PB 02245 Manual

PureBallast Ballast Water Treatment System
PureBallast Ballast Water Treatment System

System Manual - PureBallast 3.1 PB-02245
System Manual
English
1 PureBallast 3.1 System
manual
The PureBallast 3.1 is available in several sizes, defined by the system’s max treatment rated
capacity (TRC). The TRC is included in the system name and the title of each system manual.
The basic document describing the system is the connection list, and the therein stated flow chart.
Those documents are included in the system manual, chapter 6, Installation description and
drawings.
The tables in this document lists the PureBallast systems with reference to the system manual
describing them and the connection list and flow chart defining them.
There are two versions of PureBallast. The USCG version use flow control to be compliant with
USCG legislation. The USCG HP (high performance) have double reactor capacity which allows
treatment at full capacity at all time.
1.1 Manual compilation

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

PureBallast 3.1 250 USCG HP 9028182 02 9025977 9025598
PureBallast 3.1 300 USCG HP 9028184, 02 9025979 9025598
Book No.9028378 02, rev 0 1

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

Reference is made to flow chart 9025598, 9025599, 9025600, 9025601 and 9025602.
Flowchart
Component Manufacturer Model (Size according to connection list)
legend
Filter:
Automatic ACB-xx-yy, 20 µm mesh (xx=935 – 9200, yy=
self-cleaning Filtrex DN200 - DN600)
filter
PT201-71
Pressure sensor Jumo MIDAS S07
& -72
UV reactor
UV reactor, 300 or,
UV reactor Wallenius Water UV reactor, 600 or,
UV reactor, 1000
Medium pressure UV lamp, 3 kW for UV reactor
UV lamp 170, 300 and 600
Wallenius Water
Medium pressure UV lamp, 6 kW for UV reactor
1000
Lamp sleeve Wallenius Water Synthetic Quartz 9000738 02
UV-TECHNIK, SUV 20.2 Y2 C 40° 1000 W/m² or,
QT201-50 UV sensor IL Metronic SUV 20.2 Y2 C 40° 3000 W/m² for UV reactor
Sensortechnik GmbH 1000
Temperature, Bimetal Temp. Switch 60.8301
TS201-60 JUMO
switch
Thermometer, Dtrans Temp. probe 90.2815
TT201-33 JUMO
resistance
Vibration limit
LS201-29 PEPPERL+FUCHS Vibracon LVL-A7
switch
- Ifm IN5225, Inductive pos. sensor
V201-19 & -Air Torque Spa AT range, Actuator
Valve
-20
-ARI Armaturen ARI –GESA, Lugged valve
Valves:
- Siemens SIPART PS2, Positioner
Flow control - Air Torque Spa AT range, Actuator
V201-8
valve
- ARI Armaturen ARI –GESA, Lugged valve
V201-3, Filter inlet, outlet, - Rotech ALB ACR3.., Pos. switch box
-9, -32 & by-pass, & Start - Air Torque Spa AT range, Actuator
V403-35 up cooling valve - ARI Armaturen ARI –GESA, Lugged valve
Filter backflush - Air Torque Spa AT range, Actuator
V309-1
valve - ARI Armaturen ARI –GESA, Lugged valve
- Rotech ALB ACR3.., Pos. switch box
- Air Torque Spa AT range, Actuator
V212-31 By-pass valve
- Rotork ILG-D series, Handwheel
- ARI Armaturen ARI –GESA, Lugged valve
Flow meter:
Endress+Hauser Promag 50W1F,
FIT201-1 Flow transmitter
or Siemens Sitrans F, Magflo MAG 5100W
System pressure Transmitter:
2 Book No.9028378 02, rev 0

1 PureBallast 3.1 System manual 1.2 Main component makers
Flowchart
Component Manufacturer Model (Size according to connection list)
legend
Flowchart
Component Manufacturer Model
legend
Pressure
PT201-16 JUMO MIDAS S07
transmitter
Cleaning in Place (CIP) unit:
CIP cleaning
Alfa Laval 595087
module
CIP cleaning
Alfa Laval Alpacon Descalant Offshore
liquid
Lamp Drive Cabinet (LDC):
Lamp Drive
Alfa Laval LDC 3.1
Cabinet
Control Cabinet:
Control Cabinet Alfa Laval CC 3.1
Book No.9028378 02, rev 0 3

PureBallast: Ballast Water Table of Contents
Treatment System
Safety 1
System Description 2
Operating Instructions and

Control System 3
Description
Parameters 4
Alarms and Faultfinding 5
Installation and Drawings 6

Only foreseeable conditions have been taken into
consideration. No warnings are given for Service Manual 7
situations arising from unintended usage of the
system components and tools.
Spare Parts Catalogue 8
Marine & Diesel Equipment
Printed 2018
Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement of this
publication would be gratefully appreciated.
Copies of this publication can be ordered from your local AlfaLaval company.
Published by: : Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax: +46 8 530 310 40
© Alfa Laval Tumba AB

Chapter: 1. Safety
System manual — PureBallast 3.1 1000
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00
Telefax: +46 8 530 310 40

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 Introduction 5
2 Safety information 7
2.1 General safety information 7
2.2 Specif c safety information 7
2.3 Personnel requirements 9
2.4 Warning signs used in the manual 9
3 Environmental issues 11
3.1 Unpacking 11
3.2 Other materials 11
3
1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.
Book No.9028195 02 5
1 Introduction
2 Safety information
This section contains safety information. This information must be read and understood before the
system is installed, operated and maintained.
2.1 General safety information

The following general safety information apply:
• The PureBallast system is not Ex proofed and must not be installed in areas where an explosive
atmosphere may occur.
• Use the equipment only for the purpose and parameter range specified by Alfa Laval.
• Use only Alfa Laval genuine spare parts.
• Always read and follow the documentation that is included in shipment of components and
spare parts regarding handling, safety and disposal.
• Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.
• Before installation, read applicable sections in chapter 6. Installation instruction and drawings.
• Before operation, read the Preparations and conditions section for applicable instructions in
chapter 3. Operating instructions and control system description.
2.2 Specif c 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
chapter 7. Service manual. Essential safety information is stated before instruction to routines
that might involve any danger.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8.
• Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle
with a load capacity greater than the weight of the component. See the Technical data section
on page for information about weight. Any complementary lifting instructions must be followed.
• Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
UV reactor safety items
Book No.9028195 02 7
2.2 Specific safety information 2 Safety information
• 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. Hot
water may escape from the reactor when removing the drain plug.
• Never handle UV lamps before they are completely cooled down. A hot UV lamp is under
high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn
if it is touched.
• The reactor must not be under pressure when dismounting the UV lamps.
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the reactor with end caps properly closed.
• UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled and disposed of with care. Used 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.
• Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor
(indicated by level switch LS201-29), and the water temperature is below 60 °C. Improper
operation could seriously damage the equipment and injure personnel.
• Manual operation of LPS, may only be performed after cable connection. If not hazardous
situation may arise which, if not avoided, will result in death or serious injury.
• Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the
power supply. The LDC contains a fan, which can cause injury if in operation.
Flow meter safety items
• Potential hazard / Grounding: The flow meter must be earthed.

Valve safety items
• Actuators must not be pressurized at any time during installation as it may result in injury.
• Lock valve in closed position before maintenance.
CIP safety items
• CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal
protection etc.
• Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
• Always wear protective eye glasses and gloves while working on the pump.
• See Safety data sheet / CIP liquid in chapter 6.
8 Book No.9028195 02
2 Safety information 2.4 Warning signs used in the manual
Ancillary component safety items
• Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
• Temperature switch, temperature transmitter and level switch. The external surface may be hot.
Care must be taken to avoid possible burns.
2.3 Personnel requirements
The PureBallast system must be operated, installed, maintained and repaired by persons trained for
respective type of work. All persons using and working with the system must know the emergency
stopping procedures.
Personnel installing, maintaining or repairing components must be of one of the following categories:
• Skilled person: A person with technical knowledge or sufficient experience to perform

the tasks at hand and to enable him or her to perceive risks and to avoid hazards which
electricity/mechanics can create.
• Instructed person: A person adequately advised or supervised by a skilled person to enable
him or her to perceive risks and to avoid hazards which electricity/mechanics can create.
• Alfa Laval service engineer: A person with knowledge about the PureBallast system. Alfa
Laval service engineer can set parameters and repair intrinsically safe apparatuses.
In some cases special skilled personnel may need to be hired, like electricians and others. In some
of these cases the personnel has to be certified according to local regulations with experience of
similar types of work.
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.
NG
WARNI
!
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
ON
CAUTI
!
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.
Book No.9028195 02 9
2.4 Warning signs used in the manual 2 Safety information
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.
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.
3.2 Other materials
• Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed to a suitable licensed land fill site.
• Metal parts should be sent to a licensed handler for material recycling.
• Seal rings should be disposed of in a licensed land fill site. Check the local regulations.
• Worn out or defected electronic components should be sent to a licensed handler for material
recycling.
• The operator panel contain the following components with substances that might be hazardous
to health and the environment: lithium battery, electrolytic capacitor and display. They shall
be recycled according to local regulations.
• Used lithium batteries from the control unit are considered hazardous waste 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.
Book No.9028195 02 11
Chapter: 2. System description
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

Laval Tumba AB.
Contents
1 Introduction 5
1.1 Components overview 6
1.1.1 Item numbers 7
1.2 System overview 7

1.3 Abbreviations 7
2 Process overview 9
2.1 IMO and USCG mode 9
2.1.1 When to use the different modes 9
2.1.2 Flow control and power optimization 9
2.2 Start-up 12
2.3 Ballasting 13
2.3.1 Backflush 14
2.3.2 Ballast after-treatment (CIP) 15
2.4 Deballasting 16
2.4.1 Deballast after-treatment (CIP) 16
2.5 Tank stripping 17

2.5.1 Stripping after-treatment (CIP) 17
2.6 Ballast water handling in the event of

malfunction 18
3 System components description 19

3.1 UV reactor 19
3.1.1 UV reactor working principle 19
3.1.2 UV reactor description 20
3.2 Lamp drive cabinet (LDC) 21

3.2.1 LDC working principle 22
3.2.2 LDC description 22
3.3 Filter 24
3.3.1 Filter working principle 24
3.3.2 Filter description 24
3.3.3 Backflushing for different dirt loads 27
3.4 CIP (cleaning-in-place) module 29

3.4.1 CIP working principle 29
3.4.2 CIP module description 29
3
3.5 Control cabinet and control system 30
3.5.1 Control system 31
3.5.2 Main control panel 31
3.5.3 Remote control panel (optional) 32
3.5.4 Remote interface (optional) 33
3.6 Main valves 33

3.7 Flow meter 34
3.8 Pressure monitoring device 34
3.9 Sampling devices 34
4
1 Introduction
This contains general information about the PureBallast system and its components.
Book No.9028195 02 5
1.1 Components overview 1 Introduction
1.1 Components overview

The key components in PureBallast are shown below.
2 System overview Filtrex
Example of layout with 1 UV reactor.
1. Control cabinet
2. Lamp drive cabinet (LDC)
3. CIP (cleaning-in-place) module
4. UV reactor
5. Ballast water outlet
6. Control valve
7. Flow meter
8. Sampling point
9. Filter
10. Ballast water inlet
Not in illustration:
• System bypass valve

• Pressure monitoring device
6 Book No.9028195 02
1 Introduction 1.3 Abbreviations
1.1.1 Item numbers

System components are identified by unique item numbers, for example “FIT201-1” for the flow
transmitter installed before the UV reactor.
1.2 System overview

The PureBallast system is an integral part of the vessel’s ballast water system, on the discharge
side of the vessel’s ballast water pumps. During ballast operation, the water is led through the filter,
which removes larger particles and organisms, and then to the UV reactor, where the water is
treated with UV light. During deballast, the water is led the same way, but the filter is bypassed.
The UV lamps are powered by the LDC (via LPSs, lamp power supplies). The UV reactor has
one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. The control valve also
regulates pressure during backflushing of the filter.
The UV reactors are cleaned using the CIP (cleaning-in-place) module, which first rinse the UV
reactor with technical water / potable water, and then circulates CIP liquid through the UV reactor.
At the end of the process the UV reactor and thefilter (filter preservation) is filled with technical
water / potable water from the CIP.
The complete system and ongoing processes is controlled and monitored from the control cabinet.
Control can also be performed from remote control panels and the ship’s ISCS, via the remote
interface.
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).
1.3 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
AOT reactor Previous name for UV reactor. AOT stands for Advanced oxidation
technology.
Atex EU directive “Appareils destinés à être utilisés en ATmosphères

EXplosivles”
CIP Cleaning in place
CIP module Cleaning in place module. Performs the CIP process.
DIN Deutche Institut für Normung
EN Standard according to CEN (European Committee for

Standardization).
Book No.9028195 02 7
1.3 Abbreviations 1 Introduction
Abbreviation Explanation
Ex Explosion-proof
I/O Input/output (Describes a program or device handling data)
IACS International Association of Classification Societies
IECEx International Electrotechnical Commission Explosive
ISCS Integrated ship control system
IMO International Maritime Organization
JIS Japanese Industrial Standard
LED Light emitting diode
LDC Lamp drive cabinet.
LPS Lamp power supply
MCB Motor circuit breaker
PLC Programmable logical controller (PureBallast control system)
USCG United states coast guard
UV Ultra violet
UV reactor The main component, where the water is treated using UV light.
UVR UV reactor
PSU Practical salinity unit
8 Book No.9028195 02
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.
2.1 IMO and USCG mode

The PureBallast have two process modes: IMO mode and USCG mode. These different modes
set the system to run to be compliant with regulations in USA (USCG mode) or the rest of the
world (IMO mode).
Before starting a process, the operator must choose if the operation shall be run in IMO or USCG
mode, depending on location and destination. Mode is set using a function button in the control
system.
2.1.1 When to use the different modes
2.1.1.1 IMO
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.
2.1.1.2 USCG
USCG mode is used for
• ballast when the destination port is within US waters, regardless of starting point.
• deballast within US waters.
2.1.2 Flow control and power optimization

To ensure full treatment of the water, allowed flow and power to the lamps are controlled depending
on how clean the water is. Clean water (high UV intensity) allows high flow and low lamp power, and
dirty water requires lower flow and higher lamp power to treat the water according to requirements.
The illustration below show flow control and power optimization depending on the UV intensity,
together with the compliant limit.
Book No.9028195 02 9
2.1 IMO and USCG mode 2 Process overview
IMO mode
UVI_IMO1000
USCG mode
UVI_USCG1000
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.
10 Book No.9028195 02
2 Process overview 2.1 IMO and USCG mode
2.1.2.1 Flow control
In USCG mode, the flow is regulated to be as high as possible to fully treat the water. Between UVI
value a and b, the flow is regulated be between 50 % and 100 % of full flow capacity. The higher
UVI value (cleaner water) the the higher flow.
In IMO mode, the flow is always 100 % above compliant limit. But when UVI falls below the
compliant limit, the flow is decreased to maximum 50 %.
2.1.2.2 Power optimization
The purpose is to save power by dimming the lamps to minimum power required to fully treat the
water. Power is regulated when the UVI in the water is between c and d (see graph above). The
power output is regulated between 50 % and 100 % of full power.
2.1.2.3 Power optimization during special

conditions
• Start-up and the first two minutes of ballast/deballast: The UV lamps are lit to 100 % to ensure
treatment before values from the UV sensor are stable.
• Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for two minutes when
process is resumed.
• Stop: UV lamps are lit to 100 % for 10 seconds before they are stopped. This will prolong
the life of the lamps.
• Stripping: The lamps are lit to 100 % during the complete stripping process. This to have an
efficient treatment of the deballast water when it is mixed with the driving water, which has
not been treated at ballast.
• Low UV intensity: See Flow control above.
• Broken UV lamp: See Operation with broken UV lamp below.
2.1.2.4 Operation with broken UV lamp
If a UV lamp breaks, the ongoing process continues but does not fulfill the type approval certificate.
The flow is decreased to 80 % in IMO mode or 50 % in USCG mode of max flow and the UV
lamps are lit to 100 %. This is done so that the treatment shall correspond to the type approval
requirements. A warning and an additional common alarm is issued and a log is written to the
event log.
If a lamp breaks during operation, the operator will have to decide to stop the operation or to
continue operation and not comply with type approval certificate. After process is finished, it will not
be allowed to start a new process untill the broken lamp has been changed.
Book No.9028195 02 11
2.2 Start-up 2 Process overview
2.2 Start-up
Ballasting and deballasting begins with a start-up phase. There must be available power for
the system. If power management is integrated, this will be confirmed automatically. If power
management is not integrated, this is confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is pumped through the
UV reactor to secure that the UV lamps are not overheated. The temperature transmitter and level
switch secure that there is water in the UV reactor and that the UV lamps are sufficiently cooled. If
not, an alarm is issued and the system is shut down.
2 Startup Filtrex
Ballast and deballast start-up
12 Book No.9028195 02
2 Process overview 2.3 Ballasting
2.3 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 is 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.
2 BallastFiltrex
Ballasting
Book No.9028195 02 13
2.3 Ballasting 2 Process overview
2.3.1 Backf ush

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.
2 BackflushFiltrex
Filter backflush
14 Book No.9028195 02
2 Process overview 2.3 Ballasting
2.3.2 Ballast after-treatment (CIP)

After a ballast operation, a cleaning-in-place (CIP) process should be performed to clean the UV
reactor. This process can either be performed immediately after a ballast operation or within 30
hours after. Note, that it is possible to perform new processes during these 30 hours. A CIP
process takes about 25 minutes , if default parameters are used.
We recommend that a CIP process is performed within the same ecological zone or in international
waters (200 nautical miles from the base line). This will avoid untreated water from the UV reactor
and the filter to enter a different ecological zone.
First, the UV reactor is rinsed with technical water / potable water. Then the cleaning-in-place (CIP)
module circulates a biodegradable solution through the UV reactor to remove seawater scaling.
After the cleaning is finished, the UV reactor is filled with technical water / potable water to preserve
the UV reactor and prevent scaling, algae growth etc. Finally, the filter filled with technical water
/ potable water to prevent scaling and algea growth. The cleaning liquid is reused between the
cleaning operations.
2 CIP Filtrex
CIP circulation during CIP process
Book No.9028195 02 15
2.4 Deballasting 2 Process overview
2.4 Deballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The water passes through the UV reactor, but the filter is bypassed since the water has already
been filtered during ballasting. The reason for treating the water a second time during deballasting
is to secure that the treatment is fully effective. The minor part of the organisms, which were only
injured during ballast, will be rendered totally harmless during the deballast.
The process flow and power optimization are controlled in the same way as during ballasting.
2 DeballastFiltrex
Deballasting
2.4.1 Deballast after-treatment (CIP)

After deballast operation, a cleaning cycle is performed to clean the UV reactor. It is performed
in the same way as described for the ballasting process. If only deballast operations has been
performed since the last CIP process, the filter does not need to be filled with technical water /
potable water at the end of the cycle, since the filter has not been used.
16 Book No.9028195 02
2 Process overview 2.5 Tank stripping
2.5 Tank stripping

Stripping can be performed to empty the ballast tanks.
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. The flow controll is
controlled to be 1/3 of certified flow but power optimization is not active. Number of UV reactors
used during stripping is set in a parameter, to adapt to lower flow during stripping.
If a stripping eductor (not part of Alfa Laval’s scope of supply) is used it must be installed before the
PureBallast system. Minium flow for deballast water includes the driving water.
Also, the water used in the stripping process, must be filtered from particles larger than
approximately 5 mm. The sieve is not part of Alfa Laval’s scope of supply. Procedures to dispose
of sediments from the sieve must be included in the vessel’s ballast water management plan. See
also chapter 3. Operating instructions and control system description, section Stripping.
2 StrippingFiltrex
Stripping
2.5.1 Stripping after-treatment (CIP)

After stripping operation, a cleaning cycle is performed to clean the UV reactor. It is performed
in the same way as described for the ballasting process. If only stripping operations has been
performed since the last CIP process, the filter does not need to be filled with technical water /
potable water at the end of the cycle, since the filter has not been used.
Book No.9028195 02 17
2.6 Ballast water handling in the event of 2 Process overview
malfunction
2.6 Ballast water handling in the event of malfunction

PureBallast is equipped with a bypass valve. The valve can be used in case of emergency to
secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers)
without involving the ballast water treatment system. The valve is controlled by the ISCS, not
PureBallast’s control system, but all bypass valve activities are logged in the event log. Such valve
is required by the International Convention for the Control and Management of Ship’s Ballast
Water and Sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided.
The procedures concerning emergency and malfunction of the ballast water treatment system
should be implemented in the ships Ballast water management plan.
18 Book No.9028195 02
3 System components
description
This section gives an introduction to the most important PureBallast system components and
their functions in the system.
3.1 UV reactor
The main part of PureBallast is the UV reactor in combination with a lamp drive cabinet (LDC)
giving power to the UV lamps in the UV reactor. The LDC does not need to be placed in close
relation to the UV reactor.
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.
2 UVtreatment
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.
Book No.9028195 02 19
3.1 UV reactor 3 System components description
3.1.2 UV reactor description

The UV reactor consist of the reactor, sensors and valves for ballast water and CIP liquid, as
shown in the illustration below. The UV reactor accommodates 16 medium-pressure UV lamps (6
kW each) powered from the lamp drive cabinet (LDC). The UV lamps are enclosed in individual
quartz-glass sleeves.
The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there is
water in the reactor when the lamps are lit, each reactor is equipped with a level switch. The level
switch also secures that enough CIP liquid is pumped into the reactor during the CIP process. To
secure that the lamps are adequately cooled by the ballast water, each UV reactor has a threefold
heat protection:
• The temperature transmitter sends information to the control system. The UV reactor is shut
down at 60 °C.
• The temperature transmitter sends information to a safety relay in the LDC. The UV reactor is
shut down at 62.5 °C.
• 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. The UV lamps will be dimmed to lowest possible level, where they are still effective.
Note, that 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.
20 Book No.9028195 02
3 System components description 3.2 Lamp drive cabinet (LDC)
2 reactor module Obe
UV reactor
1. Ballast water outlet valve

2. CIP liquid outlet valve (actuator indicated)
3. Level switch
4. Junction box
5. UV lamp cap (UV lamp and quartz sleeve inside)
6. Access hatch
7. Inlet valve from CIP module and reactor drain
valve (actuator indicated)
8. Ballast water inlet valve (actuator indicated)
9. UV sensor
10. Junction box
11. Cooling water outlet valve
12. Ballast water outlet valve actuator (actuator
indicated)
3.2 Lamp drive cabinet (LDC)

The lamp drive cabinet gives power to the UV reactor.
Book No.9028195 02 21
3.2 Lamp drive cabinet (LDC) 3 System components description
3.2.1 LDC working principle

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

The LDC is equipped with a cooling system to maintain correct operating temperature in the LDC,
using low-temperature cooling water. The cooling water flow is constant, but the fan is regulated
based on heat inside the cabinet. When lamps are lit, the fan starts at 30 % of full effect. When
the temperature reaches 40°, the fan starts to regulated between 30 % and 100 %, according to
parameter settings based on input from the temperature transmitter in the LDC.
The humidity in the cabinet is monitored by a liquid sensor. If a leakage from the heat exchanger
is detected, a warning is issued, the reactor is shut down and the cooling water inlet valve to
the LDC is shut.
The LDC can be placed up to 150 meters (cable length) from the UV reactor. The main breaker
cut the power to the LDC and the UV reactor.
22 Book No.9028195 02
3 System components description 3.2 Lamp drive cabinet (LDC)
2 LDC
LDC with one door removed.
1. Fan
2. Heat exchanger
3. Lamp power supplies (LPS)
4. Fuses
5. Cooling water inlet and outlet
6. Main breaker
7. Status lights and reset button
Book No.9028195 02 23
3.3 Filter 3 System components description
3.3 Filter
3.3.1 Filter working principle

The filter 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. The filter is entirely controlled from the PureBallast control system.
3.3.2 Filter description
2 FilterFiltrex
1. Geared motor
2. Relief valve
3. Backlflush outlet
4. Backflush pump
5. Drain plug
6. Ballast water inlet
7. Adaptor plate to change flange standard and/or
diameter (in some systems)
8. Junction box (Not included in the skid version
of PureBallast)
9. Ballast water outlet
24 Book No.9028195 02
3 System components description 3.3 Filter
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.
Book No.9028195 02 25
Step 1: Filtration
The water enters from the inlet flange (A) and flows through a
pre-filter and then through the filter element (1) from the inside to
the outside. The filtered dirt is trapped on the inside of the filter
element. The filtered water passes the chamber (D) and out from
the filter through the outlet flange (B) and is lead to the UV reactor.
During filtration, the filter operates as a static filter, there are no

moving parts and the motor (2) is not running and the nozzle (3) is
standing still.
A. Inlet
B. Outlet
D. Chamber
1. filter element
2. Motor
3. Nozzle (standing still during filtration)
2 FilterFiltrationFtrx
Step 2: Backf ush
At backflush, the motor (2) starts to drives the nozzle (3). At the
same time, the backflush valve (6) opens.
The nozzle rotates inside the filter element. The dirt on the inside
of the filter element (1) is cleaned by a high-efficacy backflush flow
in front of the nozzle. The backflush flow uses filtered water from
the chamber (D) to clean the filter from the outside to the inside.
The water, together with the dirt, is lead via the nozzle through the
duct (5) and out via the backflush valve (6).
All areas of the filter element that is not in front of the nozzle are
filtering the water as in step 1: The water flows from the inlet (A)
through the filter element and out through the outlet (B).
When the backflush is done (after approxemately 20 seconds), the

motor stops and the backflush valve is closed. The filter then goes
back filtration with full flow to the ballast tank (no flow used for
backflushing.
If a new backflush is triggered within 2 minutes (parameter p302),

the filter will perform a continuous backflush for 20 minutes
(parameter p303).
A. Inlet 2 FilterBackflushFtrx
B. Outlet
D. Chamber
1. filter element
2. Motor
3. Nozzle seen from the side (rotating during backflush)
26 Book No.9028195 02
3 System components description 3.3 Filter
6. Backflush valve
3.3.3 Backf ushing for different dirt loads

Below, the filter pressure drop over time (pfilter) is illustrated for different dirt load situations in the
filter. Different dirtload depends on the water condition, which means that “normal” condition
regarding filter backflush depends on the water conditions.
3.3.3.1 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.
6 Dirtload1 Filtrex
6 Dirtload2 Filtrex
3.3.3.2 Medium dirt load
In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.5 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 ∆pfilterreaches 0.5 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.
Book No.9028195 02 27
6 Dirtload3 Filtrex
3.3.3.3 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 0.5 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 0.5 bar. It is OK that the flow
momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes.
In the example below, a series of backflushes are performed (approx. every 4 minute). After that
the pressure rises above 0.5 where the filter is backflushed constantly. After that, the normal
control is resumed, where thefilter backflush is triggered by pressure (2 times) or by time (last
backflush in the example).
6 Dirtload4 Filtrex
3.3.3.4 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 filter element shall be inspected and manually cleaned
once a year.
The extent of the long term dirt build-up is dependent on the water conditions. In the great majority
of cases this will not cause any problems – cleaning once a year is enough. But in exceptional
cases (vessels trading very muddy waters) it might be necessary to clean the filter element more
28 Book No.9028195 02
3 System components description 3.4 CIP (cleaning-in-place) module
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.
3.4 CIP (cleaning-in-place) module
3.4.1 CIP working principle

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

The CIP module consists of a tank where the CIP liquid is stored between usage. The pumps and
valves integrated in the CIP module are controlled by the valve block.
To secure that there is enough CIP liquid for the process, the level switch in the reactor indicates
when it is filled with CIP liquid. To prevent intrusion of water in the technical water / potable water
system, a backflow preventer is used in the CIP module.
The CIP module is equipped with two membrane pumps:
• Pump P320-1 circulates the CIP liquid in the UV reactor and fills it with technical water /
potable water.
• Pump P321-5 drains water (sea and technical water / potable water) overboard from the
reactor, via the drain line.
Book No.9028195 02 29
3.5 Control cabinet and control system 3 System components description
2 CIP module
CIP module
1. Deaeration valve
2. Valve block
3. Regulator
4. Pump (CIP liquid)
5. Backflow preventer
6. Pump (reactor drain)
7. Tank for CIP liquid
3.5 Control cabinet and control system

The control cabinet is used to control and monitor the entire system, via the built in main control
panel. It is also used to communicate with the the vessel’s systems and components, if integrated.
The cabinet is equipped with an emergency stop button, an audible and visible alarm indication and
USB ports for software upload and log file export.
The control cabinet functions as a single point of contact for signal cables to and from the vessel.
Examples of integration: Remote interface integration and power management system (PMS).
Remote interface will allow control of PureBallast from the vessel’s ISCS and PMS integration will
allow automatic verification that there is enough power to run an operation. If not integrated, the
operator must verify this manually. Also integration with other external components (not part of Alfa
Laval’s scope of supply), such as GPS or booster pumps, are done to the control cabinet.
30 Book No.9028195 02
3 System components description 3.5 Control cabinet and control system
2 CC
Control cabinetpanel.
3.5.1 Control system

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

The main control panel in mounted in the control cabinet, and it is included in the standard
installation of PureBallast. It is installed in the engine room. The main control panel handles
every aspect of the control system. It allows the operator to monitor the system, to operate it
manually and automatically, and to set parameters. Please note that some of the operations are
password-protected.
Book No.9028195 02 31
3.5 Control cabinet and control system 3 System components description
2 CC
Control cabinet with main control panel
3.5.3 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 same operations. The remote control panel is delivered with
a mounting plate for installations in wall, worktop etc. It can also be ordered wit an IP protective
back cover for installation on a stand or such.
2 RCP
Main control panel with integrated remote control panels.
32 Book No.9028195 02
3 System components description 3.6 Main valves
3.5.4 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.
2 RI
PureBallast control system’s main control panel integrated with the ISCS. The interface is only an example.
3.6 Main valves

The main valves in the system are:
• Inlet valves: The inlet valves directs the water flow from the vessel’s ballast water system into
the PureBallast system. Different valves are used during ballast and deballast.
- System and f lter inlet valve (201–3): Inlet valve to PureBallast during ballast. The valve
directs the water flow through the PureBallast filter.
- Filter outlet valve (V201–32): The valve directs the water flow from the filter to the UV
reactor during ballast.
- Inlet valve (201–9): Inlet valve to PureBallast during deballast. The valve directs the water
to PureBallast, but bypass the filter, since the water was filtered during ballasting.
• Control valve (V201–8): The valve have the following functions:
- Automatic regulation to maintain flow during operation so it does not exceed selected
certified maximum flow. Regulation is based on input from the flow meter.
- Automatic regulation to maintain pressure needed to perform backflush of the filter.
Regulation is based on input from the pressure transmitter.
- Outlet valve from the PureBallast system to the vessel’s ballast water system after treatment.
Book No.9028195 02 33
3.9 Sampling devices 3 System components description
• 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 equiped with a handwheel for manual operation. The component
is optional to be included in Alfa Laval’s scope of supply.
• Cooling water inlet valve (V403-35): Supplies cooling water to the reactor to secure cooling of
the lamps and prevent overheating during start-up.
3.7 Flow meter
The flow meter (FIT201–1) monitors the process-flow during operation. It has two main functions:
• It monitor that the flow within the PureBallast system does not exceed its certified flow. If the
certified flow is exceeded a warning is issued.
• Via the flow transmitter, mounted on the flow sensor, it sends 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.
The flow meter consists of two main parts: A flow sensor, which is a pipe with four electrodes
detecting the flow. On top of the pipe, the flow transmitter housing is mounted. The flow transmitter
monitors the flow and transmits the information to the PureBallast control system.
3.8 Pressure monitoring device

The pressure monitoring device is a manifold that includes the following components to monitor
and handle pressure in the system:
• Pressure transmitter(PT201-16): Send current pressure information to the control system. The
control system use the information to take actions accordingly, for example issue warnings, shut
down the system or adjusting the control valve to obtain optimal pressure during filter backflush.
• Pressure gauge (PI201-18): Analogue displayed of current pressure.
• Needle valve (V201-15): Enables connection of external instruments for calibration.
• Safety valve (RV201): Relief of over pressure.
3.9 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.
34 Book No.9028195 02
Chapter: 3. Operating instructions and control system description
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 7
1.1 Preparations and conditions 7
1.1.1 Compliant / non-compliant operation 8
1.1.2 Stripping 8
1.1.3 Heeling (internal transfer) 9
1.1.4 Gravity operation 9
1.1.5 Pipe cleaning using PureBallast 9
2 Introduction to the control system 11

2.1 Login levels 11
2.2 Control of PureBallast 12
2.2.1 Remote control panels (option) 12
2.2.2 Remote interface (option) 12
2.3 Overview of the screen 14
3 Detailed page descriptions 19

3.1 Page 1.1 – Overview 19
3.1.1 Status box 19
3.1.2 Flow chart 21
3.2 Page 1.2 – UVR and f ow selection 23

3.2.1 Flow selection 23
3.2.2 UVR selection 24
3.2.3 Status 24
3.3 Page 1.3 – CIP status 25

3.3.1 CIP status 26
3.3.2 UVR information 26
3.3.3 CIP module information 27
3.4 Page 1.4 – Power request 28

3.4.1 Power management status display 28
3.4.2 Power management simulation and faultfinding 29
3.4.3 Function buttons 30
3.5 Page 2.1 – Alarm list 31

3.5.1 Alarm list 32
3.6 Page 2.2 – Alarm history 33

3.7 Page 3.1 – Trend (15 min) 34
3.7.1 Diagram area 35
3.7.2 Component area 35
3
3.8 Page 3.2 – Trend (1 h) 37
3.9 Page 3.3 – Trend (1 h) - TT201-33 37
3.10 Page 3.4 – Trend (1 h) - TT401-2 37
3.11 Page 3.5 – Trend (1 h) - Power
optimization 37
3.12 Page 3.7 – Trend (15 min) - External feed
optimization 37
3.13 Page 3.8 – UVR 1-3 UV optimization 38
3.14 Page 4.1 – System info 39
3.15 Page 4.2 – PLC controller I/O 42
3.16 Page 4.3 – Operation timers 43
3.17 Page 4.4 Operation timers UVR 45
3.18 Page 4.5 – Remote interface 1 46
3.19 Page 4.6 – Remote interface 2 47
3.20 Page 4.7 – Log box 1 48
3.21 Page 4.9 – LPS overview 49
3.22 Page 5.1–5.7 – Parameter pages 51
3.23 Popup windows 51
3.23.1 UVR popup 51
3.23.2 Filter popup 56
4
4 Operating instructions 59
4.1 Log in 59
4.2 Perform ballast 59
4.3 Perform deballast 61
4.4 Perform tank stripping 62
4.5 Pause ballast / deballast / stripping 63
4.6 Heel (internal transfer) 64
4.7 Backf ush f lter manually 65
4.8 CIP clean UV reactor after ballast /
deballast / stripping 65
4.9 Attend to alarms 66
4.10 Shut down and deactivate system 68
4.11 Reset system after shut down 69
4.12 Operate components manually 70
4.13 Operate UV lamps manually 71
4.14 Set ship specif c component ID 72
4.15 Export control system event log f les 73
4.16 Backup control system settings 75
4.17 Restore control system settings 75
4.18 Set control panel IP address 76
4.19 Set remote control panel
communication 77
4.20 Set remote interface communication 79
4.21 Test remote interface communication 79
4.22 Simulate power request 81
4.23 Update control system softwares 82
4.24 Calibrate the control panel’s touch
screen sensibility 82
4.25 Fine tune f ow control 82
4.25.1 Calibrate pressure controlled regulation 82
4.25.2 Calibrate external feed control (optional) 84
5
5 List of logged information 87
5.1 Event log 87
6 Detailed process description 93

6.1 Standby mode 93
6.2 Ballast process 94
6.2.1 Ballast start-up 94
6.2.2 Full ballast 95
6.2.3 Filter backflush 95
6.2.4 Pause ballast (Heeling mode) 96
6.2.5 Stop ballast 97
6.3 Deballast process 98

6.3.1 Deballast start-up 98
6.3.2 Full deballast 99
6.3.3 Pause deballast (Heeling) 99
6.3.4 Stop deballast 100
6.4 Stripping process 101

6.4.1 Stripping start-up 102
6.4.2 Full stripping 103
6.4.3 Pause stripping 104
6.4.4 Stop stripping 105
6.5 CIP process 106

6.5.1 Start CIP 106
6.5.2 Drain ballast water 107
6.5.3 Fresh water filling 107
6.5.4 Fresh water draining 107
6.5.5 CIP cleaning 108
6.5.6 CIP draining 108
6.5.7 Fresh water filling 108
6.5.8 Repeat 109
6.5.9 Filter preservation 109
6.6 Manual mode 109
6
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.
1.1 Preparations and conditions

• Make sure all documentation is available, read and understood before start.
• Both ballast and deballast must be run through PureBallast to fully treat the water.
• Make sure that the flow is within defined flow range during operation (m3/h):
Ballast:195 → 1000
Deballast: 100 → 1000
Stripping: 100 → 333 .
• The input flow to the PureBallast system shall be as close as possible to the flow that has been
selected for an operation. This will reduce the stress and wear of the control valve.
• During process, the control system requests that vessel valves are opened/closed. The
valves are outside the PureBallast system control. But the control system needs feedback
(opened/closed) during process. Status can either be confirmed manually in a popup or
automatically, if feedback signals are integrated via the remote interface option or via hard wire.
Please note:
- When overboard valves are requested to be opened/closed, this means that all valves
leading the flow from the PureBallast via one of the following pipes must be opened/closed:
201, 309 and 403 and 404. During CIP process, 460.1 must be opened.
Book No.9028195 02 7
1.1 Preparations and conditions 1 Introduction
1.1.1 Compliant / non-compliant operation

To optimize operation, all ballast and deballast operations should be done using PureBallast
according to system manual, and the system should be maintained.
However, in some cases there is a risk that ballast water is not treated according to requirements,
or contaminated by untreated water.
A process is not compliant in the following cases:
• Water was ballasted with IMO mode, when the destination port is within US waters.
• PureBallast was bypassed (Alarm A33, 66, 67 and 68)
• Operation with higher flow rate than certified (Warning W12)
• System not CIP cleaned within time (Warning W140)
• Operation with one or more non-functioning lamp (Warning W130, W131)
• UV intensity lower than limit stated in the type approval certificate (Warning W151, W152,
W154).
• The ballast water is contaminated by untreated water from other pipes, i.e. there are living
organisms in the water. Even a very small amount of water, a few hundred liters, can
contaminate a ballast tank and cause non-compliance during a compliance test. It is therefore
important that PureBallast is always used for operation. The reason for this can be
- Leaking valves, if there is untreated water present in the piping.

- Internal transfer between tanks can contaminate tanks, if untreated water is present in
the piping.
- Sediment in tanks is a breeding ground for organisms. Therefore it is important to review
the vessel’s ballast water management plan regarding frequency of sediment removal.
1.1.1.1 Solution to non-compliant operation
If the ballast water is not fully treated or contaminated by untreated water, a ballast water exchange
must be performed, making sure that the tanks and pipes (including dead ends) are flushed and
replaced with with treated water.
• using PureBallast both at deballast and ballast.

• at a location where ballast water exchange is accepted
• minimum 200 NM from the US coast. Note that mid ocean is most favourable, since UV
transmittance is very high and the biological activity is low.
It is also possible to contact the captain of the port zone, both at origin and at destination. They will
inform of what measures to be taken.
1.1.2 Stripping
Stripping can be performed to empty the ballast tanks. The first time a ballast tank is stripped,
PureBallast must be bypassed.
The stripping process is basically the same as a deballast process with the following difference: A
stripping eductor (or a stripping pump) should be used to secure enough flow in the system.
8 Book No.9028195 02
1 Introduction 1.1 Preparations and conditions
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.
1.1.3 Heeling (internal transfer)

Internal transfer of ballast water between tanks, for example during heeling procedures, does not
require the use of the PureBallast system. It is possible to perform heeling during standby ballast
or deballasting.
If external component signal for heeling mode is integrated between PureBallast and the vessel’s
ISCS, ongoing process will be paused and resumed automatically. The user is notified of started
and stopped heeling via warnings, and the event is logged.
If no external signal is integrated, the ongoing process must be paused manually. During pause,
cooling water is flushed through the UV reactor to cool the UV lamps. After completed heeling,
the operator must resume the paused process.
1.1.4 Gravity operation

Gravity operation (not using the ballast water pump) is allowed if
• the requirements for backflush pressure and flow is fulfilled.

• the vessel’s classification society allow gravity operation. This is stated in the ballast water
management plan.
1.1.5 Pipe cleaning using PureBallast

In some vessels, the applicable class society may require means and procedure for flushing
ballast pipes with treated water, to clean them from untreated water. This procedure should be
implemented in the ships Ballast water management plan.
In PureBallast, a deballast process is run with the vessel’s ballast valves positioned so that the
• pump takes water from a ballast water tank with treated water and
• the water flow is directed either overboard or to another ballast tank.
Run the process for enough time so all water in the piping is treated. Time for this depends on pipe
size and length on board.
Book No.9028195 02 9
2 Introduction to the control
system
This section describes different login levels, overview of the system interface and how to navigate
and operate the control system.
2.1 Login levels

Different login level controls which information that is displayed and changeable. As an example,
pages used for commissioning purposes are hidden for normal operators.
Login level Pass- Authority

word
Guest N/A Default mode of control system. This level is not password protected.
• View all pages.
Operator aot • As Guest.

• Operate the system to perform daily routines, for example ballast
and acknowledge alarms.
• Full access to page 1.4 Power request.
• Download files and backup to a USB memory.
Advanced 2007 • As level Operator.

operator
• Operate equipment in manual mode.
• Access to set parameters, with exception from critical parameters.
See chapter 4. Parameters for information.
• Full access to page 4.3 Operation timers and 4.4 Operation timers
UVR.
AlfaLaval N/A Full access. Password only available for Alfa Laval personnel.
• Full access to all parameter pages.

• Full access to force I/O in page 4.2 PLC controller I/O.
• Full access to make settings for remote control panels and remote
interface in page 4.1 System info and 4.5/4.6 Remote interfaces 1
and 2.
Book No.9028195 02 11
2.2 Control of PureBallast 2 Introduction to the control system
2.2 Control of PureBallast

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

PureBallast can only be controlled from one control panel at a time.
To switch command from one panel to another, you log in to the new panel. This is only possible by
using the same or higher login level as used in the active control panel. When control is about to be
changed from one panel to another, the following will happen:
• The inactive control panel will display a popup 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 swithced from the first panel to the new panel.
• The active panel will display a popup message informing that another the panel is inactive
and that control is taken by another panel.
On each control panel it is possible to see which panel that is active and which login level that is
used. A panel alias can be entered to clarify where the panel is installed, for example pump room,
bridge etc. See instruction Set control panel IP address on page 76. 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
3 ActivePanel
Example: Operator logged in at remote control panel with alias “Bridge”.
2.2.2 Remote interface (option)

If the remote interface option is used, PureBallast can be controlled from the vessel’s ISCS.
It is only possible to switch command between control panel and ISCS from a PureBallast control
panel. This is done by using the Local and Remote buttons, when logged in as Operator or higher.
Control status (local or remote) is indicated by a green light under the button 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.
12 Book No.9028195 02
2 Introduction to the control system 2.2 Control of PureBallast
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.
2.2.2.1 Conditions for remote interface control

of PureBallast
PureBallast can be operated from ISCS when the conditions below are met:
Installation and settings
• The remote interface must be correctly installed, according to Remote interface implementation
guide.
• Remote interface must be activated (parameter p132) and communication settings must be
correct (parameter p700 – p704).
• The Test mode button must be deactivated (no checkmark on the button) in control system
page 4.5 Remote interface 1.
• Remote control must be activated. Check that the green lamp is lit under the Remote button
on the control panel. If not, press the button. The system must be in Standby mode to toggle
between local and remote operation.
Operation
• Heartbeat is updating. See that address 06 and 77 are updating in control system page 4.5
Remote interface 1.
• There must be no active alarms for the UV reactors to be used during operation. Always check
the alarm list (page 2.1 Alarm list in the control system) before operation.
• The UV reactor must be in standby mode.
Book No.9028195 02 13
2.3 Overview of the screen 2 Introduction to the control system
2.3 Overview of the screen

This section describes the PureBallast control system screen layout and navigation.
The control system use a touch screen, where you tap the screen to “click” or drag objects. Do not
use sharp objects to touch the screen. When the screen is left idle it will go to screensaving mode.
Time is set in page 4.1 System info. The screen is activated again by touching it once. The 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.
3 1.1 USCG
Control system screen showing the main overview page.
Login menu: Expanding menu with login fields.
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, counted from top
to bottom. Selected tabs are indicated by a white color.
Top tabs: Contain the main function areas of the control system: Overview, alarm lists, trend
indication, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab. Available side tabs change
depending on which function area that have been selected in the top tab.
Popup windows: Are used to display or enter detailed information. It is possible to move a popup
by touching the name bar and drag it. A popup is closed either by touching confirming entered
information by touching a function button (OK, Conf rm, etc.) or the X icon in the top right corner
(data is not saved).
14 Book No.9028195 02
2 Introduction to the control system 2.3 Overview of the screen
Data entry f elds: 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.
Tables: Individual table rows, for example an alarm, can be selected by pressing them. Column
widths can be adjusted. Press the column border in the head area and hold the finger on the screen.
Function buttons: Function buttons are used for main processes and control of the system. They
are placed att the bottom of the screenare and are always visible, but only available when colored
dark blue. Some buttons are dependent on parameters. For example, the Remote and Local
buttons are only visible if remote interface is activated.
Status indication – Button color: The buttons appear in different colors, indicating status:
Blue The function is enabled.
Blue with The function is activated.

checkmark
Grey The function is disabled, for example if higher login level is required for the
function.
Status indication – Button light: After a function button is pressed, a light under the button is lit
to indicate status for the activated function:
Green Command is active.
Yellow Command will be processed when possible in the data work flow.
Yellow, blinking Command is paused.
Function button description
Button Description
Start ballast process.
Resumes paused process.

3 BallastBut
Start deballast process.

3 DeballastBut
Stop current process.
3 StopBut
Start tank stripping process.

3 StripBut
Book No.9028195 02 15
Button Description
Pause ballast, deballast or stripping process. This is only possible during

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

or Strip depending on which process that was paused.
Start CIP process.
3 CIPbut
Activate operation from control panels, instead of remote interface (if option
is used). The button is only enabled in standby mode.
3 LocalButton
Activate operation from remote interface (if option is used), instead of

control panels. The button is only enabled in standby mode.
3 RemoteBut
Sets the control system in manual mode, which enables manual operation
of the system and its components. When activated, the light flashes yellow.
The button is displayed for login level Advanced operator or higher. For
3 EnableManual detailed information see Manual mode on page 109.
Disable the touch screen function for 10 seconds to make it possible to

clean the screen without the risk of starting a process or changing a setting.
3 WhipeBut
Activate night light for the panel. Night light makes the panel less bright.
Toggles between night light and day light.
3 NightBut Degree of brightness, is set in the Night light level field in page 4.1 System
info.
Contains calculator, Notepad and 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
3 Utilities
image to USB.
16 Book No.9028195 02
2 Introduction to the control system 2.3 Overview of the screen
Button Description
Sets the control system in IMO mode, which activate operation in

accordance with IMO requirements.
IMObut
Sets the control system in USCG mode, which activate operation in

accordance with USCG requirements.
USCGbut
Status indication – Alarms and warnings
Alarms and warnings for components are displayed in the flow chart and popups:
Active alarm.
3 Alarm
Active warning.
3 Warning
Book No.9028195 02 17
3 Detailed page descriptions
This section describes the pages used for operation. Note that this section does not cover the
parameter pages. Please refer to chapter 4. Parameters.
3.1 Page 1.1 – Overview

The page displays an overview of the system, overall status and detailed information regarding
the components.
The main areas are the Status box and the Flow chart.
3 1.1 USCG
3.1.1 Status box

The status box display current status for the PureBallast system. The information is updated
continuously. To see accumulated operation runtime for the components, see page 4.3 – Operation
timers.
Book No.9028195 02 19
3.1 Page 1.1 – Overview 3 Detailed page descriptions
The following status information is displayed:
Status information (unit) Description
Process and sub process Process: Ongoing process. Can be standby, ballast, deballast
and CIP.
Sub process: Sub steps of ongoing process, for example

“Start-up” during Ballast process.
Time Remaining time for the ongoing sub process in the upper right
corner.
Processed volume (m3) Amount of water processed during ongoing process. Value
remain until next process is started.
Power consumption (kW) Power consumption for ongoing process.
Certif ed f ow (m3/h) Certified flow (m3/h) selected for operation. The information is
updated after the warm up time has passed and a UV reactor
is used for process. This is also the flow the system is aiming
to keep.
Current f ow (m3/h) Water flow in the system, indicated by flow transmitter FIT201-1.
The system aims for the selected flow minus parameter p111
Undershoot certified flow, which can be set as a safety margin.
Flow selection Flow (m3/h) selected for operation.
Flow can be selected manually or automatically:
• Automatically: Activate the Auto button (checkmark). Flow

will always be selected.
• Manually: Deactivate the Auto button (no checkmark).
Flow is selected using the + button.
Note: Before first operation after power off or shutdwon,
flow must be selected using the + button.
Ballast pump Status indication for balast water pump (not part of Alfa Laval’s
scope of supply).
Status indication
3 PumpReq
Green, blinking = Request sent. Popup message “Confirm
ballast pump started” is displayed. (The popup is not displayed
if the component feedback is integrated with the control system.)
Green = Feed back that pump is running, either via hard wired
feedback, remote interface or the confirmation popup.
Grey = No request sent (not running).
Overboard valve(s) Status indication for overboard valve(s), and other relevant
valves for the process (not part of Alfa Laval’s scope of supply).
20 Book No.9028195 02
3 Detailed page descriptions 3.1 Page 1.1 – Overview
Status information (unit) Description
Status indication
Green, blinking = Request sent. Popup message message

3 OBvalveReq “Confirm overboard valve open” is displayed. (The popup is
not displayed if the component feedback is integrated with the
control system.)
Green = Feed back that valve is open, either via hard wired
feedback, remote interface or the confirmation popup.
Grey = Closed.
3.1.2 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 components can be monitored in popups (by tapping the component):
UV reactor see page 51; filter see page 56. CIP open page 1.3 CIP status, see page 25). The popup
contain status for sub components, for example valves, motors and UV lamps in the UV reactor.
UVR cooling water pump (P403–1) is only displayed if it is used and activated in the parameter
pages.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually: If a component is pressed, a popup window is displayed from which the component
can be operated.
Status indication – Component color:
Component status is indicated by a colored frame:
Pipes Pipe and flow status. Flow in pipe is indicated as below:
Status indication
Blue = Cooling water going from sea-to-sea.
Green = Ballast and deballast flow.
Yellow = CIP liquid.
Mixed colors = Mixed water, for example ballast water and technical water
/ potable water.
Book No.9028195 02 21
3.1 Page 1.1 – Overview 3 Detailed page descriptions
Valves and Status indication

pumps
Green, blinking = Travelling / starting
Green = Open / running
Grey = Closed / not running.
Red, flashing = Active alarm for the component.
It is also possible to enter ship specific ID for a component. The ID will be

visible in page 1.1 Overview and popups for the components. See instruction
Set ship specific component ID on page 72
Status information for bypass valve(s) V212–31 and external bypass valves
(not part of Alfa Laval’s scope of supply). These valves are operated from the
ISCS, due to safety reasons.
External bypass is only visible if parameters (p163–p165) for external bypass

valves are activated.
3 CV and Bypass icon
Status information for backfllush pump P309–1 (optional). Only visible if

parameter p318 is activated.
3 P309
The component is operated manually in manual mode.
3 Manual1
22 Book No.9028195 02
3 Detailed page descriptions 3.2 Page 1.2 – UVR and flow selection
3.2 Page 1.2 – UVR and f ow selection

The page is used to select UV reactors or flow for ballast and deballast and to increase (only
possible in ballast) or decrease flow during ongoing operation. It is also possible to select specific
UV reactors to be used during process, or to change UV reactor during an ongoing process.
This page is only relevant if more than one UV reactor is installed.
Normally, flow is handled from page 1.1 Overview, and this page is used during commissioning and
faultfinding when it is necessary to start individual UV reactors.
The main areas of the page are the Flow selection, UVR selection and Status.
3 1.2 USCG
3.2.1 Flow selection

Function in the same way as flow selection in page 1.1 Overview.
Book No.9028195 02 23
3.2 Page 1.2 – UVR and flow selection 3 Detailed page descriptions
3.2.2 UVR selection

The area displays a table with installed UV reactors with status information. If more than one UV
reactor is installed, it is possible to choose individual UV reactor for process in standby (if the Auto
button is deactivated) or during process (regardless of Auto button mode).
The following information is displayed:
Elements Description
Modify button Enables active selection of individual UV reactors. When pressed, the
buttons for respective UV reactor turns blue and are possible to use.
UVR 1, 2, 3 button One row for respective installed UV reactor with current status indicated
in the columns.
UVR button: Press the button to select or deselect. A checkmark on the

button indicates selected. The flow setpoint for the number of UV reactors
selected are updated in the Flow selection area.
Status indication:
Selected: Grey = Not selected. Green = Selected.
Ready: Grey = Not ready. Green = Ready for process.
Alarm: Grey = No alarm. Red = Active alarm.
Apply button Apply the new setpoint to be used for process.

Note: If ballast flow is lower than deballast flow (parameter p315), the
higher value is displayed until the Ballast button is pressed.
3.2.3 Status
The area displays current status for the flow:
Elements Description
Current f ow Ballast water flow in the system, indicated by flow transmitter FIT201-1.
Certif ed f ow Maximum allowed flow as set in Flow setpoint or limited by the number of
UV reactors selected in UVR selection popup. If a smaller filter is installed,
the ballast flow can be lower than the UV reactor capacity.
The information is updated after the warm up time has elapsed and a UV
reactor is used for process. (Before that it is not used for treatment, and
therefore not part of the certified flow.)
24 Book No.9028195 02
3 Detailed page descriptions 3.3 Page 1.3 – CIP status
3.3 Page 1.3 – CIP status

The page is used to display CIP status for all UV reactors and status for the valves and motors in
the CIP unit. The page can either be opened by selecting the tab or by tapping the CIP module in
page Overview.
3 1.3 USCG
Book No.9028195 02 25
3.3 Page 1.3 – CIP status 3 Detailed page descriptions
3.3.1 CIP status

The area displays status for the following pieces of information:
Row Content
Process and sub Process: Ongoing process. Can be standby, ballast, deballast and CIP.
process
Sub process: Sub steps of ongoing process, for example “Start-up” during
Ballast process.
3.3.2 UVR information

The area displays CIP status for respective installed UV reactor:
Row Content
UV Each row display CIP status for every installed UV reactor
Filter preservation This row indicate status and time for the filter preservation process, that
starts after completed CIP. During filter preservation, the CIP fills the filter
with technical water / potable water for preservation purpose.
Total Total estimated time for a complete CIP process including filter preservation.
Column Content
CIP error Red square: Indicates that there is an active alarm for the component.
Check alarms on page 2.1 – Alarm list.
CIP CIP status for each UV reactor.
Status indication
Yellow = CIP required. During ongoing CIP process, yellow indicates that
the UV reactor is waiting for CIP process to start.
Yellow, blinking = CIP process ongoing.
Green = CIP completed.
White = CIP required, but cannot be performed, due to active alarm on

the UV reactor.
Status Same information as column CIP, but spelled out.
26 Book No.9028195 02
3 Detailed page descriptions 3.3 Page 1.3 – CIP status
Column Content
Estimated time Time remaining CIP time. If CIP process has not been started, total time is
displayed. During CIP process, the time is counting down continuously.
The CIP process takes about 25 minutes , if default parameters are used.
Required CIP Time before a CIP process must be performed after ballast or deballast.
countdown The time disappears when the CIP process is ready. Time is displayed for
the UVR with shortest time left to required CIP.
3.3.3 CIP module information

The area displays a schematic illustration of the CIP module, with status for for the valves and
motors. For status indications, see Status indication – Component color in section Flow chart
on page 21.
Book No.9028195 02 27
3.4 Page 1.4 – Power request 3 Detailed page descriptions
3.4 Page 1.4 – Power request

The page is used to handle power management. The page have two functions: Display power
status and test power management signals.
3 1.4 USCG
3.4.1 Power management status display

If the control system is set in normal mode, the page is used to display power management status.
Column Content
Process and sub Process: Ongoing process. Can be standby, ballast, deballast and CIP.
process
Sub process: Sub steps of ongoing process, for example “Start-up” during
Ballast process.
Max power Maximum power consumption for the number of selected UV reactors. The
consumption value is updated when a process is started.
Measured power Power consumption during process. Value calculated based on number
consumption of used UV reactors.
28 Book No.9028195 02
3 Detailed page descriptions 3.4 Page 1.4 – Power request
Power status
Column Content
Power Each row represent a number of UV reactors to be used in a process.

Requests can be combined to send request for 3 UV reactors.
1 UVR: Request power for 1 UV reactor.
2 UVRs: Request power for 2 UV reactors.
The requested power is calculated as the number of UV reactor times

defined power consumption for one UV reactor.
Common power: Request maximum power, enough to run all UV reactors

installed, even if all UV reactors are not used.
Request Indication alternatives: “Requested” or “Not requested”.

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

(Input signal to
PureBallast) Indicates if power request has been granted from the ISCS. Pure Ballast
will not consume significant power until the requested power is granted.
Manual mode: Indicates if a simulated granted signal is received.
Status Indication alternatives: “Running” or “Not running”.

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

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

If the control system is set in manual mode, the page is used to simulate output from PureBallast to
the power management system during commissioning preparation.
Book No.9028195 02 29
3.4 Page 1.4 – Power request 3 Detailed page descriptions
The page can also be used to troubleshoot the power management system integration by sending
and checking each signal.
3.4.3 Function buttons

The following function buttons are available and displayed when manual mode is activated:
Buttons Content
If manual mode is activated, a hand icons are displayed on the page.

Press the hand icon to make it possible to send simulated request or
granted signal manually.
3Manual1
Request Press to manually simulate request for a power step. The button is
displayed for login level Advanced operator or higher.
Set run Press to manually simulate run signal for a power step. The button is
displayed for login level Advanced operator or higher.
30 Book No.9028195 02
3 Detailed page descriptions 3.5 Page 2.1 – Alarm list
3.5 Page 2.1 – Alarm list

The page display active alarms and warnings. When an alarm/warning is inactive and
acknowledged, it is moved to page 2.2 Alarm 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.
3 2.1 USCG
The main areas of the page are the Alarm list and the Function buttons:
Book No.9028195 02 31
3.5 Page 2.1 – Alarm list 3 Detailed page descriptions
3.5.1 Alarm list

The following information is displayed for each alarm (row):
Column Content
Text Descriptive alarm text written as: Area-Alarm type AlarmID Alarmtext.
Example: UVR2 A138 Error in LDC cabinet.
Active time The time alarm was activated.
Acknow- The time the alarm/warning was acknowledged. The alarm/warning remains
ledged time in the alarm list until the causing 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
Orange Warning = active
Yellow Warning = acknowledged, but still active

The following function buttons are available:
Button Function
Ack selected Acknowledge selected alarm (row). Press a row to indicate it, and press the
button to acknowledge it.
Ack all Acknowledge all active alarms.
32 Book No.9028195 02
3 Detailed page descriptions 3.6 Page 2.2 – Alarm history
3.6 Page 2.2 – Alarm history

The page display a list of inactive, previously acknowledged alarms.
3 2.2 USCG
Column Content
Text Same as in Page 2.1 Alarm list.
Active time Same as in Page 2.1 Alarm list.
Acknowledged Same as in Page 2.1 Alarm list.

time
Normal time The time the value that caused the alarm returned to normal.
Book No.9028195 02 33
3.7 Page 3.1 – Trend (15 min) 3 Detailed page descriptions
3.7 Page 3.1 – Trend (15 min)

The page is used to display trend curves for basic data in the system. This page display trends
with a update frequency (sample time) of 2 seconds and the time span for trends displayed on the
screen is 15 minutes. Trend curves are saved in the trend history for 2 hours, and are then deleted.
This page is useful for analyzing processes, for example backflushes.
3 3.1 USCG
Trends can be plotted for the following components (identified by item number) and key values:
Component / Unit Description

Key value
Filter diff. pressure Bar Differential pressure over filter, indicated by pressure
transmitter 201–71 and 201–72.
V201–8 % Control valve open, percent.
PT201-16 Bar System pressure, indicated by the pressure transmitter.
V309-1 Status Filter backflush valve opened or closed.
FIT 201-1 m3 h System flow, indicated by the flow meter.
External feed % External feed signal, to request increased/decreased flow

from external ballast water pump/valve.
34 Book No.9028195 02
3 Detailed page descriptions 3.7 Page 3.1 – Trend (15 min)
3.7.1 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 always 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.
3.7.2 Component area

The following fields and buttons are available for each component in the component area:
Column Content / Function
Settings Press the button to make settings for the component’s curve. Settings are
button done in a popup.
3 TrendCurveSet1Nr
1: Press (not slide) the top right button to display or hide trend curve in the
diagram. A green I indicate displayed, and a grey O indicates not displayed.
2: Press the entry field to change start and stop value for the components Y
axis scale (when this component’s scale setting is used).
3: Press this button to use this component’s scale setting in the diagram.
4. Press the entry field to enter number of decimals in the component area, or
use the - - or ++ buttons to increase or decrease.
Book No.9028195 02 35
3.7 Page 3.1 – Trend (15 min) 3 Detailed page descriptions
Status Filled = Selected. Component values is plotted in the diagram,

indication in the same color as the icon.
3 TrendActive
Empty = Not selected. Component values is not plotted in the

diagram.
3 TrendInactive
Scale icon = The component scale setting is used in the

diagram’s Y axis. If several components have the same scale
3 TrendScale
setting, this icon is displayed for all these items.
Component Item number or name.
Value Current value for the component is displayed in the gray field. (This
corresponds to the diagram.)
If history mode is selected, historic value is displayed.

The following function buttons are available.
Buttons Content
Export long- Export trend curve history as a csv file. The file can be sent to Alfa Laval for
term trend advanced trouble shooting.
data to USB
Insert a USB memory in USB panel port on the cabinet door. Press Export
long-term data to USB button. Wait for the message “Exporting database
table …” to disappear. The file has been downloaded to the USB memory,
in a folder named DatabaseExport.
History mode Only available for page 3.1. Press the button to display this popup:
3 TrendCurveTime
Press one time unit (year, moth, day etc) and then press – or + to set time.
Real time Press the button to display current trend curve.
36 Book No.9028195 02
3 Detailed page descriptions 3.12 Page 3.7 – Trend (15 min) - External
feed optimization
3.8 Page 3.2 – Trend (1 h)

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 15 seconds and the time span for trends displayed on the
screen is 24 hours. Trend curves are saved in the trend history for 2 hours, and are then deleted.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
3.9 Page 3.3 – Trend (1 h) - TT201-33

The page is used to display trend curves for water temperature in the UV reactor, indicated by
temperature transmitter TT201–33. This page display trends with a update frequency (sample
time) of 30 seconds.
3.10 Page 3.4 – Trend (1 h) - TT401-2

The page is used to display trend curves for air temperature in LDC, indicated by temperature
transmitter TT401–2. This page display trends with a update frequency (sample time) of 30 seconds.
3.11 Page 3.5 – Trend (1 h) - Power optimization

The page is used to display trend curves for data valid for the power optimization. This page display
trends with a update frequency (sample time) of 30 seconds.
See page 3.1 Trend (15 min.) for information about function, fields and buttons. See chapter 2.
System description, section Power optimization for details.
• UVR UV setpoint: The UV intensity the system is aiming to attain by increasing or decreasing
power effect to the LPS controlling the dimming of the UV lamps. The setpoint is based on
actual transmittance and is updated every 15 seconds.
• UV measurement: Actual UV intensity (W/m2) measured by UV sensor QT201–50. If intensity
is lower or higher than needed, the power to LPS will increase or decrease to attain setpoint
for UV intensity.
• Power output: Actual LPS power to UV lamps. The power is adjusted to attain the setpoint for
UV intensity based on measured water transmittance. Output is adjusted based on input from
UV sensor QT201–50. Power can be 50–100 %.
3.12 Page 3.7 – Trend (15 min) - External feed
optimization
The page is used to display the trend curves for detailed data valid for the external feed.
Book No.9028195 02 37
3.13 Page 3.8 – UVR 1-3 UV optimization 3 Detailed page descriptions
We recommend that page 3.1 is used to monitor external feed trend curves. This page is mainly
used for advanced trouble shooting.
The external feed is used to fine tune the control of the flow that comes to PureBallast. It works as
an addition to the flow controlled by the control valve (V201-8).
3.13 Page 3.8 – UVR 1-3 UV optimization

The page is used to display the trend curves for detailed data valild for UV optimization.
38 Book No.9028195 02
3 Detailed page descriptions 3.14 Page 4.1 – System info
3.14 Page 4.1 – System info

The page is used to display status information for the control system and the control panel. It is also
used to backup information and restore information from a backup.
3 4.1 USCG
Section on page Description
HMI info CPU: Control panel’s usage of the central processor unit (CPU) in
percent of total capacity and temperature (°C). The control panel will
shut down when the CPU reaches 100 °C.
Used RAM: Control panel’s used random access memory (RAM) in

percent of total capacity and in kB.
Used storage: PLC flash card’s used storage in percent and MB.
Storage used for the event and alarm log.
iX version: N/A.
T15BR f rmware: Version of internal firmware for the control panel.
CAT control version: N/A.
PureBalalst HMI software version: Version of HMI software.
IP settings: Display current IP address for the panel.
Book No.9028195 02 39
3.14 Page 4.1 – System info 3 Detailed page descriptions
Setup button: Opens popup to set IP address for the main panel and
the remote control panels (optional). Requires login level AlfaLaval.
HMI date and time UTC Date and time: Set and synchronize date and time. (If parameter
p160 is activated, date and time is is retrieved from GPS with RMC
protocoll instead. Requires login level Advanced operator.
Set button: Set time and date for the main control panel. Remote
control panels are updated with this time within 15 minutes after
syncronization.
Regional settings button: Set time zone.
Synchronize button: PLC is synchronized to use same date and

time as set in the control panel.
HMI Backlight Screen saver timeout: Defines time before the panel is set to
screen save mode. This is set individually per control panel.
Night light level: Defines percent of full light for the night light
mode. Night light is activated by the Night function button.
PLC Info CPU temperature (°C): Temperature of the central processor unit
(CPU) in the PLC.
PureBallast PLC sotfware version: Version of the PureBallast

PLC program.
GPS position: Shows current GPS position, if the control system

is connected to a GPS. This position is used in the event log. First
GPS field display position as decimal and second as position with
correct notation (degrees).
Control cabinet conf guration: Indicates if control of booster

pumps can be controlled from PureBallast control cabinet.
1: Pump started by signal from PureBallast control cabinet: Power
supply with over current protection relay and contactors and are
handled externally.
2: Pump completely controlled from PureBallast control cabinet:
Start signal and power supply with over current protection relays
and contactors from control cabinet. It is still possible to connect
pumps according to configuration 1.
Control cabinet configuration affect parameter p129, p130 and p310.
40 Book No.9028195 02
3 Detailed page descriptions 3.14 Page 4.1 – System info
Backup and restore Settings to/from USB panel: Export and inport information to the
USB panel port on the cabinet door.
Backup button: The following information is saved in a folder named

“PureBallast Backup”:
• Parameter settings. File: Parameters.csv.

• Operating timers for UVR, UV lamps etc. File:
operatingtimers.csv.
• Settings for components in the trend curve pages. File:
ValueSaved.xml and ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different
components. File: ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
Restore button: Restore all information from a USB backup to
the control system. See Backup above. This shall not be used to
restore parameter settings after software update. Requires login
level Advanced operator.
Parameters: Parameter restore.
Set default button: Set all parameter values to the default values.
Requires login level Advanced operator.
Export log f les Export button: Opens the Export log f les popup to export (copy)
event log files and alarm list.
For specific information about logged events, see section List of

logged information, Event log on page 87.
Remote control panels Remote control panels button: Open a popup used for setting IP
addresses for remote control panels (optional). See instruction Set
control panel IP address on page 76.
Requires login level AlfaLaval.
Book No.9028195 02 41
3.15 Page 4.2 – PLC controller I/O 3 Detailed page descriptions
3.15 Page 4.2 – PLC controller I/O

The page is used to display status for the PLC I/O modules and to control them manually.
Note that this page is only intended for Alfa Laval’s personnel and only visible and available for
login level AlfaLaval.
42 Book No.9028195 02
3 Detailed page descriptions 3.16 Page 4.3 – Operation timers
3.16 Page 4.3 – Operation timers

The page is used to display operation counters for the components indicted in the illustration.
3 4.3 USCG
Row Unit
Accumulated ballast volume (FIT 201-1) m3 processed
Accumulated deballast volume (FIT 201-1) m3 processed
Control valve V201-8 total runtime Time opened in hours
LDC cooling booster pump total runtime (P401–1) Runtime in hours
Reactor cooling booster pump total runtime (P403–1) Runtime in hours
Filter backflush cycles Number of backflushes
Filter motor (M709–43) total runtime Runtime in hours
Filter backflush pump (P309) total rumtime Number of times opened
CIP pump P320-1 Runtime in hours
Book No.9028195 02 43
3.16 Page 4.3 – Operation timers 3 Detailed page descriptions
Row Unit
CIP pump P321-5 Runtime in hours
CIP: Number of cleaned UVRs. Number of cleaned UV reactors
Reset button: Reset to 0. If this is done each time the CIP

liquid is changed, it is possible to build up experience on how
many UV reactors it is possible to CIP before it is time to change
CIP liquid. Requires login level Advanced operator or higher.
44 Book No.9028195 02
3 Detailed page descriptions 3.17 Page 4.4 Operation timers UVR
3.17 Page 4.4 Operation timers UVR

The page is used to display operation runtime for UV reactors:
3 4.4 USCG
UVR operation Total Lap time

timers
UVR 1–3: Total runtime for the UV lamps in Lap time for installed UV lamps, since
Lamps on respective UV reactor. the counter was reset after previous
reset at UV lamp change.
Reset button: Reset the value. Shall

be done after UV lamp change.
Requires login level Advanced
operator or higher.
UVR 1–3: LDC Total runtime for the LDC for

power on respective UV reactor.
Book No.9028195 02 45
3.18 Page 4.5 – Remote interface 1 3 Detailed page descriptions
3.18 Page 4.5 – Remote interface 1

This page is used to monitor data sent between PureBallast’s PLC and the vessel’s ISCS.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).
3 4.5 USCG
Function buttons Description
Test mode Activates test mode. Communication can be sent between the
ISCS and PureBallast’s PLC without actually affecting the control
system (start process etc). To send information, enter desired
digits in the entry field.
Active: Check mark on the button.

Deactivated: No check mark on the button.
46 Book No.9028195 02
3 Detailed page descriptions 3.19 Page 4.6 – Remote interface 2

This page is used to monitor UV reactor and LDC specific data sent from PureBallast’s PLC to the
vessel’s ISCS.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).
3 4.6 USCG
Book No.9028195 02 47
3.20 Page 4.7 – Log box 1 3 Detailed page descriptions
3.20 Page 4.7 – Log box 1

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.
3 4.7 USCG
Column Content
Top f elds for administration
Conf guration Choose to define/view bypass or heeling configurations.

type
Conf guration Select configuration number by entering a number or using the arrow buttons.
nr Signal status and Configuration are displayed for selected configuration
number.
Save conf g Saves configuration information after a change.

button
Signal setting
48 Book No.9028195 02
3 Detailed page descriptions 3.21 Page 4.9 – LPS overview
Column Content
Top f elds for administration
Signal input Heading for input signal 1 – 32.
Signal status Indication of current status for signal 1 – 32.

Green light = Active signal.
No light = No signal.
Conf guration This is the definition of which signal that should be active to constitute a
bypass/heeling. Tap the checkbox to select or unselect it.
Selected = All selected signals, must be active for the configuration to

occur.Not selected = Not part of configuration.
3.21 Page 4.9 – LPS overview

This page is used to monitor detailed data for the lamp power supplies in the lamp drive cabinet. It
is intended for Alfa Laval’s personnel during advanced faultfinding. The number of LPSs displayed
corresponds to the number of LPSs installed per LDC.
3 4.9 Obe USCG
Book No.9028195 02 49
3.21 Page 4.9 – LPS overview 3 Detailed page descriptions
Column Content
LPS number Each row indicate status for each LPS.
Power Measured power output for UV lamp powered by the LPS.
Lamp on Status: Green = On. Grey = Off.
Ignition Status: Red = Failure to ignite UV lamp.
LPS OK Status: Green = OK. Red = LPS in fault state.
Lamp OK Status: Green = UV lamp lit and LPS is OK. Red = LPS in fault state.
Lamp open Status: Rec = No lamp, circuit open.
Voltage fault Status: Red = Too low incoming power to the LPS.
System fault General LPS error.
Air temp fault Status: Red = Temperature in LPS is higher than 45°C.
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 disapears when the alarm is acknowledged.
3 Alarm
50 Book No.9028195 02
3 Detailed page descriptions 3.23 Popup windows
3.22 Page 5.1–5.7 – Parameter pages

These pages are used to set parameters. See chapter 4. Parameters for detailed information.
3.23 Popup windows

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

The popup is displayed when the UV reactor is pressed in the flow chart. The popup displays status
values for the UV reactor and its related sub components.
manually. If the component is pressed, a popup window is displayed from which the sub
components can be operated. Operation of UV lamps in LPS control popup requires login level
Advanced operator. LDC cooling water pump (P401–1) is only displayed if it is used and activated
in the parameter pages.
UVR status: Status indication for the UV reactor: ”Stopped” or “Started”.
Book No.9028195 02 51
3.23 Popup windows 3 Detailed page descriptions
3 1.1. UVR popObe
The following information is displayed:UVR illustration
Component Description
UV lamps Status indication:
Grey = Off.
Yellow = Starting.
Green = Started.
Sensor Status indication for UV reactor sensors:

indications
LS201–29/: Level switch indicates if the UV reactor is filled with water or not.
Status indication: Green = Filled. Red = Not filled.
TS201–60/: Temperature switch automatically shuts down the UV reactor

when the temperature reaches 65 °C.
Status indication: Green = OK. Red = Not OK.
QT201–50: UV sensor QT201–50 indicates UV intensity from the UV

lamps in the UV reactor.
TT201–33: Temperature transmitter TT201-33 indicates current

temperature in the UV reactor.
Valves For status indications, see Status indication – Component color in section
Flow chart on page 21.
Water f ow Flow in pipes is indicated by coloring of the pipes.
52 Book No.9028195 02
LDC status
Open the LPS control popup, which enables manual operation of individual
UV lamps. Requires login level Advanced operator to see the button and
3 LPSctrlbut
manual mode open the popup. See LPS control popup and instruction
Operate UV lamps manually on page 71.
Open the LPS status popup, which gives an overview of status for UV
lamps and LPSs.
3 LPS StatusBut
Fan speed Fan rotation in percent of full effect. Fan effect is based on need for cooling.
Air temperature Air temperature in the LDC cabinet indicated by TT401–2.
Water temperature Temperature of incoming cooling water to the LDC cabinet indicated by
TT401–1.
Heat exchanger Indicates if the valve for LDC cooling water (SV401–51) is open.
valve Status indication: Green = Open. No indication = Closed.
P401–1 Cooling Indicates if the LDC cooling water pump is running or not. The pump is
water pump running if the cabinet needs cooling, based on temperature.
Status indication: Green = Running. No indication = Not running.
Indicates if the leakage sensor LS1 is indicating whet condition in the

cabinet.
3 LDC LS1
Status indication: Grey = Dry. Red = Whet.
3.23.1.1 LPS control popup
The popup is used for to manually start the UV lamps in the UV reactor. See instruction Operate
UV lamps manually on page 71. The popup is displayed when the LPS control button is pressed
in the UVR popup. Requires login level Advanced operator to see the button and that manual
mode is activated to open the popup.
The UV reactor is equipped with 16 UV lamps. In each lamp drive cabinet (LDC) is 16 lamp power
supplies (LPS) that supplies power to one UV lamp each. The lamps can be operated individually in
manual mode.
DANGER
!
• Manual start of the UV lamps is only allowed (and possible) when there is water in the UV
reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. All
necessary items – cooling water flow, water temperature, and power management – must be
supervised and verified by the authorized trained personnel operating the system. Improper
operation of this function could seriously damage the equipment and injure personnel.
Book No.9028195 02 53
3 LPS control popObe
UVR number Information is displayed for the UV reactor selected in the UVR number
field.
Enables manual operation of the LPSs to light the UV lamps. The button is
displayed for login level Advanced operator or higher. The button enables
3 LPS Manual
manual lcontrol of UV lamps.
LPS 1–16 Press one button (1–16) to start or stop UV lamp 1–16 manually, controlled
by the LPS.
Status indication:
Blue with checkmark = Lit
Blue without checkmark = Off
Grey = Not selectable.
Start all LPS, and thereby all lamps for the UV reactor. Requires that the
Manual mode button is pressed.
3 LPS StartAll
Stops all LPS, and thereby all lamps for the UV reactor.
3 LPS StopAll
3.23.1.2 LPS status
The popup gives detailed information about UV intensity for UV reactors and power for LPSs. The
information is mainly used for advanced trouble shooting by Alfa Laval’s personnel.
54 Book No.9028195 02
3 LPS status popObe
LPS status
UVR Information is displayed for the UV reactor selected in the UVR number
field.
LPS fail safe Displays if LPSs is active and powered on. UV lamps 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.

3 1.1 LPS active
LPS 1–16 Actual effect from each LPS to respective UV lamp. Green = LPS/Lamp
on. Gray = LPS/Lamp off.
Power optimization
Book No.9028195 02 55
Setpoint The UV intensity the system is aiming to attain by increasing or decreasing

power effect to the LPS controlling the dimming of the UV lamps.
Measured Actual UV intensity (W/m2) measured by UV sensor QT201–50. If intensity

is lower or higher than needed, the effect to LPS will increase or decrease
to attain setpoint for UV intensity.
Power output Setpoint for LPS power output (50-100 %). This is how much power the
system is set to maintain.
The power is adjusted so that the UV lamps are lit to the effect needed
to attain
the setpoint for UV intensity (based on measured transmittance in the

water). Output is adjusted based on input from UV sensor QT201–50.
Effect can be 50–100 %.
Control mode Displays current control mode. Status indication:
• Automatic: Normal mode. Power optimization is activated.

• Manual: If function button Manual is pressed, it is possible to enter a
value in the Manual power output field.
• Not used: Power optimization is disabled in parameter p237. UV
lamps are always lit to 100 %.
Manual power Manually set effect to LPS. Requires that the system is set in manual
output mode.
3.23.2 Filter popup

The popup is displayed when the Filter is pressed in the flow chart. The popup displays status
values for the filter and its related components.
manually. If the component is pressed, a popup window is displayed from which the sub component
can be operated. When manual mode is deactivated the system will return to standby mode: All
manually operated components will return to their status prior to the manual operation.
56 Book No.9028195 02
3 1.1 Filter Filtrex
Mode Filter status:

- Idle (No backflush or preservation)
- Backflush preparation
- Backflush ongoing
- Continuous backflush
- Filter preservation.
Diff. pressure Indicates differential pressure over the ilter (PT201–71 minus
PT201–72). When the pressure reach the value set in parameter p305,
a backflush is triggered.
Pressure Current pressure:
PT201–71: Inlet pressure.

PT201–72: Outlet pressure.
Press the button to start a manual backflush. See instruction Backflush

filter manually on page 65.
3 BackflushBut
Pipes, valves, motor For status indications, see Status indication – Component color in
and pump section Flow chart on page 21.
Book No.9028195 02 57
4 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 i this chapter:
• Control system pages used in the instructions: See section Control system — Detailed page
descriptions.
• Login levels required for different procedures: See section Login levels on page 11.
• Detailed information about components (valves, motors, pumps etc) involved in each step the
process. See section Detailed process description.
4.1 Log in
Follow the steps below
1. Press the expand button on the Log in tab in the top right corner of the screen.
Result: The log in menu is displayed.
2. Press the expand button on the left drop down menu to display available users. Press desired
user.
Result: A keyboard is displayed.
3. Enter password and press Enter. (See section Login levels on page 11.)
4.2 Perform ballast

Follow this instruction to ballast.
• The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
• All valves leading flow to and from PureBallast must be opened. They are not operated by
PureBallast.
• Flow must have been selected before a process can be started, either manually or automatically.
See Flow selection on page 19.
• There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
Book No.9028195 02 59
4.2 Perform ballast 4 Operating instructions
Follow the steps below:
1. Press the function button Ballast.

Comment: If the button is not blue, check that flow or UV reactors have been selected.
2. Wait for the message “Open valves ...”. Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Ballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and ballasting starts.
4. When desired amount of water has been processed, press the function button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off. An automatic filter
backflush is performed.
5. Wait for the message “Close valves ...”. Close relevant valves and then press the button in
the popup to confirm the action. Note! These valves are outside outside the PureBallast
6. Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
7. Wait for the ”Start CIP” popup.

Yes: ACIP process will be started after the UV lamp cooling time (5 minutes ).
In 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 ).
CIPpop
60 Book No.9028195 02
4 Operating instructions 4.3 Perform deballast
NOTE
A CIP cleaning process must be f nished within the time stated in the popup (30 hours from the f rst operation
after the previous CIP process). Therefore consider the time for CIP process. A CIP process takes about 25
minutes , if default parameters are used. If no CIP process is performed within the time limit an entry is made in
the control system log f le. Operations after the warning does not fullf ll the type approval certif cate.
Note that it is possible to run operations during the 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP clean UVR
after ballast / deballast on page 65.
4.3 Perform deballast

Follow this instruction to deballast.
PureBallast.
• Flow must have been selected before a process can be started, either manually or automatically.
See Flow selection on page 19.
manually.
1. Press the function button Deballast.

Comment: If the button is not blue, check that flow or UV reactor have been selected.
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message “Confirm ballast pump started”. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
Result: Cooling stops and deballasting starts.
4. When desired amount of water has been processed, press the function button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off.
6. Wait for the message “Close valves ...”. Close relevant valves and then press the button in the
Book No.9028195 02 61
4.4 Perform tank stripping 4 Operating instructions

CIPpop
NOTE
the control system log f le. Operations after the warning does not fullf ll the type approval certif cate.
4.4 Perform tank stripping

Follow this instruction to deballast.
PureBallast.
• Stripping function must be activated in parameter p170.
manually.
1. Press the function button Strip.

Comment: If the button is not blue, check that flow or UV reactor have been selected.
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.
62 Book No.9028195 02
4 Operating instructions 4.5 Pause ballast / deballast / stripping
3. Wait for the message “Confirm strip pump started”. Start the pump and then press the button
in the popup to confirm the action. Note! This component is outside the PureBallast system
control. (The popup is not displayed if the component feedback is integrated with the control
system.)
Result: Cooling stops and stripping starts.
4. When desired amount of water has been stripped, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message “Stop stripping water pump”. Stop the pump and then press the button
in the popup to confirm the action. Note! This component is outside the PureBallast system
control. (The popup is not displayed if the component feedback is integrated with the control
system.)
6. Wait for the message “Close valves ...”. Close relevant valves and then press the button in the

CIPpop
NOTE
the control system log f le. Operations after the warning does not fulf ll the type approval certif cate.
4.5 Pause ballast / deballast / stripping

Follow this instruction to pause an ongoing process.
Book No.9028195 02 63
4.6 Heel (internal transfer) 4 Operating instructions
• This is only possible in sub process full ballast or full deballast. This is indicated by the lit
Pause button.
• Allowed in sub process full stripping if activated in parameter (p170). After defined time, the
paused process is stopped.
• Allowed length of a pause is parameter set (p138). After defined time, the paused process
is stopped.
1. Press the function button Pause.
Result: Ongoing process is paused. The UV lamps remains on at reduced power and cooling
water is run through the UV reactor to cool the lamps. Pause mode is indicated by yellow light
under the Pause button and blinking yellow under the function button Ballast, Deballast or
Strip.
3. To resume the process. Press the Ballast or Deballast button.

Result: PureBallast goes to Ballast or Deballast mode.
4. Press the Ballast, Deballast or Strip button to resume the process.
5. Wait for the message “Confirm ballast pump started”. Start the pump and press the button in the
Result: The process is resumed.
4.6 Heel (internal transfer)

Follow this instruction to pause an ongoing ballast or deballast process to enable heeling (internal
transfer).
• This requires that a signal for heeling mode is integrated between PureBallast and the vessel’s
ISCS.
• This is only possible in sub process standby, full ballast and full deballast.
• Allowed length of heeling is parameter set (p138). After defined time, the system is stopped.
1. Activate heeling from ISCS, which means that a heeling signal is sent to PureBallast.
64 Book No.9028195 02
4 Operating instructions 4.8 CIP clean UV reactor after ballast
/ deballast / stripping
2. In PureBallast: Wait for the message “Stop ballast water pump”. Note! This component is
outside the PureBallast system control. (The popup is not displayed if the component feedback
is integrated with the control system.)
Note: If you you need the ballast pump for heeling, confirm the request without stopping the
ballast water pump.
Result: System goes to heeling mode (ongoing process is paused). The UV lamps remains
on at reduced power and cooling water is run through the UVR to avoid overheating of the
lamps. During heeling, the yellow light under the Pause button is lit and the yellow light under
the function button Ballast or Deballast is blinking.
3. To resume the paused process. Deactivate the heeling from ISCS.

Result: PureBallast goes to Pause mode.
4. Press the Ballast or Deballast button to resume the process.
5. Wait for the message “Confirm ballast pump started”. Start the pump and press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
Result: The process is resumed.
4.7 Backf ush f lter manually

Follow this instruction to backflush the filter manually.
• The system must be in full ballast mode.

1. Go to page 1.1 Overview.
2. Press the Filter in the flow chart.

Result: The Filter popup is displayed.
3. Press the Start backf ush button.

Result: A backflush is performed. The default backflush process time is 20 seconds.
4.8 CIP clean UV reactor after ballast / deballast /

stripping
Follow this instruction to clean the UV reactor(s) using the cleaning in place (CIP) process.
If system shut down is activated during the CIP process, the CIP liquid is drained to the CIP tank.
Water in the UV reactors is drained overboard.
• The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
Book No.9028195 02 65
4.9 Attend to alarms 4 Operating instructions
• We recommend that a CIP process is performed within the same ecological zone or in
international waters (200 nautical miles from the base line). This will avoid untreated water from
the UVR and the filter to enter a different ecological zone.
• Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual UV reactors
are required to be CIP:ed etc.
• If a ballast operation has been performed since the last CIP process, the process is completed
with a filter preservation, where the filter is filled up with technical water / potable water.
1. Press the function button CIP.
2. Wait for the message “Open valves ...”. Open relevant valves and then press button in the
Result: The CIP process starts. The CIP process takes about 25 minutes , if default
parameters are used.
Note: If CIP process is started after a process the CIP process will start after 2 minutes, when
the UV lamps have been cooled.
3. Wait for the message “Close valves ...”. Close relevant valves and then press button in the
4.9 Attend to alarms

Follow this instruction to attend to alarms and warnings. For descriptions of alarms and trouble
shooting, see chapter 5. Alarms and faultfinding.
An alarm or warning is indicated by a audible signal and that the icon on the alarm list tab is blinking:
3 Alarm
• 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 silenzed by touching the buzzer, but note that the alarm is not acknowledged by this.
66 Book No.9028195 02
4 Operating instructions 4.9 Attend to alarms
NG
WARNI
!
• 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 32.
1. Go to page 2.1 Alarm list to view active alarms.
• If the alarm has caused the system to automatically stop, go to step 2.

• If the alarm allows the ballast process to continue, go to step 3.
2. If the process have stopped: Take action to eliminate what has caused the alarm.
3. If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
4. After the problem has been dealt with Press the Ack all button to acknowledge all alarms, or
press the alarm row and press Ack selected button to acknowledge only this alarm.
Result: The alarm will change color to indicate change of status. See section Page 2.1 Alarm
list in this chapter. The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.
Book No.9028195 02 67
4.10 Shut down and deactivate system 4 Operating instructions
4.10 Shut down and deactivate system

Follow this instruction to quickly stop any ongoing operation in the PureBallast system, for example,
when a critical fault has been detected, or to make the system deactivated (currentless).
PureBallast will shut down if the system loose power (intentionally or unintentionally) or if an alarm
is issued. Alarm has alarm ID beginning with an “A”.
Events at shutdown:
• Any ongoing process will stop.

• Valves will return to closed position. Valves are opened at high signal from the control system,
and when this signal is lost, the valves are closed pneumatically.
• The following signals to ISCS are lost, which means that PureBallast no longer require
overboard valve open, ballast pump running and request for dedicated power if power
management (optional) is used.
• An evnt is written to the eventlog.
Control cabinet Lamp drive cabinet
3 Emergency stop 3 Emergency stop LDC
One of the following methods can be used to abort any ongoing operation and stop the system:
68 Book No.9028195 02
4 Operating instructions 4.11 Reset system after shut down
Action Method
Stop ongoing Press the Stop button in the control panel.

process Result: Ongoing process is stopped in a controlled way. Valves are
returned to starting position.
3StopButtonBlue
System stop Press the Stop button (2) on the control cabinet door.
Result: Ongoing process is stopped and valves are returned to starting
position as fast as possible. Note: The power is still on.
System stop If an external system stop button has been installed and integrated, it
(External button) will function as the system stop above.
Deactivate Complete deactivation is performed in two steps:

PureBallast to
make it completely 1. Turn off the main breaker (1) at the side of the control cabinet.
deactivated
2. Turn off the main breaker (A) on the LDC door.
(currentless).
The system is then currentless on the PureBallast side of the breaker
(Q1 in control cabinet and Q1 in the LDC.
To make the complete system currentless, power to PureBallast must

be switched off using the ship’s switch board.
Note: Both breakers can be locked in off position using a padlock.
4.11 Reset system after shut down

Follow this instruction to reset the system if deactivated. Numbers refer to the illustration under
instruction Shut down and deactivate system on page 68.
The system may only be reset after the reason for shut down is known. If the reason is not known,
follow the instruction Attend to alarms.
Depending on how the system was shut down:
Manual on control cabinet: Turn the main breaker (1) and acknowledge the alarm in the control
system. Release the button on the control cabinet.
Automatic in LDC: Follow the instruction below if a reactor has been shut down by temperature
switch TS201-60 (alarm A137) or if the cabinet or system has been shut down by a blackout or
electrical faults in the cabinet:
1. Make sure that the main breaker (A) on the LDC door is turned on.
2. Press the blue reset button (B) on the LDC door (when the reactor has cooled down or when
the power is back on).
3. Acknowledge all alarm related to the shut down in the control system.
Book No.9028195 02 69
4.12 Operate components manually 4 Operating instructions
4.12 Operate components manually

Follow this instruction to operate components manually. This shall only be done during
commissioning, advanced faultfinding or service.
Valves are recommended to be operated via the PureBallast control system. It is also possible to
open/close them manually according to instruction in chapter 7. Service manual, section Operate
valves manually.
The following components can be operated manually:
• Filter motor (M709-43)

• CIP pump for CIP liquid (P320-1)
• CIP pump for draining (P321-5)
• LDC cooling water pump (401–1), if installed
• UVR cooling water pump (403–1), if installed
• UV lamps in the UV reactor
• UV lamp effect.
• This operation requires login level Advanced operator or higher.

• It is not possible to run any processes in manual mode. Only individual components can be
operated.
• When operating valves, the positioning screw on the valve must be in position 0: Closed
(default position).
1. Go to page 1.1 Overview or 1.4 CIP status.
2. Press the button Manual function button.

Result: The control system is set in manual mode.
3. Press desired component.

Result: A popup is opened. Current status is indicated. If an existing alarm exist, it is indicated
with an alarm icon. If the UV reactor or filter was pressed, a popup is opened with sub
components. If the CIP was pressed, page 1.4 CIP status is opened.
70 Book No.9028195 02
4 Operating instructions 4.13 Operate UV lamps manually
3 PopValve
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 flow chart to indicate that it is manually operated.
5. Operate the component using the open/run (left) and closed/not running (right) buttons in
the popup.
6. Press Hand button to stop manual mode for the component and the X button to close the popup.
or
Press the X button to close the popup and let the component remain in manually set status.
The popup is closed, and a hand icon is displayed by the component to indicate it is manually
operated.
7. Press the Manual function button to exit manual mode.

Result: All manually operated components are restored to their previous status.
4.13 Operate UV lamps manually

Follow this instruction to start and stop individual UV lamps in an UV reactor and to dim the UV
lamps. This can, for example, be done to check that a changed lamp functions OK.

• The control system must be in manual mode.
NGE R
! DA
• 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. Inappropriate
operation of this function could seriously damage the equipment and injure personnel.
Book No.9028195 02 71
4.14 Set ship specific component ID 4 Operating instructions
1. Go to page 1.1 Overview. Press the Manual function button to activate manual mode.
2. Press the UVR image.

Result: The UVRpopup opens. (See description on page 51.)
3. Select which UV reactor to operate in the UVR number entry field.
4. Open, in stated order, the following valves to fill the UV reactor with water: 201-19, 404-36
and 403-35.
Result: The UV reactor is now filled with water through the cooling water line 403.
5. Wait until the UV reactor is filled with water, indicated by the level switch (LS201–29) turning
green.
6. Press the LPS control button.

Result: The LPS control popup is displayed for selected UV reactor.
7. Press the Manual mode button to enable manual operation of the UV lamps.
8. Operate lamps by pressing one of the following buttons:

Start all LPS units.
Stop all LPS units.
LPS1-16: Start / stop individual lamps. Each lamp power supply (LPS) powers to
corresponding UV lamp. The buttons toggles between started and stopped. Place the UVR
and the LPS control popups side to side to see that the lams are started.
UV lamp stauts: Grey = Stopped; Green = Started; Yellow = Starting.
9. If desired, the UV lamps can be dimmed manually: Press the LPS status button in the UV
reactor popup. Press the Manual output filed, and enter desired percentage between 50
and 100 %. The LPS will give the entered percentage of full effect to the UV lamps. This is
indicated in the Power output field.
10. Press the Stop all LPS units button.

Result: Any lit UV lamps are stopped and the popup is closed.
11. Press the Close button to close the popup.

Result: All manually operated components are restored to standby status.
4.14 Set ship specif c component ID

Follow this instruction to set ship specific IDs for valves and pumps. The ID will be visible in page
1.1 Overview and popups for the components.
• If remote control panels (option) are used, enterd IDs will be displayed on all panels.
• Requires login level Advanced operator.
72 Book No.9028195 02
4 Operating instructions 4.15 Export control system event log files
2. Press desired component.

Result: A popup is opened.
3 ShipIDComp
Example: Popup with ship specific ID. Entered ID is

displayed on the component to the left.
3. Press the input field at the bottom.
4. Use the keyboard to enter an ID. Press Enter to finish.

Result: The name is saved and visible in page 1.1 Overview and the popup. .
4.15 Export control system event log f les

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) is recommended to be opened in Visualog, but
can also be opened in Excel or similar tools. Visualog is a tool designed to present and analyze
the information from the PureBallast log files.
The following information can be exported:
Information to be Description
exported
Event log The event log includes all important events in the PureBallast system. The
log also include components connected via the log box. Intended to be
used mainly by service technicians.
Event log - Contains a selection of the complete event log, relevant to comply with
Certif cate the IMO regulations.
Alarms and A list of all alarms and warnings that has been issued from the control
warnings system. Intended to be used mainly by service technicians.
For specific information about logged events, see section List of logged information on page 87.
Book No.9028195 02 73
4.15 Export control system event log files 4 Operating instructions
• 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
4.5 Installation parameters.
• The easiest way of reading the log file is to use the program Visualog, but the file can also
be read in Exel.
1. Go to page 4.1 System info.
2. Press the Export button in page section Export log f les.

Result: A popup is displayed.
3 ExportLog
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 fields. Default
start date is the oldest file in the system, and default end date is today’s date.
• Select the Specify time interval box, and enter desired interval in the Start and End fields.
5. Press one of the following function buttons: Events or Alarms. (The Update export is only
used when updating softwares.)
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
74 Book No.9028195 02
4 Operating instructions 4.17 Restore control system settings
6. Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been saved to the USB. It contains two sub folders:
Alarm and Event. The folder corresponding to your export choices contains a CSV file.
7. Press Close and remove the USB memory
4.16 Backup control system settings

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

• Operating timers for UVR, UV lamps etc. File: operatingtimers.csv.
• Settings for components in the trend curve pages. File: ValueSaved.xml and
ValueTrendLegend.xml.
• Settings for trend pages, e.g. min and max values for different components. File:
ValueTrendLegend.xml.
• Notpad.txt. Can be used to make notes for the backup.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Backup button in page section Backup and restore.

Result: A popup is displayed and the process is started. Read the final line of list before
closing the popup: Important information might be displayed.
4. Wait for the OK / Close button to turn blue again. If the backup was successful, the last line
shall state "Backup done".
Result: A folder named PureBallast backup has been saved containing the backup files.
5. Remove the USB memory.
4.17 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 trend pages 3.1 — 3.5.

• 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 4.1 System info, section on page 39.
Book No.9028195 02 75
4.18 Set control panel IP address 4 Operating instructions
• This method shall not be used to restore parameter settings after software update.
• If you do not wish to update a certain type of setting, remove the specific file from the USB
memory before inserting the USB memory in the USB panel port on the cabinet door.
• Remove the file Parameters.csv from the USB before following this instruction.
2. Insert a USB memory in USB panel port on the cabinet door.
3. Press the Restore button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started.
4. Wait for the OK / Close button to turn blue.
5. Read the second last line in popup: If the restore was successful, it shall state "Restore done".
6. Press the OK / Close button on the popup.
7. Remove the USB memory.
8. The control panel must be rebooted. At the rear side of the control panel: Pull out the power
cable from the 24V DC port, and insert it again.
4.18 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 A 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.

76 Book No.9028195 02
4 Operating instructions 4.19 Set remote control panel communication
3 IPaddress
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.
3 IPaddress
Note: Only the IP address shall be changed.
5. Press OK.
6. Reboot the panel to update communication with the new IP address. Make sure that the new
IP address is displayed on page 4.1 System info.
7. Repeat this instruction for all installed control panels, both main and remote control panels, if
installed.
8. Follow the instruction Set remote control panel communication to activate remote control panel.
4.19 Set remote control panel communication

Follow this instruction to connect remote control panels (optional) to the PLC.

• 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 panelse is used, address 192.168.0.11 shall be removed.
Book No.9028195 02 77
4.19 Set remote control panel communication 4 Operating instructions
• All remote control panels must be on and connected with an Ethernet cable.
1. On the main panel in the control cabinet: Go to page 4.1 System info.
2. In the Remote control panels box, press the Set button.

3 RCP communication
3. Select an available remote control panel in the left hand side.
4. Press the >> button.

Result: The panel is connected and moved to the right hand side.
Note: Server port shall always be “1001”.
5. Press the Panel alias field for the new control panel. Use the keyboard to enter a name, for
example the location it is placed.
Note: Panel alias for all control panels shall be entered (with the same wording) in all panels
to be displayed in a correct way.
6. Press the save (USB symbol) button.

Result: The information is saved and the popup is closed.
7. Repeat step 4–7 to connect more remote control panels.
8. Repeat this entire instruction for all installed panels.
Delete a remote control panel
If remote control panels are not used, any added control panels shall be deleted from the list.
78 Book No.9028195 02
4 Operating instructions 4.21 Test remote interface communication
To delete a connected panel: Select it a panel in the hand side and press the delete (X) button. If a
keyboard is displayed, pres Esc to remove it.
4.20 Set remote interface communication

Follow this instruction to make settings for the remote interface (optional) communication between
the ISCS and PureBallast.

1. Go to page 5.7 Remote interface.
2. Set parameters to match ISCS’s RTU server data according to the information in chapter 4.
Parameters, section 5.7 – Remote interface.
4.21 Test remote interface communication

Follow this instruction to test that the remote interface (optional) communication between
PureBallast’s PLC and the ISCS is correct and functioning.
Test communication
The first test is to see that the two systems communicate.
1. Go to page 4.5 Remote interface 1. Make sure that the system is not in test mode (no
checkmark on the button). If not, press the Test mode button to deactivate it. Make sure that
Local operation is activated. If not, press the Local function button.
2. Check that the heartbeat signal is updated in both systems (06 and 77). Also check that values
are read from the PureBallast system, for example temperature (address 116 and 117).
This will confirm that the systems communicate.
Test values sent from PureBallast to ISCS
Values are entered and displayed in the control system as actual values, but are sent to ISCS using
the binary numeral system. This information is found in group Data to ISCS and Cmd/status to
ISCS on page 4.5 Remote interface 1, and is indicated by a unit (m3, hour, second, kW etc).
Addresses with special conditions
The following addresses does not display correct values in page 4.5:
• 50 Process volume
• 114/124/134 UV reactor temperature for UV reactor 1, 2 and 3
• 115/125/135 LDC water temperature for UV reactor 1, 2 and 3
Book No.9028195 02 79
4.21 Test remote interface communication 4 Operating instructions
• 52 System pressure
• 63 Filter differential pressure
• 64 Filter inlet pressure V201–71 (Hydac filter)
• 65 Filter outlet pressure V201–72 (Hydac filter)
• 66 V201-8 setpoint
• 57058. Current time
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 input field for the address to send simulated information to
the ISCS. Information in decimal form, for example processed volume, is written as actual
values. Information in binary form, for example command status, is written as a bit pattern.
The key for the bit pattern is found in chapter 6. Installation description and drawings, section
System interfaces.
3. Make sure that values and status information is displayed correspondingly in the ISCS.
4. Repeat the simulation for the information you which to test.

Note: Only implemented signals needs to be tested.
Test commands from ISCS to PureBallast
In the ISCS, activate input commands corresponding to the addresses displayed in page 4.5. (Note
that address 06 does not need to be tested; it was tested at the beginning of this procedure.)
1. Activate a command from ISCS, according to the HMI implementation.
2. Make sure that the command is received in page 4.5. Use the directory of addresses to see
that the bit pattern is updated correctly.
3. In the control panel, restore all changed values after the communication test. If not, commands
might be executed involuntarily, when the system is set to online again. Most important is that
address 001 displays ”00000000”.
Test alarms and warnings
Alarms and warnings are tested by simulation in control page 4.5 Remote interface 1 and 4.6
Remote interface 2. 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.
UV reactor alarms/warnings: Each installed UV reactor has a unique address:
80 Book No.9028195 02
4 Operating instructions 4.22 Simulate power request
• UV reactor 1/ LDC 1: Address 910 – 912

• UV reactor 2 / LDC 2: Address 913 – 915
• UV reactor 3 / LDC 3: Address 916 – 918
1. Enter the desired bit pattern in the input 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 input 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.
4.22 Simulate power request

Follow this instruction to test the power management signals if PureBallast is integrated with the
vessel’s power management system. This instruction can also be used in manual mode during
faultfinding.
• This instruction requires login level Advanced operator or higher.

1. Go to page 1.4 Power request. Press the Manual function button.

Result: The control system is set in manual mode, indicated by a green checkmark on the
button.
2. Press the hand button in the Request column for a row with power step for desired number of
UV reactors. For details, see description of page 1.4 – Power request.
3. Press the Request button for the row to simulate power request signal.
Result: Status is updated to “Requested” in the Request column.
4. Wait until the status is updated to “Yes” in the Granted column.
5. Press the hand button in the Status column.
6. Press the Set run button to simulate running signal.

Result: Status is updated to “Running” in the Status column.
7. Press the Set run button to deactivate the simulate running signal.
Book No.9028195 02 81
4.25 Fine tune flow control 4 Operating instructions
4.23 Update control system softwares

Control system softwares must be updated according the Release note for the specific version of
the softwares. The release note contains instructions for updating the softwares and information
about new features, changes in the software etc.
The following is needed:
• A flash card with correct version of the PLC software.

• A USB memory with HMI software. Note that the same version must be used for the HMI
and PLC software (same version number).
• A USB memory with the T15BR firmware.
4.24 Calibrate the control panel’s touch screen
sensibility
Follow this instruction to improve the touch precision on the screen, if it is hard to hit buttons and
icons with precision.
1. Pull out the power cable from the 24V DC port on the rear side of the control panel. And
then reconnect the power cable.
For remote control panels: Use the Power button to turn off, and then turn on the power.
2. Wait for a sandglass to appear and disappear. When it appears again, press a finger on the
screen and hold it there for approximately 20 seconds.
Note: Keep holding the finger on the screen even when the panel turns white with a red
message “Welcome to ...”.
3. Wait for the screen to turn completely white with a message “Tap anywhere on the screen
within 10 seconds”. Release the finger and tap once on the screen.
4. Follow the instructions on the screen.
4.25 Fine tune f ow control

Calibration of flow and presure regulation is performed to fine tune the system so it runs with a
steady and even flow and pressure.
4.25.1 Calibrate pressure controlled regulation

During ballast and deballast operation, the control valve is PID regulated based on input from the
flow transmitter FIT201-1 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 PID regulated based on input from the pressure transmitter
PT201-16 to maintain stable pressure for efficient backflush. Desired pressure is defined in
parameter p304.
82 Book No.9028195 02
4 Operating instructions 4.25 Fine tune flow control
The purpose is to adjust the movement of V201-8 when it changes from flow controlled regulation to
pressure controlled regulation which it does during backflushing of the filter. The first goal is that
the valve travels as fast as possible to a steady position where it creates required pressure (as
defined in parameter p304).
The second goal is to shorten the time from backflush trigger to start of actual backflush. This is
done by shortening the time in p310 (Backflush initial delay) that is done after the movement of
V201-8 has been calibrated.
• This operation requires login level AlfaLaval.

• All components on page 3.1 Trend (15 min) shall be selected for plotting, and FIT201-1 shall be
used for Y axis selection.
This instruction shall be read together with the example after the instruction.
1. Perform a backflush.
2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8.
Before the backflush, the valve shall move as fast as possible to a steady position where it
creates required pressure. If not, parameter p166 shall be adjusted.
3. Adjust parameters, and perform a new backflush.
4. See if the curve has improved. Repeat until satisfactory result has been achieved.
5. See if the time between backflush initiation and backflush can be shortened . If possible, adjust
parameter p310. See parameter p310 in the example below.
Example
In this example, five backflushes are performed. After the first four backflushes, the PID parameters
where changed for pressure regulation to adjust the movement of the control valve V201-8 before
the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated by the movement
of the backflush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated
by the blue line.
1st backflush Parameter p166 is set to 0.30. But it takes too long time for V201-8 to get into
position to create desired pressure (1). The curve slops downwards in a long bend,
which means that it takes time for V201-8 to find correct position.
2nd backflush Parameter p166 was adjusted to 0.6. This made the valve movement much faster
in the beginning, shown by the steep curve at the beginning. But then a more
slow regulation starts, shown by the soft slope (2). This was a change for the
better, but not enough.
3rd backflush Parameter p166 was increased to 1.2 which resulted in a satisfactory valve
movement (3): A fast movement, followed by a minor adjustment. A small
overcompensation can be noted (curve goes too low), that might be adjusted by
decreasing the value to 1.1.
Book No.9028195 02 83
4th backflush During the first backflushes, parameter p310 was set to 60 seconds. The parameter
defines time between a backflush is triggered and it actually starts. But now, when
V201-8 is calibrated, this time can be shortened. Before the fourth backflush
parameter p310 is set to 15 seconds. The shortened time span is indicated by
the braces in the illustration.
5th backflush No parameter was changed. This backflush is only showed to confirm that the
parameter setting is OK and that the curve (5) for V201-8 is basically the same as
for backflush three and four (3 and 4).
3 CalibExample
4.25.2 Calibrate external feed control (optional)

External feed control allows PureBallast to control the flow delivered from the vessel’s ballast water
system by regulating either the ballast water pump via a variable frequency driver (VFD) or a
valve installed before PureBallast. If this optional signal is used to control flow to PureBallast, the
regulation can be finetuned to function as smooth as possible.
When the flow in the system is too high, PureBallast’s control valve V201-8 will close to reduce flow.
If the V201-8 closes more than a parameter set degree, the control system sends a signal requesting
the ballast pump to reduce the speed (and so the flow). When the flow is reduced, V201-8 can open.
Valve V201-8 operates (open/closes) in a range between a parameter set value (p157) and 100 %,
where default is 70 %. Within this range, flow is regulated by V201-8 without cavitation.
• This operation requires login level AlfaLaval.

84 Book No.9028195 02
4 Operating instructions 4.25 Fine tune flow control
This instruction shall be read together with the example after the instruction.
1. Start a ballast process. Wait untill the system is in mode Full ballast. Listen for cavitation
noises at V201-8.
If cavitation, go to step 2. It not, go to step 5.
2. Go to page 5.2 main parameters 2.
3. Increase parameter p157 in steps of 5 % at a time. After each change, wait until the parameter
change take effect (a couple of minutes). Listen for cavitation noises at V201-8. Note: The
effect can not be observed during backflush, since the external feed function is disabled.
4. Stop raising when the noises from cavitation stops.
5. Look at the movement of V201-8. If the movement is continuously changing and the curve is
unstable, parameter p156 must be adjusted. The goal is to get a smooth regulation with long
and steady curves.
6. Increase parameter p156 in steps of 1 second per % at a time. After each change, wait until the
parameter change take effect (a couple of minutes).
7. Stop when the regulation curve flattens out and the trend curve is long and smooth. See
exemple below.
8. Stop the process.
9. Start another ballast operation. Verify settings during startup and process.
10. Perform a manual backflush. Verify settings during and after backflush.
Note: When the backflush is done, V201-8 is closed under 70 % (defined in parameter p157).
The external feed control signal is lowered to request less flow from the pump, so that V201-8
can open. Less flow is needed after the backflush, since the the filter is clean.
11. Stop the process.
12. Start a deballast. Verify settings during startup and process.
Example
In this example, parameter p156 External feed change rate is adjusted to get a stable regulation.
The illustration is taken from page 3.1 Trend (15 min).
Area 1 Parameter p156 was set to 2 s / % when process was started. The curves for
V201-8 (blue) and external feed (black) signal are chasing each other. The reason
is that the request signal changes too fast which makes V201-8 compensate, which
affects the signal in return.
Area 2 Parameter p156 is raised to 6 seconds which makes the request signal change
more slowly, which results in a smooth movement of V201-8 when regulating the
external flow.
Book No.9028195 02 85
3 CalibExampleExtFeed
86 Book No.9028195 02
5 List of logged information
Alarm history and important events are logged in the control system. 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 log files on page 73.
5.1 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 Description GPS

code stamp
70 Operator command, set certified flow to [x] m3/h N
80 Operator command, start stripping is issued N
100 Manual mode set by operator. N
110 Heeling mode set by ISCS. N
120 Heeling mode canceled by ISCS. N
150 Overboard valve opened. Feedback from ISCS. Y
155 Ballast water pump started. Feedback from ISCS. Y
160 Overboard valve closed. Feedback from ISCS. N
165 Ballast water pump stopped. Feedback from ISCS. Y
170 External shutdown issued. (System stop button on control cabinet N

or external system stop button)
190 Standby mode N
210 Ballast Start-up mode N
220 Full Ballast mode Y
230 Pause Ballast N
Book No.9028195 02 87
5.1 Event log 5 List of logged information

code stamp
240 Filter backflush mode N
250 PureBallast is in mode Stop Ballast N
260 Deballast Start-up mode N
270 Full Deballast mode Y
280 Pause Deballast mode N
290 Stop Deballast mode N
300 CIP process started, UVR [x, y, z ...] N

x, y, z ...= units that has been subjected to CIP
310 E-stop N
320 Power tuned on. PureBallast has been powered off for N
[x]days:[y]hrs:[z]min
Time of how long the power has been switched off
330 Amount (m3) of ballast intake treated Y
331 Amount (m3) of ballast intake treated. Time interval according to Y

parameter p161.
340 [X] m3 of ballast discharge treated Y
341 [X] m3 of ballast discharge treated. Time interval according to Y

parameter p162.
350 PureBallast is bypassed. Valve V212-31 open. Y
360 PureBallast bypass discontinued. Valve V212-31 closed. Y
370 Request sent to ISCS: Open overboard valve. N
380 Request sent to ISCS: Close overboard valve. N
390 Request sent to ISCS: Start ballast water pump. N
400 Request sent to ISCS: Stop ballast water pump. N
410 Power requested from ISCS. N
420 Power granted by ISCS. N
430 Power used for process. N
450 PureBallast shut down and/or start blocked due to alarm(s). Y
460 PureBallast is bypassed. Additional (external) bypass valve 1 open. Y
88 Book No.9028195 02
5 List of logged information 5.1 Event log

code stamp
470 PureBallast bypass discontinued. Additional (external) bypass Y

valve 1 closed.

valve 2 closed.

valve 3 closed.
515 PureBallast is bypassed. Additional (external) bypass valve opened Y

from ISCS. Valve information from ISCS:
520 Low UV intensity in UVR 1. Y
640 UV intensity in UVR 1: [X] W/m2 Y
701 UVR 1 UV lamp time reset N
Book No.9028195 02 89

code stamp
760 Power setpoint (%) for UVR 1: Y
800 Flow higer than certified flow. Y
801 Flow restored to certified flow. Y
805 System started in IMO mode Y
806 System started in mode USCG 3d mode Y
807 System started in mode USCG 0d mode Y
808 System running in IMO BW/MW mode: X PSU Y
809 System running in IMO FW mode: X PSU Y
810 UVR 1 was not CIP cleaned within required time. Y
811 CIP cleaning completed for UVR 1. Y
90 Book No.9028195 02
5 List of logged information 5.1 Event log

code stamp
5010 Log box: V01 Closed position change: [value]. 1=Closed. 0=Not N
closed.
5011 Log box: V01 Open position change: [value]. 1=Open. 0=Not open. N
closed.
closed.
etc until 5181 N
5190 Log box: Pump 01 operation change: [value]. 1=Started. N

0=Stopped.
5200 Log box: Pump 02 operation change: [value]. 1=Started. N

0=Stopped.
etc until 5220 N
Book No.9028195 02 91
6 Detailed process description
This section gives a detailed description of the PureBallast processes. The processes are divided
into three main processes, with sub processes, with indications of automatic and manually initiated
steps.
All steps are not valid for all installations.
6.1 Standby mode

Standby mode is the starting point of PureBallast. Standby mode is active at system start-up or
when no other process is active. From Standby mode, the following processes and sub processes
can be started.
• Ballast
• Deballast
• CIP
• Deactivate system
• Change flow
• Manual mode.
Book No.9028195 02 93
6.2 Ballast process 6 Detailed process description
6.2 Ballast process

The ballast process and sub processes are illustrated and described below. Note that the process
can be stopped at any time.
3 BallastProcess
6.2.1 Ballast start-up

Purpose: To warm UV lamps under controlled conditions before water treatment.
1. Operator starts the process from the control system.
2. Request from control system to open overboard (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. Overboard valve opened by operator and confirmed in control system. (Handled automatic, if
external component signal is enabled.)
Component activities:
• - Start P401-1 (LDC cooling water pump) (if used)

- Open V403-35 (cooling water inlet)
- Open V401-51 (LDC cooling water inlet)
- Open V201-32 (filter outlet)
• Start P403-1 (UVR cooling water pump) (if used).
4. Power management
Automatic power request from PureBallast to vessel’s power management system (if
integrated).
94 Book No.9028195 02
6 Detailed process description 6.2 Ballast process
5. UV lamp warming
• Open V404-36 (UV reactor outlet, cooling water)

• Open V201-19 (reactor inlet).
6. Cooling water fills the UV reactors. When filled, indicated by LS201-29:
• Start UV lamps (100 %). If all lamps are not lit within p212, process is stopped.
• Start counter: UV lamp runtime.
• Start LDC fan.
• Set V201-8 (control valve) to 50 %.
7. Time p210 after all lamps are lit: Request from control system to start ballast water pump
(outside PureBallast system). (Handled automatic, if external component signal is enabled.)
8. Ballast water pump started by operator and confirmed in control system. If not confirmed
within 20 seconds, lamp power is reduced to 50 %. If not confirmed within p141 (including the
20 seconds), process is stopped.
9. Open V201-3 (filter inlet).
6.2.2 Full ballast

Purpose: To treat ballast water.
1. Component activities:
• - Open V201-20 (reactor outlet)

- Start counter: Accumulated water and CIP required.
- Wait for flow p116 to be established. If not established, process is stopped.
- Stop P403-1 (UVR cooling water pump) (if used)
• - Close 403-35 (cooling water inlet)
- Close V404-36 (UV reactor outlet, cooling water)
- When flow is established: Start automatic control of control valve (V201-8) based on input
from the flow meter and input from UV sensor (QT201–50).
• USCG mode: Start flow control based on input from UV sensor (QT201–50).
• After 2 minutes in full ballast: Start power optimization based on input from UV sensor
(QT201–50).
6.2.3 Filter backf ush

Purpose: To clean the filter. This sub process is either triggered by too high differential pressure
or by time set interval. It can also be started manually. It is normally repeated several times
during a ballast process.
Book No.9028195 02 95
6.2 Ballast process 6 Detailed process description
1. Filter backflush triggered by high differential pressure over the filter.

• Start automatic control of control valve (V201-8) based on input from the pressure transmitter
• Start filter motor M709-43.
• Start backflush pump P309–1 (optional)
• After p319 seconds, open V309-1
2. Filter backflush is performed for p308 seconds.
• Stop M709-43
• Close V309-1
• Stop backflush pump P309–1 (optional)
• Start automatic control of control valve (V201-8) based on input from the flow meter.
3. Differential pressure check. If necessary, the process is repeated.
6.2.4 Pause ballast (Heeling mode)

Purpose: To pause the ballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
1. Operator pause the ballast process manually. Pause can also be initiated by an external signal,
for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
2. Set V201-8 (control valve) to parameter (p113) set opening percent.
3. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
4. BW pump stopped by operator and confirmed in control system. Component activities:
• - Open V404-36 (UV reactor outlet, cooling water) on running UV reactors

- Stop counter: Accumulated water
• Start P403-1 (UVR cooling water pump) (if used)
- Close V201-3 (filter inlet)
- Close V201-20 (reactor outlet) on running UV reactors
- UV lamps dimmed to 50 %
• Close V201-8 (control valve).
5. System in pause mode
6.
Resume ballasting
Operator resumes the ballast process manually.

• UV lamps are lit at 100 %
• Open V201-20 (reactor outlet) on running UV reactors.
96 Book No.9028195 02
6 Detailed process description 6.2 Ballast process
7. Request from control system to start ballast water pump” (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8. BW pump started by operator and confirmed in control system. (Handled automatic, if external
component signal is enabled.)
• Open 201-3 (filter inlet)

9. Component activities when minimum process flow established, indicated by FIT201-1:
• - Start counter: Accumulated water.

- Close V404-36 (UV reactor outlet, cooling water) on running UV reactors
- Start automatic control of control valve (V201-8) based on input from the flow meter.
- After 2 minutes in full ballast: Start power optimization based on input from UV sensor
QT201–50.
6.2.5 Stop ballast

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

• Stop P401-1 (LDC cooling water pump) (if used)

• Stop P403-1 (UVR cooling water pump) (if used), only needed if stop from pause mode
• Close V403-35 (cooling water inlet), only needed if stop from pause mode
• Run backflush process. (See section Filter backflush in Ballast process. )
• Close V401–51 LDC (LDC cooling water inlet)
• Set V201-8 (control valve) to parameter set opening percent
• Close V201-3 (main inlet valve) Wait for feed back “closed” or max time 15 seconds.
• Close V201-8 (control valve) completely.
• UV lamps are lit at 100 % for 10 seconds, then switched off.
• Start counter UV lamp cooling time. A new process can only be started after UV lamps have
been cooled down for 5 minutes.
• Stop counter: UV lamp runtime
• - Close V201-19 (reactor inlet)
- Close V201-20 (reactor outlet)
2. Request from control system stop ballast water pump (outside PureBallast system). (Handled
3. BW pump stopped by operator and confirmed in control system.
• Automatic withdrawal of power allocation (if integrated)

• Close V201-32
• Stop counter: Accumulated water.
4. Request from control system to close overboard. (Handled automatic, if external component
signal is enabled.)
Book No.9028195 02 97
6.3 Deballast process 6 Detailed process description
5. Popup reminder “Start CIP”. Option to start CIP or delay.

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

1. Operator start the deballast process manually.

2. Request from control system to open overboard valve (outside PureBallast system). (Handled
3. Overboard valve opened by operator and confirmed in control system.

4. Power management
Automatic power request from PureBallast to vessel’s power management system (if integrated).
98 Book No.9028195 02
6 Detailed process description 6.3 Deballast process
5. UV lamp warming
Component activities when power has been granted:

6. Water fills the UV reactors.
7. Component activities, when UV reactors are filled, indicated by LS201-29:
• Start LDC fan.
8. Time p210 after all lamps are lit: Request from control system to start ballast water pump
(outside PureBallast system). (Handled automatic, if external component signal is enabled.)
9. BW pump started by operator and confirmed in control system. If not confirmed within 20
seconds, lamp power is reduced to 50 %. If not confirmed within p141 (including the 20
seconds), process is stopped.
• Open V201-9 (main inlet valve).
6.3.2 Full deballast

Purpose: To treat deballast water.
• - Open V201-20 (reactor outlet)

- Start counter: Accumulated water and CIP required.
- When flow is established: Start automatic control of control valve (V201-8) based on input
from the flow meter and input from UV sensor (QT201–50).
• USCG mode: Start flow control based on input from UV sensor (QT201–50).
• After 2 minutes in full ballast: Start power optimization based on input from UV sensor
(QT201–50).
6.3.3 Pause deballast (Heeling)

Purpose: To pause the deballast process temporarily. During pause, the lamps are cooled with
cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).
Book No.9028195 02 99
6.3 Deballast process 6 Detailed process description
1. Operator pause the deballast process manually. Pause can also be initiated by an external
signal, for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.

• Open V403-35 (cooling water inlet)
• - Start P403-1 (UVR cooling water pump) (if used)
- Open V404-36 (UV reactor outlet, cooling water) on running UV reactors.
2. Request from control system to stop ballast water pump (outside the PureBallast system
control). (Handled automatic, if external component signal is enabled.)
• - Stop counter: Accumulated water

- Close V201-9 (main inlet valve)
- Close V201-8 (control valve)
- UV lamps dimmed to 50 %.
4. Resume deballasting
Operator resume the deballast process manually.

5. Request from control system to start ballast water pump” (outside PureBallast system).
6. BW pump started by operator and confirmed in control system.
• Open V201-9 (main inlet valve)


Stop P403-1 (UVR cooling water pump) (if used)
- Close 404-36 (UV reactor outlet, cooling water)
- After 2 minutes in full deballast: Start power optimization based on input from UV sensor
QT201–50.
6.3.4 Stop deballast

Purpose: To stop the deballast process.
100 Book No.9028195 02

6 Detailed process description 6.4 Stripping process
1. Operator stops the ballast process manually.


2. Request from control system stop ballast water pump (outside PureBallast system). (Handled
3. BW pump stopped by operator and confirmed in control system.

signal is enabled.)
6.4 Stripping process
The stripping process and sub processes are illustrated and described below. Number of UV
reactors used during stripping is defined in p171. Pump used can either be a dedicated stripping
pump or the ballast water pump. Note that the process can be stopped at any time.
Book No.9028195 02 101

6.4 Stripping process 6 Detailed process description
3 StrippingProcess
6.4.1 Stripping start-up

1. Operator start the stripping process manually.


4. Power management
Automatic power request from PureBallast to vessel’s power management system (if integrated).
102 Book No.9028195 02

5. UV lamp warming
Component activities when power has been granted:

6. Water fills the UV reactors.
• Start LDC fan.
• Open V201-20 (reactor outlet)
8. Time p210 after all lamps are lit: Request from control system to start stripping pump (outside
PureBallast system). (Handled automatic, if external component signal is enabled.)
9. Stripping pump started by operator and confirmed in control system. If not confirmed within
20 seconds, lamp power is reduced to 50 %. If not confirmed within p141 (including the
20 seconds), process is stopped.
• Open V201-9 (main inlet valve).
6.4.2 Full stripping

Purpose: To treat stripping water.
1. Component activities when minimum process flow established (p172), indicated by FIT201-1:
• - Start counter: Accumulated water and CIP required.

- When flow is established: Start automatic control of control valve (V201-8) based on
input from the flow meter.
6.4.2.1 Change f ow - Decrease f ow
Purpose: To decrease flow during operation.
1. Operator adjusts the certified flow manually from the control system.
Book No.9028195 02 103

6.4 Stripping process 6 Detailed process description
• Automatic pressure and flow adjustment.

• One or more UV reactors are switched of
• Component activities for switched of UV reactors:
– UV lamps are lit at 100 % for 10 seconds, then switched off.
– Start counter UV lamp cooling time. A new process can only be started after UV lamps
have been cooled down for 5 minutes.
– Stop counter: UV lamp runtime
– Close V201-19 (reactor inlet)
– Close V201-20 (reactor outlet)
– Automatic power request adjustment (if integrated).
6.4.3 Pause stripping

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


• Open V403-35 (cooling water inlet)
• - Start P403-1 (UVR cooling water pump) (if used)
- Open V404-36 (UV reactor outlet, cooling water) on running UV reactors.
2. Request from control system to stop stripping pump (outside the PureBallast system control).
• - Stop counter: Accumulated water

- Close V201-9 (main inlet valve)
- Close V201-8 (control valve)
- UV lamps dimmed to 50 %.
4. Resume stripping
Operator resume the stripping process manually.

5. Request from control system to start stripping pump” (outside PureBallast system). (Handled
104 Book No.9028195 02

6. Stripping pump started by operator and confirmed in control system.

• Open V201-9 (main inlet valve)


Stop P403-1 (UVR cooling water pump) (if used)
- Close 404-36 (UVR reactor outlet, cooling water)
- After 2 minutes in full stripping: Start power optimization based on input from UV sensor
QT201–50.
6.4.4 Stop stripping

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


2. Request from control system stop stripping pump (outside PureBallast system). (Handled
3. Stripping pump stopped by operator and confirmed in control system.

• Close V201-8
signal is enabled.)
Book No.9028195 02 105

6.5 CIP process 6 Detailed process description
6.5 CIP process

The CIP process is run to remove seawater scaling from the UV reactor after ballast and deballast.
The process is performed for used UV reactor in sequence. The process can start directly after
ballast or deballast process, or be delayed. A CIP process is started manually according to
instruction CIP clean UVR after ballast / debalalst on page 65. Note that the process can be
stopped at any time.
3 CIPprocess
6.5.1 Start CIP

1. Operator starts the CIP process manually.
Note: If CIP process is started after a process the CIP process will start after 2 minutes, when
the UV lamps have been cooled.
106 Book No.9028195 02

6 Detailed process description 6.5 CIP process
6.5.2 Drain ballast water

1.
Component activities (in no specific order):
• - Open V460-2 (CIP, drain valve)

- Open V321–2 (UV reactor, upper CIP return valve)
- Open V320–4 (UV reactor, lower CIP return valve)
- Open V571-1 (CIP, deaeration valve)
- Start P321-5 (CIP, water pump)
2. Component activities, when UV reactors are empty, indicated by LS201-29:
• - Stop P321-5
- Close V571-1 (CIP, deaeration valve)
- Close V460-2 (CIP, drain valve)
- Close V321–2 (UV reactor, upper CIP return valve)
- Close V320–4 (UV reactor, lower CIP return valve).
6.5.3 Fresh water f lling

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

- Open V310-6 (CIP, UV reactor fresh water filling)
- Open V320–4 (UV reactor, lower CIP return valve).
• - Close V310-6 (CIP, UV reactor fresh water filling)

- Close V320–4 (UV reactor, lower CIP return valve).
6.5.4 Fresh water draining

Purpose: to drain UV reactor with technical water/ potable water.
• - Open V460-2 (CIP, drain valve)

- Open V571-1 (CIP, deaeration valve)
- Open V320–4 (UV reactor, lower CIP return valve)
- Start P321-5 (CIP, water pump).
Book No.9028195 02 107

6.5 CIP process 6 Detailed process description
2. Component activities when UV reactor is empty, indicated by LS201-29 + drain time (p200):
• - Stop P321-5 (CIP, water pump)

- Close V460-2 (CIP, drain valve)
- Close V320–4 (UV reactor, lower CIP return valve)
6.5.5 CIP cleaning

• - Open V320–2 (CIP outlet to UV reactor)

- Open V320-4 (UV reactor, lower CIP return valve)
- Open V321-2 (UV reactor, upper CIP return valve)
- Open 321–4
- Start P320-1 (CIP, liquid pump).
2. When UV reactors are filled, indicated by LS201-29, CIP liquid is circulated for 15 minutes.
3. Component activities after finished CIP process .
• - Stop P320-1 (CIP, liquid pump)

- Close V320-2 (CIP outlet to UV reactor)
- Close V320-4 (UV reactor, lower CIP return valve)
- Status update for the UV reactor: CIP completed.
6.5.6 CIP draining

• Open V321-4 (CIP, return valve)

Open V321–1 (CIP, outlet valve)
- Open V320-4 (UV reactor, lower CIP return valve)
- Start P321-5 (CIP, water pump).
2. Component activities, when UV reactor is empty, indicated by LS201-29 + drain time (p200):
• - Stop P321-5 (CIP, water pump)

- Close V321-2 (UV reactor, upper CIP return valve)
- Close V 321-4 (CIP, return valve)
- Close V321-1 (CIP, outlet valve).
6.5.7 Fresh water f lling

1.
• - Open V571-1 (CIP, deaeration valve)

- Open V310-6 (CIP, UV reactor fresh water filling)
- Open V320-4 (UV reactor, lower CIP return valve).
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6 Detailed process description 6.6 Manual mode
2. Component activities, when UV reactor is filled, indicated by LS201-29:
• Close V310-6 (CIP, UV reactor fresh water filling)

• Close V571-1 (CIP, deaeration valve)
- Close V321-2 (UV reactor, upper CIP return valve)
- Close V320-4 (UV reactor, lower CIP return valve).
6.5.8 Repeat
When CIP process is done for the first UV reactor, the remaining UV reactors with status CIP
required are processed in the same way.
6.5.9 Filter preservation

Only performed if ballast has been performed since last filter preservation.
1.
Component activities when all required UV reactors are processed:
• - Open V310-1
- Open V309-1
- Start M709-43.
2. Component activities after the filter is filled:
• - Stop M709-43
- Close V309-1
- Close V310-1.
3. Request from control system to close overboard valve (outside PureBallast system). (Handled
4. Overboard valve closed by operator and confirmed in control system.
6.6 Manual mode

PureBallast can be set in manual mode, which enables the operator to operate components
manually and to set digital outputs.
The following can be performed in manual mode:
• Operate components from control panel.

• Operate and simulate power management.
The following limitations exist for manual mode:
• Requires login level 2. The Manual mode button is only displayed for login level 2.
• Flow in pipes is not indicated in flow chart.
• Can only be activate from standby mode.
• No automatic processes can be run.
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6.6 Manual mode 6 Detailed process description
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 and Operate UV lamps manually.
110 Book No.9028195 02

1 Quick guide to PureBallast
operations
1.1 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 UVR
• Basic alarm handling
• Save log file and parameters to USB memory
• Flow must have been selected before a process can be started. If the Auto button is selected
(checkmark) maximum flow is automatically selected, and flow can only be changed during
process according to instruction Change ballast / deballast / stripping flow. If parameter the
Auto button is deselected (no checkmark) last selected flow is used. Otherwise, flow is selected
on page 1.1 Overview or 1.2 UVR and flow selection.
1.2 Ballast, deballast and stripping
1. Go to page 1.1 Overview
2. Press the Ballast, Deballast or Strip function button.

Comment: If the button is not blue, check that flow or UVR reactors have been selected.
3. Wait for the message “Open valves ...”. Open relevant valves and then press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
4. Wait for the message “Confirm ballast pump started”. Start the pump and then press the button
in the popup to confirm the action. (The popup is not displayed if the component feedback is
5. When desired amount of water has been processed, press the function button Stop to end
the process.
6. Wait for the message “Close valves ...” and “Stop ballast water pump”. Handle accordingly.
(The popups are not displayed if the component feedback is integrated with the control system.)
1.4 CIP clean UVR 1 Quick guide to PureBallast operations
7. Wait for the ”Start CIP” popup. Choose to start a CIP or wait maximum the time stated in
the popup.
CIPpop
1.3 Alarm handling

Follow this instruction to attend to alarms and to acknowledge them afterwards. For descriptions of
alarms and trouble shooting, see chapter 5. Alarms and fault finding.
An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.
• Never reset an alarm without first finding and attending to the problem.
1. Go to page 2.1 Alarm list.
2. Select an alarm by pressing the alarm row.
3. If the process have stopped: Take action to eliminate what has caused the alarm.
4. If the alarm is caused by a faulty UVR module, the ballast/deballast process has to be restarted
with another UVR according to the Perform ballast instruction.
5. If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
Press the Ack selected or Ack all button after the problem has been dealt with.
1.4 CIP clean UVR

• The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
• 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 Quick guide to PureBallast operations 1.5 Export control system log files
2. Press the function button CIP.
3. Wait for the message “Open valves ...”. Open relevant valves and then press button in the
popup to confirm the action.
Result: The automatic CIP cycle starts. The CIP cycle takes about 25 minutes per UVR.
4. Wait for the message “Confirm overboard valve closed”. Close the valve and then press button
in the popup to confirm the action.
1.5 Export control system log f les

Follow this instruction to copy control system information as text files to a USB memory.
• Required USB memory.

2. Press the Export button in page section Export log f les.

Result: Popup Export PLC events is displayed.
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:
• Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is today’s date.
• Select the Specify time interval box, and enter desired interval in the Start and End fields.
5. Press one of the following function buttons: Events, Cert events or Alarms.
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. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been downloaded. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choice contains a CSV file.
7. Prtess Close and remove the USB memory

Chapter: 4. Parameters
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00
Telefax: +46 8 530 310 40

Laval Tumba AB.
Contents
1 Introduction 5
2 Control system parameters 7

2.1 Introduction to parameters and
parameter settings 7
2.2 Page 5.1 – Main parameters 1 9
2.3 Page 5.2 – Main parameters 2 12
2.4 Page 5.3 – UVR parameters 18
2.5 Page 5.4 – Filter parameters 21
2.6 Page 5.5 – CIP parameters 25
2.7 Page 5.6 – Installation parameters 26
3 Lamp power supply (LPS)

parameters 33
3.1 DIP switch settings 33
3.2 Change DIP switch setting 34
4 Fuse settings for f lter motor and

installed (optional) pump motors 37
5 Flow transmitter parameters 39
3
1 Introduction
This chapter contains information about parameters in the control system and parameter controlled
compoents. It covers:
• Parameter page descriptions.

• Parameter lists including information about setting range, default values etc.
Book No.9028195 02 5
1 Introduction
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 V3.1.15.
• Parameters are roughly sorted by area, for example UV reactor, filter and remote interface,
but the sorting is not strict.
2.1 Introduction to parameters and parameter settings

All parameters are checked and adjusted at first start up during commissioning.
How the parameters are explained
NOTE
• Parameters shall only 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 three categories according to tab le below:
Parameter must be considered during commissioning. The parameter should
match the conditions of the installed system. After that, the parameter should
4 Must
normally not be changed.
Parameter should never be changed. Parameter only exist to allow advanced
faultfinding by Alfa Laval.
4 MustNot
No icon Parameter should normally be left alone. If there are specific reasons, the
parameter may be changed.
p000 Parameters in bold can only be changed by login level AlfaLaval. Parameters
in normal text can be changed by login level Advanced operator.
Follow this instruction to set parameters:
Book No.9028195 02 7
2.1 Introduction to parameters and parameter 2 Control system parameters
settings
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.
4 ParaIntervalSet
Press the ≤ ≥ sign to display range. Entered parameter value must be within defined setting
range.
4 MinMax
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.
8 Book No.9028195 02
2 Control system parameters 2.2 Page 5.1 – Main parameters 1
2.2 Page 5.1 – Main parameters 1

This section describes the main system parameters set in page 5.1 Main parameters 1.
4 5.1 USCG
ID Parameter De- Min- Unit Description

fault Max
value
p100 High pressure, 7.00 1–10 bar Setpoint for shut down due to high
shutdown trigger pressure at PT201-16. Default value
(PT201-16) shall be used for standard system.
4 Must Max. working pressure for standard

system: 6 bar.
Max. working pressure for high pressure

system:
9 bar.
p101 High pressure, 6.00 0–10 bar Setpoint for warning due to high pressure
warning trigger at PT201-16. Default value shall be used
(PT201-16) for standard system.
4 Must Max. working pressure: See parameter

p100.
Book No.9028195 02 9
2.2 Page 5.1 – Main parameters 1 2 Control system parameters

fault Max
value
p103 Low pressure, 0.1 -1–2 bar Setpoint for warning due to low pressure
warning trigger at PT201-16.
(PT201–16)
p104 Pressure range 0 to N/A bar Defines range for pressure transmitter
for PT201–16 10 PT201–16. Set according to range
printed on the transmitter.
4 Must Alternatives:
0 to 10
-1 to 15
p111 Undershoot 5 0–80 % Safety margin between defined max

certified flow flow and actual max flow to avoid
unnecessary shut down.
p113 Min % open for 20 10–100 % During ballast and deballast, valve
V201-8 V201–8 handles the automatic pressure
and flow control.
This parameter defines minimum

opening, to secure an even flow without
interruptions.
p116 Low flow shut 10 10–90 % Set point for shut down due to low flow,
down limit defined as percent of UVR capacity.
(FIT201-1)
4 MustNot
p117 Max delay of CIP 6 0–24 hrs Define max delay, in hours, before a CIP
cycle, hours process must be performed after ballast
or deballast.
4 MustNot
p118 Max delay of CIP 1 0–30 day Define max delay, in days, before a CIP
cycle, days process must be performed after ballast
or deballast.
4 MustNot
p119 Valve travelling 5 1–10 sec Maximum time for V201–8 to go from
time for 201-8 opened to closed, and vice versa, before
a warning is issued.
10 Book No.9028195 02

fault Max
value
p120 Flow PID 0.30 0.00 N/A Defines proportional gain (Pf) value used
proportional gain – for PID regulation of V201–8 during
10.00 ballast and deballast.
4 Must Normal value: 0.1 – 1.5.
The PID regulation during ballast and

deballast is based on input from flow
transmitter FIT201–1.
p121 Flow PID integral 7.00 0–100 sec Defines integral time (If) value used for
time PID regulation of V201–8 during ballast
and deballast.
4 Must Normal value: 5 – 12.
For details, see p120.
p122 Flow PID 0.0 0.0–100.0N/A Defines derivate gain (Df) value used for
derivative gain PID regulation of V201–8 during ballast
and deballast.
4 MustNot For details, see p120.
p138 Timeout: Time 5 1–30 min Defines maximum time a ballast and
in Pause before deballast process can be manually
going to Stop paused. After defined time, the process
is stopped.
p140 Timeout: Request 5 1–30 min Time the control system will wait for
"Open overboard confirmation signal from ISCS, hard
valve" wire or manually in popup before
displaying message that operation was
not performed.
p141 Timeout: Request 1 1–3 min Time the control system will wait for
"Start BW confirmation signal from ISCS, hard wire
pump/strip pump" or manually in popup. After that the
process is stopped.
The parameter is used for both BW pump

during ballast/deballast and for stripping
pump during stripping.
p143 Timeout: Power 60 1–300 sec Time the control system will wait for
granted signal not confirmation signal from ISCS that the
received operation was performed.
Only used if parameter p127 is set to

Activated (Hardwire ranged or fixed).
Book No.9028195 02 11
2.3 Page 5.2 – Main parameters 2

This section describes the main system parameters set in page 5.2 Main parameters 2.
4 5.2 USCG

fault Max
value
p127 Power Not N/A Drop Defines if power management is used.

management used list
Alternatives:
4 Must • Not used

• Hardwire ranged
• Hardwire fixed
• Remote interface (requires that p132
is activated)
p128 Max time 60 15–240 Sec Define max delay before the system
communication shuts down after communication is
loss PLC/remote lost between the PLC and the remote
interface interface (optional). The value must be
greater than the heartbeat signal interval
defined in the ISCS.
For further information see Remote

interface implementation guide.
12 Book No.9028195 02

fault Max
value
p129 Booster pump Not N/A Drop Defines if an LDC cooling water pump
(P401-1) for LDC used list or closed cooling unit is used to create
cooling water sufficient cooling water flow to the LDC.
– Not used.
– External: Pump started by signal
from PureBallast control cabinet: Power
supply with over current protection
relay and contactors and are handled
externally.
– Internal: Pump completely controlled
from PureBallast control cabinet:
Start signal and power supply with
over current protection relays and
contactors from control cabinet. It is still
possible to connect pumps according to
configuration 1.
Note: In internal mode, external signal

will also be activated.
Note: Internal is only displayed for

control cabinets of configuration 2. See
control system page 4.1, field Control
cabinet configuration.
p130 Booster pump Not N/A Drop Defines if an UVR cooling water pump
(P403-1) for used list is used to create sufficient cooling water
reactor cooling flow to the UV reactor.
water
– Not used.
– External: Pump started by signal
from PureBallast control cabinet: Power
supply with over current protection
relay and contactors and are handled
externally.
from PureBallast control cabinet:
Start signal and power supply with
over current protection relays and
contactors from control cabinet. It is still
possible to connect pumps according to
configuration 1.
Note: In internal mode, external signal

will also be activated.
Note: Internal is only displayed for

control cabinets of configuration 2. See
Book No.9028195 02 13

fault Max
value
control system page 4.1, field Control
cabinet configuration.
p132 Remote interface Not N/A Drop Defines if remote interface (optional) is
via modubus used list used and connected via modbus.
If connected, the Local and Remote

4 Must buttons are visible in the control panel.
They are used to choose if operation
shall be done from the remote interface
or a control panel.
Alternatives: Activated or Not used.
p135 External system Not N/A Drop Defines if an external system stop button
stop used list (or signal) is installed.
4 Must Purpose: Ongoing process is stopped

and valves are returned to starting
position as fast as possible.
p137 Hide Pause Acti- N/A Drop Defines if the Pause button is visible or
button vated list hidden in the control system. If activated,
the button is hidden.
4 Must Alternatives: Activated or Not used.
p155 External feed min 50 50 – % Defines lowest value PureBallast can

setpoint 100 request from external feed. Only valid
if PureBallast is contolling ballast water
flow by sending signals to vessels ballast
water pump or throttle valve before
PureBallast.
If external feed controls a ballast water

pump, PureBallast will never request
it to run on a lower speed than the
percentage set in this parameter. If a
valve is controlled, the parameter defines
percent open.
The parameter also defines starting point

for flow regulation when a process is
started, to ensure a smooth start with
a gradually increased flow until desired
value is reached.
Default value should normally be used.
14 Book No.9028195 02

fault Max
value
p156 External feed 5 2 – 30 s / Defines how many seconds it takes to

change rate % change the external feed signal 1 %.
Note: It might take a little longer for the

4 Must actual change of the pump or the valve
to adjust the flow.
p157 External feed 70 50 – % Defines when external feed control is

V201–8 low 90 activated, based on V201-8.
trigger limit
PureBallast will start to request reduced
4 Must flow when V201-8 closes to reach this
degree of percent open.
p160 GPS time Acti- N/A Drop Only valid if RMC protocol is used for
synchronization vated list GPS integration.
via RMC-protocol
If activated, time and date in the control
system is retrieved from vessel’s GPS.
If not activated, time and date must be

set in control system page 4.1. System
info.
p161 Time interval for 1.0 0.1 – Min. Time interval to update the amount (m3)
log event 331 60.0 of ballast water treated in log file.
p162 Time interval for 1.0 0.1 – Min. Time interval to update the amount (m3)
log event 341 60.0 of deballast water treated in log file.
p163 Additional bypass Not N/A Drop Defines if an additional bypass valve is
signal 1 used list used. The signal gives information if the
valve is opened during process, so that
PureBallast is bypassed.
4 Must
p164 Additional bypass Not N/A Drop Defines if a second additional bypass
signal 2 used list valve is used. The signal gives
information if the valve is opened during
process, so that PureBallast is bypassed.
4 Must
p165 Additional bypass Not N/A Drop Defines if a third additional bypass valve
signal 3 used list is used. The signal gives information if
the valve is opened during process, so
that PureBallast is bypassed.
4 Must
Book No.9028195 02 15

fault Max
value
p166 Pressure PID 0.60 0.00 – N/A Defines proportional gain (Pf) value used
proportional gain 10.00 for PID regulation of V201–8 during
backflush.
4 Must The PID regulation during backflush is

based on input from pressure transmitter
PT201-27.
Normal value: 0.1 – 1.5.
p167 Pressure PID 7.0 0.0 – sec Defines integral time (If) value used
integral time 100.0 for PID regulation of V201–8 during
backflush.
4 Must This parameter shall normally not be

changed.
Normal value: 5 – 12.
p168 Pressure PID 0.0 0.0 – N/A Defines derivate gain (Df) value used
derivate gain 100.0 for PID regulation of V201–8 during
backflush.
4 MustNot
p170 Stripping enabled Not N/A Drop Defines if stripping is used.

used list
Purpose: Enables stripping to be used
with stripping events written to event log.
4 Must Possible to connect a stripping pump via
hard wire or remote interface to be used.

p171 No. UV reactors 1 Min: 1 No. Defines how many UV reactors to be
to use when used for stripping process.
stripping Max:
p106
4 Must
p172 Minimum flow 10 7–90 % Set point for shut down due to low flow,
when stripping defined as percent of certified flow.
(FIT201–1)
4 MustNot
16 Book No.9028195 02

fault Max
value
p173 Stripping certified Not N/A Drop Defines maximum flow during stripping.
for full flow used list
If Activated: Max flow during stripping
is 1000 m3/h per UVR used (which is
4 Must defined in parameter p171).
Activation criteria: Should be activated if

the system is installed in accordance with
DNV GL certificate TAP0000010 rev. 0
and/or maximum stripping flow has been
accepted by the vessel’s flag state.
If Not used: Max flow (m3/h) during

stripping is limited to333. “Not used
should be chosen if activation criterias
are not met.
Book No.9028195 02 17
2.4 Page 5.3 – UVR parameters 2 Control system parameters
2.4 Page 5.3 – UVR parameters

This section describes parameters controlling the UV reactor set in page 5.3 UVR parameters.
4 5.3 USCG
ID Parameter De- Min- Unit Comment

fault Max
value
p200 Timeout: UV 2 1–10 min Time the control system will wait for
reactor draining confirmation that an UV reactor is
drained before an alarm is issued.
Recommended setting: Approximately 1
4 Must minute more than actual drain time.
p201 Timeout: Reactor 2 1–10 min Time the control system will wait for
cooling water confirmation that cooling water has filled
(LS201-29) the UV reactor before an alarm is issued.
4 Must
p202 High temp, 60 10–100 ºC Setpoint for high water temperature

alarm trigger alarm, indicated by temperature
(TT201-33) transmitter in UV reactor.
4 MustNot
p204 Low temp, -2 -5–40 ºC Setpoint for low water temperature alarm,
alarm trigger indicated by temperature transmitter in
(TT201-33) the UV reactor.
4 MustNot
18 Book No.9028195 02
2 Control system parameters 2.4 Page 5.3 – UVR parameters

fault Max
value
p206 Alarm delay for 5 0–10 sec Delay before alarm is issued after
sensor TT201-33 setpoint temperature (p202 and p204) is
reached.
p208 Timeout: CIP 5 1–15 min Setpoint for max time to fill an UV reactor
fluid fill-up time with CIP liquid during CIP process before
UV reactor an alarm is issued.
p210 UV lamp warm-up 90 0–90 sec Warm up time for UV lamps before full
time ballast, deballast or stripping starts.
4 MustNot
p211 UV lamp cooling 300 180–600 sec Cooling time for UV lamps after ballast
time or deballast.
4 MustNot
p212 Timeout: UV 70 10–70 sec Time the control system will wait for
lamp ignition confirmation signal that UV lamps are
ignited. If no lamps are ignited or if
less lamps than set in parameter p213
4 MustNot are ignited, the UV reactor will be
automatically stopped.
p214 High temp, 45 20–100 ºC Incoming cooling water temperature

warning trigger warning, indicated by temperature
in LDC (TT401-1) transmitter in LDC.
4 MustNot
p215 Alarm delay for 5 0–10 sec Delay before shutdown when there is no
LS201-29 water in an UV reactor, indicated by level
switch in UV reactor (LS201-29).
4 MustNot
p216 Timeout: Fluid 5 2–10 min Setpoint for max time to fill an UV reactor
fill-up time UV with technical water / potable water
reactor during CIP process before an alarm is
issued.
p230 Cabinet 2 0.5–5.0 °C Accepted temperature change without

temperature effect on the fan.
hysteresis
(TT401-2)
4 MustNot
Book No.9028195 02 19
2.4 Page 5.3 – UVR parameters 2 Control system parameters

fault Max
value
p231 Cabinet 40.0 20.0 – °C Setpoint for LDC cooling fan regulation.
temperature 60.0 When the temperature is below setpoint,
low threshold the fan is running at 30 % of full effect.
(TT401-2)
4 MustNot At setpoint the fan effect is increased
proportional to temperature from 30 % up
to 100 % at temperature set in p232.
p232 Cabinet 45.0 20.0 – °C Setpoint for running the LDC cooling fan
temperature 60.0 at 100 %.
high threshold
(TT401-2)
4 MustNot
p234 UV control 0.10 0.00 – N/A Defines proportional gain (Pf) value used
proportional gain 100.00 for PID regulation of UV lamp effect.
The PID regulation is based on input from

4 MustNot UV sensor QT201–50.
p235 UV control 15 0–100 sec Defines integral time (If) value used for
integral time PID regulation of UV lamp effect.
4 MustNot
p237 Power Acti- N/A Drop Activates UV optimization to regulate

optimization vated list the UV lamp effect based on actual
transmittance in the UV reactor. This
means that the lamps are lit to the degree
4 MustNot needed for full treatment, but not more.
If disabled, UV lamps are lit at 100 % all

the time. Disable if the UV optimization
malfunctions, to avoid alarms.
p238 High 50.0 20.0 – °C Air temperature warning, indicated by

temperature, 100.0 temperature transmitter in LDC.
warning trigger
in LDC (TT401-2)
4 MustNot
20 Book No.9028195 02
2 Control system parameters 2.5 Page 5.4 – Filter parameters
2.5 Page 5.4 – Filter parameters

This section describes parameters controlling the filter set in page 8.4 Filter parameters.
4 5.4 USCG

fault Max
value
p300 High filter 3 1–10 bar Setpoint for shut down due to high
diff. pressure differential pressure over the filter.
shutdown trigger
4 MustNot
p301 High filter 1.5 0.0- bar Setpoint for high pressure warning,
differential 2.0 indicated by pressure transmitter in the
pressure, filter.
warning trigger
4 MustNot
p302 Continuous 2 1–5 min Only valid for Filtrex filter.

backflush trigger
time If two backflushes are triggered by
differential pressure within this time, the
filter will run continuous backflushes for
p303 minutes.
Book No.9028195 02 21
2.5 Page 5.4 – Filter parameters 2 Control system parameters

fault Max
value
p303 Continuous 20 10-30 min Only valid for Filtrex filter.

backflush length
Defines for how many minutes the filter
will run continuous backflushes, after
triggered by p302.
p304 Pressure 2.50 1.00– bar Defines desired pressure for efficient
setpoint during 5.00 backflushing.
backflush
When a backflush is triggered, control
4 Must valve V201–8 will regulate to obtain this
pressure. After 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 pressure transmitter
PT201-16.
Parameter is set according to the formula

below:
p304 ≥ 1.0 bar + calculated pressure
drop for pipe 309.
p305 Backflush 0.50 0.00– bar Setpoint for automatic start of filter
trigger, 2.00 backflush due to dirt in the filter, indicated
differential by high differential pressure over filter
pressure (PT201-71 and PT201-72).
Note: This parameter can be adjusted, but

only by Alfa Laval during commissioning.
If adjusted, parameter p301 shall be set
to 30 percent higher.
(0.50 bar = 0.050 MPa)
p306 Filter 5 1–30 min Defines duration of filter preservation

preservation time (filling with technical water / potable water)
after ballasting.
p308 Backflush cycle 20 1– sec Defines duration of one filter backflush.

time 100
The parameter should be set to: 20
seconds.
4 MustNot
p309 Time controlled 30 1– min Defines time between automatic backflush

backflush 120 of the filter. Automatic backflushes
interval are performed with this set interval to
secure performance, regardles of current
differential pressure.
22 Book No.9028195 02
2 Control system parameters 2.5 Page 5.4 – Filter parameters

fault Max
value
p310 Backflush initial 5 0–60 sec Defines how long time that should pass
delay from a backflush is triggered until is
actually started.
4 Must During this time, the control valve is PID

regulated to create the required pressure
defined in parameter p304.
p311 Backflush delay 2.0 0.0– sec Defines for how many seconds the
(p305 during x 10.0 differential pressure defined in p305 must
sec). last, before automatic backflush starts.
p313 Differential 5 0–30 sec Time constant for low pass filter used for
pressure the differential pressure over the filter.
measurement The low pass filter is used to smoothen
filter the effect of sudden changes in differential
pressure (primarily pressure peaks after
completed backflush).
Value for low pass filtered differential

pressure is indicated as “dp” on the filter
in the filter popup, when logged in as login
level Operator or higher.
Actual differential pressure (PT201-71 and

PT201-72) is indicated in the filter popup.
This parameter shall normally not be

changed, but time can be increased to
flatten the differential pressure curves.
p314 Filter Type N/A Drop Defines type of filter installed.

3 list
Alternatives: Type 1 (Boll), Type 2
(Hydac) and Type 3 (Filtrex).
p315 Filter type 500 100 – m3/h Parameter p314 should be set before this
6000 parameter. Available alternatives depend
on selection in p314.
4 Must Defines filter type and capacity according

to plate mounted on the filter.
The parameter shall be set to

ACB-999–350.
Note: If the parameter is called Filter

size, set the parameter to maximum
capacity for installed filter. This is same
as the maximum ballast flow. See item
201 in in the Connection list in chapter 6.
Installation description and drawings.
Book No.9028195 02 23
2.5 Page 5.4 – Filter parameters 2 Control system parameters

fault Max
value
p316 Pressure -1 to N/A bar Defines range for pressure transmitter

range for filter 9 PT201–16. Set according to range printed
transmitters on the transmitter.
-1 to 9
-1 to 15
p318 Backflush pump Not N/A Drop Defines if an LDC cooling water pump
(P309–1) used list (optional) is used to create sufficient
backflush flow in pipe 309.
– Not used.
– External: Pump started by signal from
PureBallast control cabinet: Power supply
with over current protection relay and
contactors and are handled externally.
from PureBallast control cabinet: Start
signal and power supply with over current
protection relays and contactors from
control cabinet. It is still possible to
connect pumps according to configuration
1.
Note: In internal mode, external signal will

also be activated.
Note: Internal is only displayed for control

cabinets of configuration 2. See control
system page 4.1, field Control cabinet
configuration.
p319 Backflush pump 5 0 – 10 sec Delay from backflush pump P309–1

(P309) lead time (optional) start to opening of backflush
valve V309–1.
Only used if parameter p318 is activated.
p323 Backflush pump Not N/A Drop Defines if the backflush pump is used
during filter used list during filter preservation (when the water
preservation is drained from the filter via pipe 309 and
filled with new water via pipe 310.2. The
backflush pump should not be used if the
filter is emptied.
Alternatives: Not used. Activated.
24 Book No.9028195 02
2 Control system parameters 2.6 Page 5.5 – CIP parameters
2.6 Page 5.5 – CIP parameters

This section describes parameters controlling the CIP module set in page 5.5 CIP parameters.
4 5.5 USCG

fault Max
value
p400 CIP cycle time 15 1–60 min Duration of circulation of CIP liquid
during a CIP process.
4 MustNot
Book No.9028195 02 25
2.7 Page 5.6 – Installation parameters 2 Control system parameters
2.7 Page 5.6 – Installation parameters

This section describes the installation specific system parameters set in page 5.6 Installation
parameters.
4 5.6 USCG

fault Max
value
System name N/A N/A N/A Possibility to enter a system name for
the system, for example Vessel name
when logged in as login level Advanced
operator or higher. If two systems is
4 Must installed information about starbord and
port side.
The text is entered in the event log

file and alarm lists exported from the
control systen for easy identification.
fisk
Serial number N/A N/A N/A Possibility to enter the PureBallast

serial number when logged in as login
level Advanced operator or higher.
4 Must
26 Book No.9028195 02
2 Control system parameters 2.7 Page 5.6 – Installation parameters
p106 Number of UV 1 1–6 # Defines number of installed UV

reactors installed reactors.
4 Must
p112 Maximum flow 1200 0– m3/h The parameter shall be set according to
(FIT201-1) 3300 pipe dimension for the flow meter pipe.
Pipe – Max f ow (FIT201-1) (m3/h)

4 Must 80 – 150
100 – 250
150 – 500
200 – 700
250 – 1200
300 – 1200
350 – 1700
400 – 2200
450 – 3300
500 – 3300
600 – 3300
p131 Automatic UV Not N/A Drop Defines if UV reactors shall be

reactor selection used list automatically selected for process.
It is pissible to toggle the parameter with

4 Must the Auto button in page 1.1 Overview.
If activated: All UV reactors (without

alarms) will be automatically selected,
to enable operation in full capacity.
Activation disables the possibility
to select a lowr flow before starting
a process (during standby mode).
However flow can be changed during
process.
If deactivated: Flow must be selected

manually at first start-up and after
shutdown.
p213 Allowed number 0 0–1 No. If more lamps than set in this parameter
of failed UV are broken, it is not allowed to start a
lamps per UV new operation.
reactor
4 MustNot If a UV lamp fails during ongoing
operation, the flow is set 80 % in IMO
mode and 50 % in USCG mode of flow
capacity. The UV lamps are lit to 100 %.
Operation with faulty LPS or lamps does

not fulfill the type approval certificate.
Book No.9028195 02 27
2.7 Page 5.6 – Installation parameters 2 Control system parameters
p217 UV reactor size 300 N/A Drop Defines size of the UV reactor, defined
(m3/h) list as max capacity (m3/h).
Alternatives: 300, 600 and 1000.
4 Must
p218 Estimated UV 3 000 0 – hrs Setpoint for UV lamp change warning.

lamp lifetime 20000 Counter for UV lamp run time is reset
in page 4.4 Operation timers UVR after
all UV lamps have been changed in an
4 MustNot UV reactor.
p150 Ex proof system Not N/A Drop Defines if the Ex proof version of
used list PureBallast is installed. This affects
both installation and control system.
4 Must Alternatives: Activated or Not used.
p151 Ex-I barrier fault Not N/A Drop Defines if alarm for barrier box is
used list activated.
Mandatory for IECEx installations. Only

4 Must used for Ex US flag installations.
p155 External feed min 50 50 – % Defines lowest value PureBallast can

setpoint 100 request from external feed. Only valid if
PureBallast is controlling ballast water
flow by sending signals to vessels
ballast water pump or throttle valve
before PureBallast.
If external feed controls a ballast water

pump, PureBallast will never request
it to run on a lower speed than the
percentage set in this parameter. If
a valve is controlled, the parameter
defines percent open.
The parameter also defines starting

point for flow regulation when a process
is started, to ensure a smooth start with
a gradually increased flow until desired
value is reached.
Default value should normally be used.
p156 External feed 5 2 – 30 s / Defines how many seconds it takes to

change rate % change the external feed signal 1 %.
Note: It might take a little longer for the

4 Must actual change of the pump or the valve
to adjust the flow.
28 Book No.9028195 02
2 Control system parameters 2.7 Page 5.6 – Installation parameters
p157 External feed 70 50 – % Defines when external feed control is

V201–8 low 90 activated, based on V201-8.
trigger limit
PureBallast will start to request reduced
4 Must flow when V201-8 closes to reach this
degree of percent open.
p180 USCG system Not N/A Drop Defines if the system is an USCG
used list system according to the system plate
on the control cabinet. If activated, it
is possible to run the system in USCG
4 Must 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.
p181 USCG high Not N/A Drop Defines if the high performance version
performance used list of PureBallast is activated.
(HP)
Defines if the system is an USCG HP
4 Must 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.
p500 Log box Not N/A Drop Defines if the log box (optional ) is
used list installed to monitor and log external
valves and pumps, that are not part of
Alfa Laval’s scope of supply.
4 Must
Parameters to activate feedback signals

for components are set in page 4.7 Log
box 1 and 4.8 Log box 2. See chapter
3. Operating instructions and control
system description.
Book No.9028195 02 29
2.8 Page 5.7 – Remote interface 2 Control system parameters
2.8 Page 5.7 – Remote interface

This section describes the installation specific system parameters set in page 5.7 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 interface (optional) is used.
4 5.7 USCG
Parameters for the ISCS modbus RTU server data shall be set according to the information below.

fault Max
value
p700 Interface type RS485 N/A Drop Defines communication (cable) type
list used for communication between the
ISCS and PureBallast.
Alternatives: RS485 and RS422.
30 Book No.9028195 02
2 Control system parameters 2.8 Page 5.7 – Remote interface
p701 Baud rate 9600 N/A Drop Defines baud rate in bits per second.
list
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: 300, 600, 1200, 2400,

4800, 9600, 19200, 38400, 57600,
115200.
p702 Parity No N/A Drop Defines parity.

parity list
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
Alternatives: None, Odd, Even, High,

Low.
p703 Data bits 8 N/A Drop Defines data bits per character.
list
Alternatives: 7 or 8.
4 MustNot
p704 Stop bits 1 N/A Drop Defines number of stop bits.

list
Alternatives: 1 or 2.
4 MustNot
Book No.9028195 02 31
2.8 Page 5.7 – Remote interface 2 Control system parameters
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.
3.1 DIP switch settings

The table below show the correct settings for respective LPS.
Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the individual LPS according
to the table below. Only position ON is indicated. For empty cells in the table, the switch shall be
in position OFF.
LPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1–16
SW 1
SW 2
SW 3
SW 4 ON
SW 5 ON ON ON ON ON ON ON ON
Example
In the illustration, the DIP switches is set for LPS no. 5.
Book No.9028195 02 33
3.2 Change DIP switch setting 3 Lamp power supply (LPS) parameters
4 LPSdip
3.2 Change DIP switch setting

Follow this instruction to change the DIP switch settings for an LPS. Note that the DIP switch
settings for LPS shall only be changed if faulty, indicated by all LEDs lit in LPS in combination with
alarm W130 in the control system.
NGE R
! DA
• Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside
and on the lamp power connector, even when UV lamps are not lit.
• The LDC contains a fan, which can cause injury if in operatoin.
1. Unscrew the plastic lid (1) over the DIP switches on the fron of the LPS.
34 Book No.9028195 02
3 Lamp power supply (LPS) parameters 3.2 Change DIP switch setting
7 LPSdip
2. Use a small screw driver to change position of the swithces according to the table under
instruction DIP switch settings.
3. Re-fit the plastic lid of the DIP switches.
4. Turn back the power to the cabintet.
Book No.9028195 02 35
3.2 Change DIP switch setting 3 Lamp power supply (LPS) parameters
4 Fuse settings for filter motor
and installed (optional) pump
motors
Follow this instruction to change the fuse settings for filter motor M709–43 (F2) and installed
(optional) pump motors P401-1 (F3), P309-1 (F4) and P403-1 (F5) in the control cabinet.
1. On the filter motor and installed (optional) pump motors: Find area on the mark plate where
information is displayed for the frequency used for the system (50 or 60 Hz).
2. Look at voltage (V), stated as an interval.
3. Look at interval for Imax amp setting (A), also stated as an interval.
4. Make an estimation for Imax amp setting, so that it “match” the voltage in the range from
min to max.
5. On the fuse: Press Reset button until LEDs flash (6 seconds).
6. Turn the potentiometer to estimated amp setting according to mark plate.
7. Check that the setting is correct according to the LEDs. Compare to the table below.
4 FuseSettingBoosterPumps
8. Press Reset button to save the value.
Book No.9028195 02 37
4 Fuse settings for filter motor and installed
(optional) pump motors
5 Flow transmitter parameters
The parameters are pre-set in the flow meter transmitter.
Book No.9028195 02 39
Chapter: 5. Alarms and faultfinding
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 5
2 List of alarms and warnings 7

2.1 Control system 7
2.1.1 Alarm indication 7
2.1.2 Key to the table of alarms and warnings 7
2.1.3 List of alarms and warnings 8
2.2 Lamp power supply (LPS) 52

2.2.1 List of alarms and status indications 52
2.3 Flow meter 53

2.3.1 Fault finding instruction 53
2.3.2 Error messages on the display 53
2.4 Level switch 55

2.5 I/O system and X20 modules 56
2.5.1 List of alarms and status indications 57
3 List of problems and solutions 63

3.1 General problems 63
3.2 Filter 67
3.3 CIP 69
3.4 Valve V201–8 72
3
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 3. Operating instructions and control system description to find information about
the alarm pages and how to attend to alarms.
Book No.9028195 02 5
1 Introduction
2 List of alarms and warnings
This section lists all alarms and warnings related to the PureBallast system.
2.1 Control system

This sub section lists all alarms and warnings in the PureBallast control system. The alarms are
sorted in a strict numerical order.
2.1.1 Alarm indication

An alarm or warning will activate the alarm buzzer (sound and light) on the cabinet. The sound is
silenzed by touching the buzzer, but note that the alarm is not acknowledged by this.
An alarm is indicated in the following ways in the control panel.
Alarms
Alarms are indicated by:

3 Alarm
• 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 panel frame is lit.
• A sound is heard.
New alarm = blinking. Acknowledged alarm = Steady.
Warning
Works as alarms, but indicated in yellow.

3 Warning
No sound is heard for warnings. Exceptions: W12, W152 and W154.
All alarms are displayed in the control panel’s page 2.1 Alarm list and are sorted in order of
occurrence; most recent alarm at the top of the list.
2.1.2 Key to the table of alarms and warnings

The table below explains the information given in the alarms list table. The table contains the
following columns and information:
Book No.9028195 02 7
2.1 Control system 2 List of alarms and warnings
Column in Description
table
Alarm ID Identification 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 text / The text displayed in the control system. Note that UV reactor number is
Problem indicated by “x” in the table, instead of the actual UV reactor number. In the
control system alarm text, the actual UV reactor number is stated for the UV
reactor concerned.
For problems not indicated by an alarm, the text gives a general explanation
of a problem that can occur.
Trigger / Trigger: Source of the alarm or warning, identified by the input sensor’s item
Parameter number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.
Description 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 Possible causes that might have triggered the alarm.

cause
What to do? Suggested action to solve the problem.
2.1.3 List of alarms and warnings

The table below explains alarms triggered by and displayed in the control system.
See next page.
8 Book No.9028195 02
2
Alarms and warnings — PureBallast control system
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A01 Process Trigger: PT201-16 Delay: 30 sec. Ballast water pump Check pressure and flow from
Book No.9028195 02
pressure too Parameter: p100 gives too high ballast pump(s). If the pressure
high (PT201- Comment: Pressure pressure. exceeds set value: Adjust incoming
16). Automatic transmitter PT201-16 pressure to PureBallast.
stop. indicates pressure
higher than set in Valves in the system Control that correct valves are
parameter p100. after pressure functioning and opened for current
List of alarms and warnings
transmitter are process. See chapter 3. Operating

closed. instructions and control system
description, section Detailed
process description.
Material is stocked Check the entire system for

after pressure blocking material.
transmitter PT201-16
(i.e. in an UV reactor).
Pressure transmitter 1. Check cables to pressure

PT201-16 is faulty. transmitter PT201-16. See
Control cabinet / Circuit diagram
in chapter 6. Installation
description and drawings.
2. Replace pressure transmitter
PT201-16.
2.1
9
Control system
10
2.1
ID
A03 Process Trigger: PT201-16 Delay: 30 sec. Signal missing 1. Check fuse F45 in Control
pressure or pressure cabinet to see what circuit
signal missing Comment: Error transmitter PT201-16 caused the fuse trip.
(PT201-16). in system pressure malfunction.
2. Use the circuit diagram to
Control system
Automatic stop. sensor. Indication of

pressure -1.0 bar (-0.1 check the fuse setting, adjust
MPa) is not an error. according to figures in circuit
diagram if necessary and reset
fuse.
locate the component or find
the reason that caused the fuse
trip and attend to it.
4. Check cables to the component.
See Control cabinet / Circuit
diagram in chapter 6.
Installation description and
drawings.
5. Check that all electrical
connections are OK and that
the electrical wiring is not
damaged.
2
6. Replace transmitter PT201-16.
W04 Process Trigger: PT201-16 Delay: 30 sec. See possible cause See A01.
pressure Parameter: p101 for A01.
too high Comment: Pressure
(PT201-16). higher than parameter
set limit.
Book No.9028195 02
2
ID
A10 Process flow Trigger: FIT201-1. Delay: 5 sec. Signal missing or flow 1. Check fuse F45 in Control
signal missing Parameter: N/A transmitter FIT201-1 cabinet to see what circuit
(FIT201-1). Comment: Error in malfunction. caused the fuse trip.
Book No.9028195 02
system flow sensor.
check the fuse setting, adjust
according to figures in circuit
fuse.

drawings.
damaged.
6. Replace flow transmitter
FIT201-1.
Flow transmitter Check the flow transmitter. See

FIT201-1 malfunction section Flow meter in chapter 7.
(no text on the Service manual and on page 53.
2.1
transmitter display,
message error)
Flow meter See section Flow meter on page

malfunction. 53.
11
Control system
12
2.1
ID
W11 This warning is

not relevant for
this installation.
Control system
W12 Process Trigger: FIT201–1 Delay: 30 sec. Flow rate higher than Reduce the incoming ballast water
flow higher Parameter: N/A certified flow. See flow to the PureBallast system.
than certified Comment: An field Certified flow in
(FIT201-1). additional common page 1.1 Overview.
Reduce flow! alarm signal is issued.
Note: Operation
continues but is not
compliant and does not Wrong setting in See chapter 4. Parameters, section
fullfil tequirements FIT201-1. Flow transmitter.
for treatment of
ballast water. Act Flow sensor See section Flow meter on page
according to ballast malfunctions. 53.
water management
plan.
A13 Process flow too Trigger: FIT201–1 Delay: 20 sec. Flow too low. • Increase flow.
low (FIT201-1). Parameter: p116
• Make sure the ballast water
Automatic stop. Comment: If flow
is less than set in from the ballast pump is
directed to PureBallast. When
2
parameter p116, the

system is shut down. OK the process will continue
automatically.
• Check pressure and flow
from ballast pump(s).
Adjust incoming pressure
to PureBallast, if necessary.
Wrong setting in See chapter 4. Parameters, section

FIT201-1. Flow transmitter.
Book No.9028195 02
2
ID
Flow sensor See section Flow meter on page

malfunctions. 53.
Book No.9028195 02
Valves in ballast Control that correct valves are
system closed. opened for current process.
See chapter 3. Operating
instructions and control system
description, section Detailed
process description.
If not, check mechanical function of

the valve and check that the cables
to the component is according
with the Control cabinet / Circuit
diagram.
Ballast water Attend to. Note: This component

pump stopped or is outside the PureBallast system
malfunctions control.
A14 Process Trigger: FIT201-1 Comment: Triggered Control valve V201–8 See alarm A17.
flow too low Parameter: p116 if flow defined in p116 malfunctions.
during start-up is not established
(FIT201-1). within 60 seconds after Flow too low. See alarm A13.
Automatic stop. ballast water pump is
started.
2.1
13
Control system
14
2.1
ID
A17 Valve error Trigger: Limit switch Delay: 25 sec. Fuse tripped. 1. Check fuses F43 in control
(V201-3). GS201-3. cabinet to see what circuit
Parameter: N/A. Comment: Error on caused the fuse trip.
valve V201–3.
2. Check relay K1 and K2 on
Control system
module X10 in control cabinet.

3. Use the Control cabinet /
Circuit diagram to check the
fuse setting, adjust according
to figures in circuit diagram if
necessary and reset fuse.
connections to actuator and
sensors on the valve are OK
and that the electrical wiring is
not damaged.
Position sensor is Adjust sensor. See chapter 7.

not in correct position Service manual, section Adjust
2
to sense indicator position sensor.

screws. Position
screws are in wrong Hint: Valves can be manually
position. operated. See instruction Operate
components manually in chapter 3.
Position sensor Operating instructions and control
mounted upside system description and Operate
down. valves manually in chapter 7.
Service manual.
Book No.9028195 02
2
ID
Position sensor or 1. Check cables.

cables to position
2. Replace position sensor if
sensor malfunction.
faulty.
Book No.9028195 02
Too long 1. Follow the instruction Adjust
opening/closing time valve traveling speed in chapter
(valve travel time) 7. Service manual.
2. Adjust exhaust valves on
actuator.
3. Check that instrument air
pressure is according to
requirements in chapter 6.
drawings, section Connection
list.
Pilot valve on actuator The red LED on pilot valve contact

malfunction lights if opening signal comes to the
pilot. If the LED lights although the
valve malfunctions, the pilot valve
is faulty: Replace pilot valve.
Valve cannot Clean. If required dismount valve.

open/close due to See chapter 7. Service manual for
obstruction. instructions.
A19 Valve error Trigger: Limit switch Delay: 25 sec. See possible cause Check relay K7 and K8 on module
(201-32) GS201-32. for A17. X10.
2.1
Parameter: N/A. Comment: Error on

valve V201–32.
15
Control system
16
2.1
ID
A23 Valve error Trigger: Limit switch Delay: 25 sec. See possible cause Check relay K5 and K6 on module
(V201-9). GS201-9. for A17. X10.
valve V201–9.
Control system
A25 Valve error Trigger: Limit switch Delay: 25 sec. See possible cause
(V404-35) GS201-35. for A17.
valve V201–35.
(V201-8). GS201-8. for A17.
control valve V201–8. • Sensor error. 1. Check open indication in the
Shows open all pneumatic positioner.
the time.
2. Check fuses F43 in control
• Signal error 4–20 cabinet to see what circuit
mA. caused the fuse trip.
3. Check relay K3 on module X10.
4. Use the Control cabinet /
Circuit diagram to check the
2

connections to actuator and
sensors on the valve are OK
and that the electrical wiring is
not damaged.
Book No.9028195 02
2
ID
Positioner is not Calibrate according to chapter 7.

correcly set or Service manual, section Calibrate
calibrated. positioner on V201-8.
Book No.9028195 02
The air filters on Clean the filter on the possitioner.
V201-8 might be
clogged.
A33 Bypass valve is The valve has been If not opened intentionally, close
Trigger: Limit switch Delay: 25 sec.

open (V212-31). GS212-31. opened manually or valve V212-31.
Parameter: N/A Comment: If the valve via the ISCS.
(not controlled by
PureBallast) is opened, See possible cause
any ongoing process for A17.
is stopped. A new
process can not be
started.
(V212-31). GS212-31. for A17.
Parameter: N/A Comment: Shutdown
of all steps except CIP.
The alarm does not
prevent completion or
start of CIP process.
2.1
17
Control system
18
2.1
ID
W40 Process Trigger: Pressure Delay: 2 sec. Ballast water pump Check that pressure and flow
pressure too transmitter: gives too low from ballast pump(s) is according
low (PT201-16). PT201-16. pressure. to requirements in chapter 6.
Parameter: p103. Installation description and
Control system
drawings, section Connection list.
Pressure safety valve Check the valve, and repair or

V201 is faulty. change.
Pressure transmitter 1. Check cables to pressure

PT201-16 is faulty. transmitter PT201-16. See
2. Replace pressure transmitter
PT201-16.
A48 System stop Trigger: Stop button Delay: None. Process has been
activated (Stop on control cabinet stopped. NOTE
button). Parameter: N/A
Find out the reason why the process
has been stopped before releasing the
button and starting another process.
2
A49 System stop Trigger: Stop button Delay: None See A48.
activated during on control cabinet
CIP (Stop Parameter: N/A
button).
A50 System stop Trigger: External Delay: None. Process has been
activated stop button on control stopped by external NOTE
(External stop cabinet (or signal). stop button or signal
button). Parameter: p135 from the ISCS Find out the reason why the process
(integrated ship has been stopped before releasing the
control system). button and starting another process.
Book No.9028195 02
2
ID
A51 System stop Trigger: External Delay: None. See A50.

activated during stop button on control
CIP (External cabinet (or signal).
Book No.9028195 02
stop button). Parameter: p135
W58 Fuse tripped in Trigger: Control Delay: None. Possible reasons: 1. Check fuse F43–F45 in control
control cabinet. cabinet. • cabinet to see what circuit
Parameter: N/A caused the fuse trip.
• short circuit

• overheated fuse
3. Use the circuit diagram for
control cabinet to check the
A66 Additional Trigger: External Delay: 2 sec. The valve has been If not opened intentionally, close
bypass valve system. opened manually or the valve.
1 is open. Parameter: p163 Comment: If the valve via the ISCS.
(not controlled by
PureBallast) is opened,
any ongoing process
is stopped. A new
process can not be
started.
2.1
A67 Additional Trigger: External Delay: 2 sec. See A66.

bypass valve system.
2 is open. Parameter: p164
A68 Additional Trigger: External Delay: 2 sec. See A66.

bypass valve system.
3 is open. Parameter: p165
19
Control system
20
2.1
ID
A69 Remote system Trigger: External Delay: 2 sec. PureBallast is If valve is not opened intentionally,
reports system system. bypassed via the close the valve.
is bypassed. Parameter: ISCS.
Control system
A71 Ballast water Trigger: Control Delay: Set in Faulty connection of Check that all electrical connections
pump is system timer. parameter p141. signal cable. are OK. Check that the signal
not running. Parameter: p141. wiring is according to information in
Automatic stop. Comment: Feed back chapter 6. Installation description
signal “BW pump is and drawings, section Control
running” is deactivated cabinet / interconnection diagram.
If remote interface Test relevant addresses. See

(optinal) is used: chapter 3. Operating instructions
Communication and control system descriptionTest
between PureBallast remote interface communication
and ISCS is wrong.
Time set in parameter Check/change parameter in control

is lower than needed. system page 5.1 – main parameters
1.
A72 Stripping pump Trigger: Control Delay: Set in See possible cause
not running. system timer. parameter p141. for A71.
Automatic stop. Parameter: p141.
2
Comment: Feed
back signal “Stripping
pump is running” is
deactivated
A75 Overboard valve Trigger: Control Delay: Set in See possible cause
is not open. system timer. parameter p140. for A71.
Automatic stop. Parameter: p140
Comment: Feedback
“overboard valve is
OPEN”.
Book No.9028195 02
2
ID
A77 Error on all Trigger: UV reactors Delay: None An active alarm exist Check control sytem page 2.1
operating Parameter: N/A on all installed UV Alarm list in control panel for
UVR:s. Comment: All reactors. It can be the related alarms.
Book No.9028195 02
Automatic stop. UV reactors are same error for all UV
deactivated. reactors, or different
errors.
A79 Power is Trigger: Control Delay: Set in Power management Investigate if the reasons for not
not granted. system timer. parameter p143. master system not granting power is outside the
Automatic stop. Parameter: p127. granting power . PureBallast system.
Comment: No
power steps have Feedback signal from See A71.
been granted within power management
parameter set time. master is faulty. Check signal transmission to/from
PureBallast corresponds to
the specifications in chapter
6. Installation description and
drawings, section Control cabinet /
interconnection diagram.
Hint: If problem persists, see control

sytem page 1.4 – PureBallast power
request to find which GRANTED
signal that was interrupted during
thfe ballast/deballast process.
W80 Power is not Trigger: Power Delay: None. See possible cause
fully granted. management system. for A79.
Flow capacity Parameter: p127. Comment: Not all
reduced. requested power steps Not enough power Continue process with lower flow
are granted. Triggered has been granted. capacity or try later.
2.1
if number or requested
power steps does
not match number of
granted power steps.
21
Control system
22
2.1
ID
W82 Heeling mode Trigger: Heeling Delay: None. Heeling mode has
requested (internal transfer) been activated by
by operator. requested in control Comment: The system external system.
Automatic system. is set in pause mode.
Control system
pause. Parameter: N/A If operation has not

been requested: See
A71.
W83 Heeling mode Trigger: Heeling Delay: None. See possible cause
cancelled (internal transfer) not for W82.
by operator. requested in control Comment: Process
Process system. is resumed after being
resumed. Parameter: N/A phased during heeling.
A91 PLC lost Trigger: Control Delay: 60 sec. Panel is switched off 1. Switch on the panel.
communication system PLC. or faulty.
2. Restart the panel. See problem
with all control Parameter: N/A Comment: After
1 B in the general problems list
panels. 60 seconds of lost
on page .
communication,
ongoing process is 3. Replace if faulty.
stopped in a controlled
way and the system Wrong software Check that the HMI and PLC
is shut down. This version software have the save program
message is visible in version. This is visible in control
2
the control panels and system page 4.1 System info.

saved in the log after
the communication is Wrong network Check settings for each panel
restored. But, W92 will setting according to chapter 3, section Set
be visible in the main control panel IP settings.
control panel.
Check that the remote control
panel is added in the main panel
according to Set remote control
panel communication.
Book No.9028195 02
2
ID
Faulty cable Check cables to the component.

connection. For reference, see Control cabinet
/ Interconnection diagram Remote
Book No.9028195 02
control panel / Circuit diagram and
in chapter 6. Installation description
and drawings.
W92 Main control Trigger: Control Delay: 30 sec. Master panel is See A91.
panel lost system PLC. switched off or faulty.
communication Parameter: N/A Comment: After

with the PLC. communication is lost, Faulty cable See A91.
ongoing process is connection.
stopped in a controlled
way and the system
is shut down. This
message is visible in
the main control panel.
A93 Heart beat Trigger: Control Delay: Set in To operate PureBallast when communication is down,
signal from system PLC. parameter p128. follow the steps below:
remote interface Parameter: p132
is not updating. Comment: After 1. Set the system to Local mode: Press the Local button
communication is on the control panel.
lost between ISCS
2. Run the system from the control panel. Note that you
and PLC, ongoing
will need to confirm two messages from the control
process is stopped in a
panel during operation: "Confirm ballast pump started"
controlled way and the
and "Confirm overboard valve open".
system is shut down.
3. Restore these settings when the communication is
2.1
The Heartbeat field working.

in control sytem
4. Make sure that the system is not in test mode in 4.5
page 4.5 Remote
Remote interface (no check mark on the Test mode
interface, indicates
button).
communication.
System is set to Test If you deliberately set the system
mode. to test mode (for example to test
23
Control system
24
2.1
ID
remote interface integration, you
can disregard this alarm. If not
deactivate the test mode again in
4.5 Remote interface 1.
Control system
Faulty settings. 1. Check that parameter p700 is

set to match the modbus cable
type used (RS422 or RS485).
2. Check if remote operation is
deactivated in the control panel
(The Remote button at the
bottom of the screen is gray). If
so, press the Remote button.
3. Check if test mode is activated
in 4.5 Remote interface (check
mark on button). If so, press the
Test mode button. Requires
login level Advanced operator.
4. Check that the communication
settings is OK according to
instruction Set remote interface
communication in chapter 3.
Operating instructions and
2
control system description.
Faulty cable Check cable between the ISCS

connection. and the main control panel and
the cable between the PLC and
the main control panel. For
reference, see Control cabinet /
Interconnection diagram in chapter
drawings.
Book No.9028195 02
2
ID
Tips: Make sure that the modbus

cables in terminal X15 are correct
Book No.9028195 02
(not switched).
Communication See W92.

between PLC and
main control panel is
lost.
ISCS is faulty. Investigate problem in ISCS, and

attend to found problems.
A94 Barrier fault Trigger: Barrier in Delay: N/A. To be completed To be completed

LDC cabinet
Parameter: p151 Comment: This alarm
is specific for the
Ex proof version of
PureBallast for US
flag.
W95 PLC battery low. Trigger: Control Delay: 10 sec. The voltage in the Replace PLC battery in the control
system PLC. battery in the control cabinet.
Parameter: N/A system PLC is too
low.
W96 GPS signal not Trigger: Control Delay: 5 sec. Faulty electrical Check that the signal wiring
valid. system PLC. connection. is according to in chapter 6.
Parameter: p160 Installation description and
2.1
drawings, section Control cabinet /

Interconnection diagram
25
Control system
26
2.1
ID
W97 PLC error in Trigger: N/A Delay: 2 sec. Error in module. Check the LED error indication for
control cabinet. Parameter: N/A the electronic modules in the LDC.
See section I/O system and X20
modules on page 56.
Control system
Faulty electrical • Check that the signal wiring is

connection. according to electrical drawings
in Chapter 6. Installation
• Check that all electrical
connections are OK on bus
modules and that the electrical
wiring is not damaged.
W100 UVR [x]: UVR Trigger: UVR Delay: Set in High temperature • Check that the inlet valves
temp too high temperature parameter p206. due to obstacles or (V201-19.x, V403-35) and
(TT201-33). transmitter TT201-33. error in one or more outlet valves (V201-20.x,
UVR shutdown. Parameter: p202 Comment: If components involved. 404-36.x) open properly by
temperature rises operating them manually.
above parameter set See the instruction Operate
value, the UV reactor components manually
will shutdown. in chapter 3. Operating
2
If the alarm trips during description.

operation with a flow
through the UV reactor, • Check that cooling water supply
the valves V201-19.x (403) is within specification
and V201-20.x will in chapter 6. Installation
close. description and drawings,
section Connection list.
If the alarm trips during
ballast start-up, valve Low flow of cooling Check pump, valves and other
V404-36.x will close. water during start-up. components involved in the sea
water cooling system.
Book No.9028195 02
2
ID
Parameter p202 not Check/change parameter in control

correctly set. system 5.3 – UVR parameters.
Book No.9028195 02
TT201-33.x Replace transmitter TT201–33
malfunction. according to instruction in
chapter 7. Service manual
section Temperature switch and
temperature transmitter.
W101 UVR [x]: UVR Trigger: UVR Delay: Set in See possible cause
temp too low temperature parameter p206. for W100.
(TT201-33). transmitter TT201-33.
UVR shutdown. Parameter: p204. Ballast water too cold; See to that incoming water is
temperature below 0 warmer than 0 C°.
C°.
Engine room too cold; Increase temperature.

temperature below 0
C°.
W102 UVR [x]: Trigger: UVR Delay: Set in parameter Signal missing 1. Check fuse F42 in LDC to see
UVR temp temperature p206. or transmitter what circuit caused the fuse
signal missing transmitter TT201-33 TT201-33.x trip.
(TT201-33). error. malfunction.
UVR shutdown.
Parameter: N/A. check the fuse setting, adjust
fuse.
2.1

27
Control system
28
2.1
ID

See UVR / Circuit diagram and
Lamp drive cabinet (LDC) /
Circuit diagram in chapter 6.
Control system

drawings.
damaged.
6. Replace transmitter TT201-33.
7. Restart the process from the
beginning.
W105 Temp below 0 Trigger: LDC Delay: Set in parameter

°C. temperature p206.
transmitter TT401.
W107 UVR [x]: LDC Trigger: LDC Delay: 15 sec. No cooling water to Check that cooling water supply
cooling water temperature the heat exchanger. (401) is within specification in
temp too high transmitter TT401. chapter 6. Installation description
(TT401–1). Parameter: p214 and drawings, section Connection
2
list in the General drawings section.
Incoming cooling Feel the water pipe, if it is too

water too warm. warm. If so, investigate and attend
to problem.
Cooling water valve Check and attend to.

SV401–51 and/or
CV402 blocked or
closed.
Book No.9028195 02
2
ID
Parameter p214 not Check/change parameter in control

correctly set in control system 5.3 – UVR parameters.
system.
Book No.9028195 02
W109 UVR [x]: Trigger: LDC Delay: 5 sec. Signal missing or 1. Check fuse F42 in LDC to see
LDC cabinet temperature transmitter TT401 what circuit caused the fuse
temp missing transmitter TT401–1. malfunction. trip.
(TT401–1). Parameter: N/A
2. Use the circuit diagram for the
LDC to check the fuse setting,

adjust according to figures in
circuit diagram if necessary and
reset fuse.
3. Use the circuit diagrams for
the LDC and UV reactor to
See Lamp drive cabinet (LDC)
/ Circuit diagram in chapter
drawings.
damaged.
6. Replace transmitter TT401.
2.1

beginning.
Faulty connection to Check that all electrical connections

X20 module. are OK on X20 module and that the
electrical wiring is not damaged.
29
Control system
30
2.1
ID
Faulty X20 module. Check component. See section I/O

system and X20 modules on page
56.
Control system
Change according to instruction in

chapter 7. Service manual, section
Control cabinet.
W111 LDC air Trigger: Delay: 15 sec. LDC faulty. Check 2. Alarm list in control panel
temperature too Temperature for related alarms.
high (TT401–2) transmitter TT401–2.
Parameter: p238 Faulty fan. Check electrical and mechanical
problems, and attend to.
W113 LDC cabinet Trigger: Delay: 5 sec. Signal missing or flow 1. Check fuse F42 in Control
temperature Temperature transmitter TT401-2 cabinet to see what circuit
missing transmitter TT401–2. malfunction. caused the fuse trip.
(TT401–2) Parameter: N/A
2

fuse.
drawings.
Book No.9028195 02
2
ID

Book No.9028195 02
damaged.
6. Replace transmitter FIT201-27.
beginning.
W116 UVR [x]: UVR Trigger: Level sensor Delay: Set in Signal missing or 1. Check fuse F42 in LDC to see
fluid level LS201-29. parameter p215. sensor LS201-29.x which circuit that caused the
signal missing Parameter: N/A malfunction. fuse trip.
(LS201-29).
2. Check relay KS02.
3. Use the circuit diagrams for the
reset fuse.
4. Use the circuit diagrams for
5. Check cables to the level switch
LS201-29.x. See drawing UVR
/ Circuit diagram and Control
cabinet / Circuit diagram
2.1
31
Control system
32
2.1
ID
6. Check that the level switch is

working correctly. See section
Level switch on page 55.
Hint 2: Dismount level switch
Control system
and put the forks into a cup of

water to check dry/wet function.
7. Replace LS201-29.x. (Turn the
level switch so the forks are in
the right position. See chapter
7. Service manual.
W117 UVR [x]: UVR Trigger: Level sensor Delay: Set in No fluid in UV reactor. 1. Control that correct valves are
fluid missing LS201-29. parameter p215. opened for current process. See
(LS201–29) in Parameter: N/A Detailed process description
manual mode Comment: The UV in chapter 3. Operating
reactor is shut down. instructions and control system
Prevents start of LPS description.
(UV lamps) in manual
mode. 2. Check that the flow is equal
through all UV reactors and that
the UVR.x is not clogged.
beginning.
2
W118 UVR [x]: CIP Trigger: Level sensor Delay: Set in No fluid in UV reactor 1. Check that valves V320-2,
flow missing LS201-29. parameter p208. “x”. LS201-29.x V320-4.x, V321-4 and 321-2.x
(LS201-29). Parameter: p208 is indicating dry open and close correctly.
condition.
2. Check that pump P320-1
is functioning correctly. See
problem 6D−6I in the general
problems list on page .
Book No.9028195 02
2
ID
3. Hint: Valves can be manually

operated. See the instruction
Operate valves manually
Book No.9028195 02
in chapter 3. Operating
description.
Note that the manual operations
are password-protected and
must only be performed by
authorized trained personnel.

The PureBallast equipment or
connected equipment can be
irreparably damaged if handled
incorrectly.
4. Examine the pipes related to
the CIP circuit. Make sure
that no material is clogging the
pipes.
5. Check that the level switch is
working correctly. See section
Level switch on page 55.
Time set in parameter Change parameter.

is lower than needed.
Level switch at UV See W116 to troubleshoot the level

reactor LS201-29.x switch electrically.
malfunction.
2.1
Too low level in CIP Refill the tank with CIP liquid. See
tank. instruction Change and refill CIP
liquid in chapter 7. Service manual.
Air in fluid. The level Deaerate the CIP, using the

switch indicates this deaeration valve on the CIP.
33
Control system
as no fluid in UV
reactor.
34
2.1
ID
W119 UVR [x]: No Trigger: Level sensor Delay: Set in No liquid in UV reactor 1. Check that pressure flushing
freshwater LS201-29. parameter p208. “x”. LS201-29.x water in pipe 310 is according
filling in UVR Parameter: p216 is indicating dry to requirements in chapter 6.
(LS201-29). condition. Installation description and
Control system
drawings, section Connection

list.
2. Check that valves (V310-6,
V320-4.x, V321-2.x and
V571-1) are operating correctly.
Also check that valve V310-3 is
OK and that V310–8 is opened.
Operate the components
manually.

Level switch at UV See W116 to troubleshoot the level

reactor LS201-29.x switch electrically.
malfunction.
W120 UVR [x]: UVR Trigger: Level sensor Delay: Set in Fluid in UV reactor Restart the process from the
was not drained LS201-29. parameter p200. “x”. LS201-29.x beginning.
2
(LS201-29). Parameter: p200 is indicating wet

condition.

Level switch at UV See W116.

reactor LS201-29.x
malfunction.
Faulty valves in the Control that correct valves

CIP unit. (V320–4, V460–2, V231–2,
V571–1, overboard valve) are
Book No.9028195 02
2
ID
opened for current process. Also
control that pump P321–5 is
functioning.
Book No.9028195 02
W122 UVR [x]: Fuse Trigger: LDC cabinet Delay: 1 sec. Fuse in LDC has Check fuse F42–43 in LDC cabinet
tripped in LDC for UVR tripped or has been to see what circuit caused the fuse
cabinet. Parameter: N/A switched off. trip. Check according to bullets.
• Use the circuit diagram for the


reset fuse.
• Use the circuit diagrams for
• Check cables to the component.
See UVR / Circuit diagram and
Lamp drive cabinet (LDC) /
Circuit diagram in chapter 6.
drawings.
2.1
35
Control system
36
2.1
ID
W126 UVR [x]: MCB Trigger: LCD x-1 Delay: 1 sec. Motor circuit breaker 1. See LPS alarms in section
tripped in LDC Parameter: N/A (MCB) for an LPS in Lamp power supply (LPS) on
cabinet. Comment: UVR.x has tripped or page 52.
MCB=Motor circuit has been switched
2. Check Q101–Q116 in LDC and
Control system
breaker. UV reactor is off.

deactivated. respective cables and LPS unit.
check the Ampere setting for
the MCB, adjust according
necessary and reset MCB.
Breaker on LDC has Reset the breaker by turning the

tripped or has been handle.
switched off.
W128 UVR [x]: LDC Q117 Delay: 5 sec. Motor circuit breaker Check Q117 in LDC.
cabinet fan (MCB) F1 in control
alarm cabinet has tripped
or has been switched
off.
Faulty fan. Check electrical and mechanical

problems, and attend to.
2
Faulty electrical Check that all electrical connections

connection. are OK and that the electrical wiring
is not damaged.
Book No.9028195 02
2
ID
W129 UVR [x]: LDC Trigger: Water Delay: 5 sec. Leakage in cooling Repair.
cabinet water sensor LS below water piping.
alarm. heat exchanger in Dry wet areas in the cabinet.
Book No.9028195 02
LDC. Remove the sensor and dry it with
Parameter: N/A paper.
Condensation in the See above.

cabinet.
W130 UVR [x]: LPS Trigger: Lamp power Delay: 5 sec. • LPS malfunction. Check LED indication on the LPS
sum alarm. supply in UV reactors that triggered the alarm. See LPS
• Number of broken
LDC. alarms in section Lamp power
UV lamps exeeds
Parameter: N/A supply (LPS) on page 52.
number set in
parameter p213. Check which lamps that are broken
in column Lamp OK in page 4.9
LPS overview.
UV lamp OK signal Check that the signal wiring is

malfunction. according to electrical drawings.
Check that all electrical connections

are OK on bus modules and that
the electrical wiring is not damaged.
W131 UVR [x]: UV Trigger: Lamp power Delay: 5 sec. One or more UV lamp Check which lamps that are broken
system failure. supply. is broken. in column Lamp OK in 4.9 LPS
Too many failed Parameter: p213. Comment: UV reactor overview.
lamps. is deactivated.
2.1
Change according to instruction in

Note: Operation chapter 7. Service manual.
compliant and does not
fullfil tequirements
for treatment of
ballast water. Act
according to ballast
37
Control system
38
2.1
ID
water management
plan.
W132 Estimated UV Trigger: UV reactor Delay: 1 sec. Lifetime for UV Recommended to change all lamps
lamp lifetime lap time. lamps are too after 3000 hours of operation.
Control system
exceeded. Parameter: p218. exceed according

to estimated lifetime Change according to instruction
in parameter. Replace UV lamp and quartz sleeve
in chapter 7. Service manual.
A137 UVR [x]: To high Trigger: TS201-60 Delay: 1 sec. No flow in UV reactor See W100.
temperature Parameter: N/A or too low flow.
(TS201-60 Comment: UV reactor After problem has been attended
tripped) and/or is deactivated. to, the LDC needs to be reset.
LDC powered
off. Reset LDC
1. Turn on the power to the

cabinet/system.
2. Push the reset button on the
LDC. The button is placed
at the side facing the UV
reactor. All LDCs must be reset
individually.
2
3. Acknowledge alarm A137 in the

control system.
Faulty pump (ballast Check components.

or UVR cooling water Control that valves and pumps are
pump) or valve. functioning.
LDC has been The LDC needs to be reset, see

powered off. above in this alarm description.
Faulty electrical • Check that the signal wiring

Book No.9028195 02
2
ID
connection. is according to electrical
drawings.
• Check that all electrical
Book No.9028195 02
damaged.
A138 UVR [x]: PLC Trigger UV reactor x. Delay: 2 sec. Error in module. Check the LED error indication for
error in LDC Parameter: N/A the electronic modules in the LDC.

cabinet. Comment: UV reactor See section I/O system and X20
is deactivated. modules on page 56.
W140 CIP schedule Trigger: Control Delay: Set in CIP not performed Control CIP status on 1.3 CIP
timer elapsed system timer. parameter p117 and after operation. status in control system.
Start CIP! Parameter: N/A. p118.
Start CIP process.
Comment: CIP has not
been performed within
parameter set time limit
after (de)ballast.
Note: Operation
for treatment of
ballast water. Act
water management
2.1
plan.
39
Control system
40
2.1
ID
W151 UVR [x]: Trigger: UV sensor Delay: 20 sec. See W152.

UV intensity QT201-50.
signal missing Note: Operation Signal missing. 1. Check fuse F42 in LDC to see
(QT201-50) continues but is not which circuit that caused the
Control system
compliant and does not fuse trip.

for treatment of 2. Use the circuit diagram to
ballast water. Act check the fuse setting, adjust
according to ballast according to figures in circuit
water management diagram if necessary and reset
plan. fuse.
4. Check cables to QT201-50.x.
See the drawing Control cabinet
drawings.
5. If the above is OK, the UV
sensor is probably broke and
needs to be replaced. Replace
2
the component.
Book No.9028195 02
2
ID
W152 UVR [x]: UV Trigger: UV sensor Delay: 30 sec. Note: Operation continues, but
intensity low. QT201-50. does not fulfill the type approval
System flow Comment: The flow certificate. Act according to ballast
Book No.9028195 02
reduced. is reduced when UV water plan.
intensity (W/m2) is
below 252 according to See chapter 2. System overview,
IMO legislation. Power section Power optimization.
is set to 100% and the
flow is reduced to 50 Water is dirty or have Check water.
%. low UV transmittance.
It is also possible to fill the reactor
Note: Operation with technical water / potable water
continues but is not to rule out dirty water as reason for
compliant and does not the warning.
fullfil the requirements
for treatment of Quartz sleeves dirty. Run CIP process, and try again.
ballast water. Act
according to ballast If problem remains, check and
water management clean quarts sleeves according to
plan. instruction Replace UV lamp and
quartz sleeves in chapter 7.
Comment: An
additional common Old UV lamps. Check runtime on 4.3 Timers in
alarm signal is issued. control system. Change if old.
Lamps loose effect when maximum
Note: See chapter runtime has been exceeded.
3. Operating
instructions and control Transmitter Test the UV sensor:
system description, QT201-50.x 1. Stop the process and restart
2.1
section Compliant malfunction. the process again.

/ non-compliant
operation. 2. In the control system’s UVR
popup, see if the UV values are
OK during the start-up phase.
UV values shall be OK, since
clean cooling water is used.
41
Control system
42
2.1
ID
W153 UVR [x]: UV Trigger: UV reactor. Delay: 30 sec. See chapter 2. System overview,
lamp broken. Parameter: p213 section Operation with broken UV
System flow Comment: If a UV lamp.
reduced. lamp fails during
Control system
ongoing operation,
the flow is set 80 % in
IMO mode and 50 %
in USCG mode of flow
capacity.
The UV lamps are lit to

100 %.
After the process, it is

not possible to start a
new process.
Note: See chapter

3. Operating
instructions and control
system description,
section Compliant
/ non-compliant
operation.
2
W154 UV intensity Trigger: UV sensor Delay: 20 sec. See W152.

USCG low. QT201-50.
System flow Only relevant for
mainted at 50%. PureBallast USCG
systems.
Comment:
Warning issued when

UV intensity falls
Book No.9028195 02
2
ID
below compliance
limit (W/m2): 772 and
252 in IMO mode.
Book No.9028195 02
At this stage power
is 100% and flow is
reduced to 50 %.
Note: Operation

fullfil requirements
for treatment of
ballast water. Act
water management
plan. A new process is
not allowed to start.
W160 UVR [x]: No Trigger: N/A. Delay: 1 sec.

response from Parameter: N/A
LDC. UVR
shutdown.
W161 UVR [x]: LPS Trigger: LPS Delay: 1 sec. Faulty connection of Check the three cable connectors
communication Parameter: N/A electricity or signal on the LPS .
error. UVR cable.
shutdown.
Wrong LPS setting. Check that the DIP switches
are correctly set for every LPS.
2.1
See chapter 4. Parameters,

section Lamp power supply (LPS)
parameters.
Faulty LPS. Change LPS. See instruction in

chapter 7. Service manual.
43
Control system
44
2.1
ID
W163 UVR [x]: Lamp Trigger: LPS in UV Delay: 20 sec. Broken UV lamp. Change according to instruction in
error feedback reactor’s LDC. chapter 7. Service manual.
from LPS. Parameter: N/A Comment: No lamp
feedback when it is Faulty connection of Check UV lamp power cable.
Control system
requested to be started UV lamp cable.

by the LPS.
W164 UVR [x]: LPS Trigger: LPS in UV Delay: 20 sec. Faulty LPS. Check 4.9 LPS power overview
error feedback reactor’s LDC. and LED indication on the LPS
from LPS. Parameter: N/A Comment: No LPS that triggered the alarm. See LPS
feedback when it is alarms in section Lamp power
requested to start its supply (LPS) on page 52.
lamp. UV reactor is
deactivated If the power is on but there are
no indication, the LPS is probably
broken.
W165 UVR [x]: LPS in Trigger: LPS in UV Delay: 5 sec. One or more of the Check 4.9 LPS power overview
fault state. reactor’s LDC. below: and LED indication on the LPS
Parameter: N/A Comment: UV reactor that triggered the alarm. See LPS
is deactivated. • Air temp fault alarms in section Lamp power
• Driver fault supply (LPS) on page 52.
Note: Operation
continues but is not • Fan fault During commissioning: Alfa
2
compliant and does not Laval can run a process with one
fullfil tequirements • Heat sink fault
faulty LPS, to be able to fulfill
for treatment of • System fault commissioning. Parameter p213
ballast water. Act (Allowed nr. of failed UV lamps) is
according to ballast • Voltage fault
set to 1. Parameter must be reset
water management • Broken UV lamp to 0. Operation with faulty LPS
plan. or lamps does not fulfill the type
approval certificate.
Fan fault and temperature faults

can be caused by something that is
preventing the fan from rotate.
Book No.9028195 02
2
ID
Change LPS. See instruction in

chapter 7. Service manual.
Book No.9028195 02
W170 Valve error Trigger: Limit switch Delay: 25 sec. See possible cause
(V201–19) GS201–19. for A17.
Comment: UV reactor
Parameter: N/A is deactivated.
W171 Valve error Trigger: Limit switch Delay: 25 sec. See possible cause
(V201–20) GS201–20. for A17.
Comment: UV reactor
Parameter: N/A is deactivated.
W180 LDC ring Trigger: LDC. Delay: 1 sec. Faulty connection of Check that the power link (LAN)
redundancy signal cable cable from the control cabinet (in a
error Parameter: N/A loop to all LDCs) and back is OK.
Filter sum alarm. Delay: 1 sec. Reset or trun on.

W300 Trigger: Filter. Motor circuit breaker
Parameter: N/A Comment: The (MCB) F1 in control
feedback signal “Filter cabinet has tripped
SUM alarm” is not or has been switched
detected. off.
Motor problem. 1. Check that the motor is not

overloaded and can rotate
easily.
2.1
45
Control system
46
2.1
ID
2. Start the motor and check

that the operation is normal.
See chapter 3. Operating
Control system
description, section Operate

components manually and
chapter 7. Service manual,
section Check filter gear motor
function.
Mechanical obstacles Check that the nozzle can rotate

freely inside the filter. See 7.
Service manual, section Filter for
instructions.
Filter flanges Loosen the pipe connections to

missaligned, and the filter and try to rotate the filter
forced together manually. If the nozzel can rotate,
causing stress and the pipe connections must be
deformation of the renewed. Cut pipe 201 shorter and
filter body. preventing insert a tailor made spool piece
the nozzle to rotate with perfect fitting.
freely inside the filter.
2
W302 Filter 2 sum Trigger: Filter. Delay: 1 sec. See W300

alarm Parameter: N/A
Comment: Only valid
for systems with two
Filtrex filter and flow
1200–2000.
Book No.9028195 02
2
ID
W303 Filter 3 sum Trigger: Filter. Delay: 1 sec. See W300

alarm Parameter: N/A
Comment: Only valid
Book No.9028195 02
for systems with three
Filtrex filter and flow
3000.
W306 Filter differential Trigger: Pressure Delay: 2 sec. Filter is clogged. Backflush manually from control
pressure too transmitter PT201-71 system. If not sufficient, clean
high and PT201-72. the filter element according to

Parameter: p301, instruction in chapter 7. Service
p314. manual.
Valves connected Make sure that the two valves

to filter pressure connected to the filter differential
transmitter closed. transmitter are open.
Pressure transmitters Hint: Pressure signals are

does not work displayed on in the Filter popup
correctly. opened from 1.1 Overview.
1. Check fuse F45 in Control

cabinet to see what circuit
caused the fuse trip.
fuse.
2.1

47
Control system
48
2.1
ID

Control system
drawings.
damaged.
6. Replace faulty transmitter.
beginning.
W308 Filter pressure Trigger: Pressure Delay: 30 sec. Signal missing 1. Check fuse F42 in LDC to see
signal missing transmitter or component which circuit that caused the
(PT201-71) PT201-71. Comment: Alarm malfunction. fuse trip.
Parameter: p314. deactivated in Standby.
fuse.
2

4. Check cables to PT201-71. See
the drawing Control cabinet
drawings.
Book No.9028195 02
2
ID
5. If the above is OK, the UV

sensor is probably broke and
needs to be replaced. Replace
Book No.9028195 02
the component.
W310 Filter pressure Trigger: Pressure Delay: 30 sec. See W308.

signal missing transmitter
(PT201-72) PT201-72. Comment: Alarm
W312 Filter pressure Trigger: Pressure Delay: 30 sec. See W308.

signal missing transmitter PT309-2
(PT309-2) on Hydac filter. Comment: Alarm
W314 Backflush Trigger: Hydac filter. Delay: 15 sec. See W308.

failed to start Parameter: p314.
(timeout).
A315 Diff pressure too Trigger: Pressure Delay: 5 sec. See W306.
high. Automatic transmitter PT201-71
shutdown. and PT201-72. Comment: Pressure
Parameter: p300. transmitters indicates
pressure higher than
set in p300.
2.1
49
Control system
50
2.1
ID
A501 Log box error Trigger: Log box Delay: 10 sec. Wrong setting. 1. Check that parameter p500 is
(optional). activated in the control system.
Parameter: p500.
2. Acknowledge the alarm in the
control system, to be able to
Control system
see when it disappears.
Wrong setting. Check that the switches on the

A40A module is as below:
x16 = 0.
x1 = 1.
Faulty cable 1. Check that there is power to

connection. the A40A and A40B modules.
Power is on if any LED on
the modules have stable or
flickering light.
2. Check power cable (W10) to
the Log box.
Faulty connection. 1. If there is no connection

between control system and log
box (warning W501 still present
in the alarm list. Move the LAN
2
cable from the used port to

the not used port on the A40A
module.
2. Check LAN cable connection in
the LDC.
3. Verify that the cable is not
longer that maximum allowed
cable length of 100 meters.
Book No.9028195 02
2
ID
4. Replace the LAN cable with a

new one. (Try with a temporary
before installing it through the
Book No.9028195 02
cable gland.)
Fuse in the log box Check fuse F02 and F03 in the log
has tripped or has box.
been switched off.
Error in module. Check the LED error indication for

the electronic modules in the log
box. See section I/O system and
X20 modules on page 56.
W502 External bypass Trigger: Log box Delay: 10 sec. See A33.
is open (optional).
Parameter: p500. Comment: If
detected by bypass
configuration in 4.7
Log box.
W503 Heeling mode Trigger: Log box Comment: If See A33.

requested (optional). detected by heeling
Parameter: p500. configuration in 4.7
Log box.
2.1
51
Control system
2.2 Lamp power supply (LPS) 2 List of alarms and warnings
2.2 Lamp power supply (LPS)

This section explains alarms triggered by and displayed on the lamp power supply (LPS) in the
lamp drive cabinet (LDC). LPS alarms are indicated in the control system by alarm W130 – Sum
alarm LPS unit.
2.2.1 List of alarms and status indications

The table below explains alarms triggered by and displayed in the LPS.
LED indication key
The LPS is equipped whit four light indications:
LPS on and communication is functioning.
5 LPSledG
Flashes (once per second) when processor is running.
5 LPSledG2 Flickering light during modbus communication.

Internal fault. Possible causes:
5 LPSledY
• LPS temperature too high (> 50° C).
• LPS fan faulty.
Lamp error. Possible causes:
5 LPSledR
• Two lamp ignition failures.
• Broken UV lamp.
• Loose cables to UV lamp.
Lamp on.
5 LPSledB
Flickering during lamp ignition, approx 2 seconds when lamp is started.
5 LPSledB2
All lamps on Possible causes:
• Faulty DIP switch setting on one or more LPS. This fault occur after a 10 seconds
delay after start.
• Voltage on the fail safe is missing.
52 Book No.9028195 02
2 List of alarms and warnings 2.3 Flow meter
2.3 Flow meter

This section explains faults and alarms triggered by and displayed in the flow transmitter, mounted
on the flow meter (FIT201-1). During normal conditions, all relevant alarms are displayed in the
PureBallast control panel.
Display lines on f ow transmitter
4 Display lines
Flow transmitter: display lines/fields:

1. Main line for primary measured values.
2. Additional line for additional measured variables/status variables.
3. Current measured values.
4. Engineering units/time units.
2.3.1 Fault f nding instruction

Always start troubleshooting with the checklist below if faults occur after start-up or during operation.
1. Check the display, as described below.
2. Restart.
3. If the problem cannot be detected or corrected, the flowmeter, its transmitter or display must be
replaced. Follow the instruction in chapter 7 Service manual , section Replace display and fuse.
2.3.2 Error messages on the display

Errors which occur during commissioning or measuring operation are displayed immediately. If
two or more system or process errors occur, the error with the highest priority is the one shown
on the display.
The measuring system distinguishes between two types of error:
• System errors: This group comprises all device errors, e.g. communication errors, hardware
faults, etc.
• Process errors: This group comprises all application errors, e.g. empty pipe, etc.
There are two error message types:

• Notice message: Displayed as exclamation mark.
The error in question has no effect on the outputs of the measuring device.
• Fault message: Displayed as a lightning flash.
The error in question has a direct effect on the outputs. Serious system errors are always
recognized by the device as "Fault message", and are shown as a lightning flash on the display.
Fault messages immediately affect the outputs.
Error messages on the display
Book No.9028195 02 53
2.3 Flow meter 2 List of alarms and warnings
5 Error messages on the display
Error message on the display

1. Error type; process error or system error
2. Error message type; fault message or notice message
3. Error designation: e.g. EMPTY PIPE = measuring tube is only partly filled or completely empty
4. Error number: e.g. #401
5. Duration of most recent error occurrence (in hours, minutes and seconds)
The table below explains errors displayed on the flow meter display.
Check the display

No display visible and no output 1. Check the supply voltage.
signals present 2. Check the power line fuse.
See chapter 7. Service manual, section Replace display and
fuse for detailed information.
3. Measuring electronics defective.
No display visible, but output 1. Check whether the ribbon-cable connector of the display
signals present module is correctly plugged into the amplifier board.
2. Display module defective.
3. Measuring electronics defective.
Display texts are in a foreign Switch off power supply. Press and hold down both the OS
language. buttons and switch on the measuring device. The display text
will appear in English (default) and is displayed at maximum
contrast.
Error messages on the display
Error messages consist of a variety of icons: the meanings of these icons are as follows (example):
Error type:
S = system error
P = process error
Error message type:
5 Flash
$ = fault message
! = notice message
EMPTY PIPE = Type of error, e.g. measuring tube is only partly filled or completely empty
03:00:05 = duration of error occurrence (in hours, minutes and seconds)
#401 = error number
Error number: System error (device error) has occurred
No. 001 – 399
No. 501 – 699
Error number: Process error (application error) has occurred
No. 401 - 499
54 Book No.9028195 02
2 List of alarms and warnings 2.4 Level switch
351 to 354 S: CURRENT Current output: flow is out of 1. Change the upper or lower
RANGE n range. limit setting, as applicable.
!: # 351 to 354 2. Increase or reduce flow, as
applicable
401 EMPTY PIPE Measuring tube partially filled 1. Check the process conditions
$: # 401 or empty of the plant
2. Fill the measuring tube
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 LED:s on the module.
Color State Description What to do?
Green Steady Power on and in operation.
Green Off No power supply. Check plug, cable and power

supply.
Yellow Steady Wet condition.
Red Blinking Error: Internal sensor error or sensor Replace the component.
corroded.
Red Steady Error: Overload or short-circuit in load Rectify the short-circuit.

circuit.
Reduce maximum load current
to below 250 mA.
Book No.9028195 02 55
2.5 I/O system and X20 modules 2 List of alarms and warnings
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 LED:s on the module.
All modules are identified on the front, for example “X20 DO 6529” in the illustration below. To the
right, the stat indication LEDs are visible, for example “r, e, X, I” in the illustration below.
5X20
56 Book No.9028195 02
2 List of alarms and warnings 2.5 I/O system and X20 modules
The following modules are installed in the LDC or control cabinet:
Identif cation Function Installed in cabinet
AI4622 Analogue input Control cabinet
AO2622 Analogue output Lamp drive cabinet
AO4622 Analogue output Control cabinet
CP3585 PLC module (System module CPU) Control cabinet
IF1082-2 Interface module, power link Control cabinet
PS2100 Power feed, 24V Control cabinet
DI9371 Digital input Control cabinet
DO6529 Digital output Control cabinet

Lamp drive cabinet
DO9322 Digital output, 12 outputs Control cabinet

Lamp drive cabinet
AI2622 Analogue input Control cabinet

Lamp drive cabinet
AT4222 Temperature input module Lamp drive cabinet
BC0083 Bus controller, power link Lamp drive cabinet
CS1030 Interface module Lamp drive cabinet
DI8371 Digital input Lamp drive cabinet
IF1030 Interface module, RS422/RS485 Control cabinet
PS9400 24V power feed, bus supply Lamp drive cabinet
2.5.1 List of alarms and status indications

Below, alarm and status indications displayed on the modules are explained.
NOTE
• Note that all status indications are not valid for all modules.
• The meaning of a status indication might vary for some modules. These variations are specified
in the Description column.
• Module BC0083, CP3585 and IF1082-2 are described in separate tables below the generic
table.
The table contains the following columns and information:
Book No.9028195 02 57
Light Lights on the module.

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

r Green Off 24 V DC supply not connected, check fuse.
Single flashes Reset mode.
Blinking Preoperational mode.
On RUN mode.
e Red Off Module not supplied or everything is OK.
Single flashes Warning / error for an I/O channel. Level
monitoring for digital outputs has responded.
AT4222: Overflow or underflow of the analog

inputs.
Double flashes Indicates one of the following conditions:
• X2X bus power supply is overloaded.
• I/O supply too low.
• For PS9400: Input voltage for the X2X bus
supply too low.
On Error or reset state.
r+e Red/Green Red - steady / Invalid firmware.
Green - single
flashes
X Orange Off No communication at the X2X bus.
On X2X bus communication in progress.
I Red Off Bus controller / X2X link supply in acceptable
range.
On Bus controller / X2X link supply overloaded.
S Yellow Off No data traffic over service interface; no activity.
On Data is transferred over the service interface.
1–6 Orange On In/output status of the corresponding digital
in/output.
1–8 Green
Output status of the corresponding digital output.
1–12 Orange
In/output status of the corresponding digital
1–12 Green in/output.
1–16 Green In/output status of the corresponding digital

in/output.
Input status of the corresponding digital input.
58 Book No.9028195 02
Light Color State Description

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

L/A IF2 Blinking On and Ethernet activity present on the bus.
S/E Red On Bus controller error: Failed Ethernet frames, increased
number of collisions on the network etc.
Blinking Only during startup. This is not an error.
Green Off Bus controller is either powered of or not active.
Communication is not possible with the bus controller. After
5 seconds in this state, the bus controller restarts.
If POWERLINK communication is detected during

the 5 seconds, the bus controller goes to status
PRE_OPERATIONAL_1 (single flash).
If no powerlink communication is detected, the bus controller

goes to BASIC_ETHERNET state (flickering).
Green On Bus controler in operation.
Green Flickering No Powerlink communication detected by bus controller.
(approx. 10 Hz) In this state you can communicate directly with the bus
controller using UDP.
Book No.9028195 02 59
If POWERLINK communication is detected in this state, the

bus controller goes to state PRE_OPERATIONAL_1 (single
flash).
Green Single flash Bus controller in PRE_OPERATIONAL_1.
(approx. 1 Hz)
With operation on a POWERLINK V1 master, the bus
controller goes directly into PRE_OPERATIONAL_2.
With operation on a POWERLINK V2 manager, the CN

(Controlled Node) waits for the reception of a SoC frame
and then switches over to PRE_OPERATIONAL_2 (double
flash).
Green Double flash Bus controller in PRE_OPERATIONAL_2.
(approx. 1 Hz)
In this state the bus controller is normally configured by the
manager. A command (POWERLINK V2) or setting the data
valid flag in the output data (POWERLINK V1) then switches
the state to READY_TO_OPERATE (triple flash).
Green Triple flash Bus controller in READY_TO_OPERATE.
(approx. 1 Hz)
In a POWERLINK V2 network, the manager then switches
via command to OPERATIONAL.
In a POWERLINK V1 network, the bus controller then

switches automatically to OPERATIONAL as soon as input
data are present.
Green Blinking Bus controller is in STOPPED.
(approx. 2.5
Hz) No output data is produced and no input data is received.
Only the appropriate command from the manager can enter
or leave this state.
Module CP3585
R/E Green On Application is running.

Red On Service mode.
RD/F Yellow On Service or boot mode.
Red On Over-temperature.
60 Book No.9028195 02
S/E Green Green Red Powerlink OK.

/Red on off
Green Red Fatal and irreparable system error. See control
off on system for alarm or warning. This status can only
be changed by resetting the module.
Blinking The powerlink managing node failed. This error
alternately code can only occur in controlled node operation.
This means that the set station number lies within
the range $01 - $FD.
Green Red System failure according to blinking pattern:
off blink-
ing ●●● — Pause ●●● — Pause: RAM error.
— ●● — Pause — ●● — Pause: Hardware error.

EPL Green On Link to powerlink remote station is established.
Blinking On and Ethernet activity present on the bus.
ETH Green On Link to Ethernet remote station is established.
Blinking On and Ethernet activity present on the bus.
CF Yellow On Flash card OK.
Green On Flash card active.
DC Yellow On CPU power supply OK.
OK Red On Backup battery is empty.
Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated in two moedes: Either
in Powerlink V mode or as an Ethernet TCP/IP interface. Status light depends on mode. For
TCP/IP mode, only SE green is valid.

Green Red
L/A X1 Green On Link to the remote station is established.
L/A X2 Blinking On and Ethernet activity present on the bus.
S/E On Off TCP/IP mode: Powerlink interface is operated purely as
an Ethernet TCP/EP interface.
Powerlink mode: Powerlinkt station is running, no errors.

Off On Fatal and irreparable system error. See control system
for alarm or warning. This status can only be changed by
resetting the module.
Blinking alternately The powerlink managing node failed. This error code can
only occur in controlled node operation. This means that
the set station number lies within the range $01 - $FD.
Off Red blinking System failure according to blinking pattern:
●●● — Pause ●●● — Pause: RAM error.
— ●● — Pause — ●● — Pause: Hardware error.
Book No.9028195 02 61
Module DI9371
Light Green Red Description
S Off Off Module not supplied, check fuse.

Single Off Reset mode.
flash
Blink- Off Prepoerational mode.
ing
On Off Run mode.
Off Module not supplied or everything is OK.
Single On Invalid firmware
flash
62 Book No.9028195 02
3 List of problems and solutions
This section contains problems that can occur, but is not indicated by an alarm.
3.1 General problems
Book No.9028195 02 63
64
3.1
Problem Description Possible cause What to do?
ID
1A The system does not start. Main breaker Q1 on control Turn on the breaker and measure that incoming 24 V DC to
The control panel does and LDC cabinet turned off, the control panel is present.
not light up. or power not connected to the
control panel.
General problems
Power turned off at main switch Turn on the power.

board
Fuse F42 tripped. 1. Check fuse F42 in control cabinet to see what circuit
caused the fuse trip.
2. Use the circuit diagram to check the fuse setting, adjust
according to figures in circuit diagram if necessary and
reset fuse.
3. Use the circuit diagram to locate the component or find the
reason that caused the fuse trip and attend to it.
Fuse F41 in control cabinet 1. Check fuse F41 in control cabinet to see what circuit
tripped. caused the fuse trip.
2. Use the circuit diagram to check the fuse setting, adjust
according to figures in circuit diagram if necessary and
reset fuse.
3
3. Use the circuit diagram to locate the component or find the

reason that caused the fuse trip and attend to it.
Control panel error. Can be Replace control panel.

caused by overheating etc.
Control panel error due to Let the panel dry and try again.
damp.
Book No.9028195 02
List of problems and solutions
3

ID
1B Control panel is not Abnormal operating condition. 1. Restart the control panel: Cut the power by removing the
displaying a normal page. power cable at the back of the control panel. Wait 30
seconds, and reconnect the cable again.
Book No.9028195 02
2. Restart the entire PureBallast system: Cut the power by
switching of the main breaker on the control cabinet. Wait
30 seconds, and switch on the main breaker again.
3. If panel is not OK, it is probably broke and needs to be
replaced. Replace the component.
Wrong software version Check that the HMI and PLC software have the save program
version. This is visible in control system page 4.1 System info .
HMI software problem Re-load the HMI software according to the software Release
note.
1C PureBallast can not be Communication is broken See the What to do column for alarm A93.
controlled or monitored between ISCS and PLC.
from the ISCS’ graphical
user interface via the
remote interface (optional)
1D Error message on the screen.

3.1
5 PanelCommunicationError
These messages can appear alone or in combination. The message does not appear in remote control panels (option).
“PureBallast: Comm Error ...”: Check the following:

• See the What to do column for alarm A91.
Communication is broken between remote control panel
and PLC. • If the electrical and signal cables are disconnected or
broken. See Remote control panel / Circuit diagram.
General problems
65
66
3.1
ID
• If the control cabinet is turned off.

• If the PLC is broken.
If control panels are not used: Remove IP address for Remote
control panel 1 according to instruction is set for the remote
General problems
control panel. See chapter 3. Operating instructions and

control system description, section Set remote control panel
communication.
“Disconnected from ...”: Check the following:

• If the electrical and signal cables are disconnected or
Communication is broken between remote control panel broken.
and main panel.
• If the control cabinet is turned off.
• If the main panel is turned off or broken.
If control panels are not used: See 1D.
3
Book No.9028195 02
3 List of problems and solutions 3.2 Filter
3.2 Filter
Book No.9028195 02 67
68
3.2
5A Backflush sequence Pressure transmitters Dismantle the component and inspect/rinse.
starting error (general) PT201–71 and PT201–72
may be faulty.
Filter
Pressure transmitters
PT201–71 and PT201–72 Error with the pressure gauge Dismantle the component and inspect/attend to.
may be faulty. electric switches.
Valves for air pressure to valve Open the valve (ball cock) connected to V309-1.
V309-1 are closed.
5B Excessive backflushing The filter house is not properly Deaerate using the deaeration valve V201-50 on the filter lid.
or long backflushing deaerated.
sequences (general)
Damaged filter element. Check filter element for damage. Replace if necessary.
Large obstructions have Open the filter and remove the obstructions. See chapter 7.
entered the filter. Service manual, section Filter.
Dirty water See chapter 2. System description, section Backflushing for

different dirt loads.
Dirt build-up in the filter element. Clean the filter element.

3
Book No.9028195 02
3 List of problems and solutions 3.3 CIP
3.3 CIP
Book No.9028195 02 69
70
3.3
6A Insufficient pump capacity Leakage in air hoses or Locate leakage and attend to.
(general). sealings.
CIP
Air pressure too low due to Adjust setting with the manual valve under the valve block on
incorrect setting on valve block the CIP module.
on CIP.
The diaphragm in the CIP pump Examine the pump. See chapter 7. Service manual, section
is broken. Repair CIP pump.
Pump is clogged. Examine the pump. See chapter 7. Service manual, section
Repair CIP pump.
6B Too high consumption Leakage in the CIP tank, CIP Locate leakage and attend to.
of CIP liquid (> 1 cm/UV pump, pipes or UV reactor.
reactor cycle).
6C CIP liquid is not returned Insufficient pump capacity 1. Increase airflow to the pump to increase pump capacity
to CIP tank. (P321-5). with the manual valve under the valve block on the CIP
module.
2. Check that pump P321-5 is functioning correctly. See
problem 6D−6I in this chapter.
Broken valve. Examine the following valves: V571-1, V321-2.x, V320-4.x

and V321-1.
3
Pipe blockage Investigate if there is a pipe blockage.
6D CIP pump does not run • The air pressure is to low Examine the pump and attend to problem. See chapter 7.
Service manual, section Test CIP pump.
• The air connection is
blocked
• Muffler is blocked
• Air valve is defect
• Dirt in the pump chamber
• Diaphragm breakdown
Book No.9028195 02
3
6E CIP pump runs irregularly • Valve balls are blocked Examine the pump and attend to problem.
• Sealings are defect in air
valve or center block
• Diaphragm breakdown
Book No.9028195 02
6F Insufficient CIP pump • Suction connection blocked Examine the pump and attend to problem.
suction or not tight.
• Valve balls are blocked or
damaged
6G Bad flow or pressure in • Pressure fall in incoming air Examine the pump and attend to problem.
CIP pump
• Suction or air connection
blocked
• Air valve is defect
• Valve balls worn out/broken
• Air in liquid Diaphragm
breakdown
6H CIP pump leakage Screws on the housing not Tighten the screws.
properly fastened
6I CIP pump muffler leakage Diaphragm breakdown Change diaphragm.

3.3
71
CIP
3.4 Valve V201–8 3 List of problems and solutions
3.4 Valve V201–8
72 Book No.9028195 02
3
8A Signal change has no effect on Faulty air supply Check air supply to the valve and tubing to the actuator.
the actuator position See chapter 7. Service manual, section Proportional
valve for instructions regarding the proportional valve.
Faulty signal • Check input signal to proportional valve.

• Check I/P output.
Book No.9028195 02
8B Signal change results in actuator Connection or signal problem • Check coupling between proportional valve and
running to end positions actuator.
• Check input signal.
Signal and positioning problems. • Inaccurate positioning. Adjust position sensor. See chapter 7. Service manual,
8C
section Calibrate positioner on V201-8.
• Input signal fluctuates.
Check electric connection.
3.4
Valve V201–8
73
Chapter: 6. Technical data and drawings
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
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 Introduction 5
1.1 Ship specif c information 5
2 Technical data 7
2.1 Water and f ow requirements 7
2.2 Power requirements 8
2.3 System pressure 9
2.4 Pressure requirements — Backf ush 10
2.4.1 Calculate backflush parameter setting 11
2.5 PureBallast components 11
3 Control system integration 13
4 Drawings 15
4.1 Graphic symbols used in drawings 16
4.2 General drawings 17
4.2.1 Flow chart 18
4.2.2 Connection list 20
4.2.3 Electrical system layout (2 pages) 26
4.2.4 Instrument air distribution 28
4.2.5 Quality specification / Instrument air 29
4.2.6 Quality specification / Technical water / potable
water 30
4.2.7 Quality specification / CIP liquid 31
4.2.8 Material data sheet / UV lamp 32
4.2.9 Safety data sheet / CIP liquid 42
3
4.3 Dimension drawings including technical
data 50
4.3.1 UV reactor (previously called AOT reactor) 50
4.3.2 Filter 51
4.3.3 CIP module (2 pages) 52
4.3.4 Flow transmitter FIT201-1 54
4.3.5 Pressure monitoring device 6 bar system (Incl.
PT201-16, PI201-18, RV201 and 201-15) 55
4.3.6 Pressure monitoring device high pressure system
(Incl. PT201-16, PI201-18, RV201 and 201-15) 56
4.3.7 Valve V201-3 and V201-9 57
4.3.8 Valve V201-32 and V403-35 58
4.3.9 Valve V212-31 (Optional in scope of supply) 59
4.3.10 Control valve V201-8 61
4.3.11 Backflush valve V309-1 62
4.3.12 Sampling device Q201.1 and Q201.2 (3 pages)
(Optional in scope of supply) 63
4.3.13 Lamp drive cabinet (LDC) 66
4.3.14 Control cabinet 67
4.3.15 Remote control panel (Optional) 68
4.3.16 Log box (Optional) 69
4.3.17 Transformer (Optional) 70
4.3.18 Air filter / Filter regulator 71
4.3.19 Additional pumps (Optional) 72
4.3.20 Closed cooling unit, LDC / Dimension drawing
(Optional) 75
4.3.21 UV reactor and LDC / Lamp power cable 76
4.4 Electrical drawings 77

4.4.1 Control cabinet / Interconnection diagram 77
4.4.2 Control cabinet / Circuit diagram 85
4.4.3 Control cabinet / Cable list 106
4.4.4 Lamp Drive Cabinet (LDC) / Interconnection
diagram 107
4.4.5 Lamp Drive Cabinet (LDC) / Circuit diagram 109
4.4.6 Lamp Drive Cabinet (LDC) / Cable list 125
4.4.7 UV reactor / Interconnection diagram 126
4.4.8 UV reactor / Circuit diagram 128
4.4.9 UV reactor / Cable list 131
4.4.10 Remote control panel (optional) / Circuit diagram 132
4.4.11 Transformer (optional) / Interconnection diagram 133
4.4.12 Transformer (optional) / Circuit diagram 134
4.4.13 Transformer (optional) / Cable list 135
4
1 Introduction
This chapter contains technical information about PureBallast together with mechanical and
electrical drawings.
1.1 Ship specif c 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.
Data Value
Flange standard (EN or JIS): _______________
Main valve and piping Dimension: ________________
Control valve (201-8) Dimension: ________________
Bypass valve (V212–31) Dimension: ________________
Alfa Laval’s or other. Location: __________________
Cooling water valve (V403-35) Dimension: ________________
Remote operation (optional) Remote control panel (number): _________
Remote interface integration (yes/no): _____
Book No.9028195 02 5
1.1 Ship specific information 1 Introduction
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.
2.1 Water and f ow requirements

For details, see Connection list.
Water requirements
Ballast water Used for cooling UV lamps in the UV reactor during start-up. Pipe
403 is recommended to be connected to the vessel’s sea water
cooling system or dedicated UV cooling water pump (P403-1) for UV
reactor cooling. Booster pump is not part of Alfa Laval’s scope of
supply.
Min temperature: Freezing point of water (varies with salinity).

Max temperature: 40 °C.
Salinity: PureBallast water treatment system can treat water with

all salinities.
Technical water / potable Used:
water During CIP process, cleaning the UV reactor and filter after ballast
water treatment.
After CIP process, filling the UV reactor and filter after ballast water
treatment for preservation purpose.
Temperature: 0–38 °C.
For details, see Quality specification / Technical water / Potable
water on page 42.
Treated cooling water / Used for cooling the lamp drive cabinet (LDC) during operation.
technical water Pipe 401 and 402 can be connected as a loop to the cooling water
system using treated cooling water / technical water.
Max temperature: 38 °C (± 2 °C).

UV intensity limit The system have been tested and found to give full treatment of
the ballast water when the measured UV intensity (w/m2) is above
772 and 252 in IMO mode.
UV intensity is measured by UV transmitter QT201–50.
Book No.9028195 02 7
2.2 Power requirements 2 Technical data
Flow requirements
Flow range (m3/h) Ballast: 195 → 1000
Pipe 201 Deballast: 100 → 1000
Stripping: 100 → 333 .
During operation, the input flow to the PureBallast system shall be

as close as possible to the max flow. This will reduce the stress
and wear of the control valve.
Filter backflush water Minimum flow: 95 m3/h.
Pipe 309
Technical water / potable Consumption: 565 liters.

water during CIP process
Pipe 310.1
Cooling water to LDC Minimum flow: 1.5 m3/h

(Treated cooling water /
Technical water)
Pipe 401
Start-up cooling water to UV Minimum flow: 20 m3/h

reactor.
Pipe 403
2.2 Power requirements

General power requirements
Nominal voltage and 400–440 VAC, 50/60 Hz 3 phase.

frequency If voltage does not meet the requirements, a transformer can be used.
The transformer is recommended to give voltage in the higher range,
as close as possible to 440 VAC.
Max Icu 50 KA.
Power factor: 0.95.
24VDC - Remote control panel (optional).
8 Book No.9028195 02
2 Technical data 2.3 System pressure
IP rating >IP44
LDC — Heat dissipation Heat transfer from/to the LDC is depending on ambient temperature.
The need for cooling the area where the LDC is placed, is therefore
dependent on ambient temperature.
The calculations below can be used as a guide.
At an ambient temperature of
1. 10 °C, about 1200 W is transferred to the surroundings.

2. 25 °C, about 600 W is transferred to the surroundings.
3. 40 °C, no heat is transfer in either direction.
4. 45 °C, about 200 W is absorbed from the surroundings.
5. 50 °C, about 400 W is absorbed from the surroundings.
All calculations are done with cooling water temperature of 38 °C
degrees which is worse case.
Component Power consumption (kW)

Control cabinet 1
Control cabinet including filter motor.

Lamp drive cabinet 100.0
Power to UV reactor.
Note: PureBallast only use power needed for treatment. PureBallast

automatically regulates the lamp power between 50 and 100 % to
secure the treatment efficiency.
Pump P309–1 (optional) 7.5
For filter backflush water.

For LDC cooling water.

For UVR cooling water.
2.3 System pressure

The table gives a description of system presure range for piping and instrument air.
Book No.9028195 02 9
2.4 Pressure requirements — Backflush 2 Technical data
System working pressure range
Piping Standard system: 0–6 bar.
High pressure system:
0–9 bar.
Instrument air 5.5 – 8.0 bar to operate valves and CIP pumps. For
detailed requirements, see
• Connection list on page 20.
2.4 Pressure requirements — Backf ush

This section gives a description of installation specific requirements regarding presure during
ballast and backflush operation.
Minimum required pressure at filter inlet:
With backf ush pump : 1.7 bar. For details, see table below.
Without backf ush pump : If backflush pump P309 is not used, pressure drop in pipe 309 ( p309)
must be calculated and added according to the table blow.
Note This pressure will overcome pressure drop for PureBallast components and ensure filter
backflush. Piping is not included.
Pressure (bar) Comment
Pressure drop during ballast
≤ 0.2 Pressure drop for UV reactor and PureBallast’s valves.
≤ 0.5 Max differential pressure over the filter during ballast operation. When
the differential pressure reaches 0.5 bar due to dirt in the filter, a
backflush is started automatically.
Pressure needed for backf ush
1.0 Required pressure to backflush the filter.
p309 If a backflush pump P309 is not used, pressure drop in pipe 309 must
be calculated and added to secure effcient backflush. This is vessel
specific and must be calculated using required flow in pipe 309:
95 m3/h.
The result of this calculation is used to set parameter p304, crucial for
the backflush. See Calculate backflush parameter setting below.
10 Book No.9028195 02
2 Technical data 2.5 PureBallast components
Total The ballast water pump must deliver pressure at filter inlet, covering
total pressure drop over PureBallast.
Calculated value give
• maximum pressure drop during backflush

• minimum ballast water pump capacity required for PureBallast.
If the value is greater than existing pump capacity, steps must be taken,
for example:
• Reduce the total pressure drop by reducing p309. This can, for
example, be done by increasing the pipe diameter or by reducing
the number of bends etc in pipe 309.
• Upgrade ballast water pump or impeller.
• Use a backflush pump, if not already done.
2.4.1 Calculate backf ush parameter setting

System pressure (PT201-16) needed for backflush is set in parameter p304 (Pressure setpoint
during backflush). If this pressure is not fulfilled when a backflush is triggered, control valve V201-8
will operate to build up and maintain this pressure.
The parameter setting is depending on if a backflush pump is used or not.
Without, the setting must be calculated according to below. With backflush pump, a fixed value is
used.
p304 - Pressure setpoint during backf ush
• Setting without backflush pump = 1.0 + ∆P309.

• Setting with backflush pump = 1.0.
2.5 PureBallast components
The table below states basic information about weight and volume for major component in the
PureBallast system.
For detailed information, see dimension drawings in section Dimension drawings including technical
data on page 50.
Component Type of data Value
UV reactor Weight, empty 330 kg.

(kg)
Volume (l) 190
Remote control panel Weight (kg) 15.

(optional)
Book No.9028195 02 11
2.5 PureBallast components 2 Technical data
Filter Weight, empty 1150

with adaptor plates
on flanges (kg)
Volume (dm3) 370.
CIP module Weight, empty 155.

(kg)
Tank volume (l) 250. Note: Total tank volume is 300, but shall
only be filled to max 250.
Valves Type Instrument air operated.
12 Book No.9028195 02
3 Control system integration
It is possible to is integrate PureBallast with the vessels ISCS as an option. The purpouse is to
monitor and controll external components on the vessel to make a more smooth integration.
This integration is normally done during installation.
For remote integration, please refer to the following documents, together with the Electrical dwg
- CC.
• Design and installation guide for information about remote control panels, power management
system, external components and GPS integration.
• Remote interface implementation guide
• Logbox installation guide.
Book No.9028195 02 13
3 Control system integration
4 Drawings
This section contains drawings for the PureBallast system. It is divided into three main parts:
• General drawings – overall and principle information for system layout (pipes, components,
electricity, air and water).
• Dimension drawing – detailed component information (dimensions, sizes etc).
• Electrical drawings – detailed electric information (circuit diagrams, cable lists etc).
See the Contents section at the beginning of this chapter to get an overview of included drawings.
Book No.9028195 02 15
4.1 Graphic symbols used in drawings 4 Drawings
4.1 Graphic symbols used in drawings

Symbols used in drawings are according to ISO 14617. Below, a guiding extract is shown.
573644
16 Book No.9028195 02
4 Drawings 4.2 General drawings
4.2 General drawings
Book No.9028195 02 17
4.2 General drawings 4 Drawings
4.2.1 Flow chart

If closed cooling unit, LDC is used see flow chart for closed cooling unit, for item 401 and 402.
9025598
18 Book No.9028195 02
Closed cooling unit, LDC (Optional) / Flow chart
9033711
Book No.9028195 02 19
4.2.2 Connection list

If closed cooling unit, LDC is used see connection list for closed cooling unit, for item 401 and 402.
9025986_Page_1
20 Book No.9028195 02
9025986_Page_2
Book No.9028195 02 21
9025986_Page_3
22 Book No.9028195 02
9025986_Page_4
Book No.9028195 02 23
9025986_Page_5
24 Book No.9028195 02
Closed cooling unit, LDC (Optional) / Connection list
9033710
Book No.9028195 02 25
Book No.9028195 02
Drawings

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9010001
28 Book No.9028195 02
4.2.5 Quality specif cation / Instrument air
553407
Book No.9028195 02 29
4.2.6 Quality specif cation / Technical water / potable water
590773
30 Book No.9028195 02
4.2.7 Quality specif cation / CIP liquid
Book No.9028195 02 31
594956
4.2.8 Material data sheet / UV lamp
32 Book No.9028195 02
Book No.9028195 02 33
34 Book No.9028195 02
Book No.9028195 02 35
36 Book No.9028195 02
Book No.9028195 02 37
38 Book No.9028195 02
Book No.9028195 02 39
40 Book No.9028195 02
Book No.9028195 02 41
4.2.9 Safety data sheet / CIP liquid
42 Book No.9028195 02
Book No.9028195 02 43
44 Book No.9028195 02
Book No.9028195 02 45
46 Book No.9028195 02
Book No.9028195 02 47
48 Book No.9028195 02
Book No.9028195 02 49
4.3 Dimension drawings including technical 4 Drawings
data
4.3 Dimension drawings including technical data
4.3.1 UV reactor (previously called AOT reactor)
50 Book No.9028195 02
9003516
4 Drawings 4.3 Dimension drawings including technical data
4.3.2 Filter
Book No.9028195 02
9024508 51
data
4.3.3 CIP module (2 pages)
9004714_p1
52 Book No.9028195 02
9004714_p2
Book No.9028195 02 53
data
4.3.4 Flow transmitter FIT201-1
54 Book No.9028195 02
9024584
4.3.5 Pressure monitoring device 6 bar system (Incl. PT201-16,

PI201-18, RV201 and 201-15)
Book No.9028195 02
9015501
55
data
4.3.6 Pressure monitoring device high pressure system (Incl.

PT201-16, PI201-18, RV201 and 201-15)
56 Book No.9028195 02
9011457
4.3.7 Valve V201-3 and V201-9
9007178
Book No.9028195 02 57
data
4.3.8 Valve V201-32 and V403-35
9007180
58 Book No.9028195 02
4.3.9 Valve V212-31 (Optional in scope of supply)

Note: For pipe dimension 600, see drawing 9008461.
9007176
Book No.9028195 02 59
data
9008461
60 Book No.9028195 02
4.3.10 Control valve V201-8
9007182
Book No.9028195 02 61
data
4.3.11 Backf ush valve V309-1

Note: If backflush pump P309–1 (optional) is installed, this valve is not used.
9025645
62 Book No.9028195 02
4.3.12 Sampling device Q201.1 and Q201.2 (3 pages) (Optional in scope

of supply)
Book No.9028195 02 590066 1

63
data
590066 2
64 Book No.9028195 02
590066 3
Book No.9028195 02 65
data
4.3.13 Lamp drive cabinet (LDC)
9011945
66 Book No.9028195 02
4.3.14 Control cabinet
9012103
Book No.9028195 02 67
data
4.3.15 Remote control panel (Optional)
9012094
68 Book No.9028195 02
4.3.16 Log box (Optional)
9002906
Book No.9028195 02 69
data
4.3.17 Transformer (Optional)
9029115
70 Book No.9028195 02
4.3.18 Air f lter / Filter regulator
9018092
Book No.9028195 02 71
data
4.3.19 Additional pumps (Optional)

LDC cooling water pump P401–1 (Optional)
9019602
72 Book No.9028195 02
UVR cooling water pump P403–1 (Optional)
9019614
Book No.9028195 02 73
data
Backf ush pump P309–1 (Optional)
9025762
74 Book No.9028195 02
4.3.20 Closed cooling unit, LDC / Dimension drawing (Optional)
9033706
Book No.9028195 02 75
data
4.3.21 UV reactor and LDC / Lamp power cable
9007280
76 Book No.9028195 02
4 Drawings 4.4 Electrical drawings
4.4 Electrical drawings
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Chapter: 7. Service manual
USCG
Book No. 9028195 02, rev. 5

Published By:
Alfa Laval Tumba AB

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40
Laval Tumba AB.
Contents
1 Introduction 7
2 Maintenance schedule 9
2.1 Calibration schedule 11
2.2 Recommended spare parts on board 13
2.3 Serial number information 13
2.3.1 Indicating serial number 13
2.3.2 Example 14
2.4 Placing of serial numbers 15
3 Operate valves manually 19

3.1 Open and close valves manually (CIP
valves) 19
3.2 Open and close valves manually 19
3.3 Lock valve in closed position 20
3.4 Unlock valve 21
4 UV reactor 23
4.1 Safety information 23
4.2 Replace UV lamp and quartz sleeve 25
4.2.1 Disassemble UV lamp 25
4.2.2 Disassemble quartz sleeve 28
4.2.3 Assemble quartz sleeve 28
4.2.4 Check for leaks after quartz sleeve assembly 29
4.2.5 Assemble UV lamp 29
3
4.3 Dismount and mount lamp power
supply (LPS) 30
4.4 Test LPS installation 32
5 Filter 33
5.1 Remove f lter cover and f lter element 36
5.2 Mount f lter element and f lter cover 38
5.3 Clean f lter element and pre-f lter 38
6 CIP module 41
6.1 Change and ref ll CIP liquid 41
6.1.1 Change CIP liquid 43
6.1.2 Refill CIP liquid 43
6.2 Repair CIP pump 44

6.2.1 Clean CIP pump 44
6.2.2 Disassemble CIP pump 45
6.2.3 Assemble CIP pump 46
6.3 Test CIP pump 47

6.4 Repair junction box and valve blocks 47
6.5 Repair valve block 47
6.5.1 Change valve body 48
6.5.2 Connect electrical cables to valve block 48
6.5.3 Clean valve block 49
6.5.4 Connect pneumatic hoses to valve block 49
7 Flow meter 51
7.1 Replace display and fuse 51
8 Valve actuator 53
8.1.1 Tightening torques for actuators 54
4
8.2 Dismount actuator 55
8.3 Mount actuator on valve 55
8.4 Change direction of actuator – without
position sensor (V404–36, V320–4 and
V321–2) 57
8.5 Change direction of actuator – with
switch box (V201–3, V201–9, V201–32,
V212–31 and V403–35) 58
position sensor (201-19 and 201–20) 58
positioner (201–8) 60
8.8 Mount pilot valve on actuator 60
8.9 Adjust valve end position 61
8.10 Adjust valve traveling speed 62
8.11 Calibrate positioner on V201-8 64
8.12 Adjust cam position on V201-8 68
9 Ball valve 69
9.1 Replace seals in ball valve 69
10 Level switch 71
10.1 Mount level switch 71
10.2 Dismount level switch 72
10.3 Test level switch 72
11 Temperature switch and

temperature transmitter 73
11.1 Mount temperature switch / temperature
transmitter 73
11.2 Dismount temperature switch /
temperature transmitter 74
12 Control panel 75
12.1 Clean control panel 75
12.2 Replace control panel 75
13 Remote control panel (optional) 77

13.1 Mount and connect remote control
panel 77
14 Control cabinet and lamp drive 5
cabinet (LDC) 79
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.
NGE R
! DA
• Before maintaining the PureBallast system, the power supply must be switched off, to avoid
accidental starts. See instruction Shut down and deactivate system in chapter 3. Operating
instructions and control system description.
NOTE
• All maintenance and calibration activities must be recorded in the vessel’s maintenance log.
This is required by the ballast water convention. It is therefore recommended that the activities
in the maintenance and callibration schedules below are entered in the vessel’s general
maintenance system.
• Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.
• Electrical welding requirements: Connect the welding unit’s negative lead (work lead) to the
component you will weld, close to the welding area.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 20.
• Follow local regulations for electrical installation and grounding (earthing).
• Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.
• Point of contact: To order service or spare parts, contact your local Alfa Laval office. For
more information, see www.alfalaval.com.
Book No.9028195 02 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
General Testrun the Once a month. See 3. Operating If the system, for
system: Run a instructions and some reason, is not
ballast and/or control system operated by normal
deballast process. description. ballast operations,
Follow up with a it needs to be run
CIP process. Manual operation to verify that it is in
of valves: See good condition.
Note: If system is chapter 7. Service
used, but certain manual, section This will also
valves are not Valves. exercise the valves,
used, for example actuators and other
V212–31, those components to
should be opened keep them in good
and closed condition.
manually. For
relief valves,
see Calibration
schedule.
General Inspect for Once a year.

corrosion and
erosion damage.
General Calibration of According to See Calibration

sensors Calibration schedule
schedule
UV reactor Outer inspection Once a year. See Spare parts

of seals for catalogue for
leakage. service kit.
Check UV lamps Once a year. See Disassemble See Spare parts

for leakage. quartz sleeve. catalogue for
service kit.
Replace of UV Recommended to See Replace UV 16 UV lamp sets.

lamps. change all lamps lamp and quartz Spare part number:
after 3000 hours of sleeve. 9009521 80
operation.
Book No.9028195 02 9
2 Maintenance schedule
Replace IMO requirement: Sparepart number:

UV sensor Every second year. 9001357 03
(QT201–50) EPA requirement:
Every year.
Filter Inspection and Once a year. See Remove Replace filter

cleaning of filter filter element and element, if
element. pre-filter. damaged.
Cleaning once a See Spare parts

year nomally is catalogue for
enough. But in service kit.
exceptional cases
(vessels trading
very muddy
waters) it might
be necessary to
clean the element
more often than
once year.
Outer inspection Once a year. If necessary,

of seals for change faulty seals.
leakage.
CIP liquid pH value check. Every 3rd months, See Change CIP
whichever comes liquid.
first.
CIP liquid level Rule of thumb: See Change CIP If the CIP liquid
check. Once every 3 liquid or Refill CIP level is low but the
months. liquid. pH value is below
Depending 3, CIP liquid and
on number of water can be added
UV reactor to fill up the liquid
and ballasting level in the tank.
frequency, the liquid Note: pH value
check might have to must be checked
be performed more afterwards to
regularly. secure correct pH
value.
Replacement of When the pH value See Refill CIP Recommendation

CIP liquid. is higher than pH 3 liquid. to order 2 cans at a
or once a year. time. Part number:
or 596250 01
When the CIP
module has been
inactive for over
one year.
Control of stored Visual inspection See Preparations

CIP liquid. after three years. and conditions
under Change and
refill CIP liquid
instruction.
10 Book No.9028195 02
2 Maintenance schedule 2.1 Calibration schedule
Valve block Control that the Once a year. See chapter 7.

on CIP cables are firmly Service manual,
module attached to the section Connect
terminal strip in electrical cables to
the valve block. valve block.
Valves and Control that Once a year. See chapter 7.

actuators the component, Service manual,
cables and section Valve
hoses are firmly actuator for
attached. instructions.
Power Check power Once a year. See instruction

cables cables screw Power cable check
connections on page .
Control Replace battery in When alarm PLC Automatic check

system PLC module. battery low is when the control
indicated in the cabinet is turned on
control system. and every 24 hours.
or:
After 5 years. The battery is
or: placed in the
Before storage for PLC module in
longer periods. the control cabinet.
2.1 Calibration schedule

Follow this calibration schedule to secure performance of the system and its components. The
schedule is sorted per component.
Interval: Once a year, if nothing else is stated.
Component Informatoin / instruction
Flow meter Every second year.
1. Connect a calibrated portable ultrasonic flow meter close to the flow meter.
2. Establish flow in the system.
3. Compare value indicated in control system and measure equipment.
Relief valves 1. Remove the relief valves.
Pressure 2. Connect them to an external pressure point and apply higher pressure
transmitter: than approved.
(RV201) 3. Make sure that they relief pressure.
UVR: 4. Mount the relief valves again.

(RV201–23)
Book No.9028195 02 11
2.1 Calibration schedule 2 Maintenance schedule
Pressure 1. Connect calibrated portable measure equipment to the measure point

transmitters (screw to the side, under the handle).
Filter: (PT201-71, 2. Open V201-32 from the control system.

PT201-72) PT201-71 and PT201-72
Pressure 3. Compare values indicated for the three transmitters in control system
transmitter and measure equipment.
(PT201-16)
4. Open 403-35 from the control system, and compare again.
Pressure gauge PT201-16
(PI201-18)
5. Open V403-35 to apply pressure to the system.
Pressure service
valve (PT201-15) 6. Adjust handle on PT201-16 to establish pressure to measure point.
7. Compare value indicated in control system and measure equipment.
PI201-18
8. Compare value indicated in pressure gauge and measure equipment.

V201-15
9. If above tests are OK, valve V201–15 is OK.
QT201–50 Not calibrated. The component is replaced. See Maintenance schedule

above.
UV reactor 1. Depressurize and drain the reactor: Remove the drain plug at the bottom
components of the UV reactor.
Temperature TT201–33
transmitter
2. Dismount the transmitter and place in water with known temperature
(TT201-33)
(calibrated measure instrument).
Temperature 3. Compare value indicated in the control system and measure equipment.
switch (TS201-
60) TS201-60
Level switch 4. Dismount the switch and place in water with temperature < 65 ˚C.
(LS201-29) 5. Check that alarm A137 is displayed in the control system.
LS201-29
6. Dismount the sensor and lace it in a glass of water.

7. Check that you get a signal for the UV reactor in the control system.
8. Fill the UV reactor with technical water / potable water.
Temperature Place a calibrated thermometer inside the cabinet and compare after 30
transmitter in minutes.
LDC (TT401)
12 Book No.9028195 02
2 Maintenance schedule 2.3 Serial number information
2.2 Recommended spare parts on board

One of each spare part or spare part kit is recommended to be stored onboard.
UV reactor
UV lamp set Content: 1 UV lamp and 2 O rings
Spare part number: 9009521 80
Quartz sleeve Content: 1 quartz sleeve and 2 O rings

set
Temperature Spare part number: 9006325 02

transmitter
Temperature Spare part number: 9006324 02

switch
Lamp drive cabinet (LDC)
Lamp power Spare part number: 9012146 01

supply (LPS)
CIP module
Spare part set Content: Diaphragm, muffler, ball and O rings
Filter
Spare part set Spare part number: 9011963 85
2.3 Serial number information

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

Serial numbers shall be stated, including the following information:
Book No.9028195 02 13
2.3 Serial number information 2 Maintenance schedule
• Serial number for the complete PureBallast system. See label on the side of the control cabinet.
• 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),
P (pump) and PI (pressure gauge). A complete list of abbreviations is found in chapter 6.
Installation description and drawings, section Connection list.
2.3.2 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)
14 Book No.9028195 02
2 Maintenance schedule 2.4 Placing of serial numbers
2.4 Placing of serial numbers

The table below indicates the position of the serial number plate per component.
PureBallast water treatment system

Serial number for the complete PureBallast
system.
Electrical cabinets: Control cabinet and LDC

Including breakers.
Placing: Plate inside cabinet.
UV reactor
At the side of the UV reactor, as indicated in the

illustration.
7 AOT Snr
Book No.9028195 02 15
2.4 Placing of serial numbers 2 Maintenance schedule
Filter
Placing: At the side of the filter, as indicated

in the illustration.
7 FilterSnr Filtrex
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.
7 LDC sernr
16 Book No.9028195 02
2 Maintenance schedule 2.4 Placing of serial numbers
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.
7 Valve Snr 591890
Flow meter
(Including flow transmitter and flow sensor)
Placing: At the side of the transmitter housing,

as indicated in the illustration.
7 serial#
NOTE
The serial number for the f ow transmitter is also valid

for the f ow sensor.
Book No.9028195 02 17
2.4 Placing of serial numbers 2 Maintenance schedule
3 Operate valves manually
This section covers instructions on how to open, close and lock/unlock valves manually.
Avoid operating valves manually. Valves are normally operated from page 1.1 Overview in
the control system (manual mode). See chapter 3. Operating instructions and control system
description for instruction.
3.1 Open and close valves manually (CIP valves)

Follow this instruction to manually operate the valves installed in the CIP module: V571-1, V321-4,
V321-1, V460-2, V320-2 and V310-6. Note that the orange diode on the valve body will not light
during manual operation.
1. Identify which button (illustrated on page 47) on the valve block that controls the valve. The
lower button operates the inner hose under the valve block, and vice versa. Also see the
sticker under the valve block.
2. Press the button on the valve body with a screw driver to operate the valve.
3.2 Open and close valves manually

Follow this instruction to manually operate valves using the position screw on the pilot valve.
Position 0 Closed (default position). If the position screw is in position 0 and the valve is
closed, it can be manually opened. But if the position screw is in position 0 and
the valve is opened, it cannot be manually closed.
Position 1 Opened.
• Air must be connected, but power does not have to be connected.

1. If there is limited access to the screw, it is possible to remove the DIN connector.
2. Place a screw driver in the position screw groove.

Note: Some pilote valves have a spring supported plastic screw that is pressed down before
the screw is turned.
Book No.9028195 02 19
3.3 Lock valve in closed position 3 Operate valves manually
3. Turn the screw to desired position.

— Position 1 to open.
— Position 0 to close.
4. When done, turn back the screw to position 0. If the DIN connector was removed, connect it
again.
3.3 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.
• Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
1. Set the valve to closed position from the control system. Control the position indicator, to make
sure. The yellow position indicator is in line with the valve throttle (indicating open when
the position indicator is in line with the pipe).
2. Disconnect power and instrument air. Verify that the valve is not under pressure.
3. Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
7 576075_lock_manual
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.
20 Book No.9028195 02
3 Operate valves manually 3.4 Unlock valve
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.
3.4 Unlock valve

Follow this instruction to unlock valves from closed position.
• Note that the end positions of the end stop bolts are factory adjusted and must 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.
Book No.9028195 02 21
3.4 Unlock valve 3 Operate valves manually
7. Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.
22 Book No.9028195 02
4 UV reactor
This section covers instruction for service of the UV reactor.
4.1 Safety information

• 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.
• When performing these routines, consider the need for service kits for UV and quartz sleeves,
containing O-rings, lamps, quartz sleeves etc. See Spare parts catalogue.
• Keep the UV lamp in its original protective cover and case when transporting, storing and
disposing of the lamp. Otherwise it could cause injury if the lamp breaks. Do not dispose of
original protective cover and case for the UV lamp, as they should be re-used for storage and
disposal of the old lamp. Mark cases with used UV lamps accordingly, so that they will not be
mistaken for new lamps.
NGE R
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• 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 on page .
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the UV reactor with end caps properly closed.
• 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.
• Before installation, check that the UV lamps and quartz sleeves are not broken.
• 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.
Book No.9028195 02 23
4.1 Safety information 4 UV reactor
NGE R
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• 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.
24 Book No.9028195 02
4 UV reactor 4.2 Replace UV lamp and quartz sleeve
4.2 Replace UV lamp and quartz sleeve
7 AOTexploded2
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
4.2.1 Disassemble UV lamp

Follow this instruction to dismount the UV lamps.
• The PureBallast system must be turned off, and the power disconnected.
• After UV lamps have been changed, the runtime must be reset in page control system page 4.4
Operation timers UVR 1–3. Requires login level Advanced operator.
Book No.9028195 02 25
4.2 Replace UV lamp and quartz sleeve 4 UV reactor
• 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.
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• The UV reactor must not be under pressure when dismounting the UV lamps.
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• Burn hazard: UV lamps can be hot and cause burns.
1. Unscrew the cap nuts (2) holding the caps (1). There is one nut on each side of the UV reactor
per UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.
2. Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).
7UVlampConnection
3. Carefully draw out the lamp bushes (3) on both sides.
Carefully draw out the UV lamp (9) with the electric cable, by holding the electric cables in
both ends. When pulled out, only hold the UV lamp by the ceramic ends. Immediately after
removal, place the old lamp in the new lamp’s protective cover.
If required, use a screwdriver to press on the ceramic end of the lamp inside the bush on the
other side while carefully pulling the electric cable at the other end.
26 Book No.9028195 02
7UVBushScrewdriver
4. Check that the quartz sleeve (10) is not broken.
5. If the quartz sleeves is not broken, mount the new UV lamp according to the instruction
Assemble UV lamp on page 29. If broken, follow the instruction Disassemble quartz sleeve
below.
Book No.9028195 02 27
4.2 Replace UV lamp and quartz sleeve 4 UV reactor
4.2.2 Disassemble quartz sleeve

Follow this instruction to disassemble the quartz sleeve.
1. Close the UV reactor inlet (V201-19.n) and outlet (V201-20.n) valves from the control system
set in manual mode.
2. Drain the UV reactor:

— Open the overboard valve for pipe 460.1.
— Set the system in manual mode.
— Open the following valves: V571-1, V321-2, V321-3 and 460-2. Start pump P321-5. Let the
pump run for the time entered in parameter p200 UV reactor draining.
3. Disconnect the instrument air, as a safety precaution.
4. Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 25.
5. Loosen the three Allen screws (6) of the glass socket (7) on both sides; just a few turns to
release them.
6. Unscrew the Allen screws completely at one side. Carefully remove the glass socket, to avoid
breaking the quartz sleeve. Then remove the glass socket on the other side.
7. Remove the O-rings (8) on both sides. The O-rings are firmly stuck in their seat, and will be
damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring
tool to loosen and remove the O-ring. Be careful to avoid to break the glass.
If the O-ring is hard to remove, try the following:
– Moisten the O-ring with acetone or denatured alcohol.
– Loose the O-ring in a couple of places before removing it.
– Perforate the O-ring to get a good grip.
8. Carefully remove the quartz sleeve (10).
9. Carefully clean the surface and remove any small parts, for example glass or rubber.
4.2.3 Assemble quartz sleeve

Follow the instruction below to assemble quartz sleeve and check for leaks.
• Two new O-rings (8) for each quartz sleeve (10).

• Two new O-rings for each glass socket (7) might be needed.
• Glass sockets and bushes must be dry and clean before mounting.
1. Insert the quartz sleeve (10) in the UV reactor.
2. Check the condition of the glass socket O-rings. If needed, replace them with new O-rings.
28 Book No.9028195 02
3. Wet the O-rings (8) with water and some soap and slip them over respective side of the
quartz sleeve.
Check that the O-ring are positioned evenly on both sides. If not, they may be damaged
and cause leaks.
The O-rings shall not be pressed into position, the glass socket will press them into position
when fastened later.
4. Check the condition of the screws. They must be waxed to to avoid seizing.
Carefully mount the glass sockets on both sides on the quartz sleeve. Fasten the glass sockets
with three Allen screws, but do not tighten the screws.
7QuartzSleeve
5. Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.
6. Mount the second glass socket.
7. Connect the instrument air.
8. Follow the instruction Check for leaks after quartz sleeve assembly.
4.2.4 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 (0.2 and 0.4 MPa).
2. Visually check for leaks.
4.2.5 Assemble UV lamp

Follow the instruction below to mount UV lamps.
Book No.9028195 02 29
4.3 Dismount and mount lamp power supply 4 UV reactor
(LPS)
• A leakage check must have been performed according to the instruction Check for leaks after
quartz sleeve assembly.
• New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.
• Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the
lamp; hold the lamp by its ceramic end parts.
• Glass sockets and bushes must be dry and clean before mounting.
• After UV lamps hav e been changed, the runtime must be reset in control system page 4.4
Operation timers UVRs.
1. Mount the new heat resistent O-rings in the two lamp bushes (3).
2. Place one bush on the UV lamp (9).
3. Insert the UV lamp and bush into the UV reactor.
4. Insert the other bush in the opposite side of the UV reactor.
5. Make sure that the connection is clean to ensure good electric connection (no rust, burning or
fading on the connectors). Reconnect the two cable connectors for the UV lamp.
7UVlampConnection
6. Mount the UV lamp caps and tighten the cap nut at both ends of the UV lamp, by hand only.
Make sure that the electric cable is is not squeezed between the cap and the bush when the
cap is mounted. Slack can be pushed into the bush.
7. Control the control system page 3.1 Alarm list, to make sure there is no alarm when after
the the lamp power supply is on.
4.3 Dismount and mount lamp power supply (LPS)

Follow this instruction to replace a lamp power supply inside a lamp drive cabinet (LDC).
30 Book No.9028195 02
4 UV reactor 4.3 Dismount and mount lamp power
supply (LPS)
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• Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V)
inside and on the lamp power connector, even when UV lamps are not lit.
• The LDC contains a fan, which can cause injury if in operation.
7 LPSmaint
1. Dismount LPS
Release two power connectors at the bottom of the LPS and the signal cable connector
at the top.
2. Loosen the nuts at the bottom (1) and the top (2) of the two rods holding the LPS. If necessary,
loosen nuts for adjacent LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short circuit.
3. Pull the handle to remove the LPS.
4. Mount LPS
Set the DIP switches on the LPS according to chapter 4. Parameters, section Lamp power
supply (LPS) parameters.
5. Push the new LPS to the wall of the cabinet.
6. Reconnect the three connectors. Make sure the connectors sit tight.
Book No.9028195 02 31
4.4 Test LPS installation 4 UV reactor
7. Tighten the nuts to attach the LPS.
8. Turn on the fuse to the LPS.
9. Switch on the main breaker on the LDC door and check that both LPS:s function correctly
according to instruction Test LPS installation below.
10. Send the replaced LPS to Alfa Laval for repair.
4.4 Test LPS installation

Follow this instruction to make sure that the installation is OK and safe to use.
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• 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.
NGE R
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• Before operating the UV reactor, make sure that there is water in the UV reactor.
1. Make sure that the UV reactor breaker is switched off.
2. Check that there is water in the UV reactor(s) (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the UV reactor.
3. Switch on the main breaker on the LDC door. Switch on the power to the UV reactor using the
switches on the breaker cabinet(s).
4. Start UV lamps one by one from the control system (set to manual mode). Make sure that the
UV lamps are lit. This is checked in the UV reactor popup and on the LPS.
Note: It can take up to 90 seconds for the lamp to start.
5. Check LEDs on the LPS and the alarm list in the control system. Make sure that no alarms
have been triggered by the LPS.
6. Turn off the lamp.
32 Book No.9028195 02
5 Filter
This section covers the instructions for filter service.
These preparations and conditions are valid for all instructions.
• Disconnect the power to the filter, using the main switch on the control cabinet.
• Always lock valve V201–3 and V201–32 if you open the filter. See Lock valve in closed position
on page .
• Only perform maintenance and servicing work when the filter is cooled, depressurized and
drained.
• Shut off the air supply to the filter.
• Visually inspect gasket during maintenance. Replace if necessary.
• Lifting device is needed for this instruction.
Filter cover and element weight (kg): 285.
Tightening torques for f lter bolts
Torque is stated in Nm.
M4 3
M6 7
M8 12
M10 18
M12 25
M14 35
M16 45
M18 60
M20 75
M22 90
M24 105
Filter – Exploded view
Book No.9028195 02 33
5 Filter
34 Book No.9028195 02
7 FiltrexExploded
5 Filter
1 Gear reducer
2 Gear shaft
3 Electric motor
4 Thrust bearing flange fixing bolt
5 Gear reducer flange / cover fixing bolt
6 Thrust bearing
7 Backflush shaft bushing gasket
7a Backflush shaft bushing asket
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
41 Thrust bearing upper flange
42 Thrust bearing lower flange
43 Seeger
44 Cover lifting lug
45 Rotation indicator
70 Nameplate
80 Prefilter
Book No.9028195 02 35
5.1 Remove filter cover and filter element 5 Filter
5.1 Remove f lter cover and f lter element

Follow this instruction to remove filter cover and filter element.
1. Close the following valves: V201-3, V201-32, and V310-2 according to the instruction in
the Operate valves manually on page 19.
2. Unscrew the bolts (5) holding the gear motor (1).

If the electrical cable is short, it might be necessary to disconnect it before removing the motor.
3. 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 FilterMotor
4. Remove the cover bolts (10) and the lifting lugs (44).
5. Screw two filter cover bolts in the lifting lugs holes until the cover raises slightly from the filter
house.
7 LiftingBolt
36 Book No.9028195 02
5 Filter 5.1 Remove filter cover and filter element
6. Remove the cover bolts and fasten the lifting lugs in their holes again.
7 LiftingLug
7. Fasten a lifting device in the lifting lugs and lift the filter cover (9) with the filter element carefully
out of the filter.
Note: The filter should be lifted in one continuous movement, without sudden jerks – even if
the filter element is slightly stuck in the filter house.
8. Place the filter element on its side.
9. Remove bolts to the bottom shaft support that holds the shaft inside the filter element (15).
Remove it carefully.
10. Remove the seeger ring (43) from the backflush shaft bushing (11).
7 FiltrexSeeger
11. Pull out the backflush shaft bushing. If it is stuck, give a couple of light blows with a wooden
hammer on the top of the shaft to release it.
12. Place the filter element upside-down.
Book No.9028195 02 37
5.3 Clean filter element and pre-filter 5 Filter
13. Unscrew the four Allen screws inside the element to loosen the filter cover.
7 FiltrexAllenS
14. Lift the filter element from the cover.
15. Lift the pre-filter (80) from the bottom of the filter house.
5.2 Mount f lter element and f lter cover

Filter element and cover is mounted in reverse order as described in instruction Remove filter
cover and filter element.
Note:
• Clean the upper inside of the house. The area where the gasket meet the housing should
be clean.
• No force should be used to fit the filter element in the filter house or to fit the motor in its seat.
• Check the gaskets. Replace if necessary.
• Fill up the filter with technical water / potable water after it is mounted.
• There is not need to de-air the filter when it is filled up.
5.3 Clean f lter element and pre-f lter
Follow this instruction to clean the filter element. At the same time, check that the filter element
is in good condition.
• Alpacon descalant offshore may be used as cleaning agent. See Safety data sheet / CIP liquid
in chapter 6. Installation description and drawings.
• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant to 20 parts
technical water / potable water. Follow this mixing ratio, regardless of recommendation on label.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.
38 Book No.9028195 02
5 Filter 5.3 Clean filter element and pre-filter
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• 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.
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• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• The pH value should be approximately 2.0–3.0.
• Proceed with the utmost caution when transporting, assembling, disassembling and cleaning
the filter element.
1. Follow the instructions Remove filter element (page 36) to remove the filter element.
2. Rinse the pre-filter with water and a brush.
3. Remove the filter element gasket (17).
4. Soak the filter element in the cleaning agent with the opening facing upwards. Leave it to soak
for 1–4 hours. Let the element dip dry before next step.
5. Place the element in so it does not fall over when cleaning it.
6. Spray the filter element with water (60–80 °C) from the outside, using a flat nozzle. Note: If a
high-pressure cleaner is used, the pressure must not exceed a maximum of 15 bar. If a cleaner
with higher capacity is used, compensate by increasing the distance, minimum 30 cm.
7. Blow the filter element with instrument air (with 10 micron filter or finer), from the outside.
8. Inspect the filter element from the outside with a magnifier to make sure that it is clean. If
needed, repeat the procedure. This time it is enough to let the element soak for 5 minutes.
9. Clean the inside of the filter house.
10. Put the filter element gasket back. Reassemble the rest of the filter.
Book No.9028195 02 39
5.3 Clean filter element and pre-filter 5 Filter
6 CIP module
This section covers instruction for service of the CIP module.
6.1 Change and ref ll CIP liquid

Alpacon descalant is used as cleaning agent in the CIP module. It contains no solvents and no
inorganic acids. It is non-flammable and non-hazardous. See Safety data sheet / CIP liquid in
chapter 6. Installation description and drawings.
ON
CAUTI
!
• 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.
ON
CAUTI
!
• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• Max tightening torque for bolts on flanges: 20 Nm.
• The instructions requires pH test equipment (paper indicator or pH meter). This is not a part of
Alfa Laval’s scope of supply.
• The pH value should be between 2.0 and 3.0. From the beginning, the pH value is approximately
2.0. When the pH value rises to 3.0 the cleaning liquid must be changed.
• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant offshore to
20 parts technical water / potable water. Follow this mixing ratio, regardless of recommendation
on label.
• The CIP tank shall be filled with maximum 250 liters. Min and max filling of CIP liquid can
be read on the CIP tank.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.
• Used CIP liquid may contain residues from the cleaning process that can potentially have an
impact on the environment, although this impact is regarded as very small. There are no
transport restrictions.
• Used CIP liquid is drained to one of the following: drain, waste or sludge tank. Do not drain to
bilge. Handle according to local regulations.
• When performing these routines, consider the need for service kits. See Spare parts catalogue.
Book No.9028195 02 41
6.1 Change and refill CIP liquid 6 CIP module
7 CIP
CIP module
1. CIP liquid tank cap

2. Valve block
3. Pump P321–5 (UVR reactor drain)
4. Pump P320–1 (CIP liquid)
5. Drain line with manual valve
42 Book No.9028195 02
6 CIP module 6.1 Change and refill CIP liquid
6.1.1 Change CIP liquid

Follow this instruction to change CIP liquid, when necessary due to high pH value.
1. If the drain valve (3) is connected to tank, follow the sub steps below. Otherwise, go to step 2.
a. Open the manual drain valve V460-3 under the CIP tank.
b. Wait for the tank to be totally drained. Then close the drain valve.
2. If the drain valve is not connected to the tank, the steps below can be followed. This operation
requires login level Advanced operator or higher.
a. Open valve V230–11 manually. Open V320-2, V460-2 and V321–3 from the control panel.
Start pump P321-5 (3) and P320-1 (4).
b. Wait for the tank to be totally drained. Then stop the pumps and close the valves in
reversed order. Go to step 3.
3. Open the cap (1) on top of the CIP tank.
4. Fill the tank with technical water / potable water as described below:
a. Open valves V310–6, V321–3 andV321–1. Start pump P321–5.

b. Wait for the tank to be filled with approximately 240 liters of technical water / potable water,
almost up to the Max indication on the tank.
5. Pour the CIP liquid into the tank.
6. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.
7. Go to control system page 4.3 – Operation timers. Make a note of the number of UV reactors
that has been CIPed since last time the CIP liquid was changed. Press the Reset button for
“Total number CIP:ed reactors”. Requires login level Advanced operator. If this is done each
time the CIP liquid is changed, it is possible to build up experience on how many UV reactors it
is possible to CIP before it is time to change CIP liquid.
6.1.2 Ref ll CIP liquid

Follow this instruction to refill CIP the CIP tank when there is low liquid level in the tank.
1. Measure the pH value in the tank. Based on the pH value, estimation must be done regarding
the proportions between Alpacon descalant offshore and water. Note that the mixing ratio is
stated under Preparations and conditions above.
2. Mix the cleaning agent with water separately. The result will get better than if mixed mix in
the tank.
3. Pour the mixed CIP liquid into the tank. Do not fill over Max indication on the tank.
4. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is still too high, the CIP liquid must be changed. See the Change
CIP liquid instruction in this chapter.
Book No.9028195 02 43
6.2 Repair CIP pump 6 CIP module
6.2 Repair CIP pump

Follow this instruction to repair CIP pump.
ON
CAUTI
!
• Always wear protective eye glasses and gloves while working on the pump.
NG
WARNI
!
• 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.
7 CIP pump
CIP pump, exploded view
6.2.1 Clean CIP pump

44 Book No.9028195 02
6 CIP module 6.2 Repair CIP pump
1. Remove the pump from the CIP tank.
2. Rinse the pump with technical water / potable water.
6.2.2 Disassemble CIP pump

Follow this instruction to disassemble the CIP pump.
6.2.2.1 Disassemble the main parts
1. Remove the CIP pump from the CIP module 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).
6.2.2.2 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.
Book No.9028195 02 45
6.2 Repair CIP pump 6 CIP module
6.2.2.3 Disassemble the center block
Follow this instruction to disassemble the centre block.
• Have backup spares of the sealing (36) and backup O-ring (47). There is a risk that these parts
get damaged during this operation.
1. Press the diaphragms (15) to their neutral position (both have the same distance to the
centre block).
2. Hold one of the diaphragms (15) and unscrew the other. Then pull out the remaining diaphragm
with the diaphragm shaft (16).
3. Disassemble the circlips (27) which keep the air valve (61) on its place.
4. Press out the air valve. A wood shaft of a hammer can be used. Be careful not to damage the
sealing edges towards the diaphragm or the air valve.
5. If the shaft sealings (36) seem to be worn out, carefully remove them with a pointed tool.
6.2.3 Assemble CIP pump

Follow the instructions below to assemble the CIP pump.
6.2.3.1 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.
6.2.3.2 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.
46 Book No.9028195 02
6 CIP module 6.5 Repair valve block
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.
6.3 Test CIP pump

Follow the instruction below to verify that the CIP motor is functioning.
1. Open valves V320-2 and V460-2 from the control system, and V230–11 manually. Start
pump P321-5 (4) and P320-1 (4).
2. Observe if the motors sound and functions OK. If not, check installation and connections and
attend to and test again.
3. Stop the pumps and close the valves in reversed order.
6.4 Repair junction box and valve blocks

Read the conditions below before reparing the junction box or valve blocks.
6.5 Repair valve block

Follow this instruction to repair the valve block, mounted on the CIP module.
• The valve bodies does not have individual placing, they can be placed in any order.
DANGER
!
• Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.
Book No.9028195 02 47
6.5 Repair valve block 6 CIP module
7 Valve block
Valve block
1. Cover (Terminal strip inside)

2. Valve body
3. Button to operate valve
4. Signal plate
5. Cable gland
6.5.1 Change valve body

1. Remove the scresw 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.
6.5.2 Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the control cabinet to the CIP valve block.
48 Book No.9028195 02
6 CIP module 6.5 Repair valve block
1. Open the cover (1) on the front.
2. Attach the cables according to electrical drawing Control cabinet / interconnection diagram in
chapter 6. Installation description and drawings.
3. Fasten the cable to the cable gland (5).
4. Fasten the cover (1).
6.5.3 Clean valve block

Follow this instruction to clean the valve block house from dirt.
1. Disconnect the outgoing air hoses from the valve block.
2. Operate the service air according to instruction Open and close valves manually (CIP valves)
on page 19 to blow out the dust.
3. Connect the air hoses again.
6.5.4 Connect pneumatic hoses to valve block

Follow this instruction to connect pneumatic hoses to the valve block, if they have been
disconnected.
1. Connect the hoses according to the signal plate (4) on the valve block.
Book No.9028195 02 49
6.5 Repair valve block 6 CIP module
7 Flow meter
The flow meter consists of two main parts:
• Flow sensor: A pipe with four electrodes detecting the flow. On top of the pipe, there is a
terminal box, where the flow transmitter is mounted.
• Flow transmitter: Monitors and transmits information to the PureBallast control system.
• The flow sensor and flow transmitter are pre-assembled from factory, and the parameters
are pre-set.
7.1 Replace display and fuse
NG
WARNI
!
• Risk of electric shock! Exposed components carry dangerous voltages.
Make sure that the power supply is switched off before you remove the cover of the electronics
compartment.
To replace display: See step 1–3 below.
To replace fuse : Se step 1–6 below.
The main fuse is located on the power supply board.
1. Switch off power supply.
2. Unscrew cover of the electronics compartment from the transmittor housing.
3. Remove the local display as follows:

-Press the latches at the side and remove the display module
-Disconnect the ribbon cable of the display from the amplifier board.
Book No.9028195 02 51
7.1 Replace display and fuse 7 Flow meter
7 Opening Field housing and replacing display
Opening Fileld housing and replacing display
4. Remove the screws and remove the cover from the electronics compartment.
5. Remove the power supply board. Insert a suitable tool into the hole, provided for the purpose
and pull the board clear of its holder.
6. Remove cap (1) and replace the device fuse (2).
Use only fuses of the following type:

– Power supply 20 to 55 V AC / 16 to 62 V DC use a 2.0 A slow-blow / 250 V; 5.2 × 20 mm
7 Replacing the fuse
Replacing the device fuse on the power supply board (step 5–6)
1. Protective cap
2. Device fuse
7. Installation is the reverse of the removal procedure.
7 Re-assembly
Re-assembly
52 Book No.9028195 02
8 Valve actuator
This section contain instructions for the valve actuator.
7 Actuator and switch
Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilote valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves
with dimension 400
7. DIN connector
8. Position indicator
Book No.9028195 02 53
8.1 Preparations and conditions 8 Valve actuator
7 Actuator
Valve actuator with puck for position sensor
1. Safety cover
2. Pad lock
3. Lower position for indicator screw
4. Upper position for indicator screw — with screw
5. Position indicator
6. Center screw
7. Bracket
8. Puck
9. Locking bolt
10. End stop bolt.

• Do not operate the actuator over pressure limits. It will damage internal parts as well as cause
damage to the housing.
• 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.
• 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.
8.1.1 Tightening torques for actuators

Torque is stated in Nm.
54 Book No.9028195 02
8 Valve actuator 8.3 Mount actuator on valve
M5 05–06
M6 10–11
M8 23–25
M10 48–52
M12 82–86
M14 132–138
M16 200–210
M20 390–410
8.2 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 DIN connector to disconnect the power. Let the air connection remain.
Result: Valve goes to closed position (due to the 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. Disconnect the air hose to the pilot valve. 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.
8.3 Mount actuator on valve

Follow this instruction to mount an actuator.
Book No.9028195 02 55
8.3 Mount actuator on valve 8 Valve actuator
ON
CAUTI
!
• The actuator must not be pressurized at any time during installation as it may result in injury.
• The utmost cleanliness is required during air supply connection to the actuator, that is, the
connecting pipe thread, fittings and seals must be clean and dirt-free.
• Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on
which direction of rotation is required.
1. Note the position of the groove (2) of the valve stem (3). It indicates the position of the valve
throttle. The illustration shows a square variant, but octagonal versions exist.
7 ValveStem
1. Allowed travel sector.

2. Valve stem groove
3. Valve stem
5. Lock pin opening (covered by rubber plug).
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 on page 54.
56 Book No.9028195 02
8 Valve actuator 8.4 Change direction of actuator – without
position sensor (V404–36, V320–4 and V321–2)
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.
8.4 Change direction of actuator – without position

sensor (V404–36, V320–4 and V321–2)
Follow this instruction to turn an actuator without position sensors on the UV reactor.

1. Loosen the four screws holding the actuator to the valve.
2. Lift the actuator from the valve.
3. Note the position of the groove of the valve stem. It indicates the position of the valve throttle.
4. Fit the actuator onto the valve stem.
5. Unscrew the center screw (4) holding the puck (6) and a bracket (5).
7 ActDirectWithout
6. Lift the puck (6), rotate it 90° and fasten it with the center screw (4) and bracket (5).
Book No.9028195 02 57
8.6 Change direction of actuator – with 8 Valve actuator
position sensor (201-19 and 201–20)
7. Make sure that the yellow position indicators (3) is in line with the throttle (according to the
groove in the valve stem). The yellow position indicators shall be in line with the valve throttle
(indicating open when the position indicator is in line with the pipe). If not, remove the position
indicators, turn them 90° and refit.
8. Connect power and air.
8.5 Change direction of actuator – with switch box

(V201–3, V201–9, V201–32, V212–31 and V403–35)
Follow this instruction to turn an actuator with switch box.

• The valve must be mounted and connected to air and power before adjustment.
1. Dismount the actuator according to Dismount actuator on page 55.
2. Remount the actuator according to Mount actuator on valve on page 55.
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 on valve.
8.6 Change direction of actuator – with position

sensor (201-19 and 201–20)
Follow this instruction to turn an actuator with a position sensor, if necessary due to lack of space.
Note that the actuator normally should not be altered.
This instruction is valid for the following valves: V201-19 and V201-20 on the UV reactor.

• The valve must be mounted and connected to air and power before adjustment.
1. Dismount the actuator from the valve according to instruction Dismount actuator on page 55.
Put the actuator on a work bench.
58 Book No.9028195 02
8 Valve actuator 8.6 Change direction of actuator – with position
sensor (201-19 and 201–20)
2. Disconnect the DIN connector (2) from the coil: First loosen the screw (1), and then pull up
the connector.
7 DisconDINcon
3. Unscrew the center screw (6) holding the puck (8) and a bracket (7).
7 DirActPosSnsr
4. Lift the puck (8), rotate it 90° so that one position indicator (5) with a screw is in contact with the
position sensor. Fasten the puck with the center screw (6) and bracket (7).
5. Move the screw on yellow position indicator to the top position and move the screw on black
position indicator to the bottom position.
6. Make sure that the position sensor have a maximum distance of 1 mm from the puck (7). The
position sensor and the position indicator screws must be close to give a signal. If not, loosen
the screws and adjust the position. Tighten the screws to fixate the position.
7. Fit the actuator onto the valve stem in its new position according to instruction Mount actuator
on valve on page 55.
Book No.9028195 02 59
8.8 Mount pilot valve on actuator 8 Valve actuator
8. Make sure that the yellow indicator (5) in line with the valve throttle according to the groove in
the valve stem.
9. Reconnect the DIN connector.
10. Connect power.
11. Check that the installation is OK, by making sure that the A1 LED is lit on the position sensor
(visible from the side).
12. Connect air.
8.7 Change direction of actuator – with positioner

(201–8)
Follow this instruction to turn the actuator on control valve 201–8, if necessary due to lack of space.
Note that the actuator normally should not be altered.

1. Dismount the actuator from the valve according to instruction Dismount actuator on page 55.
2. Fit the actuator onto the valve stem in its new position and mount it on the valve with the four
hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten
with torque according to the table Tightening torques for actuators on page 54.
3. The position indicator scale shall be correct, but make sure that the scale still indicates correct
opening percent according to the valve throttle position. If not, loosen the four bolts to the
bracket holding the switch box. Lift it and turn the scale so it is correct.
4. Refit the switch box. Make sure that the peg on the scale fits to the carrier on the puck
mounted on the actuator.
8.8 Mount pilot valve on actuator

Follow this instruction to mount a pilot valve on actuator and connect them.

• Air and power must be disconnected. The valve position must not be adjusted during the routine.
60 Book No.9028195 02
8 Valve actuator 8.9 Adjust valve end position
7 MountPilote
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).
8.9 Adjust valve end position

Follow this instruction to tune the open and closed end positions for a valve. This is done if the
valve tends to get stuck in the end position or not close completely.
Book No.9028195 02 61
8.10 Adjust valve traveling speed 8 Valve actuator
• The valve shall be closed (0°) position 0.

1. Note the exact position of the position indicator for reference after adjustment.
2. Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing position and the left
set adjusts open position.
3. Loosen the locking bolt (3).
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).
8.10 Adjust valve traveling speed

Follow this instruction to adjust valve traveling speed.
62 Book No.9028195 02
8 Valve actuator 8.10 Adjust valve traveling speed
7 AdjustTravel
1. Operate the valve manually to check traveling speed according to the instruction in the Operate
valves manually on page 19.
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.
Book No.9028195 02 63
8.11 Calibrate positioner on V201-8 8 Valve actuator
8.11 Calibrate positioner on V201-8

Follow this instruction to calibrate the positioner at installation or when needed.
7 201-8Positioner4
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:
7 201-8Positioner
64 Book No.9028195 02
8 Valve actuator 8.11 Calibrate positioner on V201-8
Software settings - Alfa Laval values:
Parameter Settings in menu

1 turn
(Note: Do not chose “– turn”.)
2 90° (is automatically 90° when turn is used)
34 0.7
1. Make sure that the transmission ratio selector (6) is set to 90° according to sticker on the
component. If not: Adjust by pressing the bar with a screw driver.
2. Make sure that the Arrestor device wheel (1) is set to 90°. If not: Adjust by turning.
3. Press HAND button for 5 seconds to enter the parameter list.
4. Make sure that Menu 1 is displyaed. 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.
Note: Do not choose “– turn”.
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:
7 201-8Positioner2
- 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.
7 201-8Positioner3
- 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.
Book No.9028195 02 65
8.11 Calibrate positioner on V201-8 8 Valve actuator
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.
66 Book No.9028195 02
8 Valve actuator 8.11 Calibrate positioner on V201-8
Trouble shooting
If any problem occurs, do the following:
1. Check the mechanical installation and air supply.
2. Reset factory settings and restart calibration:
- Reset to factory settings: Press HAND button repeatedly until menu 50 is displayed.
- Press + button until “oCAY” is displayed.
- Restart instruction Calibrate positioner on V201-8 from step 4.
- Set the parameters according to Alfa Laval software settings. See table above.
Book No.9028195 02 67
8.12 Adjust cam position on V201-8 8 Valve actuator
8.12 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) on page 64.
5. Turn the cam wheels in any direction until it valve indicates steady green in the control panel.
Miltimeter 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). Miltimeter indicate circuit open. Repeat from
step 2 until setting is OK.
68 Book No.9028195 02
9 Ball valve
This section contains maintenance information for the ball valve.
9.1 Replace seals in ball valve

Follow this instruction to replace the seals in ball valve.
7 BallV
Ball valve, exploded view
Maximum tightening torque
Valve size Max. torque of Max. torque of stem nut (14)

body bolts (8)
25 = 1 inch 13–16 Nm 14.3 Nm
32 = 1¼ 20–25 Nm 14.3 Nm
inches
50 = 2 inches 35–40 Nm 19.4 Nm
Book No.9028195 02 69
9.1 Replace seals in ball valve 9 Ball valve
1. Relieve the line pressure.
2. With the valve in the open position (lever to be parallel to the axis of the pipe), remove all the
body bolts (19) except one.
3. Loosen the nut (20) on the remaining bolt. Swing the body outside the pipe.
4. Dismount the stem (8).
5. Replace seals (5, 6, 7, 9, 10, and 24). They are available in a spare parts kit for the ball valve.
6. Mount in reverse order. The body bolts of the valve should be tightened evenly. Tighten
one-side snugly, then the one diagonally across. Repeat for the other bolts, bringing them all
down tightly in sequence. Make sure the maximum tightening torque is observed according
to the table above:
7. Check that the valve is operating correctly.
8. Check for leaks when the water flow is on.
70 Book No.9028195 02
10 Level switch
This section contains information about the level switch LS201-29 installed in the UV reactor. For
information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.
7LS Component
Level switch
10.1 Mount level switch

• Do not alter the forks in any way.

• Be careful not to damage the fork in any way.
NOTE
• Disconnect power supply before mounting or dismounting the component.

1. Connect the level switch according to the label on the component.
2. Seal the level switch with lock tight or equivalent pipe seal.
3. Mount the sensor until the joint is finger-tight.
4. Identify the sensor align mark (▼) on the component. Make sure that it is positioned on the
upper side of the level switch.
Book No.9028195 02 71
10.3 Test level switch 10 Level switch
5. Complete the seal carefully by tightening the component with a spanner. Use the spanner on
the hexagon flats, but not on the level switch body.
10.2 Dismount level switch

• The external surface may be hot. Care must be taken to avoid possible burns.
1. Disconnect the level switch according to the label on the device.
2. Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the level switch body.
3. Remove the level switch and remove the old seal from the threads.
10.3 Test level switch

Follow the instruction below to test that a level switch functions OK.
1. Make sure that the component i powered (the green LED shall be lit).
2. Hold a magnet to the test point indicated on the on the level switch, indicated below.
7LS Test
3. Make sure the level switch reacts to the magnet. The component is OK if the green and
yellow LED is lit.
72 Book No.9028195 02
11 Temperature switch and
temperature transmitter
This section contains information about the temperature switch TS201-60 and the temperature
transmitter TT201–33 installed in the UV reactor. The two components are similar in design, so
the same instructions can be used.
7 TS and TT
Temperature switch and temperature transmitter
NOTE
• Disconnect power supply before mounting or dismounting the component.

11.1 Mount temperature switch / temperature
transmitter
1. Seal the component’s threads using lock tight or equivalent pipe seal.
2. Mount the component until the joint is finger-tight.
3. Tighten the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
4. Connect the component’s screwed-on power cord.
Book No.9028195 02 73
11.2 Dismount temperature switch / 11 Temperature switch and temper-
temperature transmitter ature transmitter
11.2 Dismount temperature switch / temperature

transmitter
• The external surface may be hot. Care must be taken to avoid possible burns.
1. Disconnect the component’s screwed-on power cord.
2. Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
3. Remove the level switch and remove the old seal from the threads.
74 Book No.9028195 02
12 Control panel
This section covers instructions for service of the control system.
12.1 Clean control panel
NOTE
• Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
• Never use aggressive solvents, chemicals, scouring agents, pressurized air or steam jet.
1. Press the Wipe button on the screen.

Result: Disable the touch screen function for 10 seconds to make it possible to clean the
screen without the risk of starting a process or changing a setting.
2. Clean the display and surrounding front cover with a soft cloth and mild detergent. Do not
spray detergent directly on the control panel.
12.2 Replace control panel

Follow this instruction to replace the control panel.
Preparations and conditions:
• The system must be shut down.

• Connect cables as in the old control panel. Port LAN A must be used for the Ethernet cable at
the backside of the panel.
• After the panel is mounted: Load new software to the panel according to the release note
for the software. Also set communication according to Set control panel IP address and Set
remote control panel communication.
Book No.9028195 02 75
12.2 Replace control panel 12 Control panel
13 Remote control panel
(optional)
This section covers information on how to mount and connect the remote control panel. The remote
control panel is either ordered with a mounting plate (for installations in wall, worktop etc) or an IP
protective back cover (for installation on stand etc).
13.1 Mount and connect remote control panel

• Remote control panel is mounted according to according to drawing Remote control panel /
Dimension drawing. Note the clearance area.
• Use a 24 VDC power 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 control cabinet can be
either Ethernet or 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 panel s to terminal X13 in the control
cabinet. Two From terminal X2 in second remote control panel to either switch SW1 in
control cabinet or to switch SW1 in the first remote control panel.
- Fiber cable – Type: Multi-mode fiber cable with LC connector. Max length: 500 meters.
From remote control panel’s switch SW1 to switch SW1 in control cabinet.
See Remote control panel / Circuit diagram on page .
Book No.9028195 02 77
13.1 Mount and connect remote control panel 13 Remote control panel (optional)
14 Control cabinet and lamp
drive cabinet (LDC)
This section covers maintenance information for the control cabinet.
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, pleas see chapter 5. Alarms and fault finding.
1. Hold down the plastic clip on the top of the terminal block and pivot the block towards you.
7IO1_X025002A
2. Pull away the terminal block.
3. Hold down the triangle on the top of the I/O board and loosen the board.
7IO2_X025003A
Book No.9028195 02 79
14.1 Disassemble and assemble I/O system 14 Control cabinet and lamp drive cabinet (LDC)
4. Pull the board straight out (otherwise it can fasten in one of its guides).
7IO3_X025004A
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.
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.
7IO4_X025005A
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.
7IO5_X025007A
80 Book No.9028195 02
14 Control cabinet and lamp drive cabinet 14.2 Cable gland installation – General cables
(LDC)
9. Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in
the I/O board.
7IO6_X025006A
14.2 Cable gland installation – General cables

This section covers information about how to install the cables into the control cabinet and LDC
using the cable glands. Power cables to the LDC are installed according to instruction Cable gland
installation – Power cable to LDC.
Follow this instruction to mount cables into the cabinets.
1. Lubricate the inside surfaces of the frame with Roxtec Assembly Gel or equivalent, specially
in the corners.
7 Cable1
2. Insert the cables through the frame.
3. Adapt the modules, which are to hold cables.
4. Peel off layers until you achieve a 0.1-1.0 mm gap between the two module halves when
held against the cable.
Book No.9028195 02 81
14.2 Cable gland installation – General cables 14 Control cabinet and lamp drive cabinet (LDC)
7 Cable2
7 Cable3
5. Lubricate all modules thoroughly, both on the inside and the outside surfaces.
7 Cable4
6. Insert the modules from the back of the frame opening. If possible, start with the largest
modules.
7 Cable5
82 Book No.9028195 02
14 Control cabinet and lamp drive cabinet 14.3 Cable gland installation – Power
(LDC) cable to LDC
7. Tighten the compression unit firmly to seal the frame. Maximum 10 Nm. A good indication is
when the lubrication is squeezed out between the modules.
7 Cable6
14.3 Cable gland installation – Power cable to LDC

Follow this instruction to install the power cable to the LDC using the cable gland.
1. Adapt the seal to the cable by removing layers from the halves. The halves may not differ by
more than one layer.
7 LDC gland1
2. Achieve an approximate 0.1–1 mm gap between the halves when testing against the cable.
There shall be a visual gap.
7 LDC gland2
3. Lubricate thoroughly on the inside surfaces and sparsely on the outside of the seal.
Book No.9028195 02 83
14.5 Install IFS-confstick in safety relay KS1 14 Control cabinet and lamp drive cabinet (LDC)
in LDC
4. Insert the halves one by one into the sleeve.
7 LDC gland8
5. Tighten the Allen screws crosswise. The seal will compress and seal the transit.
14.4 Power cable check

Check power cables screw connections, to eliminate potential risk of fire due to loose cables.
This check should be performed in LDC, control cabinet, UVR junction box.
1. Turn off power to PureBallast from the vessel’s switch board, to make it currentless. Where
applicable, turn off power to the individual cabinet.
2. Make a random check of approximately 10 % the cables in different areas of the cabinet.
- Make sure that the cables are fastened with sufficiently tightened screws.
- If one cable is loose, check all cables connected to this component / component of the
same type.
- Note: Be careful not to tighten the screws so that the cables are damaged.
14.5 Install IFS-confstick in safety relay KS1 in LDC
Follow this instruction to install a new IFS confstick in the safety relay. This is done when the IFS
confstick is broke or when a new safety relay is installed.
84 Book No.9028195 02
14 Control cabinet and lamp drive cabinet 14.5 Install IFS-confstick in safety relay
(LDC) KS1 in LDC
7 KS1
1. Switch off the power to the lamp drive cabinet (LDC).
2. Insert the new IFS confstick in the safety module. The IFS confstick can only be inserted in
one way.
3. Switch on the power to the LDC. Wait until the safety relay has initialized (all four status LEDs
light up once during initialization).
4. The safety relay now detects that a new IFS confstick has been inserted. The LED "CONF"
is flashing.
5. Remove the IFS confstick again.
6. Press the Conf rm button on and hold it pressed down.
7. Reinsert the IFS confstick while holding down the Conf rm button.
8. Release the Conf rm button when IFS confstick has been inserted. The safety relay will start
an initialization with the new configuration.
Book No.9028195 02 85
.
Spare parts catalogue

PureBallast 3.1 1000
Specification No. 9005247-03/5

Book No. 9032061 02 Rev. 2
Published By:
Alfa Laval Tumba AB
Telephone: +46 8 530 650 00

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

Original instructions
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1 Important information 5
2 Control cabinet 6
2.1 Cabinet 10
2.2 I/O module 12
2.3 Relay module 14
2.4 Wire set 16
3 Lamp drive cabinet 18

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

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

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

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

2 Control cabinet
Machine unit number or
Subassembly description
9025738-
Ref Part No Description -80 Notes
Quantity
1 9012086 83 Cabinet 1 See page 10
2 9006851 01 Software, PLC, PB3.0 1
3 9006852 01 Software, panel 1
4 592122 03 HMI Panel wide without co 1
8 221891 04 Lock nut 12
9 223101 47 Washer 12
10 582212 148 End stop (clip fix) 14
11 582212 122 Terminal block 3
12 582212 13 End plate 3
13 9019135 03 Contactor AF09Z 1 K2
13.1 9019138 01 Over current prot. Relay Ex 1 F2
14 9019135 03 Contactor AF09Z 1 K3
15 9014707 01 Power supply unit 1
16 9004299 04 Fuse 4
17 582212 67 Terminal, PIT 2,5-3PV 7
17.1 582212 71 Plug In Bridge, FBS 3-5BU 1
18 582212 63 Terminal D-PIT 2,5-3L 1
19 9019135 04 Contactor AF16Z 1 K4
20 9019135 04 Contactor AF16Z 1 K5
21 9025840 80 I/O module 1 See page 12
22 582212 147 Patch panel 2
23 582212 91 VIP-2, D 9SUB 1
24 9019186 05 Terminal, PT 4-PE/3L 4
25 582212 102 Terminal PITTB 2,5 PE 1
26 9019186 06 End cover, D-PT 4-PE/3L 1
27 582212 104 Terminal PITTB 2,5 42
29 582212 67 Terminal, PIT 2,5-3PV 4
30 582212 63 Terminal D-PIT 2,5-3L 1
31 582212 168 Separating plate 2
32 582212 123 Power terminal block, 1
33 9002362 80 Relay module 3 See page 14
34 593724 03 Distance screw 4
35 582221 90 PE Connection bar 1 245mm
36 594009 03 Screw 2
37 582212 206 Bar holder 3
38 582212 15 PE/SC Bar 1 500mm
39 594009 02 Screw 3
40 582212 207 Cable clamp 10
41 9006814 01 Cable channel 100x80 1
42 583556 17 Cable channel 40x80 1
43 583556 16 Cable channel 40x80 2
44 9003522 06 Cable channel, 25x80 1
45 9003522 07 Cable channel, 25x80 2
48 223101 47 Washer 2
49 221851 05 Cap nut 2
50 9019186 07 Safety relays, PSR-MC30 1
51 221701 03 Screw 16
52 591103 67 Emergency stop 1
54 9011552 01 Buzzer 1
56 582212 155 Socket with USB 2
59 9025837 01 Switch OT63FT3 1
59.1 591103 37 Breaker handles 1
59.2 9025837 02 Shroud OTS63T3 2
61 9006853 01 Fan 1
62 9006854 01 Air outlet 1
63 595361 02 Cable seal 2
6 Book No. 9032061 02 Rev. 2

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


9025738-
Quantity
66 9012150 81 Wire set 1 See page 16
67 582221 101 Splicing connector 2
74 1270001 Lifting instruction 1
76 591103 86 Over current prot. 1 Q2
76.2 591103 64 Connection 1
76.3 591103 10 Auxiliary contact 3
77 591103 54 Over current prot. Relay 1 Q3
78 591103 60 Over current prot. Relay 1 Q4
80 595728 02 Switch 1
82 595673 03 Ethernet cable 2
83 582212 147 Patch panel 1
84 582212 91 VIP-2, D 9SUB 1
86 582212 90 Cable-D 9SUB 1
87 580986 76 Communication module 1
8 Book No. 9032061 02 Rev. 2

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

2.1 Cabinet
9012086-
Quantity
2 9012091 81 Door 1
4 26556 Spring washer 6
5 9025887 01 Mounting plate 1
6 587276 02 Washer 16
7 221891 05 Hexagon lock nut 12
8 221716 01 Screw 4
10 593778 01 Latch, housing 1
11 593779 01 Latch, insert 1
12 593991 01 Latch 1
13 9003013 01 Rod Guide 2
14 9003024 02 Rod for latching 2
15 593780 01 Key 1
17 223107 34 Spring washer 4
18 221891 04 Lock nut 4
20 593254 01 Retaining ring 1
21 221711 19 Screw 1
22 593282 01 Washer 1
23 221803 02 Nut 2
24 223101 73 Washer 1
25 593239 01 Nut 1
26 581688 01 Bracket 4
27 594488 01 Washer 4
28 221711 16 Screw 8
29 223101 47 Washer 8
30 221891 04 Lock nut 8
31 587276 02 Washer 6
32 70560 Washer 6
34 9014753 01 Piano hinge 1
35 9014815 01 Cover panel 1
36 598571 01 Torx head pan screw M4 8
37 221851 18 Cap nut 8
38 223101 31 Washer 4
39 9015118 01 Mounting spacer hole thro 2
40 9015117 01 Mounting spacer single ta 2
41 9012093 01 Magnet 4
44 587276 01 Washer 2
45 223101 47 Washer 2
46 221891 04 Lock nut 2
10 Book No. 9032061 02 Rev. 2

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

2.2 I/O module

9025840-
Quantity
1 597033 22 PLC 1 Incl. locking plate.
1.1 597033 18 Interface module 1
1.2 580986 76 Communication module 1
2 580986 17 Bus module 11
3 580986 30 Supply Bus Module 1
4 580986 51 12 Digital Input 3
5 580986 08 4 Analogue input 1
6 580986 53 2 Analogue Output 1
7 580986 32 Supply Module 1
8 580986 59 12 Digital Output 1
9 580986 06 6 Relay output 5
10 580986 16 Terminal block 12-pin 12
11 580986 20 Locking Plate right 0 Included in pos:1
12 580986 55 Compact flash card 1
12 Book No. 9032061 02 Rev. 2

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

2.3 Relay module

9002362-
Quantity
1 582212 119 Interface relay, 24V 8
2 582212 120 Input adapter 1
3 582212 121 System cable 1
Z 582212 172 Relay, mini
14 Book No. 9032061 02 Rev. 2

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

2.4 Wire set

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

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

3 Lamp drive cabinet

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

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

3.1 Lamp drive cabinet, subas

9012046-
Quantity
2 9004211 01 Centrifugal fan 1
3 221030 10 Screw 5
3.1 223101 47 Washer 5
4 9012058 80 Terminal block 1 See page 28
5 594009 04 Screw 2
6 223101 03 Washer 4
7 221891 01 Lock nut 2
8 594728 01 Temperature sensor 1
9 9004214 01 Heat exchanger 1
10 221030 10 Screw 12
11 223101 47 Washer 6
11.1 223101 04 Washer 11
12 221803 02 Nut 5
13 590624 03 Temperature sensor 1
14 9004303 02 Sensor, liquid 1
15 221803 03 Nut 1
16 223101 17 Washer 1
17 9008403 80 Solenoid valve 1
18 9004254 01 Check valve 1
19 523127 04 Hexagon nipple 2
20 9004426 01 Hose 2
21 591103 69 Pilot light Green 1
24 591103 70 Pilot light White 1
26 591103 71 Pushbutton, ill. Blue 1
26.1 591103 87 Blue LED 1
26.2 591103 88 Holder for 3 pos 1
26.3 591103 89 Contact block 1 NO 1
27 9004442 03 Marking, Reset 1
28 582212 164 Phoenix Contact 16
29 581803 43 Plug M 3p 16
30 582212 165 Phoenix Contact 16
33 594009 03 Screw 2
34 582212 148 End stop (clip fix) 16
35 591103 86 Over current prot. 8
35.1 591103 10 Auxiliary contact 8
37 591103 64 Connection 3
39 9004299 04 Fuse 2
40 9012135 80 I/O module 1 See page 30
42 582212 13 End plate 1
43 591103 32 Fuse 2
44 591103 91 Bus bar 1
45 582212 182 Safety module 1
46 582212 146 Interface relay, 24V 3
47 9014546 01 Temperature relay 1
50 9006677 01 Filter 1
51 223101 47 Washer 4
52 221891 04 Lock nut 4
53 9004313 82 Breaker 1
54 9005494 04 Transmitted handle kit 1
55 591103 46 Breaker door seal 1
56 591103 61 Self-res. short-circ. lim 3
57 591103 40 Supply block 1
58 591103 03 Bus bar 250A 1 12 terminal lugs
20 Book No. 9032061 02 Rev. 2

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


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

3009A
Book No. 9032061 02 Rev. 2 23

3.1.1 Cabinet
9011952-
Quantity
2 9012193 01 Mounting plate 1
3 587276 02 Washer 18
5 221716 01 Screw 8
6 9015611 01 Sheet 1
7 223101 47 Washer 4
8 221891 04 Lock nut 4
10 223101 47 Washer 6
11 221891 04 Lock nut 6
13 592005 15 DIN-rail, 35x15 1
14 9003565 03 DIN-rail, 35x15 1
15 9003565 02 DIN-rail, 35x15 1
16 223101 47 Washer 17
17 221891 04 Lock nut 14
18 583556 20 Cable channel 40x80 1
19 583556 19 Cable channel 40x80 1
20 583556 21 Cable channel 40x80 1
21 583556 04 Cable channel 1
22 586056 07 Cable channel 60x80 1
34 223101 47 Washer 13
35 221851 05 Cap nut 13
37 9004212 01 Inlet duct 1
38 9004213 01 Protection 1
39 221891 02 Nut 4
40 223101 16 Washer 4
41 594009 02 Screw 4
42 9003390 01 Bracket, fan 1
43 9006316 01 Cover, fan 1
44 223101 47 Washer 9
45 221030 10 Screw 9
46 591889 01 Cable tie mount 3
50 9003030 01 Drawing Pocket 1
51 223101 47 Washer 2
52 221803 02 Nut 2
53 9014585 01 Sheet, LPS 1
54 9014554 01 Sheet, LPS 1
55 594009 05 Screw 8
56 9002947 01 Yoke 18
57 9002942 01 Stud bolt 36
61 9006322 01 Sheet 1
62 221030 02 Screw 36
63 223101 47 Washer 72
64 221891 04 Lock nut 36
65 9015616 01 Sheet 1
66 70560 Washer 2
68 221716 01 Screw 1
24 Book No. 9032061 02 Rev. 2

2881A
Book No. 9032061 02 Rev. 2 25

3.1.2 Cabinet
9011951-
Quantity
3 9008903 05 Washer 12
4 221035 51 Screw 12
5 9014640 01 Door, RH 1
6 9014642 01 Door, LH 1
9 223101 47 Washer 12
10 221803 02 Nut 12
15 9003075 01 Sheet 2
17 9003410 01 Sheet, heat exchanger 1
18 221030 10 Screw 9
19 223101 47 Washer 2
20 9003401 01 Sheet, heat exchanger 1
21 221030 10 Screw 3
22 223101 47 Washer 3
23 9003186 01 Plug 1
29 591874 04 Seal 1 Upper LPS rack, left
30 591874 06 Seal 1 Upper LPS rack, right
34 9014759 01 Sheet, EMC 1
49 9014762 01 Handle 1
50.1 9016270 01 Rod adapter 4
51 9016268 01 Rod guide 8
52 9014732 01 Three point lock 1
53 9014735 01 Handle 1
54A 9003024 01 Rod for latching 1
55 593780 01 Key 1
56 9003114 02 Cable gland 1
57 9003113 01 Cable seal 1
58 223101 41 Washer, 4,3x9x0,8 10
59 221891 02 Nut 10
64 9003031 01 Condensation outlet 2 Cabinet floor and heat exchanger floor
65 9003186 02 Plug 3
66 9008424 01 Protection 9
67 9003089 02 Vibration damper 2
68 223101 49 Washer 13x24x2,5 2
69 221726 10 Screw 2
26 Book No. 9032061 02 Rev. 2

2882A
Book No. 9032061 02 Rev. 2 27

3.1.3 Terminal block

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

2880A
Book No. 9032061 02 Rev. 2 29

3.1.4 I/O module

9012135-
Quantity
1 580986 64 Bus Module 1
2 580986 17 Bus module 7
3 580986 62 Interface Module 1
4 580986 63 Bus Supply 1
5 580986 72 Communication module 1
6 597033 10 8 Digital input Module 2
7 580986 59 12 Digital Output 1
8 580986 40 Input Module 1
9 580986 53 2 Analogue Output 1
10 580986 61 4 Analog Input (PT100) 1
11 580986 16 Terminal block 12-pin 8
12 580986 19 Locking Plate left 1
13 580986 20 Locking Plate right 1
30 Book No. 9032061 02 Rev. 2

2870A
Book No. 9032061 02 Rev. 2 31


9014704-
Quantity
1 582212 67 Terminal, PIT 2,5-3PV 6
2 582212 64 Terminal PIT 2,5-3PE 1
3 582212 63 Terminal D-PIT 2,5-3L 1
4 582212 71 Plug In Bridge, FBS 3-5BU 1
5 582212 03 Plug In Bridge 1
6 582212 148 End stop (clip fix) 2
32 Book No. 9032061 02 Rev. 2

2871A
Book No. 9032061 02 Rev. 2 33


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

2872A
Book No. 9032061 02 Rev. 2 35


9012198-
Quantity
4 582212 13 End plate 1
5 582212 132 Sealable cover profile 2
6 582212 130 Support, L=95,5 2
7 582212 156 Terminal, PT 6 32
8 582212 15 PE/SC Bar 1 285mm
9 582212 137 Sc clamp SK 20 4
10 582212 157 End cover, D-PT 6 1
11 582212 133 Cover profile (AP-3) L=1m 1 292mm
36 Book No. 9032061 02 Rev. 2

2873A
Book No. 9032061 02 Rev. 2 37

3.1.8 Wire set

9015197-
Quantity
1 9008383 01 Cable, 70mm² 5
2 9008383 02 Cable, 35mm² 15
3 9015704 01 Cable, 4mm² 25
4 9015704 02 Cable, 4mm² 25
5 9015704 03 Cable, 4mm² 25
6 9008383 06 Cable, 2,5mm² PE 5
7 9008383 12 Cable, 25mm² PE 1
8 9008383 13 Cable, 6mm² PE 2
9 9008383 08 Cable, 1,5mm² 6
11 9008387 01 Cable 150
12 9008693 01 Cable, 2x2x0,5mm² 6
15 9004439 01 Cable 1
16 9015692 01 Cable, 1,5mm² 65
17 9015704 04 Cable, 4mm² PE 25
38 Book No. 9032061 02 Rev. 2

2377A
Book No. 9032061 02 Rev. 2 39

4 Remote control panel (optional)

9012055-
Quantity
1 9014979 01 Top plate 1
3 221711 16 Screw 8
3.1 9016593 01 Spacer 8
4 592122 03 HMI Panel wide without co 1
6 223101 47 Washer 3
7 221851 05 Cap nut 3
8 592005 14 DIN-rail, 35x15 1
9 223101 47 Washer 2
10 221891 04 Lock nut 2
12 582212 95 Terminal, PIT 2,5 TWIN 4
12.1 582212 03 Plug In Bridge 1
13 582212 96 Terminal, PIT 2,5 TWIN-PE 1
14 582212 04 End plate 1
15 582212 147 Patch panel 1
16 582212 155 Socket with USB 1
18 9011552 01 Buzzer 1
20 591103 72 Pushbutton Black 1
20.1 591103 92 Cover 1
22 9009760 01 Relay, D-sub 1
22.1 582212 214 D-SUB gender changer 1
24 9011960 01 Bracket 1
25 223101 47 Washer 2
26 221891 04 Lock nut 2
28 594009 06 Screw 2
29 223101 47 Washer 2
30 221891 04 Lock nut 2
32 595728 02 Switch 1
34 587276 02 Washer 2
35 70560 Washer 2
37 9015557 80 Wire set 1
38 9011943 80 Cover 1 See page 42
39 582212 215 Connector 1
40 Book No. 9032061 02 Rev. 2

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

4.1 Cover
9011943-
Quantity
1 9011944 01 Cover 1
2 594488 01 Washer 4
3 581688 01 Bracket 4
4 221711 16 Screw 8
5 223101 47 Washer 8
6 221891 04 Lock nut 8
7 589569 79 Cable Gland - M25 2
8 589569 35 Counter nut M25 2
9 589569 48 Cable Gland - M16 2
10 589569 33 Counter nut M16 2
11 587276 02 Washer 2
12 70560 Washer 2
42 Book No. 9032061 02 Rev. 2

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

5 Log box (optional)

9002245-
Quantity
1 582212 05 End stop 7
3 582212 123 Power terminal block, 1
4 582212 124 Circuit breaker 2
9 582212 88 PIT 2,5 3
10 582212 89 D-ST2,5 1
12 591103 56 Over current prot. Relay 1
15 594781 01 Distance 2
19 9002362 80 Relay module 5 See page 14
24 594009 03 Screw 8
29 9003490 01 Bracket set 1
44 Book No. 9032061 02 Rev. 2

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

6 UV Reactor EN
9002700-
Quantity
1 9002699 81 UV reactor EN 1 See page 48
2 9010984 81 Junction box, A side 1 Valves, sensors & feed back
See page 50
3 9010987 80 Junction box 1 Lamp cables
See page 52
4 221803 02 Nut 8
5 223101 32 Washer 8
7 9001357 03 Sensor AT201-50 1
8 9014966 69 Valve, EN DN350 1 V201-19
See page 54
8.1 9014966 69 Valve, EN DN350 1 V201-20
See page 54
9 260192 01 Screw 32
10 223101 39 Washer 32
12 9006325 02 Thermometer, resistance 1 TT201-33
13 9006324 02 Temperature, switch 1 TS201-60
14 558663 04 Gasket washer 2
15 594171 01 Limit switch (vibration) 1 LS201-29
16A 9010631 99 Cable (valves and signals)
18 526350 05 Plug 1
19 558663 03 Gasket washer 2
20 594413 80 Valve 1 V320-4
See page 56
20.1 594413 80 Valve 1 V321-2
See page 56
20.2 594413 80 Valve 1 V404-36
See page 56
21 2210463 23 Screw 12
22 223101 37 Washer 12
23 9006822 01 Relief valve, 6 bar 1 RV201-23
24 597049 01 Coupling, elbow 90 1
25 594707 02 Pipe 1
26 581534 01 Distributor 1
27 260321 25 Hexagon screw 2
28 592304 01 Plug 1
29 592304 02 Plug, 1/4 1
30 552801 50 Push-on connector 5
31 9004638 01 Clamp 1
32 2210296 02 Screw 1
33 223101 33 Washer 2
34 221803 03 Nut 1
35A 9011226 99 Cable (UV lamp to junction box)
37 595272 01 Tube, 6x1 mm 4
38 558710 02 Air Hose Nipple 5
64 526336 04 Nipple 1
70 597044 03 Cable 2 PE, junction box - reactor
71 597044 04 Cable 1 PE, AOT reactor - hull.
74 223101 32 Washer 3
81 221803 26 Nut 4
82 223101 41 Washer, 4,3x9x0,8 4
83 221031 22 Screw 3
93 593301 02 Insulating washer 32
94 593300 04 Insulating sleeve 32
Z 9009521 80 Lamp, spare set Includes UV lamps and 2 O-rings.
Z0.1 594645 82 Quartz sleeve set Includes Quartz sleeve and 2 O-rings.
46 Book No. 9032061 02 Rev. 2

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

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

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

6.2 Junction box, A side

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

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

6.3 Junction box

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

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

6.4 Valve, EN DN350

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

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

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

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

7 Filter, ACB-999-350
9023678-
Quantity
1 9023658 60 Filter, ACB-999-350 1 See page 60
2 591090 04 Flange 1 1/4" 1
3 526337 08 Reducing hexagon nipple 1
5 221711 07 Screw 2
6 9024168 01 Elbow union 2
7 526337 02 Reducing hexagon nipple 2
8 1767267 01 Needle valve 2
9 9017973 01 Pressure transmitter 2
13 526336 04 Nipple 1
14 9006822 03 Relief valve, 10 bar 1
15 561094 06 Straight coupling 1
16 9019487 02 Tube 1
19 9023647 83 Gear motor 1
20 221046 01 Screw 4
22 9024155 01 Bracket 1
23 7007238 01 Screw 4
24 9012246 80 Junction box 1 See page 62
25 221711 25 Screw 4
25.1 223101 32 Washer 4
25.2 221803 28 Nut 4
26 9026074 01 Cable bracket 1
27 221711 07 Screw 2
28 223101 32 Washer 2
29 9026072 01 Bracket 1
30 221711 07 Screw 2
31 221711 13 Screw 1
32 223101 32 Washer 3
33 587276 01 Washer 1
34 9025165 02 Cable 1
58 Book No. 9032061 02 Rev. 2

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

7.1 Filter, ACB-999-350

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

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

7.2 Junction box

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

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

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

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

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

9 Backf ush pump (optional)

9025646-
Quantity
1 9018653 05 Centrifugal pump 1
1.1 589569 79 Cable Gland - M25 1
1.2 589569 35 Counter nut M25 1
2 9018543 63 Valve, EN DN65 1
2A 9007167 02 Valve, DN65 1
2B 9007166 01 Air actuator, AT 101U 1
2C 9007185 01 Pilot valve 1
2D 9007192 01 Throttle valve, 1/4 2
2.1 594410 01 Valve connector 1
6 2210463 09 Screw 8
7 223101 37 Washer 16
8 221803 40 Nut 8
9 2210463 03 Screw 4
10 223101 37 Washer 4
11 1765908 08 Gasket 1
12 9025753 01 Elbow adaptor, 65 1
13 2210463 03 Screw 4
14 223101 37 Washer 4
66 Book No. 9032061 02 Rev. 2

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

10 Valve V201-3 and V201-9

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

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

11 Valve V201-32 and 403-35

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

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

12 Valve V212-31 (optional)

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

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

13 Control valve V201-8

9007174-
Quantity
1 9007167 09 Valve, DN300 1
2 9007166 06 Air actuator, AT 451U 1
7 9007196 02 Bracket 1
9 9034058 80 Driver 1
10 9007190 01 Positioner 1
10.2 9029781 01 Insert, M20 1 See comment on assembly drawing.
16 569035 05 Flexible pipe, PA12, 8/6 1
27 9007200 01 Manifold 1
28 9007201 01 Filter 1
29 571697 01 O-ring, small 1
30 523127 01 Hexagon nipple 1
31 592304 02 Plug, 1/4 1
Z 9007184 04 Insulate plate
74 Book No. 9032061 02 Rev. 2

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

14 Flow transmitter, EN350

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

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

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

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

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

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

9002547-
Ref Part No Description -80* Notes
Quantity
53 221716 02 Screw 2
54 221711 17 Screw 2
55 221701 04 Screw 4
56 223101 41 Washer, 4,3x9x0,8 4
57 221711 16 Screw 18
58 223101 47 Washer 18
59 587276 02 Washer 2
60 27345 Nut, M8 12
61 70560 Washer 14
62 9005147 01 Pipe #22 1
63 552801 50 Push-on connector 7
64 221040 53 Screw 5
65 590539 03 Clip list 1
66 548152 03 Washer 5
67 9014736 01 Coupling 1
68 580758 06 Push-In Fittings 2
Z 590414 02 Tanck screw cap
Z0.1 9014527 81 Conversion kit, CIP Only relevant for CIP modules before
2012-11-13
80 Book No. 9032061 02 Rev. 2

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

15.1 Pump P320-1 and P321-5

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

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

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

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

15.3 Valve block

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

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

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

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

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

17 Pressure monitoring device

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

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

18 Booster pump, P401-1 (optional)

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

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

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

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

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

20 Air f lter regulator

9018092-
Quantity
1 9018092 01 Filter regulator 1
2 9018092 02 Pressure relief valve 1
3 9018092 03 Bracket 1
Z 9018092 99 Filter element Replace every 2 years
96 Book No. 9032061 02 Rev. 2

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

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

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

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

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

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

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

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

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

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

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

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

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PureBallast Ballast Water Treatment System

PureBallast Ballast Water Treatment System

1.1 Manual compilation

PureBallst system Manual no. Connection list Flowchart

Book No.9028378 02, rev 0 1

1.2 Main component makers

2 Book No.9028378 02, rev 0

Book No.9028378 02, rev 0 3

Operating Instructions and

Alarms and Faultfinding 5

Installation and Drawings 6

Spare Parts Catalogue 8

Marine & Diesel Equipment

© Alfa Laval Tumba AB

Book No. 9028195 02, rev. 5

Telephone: +46 8 530 650 00

Telefax: +46 8 530 310 40

2.1 General safety information

Maintenance safety items

• Potential hazard / Grounding: The flow meter must be earthed.

Ancillary component safety items

• Skilled person: A person with technical knowledge or sufficient experience to perform

2.4 Warning signs used in the manual

Book No. 9028195 02, rev. 5

Telephone: +46 8 530 650 00

This publication or any part there of may not be

1.2 System overview 7

2.5 Tank stripping 17

2.6 Ballast water handling in the event of

3 System components description 19

3.2 Lamp drive cabinet (LDC) 21

3.4 CIP (cleaning-in-place) module 29

3.6 Main valves 33

1.1 Components overview

2 System overview Filtrex

Example of layout with 1 UV reactor.

• System bypass valve

1.1.1 Item numbers

1.2 System overview

Atex EU directive “Appareils destinés à être utilisés en ATmosphères

CIP Cleaning in place

CIP module Cleaning in place module. Performs the CIP process.

DIN Deutche Institut für Normung

EN Standard according to CEN (European Committee for

I/O Input/output (Describes a program or device handling data)

IACS International Association of Classification Societies

IECEx International Electrotechnical Commission Explosive

ISCS Integrated ship control system

IMO International Maritime Organization

JIS Japanese Industrial Standard

LED Light emitting diode

LDC Lamp drive cabinet.

LPS Lamp power supply

MCB Motor circuit breaker

PLC Programmable logical controller (PureBallast control system)

USCG United states coast guard

PSU Practical salinity unit

2.1 IMO and USCG mode

2.1.1 When to use the different modes

IMO mode is used for