ALFALAVAL BWTP System Manual PB-750 - Rev00 PDF [PDF]

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Hanjin Heavy Ind. Co. Subic Bay Shipyard - Philippines Hulls: NCP 0104/05/06/07/08/09/10/11/18/19

PureBallast Ballast Water Treatment System

System Manual English

Hanjin Heavy Ind. Co. Subic Bay Shipyard Philippines Hulls: NCP 0104/05/06/07/08/09/10/11/18/19 PureBallast Ballast Water Treatment System System Manual - PureBallast 3.0 Flow 750

PureBallast: Ballast Water Treatment System

Table of Contents Safety

1

System Description

2

Operating Instructions and Control System 3 Description

Only foreseeable conditions have been taken into consideration. No warnings are given for situations arising from unintended usage of the system components and tools.

Marine & Diesel Equipment

Printed 2013

Parameters

4

Alarms and Faultfinding

5

Installation and Drawings

6

Service Manual

7

Spare Parts Catalogue

8

Alfa Laval reserves the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local AlfaLaval company. Published by: :

Alfa Laval Tumba AB E-147 80 Tumba, Schweden Telefon: +46 8 530 650 00 Telefax: +46 8 530 310 40

© Alfa Laval Tumba AB 2013

Chapter: 1. Safety System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

Introduction

5

2

Safety information

7

2.1

General safety information

7

2.2

Specific safety information

7

2.3

Personnel requirements

9

2.4

Warning signs used in the manual

9

3

Environmental issues

11

3.1

Unpacking

11

3.2

Other materials

11

3

1 Introduction This chapter contains general safety and environmental information, personnel requirements and explanations of symbols used for the PureBallast system.

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1

Introduction

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

2.1

General safety information

The following general safety information apply: •

The PureBallast system is not EX proofed and must not be installed in areas where an explosive atmosphere may occur.

•

Use the equipment only for the purpose and parameter range specified by Alfa Laval.

•

Use only Alfa Laval genuine spare parts.

•

Always read and follow the documentation that is included in shipment of components and spare parts regarding handling, safety and disposal.

•

Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.

•

Before installation, read applicable sections in chapter 6. Installation instruction and drawings.

•

Before operation, read the Preparations and conditions section for applicable instructions in chapter 3. Operating instructions and control system description.

2.2

Specific safety information

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

Before maintenance, read the Preparations and conditions section for applicable instructions in chapter 7. Service manual. Essential safety information is stated before instruction to routines that might involve any danger.

•

Before maintaining the PureBallast system, the following valves must be locked in closed position: V201-3, V201-9, and V201-8.

•

Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle with a load capacity greater than the weight of the component. See the Technical data section on page for information about weight. Any complementary lifting instructions must be followed.

•

Always disconnect the PureBallast system from the power supply before disassembling, and secure it from being switched on.

Reactor module safety items •

Cut hazards: Sharp edges on broken UV lamps and quartz sleeves can cause cuts. Exercise great care when handling them.

•

Before installation, check that the UV lamps and quartz sleeves are not broken.

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2.2

Specific safety information

2

Safety information

•

Depressurize reactors and allow equipment to cool down completely before disassembling. Hot water may escape from the reactor when removing the drain plug.

•

Never handle UV lamps before they are completely cooled down. A hot UV lamp is under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn if it is touched.

•

The reactor must not be under pressure when dismounting the UV lamps.

•

UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly installed inside the reactor with end caps properly closed.

•

UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be handled with care. Please refer to national regulations regarding disposal of used lamps. If a UV lamp is broken, mercury could be spilt. Remove mercury with a special tool such as a syringe (or use pure sulphure to bind the mercury for easy collection). -

Do not allow mercury to come in contact with your eyes or skin.

-

Do not inhale mercury fumes. In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.

-

Free mercury must be kept in an airtight bottle, and must be disposed of according to national regulations.

•

Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. Improper operation could seriously damage the equipment and injure personnel.

•

Manual operation of LPS, may only be performed after cable connection. If not hazardous situation may arise which, if not avoided, will result in death or serious injury.

•

Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the power supply. The LDC contains a fan, which can cause injury if in operation.

Flow meter safety items •

Potential hazards / Grounding: The mains protective grounding wire must be connected to the terminals in accordance with the diagram (class 1 power supply).

Valve safety items •

Actuators must not be pressurized at any time during installation as it may result in injury.

•

Lock valve in closed position before maintenance.

CIP safety items •

CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal protection etc.

•

Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension pipe must be removed and blocked.

•

Always wear protective eye glasses and gloves while working on the pump.

Ancillary component safety items •

Control panels may only be cleaned when set in wipe mode. This is to prevent unintended functions from being triggered by buttons pressed during cleaning.

•

Temperature switch, temperature transmitter and level switch. The external surface may be hot. Care must be taken to avoid possible burns.

8

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Safety information

2.3

2.4

Warning signs used in the manual

Personnel requirements

The PureBallast system must be operated, installed, maintained and repaired by persons trained for respective type of work. All persons using and working with the system must know the emergency stopping procedures. Personnel installing, maintaining or repairing components must be of one of the following categories: •

Skilled person: A person with technical knowledge or sufficient experience to perform the tasks at hand and to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

•

Instructed person: A person adequately advised or supervised by a skilled person to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

•

Alfa Laval service engineer: A person with vast knowledge about the PureBallast system. Alfa Laval service engineer can set parameters and repair intrinsically safe apparatuses. The person must have experience of similar types of work and be certified in accordance with local regulations.

In some cases special skilled personnel may need to be hired, like electricians and others. In some of these cases the personnel has to be certified according to local regulations with experience of similar types of work.

2.4

Warning signs used in the manual

ANGER D ! DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

!

NG WARNI

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

!

ON CAUTI

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTE NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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2.4

Warning signs used in the manual

2

Safety information

3 Environmental issues This section contains general rules regarding environmental issues. However, local rules and regulations should be consulted for detailed handling of each material.

3.1

Unpacking

•

Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.

•

Wood and cardboard boxes can be reused, recycled or used for energy recovery.

•

Plastics should be recycled or burnt at a licensed waste incineration plant.

•

Metal straps should be sent for material recycling.

3.2

Other materials

•

Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they should be disposed to a suitable licensed land fill site.

•

Metal parts should be sent to a licensed handler for material recycling.

•

Seal rings should be disposed of in a licensed land fill site. Check the local regulations.

•

Worn out or defected electronic components should be sent to a licensed handler for material recycling.

•

The operator panel contain the following components with substances that might be hazardous to health and the environment: lithium battery, electrolytic capacitor and display. They shall be recycled according to local regulations.

•

Used lithium batteries from the control unit are considered hazardous waste and should be disposed of accordingly.

•

Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please refer to national regulations.

•

Used quarts sleeves should be disposed of as ordinary glass.

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Chapter: 2. System description System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

2

3

Introduction

5

1.1

Abbreviations

5

1.2

System overview

6

1.3

Components overview

7

1.3.1

Item numbers

7

Process overview

9

2.1

Start-up

10

2.2

Ballasting

11

2.2.1 2.2.2 2.2.3

Power optimization Backflush Ballast after-treatment (CIP)

11 12 14

2.3

Deballasting

15

2.3.1

Deballast after-treatment (CIP)

15

2.4

Stripping with eductor

16

2.5

Ballast water handling in the event of malfunction

17

System components description

19

3.1

AOT reactor

19

3.1.1 3.1.2

AOT reactor working principle AOT reactor description

19 20

3.2

Lamp drive cabinet (LDC)

21

3.2.1 3.2.2

LDC working principle LDC description

21 22

3.3

Filter

23

3.3.1 3.3.2 3.3.3

Filter working principle Filter description Backflushing for different dirt loads

23 24 26

3.4

CIP (cleaning-in-place) module

28

3.4.1 3.4.2

CIP working principle CIP module description

28 28

3.5

Control cabinet and control system

29

3.5.1 3.5.2 3.5.3 3.5.4

Control system Main control panel Remote control panel (optional) Remote interface (optional)

30 30 30 32

3

4

3.6

Main valves

32

3.7

Flow meter

33

3.8

Pressure monitoring device

33

3.9

Sampling devices

33

1 Introduction This contains general information about the PureBallast system and its components.

1.1

Abbreviations

The table below is a list of abbreviations used in this manual. Abbreviation

Explanation

AOT

Advanced oxidation technology

AOT reactor

The main component, where the water is treated using advanced oxidation technology

Atex

EU directive “Appareils destinés à être utilisés en ATmosphères EXplosivles”

CIP

Cleaning in place

CIP module

Cleaning in place module. Performs the CIP process.

DIN

Deutche Institut für Normung

EN

Standard according to CEN (European Committee for Standardization).

EX

Explosion-proof

I/O

Input/output (Describes a program or device handling data)

IACS

International Association of Classification Societies

ISCS

Integrated ship control system

IMO

International Maritime Organization

JIS

Japanese Industrial Standard

LED

Light emitting diode

LDC

Lamp drive cabinet.

LPS

Lamp power supply

MCB

Motor circuit breaker

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1.2

System overview

1

Introduction

Abbreviation

Explanation

PLC

Programmable logical controller (PureBallast control system)

UV

Ultra violet

1.2

System overview

The PureBallast system is an integral part of the vessel’s ballast water system, on the discharge side of the vessel’s ballast water pumps. During ballast operation, the water is led through the filter, which removes larger particles and organisms, and then to the AOT reactor, where the water is treated with UV light and advanced oxidation technology (AOT). During deballast, the water is led the same way, but the filter is bypassed. The UV lamps are powered by the LDC (via LPSs, lamp power supplies). The AOT reactor has one dedicated LDC. Flow is monitored by the flow meter and regulated by the control valve. The control valve also regulates pressure during back-flushing of the filter. The AOT reactors are cleaned using the CIP (cleaning-in-place) module, which first rinse the AOT reactor with fresh water, and then circulates CIP liquid through the AOT. At the end of the process the AOT reactor and the filter (filter preservation) is filled with fresh water from the CIP. The complete system and ongoing processes is controlled and monitored from the control cabinet. Control can also be performed from remote control panels and the ship’s ISCS, via the remote interface. The by-pass valve makes it possible to by-pass the entire system, for example to secure ballast operation if the system is not functioning. The valve is controlled from the ISCS (integrated ship control system).

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Introduction

1.3

1.3

Components overview

Components overview

The key components in PureBallast are shown below. Note that the filter is just an example of a filter unit; others may be chosen.

2 SystemOverview

Example of layout with 1 AOT reactor. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Filter inlet valve Filter Filter bypass valve Lamp drive cabinet (LDC) Control cabinet with main control panel AOT reactor Control valve CIP (cleaning-in-place) module Flow meter Backflush valve Filter outlet valve

Not in illustration: •

System bypass valve

•

Sampling devices, before and after treatment

•

Pressure monitoring device

1.3.1

Item numbers

System components are identified by unique item numbers, for example “FIT201-1” for the flow transmitter installed before the AOT reactor. Book No.9010182 02, rev. 0

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1.3

Components overview

1

Introduction

2 Process overview This section gives an overview of the main processes performed by PureBallast. In the flow chart illustrations, involved pipes are marked in bold.

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2.1

2.1

Start-up

2

Process overview

Start-up

Ballasting and deballasting begins with a start-up phase. There must be available power for the system. If power management is integrated, this will be confirmed automatically. If power management is not integrated, this is confirmed manually. During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is pumped through the AOT reactor to secure that the UV lamps are not overheated. The flow is monitored by the flow meter to secure that there is enough flow to cool the UV lamps. If flow deviates from parameter set values, an alarm is issued and the system is shut down.

2 Startup

Ballast and deballast start-up

10

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Process overview

2.2

2.2

Ballasting

Ballasting

After the start-up, when the lamps are ready, the operator is requested to start the ballast pump. The ballast water is pumped from the sea chest to the filter, that removes larger particles and organisms. This also reduces the amount of sediment build-up in the ballast water tanks. The organisms and sediments caught in the filter are flushed overboard via regular filter backflush operations. The water is finally led to the AOT reactor, which produces radicals and UV light that breaks down and neutralize the organisms.

2 FullBallast

Ballasting

2.2.1

Power optimization

It is possible to activate power optimization (parameter p237). During ballast and deballast, the lamp power is adjusted according to the value from the UV intensity sensor, which constantly measure the water transmittance. In clear water with good transmittance, the lamps are automatically dimmed, to lower the power consumption. This means that the lamps are lit to the degree needed for full treatment, but not more. The purpose is to save power by dimming the lamps to minimum power required to fully treat the water. The UV lamps are regulated individual on all AOT reactors between 50 % and 100 % of full effect. Power optimization during special conditions. •

During start-up and the first two minutes of ballast/deballast, the UV lamps are lit to 100 % to ensure treatment befor values from the UV sensor are stable.

•

Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for 2 minutes when process is resumed.

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2.2

Ballasting

2

Process overview

•

Stop: UV lamps are lit to 100 % for 10 seconds before they are stoped. This will prolong the life of the lamps.

•

Low UV intensity: See Actions at low UV intensity below.

•

Broken UV lamps: See Operation with broken UV lamp below.

2.2.1.1

Actions at low UV intensity

If the UV intensity falls below minimum (defined in parameter p221) for one AOT reactor, a warning is issued, but process continnues. When UV intensity falls below limit defined in the type certificate, a new warning is issued and a log is written to the event log. The operation continues but does not fullfill the type approval certificate. However, the flow is decreased so that the treatment shall correspond to the type approval requirements. The operator will have do decide to continnue or stop the operation.

2.2.1.2

Operation with broken UV lamp

If a UV lamp breakes a warning is issued and a log is written to the event log. The operation continues but does not fullfill the type approval certificate. However, the flow is decreased to 80 % of current flow for all AOT reactors and the UV lamps are lit to 100 %. These actions are taken so that the treatment shall correspond to the type approval requirements. The operator will have do choose one alternative: •

Stop the operation.

•

Continnue operation and not comply with type approval certificate.

•

2.2.2

Backflush

To keep the filter clean, it is automatically backflushed. The backflush is performed during ongoing process without interrupting the ballasting process. When a ballast operation is stopped, a backflush is performed before the system comes to a full stop. The water used for backflushing is returned to the sea directly at the ballasting site.

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Process overview

2.2

Ballasting

2 Back-flush

Filter backflush

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2.2

Ballasting

2.2.3

2

Process overview

Ballast after-treatment (CIP)

After a ballast operation, a cleaning-in-place (CIP) process is performed to clean the AOT reactor. This process can either be performed immediately after a ballast operation or within 30 hours after. Note, that it is possible to perform new processes during these 30 hours. A CIP process takes about 25 minutes per AOT reactor, if default parameters are used. The AOT reactors are cleaned one at a time. First, the AOT reactor is rinsed with fresh water. Then the cleaning-in-place (CIP) module circulates a biodegradable solution through the AOT reactor to remove seawater scaling. After the cleaning is finished, the AOT reactor is filled with fresh water to preserve the filter and prevent scaling, algae growth etc. Then the system continues with the same procedure for the next AOT reactor. Finally, the filter is filled with fresh water to prevent scaling and algea growth. The cleaning liquid is reused between the cleaning operations.

2 CIP

CIP process

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Process overview

2.3

2.3

Deballasting

Deballasting

After the start-up, when the lamps are ready, the operator is requested to start the ballast pump. The water passes through the AOT reactor, but the the filter is bypassed since the water has already been filtered during ballasting. The reason for treating the water a second time during deballasting is to secure that the treatment is fully effective. The minor part of the organisms, which were only injured during ballast, will be rendered totally harmless during the deballast. The process flow and power optimization are controlled in the same way as during ballasting.

2 FullDeballast

Deballasting

2.3.1

Deballast after-treatment (CIP)

After deballast operation, a cleaning cycle is performed to clean the AOT reactor. It is performed in the same way as described for the ballasting process. If only deballast operations has been performed since the last CIP process, the filter does not need to be filled with fresh water at the end of the cycle, since the filter has not been used.

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2.4

Stripping with eductor

2.4

2

Process overview

Stripping with eductor

Stripping can be performed to achieve total emptying of the ballast tanks via a stripping eductor. To use PureBallast during a stripping process an eductor must be installed before the PureBallast system. The water used in the stripping process, must be filtered from particles larger than approximately 5 mm. The water passes through the PureBallast system as a regular deballasting process (with the filter by-passed). The water is finally pumped into the sea. Note the following: •

The eductor is not part of Alfa Laval’s scope of supply.

•

Procedures to dispose of sediments from the sieve must be included in the vessel’s ballast water management plan.

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Process overview

2.5

2.5

Ballast water handling in the event of malfunction

Ballast water handling in the event of malfunction

PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers) without involving the ballast water treatment system. The valve is controlled by the ISCS, not PureBallast’s control system, but all by-pass valve activities are logged in the event log. Such valve is required by the International Convention for the Control and Management of Ship’s Ballast Water and Sediments 2004. If the system malfunction in connection with general cargo operation, ballast and deballast operations should be avoided. In case untreated water is pumped to a ballast tank, this water shall be discharged on open sea (according to regulations) and exchanged for treated water. Note that full treatment requires treatment both during ballast and deballast. The procedures concerning emergency and malfunction of the ballast water treatment system should be implemented in the ships Ballast water management plan.

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2.5 Ballast water handling in the event of malfunction

2

Process overview

3 System components description This section gives an introduction to the most important PureBallast system components and their functions in the system.

3.1

AOT reactor

The main part of PureBallast is the AOT reactor in combination with a lamp drive cabinet (LDC) giving power to the UV lamps in the AOT reactor. The LDC does not need to be placed in close relation to the AOT reactor.

3.1.1

AOT reactor working principle

The main treatment process take place inside the AOT reactor, where the UV light inactivates the cell DNA to prevent regrowth of organisms. The UV light also generates radicals. The radicals are extremely reactive and react instantaneously with micro organisms and other organic contaminants destructing their membranes. The radicals are extremely short-lived and exist only for some milliseconds. This means that they will only exist inside the AOT reactor. The quantity of radicals produced in the reactor is sufficient to treat the water as it passes through the reactor.

2 10_2_1_1 Cell

Destruction of cell membranes 1. Radical 2. Cell membrane

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3.1

AOT reactor

3

System components description

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.

3.1.2

AOT reactor description

The AOT reactor consist of the reactor, sensors and valves for ballast water, fresh water and CIP liquid, as shown in the illustration below. The AOT reactor accommodates 16 medium-pressure UV lamps (6 kW each) powered from the lamp drive cabinet (LDC). The UV lamps are enclosed in individual quartz-glass sleeves. The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there is water in the reactor when the lamps are lit, each reactor is equipped with a level switch. The level switch also secures that enough CIP liquid is pumped into the reactor during the CIP process. To secure that the lamps are adequately cooled by the ballast water, each reactor is equipped with a temperature transmitter, monitored by the control system. If the temperature deviates from parameter set values, the AOT reactor will shut down. The temperature transmitter is completed with a temperature switch that automatically shuts down the reactor at 65 °C. A UV sensor monitors the UV lamp efficiency in relation to the water transmittance inside the AOT reactor. Based on this input, the power to the UV lamps are regulated between 50 and 100 % of full capacity. The UV lamps will be dimmed to lowest possible level, where they are still effective. Note, that the lamps are always lit with full effect during start-up and the first two minutes of full ballast to secure full efficiency independent of transmittance. The lamps are also turned up to full effect for 10 seconds before stop and normal shut down. This method will prolong the UV lamp life time. The illustration below show the main components for the AOT reactor.

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System components description

3.2

Lamp drive cabinet (LDC)

2 reactor module Obe

AOT reactor 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Ballast water outlet valve CIP liquid outlet valve (actuator indicated) Level switch Junction box UV lamp cap (UV lamp and quartz sleeve inside) Access hatch CIP liquid / fresh water inlet valve and reactor drain valve (actuator indicated) Ballast water inlet valve (actuator indicated) UV sensor Junction box Cooling water outlet valve Ballast water outlet valve actuator (actuator indicated)

3.2

Lamp drive cabinet (LDC)

The lamp drive cabinet gives power to the AOT.

3.2.1

LDC working principle

Each AOT reactor is connected to a lamp drive cabinet (LDC) containing 16 lamp power supplies (LPS), each feeding one lamp with power. The LPS also monitors the function of each UV lamp and Book No.9010182 02, rev. 0

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3.2

Lamp drive cabinet (LDC)

3

System components description

takes action if a fault occurs. Lamps on the cabinet indicates if power is on, UV lamps are lit and if the cabinet needs to be reset after a shutdown or power off.

3.2.2

LDC description

The LDC is equipped with a cooling system to maintain correct operating temperature in the LDC, using low-temperature cooling water. The cooling water flow is constant, but the fan only runs when needed. When the temperature reaches 40°, the fan starts at 15 % of full effect. After that, the fan speed is regulated between 15 % and 100 %, based on input from the temperature transmitter in the LDC. The humidity in the cabinet is monitored by a liquid sensor. If a leakage from the heat exchanger is detected, a warning is issued, the reactor is shut down and the cooling water inlet valve to the LDC is shut. The LDC can be placed up to 150 meters (cable length) from the AOT reactor. The main breaker cut the power to the LDC and the AOT reactor.

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System components description

3.3

Filter

2 LDC

LPS with one door removed. 1. 2. 3. 4. 5. 6. 7.

Fan Heat exchanger 16 LPS Fuses Cooling water inlet and outlet Main breaker Status lights and reset button

3.3

Filter

3.3.1

Filter working principle

The filter is a fully automatic self-rinsing component, equipped with filter elements to remove particles and organisms from the ballast water flow. The ballast water is lead through the filter, and filtered particles are trapped in the filter element.

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3.3

Filter

3.3.2

3

System components description

Filter description

2 FilterHydac

1. 2. 3. 4. 5. 6. 7. 8.

Geared motor Water outlet Pressure transmitter, outlet Filter control cabinet. Only used for connections. The filter is entirely controlled from the PureBallast control system. Pressure transmitter, backflush line Backflush outlet Pressure transmitter, inlet Water inlet

To secure efficient filtration, the filter performs a self-rinsing backflush operation at time set intervals or when triggered by indication of dirt in the filter. Pressure drop over the filter is monitored by pressure transmitters on the filter inlet and outlet. Dirt is detected by an increased differential pressure drop caused by particles in the filter candles. When the differential pressure reaches a parameter set value, an automatic backflush operation starts. The backflushing does not interrupt the filtration process, since the filter candles are cleaned one by one. The other filter candles continue the filtration of the ballast water. It is also possible to start backflush manually from the control system.

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System components description

3.3

Filter

The filter candles are backflushed in two steps: Step 1: The flushing arm is positioned under the first filter candle to be backflushed. The purpose of the flushing arm is to collect the backflush water and lead it, with the flushed particles, to the backflush line. From this point, this filter candle is not used for filtering. A valve on top of the filter candle is opened to lead water through the filter candle from the top downwards. The water flow through the filter candle down to the flushing arm, flushes particles from the filter candle walls and lead them to the backflush line.

2 BackFlush1

Step 2: The valve on top of the filter candle is closed to stop the axial flow to the filter element. The existing water pillar inside the candle continues the flow downwards, which creates an under pressure. This under pressure forces water to flow radial through the filter candle from the outside (filtered side) to the inside (unfiltered side), which pulls remaining particles from the mesh and downwards to the backflush line. When the first candle is backflushed, the flushing arm change position and the process is repeated until all filter candles are rinsed.

2 BackFlush2

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3.3

Filter

3.3.3

3

System components description

Backflushing for different dirt loads

Below, the filter pressure drop over time (pfilter) is illustrated for different dirt load situations in the filter. Different dirtload depends on the water condition, which means that “normal” condition regarding filter backflush depends on the water conditions.

3.3.3.1

Low dirt load

In water with low dirt load, the backflush cycle is started by the time trigger (default: every 30 minutes). As long as the pressure is below 0.5 bar (0.05 MPa), there is no need for the pressure triggered backflush. See examples below.

6 Dirtload1 Hydac

6 Dirtload2 Hydac

3.3.3.2

Medium dirt load

In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.5 bar, which indicates dirt in the filter candles. After each backflush, the backflush timer is reset. The filter will be backflushed again after 30 minutes or when ∆pfilterreaches 0.5 bar, whichever comes first. In the example below, three backflushes are triggered due to high differential pressure over the filter. After that, there is not so much dirt build up, so the next backflush is performed after 30 minutes.

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System components description

3.3

Filter

6 Dirtload3 Hydac

3.3.3.3

Heavy dirt load

In conditions with heavy dirtload, the system will perform more frequent backflushes to keep the filter clean. Also, the 0.5 limit might be exceeded. In this case the self rinsing cycle will run continuously until the problem is solved and the pressure has returned below 0.5 bar. It is OK that the flow momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes. In the example below, a series of backflushes are performed (approx. every 4 minute). After that the pressure rises above 0.5 where the filter is backflushed constantly. After that, the normal control is resumed, where the filter backflush is triggered by pressure (2 times) or by time (last backflush in the example.

6 Dirtload4 Hydac

3.3.3.4

Long term dirt build-up

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

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3.4

CIP (cleaning-in-place) module

3

3.4

CIP (cleaning-in-place) module

3.4.1

CIP working principle

System components description

To ensure full performance in PureBallast, an automatic cleaning cycle is performed after ballast and deballast operation. The purpose is to keep the quartz sleeves covering the UV lamps and the UV sensor clean, to maximize the effect of the UV lamps, and thereby treatment efficiency. During a cleaning cycle, the CIP module rinse the reactor with fresh water and circulates a CIP liquid through the AOT reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion build-up and chemical fouling on the lamps’ quartz glass sleeves. After finished cycle, the liquid is returned to the CIP module tank; the CIP liquid is reusable for a great number of cycles. The sequence is finalized by filling the AOT reactor with fresh water.

3.4.2

CIP module description

The CIP module consists of a tank where the CIP liquid is stored between usage. The pumps and valves integrated in the CIP module are controlled by the valve block. To secure that there is enough CIP liquid for the process, the level switch in the reactor indicates when it is filled with CIP liquid. To prevent intrusion of water in the fresh water system, a backflow preventer is used in the CIP module. The CIP module is equipped with two membrane pumps: •

Pump P320-1 circulates the CIP liquid in the AOT reactor and fills it with fresh water.

•

Pump P321-5 drains water (sea and fresh water) overboard from the reactor, via the drain line.

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System components description

3.5

Control cabinet and control system

2 CIP module

CIP module 1. 2. 3. 4. 5. 6. 7.

Deaeration valve Valve block Regulator Pump (CIP liquid) Backflow preventer Pump (reactor drain) Tank for CIP liquid

3.5

Control cabinet and control system

The control cabinet is used to control and monitor the entire system, via the built in main control panel. It is also used to communicate with the the vessel’s systems and components, if integrated. The control cabinet functions as a signle point of contact for signal cables to and from the vessel. Examples of integration: Remote interface integration and power management system (PMS). Remote interface will allow control of PureBallast from the vessel’s ISCS and PMS integration will allow automatic verification that there is enough power to run an operation. If not integrated, the operator must verify this manually. Also integration with other external components (not part of Alfa Laval’s scope of supply), such as GPS or booster pumps, are done to the control cabinet.

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3.5

Control cabinet and control system

3.5.1

3

System components description

Control system

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

3.5.2

Main control panel

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

2ControlPanel

Main control panel

3.5.3

Remote control panel (optional)

As an option, it is possible to install 1–4 additional panels to be placed in locations from where ballast operations are performed. A remote control panel looks and functions in the same way as the main control panel, and it allows same operations.

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System components description

3.5

Control cabinet and control system

2RemotePanels

Main control panel with four integrated remote control panels.

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3.6

Main valves

3.5.4

3

System components description

Remote interface (optional)

As an option, the control system can be integrated with the vessel’s ISCS via modbus. This allows monitoring and operation of PureBallast from the ISCS’s graphical user interface. Note that Alfa Laval does not supply the graphical user interface to handle PureBallast in the ISCS, only the means to enable the integration.

2RemoteInterface

PureBallast control system’s main control panel integrated with the ISCS. The interface is only an example.

3.6

Main valves

The main valves in the system are: •

•

Inlet valves: The inlet valves directs the water flow from the vessel’s ballast water system into the PureBallast system. Different valves are used during ballast and deballast. -

System and filter inlet valve (201–3): Inlet valve to PureBallast during ballast. The valve directs the water flow through the PureBallast filter.

-

Filter outlet valve (V201–32): The valve directs the water flow from the filter to the AOT reactor during ballast.

-

Inlet valve (201–9): Inlet valve to PureBallast during deballast. The valve directs the water to PureBallast, but bypass the filter, since the water was filtered during ballasting.

Control valve (V201–8): The valve have the following functions: -

Automatic regulation to maintain flow during operation so it does not exceed selected certified maximum flow. Regulation is based on input from the flow meter.

-

Automatic regulation to maintain pressure needed to perform backflush of the filter. Regulation is based on input from the pressure transmitter.

-

Outlet valve from the PureBallast system to the vessel’s ballast water system after treatment.

•

PureBallast bypass valve (V212–31): Makes it possible to completely bypass the PureBallast system. The valve is solely operated from the ISCS, but the valve positioning is (and must be) indicated in the PureBallast control system. When PureBallast is bypassed, an event is written to the event log. The component is optional to be included in Alfa Laval’s scope of supply.

•

Cooling water inlet valve (V403-35): Supplies cooling water to the reactor to secure cooling of the lamps and prevent overheating during start-up.

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System components description

3.7

3.9

Sampling devices

Flow meter

The flow meter (FIT201–1) monitors the process-flow during operation. It has two main functions: •

It monitor that the flow within the PureBallast system does not exceed its certified flow. If the certified flow is exceeded a warning is issued.

•

Via the flow transmitter, mounted on the flow meter, it sends valuable data to the PureBallast control system, where it is displayed. Example of information: Current flow and data about total amount of treated ballast water.

The flow meter consists of two main parts: A flow sensor, which is a pipe with four electrodes detecting the flow. On top of the pipe, there is a terminal box, where the flow transmitter is mounted. The flow transmitter monitors the flow and transmits the information to the PureBallast control system.

3.8

Pressure monitoring device

The pressure monitoring device is a manifold that includes the following components to monitor and handle pressure in the system: •

Pressure transmitter(PT201-16): Send current pressure information to the control system. The control system use the information to take actions accordingly, for example issue warnings, shut down the system or adjusting the control valve to obtain optimal pressure during filter backflush.

•

Pressure gauge (PI201-18): Analogue displayed of current pressure.

•

Needle valve (V201-15): Enables connection of external instruments for calibration.

•

Safety valve (RV201): Relief of over pressure.

3.9

Sampling devices

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

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Chapter: 3. Operating instructions and control system description System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

2

Introduction

7

1.1

Preparations and conditions

7

1.1.1 1.1.2 1.1.3 1.1.4

Stripping Heeling (internal transfer) Ballast water handling in the event of malfunction Pipe cleaning using PureBallast

7 8 8 9

Introduction to the control system

11

2.1

Login levels

11

2.2

Control of PureBallast

12

2.3

Remote interface (option)

12

2.3.1

Conditions for remote interface control of PureBallast

13

Overview of the screen

14

Detailed page descriptions

19

3.1

Page 1.1 – Overview

19

3.1.1 3.1.2

Status box Flow chart

20 21

3.2

Page 1.2 – AOT and flow selection

23

3.2.1 3.2.2 3.2.3

Flow selection AOT selection Status

23 24 24

3.3

Page 1.3 – CIP status

25

3.3.1 3.3.2 3.3.3

CIP status AOT information CIP module information

26 26 27

3.4

Page 1.4 – Power request

28

3.4.1 3.4.2 3.4.3

Power management status display Power management simulation and faultfinding Function buttons

28 30 30

3.5

Page 2.1 – Alarm list

31

3.5.1 3.5.2

Alarm list Function buttons

32 32

3.6

Page 2.2 – Alarm history

33

3.7

Page 3.1 – Trend (15 min)

34

3.7.1 3.7.2 3.7.3

Diagram area Component area Function buttons

35 35 36

2.4

3

3

4

4

3.8

Page 3.2 – Trend (1 h)

37

3.9

Page 3.3 – Trend (1 h) - TT201-33

37

3.10

Page 3.4 – Trend (1 h) - TT401-2

37

3.11

Page 3.5 – Trend (1 h) - Power optimization

37

3.12

Page 4.1 – System info

38

3.13

Page 4.2 – PLC controller I/O

41

3.14

Page 4.3 – Operation timers

42

3.15

Page 4.4 Operation timers AOT

44

3.16

Page 4.5 – Remote interface 1

45

3.17

Page 4.6 – Remote interface 2

46

3.18

Page 4.7 – Log box 1

47

3.19

Page 4.8 – Log box 2

48

3.20

Page 4.9 – LPS overview

50

3.21

Page 4.10 – LDC power

52

3.22

Page 5.1–5.7 – Parameter pages

53

3.23

Popup windows

53

3.23.1 AOT popup 3.23.2 Filter popup

53 59

Operating instructions

61

4.1

Log in

61

4.2

Perform ballast

61

4.2.1

Start ballasting

62

4.3

Perform deballast

62

4.4

Pause ballast / deballast

64

4.5

Backflush filter manually

64

4.6

CIP clean AOT reactor after ballast / deballast

65

4.7

Stop ballast / deballast

65

4.8

Attend to alarms

66

4.9

Shut down and deactivate system

67

4.10

Reset system after shut down

68

4.11

Operate components manually

68

4.12

Operate UV lamps manually

70

4.13

Set ship specific component ID

71

4.14

Export control system log files

72

4.14.1 Read event log in Excel

74

4.15

Set control panel IP address

74

4.16

Set remote control panel communication

76

4.17

Set remote interface communication

77

4.18

Test remote interface communication

77

4.19

Simulate power request

79

4.20

Set default parameters

80

4.21

Update PLC software

80

4.22

Install TA150 firmware

81

4.23

Update HMI software

82

4.24

Calibrate the control panel’s touch screen sensibility

83

4.25

Backup control system settings

84

4.26

Restore control system settings

84

4.27

Export control system history files

85

4.28

PID calibrate system

86

4.28.1 Calibrate pressure controlled regulation

86

5

5

6

6

List of logged information

89

5.1

89

Event log

Detailed process description

95

6.1

Standby mode

95

6.2

Ballast process

96

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

Ballast start-up Full ballast Filter backflush Pause ballast (Heeling mode) Stop ballast

96 97 97 98 99

6.3

Deballast process

6.3.1 6.3.2 6.3.3 6.3.4

Deballast start-up Full deballast Pause deballast (Heeling) Stop deballast

6.4

CIP process

6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9

Start CIP Drain ballast water Fresh water filling Fresh water draining CIP cleaning CIP draining Fresh water filling Repeat Filter preservation

6.5

Manual mode

100 100 101 101 102

103 104 104 105 105 105 106 106 106 106

107

1 Introduction The control system is used to operate and monitor the PureBallast system. It also contains functions for setting parameters, saving log files etc. This chapter describes the control system. It includes general description of the control system pages, step-by-step instructions and a process description with detailed information about the components (valves, motors, pumps etc) involved in each step of respective process. The following control system related information is given in other chapters of the manual: •

Parameters are described in chapter 4. Parameters.

•

Alarms and warnings including information about faultfinding and how to solve problems is described in chapter 5. Alarms and faultfinding.

•

Information about integrating the control system with the vessel’s ISCS and power management is described in chapter 6. Installation description and drawings.

1.1

Preparations and conditions

•

Make sure all documentation is available, read and understood before start.

•

Make sure that the flow is within defined flow range during operation: Ballast (m3/h): 190 → 300190 → 600190 → 750 Deballast (m3/h): 100 → 1000

•

During process, the control system requests that vessel valves are opened/closed. The valves are outside the PureBallast system control. But the control system needs feedback (opened/closed) during process. Status can either be confirmed manually in a popup or automatically, if feedback signals are integrated via the remote interface option or via hard wire. Please note:

•

-

When overboard valves are requested to be opened/closed, this means that all valves leading the flow from the PureBallast via one of the following pipes must be opened/closed: 201, 309 and 403 and 404. During CIP process, 460.1 must be opened.

-

Such water as described above does not need to be transported overboard. For example, the flow can be lead to the bilge tank. In such cases, all relevant valves leading the water from the PureBallast system shall be opened.

The input flow to the PureBallast system shall be as close as possible to the flow that has been selected for an operation. This will reduce the stress and wear of the control valve.

1.1.1

Stripping

The first time a ballast tank is stripped, PureBallast must be by-passed. Recommended stripping procedure

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1.1

Preparations and conditions

1

Introduction

If stripping is performed with a low flow for a long period of time, we recommend that stripping is performed from the ballast tanks to a “collection tank”. After that it is possible pump the water from this tank with full flow using the ballast pump, and finally empty it by stripping. This will reduce the power consumption and UV lamp runtime. If all tanks are stripped (with a low flow) the power consumption per treated cubic meter will be unnecessary high, since the power consumption will be high in relation to the low flow. Example: If a process is run with a flow of 100 m3/h for 10 hours, it will give a power consumption of 1000 kwh, not including the ballast water pump. But if the same amount of water is collected and then processed with a flow of 1000 m3/h using the ballast water pump, the power consumption will be 100 kwh.

1.1.2

Heeling (internal transfer)

Internal transfer of ballast water between tanks, for example during heeling procedures, does not require the use of the PureBallast system. It is possible to perform heeling when PureBallast is in standby mode. If external component signal for heeling mode is integrated between PureBallast and the vessel’s ISCS, any ongoing process will be paused and resumed automatically. The user is notified of started and stopped heeling via a message in the control system, and the event is logged. If no external signal is integrated, the ongoing process must be paused manually. During pause, cooling water is flushed through the AOT reactor to cool the UV lamps. After completed heeling, the operator must resume the paused process. Warning W82 will appear in the alarm list. See instruction Pause ballast / deballast on page 64.

1.1.3

Ballast water handling in the event of malfunction

If the ballast water treatment system malfunctions, follow the procedures stated in the ship’s ballast water management plan. This is valid both if the system malfunctions, for example mechanical problems, or if full treatment cannot be guaranteed, for example a lamp failure or low UV intensity. General recommendations are given blow. PureBallast is equipped with a by-pass valve. The valve can be used in case of emergency to secure the ship, by allowing ballast water operations (ballast, deballast and internal transfers) without involving the ballast water treatment system. The valve is controlled by the ISCS, not PureBallast’s control system, but all valve activities are logged in the event log. Such valve is required by the International convention for the control and management of ship’s ballast water and sediments 2004. If the system malfunction in connection with general cargo operation, ballast and deballast operations should be avoided. Note that the system requires treatment both during ballast and deballast. If untreated water is pumped to a ballast tank, this water shall primarily be discharged to a reception facility. When this is not possible, other discharge possibilities must be agreed with the port state responsible for the waters where the ship is sailing and most importantly be agreed with the flag state administration of the ship; the procedures concerning emergency and malfunction of the ballast water treatment system should be implemented in the ships Ballast Water Management Plan which must be approved by the flag state administration.

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Introduction

1.1.4

1.1

Preparations and conditions

Pipe cleaning using PureBallast

In some vessels, the applicable class society may require means and procedure for flushing ballast pipes with treated water, to clean them from untreated water. This procedure should be implemented in the ships Ballast water management plan. In PureBallast, a deballast process is run with the vessel’s ballast valves positioned so that the •

pump takes water from a ballast water tank with treated water and

•

the water flow is directed either overboard or to another ballast tank.

Run the process for enough time so all water in the piping is treated. Time for this depends on pipe size and length on board.

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1.1

Preparations and conditions

1

Introduction

2 Introduction to the control system This section describes different login levels, overview of the system interface and how to navigate and operate the control system.

2.1

Login levels

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

Password

Authority

Guest

N/A

Default mode of control system. This level is not password protected.

Operator

Advanced operator

AlfaLaval

aot

2007

N/A

Book No.9010182 02, rev. 0

•

View all pages.

•

As Guest.

•

Operate the system to perform daily routines, for example ballast and acknowledge alarms.

•

Full access to page 1.4 Power request.

•

Download files and backup to a USB memory.

•

As level Operator.

•

Operate equipment in manual mode.

•

Access to set parameters, with exception from critical parameters (which are grey).

•

Full access to page 4.3 Operation timers and 4.4 Operation timers AOT.

Full access. Password only available for Alfa Laval personnel. •

Full access to all parameter pages.

•

Full access to force I/O in page 4.2 PLC controller I/O.

•

Full access to make settings for remote control panels and remote interface in page 4.1 System info and 4.5/4.6 Remote interfaces 1 and 2.

11

2.3

Remote interface (option)

2.2

2

Introduction to the control system

Control of PureBallast

PureBallast can be monitored and controlled in three ways: Main control panel, remote control panel (optional) and remote interface (optional). The system can only be controlled from one place at a time. The information below is only valid if remote control panels and/or remote interface is installed. Remote control panels. It is possible to log in on one panel, even if a user is logged on another panel. This requires that the new operator log in with the same login level or higher. The new operator will get a popup message saying that another user is logged in. The popup gives the alternative to cancel or to continue. If continue is chosen, the first operator will get a popup message and is then logged out. On each control panel it is possible to see which panel that is active and which login level that is used. This is visible in the upper right corner of the system according to syntax: login level@control panel. “Login level” can be: Guest, Operator, Advanced operator or AlfaLaval. “Control panel” can be: •

192.168.0.10 (Master) = Main control panel

•

192.168.0.11 = Remote control panel 1

•

192.168.0.12 = Remote control panel 2

•

192.168.0.13 = Remote control panel 3

•

192.168.0.14 = Remote control panel 4

Note: A panel alias can be entered to clarify where the panel is installed, for example pump room, bridge etc. See instruction Set remote control panel communication. Remote interface: The buttons Local and Remote are used to select which system that shall be in command. A green light is lit under the button that corresponds to the system currently in command. It is only possible to change between local and remote using these buttons.

2.3

Remote interface (option)

If the remote interface option is used, PureBallast can be controlled from the vessel’s ISCS. It is possible to access the same pages and perform the same operations from the remote interface as for login level Operator (if allowed by the ISCS). When the remote interface is used, the panel(s) cannot be used to operate the system; it is only possible to monitor the system and to export log files. It is possible to turn of the remote interface, and thus activate the panels when logged in as Operator or higher. The PureBallast system manual does not give any information about how to run PureBallast from the remote interface. This is due to the fact that the remote interface is custom-made. Please refer to the vessel specific manual.

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Introduction to the control system

2.3.1

2.3

Remote interface (option)

Conditions for remote interface control of PureBallast

PureBallast can be operated from ISCS when the conditions below are met: Installation and settings •

The remote interface must be correctly installed, according to received information.

•

Remote interface must be activated (parameter p132) and communication settings must be correct (parameter p700 – p704).

•

Remote operation must be in online mode. Check that the Test mode button is deactivated (no checkmark on the button) in control system page 4.5 Remote interface 1.

•

Remote mode must be activated. Check that the green lamp is lit under the Remote button on the control panel. If not, press the button. The system must be in Standby mode to toggle between local and remote operation.

Operation •

Heartbeat is updating. See that address +006 +077 are updating in control system page 4.5 Remote interface 1.

•

There must be no active alarms for the AOT reactors to be used during operation. Always check the alarm list (page 2.1 Alarm list in the control system) before operation.

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2.4

2.4

Overview of the screen

2

Introduction to the control system

Overview of the screen

This section describes the PureBallast control system screen layout and navigation. The control system use a touch screen, where you tap the screen to “click” or drag objects. Do not use sharp objects to touch the screen. When the screen is left idle it will go to screensaving mode. Time is set in page 4.1 System info. The screen is activated again by touching it once. The touch will not activate any button that might be placed where you touch. The illustration below shows the main areas and function buttons on the screen.

3 1.1

Control system screen showing the main overview page.

Login menu: Expanding menu with login fields. Tabs: The top and side tabs are used to choose which page to display in the screen. Pages are referred to as a number and a name, for example 2.1 Alarm list. The first number refers to selected top tab, counted from left to right. The second number refers to selected side tab, counted from top to bottom. Selected tabs are indicated by a white color. Top tabs: Contain the main function areas of the control system: Overview, alarm lists, trend indication, system information and parameters. Side tabs: Contain sub pages for the area selected in the top tab. Available side tabs change depending on which function area that have been selected in the top tab. 14

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Introduction to the control system

2.4

Overview of the screen

Popup windows: Are used to display or enter detailed information. It is possible to move a popup by touching the name bar and drag it. A popup is closed either by touching confirming entered information by touching a function button (OK, Confirm, etc.) or the X icon in the top right corner (data is not saved). Data entry fields: A white field indicates that it is possible to enter data. When the field is touched, a keyboard is displayed, which is used to enter information. Enter data is confirmed by touching the Enter button. To close the keyboard without saving data, touch the Esc button. Tables: Individual table rows, for example an alarm, can be selected by pressing them. Column widths can be adjusted. Press the column border in the head area and hold the finger on the screen. Function buttons: Function buttons are used for main processes and control of the system. They are placed att the bootom of the screenare and are always visible, but only available when colored dark blue. Some buttons are dependent on parameters. For example, the Remote and Local buttons are only visible if remote interface is activated. Status indication – Button color: The buttons appear in different colors, indicating status: Blue

The function is enabled.

Blue with checkmark

The function is activated.

Grey

The function is disabled, for example if higher login level is required for the function.

Status indication – Button light: After a function button is pressed, a light under the button is lit to indicate status for the activated function: Green

Command is active.

Yellow

Command will be processed when possible in the data work flow.

Yellow, blinking

Command is paused.

Function button description Button

Description Start ballast process. Resumes paused process. 3Ballast

Start deballast process. Resumes paused process. 3Deballast

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2.4

Overview of the screen

Button

2

Introduction to the control system

Description Stop current process.

3StopButtonBlue

3Pause

Pause ballast or deballast process. This is only possible during full ballast or full deballast. The button can be hidden, using parameter p137. Allowed length of a pause is parameter set (p138). After defined time, the paused process is stopped. To resume a paused process, press the function Ballast or Deballast depending on which process that was paused. Start CIP process.

3CIP

Activate operation from control panels, instead of remote interface (if option is used). The button is only enabled in standby mode. 2 LocalButton

Activate operation from remote interface (if option is used), instead of control panels. The button is only enabled in standby mode. 2 RIbutton

3 EnableManual

Sets the control system in manual mode, which enables manual operation of the system and its components. When activated, the light flashes yellow. The button is displayed for login level Advanced operator or higher. For detailed information see Manual mode on page 107. Disable the touch screen function for 10 seconds to make it possible to clean the screen without the risk of starting a process or changing a setting.

3Wipe

Activate night light for the panel. Night light makes the panel less bright. Toggles between night light and day light. 3 Night

Degree of brightness, is set in the Night light level field in page 4.1 System info. Contains calculator, Notepad and print function. To print a screen image to USB: Insert a USB memory in USB panel port on the cabinet door. Press Utilities, and then Print to save a screen image to USB.

3 Utilities

Status indication – Alarms and warnings 16

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Introduction to the control system

2.4

Overview of the screen

Alarms and warnings for components are displayed in the flow chart and popups: Active alarm. 3Alarm

Active warning. 2 Warning

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2.4

Overview of the screen

2

Introduction to the control system

3 Detailed page descriptions This section describes the pages used for operation. Note that this section does not cover the parameter pages. Please refer to chapter 4. Parameters.

3.1

Page 1.1 – Overview

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

3 1.1

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3.1

Page 1.1 – Overview

3.1.1

3

Detailed page descriptions

Status box

The status box display current status for the PureBallast system. The information is updated continuously. To see accumulated operation runtime for the components, see page 4.3 – Operation timers. The following status information is displayed: Status information (unit)

Description

Process and sub process

Process: Ongoing process. Can be standby, ballast, deballast and CIP. Sub process: Sub steps of ongoing process, for example “Start-up” during Ballast process.

Time

Remaining time for the ongoing sub process.

Processed volume (m3)

Amount of water processed during ongoing process. Value remain until next process is started.

Power consumption (kW)

Power consumption during process. Value is either exact value for the AOT reactor(including LDC cabinet), or calculated value including power optimization. This is set in parameter p239.

Certified flow (m3/h)

Certified flow (m3/h) selected for operation. The information is updated after the warm up time has passed and a AOT reactor is used for process. This is also the flow the system is aiming to keep.

Current flow (m3/h)

Ballast water flow in the system, indicated by flow transmitter FIT201-1.

Flow selection

Flow (m3/h) selected for operation. Flow is set using the arrow buttons. Flow selection depends on parameter p131 Automatic AOT selection:

20

•

If activated: All ready AOT reactors are selected.

•

If deactivated: Last used flow is default. Flow must be set after power off. Flow can be changed using the + and – arrows. •

+ = Increase flow. – = Decrease flow. The Flow selection field is updated with 1000 m3/h each time the button is pressed, but is not changed until the Apply button is pressed.

•

Apply = Apply the new setpoint to be used for process. Note: If ballast flow is lower than deballast flow (parameter p315), the higher value is displayed until the Ballast button is pressed.

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Detailed page descriptions

3.1.2

3.1

Page 1.1 – Overview

Flow chart

The flow chart display a schematic overview of the PureBallast system and its components. Relevant information regarding ongoing process and component status can be monitored directly in the flow chart. Flow in pipes is indicated by coloring of the pipes and component status are displayed by color indications. Pressure, flow and control valve opening percentage are displayed directly on component. Detailed information about components can be monitored in popups (by tapping the component): AOT reactor see page 53; filter see page 59. CIP open page 1.3 CIP status, see page 25). The popup contain status for sub components, for example valves, motors and UV lamps in the AOT reactor. Booster pump for AOT reactor (P403–1) and LDC (P401–1) are only displayed if these components are used and activated in the parameter pages. In manual mode (login level Advanced operator or higher) it is also possible to operate components manually: If a component is pressed, a popup window is displayed from which the component can be operated. Status indication – Component color: Component status is indicated by a colored frame: Pipes

Pipe and flow status. Flow in pipe is indicated as below: Status indication Blue = Fresh water or sea water, when flow goes sea-to-sea. Green = Ballast and deballast flow. Yellow = CIP liquid. Mixed colors = Mixed water, for example ballast water and fresh water.

Valves and pumps

Status indication Green, blinking = Travelling / starting Green = Open / running Grey = Closed / not running. Red, flashing = Active alarm for the component. It is also possible to enter ship specific ID for a component. The ID will be visible in page 1.1 Overview and popups for the components. See instruction Set ship specific component ID on page 71

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3.1

Page 1.1 – Overview

3

Detailed page descriptions

Status indication for balast water pump (not part of Alfa Laval’s scope of supply). 3 PumpReq

Status indication Green, blinking = Request sent. Popup message message “Confirm ballast pump started” is displayed. (The popup is not displayed if the component feedback is integrated with the control system.) Green = Feed back that pump is running, either via hard wired feedback, remote interface or the confirmation popup. Grey = No request sent (not running). Status indication for overboard valve(s), and other relevant valves for the process (not part of Alfa Laval’s scope of supply).

3 OBvalveReq

Status indication Green, blinking = Request sent. Popup message message “Confirm overboard valve open” is displayed. (The popup is not displayed if the component feedback is integrated with the control system.) Green = Feed back that valve is open, either via hard wired feedback, remote interface or the confirmation popup. Grey = Closed. Status information for bypass valve(s) V212–31 and external bypass valves (not part of Alfa Laval’s scope of supply). These valves are operated from the ISCS, due to safety reasons. External bypass is only visible if parameters (p163–p165) for external bypass valves are activated.

3 CV and Bypass icon

The component is operated manually in manual mode. 3Manual1

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Detailed page descriptions

3.2

3.2

Page 1.2 – AOT and flow selection

Page 1.2 – AOT and flow selection

The page is used to select AOT reactors or flow for ballast and deballast and to increase/decrease flow during ongoing operation. It is also possible to select specific AOT reactors to be used during process, or to change AOT reactor during an ongoing process. This page is only relevant if more than one AOT reactor is installed. Note, that if parameter p131 Automatic AOT selection is activated, it is only possible to change flow during operation, not in standby mode. Normally, flow is handled from page 1.1 Overview, and this page is used during commissioning and faultfinding when it is necessary to start individual AOT reactors. The main areas of the page are the Flow selection, AOT selection and Status.

3 1.2

3.2.1

Flow selection

Function in the same way as flow selection in page 1.1 Overview.

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3.2

Page 1.2 – AOT and flow selection

3.2.2

3

Detailed page descriptions

AOT selection

The area displays a table with installed AOT reactors with status information. It is possible to choose individual AOT reactor for process in standby (if parameter p131 is disabled) or during process (regardless of p131 setting). The following information is displayed: Elements

Description

Modify button

Enables active selection of individual AOT reactors. When pressed, the buttons for respective AOT reactor turns blue and are possible to use.

AOT 1, 2, 3 button

One row for respective installed AOT reactor with current status indicated in the columns. AOT n button: Press the button to select or deselect. A checkmark on the button indicates selected. The flow setpoint for the number of AOT reactors selected are updated in the Flow selection area. The field is updated with m3/h for each selected AOT reactor. Status indication: Selected: Grey = Not selected. Green = Selected. Ready: Grey = Not ready. Green = Ready for process. Alarm: Grey = No alarm. Red = Active alarm.

Apply button

3.2.3

Apply the new setpoint to be used for process. Note: If ballast flow is lower than deballast flow (parameter p315), the higher value is displayed until the Ballast button is pressed.

Status

The area displays current status for the flow: Elements

Description

Current flow

Ballast water flow in the system, indicated by flow transmitter FIT201-1.

Certified flow

Maximum allowed flow as set in Flow setpoint or limited by the number of AOT reactors selected in AOT selection popup. If a smaller filter is installed, the ballast flow can be lower than the AOT reactor capacity. The information is updated after the warm up time has elapsed and a AOT reactor is used for process. (Before that it is not used for treatment, and therefore not part of the certified flow.)

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Detailed page descriptions

3.3

3.3

Page 1.3 – CIP status

Page 1.3 – CIP status

The page is used to display CIP status for all AOT reactors and status for the valves and motors in the CIP unit. The page can either be opened by selecting the tab or by tapping the CIP module in page 1.1 Overview. The page also display time remaining for ongoing CIP process. If no CIP required process has been started after a ballast or deballast operation, the time remaining before CIP must be performed is displayed.

3 1.3

The following information is displayed:

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3.3

Page 1.3 – CIP status

3.3.1

3

Detailed page descriptions

CIP status

The area displays status for the following pieces of information: Row

Content

Process and sub process

Process: Ongoing process. Can be standby, ballast, deballast and CIP.

3.3.2

Sub process: Sub steps of ongoing process, for example “Start-up” during Ballast process.

AOT information

The area displays CIP status for respective installed AOT reactor: Row

Content

AOT

Each row display CIP status for every installed AOT reactor

Filter preservation This row indicate status and time for the filter preservation process, that starts after completed CIP. During filter preservation, the CIP fills the filter with fresh water for preservation purpose. Total

Total estimated time for a complete CIP process including filter preservation.

Column

Content

CIP error

Red square: Indicates that there is an active alarm for the component. Check alarms on page 2.1 – Alarm list.

CIP

CIP status for each AOT reactor. Status indication Yellow = CIP required. During ongoing CIP process, yellow indicates that the AOT reactor is waiting for CIP process to start. Yellow, blinking = CIP process ongoing. Green = CIP completed. White = CIP required, but cannot be performed, due to active alarm on the AOT reactor.

Status

26

Same information as column CIP, but spelled out.

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Detailed page descriptions

3.3

Page 1.3 – CIP status

Column

Content

Estimated time

Time remaining CIP time. If CIP process has not been started, total time is displayed. During CIP process, the time is counting down continuously. The CIP process takes about 25 minutes per AOT reactor, if default parameters are used.

Required CIP countdown

3.3.3

Time before a CIP process must be performed after ballast or deballast. The time disappears when the CIP process is ready.

CIP module information

The area displays a schematic illustration of the CIP module, with status for for the valves and motors. For status indications, see Status indication – Component color in section Flow chart on page 21.

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3.4

Page 1.4 – Power request

3.4

3

Detailed page descriptions

Page 1.4 – Power request

The page is used to handle power management. The page have two functions: Display power status and test power management signals.

3 1.4

3.4.1

Power management status display

If the control system is set in normal mode, the page is used to display power management status. Column

Content

Process and sub process

Process: Ongoing process. Can be standby, ballast, deballast and CIP.

Max power consumption

Maximum power consumption for the number of selected AOT reactors. The value is updated when a process is started.

28

Sub process: Sub steps of ongoing process, for example “Start-up” during Ballast process.

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Detailed page descriptions

3.4

Page 1.4 – Power request

Column

Content

Measured power consumption

Power consumption during process. Value is either exact value for all AOT reactors in use (including LDC cabinets), or calculated value based on number of used AOT reactors and UV lamp dimming. This is set in parameter p239.

Power status Column

Content

Power

Each row represent a number of AOT reactors to be used in a process. Requests can be combined to send request for 3 AOT reactors. 1 AOT: Request power for 1 AOT reactor. 2 AOTs: Request power for 2 AOT reactors. The requested power is calculated as the number of AOT reactor times defined power consumption for one AOT reactor. Common power: Request maximum power, enough to run all AOT reactors installed, even if all AOT reactors are not used.

Request (Output signal from PureBallast)

Indication alternatives: “Requested” or “Not requested”. Indicates if power request has been sent to the ISCS. Pure Ballast always asks for power before the UV lamps are lit during ballast or deballast start-up. When a request has been sent, the vessels power management performs a power check before the generator is started. Manual mode: Indicates if a simulated request signal is sent.

Granted (Input signal to PureBallast)

Indication alternatives: “Yes” or “No”. Indicates if power request has been granted from the ISCS. Pure Ballast will not consume significant power until the requested power is granted. Manual mode: Indicates if a simulated granted signal is received.

Status (Output signal from PureBallast)

Indication alternatives: “Running” or “Not running”. Indicates if power running signal is sent to the ISCS for respective number of AOT reactors. This means that the AOT reactor is started and is consuming power. Manual mode: Indicates if a simulated running signal is sent.

Calculated power consumption

The field display the calculated power consumption. If individual rows have been selected, the value is the sum of the number of AOT reactor for the request times the set power consumption per AOT reactor.

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3.4

Page 1.4 – Power request

Column

3

Detailed page descriptions

Content If Common power has been selected, the value is 100 kW.

3.4.2

Power management simulation and faultfinding

If the control system is set in manual mode, the page is used to simulate output from PureBallast to the power management system during commissioning preparation. The page can also be used to troubleshoot the power management system integration by sending and checking each signal.

3.4.3

Function buttons

The following function buttons are available and displayed when manual mode is activated: Buttons

Content

3Manual1

If manual mode is activated, a hand icons are displayed on the page. Press the hand icon to make it possible to send simulated request or granted signal manually.

Request

Press to manually simulate request for a power step. The button is displayed for login level Advanced operator or higher.

Set run

Press to manually simulate run signal for a power step. The button is displayed for login level Advanced operator or higher.

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Detailed page descriptions

3.5

3.5

Page 2.1 – Alarm list

Page 2.1 – Alarm list

The page display active alarms and warnings. When an alarm/warning is inactive and acknowledged, it is moved to page 2.2 Alarm history. Alarm type can be of two types: -

A = Alarms stop the ongoing process, which can be restarted after the problem has been attended to.

-

W = Warnings are notification of a status change, request for action or a problem that must be attended to. Warnings allow the process to continue.

For detailed information about alarms and warnings see chapter 5. Alarms and faultfinding.

3 2.1

The main areas of the page are the Alarm list and the Function buttons:

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3.5

Page 2.1 – Alarm list

3.5.1

3

Detailed page descriptions

Alarm list

The following information is displayed for each alarm (row): Column

Content

Text

Descriptive alarm text written as: Area-Alarm type AlarmID Alarmtext. Example: AOT2 A138 Error in LDC cabinet.

Active time

The time alarm was activated.

Acknowledged 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 will remain visible, until the temperature is below the limit value for the alarm/warning.

Status indication – Alarm color The table below shows status indication for alarms and warnings in the alarm list. Red

Alarm = active

Pink

Alarm = acknowledged, but still active

Orange

Warning = active

Yellow

Warning = acknowledged, but still active

3.5.2

Function buttons

The following function buttons are available: Button

Function

Ack selected

Acknowledge selected alarm (row). Press a row to indicate it, and press the button to acknowledge it.

Ack all

Acknowledge all active alarms.

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Detailed page descriptions

3.6

3.6

Page 2.2 – Alarm history

Page 2.2 – Alarm history

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

3 2.2

The following information is displayed: Column

Content

Text

Same as in Page 2.1 Alarm list.

Active time

Same as in Page 2.1 Alarm list.

Acknowledged time

Same as in Page 2.1 Alarm list.

Normal time

The time the value that caused the alarm returned to normal.

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3.7

Page 3.1 – Trend (15 min)

3.7

3

Detailed page descriptions

Page 3.1 – Trend (15 min)

The page is used to display trend curves for basic data in the system. This page display trends with a update frequency (sample time) of 1 second. This page is useful for analyzing processes, for example backflushes.

3 3.1

Trends can be plotted for the following components (identified by item number) and key values: Component / Key value

Unit

Description

Filter diff. pressure

Bar

Differential pressure over filter, indicated by pressure transmitter 201–71 and 201–72.

V201–8

%

Control valve open, percent.

PT201-16

Bar

System pressure, indicated by the pressure transmitter.

V309-1

Status

Filter backflush valve opened or closed.

FIT 201-1

m3 h

System flow, indicated by the flow meter.

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Detailed page descriptions

3.7.1

3.7

Page 3.1 – Trend (15 min)

Diagram area

In the diagram area, trend curves are displayed for one or more components. Components available for plotting is displayed at the bottom of the screen. Trend curves can be activated or inactivated for respective component. The scale of the diagram: X axis: The time interval is always 15 minutes. Y axis: The scale and unit used for the Y axis is set in the Settings popup for respective component. For details, see the Component area section below.

3.7.2

Component area

The following fields and buttons are available for each component in the component area: Column

Content / Function

Settings button

Press the button to make settings for the component’s curve. Settings is done in a popup.

3 TrendCurveSet1Nr

1: Press (not slide) the button to display or hide trend curve in the diagram. An I indicate displayed, and an O indicates inactive. 2: Press the entry field to change start and stop value for the components Y axis scale (when this component’s scale setting is used. 3: Press this button to use this component’s scale setting in the diagram. 4. Press the entry field and increase or decrease the number of decimals in the component area.

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3.7

Page 3.1 – Trend (15 min)

3

Detailed page descriptions

Filled = Selected. Component values is plotted in the diagram, in the same color as the icon.

Status indication 3 TrendActive

Empty = Not selected. Component values is not plotted in the diagram. 3 TrendInactive

3 TrendScale

Scale icon = The component scale setting is used in the diagram’s Y axis. If several components have the same scale setting, this icon is displayed for all these items.

Component

Item number or name.

Value

Current value for the component is displayed in the gray field. (This corresponds to the diagram.) If history mode is selected, historic value is displayed.

3.7.3

Function buttons

The following function buttons are available. Buttons

Content

Export data to USB

Export trend curve history as a csv file. The file can be sent to Alfa Laval for advanced trouble shooting. Insert a USB memory in USB panel port on the cabinet door. Press Export data to USB button. Wait for the message “Exporting database table …” to disappear. The file has been downloaded to the USB memory, in a folder named DatabaseExport.

History mode

Press the button to display this popup:

3 TrendCurveTime

Press one time unit (year, moth, day etc) and then press – or + to set time. Real time

36

Press the button to display current trend curve.

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Detailed page descriptions

3.8

3.11

Page 3.5 – Trend (1 h) - Power optimization

Page 3.2 – Trend (1 h)

The page is used to display trend curves for basic data in the system. This page display trends with a update frequency (sample time) of 30 seconds. See page 3.1 Trend (15 min.) for information about function, fields and buttons.

3.9

Page 3.3 – Trend (1 h) - TT201-33

The page is used to display trend curves for water temperature in the AOT reactor, indicated by temperature transmitter TT201–33. This page display trends with a update frequency (sample time) of 30 seconds. See page 3.1 Trend (15 min.) for information about function, fields and buttons.

3.10 Page 3.4 – Trend (1 h) - TT401-2 The page is used to display trend curves for air temperature in LDC, indicated by temperature transmitter TT401–2. This page display trends with a update frequency (sample time) of 30 seconds. See page 3.1 Trend (15 min.) for information about function, fields and buttons.

3.11 Page 3.5 – Trend (1 h) - Power optimization The page is used to display trend curves for data valid for the power optimization. This page display trends with a update frequency (sample time) of 30 seconds. See page 3.1 Trend (15 min.) for information about function, fields and buttons. See chapter 2. System description, section Power optimization for details. The following information is displayed: •

AOT UV setpoint: The UV intensity the system is aiming to attain by increasing or decreasing power effect to the LPS controlling the dimming of the UV lamps. The setpoint is based on actual transmittance and is updated every 15 seconds.

•

UV measurement: Actual UV intensity (W/m2) measured by UV sensor QT201–50. If intensity is lower or higher than needed, the power to LPS will increase or decrease to attain setpoint for UV intensity.

•

Power output: Actual LPS power to UV lamps. The power is adjusted to attain the setpoint for UV intensity based on measured water transmittance. Output is adjusted based on input from UV sensor QT201–50. Power can be 50–100 %.

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3.12

Page 4.1 – System info

3

Detailed page descriptions

3.12 Page 4.1 – System info The page is used to display status information for the control system and the control panel. It is also used to backup information and restore information from a backup.

3 4.1

The following information is displayed: Section on page

Description

HMI info

CPU: Control panel’s usage of the central processor unit (CPU) in percent of total capacity and temperature (°C). Used RAM: Control panel’s used random access memory (RAM) in percent of total capacity and in kB. Used storage: PLC flash card’s used storage in percent and MB. Storage used for the event and alarm log. iX version: N/A. IMG version: Version of TA150 firmware for the control panel. CAT control version: N/A.

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Detailed page descriptions

Section on page

3.12

Page 4.1 – System info

Description Program version: Version of HMI software. IP settings: Display current IP address. Setup button: Opens popup to set IP address for the main panel and the remote control panels (optional). Requires login level AlfaLaval

HMI date and time UTC

Date and time: Only used if no GPS is 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 control panel. Synchronize button: PLC is synchronized to use same date and time as the control panel.

HMI Backlight

Screen saver timeout: Defines time before the panel is set to screen save mode. This is set individually per control panel. Night light level: Defines percent of full light for the night light mode. Night light is activated by the Night function button.

PLC Info

CPU temperature (°C): Temperature of the central processor unit (CPU) in the PLC. Program version: Version of the PureBallast PLC program. GPS position: Shows current GPS position, if the control system is connected to a GPS (p160). This position is used in the event log.

Backup and restore

Settings to/from USB panel: Export and inport information to the USB panel port on the cabinet door. Backup button: The following information is saved in a folder named “PureBallast Backup”: •

Parameter settings. Saved in file Parameters.csv.

•

Audit trail (tracking of actions in the control system, e.g. changed password, acknowledged alarms, changed parameter values). Saved in file AuditTrail.sdf.

•

Settings for trend pages, e.g. min and max values for different components. Saved in file ValueTrendLegend.xml.

•

Passwords. Saved in file Security.xml.

•

Notpad.txt. Can be used to make notes for the backup.

Restore button: Restore all information from a USB backup to the control system. See Backup above. This shall not be used to restore parameter settings after software update. Requires login level Advanced operator.

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3.12

Page 4.1 – System info

Section on page

3

Detailed page descriptions

Description Parameters: Restore manually changed parameter to default values. Set default button: Set all parameter values to the default values. Requires login level Advanced operator. History to USB panel: Export information to the USB panel port on the cabinet door Backup button: The following information is saved in a folder named “PureBallast Export”:

Export log files

•

Database including alarm history, trend history etc. Saved in file Database.sdf.

•

Audit trail (tracking of actions in the control system, e.g. changed password, acknowledged alarms, changed parameter values). Saved in file AuditTrail.sdf.

•

Settings for trend pages, e.g. min and max values for different components. Saved in file ValueTrendLegend.xml.

•

Passwords. Saved in file Security.xml.

•

Notpad.txt. Can be used to make notes for the backup.

Export: Opens the Export log files popup to export (copy) event log and alarm list as a set of files in a folder named “PureBallast”. For specific information about logged events, see section List of logged information, Event log on page 89.

Remote control panels

Set: Open a popup used for setting IP addresses for remote control panels (optional). See instruction Set control panel IP address on page 74. Requires login level Advanced operator.

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Detailed page descriptions

3.13

Page 4.2 – PLC controller I/O

3.13 Page 4.2 – PLC controller I/O The page is used to display status for the PLC I/O modules and to control them manually. Note that this page is only intended for Alfa Laval’s personnel and only visible and available for login level AlfaLaval.

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3.14

Page 4.3 – Operation timers

3

Detailed page descriptions

3.14 Page 4.3 – Operation timers The page is used to display operation counters for the components indicted in the illustration. Note that these timers are reset when the PLC software is updated.

3 4.3

The following information is displayed: Row

Unit

Accumulated ballast volume (FIT 201-1)

m3 processed

Accumulated deballast volume (FIT 201-1)

m3 processed

Control valve V201-8 total runtime

Time opened in hours

Filter backflush via V309-1

Number of times opened

Filter motor M709–42

Runtime in hours

CIP pump P320-1

Runtime in hours

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Detailed page descriptions

3.14

Page 4.3 – Operation timers

Row

Unit

CIP pump P321-5

Runtime in hours

CIP: Number of cleaned AOTs.

Number of cleaned AOT reactors

Reset button: Reset to 0. If this is done each time the CIP liquid is changed, it is possible to build up experience on how many AOT reactors it is possible to CIP before it is time to change CIP liquid. Requires login level Advanced operator or higher.

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3.15

Page 4.4 Operation timers AOT

3

Detailed page descriptions

3.15 Page 4.4 Operation timers AOT The page is used to display operation runtime for AOT reactors:

3 4.4

The following information is displayed: AOT operation timers

Total

Lap time

AOT 1–3: Lamps on

Total runtime for the UV lamps in respective AOT reactor.

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.

AOT 1–3: LDC power on

44

Total runtime for the LDC for respective AOT reactor.

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Detailed page descriptions

3.16

Page 4.5 – Remote interface 1

3.16 Page 4.5 – Remote interface 1 This page is used to monitor data sent between PureBallast’s PLC and the vessel’s ISCS. For detailed information about addresses, information and format, see chapter 6. Installation description and drawings, section Remote interface integration (optional).

3 4.5

Function buttons

Description

Test mode

Activates test mode. Communication can be sent between the ISCS and PureBallast’s PLC without actually affecting the control system (start process etc). To send information, enter desired digits in the entry field. Active: Check mark on the button. Deactivated: No check mark on the button.

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3.17

Page 4.6 – Remote interface 2

3

Detailed page descriptions

3.17 Page 4.6 – Remote interface 2 This page is used to monitor AOT reactor and LDC specific data sent from PureBallast’s PLC to the vessel’s ISCS. For detailed information about addresses, information and format, see chapter 6. Installation description and drawings, section Remote interface integration (optional).

3 4.6

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Detailed page descriptions

3.18

Page 4.7 – Log box 1

3.18 Page 4.7 – Log box 1 This page is used to administer and monitor the feedback from external components connected via the log box (optional).

3 4.7

The following information is displayed: Column

Content

Vessel ID

Each row represent a component (valve). In the Vessel ID column, it is possible to enter the actual component ID used on the vessel for easier identification on the panel. This ID is not used in the Event log. Example: In the illustration the first valve is named “Valve X45”. To enter a vessel ID: Press the entry field or the document icon for the component, and enter the ID using the keyboard displayed on the screen.

Position

Each component is identified with a component ID and position. Component ID: This ID is used in the Event log.

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3.19

Page 4.8 – Log box 2

Column

3

Detailed page descriptions

Content

Position: For each valve, it is possible to connect two signals to log feedback on open, closed or both. If signal “Closed” is used for a valve, the event log will make a record each time the valve is detected closed, and each time it is detected not closed. Status

Active signal is indicated with a green light on the I/O icon.

Logging

Two parameters per valve defines if opened and/or closed signals are connected for respective position (valve). If parameter is set to Active, activities for the component is logged in the event log. Alternatives: Activated or Not used.

3.19 Page 4.8 – Log box 2 This page is used to administer and monitor the feedback from external valves (V) and pumps (P) connected via the log box (optional). See page 4.7 Log box 1 for information about function, fields and buttons.

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Detailed page descriptions

3.19

Page 4.8 – Log box 2

3 4.8

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3.20

Page 4.9 – LPS overview

3

Detailed page descriptions

3.20 Page 4.9 – LPS overview This page is used to monitor detailed data for the lamp power supplies in the lamp drive cabinet. It is intended for Alfa Laval’s personnel during advanced faultfinding.

3 4.9Obe

Column

Content

LPS number

Each row indicate status for each LDC.

Power

Measured power output for UV lamp powered by the LPS.

Lamp on

Status: Green = On. Grey = Off.

Reignite

Status: Red = Failure to ignite UV lamp.

LPS OK

Status: Green = OK. Red = LPS in fault state.

Lamp OK

Status: Green = UV lamp lit and LPS is OK. Red = LPS in fault state.

Voltage fault

Status: Red = Too low incoming power to the LPS.

System fault

General LPS error.

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Detailed page descriptions

3.20

Page 4.9 – LPS overview

Column

Content

Air temp fault

Status: Red = Temperature in LPS is higher than 55 °C.

Heatsink fault

LPS internal heat protection tripped.

Fan fault

LPS fan broken.

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3.21

Page 4.10 – LDC power

3

Detailed page descriptions

3.21 Page 4.10 – LDC power This page is used to monitor detailed data for the lamp power cabinet. It is intended for Alfa Laval’s personnel during advanced faultfinding.

3 4.10

Column

Content

AOT

Each row indicate status for the LDC for each AOT reactor.

Current

Power through phase L1 – L3.

Voltage

Voltage through phase U12–U31.

Power total

Total effect at LDC main breaker Q1. Presented as active, reactive and apparent values.

Freq.

Frequency of incoming power to LDC.

L, S and I

Trip characteristics of breaker settings for L, S and I.

Read button

Press the button to update data for the row. (The data is not uppdated continuously.)

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Detailed page descriptions

3.23

Popup windows

3.22 Page 5.1–5.7 – Parameter pages These pages are used to set parameters. See chapter 4. Parameters for detailed information.

3.23 Popup windows This section describes the popup windows for the AOT reactor, filter and CIP opened from page 1.1 Overview.

3.23.1 AOT popup The popup is displayed when the AOT reactor is pressed in the flow chart. The popup displays status values for the AOT reactor and its related sub components. In manual mode (login level Advanced operator or higher) it is also possible to operate components manually. If the component is pressed, a popup window is displayed from which the sub components can be operated. Operation of UV lamps in LPS control popup requires login level Advanced operator. AOT status: Status indication for the AOT reactor: ”Stopped” or “Started”.

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Popup windows

3

Detailed page descriptions

3 1.1 AOT popObe

The following information is displayed: AOT illustration The following information is displayed: Component

Description

UV lamps

Status indication: Grey = Off. Yellow = Starting. Green = Started.

Sensor indications

Status indication for AOT reactor sensors: LS201–29: Level switch indicates if the AOT reactor is filled with water or not. Status indication: Green = Filled. Red = Not filled. TS201–60: Temperature switch TS201–60 automatically shuts down the AOT reactor when the temperature reaches 65 °C. Status indication: Green = OK. Red = Not OK.

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Detailed page descriptions

Component

3.23

Popup windows

Description QT201–50: UV sensor QT201–50 indicates UV intensity from the UV lamps in the AOT reactor. When transmittance falls below value set in parameter p221 a warning is issued. TT201–33: Temperature indicator TT201-33 indicates current temperature in the AOT reactor.

Valves

For status indications, see Status indication – Component color in section Flow chart on page 21.

Water flow

Flow in pipes is indicated by coloring of the pipes.

LDC status Component

3 LPSctlrbut

Description Open the LPS control popup, which enables manual operation of individual UV lamps. Requires login level Advanced operator to see the button and manual mode open the popup. See LPS control popup and instruction Operate UV lamps manually on page 70. Open the LPS status popup, which gives an overview of status for UV lamps and LPSs.

3 LPS StatusBut

LDC fan setpoint

Fan rotation in percent of full effect. Fan effect is based on need for cooling.

Heat exchanger valve

Indicates if the valve for LDC cooling water (SV401–51) is open. Status indication: Green = Open . No indication = Closed.

TT401–1

Temperature of incoming cooling water to the LDC cabinet.

TT401–2

Air temperature in the LDC cabinet.

Power

Current power consumption for the AOT reactor/LDC.

3.23.1.1 LPS control popup The popup is used for to manually start the UV lamps in the AOT reactor. See instruction Operate UV lamps manually on page 70. The popup is displayed when the LPS control button is pressed in the AOT popup. Requires login level Advanced operator to see the button and that manual mode is activated to open the popup. The AOT reactor is equipped with 16 UV lamps. In each lamp drive cabinet (LDC) is 16 lamp power supplies (LPS) that supplies power to one UV lamp each. The lamps can be operated individually in manual mode.

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3.23

Popup windows

NGE ! DA •

3

Detailed page descriptions

R

Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. All necessary items – cooling water flow, water temperature, and power management – must be supervised and verified by the authorized trained personnel operating the system. Improper operation of this function could seriously damage the equipment and injure personnel.

3 LPS Manual popObe

The following information is displayed: Component

Description

AOT number

Information is displayed for the AOT reactor selected in the AOT number field. Enables manual operation of the LPSs to light the UV lamps. The button is displayed for login level Advanced operator or higher. The button enables manual lcontrol of UV lamps.

3 ManModeBut

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3.23

Popup windows

Component

Description

LPS 1–16

Press one button (1–16) to start or stop UV lamp 1–16 manually, controlled by the LPS. Status indication: Blue with checkmark = Lit Blue without checkmark = Off Grey = Not selectable. Start all LPS, and thereby all lamps for the AOT reactor. Requires that the Manual mode button is pressed.

3 StartLPSBut

Stops all LPS, and thereby all lamps for the AOT reactor.

3 StopLPSBut

3.23.1.2 LPS status The popup gives detailed information about UV intensity for AOT reactors and power for LPSs. The information is mainly used for advanced trouble shooting by Alfa Laval’s personnel.

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Popup windows

3

Detailed page descriptions

3 LPS popObe

The following information is displayed: LPS status Component

Description

AOT

Information is displayed for the AOT reactor selected in the AOT number field.

Fail safe

Displays if LPSs is active and powered on. UV lamps can only be lit if an LPS is active. When a critical alarm (e.g. no water in the AOT reactor) is issued, the fail safe function inactivates the LPSs and cut the power. Status indication: Green = Active. Grey = Not active.

3 1.1 LPS active

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3.23

Popup windows

Component

Description

LPS 1–16

Actual effect from each LPS to respective UV lamp. Green = LPS/Lamp on. Gray = LPS/Lamp off.

Power optimization Component

Description

Setpoint

The UV intensity the system is aiming to attain by increasing or decreasing power effect to the LPS controlling the dimming of the UV lamps.

Measured

Actual UV intensity (W/m2) measured by UV sensor QT201–50. If intensity is lower or higher than needed, the effect to LPS will increase or decrease to attain setpoint for UV intensity.

Power output

Actual LPS power effect to UV lamps. The effect is adjusted to attain the setpoint for UV intensity based on measured water transmittance. Output is adjusted based on input from UV sensor QT201–50. Effect can be 50–100 %.

Control mode

Manual power output

Displays current control mode. Status indication: •

Automatic: Normal mode. Power optimization is activated.

•

Manual: If function button Manual is pressed, it is possible to enter a value in the Manual power output field.

•

Not used: Power optimization is disabled in parameter p237. UV lamps are always lit to 100 %.

Manually set effect to LPS. Requires that the system is set in manual mode.

3.23.2 Filter popup The popup is displayed when the Filter is pressed in the flow chart. The popup displays status values for the filter and its related components. In manual mode (login level Advanced operator or higher) it is also possible to operate components manually. If the component is pressed, a popup window is displayed from which the sub component can be operated. When manual mode is deactivated the system will return to standby mode: All manually operated components will return to their status prior to the manual operation.

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Popup windows

3

Detailed page descriptions

3 1.1 Filter Hydac

The following information is displayed: Component

Description

Mode

Filter status: - Idle (No backflush or preservation) - Backflush preparation - Backflush ongoing - Filter preservation.

Diff. pressure

Indicates differential pressure over the filter (PT201–71 minus PT201–72). When the pressure reach the value set in parameter p305, a backflush is triggered.

Pressure

Current pressure: PT201–71: Inlet pressure. PT201–72: Outlet pressure. PT309–2: Backflush pressure.

Start backflush

Press the button to start a manual backflush. See instruction Backflush filter manually on page 64.

Pipes, valves and motor

For status indications, see Status indication – Component color in section Flow chart on page 21.

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4 Operating instructions This section contains step-by-step instructions for operating the PureBallast system. Please read and follow the preparations and conditions carefully, as well as any danger or warning notes. Preparations and conditions For reference information, see the following sections i this chapter: •

Control system pages used in the instructions: See section Control system — Detailed page descriptions.

•

Login levels required for different procedures: See section Login levels on page 11.

•

Detailed information about components (valves, motors, pumps etc) involved in each step the process. See section Detailed process description.

4.1

Log in

Follow the steps below 1.

Press the expand button on the Log in tab in the top right corner of the screen. Result: The log in menu is displayed.

2.

Press the expand button on the left drop down menu to display available users. Press desired user. Result: A keyboard is displayed.

3.

Enter password and press Enter. (See section Login levels on page 11.)

4.2

Perform ballast

Follow this instruction to ballast. Preparations and conditions •

The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.

•

All ballast system valves outside the PureBallast system must be set in the correct positions for ballasting. The valve after the ballast pump must be closed (not part of Alfa Laval’s scope of supply).

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4.3

Perform deballast

4

Operating instructions

•

Flow must have been selected before a process can be started. If parameter p131 is activated maximum flow is automatically selected, and flow can only be changed during process according to instruction Change ballast / deballast flow on page . If parameter p131 is deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or 1.2 AOT and flow selection.

•

There must be available power for the system. If power management is integrated, this will be handled automatically. If power management is not integrated, confirm available power manually.

4.2.1

Start ballasting

Follow the steps below: 1.

Press the function button Ballast. Comment: If the button is not blue, check that flow or AOT reactors have been selected.

2.

Wait for the message “Open valves ...”. Open relevant valves and then press the button in the popup to confirm the action. Note! These valves are outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Result: Ballast start-up starts, with cooling water cooling the lamps during warm-up.

3.

Wait for the message “Confirm ballast pump started”. Start the pump and then press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Result: Cooling stops and ballasting starts.

4.

When desired amount of water has been processed, press the function button Stop. Result: Ongoing process is stopped and the lamps are switched off. An automatic filter backflush is performed.

5.

Wait for the message “Close valves ...”. Close relevant valves and then press the button in the popup to confirm the action. Note! These valves are outside outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.)

6.

Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) NOTE

A CIP cleaning process must be performed after ballasting. It can be done immediately or within 30 hours. When time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made in the control system’s log as a deviation from a correct handling of the system. Note, that it is possible to perform processes during these 30 hours. Complete status information regarding CIP is displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP clean AOT after ballast / deballast on page 65.

4.3

Perform deballast

Follow this instruction to deballast. 62

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Operating instructions

4.3

Perform deballast

Preparations and conditions •

The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.

•

All ballast system valves outside the PureBallast system must be set in the correct positions for ballasting. The valve after the ballast pump must be closed (not part of Alfa Laval’s scope of supply).

•

Flow must have been selected before a process can be started. If parameter p131 is activated maximum flow is automatically selected, and flow can only be changed during process according to instruction Change ballast / deballast flow on page . If parameter p131 is deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or 1.2 AOT and flow selection.

•

There must be available power for the system. If power management is integrated, this will be handled automatically. If power management is not integrated, confirm available power manually.

Follow the steps below: 1.

Press the function button Deballast. Comment: If the button is not blue, check that flow or AOT reactor have been selected.

2.

Wait for the message “Open valves ...”. Open relevant valves and then press the button in the popup to confirm the action. Note! These valves are outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.

3.

Wait for the message “Confirm ballast pump started”. Start the pump and then press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Result: Cooling stops and deballasting starts.

4.

When desired amount of water has been processed, press the function button Stop. Result: Ongoing process is stopped and the lamps are switched off.

5.

Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.)

6.

Wait for the message “Close valves ...”. Close relevant valves and then press the button in the popup to confirm the action. Note! These valves are outside 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 performed after deballasting. It can be done immediately or within 30 hours. When time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made in the control system’s log as a deviation from a correct handling of the system. Note, that it is possible to perform processes during these 30 hours. Complete status information regarding CIP is displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP clean AOT after ballast / deballast on page 65.

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4.5

Backflush filter manually

4.4

4

Operating instructions

Pause ballast / deballast

Follow this instruction to pause an ongoing ballast or deballast process. This instruction is also used before heeling (internal transfer), if no external signal for heeling mode is integrated between PureBallast and the vessel’s ISCS. Preparations and conditions •

This is only possible in sub process full ballast or full deballast. This is indicated by the lit Pause button.

•

Allowed length of a pause is parameter set (p138). After defined time, the paused process is stopped.

Follow the steps below: 1.

Press the function button Pause.

2.

Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Note: If you pause to perform heeling (internal transfer) you confirm the request without stopping the ballast water pump. Result: Ongoing process is paused. The UV lamps remains on at reduced power and cooling water is run through the AOT reactor to cool the lamps. Pause mode is indicated by yellow light under the Pause button and blinking yellow under the function button Ballast or Deballast.

3.

To resume the paused process, press the function button Ballast or Deballast.

4.

Wait for the message “Confirm ballast pump started”. Start the pump and press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Result: The process is resumed.

4.5

Backflush filter manually

Follow this instruction to backflush rinse the filter manually. Preparations and conditions •

The system must be in full ballast mode.

Follow the steps below: 1.

Go to page 1.1 Overview.

2.

Press the Filter in the flow chart. Result: The Filter popup is displayed.

3.

Press the Start backflush button. Result: A backflush is performed. The default backflush process time is 35 seconds.

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Operating instructions

4.6

4.7

Stop ballast / deballast

CIP clean AOT reactor after ballast / deballast

Follow this instruction to clean the AOT reactor(s) using the cleaning in place (CIP) process. If system shut down is activated during the CIP process, the CIP liquid is drained to the CIP tank. Water in the AOT reactors is drained overboard. Preparations and conditions •

The system must be in standby mode. This means that this operation cannot be executed during ballast or deballast.

•

Complete status information regarding CIP is displayed in page 1.4 CIP status. The page displays remaining time for ongoing CIP cycles, remaining time before individual AOT reactors are required to be CIP:ed etc.

•

If a ballast operation has been performed since the last CIP process, the process is completed with a filter preservation, where the filter is filled up with fresh water.

Follow the steps below: 1.

Press the function button CIP.

2.

Wait for the message “Open valves ...”. Open relevant valves and then press button in the popup to confirm the action. Note! These valves are outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.) Result: The automatic CIP process starts. The CIP process takes about 25 minutes per AOT reactor, if default parameters are used.

3.

Wait for the message “Close valves ...”. Close relevant valves and then press button in the popup to confirm the action. Note! These valves are outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.)

4.7

Stop ballast / deballast

Follow this instruction to stop an ongoing ballasting or deballasting operation. Each ballast and deballast operation must be stopped manually. Follow the steps below: 1.

When desired amount of water has been processed, press the function button Stop. To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %. Result: Ongoing process is stopped and the lamps are switched off. If ballasting, an automatic backflush is performed before the system is stopped.

2.

Wait for the message “Stop ballast water pump”. Stop the pump and then press the button in the popup to confirm the action. Note! This component is outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.)

3.

Wait for the message “Close valves ...”. Close relevant valves and then press the button in the popup to confirm the action. Note! These valves are outside the PureBallast system control. (The popup is not displayed if the component feedback is integrated with the control system.)

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4.8

Attend to alarms

4

Operating instructions

NOTE A CIP cleaning process must be performed after ballasting and deballasting. It can be done immediately or within a 30 hours. When time is about to elaps, a warning is issued. If no action is taken within the time limit, an entry is made in the control system’s log as a deviation from a correct handling of the system. Note, that it is possible to perform processes during these 30 hours. Complete status information regarding CIP is displayed in page 1.3 CIP status.

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. An alarm or warning is indicated by a audible signal and by a blinking alarm icon: Warning: Warnings are notification of a status change or a problem. Warnings allow the process to continue. 2 Warning

Alarm: Alarms stop the ongoing process, which can be restarted after the problem has been attended to.

3Alarm

Preparations and conditions •

If the alarm is caused by a faulty AOT reactor, the AOT reactor will shut down but the process will continue with remaining AOT reactors.

!

NG WARNI

•

Never reset an alarm without first finding and attending to the problem.

•

For color indication of alarms. See page 32.

Follow the steps below: 1.

Go to page 2.1 Alarm list to view active alarms. •

If the alarm has caused the system to automatically stop, go to step 2.

•

If the alarm allows the ballast process to continue, go to step 3.

2.

If the process have stopped: Take action to eliminate what has caused the alarm.

3.

If the process continues: Consider if the process shall be terminated. Take action to eliminate what has caused the alarm.

4.

After the problem has been dealt with Press the Ack all button to acknowledge all alarms, or press the alarm row and press Ack selected button to acknowledge only this alarm. Result: The alarm will change color to indicate change of status. See section Page 2.1 Alarm list in this chapter. The acknowledge time is updated, and the Normal time will be updated when the problem is resolved.

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Operating instructions

4.9

4.9

Shut down and deactivate system

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). Lamp drive cabinet

Control cabinet

3 Emergency stop

3 LDC Main breaker

Follow the steps below: One of the following methods can be used to abort any ongoing operation and stop the system: Action

Method

Stop ongoing process

Press the Stop button in the control panel. Result: Ongoing process is stopped in a controlled way. Valves are returned to starting position.

3StopButtonBlue

Shut down

Book No.9010182 02, rev. 0

Press the Stop button (2) on the control cabinet door. Result: Ongoing process is shut down and valves are returned to starting position as fast as possible. Note: The power is still on.

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4.11

Operate components manually

4

Operating instructions

Action

Method

External shut down button

If an external system stop button has been installed and integrated, it will function as the shut down above.

Deactivate PureBallast to make it completely deactivated (currentless).

Complete deactivation is performed in two steps: Stop any ongoing process: 1. Turn off the main breaker (1) at the side of the control cabinet. 2. Turn off the main breaker on the LDC door. The system is then currentless on the PureBallast side of the breaker (Q1 in control cabinet and Q1 in the LDC. To make the complete system currentless, power to PureBallast must be switched off using the ship’s switch board. Note: Both breakers can be locked in off position using a padlock.

4.10 Reset system after shut down Follow this instruction to reset the system if deactivated. Numbers refer to the illustration under instruction Shut down and deactivate system on page 67. The system may only be reset after the reason for shut down is known. If the reason is not known, follow the instruction Attend to alarms. Depending on how the system was shut down: Manual on control cabinet: Turn the main breaker (1) and acknowledge alarm A48 in the control system. Automatic in LDC: Follow the instruction below if a reactor has been shut down by temperature switch TS201-60 (alarm A137) or if the cabinet or system has been shut down by a blackout or electrical faults in the cabinet: 1. Make sure that the main breaker on the LDC door is turned on. 2. Press. the blue reset button on the LDC door (when the reactor has cooled down or when the power is back on). All LDCs must be reset individually. 3. Acknowledge all alarm related to the shut down in the control system.

4.11 Operate components manually Follow this instruction to operate components manually. This shall only be done during commissioning, advanced faultfinding or service. Valves are recommended to be operated via the PureBallast control system. It is also possible to open/close them manually according to instruction in chapter 7. Service manual, section Operate valves manually. The following components can be operated manually: 68

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Operating instructions

•

Filter motor (M709-43)

•

CIP pump for CIP liquid (P320-1)

•

CIP pump for draining (P321-5)

•

Booster pump, LDC cooling (401–1), if installed

•

Booster pump, AOT reactor cooling (403–1), if installed

•

UV lamps in the AOT reactor

•

UV lamp effect.

4.11

Operate components manually

Preparations and conditions •

This operation requires login level Advanced operator or higher.

•

It is not possible to run any processes in manual mode. Only individual components can be operated.

•

When operating valves, the positioning screw on the valve must be in position 0: Closed (default position).

Follow the steps below: 1.

Go to page 1.1 Overview or 1.4 CIP status.

2.

Press the button Manual function button. Result: The control system is set in manual mode.

3.

Press desired component. Result: A popup is opened. Current status is indicated. If an existing alarm exist, it is indicated with an alarm icon. If the AOT reactor or filter was pressed, a popup is opened with sub components. If the CIP was pressed, page 1.4 CIP status is opened.

3 PopValve

Example popup for a valve.

4.

Press (not slide) the Hand button icon to enable manual operation of the component. Result: The open and closed buttons turn blue for operation. A hand icon is also displayed on the component in the popup and the flow chart to indicate that it is manually operated.

5.

Operate the component using the open/run (left) and closed/not running (right) buttons in the popup.

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4.12

Operate UV lamps manually

4

Operating instructions

6.

Press Hand button to stop manual mode for the component and the X button to close the popup. or Press the X button to close the popup and let the component remain in manually set status. The popup is closed, and a hand icon is displayed by the component to indicate it is manually operated.

7.

Press the Manual function button to exit manual mode. Result: All manually operated components are restored to their previous status.

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

This operation requires login level Advanced operator or higher.

•

The control system must be in manual mode.

NGE ! DA •

R

Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT reactor (indicated by level switch LS201-29), and the water temperature is below 60 °C. All necessary items – cooling water flow, water temperature, and power management – must be supervised and verified by the authorized trained personnel operating the system. Inappropriate operation of this function could seriously damage the equipment and injure personnel.

Follow the steps below: 1.

Go to page 1.1 Overview. Press the Manual function button to activate manual mode.

2.

Press the AOT image. Result: The AOT popup opens. (See description on page 53.)

3.

Select which AOT reactor to operate in the AOT number entry field.

4.

Open, in stated order, the following valves to fill the AOT reactor with water: 201-19, 404-36 and 403-35. Result: The AOT reactor is now filled with water through the cooling water line 403.

5.

Wait until the AOT reactor is filled with water, indicated by the level switch (LS201–29) turning green.

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6.

Operating instructions

4.13

Set ship specific component ID

Press the LPS control button. Result: The LPS control popup is displayed for selected AOT reactor.

3 LPS Manual popObe

7.

Press the Manual mode button to enable manual operation of the UV lamps.

8.

Operate lamps by pressing one of the following buttons: Start all LPS units. Stop all LPS units. LPS1-16: Start / stop individual lamps. Each lamp power supply (LPS) powers to corresponding UV lamp. The buttons toggles between started and stopped. Place the AOT and the LPS control popups side to side to see that the lams are started. UV lamp stauts: Grey = Stopped; Green = Started; Yellow = Starting.

9.

If desired, the UV lamps can be dimmed manually: Press the LPS status button in the AOT reactor popup. Press the Manual output filed, and enter desired percentage between 50 and 100 %. The LPS will give the entered percentage of full effect to the UV lamps. This is indicated in the Power output field.

10. Press the Stop all LPS units button. Result: Any lit UV lamps are stopped and the popup is closed. 11. Press the Close button to close the popup. 12. Press the Manual function button to exit manual mode. Result: All manually operated components are restored to standby status.

4.13 Set ship specific component ID Follow this instruction to set ship specific IDs for valves and pumps. The ID will be visible in page 1.1 Overview and popups for the components. Book No.9010182 02, rev. 0

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4.14

Export control system log files

4

Operating instructions

Preparations and conditions •

IDs are only displayed in the control panel it is entered. If desired the settings can be entered in remote control panels (optional).

•

IDs are not included in the backup of control system settings.

Follow the steps below: 1.

Go to page 1.1 Overview.

2.

Press desired component. Result: A popup is opened.

3 ShipIDComp

Example: Popup with ship specific ID. Entered ID is displayed on the component to the right.

3.

Press the input field at the bottom.

4.

Use the keyboard to enter an ID. Press Enter to finish. Result: The name is saved and visible in page 1.1 Overview and the popup. .

4.14 Export control system log files Follow this instruction to copy control system information as a text file to a USB memory. The text file can then be analyzed either in Excel (or similar tools) or in Visualog. Visualog is a tool designed to present and analyze the information from the PureBallast log files. The following information can be exported:

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4.14

Export control system log files

Information to be exported

Description

Event log

The event log includes all important events in the PureBallast system. The log also include components connected via the log box. Intended to be used mainly by service technicians.

Event log Certificate

Contains a selection of the complete event log, relevant to comply with the IMO regulations.

Alarm history

A list of all alarms and warnings that has been issued from the control system. Intended to be used mainly by service technicians.

For specific information about logged events, see section List of logged information on page 89. Preparations and conditions •

Events are only copied, hence they will remain in the control system.

•

Required USB memory capacity is indicated in the Export PLC events popup.

•

The easiest way of reading the log file is to use the program Visualog, but the file can also be read in Exel. See Read event log in Excel below.

Follow the steps below: 1.

Go to page 4.1 System info.

2.

Press the Export button in page section Export log files. Result: Popup Export log files is displayed.

3 ExportLog

3.

Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet door.

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4.15

4.

Set control panel IP address

4

Operating instructions

Chose one of the following alternatives to decide time interval for the information to be copied: •

Accept suggested default time interval in the Start and End fields. Default start date is the oldest file in the system, and default end date is today’s date.

•

Select the Specify time interval box, and enter desired interval in the Start and End fields.

5.

Press one of the following function buttons: Events, Cert events or Alarms. Result: The information is copied to the USB memory indicated by a green checkmark on the button during copying.

6.

Wait for the message "Export OK" to appear. If desired, export next category of events using the function buttons. Result: A folder named PureBallast has been saved to the USB. It contains three sub folders: Alarm, Cert and Event. The folder corresponding to your export choices contains a CSV file.

7.

Press Close and remove the USB memory

4.14.1 Read event log in Excel Follow this instruction to read event logs in Excel. Note: In Excel, time and date is expressed as seconds since 1970-01-01. This instruction will help you to display date and time in clear figures. Also, events are displayed with their event code. For reference, see section Event log on page 89. Preparations and conditions •

Event log must have been downloaded.

Follow the steps below 1.

Open the event log in Excel.

2.

Add two new columns to the furthers left. (They will become new column A and B.)

3.

Write “1970-01-01” in cell H1. Write “=A2” in cell B2.

4.

Copy cell B2 to all lines in column B.

5.

Write “=C2/(60*60*24)+$H$1” in cell A2. (It is important that all characters are correct, so it is better to type the formula rather than copying this text.)

6.

Copy cell A2 to all lines in column A. Result: Date is displayed in Column A as YYYY-MM-DD. Time is displayed in column B as HH:MM:SS. Note: If date and time does not show correct, format the cells as date and time. To do this: Select the cells, right click on the cells. In tab Number, select date/time and select the format it shall be displayed in.

4.15 Set control panel IP address Follow this instruction to set IP address for the main panel and the remote control panels (optional). Preparations and conditions • 74

This setting shall be done for all panels installed. Book No.9010182 02, rev. 0

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Operating instructions

4.15

Set control panel IP address

•

These instructions require login level AlfaLaval.

•

Port 1 must be used for the Ethernet cable at the backside of the panel. It is marked with the symbol below.

3 USB

Follow the steps below: 1.

Go to page 4.1 System info.

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.

3 IPaddress

4.

In the Port 1 tab select the radio button Specify an IP address. Enter the IP address according to the list below. Also check that correct setting is done for Port 2 in the Port 2 tab.

3 IPaddress

Note: Only the IP address shall be changed. 5.

Press OK.

6.

Repeat this instruction for all installed control panels, both main and remote control panels, if installed.

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4.16

7.

Set remote control panel communication

4

Operating instructions

Follow the instruction Set remote control panel communication to activate remote control panel.

4.16 Set remote control panel communication Follow this instruction to connect remote control panels (optional) to the PLC. Preparations and conditions •

These instructions require login level Advanced operator or higher.

•

The same setting shall be done for all panels installed.

•

IP addresses must have been set according to instruction Set control panel IP address.

•

Main control panel and remote control panel 1 (192.168.0.11) are added as default . If no remote control panelse is used, address 192.168.0.11 shall be removed.

•

All remote control panels must be on and connected with an Ethernet cable.

Follow the steps below: 1.

On the main panel in the control cabinet: Go to page 4.1 System info.

2.

In the Remote control panels box, press the Set button. Result: The Remote panels setting popup is displayed.

3 RCP communication

3.

Select an available remote control panel in the left hand side.

4.

Press the >> button. Result: The panel is connected and moved to the right hand side. Note: Server port shall always be “1001”.

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Test remote interface communication

5.

Press the Panel alias field for the new control panel. Use the keyboard to enter a name, for example the location it is placed. Note: Panel alias for all control panels shall be entered (with the same wording) in all panels to be displayed in a correct way.

6.

Press the save (diskette) icon. Result: The information is saved and the popup is closed.

7.

Repeat step 4–7 to connect more remote control panels.

8.

Repeat this entire instruction for all installed panels.

Delete a remote control panel If remote control panels are not used, any added control panels shall be deleted from the list. To delete a connected panel: Select it a panel in the hand side and press the delete (X) icon. If a keyboard is displayed, pres Esc to remove it.

4.17 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 5.7 Remote interface.

2.

Set parameters to match ISCS’s RTU server data according to the information in chapter 4. Parameters, section 5.7 – Remote interface.

4.18 Test remote interface communication Follow this instruction to test that the remote interface (optional) communication between PureBallast’s PLC and the ISCS is correct and functioning. Test communication The first test is to see that the two systems communicate. 1.

Go to page 4.5 Remote interface 1. Make sure that the system is not in test mode (no checkmark on the button). If not, press the Test mode button to deactivate it. Make sure that Local operation is activated. If not, press the Local function button.

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2.

Test remote interface communication

4

Operating instructions

Check that the heartbeat signal is updated in both systems (+006 and +077). Also check that values are read from the PureBallast system, for example temperature (address +116 and +117). This will confirm that the systems communicate.

Test values sent from PureBallast to ISCS Values are entered and displayed in the control system as actual values, but are sent to ISCS using the binary numeral system. This information is found in group Data to ISCS and Cmd/status to ISCS on page 4.5 Remote interface 1, and is indicated by a unit (m3, hour, second, kW etc). Addresses with special conditions The following addresses does not display correct values in page 4.5: •

+050 Process volume

•

+114/124/134 AOT reactor temperature for AOT reactor 1, 2 and 3

•

+115/125/135 LDC water temperature for AOT reactor 1, 2 and 3

•

+052 System pressure

•

+063 Filter differential pressure

•

+064 Filter inlet pressure V201–71 (Hydac filter)

•

+065 Filter outlet pressure V201–72 (Hydac filter)

•

+066 V201-8 setpoint

•

+057/+058. Current time

For detailed information, see the directory of addresses. Follow the steps below: 1.

Press the Remote function button. Result: Test mode is activated enabling that communication is sent between the systems without actually affecting the control system (start processes etc). This also result in alarm A93 Heartbeat signal missing. This alarm shall be ignored during this test.

2.

Enter actual values in the in the input field for the address to send simulated information to the ISCS. Information in decimal form, for example processed volume, is written as actual values. Information in binary form, for example command status, is written as a bit pattern. The key for the bit pattern is found in chapter 6. Installation description and drawings, section System interfaces.

3.

Make sure that values and status information is displayed correspondingly in the ISCS.

4.

Repeat the simulation for the information you which to test. Note: Only implemented signals needs to be tested.

Test commands from ISCS to PureBallast In the ISCS, activate input commands corresponding to the addresses displayed in page 4.5. (Note that address 006 does not need to be tested; it was tested at the beginning of this procedure.) 1.

Activate a command from ISCS, according to the HMI implementation.

2.

Make sure that the command is received in page 4.5. Use the directory of addresses to see that the bit pattern is updated correctly.

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3.

Operating instructions

4.19

Simulate power request

In the control panel, restore all changed values after the communication test. If not, commands might be executed involuntarily, when the system is set to online again. Most important is that address 001 displays ”00000000”.

Test alarms and warnings Alarms and warnings are tested by simulation in control page 4.5 Remote interface 1 and 4.6 Remote interface 2. Use the alarm list to identify addresses and bit patterns for the alarms. You want to simulate alarm W40 (Process pressure too low). When you find W40 in the table, you use the column heading to see which address the alarm shall be sent to and the row heading to see which bit in the bit pattern that shall be high. For W40 the signal shall be sent to address +902, and bit 12 shall be high. Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first digit from right is counted as zero, second digit counted as 1 etc). This gives the following bit pattern: 0010000000000000. AOT reactor alarms/warnings: Each installed AOT reactor has a unique address: •

AOT reactor 1/ LDC 1: Address +910 – 912

•

AOT reactor 2 / LDC 2: Address +913 – 915

•

AOT reactor 3 / LDC 3: Address +916 – 918

Follow the steps below: 1.

Enter the desired bit pattern in the input field for the address.

2.

Make sure that the alarm/warning is indicated in ISCS.

3.

If common alarm and warnings are used, make sure that address +070:7 and +070:8 are updated. It is only necessary to check this for the first alarm.

4.

Clear the bit pattern in the input field.

5.

Repeat the simulation for those alarms/warnings you which to test.

6.

Press the Test mode button to set the system in online mode (no check mark on the button). Press the Remote function button if you want to activate remote control.

4.19 Simulate power request Follow this instruction to test the power management signals if PureBallast is integrated with the vessel’s power management system. This instruction can also be used in manual mode during faultfinding. Preparations and conditions •

This instruction requires login level Advanced operator or higher.

Follow the steps below: 1.

Go to page 1.4 Power request. Press the Manual function button. Result: The control system is set in manual mode, indicated by a green checkmark on the button.

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Update PLC software

4

Operating instructions

2.

Press the hand button in the Request column for a row with power step for desired number of AOT reactors. For details, see description of page 1.4 – Power request.

3.

Press the Request button for the row to simulate power request signal. Result: Status is updated to “Requested” in the Request column.

4.

Wait until the status is updated to “Yes” in the Granted column.

5.

Press the hand button in the Status column.

6.

Press the Set run button to simulate running signal. Result: Status is updated to “Running” in the Status column.

7.

Press the Set run button to deactivate the simulate running signal.

8.

Press the Manual function button to exit manual mode.

4.20 Set default parameters Follow this instruction to set or reset all parameters in the control system to the factory set default values. Preparations and conditions •

This operation requires login level Advanced operator or higher.

Follow the steps below 1.

Go to page 4.1 System info.

2.

Press the Default parameters button in page section Parameters. Result: A popup is displayed.

3.

Press Yes in the popup. Result: All parameters are reset.

4.21 Update PLC software Follow this instruction to update the PLC software for the control system. Preparations and conditions •

Take a backup according to instruction Export control system log files on page 72. The files are required to be saved for at least 24 months. The log files are erased when the software is updated.

•

Take a backup according to instruction Backup control system settings. Note that this backup is not used to reload settings, it is only a safety backup.

•

We recommend that a screen dump is taken for all parameter pages. (To do that: Insert a USB memory in USB panel port on the cabinet door and press function button Utilities, and Print for all pages.) Alternatively, take a photo. This will facilitate resetting of the parameters.

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Operating instructions

4.22

•

The release notes must have been read for the version to be installed.

•

Flash card with correct version of the PLC software.

Install TA150 firmware

Follow the steps below 1.

Shut off the power to the control cabinet using the main breaker on the side of the cabinet.

2.

Pull out the Ethernet cable from port IF2 ETH in the PLC module.

3.

Turn on the power to the control cabinet and wait for the panel to restart. Let the power to the control cabinet remain on. Ignore the message “Disconnected from remote alarm server”, it is due to the unconnected Ethernet cable. It is reconnected at the end of the Update HMI software instruction.

4.

Next step is to install TA150 firmware, if needed. If not, next step is to install the HMI software.

4.22 Install TA150 firmware Follow this instruction to update the TA150 firmware for the control panel. Preparations and conditions •

USB with correct version of the software.

Follow the steps below 1.

At the rear side of the main control panel: Pull out the power cable from the 24V DC port. Open the small cover on the rear side. Turn DIP switch 1 to position ON.

7BeijerMODE

2.

Insert a USB memory with the TA150 firmware in USB panel port on the cabinet door. Reconnect the power.

3.

Wait for requests to update and delete project. Answer Yes to both. (If you don’t get the question, set DIP switch to OFF, and try again. Or copy the files to another type of USB memory.) Result: The new software is updated to the panel.

4.

Wait for message: “Remove USB memory to continue”. Remove the USB.

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4.23

Update HMI software

4

Operating instructions

5.

Wait for message: “Please reboot panel to complete update”. Pull out the power cable and reconnect it to restart the panel. (If the reboot request does not appear on the screen (some older panels freeze), pull out the power cable and reconnect it to restart. When the panel restarts, the reboot request will not appear, since the panel was already restarted.)

6.

When the panel has restarted, tap the screen within 10 seconds. Press Touch calibrate: Follow the instructions on screen.

7.

In the menu displayed: Press IP settings, and set according to instruction Set control panel IP address on page 74. (This must be done, since the older IP setting was deleted during installation of the new TA150 firmware.) . The firmware is now installed.

8.

Let the panel remain with the menu displayed and the DIP switch in position ON.

9.

Next step is to install the HMI software on the control panel.

4.23 Update HMI software Follow this instruction to update the HMI software on remote control panels after the PLC software has been updated, or after the control panel firmware has been updated. Preparations and conditions •

USB with correct version of the software. Note that the same version must be used for the HMI and PLC software (same version number).

Follow the steps below If you have installed TA150 firmware on the control panel, go directly to step 4. 1.

At the rear side of the main control panel: Pull out the power cable from the 24V DC port. Open the small cover on the rear side. Turn DIP switch 1 to position ON.

7BeijerMODE

2.

Re-connect the power cable and wait for the panel to restart. (If the system requests a touch calibration, perform it.)

3.

Touch the screen to display a menu.

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Operating instructions

4.24

Calibrate the control panel’s touch screen sensibility

4.

Press Erase project in the menu. Answer Yes in the popup. Wait for the popup to close.

5.

At the rear side: Pull out the power cable from the control panel, turn DIP switch 1 to position OFF.

6.

Insert a USB memory with the HMI software in USB Panel port on the cabinet door. Reconnect the power.

7.

Wait for the message “Copy project from USB”. Press Yes.

8.

Wait until the program is started and page 1.1 Overview is displayed. Ignore the message “Disconnected from remote alarm server”, it is due to the unconnected Ethernet cable.

9.

Pull out the USB memory.

10. If remote control panels are installed, repeat this instruction for all remote control panels. Do not forget to update TA150 firmware if needed. 11. Make sure that the CF light on the PLC module is green. (It takes approximately 10 minutes from the PLC software is loaded.) 12. Insert the Ethernet cable in port IF2 ETH in the PLC module. 13. Restart the system: Shut off the power to the control cabinet using the breaker at the side, and then turn it on again.

4.24 Calibrate the control panel’s touch screen sensibility Follow this instruction to improve the touch precision on the screen, if it is hard to hit buttons and icons with precision. Follow the steps below 1.

Pull out the power cable from the 24V DC port on the rear side of the control panel.

2.

Open the small cover on the rear side. Turn DIP switch 1 to position ON.

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4.26

Restore control system settings

4

Operating instructions

3.

Re-connect the power cable. Wait for a cross is displayed on the screen.

4.

Press the cross until it changes position. Repeat until the menu is displayed again. Result: Calibration is ready.

5.

Pull out the power cable from the 24V DC port.

6.

Turn DIP switch 1 to position OFF.

7.

Re-connect the power cable.

4.25 Backup control system settings Follow this instruction to export all settings made in the control system to a backup on a USB memory. Alsmost the same information is saved as history files, appart from that parameter settings are saved here and alarms and trend history is saved in the control system history files. The following information is saved: •

Parameter settings. Saved in file Parameters.csv.

•

Audit trail (tracking of actions in the control system, e.g. acknowledged alarms, changed parameter values). Saved in file AuditTrail.sdf.

•

Parameters. It is only possible to restore parameters to the same version of the PLC software as the back-up was taken from.

•

Settings for trend pages, e.g. min and max values for different components. Saved in file ValueTrendLegend.xml.

•

Notpad.txt. Can be used to make notes for the backup.

Follow the steps below 1.

Go to page 4.1 System info.

2.

Insert a USB memory in USB panel port on the cabinet door.

3.

Press the Backup button in page section Backup and restore, Settings to/from HMI USB. Result: A popup is displayed and the process is started. All activities are displayed as the occur. Read the final line of list before closing the popup: Important information might be displayed.

4.

Wait for the OK / Close button to turn blue again. If the backup was successful, the last line shall state "Backup done". Result: A folder named PureBallast backup has been downloaded containing the backup files.

5.

Remove the USB memory.

4.26 Restore control system settings Follow this instruction to restore all control system settings, previously saved to a USB memory. This includes parameters and settings for the trend pages 3.1 — 3.5. Preparations and conditions 84

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Operating instructions

4.27

Export control system history files

•

This operation requires login level Advanced operator or higher.

•

Parameters can only be restored to the same version of the PLC software.

•

A USB memory with backup files. When the files where backuped, the backup files where saved in a folder named “PureBallast Backup”. For information about backup files, see section “Backup and restore” in the page description for 4.1 System info, section on page 38.

•

This method shall not be used to restore parameter settings after software update. Instead, follow instruction Update PLC software using a flash card.

•

If you do not wish to update a certain type of setting, remove the specific file from the USB memory before inserting the USB memory in the USB panel port on the cabinet door.

Follow the steps below 1.

Go to page 4.1 System info.

2.

Insert a USB memory in USB panel port on the cabinet door.

3.

Press the Restore button in page section Backup and restore, Settings to/from HMI USB. Result: A popup is displayed and the process is started. All activities are displayed as the occur.

4.

Wait for the OK / Close button to turn blue again.

5.

Read the final line of list before closing the popup: Important information might be displayed. If the restore was successful, the last line shall state "Restore done".

6.

Press the OK button on the popup and remove the USB memory.

7.

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

4.27 Export control system history files Follow this instruction to export all settings made in the control system to a backup on a USB memory. Alsmost the same information is saved as history files, appart from that alarms and trend history is saved here and parameter settings are saved in the control system settings. The following information is saved: •

Database, including alarm history, trend history etc. Saved in file Database.sdf.

•

Audit trail (tracking of actions in the control system, e.g. acknowledged alarms, changed parameter values). Saved in file AuditTrail.sdf.

•

Settings for trend pages, e.g. min and max values for different components. Saved in file ValueTrendLegend.xml.

•

Notpad.txt. Can be used to make notes for the backup.

Preparations and conditions •

This operation requires login level Operator or higher.

Follow the steps below 1.

Go to page 4.1 System info.

2.

Insert a USB memory in USB panel port on the cabinet door.

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PID calibrate system

4

Operating instructions

3.

Press the Backup button in page section Backup and restore, History to HMI USB. Result: A popup is displayed and the process is started. All activities are displayed as the occur. Be sure to read the final line of list before closing the popup: Important information might be displayed.

4.

When the message “Export done” is displayed, press the OK button on the popup. Result: A folder called PureBallast Export is created on the USB memory.

5.

Remove the USB memory.

4.28 PID calibrate system PID calibration is performed to fine tune the system so it runs with a steady and even flow and pressure. During ballast and deballast operation, the control valve is PID regulated based on input from the flow transmitter FIT201-1 to maintain stable flow. Desired flow is defined as selected certified flow for the operation minus the Undershoot percentage set in parameter p111. During backflush, the control valve is PID regulated based on input from the pressure transmitter PT201-16 to maintain stable pressure for efficient backflush. Desired pressure is defined in parameter p304.

4.28.1 Calibrate pressure controlled regulation The purpose is to adjust the movement of V201-8 when it changes from flow controlled regulation to pressure controlled regulation which it does during backflushing of the filter. The first goal is that the valve travels as fast as possible to a steady position where it creates required pressure (as defined in parameter p304). The second goal is to shorten the time from backflush trigger to start of actual backflush. This is done by shortening the time in p310 (Backflush initial delay) that is done after the movement of V201-8 has been calibrated. Preparations and conditions •

This operation requires login level AlfaLaval.

•

All components on page 3.1 Trend (15 min) shall be selected for plotting, and FIT201-1 shall be used for Y axis selection.

Follow the steps below: This instruction shall be read together with the example after the instruction. 1. Perform a backflush. 2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8. Before the backflush, the valve shall move as fast as possible to a steady position where it creates required pressure. If not, parameter p166 shall be adjusted. 3. Adjust parameters, and perform a new backflush. 4. See if the curve has improved. Repeat until satisfactory result has been achieved.

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4.28

PID calibrate system

5. See if the time between backflush initiation and backflush can be shortened . If possible, adjust parameter p310. See parameter p310 in the example below. Example In this example, five backflushes are performed. After the first four backflushes, the PID parameters where changed for pressure regulation to adjust the movement of the control valve V201-8 before the backflush. The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated by the movement of the backflush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated by the blue line. 1st backflush

Parameter p166 is set to 0.30. But it takes too long time for V201-8 to get into position to create desired pressure (1). The curve slops downwards in a long bend, which means that it takes time for V201-8 to find correct position. 2nd backflush Parameter p166 was adjusted to 0.6. This made the valve movement much faster in the beginning, shown by the steep curve at the beginning. But then a more slow regulation starts, shown by the soft slope (2). This was a change for the better, but not enough. 3rd backflush Parameter p166 was increased to 1.2 which resulted in a satisfactory valve movement (3): A fast movement, followed by a minor adjustment. A small overcompensation can be noted (curve goes too low), that might be adjusted by decreasing the value to 1.1. 4th backflush During the first backflushes, parameter p310 was set to 60 seconds. The parameter defines time between a backflush is triggered and it actually starts. But now, when V201-8 is calibrated, this time can be shortened. Before the fourth backflush parameter p310 is set to 15 seconds. The shortened time span is indicated by the braces in the illustration. 5th backflush No parameter was changed. This backflush is only showed to confirm that the parameter setting is OK and that the curve (5) for V201-8 is basically the same as for backflush three and four (3 and 4).

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4.28

PID calibrate system

4

Operating instructions

3 CalibExample

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5 List of logged information Alarm history and important events are logged in the control system. The log also include components connected via the log box (optional). The control system store all alarms and relevant events for at least 24 months. The memory has a vast safety margin but when it is full, data will be deleted starting with the oldest data. Logged information can be exported to a USB memory stick. See Export control system log files on page 72. Event log certificate: Contains events relevant to the IMO certificate. These events are stored for 24 months. Events included are equal to the events that are GPS stamped in the table below, with exception for events regarding the log box (5010—5220).

5.1

Event log

The table below shows which information that is saved in the log file. The GPS stamp column indicates if the event is stamped with GPS position (Y=yes, N=no). Event code

Description

GPS stamp

10 Operator command, start Ballast is issued

Y

20 Operator command, start deballast is issued

Y

30 Operator command, start CIP is issued

N

40 Operator command, stop process is issued

Y

50 Operator command, initiate pause is issued

Y

60 Operator command, resume from pause is issued

Y

70 Operator command, set certified flow to [x] m3/h

N

100 PureBallast is set in mode Manual by operator

N

110 Heeling (internal transfer) mode request issued by external

Y

120 Heeling (internal transfer) mode request cancelled by external

Y

130 Additional (external) bypass of PureBallast is detected open

Y

140 Additional (external) bypass of PureBallast is detected closed

Y

150 Feedback received, "overboard valve is OPEN"

Y

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Event log

Event code

90

5

List of logged information

Description

GPS stamp

160 Feedback received, "BW-pump is running"

N

170 External Shutdown of PureBallast issued

N

190 PureBallast is in mode Standby

N

210 PureBallast is in mode Start-up Ballast

N

220 PureBallast is in mode Full Ballast

N

230 PureBallast is in mode Pause Ballast

N

240 PureBallast is in mode Backflush

N

250 PureBallast is in mode Stop Ballast

N

260 PureBallast is in mode Start-up Deballast

N

270 PureBallast is in mode Full Deballast

N

280 PureBallast is in mode Pause Deballast

N

290 PureBallast is in mode Stop Deballast

N

300 PureBallast is in mode CIP, AOT [x, y, z ...] x, y, z ...= units that has been subjected to CIP

N

310 PureBallast is in mode E-stop

N

320 PureBallast has been powered off for [x]days:[y]hrs:[z]min Time of how long the power has been switched off

Y

330 Amount (m3) of ballast intake treated according to standard

Y

331 Amount (m3) of ballast intake treated. Time interval according to parameter p161.

Y

340 [X] m3 of ballast discharge treated according to standard

Y

341 [X] m3 of ballast discharge treated. Time interval according to parameter p162.

Y

350 V212-31 bypass valve in open position

Y

360 V212-31 bypass valve in closed position

Y

370 Request sent to ISCS; open overboard/outlet valve

N

380 Request cancelled to ISCS; open overboard/outlet valve

N

390 Request sent to ISCS; start BW-pump

N

400 Request cancelled to ISCS; start BW-pump

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List of logged information

Event code

Description

5.1

Event log

GPS stamp

410 Power requested sent

N

420 Power granted received

N

430 Power running sent

N

450 Pure Ballast is shut down due to failure

Y

460 Additional (external) bypass 1 is detected open

Y

470 Additional (external) bypass 1 is detected closed

Y

480 Additional (external) bypass 2 is detected open

Y

490 Additional (external) bypass 2 is detected closed

Y

500 Additional (external) bypass 3 is detected open

Y

510 Additional (external) bypass 3 is detected closed

Y

520 AOT 1 UV sensor low level

Y

530 AOT 2 UV sensor low level

Y

540 AOT 3 UV sensor low level

Y

640 AOT 1 UV sensor value: [X] W/m2

Y

650 AOT 2 UV sensor value: [X] W/m2

Y

660 AOT 3 UV sensor value: [X] W/m2

Y

700 AOT1 LPS power % to UV lamps

Y

710 AOT2 LPS power % to UV lamps 720 AOT3 LPS power % to UV lamp 1152

AOT1 UV intensity low. System flow reduced.

1153

AOT1 UV lamp fail. System flow reduced.

Y

2153 AOT2 UV lamp fail. System flow reduced. 5010 Log box: Valve V01 position change: [X]. 1=Closed. 0=Not closed.

Y

5011 Log box: Valve V01 position change: [X]. 1=Open. 0=Not open.

Y

5020 Log box: Valve V02 position change: [X]. 1=Closed. 0=Not closed.

Y

5021 Log box: Valve V02 position change: [X]. 1=Open. 0=Not open.

Y

5030 Log box: Valve V03 position change: [X]. 1=Closed. 0=Not closed.

Y

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Event log

Event code

5

List of logged information

Description

GPS stamp

5031 Log box: Valve V03 position change: [X]. 1=Open. 0=Not open.

Y

5040 Log box: Valve V04 position change: [X]. 1=Closed. 0=Not closed.

Y

5041 Log box: Valve V04 position change: [X]. 1=Open. 0=Not open.

Y

5050 Log box: Valve V05 position change: [X]. 1=Closed. 0=Not closed.

Y

5051 Log box: Valve V05 position change: [X]. 1=Open. 0=Not open.

Y

5060 Log box: Valve V06 position change: [X]. 1=Closed. 0=Not closed.

Y

5061 Log box: Valve V06 position change: [X]. 1=Open. 0=Not open.

Y

5070 Log box: Valve V07 position change: [X]. 1=Closed. 0=Not closed.

Y

5071 Log box: Valve V071 position change: [X]. 1=Open. 0=Not open.

Y

5080 Log box: Valve V08 position change: [X]. 1=Closed. 0=Not closed.

Y

5081 Log box: Valve V08 position change: [X]. 1=Open. 0=Not open.

Y

5090 Log box: Valve V09 position change: [X]. 1=Closed. 0=Not closed.

Y

5091 Log box: Valve V09 position change: [X]. 1=Open. 0=Not open.

Y

5100 Log box: Valve V10 position change: [X]. 1=Closed. 0=Not closed.

Y

5101 Log box: Valve V10 position change: [X]. 1=Open. 0=Not open.

Y

5110 Log box: Valve V11 position change: [X]. 1=Closed. 0=Not closed.

Y

5111 Log box: Valve V11 position change: [X]. 1=Open. 0=Not open.

Y

5120 Log box: Valve V12 position change: [X]. 1=Closed. 0=Not closed.

Y

5121 Log box: Valve V12 position change: [X]. 1=Open. 0=Not open.

Y

5130 Log box: Valve V13 position change: [X]. 1=Closed. 0=Not closed.

Y

5131 Log box: Valve V13 position change: [X]. 1=Open. 0=Not open.

Y

5140 Log box: Valve V14 position change: [X]. 1=Closed. 0=Not closed.

Y

5141 Log box: Valve V14 position change: [X]. 1=Open. 0=Not open.

Y

5150 Log box: Valve V15 position change: [X]. 1=Closed. 0=Not closed.

Y

5151 Log box: Valve V15 position change: [X]. 1=Open. 0=Not open.

Y

5160 Log box: Valve V16 position change: [X]. 1=Closed. 0=Not closed.

Y

5161 Log box: Valve V16 position change: [X]. 1=Open. 0=Not open.

Y

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Event code

Description

5.1

GPS stamp

5170 Log box: Valve V17 position change: [X]. 1=Closed. 0=Not closed.

Y

5171 Log box: Valve V17 position change: [X]. 1=Open. 0=Not open.

Y

5180 Log box: Valve V18 position change: [X]. 1=Closed. 0=Not closed.

Y

5181 Log box: Valve V18 position change: [X]. 1=Open. 0=Not open.

Y

5190 Log box: Pump 01 operation change: [X]. 1=Running. 0=Not running.

Y

5200 Log box: Pump 02 operation change: [X]. 1=Running. 0=Not running.

Y

5210 Log box: Pump 03 operation change: [X]. 1=Running. 0=Not running.

Y

5220 Log box: Pump 03 operation change: [X]. 1=Running. 0=Not running.

Y

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5.1

Event log

5

List of logged information

6 Detailed process description This section gives a detailed description of the PureBallast processes. The processes are divided into three main processes, with sub processes, with indications of automatic and manually initiated steps. All steps are not valid for all installations.

6.1

Standby mode

Standby mode is the starting point of PureBallast. Standby mode is active at system start-up or when no other process is active. From Standby mode, the following processes and sub processes can be started. •

Ballast

•

Deballast

•

CIP

•

Deactivate system

•

Change flow (set flow before a ballast or deballast process)

•

Manual mode.

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6.2

Ballast process

6.2

6

Detailed process description

Ballast process

The ballast process and sub processes are illustrated and described below. Note that the process can be stopped at any time.

3 BallastProcess

6.2.1

Ballast start-up

Purpose: To warm UV lamps under controlled conditions before water treatment. 1.

Operator starts the process from the control system.

2.

Request from control system to open overboard (outside PureBallast system). (Handled automatic, if external component signal is enabled.)

3.

Overboard valve opened by operator and confirmed in control system. (Handled automatic, if external component signal is enabled.) Component activities:

4.

96

•

- Start P401-1 (booster pump for LDC cooling water) (if used) - Open V403-35 (cooling water inlet) - Open V201-32 (filter outlet)

•

Start P403-1 (booster pump for reactor cooling water) (if used).

Power management Automatic power request from PureBallast to vessel’s power management system (if integrated).

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Detailed process description

5.

6.2

Ballast process

UV lamp warming Component activities:

6.

•

Open V404-36 (AOT reactor outlet, cooling water)

•

Open V201-19 (reactor inlet).

•

Start counter: CIP required.

Cooling water fills the AOT reactors. When filled, indicated by LS201-29: •

Start UV lamps (100 %).

•

Start counter: UV lamp runtime.

•

Start LDC fan.

•

Open V201-20 (reactor outlet)

•

Set V201-8 (control valve) to 50 %.

7.

Request from control system to start ballast water pump (outside PureBallast system). (Handled automatic, if external component signal is enabled.)

8.

Ballast water pump started by operator and confirmed in control system.

9.

Open V201-3 (filter inlet).

6.2.2

Full ballast

Purpose: To treat ballast water. 1. Component activities: •

- Start counter: Accumulated water - Stop P403-1 (booster pump for reactor cooling water) (if used)

•

- Close 403-35 (cooling water inlet) - Close V404-36 (AOT reactor outlet, cooling water) - When flow is established: Start automatic control of control valve (V201-8) based on input from the flow meter.

•

After 2 minutes in full ballast: Start power optimization based on input from UV sensor QT201–50.

6.2.3

Filter backflush

Purpose: To clean the filter when clogged. This sub process is either triggered by too high differential pressure or by time set interval. It can also be started manually. It is normally repeated several times during a ballast process. 1. Filter backflush triggered by high differential pressure over filter. Component activities: •

Start automatic control of control valve (V201-8) based on input from the pressure transmitter

•

Open V309-1

•

Start M709-42.

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Ballast process

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Detailed process description

2. Filter backflush is performed (1-100 seconds). Component activities: •

Stop M709-42

•

Close V309-1

•

Start automatic control of control valve (V201-8) based on input from the flow meter.

3. Differential pressure check. If necessary, the process is repeated.

6.2.4

Pause ballast (Heeling mode)

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

- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors - Stop counter: Accumulated water - Open V403-35 (cooling water inlet)

•

Start P403-1 (booster pump for reactor cooling water) (if used) - Close V201-3 (filter inlet) - Close V201-20 (reactor outlet) on running AOT reactors - UV lamps dimmed to 50 %

•

Close V201-8 (control valve).

5. System in pause mode 6.

Resume ballasting Operator resumes the ballast process manually. Component activities: •

Set V201-8 (control valve) to parameter set opening percent

•

UV lamps are lit at 100 %

•

Open V201-20 (reactor outlet) on running AOT reactors.

7. Request from control system to start ballast water pump” (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 8. BW pump started by operator and confirmed in control system. (Handled automatic, if external component signal is enabled.) •

98

Open 201-3 (filter inlet)

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Detailed process description

6.2

Ballast process

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

- Start counter: Accumulated water. - Stop P403-1 (booster pump for reactor cooling water) (if used)

•

- Close 403-35 (cooling water inlet) - Close V404-36 (AOT reactor outlet, cooling water) on running AOT reactors - Start automatic control of control valve (V201-8) based on input from the flow meter. - After 2 minutes in full ballast: Start power optimization based on input from UV sensor QT201–50.

6.2.5

Stop ballast

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

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

•

Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from pause mode

•

Stop counter: Accumulated water

•

- Close V403-35 (cooling water inlet), only needed if stop from pause mode - Set V201-8 (control valve) to parameter set opening percent. - Close V201-32 (filter outlet) Delay: the longes time between of p146 and p119.

•

UV lamps are lit at 100 % for 10 seconds, then switched off.

•

Stop counter: UV lamp runtime

•

- Close V201-19 (reactor inlet) - Close V201-20 (reactor outlet)

•

Automatic withdrawal of power allocation (if integrated).

2. Filter backflush Backflushing of filter starts, including the following activities: •

- Start automatic control of control valve (V201-8) based on input from the pressure transmitter - Open V309-1 - Start M709-42.

3. Backflush is performed. Approximate duration: 20 seconds. •

- Stop M709-42 - Close V309-1.

4. Request from control system to stop ballast water pump (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 5. BW pump stopped by operator and confirmed in control system. •

- Close V201-8 (control valve) - Close V201-3 (filter inlet).

6. Request from control system to close overboard. (Handled automatic, if external component signal is enabled.)

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6.3

Deballast process

6.3

6

Detailed process description

Deballast process

The deballast process and sub processes are illustrated and described below. Note that the process can be stopped at any time.

3 DeBallastProcess

6.3.1

Deballast start-up

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

- Start P401-1 (booster pump for LDC cooling water) (if used) - Open V403-35 (cooling water inlet)

•

Start P403-1 (booster pump for reactor cooling water) (if used).

4. Power management Automatic power request from PureBallast to vessel’s power management system (if integrated).

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Detailed process description

6.3

Deballast process

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

Open V404-36 (AOT reactor outlet, cooling water)

•

Open V201-19 (reactor inlet).

•

Start counter: CIP required.

6. Water fills the AOT reactors. 7. Component activities, when AOT reactors are filled, indicated by LS201-29: •

Start UV lamps (100 %).

•

Start counter: UV lamp runtime.

•

Start LDC fan.

•

Open V201-20 (reactor outlet)

•

Set V201-8 (control valve) to 50 %.

8. Request from control system to start ballast water pump (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 9. BW pump started by operator and confirmed in control system. Component activities: •

6.3.2

Open V201-9 (main inlet valve).

Full deballast

Purpose: To treat deballast water. 1. Component activities when minimum process flow established, indicated by FIT201-1: •

- Start counter: Accumulated water. - Stop P403-1 (booster pump for reactor cooling water) (if used)

•

- Close 403-35 (cooling water inlet) - Close V404-36 (AOT reactor outlet, cooling water) on running AOT reactors - When flow is established: Start automatic control of control valve (V201-8) based on input from the flow meter.

•

After 2 minutes in full ballast: Start power optimization based on input from UV sensor QT201–50.

6.3.3

Pause deballast (Heeling)

Purpose: To pause the deballast process temporarily. During pause, the lamps are cooled with cooling water, sea-to-sea. This mode is also used during heeling (internal transfer).

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6.3

Deballast process

6

Detailed process description

1. Operator pause the deballast process manually. Pause can also be initiated by an external signal, for example when heeling is initiated from the ISCS. In this case, the process is resumed automatically when the heeling signal is deactivated. Component activities: •

Set V201-8 (control valve) to parameter set opening percent

•

Open V403-35 (cooling water inlet)

•

- Start P403-1 (booster pump for reactor cooling water) (if used) - Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors.

2. Request from control system to stop ballast water pump (outside the PureBallast system control). (Handled automatic, if external component signal is enabled.) Component activities: •

-

Stop counter: Accumulated water Close V201-9 (main inlet valve) Close V201-8 (control valve) Close V201-20 (reactor outlet) on running AOT reactors UV lamps dimmed to 50 %.

3. System in pause mode 4. Resume deballasting Operator resume the deballast process manually. Component activities: •

Set V201-8 (control valve) to parameter set opening percent.

•

UV lamps are lit at 100 %

•

Open V201-20 (reactor outlet) on running AOT reactors.

5. Request from control system to start ballast water pump” (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 6. BW pump started by operator and confirmed in control system. Component activities: •

Open V201-9 (main inlet valve)

7. Component activities when minimum process flow established, indicated by FIT201-1: •

- Start counter: Accumulated water. Stop P403-1 (booster pump for reactor cooling water) (if used)

•

- Close 403-35 (cooling water inlet) - Close 404-36 (AOT reactor outlet, cooling water) - Start automatic control of control valve (V201-8) based on input from the flow meter. - After 2 minutes in full deballast: Start power optimization based on input from UV sensor QT201–50.

6.3.4

Stop deballast

Purpose: To stop the deballast process.

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Detailed process description

6.4

CIP process

1. Operator stops the ballast process manually. Component activities: •

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

•

Stop P403-1 (booster pump for reactor cooling water) (if used), only needed if stop from pause mode

•

Close V403-35 (cooling water inlet), only needed if stop from pause mode

•

Set V201-8 (control valve) to parameter set opening percent

•

Close V201-9 (main inlet valve) Wait for feed back “closed” or delay according to p 115.

•

UV lamps are lit at 100 % for 10 seconds, then switched off.

•

Stop counter: UV lamp runtime

•

- Close V201-19 (reactor inlet) - Close V201-20 (reactor outlet)

2. Request from control system stop ballast water pump (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 3. BW pump stopped by operator and confirmed in control system. •

Automatic withdrawal of power allocation (if integrated)

•

Close V201-8

•

Stop counter: Accumulated water.

4. Request from control system to close overboard. (Handled automatic, if external component signal is enabled.)

6.4

CIP process

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

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6.4

CIP process

6

Detailed process description

3 CIPprocess

6.4.1

Start CIP

1. Operator starts the CIP process manually. 2. Request from control system to open overboard valve (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 3. Overboard valve opened by operator and confirmed in control system.

6.4.2 1.

Component activities (in no specific order): •

104

Drain ballast water

-

Open V460-2 (CIP, drain valve) Open V321–2 (AOT reactor, upper CIP return valve) Open V320–4 (AOT reactor, lower CIP return valve) Open V571-1 (CIP, deaeration valve) Start P321-5 (CIP, water pump)

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Detailed process description

6.4

CIP process

2. Component activities, when AOT reactors are empty, indicated by LS201-29: •

-

6.4.3 1.

Stop P321-5 Close V571-1 (CIP, deaeration valve) Close V460-2 (CIP, drain valve) Close V321–2 (AOT reactor, upper CIP return valve) Close V320–4 (AOT reactor, lower CIP return valve).

Fresh water filling

Component activities: •

-

Open V571-1 (CIP, deaeration valve) Open V310-6 (CIP, AOT reactor fresh water filling) Open V321–2 (AOT reactor, upper CIP return valve) Open V320–4 (AOT reactor, lower CIP return valve).

2. Component activities, when AOT reactors are filled, indicated by LS201-29: •

-

6.4.4

Close V310-6 (CIP, AOT reactor fresh water filling) Close V571-1 (CIP, deaeration valve) Close V321–2 (AOT reactor, upper CIP return valve) Close V320–4 (AOT reactor, lower CIP return valve).

Fresh water draining

1. Component activities: •

-

Open V460-2 (CIP, drain valve) Open V571-1 (CIP, deaeration valve) Open V321–2 (AOT reactor, upper CIP return valve) Open V320–4 (AOT reactor, lower CIP return valve) Start P321-5 (CIP, water pump).

2. Component activities when AOT reactor is empty, indicated by LS201-29 + drain time (p200): •

-

6.4.5

Stop P321-5 (CIP, water pump) Close V571-1 (CIP, deaeration valve) Close V460-2 (CIP, drain valve) Close V321–2 (AOT reactor, upper CIP return valve) Close V320–4 (AOT reactor, lower CIP return valve)

CIP cleaning

1. Component activities: •

-

Open V320–2 (CIP outlet to AOT reactor) Open V320-4 (AOT reactor, lower CIP return valve) Open V321-2 (AOT reactor, upper CIP return valve) Open 321–4 Start P320-1 (CIP, liquid pump).

2. When AOT reactors are filled, indicated by LS201-29, CIP liquid is circulated for 15 minutes. Book No.9010182 02, rev. 0

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CIP process

6

Detailed process description

3. Component activities after finished CIP process . •

-

6.4.6

Stop P320-1 (CIP, liquid pump) Close V320-2 (CIP outlet to AOT reactor) Close V320-4 (AOT reactor, lower CIP return valve) Status update for the AOT reactor: CIP completed.

CIP draining

1. Component activities: •

Open V321-4 (CIP, return valve) Open V321–1 (CIP, outlet valve) - Open V321-2 (AOT reactor, upper CIP return valve) - Open V320-4 (AOT reactor, lower CIP return valve) - Start P321-5 (CIP, water pump).

2. Component activities, when AOT reactor is empty, indicated by LS201-29 + drain time (p200): •

-

6.4.7 1.

Stop P321-5 (CIP, water pump) Close V321-2 (AOT reactor, upper CIP return valve) Close V 321-4 (CIP, return valve) Close V321-1 (CIP, outlet valve).

Fresh water filling

Component activities: •

-

Open V571-1 (CIP, deaeration valve) Open V310-6 (CIP, AOT reactor fresh water filling) Open V321-2 (AOT reactor, upper CIP return valve) Open V320-4 (AOT reactor, lower CIP return valve).

2. Component activities, when AOT reactor is filled, indicated by LS201-29: •

Close V310-6 (CIP, AOT reactor fresh water filling)

•

Close V571-1 (CIP, deaeration valve) - Close V321-2 (AOT reactor, upper CIP return valve) - Close V320-4 (AOT reactor, lower CIP return valve).

6.4.8

Repeat

When CIP process is done for the first AOT reactor, the remaining AOT reactors with status CIP required are processed in the same way.

6.4.9

Filter preservation

Only performed if ballast has been performed since last filter preservation.

106

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1.

Detailed process description

6.5

Manual mode

Component activities when all required AOT reactors are processed: •

- Open V310-1 - Open V309-1 - Start M709-42.

2. Component activities after the filter is filled: •

- Stop M709-42 - Close V309-1 - Close V310-1.

3. Request from control system to close overboard valve (outside PureBallast system). (Handled automatic, if external component signal is enabled.) 4. Overboard valve closed by operator and confirmed in control system.

6.5

Manual mode

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

Operate components from the flow chart. Tap a component to operate it from the displayed popup window. The following components can be operated: valves, motors, UV lamps etc, digital output signals.

•

Operate and simulate power management.

The following limitations exist for manual mode: •

Requires login level 2. The Manual mode button is only displayed for login level 2.

•

Flow in pipes is not indicated in flow chart.

•

Can only be activate from standby mode.

•

No automatic processes can be run.

To activate: Press the Manual mode button in page 1.1 Flow chart and follow the instructions Operate UV components manually and Operate UV lamps manually. To deactivate: Press the Manual mode button again in page 1.1 Flow chart or log out. All forced outputs and manual changes are reset and the system goes to Standby mode.

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1 Quick guide to PureBallast operations 1.1

Introduction

This is a quick guide to the most common routines performed in the PureBallast control system. More detailed instructions are found in the PureBallast manual. This guide covers the following routines: •

Ballast and deballast

•

CIP clean AOT

•

Basic alarm handling

•

Save log file and parameters to USB memory

Preparations and conditions •

The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.

•

Flow must have been selected before a process can be started. If parameter p131 is activated maximum flow is automatically selected, and flow can only be changed during process according to instruction Change ballast / deballast flow on page . If parameter p131 is deactivated last selected flow is used. Otherwise, flow is selected on page 1.1 Overview or 1.2 AOT and flow selection.

•

There must be available power for the system. If power management is integrated, this will be done automatically. If power management is not integrated, confirm this manually.

1.2

Ballast and deballast

Follow the steps below 1.

Go to page 1.1 Overview

2.

Press the Ballast or Deballast function button. Comment: If the button is not blue, check that flow or AOT reactors have been selected

3.

Wait for the message “Open valves ...”. Open relevant valves and then press the button in the popup to confirm the action. (The popup is not displayed if the component feedback is integrated with the control system.)

4.

Wait for the message “Confirm ballast pump started”. Start the pump and then press the button in the popup to confirm the action. (The popup is not displayed if the component feedback is integrated with the control system.)

5.

When desired amount of water has been processed, press the function button Stop to end the process.

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1.4

CIP clean AOT

1

Quick guide to PureBallast operations

6.

Wait for the message “Close valves ...” and “Stop ballast water pump”. Handle accordingly. (The popups are not displayed if the component feedback is integrated with the control system.)

7.

Perform a CIP process if no operation is planned soon. A CIP process must be performed within 30 hours after operation.

1.3

Alarm handling

Follow this instruction to attend to alarms and to acknowledge them afterwards. For descriptions of alarms and trouble shooting, see chapter 5. Alarms and fault finding. An alarm is indicated by a audible signal and by a blinking warning icon in the control panel. Preparations and conditions •

Never reset an alarm without first finding and attending to the problem.

Follow the steps below: 1.

Go to page 2.1 Alarm list.

2.

Select an alarm by pressing the alarm row.

3.

If the process have stopped: Take action to eliminate what has caused the alarm.

4.

If the alarm is caused by a faulty AOT module, the ballast/deballast process has to be restarted with another AOT according to the Perform ballast instruction.

5.

If the process continues: Consider if the process shall be terminated. Take action to eliminate what has caused the alarm. Press the Ack selected or Ack all button after the problem has been dealt with.

1.4

CIP clean AOT

Preparations and conditions •

The system must be in standby mode. This means that this operation cannot be executed during ballast or deballast.

•

Complete status information regarding CIP is displayed in page 1.4 CIP status. The page displays remaining time for ongoing CIP cycles, remaining time before individual AOTs are required to be CIP:ed etc.

Follow the steps below 1.

Go to page 1.1 Overview.

2.

Press the function button CIP.

3.

Wait for the message “Open valves ...”. Open relevant valves and then press button in the popup to confirm the action. Result: The automatic CIP cycle starts. The CIP cycle takes about 25 minutes per AOT.

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4.

Quick guide to PureBallast operations

1.5

Export control system log files

Wait for the message “Confirm overboard valve closed”. Close the valve and then press button in the popup to confirm the action.

1.5

Export control system log files

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

Required USB memory.

Follow the steps below: 1.

Go to page 4.1 System info.

2.

Press the Export button in page section Export log files. Result: Popup Export PLC events is displayed.

3.

Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet door.

4.

Chose one of the following alternatives to decide time interval for the information to be copied: •

Accept suggested default time interval in the Start and End fields. Default start date is the oldest file in the system, and default end date is today’s date.

•

Select the Specify time interval box, and enter desired interval in the Start and End fields.

5.

Press one of the following function buttons: Events, Cert events or Alarms. Result: The information is copied to the USB memory indicated by a green checkmark on the button during copying.

6.

Wait for the message "Export OK" to appear. If desired, export next category of events using the function buttons. Result: A folder named PureBallast has been downloaded. It contains three sub folders: Alarm, Cert and Event. The folder corresponding to your export choice contains a CSV file.

7.

Prtess Close and remove the USB memory

Book No.9010182 02,

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Chapter: 4. Parameters System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

Introduction

5

2

Control system parameters

7

2.1

Setting parameters

7

2.2

Introduction to the parameter pages

8

2.3

Set parameters

8

2.4

Page 5.1 – Main parameters 1

10

2.5

Page 5.2 – Main parameters 2

14

2.6

Page 5.3 – AOT parameters

18

2.7

Page 5.4 – Filter parameters

22

2.8

Page 5.5 – CIP parameters

25

2.9

Page 5.6 – Installation parameters

26

2.10

Page 5.7 – Remote interface

29

3

4

Flow transmitter parameters

31

3.1

32

Check and set parameters

Lamp power supply (LPS) parameters

35

4.1

DIP switch settings

35

4.2

Change DIP switch setting

36

3

1 Introduction This chapter contains information about parameters in the control system and flow transmitter. It covers: •

Parameter page descriptions.

•

Parameter lists including information about setting range, default values etc.

Book No.9010182 02, rev. 0

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1

Introduction

2 Control system parameters This section describes all parameters set in the PureBallast control system. Preparations and conditions •

Parameters shall only be set when the system is in mode Standby.

•

Only authorized trained personnel must set parameters in the control system – both manual operations and parameter settings. The PureBallast equipment or connected equipment can be irreparably damaged if set or handled incorrectly. NOTE

•

To change system parameters, at least login level 2 Advanced operator is required. To get full access, login level 3 AlfaLava is required.

•

The parameter settings can be exported to a USB memory for safety backup, and be restored from a backup. See chapter 3. Operating instructions and control system description for instructions. Parameters are valid for PLC software version V3.0.2.

2.1

Setting parameters

General (non-installation specific) parameters are preset to function for all systems. They must only be adjusted, by Alfa Laval (or authorized trained personnel), if required by performance reasons or similar. The installation specific parameters are set to reflect the specific installation and shall normally only be checked and adjusted at first start up, during preparations for commissioning. The installation specific parameters are found in the pages listed below: •

•

Page 5.1 Main parameters 1. -

p126: LDC after-cooling.

-

p140–p144: Time-out for requests from PureBallast.

Page 5.2 Main parameters 2. -

•

All parameters on the page, except p168.

Page 5.3 AOT parameters: -

p200, p201, p208 and p216: Time-out parameters for draining and filling AOT reactor. These parameter are evaluated during the commissioning preparation test and adjusted if necessary.

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2.3

•

Set parameters

2

Control system parameters

Page 5.4 Filter parameters:

•

-

p304: Required pressure to start backflush (PT201–16). This parameter is calculated to reflect pressure in the specific installation.

-

p314: Filter type.

-

p306: Filter preservation time. This parameter is evaluated during the commissioning preparation test and adjusted if necessary.

-

p315: Filter size. Defines maximum capacity for installed filter.

Page 5.6 – Installation parameters. -

All parameters on the page, except p218 (Estimated UV lamp time) .

2.2

Introduction to the parameter pages

This section describes the principles for the control system parameters and the parameter pages. Parameters are roughly sorted by area, for example AOT reactor, filter and remote interface, but the sorting is not strict. Key to parameter numbers Control system parameters are identified by item numbers with the following syntax: pX00. p

stands for parameter

X

identifies the area/component the parameter controls. X can be 1 = Main parameters 2 = AOT reactor 3 = Filter 4 = CIP

00

unique number for the parameter.

2.3

Set parameters

Follow this instruction to set or change parameters. Preparations and conditions NOTE

•

Parameters shall only be set by Alfa Laval.

•

These instructions require login level 2 or 3. Level 2 gives access to set parameters, with exception from crucial parameters, which requires level 3.

Follow the steps below: 1.

8

Go to desired parameter page 5.1–5.7. Result: The page is displayed with all parameters listed with current setting and unit.

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2.

Control system parameters

2.3

Set parameters

To see allowed range (maximum and minimum values) and change setting, press the blue button (with the parameter ID). A button pair is displayed.

4 ParaIntervalSet

Press the ≥ sign to display range. Entered parameter value must be within defined setting range.

4 MinMax

3.

To set parameter, press 3.14 button. Result: A keyboard is displayed.

4.

Enter the setting and confirm by touching the Enter button. To close the keyboard without saving data, touch the Esc button. If the parameter is set with a drop down menu, select desired choice by touching the value. Result: The setting is saved directly, it is now safe to leave the page.

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2.4

Page 5.1 – Main parameters 1

2.4

2

Control system parameters

Page 5.1 – Main parameters 1

This section describes the main system parameters set in page 5.1 Main parameters 1.

4 5.1

The following information is displayed: ID

Parameter

p100

High pressure, shutdown trigger (PT201-16)

Default value

MinMax

Unit

Description

7.00

1–10

bar

Setpoint for shut down due to high pressure at PT201-16. Default value shall be used. (7 bar = 0.7 MPa)

p101

10

High pressure, warning trigger (PT201-16)

6.00

0–10

bar

Setpoint for warning due to high pressure at PT201-16. Default value shall be used. (6 bar = 0.6 MPa)

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Control system parameters

2.4

Page 5.1 – Main parameters 1

ID

Parameter

Default value

MinMax

Unit

Description

p103

Low pressure, warning trigger (PT201–16)

0,0

-1–2

bar

Setpoint for warning due to low pressure at PT201-16.

p105

Transition trigger, ballast flow established (FIT201-1)

p111

Undershoot certified flow

p113

Min % open for V201-8

(1 bar = 0.1 MPa) 50

10– 500

m3/h

Defines which flow that must be established, before the process goes from ballast start-up to full ballast.

5

0–80

%

Safety margin between defined max flow and actual max flow to avoid unnecessary shut down.

20

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. Min position during backflush is set in p312.

p115

Maximum travel time for valves

10

2–30

sec

Maximum time for V201–3 and V201–9 to go from opened to closed, and vice versa, before a warning is issued. Default value shall be used.

p116

Low flow, warning trigger (FIT201-1)

10

10–90

%

Set point for low flow warning, defined as percent of certified flow. This parameter shall be > 10 % to obtain efficient cooling.

p117

Max delay of CIP cycle, hours

6

0–24

hrs

Define max delay, in hours, before a CIP process must be performed after ballast or deballast. Default value shall be used.

p118

Max delay of CIP cycle, days

1

0–30

day

Define max delay, in days, before a CIP process must be performed after ballast or deballast. Default value shall be used.

p119

Valve travelling time for 201-8

5

1–10

sec

Maximum time for V201–8 to go from opened to closed, and vice versa, before a warning is issued.

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2.4

Page 5.1 – Main parameters 1

ID

Parameter

p120

V201–8 PID proportional gain

Default value 0.30

2

Control system parameters

MinMax

Unit

Description

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 – 1.5. The PID regulation during ballast and deballast is based on input from flow transmitter FIT201–1.

p121

V201–8 PID integral time

7.00

0–100

sec

Defines integral time (If) value used for PID regulation of V201–8 during ballast and deballast. Normal value: 5 – 12. For details, see p120.

p122

V201–8 PID derivative gain

0.0

0.0–100.0N/A

Defines derivate gain (Df) value used for PID regulation of V201–8 during ballast and deballast. Normal value: 0. For details, see p120.

p126

LDC after-cooling. (Stop delay for 401-1, if installed)

5

0–60

min

Defines how long after a ballast or deballast process the booster pump shall run to cool the LDC. Only used if parameter p129 is set to “Activated”.

p138

Timeout: Time in Pause before going to Stop

5

1–30

min

Defines maximum time a ballast and deballast process can be manually paused. After defined time, the process is stopped.

p140

Timeout: Request "Confirm overboard valve open"

5

1–30

min

Time the control system will wait for confirmation signal from ISCS, hard wire or manually in popup before displaying message that operation was not performed.

p141

Timeout: Request "Confirm ballast pump started"

5

1–30

min

Time the control system will wait for confirmation signal from ISCS, hard wire or manually in popup before displaying message that operation was not performed.

12

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Control system parameters

ID

Parameter

p143

Timeout: Power granted signal not received

2.4

Default value 60

Page 5.1 – Main parameters 1

MinMax

Unit

Description

1–300

sec

Time the control system will wait for confirmation signal from ISCS that the operation was performed. Only used if parameter p127 is set to Activated (Hardwire ranged or fixed).

60

30–300 sec

p144

Timeout: Start-up ballast flow established

p145

Sequence step delay

1

0–5

sec

Defines delay between each step in the process.

p146

System valve close delay

5

0–15

sec

Defines delay before AOT reactor is closed after the filter outlet has been closed during ballast operation. See Detailed process description in chapter 3.

p149

Timeout: Time in Auto pause before going to stop

10–300 sec

Defines maximum time a ballast and deballast process can be automatically paused by the system. Example: When process is paused during heeling.

45

Time the control system will wait for accepted minimum flow (p105) to be established before automatic stop.

After defined time, the process is stopped.

Book No.9010182 02, rev. 0

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2.5

Page 5.2 – Main parameters 2

2.5

2

Control system parameters

Page 5.2 – Main parameters 2

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

4 5.2

The following information is displayed: ID

Parameter

Default value

MinMax

Unit

Description

p127

Power management

Not used

N/A

Drop list

Defines if power management is used.

14

Alternatives: •

Not used

•

Hardwire ranged

•

Hardwire fixed

•

Remote interface (requires that p132 is activated)

Book No.9010182 02, rev. 0

2

Control system parameters

2.5

ID

Parameter

Default value

MinMax

Unit

p128

Max time communication loss PLC/remote interface

60

15–240 Sec

Page 5.2 – Main parameters 2

Description

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 chapter 6. Installation description and drawings, section Remote interface integration (optional). See address +006 and +047.

p129

Booster pump (P401-1) for LDC cooling water

Not used

N/A

Drop list

Defines if a booster pump (not part of Alfa Laval’s scope of suppy) is used to create sufficient cooling water flow to the LDC. Alternatives: Activated or Not used.

p130

Booster pump (P403-1) for reactor cooling water

Not used

N/A

Drop list

Defines if a booster pump (not part of Alfa Laval’s scope of suppy) is used to create sufficient cooling water flow to the AOT reactor. Alternatives: Activated or Not used.

p132

Remote interface via modubus

Not used

N/A

Drop list

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.

p135

External shut down signal

Not used

N/A

Drop list

Defines if an external shut down button (or signal) is installed. Purpose: Ongoing process is shut down and valves are returned to starting position as fast as possible. Alternatives: Activated or Not used.

p137

Hide Pause button

Not used

N/A

Drop list

Defines if the Pause button is visible or hidden in the control system. If activated, the button is hidden. Alternatives: Activated or Not used.

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2.5

Page 5.2 – Main parameters 2

2

Control system parameters

ID

Parameter

Default value

MinMax

Unit

Description

p160

GPS

Not used

N/A

Drop list

Defines if a GPS is connected to the control system. If so, the event log will be complete with position for the events defined to include GPS stamp. If no GPS is connected, time and date must be set in control system page 4.1. System info. Alternatives: Activated or Not used.

p161

Time interval for log event 331

1.0

0.1 – 60.0

Min.

Time interval to update the amount (m3) of ballast water treated in log file.

p162

Time interval for log event 341

1.0

0.1 – 60.0

Min.

Time interval to update the amount (m3) of deballast water treated in log file.

p163

Additional by-pass signal 1

N/A

Drop list

Defines if an additional by-pass valve is used. The signal gives information if the valve is opened during process, so that PureBallast is by-passed.

Not used

Alternatives: Activated or Not used. p164

Additional by-pass signal 2

Not used

N/A

Drop list

Defines if a second additional by-pass valve is used. The signal gives information if the valve is opened during process, so that PureBallast is by-passed. Alternatives: Activated or Not used.

p165

Additional by-pass signal 3

Not used

N/A

Drop list

Defines if a third additional by-pass valve is used. The signal gives information if the valve is opened during process, so that PureBallast is by-passed. Alternatives: Activated or Not used.

p166

Pressure PID proportional gain

0.60

0.00 – 10.00

N/A

Defines proportional gain (Pf) value used for PID regulation of V201–8 during backflush. The PID regulation during backflush is based on input from pressure transmitter PT201-27. Normal value: 0.1 – 1.5.

16

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Control system parameters

2.5

Page 5.2 – Main parameters 2

ID

Parameter

Default value

MinMax

Unit

Description

p167

Pressure PID integral time

7.0

0.0 – 100.0

sec

Defines integral time (If) value used for PID regulation of V201–8 during backflush. This parameter shall normally not be changed. Normal value: 5 – 12.

p168

Pressure PID derivate gain

0.0

0.0 – 100.0

N/A

Defines derivate gain (Df) value used for PID regulation of V201–8 during backflush. Default value shall be used. Normal value: 0.

Book No.9010182 02, rev. 0

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2.6

Page 5.3 – AOT parameters

2.6

2

Control system parameters

Page 5.3 – AOT parameters

This section describes parameters controlling the AOT reactor set in page 5.3 AOT parameters.

4 5.3

The following information is displayed: ID

Parameter

p200

Timeout: AOT draining

p201

Timeout: Reactor cooling water (LS201-29)

18

Default value 2

2

MinMax

Unit

Comment

1–5

min

Time the control system will wait for confirmation that an AOT reactor is drained before an alarm is issued. Recommended setting: Approximately 1 minute more than actual drain time.

1–10

min

Time the control system will wait for confirmation that cooling water has filled the AOT reactor before an alarm is issued.

Book No.9010182 02, rev. 0

2

Control system parameters

2.6

Unit

Page 5.3 – AOT parameters

ID

Parameter

Default value

MinMax

p202

High temp, alarm trigger (TT201-33)

60

10–100 ºC

Setpoint for high water temperature alarm, indicated by temperature transmitter in AOT reactor. Default value shall be used.

p204

Low temp, alarm trigger (TT201-33)

0

0–40

ºC

Setpoint for low water temperature alarm, indicated by temperature transmitter in the AOT reactor. Default value shall be used.

p206

Alarm delay for sensor TT201-33

5

0–10

sec

Delay before alarm is issued after setpoint temperature (p202 and p204) is reached.

p208

Timeout: CIP fluid fill-up time AOT

5

1–15

min

Setpoint for max time to fill an AOT reactor with CIP liquid during CIP process before an alarm is issued.

p210

UV lamp warm-up time

90

0–90

sec

Warm up time for UV lamps before full ballast or deballast starts. Default value shall be used.

p211

UV lamp cooling time

120

30–300 sec

Cooling time for UV lamps after ballast or deballast. Default value shall be used.

p212

Timeout: UV lamp ignition

200

10–200 sec

Time the control system will wait for confirmation signal that UV lamps are ignited. If no lamps are ignited or if less lamps than set in parameter p213 are ignited, the AOT reactor will be automatically stopped. Default value shall be used.

p214

High temp, warning trigger in LDC (TT401-1)

45

20–100 ºC

Incoming cooling water temperature warning, indicated by temperature transmitter in LDC.

Comment

Default value shall be used. p215

Alarm delay for LS201-29

5

0–10

sec

Delay before shutdown when there is no water in an AOT reactor, indicated by level switch in AOT reactor (LS201-29). Default value shall be used.

p216

Timeout: Fluid fill-up time AOT

5

2–10

min

Setpoint for max time to fill an AOT reactor with fresh water during CIP process before an alarm is issued.

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2.6

Page 5.3 – AOT parameters

2

Control system parameters

ID

Parameter

Default value

MinMax

Unit

Comment

p220

UV intensity sensor

Not used

N/A

Drop list

Activates measuring of UV intensity in AOT reactor. If activated, UV value will be logged in the Event log every 60 seconds during ballast and deballast. Disable if the UV sensor (QT201–50) is out of order, to avoid alarms. Alternatives: Activated or Not used.

p221

Low UV intensity warning trigger

550.0

0.0 – 500.0

W/m2 Setpoint for warning due to low UV intensity indicated by UV sensor QT201–50 in the AOT reactor. This warning will be logged in the Event log. Default setting: 550. Only used if p220 is set to "Activated".

p230

Cabinet temperature hysteresis (TT401-2)

2.0

1.0–5.0 °C

Accepted temperature change without effect on the fan.

p231

Cabinet temperature low threshold (TT401-2)

40.0

20.0 – 60.0

°C

Setpoint for starting the LDC cooling fan, indicated by air temperature transmitter. The fan will start at 15 % of full effect. The effect is increase proportional to temperature up to 100 % at temperature set in p232. Default value shall be used.

p232

Cabinet temperature high threshold (TT401-2)

45.0

20.0 – 60.0

°C

Setpoint for running the LDC cooling fan at 100 %.

p234

UV control proportional gain

0.10

0.00 – 100.00

N/A

Defines proportional gain (Pf) value used for PID regulation of UV lamp effect. Default value shall be used. The PID regulation is based on input from UV sensor QT201–50.

p235

UV control integral time

15

0–100

sec

Defines integral time (If) value used for PID regulation of UV lamp effect. Default value shall be used.

p236

UV control derivative time

0

0–100

sec

Defines derivate gain (Df) value used for PID regulation of UV lamp effect. Default value shall be used.

20

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Control system parameters

2.6

Page 5.3 – AOT parameters

ID

Parameter

Default value

MinMax

Unit

Comment

p237

Power optimization

Activated

N/A

Drop list

Activates UV optimization to regulate the UV lamp effect based on actual transmittance in the AOT reactor. This means that the lamps are lit to the degree needed for full treatment, but not more. Parameter p220 must be activated to activate this parameter. If disabled, UV lamps are lit at 100 % all the time. Disable if the UV optimization malfunctions, to avoid alarms. Alternatives: Activated or Not used.

p238

p239

High temperature, warning trigger in LDC (TT401-2)

50.0

Enable circuit breaker data

Not used

Book No.9010182 02, rev. 0

20.0 – 100.0

°C

Air temperature warning, indicated by temperature transmitter in LDC. Default value shall be used.

N/A

Drop list

Activates modbus communication with the LDC breaker. If activated, measured power consumption is displayed in page 1.1 Overview. If deactivated, calculated power consumption is displayed instead. Parameter can be deactivated if communication with LDC breaker does not work.

21

2.7

Page 5.4 – Filter parameters

2.7

2

Control system parameters

Page 5.4 – Filter parameters

This section describes parameters controlling the filter module set in page 8.4 Filter parameters.

4 5.4

The following information is displayed: ID

Parameter

p301

p304

22

Default value

MinMax

Unit Comment

High filter differential pressure, warning trigger (PT201-27)

0.50

0.00– 0.1

bar

Required pressure to start backflush (PT201-16)

2.50

Setpoint for high pressure warning, indicated by pressure transmitter PT201-27. (0,7 bar = 0.07 MPa)

1.00– 5.00

bar

Defines pressure needed for efficient backflushing. This pressure must be attained to start backflush. This parameter also defines setpoint for desired pressure during backflush: To maintain this pressure, control valve

Book No.9010182 02, rev. 0

2

Control system parameters

ID

Parameter

2.7

Default value

MinMax

Page 5.4 – Filter parameters

Unit Comment

V201-8 is PID regulated, based on input from pressure transmitter PT201-16. This parameter shall be set according the formula in chapter 6. Installation description and drawings, section Working pressure for filter during ballast operation. (2.5 bar = 0.25 MPa) p305

Backflush trigger, differential pressure (PT201-27)

0.5

0.00– 1.00

bar

Setpoint for automatic start of filter backflush due to dirt in the filter, indicated by differential pressure transmitter on the filter. Note: This parameter can be adjusted, but only by Alfa Laval during commissioning. If adjusted, parameter p301 shall be set to 30 percent higher. (0.5 bar = 0.05 MPa)

5

1–30

min

Defines duration of filter preservation (fresh water filling of filter) after ballasting.

Backflush cycle time

20

1– 100

sec

Defines duration of one filter backflush. This parameter is only relevant for filter type 1 (Boll). Default value shall be used.

p309

Time controlled backflush interval

30

1– 120

min

Defines time between automatic backflush of the filter. Automatic backflushes are performed with this set interval to secure performance, regardles of current differential pressure.

p310

Backflush initial delay

10

0–60

sec

Time from backflush trigger until backflush is started. During this delay the control valve is PID regulated to create the required pressure defined in parameter p304.

p311

Backflush delay (p305 during x sec).

2.0

0.0– 10.0

sec

Defines for how many seconds the differential pressure defined in p305 must last, before automatic backflush starts.

p312

V201-8 min position during backflush

20

15–50

%

Minimum allowed opening percentage for V201-8 during backflush.

p306

Filter preservation time

p308

Book No.9010182 02, rev. 0

Must be higher than value set in p113. Shall not be lower than 15 %.

23

2.7

Page 5.4 – Filter parameters

ID

Parameter

p313

Differential pressure measurement filter

2

Default value

MinMax

Unit Comment

5

0–30

sec

Control system parameters

Time constant for low pass filter used for the differential pressure over the filter. The low pass filter is used to smoothen the effect of sudden changes in differential pressure (primarily pressure peaks after completed backflush). Value for low pass filtered differential pressure is indicated as “dp” on the filter in the filter popup, when logged in as login level Operator or higher. Actual differential pressure (PT201-27) is indicated in the filter popup. This parameter shall normally not be changed, but time can be increased to flatten the differential pressure curves.

p314

Filter type

Type 1

N/A

Drop Defines type of filter installed. list Alternatives: Type 1 (Boll) and Type 2 (Hydac).

p315

Filter size

6000

100 – 6000

m3/h Defines maximum capacity for installed filter. The parameter shall be set to 750 m3/h for a 300600750 system.

24

Book No.9010182 02, rev. 0

2

Control system parameters

2.8

2.8

Page 5.5 – CIP parameters

Page 5.5 – CIP parameters

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

4 5.5

The following information is displayed: ID

Parameter

p400

CIP cycle time

Default value

MinMax

Unit

Comment

15

1–60

min

Duration of circulation of CIP liquid during a CIP process. Default value shall be used.

Book No.9010182 02, rev. 0

25

2.9

Page 5.6 – Installation parameters

2.9

2

Control system parameters

Page 5.6 – Installation parameters

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

4 5.6

The following information is displayed: ID

Parameter

p106

No of AOT reactors installed

26

Default value 1

MinMax

Unit

Comment

1–6

#

Defines number of installed AOT reactors.

Book No.9010182 02, rev. 0

2

Control system parameters

p112

Maximum flow (FIT201-1)

2.9

1200

0– 10000

m3/h

Page 5.6 – Installation parameters

The parameter shall be set according to pipe dimension for the flow meter pipe. Pipe - Qmax (m3/h) 100 – 300 150 – 300 200 – 700 250 – 1200 300 – 1200 350 – 1700 400 – 2200 150 – 2200 500 – 2200 600 – 2200 The parameter shall be set to the same value as the Qmax value in the flow meter (FIT201-1). Qmax setting in the flow meter can be checked according to instruction Check and set parameters on page 32.

p131

Automatic AOT selection

Not used

N/A

Drop list

Defines if AOT reactors shall be automatically selected for process. If activated: All AOT reactors (without alarms) will be automatically selected, to enable operation in full capacity. Activation disables the possibility to select a lowr flow before starting a process (during standby mode). However flow can be changed during process. If deactivated: Flow must be selected manually at first start-up and after shutdown.

p213

p217

Allowed no. of failed UV lamps per AOT reactor

AOT reactor size

Book No.9010182 02, rev. 0

0

0–1

No.

If more lamps than set in this parameter are broken, operation will be denied. If a UV lamp fails the flow is set to 80 % of current flow. The UV lamps are lit to 100 %. A warning is issued and a log is written to the event log, and the operator will have do decide to continue or stop the operation.

300

N/A

Drop list

Defines size of the AOT reactor, defined as max capacity (m3/h). Alternatives: 300 and 1000.

27

2.9

Page 5.6 – Installation parameters

p218

Estimated UV lamp lifetime

p150

EX proof system

3 000

Not used

2

Control system parameters

0 – 20000

hrs

Setpoint for UV lamp change warning. Counter for UV lamp run time is reset in page 4.5 Operation timers AOT after all UV lamps have been changed in an AOT reactor. Default value shall be used.

N/A

Drop list

Defines if the EX proof version of PureBallast is installed. This affects both installation and control system. Alternatives: Activated or Not used.

p500

Log box

Not used

N/A

Drop list

Defines if the log box (optional ) is installed to monitor and log external valves and pumps, that are not part of Alfa Laval’s scope of supply. Parameters to activate feedback signals for components are set in page 4.7 Log box 1 and 4.8 Log box 2. See chapter 3. Operating instructions and control system description. Alternatives: Activated or Not used.

28

Book No.9010182 02, rev. 0

2

Control system parameters

2.10

Page 5.7 – Remote interface

2.10 Page 5.7 – Remote interface This section describes the installation specific system parameters set in page 5.7 Installation parameters. Further information about RTU server data is found in chapter 6. Installation description and drawings section Communication between PureBallast PLC and remote interface. This page is only relevant if remote interface (optional) is used.

4 5.7

The following information is displayed: Parameters for the ISCS modbus RTU server data shall be set according to the information below. ID

Parameter

Default value

MinMax

Unit

Comment

p700

Interface type

RS485

N/A

Drop list

Defines communication (cable) type used for communication between the ISCS and PureBallast. Alternatives: RS485 and RS422.

Book No.9010182 02, rev. 0

29

2.10

p701

Page 5.7 – Remote interface

Baud rate

9600

2

N/A

Drop list

Control system parameters

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

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

p703

p704

30

Data bits

Stop bits

8

1

N/A

N/A

Drop list

Defines data bits per character.

Drop list

Defines number of stop bits.

Alternatives: 7 or 8.

Alternatives: 1 or 2.

Book No.9010182 02, rev. 0

3 Flow transmitter parameters This section describes the parameters set in the parameter pages in the flow transmitter, installed on the flow meter. General (non-installation specific) parameters are preset to function for all systems. They must only be adjusted, by Alfa Laval, if required by performance reasons or similar. They are checked during preparations for commissioning and shall normally not be adjusted after start up. The parameters are set in the flow transmitter panel.

4FTPanel

Buttons used:

4FTLock

4FTChange

4FTBack

4FTFwd

4FTSelect

Padlock

Change

Back

Forward

Select

4FT_Topup

Top up

Book No.9010182 02, rev. 0

31

3.1

Check and set parameters

3.1

3

Flow transmitter parameters

Check and set parameters

Follow this instruction to check and set parameters in the flow meter. 1.

Press Top up for three seconds.

2.

To enter password (1000): Press Padlock. (A line appears under the first zero.) - Press Change to change the first 0 to 1. - Press Padlock to set the value. - Result: The “Basic settings” menu appears after two seconds.

3.

Press Padlock to unlock the menu. Set Qmax (Measuring range for the flow meter: the analog outputs and the frequency output.)

4.

Press Forward until “Qmax” is displayed. Check that the parameter is set according to pipe dimension for the flow meter pipe: Pipe - Qmax (m3/h) 100 – 300 150 – 300 200 – 700 250 – 1200 300 – 1200 350 – 1700 400 – 2200 150 – 2200 500 – 2200 600 – 2200 - To change: Press Padlock. - Press Select to select digit to change (A line is placed under the changeable digit). - Press Change to change (toggle) the digit. - Press Padlock to set the value. Set Empty pipe

5.

Press Forward until “Empty pipe” is displayed. Check that the parameter is set to “On”. - To change: Press Padlock. - Press Change to change (toggle) the setting. - Press Padlock to set the value. Set Empty pipe (Activates alarm when flow meter is empty.)

6.

Press Forward until “Output” is displayed.

7.

Press Padlock to unlock the menu. Result: “Current output” is displayed.

8.

Press Padlock to display the setting. Check that the parameter is set to “On”. - To change: Press Padlock. - Press Change to change (toggle) setting. - Press Padlock to set the value. Set Current output 4-20 mA

32

Book No.9010182 02, rev. 0

3

9.

Flow transmitter parameters

3.1

Check and set parameters

Press Forward until Current output (mA setting) is displayed. Check that the parameter is set to “4-20 mA”. - To change: Press Padlock. - Press Change to change (toggle) setting. - Press Padlock to set the value.

10. Press Top up three times to exit. Result: ”Totalizer 1” is displayed.

Book No.9010182 02, rev. 0

33

3.1

Check and set parameters

3

Flow transmitter parameters

4 Lamp power supply (LPS) parameters This section describes the parameters (DIP switch settings) set in the LPS, installed in the lamp drive cabinet (LDC). Each LPS is set to identify the individual LPS in the installation.

4.1

DIP switch settings

The table below show the correct settings for respective LPS. Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the individual LPS according to the table below. Only position ON is indicated. For empty cells in the table, the switch shall be in position off. LPS nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

SW 4

SW 5

SW 6

SW 7 ON ON

ON ON ON ON ON ON ON ON ON ON ON ON

SW 8 ON ON ON

ON ON

ON ON

ON ON ON ON ON ON

ON ON

ON ON

ON

ON

Example In the illustration, the DIP switches is set for LPS no. 5.

Book No.9010182 02, rev. 0

35

4.2

Change DIP switch setting

4

Lamp power supply (LPS) parameters

7 LPSdipEx

4.2

Change DIP switch setting

Follow this instruction to change the DIP switch settings for an LPS. Note that the DIP switch settings for LPS shall only be changed if faulty, indicated by all LEDs lit in LPS in combination with alarm A130 in the control system. Preparations and conditions

ANGER D ! •

Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside and on the lamp power connector, even when UV lamps are not lit.

•

The LDC contains a fan, which can cause injuryt if in operatoin.

Follow the steps below 1.

Unscrew the plastic lid (1) over the DIP switches on the fron of the LPS.

7 LPSdip

2.

36

Use a small screw driver to change position of the swithces according to the table under instruction DIP switch settings.

Book No.9010182 02, rev. 0

4

Lamp power supply (LPS) parameters

3.

Re-fit the plastic lid of the DIP switches.

4.

Turn back the power to the cabintet.

Book No.9010182 02, rev. 0

4.2

Change DIP switch setting

37

Chapter: 5. Alarms and faultfinding System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

Introduction

5

2

List of alarms and warnings

7

2.1

Control system

7

2.1.1 2.1.2 2.1.3

Alarm indication Key to the table of alarms and warnings List of alarms and warnings

7 7 8

3

2.2

Lamp power supply (LPS)

49

2.2.1

List of alarms and status indications

49

2.3

Flow meter

50

2.3.1 2.3.2 2.3.3

Fault finding instruction Check flow meter error list List of alarms and problems

50 51 51

2.4

Level switch

54

2.5

I/O system and X20 modules

56

2.5.1

List of alarms and status indications

57

List of problems and solutions

63

3.1

General problems

63

3.2

Filter

66

3.3

CIP

68

3.4

Valve V201–8

71

3

1 Introduction This chapter covers information about alarms and warnings, together with information about how to solve the problems causing the alarms to trip. The chapter also contains a list of solutions for problems that may occur, but that is not indicated by any system. The chapter contains lists of alarms indicated by: •

control system

•

lamp power supply (LPS)

•

flow meter (with fault finding instruction)

•

I/O system and X20 modules.

See chapter 3. Operating instructions and control system description to find information about the alarm pages and how to attend to alarms.

Book No.9010182 02, rev. 0

5

1

Introduction

2 List of alarms and warnings This section lists all alarms and warnings related to the PureBallast system.

2.1

Control system

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

2.1.1

Alarm indication

An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.

3Alarm

2 Warning

All alarms are displayed in the control panel’s page 2.1 Alarm list and are sorted in order of occurrence; most recent alarm at the top of the list.

2.1.2

Key to the table of alarms and warnings

The table below explains the information given in the alarms list table. The table contains the following columns and information: Column in table

Description

Alarm ID

Identification number of the alarm. The number is also indicated in the control system alarm list. Alarm ID:s are composed of the following elements: L100 •

L: First letter indicate it is an alarm or a warning. -

A = Alarms stop the ongoing process, which can be restarted after the problem has been attended to.

-

W = Warnings are notification of a status change or a problem. Warnings allow the process to continue.

Book No.9010182 02, rev. 0

7

2.1

Control system

Alarm text / Problem

2

List of alarms and warnings

•

1: If the alarm contains three digits, the first digit indicates component according to: 1=AOT reactor and 2 =Filter. If the alarm contains two digits, the alarm is general and is not connected to a specific component.

•

00: Unique number for the alarm/warning.

The text displayed in the control system. Note that AOT reactor number is indicated by “x” in the table, instead of the actual AOT reactor number. In the control system alarm text, the actual AOT reactor number is stated for the AOT reactor concerned. For problems not indicated by an alarm, the text gives a general explanation of a problem that can occur.

Trigger / Parameter

Trigger: Source of the alarm or warning, identified by the input sensor’s item number or equivalent. Parameter: The parameter controlling the alarm, when applicable.

Description

Detailed information sorted on the following headings, when applicable: Delay: Time before the alarm is activated after the condition of the alarm is met. Comments: Additional information or explanations.

Possible cause

Possible causes that might have triggered the alarm.

What to do?

Suggested action to solve the problem.

2.1.3

List of alarms and warnings

The table below explains alarms triggered by and displayed in the control system. See next page.

8

Book No.9010182 02, rev. 0

A01

Trigger / Parameter

Trigger: PT201-16 Process Parameter: p100 pressure too high (PT201-16). Automatic stop.

Alarm Alarm text ID

Comment: Pressure transmitter PT201-16 indicates pressure higher than set in parameter p100.

Delay: 2 sec.

Description

Alarms and warnings — PureBallast control system

Control that correct valves are functioning and opened for current process. See chapter 3. Operating instructions and control system description, section Detailed process description. Check the entire system for blocking material.

1. Check cables to pressure transmitter PT201-16. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

Valves in the system after pressure transmitter are closed.

Material is stocked after pressure transmitter PT201-16 (i.e. in an AOT reactor). Pressure transmitter PT201-16 is faulty.

List of alarms and warnings

Book No.9010182 02, rev. 0

2. Replace pressure transmitter PT201-16.

Check pressure and flow from ballast pump(s). If the pressure exceeds set value: Adjust incoming pressure to PureBallast.

What to do?

Ballast water pump gives too high pressure.

Possible cause

2 2.1 Control system

9

Trigger / Parameter

Trigger: PT201-16

Alarm Alarm text ID

Process pressure signal missing (PT201-16). Automatic stop.

Trigger: PT201-16 Process Parameter: p101 pressure too high (PT201-16).

A03

10

W04 Comment: Pressure higher than parameter set limit.

See A01.

6. Replace transmitter PT201-16.

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

4. Check cables to the component. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

1. Check fuse F45 in Control cabinet to see what circuit caused the fuse trip.

What to do?

2

See possible cause for A01.

Signal missing or pressure transmitter PT201-16 malfunction.

Possible cause

Control system

Delay: 2 sec.

Comment: Error in system pressure sensor. Indication of pressure -1.0 bar (-0.1 MPa) is not an error.

Delay: 2 sec.

Description

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger: FIT201-1. Parameter: N/A

A10

Process flow signal missing (FIT201-1).

Trigger / Parameter

Alarm Alarm text ID

Comment: Error in system flow sensor.

Delay: 5 sec.

Description

What to do?

Book No.9010182 02, rev. 0

Check the flow transmitter. See chapter 7. Service manual.

See section Flow meter on page 50.

Flow meter malfunction.

List of alarms and warnings

Flow transmitter FIT201-1 malfunction (no text on the transmitter display, message error)

6. Replace flow transmitter FIT201-1.

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

4. Check cables to the component. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

Signal missing or flow 1. Check fuse F45 in Control transmitter FIT201-1 cabinet to see what circuit malfunction. caused the fuse trip.

Possible cause

2 2.1 Control system

11

12

Trigger: FIT201–1 Parameter: N/A

Process flow higher than certified (FIT201-1). Reduce flow!

Process flow too low (FIT201-1). Automatic pause.

W12

A13

Trigger: FIT201–1 Parameter: p116

Trigger / Parameter

Alarm Alarm text ID

Comment: If flow is less than set in parameter p116, the system is shut down.

Delay: 20 sec.

Delay: 30 sec.

Description

Check that the flow sensor is OK as described in Problem 7 B and 7 I in the general problems list on page .

Flow sensor malfunctions.

Check that the flow sensor is OK as described in Problem 7 B and 7 I in the general problems list on page .

Check pressure and flow from ballast pump(s). Adjust incoming pressure to PureBallast, if necessary.

•

Flow sensor malfunctions.

Make sure the ballast water from the ballast pump is directed to PureBallast. When OK the process will continue automatically.

•

2

See chapter 4. Parameters, section Flow transmitter.

Increase flow.

•

Control system

Wrong setting in FIT201-1.

Flow too low.

See chapter 4. Parameters, section Flow transmitter.

Wrong setting in FIT201-1.

See section Flow meter on page 50.

Reduce the incoming ballast water flow to the PureBallast system.

What to do?

Flow rate higher than selected certified flow, for the number of AOT reactors in operation.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: FIT201-1 Parameter: p105

A14

Process flow too low during start-up (FIT201-1). Automatic stop.

Trigger / Parameter

Alarm Alarm text ID

Delay: Set in parameter p144.

Description

Attend to. Note: This component is outside the PureBallast system control.

If not, check mechanical function of the valve and check that the cables to the component is according with the Control cabinet / Circuit diagram.

Control that correct valves are opened for current process. See chapter 3. Operating instructions and control system description, section Detailed process description.

See section Flow meter on page 50.

What to do?

Flow too low.

See alarm A13.

Control valve V201–8 See alarm A17. malfunctions.

Ballast water pump stopped or malfunctions

Valves in ballast system closed.

Possible cause

2 List of alarms and warnings 2.1 Control system

13

14

Trigger: Limit switch GS201-3. Parameter: N/A.

A17

Valve error (V201-3).

Trigger / Parameter

Alarm Alarm text ID

Comment: Error on valve V201–3.

Delay: 15 sec.

Description

2

Hint: Valves can be manually operated. See instruction Operate components manually in chapter 3. Operating instructions and control system description and Operate valves manually in chapter 7. Service manual.

Adjust sensor. See chapter 7. Service manual, section Adjust position sensor.

5. Check that all electrical connections to actuator and sensors on the valve are OK and that the electrical wiring is not damaged.

4. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

3. Use the Control cabinet / Circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

2. Check relay K1 and K2 on module X10 in control cabinet.

1. Check fuses F43 in control cabinet to see what circuit caused the fuse trip.

What to do?

Control system

Position sensor mounted upside down.

Position sensor is not in correct position to sense indicator screws. Position screws are in wrong position.

Fuse tripped.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger: Limit switch GS201-9. Parameter: N/A.

A23

Book No.9010182 02, rev. 0

Comment: Error on valve V201–9.

Delay: 15 sec.

Description

3. Check that compressed air pressure is according to requirements in chapter 6. Installation description and drawings, section Connection list.

2. Adjust exhaust valves on actuator.

1. Follow the instruction Adjust valve traveling speed in chapter 7. Service manual.

See possible cause for A17.

Valve cannot open/close due to obstruction.

Check relay K5 and K6 on module X10.

Clean. If required dismount valve. See chapter 7. Service manual for instructions.

Pilot valve on actuator The red LED on pilot valve contact malfunction lights if opening signal comes to the pilot. If the LED lights although the valve malfunctions, the pilot valve is faulty: Replace pilot valve.

Too long opening/closing time (valve travel time)

1. Check cables.

Position sensor or cables to position sensor malfunction. 2. Replace position sensor if faulty.

What to do?

Possible cause

List of alarms and warnings

Valve error (V201-9).

Trigger / Parameter

Alarm Alarm text ID

2 2.1 Control system

15

16

Trigger: Limit switch GS201-8. Parameter: N/A.

A29

Valve error (V201-8).

Trigger / Parameter

Alarm Alarm text ID

Comment: Error on control valve V201–8.

Delay: 15 sec.

Description

Clean the filter on the possitioner.

The air filters on V201-8 might be clogged.

6. Check that all electrical connections to actuator and sensors on the valve are OK and that the electrical wiring is not damaged.

5. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

4. Use the Control cabinet / Circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

3. Check relay K3 and K4 on module X10.

2. Check fuses F43 in control cabinet to see what circuit caused the fuse trip.

2

Calibrate according to chapter 7. Service manual, section Calibrate positioner on V201-8.

Signal error 4–20 mA.

•

1. Check open indication in the pneumatic positioner.

What to do?

Control system

Positioner is not correcly set or calibrated.

Sensor error. Shows open all the time.

•

See possible cause for A17.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Limit switch GS212-31. Parameter: N/A

Bypass valve is open (V212-31).

Valve error (V212-31).

Process pressure too low (PT201-16).

A33

A35

W40

Trigger: Pressure transmitter: PT201-16. Parameter: p103.

Trigger: Limit switch GS212-31. Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Delay: 2 sec.

Comment: Shutdown of all steps except CIP. The alarm does not prevent completion or start of CIP process.

Delay: 15 sec.

Comment: If valve V212-31 is in open position, ballast or deballast is cancelled. The bypass valve is not controlled by the PureBallast system.

Delay: 15 sec.

Description

Check that pressure and flow from ballast pump(s) is according to requirements in chapter 6. Installation description and drawings, section Connection list.

If not opened intentionally, close valve V212-31.

What to do?

1. Check cables to pressure transmitter PT201-16. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

List of alarms and warnings

Pressure transmitter PT201-16 is faulty.

Pressure safety valve Check the valve, and repair or V201 is faulty. change.

Ballast water pump gives too low pressure.

See possible cause for A17.

See possible cause for A17.

The valve has been opened manually or via the ISCS.

Possible cause

2 2.1 Control system

17

18

Trigger: Shutdown button on control cabinet Parameter: N/A

Shutdown activated (Shutdown button).

Shutdown activated during CIP (Shutdown button).

Shutdown activated (External system).

Shutdown activated during CIP (External system).

A48

A49

A50

A51

Trigger: External shut down signal. Parameter: p135

Trigger: External shut down signal. Parameter: p135

Trigger: Shutdown button on control cabinet Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Delay: None.

Delay: None.

See A50.

Manual shutdown from the ISCS (integrated ship control system).

See A48.

System has been shutdown by the shutdown button on the control cabinet.

Delay: None.

Delay: None

Possible cause

Description

Find out the reason why the system has been shut down before releasing the button.

NOTE

Find out the reason why the system has been shut down before releasing the button.

NOTE

2. Replace pressure transmitter PT201-16.

What to do?

2.1 Control system 2 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Control cabinet. Parameter: N/A

Fuse tripped in control cabinet.

Additional bypass valve 1 is open.

Additional bypass valve 2 is open.

Additional bypass valve 3 is open.

W58

A66

A67

A68

Trigger: External system. Parameter: p165

Trigger: External system. Parameter: p164

Trigger: External system. Parameter: p163

Trigger / Parameter

Alarm Alarm text ID

Delay: 5 sec.

Delay: 5 sec.

Delay: 5 sec.

Delay: None.

Description

overheated fuse

•

See A66.

See A66.

The valve has been opened manually or via the ISCS.

short circuit

•

Possible reasons: • overload

Possible cause

If not opened intentionally, close the valve.

3. Use the circuit diagram for control cabinet to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

2. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

1. Check fuse F43–F45 in control cabinet to see what circuit caused the fuse trip.

What to do?

2 List of alarms and warnings 2.1 Control system

19

20

Trigger: Control system timer. Parameter: p141.

Ballast water pump is not running. Automatic stop.

Overboard valve is not open. Automatic stop.

Error on all operating AOT:s. Automatic stop.

A71

A75

A77

Simulate power request between the systems. See chapter 3. Operating instructions and control system description.

If remote interface (optinal) is used: Communication between PureBallast and ISCS is wrong.

An active alarm exist on all installed AOT reactors. It can be the same error for all AOT reactors, or different errors.

See possible cause for A71.

Check page 2. Alarm list to for related alarms.

Time set in parameter Check/change parameter in is lower than needed. control system page 5.1 – main parameters 1.

Check that all electrical connections are OK. Check that the signal wiring is according to information in chapter 6. Installation description and drawings, section External component signal integration.

What to do?

Faulty connection of signal cable.

Possible cause

2

Comment: All AOT reactors are deactivated.

Delay: None

Comment: Feedback “overboard valve is OPEN”.

Delay: Set in parameter p140.

Comment: Feed back signal “BW pump is running” is deactivated

Delay: Set in parameter p141.

Description

Control system

Trigger: AOT reactors Parameter: N/A

Trigger: Control system timer. Parameter: p140

Trigger / Parameter

Alarm Alarm text ID

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Control system timer. Parameter: p127.

Power is not granted. Automatic stop.

Power is not fully granted. Flow capacity reduced.

W79

W80

Comment: No power steps have been granted within parameter set time.

Delay: Set in parameter p143.

Description

Trigger: Power Delay: None. management system. Comment: Not all Parameter: p127. requested power steps are granted. Triggered if number or requested power steps does not match number of granted power steps.

Trigger / Parameter

Alarm Alarm text ID Investigate if the reasons for not granting power is outside the PureBallast system.

What to do?

Not enough power has been granted.

See possible cause for W79. Continue process with lower flow capacity or try later.

Hint: If problem persists, see page 1.4 – PureBallast power request to find which GRANTED signal that was interrupted during the ballast/deballast process.

Feedback signal from See A71. power management Check signal transmission to/from master is faulty. PureBallast corresponds to the specifications in chapter 6. Installation description and drawings, section Power management system integration.

Power management master system not granting power for one or more AOT reactors.

Possible cause

2 List of alarms and warnings 2.1 Control system

21

22

Trigger: Heeling (internal transfer) requested in control system. Parameter: N/A

Heeling mode requested by operator. Automatic pause.

Heeling mode cancelled by operator. Process resumed.

PLC lost communication with all control panels.

W82

W83

A91

Trigger: Control system PLC. Parameter: N/A

Trigger: Heeling (internal transfer) not requested in control system. Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Possible cause

Comment: After 60 seconds of lost communication, ongoing process is stopped in a controlled way and the system is shut down. This message is visible in the control panels and saved in the log after the communication is restored. But, W92 will be visible in the master control panel.

Delay: 60 sec.

Comment: Process is resumed after being phased during heeling.

Delay: None.

Check settings for each panel according to chapter 3, section Set control panel IP settings.

Wrong network setting

Control system 2

Check that the remote control panel is added in the main panel according to Set remote control panel communication.

Check that the HMI and PLC software have the save program version. This is visible in control system page 4.1 System info.

3. Replace if faulty.

2. Restart the panel. See problem 1 B in the general problems list on page .

1. Switch on the panel.

What to do?

Wrong software version

Panel is switched off or faulty.

See possible cause for W82.

Heeling mode has been activated by Comment: The system external system. is set in pause mode. If operation has not been requested: See A71.

Delay: 2 sec.

Description

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger / Parameter

Trigger: Control system PLC. Parameter: N/A

Alarm Alarm text ID

Master control panel lost communication with the PLC.

Heart beat signal Trigger: Control from remote system PLC. Parameter: p128 interface is not updating.

W92

Book No.9010182 02, rev. 0

A93

See A91.

To operate PureBallast when communication is down, follow the steps below:

Faulty cable connection.

See A91.

Check cables to the component. For reference, see Control cabinet / Interconnection diagram in chapter 6. Installation description and drawings.

Faulty cable connection.

Master panel is switched off or faulty.

What to do?

Possible cause

2.1

If you deliberately set the system to test mode (for example to test

List of alarms and warnings

System is set to Test mode.

Comment: After 1. Set the system to Local mode: Press the Local button on the control panel. communication is lost between ISCS 2. Run the system from the control panel. Note that you and PLC, ongoing will need to confirm two messages from the control process is stopped in a panel during operation: "Confirm ballast pump started" controlled way and the and "Confirm overboard valve open". system is shut down. 3. Restore these settings when the communication is The Heartbeat field working. in page 4.5 Remote 4. Make sure that the system is not in test mode in page interface, indicates 4.5 Remote interface (no check mark on the Test communication. mode button).

Delay: Set in parameter p128.

Comment: After communication is lost, ongoing process is stopped in a controlled way and the system is shut down. This message is visible in the master control panel.

Delay: 30 sec.

Description

2 Control system

23

Alarm Alarm text ID

Trigger / Parameter

Description

24

2

Check cable between the ISCS and the master control panel and the cable between the PLC and the master control panel. For reference, see Control cabinet / Interconnection diagram in chapter 6. Installation description and drawings.

4. Check that the communication settings is OK according to instruction Set remote interface communication in chapter 3. Operating instructions and control system description.

3. Check if test mode is activated in page 4.5 Remote interface (check mark on button). If so, press the Test mode button. Requires login level Advanced operator.

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.

1. Check that parameter p700 is set to match the modbus cable type used (RS422 or RS485).

remote interface integration, you can disregard this alarm. If not deactivate the test mode again in page 4.5 Remote interface 1.

What to do?

Control system

Faulty cable connection.

Faulty settings.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Control system PLC. Parameter: N/A

PLC battery low.

GPS signal not valid.

PLC error in control cabinet.

W95

W96

W97

Trigger: N/A Parameter: N/A

Trigger: Control system PLC. Parameter: p160

Trigger / Parameter

Alarm Alarm text ID

Delay: 2 sec.

Delay: 5 sec.

Delay: 10 sec.

Description

•

Faulty electrical connection.

List of alarms and warnings 2.1

Check that the signal wiring is according to electrical drawings in Chapter 6. Installation description and drawings.

Check the LED error indication for the electronic modules in the LDC. See section I/O system and X20 modules on page 56.

Check that the signal wiring is according to in chapter 6. Installation description and drawings, section GPS signal integration and Control cabinet / Interconnection diagram

Error in module.

Faulty electrical connection.

Replace PLC battery in the control cabinet.

Investigate problem in ISCS, and attend to found problems.

ISCS is faulty. The voltage in the battery in the control system PLC is too low.

See W92.

Tips: Make sure that the modbus cables in terminal X15 are correct (not switched).

What to do?

Communication between PLC and master control panel is lost.

Possible cause

2 Control system

25

26

Check that cooling water supply (403) is within specification in chapter 6. Installation description and drawings, section Connection list.

•

Check that all electrical connections are OK on bus modules and that the electrical wiring is not damaged. Check that the inlet valves (V201-19.x, V403-35) and outlet valves (V201-20.x, 404-36.x) open properly by operating them manually. See the instruction Operate components manually in chapter 3. Operating instructions and control system description.

•

What to do?

High temperature • due to obstacles or error in one or more components involved.

Possible cause

Check/change parameter in control system page 5.3 – AOT parameters. Replace transmitter TT201–33 according to instruction in chapter 7. Service manual section Temperature switch and temperature transmitter.

TT201-33.x malfunction.

2

Parameter p202 not correctly set.

Control system

If the alarm trips during Low flow of sea water Check pump, valves and other ballast start-up, valve during start-up. components involved in the sea V404-36.x will close. water cooling system.

If the alarm trips during operation with a flow through the AOT reactor, the valves V201-19.x and V201-20.x will close.

Trigger: AOT Delay: Set in temperature parameter p206. transmitter TT201-33. Comment: If Parameter: p202 temperature rises above parameter set value, the AOT reactor will shutdown.

AOT [x]: AOT temp too high (TT201-33). AOT shutdown.

W100

Description

Trigger / Parameter

Alarm Alarm text ID

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Parameter: N/A.

See to that incoming water is warmer than 0 C°.

What to do?

6. Replace transmitter TT201-33.

2.1

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

List of alarms and warnings

4. Check cables to the component. See AOT / Circuit diagram and Lamp drive cabinet (LDC) / Circuit diagram in chapter 6. Installation description and drawings.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

1. Check fuse F42 in LDC to see what circuit caused the fuse trip.

Engine room too cold; Increase temperature. temperature below 0 C°.

Sea water too cold; temperature below 0 C°.

See possible cause for W100.

Possible cause

Delay: Set in parameter Signal missing p206. or transmitter TT201-33.x malfunction.

AOT [x]: AOT temp signal missing (TT201-33). AOT shutdown.

W102

Trigger: AOT temperature transmitter TT201-33 error.

Trigger: AOT Delay: Set in temperature parameter p206. transmitter TT201-33. Parameter: p204.

AOT [x]: AOT temp too low (TT201-33). AOT shutdown.

W101

Description

Trigger / Parameter

Alarm Alarm text ID

2 Control system

27

28

Trigger: LDC temperature transmitter TT401. Parameter: p214

AOT [x]: LDC cooling water temp too high (TT401–1).

AOT [x]: LDC cabinet temp missing (TT401–1).

W107

W109

Trigger: LDC temperature transmitter TT401–1. Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Feel the water pipe, if it is too warm. If so, investigate and attend to problem.

Incoming cooling water too warm.

Delay: 5 sec.

Check that cooling water supply (401) is within specification in chapter 6. Installation description and drawings, section Connection list in the General drawings section.

No cooling water to the heat exchanger.

Signal missing or transmitter TT401 malfunction.

2

3. Use the circuit diagrams for the LDC and AOT reactor to locate the component or find the reason that caused the fuse trip and attend to it.

Control system

2. Use the circuit diagram for the LDC to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

1. Check fuse F42 in LDC to see what circuit caused the fuse trip.

Parameter p214 not Check/change parameter in correctly set in control control system page 5.3 – AOT system. parameters.

Incoming cooling Check and attend to. water valve V401–1 and/or outgoing valve blocked or closed.

7. Restart the process from the beginning. Delay: 15 sec.

What to do?

Possible cause

Description

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Temperature transmitter TT401–2. Parameter: p238

W111

LDC air temperature too high (TT401–2)

Trigger / Parameter

Alarm Alarm text ID

Delay: 15 sec.

Description

Check component. See section I/O system and X20 modules on page 56.

Faulty X20 module.

Check page 2. Alarm list to for related alarms. Check electrical and mechanical problems, and attend to.

LDC faulty. Faulty fan.

Change according to instruction in chapter 7. Service manual, section Control cabinet.

Check that all electrical connections are OK on X20 module and that the electrical wiring is not damaged.

7. Restart the process from the beginning.

6. Replace transmitter TT401.

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

4. Check cables to the component. See Lamp drive cabinet (LDC) / Circuit diagram in chapter 6. Installation description and drawings.

What to do?

Faulty connection to X20 module.

Possible cause

2 List of alarms and warnings 2.1 Control system

29

30

Trigger: Temperature transmitter TT401–2. Parameter: N/A

W113

LDC cabinet temperature missing (TT401–2)

Trigger / Parameter

Alarm Alarm text ID Delay: 5 sec.

Description

What to do?

2

7. Restart the process from the beginning.

Control system

6. Replace transmitter FIT201-27.

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

4. Check cables to the component. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

Signal missing or flow 1. Check fuse F42 in Control transmitter TT401-2 cabinet to see what circuit malfunction. caused the fuse trip.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger: Level sensor Delay: Set in LS201-29. parameter p215. Parameter: N/A

AOT [x]: AOT fluid level signal missing (LS201-29).

W116

Description

Trigger / Parameter

Alarm Alarm text ID Signal missing or sensor LS201-29.x malfunction.

Possible cause

Book No.9010182 02, rev. 0

7. Replace LS201-29.x. (Turn the level switch so the forks are in the right position. See chapter 7. Service manual.

List of alarms and warnings

6. Check that the level switch is working correctly. See section Level switch on page 54. Hint 2: Dismount level switch and put the forks into a cup of water to check dry/wet function.

5. Check cables to the level switch LS201-29.x. See drawing AOT / Circuit diagram and Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

4. Use the circuit diagrams for the LDC and AOT reactor to locate the component or find the reason that caused the fuse trip and attend to it.

3. Use the circuit diagrams for the LDC to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

2. Check relay KS02.

1. Check fuse F43 in LDC to see which circuit that caused the fuse trip.

What to do?

2 2.1 Control system

31

32

No fluid in AOT reactor “x”. LS201-29.x is indicating dry condition.

AOT [x]: CIP flow missing (LS201-29).

W118

Trigger: Level sensor Delay: Set in LS201-29. parameter p215. Parameter: p208

Trigger: Level sensor Delay: Set in No fluid in AOT LS201-29. parameter p215. reactor. Parameter: N/A Comment: Prevents start of LPS (UV lamps) in manual mode.

AOT [x]: AOT fluid missing (LS201–29) in manual mode

Possible cause

A117

Description

Trigger / Parameter

Alarm Alarm text ID

Check that pump P320-1 is functioning correctly. See problem 6D−6I in the general problems list on page .

Control system

3. Hint: Valves can be manually operated. See the instruction Operate valves manually in chapter 3. Operating instructions and control system description. Note that the manual operations are passwordprotected and must only be performed by authorized trained personnel. The PureBallast equipment or connected equipment can be irreparably damaged if handled incorrectly.

2.

1. Check that valves V320-2, V320-4.x, V321-4 and 321-2.x open and close correctly.

3. Restart the process from the beginning.

2. Check that the flow is equal through all AOT reactors and that the AOT.x is not clogged.

1. Control that correct valves are opened for current process. See Detailed process description in chapter 3. Operating instructions and control system description.

What to do?

2.1 2 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Level sensor Delay: Set in LS201-29. parameter p215. Parameter: p216

AOT [x]: No freshwater filling in AOT (LS201-29).

A119

Description

Trigger / Parameter

Alarm Alarm text ID

5. Check that the level switch is working correctly. See section Level switch on page 54.

4. Examine the pipes related to the CIP circuit. Make sure that no material is clogging the pipes.

What to do?

Deaerate the CIP, using the deaeration valve on the CIP.

Air in fluid. The level switch indicates this as no fluid in AOT reactor.

1. Check that pressure flushing water in pipe 310 is according to requirements in chapter 6. Installation description and drawings, section Connection list.

Refill the tank with CIP liquid. See instruction Change and refill CIP liquid in chapter 7. Service manual.

Too low level in CIP tank.

No liquid in AOT reactor “x”. LS201-29.x is indicating dry condition.

See W116 to troubleshoot the level switch electrically.

Level switch at AOT reactor LS201-29.x malfunction.

Time set in parameter Change parameter. is lower than needed.

Possible cause

2 List of alarms and warnings 2.1 Control system

33

34

Trigger: Level sensor Delay: Set in LS201-29. parameter p215. Parameter: p200

AOT [x]: AOT was not drained (LS201-29).

W120

Description

Trigger / Parameter

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

What to do?

Restart the process from the beginning.

See W116 to troubleshoot the level switch electrically.

Control that correct valves (V320–4, V460–2, V231–2, V571–1, overboard valve) are opened for current process. Also control that pump P321–5 is functioning.

2

Faulty valves in the CIP unit.

See W116.

Control system

Level switch at AOT reactor LS201-29.x malfunction.

Time set in parameter Change parameter. is lower than needed.

Fluid in AOT reactor “x”. LS201-29.x is indicating wet condition.

Level switch at AOT reactor LS201-29.x malfunction.

Time set in parameter Change parameter. is lower than needed.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: LDC cabinet for AOT Parameter: N/A

AOT [x]: Fuse tripped in LDC cabinet.

AOT [x]: MCB tripped in LDC cabinet.

W122

W126

Trigger: LCD x-1 Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Comment: MCB=Motor circuit breaker. AOT reactor is deactivated.

Delay: 1 sec.

Delay: 1 sec.

Description

Motor circuit breaker (MCB) for an LPS in AOT.x has tripped or has been switched off.

Fuse in LDC has tripped or has been switched off.

Possible cause

Use the circuit diagrams for the LDC and AOT reactor to locate the component or find the reason that caused the fuse trip and attend to it. Check cables to the component. See AOT / Circuit diagram and Lamp drive cabinet (LDC) / Circuit diagram in chapter 6. Installation description and drawings.

•

•

List of alarms and warnings

3. Use the circuit diagram to check the Ampere setting for the MCB, adjust according to figures in circuit diagram if necessary and reset MCB.

2. Check Q101–Q116 in LDC and respective cables and LPS unit.

1. See LPS alarms in section Lamp power supply (LPS) on page 49.

Use the circuit diagram for the LDC to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

•

Check fuse F42–43 in LDC cabinet to see what circuit caused the fuse trip. Check according to bullets.

What to do?

2 2.1 Control system

35

36

Q117.

AOT [x]: LDC cabinet fan alarm

AOT [x]: LDC cabinet water alarm.

W128

W129

Trigger: Water sensor LS below heat exchanger in LDC. Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Delay: 5 sec.

Delay: 5 sec.

Description

Check that all electrical connections are OK and that the electrical wiring is not damaged.

Faulty electrical connection.

See above.

Control system

Condensation in the cabinet.

Dry wet areas in the cabinet. Remove the sensor and dry it with paper.

Repair.

Check electrical and mechanical problems, and attend to.

Faulty fan.

Leakage in cooling water piping.

Check Q117 in LDC.

Reset the breaker by turning the handle.

Breaker on LDC has tripped or has been switched off. Motor circuit breaker (MCB) F1 in control cabinet has tripped or has been switched off.

What to do?

Possible cause

2.1 2 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Lamp power supply in AOT reactors LDC. Parameter: N/A

AOT [x]: LPS sum alarm.

AOT [x]: UV system failure. Too many failed lamps.

Estimated UV lamp lifetime exceeded.

A130

W131

W132

Delay: 2 sec.

Description

Trigger: AOT reactor lap time. Parameter: p218.

Delay: 1 sec.

Trigger: Lamp power Delay: 1 sec. supply. Comment: AOT Parameter: p213. reactor is deactivated.

Trigger / Parameter

Alarm Alarm text ID

Lifetime for UV lamps are too exceed according to estimated lifetime in parameter.

Change according to instruction Replace UV lamp and quartz sleeve in chapter 7. Service manual.

Recommended to change all lamps after 3000 hours of operation.

Change according to instruction in chapter 7. Service manual.

One or more UV lamp Check which lamps that are broken is broken. in column Lamp OK in page 4.9 LPS overview.

Check that all electrical connections are OK on bus modules and that the electrical wiring is not damaged.

Check that the signal wiring is according to electrical drawings.

in column Lamp OK in page 4.9 LPS overview.

What to do?

Check LED indication on the LPS that triggered the alarm. See LPS Number of broken alarms in section Lamp power UV lamps exeeds supply (LPS) on page 49. number set in parameter p213. Check which lamps that are broken

LPS malfunction.

UV lamp OK signal malfunction.

•

•

Possible cause

2 List of alarms and warnings 2.1 Control system

37

38

Trigger: TS201-60 Parameter: N/A

A137

AOT [x]: High temperature (TS201-60 tripped) and/or LDC powered off.

Trigger / Parameter

Alarm Alarm text ID

Comment: AOT reactor is deactivated.

Delay: 1 sec.

Description

Check components. Control that valves and pumps are functioning. The LDC needs to be reset, see above in this alarm description. Check that the signal wiring is according to electrical drawings. Check that all electrical connections are OK and that the electrical wiring is not damaged.

•

•

LDC has been powered off. Faulty electrical connection.

3. Acknowledge alarm A137 in the control system.

2. Push the reset button on the LDC. The button is placed at the side facing the AOT reactor. All LDCs must be reset individually.

1. Turn on the power to the cabinet/system.

Reset LDC

After problem has been attended to, the LDC needs to be reset.

See W100.

What to do?

Faulty pump (ballast or booster pump) or valve.

No flow in AOT reactor or too low flow.

Possible cause

2.1 Control system 2 List of alarms and warnings

Book No.9010182 02, rev. 0

Trigger AOT reactor x. Parameter: N/A

AOT [x]: PLC error in LDC cabinet.

CIP schedule timer elapsed Start CIP!

AOT [x]: Low UV intensity (QT201-50)

A138

W140

W150

Book No.9010182 02, rev. 0

Comment: CIP has not been performed within parameter set time limit after (de)ballast.

Delay: Set in parameter p117 and p118.

Comment: AOT reactor is deactivated.

Delay: 2 sec.

Description

Note: See chapter 3. Operating instructions and control system description, section Ballast water handling in the event of malfunction.

Trigger: UV sensor Delay: 20 sec. QT201-50. Parameter: p220 and Comment: The warning is issued if p221. the UV intensity falls below value set in parameter p221.

Trigger: Control system timer. Parameter: N/A.

Trigger / Parameter

Alarm Alarm text ID

Old UV lamps.

Quartz sleeves dirty.

Low UV intensity in AOT reactor.

CIP not performed after operation.

Error in module.

Possible cause

Check runtime on page 4.4 Operation timers AOT in control system. Change if old. Lamps loose effect when maximum runtime has been exceeded.

If problem remains, check and clean quarts sleeves according to instruction Replace UV lamp and quartz sleeves in chapter 7.

Run CIP process, and try again.

It is also possible to fill the reactor with fresh water to rule out muddy water as reason for the warning.

Check water.

Start CIP process.

Control CIP status on page 1.3 CIP status in control system.

Check the LED error indication for the electronic modules in the LDC. See section I/O system and X20 modules on page 56.

What to do?

2 List of alarms and warnings 2.1 Control system

39

40

Trigger: UV sensor QT201-50. Parameter: p220.

W151

AOT [x]: UV intensity signal missing (QT201-50)

Trigger / Parameter

Alarm Alarm text ID

See W150.

Test the UV sensor: 1. Stop the process and restart the process again.

Transmitter QT201-50.x malfunction.

4. Check cables to QT201-50.x. See the drawing Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

2

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

Control system

Note: Operation does not fulfill the type approval certificate. Act according to ballast water plan.

1. Check fuse F42 in LDC to see which circuit that caused the fuse trip.

Disable parameter p220 if the UV sensor is out of order, to avoid alarms.

2. In the control system’s AOT popup, see if the UV values are OK during the start-up phase. UV values shall be OK, since clean cooling water is used.

What to do?

Possible cause

Comment: The Signal missing. warning is issued if the UV intensity falls below 484 w/m2. Power is set to 100% for the AOT reactor and the flow is reduced.

Delay: 20 sec.

Description

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

AOT [x]: LPS communication error. AOT shutdown.

W161

Trigger: LPS Parameter: N/A

Check that the DIP switches are correctly set for every LPS. See chapter 4. Parameters, section Lamp power supply (LPS) parameters. Change LPS. See instruction in chapter 7. Service manual.

Faulty LPS.

Check modubus cable and power cables.

Check the three LPS cable connectors.

Wrong LPS setting.

Faulty connection of electricity or signal cable.

Delay: 1 sec.

AOT [x]: No response from LDC. AOT shutdown.

W160

Delay: 1 sec.

See chapter 2. System overview, section Operation with broken UV lamp.

Trigger: AOT reactor. Delay: None. AOT [x]: UV lamp fail. System Parameter: p213 flow reduced.

W153

Trigger: N/A. Parameter: N/A

See chapter 2. System overview, section Power optimization.

Delay: None.

5. If the above is OK, the UV sensor is probably broke and needs to be replaced. Replace the component.

Trigger: UV sensor QT201-50. Parameter: p221 and p237

What to do?

AOT [x]: UV intensity low. System flow reduced.

Possible cause

W152

Description

Trigger / Parameter

Alarm Alarm text ID

2 List of alarms and warnings 2.1 Control system

41

42

Trigger: None. Parameter: p239

AOT [x]: Circuit breaker communication error.

AOT [x]: Lamp error feedback from LPS.

AOT [x]: LPS error feedback from LPS.

AOT [x]: LPS in fault state.

W162

W163

W164

W165

Warning is active if parameter p239 Enable circuit breaker data is activated.

Delay: None.

Description

Faulty modubus signal cable.

Motor circuit breaker (MCB) is broken.

Possible cause

Driver fault Fan fault Heat sink fault System fault Voltage fault

• • • • •

To continue process with one faulty LPS, it is possible to set parameter p213 (Allowed nr. of failed UV lamps) to 1. Operation is allowed, but does not fulfill the type approval certificate.

Air temp fault

2

•

Check page 4.9 LPS power overview and LED indication on the LPS that triggered the alarm. See LPS alarms in section Lamp power supply (LPS) on page 49.

If the power is on but there are no indication, the LPS is probably broken.

Check page 4.9 LPS power overview and LED indication on the LPS that triggered the alarm. See LPS alarms in section Lamp power supply (LPS) on page 49.

One or more of the below:

Faulty LPS.

Check UV lamp power cable.

Change according to instruction in chapter 7. Service manual.

Check modubus cable W1 and W2.

Replace.

What to do?

Control system

Trigger: LPS in AOT Delay: 1 sec. reactor’s LDC. Parameter: N/A

Trigger: LPS in AOT Delay: 20 sec. reactor’s LDC. Comment: No LPS Parameter: N/A feedback when it is requested to star its lamp.

Trigger: LPS in AOT Delay: 20 sec. Broken UV lamp. reactor’s LDC. Comment: No lamp Parameter: N/A feedback when it is Faulty connection of requested to be started UV lamp cable. by the LPS.

Trigger / Parameter

Alarm Alarm text ID

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Limit switch GS201–19.

Valve error (V201–19)

Valve error (V201–20)

LDC ring redundancy error

Filter: Sum alarm.

W170

W171

W180

W300

Trigger: Filter. Parameter: N/A

Parameter: N/A

Trigger: Limit switch GS201–20.

Parameter: N/A

Trigger: Limit switch GS201–20.

Parameter: N/A

Trigger / Parameter

Alarm Alarm text ID

Comment: The feedback signal “Filter SUM alarm” is not detected.

Delay: 1 sec.

Delay: None.

Delay: 15 sec.

Delay: 15 sec.

Description Broken UV lamp

1. Check that breaker on the filter junction box is on.

Motor problem.

List of alarms and warnings 2.1

2. Check that the motor is not overloaded and can rotate easily.

See LPS alarms in section Lamp power supply (LPS) on page 49.

Check that the power link (LAN) cable from the control cabinet (in a loop to all LDCs) and back is OK.

Change LPS. See instruction in chapter 7. Service manual.

Fan fault and temperature faults can be caused by something that is preventing the fan from rotate.

What to do?

Motor circuit breaker (MCB) F1 in control cabinet has tripped or has been switched off.

Faulty connection of signal cable

See possible cause for A17.

See possible cause for A17.

•

Possible cause

2 Control system

43

44

Trigger: Pressure transmitter PT201-27 on Boll filter. Parameter: p314.

W304

Filter pressure signal missing (PT201-27).

Trigger / Parameter

Alarm Alarm text ID

Comment: Error in pressure transmitter. Indication of pressure -1.0 bar (-0.1 MPa) is not an error.

Delay: 2 sec.

Description

Check that the filter flushing arm can rotate freely. See 7. Service manual, section Filter for instructions.

3. Start the motor and check that the operation is normal. See chapter 3. Operating instructions and control system description, section Operate components manually and chapter 7. Service manual, section Check filter gear motor function.

What to do?

2

4. Check cables to the component. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

Control system

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

Signal missing or flow 1. Check fuse F45 in Control transmitter PT201-27 cabinet to see what circuit malfunction. caused the fuse trip.

Filter candle is jammed, preventing the flushing arm to rotate.

Possible cause

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Trigger: Pressure transmitter PT201-27 on Boll filter. Parameter: p301, p314.

W306

Filter differential pressure too high (PT-201–27)

Trigger / Parameter

Alarm Alarm text ID

Delay: 2 sec.

Description

Hint: Pressure signal from PT201-27 is displayed on in the Filter popup opened from page 1.1 Overview.

Pressure transmitter PT201-27 does not work correctly.

List of alarms and warnings 2.1

1. Check fuse F45 in Control cabinet to see what circuit caused the fuse trip.

Make sure that the two valves connected to the filter differential transmitter are open.

Valves connected to filter differential pressure transmitter closed.

Check that the valve V201-26 in the filter is open.

•

Backflush manually from control system. If not sufficient, clean the filter candles according to instruction in chapter 7. Service manual.

Hint: Check pressure signal from PT201-27 is displayed in the Filter popup opened from page 1.1 Overview.

•

7. Restart the process from the beginning.

6. Replace transmitter FIT201-27.

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

What to do?

Filter is clogged.

Relative pressure in filter is below 0 bar.

Possible cause

2 Control system

45

Trigger: Pressure transmitter PT201-71 on Hydac filter. Parameter: p314.

W308

46

Signal missing or component malfunction.

Possible cause 2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

1. Check fuse F43 in LDC to see which circuit that caused the fuse trip.

7. Restart the process from the beginning.

6. Replace transmitter FIT201-27.

5. Check that all electrical connections are OK and that the electrical wiring is not damaged.

4. Check cables to the component. See Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

What to do?

2

Delay: 2 sec.

Description

Control system

Filter pressure signal missing (PT201-71)

Trigger / Parameter

Alarm Alarm text ID

2.1 List of alarms and warnings

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Backflush failed Trigger: Hydac filter. to start (timeout). Parameter: p314.

W314

Diff pressure too high. Automatic shutdown.

Filter pressure signal missing (PT309-2)

W312

Trigger: Pressure transmitter on filter. Parameter: N/A.

Delay: 15 sec.

Delay: 2 sec.

Delay: 2 sec.

Description

See W306.

See W308.

See W308.

See W308.

Possible cause

5. If the above is OK, the UV sensor is probably broke and needs to be replaced. Replace the component.

4. Check cables to QT201-50.x. See the drawing Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

What to do?

List of alarms and warnings

W315

Trigger: Pressure transmitter PT201-72 on Hydac filter. Parameter: p314.

Filter pressure signal missing (PT201-72)

W310

Trigger: Pressure transmitter PT309-2 on Hydac filter. Parameter: p314.

Trigger / Parameter

Alarm Alarm text ID

2 2.1 Control system

47

48

Trigger: Log box (optional). Parameter: p314.

W500

Log box hard ware error.

Trigger / Parameter

Alarm Alarm text ID Delay: 10 sec.

Description Check connections and cable for power cable (W10) and Ehternet cable (W104) between Control cabinet and Log box. Check fuse F02 and F03 in the log box. Check the LED error indication for the electronic modules in the log box. See section I/O system and X20 modules on page 56.

Fuse in the log box has tripped or has been switched off. Error in module.

What to do?

Faulty cable connection.

Possible cause

2.1 Control system 2 List of alarms and warnings

Book No.9010182 02, rev. 0

2

List of alarms and warnings

2.2

2.2

Lamp power supply (LPS)

Lamp power supply (LPS)

This section explains alarms triggered by and displayed on the lamp power supply (LPS) in the lamp drive cabinet (LDC). LPS alarms are indicated in the control system by alarm A130 – Sum alarm LPS unit.

2.2.1

List of alarms and status indications

The table below explains alarms triggered by and displayed in the LPS. LED indication key The LPS is equipped whit four light indications: LPS on and communication is functioning. 5 LPSledG

5 LPSledG2

5 LPSledY

Flashes (once per second) when processor is running. Flickering light during modbus communication. Internal fault. Possible causes: •

LPS temperature too high (> 50° C).

• LPS fan faulty. Lamp error. Possible causes: 5 LPSledR

•

Two lamp ignition failures.

•

Broken UV lamp.

• Loose cables to UV lamp. Lamp on. 5 LPSledB

Flickering during lamp ignition, approx 2 seconds when lamp is started.

5 LPSledB2

All lamps on Possible causes: •

Faulty DIP switch setting on one or more LPS. This fault occur after a 10 seconds delay after start.

•

Voltage on the fail safe is missing.

Book No.9010182 02, rev. 0

49

2.3

Flow meter

2.3

2

List of alarms and warnings

Flow meter

This section explains alarms triggered by and displayed in the flow transmitter, mounted on the flow meter (FIT201-1). An alarm is indicated by two flashing triangles on the flow transmitter. During normal conditions, all relevant alarms are displayed in the PureBallast control panel.

4FlowT_Alarm

Alarm time is displayed as time elapsed since the error occurred, and is showed as days, minutes and hours. Alarms and status are displayed in two lists, accessible from the Service mode screen in the flow transmitter: •

Pending error list: A list of the 9 most recent errors. When an error is removed from the pending error list, it is moved to and stored in the status log.

•

Status log list. All errors are stored in the log for 180 days.

2.3.1

Fault finding instruction

1.

Does the light indicate power on? Yes: Go to step 4. No: Go to step 2.

2.

Check the following: •

Cables and connections

•

Connection board

•

Pins in transmitter multiplug.

Are they OK? Yes: Go to step 3. No: Correct the fault. 3.

Is output reading OK? Yes: The display is defect. Change. No: The transmitter is defect. Change.

4.

Is the error triangle flashing? Yes: Go to step 5. No: The tranmsitter is defect. Change.

5.

Are the output and display readings OK? Yes: Go to step 7. No: Go to step 6.

50

Book No.9010182 02, rev. 0

2

6.

List of alarms and warnings

2.3

Flow meter

Check the following: •

Cables and connections

•

Connection board

•

Pins in transmitter multiplug.

Are they OK? Yes: Go to step 7. No: Correct the fault. 7.

The transmitter is OK. Check the following: Settings, application, installation, sensor, earthing, connections etc.

8.

The transmitter still not OK? Change settings according to chapter 4. Parameters, section Flow transmitter parameters.

9.

If the problem cannot be detected or corrected, the transmitter must be replaced according to the instruction Mount flow transmitter. Note that it is not necessary to reset parameters in the new transmitter. The settings are stored in the Sensorprom unit. When the new transmitter is replaced, settings are downloaded automatically.

2.3.2

Check flow meter error list

Follow this instruction to check the error list in the flow meter. Buttons used:

4FT_Topup

Top up

4FTLock

4FTChange

4FTFwd

4FTBack

Padlock

Change

Forward

Back

1.

Press Top up for three seconds.

2.

To enter password (1000): Press Padlock. (A line appears under the first zero.) - Press Change to change the first 0 to 1. - Press Padlock to set the value. - Result: The “Basic settings” menu appears after two seconds.

3.

Press Forward until the “Service mode” menu appears.

4.

Press Padlock, and then Forward until the “Error pending” menu appears.

5.

Press Padlock to display the error list.

6.

When done, press Top up three times to exit. Result: ”Totalizer 1” is displayed.

2.3.3

List of alarms and problems

The table below explains alarms triggered by and displayed in the flow transmitter.

Book No.9010182 02, rev. 0

51

2.3

Flow meter

2

Problem ID

Description

Output signals

Error Possible cause code (transmitter)

7A

Empty display

Minimum

N/A.

7B

No flow signal Minimum

Undefined

7C

52

Indicates flow Undefined with no flow in pipe

N/A.

List of alarms and warnings

What to do?

No power supply

Power supply Check flow transmitter for bended pins on the connector

Flow transmitter defective

Replace transmitter. See chapter 7. Service manual, section Flow meter.

Current output disabled

Turn on current output

Digital output disabled

Turn on digital output

Reverse flow direction

Change direction

F70

Incorrect or no coil Check cables/connections current

W31

Flow sensor (pipe) Ensure that the flow sensor empty (pipe) is full

F60

Internal error

P42

No load on current Check cables/connections output

Replace transmitter. See chapter 7. Service manual, section Flow meter.

Transmitter defective

Replace transmitter. See chapter 7. Service manual, section Flow meter.

P41

Initializing error

Switch off transmitter, wait 5 seconds and switch on again

N/A.

Measuring flow sensor (pipe) empty

Select empty pipe cut-off

Empty flow sensor (pipe) cut-off is OFF

Ensure that the flow sensor (pipe) is full

Electrode connection missing/electrode cable is

Ensure that electrode cable is connected and sufficiently screened

Book No.9010182 02, rev. 0

2

List of alarms and warnings

Problem ID

Description

Output signals

2.3

Error Possible cause code (transmitter)

Flow meter

What to do?

insufficiently screened 7D

Unstable flow signal

Unstable N/A.

Pulsating flow

Increase time constant

Conductivity of medium too low

Use special electrode cable

Electrical noise potential between medium and sensor

Ensure sufficient potential equalization

Air bubbles in medium

Ensure medium does not contain air bubbles. Deareate the filter, using valve V201-50.

High concentration Increase time constant of particles or fibers 7E

Measuring error

Undefined

Maximum

Book No.9010182 02, rev. 0

N/A.

Incorrect installation

Check installation

P40

No Sensorprom unit

install Sensorprom unit

P44

CT Sensorprom unit

Replace Sensorprom unit or reset Sensorprom unit with MAG CT transmitter

F61

Deficient Sensorprom unit

Replace Sensorprom unit

F62

Wrong type of Sensorprom unit

Replace Sensorprom unit

F63

Deficient Sensorprom unit

Replace Sensorprom unit

F71

Loss of internal data

Replace transmitter

W30

Flow exceeds 100% of Qmax.

Check Qmax. (Basic Settings). See parameters for flow transmitter in chapter 4. Parameters, section Flow transmitter.

W21

Pulse overflow

53

2.4

Level switch

Problem ID

Description

2

Output signals

Error Possible cause code (transmitter)

List of alarms and warnings

What to do?

- Volume/pulse too Change volume/pulse small - Pulse width too large

Change pulse width

N/A.

Missing one electrode connection

Check cables

7F

Measuring approx. 50%

7G

Loss of totalizer data

OK

W20

Initializing error

Reset totalizer manually

7H

Signs in display: #####

OK

N/A.

Totalizer roll over

Reset totalizer or increase totalizer unit

7I

Too low flow signal

N/A.

Clogged sensor electrodes in sensor tube

Dismount sensor tube and clean 4 sensor electrodes

7J

Negative flow is indicated

N/A.

Flow meter is mounted the wrong way round.

Change parameter setting in flow transmitter. See section Flow transmitter parameters in chapter 4. Parameters.

Parameter Flow direction is incorrectly set.

2.4

Level switch

This section explains the different status indications on the level switch LS201-29 in the AOT reactor. Alarms and status are indicated by LED:s on the module. Color

State

Description

Green

Steady

Power on and in operation.

Green

Off

No power supply.

Yellow

Steady

Wet condition.

54

What to do?

Check plug, cable and power supply.

Book No.9010182 02, rev. 0

2

List of alarms and warnings

2.4

Level switch

Red

Blinking

Error: Internal sensor error or sensor corroded.

Red

Steady

Error: Overload or short-circuit in load Rectify the short-circuit. circuit. Reduce maximum load current to below 250 mA.

Book No.9010182 02, rev. 0

Replace the component.

55

2.5

2.5

I/O system and X20 modules

2

List of alarms and warnings

I/O system and X20 modules

This section explains the different status indications on the X20 modules. Alarms and status are indicated by LED:s on the module. All modules are identified on the front, for example “X20 DO 6529” in the illustration below. To the right, the stat indication LEDs are visible, for example “r, e, X, I” in the illustration below.

5X20

56

Book No.9010182 02, rev. 0

2

List of alarms and warnings

2.5

I/O system and X20 modules

The following modules are installed in the LDC or control cabinet: Identification

Function

Installed in cabinet

CP3485-1

System module CPU

Control cabinet

DO6529

DO module, 6 x relay

Control cabinet

IF1082-2

Interface module, power link

Control cabinet

PS2100

Power feed, 24V

Control cabinet

AO4622

Analogue output

Control cabinet Lamp drive cabinet

DIF371

Digital input

Control cabinet Lamp drive cabinet

DO6529

Digital output

Control cabinet Lamp drive cabinet

DO9322

Digital output, 12 outputs

Control cabinet Lamp drive cabinet

AI4622

Analogue input

Lamp drive cabinet

AT4222

Temperature input module

Lamp drive cabinet

BC0083

Bus controller, power link

Lamp drive cabinet

CS1030

Interface module

Lamp drive cabinet

IF1030

Interface module, RS422/RS485

Lamp drive cabinet

S9400

24V power feed, bus supply

Lamp drive cabinet

2.5.1

List of alarms and status indications

Below, alarm and status indications displayed on the modules are explained. NOTE

•

Note that all status indications are not valid for all modules.

•

The meaning of a status indication might vary for some modules. These variations are specified in the Description column.

•

Module BC083, CP3485-1 and IF1082-2 are described in separate tables below the generic table.

The table contains the following columns and information:

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57

2.5

I/O system and X20 modules

2

List of alarms and warnings

Light Color

Lights on the module. Description of each light’s color and behavior.

State Description

Different status is indicated by various light states. Meaning of the light state.

Light

Color

State

Description

r

Green

e

Red

Off Single flashes Blinking On Off Single flashes

24 V DC supply not connected, check fuse. Reset mode. Preoperational mode. RUN mode. Module not supplied or everything is OK. Warning / error for an I/O channel. Level monitoring for digital outputs has responded.

Double flashes

AT4222: Overflow or underflow of the analog inputs. Indicates one of the following conditions: • X2X bus power supply is overloaded. •

I/O supply too low.

•

r+e

X I

S

On Red/Green Red - steady / Green - single flashes Off Orange On Red Off

Yellow

1–6

Orange

1–8

Green

1–12

Orange

1–12

Green

1–16

Green

On Off On On

For PS9400: Input voltage for the X2X bus supply too low. Error or reset state. Invalid firmware.

No communication at the X2X bus. X2X bus communication in progress. Bus controller / X2X link supply in acceptable range. Bus controller / X2X link supply overloaded. No data traffic over service interface; no activity. Data is transferred over the service interface. In/output status of the corresponding digital in/output. Output status of the corresponding digital output. In/output status of the corresponding digital in/output. In/output status of the corresponding digital in/output. Input status of the corresponding digital input.

58

Book No.9010182 02, rev. 0

2

List of alarms and warnings

2.5

I/O system and X20 modules

Light

Color

State

Description

1–2

Green

Off Blinking

The input is switched off. Overflow / underflow of the signal, or broken connection. The analog/digital converter is running, values OK. Value = 0. Value ≠ 0. Interface module is active. CPU starting up. The module is receiving data via RS485 (or RS422) interface. The module is sending data via RS485 (or RS422) interface. For CS1030: The module is sending data via RS485 (or RS422) interface. For CS1030: The module is receiving data via (RS485 or RS422) interface. For CS1030: The terminating resistor integrated in the module is turned on.

On 1–4

Orange

Status RxD

Green Red Yellow

Off On On On On

TxD

Yellow

On

Tx

Yellow

On

Rx

Yellow

On

T

Yellow

On

Module BC0083 Light L/A IF1 Green L/A IF2 S/E

Red

Color

Description

On Blinking

Link to the remote station is established. On and Ethernet activity present on the bus. Bus controller error: Failed Ethernet frames, increased number of collisions on the network etc. Only during startup. This is not an error. Bus controller is either powered of or not active. Communication is not possible with the bus controller. After 5 seconds in this state, the bus controller restarts.

On Blinking

Green

Off

If POWERLINK communication is detected during the 5 seconds, the bus controller goes to status PRE_OPERATIONAL_1 (single flash).

Green Green

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

Book No.9010182 02, rev. 0

59

2.5

I/O system and X20 modules

Light

Color

Green

Green

Green

Green

Single flash (approx. 1 Hz)

Double flash (approx. 1 Hz)

Triple flash (approx. 1 Hz)

Blinking (approx. 2.5 Hz)

2

List of alarms and warnings

Description

If POWERLINK communication is detected in this state, the bus controller goes to state PRE_OPERATIONAL_1 (single flash). Bus controller in PRE_OPERATIONAL_1. With operation on a POWERLINK V1 master, the bus controller goes directly into PRE_OPERATIONAL_2. With operation on a POWERLINK V2 manager, the CN (Controlled Node) waits for the reception of a SoC frame and then switches over to PRE_OPERATIONAL_2 (double flash). Bus controller in PRE_OPERATIONAL_2. In this state the bus controller is normally configured by the manager. A command (POWERLINK V2) or setting the data valid flag in the output data (POWERLINK V1) then switches the state to READY_TO_OPERATE (triple flash). Bus controller in READY_TO_OPERATE. In a POWERLINK V2 network, the manager then switches via command to OPERATIONAL. In a POWERLINK V1 network, the bus controller then switches automatically to OPERATIONAL as soon as input data are present. Bus controller is in STOPPED. No output data is produced and no input data is received. Only the appropriate command from the manager can enter or leave this state.

Module CP3485-1 R/E RD/F

60

Green Red Yellow Red

On On On On

Application is running. Service mode. Service or boot mode. Over-temperature.

Book No.9010182 02, rev. 0

2

List of alarms and warnings

S/E

Green /Red

Green on Green off

Red off Red on

Blinking alternately

Green off

EPL

Green

ETH

Green

CF

Yellow Green Yellow Red

DC OK

Red blinking

On Blinking On Blinking On On On On

2.5

I/O system and X20 modules

Powerlink OK. Fatal and irreparable system error. See control system for alarm or warning. This status can only be changed by resetting the module. The powerlink managing node failed. This error code can only occur in controlled node operation. This means that the set station number lies within the range $01 - $FD. System failure according to blinking pattern: ●●● — Pause ●●● — Pause: RAM error. — ●● — Pause — ●● — Pause: Hardware error. Link to powerlink remote station is established. On and Ethernet activity present on the bus. Link to Ethernet remote station is established. On and Ethernet activity present on the bus. Flash card OK. Flash card active. CPU power supply OK. Backup battery is empty.

Module IF1082-2 The status/error light is a green/red dual LED. The interface can be operated in two moedes: Either in Powerlink V mode or as an Ethernet TCP/IP interface. Status light depends on mode. For TCP/IP mode, only SE green is valid. Light L/A X1 L/A X2 S/E

Green Green On

Off

Color Red On Blinking Off

On

Blinking alternately

Off

Red blinking

Description Link to the remote station is established. On and Ethernet activity present on the bus. TCP/IP mode: Powerlink interface is operated purely as an Ethernet TCP/EP interface. Powerlink mode: Powerlinkt station is running, no errors. Fatal and irreparable system error. See control system for alarm or warning. This status can only be changed by resetting the module. The powerlink managing node failed. This error code can only occur in controlled node operation. This means that the set station number lies within the range $01 - $FD. System failure according to blinking pattern: ●●● — Pause ●●● — Pause: RAM error. — ●● — Pause — ●● — Pause: Hardware error.

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2.5

I/O system and X20 modules

2

List of alarms and warnings

Module DIF371 Light S

Green Red

Description

Off Single flash Blinking On

Off Off

Module not supplied, check fuse. Reset mode.

Off

Prepoerational mode.

Off Off On

Run mode. Module not supplied or everything is OK. Invalid firmware

Single flash

62

Book No.9010182 02, rev. 0

3 List of problems and solutions This section contains problems that can occur, but is not indicated by an alarm.

3.1

General problems

Book No.9010182 02, rev. 0

63

Description

The system does not start. The control panel does not light up.

Problem ID

1A

64

1. Check fuse F42 in control cabinet to see what circuit caused the fuse trip.

Fuse F42 tripped.

Replace control panel. Let the panel dry and try again.

Control panel error due to damp.

3

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

1. Check fuse F41 in control cabinet to see what circuit caused the fuse trip.

3. Use the circuit diagram to locate the component or find the reason that caused the fuse trip and attend to it.

General problems

Control panel error. Can be caused by overheating etc.

Fuse F41 in control cabinet tripped.

Turn on the power.

Power turned off at main switch board

2. Use the circuit diagram to check the fuse setting, adjust according to figures in circuit diagram if necessary and reset fuse.

Turn on the breaker and measure that incoming 24 V DC to the control panel is present.

What to do?

Main breaker Q1 on control and LDC cabinet turned off, or power not connected to the control panel.

Possible cause

3.1 List of problems and solutions

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

Error message on the screen.

1D

Communication is broken If control panels are used: See the What to do column between remote control panel for alarm A91. and PLC. If control panels are not used: Remove IP address for Remote control panel 1 according to instruction is set for the remote control panel. See chapter 3. Operating instructions and control system description, section Set remote control panel communication.

See the What to do column for alarm A93.

List of problems and solutions 3.1

5 PanelCommunicationError

PureBallast can not be controlled Communication is broken or monitored from the ISCS’ between ISCS and PLC. graphical user interface via the remote interface (optional)

Re-load the HMI software according to instruction Update HMI software in chapter 3. Operating instructions and control system description.

HMI software problem

1C

Check that the HMI and PLC software have the save program version. This is visible in control system page 4.1 System info .

Wrong software version

3. If panel is not OK, it is probably broke and needs to be replaced. Replace the component.

2. Restart the entire PureBallast system: Cut the power by switching of the main breaker on the control cabinet. Wait 30 seconds, and switch on the main breaker again.

1. Restart the control panel: Cut the power by removing the power cable at the back of the control panel. Wait 30 seconds, and reconnect the cable again.

Abnormal operating condition.

Control panel is not displaying a normal page.

1B

What to do?

Possible cause

Description

Problem ID

3 General problems

65

3.2

3.2

66

Filter

3

List of problems and solutions

Filter

Book No.9010182 02, rev. 0

Book No.9010182 02, rev. 0

5B

5A Differential pressure transmitter PT201–27 (Boll) may be faulty.

Excessive back flushing or long backflushing sequences (general)

See chapter 2. System description

Dirty water

Dirt build-up in the filter candles.

Open the filter and remove the obstructions. See chapter 7. Service manual, section Filter.

Large obstructions have entered the filter.

Clean the filter candles.

, section Backflushing for different dirt loads.

Check filter candles for damage. Replace if necessary.

Damaged filter candle.

Open the valve (ball cock) connected to V309-1.

Valves for air pressure to valve V309-1 are closed.

Deaerate using the deaeration valve V201-50 on the filter lid.

Open the two valves (ball cocks) connected to PT201-27.

Valves for differential pressure gauge PT201–27 (Boll) are closed.

The filter house is not properly deaerated.

Dismantle the component and inspect/attend to.

Dismantle the component and inspect/rinse.

Error with the differential pressure gauge electric switches.

Differential pressure transmitters Differential pressure PT201–71 and PT201–72 transmitters PT201–71 (Hydac) may be faulty. and PT201–72 (Hydac) may be faulty.

Back flush sequence starting error (general)

3 List of problems and solutions 3.2 Filter

67

3.3

3.3

68

CIP

3

List of problems and solutions

CIP

Book No.9010182 02, rev. 0

Insufficient pump capacity (general).

Too high consumption of CIP liquid (> 1 cm/AOT reactor cycle).

CIP liquid is not returned to CIP tank.

CIP pump does not run

6A

6B

Book No.9010182 02, rev. 0

6C

6D

Adjust setting with the manual valve under the valve block on the CIP module. Examine the pump. See chapter 7. Service manual, section Repair CIP pump. Examine the pump. See chapter 7. Service manual, section Repair CIP pump.

Air pressure too low due to incorrect setting on valve block on CIP. The diaphragm in the CIP pump is broken. Pump is clogged.

The air pressure is to low The air connection is blocked Muffler is blocked Air valve is defect Dirt in the pump chamber Diaphragm breakdown

• • • • •

Examine the pump and attend to problem. See chapter 7. Service manual, section Test CIP pump.

Investigate if there is a pipe blockage.

Pipe blockage •

Examine the following valves: V571-1, V321-2.x, V320-4.x and V321-1.

2. Check that pump P321-5 is functioning correctly. See problem 6D−6I in this chapter.

1. Increase airflow to the pump to increase pump capacity with the manual valve under the valve block on the CIP module.

Broken valve.

Insufficient pump capacity (P321-5).

Leakage in the CIP tank, CIP Locate leakage and attend to. pump, pipes or AOT reactor.

Locate leakage and attend to.

Leakage in air hoses or sealings.

3 List of problems and solutions 3.3 CIP

69

CIP pump runs irregularly

Insufficient CIP pump suction

Bad flow or pressure in CIP pump

CIP pump leakage

CIP pump muffler leakage

6E

6F

70

6G

6H

6I

Suction or air connection blocked Muffler is blocked Air valve is defect Valve balls worn out/broken Air in liquid Diaphragm breakdown

• • • • •

Change diaphragm.

3

Diaphragm breakdown

Tighten the screws.

Examine the pump and attend to problem.

Examine the pump and attend to problem.

Examine the pump and attend to problem.

CIP

Screws on the housing not properly fastened

Pressure fall in incoming air

Valve balls are blocked or damaged

• •

Muffler is blocked

•

Diaphragm breakdown

• Suction connection blocked or not tight.

Sealings are defect in air valve or center block

•

•

Valve balls are blocked

•

3.3 List of problems and solutions

Book No.9010182 02, rev. 0

3

List of problems and solutions

3.4

3.4

Valve V201–8

Valve V201–8

Book No.9010182 02, rev. 0

71

72

8C

Inaccurate positioning. Input signal fluctuates.

Signal and positioning problems. • •

Check input signal.

Check electric connection.

Adjust position sensor. See chapter 7. Service manual, section Calibrate positioner on V201-8.

•

Check coupling between proportional valve and actuator.

Check I/P output.

•

Signal change results in actuator Connection or signal problem • running to end positions

Check input signal to proportional valve.

•

Faulty signal

8B

Check air supply to the valve and tubing to the actuator. See chapter 7. Service manual, section Proportional valve for instructions regarding the proportional valve.

Faulty air supply

Signal change has no effect on the actuator position

8A

3.4 Valve V201–8 3 List of problems and solutions

Book No.9010182 02, rev. 0

Chapter: 6. Installation description and drawings System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

Introduction

7

2

Ship specific information

9

3

Technical data

11

3.1

PureBallast system

11

3.2

PureBallast components

12

3.3

Working pressure and pressure drop

14

3.3.1

Working pressure during ballast operation and during backflush Pressure calculation

14 14

3.3.2

4

5

Installation guidelines

17

4.1

Preparations and conditions

17

4.1.1 4.1.2 4.1.3

Safety information General installation requirements Installation of components supplied by shipyard

17 17 18

4.2

AOT reactor

18

4.3

Filter

19

4.4

CIP module

20

4.5

Cabinets and cables

20

4.6

Flow meter

21

4.7

Pressure monitoring device

22

4.8

Pipes and valves

22

4.9

Air supply

23

System interfaces

25

5.1

Remote control panel integration (optional)

25

5.2

Remote interface integration (optional)

27

5.2.1

Communication between PureBallast PLC and remote interface Directory of addresses

27 28

5.2.2

3

5.3

Power management system integration

45

5.3.1 5.3.2 5.3.3

Overall power request process Power steps and power signals Power management installation

46 46 47

5.4

External component signal integration

48

5.4.1

External component signal installation

50

5.5

GPS signal installation

50

6

Start-up procedures

53

7

Drawings

55

7.1

Graphic symbols used in drawings

56

7.2

General drawings

57

7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7

Flow chart Connection list Electrical system layout Air distribution Quality specification / Compressed air Quality specification / Water Quality specification / CIP liquid

57 58 64 65 66 67 68

7.3

Dimension drawings including technical data

69

7.3.1 7.3.2 7.3.3 7.3.4 7.3.5

AOT reactor / Dimension drawing Filter / Dimension drawing CIP module / Dimension drawing (2 pages) Flow transmitter FIT201-1 / Dimension drawing Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and 201-15) / Dimension drawing Control valve V201-8 / Dimension drawing Valve V201-3 and V201-9 / Dimension drawing Valve V201-32 and V403-35 / Dimension drawing Valve V212-31 / Dimension drawing (Optional in scope of supply) Sampling device Q201.1 and Q201.2 / Dimension drawing (3 pages) (Optional in scope of supply) Lamp drive cabinet (LDC) / Dimension drawing Control cabinet / Dimension drawing Remote control panel / Dimension drawing (2 pages)

7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12 7.3.13

4

69 70 71 73 74 75 76 77 78 79 82 83 85

7.4

Electrical drawings

7.4.1 7.4.2 7.4.3 7.4.4

Control cabinet / Interconnection diagram (7 pages) Control cabinet / Circuit diagram (20 pages) Control cabinet / Cable list Lamp Drive Cabinet (LDC) / Interconnection diagram (2 pages) Lamp Drive Cabinet (LDC) / Circuit diagram (14 pages) Lamp Drive Cabinet (LDC) / Cable list AOT reactor module / Interconnection diagram (2 pages) AOT reactor module / Circuit diagram (3 pages) AOT reactor module / Cable list

7.4.5 7.4.6 7.4.7 7.4.8 7.4.9

8

9

87 87 95 115 116 118 132 133 135 138

Shutdown and storage

139

8.1

Decommissioning

139

8.2

Protection

140

8.3

Storage and long term decommissioning

140

8.4

Start-up after shutdown

141

Delivery and transport information

143

9.1

Delivery and transport

143

9.2

Lifting instructions

143

9.2.1 9.2.2 9.2.3 9.2.4

AOT reactor Filter CIP module Cabinets

144 145 147 147

5

1 Introduction This chapter contains information about how the PureBallast system is to be installed and drawings. The information is presented as installation guidelines per component, relevant standards and drawings. The chapter is opened with a summary of the main technical data.

Book No.9010182 02, rev. 0

7

1

Introduction

2 Ship specific information Enter vessel specific information in the table below. This will facilitate reading information and drawings in this document, since some drawings include information for all system sizes / dimensions, and the document contains information for options only used by on some vessels. Data

Value

Flange standard

(EN or JIS): _______________

Main valve and piping

Dimension: ________________

Control valve (201-8)

Dimension: ________________

Bypass valve (V212–31)

Dimension: ________________

Alfa Laval’s or other.

Location: __________________

Cooling water valve (V403-35)

Dimension: ________________

Remote operation (optional)

Remote control panel (number): _________ Remote interface integration (yes/no): _____

Book No.9010182 02, rev. 0

9

2

Ship specific information

3 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.

3.1

PureBallast system

The table below states conditions, limit values etc. for the PureBallast system. Type of data

Value

Water requirements

See section Quality specification / Water on page 67 and data for different components in the Connection list on page 58. Water temperature — AOT reactor: 0–40 °C. Water temperature — LDC cooling water: Max: 38 °C (± 2 °C). Water types used in PureBallast: •

Sea water: Used for cooling UV lamps in the AOT reactor during start-up.

•

LT (low temperature) fresh water: Used for cooling the lamp drive cabinet (LDC) during operation.

•

Fresh water: Used for flushing and filling up of AOT reactors after treatment.

Ambient air temperature

0–55 °C.

Relative humidity

Max. 90 %.

System flow

Flow range ballast (m3/h): 190 → 750

Power consumption

Maximum power consumption (kW): 101

Flow range deballast (m3/h): 100 → 1000

Based on maximum: • • Compressed air requirements

Book No.9010182 02, rev. 0

100 kW 1 kW (Control system including PLC, 24 V feeding, CIP motor supply, filter motor supply)

See data for individual components in Connection list on page 58 and the Quality specification for compressed air on page 66.

11

3.2

PureBallast components

3

Technical data

Type of data

Value

Piping connections

See data for different components in Connection list on page 58.

Working pressure – PureBallast system

Max. 6 bar (PN 6). (0.6 MPa).

Working pressure – compressed air

See Connection list on page 58.

Power: Nominal voltage/Frequency

400VAC +/-10% − 50Hz 440VAC +/-10% − 60Hz 24VDC - Remote control panel (optional). Power to LDC: Max Icu 50 KA. (Fixed breaker setting: 200 amp.

IP raiting

Components within range IP44–IP67. See dimensional drawing for respective component in section Drawings. Encapsulated components, for example in the control cabinet, can have lower classification.

3.2

PureBallast components

The table below states conditions, limit values etc. for the individual component in the PureBallast system. Dimensions are given in dimension drawings including technical data in the Drawings section. Component

Type of data

Value

AOT reactor

Pressure drop

See data for different components in Connection list on page 58.

Weight (empty)

330 kg.

Volume Filter

12

Pressure drop and working pressure for filter

0.2–0.50 bar (0.005–0.05 MPA).

Weight, empty with adaptor plates on flanges (kg)

825

Volume (dm3)

304

See Working pressure and pressure drop on page 14.

Book No.9010182 02, rev. 0

3

Technical data

3.2

PureBallast components

Weight, empty (kg)

155 kg

Tank volume

250 liters. Note: Total tank volume is 300, but shall only be filled to max 250.

Flow transmitter

Measures, weight etc.

See dimensional drawing on 73.

Valves

Measures, weight etc.

See section Dimension drawings including technical data on page 69.

Type

See data for different components in Connection list on page 58.

Connection type

EN or JIS.

Electrical cabinets

Measures, weight etc.

See section Dimension drawings including technical data on page 69.

Remote control panel (optional)

Dimensions

See Remote control panel / Dimension drawing on page 85 and on Remote control panel integration page 25.

CIP module

Book No.9010182 02, rev. 0

13

3.3

Working pressure and pressure drop

3.3

3

Technical data

Working pressure and pressure drop

This section gives a description of working pressure and pressure drops in the system.

3.3.1

Working pressure during ballast operation and during backflush

During ballast operation, the ballast water flow goes through the filter and AOT reactor which gives an approximate maximum pressure drop of 0.70 bar at maximum flow rate. Note that piping outside the PureBallast system is not included. The pressure drop over the filter fluctuates between approximately 0.2−0.5 bar depending on dirt load in the filter. The differential pressure over the filter is monitored by one pressure transmitters on the filter inlet 201 and one on the filter outlet 201. When the differential pressure reaches a parameter set limit (default is 0.5 bar), a backflush operation is started automatically. To secure sufficient backflush flow, the pressure at Pfilter inlet p309 (pressure loss in the backflush line). For detailed information “201” must be at least 1.0 bar + about backflush, see chapter 2. System description, section Filter.

6 Working_Pressure_Hydac

Note: According to default parameter setting.

3.3.2

Pressure calculation

The information below is used when the ballast water system is dimensioned. 14

Book No.9010182 02, rev. 0

3

Technical data

3.3

Working pressure and pressure drop

Pressure during ballasting During ballast operation, the ballast water flow goes through the AOT reactor which gives a maximum pressure drop of 0.70 bar (not including vessel’s piping), as described in the table below. Note that the total pressure drop only includes the PureBallast components, not the vessel’s piping before the first PureBallast component (Q201.1 ) or after the last (V201–8). Filter

≤ 0.50 bar

AOT reactor

≤ 0.20 bar

pAOT: 0.20 bar (0.02 MPa) including PureBallast valves. Piping is not included, since it is installation specific.

Total

≤ 0.70 bar

≤ 0.70 bar (0.07 MPa) if parameter p305 is set to 0.50 bar.

Pressure during backflush During backflush, the ballast water flow goes through the filter and AOT reactor, and the backflush discharge flow goes through the filter and pipe 309. A pressure calculation must be done to secure sufficient backflush flow in pipe 309 and to secure that the ballast water pump can overcome the pressure drop (see table below). Note that the calculated total pressure drop only includes components from the PureBallast inlet valve V201–2 to the backflush over board valve. Backflush differential pressure

≥ 1.0 bar

Difference between filter inlet “201” and filter backflush outlet “309”.

∆P309

Calculated

The pressure drop for pipe 309 is installation specific and must be calculated. The connection list specifies required flow in pipe 309 to be in range 60–120 m3/h. Use this flow to calculate the pressure drop in ∆P309. Note that ∆P309 includes both static pressure and dynamic pressure (pipe length, bends, valves etc) for pipe 309.

Total pressure drop

Calculated

Calculated pressure drop during backflushing give minimum BW pump capacity required for PureBallast. If the value is greater than existing pump capacity, steps must be taken, for example: •

Reduce the total pressure drop by reducing ∆p309. This can, for example, be done by increasing the pipe diameter or by reducing the number of bends etc in pipe 309.

•

Upgrade to a pump with bigger capacity.

Calculate value for parameter Required pressure to start backflush To ensure sufficient pressure at pfilter inlet “201”, the total pressure drop during backflush operation must be calculated according to the formula below:

Book No.9010182 02, rev. 0

15

3.3

•

Working pressure and pressure drop

3

Technical data

Pfilter inlet 201” ≥ 1 bar + ∆p309

Enter this value in parameter p304 (Required pressure to start backflush) in the control system page 5.4 – Filter parameters. The parameter defines pressure needed to start a backflush operation. The parameter is also the setpoint for the pressure that the control valve (V201-8) will maintain during backflush.

16

Book No.9010182 02, rev. 0

4 Installation guidelines This section covers requirements for installing different components of the system.

4.1

Preparations and conditions

Read this section before the system is installed.

4.1.1

Safety information

•

Earth connection must be made before any welding is done. The ground cable must have a cross-section large enough in relation to the supply cables from the vessel. Otherwise the equipment might be damaged during welding.

•

Follow local regulations for electrical installation and earthing (grounding).

•

Instructions on how to mount and install components are given in chapter 7. Service manual.

!

NG WARNI

•

Read chapter 1. Safety.

•

Installation must be done by a fully trained professional installer.

•

Damages related to transport and installation should be recorded.

4.1.2

General installation requirements

The following requirements are valid for all components. •

The Installation guidelines in this section must be followed.

•

Installation requirements given in the dimension drawings must be followed. See section Drawings in this chapter.

•

Components must be properly suspended and supported.

•

There must be sufficient access to maintain the components. Access area is defined in the dimension drawings.

•

Installed component must not amplify vibrations to or from the hull.

•

All piping connected to the PureBallast components (AOT reactor, filter and CiP module shall be propperly self supported. No load shall be transferred to or from any major components.

Book No.9010182 02, rev. 0

17

4.2

•

AOT reactor

4

Installation guidelines

All components must be installed and marked as specified in dimension drawings, flow charts and other drawings included in this manual. -

General drawings – overall and principle information for system layout (pipes, components, electricity, air and water).

-

Dimension drawing – detailed component information (dimensions, sizes etc).

-

Electrical drawings – detailed electric information (circuit diagrams, cable lists etc).

4.1.3

Installation of components supplied by shipyard

Additional equipment, not part of Alfa Laval’s scope of supply (for example cables, pipes) must be installed according to the following sections of the manual: •

Connection list

•

Quality specification for water

•

Quality specification for compressed air

•

Installation guidelines

•

Electrical drawings

4.2

AOT reactor

Follow the guidelines below when installing the reactor module.

18

Book No.9010182 02, rev. 0

4

Installation guidelines

4.3

Filter

•

The AOT reactor must be fixated at the bottom and supported at the top to carry the weight of the component. Use the upper and lower fixing holes (1) in the support structure to fixate the component to the steel construction of the hull. If this is not enough, completing stays has to be made. There are four fixing holes on each side at the bottom and four at the top, after the lifting beam has been removed.

6 AOT installation

•

Prepare the inlet piping first. Then mount the AOT reactor onto the inlet flange and secure it. Finally install the outlet piping onto the top of the AOT reactor.

•

We recommend that the installation of the reactor is planned to be supported by its lifting point until the units lower part is completely secured to the foundation and inlet flange.

•

No fixtures should be attached to the reactor housing by welding, since this will damage or distort the reactor, and potentially affect the biological performance of the component.

•

The AOT reactor must be earthed. The earth nut is indicated as “791” in the dimension drawing.

4.3

Filter

Follow the guidelines below when installing the filter. •

The component must be placed on a firm level surface. The legs of the component can be bolted or welded in place on a steady foundation.

•

Pipe 309 (filter back flush overboard line), with its valve, must be correctly connected.

•

The component must be earthed. The earth nut is indicated as “791” in the dimension drawing.

Book No.9010182 02, rev. 0

19

4.5

Cabinets and cables

4.4

4

Installation guidelines

CIP module

Follow the guidelines below when installing the CIP module. •

The electrical cable is connected from the control cabinet to the CIP valve block. See chapter 7. Service manual, section Connect electrical cables to valve block.

•

The component must be earthed. The earth nut is indicated as “PE bolt” in the dimension drawing.

•

The component must be placed on a firm level surface. The legs of the component can be bolted or welded in place on a steady foundation.

•

Connections to the flanges must be made so that the connection is not exposed to any moment or load. This is particularly important when connecting the plastic flanges.

4.5

Cabinets and cables

Follow the guidelines below when installing cabinets and cables. NOTE

•

System interfaces (optional) must be integrated according to section System interfaces on page : -

remote control panels

-

remote interface

-

power management

-

external component integration

-

GPS integration

Cabinets – General •

Cabinets must be firmly attached.

•

Cabinets must be earthed. The earth nut is indicated as “791” in the dimension drawing.

LDC cabinet •

The cabinets maximum distance (cable length) to the AOT reactor: 150 meters.

•

The component must be placed on a firm level surface. The legs of the component can be bolted or welded in place on a steady foundation. It is possible to detach the cabinet from the bottom frame to facilitate installation. The cabinet shall also be attached to the bulkhead using the attachment bolts on the top of the cabinet.

•

It is possible to dismount the doors during installation: Slide the red catch on the hinge backwards and release the locking mechanism.

•

Cables can be lead to the cabinet either from the floor or from the side of of the cabinet, depending on which is most convenient. If needed, the location of the cable gland cassette and the cover is exchanged. Power cable W201.1 to be connected to LDC: Max Icu 50 KA. (Fixed breaker setting: 200 amp).

20

Book No.9010182 02, rev. 0

4

Installation guidelines

4.6

Flow meter

•

Signal cables W210A and B to be connected from X1 in LDC to junction box on the AOT reactor. Cables from junction box to components are pre-assembled.

•

Lamp power cables W211A-D (included in scope of supply) shall be connected from X2 in LDC to the (B side) junction box on the AOT reactor. Cables from junction box to lamps are pre-assembled.

Control cabinet •

Power cable W1 to be connected to control cabinet (Q1).

•

One power link cable shall be connected from the control cabinet (X6) to LDC1 (X5). Another power link cable shall be connected from X6 back to A1.1 in the control cabinet.

Cables – General •

Recommendation: Make notes of the actual connections made to the vessel’s systems with part number and cable number in the electrical drawings. The drawings are prepared with indicated, empty squared for this purpose. The electrical diagrams are found in the Drawings section. These notes can be used to make notes of the exact connections done during installation to simplify future faultfinding.

•

Electrical cables must be properly routed and supported according to applicable regulations.

•

Cable entries to cabinets must be sealed, using the built in cable glands. See instruction Cable glands in chapter 7. Service manual.

•

Cabling shall be done according to specification in Electrical system layout on page 64, and the electrical drawings. This includes cable routing, cable types and cable marking to simplify identification and fault finding.

•

Power cables shall be separated from signal and bus cables. Distance between them reduces electrical noise transfer.

•

-

If placed on a cable rack, place power and signal cables on opposite sides.

-

If cables are routed in tubes due to narrow space, the power and signal cables shall be routed in separate tubes.

EMC: Cables shall be peeled down to the cable shield. The nut holding the cable must be in contact with the screen bar.

4.6

Flow meter

Follow the guidelines below. •

The ballast water flow direction must be according to the arrow on the flow sensor.

•

The flow transmitter must be mounted on the flow sensor pipe. It is not pre-assembled from factory. See chapter 7. Service manual for instructions.

Book No.9010182 02, rev. 0

21

4.8

Pipes and valves

4.7

4

Installation guidelines

Pressure monitoring device

Follow the guidelines below. •

A drain solution (not part of Alfa Laval’s scope of supply) must be attached to safety valve RV201. The valve shall be drained to a scupper, with a solution which always allows water to be drained from the valve. See Pressure monitoring device / Dimension drawing.

4.8

Pipes and valves

Follow the guidelines below when installing pipes and valves. •

Inlet and outlet pipes must be correctly connected. They must also be pressure approved by a classification society or equivalent, or be tested under supervision of a classification society and/or at the ship yards pipe shop etc.

•

Pipes shall be designed to carry the weight of the component and media.

•

A bypass valve (optional part of Alfa Laval’s scope of supply) must be installed. The bypass valve (V212-31) shall be connected to the the vessel’s ISCS, to enable control of the valve, and PureBallast control system to indicate valve position. See Control cabinet / Interconnection diagram on page 87.

•

If PureBallast can be bypassed using other valves (apart from V212-31), status signals from them must be connected to the control cabinet. All bypass cases must be logged. Three additional by-pass valves can be handled, identified as additional bypass valve 1, 2 and 3. If more valves are used, they must be connected in series, which means that they are handled as one regarding alarms and logging in PureBallast. Signal cables for additional bypass valves are installed according to section External component signal integration.

•

The yellow position indicator on actuators must be in line with the valve throttle. For pipes with dimension 400, the red position indicator on the actuator coupling (see drawing) must also be in line with the thottle. The position indicator must be in line with the pipe when the valve is open. If not correct, change according to instruction in chapter 7. Service manual for instructions.

•

Valves shall be opened when installed. This is important to avoid that the rubber gaskets are squeezed and damaged during installation.

•

Valve actuator’s pneumatic lines must be correctly connected and supported. See chapter 7. Service manual for instructions.

•

Valve actuators electric connectors must be correctly connected.

•

Sampling device Q201.1 and Q201.2.

22

-

If delivered by Alfa Laval: Must be mounted with the pin pointing in the flow direction (see drawing on page 79).

-

Flanges for connecting the sampling devices must be installed before the pipe is coated.

Book No.9010182 02, rev. 0

4

Installation guidelines

4.9

4.9

Air supply

Air supply

Follow the guidelines below. •

Components shall be connected to air supply that meets the requirements or the Quality specification / Compressed air 66. Air shall always be connected.

Book No.9010182 02, rev. 0

23

4.9

Air supply

4

Installation guidelines

5 System interfaces This section covers guidelines for how to install and integrate the following, if used: •

remote control panels

•

remote interface (Not yet defined)

•

power management system (Not yet defined)

•

external components

•

GPS integration

Note that options are not applicable for all installations.

5.1

Remote control panel integration (optional)

The PureBallast system can, as an option, be equipped with up to four remote control panels. Remote control panel integration requires the following: •

1–4 remote control panels to be mounted at an optional location.

•

Communication cable (W501) between the switch (X13) in the control cabinet and the remote control panel can be either Ethernet or fiber. -

Ethernet cable – Type: Cat 5e (or better). Max length: 100 meters. One free Ethernet connection point (X13) in the switch in the control cabinet.

-

Fiber cable – Type: Multi-mode fiber cable with LC connector. Max length: 500 meters. Ports: Two free ports in the switch in the control cabinet. If fiber is used, a network switch must be used, since the cable to the panel must be of Ethernet type. One network switch and a 1.5 meter Ethernet cable is delivered with each remote control panel.

•

If more remote control panels are to be installed than there are free fiber ports in the control cabinet, one of the delivered network switches can be used for connection. From this switch, it is possible to connect more panels using the free ports. Keep in mind that the cable to the panel must be of Ethernet type. The extra switch shall be placed close to the first remote control panel so the 1.5 meter Ethernet cable can be used.

•

External network switch including a terminal to handle the communication, placed near the remote control panel. We recommend to use the external network switch close to the remote control panel, even if it is not necessarey (if there are free ports in the control cabinet).

•

Network switch in control cabinet. It is installed if remote control panels have been ordered, but can also be installed at a later stage.

•

A signal device must be installed according information in section Cabinets and cables on page 20. Not part of Alfa Laval’s scope of supply.

Switches and cables are installed according to instructions in chapter 7. Service manual, section Remote control panel (optional).

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5.1

Remote control panel integration (optional)

5

System interfaces

Communication settings must be done according to instruction in chapter 3. Operating instructions and control system description, section Set control panel IP address and Set remote control panel communication.

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System interfaces

5.2

5.2

Remote interface integration (optional)

Remote interface integration (optional)

The PureBallast system can, as an option, be integrated with the ISCS. This will allow operation and monitoring of the system from the ISCS. This section presents guidelines for how to connect and implement the integration via the remote interface. PureBallast’s PLC communicate with the vessel’s ISCS via the remote interface. Data is sent to and from dedicated addresses via modbus. Data can be commands, values (sum of bits), alarms and status information. The data is then presented in the ISCS according to the vessel’s graphical standard. It is possible to present all information (all addresses) or a selection. Data is sent as binary code, with exception for time, which is sent as hexadecimal code. Remote interface integration requires the following: •

Cable W602 to be connected from connection terminal (X15) in control cabinet to ISCS.

•

Modbus connection from ISCS to PureBallast connection terminal X15 in the control cabinet. Connection standard: RS485 (or RS422, not described in electrical drawings) according to Control cabinet / Interconnection diagram. Recommended max length: 500 meters.

•

Implementation of remote interface signals in the ISCS according to the guidelines in this section.

•

Communication settings must be done according to chapter 3. Operating instructions and control system description, section Set remote interface communication.

•

Parameter p132 and p128 must be set in the control system.

•

After installation and integration, the function of the remote interface must be verified according to chapter 3. Operating instructions and control system description, section Test remote interface communication.

•

A signal device must be installed according to information in section Cabinets and cables on page 20. Not part of Alfa Laval’s scope of supply.

Reference information about the logical flow of the PureBallast processes can be found in chapter 3. Operating instructions and control system description, section Detailed process description.

5.2.1

Communication between PureBallast PLC and remote interface

This section describes all addresses in the remote interface, to handle the communication. These addresses are displayed in the control system page 5.5 Remote interface 1 and 5.6 Remote interface 2, described in chapter 3. Operating instructions and control system description. Page 4.5 and 4.6 are used to verify that the integration functions and that correct information is displayed in the ISCS. Modbus settings The ISCS modbus RTU server data shall be set according to the table below: Area

Value

Interface type Baud rate Parity Databits Stop bits Modbus

Parameter option Set in parameter p700 –p704 in page 4.7 Remote interface. See chapter 4 Parameters for detailed information.

RTU

Book No.9010182 02, rev. 0

N/A

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Remote interface integration (optional)

Communication meth,od

Serial

N/A

Slave ID

10

N/A

5

System interfaces

PureBallast is slave and ISCS is master.

5.2.2

Directory of addresses

This section list all addresses for the information sent between the systems. The following terms are used to explain the signals in the tables below: Address:Bit

The start address is 40000. Individual address and bit for each signal (data), is written as “Address:Bit”, for example +073:14. Values for an address is written as “Address=Value”, for example 015=125. Bits are the Signal reference number. Bits are right aligned in the table.

Function

Name of the function. The name corresponds to the text used in the PureBallast control system HMI. Parenthesis gives reference to the control system page where the information is used/displayed. For further information about respective piece of information, see chapter 3. Operating instructions and control system description.

Description

Additional information, for example specific conditions that must be met before a command can be sent.

The directory starts on next page.

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System interfaces

5.2.2.1

5.2

Remote interface integration (optional)

Data from ISCS

The addresses below are used to send commands and status information from ISCS to PureBallast. Example of data: Command to start a ballast process and feedback that the ballast water pump is running. Address: 40000 +

Function

Description

+001

Commands Condition: All signals for +001 must be high until PureBallast return an accept or reject signal (see +140). Bit 0

Start ballast

Command: Start ballast

Bit 1

Start deballast

Command: Deballast

Bit 2

Start CIP

Command: Start CIP Prerequisite: Only possible during standby. Note: CIP will be performed for AOT reactors that requires CIP, indicated by signal AOT reactor (100:6, 200:6or 300:6 = 0)

Bit 3

Stop

Command: Stop ongoing process. It shall always be possible to send this command.

Bit 4

Pause/Heeling

Command: Pause ongoing process. Condition: Only possible during full ballast (+042=2) and full deballast (+042=9).

Bit 5

Bit 6

Bit 7

Manual backflush (Filter popup)

Command: Start backflush.

Ack all alarms and warnings (2.1)

Command: Acknowledge all alarms and warnings.

Apply new flow (1.1 and 1.2)

Confirm activation of new flow selected using address +003 (Selected flow).

Condition: Only possible during full ballast (+042=2).

Condition: Signal shall be high so long it can be assumed that it is received by the PureBallast, considering the installation specific conditions.

Condition: Only possible during Standby (+041=1), full ballast (+042=2) and full deballast (+042=9). Condition: Signal high to confirm. Signal shall be high until a response to the selection in +001:7 is sent. We recommend that the signal is high the new flow is confirmed (address +018 is updated with the new flow).

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Remote interface integration (optional)

Address: 40000 +

Function

+002

Feedback Bit 0

Bit 1

+003

5

System interfaces

Description

Ballast water pump status (1.1)

Status: 1=Started. 0=Stopped.

Overboard valve status (1.1)

Status: 1=Open. 0=Closed.

Select AOTs) (1.1, 1.2)

If set during standby: Defines which flow to be used when ballast or deballast is started. If set during ballast or deballast: Defines that the flow shall be increased or decreased to the new flow.

Response to address +040:8.

Response to address +040=9.

Number of AOT reactors is sent to PureBallast as a value, which represent the maximum flow for process (for a 300 respective 1000 reactor): 1=300 / 1000 m3/h 2=600 / 2000 m3/h 3=600 / 3=3000 m3/h. In some installations the filter capacity is lower than the total capacity of installed AOT reactors, defined in parameter p315. In this case current max flow will be reduced to this flow by PureBallast. The reduced will be sent to address +056. The selection can be visualized in ISCS either as number of AOT reactors (1, 2, 3 etc) or the flow that corresponds to the number of AOT reactors. Condition: Only possible during Standby (+041=1), full ballast (+042=2) and full deballast (+042=9). Condition: The number of AOT reactors required for the selected flow must not be greater than the number of AOT reactors indicated as ready in address +054 (Numbers of AOT reactor ready). Condition: The selection must be applied using +001:7. Note: This signal shall only be changed when the operator want to change flow; all other times it shall be constant. This will simplify operation, since the selection for last process is set as default for next process.

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Remote interface integration (optional)

Address: 40000 +

Function

Description

+004

By-pass (1.1)

Status: PureBallast system bypassed. Condition: If this address is > 0 PureBallast is by-passed. Ongoing process is shut down and an event is written to the event log with the value in this address.

Bit 0–15

The bits can represent integer values between 0 and 32 767. The value can be used to log a component or a combination of components that result in a by-pass of PureBallast. If it is not possible to use value that correspond to valve ID:s, a key must be kept on board that state which valve or combination of valves the value represent. This is necessary to be able to understand the event log.

+005

Power granted (1.4)

Only relevant if PureBallast is integrated with the vessel’s power management system. Condition: Response to address +045:0–3. Signal shall be high until signal +046:0-3 goes high. Note that it is possible for the vessel’s power management system to grant lower power than requested.

Bit 0–4

Power granted 1–4.

Bit 1–3: Power granted for the number of AOT reactors sent. Bit 4: Power granted for the total number of AOT reactors installed.

+006

Heartbeat (4.5)

Status: Handshaking between PureBallast and ISCS. ISCS send an arbitrary value to address +047. PureBallast return same counter to confirm communication. After defined interval, ISCS send a new number, in a continuous loop. A counter can be used as value. Recommended interval: 10 seconds. Condition: Value must be sent as a signed 16 bit integer between 0 and 32 767.

5.2.2.2

Data to ISCS

The addresses below are used to send data from PureBallast to ISCS. Example of data: System flow and pressure. Book No.9010182 02, rev. 0

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Remote interface integration (optional)

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System interfaces

Address: 40000 +

Function

Description

+050

Processed volume (1.1)

Value: Processed volume [m3] during current ballast or deballast process. The value is resets during next start-up.

+051

Flow measurement (1.1, 1.2)

Value: Current flow indicated by FIT201-1 (/m3/h).

+052

System pressure PT201–16 (1.1)

Value: System pressure indicated by PT201-16. Condition: The value sent from PureBallast must be multiplied by 0.01 before presented in ISCS. Example: If value 450 is sent (and displayed in page 5.5), this means that actual pressure is 4.50 bar.

+053

Selected AOTs (1.2)

Value: Number of AOT reactors selected for operation. Response to address +003 after applied by address +001:7. Alternative, response to parameter p131 (Automatic selection of AOT reactors) if activated in control panel. Note that PureBallast can respond with a lower number of AOT reactors than set in +003, for example if one AOT reactor is not ready. It is recommended that this address is compared to +003. If the number is lower, a message can be displayed in the ISCS to inform the operator that process will run with a lower flow than expected. If flow is increased during operation, this address will be updated when the new AOT reactors are started. If flow is decreased during operation, this address will be updated immediately.

+054

Number of AOTs ready (1.2)

Number of AOT reactors that are ready for use in process.

+055

Selected flow (1.2)

Flow selected for process in m3/h. Response to address +003 after applied by address +001:7.

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Remote interface integration (optional)

Address: 40000 +

Function

Description

+056

Current max flow (1.1, 1.2)

Maximum flow in m3/h for process, based on number of selected AOT reactors and filter capacity. Max flow is calculated as number of selected AOT reactors multiplied with AOT reactor capacity (300 or 1000 depending on size). In some installations the filter capacity is lower than the total capacity of installed AOT reactors, defined in parameter p315. In this case current max flow will be reduced to this flow by PureBallast. Response to address +003 after applied by address +001:7.

+057

Current time - Low (4.1)

Value: Seconds since 1970-01-01 00:00, in combination with address +058. Sent as hexadecimal code. Condition: The value sent from PureBallast must be calculated from seconds since 1970-01-01 00:00 to actual date and time.

+058

Current time - Hi (1.2)

Value: Seconds since 1970-01-01 00:00, in combination with address +057.

+059

Remaining time for CIP (hours) (1.3)

Value: Total estimated remaining time (hours) for all CIP sequences and filter preservation

+060

Remaining time for CIP (min) (1.3)

Value: Total estimated remaining (minutes) time for all CIP sequences and filter preservation.

+061

Remaining time until CIP req. (hours) (1.3)

Value: Hours before CIP must be performed. Displayed per AOT reactor. Note: In the control system, the counter is set to 0 after an AOT reactor has been CIP cleaned. The countdown starts after next ballast or deballast operation. However, for remote interface, the value “30” is sent after CIP cleaning, but without countdown. The countdown starts after next operation.

+062

Remaining time until CIP req. (min) (1.3)

Value: Minutes before CIP must be performed. Displayed per AOT reactor. For details, see +062.

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Remote interface integration (optional)

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System interfaces

Address: 40000 +

Function

Description

+063

Filter differential pressure (Filter popup: dP inlet/outlet)

Value: Filter differential pressure indicated by PT201-71 and PT201-72. Condition: The value sent from PureBallast must be multiplied by 0.01 before presented in ISCS. Example: If value 34 is sent (and displayed in page 5.5), this means that actual pressure is 0.34 bar.

+064

Filter inlet pressure V201–71 (Filter popup)

Value: Filter differential pressure indicated by PT201-71. Condition: The value sent from PureBallast must be multiplied by 0.01 before presented in ISCS. Example: If value 34 is sent (and displayed in page 5.5), this means that actual pressure is 0.34 bar.

+065

Filter outlet pressure V201–72 (Filter popup)

Value: Filter differential pressure indicated by PT201-72. Condition: The value sent from PureBallast must be multiplied by 0.01 before presented in ISCS. Example: If value 34 is sent (and displayed in page 5.5), this means that actual pressure is 0.34 bar.

+066

V201–8 setpoint (1.1)

Control valve output signal (%).

+067

Power consumption (1.1, 1.4)

Only relevant if PureBallast is integrated with the vessel’s power management system. Value: Calculated maximum power consumption [kW] based on number of selected AOT reactors. Calculated or measured power consumption (kW).

5.2.2.3

Commands and status to ISCS

The addresses below are used to send commands and status information from PureBallast to ISCS. Example of data: Process mode (standby, ballast, CIP), acceptance of command from ISCS, and request to ISCS to start ballast pump.

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System interfaces

Address: 40000 +

Function

5.2

Remote interface integration (optional)

Description

/ Bit +070

Command status Bit 0

Start ballast accepted

Status: Confirmation from PureBallast that requested command is executed. Response to command from ISCS on address +001:0.

Bit 1

Start deballast accepted

Status: Confirmation from PureBallast that requested command is executed. Response to command from ISCS on address +001:1.

Bit 2

Start CIP accepted

Status: Confirmation from PureBallast that requested command is executed. Response to command from ISCS on address +001:2.

Bit 3

Stop accepted

Status: Confirmation from PureBallast that requested command is executed. Response to command from ISCS on address +001:3.

Bit 4

Pause/Heeling accepted

Status: Confirmation from PureBallast that requested command is executed. Response to command from ISCS on address +001:4.

Bit 5

Manual backflush accepted (filter popup)

Command: Start backflush. Response to command from ISCS on address +001:5. Condition: Only possible during full ballast (+073:2)

Bit 6

Command rejected

Status: Information that requested command cannot be executed. Reason not specified. Response to command from ISCS on address +001:0-7.

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Remote interface integration (optional)

Address: 40000 + Bit 7

5

System interfaces

Function

Description

Sum alarm

Common alarm indicating that one (any) alarm is active. Alternative to implementation of individual alarm signals and hard wired common alarm. Functions in the same way as hard wired external signal “Common alarm”. Note: If common alarm is issued when there already is an active alarm (this signal already high), PureBallast will lower the signal for 3 seconds, and then re-activate it as high.

Bit 8

Sum warning

Common warning indicating that one (any) warning is active. Alternative to implementation of individual warning signals and hard wired common warning. Functions in the same way as hard wired external signal “Common warning”. Note: If common warnings issued when there already is an active warning (this signal already high), PureBallast will lower the signal for 3 seconds, and then re-activate it as high.

Bit 9

New flow in progress (1.3)

Status: New flow in progress. Response to command from ISCS to change flow during ongoing operation applied by address +001:7.

Bit 10

+071

36

Local / Remote (5.5)

Request: Address values. 1=Activate operation from remote interface. 0=Activate operation from control panels.

Commands Bit 0

Start ballast water pump (1.1)

Request to ISCS to start ballast water pump: Address values. 1=Request to start. 0=Request to stop.

Bit 1

Open overboard valve (1.1)

Request to ISCS to open overboard valve: Address values: 1=Request to open. 0=Request to close.

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System interfaces

5.2

Remote interface integration (optional)

Address: 40000 +

Function

Description

+072

Process mode (1.1, 1.3)

Status: Address values: Values indicating system mode. 0=Booting 1=Standby 2=Ballast 3=Deballast 4=CIP 5=Emergency stop 6=Manual mode

+073

Subprocess mode (1.1, 1.3)

Status: Address values: Values indicating system mode. 0=None 1=Start-up ballast 2=Full ballast 3=Backflush 4=Pause 5=Stop with backflush 6=Increasing ballast flow capacity 7=Decreasing ballast flow capacity 8=Start-up deballast 9=Full deballast 10=Pause deballast 11=Stop deballast 12=Increasing deballast flow capacity 13=Decreasing deballast flow capacity 14=AOT reactor drain 1 – Sea water 15=AOT reactor fill 1 – Fresh water 16=AOT reactor drain 2 – Fresh water 17=CIP 18=AOT reactor fill 2 – Fresh water 19=Preservation filter – Fresh water 20=Heeling mode 21=CIP drain 22=Stop (If ballast process is stopped before mode Full ballast, no backflush is performed.)

+074

Filter mode

Status: Address values: 0=Idle (No backflush or preservation). 1=Backflush preparation. 2=Backflush ongoing. 3=Filter preservation.

+075

Power request [1–4] (1.4)

Only relevant if PureBallast is integrated with the vessel’s power management system. Value: Calculated maximum power consumption [kW] based on number of selected AOT reactors.

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5.2

Remote interface integration (optional)

Address: 40000 + Bit 0–4

5

System interfaces

Function

Description

Power request [1–4] (1.4).

It is only necessary to use signals (bits) to cover the need for power request. This is defined by the number of AOT reactors, alternatively use of common power. Bit 1–3: Power request for the number of AOT reactors to be used in operation. Bit 4: Power request for the total number of AOT reactors installed.

Power running [1–4] (1.4)

+076

Only relevant if PureBallast is integrated with the vessel’s power management system. For information about power request, see system manual chapter 6. Installation description and drawings, section Power management. Power request to power management system.

Bit 0–4

Response to address +005:0–4.

Power running [1–4] (1.4).

Bit 1–3: Power running for the number of AOT reactors used in operation. Bit 4: Power running for the total number of AOT reactors installed. Heartbeat echo (4.5)

+077

5.2.2.4

Status: Handshaking between PureBallast and ISCS. Receive counter from address +006 and return same counter to confirm communication. See address +006.

I/O status to ISCS

The addresses below are used to send status information for components to ISCS. Example of data: Status for valves and pumps. Address: 40000+

Function

Description

/ Bit +080

38

Main valve status (1.1, 1.3 and popups for AOT reactor and filter) Bit 0

V403-35

Status: Address value: 1=Open. 0=Closed.

Bit 1

V201-9

Status: Address value: 1=Open. 0=Closed. Book No.9010182 02, rev. 0

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System interfaces

5.2

Remote interface integration (optional)

Bit 2

V201-3

Status: Address value: 1=Open. 0=Closed.

Bit 3

V201-8

Status: Address value: 1=Open. 0=Closed.

Bit 4

V201-32

Status: Address value: 1=Open. 0=Closed.

Main pump status (AOT reactor popup)

+081 Bit 0

P401-1

Status: Address value: 1=Pump running request. 0=Stopp request.

Bit 1

P403-1

Status: Address value: 1=Pump running request. 0=Stopped request.

Main bypass valve status (1.1)

+082 Bit 0

V212-31

Status: Address value: 1=Open (PureBallast bypassed). 0=Closed.

Bit 1

External bypass valve 1

Status: Address value: 1=Open (PureBallast bypassed). 0=Closed.

Bit 2

External bypass nr. 2

Status: Address value: 1=Open (PureBallast bypassed). 0=Closed.

Bit 3

External bypass nr. 3

Status: Address value: 1=Open (PureBallast bypassed). 0=Closed.

CIP status (1.3)

+083 Bit 0

V571-1

Status: Address value: 1=Open. 0=Closed.

Bit 1

V321-4

Status: Address value: 1=Open. 0=Closed.

Bit 2

V321-1

Status: Address value: 1=Open. 0=Closed.

Bit 3

V460-2

Status: Address value: 1=Open. 0=Closed.

Bit 4

V320-2

Status: Address value: 1=Open. 0=Closed.

Bit 5

V310-1

Status: Address value: 1=Open. 0=Closed.

Bit 6

V310-6

Status: Address value: 1=Open. 0=Closed.

Bit 7

P320-1

Status: Address value: 1=Pump running. 0=Stopped.

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Remote interface integration (optional)

Bit 8

P321-5

5

System interfaces

Status: Address value: 1=Pump running. 0=Stopped.

Filter status (Filter popup)

+084 Bit 0

V309-1

Status: Address value: 1=Open. 0=Closed.

Bit 1

M709-42

Status: Address value: 1=Running. 0=Stopped.

5.2.2.5

Alarms to ISCS

The tables below lists all alarms and warnings sent from PureBallast to the ISCS. Each alarm is defined as a specific bit. The bit is set to 1 when the alarm is activated. The alarm IDs refer to alarms described in chapter 5. Alarms and faultfinding, where texts to be displayed in ISCS can be found. Example: If data at address 40902 is 000010000000100, this means that alarm W04 and warning A33 are active (bit 2 and 10). Empty fields are not used. General alarms and warnings Common alarms and common warnings (+900 and +901) indicate that there exist a common alarm for the area or component specified. Example of alarms and warnings: Process flow too high, valve error, component signals missing. Address 40000 +

Common alarms +900

Common warnings +901

Main 1 +902

Main 2 +903

Main 3 +904

Filter +905

0

Sum

Sum

A01

A51

W96

W300

1

Main

Main

A03

W58

W97

W304

2

AOT

AOT

W04

A66

A98 1

W306

3

CIP

CIP

A10

A67

A99 1

W308

4

Filter

Filter

W12

A68

W310

5

Power

Power

A13

A71

W312

6

Logbox

Logbox

A14

A75

W314

7

A17

A77

A315

8

A23

W79

9

A29

W80

Bit

40

W500

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System interfaces

Address 40000 +

5.2

Remote interface integration (optional)

Main 1 +902

Main 2 +903

10

A33

W82

11

A35

W83

12

W40

A91

13

A48

W92

14

A49

A93

15

A50

W95

Common alarms +900

Common warnings +901

Main 3 +904

Filter +905

Note 1: These alarms are only relevant for PureBallast 3.0 EX.

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Remote interface integration (optional)

5.2.2.6

5

System interfaces

AOT reactor status to ISCS

The addresses below are used to send status information, alarms and warning for AOT reactors and LDC to ISCS. Status information Addresses for data regarding AOT reactor and respective LDC are separated in number series to distinguish information for individual AOT reactor/LDC, if more than one. •

AOT reactor 1 / LDC 1 — Addresses starting with +110

•

AOT reactor 2 / LDC 2 — Addresses starting with +120

•

AOT reactor 3 / LDC 3 — Addresses starting with +130

Empty fields are not used. Example of data: Status for AOT reactor and LDC and their components, for example temperature, UV intensity and valve status. Address: 40000+

Function

Description

/ Bit +110 / +120 / +130

AOT status (AOT reactor popup)

Bit 0

AOT: Stopped (AOT popup)

Status: AOT reactor stopped.

Bit 1

AOT ready (1.2)

Status: AOT reactor is ready, which means that there exist no critical alarms or warnings for the AOT reactor (110:5, 120:5 and 130:5 = 0). 0=Not ready. 1=Ready. The AOT reactor can be selected and used for process.

Bit 2

AOT selected (1.2)

Status: AOT reactor selected for process by operator. In PureBallast, the AOT reactor is visible in the list AOT reactors selected for process in 1.3. Response to address 001:7, apply of flow selection. Alternative, response to parameter p131 (Automatic selection of AOT reactors) if activated in control panel.

42

Bit 3

AOT starting (1.1, 1.2)

Status: AOT reactor starting.

Bit 4

AOT Started (AOT popup)

Status: AOT reactor started.

Bit 5

AOT sum alarm (1.2 and AOT popup)

Status: Common alarm indication for AOT reactor. The AOT reactor is not ready. Book No.9010182 02, rev. 0

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System interfaces

5.2

Remote interface integration (optional)

Bit 6

AOT sum warning (1.2 and AOT popup)

Status: Common warning indication for AOT reactor. If the warning is not critical, the AOT reactor may have status AOT ready.

Bit 7

AOT CIP required (1.3)

Status: CIP status for AOT reactor: 0=Not required. 1=Required.

Bit 8

AOT CIP ongoing (1.3)

Status: CIP status for AOT reactor: 0=CIP not ongoing. 1=CIP ongoing.

Bit 9

AOT CIP error (1.3)

Status: Error for AOT reactor during CIP process.

AOT I/O status (AOT popup)

+111 / +121/ +131 Bit 0

LS201-29

Status: 1=Wet condition. 0=Dry condition.

Bit 1

TS201-60

Status: 1=OK (temp within limit). 0=Not OK (temp exceeded limit).

Bit 2

V201-19

Status: Address value: 1=Open. 0=Closed.

Bit 3

V201-20

Status: Address value: 1=Open. 0=Closed.

Bit 4

V404-36

Status: Address value: 1=Open. 0=Closed.

Bit 5

V321-2

Status: Address value: 1=Open. 0=Closed.

Bit 6

Heat exchange valve (V401–51)

Status: : 1=Open. 0=Closed.

AOT LPS status 1 (4.9 and AOT popup)

Status: Status per individual LPS in the AOT reactor.

+112 / +122 / +132 Bit 0–15 +113/ +123/ +133

Status: Address value: 1=Lamp on. 0=Lamp off. AOT LPS status 2 (4.9 and AOT popup)

Bit 0–15

Book No.9010182 02, rev. 0

Status: Status per individual LPS in the AOT reactor. Status: Address value: 1=LPS error. 0=LPS OK. Status: Address value: 1=Lamp error. 0=Lamp OK.

43

5.2

Remote interface integration (optional)

+114/ +124/ +134

AOT temperature (AOT popup)

5

System interfaces

Value: Temperature indicated by TT201-33. Value displayed for selected AOT reactor. Condition: The value sent from PureBallast must be multiplied by 0.1 before presented in ISCS. Example: If value 221 is sent (and displayed in page 5.5), this means that actual temperature is 22.1 °C.

+115/ 125/ 135 +116 / +126 / +136

LDC water temperature (AOT popup)

Value: LDC cooling water temperature in cabinet indicated by TT401-1. Condition: See +114.

LDC air temperature (AOT popup)

Value: LDC air temperature in cabinet indicated by TT401-2. Condition: See +114.

+117 / +127 / +137

UV intensity (AOT popup)

UV intensity in AOT reactor indicated by QT201-50.

+118 / +128 / +138

Power output (4.9)

Current LPS power consumption (50-100 %).

Alarms and warnings Alarms and warnings for individual AOT reactors and LDCs are separated into different number series according to the list below: •

AOT reactor 1/ LDC 1: Address +910 – 912

•

AOT reactor 2 / LDC 2: Address +913 – 915

•

AOT reactor 3 / LDC 3: Address +916 – 918

Empty fields are not used. Example of alarms and warnings: Hight temperature, fuse tripped, communication error for LPSs. Address 40000 +

Alarms / warnings 1 +910 / +913 / +916

Alarms / warnings +911 / +914 / +917

Alarms / warnings +912 / +915 / +918

Bit 0

W100

W130

W170

1

W101

W131

W171

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System interfaces

5.3

Address 40000 +

Alarms / warnings 1

2

W102

W132

3

W107

W137

4

W109

A138

5

W111

6

W113

W140

7

W116

W150

8

W117

W151

9

W118

W160

10

W119

W161

11

A120

W162

12

W122

W163

13

W126

W164

14

W128

W165

15

W129

5.3

+910 / +913 / +916

Alarms / warnings +911 / +914 / +917

Power management system integration

Alarms / warnings +912 / +915 / +918

Power management system integration

It is possible to connect the PureBallast control system to the vessel’s power management system or ISCS. The purpose is to automatically handle power request from PureBallast to secure that enough power is available for each ballast and deballast process. A process can only start after acceptance from the ISCS. The communication is either handled by the remote interface (if the option is integrated) or via hard wires between the vessel’s ISCS and PureBallast’s control cabinet. It is also possible to use hard wire, even if remote interface is integrated. Power management requires the following: •

Parameter setting must be done for parameter p127.

•

Integration and connection of signals must be done according to the guidelines in this section.

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5.3

Power management system integration

5.3.1

5

System interfaces

Overall power request process

Below, the overall power request process is described. The process is based on three signals types: Power request, power granted and power running. 1. A ballast or deballast process is started from the PureBallast control system. 2. Before the UV lamps are lit, a power request is sent from the PureBallast control system to the ISCS. 3. After power check, the power management reserves the requested power for PureBallast and then send power granted to the control system. If the vessel cannot provide the requested power, less power might be granted. The exact granted power is always visible in the field Calculated power consumption in control system page 1.5 Power request or 1.1 Overview. 4. The ballast/deballast continues the start-up process and the UV lamps are lit. The control system confirms this by sending back a power running signal to confirm that the power is used. 5. When the process is stopped from the control system, the power running signal is deactivated.

5.3.2

Power steps and power signals

The power management system is based on defined power steps, defining the power needed for 1-3 AOT reactors: Step 1 extend to one AOT reactor and step 2 extend to three AOT reactors. . Signals are defined to handle all combinations of power step (amount of power) and function (request, grant and run). More than one signal can be sent (or received) at the same time to achieve, for example step 1 and 2 to request power for 3 AOT reactors. As an alternative, it is possible to use power step 4 (common) that always will be used, regardless of the number of AOT reactors used for a specific process. The common power is defined as the number of installed AOT reactor times the defined power consumption for one AOT reactor. Function signal

No. of AOT reactor:s

Signal to terminal

Power (kW)

Request, step 1

1

Terminal strip X2 Terminal 41/42.

33

Terminal strip X2 Terminal 43/44.

65

Terminal strip X2 Terminal 47/48.

33-97

Relay module X12. Relay K5. Connection point BB and A1.

33

Request, step 2

2

Request, step 4 (common)

1-3

Granted, step 1

1

46

101

201

101-401

101

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System interfaces

5.3

Power management system integration

Function signal

No. of AOT reactor:s

Signal to terminal

Power (kW)

Granted, step 2

2

Relay module X12. Relay K6. Connection point BB and A1.

65

Relay module X12. Relay K8. Connection point BB and A1.

33-97

Terminal strip X3 Terminal 49/50.

33

Terminal strip X3 Terminal 51/52.

65

Terminal strip X3 Terminal 55/56.

33-97

Granted, step 4 (common)

1-3

Running, step 1

1

Running, step 2

Running, step 4 (common)

5.3.3

2

1-3

201

101-401

101

201

101-401

Power management installation

The signals are hard wired and shall be connected to corresponding terminals (same ID) in the control cabinet according to Control cabinet / Interconnection diagram on page 87. Note that the drawing indicate a Step 4, which is not used. Note that It is only necessary to connect enough signals to cover the number of AOT reactors installed on the vessel. If one AOT reactor is installed it is only necessary to connect step 1 for request, granted and running. After installation, the signals need to be tested. This is done by simulating signals from the control system, page 1.4 Power request. See chapter 3. Operating instructions and control system description, instruction Simulate power request.

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5.4

External component signal integration

5.4

5

System interfaces

External component signal integration

The following components and functions (not part of Alfa Laval’s scope of supply) can be integrated with the control system. The communication is either handled by the remote interface (if the option is integrated) or via hard wires. Each signal that is used must be activated in the control system page 5.2 – Main parameters 2. Output indicates signal from PureBallast and Input indicates signal from ISCS. Signal

Control cabinet

Explanation

Common alarm (strongly recommended to be integrated)

Output

What: Output signal from PureBallast that there is an (any) active alarm. An alarm shuts down ongoing process.

Common warning

Output

How: Active alarm = Open circuit. If an alarm is already present and a new alarm is issued, the signal will go low for three seconds, and the be re-activated as high. What: As common alarm, but for warnings. A warning is a notification of status change or a problem. How: See common alarm.

External system stop

Input

What: Input signal to PureBallast to shut down the system. If extra button (not part of AL scope of supply) to shut down PureBallast are desired on board. The power is still on. How: Open circuit = System stop command. Must be connected via hardwire (W117).

Heeling mode (internal transfer)

Input

What: Input signal to PureBallast to to enter heeling mode. Equal to pushing the Pause button in control system. If integration of heeling command from ISCS is desired to automatically pause ongoing ballast/deballast process for a healing operation. How: Closed circuit = Heeling mode command. Only possible in standby, ballast or deballast.

Additional bypass 1 is open Additional bypass 2 is open Additional bypass 3 is open

Input

What: Input signal to PureBallast that an external by-pass valve (not part of Alfa Laval’s scope of supply). If PureBallast can be bypassed using other valves (apart from V212-31), status signals from them must be integrated to the control system. All bypass cases must be logged. When any bypass valve is opened, ongoing process is terminated and the event is logged. Three additional by-pass valves can be handled via hard wire, identified as additional bypass valve 1, 2 and 3. If more valves are used, they must be connected in series, which means that they are handled as one regarding alarms and logging in PureBallast.

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5

System interfaces

Signal

5.4

Control cabinet

External component signal integration

Explanation

If remote interface is implemented, feedback signals can be connected via the remote interface, which allows a great number of components to be connected. How: Open circuit = Valve open. Request ’’Start BW pump’’

Output

What: Output signal from PureBallast to request opening of relevant valves (not operated by PureBallast). After process is stopped, the signal goes low to request that the valve are closed. If Request and Feedback signals are integrated, the operator does not have to confirm that the OB valve is open/closed in a popup in the control panel during operation. How: Request = Closed circuit. No request and request withdrawal = Open circuit.

Feed back ’’Ballast water pump is running’’

Input

What: Input signal to PureBallast to confirm that the ballast pump is started. How: Closed circuit = Pump running.

Request “Open overboard valves”

Output

What: Output signal from PureBallast to request opening of relevant valves (not operated by PureBallast). After process is stopped, the signal goes low to request that the valve are closed. Relevant valves: 201, 309 and 403 and 404 (and 460.1 during CIP process). Note that the signal is mainly intended for the valves apart from those leading to and from pipe 201 If Request and Feedback signals are integrated, the operator does not have to confirm that the OB valve is open/closed in a popup in the control panel during operation. How: Request = Closed circuit. No request and request withdrawal = Open circuit.

Feed back ’’Overboard valve is open’’

Input

What: Input signal to PureBallast to confirm that relevant valves are open. How: Closed circuit = Valve open.

Booster pump (P401-1), for LDC cooling

Output

What: Output signal from PureBallast to request start of the LDC cooling pump for line 401. Pump P401-1 is used during ballast, deballast, pause and heeling mode. How: Request = Closed circuit. No request and request withdrawal = Open circuit.

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5.5

GPS signal installation

5

System interfaces

Signal

Control cabinet

Explanation

Booster pump (P403-1), for AOT reactor reactor cooling

Output

What: Output signal from PureBallast to request start of the AOT reactor cooling pump for line 403. Pump P403-1 is used during start-up, ballast, deballast, pause and heeling mode. How: Request = Closed circuit. No request and request withdrawal = Open circuit.

PureBallast running

Output

What: Output signal from PureBallast that a process is running. How: Pump running = Closed circuit.

5.4.1

External component signal installation

The input and output signal cables must be connected according to the drawing Control cabinet / Interconnection diagram on page 87. This section gives additional information to the drawing on how to connect the cables. Input signals Chosen input signals must be connected from the control cabinet according to Control cabinet / Interconnection diagram on page 87. Output signals Chosen output signals must be connected from the control cabinet according to Control cabinet / Interconnection diagram on page 87. Output signals are connected via potential free relays.

5.5

GPS signal installation

This section describes the installation of GPS position signal to PureBallast. This installation is optional. If used, the GPS position is used to stamp events in the event log. The GPS must be connected to the module X20IF1030 in the control cabinet, using an NMEA (RS422) serial interface with the following settings: •

Baud rate: 4800 bps

•

Parity: None

•

Bits/characters: 8

•

Stop bits: 1

The position data shall be sent as RMC messages. For details, see the illustration below (based on the Control cabinet / Interconnection diagram on page 87).

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System interfaces

5.5

GPS signal installation

6 GPS

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5.5

GPS signal installation

5

System interfaces

6 Start-up procedures The actions below must be performed after installation, before system is put into operation. This is important to avoid that the filter and the AOT reactor is damaged by material from the ballast tanks or remainders from the installation. These actions shall be performed both for new builds and retrofit installations. Before first operation Before the system is operated the first time the actions below must be done. NOTE

•

All pipes leading to PureBallast must be well flushed to avoid that debris harm the filter and AOT reactor quartz sleeves.

•

All ballast water tanks must be well cleaned before PureBallast is tested or put into operation. This is valid both for new builds and retrofit installations.

First operation Before first operation the actions below must be done:

•

During the first operation, the filter shall be bypassed, to avoid that debris harms the filter elements.

•

We recommend that a strainer is used during the first operations, to avoid that debris harms the system.

•

The first time a tank is stripped, PureBallast must be bypassed, to avoid that debris harms the system.

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6

Start-up procedures

7 Drawings This section contains drawings for the PureBallast system. It is divided into three main parts: •

General drawings – overall and principle information for system layout (pipes, components, electricity, air and water).

•

Dimension drawing – detailed component information (dimensions, sizes etc).

•

Electrical drawings – detailed electric information (circuit diagrams, cable lists etc).

See the Contents section at the beginning of this chapter to get an overview of included drawings.

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7.1

7.1

Graphic symbols used in drawings

7

Drawings

Graphic symbols used in drawings

Symbols used in drawings are according to ISO 14617. Below, a guiding extract is shown.

573644

56

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Drawings

7.2

General drawings

7.2.1

Flow chart

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7.2

9007243

General drawings

57

7.2

General drawings

7.2.2

7

Drawings

Connection list

Connection list for Ballast water treatment system according to flow chart 9007243. Item / Connection

Description

Requirements/limits

Main components 201

Ballast water Inlet/Outlet

•

Flow range ballast (m3/h): 140 → 300190 → 750

•

Flow range deballast (m3/h): 100 → 1000

•

Sea water

•

Max. particle size: 10 mm

•

Temperature: → 40 °C (liquid form)

•

Min flow deballast with one AOT reactor reactor in operation (m3/h): 100

•

Max pressure: 6 bar (0.6 MPa)

Ref: figure Pressure and pressure drop after the table. Q201.1 V201-2

Sampling device Valve (optional)

Ref. drawing 590066 on page 79

As above.

Q201.2 V201-25 V201-3

•

Main valves

V201-9 V201–32

•

Ref. drawing 9007178 or 9008463

•

Ref. drawing 9007178 or 9008463

•

Ref. drawing 9007178 or 9008464

•

Ref. drawing 9007176 or 9008461 (Optional)

V212-31 V201-8

• Control valve (flow control during normal • operation and pressure • control during filter back flushing)

IP201-7

IP converter

S201-7

Strainer

58

Ref. drawing 9007182 or 9008467, on page 75 Flow restriction acc. to certified flow rate. Control of pressure, min 0.15 MPa.

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Drawings

7.2

General drawings

Item / Connection

Description

Requirements/limits

403

Cooling water Reactor Inlet

•

Sea water

•

Max pressure: 6 bar (0.6 MPa)

•

Pressure drop: 0,05 bar (0.005 MPa)

•

Min. flow: 20 m³/h (during start up, ~ 5 min.)

•

Max. particle size: 5 mm

V403-35

Valve

•

Ref. drawing 9007180 or 9008465 on page

FIT201-1

Flow transmitter

•

Ref. drawing 586502 on page 73

V201-15 PI201-18 RV201 PT201-16

Needle valve Pressure gauge Safety valve Pressure transmitter

•

Ref. Pressure monitoring device drawing 9007999 on page 74

Filter connections, drawing 9006982 201

Filter inlet / outlet

•

Ref. filter connections drawing on page 70.

309

Backflush water

•

Sea water

•

Backflush range (m3/h):60 → 120 (Intermittent, approx. 35 sec during backflush). Ref: figure Pressure and pressure drop after the table.

V309-1

Reject valve

•

Ref. filter connections drawing, connection 309 on page 70.

310.2

Flushing miscellaneous

•

Ref. filter connections drawing, connection 310.2 on page 70.

•

Fresh water preservation volume: 152 L

•

Flanged, blanked

•

Ref. filter dimension drawing, connection 460 on page 70.

460

Drain Filter

AOT reactor connections, drawing 9003516 V201-19 V201-20

Inlet / outlet

•

Ref. AOT reactor dimension drawing

404

Cooling water Reactor outlet

•

Over board

•

Flow: ref. to con. 403

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7.2

General drawings

7

Item / Connection

Description

Requirements/limits

V320-4

CIP / Drain

•

V321-2

Reactor outlet

V404-36

Cooling water

Drawings

Ref. AOT reactor dimension drawing on page 69.

Lamp drive cabinet (LDC), drawing 9005331

401

Cooling water Lamp Drive Cabinet (LDC) Inlet

•

Fresh water (existing cooling system)

•

Max. particle size: 600 μm

•

Temperature: 0 → 38 ºC

•

Cooling capacity: 5 kW

•

Working pressure: 1 → 10 bar (0.1 → 1.0 MPa)

•

Pressure drop: 15 bar (0.15 MPa)

•

Min. flow: 1.5 m³/h (1.5 m3/h each LDC) @ 38 °C

SV401-51

Valve

•

Ref. LDC dimension drawing on page 82.

402

Cooling water LDC outlet

•

Back to recirculation (suction side)

CV402

Valve

•

Ref. LDC dimension drawing on page 82.

CIP unit connections, drawing 9004714

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Drawings

7.2

General drawings

Item / Connection

Description

Requirements/limits

310.1 310.2

Flushing miscellaneous

•

Fresh water (potable)

•

Quality requirements: see 590773 on page 67

•

Volume: 380 L/ rinsing & preservation (2 cycles x 1 reactor x 190 L) .

•

Min pressure: 3 bar (0.3 MPa)

•

Ref. CIP module dimension drawing on page on page 71.

V310-1

Valve

V310-3

Backflow preventer

V310-6 V310-8

Valve

CV310-7

Strainer

320

Flushing miscellaneous, reactor module

•

Sea water / fresh water

•

CIP liquid quality requirements, see 594956 on page 68

V320-2 V320-11

Valve

•

Ref. CIP module dimension drawing on page 71.

P320-1

Pump

•

Diaphragm pump (pneumatic)

321

Flushing miscellaneous, reactor modue

•

Sea water / fresh water

•

CIP liquid

Pump

•

Ref. CIP module dimension drawing on page 71.

•

Diaphragm pump (pneumatic)

•

Sea water / fresh water

•

Normally no flow

•

Volume: 380 L (1 reactor x 190 L sea water drained and 1 reactors x 190 L fresh water drained before CIP sequence). Flow: 60 L/min.

•

Ref. CIP module dimension drawing on page 71.

P321-5

V321-1 V321-4

Valve

460.1

Drain Reactor

V460-2

Valve

CV460-4

Check valve

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General drawings

7

Item / Connection

Description

Requirements/limits

460.2

Drain CIP module

•

By gravity

•

Normally no flow

•

Volume: 300 L

Drawings

V460-3

Valve

•

Ref. CIP module dimension drawing on page 71.

571

De-aeration AOT reactor / CIP

•

Air

V571-1

Valve

•

Ref. CIP module dimension drawing on page 71.

•

Ref. 595208 on page 65

•

Required pressure: 5.5 – 8.0 bar

Air (total system consumption) 501

Instrument air

Max consumption:

62

•

During ballast and deballast operation: Max 30 NL/min.

•

Consumption: continuous, max 30 NL/min, peak load, 0.6 Nm3/min (during CIP sequence: 25 min, pump running.

•

Quality requirements: see 553407 on page 66

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Drawings

7.2

General drawings

6 Working_Pressure_Hydac

∆pfilter

∆pAOT ∆pfilter inlet ∆p309

- Filter pressure drop, depending on filter contamination. (dynamic and static pressure). 0.2 – 0.5 bar — Normal operation. 0.5 bar — Filter backflushing sequence triggered. - AOT reactor pressure drop (dynamic and static pressure). - 1.0 bar + p309: Required pressure to establish effective back flushing of filter. - Pressure drop, (dynamic and static pressure), line 309 (back flush over board).

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7.2

General drawings

7.2.3

7

Drawings

Electrical system layout

9005353

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Drawings

7.2.4

7.2

General drawings

Air distribution

585828

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7.2

General drawings

7.2.5

7

Drawings

Quality specification / Compressed air

553407

66

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Drawings

7.2.6

7.2

General drawings

Quality specification / Water

590773

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7.2

General drawings

7.2.7

68 594956

7

Drawings

Quality specification / CIP liquid

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Drawings

7.3

Dimension drawings including technical data

7.3

Dimension drawings including technical data

7.3.1

AOT reactor / Dimension drawing

Book No.9010182 02, rev. 0 9003516

69

7.3 Dimension drawings including technical data

7.3.2

70

9006982

7

Drawings

Filter / Dimension drawing

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Drawings

7.3.3

7.3

Dimension drawings including technical data

CIP module / Dimension drawing (2 pages)

71

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7.3 Dimension drawings including technical data

7

Drawings

9004714_p2

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Drawings

7.3.4

7.3

Dimension drawings including technical data

Flow transmitter FIT201-1 / Dimension drawing

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586502

73

7.3 Dimension drawings including technical data

7.3.5

7

Drawings

Pressure monitoring device (Incl. PT201-16, PI201-18, RV201 and 201-15) / Dimension drawing

74

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7

Drawings

7.3.6

7.3

Dimension drawings including technical data

Control valve V201-8 / Dimension drawing

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9007182

75

7.3 Dimension drawings including technical data

7.3.7

76

7

Drawings

Valve V201-3 and V201-9 / Dimension drawing

9007178

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Drawings

7.3.8

7.3

Dimension drawings including technical data

Valve V201-32 and V403-35 / Dimension drawing

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9007180

77

7.3 Dimension drawings including technical data

7.3.9

78

7

Drawings

Valve V212-31 / Dimension drawing (Optional in scope of supply)

9007176

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Drawings

7.3

Dimension drawings including technical data

7.3.10 Sampling device Q201.1 and Q201.2 / Dimension drawing (3 pages) (Optional in scope of supply)

590066 1

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7

Drawings

590066 2

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Drawings

7.3

Dimension drawings including technical data

590066 3

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7.3 Dimension drawings including technical data

7

Drawings

7.3.11 Lamp drive cabinet (LDC) / Dimension drawing

9005331

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Drawings

7.3

Dimension drawings including technical data

7.3.12 Control cabinet / Dimension drawing

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9005261_p1

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7.3 Dimension drawings including technical data

7

Drawings

9005261_p2

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Drawings

7.3

Dimension drawings including technical data

7.3.13 Remote control panel / Dimension drawing (2 pages)

595261_p1

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7

Drawings

595261_p2

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Drawings

7.4

Electrical drawings

7.4

Electrical drawings

7.4.1

Control cabinet / Interconnection diagram (7 pages)

Filter type 1 = Boll filter. Filter type 2 = Hydac filter.

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Electrical drawings

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Drawings

9005343_Page_22

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Electrical drawings

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Electrical drawings

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Drawings

9005343_Page_24

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Electrical drawings

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Electrical drawings

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Drawings

9005343_Page_26

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Electrical drawings

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Electrical drawings

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Drawings

9005343_Page_28

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Drawings

7.4.2

7.4

Electrical drawings

Control cabinet / Circuit diagram (20 pages)

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Electrical drawings

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Drawings

9005343_Page_02

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Electrical drawings

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Electrical drawings

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Drawings

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Electrical drawings

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Electrical drawings

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Drawings

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Electrical drawings

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Electrical drawings

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8 Shutdown and storage This section describes requirements for decommissioning and storage. The rules must be followed when the system shall be shutdown for a long period. A copy of the decommissioning report must be placed inside the control cabinet. The report must include all important information from the decommissioning, for example notes and information about where to find stored components.

8.1

Decommissioning

Follow the process below to decommission the PureBallast system. Note that if there is a freeze risk, the system must be completely emptied of water. 1. Run the back flush sequence for the filter three times. 2. Drain all water from the filter. Leave the drain open afterwards. 3. Run the CIP process twice. 4. Drain all liquid from the AOT reactors. Leave the drains open. (Use the drain plug at the bottom of the AOT reactor.) 5. Shut off the main valves for the start-up cooling system. Drain the system afterwards. 6. Isolate the start-up cooling system: Close installed service valve, or use a blind flange, to prevent fluid to enter the section. (Pipe connection 403, 404.) 7. Drain all water from the LDC heatexchangers. Leave the drains open afterwards (disconnect hoses). Shut off the main valves for the cooling system (pipe connection 401). 8. Clean the CIP module with fresh water. Rinse the tank. Drain all water/liquid from the CIP system and leave the drains open afterwards. 9. Isolate the system: Close installed service valves, or use a blind flange, to prevent fluid to enter the section. (Pipe connection 310, 460.) 10. Drain water from the pipe systems between the main inlet valve (V201-3, V201-9) and control valve (V201-8). Leave any open drains open afterwards. 11. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter the section. (Pipe connection 201.) 12. Drain all water from the filter back flush line. Leave the drain flange in the bottom of the filter open afterwards. 13. Isolate the system: Close installed service valve, or use a blind flange, to prevent fluid to enter the section. (Pipe connection 309.) 14. Shut off the breakers on the control cabinet and the lamp drive cabinet. Lock them in that position. Label them to avoid connection by mistake.

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8.3

Storage and long term decommissioning

8.2

8

Shutdown and storage

Protection

Perform the actions below to protect the system: •

Protect all electrical cabinets from humidity with Silica gel or similar.

•

Protect all metal surfaces from corrosion attacks with anti-rust oil. The oil must have long lasting effective treatment for external surfaces.

•

Disconnect the air supply to the CIP module. Use service valve if possible, otherwise plug the air supply inlet.

•

Disconnect and drain the membrane pumps (P320-1, P321-5 or P460-7). Rinse with fresh water and reconnect the pump.

•

Articles made of rubber or plastics (for example seals) must not be treated with antirust oil.

•

Protect pressure monitoring device etc. from mechanical damages. The following components are recommended to be removed and stored safely: PT201-27, PT201-16, and PI201-18.

•

Protect components equipped with circuit boards from condensation. Recommendations:

-

Remove IP201-7 and FIT201-1 and store in a non condensing environment.

-

Remove and store the display for FIT201-1.

-

Protect the flow sensor with silica gel or similar. Protect the sensor with the supplied plastic cover.

•

Change the battery in the control panel. If not, the stored log information can be lost during storage.

•

Put all pneumatic valves in open position.

•

Every 3 months, operate each valve by close/open exercise. This will keep the valves and actuators in best condition. Note that control valve V201-8 must be exercised manually at the same time as the IP201-7 is removed. Use a wrench to apply appropriate torque.

8.3

Storage and long term decommissioning

•

All system equipment must be stored indoors at 5–55°C, in a non-condensing environment.

•

If there is a risk for condensation of water during storage, the equipment must be protected by ventilation and heating above dew point.

•

All articles made of rubber / elastomer has a limited useful life time. Therefore, the following instructions must be followed:

-

If the filter or any filter candles are stored for more than 12 months, we recommend that the seals are checked, and changed if necessary, before the system is put in service.

-

If the system is stored for more than 24 months, all articles made of rubber and elastomer (gaskets, O-rings etc) must be changed before the system is put in service. Such articles are found in the following components: UV lamps, quartz sleeves and catalytic candles in the AOT reactors and the filter candles.

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Shutdown and storage

8.4

8.4

Start-up after shutdown

Start-up after shutdown

Follow the overhaul process below to star-up the PureBallast system after decommission. 1. Locate the decommissioning report stored inside the control cabinet. Use this report to the re-commissioning of the PureBallast system. 2. Clean away the anti-rust oil with a solvent, for example, white spirit. 3. Assemble items that have been disassembled. 4. If applicable: Remove the silica gel bags from all units. 5. Before the system can be activated, it must be checked according to the commissioning checklist.

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8.4

Start-up after shutdown

8

Shutdown and storage

9 Delivery and transport information This section contains information about how to handle PureBallast components during transport, delivery and installation.

9.1

Delivery and transport

Preparations and conditions: •

Always read and follow the documentation included in shipment of components and spare parts regarding handling, safety and disposal.

•

Handle the delivery with care in order not to damage the equipment or cause personal injuries.

•

If the PureBallast system is stored before installation, make sure to store the components according to the Shutdown and storage section.

9.2

Lifting instructions

This section describes how to lift PureBallasts components. Preparations and conditions

!

NG WARNI

•

Components must be lifted using correct lifting tools (such as a forklift truck, a crane) and tackle with a load capacity greater than the weight of the component stated in the section below.

•

Any complementary lifting instructions must be followed.

•

Components must be empty when lifted.

•

The AOT reactor, filter, CIP and control cabinet must be lifted according to the instructions in the following sections.

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9.2

Lifting instructions

9.2.1

9

Delivery and transport information

AOT reactor

Weight of AOT reactor (empty): 330 kg. L = 75 cm

6 AOT Lift

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Delivery and transport information

9.2.2

9.2

Lifting instructions

Filter

Weight of filter (empty with adaptor plates on flanges): 825 kg. A=98 cm.

6 FilterLift

9.2.2.1

Raise and lift filter

Follow the instruction to raise the filter to standing position and to lift it for transportation. 1.

When the filter is resting in the bottom of the wooden case: Attach a 2 string-round sling to the two upper lifting bolts.

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9.2

Lifting instructions

9

Delivery and transport information

6 FilterLift Hydac2

2.

Use a lifting gear to raise the filter to upright position. Use the bottom filter legs as turning point.

3.

When the filter is in upright position: Attach a 3 string-round sling to all three lifting bolts.

6 FilterLift Hydac

4.

146

Lift and transport the filter.

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9

Delivery and transport information

9.2.3

9.2

Lifting instructions

CIP module

6 CIP Lift, new 9004908

9.2.4

Cabinets

Use intended lifting attachment at the top of the cabinet.

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9.2

Lifting instructions

9

Delivery and transport information

XXXXX

6 CabinetLift

Example: Control cabinet

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Chapter: 7. Service manual System manual — PureBallast 3.0 Flow 750

Book No.

9010182 02, rev. 0

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax:

+46 8 530 310 40

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1 2

3

4

Introduction

7

1.1

7

Preparations and conditions

Maintenance schedule

9

2.1

Calibration schedule

11

2.2

Serial number information

12

2.2.1 2.2.2

Indicating serial number Example

12 13

2.3

Placing of serial numbers

14

Operate valves manually

19

3.1

Open and close valves manually (CIP valves)

19

3.2

Open and close valves manually (V201-3, V201-9 and V201-8)

19

3.3

Lock valve in closed position

20

3.4

Unlock valve

21

AOT reactor

23

4.1

Safety information

23

4.2

Replace UV lamp and quartz sleeve

24

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

Disassemble UV lamp Disassemble quartz sleeve Assemble quartz sleeve Check for leaks after quartz sleeve assembly Assemble UV lamp

24 27 27 28 28

4.3

Open AOT reactor

29

4.3.1

Disassemble AOT reactor

29

3

5

6

7

8

4

4.4

Dismount and mount lamp power supply (LPS)

31

4.5

Test LPS installation

32

Filter

35

5.1

Disconnect power to filter

37

5.2

Remove filter cover and filter candles

37

5.3

Mount filter candles and filter cover

38

5.4

Replace filter candles

39

5.5

Clean filter candles

39

5.6

Change sacrificial anode

40

CIP module

41

6.1

Change and refill CIP liquid

41

6.1.1 6.1.2

Change CIP liquid Refill CIP liquid

43 43

6.2

Repair CIP pump

44

6.2.1 6.2.2 6.2.3

Clean CIP pump Disassemble CIP pump Assemble CIP pump

45 45 46

6.3

Test CIP pump

47

6.4

Repair junction box and valve blocks

47

6.5

Repair valve block

47

6.5.1 6.5.2 6.5.3 6.5.4

Change valve body Connect electrical cables to valve block Clean valve block Connect pneumatic hoses to valve block

48 48 49 49

Flow meter

51

7.1

Mount flow transmitter

51

7.2

Change direction of flow transmitter

53

7.3

Change direction of flow transmitter control pad

54

7.4

Clean flow meter electrodes

56

Valve actuator

57

8.1

Preparations and conditions

58

8.1.1

Tightening torques for actuators

58

8.2

Dismount actuator

59

8.3

Mount actuator on valve

59

8.4

Change direction of actuator – without position sensor (V404–36, V320–4 and V321–2)

61

Change direction of actuator – with switch box (V201–3, V201–9, V201–32, V212–31 and V403–35)

62

8.6

Change direction of actuator – with position sensor (201-19 and 201–20)

62

8.7

Change direction of actuator – with positioner (201–8)

64

8.8

Mount pilot valve on actuator

64

8.9

Adjust valve end position

65

8.10

Adjust valve traveling speed

66

8.11

Calibrate positioner on V201-8

68

8.5

9

Ball valve

71

9.1

71

Replace seals in ball valve

10 Level switch

73

10.1

Mount level switch

73

10.2

Dismount level switch

74

10.3

Test level switch

74

11 Temperature switch and temperature transmitter

75

11.1

Mount temperature switch / temperature transmitter

75

11.2

Dismount temperature switch / temperature transmitter

76

12 Control panel

77

12.1

Clean control panel

77

12.2

Replace control panel

77

12.2.1 Dismount the panel 12.2.2 Mount the panel

77 78

5

13 Remote control panel (optional) 13.1

Mount and connect network switch for remote control panel

81

13.2

Mount and connect network switch for remote control panel (retrofit)

83

14 Control cabinet and lamp drive cabinet (LDC)

6

81

85

14.1

Disassemble and assemble I/O system

85

14.2

Cable gland installation

87

1 Introduction This chapter contains information and instructions about how to service the PureBallast system. Instructions are sorted per component. The chapter is opened with a maintenance schedule covering checks and services that must be performed with specified intervals.

1.1

Preparations and conditions

NGE ! DA •

R

Before maintaining the PureBallast system, the power supply must be switched off, to avoid accidental starts. See instruction Abort operation and deactivate the system in chapter 3. Operating instructions and control system description. NOTE

•

All maintenance of the PureBallast system must be logged in the vessel’s maintenance log.

•

Always read and follow the documentation that are included in shipment of components and spare parts regarding handling, safety and disposal.

•

Before maintaining the PureBallast system, the following valves must be locked in closed position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 20.

•

Follow local regulations for electrical installation and grounding (earthing).

•

Follow general rules when handling of Alpacon descalant offshore cleaning agent, regarding ventilation, personal protection etc.

•

Point of contact: To order service or spare parts, contact your local Alfa Laval office. For more information, see www.alfalaval.com.

Book No.9010182 02, rev. 0

7

1.1

Preparations and conditions

1

Introduction

2 Maintenance schedule Follow this maintenance schedule to secure performance, safety and durability of the system and its components. The schedule is sorted per component. The table refers to instructions usable when performing the respective action. Component

Action

Time interval

General

Inspect for corrosion and erosion damage.

Once a year.

General

Calibration of sensors

According to Calibration schedule

See Calibration schedule

AOT reactor

Outer inspection of seals for leakage.

Once a year.

If necessary, change according to Open AOT reactor.

See Spare parts catalogue for service kit.

Check UV lamps for leakage.

Once a year.

See Disassemble quartz sleeve.

See Spare parts catalogue for service kit.

Replacement of UV lamps.

Recommended to change all lamps after 3000 hours of operation.

See Replace UV lamp and quartz sleeve.

See Spare parts catalogue for service kit.

Inspection and cleaning of filter insert, including filter candles.

Once a year.

See Remove filter insert.

Replace filter candles, if damaged.

Outer inspection of seals for leakage.

Once a year.

Check sacrificial anode.

Once a year.

Filter

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Instructions

Notes

See Spare parts catalogue for service kit.

Change if needed or every five years.

If necessary, change faulty seals. See Change sacrificial anode.

Change if the anode has lost approximately 80 % of the zinc mass.

9

2

Maintenance schedule

pH value check.

Before each filling-up or once every 3 months, whichever comes first.

CIP liquid level check.

Rule of thumb: See Change CIP Once every 3 liquid or Refill CIP months. liquid. Depending on number of AOT reactor and ballasting frequency, the liquid check might have to be performed more regularly.

Replacement.

When the pH value is higher than pH 3 or once a year. or When the CIP module has been inactive for over one year.

See Refill CIP liquid.

Control of stored CIP liquid.

Visual inspection after three years.

See Preparations and conditions under Change and refill CIP liquid instruction.

Valve block on CIP module

Control that the cables are firmly attached to the terminal strip in the valve block.

Once a year.

See chapter 7. Service manual, section Connect electrical cables to valve block.

Flow meter

Clean flow meter electrodes.

Once a year.

See Clean flow meter electrodes.

Control system

Cleaning of display.

Displays should be cleaned at regular intervals or when dirty.

See Clean control panel.

Battery check (PLC module).

Automatically every when turned on and every 24 hours.

CIP liquid

Battery When alarm PLC replacement (PLC battery low is module). indicated in the control system. or: 10

See Change CIP liquid or Refill CIP liquid.

If the CIP liquid is low but the pH value is below 3, CIP liquid and water can be added to fill up the liquid level in the tank. Note: pH value must be checked afterwards to secure correct pH value.

Alarm PLC battery low issued when battery is low. The battery is placed in the PLC module in the control cabinet. Book No.9010182 02, rev. 0

2

Maintenance schedule

2.1

Calibration schedule

After 5 years. or: Before storage for longer periods.

2.1

Calibration schedule

Follow this calibration schedule to secure performance of the system and its components. The schedule is sorted per component. Interval: Once a year, if nothing else is stated. Component

Informatoin / instruction

Flow meter

Every second year. 1. Connect a calibrated portable ultrasonic flow meter close to the flow meter. 2. Establish flow in the system. 3. Compare value indicated in control system and measure equipment.

Pressure transmitters

1. Connect calibrated portable measure equipment to the measure point (screw to the side, under the handle).

Filter: (PT201-71, 2. Open V201-32 from the control system. PT201-72 and PT201-71, PT201-72 and PT309-2 PT309-2) 3. Compare values indicated for the three transmitters in control system Pressure and measure equipment. transmitter 4. Open 403-35 from the control system, and compare again. (PT201-16) PT201-16 Pressure gauge (PI201-18) 5. Open V403-35 to apply pressure to the system. 6. Adjust handle on PT201-16 to establish pressure to measure point. 7. Compare value indicated in control system and measure equipment. PI201-18 8. Compare value indicated in pressure gauge and measure equipment.

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2.2

Serial number information

2

Maintenance schedule

AOT reactor components

1. Depressurize and drain the reactor: Remove the drain plug at the bottom of the AOT reactor.

Temperature transmitter (TT201-33)

TT201–33

Temperature switch (TS20160)

3. Compare value indicated in the control system and measure equipment.

Level switch (LS201-29)

2. Dismount the transmitter and place in water with known temperature (calibrated measure instrument). TS201-60 4. Dismount the switch and place in water with temperature < 65 ˚C. 5. Check that alarm A137 is displayed in the control system. LS201-29 6. Dismount the sensor and lace it in a glass of water. 7. Check that you get a signal for the AOT reactor in the control system. 8. Fill the AOT reactor with fresh water.

UV sensor in AOT reactor (QT201-50)

Every second year.

Temperature transmitter in LDC (TT401)

Place a calibrated thermometer inside the cabinet and compare after 30 minutes.

2.2

Order a exchange sensor from your local Alfa Laval office (parts and service) to be installed and used during the time the sensor is calibration at factory.

Serial number information

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

2.2.1

Indicating serial number

Serial numbers shall be stated, including the following information: •

Serial number for the complete PureBallast system. See label on the side of the control cabinet.

•

Serial number for the component in question. If the component is installed on, or in, another component, the number for the mother component shall be stated.

•

Item number for the component. The item number identifies a unique component in the system. It begins with a letter abbreviation indicating the component type, for example: LS (level switch), P (pump) and PI (pressure gauge). A complete list of abbreviations is found in chapter 6. Installation description and drawings, section Connection list.

12

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2

Maintenance schedule

2.2.2

2.2

Serial number information

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 AOT reactor on which the level switch is installed.

•

Item number for the component (LS00000)

Book No.9010182 02, rev. 0

13

2.3

2.3

Placing of serial numbers

2

Maintenance schedule

Placing of serial numbers

The table below indicates the position of the serial number plate per component. PureBallast water treatment system Serial number for the complete PureBallast system. Placing: On the right-hand side gable of the control cabinet.

7 PB 591098_SerialNo

AOT reactor At the side of the AOT reactor, as indicated in the illustration.

7 AOT Snr

14

Book No.9010182 02, rev. 0

2

Maintenance schedule

2.3

Placing of serial numbers

Filter Placing: At the side of the filter, as indicated in the illustration.

7 FilterSnr Hydac

Electrical cabinets (Including breakers) Placing: At the inside of the door (illustration shows control cabinet). •

Control cabinet

•

Lamp drive cabinet (LDC): Inside top left door.

7 CC Sernr 591773#1

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15

2.3

Placing of serial numbers

2

Maintenance schedule

Lamp power supply LPSs are installed in the lamp drive cabinet. NOTE Version must be stated together with the serial number. Version is stated on the serial number plate.

Placing: At the front of each LPS.

7 LDC sernr

Valves and actuators Serial number plate for various valves are placed at the side of the actuator. One example is illustrated to the right. NOTE This number shall be used both for the actuator and the mechanical valve.

7 Valve Snr 591890

16

Book No.9010182 02, rev. 0

2

Maintenance schedule

2.3

Placing of serial numbers

Flow meter (Including flow transmitter and flow sensor) Placing: At the side of the pipe, as indicated in the illustration. NOTE The flow transmitter and flow sensor have individual serial numbers. But it is sufficient to state the flow meter serial number.

7 FM snr 576179_manual 2

Book No.9010182 02, rev. 0

17

2.3

Placing of serial numbers

2

Maintenance schedule

3 Operate valves manually This section covers instructions on how to open, close and lock/unlock valves manually. Avoid operating valves manually. Valves are normally operated from page 1.1 Overview in the control system (manual mode). See chapter 3. Operating instructions and control system description for instruction.

3.1

Open and close valves manually (CIP valves)

Follow this instruction to manually operate the valves installed in the CIP module: V571-1, V321-4, V321-1, V460-2, V320-2 and V310-6. Note that the orange diode on the valve body will not light during manual operation. Follow the steps below 1.

Identify which button (illustrated on page 47) on the valve block that controls the valve. The lower button operates the inner hose under the valve block, and vice versa. Also see the sticker under the valve block.

2.

Press the button on the valve body with a screw driver to operate the valve.

3.2

Open and close valves manually (V201-3, V201-9 and V201-8)

Follow this instruction to manually operate valves V201-3, V201-8 and V201-9. Valves can be operated using the position screw on the pilot valve. Position 0 Position 1

Closed (default position). If the position screw is in position 0 and the valve is closed, it can be manually opened. But if the position screw is in position 0 and the valve is opened, it cannot be manually closed. Opened.

Follow the steps below •

Air must be connected, but power does not have to be connected.

Follow the steps below 1.

If there is limited access to the screw, it is possible to remove the DIN connector.

2.

Place a screw driver in the position screw groove.

Book No.9010182 02, rev. 0

19

3.3

Lock valve in closed position

3

Operate valves manually

3.

Turn the screw to desired position. — Position 1 to open. — Position 0 to close.

4.

When done, turn back the screw to position 0. If the DIN connector was removed, connect it again.

3.3

Lock valve in closed position

Follow this instruction to lock valves V201-3, V201-9, V201-8 and 212-31 in closed position. These valves are locked mechanically with two bolts on the actuator. Preparations and conditions •

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

Follow the steps below 1.

Set the valve to closed position from the control system. Control the position indicator, to make sure. The yellow position indicator is in line with the valve throttle (indicating open when the position indicator is in line with the pipe).

2.

Disconnect power and compressed air. Verify that the valve is not under pressure.

3.

Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).

7 576075_lock_manual

4.

Measure exactly how far out the end stop bolt (4) is from a reference surface, for example the actuator house. Make a note of the distance. This information is needed when unlocking the valve.

5.

Open the locking bolt (3) and turn them a couple of turns.

6.

Screw the end stop bolt (4) to its bottom position and tighten the locking bolt.

7.

Verify that the valve cannot be opened.

20

Book No.9010182 02, rev. 0

3

Operate valves manually

3.4

Unlock valve

8.

Slide the safety cover over the end bolts and lock the safety cover with the pad lock.

9.

Repeat the above procedure for all valves concerned.

3.4

Unlock valve

Follow this instruction to unlock valves V201-3, V201-9, V201-8 and 212-31 from closed position. Preparations and conditions •

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

Follow the steps below 1.

Disconnect all power and compressed air. Verify that the valve is not under pressure.

2.

Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).

7 576075_lock_manual

3.

Open the locking bolt (3) slightly.

4.

Adjust the end stop bolt (4) to the same position (distance from reference surface) as before locking the valve, according to the notes made during locking. NOTE

•

It is important to adjust the ends stop bolt to the correct position. Otherwise the actuator may be damaged.

5.

Tighten the locking bolt (3).

6.

Verify that the valve can open and close.

Book No.9010182 02, rev. 0

21

3.4

7.

22

Unlock valve

3

Operate valves manually

Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad lock.

Book No.9010182 02, rev. 0

4 AOT reactor This section covers instruction for service of the AOT reactor.

4.1

Safety information

NGE ! DA

R

•

Always disconnect the PureBallast system from the power supply before disassembling, and secure it from being switched on.

•

UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly installed inside the AOT reactor with end caps properly closed.

•

Never dismount or handle UV lamps before they are completely cooled down. A hot UV lamp is under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn if it is touched.

!

ON CAUTI

•

Before installation, check that the UV lamps and quartz sleeves are not broken.

•

UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.

•

UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be handled and disposed of with care. Used lamps UV can be handled and disposed of in the same way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe (or use pure sulphure to bind the mercury for easy collection). •

Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.

•

Free mercury must be kept in an airtight bottle, and must be disposed of according to national regulations.

•

In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.

•

When performing these routines, consider the need for service kits for UV and quartz sleeves, containing O-rings, lamps, quartz sleeves etc. See Spare parts catalogue.

•

Do not touch the glass of the UV lamp. Wear gloves and hold the lamp by the ceramic end parts only. If a lamp is stained on its surface, wipe off the glass with a clean soft piece of cloth soaked with alcohol. If not, it could cause breakage and shorten lamp life.

Book No.9010182 02, rev. 0

23

4.2

•

Replace UV lamp and quartz sleeve

4

AOT reactor

Keep the UV lamp in its original protective cover and case when transporting, storing and disposing of the lamp. Otherwise it could cause injury if the lamp breaks. Do not dispose of original protective cover and case for the UV lamp, as they should be re-used for storage and disposal. Mark cases with used UV lamps accordingly, so that they will not be mistaken for new lamps.

4.2

Replace UV lamp and quartz sleeve

7 AOTexploded2

AOT reactor, exploded (Example shows a 300 AOT reactor). 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Cap Cap nut Bush O-ring (inside bush) Cable connector Allen screw Glass socket O-ring UV lamp Quartz sleeve

4.2.1

Disassemble UV lamp

Follow this instruction to dismount the UV lamps. Preparations and conditions • 24

The PureBallast system must be turned off, and the power disconnected. Book No.9010182 02, rev. 0

4

AOT reactor

•

After UV lamps have been changed, the runtime must be reset in page control system page 4.4 Operation timers AOT 1–3. Requires login level Advanced operator.

•

Wait at least 10 minutes after completed ballast or deballast process, to allow the AOT reactor to cool down to ambient temperature. If the UV lamps are hot they are under internal positive pressure and may burst if broken.

! •

Replace UV lamp and quartz sleeve

NG WARNI

The AOT reactor must not be under pressure when dismounting the UV lamps.

! •

4.2

NG WARNI

Burn hazard: UV lamps can be hot and cause burns.

Follow the steps below 1.

Unscrew the nut (2) holding the caps (1). There is one nut on each side of the AOT reactor per UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.

2.

Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).

7UVlampConnection

3.

Carefully draw out the UV lamp and one of its bushes (3) with the electric cable, by holding the electric cables in both ends. If required, use a screwdriver to press on the ceramic end of the lamp inside the bush on the other side whilst carefully pulling the electric cable at the other end.

Book No.9010182 02, rev. 0

25

4.2

Replace UV lamp and quartz sleeve

4

AOT reactor

7UVBushScrewdriver

4.

Hold the UV lamp by the ceramic ends after the bushes have been removed. Immediately after removal, place the lamp in its protective cover.

5.

Check that no quartz sleeves (10) are broken. To disassemble the quartz sleeves, see the instruction Disassemble the quartz sleeve.

6.

If no quartz sleeves are broken, mount new UV lamps according to the instruction Assemble UV lamp on page 28. If broken see the Preparations and conditions section above.

26

Book No.9010182 02, rev. 0

4

AOT reactor

4.2.2

4.2

Replace UV lamp and quartz sleeve

Disassemble quartz sleeve

Follow this instruction to disassemble the quartz sleeve.

! •

NG WARNI

Hot water may escape from the AOT reactor when removing the drain plug.

Follow the steps below 1.

Close the AOT reactor inlet (V201-19.n) and outlet (V201-20.n) valves from the main panel.

2.

Depressurize and drain the AOT reactor: Remove the drain plug at the bottom of the AOT reactor.

3.

Disconnect the compressed air, as a safety precaution.

4.

Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 24.

5.

Unscrew the three Allen screws (6) of the glass socket (7), just a few turns to release the sockets on both sides.

6.

Unscrew the glass sockets on both sides completely.

7.

Carefully remove the glass sockets and the quartz sleeve (10).

8.

Remove the O-rings (8) on both sides. The O-rings are firmly stuck in their seat, and will be damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring tool to loosen and remove the O-ring. Be careful to avoid to break the glass. If the O-ring is hard to remove, try the following: – Moisten the O-ring with acetone or denatured alcohol. – Loose the O-ring in a couple of places before removing it. – Perforate the O-ring to get a good grip.

9.

Carefully remove the quartz sleeve (10).

10. Carefully clean the surface and remove any small parts, for example glass or rubber.

4.2.3

Assemble quartz sleeve

Follow the instruction below to assemble quartz sleeve and check for leaks. Preparations and conditions •

Two new O-rings for each glass socket (7) might be needed.

•

Two new O-rings (8) for each quartz sleeve (10).

•

Use waxed screws.

•

Glass sockets and bushes must be dry and clean before mounting.

Follow the steps below 1.

Insert the quartz sleeve (10) in the AOT reactor.

Book No.9010182 02, rev. 0

27

4.2

Replace UV lamp and quartz sleeve

4

AOT reactor

2.

Wet the O-rings (8) with water and slip them over respective side of the quartz sleeve. Check that the O-ring is correctly placed, or they may be damaged and cause leaks.

3.

Check the condition of the glass socket O-rings . If needed, replace them with new O-rings.

4.

Adjust the quartz sleeve, so it is placed in the middle of the AOT reactor. Adjust the O-rings, so they are placed equally on both sides of the quartz sleeve.

5.

Carefully mount the first glass socket on the quartz sleeve with three Allen screws evenly, but do not tighten the screws. Note that the waxed screws must be used to avoid seizing.

7QuartzSleeve

6.

Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.

7.

Mount the second glass socket.

8.

Connect the compressed air.

4.2.4

Check for leaks after quartz sleeve assembly

Follow the instruction below to secure that there are no leaks that may damage the UV lamps. Follow the steps below 1.

Pressurize the AOT reactor with water to between 2 and 4 bar (0.2 and 0.4 MPa).

2.

Visually check for leaks.

4.2.5

Assemble UV lamp

Follow the instruction below to mount UV lamps. Preparations and conditions •

A leakage check must have been performed according to the instruction Check for leaks after quartz sleeve assembly.

•

Use waxed screws.

28

Book No.9010182 02, rev. 0

4

AOT reactor

4.3

Open AOT reactor

•

New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.

•

Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the lamp; hold the lamp by its ceramic end parts.

•

Glass sockets and bushes must be dry and clean before mounting.

Follow the steps below 1.

Mount the new O-rings (4) in the two bushes (3).

2.

Place one bush on the UV lamp (9).

3.

Insert the UV lamp and bush into the AOT reactor.

4.

Insert the other bush in the opposite side of the AOT reactor.

5.

Make sure that the connection is clean to ensure good electric connection (no rust, burning or fading on the connectors). Reconnect the two cable connectors for the UV lamp.

7UVlampConnection

6.

Mount the UV lamp caps and tighten three Allen screws at both ends of the UV lamp, by hand only. Make sure that the electric cable is is not squeezed between the cap and the bush when the cap is mounted. Slack can be pushed into the bush.

7.

Re-fit the drain plugs at the bottom of the AOT reactor and/or at the flanges under the AOT reactor.

8.

Make sure there is no UV lamp failure when the lamp power supply is on.

4.3

Open AOT reactor

4.3.1

Disassemble AOT reactor

Follow this instruction to open the AOT reactor for internal inspection and cleaning.

Book No.9010182 02, rev. 0

29

4.3

Open AOT reactor

4

AOT reactor

7 OpenAOT

1. Access hatch

Preparations and conditions

NGE ! DA •

R

Always disconnect the PureBallast system from the power supply before disassembling, and make sure it remains switched off during service.

Follow the steps below 1.

Remove the bolts on the access hatch (1).

2.

Inspect the bottom of the AOT reactor to see if there are any dirt or larger particles. If so, remove. Note: Be careful not to break the quartz sleeves.

3.

Check the sealing. Replace if necessary.

4.

Reassemble when done.

30

Book No.9010182 02, rev. 0

4

AOT reactor

4.4

4.4

Dismount and mount lamp power supply (LPS)

Dismount and mount lamp power supply (LPS)

Follow this instruction to replace a lamp power supply inside a lamp drive cabinet (LDC). Preparations and conditions •

!

NG WARNI

•

Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside and on the lamp power connector, even when UV lamps are not lit.

•

The LDC contains a fan, which can cause injury if in operation.

Follow the steps below

7 LPSmaint

1.

Dismount LPS Release two power connectors at the bottom of the LPS and the signal cable connector at the top.

2.

Loosen the nuts at the bottom (1) and the top (2) of the two rods holding the LPS. If necessary, loosen nuts for adjacent LPS. NOTE Make sure not to drop the washer into the LPS. It may cause short circuit.

3.

Pull the handle to remove the LPS.

Book No.9010182 02, rev. 0

31

4.5

Test LPS installation

4.

4

AOT reactor

Mount LPS Set the DIP switches on the LPS according to chapter 5. Parameters, section Lamp power supply (LPS) parameters.

5.

Push the new LPS to the wall of the cabinet.

6.

Reconnect the three connectors. Make sure the connectors sit tight.

7.

Tighten the nuts to attach the LPS.

8.

Turn on the fuse to the LPS.

9.

Switch on the main breaker on the LDC door and check that both LPS:s function correctly according to instruction Test LPS installation below.

10. Send the replaced LPS to Alfa Laval for repair.

4.5

Test LPS installation

Follow this instruction to make sure that the installation is OK and safe to use. Preparations and conditions

! •

NG WARNI

This instruction must be performed after cable connection. If not hazardous situation may arise which, if not avoided, will result in death or serious injury.

NGE ! DA •

R

Before operating the AOT reactor, make sure that there is water in the AOT reactor.

Follow the steps below 1.

Make sure that the AOT reactor breaker is switched off.

2.

Check that there is water in the AOT reactor(s) (LS201-29). Check the LED on the level switch: Steady yellow light indicates that there is water in the AOT reactor.

3.

Switch on the main breaker on the LDC door. Switch on the power to the AOT reactor using the switches on the breaker cabinet(s).

4.

Start UV lamps one by one from the control system (set to manual mode). Make sure that the UV lamps are lit. This is checked in the AOT reactor popup and on the LPS. Note: It can take up to 150 seconds for the lamp to start.

5.

Check LEDs on the LPS and the alarm list in the control system. Make sure that no alarms have been triggered by the LPS.

32

Book No.9010182 02, rev. 0

4

6.

AOT reactor

4.5

Test LPS installation

Close the lamp.

Book No.9010182 02, rev. 0

33

4.5

Test LPS installation

4

AOT reactor

5 Filter This section covers the instructions for service of the filter. Preparations and conditions These preparations and conditions are valid for all instructions. •

Galvanic circuits must always be restored after maintenance, if dismounted.

•

Disconnect the power to the filter, using the main switch on the filter cabinet.

•

Shut off the air supply to the filter.

•

Depressurize the filter: Alternative 1: Open the valve on the drain pipe. Alternative 2: Open the valve on the back flush pipe manually and then open the safety valve.

•

Note: The motor does not need to be lubricated.

Filter – Exploded view

Book No.9010182 02, rev. 0

35

5

Filter

7 Filter Exploded Hydac

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

36

Filter cover bolts Filter cover Motor Protective hood Valve connection plate Drive shaft Gasket Retaining plate Locking pin Gasket Filter candle Hole for locking pin Lid for anode Drain pipe Air pipe Safety valve

Book No.9010182 02, rev. 0

5

Filter

5.1

5.2

Remove filter cover and filter candles

Disconnect power to filter

Follow the instruction below to disconnect the power supply to the filter and to secure it from being switched on.

7 FilterLock

Safety lock with wire legs pulled out

Follow the steps below 1.

Open the control cabinet.

2.

Turn the filter main switch to cut currency to the filter.

3.

Take the separate safety lock (illustrated above) and slide the plastic part backwards, to reveal the wire legs.

4.

Put the end of the wire leg into the hole under the switch knob.

5.

Compress the legs and put the other steel wire leg into the slot to the right of the knob.

6.

Slide the plastic part back to cover the wire legs. It is now possible to lock the safety lock with a padlock, inserted in the loop at the top of the safety lock.

5.2

Remove filter cover and filter candles

Follow this instruction to remove the filter cover and filter candles. Preparations and conditions •

Read the general preparations and conditions.

•

Disconnect the power to the filter, using the main switch on the filter cabinet.

•

Lifting device is needed for this instruction. Filter cover weight (kg), per system size: 120. Retaining plate (kg): 50.

Follow the steps below

Book No.9010182 02, rev. 0

37

5.3

Mount filter candles and filter cover

1.

Remove the following components:

5

-

Safety valve pipe (16)

-

Air pipe, loosened (15)

-

Electrical connections to the motor and valves

-

Connection plate for valve connections (5)

-

Motor (1)

-

Protective hood (4) fasten with four of the filter cover bolts (1)

-

Galvanic protection between the filter cover, retaining plate and housing.

2.

Remove the filter cover (2) by lifting it using the ring bolts.

3.

Remove the gasket (7) on the retaining plate (8).

4.

Lift the retaining plate. Four threaded holes that can be used to attach lifting devices.

Filter

NOTE

•

The plate must be level when lifted, to avoid damaging the gasket and filter candle O-rings.

•

It is important not to turn the shaft, after the retaining plate has been removed. If the rotation is changed, this will make the mounting much more complicated.

5.

Remove the gasket under the retaining plate.

6.

Carefully pull out the filter candles (11).

5.3

Mount filter candles and filter cover

Follow the instruction to mount filter candles and filter cover Preparations and conditions •

Read the general preparations and conditions.

•

Gaskets for the retaining plate and O-rings for the filter candle must be in good condition.

Follow the steps below 1.

Make sure that the filter candle O-rings are in position in their groove.

2.

Carefully insert the filter candles (11). Make sure that they are fitted in the hole in the lower retaining plate and that they they snap into position.

3.

Place the gasket (10) on the filter housing. Make sure that the hole (12) for the locking pin (9) is not covered by the gasket.

4.

Before re-fitting the retaining plate (8), note that the locking pin shall fit into the hole in the retaining plate.

38

Book No.9010182 02, rev. 0

5

5.

Filter

5.5

Clean filter candles

Carefully lower the retaining plate onto the housing. NOTE

•

The locking pin shall be fitted into its hole.

•

The candles must be guided into the holes in the retaining plate.

6.

Place the gasket (7) on the retaining plate. Make sure to fit the gasket to the locking pin.

7.

Carefully lower the filter cover (2) onto the retaining plate. NOTE

8.

•

The filter cover must be level when lowered to the housing.

•

The drive shaft (6) must fit the shaft in the filter housing. If not: Lift the retaining plate, turn the shaft in the filter housing and try again.

Refit the following components: -

Protective hood (4) fasten with four of the filter cover bolts (1)

-

Motor (1)

-

Galvanic protection between the filter cover, retaining plate and housing

-

Connection plate for valve connections (5)

-

Electrical connections to the motor and valves

-

Air pipe, loosened (15)

-

Safety valve pipe (16).

5.4

Replace filter candles

Follow the instruction to replace damaged filter candles. Follow the steps below 1.

To replace filter candles, follow the Remove filter candles instruction on page 37, and simply replace damaged elements.

5.5

Clean filter candles

Follow the instruction to Preparations and conditions •

Read the general preparations and conditions.

Follow the steps below Book No.9010182 02, rev. 0

39

5.6

Change sacrificial anode

5

Filter

1.

Follow the instruction Remove filter cover and filter candles on page 0 to remove the filter candles.

2.

If there is scaling on the filter candles: Soak the filter candles in the cleaning agent and leave them to soak for 1–3 hours. Read the Preparations and conditions section for instruction Change and refill CIP liquid.

3.

Secure the filter candle, to avoid that it rolls away.

4.

Spray the filter candles with water from the outside. Start at a distance of 100 cm and reduce to 50 cm, which is the minimum distance. The water must not be warmer than 60 °C. Note: If a high-pressure cleaner is used, the pressure must not exceed 100 bar (10.0 MPa). Minimum: 20 bar. If a cleaner with higher capacity than 100 bar is used, compensate by increasing the distance.

5.6

Change sacrificial anode

Follow the instruction to check and change the sacrificial anode. Preparations and conditions •

Read the general preparations and conditions.

Follow the steps below 1.

Close inlet and outlet valves to the filter.

2.

Drain the filter by opening the drain pipe (14).

3.

Open the lid (13).

4.

Inspect the anode. Change if the anode has lost approximately 80 % of the zinc mass.

5.

Remove the old anode and install the new one.

6.

Fasten the lid on the filter and restore the valves in their original positions.

40

Book No.9010182 02, rev. 0

6 CIP module This section covers instruction for service of the CIP module.

6.1

Change and refill CIP liquid

Alpacon descalant is used as cleaning agent in the CIP module. Alpacon descalant offshore contains no solvents and no inorganic acids. It is non-flammable and non-hazardous. Preparations and conditions

! •

ON CAUTI

Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal protection etc.

!

ON CAUTI

•

If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold water.

•

Before usage, Alpacon descalant offshore must be visually checked. It shall be transparent light pink in color.

•

The instructions requires pH test equipment (paper indicator or pH meter). This is not a part of Alfa Laval’s scope of supply.

•

The pH value should be between 2.0 and 3.0. From the beginning, the pH value is approximately 2.0. When the pH value rises to 3.0 the cleaning liquid must be changed.

•

Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant offshore to 20 parts fresh water. Follow this mixing ratio, regardless of recommendation on label.

•

The CIP tank shall be filled with maximum 250 liters. Min and max filling of CIP liquid can be read on the CIP tank.

•

Store the CIP liquid according to the instructions on the bottle. General guidelines are: -

Storage temperature 0 °C to +55 °C.

-

The Alpacon descalant offshore can be frozen and thawed without impairing performance.

•

Used CIP liquid may contain residues from the cleaning process that can potentially have an impact on the environment, although this impact is regarded as very small. There are no transport restrictions.

•

Used CIP liquid is drained to one of the following: bilge tank, drain tank, sludge tank or bilge well.

•

When performing these routines, consider the need for service kits. See Spare parts catalogue.

Book No.9010182 02, rev. 0

41

6.1

Change and refill CIP liquid

6

CIP module

7 CIP 589741_description

CIP module 1. 2. 3. 4.

42

CIP liquid tank cap Drain valve Pump (AOT reactor drain) Pump (CIP liquid)

Book No.9010182 02, rev. 0

6

CIP module

6.1.1

6.1

Change and refill CIP liquid

Change CIP liquid

Follow this instruction to change CIP liquid, when necessary according to the Maintenance schedule. Follow the steps below 1.

If the drain valve (2) is connected to the bilge tank, follow the sub steps below. Otherwise, go to step 2. 1. Open the drain valve V460-3 (2) under the CIP tank. 2. Wait for the tank to be totally drained. Then close the drain valve (2).

2.

If the drain valve is not connected to the bilge tank, the steps below can be followed. This operation requires login level Advanced operator or higher. 1. Open valves V320-2 and V460-2 from the control valve, and V230–11 manually. Start pump P321-5 (4) and P320-1 (4). 2. Wait for the tank to be totally drained. Then stop the pumps and close the valves in reversed order. Go to step 3.

3.

Open the cap (1) on top of the CIP tank and pour 12 liters of CIP cleaning agent into the tank.

4.

Fill the tank with fresh water to the Max indication on the tank.

5.

Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.

6.

Go to control system page 4.3 – Operation timers. Make a note of the number of AOT reactors that has been CIPed since last time the CIP liquid was changed. Press the Reset button for “Total number CIP:ed reactors”. Requires login level Advanced operator. If this is done each time the CIP liquid is changed, it is possible to build up experience on how many AOT reactors it is possible to CIP before it is time to change CIP liquid.

6.1.2

Refill CIP liquid

Follow this instruction to refill CIP the CIP tank when there is low liquid level in the tank. Follow the steps below 1.

Measure the pH value in the tank. Based on the pH value, estimation must be done regarding the proportions between Alpacon descalant offshore and water. Note that the mixing ratio is stated under Preparations and conditions above.

2.

Mix the cleaning agent with water separately. The result will get better than if mixed mix in the tank.

3.

Pour the mixed CIP liquid into the tank. Do not fill over Max indication on the tank.

4.

Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the proportions: If the pH value is still too high, the CIP liquid must be changed. See the Change CIP liquid instruction in this chapter.

Book No.9010182 02, rev. 0

43

6.2

Repair CIP pump

6.2

6

CIP module

Repair CIP pump

Follow this instruction to repair the CIP pump. For spare parts ordering, please specify pump model and serial no. Preparations and conditions

! •

ON CAUTI

Always wear protective eye glasses and gloves while working on the pump.

!

NG WARNI

•

Always disconnect the PureBallast system from the power supply before disassembling, and secure it from being switched on.

•

Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension pipe must be removed and blocked.

•

Drain the pump from liquids.

•

The pump should be placed horizontally on a work bench.

7 CIP pump

CIP pump, exploded view

44

Book No.9010182 02, rev. 0

6

CIP module

6.2.1

6.2

Repair CIP pump

Clean CIP pump

Follow the steps below 1.

Remove the pump from the CIP tank.

2.

Rinse the pump with fresh water.

6.2.2

Disassemble CIP pump

Follow this instruction to disassemble the CIP pump.

6.2.2.1

Disassemble the main parts

Follow the steps below 1.

Remove the CIP pump from the CIP module and place it on a work bench.

2.

Unscrew the nuts (37) on one side of the housing (11).

3.

Place the pump on the side that still has the nuts (the pump lays on the nuts) on a stable ground.

4.

Carefully remove the "loose housing" (11).

5.

Carefully lift up the suction and discharge connections (13). You have the centre block (12) and one of the housings with pin screws (14) left.

6.

Upend the pump and carefully pull out the pin screws (14). Be careful not to damage the diaphragms (15).

6.2.2.2

Disassemble the housing

Follow this instruction to disassemble the housing. Follow the steps 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 carefully against the lower valve seat (21) until it is free and can be put out.

3.

Stick a something not pointed into the hole for the discharge connection and gently press out the upper valve seat (20).

4.

Place one of the pin screws on the inside (behind) the valve ball stopper on the lower valve seat (21). Carefully pull out the valve seat in the housing.

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6.2

5.

Repair CIP pump

6

CIP module

Remove the valve ball (23) from the valve seat, buy using a pin screw: Press out the valve ball stopper (22), which will release the valve ball.

6.2.2.3

Disassemble the center block

Follow this instruction to disassemble the centre block. Preparations and conditions •

Have backup spares of the sealing (36) and backup O-ring (47). There is a risk that these parts get damaged during this operation.

Follow the steps below 1.

Press the diaphragms (15) to their neutral position (both have the same distance to the centre block).

2.

Hold one of the diaphragms (15) and unscrew the other. Then pull out the remaining diaphragm with the diaphragm shaft (16).

3.

Disassemble the circlips (27) which keep the air valve (61) on its place.

4.

Press out the air valve. A wood shaft of a hammer can be used. Be careful not to damage the sealing edges towards the diaphragm or the air valve.

5.

If the shaft sealings (36) seem to be worn out, carefully remove them with a pointed tool.

6.2.3

Assemble CIP pump

Follow the instructions below to assemble the CIP pump.

6.2.3.1

Assemble center block

Follow the steps below 1.

Mount the circlip (27) on one side.

2.

Apply some soft soap solution on the air valve O-rings (30).

3.

Push the air valve (61) into the housing. Make sure that the O-rings (30) remain in the right position. Put the circlip (27) on the other side.

4.

Put the diaphragm (15) with shaft (16) into the centre block. Screw the next diaphragm (15) onto the shaft (16) and fix the holes.

6.2.3.2

Assemble the main parts

Follow the steps below 1.

Make sure that the O-rings (18) are placed on the in/outlet (13) before assembling of pump.

2.

Turn the housing (11) with the flat side up.

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CIP module

6.5

Repair valve block

3.

Make sure all pin screws (14) have one nut (37) and one washer (38) each. Nut should only be put on one or two threads.

4.

Put all the pin screws through the housing and then turn the housing so it rests on the nuts.

5.

Put the centre block (12) to the housing with screws through the centre block. Be careful not to damage the diaphragms.

6.

Place suction and discharge connections (13) in their positions in the housing. Be careful not to damage the O-rings (18).

7.

Put the second housing (11) onto the pin screws (14). Make sure that suction/discharge connections are in right direction. Be careful with the O-rings.

8.

Fasten the nuts (37) crosswise by hand, with or without washers depending on how much of the thread comes out. Turn the nuts gently with a tool to close the pump. If some of the nuts were fastened without washer, unscrew those and put washers underneath. After a few weeks operation a follow up draft of the nuts is recommended.

6.3

Test CIP pump

Follow the instruction below to verify that the CIP motor is functioning. 1.

Open valves V320-2 and V460-2 from the control system, and V230–11 manually. Start pump P321-5 (4) and P320-1 (4).

2.

Observe if the motors sound and functions OK. If not, check installation and connections and attend to and test again.

3.

Stop the pumps and close the valves in reversed order.

6.4

Repair junction box and valve blocks

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

6.5

Repair valve block

Follow this instruction to repair the valve block, mounted on the CIP module. Preparations and conditions •

The valve bodies does not have individual placing, they can be placed in any order.

NGE ! DA •

R

Always disconnect the PureBallast system from the power and air supply before disassembling, and secure it from being switched on.

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6.5

Repair valve block

6

CIP module

7 Valve block

Valve block 1. 2. 3. 4. 5.

Cover (Terminal strip inside) Valve body Button to operate valve Signal plate Cable gland

6.5.1

Change valve body

Follow the steps below 1.

Remove the scresw holding the valve bodies (2) and the signal plate (4).

2.

Unscrew the screws holding the valve body (2).

3.

Lift the valve body.

4.

Attach a new sealing on the new valve body and fasten the valve body to the valve block.

6.5.2

Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the control cabinet to the CIP valve block. Follow the steps below

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CIP module

6.5

Repair valve block

1.

Open the cover (1) on the front.

2.

Attach the cables according to electrical drawing Control cabinet / interconnection diagram in chapter 6. Installation description and drawings.

3.

Fasten the cable to the cable gland (5).

4.

Fasten the cover (1).

6.5.3

Clean valve block

Follow this instruction to clean the valve block house from dirt. 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 (CIP valves) on page 19 to blow out the dust.

3.

Connect the air hoses again.

6.5.4

Connect pneumatic hoses to valve block

Follow this instruction to connect pneumatic hoses to the valve block, if they have been disconnected. Follow the steps below 1.

Connect the hoses according to the signal plate (4) on the valve block.

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6.5

Repair valve block

6

CIP module

7 Flow meter The flow meter consists of two main parts. •

Flow sensor: A pipe with four electrodes detecting the flow. On top of the pipe, there is a terminal box, where the flow transmitter is mounted.

•

Flow transmitter: Monitors and transmits information to the PureBallast control system. The flow transmitter is also used to set parameters for the flow meter. A Sensorprom in the flow transmitter contains the data.

•

If the flow meter is replaced, settings must be checked according to chapter 4. Parameters, section Flow transmitter parameters.

7.1

Mount flow transmitter

Follow the steps below to mount the flow transmitter on the flow sensor. The flow transmitter is not factory mounted, to avoid damage during installation of the flow sensor. Preparation and conditions •

See chapter 6. Installation description and drawings, section Control cabinet / Interconnection diagram for detailed information.

•

It is recommend that a shielded power cable is used.

! •

NG WARNI

Potential hazards / Grounding: The mains protective grounding wire must be connected to the terminals in accordance with the diagram (class 1 power supply).

Follow the steps below 1.

Remove and discard the lid from the terminal box on the flow sensor.

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7.1

Mount flow transmitter

7

Flow meter

7 FM Lid

2.

Fit PG13.5 cable gland for the power and signal cable.

3.

Connect power and grounding to the following terminal positions marked on the circuit board: 1=+ 2=– Grounding.

4.

Connect current output signals to the following terminal positions marked on the circuit board: 31 = + 32 = –

5.

Tighten the cable gland to obtain optimal sealing.

6.

Mount the flow transmitter on the terminal box using the two screws. If other direction of the flow transmitter is desired, please follow the instruction Change direction of flow transmitter on page 53.

7 FM MountTM

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7

Flow meter

7.2

7.2

Change direction of flow transmitter

Change direction of flow transmitter

The flow transmitter can be mounted in different directions in relation to the flow sensor. It can be directed in steps of 90º. Follow the steps below 1.

Remove the flow transmitter from the terminal box.

7 FM MountTM

2.

Disconnect the power supply (terminal positions 1, 2 and grounding) and output signal cables (terminal positions 31 and 32) from the circuit board.

3.

Remove the coil plug (1) from terminal positions 85 and 86. Remove the plug (2) from terminal positions 82, 0 and 83.

4.

Unscrew the two screws (indicated below) holding the circuit board to the terminal box and lift up the circuit board. Note that the sensorprom is mounted on the underside of circuit board; be careful not to loose it. Sometimes, the sensorprom remains in its seat on the terminal box.

7 FM ScrewCricuit

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7.3 Change direction of flow transmitter control pad 5.

6.

7

Flow meter

Disconnect the grounding wire holding the circuit board to the terminal box. •

If the flow transmitter shall be turned 180°: Move the sensorprom (1 in the illustration below) to the position on the opposite side of the circuit board and refit in reversed order.

•

If the flow transmitter shall be turned 90°: Continue with next step.

Unscrew the four screws (2) on the terminal box to loosen it from the flow sensor.

7 FM LooseTB

7.

Turn the terminal box to 90° and fasten it with the four screws.

8.

Refit in reversed order.

7.3

Change direction of flow transmitter control pad

The control pad of the flow transmitter can be mounted in different directions in relation to the transmitter. It can be directed in steps of 90º. Follow the steps below 1.

Remove the outer frame with the help of a screw driver.

7 FM LoosFrame

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2.

Flow meter

7.3

Change direction of flow transmitter control pad

Loosen the four screws holding the control pad.

7 FMScrewPad

3.

Withdraw the control pad and turn it to the required orientation.

7 FM TurnPad

4.

Tighten the four screws until a mechanical stop is felt.

7 FMScrewPad

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7.4

5.

Clean flow meter electrodes

7

Flow meter

Snap-lock (a click is heard) the outer frame onto the control pad.

7 FM FastCover

7.4

Clean flow meter electrodes

Follow this instruction to clean the electrodes. It is important that the electrodes are clean to secure accurate output. If the four electrodes in the flow sensor get dirty, it may result in inaccurate and varying output. Follow the steps below 1.

Drain the entire pipe where the flow meter is mounted.

2.

Close the main valves connecting the PureBallast pipe net to the vessel’s ballast pipe net and secure it from being switched on. See instruction Lock valve in closed position on page 20.

3.

Remove all the flange bolts on the flow meter, except one on each flange. Note that the remaining bolts on each side must be in the same position on respective flange.

4.

Loosen the nuts on the remaining bolts. Swing the flow meter outside the pipe.

5.

Clean the four electrodes with a mild washing detergent.

6.

Refit the flow meter in reversed order.

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8 Valve actuator This section contain instructions for the valve actuator.

7 Actuator and switch

Valve actuator with switch box for position feedback to control system 1. 2. 3. 4. 5. 6.

Switch box Bracket Actuator

Bracket - Used for valves with dimension 400 Coupling with position indicator - Used for valves with dimension 400 7. DIN connector 8. Position indicator

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8.1

Preparations and conditions

8

Valve actuator

7 Actuator

Valve actuator with puck for position sensor 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Safety cover Pad lock Lower position for indicator screw Upper position for indicator screw — with screw Position indicator Center screw Bracket Puck Locking bolt End stop bolt.

8.1

Preparations and conditions

•

Do not operate the actuator over pressure limits. It will damage internal parts as well as cause damage to the housing.

•

Do not disassemble individual spring elements. Disassembly may result in personal injury.

•

Do not remove end caps or disassemble the actuator while the actuator is pressurized.

•

The actuator must not be lubricated. It is factory lubricated for the life of the actuator during normal working conditions. The standard lubricant is suitable for use from −20 °C (−4 °F) to +80 °C (+176 °F).

•

If a valve actuator is removed, check for loose spindle-bushing. Then make sure the loose bushing is refitted to avoid play between the actuator and the valve spindle.

•

Actuator are mounted together with the valve body and pilot valve at delivery. Valve and actuator mounting are sealed to guarantee correct position indication in relation to throttle position.

8.1.1

Tightening torques for actuators

Torque is stated in Nm.

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Valve actuator

M5 M6 M8 M10 M12 M14 M16 M20

8.2

8.3

Mount actuator on valve

05–06 10–11 23–25 48–52 82–86 132–138 200–210 390–410

Dismount actuator

Follow this instruction to dismount an actuator. Preparations and conditions •

The valve must be in closed position.

•

The valve position must not be adjusted during the routine.

Follow the steps below 1.

Remove the DIN connector to disconnect the power. Let the air connection remain. Result: Valve goes to closed position (due to the air connection). The yellow indicators on the puck shows position of valve: closed. The yellow position indicators are in line with the valve throttle (indicating closed when the position indicators are in opposite line with the pipe).

2.

Disconnect the air hose to the pilot valve. Verify that the actuator is not pressurized. Always use caution and double-check that ports 2 and 4 are vented and are free from any accessory and/or device.

3.

If the actuator have a switch box at the top: Loosen the four screws holding the switch box to the actuator. Remove the switch box together with its bracket.

4.

Loosen the four hexagonal screws holding the actuator to the valve.

5.

If the actuator is mounted on the valve with a bracket and coupling (dimension 400): Loosen the screws holding the bracket to the valve. Make sure not to loose the coupling between the valve and actuator when lifting the actuator.

6.

Lift the actuator from the valve.

8.3

Mount actuator on valve

Follow this instruction to mount an actuator. Preparations and conditions

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8.3

Mount actuator on valve

!

8

Valve actuator

ON CAUTI

•

The actuator must not be pressurized at any time during installation as it may result in injury.

•

The valve must be in closed position.

•

The valve position must not be adjusted during the routine.

•

The utmost cleanliness is required during air supply connection to the actuator, that is, the connecting pipe thread, fittings and seals must be clean and dirt-free.

•

Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on which direction of rotation is required.

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.

7 ValveStem

1. 2. 3. 5.

Allowed travel sector. Valve stem groove Valve stem Lock pin opening (covered by rubber plug).

2.

Make sure that the lock pin (inside the valve stem) only travels in the allowed sector (1) and that it does not pass the opening (5).

3.

If the actuator is mounted on the valve with a bracket and coupling (dimension 400): First fit the coupling on the valve stem. Make sure that the red position indicator on the coupling is in line with the pipe when the valve is open.

4.

Fit the actuator onto the valve stem (or the coupling). The actuator may only be positioned in even 90° intervals in relation to the valve. It is not allowed to adjust the position by turning the actuator by hand after it is fitted on the valve stem.

5.

Mount the actuator on the valve with the four hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten with torque according to the table Tightening torques for actuators on page 58.

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Valve actuator

8.4 Change direction of actuator – without position sensor (V404–36, V320–4 and V321–2)

6.

If the actuator have a switch box at the top: Make sure that the yellow position indicator under the switch box is in line with the throttle (according to the groove in the valve stem). The yellow position indicator shall be in line with the valve throttle (indicating open when the position indicator is in line with the pipe). If not, remove the position indicator, turn it 90° and refit it. Mount the switch box with the bracket on the actuator, using the four bolts.

7.

Reconnect the air hose to the pilot valve.

8.

Operate the valve to make sure it operates in the desired direction of rotation.

8.4

Change direction of actuator – without position sensor (V404–36, V320–4 and V321–2)

Follow this instruction to turn an actuator without position sensors on the AOT reactor. Preparations and conditions •

The valve must be in closed position.

•

The valve position must not be adjusted during the routine.

Follow the steps below 1.

Loosen the four screws holding the actuator to the valve.

2.

Lift the actuator from the valve.

3.

Note the position of the groove of the valve stem. It indicates the position of the valve throttle.

4.

Fit the actuator onto the valve stem.

5.

Unscrew the center screw (4) holding the puck (6) and a bracket (5).

7 ActDirectWithout

6.

Lift the puck (6), rotate it 90° and fasten it with the center screw (4) and bracket (5).

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8.6 Change direction of actuator – with position sensor (201-19 and 201–20)

8

Valve actuator

7.

Make sure that the yellow position indicators (3) is in line with the throttle (according to the groove in the valve stem). The yellow position indicators shall be in line with the valve throttle (indicating open when the position indicator is in line with the pipe). If not, remove the position indicators, turn them 90° and refit.

8.

Connect power and air.

8.5

Change direction of actuator – with switch box (V201–3, V201–9, V201–32, V212–31 and V403–35)

Follow this instruction to turn an actuator with switch box. Preparations and conditions •

The valve must be in closed position.

•

The valve position must not be adjusted during the routine.

•

The valve must be mounted and connected to air and power before adjustment.

Follow the steps below 1.

Dismount the actuator according to Dismount actuator on page 59.

2.

Remount the actuator according to Mount actuator on valve on page 59.

3.

Before mounting the switch box, change the position of the yellow position indicator, so it is in line with the throttle.

4.

Remount the switch box according to Mount actuator on valve.

8.6

Change direction of actuator – with position sensor (201-19 and 201–20)

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

The valve must be in closed position.

•

The valve position must not be adjusted during the routine.

•

The valve must be mounted and connected to air and power before adjustment.

Follow the steps below 1.

62

Dismount the actuator from the valve according to instruction Dismount actuator on page 59. Put the actuator on a work bench.

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2.

Valve actuator

8.6

Change direction of actuator – with position sensor (201-19 and 201–20)

Disconnect the DIN connector (2) from the coil: First loosen the screw (1), and then pull up the connector.

7 DisconDINcon

3.

Unscrew the center screw (6) holding the puck (8) and a bracket (7).

7 DirActPosSnsr

4.

Lift the puck (8), rotate it 90° so that one position indicator (5) with a screw is in contact with the position sensor. Fasten the puck with the center screw (6) and bracket (7).

5.

Move the screw on yellow position indicator to the top position and move the screw on black position indicator to the bottom position.

6.

Make sure that the position sensor have a maximum distance of 1 mm from the puck (7). The position sensor and the position indicator screws must be close to give a signal. If not, loosen the screws and adjust the position. Tighten the screws to fixate the position.

7.

Fit the actuator onto the valve stem in its new position according to instruction Mount actuator on valve on page 59.

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8.8

Mount pilot valve on actuator

8

Valve actuator

8.

Make sure that the yellow indicator (5) in line with the valve throttle according to the groove in the valve stem.

9.

Reconnect the DIN connector.

10. Connect power. 11. Check that the installation is OK, by making sure that the A1 LED is lit on the position sensor (visible from the side). 12. Connect air.

8.7

Change direction of actuator – with positioner (201–8)

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

The valve must be in closed position.

•

The valve position must not be adjusted during the routine.

Follow the steps below 1.

Dismount the actuator from the valve according to instruction Dismount actuator on page 59.

2.

Fit the actuator onto the valve stem in its new position and mount it on the valve with the four hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten with torque according to the table Tightening torques for actuators on page 58.

3.

The position indicator scale shall be correct, but make sure that the scale still indicates correct opening percent according to the valve throttle position. If not, loosen the four bolts to the bracket holding the switch box. Lift it and turn the scale so it is correct.

4.

Refit the switch box. Make sure that the peg on the scale fits to the carrier on the puck mounted on the actuator.

8.8

Mount pilot valve on actuator

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

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Valve actuator

8.9

Adjust valve end position

7 MountPilote

Pilot valve and actuator 1. 2. 3. 4. 5. 6.

Mounting screw holes Throttle valve Port 1 for air connection (under) Throttle valve DIN connector Screw.

Follow the steps below 1.

Check that the O-rings are fitted on the pilot valve, on the side facing the actuator.

2.

Fit the pilot valve on in the actuator, so that the pin on the actuator fits the hole on the pilot valve. The throttle valves (2 and 4) shall be directed downwards.

3.

Mount the pilot valve with two Allen screws in the holes (1).

4.

Connect air to port 1 (3) on the pilot valve.

5.

Fit the DIN connector (5) on the coil, including gasket. Then fasten the connector with the screw (6).

8.9

Adjust valve end position

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

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8.10

Adjust valve traveling speed

8

Valve actuator

7 576075_lock_manual

Preparations and conditions •

The valve shall be closed (0°) position 0.

Follow the steps below 1.

Note the exact position of the position indicator for reference after adjustment.

2.

Open the padlock (2) on the actuator and remove the safety cover (1). Result: Two sets of bolts are displayed. The right set adjusts closing position and the left set adjusts open position.

3.

Loosen the locking bolt (3).

4.

Adjust end position by turning the end stop blot (4) with small turns. – Clockwise decrease the end position. – Counterclockwise increase the end position. NOTE

•

The total adjustment degree is 10° for each position.

5.

Operate the valve. Compare the new position of the position indicator to see the result on the adjustment. If needed, adjust again.

6.

Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).

8.10 Adjust valve traveling speed Follow this instruction to adjust valve traveling speed.

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Valve actuator

8.10

Adjust valve traveling speed

7 AdjustTravel

Follow the steps below 1.

Operate the valve manually to check traveling speed according to the instruction in the Operate valves manually on page 19.

2.

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

3.

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

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8.11

Calibrate positioner on V201-8

8

Valve actuator

8.11 Calibrate positioner on V201-8 Follow this instruction to calibrate the positioner at installation or when needed.

7 201-8Positioner4

1. 2. 3. 4. 5. 6.

Arrestor device (screw driver adjusting) Unlock the wheel Locking wheel (screw driver adjusting) Direction to lock the wheel Adjustment wheel Transmission ratio selector

Preparations and conditions •

The valve must be installed and connected to air and power.

•

The valve must be closed.

•

The cover must be removed.

•

Do not adjust the cam wheel: 2 grey wheels above the adjustment wheel (5).

•

Buttons on the positioner:

7 201-8Positioner

Follow the steps below 1.

Make sure that the transmission ratio selector (6) is set to 90° according to sticker on the component. If not: Adjust by pressing the bar with a screw driver.

2.

Make sure that the Arrestor device wheel (1) is set to 90°. If not: Adjust by turning.

3.

If the positioner display is empty (no power): Open V201-8 manually (approximately 1-5°) from control system to supply power to the positioner. Result: Menu 1 and “turn” should be displayed. If not: Press — button until it is displayed.

4.

Press the hand button. Result: Menu 2 and “90°” is displayed.

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Valve actuator

8.11

Calibrate positioner on V201-8

5.

Press the hand button. Result: Menu 4 and “no” is displayed

6.

Go to step 8.

7.

(Skip this step if installing a new positioner) Press the hand button (approx. 5 sec.) until a (any) menus is displayed. Press the hand button till menu 4 is displayed.

8.

Press + button for 5 seconds to start automatic calibration.

9.

If calibration stops (as displayed below), follow these steps:

7 201-8Positioner2

-

Use a screw driver to loosen the yellow locking wheel (counter clockwise).

-

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

7 201-8Positioner3

-

Lock the locking wheel (3) with a screw driver.

-

Press the + button to continue the calibration.

10. Wait until “FINISH” is displayed on the screen. 11. Press the hand button once. Result: Menu 4 “INITA” is displayed. 12. Press the hand button until “VER” is displayed (approx. 5 sec.) Result: “MAN” is displayed”. 13. Press the hand button. Result: “AUT” is displayed. Trouble shooting If any problem occurs, do the following: 1.

Check the mechanical installation and air supply.

2.

Rest factory settings and restart calibration: -

Reset to factory settings: Press hand button until menu 50 is displayed.

-

Press + button until “oCAY” is displayed.

-

Restart instruction from the beginning.

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8.11

Calibrate positioner on V201-8

8

Valve actuator

9 Ball valve This section contains maintenance information for the ball valve.

9.1

Replace seals in ball valve

Follow this instruction to replace the seals in ball valve.

7 BallV

Ball valve, exploded view

Preparations and conditions Maximum tightening torque Valve size

Max. torque of body bolts (8)

Max. torque of stem nut (14)

25 = 1 inch

13–16 Nm

14.3 Nm

32 = 1¼ inches

20–25 Nm

14.3 Nm

50 = 2 inches

35–40 Nm

19.4 Nm

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9.1

Replace seals in ball valve

9

Ball valve

Follow the steps below 1.

Relieve the line pressure.

2.

With the valve in the open position (lever to be parallel to the axis of the pipe), remove all the body bolts (19) except one.

3.

Loosen the nut (20) on the remaining bolt. Swing the body outside the pipe.

4.

Dismount the stem (8).

5.

Replace seals (5, 6, 7, 9, 10, and 24). They are available in a spare parts kit for the ball valve.

6.

Mount in reverse order. The body bolts of the valve should be tightened evenly. Tighten one-side snugly, then the one diagonally across. Repeat for the other bolts, bringing them all down tightly in sequence. Make sure the maximum tightening torque is observed according to the table above:

7.

Check that the valve is operating correctly.

8.

Check for leaks when the water flow is on.

72

Book No.9010182 02, rev. 0

10 Level switch This section contains information about the level switch LS201-29 installed in the AOT reactor. For information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.

7LS Component

Level switch

10.1 Mount level switch Preparations and conditions •

Do not alter the forks in any way.

•

Be careful not to damage the fork in any way. NOTE

•

Disconnect power supply before mounting or dismounting the component.

Follow the steps 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.

Book No.9010182 02, rev. 0

73

10.3

5.

Test level switch

10

Level switch

Complete the seal carefully by tightening the component with a spanner. Use the spanner on the hexagon flats, but not on the level switch body.

10.2 Dismount level switch Preparations and conditions •

The external surface may be hot. Care must be taken to avoid possible burns.

Follow the steps below 1.

Disconnect the level switch according to the label on the device.

2.

Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on the level switch body.

3.

Remove the level switch and remove the old seal from the threads.

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.

7LS Test

3.

74

Make sure the level switch reacts to the magnet. The component is OK if the green and yellow LED is lit.

Book No.9010182 02, rev. 0

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

7 TS and TT

Temperature switch and temperature transmitter

Preparations and conditions NOTE

•

Disconnect power supply before mounting or dismounting the component.

11.1 Mount temperature switch / temperature transmitter Follow the steps below 1.

Seal the component’s threads using lock tight or equivalent pipe seal.

2.

Mount the component until the joint is finger-tight.

3.

Tighten the component with a spanner. Use the spanner on the hexagon flats, but not on the components body.

4.

Connect the component’s screwed-on power cord.

Book No.9010182 02, rev. 0

75

11.2 Dismount temperature switch / temperature transmitter

11

Temperature switch and temperature transmitter

11.2 Dismount temperature switch / temperature transmitter Preparations and conditions •

The external surface may be hot. Care must be taken to avoid possible burns.

Follow the steps below 1.

Disconnect the component’s screwed-on power cord.

2.

Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on the components body.

3.

Remove the level switch and remove the old seal from the threads.

76

Book No.9010182 02, rev. 0

12 Control panel This section covers instructions for service of the control system.

12.1 Clean control panel NOTE

•

Control panels may only be cleaned when set in wipe mode. This is to prevent unintended functions from being triggered by buttons pressed during cleaning.

Preparations and conditions •

Never use aggressive solvents, chemicals, scouring agents, pressurized air or steam jet.

Follow the steps below 1.

Press the Wipe button on the screen. Result: Disable the touch screen function for 10 seconds to make it possible to clean the screen without the risk of starting a process or changing a setting.

2.

Clean the display and surrounding front cover with a soft cloth and mild detergent. Do not spray detergent directly on the control panel.

12.2 Replace control panel Follow this instruction to replace the control panel. Preparations and conditions: •

The system must be shut down.

•

When the panel is mounted, software must be updated and settings performed accroding to last step of the instruction.

12.2.1 Dismount the panel Follow this instruction to dismount the control panel. Follow the steps below 1.

Open the control cabinet.

2.

Pull out the power and signal cables.

Book No.9010182 02, rev. 0

77

12.2

3.

Replace control panel

12

Control panel

Loosen the screws on the inside of the cabinet door.

7BeijerScrews

4.

Hold the panel on the outside so it does not fall out. At the same time: Slide the brackets and remove them. Then remove the panel.

7BeijerBracket

12.2.2 Mount the panel Follow this instruction to mount the control panel. 1.

Put the panel in place.

2.

Hold the panel on the outside so it does not fall out. At the same time: Attach the brackets on the inside by sliding them into place.

7BeijerBracket

78

Book No.9010182 02, rev. 0

12

Control panel

3.

Fasten the screws on the inside of the cabinet door.

12.2

Replace control panel

7BeijerScrews

4.

Open the small cover on the rear side. Make sure that all DIP switches are in position OFF.

7BeijerMODE

5.

Connect the signal cable in the 10/100 port.

6.

Connect the power cable in the 24V DC port.

7.

Remove the laminated film, to avoid static electricity that could damage the terminal.

8.

Make sure that the control panel is brought to ambient temperature before it is started. If condensation forms, ensure that the operator panel is dry before connecting it to the power outlet. Ensure that the voltage and polarity of the power source is correct.

9.

Load new software to the panel according to instruction Update PLC software and Install TA150 firmware in chapter 3. Operating instruction and control system description. Also set communication according to Set control panel IP address and Set remote control panel communication.

Book No.9010182 02, rev. 0

79

12.2

Replace control panel

12

Control panel

13 Remote control panel (optional) This section covers information on how to mount and connect communication components for the remote control panel. The information in this instruction is also given in the Control cabinet / Circuit diagram in chapter 6. Installation description and drawings.

13.1 Mount and connect network switch for remote control panel

7 594060 RCP

Network switch and terminals 1. Ethernet ports (3 pieces) 2. 24 VDC port (connection to terminals connected at delivery) 3. Network switch 4. Terminal (+ 24 V power connection) 5. Terminal (– 24 V power connection). 6. Terminal (grounding) 7. Fiber ports (2 pieces)

Book No.9010182 02, rev. 0

81

13.1 Mount and connect network switch for remote control panel

13

Remote control panel (optional)

7 RemotPanelCon

Back of remote control panel, side view

Preparations and conditions •

If used, a network switch (3) is installed at a location of your choice, near the position of the remote control panel.

•

24 VDC cables are not included in scope of supply. Use a cable with minimum cross section of 0.75 mm2, preferably halogen free and flexible.

•

The remote control panel must have been mounted on a location of your choice. See Remote control panel (optional) / Dimensional drawing in chapter 6. Installation description and drawings.

•

Two wires are mounted between terminal and switch power contact (2) no 1=DC–, no 2=DC+, cables are marked + and –.

•

Prerequisites for cable length and cable types are stated in chapter 6. Installation description and drawings, section Remote control panel integration (optional). Ethernet and fiber cable can be used. This instruction is written for Ethernet, but if fiber is used use fiber cable and connect them to the fiber ports instead of Ethernet ports.

•

Switch off the PureBallast system and disconnect it from the power supply.

Follow the steps below 1.

At the back of the remote control panel, fasten the Ethernet cable in Ethernet port 1. Fasten the other end of the cable in the network switch’s Ethernet port number 1 (1).

2.

Connect an Ethernet cable from the network switch near the remote control panel to the network switch in the control cabinet (see position 1 in illustration on page 83). Also see cable W501 in Control cabinet / Interconnection diagram.

3.

If more than one remote control panel is installed, connect an Ethernet cable from Ethernet port number 2 (1) in the network switch (near the remote control panel) to the second remote control panel (or via a second network switch, if used).

4.

Connect a 3 core cable from network switch terminals 4 (+), 5 (–) and 6 (GND) to the remote control panel’s 24 VDC port (2).

5.

Connect a 24 VDC power supply cable to the terminals 4 and 5 and 6.

82

Book No.9010182 02, rev. 0

13

Remote control panel (optional)

13.2

Mount and connect network switch for remote control panel (retrofit)

13.2 Mount and connect network switch for remote control panel (retrofit) The information is only relevant if this option is added after installation. If remote control panel is included in the original order, the network switch is already mounted in the control cabinet. .

7 591773 RI

Control cabinet, opened

Follow the steps below 1.

Loosen the right end stop on the DIN rail at position (1).

2.

Mount the network switch on the DIN rail at position (1).

3.

Fasten the end stop to fixate the network switch at position (1).

4.

On the PLC, disconnect the Ethernet cable (coming from the main control panel) from port IF2 and connect it to the network switch port: 1.

5.

Connect an Ethernet cable in the IF2 on the PLC and connect the other cable end to the network switch port: 2.

6.

Connect wire 400 (DC–) to terminal 400 (3) and to network switch (1) terminal no: 1.

7.

Connect wire 402 (DC+) to PLC terminal 15 (2) and to network switch (1) terminal no: 2.

8.

Follow instruction Mount and connect network switch for remote control panel to connect remote control panel.

Book No.9010182 02, rev. 0

83

13.2 Mount and connect network switch for remote control panel (retrofit)

13

Remote control panel (optional)

14 Control cabinet and lamp drive cabinet (LDC) This section covers maintenance information for the control cabinet.

14.1 Disassemble and assemble I/O system This section covers maintenance information about the I/O system (X20 electronic modules). For information about status and error indications, pleas see chapter 5. Alarms and fault finding. Follow the steps below 1.

Hold down the plastic clip on the top of the terminal block and pivot the block towards you.

7IO1_X025002A

2.

Pull away the terminal block.

3.

Hold down the triangle on the top of the I/O board and loosen the board.

7IO2_X025003A

Book No.9010182 02, rev. 0

85

14.1

4.

Disassemble and assemble I/O system

14

Control cabinet and lamp drive cabinet (LDC)

Pull the board straight out (otherwise it can fasten in one of its guides).

7IO3_X025004A

5.

Compare the part number of the new I/O board to the old board, to make sure it is correct.

6.

If changing more than one board at a time, check with the electrical diagram to ensure that the boards are mounted in the right places.

7.

Mount the new I/O board by pressing it straight into place. Make sure the board is firmly in place, otherwise it will be impossible to mount the cable terminal.

7IO4_X025005A

8.

Remount the terminal block. Make sure the clip on the bottom of the block fastens properly in place on the axel on the bus holder.

7IO5_X025007A

86

Book No.9010182 02, rev. 0

14 Control cabinet and lamp drive cabinet (LDC) 9.

14.2

Cable gland installation

Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in the I/O board.

7IO6_X025006A

14.2 Cable gland installation This section covers information about how to install the cables into the control cabinet and LDC using the cable glands. Follow this instruction to mount cables into the cabinets. Follow the steps below 1.

Lubricate the inside surfaces of the frame with Roxtec Assembly Gel or equivalent, specially in the corners.

7 Cable1

2.

Insert the cables through the frame.

3.

Adapt the modules, which are to hold cables.

4.

Peel off layers until you achieve a 0.1-1.0 mm gap between the two module halves when held against the cable.

Book No.9010182 02, rev. 0

87

14.2

Cable gland installation

14

Control cabinet and lamp drive cabinet (LDC)

7 Cable2

7 Cable3

5.

Lubricate all modules thoroughly, both on the inside and the outside surfaces.

7 Cable4

6.

Insert the modules from the back of the frame opening. If possible, start with the largest modules.

7 Cable5

88

Book No.9010182 02, rev. 0

14 Control cabinet and lamp drive cabinet (LDC) 7.

14.2

Cable gland installation

Tighten the compression unit firmly to seal the frame. Maximum 10 Nm. A good indication is when the lubrication is squeezed out between the modules.

7 Cable6

Book No.9010182 02, rev. 0

89

.

Spare parts catalogue PureBallast 3.0 Flow 750

Specification No. 9005247-01/2 Book No. 9010670 02

Published By: Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: Telefax:

+46 8 530 650 00 +46 8 530 310 40

© Alfa Laval Tumba AB 2014-02-03 Original instructions This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents 1

Important information

5

2

Control Cabinet

6

2.1 Cabinet

10

2.2 I/O module

12

2.3 Relay module

14

Lamp Drive Cabinet

16

3.1 Cabinet

18

AOT reactor

34

4.1 AOT reactor JIS

38

4.2 Junction box

40

4.3 Junction box

42

4.4 Valve V201-19 and V201-20

44

4.5 Valve

46

Filter, RF10-30

48

5.1 Valve, V309-1

54

6

Valve, JIS A300

56

7

Valve, JIS A300

58

8

Valve, JIS A300

60

9

Control valve V201-8

62

3

4

5

10 Flow transmitter, A300

64

11 CIP module

66

11.1Pump P320-1 and P321-5

70

11.2Valve

72

3

11.3Valve block

74

11.4Air distribution

76

12 Sampling device (QT201.1, QT201.1)

78

13 Pressure monitoring device

80

14 Cross reference list

82

4

1

Important information

1 Important information • •

State number of ordered parts. Note that the quantity in the tables do not states number of parts delivered (only the how many of that parts that are included in the mother component). It is only possible to order parts included in the tables.

•

Safeguard your commitment to quality by always using genuine Alfa Laval spare parts. Remember, Alfa Laval cannot accept responsibility for the failure of separator equipped with non-original spare parts. We guarantee the quality and reliability of our products.

•

This manual refers to unit number printed on the equipment name-plate.

•

When ordering, refer to part number listed in this catalogue and serial number, described in chapter 7. Service manual, section Serial number information.

Book No.

5

PureBallast 3.0 Flow 750

2 Control Cabinet Machine unit number or Subassembly description

6

Ref

Part No

Description

1 3 4 5 6 7 8 8.1 9 10 10.1 11 12 13 14 14.1 15 16 16.1 17 18 19 20 21 22 23 24 24.1 24.2

9006237 80 9006852 01 595670 80 9006804 01 9006805 01 9006806 01 221891 04 223101 47 582212 148 591103 60 591103 10 591103 45 582212 125 9004299 04 582212 67 582212 60 582212 63 591103 38 591103 81 221701 03 9005006 80 582212 91 582212 147 582212 104 582212 102 582212 105 582212 104 582212 171 582212 167

Cabinet Software, panel Panel DIN-rail 35x15 DIN-rail 35x15 DIN-rail 35x15 Lock nut Washer End stop (clip fix) Over current prot. Relay Auxiliary contact Breaker handles Power supply unit Fuse Terminal, PIT 2,5-3PV Bus bar blue Terminal D-PIT 2,5-3L Contactor Relay, over current prot. Screw I/O module VIP-2, D 9SUB Patch panel Terminal PITTB 2,5 Terminal PITTB 2,5 PE End plate D-PITTB Terminal PITTB 2,5 Busbar 1/3/5-5, red Busbar 20-5 Blue

25 26 26.1 26.2 27 28 29 29.1 29.2 30 31 32 33 34 36 37 38 39 41 42 44 45 46 47 48 49 51.1 51.2 52 52A

582212 105 582212 67 582212 60 582212 03 582212 63 582212 168 582212 123 582212 86 582212 87 9002362 81 582221 90 582212 15 593724 03 594009 03 583556 16 583556 17 9003522 07 9003522 06 591922 01 595361 01 223101 47 221803 02 582221 89 582356 18 582212 155 591103 36 596894 01 596894 01 9009695 80 9006853 01

End plate D-PITTB Terminal, PIT 2,5-3PV Bus bar blue Plug In Bridge Terminal D-PIT 2,5-3L Separating plate Power terminal block, Bus bar, blue 500mm Bus bar, red, 500mm Relay module PE Connection bar PE/SC Bar Distance screw Screw Cable channel 40x80 Cable channel 40x80 Cable channel, 25x80 Cable channel, 25x80 Cable seal Cable seal Washer Nut Cable fixing spiral Puschbutton switch Socket with USB Main breaker PE cable, 2,5mm² PE cable, 2,5mm² Fan Fan

-80 1 1 1 1 2 1 13 13 13 1 1 1 1 4 6 1 1 1 1 4 1 2 2 3 1 1 40 1 1 1 4 1 1 1 2 1 1 1 3 1 1 7 5 2 1 2 1 1 1 2 2 1 1 2 1 1 1 1 1

9004429Quantity

Notes See page 10

See page 12

Connected: 11,15,19 Short end 15 pin, connected: 12,18,32,34,36,38,40

155mm 155mm See page 14 245mm 500mm

BRB 6,4x12x1,6 fzb M6M 6 fzb

L= approx. 500mm (door) L= approx. 300mm (PE bar)

Book No.

Control Cabinet

2690A

2

Book No.

7

PureBallast 3.0 Flow 750

Machine unit number or Subassembly description

8

Ref

Part No

Description

52B 53 55 68 69 70 Z Z0.1

9009688 01 9009696 80 595673 01 9008672 80 582212 122 582212 13 597330 01 597331 01

Filter Air outlet Ethernet cable Cable set Terminal block End plate Cable seal Cable seal

-80

9004429Quantity

Notes

1 1 1 3 3

Book No.

Control Cabinet

2690A

2

Book No.

9

PureBallast 3.0 Flow 750

2.1 Cabinet Machine unit number or Subassembly description

Ref

Part No

2 3 4 5 6 7 8 10 11 12 13 15 16 19 22 23 24 25 26 27 28 29 30 31 32 33 34 35

9006246 594009 26556 9006761 70915 221891 221716 579385 9003013 593991 9003024 223107 221891 593254 221711 593282 221803 223101 593239 581688 594488 221711 223101 221891 587276 70560 221891 544465

10

Description

01 Door 01 Screw Spring washer 80 Mounting plate Spring washer 05 Hexagon lock nut 01 Screw 01 T-handle 01 Rod Guide 01 Latch 02 Rod for latching 34 Spring washer 04 Lock nut 01 Retaining ring 19 Screw 01 Washer 02 Nut 73 Washer 01 Nut 01 Bracket 01 Washer 16 Screw 47 Washer 04 Lock nut 02 Washer Washer 05 Hexagon lock nut 04 Locking liquid

-80 1 6 6 1 16 12 4 1 2 1 2 4 4 1 1 1 2 1 1 4 4 8 8 8 6 6 6 1

9006237Quantity

Notes MRX-Z5x6 fzb FBB 5,1 fzb M6M 8 fzb

FBB 6,1 fzb M6M 6 fzb MC6S 6x25 fzb BRB 6,4x12x1,6 polyamide M6M 6 fzb BRB 6,7x16x1,5 fzb

MC6S 6x16 fzb MRM 6,4x12x1,6 fzb M6M 6 fzb M6M 8 fzb Loctite 270

Book No.

Cabinet

2

Control Cabinet

2718A

2.1

Book No.

11

PureBallast 3.0 Flow 750

2.2 I/O module Machine unit number or Subassembly description

Ref

Part No

1 1.1 1.2 1.3 2 3 4 5 6 7 8 9 10 12

580986 597033 580986 580986 580986 580986 580986 580986 580986 580986 580986 580986 580986 580986

12

67 18 76 76 17 30 51 08 33 32 59 06 16 55

Description PLC unit Interface module Communication module Communication module Bus module Supply Bus Module 12 Digital Input 4 Analogue input Output Module Supply Module 12 Digital Output 6 Relay output Terminal block 12-pin Compact flash card

-80 1 1 1 1 11 1 3 2 1 1 1 4 12 1

9005006Quantity

Notes Incl. locking plate.

Book No.

I/O module

2

Control Cabinet

2772A

2.2

Book No.

13

PureBallast 3.0 Flow 750

2.3 Relay module Machine unit number or Subassembly description

Ref 1 2 3 Z

14

Part No

Description

582212 582212 582212 582212

Interface relay, 24V Input adapter System cable Relay, mini

119 120 186 172

-81 8 1 1

9002362Quantity

Notes

Spare part only

Book No.

Relay module

2

Control Cabinet

2692A

2.3

Book No.

15

PureBallast 3.0 Flow 750

3 Lamp Drive Cabinet Machine unit number or Subassembly description

Ref 1 19

16

Part No

Description

9011549 80 Cabinet 9005496 01 Lamp Power Supply

-80 1 16

9004480Quantity

Notes See page 18

Book No.

Lamp Drive Cabinet

2774A

3

Book No.

17

PureBallast 3.0 Flow 750

3.1 Cabinet Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 4 5 6 7 9 9.2 10 11 12 13 14 15 19.1 19.2 19.3 20 21 22 23 24 25 26 26.1 27 28 29 30 31 32 33 34 35 36 37 37.1 38 39 40 41 42 43 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

9003628 80 9004211 01 9004212 01 9004213 01 9004506 80 9004214 01 590624 03 9004254 01 595558 01 523127 04 9004426 01 582356 30 582356 26 582356 28 582356 27 582212 164 582212 163 582212 165 582221 90 9006677 01 9004313 80 9005494 01 591103 46 591103 60 591103 54 591103 10 591103 66 591103 64 591103 61 582212 125 9004299 04 9004299 01 9004299 02 9004299 03 9006326 01 582212 146 9004174 80 594728 01 9004507 80 9004329 80 9004303 02 582212 147 9004508 80 582212 148 9004299 07 582212 141 70560 221030 10 221803 02 221803 03 221891 01 221891 02 221891 04 221891 05 223101 03 223101 16 223101 17 223101 47 587276 02

Cabinet Centrifugal fan Inlet duct Protection Terminal block Heat exchanger Temperature sensor Check valve Wire Hexagon nipple Hose Lamp green, compl. Signal lamp, White Button ill. blue, compl. Sign holder Phoenix Contact Phoenix Contact Phoenix Contact PE Connection bar Filter Main breaker Transmitted handle kit Breaker door seal Over current prot. Relay Over current prot. Relay Auxiliary contact Bus bar Connection Self-res. short-circ. lim Power supply unit Fuse Relay safety Relay safety Relay safety Temperature relay Interface relay, 24V I/O module Temperature sensor Terminal block Liquid leakage amplifier Sensor, liquid Patch panel Terminal block End stop (clip fix) Terminal Cable holder Washer Screw Nut Nut Lock nut Nut Lock nut Hexagon lock nut Washer Washer Washer Washer Washer

18

-80 1 1 1 1 1 1 1 1 1 2 2 1 1 1 3 16 16 16 1 1 1 1 1 2 16 16 6 3 3 1 3 1 1 1 1 1 1 1 1 1 1 2 1 13 3 2 3 12 5 1 2 4 4 3 2 4 1 21 3

9011549Quantity

Notes See page 22

Fully exchangable with 9008407.

830mm

See page 26 See page 28

See page 30

Book No.

Cabinet

3

Lamp Drive Cabinet

2775A

3.1

Book No.

19

PureBallast 3.0 Flow 750

Machine unit number or Subassembly description

Ref 61 62 63 64 66 67 69 73 74 75 76

20

Part No

Description

593724 03 594009 02 594009 03 594009 04 594009 07 9005626 01 582212 181 9008374 01 9008382 80 582212 122 582212 13

Distance screw Screw Screw Screw Screw Self-tapping screw Sc clamp SK 35 D Igniter Cable set Terminal block End plate

-80 6 4 3 2 2 5 2 2 1 1 1

9011549Quantity

Notes

See page 32

Book No.

Cabinet

3

Lamp Drive Cabinet

2775A

3.1

Book No.

21

PureBallast 3.0 Flow 750

3.1.1 Cabinet Machine unit number or Subassembly description

Ref

Part No

Description

1 1A 1B 1C 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 30 31 33 34 35 42 42.1 58 59 60 62 63 64 66 67 69 70 72 73 74 76 77 79 80 82 83 88 89

9005142 591874 591874 9003031 9005143 9005144 221803 223101 9005145 9008903 221891 9003089 223101 221726 9003394 587276 221891 221716 9003390 223101 221030 9003401 223101 221030 9003186 9003410 223101 221030 593287 9003113 9003114 9002947 9002942 223101 221030 221891 221891 223101 587276 221851 591889 593780 9003186 9006316 221030 223101 9006322 9006519 221891 223101 9008424 221851 587276 221891 223101 223101 221891 587276 221851

Cabinet Seal Seal Condensation outlet Door, RH Door, LH Nut Washer Stand Washer Hexagon lock nut Vibration damper Washer 13x24x2,5 Screw Mounting plate Washer Hexagon lock nut Screw Bracket, fan Washer Screw Sheet, heat exchanger Washer Screw Plug Sheet, heat exchanger Washer Screw Pop rivet, multi grip Cable seal Cable gland Yoke Stud bolt Washer Screw Lock nut Lock nut Washer Washer Cap nut Cable tie mount Key Plug Cover, fan Screw Washer Sheet Cover Nut Washer, 4,3x9x0,8 Protection Cap nut Washer Lock nut Washer Washer Lock nut Washer Cap nut

22

80 04 05 01 80 80 02 47 80 05 05 02 49 10 01 02 05 01 01 47 10 01 47 10 01 01 47 10 01 01 02 01 01 47 02 04 04 47 01 05 01 01 02 01 10 47 01 01 02 41 01 05 01 04 47 47 04 01 05

-80 1 1 1 2 1 1 12 12 1 12 12 2 2 2 1 15 12 3 1 6 6 1 3 3 1 1 9 9 3 1 2 18 36 72 36 36 17 17 8 8 3 1 2 1 3 3 2 1 20 20 3 5 5 2 2 7 7 17 17

9003628Quantity

Notes Upper LPS rack, left Upper LPS rack, right Cabinet floor and heat exchanger floor

Book No.

Cabinet

3

Lamp Drive Cabinet

2700A

3.1

Book No.

23

PureBallast 3.0 Flow 750

Machine unit number or Subassembly description

Ref

Part No

Description

90 91 92 Z Z0.1

9009714 221891 223101 597330 597331

Sheet Lock nut Washer Cable seal Cable seal

24

01 04 47 01 01

-80 1 1 1

9003628Quantity

Notes

Book No.

Cabinet

3

Lamp Drive Cabinet

2700A

3.1

Book No.

25

PureBallast 3.0 Flow 750

3.1.2 I/O module Machine unit number or Subassembly description

Ref

Part No

1 2 3 4 5 6 7 8 9 10 11 12 13 14

580986 580986 580986 580986 580986 597033 580986 580986 580986 580986 580986 580986 580986 597033

26

64 17 62 63 72 19 59 08 53 61 16 19 20 20

Description Bus Module Bus module Interface Module Bus Supply Communication module 16 Digital input 12 Digital Output 4 Analogue input 2 Analogue Output 4 Analog Input (PT100) Terminal block 12-pin Locking Plate left Locking Plate right Terminal Block 16-pin

-80 1 6 1 1 1 1 1 1 1 1 6 0 0 1

9004174Quantity

Notes

Included in pos:1 Included in pos:1

Book No.

Cabinet

3

Lamp Drive Cabinet

2702A

3.1

Book No.

27

PureBallast 3.0 Flow 750

3.1.3 Terminal block Machine unit number or Subassembly description

Ref 1 2 3 4 5 6 7

28

Part No

Description

582212 67 582212 64 582212 65 582212 63 582212 71 582212 03 582212 148

Terminal, PIT 2,5-3PV Terminal PIT 2,5-3PE Terminal PIT 2,5-3L Terminal D-PIT 2,5-3L Plug In Bridge, FBS 3-5BU Plug In Bridge End stop (clip fix)

-80 7 1 2 1 1 1 1

9004507Quantity

Notes

Book No.

Cabinet

3

Lamp Drive Cabinet

2704A

3.1

Book No.

29

PureBallast 3.0 Flow 750

3.1.4 Terminal block Machine unit number or Subassembly description

Ref 1 3 4 5 6 7 8 9 10 11 12 13 15 16

30

Part No

Description

582212 148 582212 130 582212 122 582212 88 582212 89 582212 132 582212 131 582212 156 582212 157 582212 133 582212 15 582212 15 582212 137 582212 136

End stop (clip fix) Support, L=95,5 Terminal block PIT 2,5 D-ST2,5 Sealable cover profile Support, L=150 Terminal, PT 6 End cover, D-PT 6 Cover profile (AP-3) L=1m PE/SC Bar PE/SC Bar Sc clamp SK 20 Sc clamp SK 14

-80 2 1 2 22 1 2 2 32 1 1 1 1 9 1

9004508Quantity

Notes

Cut to 294 mm Cut to 289 mm Cut to 431 mm

Book No.

Cabinet

3

Lamp Drive Cabinet

2705A

3.1

Book No.

31

PureBallast 3.0 Flow 750

3.1.5 Cable set Machine unit number or Subassembly description

Ref 1 2 3 4 5 6 7 8 9 11 12 14 15 16 50 51

32

Part No

Description

-80

9008383 01 9008383 02 9008383 03 9008383 04 9008383 05 9008383 06 9008383 12 9008383 13 9008383 08 9008387 01 9008693 01 595673 04 9004439 01 9008388 01 582221 99 582221 100

Cable, 70mm² Cable, 35mm² Cable, 2,5mm² Cable, 2,5mm² Cable, 2,5mm² Cable, 2,5mm² PE Cable, 25mm² PE Cable, 6mm² PE Cable, 1,5mm² Cable, 0,75mm² Cable, 2x2x0,5mm² Ethernet cable Cable Cable, 2x1,5mm² Ferrite Ferrite

5 15 20 20 20 25 1 2 6 150 6 2 1 35 2 2

9008382Quantity

Notes

on 595673 04 On incomming LAN cable

Book No.

Cabinet

3

Lamp Drive Cabinet

2377A

3.1

Book No.

33

PureBallast 3.0 Flow 750

4 AOT reactor Machine unit number or Subassembly description

Ref

Part No

Description

-82

1 2

9002699 82 AOT reactor JIS 9003748 80 Junction box

1 1

3

9004960 80 Junction box

1

4 5 7 8

221711 223101 9001357 594412

Screw Washer Sensor Valve V201-19 and V201-20

8 8 1 1

594412 92 Valve V201-19 and V201-20

1

8.1 8.2 9 10 12 13 14 15 16 16.1 16.2 16.3 16.4 17 17.1 17.2 17.3 17.4 17.5 18 19 20

590667 9011365 223101 9006325 9006324 558663 594171 9005051 9005051 9005051 9005051 9005051 9005052 9005052 9005052 9005052 9005052 9005052 526350 558663 594413

08 32 03 92

01 01 64 01 01 04 01 04 07 06 08 05 01 05 07 10 09 08 05 03 80

V201-19 Hexagon head screw Washer Thermometer, resistance Temperature, switch Gasket washer Vibration limit switch Cable Cable Cable Cable Cable Cable Cable Cable Cable Cable Cable Plug Gasket washer Valve

1 32 32 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1

20.1

594413 80 Valve

1

20.2

594413 80 Valve

1

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

2210463 223101 1761805 597049 594707 581534 260321 592304 592304 552801 9004638 2210296 223101 221803 9006320

36

9006320 81 Lamp cable

37 38 39 63 95

34

595272 558710 597044 596103 554214

03 37 01 01 02 01 25 01 02 50 01 02 33 27 80

01 02 04 01 06

Screw Washer Safety valve, 6 bar Coupling, elbow 90 Pipe Distributor Hexagon screw Plug Plug, 1/4 Push-on connector Clamp Screw Washer Nut Lamp cable

Tube, 6x1 mm Air Hose Nipple Cable Screw Cable tie

12 12 1 1 1 1 2 1 1 5 1 1 3 1 16 16 4 5 1 4 30

9002700Quantity

Notes See page 38 A-side See page 40 B-side See page 42

V201-19 See page 44 V201-20 See page 44

TT201-33 TS201-60 LS201-29 V201-19 V201-20 V320-4 V404-36 V321-2 GS201-19 GS201-20 QT201-50 TS201-60 TT201-33 LS201-29 V320-4 See page 46 V321-2 See page 46 V404-36 See page 46 RV201-23

Marked acc. to circuit diagram. Incl. cap, collet, gland and nut. Marked acc. to circuit diagram. Incl. cap, collet, gland and nut.

Book No.

AOT reactor

2688A

4

Book No.

35

PureBallast 3.0 Flow 750

Machine unit number or Subassembly description

Ref

Part No

Description

96 Z ZA ZB Z0.1 Z0.1A Z0.1B

544465 9009521 9007810 579380 594645 9000738 599555

Pipe-Seal Lamp, spare set UV lamp with contact O-ring, 15,1x2,7 Quartz sleeve set Quartz sleeve O-ring

36

15 80 80 01 82 02 01

-82 1

9002700Quantity

Notes

1 2 1 2

Book No.

AOT reactor

2688A

4

Book No.

37

PureBallast 3.0 Flow 750

4.1 AOT reactor JIS Machine unit number or Subassembly description

Ref

Part No

Description

-82

3 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 33A 34 35 36 38 39 40 41

66169 9003326 221711 9002009 9004878 9002860 9001098 9001897 221036 223101 526350 558663 9001539 221711 9003669 221040 41456 221035 70560 9003661 221035 9003662 2210295 223101 9003672 221035 9004889 9004886 221040 35120 9007794 9009416 221031 223101 221803

Drive screw Glass socket Screw Lamp bush Cap Nut Blind flange O-ring Screw Washer Plug Gasket washer Cable bracket Screw Bottom bracket Screw Washer Screw Washer Stay Screw Plate Screw Washer Upper bracket Screw Lifting bracket Bracket Screw Nut Cable rail Cable rail Screw Washer Nut

8 32 96 32 32 32 1 1 10 10 1 1 8 16 2 16 24 4 24 2 12 1 1 2 2 8 1 1 4 4 2 2 4 8 4

38

01 13 81 80 01 01 01 02 33 05 03 01 23 01 04 06 01 36 01 03 17 01 03 01 80 55 01 01 21 32 28

9002699Quantity

Notes

Book No.

AOT reactor JIS

4

AOT reactor

2685A

4.1

Book No.

39

PureBallast 3.0 Flow 750

4.2 Junction box Machine unit number or Subassembly description

Ref 1 2 3 4 5 6 7 11 12 18 19 20 22 25

40

Part No

Description

9004825 80 582212 148 582212 88 582212 122 582212 154 582212 70 582212 89 582212 151 582212 150 9003031 01 589569 21 589569 44 582356 26 582356 30

Enclosure End stop (clip fix) PIT 2,5 Terminal block Busbar 5-5 Bu Plug In Bridge, FBS 3-5 D-ST2,5 Socket Socket Condensation outlet Cable Gland EMC M32 Counter nut EMC M32 Signal lamp, White Lamp green, compl.

-80 1 2 28 3 1 1 1 6 5 1 2 2 1 1

9003748Quantity

Notes Marked acc. to interconnection diagram. 400 402

Book No.

Junction box

4

AOT reactor

2679A

4.2

Book No.

41

PureBallast 3.0 Flow 750

4.3 Junction box Machine unit number or Subassembly description

Ref 1 2 3 4 5 6 7 8 9 10

42

Part No

Description

9004844 80 582212 148 582212 156 582212 157 9003031 01 589569 59 9004959 01 589569 45 589569 21 589569 44

Enclosure End stop (clip fix) Terminal, PT 6 End cover, D-PT 6 Condensation outlet Cable gland EMC-brush M40 Insert, 8x6 mm Counter nut EMC M40 Cable Gland EMC M32 Counter nut EMC M32

-80 1 2 32 1 1 4 4 4 4 4

9004960Quantity

Notes Marked acc. to interconnection diagram.

Book No.

Junction box

4

AOT reactor

2680A

4.3

Book No.

43

PureBallast 3.0 Flow 750

4.4 Valve V201-19 and V201-20 Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 4 5 6 8 9 Z

576886 576075 576071 585976 594410 583012 9009912 595215 576075

Valve, A350 Air actuator, DA551 Pilot valve Coil, 24 V DC Valve connector Throttle valve, 1/4 Sensor Plate Actuator spare part kit, DA/SR 551

44

26 05 01 01 01 01 01 01 65

-92 1 1 1 1 1 2 1 1

594412Quantity

Notes Lug type

Book No.

Valve V201-19 and V201-20

4

AOT reactor

2686A

4.4

Book No.

45

PureBallast 3.0 Flow 750

4.5 Valve Machine unit number or Subassembly description

Ref

Part No

1 2 3 4 5 6 Z

590037 576075 576071 585976 594410 583012 576075

46

01 21 01 01 01 01 71

Description Valve, DN32 Air actuator, SR101 Pilot valve Coil, 24 V DC Valve connector Throttle valve, 1/4 Actuator spare part kit, DA/SR 101

-80 1 1 1 1 1 2 1

594413Quantity

Notes

Book No.

Valve

4

AOT reactor

2330A

4.5

Book No.

47

PureBallast 3.0 Flow 750

5 Filter, RF10-30 *=On request only, contact your local Alfa Laval representative Machine unit number or Subassembly description

Ref

Part No

Description

11 11.5 12 13 14 15 17 18 18.5 19 19.1 19.2 19.3 19.4 19.5 21 23 24 25 26 27 28 29 30 31 32 33 34 34.5 35 36 37 38 39 39.6 39.7 39.8 39.9 40 40.5 41 51 52 53 61 65 65.3 65.5 68 70 70.5 71 71.5 72 72.5 73 74 75 76

9006822 9000396 9000396 9006771 9000396 9000397 9000394 9000394 9000396 9000398 9000398 9000398 9000398 9000398 9000398 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000398 9000395 9000395 9000398 9000394 9000394 9000398 9000398 9000395 9000398 9000397 9000395 9000397 9000397 9000398 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000398 9000396 9000396 9000396

Safety valve, 8 bar Union nut Tube 2/2-way piston valve Double nipple O-ring 81.2 x 5.33 - NBR Protective box RF10-30 RA Sacrificial anode RF10-30 Extension RF10 vent 200 L Litz wire VDE0281 H07V-K Cable shoe DIN46235 - 8 Washer ISO7089-8 - 200 HV Hex-screw ISO 4017-M8 x 2 Stud screw DIN939-M 8 x 9 Hex-nut ISO 4032-M8 Drive shaft RF10-30/35 Locking ring DIN471 - 35 Washer RF3-3/4 Washer RF3-3/4 bearing bu DUB-bearing - id =3 5, ad Support ring spiral sprin Quad-ring - 32.92 x 39.98 Washer RF3-3/4 upper driv Intermediate shaft RF10-3 Lower drive shaft RF10-30 Washer RF3-3/4 Lower driv Lower bearing bush RF3-3/ Nut RF3-3/4 Nut RF3-3/4 DUB-bearing - id = 50, ad Cylinder screw ISO 4762Washer RF3-3/4 lever arm Lever arm Cylinder screw ISO 4762Upper plate RF10-30 compl Lower plate RF10-30 compl Cylinder pin Cylinder pin Sleeve Hex screw O-ring Coupling bush RF10-25/30 O-Ring 113.67 x 5.33 O-Ring 113.67 x 5.33 Cylinder pin Coupling Manometer connection Coupling Blind rivet ISO 15983 - 3 Plate Inlet - English Plate Plate Outlet - English Plate Draining - English Plate Backflushline - Eng Plate Dilute - English Grooved drive stud ISO 87 Ring bolt DIN580 - M20 Cable tape Betz -TYB23M n Sticker "directional arro

48

02 55 51 02 92 06 03 62 12 51 50 33 21 45 11 42 20 21 22 23 24 25 26 62 63 27 28 29 29 32 09 34 69 08 23 43 64 65 84 72 20 51 07 07 93 96 37 97 02 72 77 73 74 75 76 46 30 04 21

-80* 1 1 1 9 1 1 1 1 1 1 22 20 18 2 4 1 3 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 1 4 1 1 1 1 1 2 1 1 1 1 1 2 2 2 3 1 1 1 1 1 1 12 3 16 1

9006972Quantity

Notes 0,5m

1,0m

Book No.

Filter, RF10-30

2693A

5

Book No.

49

PureBallast 3.0 Flow 750

*=On request only, contact your local Alfa Laval representative Machine unit number or Subassembly description

Ref

Part No

Description

77 81 82 83 83.5 83.6 83.7 83.8 84 85 85.5 86 86.5 87 87.5 88 88.5 88.6 89 89.1 89.2 89.3 89.6 89.8 91 92 95 112 113 113.5 114 114.5 120 120.5 121 121.5 122 126 130 140 145 155 155 155.5 155.6 155.7 156.5 157 157.5 158 160.5 161 161.5 162 162.5 163 167.5 168 168.5 169

9000396 19 9000396 13 9000396 24 9000396 63 9000398 02 9000398 40 9000398 11 9000398 59 9000398 01 9000396 52 9000398 92 9000396 57 9000396 14 9000396 58 9000396 59 9000398 20 9000398 10 9000398 42 9000396 91 9000396 50 9000396 40 9000396 54 9000396 53 9000396 34 9006769 02 9000395 39 9000395 85 9000398 03 9000398 41 9000398 02 9000398 40 9000398 11 9000395 31 9000395 81 9000398 32 9000398 07 9000395 45 9000396 29 9000394 13 9000394 123 9000394 132 9000394 91 9000394 92 9000394 94 9000398 38 9000398 91 9000394 69 9000398 18 9000398 90 9000397 22 9000396 89 9000398 77 9000398 78 9000398 67 9000397 22 9000396 85 9000396 90 9000398 97 9000398 17 9000398 90

Screw cap OBO Thom. u. B Hose - PAN - 6 x 1 Bl* T-connection QST-6 Fixing plate Cylinder screw ISO 4762 Spring ring DIN127-A 8 Hex-nut ISO 4032-M8 Thread rod Cylinder screw ISO 4762 Tube Screw-in connector T-connection Connection ISO8438-1-SWO Connection Clamp Hex-screw ISO 4017 M 6 x Hex-nut ISO 4032-M 6 Spring ring DIN 127-B6 Cable channel Fixing bracket piping RF1 Fixing bracket piping RF1 Pipe nut Pipe Pipe clamp 25-28 mm M8/M1 Gear motor Paralel key DIN 6885 - A Proximity switch Cylinder screw ISO 4762 Spring ring DIN127-B 10 Cylinder screw ISO 4762 Spring ring DIN127-A 8 Hex-nut ISO 4032-M8 Control plate RF10-30 Washer RF10-30/35 bored Washer ISO7089-3 200 HV Cylinder screw ISO4762-M Saftey plate Warning sticker Hein 1 pc Cover RF10-30A-x-PF compl Vessel upper part Vessel lower part Reducer JIS A100-A80 LH Reducer JIS A100-A80 RH Reducer Lock screw VSTI G 1 1/2-E Lock screw Elbow Hex-screw Washer Sealing Blind flange Hex-screw Hex-screw Washer Sealing Drain plug Blind flange Hex-screw Hex-nut Washer

50

-80* 8 1 10 1 4 4 4 2 8 1 2 1 1 1 1 8 8 8 1 1 1 1 1 2 1 1 3 4 4 4 4 4 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 4 4 4 1 1 2 8 8 8

9006972Quantity

Notes 3,0m

3,0m

2m

Book No.

Filter, RF10-30

2693A

5

Book No.

51

PureBallast 3.0 Flow 750

*=On request only, contact your local Alfa Laval representative Machine unit number or Subassembly description

Ref

Part No

Description

169.5 170 171 172 173 177 178 178.1 178.2 178.5 179 180 183 184 186 188 189 189.5 190 191 191.5 192 200 200A 200B 200C 200D 200E 200F 200G 200H 200I 200J 200K 200L 200M 200N 200O 200P 200Q 203 301 302 303 Z Z0.1 Z0.2

9000397 21 9000398 103 9000398 108 9000398 150 9000398 94 9000397 14 9000398 141 9000398 87 9000398 95 9000398 83 9000398 95 9000398 87 9000395 86 9000398 84 9000398 43 9000396 71 9000397 10 9000397 19 9007128 80 9000398 85 9000398 95 9000398 87 9007005 82 9000396 95 9007239 01 9007239 02 9007239 03 9007239 04 9007239 05 9007239 06 9007239 07 9007239 08 9007239 23 9007239 11 9007239 10 9007239 12 9007239 13 9007239 24 9007239 25 9007239 26 9007007 01 9000395 83 9000397 08 9000397 09 9007098 82 9007100 82 9007099 80

Sealing Hex-screw Hex-screw Washer Hex-nut Sealing Hex-screw Washer Hex-nut Hex-screw Hex-nut Washer Distance piece Hex-screw Spring ring Fixing plate for Control Sealing EN1514-1-IBC-DN 1 Sealing Valve, V309-1 Hex-screw Hex-nut Washer Electrical cabinet Cabinet Display Main switch Power supply CPU Digital output Relay Prot. switch Contactor Terminal PE terminal Terminal Fuse Sensor box Fuse Fuse Fuse Pressure transmitter Filter element O-ring 72.62 x 3.53* O-ring 110.72 x 3.53* Sealing kit Filter element kit Proximity switch kit

52

-80* 2 20 20 80 40 4 8 8 8 8 8 16 1 8 8 2 1 1 1 4 4 8 1 1 1 1 1 1 1 2 1 1 19 7 4 4 2

9006972Quantity

Notes

See page 54

3 9 9 9

Book No.

Filter, RF10-30

2693A

5

Book No.

53

PureBallast 3.0 Flow 750

5.1 Valve, V309-1 Machine unit number or Subassembly description

Ref

Part No

Description

1 2 16 85.5 193 193.1 194 196 197

9000394 141 9000394 144 9000396 08 9000398 92 9000396 01 9000396 93 9000396 11 9000396 07 9000398 04

Butterfly valve Actuator Coupling M12 x 1, 5-pole, Screw-in connector 3/2-Way valve MND310701 G Coil Exhaust throttle valve -G Control plate RF3-x-EPT R Cylinder screw ISO 4762-M

54

-80 1 1 1 1 1 1 1 1 2

9007128Quantity

Notes

Book No.

Valve, V309-1

5

Filter, RF10-30

2698A

5.1

Book No.

55

PureBallast 3.0 Flow 750

6 Valve, JIS A300 Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 5 6 7 8 19

9007167 9007166 9007185 9007192 9007193 9007196 9007186 587927

Valve, A300 Air actuator, AT 451U Pilot valve Throttle valve, 1/4 Actuator cable Bracket Switch box Locking device, AL79 451

56

23 06 01 01 01 02 01 07

-88 1 1 1 2 1 1 1 1

9007170Quantity

Notes

Book No.

Valve, JIS A300

2710A

6

Book No.

57

PureBallast 3.0 Flow 750

7 Valve, JIS A300 Machine unit number or Subassembly description

Ref

Part No

Description

1 1 2 2 3 5 6 7 7 8 22 23 Z

9007167 9007167 9007166 9007166 9007185 9007192 9007193 9007196 9007196 9007186 9007198 595558 9007184

Valve, A50 Valve, A300 Air actuator, AT 101U Air actuator, AT 451U Pilot valve Throttle valve, 1/4 Actuator cable Bracket Bracket Switch box Serial no. plate Wire Insulate plate

58

15 23 01 06 01 01 01 01 02 01 01 01 01

9007172-88 -80 1 1 1 2 1 1 1

Quantity 1

Notes

1 1 2 1 1 1 1 1

Book No.

Valve, JIS A300

2714A

7

Book No.

59

PureBallast 3.0 Flow 750

8 Valve, JIS A300 Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 5 6 7 8 12 13 14 15 16 17 18 19

9007167 9007166 9007185 9007192 9007193 9007196 9007186 9005789 552801 1764011 592304 569035 580758 9005792 587927

Valve, A300 Air actuator, AT 451U Pilot valve Throttle valve, 1/4 Actuator cable Bracket Switch box Gearbox Push-in connector Silencer Plug, 1/4 Flexible pipe, PA12, 8/6 Push-In Fittings Handwheel Locking device, AL79 451

60

23 06 01 01 01 02 01 03 02 02 02 05 06 02 07

-88 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

9007168Quantity

Notes

Book No.

Valve, JIS A300

2716A

8

Book No.

61

PureBallast 3.0 Flow 750

9 Control valve V201-8 Machine unit number or Subassembly description

Ref

Part No

Description

1 2 7 9 10 13 16 19 24 27 28 30 31 Z

9007167 9007166 9007196 9007191 9007190 552801 569035 587927 552801 9007200 9007201 523127 592304 9007184

Valve, A250 Air actuator, AT 351U Bracket Mounting kit, Positioner Positioner Push-in connector Flexible pipe, PA12, 8/6 Locking device, AL79 351 Push-in connector Manifold Filter Hexagon nipple Plug, 1/4 Insulate plate

62

22 05 02 01 01 02 05 05 02 01 01 01 02 04

-87 1 1 1 1 1 2 1 1 2 1 1 1 1

9007174Quantity

Notes

Book No.

Control valve V201-8

2712A

9

Book No.

63

PureBallast 3.0 Flow 750

10 Flow transmitter, A300 Machine unit number or Subassembly description

Ref 1 2 5

64

Part No

Description

585345 61 Sensing tube, A300 586907 01 Transmitter, MAG 5000 595229 01 Cable gland

-93 1 1 1

576179Quantity

Notes

Book No.

Flow transmitter, A300

2363A

10

Book No.

65

PureBallast 3.0 Flow 750

11 CIP module Machine unit number or Subassembly description

Ref

Part No

1 2 3 4 5 6 7 8 9 10 11 12 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 53 54 55 56 57 58 59 60 61 62 63

9003450 590414 9004533 9002825 9003730 9002915 9003732 590313 590476 9005046 589526 526350 9003172 9004479 9003514 9004517 9002962 9002963 9004237 9003935 9002964 9002584 9002586 9003570 9003949 9002589 9003792 9002591 9003837 9004247 9002592 9003851 9003853 9003854 9003863 9003886 9003888 592649 591675 569038 592665 9003574 9005743 599223 599223 592676 592676 592790 221716 221711 221701 223101 221711 223101 587276 27345 70560 9005147 9005394

66

01 01 80 80 01 01 01 01 01 01 07 06 80 80 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 05 01 01 01 03 02 05 07 01 02 17 04 41 16 47 02

Description

Frame complete Tank Pump P320-1 and P321-5 Valve Valve housing Check valve O-ring Valve, angle seat Nipple, ISO-R 3/4-1/2 Backflow preventer U-bolt clamp, c-c 56,5 Plug Valve block Filter regulator Speed controller Reducer Pipe #1 Pipe #2 Pipe #3 Pipe #4 Pipe #5 Pipe #6 Pipe #7 Pipe #8 Pipe #9 Pipe #10 Pipe #11 Pipe #12 Pipe #13 Pipe #14 Pipe #15 Pipe #16 Pipe #17 Pipe #18 Pipe #19 Pipe #20 Pipe #21 Nipple Hose, 32 Hose, 32 Hose, 25 O-ring Pipe clamp Hose clamp 38-50 Hose clamp 32-44 Insulation sheet, 10mm Insulation sheet, 5mm Insulation sheet Screw Screw Screw Washer, 4,3x9x0,8 Screw Washer Washer Nut, M8 Washer 01 Pipe #22 80 Air distribution

-81 1 1 2 6 3 2 6 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 4 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 6 5 10 3 4 7 1 2 2 4 4 16 16 2 12 19 1 1

9002547Quantity

Notes See page 70 See page 72

See page 74

See page 76

Book No.

CIP module

2605A

11

Book No.

67

PureBallast 3.0 Flow 750

Machine unit number or Subassembly description

Ref

Part No

64 65 66 Z

221040 590539 548152 590414

68

53 03 03 02

Description Screw Clip list Washer Tanck screw cap

-81 5 1 5

9002547Quantity

Notes

Book No.

CIP module

2605A

11

Book No.

69

PureBallast 3.0 Flow 750

11.1 Pump P320-1 and P321-5 Machine unit number or Subassembly description

Ref

Part No

Description

1 Z

9004533 01 Pump 9004587 80 Spare part set

Z0.1

9004588 80 Spare part set

70

-80 1

9004533Quantity

Notes Incl. O-rings, diaphragm, ball, muffler indicated in dwg. Incl. air valve, sealings and O-rings, indicated in dwg.

Book No.

Pump P320-1 and P321-5

11

CIP module

2606A

11.1

Book No.

71

PureBallast 3.0 Flow 750

11.2 Valve Machine unit number or Subassembly description

Ref Z

72

Part No

Description

9003574 01 O-ring

-80

9002825Quantity

Notes

Book No.

Valve

11

CIP module

2609A

11.2

Book No.

73

PureBallast 3.0 Flow 750

11.3 Valve block Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 4 5 6 7 8 9 10 11 13

9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172

Valve block side Valve block Valve block side Valve 2x 3/2 Connection box Cable gland NPT3/4 Plug Plug O-ring Sign bracket Sign plate Cable gland, M32

74

01 02 03 04 05 06 07 08 09 10 11 12

-80 1 5 1 5 1 1 1 1 1 2 1 1

9003172Quantity

Notes

Book No.

Valve block

11

CIP module

2607A

11.3

Book No.

75

PureBallast 3.0 Flow 750

11.4 Air distribution Machine unit number or Subassembly description

Ref

Part No

1 2 3 4 5

569035 569035 552801 558710 580758

76

05 01 50 01 06

Description Flexible pipe, PA12, 8/6 Flexible pipe, PA12, 6/4 Push-on connector Air Hose Nipple Push-In Fittings

-80 1 1 6 1 2

9005394Quantity

Notes

Book No.

Air distribution

11

CIP module

2608A

11.4

Book No.

77

PureBallast 3.0 Flow 750

12 Sampling device (QT201.1, QT201.1) Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 4 5 6 7 8 9 9 10 10 11 14

591662 591667 1765908 2210462 221803 70490 591631 591628 2210462 2210462 590667 590667 556563 591666

Adaptor pipe Pitot tube Gasket Screw Nut, M16 Washer Blind flange, DN50/A50 Valve, manual A50 Screw Screw, M16x45 Q201.1 Q201.2 Wire Rod

78

80 01 07 30 34 01 81 28 45 27 28 01 01

589745-90 -91 1 1 2 4 4 16 1 1 8 1 1 1

Quantity 1 1 2 4 4 16 1 1 8

Notes

M6S 16x70 fzb M6M 16 fzb BRB 17x30x3 fzb M6S 16x45 fzb M6S 16x45 fzb

1 1 1

Book No.

Sampling device (QT201.1, QT201.1)

2780A

12

Book No.

79

PureBallast 3.0 Flow 750

13 Pressure monitoring device Machine unit number or Subassembly description

Ref

Part No

Description

1 2 3 4 5 6 7 9

9007231 526336 9006075 9001406 543054 9006822 546600 595558

Needle valve, DN15 Nipple Manifold Pressure transmitter kit Pressure gauge Safety valve, 8 bar Pipe union Wire

80

01 04 01 82 03 02 02 01

-80 1 3 1 1 1 1 1 4

9006076Quantity

Notes

Incl. pressure transmitter and connector

Book No.

Pressure monitoring device

2709A

13

Book No.

81

14

Cross reference list

14 Cross reference list +

Part No. 1761805 1764011 1765908 2210295 2210296 221030 221030 221030 221030 221030 221030 221031 221035 221035 221035 221036 221040 221040 221040 2210462 2210462 2210462 2210463 221701 221701 221711 221711 221711 221711 221711 221711 221711 221716 221716 221716 221726 221803 221803 221803 221803 221803 221803 221803 221803 221851 221851 221851 221891 221891 221891

82

01 02 07 03 02 02 10 10 10 10 10 21 03 06 36 02 04 53 55 28 30 45 03 03 04 08 13 16 16 17 19 23 01 01 02 10 02 02 02 02 03 27 28 34 05 05 05 01 02 02

Page 34 60 78 38 34 22 18 22 22 22 22 38 38 38 38 38 38 67 38 78 78 78 34 6 66 34 38 66 10 66 10 38 22 10 66 22 18 22 6 10 18 34 38 78 22 22 22 18 18 22

Ref.

Part No. 23 14 3 29 32 34 49 18 21 25 66 39 32 24 27 13 22 64 34 9 4 9 21 17 55 4 7 57 29 54 22 20 15 8 53 11 50 4 45 24 51 34 41 5 59 76 89 52 53 72

221891 221891 221891 221891 221891 221891 221891 221891 221891 221891 221891 221891 221891 221891 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223101 223107 260321 26556 27345 35120 41456 523127

04 04 04 04 04 04 04 04 04 05 05 05 05 05 03 16 17 17 32 32 33 33 37 41 41 47 47 47 47 47 47 47 47 47 47 47 47 47 47 47 49 64 73 34 25

01

Page 18 22 22 22 22 23 6 10 10 18 22 22 10 10 18 18 18 38 34 38 34 38 34 22 66 18 22 22 22 22 22 22 22 22 22 23 6 66 6 10 22 34 10 10 34 10 66 38 38 62

Ref.

Part No. 54 35 42 79 83 91 8 16 31 55 8 14 7 34 56 57 58 30 5 40 33 14 22 73 56 59 5 17 20 24 33 42.1 67 80 82 92 44 58 8.1 30 10 10 25 15 27 4 60 35 23 30

523127 526336 526350 526350 526350 543054 544465 544465 546600 548152 552801 552801 552801 552801 552801 554214 556563 558663 558663 558663 558710 558710 569035 569035 569035 569035 569038 576071 576071 576075 576075 576075 576075 576886 579380 579385 580758 580758 580986 580986 580986 580986 580986 580986 580986 580986 580986 580986 580986 580986

04 04 05 05 06 03 04 15 02 03 02 02 02 50 50 06 01 03 03 04 01 02 01 05 05 05 05 01 01 05 21 65 71 26 01 01 06 06 06 08 08 16 16 17 17 19 20 30 32 33

Page 18 80 34 38 66 80 10 35 80 67 60 62 62 34 76 34 78 34 38 34 76 34 76 60 62 76 66 44 46 44 46 44 46 44 35 10 60 76 12 12 26 12 26 12 26 26 26 12 12 12

Ref. 10 2 18 15 12 5 35 96 7 66 13 13 24 30 3 95 11 19 16 14 4 38 2 16 16 1 43 3 3 2 2 Z Z 1 ZB 10 17 5 9 5 8 10 11 2 2 12 13 3 7 6

Book No.

PureBallast 3.0 Flow 750

Part No.

Page

580986 51 580986 53 580986 55 580986 59 580986 59 580986 61 580986 62 580986 63 580986 64 580986 67 580986 72 580986 76 580986 76 581534 01 581688 01 582212 03 582212 03 582212 102 582212 104 582212 104 582212 105 582212 105 582212 119 582212 120 582212 122 582212 122 582212 122 582212 122 582212 123 582212 125 582212 125 582212 130 582212 131 582212 132 582212 133 582212 136 582212 137 582212 13 582212 13 582212 141 582212 146 582212 147 582212 147 582212 148 582212 148 582212 148 582212 148 582212 148 582212 148 582212 150

12 26 12 12 26 26 26 26 26 12 26 12 12 34 10 28 6 6 6 6 6 6 14 14 19 30 40 7 6 6 18 30 30 30 30 30 30 19 7 18 18 18 6 18 28 30 40 42 6 40

Book No.

Ref. 4 9 12 8 7 10 3 4 1 1 5 1.2 1.3 26 27 6 26.2 22 21 24 23 25 1 2 75 4 4 69 29 12 30 3 8 7 11 16 15 76 70 47 36 41 20 43 7 1 2 2 9 12

Part No.

Page

582212 151 582212 154 582212 155 582212 156 582212 156 582212 157 582212 157 582212 15 582212 15 582212 15 582212 163 582212 164 582212 165 582212 167 582212 168 582212 171 582212 172 582212 181 582212 186 582212 60 582212 60 582212 63 582212 63 582212 63 582212 64 582212 65 582212 67 582212 67 582212 67 582212 70 582212 71 582212 86 582212 87 582212 88 582212 88 582212 89 582212 89 582212 91 582221 100 582221 89 582221 90 582221 90 582221 99 582356 18 582356 26 582356 26 582356 27 582356 28 582356 30 582356 30

40 40 6 30 42 30 42 30 30 6 18 18 18 6 6 6 14 19 14 6 6 6 28 6 28 28 6 28 6 40 28 6 6 30 40 30 40 6 32 6 18 6 32 6 18 40 18 18 18 40

Ref.

Part No. 11 5 48 9 3 10 4 12 13 32 19.2 19.1 19.3 24.2 28 24.1 Z 69 3 14.1 26.1 15 4 27 2 3 14 1 26 6 5 29.1 29.2 5 3 6 7 19 51 46 20 31 50 47 13 22 15 14 12 25

583012 583012 583556 583556 585345 585976 585976 586907 587276 587276 587276 587276 587276 587276 587276 587927 587927 587927 589526 589569 589569 589569 589569 589569 589569 590037 590313 590414 590414 590476 590539 590624 590667 590667 590667 591103 591103 591103 591103 591103 591103 591103 591103 591103 591103 591103 591103 591103 591628 591631

01 01 16 17 61 01 01 01 01 01 01 02 02 02 02 05 07 07 07 21 21 44 44 45 59 01 01 01 02 01 03 03 01 27 28 10 10 36 38 45 46 54 60 60 61 64 66 81 81 01

Page 44 46 6 6 64 44 46 64 22 22 22 18 22 66 10 62 56 60 66 40 42 40 42 42 42 46 66 66 67 66 67 18 34 78 78 6 18 6 6 6 18 18 6 18 18 18 18 6 78 78

Ref. 6 6 36 37 1 4 4 2 58 77 88 60 13 59 32 19 19 19 11 19 9 20 10 8 6 1 8 2 Z 9 65 7 8.2 10 10 10.1 26.1 49 16 11 24 26 10 25 29 28 27 16.1 8 7

83

14

Part No. 591662 591666 591667 591675 591874 591874 591889 591922 592304 592304 592304 592304 592649 592665 592676 592676 592790 593239 593254 593282 593287 593724 593724 593780 593991 594009 594009 594009 594009 594009 594009 594171 594410 594410 594412 594412 594413 594413 594413 594488 594645 594707 594728 595215 595229 595272 595361 595558 595558 595558

84

80 01 01 01 04 05 01 01 01 02 02 02 01 01 05 07 01 01 01 01 01 03 03 01 01 01 02 03 03 04 07 01 01 01 92 92 80 80 80 01 82 02 01 01 01 01 01 01 01 01

Page 78 78 78 66 22 22 22 6 34 34 60 62 66 66 66 66 66 10 10 10 22 19 6 22 10 10 19 19 6 19 19 34 44 46 34 34 34 34 34 10 35 34 18 44 64 34 6 18 58 80

Ref. 1 14 2 42 1A 1B 60 41 28 29 15 31 41 44 49 50 51 26 19 23 27 61 33 62 12 3 62 63 34 64 66 15 5 5 8 8.1 20 20.1 20.2 28 Z0.1 25 37.1 9 5 37 42 9.2 23 9

Part No.

Page

595670 80 595673 01 595673 04 596103 01 596894 01 596894 01 597033 18 597033 19 597033 20 597044 04 597049 01 597330 01 597330 01 597331 01 597331 01 599223 02 599223 03 599555 01 66169 70490 70560 70560 70560 70560 70915 9000394 03 9000394 123 9000394 132 9000394 13 9000394 141 9000394 144 9000394 23 9000394 43 9000394 62 9000394 69 9000394 91 9000394 92 9000394 94 9000395 20 9000395 21 9000395 22 9000395 23 9000395 24 9000395 25 9000395 26 9000395 27 9000395 28 9000395 29 9000395 29 9000395 31

6 7 32 34 6 6 12 26 26 34 34 23 7 23 7 66 66 35 38 78 18 38 66 10 10 48 50 50 50 54 54 48 48 48 50 50 50 50 48 48 48 48 48 48 48 48 48 48 48 50

Ref. 4 55 14 63 51.1 51.2 1.1 6 14 39 24 Z Z Z0.1 Z0.1 48 47 Z0.1B 3 6 48 25 61 33 6 17 140 145 130 1 2 39.6 39.7 18 156.5 155 155 155.5 23 24 25 26 27 28 29 32 33 34 34.5 120

Cross reference list

Part No. 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000395 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396 9000396

32 34 39 42 45 51 62 63 69 81 83 84 85 86 01 02 04 07 08 11 12 13 14 19 21 24 29 30 34 37 40 50 51 52 53 54 55 57 58 59 63 71 72 73 74 75 76 77 85 89

Page 48 48 50 48 50 48 48 48 48 50 52 48 50 52 54 48 48 54 54 54 48 50 50 50 48 50 50 48 50 48 50 50 48 50 50 50 48 50 50 50 50 52 48 48 48 48 48 48 50 50

Ref. 35 37 92 21 122 51 30 31 38 120.5 301 40 95 183 193 68 75 196 16 194 18.5 81 86.5 77 76 82 126 74 89.8 65.3 89.2 89.1 12 85 89.6 89.3 11.5 86 87 87.5 83 188 70 71 71.5 72 72.5 70.5 163 160.5

Book No.

PureBallast 3.0 Flow 750

Part No.

Page

9000396 90 9000396 91 9000396 92 9000396 93 9000396 95 9000396 96 9000396 97 9000397 06 9000397 07 9000397 07 9000397 08 9000397 09 9000397 10 9000397 14 9000397 19 9000397 20 9000397 21 9000397 22 9000397 22 9000398 01 9000398 02 9000398 02 9000398 03 9000398 04 9000398 07 9000398 08 9000398 09 9000398 103 9000398 108 9000398 10 9000398 11 9000398 11 9000398 11 9000398 141 9000398 150 9000398 17 9000398 18 9000398 20 9000398 21 9000398 32 9000398 33 9000398 38 9000398 40 9000398 40 9000398 41 9000398 42 9000398 43 9000398 45 9000398 46 9000398 50

50 50 48 54 52 48 48 48 48 48 52 52 52 52 52 48 52 50 50 50 50 50 50 54 50 48 48 52 52 50 48 50 50 52 52 50 50 50 48 50 48 50 50 50 50 50 52 48 48 48

Book No.

Ref. 167.5 89 14 193.1 200A 65 65.5 15 52 53 302 303 189 177 189.5 41 169.5 158 162.5 84 83.5 113.5 112 197 121.5 39 36 170 171 88.5 19.5 83.7 114.5 178 172 168.5 157 88 19.3 121 19.2 155.6 83.6 114 113 88.6 186 19.4 73 19.1

Part No. 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000398 9000738 9001098 9001357 9001406 9001539 9001897 9002009 9002362 9002584 9002586 9002589 9002591 9002592 9002699 9002825 9002860 9002915 9002942 9002947 9002962 9002963 9002964 9003013 9003024 9003031

51 59 64 65 67 72 77 78 83 84 85 87 87 87 90 90 91 92 92 93 94 95 95 95 97 02 01 03 82 01 01 81 81 01 01 01 01 01 82 80 01 01 01 01 01 01 01 01 02 01

Page 48 50 48 48 50 48 50 50 52 52 52 52 52 52 50 50 50 50 54 48 52 52 52 52 50 35 38 34 80 38 38 38 6 66 66 66 66 66 34 66 38 66 22 22 66 66 66 10 10 22

Ref. 19 83.8 39.8 39.9 162 40.5 161 161.5 178.5 184 191 178.1 180 192 157.5 169 155.7 85.5 85.5 61 173 178.2 179 191.5 168 Z0.1A 11 7 4 19 12 8 30 25 26 29 31 34 1 4 10 6 31 30 20 21 24 11 13 1C

Part No. 9003031 9003031 9003089 9003113 9003114 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003172 9003186 9003186 9003326 9003390 9003394 9003401 9003410 9003450 9003514 9003522 9003522 9003570 9003574 9003574 9003628 9003661 9003662 9003669 9003672 9003730 9003732 9003748 9003792 9003837 9003851 9003853 9003854 9003863 9003886 9003888 9003935 9003949

01 01 02 01 02 01 02 03 04 05 06 07 08 09 10 11 12 80 01 02 01 01 01 01 01 01 01 06 07 01 01 01 80 01 01 01 01 01 01 80 01 01 01 01 01 01 01 01 01 01

Page 40 42 22 22 22 74 74 74 74 74 74 74 74 74 74 74 74 66 22 22 38 22 22 22 22 66 66 6 6 66 66 72 18 38 38 38 38 66 66 34 66 66 66 66 66 66 66 66 66 66

Ref. 18 5 9 28 29 1 2 3 4 5 6 7 8 9 10 11 13 15 22 63 6 16 12 19 23 1 18 39 38 27 45 Z 1 26 28 21 31 5 7 2 30 32 35 36 37 38 39 40 23 28

85

14

Part No. 9004174 9004211 9004212 9004213 9004214 9004237 9004247 9004254 9004299 9004299 9004299 9004299 9004299 9004299 9004303 9004313 9004329 9004426 9004439 9004479 9004506 9004507 9004508 9004517 9004533 9004533 9004587 9004588 9004638 9004825 9004844 9004878 9004886 9004889 9004959 9004960 9005006 9005046 9005051 9005051 9005051 9005051 9005051 9005052 9005052 9005052 9005052 9005052 9005052 9005142

86

80 01 01 01 01 01 01 01 01 02 03 04 04 07 02 80 80 01 01 80 80 80 80 01 01 80 80 80 01 80 80 80 80 01 01 80 80 01 04 05 06 07 08 01 05 07 08 09 10 80

Page 18 18 18 18 18 66 66 18 18 18 18 6 18 18 18 18 18 18 32 66 18 18 18 66 70 66 70 70 34 40 42 38 38 38 42 34 6 66 34 34 34 34 34 34 34 34 34 34 34 22

Ref.

Part No. 37 2 3 4 6 22 33 9 32 33 34 13 31 46 40 22 39 11 15 16 5 38 42 19 1 3 Z Z0.1 31 1 1 9 33A 33 7 3 18 10 16 16.4 16.2 16.1 16.3 17 17.1 17.2 17.5 17.4 17.3 1

9005143 9005144 9005145 9005147 9005394 9005494 9005496 9005626 9005743 9005789 9005792 9006075 9006237 9006246 9006316 9006320 9006320 9006322 9006324 9006325 9006326 9006519 9006677 9006761 9006769 9006771 9006804 9006805 9006806 9006822 9006822 9006852 9006853 9007005 9007007 9007098 9007099 9007100 9007128 9007166 9007166 9007166 9007166 9007166 9007167 9007167 9007167 9007167 9007167 9007184

80 80 80 01 80 01 01 01 01 03 02 01 80 01 01 80 81 01 01 01 01 01 01 80 02 02 01 01 01 02 02 01 01 82 01 82 80 82 80 01 05 06 06 06 15 22 23 23 23 01

Page 22 22 22 66 66 18 16 19 66 60 60 80 6 10 22 34 34 22 34 34 18 22 18 10 50 48 6 6 6 48 80 6 6 52 52 52 52 52 52 58 62 56 58 60 58 62 56 58 60 58

Ref.

Cross reference list

Part No. 2 3 6 62 63 23 19 67 46 12 18 3 1 2 64 35 36 69 13 12 35 70 21 5 91 13 5 6 7 11 6 3 52A 200 203 Z Z0.2 Z0.1 190 2 2 2 2 2 1 1 1 1 1 Z

9007184 9007185 9007185 9007185 9007186 9007186 9007186 9007190 9007191 9007192 9007192 9007192 9007193 9007193 9007193 9007196 9007196 9007196 9007196 9007196 9007198 9007200 9007201 9007231 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007239 9007794 9007810 9008374 9008382 9008383 9008383 9008383 9008383 9008383 9008383

04 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 02 02 02 02 01 01 01 01 01 02 03 04 05 06 07 08 10 11 12 13 23 24 25 26 01 80 01 80 01 02 03 04 05 06

Page 62 56 58 60 56 58 60 62 62 56 58 60 56 58 60 58 56 58 60 62 58 62 62 80 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 38 35 19 19 32 32 32 32 32 32

Ref. Z 3 3 3 8 8 8 10 9 5 5 5 6 6 6 7 7 7 7 7 22 27 28 1 200B 200C 200D 200E 200F 200G 200H 200I 200L 200K 200M 200N 200J 200O 200P 200Q 36 ZA 73 74 1 2 3 4 5 6

Book No.

PureBallast 3.0 Flow 750

Part No. 9008383 9008383 9008383 9008387 9008388 9008424 9008672 9008693 9008903 9009416 9009521 9009688 9009695 9009696 9009714 9009912 9011365 9011549

Book No.

08 12 13 01 01 01 80 01 05 01 80 01 80 80 01 01 01 80

Page 32 32 32 32 32 22 7 32 22 38 35 7 6 7 23 44 34 16

Ref. 9 7 8 11 16 74 68 12 7 38 Z 52B 52 53 90 8 9 1

87