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Alfa Laval PureBallast 135 Compact USCG, System Manual

The Alfa Laval PureBallast 135 Compact USCG is an innovative ballast water treatment system designed to meet US Coast Guard requirements. Ensure smooth sailing with this reliable product that effectively removes harmful organisms from ballast water. Access the comprehensive System Manual for free download on our manualshive.com, providing all the necessary information for easy installation and operation.

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Spc for 9032172 80 v.0 - Module 85, non std

Module 85

Machine unit number or

Subassembly description

9018348-

Ref

Part No

Description

-82

Notes

Quantity

1

9017906 82 Sub module, small

1

See page

 3

0

2

1767267 01 Needle valve

2

V201-15, V201-17

3

9017973 01 Pressure transmitter

2

PT201-16, PT201-72

4

9006822 03 Relief valve, 10 bar

2

RV201-23, RV201-50

6

9019942 80 Release valve, automatic

1

V571-2

6.2

9024839 01 Stud elbow, male

1

7

9001689 81 Housing

1

8

9001357 01 UV sensor QT201-50

1

QT201-50

9

9006324 02 Temperature, switch

1

TS201-60

10

558663 04 Gasket washer

2

11

9006325 02 Thermometer, resistance

1

TT201-33

12

594171 01 Limit switch (vibration)

1

LS201-29

14

9016298 01 Check valve, DN20

1

CV310

15

9017571 01 Valve, DN20

7

V310-1, V320, V460-1, V460-2, V460-3,
V460-4, V571,

16

1779813 04 Valve

1

V310-2

17

9004533 80 Pump P320-1 and P321-5

1

P460
See page

  

4

4

21

9019583 80 Valve block

1

See page

  

46

22

9017895 01 Sensor box

2

Marked X10, W10, X11, W11

23

9017895 02 Sensor box

1

Marked X12, W12

24

9024792 80 Filter regulator

1

See page

 

4

8

25

9017332 01 Pump

1

P320

28

9017336 01 Strap

1

29

9018554 01 Winch

1

30

9018144 80 Junction box

1

See page

 

5

0

31

9018775 02 Pipe

1

32

9021363 02 Pipe

1

34

9018778 02 Pipe

1

38

9021992 02 Pipe

1

40

9018145 01 Deaeration pipe

1

41

9019487 01 Tube

1

42

9019412 01 Tube

1

44

9019447 01 Pipe clamp

5

54.1

9024692 01 Nut, function

18

55.1

9024691 01 Straight coupling, swivel

1

61

9022150 80 Lifting adapter

1

65

9021827 01 Spacer

1

66

9021922 01 Stay

1

67

9004638 01 Clamp

2

68

9019593 80 Cable set

1

See page

 

5

2

73

597044 03 Cable

1

PE, reactor - junction box

76

9004638 02 Clamp

5

77

9022014 01 Clip

1

78

9022023 01 Shim

2

79

589569 01 Cable Gland M12

1

81

221031 02 Screw

16

82

260262 07 Screw

2

ISO 10642 - M3 x 10

84

221031 03 Screw

5

85

221701 11 Screw

2

86

221701 12 Screw

9

87

221701 20 Screw

4

88

221701 23 Screw

4

89

221701 08 Screw

2

90

221701 09 Screw

3

91

223101 30 Washer

15

92

223101 32 Washer

28

93

223101 33 Washer

20

94

221803 26 Nut

13

95

221803 28 Nut

2

6

Book No.

Summary of Contents for PureBallast 135 Compact USCG

Page 1: ...System Manual PureBallast 3 1 Compact 3 PureBallast Ballast Water Treatment System PureBallast Ballast Water Treatment System System Manual English ...

Page 2: ......

Page 3: ...them and the connection list and flow chart defining them Versions The USCG version use flow control to be compliant with USCG legislation The USCG HP high performance have double reactor capacity which allows treatment at full capacity at all time 1 1 Manual compillation PureBallst system Manual no Connection list Flowchart 85 Compact USCG 9028175 02 9018539 9015279 135 Compact USCG 9028177 02 90...

Page 4: ...h PEPPERL FUCHS Vibracon LVL A7 Valves Siemens SIPART PS2 Positioner Air Torque Spa AT range Actuator V201 8 Flow control valve ARI Armaturen ARI GESA Lugged valve PEPPERL FUCHS NBN3 Inductive pos sensor Air Torque Spa AT range Actuator V201 3 9 19 32 Filter inlet outlet by pass Start up cooling valve ARI Armaturen ARI GESA Lugged valve Air Torque Spa AT range Actuator V309 1 Filter backflush valv...

Page 5: ...nd Component Manufacturer Model Size according to connection list LS320 3 Level sensor PEPPERL FUCHS CBN10 Capacitive sensor T320 CIP cleaning liquid Alfa Laval Alpacon Descalant Offshore Electrical cabinet EC Electrical cabinet Alfa Laval EC 3 1 Book No 9028495 02 rev 1 3 ...

Page 6: ...PureBallast 3 1 85 Compact USCG Lit Code 200000695 1 EN GB Manual No 9028175 02 v 6 System manual ...

Page 7: ...ed by Alfa Laval Corporate AB No part of this document may be copied re produced or transmitted in any form or by any means or for any purpose without Alfa Laval Corporate AB s prior express written permission Information and services provided in this document are made as a benefit and service to the user and no representations or warranties are made about the accuracy or suitability of this infor...

Page 8: ...USCG mode 19 2 2 2 Flow control and power optimization 19 2 2 3 Start up 21 2 2 4 Ballasting 22 2 2 5 Deballasting 24 2 2 6 Tank stripping 25 2 2 7 Ballast water handling in the event of malfunction 25 2 3 System components description 26 2 3 1 UV reactor 26 2 3 2 Filter 27 2 3 3 CIP components 32 2 3 4 Cabinets and control system 33 2 3 5 Main valves 36 2 3 6 Flow meter 37 2 3 7 Pressure monitori...

Page 9: ... tank stripping 76 3 4 5 Heel internal transfer 77 3 4 6 Backflush filter manually 78 3 4 7 CIP clean UV reactor after ballast deballast 79 3 4 8 Attend to alarms 79 3 4 9 Shut down and deactivate system 80 3 4 10 Operate components manually 81 3 4 11 Operate UV lamps manually 82 3 4 12 Set ship specific component ID 83 3 4 13 Export control system event log files 84 3 4 14 Backup control system s...

Page 10: ...ttings 118 4 2 2 Page 5 1 Main parameters 120 4 2 3 Page 5 2 UVR parameters 123 4 2 4 Page 5 3 Filter parameters 124 4 2 5 Page 5 4 CIP parameters 126 4 2 6 Page 5 5 Remote parameters 127 4 2 7 Page 5 6 Installation parameters 128 4 3 Lamp power supply LPS parameters 130 4 3 1 DIP switch settings 130 4 4 Fuse settings for filter motor and installed optional pump motors 131 4 5 Flow meter parameter...

Page 11: ...eparations and conditions 278 7 1 2 Welding requirements 278 7 1 3 Tightening torques 278 7 2 Maintenance schedule 280 7 2 1 Calibration schedule 282 7 2 2 Recommended spare parts on board 285 7 2 3 Serial number information 285 7 3 UV reactor 290 7 3 1 Safety information 290 7 3 2 Replace UV lamp 291 7 3 3 Replace quartz sleeve 293 7 3 4 Dismount and mount lamp power supply 295 7 3 5 Test lamp po...

Page 12: ...alve on actuator V212 31 optional 322 7 8 12 Adjust valve traveling speed for V212 31 optional 323 7 9 Flow meter 324 7 9 1 Replace display and fuse 324 7 9 2 Replace a circuit board 325 7 10 Level switch 328 7 10 1 Mount level switch 328 7 10 2 Dismount level switch 328 7 10 3 Test level switch 329 7 11 Temperature switch and temperature transmitter 330 7 11 1 Mount temperature switch temperature...

Page 13: ......

Page 14: ...1 Safety 200000695 1 EN GB 9 EN Safety ...

Page 15: ...se only Alfa Laval genuine spare parts Always read and follow the documentation that is included in shipment of components and spare parts regarding handling safety and disposal Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door Before installation read applicable sections Technical data and drawings on page 165 and in the Design and installation guideli...

Page 16: ... quartz glass sleeves See Material data sheet UV lamp in chapter 6 UV lamps are stored according to local regulations Before installation check that the UV lamps and quartz sleeves are not broken Depressurize reactors and allow equipment to cool down completely before disassembling Never handle UV lamps before they are completely cooled down A hot UV lamp is under high internal pressure and the ri...

Page 17: ...t CIP liquid on page 256 CIP safety items CIP liquid Risk for eye and skin irritation Avoid contact with eyes and wear protective gloves and goggles Follow rules when handling CIP liquid agent regarding ventilation personal protection etc If CIP liquid Alpacon descalant offshore comes in contact with eyes or skin rinse thoroughly with cold water See Safety data sheet CIP liquid on page 256 Always ...

Page 18: ...ersonnel 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 o...

Page 19: ...cs 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 recyclin...

Page 20: ...2 System description 200000695 1 EN GB 15 EN ...

Page 21: ...2 1 Introduction This contains general information about the PureBallast system and its components 200000695 1 EN GB 16 2 System description EN ...

Page 22: ...part of the vessel s ballast water system on the discharge side of the vessel s ballast water pumps During ballast operation the water is led through the filter which removes larger particles and organisms and then to the UV reactor where the water is treated with UV light During deballast the water is led the same way but the filter is bypassed The UV lamps are powered by the EC via LPSs lamp pow...

Page 23: ...ned Optional as part of scope of supply 2 1 2 Item numbers System components are identified by unique item numbers for example FT201 1 for the flow transmitter installed before the UV reactor 2 1 3 Abbreviations The table below is a list of abbreviations used in this manual Abbreviation Explanation AOT reactor Previous name for UV reactor AOT stands for Advanced oxidation technology CIP Cleaning i...

Page 24: ...rs Hold time USCG mode can be run with a 3 days hold time or 0 day hold time Choose 0 3 days hold time in parameter p182 3 days hold time The time between a completed ballast and the start of deballast or stripping must be at least 72 hours 0 day hold time The time between a completed ballast and the start of deballast or stripping must be at least 2 5 hours Note If ballast water will be stored in...

Page 25: ...log is written to the event log The operator must take action according to the ballast water plan to stop the operation or to continue operation and not comply with type approval certificate 2 2 2 1 Flow control Above compliant limit the flow is always 100 But when UVI value falls under compliant limit the flow is decreased to maximum 50 200000695 1 EN GB 20 2 System description EN ...

Page 26: ...oken UV lamp See Operation with broken UV lamp below 2 2 2 4 Operation with broken UV lamp If a UV lamp breaks during operation the ongoing process continues but is not compliant A warning and an additional common alarm is issued and a log is written to the event log The operator should act according to the ballast water management plan After process is finished it will not be possible to start a ...

Page 27: ...ast start up 2 2 4 Ballasting After the start up when the lamps are ready the operator is requested to start the ballast pump The ballast water is pumped from the sea chest to the filter that removes larger particles and organisms This also reduces the amount of sediment build up in the ballast water tanks The organisms and sediments caught in the filter are flushed overboard via regular filter ba...

Page 28: ...hin 30 hours counted from when the process was started Note that it is possible to perform new processes during these 30 hours We recommend that a CIP process is performed within the same ecological zone or in international waters 200 nautical miles from the base line This will avoid untreated water from the UV reactor and the filter to enter a different ecological zones The UV reactor and filter ...

Page 29: ...r is bypassed since the water has already been filtered during ballasting The reason for treating the water a second time during deballasting is to secure that the treatment is fully effective The minor part of the organisms which were only injured during ballast will be rendered totally harmless during the deballast The flow control and power optimization functions in the same way as during balla...

Page 30: ...g water Stripping 2 2 6 1 Stripping after treatment CIP process After stripping operation a cleaning cycle is performed to clean the UV reactor It is performed in the same way as described for the ballasting process If only stripping operations has been performed since the last CIP process the filter is not be filled with technical water potable water at the end of the CIP cycle since the filter h...

Page 31: ... micro organisms to reproduce Destruction of DNA There are no chemical substances added to the process and there are no toxic residuals created Since the water is not affected chemically there are no environmental impact and the process does not influence corrosion in any way 2 3 1 2 UV reactor description The UV reactor consist of the reactor sensors and valves for water and CIP liquid as shown i...

Page 32: ...l where they are still effective Note The lamps are always lit with full effect during start up and the first two minutes of full ballast to secure full efficiency independent of transmittance The lamps are also turned up to full effect for 10 seconds before stop and normal shut down This method will prolong the UV lamp life time The illustration below show the main components for the UV reactor U...

Page 33: ...f 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 ...

Page 34: ...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 200000695 1 EN GB 29 System...

Page 35: ... filter then goes back filtration with full flow to the ballast tank no flow used for backflushing If a new backflush is triggered within 2 minutes parameter p302 the filter will perform a continuous backflush for 20 minutes parameter p303 A Inlet B Outlet D Chamber 1 Filter element 2 Motor 3 Nozzle seen from the side rotating during backflush 6 Backflush valve 2 3 2 3 Backflushing for different d...

Page 36: ...m 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 tri...

Page 37: ...rt intervals we suggest that the filter element is manually cleaned more often than once year 2 3 3 CIP components 2 3 3 1 CIP working principle The purpose of the CIP cleaning in place process is to clean the quartz sleeves covering the UV lamps and the UV sensor This will ensure that the UV light will treat the water efficiently and that the flow control and power optimization functions based on...

Page 38: ...ontains all electrical equipment needed for the system The electrical cabinet is also fitted with 3 lamp power supplies LPS which are feeding power to the UV lamps One LPS feeds power to two UV lamps The LPS also monitors the function of each UV lamp and takes action if a fault occurs The electrical cabinet functions as a single point of contact for signal cables to all components and installed op...

Page 39: ...en 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 It is only possible to operate PureBallast from one place at a time 2 3 4 2 1 Main control panel The main control panel in mounted in the c...

Page 40: ...tallation on bulkhead or on a stand It is possible to remove the back cover to use the front as a mounting plate for installations in wall worktop etc Main control panel with integrated remote control panels 2 3 4 2 3 Remote interface optional As an option the control system can be integrated with the vessel s ISCS via modbus This allows monitoring and operation of PureBallast from the ISCS s grap...

Page 41: ...ltered during ballasting Filter outlet V201 19 The valve directs the water flow from the filter to the UV reactor during ballast The valve is also used to drain the UV reactor and for filter preservation during CIP process to lead technical water potable water from the UV reactor to the filter Backfllush valve V309 1 The valve directs the dirty backflush water flow from the filter over board durin...

Page 42: ...n the PureBallast system to secure that certified flow is not exceeded If so a warning is issued The flow meter send valuable data to the PureBallast control system where it is displayed Example of information Current flow and data about total amount of treated ballast water 2 3 7 Pressure monitoring Two pressure transmitters monitor the pressure in the system PT201 16 System pressure before filte...

Page 43: ...200000695 1 EN GB 38 2 System description EN ...

Page 44: ...3 Operating instructions and control system description 200000695 1 EN GB 39 EN ...

Page 45: ...ast in US waters all water in each tank must be treated using the same hold time mode Hold time is set in parameter p182 USCG hold time It is not allowed to mix waters treated using different modes in each tank Example If you intend to deballast using 0 day mode 0 day mode must be used during ballast If a tank will be filled with water treated using a different mode than the water stored in the ta...

Page 46: ...ant 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 sedim...

Page 47: ... integrated between PureBallast and the vessel s ISCS 3 1 1 4 Gravity operation Gravity operation not using the ballast water pump can only be allowed if the following prerequisites are fulfilled The requirements for flow and backflush pressure is fulfilled The vessel s flag state and classification society allow gravity operation It is stated in the vessels s approved ballast water management pla...

Page 48: ...See chapter 4 Parameters for information Full access to page 4 3 Timers 3 AlfaLaval N A Full access Password only available for Alfa Laval personnel Full access to all parameter pages Full access to make settings for remote control panels and remote interface in page 4 1 System 1 and 4 4 4 5 Remote interfaces 1 and 2 3 2 2 Control of PureBallast PureBallast can be monitored and controlled in three...

Page 49: ...nd ISCS from a PureBallast control panel This is done by using the Local local and Remote remote buttons when logged in as Operator or higher Control status local or remote is indicated by a green frame that corresponds to the system currently in command In the ISCS control status can be indicated by using the status signal dedicated to this It is recommended that this signal is implemented in the...

Page 50: ...e 1 There must be no active alarms for the UV reactors to be used during operation Always check the alarm list page 2 1 Alarm list in the control system before operation The UV reactor must be in standby mode 3 2 3 Overview of the screen This section describes the PureBallast control system screen layout and navigation The control system use a touch screen where you tap the screen to click or drag...

Page 51: ... Alarm list The first number refers to selected top tab counted from left to right The second number refers to selected side tab Selected tabs are indicated by a white color Top tabs Contain the main function areas of the control system Overview alarm lists trend curves system information and parameters Side tabs Contain sub pages for the area selected in the top tab 200000695 1 EN GB 46 3 Operati...

Page 52: ...required for the function Status indication Button light After a function button is pressed a frame is lit to indicate status Green Command is active Green blinking Command will be processed when possible in the data work flow Function button description The illustration below shows the main areas and function buttons on the screen Button Description Start ballast process Start deballast process S...

Page 53: ...e control system in IMO mode which activate operation in accordance with IMO requirements Sets the control system in USCG mode which activate operation in accordance with USCG requirements The text under the button indicates if the system is run as USCG 0 days holdtime or USCG 3 days holdtime according to parameter p182 Status indication Alarms and warnings Alarms and warnings for components are d...

Page 54: ...nuously To see accumulated operation runtime for the components see page 4 3 Timers The following status information is displayed Status information unit Description Process and subprocess Process Ongoing process Subprocess Sub steps of ongoing process for example Start up during Ballast process Remaining time Remaining time for the ongoing subprocess in the upper right corner Flow chart The flow ...

Page 55: ...l system screen showing the main overview page Status box The status box display current status for the PureBallast system The information is updated continuously To see accumulated operation runtime for the components see page 4 3 Timers The following status information is displayed Status information unit Description Process and subprocess Process Ongoing process Subprocess Sub steps of ongoing ...

Page 56: ...level Advanced operator or higher it is also possible to operate components manually If a component is pressed a popup window is displayed from which the component can be operated Status indication Component colour Component status is indicated by a coloured frame The symbol indicates that you can change the components symbol name ID A popup window will appear when you press the component symbol T...

Page 57: ...er ship specific ID for a component The ID will be visible in page 1 2 Overview and popups for the components See instruction Set ship specific component ID Toggle between show hide component ID in flow chart The component is operated manually in manual mode Status information for the motor M703 1 of the backflush pump P309 1 optional Only visible if parameter p318 is activated 200000695 1 EN GB 5...

Page 58: ...active LPS 1 3 The buttons are used to start stop UV lamps manually Press one button 1 to start stop UV lamp LPS 1 controls lamp 1 and 2 LPS 2 lamp 3 and 4 etc Status indication Lit Green circle Off Grey circle Power indication Actual effect from each LPS to UV lamps Enables manual operation of the LPSs The button is displayed for login level Advanced operator or higher The button enables manual c...

Page 59: ...wer optimization 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 Power output Calculated power consumption for ongoing process The effect is adjusted to attain the setpoint for UV intensity based on measured water transmittance based on input from UV sensor QT201 50 Effect can be 50 100 200000695 1...

Page 60: ...1 16 minus PT201 72 When the pressure reach 0 5 bar a backflush is triggered Press the button to start a manual backflush See instruction Backflush filter manually on page 78 Filter information Status for the filter and relevant components are displayed in the illustration Elements Description Pressure transmitters Current pressure PT201 16 Pressure before filter PT201 72 Pressure after filter Pip...

Page 61: ... required Yellow CIP ongoing Yellow blinking CIP completed Green CIP required White Required but cannot be performed due to active alarm on the UV reactor Filter preservation Status indication for filter preservation Indication As CIP During filter preservation the filter is drained from sea water and filled with fresh water for preservation purpose CIP error Red square Indicates that there is an ...

Page 62: ...m is set in normal mode the page is used to display power management status Column Content LPS activation 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 LPS power Power consumption for all...

Page 63: ...n On Grey Off Alarm Red Active alarm Grey No alarm TT401 Air temperature in the electrical cabinet indicated by temperature transmitter TT401 M1 Fan rotation in percent of full effect Fan effect is based on need for cooling Fan starts at 30 at 30 C and rotates at 100 at 45 C External feed Percent of full effect PureBallast is requesting from the vessel s ballast water pump or percent open if the e...

Page 64: ...llowing information is displayed for each alarm row Column Content Text Descriptive alarm text written as Area Alarm type AlarmID Alarm text Example A29 Valve error V201 8 Active time The time alarm was activated Acknow ledged time The time the alarm warning was acknowledged The alarm warning remains in the alarm list until the causing condition is resolved For example a high temperature alarm wil...

Page 65: ...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 200000695 1 EN GB 60 3 Operating instructions and control system description EN ...

Page 66: ...ollowing information is displayed Column Content Text Same as in Page 2 1 Alarm list Active time Same as in Page 2 1 Alarm list The Clear button is used to clear the screen The alarm history is saved in the log files 200000695 1 EN GB 61 Operating instructions and control system description 3 EN ...

Page 67: ... USB memory from page 4 1 System 1 For each activity the following information is displayed in the different column Event Before Value before change if a value parameter etc has been changed After New value if a value parameter etc has been changed Time stamp Time for the action User name Login level who performed the action 200000695 1 EN GB 62 3 Operating instructions and control system descript...

Page 68: ...201 72 Diff pressure bar Differential pressure over filter indicated by pressure transmitter PT201 72 and PT201 16 V201 8 Control valve V201 8 open percent UVI W m2 UV intensity in UV reactor indicated by UV intensity sensor QT201 50 Power kW Electrical power feed Diagram area In the diagram area trend curves are displayed for one or more components Components available for plotting is displayed a...

Page 69: ...t 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 Status indication Filled Selected Component values is plotted in the diagram in the same color as the icon Empty Not selected Component values is not plotted in the diagram Scale icon The component scale setting is used in the diagram s Y axis If ...

Page 70: ...age PLC used storage in percent and MB Storage used for the event and alarm log iX version N A Panel firmware Version of internal firmware for the control panel CAT control version N A PureBallast HMI software version Version of HMI software IP settings Display current IP address for the panel Setup button Opens popup to set IP address for the main panel and the remote control panels optional Requ...

Page 71: ...vanced operator 3 3 12 Page 4 2 System 2 The page is used to set system settings and export log files The following information is displayed Section on page Description HMI date and time UTC Date and time Only used if GPS is not connected to the control system If so time is retrieved from the GPS Requires login level Advanced operator Set button Set time and date for the main control panel Remote ...

Page 72: ...els optional See instruction Set control panel IP address on page 87 Requires login level AlfaLaval Night button Activate night light for the panel Night light makes the panel less bright Toggles between night light and day light Degree of brightness is set in the Night light level field in page 4 2 System 2 Wipe button Disable the touch screen function for 10 seconds to make it possible to clean ...

Page 73: ...UV reactor Lap time Lap time for installed UV lamps since 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 Hours Reactor EC power on Hours CIP pump P320 1 pulses Number CIP Number cleaned UVRs Reset button Reset to 0 If this is done each time the CIP liquid is changed it is ...

Page 74: ... without actually affecting the control system start process etc To send information enter desired digits in the entry field Requires loginlevel Advanced operator or higher Active Check mark on the button Deactivated No check mark on the button 3 3 15 Page 4 5 Remote 2 This page is used to monitor data sent between PureBallast s PLC and the vessel s ISCS For detailed information about addresses in...

Page 75: ...200000695 1 EN GB 70 3 Operating instructions and control system description EN ...

Page 76: ... 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 Short circuit Status Red Short circuit alarm Lamp open Status Red No lamp circuit open Air temp fault Status Red Temperature in LPS is too high Heatsink fault LPS internal heat protection tripped Fan fault LPS fan broken If a sum alarm is issued for an LPS an alarm...

Page 77: ... 3 17 Page 5 1 5 6 Parameter pages These pages are used to set parameters See chapter 4 Parameters for detailed information 200000695 1 EN GB 72 3 Operating instructions and control system description EN ...

Page 78: ... Detailed page descriptions on page 49 Login levels required for different procedures See section Login levels on page 43 Detailed information about components valves motors pumps etc involved in each step the process See section Detailed process description on page 98 3 4 1 Log in Follow the steps below 1 Press the Login function button Result A login popup is displayed 2 Press the dropdown menu ...

Page 79: ...arted if needed 3 Open relevant valves leading flow to and from PureBallast See section Preparations and conditions on page 40 Note These valves are outside the PureBallast system control 4 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 displ...

Page 80: ... right mode same mode as for ballast to respective tank All valves leading flow to and from PureBallast must be opened They are not operated by PureBallast See section Preparations and conditions on page 40 The Alarm list page 2 1 must be controlled to verify that there are no alarms needing attention There must be available power for the system If power management is integrated this will be handl...

Page 81: ... CIP is displayed in page 1 5 CIP A CIP process is started manually according to instruction CIP clean UV reactor after ballast deballast on page 79 3 4 4 Perform tank stripping Follow this instruction to strip Preparations and conditions IMO or USCG mode must be selected by IMO or USCG function buttons based on which legislation that should be followed For USCG Choose in parameter p182 if 3 days ...

Page 82: ...ponent feedback is integrated with the control system 6 Close relevant valves and then press the button in the popup to confirm the action See section Preparations and conditions on page 40 Note These valves are outside the PureBallast system control The popup is not displayed if the component feedback is integrated with the control system NOTE A CIP cleaning process must be finished within the ti...

Page 83: ...manually Follow this instruction to backflush rinse the filter manually Preparations and conditions The system must be in full ballast mode The system can be in standby to test the backflush motor but the filter will not be cleaned Follow the steps below 1 Go to page 1 4 Filter 2 Press the Start backflush button Result A backflush is performed for 20 seconds defined in parameter p308 200000695 1 E...

Page 84: ...ocess the CIP process will start after 5 minutes when the UV lamps have been cooled 3 After completed process Close relevant valves leading flow to and from PureBallast See section Preparations and conditions on page 40 3 4 8 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 Preparations a...

Page 85: ...and press Ack selected button to acknowledge only this alarm Result The alarm will change color to indicate change of status See section Page 2 1 Alarm list in this chapter 3 4 9 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 1 E...

Page 86: ...ss power to PureBallast must be switched off using the ship s switch board Reset the system by pressing the blue Reset button 2 3 4 10 Operate components manually Follow this instruction to operate components manually This shall only be done during commissioning advanced faultfinding or service This is the recommended way to operate components manually Valves can also be operated manually accordin...

Page 87: ...ually 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 operate...

Page 88: ...r Operate the lamps by pressing one of the LPS1 3 buttons to start stop lamps Each LPS supply powers to two UV lamps which means that it is only possible to start two lamps at a time The buttons toggles between started and stopped Result UV lamps are lit Status is indicated Grey Stopped Green Started Yellow Starting 6 If desired the UV lamps can be dimmed manually Press the entry field for Manual ...

Page 89: ...s been issued from the control system Intended to be used mainly by service technicians Update export Only used when PLC soft ware is updated The system export events and parameter settings to a USB where the information is stored temporarily during the update After update the system retrieves the information back to the PLC For specific information about logged events see section List of logged i...

Page 90: ...x and enter desired interval in the Start and End filelds 5 Press the function buttons Events Result The information is copied to the USB memory indicated by a green checkmark on the button during copying 6 Wait for the message Export OK to appear Press the function buttons Alarms 7 Wait for the message Export OK to appear Result A folder named PureBallast has been downloaded It contains three sub...

Page 91: ...quires login level Advanced operator or higher A USB memory with backup files When the files where backuped the backup files where saved in a folder named PureBallast Backup For information about backup files see section Backup and restore in the page description for Page 4 1 System 1 on page 65 This method shall not be used to restore parameter settings after software update If you do not wish to...

Page 92: ...at the backside of the panel Follow the steps below 1 Go to page 4 1 System 1 2 Press the Setup button in the IP settings box Result The IP settings popup is displayed 3 Press the IP settings button Result A popup is displayed 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 ...

Page 93: ...ls installed IP addresses must have been set according to instruction Set control panel IP address Main control panel and remote control panel 1 192 168 0 11 are added as default If no remote control panels is used address 192 168 0 11 shall be removed All remote control panels must be on and connected with an Ethernet cable Follow the steps below 1 On the main panel in the electrical cabinet Go t...

Page 94: ...nnected panel Select it a panel in the hand side and press the delete X button If a keyboard is displayed press Esc to remove it 3 4 18 Set remote interface communication Follow this instruction to make settings for the remote interface optional communication between the ISCS and PureBallast Preparations and conditions These instructions require login level AlfaLaval Follow the steps below 1 Go to...

Page 95: ...ctric cabinet TT401 65 Filter outlet pressure V201 72 66 Power consumption 57 58 Current time 114 UV reactor temperature TT201 33 For detailed information see the directory of addresses Follow the steps below 1 Press the Remote function button Result Test mode is activated enabling that communication is sent between the systems without actually affecting the control system start processes etc This...

Page 96: ...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 Follow the steps below 1 Enter the desired bit pattern in the entry field for the address 2 Make sure that the alarm warning is indicated in ISCS 3 If common alarm and warnings are used m...

Page 97: ...he flow transmitter FT201 1 to maintain stable flow Desired flow is defined as selected certified flow for the operation minus the Undershoot percentage set in parameter p111 During backflush the control valve is regulated based on input from the pressure transmitter PT201 72 to maintain stable pressure for efficient backflush Desired pressure is defined in parameter p304 The purpose is to adjust ...

Page 98: ...he 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 wa...

Page 99: ...ee 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 Preparations and conditions This operation requires login level AlfaLaval Follow the ...

Page 100: ...s stable with slow changes 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 need...

Page 101: ...tor command start stripping is issued N 100 Manual mode set by operator N 190 Standby mode N 210 Ballast Start up mode N 220 Full ballast mode Y 240 Filter backflush mode N 250 Stop ballast mode N 260 Deballast start up mode N 270 Full deballast mode Y 290 Stop deballast mode N 300 CIP process started N 310 E stop N 320 Power turned on PureBallast has been powered off for XX days YY hrs ZZ min Tim...

Page 102: ...SCG 3d mode Y 807 System started in USCG 0d mode Y 810 UVR 1 was not CIP cleaned within required time Y 811 CIP cleaning completed Y 1152 UV intensity low System flow reduced Y 1153 UV lamp fail System flow reduced Y 1154 UV intensity USCG low System flow maintained at 50 Y 200000695 1 EN GB 97 Operating instructions and control system description 3 EN ...

Page 103: ...the PureBallast processes The processes are divided into three main processes with subprocesses with indications of automatic and manually initiated steps All steps are not valid for all installations 200000695 1 EN GB 98 3 Operating instructions and control system description EN ...

Page 104: ...ther process is active Pumps motors and UV lamps are not running and all valves are closed The following processes modes can be activated from standby Ballast Deballast CIP UV reactor and filter filling UV reactor and filter draining Manual mode 200000695 1 EN GB 99 Operating instructions and control system description 3 EN ...

Page 105: ...ower management Automatic power request from PureBallast to vessel s power management system if integrated 4 UV lamp warming Component activities Activate UV reactor cooling If UV reactor temperature is above 45 C p225 V310 1 is opened to cool the UV lamps Valve is closed when temperature is below 45 C Start UV lamps 100 Start counter UV lamp runtime 5 Ballast water pump request After 90 seconds p...

Page 106: ...st Start power optimization based on input from UV sensor QT201 50 3 6 2 3 Filter backflush Purpose To clean the filter This subprocess is either triggered when differential pressure is more than p305 bar or by time interval every 30th minute It can also be started manually It is normally repeated several times during a ballast process 1 Filter backflush triggered Component activities Start automa...

Page 107: ...ulated water Run backflush process See section Filter backflush in Ballast process Close V201 8 to p113 Close V201 3 Close V201 8 control valve 2 Request from control system stop ballast water pump outside PureBallast system 3 Stop UV lamps Component activities 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 lam...

Page 108: ...5 Close valves Valves leading flow to and from PureBallast closed 200000695 1 EN GB 103 Operating instructions and control system description 3 EN ...

Page 109: ...wer request from PureBallast to vessel s power management system if integrated 4 UV lamp warming Component activities Activate UV reactor cooling If UV reactor temperature is above 45 C p225 V310 1 is opened to cool the UV lamps Valve is closed when temperature is below 45 C Start UV lamps 100 Start counter UV lamp runtime 5 Ballast water pump request After 90 seconds p210 after all UV lamps are l...

Page 110: ...2 minutes in full deballast Start power optimization based on input from UV sensor QT201 50 3 6 3 3 Stop deballast Purpose To stop the deballast process 1 Operator stops the deballast process manually Component activities Stop counter Accumulated water Set V201 8 control valve to p113 open Close V201 9 inlet valve Close V201 8 control valve UV lamps are lit at 100 for 10 seconds then switched off ...

Page 111: ...st water pump outside PureBallast system 3 BW pump stopped by operator and confirmed in control system Handled automatic if external component signal is enabled 200000695 1 EN GB 106 3 Operating instructions and control system description EN ...

Page 112: ...ater The stripping process works as a deballast operation with below specified exceptions Power optimization is deactivated which means that the lamps are lit to 100 200000695 1 EN GB 107 Operating instructions and control system description 3 EN ...

Page 113: ...t activities simultaneous Open V201 19 Filter outlet valve Open V460 3 Open V460 4 Start pump P460 2 Open deaeration valve V571 1 3 Component activities when LS201 29 indicate dry condition Wait p200 minutes After p317 minutes Open V460 1 and Close V460 4 After 10 seconds Close V460 1 and V460 3 Stop pump P460 3 6 5 3 Drain ballast water if only deballast operation after previous CIP 1 Component a...

Page 114: ...th technical water potable water and CIP liquid 1 Component activities simultaneous Open V310 1 until LS201 29 indicate wet condition Close V310 1 Open V320 2 Start pump P320 1 Stop pump P320 1 when parameter set volume of CIP liquid is injected into the UV reactor Close V320 2 Close V571 1 3 6 5 6 CIP cleaning 1 Component activities Open V460 1 CIP valve and V460 2 CIP circulation valve 2 Start p...

Page 115: ...otable water valve 2 Component activities when UV reactor is filled indicated by LS201 29 Close V310 1 technical water potable water valve Close V571 1 deaeration valve Reset timer Elapsed time since last CIP 3 Valves leading flow to and from PureBallast are closed 3 6 6 UV reactor and filter draining Operator starts the process from the control system function button Drain 1 Operator starts the p...

Page 116: ...e V201 19 Close valve V460 3 Stop pump P460 4 3 6 7 UV reactor and filter filling The process is run to drain water from the UV reactor and filter for example before service 1 Component activities Open V310 1 until LS201 29 indicate wet condition Close V310 1 and V201 19 200000695 1 EN GB 111 Operating instructions and control system description 3 EN ...

Page 117: ...or higher The Manual button is only displayed for login level Advanced operator Flow in pipes is not indicated in flow chart Can only be activated from standby mode No automatic processes can be run If another operator take over command by logging in on another control panel manual mode is deactivated and the system returns to standby See instructions Operate components manually on page 81 and Ope...

Page 118: ...ollowing instructions are applicable for Ballast Deballast and Strip procedure Follow the steps below 1 Press to login as operator with password aot 2 Press to check that there are no active alarms needing attention 3 Select the applicable flow setting Press and to change flow setting 4 Press the Ballast Deballast or Strip function button to start a If the popup windows are displayed follow the in...

Page 119: ...R Preparations and conditions The system must be in stand by mode Complete status information regarding CIP is displayed in page 1 4 CIP status The page displays remaining time for ongoing CIP cycles remaining time before individual UVRs are required to be CIP ed etc Follow the steps below 1 Go to page 1 1 Overview 2 Press the CIP button 3 If popup windows are displayed follow the instructions in ...

Page 120: ... not specify time interval 6 Press Events to copy the information to the USB memory 7 After export is completed press Alarm 8 Press Close and remove the USB memory 200000695 1 EN GB 115 Operating instructions and control system description 3 EN ...

Page 121: ...200000695 1 EN GB 116 3 Operating instructions and control system description EN ...

Page 122: ...4 Parameters 200000695 1 EN GB 117 EN ...

Page 123: ...oughly sorted by area for example UV reactor filter and remote interface but the sorting is not strict 4 2 1 Introduction to parameters and parameter settings All parameters are checked and adjusted at first start up during commissioning NOTE Parameters shall normally be set by Alfa Laval Login level 2 or 3 is required to change parameters Login level 2 gives access to set parameters with exceptio...

Page 124: ...s displayed Press the sign to display range Entered parameter value must be within defined setting range 3 To set parameter press the 123 button Result A keyboard is displayed 4 Enter the setting and confirm by touching the Enter button To close the keyboard without saving data touch the Esc button If the parameter is set with a drop down menu select desired choice by touching the value Result The...

Page 125: ...id unnecessary shut down p113 Min opening for V201 8 28 10 100 During ballast and deballast valve V201 8 handles the automatic pressure and flow control This parameter defines minimum opening to secure an even flow without interruptions p120 PID proportional gain 0 69 0 00 10 00 N A Defines proportional gain Pf value used for PID regulation of V201 8 during ballast and deballast Normal value 0 1 1...

Page 126: ... 8 closes to reach this degree of percent open p128 Max time communication loss 60 15 240 sec Define max delay before the system shuts down after communication is lost between the PLC and the remote interface optional The value must be greater than the heartbeat signal interval defined in the ISCS For further information see Remote interface implementation guide p141 Timeout Request Start BW pump ...

Page 127: ...aters If 0 days mode is chosen more power will be used to treat the water according to legislation and hold time This parameter can only be changed if parameter p180 is set to option USCG 3d 0d Note This parameter is only relevant for USCG systems Alternatives 3 days hold time The time between a completed ballast and the start of deballast or stripping must be at least 72 hours 0 day hold time The...

Page 128: ...ter has filled the UV reactor before an alarm is issued Estimated value 3 min Set during commissioning p202 High temp alarm trigger TT201 33 60 10 100 ºC Setpoint for high water temperature alarm indicated by temperature transmitter in UV reactor p210 UV lamp warm up time 50 0 130 sec Warm up time for UV lamps before full ballast deballast or stripping starts p211 UV lamp cooling time 300 180 600 ...

Page 129: ... bar Defines desired pressure for efficient backflushing When a backflush is triggered control valve V201 8 will regulate to reach this pressure After time set in parameter p310 the backflush 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 a...

Page 130: ...raining 3 1 15 min Time the control system will wait for confirmation that the filter is drained Default value shall be used p319 Timeout filter filling 3 1 15 min Time the control system will wait for confirmation that water has filled the filter Default value shall be used Set during commissioning p320 Preservation pressure setpoint 0 5 0 2 bar Target pressure in filter to end filter preservatio...

Page 131: ...val 15 15 180 min Defines how often a CIP liquid circulation shall be started p402 CIP circulation duration 2 1 10 min Defines for how long time the CIP liquid shall be circulated each time p403 CIP pump injection volume 30 1 100 pulses Defines the amount of CIP liquid that is injected 1 pulse 11 5 mL Value should be set to 30 p405 CIP pump flow rate 1 1 10 Hz Defines flow rate for the CIP pump P3...

Page 132: ... used for communication between the ISCS and PureBallast Alternatives RS485 and RS422 p701 Baud rate 9600 N A Drop list Defines baud rate in bits per second 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 parity N A Drop list Defi...

Page 133: ...quires that p132 is activated p132 Remote interface via modbus Not used Defines if remote interface optional is used and connected via modbus If connected the Local and Remote 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 stop Not used Defines if an ext...

Page 134: ...USCG high performance HP Not used Defines if the high performance version of PureBallast is activated Defines if the system is an USCG HP 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 Alternatives Acti...

Page 135: ...ording to the table below Switch 1 3 shall always be in position off Switch 4 8 is set to identify the individual LPS according to the table below Only position ON is indicated For empty cells in the table the switch shall be in position OFF Note LPS 1 3 are installed in the electrical cabinet SW 1 SW 2 SW 3 SW 3 SW 4 16 SW 5 8 SW 6 4 SW 7 2 SW 8 1 1 ON 2 ON 3 ON ON Example In the illustration the...

Page 136: ...eset button until LEDs flash 6 seconds 6 Turn the potentiometer to estimated amp setting according to mark plate 7 Check that the setting is correct according to the LEDs Compare to the table below 8 Press Reset button to save the value 4 5 Flow meter parameters The parameters are preset in the flow meter transmitter Follow this instruction to check and set internal parameters in the flow meter tr...

Page 137: ...UNIT VOLUME FLOW m3 h UNIT VOLUME m3 UNIT LENGTH MILLIMETER FORMAT DATE TIME DD MM YY 24H QUICK SETUP QUICK SETUP COMMISSIONING NO OPERATION LANGUAGE ENGLISH ACCESS CODE N A DEF PRIVATE CODE 50 STATUS ACCESS N A ACCESS CODE COUNTER 0 USER INTERFACE ASSIGN LINE 1 VOLUME FLOW ASSIGN LINE 2 TOTALIZER 1 FORMAT X XXXX DISPLAY DAMPING 3 s CONTRAST LCD 50 BACKLIGHT 50 TEST DISPLAY OFF TOTALIZER 1 2 both ...

Page 138: ...RO RETURN OFF SYSTEM DAMPING 9 INTEGRATION TIME 20 ms at 50 Hz 16 7 ms at 60 Hz SENSOR DATA N A N A SUPERVISION CURRENT SYSTEM CONDITION N A PREV SYS COND N A ASSIGN SYS ERROR CANCEL ASSIGN PROCESS ERRORS CANCEL ALARM DELAY 0 s SYSTEM RESET NO OPERATION HOURS N A PERMANENT STORAGE ON SIMULATION SYSTEM SIM FAILSAFE MODE OFF SIM MEASURAND OFF SENSOR VERSION N A N A AMP VERSION N A N A Set parameter ...

Page 139: ...ERVISION 3 Press E key to find parameter SYSTEM RESET 4 Set access code 0050 by pressing or the correct digit and then press E after each digit 5 Change the setting from NO to YES 6 Press E key 7 Press and simultaneously for minimum 3 sec to escape the programming mode 200000695 1 EN GB 134 4 Parameters EN ...

Page 140: ...5 Alarms and faultfinding 200000695 1 EN GB 135 EN ...

Page 141: ...vate the alarm buzzer sound and light on the cabinet The sound is silenced by touching the buzzer but note that the alarm is not acknowledged by this Alarms will shut down ongoing process and disable the start of the process Warnings are information to the operator and will not shut down ongoing or disable start of process Alarms and warnings are indicated in the following ways in the control pane...

Page 142: ... parameter p100 Ballast water pump gives too high pressure Check pressure and flow from ballast pump s If the pressure exceeds set value Adjust incoming pressure to PureBallast Valves in the system after pressure transmitter are closed Control that correct valves are functioning and opened for current process See Detailed process description on page 98 Material is stocked after pressure transmitte...

Page 143: ... the obstruction A10 Process flow signal missing FT201 1 Trigger Flow meter FT201 1 Delay 5 sec Comment Error in system flow sensor Signal missing or flow meter FT201 1 malfunction 1 Check fuse F43 in electrical cabinet to see what circuit caused the fuse trip 2 Use the circuit diagram for electrical cabinet in section Electrical drawings on page 199 to locate the component or find the reason that...

Page 144: ...n page 136 Valves in ballast system closed 1 Control that correct valves are opened for current process See Detailed process description on page 98 2 Check mechanical function of the valve and check that the cables to the component is according with the circuit diagram for electrical cabinet in section Electrical drawings on page 199 Ballast water pump stopped or malfunctions Attend to Note This c...

Page 145: ... on page 311 Position sensor or cables to position sensor malfunction 1 Check cables 2 Replace position sensor if faulty Too long opening closing time valve travel time 1 Follow the instruction Adjust valve traveling speed for V212 31 optional on page 323 2 Check that instrument air pressure is according to requirements in Connection list on page 174 Valve block malfunction Check LED indication on...

Page 146: ...8 on page 318 Cam wheel not correctly set in positioner which results in wrong feed back to control cabinet Adjust according to Adjust cam position on V201 8 on page 320 The air filter on the positioner is clogged Clean the filter A33 Bypass valve is open V212 31 Trigger Bypass valve s Delay 15 sec Comment If the valve not controlled by PureBallast is opened any ongoing process is stopped A new pr...

Page 147: ...ned intentionally close opened bypass valve A71 Ballast water pump is not running Trigger Control system timer Parameter p141 Delay Set in parameter p141 Comment Feed back signal BW pump is running is not activated after request Faulty connection of signal cable Check that all electrical connections are OK Check that the signal wiring is according to information in Electrical cabinet Interconnecti...

Page 148: ...h on the panel 2 Restart the panel See problem 1 B in General problems on page 160 3 Replace if faulty 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 1 Wrong network setting Check settings for each panel according to Set control panel IP address on page 87 Faulty cable connection Check cables to the compone...

Page 149: ...gs 1 Check that parameter p700 is set to match the modbus cable type used RS422 or RS485 2 Check if remote operation is deactivated in the control panel The Remote button at the bottom of the screen is gray If so press the Remote button 3 Check if test mode is activated in page 4 4 Remote 1 check mark on button If so press the Test mode button Requires login level Advanced operator 4 Check that th...

Page 150: ...mperature transmitter TT201 33 Parameter p202 Delay 5 sec Comment Temperature in UV reactor is above 60 C The system is shut down High temperature due to obstacles or error in one or more components involved After problem is resolved Press the Reset button on the electrical cabinet Check that the main inlet valves V201 19 V410 1 and outlet valve V201 8 open properly by operating them manually See ...

Page 151: ...and attend to it 4 Check cables to the component See Electrical cabinet Circuit diagram in Technical data and drawings on page 165 5 Check that all electrical connections are OK and that the electrical wiring is not damaged 6 Replace transmitter TT201 33 7 Restart the process from the beginning A103 Reactor temp high TS201 33 Trigger UV reactor temperature switch TS201 33 Delay 5 sec Comment Tempe...

Page 152: ...ing dry condition 1 Check that valve V310 1 open and close correctly Valves can be manually operated See Valves on page 311 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 2 Examine the pipes related to the CIP process Make sure that n...

Page 153: ...it caused the fuse trip Use the circuit diagram for the electrical cabinet to check the fuse setting adjust according to figures in circuit diagram if necessary and reset fuse A131 Lamp failure Eventual ongoing process not compliant Trigger Lamp power supply 1 3 Delay 5 sec Note Operation continues but is not compliant and does not fullfil requirements for treatment of ballast water Act according ...

Page 154: ...allast water management plan Signal missing 1 Check fuse F43 in electrical cabinet to see which circuit that 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 4 Check cables to QT201 50 See ...

Page 155: ... as reason for the warning Quartz sleeves dirty Run CIP process and try again If problem remains check and clean quarts sleeves according to instruction Service manual on page 277 Old UV lamps Check runtime on page 4 3 Timers in control system Change if old Lamps loose effect when maximum runtime has been exceeded W153 UV lamp broken System flow reduced Process not compliant Trigger UV reactor Par...

Page 156: ...ion continues but is not compliant and does not fullfil requirements for treatment of ballast water Act according to ballast water management plan A new process is not allowed to start Faulty connection of electricity or signal cable Check cables to the component modubus connection LPS See Electrical cabinet Circuit diagram on page 209 Check the threecable connectors on the LPS LPS in faulty state...

Page 157: ...otate easily 4 Start the motor and check that the operation is normal See Service manual on page 277 Mechanical obstacles Check that mechanical parts in the filter can rotate freely See Service manual on page 277 W301 Backflush pump tripped P309 1 M709 43 Trigger K FM2 Delay 1 sec Comment The pump is optional Motor circuit breaker MCB K FM2 in electrical cabinet has tripped or has been switched of...

Page 158: ...ram in section Electrical drawings on page 199 5 Check that all electrical connections are OK and that the electrical wiring is not damaged 6 Replace faulty transmitter 7 Restart the process from the beginning W400 CIP cycle stopped before completed Trigger CIP Delay 5 sec CIP process stopped manually by operator or automatically for some reason If not stopped by operator check page 2 1 Alarm list...

Page 159: ...ll functions and settings can be monitored from the PureBallast control system If the unit has a display it can be used to check errors It is possible to connect a loose display to the flow meter and use it temporarily to troubleshoot the unit During normal conditions all relevant alarms are displayed in the PureBallast control panel Display lines on flow transmitter Display lines fields 1 Main li...

Page 160: ...ess 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 mes...

Page 161: ... these icons can be seen in the table below Problem ID Description S System error P Process error Error message type Fault message Notice message EMPTY PIPE Type of error eg measuring tube is only partly filled or completely empty 03 00 05 Duration of error occurrence in hour minutes and secounds 401 Error number No 001 399 No 501 699 System error device error has occurred Error number No 401 499 ...

Page 162: ...2222 in the illustration below To the right the stat indication LEDs are visible for example r e X I in the illustration below The following modules are installed in the electrical cabinet Identification Function AI2622 Analogue input AO2622 Analogue output CP1382 PLC module System module CPU DO9322 Digital output 12 outputs AT2222 Temperature input module CS1030 Interface module IF1030 Interface ...

Page 163: ...ink 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 1 8 1 12 1 12 1 16 Orange Green Orange Green Green On In output status of the corresponding digital in output Output status of the corresponding digital output In output status of the corresponding digital ...

Page 164: ...re according to blinking pattern 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 OK Yellow On CPU power supply OK R...

Page 165: ... 1 Check fuse F42 in electrical 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 electrical cabinet tripped 1 Check fuse F41 in electrical cabinet to...

Page 166: ...h on the main breaker again 3 If panel is not OK it is probably broke and needs to be replaced Replace the component Wrong software version Check that the HMI and PLC software have the save program version This is visible in control system page Page 4 1 System 1 on page 65 HMI software problem Re load the HMI software according to the software Release note 1 C PureBallast can not be controlled or ...

Page 167: ...t for the remote control panel See Set remote control panel communication on page 88 Disconnected from Communication is broken between remote control panel and main panel Check the following If the electrical and signal cables are disconnected or broken If the electrical cabinet is turned off If the main panel is turned off or broken If control panels are not used See 1 D 5 3 2 Filter Problem ID D...

Page 168: ...e to incorrect setting on valve block Adjust setting with the manual valve under the valve block Pump is clogged Examine the pump and attend to problem See Test pumps on page 308 6 B Too high consumption of CIP liquid Leakage in the CIP tank CIP pump pipes or UV reactor Locate leakage and attend to 6 C CIP pump does not run The air pressure is to low The air connection is blocked Muffler is blocke...

Page 169: ... V201 8 Problem ID Description Possible cause What do to 8 A Signal change has no effect on the actuator position Faulty air supply Check that the air supply is correctly mounted on the valve Faulty signal Check input signal to proportional valve Check I P output 8 B Signal change results in actuator running to end positions Connection or signal problem Check coupling between proportional valve an...

Page 170: ...6 Technical data and drawings 200000695 1 EN GB 165 EN ...

Page 171: ...Power consumption max kW ___________ Remote operation optional Location Remote control panel 1 ___________ Remote control panel 2 ___________ Remote interface integration yes no ___________ 6 2 Technical data This section states technical data for the complete PureBallast system and for individual components In some cases references are given to data in drawings included in this chapter For detail...

Page 172: ...n Technical and potable water on page 181 6 2 3 Power requirements General power requirements Nominal voltage and frequency 400 440 VAC 50 60 Hz 3 phase If voltage does not meet the requirements a transformer can be used The transformer is recommended to give voltage in the higher range as close as possible to 440 VAC Max Icu 50 KA Power factor 0 95 24VDC Remote control panel optional IP rating El...

Page 173: ...ust be calculated and added according to the table below Bar Comment Pressure drop during ballast 0 2 Pressure drop for UV reactors 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 backflush 1 0 Required pressure to clean t...

Page 174: ...her integrations are optional 6 4 Drawings This section contains drawings for the PureBallast system It is divided into three main parts General drawings overall and principle information for system layout pipes components electricity air and water Dimension drawing detailed component information dimensions sizes etc Electrical drawings detailed electric information circuit diagrams cable lists et...

Page 175: ...6 4 1 Graphic symbols used in drawings 200000695 1 EN GB 170 6 Technical data and drawings EN ...

Page 176: ...6 4 2 General drawings This section contains the general drawings 200000695 1 EN GB 171 Technical data and drawings 6 EN ...

Page 177: ...6 4 2 1 Flow chart Note If vacuum relief valve VB201 and VB309 optional is used see additional flow chart 200000695 1 EN GB 172 6 Technical data and drawings EN ...

Page 178: ...6 4 2 2 Flow chart Vacuum relief valve VB201 and VB309 optional 200000695 1 EN GB 173 Technical data and drawings 6 EN ...

Page 179: ...6 4 2 3 Connection list 200000695 1 EN GB 174 6 Technical data and drawings EN ...

Page 180: ...200000695 1 EN GB 175 Technical data and drawings 6 EN ...

Page 181: ...200000695 1 EN GB 176 6 Technical data and drawings EN ...

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Page 184: ...6 4 2 5 Instrument air distribution 200000695 1 EN GB 179 Technical data and drawings 6 EN ...

Page 185: ...6 4 2 6 Quality specification Instrument air 200000695 1 EN GB 180 6 Technical data and drawings EN ...

Page 186: ...6 4 2 7 Quality specification Technical and potable water 200000695 1 EN GB 181 Technical data and drawings 6 EN ...

Page 187: ...6 4 2 8 Quality specification CIP liquid Note that the information below regarding dilution is not valid for compact or compact flex systems 200000695 1 EN GB 182 6 Technical data and drawings EN ...

Page 188: ...200000695 1 EN GB 183 Technical data and drawings 6 EN ...

Page 189: ...6 4 3 Dimension drawings This section contains the dimension drawings 200000695 1 EN GB 184 6 Technical data and drawings EN ...

Page 190: ...6 4 3 1 Skid with backflush pump pump is optional 200000695 1 EN GB 185 Technical data and drawings 6 EN ...

Page 191: ...6 4 3 2 Skid without backflush pump pump is optional 200000695 1 EN GB 186 6 Technical data and drawings EN ...

Page 192: ...6 4 3 3 Electrical cabinet 200000695 1 EN GB 187 Technical data and drawings 6 EN ...

Page 193: ...6 4 3 4 UV reactor and electrical cabinet Lamp power cable 200000695 1 EN GB 188 6 Technical data and drawings EN ...

Page 194: ...6 4 3 5 Valve V212 31 optional 200000695 1 EN GB 189 Technical data and drawings 6 EN ...

Page 195: ...6 4 3 6 Vacuum relief valve VB201 optional 200000695 1 EN GB 190 6 Technical data and drawings EN ...

Page 196: ...6 4 3 7 Vacuum relief valve VB309 optional 200000695 1 EN GB 191 Technical data and drawings 6 EN ...

Page 197: ...6 4 3 8 Sampling device Q201 1 and Q201 2 optional 200000695 1 EN GB 192 6 Technical data and drawings EN ...

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Page 200: ...6 4 3 9 Remote control panel optional 200000695 1 EN GB 195 Technical data and drawings 6 EN ...

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Page 202: ...6 4 3 10 Air preparation unit optional 200000695 1 EN GB 197 Technical data and drawings 6 EN ...

Page 203: ...6 4 3 11 Transformer optional 200000695 1 EN GB 198 6 Technical data and drawings EN ...

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Page 260: ...6 4 4 4 Remote control panel Circuit diagram optional 200000695 1 EN GB 255 Technical data and drawings 6 EN ...

Page 261: ...6 4 5 Saftey Data Sheets 6 4 5 1 Safety data sheet CIP liquid 200000695 1 EN GB 256 6 Technical data and drawings EN ...

Page 262: ...200000695 1 EN GB 257 Technical data and drawings 6 EN ...

Page 263: ...200000695 1 EN GB 258 6 Technical data and drawings EN ...

Page 264: ...200000695 1 EN GB 259 Technical data and drawings 6 EN ...

Page 265: ...200000695 1 EN GB 260 6 Technical data and drawings EN ...

Page 266: ...200000695 1 EN GB 261 Technical data and drawings 6 EN ...

Page 267: ...200000695 1 EN GB 262 6 Technical data and drawings EN ...

Page 268: ...200000695 1 EN GB 263 Technical data and drawings 6 EN ...

Page 269: ...200000695 1 EN GB 264 6 Technical data and drawings EN ...

Page 270: ...6 4 5 2 Safety data sheet UV lamp 200000695 1 EN GB 265 Technical data and drawings 6 EN ...

Page 271: ...200000695 1 EN GB 266 6 Technical data and drawings EN ...

Page 272: ...200000695 1 EN GB 267 Technical data and drawings 6 EN ...

Page 273: ...200000695 1 EN GB 268 6 Technical data and drawings EN ...

Page 274: ...200000695 1 EN GB 269 Technical data and drawings 6 EN ...

Page 275: ...200000695 1 EN GB 270 6 Technical data and drawings EN ...

Page 276: ...200000695 1 EN GB 271 Technical data and drawings 6 EN ...

Page 277: ...200000695 1 EN GB 272 6 Technical data and drawings EN ...

Page 278: ...200000695 1 EN GB 273 Technical data and drawings 6 EN ...

Page 279: ...200000695 1 EN GB 274 6 Technical data and drawings EN ...

Page 280: ...200000695 1 EN GB 275 Technical data and drawings 6 EN ...

Page 281: ...200000695 1 EN GB 276 6 Technical data and drawings EN ...

Page 282: ...7 Service manual 200000695 1 EN GB 277 EN ...

Page 283: ...re included in shipment of components and spare parts regarding handling safety and disposal Before maintaining the PureBallast system the following valves must be locked in closed position V201 3 and V201 8 See instruction Lock valve in closed position on page 313 Point of contact To order service or spare parts contact your local Alfa Laval office For more information see www alfalaval com 7 1 2...

Page 284: ...5 M22 90 M24 105 Actuator Thread Tightening torque Nm M5 5 6 M6 10 11 M8 23 25 M10 48 52 M12 82 86 M14 132 138 M16 200 210 M20 390 410 General Tightening Torques Thread Stainless steel Maximum tightening torque Nm Carbon steel Maximum tightening torque Nm M6 7 10 M8 17 25 M10 33 48 M12 57 83 M16 140 204 M20 270 408 M24 470 696 M30 M36 2500 200000695 1 EN GB 279 Service manual 7 EN ...

Page 285: ...rs and other components to keep them in good condition Inspect for corrosion and erosion damage Once a year Calibration of sensors According to Calibration schedule on page 282 See Calibration schedule on page 282 Electrical cabinet Check air filter Every six month Upper filter Change filter mat when dirty Lower filter Wash with hot water and degreasing liquid when dirty Filters 9017400 02 UV reac...

Page 286: ...Outer inspection of seals for leakage Once a year If necessary change faulty seals See Spare parts catalogue for maintenance kit Check relief valve RV201 50 Once a year Dismount the valve and make sure you can blow air through it from the inside out CIP liquid level check Rule of thumb Once every 3 months Depending on ballasting frequency the liquid check might have to be performed more regularly ...

Page 287: ...hing else is stated 7 2 1 1 Calibrate flow meter This section contains step by step instructions on how to calibrate the flow meter FT201 1 There are two alternative methods to calibrate the flow Calibration using the vessels tank sounding systems calculating the flow Calibration using an ultrasonic device 7 2 1 1 1 Calibration using the vessels tank sounding systems calculating the flow Calibrati...

Page 288: ...ter 2 Establish stable flow in the system 3 Note the PureBallast flow meter reading value A below 4 Note the ultrasonic flow meter reading value C 5 Compare the figures and calculate the variance a Reading Actual variance Allowed variance A FT201 1 value m3 h A C Min 0 95 Max 1 05 C value m3 h 7 2 1 2 Calibrate pressure transmitters This section contains step by step instructions on how to calibra...

Page 289: ...rator or higher Depressurize and drain the reactor by pressing the Drain function button in the control panel page 1 3 Reactor 2 Temperature transmitter TT201 33 a Dismount the transmitter and place in water with known temperature calibrated measure instrument b Compare value indicated in the control system and measure equipment Reading Actual variance Allowed variance A TT201 33 value C A C Min 0...

Page 290: ...O rings 579367 98 Quartz sleeve set 1 quartz sleeve 2 O rings 594645 81 Temperature transmitter 9006325 02 Temperature switch 9006324 02 Lamp power supply LPS 9012146 01 UV sensor 9001357 01 Filter Filter sealing kit 9011963 87 CIP module CIP liquid 9012167 01 Recommendation to order 2 cans at a time CIP pump P320 1 9017332 01 Drain and circulation pump P460 spare part kit Diaphragm Muffler Ball O...

Page 291: ... component in the system It begins with a letter abbreviation indicating the component type for example LS level switch or P pump A complete list of abbreviations is found in Connection list on page 174 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 swit...

Page 292: ...ent system Serial number for the complete PureBallast system Placing At the right side of the electrical cabinet Electrical cabinet Placing Inside the cabinet at the left or right side 200000695 1 EN GB 287 Service manual 7 EN ...

Page 293: ...t the side of the filter as indicated in the illustration Lamp power supply LPSs are installed in the lamp drive cabinet Note Version must be stated together with the serial number Version is stated on the serial number plate Placing At the front of each LPS 200000695 1 EN GB 288 7 Service manual EN ...

Page 294: ...ht Note This number shall be used both for the actuator and the mechanical valve Flow meter Including flow transmitter and flow sensor Placing At the side of the transmitter housing as indicated in the illustration Note The serial number for the flow transmitter is also valid for the flow sensor 200000695 1 EN GB 289 Service manual 7 EN ...

Page 295: ...V lamp 10 Quartz sleeve 7 3 1 Safety information DANGER Always disconnect the PureBallast system from the power supply before disassembling and secure it from being switched on Always lock valve V201 9 V201 3 and V201 8 if you open the UV reactor in some way See Lock valve in closed position Before installation check that the UV lamps and quartz sleeves are not broken 200000695 1 EN GB 290 7 Servi...

Page 296: ...use a burn if it is touched It is not allowed to cover any part of the lamp fittings There must be free flow of air surrounding the lamp caps to ensure sufficient cooling UV lamps and quartz sleeves are fragile and can easily become damaged Exercise great care when handling them Do not apply vibrations or shock to the UV lamp This can cause breakage and shorten lamp life Broken glass quartz can al...

Page 297: ... the lamp through the hole in the lamp bush while carefully pulling the electric cable at the other end After removal place the old lamp in the new lamp s protective cover 5 Check that the quartz sleeve is not broken inside the UV reactor and that there is no leakage around the glass socket and adaptor 6 If the quartz sleeves is not broken mount the new UV lamp according to the instruction Assembl...

Page 298: ...ot squeezed between the cap and the bush when the cap is mounted Slack can be pushed into the bush 7 Control the control system page 3 1 Alarm list to make sure there is no alarm when after the lamp power supply is on 7 3 3 Replace quartz sleeve 7 3 3 1 Disassemble quartz sleeve Follow this instruction to disassemble the quartz sleeve Follow the steps below 1 Log in as Advanced operator or higher ...

Page 299: ...adaptor and remove any small parts for example glass or rubber 7 3 3 2 Assemble quartz sleeve Follow this instruction to assemble the quartz sleeve Preparations and conditions Two new O rings for each quartz sleeve Included in quartz sleeve set Wax for the screws They must be waxed to avoid seizing Glass sockets and lamp bushes must be dry and clean before mounting Before installation check that t...

Page 300: ...uction below to secure that there are no leaks that may damage the UV lamps Follow the steps below 1 Pressurize the UV reactor with water to between 2 and 4 bar 2 Visually check for leaks 7 3 4 Dismount and mount lamp power supply Follow this instruction to replace a lamp power supply LPS inside the electrical cabinet EC Preparations and conditions WARNING Make the system currentless according to ...

Page 301: ...it tight 7 Tighten the nuts to attach the LPS with the arc 8 Turn on the manual motor starter to the LPS The motor starter is located inside the cabinet 9 Switch on the main breaker on the cabinet door and check that LPS s function correctly according to instruction Test lamp power supply installation on page 296 7 3 5 Test lamp power supply installation Follow this instruction to make sure that t...

Page 302: ...ches on the breaker cabinet 2 Set the control system in manual mode requires login level Advanced operator 3 Go to page 1 3 Reactor and start LPS 1 Make sure that two UV lamps are lit Note It can take up to 90 seconds for the lamp to start 4 Directly after the lamps are lit turn of the LPS 5 Repeat the test for all LPS 6 Check that no error indication on the LPS and that there are no alarms in pag...

Page 303: ... perform maintenance and servicing work when the filter is cooled depressurized and drained Shut off the air supply to the filter Visually inspect gasket during maintenance Replace if necessary Lifting device is needed for this instruction See complementary lifting instructions in the Design and installation guidelines Weight on filter cover and filter insert can be found on the dimension drawing ...

Page 304: ...in plug 20 Backflush line gasket 22 Pressure transmitter 29 Junction box 30 Backflush nozzle support 31 Backflush nozzle fixing bolt 32 Backflush nozzle support gasket 33 Base frame 34 Base frame fixing bolt 40 Ring spear 44 Cover lifting lug 41 Thrust bearing upper flange 45 Rotation indicator 42 Thrust bearing lower flange 70 Nameplate 43 Seeger 80 Prefilter 7 4 1 Remove filter cover and filter ...

Page 305: ... motor 1 If the electrical cable is short it might be necessary to disconnect it before removing the motor 5 Remove the motor using a lifting device if necessary Be careful not to harm the motor fitting when lifting it from it s seat 6 Remove the cover bolts 10 and the lifting lugs 44 7 Screw two filter cover bolts in the lifting lugs holes until the cover raises slightly from the filter house 200...

Page 306: ...lifted in one continuous movement without sudden jerks even if the filter element is slightly stuck in the filter house 10 Place the filter element on its side 11 Remove bolts to the bottom shaft support that holds the shaft inside the filter element 15 Remove it carefully 12 Remove the seeger ring 43 from the backflush shaft bushing 11 13 Pull out the backflush shaft bushing If it is stuck give a...

Page 307: ...s gaskets Replace if necessary Fill up the filter with technical potable water after it is mounted Use the Fill function button in the control panel Requires login as Advanced operator or higher There is not need to de air the filter when it is filled up 7 4 3 Clean filter element and pre filter Follow this instruction to clean the filter element At the same time check that the filter element is i...

Page 308: ...er 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 c...

Page 309: ...perature 0 C to 55 C Follow the steps below 1 Pull the pipe from the CIP liquid can 2 Loosen the strap holding the CIP liquid can 3 Replace the old can with a new Remove the cap from the new CIP liquid can 4 Reconnect the CIP cap with the pipe in the can 5 Remove the small cap on the cip liquid can throw it away and cut a hole in the membrane under the cap The purpouse is to let air into the can t...

Page 310: ...as long as the button is pressed 7 6 2 Repair drain pump Follow this instruction to repair the drain pump P460 Preparations and conditions WARNING Always disconnect the PureBallast system from the power supply before disassembling and secure it from being switched on CAUTION Always wear protective eye glasses and gloves while working on the pump Before disassembling the pump the pneumatic hoses mu...

Page 311: ...below 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 car...

Page 312: ...t the circlip 27 on one side 2 Apply some soft soap solution on the air valve O rings 30 3 Push the air valve 61 into the housing Make sure that the O rings 30 remain in the right position Put the circlip 27 on the other side 4 Put the diaphragm 15 with shaft 16 into the centre block Screw the next diaphragm 15 onto the shaft 16 and fix the holes Assemble the main parts Follow the steps below 1 Ma...

Page 313: ...unction button in the control system and wait for the UV reactor to be filled 3 Press the Drain function button in the control system 4 Observe if functions OK If not check installation and connections and test again 5 Observe if the pump sounds OK and that it strikes the number or times set in p403 with hertz as set in p405 If not Check change parameter settings 6 When the process ends fill the U...

Page 314: ... they can be placed in any order Valve block general illustration 1 Cover Terminal strip inside 2 Valve body 3 Button to operate valve 4 Signal plate 5 Cable gland 7 7 1 Change valve body Follow the steps below 1 Remove the screws holding the valve bodies 2 and the signal plate 4 2 Unscrew the screws holding the valve body 2 3 Lift the valve body 4 Attach a new sealing on the new valve body and fa...

Page 315: ... cabinet interconnection diagram 3 Fasten the cable to the cable gland 5 4 Fasten the cover 1 7 7 3 Clean valve block Follow this instruction to clean the valve block house from dirt Follow the steps below 1 Disconnect the outgoing air hoses from the valve block 2 Operate the service air according to instruction Open and close valves manually in section Valves on page 311 to blow out the dust 3 Co...

Page 316: ...ator with puck for position sensor 1 Safety cover 2 Padlock 3 Lower position for indicator screw 4 Upper position for indicator screw with screw 5 Position indicator 6 Center screw 8 Puck 9 Locking bolt 10 End stop bolt Not on all valves 200000695 1 EN GB 311 Service manual 7 EN ...

Page 317: ...n indicator Used for valves with dimension 400 7 DIN connector 8 Position indicator 7 8 1 Preparations and conditions CAUTION Lock valve in closed position before maintenance Do not disassemble individual spring elements Disassembly may result in personal injury Do not remove end caps or disassemble the actuator while the actuator is pressurized 200000695 1 EN GB 312 7 Service manual EN ...

Page 318: ...nditions on page 278 7 8 2 Open and close valves manually Follow this instruction to manually operate valves from the valve blockon the skid Normally we recommend that valves are operated from the control system See Operating instructions and control system description on page 39 for instruction Follow the steps below 1 Look at the signal plate on the valve block to identify which button that cont...

Page 319: ...use Make a note of the distance This information is needed when unlocking the valve 5 Open the locking bolt 3 and turn them a couple of turns 6 Screw the end stop bolt 4 to its bottom position and tighten the locking bolt 7 Verify that the valve cannot be opened 8 Slide the safety cover over the end bolts and lock the safety cover with the pad lock 9 Repeat the above procedure for all valves conce...

Page 320: ...ion remain Verify that the valve is in closed position Result Valve goes to closed position due to air connection The yellow indicators on the puck shows position of valve closed The yellow position indicators are in line with the valve throttle indicating closed when the position indicators are in opposite line with the pipe 2 Close air supply Remove air hose to the pilot valve and attend to thei...

Page 321: ...an and dirt free Before fitting onto the valve make sure the actuator valve is correctly orientated depending on which direction of rotation is required Follow the steps below 1 Note the position of the groove 2 of the valve stem 3 It indicates the position of the valve throttle The illustration shows a square variant but octagonal versions exist 2 Make sure that the lock pin inside the valve stem...

Page 322: ... position indicator is in line with the pipe If not remove the position indicator turn it 90 and refit it Mount the switch box with the bracket on the actuator using the four bolts 7 Reconnect the air hose to the pilot valve 8 Operate the valve to make sure it operates in the desired direction of rotation 7 8 7 Adjust valve end position Follow this instruction to tune the open and closed end posit...

Page 323: ...positioner on V201 8 Follow this instruction to calibrate the positioner at installation or when needed 1 Arrestor device screw driver adjusting 2 Unlock the wheel 3 Locking wheel screw driver adjusting 4 Direction to lock the wheel 5 Adjustment wheel 6 Transmission ratio selector Preparations and conditions The valve must be installed and connected to air and power The valve must be closed The co...

Page 324: ...ot Press HAND button repeatedly until it is Make sure that turn is displayed in the menu If not press or repeatedly until it is 5 Press the hand button repeatedly until Menu 4 is displayed To go backward press HAND button and button 6 Press button for 5 seconds to start automatic calibration 7 If calibration stops as displayed below follow these steps Use a screw driver to loosen the yellow lockin...

Page 325: ...rrect 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 Follow the steps below 1 In control...

Page 326: ... indicate circuit open Repeat from step 2 until setting is OK 7 8 10 Change direction of actuator for bypass valve V212 31 optional Follow this instruction to turn an actuator with switch box Valve actuator with switch box for position feedback to control system 1 Switch box 2 Bracket 3 Actuator 4 Pilot valve 5 Bracket Used for valves with dimension 400 6 Coupling with position indicator Used for ...

Page 327: ...nal Follow this instruction to mount a pilot valve on actuator and connect it Preparations and conditions The valve must be in closed position Air and power must be disconnected The valve position must not be adjusted during the routine Pilot valve and actuator 1 Mounting screw holes 2 Throttle valve 3 Port 1 for air connection under 4 Throttle valve 5 DIN connector 6 Screw Follow the steps below ...

Page 328: ...steps below 1 Operate the valve manually to check travelling speed according to the instruction Open and close valves manually in section Valves on page 311 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 throttl...

Page 329: ...the cover of the electronics compartment Follow the steps below To replace display See step 1 3 To replace fuse See step 1 6 The main fuse is located on the power supply board 1 Turn off power supply using the main breaker on the electrical cabinet 2 Unscrew cover of the electronics compartment from the transmittor housing 3 Remove the local display as follows Press the latches at the side and rem...

Page 330: ...y dangerous voltages Make sure that the power supply is switched off before you remove the cover of the electronics compartment NOTE The circuit boards may break if you yourself or your tools not are grounded at the same ground point as the component that you will work with Always use an electrostatic discharge wrist strap connected to the same earth ground as the component Always place your tools...

Page 331: ...ircuit board 3 The I O module circuit board 1 Turn off the power supply using the main breaker on the electrical cabinet 2 Remove the cover c from the electronics compartment b The cover threads are sensitive so place the cover with its threads facing upwards 200000695 1 EN GB 326 7 Service manual EN ...

Page 332: ...re module 4 Disconnect the ribbon cable from the circuit board 5 Grip the circuit board around its edges the circuit board may break if you touch its components and pull it out carefully 6 Grip the new circuit board around its edges and insert it carefully Then follow the above steps to put back the ribbon cable the display module and the lid 200000695 1 EN GB 327 Service manual 7 EN ...

Page 333: ...ps below 1 Connect the level switch according to the label on the component 2 Seal the level switch with lock tight or equivalent pipe seal 3 Mount the sensor until the joint is finger tight 4 Identify the sensor align mark on the component Make sure that it is positioned on the upper side of the level switch 5 Complete the seal carefully by tightening the component with a spanner Use the spanner ...

Page 334: ...the threads 7 10 3 Test level switch Follow the instruction below to test that a level switch functions OK Follow the steps below 1 Make sure that the component i powered the green LED shall be lit 2 Hold a magnet to the test point indicated on the on the level switch indicated below 3 Make sure the level switch reacts to the magnet The component is OK if the green and yellow LED is lit 200000695 ...

Page 335: ...he component s threads using lock tight or equivalent pipe seal 2 Mount the component until the joint is finger tight 3 Tighten the component with a spanner Use the spanner on the hexagon flats but not on the components body 4 Connect the component s screwed on power cord 7 11 2 Dismount temperature switch temperature transmitter Preparations and conditions The external surface may be hot Care mus...

Page 336: ...function for 10 seconds to make it possible to clean the screen without the risk of starting a process or changing a setting 2 Clean the display and surrounding front cover with a soft cloth and mild detergent Do not spray detergent directly on the control panel 7 12 2 Replace control panel Follow this instruction to replace the control panel Preparations and conditions The system must be shut dow...

Page 337: ...e either Ethernet or optical fiber Cable requirements and connection points below Communication cable W501 between the remote control panel and electrical cabinet can be either Ethernet or optical fiber Cable requirements and connection points below Ethernet cable Type Cat 5e or better shielded Max length 100 meters One remote control panel From terminal X2 in remote control panels to terminal X7 ...

Page 338: ...ow 1 Hold down the plastic clip on the top of the terminal block and pivot the block towards you 2 Pull away the terminal block 3 Hold down the triangle on the top of the I O board and loosen the board 4 Pull the board straight out otherwise it can fasten in one of its guides 5 Compare the part number of the new I O board to the old board to make sure it is correct 6 If changing more than one boar...

Page 339: ...possible to mount the cable terminal 8 Remount the terminal block Make sure the clip on the bottom of the block fastens properly in place on the axel on the bus holder 9 Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in the I O board 200000695 1 EN GB 334 7 Service manual EN ...

Page 340: ...Spare parts catalogue PureBallast 3 1 85 Compact Specification No 9018350 81 3 Book No 9038941 02 Rev 1 ...

Page 341: ...Telephone 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 2018 11 05 Original instructions This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB ...

Page 342: ...Pump P320 1 and P321 5 44 3 3 Valve block 46 3 4 Filter regulator 48 3 5 Junction box 50 3 6 Cable set 52 3 7 Lamp cable set 54 4 Cable set 56 5 Valve V212 31 optional 58 6 Sampling device EN optional 60 7 Remote control panel optional 62 7 1 Cover 64 8 Extended options SPC 66 8 1 Transformer optional 68 9 Cross reference list 70 3 ...

Page 343: ...4 ...

Page 344: ...d 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 de...

Page 345: ...cal cabinet non std 2 Electrical cabinet Machine unit number or Subassembly description 9018280 Ref Part No Description 80 Notes Quantity 1 9019481 80 Electrical cabinet subas 1 See page 8 2 9012146 01 Lamp Power supply 3 6 Book No ...

Page 346: ...2 Electrical cabinet 2921A Book No 7 ...

Page 347: ...ct housing 1 29 9017442 03 Contact cable gland 1 30 9017442 04 Socket insert 1 31 9017442 05 Pin insert 1 35 9018995 02 Connector 12 pos 3 36 9018995 03 Connector 17 pos 1 37 9018995 01 Connector 4 pos 1 38 589569 78 Cable Gland M20 3 38 1 589569 71 Cable gland sealing M20 3 39 589569 34 Counter nut M20 3 40 589569 80 Cable Gland M32 2 40 1 589569 73 Cable gland sealing M32 2 41 589569 36 Counter ...

Page 348: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2922A Book No 9 ...

Page 349: ...5 9018411 01 Yoke 2 16 9017498 01 Knob 4 17 223101 47 Washer 7 18 221891 04 Lock nut 7 19 9002984 01 Hinge 3 20 596105 02 Screw 6 21 223101 47 Washer 6 22 221803 02 Nut 6 23 9019141 01 Handle 1 24 9019142 01 Control mechanism 1 25 9019144 01 Rod 1 26 9019143 01 Latch point 3 27 221891 04 Lock nut 6 28 596105 02 Screw 6 29 9019576 01 Sheet 1 30 221891 04 Lock nut 2 31 9019624 01 Sheet 1 32 594009 0...

Page 350: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2950A Book No 11 ...

Page 351: ...3 9017743 02 Fuse 2A 2 24 9017743 10 Fuse 8A thermomagnetic 1 25 582212 182 Safety module 1 26 9014546 01 Temperature relay 1 27 9017745 01 Relay RIF 0 3 28 9019488 80 Terminal block 1 See page 16 29 9017388 02 Main breaker 1 29 1 9019140 02 Fuse 3 30 594009 07 Screw 4 31 9019489 80 Terminal block 1 See page 18 32 591103 54 Over current prot Relay 3 33 591103 10 Auxiliary contact 3 35 591103 64 Co...

Page 352: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2951A Book No 13 ...

Page 353: ...art No Description 80 Notes Quantity 1 597033 25 CPU w intergrated IO 1 2 580986 17 Bus module 7 3 580986 16 Terminal block 12 pin 7 4 580986 72 Communication module 2 5 580986 69 8DI 4DO 1 6 580986 40 Input Module 1 7 580986 53 2 Analogue Output 1 8 580986 09 2 Analogue input 1 9 580986 59 12 Digital Output 1 14 Book No ...

Page 354: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2953A Book No 15 ...

Page 355: ...hine unit number or Subassembly description 9019488 Ref Part No Description 80 Notes Quantity 1 9017746 01 End stop clipfix 35 2 2 582212 67 Terminal PIT 2 5 3PV 10 3 582212 64 Terminal PIT 2 5 3PE 2 4 582212 63 Terminal D PIT 2 5 3L 1 6 582212 03 Plug In Bridge 2 16 Book No ...

Page 356: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2954A Book No 17 ...

Page 357: ... 1 9017746 01 End stop clipfix 35 4 4 582212 104 Terminal PITTB 2 5 8 5 582212 102 Terminal PITTB 2 5 PE 4 6 582212 70 Plug In Bridge FBS 3 5 1 7 582212 66 Plug In Bridge FBS 4 5BU 1 8 9017745 01 Relay RIF 0 6 9 582212 168 Separating plate 2 10 582212 123 Power terminal block 1 11 9002362 81 Relay module 1 See page 20 14 9015584 08 Plug in bridge 10 6 BU 1 18 Book No ...

Page 358: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2955A Book No 19 ...

Page 359: ... std 2 1 6 Relay module Machine unit number or Subassembly description 9002362 Ref Part No Description 81 Notes Quantity 1 582212 119 Interface relay 24V 8 2 582212 120 Input adapter 1 3 582212 186 System cable 1 Z 582212 172 Relay mini 20 Book No ...

Page 360: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2692A Book No 21 ...

Page 361: ...or Subassembly description 9019490 Ref Part No Description 80 Notes Quantity 1 9017746 01 End stop clipfix 35 2 3 9017746 02 End plate D ST 2 5 1 4 582212 122 Terminal block 1 5 9017747 01 Terminal block feed thro 4 6 9017747 04 Plug R 1 7 9017747 03 Plug M 2 8 9017747 02 Plug L 1 22 Book No ...

Page 362: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2956A Book No 23 ...

Page 363: ...r Subassembly description 9019514 Ref Part No Description 80 Notes Quantity 1 9017746 01 End stop clipfix 35 2 3 582212 04 End plate 1 4 9017747 06 Terminal PT2 5 Twin 1P 9 5 9017747 07 Terminal PT2 5 Twin 1P PE 1 6 9017747 04 Plug R 1 7 9017747 03 Plug M 8 8 9017747 05 Plug L PE 1 24 Book No ...

Page 364: ...2 1 Electrical cabinet subas 2 Electrical cabinet 2958A Book No 25 ...

Page 365: ...95 01 Sensor box 2 Marked X10 W10 X11 W11 23 9017895 02 Sensor box 1 Marked X12 W12 24 9024792 80 Filter regulator 1 See page 48 25 9017332 01 Pump 1 P320 28 9017336 01 Strap 1 29 9018554 01 Winch 1 30 9018144 80 Junction box 1 See page 50 31 9018775 02 Pipe 1 32 9021363 02 Pipe 1 34 9018778 02 Pipe 1 38 9021992 02 Pipe 1 40 9018145 01 Deaeration pipe 1 41 9019487 01 Tube 1 42 9019412 01 Tube 1 44...

Page 366: ...2 Module 85 2923A Book No 7 ...

Page 367: ...Spc for 9032172 80 v 0 Module 85 non std Machine unit number or Subassembly description 9018348 Ref Part No Description 82 Notes Quantity 96 221803 21 Nut 17 97 1270001 Lifting instruction 1 8 Book No ...

Page 368: ...2 Module 85 2923A Book No 9 ...

Page 369: ...lve DN50 1 V309 1 See page 42 51 260321 15 Hexagon screw 6 52 221031 02 Screw 4 53 67141 Screw 2 54 221041 02 Screw 16 55 221041 20 Screw 19 56 221041 01 Screw 28 57 221046 30 Screw 4 58 2210463 22 Screw 8 59 2210463 23 Screw 16 60 2210463 05 Screw 48 61 2210463 09 Screw 16 62 260192 35 Screw 16 63 221711 26 Screw 1 66 221036 19 Screw 4 71 223101 30 Washer 18 72 223101 32 Washer 5 73 223101 33 Was...

Page 370: ...2 1 Sub module small 2 Module 85 3136A ...

Page 371: ...ion 80 Notes Quantity 1 9015168 01 Reactor machining 1 PN6 3 66169 Drive screw 8 6 9003326 01 Glass socket 12 7 221711 02 Screw 36 8 9002009 81 Lamp bush 12 9 9004878 80 Cap 12 10 9002860 01 Nut 12 Z 579367 98 UV Lamp set Includes UV lamp and 2 O rings Z0 1 594645 81 Quartz sleeve set Includes quartz sleeve and 2 O rings 2 Book No ...

Page 372: ...2 1 Sub module small 2 Module 85 2960A ...

Page 373: ...ne unit number or Subassembly description 9018589 Ref Part No Description 71 81 Notes Quantity 1 9007167 04 Valve DN100 1 1 2 9007166 02 Air actuator AT 201U 1 1 3 9018592 01 Inductive sensor 1 4 9018613 01 Assembly kit BT32 F25 0 1 Z 9007184 02 Insulate plate Book No ...

Page 374: ...2 1 Sub module small 2 Module 85 2962A ...

Page 375: ...lve DN80 1 2 9007166 02 Air actuator AT 201U 1 7 9007196 01 Bracket 1 9 9034058 80 Driver 1 10 9007190 01 Positioner 1 Also order reducer and cable gland for the positioner 10 1 9029781 01 Insert M20 1 13 552801 50 Push on connector 2 16 569035 01 Flexible pipe PA12 6 4 1 24 552801 01 Push in connector 2 Z 9007184 02 Insulate plate Z0 1 9030002 81 Cable gland kit Book No ...

Page 376: ...2 1 Sub module small 2 Module 85 3026A ...

Page 377: ...d 2 1 4 Flow transmitter EN80C Machine unit number or Subassembly description 9024585 Ref Part No Description 58 Notes Quantity 1 9024593 21 Flow transmitter EN DN80 1 Z 9025145 01 Transmitter display Z0 1 9030002 80 Cable gland kit Book No ...

Page 378: ...2 1 Sub module small 2 Module 85 3035A ...

Page 379: ... 9011972 38 Gasket 1 15 9011975 07 Filter element 1 16 9011972 41 Gasket 1 17 9011972 44 Gasket 1 18 9011973 25 Bushing 1 19 9024206 09 Plug 3 20 9011972 47 Gasket 1 30 9024207 01 Nozzle support 1 31 9024205 25 Bolt 4 34 9024205 33 Bolt 4 36 9011970 26 Grease fitting 1 40 9024208 01 Ring spear 1 41 9011970 10 Bearing flange 1 42 9011970 18 Bearing flange 1 43 9024209 01 Retaining ring 1 44 9024210...

Page 380: ...2 1 Sub module small 2 Module 85 3025A ...

Page 381: ...ve DN50 Machine unit number or Subassembly description 9017578 Ref Part No Description 81 Notes Quantity 1 9007167 01 Valve DN50 1 2 9020930 01 Air actuator AT 101U 1 3 221031 04 Screw 4 4 223101 32 Washer 4 5 9009153 03 Throttle valve 1 8 1 2 Book No ...

Page 382: ...2 1 Sub module small 2 Module 85 2961A ...

Page 383: ...t number or Subassembly description 9004533 Ref Part No Description 80 Notes 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 4 Book No ...

Page 384: ...2 2 Pump P320 1 and P321 5 2 Module 85 2606A ...

Page 385: ...83 Ref Part No Description 80 Notes Quantity 1 9019794 01 Circular connector 26 pi 1 2 9003172 01 Valve block side 1 3 9003172 02 Valve block 8 4 9019792 01 Tie rod 1 5 9003172 03 Valve block side 1 6 9019793 01 Valve 5 2 monostable 3 7 9003172 04 Valve 2x 3 2 5 11 9014552 01 Fitting reducer 1 8 6 mm 6 Book No ...

Page 386: ...2 3 Valve block 2 Module 85 2959A 7 ...

Page 387: ...ulator Machine unit number or Subassembly description 9024792 Ref Part No Description 80 Notes Quantity 1 9024792 01 Filter regulator 1 2 9024792 02 Pressure relief valve 1 3 9024792 03 Bracket 1 Z 9024792 99 Filter element Replace every 2 years 48 Book No ...

Page 388: ...2 4 Filter regulator 2 Module 85 3091A4 49 ...

Page 389: ...n 80 Notes Quantity 1 9019781 01 Enclosure 1 2 9019782 01 DIN rail 35x7 5 1 3 589569 58 Cable gland EMC brush M32 2 4 9004959 04 Insert 6x6mm 1 5 589569 44 Counter nut EMC M32 2 6 582212 88 PIT 2 5 10 7 582212 122 Terminal block 6 8 582212 13 End plate 1 9 9017746 01 End stop clipfix 35 2 11 9003031 01 Condensation outlet 1 50 Book No ...

Page 390: ...2 5 Junction box 2 Module 85 2957A 51 ...

Page 391: ...730 03 Cable 1 V201 8 2 9021730 02 Cable 1 FT201 1 3 9019849 01 Cable 1 GS201 3 4 9019849 01 Cable 1 GS201 9 5 9019849 01 Cable 1 PT201 16 6 9019849 01 Cable 1 PT201 72 7 9019849 05 Cable 1 LS201 29 8 9019849 06 Cable 1 TT201 33 9 9019849 06 Cable 1 TS201 60 10 9019849 03 Cable 1 QT201 50 12 9022042 01 M12 plug 1 Fit to socket X4 on sensor box X11 52 Book No ...

Page 392: ...2 6 Cable set 2 Module 85 2377A 53 ...

Page 393: ...ine unit number or Subassembly description 9011001 Ref Part No Description 83 Notes Quantity Z 9006321 80 Cable Lamp to lamp Incl cable gland cap collet and nut pos 7 9 Z0 1 9011226 99 Cable UV lamp to junction box Incl cable gland cap and collet pos 1 6 54 Book No ...

Page 394: ...2 7 Lamp cable set 2 Module 85 2377A 55 ...

Page 395: ...on 9019986 Ref Part No Description 81 Notes Quantity 1 9011609 03 Cable 1 Marked W20 A lamp power cable 2 9020035 01 Cable 1 W13 3 9020027 01 Cable 1 Marked W14 filter motor 4 9020106 01 Cable 3 W10 W11 W12 5 9020107 01 Cable 1 W13 6 9020108 01 Cable 1 W14 56 Book No 9038941 02 Rev 1 ...

Page 396: ...4 Cable set 2377A Book No 9038941 02 Rev 1 57 ...

Page 397: ...1 Pilot valve 1 5 9007192 01 Throttle valve 1 4 2 6 9007193 01 Actuator cable 1 7 9007196 01 Bracket 1 8 9007186 01 Switch box 1 12 9005789 01 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 01 Handwheel 1 19 587927 02 Locking device AL79 201 1 Z 9007184 02 Insulate plate 58...

Page 398: ...5 Valve V212 31 optional 2716A Book No 9038941 02 Rev 1 59 ...

Page 399: ...ube 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 60 Book No 9038941 02...

Page 400: ...6 Sampling device EN optional 2780A Book No 9038941 02 Rev 1 61 ...

Page 401: ... PIT 2 5 TWIN PE 1 1 14 582212 04 End plate 1 1 15 582212 147 Patch panel 1 1 16 582212 155 Socket with USB 1 1 18 9011552 01 Buzzer 1 1 20 591103 72 Pushbutton Black 1 1 20 1 591103 92 Cover 1 1 22 9009760 01 Relay D sub 1 1 22 1 582212 214 D SUB gender changer 1 1 23 595673 04 Ethernet cable 1 1 24 9011960 01 Bracket 1 1 25 223101 47 Washer 2 2 26 221891 04 Lock nut 2 2 28 594009 06 Screw 2 2 29...

Page 402: ...7 Remote control panel optional 2875A Book No 9038941 02 Rev 1 63 ...

Page 403: ...944 01 Cover 1 2 594488 01 Washer 4 3 581688 01 Bracket 4 4 221711 16 Screw 8 5 223101 47 Washer 8 6 221891 04 Lock nut 8 7 589569 79 Cable Gland M25 2 8 589569 35 Counter nut M25 2 9 589569 48 Cable Gland M16 2 10 589569 33 Counter nut M16 2 11 587276 02 Washer 2 12 70560 Washer 2 13 221891 05 Hexagon lock nut 2 64 Book No 9038941 02 Rev 1 ...

Page 404: ...7 1 Cover 7 Remote control panel optional 2883A Book No 9038941 02 Rev 1 65 ...

Page 405: ...PureBallast 3 1 85 Compact 8 Extended options SPC 66 Book No 9038941 02 Rev 1 ...

Page 406: ...8 Extended options SPC 2377A Book No 9038941 02 Rev 1 67 ...

Page 407: ...ureBallast 3 1 85 Compact 8 1 Transformer optional Machine unit number or Subassembly description 9029226 Ref Part No Description 82 Notes Quantity 1 9029225 02 Transformer 1 68 Book No 9038941 02 Rev 1 ...

Page 408: ...8 1 Transformer optional 8 Extended options SPC 3084A Book No 9038941 02 Rev 1 69 ...

Page 409: ... 47 62 9 223101 47 8 57 223101 47 62 25 223101 47 62 29 223101 47 64 5 223101 47 10 10 223101 47 10 17 223101 47 10 21 223101 47 10 39 223101 47 12 3 223101 61 30 74 260154 02 10 37 260192 35 30 62 260262 07 26 82 260321 15 30 51 552801 01 36 24 552801 02 58 13 552801 50 36 13 558663 04 26 10 569035 01 36 16 569035 05 58 16 579367 98 32 Z 580758 06 58 17 580986 09 14 8 580986 16 14 3 580986 17 14 ...

Page 410: ...10 38 9003031 01 50 11 9003031 01 8 65 9003172 01 46 2 9003172 02 46 3 9003172 03 46 5 9003172 04 46 7 9003326 01 32 6 9004232 01 8 6 9004533 01 44 1 9004533 80 26 17 9004587 80 44 Z 9004588 80 44 Z0 1 9004638 01 26 67 9004638 02 26 76 9004878 80 32 9 9004959 04 50 4 9005774 06 8 12 9005789 01 58 12 9005792 01 58 18 9006321 80 54 Z 9006324 02 26 9 9006325 02 26 11 9006822 03 26 4 9007166 02 34 2 9...

Page 411: ...9018411 01 10 15 9018550 80 30 24 9018554 01 26 29 9018589 71 30 40 9018589 81 30 41 9018592 01 34 3 9018613 01 34 4 9018775 02 26 31 9018778 02 26 34 9018992 01 8 44 9018993 01 8 45 9018995 01 8 37 9018995 02 8 35 9018995 03 8 36 9019000 01 8 20 9019012 01 8 18 9019140 02 12 29 1 9019140 02 8 Z 9019141 01 10 23 9019142 01 10 24 9019143 01 10 26 9019144 01 10 25 9019412 01 26 42 9019447 01 26 44 9...

Page 412: ...40 44 9024585 58 30 43 9024593 21 38 1 9024691 01 26 55 1 9024692 01 26 54 1 9024792 01 48 1 9024792 02 48 2 9024792 03 48 3 9024792 80 26 24 9024792 99 48 Z 9024839 01 26 6 2 9025145 01 38 Z 9029225 02 68 1 9029781 01 36 10 1 9030002 80 38 Z0 1 9030002 81 36 Z0 1 9034058 80 36 9 9037347 01 60 8B Book No 9038941 02 Rev 1 73 ...

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