TECHNICAL MANUAL - SECTION 1

Chapter: 7. Service manual

System manual — PureBallast 3.1 85 Compact
USCG

Book No. 9028175 02, rev. 3

 TECHNICAL MANUAL - SECTION 1

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.
 TECHNICAL MANUAL - SECTION 1

Contents
1 Introduction 7
1.1 Preparations and conditions 7

2 Maintenance schedule 9
2.1 Calibration schedule 12
2.2 Recommended spare parts on board 13
2.3 Serial number information 15
2.3.1 Indicating serial number 15
2.3.2 Example 15

2.4 Placing of serial numbers 16

3 UV reactor 19
3.1 Safety information 19
3.2 Replace UV lamp and quartz sleeve 20
3.2.1 Disassemble UV lamp 21
3.2.2 Disassemble quartz sleeve 22
3.2.3 Assemble quartz sleeve 23
3.2.4 Check for leaks after quartz sleeve assembly 24
3.2.5 Assemble UV lamp 24

3
 TECHNICAL MANUAL - SECTION 1

3.3 Dismount and mount lamp power

supply (LPS) 24
3.4 Test LPS installation 26

4 Filter 27
4.1 Remove filter cover and filter element 30
4.2 Mount filter element and filter cover 32
4.3 Clean filter element and pre-filter 32

5 CIP 35
5.1 Change CIP liquid 35

6 Flow meter 37
6.1 Replace display and fuse 37

7 Pumps 39
7.1 Operate pumps manually 39
7.2 Repair drain pump 39
7.2.1 Clean drain pump 40
7.2.2 Disassemble drain pump 40
7.2.3 Assemble drain pump 42

7.3 Test drain pump (P460) 42

7.4 Test CIP pump (P320) 43

8 Valves 45
8.1 Preparations and conditions 45
8.1.1 Tightening torques for actuators 46

4
 TECHNICAL MANUAL - SECTION 1

8.2 Open and close valves manually 46

8.3 Lock valve in closed position (V201–3,
V201–9, V201–32, V212–19, V201–31
and V201–8) 46
8.4 Unlock valve (V201–3, V201–9, V201–19,
V212–31, V201–32 and V201–8) 47
8.5 Dismount actuator 48
8.6 Mount actuator 49
8.7 Adjust valve end position (V201–1,
V201–9, V201–19, V212–31, V212–32
and V201–8) 50
8.8 Calibrate positioner on V201-8 51
8.9 Adjust cam position on V201-8 56
8.10 Change direction of actuator for bypass
valve V212–31 (optional) 56
8.11 Mount pilot valve on actuator V212–31
(optional) 58
8.12 Adjust valve traveling speed for
V212–31 (optional) 59

9 Valve block 61
9.1 Change valve body 62
9.2 Connect electrical cables to valve block 62
9.3 Clean valve block 62

10 Level switch 63
10.1 Mount level switch 63
10.2 Dismount level switch 64
10.3 Test level switch 64

11 Temperature switch and

temperature transmitter 65
11.1 Mount temperature switch / temperature
transmitter 65
11.2 Dismount temperature switch /
temperature transmitter 66

12 Control panel 67
12.1 Clean control panel 67
12.2 Replace control panel 67

13 Remote control panel (optional) 5

69
13.1 Mount and connect remote control
panel 69
TECHNICAL MANUAL - SECTION 1
 TECHNICAL MANUAL - SECTION 1

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 R
! DA
• Before maintaining the PureBallast system, the power supply must be switched off, to avoid
accidental starts. See instruction Shut down and deactivate the system in chapter 3. Operating
instructions and control system description.

NG
WARNI
!
• Read chapter 1. Safety.
• Installation must be done by a fully trained professional installer.

NOTE

• All maintenance and calibration activities must be recorded in the vessel’s maintenance log.
This is required by the ballast water convention. It is therefore recommended that the activities
in the maintenance and calibration schedules below are entered in the vessel’s general
maintenance system.
• Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.
• Earth connection must be made before any welding is done.
• Follow local regulations for electrical installation and protective earthing.
• Electrical welding requirements: Connect the welding unit’s negative lead (work lead) to the
component you will weld, close to the welding area.
• Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3 and V201-8. See instruction Lock valve in closed position on page 46.
• Follow local regulations for electrical installation and protective earth (ground).
• Follow rules when handling CIP liquid, 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.9028175 02 7
 TECHNICAL MANUAL - SECTION 1

1.1 Preparations and conditions 1 Introduction

 TECHNICAL MANUAL - SECTION 1

2 Maintenance schedule

Follow this maintenance schedule to secure performance, safety and durability of the system and
its components. The schedule is sorted per component. The table refers to instructions usable
when performing the respective action.

Component Action Time interval Instructions Notes

General Testrun the Once a month. See 3. Operating If the system, for
system: Run a instructions and some reason, is not
ballast and/or control system operated by normal
deballast process. description. ballast operations,
Follow up with a it needs to be run
CIP process. Manual operation to verify that it is in
of valves: See good condition.
Note: If system is chapter 7. Service
used, but certain manual, section This will also
valves are not Valves. exercise the valves,
used, for example actuators and other
V212–31, those components to
should be opened keep them in good
and closed condition.
manually. For
relief valves,
see Calibration
schedule.

General Inspect for Once a year.

corrosion and
erosion damage.

General Calibration of According to See Calibration

sensors Calibration schedule
schedule

Electrical Check air filter Every six month. Upper filter: Filter mat: 9017400
cabinet Change filter mat 02.
when dirty.

Lower filter: Wash

with hot water and
degreasing liquid
when dirty.

Book No.9028175 02 9
 TECHNICAL MANUAL - SECTION 1

2 Maintenance schedule

UV reactor Outer inspection Once a year. See Spare parts

of seals for catalogue for
leakage. service kit.

Check UV lamps Once a year. See Disassemble See Spare parts

for leakage. quartz sleeve. catalogue for
service kit.

Replacement of Recommended to See Replace UV 5 UV lamp sets.

UV lamps. change all lamps lamp and quartz Spare part number:
after 3000 hours of sleeve. 579367 98
operation.

Replacement IMO requirement: 9001357 01

of UV sensor Every second year.
(QT201–50) EPA requirement:
Every year.

Check relief valve Once a year. Dismount the

RV201–23. valve and make
sure you can blow
air through it from
the inside out.

Filter Inspection and Once a year. See Remove filter Replace filter
cleaning of filter element. element, if
insert, including damaged.
filter element. Cleaning once a
year normally is See Spare parts
enough. But in catalogue for
exceptional cases service kit.
(vessels trading
very muddy
waters) it might
be necessary to
clean the more
often.

If the pressure
triggered
backflushing is
performed with
short intervals,
we suggest that
the filter element
manually cleaned
more often than
once year.

Outer inspection Once a year. If necessary,

of seals for change faulty seals.
leakage.

Check relief valve Once a year. Dismount the

RV201–50. valve and make
sure you can blow

10 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

2 Maintenance schedule

air through it from

the inside out.

CIP liquid CIP liquid level Rule of thumb: One can of CIP
check. Once every 3 liquid lasts for
months. approximately 50
Depending CIP processes.
on ballasting
frequency, the liquid
check might have to
be performed more
regularly.

Replacement. When alarm W401 See Change CIP Recommendation

CIP liquid low level liquid. to order 2 cans at a
is issued. time. Part number:
9012167 01

Valve block Control that the Once a year. See chapter 7.

cables are firmly Service manual,
attached to the section Connect
terminal strip in electrical cables to
the valve block. valve block.

Valves and Control that Once a year. See chapter 7.

actuators the component, Service manual,
cables and section Valves for
hoses are firmly instructions.
attached.

Control opening Once a year. See chapter 7. Open and close the
and closing end Service manual, valves and inspect
stops. section Valves for visually.
instructions.

Book No.9028175 02 11
 TECHNICAL MANUAL - SECTION 1

2.1 Calibration schedule 2 Maintenance schedule

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 Information / 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 1. Connect calibrated portable measure equipment to the measure point

transmitters (screw to the side, under the handle).

PT201-16 and 2. Open V201-9 from the control system.

PT201-72 PT201-72

3. Compare values indicated for the three transmitters in control system

and measure equipment.
PT201-16

4. Adjust handle on PT201-16 to establish pressure to measure point.

5. Compare value indicated in control system and measure equipment.
6. Compare that the two pressure transmitters are indicating the same value.

UV reactor 1. Log in as Advanced operator or higher.

components
2. Depressurize and drain the reactor by pressing the Drain function button
Temperature in the control panel page 1.3 Reactor.
transmitter TT201–33
(TT201-33)
3. Dismount the transmitter and place in water with known temperature
Temperature (calibrated measure instrument).
switch (TS201-
60) 4. Compare value indicated in the control system and measure equipment.
TS201-60

5. Dismount the switch and place in water with temperature < 65 ˚C.
6. Check that alarm A104 is displayed in the control system.

12 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

2 Maintenance schedule 2.2 Recommended spare parts on board

Level switch LS201-29

(LS201-29)
1. Dismount the sensor and lace it in a glass of water.
2. Check that you get a signal for the UV reactor in the control system.
3. Fill the UV reactor with technical water / potable water by pressing the Fill
function button in the control panel.

QT201-50 Not calibrated. The component is replaced. See Maintenance schedule

above.

2.2 Recommended spare parts on board

One of each spare part or spare part kit is recommended to be stored on board.

UV reactor

UV lamp set Content: 1 UV lamp and 2 O rings

Spare part number: 579367 98

Quartz sleeve Content: 1 quartz sleeve and 2 O rings

set
Spare part number: 594645 81

Temperature Spare part number: 9006325 02

transmitter

Temperature Spare part number: 9006324 02

switch

Electrical cabinet

Lamp power Spare part number: 9012146 01

supply (LPS)

Filter

Spare part set Spare part number: 9011963 87

CIP pump (P320–1)

Pump Spare part number: 9017332 01.

Book No.9028175 02 13
 TECHNICAL MANUAL - SECTION 1

2.2 Recommended spare parts on board 2 Maintenance schedule

Drain and circulation pump (P460)

Spare part set Content: Diaphragm, muffler, ball and O rings

Spare part number: 9004587 80.

14 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

2 Maintenance schedule 2.3 Serial number information

2.3 Serial number information

This section describes where the serial number plate is placed on the PureBallast system
components.

Serial numbers shall be used at error reporting and other contacts where a specific component is
discussed.

2.3.1 Indicating serial number

Serial numbers shall be stated, including the following information:

• Serial number for the complete PureBallast system. See label on the side of the electrical
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)
or P (pump). A complete list of abbreviations is found in chapter 6. Installation description and
drawings, section Connection list.

2.3.2 Example
If the level switch is faulty, the following information shall be stated:

• PureBallast serial number

• Level switch serial number and the serial number for the UV reactor on which the level switch is
installed.
• Item number for the component (LS00000)

Book No.9028175 02 15
 TECHNICAL MANUAL - SECTION 1

2.4 Placing of serial numbers 2 Maintenance schedule

2.4 Placing of serial numbers

The table below indicates the position of the serial number plate per component.

PureBallast water treatment

system
Serial number for the complete
PureBallast system.

Electrical cabinet

Placing: Name plate on left right side

gable.

7 SerialNrEC

7 SystemPlate

UV reactor

At the side of the UV reactor, as

indicated in the illustration.

7 AOT SnrSkid

16 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

2 Maintenance schedule 2.4 Placing of serial numbers

Filter

Placing: At the side of the filter, as

indicated in the illustration.

7 FilterSnr Filtrex

Lamp power supply

LPSs are installed in the lamp drive

cabinet.

NOTE

Version must be stated together with the

serial number. Version is stated on the
serial number plate.

Placing: At the front of each LPS.

7 LDC sernr

Book No.9028175 02 17
 TECHNICAL MANUAL - SECTION 1

2.4 Placing of serial numbers 2 Maintenance schedule

Valves and actuators

Serial number plate for various valves

are placed at the side of the actuator.
One example is illustrated to the right.

NOTE

This number shall be used both for the

actuator and the mechanical valve.

7 Valve Snr 591890

Flow meter

(Including flow transmitter and flow

sensor)

Placing: At the side of the transmitter

housing, as indicated in the
illustration.
7 serial#

NOTE

The serial number for the flow transmitter

is also valid for the flow sensor.

18 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

3 UV reactor

This section covers instruction for service of the UV reactor.

3.1 Safety information

• Do not touch the glass of the UV lamp. Wear gloves and hold the lamp by the ceramic end
parts only. If a lamp is stained on its surface, wipe off the glass with a clean soft piece of cloth
soaked with alcohol. If not, it could cause breakage and shorten lamp life.
• When performing these routines, consider the need for service kits for UV and quartz sleeves,
containing O-rings, lamps, quartz sleeves etc. See Spare parts catalogue.
• Keep the UV lamp in its original protective cover and case when transporting, storing and
disposing of the lamp. Otherwise it could cause injury if the lamp breaks. Do not dispose of
original protective cover and case for the UV lamp, as they should be re-used for storage
and disposal. Mark cases with used UV lamps accordingly, so that they will not be mistaken
for new lamps.

NGE R
! DA
• Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
• Always lock valve V201–19 and V201–8 if you open the UV reactor in some way. See Lock
valve in closed position on page .
• UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the UV reactor with end caps properly closed.
• Never dismount or handle UV lamps before they are completely cooled down. A hot UV lamp is
under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a
burn if it is touched.
• Before installation, check that the UV lamps and quartz sleeves are not broken.
• UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care
when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage
and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective
eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.

Book No.9028175 02 19
 TECHNICAL MANUAL - SECTION 1

3.2 Replace UV lamp and quartz sleeve 3 UV reactor

NGE R
! DA
• 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.
3.2 Replace UV lamp and quartz sleeve

7 AOTexploded

UV reactor, exploded (principle).

1. Cap
2. Cap nut
3. Bush
4. O-ring (inside bush)
5. Cable connector
6. Allen screw
7. Glass socket
8. O-ring
9. UV lamp
10. Quartz sleeve

20 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

3 UV reactor 3.2 Replace UV lamp and quartz sleeve

3.2.1 Disassemble UV lamp

Follow this instruction to dismount the UV lamps.

Preparations and conditions

• The PureBallast system must be turned off, and the power disconnected.
• After UV lamps have been changed, the runtime must be reset in page control system page 4.3
Timers. Requires login level Advanced operator.
• Wait at least 10 minutes after completed ballast or deballast process, to allow the UV reactor
to cool down to ambient temperature. If the UV lamps are hot they are under internal positive
pressure and may burst if broken.

NG
WARNI
!
• The UV reactor must not be under pressure when dismounting the UV lamps.

NG
WARNI
!
• Burn hazard: UV lamps can be hot and cause burns.
Follow the steps below

1. Unscrew the cap nuts (2) holding the caps (1). There is one nut on each side of the UV reactor
per UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.

2. Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).

3. Carefully draw out the lamp bushes (3) on both sides.

Carefully draw out the UV lamp (3) with the electric cable, by holding the electric cables in
both ends. When pulled out, only hold the UV lamp by the ceramic ends. Immediately after
removal, place the lamp in its protective cover.
If required, use a screwdriver to press on the ceramic end of the lamp inside the bush on the
other side while carefully pulling the electric cable at the other end.

Book No.9028175 02 21
 TECHNICAL MANUAL - SECTION 1

3.2 Replace UV lamp and quartz sleeve 3 UV reactor

7UVBushScrewdriver

4. Check that the quartz sleeve (10) is not broken.

To disassemble the quartz sleeves, see the instruction Disassemble the quartz sleeve.

5. If the quartz sleeves is not broken, mount the new UV lamp according to the instruction
Assemble UV lamp on page 24. If broken see the Preparations and conditions section above.

3.2.2 Disassemble quartz sleeve

Follow this instruction to disassemble the quartz sleeve.

Follow the steps below

1. Log in as Advanced operator or higher.

2. Make sure that the following valves are closed: Control valve (V201-8), inlet valve (V201-9)
and UV reactor inlet (V201-19). If not, close them with control system set in manual mode.

3. Depressurize and drain the reactor by pressing the Drain function button in the control panel.

4. Disconnect the instrument air, as a safety precaution.

5. Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 21.

6. Loosen the three Allen screws (6) of the glass socket (7) on both sides; just a few turns to
release them.

7. Unscrew the Allen screws completely at one side. Carefully remove the glass socket, to avoid
breaking the quartz sleeve. Then remove the glass socket on the other side.

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.

22 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

3 UV reactor 3.2 Replace UV lamp and quartz sleeve

9. Carefully remove the quartz sleeve (10).

10. Carefully clean the surface and remove any small parts, for example glass or rubber.

3.2.3 Assemble quartz sleeve

Follow the instruction below to assemble quartz sleeve and check for leaks.

Preparations and conditions

• Two new O-rings (8) for each quartz sleeve (10).

• Two new O-rings for each glass socket (7) might be needed.
• 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 UV reactor.

2. Wet the O-rings (8) with water and slip them over respective side of the quartz sleeve.
Check that the O-ring are positioned evenly on both sides. If not, they may be damaged
and cause leaks.
The O-rings shall not be pressed into position, the glass socket will press them into position
when fastened later.

3. 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

4. Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.

5. Mount the second glass socket.

6. Connect the instrument air.

7. Follow the instruction Check for leaks after quartz sleeve assembly.

Book No.9028175 02 23
 TECHNICAL MANUAL - SECTION 1

3.3 Dismount and mount lamp power supply 3 UV reactor

(LPS)

3.2.4 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 UV reactor with water to between 2 and 4 bar (0.2 and 0.4 MPa).

2. Visually check for leaks.

3.2.5 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.
• New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.
• Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the
lamp; hold the lamp by its ceramic end parts.
• Glass sockets and bushes must be dry and clean before mounting.
• After UV lamps have been changed, the runtime must be reset in control system page 4.3
Timers.
Follow the steps below

1. Mount the new heat resistant O-rings in the two lamp bushes (3).

2. Place one bush on the UV lamp (9).

3. Insert the UV lamp and bush into the UV reactor.

4. Insert the other bush in the opposite side of the UV reactor.

5. Make sure that the connection is clean to ensure good electric connection (no rust, burning or
fading on the connectors). Reconnect the two cable connectors for the UV lamp.

6. Mount the UV lamp caps and tighten the cap nut at both ends of the UV lamp, by hand only.
Make sure that the electric cable is not squeezed between the cap and the bush when the cap
is mounted. Slack can be pushed into the bush.

7. Control the control system page 3.1 Alarm list, to make sure there is no alarm when after the
lamp power supply is on.

3.3 Dismount and mount lamp power supply (LPS)

Follow this instruction to replace a lamp power supply inside the electrical cabinet.

Preparations and conditions

24 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

3 UV reactor 3.3 Dismount and mount lamp power

supply (LPS)

NG
WARNI
!

• Switch off the main breaker on the cabinet door. The LPS has high voltage/power (600 V)
inside and on the lamp power connector, even when UV lamps are not lit.
• The cabinet contains a fan, which can cause injury if in operation.
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) of the arc holding the LPS.

NOTE

Make sure not to drop the washer into the LPS. It may cause short circuit.

3. Pull the handle to remove the LPS.

4. Mount LPS

Set the DIP switches on the LPS according to chapter 4. Parameters, section Lamp power
supply (LPS) parameters.

5. Push the new LPS to the wall of the cabinet.

6. Reconnect the three connectors. Make sure the connectors sit tight.

7. Tighten the nuts to attach the LPS with the arc.

8. Turn on the fuse to the LPS.

Book No.9028175 02 25
 TECHNICAL MANUAL - SECTION 1

3.4 Test LPS installation 3 UV reactor

9. Switch on the main breaker on the cabinet door and check that LPS:s function correctly
according to instruction Test LPS installation below.

10. Send the replaced LPS to Alfa Laval for repair.

3.4 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.

DANGER
!
• Before operating the UV reactor, make sure that there is water in the UV reactor. Check the
LED on the level switch: Steady yellow light indicates that there is water in the UV reactor.
Follow the steps below

1. Switch on the main breaker on the electrical cabinet door. Switch on the power to the UV
reactor using the switches on the breaker cabinet.

2. Set the control system in manual mode (requires login level Advanced operator).

3. Go to page 1.2 Reactor and start LPS 1. Make sure that two UV lamps are lit.
Note: It can take up to 90 seconds for the lamp to start.

4. Directly after the lamps are lit, turn of the LPS.

5. Repeat the test for LPS 2 and 3.

6. Check that no error indication on the LPS and that there are no alarms in page 2.1 Alarm
list in the control system.

7. Exit manual mode.

26 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

4 Filter

This section covers the instructions for filter service.

Preparations and conditions

These preparations and conditions are valid for all instructions.

• Disconnect the power to the filter, using the main switch on the control cabinet.
• Always lock valve V201–3 and V201–19 if you open the filter in some way.
• Only perform maintenance and servicing work when the filter is cooled, depressurized and
drained.
• Shut off the air supply to the filter.
• Visually inspect gasket during maintenance. Replace if necessary.
Tightening torques for filter bolts

Torque is stated in Nm.

M4 3
M6 7
M8 12
M10 18
M12 25
M14 35
M16 45
M18 60
M20 75
M22 90
M24 105

Filter – Exploded view

Book No.9028175 02 27
 TECHNICAL MANUAL - SECTION 1

4 Filter

28 Book No.9028175 02
7 FiltrexExploded
 TECHNICAL MANUAL - SECTION 1

4 Filter

1 Gear reducer
2 Gear shaft
3 Electric motor
4 Thrust bearing flange fixing bolt
5 Gear reducer flange / cover fixing bolt
6 Thrust bearing
7 Backflush shaft bushing gasket
7a Backflush shaft bushing asket
8 Filter vent plug
9 Filter cover
10 Cover bolt
11 Backflush shaft bushing
12 Filter element fixing bolt
13 Filter cover gasket
14 Filter body
15 Filter element
16 Backflush nozzle
17 Filter element gasket
18 Backflush shaft bushing
19 Filter drain plug
20 Backflush line gasket
22 Pressure transmitter
29 Junction box
30 Backflush nozzle support
31 Backflush nozzle fixing bolt
32 Backflush nozzle support gasket
33 Base frame
34 Base frame fixing bolt
40 Ring spear
41 Thrust bearing upper flange
42 Thrust bearing lower flange
43 Seeger
44 Cover lifting lug
45 Rotation indicator
70 Nameplate
80 Prefilter

Book No.9028175 02 29
 TECHNICAL MANUAL - SECTION 1

4.1 Remove filter cover and filter element 4 Filter

4.1 Remove filter cover and filter element

Follow this instruction to remove filter cover and filter element.

Follow the steps below

1. Log in as Advanced operator or higher.

2. Depressurize and drain the filter by pressing the Drain function button in the control panel.

3. Close the following valves: V201-1 and V201-32 according to the instruction in the Open and
close valves manually on page 46 and Lock valve in closed position on page .

4. Unscrew the bolts (5) holding the gear motor (1).

If the electrical cable is short, it might be necessary to disconnect it before removing the motor.

5. Remove the motor (using a lifting device, if necessary). Be careful not to harm the motor
fitting when lifting it from it’s seat.

7 FilterMotor

6. Remove the cover bolts (10) and the lifting lugs (44).

7. Screw two filter cover bolts in the lifting lugs holes until the cover raises slightly from the filter
house.

7 LiftingBolt

30 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

4 Filter 4.1 Remove filter cover and filter element

8. Remove the cover bolts and fasten the lifting lugs in their holes again.

7 LiftingLug

9. If not present: Fasten the lifting device of the winch on the filter cover. Fasten it in the same
holes as the motor, using the same bolts.

Use the winch to lift the filter cover with the filter element out of the filter. Be careful not to
harm the filter element.
Note: The filter should be lifted in one continuous movement, without sudden jerks – even if
the filter element is slightly stuck in the filter house.

10. Place the filter element on its side.

11. Remove bolts to the bottom shaft support that holds the shaft inside the filter element (15).
Remove it carefully.

12. Remove the seeger ring (43) from the backflush shaft bushing (11).

7 FiltrexSeeger

13. Pull out the backflush shaft bushing. If it is stuck, give a couple of light blows with a wooden
hammer on the top of the shaft to release it.

14. Place the filter element upside-down.

Book No.9028175 02 31
 TECHNICAL MANUAL - SECTION 1

4.3 Clean filter element and pre-filter 4 Filter

15. Unscrew the four Allen screws inside the element to loosen the filter cover.

7 FiltrexAllenS

16. Lift the filter element from the cover.

17. Lift the pre-filter (80) from the bottom of the filter house.

4.2 Mount filter element and filter cover

Filter element and cover is mounted in reverse order as described in instruction Remove filter
cover and filter element.

Note:

• Clean the upper inside of the house at the top of the. The area where the O rings meet the
housing should be clean.
• No force should be used to fit the filter element in the filter house or to fit the motor in its seat.
• Check the O rings. Replace if necessary.
• Fill up the filter with technical water / potable water after it is mounted. Use the Fill function
button in the control panel. Requires login as Advanced operator or higher.
• There is not need to de-air the filter when it is filled up.
4.3 Clean filter element and pre-filter
Follow this instruction to clean the filter element. At the same time, check that the filter element
is in good condition.

Preparations and conditions

• Alpacon descalant offshore may be used as cleaning agent. See Safety data sheet / CIP liquid
in chapter 6. Installation description and drawings.
• Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant to 20 parts
technical water / potable water. Follow this mixing ratio, regardless of recommendation on label.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.

32 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

4 Filter 4.3 Clean filter element and pre-filter

NG
WARNI
!
• Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves and goggles.
Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.

NG
WARNI
!
• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• The pH value should be approximately 2.0–3.0.
• Proceed with the utmost caution when transporting, assembling, disassembling and cleaning
the filter element.
Follow the steps below

1. Follow the instructions Remove filter element (page 30) to remove the filter element.

2. Rinse the pre-filter with water and a brush.

3. Remove the filter element gasket (17).

4. Soak the filter element in the cleaning agent with the opening facing upwards. Leave it to soak
for 1–4 hours. Let the element dip dry before next step.

5. Place the element in so it does not fall over when cleaning it.

6. Spray the filter element with water (60–80 °C) from the outside, using a flat nozzle. Note: If a
high-pressure cleaner is used, the pressure must not exceed a maximum of 15 bar. If a cleaner
with higher capacity is used, compensate by increasing the distance, minimum 30 cm.

7. Blow the filter element with instrument air (with 10 micron filter or finer), from the outside.

8. 8. Inspect the filter element from the outside with a magnifier to make sure that it is clean. If
needed, repeat the procedure. This time it is enough to let the element soak for 5 minutes.

9. Clean the inside of the filter house.

10. Put the filter element gasket back. Reassemble the rest of the filter.

Book No.9028175 02 33
 TECHNICAL MANUAL - SECTION 1

4.3 Clean filter element and pre-filter 4 Filter

 TECHNICAL MANUAL - SECTION 1

5 CIP

Follow this instruction to change CIP liquid can.

5.1 Change CIP liquid

Preparations and conditions

Alpacon descalant is used as cleaning agent for the CIP process. It contains no solvents and no
inorganic acids and it is non-flammable. See Safety data sheet / CIP liquid in chapter 6. Installation
description and drawings.

• Avoid letting the CIP cap with the pipe be out of the can for too long, to avoid loosing CIP
liquid in the pipe and hose.

ON
CAUTI
!
• Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves and goggles.
Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.

ON
CAUTI
!
• If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
• Alpacon descalant offshore storage temperature: 0 °C to +55 °C.

Follow the steps below

1. Pull the pipe from the CIP liquid can.

2. Loosen the strap holding the CIP liquid can.

3. Replace the old can with a new. Remove the cap from the new CIP liquid can.

4. Reconnect the CIP cap with the pipe in the can.

5. Remove the small cap on the cip liquid can, throw it away and cut a hole in the membrane
under the cap. The purpouse is to let air into the can to let CIP liquid out.

6. Fasten the CIP liquid can with the strap.

Book No.9028175 02 35
 TECHNICAL MANUAL - SECTION 1

5.1 Change CIP liquid 5 CIP

7. Go to control system page 1.5 CIP and make sure that level switch LS320 indicates wet
condition (green).

8. Go to control system page 4.3 Timers. Reset CIP Number of cleaned UV reactors. If this is
done each time the CIP liquid is changed, it is possible to build up experience on how many
CIP processes it is possible to perform before it is time to change CIP liquid. Requires login
level Advanced operator.

36 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

6 Flow meter

The flow meter consists of two main parts.

• Flow sensor: A pipe with two electrodes detecting the flow.

• Flow transmitter: Monitors and transmits information to the PureBallast control system.
Note: The display mounted on the flow transmitter is not supplied for all system sizes. The
display is optional.
• The flow sensor and flow transmitter are pre-assembled from factory, and the parameters
are pre-set.
6.1 Replace display and fuse

NG
WARNI
!
• Risk of electric shock! Exposed components carry dangerous voltages.
Make sure that the power supply is switched off before you remove the cover of the electronics
compartment.
Follow the steps below

To replace display: See step 1–3 below.

To replace fuse : Se step 1–6 below.

The main fuse is located on the power supply board.

1. Switch off power supply.

2. Unscrew cover of the electronics compartment from the transmittor housing.

3. Remove the local display as follows:

-Press the latches at the side and remove the display module
-Disconnect the ribbon cable of the display from the amplifier board.

7 Opening Field housing and replacing display

Opening Fileld housing and replacing display

4. Remove the screws and remove the cover from the electronics compartment.

Book No.9028175 02 37
 TECHNICAL MANUAL - SECTION 1

6.1 Replace display and fuse 6 Flow meter

5. Remove the power supply board. Insert a suitable tool into the hole, provided for the purpose
and pull the board clear of its holder.

6. Remove cap (1) and replace the device fuse (2).

Use only fuses of the following type:
– Power supply 20 to 55 V AC / 16 to 62 V DC use a 2.0 A slow-blow / 250 V; 5.2 × 20 mm

7 Replacing the fuse

Replacing the device fuse on the power supply board (step 5–6)
1. Protective cap
2. Device fuse

7. Installation is the reverse of the removal procedure.

7 Re-assembly

Re-assembly

38 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

7 Pumps

This section contain instructions for the CIP and drain pumps.

7.1 Operate pumps manually

Follow this instruction to manually operate pumps.

Follow the steps below

1. Look at the signal plate on the valve block to identify which button that controls the pump.
See page for an illustration.

2. Press the button on the valve body with a pointy object to start the pump. The pump remains
running as long as the button is pressed.

7.2 Repair drain pump

Follow this instruction to repair the drain pump P460.

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, tand
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.

Book No.9028175 02 39
 TECHNICAL MANUAL - SECTION 1

7.2 Repair drain pump 7 Pumps

7 CIP pump

Drain pump, exploded view

7.2.1 Clean drain pump

Follow the steps below

1. Remove the pump from the skid.

2. Rinse the pump with technical water / potable water.

7.2.2 Disassemble drain pump

Follow this instruction to disassemble the drain pump.

7.2.2.1 Disassemble the main parts

Follow the steps below

1. Remove the drain pump from the skid and place it on a work bench.

2. Unscrew the nuts (37) on one side of the housing (11).

3. Place the pump on the side that still has the nuts (the pump lays on the nuts) on a stable ground.

4. Carefully remove the "loose housing" (11).

5. Carefully lift up the suction and discharge connections (13). You have the centre block (12)
and one of the housings with pin screws (14) left.

40 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

7 Pumps 7.2 Repair drain pump

6. Upend the pump and carefully pull out the pin screws (14). Be careful not to damage the
diaphragms (15).

7.2.2.2 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.

5. Remove the valve ball (23) from the valve seat, buy using a pin screw: Press out the valve ball
stopper (22), which will release the valve ball.

7.2.2.3 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.

Book No.9028175 02 41
 TECHNICAL MANUAL - SECTION 1

7.3 Test drain pump (P460) 7 Pumps

7.2.3 Assemble drain pump

Follow the instructions below to assemble the drain pump P460.

7.2.3.1 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.

7.2.3.2 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.

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.

7.3 Test drain pump (P460)

Follow the instruction below to verify that pump is functioning.

Preparations and condicions

1. Log in as Advanced operator or higher.

42 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

7 Pumps 7.4 Test CIP pump (P320)

2. Check that there is water in the UV reactor (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the UV reactor.
If not, press the Fill function button in the control system and wait for the UV reactor to be filled.

3. Press the Drain function button in the control system.

4. Observe if the motor sound and functions OK. If not, check installation and connections and
attend to and test again.

5. Observe if the pump sounds OK and that it strikes the number or times set in p403 with hertz
as set in p405. If not: Check/change parameter settings.

6. When the process ends, fill the UV reactor again.

7.4 Test CIP pump (P320)

Follow the instruction below to verify that pump is functioning.

1. Pull the pipe from the CIP liquid can and stick it to a bottle filled with at least 3 dl of water.(This
is to avoid waisting CIP liquid during the test.)

2. Go to page 1.5 CIP and press the Run CIP pump button.

3. Observe if the pump sounds OK and that it strikes 26 times with 2 hz (approximately 2 times
per second).
If not: Check settings for parameter p403 and p405.

4. Reconnect the pipe in the can.

5. Make sure that about 3 dl have disappeared from the bottle.

Book No.9028175 02 43
 TECHNICAL MANUAL - SECTION 1

7.4 Test CIP pump (P320) 7 Pumps

 TECHNICAL MANUAL - SECTION 1

8 Valves

This section contain instructions for the valve actuator.

7 Actuator

Valve actuator with puck for position sensor

1. Safety cover
2. Pad lock
3. Lower position for indicator screw
4. Upper position for indicator screw — with screw
5. Position indicator
6. Center screw
7. Bracket
8. Puck
9. Locking bolt
10. End stop bolt.

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.

Book No.9028175 02 45
 TECHNICAL MANUAL - SECTION 1

8.3 Lock valve in closed position (V201–3, 8 Valves

V201–9, V201–32, V212–19, V201–31 and
V201–8)
• 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.

M5 05–06
M6 10–11
M8 23–25
M10 48–52
M12 82–86
M14 132–138
M16 200–210
M20 390–410

8.2 Open and close valves manually

Follow this instruction to manually operate valves from the valveblock on the skid. Normally, we
recommend that valves are operated from the control system. See chapter 3. Operating instructions
and control system description for instruction.

Follow the steps below

1. Look at the signal plate on the valve block to identify which button that controls the valve.

2. Press the button on the valve body with a pointy object to open the valve. The valve remains
open as long as the button is pressed.

8.3 Lock valve in closed position (V201–3, V201–9,

V201–32, V212–19, V201–31 and V201–8)
Follow this instruction to lock valves 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 should normally 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 instrument air. Verify that the valve is not under pressure.

46 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.4 Unlock valve (V201–3, V201–9, V201–19,

V212–31, V201–32 and V201–8)

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.

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.

8.4 Unlock valve (V201–3, V201–9, V201–19, V212–31,

V201–32 and V201–8)
Follow this instruction to unlock valves from closed position.

Preparations and conditions

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

1. Disconnect all power and instrument air. Verify that the valve is not under pressure.

Book No.9028175 02 47
 TECHNICAL MANUAL - SECTION 1

8.5 Dismount actuator 8 Valves

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.

7. Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.

8.5 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

48 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.6 Mount actuator

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.

8.6 Mount actuator

Follow this instruction to mount an actuator.

Preparations and conditions

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.

Book No.9028175 02 49
 TECHNICAL MANUAL - SECTION 1

8.7 Adjust valve end position (V201–1, 8 Valves

V201–9, V201–19, V212–31, V212–32 and
V201–8)

7 ValveStem

1. Allowed travel sector.

2. Valve stem groove
3. Valve stem
5. Lock pin opening (covered by rubber plug).

2. Make sure that the lock pin (inside the valve stem) only travels in the allowed sector (1) and
that it does not pass the opening (5).

3. If the actuator is mounted on the valve with a bracket and coupling (dimension 400): First fit
the coupling on the valve stem. Make sure that the red position indicator on the coupling is in
line with the pipe when the valve is open.

4. Fit the actuator onto the valve stem (or the coupling). The actuator may only be positioned in
even 90° intervals in relation to the valve. It is not allowed to adjust the position by turning the
actuator by hand after it is fitted on the valve stem.

5. Mount the actuator on the valve with the four hexagonal screws. For each screw, one washer
and one spring washer shall be used. Tighten with torque according to the table Tightening
torques for actuators on page 46.

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.

8.7 Adjust valve end position (V201–1, V201–9,

V201–19, V212–31, V212–32 and V201–8)
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.

50 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.8 Calibrate positioner on V201-8

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).

8.8 Calibrate positioner on V201-8

Follow this instruction to calibrate the positioner at installation or when needed.

Book No.9028175 02 51
 TECHNICAL MANUAL - SECTION 1

8.8 Calibrate positioner on V201-8 8 Valves

7 201-8Positioner4

1. Arrestor device (screw driver adjusting)

2. Unlock the wheel
3. Locking wheel (screw driver adjusting)
4. Direction to lock the wheel
5. Adjustment wheel
6. Transmission ratio selector

Preparations and conditions

• The valve must be installed and connected to air and power.

• The valve must be closed.
• The cover must be removed.
• The positioner must have power. If the positioner display is empty (no power): Open V201-8
manually (approximately 1-5 %) from control system to supply power to the positioner.
• Do not adjust the cam wheels: 2 grey wheels above the adjustment wheel (5).
• Buttons on the positioner:

7 201-8Positioner

52 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.8 Calibrate positioner on V201-8

Software settings - Alfa Laval values:

Parameter Settings in menu

1 turn
(Note: Do not chose “– turn”.)
2 90° (is automatically 90° when turn is used)
34 0.7

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. Press HAND button for 5 seconds to enter the parameter list.

4. Make sure that Menu 1 is displyaed. If not: Press HAND button repeatedly until it is.
Make sure that “turn” is displayed in the menu. If not: press + or – repeatedly until it is.
Note: Do not choose “– turn”.

5. Press the hand button repeatedly until Menu 4 is displayed.

(To go backward, press HAND button and – button.)

6. Press + button for 5 seconds to start automatic calibration.

7. If calibration stops (as displayed below), follow these steps:

7 201-8Positioner2

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

7 201-8Positioner3

- Lock the locking wheel (3) with a screw driver (clockwise).

- Press the + button to continue the calibration.
8. Wait until “FINISH” is displayed on the screen.

9. Press the hand button once.

Result: Menu 4 “INITA” is displayed.

Book No.9028175 02 53
 TECHNICAL MANUAL - SECTION 1

8.8 Calibrate positioner on V201-8 8 Valves

10. Press the hand button for 5 seconds until a number or “VER” is displayed, then let go of the
button.
Result: “MAN” is displayed”.

11. Press the hand button once.

Result: A final adjustment is started, and then “AUT” is displayed.

54 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.8 Calibrate positioner on V201-8

Trouble shooting

If any problem occurs, do the following:

1. Check the mechanical installation and air supply.

2. Reset factory settings and restart calibration:

- Reset to factory settings: Press HAND button repeatedly until menu 50 is displayed.
- Press + button until “oCAY” is displayed.
- Restart instruction Calibrate positioner on V201-8 from step 4.
- Set the parameters according to Alfa Laval software settings. See table above.

Book No.9028175 02 55
 TECHNICAL MANUAL - SECTION 1

8.10 Change direction of actuator for bypass 8 Valves

valve V212–31 (optional)

8.9 Adjust cam position on V201-8

Follow this instruction to adjust cam setting for the pneumatic positioner feedback on valve V201-8,
so that the operating indication is correct in the control system.

Hint: A multimeter can be used to indicate position of the cam wheels, if it is hard to hear the click
from the micro switch, or if it is inconvenient to see valve position in control panel. Connect a
multimeter to connection point 41 and 42 in the positioner.

- Closed circuit = 0 ohm.

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

Follow the steps below

1. In control panel: Set system in manual mode.

2. Open V201-8 manually to approximately 50 % in the panel.

3. Close it to approximately 10 %.

4. On the positioner: Adjust both cam wheels to same position. Cam wheels are above the
adjustment wheel (5) on page 51.

5. Turn the cam wheels in any direction until it valve indicates steady green in the control panel.
Miltimeter indicate circuit closed.

6. Turn the cam wheel slowly counter clock wise until you hear a click from the micro switch in
the positioner. Stop directly after the click. Stop directly after the multimeter changes to
indicate circuit open.

7. Check that the valve is indicated as open (steady green) in the control panel.

8. Close the valve to 0 %.

Result 1: Valve closed, indicated with no color. Circuit closed. Setting is OK. You are done.

Result 2: Valve indicated as red. Cam wheels are in wrong position, for example due to the
wheels been turned too much after the click). Miltimeter indicate circuit open. Repeat from
step 2 until setting is OK.

8.10 Change direction of actuator for bypass valve

V212–31 (optional)
Follow this instruction to turn an actuator with switch box.

56 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.10 Change direction of actuator for bypass

valve V212–31 (optional)

7 Actuator and switch

Valve actuator with switch box for position feedback to control system

1. Switch box
2. Bracket
3. Actuator
4. Pilot valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves
with dimension 400
7. DIN connector
8. Position indicator

Preparations and conditions

• The valve must be in closed position.

• The valve position must not be adjusted during the routine.
• The valve must be mounted and connected to air and power before adjustment.
Follow the steps below

1. Dismount the actuator according to Dismount actuator on page 48.

2. Remount the actuator according to Mount actuator on valve on page 49.

Book No.9028175 02 57
 TECHNICAL MANUAL - SECTION 1

8.11 Mount pilot valve on actuator V212–31 8 Valves

(optional)

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.

8.11 Mount pilot valve on actuator V212–31 (optional)

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

Preparations and conditions

• The valve must be in closed position.

• Air and power must be disconnected. The valve position must not be adjusted during the routine.

7 MountPilote

Pilot valve and actuator

1. Mounting screw holes

2. Throttle valve
3. Port 1 for air connection (under)
4. Throttle valve
5. DIN connector
6. Screw.

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).

58 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

8 Valves 8.12 Adjust valve traveling speed for

V212–31 (optional)

8.12 Adjust valve traveling speed for V212–31 (optional)

Follow this instruction to 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 46.

2. To adjust opening speed:

Faster: Screw the throttle (1) valve port 3 counterclockwise.
Slower: Screw the throttle valve (1) port 3 clockwise.

3. To adjust closing speed:

Faster: Screw the throttle valve (2) port 5 counterclockwise.
Slower: Screw the throttle valve (2) port 5 clockwise.

Book No.9028175 02 59
 TECHNICAL MANUAL - SECTION 1

8.12 Adjust valve traveling speed for V212–31 8 Valves

(optional)
 TECHNICAL MANUAL - SECTION 1

9 Valve block

Follow this instruction to repair the valve block.

Preparations and conditions

• The valve bodies does not have individual placing, they can be placed in any order.

NGE R
! DA
• Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.

7 Valve block

Valve block

1. Cover (Terminal strip inside)

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

Book No.9028175 02 61
 TECHNICAL MANUAL - SECTION 1

9.3 Clean valve block 9 Valve block

9.1 Change valve body

Follow the steps below

1. Remove the screws holding the valve bodies (2) and the signal plate (4).

2. Unscrew the screws holding the valve body (2).

3. Lift the valve body.

4. Attach a new sealing on the new valve body and fasten the valve body to the valve block.

9.2 Connect electrical cables to valve block

Follow this instruction to connect the electrical cable from the electrical cabinet to the CIP valve
block.

Follow the steps below

1. Open the cover (1) on the front.

2. Attach the cables according to electrical drawing Electrical cabinet / interconnection diagram in
chapter 6. Installation description and drawings.

3. Fasten the cable to the cable gland (5).

4. Fasten the cover (1).

9.3 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 on page 46
to blow out the dust.

3. Connect the air hoses again.

62 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

10 Level switch

This section contains information about the level switch LS201-29 installed in the UV reactor. For
information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.

7LS Component

Level switch

10.1 Mount level switch

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.9028175 02 63
 TECHNICAL MANUAL - SECTION 1

10.3 Test level switch 10 Level switch

5. Complete the seal carefully by tightening the component with a spanner. Use the spanner on
the hexagon flats, but not on the level switch body.

10.2 Dismount level switch

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. Make sure the level switch reacts to the magnet. The component is OK if the green and
yellow LED is lit.

64 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

11 Temperature switch and

temperature transmitter

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

7 TS and TT

Temperature switch and temperature transmitter looks similar

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.

Book No.9028175 02 65
 TECHNICAL MANUAL - SECTION 1

11.2 Dismount temperature switch / 11 Temperature switch and temper-

temperature transmitter ature transmitter

4. Connect the component’s screwed-on power cord.

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.

66 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

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.

• After the panel is mounted: Load new software to the panel according to the release note
for the software. Also set communication according to Set control panel IP address and Set
remote control panel communication.

Book No.9028175 02 67
 TECHNICAL MANUAL - SECTION 1

12.2 Replace control panel 12 Control panel

 TECHNICAL MANUAL - SECTION 1

13 Remote control panel

(optional)

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

13.1 Mount and connect remote control panel

Preparations and conditions

• Remote control panel is mounted according to according to drawing Remote control panel /
Dimension drawing. Note the clearance area.
• Use a 24 VDC, 2 amp power supply cable with minimum cross section of 0.75 mm2, preferably
halogen free and flexible. Connect power cable to terminal X1 in remote control panel.
• Communication cable (W501) between the remote control panel and electrical cabinet can be
either Ethernet or optical fiber. Cable requirements and connection points below:

- Ethernet cable – Type: Cat 5e (or better), shielded. Max length: 100 meters. One remote
control panel: From terminal X2 in remote control panels to terminal X7 in the electrical
cabinet. Two remote control panels: From terminal X2 in second remote control panel to
either switch SW1 in electrical cabinet or to switch SW1 in the first remote control panel.
- Optical fiber cable – Type: Multi-mode optical fiber cable with LC connector. Max length:
500 meters. From remote control panel’s switch SW1 to switch SW1 in electrical cabinet.
See Remote control panel / Circuit diagram.

Book No.9028175 02 69
 TECHNICAL MANUAL - SECTION 1

13.1 Mount and connect remote control panel 13 Remote control panel (optional)
 TECHNICAL MANUAL - SECTION 1

14 Electrical cabinet

This section covers maintenance information for the electrical 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.9028175 02 71
 TECHNICAL MANUAL - SECTION 1

14.1 Disassemble and assemble I/O system 14 Electrical cabinet

4. Pull the board straight out (otherwise it can fasten in one of its guides).

7IO3_X025004A

5. Compare the part number of the new I/O board to the old board, to make sure it is correct.

6. If changing more than one board at a time, check with the electrical diagram to ensure that
the boards are mounted in the right places.

7. Mount the new I/O board by pressing it straight into place. Make sure the board is firmly in
place, otherwise it will be impossible to mount the cable terminal.

7IO4_X025005A

8. Remount the terminal block. Make sure the clip on the bottom of the block fastens properly in
place on the axel on the bus holder.

7IO5_X025007A

72 Book No.9028175 02
 TECHNICAL MANUAL - SECTION 1

14 Electrical cabinet 14.1 Disassemble and assemble I/O system

9. Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in
the I/O board.

7IO6_X025006A

Book No.9028175 02 73
Version OPEX2018 TECHNICAL MANUAL - SECTION 2

OPEX - PureBallast 3.1

Output Form Flow Capacity: 85 cu/hr

Owner/Manager :: Art Anderson Associates

VesselName :: NOAA Vessels
VesselType :: Other / Misc
No of BW Pumps :: 1
BWPumpCap :: 40 m3/hr
Desired No BWTS :: 1
Hrs/Year :: 200 hrs
BW Treated/Year :: 8,000 m3
BW Treated over 10 Years :: 80,000 m3

Compliance :: USCG
Product :: PureBallast 3.1-85 USCG FLEX
Capacity :: 32 - 85 m3/hr

Pump Options 0 Back flush pump

0 UV Reactor cooling pump
0 LDC cooling pump

PureBallast Major Components

FlexPic

Estimated Life Equipment

Lamp power supply 10000 hours CIP pump spare part set 2 yr
Quartz sleeve set 131040 hours UV sensor 1 yr
UV lamp set 3000 hours Filter Insert 7 yr
Filter maintenance kit 1 yr
OPEX WorkUp for Art Anderson Associates's NOAA Vessels over 10 years

1 of 4
Version OPEX2018 TECHNICAL MANUAL - SECTION 2

Evaluation based upon 1 PureBallast 3.1-85 USCG FLEX systems installed

Usage per
Installed Items System Vessel Price Ea Extended
1 CIP liquid (Spare part) 9 9 € 84 € 756
3 Lamp power supply 0 0 € 1,252 € -
CONSUMABLES

6 Quartz sleeve set 0 0 € 154 € -

6 UV lamp set 0 0 € 284 € -
1 Filter maintenance kit 9 9 € 473 € 4,259
2 CIP pump spare part kit 8 8 € 656 € 5,251
1 UV sensor 9 9 € 611 € 5,503
1 Filter Insert 1 1 € 5,927 € 5,927

NOTE! Pricing does not account Total Consumables = € 21,697

for annual price increases.

Items Usage Hr/Item Total

CIP liquid (Spare part) 9 0.2 1.5
LABOR ESTIMATES

Lamp power supply 0 1 0

Quartz sleeve set 0 1 0
UV lamp set 0 1 0
Filter maintenance kit 9 2 18
CIP pump spare part kit 8 2 16
UV sensor 9 0.5 4.5
Filter Insert 1 4 4

Total Estimated Labor Hours = 44

PureBallast 3.1-85 USCG FLEX (including optional pumps if selected)

Maximum Power Required 20 kW
Expected Average Power 16 kW
Average UVT based upon selected ports 72% UVT
POWER & FUEL DATA

Power Factor based upon system Type Approval and UVT 80%

per Year over 10 years

Estimated hours operation per year (per system) 200 2000 hrs
Estimated kW hours per system 3200 32000 kW/hours
Fuel Calculations have been excluded - select "Include" from the Quote page to show this data.

OPEX for Art Anderson Associates's NOAA Vessels over 10 years

2 of 4
Version OPEX2018 TECHNICAL MANUAL - SECTION 2

Evaluation based upon 1 PureBallast 3.1-85 USCG FLEX systems installed

Flow Capacity: 85 cu/hr

Owner/Manager :: Art Anderson Associates

VesselName :: NOAA Vessels
VesselType :: Other / Misc
No of BW Pumps :: 1
BWPumpCap :: 40 m3/hr
Desired No BWTS :: 1
Hrs/Year :: 200 hrs
BW Treated/Year :: 8,000 m3
BW Treated over 10 Years :: 80,000 m3

Compliance :: USCG
Product :: PureBallast 3.1-85 USCG FLEX
Capacity :: 32 - 85 m3/hr

Pump Options 0 Back flush pump

0 UV Reactor cooling pump
0 LDC cooling pump

OPEX Summary

Consumables =======================> € 21,697

(Labor Rate: € 90 /hr) Labor =======================> € 3,960
Power =======================> 32,000 kw hrs
Services =======================> 0

OPEX TOTAL =======================> € 25,657

Fuel Calculations have been excluded - select "Include" from the Quote page to show this data.

Euro per treated m3 anually € 3.21

3
Euro per treated m over life of vessel € 0.32
NOTE: The data presented is estimated based upon user input and recommended service intervals.
Installation costs are not included. Pricing subject to change without notice.

3 of 4
Version OPEX2018 TECHNICAL MANUAL - SECTION 2

Annual OPEX overview for Art Anderson Associates's NOAA Vessels over 10 years
Evaluation based upon 1 PureBallast 3.1-85 USCG FLEX systems installed, excludes labor estimates.
Item \ Year 1 2 3 4 5
CIP liquid € - € 84 € 84 € 84 € 84
Lamp power supply € - € - € - € - € -
Quartz sleeve set € - € - € - € - € -
UV lamp set € - € - € - € - € -
Filter maintenance kit € - € 473 € 473 € 473 € 473
CIP pump spare kit € - € - € 1,313 € - € 1,313
UV sensor € - € 611 € 611 € 611 € 611
Filter Insert € - € - € - € - € -
Service € - € - € - € - € -
TOTAL € - € 1,169 € 2,482 € 1,169 € 2,482
Item \ Year 6 7 8 9 10
CIP liquid € 84 € 84 € 84 € 84 € 84
Lamp power supply € - € - € - € - € -
Quartz sleeve set € - € - € - € - € -
UV lamp set € - € - € - € - € -
Filter maintenance kit € 473 € 473 € 473 € 473 € 473
CIP pump spare kit € - € 1,313 € - € 1,313 € -
UV sensor € 611 € 611 € 611 € 611 € 611
Filter Insert € - € - € 5,927 € - € -
Service € - € - € - € - € -
TOTAL € 1,169 € 2,482 € 7,096 € 2,482 € 1,169

4 of 4
 TECHNICAL MANUAL - SECTION 3

ART
ANDERSON
202 PACIFIC AVE, BREMERTON, WA 98337
® (360) 479-5600
TECHNICAL MANUAL - SECTION 3
TECHNICAL MANUAL - SECTION 3
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TECHNICAL MANUAL - SECTION 3
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