cable on the UV reactor (TT201-33,
TS201-60, LS201-29 and LS201-30) is damaged during the installation or
maintenance, it must be replaced with the exact same type of cable, and
the Intrinsically safe system descriptive document must be updated. If the
signal cable is affected in any way it must restored.
The UV lamp sockets have been designed to eliminate potential flame
channels around the fittings and cable connections. These components,
illustrated below, constitute the Ex protection. The components or flame
paths must not be damaged in any way. The components must not be
repaired. When faulty, they must be replaced. If the cap, glass socket or
adaptor is damaged, both must be changed.
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Ex components and flame paths (illustration show a reactor fro 300 m3/h, but the
components are the same for a 1000 m3/h reactor)
1. Cable gland (Ex protection)
2. Cap (Ex protection)
3. Lamp bush
4. Glass socket (Ex protection)
5. O-ring
6. Adaptor (Ex protection)
NOTE If the UV lamps are hot they are under internal positive
pressure and may burst if broken.
Wait at least 10 minutes after completed ballast or deballast process, to
allow the UV reactor to cool down to ambient temperature.
CAUTION
Protect the flame path of the cap from being damaged. If the surface is
scratched, dented or damaged in any way, the component must be
replaced. See Safety information for Ex components at the beginning
of this section.
Protect the cable gland from being damaged. If bent or damaged in
any way, the component, including cable, must be replaced. See
Safety information for Ex components at the beginning of this section.
2. Carefully disconnect the two cable connectors in both ends of the UV lamp.
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3. Unscrew the three screws holding the glass socket and remove it on one
side. Carefully draw out the lamp bushes on both sides.
4. Carefully draw out the UV lamp. Do not touch the glass. Only hold the UV
lamp by the ceramic ends.(If required, use a screwdriver to press on the
ceramic end of the lamp through the hole in the lamp bush while carefully
pulling the electric cable at the other end.
After removal, place the old lamp in the new lamp’s protective cover.
5. Check that the quartz sleeve is not broken inside the UV reactor, and that
there is no leakage around the glass socket and adaptor.
6. If the quartz sleeves is not broken, mount the new UV lamp according to
the instruction Assemble UV lamp. If broken, follow the instruction
Disassemble quartz sleeve below.
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CAUTION
Protect the flame path of the glass socket and the adaptor from being
damaged. If the surface is scratched, dented or damaged in any way,
the component must be replaced. See Safety information for Ex
components at the beginning of this section.
No lubrication may be used for the flame path.
4. Once the Allen screws are evenly entered, carefully tighten them evenly to
a torque of 7 Nm.
5. Mount the new heat resistant O-rings in the two lamp bushes.
6. Place one bush on the UV lamp.
7. Insert the other bush in the opposite side of the UV reactor.
8. Make sure that the connection is clean to ensure good electric connection
(no rust, burning or fading on the connectors). Reconnect the two cable
connectors for the UV lamp.
9. Clean the flame path of the cap with a clean, soft cloth. The surface must
be totally clean and free from scratches. See Safety information for Ex
components at the beginning of this section.
CAUTION
Protect the flame path of the glass socket and the adaptor from being
damaged. If the surface is scratched, dented or damaged in any way,
the component must be replaced. See Safety information for Ex
components at the beginning of this section.
No lubrication may be used for the flame path.
10. Connect the cable's shield to the to the PE screw (grounding) at the bottom
of the cap.
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11. Mount the caps and tighten the three Allen screws at both ends of the UV
lamp to a torque of 7 Nm. Make sure the electric cable is free when
mounting.
CAUTION
When mounting the caps, protect the cable gland from being
damaged. If bent or damaged in any way, the component, including
cable, must be replaced.
12. Control the control system page 3.1 Alarm list, to make sure there is no
alarm when after the lamp power supply is on.
CAUTION
Protect the flame path of the glass socket and the adaptor from being
damaged. If the surface is scratched, dented or damaged in any way,
the component must be replaced. See Safety information for Ex
components at the beginning of this section.
Do not jerk the glass sockets when removing them. Otherwise the
quartz sleeves may break.
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7. Remove the quartz sleeve O-rings in the adaptor on both sides. The O-
rings are firmly stuck in their seat, and will be damaged during removal, but
shall be replaced at assembly. Use an angled or hooked O-ring tool to
loosen and remove the O-ring. Be careful to avoid to break the glass.If the
O-ring is hard to remove, try the following:
• Perforate the O-ring to get a good grip.
• Moisten the O-ring with acetone or denatured alcohol.
• Loose the O-ring in a couple of places before removing it.
8. Carefully remove the quartz sleeve.
9. Carefully clean the surface between the UVR and the adaptor and remove
any small parts, for example glass or rubber.
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CAUTION
Protect the flame path of the glass socket and the adaptor from being
damaged. If the surface is scratched, dented or damaged in any way,
the component must be replaced. See Safety information for Ex
components at the beginning of this section.
No lubrication may be used for the flame path.
6. Once the screws are evenly entered on both sides, carefully tighten them
evenly to a torque of 7 Nm.
7. Connect the instrument air.
8. Follow the instruction Check for leaks after quartz sleeve assembly on
page 414.
WARNING
Make the system currentless according to Shut down and deactivate
system on page 101. The LPS has high voltage/power (600 V) inside and
on the lamp power connector, even when UV lamps are not lit.
The LDC contains a fan, which can cause injury if in operation.
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CAUTION
If the signal cable for this component is damaged during the installation or
maintenance, it must be replaced with the exact same type of cable, and
the Intrinsically safe system descriptive document must be updated. If the
signal cable is affected in any way it must be restored.
1. Dismount LPS
Release two power connectors at the bottom of the LPS and the signal
cable connector at the top.
2. Loosen the nuts at the bottom (1) of the arc holding the LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short
circuit.
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DANGER
Before operating the UV reactor, make sure that there is water in the UV
reactor.
Check the LED on the level switch: Steady yellow light indicates that there
is water in the UV reactor.
WARNING
This instruction must be performed after cable connection. If not
hazardous situation may arise which, if not avoided, will result in death or
serious injury.
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7.4 Filter
This section covers the instructions for filter service.
Preparations and conditions
These preparations and conditions are valid for all instructions.
• Make sure that the there is no explosive gas present.
• Disconnect the power to the filter, using the main breaker on the control
cabinet.
• Always lock valve V201–3 and V201–32 if you open the filter in some way.
See Lock valve in closed position on page 434.
• Only perform maintenance and servicing work when the filter is cooled,
depressurized and drained.
• Shut off the air supply to the filter.
• Visually inspect gasket during maintenance. Replace if necessary.
• Lifting device is needed for this instruction. See complementary lifting
instructions in the Design and installation guidelines.
Filter cover and element weight (kg):
Filter Weight, empty with adaptor plates on
flanges (kg)
ACB–9120–500 1780
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1. Gear reducer
2. Gear shaft
3. Electric motor
4. Thrust bearing flange fixing bolt
5. Gear reducer flange / cover fixing bolt
6. Thrust bearing
7. Backflush shaft bushing gasket
7a. Backflush shaft bushing gasket
8. Filter vent plug
9. Filter cover
10. Cover bolt
11. Backflush shaft bushing
12. Filter element fixing bolt
13. Filter cover gasket
14. Filter body
15. Filter element
16. Backflush nozzle
17. Filter element gasket
18. Backflush shaft bushing
19. Filter drain plug
20. Backflush line gasket
22. Pressure transmitter
29. Junction box
30. Backflush nozzle support
31. Backflush nozzle fixing bolt
32. Backflush nozzle support gasket
33. Base frame
34. Base frame fixing bolt
40. Ring spear 44. Cover lifting lug
41. Thrust bearing upper flange 45. Rotation indicator
42. Thrust bearing lower flange 70. Nameplate
43. Seeger 80. Prefilter
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3. Close the following valves: V201-3, V310–2 and V201-32 according to the
instruction in the section Open and close valves manually in chapter
Valves on page 431 and Lock valve in closed position on page 434.
4. Unscrew the bolts (5) holding the gear motor (1).If the electrical cable is
short, it might be necessary to disconnect it before removing the motor.
5. Remove the motor (using a lifting device, if necessary). Be careful not to
harm the motor fitting when lifting it from it’s seat.
6. Remove the cover bolts (10) and the lifting lugs (44).
7. Screw two filter cover bolts in the lifting lugs holes until the cover raises
slightly from the filter house.
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8. Remove the cover bolts and fasten the lifting lugs in their holes again.
9. Fasten a lifting device in the lifting lugs and lift the filter cover (9) with the
filter element carefully out of the filter.
NOTE
Be careful not to harm the filter element.
The filter should be lifted in one continuous movement, without sudden
jerks – even if the filter element is slightly stuck in the filter house.
13. Pull out the backflush shaft bushing. If it is stuck, give a couple of light
blows with a wooden hammer on the top of the shaft to release it.
14. Place the filter element upside-down.
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15. Unscrew the four Allen screws inside the element to loosen the filter cover.
NOTE
No force should be used to fit the filter element in the filter house or to fit
the motor in its seat.
• Clean the upper inside of the house at the top of the. The area where the O
rings (gaskets) meet the housing should be clean.
• Check the O rings (gaskets). Replace if necessary.
• Fill up the filter with technical / potable water after it is mounted.
• There is not need to de-air the filter when it is filled up.
WARNING
Risk for eye and skin irritation.
Follow rules when handling CIP liquid agent; Alpacon descalant offshore,
regarding ventilation, personal protection etc. Avoid contact with eyes and
wear protective gloves and goggles.
If Alpacon descalant offshore comes in contact with eyes or skin, rinse
thoroughly with cold water.
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7.5 CIP
This section covers instruction for service of the CIP module.
WARNING
Risk for eye and skin irritation. Avoid contact with eyes and wear
protective gloves and goggles. Follow rules when handling CIP liquid
agent, regarding ventilation, personal protection etc.
If Alpacon descalant offshore comes in contact with eyes or skin, rinse
thoroughly with cold water.
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CIP module
1. CIP liquid tank cap
2. Valve block
3. Pump P321–5 (UVR reactor drain)
4. Pump P320–1 (CIP liquid)
5. Drain line 460.2 with manual valve
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7.6 Pump
This section contain instructions for the CIP pump.
WARNING
Always disconnect the PureBallast system from the power supply before
disassembling, and secure it from being switched on.
CAUTION
Always wear protective eye glasses and gloves while working on the
pump.
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4. Press out the air valve. A wood shaft of a hammer can be used. Be careful
not to damage the sealing edges towards the diaphragm or the air valve.
5. If the shaft sealings (36) seem to be worn out, carefully remove them with
a pointed tool.
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1. Open valves V320-2 and V460-2 from the control system, and V230–11
manually. Start pump P321-5 (4) and P320-1 (4).
2. Observe if the motors sound and functions OK. If not, check installation
and connections and attend to and test again.
3. Stop the pumps and close the valves in reversed order.
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Valve block
Preparations and conditions
• The junction box and valve blocks, including cabel glands and electrical
components (valve coils, fuses and terminals), are part of the Ex protection.
These components may not be repaired. When faulty, they must be
replaced with components that maintain the Ex protection. Install according
to the Control cabinet / Circuit diagram.
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7.8 Valves
This section contain instructions for the valve actuator.
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Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilot valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves with dimension 400
7. DIN connector
8. Position indicator
CAUTION
Lock valve in closed position before maintenance.
Do not disassemble individual spring elements. Disassembly may result in
personal injury.
Do not remove end caps or disassemble the actuator while the actuator is
pressurized.
• If the signal cable for this component is damaged during the installation or
maintenance, it must be replaced with the exact same type of cable, and
the Intrinsically safe system descriptive document must be updated. If the
signal cable is affected in any way it must restored.
• Do not operate the actuator over pressure limits. It will damage internal
parts as well as cause damage to the housing.
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• The actuator must not be lubricated. It is factory lubricated for the life of the
actuator during normal working conditions. The standard lubricant is
suitable for use from −20 °C (−4 °F) to +80 °C (+176 °F).
• If a valve actuator is removed, check for loose spindle-bushing. Then make
sure the loose bushing is refitted to avoid play between the actuator and
the valve spindle.
• Actuator are mounted together with the valve body and pilot valve at
delivery. Valve and actuator mounting are sealed to guarantee correct
position indication in relation to throttle position.
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4. Measure exactly how far out the end stop bolt (4) is from a reference
surface, for example the actuator house. Make a note of the distance. This
information is needed when unlocking the valve.
5. Open the locking bolt (3) and turn them a couple of turns.
6. Screw the end stop bolt (4) to its bottom position and tighten the locking
bolt.
7. Verify that the valve cannot be opened.
8. Slide the safety cover over the end bolts and lock the safety cover with the
pad lock.
9. Repeat the above procedure for all valves concerned.
NOTE
It is important to adjust the ends stop bolt to the correct position.
Otherwise the actuator may be damaged.
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CAUTION
The actuator must not be pressurized at any time during installation as it
may result in injury.
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5. Mount the actuator on the valve with the four hexagonal screws. For each
screw, one washer and one spring washer shall be used. Tighten with
torque according to the table Tightening torques for actuators in
Preparations and conditions on page 432.
6. If the actuator have a switch box at the top: Make sure that the yellow
position indicator under the switch box is in line with the throttle (according
to the groove in the valve stem). The yellow position indicator shall be in
line with the valve throttle (indicating open when the position indicator is in
line with the pipe). If not, remove the position indicator, turn it 90° and refit
it.
Mount the switch box with the bracket on the actuator, using the four bolts.
7. Reconnect the air hose to the pilot valve.
8. Operate the valve to make sure it operates in the desired direction of
rotation.
1. Note the exact position of the position indicator for reference after
adjustment.
2. Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing
position and the left set adjusts open position.
3. Loosen the locking bolt (3).
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4. Adjust end position by turning the end stop blot (4) with small turns.
NOTE
The total adjustment degree is 10° for each position.
5. Operate the valve. Compare the new position of the position indicator to
see the result on the adjustment. If needed, adjust again.
6. Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).
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• Do not adjust the cam wheels: 2 grey wheels above the adjustment wheel
(5).
• Buttons on the positioner:
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Trouble shooting
If any problem occurs, do the following:
1. Check the mechanical installation and air supply.
2. Reset factory settings and restart calibration:
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7. Check that the valve is indicated as open (steady green) in the control
panel.
8. Close the valve to 0 %.
Result 1: Valve closed, indicated with no color. Circuit closed. Setting is
OK. You are done.
Result 2: Valve indicated as red. Cam wheels are in wrong position, for
example due to the wheels been turned too much after the click).
Multimeter indicate circuit open. Repeat from step 2 until setting is OK.
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7.8.13 Change direction of actuator – with position sensor (201-19 and 201–
20)
Follow this instruction to turn an actuator with a position sensor, if necessary due to lack of space.
Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-19 and V201-20 on the UV reactor.
Preparations and conditions
• The valve must be in closed position.
• The valve position must not be adjusted during the routine.
• The valve must be mounted and connected to air and power before adjustment.
• Ex connections in the junction box: Intrinsically safe (feedback) and non-intrinsically (open/close)
circuits fitted with the same enclosure shall be separated as required by EN 60079–14.
Follow the steps below
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10 Connect power.
12 Connect air.
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Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilot valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves with dimension 400
7. DIN connector
8. Position indicator
Preparations and conditions
• The valve must be in closed position.
• The valve position must not be adjusted during the routine.
• The valve must be mounted and connected to air and power before
adjustment.
Follow the steps below
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WARNING
Risk of electric shock! Exposed components carry dangerous voltages.
Make sure that the power supply is switched off before you remove the
cover of the electronics compartment.
Only open the device in a de-energized state (once a delay of 10 minutes
has elapsed after switching off the power supply) or in environments
which do not have a potentially explosive atmosphere.
- Press the latches at the side and remove the display module.
- Disconnect the ribbon cable of the display from the amplifier board.
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4. Remove the screws and remove the cover from the electronics
compartment.
5. Remove the power supply board. Insert a suitable tool into the hole,
provided for the purpose and pull the board clear of its holder.
6. Remove cap (1) and replace the device fuse (2).
For Ex-rated devices:
Use only fuses of the following type; the fuses are installed on the power
supply board:
- Voltage 20 to 55 V AC / 16 to 62 V DC: fuse 2.0 A slow-blow, disconnect
capacity 1500 A (Schurter, 0001.2503 or Wickmann, Standard Type 181
2.0 A)
Replacing the device fuse on the power supply board (step 5–6)
1. Protective cap
2. Device fuse
7. Installation is the reverse of the removal procedure.
Re-assembly
WARNING
Risk of electric shock! Exposed components carry dangerous voltages.
Make sure that the power supply is switched off before you remove the cover of the electronics
compartment.
Only open the device in a de-energized state (once a delay of 10 minutes has elapsed after
switching off the power supply) or in environments which do not have a potentially explosive
atmosphere.
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NOTE
The circuit boards may break if you yourself or your tools not are grounded at the same
ground point as the component that you will work with. Always use an electrostatic discharge
wrist strap connected to the same earth/ground as the component. Always place your tools on
the same earth/ground as the component you will work with before using them. Follow general
rules on how to avoid electrostatic discharge.
Follow the steps below
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Level switch
NOTE
Disconnect power supply before mounting or dismounting the component.
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• The external surface may be hot. Care must be taken to avoid possible
burns.
Follow the steps below
1. Disconnect the level switch according to the label on the device.
2. Loosen the component with a spanner. Use the spanner on the hexagon
flats, but not on the level switch body.
3. Remove the level switch and remove the old seal from the threads.
3. Make sure the level switch reacts to the magnet. The component is OK if
the green and yellow LED is lit.
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NOTE
Disconnect power supply before mounting or dismounting the component.
• If the signal cable for this component is damaged during the installation or
maintenance, it must be replaced with the exact same type of cable, and
the Intrinsically safe system descriptive document must be updated. If the
signal cable is affected in any way it must restored.
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NOTE
Control panels may only be cleaned when set in wipe mode. This is to
prevent unintended functions from being triggered by buttons pressed
during cleaning.
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4. Pull the board straight out (otherwise it can fasten in one of its guides).
5. Compare the part number of the new I/O board to the old board, to make
sure it is correct.
6. If changing more than one board at a time, check with the electrical
diagram to ensure that the boards are mounted in the right places.
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7. Mount the new I/O board by pressing it straight into place. Make sure the
board is firmly in place, otherwise it will be impossible to mount the cable
terminal.
8. Remount the terminal block. Make sure the clip on the bottom of the block
fastens properly in place on the axel on the bus holder.
9. Pivot the terminal block on the axel until the clip on the terminal block top
fastens into place in the I/O board.
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This check should be performed in LDC, control cabinet, UVR junction box
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.
2 Control cabinet, Ex 6
2.1 Cabinet 10
2.2 I/O module 12
2.3 Terminal block 14
2.4 Relay module 16
6 Filter, ACB-9120-500 EX 60
6.1 Filter, ACB-9120-500 64
6.2 Junction box, Ex 66
7 Adaptor 68
3
11 Valve V201-32 and V403-35 76
15 CIP module, Ex 84
15.1Pump, Ex 88
15.2Valve, Ex 90
15.3Valve block 92
15.4Filter regulator 94
15.5Valve block, Ex 96
4
1 Important information
1 Important information
• State number of ordered parts. Note that the quantity in the tables do not states number of parts
delivered (only the how many of that parts that are included in the mother component).
• Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with
non-original spare parts. We guarantee the quality and reliability of our products.
• When ordering, refer to part number listed in this catalogue and serial number, described in
chapter 7. Service manual, section Serial number information.
2 Control cabinet, Ex
Machine unit number or
Subassembly description
9028388-
Ref Part No Description -82 Notes
Quantity
1 9012086 84 Cabinet 1 See page 10
2 9006851 01 Software, PLC, PB3.0 1
3 9006852 01 Software, panel 1
4 9017691 03 HMI Panel 15" 1
8 221891 04 Lock nut 12
9 223101 47 Washer 12
10 582212 148 End stop (clip fix) 13
11 582212 122 Terminal block 3
12 582212 13 End plate 3
13 9019135 03 Contactor AF09Z 1 K2
13.1 9019138 01 Over current prot. Relay Ex 1 F2
14 9019135 03 Contactor AF09Z 1 K3
14.1 9019138 01 Over current prot. Relay Ex 1 F3
15 9014707 01 Power supply unit 1 T1
16 9004299 04 Fuse 4
17 582212 67 Terminal, PT 2,5-3PV 7
17.1 582212 71 Plug In Bridge, FBS 3-5BU 1
18 582212 63 Terminal D-PIT 2,5-3L 1
19.1 9019138 04 Over current prot. Relay Ex 1 F4
19.2 591103 84 Aux block 1nc 1 K4
20.1 9019138 04 Over current prot. Relay Ex 1 F5
20.2 591103 84 Aux block 1nc 1 K5
21 9025840 80 I/O module 1 See page 12
22 582212 147 Patch panel 2
23 582212 91 VIP-2, D 9SUB 1
30 221701 03 Screw 16
31 582212 168 Separating plate 2
32 582212 123 Power terminal block, 1
33 9002362 80 Relay module 3 See page 16
34 593724 03 Distance screw 4
35 582221 90 PE Connection bar 1 245mm
36 594009 03 Screw 2
37 582212 206 Bar holder 3
38 582212 15 PE/SC Bar 1 500mm
39 594009 02 Screw 3
40 582212 207 Cable clamp 10
42 583556 17 Cable channel 40x80 1
43 583556 16 Cable channel 40x80 2
44 9003522 06 Cable channel, 25x80 1
45 9003522 07 Cable channel, 25x80 2
48 223101 47 Washer 2
49 221851 05 Cap nut 2
50 591103 71 Pushbutton, ill. Blue 1
50.1 591103 87 Blue LED 1
50.2 591103 88 Holder for 3 pos 1
50.3 591103 89 Contact block 1 NO 1
52 591103 67 Emergency stop 1
52.1 591103 93 Shroud Ye 1
54 9011552 01 Buzzer 1
56 582212 155 Socket with USB 2
59 9025837 01 Switch OT63FT3 1
59.1 591103 37 Breaker handles 1
59.2 9025837 02 Shroud OTS63T3 2
61 9006853 01 Fan 1
62 9006854 01 Air outlet 1
63 595361 02 Cable seal 2
66A 9008383 06 Cable, 2,5mm² PE 5
66B 9008383 08 Cable, 1,5mm² 9
66C 9008387 01 Cable 100
3073A
3073A
2.1 Cabinet
Machine unit number or
Subassembly description
9012086-
Ref Part No Description -84 Notes
Quantity
1 9012088 80 Cabinet 1
2 9012091 80 Door 1
4 26556 Spring washer 6
5 9025887 01 Mounting plate 1
6 587276 02 Washer 16
7 221891 05 Hexagon lock nut 12
8 221716 01 Screw 4
10 593778 01 Latch, housing 1
11 593779 01 Latch, insert 1
12 593991 01 Latch 1
13 9003013 01 Rod Guide 2
14 9003024 02 Rod for latching 2
15 593780 01 Key 1
17 223107 34 Spring washer 4
18 221891 04 Lock nut 4
20 593254 01 Retaining ring 1
21 221711 19 Screw 1
22 593282 01 Washer 1
23 221803 02 Nut 2
24 223101 73 Washer 1
25 593239 01 Nut 1
26 581688 01 Bracket 4
27 594488 01 Washer 4
28 221711 16 Screw 8
29 223101 47 Washer 8
30 221891 04 Lock nut 8
31 587276 02 Washer 6
32 70560 Washer 6
33 221891 05 Hexagon lock nut 6
34 9014753 01 Piano hinge 1
35 9014815 01 Cover panel 1
36 598571 01 Torx head pan screw M4 8
37 221851 18 Cap nut 8
38 223101 31 Washer 4
39 9015118 01 Mounting spacer hole thro 2
40 9015117 01 Mounting spacer single ta 2
41 9012093 01 Magnet 4
42 9015123 01 Torx head pan screw M5 4
43 544465 04 Locking liquid 1 Loctite 270
44 587276 01 Washer 2
45 223101 47 Washer 2
46 221891 04 Lock nut 2
2900A
3030A
3075A
2724A
2906A
3083A
3083A
3.1.1 Cabinet
Machine unit number or
Subassembly description
9011952-
Ref Part No Description -80 Notes
Quantity
1 9011951 80 Cabinet 1 See page 26
2 9012193 01 Mounting plate 1
3 587276 02 Washer 18
4 221891 05 Hexagon lock nut 10
5 221716 01 Screw 8
6 9015611 01 Sheet 1
7 223101 47 Washer 4
8 221891 04 Lock nut 4
10 223101 47 Washer 6
11 221891 04 Lock nut 6
13 592005 15 DIN-rail, 35x15 1
14 9003565 03 DIN-rail, 35x15 1
15 9003565 02 DIN-rail, 35x15 1
16 223101 47 Washer 17
17 221891 04 Lock nut 14
18 583556 20 Cable channel 40x80 1
19 583556 19 Cable channel 40x80 1
20 583556 21 Cable channel 40x80 1
21 583556 04 Cable channel 1
22 586056 07 Cable channel 60x80 1
34 223101 47 Washer 13
35 221851 05 Cap nut 13
37 9004212 01 Inlet duct 1
38 9004213 01 Protection 1
39 221891 02 Nut 4
40 223101 16 Washer 4
41 594009 02 Screw 4
42 9003390 01 Bracket, fan 1
43 9006316 01 Cover, fan 1
44 223101 47 Washer 9
45 221030 10 Screw 9
46 591889 01 Cable tie mount 3
50 9003030 01 Drawing Pocket 1
51 223101 47 Washer 2
52 221803 02 Nut 2
53 9014585 01 Sheet, LPS 1
54 9014554 01 Sheet, LPS 1
55 594009 05 Screw 8
56 9002947 01 Yoke 18
57 9002942 01 Stud bolt 36
61 9006322 01 Sheet 1
62 221030 02 Screw 36
63 223101 47 Washer 72
64 221891 04 Lock nut 36
65 9015616 01 Sheet 1
66 70560 Washer 2
67 221891 05 Hexagon lock nut 1
68 221716 01 Screw 1
2881A
3.1.2 Cabinet
Machine unit number or
Subassembly description
9011951-
Ref Part No Description -80 Notes
Quantity
3 9008903 05 Washer 12
4 221035 51 Screw 12
5 9014640 01 Door, RH 1
6 9014642 01 Door, LH 1
9 223101 47 Washer 12
10 221803 02 Nut 12
15 9003075 01 Sheet 2
16 593254 01 Retaining ring 2
17 9003410 01 Sheet, heat exchanger 1
18 221030 10 Screw 9
19 223101 47 Washer 2
20 9003401 01 Sheet, heat exchanger 1
21 221030 10 Screw 3
22 223101 47 Washer 3
23 9003186 01 Plug 1
29 591874 04 Seal 1 Upper LPS rack, left
30 591874 06 Seal 1 Upper LPS rack, right
34 9014759 01 Sheet, EMC 1
49 9014762 01 Handle 1
50 9016266 01 Rod for latching 2
50.1 9016270 01 Rod adapter 4
51 9016268 01 Rod guide 8
52 9014732 01 Three point lock 1
53 9014735 01 Handle 1
54 9016266 02 Rod for latching 2
54A 9003024 01 Rod for latching 1
55 593780 01 Key 1
56 9003114 02 Cable gland 1
57 9003113 01 Cable seal 1
58 223101 41 Washer, 4,3x9x0,8 10
59 221891 02 Nut 10
64 9003031 01 Condensation outlet 2 Cabinet floor and heat exchanger floor
65 9003186 02 Plug 3
66 9008424 01 Protection 9
67 9003089 02 Vibration damper 2
68 223101 49 Washer 13x24x2,5 2
69 221726 10 Screw 2
2882A
2880A
2870A
2871A
2904A
2873A
2377A
2907A
2875A
4.1 Cover
Machine unit number or
Subassembly description
9011943-
Ref Part No Description -80 Notes
Quantity
1 9011944 01 Cover 1
2 594488 01 Washer 4
3 581688 01 Bracket 4
4 221711 16 Screw 8
5 223101 47 Washer 8
6 221891 04 Lock nut 8
7 589569 79 Cable Gland - M25 2
8 589569 35 Counter nut M25 2
9 589569 48 Cable Gland - M16 2
10 589569 33 Counter nut M16 2
11 587276 02 Washer 2
12 70560 Washer 2
13 221891 05 Hexagon lock nut 2
2883A
2748A
2748A
2781A
2863A
2914A
2909A
2491A
6 Filter, ACB-9120-500 EX
Machine unit number or
Subassembly description
9025132-
Ref Part No Description -60 Notes
Quantity
1 9023662 60 Filter, ACB-9120-500 1 See page 64
2 591090 04 Flange 1 1/4" 1
3 526337 08 Reducing hexagon nipple 1
5 221711 07 Screw 2
6 9024168 01 Elbow union 2
7 526337 02 Reducing hexagon nipple 2
8 1767267 01 Needle valve 2
9 9015682 01 Press. transmitter, Ex 2
13 526336 04 Nipple 5
14 9006822 03 Relief valve, 10 bar 1
15 561094 06 Straight coupling 1
16 9019487 02 Tube 1
19 9023648 85 Gear motor EX 1
19A 9038011 06 Gear motor, Ex 1
19B 9025172 01 Cable gland, Ex d M25x1,5 1
20.1 221803 22 Nut 4
22 9024155 01 Bracket 1
23 7007238 01 Screw 4
24 9011979 80 Junction box, Ex 1 See page 66
24.1 595928 20 Cable gland, Ex e, M32x1,5 1
24.2 595928 06 Cable gland, Ex e, M16x1,5 3
25 221711 25 Screw 4
25.1 223101 32 Washer 4
25.2 221803 28 Nut 4
26 9026076 01 Cable bracket 1
27 221711 07 Screw 2
28 223101 32 Washer 2
29 9026073 01 Bracket 1
30 221711 07 Screw 2
31 221711 13 Screw 1
32 223101 32 Washer 3
33 587276 01 Washer 1
34 9025165 03 Cable 1
40 1270001 Lifting instruction 1
42 9039248 80 Release valve automatic, Ex 1 V571-2
42A 9039248 01 Check valve 1
42B 9039248 02 O-ring, small 1
42C 9039248 03 Clamping stem 1
42D 9039248 04 Rolling seal 1
42E 9039248 05 Float 1
42F 9039248 06 Body 1
42G 9039248 07 Casing 1
42H 9039248 08 O-ring 1
42I 9039248 09 Base 1
42J 9039248 10 Strainer 1
43 9024839 01 Stud elbow, male 1
44 1779813 03 Valve, 1/2" AISI 316 1 V571-4
45 9029394 01 Union, conical sealing 1
46 569035 05 Flexible pipe, PA12, 8/6 1 4m
47 544465 06 Locking liquid 1 50 ml
48 526345 04 Elbow 2
49 526344 04 T-piece 1
50 590667 49 V571-4 1
ZA 526336 04 Nipple 4
ZB 526344 04 T-piece 1
ZC 526345 04 Elbow 2
ZD 9029394 01 Union, conical sealing 1
ZE 9039248 80 Release valve automatic, Ex 1 V571-2
ZEA 9039248 01 Check valve 1
3032A
3032A
3045A
3113A
7 Adaptor
Machine unit number or
Subassembly description
9021972-
Ref Part No Description -93 Notes
Quantity
1 9025949 01 Adaptor plate, DN500-DN/A 1
2 9017549 12 Gasket, DN500 1
3 260193 34 Screw 20
4 223101 65 Washer 20
3033A
3055A
3076A
2732A
2736A
2738A
2734A
3056A
15 CIP module, Ex
2924A
2924A
15.1 Pump, Ex
Machine unit number or
Subassembly description
9012420-
Ref Part No Description -80 Notes
Quantity
1 9012420 01 Pump, EX 1
Z 9004587 80 Spare part set Incl. O-rings, diaphragm, ball, muffler
indicated in dwg.
Z0.1 9004588 80 Spare part set Incl. air valve, sealings and O-rings,
indicated in dwg.
2925A
15.2 Valve, Ex
Machine unit number or
Subassembly description
9002825-
Ref Part No Description -81 Notes
Quantity
1 9002825 02 Valve, EX 1
Z 9003574 01 O-ring
2609A
2765A
2766A
2742A
2780A
2760A
3036A
3077A
3039A
2377A
2739A
3140A
3082A
+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
Specification No.
Book No. 9043646 02 Rev. 1
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
3
4
1 Important information
1 Important information
• State number of ordered parts. Note that the quantity in the tables do not states number of parts
delivered (only the how many of that parts that are included in the mother component).
• Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with
non-original spare parts. We guarantee the quality and reliability of our products.
• When ordering, refer to part number listed in this catalogue and serial number, described in
chapter 7. Service manual, section Serial number information.
3197A
3180A
2.2 VFD
Machine unit number or
Subassembly description
9038554-
Ref Part No Description -86 Notes
Quantity
1 9042446 01 VFD, R9 1
3 593950 18 Marking, VFD 1
Z0.1 9038547 02 Fan Internal fan
Z0.2 9038547 09 Fan Main cooling fan kit
Z0.3 9040657 01 Control panel
Z0.4 9040658 01 Options kit
Z0.5 9040659 04 Memory Unit kit
Z0.6 9038547 04 Fan Additional internal fan
Z0.7 9040673 01 Battery Remote control
3181A
3182A
2760A
16 Book No.
3202A2
Book No. 17