SVIB 2 269565941 PB-05853 v0 (2) ENG

PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System

- PureBallast 3.2 Compact FlexPB-05853
System Manual
System Manual
English
PureBallast 3.2 Compact Flex
Lit. Code 200000887-3-EN-GB System manual
BRITISH ENGLISH
Published by
Alfa Laval Tumba AB
Hans Stahles väg 7
SE-147 80 Tumba, Sweden
+46 8 530 650 00
The original instructions are in English
© Alfa Laval Corporate AB 2021-03
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.
EN
1 PureBallast 3.2 System manual

The PureBallast 3.2 is available in several sizes, defined by the system’s max
treatment rated capacity (TRC). The TRC is included in the system name and
the title of each system manual.
The basic document describing the system is the connection list, and the
therein stated flow chart. Those documents are included in the system
manual, chapter 6, Installation description and drawings.
The tables in this document lists the PureBallast systems with reference to the
system manual describing them.
PureBallast system Manual no. Connection list Flow chart
PureBallast 3.2 85 Compact Flex 200000876 9034739 9034867
Main component makers

Reference is made to flow chart 9034867.
Flow chart Component Manufacturer Model
legend Size according to Connection list
Filter
Automatic self- Filtrex ACB-xx-yy, 20 µm mesh
cleaning filter
(xx=906 – 999
yy= DN100 - DN350)
Junction box Alfa Laval
Valve block SMC SS5Y3
Backflush pump Grundfos NB65–125/120
UV reactor
UV reactor AlfaWall UV reactor: 170, 300, 600 or 1000
UV lamp Alfa Laval Medium pressure UV lamp, 3 kW and 6 kW
Lamp sleeve Alfa Laval Synthetic Quartz
UV-TECHNIK, IL SUV 20.2 Y2 C 40° 1000 W/m²
QT201-50 UV sensor Metronic Sensor-
technik GmbH SUV 20.2 Y2 C 40° 3000 W/m²
Temperature,
TS201-60 JUMO Bimetal Temp. Switch 60.8301
switch
Thermometer,
TT201-33 JUMO Dtrans Temp. probe 90.2815
resistance
200000887-3-EN-GB 5
EN 1 PureBallast 3.2 System manual

Vibration limit
LS201-29 PEPPERL+FUCHS Vibracon LVL-A7
switch
Junction box Alfa Laval
Axel Larsson or, Actuator AL 79, Valve DN 32
V321-2 & Air Torque Spa or, AT range, Actuator
Valve
V320-4 VTORK VT range, Actuator
LK Valves Valve DN 32
Valves
Affco Lug Type S640
Siemens SIPART PS2, Positioner
Air Torque Spa or AT range, Actuator
V201-8 Flow control valve VTORK VT range, Actuator
ARI Armaturen or, ARI – GESA, Lugged valve
Wouter Witzel or, EVTLS, Lugged valve
LK Valves 710701, 2, Lugged valve
Affco Lug Type S640
PEPPERL+FUCHS NBN3…, Inductive pos. sensor
Air Torque Spa or, AT range, Actuator
Filter inlet, filter
V201-3, -9, by-pass, UVR VTORK VT range, Actuator
-19, -32 inlet, filter outlet
ARI Armaturen or, ARI –GESA, Lugged valve
Affco Lug Type S640
Air Torque Spa or, AT range, Actuator
Filter backflush VTORK VT range, Actuator
V309-1 valve ARI Armaturen ARI –GESA, Lugged valve
LK Valves 710701, 710702 Lugged valve
Flow meter
Promag 300W or,
FT201-1 Flow transmitter Endress+Hauser
Promag 300P
System and diff. pressure Transmitter
PT201-16 & Pressure trans- JUMO MIDAS S07
-71 mitter
Cleaning in Place (CIP) components
V571-1 & Valve SMC VNB
V571-3
V320-2 SMC LVA
V310-1, -3,
V460-2, -3, GF Diastar
-4, -5
6 200000887-3-EN-GB
PureBallast 3.2 System manual 1 EN

P460-1 Pump Tapflo T100, Pneumatic pump
P320-1 Pump SMC PB1013A, Pneumatic dosing pump
PEPPERL+FUCHS CBN10.., Capacitive sensor
LS320-3 Level sensor
IFM KQ6004
CIP cleaning liq- Alfa Laval
T320 uid Alpacon Descalant Offshore
Electrical cabinet:
Electrical cabi-
net Alfa Laval EC 3.2
Lamp drive cabinet:

Lamp drive cab- Alfa Laval LDC 1
inet
Lamp drive cab- Alfa Laval LDC 2

inet
Optional System Components (Alfa Laval supply)

Connectivity:
Hardware for in-
ternet of things Alfa Laval
solution
Log Box:
Connection box
to monitor addi- Alfa Laval
tional valves
and pumps
Booster pump:
Centrifugal pump
Filter backflush Pump: Grundfos
P309-1 NB 32-125 – NB 65-125
pump Motor: ABB
MG90SB – MG132SB
Optional System Components (Other supply possible. Alfa Laval supply is

listed)
Vacuum relief valves:
Weflo Fig.9105, DN80-DN125
VB201
A.R.I K-060, DN80 – DN100
Weflo Fig.9105, DN80

VB309
A.R.I K-060, DN50
BWTS bypass valve:
200000887-3-EN-GB 7
EN 1 PureBallast 3.2 System manual

Rotech ALB ACR1.., Pos. switch box
Ar Torque Spa or, AT range, Actuator
VTORK VT range, Actuator
V212-31 By-pass valve Rotork ILG-D series, Handwheel
ARI Armaturen ARI –GESA, Lugged valve
8 200000887-3-EN-GB
PureBallast 3.2 170 Compact Flex
Lit. Code 200000878-6-EN-GB Size specific manual
BRITISH ENGLISH
Published by
Alfa Laval Tumba AB
Hans Stahles väg 7
+46 8 530 650 00
The original instructions are in English
© Alfa Laval Corporate AB 2021-05
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.
Contents
1 Safety............................................................................................................................... 9
1.1 Introduction..............................................................................................................10
1.2 Safety information....................................................................................................10
1.2.1 General safety information.........................................................................10
1.2.2 Specific safety information ........................................................................ 10
1.2.3 Personnel requirements.............................................................................13
1.2.4 Warning signs used in the manual............................................................. 13
1.3 Environmental issues ............................................................................................. 14
1.3.1 Unpacking.................................................................................................. 14
1.3.2 Other materials.......................................................................................... 14
2 System description................................................................................................ 15
2.1 Introduction..............................................................................................................16
2.1.1 Components overview............................................................................... 17
2.1.2 Item numbers............................................................................................. 18
2.1.3 Abbreviations............................................................................................. 18
2.2 Process overview.................................................................................................... 18
2.2.1 IMO and USCG mode................................................................................18
2.2.2 Flow control and power optimization..........................................................18
2.2.3 Start-up...................................................................................................... 21
2.2.4 Ballasting................................................................................................... 22
2.2.5 Deballasting............................................................................................... 24
2.2.6 Tank stripping.............................................................................................25
2.2.7 Ballast water handling in the event of malfunction.....................................25
2.3 System components description..............................................................................25
2.3.1 UV reactor..................................................................................................26
2.3.2 Filter .......................................................................................................... 27
2.3.3 CIP (cleaning-in-place) module..................................................................32
2.3.4 Cabinets and control system......................................................................33
2.3.5 Main valves................................................................................................ 37
2.3.6 Flow meter................................................................................................. 37
2.3.7 Pressure monitoring...................................................................................38
2.3.8 Sampling devices.......................................................................................38
2.3.9 Booster pumps (optional)...........................................................................38
2.3.10 Vacuum relief valves (optional).................................................................. 39
3 Operating instructions and control system description................. 41

3.1 Introduction..............................................................................................................42
3.1.1 Operational conditions............................................................................... 42
3.2 Compliant / Non-compliant operation...................................................................... 44
3.3 Introduction to the control system............................................................................50
3.3.1 Cyber security............................................................................................ 50
3.3.2 Login levels................................................................................................ 53
3.3.3 Control of PureBallast................................................................................ 54
3.3.4 Overview of the screen.............................................................................. 56
3.4 Detailed page descriptions...................................................................................... 60
3.4.1 Page 1.1 – Main.........................................................................................60
3.4.2 Page 1.2 – Overview..................................................................................60
3.4.3 Page 1.3 – Reactor.................................................................................... 64
3.4.4 Page 1.4 – Filter.........................................................................................66
3.4.5 Page 1.5 – CIP...........................................................................................67
3.4.6 Page 1.6 – Cabinet.................................................................................... 68
3.4.7 Page 2.1 – Alarm list..................................................................................70
3.4.8 Page 2.2 – History..................................................................................... 72
3.4.9 Page 2.3 – Audit trail..................................................................................73
3.4.10 Page 3.1 – Trend....................................................................................... 74
3.4.11 Page 3.2 - Trend 2..................................................................................... 75
3.4.12 Page 3.6 – Trend - P201–1 (optional)........................................................76
3.4.13 Page 3.6 — Log box.................................................................................. 77
3.4.14 Page 4.1 – System 1..................................................................................79
3.4.15 Page 4.2 – System 2..................................................................................80
3.4.16 Page 4.3 – Timers......................................................................................82
3.4.17 Page 4.4 – Remote 1................................................................................. 83
3.4.18 Page 4.5 – Remote 2................................................................................. 83
3.4.19 Page 4.6 – LPS..........................................................................................85
3.4.20 Page 5.1–5.6 – Parameter pages.............................................................. 86
3.4.21 Page 6.1 – Installation parameters............................................................ 87
3.5 Operating instructions..............................................................................................87
3.5.1 Log in......................................................................................................... 87
3.5.2 Prepare operation...................................................................................... 88
3.5.3 Best practice operation – Soft start/stop using flow control....................... 88
3.5.4 Best practice — Priming............................................................................ 90
3.5.5 Best practice — Challenging waters.......................................................... 90
3.5.6 Perform ballast...........................................................................................91
3.5.7 Perform deballast.......................................................................................92
3.5.8 Perform tank stripping................................................................................93
3.5.9 Heel (internal transfer)............................................................................... 94
3.5.10 Backflush filter manually............................................................................ 96
3.5.11 CIP clean UV reactor after ballast / deballast ........................................... 97
3.5.12 Drain/fill UV reactor and filter..................................................................... 97
3.5.13 Attend to alarms.........................................................................................97
3.5.14 Shut down and deactivate system............................................................. 98
3.5.15 Operate components manually................................................................ 101
3.5.16 Operate UV lamps manually.................................................................... 103
3.5.17 Export control system event log files....................................................... 104
3.5.18 Backup control system settings............................................................... 105
3.5.19 Download crash trends............................................................................ 106
3.5.20 Restore control system settings...............................................................107
3.5.21 Set control panel IP address....................................................................108
3.5.22 Set remote control panel communication.................................................109
3.5.23 Set remote interface communication........................................................110
3.5.24 Test remote interface communication...................................................... 110
3.5.25 Update control system softwares............................................................. 112
3.5.26 Calibrate the control panel’s touch screen sensibility.............................. 113
3.5.27 Fine tune flow and pressure control ........................................................ 113
3.5.28 Adjust valve travelling speed of vessel’s valves and PureBallast’s
valves....................................................................................................... 116
3.6 List of logged information.......................................................................................118
3.6.1 Event log.................................................................................................. 118
3.7 Detailed process description................................................................................. 120
3.7.1 Fuse settings for filter motor and installed (optional) pump motors......... 120
3.7.2 Standby mode..........................................................................................121
3.7.3 Ballast process.........................................................................................123
3.7.4 Deballast process.................................................................................... 130
3.7.5 Stripping...................................................................................................135
3.7.6 CIP process............................................................................................. 136
3.7.7 Manual mode........................................................................................... 139
3.8 Quick guide............................................................................................................140
3.8.1 Introduction.............................................................................................. 140
3.8.2 Ballast, deballast or strip..........................................................................140
3.8.3 Alarm handling......................................................................................... 141
3.8.4 CIP clean UVR.........................................................................................141
3.8.5 Export control system log files................................................................. 141
4 Parameters............................................................................................................... 143
4.1 Introduction............................................................................................................144
4.2 Control system parameters................................................................................... 144
4.2.1 Introduction to parameters and parameter settings................................. 144
4.2.2 Page 5.1 — Main parameters.................................................................. 146
4.2.3 Page 5.2 — Main parameters ................................................................. 148
4.2.4 Page 5.3 — UVR parameters.................................................................. 149
4.2.5 Page 5.4 — Filter parameters..................................................................150
4.2.6 Page 5.5 — CIP parameters....................................................................152
4.2.7 Page 5.6 — Remote parameters............................................................. 153
4.2.8 Page 6.1 — Installation parameters.........................................................155
4.3 Lamp power supply (LPS) parameters.................................................................. 157
4.3.1 DIP switch settings...................................................................................157
4.4 Fuse settings for filter motor and installed (optional) pump motors.......................158
4.5 Conductivity sensor parameters............................................................................158
4.6 Flow transmitter parameters..................................................................................158
5 Alarms and faultfinding..................................................................................... 159
5.1 Introduction............................................................................................................160
5.2 List of alarms and warnings...................................................................................160
5.2.1 Control system......................................................................................... 160
5.2.2 Lamp power supply (LPS)........................................................................182
5.2.3 Flow meter............................................................................................... 183
5.2.4 Level switch............................................................................................. 186
5.2.5 I/O system and X20 modules...................................................................186
5.3 List of problems and solutions...............................................................................190
5.3.1 General problems.................................................................................... 190
5.3.2 Filter......................................................................................................... 191
5.3.3 CIP........................................................................................................... 192
5.3.4 Valve V201–8...........................................................................................193
6 Technical data and drawings........................................................................ 195

6.1 Introduction............................................................................................................196
6.1.1 Ship specific information.......................................................................... 196
6.2 Technical data........................................................................................................196
6.2.1 Flow requirements................................................................................... 197
6.2.2 Water requirements..................................................................................197
6.2.3 Power requirements.................................................................................198
6.2.4 Pressure requirements.............................................................................198
6.3 Control system integration.....................................................................................199
6.4 Drawings................................................................................................................199
6.4.1 Graphic symbols used in drawings.......................................................... 201
6.4.2 General drawings.....................................................................................202
6.4.3 Dimension drawings.................................................................................223
6.4.4 Electrical drawings................................................................................... 256
6.4.5 Bypass and heeling configurations.......................................................... 291
6.4.6 Safety Data Sheets.................................................................................. 294
7 Service manual .....................................................................................................315

7.1 Introduction............................................................................................................316
7.1.1 Preparations and conditions.................................................................... 316
7.1.2 Welding requirements.............................................................................. 316
7.1.3 Tightening torques................................................................................... 317
7.2 Maintenance schedule.......................................................................................... 319
7.3 Calibration schedule..............................................................................................322
7.3.1 Calibrate flow meter ................................................................................ 322
7.3.2 Calibrate pressure transmitters................................................................324
7.3.3 Calibrate UV reactor components, transmitters and switches ................ 325
7.3.4 Calibrate UV reactor components, UV sensor......................................... 325
7.3.5 Calibrate temperature transmitter in electrical cabinet.............................325
7.4 Water sampling......................................................................................................327
7.4.1 Sampling requirements............................................................................ 327
7.5 Recommended spare parts on board....................................................................328
7.6 Serial number information..................................................................................... 329
7.6.1 Placing of serial numbers.........................................................................329
7.7 UV reactor............................................................................................................. 333
7.7.1 Safety information.................................................................................... 333
7.7.2 Replace UV lamp..................................................................................... 334
7.7.3 Replace quartz sleeve............................................................................. 336
7.7.4 Replace lamp power supply (LPS)...........................................................339
7.7.5 Test lamp power supply (LPS) installation............................................... 340
7.7.6 Level switch............................................................................................. 340
7.7.7 Replace UV sensor.................................................................................. 342
7.7.8 Temperature switch and temperature transmitter.................................... 343
7.8 Filter.......................................................................................................................344
7.8.1 Remove filter cover and filter element..................................................... 345
7.8.2 Mount filter element and filter cover.........................................................348
7.8.3 Clean filter element and pre-filter.............................................................349
7.9 CIP ........................................................................................................................352
7.9.1 Change CIP liquid.................................................................................... 352
7.9.2 Pumps......................................................................................................352
7.9.3 Valve block ..............................................................................................356
7.10 Valves.................................................................................................................... 359
7.10.1 Preparations and conditions.................................................................... 360
7.10.2 Open and close valves manually............................................................. 361
7.10.3 Lock valve in closed position................................................................... 361
7.10.4 Unlock valve.............................................................................................362
7.10.5 Dismount actuator....................................................................................364
7.10.6 Mount actuator......................................................................................... 365
7.10.7 Adjust valve end position ........................................................................ 367
7.10.8 Calibrate positioner on V201-8................................................................ 367
7.10.9 Adjust cam position on V201-8................................................................ 370
7.10.10 Change direction of actuator for bypass valve V212–31 (optional)......... 370
7.10.11 Mount pilot valve on actuator V212–31 (optional)....................................372
7.10.12 Adjust valve traveling speed for V212–31 (optional)................................372
7.11 Flow meter.............................................................................................................374
7.11.1 Backing up the data ................................................................................ 374
7.11.2 Replace display module...........................................................................374
7.11.3 Replace the memory card (T-DAT).......................................................... 376
7.11.4 Replace module carrier and ISEM module.............................................. 376
7.12 Control panel......................................................................................................... 379
7.12.1 Clean control panel.................................................................................. 379
7.12.2 Replace control panel.............................................................................. 379
7.13 Remote control panel (optional)............................................................................ 380
7.13.1 Mount and connect remote control panel ................................................380
7.14 Electrical cabinet................................................................................................... 381
7.14.1 Disassemble and assemble I/O system...................................................381
7.14.2 Install IFS confstick in safety relay KS1 in LDC....................................... 382
8 Revision history..................................................................................................... 385
9 SPC............................................................................................................................... 389
EN
1 Safety
Safety
200000878-6-EN-GB 9
EN 1 Safety
1.1 Introduction
This chapter contains general safety and environmental information, personnel
requirements and explanations of symbols used for the PureBallast system.
1.2 Safety information

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

The following general safety information apply:
• The PureBallast system is not Ex proofed and must not be installed in
areas where an explosive atmosphere may occur.
• Use the equipment only for the purpose and parameter range specified by
Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Always read and follow the documentation that is included in shipment of
components and spare parts regarding handling, safety and disposal.
• Before installation, read applicable sections Technical data and drawings
on page 195 and in the Design and installation guidelines.
• Before operation, read the section Operational conditions for applicable
instructions in Operating instructions and control system description on
Safety
page 41.
1.2.2 Specific safety information

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

• Before maintenance, read the Preparations and conditions section for
applicable instructions in Service manual on page 315. Essential safety
information is stated before instruction to routines that might involve any
danger.
• Before maintaining the PureBallast system, the following valves must be
locked in closed position: V201-3 and V201-8.
• Components must be lifted using correct lifting tools (such as a fork-lift
truck, a crane) and tackle with a load capacity greater than the weight of
the component. See the section PureBallast components in Introduction on
page 196 for information about approximate weight. Complementary lifting
instructions in the Design and installation guidelines must be followed.
• Always disconnect the PureBallast system from the power supply before
disassembling, and secure it from being switched on.
10 200000878-6-EN-GB
Safety 1 EN
Electrical cabinets
• Risk of electric shock! Exposed components carry dangerous voltages.
Always disconnect the power supply before disassembling. Note that
electrical components are live with main power switched off.
UV reactor safety items

• UV lamps and quartz sleeves are fragile and can easily become damaged.
Exercise great care when handling them. Do not apply vibrations or shock
to the UV lamp. This can cause breakage and shorten lamp life. Broken
glass/quartz can also cause severe cuts. Always use protective eye
glasses and clean cotton gloves when handling UV lamps and quartz glass
sleeves. See Material data sheet / UV lamp in chapter 6.
• UV lamps are stored according to local regulations.
• Before installation, check that the UV lamps and quartz sleeves are not
broken.
• Depressurize reactors and allow equipment to cool down completely before
disassembling.
• Never handle UV lamps before they are completely cooled down. A hot UV
lamp is under high internal pressure, and the risk of bursting exists. A hot
lamp could also cause a burn if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp
Safety
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 sulphur to bind the mercury for easy collection). A
mercury absorption kit can be ordered from Alfa Laval to clean spilled
mercury.
• Do not allow mercury to come in contact with your eyes or skin. Do not
inhale mercury fumes.
• Free mercury must be kept in an airtight bottle, and must be disposed of
according to national regulations
• In case of having inhaled mercury fumes, consult a doctor and follow
medical instructions.
• Operation and/or manual start of the UV lamps is only allowed when there
is water in the reactor (indicated by level switch LS201-29), and the water
temperature is below 60 °C.
Improper operation could seriously damage the equipment and injure
personnel.
200000878-6-EN-GB 11
EN 1 Safety
• 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 EC: Switch off the PureBallast system and
disconnect it from the power supply. See section Shut down and deactivate
system on page 98. The cabinet contains a fan, which can cause injury if
in operation.
Filter safety items

• CIP liquid agent; Alpacon descalant offshore, may be used as cleaning
agent. Follow rules when handling CIP liquid agent, regarding ventilation,
personal protection etc. See Safety data sheet / CIP liquid on page 294.
CIP safety items

• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear
protective gloves and goggles. Follow rules when handling CIP liquid agent,
regarding ventilation, personal protection etc.
• If CIP liquid; Alpacon descalant offshore, comes in contact with eyes or
skin, rinse thoroughly with cold water.
• See Safety data sheet / CIP liquid on page 294
• CIP and drain pumps: Always wear protective eye glasses and gloves while
working on the pump.
Safety
Booster pumps
• Always disconnect the power supply before disassembling, and secure it
from being switched on. Empty the pipe, and assure that nobody can open
valves etc.
Flow meter safety items

• Make sure that the power supply is switched off, before the cover of the
electronics compartment are removed. Risk of electric shock! Exposed
components carry dangerous voltages .
Valve safety items

• Lock valve in closed position before maintenance.
• Actuators must not be pressurized at any time during installation as it may
result in injury.
• Do not remove end caps or disassemble the actuator while the actuator is
pressurized.
• Do not disassemble individual spring elements. Disassembly may result in
personal injury.
• Valve block: Always disconnect the PureBallast system from the power and
air supply before disassembling, and secure it from being switched on.
12 200000878-6-EN-GB
Safety 1 EN
Ancillary component safety items

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

The PureBallast system must be installed, operated, maintained and repaired
by persons trained and authorized for their respective type of work.
In some cases special skilled personnel may need to be hired, like electricians
and others. In some of these cases the personnel has to be certified according
to local regulations with experience of similar types of work.
The person must have knowledge or sufficient experience to perform the tasks
at hand. The person must be able to perceive risks and to avoid hazards
which electricity/mechanics can create. The person must have knowledge
about the specific Ex standard used to eliminate the risk of explosion, for
example IEC 60079 series.
Safety
In some cases special skilled personnel may need to be appointed for the job,
e.g. electricians and others. In some of these cases the personnel has to be
certified according to local regulations with experience of similar types of work.
1.2.4 Warning signs used in the manual
DANGER
DANGER: indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.
WARNING
WARNING: indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.
CAUTION
CAUTION: indicates a potentially hazardous situation which, if not avoided, may

result in minor or moderate injury.
NOTE
Note: indicates a potentially hazardous situation which, if not avoided, may result
in property damage.
200000878-6-EN-GB 13
EN 1 Safety
1.3 Environmental issues

This section contains general rules regarding environmental issues. However,
local rules and regulations should be consulted for detailed handling of each
material.
1.3.1 Unpacking
• Packing material consists of wood, plastics, cardboard boxes and in some
cases metal straps.
• Wood and cardboard boxes can be reused, recycled or used for energy
recovery.
• Plastics should be recycled or burnt at a licensed waste incineration plant.
• Metal straps should be sent for material recycling.
1.3.2 Other materials

• Rubber and plastics should be burnt at a licensed waste incineration plant.
If not available they should be disposed to a suitable licensed land fill site.
• Metal parts should be sent to a licensed handler for material recycling.
• Seal rings should be disposed of in a licensed land fill site. Check the local
regulations.
• Worn out or defected electronic components should be sent to a licensed
handler for material recycling.
Safety
• The operator panel contain the following components with substances that
might be hazardous to health and the environment: lithium battery,
electrolytic capacitor and display. They shall be recycled according to local
regulations.
• Used lithium batteries* from the control unit are considered hazardous
waste and should be disposed of accordingly.
• Used UV lamps can be handled and disposed of in the same way as
fluorescent lamps. Please refer to national regulations.
• Used quarts sleeves should be disposed of as ordinary glass.
* If the unit have lithium batteries.
14 200000878-6-EN-GB
EN
2 System description
200000878-6-EN-GB 15
EN 2 System description
2.1 Introduction
This contains general information about the PureBallast system and its
components.
16 200000878-6-EN-GB
System description 2 EN
2.1.1 Components overview

The key components in PureBallast 3.2 are shown below.
1. Filter
2. Flow meterwith conductivity sensor
3. UV reactor
4. CIP (cleaning-in-place) module
5. Electrical cabinet (EC)
6. Lamp drive cabinet/cabinets (LDC), not included in all system sizes
7. Control valve
Not in illustration:
• System bypass valve
• Sampling device
• Pressure monitoring device
System overview
The PureBallast system is an integral part of the vessel’s ballast water system,
on the discharge side of the vessel’s ballast water pumps. During ballast
operation, the water is led through the filter, which removes larger particles
and organisms, and then to the UV reactor, where the water is treated with UV
light. During deballast, the water is led the same way, but the filter is
bypassed.
The UV lamps are powered by the EC (via LPSs, lamp power supplies).
Flow is monitored by the flow meter and regulated by the control valve. Note
that full treatment requires treatment both during ballast and deballast.
After operation, the UV reactor is cleaned by a CIP (cleaning-in-place)
process.
The complete system and ongoing processes is controlled and monitored from
the electrical 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).
200000878-6-EN-GB 17
2.1.2 Item numbers

System components are identified by unique item numbers, for example
“FT201-1” for the flow transmitter installed before the UV reactor.
2.1.3 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
CIP Cleaning in place
CIP module Cleaning in place module. Performs the CIP process.
DIN Deutche Institut für Normung
EC Electrical cabinet
EN Standard according to CEN (European Committee for Standardiza-

tion).
Ex Explosion-proof
I/O Input/output (Describes a program or device handling data)
IACS International Association of Classification Societies
ISCS Integrated ship control system
IMO International Maritime Organization
JIS Japanese Industrial Standard
LED Light emitting diode
LDC Lamp drive cabinet.
LPS Lamp power supply
MCB Motor circuit breaker
PLC Programmable logical controller (PureBallast control system)
PSU Practical Salinity Unit
USCG United states coast guard
UV Ultra violet
UV reactor The main component, where the water is treated using UV light.
UVR UV reactor
2.2 Process overview

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

The PureBallast has two process modes: IMO mode and USCG mode. These
different modes set the system to run to be compliant with regulations in USA
(USCG mode) or the rest of the world (IMO mode).
USCG mode can be run with a 3 days or 0 day hold-time.
Fore more information about conditions, see section Operational conditions on
page 42.
2.2.2 Flow control and power optimization

To ensure full treatment of the water, allowed flow and power to the lamps are
controlled depending on how clean the water is. Clean water (high UV
18 200000878-6-EN-GB
intensity) allows high flow and low lamp power, and dirty water requires lower
flow and higher lamp power to treat the water according to requirements.
During ballast the flow is also limited by the maximum capacity of the used
filter and the actual allowed flow is determined by whichever is smaller; filter
capacity or UV reactor capacity as described in following paragraphs.
IMO mode
Treating fresh water (salinity ≤1 PSU) requires a different power optimization
and flow control to be efficient. Therefore, the power optimization and flow
control differs when fresh water is treated compared to brackish and marine
water. When fresh water is treated, this is indicated by an “FW” in the
subprocess field in page Page 1.2 – Overview on page 60.
Salinity is calculated by the control system based on input from the
conductivity sensor (QIT201-51) and temperature transmitter (TT201-33).
The illustration below show flow control and power optimization depending on
the UV intensity and salinity, together with the compliant limit.
Fresh water
Brackish and marine water
200000878-6-EN-GB 19
USCG mode
Compliant limit: When UVI falls below compliant limit, the operation
continues but does not fulfill the type approval certificate. A warning and a
common alarm is issued and a log is written to the event log. The operator
must take action according to the ballast water plan to stop the operation or to
continue operation and not comply with type approval certificate.
2.2.2.1 Flow control

When treating fresh water, the flow is regulated to be as high as possible to
fully treat the water. Between UVI value a and b, the flow is regulated be
20 200000878-6-EN-GB
between 50 % and 100 % of full flow capacity. The higher UVI value (cleaner
water) the higher flow.
When treating brackish and marine water above complaint limit, the flow is
always 100 % of full flow capacity. But when UVI falls below the compliant
limit, the flow is decreased to maximum 50 %.
2.2.2.2 Power optimization

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

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

If a UV lamp breaks during operation, the ongoing process continues but is not
compliant. A warning and an additional common alarm is issued and a log is
written to the event log. The operator should act according to the ballast water
management plan. After process is finished, it will not be possible to start a
new process until the broken lamp has been changed.
The flow is decreased to 65 % in IMO mode and 50 % in USCG mode of max

flow and the UV lamps are lit to 100 %. This is done so that the treatment shall
correspond to the type approval requirements.
If a lamp breaks in standby mode, it is not possible to start a process.
2.2.3 Start-up
Ballasting and deballasting begins with a start-up phase. During start-up, the
UV lamps are warmed up for 90 seconds.
The temperature transmitter and level switch secure that there is water in the
UV reactor and that the UV lamps are sufficiently cooled. If the temperature in
the UV reactor reach 38°C, cooling water (technical water / potable water) is
pumped through the UV reactor to secure that the UV lamps are not
overheated.
200000878-6-EN-GB 21
Ballast and deballast start-up
2.2.4 Ballasting
After the start-up, when the lamps are ready, the operator is requested to start
the ballast pump. The ballast water is pumped from the sea chest to the filter,
that removes larger particles and organisms. This also reduces the amount of
sediment build-up in the ballast water tanks. The organisms and sediments
caught in the filter are flushed overboard via regular filter backflush operations.
The water is finally led to the UV reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.
Ballasting
2.2.4.1 Backflush
To keep the filter clean, it is automatically backflushed. The backflush is
performed during ongoing process without interrupting the ballasting process.
When a ballast operation is stopped, a backflush is performed before the
system comes to a full stop. The ballast water used for backflushing is
returned to the sea directly at the ballasting site.
22 200000878-6-EN-GB
Filter backflush
2.2.4.2 Ballast after-treatment (CIP process)

After a ballast operation, a CIP (cleaning-in-place) process is performed to
clean the UV reactor. This process can either be performed immediately after
a ballast operation or started within 30 hours counted from when the process
was started. Note, that it is possible to perform new processes during these 30
hours.
We recommend that a CIP process is performed in the same location as the
ballast operation was done. If not possible, in international waters (200
nautical miles from the baseline). This due to risk of untreated or not fully
treated water remaining in reactor/filter.
The UV reactor and filter are rinsed with technical water / potable water. Then,
the UV reactor is filled with biodegradable CIP liquid and technical water /
potable water, which is circulated periodically, approximately four times per
hour, during the 6 hours CIP process to remove scaling from the quartz
sleeves and UV sensor glass. After the cleaning is finished, the UV reactor is
filled with technical water / potable water to prevent scaling, algae growth etc.
200000878-6-EN-GB 23
CIP circulation during CIP process
2.2.5 Deballasting
Deballast use the same start-up process as during ballast. 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
2.2.5.1 Deballast after-treatment (CIP process)

As after ballasting, a CIP process is performed after a deballast operation.
24 200000878-6-EN-GB
2.2.6 Tank stripping

Stripping can be performed to empty the ballast tanks. A stripping process is
similar to a deballast process; in both processes the filter is bypassed.
After the start-up, when the lamps are ready, the operator is requested to start
a stripping pump. Pump used can either be a dedicated stripping pump or a
ballast water pump. Power optimization is not active. Minimum flow includes
the driving water.
Stripping
2.2.6.1 Stripping after-treatment (CIP process)
As after ballasting, a CIP process is performed after a stripping operation.
2.2.7 Ballast water handling in the event of malfunction

For safety reasons, it must be possible to bypass the PureBallast system if it
malfunctions. According to the BWM Convention, the system must be
equipped with at least one bypass valve. The valve(s) must be controlled by
the control system of the vessel, not by the PureBallast control system. All
bypass valve activities are logged in the event log.
Several combinations of valves can be used to bypass the system. According
to legislations, all bypass configurations must be monitored – both those that
are driven by pumps and by gravity.
Monitoring can be done via the Remote interface, Log box or be hardwired
directly to control cabinet. Refer to the respective installation guide for more
details.
If the PureBallast system malfunctions in connection to general cargo
operation, avoid ballasting and deballasting, if possible. The procedures
concerning emergency and malfunction of the ballast water treatment system
should be implemented in the Ballast water management plan.
2.3 System components description

This section gives an introduction to the most important PureBallast system
components and their functions in the system.
200000878-6-EN-GB 25
2.3.1 UV reactor
The main part of PureBallast is the UV reactor.
2.3.1.1 UV reactor working principle

The main treatment process take place inside the UV reactor, where the
micoro organisms in the water is exposed to UV light, which renders them
completely harmless.
The UV light breaks the DNA chain resulting in an internal connection (T+T)
making it impossible for the micro organisms to reproduce.
Destruction of DNA
There are no chemical substances added to the process, and there are no
toxic residuals created. Since the water is not affected chemically, there are no
environmental impact and the process does not influence corrosion in any
way.
2.3.1.2 UV reactor description

The UV reactor consist of the reactor, sensors and valves for water and CIP
liquid, as shown in the illustration below. The UV reactor accommodates 6
medium-pressure UV lamps (3 kW each).
The UV lamps are enclosed in individual quartz-glass sleeves.
The UV lamps get very warm, so they must be cooled whenever they are lit.
To secure that there is water in the reactor when the lamps are lit, the reactor
is equipped with a level switch. The level switch also secures that enough CIP
liquid is pumped into the reactor during the CIP process. To secure that the
lamps are adequately cooled by the ballast water,
the UV reactor has a threefold heat protection:
Level 1: The temperature transmitter sends information to the control system.
The UV reactor is shut down at 60 °C.
Level 2: The temperature transmitter sends information to a safety relay in the
EC . The UV reactor is shut down at 62.5 °C.
Level 3: The temperature switch automatically shuts down the UV reactor at
65 °C.
A UV sensor monitors the UV lamp efficiency in relation to the water
transmittance inside the UV reactor. Based on this input, the power to the UV
lamps are regulated between 50 and 100 % of full capacity. To save power, the
UV lamps will be dimmed to lowest possible level, where they are still
effective.
26 200000878-6-EN-GB
Note:The lamps are always lit with full effect during start-up and the first two
minutes of full ballast to secure full efficiency independent of transmittance.
The lamps are also turned up to full effect for 10 seconds before stop and
normal shut down. This method will prolong the UV lamp life time
The illustration below show the main components for the UV reactor.
UV reactor
1. Inlet valve
2. UV sensor
3. Level switch
4. Control box
5. Regulator, air
6. Junction box
7. UV lamp cap (UV lamp an quartz sleeve inside)
8. CIP service valve
2.3.2 Filter
2.3.2.1 Filter working principle
The filter is a fully automatic self-rinsing component, equipped with a filter
element to remove particles and organisms from the ballast water flow. The
ballast water is lead through the filter, and filtered particles are trapped in the
filter.
An optional backflush pump can be mounted to secure correct flow in the
backflush pipe 309.
200000878-6-EN-GB 27
2.3.2.2 Filter description
1. Inlet valve
2. Regulator, inlet air
3. Outlet valve
4. Relief valve (overpressure)
5. Geared motor
6. Automatic de-airiation valve during filling and a PLC-controlled valve for letting air
in during draining
7. Junction box
8. Valve block
9. Backflush outlet
10. Backflush pump (optional)
11. Backflush valve
12. Drain plug
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.
28 200000878-6-EN-GB
Step 1: Filtration
The water enters from the inlet flange (A)

and flows through a pre-filter and then
through the filter element (1) from the in-
side to the outside. The filtered dirt is
trapped on the inside of the filter element.
The filtered water passes the chamber
(D) and out from the filter through the out-
let flange (B) and is lead to the UV reac-
tor.
During filtration, the filter operates as a
static filter, there are no moving parts and
the motor (2) is not running and the noz-
zle (3) is standing still.
A. Inlet
B. Outlet
D. Chamber
1. Filter element
2. Motor
3. Nozzle (standing still during filtration)
200000878-6-EN-GB 29
Step 2: Backflush
At backflush, the motor (2) starts to
drives the nozzle (3). At the same time,
the backflush valve (6) opens.
The nozzle rotates inside the filter ele-
ment. The dirt on the inside of the filter el-
ement (1) is cleaned by a high-efficacy
backflush flow in front of the nozzle. The
backflush flow uses filtered water from
the chamber (D) to clean the filter from
the outside to the inside. The water, to-
gether with the dirt, is lead via the nozzle
through the duct (5) and out via the back-
flush valve (6).
All areas of the filter element that is not in
front of the nozzle are filtering the water
as in step 1: The water flows from the in-
let (A) through the filter element and out
through the outlet (B).
When the backflush is done (after ap-
proximately 40 seconds), the motor stops
and the backflush valve is closed. The fil-
ter then goes back filtration with full flow
to the ballast tank (no flow used for back-
flushing.
If a new backflush is triggered within 2
minutes (parameter p302), the filter will
perform a continuous backflush for 20 mi-
nutes (parameter p303).
A. Inlet
B. Outlet
D. Chamber
1. Filter element
2. Motor
3. Nozzle seen from the side (rotating
during backflush)
6. Backflush valve
2.3.2.3 Backflushing for different dirt loads

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

In water with low dirt load, the backflush cycle is started by the time trigger
(default: every 30 minutes). As long as the pressure is below the differential
pressure trigger (0.50 bar), there is no need for the pressure triggered
backflush. See examples below.
30 200000878-6-EN-GB
2.3.2.3.2 Medium dirt load

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

In conditions with heavy dirt load, the system can perform continuous
backflushes to keep the filter clean. If the filter preforms one backflush, and
the differential pressure trigger a new backflush within a parameter set time,
the filter will perform continuous backflushes for a parameter set time to clean
the filter thoroughly. After the continuous backflush time, a check is made to
make sure that the differential pressure is below 80 % of the backflush trigger
pressure. If not, the backflush continues until this is true.
Also, the 0.50 bar limit might be exceeded. In this case the self rinsing cycle
will run continuously until the problem is solved and the pressure has returned
below 0.50 bar. It is OK that the flow momentarily fluctuates in an irregular
curve, but it is important that the curve stabilizes.
200000878-6-EN-GB 31
In the example below, a series of backflushes are performed (approx. every 4

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

Over time, the filter element will undergo a long term build-up of particles that
are not removed by backflushing. One effect of this is that “normal” pressure
will increase over time. Therefore, the maintenance schedule state that the
element shall be inspected and manually cleaned once a year.
The extent of the long term dirt build-up is dependent on the water conditions.
In the great majority of cases this will not cause any problems – cleaning once
a year is enough. But in exceptional cases (vessels trading very challenging
waters) it might be necessary to clean the filter element more often. If the
pressure triggered backflushing is performed with short intervals, we suggest
that the filter element is manually cleaned more often than once year.
2.3.3 CIP (cleaning-in-place) module

2.3.3.1 CIP working principle
The purpose of the CIP (cleaning-in-place) process is to clean the quartz
sleeves covering the UV lamps and the UV sensor. This will ensure that the
UV light will treat the water efficiently and that the flow control and power
optimization functions, based on correct input from the UV sensor.
After the UV reactor (and filter, when CIP is done after ballast) is drained from
sea water, the UV reactor and filter is filled with technical water / potable
water. The UV reactor is filled with 0.3 l concentrated CIP liquid to the UV
reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion
build-up and chemical fouling on the lamps quartz glass sleeves. The mixed
CIP liquid is left in the UV reactor for 6 hours.
Approximately four times per hour, the CIP liquid is circulated to improve the
cleaning efficiency. As a last step, the UV reactor is filled with technical water /
potable water to prevent scaling, algae growth etc.
2.3.3.2 CIP module description

The CIP module consists of a container where the concentrated CIP liquid is
stored. The pumps and valves integrated in the CIP module are controlled by
the valve block.
32 200000878-6-EN-GB
The following components are involved in the CIP process:

• T320: A container with concentrated CIP liquid.
• Pump P320–1: Dose concentrated CIP liquid into the pipe that leads to the
UV reactor.
• Pump P460–1: Drains UV reactor and filter. Circulates the CIP liquid in the
UV reactor during CIP process.
• Valve V320–2: Leads the CIP liquid to the UV reactor.
• LS320–3: Level switch to give a warning when the CIP liquid level is low.
1. Service valve (5 pieces)

2. Container CIP concentrate
3. Pump P460-1, drain and circulation
4. Regulating valve for diaphragm pump P460-1
5. Regulator, air
6. Valve block
7. Dosing pump P320–1 for CIP concentrate
8. Level switch (sensor low)
9. Check valve
2.3.4 Cabinets and control system

2.3.4.1 Electrical cabinet
The electrical cabinet (EC) is equipped with the control panel, which is used to
control and monitor the system. The cabinet is equipped with an emergency
200000878-6-EN-GB 33
stop button, an audible and visible alarm indication and USB ports for software
upload and log file export. Lamps on the cabinet indicates if power is on, UV
lamps are lit and if the cabinet needs to be reset after a shutdown or power off.
The electrical cabinet is also fitted with 3 lamp power supplies (LPS), which
are feeding power to the UV lamps.
One LPS feeds power to two UV lamps.
The LPS also monitors the function of each UV lamp and takes action if a fault
occurs.
The electrical cabinet functions as a single point of contact for signal cables to
all components and installed options: remote interface, remote control panels
and power management system (PMS).. Also integration with other external
components (not part of Alfa Laval’s scope of supply), such as GPS and
ballast water pump, are done to the electrical cabinet.
The electrical cabinet is equipped with a cooling fan. The fan is regulated
based on heat inside the cabinet. When the temperature reaches 30°, the fan
starts to regulated between 30 % and 100 % (at 45°), according to parameter
settings based on input from the temperature transmitter in the cabinet. When
temperature reaches 27° the fan stops.
Electrical cabinet with main control panel.

1. Main breaker
2. Main power cable
3. Main control panel
4. Lamp power cable to UVR
5. Signals to LDC 1
2.3.4.2 Control system

The control system is used to set parameters, operate and monitor the
PureBallast system. The control system continuously monitor PureBallast
(sensors, communication and PLC status), both during operation and in
standby mode. Any deviation is either communicated to the operator or
handled automatically, based on parameter settings. Safety risks are always
handled automatically.
34 200000878-6-EN-GB
The control system store all alarms and relevant events for at least 24 months.
The memory has a vast safety margin but when it is full, data will be deleted
starting with the oldest logs. Logged information can be exported to a USB
memory stick.
There are three alternative ways to monitor and control PureBallast: Main
panel, remote control panel (optional) and remote interface (optional).
2.3.4.2.1 Main control panel

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

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

As an option, the control system can be integrated with the vessel's ISCS via
modbus. This allows monitoring and operation of PureBallast from the ISCS's
graphical user interface
Note that Alfa Laval does not supply the graphical user interface to handle
PureBallast in the ISCS, only the means to enable the integration.
200000878-6-EN-GB 35
PureBallast control system´s main control panel integrated with the ISCS. The
interface is only an example.
2.3.4.2.4 Connectivity (optional)

The PureBallast Connectivity solution enables data transfer for Alfa Laval
systems onboard vessels to Alfa Laval IoT web platform, referred to as ALIoT
PureBallast Connectivity is a connectivity platform that helps the user to
monitor the PureBallast system. It establishes secure communication between
the PureBallast system onboard and the Alfa Laval data cloud. The user can
see the system performance via an online portal. To get an account, contact
your Alfa Laval contact person.
36 200000878-6-EN-GB
Overview of the connectivity communication
2.3.4.2.5 Log box (optional)

If one or several valves can be used as both bypass and heeling, a log box
can be used to define different combinations of valves and pumps, that
constitutes bypass or heeling operation. For more information, see Log box
installation guide.
2.3.5 Main valves

The main valves in the system are:
• Filter inlet valve
(V201–3): Inlet from the vessel's ballast water system during ballast. The
water is directed via the filter to the UV reactor.
• Filter outlet valve (V201–32): The valve directs the water flow from the
filter to the UV reactor during ballast.
• Filter bypass 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.
• UVR inlet valve (V201–19): Inlet valve to UV reactor.
• 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.
• Technical water / potable water valve (V310-1): The valve have the
following functions:
• Supplies cooling water to the reactor to secure cooling of the lamps if
temperature exceed 38 °C during process.
• Supplies water to the UV reactor and filter during CIP process.
• PureBallast bypass valve (V212–31): Makes it possible to completely
bypass the PureBallast system. The valve is solely operated from the ISCS,
but the valve positioning is (and must be) indicated in the PureBallast
control system. When PureBallast is bypassed, an event is written to the
event log. The valve is equipped with a handwheel for manual operation.
The component is optional to be included in Alfa Laval’s scope of supply.
2.3.6 Flow meter

The flow meter (FT201–1) have two functions:
• Monitor flow
• Monitor conductivity.
The flow meter consists of three parts:
200000878-6-EN-GB 37
• Flow sensor monitor the flow in the system. Functions together with the
flow transmitter.
• Flow transmitter send flow information to the control system. It is mounted
on the flow sensor.
• The conductivity sensor measure conductivity in the water.
Monitor flow
The flow meter monitor the flow within the PureBallast system, to secure that
certified flow is not exceeded. If so, a warning is issued. The flow meter send
valuable data to the PureBallast control system, where it is displayed.
Example of information: Current flow and data about total amount of treated
ballast water.
Monitor conductivity
The flow meter measure conductivity in the water. This information is used
together with temperature to calculate salinity in the water.
Treating fresh water (salinity ≤1 PSU) requires a different power optimization
and flow control to be efficient. Therefore, the power optimization and flow
control differs when fresh water is treated compared to brackish and marine
water.
2.3.7 Pressure monitoring

Two pressure transmitters monitor the pressure in the system:
• PT201-16: System pressure after filter. The control system use the
information to take actions accordingly, for example issue warnings, shut
down the system and adjusting the control valve to obtain optimal pressure
during filter backflush.
• Pressure gauge (PI201-18): Analogue displayed of current pressure.
• Needle valve (V201-17): Enables connection of external instruments for
calibration.
• Relief valve (RV201): Safety valve for relief of over pressure.
• PT201-71: System pressure on filter. Use to calculate differential pressure
over the filter to indicate dirty filter element.
2.3.8 Sampling devices

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

Booster pumps can be installed to achieve sufficient flow. Start and stop of
optional booster pumps are handled by signals sent from the control system.
See Control system integration on page 199 .
38 200000878-6-EN-GB
Filter backflush pump (P309-1) (optional)

Booster pump to secure enough flow in pipe 309 for enough filter backflush.
The pump is started and stopped from the control cabinet by giving power to
the pump.
2.3.10 Vacuum relief valves (optional)

If the PureBallast system is placed high up in ship’s pump rooms or even on
deck in a deckhouse the fall height in the downward going pipes between the
PureBallast system and the tanks/overboard can be considerable. Whenever
the water in the pipes free fall in downward going pipes the pressure upstream
will be affected and low pressure will appear. Depending of the geometry of
the system the low pressure can be considerable and can potentially cause
cavitation and pressure waves which is harmful to the PureBallast installation.
To solve the problems with cavitation and vacuum, the system should be
equipped with vacuum relief valves:
In pipe 201. Float operated vacuum relief valve providing both air re-
VB201 lease upon startup of the system and vacuum relief during operation.
In pipe 309. Only vacuum relief, without air venting function. The valve
VB309 is spring loaded (normally closed) to avoid water spillage during initia-
tion of backflush.
200000878-6-EN-GB 39
40 200000878-6-EN-GB
EN
3 Operating instructions and control system description
200000878-6-EN-GB 41
EN 3 Operating instructions and control system description
3.1 Introduction
The control system is used to operate and monitor the PureBallast system. It
also contains functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of
the control system pages, step-by-step instructions and a process description
with detailed information about the components (valves, motors, pumps etc)
involved in each step of respective process.
Disclaimer
The supplier has no responsibility for damage caused to the equipment by:
• Ordinary wear and tear.
• Unintended use, misuse, non-compliance with supplier’s system manual and/or
design and installation guideline, abuse, or improper storage, installation, mainte-
nance, operation or repairs by the customer or by persons not under the suppli-
er’s supervision.
3.1.1 Operational conditions

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

The PureBallast has two process modes: IMO mode and USCG mode. These
different modes set the system to run to be compliant with regulations in USA
(USCG mode) or the rest of the world (IMO mode).
Before starting a process, the operator must choose if the operation shall be
run in IMO or USCG mode, depending on location and destination. Mode is
set using a function button in the control system.
When to use the different modes
IMO mode
IMO mode is used for:
• Ballast, when the destination is outside US waters.
• Deballast, outside US waters.
IMO mode can also be used if the vessel has an AMS and is operating under
an extended compliance date authorized by USCG.
USCG mode
USCG mode is used for:
• Ballast, when the destination port is within US waters, regardless of starting
point.
• Deballast, within US waters.
USCG hold-time
USCG mode can be run with a 3 days hold-time or 0 day hold-time. Hold time
is set in parameter p182 USCG hold-time.
42 200000878-6-EN-GB
Operating instructions and control system description 3 EN
The time between a completed ballast and the start of deballast

3 days hold-time or stripping must be at least 72 hours.
The time between a completed ballast and the start of deballast
0 day hold-time or stripping must be at least 2.5 hours.
0 day or 3 days hold-time

• Before starting ballast, select 0 day or 3 days hold-time.
• Use the same hold-time setting for deballast and stripping that was used for
ballast.
Example: If you intend to deballast water using 0 day mode, 0 day mode
must be used during ballast.
• Do not mix waters treated with different modes in the same tank. Empty the
tank completely first, preferably using stripping mode.
• Keep track of which treatment mode is used for the water in each individual
tank. Use the ballast water record book for this purpose. How this should
be done is described in the ballast water management plan.
Overboard valves
• The PureBallast control system requests that overboard valves are opened/
closed during process. This means the following:
• When a ballast, deballast or stripping process is started, all valves
leading the flow from the PureBallast via pipe 201 and 309 must be
opened.
• When a CIP process is started, valves leading water to pipe 310 and
from pipe 309 and 460 must be opened.
• The PureBallast control system needs feedback (opened/closed) since the
valves are outside the system control. This is done in a popup.
3.1.1.1 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 deballast process with the
following difference: A stripping eductor (or a stripping pump) should be used
to secure enough flow in the system.
We recommend that the driving water alone (without the ballast water flow
from the tank) fulfils the minimum flow requirement for deballast operation.
This will minimize the risk of shut down due to low flow when flow of ballast
water is uneven.
3.1.1.2 Heeling (internal transfer)

Internal transfer of ballast water between tanks, for example during heeling
procedures, does not require the use of the PureBallast system. Operation
differs depending on if a signal for heeling mode is integrated or not.
With integrated heeling signal
If a signal for heeling mode is integrated between PureBallast and the vessel's
ISCS (via hard wire, remote interface or log box), an ongoing process (ballast,
deballast or stripping) will be stopped and system is set to standby. Ballast
200000878-6-EN-GB 43
pump will be requested to be stopped. If start/stop of the ballast pump is

integrated, the pump will stop automatically. It is not possible to start a new
process while heeling mode is active. The user is notified via warnings when
heeling is started and stopped and an event is written to the event log.
It is not possible to start a new process while heeling mode is active. The user
is notified via warnings when heeling is started and stopped and an event is
written to the event log. Stopped process must be restarted manually.
Heeling mode will inhibit any bypass warnings and events, which means that
bypass valves can be opened freely when this mode is active. To ensure legal
operation, it is the customers responsibility to connect and monitor the
applicable valves, so that heeling mode can only be activated when the valves
are in the correct position e.g. sea chests and overboard are closed. Any
bypass valves involved e.g. V212-31, must be opened last in order of all
valves included in the heeling operation, to ensure legal operation and to
avoid triggering bypass warnings. Please refer to the vessels BWMP for
correct valve positions.
Without integrated heeling signal
If no signal is integrated, ongoing process must be stopped manually. If a
bypass valve is opened for internal transfer, a bypass event is written to the
event log. Therefore it is necessary to write an explanation in the ballast water
record book to explain why the bypass valve was opened. After completed
heeling, the operator must restart the stopped process manually.
3.1.1.3 Gravity operation

Gravity operation (not using the ballast water pump) can only be allowed if the
following prerequisites are fulfilled:
• The requirements for flow and backflush pressure is fulfilled.
• The vessel’s flag state and classification society allow gravity operation.
• It is stated in the vessels’s approved ballast water management plan.
3.1.1.4 Pipe cleaning using PureBallast

In some vessels, the applicable class society may require means and
procedure for flushing ballast pipes with treated water, to clean them from
untreated water. This procedure should be implemented in the ships Ballast
water management plan.
In PureBallast, a deballast process is run with the vessel’s ballast valves
positioned so that the
• pump takes water from a ballast water tank with treated water and
• the water flow is directed either overboard or to another ballast tank.
Run the process for enough time so all water in the piping is treated. Time for
this depends on pipe size and length on board.
3.2 Compliant / Non-compliant operation

To manage to operate in a compliant way according to applicable legislation,
the vessel specific routines for ballast operations must be well defined in the
ballast water management plan (BWMP). The system must always be used for
ballast operation. For information about operation and best practice, see
44 200000878-6-EN-GB
system manual chapter 3 Operating instructions and control system

description.
This section contains important information about issues and areas that must
be considered and defined in the vessel’s BWMP.
Note that all issues are not applicable for all vessels. Also note that this is a
general compilation. For each vessel it is also important to consider if there
are applicable requirements by the following listed below (or others):
• IMO
• USCG
• US EPA
• States in USA
• Flag state
• Classification society
Compliant operation
A ballast, deballast or stripping operation is compliant if it is performed using
the treatment system within stated limitations and in accordance with the
system manual. It is important to use correct operational mode based on
location and to observe stated holding times. The operation and/or storage of
the water must not be submitted to any non-compliant issues, such as these
described in section Non-compliant operation below.
Non-compliant operation
All ballast, deballast and stripping operations must be done using PureBallast
according to system manual. In some cases there is a risk that ballast water is
not treated according to requirements or becomes contaminated by untreated
water.
If water in a tank is not compliant due to any reason listed below, or other
reasons, it is not allowed to deballast that tank at port.
The BWMP must therefore be defined to avoid these cases and define
contingency measures to solve any arisen situation.
When the system goes out of compliance during operation, an event is written
in the event log. When the system is in compliance again, this is also written in
the event log.
A process is not compliant in the following cases:
200000878-6-EN-GB 45
Area Reason
PureBallast was bypassed during ballast/deballast/stripping, so the
water was not treated (warnings W33, W66, W67, W68, W69 and
Bypass W502).
Note that if heeling mode signal is implemented incorrectly, system
can be bypassed without any warning, which is not allowed.
Wrong opera- • Ballast operation using IMO mode within US waters.

tional mode
• Deballast or stripping of water that was ballasted using IMO
mode when the destination port is within US waters. It is there-
fore necessary to keep track of which mode was used for ballast
for respective tank.
• Water was stored in tank shorter time than required by the
USCG mode (3 or 0 days) used during ballast:
• Deballast was done before 2.5 hours storing in tank if water
was ballasted using 0 day holding time.
• Deballast was done before 72 hours storing in tank if water
was ballasted using 3 day holding time.
Flow Operation with higher flow rate than certified (warning W12).
System not CIP cleaned within time (warning W140). CIP cleaning
CIP cleaning is necessary to make sure the UV light is unhindered by dirty/scaled
quartz sleeves.
Broken UV Operation with one or more broken lamps (warnings W130, W131,
lamp W153).
Operation with lower UV intensity than certified (warnings W151,

UV intensity W152, W154).
LPS in fault Operation with LPS in fault state (warning W165).

state
Contamination Contamination by untreated water in the ballast water piping, includ-

of ballast water ing the dead ends, or other pipes, i.e. due to living organisms in the
water. Even a very small amount of water, a few hundred litres, can
contaminate a ballast tank and cause non-compliancy. The reason
for contamination can be:
• Leaking valves.
• Internal transfer between tanks with water treated with different
operational modes or holding times.
• Sediment in tanks is a breeding ground for organisms. Therefore
it is important to review the vessel’s ballast water management
plan regarding frequency of sediment removal.
• Tanks not cleaned. Tanks must be cleaned after retrofit installa-
tion before taking system into operation.
Calibration not System not calibrated according to calibration schedule in the sys-
done tem manual.
Maintenance System not maintained according to maintenance schedule in the

not done system manual.
VGP water Approved VGP sampling must be fulfilled according to US EPA

sampling re-
quirements not 2013 VGP before discharging in US waters. Note that state specific
regulations might apply.
fulfilled
46 200000878-6-EN-GB
Contingency measures and preventive measures

Recommended measures to stay compliant are listed below.
Contingency measures
• Wrong operational mode in US waters:
If a tank is changed to hold water that was treated in IMO mode, the tank
needs to be stripped first. To make sure that the whole water volume is
treated in USCG mode, strip the tank as far as possible.
• VGP sampling not done:
If VGP sampling was not done during the last 12 months, ballast water
cannot be discharged in US waters. Since the VGP water sample must be
approved before discharge in US waters, if there is enough time, submit a
water sample for approval. If there is no time, contact the captain of the port
(COP).
• At a non-compliancy alarm, the process must be stopped immediately,
otherwise the water in the tank is considered as non-compliant and must be
handled accordingly. The reason is that only 0.02 % of untreated water can
contaminate the whole tank. For all non-compliant operations that trigger
alarms, repair or fix the problem according to system manual, chapter 5.
Alarms and faultfinding. Also see section Re-treatment on board below.
Preventive measures
• Sediment in tanks:
Tanks must be cleaned from sediment. This needs to be done regularly
according to the BWMP.
• Maintenance:
The BWTS must be maintained to stay compliant. Maintenance must be
done according to the system manual, chapter 7. Service manual, section
Maintenance schedule.
• Calibration:
If the system was not calibrated for the last 12 months, ballast water cannot
be discharged in US waters. Calibrate before entering US waters according
to the system manual, chapter 7. Service manual, section Callibration
schedule.
• Spare parts
Always have spar parts available on board to be able to repair the system.
See system manual chapter 7. Service manual secton Recommended
spare parts on board.
• VGP sampling not approved when sailing in US waters:
Analyse why sampling failed, attend to the problems if possible (e.g.
change broken UV lamp), then perform a new test.
Before applying any measure (according to BWMP or otherwise), contact the
captain of the port (COP) to discuss and to get instructions of what to do with
the non-complaint water in tank(s). To discharge the water as close as
possible to the place where the ballasting was performed, ask the COP at the
last port for approval. The COP will decide which measures are applicable in
the current situation, for example ballast water exchange (BWE). The COP will
take environmental, safety, operational and logistical implications into
consideration.
200000878-6-EN-GB 47
All correspondence regarding contingency measures must be well

documented on board.
Ballast water exchange

Note that this is allowed only if it at leas one of the below is true:
• Approved by the COP at the last or the next port.
• The vessel holds a D-1 certificate (only applicable for IMO). The D-1
certificate is relevant only for vessels that did not pass their compliance
date.
• BWE is defined in the BWMP and approved by the COP.
If BWE is allowed, it must be performed according to the below, according to
both IMO and USCG legislation:
• By using PureBallast system both at deballast/stripping and ballast.
• Making sure that the tank(s) and pipes are flushed and replaced with fully
treated water.
• At a location where BWE is allowed or advised by the COP.
• As close as possible to the place where the ballasting was performed but
minimum 200 nautical miles from the coast line and 200 meters deep. The
mid ocean is most favourable, since UV transmittance is very high, and the
biological activity is low.
NOTE There are local regulations to be considered, for example before entering the
Great Lakes.
Re-treatment on board
Some cases can be solved by treating the water on board, by moving the
water from one tank to another, for example:
• Water treated in IMO mode can be re-treated in USCG mode to be allowed
to discharge in US waters.
• Water treated in USCG 3 days holding time can be retreated in USCG
mode with 0 days holding time, to be allowed to discharge sooner than 3
days.
Note that the procedure for this must be written in the BWMP. The water must
be moved from one tank to another. It is not allowed to circulate water from
and to the same tank.
Ballast water management plan (BWMP)

The following areas needs to be described in the BWMP, in regards of if they
are allowed on the vessel. If allowed, routines frequency etc must be defined
for respective operation or task should be stated in the BWMP.
• Compliant operation / contingency measures.
• Ballast water reporting.
• Stripping routines.
48 200000878-6-EN-GB
• Healing routines: Requires that a healing signal is integrated between

PureBallast and the vessels ISCS. For more information, see External
components signal in this document.
• Pipe emptying: Some classification societies requires that pipes before the
treatment system (valve V201-3 and V201-9) should be drained and
discharged at same location or at open sea.
• Emergency routines, if the treatment system cannot be used and ballast
operations needs to be performed.
• Pipe cleaning routines.
• Sediment handling routines.
• Vessel general permit.
• Gravity operation (not using the ballast water pump) can only be allowed if
the following prerequisites are fulfilled:
• The requirements for flow and backflush pressure is fulfilled.
• The vessel’s flag state and classification society allow gravity operation.
• It is stated in the vessels’s approved BWMP.
200000878-6-EN-GB 49
3.3 Introduction to the control system

This section describes different login levels, overview of the system interface
and how to navigate and operate the control system.
3.3.1 Cyber security
Strategy to increase security

This section covers security aspects of protecting the PureBallast equipment
and operation of the system. Possible critical points are described together
with measures to minimize the risks of cyber attacks and other cyber threats,
e.g. malware and viruses, at all times.
Entry point for PureBallast network

The overall system design of PureBallast is illustrated below. The point of
connection to the PureBallast system is the PB network switch shown below.
WARNING
Do not connect a laptop directly to the switch! If the laptop is infected with
malware or virus, it can affect the communication between HMI and PLC.
3.3.1.1 HMI security

Areas that are exposed to cyberattacks on HMI are the following:
• Network interfaces
• USB or SD interface
• HMI user interface
50 200000878-6-EN-GB
HMI security
For more detailed information about the different risk areas regarding HMI
security and how to avoid them, see the table below.
Area Rule How to avoid risks
Network inter- Risk of introducing malware or virus into the Do not connect the laptop directly to the HMI.
faces system affecting the communication between This is only allowed for Alfa Laval authorized
PLC and HMI. When this communication is personnel.
lost, the system can no longer be operated
from HMI.
USB/SD mo- Software updates must always be done by Do not connect unscanned and unsecured
bile interfaces using a virus-free device, e.g. USB, SD or CF mobile devices directly to the HMI.
card.
HMI user inter- Alfa Laval user handling policies allow users Make sure that only authorized personnel
face and user to operate the system based on predefined have access to PureBallast and that account
account user accounts. In order not to obstruct the OT policy is aligned internally. This is the respon-
availability, the users and passwords are lis- sibility of the asset manager.
ted in the manual.
Project transfer Project transfer to the HMI panel is allowed Make sure the software is virus- and malware
to HMI only from a secured, virus- and malware free free.
device, e.g. USB, SD or CF card.
Tag access via OPC UA is a vendor independent standard for Make sure OPC UA is always enabled. If
OPC UA interface communication that allows field devi- OPC UA authorization is not enabled, it is
ces to communicate with each other. very important to limit the physical access to
the HMI to protect OT security.
Backup and re- When executing a system backup or parame- Always scan your USB for malware and virus
store from HMI ter export, always use a a virus-free USB. before executing any operations on the HMI.
to and from a
USB Always store your backup USB in a secure lo-
cation and activate the write lock if possible.
Security matrix
All PureBallast systems, generation 2 and 3, have the following
characteristics:
System OPC/UA FTP HTTP NTP VNC remote
generation (DA)
PB3.2 UA1 Yes1 No No Yes
PB3.1 UA1 Yes1 No No Yes
PB3.0 DA2 Yes1 No No Yes
PB2 DA2 Yes1 No No Yes
PB1 Serial - No No No
1 Authorized and password protected. The
protocol is unprotected if nothing else is sta-
ted.
2 PB3.0 and PB2.0 systems that are upgraded
with the X2 panel use OPC/UA and are au-
thorised and password protected.
200000878-6-EN-GB 51
3.3.1.2 PLC security

Increased networking and cloud solutions require increased security. This is
more important when IoT and OT are merged, eliminating the physical
segregation.
Main strategy for OT security

The priority is to maintain control over the process and protect PureBallast
software. Our security concept, also known as defence in depth, is defined as
general defence strategy to resist the following attacks:
• Decrease availability.
• Bypassing single security mechanisms.
• Intentional incorrect operation by authorized users (and, if not possible,
compensate with auditing all events)
• Incorrect operations due to misconfigured user privileges.
• Unauthorized monitoring of data, such as recipes and business secrets or
the functioning of the machines and systems and their security
mechanisms.
• Modifying data, for example, to alter alarm levels.
PLC security
For more detailed information about different risk areas regarding the PLC
security, see the table below.
Area Rule Note
Authorized PureBallast limits the communication only The level of OT security is defined by the sys-
OPC/UA com- through password protected authorized com- tem platform generation. New releases offer
munication munication between HMI and PLC. increased security features. See section Se-
curity matrix.
Application The application code in the PLC from Pure- There is no possibility to retrieve the code
software and Ballast is complied and in binary form. from the PLC. The software package cannot
code protec- be tampered with as it is also in binary form.
tion.
FTP (File The FTP is used for transferring a backup Make sure no other clients are connected to
transfer proto- from PLC to HMI and to route the parameter PLCs except from Alfa Laval devices.
col) export to the HMI USB interface of remote
panels. FTP services on the PLC are protec-
ted by username and password, but informa-
tion is not encrypted
HTTP (Hyper- The HTTP is standardized procedure for In PureBallast there is no information ex-
text transfer transferring data within a network. It is part of change between the HMI’s, only between
protocol) the family of internet protocols and primarily HMI’s and the PLC.
used for loading websites from a web server
to a web browser.
NTP (Network NTP is a standardized protocol for synchro- NTP is not used in PureBallast.
time protocol) nizing the time on several computers / com-
ponents across the network.
52 200000878-6-EN-GB
Area Rule Note

SNMP (Simple SNMP is a UDP based protocol specified for
network man- the administration of data networks. Also
agement proto- used in administering PLC networks with
col) TCP/IP.
PVI Native pro- PVI is native protocol from PLC supplier used Only Alfa Laval authorized personnel is al-
tocol to fail search the system for technical support. lowed to connect to PLC by using PVI proto-
The protocol requires special tool from PLC col and B&R tool.
supplier.
Event log security

The alarm and events are logged in binary format and exported to .csv.
The logs are tamper-proof in the PLC, but become editable when exported
to .csv for analysing in VisuAlog.
WARNING
The log files must be downloaded from the control system and directly opened in
VisuAlog for analysis or generation of a report, to avoid any manipulation of the
content. This is customer’s responsibility.
Security matrix
All PureBallast systems, generation 2 and 3, have the following
characteristics:
System OPC/UA FTP HTTP NTP SNMP PVI
genera- (DA)
tion
PB3.2 UA1 Yes1 No No Yes Yes
PB3.1 UA1 Yes1 No No Yes Yes
PB3.0 DA2 Yes1 No No Yes Yes
PB2 DA2 Yes1 No No No Yes
PB1 Serial - No No No Yes

1 Authorized and password protected. The
protocol is unprotected if nothing else is sta-
ted.
2 PB3.0 and PB2.0 systems that are upgraded
with the X2 panel use OPC/UA and are au-
thorised and password protected.
3.3.2 Login levels

Different login levels controls which information that is displayed and
changeable. As an example, pages used for commissioning purposes are
hidden for normal operators.
200000878-6-EN-GB 53
Login level Password Authority

Default mode of control system. This level is not password protec-
ted.
0 Guest N/A
• View all pages.
• As Guest.
• Operate the system to perform daily routines, for example bal-
1 Operator aot last and acknowledge alarms. Toggle between IMO and USCG
mode.
• Download files and backup to a USB memory.
• As level Operator.
• Operate equipment in manual mode.
• Fill and drain the UV reactor and filter using the Fill and Drain
2 Advanced operator 2007 buttons.
• Access to set parameters, with exception from critical parame-
ters. See chapter Parameters on page 143 for information.
• Full access to page Page 4.3 – Timers on page 82.
Full access. Password only available for Alfa Laval personnel.

• Full access to all parameter pages.
• Full access to make settings for remote control panels and re-
mote interface in page Page 4.2 – System 2 on page 80 and
3 AlfaLaval N/A Page 4.4 – Remote 1 on page 83/Page 4.5 – Remote 2 on
page 83.
Note: If logged in as Alfa Laval user, the user will be automatically
logged out after being inactive in standby for 90 minutes. When
the user is logged out, an audible signal is triggered for 3 seconds
from the same panel.
3.3.3 Control of PureBallast

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

PureBallast can only be controlled from one control panel at a time.
To switch command from one panel to another, you log in to the new panel.
This is only possible by using the same or higher login level as used in the
active control panel. When control is about to be changed from one panel to
another, the following will happen:
• 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
54 200000878-6-EN-GB
is installed, for example pump room, bridge etc. See instruction Set control
panel IP address. This information is visible in the upper right corner of the
system according to syntax: login level@control panel.
“Login level” can be: Guest, Operator, Advanced operator or AlfaLaval.
“Control panel” can be:
• 192.168.0.10 (Master) = Main control panel
• 192.168.0.11 = Remote control panel 1
• 192.168.0.12 = Remote control panel 2
Example: Operator logged in at remote control panel with alias “Bridge”.
3.3.3.2 Remote interface (option)

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

PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings
200000878-6-EN-GB 55
• The remote interface must be correctly installed, according to Remote

interface implementation guide.
• Remote interface must be activated (parameter p132) and communication
settings must be correct (parameter p700 – p704).
• The Test mode button must be deactivated (no checkmark on the button)
in control system page 4.4 Remote 1.
• Remote control must be activated. Check that there is a green frame round
the Remote button on the control panel. If not, press the button. The
system must be in Standby mode to toggle between local and remote
operation.
Operation
• Heartbeat is updating. See that address 06 and 77 are updating in control
system page 4.4 Remote 1.
• There must be no active alarms for the UV reactors to be used during
operation. Always check the alarm list (page 2.1 Alarm list in the control
system) before operation.
• The UV reactor must be in standby mode.
3.3.4 Overview of the screen

This section describes the PureBallast control system screen layout and
navigation.
The control system use a touch screen, where you tap the screen to “click” or
drag objects. Do not use sharp objects to touch the screen. When the screen
is left idle it will go to screen saving mode. Time is set in page 4.2 System 2.
The screen is activated again by touching it once. That first touch will not
activate any button that might be placed where you touch.
The illustration below shows the main areas and function buttons on the
screen.
56 200000878-6-EN-GB
Control system screen showing the main overview page.

Tabs: The top and side tabs are used to choose which page to display in the
screen. Pages are referred to as a number and a name, for example 2.1 Alarm
list. The first number refers to selected top tab, counted from left to right. The
second number refers to selected side tab. Selected tabs are indicated by a
white color.
Top tabs: Contain the main function areas of the control system: Overview,
alarm lists, trend curves, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab.
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, indicat-
ing status:
Blue The function is enabled.
Blue with check- The function is activated.
mark
The function is not possible to activate, for example if higher login
Grey level is required for the function.
200000878-6-EN-GB 57
Status indication – Button light: After a function button is pressed, a frame is lit to
indicate status:
Green Command is active.
Green, blinking Command will be processed when possible in the data work flow.
Function button description

The illustration below shows the main areas and function buttons on the
screen.
Button Description
Start ballast process.
Start deballast process.
Stop current process.
Start tank stripping process.
Start CIP process.
Activate operation from control panels, instead of remote interface (if

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

control panels. The button is only enabled in standby mode.
Sets the control system in manual mode, which enables manual oper-
ation of the system and its components. When activated, the light
flashes yellow. Requires login level Advanced operator or higher. For
detailed information see Manual mode on page 139.
Contains a print function. To print a screen image to USB: Insert a

USB memory in USB panel port on the cabinet door. Press Utilities,
and then Print to save a screen image to USB.
Login: Expanding menu with login fields. See section Login levels in
Operating instructions and control system description on page 41.
58 200000878-6-EN-GB
Button Description
Sets the control system in IMO mode, which activate operation in ac-
cordance with IMO requirements.
Sets the control system in USCG mode, which activate operation in

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

Alarms and warnings for components are displayed directly on the component
they regard:
Active alarm.
Active warning.
200000878-6-EN-GB 59
3.4 Detailed page descriptions

This section describes the pages used for operation. Note that this section
does not cover the parameter pages. Please refer to chapter 4. Parameters.
3.4.1 Page 1.1 – Main

The page displays an overview of main status, current status and the most
useful function buttons.
Information and function buttons

Respective button can be pressed to start and stop processes. In the middle,
ongoing subprocess is displayed, and at the top information about volume
(Processed volume) and flow (Current flow).
Chosen process is marked with green, and buttons that can be chosen are
blue.
Detailed information about the system is found on page 1.2 Overview.
3.4.2 Page 1.2 – Overview

The page displays an overview of the system, overall status and detailed
information regarding the components.
The main areas are the Status box and the Flow chart.
60 200000878-6-EN-GB
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 – Timers.
The following status information is displayed:
Status information (unit) Description
Process: Ongoing process.
Subprocess: Sub steps of ongoing process, for
example Start-up during Ballast process.
Process and subprocess
If fresh water is processed in IMO mode “FW” is
stated after the subprocess. See section Flow
control and power optimization in chapter 2.
Remaining time for the ongoing subprocess in
Remaining time the upper right corner.
Amount of water processed during ongoing
Processed volume (m3/h) process. Value remain until next process is star-
ted.
Power (kW) Power consumption for ongoing process.
Certified flow (m3/h) selected for operation. The
information is updated after the warm up time
Certified flow (m3/h) has passed and a UV reactor is used for proc-
ess. This is also the flow the system is aiming to
keep.
200000878-6-EN-GB 61
Status information (unit) Description

Status indication for ballast water pump (not part
of Alfa Laval’s scope of supply).
Ballast pump Status indication
Green, blinking = Request sent. Popup message
“Confirm ballast pump started” is displayed.
Green = Pump running. Feedback from popup,
via hard wire or remote interface.
Grey = No request sent (not running).
Indicates differential pressure over the filter

Filter diff. pressure (bar) (PT201–71 minus PT201–16). When the pres-
sure reach 0.5 bar, a backflush is triggered.
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.
In manual mode (login level Advanced operator or higher) it is also possible to
operate components manually: If a component is pressed, a popup window is
displayed from which the component can be operated.
Status indication – Component colour
Component status is indicated by a coloured frame:
The symbol indicates that you can change the compo-

nents symbol name (ID). A popup window will appear
when you press the component symbol.
To find out how you enter data, see section Overview
of the screen in section Operating instructions and
control system description on page 41.
The chain symbol indicates that you cannot control the

component by pressing the component symbol.
You can only control the components in manual mode.
Read about manual mode in section Overiew of the
screen in section Operating instructions and control
system description on page 41.
Current flow (m3/h) indicated by flow meter FT201–1.

The system aims for the selected flow minus parame-
ter p111 Undershoot certified flow, which can be set as
a safety margin.
Current system pressure (bar) indicated by pressure

transmitter PT201-16.
Status indication
Pipes A pipe filled with colour indicates that there is flow in
the pipe.
62 200000878-6-EN-GB
Status indication – Component colour

Component status is indicated by a coloured frame:
Status indication
Green, blinking = Travelling / starting
Valves and pumps Green = Open / running
Grey = Closed / not running.
Red, flashing = Valve opening/closing.
Toggle between show/hide component ID in flow chart.
The component is operated manually in manual mode.
Status information for the backflush pump P309–1 (op-

tional). Only visible if parameter p318 is activated.
200000878-6-EN-GB 63
3.4.3 Page 1.3 – Reactor

The page gives an overview of the UV reactor status, including information
from the LPSs and all sensors.
The main areas of the page are the Status box and the UV reactor.
Status box
Elements Description
Displays if LPSs is active and powered on. UV lamps
LPS activation can only be lit if an LPS is active. When a critical
alarm (e.g. no water in the UV reactor) is issued, the
fail safe function inactivates the LPSs and cut the
power.
Status indication: Green = Active. Grey = Not active.
The buttons are used to start/stop UV lamps manual-

ly. Press one button 1 to start/stop UV lamp. LPS 1
controls lamp 1 and 2, LPS 2 lamp 3 and 4 etc.
Status indication:
LPS 1–3 Lit = Green circle
Off = Grey circle.
Power indication
Actual effect from each LPS to UV lamps.
Enables manual operation of the LPSs. The button is
displayed for login level Advanced operator or higher.
The button enables manual control of UV lamps, if
manual mode is selected.
Manually set effect to LPS. Requires that the system
Manual power output is set in manual mode.
UVR information
The UV reactor icon displays current status from sensors:
64 200000878-6-EN-GB
Status information from respective sensor:
LS201–29, TS201–60, TS201–33: Green = OK. Red =
Sensor information Alarm.
QT201–50: Current UV transmittance.
TT201–33: Current temperature in UVR.
Status indication:
Grey = Off.
UV lamps
Yellow = Starting.
Green = Started.
The UV intensity the system is aiming to attain by in-
Power optimization set- creasing or decreasing power effect to the LPS control-
point ling the dimming of the UV lamps.
Calculated power consumption for ongoing process.
The effect is adjusted to attain the setpoint for UV in-
Power output tensity based on measured water transmittance based
on input from UV sensor QT201–50. Effect can be 50–
100 %.
200000878-6-EN-GB 65
3.4.4 Page 1.4 – Filter

The page is used to display filter status values for the filter and its related
components.
The following information is displayed:
Status box
Component Description
Process Ongoing process.
Sub steps of ongoing process, for exam-
Subprocess ple start-up during ballast process.
Remaining time for the ongoing subpro-
Remaining time cess.
Indicates differential pressure over the fil-
ter (PT201–71 minus PT201–16). When
Diff. pressure the pressure reach 0.5 bar, a backflush is
triggered.
Press the button to start a manual back-
flush. See instruction Backflush filter
manually on page 96.
Filter information
Status for the filter and relevant components are displayed in the illustration.
Current pressure:
Pressure transmitters PT201–71: Pressure before filter.
PT201–16: Pressure after filter.
Pipes, valves and motor. For status indications, see Status indica-
tion – Component color in section Page
Pump if installed 1.2 – Overview on page 60.
66 200000878-6-EN-GB
3.4.5 Page 1.5 – CIP

The page is used to display CIP status, and status for valves, pipes and
pumps involved in the CIP process.
Status box
The area displays status for the following pieces of information:
Row Content
Process Ongoing process.
Sub steps of ongoing process, for exam-
Subprocess ple start-up during ballast process.
Remaining time for the ongoing subpro-
Remaining time cess.
Status indication for UV reactor
CIP required (Yellow).
CIP status
CIP completed (Green).
CIP ongoing (Grey)
Status indication for filter preservation
Indication: As CIP.
Filter preservation During filter preservation, the filter is
drained from sea water and filled with
fresh water for preservation purpose.
Red square: Indicates that there is an ac-
tive alarm for the component. Check
CIP error alarms on page 2.1 – Alarm list. Red =
Alarm.
CIP and UVR information

Status for components relevant for the CIP process are displayed in the
illustration.
200000878-6-EN-GB 67
Column Content
Status information from respective sen-
Sensor information sor: LS201–29 and LS320–3: Green =
OK. Red = Alarm.
For status indications, see Status indica-
Pipes, valves and pump. tion – Component color in section Page
1.2 – Overview on page 60.
Fill the UV reactor and the filter with fresh

water. Requires login level Advanced op-
erator.
Drain the UV reactor and the filter. Re-

quires login level Advanced operator.
3.4.6 Page 1.6 – Cabinet

The page is used to display status for electrical cabinet.
Electrical cabinet status

If the control system is set in normal mode, the page is used to display power
management status.
Column Content
Displays if LPSs is active and powered
on. UV lamps can only be lit if an LPS is
LPS activation active. When a critical alarm (e.g. no wa-
ter in the UV reactor) is issued, the fail
safe function inactivates the LPSs and
cut the power.
Status indication: Green = Active. Grey =
Not active.
LPS power Power consumption for all LPS:s.
68 200000878-6-EN-GB
Column Content
Status for safety relay KS1 in the cabinet.
Relay shuts down the system when the
emergency button on cabinet door is
KS 1 (safety relay) pressed.
Status indication: Green = OK. Red =
System shut down.
Status for LPS circuit breaker.
MS132 (LPS fuse) Status indication: Green = OK. Grey =
Not active. Red = Alarm.
EC fuse
Status for 24 V DC fuse in electrical cabi-
Fuse net.
Status indication: Green = OK. Grey =
Not active. Red = Alarm.
Cabinet information
Column Content
Status indication as on the cabinet:
Reset: Blue = Cabinet must be reset. Grey = OK.
Status lamps Power: White = Power on. Grey = Power off.
Lamp: Green = On. Grey. Off
Alarm: Red = Active alarm. Grey = No alarm.
Air temperature in the electrical cabinet indicated by temperature

TT401 transmitter TT401.
Fan rotation in percent of full effect. Fan effect is based on need

M1 for cooling.
Fan starts at 30 % at 30 °C and rotates at 100 % at 45 °C.
Percent of full effect PureBallast is requesting from the vessel’s

ballast water pump, or percent open if the external feed signal
External feed controls a throttle valve before PureBallast.
Only relevant if External feed (optional) is used.
200000878-6-EN-GB 69
3.4.7 Page 2.1 – Alarm list

The page display active alarms and warnings. When an alarm/warning is
inactive and acknowledged, it is moved to page 2.2 History.
Alarm type can be of two types:
• A= Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
• W= Warnings are notification of a status change, request for action or a
problem that must be attended to. Warnings allow the process to continue.
For detailed information about alarms and warnings see chapter 5. Alarms and
faultfinding.
The main areas of the page are the Alarm list and the Function buttons:
Alarm list
The following information is displayed for each alarm (row):
Column Content
Descriptive alarm text written as: Area-Alarm type Alar-
Text mID Alarm text.
Example: A29 Valve error (V201–8).
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.
Status indication – Alarm color

The table below shows status indication for alarms and warnings in the alarm list.
Red Alarm = active
Pink Alarm = acknowledged, but still active
70 200000878-6-EN-GB
Orange Warning = active

Yellow Warning = acknowledged, but still active
Function buttons
The following function buttons are available:
Button Function
Acknowledge selected alarm (row). Press
Ack selected a row to indicate it, and press the button
to acknowledge it.
Ack all Acknowledge all active alarms.
200000878-6-EN-GB 71
3.4.8 Page 2.2 – History

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

Column Content
Text Same as in Page 2.1 Alarm list.
Active time Same as in Page 2.1 Alarm list.
The Clear button is used to clear the screen. The alarm history is saved in the
log files.
72 200000878-6-EN-GB
3.4.9 Page 2.3 – Audit trail

The page display audit trail: tracking of actions in the control system, e.g.
changed password, acknowledged alarms, changed parameter values.
The information can also be exported to a USB memory from page 4.1 System
1.
For each activity, the following information is displayed in the different column:
• Event
• Before: Value before change, if a value, parameter etc has been changed.
• After: New value, if a value, parameter etc has been changed.
• Time stamp: Time for the action.
• User name: Login level, who performed the action.
200000878-6-EN-GB 73
3.4.10 Page 3.1 – Trend

The page is used to display trend curves for basic data in the system.
This page display trends with a update frequency (sample time) of 1 second
and the time span for trends displayed on the screen is 15 minutes. Trend
curves are saved in the trend history for 1 hour, and are then deleted.
This page is useful for analyzing processes, for example backflushes and to
monitor power optimization.
Trends can be plotted for the following components:

Component / Key val- Unit Description
ue
System flow, indicated by the flow meter
Flow m3/h FT201–1.
Pressure, indicated by the pressure trans-
PT201-71 bar mitter PT201–71
Differential pressure over filter, indicated by
Diff. pressure bar pressure transmitter PT201–71 and PT201–
16.
V201–8 % Control valve V201–8 open, percent.
UV intensity in UV reactor, indicated by UV
UVI W/m2 intensity sensor QT201–50.
Power kW Electrical power feed
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.
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.
74 200000878-6-EN-GB
Component area
The following fields and buttons are available for each component in the
component area:
Column Content / Function
Press the button to make settings for the component’s
curve. Settings are done in a popup.
Settings button
1. Press (not slide) the top right button to display or
hide trend curve in the diagram. A green I indicate
displayed, and a grey O indicates not displayed.
2. Press the entry field to change start and stop value
for the components Y axis scale (when this compo-
nent’s scale setting is used).
3. Press this button to use this component’s scale set-
ting in the diagram.
4. Press the entry field to enter number of decimals in
the component area, or use the -- or
++ buttons to increase or decrease.
Filled = Selected. Component values is

plotted in the diagram, in the same col-
or as the icon.
Empty = Not selected. Component val-
ues is not plotted in the diagram.
Status indication
Scale icon = The component scale set-
ting is used in the diagram’s Y axis. If
several components have the same
scale setting, this icon is displayed for
all these items.
Component Item number or name.
Current value for the component is displayed in the gray
Value field. (This corresponds to the diagram.)
If history mode is selected, historic value is displayed.
3.4.11 Page 3.2 - Trend 2

The page is used to display trend curves for basic data in the system.
This page display trends with a update frequency (sample time) of 1 second
and the time span for trends displayed on the screen is 15 minutes. Trend
curves are saved in the trend history for 1 hour, and are then deleted.
This page is useful for analyzing processes and monitor external feed trend
curves. See page 3.1 Trend for information about function, fields and buttons.
200000878-6-EN-GB 75
Trends can be plotted for the following components:

Component / Key val- Unit Description
ue
System flow, indicated by the flow meter
Flow m3/h FT201–1.
Pressure, indicated by the pressure trans-
PT201-71 bar mitter PT201–71
Differential pressure over filter, indicated by
Diff. pressure bar pressure transmitter PT201–71 and PT201–
16.
V201–8 % Control valve V201–8 open, percent.
External feed signal, to request increased/
ExtFeed % decreased flow from external ballast water
pump/valve.
3.4.12 Page 3.6 – Trend - P201–1 (optional)

The page is used to display trend curves for data valid for the ballast water
booster pump (P201-1, optional in Ex installations). This page displays trends
with an update frequency (sample time) of 15 seconds and the time span for
trends displayed on the screen is 1 hour. Trend curves are saved in the trend
history for 24 hours, and then deleted.
• Booster pump speed: Blue curve, range 0 to 100 %.
• Booster pump current: Red curve, range 0 to 100 %.
• Booster pump power: Green curve, range 0 to 100 %.
• Booster pump inlet pressure (P201–1–PT1): Black curve, range -1 to 15
bar.
76 200000878-6-EN-GB
3.4.13 Page 3.6 — Log box

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

Column Content
Top fields for administration
Choose to define/view bypass or heeling con-
Configuration type figurations.
Select configuration number by entering a
number or using the arrow buttons. Signal sta-
Configuration number tus and Configuration are displayed for selec-
ted configuration number.
Saves configuration information after a
Save configuration button change.
Column Content
Signal settings
Signal input Number of the input signals (1 – 32).
Indication of the current status for signal 1 –
32.
Status Green light = Active signal.
No light = No signal.
Marked checkboxes inverts the signal chosen
in the configuration row. In that way you can
Signal invert chose to have the active signal as 0 V. If the
signal invert checkbox is not marked, the ac-
tive signal is 24 V.
200000878-6-EN-GB 77
Column Content
Signal settings
This is the definition of which signal that
should be active to constitute a bypass/heel-
ing. Tap the checkbox to select or unselect it.
Configuration Selected = All selected signals, must be active
for the modes bypass or heeling to occur.
Not selected = Not part of configuration for By-
pass or Heeling.
If a bypass or heeling configuration is active,
Active configuration numbers the numbers of the active configuration is indi-
cated here.
78 200000878-6-EN-GB
3.4.14 Page 4.1 – System 1

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

Section Description
on page
HMI info CPU: Control panel’s usage of the central processor unit (CPU) in percent
of total capacity and temperature (°C). The control panel will shut down
when the CPU reaches 100 °C.
Used RAM: Control panel’s used random access memory (RAM) in per-
cent of total capacity and in kB.
Used storage: PLC, used storage in percent and MB. Storage used for
the event and alarm log.
iX version: N/A.
X2 firmware: Version of internal firmware for the control panel.
CAT control version: N/A.
PureBallast HMI software version: Version of HMI software.
IP settings: Display current IP address for the panel.
Setup button: Opens popup to set IP address for the main panel and the
remote control panels (optional). Requires login level AlfaLaval.
PLC info CPU temperature (°C): Temperature of the central processor unit (CPU)
in the PLC.
PureBallast PLC software version: Version of the PureBallast PLC pro-
gram.
GPS position: Shows current GPS position. The position is used in the
event log.
200000878-6-EN-GB 79
Section Description
on page
Backup Settings to/from USB panel: Export and import information to the USB
and re- panel port on the cabinet door.
store
Backup button: The following information is saved in a folder named
“PureBallast Backup”:
• Parameter settings. File: Parameters.csv.
• Operating timers for UVR, UV lamps etc. File: operatingtimers.csv.
• Folder CrashTrend: Crash trends are a detailed log file with an extreme
level of details. For more information, see instruction Download crash
trends.
Restore button: Restore all information from a USB backup to the control
system. See Backup above. This shall not be used to restore parameter
settings after software update. Requires login level Advanced operator.
Parameters: Parameter restore.
Set default button: Set all parameter values to the default values. Re-
quires login level Advanced operator.
Crash logging:
Trig log button: Saves a crash log, that can be down-loaded in section
Backup and restore. It’s for Alfa Laval’s internal analyzes and fault find-
ing of the control system. For more information, see instruction Download
crash trends.
3.4.15 Page 4.2 – System 2

The page is used to set system settings and export log files.
80 200000878-6-EN-GB
Section on page Description

Date and time: Only used if GPS is not connec-
ted to the control system. If so, time is retrieved
from the GPS. Requires login level Advanced op-
erator.
HMI date and time UTC Set button: Set time and date for the main control
panel. Remote control panels are updated with
this time within 15 minutes after synchronization.
Synchronize button: PLC is synchronized to use
same date and time as set in the control panel.
Screen saver timeout: Defines time before the
panel is set to screen save mode. This is set indi-
vidually per control panel.
HMI Backlight
Night light level: Defines percent of full light for
the night light mode. Night light is activated by the
Night function button.
Export button: Opens the Export log files popup
to export (copy) event log files and alarm list.
Export log files
For specific information about logged events, see
section List of logged information on page 118.
Remote control panels button: Open a popup
used for setting IP addresses for remote control
Remote control panels panels (optional). See instruction Set control pan-
el IP address on page 108.
Requires login level AlfaLaval.
Night button: 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 4.2 System 2.
200000878-6-EN-GB 81
3.4.16 Page 4.3 – Timers

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

Row Unit
Accumulated ballast volume m3 processed
Accumulated deballast volume m3 processed
Control valve V201-8 total runtime Time opened in hours
Filter backflush cycles Number
Filter motor total runtime Runtime in hours
CIP pump P320–1 (pulses) Number
CIP: Number cleaned UVRs.

Reset button: Reset to 0. If this is done each time the
CIP liquid is changed, it is possible to build up experi- Number of performed CIP
ence on how many CIP processes it is possible to processes.
perform before it is time to change CIP liquid contain-
er. Requires login level Advanced operator or higher.
Reactor: Lamps on
Total Total runtime for the UV lamps in the UV reac-
tor.
Lap time Lap time for installed UV lamps, since the
counter was reset after previous reset at UV lamp Hours
change.
Reset button: Reset the value. Shall be done after
UV lamp change. Requires login level Advanced op-
erator or higher.
Reactor: EC power on Hours
82 200000878-6-EN-GB
3.4.17 Page 4.4 – Remote 1

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

Activates test mode. Communication can
be sent between the ISCS and PureBal-
last’s PLC without actually affecting the
control system (start process etc). To
send information, enter desired digits in
the entry field.
Test mode
Requires login level Advanced operator
or higher.
Active: Check mark on the button.
Deactivated: No check mark on the but-
ton.
3.4.18 Page 4.5 – Remote 2

This page is used to monitor data sent between PureBallast's PLC and the
vessel's ISCS.
For detailed information about addresses, information and format, see chapter
6. Installation description and drawings, section Remote interface integration
(optional).
200000878-6-EN-GB 83
84 200000878-6-EN-GB
3.4.19 Page 4.6 – LPS

This page is used to monitor detailed data for the lamp power supplies in the
lamp drive cabinet. It is intended for Alfa Laval’s personnel during advanced
faultfinding.
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.
Short circuit Status: Red = Short circuit alarm.
Lamp open Status: Red = No lamp, circuit open.
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.
200000878-6-EN-GB 85
3.4.20 Page 5.1–5.6 – Parameter pages

These pages are used to set parameters. See chapter 4. Parameters for
detailed information.
86 200000878-6-EN-GB
3.4.21 Page 6.1 – Installation parameters

This page is used to set installation parameters. See chapter 4. Parameters
for detailed information.
3.5 Operating instructions

This section contains step-by-step instructions for operating the PureBallast
system. Please read and follow the preparations and conditions carefully, as
well as any danger or warning notes.
Preparations and conditions

For reference information, see the following sections in this chapter:
• Control system pages used in the instructions: See section Introduction to
the control system on page 50 and Detailed page descriptions on page 60.
• Login levels required for different procedures: See section Login levels on
page 53.
• Detailed information about components (valves, motors, pumps etc)
involved in each step the process. See section Detailed process description
on page 120.
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 53.)
200000878-6-EN-GB 87
3.5.2 Prepare operation

Before ballast operation, check the following:
• The flow must be within defined flow range during operation:
• Ballast: 52 – 170 m3/h
Note: If you have filter the data is correct. The system may be supplied
with a filter of larger size. If so, consult the Filter size addendum for
correct data.
• Deballast: 17 – 170 m3/h
• Stripping: 17 – 170 m3/h
Preparations
Before ballast operation, do the following:
• Select IMO or USCG mode by using IMO or USCG function buttons, based
on which legislation that must be followed.
• For USCG: Select 3days or 0 day hold-time in parameter p182. If ballast
water is stored in tank shorter than 72 hours, the water must be treated
using 0 days mode at ballast.
• Make sure that all valves that lead the flow to and from PureBallast are
opened. They are not operated by PureBallast.
• Check the Alarm list (page 2.1) to verify that no alarms need attention.
• Select the flow before starting a process, either manually or automatically.
See Page 1.2 – Overview on page 60.
• Power for the system must be available. This is handled automatically if
power management is integrated. If power management is not integrated,
confirm the availability of the power manually.
3.5.3 Best practice operation – Soft start/stop using flow control

This section covers important information on best practice operation to run
smooth process, avoid pressure spikes and save the system.
It is important to start and stop an operation in soft and controlled way. When
starting an operation, the flow is recommended to be low in the beginning, and
then slowly increased to full flow. When stopping, the flow must be slowly
decreased.
Soft start/stop prevents pressure waves in the piping. At abrupt start/stop
there is high risk of water column separation, pressure spikes and surges.
Flow can either be controlled in a smooth way by regulating the speed of the
pump via a VFD (optional), or by regulating the flow using a throttle valve.
Best practice for both alternatives are described in the sections below.
An important factor contributing to smooth flow in the system is that valves are
adjusted to be opened and closed slowly. This is valid for both the PureBallast
valves, as well as the vessel’s valves involved in ballast water handling. See
instructions in the system manual, chapter 7. Service manual for instructions
on how to adjust travelling speed Service manual on page 315.
88 200000878-6-EN-GB
VFD controlled flow

Follow the procedures below to start and stop operation in a smooth way
using a VFD.
A VFD controlled flow allows for a more automated and dynamic controlled
flow regulation than the use of a throttle valve.
If the VFD also is integrated with the PureBallast via an external feed signal,
the ramp up/down and flow control will be automatically monitored and
adjusted from PureBallast control system.
Start operation
When system requires ballast pump to be started:
1. Start ballast water pump with required minimum flow.
2. Increase the flow from the VFD in a slow and controlled manner until full
flow is achieved.
3. Monitor the flow during operation and regulate the flow from the VFD to
increase or decrease the flow to PureBallast if needed. The input flow to
the PureBallast system must be as close as possible to the certified flow
for an operation. This will reduce the stress and wear of the control valve.
Stop operation - Ballast
1. Before stopping the ballast process: Slowly reduce the flow from the VFD
to approximately 50 %. A certain flow is needed for the final filter backflush
before the operation is stopped.
2. Stop the operation. When flow rate is low the system can be stopped with
no risk of pressure waves.
Stop operation - Deballast

1. Before stopping the ballast process: Slowly reduce the flow from the VFD
to approximately 50 %. The reason is that when the flow is low, the system
will stop with no risk of pressure waves.
2. Stop the operation.
Throttle valve controlled flow

Follow the procedures below to start and stop operation in a smooth way
using a throttle valve before PureBallast.
Start operation
When system requires ballast pump to be started:
1. Start the ballast water pump with the throttle valve opened at 20 %.
2. Open the throttle valve slowly to reach required minimum flow.
3. Open the throttle valve in a slow and controlled manner until full flow is
achieved.
4. Monitor the flow during operation and regulate the throttle valve to increase
or decrease the flow to PureBallast if needed. The input flow to the
PureBallast system must be as close as possible to the certified flow for an
operation. This will reduce the stress and wear of the control valve.
200000878-6-EN-GB 89
Stop operation - Ballast

1. Before stopping the ballast process: Slowly reduce the flow by closing the
throttle valve to approximately 50 %. A certain flow is needed for the final
filter backflush before the operation is stopped.
2. Stop the operation. When flow rate is low the system can be stopped with
no risk of pressure waves.
Stop operation - Deballast
1. Before stopping the ballast process: Slowly reduce the flow by closing the
throttle valve to approximately 50 %.
2. Stop the operation.
3.5.4 Best practice — Priming

To reduce the stress and wear of the complete ballast water system, follow the
steps below:
• Prime the system before starting operation:
1. Open sea chest valve to prime pipes upstream PureBallast.
2. Open valves to ballast water tank(s) to prime the pipes between
PureBallast and the tanks to be filled. Note! Do not mix waters treated
with different modes.
3. Close valves to tank(s) when system is primed.
• Select the high or the low sea chest depending on water conditions.
• If the water is challenging (for example in port), select high sea chest.
See section Challenging waters below.
• If the water is icy waters, select low sea chest.
• Deaerate the piping, especially at high points.
3.5.5 Best practice — Challenging waters

Before entering challenging waters, follow the list of preparations below.
• Backflush the filter manually in the open sea to make sure the filter is fully
cleaned on arrival.
• During backflush, check the following:
• The backflush operates correctly.
• Make sure the valve V309-1 opens.
• The system pressure is over the value set in parameter p304.
During operation:
90 200000878-6-EN-GB
• Use the upper sea chest water to avoid picking up mud and particles from
the bottom.
• Start ballast with reduced flow and monitor if the filter differential pressure
increases too fast.
• Gradually increase flow while monitoring filter differential pressure.
• Reduce flow if backflush is triggered too often.
After operation:
Do backflush in open water several times to clean the filter completely. Clean
the filter manually if needed
3.5.6 Perform ballast

Follow this instruction to ballast.
• See information in section Prepare operation on page 88.
Follow the steps below:
1. Open valves leading technical water / potable water to pipe 310 and drain
water from pipe 309 to overboard. They are not operated by PureBallast.
2. Press the function button Ballast.
Result: The UV lamps are lit and warmed up. UV reactor cooling started if
needed.
3. Wait for the message “Confirm ballast pump started” and act accordingly.
See section Operational conditions on page 42.
Result: Ev. cooling is stopped and ballast process starts.
4. When desired amount of water has been processed, press the function
button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but
not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off. An
automatic filter backflush is performed.
5. Wait for the message “Stop ballast water pump” and act accordingly.
200000878-6-EN-GB 91
6. Close relevant valves leading flow to and from PureBallast.

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 6 hours. 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 1.5 CIP. A CIP process is started
manually according to instruction CIP clean UV reactor after ballast / deballast on
page 97.
3.5.7 Perform deballast

Follow this instruction to ballast.
1. Press the function button Deballast.
Result: The UV lamps are lit and warmed up. UV reactor cooling started if
needed.
2. Wait for the message “Confirm ballast pump started” and act accordingly.
See section Operational conditions on page 42.
Result: Ev. cooling is stopped and deballast process starts.
3. 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.
4. Wait for the message “Stop ballast water pump” and act accordingly.
92 200000878-6-EN-GB
5. Close relevant valves leading flow to and from PureBallast.

minutes ).
minutes ).
NOTE
page 97.
3.5.8 Perform tank stripping

Follow this instruction to strip .
• Stripping function must be activated in parameter p170.
1. Press the function button Strip.
Comment: If the button is not blue, check that flow or UV reactor have
been selected.
2. Open relevant valves and then press the button in the popup to confirm the
action. See section Operational conditions on page 42
Result: Ev. cooling is stopped and stripping process starts.
3. Wait for the message “Confirm strip pump started” and act accordingly.
Result: Cooling stops and stripping starts.
4. When desired amount of water has been stripped, press the function
button Stop.
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message “Stop stripping water pump” and act accordingly.
200000878-6-EN-GB 93
6. Wait for the message “Close valves ...” and act accordingly.
minutes ).
minutes ).
NOTE
page 97.
3.5.9 Heel (internal transfer)

Follow this instruction to enable heeling (internal transfer).
• Internal transfer of ballast water between tanks, for example during heeling
procedures, does not require the use of the PureBallast system.
• The operation procedure is different depending on if a heeling signal is
integrated, and if it is integrated via hardwire/remote interface or via logbox
(optional).
• Heeling mode request signal can be integrated, which will inhibit any
bypass warnings from triggering. It is only possible to perform heeling
during processes standby and CIP. If any other process is running it will be
stopped automatically when heeling mode is activated and then resumed
after heeling mode is deactivated. Heeling mode signal can be activated via
hardwire, remote interface or log box.
Follow the steps below - If heeling signal is integrated via hardwire or
remote interface:
94 200000878-6-EN-GB
1. Activate heeling from ISCS.

Result: Heeling mode activated. A warning and an event are issued. An
ongoing process (ballast, deballast or stripping) will be stopped and system
is set to standby. Ballast/deballast/stripping is disabled as long as heeling
mode is active.
2. Wait for the message “Stop ballast water pump” to appear on the
PureBallast control panel. If start/stop ballast pump request is integrated,
the pump will stop automatically. If not integrated, stop the pump manually.
If you need the same ballast pump for heeling, confirm the request without
stopping the ballast water pump.
3. Set the valves in the correct position e.g. sea chests and overboard valves
are closed. Any bypass valves involved e.g. V212-31, must be opened last
in order of all valves included in the heeling operation, to ensure legal
operation and to avoid triggering bypass warnings. Please refer to the
vessels BWMP for correct valve operation.
4. Untreated water in piping should be handled according to BWMP.
5. Start heeling pump, if not already running.
6. Stop heeling pump after heeling is completed.
7. Deactivate heeling from ISCS.
Result: Heeling mode deactivated. It is possible to start a process.
Follow the steps below - If heeling signal is integrated via log box:
1. Stop any ongoing ballast, deballast or stripping process. If system is
already in standby or CIP process, please proceed to step 3.
3. Set valves outside of PureBallast in correct position e.g. sea chests and
overboard valves are closed. Any bypass valves involved, e.g. V212-31,
must be opened last in order of all valves included in the heeling operation,
to ensure legal operation and to avoid triggering bypass warnings. Please
refer to the vessels BWMP for correct valve positions.
Result: The heeling signal will be activated via the log box heeling
configurations. A warning and an event are issued. Heeling mode will only
activate if the valves that are integrated to the log box are in the correct
position according to the heeling configurations.
If there is an ongoing process (ballast, deballast or stripping), it will be
paused. Ballast/deballast/stripping is disabled as long as heeling mode is
active.
4. Start heeling pump.
6. Deactivate heeling via log box by changing the valves position e.g. closing
the bypass valve V212-31.
Result: Heeling mode deactivated. It is possible to start a process.
Follow the steps below - If heeling signal is not implemented:
200000878-6-EN-GB 95
1. Stop any ongoing ballast, deballast or stripping process. If system is

already in standby or CIP process, please proceed to step 3.
3. Set valves outside of PureBallast in correct position e.g. sea chests and
overboard valves are closed. Any bypass valves involved, e.g. V212-31,
must be opened last in order of all valves included in the heeling operation,
to ensure legal operation and to avoid triggering bypass warnings. Please
refer to the vessels BWMP for correct valve positions.
Result: If a bypass valve is opened, a warning and an event are issued.
4. Start heeling pump.
6. Make an entry in the ballast water record book that heeling was performed.
This is necessary to explain to any inspector why the bypass valve was
opened.
3.5.10 Backflush filter manually

Follow this instruction to backflush rinse the filter manually.
• The system must be in full ballast mode.
• The system can be in standby to test the backflush motor, but the filter will
not be cleaned.
1. Go to page 1.4 Filter.
2. Press the Start backflush button.
Result: A backflush is performed for 40 seconds (defined in parameter
p308).
96 200000878-6-EN-GB
3.5.11 CIP clean UV reactor after ballast / deballast

Follow this instruction to clean the UV reactor using the cleaning in place (CIP)
process.
• The system must be in standby mode.
• Complete status information regarding CIP is displayed in page 1.5 CIP.
The page displays time before a CIP process must be started and
remaining time for ongoing CIP cycle.

1. Open valves leading technical water / potable water to pipe 310 and drain
water from pipe 309 to overboard.
2. Press the function button CIP.
Result: The CIP process starts. The CIP process takes approximately 6
hours.
3. After completed process: Close relevant valves leading flow to and from
PureBallast. See section Operational conditions on page 42.
3.5.12 Drain/fill UV reactor and filter

Make sure that the following valves are closed: Control valve (V201-8), inlet valve (V201-9) and UV
reactor inlet (V201-19).
The buttons Drain and Fill are only active in standby mode.
1 Log in as Advanced operator or higher
2 Press the function button Drain.

The UV reactor and filter is drained.
To fill the UV reactor and filter, press the function button Fill.
3.5.13 Attend to alarms

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

• Alarms will shut down ongoing process and disable start of process.
• Warnings are information to the operator and will not shut down ongoing or
disable start of process.
• An alarm or warning will activate the alarm buzzer (sound and light) on the
cabinet. The sound is silenced by touching the buzzer, but note that the
alarm is not acknowledged by this.
200000878-6-EN-GB 97
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 70.

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

Follow this instruction to quickly stop any ongoing operation in the PureBallast
system, for example, when a critical fault has been detected, or to make the
system deactivated (powered off/isolated).
All valves are designed to be normally closed. At shutdown and/or power off,
all valves are closed by the pneumatic pressure. The valves are pneumatically
driven and are opened at request signal to open. In case of power off, the
signal disappears, and valves are closed by the pneumatic pressure.
98 200000878-6-EN-GB
Electrical cabinet
1. Main breaker
2. Reset button
3. Emergency stop button
One of the following methods can be used to abort any ongoing operation and
stop the system:
200000878-6-EN-GB 99
Action Method
Stop ongoing process Press the Stop button in the control pan-
el.
Result: Ongoing process is stopped in a
controlled way. Valves are returned to
starting position.
Press the Emergency stop button (3) on
Result: Ongoing process is stopped im-
mediately, without controlled closing of
Emergency stop any valves, UV lamps etc.
Reset the system by turning and pulling
the Emergency stop button (3) and
pressing the blue Reset button (2).
Complete deactivation is performed in
two steps:
1. Turn off the main breaker (1) at the
side of the electrical cabinet. The sys-
tem is then powered off/isolated on
the PureBallast side of the main
Deactivate PureBallast to make it com- breaker.
pletely deactivated (powered off/isola-
ted). 2. To make the complete system totally
powered off/isolated, power to Pure-
Ballast must be switched off using the
ship’s switch board.
Reset the system by pressing the blue
Reset button (2).
PureBallast will shut down if the system loose power (intentionally or

unintentionally) or if an alarm is issued. Alarm has alarm ID beginning with an
“A”.
Events at shutdown
• Any ongoing process will stop.
• Valves will return to closed position. Valves are opened at high signal from
the control system, and when this signal is lost, the valves are closed
pneumatically.
• The following signals to ISCS are lost, which means that PureBallast no
longer require overboard valve open, ballast pump running and request for
dedicated power if power management (optional) is used.
• An event is written to the event log.
1. Main breaker
2. Emergency stop button
A. Main breaker
B. Reset button
One of the following methods can be used to abort any ongoing operation and
stop the system:
100 200000878-6-EN-GB
Action Method
Stop ongoing process Press the Stop button in the control pan-
el.
Result: Ongoing process is stopped in a
controlled way. Valves are returned to
starting position.
If an external system stop button has
been installed and integrated.
Result: Ongoing process is stopped and
System stop (External button) valves are returned to starting position as
fast as possible.
Note: The power is still on.
Press the Emergency stop button (2) on
the control cabinet.
Emergency stop Result: Ongoing process is stopped im-
mediately, without controlled closing of
any valves, UV lamps etc.
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)
Deactivate PureBallast to make it com- door.
pletely deactivated (powered off/isola- The system is then powered off/isola-
ted). ted on the PureBallast side of the
main breaker in the control cabinet
and in the lamp drive cabinet.
2. To make the complete system pow-
ered off/isolated, power to PureBal-
last must be switched off using the
ship’s switch board.
Reset system after shut down

Follow this instruction to reset the system if deactivated. Numbers refer to the
illustration above.
The system may only be reset after the reason for shut down is known. If the
reason is not known, follow the instruction Attend to alarms.
3.5.15 Operate components manually

Follow this instruction to operate components manually. This shall only be
done during commissioning, advanced faultfinding or service.
This is the recommended way to operate components manually. Valves can
also be operated manually according to instruction in chapter 7. Service
manual, section Valves.
The following components can be operated manually:
• Valves
• Filter motor (M709-43)
• Drain / circulation pump (P460-1)
• Backfush pump (P309–1), if installed
200000878-6-EN-GB 101
• UV lamps in the UV reactor

• UV lamp power.
• This operation requires login level Advanced operator or higher.
• It is not possible to run a processes in manual mode. Only individual
components can be operated.
1. Go to the page containing the component you want to operate manually.
Go to page 1.1 Overview or 1.4 CIP status.
2. Press the button Manual function button.
Result: The control system is set in manual mode.
3. Press desired component.
Result: A popup is opened. Current status is indicated. If an existing alarm
exist, it is indicated with an alarm icon.
Example popup for a valve.

4. Press (not slide) the Hand button icon to enable manual operation of the
component.
Result: The open and closed buttons turn blue for operation. A hand icon is
also displayed on the component in the popup and the page to indicate
that it is manually operated.
5. Operate the component using the open/run (left) and closed/not running
(right) buttons in the popup.
102 200000878-6-EN-GB
6. Press Hand button to stop manual mode for the component and the X
button to close the popup.
or
Press the X button to close the popup and let the component remain in
manually set status. The popup is closed, and a hand icon is displayed by
the component to indicate it is manually operated.
7. Press the Manual function button to exit manual mode.
Result: All manually operated components are restored to their default
status.
3.5.16 Operate UV lamps manually

Follow this instruction to start and stop UV lamps in the UV reactor and to dim
the UV lamps. This can, for example, be done to check that a changed lamp is
working.
• The control system must be in manual mode.
DANGER
Manual start of the UV lamps is only allowed (and possible) when there is water
in the UV reactor (indicated by level switch LS201-29 ), and the water
temperature is below 60 °C. All necessary items – cooling water flow, water
temperature, and power management – must be supervised and verified by the
authorized trained personnel operating the system. Improper operation of this
function could seriously damage the equipment and injure personnel.

1. Go to page 1.2 Overview. Press the Manual function button to activate
manual mode.
2. Open valves for freshwater flow to UVR and filter. For details see step 2 in
section Startup ballast, in Detailed process description on page 120.
Result: The UV reactor is now filled with water through the cooling water
line 310.
3. Wait until there is a flow through the UV reactor, indicated by the level
switch (LS201–29) turning green.
4. Press the Manual mode button to enable manual operation of the UV
lamps.
5. Go to page 1.3 Reactor. Operate the lamps by pressing one of the LPS1–3
buttons to start / stop lamps. Each LPS supply powers to two UV lamps,
which means that it is only possible to start two lamps at a time. The
buttons toggles between started and stopped.
Result: UV lamps are lit. Status is indicated: Grey = Stopped; Green =
Started; Yellow = Starting.
6. If desired, the UV lamps can be dimmed manually: Press the entry field for
Manual output, and enter desired percentage between 50 and 100 %. The
LPS will give the entered percentage of full effect to the UV lamps. This is
indicated in the Power output field.
200000878-6-EN-GB 103
7. Press activated LPS1–3 button.

Result: Lit UV lamps are stopped.
8. Press the Manual function button to exit manual mode.
Result: Manually operated components are restored to standby status.
3.5.17 Export control system event log files

Follow this instruction to copy event log files and alarm lists from the control
system. The information (copied as text files to a USB memory).
The following information can be exported:
Information to be ex- Description
ported
The event log includes all events in the PureBallast sys-
Event log tem. Also additional information is stored, for example
processed volume, UV intensity and power consumption.
A list of all alarms and warnings that has been issued
Alarms and warnings from the control system. Intended to be used mainly by
service technicians.
Only used when PLC soft ware is updated. The system
export events and parameter settings to a USB, where
Update export the information is stored temporarily during the update.
After update, the system retrieves the information back to
the PLC.
For specific information about logged events, see section List of logged
information on page 118.
• 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 6.1 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.
104 200000878-6-EN-GB
1. Go to page 4.2 System 2.

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.
7. Wait for the message "Export OK" to appear.
Result: A folder named PureBallast has been downloaded. It contains two
sub folders: Alarm and Event. The folder corresponding to your export
choice contains a CSV file.
8. Press Close and remove the USB memory.
3.5.18 Backup control system settings

Follow this instruction to export all settings made in the control system to a
backup on a USB memory.
The following information is saved:
200000878-6-EN-GB 105
• Parameter settings. File: Parameters.csv.

• Operating timers for UVR, UV lamps etc. File: operatingtimers.csv.
• Notpad.txt. Can be used to make notes for the backup.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Backup button in page section Backup and restore.
Result: A popup is displayed and the process is started. Read the final line
of list before closing the popup: Important information might be displayed.
4. Wait for the OK / Close button to turn blue again. If the backup was
successful, the last line shall state "Backup done".
Result: A folder named PureBallast backup has been saved containing the
backup files.
5. Remove the USB memory.
3.5.19 Download crash trends

Follow this instruction to download crash trends from the control system.
Crash trends are a detailed log file with an extreme level of details regarding
logging of values in the system. The crash trends will show values that are not
normally captured by the event log (each 200 milli second during operation).
The crash trend contain 10 minutes of information after an alarm has been
issued during operation and 10 hours during stand-by.
The trends are only downloaded and used for detailed analysis in contact with
Alfa Laval, for example for advanced fault-finding and fine tuning of the
system. Note that the crash trend needs to be opened using a specific tool,
not available for the customers.
Follow the steps below - Short time log
1. Insert a USB memory in the HMI USB port in the control cabinet door.
2. Start an operation from which you want to collet detailed data, for example
when an unwanted warning/alarm is issued.
3. Open page 4.1 System info, and press Trig log in section Debug
logResult: The button turns light blue while it saves the log.
4. Make a backup according to instruction Backup control system settings to
download the crash log.Result: Crash trend file are downloaded together
with the other back-up files, stored in the folder CrashTrend.
5. Send the folder to Alfa Laval Technical support to get assixtance.
Follow the steps below - Long time log
Note: At least version V3.2.3.4 is needed to be able to download long time log.
Note: At least version V3.2.2.2 is needed to be able to download long time log.
106 200000878-6-EN-GB
1. Create a folder named CrashTrend to a USB memory

2. Insert the USB memory in a USB port in PLC inside the control cabinet.
Result: Crash trends are downloaded to the USB every ten minute. Time
until next down-load is displayed in section Debug log together with
information that continuous download is performed. Button changes text to
Flush to USB.See below:
3. Let the USB memory stay in the PLC for desired period required by Alfa
Laval. The USB memory can be left in the PLC for over a month.
4. Before removing the USB memory, press Flush to USB to save the latest
information since last download, regardless of the ten-minute interval.
3.5.20 Restore control system settings

Follow this instruction to restore all control system settings, previously saved
to a USB memory. This includes parameters and settings for the page 3.1
Trend.
• A USB memory with backup files. When the files where backuped, the
backup files where saved in a folder named “PureBallast Backup”. For
information about backup files, see section “Backup and restore” in the
page description for Page 4.1 – System 1 on page 79.
• This method shall not be used to restore parameter settings after software
update.
• If you do not wish to update a certain type of setting, remove the specific
file from the USB memory before inserting the USB memory in the USB
panel port on the cabinet door.
• Remove the file Parameters.csv from the USB before following this
instruction.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Restore button in page section Backup and restore, Settings
to/from HMI USB.
Result: A popup is displayed and the process is started.
4. Wait for the OK / Close button to turn blue.
5. Read the second last line in popup: If the restore was successful, it shall
state "Restore done".
6. Press the OK / Close button on the popup.
200000878-6-EN-GB 107
7. Remove the USB memory.

8. The control panel must be rebooted. At the rear side of the control panel:
Pull out the power cable from the 24V DC port, and insert it again.
3.5.21 Set control panel IP address

Follow this instruction to set IP address for the main panel and the remote
control panels (optional).
• This setting shall be done for all panels installed.
• These instructions require login level AlfaLaval.
• Port LAN 1 must be used for the Ethernet cable at the backside of the
panel.
2. Press the Setup button in the IP settings box.
Result: The IP settings popup is displayed.
3. Press the IP settings button.
4. In the Port 1 tab select the radio button Specify an IP address.

Enter the IP address according to the list below. Also check that correct
setting is done for Port 2 in the Port 2 tab.
NOTE
Only the IP address shall be changed.
5. Press OK.
6. Reboot the panel to update communication with the new IP address. Make
sure that the new IP address is displayed on page 4.1 System 1.
108 200000878-6-EN-GB
7. Repeat this instruction for all installed control panels, both main and
remote control panels, if installed.
8. Follow the instruction Set remote control panel communication to activate
remote control panel.
3.5.22 Set remote control panel communication

Follow this instruction to connect remote control panels (optional) to the PLC.
• These instructions require login level AlfaLava.
• The same setting shall be done for all panels installed.
• IP addresses must have been set according to instruction Set control panel
IP address.
• Main control panel and remote control panel 1 (192.168.0.11) are added as
default . If no remote control panels is used, address 192.168.0.11 shall be
removed.
• All remote control panels must be on and connected with an Ethernet
cable.
1. On the main panel in the electrical cabinet: Go to page 4.1 System 1.
2. In the Remote control panels box, press the Set button.
3. Select an available remote control panel in the left hand side.
200000878-6-EN-GB 109
4. Press the >> button.

Result: The panel is connected and moved to the right hand side.
NOTE
Server port shall always be “1001”.
5. Press the Panel alias field for the new control panel. Use the keyboard to
enter a name, for example the location it is placed.
NOTE
Panel alias for all control panels shall be entered (with the same wording)
in all panels to be displayed in a correct way.
6. Press the save (USB symbol) button.
Result: The information is saved and the popup is closed.
7. Repeat step 4–7 to connect more remote control panels.
8. Repeat this entire instruction for all installed panels.
Delete a remote control panel
If remote control panels are not used, any added control panels shall be
deleted from the list.
To delete a connected panel: Select it a panel in the hand side and press the
delete (X) button. If a keyboard is displayed, press Esc to remove it.
3.5.23 Set remote interface communication

Follow this instruction to make settings for the remote interface (optional)
communication between the ISCS and PureBallast.
• These instructions require login level AlfaLaval.
1. Go to page and 4.4 Remote 1 and 4.5 Remote 2.
2. Set parameters to match ISCS’s RTU server data according to the
information in chapter 4. Parameters, section 5.6 Remote parameters.
3.5.24 Test remote interface communication

Follow this instruction to test that the remote interface (optional)
communication between PureBallast's PLC and the ISCS is correct and
functioning.
Test communication
The first test is to see that the two systems communicate.
110 200000878-6-EN-GB
1. Go to page 4.4 Remote 1 . Make sure that the system is not in test mode
(no checkmark on the button). If not, press the Test mode button to
deactivate it. Make sure that Local operation is activated. If not, press the
Local function button.
2. Check that the heartbeat signal is updated in both systems (06 and 77).
Also check that values are read from the PureBallast system, for example
temperature (address 116 and 117).
This will confirm that the systems communicate.
Test values sent from PureBallast to ISCS
Values are entered and displayed in the control system as actual values, but
are sent to ISCS using the binary numeral system. This information is found in
group Data to ISCS and Cmd/status to ISCS on page 4.4 Remote 1 , and is
indicated by a unit (m3, hour, second, kW etc).
Addresses with special conditions
The following addresses does not display correct values in page 4.5:
• 50 Process volume
• 52 System pressure
• 63 Differential pressure over filter
• 64 Temperature in electric cabinet (TT401)
• 65 Filter outlet pressure V201–72
• 66 Power consumption
• 57/58 Current time
• 114 UV reactor temperature (TT201–33)
For detailed information, see the directory of addresses.
1. Press the Remote function button.
Result: Test mode is activated enabling that communication is sent
between the systems without actually affecting the control system (start
processes etc). This also result in alarm A93 Heartbeat signal missing.
This alarm shall be ignored during this test.
2. Enter actual values in the in the entry field for the address to send
simulated information to the ISCS. Information in decimal form, for
example processed volume, is written as actual values. Information in
binary form, for example command status, is written as a bit pattern. The
key for the bit pattern is found in chapter 6. Installation description and
drawings, section
System interfaces.
3. Make sure that values and status information is displayed correspondingly
in the ISCS.
4. Repeat the simulation for the information you which to test.
NOTE
Only implemented signals needs to be tested.
200000878-6-EN-GB 111
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 and 4.4 Remote
1 and 4.5 Remote 2. 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.
Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first
digit from right is counted as zero, second digit counted as 1 etc). This gives
the following bit pattern: 0010000000000000.
1. Enter the desired bit pattern in the entry field for the address.
2. Make sure that the alarm/warning is indicated in ISCS.
3. If common alarm and warnings are used, make sure that address 70:7 and
70:8 are updated. It is only necessary to check this for the first alarm.
4. Clear the bit pattern in the entry field.
5. Repeat the simulation for those alarms/warnings you which to test.
6. Press the Test mode button to set the system in online mode (no check
mark on the button).
Press the Remote function button if you want to activate remote control.
3.5.25 Update control system softwares

Control system softwares must be updated according the Release note for the
specific version of the softwares. The release note contains instructions for
updating the softwares and information about new features, changes in the
software etc.
The following is needed:
• A USB memory with HMI software. Note that the same version must be
used for the HMI and PLC software (same version number).
• A USB memory with the X2 firmware.
112 200000878-6-EN-GB
3.5.26 Calibrate the control panel’s touch screen sensibility

Follow this instruction to improve the touch precision on the screen, if it is
difficult to hit buttons and icons with precision.
Tip: It is possible to connect an external mouse to the control panel. Connect
the mouse’s USB to the USB PLC port on the cabinet door.
1. Pull out the power cable from the 24VDC port on the bottom side of the
control panel. And then reconnect the power cable.
For remote control panels: Use the Power button to turn off, and then turn
on the power.
2. Wait for a sandglass to appear: Press a finger on the screen and hold it
there for approximately 20 seconds.
3. Keep holding the finger on the screen until it turns completely white with a
message “Tap anywhere on the screen within 10 seconds”. Release the
finger and tap once on the screen.
4. Follow the instructions on the screen.
5. If needed, restart panel by removing and put back power cable.
3.5.27 Fine tune flow and pressure control

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

During operation, the control valve is regulated based on input from the flow
transmitter FT201–1 to maintain stable flow. Desired flow 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 Pressure setpoint
during backflush.
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.
• This operation requires login level AlfaLaval.
• This procedure should be done after other valves have been adjusted
according to instruction Adjust valve travelling speed of vessel’s valves and
PureBallast’s valves in system manual chapter 3. Operating instructions
and control system description.
• All components on page 3.1 Trend shall be selected for plotting, and Flow
FT201–1 shall be used for Y axis selection.
Flow control – Follow the steps below:
200000878-6-EN-GB 113
The aim is to find a setting for parameter p113 Min opening for V201–8 that is
as high as possible while still being able to create sufficient back flush
pressure as set in parameter p304 Pressure setpoint during backflush without
experiencing cavitation after control valve V201-8. This is especially important
for larger systems as an irregular valve movement can cause pressure surges
in the system.
1. Set parameter p113 to 90 %.
2. Initiate a backflush and listen for cavitation at V201-8.
3. If OK, lower to 85 %, and continue to lower in steps of 5 percent until
cavitation is attained.
4. Set parameter p113 to at least 3 % higher, and check for cavitation again.
• Note: It is not allowed to set p113 to 100 %.
• Note: It is not allowed to set p113 so high that the valve cannot regulate
pressure for backflush and 50 % flow at low UV transmittance. In case
p113 is set so high that V201-8 cannot close enough to obtain
designated flow, then the control of system flow needs to be assisted by
external measures (manually, VFD, throttle valve before the system).
5. Let the process continue for next step.
Pressure control – Follow the steps below:

The first aim is to find a setting which provides a smooth transition with a
minimal delay and overshoot from flow control to pressure control. Parameters
to use: p166 Pressure PID proportional gain and p167 Pressure PID integral
time. The second aim is to find a setting which provides a smooth transition
back from pressure control to flow control. Parameters to use: p120 Flow PID
proportional gain and p121 Flow PID integral time.
This is especially important for larger systems as an irregular valve movement
can cause pressure surges in the system.
1. Initiate a backflush from the Filter popup.
2. Control in page 3.1 – Trend (15 min) that V201-8 travels to a steady
position to create required pressure set in p304 Pressure setpoint during
backflush at a stable movement.
3. If needed, adjust parameter p166 and p167 for pressure control and
perform a new back flush. (To avoid Extended backflush do not trigger two
backflushes within time in parameter p302 Extended backflush timer
trigger.) Repeat this until stable movement is attained.
4. After a backflush, control that V201-8 regulates the flow in a stable
movement.
5. If needed, adjust parameters p120 and p121 for flow control and perform a
new back flush. Repeat this until good operation is attained.
6. Stop the process.
3.5.27.2 External feed

External feed control is mandatory for PureBallast system configurations
where the permissible ballast flow differs from the permissible deballast flow
(the control valve V201–8 itself cannot control such large flow interval).
114 200000878-6-EN-GB
The external feed is used to fine tune the control of the flow that comes to
PureBallast. It works as an addition to the flow controlled by the control valve
(V201-8).
3.5.27.2.1 Fine tune external feed control (optional)

External feed control allows PureBallast to control the flow delivered from the
vessel’s ballast water system by regulating either the ballast water pump via a
variable frequency driver (VFD) (optional) or a valve installed before
PureBallast.
If this optional signal is used to control flow to PureBallast, the regulation can
be finetuned to function as smooth as possible.
When the flow in the system is too high, PureBallast’s control valve V201-8 will
close to reduce flow. If the V201-8 closes more than a parameter set degree,
the control system sends a signal requesting the ballast pump to reduce the
speed (and so the flow). When the flow is reduced, V201-8 can open.
Valve V201-8 operates (open/closes) in a range between a parameter set
value (p157) and 100 %, where default is 70 %. Within this range, flow is
regulated by V201-8 without cavitation.
• This operation requires login level AlfaLaval.
1. Start a ballast process. Wait until the system is in mode Full ballast. Listen
for cavitation noises at V201-8.
If cavitation, go to step 2. It not, go to step 5.
2. Go to page 5.2 Main parameters.
3. Increase parameter p157 in steps of 5 % at a time. After each change, wait
until the parameter change take effect (a couple of minutes). Listen for
cavitation noises at V201-8.
Note: The effect can not be observed during backflush, since the external
feed function is disabled.
4. Stop raising when the noises from cavitation stops.
5. Listen to the movement of V201-8. If the valve is continuously changing
and the in an unstable fashion, parameter p156 must be adjusted. The
goal is to get a slow and steady regulation.
6. Increase parameter p156 in steps of 1 second per % at a time. After each
change, wait until the parameter change take effect (a couple of minutes).
7. Stop when the regulation curve is stable with slow changes.
9. Start another ballast operation. Verify settings during startup and process.
10. Perform a manual backflush. Verify settings during and after backflush.
Note: When the backflush is done, V201-8 is closed under 70 % (defined in
parameter p157). The external feed control signal is lowered to request
less flow from the pump, so that V201-8 can open. Less flow is needed
after the backflush, since the the filter is clean.
200000878-6-EN-GB 115

12. Start a deballast. Verify settings during startup and process.
3.5.28 Adjust valve travelling speed of vessel’s valves and

PureBallast’s valves
This section describes the need for adjusting the valve travelling speed.
Each ballast water treatment system has specific characteristics depending on
the installation: tanks placements, piping arrangements, fall heights, possibility
to control the ballast water pump via a VFD (optional) etc. All these specifics
affect the flow, velocity and pressure, both in PureBallast and the vessel’s
piping and components.
Therefore, each system must be operated and fine tuned to work as smooth
and correct as possible for the specific system, vessel and loading patterns.
The general adjustment of valve travelling speed must be done in the
complete ballast piping system to avoid that valves travel too fast which
creates problems regarding flow and pressure. If the valve travels too fast, it
can result in vibrations, cavitation and pressure waves in the piping, which can
harm installed components.
See illustrations below that describe a valve that is closed fast resulting in
pressure waves that are distributed in the pipes:
Slow valve travelling speed enables laminar flow and avoids pressure waves
in the pipes. This is especially important in systems with large flow but is
applicable for all system sizes.
Also, the valves must be trimmed to avoid too much closing, creating
problems with valves stuck in the rubber lining of the valve. A stuck valve can
also release fast, resulting in a fast travelling speed from close to open.
Flow and pressure control

There are two types of flow regulations:
116 200000878-6-EN-GB
1. Internal flow and pressure control. This is done via the Control valve
V201-8. It will regulate the pressure during backflush and fine tune the flow
according to the different processes.
2. External flow and pressure control. The incoming flow and pressure to the
system has to be regulated to ensure that the system design limitations are
not exceeded. For more information, see Flow requirements on page 197.
The flow regulation shall be smooth, and it shall allow for soft start and stop to
avoid pressure waves in the system. It is recommended that incoming flow is
controlled via a VFD. A VFD makes it possible to ramp up the flow and
thereby avoid large changes in the water velocity and pressure through the
piping.
Fine tune valve travelling speed in PureBallast

All PureBallast valves must be fine tuned to be opened and closed as slow as
possible within the time limit of 40 seconds. This is especially important for
UVR inlet valve V201-19 and UVR outlet valve V201-20.
The PureBallast main valves are adjusted using the throttle valves (except for
control valve V201-8). For detailed instructions, see sections Adjust valve
travelling speed in vessel’s piping and Adjust valve end position in system
manual chapter 7. Service manual.
Adjust valve travelling speed in vessel’s piping

Also, the vessel’s valve involved in ballast water operation must be adjusted in
a similar way to achieve smooth operation in the complete system.
Fine tune operation of control valve V201–8 in PureBallast

The control valve is regulated based on flow and pressure, depending on
operation. The valve must be fine tuned by parameter settings according to
instructions in system manual chapter 3. Operating instructions and control
system description, section Fine tune flow and pressure control.
Note: This must be done after adjusting other valves.
Note: Confirm the supply of instrument air pressure (measured at the
positioner) is set at minimum 5.5 bar. Do not set air pressure to more than
maximum pressure for the positioner: 8 bar. If the control valve is not stable at
higher flow, the air pressure can be increased to get more stable regulation.
200000878-6-EN-GB 117
3.6 List of logged information

Important events and alarm history are logged in the control system and
stored in the PLC for at least 24 months. The log also include components
connected via the log box (optional).
The control system store all alarms and relevant events for at least 24 months.
The memory has a vast safety margin, but when it is full, data will be deleted
starting with the oldest data. Logged information can be exported to a USB
memory stick. See Export control system event log files on page 104.
UVR is stated as ”UVR X”, where “X” indicates which UVR number the event
is valid for. This is not applicable for one UVR installations.
3.6.1 Event log

The table below shows which information that is saved in the log file.
The GPS stamp column indicates if the event is stamped with GPS position
(Y=yes, N=no). All events relevant to the IMO certificate are GPS stamped.
Event code Description GPS stamp
E80 Operator command, start stripping is issued N
E100 Manual mode set by operator N
E110 Heeling mode set by ISCS. N
E120 Heeling mode cancelled by ISCS. N
E190 Standby mode N
E210 Ballast Start-up mode N
E220 Full ballast mode Y
E240 Filter backflush mode N
E250 Stop ballast mode N
E260 Deballast start-up mode N
E270 Full deballast mode Y
E290 Stop deballast mode N
E300 CIP process started N
E310 E-stop N
Power turned on. PureBallast has been powered
E320 off for XX days YY hrs ZZ min. Time of how long N
the power has been switched off
E330 X m3 of ballast intake treated Y
E331 Amount (m3) of ballast intake treated. Time interval Y

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

minute.
E350 PureBallast is bypassed. Valve V212-31 open. Y
PureBallast bypass discontinued. Valve V212-31
E360 Y
closed.
PureBallast shut down and/or start blocked due to
E450 Y
alarm(s).
118 200000878-6-EN-GB
PureBallast is bypassed. Additional (external) by-

E515 Y
pass valve opened from ISCS (remote interface).
System heeling via ISCS (remote interface) detec- Y
E517 ted.
E640 UV intensity in UVR Y
E701 UVR 1 UV lamp time reset N
E760 Power setpoint Y
E800 Flow higher than certified flow. Y
E801 Flow restored to certified flow Y
E802 Out of compliance Y
E803 In compliance Y
E805 System started in IMO mode Y
E806 System started in USCG 3d mode Y
E807 System started in USCG 0d mode Y
E808 Salinity changed to saltwater Y
E809 Salinity changed to freshwater Y
E810 UVR 1 was not CIP cleaned within required time. N
E811 CIP cleaning completed. N
E1152 UV intensity low. System flow reduced. Y
E1153 UV lamp fail. System flow reduced. Y
UV intensity USCG low. System flow maintained at Y
E1154 50 %.
E5500 Bypass detected by Log box. Y
E5501 Heeling detected by Log box. Y
200000878-6-EN-GB 119
3.7 Detailed process description

This section gives a detailed description of the PureBallast processes. The
processes are divided into three main processes, with subprocesses, with
indications of automatic and manually initiated steps.
All steps are not valid for all installations.
3.7.1 Fuse settings for filter motor and installed (optional) pump motors
Follow this instruction to change the fuse settings for filter motor M709–43
(F2) and installed (optional) pump motors P401-1 (F3) (included in Closed
cooling unit, if installed), P309-1 (F4) and P403-1 (F5) in the electrical cabinet.
1. On the filter motor and installed (optional) pump motors: Find area on the
mark plate where information is displayed for the frequency used for the
system (50 or 60 Hz).
2. Look at voltage (V), stated as an interval.
3. Look at interval for Imax amp setting (A), also stated as an interval.
4. Make an estimation for Imax amp setting, so that it “match” the voltage in
the range from min to max.
5. On the fuse: Press Reset button until LEDs flash (6 seconds).
6. Turn the potentiometer to estimated amp setting according to mark plate.
7. Check that the setting is correct according to the LEDs. Compare to the
table below.
8. Press Reset button to save the value.
120 200000878-6-EN-GB
3.7.2 Standby mode

Standby mode is the starting point of PureBallast. Standby mode is active
when no other process is active. Pumps, motors and UV lamps are not
running and all valves are closed.
The following processes can be started from standby.
• Ballast
• Deballast
• Stripping
• CIP process
• Manual mode
Note: Any process can be stopped at any time.
Overview operation modes
3.7.2.1 Drain/Fill
Purpose: For service purpose there are buttons that drains UVR and filter as
well as fill UVR and filter. These buttons are only active in standby mode.
Stop button could be pressed anytime in the process.
Table 1: Activation table: Drain
200000878-6-EN-GB 121
Step Function
1. Drain button is
pressed by opera-
tor.
2. Pressure is re- Valves are opened for 10
x x x x x
leased. seconds to let pressure out.
When UVR level switch

3. UVR is drained. x x x x x x LS201-29 indicates dry con-
dition, p200 minutes.
Filter is drained for p317

4. Filter is drained. x x x x x seconds.
X = Valve open.
Table 2: Activation table: Fill
Step Function
1. Fill button is
pressed by opera-
tor.
UVR is filled with fresh wa-
2. UVR is filled with ter until level switch
x x x x
fresh water LS201-2 indicates wet con-
dition.
Filter is filled with fresh wa-

3. Filter is filled with ter.
fresh water xa) x
V310-1 is closed when
PT201-71 > 1.0 bar.
4. Pressure is re- Valves are opened to let
x x
leased pressure out.
X = Valve open.
Until PT201-71 > 1.0 bar (+ 5 seconds)
122 200000878-6-EN-GB
3.7.3 Ballast process

The ballast process and subprocesses are illustrated and described below.
3.7.3.1 Startup ballast

Purpose: To warm the UV lamps under controlled conditions before water
treatment.
Table 3: Activation table: Startup ballast
Step
1. Start
The operator starts the ballast
process manually.
2. UVR and filter are filled

with fresh water
Valves are opened for freshwa-
ter filling of UVR and filter. x xa) xa) xa) xa) xc) xa)
5 seconds of delay to ensure

wet condition.
3. Power request
Automatic power request from
PureBallast to vessel’s power x x
management system (if inte-
grated b)).
4. UV lamps are started

Counter: UV lamp runtime, is x x x
started.
200000878-6-EN-GB 123
Step
5. UVR cooling is activated

The cooling process is started
if UVR temperature reach p225
degrees. Fresh water flows
throw UVR and out by main x xd) xd) x x
line 201.
Valves are opened for fresh
water. If temperature falls,
valves are closed d).
6. BW pump is started
Request from control system to
start ballast water pump (out-
side PureBallast system).
BW pump is started by opera-
tor and confirmed in control x xd) xd) x x
system (Handled automatic, if
external component signal is
enabled.) . If not confirmed
within 20 seconds, lamp power
is reduced to 50 % until confir-
mation, and then increased to
100 %.
7. Inlet is opened
Counter: Accumulated water is,
started. x x xd) xd) x x
Flow is established to over
10 % of maximum flow (p315).
8. UVR cooling is inactivated

Valves for fresh water are
closed if opened. x x x x
Counter: CIP required is star-
ted.
X = Valve open.
a) Open if LS201-29 indicate dry condition. Close when LS201-29 indicate wet
condition.
b) If (P127) activated. Otherwise this step is ignored.
c) Open V201-8 to 50%.
d) Open if UVR temp >(p225). Close when UVR temp below (p225 – 3)°C.
3.7.3.2 Full ballast

Purpose: To treat ballast water.
Subprocess: Filter backflush with purpose to clean the filter. This subprocess
is either triggered when the filter differential pressure is more than p305 bar or
by time interval every 30th minute. It can also be started manually. It is
normally repeated several times during a ballast process.
124 200000878-6-EN-GB
Table 5: Activation table: Full ballast
Step *
1. Full ballast
To treat ballast water during bal- x x xa) xc)
last operation.
2. Flow control
Automatic control of control valve
V201-8 is started based on input
from the flow meter, and input
from UV sensor (QT201–50) and
salinity (conductivity sensor x x xa) xc)
QT201–1 and temperature sensor
TT201–33).
USCG mode: flow control is star-
ted based on input from UV sen-
sor (QT201–50).
200000878-6-EN-GB 125
Step *
3. Filter backflush
Subprocess: Filter backflush trig-
gered.
• Pressure control
Automatic pressure control of
control valve V201-8 is started
based on input from the pres-
sure transmitter.
• Backflush
After p310 seconds; filter mo-
tor M709–43 is started.
Backflush pump p309-1* is
started.
Backflush valve V309-1 is
opened.
Filter backflush is performed
for p308 seconds. x x x xb) (x) xc)
• Backflush is stopped
M709–43 is stopped.
V309-1 is closed.
If option backflush pump;
Pump is stopped and back-
flush valve is closed.
Automatic flow control of con-
trol valve V201-8 is started
based on input from the flow
meter.
• Differential pressure check
If necessary, the process is re-
peated. If a new backflush is
triggered within 10 minutes
(p302), a continuous backflush
will be started and run for p303
minutes.
4. Power optimization
After 2 minutes in full ballast:
power optimization is started x x xa) xc)
based on input from UV sensor
QT201–50.
5. Full ballast x x xa) xc)
*Optional.
X = Valve open.
a) Regulates flow to certified.
b) Regulates pressure based on PT201-16.
c) Regulates lamp power based on QT201-50.
3.7.3.3 Stop ballast

Purpose: To stop the ballast process.
126 200000878-6-EN-GB
Before the UVR and all valves are stopped, a backflush is done. It means that
after the operator pressed the stop button the flow to tanks continue for 20-30
seconds during backflush before the system is stopped.
Table 6: Activation table: Stop ballast
200000878-6-EN-GB 127
Step *
1. Initiate Stop
The ballast process is stopped by
the operator. x x x x x
Counter: Accumulated water vol-
ume, is stopped.
2. Filter backflush
Backflush sequence is started.
Extended backflush disabled.
• Pressure control
Automatic pressure control of
control valve (V201-8) is star-
ted based on input from the
pressure transmitter.
• Backflush
After p310 seconds; filtermotor x x x x x x (x)
M709–43 is started.
Backflush pump p309–1* is
started.
Backflush valve V309–1 is
opened.
Filter backflush is performed
for p308 seconds.
• Backflush is stopped
Backflush pump (if used) is
stopped.
3. BW pump is stopped
Request from control system is
sent to stop ballast water pump x x x x x
(outside PureBallast system).
(Handled automatic, if external
component signal is enabled.)
4. Valves are set

Control valve (V201-8) is closed
to p113 %.
When one of the following occurs,
V201–3 is closed:
• BW pump stopped. xa) x x x x x
• Flow is below p116.

• 10 seconds timeout.
V460–4 and V320–4 are opened
to release pressure from filter.
128 200000878-6-EN-GB
Step *
5. UVR lamps are stopped

V201–8 is completely closed.
V201–19 is closed.
UV lamps are lit at 100% for 10
sec, then switched off.
Counter: UV lamp cooling time is x x x x x
started. A new process can only
be started after UV lamps have
been cooled down for 5 minutes.
Counter: UV lamp run time, is
stopped.
Automatic withdrawal of power al-
location if integrated (p127).
6. All ballast valves are closed

Confirmation that BW pump is
stopped by operator. (Handled au-
tomatic, if external component
signal is enabled.)
V460–4 and V320–4 are closed.
Popup reminder “Start CIP”. Op-
tion to start CIP or delay.
X = Valve open.
*Optional.
a) Closed after 10 seconds or when BW pump stopped or when flow below
p116 %.
200000878-6-EN-GB 129
3.7.4 Deballast process

The deballast process and subprocesses are illustrated and described below.
3.7.4.1 Startup deballast

Purpose: To warm the UV lamps under controlled conditions before water
treatment.
Table 7: Activation table: Startup deballast
Step
1. Start
The operator starts the de-
ballast process manually.
2. UVR is filled with fresh

water
Valves for freshwater filling
of UVR and filter are x xa) xa) xa) xc) xa)
opened.
5 seconds of delay to ensure
wet condition.
3. Power request
Automatic power request
from PureBallast to vessel’s x x
power management system
(if integrated b)).
4. UV lamps are started

Counter: UV lamp runtime, is x x x
started.
130 200000878-6-EN-GB
Step
5. UVR cooling is inactiva-

ted
The cooling process is star-
ted if UVR temperature
reach p225 degrees. Fresh
water flows throw UVR and x xd) xd) x x
out by main line 201.
Valves are opened for fresh
water. Valves are closed if
temperature falls d).
6. BW pump is started
Request from control system
to start ballast water pump
(outside PureBallast sys-
tem).
BW pump is started by oper-
ator and confirmed in control x xd) xd) x x
system (Handled automatic,
if external component signal
is enabled.). If not confirmed
within 20 seconds, lamp
power is reduced to 50 %
until confirmation, and then
increased to 100 %.
7. Inlet is opened
Counter: Accumulated water,
is started. x x xd) xd) x x
Wait for flow to establish
over 10 % of maximum flow
(p315).
8. UVR cooling is inactiva-

ted
Valves for fresh water are x x x x
closed if opened.
Counter: CIP required, is
started.
X = Valve open.
a) Open if LS201-29 indicate dry condition. Close when LS201-29 indicate wet
condition.
b) If (P127) activated. Otherwise this step is ignored.
c) Open V201-8 to 50%.
d) Open if UVR temp >(p225). Close when UVR temp below (p225 – 3)°C.
3.7.4.2 Full deballast

Purpose: To treat ballast water
200000878-6-EN-GB 131
Table 8: Activation table: Full deballast
Step *
1. Full deballast
To treat ballast water during de- x x xa) xc)
ballast operation.
2. Flow control
Automatic control of control valve
V201-8 is started based on input
from the flow meter and input
from UV sensor (QT201–50) and
salinity (conductivity sensor x x xa) xc)
QT201–1 and temperature sen-
sor TT201–33).
USCG mode: Flow control is
started based on input from UV
sensor (QT201–50).
3. Power optimization
After 2 minutes in full deballast:
Power optimization is started x x xa) xc)
based on input from UV sensor
QT201–50.
4. Full deballast x x xa) xc)
X = Valve open.
a) Regulates flow to certified.
c) Regulates lamp power based on QT201-50.
*Optional.
3.7.4.3 Stop deballast

Purpose: To stop the deballast process.
132 200000878-6-EN-GB
Table 9: Activation table: Stop deballast
Step *
1. Stop is initiated
The ballast process is stopped by
the operator. x x x x x
Counter: Accumulated water vol-
ume, is stopped.
3. BW pump is stopped
Request from control system to stop
ballast water pump (outside Pure- x x x x x
Ballast system). (Handled automat-
ic, if external component signal is
enabled.)
4. Valves are set

Control valve (V201-8) to (p113) %
is closed. xa) x x x
Delay for 10 seconds, then V201-9
is closed.
200000878-6-EN-GB 133
Step *
5. UV lamps are stopped

Counter: UV lamp cooling time, is
started. A new process can only be
started after UV lamps have been
cooled down for 5 minutes. x x x
Counter: UV lamp run time, is stop-
ped.
Automatic withdrawal of power allo-
cation if integrated (p127).
6. All deballast valves are closed

V201–8 is completely closed.
V201–19 is closed.
Confirmation that BW pump is stop-
ped by operator. (Handled automat-
ic, if external component signal is
enabled.)
Popup reminder “Start CIP”. Option
to start CIP or delay.
X = Valve open.
*Optional.
a) Closed after 10 seconds or when BW pump stopped or when flow below
p116 %.
134 200000878-6-EN-GB
3.7.5 Stripping
Purpose: To treat stripping water.
The stripping process works as a deballast operation, but the power
optimization is deactivated, which means that the lamps are lit to 100 %.
200000878-6-EN-GB 135
3.7.6 CIP process

Purpose: The CIP process is run to remove seawater scaling from the UV
reactor after ballast and deballast. The process shall be peformed within 30
hours after last ballast/deballast operation.
CIP process start is not possible until reactor cooldown period is finished.
Stop button could be pressed anytime in the process.
Table 10: Activation table : CIP sequence
Step
1. Standby
Operator starts the CIP
process.
2. Pressure is released
Valves are opened for 10 x x x x x
seconds.
3. UVR is drained from

ballast water
De-ariation valve (V571–1) x x xa) x x x
is opened 5 seconds after
pump P460–1 is started.
136 200000878-6-EN-GB
Step

water
Valves opened for fresh
water through CIP to UVR. x x x x
Valves are closed when
LS201-29 indicate wet con-
dition.
5. CIP fluid is injected

Pump (P320–1) is started
to pump concentrated CIP
liquid to UVR. x x x x x x
Valves are opened from
the dosage pump into the
UVR and start the pump.
6. UVR is CIP cleaned

Pump (P460–1) is started
to circulate the CIP liquid x x x x x
for p402 minutes. Repeat
each p401 minutes.
Stopped after p400 hours.
7. UVR is drained from

CIP liquid
When UVR level switch
LS201-29 indicates dry x x x x x x
condition, p200 minutes.
Valves are closed and
P460–1 is stopped.

water
Valves are closed for fresh x x x x
water filling when
LS201-29 indicate wet con-
dition.
9. Fresh water is circula-

ted
Fresh water is mixed for 30 x x x x x
seconds in all pipes. Then
UVR and CIP are drained.
10. Filter is drained from

ballast water
Filter is drained for p317
seconds. x x x x x
Note: After deballast the fil-
ter will only be drained
50 % of p317 time.
200000878-6-EN-GB 137
Step
11. Filter preservation

Filter is filled with fresh wa-
ter. x x
V310-1 is closed when
PT201-71 > 1.0 bar.
12. Pressure is released

Valves are opened for 10 x x
seconds to let pressure
out.
X = Valve open.
a) Wait 5 sec to open.
138 200000878-6-EN-GB
3.7.7 Manual mode

PureBallast can be set in manual mode, which enables the operator to operate
components manually.
The following can be performed in manual mode:
• Operate components from control panel.
The following limitations exist for manual mode:
• Requires login level; Advanced operator or higher. The Manual button is
only displayed for login level Advanced operator.
• Flow in pipes is not indicated in flow chart.
• Can only be activated from standby mode.
• No automatic processes can be run.
If another operator take over command by logging in on another control panel,
manual mode is deactivated, and the system returns to standby.
See instructions Operate components manually on page 101 and Operate UV
lamps manually on page 103.
200000878-6-EN-GB 139
3.8 Quick guide

3.8.1 Introduction
This is a quick guide to the most common routines performed in the
PureBallast control system. More detailed instructions are found in the
PureBallast manual.
This guide covers the following routines:
• Ballast and deballast
• CIP clean UV reactor (UVR)
• Basic alarm handling
• Save log files to USB memory
• The Alarm list page 2.1 must be controlled to verify that there are no alarms
needing attention.
3.8.2 Ballast, deballast or strip

The following instructions are applicable for Ballast, Deballast and Strip
procedure.
1.
Press to login as operator with password aot.
2.
Press to check that there are no active alarms needing attention.
3.
Select the applicable flow setting. Press and to
change flow setting.
4.
Press the Ballast, Deballast, or Strip function button to
start.
a. If the popup windows are displayed, follow the instructions in them.
5.
Press Stop button after processing desired amount of water.
a. If the popup windows are displayed, follow the instructions in them.
6. A CIP reminder is displayed. Chose to CIP the system or to wait.
140 200000878-6-EN-GB
3.8.3 Alarm handling

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

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

• The system must be in stand by mode.
• Complete status information regarding CIP is displayed in page 1.4 CIP
status. The page displays remaining time for ongoing CIP cycles, remaining
time before individual UVRs are required to be CIP:ed etc.
1. Go to page 1.1 Overview.
2.
Press the CIP button.
3. If popup windows are displayed, follow the instructions in them.
4. Close the overboard valve after the process is finished.
3.8.5 Export control system log files

Follow this instruction to copy control system information as text files to a USB
memory.
• Required USB memory.
1. Insert a USB memory in USB PLC port on the cabinet door.
2. Go to page 4.1 System info.
3. Press the Export button in page section Export log files.
200000878-6-EN-GB 141
4. Popup Export PLC events is displayed.
5. Do not specify time interval.

6. Press Events to copy the information to the USB memory.
7. After export is completed, press Alarm.
8. Press Close and remove the USB memory.
142 200000878-6-EN-GB
EN
4 Parameters
200000878-6-EN-GB 143
EN 4 Parameters
4.1 Introduction
This chapter contains information about parameters in the control system and
parameter controlled components. It covers:
• Parameter page descriptions.
• Parameter lists including information about setting range, default values
etc.
4.2 Control system parameters

This section describes all parameters set in the PureBallast control system.
• Parameters shall only be set when the system is in mode Standby.
• Only authorized trained personnel must set parameters in the control
system. The PureBallast equipment or connected equipment can be
irreparably damaged if set or handled incorrectly.
• The parameter settings can be exported to a USB memory for safety
backup, and be restored from a backup. See chapter 3. Operating
instructions and control system description for instructions.
• Parameters are valid for PLC software version 3.2.2.3.
• Parameters are roughly sorted by area, for example UV reactor, filter and
remote interface, but the sorting is not strict.
4.2.1 Introduction to parameters and parameter settings

All parameters are checked and adjusted at first start up during
commissioning.
NOTE Parameters shall normally be set by Alfa Laval.
Login level 2 or 3 is required to change parameters. Login level 2 gives access to

set parameters, with exception from crucial parameters, which requires level 3.
Parameters are divided into four categories according to table below:

Parameter must be considered during commissioning. The
parameter should match the conditions of the installed sys-
tem. After that, the parameter should normally not be
changed.
Parameter should never be changed. Parameter only exist
to allow advanced faultfinding by Alfa Laval.
Parameter should normally be left alone. If there are specific
No icon reasons, the parameter may be changed.
Parameters in bold can only be changed by login level Alfa
p000 Laval. Parameters in normal text can be changed by login
level Advanced operator.
144 200000878-6-EN-GB
Parameters 4 EN
Follow this instruction to set parameters

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

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

Result: A keyboard is displayed.
4. Enter the setting and confirm by touching the Enter button. To close the
keyboard without saving data, touch the Esc button.
If the parameter is set with a drop down menu, select desired choice by
touching the value.
Result: The setting is saved directly, it is now safe to leave the page.
200000878-6-EN-GB 145
EN 4 Parameters
4.2.2 Page 5.1 — Main parameters

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

value
Setpoint for shut down due to high pressure
at PT201–16. Default value shall be used for
p100 High pressure, shut- standard system.
down trigger 6.00 0–10 bar Max working pressure for standard system: 6
(PT201–16) bar.
Max working pressure for high pressure sys-
tem: 10 bar.
Safety margin between defined max flow and

actual max flow to avoid unnecessary shut
Undershoot certified down.
p111 5 0–80 %
flow If flow meter FIT 201–1 is installed with a
bend before and after the parameter should
be set to at least 2 %.
During process, valve V201–8 handles the

automatic pressure and flow control.
This parameter defines minimum opening, to
secure a smooth and compliant process. The
Min opening for
p113 28 10–100 % parameter is set by Alfa Laval during commis-
V201–8 sioning.
Note: It is not allowed to set the parameter to
100 %, since the valve must be able to con-
trol flow and pressure.
Defines proportional gain (Pf) value used for
PID regulation of V201–8 during ballast and
p120 deballast.
0.00– Normal value: 0.1 – 1.5.
PID proportional gain 0.30 N/A
10.00
The PID regulation during ballast and debal-
last is based on input from flow meter FT201–
1.
Defines integral time (If) value used for PID
p121 regulation of V201–8 during ballast and de-
ballast.
PID integral time 5.00 0–100 sec
Normal value: 5 – 12.
For details, see p120.
146 200000878-6-EN-GB
Parameters 4 EN

value
Time the control system will wait for confirma-
tion (hard wired from ISCS or manually in
popup). After defined time, the process is
Timeout: Request stopped.
p141 3 1–3 min
“Start BW pump”
The parameter is used for both BW pump
during ballast/deballast and for stripping
pump during stripping.
Timeout: Start-up Time the control system will wait for accepted
p144 process flow estab- 60 30–180 sec minimum flow (10 % of full capacity) to be es-
lished tablished before automatic stop.
Defines proportional gain (Pf) value used for

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

p167 regulation of V201–8 during backflush.
Pressure PID integral 2.0 0.0– sec This parameter shall normally not be
time 100.0 changed.
Normal value: 5 – 12.
Defines how long time the water must remain

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

booster pump will try to maintain.
p186 The variable-frequency drive (VFD) (optional)
Booster pump P201– gets information about the PureBallast water
1 setpoint (PT201– 0.5 0.1–2 Bar pressure from the pressure sensor PT201–
16) 16. The VFD then controls the speed on the
booster pump and increases or decreases it,
so that the pressure is always according to
the value set in p186.
200000878-6-EN-GB 147
EN 4 Parameters
4.2.3 Page 5.2 — Main parameters

value
Defines lowest value PureBallast can request
from external feed. Only valid if external feed
(optional) is integrated. This means that
PureBallast is contolling ballast water flow by
sending signals to vessels ballast water
pump or throttle valve to control flow before
PureBallast.
If external feed controls a ballast water pump,
External feed min PureBallast will never request it to run on a
p155 50 50–100 %
setpoint lower speed than the percentage set in this
parameter. If a valve is controlled, the param-
eter defines percent open.
The parameter also defines starting point for
flow regulation when a process is started, to
ensure a smooth start with a gradually in-
creased flow until desired value is reached.
Default value should normally be used.
Defines how many seconds it takes to
p156 change the external feed signal 1%.
External feed change 5 2–30 s/% Note: It might take a little longer for the actual
rate
change of the pump or the valve to adjust the
flow.
Defines when external feed control is activa-
p157 ted, based on V201-8.
External feed V201– 70 50–90 % PureBallast will start to request reduced flow
8 low trigger limit
when V201-8 closes to reach this degree of
percent open.
Defines if stripping is used.

p170 Purpose: Enables stripping to be used with
stripping events written to event log. Possible
Stripping enabled Not used N/A Drop list to connect a stripping pump via hard wire or
remote interface to be used.
Alternatives: Activated or Not used.
148 200000878-6-EN-GB
Parameters 4 EN
4.2.4 Page 5.3 — UVR parameters

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

value Max
p200 tion that an UV reactor is drained before an
Timeout: Draining alarm is issued. Approximate value: 3 min.
10 1–30 min
(LS201–29) Recommended setting: Approximately 1 mi-
nute more than actual drain time. Set during
commissioning.
tion that technical water / potable water has
p201 filled the UV reactor before an alarm is is-
Timeout: Filling sued.
10 1–30 min
(LS201–29) Value between 1–12 minutes depending on
flow and UVR size.
Set during commissioning.
p202 Setpoint for high water temperature alarm, in-
High temp, alarm 60 10–100 ºC dicated by temperature transmitter in UV re-
trigger (TT201–33) actor.
p210
UV lamp warm-up Warm-up time for UV lamps before full ballast,
90 0–130 sec
time deballast or stripping starts.
p211
Cooling time for UV lamps after ballast or de-
UV lamp cooling time 300 180–600 sec ballast.
When temperature in UV reactor reach this

temperature, cooling water is lead to the UV
p225 Start reactor cooling 38 20–55 ºC reactor and out by main line 201. Cooling wa-
ter will be turned off when temperature re-
turns - 3 °C below this temperature.
UVR power limit to Measure total power during start-up. Checks
p226 80 50–100 %
start BWP when % of UVR max power exceeded.
200000878-6-EN-GB 149
EN 4 Parameters
4.2.5 Page 5.4 — Filter parameters

This section describes parameters controlling the filter module.

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

Extended backflush
p302 2 1–30 min pressure within this time, the filter will run an
time trigger extended backflush for p303 minutes.
Continous backflush Defines the duration for the extended back-
p303 20 10–30 min
length flush , after triggered by p302.
Defines desired pressure for efficient back-
flushing.
Set according to the result of vessel specific
calculations made based on information sec-
tion Pressure requirements in the system man-
ual or Design and installation guide.
p304
Pressure setpoint 1.5 When a backflush is triggered, control valve
1.0–5.0 bar
during backflush 2.0 V201–8 will regulate to reach this pressure. Af-
ter time set in parameter p310 the backflush
will start, regardless of if the pressure has
been reached.
During backflush pressure is maintained by
PID regulation of control valve V201-8, based
on input from the pressure transmitter.
p305 Setpoint for automatic start of filter backflush

Backflush trigger: due to dirt in the filter, indicated by high differ-
0.5 0.0–2.0 bar
Differential pressure ential pressure over filter (PT201-71 and
PT201-16).
p308
Backflush cycle time 40 20–100 sec Defines duration of one filter backflush.
150 200000878-6-EN-GB
Parameters 4 EN

value Max
Defines time between automatic backflush of
Time controlled the filter. Automatic backflushes are performed
p309 30 1–120 min
backflush interval with this set interval to secure performance, re-
gardless of current differential pressure.
Defines how long time that should pass from a
p310 backflush is triggered until is actually started.
Backflush initial de- 0 0–60
lay During this time, the control valve is PID regu-
lated to create the required pressure defined in
parameter p304.
p317 Time the control system will wait for confirma-

Timeout filter drain- tion that the filter is drained.
12 1–30 min
ing
Estimated value: 2 min.
p319 tion that water has filled the filter.
Timeout filter filling 12 1–20 min Estimated value: 6 min.
Set during commissioning.
After pressure 1 bar is reached, the system will

wait for defined number of seconds to secure
stable pressure in filter. If pressure falls below
p322 Filter filled timer 10 0–30 sec 1 bar during this time, filling starts again to
reach 1 bar. If pressure is over 1 bar, filter
preservation is completely stopped.
200000878-6-EN-GB 151
EN 4 Parameters
4.2.6 Page 5.5 — CIP parameters

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

p400 Duration of a CIP cy-
6.00 1–60 hours
CIP cycle time cle.
p401 Defines how often a

CIP circulation inter- 15 15–180 min CIP liquid circulation
val shall be started.
p402 Defines for how long

CIP circulation dura- time the CIP liquid
2 1–10 min
tion shall be circulated
each time.
Defines the amount
p403 of CIP liquid that is
CIP pump injection injected. 1 pulse ≈
30 15–200 pulses 11.5 mL.
volume
Value should be set
to 30.
p405 Defines flow rate for
CIP pump flow rate 1 1–10 Hz the CIP pump P320–
1.
152 200000878-6-EN-GB
Parameters 4 EN
4.2.7 Page 5.6 — Remote parameters

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

Data bits 8 N/A Drop list shall be used.
Alternatives: 7 or 8.
200000878-6-EN-GB 153
EN 4 Parameters

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

Modbus station num- 10 dress. The address must be unique for each
1–247 Drop list
ber PureBallast system communicating with com-
mon ISCS (ship system).
154 200000878-6-EN-GB
Parameters 4 EN
4.2.8 Page 6.1 — Installation parameters

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

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

p127 Alternatives:
Power management Not used • Not used
• Hardwired
• Remote interface (requires that p132 is activated)
Defines if remote interface (optional) is used and connected via

modbus.
p132
Remote interface via Not used If connected, the Local and Remote buttons are visible in the con-
modbus trol panel. They are used to choose if operation shall be done from
the remote interface or a control panel.
Defines if an external system stop button (or signal) is installed.

p135
External system stop Not used Purpose: Ongoing process is stopped and the system goes to
standby.
200000878-6-EN-GB 155
EN 4 Parameters
ID Parameter Default Description

value
Only valid if RMC protocol is used for GPS integration.
If activated, time and date in the control system is retrieved from
vessel’s GPS.
p160 GPS Not used
If no GPS is connected, time and date must be set in control sys-
tem page 4.2 System 2.
Defines if the system is an USCG system according to the system

plate on the control cabinet. If activated, it is possible to run the
system in USCG mode and IMO mode. This is changed by the
IMO and USCG function buttons.
Note: This parameter can only be activated for a USCG system.
p180 Alternatives:
USCG
USCG system 3d+0d • USCG 3d+0d: It is possible to choose to run process in 3 days
or 0 day hold-time mode. This is set in parameter p182. This al-
ternative is system set and not changeable.
• Not used.
• USCG 3 days: It is only allowed to treat water with 3 days hold-
time.
Defines size of the UV reactor, defined as max capacity (m3/h).

p217 Used to determine certified flow and if one or two LDC´s is used in
UV reactor size the system.
1000
(m3/h)
Alternatives: 170, 300, 600 and 1000
Set parameter to: 170
Defines filter capacity.

Alternatives: 85, 135, 170, 250, 300, 500, 750, 1000.
p315
Set parameter to: 170
Filter size (m3/h) 1000
Note: Do not set the parameter according to actual filter size ac-
cording to the marking plate on the filter. The setting should corre-
spond to maximum ballast flow. See item 201 in in the Connection
list in chapter 6. Installation description and drawings.
p318 Defines if a backflush pump P309–1 (optional) is used to create

Backflush pump Not used sufficient flow in pipe 309 during backflush.
(M703–1)
p500 Defines if the logbox (optional) is installed to monitor and log exter-
nal valves and pumps, that are not part of Alfa Laval’s scope of
Log box Not used supply.
156 200000878-6-EN-GB
Parameters 4 EN
4.3 Lamp power supply (LPS) parameters

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

The DIP switches should be set according to the table below.
Leave switches 1-3 in the same position as when delivered.
Switch 4-8 is set to identify the individual LPS according to the table below
(only position ON is indicated). For empty cells, set switch 4–8 to OFF.
Note:
LPS 1–3 are installed in the electrical cabinet.
SW SW SW SW SW
SW SW SW 4 5 6 7 8
1 2 3
(16) (8) (4) (2) (1)
LPS 1 ON
LPS 2 ON
LPS 3 ON ON
Example
In the illustration, the DIP switches is set for LPS no. 5.
200000878-6-EN-GB 157
EN 4 Parameters
4.4 Fuse settings for filter motor and installed (optional)

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

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

The parameters are pre-set in the flow meter transmitter.
158 200000878-6-EN-GB
EN
5 Alarms and faultfinding
200000878-6-EN-GB 159
EN 5 Alarms and faultfinding
5.1 Introduction
This chapter covers information about alarms and warnings, together with
information about how to solve the problems causing the alarms to trip. The
chapter also contains a list of solutions for problems that may occur, but that is
not indicated by any system. The chapter contains lists of alarms indicated by:
• Control system.
• Lamp power supply (LPS).
• Flow meter (with fault finding instruction).
• I/O system and X20 modules.
See chapter Operating instructions and control system description on page 41
to find information about the alarm pages and how to attend to alarms.
5.2 List of alarms and warnings

This section lists all alarms and warnings.
5.2.1 Control system

This section lists all alarms and warnings in the PureBallast control system.
The alarms are sorted in a strict numerical order.
Alarm Indication
An alarm or warning will activate the alarm buzzer (sound and light) on the
cabinet. The sound is silenced by acknowledge the alarm. On remote control
panel it is silenced by touching the buzzer, but note that the alarm is not
acknowledged by this. Alarms will shut down ongoing process and disable the
start of the process.
Warnings are information to the operator and will not shut down ongoing or
disable start of process.
Alarms and warnings are indicated in the following ways in the control panel.
Alarms
• The icon in the alarm tab starts to blink.
• The icon is also displayed by the faulty component in the screen.
• A red light in the exclamation mark on the alarm panel frame is lit.
• A sound is issued.
• A blinking light indicates a new alarm
• An acknowledged alarm is indicated by a steady light.
Warnings
Warnings is indicated in the same way as alarms, but with the yellow sym-
bol to the left. No sound is issued for warnings, except for, for example
W11, W12, W151, 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.
160 200000878-6-EN-GB
Alarms and faultfinding 5 EN
Key to the table of alarms and warnings

The following information is available in the List of alarms and warnings. Note
that all of the below is not applicable for all alarms/warnings.
ID number of the alarm. First letter indicate if it is an alarm or a warning.
• A: Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
• W: Warnings are notification of a status change or a problem. Warnings
allow the process to continue.
Alarm/warning name
Trigger: Source of the alarm or warning, identified by the input sensor's item
number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.
Detailed information sorted on the following headings, when applicable:
Delay: Time before the alarm is activated after the condition of the alarm is
met.
Comments: Additional information or explanations.
Possible cause: Possible causes that might have triggered the alarm.
What to do? Suggested action to solve the problem.
List of alarms and warnings

The table explains alarms triggered by and displayed in the control system.
Alarm details Possible cause What to do?
A01 Check pressure and flow from bal-
last pump(s). If the pressure ex-
Process pressure too high ceeds set value: Adjust incoming
(PT201-16). pressure to PureBallast.
Trigger: PT201–16. Ballast water pump gives too high Control that correct valves are func-
Parameter: p100. pressure. tioning and opened for current
process. See Detailed process de-
Delay: 30 sec. scription on page 120.
Comment: Pressure transmitter Valves in the system after pressure Control that correct valves are func-
PT201-16 indicates pressure higher transmitter are closed. tioning and opened for current
than set in parameter p100. process. See Detailed process de-
scription on page 120.
Material is stocked after pressure Check the entire system for block-
transmitter PT201-16. ing material.
Pressure transmitter PT201-16 is 1. Check cables to pressure trans-
faulty. mitter PT201-16. See circuit di-
agram for electrical cabinet, in
section Electrical drawings on
page 256.
2. Replace pressure transmitter
PT201-16.
200000878-6-EN-GB 161

A03 Signal missing or pressure trans- 1. Check fuses F41–F44 in electri-
mitter PT201-16 malfunction. cal cabinet to see what circuit
Process pressure signal missing caused the fuse trip.
(PT201-16).
Trigger: PT201-16. 2. Use the circuit diagram, for
electrical cabinet, in section
Delay: 30 sec. Electrical drawings on page 256
to check the fuse setting, adjust
Comment: Error in system pres- according to figures in circuit di-
sure sensor. Indication of pressure agram if necessary and reset
-1.0 bar is not an error. fuse.
3. Use the circuit diagram to lo-
cate the component or find the
reason that caused the fuse trip
and attend to it.
4. Check that all electrical connec-
tions are OK and that the elec-
trical wiring is not damaged.
5. Replace transmitter PT201-16.
A05 The inlet and/or outlet air filter is Clean the filters.
dirty.
EC air temp high (TT401). Trigger:
TT401 in electrical cabinet. Mechanical obstacles. Check that mechanical parts in the
fan can rotate freely.
Delay: 15 sec.
Ambient temperature is too hot. Wait until cooler.
Comment: Temperature in electri-
cal cabinet over 60 °C. Electrical problem. Check that all electrical connec-
tions are OK and that the electrical
wiring is not damaged. See Electri-
cal cabinet / Circuit diagram on
page 263.
A06 Signal missing or temperature See A05.

transmitter malfunction.
EC cabinet air temp missing
(TT401). Electrical problem. See A05.
Trigger: TT401 in electrical cabi-
net.
Delay: 5 sec.
Comment: Signal from TT401 is
missing.
W07 Faulty connection of signal cable or 1. Check cables to the component

faulty cable. “M1 fan”. See Electrical cabi-
EC cabinet fan error. net / Circuit diagram on page
Trigger: Fan speed counter in elec- 263.
trical cabinet. 2. Check fuses F41–F44 in electri-
Delay: 60 sec. cal cabinet.
Obstructions have entered the fan. Turn off the power and remove the
obstruction.
162 200000878-6-EN-GB

A10 Signal missing or flow meter 1. Check fuses F41–F44 in electri-
FT201-1 malfunction. cal cabinet to see what circuit
Process flow signal missing caused the fuse trip.
(FT201-1).
Trigger: Flow meter FT201-1. 2. Use the circuit diagram for elec-
trical cabinet, in section Electri-
Delay: 5 sec. cal drawings on page 256, to lo-
Comment: Error in system flow reason that caused the fuse trip
sensor. and attend to it.
4. Check that system flow has not
been significantly over maxi-
mum flow for the system.
5. Replace memory card or mod-
ule carrier. See instruction in
chapter 7. Service manual.
6. Replace flow meter.
W11 Signal missing. 1. Check fuses F41–F44 in electri-

cal cabinet to see which circuit
Conductivity signal missing that caused the fuse trip.
(QIT201–1).
2. Use the circuit diagram to
Trigger: Conductivity sensor check the fuse setting, adjust
(QT201–1) in flow meter FT201-1. according to figures in circuit di-
Delay: 20 sec. agram if necessary and reset
fuse.
and attend to it.
4. Check cables to FT201-1. See
circuit diagram for electrical
cabinet in section Electrical
drawings on page 256.
5. If the above is OK, the conduc-
tivity sensor is probably broke
and needs to be replaced. Re-
place the component.
W12 Flow rate higher than selected cer- Reduce the incoming ballast water
tified flow. See field certified flow in flow to the PureBallast system.
Process flow higher than certified. Page 1.2 – Overview on page 60.
Process not compliant. Reduce
flow! Wrong setting in FT201-1 See chapter Parameters on page
143.
Trigger: FT201-1.
Delay: 30 sec. Flow sensor malfunctions. See section Flow meter in List of
alarms and warnings on page 160.
Note: Operation continues but is
not compliant and does not fullfil re-
quirements for treatment of ballast
water. Act according to ballast wa-
ter management plan.
200000878-6-EN-GB 163

A13 Flow is too low. 1. Increase flow.
Process flow too low FT201-1. 2. Make sure the ballast water
from the ballast pump is direc-
Trigger: FT201-1. ted to PureBallast. When OK
Delay: 20 sec. the process will continue auto-
matically.
Comment: If flow is less than 17
m3/h, the system is shut down. 3. Check pressure and flow from
ballast pump(s). Adjust incom-
ing pressure to PureBallast, if
necessary.
Wrong setting in FT201-1 See chapter Parameters on page

143.
Flow sensor malfunctions. See section Flow meter in List of

alarms and warnings on page 160.
Valves in ballast system closed. 1. Control that correct valves are
opened for current process.
See Detailed process descrip-
tion on page 120
2. Check mechanical function of
the valve and check that the ca-
bles to the component is ac-
cording with the circuit diagram
for electrical cabinet in section
Electrical drawings on page
256.
Ballast water pump stopped or mal- Attend to. Note: This component is
functions. outside the PureBallast system
control.
A14 See possible cause for A13.
Insufficient flow during startup Control valve V201–8 malfunctions. See A29.
(FT201–1).
Trigger: FT201-1.
Delay: Flow must be established
within the time set in parameter
p144.
Comment: If flow is less than min
flow the system is shut down.
164 200000878-6-EN-GB

A17 Fuse tripped. 1. Check fuses F41–F44 in electri-
cal cabinet to see what circuit
Valve error (V201-3). caused the fuse trip.
Trigger: Limit switch GS201-3. 2. Use the circuit diagram for elec-
Delay: 40 sec. trical cabinet, in section Electri-
cal drawings on page 256, to
Comment: Error on valve V201–3. check the fuse setting, adjust
according to figures in circuit di-
agram if necessary and reset
fuse.
3. Use the Circuit diagram to lo-
and attend to it.
tions to actuator and sensors
on the valve are OK and that
the electrical wiring is not dam-
aged.
Position sensor can not detect the Adjust sensor or puck.

metal on the puck on the actuator,
or the metal is in wrong position. Hint: Valves can be manually oper-
ated. See instruction Operate com-
Position sensor mounted upside ponents manually on page 101 and
down. Open and close valves manually in
section Valves on page 359.
Position sensor or cables to posi- 1. Check cables.
tion sensor malfunction.
2. Replace position sensor if faul-
ty.
Too long opening/closing time 1. Follow the instruction Adjust

(valve travel time). valve traveling speed for V212–
31 (optional) on page 372.
2. Check that instrument air pres-
sure is according to require-
ments in Connection list on
page 205.
Valve block malfunction. Check LED indication on the valve

block contact. Use the sticker on
the valve block to interpret the indi-
cation.
The red LED on the valve block
contact lights if opening signal
comes to the valve block. If the
LED lights, and air is supplied, al-
though the valve malfunctions, the
valve block is faulty: Replace valve
block.
Pilot valve on actuator malfunction. • The red LED on pilot valve con-
tact lights if opening signal
or comes to the pilot. If the LED
Valve cannot open/close due to ob- lights although the valve mal-
struction. functions, the pilot valve is faul-
ty: Replace pilot valve.
• Clean. If required dismount
valve. See Service manual on
page 315 for instructions.
200000878-6-EN-GB 165

A23
Valve error (V201-9).
Trigger: Limit switch GS201-9. See possible cause for A17.
Delay: 40 sec.
Comment: Error on valve V201–9.
See possible cause for A17.
1. Check open indication in the
pneumatic positioner.
2. Check fuses F41–F44 in electri-
caused the fuse trip.
• Sensor error. Shows open all 3. Use the circuit diagram to lo-
A29 the time. cate the component or find the
Valve error (V201-8). • Signal error 4–20 mA. and attend to it.
Trigger: Limit switch IP201-8 4. Check that all electrical connec-
Delay: 40 sec. tions to actuator and sensors
on the valve are OK and that
Comment: Error on control valve the electrical wiring is not dam-
V201–8 aged.
Positioner is not correctly set or Calibrate according to Calibrate po-

calibrated. sitioner on V201-8 on page 367.
Cam wheel not correctly set in posi- Adjust according to Adjust cam po-
tioner, which results in wrong feed sition on V201-8 on page 370.
back to control cabinet.
The air filter on the positioner is Clean the filter.
clogged.
W33 Bypass valve has been opened If not opened intentionally, close
manually or via the ISCS. opened bypass valve.
Bypass valve is open (V212-31).
Trigger: Bypass valve(s).
Specific for this warning compared
Delay: 40 sec. to A17:
Comment: If the valve (not control- If not opened: See possible cause • Check relay K5 and K6 on mod-
led by PureBallast) is opened dur- for A17. ule X10.
ing operation, the operation will
continue. A visual and audible • Check barrier TI2.
alarm will be triggered.
W52
External stop requested.
Trigger: External stop button.
Parameter: p135. Check that all electrical connection
If this alarm is visible in the alarm
Delay: 15 sec. list, the button is still pressed, inten- is OK.
tionally or unintentionally. Make sure that the button is OK.
Comment: The alarm is visible af-
ter the button has been pressed for
15 seconds. When the button is re-
leased, the alarm is automatically
acknowledged and moved to 2.2
Alarm list.
166 200000878-6-EN-GB

A58 2. Use the circuit diagram to lo-
Fuse tripped in cate the component or find the
Short circuit. reason that caused the fuse trip
EC. Trigger: Fuse in electrical cabi- Overheated fuse. and attend to it.
net.
3. Use the circuit diagram for elec-
Comment: EC fuse alarm trical cabinet to check the fuse
size, adjust according to figures
in circuit diagram if necessary
and reset fuse.
W69
Remote interface: External bypass
is open. Bypass valve opened by ISCS via If not opened intentionally, close
remote interface. opened bypass valve.
Trigger: External bypass valve.
Delay: 10 sec.
Check that all electrical connec-
A71 tions are OK. Check that the signal
wiring is according to information in
Ballast water pump is not running. Faulty connection of signal cable. Electrical cabinet / Interconnection
Trigger: Control system timer. diagram, in section Electrical draw-
ings on page 256.
Parameter: p141.
If remote interface (optional) is Test relevant addresses. See Test
Delay: Set in parameter p141. used: Communication between remote interface communication on
PureBallast and ISCS is wrong. page 110.
Comment: Feed back signal “BW
pump is running” is not activated af-
Time set in parameter is lower than Check/change parameter in control
ter request. system page 5.1 – Main parame-
needed. ters 1.
A72
Stripping pump is not running
Trigger: Control system timer.
Parameter: p141. See possible cause for A71.
Delay: Set in parameter p141.
Comment: Feed back signal “BW
pump is running” is not activated af-
ter request.
Power management master system Investigate if the reasons for not
A79 not granting power to UV reac- granting power is outside the Pure-
tor(s). Ballast system.
Power is not granted.
Trigger: Control system timer. See A71.
Delay: 60 sec. Check signal transmission to/from

Feedback signal from power man- PureBallast corresponds to the
Comment: Process is not started, agement master is faulty. specifications in Electrical cabinet /
since power is not granted. Interconnection diagram, in section
Electrical drawings on page 256.
200000878-6-EN-GB 167

W82
Heeling mode requested by opera-
tor.
Trigger: ISCS.
Delay: 10 sec.
If heeling mode has not been re-
Comment: Ongoing process (bal- quested: See first two possible cau-
last, deballast and stripping) is ses for A71.
stopped. If in standby, system re-
mains in standby, but it is not possi-
ble to start a process as long as the
system is in heeling mode (except
CIP). This warning is automatically
acknowledged when the heeling
mode is redrawn from ISCS..
W84
Heeling mode requested from ves-
sel’s ISCS.
Trigger: ISCS.
Delay: 10 sec. If heeling mode has not been re-
quested: See first two possible cau-
Comment: Ongoing process (bal- ses for A71.
last, deballast and stripping) is
stopped. If in standby, system re- See possible cause for W82.
mains in standby, but it is not possi-
ble to start a process as long as the
system is in heeling mode (except
CIP). This warning is automatically
acknowledged when the heeling
mode is redrawn from ISCS..
1. Switch on the panel.

2. Restart the panel. See problem
Panel is switched off or faulty. 1 B in General problems on
A91 page 190.
PLC lost communication with all 3. Replace if faulty.
control panels.
Trigger: Control system PLC. Check that the HMI and PLC soft-
ware have the save program ver-
Delay: 60 sec. Wrong software version. sion. This is visible in control sys-
Comment: After 60 seconds of lost tem page 4.1 System 1.
communication, ongoing process is Check settings for each panel ac-
stopped in a controlled way and the Wrong network setting. cording to Set control panel IP ad-
system is shut down. This message dress on page 108
is visible in the control panels and
saved in the log after the communi- Check cables to the component.
cation is restored. But, W92 will be For reference, see Electrical cabi-
visible in the main control panel. net / Interconnection diagram, in
Faulty cable connection. section Electrical drawings on page
256 and Remote control panel / Cir-
cuit diagram (optional) on page
287.
168 200000878-6-EN-GB

W92 Master panel is switched off or faul- See A91.
ty.
Master control panel lost communi-
cation with the PLC
Trigger: Control system PLC.
Delay: 30 sec.
Comment: After communication is Faulty cable connection. See A91.
lost, ongoing process is stopped in
a controlled way and the system is
shut down. This message is visible
in the main control panel.
200000878-6-EN-GB 169

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

test mode (for example to test re-
A93 mote interface integration, you can
System is set to Test mode.
Heartbeat signal from remote inter- disregard this alarm. If not deacti-
face is not updating. vate the test mode again in page
4.4 Remote 1.
Trigger: Control system PLC.
1. Check that parameter p700 is
Parameter: p132. set to match the modbus cable
Delay: 60 sec. type used (RS422 or RS485).
Comment: After communication is 2. Check if remote operation is de-
lost between ISCS and PLC, ongo- activated in the control panel
ing process is stopped in a control- (The Remote button at the bot-
led way and the system is shut tom of the screen is gray). If so,
down. press the Remote button.
The Heartbeat field in page 4.4 Re- Faulty settings. 3. Check if test mode is activated
mote 1, indicates communication. in page 4.4 Remote 1 (check
mark on button). If so, press the
Test mode button. Requires
login level Advanced operator.
4. Check that the communication
settings is OK according to in-
struction Set remote interface
communication on page 110
Check cable between the ISCS and

the main control panel and the ca-
ble between the PLC and the main
control panel. For reference, see
Electrical cabinet / Interconnection
Faulty cable connection diagram, in section Electrical draw-
ings on page 256.
Tips: Make sure that the modbus
cables in terminal X6are correct
(not switched).
Communication between PLC and See W92.
main control panel is lost
Investigate problem in ISCS, and
ISCS is faulty attend to found problems.
170 200000878-6-EN-GB

A94 Specific for this alarm compared to
Fault in barrier box. A17: Check if barrier TA, TI or TO
Barrier fault in barrier box are faulty.
Trigger: Barrier in LDC cabinet
Parameter: p151 Check that all electrical connec-
tions are OK. Check that the signal
Delay: N/A. wiring is according to information in
Faulty wire connection.
Comment: This alarm is specific Control cabinet / Interconnection di-
for the Ex proof version of PureBal- agram, in section Electrical draw-
last for US flag. ings on page 256
W96
GPS signal not valid.
Trigger: Control system PLC. Faulty electrical connection.
Parameter: p160.
Delay: 5 sec.
Check the LED error indication for
the electronic modules in the cabi-
Error in module. net. See I/O system and X20 mod-
ules on page 186.
A97
PLC error in EC. 1. Check that the signal wiring is
according to electrical drawings
Trigger: Control system PLC in in Technical data and drawings
electrical cabinet (EC). on page 195.
Faulty electrical connection.
Delay: 2 sec. 2. Check that all electrical connec-
tions are OK on bus modules
and that the electrical wiring is
not damaged.
A98 Note: Find out the reason why the

process has been stopped. Then:
KS1 Safety relay not OK. Emergency stop button pressed Release the Emergency button and
(electrical cabinet or external).
Trigger: press the button on the electrical
cabinet.
• Emergency stop button on elec-
trical cabinet (safety relay Check that all electrical connec-
KS01). tions are OK on bus modules and
Faulty connection of signal cable. that the electrical wiring is not dam-
• Temp switch TS201–60. aged.
• Temp switch TS201–33 (only for
Ex systems)
200000878-6-EN-GB 171

After problem is resolved: Press the
Reset button on the electrical cabi-
net.
Check that the main inlet valves
High temperature due to obstacles (V201-19, V201–3, V201–32 or
or error in one or more components V201–4) and outlet valve (V201-8)
A100 open properly by operating them
involved
Reactor temp high (TT201-33). manually. See Open and close
valves manually on page 361.
Trigger: UV reactor temperature
transmitter TT201-33. Check that cooling water supply
(310) is within specification in Con-
Parameter: p202. nection list on page 205.
Delay: 5 sec. Check pump, valves and other
Comment: Temperature in UV re- Low flow of water during start-up. components involved in the cooling
actor is above 60 °C. system.
The system is shut down. Check/change parameter in control
Parameter p202 not correctly set. system page 5.2 – UV reactor pa-
rameters.
Replace transmitter TT201–33 ac-
cording to instruction in Tempera-
TT201-33 malfunction. ture switch and temperature trans-
mitter on page 343.
A101 See possible cause for A100.
Reactor temp low (TT201-33). See to that incoming water is
Ballast water too cold. warmer than – 2 C°
transmitter TT201-33.
Delay: 5 sec. Engine room too cold; temperature Increase temperature.
below 0 C°.
Comment: Temperature in UV re-
actor is below 0 °C.
1. Check fuses F41–F44in electri-

check the fuse setting, adjust
A102 fuse.
Reactor temp signal missing 3. Use the circuit diagram to lo-
(TT201-33). cate the component or find the
Trigger: Temperature transmitter Signal missing or transmitter and attend to it.
TT201-33. TT201-33 malfunction.
4. Check cables to the compo-
Delay: 5 sec. nent. See Electrical cabinet /
Comment: The system is shut Circuit diagram in Technical da-
down. ta and drawings on page 195
6. Replace transmitter TT201-33.
7. Restart the process from the
beginning.
172 200000878-6-EN-GB

A103
Reactor temp high (TS201-33).
switch TS201-33.
Delay: 5 sec.
actor over 62.5 °C.
The system is shut down.
A104
Reactor temp high (TS201-60).
switch TS201-60.
Delay: 5 sec.
actor over 65 °C.
The system is shut down.
The inlet and/or outlet air filter is Clean the filters.

A107 dirty.
LDC1 air temp high (TT401) Check that mechanical parts in the
Mechanical obstacles.
Trigger: TT401 in lamp drive cabi- fan can rotate freely.
net 1.
Delay: 15 sec. Ambient temperature is too hot. Wait until cooler.
Comment: Temperature in lamp Check that all electrical connec-

drive cabinet 1, over 60 °C. Electrical problem. tions, are OK and that the electrical
wiring is not damaged.

LDC1 air temp missing (TT401)
Trigger: TT401 in lamp drive cabi-
net 1.
Delay: 5 sec. Electrical problem. See A107.
missing.
The inlet and/or outlet air filter is Clean the filters.

A111 dirty.
LDC2 air temp high (TT401) Check that mechanical parts in the
Mechanical obstacles.
Trigger: TT401 in lamp drive cabi- fan can rotate freely.
net 2.
Delay: 15 sec. Ambient temperature is too hot. Wait until cooler.
Comment: Temperature in lamp Check that all electrical connec-

drive cabinet 2, over 60 °C. Electrical problem. tions, are OK and that the electrical
wiring is not damaged.
200000878-6-EN-GB 173

LDC2 air temp missing (TT401)
Trigger: TT401 in lamp drive cabi-
net 2.
Delay: 5 sec. Electrical problem. See A111.
missing.

that caused the fuse trip.
2. Use the circuit diagrams for the
electrical cabinet to check the
fuse setting, adjust according to
figures in circuit diagram if nec-
essary and reset fuse.
A116 reason that caused the fuse trip
and attend to it.
Reactor fluid level signal missing
(LS201-29). Signal missing or switch LS201-29 4. Check cables to the level switch
malfunction. LS201-29. See Electrical cabi-
Trigger: Level switch LS201-29. net / Circuit diagram in Electri-
Delay: 5 sec. cal drawings on page 256.
5. Check that the level switch is
working correctly. See Level
switch on page 186.
Dismount level switch and put
the forks into a cup of water to
check dry/wet function.
6. Replace LS201-29. (Turn the
level switch so the forks are in
the right position. See Service
manual on page 315.
W117
UVR [x]: UVR fluid level signal
missing (LS201-29) in manual
mode. See W116.
Trigger: Level sensor LS201-29.
Delay: 5 sec.
174 200000878-6-EN-GB

1. Check that valve V310–1 ,
V320–4, V321–2 and V571–1
open and close correctly.
Valves can be manually operat-
ed. See Valves on page 359.
Note that the manual opera-
tions are password-protected
and must only be performed by
authorized trained personnel.
The PureBallast equipment or
A118 No fluid in UV reactor. LS201-29 is connected equipment can be ir-
indicating dry condition. reparably damaged if handled
No CIP liquid filling in UV reactor
(LS201-29). incorrectly.
Trigger: Level sensor LS201-29. 2. Examine the pipes related to

the CIP process. Make sure
Delay: 15 sec. that no material is clogging the
pipes.
3. Check that the level switch is
working correctly. See Level
switch on page 186.
Time set in parameter is lower than Change parameter.

needed.
Level switch at UV reactor See W116 to troubleshoot the level
LS201-29 malfunction. switch electrically.
1. Check that pressure in pipe 310
is according to requirements in
Connection list on page 205.
A119 No liquid in UV reactor. LS201-29 is 2. Check that valve (V310-1,

indicating dry condition. V320–4, V321–2 and V571–1)
No freshwater filling in reactor areoperating correctly. Also
(LS201-29). check that CV310 isopened.
Operate the components man-
Trigger: Level switch LS201-29. ually.
Parameter: p201.
Time set in parameter is lower than Change parameter.
needed.
Level switch at UV reactor See W116 to troubleshoot the level
LS201-29 malfunction. switch electrically.
Fluid in UV reactor. LS201-29 is in- Restart the process from the begin-
dicating wet condition. ning.
A120 Time set in parameter is lower than Change parameter.

needed
Reactor was not drained
(LS201-29). Level switch at UV reactor See A116
LS201-29 malfunction.
Trigger: Level switch LS201-29.
Control that valves ( V460–3,
Parameter: p200. V460–2, V571-1, V320–4, V321–2
Faulty valves and overboard valve) are opened
for current process. Also control
that pump P460–1 is functioning.
Check fuses Q101–105 and F2in
A122 electrical cabinet to see what circuit
LPS fuse alarm (MS132).
Fuse in electrical cabinet has trip- Use the circuit diagram for the elec-
Trigger: Micro switch MS132 in ped or has been switched off. trical cabinet to check the fuse set-
electrical cabinet. ting, adjust according to figures in
Delay: 5 sec. circuit diagram if necessary and re-
set fuse.
200000878-6-EN-GB 175

1. Check fuse in lamp drive cabi-
net 1 to see what circuit caused
the fuse trip.
Fuse tripped in LDC1 cate the component or find the
Trigger: Fuse in lamp drive cabinet Overheated fuse. and attend to it.
1.
3. Use the circuit diagram for lamp
Comment: LDC1 fuse alarm drive cabinet to check the fuse
and reset fuse.
1. Check fuse in lamp drive cabi-

net 2 to see what circuit caused
the fuse trip.
Fuse tripped in LDC2 cate the component or find the
Trigger: Fuse in lamp drive cabinet Overheated fuse. and attend to it.
2.
3. Use the circuit diagram for lamp
Comment: LDC2 fuse alarm drive cabinet to check the fuse
and reset fuse.
A131
Lamp failure. Eventual ongoing
process not compliant.
Check which lamps that are broken
Trigger: Lamp power supply 1–3. in column Lamp OK in page 4.6
Delay: 5 sec. One or more UV lamp is broken. LPS.
Note: Operation continues but is Change according to instruction in

not compliant and does not fullfil re- Service manual on page 315.
ter management plan.
W132
Estimated UV lamp lifetime excee-
ded.
Trigger: UV reactor lap time. Estimated lifetime for UV lamps Change according to instruction in
(3000 hours) is exceeded. Service manual on page 315.
Delay: 1 sec.
Comment: Recommended to
change all lamps after 3000 hours
of operation.
176 200000878-6-EN-GB

W140
CIP required. Start CIP! Risk for not
compliant operation.
Trigger: Control system timer.
Comment: CIP process must be
started within 30 hours counted CIP not performed after operation. Start CIP process.
from when a ballast or deballast
process was started.
not compliant and does not fullfil
the requirements for treatment of
ballast water. Act according to bal-
last water management plan.

fuse.
W151 Signal missing. reason that caused the fuse trip
UV sensor signal missing. Ongoing and attend to it.
process not compliant. 4. Check cables to QT201-50.
Trigger: UV sensor QT201-50. See the drawing Electrical cabi-
net / Circuit diagram in chapter
Delay: 20 sec. 6. Technical data and drawings.
Note: Operation continues but is 5. If the above is OK, the UV sen-
not compliant and does not fullfil sor is probably broke and
the requirements for treatment of needs to be replaced. Replace
ballast water. Act according to bal- the component.
last water management plan.
Test the UV sensor:
1. Stop the process and restart
the process again.
2. In the control system's UV reac-
Transmitter QT201-50 malfunction tor popup, see if the UV values
are OK during the start-up
phase. UV values shall be OK,
since clean cooling water is
used.
200000878-6-EN-GB 177

Perform a CIP process. CIP clean-
ing is necessary to make sure the
CIP not performed UV light is unhindered by dirty/
scaled quartz sleeves.
pH value in CIP liquid higher than Check pH value, if higher than 3
3. change CIP liquid.
Note: Operation continues, but
does not fulfill the type approval
certificate. Act according to ballast
water plan.
See Power optimization on page
W152 21.
UV intensity low. System flow re-
duced. Process not compliant. Check water.
Trigger: UV sensor QT201-50. Water is dirty or have low UV trans- It is also possible to fill the reactor
mittance. with technical water / potable water
Delay: 20 sec. to rule out challenging water as
Comment: The flow is reduced reason for the warning.
when UV intensity (W/m3) is below
410 for fresh water and 210for Run CIP process, and try again.
brackish and marine water, accord- If problem remains, check and
ing to IMO legislation. Power is set Quartz sleeves dirty. clean quarts sleeves according to
to 100% and the flow is reduced to instruction Service manual on page
50 % 315.
Note: See Compliant / Non-compli-
ant operation on page 44. Check runtime on page 4.3 Timers
in control system. Change if old.
Old UV lamps. Lamps loose effect when maximum
runtime has been exceeded.
Sediments in the tank. If the tank
has not been thoroughly cleaned,
sediment in the tank might obstruct Clean all ballast water tanks.
the light in the UVR proventing the
light from treating the water and
reaching the UV sensor.
Dirty UV sensor or not installed cor- Check UV sensor and install ac-
cording to instructionReplace UV
rectly. sensor on page 342.
W153
UV lamp broken. System flow re-
duced. Process not compliant.
Trigger: UV reactor.
Parameter: p213
Comment: Process is allowed to
finish. Note: Operation continues, but
If a UV lamp fails during ongoing does not fulfill the type approval
operation, the flow is set to 65 % is certificate. Act according to ballast
set 65 % in IMO mode and 50 % in water plan.
USCG mode of max flow. See Operation with broken UV
The UV lamps are lit to 100 % . lamp on page 21
This is done so that the treatment

shall correspond to the type appro-
val requirements. After the process,
it is not possible to start a new
process.
Note: See Compliant / Non-compli-
ant operation on page 44.
178 200000878-6-EN-GB

W154
Low UV intensity (USCG). Flow =
50%. Process not compliant.
Trigger: UV sensor QT201-50.
Parameter: p182
Delay: 20 sec.
Comment: Warning issued when
UV intensity falls below compliance
limit (W/m2): 530 in USCG 3 day
and 750 in USCG 0 day mode. At See W152.
this stage power is 100% and flow
is reduced to 50 %.
not compliant and does not fulfill re-
ter management plan. A new proc-
ess is not allowed to start.
Only relevant for PureBallast
USCG systems.
Check cables to the component

“modubus connection LPS”. See
Faulty connection of electricity or Electrical cabinet / Circuit diagram
A160 on page 263.
signal cable.
No response from LPS. Check allcable connectors on the
Trigger: LPS. LPS .
Delay: 10 sec. Check LED indication on the LPS.
Note: Operation continues but is LPS in faulty state. See LPS indication in Lamp power
not compliant and does not fullfil re- supply (LPS) on page 182
quirements for treatment of ballast Change LPS. See instruction in
water. Act according to ballast wa- LPS broken. Service manual on page 315.
ter management plan. A new proc-
ess is not allowed to start. Check that the DIP switches are
correctly set for every LPS. See
Wrong LPS setting. Lamp power supply (LPS) parame-
ters on page 157.
A161
LPS communication error. Reactor
shutdown. See A160.
Trigger: LPS in electrical cabinet.
Delay: 1 sec.
Check page 4.6 LPS and LED indi-

One or more of the below: cation on the LPS that triggered the
W165 alarm. See LPS alarms in Lamp
• Air intake temp fault. power supply (LPS) on page 182.
LPS in fault state. Process not
compliant. • Fan fault. Fan fault and temperature faults
Trigger: can be caused by something that is
• Heat sink fault. preventing the fan from rotate.
Delay: 5 sec. • UV lamp open (broken). Change LPS. See instruction in
Service manual on page 315.
200000878-6-EN-GB 179

Motor circuit breaker (MCB) -K4 in
electrical cabinet has tripped or has Reset or turn on.
been switched off.
1. Check that the cable W14 is
connected to the electrical cabi-
net.
2. Check the power cable be-
tween the filter junction box and
the filter motor, including the
condition of the connector at
Motor problem. the filter motor side.
W300
3. Check that the motor is not
Filter motor tripped (M709-43). overloaded and can rotate easi-
Trigger: . ly.
Delay: 1 sec. 4. Start the motor and check that
the operation is normal. See
Parameter: p318. Service manual on page 315.
Check that mechanical parts in the

Mechanical obstacles. filter can rotate freely. See Service
manual on page 315.
Loosen the pipe connections to the
Filter flanges misaligned, and filter and try to rotate the filter man-
forced together causing stress and ually. If the nozzle can rotate, the
deformation of the filter body. pre- pipe connections must be renewed.
venting the nozzle to rotate freely Cut pipe 201 shorter and insert a
inside the filter. tailor made spool piece with perfect
fitting.
W301
Backflush pump tripped (P309-1)/
M703–1. Motor circuit breaker (MCB)-F5 in
electrical cabinet has tripped or has
Trigger: Check cableing.
been switched off.
-F5. See W300.
Delay: 1 sec.
Comment: The pump is optional.
1. Check fuses F41–F44in electri-

A310 according to figures in circuit di-
Filter pressure signal missing fuse.
(PT201-71).
Trigger: Pressure transmitter Signal missing or component mal- cate the component or find the
(PT201-71). function. reason that caused the fuse trip
Delay: 30 sec. and attend to it.
Comment: Alarm deactivated in 4. Check cables to (PT201-71).
Standby. See the drawing Electrical cabi-
net / Circuit diagram in chapter
6. Technical data and drawings.
5. If the above is OK, the pressure
transmitter is probably broken
and needs to be replaced.
180 200000878-6-EN-GB

Backflush manually from control
system. If not sufficient, clean the
Filter is clogged. filter element according to instruc-
tion in Service manual on page
315.
Make sure that the valve connected
Valves connected to pressure to each pressure transmitter is
transmitters closed. open.
1. Check fuses F41–F44F45 in
electrical cabinet to see what
circuit caused the fuse trip.
A315
Filter diff. pressure to high. check the fuse setting, adjust
Trigger: Pressure transmitter agram if necessary and reset
PT201-16 and (PT201-71). fuse.
Parameter: p300.
Delay: 5 sec. cate the component or find the
Comment: Diff. pressure higher Pressure transmitters does not and attend to it.
than set in parameter p300. work correctly.
4. Check cables to the compo-
nent. See Electrical cabinet /
Circuit diagram in section Elec-
trical drawings on page 256.
6. Replace faulty transmitter.
7. Restart the process from the
beginning.
W400
If not stopped by operator, check
CIP cycle stopped before comple- CIP process stopped manually by page 2.1 Alarm list.
ted. operator or automatically for some Check CIP required time in page
Trigger: CIP. reason. 1.3 CIP and make sure to run the
CIP process within stated time.
Delay: 5 sec.
W401 CIP liquid running out. Change CIP liquid can T320
CIP liquid low level (LS320–3).
Trigger: Level switch LS320–3. CIP liquid can T320 placed too far Place the can closer to the level
from level switch LS320–3. switch.
Delay: 600 sec.
200000878-6-EN-GB 181

No log box is installed. Parameter Change parameter to Not used.
activated by mistake.
Check connections and cable for

power cable (W10) and Ehternet
Faulty cable connection. cable (A104) between electrical
cabinet and Log box.
Fuse in the log box has tripped or Check fuse F02 and F03 in the log
has been switched off. box.
A501
Log box error • Make sure that the setting on
the X20 BC 0083 module is:
Trigger: Log box (optional). X16=0, X1=1
Delay: 15 sec.
• 1. Check that parameter p500
Comment: Only valid if Log box is activated in the control
have been activated. Faulty setting. system.
2. Acknowledge the alarm in
the control system, to be
able to see when it disap-
pears.
Check the LED error indication for

the electronic modules in the log
Error in module. box. See I/O system and X20 mod-
ules on page 186.
W502
Log box: External bypass is open
See W33.
Trigger: Log box (optional).
Delay: 10
W503
Heeling mode requested by log
box. See W82 and W33.
Trigger: ISCS.
Delay: 10 sec.
5.2.2 Lamp power supply (LPS)

The table explains alarms triggered by and displayed in the electrical cabinet.
The LPS is equipped with four light indications.
LPS on and communication is functioning.
Flickering during communication with PureBallast system.
Internal fault. The cause can be seen on page 4:9 of the LPS overview in
the HMI. Possible causes:
• Broken UV lamp.
• Loose cables to UV lamp.
• LPS temperature too high.
• LPS fan faulty.
182 200000878-6-EN-GB
Lamp error. Possible causes:

• Ignition failures due to broken UV lamp or loose cable to UV lamp.
• One phase missing on input to LPS.
• Short circuit detected (implemented from LPS version 3, se revision
number on sticker). To reset the LPS, turn off the power to the LPS and
turn it on again by turning the main breaker on the outside of the LDC.
UV Lamp on. Flickering during UV lamp ignition.
Possible causes:
All
LEDs • Voltage for the fail-safe signal (24V) is missing. It can be caused, for ex-
on. ample, by various alarms, wrong DIP switch settings on one ore several
LPS, safety relay tripped.
Possible causes:
All
LEDs • No power to the LPS.
off. • Power to the LPS, but the LPS is broken (needs to be replaced).
5.2.3 Flow meter
This section explains faults and alarms triggered by and displayed in the flow
transmitter, mounted on the flow meter (FT201-1).
The display mounted on the flow transmitter is not supplied for all system
types. It is possible to connect a loose display to the flow meter, and use it
temporarily to troubleshoot the unit.
During normal conditions, relevant alarms are displayed in the PureBallast
control panel. See Control system on page 160.
Diagnostic information via LED

Different LEDs in the transmitter provide information on the device status.
1. Supply voltage
2. Device status
3. Not used
4. Communication
5. Service interface (CDI) active
LED Color Meaning

Off Supply voltage is off or too low.
1. Supply voltage
Green Supply voltage is ok.
200000878-6-EN-GB 183
LED Color Meaning

Off Firmware error.
Green Device status is ok.
Flashing green Device is not configured.
2. Device status (normal A diagnostic event with “Alarm” di-
operation) Red agnostic behaviour has occurred.
A diagnostic event with “Warning”
Flashing red diagnostic behaviour has occurred.
Flashing red/green The device restarts.
If > 30 seconds: problem with the
Flashes red slowly boot loader.
2. Device status (during
start-up) If > 30 seconds: compatibility prob-
Flashes red quickly lem when reading the firmware.
3. Not used — —
Off Communication not active.
4. Communication
White Communication active.
Not connected or no connection es-
Off tablished.
5. Service interface Connected and connection estab-
(CDI) Yellow lished.
Flashing yellow Service interface active.
5.2.3.1 Fault finding instruction
Always start troubleshooting with the checklist below if faults occur after start-up or during operation.
Note: Step 1–3 are only valid if the unit has a display.
1 Check the diagnostic message on the display.

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

The Diagnostic list submenu opens.
1. Diagnostic message
184 200000878-6-EN-GB
b) Select the desired diagnostic event with +

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

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

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

electronics module or module carrier if the
problem cannot be detected or corrected.
See instructions in Flow meter on page 374.
200000878-6-EN-GB 185
5.2.4 Level switch

This section explains the different status indications on the level switch
LS201-29 in the UV reactor. Alarms and status are indicated by LEDs on the
module.
Color State Description What to do?
Green Steady Power on and in operation.
Check plug, cable and power
Green Off No power supply. supply.
Yellow Steady Wet condition.
Error: Internal sensor error or Replace the component.
Red Blinking sensor corroded.
Rectify the short-circuit.
Red Steady Error: Overload or short-cir-
cuit in load circuit. Reduce maximum load current
to below 250 mA.
5.2.5 I/O system and X20 modules

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

Identification Function
AI4622 Analogue input
AO2622 Analogue output
CP1382 PLC module (System module CPU)
DO9322 Digital output, 12 outputs
AT2222 Temperature input module
CS1030 Interface module
IF1030 Interface module, RS422/RS485
DM9324 Digital input / output
186 200000878-6-EN-GB
List of alarms and status indications
NOTE
All status indications are not valid for all modules

The meaning of a status indication might vary for some modules. These
variations are specified in the Description column.
Module CP3585 and DM9324 are described in separate tables below the generic
table.
Light Lights on the module.

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

Off 24 V DC supply not connected, check fuse.
Single flashes Reset mode.
r Green
Blinking Preoperational mode.
On RUN mode.
Off Module not supplied or everything is OK.
Warning / error for an I/O channel. Level monitoring for digital out-
Single flashes puts has responded.
AT: Overflow or underflow of the analog inputs.
e Red
Indicates one of the following conditions:
Double flashes • X2X bus power supply is overloaded.
• I/O supply too low.
On Error or reset state.

Red - steady /
r+e Red/Green Green - single Invalid firmware.
flashes
Off No communication at the X2X bus.
X Orange
On X2X bus communication in progress.
Off Bus controller / X2X link supply in acceptable range.
I Red
On Bus controller / X2X link supply overloaded.
Off No data traffic over service interface; no activity.
S Yellow
On Data is transferred over the service interface.
1–6 Orange In/output status of the corresponding digital in/output.
1–8 Green Output status of the corresponding digital output.
1–12 Orange On In/output status of the corresponding digital in/output.
1–12 Green In/output status of the corresponding digital in/output.
1–16 Green Input status of the corresponding digital input.
Off The input is switched off.
1–2 Green Blinking Overflow / underflow of the signal, or broken connection.
On The analog/digital converter is running, values OK.
200000878-6-EN-GB 187

Off Value = 0.
1–4 Orange
On Value ≠ 0.
Green On Interface module is active.
Status
Red On CPU starting up.
RxD Yellow On The module is receiving data via RS485 (or RS422) interface.
TxD Yellow On The module is sending data via RS485 (or RS422) interface.
For CSmodules: The module is sending data via RS485 (or
Tx Yellow On RS422) interface.
For CSmodules: The module is receiving data via (RS485 or
Rx Yellow On RS422) interface.
For CSmodules: The terminating resistor integrated in the module
T Yellow On is turned on.
Module CP1382
Green On Application is running.
R/E
Red On Service mode.
Yellow On Service or boot mode.
RD/F
Red On Over-temperature.
Green on, red off Powerlink OK.
Fatal and irreparable system error. See control system for alarm
Green off, red on or warning. This status can only be changed by resetting the
module.
The powerlink managing node failed. This error code can only oc-
Blinking alter-
S/E Green/Red nately cur in controlled node operation. This means that the set station
number lies within the range $01 - $FD.
System failure according to blinking pattern:
Green off, red ●●● ▬ Pause ●●● ▬ Pause: RAM error.
blinking
▬ ●● ▬ Pause ▬ ●● ▬ Pause: Hardware error.
On Link to powerlink remote station is established.
EPL Green
Blinking On and Ethernet activity present on the bus.
On Link to Ethernet remote station is established.
ETH Green
Blinking On and Ethernet activity present on the bus.
Yellow On Flash card OK.
CF
Green On Flash card active.
DC Yellow On CPU power supply OK.
OK Red On Backup battery is empty.
Module DM9324
Off 24 V DC supply not connected, check fuse.
Single flashes Reset mode.
r Green
Blinking Preoperational mode.
On RUN mode.
188 200000878-6-EN-GB

Off Module not supplied or everything is OK.
e Red Warning / error for an I/O channel. Level monitoring for digital
Single flashes outputs has responded.
Red/Green Red is steady,

e+r green flashes Invalid firmware.
1–8 Green Input status of the corresponding digital input.

1–4 Orange Output status of the corresponding digital output.
200000878-6-EN-GB 189
5.3 List of problems and solutions

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

Prob- Description Possible cause What to do?
lem
ID
1A The system does not start. The Main breaker on electrical cabi- Turn on the breaker and meas-
control panel does not light up. net turned off, or power not con- ure that incoming 24 V DC to the
Control panel is not displaying a nected to the control panel. control panel is present.
normal page. PureBallast can
not be controlled or monitored Power turned off at main switch Turn on the power.
from the ISCS' graphical user in- board.
terface via the remote interface Fuse F41–F44tripped.
(optional). 1. Check fuse F41–F44 in elec-
trical cabinet to see what cir-
cuit caused the fuse trip.
according to figures in circuit
diagram if necessary and re-
set fuse.
cate the component or find
the reason that caused the
fuse trip and attend to it.
Control panel error. Can be Replace control panel.

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

software have the save program
version. This is visible in control
system page Page 4.1 – System
1 on page 79.
HMI software problem. Re-load the HMI software ac-
cording to the software Release
note.
1C PureBallast can not be controlled Communication is broken be- See the What to do column for
or monitored from the ISCS' tween ISCS and PLC. alarm A93.
graphical user interface via the
remote interface (optional).
190 200000878-6-EN-GB
Prob- Description Possible cause What to do?

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

Communication is broken between remote control panel and PLC. • See the What to do column
for alarm A91.
• If the electrical and signal ca-
bles are disconnected or bro-
ken. See Remote control
panel / Circuit diagram.
• If the electrical cabinet is
turned off.
• If the PLC is broken.
If control panels are not used:
Remove IP address for Remote
control panel 1 according to in-
struction is set for the remote
control panel. See Set remote
control panel communication on
page 109.
“Disconnected from ...”: Check the following:

Communication is broken between remote control panel and main • If the electrical and signal ca-
panel. bles are disconnected or bro-
ken.
• If the electrical cabinet is
turned off.
• If the main panel is turned off
or broken.
If control panels are not used:
See 1 D.
It is possible to connect an exter-
nal mouse to the control panel.
Touch screen in control panel
1E Touch function is out of order. Connect the mouse’s USB to the
does not work. USB PLC port on the cabinet
door.
5.3.2 Filter
Problem Description Possible cause What to do?
ID
Pressure transmitter PT201–71 Dismantle the component and
may be faulty. inspect/rinse.
Backflush sequence starting er-
5A ror (general).
Valves for air pressure to filter Open the valve block to filter
are closed. valve block.
200000878-6-EN-GB 191

ID
The filter house is not properly Deaerate using deaeration
deaerated. valve V571-3 on the filter lid.
Check filter element for dam-
Damaged filter element. age. Replace if necessary.
Excessive backflushing or long Open the filter and remove the
5B backflushing sequences (gener- Large obstructions have en- obstructions. See Filter on page
tered the filter.
al). 344.
See Backflushing for different
Dirty water. dirt loads on page 30.
Dirt build-up in the filter ele-
ment. Clean the filter element.
5.3.3 CIP
ID
6A Insufficient pump capacity (gen- Leakage in air hoses or seal- Locate leakage and attend to.
eral). ings.
Air pressure too low due to in- Adjust setting with the manual
correct setting on valve block. valve under the valve block.
Examine the pump and attend
Pump is clogged. to problem. See Test pumps on
page 356.
6B Too high consumption of CIP Leakage in the CIP pump or Locate leakage and attend to.
liquid. pipes.
6C CIP pump does not run. • The air pressure is to low. Examine the pump and attend
to problem. See Test pumps on
• The air connection is page 356.
blocked.
• Muffler is blocked.
• Valve block is defect.
• Dirt in the pump chamber.
• Diaphragm breakdown.
6D CIP pump runs irregularly. • Valve isblocked. Examine the pump and attend
to problem.
• Sealings are defect in air
valve or center block.
• Diaphragm breakdown.
6E Insufficient CIP pump suction. • Suction connection blocked Examine the pump and attend
or not tight. to problem.
• Valve is blocked or dam-
aged.
192 200000878-6-EN-GB

ID
6F Bad flow or pressure in CIP • Pressure fall in incoming air. Examine the pump and attend
pump. to problem.
• Suction or air connection
blocked.
• Valve block is defect.
• Valve balls worn out/broken.
• Diaphragm breakdown, due
to air in liquid.
6G CIP pump leakage. Screws on the housing not Tighten the screws.
properly fastened
6H CIP pump muffler leakage. Diaphragm breakdown Change diaphragm.
5.3.4 Valve V201–8

Problem Description Possible cause What do to?
ID
8A Signal change has no effect on Faulty air supply. Check that the air supply is cor-
the actuator position. rectly mounted on the valve.
Faulty signal. • Check input signal to propor-
tional valve.
• Check I/P output.
8B Signal change results in actua- Connection or signal problem. • Check coupling between
tor running to end positions. proportional valve and actua-
tor.
• Check input signal.
8C Signal and positioning prob- • Inaccurate positioning. Adjust position sensor. See Cal-
lems. ibrate positioner on V201-8 on
• Input signal fluctuates. page 367.
Check electric connection.
200000878-6-EN-GB 193
194 200000878-6-EN-GB
EN
6 Technical data and drawings
200000878-6-EN-GB 195
EN 6 Technical data and drawings
6.1 Introduction
This chapter contains technical information about PureBallast together with
mechanical and electrical drawings.
6.1.1 Ship specific information

Enter vessel specific information in the table below. This will facilitate reading
information and drawings in this document, since some drawings include
information for all system sizes / dimensions, and the document contains
information for options only used by on some vessels. In PDF, either edit the
document or add a text box.
Data Value
Flange standard (EN or JIS) _____________
Control valve (V201-8) 100
Bypass valve (V212–31)

Dimension: _____________
Alfa Laval’s or other
Filter module connections:

Inlet valve (V201–3) Integrated components premounted at delivery.
Outlet valve (V201-32)
UV reactor connections:
Inlet valve (V201-19)
Integrated components premounted at delivery.
CIP unit connection (V321-2)
CIP unit connection (V320-4)
CIP unit connections:

Line 460
Line 320 Dimension: _____________
Line 321
Line 310
Sampling device Location Q201.1: _____________

Alfa Laval’s or other Location Q201.2: _____________
Power consumption, max (kW) ___________
Location:
Remote control panel 1: _____________
Remote operation (optional) Remote control panel 2: _____________
Remote interface integration (yes/no):
_____________
6.2 Technical data

This section states technical data for the complete PureBallast system and for
individual components. In some cases references are given to data in
drawings included in this chapter.
196 200000878-6-EN-GB
Technical data and drawings 6 EN
For detailed information about weight and volume for major component in the
PureBallast system, see dimension drawings in section Dimension drawings
on page 223
6.2.1 Flow requirements

BW pump and other pumps must give min and max flow according to the table
below:
Media Flow / consump-
tion
Flow range – Pipe 201, ballast 52 – 170 m3/h
Flow range – Pipe 201, deballast 17 – 170 m3/h
Flow range – Pipe 201, stripping 17 – 170 m3/h
Pipe 310, technical water / potable water
• Start-up cooling water flow 15 l /min (max 18 l)
• CIP process, volume 123 l
Minimum flow – Pipe 309, filter backflush 35 m3/h
6.2.2 Water requirements

Ballast water Temperature: -2 to 40 °C (liquid form)
Salinity: PureBallast can treat the following types of water:
• Fresh water (salinity ≤ 1 PSU)
• Brackish water
• Marine water
UV intensity limit: The system have been tested and

found to give full treatment according to below:
IMO mode–fresh water: >410 w/m2
Ballast water
IMO mode–brackish and marine water: >210 w/m2
USCG mode: > 530 w/m2 in USCG 3 day mode and 750
w/m2 in USCG 0 day mode.
Technical water / pota- UVR and filter preservation
ble water
For details, see Quality specification / Technical and pota-
ble water on page 220
200000878-6-EN-GB 197
6.2.3 Power requirements

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

IP rating For IP rating for specific component, see respective dimension
drawings in section Dimension drawings on page 223.
Component Power consumption

(kW)
Electrical cabinet 20
Power to UV reactor, electrical cabinet and filter motor.
Note: PureBallast only use power needed for treatment.
PureBallast automatically regulates the lamp power be-
tween 50 and 100 % to secure the treatment efficiency.
Electrical cabinet
Power to UV reactor.
20
Note: PureBallast only use power needed for treatment.
PureBallast automatically regulates the lamp power be-
tween 50 and 100 % to secure the treatment efficiency.
Total (EC, LDC 1, LDC 2): 20
Pump P309–1 (optional)

For filter backflush water.
Note: Inspect the filter marking plate. If you have filter the
data is correct. The system may be supplied with a filter of 3.0
larger size. If so, consult the Filter size addendum for cor-
rect data.
Powered from control cabinet.
6.2.4 Pressure requirements

This section describes system pressure limitations as well as pressure
requirements. Pressure must be calculated according information in this
section to ensure that there is enough pressure to perform efficient operation.
6.2.4.1 System pressure limitations

Maximum allowed system pressure:
Max pressure for standardsystem: 6 bar.

Water piping
Max pressure for high pressure system: 10 bar.
198 200000878-6-EN-GB
6.2.4.2 Introduction to pressure requirements for filter backflush

This section presents how to make pressure calculations. The ballast water
pump must deliver enough pressure to overcome …
1. … pressure drops for both PureBallast components and vessel’s piping
system to be able to fill/empty ballast water tanks within flow capacity, flow
velocity and pressure limitations. This means from sea chest via
PureBallast to all tanks during ballast, and from all tanks via PureBallast to
overboard valve during deballast and stripping.
2. … pressure requirements for filter backflush to ensure efficient backflush
cleaning of the filter during ballast. If pressure is not high enough the
control valve will close to achieve required pressure, with lower flow as a
result.
6.3 Control system integration

To facilitate monitoring and control of PureBallast, it is possible to integrate the
system to communicate with other components on board the vessel, for
example GPS.
The following optional integrations are possible:
• Remote control panels
• Remote interface
• Power management
• External feed (Recommended for bulker and tanker fit configurations)
• Component signals (hardwired connection of individual components and
features)
• GPS
• Connect
• Log box
For complete component information about integration and installation, please
refer to the following documents:
• Design and installation guide
• Remote interface implementation guide
• Connectivity installation guide
• Connect installation guide
Mandatory and optional integration

Status of all valves and valve combinations that enable bypassing PureBallast
must be integrated to be logged by PureBallast event log. See detailed
information in Design and installation guide, section Mechanical installation,
subsection Bypass and heeling valves. All other integrations are optional.
6.4 Drawings
This section contains drawings for the PureBallast system. It is divided into
three main parts:
200000878-6-EN-GB 199
• 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.
200 200000878-6-EN-GB
6.4.1 Graphic symbols used in drawings
200000878-6-EN-GB 201
6.4.2 General drawings

This section contains the general drawings.
202 200000878-6-EN-GB
6.4.2.1 Flow chart
Note: If vacuum relief valve, VB201 and VB309 (optional) is used see
additional flow chart.
200000878-6-EN-GB 203
6.4.2.2 Flow chart — Vacuum relief valve, VB201 and VB309 (optional)
204 200000878-6-EN-GB
6.4.2.3 Connection list

Note: Inspect the filter marking plate. If you have filter the drawing is correct.
The system may be supplied with a filter of larger size. If so, consult the Filter
size addendum for correct data.
200000878-6-EN-GB 205
206 200000878-6-EN-GB
200000878-6-EN-GB 207
6.4.2.4 Electrical system layout

This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related rights. Without limiting any rights related to
this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any This document may constitute a contractual obligation on the
purpose, without the expressed permission of Alfa Laval. Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution. part of Alfa Laval AB only to the extent expressly agreed upon.
Modification
A
B
E
F
Field
-W117
+EC
++SHIPSYSTEM
Vessel control system
-PE1
+Ship
0
-W14
Date
-W118
-M709-43
3~
M
3+PE
Name
-W110.1
-W15
-M703-1
P309-1
Option
3~
M
-V212.31 V212-31
1
3+PE
Original
Appr
Ed.
Date
1
SETUJAD
SETUGNH
2021-04-14
-W17
+RCP.1
-FT201-1
-W501.1
Remote Control
24VDC±3V(2A)
-W501.1F
(Option)
-W502.1
Panel
-PE5
+Ship
-W10
-UVR Module
2
+RCP.2
-W501.2
Replacement of
PureBallast Compact Flex

PB85-1000
Remote Control
24VDC±3V(2A)
(Option)
-W502.2
Panel
-Filter Module
-W11
-PE6
+Ship
3
-W12
-CIP Module
Interface
(Option)
Remote
-W602
-W212.31
Replaced by
V212-31
-V212-31
(option)
Bypass Valve
++SHIPSYSTEM
Interface
(Option)
1 -W601
GPS
4
-W9A
(20-36kW)
distribution central
Electrical power
50/60Hz, 3 phase
400-440VAC,
-W1
JB.A
-UVR
5
Electrical system layout
-W13A
-W16A
UVR size 600 & 1000.

Included if
(31,5kW)
-PE2
-LDC1:Module
6
-W2
+Ship
-W9B
9035102_ver4
Document No.
7
-W13B
Customer description
-W16B
UVR size 1000.

Included if
-W9C
(38kW)
-LDC2:Module
-W3
-PE3
+Ship
-W9D
8
Nn
1A
Page
+
= PB3
Nn
1A
-PE4
+Ship
9
-UVR
UV Reactor
1/3
208 200000878-6-EN-GB
209
0 1 2 3 4 5 6 7 8 9
Cable list
A Conductors Cables used should be shipboard cables
part of Alfa Laval AB only to the extent expressly agreed upon.
This document may constitute a contractual obligation on the
Cable no Source (from) Target (to) Cable type Min cross-section Function text Remark
[mm] designed according to IEC 60092
Flame retardent: IEC 60332-1-2
PE1 +Ship +EC Single core earth conductor 1x16 Earth connection x
PE2 -LDC1 +Ship Single core earth conductor 1x16 Earth connection x Halogen free: IEC 60754-1 & IEC 60754-2
Flexible insulating sleeving: IEC 60684-2
PE3 -LDC2 +Ship Single core earth conductor 1x16 Earth connection x
PE4 -UVR +Ship Single core earth conductor 1x16 Earth connection x Other equivalent and approved cables
may be used.
B PE5 +Ship +RCP.1 Single core earth conductor 1x6 Earth connection x
Cable areas are calculated with
PE6 +Ship +RCP.2 Single core earth conductor 1x6 Earth connection x correction factor 0,8
Code designations for cables obtainable
W1 ++SHIPSYSTEM +EC Power cable 3x16-25 (20-36kW) Power Supply x5
through cable producers Nexans, Sweden
W2 ++SHIPSYSTEM -LDC1 Power cable 3x25 (31,5kW) If UVR size 600 & 1000. x5
Recommendation of voltage class
W3 ++SHIPSYSTEM -LDC2 Power cable 3x25 (38kW) If UVR size 1000. x5 Rated voltage
purpose, without the expressed permission of Alfa Laval. Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
- Power cables 0,6/1kV

this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any
W9A +EC -UVR-JB.A Alfa Laval 10x1,5 ALFA LAVAL supply 10m
- Instrumentation cables min 150V
C W9B -LDC1 -UVR-JB.A Alfa Laval 10x1,5 ALFA LAVAL supply, Included if UVR size 600 & 1000 10m
W9C -LDC2 -UVR-JB.A Alfa Laval 10x1,5 ALFA LAVAL supply, Included if UVR size 1000. 10m
x Cable not included in Alfa Laval delivery
W9D -LDC2 -UVR-JB.A Alfa Laval 10x1,5 ALFA LAVAL supply, Included if UVR size 1000. 10m
W10 +EC -UVR Module Signal cable shielded 17x0,14 ALFA LAVAL supply 10m
W11 +EC -Filter Module Signal cable shielded 17x0,14 ALFA LAVAL supply 10m
W12 +EC -CIP Module Signal cable shielded 12x0,14 ALFA LAVAL supply 10m
D
W13A +EC -LDC1 Signal cable shielded 2x2x0,25/0,35 ALFA LAVAL supply, If UVR size 600 & 1000. 10m
W13B -LDC1 -LDC2 Signal cable shielded 2x2x0,25/0,35 ALFA LAVAL supply, Included if UVR size 1000. 10m
W14 +EC -M709-43 Power cable shielded 4G1,5 ALFA LAVAL supply 10m
W15 +EC -M703-1 Power cable shielded 4G2,5 ALFA LAVAL supply (Option) 10m
W16A +EC -LDC1 Signal cable shielded 6x2x0,75 ALFA LAVAL supply, If UVR size 600 & 1000. 10m
W16B -LDC1 -LDC2 Signal cable shielded 6x2x0,75 ALFA LAVAL supply, Included if UVR size 1000. 10m
E
W17 +EC -FT201-1 Signal cable shielded 8x0,25 ALFA LAVAL supply 10m
W110.1 ++SHIPSYSTEM -V212.31 Signal cable shielded 5x0,75 Customer Supply (option) x
W117 ++SHIPSYSTEM +EC Signal cable shielded 12x0,75 ISCS Interface connection x3
REMARK
x1 Feedback & open/close signal for bypass valve. x1, x2, x3 can be integrated in same cable.
x2 System size dependant (min 5x0,75 max 16x0,75) x1, x2, x3 can be integrated in same cable.
F x3 System size dependant (min common alarm) x1, x2, x3 can be integrated in same cable.
200000878-6-EN-GB
x4 Shielded CAT5e or better, multimode fiber 62.5/125um RJ45 contact (W501.n) or fiber LC contact (W501.nF)
x5 Cable cross section depend on length and class society regulations.
x6 Shielded Bus Cable RS485 with impedance 100-120 ohm.
Date 2021-04-14 PB85-1000 Document No. = PB3
Ed. SETUGNH PureBallast Compact Flex 9035102_ver4 +
Appr SETUJAD Customer description
Modification Date Name Original Replacement of Replaced by Cable list Page 2/3
200000878-6-EN-GB
0 1 2 3 4 5 6 7 8 9
Cable list
A Conductors Cables used should be shipboard cables
Cable no Source (from) Target (to) Cable type Min cross-section Function text Remark
[mm] designed according to IEC 60092
W118 ++SHIPSYSTEM +EC Signal cable shielded 12x0,75 ISCS Interface connection x3
W212.31 +EC -V212-31 Signal cable 2x0,75 Customer Supply (option) x Halogen free: IEC 60754-1 & IEC 60754-2
Flexible insulating sleeving: IEC 60684-2
W501.1 +EC +RCP.1 LAN CAT5e Shielded or better Remote Control Panel, Max:100m, (Option) x4
W501.1F +EC +RCP.1 Multimode fiber 62.5/125um Remote Control Panel, If more than 100m use fiber cable, (Option) x4 Other equivalent and approved cables
may be used.
B W501.2 +RCP.1 +RCP.2 LAN CAT5e Shielded or better Remote Control Panel, Max:100m, (Option) x4
Cable areas are calculated with
W502.1 ++SHIPSYSTEM +RCP.1 Power Supply 2x Remote Control Panel, 24VDC±3V(2A), (Option) x5 correction factor 0,8
Code designations for cables obtainable
W502.2 ++SHIPSYSTEM +RCP.2 Power Supply 2x Remote Control Panel, 24VDC±3V(2A), (Option) x5
through cable producers Nexans, Sweden
W601 +EC ++SHIPSYSTEM+GPS Signal cable shielded 2x2x0,75 GPS Interface connection (Option) x
Recommendation of voltage class
W602 +EC ++SHIPSYSTEM+RI Signal cable shielded 2x2x0,75 Remote Interface connection (Option) x Rated voltage
- Power cables 0,6/1kV

- Instrumentation cables min 150V

C
x Cable not included in Alfa Laval delivery
D
E
REMARK
F x3 System size dependant (min common alarm) x1, x2, x3 can be integrated in same cable.
x4 Shielded CAT5e or better, multimode fiber 62.5/125um RJ45 contact (W501.n) or fiber LC contact (W501.nF)
Date 2021-04-14 PB85-1000 Document No. = PB3
Ed. SETUGNH PureBallast Compact Flex 9035102_ver4 +
210
6.4.2.5 Electrical system layout – log box (optional)

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

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

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

-W104
8
Page
+
= PB3.x
1/3
200000878-6-EN-GB 211
200000878-6-EN-GB
0 1 2 3 4 5 6 7 8 9
Cable overview AlfaWall_2018 (FEN)
A
Min cross-section
Cable no Source (from) Target (to) Cable type Conductors Function text
[mm]
-W10 ++SHIPSYSTEM +Log Box Power cable armoured 3 1,5 Mains Supply
-W104 +Log Box +CC/EC LAN CAT5e Shielded or better Max:100m
-W201 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Digital Input
B -W203 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Digital Input
This document constitutes a contractual obligation on our
part only to the extent expressly agreed upon.
C
D
and may not be copied, reproduced, transmitted or communicated to a third party,
E
nor used for any pupose without written permission.
F
Date 2020-03-13 Document No. = PB3.x
Ed. SETUGNH PureBallast 9049242_ver1 +
Appr SETURWAA Customer description
212
213
0 1 2 3 4 5 6 7 8 9
A
Min cross-section
[mm]
B -W230 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Digital Input
-W321 +Log Box ++SHIPSYSTEM Signal cable shielded 1x2 0,75 Analog Input
C
D
E
200000878-6-EN-GB
200000878-6-EN-GB
0 1 2 3 4 5 6 7 8 9
++SHIPSYSTEM
Electrical power Vessel control system
A
110-230VAC, 50/60Hz
-W11 -W10.LAN
B
+Connectivity
Connectivity Cabinet
C
6.4.2.6 Electrical system layout – Connectivity (optional)
D
-W1.LAN -W2.LAN -W3.LAN -W4.LAN -W5.LAN -W6.LAN -W7.LAN
E
Machine 1 Machine 2 Machine 3 Machine 4 Machine 5 Machine 6 Machine 7

F
Modification Date Name Original Replacement of Replaced by Electrical system layout Page 1/2
214
215
0 1 2 3 4 5 6 7 8 9
A
Min cross-section
[mm]
-W1.LAN +Connectivity +Machine 1 LAN CAT5e Shielded or better Max:100m
B -W5.LAN +Connectivity +Machine 5 LAN CAT5e Shielded or better Max:100m
-W10.LAN +Connectivity ++SHIPSYSTEM LAN CAT5e Shielded or better Max:100m, Customer

-W11 ++SHIPSYSTEM +Connectivity Power cable armoured 3G 1,5 Mains Supply
C
D
E
200000878-6-EN-GB
6.4.2.7 Instrument air distribution
216 200000878-6-EN-GB
Instrument air distribution — Filter
200000878-6-EN-GB 217
Instrument air distribution — UVR
218 200000878-6-EN-GB
6.4.2.8 Quality specification / Instrument air
200000878-6-EN-GB 219
6.4.2.9 Quality specification / Technical and potable water
220 200000878-6-EN-GB
6.4.2.10 Quality specification / CIP liquid

Note that the information below regarding dilution is not valid for compact or
compact flex systems.
200000878-6-EN-GB 221
222 200000878-6-EN-GB
6.4.3 Dimension drawings

This section contains the dimension drawings.
200000878-6-EN-GB 223
6.4.3.1 UV reactor
224 200000878-6-EN-GB
6.4.3.2 Electrical cabinet
200000878-6-EN-GB 225
6.4.3.3 Filter
size addendum for correct data.
226 200000878-6-EN-GB
200000878-6-EN-GB 227
6.4.3.4 CIP module
228 200000878-6-EN-GB
6.4.3.5 Flow transmitter FT201-1
200000878-6-EN-GB 229
6.4.3.6 Pressure monitoring device (PT201-16, PI201-18, RV201, V201-17)
230 200000878-6-EN-GB
6.4.3.7 Control valve V201-8
200000878-6-EN-GB 231
6.4.3.8 Valve V201-9
232 200000878-6-EN-GB
6.4.3.9 Valve V212-31 (optional)
200000878-6-EN-GB 233
6.4.3.10 Backflush valve V309-1
If backflush pump P309–1 (optional) is installed, this valve is delivered

mounted on the pump. If backflush pump is not used, the valve is mounted on
the filter.
234 200000878-6-EN-GB
6.4.3.11 Vacuum relief valve VB201 (optional)

NOTE There are two different configurations of the vacuum relief valve VB201 described
in two different drawings. Please check the order confirmation document to find out which
item that is delivered for each specific order.
Article number Dimension drawing
9047958 XX 9047959
9041133 XX 9041134
200000878-6-EN-GB 235
236 200000878-6-EN-GB
200000878-6-EN-GB 237
6.4.3.12 Vacuum relief valve VB309 (optional)

NOTE There are two different configurations of the vacuum relief valve VB309 described
in two different drawings. Please check the order confirmation document to find out which
item that is delivered for each specific order.
9047958 XX 9047959
9041153 XX 9041154
238 200000878-6-EN-GB
200000878-6-EN-GB 239
240 200000878-6-EN-GB
6.4.3.13 Sampling device Q201.1 and Q201.2 (optional)

NOTE There are two different configurations of the Sampling device Q201.1 and Q201.2
described in two different drawings. Please check the order confirmation document to find out
which item is delivered for each specific order.
589745 XX 590066
9052773 XX 9053398
200000878-6-EN-GB 241
242 200000878-6-EN-GB
200000878-6-EN-GB 243
244 200000878-6-EN-GB
200000878-6-EN-GB 245
246 200000878-6-EN-GB
6.4.3.14 Air filter regulator
200000878-6-EN-GB 247
6.4.3.15 Air preparation unit (optional)
248 200000878-6-EN-GB
6.4.3.16 Remote control panel (optional)
200000878-6-EN-GB 249
250 200000878-6-EN-GB
6.4.3.17 Log box (optional)
200000878-6-EN-GB 251
200000878-6-EN-GB 252
This document and its contents is owned by Alfa Laval AB (publ.) and protected by laws governing intellectual property and thereto related rights. Without This document may constitute a
limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, contractual obligation on the
mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval. Alfa Laval will enforce its rights part of Alfa Laval AB only
related to this document to the fullest extent of the law, including the seeking of criminal prosecution to the extent expressly agreed upon.
600 50
0
Revision No.
701
Date
799 -Signals
2019-11-14
701 -Power supply
Revised
RNE
380
Approved
Legend: (ref. to electrical system layout)
JoEn
799
-signal cables, 10xM16, cable n4,5-10mm

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

Title
ISO E
Method
542
projection
First angle
Creator
RNE
BALLAST
Responsible Department
Date
NB Review Article Data report for additional demands
Approved
Connectivity cabinet dim. dwg.
JoEn
Aerial view
507
2019-11-14
No.
110°
Sheet
1
Document No.
No. of
sheets
127
1 No.
9046270
Revision
0
584
A2
6.4.3.18 Connectivity cabinet (optional)
6.4.3.19 Transformer (optional)
200000878-6-EN-GB 253
6.4.3.20 Backflush pump P309–1 (optional)

size addendum for correct drawing.
254 200000878-6-EN-GB
200000878-6-EN-GB 255
6.4.4 Electrical drawings

This section contains the electrical drawings.
256 200000878-6-EN-GB
6.4.4.1 Electrical cabinet / Interconnection diagram

Modification
A
B
E
F
Target (to) Source (from)
0
Date
+EC / 1 +SHIPSYSTEM / 1
L1(R) L1(R)
1 3x16-25 L1
Name
Power cable
L2(S) L2(S)
Q1 3 -W1 L2
L3(T) L3(T)
5
x5
L3 X1
+EC / 1
Original
Appr
Ed.
Date
1
PE PE
PE PE
SETUJAD
SETUGNH
2021-03-30
+UVR / 1 +EC / 1
1 1
1 3
2
2 2
2 5
3 3
3 7
Replacement of
4 4
4 10x1,5 9
5 5
Lamp cable
5 -W9A 11
6 6
JB.A-X20.A 6
10m
14 X9A
7 7
7 16
3
8 8
8 18
9 9
9 20
10 10
10 22
Replaced by
SH SH
PE PE
4
+UVR / 19 +EC / 19
BN BN
1 1
BU BU
2 2
WH WH
3 3
GN GN
4 4
5
Interconnection diagram
PK PK
5 5
YE YE
EC
6 6
BK BK
7 7
8
GY 17x0,14 GY
8
-W10
UVR JB.B
RD RD
9 9
JB.B-X1 VT 10m VT X10
10 10
6
GYPK GYPK
11 11
RDBU RDBU
15 12
WHGN WHGN
9034898_ver7
Document No.
16 13
BNGN BNGN
17 14
WHYE WHYE
18 15
YEBN YEBN
19 16
7
WHGY WHGY
20 17
SH SH
PE SH
8
Page 23 / 29
+ EC
= PB3.2
200000878-6-EN-GB 257
Modification
A
B
E
F
0
Date
+Filter / 20 +EC / 20
BN BN
1 1
Name
BU BU
2 2
WH WH
3 3
GN GN
4 4
Original
Appr
Ed.
Date
1
PK PK
5 5
YE YE
6 6
SETUJAD
SETUGNH
2021-03-30
BK BK
7 7
8
GY 17x0,14 GY
8
RD -W11 RD
Filter JB
9 9
JB-X1 VT 10m VT X11
10 10
2
GYPK GYPK
11 11
RDBU RDBU
12 12
Replacement of
WHGN WHGN
17 13
BNGN BNGN
16 14
WHYE WHYE
18 15
YEBN YEBN
20 16
3
WHGY WHGY
21 17
SH SH
PE SH
Replaced by
+CIP / 18 +EC / 18
4
BN BN
1A 1
BU BU
1B 2
WH WH
2A 3
GN GN
2B 4
PK PK
3A 5
YE 12x0,14 YE
CIP Valve block
3B 6
5
X1 -W12
BK BK
4A 7
GY 10m GY X12
EC
4B 8
RD RD
5A 9
VT VT
5B 10
GYPK GYPK
COM 11
RDBU RDBU
6A 12
6
+CIP / 18
SH SH
SH Insulated SH
9034898_ver7
Document No.
7
8
Page 24 / 29
+ EC
= PB3.2
258 200000878-6-EN-GB
Modification
A
B
E
F
0
Date
+LDC1 / 11 +EC / 11
LPS communication RD RD
2 2x0,25/2x0,34 2
Name
BK BK
3 -W13A 3
WH WH
X13A 4
10 m
4 X13A
BU BU
5 5
Original
Appr
Ed.
Date
1
SH SH
1 1
SETUJAD
SETUGNH
2021-03-30
+Filter / 2 +EC / 2
1 1
U1 4G1,5 1
2
2 2
Filter motor
V1 -W14 2
3 3
M709-43 W1 3 X14
Replacement of
10m
GNYE GNYE
PE PE
SH SH
Isolated SH
3
+Filter / 2 +EC / 2
1 1
U1 4G2,5 1
Replaced by
Pump motor
2 2
V1 -W15 2
3 3
M703-1 W1
10m
3 X15
GNYE GNYE
PE PE
4
SH SH
Isolated SH
+EXT / 21 +EC / 21
WH WH
1 1
5
BN BN
2 2
8x0,25
EC
GN GN
System Flow/
26 3
Conductivity
27
YE -W17 YE
4
FT201-1 GY 10m GY
24 5 X17
PK PK
25 6
BU BU
Isolated 7
6
RD RD
Isolated 8
SH SH
SH
9034898_ver7
Document No.
7
8
Page 25 / 29
+ EC
= PB3.2
200000878-6-EN-GB 259
Modification
A
B
E
F
0
Date
+Log box / 4 +EC / 4

OG/WH OG/WH
1 1
Name
OG OG
2 2
GN/WH GN/WH
CAT5e SF/UTP
Log box interface
3 3
BU BU
Connection
4 -W104 4
Original
Appr
Ed.
Date
1
BU/WH BU/WH
X6 5
x4
5 X8
GN GN
6 6
SETUJAD
SETUGNH
2021-03-30
BN/WH BN/WH
7 7
BN BN
8 8
SH SH
SH SH
2
Replacement of
+SHIPSYSTEM / 13 +SHIPSYSTEM / 13
1 1
1 5x0,75 U3
Bypass valve
2 2
2 -W110.1 U3
3 3
V212-31 3
x
U3 *
3
4 4
4 U3
5 5
6 U3
SH SH
Replaced by
4
+SHIPSYSTEM / 10 +EC / 10
1 1
11
2 2 K10
14
+EC / 10
3 3
11
4 4 K11
14
5
+EC / 10
5 5
EC
12x0,75 11
ISCS interface
6 6 K12
connection
-W117 14
U2 x3 +EC / 10
7 7
11
8 8 K13
14
6
+EC / 10
9 9
11
10 10 K14
9034898_ver7
Document No.
14
+EC / 10
11 11
11
12 12 K15
14
7
+EC / 10
SH SH
PE PE
8
Page 26 / 29
+ EC
= PB3.2
260 200000878-6-EN-GB
Modification
A
B
E
F
0
Date
1 1
404:4 X3
Name
+EC / 13
2 2
A1 K21
+EC / 13
Original
Appr
Ed.
Date
1
3 3
404:5 X3
+EC / 13
SETUJAD
SETUGNH
2021-03-30
4 4
A1 K22
+EC / 13
5 5
404:6 X3
12x0,75 +EC / 13
ISCS interface
2
6 6
connection
-W118 A1 K23
U4 x3 +EC / 13
Replacement of
7 7
404:10 X3
+EC / 13
8 8
A1 K24
+EC / 13
3
9 9
404:11 X3
+EC / 13
10 10
A1 K25
Replaced by
+EC / 13
11 11
404:12 X3
+EC / 13
4
12 12
A1 K26
+EC / 13
SH SH
PE PE
2x0,75
5
+SHIPSYSTEM / 13 +SHIPSYSTEM / 13
Bypass valve
-W212.31
Feedback
1 1
EC
8
U4 2 x 2 V212-31
SH SH
6
9034898_ver7
Document No.
7
8
Page 27 / 29
+ EC
= PB3.2
200000878-6-EN-GB 261
Modification
A
B
E
F
0
Date
+RCP / 4 +EC / 4
OG/WH OG/WH
1 1
Name
OG OG
2 2
Remote control panel
GN/WH GN/WH
3 CAT5e SF/UTP 3
BU BU
Connection
4 -W501.1 4
Original
Appr
Ed.
Date
1
BU/WH BU/WH
X2 5
x4
5 X7
GN GN
6 6
SETUJAD
SETUGNH
2021-03-30
BN/WH BN/WH
7 7
BN BN
8 8
SH SH
SH SH
2
Replacement of
2x62,5/125um
Remote Panel
+RCP / 4 +EC / 4
Optical Fiber
Connection
OUT
RX- -W501.1F RX-
IN
SW1 TX- x3 TX- SW1
IN OUT
3
2x
Remote Panel
Power Supply
+RCP / 4 +SHIPSYSTEM / 4
Replaced by
Connection
+
1 -W502.1 1
+
X1 2 x3 2 PS
- -
4
1A 1A
TX+ 1Rx+
1B 2x2x0,75 1B
GPS Interface
TX- 2Rx-
connection
GND
2A -W601 2A
GND
X2
5
GPS 2B x 2B
GND GND
EC
+EC / 12
SH SH
Insulated -PE
6
1A 1A
2x2x0,75
Remote interface
3 3
9034898_ver7
Document No.
1B 1B
connection
8 -W602 8
2A 2A
RI 5
x
5 X6
2B 2B
SH SH
7
PE PE
8
Page 28 / 29
+ EC
= PB3.2
262 200000878-6-EN-GB
6.4.4.2 Electrical cabinet / Circuit diagram

Modification
A
B
E
F
Use uninsulated tin plated Ø8mm ring cable lugs
(Recommended fuse 45-125A)

400-440VAC, 50/60Hz
Power supply
+SHIPSYSTEM
and heat shrink tube when connecting cable on -Q1.
Max:80A
3x16-25
-Q1
0
Date
-W1
-Z1
-X1
25 mm²
Line
1
2
Load
L1
L1'
01 Flexbar 04 BK
L1
L1(R)
25 mm²
3
Line
3
4
Load
L2
L2'
Name
02 Flexbar 05 BK
L2
L2(S)
25 mm²
Line
5
6
Load
L3
L3'
03 Flexbar 06 BK
L3
L3(T)
PE
10 mm²
-PE
-PE
GNYE
PE
PE
Original
Appr
Ed.
Date
1
+UVR
-Q101
LPS cable
-X9A
SETUJAD
SETUGNH
2021-03-30
10x1,5
12A
-W9A
10m
-LPS1
/11.2:C
UVR size 250-300 LPS1-5 terminal 1-10 connected
UVR size 85-170 LPS1-3 terminal 1-6 connected
-JB.A
supply
power
Lamp
-X20.A
1,5 mm² 2,5 mm²
I>
-L1
L1
1
2
1 0121 BK 0101 BK
1
3
2,5 mm²
I>
-L2
L2
OUTPUT
INPUT
4
0102 WH
2
1,5 mm² 2,5 mm²
I>
-L3
L3
2
6
2 0122 BK 0103 BN
2
5
2,5 mm²
-PE
PE
PE
Replacement of
GNYE /6.4:B
14
13
22
21
-Q102
12A
-X401
-LPS2
/11.3:C
supply
power
Lamp
3
1,5 mm² 2,5 mm²
I>
L1
1
2
3 0123 BK 0104 BK
3
-L1
7
2,5 mm²
I>
L2
OUTPUT
INPUT
4
0105 WH
-L2
Replaced by
1,5 mm² 2,5 mm²
I>
L3
2
6
4 0124 BK 0106 BN
4
-L3
9
2,5 mm²
-PE
PE
PE
GNYE /6.4:B
14
13
22
21
4
-Q103
12A
-X402
-LPS3
/11.4:C
supply
power
Lamp
1,5 mm² 2,5 mm²

I>
L1
1
2
5 0125 BK 0107 BK
5
-L1
11
2,5 mm²
I>
L2
OUTPUT
INPUT
4
0108 WH
-L2
5
Incoming power supply
1,5 mm² 2,5 mm²

I>
L3
2
6 0126 BK 0109 BN
6
-L3
14
2,5 mm²
EC
-PE
PE
PE
GNYE /6.4:C
14
13
6 mm²
6 mm²
6 mm²
09 BK
08 BK
07 BK
22
21
-Q104
9 / 3.0:A
8 / 3.0:A
7 / 3.0:A
12A
-LPS4
/11.5:C
supply
6
power
Lamp
1,5 mm² 2,5 mm²

I>
-L1
L1
1
09.1 BK
08.1 BK
07.1 BK
1
7 0127 BK 0110 BK
7
16
6 mm²
6 mm²
6 mm²
2,5 mm²
I>
-L2
9034898_ver7
Document No.
L2
OUTPUT
INPUT
0112 WH
1,5 mm² 2,5 mm²
I>
-L3
L3
2
8 0128 BK 0113 BN
8
18
9.1 / 2.0:A
8.1 / 2.0:A
7.1 / 2.0:A
2,5 mm²
-PE
PE
PE
GNYE /6.4:C
14
13
7
22
21
Signal conductors shall be blue 0,75 mm²

Standard: IPC/WHMA-A-620A Class 2
25 mm² and up use pin or ring cable lug.
Insulated end ferrules shall be used up to 16 mm².
-Q105
12A
-LPS5
/11.6:C
supply
power
Lamp
1,5 mm² 2,5 mm²

I>
-L1
L1
1
9 0129 BK 0114 BK
9
20
2,5 mm²
I>
-L2
L2
OUTPUT
INPUT
8
3
0115 WH
1,5 mm² 2,5 mm²
I>
-L3
L3
2
10 0130 BK 0116 BN
10
22
2,5 mm²
-PE
PE
PE
GNYE /6.4:D
14
13
22
21
Black 1,5 mm²

BETAterm 120 1.8 / 3 kV
LPS OUTPUT Wires:
-Ship
-AOT
X9.1 / 22.8:A
091
1
Page
+ EC
= PB3.2
Structure
161 / 11.3:E
0161
24
PE
9
PE
PE
PE
-PE
1 / 29
SH
PE
PE
PE
200000878-6-EN-GB 263
Modification
A
B
E
F
1.7:A /
1.7:A /
1.7:A /
0
Date
9.1
8.1
7.1
Name
+Filter
-F2
-M709-43
20A
-X14
-W014
4G1,5
4G1,5
-W14
Original
Appr
Ed.
Date
10 m
-K4
1
Filter
2,5 mm²
FILTER MOTOR
2/T1
1/L1
I>
U1
1
SETUJAD
SETUGNH
2021-03-30
1 1 010 BK
M709-43
1
2,5 mm²
3
4/T2
3/L2
I>
M
V1
3
2 2 011 BK
2
2,5 mm²
6/T3
5/L3
I>
W1
5
3 3 012 BK
3
PE
GNYE GNYE /6.4:D
PE
14
13
PE
22
21
2
SH
SH Frame
Replacement of
Us
96
402.4 402.2
GND
95
070 400.2
97
ON
074
3
0,18
Setpoint according
to marking plate.
0,87
Reset
402.4 / 3.2:E
070 / 6.7:A
074 / 9.4:C
400.2 / 3.2:B
402.2 / 3.2:E
1,63
2,4
Replaced by
4
Setpoint according to marking plate.
2
1
Alternative
+Filter
5,7-18,9
1,9-6,3
Current (A)
-X15
-M703-1
/2.7:C
/2.8:C
4G2,5
-W15
10 m
P309-1
-F5
/2.7:D
5
400-440V AC
-K5
2,5 mm² 2,5 mm²

BOOSTER PUMP
U1
1
EC
1 031 BK 013 BK
OPTION
1
P309-1
2,5 mm² 2,5 mm²

3
M
V1
2 032 BK 014 BK
2
2,5 mm² 2,5 mm²

W1
3 033 BK 015 BK
3
2,5 mm²
PE
GNYE GNYE
PE
PE
SH 6
SH Frame
9034898_ver7
Document No.
-K5
/2.5:C
-F5
21
5
3
1
A2
A1
96
95
400.3 099 075

7
22
6 /2.6:C
4 /2.5:C
2 /2.5:C
400.3 / 3.2:B
075 / 9.5:C
/2.5:C
-F5
8
98
97
071 402.3
071 / 7.1:A
402.3 / 3.2:E
Page
+ EC
= PB3.2
9
2 / 29
264 200000878-6-EN-GB
Modification
A
B
E
F
1.6:A /
1.6:A / 8
1.6:A / 7
0
Date
9
-F41
24V/10A
-F1
10A
-X1
PLC/HMI
-T1
1,5 mm²
Electronic fuse
9.6:C / 401.2 1 LOAD (optional)+ 7
401.2 1,5 mm² 2,5 mm²
Name
401.1
I:3 / C:3
V+
L1
4.2:A / 401.3 2 SET/RESET + 6
401.3
1
4.4:B / 401.4 3 STATUS
401 BU 016 BK
OUTPUT
401.4 1,5 mm² 2,5 mm²
INPUT
V+
L2
4 NC GND 5
3
404 BU 017 BK
Busbar white
Busbar blue
Busbar red
2,5 mm²
401
L3
V-
5
Original
Appr
Ed.
Date
018 BK
1
2,5 mm²
-PE
V-'
PE
GNYE
SETUJAD
SETUGNH
2021-03-30
V-''
-F42
2,5 mm²
-PE
GNYE
1,5 mm²
Electronic fuse
2.3:B / 402.2 1 LOAD (optional)+ 7
402.2 402.1 2,5 mm²
I:2 / C:2
2.8:C / 402.3 2 SET/RESET + 6
INTERN
402.3 400.1 BU
2.3:D / 402.4 3 STATUS
402.4
4 NC GND 5
-X1
2
6.4:A / 402.6
402.6
402
2.3:B /400.2
400.2
11.0:F / 402.7 2.7:D / 400.3
402.7 400.3
Replacement of
17.7:D / 402.8 3.8:D / 400.4

402.8 400.4
22.1:C / 402.9 4.2:A / 400.5
402.9 400.5
4.4:B / 400.6
400.6
400
6.3:A / 400.7
400.7
402
22.4:E / 400.8
400.8
9.7:C / 400.9
400.9
3
10.1:D / 400.10
400.10
10.7:C / 400.11
-F43
400.11
11.1:F / 400.12
086
400
1,5 mm²
Electronic fuse
10.6:C / 403.2 1 LOAD (optional)+ 7 13.6:D / 400.13

403.2 403.1 400.13
I:2 / C:2
403.3 400.14
Replaced by
19.6:A / 2 SET/RESET + 6 15.3:A /

I/O
1012 400.14
20.0:A / 403.4 3 STATUS 15.4:A / 400.15
1112 400.15
21.1:B / 403.5 4 NC GND 5 17.8:D / 400.16
1701 400.16
18.9:B / 403.6 19.9:A / 400.17
1210 1017
403
20.1:A / 400.18
1115
400
16.8:B / 403.7
4
403.7
21.2:B / 400.19
1702
22.1:C / 400.20
400.20
9.1:E / 400.21
400.21
22.8:E / 400.22
400.22
400.23
403
20.9:A / 400.24
1117
400
18.9:B / 400.25
1211
400.23
18.9:B / 400.26
-F44
1212
16.9:B / 400.27
400.27
5
11.5:E / 400.28
24V DC
D/O
1,5 mm² 400.28

Electronic fuse
13.0:C / 404.1 1 LOAD (optional)+ 7

404.1
I:8 / C:3
2 SET/RESET + 6
EC
400
3 STATUS
4 NC GND 5
1,5 mm²
13.0:C / 404.2
404.2
6
9034898_ver7
Document No.
-X4
-M1
1,5 mm² 1,5 mm²

Un
Fan
M1
1 BU 404.2
1
1,5 mm² 1,5 mm²

GND
7
M
2 BU 400.4
2
0,75 mm²
Tach
3 BU 072
3
0,75 mm²
0-10V
PLC DIN-Rail
4 BU 090
4
2,5 mm²
-X1
-X2
x1
-PE
PE
4,7K Ohm
GNYE 2,5 mm² 2,5 mm² 2,5 mm²

-R1
PE
GNYE GNYE GNYE

PE
PE
PE
Busbar
x2
Cabinet
6 mm²
PE
PE
GNYE
069
Busbar
090 / 16.4:D
072 / 8.3:A
400.4 / 3.2:B
069 / 6.6:A
Mounting plate
6 mm²
PE
PE
Page
+ EC
= PB3.2
GNYE
Busbar
9
3 / 29
200000878-6-EN-GB 265
Modification
A
B
E
F
0
Date
CAT5e SF/UTP
CAT5e SF/UTP
-W01.LAN
-W02.LAN
-OP1
Name
5.4:A / LAN01
LAN
Original
Appr
Ed.
Date
Control panel
1
door
051.1 / 22.0:F
SETUJAD
SETUGNH
2021-03-30
051.1
Door upper
052.1 / 22.5:F
-USB1
052.1
-X5
USB
401.3 / 3.1:E
+
+RCP
+SHIPSYSTEM
USB1 051 401.3
1
400.5 / 3.2:B
2
-W502.1
24VDC
PS
052 400.5
2
-X1
2,5 mm²
PE
24VDC ±3V (2A)
2x
GNYE
Replacement of
+
1
+
2,5 mm² 2,5 mm²
PE
-
2
PE
-
GNYE GNYE
PE
6 mm²
Door
PE
PE
GNYE
3
Cabinet frame
CAT5e SF/UTP
-SW1
-W501.1
Replaced by
X1
400.6 / 3.3:B
1
-X2
-X7
COM
LAN 01 400.6
1
1
1
OG/WH
401.4 / 3.1:E
2
Remote control panel connection
+VA
401.4
CAT5e SF/UTP
4
2
2
2
OG
X2
LAN 02
-W03.LAN
3
3
3
3
+VB
GN/WH
4
4
4
BU
X3
5
5
5
BU/WH LAN 03
RJ45
RJ45
6
6
6
GN
7
7
7
BN/WH
5
X4
HMI Panel
8
8
BN
EC
Optic fiber cable

2x62,5/125um
SH
SH
SH
-W501.1F
-SW1
IN
IN
(Optional)
RX-
TX-
RX-
TD
TD
6
OUT
OUT
TX-
RX-
TX-
RD
RD
9034898_ver7
Document No.
CAT5e SF/UTP
Log box interface
+Log box
-W104
7
-X6
-X8
1
1
OG/WH
CAT5e SF/UTP
2
2
2
OG
-W04.LAN
3
3
3
GN/WH
4
4
4
BU
LAN04 / 5.4:A
8
5
5
5
BU/WH
RJ45
RJ45
6
6
6
GN
7
7
7
BN/WH
8
8
8
BN
Terminal layout for
Ethernet cables
Page
+ EC
= PB3.2
SH
SH
SH
9
4 / 29
266 200000878-6-EN-GB
267
0 1 2 3 4 5 6 7 8 9
LAN04 / 4.8:B
LAN01 / 4.1:E
A
LAN 01
LAN 04
-A1 X1 16 X1 17 X1 18 X1 26 X1 27 X1 28 IF2 1 IF3 1

B CANH CANL GND TxD RxD GND ETH PLK
Part 1 of 6
CANH CANL GND TxD RxD GND
V2.91
Ethernet PLK -SS1
X20IF1030
Channel 4 Channel 4 IF2 IF3
X20CP1382
n.c. TxD RxD n.c. GND VDC TxD\ RxD\ n.c. SH
IF1 1 2 3 4 5 6 7 8 9
RS422
USB USB SH SH SH
n.c. n.c. DATA n.c. GND VDC n.c. DATA/ n.c. SH
USB USB SH SH SH
RS485
IF4 1 IF5 1 X0 1 X0 2 X0 3 IF1 1 2 3 4 5 6 7 8 9

C V3.01
USB2
-W06 1 2 3 4 5 6 7 8 9 SHD
CABLE-D 9SUB
D -USB2 -X6 PE RI connection 485 (*)
Door lower 1 2 3 4 5 6 7 8 9
Term. 3 DATA
1 2 3 4 5 6 7 8 9 PE
Term. 5 Signal gnd
Term. 8 DATA\
RI connection 422
Term. 2 TxD
-W602 1A 2A 1B SH Term. 3 RxD
Signal Term. 5 Signal gnd
cable Term. 7 TxD\
shielded Term. 8 RxD\
E
2x2x0,75
+SHIPSYSTEM
(*) Default connection
-RI
3 5 8 PE
F
Remote interface connection
200000878-6-EN-GB
Date 2021-03-30 Document No. = PB3.2
Ed. SETUGNH PureBallast Compact Flex EC 9034898_ver7 + EC
Modification Date Name Original Replacement of Replaced by A1 - CPU Page 5 / 29
Modification
A
B
E
F
0
Date
Name
-A1-X1
Original
Appr
Ed.
Date
1
SETUJAD
SETUGNH
2021-03-30
AnalogInput01
UV sensor
QT201-50
4-20 mA
X1
AI+01I
1011 / 19.3:A
1011 / GYPK
11
Analog input
AnalogInput01
Channel 1
X1
AI+01U
2
12
Replacement of
AnalogInput01
X1
AI-01
400.7 / 3.3:B
400.7
13
DigitalInput01
3
X1
KS1 OK
DI-01
063 / 22.3:E
063
14
Digital input
-Q105
-Q104
-Q103
-Q102
-Q101
/2.1:A
/1.8:B
/1.6:B
/1.5:B
/1.3:B
/1.2:B
Replaced by
-F2
MS132 LPS
fuse alarm
DigitalInput03
X1
DI-03
402.6 / 3.2:E
14
13
14
13
14
13
14
13
14
13
14
13
098 097 096 095 094 093 402.6
15
4
AnalogInput02
flow 4-20
FT201-1
X1
System
AI+02I
mA
1703 / 21.2:B
1703
21
Analog input
AnalogInput02
Channel 2
X1
AI+02U
22
5
A1-X1 - Analog/Digital Inputs
AnalogInput02
EC
X1
AI-02
1704 / 21.2:B
1704
23
DigitalInput02
X1
EC fuse
alarm
DI-02
069 / 3.8:D
069 6
24
Digital input
DigitalInput04
M709-43
X1
9034898_ver7
Document No.
alarm
DI-04
070 / 2.3:D
070
25
7
Part 2
of 6
V3.01
8
Page
+ EC
= PB3.2
9
6 / 29
268 200000878-6-EN-GB
Modification
A
B
E
F
0
Date
Name
-A1-X2
Original
Appr
Ed.
Date
DigitalInput01
1
X2
M703-1
alarm
DI-01
071 / 2.8:D
071
11
SETUJAD
SETUGNH
2021-03-30
Digital input
DigitalInput02
TS201-33
X2
DI-02
060 / 22.2:E
060
21
2
Replacement of
DigitalInput03
TS201-60
X2
DI-03
061 / 22.2:E
061
12
3
DigitalInput04
LS201-29
X2
DI-04
062 / 22.3:E
062
22
Replaced by
4
DigitalInput05
LS320-3
X2
CIP low
level
DI-05
129 / 18.9:B
129 / RD
13
DigitalInput06
X2
V201-3
closed
DI-06
111 / 20.1:A
111 / BN
5
23
A1-X2 - Digital Inputs
EC
DigitalInput07
X2
opened
V201-3
DI-07
113 / 20.1:A
113 / WH
14
6
X2
GND
GND
9034898_ver7
Document No.
18
Part 3
7
X0
SH
of 6
SH
4
V3.01
8
Page
+ EC
= PB3.2
9
7 / 29
200000878-6-EN-GB 269
Modification
A
B
E
F
0
Date
Name
-A1-X2
Original
Appr
Ed.
Date
DigitalInput08
1
X2
V201-9
closed
DI-08
116 / 20.2:A
116 / YE
24
SETUJAD
SETUGNH
2021-03-30
Digital input
DigitalInput09
X2
opened
V201-9
DI-09
114 / 20.2:A
114 / GN
15
2
Replacement of
DigitalInput10
X2
V201-8
closed
DI-10
102 / 19.6:A
102 / BU
25
3
DigitalInput11
M1 speed
X2
counter
DI-11
072 / 3.8:D
072
16
Replaced by
4
LDC 1 Fuse
DigitalInput12
X2
alarm
DI-12
163 / 11.3:E
0163 OG
26
LDC 2 Fuse
DigitalInput13
X2
alarm
DI-13
173 / 11.5:E
0173 OG
5
17
A1-X2 - Digital Inputs
EC
DigitalInput14
X2
Spare
DI-14
27
6
X2
24V+
24V+
9034898_ver7
Document No.
28
Part 4
7
of 6
V3.01
8
Page
+ EC
= PB3.2
9
8 / 29
270 200000878-6-EN-GB
Modification
A
B
E
F
0
Date
Name
-A1-X3
Original
Appr
Ed.
Date
1
/11.0:D
-K2
DigitalOutput01
K2 Activate
SETUJAD
SETUGNH
2021-03-30
X3
LPS
DO-01
3.4:B / 400.21
A2
A1
400.21 073
11
Digital output
Green
-X5
-H2
Door
2
DigitalOutput02
lamp on
X3
H2 UV
DO-02
22.1:F / 052.3
x2
x1
052.3 055 055
21
Replacement of
Alarm / bell
-H3
Door
DigitalOutput03
Alarm/bell
X3
DO-03
H3
x2
x1
052.4 056 056
3
12
Replaced by
DigitalOutput04
X3
DO-04
.
22
4
Filter motor
DigitalOutput05
M709-43
X3
DO-05
2.3:B / 074
074 13
5
A1-X3 - Digital Outputs
DigitalOutput06
X3
M703-1
motor
Pump
DO-06
2.7:C / 075
EC
075
23
Link supply
CPU/X2X
X3
24VDC
VDC
VDC
3.0:E / 401.2
6
401.2
17
9034898_ver7
Document No.
Link supply
CPU/X2X
X3
GND
GND
GND
3.3:B / 400.9
400.9
18
7
Part 5
of 6
V3.01
8
Page
+ EC
= PB3.2
9
9 / 29
200000878-6-EN-GB 271
200000878-6-EN-GB
0 1 2 3 4 5 6 7 8 9
A
V3.01
-A1-X3
Part 6 of 6
Digital output
DigitalOutput07 DigitalOutput08 DigitalOutput09 DigitalOutput10 DigitalOutput11 DigitalOutput12 VDC GND
B DO-07 DO-08 DO-09 DO-10 DO-11 DO-12 VDC GND
X3 14 X3 24 X3 15 X3 25 X3 16 X3 26 X3 27 X3 28
400.11
403.2
076
077
078
079
080
081
A1 A1 A1 A1 A1 A1
C -K10 -K11 -K12 -K13 -K14 -K15
/10.1:D A2 /10.2:D A2 /10.3:D A2 /10.4:D A2 /10.4:D A2 /10.5:D A2
403.2
400.11
3.3:E /
400.10 Busbar 6pol Blue
3.3:B /
3.3:B / 400.10
D Contact Rating:
250VAC -K10 11 -K11 11 -K12 11 -K13 11 -K14 11 -K15 11
/10.1:C /10.2:C /10.3:C /10.4:C /10.4:C /10.5:C
Max:2A
14 12 14 12 14 12 14 12 14 12 14 12
Min:10mA @5VDC
PE:PE
SH
10
11
12
1
9
-W117
Signal
cable
shielded
E
12x0,75
+SHIPSYSTEM
Common Common PMS PMS PB BW pump Stripping I/O supply I/O supply
alarm warning request running req start pump req 24VDC GND
F (normal=high) (normal=high) start
Modification Date Name Original Replacement of Replaced by A1-X3 - Digital Outputs Page 10 / 29
272
273
0 1 2 3 4 5 6 7 8 9
Twisted Wires
-X16A 1 2 5 6 7 8 -X13A 1 2 3 4 5
max. 30 mm / turn
120 Ohm
120 Ohm
120 Ohm
V2.91
A -A2
X20CS1030
Jumper in external connector if not LDC1 Terminator plug if not LDC1

TxD+ RxD+ GND TxD- RxD- GND
TxD+ RxD+ GND TxD- RxD- GND
X1 11 X1 12 X1 13 X1 21 X1 22 X1 23
082
084
083
B
WH/BN Twisted wires WH/BN Twisted wires WH/BN Twisted wires WH/BN Twisted wires
WH BN 0,5 mm² BN 0,5 mm² BN 0,5 mm² BN 0,5 mm²
BN WH 0,5 mm² WH 0,5 mm² WH 0,5 mm² WH 0,5 mm²
BU BU 0,5 mm² BU 0,5 mm² BU 0,5 mm² BU 0,5 mm²
-LPS1 -LPS2 -LPS3 -LPS4 -LPS5

/1.2:C 1 2 3 /1.3:C 1 2 3 /1.5:C 1 2 3 /1.6:C 1 2 3 /1.8:C 1 2 3

C
4+ 5- 4+ 5- 4+ 5- 4+ 5- 4+ 5-
GN GN 0,5 mm² GN 0,5 mm² GN 0,5 mm² GN 0,5 mm²
YE YE 0,5 mm² YE 0,5 mm² YE 0,5 mm² YE 0,5 mm²
-W01
085
086
5x0,5
D
11
-K2
/9.1:D 14
400.28 / 3.5:B
-PE
164 / 16.5:D
172 / 22.8:A
165 / 17.4:A
166 / 17.4:A
175 / 17.5:A
176 / 17.6:A
161 / 1.9:C
163 / 8.4:A
173 / 8.5:A
040
11
-W013 SH RD BK WH BU
0163 OG
0173 OG
-K1 -PE 2x0,25/2x0,34
400.28
01610
/22.4:D 14
0161
0172
0164
0165
0166
0175
0176
1,5 m RD/BK Twisted wires
E WH/BU Twisted wires
402.7
-X16A 1 2 3 4 5 6 7 8 9 10 11 12 PE -X13A 1 2 3 4 5
-X16A 1 2 3 4 5 6 7 8 9 10 11 12 PE -X13A 1 2 3 4 5
SH
10
11
12
1
9
-W16A -W13A SH RD BK WH BU
6x2x0,75 2x0,25/2x0,34
402.7
400.12 10 m 10 m
3.2:E /
3.3:B /
F
200000878-6-EN-GB
+LDC1 +LDC1
X16A 1 2 3 4 5 6 7 8 9 10 11 12 PE X13A 1 2 3 4 5
Modification Date Name Original Replacement of Replaced by A2 - LPS Communication Page 11 / 29
Modification
A
B
E
F
0
Date
Name
Original
Appr
Ed.
Date
-A3
1
SETUJAD
SETUGNH
2021-03-30
X1
+SHIPSYSTEM
TxD+
GPS Interface
TxD+
connection
11
X20CS1030
-GPS
2x2x0,75
shielded
-W601
Signal
cable
-X2
X1
RxD+
TX+
RxD+
2
1A 021
1Rx+
12
Replacement of
X1
GND
GND
13
3
X1
TxD-
TxD-
21
Replaced by
X1
RxD-
RxD-
TX-
1B 022
2Rx-
22
4
X1
GND
GND
GND
2A 020
GND
23
V2.91
2B
-PE
SH
Busbar
5
A3 - GPS Communication
EC
6
9034898_ver7
Document No.
7
8
Page 12 / 29
+ EC
= PB3.2
274 200000878-6-EN-GB
275
0 1 2 3 4 5 6 7 8 9
+SHIPSYSTEM
EXAMPLE CONNECTION Coil data @23°C * Bypass valve/valves
24VDC Connect in a loop with
5
4
3
2
1
-W110.1
13.3mA 5x0,75 below alternatives.
F/B O
+24V
+24V
F/B C
300mW (approx) Closed loop when no bypass.

0V
A Alt1. Alfa Laval bypass valve

V212-31 V212.31 contact in loop.

Alt1. Alt2. Alt2. Bypass valve/valves in loop.
PE 6 4 3 2 1 Alt3. Both Alt1. and Alt2.
1 1 2 2
1
O C O C
2 2 1 1
2
10 9 8 7
1
-W212.31
2x0,75
B
10
11
12
1
9
-W118
Signal
cable
3.6:E / 404.2 shielded
SH
12x0,75
3.5:E / 404.1
PE PE
-X3:404.4
-X3:404.5
C -X3:404.6
-X3 404
-X3:404.10
-X3:404.11
-X3:404.12
-X3 404
A1 A1 A1 A1 A1 A1
-K21 -K22 -K23 -K24 -K25 -K26
/13.1:E A2 /13.2:E A2 /13.3:E A2 /13.4:E A2 /13.5:E A2 /13.6:E A2
Busbar 6pol Blue
D 400.13 / 3.3:B
-X3:404.7 Busbar 6pol Red
11 11 11 11 11 11
-K21 -K22 -K23 -K24 -K25 -K26
/13.2:D 14 12 /13.2:D 14 12 /13.3:D 14 12 /13.4:D 14 12 /13.5:D 14 12 /13.6:D 14 12
041
042
043
044
045
046
E
-A4 X1 11 X1 21 X1 12 X1 22 X1 13 X1 23 X1 14 X1 24
/14.1:A DI-01 DI-02 DI-03 DI-04 DI-05 DI-06 DI-07 DI-08
DigitalInput01 DigitalInput02 DigitalInput03 DigitalInput04 DigitalInput05 DigitalInput06 DigitalInput07 DigitalInput08
X20DM9324
V2.91
F
200000878-6-EN-GB
External BW pump Ship Heeling PMS Stripping . .
stop running Bypass mode granted pump
feedback valve(s) running
closed feedback
Modification Date Name Original Replacement of Replaced by A4 - Digital Inputs Page 13 / 29
Modification
A
B
E
F
0
Date
Name
/13.1:E
Original
Appr
Ed.
Date
-A4
1
DigitalOutput01
SETUJAD
SETUGNH
2021-03-30
UVR inlet
V201-19
X1
valve
DO-01
19.7:A / 1013
1013 / WHGN
15
X20DM9324
2
outlet valve
V320-4 CIP
DigitalOutput02
X1
DO-02
19.8:A / 1014
Replacement of
1014 / BNGN
25
V321-2 CIP
DigitalOutput03
inlet valve
3
X1
DO-03
19.8:A / 1015
1015 / WHYE
16
Replaced by
DigitalOutput04
Dearation
X1
V571-1
valve
DO-04
19.9:A / 1016
4
1016 / YEBN
26
V2.91
5
A4 - Digital Outputs
EC
6
9034898_ver7
Document No.
7
8
Page 14 / 29
+ EC
= PB3.2
276 200000878-6-EN-GB
Modification
A
B
E
F
0
Date
Name
Original
Appr
Ed.
Date
-A5
1
pressure in
AnalogInput01
SETUJAD
SETUGNH
2021-03-30
PT201-71
X1
Water
AI+01I
1113 / 20.6:A
1113 / WHGN
11
X20AI4622
AnalogInput01
Channel 1
X1
AI+01U
2
12
Replacement of
AnalogInput01
X1
AI-01
400.14 / 3.4:B
400.14
13
AnalogInput02
PT201-16
pressure
3
X1
Water
AI+02I
out
1111 / 20.5:A
1111 / GYPK
21
Replaced by
AnalogInput02
Channel 2
X1
AI+02U
22
4
AnalogInput02
X1
AI-02
400.15 / 3.4:B
400.15
23
Conductivity
AnalogInput03
QT201-1
X1
AI+03I
1705 / 21.2:B
1705
14
5
A5 - Analog Inputs
AnalogInput03
EC
Channel 3
X1
AI+03U
15
AnalogInput03
X1
AI-03
1706 / 21.2:B
6
1706
16
AnalogInput04
X1
9034898_ver7
Document No.
AI+04I
24
AnalogInput04
Channel 4
7
X1
AI+04U
25
AnalogInput04
X1
AI-04
26
V2.91
8
Page 15 / 29
+ EC
= PB3.2
200000878-6-EN-GB 277
Modification
A
B
E
F
0
Date
Name
Original
Appr
Ed.
Date
-A6
1
AnalogOutput01
SETUJAD
SETUGNH
2021-03-30
X1
Control
V201-8
valve
AO+01I
19.6:A / 105
105 / PK
11
X20AO4622
AnalogOutput01
Channel 1
X1
AO+01U
2
12
Replacement of
AnalogOutput01
X1
AO-01
19.6:A / 108
108 / GY
13
AnalogOutput02
3
X1
AO+02I
21
Replaced by
AnalogOutput02
Channel 2
X1
M1 Fan
0-10V
AO+02U
3.8:D / 090
090
22
4
AnalogOutput02
X1
AO-02
23
AnalogOutput03
X1
AO+03I
14
5
A6 - Analog Outputs
AnalogOutput03
EC
Channel 3
LDC1+2
X1
M1 Fan
0-10V
AO+03U
11.4:E / 164
0164
15
AnalogOutput03
X1
AO-03
6
16
-X2
AnalogOutput04
X1
9034898_ver7
Document No.
AO+04I
023
3
24
AnalogOutput04
Channel 4
analogue
7
Ext feed
X1
AO+04U
out
024
4
25
AnalogOutput04
X1
AO-04
-X2:5=Load -
-X2:3=Load +
Current 4-20mA (Max load 600!)
-X2:5=Load +
-X2:4=Load -
Voltage 0-10V (Max load 10mA)
025
5
26
V2.91
403.7 / 3.4:E
403.7
6
Page 16 / 29
+ EC
= PB3.2
400.27 / 3.5:B
400.27
7
278 200000878-6-EN-GB
Modification
A
B
E
F
-A7
0
Temperature01
Cabinet air
Date
X1
2x0,75
-W401
TT401
Sensor+01
temp
11
X20AT4222
x2
-TT401
1
Name
x1
Temperature01
Channel 1
X1
-A7:X1:11
2
Sense-01
12
Original
Appr
Ed.
Date
1
Temperature01
X1
Sensor-01
SETUJAD
SETUGNH
2021-03-30
13
water temp
Temperature02
TT201-33
Ch2 UVR
X1
Sensor+02
104 / 19.1:A
104 / GN
21
2
Temperature02
Replacement of
Channel 2
X1
+UVR-JB.B
Sense-02
106 / 19.1:A
106 / YE
22
Temperature02
X1
Sensor-02
3
23
Temperature03
LDC1 air
X1
Replaced by
TT401
Sensor+03
temp
165 / 11.4:E
0165
14
4
Temperature03
Channel 3
X1
-X16A:6
Sense-03
166 / 11.4:E
0166
15
Temperature03
X1
Sensor-03
16
5
A7 - Temperature Inputs
Temperature04
LDC2 air
X1
TT401
Sensor+04
temp
EC
175 / 11.4:E
0175
24
Temperature04
Channel 4
X1
-X16A:8
Sense-04
176 / 11.4:E
0176
25
6
Temperature04
X1
Sensor-04
9034898_ver7
Document No.
26
V2.91
-K33
7
1+
3.2:E / 402.8 101 / 19.0:A

24V DC
water temp
Ch1 UVR
TT201-33
402.8 101 / BN
12
PWR
2-
3.4:B / 400.16 103 / 19.1:A

400.16 103 / WH
13
14
22.4:C / 065
065
5
OUT1
22.6:C / 066
066
6
Page 17 / 29
+ EC
= PB3.2
200000878-6-EN-GB 279
200000878-6-EN-GB
0 1 2 3 4 5 6 7 8 9
V2.91
A -A8
X20DO9322
DigitalOutput01
DO-01
DigitalOutput02
DO-02
DigitalOutput03
DO-03
DigitalOutput04
DO-04
DigitalOutput05
DO-05
DigitalOutput06
DO-06
DigitalOutput07
DO-07
DigitalOutput08
DO-08
DigitalOutput09
DO-09
DigitalOutput10
DO-10
DigitalOutput11
DO-11
DigitalOutput12
DO-12
400.25 / 3.5:B
X1 11 X1 21 X1 12 X1 22 X1 13 X1 23 X1 14 X1 24 X1 15 X1 25 X1 16 X1 26 129 / 7.4:A
403.6 / 3.4:E
400.26 / 3.5:B
B
1110 / VT
119 / RD
112 / BU
117 / BK
1211
1210
1212
121
122
123
124
125
126
127
128
129
RDBU
GYPK
WH
GN
RD
BN
BU
GY
VT
BK
PK
YE
-W012
117
1110
119
112
12x0,14
20.7:A /
20.8:A /
20.9:A /
20.8:A /
-X12
1 2 3 4 5 6 7 8 11 9 10 12 SH Frame
C
RDBU
GYPK
WH
GN
RD
BN
BU
GY
VT
BK
PK
YE
-W12
10 m
12x0,14
+CIP
Insulated
D X1 1A 1B 2A 2B 3A 3B 4A 4B COM 5A 5B 6A
BN
BU
BK
-X320-3 4 1 3
4 1 3
BN
BU
BK
-W320.3
M12
-X12.31 4 1 3
E
BN
BU
BK
-W3203
M8
+CIP
DC+
DC-
SIG
4 1 3
F -LS320-3
V201-3 V201-9 V309-1 V571-3 V320-2 V310-1 V310-3 P320-1 P460-1 V460-2 V460-3 V460-4
V201-32 Main inlet Backflush Deaeration CIP FW-inlet FW-valve CIP-pump Drain & CIP-valve Drain valve Filter valve CIP low level
inlet valve valve valve Dosage valve CIP-pump
valve´s deballast valve
ballast
Modification Date Name Original Replacement of Replaced by A8 - Digital Outputs Page 18 / 29
280
Modification
A
B
E
F
+UVR
-X10
BK=4
BU=3
WH=2
BN=1
M12 cable
-W201.33
-JB.B
0
Date
17x0,14
17x0,14
-W010
-W10
-X10.1
10 m
M12
M12
-X1
X1.1
101 / 17.7:A
1
BN BN BN BN 101
Ch1
1
-TT201-33
Water temp
X1.2
Name
103 / 17.8:A
2
2
WH WH WH WH 103
3
X1.3
104 / 17.2:A
3
3
BU BU GN GN 104
Ch2
4
X1.4
106 / 17.2:A
4
Original
Appr
Ed.
Date
4
BK BK YE YE 106
1
6
X1.5
PE
-W201.29
SETUJAD
SETUGNH
2021-03-30
-X10.2
M12
X2.1
1
1
BN BN
12
DC+
-LS201-29
Level switch
X2.2
2
WH
X2.3
3
2
3
BU BU
21
DC-
X2.4
109 / 22.8:C
4
BK BK RD RD 109
9
SIG
9
X2.5
Replacement of
PE
-W201.50
-X10.3
M12
X3.1
1
DC+ BN BN 13
3
-QT201-50
X3.2
UV sensor
WH
X3.3
1011 / 6.2:A
3
BU BU GYPK GYPK 1011

11
SIG
11
X3.4
Replaced by
BK
X3.5
PE
-W201.60
4
-X10.4
M12
X4.1
107 / 22.5:C
1
BN BN BK BK 107
7
DC+
7
Temp switch
-TS201-60
X4.2
1010 / 22.6:C
2
WH WH VT VT 1010
10
SIG
10
X4.3
3
BU
X4.4
4
BK
X4.5
5
X10 UVR
PE
-W201.8
-X10.5
EC
10 m
M12
X5.1
41
DC+
1
BN BN
14
Control valve
X5.2
-IP201-8
42
102 / 8.3:A
V201-8
SIG
2
WH WH BU BU 102
2
X5.3
6+
105 / 16.1:D
AO+
3
BU BU PK PK 105
5
6
X5.4
7-
108 / 16.3:D
AO-
4
BK BK GY GY 108
8
X5.5
White
-H1
PE
403.3 / 3.4:E
9034898_ver7
Document No.
x2
x1
15 RDBU RDBU 1012

15
12
21
UVR inlet
V201-19
valve
1013 / 14.1:D
COM
1A
BK WHGN WHGN 1013

16
7
13
CIP outlet
V320-4
valve
1014 / 14.2:D
COM
2A
GY BNGN BNGN 1014

17
14
CIP inlet
V321-2
8
valve
1015 / 14.3:D
COM
2B
VT WHYE WHYE 1015

18
15
Dearation
V571-1
valve
1016 / 14.4:D
COM
3A
BU YEBN YEBN 1016

19
16
Page 19 / 29
+ EC
= PB3.2
400.17 / 3.4:B
BN WHGY WHGY 1017
20
17
PE
PE
SH Frame
PE
200000878-6-EN-GB 281
Modification
A
B
E
F
+Filter
BK=4
BU=3
WH=2
BN=1
M12 cable
-X11
-JB
0
-W201.3
Date
17x0,14
17x0,14
-W011
-W11
-X11.1
10 m
M12
M12
-X1
X1.1
1+
403.4 / 3.4:E
Closed / Opened
1
BN 11 BN RDBU RDBU 1112
12
+
12
Limit switch
-GS201-3
X1.2
Name
111 / 7.5:A
V201-3
2
WH 12 WH BN BN 111
1
Close
1
X1.3
400.18 / 3.4:B
3-
3
BU 13 BU WHYE WHYE 1115
18
-
15
X1.4
113 / 7.6:A
4
Original
Appr
Ed.
Date
4
BK 14 BK WH WH 113
3
Open
1
3
X1.5
Busbar blue
Busbar red
PE
SETUJAD
SETUGNH
2021-03-30
-W201.9
-X11.2
10 m
M12
X2.1
1+
Closed / Opened
BN 21 BN
13
+
Limit switch
-GS201-9
X2.2
116 / 8.1:A
V201-9
2
2
WH 22 WH YE YE 116
6
Close
6
X2.3
3-
BU 23 BU
19
-
X2.4
Replacement of
114 / 8.2:A
4
Open BK 24 BK 4 GN GN 114
4
X2.5
PE
3
BNGN BNGN
16
14
PK PK
5
5
Replaced by
YEBN YEBN
20
16
GY GY
8
8
-W201.16
4
-X11.4
10 m
M12
X4.1
Water pressure out
BN 41 BN
14
DC+
+
-PT201-16
X4.2
2
WH
X4.3
1111 / 15.3:A
3
BU 43 BU GYPK GYPK 1111

11
SIG
-
11
X4.4
4
BK
5
X11 Filter
X4.5
PE
-W201.71
EC
-X11.5
M12
X5.1
1
Water pressure in
BN 51 BN
15
DC+
+
-PT201-71
X5.2
2
WH
X5.3
1113 / 15.1:A
3
6
3
BU 53 BU WHGN WHGN 1113

17
SIG
-
13
X5.4
4
BK
X5.5
PE
9034898_ver7
Document No.
-Valveblock
-W11.1
inlet valve´s
V201-3 &
V201-32
ballast
117 / 18.0:C
COM
1A
OG+RD OG+RD BK BK 117

7
7
7
valve deballast
Main inlet
V201-9
1110 / 18.1:C
COM
2A
GY+RD GY+RD VT VT 1110

10
10
Backflush
V309-1
8
valve
119 / 18.1:C
COM
3A
WH+RD WH+RD RD RD 119

9
9
Deaeration
V571-3
valve
112 / 18.2:C
COM
3B
WH+BK WH+BK BU BU 112

2
2
Page 20 / 29
+ EC
= PB3.2
400.24 / 3.5:B
PK PK WHGY WHGY 1117
21
9
17
PE
PE
SH Frame
PE
282 200000878-6-EN-GB
Modification
A
B
E
F
0
Date
Name
+EXT
-X17
-FT201-1
Original
Appr
Ed.
Date
1
8x0,25
8x0,25
-W017
-W17
10m
M12
SETUJAD
SETUGNH
2021-03-30
403.5 / 3.4:E
1
Supply
DC+
WH WH 1701
1
400.19 / 3.4:B
2
DC-
BN BN 1702
2
System flow/
Conductivity
FT201-1
26
1703 / 6.4:A
Output 1
AI+
GN GN 1703
3
27
1704 / 6.5:A
AI-
YE YE 1704
2
24
1705 / 15.5:A
Output 2
AI+
GY GY 1705
5
25
1706 / 15.6:A
Replacement of
AI-
PK PK 1706
6
BU BU 1707
7
RD RD 1708
8
SH
SH Frame
3
Replaced by
4
5
X17 Flow/Conductivity
EC
6
9034898_ver7
Document No.
7
8
Page 21 / 29
+ EC
= PB3.2
200000878-6-EN-GB 283
Modification
A
B
E
F
/22.5:E
Reset
-S1
door
-KS1
-X5
0
Date
4.1:A / 051.1
14
13
051.1 057 057
I4
A1
7
Power on
-H1
door
Name
402.9 / 3.2:E
402.9
I5
A1
9.2:E / 052.3
x2
x1
052.3 051.2
Original
Appr
Ed.
Date
052.2
1
400.20 / 3.4:B
400.20
I6
A2
SETUJAD
SETUGNH
2021-03-30
I7
A2
TS201-33
7.2:A / 060
2
060
M0
24V
TS201-60
Replacement of
7.3:A / 061
061
M1
0V
LS201-29
7.3:A / 062
062
M2
O0-
3
S2
6.3:A / 063
063
M3
O1-
Replaced by
/11.0:E
-K1
/22.8:D
3.3:B / 400.8 065 / 17.8:D
-K3
A2
A1
400.8 064 065

O0
T0
4
11
14
Emergency stop
067
O1
T0
-S2
door
-X5
-X5
12
11
054 054 053 091

O2
T1
5
Safety relay circuit
/22.0:E
052.2
-X5
Reset
-S1
door
EC
4.1:A / 052.1 107 / 19.4:A

x2
x1
052.1 058 058 107 / BK

O3
T1
8
TT201-33
066 / 17.9:D
066
I0
6
TS201-60
1010 / 19.4:A
1010 / VT
I1
9034898_ver7
Document No.
LS201-29
068
I2
S2 push button
7
0172
I3
172 / 11.3:E
X9.1 / 1.9:C
/22.4:A
-K3
3.4:B / 400.22 109 / 19.2:A

A2
A1
400.22 109 / RD
Page 22 / 29
+ EC
= PB3.2
284 200000878-6-EN-GB
285
0 1 2 3 4 5 6 7 8 9
A Cables used should be shipboard cables designed
NO TYPE Source (from) INSTRUCTION Target (to) REMARK

according to IEC 60092.
-W1 3x16-25 +SHIPSYSTEM -X1 +EC -Q1 x5 Flame retardent according to IEC 60332-1-2.
-W9A 10x1,5 +EC -X9A +UVR -JB.A-X20.A 10m Flame retardent according to IEC 60332-3-22.
-W10 17x0,14 +EC -X10 +UVR -JB.B-X1 10m Halogen free according to IEC 60754-1 & IEC 60754-2.
-W11 17x0,14 +EC -X11 +Filter -JB-X1 10m
Flexible insulating sleeving according to IEC 60684-2.
-W12 12x0,14 +EC -X12 +CIP -X1 10m
-W13A 2x0,25/2x0,34 +EC -X13A +LDC1 -X13A 10 m Other equivalent and approved cables may be used.
-W14 4G1,5 +EC -X14 +Filter -M709-43 10m Cable areas are calculated with correction factor 0,8.
B -W15 4G2,5 +EC -X15 +Filter -M703-1 10m Code designations for cables obtainable through cable
-W17 8x0,25 +EC -X17 +EXT -FT201-1 10m producers Nexans, Sweden.
-W104 CAT5e SF/UTP +EC -X8 +Log box -X6 x4
-W110.1 5x0,75 +SHIPSYSTEM -* SSC +SHIPSYSTEM -V212-31 x Where SSC is indicated it should be a signal shielded cable
-W117 12x0,75 +EC -K10 SSC +SHIPSYSTEM -U2 x3 with the shield properly connected to earth as shown in the
-W118 12x0,75 +EC -PE SSC +SHIPSYSTEM -U4 x3 electrical drawings.
-W212.31 2x0,75 +SHIPSYSTEM -V212-31 SSC +SHIPSYSTEM -U4 x
-W501.1 CAT5e SF/UTP +EC -X7 +RCP -X2 x4 Recommendation of voltage class
-W501.1F 2x62,5/125um +EC -SW1 +RCP -SW1 x3 Rated voltage of power cables 0,6/1kV
-W502.1 2x +SHIPSYSTEM -PS +RCP -X1 x3 Rated voltage of instrumentation cables min 150V
C
-W601 2x2x0,75 +EC -X2 SSC +SHIPSYSTEM -GPS x
-W602 2x2x0,75 +EC -X6 SSC +SHIPSYSTEM -RI x
x Cable not included in Alfa Laval delivery.
D
6.4.4.3 Electrical cabinet / Cable list
E
REMARKS
x3 System size dependant (min common alarm) x1, x2, x3 can be integrated in same cable.
x4 Shielded CAT5e or better, multimode fiber 62.5/125um RJ45 contact or fiber LC contact (W501.nF)
F
200000878-6-EN-GB
Modification Date Name Original Replacement of Replaced by Cable list Page 29 / 29
200000878-6-EN-GB

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6.4.4.4 UV reactor / Circuit diagram
: : : : : : : : : :
(
)

895VL]HKDYHODPSFRQQHFWHG
895VL]HKDYHODPSFRQQHFWHG
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Signal conductors can be 0.5-0.75 mm² if not otherwise stated.
Signal conductors shall be blue if not otherwise stated.
Insulated end ferrules shall be used.
A
Optional
-OP1 -SW1
Control panel
24VDC ±3V (2A)
LAN A LAN B
24VDC (350mA) X1 X2 X3 X4
Ring for M5
USB1 COM1 + - GND PE 1 2 3 LC1IN LC1OUT
COM +VA +VB TD RD
B
-R1
03
-W501.1F
2x62,5/125um
Optic fiber cable
4 3 2 1 TX- RX-
11
-S1
On/Off 12
Door
-W1.USB
02
01
C -W2.LAN
CAT5e SF/UTP
-H1
6.4.4.5 Remote control panel / Circuit diagram (optional)
Door
x2 x1
x3
-USB1
-W1.LAN Connect to -OP1:LAN A
GNYE 2,5 mm²

GNYE 2,5 mm²
Door
CAT5e SF/UTP if -SW1 is not present.
-X2
D
401 -W801 cable
401
401
401
400
400
400
400
RJ45
CAT5e SF/UTP
1 2 3 4 5 6 7 8 SH
OG/WH
GN/WH
BN/WH
BU/WH
-X1 1+ 2+ 3- 4- PE
OG
GN
BN
BU
SH
24V -W501.1
CAT5e SF/UTP
-W502.1 1 2 -PE
Ring for M8
2x 1 2 3 4 6 7 8 SH
2,5 mm²
2,5 mm²
E
GNYE
GNYE
1m
OG/WH
OG
GN/WH
BU
BU/WH
GN
BN/WH
BN
SH
-PE Ring for M8 RX- TX-
Ring for M8
+CC +Connectivity
+SHIPSYSTEM
-X13 -SW1 -A3
PS 1 2 3 4 5 6 7 8 SH TD RD RJ45
F 24VDC + -
RJ45
IN OUT
200000878-6-EN-GB
(Optional)
Remote Control Panel Connectivity
(Option) (Option)
Date 2020-03-12 Document No. = RCP
Ed. SETUGNH RCP 9015558_ver5 + RCP
Modification Date Name Original Replacement of Replaced by RCP Page 1/1
200000878-6-EN-GB

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6.4.4.6 Transformer (optional) / Interconnection diagram
;
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/ 7
/ 6
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6.4.5 Bypass and heeling configurations

Type which valve is connected to each input and also type if the active signal
(24VDC) is sent when the valve is open or closed .
If Alva Laval log box is used, the signal can be inverted so that an active
signal is 0VDC instead of 24VDC. If the 24VDC signal is sent when the valve
is open , the signal can be inverted to be active when the valve is closed. To
invert the signal, type the letters “CI” (Closed Inverted) in the configuration,
then this signal will be treated as active when the valve is closed at 0VDC.
Analogue signal (0–20 mA or 0–10 VDC) can also be used and inverted.
Bypass configurations
Note that condition for triggering a configuration uses AND-logic. For example,
to trigger Configuration 1 (see the Bypass configurations table below), Valve in
column 1 AND Valve in column 2, must both be open at the same time.
Type “O” for open.
Type “C” for closed.
The first letter shows which position of the valve causes a bypass. Type “OI”
or “CI” for inverted signals.
200000878-6-EN-GB 291
Heeling configurations
The simplest way to configure heeling is to monitor that all sea chests and
overboard valves are closed at the same time. Then the different bypass
valves to/from the tanks can be added to different configurations as open
together with the sea chest and overboard valves. Usually, it is enough with
the main bypass valve V212-31 together with the sea chest and overboard
valves.
Note that condition for triggering a configuration uses the same AND-logic as
bypass configuration (see the Bypass configurations table).
Type “O” for open.
Type “C” for closed.
The first letter shows which position of the valve causes a bypass. Type “OI”
or “CI” for inverted signals.
292 200000878-6-EN-GB
200000878-6-EN-GB 293
6.4.6 Safety Data Sheets

6.4.6.1 Safety data sheet / CIP liquid
294 200000878-6-EN-GB
200000878-6-EN-GB 295
296 200000878-6-EN-GB
200000878-6-EN-GB 297
298 200000878-6-EN-GB
200000878-6-EN-GB 299
300 200000878-6-EN-GB
200000878-6-EN-GB 301
302 200000878-6-EN-GB
6.4.6.2 Safety data sheet / UV lamp
200000878-6-EN-GB 303
304 200000878-6-EN-GB
200000878-6-EN-GB 305
306 200000878-6-EN-GB
200000878-6-EN-GB 307
308 200000878-6-EN-GB
200000878-6-EN-GB 309
310 200000878-6-EN-GB
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312 200000878-6-EN-GB
200000878-6-EN-GB 313
314 200000878-6-EN-GB
EN
7 Service manual
200000878-6-EN-GB 315
EN 7 Service manual
7.1 Introduction
This chapter contains information and instructions about how to service the
PureBallast system. Instructions are sorted per component. The chapter is
opened with a maintenance schedule covering checks and services that must
be performed with specified intervals.
7.1.1 Preparations and conditions
DANGER
Before maintaining the PureBallast system, the power supply must be switched
off from the vessel’s main switch board.
WARNING
Read Safety on page 9.

Installation must be done by a fully trained professional installer.
Electrical cabinets: Risk of electric shock! Exposed components carry dangerous
voltages. Always disconnect the power supply before disassembling. Note that
electrical components are live with main power switched off.
When maintaining the UV reactor always follow safety instructions. See Safety
information on page 333.
Follow rules when handling CIP liquid, regarding ventilation, personal protection
etc.
• Always read and follow the documentation that are included in shipment of
components and spare parts regarding handling, safety and disposal.
• Before maintaining the PureBallast system, the following valves must be
locked in closed position: V201-3 and V201-8. See instruction Lock valve in
closed position on page 361
• Point of contact: To order service or spare parts, contact your local Alfa
Laval office. For more information, see www.alfalaval.com.
7.1.2 Welding requirements

Earth connection must be done according to the below. If not, the equipment
can be seriously damaged:
• Ensure that all solenoid valve connectors on the reactor valves (V201-19,
V320-4, V321-2, V404-36) are disconnected prior to any welding on- or
nearby components of the PureBallast system.
• Earth connection must be made before any welding is done.
• Electrical welding: Connect the welding unit’s negative lead (work lead) to
the component you will weld close to the welding area.
• Follow local regulations for electrical installation and earthing (grounding).
• Installation must be done by a fully trained professional installer.
316 200000878-6-EN-GB
Service manual 7 EN
7.1.3 Tightening torques

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

Thread Stainless steel Carbon steel
Maximum tightening torque, Maximum tightening torque, Nm
Nm
M6 7 10
M8 17 25
M10 33 48
M12 57 83
200000878-6-EN-GB 317
EN 7 Service manual
M16 140 204

M20 270 408
M24 470 696
M30 - -
M36 - 2500
318 200000878-6-EN-GB
Service manual 7 EN
7.2 Maintenance schedule

Follow this maintenance schedule to secure performance, safety and durability
of the system and its components. The schedule is sorted per component. The
table refers to instructions usable when performing the respective action.
Component Action Time interval Instructions Notes
Testrun the system:
Run a ballast
and/or deballast
process. Follow up See Operating in- If the system, for some rea-
with a CIP process. structions and con- son, is not operated by nor-
trol system de- mal ballast operations, it
Note: If system is scription on page needs to be run to verify
used, but certain 41 that it is in good condition.
General valves are not Once a month.
used, for example Manual operation This will also exercise the
V212–31, those of valves: See valves, actuators and other
should be opened Valves on page components to keep them in
and closed man- 359. good condition.
ually. For relief
valves, see Cali-
bration schedule.
Inspect for corro-
General sion and erosion Once a year.
damage.
According to Cali- See Calibration
Calibration of sen-
General bration schedule schedule on page
sors on page 322. 322.
Upper filter:
Change filter mat
when dirty.
Electrical cabi- Check air filter. Every six month. Lower filter: Wash Filters: 9023297 02
net
with hot water and
degreasing liquid
when dirty.
Outer inspection of Once a year. See Spare parts catalogue
UV reactor seals for leakage. for service kit.
See Disassemble
Check UV lamps See Spare parts catalogue
UV reactor Once a year. quartz sleeve on
for leakage. for service kit.
page 336.
Recommended to See Recommended spare
Replacement of UV change all lamps See Replace UV
UV reactor parts on board for spare
lamps. after 3000 hours of lamp on page 334. part number.
operation
IMO requirement:
Replacement of UV Every second year.
UV reactor 9001357 01
sensor (QT201–50) EPA requirement:
Every year.
Dismount the valve
and make sure you
Check relief valve
UV reactor Once a year. can blow air
RV201–23. through it from the
inside out.
200000878-6-EN-GB 319
EN 7 Service manual

See the filter
cleaning instruction
in this document.
Cleaning once a
year normally is
enough. But in ex-
ceptional cases
(vessels trading
very challenging Replace filter basket, if
Inspect and clean waters) it might be damaged.
the filter insert, in- necessary to clean
Filter Once a year.
cluding the filter the more often. See Spare parts catalogue
basket. for maintenance kit.
If the pressure trig-
gered backflushing
is performed with
short intervals, we
suggest that the fil-
ter element man-
ually cleaned more
often than once
year.
If necessary, change faulty

Outer inspection of Once a year. seals.
Filter seals for leakage. See Spare parts catalogue
for maintenance kit.
Dismount the valve
and make sure you
Check relief valve
Filter Once a year. can blow air
RV201–50. through it from the
inside out.
Rule of thumb:
Once every 3
months. Depending
CIP liquid level on ballasting fre-
CIP liquid check. quency, the liquid
check might have
to be performed
more regularly.
When alarm W401 See Change CIP
CIP liquid Replacement. CIP liquid low level liquid on page 352.
is issued.
Valve block
Control that the ca- See Connect elec-
Located on filter, bles are firmly at- trical cables to
UVR and CIP tached to the termi- Once a year. valve block on
unit. nal strip in the page 357.
valve block.
320 200000878-6-EN-GB
Service manual 7 EN

Open and close the valves
and inspect visually.
Control that the If the system has been de-
Valves and ac- component, cables Once a year. See Valves on activated and stored at an
tuators and hoses are firm- page 359. ambient temperature below
ly attached. -5 °C, valves and actuators
needs to be controlled be-
fore activation of the sys-
tem.
Remove and disas-
semble the valve.
Remove debris and
Vacuum relief clean the interior Once a year.
valves parts if needed. In-
spect the seal and
replace if broken.
200000878-6-EN-GB 321
EN 7 Service manual
7.3 Calibration schedule

Follow this calibration schedule to secure performance of the system and its components. The
schedule is sorted per component.
Interval: Once a year, if nothing else is stated.
Action if value is out of tolerance: If a value deviates more than allowed, the component must be
replaced. Only the flow meter can be re-calibrated. Contact Alfa Laval.
7.3.1 Calibrate flow meter

This section contains step-by-step instructions on how to calibrate the flow meter FT201–1.
There are two alternative methods to calibrate the flow, and a separate method to calibrate the
conductivity measurement:
• Calibrate flow in flow meter:
• Calibration using the vessels tank sounding systems calculating the flow.
• Calibration using an ultrasonic device.
• Calibrate conductivity measurement in flow meter.
7.3.1.1 Calibration using the vessels tank sounding systems calculating the flow
Calibration frequency: IMO: Every second year. USCG: Every year.
1 Decide which tank to use for measuring.
2 Note the start level in tank.
3 Establish stable flow in the system.
4 Note the flow according to PureBallast flow

meter FT201–1 in control system page Page
1.2 – Overview on page 60, (value A below).
5 Pump for 10-20 minutes.
6 Stop pump and note exact time used.
7 Note finish level in tank and use vessel tank

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

sounding system calculation by dividing the
volume pumped (m3) with the time used
(hours).
322 200000878-6-EN-GB
Service manual 7 EN
9 Compare the figures and calculate the

variance.
a)
Reading Actual var- Allowed
iance variance
A FT201–1value Min: 0.95
A/ C
(m3/h) Max: 1.05
C Calculated val-
ue (m3/h)
7.3.1.2 Calibration using an ultrasonic device

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

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

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

C).

variance.
a)
iance variance
A FT201–1 value Min: 0.95
A/C
(m3/h) Max: 1.05
C value (m3/h)
7.3.1.3 Calibrate conductivity measurement in flow meter
1 Note the conductivity measurement QT201-1

according to PureBallast flow meter FT201–1
in control system page Page 1.2 – Overview
on page 60, (value A below).
2 Take a ballast water sample.
3 Measure the conductivity in the ballast water

sample with a separate conductivity sensor
C25 sample.
The separate conductivity sensor should
measure the conductivity with a temperature
compensated at 25 Celsius measurement in
μS/cm.
200000878-6-EN-GB 323
EN 7 Service manual
If not, calculate C25 sample:
C25 sample = C / (1 + α * (T – T25))

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

variance.
a)
iance variance
A QT201-1 value A/ C25 sam- Min: 0.95
(μS/cm) ple Max: 1.05
C25 sample
(μS/cm)
7.3.2 Calibrate pressure transmitters

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

equipment to the measure point (screw to the
side, under the handle).
2 Open V201-9. 201–3 and 201–32 from the

control system.
3 PT201–16
a) Compare values indicated for the
transmitters in control system and the
measure equipment.
4 PT201–71
a) Adjust handle on PT201–71 to establish
pressure to measure point.
b) Compare value indicated in control
system and measure equipment.
5 Compare that the two pressure transmitters

are indicating the same value.
324 200000878-6-EN-GB
Service manual 7 EN
7.3.3 Calibrate UV reactor components, transmitters and switches

This section contains step-by-step instructions on how to calibrate the UV reactor components
TT201-33, TS201-60 and LS201-29.
1 Log in as Advanced operator or higher.

Depressurize and drain the reactor by
pressing the Drain function button in the
control panel page 1.5 CIP.
2 Temperature transmitter TT201–33:

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

a) Dismount the switch and place in device
with slowly raising temperature starting at
appr 50 going to appr 70 C°.
b) Check that alarm A104 is displayed in the
control system at 65 ˚C.
4 Level switch LS201–29 :

a) Dismount the sensor and lace it in a glass
of water.
b) Check that you get a signal for the UV
reactor in the control system.
c) Fill the UV reactor with water by pressing
the Fill function button in the control
panel.
7.3.4 Calibrate UV reactor components, UV sensor

The UV sensor QT201–50, is not calibrated. The component is replaced. See Maintenance schedule
on page 319.
7.3.5 Calibrate temperature transmitter in electrical cabinet

This section contains step-by-step instructions on how to calibrate the temperature transmitter TT401,
in the electrical cabinet.
200000878-6-EN-GB 325
EN 7 Service manual
1 Place a calibrated thermometer inside the

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

thermometer value.
Reading Actual var- Allowed var-
iance iance
A TT401 value Min: 0.95
(EC) (C°) A/C Max: 1.05
C Calibration de-
vice value (C°)
326 200000878-6-EN-GB
Service manual 7 EN
7.4 Water sampling

This section contains information about basic system specific requirements for
water sampling.
Note that this section does not contain detailed instructions about the
sampling procedure. For detailed sampling guide in form of checklists, contact
Alfa Laval sales company.
7.4.1 Sampling requirements

The list compiles the system specific requirements for a successful water
sampling. The requirements are common for IMO and USCG.
• Sampling must be done during deballast.
• Both ballast and deballast water must be treated within system design
limitations (SDL), for example without any alarms stating “non-compliant
operation”. For a complete list of these alarms and other reasons for non-
compliancy, see Compliant / Non-compliant operation on page 44.
• Sampled water must have been treated in the same mode (IMO, USCG 0
days or USCG 3 days) during deballast as in ballast. In USCG mode. In
USCG mode, the water must be stored in tank according to the used
holding time mode: 3 days meaning 72 hours. 0 days meaning 2.5 hours.
• Sampled water must be collected from the sampling device installed after
the PB system.
• Before sampling is taken to a bottle/container make sure that the following
is observed:
• The system has been running in mode Full deballast for 5 minutes, so
that the pipes are well flushed before the sampling device is opened. if
the deballast pipe is used for multiple types of water (e.g. ballast, grey
and bilge water) let deballast run for 10 minutes.
• The sampling device is flushed to a waste bucket or such for 5 minutes
before the water is collected.
• Ballast water tanks must be cleaned from sediment and untreated water.
• Sampling must be done in accordance with applicable legislation and local
regulations.
• We recommend that Alfa Laval’s step-by-step checklist is used as a guide
when planning and performing the water sample. Require the applicable
checklist depending on legislation from Alfa Laval.
• IMO Commissioning sampling checklist
• VGP 2013 water sampling checklist
• Always investigate additional and/or specific requirements with the flag
state and classification society.
200000878-6-EN-GB 327
EN 7 Service manual
7.5 Recommended spare parts on board

One of each spare part or spare part kit is recommended to be stored on
board.
Spare part Spare part number
UV reactor
UV lamp set
• 1 UV lamp 579367 98
• 2 O rings
Quartz sleeve set

• 1 quartz sleeve 594645 81
• 2 O rings
Mercury absorption kit 9045685 01

Temperature transmitter 9006325 02
Temperature switch 9006324 02
Lamp power supply (LPS) 9012146 01
UV sensor 9001357 01
Filter
Filter maintenance kit
Note: Inspect the filter
marking plate. If you have
filter the data is correct.
The system may be sup- 9011963 89
plied with a filter of larger
size. If so, consult the Fil-
ter size addendum for cor-
rect data.
CIP module
9012167 01 Recommendation to order 2 cans at a time.
CIP liquid Note that the CIP liquid should not be older than 2 years
from the date mentioned on the sticker of the canister.
CIP pump (P320–1) 9017332 01
Drain and circulation pump
(460–1) spare part kit
• Diaphragm
• Muffler 586773 02
• Ball
• O rings
328 200000878-6-EN-GB
Service manual 7 EN
7.6 Serial number information

This section describes where the serial number plate is placed on the
PureBallast system components. Serial numbers shall be used at error
reporting and other contacts where a specific component is discussed.
Indicating serial number

Serial numbers shall be stated, including the following information:
• Serial number for the complete PureBallast system. See label on the side
of the electricalcabinet.
• Serial number for the component in question. If the component is installed
on, or in, another component, the number for the mother component shall
be stated.
• Item number for the component. The item number identifies a unique
component in the system. It begins with a letter abbreviation indicating the
component type, for example: LS (level switch) or P (pump). A complete list
of abbreviations is found in Connection list on page 205.
Example
If the level switch is faulty, the following information shall be stated:
• PureBallast serial number.
• Level switch serial number and the serial number for the UV reactor on
which the level switch is installed.
• Item number for the component (LS00000).
7.6.1 Placing of serial numbers

The table below indicates the position of the serial number plate per
component.
200000878-6-EN-GB 329
EN 7 Service manual
PureBallast water treatment system

Serial number for the complete PureBallast system.
Placing: At the right side of the electrical cabinet.
Cabinets
Placing: Inside the cabinet, at the left or right side.
The picture showing the electrical cabinet is an exam-
ple, but the placement is valid for all cabinets.
330 200000878-6-EN-GB
Service manual 7 EN
UV reactor
Placing: At the side of the UV reactor, as indicated in
the illustration.
Filter
Placing: At the side of the filter, as indicated in the il-
lustration.
Lamp power supply

LPSs are installed in the lamp drive cabinet.
Note: Version must be stated together with the serial
number. Version is stated on the serial number plate.
Placing: At the front of each LPS.
200000878-6-EN-GB 331
EN 7 Service manual
Valves and actuators

Serial number plate for various valves are placed at
the side of the actuator. One example is illustrated to
the right.
Note: This number shall be used both for the actuator
and the mechanical valve.
Flow meter
Including flow transmitter and flow sensor
Placing: At the side of the transmitter housing, as in-
dicated in the illustration.
Note: The serial number for the flow transmitter is also
valid for the flow sensor.
332 200000878-6-EN-GB
Service manual 7 EN
7.7 UV reactor
This section covers instruction for service of the UV reactor.
UV reactor, exploded (principle).

1. Cap
2. Cap nut
3. Bush
4. O-ring (inside bush)
5. Cable connector
6. Allen screw
7. Glass socket
8. O-ring
9. UV lamp
10. Quartz sleeve
7.7.1 Safety information
DANGER
Always disconnect the PureBallast system from the power supply before
Always lock valve V201–9, V201–3 and V201–8 if you open the UV reactor in
some way. See Lock valve in closed position.
Before installation, check that the UV lamps and quartz sleeves are not broken.
200000878-6-EN-GB 333
EN 7 Service manual
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 303 for detailed safety
information.
7.7.2 Replace UV lamp

7.7.2.1 Disassemble UV lamp
Follow this instruction to dismount the UV lamp.
NOTE
If the UV lamps are hot they are under internal positive pressure and may burst if
broken.
Wait at least 10 minutes after completed ballast or deballast process, to allow the
UV reactor to cool down to ambient temperature.
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• Wait at least 10 minutes after completed ballast or deballast process, to

allow the UV reactor to cool down to ambient temperature. If the UV lamps
are hot they are under internal positive pressure and may burst if broken.
• The PureBallast system must be turned off, and the power disconnected.
1. Unscrew the cap nut holding the cap and remove the cap.
2. Disconnect the cable connector that is attached to the UV lamp.
3. Repeat step 1–2 on the other side of the UV reactor.
4. Carefully pull out the UV lamp and the lamp bush. 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.
5. Place the old lamp in the new lamp’s box.

6. Remove the second lamp bush that is sitting in the glass socket in the UV
reactor.
7. Look for cracks and other defects in the quartz sleeve. Replace if needed.
See instruction Disassemble quartz sleeve. Also make sure that there is no
trace of water leakage.
8. If the quartz sleeves is not broken, mount the new UV lamp according to
the instruction Assemble UV lamp.
9. Dispose of the old lamp according to the safety data sheet, see Safety data
sheet / UV lamp on page 303.
7.7.2.2 Assemble UV lamp

Follow the instruction below to assemble the UV lamp.
• A leakage check must have been performed according to the instruction
Check for leaks after quartz sleeve assembly on page 338.
• Use waxed screws.
• If needed, replace the heat resistant O-rings in the lamp bushes.
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• Keep the UV lamp in its protective cover as long as possible. Do not touch
the glass of the lamp; hold the lamp by its ceramic ends. If needed, use the
cleaning wipes in the UV lamp box to clean the UV lamp.
• Glass sockets and lamp bushes must be dry and clean before mounting.
• It is recommended to replace all UV lamps after 3000 hours of operation.
The timers should then be reset in the control system on page 4.3 Timers.
1. Check the condition of the O-rings inside the lamp bushes. Replace with
new heat resistant O-rings if needed.
2. Place one lamp bush on the UV lamp.
3. Carefully insert the UV lamp and the lamp bush into the UV reactor. Be
careful with the glass bump! It can easily break the UV lamp if it clashes
into the quartz sleeve.
4. Insert the other lamp bush in the glass socket on the opposite side of the
UV reactor.
5. Check the condition of the cable connectors for the UV lamp. Look for rust,
burning or fading. Replace the UV lamp if needed.
6. Reconnect the cable connector.
7. Mount the UV lamp cap and tighten the cap nut, by hand only. Make sure
that the electric cable is not squeezed between the cap and the bush when
the cap is mounted. Slack can be pushed into the bush.
9. Power on the PureBallast system and check the alarm list on page 3.1
Alarm list, to make sure there is no active alarms.
7.7.3 Replace quartz sleeve

7.7.3.1 Disassemble quartz sleeve
Follow this instruction to disassemble the quartz sleeve.
• Lock valve V201–3, V201–9, V201–8, V201–19.x and V201–20.x in closed
position.
• Drain the UV reactor.
• Disconnect the instrument air.
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• Shut down the PureBallast system and secure it from being switched on.
• Remove the UV lamp according to instruction Disassemble UV lamp on
page 334.
1. Loosen the three screws holding the glass socket; just a few turns to
release the glass sockets.
2. On the other side of the UV reactor, unscrew the screws holding the glass
sockets and remove the glass socket.
3. Repeat step 2 on the other side of the UV reactor.
4. Wet the O-ring around the quartz sleeve with soapy water.
5. Use an angled or hooked O-ring tool to remove the O-ring. The O-ring are
firmly stuck in their seat, and will be damaged during removal, but shall be
replaced at assembly. Be careful not to break the glass. If the O-ring is
hard to remove, try the following:
• Perforate the O-ring to get a good grip.
• Moisten the O-ring with acetone or denatured alcohol.
• Loose the O-ring in a couple of places before removing it.
7. Carefully remove the quartz sleeve.
8. Use a soft cloth to clean the surface between the UV reactor and the glass
socket. Remove any small parts, for example glass or rubber.
9. Assemble the new quartz glass according to the instruction Assemble
quartz sleeve on page 337.
7.7.3.2 Assemble quartz sleeve

Follow this instruction to assemble the quartz sleeve.
• Two new O-rings for each quartz sleeve. Included in quartz sleeve set.
• Wax for the screws. They must be waxed to avoid seizing.
• Soapy water to lubricate the O-rings.
• Glass sockets and lamp bushes must be dry and clean before mounting.
Use a soft cloth to clean the surface between the UV reactor and the glass
socket. Remove any small parts, for example glass or rubber.
• Before installation, check that the quartz sleeves are not broken.
1. Lubricate a new set of O-rings in soapy water. Do not use Vaseline, oil or
similar.
2. Attach the first O-ring on to the quartz sleeve and carefully insert the quartz
sleeve into the UV reactor.
3. Attach the second O-ring to the other side of the quartz sleeve.
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4. Adjust the quartz sleeve so it is centred in the UV reactor. The O-ring

should be positioned evenly both sides. If not, they may be damaged and
cause leaks.
5. To push the O-ring into place, attach the glass socket and tighten one of
the screws.
6. Unscrew the screw and remove the glass socket.
8. Check the condition of the screws. Wax them if needed.
9. Attach the glass sockets and the screws on both sides on the UV reactor,
but to not tighten them.
10. Once the screws are evenly entered on both sides of the UV reactor, cross
tighten the screws until a torque of 7 Nm.
11. Check that the O-rings are positioned evenly both sides. If not, they may
be damaged and cause leaks.
The O-rings shall not be pressed into position, the glass socket press them
into position when fastened later.
Check the condition of the screws. Wax them if needed.
Carefully mount the glass sockets on both sides on the quartz sleeve.
Fasten the glass sockets with three screws, but do not tighten the screws.
12. Once the screws are evenly entered on both sides, carefully tighten them
evenly to a torque of 7 Nm.
13. Follow the instruction Check for leaks after quartz sleeve assembly on
page 338.
14. To assemble the UV lamp, follow the instruction Assemble UV lamp on
page 335
7.7.3.3 Check for leaks after quartz sleeve assembly

Follow the instruction below to secure that there are no leaks that may
damage the UV lamps.
1. Pressurize the UV reactor with water to between 2 and 4 bar.
2. Visually check for leaks.
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7.7.4 Replace lamp power supply (LPS)

Follow this instruction to replace a lamp power supply (LPS).
WARNING
Shut down the PureBallast system according to Shut down and deactivate system
on page 98. The LPS has a voltage of 600 V inside and on the lamp power
connector, even when UV lamps are not lit.
The cabinet contains a fan, which can cause injury if in operation.
1. Open the doors to the lamp drive cabinet.

2. The LPS is connected with three connectors. On the green connector,
press in the two latches and pull up the connector.
3. On the black connector, press in the red latch and pull down the connector.
4. On the green connector, press up the two orange latches and pull down
the connector.
5. Loosen, but do not remove the nuts under the LPS.
NOTE Risk of short circuit.
Be careful not to drop the nut or washer into the LPS.
6. Pull the handle to remove the LPS.

7. On the new LPS, set the DIP switches according to Lamp power supply
(LPS) parameters on page 157.
8. Mount the LPS in the cabinet.
9. Tighten the nuts under the LPS to attach it. Be careful not to tighten the
nuts too much, since that can cause the LPS to deform.
10. Reconnect the three connectors. Make sure the connectors sit tight.
11. Make sure that the motor circuit breakers are on. Turn on if necessary.
12. Power on the PureBallast system and check that LPS:s function correctly
according to instruction Test lamp power supply (LPS) installation on page
340.
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7.7.5 Test lamp power supply (LPS) installation

Follow this instruction to make sure that the installation is correct and safe to
use.
Preparation and conditions
• The PureBallast system should be powered on.
DANGER
Risk of overheating. There must be water in the UV reactor. Check status of level
switch (LS201–29).
WARNING
This instruction must be performed after cable connection. If not hazardous

situation may arise which, if not avoided, will result in death or serious injury.

1. Switch on the main breaker on the side of the electrical cabinet . Switch on
the power to the UV reactor using the switches on the breaker cabinet.
2. Set the control system in manual mode (requires login level Advanced
operator).
3. Go to page 1.3 Reactor and start LPS 1. Make sure that two UV lamps are
lit.
Note: It can take up to 90 seconds for the lamp to start.
4. Directly after the lamps are lit, turn of the LPS.
5. Repeat the test for all LPS.
6. Check that no error indication on the LPS and that there are no alarms in
page 2.1 Alarm list in the control system.
7. Exit manual mode.
7.7.6 Level switch

This section contains information about the level switch LS201-29 installed in
the UV reactor. For information about status indications, see Alarms and
faultfinding on page 159, section Level switch.
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Level switch
7.7.6.1 Mount level switch

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

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

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

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

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

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

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

spacer and UV sensor (from left to right, as
shown in the illustration).
7 Insert the assembled UV sensor into the UV

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

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

NOTE
7.7.8.1 Mount temperature switch / temperature transmitter

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

• The external surface may be hot. Care must be taken to avoid possible
burns.
1. Disconnect the component's screwed-on power cord.
2. Loosen the component with a spanner. Use the spanner on the hexagon
flats, but not on the components body.
3. Remove the temperature switch and remove the old seal from the threads.
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7.8 Filter
This section covers the instructions for filter service.
These preparations and conditions are valid for all instructions.
• Lifting device is needed for this instruction. See complementary lifting
instructions in the Design and installation guidelines.
• Filter cover and element weight (kg): Note: If you have filter the data is
correct. The system may be supplied with a filter of larger size. If so,
consult the Filter size addendum for correct data.
• Only perform maintenance and servicing work when the filter is cooled,
depressurized and drained. To drain the filter, press the Drain function
button in the control panel.
• Disconnect the power to the filter, using the main breaker on the electrical
cabinet.
• Always lock valve V201–3, V201–9, V201–8 and V201–32 if you open the
filter in some way. See Lock valve in closed position on page 361.
• Shut off the air supply to the filter.
• Visually inspect gasket during maintenance. Replace if necessary.
Tightening torques for filter

See section Preparations and conditions on page 316.
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Filter – Exploded view
1. Gear reducer
2. Gear shaft
3. Gear motor
4. Thrust bearing flange fixing bolt
5. Gear reducer flange / cover fixing bolt
6. Thrust bearing
7. Backflush shaft bushing gasket
7a. Backflush shaft bushing gasket
8. Filter vent plug
9. Filter cover
10. Cover bolt
11. Backflush shaft bushing
12. Filter element fixing bolt
13. Filter cover gasket
14. Filter body
15. Filter element
16. Backflush nozzle
17. Filter element gasket
18. Backflush shaft bushing
19. Filter drain plug
20. Backflush line gasket
22. Pressure transmitter*
29. Junction box
30. Backflush nozzle support
31. Backflush nozzle fixing bolt
32. Backflush nozzle support gasket
33. Base frame
34. Base frame fixing bolt
40. Ring spear 44. Cover lifting lug
41. Thrust bearing upper flange 45. Rotation indicator
42. Thrust bearing lower flange 70. Nameplate
43. Circlip 80. Prefilter
* Only one piece on the Flex filter module
This is a general illustration of filter components. Note; that not all components on the filter module are inclu-
ded in the illustration.
7.8.1 Remove filter cover and filter element

Follow this instruction to remove filter cover and filter element.
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1. Close pressure reducing valve, PRV501 on the filtermodule.

2. Disconnect the air tubing to RV201–50, V571–2 (one tubing each) and to
V571–3 (two tubings).
3. Divide the union connections to RV201–50, V571–2 and V571–3, and

remove RV201–50, V571–2 and V571–3.
4. Disconnect the electrical cable to the gear motor, M709–43.
5. Unscrew the bolts (5) holding the gear motor (1).
6. Remove the motor (using a lifting device, if necessary). Be careful not to
harm the motor fitting when lifting it from it’s seat.
7. Remove the cover bolts (10) and the lifting lugs (44).
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8. Screw two filter cover bolts in the lifting lugs holes until the cover raises
slightly from the filter house.
9. Remove the cover bolts and fasten the lifting lugs in their holes again.
10. Fasten a lifting device in the lifting lugs and lift the filter cover (9) with the
filter element carefully out of the filter.
NOTE
Be careful not to harm the filter element.

The filter should be lifted in one continuous movement, without sudden jerks –
even if the filter element is slightly stuck in the filter housing.
11. Place the filter element on its side.

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

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

Filter element and cover is mounted in reverse order as described in
instruction Remove filter cover and filter element on page 345.
NOTE
No force should be used to fit the filter element in the filter body or to fit the motor
in its seat.
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• Clean the upper inside of the filter body. The area where the O rings
(gaskets) meet the sealing surface of the housing should be clean.
• Check the O rings (gaskets). Replace if necessary.
• Fill up the filter body with technical / potable water after it is mounted. Use
the Fill function button in the control panel. See Drain/Fill on page 121.
Requires login as Advanced operator or higher.
7.8.3 Clean filter element and pre-filter

Follow this instruction to clean the filter element. At the same time, check that
the filter element is in good condition.
WARNING
Risk for eye and skin irritation.

Follow rules when handling CIP liquid agent; Alpacon descalant offshore,
regarding ventilation, personal protection etc. Avoid contact with eyes and wear
protective gloves and goggles.
If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly
with cold water.
• Alpacon descalant offshore may be used as cleaning agent. See Safety

data sheet / CIP liquid on page 294.
• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon
descalant to 20 parts technical / potable water. Follow this mixing ratio,
regardless of recommendation on label so that the pH value is
approximately 2.0–3.0.
• The used CIP liquid can be drained by using the drain plug (460 Drain) on
the filter.
• Used CIP liquid is drained to one of the following: drain, waste or sludge
tank. Do not drain to bilge. Handle according to local regulations.
• Be careful when transporting, assembling, disassembling and cleaning the
filter element.
• There are two ways to soak the filter element: In a loose soaking tub, or
inside the filter body. See respective instruction below.
• If you choose to soak the filter element inside the filter body, check the
volume of the filter body in the filter’s dimension drawing. See section
Dimension drawings on page 223or on the marking plate. This is necessary
in order to create correct mixing ratio.
Loose soaking tub — Follow the steps below:
1. Remove the filter cover with the filter element. See the instruction Remove
filter cover and filter element on page 345.
2. Rinse the pre-filter with water and a brush.
3. Remove the filter element gasket (17).
4. Soak the filter element in CIP liquid (1 part of Alpacon descalant liquid with
20 parts of technical water / potable water) for 1-4 hours.
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5. Spray the filter element with water (60–80 °C) from the outside, using a flat
nozzle. Note: To avoid damage of the filter mesh: the high-pressure
cleaner must not exceed a maximum of 15 bar. If a cleaner with higher
capacity is used, compensate by increasing the distance, minimum 30 cm.
6. Blow through the filter element with instrument air (with 10 micron filter or
finer), from the outside.
7. Repeat step 4 to 6.
8. Inspect the filter element from the outside with a magnifier to make sure
that it is clean.
9. Clean the inside of the filter body.
10. Put the filter element gasket back. Reassemble the rest of the filter.
Inside filter body — Follow the steps below:
1. Remove the filter cover with the filter element. See the instruction Remove
filter cover and filter element on page 345, but do not separate the filter
cover from the nozzle and the filter element.
2. Remove the filter element gasket (17).
3. Rinse the pre-filter (80) with water and a brush.
4. Rinse inside of the filter body and the filter element from larger debris using
a brush.
5. Insert the filter element back to the filter body and fasten it with 4 bolts.
6. Remove the relief valve RV201-50 and deaeration valve V571-4 from the
filter cover.
7. Fill the filter body with water through the hole using a hose to
approximately 50%.
8. Pour in the CIP liquid to correct mixing ratio.
9. Top up with water.
10. Let the filter element soak for 4 hours.
11. Drain the filter body from CIP liquid.
12. Lift the filter element out of the filter body.
13. Spray the filter element with water (60–80 °C) from the outside, using a flat
nozzle. Note: To avoid damage of the filter mesh, the high-pressure
cleaner must not exceed a maximum of 15 bar. If a cleaner with higher
capacity is used, compensate by increasing the distance, minimum 30 cm.
14. Blow through the filter element with instrument air (with 10 micron filter or
finer), from the outside.
15. Inspect the filter element from the outside with a magnifier to make sure
that it is clean.
16. In order for the filter element to be properly cleaned, repeat all the cleaning
steps for the filter element one more time.
17. Put the filter element gasket back.
18. Reassemble the rest of the filter.
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19. Run a ballast operation sea to sea for 5 minutes to remove any residual
CIP liquid from the filter.
20. Do a manual backflush to ensure good function of the filter.
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7.9 CIP
Follow this instruction to change CIP liquid can.
7.9.1 Change CIP liquid

The CIP liquid is an acidic solution that is used to clean the UV reactor after
ballast and deballast operations. It contains no solvents or no inorganic acids
and it is non-flammable. For more information, see Safety data sheet / CIP
liquid on page 294. The CIP liquid must be replaced when the pH is above
3.0. Use a pH meter or indication paper to measure. Check the pH regularly
according to the maintenance schedule.
WARNING
Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves and goggles. Follow rules when handling CIP liquid agent, regarding
ventilation, personal protection etc.
If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly
with cold water.
• Avoid letting the CIP cap with the pipe be out of the can for too long, to
avoid loosing CIP liquid in the pipe and hose.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.
1. Pull the pipe from the CIP liquid can.
2. Loosen the strap holding the CIP liquid can.
3. Replace the old can with a new. Remove the cap from the new CIP liquid
can.
4. Reconnect the CIP cap with the pipe in the can.
5. Remove the small cap on the cip liquid can, throw it away and cut a hole in
the membrane under the cap. The purpouse is to let air into the can to let
CIP liquid out.
6. Fasten the CIP liquid can with the strap.
7. Go to control system page Page 1.5 – CIP on page 67 and make sure that
level switch LS320-3 indicates wet condition (green).
8. Go to control system page Page 4.3 – Timers on page 82. Reset CIP
Number of cleaned UV reactors. If this is done each time the CIP liquid is
changed, it is possible to build up experience on how many CIP processes
it is possible to perform before it is time to change CIP liquid. Requires
login level Advanced operator.
7.9.2 Pumps
This section contain instructions for the CIP and drain pumps.
7.9.2.1 Operate pumps manually

Follow this instruction to manually operate pumps.
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1. Look at the signal plate on the valve block to identify which button that
controls the pump. See Valve block on page 356 for an illustration.
2. Press the button on the valve body with a pointy object to start the pump.
The pump remains running as long as the button is pressed.
7.9.2.2 Repair drain pump

Follow this instruction to repair the drain pump (P460–1).
WARNING
Always disconnect the PureBallast system from the power supply before
CAUTION
Always wear protective eye glasses and gloves while working on the pump.
• Before disassembling the pump, the pneumatic hoses must be

disconnected, and the extension pipe must be removed and blocked.
• Drain the pump from liquids.
• The pump should be placed horizontally on a work bench.
Drain pump, exploded view
7.9.2.2.1 Clean drain pump

1. Remove the pump from the skid.
2. Rinse the pump with water.
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7.9.2.2.2 Disassemble drain pump

Follow this instruction to disassemble the drain pump (P460–1).
Disassemble the main parts

1. Remove the drain pump from the skid and place it on a work bench.
2. Unscrew the nuts (37) on one side of the housing (11).
3. Place the pump on the side that still has the nuts (the pump lays on the
nuts) on a stable ground.
4. Carefully remove the "loose housing" (11).
5. Carefully lift up the suction and discharge connections (13). You have the
centre block (12) and one of the housings with pin screws (14) left.
6. Upend the pump and carefully pull out the pin screws (14). Be careful not
to damage the diaphragms (15).
Disassemble the housing

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

Follow this instruction to disassemble the centre block
• Have backup spares of the sealing (36) and backup O-ring (47). There is a
risk that these parts get damaged during this operation.
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1. Press the diaphragms (15) to their neutral position (both have the same
distance to the centre block).
2. Hold one of the diaphragms (15) and unscrew the other. Then pull out the
remaining diaphragm with the diaphragm shaft (16).
3. Disassemble the circlips (27) which keep the air valve (61) on its place.
4. Press out the air valve. A wood shaft of a hammer can be used. Be careful
not to damage the sealing edges towards the diaphragm or the air valve.
5. If the shaft sealings (36) seem to be worn out, carefully remove them with
a pointed tool.
7.9.2.2.3 Assemble drain pump

Follow the instructions below to assemble the drain pump (P460–1).
Assemble center block

1. Mount the circlip (27) on one side.
2. Apply some soft soap solution on the air valve O-rings (30).
3. Push the air valve (61) into the housing. Make sure that the O-rings (30)
remain in the right position. Put the circlip (27) on the other side.
4. Put the diaphragm (15) with shaft (16) into the centre block. Screw the next
diaphragm (15) onto the shaft (16) and fix the holes.
Assemble the main parts

1. Make sure that the O-rings (18) are placed on the in/outlet (13) before
assembling of pump.
2. Turn the housing (11) with the flat side up.
3. Make sure all pin screws (14) have one nut (37) and one washer (38)
each. Nut should only be put on one or two threads.
4. Put all the pin screws through the housing and then turn the housing so it
rests on the nuts.
5. Put the centre block (12) to the housing with screws through the centre
block. Be careful not to damage the diaphragms.
6. Place suction and discharge connections (13) in their positions in the
housing. Be careful not to damage the O-rings (18).
7. Put the second housing (11) onto the pin screws (14). Make sure that
suction/discharge connections are in right direction. Be careful with the O-
rings.
8. Fasten the nuts (37) crosswise by hand, with or without washers
depending on how much of the thread comes out. Turn the nuts gently with
a tool to close the pump. If some of the nuts were fastened without washer,
unscrew those and put washers underneath. After a few weeks operation a
follow up draft of the nuts is recommended.
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7.9.2.3 Test pumps
Test drain pump

Follow the instruction below to verify that drain pump (P460–1) is functioning.
1. Log in as Advanced operator or higher.
2. Check that there is water in the UV reactor (LS201-29). Check the LED on
the level switch: Steady yellow light indicates that there is water in the UV
reactor.
If not, press the Fill function button in the control system and wait for the
UV reactor to be filled. See Drain/Fill on page 121.
3. Press the Drain function button in the control system.
4. Observe if functions OK. If not, check installation and connections and test
again.
5. Observe if the pump sounds OK and that it strikes the number or times set
in p403 with hertz as set in p405. If not: Check/change parameter settings.
6. When the process ends, fill the UV reactor again.
Test CIP pump

Follow the instruction below to verify that CIP pump (P320–1)is functioning.
1. Pull the pipe from the CIP liquid can and stick it to a bottle filled with a
couple of dl with water. (This is to avoid waisting CIP liquid during the test.)
2. Go to page 1.5 CIP and press Manual button, to enter manual mode.
3. Open V320–2 and V460–3.
4. Activate CIP pump P320–1, and toggle between start and stop.
Observe if the pump sounds OK and that it strikes every time the button is
pressed.
5. Make sure that water has disappeared from the bottle.
6. Reconnect the pipe in the can.
7.9.3 Valve block

Follow this instruction to repair the valve block.
DANGER
Always disconnect the PureBallast system from the power and air supply before
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Valve block — general illustration

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

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

Follow this instruction to connect the electrical cable from the
- CIP valve block to the electrical cabinet.
- Filter valve block to the filter junction box, and from the filter junction box to
- UVR valve block, located in the control box (UVR junction box) to the
electrical cabinet.
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1. Open the cover (1) on the front.

2. Attach the cables according to electrical drawing Electrical cabinet /
interconnection diagram. See Electrical cabinet / Interconnection diagram
on page 257..
3. Fasten the cable to the cable gland (5).
4. Fasten the cover (1).
7.9.3.3 Clean valve block

Follow this instruction to clean the valve block house from dirt.
1. Disconnect the outgoing air hoses from the valve block.
2. Operate the service air according to instruction Open and close valves
manually in section Valves on page 359 to blow out the dust.
3. Connect the air hoses again.
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7.10 Valves
This section contain instructions for the valve actuator.
Valve actuator with puck for position sensor

1. Safety cover *
2. Padlock*
3. Lower position for indicator screw
4. Upper position for indicator screw — with screw
5. Position indicator
6. Center screw
7. Cover
8. Puck
9. Locking bolt
10. End stop bolt
* Not on all valves.
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Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilot valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves with dimension 400
7. DIN connector
7.10.1 Preparations and conditions
CAUTION
Lock valve in closed position before maintenance.

Do not disassemble individual spring elements. Disassembly may result in
personal injury.
Do not remove end caps or disassemble the actuator while the actuator is
pressurized.
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• Do not operate the actuator over pressure limits. It will damage internal
parts as well as cause damage to the housing.
• The actuator must not be lubricated. It is factory lubricated for the life of the
actuator during normal working conditions. The standard lubricant is
suitable for use from −20 °C (−4 °F) to +80 °C (+176 °F).
• If a valve actuator is removed, check for loose spindle-bushing. Then make
sure the loose bushing is refitted to avoid play between the actuator and
the valve spindle.
• Actuator are mounted together with the valve body and pilot valve at
delivery. Valve and actuator mounting are sealed to guarantee correct
position indication in relation to throttle position.
Tightening torques for actuators

See section Preparations and conditions on page 316.
7.10.2 Open and close valves manually

Follow this instruction to manually operate valves from the valve block.
Normally, we recommend that valves are operated from the control system.
See Operating instructions and control system description on page 41 for
instruction.
1. Look at the signal plate on the valve block to identify which button that
controls the valve.
2. Press the button on the valve body with a pointy object to open the valve.
The valve remains open as long as the button is pressed.
7.10.3 Lock valve in closed position

Follow this instruction to lock valves in closed position. These valves are
locked mechanically with two bolts on the actuator.
* Safety cover (1) and padlock (2), not on all valves.

• Note that the end positions of the end stop bolts are factory adjusted and
should normally not be readjusted.
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Valve V201–8 and V212–31 (optional)

1. Set the valve to closed position from the control system. Control the
position indicator, to make sure. The yellow position indicator is in line with
the valve throttle (indicating open when the position indicator is in line with
the pipe).
2. Disconnect power and instrument air. Verify that the valve is not under
pressure.
3. Open the padlock (2*) on the actuator and remove the safety cover (1*)
from the bolts (3, 4).
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.
Valve V201–3, V201–9, V201–32 and V201–19

1. Set the valve to closed position from the control system. Control the
position indicator, to make sure. The yellow position indicator is in line with
the valve throttle (indicating open when the position indicator is in line with
the pipe).
2. Disconnect instrument air. Verify that the valve is not under pressure.
3. 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.
4. Open the locking bolt (3) and turn them a couple of turns.
5. Screw the end stop bolt (4) to its bottom position and tighten the locking
bolt.
6. Verify that the valve cannot be opened.
7. Repeat the above procedure for all valves concerned.
7.10.4 Unlock valve

Follow this instruction to unlock valves from closed position.
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* Safety cover (1) and padlock (2), not on all valves.

• Note that the end positions of the end stop bolts are factory adjusted and
should normally not be readjusted.

1. Disconnect all power and instrument air. Verify that the valve is not under
pressure.
2. Open the padlock (2*) on the actuator and remove the safety cover (1*)
from the bolts (3, 4).
3. Open the locking bolt (3) slightly.
4. Adjust the end stop bolt (4) to the same position (distance from reference
surface) as before locking the valve, according to the notes made during
locking.
NOTE
It is important to adjust the ends stop bolt to the correct position. Otherwise
the actuator may be damaged.
5. Tighten the locking bolt (3).

6. Verify that the valve can open and close.
7. Slide the safety cover in position over the end stop bolts. Lock the safety
cover with the pad lock.
Valve V201–3, V201–9, V201–32 and V201–19

1. Disconnect instrument air. Verify that the valve is not under pressure.
2. Open the locking bolt (3) slightly.
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3. Adjust the end stop bolt (4) to the same position (distance from reference
surface) as before locking the valve, according to the notes made during
locking.
NOTE
• It is important to adjust the ends stop bolt to the correct position.
Otherwise the actuator may be damaged.
4. Tighten the locking bolt (3).
5. Verify that the valve can open and close.
7.10.5 Dismount actuator

Follow this instruction to dismount an actuator.
• The valve must be in closed position.
• The valve position must not be adjusted during the routine.

1. Remove the connector to disconnect the power. Let the air connection
remain.
Verify that the valve is in closed position.
Result: Valve goes to closed position due to air connection. The yellow
indicators on the puck shows position of valve: closed. The yellow position
indicators are in line with the valve throttle (indicating closed when the
position indicators are in opposite line with the pipe).
2. Close air supply: Remove air hose to the pilot valve, and attend to their
position (connection points on the air hoses). Verify that the actuator is not
pressurized. Always use caution and double-check that ports 2 and 4 are
vented and are free from any accessory and/or device.
3. If the actuator have a switch box at the top: Loosen the four screws holding
the switch box to the actuator. Remove the switch box together with its
bracket.
4. Loosen the four hexagonal screws holding the actuator to the valve.
5. If the actuator is mounted on the valve with a bracket and coupling
(dimension 400): Loosen the screws holding the bracket to the valve. Make
sure not to loose the coupling between the valve and actuator when lifting
the actuator.
6. Lift the actuator from the valve.
Valve V201–3, V201–9, V201–32 and V201–19

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1. Air shall be connected to the valve.

Verify that the valve is in closed position:
Valve goes to closed position due to air connection. The yellow indicators
on the puck shows position of valve: closed. The yellow position indicators
are in line with the valve throttle (indicating closed when the position
indicators are in opposite line with the pipe).
2. Close air supply: Remove air hose to the pilot valve, and attend to their
position (connection points on the air hoses). Verify that the actuator is not
pressurized. Always use caution and double-check that ports 2 and 4 are
vented and are free from any accessory and/or device.
3. Loosen the four hexagonal screws holding the actuator to the valve.
4. Lift the actuator from the valve.
7.10.6 Mount actuator

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

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

• The utmost cleanliness is required during air supply connection to the
actuator, that is, the connecting pipe thread, fittings and seals must be
clean and dirt-free.
• Before fitting onto the valve, make sure the actuator/valve is correctly
orientated, depending on which direction of rotation is required.
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1. Note the position of the groove (2) of the valve stem (3). It indicates the
position of the valve throttle. The illustration shows a square variant, but
octagonal versions exist.
2. Make sure that the lock pin (inside the valve stem) only travels in the
allowed sector (1) and that it does not pass the opening (5).
3. If the actuator is mounted on the valve with a bracket and coupling
(dimension 400): First fit the coupling on the valve stem. Make sure that
the red position indicator on the coupling is in line with the pipe when the
valve is open.
4. Fit the actuator onto the valve stem (or the coupling). The actuator may
only be positioned in even 90° intervals in relation to the valve. It is not
allowed to adjust the position by turning the actuator by hand after it is
fitted on the valve stem.
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 360.
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.
Valve V201–3, V201–9, V201–32 and V201–19

1. Note the position of the groove (2) of the valve stem (3). It indicates the
position of the valve throttle. The illustration shows a square variant, but
octagonal versions exist.
2. Make sure that the lock pin (inside the valve stem) only travels in the
allowed sector (1) and that it does not pass the opening (5).
3. Fit the actuator onto the valve stem. The actuator may only be positioned
in even 90° intervals in relation to the valve. It is not allowed to adjust the
position by turning the actuator by hand after it is fitted on the valve stem.
4. Mount the actuator on the valve with the four hexagonal screws. For each
screw, one washer and one spring washer shall be used. Tighten with
torque according to the table Tightening torques for actuators in
Preparations and conditions on page 360.
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5. Reconnect the air hose.

6. Operate the valve to make sure it operates in the desired direction of
rotation.
7.10.7 Adjust valve end position

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

• The valve shall be closed (0°) position 0.
V201–3, V201–9, V201–32, V201–19, V212–31 and V201–8
1. Note the exact position of the position indicator for reference after
adjustment.
2. Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing
position and the left set adjusts open position.
3. Loosen the locking bolt (3).
4. Adjust end position by turning the end stop blot (4) with small turns.
- Clockwise decrease the end position.

- Counterclockwise increase the end position.
NOTE
The total adjustment degree is 10° for each position.
5. Operate the valve. Compare the new position of the position indicator to
see the result on the adjustment. If needed, adjust again.
6. Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).
7.10.8 Calibrate positioner on V201-8

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

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

Parameter Settings in menu
1 turn
2 90° (is automatically 90° when turn is used)
34 0.7
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1. Make sure that the transmission ratio selector (6) is set to 90° according to
sticker on the component. If not: Adjust by pressing the bar with a screw
driver.
2. Make sure that the Arrestor device wheel (1) is set to 90°. If not: Adjust by
turning.
3. Press HAND button for 5 seconds to enter the parameter list.
4. Make sure that Menu 1 is displayed. If not: Press HAND button repeatedly
until it is.
Make sure that “turn” is displayed in the menu. If not: press + or -
repeatedly until it is.
5. Press the hand button repeatedly until Menu 4 is displayed.
(To go backward, press HAND button and - button.)
6. Press + button for 5 seconds to start automatic calibration.
7. If calibration stops (as displayed below), follow these steps:
- Use a screw driver to loosen the yellow locking wheel (counter

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

- Press the + button to continue the calibration.
8. Wait until “FINISH” is displayed on the screen.
9. Press the hand button once.
Result: Menu 4 “INITA” is displayed.
10. Press the hand button for 5 seconds until a number or “VER” is displayed,
then let go of the button.
Result: “MAN” is displayed”.
11. Press the hand button once.
Result: A final adjustment is started, and then “AUT” is displayed.
Trouble shooting
If any problem occurs, do the following:
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1. Check the mechanical installation and air supply.

2. Reset factory settings and restart calibration:
- Reset to factory settings: Press HAND button repeatedly until menu 50 is

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

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

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

1. In control panel: Set system in manual mode.
2. Open V201-8 manually to approximately 50 % in the panel.
3. Close it to approximately 10 %.
4. On the positioner: Adjust both cam wheels to same position. Cam wheels
are above the adjustment wheel (5). See illustration in Calibrate positioner
on V201-8 on page 367.
5. Turn the cam wheels in any direction until it valve indicates steady green in
the control panel. Multimeter indicate circuit closed.
6. Turn the cam wheel slowly counter clock wise until you hear a click from
the micro switch in the positioner. Stop directly after the click. Stop directly
after the multimeter changes to indicate circuit open.
7. Check that the valve is indicated as open (steady green) in the control
panel.
8. Close the valve to 0 %.
Result 1: Valve closed, indicated with no color. Circuit closed. Setting is
OK. You are done.
Result 2: Valve indicated as red. Cam wheels are in wrong position, for
example due to the wheels been turned too much after the click).
Multimeter indicate circuit open. Repeat from step 2 until setting is OK.
7.10.10 Change direction of actuator for bypass valve V212–31

(optional)
Follow this instruction to turn an actuator with switch box.
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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
• The valve must be mounted and connected to air and power before
adjustment.
1. Dismount the actuator according to Dismount actuator on page 364.
2. Remount the actuator according to Mount actuator on page 365
3. Before mounting the switch box, change the position of the yellow position
indicator, so it is in line with the throttle.
4. Remount the switch box according to Mount actuator.
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7.10.11 Mount pilot valve on actuator V212–31 (optional)

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

1. Mounting screw holes
2. Throttle valve
3. Port 1 for air connection (under)
4. Throttle valve
5. DIN connector
6. Screw.
1. Check that the O-rings are fitted on the pilot valve, on the side facing the
actuator.
2. Fit the pilot valve on in the actuator, so that the pin on the actuator fits the
hole on the pilot valve. The throttle valves (2 and 4) shall be directed
downwards.
3. Mount the pilot valve with two Allen screws in the holes (1).
4. Connect air to port 1 (3) on the pilot valve.
5. Fit the DIN connector (5) on the coil, including gasket. Then fasten the
connector with the screw (6).
7.10.12 Adjust valve traveling speed for V212–31 (optional)

Follow this instruction to adjust valve traveling speed.
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1. Operate the valve manually to check travelling speed according to the
instruction Open and close valves manually in section Valves on page 359.
2. To adjust opening speed:
Faster: Screw the throttle (1) valve port 3 counterclockwise.

Slower: Screw the throttle valve (1) port 3 clockwise.
3. To adjust closing speed:
Faster: Screw the throttle valve (2) port 5 counterclockwise.

Slower: Screw the throttle valve (2) port 5 clockwise.
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7.11 Flow meter

CAUTION
Risk of damaging circuit boards! Make sure not to transfer static electricity to the
circuits.
NOTE
The display mounted on the flow transmitter is not supplied for all system sizes.
The display is optional.
The flow sensor and flow transmitter are pre-assembled from factory, and the
parameters are pre-set.
7.11.1 Backing up the data

B) Read out the parameters from the memory card (T-DAT) via the web browser (Data management/
Device configuration/Upload settings from device), using the parameter download function.
Save the .xml file to the PC and by using the Download settings to device function.
Save the parameters to the new electronics module.
7.11.2 Replace display module
WARNING
Risk of electric shock! Exposed components carry dangerous voltages.

Make sure that the power supply is switched off before you remove the cover of the electronics
compartment.
NOTE
The display module is not part of the Alfa Laval’s scope of supply.

To open cover without display: See step 1–2.
To open cover with display: See step 1–3 b.
To replace display module: See step 1–5.
1 Turn off power supply, using the main breaker

on the electrical cabinet
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2 Open the cover of the electronics

compartment.
Opening the cover with display (upper
image), without display (lower image).
a) Loosen the securing clamp.
b) Unscrew the cover.
c) Remove the cover.
3 Remove the display module as follows:

a) Squeeze the tabs of the display module
holder together.
b) Remove the display module holder.
c) Disconnect the cable of the display
module from the main electronics module.
4 Remove the display module from its holder.
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5 Installation is the reverse of the removal

procedure.
7.11.3 Replace the memory card (T-DAT)

If the transmitter or measuring device is replaced: Remove the T-DAT from the old unit and insert it
into the new unit. Once the T-DAT containing the previous data has been exchanged, the new
measuring device is ready for operation.

compartment as described in instruction
Replace display module above.
2 Remove the T-DAT.

procedure.
7.11.4 Replace module carrier and ISEM module

The module carrier contain power supply module and I/O modules.
1 Switch off power supply, using the main

breaker on the electrical cabinet
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compartment.
a) Loosen the securing clamp.
b) Unscrew the cover.
c) Remove the cover.
3 a) Disconnect the cable of the module

carrier.
b) Loosen the securing clamp.
c) Remove the module carrier.
4 Remove the module carrier from the

transmitter housing.
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5 Remove the ISEM module.
6 Remove the ribbon cable.

procedure.
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7.12 Control panel

This section covers instructions for service of the control system.
7.12.1 Clean control panel
NOTE
Control panels may only be cleaned when shut off. If not, there is a risk that
functions are triggered or settings changed by buttons pressed during cleaning.

• Never use aggressive solvents, chemicals, scouring agents, pressurized air
or steam jet.
1. Turn the main breaker at the side of the electrical cabinet to turn off the
power.
2. Clean the display and surrounding front cover with a soft cloth and mild
detergent. Do not spray detergent directly on the control panel.
7.12.2 Replace control panel

Follow this instruction to replace the control panel
• The system must be shut down.
• After the panel is mounted: Load new software to the panel according to
the release note for the software. Also set communication according to Set
control panel IP address on page 108 and Set remote control panel
communication on page 109.
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7.13 Remote control panel (optional)

If included in order, 1 or 2 remote control panels can be mounted in wall,
worktop etc. at an optional location, for example the bridge, cargo control
room or back office.
7.13.1 Mount and connect remote control panel

• Remote control panel is mounted according to according to drawing
Remote control panel (optional) on page 249. Note the clearance area.
• Use a 24 VDC, 2 amp power supply cable with minimum cross section of
0.75 mm2, preferably halogen free and flexible. Connect power cable to
terminal X1 in remote control panel.
• Communication cable (W501) between the remote control panel and
electrical cabinet can be either Ethernet or optical fiber. Cable requirements
and connection points below:
• Communication cable (W501) between the remote control panel and
electrical cabinet can be either Ethernet or optical fiber. Cable requirements
and connection points below:
- Ethernet cable – Type: Cat 5e (or better), shielded. Max length: 100
meters.
One remote control panel: From terminal X2 in remote control panels to
terminal X7 in the electrical cabinet.
Two remote control panels: From terminal X2 in second remote control
panel to either switch SW1 in electrical cabinet or to switch SW1 in the first
remote control panel.
- Optical fiber cable – Type: Multi-mode optical fiber cable with LC
connector. Max length: 500 meters.We recommend a cable with four or
more cores are used to have spare cores if one is broken. From remote
control panel’s switch SW1 to switch SW1 in electrical cabinet. See Remote
control panel / Circuit diagram (optional) on page 287.
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7.14 Electrical cabinet

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

This section covers maintenance information about the I/O system (X20
electronic modules). For information about status and error indications, please
see Alarms and faultfinding on page 159.
1. Hold down the plastic clip on the top of the terminal block and pivot the
block towards you.
2. Pull away the terminal block.

3. Hold down the triangle on the top of the I/O board and loosen the board.
4. Pull the board straight out (otherwise it can fasten in one of its guides).
5. Compare the part number of the new I/O board to the old board, to make
sure it is correct.
6. If changing more than one board at a time, check with the electrical
diagram to ensure that the boards are mounted in the right places.
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7. Mount the new I/O board by pressing it straight into place. Make sure the
board is firmly in place, otherwise it will be impossible to mount the cable
terminal.
8. Remount the terminal block. Make sure the clip on the bottom of the block
fastens properly in place on the axel on the bus holder.
9. Pivot the terminal block on the axel until the clip on the terminal block top
fastens into place in the I/O board.
7.14.2 Install IFS confstick in safety relay KS1 in LDC

Follow this instruction to install a IFS confstick in the safety relay. This is done when a broken IFS
confstick is replaced or when a new safety relay is installed.
The confstick must be programmed for the specific system it is about to be installed in.
382 200000878-6-EN-GB
Service manual 7 EN
1 Switch off the power to the lamp drive cabinet

(EC).
2 If the safety relay is broken, follow the sub-

steps below. If the IFS confstick is broken,
continue with step 3. a) Replace the old
safety relay with a new. b) Remove the IFS
confstick from the old safety relay and use it
in the steps below.
3 Insert the IFS confstick in the safety module.

The IFS confstick can only be inserted in one
way.
4 Switch on the power to the EC. Wait until the

safety relay has initialized (all four status
LEDs light up once during initialization).
5 The safety relay now detects that a IFS

confstick has been inserted. The LED
"CONF" is flashing.
6 Remove the IFS confstick again.
7 Press the Confirm button on and hold it

pressed down.
8 Reinsert the IFS confstick while holding down

the Confirm button.
9 Release the Confirm button once the IFS

confstick is inserted properly. The safety
module now initializes with the new
configuration.
200000878-6-EN-GB 383
EN 7 Service manual
384 200000878-6-EN-GB
EN
8 Revision history
The revision history shows changes since the last release.
Compact Flex
Date Description
2021-03-12 Updates according to the latest software release. The most important changes:
• Warnings W11 and W151 updated.
• Auto logoff after 90 minutes added.
• Audible warning for 3 seconds when user logged off, added.
• New events about compliancy: E802 and E803 added.
• Changed valve alarm delay time to 40 seconds.
General clarification of chapter Compliant / non-compliant operation.
New chapter Water sampling added.
New chapter Cyber security added.
New chapter Best practice operation - Soft start/stop using flow control added.
Pressure requirement: Rewritten with new requirements, new calculations and new
presentation.
New chapter Download crash trends added.
New chapter Adjust travel speed of valves added.
Instruction Calibrate flow and pressure regulation re-written.
Stop Ballast – stop ballast sequence updated.
Mercury absorption kit added in Recommended spare parts, chapter 7 Service man-
ual.
CIP liquid storage time added.
New manufacturers and models added for valves, pressure transmitter, Ex pump mo-
tors.
Install IFS confstick instructions to chapter 7 Service manual, added.
Tip to connect mouse to control panel for easy control.
New/updated dimension drawings:
• Vacuum relief valves VB201
• Vacuum relief valves VB309
• Sampling device
New/updated electrical drawings:
• Electrical system layout
New/updated general drawings:
• Air distribution diagram
2020-12-15 Power requirement for backflush pump P309-1 added.
200000878-6-EN-GB 385
EN 8 Revision history
Date Description
2020-11-16 Control system – updates according to the latest software release. The most impor-
tant changes:
• Backflush time increased to 40 seconds.
• Backflush initial delay set Default = 0.
• Only main panel should manage heartbeat to PLC.
LPS – clarified alternative DIP switch setting for limited batch of LPSs in chapter 4.
Flow meter – updates and new instructions:
• Caution notice regarding damaging the circuit boards
• Instructions about replacing ISEM module
• Diagnostic information via LED added.
UVR – updated UV sensor instructions to secure accurate measure in chapter 7.
Operation – clarified Heeling instructions; legally, technically and operationally in
chapter 3.
Operation – clarified preparation for challenging (muddy) waters in chapter 3.
Event and Alarms (Event log): added events E808 and E809 regarding salinity in
chapter 3.
Closed cooing unit (CCU) – clarified that CCU includes pump P401-1 (if installed).
Several minor corrections and clarifications.
• Valve V212–31
• Flow transmitter FIT201-1
• Electrical cabinet
386 200000878-6-EN-GB
Revision history 8 EN
Date Description
2020-05-25 New section Prepare operation in SM chp 3 to contain all preparations such as
choose IMO/USCG, open relevant valves, priming etc.
Section “Operational conditions” now collects conditions and modes for an operation
(IMO, USCG, heeling, gravity filling etc.)
Heeling instruction clarified in chapter 3.
Events corrected, now containing”E” before the number.
Updated according to latest SW release.
UV reactor instruction: Added screw specification and yield stress of flame path for
lamp fittings.
Booster pump section restructured to include P201-1 on same level as others. De-
scription of other pumps clarified.
Personnel requirements for Ex system updated.
Section Flow meter parameters added to chapter 4.
Parameter p111: Setting details added for FIT201-1.
Parameter p111: Setting details added for FIT201-1.
• UVR 1000 and 1500 Ex and Std
• Filter Ex 1000
• Filter 3000 Ex and Std
• Press. mon. device
• Connectivity cabinet
• Electrical system layout
• RCP
2020-03-27 New method for filter cleaning is introduced in chapter 7.

Lifting instructions: All capacities removed.
SW 3.1.7.1:
• Start-up 90 sec. Chp 2 and parameter p210.
• Strip button page 1.1.
• Set range changed for parameter p201, p319.
• CIP popup added.
Flexible filter size information added.
200000878-6-EN-GB 387
EN 8 Revision history
388 200000878-6-EN-GB
.
Spare parts catalogue

Specification No. 9030169-02/1

Book No. 9056670 02 Rev. 1
Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB 2021-06-10

Original instructions
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1 Important information 5
2 UV Reactor 6
2.1 Reactor 10
2.2 Control box 12
2.3 Junction box 14
2.4 Valve, EN DN150 16
3 Electrical cabinet 18
3.1 Electrical cabinet, subassy 20
4 Remote control panel (optional) 34

4.1 Cover 36
5 Log box (optional) 38

5.1 Relay module 40
6 Filter 42
6.1 Filter, ACB-915-150 46
7 Backflush pump (optional) 48
8 Valve, EN DN100 50
9 Flow transmitter, EN DN150 52
10 CIP unit 54
10.1Dashboard 56
10.2Valve 58
10.3Pump 60
11 Cable set 62
3
12 Press.monitoring device 64
13 Sampling device, EN (optional) 66
14 Air preparation unit (optional) 68
15 Vacuum relief valve (VB201),

DN80 (optional) 70
16 Vacuum relief valve (VB309),

DN50 (optional) 72
17 Connectivity cabinet 74
18 Extended options (SPC) 76
19 Cross reference list 78
4
1 Important information
1 Important information
• Some parts indicated in the drawings are not included in the item list. If such part is required,
contact your local Alfa Laval office for support.
• Always include the system serial number in the order (for example PB-10789).
• Always use genuine Alfa Laval spare parts. Alfa Laval cannot accept responsibility for the failure
of components using non-original spare parts.
Book No. 9056670 02 Rev. 1 5

2 UV Reactor
Machine unit number or
Subassembly description
9029469-
Ref Part No Description -10 Notes
Quantity
1 9029442 80 Reactor 1 See page 10
2 9029831 80 Control box 1 See page 12
3 9052014 80 Junction box 1
3A 9010985 82 Junction box 1 See page 14
3B 9049548 81 Lamp cable 1 Order position Z for this item. Marked:
W01B
3C 9049548 81 Lamp cable 1 Order position Z for this item. Marked:
W02B
3D 9049548 81 Lamp cable 1 Order position Z for this item. Marked:
W03B
3E 9049548 81 Lamp cable 1 Order position Z for this item. Marked:
W04B
3F 9049548 81 Lamp cable 1 Order position Z for this item. Marked:
W05B
3G 9049548 81 Lamp cable 1 Order position Z for this item. Marked:
W06B
3H 9049548 83 Lamp cable Spare part for pos 2 to 7. Including
cable, cap, collet, cable gland and nut.
7 9015569 80 Adapter 2
11 594707 03 Pipe 1
12 9004638 01 Clamp 1
14 9018589 80 Valve, EN DN150 1 See page 16
15 594413 81 Valve 2
16 9017571 01 Valve, DN20 1
17 9001689 81 Housing 1
18 9001357 01 UV sensor QT201-50 1
19 9006325 02 Thermometer, resistance 1
20 9006324 02 Temperature, switch 1
21 594171 01 Limit switch (vibration) 1
22 9006822 01 Relief valve, 6 bar 1
23 9029834 80 Regulator w. valve 1
24 597044 03 Cable 2
25 597044 04 Cable 1
26 593301 02 Insulating washer 8
27 593300 04 Insulating sleeve 8
28 558663 04 Gasket washer 2
29 558663 03 Gasket washer 1
30 1765908 06 Gasket 1
31 69263 Hose clip 1
32 2245101 14 Hose clip 1
33 9029856 01 Hose 1 Fitted at assembly
34 526350 05 Plug 1
35 526336 04 Nipple 1
36 526336 05 Nipple 1
37 526337 06 Reducing hexagon nipple 1
38 9024693 03 Straight coupling 1
38.1 9024692 01 Nut, function 1
39 526345 05 Elbow 1
40 561094 01 Straight coupling 1
41 597049 01 Coupling, elbow 90 1
42 580758 05 Push-In Fittings 1 Valve block (Control box)
43 9021483 01 Regulating valve 2 V201-19
44 552801 50 Push-on connector 2 V320-4, V321-2, PORT 2
45 579749 02 Tee, union, 1/4-8 1
46 559022 01 Plug 1
48 583012 04 Throttle valve, 1/8 2 V320-4, V321-2, PORT 4
49 9004517 01 Reducer 1
50 552801 50 Push-on connector 1 V571-1, PORT A
51 598571 02 Torx head pan screw M4 4
52 221031 22 Screw 3
53 221031 21 Screw 2
54 2210296 02 Screw 3
55 2210463 23 Screw 8
56 2210463 07 Screw 4
57 2210463 09 Screw 4
58 260192 08 Screw 8
6 Book No. 9056670 02 Rev. 1

2 UV Reactor
3118A
Book No. 9056670 02 Rev. 1 7


9029469-
Quantity
61 221803 26 Nut 4
62 221803 27 Nut 3
63 221803 28 Nut 18
64 221803 40 Nut 4
68 223101 30 Washer 4
69 223101 31 Washer 6
70 223101 32 Washer 23
71 223101 37 Washer 20
72 223101 39 Washer 8
74A 9049546 81 Lamp cable 1 Marked: W01/02A
74B 9049546 81 Lamp cable 1 Marked: W03/04A
74C 9049546 81 Lamp cable 1 Marked: W05/06A
74D 9049546 81 Lamp cable Spare part for pos 1 to 3
75 9010631 03 Cable 1 QT201-50
76 9010631 03 Cable 1 TS201-60
77 9010631 03 Cable 1 TT201-33
78 9010631 05 Cable 1 LS201-29
79 9021730 05 Cable 1 V201-8 (IP201-7)
91 595558 01 Wire 11
Z 579367 98 UV Lamp set
Z0.1 594645 81 Quartz sleeve set
8 Book No. 9056670 02 Rev. 1

2 UV Reactor
3118A
Book No. 9056670 02 Rev. 1 9

2.1 Reactor
9029442-
Quantity
3 66169 Drive screw 8
6 9003326 01 Glass socket 12
7 221711 13 Screw 36
8 9002009 81 Lamp bush 12
9 9004878 80 Cap 12
10 9002860 01 Nut 12
20 221711 23 Screw 8
22 221040 04 Screw 16
23 223101 61 Washer 24
24 221036 01 Screw 4
25 223101 33 Washer 10
27 67141 Screw 2
28 9003662 01 Plate 1
29 2210296 02 Screw 1
30 223101 31 Washer 2
32 221036 19 Screw 4
34 221041 03 Screw 4
35 221803 29 Nut 4
37 9008695 01 Technical data 1
38 9009416 01 Cable rail 2
39 221031 21 Screw 4
40 223101 32 Washer 8
41 221803 28 Nut 4
10 Book No. 9056670 02 Rev. 1

2.1 Reactor 2 UV Reactor
3119A
Book No. 9056670 02 Rev. 1 11

2.2 Control box

9029831-
Quantity
1 9030059 01 Enclosure 1
3 9017746 01 End stop clipfix 35 2
4 582212 122 Terminal block 2
5 582212 89 D-ST2,5 1
6 582212 88 PIT 2,5 21
7 9030063 01 Gasket 1
8 9029832 80 Valve block 1
9 591103 70 Pilot light White 1
10 582212 151 Socket 5
11 9003031 01 Condensation outlet 1
12 589569 78 Cable Gland - M20 1
13 589569 42 Counter nut EMC M20 1
14 582212 02 Plug In Bridge 1
16 221701 13 Screw 4
18 9030706 01 Cable 1 Assembled
12 Book No. 9056670 02 Rev. 1

2.2 Control box 2 UV Reactor
3120A
Book No. 9056670 02 Rev. 1 13

2.3 Junction box

9010985-
Quantity
1 9010982 01 Enclosure 1
2 582212 148 End stop (clip fix) 2
3 582212 156 Terminal, PT 6 10 Marked acc. to electrical doc.
4 582212 157 End cover, D-PT 6 1
6 589569 58 Cable gland EMC-brush M32 3
7 9004959 02 Insert, 5x6 mm 2
8 589569 44 Counter nut EMC M32 7
9 589569 53 Blind plug with o-ringM32 4
19 559022 01 Plug 4 2 plug / 5x6mm insert
14 Book No. 9056670 02 Rev. 1

2.3 Junction box 2 UV Reactor
2912A
Book No. 9056670 02 Rev. 1 15

2.4 Valve, EN DN150

9018589-
Ref Part No Description -80 -70 Notes
Quantity
1 9039016 07 Valve, DN/A150 1 1 Vulcanized Liner
1 9040965 66 Valve, DN150 1 1 Loose Liner
1A 9007167 06 Valve, DN150 1 1
1B 9007184 03 Insulate plate
2 9040972 82 Air actuator, AT 251U 1 1
2 9040973 82 Air actuator, VT 095 1 1
2A 9007166 03 Air actuator, AT 251U 1 1
2A 9040493 03 Air actuator, VT 095 1 1
2B 9041119 03 Maintenance kit,VT 095
2B 9041128 03 Maintenance kit, AT 251U
3 9018592 01 Inductive sensor 1
4 9018613 01 Assembly kit, BT32-F25-0 1
6 595558 01 Wire 1
16 Book No. 9056670 02 Rev. 1

2.4 Valve, EN DN150 2 UV Reactor
2962A
Book No. 9056670 02 Rev. 1 17

3 Electrical cabinet
9034630-
Quantity
1 9034629 80 Electrical cabinet, subassy 1 See page 20
2 9012146 01 Lamp Power supply 3
3 9023358 80 Clamp (LPS) 3
4 223101 47 Washer 20
5 221891 04 Lock nut 20
6 9023360 01 Sheet 2
7 594009 06 Screw 8
18 Book No. 9056670 02 Rev. 1

3 Electrical cabinet
3214A2
Book No. 9056670 02 Rev. 1 19

3.1 Electrical cabinet, subassy

9034629-
Quantity
1[ 594009 03 Screw 2
1\ 9018236 01 Washer 4
1] 260154 02 Lifting eye bolt 4
1^ 9003030 01 Drawing Pocket 1
1_ 223101 47 Washer 2
1‘ 221803 02 Nut 2
1a 593780 01 Key 1
1A 598572 01 Torx head pan screw M6 17
1b 587276 02 Washer 8
1B 9021302 01 Cover sheet 1
1c 70560 Washer 8
1C 594009 07 Screw 6
1d 221891 05 Hexagon lock nut 8
1D 9019607 80 Frame 1
1e 587276 01 Washer 5
1E 9017465 01 Metal filter 1
1f 223101 47 Washer 5
1F 9018349 80 Fan canopy 1
1g 221891 04 Lock nut 5
1G 9018411 01 Yoke 2
1H 9017498 01 Knob 4
1I 223101 47 Washer 7
1J 221891 04 Lock nut 7
1K 9002984 01 Hinge 3
1L 596105 02 Screw 6
1M 223101 47 Washer 6
1N 221803 02 Nut 6
1O 9019141 01 Handle 1
1P 9019142 01 Control mechanism 1
1Q 9019144 01 Rod 1
1R 9019143 01 Latch point 3
1S 221891 04 Lock nut 6
1T 596105 02 Screw 6
1U 9019576 01 Sheet 1
1V 221891 04 Lock nut 2
1W 9019624 01 Sheet 1
1X 594009 05 Screw 2
1Y 9019625 80 Door stay 1
1Z 9019697 01 Sheet 2
2 9018407 01 Wire rope damper 4
3 9018993 01 Attachment, vertical 2
4 9018407 02 Wire rope damper 2
5 9018992 01 Attachment, horizontal 2
6 221711 02 Screw 24
7 9034627 80 Component assembly 1 See page 26
8 9004232 01 Filter 1
10 223101 47 Washer 14
11 221891 04 Lock nut 10
12 9030501 01 Sheet 1
13 221716 01 Screw 1
14 70560 Washer 2
15 221891 05 Hexagon lock nut 1
16 9019081 05 Main breaker 1
16.1 9019140 04 Fuse 1
17 594009 07 Screw 4
18 9019081 06 Shaft 1 Length 68±1 mm
19 9017388 03 Handle 1
20 9023282 03 Terminal shroud 2
21 599530 05 Resistor 1
20 Book No. 9056670 02 Rev. 1

3.1 Electrical cabinet, subassy 3 Electrical cabinet
3215A2
Book No. 9056670 02 Rev. 1 21


9034629-
Quantity
22 9017472 01 Fan, axial 1
23 9017456 01 Grid 1
24 2210295 03 Screw 8
25 223101 17 Washer 16
26 221803 03 Nut 8
28 592926 05 Grommet, M25 3
29 590624 03 Temperature sensor 1
30 582212 164 Phoenix Contact 5
31 581803 43 Plug M 3p 5
32 582212 165 Phoenix Contact 5
33 592005 14 DIN-rail, 35x15 1
34 9019514 80 Terminal block 1 See page 32
35 9017691 01 Panel 1
36 9019012 01 Pushbutton, blue 1
37 591103 80 Legend plate holder 4
39 591103 70 Pilot light White 1
41 591103 69 Pilot light Green 1
43 9019000 01 Buzzer, red 1
45 591103 67 Emergency stop 1
47 591103 93 Shroud Ye 1
48 9052609 01 USB socket 2
48.2 581803 66 USB cable 1,8 m 1
49 9023297 01 Filter 2
50 593243 03 Cable gland, M40x1,5 1
51 589569 37 Counter nut M40 1
52 9017442 01 Contact housing 1
53 9017442 04 Socket insert 1
54 221803 20 Nut 4
55 9029930 01 Contact housing (base) 1
56 9029930 04 Socket insert 1
57 221803 32 Nut 4
58 589569 78 Cable Gland - M20 3
59 589569 34 Counter nut M20 3
60 589569 80 Cable Gland - M32 2
60.1 589569 73 Cable gland sealing M32 2
61 589569 36 Counter nut M32 2
62 9018995 03 Connector, 17-pos. 2
63 9018995 02 Connector, 12-pos. 1
64 9018995 01 Connector, 4-pos. 1
65 9018995 06 Connector, 8-pos. 1
66 9033033 01 Connector, 5-pos 1
68 9030879 01 Sheet 3
69 221851 05 Cap nut 10
70 596904 04 Cable channel 30x30 1
73 596904 01 Cable channel 30x30 1
77A 9008383 03 Cable, 2,5mm² 6
77B 9008383 04 Cable, 2,5mm² 4
77C 9008383 05 Cable, 2,5mm² 4
77D 9008383 06 Cable, 2,5mm² PE 8
77E 9008383 13 Cable, 6mm² PE 3
77F 9008387 01 Cable 50
77G 9008383 18 Cable, 2,5mm² 3
77H 9015692 01 Cable, 1,5mm² 8 LPS signal, 5 färger
77I 9008693 01 Cable, 2x2x0,5mm² 4
77J 9008387 02 Cable 1
77K 9008383 12 Cable, 25mm² PE 1 Z1 / mounting plate / PE cab
77L 9024562 05 Cable lug 4 PE cable
88 9031733 12 Marking, X17 1
99 1270001 Lifting instruction 1
22 Book No. 9056670 02 Rev. 1

3215A2
Book No. 9056670 02 Rev. 1 23


9034629-
Quantity
101A 9036082 01 Rectangular connector 1
101B 9036086 01 Female insert 1
101C 9036087 01 Protective cover 1
102 9024317 01 Hexagon socket head screw 2
104 594009 02 Screw 4
105 223101 41 Washer, 4,3x9x0,8 4
106 9030917 01 Cable 3
108 223101 29 Washer 4
Z 9023297 02 Filter mat
Z0.1 9019140 04 Fuse
24 Book No. 9056670 02 Rev. 1

3215A2
Book No. 9056670 02 Rev. 1 25

3.1.1 Component assembly

9034627-
Quantity
3 223101 47 Washer 13
4 221891 04 Lock nut 13
11 593724 04 Distance screw 2
13 582221 90 PE Connection bar 2 220 mm
14 594009 03 Screw 4
15 9017746 01 End stop clipfix 35 12
16 591103 54 Over current prot. Relay 5
17 591103 10 Auxiliary contact 5
19 591103 64 Connection 2
20 591103 45 Breaker handles 1
21 590968 31 Motor Circuit Br. 16-20A 1
21.1 591103 10 Auxiliary contact 1
22 9017118 01 Motor starter, 2.4A 1
24 9014707 99 Wall bracket 1
24.1 594009 03 Screw 4 Omron power supply
24.1 594009 07 Screw 4 Phoenix power supply
25 9014707 02 Power supply 1
26 9034946 80 Programmable Logic Controller 1
26A 597033 25 CPU w intergrated IO 1
26B 580986 76 Communication module 1
26C 580986 17 Bus module 7
26D 580986 16 Terminal block 12-pin 7
26E 580986 72 Communication module 2
26F 580986 69 8DI 4DO 1
26G 580986 08 4 Analogue input 1
26H 580986 33 Output Module 1
26I 580986 61 4 Analog Input (PT100) 1
26J 580986 59 12 Digital Output 1
27.1 9017746 02 End plate D-ST 2,5 3
28 9004299 04 Fuse 4
29 582212 182 Safety module 1
30 9014546 01 Temperature relay 1
31 9042519 01 Relay 3
36 594009 07 Screw 2
37 9019135 04 Contactor AF16Z 1
38 9019138 02 Over current prot. Relay Ex 1
39 221701 03 Screw 4
41 582212 91 VIP-2, D 9SUB 1
42 595728 02 Switch 1
43 582212 147 Patch panel 2
44 595673 03 Ethernet cable 2
47 582212 189 Cable-D 9SUB, 1m 1
ZA 582212 182 Safety module 1
ZB 9053220 80 Memory block EC 1
Z0.1 9053220 80 Memory block EC
26 Book No. 9056670 02 Rev. 1

3285A
Book No. 9056670 02 Rev. 1 27

3.1.2 Terminal block

9019488-
Quantity
2 582212 67 Terminal, PT 2,5-3PV 10
3 582212 64 Terminal PT 2,5-3PE 2
4 582212 63 Terminal D-PIT 2,5-3L 1
28 Book No. 9056670 02 Rev. 1

2954A
Book No. 9056670 02 Rev. 1 29


9031573-
Quantity
4 582212 104 Terminal PITTB 2,5 4
5 582212 102 Terminal PITTB 2,5 PE 1
8 9042519 02 Relay 6
9 582212 67 Terminal, PT 2,5-3PV 2
10 582212 63 Terminal D-PIT 2,5-3L 1
11 9042519 01 Relay 6
12 9017746 02 End plate D-ST 2,5 1
14 9017747 01 Terminal block, feed thro 4
15 9017747 04 Plug, R 1
16 9017747 03 Plug, M 2
17 9017747 02 Plug, L 1
18 9042519 04 Bus bar, blue 2 6 terminal lugs
19 9042519 03 Bus bar, red 1 6 terminal lugs
30 Book No. 9056670 02 Rev. 1

3133A
Book No. 9056670 02 Rev. 1 31


9019514-
Quantity
3 582212 04 End plate 1
4 9017747 06 Terminal PT2,5-Twin/1P 9
5 9017747 07 Terminal PT2,5-Twin/1P PE 1
6 9017747 04 Plug, R 1
7 9017747 03 Plug, M 8
8 9017747 05 Plug, L PE 1
32 Book No. 9056670 02 Rev. 1

2958A
Book No. 9056670 02 Rev. 1 33

4 Remote control panel (optional)

9012055-
Quantity
1 9014979 01 Top plate 1
1 9014979 02 Top plate 1
3 221711 16 Screw 8 8
3.1 9016593 01 Spacer 8 8
4 9017691 01 Panel 1
4 9017691 03 HMI Panel 15" 1
6 223101 47 Washer 3 3
7 221851 05 Cap nut 3 3
8 592005 14 DIN-rail, 35x15 1
9 223101 47 Washer 2 2
10 221891 04 Lock nut 2 2
11 582212 148 End stop (clip fix) 2 2
12 582212 95 Terminal, PIT 2,5 TWIN 4 4
12.1 582212 03 Plug In Bridge 1 1
13 582212 96 Terminal, PIT 2,5 TWIN-PE 1 1
14 582212 04 End plate 1 1
15 582212 147 Patch panel 1 1
16 9052609 01 USB socket 1 1
16.1 9036476 16 USB cable 0,5 m 1 1
18 9011552 01 Buzzer 1 1
20 591103 72 Pushbutton Black 1 1
20.1 591103 92 Cover 1 1
21 593950 26 Marking, ON / OFF 1
22 9009760 01 Relay, D-sub 1 1
22.1 582212 214 D-SUB gender changer 1 1
23 595673 04 Ethernet cable 1 1
24 9011960 01 Bracket 1 1
25 223101 47 Washer 2 2
26 221891 04 Lock nut 2 2
28 594009 06 Screw 2 2
29 223101 47 Washer 2 2
30 221891 04 Lock nut 2 2
31 582212 148 End stop (clip fix) 2 2
32 595728 02 Switch 1 1
33 595673 04 Ethernet cable 1 1
34 587276 02 Washer 2 2
35 70560 Washer 2 2
36 221891 05 Hexagon lock nut 2 2
37 9015557 80 Wire set 1 1
38 9011943 80 Cover 1 1 See page 36
39 582212 215 Connector 1
34 Book No. 9056670 02 Rev. 1

4 Remote control panel (optional)
2875A
Book No. 9056670 02 Rev. 1 35

4.1 Cover
9011943-
Quantity
1 9011944 01 Cover 1
2 594488 01 Washer 4
3 581688 01 Bracket 4
4 221711 16 Screw 8
5 223101 47 Washer 8
6 221891 04 Lock nut 8
7 589569 79 Cable Gland - M25 2
8 589569 35 Counter nut M25 2
9 589569 48 Cable Gland - M16 2
10 589569 33 Counter nut M16 2
11 587276 02 Washer 2
12 70560 Washer 2
13 221891 05 Hexagon lock nut 2
36 Book No. 9056670 02 Rev. 1

4.1 Cover 4 Remote control panel (optional)
2883A
Book No. 9056670 02 Rev. 1 37

5 Log box (optional)

9002245-
Quantity
1 582212 05 End stop 9
3 582212 123 Power terminal block, 1
4 582212 124 Circuit breaker 2
5 582212 125 Power supply unit 1
9 582212 88 PIT 2,5 3
10 582212 89 D-ST2,5 1
11 582221 90 PE Connection bar 1 450mm
12 591103 56 Over current prot. Relay 1
15 594781 01 Distance 2
18 9002305 03 Cable seal 1
19 9002362 80 Relay module 4 See page 40
24 594009 03 Screw 8
29 9003490 01 Bracket set 1
30 9038504 02 Limit value switch 12
31 582212 147 Patch panel 1
33 593950 20 Marking, Log box 1
38 Book No. 9056670 02 Rev. 1

5 Log box (optional)
3021A
Book No. 9056670 02 Rev. 1 39

5.1 Relay module

9002362-
Quantity
1 582212 119 Interface relay, 24V 8
2 582212 120 Input adapter 1
3 582212 121 System cable 1
Z 582212 172 Relay, mini
40 Book No. 9056670 02 Rev. 1

5.1 Relay module 5 Log box (optional)
2724A
Book No. 9056670 02 Rev. 1 41

6 Filter
9029339-
Quantity
1 9023653 60 Filter, ACB-915-150 1 See page 46
2 9041764 80 Gear motor 1
2AA 9041781 01 Motor 1
2AB 9041784 02 Contact housing 1
2AC 9041784 01 Contact housing 1
2AD 9041784 04 Insert (male) 1
2AE 9041784 03 Insert (female) 1
2AF 9055541 01 Screw with gasket spare part for pos. 4 and 5
2B 9041791 01 Gear 1
2C 9041792 02 Shaft key, 5x5x25 1
2D 9041792 03 Shaft key, 8x7x35 1
2E 9041793 01 Shaft 1
2F 9041794 01 Washer 1
2G 2210296 02 Screw 4
2H 221036 19 Screw 1
2.1 589569 78 Cable Gland - M20 1
3 221036 19 Screw 4
3.1 223101 33 Washer 4
4 9018589 70 Valve, DN 150 1 See page 16
5 9018589 80 Valve, EN DN150 1 See page 16
6 260192 08 Screw 10
6.2 221803 23 Nut 6
7 223101 39 Washer 16
10 9029834 81 Regulator w. valve RH 1
11 9024168 01 Elbow union 1
13 9047526 01 Needle valve 1/4" 1
14 9017973 01 Pressure transmitter 1
15 526336 04 Nipple 2
16 9029394 01 Union, conical sealing 2
17 9006822 03 Relief valve, 10 bar 1
18 9019942 80 Release valve, automatic 1
19 9021770 04 Tee - ISO 4144 - G 1/2" 1
21 9022613 80 Valve 1
21A 9017571 01 Valve, DN20 1
22 526338 12 Hexagon bushing 1
23 526338 03 Bushing 1
24 552801 02 Push-in connector 2
25 552801 50 Push-on connector 1
26 9024839 01 Stud elbow, male 1
27A 9037962 01 Enclosure 1
27B 9017746 01 End stop clipfix 35 2
27C 582212 88 PIT 2,5 21
27D 582212 122 Terminal block 2
27E 582212 89 D-ST2,5 1
27F 589569 78 Cable Gland - M20 1
27G 589569 48 Cable Gland - M16 1
27H 582212 151 Socket 4
27I 9030706 01 Cable 1
27J 582212 02 Plug In Bridge 1
28 221711 25 Screw 4
28.1 223101 32 Washer 4
28.2 221803 28 Nut 4
29 9029811 80 Valve block 1
30 221701 20 Screw 4
31 223101 30 Washer 4
42 Book No. 9056670 02 Rev. 1

6 Filter
3125A
Book No. 9056670 02 Rev. 1 43


9029339-
Quantity
32 9029808 01 Sheet 1
33 9031612 01 Bracket 1
34 7007238 01 Screw 8
35 9029812 01 Bracket 1
36 9029944 01 Cable bracket 1
39 221711 07 Screw 7
40 223101 32 Washer 5
47 221711 13 Screw 1
47.1 587276 01 Washer 1
47.2 223101 32 Washer 2
47.3 221803 28 Nut 1
48 9019573 01 Hose, protective 1
51 591090 04 Flange 1 1/4" 1
52 9021483 01 Regulating valve 4
53 558912 01 T-push-on connector 2
54 580758 06 Push-In Fittings 1
57A 9020027 02 Cable 1 Filter motor to EC. Marked: W14
57B 9019849 10 Cable 1 PT201-71. Marked: W201.71
57C 9019849 07 Cable 1 GS201-3. Marked: W201.2
57D 9019849 09 Cable 1 GS201-9. Marked: W201.9
57E 9019849 09 Cable 1 PT201-16. Marked: W201.16
57F 597044 09 Cable 1 PE junctionbox to filter
58 569035 01 Flexible pipe, PA12, 6/4 2
59 569035 05 Flexible pipe, PA12, 8/6 1
60 595558 01 Wire 10
65 590667 44 V571-2 1
68.1 9021483 01 Regulating valve 2
73 223101 31 Washer 2
74 221706 12 Screw 2
44 Book No. 9056670 02 Rev. 1

6 Filter
3125A
Book No. 9056670 02 Rev. 1 45

6.1 Filter, ACB-915-150

9023653-
Quantity
4 9024205 03 Bolt 4
6 9011970 09 Bearing 1
7 9011972 37 Gasket 2
7.1 9011973 21 Bushing 1
8 9024206 03 Plug 2
9 9011974 46 Filter cover 1
10 9024205 11 Bolt 8
11 9011973 24 Bushing 1
12 9024205 19 Bolt 4
13 9011972 40 Gasket 1
15 9011975 09 Filter element 1
16 9011972 43 Nozzle 1
17 9011972 46 Gasket 1
18 9011973 27 Bushing 1
19 9024206 11 Plug 3
20 9011972 49 Gasket 1
30 9024207 03 Nozzle support 1
31 9024205 27 Bolt 4
34 9024205 35 Bolt 4
36 9011970 28 Grease fitting 1
40 9024208 03 Ring spear 1
41 9011970 12 Bearing flange 1
42 9011970 20 Bearing flange 1
43 9024209 03 Retaining ring 1
44 9024210 03 Lifting lug 2
77 9011973 30 Bushing 1
80 9011978 09 Prefilter 1
87 9024206 19 Plug 6
Z 9011963 89 Maintenance kit Yearly maintenance, incl. gaskets and
bushing
46 Book No. 9056670 02 Rev. 1

6.1 Filter, ACB-915-150 6 Filter
3025A
Book No. 9056670 02 Rev. 1 47

7 Backflush pump (optional)

9025646-
Quantity
1 9038059 80 Centrifugal pump 1
1A 9018653 03 Centrifugal pump 1
1B 9039696 02 Foot support kit 1
1C 9038535 80 Maintenance Kit 2 Year
1CA 9019944 01 Centrifugal pump spare pa 1
1CB 9038536 01 O-Ring Kit 1
1D 9038535 82 Maintenance Kit 5 year
1DA 9038537 01 Pump Shaft 1
1DB 9038538 02 Motor Bearings 1
1DC 9038539 02 Wear Ring 1 Wear Ring 1
1DD 9038539 03 Wear Ring 1 Wear Ring 2
1.1 589569 78 Cable Gland - M20 1
1.2 589569 34 Counter nut M20 1
1.4 9036098 80 Cable kit 1
2 9017578 82 Valve, EN DN40 1
2A 9040965 60 Valve, DN40 1 Loose Liner
2AA 9007167 29 Valve, A50 with 90 º rot. 1
2AB 9007184 01 Insulate plate
2B 9039016 01 Valve, DN40 1 Vulcanized Liner
2C 9040972 91 Air actuator, AT 101U 1
2CA 9020930 01 Air actuator, AT 101U 1
2CB 9041128 01 Maintenance kit, AT 101U
2D 9040973 91 Air actuator, VT 065 S08 1
2DA 9040708 01 Air actuator, VT065 S08 1
2DB 9041119 10 Maintenance kit, VT065 S08
2E 221031 04 Screw 4
2F 223101 32 Washer 4
2G 9009153 03 Throttle valve, 1/8 1
2H 595558 01 Wire 1
2.1 9021483 01 Regulating valve 1
5 595558 01 Wire 2
6 2210463 08 Screw 4
7 223101 37 Washer 8
8 221803 40 Nut 8
9 260176 03 Stud bolt 4
10 223101 37 Washer 4
11 1765908 07 Gasket 1
12 9029448 01 Elbow adaptor, 40 1
13 2210463 22 Screw 4
14 223101 37 Washer 4
48 Book No. 9056670 02 Rev. 1

7 Backflush pump (optional)
3034A
Book No. 9056670 02 Rev. 1 49

8 Valve, EN DN100
9007174-
Quantity
1 9039016 05 Valve, DN100 1 Vulcanized Liner
1 9040965 64 Valve, DN100 1 Loose Liner
1A 9007167 04 Valve, DN100 1
1B 9007184 02 Insulate plate
2 9040931 81 Air actuator, AT 201U 1
2 9040970 81 Air actuator, VT 075 1
2A 9040972 81 Air actuator, AT 201U 1
2A 9040973 81 Air actuator, VT 075 1
2AA 9007166 02 Air actuator, AT 201U 1
2AA 9040493 02 Air actuator, VT 075 1
2AB 9041119 02 Maintenance kit,VT 075
2AB 9041128 02 Maintenance kit, AT 201U
2B 587927 02 Locking device, AL79 201 1
2B 9040703 02 Locking device 1
7 9007196 01 Bracket 1
9 9034058 80 Driver 1
10 9007190 01 Positioner 1
10.2 9029781 01 Insert, M20 1 See comment on assembly drawing.
13 552801 50 Push-on connector 2
16 569035 01 Flexible pipe, PA12, 6/4 1
23 595558 01 Wire 1
24 552801 01 Push-in connector 2
27 9007200 01 Manifold 1
28 9007201 01 Filter 1
29 571697 01 O-ring, small 1
30 523127 01 Hexagon nipple 1
31 592304 02 Plug, 1/4 1
50 Book No. 9056670 02 Rev. 1

8 Valve, EN DN100
2712A
Book No. 9056670 02 Rev. 1 51

9 Flow transmitter, EN DN150

9042715-
Quantity
1 9037341 60 Flow transmitter, EN150C 1
1A 9040724 09 Flow transmitter, 150 1
1B 9040987 08 Transmitter + display, A2
1C 9040987 02 Display
1D 9040987 03 Memory card T-DAT
1E 9040987 06 Module carrier, A2
1F 9040987 07 ISEM Module, A2
2 9037818 01 Cable 1 FT201-1. Marked: W17
52 Book No. 9056670 02 Rev. 1

9 Flow transmitter, EN DN150
3216A2
Book No. 9056670 02 Rev. 1 53

10 CIP unit
9029043-
Quantity
2 9030607 01 Pipe 1
3 9029096 02 Pipe 1
4 9029096 03 Pipe 2
5 9030605 01 Pipe 1
6 9030502 01 Pipe 1
7 9029106 02 Pipe 1
8 9030598 01 Nipple, hose 2
9 9030504 01 Yoke 5
10 9030593 01 Support 1
11 9030506 01 Tie rod 10
12 9030592 01 Bracket, valve 1
13 9030508 01 Bracket 1
14 9019688 01 Suction tube 1
17 9033305 80 Dashboard 1 See page 56
19 9019689 01 Straight coupling, female 1
20 9002825 80 Valve 5 See page 58
24 586773 80 Pump 1 See page 60
27 9022262 01 Push-in fitting, straight 2
31 9019796 01 Regulating valve, Ø6 mm 1
32 9021795 01 Holder 2
33 2245102 07 Hose clip 4
34 9017336 01 Strap 1
35 569038 05 Hose, 32 1
36 569035 01 Flexible pipe, PA12, 6/4 1
38 9035427 06 Pipe clamp, 061 PP, Ø32 11
39 596187 01 Clips list
45 221706 12 Screw 4
46 221706 10 Screw 15
47 221711 14 Screw 3
48 260262 07 Screw 2
51 221803 27 Nut 36
52 221803 28 Nut 3
53 221803 21 Nut 4
61 223101 31 Washer 40
62 223101 32 Washer 3
63 223101 33 Washer 4
66 260137 06 Pop rivet 14
96 595558 01 Wire 7
54 Book No. 9056670 02 Rev. 1

10 CIP unit
3128A
Book No. 9056670 02 Rev. 1 55

10.1 Dashboard
9033305-
Quantity
2 9029834 81 Regulator w. valve RH 1
3 9032724 01 Valve 1
4 9030297 80 Valve block 1
4A 9030675 01 Gable, D-side, 8 mm 1
4B 9030676 01 Terminal box 1
4C 9030677 01 Extension part 4
4D 9030678 01 Valve, double 3/2, N/C N/C 4
4E 9030679 01 Gable, U-side, 8 mm 1
4F 9003172 08 Plug 1
4G 9031279 01 Decal 1
5 9017332 01 Pump 1
7 558710 01 Air Hose Nipple 1
8 558710 07 Air Hose Nipple 1
14 9024317 01 Hexagon socket head screw 4
15 221701 11 Screw 2
16 221701 20 Screw 6
17 221706 23 Screw 2
18 569035 01 Flexible pipe, PA12, 6/4 1 Transparent, 2 m
19 569035 05 Flexible pipe, PA12, 8/6 1 Transparent, 0,5 m
20 9030707 01 Cable 1 W12
21 9034986 01 Cable gland, NPT 3/4 1
22 9016299 03 Capacitive sensor 1
23 589569 01 Cable Gland M12 1
24 589569 09 Counter nut M12 1
56 Book No. 9056670 02 Rev. 1

10.1 Dashboard 10 CIP unit
3134A
Book No. 9056670 02 Rev. 1 57

10.2 Valve
9002825-
Quantity
1 9002825 01 Valve 1
Z 9003574 01 O-ring
58 Book No. 9056670 02 Rev. 1

10.2 Valve 10 CIP unit
2609A
Book No. 9056670 02 Rev. 1 59

10.3 Pump
586773-
Quantity
1 586773 01 Pump 1
Z 586773 02 Spare part set Diaphragm, O-ring set (in/outlet), Valve
ball, Muffler, O-ring (valve seat)
Z0.1 586773 03 Diaphragm Contains: O-ring set (in/outlet), Valve
ball, Muffler, O-ring (valve seat)
60 Book No. 9056670 02 Rev. 1

10.3 Pump 10 CIP unit
2370A
Book No. 9056670 02 Rev. 1 61

11 Cable set
9035151-
Quantity
1A 9017442 02 Contact housing 1
1B 9017442 05 Pin insert 1
1C 9017442 03 Contact cable gland 1
1D 9011609 01 Power cable (LDC-AOT) 1
1E 9024459 11 Cable kit 1 Jumper between pin 1 and 24
1EA 9008387 01 Cable 1
10A 9029930 02 Contact housing (housing) 1
10B 9029930 05 Pin insert 1
10C 589569 52 Blind plug with o-ringM25 1
10D 9024459 11 Cable kit 1 Jumper between pin 1/2
10DA 9008387 01 Cable 1
10E 599530 04 Resistor 2 Resistor between pin 5/6 and 7/8
11 9033029 01 Termination resistor 1 EC, X13A
62 Book No. 9056670 02 Rev. 1

11 Cable set
3217A2
Book No. 9056670 02 Rev. 1 63

12 Press.monitoring device
9006076-
Quantity
1 9047526 02 Needle valve 1/2" 1
2 526336 04 Nipple 3
3 9006075 01 Manifold 1
4 9017973 01 Pressure transmitter 1
5 543054 09 Pressure gauge 1 0-16 bar
6 9006822 03 Relief valve, 10 bar 1
7 546600 02 Pipe union 1
8 544465 06 Locking liquid 1
9 595558 01 Wire 4
64 Book No. 9056670 02 Rev. 1

12 Press.monitoring device
2709A
Book No. 9056670 02 Rev. 1 65

13 Sampling device, EN (optional)

589745-
Quantity
1 591662 80 Adaptor pipe 1 1
1A 591813 01 Adaptor flange, DN65/A65 1 1
1B 591618 01 Reducer 1 1
1C 591898 01 Bend, 60,3x2,9 1 1
1D 591665 01 Pipe, 60,3x2,9 1 1
1E 591625 01 Adaptor flange, DN50/A50 1 1
2 9021009 01 Pitot tube 1 1
3 1765908 07 Gasket 2 2
4 2210462 30 Screw 4 4 M6S 16x70 fzb
5 221803 34 Nut, M16 4 4 M6M 16 fzb
6 70490 Washer 16 16 BRB 17x30x3 fzb
7 591631 01 Blind flange, DN50/A50 1 1
8 591628 80 Valve, manual DN50 1 1
8 591628 82 Valve, manual DN50 1 1
8A 576886 13 Valve, DN50 1 1 Lug type
8A 9007167 01 Valve, DN50 1 1 Lug type
8B 9037347 01 Hand lever 1 1
9 2210462 45 Screw, M16x45 8 8 M6S 16x45 fzb
14 591666 01 Rod 1 1
66 Book No. 9056670 02 Rev. 1

13 Sampling device, EN (optional)
2780A
Book No. 9056670 02 Rev. 1 67

14 Air preparation unit (optional)

9041369-
Quantity
1 9041415 01 Auto drain valve 1
2 9041416 01 Spacer with bracket 1
3 9041417 01 Adapter 2
4 9041418 01 Manual shut-off valve 1
5 9041419 01 Main line filter 1
6 9041420 01 Air preparation filter 1
7 9041421 01 Membrane air dryer 1
8 9041422 01 Regulator 1
9 9041423 01 Bracket 2
10 9041424 01 Spacer 4
11 9041425 01 Assembly plate 1
12 9041426 01 Fitting, straight ISO-G 1/2 1
13 9041427 01 Fitting, elbow ISO-G 1/2 1
14 9041439 01 Fitting, straight, 3/8 - 10 1
16 544595 24 Elbow pipe 1
17 569035 07 Flexible pipe, 16/12 1
18 221711 07 Screw 4
19 223101 32 Washer 4
20 221803 28 Nut 4
21 221716 16 Screw 2
22 223101 33 Washer 2
23 221803 21 Nut 2
68 Book No. 9056670 02 Rev. 1

14 Air preparation unit (optional)
3213A2
Book No. 9056670 02 Rev. 1 69

15 Vacuum relief valve (VB201), DN80 (optional)

9041133-
Quantity
1 9040974 01 Vacuum relief valve, DN80 1
2 9018672 43 VB201 1
3 595558 01 Wire 1
Z 9041961 01 Cover assembly
Z0.1 9041965 01 O-ring
Z0.2 9041966 01 Float
70 Book No. 9056670 02 Rev. 1

3205A2
Book No. 9056670 02 Rev. 1 71


9041153-
Quantity
1 9040843 01 Vacuum relief valve, DN50 1
2 9018672 44 VB309 1
3 595558 01 Wire 1
Z 9041963 01 Cover assembly
Z0.1 9041965 03 O-ring
Z0.2 9041967 01 Float
Z0.3 9041968 01 Spring
72 Book No. 9056670 02 Rev. 1

3212A2
Book No. 9056670 02 Rev. 1 73

17 Connectivity cabinet
9041379-
Quantity
1 9045930 01 Enclosure 1
1A 9005699 53 Enclosure 380x600x210 1
2 9005699 55 Wall bracket 4pcs 1
3 9005699 06 Door stay 1
4 9006853 01 Fan 1
5 9005699 56 Filter 1
6 592001 01 Thermostat 1 (U1)
7 9037152 03 Gateway 1 (A1)
8 9036476 07 WLAN antenna 1 (A5)
9 9036476 04 Omni-directional antenna 1 (A4)
10 9036476 06 Network switch 8-port 1 (A3)
11 581803 45 Patch cable 0.5m 90° angl 1 (A3)
12 9037158 01 antenna cable 500mm 1 (A4)
13 9037158 01 antenna cable 500mm 1 (A5)
14 9036476 10 RJ45 Plug angled 7
16 583556 31 Cable channel 40x80 1
17 589945 44 Circuit breaker 6A/2P 1 (F1)
18 581803 56 Power supply 5A 1 (T1)
19 1764728 01 Label 1 (Warning electric shock)
20 582212 148 End stop (clip fix) 10
22 582212 13 End plate 2
23 582212 88 PIT 2,5 1
24 582212 97 Terminal, PIT 2,5, QUA 2
25 582212 32 End plate 1
26 589569 78 Cable Gland - M20 1
27 589569 34 Counter nut M20 1
29 589569 48 Cable Gland - M16 10
30 589569 33 Counter nut M16 10
32 593950 24 Marking, Connectivity cabinet 1
74 Book No. 9056670 02 Rev. 1

17 Connectivity cabinet
3226A2
Book No. 9056670 02 Rev. 1 75

18 Extended options (SPC)

9036296-
Ref Part No Description - Notes
Quantity
45 9029114 80 Transformer 1
47 9045685 01 Mercury absorption kit 1
76 Book No. 9056670 02 Rev. 1

18 Extended options (SPC)
2377A
Book No. 9056670 02 Rev. 1 77

19 Cross reference list
+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
1270001 21 99 221803 02 20 1N 223101 32 7 70
1270001 43 71 221803 03 21 26 223101 32 54 62
1270001 54 98 221803 20 21 54 223101 32 68 19
1764728 01 74 19 221803 21 54 53 223101 33 42 3.1
1765908 06 6 30 221803 21 68 23 223101 33 54 63
1765908 07 48 11 221803 23 42 6.2 223101 33 68 22
1765908 07 66 3 221803 26 7 61 223101 33 10 25
2210295 03 21 24 221803 27 7 62 223101 37 48 7
2210296 02 42 2G 221803 27 54 51 223101 37 48 10
2210296 02 6 54 221803 28 10 41 223101 37 48 14
2210296 02 10 29 221803 28 42 28.2 223101 37 7 71
221031 04 48 2E 221803 28 43 47.3 223101 39 42 7
221031 21 10 39 221803 28 7 63 223101 39 7 72
221031 21 6 53 221803 28 54 52 223101 41 23 105
221031 22 6 52 221803 28 68 20 223101 47 18 4
221036 01 10 24 221803 29 10 35 223101 47 20 1_
221036 19 42 2H 221803 32 21 57 223101 47 20 1f
221036 19 42 3 221803 34 66 5 223101 47 20 1I
221036 19 10 32 221803 40 48 8 223101 47 20 1M
221040 04 10 22 221803 40 7 64 223101 47 20 10
221041 03 10 34 221851 05 21 69 223101 47 26 3
2210462 30 66 4 221851 05 34 7 223101 47 34 6
2210462 45 66 9 221891 04 18 5 223101 47 34 9
2210463 07 6 56 221891 04 20 1g 223101 47 34 25
2210463 08 48 6 221891 04 20 1J 223101 47 34 29
2210463 09 6 57 221891 04 20 1S 223101 47 36 5
2210463 22 48 13 221891 04 20 1V 223101 61 10 23
2210463 23 6 55 221891 04 20 11 2245101 14 6 32
221701 03 26 39 221891 04 26 4 2245102 07 54 33
221701 11 56 15 221891 04 34 10 260137 06 54 66
221701 13 12 16 221891 04 34 26 260154 02 20 1]
221701 20 42 30 221891 04 34 30 260176 03 48 9
221701 20 56 16 221891 04 36 6 260192 08 42 6
221706 10 54 46 221891 05 20 1d 260192 08 6 58
221706 12 43 74 221891 05 20 15 260262 07 54 48
221706 12 54 45 221891 05 34 36 523127 01 50 30
221706 23 56 17 221891 05 36 13 526336 04 6 35
221711 02 20 6 223101 17 21 25 526336 04 42 15
221711 07 43 39 223101 29 23 108 526336 04 64 2
221711 07 68 18 223101 30 42 31 526336 05 6 36
221711 13 43 47 223101 30 7 68 526337 02 42 12
221711 13 10 7 223101 31 43 73 526337 06 6 37
221711 14 54 47 223101 31 7 69 526337 06 42 20
221711 16 34 3 223101 31 54 61 526337 19 43 50
221711 16 36 4 223101 31 10 30 526338 03 42 23
221711 23 10 20 223101 32 10 40 526338 12 42 22
221711 25 42 28 223101 32 42 28.1 526345 05 6 39
221716 01 20 13 223101 32 43 40 526350 05 6 34
221716 16 68 21 223101 32 43 47.2 543054 09 64 5
221803 02 20 1‘ 223101 32 48 2F 544465 06 64 8
78 Book No. 9056670 02 Rev. 1

Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.
544595 24 68 16 582212 03 30 20 582212 89 38 10

546600 02 64 7 582212 03 34 12.1 582212 89 42 27E
552801 01 50 24 582212 04 32 3 582212 91 26 41
552801 02 42 24 582212 04 34 14 582212 95 34 12
552801 50 6 44 582212 05 38 1 582212 96 34 13
552801 50 42 25 582212 102 30 5 582212 97 74 24
552801 50 6 50 582212 104 30 4 582221 90 26 13
552801 50 50 13 582212 119 40 1 582221 90 38 11
558663 03 6 29 582212 120 40 2 583012 04 6 48
558663 04 6 28 582212 121 40 3 583556 31 74 16
558710 01 56 7 582212 122 12 4 586773 01 60 1
558710 07 56 8 582212 122 26 27 586773 02 60 Z
558912 01 43 53 582212 122 30 13 586773 03 60 Z0.1
559022 01 14 19 582212 122 38 2 586773 80 54 24
559022 01 6 46 582212 122 42 27D 587276 01 20 1e
561094 01 6 40 582212 122 74 21 587276 01 43 47.1
569035 01 43 58 582212 123 38 3 587276 02 20 1b
569035 01 50 16 582212 124 38 4 587276 02 34 34
569035 01 54 36 582212 125 38 5 587276 02 36 11
569035 01 56 18 582212 13 74 22 587927 02 50 2B
569035 05 43 59 582212 147 26 43 589569 01 56 23
569035 05 56 19 582212 147 34 15 589569 09 56 24
569035 07 68 17 582212 147 38 31 589569 33 36 10
569038 05 54 35 582212 148 14 2 589569 33 74 30
571697 01 50 29 582212 148 34 11 589569 34 21 59
576886 13 66 8A 582212 148 34 31 589569 34 48 1.2
579367 98 7 Z 582212 148 74 20 589569 34 74 27
579749 02 6 45 582212 151 12 10 589569 35 36 8
580758 05 6 42 582212 151 42 27H 589569 36 21 61
580758 06 43 54 582212 156 14 3 589569 37 21 51
580759 03 54 28 582212 157 14 4 589569 42 12 13
580759 04 54 29 582212 164 21 30 589569 44 14 8
580759 06 56 6 582212 165 21 32 589569 48 36 9
580986 08 26 26G 582212 172 40 Z 589569 48 42 27G
580986 16 26 26D 582212 182 26 29 589569 48 74 29
580986 17 26 26C 582212 182 26 ZA 589569 52 62 10C
580986 33 26 26H 582212 189 26 47 589569 53 14 9
580986 59 26 26J 582212 214 34 22.1 589569 58 14 6
580986 61 26 26I 582212 215 34 39 589569 73 21 60.1
580986 69 26 26F 582212 32 74 25 589569 78 12 12
580986 72 26 26E 582212 63 28 4 589569 78 21 58
580986 76 26 26B 582212 63 30 10 589569 78 42 2.1
581688 01 36 3 582212 64 28 3 589569 78 42 27F
581803 43 21 31 582212 67 28 2 589569 78 48 1.1
581803 45 74 11 582212 67 30 9 589569 78 74 26
581803 56 74 18 582212 88 12 6 589569 79 36 7
581803 66 21 48.2 582212 88 38 9 589569 80 21 60
582212 02 12 14 582212 88 42 27C 589945 44 74 17
582212 02 42 27J 582212 88 74 23 590624 03 21 29
582212 03 28 6 582212 89 12 5 590667 44 43 65
Book No. 9056670 02 Rev. 1 79

590968 31 26 21 594009 03 38 24 70490 66 6

591090 04 43 51 594009 05 20 1X 70560 20 1c
591103 10 26 17 594009 06 18 7 70560 20 14
591103 10 26 21.1 594009 06 34 28 70560 34 35
591103 45 26 20 594009 07 20 1C 70560 36 12
591103 54 26 16 594009 07 20 17 9001357 01 6 18
591103 56 38 12 594009 07 26 24.1 9001689 81 6 17
591103 64 26 19 594009 07 26 36 9002009 81 10 8
591103 67 21 45 594171 01 6 21 9002305 03 38 18
591103 69 21 41 594413 81 6 15 9002362 80 38 19
591103 70 12 9 594488 01 36 2 9002825 01 58 1
591103 70 21 39 594645 81 7 Z0.1 9002825 80 54 20
591103 72 34 20 594707 03 6 11 9002860 01 10 10
591103 80 21 37 594781 01 38 15 9002984 01 20 1K
591103 92 34 20.1 595558 01 16 6 9003030 01 20 1^
591103 93 21 47 595558 01 43 60 9003031 01 12 11
591618 01 66 1B 595558 01 48 2H 9003031 01 14 5
591625 01 66 1E 595558 01 48 5 9003031 01 21 27
591628 80 66 8 595558 01 50 23 9003172 08 56 4F
591628 82 66 8 595558 01 54 96 9003326 01 10 6
591631 01 66 7 595558 01 64 9 9003490 01 38 29
591662 80 66 1 595558 01 70 3 9003574 01 58 Z
591665 01 66 1D 595558 01 72 3 9003662 01 10 28
591666 01 66 14 595558 01 7 91 9004232 01 20 8
591813 01 66 1A 595673 03 26 44 9004299 04 26 28
591898 01 66 1C 595673 04 26 45 9004517 01 6 49
592001 01 74 6 595673 04 34 23 9004638 01 6 12
592005 14 21 33 595673 04 34 33 9004878 80 10 9
592005 14 34 8 595673 04 38 32 9004959 02 14 7
592304 02 50 31 595673 06 26 46 9005699 06 74 3
592926 05 21 28 595728 02 26 42 9005699 53 74 1A
593243 03 21 50 595728 02 34 32 9005699 55 74 2
593300 02 48 15 596105 02 20 1L 9005699 56 74 5
593300 04 6 27 596105 02 20 1T 9006075 01 64 3
593300 04 42 9 596187 01 54 39 9006324 02 6 20
593301 01 48 16 596904 01 21 73 9006325 02 6 19
593301 02 6 26 596904 04 21 70 9006822 01 6 22
593301 02 42 8 597033 25 26 26A 9006822 03 42 17
593724 01 26 12 597044 03 6 24 9006822 03 64 6
593724 01 38 26 597044 04 6 25 9006853 01 74 4
593724 02 38 25 597044 09 43 57F 9007166 02 50 2AA
593724 04 26 11 597049 01 6 41 9007166 03 16 2A
593780 01 20 1a 598571 02 6 51 9007167 01 66 8A
593950 20 38 33 598572 01 20 1A 9007167 04 50 1A
593950 24 74 32 599530 04 62 10E 9007167 06 16 1A
593950 26 34 21 599530 05 20 21 9007167 29 48 2AA
594009 02 23 104 66169 10 3 9007184 01 48 2AB
594009 03 20 1[ 67141 10 27 9007184 02 50 1B
594009 03 26 14 69263 6 31 9007184 03 16 1B
594009 03 26 24.1 7007238 01 43 34 9007190 01 50 10
80 Book No. 9056670 02 Rev. 1

9007196 01 50 7 9014707 99 26 24 9018411 01 20 1G

9007200 01 50 27 9014979 01 34 1 9018589 70 42 4
9007201 01 50 28 9014979 02 34 1 9018589 80 6 14
9008383 03 21 77A 9015557 80 34 37 9018589 80 42 5
9008383 04 21 77B 9015569 80 6 7 9018592 01 16 3
9008383 05 21 77C 9015692 01 21 77H 9018613 01 16 4
9008383 06 21 77D 9016299 03 56 22 9018653 03 48 1A
9008383 12 21 77K 9016593 01 34 3.1 9018672 43 70 2
9008383 13 21 77E 9017118 01 26 22 9018672 44 72 2
9008383 18 21 77G 9017332 01 56 5 9018992 01 20 5
9008387 01 21 77F 9017336 01 54 34 9018993 01 20 3
9008387 01 62 1EA 9017388 03 20 19 9018995 01 21 64
9008387 01 62 10DA 9017442 01 21 52 9018995 02 21 63
9008387 02 21 77J 9017442 02 62 1A 9018995 03 21 62
9008693 01 21 77I 9017442 03 62 1C 9018995 06 21 65
9008695 01 10 37 9017442 04 21 53 9019000 01 21 43
9009153 03 48 2G 9017442 05 62 1B 9019012 01 21 36
9009416 01 10 38 9017456 01 21 23 9019081 05 20 16
9009760 01 34 22 9017465 01 20 1E 9019081 06 20 18
9010631 03 7 75 9017472 01 21 22 9019135 04 26 37
9010631 03 7 76 9017498 01 20 1H 9019138 02 26 38
9010631 03 7 77 9017571 01 6 16 9019140 04 20 16.1
9010631 05 7 78 9017571 01 42 21A 9019140 04 23 Z0.1
9010982 01 14 1 9017578 82 48 2 9019141 01 20 1O
9010985 82 6 3A 9017691 01 21 35 9019142 01 20 1P
9011552 01 34 18 9017691 01 34 4 9019143 01 20 1R
9011609 01 62 1D 9017691 03 34 4 9019144 01 20 1Q
9011943 80 34 38 9017746 01 12 3 9019488 80 26 32
9011944 01 36 1 9017746 01 26 15 9019514 80 21 34
9011960 01 34 24 9017746 01 28 1 9019573 01 43 48
9011963 89 46 Z 9017746 01 30 1 9019576 01 20 1U
9011970 09 46 6 9017746 01 32 1 9019607 80 20 1D
9011970 12 46 41 9017746 01 42 27B 9019624 01 20 1W
9011970 20 46 42 9017746 02 26 27.1 9019625 80 20 1Y
9011970 28 46 36 9017746 02 30 12 9019688 01 54 14
9011972 37 46 7 9017747 01 30 14 9019689 01 54 19
9011972 40 46 13 9017747 02 30 17 9019697 01 20 1Z
9011972 43 46 16 9017747 03 30 16 9019796 01 54 31
9011972 46 46 17 9017747 03 32 7 9019849 07 43 57C
9011972 49 46 20 9017747 04 30 15 9019849 09 43 57D
9011973 21 46 7.1 9017747 04 32 6 9019849 09 43 57E
9011973 24 46 11 9017747 05 32 8 9019849 10 43 57B
9011973 27 46 18 9017747 06 32 4 9019942 80 42 18
9011973 30 46 77 9017747 07 32 5 9019944 01 48 1CA
9011974 46 46 9 9017973 01 42 14 9020027 02 43 57A
9011975 09 46 15 9017973 01 64 4 9020930 01 48 2CA
9011978 09 46 80 9018236 01 20 1\ 9021009 01 66 2
9012146 01 18 2 9018349 80 20 1F 9021302 01 20 1B
9014546 01 26 30 9018407 01 20 2 9021483 01 6 43
9014707 02 26 25 9018407 02 20 4 9021483 01 43 52
Book No. 9056670 02 Rev. 1 81

9029856 01 6 33 9036476 10 74 14
9021483 01 43 68.1
9029930 01 21 55 9036476 16 34 16.1
9021483 01 48 2.1
9029930 02 62 10A 9037152 03 74 7
9021730 05 7 79
9029930 04 21 56 9037158 01 74 12
9021770 04 42 19
9029930 05 62 10B 9037158 01 74 13
9021795 01 54 32
9029944 01 43 36 9037341 60 52 1
9022262 01 54 27
9030059 01 12 1 9037347 01 66 8B
9022613 80 42 21
9030063 01 12 7 9037818 01 52 2
9023282 03 20 20
9030297 80 56 4 9037962 01 42 27A
9023297 01 21 49
9030501 01 20 12 9038059 80 48 1
9023297 02 23 Z
9030502 01 54 6 9038504 02 38 30
9023358 80 18 3
9030504 01 54 9 9038535 80 48 1C
9023360 01 18 6
9030506 01 54 11 9038535 82 48 1D
9023653 60 42 1
9030508 01 54 13 9038536 01 48 1CB
9024168 01 42 11
9030592 01 54 12 9038537 01 48 1DA
9024205 03 46 4
9030593 01 54 10 9038538 02 48 1DB
9024205 11 46 10
9030598 01 54 8 9038539 02 48 1DC
9024205 19 46 12
9024205 27 46 31 9030605 01 54 5 9038539 03 48 1DD
9024205 35 46 34 9030607 01 54 2 9039016 01 48 2B
9024206 03 46 8 9030675 01 56 4A 9039016 05 50 1
9024206 11 46 19 9030676 01 56 4B 9039016 07 16 1
9024206 19 46 87 9030677 01 56 4C 9039696 02 48 1B
9024207 03 46 30 9030678 01 56 4D 9040493 02 50 2AA
9024208 03 46 40 9030679 01 56 4E 9040493 03 16 2A
9024209 03 46 43 9030706 01 12 18 9040703 02 50 2B
9024210 03 46 44 9030706 01 42 27I 9040708 01 48 2DA
9024317 01 23 102 9030707 01 56 20 9040724 09 52 1A
9024317 01 56 14 9030879 01 21 68 9040843 01 72 1
9024459 11 62 1E 9030917 01 23 106 9040931 81 50 2
9024459 11 62 10D 9031279 01 56 4G 9040965 60 48 2A
9024562 05 21 77L 9031573 80 26 33 9040965 64 50 1
9024692 01 6 38.1 9031612 01 43 33 9040965 66 16 1
9024693 03 6 38 9031733 12 21 88 9040970 81 50 2
9024839 01 42 26 9032724 01 56 3 9040972 81 50 2A
9029096 02 54 3 9033029 01 62 11 9040972 82 16 2
9029096 03 54 4 9033033 01 21 66 9040972 91 48 2C
9029106 02 54 7 9033305 80 54 17 9040973 81 50 2A
9029114 80 76 45 9034058 80 50 9 9040973 82 16 2
9029394 01 42 16 9034627 80 20 7 9040973 91 48 2D
9029442 80 6 1 9034629 80 18 1 9040974 01 70 1
9029448 01 48 12 9034946 80 26 26 9040987 02 52 1C
9029781 01 50 10.2 9034986 01 56 21 9040987 03 52 1D
9029808 01 43 32 9035427 06 54 38 9040987 06 52 1E
9029811 80 42 29 9036082 01 23 101A 9040987 07 52 1F
9029812 01 43 35 9036086 01 23 101B 9040987 08 52 1B
9029831 80 6 2 9036087 01 23 101C 9041119 02 50 2AB
9029832 80 12 8 9036098 80 48 1.4 9041119 03 16 2B
9029834 80 6 23 9036476 04 74 9 9041119 10 48 2DB
9029834 81 42 10 9036476 06 74 10 9041128 01 48 2CB
9029834 81 56 2 9036476 07 74 8 9041128 02 50 2AB
82 Book No. 9056670 02 Rev. 1

Part No. Page Ref. Part No. Page Ref.
9041128 03 16 2B 9049548 81 6 3E
9041415 01 68 1 9049548 81 6 3F
9041416 01 68 2 9049548 83 6 3H
9041417 01 68 3 9052014 80 6 3
9041418 01 68 4 9052609 01 21 48
9041419 01 68 5 9052609 01 34 16
9041420 01 68 6 9053220 80 26 ZB
9041421 01 68 7 9053220 80 26 Z0.1
9041422 01 68 8 9055541 01 42 2AF
9041423 01 68 9
9041424 01 68 10
9041425 01 68 11
9041426 01 68 12
9041427 01 68 13
9041439 01 68 14
9041764 80 42 2
9041781 01 42 2AA
9041784 01 42 2AC
9041784 02 42 2AB
9041784 03 42 2AE
9041784 04 42 2AD
9041791 01 42 2B
9041792 02 42 2C
9041792 03 42 2D
9041793 01 42 2E
9041794 01 42 2F
9041961 01 70 Z
9041963 01 72 Z
9041965 01 70 Z0.1
9041965 03 72 Z0.1
9041966 01 70 Z0.2
9041967 01 72 Z0.2
9041968 01 72 Z0.3
9042519 01 26 31
9042519 01 30 11
9042519 02 30 8
9042519 03 30 19
9042519 04 30 18
9045685 01 76 47
9045930 01 74 1
9047526 01 42 13
9047526 02 64 1
9049546 81 7 74A
9049546 81 7 74B
9049546 81 7 74C
9049546 81 7 74D
9049548 81 6 3G
9049548 81 6 3B
9049548 81 6 3C
9049548 81 6 3D
Book No. 9056670 02 Rev. 1 83

SVIB 2 269565941 PB-05853 v0 (2) ENG

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PureBallast Ballast Water Treatment System

PureBallast Ballast Water Treatment System

Lit. Code 200000887-3-EN-GB System manual

The original instructions are in English

© Alfa Laval Corporate AB 2021-03

1 PureBallast 3.2 System manual

Main component makers

Flow chart Component Manufacturer Model

Flow chart Component Manufacturer Model

Lamp drive cabinet:

Lamp drive cab- Alfa Laval LDC 2

Optional System Components (Alfa Laval supply)

Optional System Components (Other supply possible. Alfa Laval supply is

Weflo Fig.9105, DN80

Flow chart Component Manufacturer Model

Lit. Code 200000878-6-EN-GB Size specific manual

The original instructions are in English

© Alfa Laval Corporate AB 2021-05

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

6 Technical data and drawings........................................................................ 195

7 Service manual .....................................................................................................315

8 Revision history..................................................................................................... 385

1.2 Safety information

1.2.1 General safety information

1.2.2 Specific safety information

Maintenance safety items

UV reactor safety items

• Manual operation of LPS, may only be performed after cable connection. If

Filter safety items

CIP safety items

Flow meter safety items

Valve safety items

Ancillary component safety items

1.2.3 Personnel requirements

1.2.4 Warning signs used in the manual

DANGER: indicates an imminently hazardous situation which, if not avoided, will

WARNING: indicates a potentially hazardous situation which, if not avoided, could

CAUTION: indicates a potentially hazardous situation which, if not avoided, may

1.3 Environmental issues

1.3.2 Other materials

2.1.1 Components overview

2.1.2 Item numbers

EN Standard according to CEN (European Committee for Standardiza-

2.2 Process overview

2.2.1 IMO and USCG mode

2.2.2 Flow control and power optimization

Brackish and marine water

2.2.2.1 Flow control

2.2.2.2 Power optimization

2.2.2.3 Power optimization during special conditions

2.2.2.4 Operation with broken UV lamp

The flow is decreased to 65 % in IMO mode and 50 % in USCG mode of max

Ballast and deballast start-up

2.2.4.2 Ballast after-treatment (CIP process)

CIP circulation during CIP process

2.2.5.1 Deballast after-treatment (CIP process)

2.2.6 Tank stripping

2.2.6.1 Stripping after-treatment (CIP process)

As after ballasting, a CIP process is performed after a stripping operation.

2.2.7 Ballast water handling in the event of malfunction

2.3 System components description

2.3.1.1 UV reactor working principle

2.3.1.2 UV reactor description