SUNRUI BalClor®

Ballast Water Management System

User Manual
Doc.: X1JK-OMSM-01-WJ

Rev.:1.56

SUNRUI MARINE ENVIRONMENT ENGINEERING Co., Ltd.

Add.:149-1 Zhuzhou Road, Laoshan District, Qingdao, P.R. China

Http://www.sunrui.com.cn

June, 2020
 Sunrui Marine Environment Engineering Co., Ltd.

Revision History
Document Document
Revision Changes Date
Description No.

initial issued according to

BalClor
DNV.GL comments with
BWMS X1JK-OMSM-01
1.0 reference NO. 2015-4-21
User -WJ
MCANO386/FIST/262.1
Manual
-011439-J-94

BalClor
Revised with DNV GL
BWMS X1JK-OMSM-01
1.1 comments for draft version 2016-8-8
User -WJ
of Filtersafe LB report
Manual

Revised with removing

BalClor
options of canceling TRO
BWMS X1JK-OMSM-01
1.2 sampling before 2016-9-29
User -WJ
neutralization and
Manual
alternative boll filter

Revised according to
BalClor
DNV.GL comments with
BWMS X1JK-OMSM-01
1.3 reference NO. 2016-10-31
User -WJ
MCANO386/FIST/262.1
Manual
-011439-J-323

Revised according to
BalClor
DNV.GL comments with
BWMS X1JK-OMSM-01
1.41 reference NO. 2016-11-21
User -WJ
MCANO386/FIST/262.1
Manual
-011439-J-352

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 Sunrui Marine Environment Engineering Co., Ltd.

Revised according to
BalClor DNV.GL comments on
BWMS X1JK-OMSM-01 alarm list and adding the
1.42 2016-12-1
User -WJ options of canceling TRO
Manual sampling before
neutralization

Revised with updated

BalClor
Annex D and updated
BWMS X1JK-OMSM-01
1.43 description on de-ballasting 2016-12-5
User -WJ
TRO sampling options in
Manual
Chapter 8.3 and Chapter 8.5

BalClor Revised with updated

BWMS X1JK-OMSM-01 Annex D and updated
1.44 2017-1-15
User -WJ description on chapter
Manual 8.4.2.2

Revised with and updated

BalClor
description on chapter 6.2.2,
BWMS X1JK-OMSM-01
1.45 7.1.2, 7.4, 8.4 and 8.5 and 2017-3-3
User -WJ
updated Annex N according
Manual
to USCG comments.

updated with TRO sampling

BalClor
distance requirement in
BWMS X1JK-OMSM-01
1.46 Chapter 7.1.2 and Revised 2017-5-19
User -WJ
with Annex D according to
Manual
USCG comments.

BalClor updated with recommended

BWMS X1JK-OMSM-01 size of main ballast pipes in
1.47 2017-6-4
User -WJ Annex D according to
Manual USCG comments.

BalClor 1.48 Revised according to 2017-7-31

X1JK-OMSM-01
BWMS DNV.GL comments with
Page 3 of 209 Manual Rev: 1.56 BalClor® BWMS
 Sunrui Marine Environment Engineering Co., Ltd.

User -WJ reference No.

Manual MCANO386/FIST/262.1
-011439-J-412

Revised according to
BalClor
DNV.GL comments with
BWMS X1JK-OMSM-01
1.49 reference No. 2017-8-25
User -WJ
MCANO386/FIST/262.1
Manual
-011439-J-418

BalClor
BWMS X1JK-OMSM-01 Revised with rearrangement
1.50 2018-1-26
User -WJ of the content
Manual

Revised with filtersafe -T,

BalClor -ST TRC and optimized
BWMS X1JK-OMSM-01 arrangement of hydrogen
1.51 2018-9-5
User -WJ evacuation system
Manual according to DNV GL
comments

Revised with data sheets

and Annex J&K for
BalClor
optimized arrangement of
BWMS X1JK-OMSM-01
1.52 hydrogen evacuation system 2018-11-13
User -WJ
and alternative components
Manual
according to DNV GL
comments

Revised with holding time

BalClor in table 7.1 and include the
BWMS X1JK-OMSM-01 alternative stripping
1.53 2018-11-29
User -WJ treatment without TRO
Manual measurement in Section
8.5.3.

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 Sunrui Marine Environment Engineering Co., Ltd.

updated with Filtersafe

BalClor
model arrangement in
BWMS X1JK-OMSM-01
1.54 Annex H.1 and Filtersafe 2018-12-17
User -WJ
super-turbo model in Annex
Manual
J and Annex K.

1.Updated for consistency

of Table 6-1a alarm set point
list and troubleshooting in
Chapter 9,
2. updated with new SunRui
BalClor filter models
BWMS X1JK-OMSM-01 SRF-60&SRF-3000 in
1.55 2020-03-05
User -WJ Annex H.2, aquaBoll 6.18.3
Manual filter models in Annex H.3
and Kanagawa filter
model arrangement in Table
6-1a, Section 7.1, Section
9.1.1, Annex C.4, Annex
H.4, and Annex J.
1Updated with holding time
in Table 7-1.
2. updating of log file
interface and description in
Section 6.4 and Table 6-4.
BalClor
3. updated with detailed
BWMS X1JK-OMSM-01
1.56 description on log file 2020-06-02
User -WJ
extracting in Section 6.4.4.
Manual
4. updated with additional
restrictions and precautions
for the stripping alternative
with no TRO analyzer in
Section8.5.3.

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TABLE OF CONTENTS
1 INTRODUCTION................................................................................................ 10
1.1 System Introduction ...................................................................................... 10
1.2 Purpose of Manual ........................................................................................ 11
1.3 Customer Support Information ..................................................................... 11
1.4 Warranty........................................................................................................ 11
1.5 Abbreviations ................................................................................................ 11
1.6 Safety Instructions ........................................................................................ 12
1.6 Warning Sign Definitions ............................................................................. 13
1.7 Marking of BaClor® BWMS ........................................................................ 14
2 PACKING AND TRANSPORTATION.............................................................. 15
2.1 Preservation .................................................................................................. 15
2.2 Packing ......................................................................................................... 15
2.3 Transportation ............................................................................................... 15
3 PRESERVATION, HANDLING AND INSTALLATION ................................ 16
3.1 Preservation and Handling............................................................................ 16
3.1.1 Preservation ...................................................................................... 16
3.1.2 Unpacking ........................................................................................ 16
3.1.3 Lifting and handling ......................................................................... 17
3.2 Installation .................................................................................................... 18
3.2.1 Safety instructions ............................................................................ 18
3.2.2 Installation instructions .................................................................... 19
3.2.3 Installation interfacing...................................................................... 23
3.2.4 Installation man-hour requirements ................................................. 24
3.2.5 Installation Locations onboard ships ................................................ 25
4 SAFETY AND PRECAUTIONS ........................................................................ 26
4.1 Pre-check Before Installation ....................................................................... 26
4.2 Safety Protection of the System.................................................................... 26
4.3 Water Leakage of Electrolytic Unit .............................................................. 27
4.4 Gas Leakage ................................................................................................. 27
4.5 Entering Ballast Tank ................................................................................... 28
4.6 Harmful Gases Inhalation ............................................................................. 28
4.7 Accidental Contact with Chemicals .............................................................. 29
4.7.1 Contact with sodium thiosulfate solution ......................................... 29
4.7.1.1 Precaution about Na2S2O3 ............................................................. 29
4.7.1.2 First aid measures about Na2S2O3 ................................................. 29
4.7.2 Contact with NaClO ......................................................................... 29
4.7.2.1 Precaution about NaClO................................................................ 30
4.7.2.2 First Aid Measures about NaClO .................................................. 30
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4.8 Personnel Training and Requirements .......................................................... 31

4.9 Machine-side Emergency Operation ............................................................ 31
5 TREATING AND SYSTEM PROCESS ............................................................ 33
5.1 Treating Process ............................................................................................ 33
5.1.1 Filtration ........................................................................................... 33
5.1.2 Disinfection ...................................................................................... 33
5.1.3 Neutralization ................................................................................... 33
5.2 System Process ............................................................................................. 34
5.2.1 Loading ballast water process .......................................................... 34
6 ALARM AND DATA .............................................................................................. 36
6.1 Alarm Signal ................................................................................................. 36
6.2 By-pass and emergency shutdown................................................................ 49
6.2.1 By-pass alarm and procedure ........................................................... 49
6.2.2 Emergency shutdown alarm and procedure ..................................... 49
6.3 Hydrogen and Chlorine Gas Alarm .............................................................. 50
6.4 Historical Data .............................................................................................. 51
6.4.1 Operation parameter record interface ............................................... 56
6.4.2 Operation event record ..................................................................... 58
6.4.3 Alarm event record interface ............................................................ 59
6.4.4 log file extracting ............................................................................. 60
6.5 Replacement of control and monitoring equipment ..................................... 69
7 TECHNICAL DESCRIPTION .............................................................................. 70
7.1 Main Components and Operation Conditions .............................................. 70
7.1.1 Main components ............................................................................. 70
7.1.2 Operation conditions ........................................................................ 70
7.2 Automatic Back-flushing Filter .................................................................... 72
7.3 Electrolytic Unit ........................................................................................... 76
7.3.1 Flow chart and arrangement of electrolysis unit .............................. 76
7.3.2 Degas unit ......................................................................................... 78
7.3.2.1 optimized arrangement of degas unit ............................................ 78
7.4 Rectifier, Controller and power distribution................................................. 79
7.5 TRO Analyzer ............................................................................................... 81
7.6 Sampling Facilities ....................................................................................... 82
7.7 Neutralizing Unit .......................................................................................... 83
7.7.1 Introduction of Neutralization .......................................................... 83
7.7.2 Preparation and storage of neutralizer .............................................. 84
8 OPERATION AND CONTROL ......................................................................... 92
8.1 General Description ...................................................................................... 92
8.2 Principles for Control of BalClor® BWMS .................................................. 93
8.3 Control Panel ................................................................................................ 97
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8.3.1 Remote Control .............................................................................. 100

8.4 Automatic Operation When Ballasting.............................................. 100
8.4.1 Automatic Operation When Ballasting for marine or brackish
water ........................................................................................................ 102
8.4.2 Automatic Operation When Ballasting for fresh water .................. 105
8.5 Automatic Operation of De-ballasting ........................................................ 110
8.5.1 Automatic Operation When De-ballasting by Ballast Pump with
TRO sampling Option 1 .......................................................................... 111
8.5.2 Automatic Operation When De-ballasting by Ballast Pump with
TRO sampling Option 2 .......................................................................... 114
8.5.3 Automatic Operation When De-ballasting with stripping eductor . 117
8.6 Manual Operation ....................................................................................... 121
8.7 Water Sampling .......................................................................................... 121
8.8 Waste Stream Treatment ............................................................................. 121
9 MAINTENANCE .................................................................................................. 122
9.1 Failure Condition ........................................................................................ 122
9.1.1 Troubleshooting for filter ............................................................... 122
9.1.2 Failure conditions of Electrolytic unit ............................................ 128
9.1.3 Failure conditions of Neutralizing unit .......................................... 131
9.1.4 Troubleshooting for TRO analyzer................................................. 131
9.1.5 Troubles hooting for BWMS .......................................................... 131
9.2 Malfunction of BWMS ............................................................................... 134
9.3 Maintenance and Inspection Program ........................................................ 134
9.3.1 Maintenance of automatic back-flushing filter .............................. 135
9.3.2 Maintenance of electrolyzer ........................................................... 135
9.3.3 Maintenance and calibration of TRO analyzer............................... 135
9.3.4 Maintenance of flow meter ............................................................ 137
9.3.5 Maintenance of rectifier and controller .......................................... 138
9.3.6 Metering pump ............................................................................... 138
9.3.7 Seawater booster pump and Dosing pump ..................................... 141
9.3.8 Other maintenances and calibration ............................................... 144
10 DATA SHEETS ................................................................................................... 146
11 CERTIFICATES ................................................................................................. 184

ANNEX A：OWNER’S MANUAL of CLX Online Residual Chlorine Monitor

ANNEX B：OPERATING MANUAL of Pro-series Model C3 Conductivity

Transmitter

ANNEX C.1：Operator’s Manual for BS-Series Models (Filtersafe)

ANNEX C.2：Operation Manual for SRF Series Automatic Back-flushing

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 Sunrui Marine Environment Engineering Co., Ltd.

Filter (Luoyang Sunrui)

ANNEX C.3 ： Operation instructions for automatic filter Type 6.18.3

(BOLLFILTER)

ANNEX C.4：KBW instruction manual (Kanagawa filter)

ANNEX D ： Flow Diagram of BalClor® BWMS (for BC150-BC8000)

(Ver. 1.3)

ANNEX E: Material Safety Data Sheet SODIUM THIOSULFATE

ANNEX F：Material Safety Data Sheet SODIUM HYPOCHLORITE

ANNEX G: Maintenances record list

ANNEX H.1：TRC and Models of BalClor ® BWMS with Filtersafe Filters

with standard, turbo (-T) and superturbo (-ST) configuration

ANNEX H.2：TRC and Models of BalClor ® BWMS with Luoyang Sunrui

Filters

ANNEX H.3：TRC and Models of BalClor ® BWMS with Boll Filters

ANNEX H.4：TRC and Models of BalClor ® BWMS with Kanagawa Filters

ANNEX J：Bill of Materials for BalClor® BWMS （BC150-BC8000）

ANNEX K：Assembly Drawing of BalClor® BWMS (for BC150‐BC8000)

ANNEX L： Electrical Wiring Drawing of BalClor® BWMS (for BC150‐

BC8000)

ANNEX M：SUNRUI BalClor® Ballast Water Management System

Installation Manual

ANNEX N: Installation, Maintenance and Repair Procedures for Valves

ANNEX P: Power consumption of BalClor® BWMS

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 Sunrui Marine Environment Engineering Co., Ltd.

1 INTRODUCTION

1.1 System Introduction

BalClor® BWMS developed and manufactured by Sunrui Marine Environment

Engineering Co., Ltd is a system specially designed to treat ballast water to kill the
harmful aquatic organisms and pathogens contained in ship’s ballast water so as to
make the treated ballast water meet the requirements of regulation D-2 in
International Convention for the Control and Management of Ships' Ballast Water
and Sediments adopted by International Maritime Organization (IMO) and USCG
discharge standard. The treating process of BalClor® BWMS is consisted of the
following three phases:

Phase 1: Filtration --- During ballasting, the ballast water is filtrated by an automatic
backwashing filter with 50µm or smaller screen to remove marine organisms larger
than 50µm.

Phase 2: Disinfection --- A small side stream of filtered water is delivered to the
electrolytic unit to generate the oxidants of high concentration (mainly sodium
hypochlorite solution), then the oxidants are injected following filtration back into the
main ballast stream to provide effective disinfection.

Sodium hypochlorite solution as a very effective germicide can be kept in ballast

water for a certain period to effectively kill the plankton, spores, larvae and
pathogens contained in the ballast water. This technology has been widely practiced
in water treatment industries like medical sterilization, water treatment plants for
many years.

Phase 3: Neutralization --- During discharging, the residual TRO level of the treated
ballast water below 0.1ppm, and then the treated ballast water can be directly
discharged. If the residual TRO level of the treated ballast water over 0.1ppm,
neutralizer (sodium thiosulfate solution) is added into the de-ballast pipe to neutralize
residual oxidants instantly automatically.

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1.2 Purpose of Manual

The purpose of this user manual is to provide instructions for the safe operation and
proper maintenance of the BalClor® BWMS and all its components.

1.3 Customer Support Information

Contact address if assistance is required:

Address 149-1# Zhuzhou Road, Laoshan District, Qingdao, P.R. China

Postcode 266101
After-sales +86-532-68725806
service Tel.
Fax. +86-532-68725001
After-sales [email protected]
service E-mail
Website www.sunrui.net

1.4 Warranty

SunRui Marine Environment Engineering Co., Ltd warrants the BalClor® BWMS
delivered in package to be free from defects in material and workmanship under
normal usage and maintenance, for a period of 12 months after operating, or 18
months after delivery.

1.5 Abbreviations

Abbreviation Description
BWMS Ballast Water Management System
BWDS Ballast Water Discharge Standard
AFU Automatic Back-Flushing Filter Unit
EDU Electrolytic Disinfection Unit
ANU Automatic Neutralization Unit

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BPU Brine preparation Unit

PLC Programmable Logic Controller
HMI Human Machine Interface
H2 Hydrogen
Cl2 Chlorine
TRO Total Residual Oxidant
NaClO Sodium Hypochlorite
Na2S2O3 Sodium Thiosulfate
LEL Lower Explosive Limit
PPE Personal Protective Equipment
RPE Respiratory Protective Equipment

1.6 Safety Instructions

All safety instructions must be respected in order to avoid injury to personnel or

damage to the environment and equipment.

(1) Prior to installation or handling of the system, read carefully the installation and
operation instruction.

(2) Confirm AC power disconnections prior to any maintenance.

(3) Wear neoprene or rubber gloves and other protective clothing as appropriate to
prevent skin contact when checking or cleaning neutralization system.

(4) Safety glasses with face shield or chemical goggles are recommended for eye
protection when checking or cleaning electrolytic cell and neutralization system.

(5) When the system is operating, the doors of electrolytic cell cabinet and rectifier
must be closed.

(6) Hydrogen and chlorine gas sensor must be installed following the instruction of
Sunrui technicians.

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 Sunrui Marine Environment Engineering Co., Ltd.

(7) Before performing any maintenance activities, read carefully maintenance

instruction.

(8) Don’t perform any maintenance activities other than these given in this manual.

1.6 Warning Sign Definitions

It indicates possibilities for immediate hazards,

which will result in fatal or severe personnel injuries

DANGER:
and substantial property damage, if the required

precautions are not taken.

It indicates possibilities for hazards or unsafe

practices, which could result in fatal or severe

WARNING: personnel injuries or substantial product or property

damage, if the required precautions are not taken.

It indicates possibilities for hazards or unsafe

practices, which could result in minor personnel

CAUTION!
injuries and/or property damage, if the required

precautions are not taken.

Special attention shall be paid to specific

NOTE
information or instructions in this manual.

It indicates possibilities for electric shock.

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 Sunrui Marine Environment Engineering Co., Ltd.

1.7 Marking of BaClor® BWMS

A name plate made of anti-corrosion material will be securely fastened for each
model of BalClor® BWMS with basic specification of the system, as shown in
Figure 1-1.

Figure 1-1 Name plate of BalClor® BWMS

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 Sunrui Marine Environment Engineering Co., Ltd.

2 PACKING AND TRANSPORTATION

2.1 Preservation

The units and equipments should be protected from contamination and heavy
weather conditions, placed in a transportation box and stored indoors.

The preserved equipment should be marked with sign.

2.2 Packing

The equipment can be packed by wooden box. There is still rain-proof and
waterproof packaging. When the goods are required to be rain-proof, external
plastic shield for the equipment inside the close case and dual layer of waterproof
material at the top cover of the case will be used.

2.3 Transportation

The coating material should be insulated.

The exact equipments should be treated by shockproof.

Protecting from laying out with chemical, nocuous and baneful materials.

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3 PRESERVATION, HANDLING AND INSTALLATION

3.1 Preservation and Handling

3.1.1 Preservation

The units and equipments should be protected from contamination and heavy
weather conditions, placed in a transportation box and stored indoors.
The solid sodium thiosulphate (Na2S2O3ꞏ5H2O) grains should be kept in a tightly
closed container, stored in a cool, dry, ventilated area and protected against physical
damage.

3.1.2 Unpacking

BalClor BWMS has been strictly tested and adjusted before it is delivered to the
customer. Before transportation, all the items will be well packed in the
transportation box before transportation. And there is a packing list attached on the
wooden transportation box indicating the item name and quantity in the box. When
arriving at the destination，please carefully inspect all items and check with the
packing list to ensure that no items are missing during shipment. If the items
received do not match the packing list, please immediately contact with Sunrui.
However, before installation, the transportation and storage of the equipment may
have some effects on the equipment. In order to ensure the good operation of the
system, the following instructions shall be followed before installation:
1) Check the equipment, valves, pipelines and rating plate on the skid whether
on serviceable conditions and compatibilities with their delivery states. If
one of the following problems is found: damage to the equipment, or lost of
parts or deviation of the setting value, notify the supplier at once. The
disassembling and refitting without permission is never permitted.
2) Before operating the rectifier and controller, an electric insulating test
would be performed.

NOTE: Do not unpack before lifting or installation.

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 Sunrui Marine Environment Engineering Co., Ltd.

3.1.3 Lifting and handling

DANGER:
Risk of accidents from falling loads!
During transportation of the units and equipments, accidents may occur due to sizes
and weights.
• Exercise extreme caution when transporting the units and equipments in order to
prevent damage to or deformation of the filter.
• Only use suitable means of transport and lifting gear with sufficient load-bearing
capacity.
• Do not stand underneath suspended loads. Do not work underneath suspended
loads.
• Wear the appropriate protective clothing.

For EDU, ANU and other units, there are four lifting pad eyes welded on the base
frame of the units. Lifting slings will be used through these lifting pad eyes when
lifting.

For AFU, Please refer to Filter User Manual for detailed information on
transportation and installation of the filter.

For rectifier, four lifting pad eyes welded on the base frame are used for lifting if the
rectifier is fastened on the base frame. Do not use lifting lugs bolted on the top of
the rectifier when it is fitted on the skid.. Lifting slings will be used through these
lifting lugs when lifting.

CAUTION!
The units and equipments shall never be laid upside down or placed on the unit side.
It shall be always placed upright.

For flow meter, Use webbing slings slung round the two process connections. Do
not use chains, as they could damage the housing.

CAUTION!
Risk of injury if the measuring device slips. The center of gravity of the assembled
measuring device might be higher than the points around which the slings are slung.
At all times, therefore, make sure that the device does not unexpectedly turn around
its axis or slip.

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NOTE: Please refer to Flow Meter Manual for detailed information on

transportation and installation of the flow meter.

For valves, please keep the screws tightly and valve balance when lifting. Please
handle valves with care. Do not stand on the valves. Do not lay other heavy things
on the valve. Do not throw valves.
NOTE: Please refer to Valve Manual as Annex N for detailed information on
transportation and installation of the valves

3.2 Installation

3.2.1 Safety instructions

CAUTION!
The following instructions must be followed during the installation of the system.

•Installation, connection to the electricity supply, commissioning and maintenance of

BalClor® BWMS must be carried out by trained, qualified personnel authorized to
perform such work. The personnel must have read and understood the relevant
drawings, diagrams and manuals, and must follow the instructions they contain.
CAUTION!
Improper installation may result in serious damage to the system and severe personal
injuries.

DANGER:
Risk of electric shock!
•Switch off the power supply before installing the system. Do not install or wire the
system while it is connected to the power supply. Failure to comply with this

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 Sunrui Marine Environment Engineering Co., Ltd.

precaution can result in irreparable damage to the electronics and sever injuries.

CAUTION!
•Some welding work will be performed in field during installation. Wear proper
Personal Protective Equipment (PPE) for eye protection and skin protection. Please
refer to general precaution requirements for welding.

CAUTION!
•Cleanser and solvent cement will be applied for UPVC piping assembling, please
refer to MSDS of Cleanser and solvent cement and handle with care when using
Cleanser and solvent cement.

CAUTION!
•UPVC pipe cutting machine will be applied during UPVC piping connection.
Please handle with care to avoid personal injuries. Please refer to safety precautions
of pipe cutting machine.

CAUTION!
•Please be aware of fall off of heavy objects during lifting and installation of units,
equipments and piping greater than 5’’.

3.2.2 Installation instructions

The BalClor® BWMS is interconnected with shipboard piping and equipments with
standard connection methods via flanges, connectors and cables. No special
installation criteria is required, but some standard criteria for flange connection and
cable specifications must be noticed and carried out.
•Piping specification
When UPVC material piping is used for connection between the components of
BalClor BWMS, The UPVC piping specification is listed as follows in Table 3.1;
Table 3.1 UPVC Piping Specification

Nominal Outer diameter thickness Piping standard and

Material
diameter (mm) (mm) Pressure rating
1/2’’ 21.3 3.7 ANSI SCH80 UPVC
1’’ 33.4 4.6 ANSI SCH80 UPVC
1-1/2’’ 48.3 5.1 ANSI SCH80 UPVC
8’’ 219.1 12.7 ANSI SCH80 UPVC
DN15 20 2.0 DIN PN10 UPVC

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Nominal Outer diameter thickness Piping standard and

Material
diameter (mm) (mm) Pressure rating
DN25 25 2.4 DIN PN10 UPVC
DN40 48 3.7 DIN PN10 UPVC
DN50 63 4.7 DIN PN10 UPVC
DN80 90 6.7 DIN PN10 UPVC
DN125 140 8.3 DIN PN10 UPVC

•flange connection
The flanges should be carefully aligned and the bolts inserted through matching
holes. A flat washer should be used beneath each nut and bolt head. Each bolt
should be partially tightened in the alternating sequence indicated in the patterns
below. A torque wrench should be used for the final tightening of the bolts. The
bolts should be tightened to the torque recommended in the table below in the same
alternating sequence used previously.
Recommended tightening torques for mounting bolts of flanges are listed follows,

Arrangement of the mounting bolts is listed as follows,

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• UPVC piping and fitting connection

Solvent cement set and cure times are a function of pipe size, temperature, relative
humidity, and tightness of fit. Drying time is faster for drier environments, smaller
pipe sizes, high temperatures, and tighter fits. The assembly must be allowed to set,
without any stress on the joint, per the time shown in the following tables.
Following the initial set period, the assembly can be handled carefully avoiding
significant stresses to the joint. Extra care should be exercised when systems are
assembled in extreme temperature conditions.
Extra set and cure times should be allowed when the temperature is below 40℉
(4℃). When the temperature is above 100℉ (38℃), the assembler should ensure
that both surfaces to be joined are still wet with cement before joining them.
After a joint is assembled using solvent cement, it should not be disturbed for a
period of time to allow for proper “setting” of the newly prepared joint.
Recommended set times are as follows:

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 Sunrui Marine Environment Engineering Co., Ltd.

After a joint is assembled using solvent cement, the cement must be allowed to
properly “cure” before the piping system is pressurized. Recommended minimum
cure times are shown below. These recommendations should only serve as a guide
since atmospheric conditions during installation will affect the curing process.
High humidity and/or colder weather will require longer cure times: typically add
50% to the recommended cure time if surroundings are humid or damp.

• Metal piping and fitting connection

The metal piping and fitting will be connected according to shipyard standard and in
compliance with rules of classification.

•Cable connection
All cables used in the BalClor® BWMS and between BalClor® BWMS and
shipboard utilities shall be halogen-free type, and suitable for use in marine
applications and meet the requirements of the classification society.
For information on cable specifications and connections used for BalClor® BWMS,

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please refer to the Electrical Wiring Diagram. The installer must ensure that the
BalClor® BWMS is correctly wired in accordance with the wiring diagrams.

3.2.3 Installation interfacing

The connection requirement for main components of BalClor BWMS are listed as
follows,
Component resource
No. code connection type remarks
name type
hydraulic flange
automatic
connector with
1 AFU backflushing Pneumatic
Φ8mm tubing
filter
electrical cable terminals
hydraulic flange
electrolytic
cable terminals
2 EDU disinfection
electrical and cord end
unit
terminals
automatic hydraulic flange
3 ANU neutralization
electrical cable terminals
unit

fresh water hydraulic flange

4* FWU
unit electrical cable terminals
brine hydraulic flange
5* BPU preparation
electrical cable terminals
unit

Dosing pump hydraulic flange

6 DPU
unit electrical cable terminals
7 EQ07 Rectifier electrical cable terminals
System
8 EQ08 electrical cable terminals
control cabinet
9 EQ25 Motor control electrical cable terminals

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cabinet
hydraulic flange
11 FT flow meter
electrical cable terminals
connector with
hydraulic Φ6/Φ12mm
12 TR TRO analyzer
tubing
electrical cable terminals
Hydrogen
13 HS01 electric al cable terminals
sensor
hydraulic flange
connector with
Pneumatic Φ8mm tubing if
14* -- Valves
applicable
cable terminals if
electrical
applicable
Note: the number of the components with “*” is dependent on different projects.

For detailed outline, interfaces and wiring of the components, please refer to
relevant flow diagram, outline drawings and wiring diagrams which will be
submitted before installation.

3.2.4 Installation man-hour requirements

The estimated man-hours is required as follows,

Installation procedures estimated man hours
units& equipments lifting and mounting 12h x 4 persons
piping connections 40h x 6 persons
wiring and cable connection 20h x 3persons
piping check after installation 8h x 2 persons
wiring check after connection 16h x 2 persons
Note: The actual installation man-hour requirement will vary according to the model
and quantity of BWMS as well as vessel types.

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3.2.5 Installation Locations onboard ships

The BalClor® BWMS can be installed in the engine room or any similar area that is
not designated as Hazardous Area where gas explosion may occur, if not specified.
The BalClor BWMS cannot be installed on open deck without protection from
weather.
For electrical components which will be installed in hazardous area, Ex proof type
shall be considered according to the requirement of classification rules and in
compliance with hazardous zone requirement.

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4 SAFETY AND PRECAUTIONS

4.1 Pre-check Before Installation

BalClor® BWMS has been strictly tested and adjusted before it is delivered to the
customer. However, before installation, the transportation and storage of the
equipment may have some effects on the equipment. In order to ensure the good
operation of the system, the following instructions shall be followed before
installation:

1) Check the equipment, valves, pipelines and rating plate on the skid whether
on serviceable conditions and compatibilities with their delivery states. If
one of the following problems is found: damage to the equipment, or
missing of parts or deviation of the setting value, notify the supplier at once.
The disassembling and refitting without permission is never permitted.

2) Before operating the rectifier and controller as well as any electrical

components, an electric insulating test would be performed.

4.2 Safety Protection of the System

During operation of BalClor® BWMS, the following operations are strictly

prohibited:

1) Open the doors of electrolytic cells and rectifier. Any maintenance of any
parts in the system.

2) Each sensor has been well set-up and adjusted, random change on the
setting of sensors will cause control system of BalClor® BWMS be
mistakes, and will lead to malfunction or even make the system stop.

For protection against interference with the BWMS, Tamper Evident Tapes and
Labels are used to provide a seal method for each access of these equipments
listed in Table 4-1.
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Table 4-1 List of equipments required factory –setting seal.

No. Name
1 Hydrogen alarm sensor
2 Chlorine alarm sensor
3 Flow meter
4 CF Card reader
5 Dosing governor valve
6 Conductivity Meter

4.3 Water Leakage of Electrolytic Unit

Steel material is used for the connections flanges and the connections of inlet pipe
and outlet pipe of BalClor® BWMS and drip tray is fitted beneath the electrolysis
unit. Meanwhile, the system can automatically detect leakage of the system based
on monitoring of environment H2 and Cl2 concentration by H2 sensor and Cl2
sensor in EDU unit. In case that any leakage occurs, an alarm signal will be sent out
and the system will be automatically stop operation.

When accident leakage happens, operator shall carry out personnel protection and
take the following measures:

1) Close the hand valve at the inlet of electrolytic unit. And deal with the
trouble.

2) Neutralize the residual solution that was leaked.

3) If the ship is in danger, then by-pass operation shall be carried out.

4.4 Gas Leakage

The degas tank removes the hydrogen gas in the water, which are generated during
the electrolyzing process, and dilute the gas to the level below Lower Explosive
Limit (LEL) and release it overboard.

Around the system there are hydrogen gas sensor and chlorine sensor installed. If

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the out-leaked gas concentration has reached the set alarm value (the hydrogen gas
exceeds 2.4%(60% LEL) in the air or the chlorine gas exceeds 0.55 ppm in the air),
the electrolytic unit will automatically stop generating TRO, and the air blower
continue operating.

4.5 Entering Ballast Tank

Before entering a ballast tank, the tank must be free of both hydrocarbon and inert
gasses to secure a safe working environment. This involves blowing fresh air into
the tank to force accumulated gasses out. There are strict requirements and thus
routines associated with securing safe breathable atmospheres before personnel are
allowed to enter any tanks on board ships. This is according to class regulation.
Specially trained personnel shall monitor the tank’s atmosphere during the process,
often using portable gas indicators which measure the percentage of hydrocarbons
present as well as e.g. oxygen. Assuming that there are a small quantities of residual
treated ballast water in ballast tank, the crews shall wear personal protective
equipment (PPE) and respiratory protective equipment (RPE) when entering into the
tank.

It is recommended to take the following measures:

1) Wear neoprene or rubber gloves and other protective clothing to protect

skin, wear safety glasses with face shield or chemical goggles to protect
eyes;

2) Wear respirator.

4.6 Harmful Gases Inhalation

When BalClor® BWMS is operating, the crew should avoid stay around the air hole
of ballast tank.

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4.7 Accidental Contact with Chemicals

4.7.1 Contact with sodium thiosulfate solution

When preparing and storing sodium thiosulfate solution, one should strictly follow
the following instructions and wear PPE/RPE. If the personnel contacted sodium
thiosulfate solution, please take the following measures:

4.7.1.1 Precaution about Na2S2O3

Note: Should wear neoprene or rubber gloves and other protective clothing to
protect skin, wear safety glasses with face shield or chemical goggles to
protect eyes, and wear respirator to avoid inhalation when checking or
cleaning neutralization system.

4.7.1.2 First aid measures about Na2S2O3

Inhalation:

Remove to fresh air. Get medical attention for any breathing difficulty.

Ingestion:

Induce vomiting immediately as directed by medical personnel. Never give anything

by mouth to an unconscious person. Get medical attention.

Skin Contact:

Wash exposed area with soap and water. Get medical advice if irritation develops.

Eye Contact:

Wash thoroughly with running water. Get medical advice if irritation develops.

4.7.2 Contact with NaClO

The main content of TRO solution is NaClO. If any accidental contact happens,
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please take the following measures:

4.7.2.1 Precaution about NaClO

Note: Please wear neoprene or rubber gloves and other protective clothing to
protect skin, wear safety glasses with face shield or chemical goggles to
protect eyes, and wear respirator to avoid inhalation when checking or
cleaning electrolytic cell.

4.7.2.2 First Aid Measures about NaClO

Inhalation:

Remove from exposure and get fresh air. Use bag valve mask or similar device to
perform artificial respiration (rescue breathing) if needed. Keep warm and at rest. Get
medical attention immediately if artificial respiration required.

Skin Contact:

Remove contaminated clothing, jewelry, and shoes immediately. Flush affected area
with large amounts of water, preferably a safety shower. Use soap or mild detergent
and large amounts of water until no evidence of chemical remains (at least 15-20
minutes). For burns, cover affected area securely with sterile, dry, loose fitting
dressing. If skin is burned, get medical attention immediately.

Eye Contact:

Wash eyes immediately with large amounts of water, occasionally lifting upper and
lower lids, until no evidence of chemical remains (at least 15 minutes). Continue
irrigating with a normal saline solution until ready to transport to physician. Cover
with sterile bandages. Get medical attention immediately.

Ingestion:

Rinse mouth with water. Drink large quantities of milk (water if no milk is available).
Milk of magnesia may be helpful. DO NOT USE ACIDIC ANTIDOTES SUCH AS
SODIUM BICARBONATE. When vomiting occurs, keep head lower than hips to
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help prevent aspiration. If person is unconscious, do not induce vomiting and turn
their head to the side. Never make an unconscious person vomit or drink fluids. Get
medical attention.

Note to Physician:

For inhalation, consider oxygen. For ingestion, avoid gastric lavage, emesis, sodium
bicarbonate and acid solutions. Consider the use of antacids.

4.8 Personnel Training and Requirements

In some situation, the crew may be required to operate valves manually to switch to
fresh water treatment mode if needed. Except for that, this system is designed to work
in a fully automatic mode. There is no special personnel requirements for operating
the system, rather than some operation and maintenance procedures as described in
Chapter 8 and Chapter 9.

Before operation on BalClor® BWMS, the following training shall be carried out to
the crew onboard,

Table 4-2 Training course and time

Course Time
BalClor® BWMS safety training 1h
Accidental contact with chemical treatment procedure 0.5h
BalClor® BWMS operation 2h
Automatic back-flushing filter Operation and maintenance 0.5h
TRO analyzer Operation and maintenance 40min
Flow meter and other sensors Operation and maintenance 20min
Preparation and storage of neutralizer 0.5h

4.9 Machine-side Emergency Operation

Note: The machine-side emergency operation will be automatically recorded in

historical data. When machine-side emergency operating, the control panel
operation will be locked.
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In emergency cases, emergency operation can be carried out in BalClor® BWMS.

The operating position can be in the place where the BalClor® BWMS installs, such
as engine room.

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5 TREATING AND SYSTEM PROCESS

5.1 Treating Process

The treating process of BalClor® BWMS consists of three phases.

5.1.1 Filtration

During ballasting, the ballast water is filtrated by an automatic backwashing filter

with 50µm or finer screen to remove marine organisms larger than 50µm.

5.1.2 Disinfection

Following filtration, a small side stream of the filtered ballast water is delivered to the
electrolytic unit to generate the oxidants of high concentration (mainly sodium
hypochlorite solution), then the oxidants are injected back into the main ballast stream
to provide effective disinfection.

Sodium hypochlorite solution as a very effective germicide can be kept in ballast

water for a certain period to effectively kill the plankton, spores, larvae and
pathogens contained in the ballast water. This technology has been widely practiced
in water treatment industries like medical sterilization, water treatment plants for
many years.

5.1.3 Neutralization

During discharging, if the residual oxidants level of the treated ballast water remains
below the maximum allowable discharge level, and then the treated ballast water can
be directly discharged. If the residual oxidants level of the treated ballast water
exceeds maximum allowable discharge level, neutralizer (sodium thiosulfate solution)
is added into the de-ballast pipe to neutralize residual oxidants instantly and
automatically.

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5.2 System Process

5.2.1 Loading ballast water process

Usually, in the process of loading ballast water automatically, a flow meter will be
installed in the main pipe to measure the flow of seawater. Once the system is filled
with ballast water (about one minute), rectifier will provide DC current to the
electrolyzer cell to start the electrolysis process. Oxidants generated will be injected
into the main ballast water pipe. Oxidant production capacity can be calculated
according to ballast water flow and TRO concentration in the main pipe seawater,
then adjust the rectifier output current to reach the required TRO concentration.

BalClor® system is in standby status until the flow meter measure the flow of ballast
water to start the system. In the process of loading ballast water, seawater firstly
flow through a 50 micron filter unit, and then into the water booster pump. After
pressure increasing, sea water can flow through the cell and the oxidant can be
injected into the main pipe. A flow meter is installed before electrolyzer in EDU to
protect the electrolysis process. If the flow is less than the required flow, EDU will
be shutdown automatically with an audible and visual alarm. During the electrolysis
process, large amounts of active substances and hydrogen will be produced in the
electrolyzer and separated by cyclone separator. After dilution, hydrogen is diluted
by blowers and evacuated to open deck directly through the ventilation ducts, not
entering into the ballast water pipeline or the ballast tank. In order to ensure smooth
flow of air, two redundant blowers are installed to ensure that the content of
hydrogen in the air is lower than the lower explosion level (LEL) after dilution.
PLC controls inspect the blower operation and will automatically shutdown the
system when the malfunction occurs to the blowers. A hydrogen gas sensor is also
installed for safety consideration.

5.2.2 Discharging ballast water process

In the process of discharging, sodium thiosulfate (Na2S2O3) as a neutralizer reacts

with chlorine in the ballast water. During the discharging process, metering pump of
neutralization unit will inject sodium solution into the main ballast pipe to react
with TRO. The TRO analyzer which takes sampling water from the overboard
ballast piping monitors the concentration of TRO in the ballast water discharged to
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ensure that TRO level is lower than discharging requirement.

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6 ALARM AND DATA

Caution: PLC will lock the system when encountering a serious fault. After
troubleshooting, crew must do “acknowledge” action to acknowledge the
alarm.

6.1 Alarm Signal

The following describes the common response of the control system to various
alarm conditions and alarm set points.
CRITICAL ALARM
 RED light and AUDIBLE indication on control console in cargo control room,
local HMI and all other stations where ballast system can be operated
 Associated system icon (pump, filter, electrolysis unit, neutralization unit, fresh
water unit, etc.) on LCD screen
o Color of each equipment in the touch screen changes
 Pump must be stopped
 All valves (within SunRui´s scope) closes within 50 (max) seconds to give the
operator possibility to either stop or bypass.
CLEARING ALARMS
 Press ”MUTE” button on front panel to and stop audible siren . After
troubleshooting, crew must press “acknowledge” to acknowledge the
alarm as shown in Figure 6‐1.
 When all alarms have been handled appropriately, the color of related
alarm information will be changed from red to black automatically as
showed as shown in Figure 6‐1.
NOTE: If one alarm condition is still valid, the color of relevant alarm item remains
red and alarm indicator lamp is blinking even silencing the audible alarm.

Figure 6-1 ALARM screen

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PLC will change alarm register status and transfer to local panel and remote panel
for displaying alarm item information simultaneously when alarm condition is valid.

The acknowledgement rights are arranged by switching “LOCAL/REMOTE”

button on system control cabinet (EQ08).
BYPASS
Bypass valve will always include a manual override in case of power failure of the
system.
LOSS OF POWER
The system can be shut down completely, including the PLC and HMI, through
blackout of the ship or loss of power from the main power supply
Bypass valve can be opened manually in case the system has lost power.

When the system restarts from loss of power, an alarm always signals that the
BalClor BWMS has been completely de-energized. The alarm must be handled as
any other alarm before the system can go to standby mode.
This function is secured through the use of an Uninterrupted Power System (UPS)
or connection to onboard emergency power supply.
SPECIAL CASES
 Sensor faults are critical alarms.
CRITICAL COMPONENTS
Flow meters in the main ballast piping and FT21 in the electrolysis unit EDU
Temperature sensor
TRO meters
Hydrogen Gas Sensor
Chlorine Gas Sensor
Air Pressure Switch
Hydrogen evacuation fans 1 and 2
System control cabinet EQ08
All signals from ship´s interface
NON-CRITICAL COMPONENTS
Salinity meter
Current and voltage meter
ALARM SET POINTS
The alarm set point for BalClor® BWMS are presented in Table 6-1a and Table
6-1b.

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Table 6-1a: System Alarm Set Point List

Location Type

Remote position
Alarm/ Troubleshooti
Alarm Range Unit Action

Non-critical
Failure ng reference

Console

Critical
Refer to Item 1
Main flow meter 110%
X X X 0-10000 m3/h alarm of Table 9-4 in
high TRC**
Section 9.1.5

AFU Refer to Item 2

Main flow meter back-flu of Table 9-4 in
X X X 0-10000 m3/h alarm
low shing Section 9.1.5
flow*
pressure differential Refer to Table
sensor high in the X X X 0~1.0 0.6 Bar Alarm 9-1a/b/c/d in
filtration Section 9.1.1
pressure differential
Alarm is triggered
sensor high-high in X X X 0~1.0 0.8 Bar
with shutdown
the filtration

Refer to Item 2
Pressure sensor high
in the filtration for X X X 0~10 5 bar Alarm of Table 9-1d in
Kanagawa filter
Section 9.1.1

Pressure sensor high Refer to Item 6

X X X 0~10 1.5 bar Alarm
in the electrolysis
of Table 9-2 in
an alarm is

Pressure sensor Section 9.1.2

triggered with
high-high in the X X X 0~10.0 2.0 bar
electrolysis independent shut

down

Salinity meter low Alarm (delay for Refer to Item 3

X X X 0~200 15 PSU
in the electrolysis 10 seconds) of Table 9-2 in

an alarm is Section 9.1.2

Salinity meter
low-low in the X X X 0~200 10 PSU triggered with
electrolysis
shut down(delay

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for 10 seconds)

70% Refer to Item 1

flow meter low in EDU
X X X 0~100 m3/h Alarm of Table 9-2 in
the electrolysis rated
flow** Section 9.1.2
60% an alarm is
flow meter low-low EDU
X X X 0~100 m3/h triggered with
in the electrolysis rated
flow** shut down

an alarm is Refer to Item 5

Temperature sensor
high in the X X X 0~100 50 °C triggered with of Table 9-2 in
electrolysis
shut down Section 9.1.2

Switch to standby Refer to Item 2

blower firstly, an of Table 9-2 in

alarm is triggered Section 9.1.2

with shut down

air Pressure switch
1.2~
low in the X X X 8 mbar (delay for 10
12.4
electrolysis
seconds) if the

alarm signal still

exists after

switching;

an alarm is Refer to Item

level meter low in
X X X 0~500 50 mm triggered with 10 of Table 9-2
the electrolysis
shut down in Section 9.1.2

chlorine sensor high Refer to Item 9

X X X 0~10.0 0.4 ppm alarm
in the electrolysis of Table 9-2 in
chlorine sensor an alarm is Section 9.1.2
high-high in the X X X 0~10.0 0.55 ppm triggered with
electrolysis shut down
hydrogen sensor Refer to Item 7
high above the X X X 0~100% 20% LEL alarm of Table 9-2 in
electrolysis Section 9.1.2
hydrogen sensor an alarm is
high-high above the X X X 0~10.0 60% LEL triggered with
electrolysis shut down

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hydrogen sensor Refer to Item 8

high in the X X X 0~100% 20% LEL alarm of Table 9-2 in
ventilation duct Section 9.1.2
an alarm is
hydrogen sensor
triggered with
high-high in the X X X 0~10.0 60% LEL
independent shut
ventilation duct
down
level meter low in Refer to Item 1
X X X 0~950 150 mm alarm
the neutralization
of Table 9-3 in
an alarm is
level meter low-low Section 9.1.3
X X X 0~950 50 mm triggered with
in the neutralization
shut down

level meter low in Refer to Item 1

X X X 0~1250 150 mm alarm
BPU(if applicable)
of Table 9-3 in
an alarm is
level meter low in Section 9.1.3
X X X 0~1250 50 mm triggered with
BPU(if applicable)
shut down

An alarm is Refer to Item 3

triggered without of Table 9-4 in

shut down if the Section 9.1.5

TRO level is

continuously

higher than 9.0

ppm in one

TRO level sensor calculation

warning high during X X X 0~10.0 9.0 mg/L
ballasting period*** .

An alarm is

triggered with

shut down if the

TRO level is

continuously

higher than 9.0

ppm in two

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continuous

calculation period.

An alarm is Refer to Item 3

triggered with of Table 9-4 in
shut down if the Section 9.1.5
TRO level sensor TRO level is
failure high during X X X 0~10.0 9.5 mg/L continuously
ballasting higher than 9.5
ppm in any
calculation period
***.
an alarm is Refer to Item 5
triggered with of Table 9-4 in
shut down after 4 Section 9.1.5
values of TRO
after
neutralization
above 0.1 ppm,
TRO level sensor
filtering the
failure high X X X 0~10.0 0.1 mg/L
deviation value
during de-ballasting
measurement
from TRO sensor
that is 1.5 times
greater than the
average of the
previous four
measurement.
An alarm is Refer to Item 4
triggered without of Table 9-4 in
shut down if the Section 9.1.5
TRO level is
continuously
lower than 6.5
ppm in one
TRO level sensor
calculation
warning low during X X X 0~10.0 6.5 mg/L
period***.
ballasting
An alarm is
triggered with
shut down if the
TRO level is
continuously
lower than 6.5
ppm in two

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continuous
calculation
periods.
An alarm is Refer to Item 4
triggered with of Table 9-4 in
shut down if the Section 9.1.5
TRO level sensor TRO level is
failure low during X X X 0~10.0 5.0 mg/L continuously
ballasting lower than 5.0
ppm in any
calculation
period***.

an alarm is Refer to Item

Voltage meter high
X X X 0~100 ** V triggered with 11 of Table 9-2
in the electrolysis
shut down in Section 9.1.2

an alarm is Refer to Item 8

Bypass mode X X X - - - triggered with of Table 9-4 in

shut down Section 9.1.5

* Low flow alarm setting value is determined according to back-flushing flow

of AFU models.
** The alarm setting values with ** will vary according to different BWMS
models according to APPENDIX H.
*** The calculation period refers to the maximum interval between the applied
current change and TRO level change in the main piping. The calculation
period is set to 8 minutes from the software version BC.02.00 and afterward.

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Table 6-1b: System Alarm List

Alarm ID Alarm tag Action Description

Emergency stop operation for the an alarm is triggered
F124~F125 Immediate active
system with shut down

an alarm is triggered
F337~F338 HMI communication fault delay for 30 seconds
with shut down

an alarm is triggered
F339 IAS communication fault delay for 30 seconds
with shut down

F030~F053 Remote control Valve position fault alarm delay for 30 seconds

an alarm is triggered
F061 EDU flow meter off line alarm delay for 20 seconds
with shut down

EDU temperature sensor off line an alarm is triggered

F066 delay for 3 seconds
alarm with shut down

an alarm is triggered
F069 H2 sensor off line alarm delay for 3 seconds
with shut down

an alarm is triggered
F075 Main flow meter off line alarm delay for 20 seconds
with shut down

an alarm is triggered

Main power Loss when system with shut down，blower

F129 Immediate active
running keep running 10 min

after 2~45s delay.

F001 spear
an alarm is triggered
F002 spear

F003 EQ05-A_Blower1#_Motor_Fault an alarm is triggered, Motor running signal fault，

both motor fault, shut delay for 2 seconds

F004 EQ05-B_Blower2#_Motor_Fault
down

F005 EQ14-X_Dosing_pump_Motor_Fault an alarm is triggered

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EQ04-X_Booster_Pump_Motor_Faul
F006
t

F007 AFU0X_Forward_Motor_Fault

F008 AFU0X_Reverse_Motor_Fault

EQ09A_Metering_pump_Motor_Faul
F014
t

EQ09B_Metering_pump
F015
_Motor_Fault

F030 EDU0XPV201_Offline Remote valve position limit

F031 EDU0XPV202_Offline an alarm is triggered switch signal fault，delay

F034 ANU_EV30X_Position_Fault for 30 seconds

F061 EDU_Flow_sensor_off_line
Critical Sensor

F075 FT01_Offline
measurement signal

F076 FT41_Offline fault.delay for 20 seconds

an alarm is triggered
F066 EDU_ Temperature sensor_offline
with shut down，
Critical Sensor
F069 EDU01_H2_1#/2# sensor_off line

measurement signal

F070 EDU01_CL2_sensor_off line fault.delay for 3 seconds

Sensor measurement signal

F080 FT02_Offline
fault.delay for 20 seconds

F065 EDU01_Salinity_sensor_off_line

F062~F064 EDU01_X#_cell_sensor_off_line
an alarm is
F067 EDU01_level_instrument_off_line Sensor measurement signal
triggered
F068 EDU01_Pressure_sensor_off_line fault.delay for 3 seconds

F071 AFU01_PS11_Offline

F072 AFU01_PV101_Offline

F073 ANU_LS31_Offline

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F077 spear

F078 spear

F079 AFU_DP_off_line

F084 spear

F085 spear

AC power phase lost or

an alarm is triggered
F129 Motor_Power_Fault！ voltage low alarm. delay for
with shut down
3 seconds

F124 Remote_Emergency_Stop
Emergency stop operation,
Emergency shut down
F125 Local_Emergency_Stop immediate active

F342 CPU Processing Error an alarm is triggered PLC CPU failure alarm,

F341 PLC_Fatal_Error with shut down immediate active

PLC battery quantity low,

F340 PLC_battery_low an alarm is triggered
immediate active

F337 Local HMI communication fault

an alarm is triggered HMI lost communication,

F338 Remote HMI communication fault with shut down delay for 30 second

If available, an alarm is
IAS lost communication,
F339 IAS communication fault triggered with shut
delay for 30 second
down

F127 EDU01_Flow_low_low_Alarm delay for 30 second

an alarm is triggered
F143 EDU01_Wind_pressure_low_alarm delay for 10 second
with shut down，EDU
F135 EDU01_Presure_High_High delay for 3 second
work out of range when
EDU01_PSU_LOW_LOW_Alarm,s
F136 ballasting, system need delay for 60 second
witch to high salinity water.
shut down.
F139 EDU01_Temp. high alarm delay for 3 second

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F140~F142 EDU01_X#cell_high_voltage delay for 3 second

EDU01_H2_1#/2#_High_High_Alar
F145 delay for 3 second
m

F147 EDU01_CL2_High_High_Alarm delay for 3 second

EDU01_Ballast_TRO_High_High_Al
F150 delay 8min
arm,BWMS_shut_down.

EDU01_Ballast_TRO_Low_Low_Al
F155 delay 8min
arm,BWMS_shut_down.

EDU01_Ballast_TRO_High_Alarm_
F157 delay 16min
Long,BWMS_shut_down.

EDU01_Ballast_TRO_Low_Alarm_L
F158 delay 16min
ong,BWMS_shut_down

F160 EDU01_LS21 low alarm delay 2min

F133 EDU01_Flow_low delay for 60 second

F131 EDU01_PMS no enable signal! delay for 20 second

EQ04-1Booster_pump cannot get

F132 delay for 5 second
water, please check valve!

F134 EDU01_Presure_High delay for 3 second

an alarm is triggered，
F137 EDU01_PSU_LOW_Alarm delay for 10 second
EDU work out of range
F144 EDU01_Blower exchange delay for 3 second
when ballasting, system
F146 EDU01_H2_1#/2#_High_Alarm delay for 3 second
need get caution.
F148 EDU01_CL2_High_Alarm delay for 3 second

EDU01_BWT_Ballast_TRO_High_A
F149 delay 8min
larm

EDU01_BWT_Ballast_TRO_Low_A
F154 delay 8min
larm

An alarm is triggered.
F130 ANU_level_low_alarm delay for 10 second
ANU work out of range

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when de-ballasting,

system need get delay 2min

F181 BWT_Discharge_TRO_high_alarm
caution.

F128 ANU_level_low_low_alarm delay for 10 second

an alarm is triggered

with shut down，ANU

work out of range when

BWT_Discharge_TRO_high_alarm,B
de-ballasting, system
F182
WMS_shut_down delay 4 min
need shut down.

F208 Pressure Switch Over Check Period!

Differential pressure sensor Over

F209
Check Period!

Wind pressure switch Over Check

F210
Period!

Conductivity Meter Over Check

F211
Period!
Sensor over check
an alarm is triggered
Temperature Sensor Over Check period,(immediate active.)
F212
Period!

F213 Hydrogen sensor Over Check Period!

F214 Chlorine sensor Over Check Period!

F216 Pressure gauge Over Check Period!

Vacuum & pressure gauge Over

F217
Check Period!

F152 Ballast pump's flow rate High_Alarm Ballast pump's flow rate out

an alarm is triggered of range, delay for 60

F158 Ballast pump's flow rate Low_Alarm
second

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Ballast pump manual

F163 Activating Override mode alarm! an alarm is triggered override alarm,(immediate

active.)

AFU bypass, delay for 3

F185 AFU0X_BYPASS_ALARM
second
an alarm is triggered
Ship Gravity Filling or
Gravity Filling or Discharging with shut down
F189 Discharging, delay for 3
ALARM
second

AFU difference pressure

F190 AFU0X_DP_high_ALARM an alarm is triggered
high, delay for 60 second

AFU difference pressure

an alarm is triggered
F191 AFU0X_DP_high_high_ALARM high high, delay for 60
with shut down
second

an alarm is triggered TRO lost communication,

F224~F227 TR0_#_communication_alarm
with shut down delay for 8 second

an alarm is triggered
TRO analyzer working
F232~F235 TR0_#_sensor_fault with 30 –minute delay
abnormal
before shutdown

F241~F260 REC 1_X #_internal_fault Rectifier module lost

communication or have

an alarm is triggered internal alarm(such as over

F266~F285 REC 1_X#_communication_fault
current etc.).(delay for 3

second)

an alarm is triggered
PT21 or HS21 high high
F126 EDU Independent Shut Down! with independent shut
alarm
down

AFU pressure high, delay

F344 AFU high pressure alarm an alarm is triggered
for 60 second

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6.2 By-pass and emergency shutdown

6.2.1 By-pass alarm and procedure

There is a by-pass for the system or gravity filling of ballast tank, when the by-pass
valve is open or any other situation of ballast water filling or discharge without
treatment, the system will send out sound-light alarm, and then by-pass operation
will be recorded automatically into historical data.

When the by-pass is activated, the system is completely separated from the ballast
system of ship; the crew may implements the suitable emergency over –rides
functions which protect ship and crew. In the state of by-pass, the operation of the
system (BWTS) should be shut down, and the ballast water will be operated in the
pipeline of the ballast system of ship without treatment.

Note: The bypass of the system is strictly prohibited in normal treatment process
unless in case of emergency .The bypass of BalClor BWMS will trigger immediate
shutdown of the system and bypass operation will be automatically recorded in the
alarm event log.

6.2.2 Emergency shutdown alarm and procedure

There is an emergency shutdown button fitted both on the system control cabinet
(EQ08) and remote control box (EQ24), as shown in the Figure 6-2. Pressing this
button will shutdown the operation of the system in case of emergency and will
trigger a emergency shutdown alarm which will be automatically recorded in the
alarm event log.

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Figure 6-2 Emergency shutdown button

6.3 Hydrogen and Chlorine Gas Alarm

When ballasting, the hydrogen gas generated during the electrolytic process has
been separated and diluted to the level below Lower Explosive Limit (LEL) and is
released overboard via air tight pipes. For pre-caution of accidental leakage,
hydrogen gas alarm is provided in the places where it is most possible to accumulate.
In the meantime, a hydrogen sensor will be installed in the ventilation duct with
independent shutdown function to monitor the dilution sufficiency. Meanwhile,
spark arrester is also provided on the discharge end of vent pipe.

Chlorine gas alarm is used to monitor the accidental leakage of electrolyzer.

The technical specifications, alarm points and locations of hydrogen gas alarm is:

Table 6-2 Hydrogen gas alarm

- detection range 0—100%LEL

Specifications - sampling mode diffuser-type
- response time ≤30S

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- Accuracy ±2% F. S.
- explosion proof mode explosion isolated type
- explosion proof marking Ex d IICT6
- service environment temperature: -40℃— +70℃
- humidity: ≤93%RH
- Low alarm: the concentration of hydrogen as in air is up
to 0.8% (V/V), （20%LEL）
Specifications
- High alarm: the concentration of hydrogen gas in air is
up to 2.4%(v/v) （60%LEL）

Chlorine gas alarm: technical specifications, alarm points and locations

Table 6-3 Chlorine gas alarm

- detection principle: electrochemical mode

- measuring range: 0~10ppm

Specifications - Accuracy : ±2% F. S.

- response time: ≤30S
- explosion proof marking Ex iaⅡC T6

- Low alarm: the concentration of chlorine in air is up to

0.4ppm
Specifications
- High alarm: the concentration of chlorine in air is up to
0.55ppm

Locations Located at places 30~60cm above the ground

6.4 Historical Data

LOG REPORT
The log report of the BalClor BWMS is designed to be in compliance with
§162.060-20 (b)& (c) and Section 3.5 of ETV´s Protocol for the Verification of
Ballast Water Treatment Technologies version 5.1 dated September 2010.
The table below lists the requirements in the ETV Protocol, the corresponding
requirements in the §162.060-20 (b) and how BalClor BWMS complies with the
requirements:
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ETV Protocol §162.060-20 (b)& (c) BalClor BWMS

Proper functioning and status of
If no alarm, the system is
all the services needed for the N/A
functioning properly
operation of the BWTS
Automatically monitors and adjusts
All parameters necessary to Parameters monitored:
necessary treatment dosages,
ensure the proper operation of TRO level, flow rate, salinity,
intensities, or other aspects required
the BWTS temperature and pressure
for proper operation
Status of the valves present in Valves status is only logged when
the BWTS, including those N/A their position is not according to
leading to overboard discharge the operation taking place
BWMS measures flow rate and
Total quantity of ballast water
N/A time that can be converted into
treated
volume
Ballast water treatment rates N/A BWMS measures the flow rate
Alarm conditions N/A BWMS logs alarm conditions
Date and time of start and end BWMS logs date and time of start
N/A
of the treatment operation and end of the treatment operation
Ballast operation monitored BWMS log identifies uptake and
N/A
(uptake, discharge) discharge
Records all events in which an alarm BWMS log identifies in the alarm
Calibration and maintenance
is activated for the purposes of list when calibration and
events
cleaning, calibration, or repair maintenance are taking place
Other system events of interest N/A N/A
Relevant and necessary
Incorporates a continuous
measurement information Parameters monitored:
self-monitoring function during the
required for control and TRO level, flow rate, salinity,
period in which the BWMS is in
monitoring operation of the temperature and pressure
operation
BWTS
Meter and sensor accuracy to
measure the suite of parameters
appropriate and necessary for
control of the BWTS,
representing the actual value of
the parameters being monitored N/A N/A
within 10% despite the presence
of contaminants normally
expected in ballast water and the
operational environment of the
BWTS
Diagnostics to enable the local BWMS logs alarms when sensors
N/A
operator to check the and meters give out of range

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ETV Protocol §162.060-20 (b)& (c) BalClor BWMS

functioning of the electrical and values, indicating need for
electronic circuitry, as well as calibration or replacement
the calibration of meters and
sensors according to the
manufacturer´s specifications
Suitable manual by-passes or
An emergency manual override
overrides to protect the safety of the Manual bypass of the system is
function to be used in the event
vessel and personnel in the event of possible
of failure of the control unit
an emergency
Audio and visual alarms and a
Audio and visual alarm signals in all
recording in the event there is
stations from which ballast water
discharge of any effluent or a
operations are controlled in case of In compliance
component failure whenever the
any failure(s) compromising the
control unit is not fully
proper operation of the BWMS
operational
The capability to print reports
and logged data, as applicable,
or stored electronically with
printout capability, upon the
following events:
§162.060-20 (b) In compliance
-the BWTS is started
- the BWTS is stopped
- an alarm condition develops
- normal conditions are restored
- manual override is engaged

BalClor® BWMS is able to automatically record the operational parameters of 3

years. These data can be displayed or printed. (Printing is an option and a printer is
needed).

Whenever the BalClor® BWMS is in operation for purpose of manual cleaning,

calibration, or repair, crew should record those events in Annex G.

BalClor® BWMS’s running parameters are recorded as shown in Figure 6-3a, and
operation and alarm events are recorded as as shown in Figure 6-3b and Figure
6-3c.

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（i）

（ii）
Figure 6-3a Operation parameter record screen

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Figure 6-3b Operation record screen

Figure 6-3c Alarm record screen

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6.4.1 Operation parameter record interface

The control system is able to record all the relevant parameter periodically as well
as the operation and alarm event and occurrence time.

For parameter record screen as shown in Figure 6-3a, all the parameters will be
shown in Page 1#/2#/3#/…. Please refer to table 6-4 for detailed parameter
description of log file.

The data can be navigated by using the following buttons :

‘Page up’- turn to next page of parameter with latter occurrence time
‘Page down’- turn to next page of parameter with former occurrence time
‘Jump to Top’- jump to the top line of the present page;
‘Jump to bottom’- jump to the bottom line of the present page;
‘Latest data’- jump to the page with latest occurrence time;

The data can be manually searched by time according to following procedures,

Enter specific time in the column at the top of the screen and then press the
“Specified Jump” button.

Press ‘BACK’ button and it will go back to the previous interface.

Press ‘OPERATION’ button and it will go operation record interface as shown in

Figure 6-3b.
Press ‘SAVE’ button and the system will immediately save the parameter.

Press the icon and the data will be printed (a printer is needed and connected
to the PLC).
Note: If the printer is not available, the present screen will be captured and saved in
the relevant files in the memory card when pressing this icon.

Table 6-4 Description on parameter code of log file

NO. Code description Unit Remark

1 FT21A/B... Flow in EDU01/02/… m3/h
2 PS21A/B... Pressure in EDU01/02/… Bar
A/B/…
Temperature in
3 TT21A/B... °C represents
EDU01/02/…
EDU01/02/…
4 CM21A/B... Salinity in EDU01/02/… PSU
5 HS21A/B... Hydrogen level in %LEL

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EDU01/02/…
Chlorine level in
6 CS21A/B... ppm
EDU01/02/…
7 LS21A/B... Level in EDU01/02/… mm
Voltage of 1#/2#/…
8 V1/2/…. V
electrolyzer
9 LS31 Level in ANU mm
Main flow of NO.1/2/…
10 FT01/2… m3/h
ballasting system
Opening of filter outlet
11 PV001/2/… %
valve PV001/2/….
TRO level of 1#/2#/…
12 TR01/2/…_BA TRO analyzer during ppm
ballasting
TRO level of 1#/2#/…
13 TR01/2/…_DE TRO analyzer during ppm
de-ballasting
Output current of 1#/2#/…
14 REC1/2/…_A A
rectifier
Output voltage of 1#/2#/…
15 REC1/2/…_V V
rectifier
Differential pressure of
16 AFU01/02/…DP bar
AFU01/02/…
Metering pump flow in
17 ANU1#/2#/… L/h
1#/2#/…ANU
Treated ballast water
18 TBWP m3
volume per ballasting
Total Treated ballast water
19 TBWT m3
volume
Treated de-ballasting water
20 TDWP m3
volume per de-ballasting
Total Treated de-ballasting
21 TDWT m3
water volume
Back-flushing times of
22 AFU01/02/….FP AFU01/02/… per /
ballasting
Total back-flushing times
23 AFU01/02/…FT /
of AFU01/02/…
24 N/S GPS location: North/South N/S N-North,

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S-South,
25 LAT. GPS location: latitude °
E-west,
26 E/W GPS location: East/West E/W
W-west,
27 LONG. GPS location: longitude °
1#/2#/… ballast pump
28 1#/2#/… BP ON/OFF
signal
29 Ship name EAGLE /
30 IMO NO. 7931454 /
31 Type BWMS type: BalClor /
32 Model BC2500 /
33 SN / /
34 NULL Reserved /
NOTE: the component items may vary in accordance with shipboard BWMS
installations.

6.4.2 Operation event record

For operation record screen as shown in Figure 6-3b, all the operation events will be
recorded automatically with operation description and occurrence time.

The data can be navigated by using the following buttons :

‘Cursor Up’- turn to upper line with highlighting color
‘Cursor Down’- turn to lower line with highlighting color

Press ‘BACK’ button and it will go back to the previous interface.

Press ‘SAVE’ button and the system will immediately save the operation event if
available.

Press the icon and the data will be printed (a printer is needed and connected
to the PLC).
Note: If the printer is not available, the present screen will be captured and saved in
the relevant files in the memory card when pressing this icon.

Press ‘Calibration Record’ button and it will go to calibration record interface as

shown in Figure 6-4.

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Figure 6-4 Calibration record screen

In the screen the last calibration check data for relevant measuring devices is shown
in the chart. A visual and audible alarm is triggered when calibration check is
required.
Press ‘RENEW’ button and the check date will be updated to the latest date. It shall
only be pressed after finishing the calibration check.

Press ‘MUTE’ button and it will silence the buzzer.

Press ‘BACK’ button and it will go back to the previous screen.

Press ‘ACTIVE’ button and it will activate a visual alarm.

CAUTION!
The ‘ACTIVE’ button shall be pressed when performing the calibration check or
any maintenance for warning of any unexpected or accidental running of the
system.

6.4.3 Alarm event record interface

For alarm record screen as shown in Figure 6-3c, all the alarm events will be
recorded automatically with alarm event description and occurrence time.
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The data can be navigated by using the following buttons,

‘Cursor Up’- turn to upper line with highlighting color
‘Cursor Down’- turn to lower line with highlighting color

Press ‘BACK’ button and it will go back to the previous interface.

Press ‘SAVE’ button and the system will immediately save the alarm event if
available.
Press ‘Self_Check’ button and it will go through a manual self checking of the
system.
‘ACKNOWLEDGE’ button is functioned as acknowledgement of an alarm as
follows,
- When an alarm is acknowledged, the visual indication shall change. An
indication shall remain if the alarm condition is still active.
- If the acknowledge alarm function is used prior to the audible signal, the
acknowledge may also silence the audible signal.

6.4.4 log file extracting

The operation parameter log file as well as operation and alarm record can be
extracted as an electrical format which can be displayed on the computer, in
addition to observation on the touch screen.
Note: It is suggested to extract the log files in TXT format in case that the extracted
CSV files cannot be recognized on the computer.
Note: Please do not open the extracted TXT file by double clicking the file and it
shall be opened by Microsoft Excel by dragging the TXT file directly into the sheet
area of Microsoft Excel.

6.4.4.1 extracting of operation parameter

The extracting of operation parameter log file is listed in the following procedures,
1) Turn on the power for the touchscreen and plug the USB flash disk into the
USB port of the touch screen.
Note: Make sure that USB flash disk is named in English otherwise the system
cannot recognize.

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2) There is a hidden button on the left-upper corner; click and hold for 3 seconds,
and a window pops out for its inner OS (operation system).

3) Please input ‘A1’ and enter into the inner OS if password is required.

4) Choose the button of ‘DATA MANAGEMENT’ at the top tool bar, choose the
icon of ‘logging information’ for extracting operation parameter log file

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5) The folder list of the memory card in the touchscreen is shown on the screen
and Choose the folder ‘PROJECT1’ and subfolder ‘LOG0001’.

6) Choose all the G2L files by clicking the square icon before the file type G2L
and then click the button “G2L-CSV” or “G2L-TXT” at the bottom for format
conversion from G2L file to CSV or TXT file.
Note: It is recommended to extract file in CSV format. But it is suggested to extract
the log files in TXT format in case that the extracted CSV files cannot be
recognized on the computer. Please do not open the extracted TXT file by double
clicking the file and it shall be opened by Microsoft Excel by dragging the TXT
file directly into the sheet area of Microsoft Excel.

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7) Click “OK” button to execute the conversion and click ‘OK’ button again after
completing the process.

8) Select desired CSV or TXT file, and click ‘COPY’ button. Select your own
flash disk by clicking desired ‘USB drive’ on the left side to enter folder list in
flash disk. Click the ‘Exec.’ Button at the bottom to execute the copy process.

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9) A window pops out and click ‘OK’ button to confirm the operation.

10) A window pops out after completing the copy process and click ‘OK’ button to
confirm the operation.

11) Click ‘X’ icon at the top right corner to quit the inner OS and unplug the flash
disk.

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6.4.4.2 extracting of alarm and operation event

The extracting of alarm and operation event log file is listed in the following
procedures,
1) Turn on the power for the touchscreen and plug the USB flash disk into the
USB port of the touch screen.
Note: Make sure that USB flash disk is named in English otherwise the system
cannot recognize.

2) There is a hidden button on the left-upper corner; click and hold for 3 seconds,
and a window pops out for its inner OS (operation system).

3) Please input ‘A1’ and enter into the inner OS if password is required.

4) Choose the button of ‘DATA MANAGEMENT’ at the top tool bar, Choose
the icon of ‘Alarm information’ for extracting alarm and operation log.

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5) The folder list of the memory card in the touchscreen is shown on the screen
and Choose the folder ‘PROJECT1’.

6) Choose the G2A file named with ‘ALARM RECORD’ or ‘OPERATION

RECORD’ for desired alarm log or operation log by clicking the square icon
before the file type G2A and then click the button “G2A-CSV” or “G2A-TXT”
on the bottom for format conversion from G2A file to CSV or TXT file..
Note: It is recommended to extract file in CSV format. But it is suggested to
extract the log files in TXT format in case that the extracted CSV files cannot
be recognized on the computer. Please do not open the extracted TXT file by
double clicking the file and it shall be opened by Microsoft Excel by dragging
the TXT file directly into the sheet area of Microsoft Excel.

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7) Click “OK” button to execute the conversion and click ‘OK’ button again after
completing the process.

8) Select desired CSV or TXT file, and click ‘COPY’ button. Select your own
flash disk by clicking desired ‘USB drive’ on the left side to enter folder list in
flash disk. Click the ‘Exec.’ Button at the bottom to execute the copy process.

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9) A window pops out and click ‘OK’ button to confirm the operation.

10) A window pops out after completing the copy process and click ‘OK’ button to
confirm the operation.

11) Click ‘X’ icon at the top right corner to quit the inner OS and unplug the flash
disk.

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6.5 Replacement of control and monitoring equipment

Caution: When replace control and monitoring equipment, crew must operate as
follows,
1) Completely stop BWMS, and power off.
2) Open the door of control panel.
3) Open the cover of CF card on the back of HMI.

Figure 6-4: Remove the CF Card

4) Remove the CF card and mark the data on it.

Figure 6-5: Mark the date

5) Remain the CF card available onboard for a minimum of 24 months.

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7 TECHNICAL DESCRIPTION

7.1 Main Components and Operation Conditions

7.1.1 Main components

BalClor® BWMS consists of the following functional modules:

- Automatic self-clean filter

- Electrolytic unit (including electrolyzer and degas unit )

- Rectifier

- Controller

- TRO analyzer

- Neutralizing unit

- Hydrogen / chlorine gas alarm

- Several sensors e.g. flow meters, conductivity sensor, pressure sensor.

7.1.2 Operation conditions

BalClor® BWMS will treat ballast water to the BWDS if operated within the
ranges identified in the table below:

Table 7-1 Working conditions of BalClor® BWMS

Name BalClor® ballast water management system

Type* BC2500
Treatment capacity* 2800m3/h

EDU flow range* 36m3/h

0～90％
Working conditions Relative Humidity range (The equipment installed in the
Engine Room)

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Air condition Salt air (Ocean atmosphere)

Environment temperature: 0～55 ℃

water salinity requirement Fresh/brackish/marine water

AFU operating Pressure

≥1.6 bar
recommendation

EDU feed water

temperature 5～40 ℃
recommendation

EDU feed Water salinity

≥15 PSU
recommendation

Static condition all directions ≤15°

Slope & Swing
Dynamic condition all directions ≤22.5°

Voltage floating ±10%

Instantaneous voltage ±20% (transient Recovery time is

Power supply floating 3 second)
variation Frequency floating ±5 %

Instantaneous frequency ±10 % (transient Recovery time is

floating 3 second)

Compressed air 4~7 bar

Portable water**

Power supply 440V, 60Hz, 3Φ or 380V, 50Hz, 3Φ

Power Consumption Please refer to Annex P

TRO level at the

Set point：7.5 ppm, average dosing range:6.5~9 ppm;
injection port

Holding time in IMO: 24 hour limitation for all the four different filters
ballast tank after
electrolysis USCG: Not applicable for Filtersafe, Luoyang SunRui and Boll
treatment filters, but 24 hour limitation for all the Kanagawa filter.

Straight distance
requirement
between TRO Please refer to Annex D on specific distance requirement for
sampling point and each BWMS models.
oxidant injection
point

* Please refer to Annex H on flow range for main units of different BWMS models.
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7.2 Automatic Back-flushing Filter

The automatic back-flushing filter can effectively remove planktons whose size
exceeds 50µm. Once the differential pressure of the filter screen or the working time
achieves the set value, the system will automatically start back-flushing cycle, and
discharge the planktons that have been filtered out of the filter.

The automatic back-flushing filter is located in the main ballast pipe, at a place that
is downstream of the ballast pump and in front of the ballast tank.

The inlet and outlet of automatic back-flushing filter are both connected to the main
ballast pipe via steel flange, whose specifications are determined based on the
diameter of the main ballast water pipe. Also, the filter has bypasses piping
arrangement to make it easy for repair and maintenance.

The residual planktons filtered out by the flushing valve are discharged directly
overboard.

Four types of filters will be used in BalClor BWMS. The 4 filter assembly are
shown in Figure 7-1a, Figure 7-1b, Figure 7-1c and Figure 7-1d .

1 Inlet 2 Coarse Screen 3 Fine Screen 4 Flushing Valve 5 Hydraulic

piston 6 Flushing chamber 7 Dirt collector 8 Suction nozzle 9 Electric motor
10 Outlet
Figure 7-1a Filtersafe automatic back-flushing filter assembly

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Table 7-2a Parameters of Filtersafe automatic back-flushing filter

Minimum operating pressure 1.6 bar
Maximum operating pressure 10 bar or in compliance with filter
specification
Clean filter pressure loss ≤0.2 bar
Maximum water temperature 60 ℃ or in compliance with filter
specification
Filtration precise 50 micron
Back-flushing duration according to filter specification
Electric motor 380V/440V or in compliance with
shipboard power source
Back-flushing control model pressure difference, time, manually
operation
Flush water consumption(at according to filter models
minimum working pressure)
Filter housing materials carbon steel with anti-corrosion coating
Filter screen materials duplex stainless steel or stainless steel
of high performance on anti corrosion

Figure 7-1b Luoyang Sunrui automatic back-flushing filter assembly

Table 7-2b Parameters of Luoyang Sunrui automatic back-flushing filter
Minimum operating pressure 1.6bar
Maximum operating pressure 10 bar or in compliance with filter
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specification
Clean filter pressure loss ≤0.2 bar
Filtration precise 50 micron
Back-flushing duration according to filter specification
Electric motor 380V/440V or in compliance with
shipboard power source
Back-flushing control model pressure difference, time, manually
operation
Flush water consumption(at according to filter models
minimum working pressure)
Filter housing materials Carbon steel with anti-corrosion coating
Filter screen materials duplex stainless steel or stainless steel
of high performance on anti corrosion

1 Gear motor 2 automatic venting 3 Suspension point 4 Type plate

5 Differential pressure sensor 6 solenoid valve 7 flushing valve 8 measuring
connection 9 Lower section housing 10 measuring connection 11 upper section
connection 12 cover 13 measuring connection
Figure 7-1c Boll&Kirch automatic back-flushing filter assembly
Table 7-2c Parameters of Boll&Kirch automatic back-flushing filter
Minimum operating pressure 1.5 bar
Maximum operating pressure 10 bar or in compliance with filter

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specification
Clean filter pressure loss ≤0.2 bar
Filtration precise 50 micron
Back-flushing duration according to filter specification
Electric motor 380V/440V or in compliance with
shipboard power source
Back-flushing control model pressure difference, time, manually
operation
Flush water consumption(at according to filter models
minimum working pressure)
Filter housing materials cast iron casting or welded steel with
epoxy coating
Filter screen materials duplex stainless steel or stainless steel
of high performance on a corrosion
resistance.

1 body
2 Element holding plate
3 element
4 Element standing plate
5 Back‐wash arm
6 motor

Figure 7-1d Kanagawa automatic back-flushing filter assembly

Table 7-2d Parameters of Kanagawa automatic back-flushing filter
Minimum operating pressure 1.5bar
Maximum operating pressure 5 bar or in compliance with filter
specification
Clean filter pressure loss ≤0.2 bar
Filtration precise 50 micron
Back-flushing duration according to filter specification
Electric motor 380V/440V or in compliance with
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shipboard power source

Back-flushing control model pressure difference, time, manually
operation
Flush water consumption(at according to filter models
minimum working pressure)
Filter housing materials welded steel with anti-corrosion coating
Filter screen materials duplex stainless steel or stainless steel
of high performance on corrosion
resistance.

7.3 Electrolytic Unit

When seawater flows through the electrolyzer, decomposition reactions take place on
the electrode surfaces, with chlorine produced at the anode and hydrogen gas at the
cathode.

The reaction principle is as follows:

Anode: 2Cl- → Cl2 + 2e

Cathode: 2H2O + 2e → 2OH- + H2↑

Chlorine gas can be dissolved in water to produce hypochlorous acid and hydrochloric
acid rapidly:

Cl2 + H2O → HOCl + Cl- + H+

The whole reaction is:

NaCl + H2O → NaOCl + H2↑

7.3.1 Flow chart and arrangement of electrolysis unit

The main working principle of electrolytic unit is shown in Figure 7-2.

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Figure 7-2 Flow diagram of electrolytic unit

A small side stream of water taken after the filtration unit outlet is delivered to
electrolysis unit for generation of oxidants. The electrolyzed water contains sodium
hypochlorite solution of high concentration, and is injected back into the main
ballast pipe.

Since the seawater in the pipe between the outlet of electrolytic cell and the dosing
point contains sodium hypochlorite solution of high concentration, special piping
material shall be applied which is recommended by Sunrui Marine Environment
Engineering Co., Ltd.

Metal isolation valves of remote control type with fail-to-safe function are fitted
between the plastic pipe and metal piping.

As the injected sodium hypochlorite solution needs to mix completely with the
ballast water in the pipe, the injection point should be located at certain distance
away from the TRO sampling port on the ballast pipe.

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7.3.2 Degas unit

PS
From electrolyzer
Wind pressure sensor

To dosing point

Figure 7-3a Degas unit

The degas unit is functioned for the effective separation and safe evacuation of the
hydrogen gas generated by electrolyzer. The degas unit mainly consists of cyclone,
wind pressure sensor and two air blowers.

As shown in Figure 7-3a, the air blowers blow fresh air into the air pipe, and the gas
generated by electrolytic unit has been diluted to the level below Lower Explosive
Limit (LEL), after dilution the gas will be evacuated to the open air. The two air
blowers are fitted for redundancy. If one blower fails in operation, the other one will
start automatically.
The air blower continues to work for 10 minutes after completing ballasting
treatment.
A spark arrestor is fitted on the discharge end of vent pipe.

7.3.2.1 optimized arrangement of degas unit

In the original design, piping has been connected between the cyclone and buffer
tank. The optimized design assembles the cyclone at the top of the buffer tank with
the bottom half of the cyclone immersed in the buffer tank for direct connection
without any piping. Extra space is spared for installation of a bigger buffer tank in
the modified arrangement. The original and optimized arrangement of cyclone and
buffer tank is shown in the Figure 7-3b. A bigger buffer tank and direct connection
will help to maintain more stable level in the cyclone without compromise of
hydrogen separation efficiency.

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Original arrangement Optimized arrangement

Figure 7-3b Original and optimized arrangement of Degas unit

7.4 Rectifier, Controller and power distribution

The rectifier is utilizing high-frequency power technique; the controller is

Programmable Logic Controller.

The rectifier transfers AC current to DC current for the purpose of electrolyzing.

Programmable Logic Controller (PLC) has been programmed the logic for control
and check. It monitors and controls the operational parameters of BalClor® BWMS
and their relevant status, and co-relates the BalClor® BWMS with the ballast water
system of the ship.

When ballasting, PLC controls the TRO concentration by adjusting the current
supplied by rectifier, the adjustment is done based on the signals sent by TRO
analyzer, flow meter and conductivity sensor. The TRO concentration in the main
ballast water pipe is then kept at a level around the set-point value, and between the
alarm range 6.5mg/L ~ 9mg/L.

In case the TRO concentration drops below the given range, the current input is
increased to increase the production of Active Substances by the electrodes.

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In case the TRO concentration increases above the given range, the current input is
decreased to decrease the production of Active Substances by the electrodes.

Main specifications of the controller and rectifier are follows:

- Rated input voltage: AC three-phase AC380V /440V

- Voltage fluctuation range: 342V~418V

- Rated frequency: 50/60Hz±5Hz

- Protection grade: IP44

The main power for BalClor BWMS comes from the ship main power panel. The
power supply of the Rectifier and the Motor control cabinet are AC440V/60Hz or
AC380V/50Hz. The rectifier is used to convert AC into DC and provide the DC
output for the electrolyzer to generate oxidants. The motor control cabinet supply
power for the pumps (such as dosing pump, metering pump and seawater pumps if
applicable), blowers, and any other motors. The system control cabinet power
comes from ship main power panel or Voltage transformer located in the Rectifier.
All control units, valves, TRO sensors and other equipments all share this control
power, as shown in Figure 7-4. For more details, please refer to “Electrical wiring
diagram”.

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Figure 7-4 Power distribution diagram

7.5 TRO Analyzer

Figure 7-5 TRO analyzer

The TRO analyzer is applied to monitor the TRO concentration in the ballast water

During ballasting, the TRO analyzer monitors the TRO concentration after injection
of oxidants, and the measurement is used to adjust the current applied to
electrolyzer to achieve effective disinfection performance.

During discharging, the TRO analyzer monitors the TRO concentration in the
ballast water overboard to ensure that TRO concentration will not exceed the
maximum allowable discharge limit.

Table 7-3 contains the main technical specifications of TRO analyzer, for detailed
technical introduction and operation information of TRO analyzer, please refer to
Annex A: OWNER’S MANUAL of CLX Online Residual Chlorine Monitor.

The technical specifications of TRO analyzer are follows:

Table 7-3 Specifications of TRO analyzer

Measurement Range 0 – 10.00 mg/L

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±5% of reading or ±0.03 mg/L, whichever is greater for range

Accuracy
of 0-6.0 mg/L ±10% of reading from 6.01-10.00 mg/L
Resolution 0.01 mg/L

Cycle Time Adjustable; 60 seconds to 10 minutes (600 seconds)

Display Multi-Line Liquid Crystal Backlit Display

Alarms Two Programmable, 120-240VAC 2A Form C Relay
Analog Output Powered 4-20mA, 600 Ω drive, isolated
Communications Port Bi-directional RS-485 with Modbus
Integral pressure regulator 0.34 bar(5.0 PSI) to 10.3 bar (150
Water Pressure
PSI.)
Flow Rate to Waste 200 – 400 ml/min.
Operating Temperature 0°C – 55°C (32°F – 131°F)
PVC, Borosilicate Glass, Reslyn(FFKM), Viton®(FKM),
Wetted Materials Polypropylene, Stainless Steel, Acetal, Nitrile, Noryl®, Nylon
Sample Temperature
0°C – 55°C (32°F – 131°F)
Range
Power Supply 100 – 240 VAC, 47 – 63 Hz, 150VA
Insulation Rating Double Insulated, Pollution Degree 2, Overvoltage Category II
Environmental Not recommended for outdoor use. Altitude up to 2000 meters
Conditions Up to 95 % RH (non-condensing)
Enclosure Rating Designed to meet IP 66 /NEMA 4X , Fan rated IP 55
Regulatory Compliance CE Approved, ETL listed to UL 61010-1-2004 & ETL
And Certifications Certified to CSA 22.2 No. 61010.1 2nd edition dated July 2004
Shipping Weight 2.5 kg (5.5 lbs.) Reagents Shipped Separately
Shipping Dimensions 520mm X 520 mm X 330mm (20½” X 20½ X 13”)
Warranty 1 Year from date of shipment

7.6 Sampling Facilities

Sampling unit consists of sampling pipe and sampling valve. The layout of the
sampling unit is at the end of the outlet pipe for the discharged ballast water in
compliance with ‘ Guidelines for ballast water sampling (G2)’.

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7.7 Neutralizing Unit

7.7.1 Introduction of Neutralization

Neutralizing unit works when ship is discharging, it is responsible for neutralization

of the TRO remaining in the discharging ballast water. The amount of neutralizer is
controlled and adjusted automatically.

The neutralizing unit is mainly composed of neutralizer tank, metering pump, liquid
level meter, stirrer and corresponding pipelines.

Na2S2O3 solution is used as the neutralizer and its chemical reaction equation with
hypochlorite is shown as follows:

S2O3 2-+ 4ClO- + 2OH- → 4Cl- + 2SO4 2-+ H2O

NaCl and Na2SO4 produced in the neutralization reaction are normally seen in
seawaters, they have no pollution to the sea.

The injection point of the neutralizer should be located in consideration of full

mixing and reaction, and location at the inlet of the ballast pump is preferred.

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Figure 7-6 Neutralization unit

7.7.2 Preparation and storage of neutralizer

Note: Before prepare neutralizer, one operator should wear neoprene or rubber
gloves and other protective clothing, wear safety glasses with face shield or
chemical goggles，and wear respirator.

Note: As the solid Na2S2O3ꞏ5H2O grains are stored in sealed bags, the crew should
check if there is any damage or breakage on the bag of Na2S2O3ꞏ5H2O before
preparation. Damages on the bags may cause long-time contact with the air, and
result in the loss of efficacy of Na2S2O3.

Note: After neutralizer is prepared, the crew must screw down the placket of the
neutralizer tank.

The neutralizer is Na2S2O3 solution, the following is the preparation process:

1) Fill the tank with fresh water to the half level as indicated on the level
meter.

2) Open the lid of dosage inlet on the tank and add sodium thiosulphate grain
into the tank.

Note: The added amount of the sodium thiosulphate is dependent on the total
discharging water volume. The added amount shall satisfy at least one de-ballasting
treatment cycle for whole ballast tanks. The required amount is determined on the
basis of total ballast tank volume and discharging interval after ballasting treatment,
as shown in Table 7-4 and Table 7-5. The recommended Na2S2O3 solution
concentration is determined on the basis of de-ballasting flow rate, max. metering
pump dosing rate in addition to discharging interval after ballasting treatment, as
shown in Table 7-6 and Table 7-7.

3) Continue to fill the tank with fresh water up to the full level as indicated on
the level meter then run the stirrer for at least 20 minutes to prepare
neutralizer solution.

Note: the start/stop button of the stirrer is located on the ANU junction box
(EQ23) at the side of neutralizer tank as shown in Figure 7-6.

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4) Screw down the lid.

Table 7-4 Preparations of neutralizer（24h）

recommended
Estimated required
volume of Total volume of
Amount of solid
neutralizer ballast water
Na2S2O3ꞏ5H2O grain1)
tank
8.3 kg 0.5 m3 1000m3
42 kg 0.5m3 5000m3
83 kg 0.5 m3 10000m3
125 kg 0.5 m3 15000 m3
166 kg 0.5 m3 20000 m3
250 kg 1m3 30000 m3
333 kg 1m3 40000 m3
420 kg 1.5m3 50000 m3
499 kg 1.5m3 60000 m3
582 kg 1.5m3 70000 m3
1) The concentration is determined based on the data that the remaining TRO
concentration in ballast water is 5 mg/L 24 hours after the treatment.

Table 7-5 Preparations of neutralize (120h)

recommended
Estimated required
volume of Total volume of
Amount of solid
neutralizer ballast water
Na2S2O3ꞏ5H2O grain1)
tank
3.3 kg 0.5 m3 1000m3
16.6 kg 0.5m3 5000m3
33 kg 0.5 m3 10000m3
50 kg 0.5 m3 15000 m3
67 kg 0.5 m3 20000 m3
100 kg 0.5 m3 30000 m3
133 kg 0.5 m3 40000 m3
166 kg 0.5 m3 50000 m3
200 kg 1.0 m3 60000 m3

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233 kg 1.0 m3 70000 m3

266 kg 1.0 m3 80000 m3
300 kg 1.0 m3 90000 m3
333 kg 1.0 m3 100000 m3
500 kg 1.5 m3 150000 m3
1) The concentration is determined based on the data that the remaining TRO
concentration is 2 mg/L in ballast water 120 hours after the treatment.
Table 7-6 Recommended Na2S2O3ꞏ5H2O solution preparation
when discharging after 24 hours

Recommended Metering De-ballasting

Na2S2O3ꞏ5H2O solution pump Max. flow
preparation1) capacity (m3/h)
(kg Na2S2O3ꞏ5H2O grain per (L/h)
m3)
100 50 ≤600
150 50 ≤900
200 50 ≤1200
250 50 ≤1500
300 50 ≤1800
350 50 ≤2100
400 50 ≤2400
100 90 ≤1000
150 90 ≤1600
200 90 ≤2100
250 90 ≤2700
300 90 ≤3200
350 90 ≤3700
400 90 ≤4300
1) The concentration is determined based on the data that the remaining TRO
concentration in ballast water is 5 mg/L 24 hours after the treatment.

Table 7-7 Recommended Na2S2O3ꞏ5H2O solution preparation

when discharging after 120 hours
Recommended Metering De-ballasting
Na2S2O3ꞏ5H2O solution pump Max. flow

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preparation1) capacity (m3/h)

(kg Na2S2O3ꞏ5H2O grain per (L/h)
3
m)
100 50 ≤1500
150 50 ≤2200
200 50 ≤3000
250 50 ≤3700
300 50 ≤4500
350 50 ≤5200
400 50 ≤6000
100 90 ≤2700
150 90 ≤4000
200 90 ≤5400
250 90 ≤6700
300 90 ≤8100
350 90 ≤9400
400 90 ≤10500
1) The concentration is determined based on the data that the remaining TRO
concentration is 2 mg/L in ballast water 120 hours after the treatment.

The solid Na2S2O3ꞏ5H2O grains’ storage and handling measures are:

(1) Keep in a tightly closed container, stored in a cool, dry, ventilated area.

(2) Protect against physical damage.

(3) Isolate from incompatible substances.

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7.8 Repair Pieces and Spare Parts

The following list is for the repair pieces and spare parts of BalClor® BWMS

Table 7-6 Repair pieces and spare parts list

No. Items* Specification* Pictures* Unit* Qty. * Remarks

Mechanical spare parts

used for dosing

1 O ring set Stubbe
pump；

Diaphragm Milton
2 Metering pump Pcs.
assembly Roy

check valve used for Milton

3 Pcs.
assembly Metering pump Roy

Liquid
injection used for Milton
4 Pcs.
valve Metering pump Roy
assembly
bottom
used for Milton
5 valve Pcs.
Metering pump Roy
assembly

Oil seal Milton

6 Metering pump Pcs.
bellows Roy

Replacemen
Used for
t HF
7 CLX-XT set
tubing/cuvett Scientific
and CLX-Ex
e kit

Sealing ring Applicable for

8 set
kit AFU

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No. Items* Specification* Pictures* Unit* Qty. * Remarks

Standard Used for
conductivity calibration
9 pack
solution check of salinity
package sensor
Electrical spare parts

G2D-F4B ,
1 Relay Pcs. Pheonix
24VDC

G2R-2-SN,DC2
2 Relay 4V, Pcs. Pheonix
P2RF-08-E

Indicator XB2-B series,

3 Pcs. Schneider
lamp RED, 24VDC;

Indicator XB2-B series ,

4 Pcs. Schneider
lamp RED ,AC220V;
XB2B,GREEN
Indicator
5 , Pcs. Schneider
lamp
24VDC;
XB2B,GREEN
Indicator
6 , Pcs. Schneider
lamp
AC220V;
XB2B,
Indicator
7 WHITE, Pcs. Schneider
lamp
AC220V;

XB2B，
8 Reset button Pcs. Schneider
BLACK 1NO

Two-posiito XB2B metal，

9 Pcs. Schneider
n switch 2NO

Motor
10 GV2-ME07C Pcs. Schneider
breaker

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No. Items* Specification* Pictures* Unit* Qty. * Remarks

Motor
11 GV2-ME05C Pcs. Schneider
breaker

Breaker
12 GV-AE20 Pcs. Schneider
contact

LC1-D09M7C
13 contactor Pcs. Schneider
，220VAC

Breaker
14 LADN20 Pcs. Schneider
contact

Glass，2A，
15 Fuse Pcs.
5*20

Glass，5A，
16 Fuse Pcs.
5*20

Glass，10A，
17 Fuse Pcs.
5*20

18 CF reader USB Pcs.

DC0~50V/4~2
19 Transducer 0mA, Pcs.
24VDC

Voltage
20 RM4 TR32 Pcs. Schneider
relay

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No. Items* Specification* Pictures* Unit* Qty. * Remarks

Terminal
21 ZDU-1.5mm2 Pcs.
block

Terminal
22 ZDU-2.5mm2 Pcs.
block

* The items, specification and quantity will vary according to different BWMS and
the pictures are only for reference.

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8 OPERATION AND CONTROL

Note: The operators should be given a special training course on the BalClor®
BWMS prior to actual operation on the system, so as to understand how the system
works and learn the relevant safety precautions.

Note: The system has local control panel and remote control panel. The remote
control panel of the BalClor® BWMS can be installed for easy access to operate,
such as engine control room or cargo control room. Then local panel installed on
system control cabinet (EQ08) which is in or near EDU. Then local/remote control
can be switched by button labeled “local/remote” on system control cabinet (EQ08).

8.1 General Description

BalClor® BWMS is a automatic system developed and manufactured by Sunrui

Marine Environment Engineering Company. The operator only needs to conduct a
few simple operations on the control panel (Human-Machine Interface) to control
the starting, running and stopping of the system.

The operational control of the system is achieved by Programmable Logic

Controller (PLC). The controller can automatically analyze the operation parameters
of the system and make adjustments accordingly. No operation input is needed for
the internal treatment processes. The parameters and system alarms are presented
visually on the control panel, which makes it very convenient for the operators to
observe the current situation of the system and make prints of the information
displayed on the screen. The control panel can be installed at places as the engine
control room or the cargo control room, as long as it is considered easy for the crew
to operate.

Whenever the system is in operation in automatic or manually mode, controller is

continuously self-monitoring the operation parameters of the system until the
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system has been shut down.

All measuring devices are checked before leaving the factory (with qualification),
which drift and repeatability meet related requirements in their check periods.
Checking procedures for measuring devices are provided by the manufacturer.

8.2 Principles for Control of BalClor® BWMS

BalClor® BWMS is designed for completely automatic operation. In emergency

cases, the system can be manually operated. During automatic operation, the
working condition of every part in this system is automatically monitored. When
emergency occurs, Programmable Logic Controller will send instruction signals to
adjust the working condition of the identified part.

Meanwhile, Programmable Logic Controller will transmit the working parameters

of the equipments and the alarm status to the control panel for observation of the
operator.

Figure 8-1a Ballasting Flow Diagram of BalClor® BWMS in Marine and brackish
waters
The hydrogen sensor is located above the cyclone of the EDU. The salinity sensor
and temperature sensor is located in the EDU.

When ballasting, the control system can maintain the TRO concentration in the

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ballast water main pipe by automatically adjusting the current applied to

electrolyzer, through measuring the amount of flow in the main ballast water pipe
and the TRO concentration of the treated ballast water in the main pipe by the TRO
analyzer.

Figure 8-1b Ballasting Flow Diagram of BalClor® BWMS in fresh water Option 1

Figure 8-1c Ballasting Flow Diagram of BalClor® BWMS in fresh water Option 2
（not applicable）

When ballasting, the main signals sent by TRO control system are listed below:

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Table 8-1 TRO control system signals when ballasting

Sensors Function Location

To measure the TRO Take sampling water from the

concentration in the treated sampling port that is behind the
water in the main pipe injection point of sodium
TRO analyzer
hypochlorite solution, and also on
the main ballast pipe that has not
reached into the ballast tank
To measure the amount of the
After the ballast pump in the main
Flow meter ballast water flow in the main
pipe
pipe

Figure 8-2a De-ballasting Flow Diagram of BalClor® BWMS with TRO Sampling
Option1

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Figure 8-2b De-ballasting Flow Diagram of BalClor® BWMS with TRO Sampling
Option 2

When de-ballasting, the ANU will be started to inject the neutralizer into main
ballast piping to guarantee that the residual TRO concentration of the ballast water
to be discharged is less than 0.1mg/L.

For de-ballasting treatment with TRO sampling option 1, two TRO analyzers are
involved to take sampling water from the sampling port before neutralization and
the discharging port, making sure that the concentration be controlled at a level less
than 0.1mg/L when discharging.

For de-ballasting treatment with TRO sampling option 2, only one TRO analyzer is
involved to take sampling water from the discharging port and monitor the TRO
level before discharging, making sure that the concentration be controlled at a level
less than 0.1mg/L when discharging.

When the discharging ballast water is detected with a concentration level higher
than 0.1mg/L, the controller will give audible and visual alarm.

The following are signals sent to the neutralizing unit:

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Table 8-2a Neutralizing unit signals when discharging for TRO Sampling Option 1

Instrument Function Location

To measure the TRO Take sampling water from

concentration in the ballast the sampling port in the
water to be discharged main pipe that is located as
TRO analyzer
overboard after close to the discharge port
neutralization and before as possible and sampling
neutralization port before neutralization
Liquid level meter in To measure the liquid level
Neutralizer tank
neutralizer tank of neutralizer
A place in the main pipe
To measure the flow of that guarantees the flow
Flow meter
main discharging pipe. meter is always filled with
water.

Table 8-2b Neutralizing unit signals when discharging for TRO Sampling Option 2

Instrument Function Location

To measure the TRO Take sampling water from

concentration in the ballast the sampling port in the
TRO analyzer water to be discharged main pipe that is located as
overboard after close to the discharge port
neutralization as possible.
Liquid level meter in To measure the liquid level
Neutralizer tank
neutralizer tank of neutralizer
A place in the main pipe
To measure the flow of that guarantees the flow
Flow meter
main discharging pipe. meter is always filled with
water.

8.3 Control Panel

Note: Before operating the control panel, the operator should switch the working
mode from emergency operation to control panel operation. If the system is in
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emergency operation, the control panel is locked by default.

Note: The control panel has “lock screen” function. Press the lock/unlock button to
change the locking status.

Note: The control panel has auto/manual operation mode.

Figure 8-3 Control panel

The remote control panel（Human-Machine Interface）can be located at places upon

requests, for example, in the engine control room or cargo control room. The
operator can conduct any operations on the control panel, and observe the operation
status of the whole system.

As presented in Figure 8-3, the control panel can be divided into three areas:
Operation, Alarm and Status, and Task areas respectively. The Operation area is for
BalClor® BWMS operation. Alarm and Operation Status area displays the current
status of the system and alarms.

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The operational data of the system will be automatically stored. The operator can
check or print the historical data anytime (need printer).

The operational interface has “Lock/Unlock screen” function, operations can be

done after unlocking the system.

Table 8-3 Function of “Lock/Unlock screen”

Condition Functions On Functions Off Aim

Lock Observation of Revisions on Lock the touch

parameters; parameters; screen to avoid
mis-operation
Press On/Off button
Checking/printing of
reports;

Unlock Observation of None Normal operation

parameters;
Checking/printing of
reports;
Revisions on parameters;
Press On/Off button

The control panel has two different preferences. Preference I is for manual setting of
parameters. This preference is protected by password. Preference II is for normal
operation, in which no password is needed.

Note: Manual operation is used for first debugging during commissioning stage and
overhauling. Manual control is not permitted in normal operation. Critical system
shutdown alarm logic is still valid even in the manual mode to guarantee the safety,
including hydrogen sensor high-high alarm, chlorine sensor high-high alarm, EDU
flow low-low alarm, air pressure low alarm, EDU temperature sensor high alarm,
EDU pressure high high alarm as well as hydrogen sensor offline alarm, chlorine
sensor offline alarm, EDU flow meter offline alarm and EDU temperature sensor
offline alarm. When recovering from power failure under manual mode, the BWMS
will be restored to normal operation mode. A self-check procedure will be gone
through before resuming operations.

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Table 8-4 Preference

Preference Functions Password

Preference II Automatic operation; No

Preference I Manual operation Yes

Press “MANUAL” button as shown in Figure 8-4a the control panel will pop out as
shown in Figure 8-4b, where the password is required.

a b

Figure 8-4 entering manual operation mode

8.3.1 Remote Control

Only one workstation shall be in control at any one time.

Control shall not be transferred before being acknowledged by the receiving work
station. Transfer of control will give an audible pre-warning.
The main work station is able to take control without acknowledgement, but an
audible warning is given at the work station that relinquishes control. The action for
taking control is not the same as the normal control action.
It is not possible to do alteration of process equipment parameters when transferring
control from one location to another.
An indication is given at each alternative work station, when control is held.

8.4 Automatic Operation When Ballasting

Note: When ballasting, the crews should avoid stay near the air vent of degas pipe
of BalClor® BWMS and the air hole of the ballast tanks for long time.

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Before powering up the system, the system must be checked as follows,

1) Check the compressed air supply and air pressure;
2) Check that the TRO reagent is in valid period;
3) Check the pre-reserved seawater before fresh water treatment;
4) Check the neutralizer preparation before de-ballasting treatment;
5) Power switch on for EQ07 (rectifier), EQ08(system control cabinet),
EQ23(ANU junction box) and EQ25(motor control cabinet).

The following parameter shall be maintained for stable operation of BalClor

BWMS,

No. Parameter Operation range Remark

1 Main water flow*
Water Temperature
2 ≥5℃
in EDU
Water Salinity in
3 ≥15 PSU
EDU
4 Water flow in EDU*
Note: *The operation range will vary according to different BWMS models.

The BalClor BWMS is designed for automatic operation for treatment and a specific
startup and shutdown procedure will be proceeded for automatic operation.

Ballasting process Start-up:

The system is ready to start after click the button “START” when finishing system
check mentioned above. Then it will give a PMS signal. When the PMS permission
signal arrive (within 10s), the main ballast pump can be started by the crew. After
receiving the ballast pump signal, dosing pump will be started after the buffer tank
containing a certain level of water. The amount of the flow-rate of the EDU reaches
the rated flow rate, the rectifier will be started. Then the system is automatically
working. (1~2 min after receiving the ballast pump signal)

Ballasting process Stop:

The system is ready to stop after clicking the button “STOP”. The system will stop
automatically 10 minutes after the ballast pump stops.

(Note: Only the blower in EDU will continue running for extra 10 minutes after
ballast treatment stops according to the requirements in ‘safety evaluation of
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BalClor BWTS’.)

8.4.1 Automatic Operation When Ballasting for marine or brackish water

Figure 8-5a Ballasting process in operation（for marine or brackish water）

When ballasting, BalClor® BWMS works according to the pre-set program. (Note:
The control system of BalClor® BWMS is integrated with IAS via serial line
communication or dry contact signal of the ship, the control panel of the BalClor®
BWMS can be installed for easy access to operate, such as engine control room or
cargo control room.)

1) Before any operations on BalClor® BWMS, relevant hand valves should be

in the right open/close position and system power should be switched on.
Before the system starts, the following items should be checked and
adjusted as shown in Table 8-5a.

Table 8-5a Items to be checked and adjusted when necessary

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No. Description Operation Location

Note: The items required to be checked and adjusted in Table 8-5a will be
identified on the basis of the shipboard BWMS installation..

2) On the control panel of BalClor® BWMS, press the button “AUTO” as

shown in Figure 8-4a，then enter “BALLAST” operation mode as shown in
Figure 8-5a.

Note: The default operation mode is ballasting treatment for marine or

brackish water. An alarm will be triggered with shut down if the PSU is
lower than 15 PSU during treatment for marine or brackish water and the
treatment shall be manually or automatically switched to fresh water
treatment operation as described in Chapter 8.4.2.

3) Press “START” button to start BalClor® BWMS when ballasting. System

will go through self-checking and prepare to start electrolytic process
before ballast pump running. Check “ALARM” screen, and make sure
none of following alarms information is displayed on the screen.

Note: The operation sequence shall be starting BWMS prior to starting the ballast
pump.
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Note: The operator can manually go through self-checking by pressing “self-check”

button as shown in “figure 6-1 alarm screen” when BWMS is not in operation.

- PMS disable

- Filter bypass alarm

- Air pressure low alarm

- Blower switch caution

- H2 sensor offline

- CL2 sensor offline

- EDU flow meter offline

- EDU Salinity sensor offline

- EDU temperature sensor offline

- EDU 1#/ 2#/ … cell voltage sensor offline

- EDU pressure sensor offline

- EDU LS21 offline

- FT01#/ 02#/ … offline

- AFU01/ 02/ … pressure sensor offline

- PV001/ 002/ … offline

- AFU01/ 02/ … motor fault alarm

- Blower 1# motor fault alarm

- Blower 2# motor fault alarm

- EV201 position fault

- EV202 position fault

- Rectifier communication fault

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- TRO analyzer communication fault

- AC Power fault

4) After system finishes self-checking, and no alarm occurs, please start

ballast pump to begin normal ballasting. And BalClor® BWMS will start
ballasting treatment process automatically when receiving ballast pump
running signal.

5) When finishing ballasting, please stop BalClor® BWMS by the steps listed
in Table 8-6a:

Table 8-6a Steps of stopping BalClor® BWMS

Steps Operation Location

1 Press “Stop” button as shown in figure Control panel

8-5a, and BWMS is still working until
ballast pump stops.

2 Stop ballast pump, and BWMS stops Ship ballast system

automatically.
Note: At the end of competition of the ballasting with filtration, it is recommended

to carry out about 10 minutes continuous back-flushing for by clicking the

button on the screen. Afterwards, it is imperative to drain and fill the filter with
fresh water (not salt water) to prevent dirt deposits on the mesh and then hardens.
Running the filter to empty must be avoided in any event.
In case of the disability of conducting fresh water filling in procedure immediately,
it is required to fill in fresh water when practical. A pressurized cleaning is
recommended.
And the interval between filling in of fresh water and completion of ballasting
filtration shall not exceed 12 hours. And pressurized cleaning of filter candles will
be required if beyond this interval.
The fresh water filling in will take about 12~15 minutes (The duration will be
longer for larger size) and no air emission will be detected from the air release valve
outlet at top of the filter after the filter is full with fresh water.

8.4.2 Automatic Operation When Ballasting for fresh water

The treatment shall be manually or automatically switched to fresh water treatment

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operation when vessel voyages in fresh water zones where the water salinity is
lower than 15 PSU. There are two fresh water treatment options for satisfying
salinity requirement for EDU intaking water. Option 1 is that EDU intakes water
from high salinity water source reserved in a seawater holding tank in advance as
shown in the treatment flow diagram in Figure 8.1b. Option 2 is preparing saline
water for EDU by mixing the fresh water with prepared brine as shown in the
treatment flow diagram in Figure 8.1c.

8.4.2.1 Automatic Operation When Ballasting for fresh water Option 1

Note: it is important to check and make sure that there is sufficient amount of
seawater pre reserved in the seawater holding tank before the fresh water treating
process.

Note: The amount of seawater required for the fresh water treating process is
calculated according to BWMS model and fresh water treatment duration.

Figure 8-5b Ballasting process in operationfor fresh water treatment Option 1

When ballasting, BalClor® BWMS works according to the pre-set program. (Note:

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The control system of BalClor® BWMS is integrated with IAS via serial line
communication or dry contact signal of the ship, the control panel of the BalClor®
BWMS can be installed for easy access to operate, such as engine control room or
cargo control room.)

1) Before any operations on BalClor® BWMS, relevant hand valves should be

in the right open/close position and system power should be switched on.
Before the system starts, the following items should be checked and
adjusted as shown in Table 8-5b.

Table 8-5b Items to be checked and adjusted when necessary

No. Description Operation Location

Note: The items required to be checked and adjusted in Table 8-5b will be
identified on the basis of the actual BWMS installation.
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2) On the control panel of BalClor® BWMS, press the button “AUTO” as

shown in Figure 8-4a，then enter “BALLAST” operation mode as shown in
Figure 8-5a,then select the operation mode for fresh water treatment by

clicking the fresh water mode as shown in Figure 8-5b.

Note: The operation sequence shall be starting BWMS prior to starting the ballast
pump.

Note: The default operation mode is ballasting treatment for marine or brackish
water.

3) Press “START” button to start BalClor® BWMS when ballasting. System

will go through self-checking and prepare to start electrolytic process
before ballast pump running. Check “ALARM” screen, and make sure
none of following alarms information is displayed on the screen.

- PMS disable

- Filter bypass alarm

- Wind pressure low alarm

- Blower switch caution

- H2 sensor offline

- Cl2 sensor offline

- EDU flow meter offline

- EDU Salinity sensor offline

- EDU temperature sensor offline

- EDU 1#/ 2#/ … cell voltage sensor offline

- EDU pressure sensor offline

- EDU LS21 offline

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- FT01#/ 02#/ …offline

- FT41# offline

- AFU01/ 02 /… pressure sensor offline

- PV001/ 002/ … offline

- AFU01/ 02/ … motor fault alarm

- Blower 1# motor fault alarm

- Blower 2# motor fault alarm

- EV201 position fault

- EV202 position fault

- Rectifier communication fault

- TRO analyzer communication fault

- AC Power fault

4) After system finishes self-checking, and no alarm occurs, please start

ballast pump to begin normal ballasting. And BalClor® BWMS will start
ballasting process automatically when receiving ballast pump running
signal.

5) When finishing ballasting, please stop BalClor® BWMS by the steps listed
in Table 8-6b:

Table 8-6b Steps of stopping BalClor® BWMS

Steps Operation Location

Press “Stop” button as shown in figure Control panel

1 8-5b, and BWMS is still working until
ballast pump stopping.

2 Stop ballast pump, and BWMS stops Ship ballast system

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automatically.
Note: At the end of competition of the ballasting with filtration, it is recommended

to carry out about 10 minutes continuous back-flushing for by clicking the

button on the screen. Afterwards, it is imperative to drain and fill the filter with
fresh water (not salt water) to prevent dirt deposits on the mesh and then hardens.
Running the filter to empty must be avoided in any event.
In case of the disability of conducting fresh water filling in procedure immediately,
it is required to fill in fresh water when practical. A pressurized cleaning is
recommended.
And the interval between filling in of fresh water and completion of ballasting
filtration shall not exceed 12 hours. And pressurized cleaning of filter candles will
be required if beyond this interval.
The fresh water filling in will take about 12~15 minutes (The duration will be
longer for larger size) and no air emission will be detected from the air release valve
outlet at top of the filter after the filter is full with fresh water.

8.4.2.2 Automatic Operation When Ballasting for fresh water Option 2

Not applicable

8.5 Automatic Operation of De-ballasting

Note: Before de-ballasting, it is important to check the liquid level of the

neutralizing tank to make sure that there are abundant amount of neutralizer in the
neutralization tank.

The neutralizer solution is prepared according to the following procedures.

Step 1: Fill the tank with fresh water to the half level as indicated on the level meter.

Step 2: add sodium thiosulphate grain into the tank. (The added amount of the
sodium thiosulphate is dependent on the ANU models and main flow as well as
de-ballasting interval after ballasting treatment.)

Step3: Continue to fill the tank with fresh water up to the full level as indicated on
the level meter then run the stirrer for at least 20 minutes to prepare neutralizer
solution.

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Note: the start/stop button of the stirrer is located on the ANU junction box (EQ23)
at the side of neutralizer tank as shown in Figure 7-4.

Note: Please refer to the neutralizer preparation instruction plate fitted in ANU for
further details on neutralizer preparation.

There are two TRO sampling options for de-ballasting treatment. Option 1 involves
two tro analyzers for TRO measurement before and after neutralization. Option 2
involves only one analyzer for TRO measurement after neutralization at discharging
port. Both of the sampling options will guarantee that the TRO level will not exceed
0.1 ppm when discharging. Please refer to ANNEX D：Flow Diagram of
BalClor® BWMS (for BC150-BC8000) for detailed information on TRO sampling
options.

The BalClor BWMS is designed for automatic operation for treatment and a specific
startup and shutdown procedure will be proceeded for automatic operation.

De-ballasting process Start-up:

The BWMS system de-ballasting treatment is started immediately (within 10s) after
clicking the button ”START” button on the HMI.

De-Ballasting process Stop:

The BWMS system de-ballasting treatment is ready to stop by clicking the

button ”Stop” button on the HMI and the system stops immediately (within 10s)
after the ballasting pump stops.

8.5.1 Automatic Operation When De-ballasting by Ballast Pump with TRO

sampling Option 1

When discharging ballast water, the control system will operate according to the
following program:

1) Before any operations on de-ballasting process, relevant hand valve should

be in the right open/close position and system power should be switched on.
Before the system starts, the following items should be checked and

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adjusted as shown in Table 8-7a.

Table 8-7a Items to be checked and adjusted when necessary

No. Description Operation Location

Note: The items required to be checked and adjusted in Table 8-7a will be
identified on the basis of the actual BWMS installation.

2) On the control panel of BalClor® BWMS, press the button “AUTO” as

shown in Figure 8-4a，then enter “BALLAST” operation mode accordingly
as shown in Figure 8-5a, then select the operation mode for De-ballasting
treatment by click the button “DEBALLAST” at the bottom and enter
De-ballasting treatment interface as shown in Figure 8-6a and then select
the operation mode for de-ballasting treatment with ballast pump by

clicking the ‘DEBALLAST’ as shown in Figure 8-6a.

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Figure 8-6a De-ballasting process in operation by ballast pump with TRO

sampling option 1

3) Press “START” button to start de-ballasting treatment process of BalClor®

BWMS. System will go through self-checking and start metering pump
before ballast pump running. Check “ALARM” screen, and make sure none
of following alarms information is displayed on the screen.

Note: The operation sequence shall be starting BWMS prior to starting the ballast
pump.

Note: The operator can manually go through self-checking by press “self-check”

button as shown in Figure 6-1“ alarm screen” when BWMS is not in operation.

- Metering pump 1#/ 2# fault alarm

- EV301/ 302/ … ANU position fault alarm

- ANU level low

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- FT01/ 02/ … offline

- ANU LS31 offline

- TRO analyzer communication alarm

4) After system finishes self-checking, and no alarm occurs, please start

ballast pump to begin normal de-ballasting.

5) After finishing de-ballasting process, stop BalClor® BWMS in accordance

with the steps shown in Table 8-8a.

Table 8-8a Steps to stop BalClor® BWMS

Step Operation Location

1 Press “Stop” button on Control panel

“DEBALLAST” screen as figure
8-6a, and BWMS is still working
until ballast pump stops

2 Stop ballast pump, and BWMS stops Ship ballast system

automatically.

8.5.2 Automatic Operation When De-ballasting by Ballast Pump with TRO

sampling Option 2

When discharging ballast water, the control system will operate according to the
following program:

1) Before any operations on de-ballasting process, relevant hand valve should

be in the right open/close position and system power should be switched on.
Before the system starts, the following items should be checked and
adjusted as shown in Table 8-7b.

Table 8-7b Items to be checked and adjusted when necessary

No. Description Operation Location

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No. Description Operation Location

Note: The items required to be checked and adjusted in Table 8-7b will be
identified on the basis of the actual BWMS installation.

2) On the control panel of BalClor® BWMS, press the button “AUTO” as

shown in Figure 8-4a，then enter “BALLAST” operation mode accordingly
as shown in Figure 8-5a, then select the operation mode for De-ballasting
treatment by click the button “DEBALLAST” at the bottom and enter
De-ballasting treatment interface as shown in Figure 8-6a and then select
the operation mode for de-ballasting treatment with ballast pump by

clicking the ‘DEBALLAST’ as shown in Figure 8-6b.

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Figure 8-6b De-ballasting process in operation with TRO sampling Option 2

3) Press “START” button to start de-ballasting treatment process of BalClor®

BWMS. System will go through self-checking and start metering pump
before ballast pump running. Check “ALARM” screen, and make sure none
of following alarms information is displayed on the screen.

Note: The operation sequence shall be starting BWMS prior to starting the ballast
pump.

Note: The operator can manually go through self-checking by press “self-check”

button as shown in Figure 6-1“ alarm screen” when BWMS is not in operation.

- Metering pump 1#/ 2# fault alarm

- EV301/ 302/ … ANU position fault alarm

- ANU level low

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- FT01/ 02/ … offline

- ANU LS31 offline

- TRO analyzer communication alarm

4) After system finishes self-checking, and no alarm occurs, please start

ballast pump to begin normal de-ballasting.

5) After finishing de-ballasting process, stop BalClor® BWMS in accordance

with the steps shown in Table 8-8b.

Table 8-8b Steps to stop BalClor® BWMS

Step Operation Location

1 Press “Stop” button on Control panel

“DEBALLAST” screen as figure 8-6
b, and BWMS is still working until
ballast pump stops

2 Stop ballast pump, and BWMS stops Ship ballast system

automatically.

8.5.3 Automatic Operation When De-ballasting with stripping eductor

When discharging ballast water, the control system will operate according to the
following program:

1) Before any operations on de-ballasting process, relevant hand valve should

be in the right open/close position and system power should be switched on.
Before the system starts, the following items should be checked and
adjusted as shown in Table 8-7c.

Table 8-7c Items to be checked and adjusted when necessary

No. Description Operation Location

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No. Description Operation Location

Note: The items required to be checked and adjusted in Table 8-7b will be
identified on the basis of the actual BWMS installation.

2) On the control panel of BalClor® BWMS, press the button “AUTO” as

shown in Figure 8-4a，then enter “BALLAST” operation mode as shown in
Figure 8-5a, then select the operation mode for De-ballasting treatment by
click the button “DEBALLAST” at the bottom and enter De-ballasting
treatment interface as shown in Figure 8-6b and then select the operation
mode for de-ballasting treatment with ballast pump by clicking the

‘STRIPPING’ as shown in Figure 8-6c or Figure 8-6d.

Figure 8-6c De-ballasting process in operation with Stripping eductor with

TRO measurement

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Figure 8-6d De-ballasting process in operation with Stripping eductor

without TRO measurement
Note: There are two TRO measurement options for stripping treatment,
one with TRO measurement after neutralization as shown in figure 8-6c
and the other without TRO measurement after neutralization as shown in
figure 8-6d.
Note: The de-ballasting treatment for stripping line with no TRO analyzer
shall only be used if the stripping arrangement allows that maximum
suction flow of stripping eductor does not exceed 1000 m3/h as illustrated
in shipboard stripping eductor capacity curve.
CAUTION! The option to include stripping with no TRO monitoring is not
allowed for discharge in US waters, only for the rest of the world (IMO).

3) Press “START” button to start de-ballasting treatment process of BalClor®

BWMS. System will go through self-checking and start metering pump
before stripping educator running. Check “ALARM” screen, and make sure
none of following alarms information is displayed on the screen.

Note: The operation sequence shall be starting BWMS prior to starting the stripping
eductor.
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Note: The operator can manually go through self-checking by press “self-check”

button as shown in Figure 6-1“ alarm screen” when BWMS is not in operation.

- Metering pump 1#/ 2# fault alarm

- EV301/ 302/ … ANU position fault alarm

- ANU level low

- FT01/ 02/ … offline

- ANU LS31 offline

- TRO analyzer communication alarm if applicable

4) After system finishes self-checking, and no alarm occurs, please start

stripping eductor to begin normal de-ballasting.

CAUTION! For the alternative without TRO analyzer, a metering pump failure
alarm (alarm ID F014&F015) implies that the system is operated outside the
approval scope and the operator shall stop stripping operation immediately.

5) After finishing de-ballasting process, stop BalClor® BWMS in accordance

with the steps shown in Table 8-8c.

Table 8-8c Steps to stop BalClor® BWMS

Step Operation Location

1 Press “Stop” button on Control panel

“DEBALLAST” screen as figure
8-6b, and BWMS is still working
until ballast pump stops

2 Stop stripping eductor, and BWMS Ship stripping system

stops automatically.

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8.6 Manual Operation

Note: the operation condition of both manual and automatic modes will be recorded
in historical data.

At normal conditions, BalClor® BWMS operates automatically. The manual

operation is generally for debugging, checking or commissioning, the system should
not be in manual operation for long periods of time. And this mode is required with
password.

CAUTION! The manual operation shall be only conducted by professional

engineers. Entering manual operation without permission may cause severe damage
to the system or personal injuries.

8.7 Water Sampling

Please refer to ‘GUIDELINES FOR BALLAST WATER SAMPLING (G2)’

and ETV Protocol Item 5.3.2 for detailed information on the water sampling
requirements.

8.8 Waste Stream Treatment

The automatic back-flushing filter can effectively remove planktons whose size
exceeds 50µm. Once the differential pressure of the filter screen or the working time
achieves the set value, the system will automatically start back-flushing cycle, and
discharge the planktons that have been filtered out of the filter. The residual planktons
filtered out by the flushing valve are discharged directly overboard through pipes.

Before maintenance the electrolyzing cell, open the drain valve of electrolytic cell,
clean out the residual liquid. The residuals shall be put in containers and mix with
neutralizer, then the neutralized water shall be led into ship sewer.

If the TRO sampling drain is collected in a drain tank before discharging, the water
containing TRO sampling drain shall be neutralized with Na2S2O3 Before
discharging.

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9 MAINTENANCE

9.1 Failure Condition

An alarm is activated when there is a problem, which event will be automatically

recorded, and operation parameters of the system are stored in the same time.

9.1.1 Troubleshooting for filter

Table 9-1a Failure conditions and troubles-shooting procedures of Filtersafe BS

filters

Item Fault Check If Solution

Check Main Switch is

ON;
System does
1 Power Main switch OFF Check Power supply is
not work
available (electricity);
Check Fuses/overload.
Isolation Valve/
not open Open then RESET
Inlet valve
No water
2 those required
flow
Manual Valves to be open are Open then RESET
not open
Initiate Manual
Flushing: (when all
required valves are
open).
Flow rate is Pressure is Low
Increase pressure to
low or Water pressure (usually below
normal:
3 Outlet (inlet) or Line 2.4 bar/35psi),
‐ Water company
pressure is pressure ‐ Pumps
low. ‐ Remote valves
‐ Main Line blocking

Normal Go to next line

Auto mode is Check and service valve,

Flushing Valve
on, but valve is piping, wiring, solenoid,
on auto mode
closed actuator or control
and open
Auto mode off Switch to auto mode

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Item Fault Check If Solution

Initiate Manual
D.P. is high ‐
Flushing.
over 0.4 bar
Check normality of the
(5.8 psi).
drive unit
Check flow rate ‐ if not
excessive (higher than
design flow rate).
Pressure drop
Repeat the above
4 mentioned (Manual
too high
Flush) and if D.P. is high:
1. Check for the
Pressure drop
following:
on Filter ‐
‐ Disconnected or
difference in
leaking
readings of
D.P. remains ‐valve/DP sensor and
pressure
high relevant control tubes
gauge
and replace the
damaged parts.
‐ Disconnected wires
2. Unusual high dirt load
beyond design ‐ call
service. Meanwhile
reduce flow rate.
3. Unusual Blocking of
Filter ‐close isolation
valves, dismantle Filter
and clean Screens.
Flushing Close water entry ‐
dirt on the
5 Valve does Dirty release pressure and
valve’s seat
not close clean.
Auto mode is Check and service valve,
Flushing Flushing Valve
on, but valve is piping, wiring, solenoid,
6 Valve does on auto mode
closed actuator or control
not open and open
Auto mode is off Switch to auto mode
Check that the Limit
Switches are operating
Gear Motor
At extremity of (and replace if Limit
is rotating
travel (left or Switches are faulty):
7 but Drive Drive Screw
right) and Drive 1. Press on Limit Switch
Shaft is not
Pin is in place and see if it activates.
advancing
2. Verify they are
properly positioned.
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Item Fault Check If Solution

3. Look for wiring

problem
increase the filter outlet
Flushing Dirt load is high pressure and Run
8 cycles are too Raw water or very soft and continuous manual
frequent* “ sticky” back‐flushing , and/or
reduce the flow

* Too frequent flushing cycles refers to the situation that the DP signal is
continuously on throughout 20 continuous flushing cycle and an alarm is triggered.
Table 9-1b Failure conditions and troubles-shooting procedures of Luoyang Sunrui
SRF filters

Item Problem Check If Solution

System Check Main Switch is on

Indicator light is
1 fails to Power Check power‐supply system
off
start Check Fuses
Gauge
2 pressure is Root Valve Not open Open root valve
zero
Flushing Auto mode is off Switch to auto mode
Valve does Flushing Check the valve, wiring,
3
not open Valve Auto mode is on piping, control system, air
or close source
Gear
Motor Gear Power system is Reset the system
4
does not Motor/Power ok Check wiring, control system
work
Outlet Increase the flow rate
Flow rate is less
5 Pressure is Flow rate Check pumps
than rated flow
low Check related valves
The pressure
difference
Outlet flow between inlet Check the wiring of DP
is Inlet and and outlet is switch and make sure that
6
abnormally outlet gauge above 0.4 bar the two wire is well
low and no connected.
backflushing is
triggered
7 Differential Gear Motor Gear Motor does Go to Item 4
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Item Problem Check If Solution

Pressure is and Drive not work

too high Shaft Normal Go to next line
Valve cannot
open or close
Go to Item 3
Flushing while on auto
Valve mode
Valve is on
Switch to auto mode
manual mode
Reduce flow rate if excessive
Reset the system
Normal Switch to manual mode and
Differential set system continuous
Pressure flushing
Switches Check power‐supply system,
wiring, control system, and
Does not work
replace the Differential
Pressure Switches
Flow rate is
Flushing
greater than Reduce the flow rate
frequency Flow
rated flow
8 is too rate/Inlet
Switch to manual mode and
water
high* Dirt load is high run system continuous
flushing

* Too frequent flushing cycles refers to the situation that the DP signal is
continuously on throughout 20 continuous flushing cycle and an DP high alarm is
triggered.
Table 9-1c Failure conditions and troubles-shooting procedures of Boll & Kirch
6.18.3 filters

Item Fault Possible cause Remedy

High level of soiling in the Determine the cause of

medium soiling in the plant
Increase the filter outlet
Flushing performed
1 pressure and run manual
often*
Filter elements blocked back‐flushing and/or
Change /clean the filter
elements
The gear motor Open the filter and remove
2 Flushing arm blocked
does not turn the cause of the blockage
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Item Fault Possible cause Remedy

No power supply Check the power supply

Controller is set Correct the setting or
incorrectly or is faulty replace the controller
1 reduce the flow for
lower dirt load and
increase filter outlet
pressure;
Filter elements blocked
2 Change / clean the filter
elements if needed;
Differential 3 contact with sunrui if DP
3 pressure will not remains high.
reduce The pressure downstream
of the filter is too low or Set the pressure, increase
the backflushing quantity the backflushing quantity
is too low
Flushing valve does not Check function / clean /
open replace
Shut‐off valves in control
Open shut‐off valves
line closed
No differential
4 Check/replace the
pressure indicator Differential pressure
differential pressure
monitoring system faulty
monitoring system
Filter with pneumatically / hydraulically actuated flushing valve
Shut‐off valve in the
Open shut‐off valve
supply line closed
The solenoid valve
5 Control pressure too low Check / set the pressure
does not activate
Controller is set Correct the setting or
incorrectly or is faulty replace the controller
* Flushing performed often refers to the situation that the DP value > 0.2 bar
always or a DP high alarm is triggered.
Table 9-1d Failure conditions and troubles-shooting procedures of Kanagawa KBW
filters

Item Fault Check Solution

Increasing of Step 1: continue high flow

differential back flushing and increase
pressure does The state of the the filter pressure
1
not Element clogging preferably higher around
stop(Exceeding 2.0~2.5bar ,
set value of Step 2:keep the high filter
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Item Fault Check Solution

high flow pressure, reduce the

back‐flushing
filtration flow* and
0.38 bar )
continue high flow
back‐flushing if the
differential pressure does
not go down after
increasing the filter
pressure in Step 1;
The element shall be
manually cleaned if the
differential pressure does
not go down after
increasing the filter
The state of the
pressure and reducing the
Element clogging
flow in Step 1 and Step 2.
Refer to Section 4‐3‐2 of
‘KBW instruction manual’
on the Clean the element
procedures.

The rotating condition

of the Driving Ref. to ITEM 3
Mechanism

①Check the main ballast

piping and make sure all the
relevant valves are opened
Increasing of
and no blockage in the main
differential Check the inlet and
2 ballast piping.
pressure does outlet piping
not stop ② check the differential
pressure and refer to ITEM
1.

Check the Motor ①Check the Electric wires

Driving operation ②Replacing the Motor part
Mechanism
3
does not ①Back washing arm Over
rotate Check the Back hauling
washing arm
②Check the sliding surface
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Item Fault Check Solution

Seawater from
the Auto Air Close the Master valve(V3)
Check the Auto Air
4 vent valve then Overhaul the Auto air
vent valve（V2）
does not stop vent valve(V2)
draining

*Adjust the filtration flow by adjusting the regulating valve at the filter outlet until
the differential pressure does not increase.
Note:
Please refer to Annex C.1: Operator’s Manual for BS-Series Models for further
details on troubleshooting and maintenance of Filtersafe Filters.
Please refer to Annex C.2: Operation Manual for SRF Series Automatic
Back-flushing Filter for further details on troubleshooting and maintenance of
Luoyang Sunrui Filters.
Please refer to Annex C.3: Operation instructions for automatic filter for further
details on maintenance of Boll & Kirch Filters.
Note: Please refer to Annex C.4: KBW instruction manual for further details on
troubleshooting and maintenance of Kanagawa Filters.

9.1.2 Failure conditions of Electrolytic unit

Note: When critical alarm occur to EDU and system shutdown, the crew shall stop
the ballast pump and stop ballasting.
Table 9-2 Failure conditions and troubles-shooting procedures of Electrolytic unit

Item Failure condition Cause and location Trouble-shooting guide

Relevant valves do not open 1. check and open all relevant
or fully open before, in or valves and fully open the
Low inlet flow alarm
after EDU. regulating valve in EDU .
and low Low inlet
Check and replace the flow
1 flow to electrolytic EDU flow meter failure
meter if needed
unit with system
Check and repair/replace the
shutdown seawater booster pump (if
seawater booster pump if
applicable) failure
needed
low air pressure Check and replace the
2 Blower failure.
alarm or low air damaged part of blower

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Item Failure condition Cause and location Trouble-shooting guide

pressure with system Check/replace Wind pressure
Wind pressure switch failure.
shutdown switch

The duct is clogged. Check and clean the duct.

Change to water source with

EDU source water salinity
Salinity low alarm higher salinity with fresh
low
and Salinity low low water treatment mode
3
alarm with system Check and recalibrate the
shutdown Salinity meter failure salinity meter, and replace
the salinity meter if needed
consecutive
unreliable salinity Check and recalibrate the
Salinity meter measurement
4 measurements ,e.g. salinity meter, and replace the
abnormality
salinity extremely salinity meter if needed
high or low
Connect to incorrect water Check the EDU water source
source connection
Temperature high
Check and recalibrate the
5 alarm with system
temperature sensor, and
shutdown Temperature sensor failure
replace the temperature
sensor if needed
Check and open all the
relevant valve does not open relevant valves in water
Pressure high alarm
piping.
and Pressure high
6 Check and recalibrate the
high alarm with
pressure transmitter, and
system shutdown Pressure transmitter failure
replace the pressure
transmitter if needed
Check the air duct leakage
and flange connection in
Air duct leakage
Hydrogen level high air duct , and fasten all the
7
(above EDU) bolts in the air duct.
Check and recalibrate the
Hydrogen sensor failure
hydrogen sensor, and

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Item Failure condition Cause and location Trouble-shooting guide

replace the hydrogen
sensor if needed
Insufficient capacity of Check and use the standby
blower blower for dilution
Hydrogen level high Check and recalibrate the
8
(in ventilation duct) hydrogen sensor, and
Hydrogen sensor failure
replace the hydrogen
sensor if needed
Check and recalibrate the
hydrogen sensor, and
Water leakage
replace the hydrogen
sensor if needed
9 Chlorine level high
Check and recalibrate the
chlorine sensor, and
Chlorine sensor failure
replace the chlorine sensor
if needed
Too much capacity margin of Increase the backpressure at
dosing pump dosing pump outlet piping
Visual check local level
Water level low in
10 indication of the level meter.
the buffer tank
level meter failure Re-calibrate the level meter if
needed. Replace the flow
meter if needed.
Flush the electrolyzer with
Too much deposit on the
fresh water to clean the
electrode surface in
DC voltage high electrodes following the
electrolyzer
11 across the procedures in Section 9.3.2.
electrolyzer Check the voltage meter and
Voltage meter failure replace the meter if
needed.

The breaker of the controller switch on the internal air

The system can’t
12 has not been switched on. switch of the controller.
start.
Power line failure. Inspect the power line.

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Item Failure condition Cause and location Trouble-shooting guide

The fuse of the controller Inspect and replace the fuse
has been fused. of the controller.

3 phase power is switched off switch on the power

1)check the power line

13 motor power fault voltage or exchange the
3 phase power voltage low phase of power line
/high or line phase fault
2)check the variation of
power supply

9.1.3 Failure conditions of Neutralizing unit

Note: When critical alarm occur to EDU and system shutdown, the crew shall stop
the ballast pump and stop ballasting.
Table 9-3 Failure conditions and troubles-shooting procedures of Neutralizing unit

Item Failure condition Cause and location Trouble-shooting guide

no sufficient neutralizer Prepare new neutralizer
solution in the tank solution.
Visual check local level
Water level low in
1 indication of the level meter.
neutralizer tank
level meter failure Re-calibrate the level meter if
needed. Replace the flow
meter if needed.

9.1.4 Troubleshooting for TRO analyzer

Please refer to section 9 of “OWNER’S MANUAL of CLX-XT Online Residual

Chlorine Monitor (TRO)” as Annex A for detailed information on troubleshooting
of TRO analyzers.

9.1.5 Troubleshooting for BWMS

Table 9-4 Failure conditions and troubles-shooting procedures of BWMS

Item Failure condition Cause and location Trouble-shooting guide

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Item Failure condition Cause and location Trouble-shooting guide

Slowly close pump outlet valve
Too much Ballast pump
and/or reduce the ballast pump
capacity margin
Main flow High motor frequency if applicable
1
alarm Check the AFU outlet
AFU outlet regulating valve
regulating valve and repair the
failure
valve if necessary
Check all the valves after
relevant valve does not
ballast pump outlet and fully
open
open the valves if needed
2 Main flow low alarm
Refer to chapter 9.1.1 for
Filter clogging trouble shooting of filter
clogging
check the TRO sensor and carry
out a calibration check of the
High TRO level TRO analyzer failure. TRO analyzer if needed.
alarm and High TRO Replace the damaged parts of
3 level with system TRO analyzer if needed.
shutdown during
increase the main flow to
ballasting
Main flow is too low. reduce the TRO level if the
TRO analyzer works smoothly.

Check the valid period of TRO

TRO analyzer reagent
reagent and replace with new
expires.
TRO reagent if needed.
Low TRO level Check the TRO sensor and
alarm and low TRO carry out a calibration check of
4 level with system TRO analyzer failure. the TRO analyzer if needed.
shutdown during Replace the damaged part of
ballasting TRO analyzer if needed.
Decrease the main flow to
Main flow too high increase the TRO level if the
TRO analyzer works smoothly.
High TRO level with Neutralizer dosing piping Check the piping and repair the
5
shutdown during leakage leakage.
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Item Failure condition Cause and location Trouble-shooting guide

de-ballasting Check and replace the damaged
parts of metering pump if
Metering pump failure
needed.

Prepare new neutralizer

Neutralizer solution expires
solution of higher
or loses efficacy.
concentration.
Check the TRO sensor and
carry out a calibration check of
TRO analyzer failure. the TRO analyzer if needed.
Replace the damaged part of
TRO analyzer if needed.
Decrease the main flow for
Main flow too high sufficient reaction with
remaining TRO.
consecutive
unreliable TRO level
measurements ,e.g. TRO analyzer measurement carry out the prime operation
6
TRO level extremely abnormality for TRO analyzers
higher than 10 ppm
during ballasting
Activate manual mode to
enable troubleshooting for TRO
No TRO reading TRO analyzer measurement
7 analyzer, referring to Chapter 9
during treatment abnormality
of Annex A for troubleshooting
for TRO analyzer.
Close the bypass valve and
Bypass alarm with Bypass valve incorrectly check the position indicator if
8
system shutdown open the valve open signal remains
after the valve is fully closed.
Circuit breaker or internal Reset the faulted power module
Rectifier
9 parts in Rectifier power and replace with new power
communication fault
module fault or failure module if trouble still occurs.

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9.2 Malfunction of BWMS

The BalClor® BWMS alarms if there are malfunctions when ballasting, and the
ballast pump will stop. After check and maintenance, if the malfunction can’t be
solved, the other BalClor® BWMS will start and treat the ballast.

If there are malfunctions of the BalClor® BWMS, and the ballast pump doesn’t stop
working, and the condition is discovered after ballasting or in ballasting process, the
ballast water should be treated as the following conditions:

If there are some emergency happened, ballast water changing will affect the safety
or steady of the ship, danger the crew or passengers. All measures were taken, but
the ballast water must be discharged. At this condition, the captain can decide to
discharge the ballast water.

All the condition, cause and measures should be recorded.

9.3 Maintenance and Inspection Program

Note: Before system maintenance, please make sure that the system is power-off.

Daily Inspection

- Check the piping for the potential leakage.

- Check for the external visual damage of all the components.

- Check the screen of the strainer after each ballasting treatment process and
clean the screen if necessary.

- Monthly Inspection

- Check the wiring connection.

- Check all the fasteners and fasten the loosen part

The Designs of SunRui BalClor® BWMS ensure all working parts of the BWMS
liable to wear or damage easily accessible for replacement and maintenance. The
equipment provided by SunRui has been considered in proper arrangement of
maintenance space.

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9.3.1 Maintenance of automatic back-flushing filter

For all the filters, it is recommended that the filter is cleaned and emptied when it is
not used for more than 1 month. It is recommended that the filter screen is manually
cleaned annually.

For detailed information on the maintenance of Filtersafe filter, please refer to

ANNEX C.1：Operator’s Manual for BS-Series Models (Filtersafe).

For detailed information on the maintenance of Luoyang Sunrui filter please refer to
ANNEX C.2：Operation Manual for SRF Series Automatic Back-flushing Filter
(Luoyang Sunrui).

For detailed information on the maintenance of bollfilter, please refer to ANNEX

C.3：Operation instructions for automatic filter (Bollfilter).

9.3.2 Maintenance of electrolyzer

Note: the electrolyzer is designed for free of maintenance, BalClor® BWMS

electrolyzer must be maintained by professional engineers from Qingdao Sunrui,
please do not disassembly or change the electrolyzer without permission.

It is required to make sure that the electrolyzer be filled with clean water after every
ballasting treatment operation. If the electrolyzer is in operation for every 4 weeks
or out of operation for more than 2 weeks, the flushing maintenance with clean
fresh water shall be conducted after the ballasting treatment. The flushing duration
is preferably above 10 minutes.

To perform the flushing maintenance, open the valve of the fresh water piping line
of the EDU and Electrolyzer drain valve and close the valve after the electrolzyer to
ensure the clean fresh water flushing through the electrolyzer. After the flushing,
switch all the relevant valves to the original position.

9.3.3 Maintenance and calibration of TRO analyzer

1) Routine Maintenance of TRO analyzer

Note: Before maintenance, personal protection shall be carried out. Open the outlet
of TRO analyzer, and let out the residual liquid.
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Note: TRO analyzer manual is written according to continuous operation conditions.

In actual usage, the operation time can be prolonged according to the actual sailing
condition of the particular ship so as to prolong the interval between maintenances.

Take example of one month per voyage, the TRO analyzer maintenance cycle will
be:

Table 9-5 TRO analyzer maintenance

Cycle Maintenance
1. The indicator reagent required for operating this instrument must be
changed at least every 90 days. The buffer reagent can be used up to one
year.
Every 90 days 2. The internal strainer should be checked and cleaned if necessary.
3. The glass cuvette should be inspected. Check for excessive debris on the
inside surface of the glass. It is suggested to keep a spare cuvette to replace
when required. The old cuvette may be cleaned, if possible, for future
replacement.
1 year 1. Both pump tubes should be replaced annually.

The indicator reagent is prepared as follows,

Remove the cap and add the contents of the DPD powder bottle (small brown bottle)
into the indicator bottle. Cap tightly and shake vigorously to fully dissolve the
powder.

The interval between maintenances can be adjusted according to ship actual

operation practice.

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For detailed information on the maintenance, please refer to “OWNER’S MANUAL of

CLX‐XT Online Residual Chlorine Monitor (TRO)” as Annex A.

2） troubleshooting

Please refer to section 9 of “OWNER’S MANUAL of CLX‐XT OnLine Residual Chlorine

Monitor (TRO)” as Annex A for detailed information on troubleshooting.

3) Calibration of TRO analyzer

The instrument was tested prior to leaving the factory. Since it operates from a
pre-determined calibration curve, no calibration is required.

Calibration can easily be performed if required. The method is by comparison

against another instrument, such as a laboratory or hand held photometer (such as
HF scientific’s Chlorine Pocket Photometer). There are two points of calibration.
The slope or gain and the zero (offset). To perform the zero the instrument must be
plumbed to a sample of known chlorine free water such as de-ionized water for a
zero adjustment. There are following procedures to be employed：

- Slope (gain) Calibration Procedure

- Zero (offset) Calibration Procedure

Restore Factory Settings

Please refer to Section 6 -7 in OWNER’S MANUAL of CLX-XT OnLine Residual

Chlorine Monitor (TRO) as Annex A of SunRui BWMS Manual for detail
information.

9.3.4 Maintenance of flow meter

No special maintenance work is required.

- Exterior cleaning
When cleaning the exterior of measuring devices, always use cleaning agents that do
not attack the surface of the housing and the seals.
- Seals
The seals of the flow meter sensor must be replaced periodically, particularly in the
case of gasket seals (aseptic version).
The period between changes depends on the frequency of cleaning cycles, the

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cleaning temperature and the fluid temperature.

For detailed information on the maintenance of flow meter, please refer to ‘Operation
instructions of flow meter’.

9.3.5 Maintenance of rectifier and controller

The periodic maintenance of rectifier and controller is:

Table 9-6 Rectifier and controller maintenance

Cycle Maintenance
monthly Visual inspection, check for the connections of wires.

9.3.6 Metering pump

1) Daily maintenance
Initially, change the oil in the pump drive assembly after the first 1000 hours of
operation. Thereafter, change the drive oil on an annual basis or after every 5000
hours of operation.
The drive should be refilled with 650 ml of Mobil gear 600 XP 220:
Viscosity @ 40℃ = 209 cSt
Viscosity Index = 95
ISO Grade = 220
Diaphragm Assembly
The diaphragm should be replaced annually or every 5000 hours of operation to
avoid the possibility of failure. Refer to the instructions in Section Diaphragm and
Oil Seal Bellows Replacement.
Oil Seal Bellows
The seal bellows should also be replaced annually. Oil seal bellows replacement
requires the removal of the diaphragm assembly, so it is recommended that the oil
seal and diaphragm assembly be replaced at the same time. Refer to the instructions
in Section Diaphragm and Oil Seal Bellows Replacement.
Check Valves
As in the case of the diaphragm, it is recommended that check valve balls, seats,
gaskets, and O-rings be replaced on an annual basis or every 5000 hours of
operation. If highly corrosive material (acids, slurries, etc.) is being pumped, more
frequent replacement may be required.

2) Corrective maintenance
Before carrying out any servicing operation on the pump or piping,
Caution! disconnect electrical power from the pump. Be sure that there is no
fluid pressure in the liquid end and piping.

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Cleaning Fouled Check Valves

Check valve assemblies are designed to be self-cleaning and should seldom need
servicing. Fouled check valves can usually be cleaned by pumping a solution of
mild detergent and warm water (if compatible with liquid being pumped) for 15
minutes, followed by flushing with water.
Check Valve Replacement
Before beginning work on the valve assemblies, make sure the suction and
discharge shut-off valves are closed and that pressure has been bled from the pump
liquid end. When replacing the valves, be sure to replace the valve O-rings. Pay
close attention to the proper assembly and orientation of the check valves as shown
in each Liquid End figure. In the case of plastic check valves for liquid end size
SD7 and SD8, be certain that the ball is placed on the sharp edge of the valve seat.
Be sure to follow instructions carefully and refer to the appropriate
Caution! figure when reassembling check valves. If check valve cartridges are
installed incorrectly, one of the following will occure:
1) Immediate and severe damage to pump will occur.
2) No pumping of fluids.
3) Reverse pumping action (fro discharge line into suction line).
Preliminary Operations
1) Set the pump capacity knob to 0%. If stroke locking screw was previously
tightened, slightly loosen the locking screw.
2) Disconnect power to pump motor. Check that the equipment cannot be
accidentally started. Place a notice at the location of the power switch indicating
that the pump is being serviced.
3) Disconnect the pump hydraulically by removing pipe or tubing connections to
suction and discharge check valves.
Check Valve Assemblies Replacement (see figure 9 or 12)

Caution! Improper ball and seat installation can cause damage to the pump. See
figure 9 or 12 for proper ball and seat orientation for both the suction
and discharge valves.
Do not apply PTFE tape to the threads of check valve body that screws into the head,
as this may prevent adequate squeeze from being applied to the valve o-ring
which could result in leakage.
1) Unscrew the valve body (360) from the pump head (370).
2) Remove the cartridge valve assembly: cartridge includes ball (357), seat
(360A), ball guide (361A), O-ring (361B), and washer (361).
3) Clean the valve body (360) and threaded port in the head (370).
4) Press a new washer (361) into valve body (360).
5) Install new check valve assembly in orientation shown.
On discharge side, drop cartridge assembly into threaded port in head. The O-ring
should be stretched around outside of cartridge on same end as ball seat. Screw
valve body into discharge side of diaphragm head until valve is hand tight. DO
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NOT OVERTIGHTEN.
On suction side, drop the cartridge assembly into check valve body. The O-ring
should be stretched around outside of cartridge on opposite end of ball seat. Screw
the suction valve body with cartridge valve into suction side of head. DO NOT
OVERTIGHTEN.
Diaphragm Replacement
Before beginning diaphragm replacement, make sure that all shutoff
Caution!
valves are closed and all pressure is bled from the liquid end.
If failure of the oil seal bellows has occurred, it is recommended that
the diaphragm assembly and oil seal bellows be replaced at the same
time.
Diaphragm Replacement: (see figures 9, 10, 12, 13 and 14 of manual)
1) Loosen the head screws (Item 103 in Figure 9&12) and remove the diaphragm
head (Item 370 in Figure 9&12). Mark the suction and discharge ports on the
diaphragm head prior to removal.
2) Remove the motor fan cover and turn the motor by hand while adjusting the
capacity control knob to 100%. With the capacity set at 100%, turn the motor fan
until the diaphragm is in the full forward position (top dead center).
3) Hold the outer edge of the diaphragm and turn it counterclockwise to unscrew
it from the pump drive.
4) Discard and replace with new diaphragm. Make sure that diaphragm support
ring (Item 700A in Figure 9) is in place. Holding the edges of the diaphragm, screw
the diaphragm assembly onto the male thread of the connecting rod (Item 60 in
Figure 7) until it reaches its mechanical stop.
5) With the capacity still set at 100% turn the motor fan until the new diaphragm
is in the farthest rearward position (bottom dead center).
6) Reattach the diaphragm head with the suction and discharge ports in the correct
positions. Tighten the screws in a crosswise pattern to a torque of 45 in-lb.
7) While turning the motor fan, set the stroke adjustment knob to the 0% position.
8) Reinstall motor fan cover.
Oil Seal Bellows Replacement
Before beginning oil seal replacement, make sure all shut-off valves
Caution! are closed and all pressure has been bled from the liquid end (pump
head). When replacing the oil seal, the diaphragm assembly must be
removed first. For ease of service, it is recommended that the oil seal
be replaced in conjunction with the diaphragm assembly.
1) Set the stroke adjusting knob to 100%.
2) Disconnect the suction and discharge connections to the pump head check
valves.
3) Mark the suction and discharge ports on the diaphragm head prior to removal.
Loosen the head screws (or bolts) (Item 103 in Figure 13 or Item 435 in Figure 17)
and remove the diaphragm head (Item 370 in Figure 13).
4) Adjust the capacity control knob to 100%, remove the motor fan cover and turn

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the motor by hand until the diaphragm assembly is in the full forward position (top
dead center).
5) Hold the outer edge of the diaphragm assembly and turn it counterclockwise to
unscrew it from the pump drive.
6) Remove the diaphragm support ring (Item 700A) from the middle section of the
head.
7) Drain the oil out of the pump drive by removing the drain plug from the pump
housing (Item 20 in Figure 8).
8) Remove oil seal bellows clamping components as follows:
On Liquid End, remove mounting screws (700F) and middle section (351).
9) Pull the oil seal (70) off the connecting rod (60).
10) Install a new oil seal onto connecting rod.
11) Apply a thin layer of O-ring type grease to top of oil seal (part adjacent to
connecting rod).
12) Reinstall parts removed in step 8. For Liquid ends GM0002~GM0050 and
GM0090~GM0500, install cross piece (351/072A) after mounting spacer (701).
13) Refill pump drive with oil (650 ml of oil).
14) Reinstall liquid end components in accordance with the procedures found in
the following:
For Liquid End Size GM0050, refer to paragraph DIAPHRAGM
REPLACEMENT, steps 3 thru 6.
1) Restarting the Pump
2) Reconnect the pump to the piping system.
3) Check that capacity is set to 0%.
4) Open system suction and discharge shut-off valves and restart pump.
5) Set the pump to 100% to obtain faster priming of liquid end.
6) After priming, set the pump to the desired capacity. Retighten locking screw.

9.3.7 Seawater booster pump and Dosing pump

1) Routine Inspection and maintenance

Perform inspections and maintenance work according to the inspection and
maintenance schedule.

For detailed information on the maintenance schedule, please refer to Section 18 of

“Operating and Maintenance Manual of Magnetically Driven Centrifugal Pump
Type SHM (Dosing pump)”.

2) Troubleshooting
When a problem arises, please read “Operating and Maintenance Manual of pump”
and try to troubleshoot the problem. If the problem cannot be found, or if
replacement parts are needed, please contact the maker.
FAULT CAUSE REMEDY

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 Sunrui Marine Environment Engineering Co., Ltd.

FAULT CAUSE REMEDY

Incorrect rotational direction of

Change over two power lines.
motor.
Pump not sufficiently filled. Fill again and vent.
Check the suction line and
Pump takes in incorrect air.
foot valve for leaks.
Route lines correctly to allow
1. Pump does not Suction line contains trapped air. air to escape. Position gate
convey fluid. valve with spindle on the side.
Fit a larger impeller or larger
Excessive geodetic delivery head.
pump.
Incorrect pump size selected.
Existing counter pressure is greater Please inform us of the precise
than the max. pump pressure. conditions with respect to the
required pump.
Blockage of the suction line, supply Flush the lines and remove the
line or impeller. impeller if necessary.
Change the pipework
Air trapped in the pipework. arrangement, install a vent
valve.
Fit a larger impeller or larger
pump. Please inform us of the
Excessive geodetic delivery head.
precise conditions with respect
to the required pump.
Use a larger pipe cross
section, larger impeller and/or
Pipework flow resistances greater
larger pump. Please do not
than assumed.
2. Insufficient hesitate to contact us for
pump flow rate. information.
Clean the suction basket and
suction line, use larger suction
line cross section if necessary.
Excessive suction height (formation Check that the foot valve
of vapours in the pump during completely opens, install the
suction process, cavitation). pump in a lower position if
necessary. If a self-priming
container is used, use a larger
container if necessary.
Reduce the temperature of the
Excessive temperature of the
fluid, install the pump in a
conveyed fluid.
lower position.

Page 142 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

FAULT CAUSE REMEDY

Fluid viscosity higher than Dilute or preheat the conveyed

originally assumed. fluid.
Reduce flow with pressure
gate valves accordingly.

Fit a smaller impeller.

3. Pump conveys Actual plant delivery head is lower
too much fluid. than the pump delivery head. Reduce rotational speed if
possible.

Possibly use a smaller pump.

Pump conveys too much fluid. Refer to point 3.

Check the data with respect to
Density or viscosity of conveyed the delivery of the fluid,
fluid is too high. possibly install a motor with a
higher rating.
4. Motor overload. Check the impeller mounting
and tighten if necessary.
Impeller makes contact. Impeller deformed due to high
temperature, replace impeller
and eliminate cause for
excessively high temperature.
Precisely align the pump and
Pump is not precisely aligned.
motor.
Sliding bearings worn. Fit new sliding bearings.

Excessive suction head. Refer to point 1.

Insufficient suction line cross
Enlarge the line cross section.
section.
5. Pump operation
Shut-off slide on the suction side is
is noisy or uneven. Open slide.
closed too far.
Pump poorly fastened to the Retighten the fastening screws
foundations. and the anchor bolts.

Cavitation. Refer to point 2.

Check bearings, renew if

Bearing damage.
necessary.

Page 143 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

9.3.8 Other maintenances and calibration

Table 9-7 Other maintenances

Name Cycle Maintenance

3 Month visual inspection
Hydrogen/ chlorine gas alarm
Every year regulate
Flow meter for main pipe 3 Month visual inspection
Sensors in electrolytic unit 3 Month visual inspection
Check the cleanness of the tank. If there is
contaminated material, clean it with fresh
Neutralizer tank 1 year
water or clean seawater. The water used can
discharge into the ship sewer.

Table 9-8 Check list of measuring devices

Ability of power Drift within
No. Name Check Period
re- zeroing the Spec
1 Pressure Switch 1 yr yes yes
2 Differential pressure 1yr yes
/
switch
3 Wind pressure 1yr yes
/
switch
4 Conductivity Meter 6 months yes yes
5 Temperature Sensor 1yr yes yes
6 Liquid level meter No requirement after yes /
factory verification
7 Hydrogen sensor 1yr / yes
8 Chlorine sensor 1yr / yes
9 Flow meter No requirement after yes /
factory verification
10 TRO analyzer No requirement after yes yes
factory verification
11 Pressure gauge 6 months yes yes
12 Vacuum & pressure 6 months
yes yes
gauge

The check list of measuring devices of the BWMS is indicated in Table 9-7. All
measuring devices of the BWMS were tested prior to leaving the certificated factory.
There are check schedule and setting value table for each measuring devices.

Page 144 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Ordinary means are recommended to check the measuring devices on drift by

measurement, repeatability of the control and ability of re-zeroing if required aboard
ship.
For Conductivity Meter calibration, please refer to ‘PART THREE-OPERATION,
SECTION 4: TRANSMITTER CALIBRATION’ of OPERATING MANUAL
Pro-series Model C3 Conductivity Transmitter as Annex B for detailed
information.

Page 145 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

10 DATA SHEETS

Data reference
No. Name Code Remarks
paper

1 AFU AFU01 DAT01

2 EDU EDU01 DAT02

3 ANU ANU DAT03

4 TSU TSU01 DAT04

5 Sludge Pump EQ02‐1# DAT05

6 Seawater Booster Pump EQ04 DAT06

7 Blower EQ05 DAT07

8 Rectifier EQ07 DAT08

9 System control cabinet EQ08 DAT09

10 Metering Pump EQ09 DAT10

11 Blender EQ11 DAT11

12 Dosing Pump EQ14 DAT12

13 Sampling Pump EQ18‐1# DAT13

14 TRO drain Pump EQ18‐2# DAT14

15 EDU junction box EQ22 DAT15

16 ANU junction box EQ23 DAT16

17 Remote Control box EQ24 DAT17

18 Motor control cabinet EQ25 DAT18

19 Heat exchanger EQ37 DAT19

20 Flow meter FT01/02 DAT20

21 TRO analyzer TR01 DAT21

22 Hydrogen Sensor HS01 DAT22

23 Chlorine Sensor CS21 DAT23

Note: The following data sheets are taking a BC‐2500 type system as an example.
The specific design parameters will be changed dependent on different BWMS installation.
Sunrui has the right of final interpretation.
Page 146 of 209 Manual Rev: 1.56 BalClor® BWMS
 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT01

Issued: Revision: Part Code : AFU01 Page:

1.0 1 of 3

Automatic Back‐flushing Filter, 3280 m3/h

Type : 6.18.3 SIZE700

Filtration grade : 50 μm
Operation flow : 2500 m3/h
Fresh water supply : ~4 m3 per time after ballasting
Inlet & outlet flange : DN600 PN6
Flushing valve flange : DN150 PN10
Allowable operating pressure : MAX 6 bar
Min flushing pressure : 2 bar
Pre‐set DP value : 0.38 bar
Flushing quantity : 316 m3/h at 1.5 bar
Back‐flushing time : ~40s at least
Pressure drop : 0.2 bar on clean screen
Motor : Electrical driven
Housing : Carbon steel with protective coating
Seal material : EPDM and natural rubber
Power : 3ph, 440V, 60 Hz
Explosion proof : None
Dimension (LxWxH) : 1360*1360*3640
Empty weight : 2000 KG

Page 147 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT01

Issued: Revision: Part Code :AFU01 Page:

1.0 2 of 3

Automatic Back‐flushing Filter,3280 m3/h

Construction of Filter

Page 148 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT01

Issued: Revision: Part Code : AFU01 Page:

1.0 3 of 3

Automatic Back‐flushing Filter, 3280 m3/h

Dimensional Drawing

Unit：mm

Page 149 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Page 150 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT02

Issued: Revision: Part Code : EDU Page:

1.0 1 of 2

Electrolytic disinfection unit (with original degas unit), BC‐250

Type : EDU‐2500
Main power : 440V 60Hz
Treatment Capacity : 2800 m3/h
Rated Seawater supply : 36 m3/h
Fresh water supply : 3 m3 per time
Empty Weight : ~3400 kg
Dimension (L x W x H ) : 2800*1800*2625
Design pressure : Max. 6 bar
Ballast water inlet flange : DN80 PN10
Oxidant outlet flange : DN125 PN10
Vent flange : PIPEφ273*4
Drain/Flushing inlet flange : DN40 PN10
Flushing outlet flange : DN40 PN10
Drain for buffer tank : DN40 PN10

Page 151 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT02

Issued: Revision: Part Code : EDU Page:

1.0 2 of 2

Electrolytic disinfection unit (with original degas unit), BC‐250

Dimensional drawing

Unit: mm；

Page 152 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT03

Issued: Revision: Part Code : ANU Page:

1 of 2

ANU, 1.0m3

Type : 1.0 m3
Main power : 440V 60Hz
Fresh water supply : ~1.0 m3 per time
Empty Weight : ~600 kg
Dimension (L x W x H ) : 1650 x 1300 x 2000
Design pressure : Max. 7 bar
Inlet flange of fresh water : DN40 PN10
Outlet flange of neutralizer : DN15 PN10
Drain : DN25 PN10

Page 153 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT03

Issued: Revision: Part Code : ANU Page:

2 of 2

ANU, 1.0m3
Dimensional drawing

Page 154 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT04

Issued: Revision: Part Code : TSU01/02 Page:

1 of 1

TSU01/02, TRO sampling unit

Sampling Pump Model : E5PP6X669，1/2"

Main power : 440V 60Hz
Empty Weight : ~40 kg
Dimension (L x W x H ) : 500 x 400 x 425mm
Inlet flange : DN15 PN10
Outlet flange : DN15 PN10
Dimensional drawing

Page 155 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT05

Issued: Revision: Part Code : EQ02 Page:

1 of 2

Sludge Pump, EQ02

Capacity : 326 m3/h

Head : 15 m
Pump Type : ESL200‐265/D02
Motor Type : 3D 160L‐4
Medium : Sludge water
Gross weight : 370 kg
Shaft : ANSI 329
Impeller : PBC
Mechanical shaft seal : SiC&CARBON
Suction flange : DN200
Discharge flange DN200
Speed : 1752 RPM
Power supply : 440V,60Hz
Rated power : 18 kW
Protection grade : IP 55

Page 156 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT05

Issued: Revision: Part Code : EQ02 Page:

2 of 3

Sludge Pump, EQ02

Dimensional drawing

Page 157 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT05

Issued: Revision: Part Code : EQ02 Page:

3 of 3

Sludge Pump, EQ02

Pump Performance Curve

Page 158 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT06

Issued: Revision: Part Code : EQ04 Page:

1 of 3

Seawater Booster Pump, EQ04

Capacity : 36 m3/h
Head : 25 m
Pump Type : ESL40‐180N/D12
Motor Type : 3D 132 S1‐2
Medium : Seawater
Gross weight : 95.7 kg
Housing : Bronze
Shaft : ANSI 329
Impeller : PBC
Mechanical shaft seal : SiC&CARBON
Suction/Discharge flange : DN40
Speed : 3456 RPM
Power supply : 440V,60Hz
Protection grade : IP 55

Page 159 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT06

Issued: Revision: Part Code : EQ04 Page:

2 of 3

Seawater Booster Pump, EQ04

Dimensional drawing

Page 160 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT06

Issued: Revision: Part Code : EQ04 Page:

3 of 3

Seawater Booster Pump, EQ04

Pump Performance Curve

Page 161 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT07

Issued: Revision: Part Code : EQ05 Page:

1 of 1

Blower

Type : CBL‐23
Motor type : YB2‐112M‐2‐H
Power supply : 3ph, 440v, 60HZ
Casing : Q235B
Impeller : SUS304
Medium : Air
Capacity : 3000 m3/h
Total pressure : 2000 Pa
Speed : 3500 RPM
Rated power : 7 kW
Protection grade : IP55
Explosion proof rating : Ex d IIC T4
Insulation grade : F
Weight : 65 kg

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 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT08

Issued: Revision: Part Code : EQ07 Page:

1 of 2

Rectifier

Type : SCR01‐G1
Rated output DC range : 1%~100%
Accuracy : ≤±1.0%
Output DC ripple factor : ≤2% （Half load）
Ambient temperature : 0℃－45℃
Communication interface : RS485
Communication protocol : MODBUS‐RTU
Enclosure protection grade : IP 44
Gross weight : 850 kg
Insulation impedance
A.C. input impedance to enclosure : ≥10MΩ
A.C. input impedance to DC output : ≥10MΩ
D.C. output impedance to enclosure : ≥10MΩ
Transformer component
Input : 440V, 60Hz
Output : AC 220/440V, 60Hz
DC 110V, 1700A
Quantity of EQ07 : 1 set per EDU

Page 163 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT08

Issued: Revision: Part Code : EQ07 Page:

2of 2

Rectifier
Dimensional drawing

Page 164 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT9

Issued: Revision: Part Code : EQ08 Page:

1 of 1

System Control Cabinet

Cabinet material : Carbon steel, plastic sprayed

Protection Grade : IP 44
Power supply : 440VAC @60Hz
Communication interface : RS485
Communication protocol : MODBUS‐RTU
Weight : ~ 150 kg
Quantity : 1 set per EDU
Dimensional drawing

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 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT10

Issued: Revision: Part Code : EQ09 Page:

1 of 1

Metering Pump

Type : MB0090S
Structure : Mechanically actuated diaphragm
Maximum flow rate : 90 L/h
Max Pressure : 7 bar
Medium : Sodium thiosulphate solution
Diaphragm material : SS316
Power supply : 440V 60Hz
Power : 0.25 kW
Protection grade : IP 55
Power factor, cosØ : 0.735
Components : Safety valve
Back‐pressure valve
Damper
Quantity : Two sets per ANU

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 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT11

Issued: Revision: Part Code : EQ 11 Page:

1 of 1

Blender

Type : GC02515F
Working temperature ：AMB
Blade rotation speed ：127rpm
Power consumption ：0.37kw
Motor speed ：1500rpm
Power source ：440V 60HZ
Protection ：IP55
Material ：316SS
Quantity : 1 set per ANU

Page 167 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT12

Issued: Revision: Part Code : EQ14 Page:

1 of 2

Dosing Pump in ODU, EQ14

Capacity : 36m3/h
Head : 40 m
Pump Type : AMX‐EPFEACV
Motor Type : M2QA‐112M 2A B5
Medium : Sodium hypochlorite solution
Gross weight : 85 kg
Housing : PP+GF
Impeller : PP
Suction flange : DN65 DIN PN10
Discharge flange : DN65 DIN PN10
Speed : 3486 RPM
Power supply : 440V,60Hz
Rated power : 8.6 kW
Protection grade : IP 55

Page 168 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT12

Issued: Revision: Part Code : EQ14 Page:

1 of 2

Dosing Pump, EQ14

Dimensional drawing

Page 169 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT13

Issued: Revision: Part Code : EQ18‐1# Page:

1 of 2

Sampling Pump in TSU

Pump Type : E5PP6X669，1/2"

Height : 310 mm
Width : 285 mm
Depth : 192 mm
Est. ship weight : 5.5 kg
Air inlet : 1/4”
Liquid inlet : 1/2”
Liquid outlet : 1/2”
Suction lift : 3.5m Dry/ 5.5m Wet
Max. flow rate : 52 lpm
Max. solids size : 3 mm
Location ： In TSU01~02
Dimensional drawing

Page 170 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT13

Issued: Revision: Part Code : EQ18‐1# Page:

2 of 2

Sampling Pump in TSU

Pump Performance Curve

Page 171 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT14

Issued: Revision: Part Code : EQ18‐2# Page:

1 of 2

Pneumatic Pump in TDU

Pump Type : TZ2/AAAAB/WFS/WF/AWF

Height : 279 mm
Width : 267mm
Depth : 204mm
Est. ship weight : 5.5 kg
Air inlet : 8mm
Liquid inlet : 22mm
Liquid outlet : 22 mm
Suction lift : 6m Dry/ 9m Wet
Max. flow rate : 52 lpm
Allowable Max. solids size : 3 mm
Location ： Near TRO drain tank
Dimensional drawing

Page 172 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT14

Issued: Revision: Part Code : EQ18‐2# Page:

2of 2

Pneumatic Pump in TDU

Pump Performance Curve

Page 173 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT15

Issued: Revision: Part Code : EQ22 Page:

1 of 1

EDU Junction Box

AC input : 220V 60Hz

DC input : DC24V, DC 0－55V
Output signal : 4~20 mA
Ambient temperature : 0℃－55℃
Enclosure protection grade : IP 44
Gross weight : 15 kg
Insulation impedance
AC input impedance to enclosure : ≥10MΩ
DC output impedance to enclosure : ≥10MΩ
Quantity : 1 set per EDU

Page 174 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT16

Issued: Revision: Part Code : EQ23 Page:

1 of 1

ANU Junction Box

AC input : AC440V/60Hz/3Ph
AC output : AC440V/3Ph
Communication protocol : Modbus‐RTU
Communication interface : 4‐20mA
Ambient temperature : 0℃－55℃
Enclosure protection grade : IP 44
Gross weight : 30kg
Insulation impedance
AC input impedance to enclosure : ≥10MΩ
DC output impedance to enclosure : ≥10MΩ
Quantity : 1 set per vessel

Page 175 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT17

Issued: Revision: Part Code : EQ24 Page:

1 of 1

Remote Control Panel

AC input : AC220V/60Hz/1h
Communication protocol : Controller Link
Communication interface : RS485
Ambient temperature : 0℃－55℃
Enclosure protection grade : IP 44
Gross weight : 5kg
Quantity : 1 set per vessel

Page 176 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT18

Issued: Revision: Part Code :EQ25 Page:

1 of 1

Motor Control Cabinet

Cabinet material : Carbon steel, plastic sprayed

Protection Grade : IP 44
Power supply : 440VAC @60Hz
Communication interface : RS485
Communication protocol : MODBUS‐RTU
Weight : ~ 150 kg
Dimensional drawing

Page 177 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT19

Issued: Revision: Part Code :EQ37 Page:

1 of 1

Heat Exchanger

Type : P60‐0.75‐4.0‐HE
Heat exchange area : 4.0 m2
Steam consumption (165℃) : 97.4‐109.6m3/h
Seawater Flow rate : 36m3/h
Temperature rise : 7℃
Design pressure : 0.75 Mpa
Overall dimension (WxDxH) : 330 x 460 x 1072 mm
Weight : 140 kg

Page 178 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT20

Issued: Revision: Part Code : FT01 Page:

1 of 1

Flow meter, DN500

Type

Sensor
Flange and housing material : Carbon steel with special coating
Installation type : Remote transmitter
Liner material : NBR
Inlet/outlet flange : A600
Pressure class : JIS 10K
IP rating : IP67
Ex rating : NONE

Electrode : Hastelloy C276

Transmitter
Type :
IP rating : IP67
Material : ABS Plastic
Power supply : 115 to 230 VAC, 50 to 60 Hz
Cable connection : M20
Weight : 287kg
Ex rating : NONE

Page 179 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT 21

Issued: Revision: Part Code : TR01/02 Page:

1 of 2

TRO analyzer，CLX‐XT

Type : CLX‐XT
Measurement : 0.00 – 10.00 mg/L (PPM)
Accuracy : ±5% of reading or ±0.03 mg/L (PPM) whichever is greater for range of
0‐6.0 mg/L(PPM) ±10% of reading from 6.01‐10.00 mg/L (PPM)
Resolution : 0.01 mg/L (PPM)
Cycle Time : Adjustable; 110 seconds to 10 minutes (600 seconds)
Note: the system defaults to 2.5 minutes
Display : Multi‐Line Liquid Crystal Backlit Display
Alarms : Two Programmable, 120‐240VAC 2A Form C Relay
Analog Output : Powered 4‐20 mA, 600  drive, isolated
Communications Port : Bi‐directional RS‐485 with Modbus
Water Pressure : Integral pressure regulator 0.34 bar (5.0 PSI) to 10.3 bar (150 PSI.)
Flow Rate to Waste : 200 – 400 ml/min.
Operating Temperature: 0°C – 55°C (32°F – 131°F)
Wetted Materials : PVC, Borosilicate Glass, Reslyn (FFKM), Viton® (FKM), Polypropylene,
316 Stainless Steel, Acetal, Noryl®, Silicone
Temperature Range : 0°C – 55°C (32°F – 131°F)

Power Supply : 100 – 240 VAC, 47 – 63 Hz, 250VA

Insulation Rating : Double Insulated, Pollution Degree 2, Overvoltage Category II

Environmental Not recommended for outdoor use. Altitude up to 2000 meters

Conditions
Up to 95 % RH (non‐condensing)
Enclosure Rating : Enclosure certified to IP 66; Fan rated IP 55

Page 180 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT 21

Issued: Revision: Part Code : TR 01/02 Page:

2 of 2

TRO analyzer，CLX‐XT

Dimensional Drawing

REAGENT VENT-INDICATOR
OPTICAL BLOCK VENT ? 312 [? .92] FOR
REAGENT VENT-BUFFER 1/4-20 UNC OR
18.277 [464.24] 18.010 [457.45] M6 FASTENERS
8.480 [215.39] 12.000 [304.80]
15.706 [398.92] 16.305 [414.14] .188 [4.78] TYP.

POWER IN
INSTRUMENT
17.140 [435.36]
SIGNAL OUT
4-20MA 15.130 [384.30]
RS-485/Modbus

SIGNAL OUT
ALARMS

INSTRUMENT DRAIN
INSTRUMENT WATER INLET EXHAUST AIR
CHILLER
INTAKE AIR
CHILLER

ENCLOSURE VENT

POWER IN
CHILLER

14.305 [363.34]

Unit: inch (mm).

Page 181 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT23

Issued: Revision: Part Code : HS01 Page:

1 of 2

Hydrogen Sensor

Type : XCD
Measuring principle : Catalytic combustion
Sampling method : Diffusion
Power supply : 10~30 VDC
Max power : 150 mA at 24 VDC
Output signal : 4~20 mA
Accuracy : ± 2% F.S.
Response time : < 15s
Electrical connection : 3/4” NPT M
IP rating : IP65
Overall dimension (HxWxD) : 225 x 164 x 99 mm
Housing material : Aluminum alloy
Weight : 2 kg
Recommended Calibration Cycle 1 year

Page 182 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

Document Ref. :
QINGDAO SUNRUI Data Sheet
DAT23

Issued: Revision: Part Code : CS21 Page:

1 of 1

Chlorine Sensor

Type : SP‐3104 PLUS

Measuring principle : Electrochemistry
Sampling method : Diffusion
Power supply : 10~30 VDC
Max power : 30 mA at 24 VDC
Output signal : 4~20 mA
Accuracy : ± 2% F.S.
Response time : < 20s
Electrical connection : ф10 I.D. cable gland
IP rating : IP65
Overall dimension (HxWxD) : 255 x 150 x 83.5 mm
Housing material : Aluminum alloy
Weight : 1.5 kg
Ex rating : Ex ia II CT6

Page 183 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

11 CERTIFICATES
BalClor® BWMS has been granted for Basic Approval by IMO at MEPC 60 in Mar.
2010.

BalClor® BWMS has been granted for Final Approval of by IMO at MEPC 61 in
Sep. 2010.

BalClor® BWMS has been granted for Type Approval Certificate issued by CCS
which is the Administration Authority in China in Jan. 2015 with Certificate No. :
QD09T00031_01.

BalClor® BWMS will be granted for Type Approval Certificate issued by DNV
with Certificate No. : TAP00000EE.

Page 184 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX A：OWNER’S MANUAL

CLX OnLine Residual Chlorine Monitor

Page 185 of 209 Manual Rev: 1.56 BalClor® BWMS

 OWNER’S MANUAL
CLX- XT TRO &
Chlorine Monitor
Catalog No. 28030

HF scientific
3170 Old Metro Parkway
Ft. Myers, FL 33916
Phone: 239-337-2116
Toll Free: 888-203-7248
Fax: 239-332-7643
Email: [email protected]
Website: www.hfscientific.com

Manual Cat #28652 (12/16)

REV 3.83
 DECLARATION OF CONFORMITY

Product Safety – Tested and passed:

ETL (Part 1: General Requirements UL61010-1 Issued May 11 2012 Ed 3 and CAN/CSA
C22.2 #61010-1 issued May 11 2012)

Emissions & Immunity – Tested and passed:

EN61326-1: 2013

Enclosure Integrity- Tested and Passed:

IP66 Tested by Intertek

Tested to: IMO MEPC. 174(58) Part 3

Reference Imanna Report # 18953-1

Manufacturer’s Name: HF scientific inc.

Manufacturer’s Address: 3170 Old Metro Parkway, Fort Myers, Florida 33916-7597

Importer’s Name:

Importer’s Address:

Catalog Number : 28030

Type of Equipment: Chlorine Process Monitor

Model No: CLX-XT

I, the undersigned, hereby declare that the equipment specified above conforms to the
above Directives and Standards.

Place: Fort Myers, Florida USA

(Signature)
Date: 18 August, 2015 Mike Trammell,
Vice President of Product Development,
Watts Water Quality

Manual Cat #28652 (12/16)

REV 3.83
 Table of Contents
Section Page

Specifications ....................................................................................................1

1.0 Overview ...........................................................................................................2

1.1 Unpacking and Inspection of the Instrument and Accessories .............2
1.2 The Display ...........................................................................................3
1.3 The Touch Pad ......................................................................................3
1.4 Orientation ............................................................................................4

2.0 Safety .................................................................................................................4

2.1 Symbols Used In CLX-XT ....................................................................5

3.0 Theory of Operation ........................................................................................6

3.1 The Measurement...................................................................................6
3.2 The Cooling Chamber ............................................................................7
3.3 The Reagents .........................................................................................7

4.0 Installation and Commissioning ....................................................................8

4.1 Mounting & Site Selection ....................................................................8
4.2 Plumbing ..............................................................................................9
4.3 Electrical Connections ..........................................................................9
4.3.1 Instrument Power ....................................................................10
4.3.2 Cooling Chamber Power .........................................................11
4.3.3 RS-485 ...................................................................................11
4.3.4 Relays.......................................................................................11
4.3.5 Remote Standby Connections .................................................12
4.3.6 4-20 mA ..................................................................................12
4.3.7 RS-485/4-20 mA Cable Ferrite ................................................12
4.4 Installing Reagents ..............................................................................13

5.0 Operation .......................................................................................................14

5.1 Routine Measurement (No Control Options) ......................................14
5.2 Routine Measurement (Modbus Control) ...........................................14
5.3 Routine Measurement (Remote Standby Control)...............................15
5.4 Operating Screens ................................................................................16
5.5 Security Access Feature .......................................................................16
5.6 The White LED ....................................................................................16

6.0 Instrument Calibration ................................................................................17

6.1 Restore Factory Settings ......................................................................17
 Table of Contents (continued)

Section Page
7.0 Instrument Configuration (CONFIG mode) ...............................................18
7.1 Setting the 4-20 mA .............................................................................18
7.2 Configuring the Error Level.................................................................18
7.3 Configuring the RS-485 Port ..............................................................19
7.4 Configuring the Alarms .......................................................................19
7.4.1 Alarm 1 ....................................................................................19
7.4.2 Alarm 2 ...................................................................................20
7.5 Enabling the Security Access...............................................................20
7.6 Extended Settings.................................................................................20
7.7 Units of Measurement ..........................................................................21
7.8 Averaging and Filtering .......................................................................21
7.9 LCD Backlight Brightness ...................................................................21
7.10 RS- 485 Parameters..............................................................................22
7.11 Cycle Time ..........................................................................................22
7.12 Water Conservation ............................................................................22
7.13 4 mA Adjustment .................................................................................23
7.14 20 mA Adjustment ...............................................................................23
8.0 Additional Features and Options ................................................................24
8.1 RS-485 Output .....................................................................................24
8.1.1 Simple Communication ...........................................................24
8.1.2 Modbus Communication..........................................................24
8.2 Remote Panel Meter.............................................................................24
8.3 Desiccant Cartridge..............................................................................24
8.4 Standby Reagent Purge ........................................................................25
8.5 Reset Reading to Zero ..........................................................................25
8.6 AutoPurge ............................................................................................25
9.0 Troubleshooting .............................................................................................26
9.1 CLX-XT Fault Detection .....................................................................26
9.2 Setting Flow Rate.................................................................................27
9.3 Clearing Faults .....................................................................................27
9.4 Reagent Clogs .....................................................................................28
9.5 Diagnostic Chart .................................................................................28
9.6 Technical and Customer Assistance ...................................................28
10.0 Routine Maintenance .....................................................................................29
10.1 Maintenance Schedule ........................................................................29
10.2 Replacing or Installing the Reagents ...................................................32
10.3 Check Valve Flushing Kit ...................................................................33
10.4 Instrument Storage ..............................................................................33
10.5 Cleaning the CLX-XT .........................................................................33
11.0 Accessories and Replacement Parts List .....................................................34
12.0 Warranty .......................................................................................................35
Specifications
Measurement Range 0.00 – 10.00 mg/L (PPM) or Optional 0.00 – 15.00 Mg/L
Accuracy Standard 0-10 mg/L range:
±5% of reading or ±0.03 mg/L (PPM) whichever is greater for range of
0-6.0 mg/L(PPM) & ±10% of reading from 6.01-10.00 mg/L (PPM)
Optional 0-15 mg/L range:
±10% of reading or ±0.03 mg/L (PPM) whichever is greater for the
entire range
Resolution 0.01 mg/L (PPM)
Cycle Time Adjustable; 60 seconds to 10 minutes (600 seconds)
Note: the system defaults to 60 seconds ( most software versions)
Display Multi-Line Liquid Crystal Backlit Display
Alarms Two Programmable, 120-240VAC 2A Form C Relay
Analog Output Powered 4-20 mA, 600  drive, isolated
Communications Port Bi-directional RS-485 with Modbus
Water Pressure Integral pressure regulator 0.34 bar (5.0 PSI) to 10.3 bar (150 PSI.)
Flow Rate to Waste 200 – 400 ml/min.
Operating Temperature 0°C – 55°C (32°F – 131°F)
®
Wetted Materials PVC, Borosilicate Glass, Reslyn (FFKM), Viton (FKM),
®
Polypropylene, 316 Stainless Steel, Acetal, Noryl , Silicone, PPS
Sample Temperature Range 0°C – 55°C (32°F – 131°F)
Power Supply 100 – 240 VAC, 47 – 63 Hz, 250VA
Insulation Rating Double Insulated, Pollution Degree 2, Overvoltage Category II
Environmental Conditions Not recommended for outdoor use.
Altitude up to 2000 meters
Up to 95 % RH (non-condensing)
Enclosure Rating Enclosure certified to IP 66, designed to meet NEMA 4X
Fan rated IP 55
Regulatory Compliance Tested to IMO MEPC. 174(58) Part 3
Reference Imanna Report # 18953-1
And Certifications CE Approved, ETL listed to UL 61010-1 3rd: 2012
ETL Certified to CSA 22.2 No. 61010-1-12: 2012
EMC to EN61326-1: 2013
Shipping Weight 11.8 kg (26lbs.) Reagents are Shipped Separately
Shipping Dimensions 63cm X 64cm X 32cm (24.5” X 25 X 12.5”)

CLX-XT (28652) (12/16) Page 1

REV 3.83
1.0 Overview
The CLX-XT TRO & Chlorine Monitor allows for the reading of oxidant levels of process
water on-line. The CLX-XT has been designed to meet the design criteria specified by
Standard Methods for the Examination of Water and Wastewater (22nd Edition) Method
4500-Cl G. DPD Colorimetric Method. The CLX-XT uses a 515nm LED as the
measurement light source.
This instrument has been designed and tested to operate in ambient temperatures of up to
55 ˚C (131˚F). A specially designed thermoelectric cooling chamber has been added to
keep the indicator reagent below 25˚C (77˚F) regardless of the ambient temperature within
the operating range of 0 ˚C - 55 ˚C. The use of this cooling chamber allows for extended
reagent life, up to 3 months.
Every effort has been made to ensure the accuracy of this manual. Due to the continuous
development and improvement of all instrumentation, there may be slight differences
between this manual and the instrument received. Therefore, no legal claims can be made
against any discrepancies herein.

1.1 Unpacking and Inspection of the Instrument and Accessories

The table below indicates the items in the shipment.

Item Quantity
CLX -XT Monitor 1

Instruction Manual 1

Tubing/Cuvette Kit: 8 black pump tubes, 2 different Cap Assemblies, 1

1 replacement cuvette

Check Valve Flushing Kit 1

Remove the instrument from the packing carton. Carefully inspect all items to ensure that
no visible damage has occurred during shipment. If the items received do not match the
order, please immediately contact the local distributor or the HF scientific Customer
Service Department.

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 1.2 The Display
Figure 1 illustrates all the items that can appear on the display. The upper row of the
display (1) is used for reporting the chlorine levels and to provide user guidance in the
customer setting routine. The lower row of the display (2) is used to communicate error
messages (message queue) and provide user guidance. The display has two icons (3) that
are used to indicate the use of access code and offset mode. In addition, mode arrows (4)
are used to indicate the current instrument operating mode; AUTO (normal operation),
CAL (calibration) and CONFIG (configuration).

Figure 1: Display used in the instrument.

1.3 The Touch Pad

Figure 2 illustrates the touch pad. The touch pad has six buttons: PRIME, SERVICE,
MODE/EXIT, ,  and 
The MODE/EXIT button is used to cycle between the three operational modes of the
instrument: CAL, CONFIG, and AUTO (Measurement) mode. The  button enters the
option or mode that is highlighted or chosen. The  and  buttons are used to change
settings.
The PRIME and SERVICE buttons are dedicated controls. The PRIME will start 75
reagent pump pulses to prime the tubing after a change or addition of reagent bottles. The
SERVICE button will drain the instrument and hold all operations until either the
SERVICE button is pushed again or the power is reset. This button should be used while
changing the tubing, the measurement cuvette or reagent bottles.

Figure 2: The CLX-XT touch pad.

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 1.4 Orientation

Front View

Standard Connections Optional Connections

Bottom View

2.0 Safety
This manual contains basic instructions that must be followed during the commissioning,
operation, care and maintenance of the instrument. The safety protection provided by this
equipment may be impaired if it is commissioned and/or used in a manner not described in
this manual. Consequently, all responsible personnel must read this manual prior to
working with this instrument.
In certain instances “Notes”, or helpful hints, have been highlighted to give further
clarification to the instructions. Refer to the Table of Contents to easily find specific
topics and to learn about unfamiliar terms.
CLX-XT (28652) (12/16) Page 4
REV 3.83
 2.1 Symbols Used In This Manual

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3.0 Theory of Operation
3.1 The Measurement
The CLX-XT has two solenoid valves, one for sample water (FLOW) and one for draining
of the cuvette (PURGE). A third solenoid, along with four check valves forms a reagent
pump. Sample water flow is controlled by the FLOW solenoid valve. The PURGE
solenoid valve is used to empty the cuvette in the measurement chamber.

The measurement chamber consists of a sample inlet, a purge drain, and an overflow. The
reagent is added from the check valves integrated into the lower portion. A green LED
provides the 515 nm source lamp, a red LED is used for sample level and flow
measurement. A single detector is located 180 º from the green LED. A replaceable glass
cuvette separates the LEDs from the detector and maintains the measurement path length.
Sample water flows in the inlet at the bottom, through the measurement cuvette and out
through an overflow drain. This flow is used to both fill the cuvette and flush the system.
The reagents are dispensed from two replaceable bottles. One bottle has a buffer to control
the pH; the second has an indicator that contains the DPD, which produces color when
chlorine is present in the sample. The degree of color is dependant on the amount of
chlorine in the sample water.
The measurement chamber is open to view operations. A white LED backlights the
chamber for a clearer view. The white LED will flash to attract attention in the case of a
warning or failure. Most warnings and failures are also displayed on the screen. To
prevent interference, the white LED is turned off during measurements.
During normal operation the CLX-XT will run through a timed cycle. A simplified cycle
will consist of the following sequences:
 Flushing – continuous sample flow
 Purging – PURGE valve opens
 Zeroing – no flow with cuvette full
 Adding Reagents – one pulse of the reagent pump
 Mixing with sample – sample flow pulses in
 Reading resulting sample – no flow with cuvette full
 Purging – PURGE valve opens to remove reacted sample
The cycle above is simplified and does not describe all the actions and testing that occurs.
The CPU continuously diagnoses the entire system for correct operation and sample water
flow. If an error occurs, a message is posted to the message queue on the LCD screen.
The reagent is added by a single pulse of the reagent solenoid. When the reagents require
replacement, the PRIME button is pushed to bring new reagents into the system. During
PRIME the reagent solenoid is pulsed several times to draw fluid from the two reagent
bottles and fill the tubes with new reagent. A complete PRIME takes less than a minute.

The SERVICE button empties the cuvette, stops the flow of sample water, and clears any
errors. This provides a convenient way to replace reagents and the measurement cuvette. If
more extensive servicing is performed, all power to the CLX-XT should be removed. If
the CLX-XT is to be turned off, it is recommended that the instrument be placed in
SERVICE mode before removing power. This ensures that the cuvette is emptied and the
flow is off.

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 3.2 The Cooling Chamber
The CLX-XT has a unique feature that allows for extended reagent life. Under
temperature conditions above 25˚C the indicator reagent would quickly oxidize resulting
in low readings.

To control this condition the CLX-XT has a built-in cooling chamber for the indicator
reagent. The temperature of this chamber is kept below 25˚C in ambient temperatures of
up to 55˚C. This cooling chamber will cycle similar to a normal refrigerator to keep the
indicator reagent at the desired temperature. This temperature is factory set and should not
be adjusted.

To allow for this feature to operate correctly, this cooling chamber must be constantly
powered.

On the right side of the enclosure is a fan. This is required for proper operation of the
cooling chamber and must never be blocked.

3.3 The Reagents

The indicator reagent reacts with any oxidant, generally chlorine, to create a pink color
which the instrument measures and compares with a sample of water without reagents.

The buffer reagent is required to control the sample pH to bring the sample to neutral.

The reagents are provided already hydrated and require little operator preparation.

The indicator reagents are packaged a plastic box. Each 125 mL indicator will require the
addition and mixing of the DPD powder contained in the small brown bottle. This
activates the indicator reagent. The indicator reagents should be changed out on a 90 day
basis even if they are not fully used.

The 500 ml buffer does not require any preparation and is good for one year.

After one year all the reagents will have been consumed and a replacement reagent set will
be required. This can be ordered through agent Catalog No.09991. This set will include a
new plastic box with four sets of Indicator reagents plus one 500 mL bottle of Buffer.

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REV 3.83
4.0 Installation and Commissioning
Prior to use for the first time, one of the reagents (the indicator) will have to be mixed.
Refer to section 10.2 Replacing or Installing the Reagents.

4.1 Mounting & Site Selection

The instrument is designed for wall mounting. If wall mounting is not practical, the
instrument can be mounted on any suitable level surface Choose a location that is easily
accessible for operation and service and ensure that the front display rests at eye level.
Consideration must be made the plumbing connections. The overall mounting dimensions
of the instrument are shown in Figure 3.

OPTICAL BLOCK VENT REAGENT VENT-INDICATOR

REAGENT BUFFER VENT 18.36 [466.28]
18.17 [461.52]
12.00 [304.80] ? 313 [? .94] FOR
8.44 [214.25] 15.92 [404.30] 16.30 [414.14] 1/4-20 UNC OR
M6 FASTENERS

POWER IN
INSTRUMENT
SIGNAL OUT
4-20 MA
RS-485/MODBUS 17.17 [436.12]
SIGNAL OUT
ALARMS

INSTRUMENT DRAIN INSTRUMENT WATER INLET EXHAUST AIR

CHILLER
ENCLOSURE VENT INTAKE AIR
CHILLER

POWER IN
CHILLER

14.30 [363.34]

Figure 3: Overall Mounting Dimensions of the Instrument

It is critical that the instrument be mounted as close as possible to the sampling point to
ensure a quick response time (within 2-3 meters (6-10 ft) of the sampling point).
Suggested mounting screws are up to M6 (¼”).

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 4.2 Plumbing
The instrument is designed to require very little head pressure to operate, but will need
around 0.34 bar (5 PSI). The maximum pressure for proper operation should not exceed
10.3 bar (150 PSI). The maximum allowable fluid temperature is 55°C (131°F).

Opaque tubing is recommended be used if the tubing will be exposed to sunlight, to

prevent algae growth. Please note that the supplied sample inlet connector is compatible
with ¼” O.D. semi-rigid or rigid tubing.

The instrument is equipped with an internal cabinet drain (vent) to prevent damage in the
event of a tubing failure.

The main sample drain tubing connects to a hose barb. The rated tubing size is ½” ID
tubing. It is recommended that opaque tubing be used to prevent algae growth. Keep this
tubing as short as possible. This drain must be kept open to the atmosphere.

The drain must be open to the Atmosphere for proper operation.

The fluid waste from drain connection of this instrument contains reagents diluted
with large quantities of sample water. If this is only drained into the ballast water
stream it is safe to discharge overboard. In most instances this wastewater should be
returned to the ballast tanks

4.3 Electrical Connections

Most of the electrical connections to the instrument are made at the termination area
which is located on the left side of the instrument. Remove the high voltage cover by
loosening the captive screw. The connections are labeled and are self-descriptive (see
photo below). Please follow all local and government recommendations for installation of
electrical connections to and between the instrument and other peripheral devices.
Plugs are inserted into the RS-485 and 4-20mA cable bulkheads when shipped, to ensure a
watertight seal. These plugs should be removed and discarded when cabling to either of
these connections.
The power cable bulkhead will accept cable diameters from 5.8mm (0.23 in.) up to 13.9
mm (0.53 in.). All terminals are designed to accept wires in the range of 14-28 AWG. All
wires should be stripped to a length of 6 mm (¼”). A strain relief strap is provided to
reduce tension on the power terminals.
It is the user’s responsibility to assure that a watertight seal is maintained after the CLX-
XT has been wired for operation. If any of the bulkheads are not tightened properly
around a cable or plug, the ratings of the instrument will be jeopardized and there is a
possibility of creating a shock hazard.

Only qualified electricians should be allowed to perform the installation of the

instrument as it involves a line voltage that could endanger life.

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 4.3.1 Instrument Power
The instrument is equipped with 100-240 VAC, 47-63 Hz power supplies requiring
150VA; please verify that the line voltage falls within these specifications. A
circuit breaker must be placed prior to the power connection in close proximity and
within easy reach to allow for service. This circuit breaker must be marked to
indicate that it is a disconnecting means for the instrument. While making
connections, refer to the photo shown above.

The CLX-XT is intended for cord connection with a

three wire non-locking grounded power cord,
however rigid or flexible conduit connections can be
used. The CLX-XT is not supplied with a power
cord. If the CLX-XT is to be used in the U.S. or
Canada the power cord must be UL Listed & CSA Certified. Please consult all
local electrical codes for proper connection. All wiring to the instrument must be
rated for 70 ˚C or higher.
The connection block is marked N for Neutral and L for line the third symbol
indicates a secure earth ground. The green removable terminal block is suitable for
wire gauges 18 to 12 AWG. In addition a chassis common earth bond point is
provided on the chassis below the instrument safety access cover.

An optional connection is shown below. In this case the power to the measurement
and cooler are made at this termination block. This termination will be located
above the reagent cooling chamber.

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 4.3.2 Cooling Chamber Power
Power must be connected to the cooling control box mounted on the top right side
of the cabinet. The requirements are 100-240VA, 47-63 Hz and 100VA. A circuit
breaker must be placed prior to the power connection in close proximity and within
easy reach to allow for service. This circuit breaker must be marked to indicate that
it is a disconnecting means for the cooling circuit for
the instrument. All wiring to the cooling chamber
must be rated for 90 ˚C or higher.
This supply is separated from the instrument power
connection because the cooling chamber must be
operated full time to prevent premature degradation
of the indicator reagent. Power cable enters from the
bottom of the cabinet. The connection block is
marked N for Neutral and L for line the third symbol
indicates a secure earth ground. The removable
terminal block is suitable for wire gauges 18 to 12
AWG. In addition a chassis common earth bond point is provided on the chassis
below the instrument safety access cover.4.3.3
4.3.3 RS-485
The RS-485 half-duplex (2-wire) digital
interface operates with differential levels that
are not susceptible to electrical interferences.
This is why cable lengths up to 3000 ft can be
implemented. The last device on each bus may
require terminating with a 120 ohm resistor to
eliminate signal reflection on the line. Do not
run RS-485 cables in the same conduit as
power. Set-up of the RS-485 is covered in 7.3
Configuring the RS–485 Port
To prevent damage to the instrument, ensure that power is disconnected prior to
making connections. For ease of connecting, remove the plug-in terminal block.
Connections are labeled beside this termination on the PC board. The
recommended cable is 22 AWG shielded twisted pair. The grey terminal block is
removable to assist in making connections.

4.3.4 Relays
The Alarm 1 and Alarm 2 relays are mechanical relays rated at 240 VAC 2A.
Please note that the relays are labeled NO (Normally Open), NC (Normally Closed)
and C (Common). As these alarms are configured fail-safe, the normal condition is
with power applied to the CLX-XT and in a non-alarm condition. Operation of
these alarms is covered in section 7.4 Configuring the Alarms.
The lever operated terminal blocks are rated for wire gauges 28-14.

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 4.3.5 Remote Standby Connections (Cat #25264)
This option allows the instrument to operate on
special user control software and hardware, where
an external control initiates each cycle. This
control line is called RSI or Remote Standby Input.

The CLX-XT will indicate the current status on

another line called RSO or Remote Standby
Output. These are a relay contact that is closed
when busy (operating) and open when in standby
mode.

The connections are labeled RSI and RSO. The

RSI has + and – polarity connection associated
with it and requires a 24VDC control signal.

The RSO is simply a relay contact and is not polarized.

The use of this option lowers the relays to one Normally Open connection.

4.3.6 4-20 mA
The 4-20 mA output is driven by a 15 VDC power source and can drive recorder
loads up to 600 ohms. Transformer isolation is provided on the CLX-XT. Do not
run 4-20 mA cables in the same conduit as power. Operation of this output is
covered in section 7.1 Setting the 4-20 mA.
To prevent damage to the instrument, and for general safety ensure that power is
disconnected to the CLX-XT prior to making any connections. Polarities of the
connections are labeled beside this termination on the PC board.
The recommended cable is 22 AWG shielded twisted pair. To prevent ground
loops, connect the shield at either the CLX-XT or at its destination, but not both.
The grey terminal block is removable to assist in making connections.
The 4-20mA is factory calibrated. An adjustment is available on the 4-20mA in
sections 7.13 and 7.14. In addition to making adjustments, these menus output
continuous 4 mA or 20 mA and can be used as a signal test. Remember that the
configuration mode will timeout after 15 minutes.
4.3.7 RS-485/4-20 mA cable Ferrite
To meet IEC requirements for RF radiated immunity a clamp-on type ferrite is
supplied in the accessory kit. It should be placed on the RS-485 or 4-20 mA cable
outside, as close as possible to the CLX-XT. If both outputs will be used, an
additional ferrite will be needed and can be ordered from HF scientific Catalog
number 24560T.

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 4.4 Installing Reagents
The CLX-XT will require that two reagents be installed prior to operation. These are a
buffer and an indicator. A 12 month supply of reagents can be ordered under catalog no.
09991. For reagent preparation refer to section 10.2 Replacing and Installing the Reagents.
The reagent life was made under assumption that the CLX-XT would be used for ballast
water monitoring and the system will operate only while the vessel is ballasting and
discharging ballast water.

The Buffer is read to use and is provided in a 500 ml bottle. The indicator requires some
preparation and is supplied in four 125 ml bottles. Each indicator reagent will last a
maximum of 3 months based on reagent aging when kept in the operating cooling
chamber.

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5.0 Operation
The CLX-XT TRO values are reported in milligrams per Liter (mg/L), or if preferred the
equivalent Parts Per Million (PPM).
Readings above 10.00 mg/L are outside the range of this instrument. Although the CLX-
XT may display above 10.0 mg/L, these readings will not be within the stated accuracy.
As the reagents degrade due to aging, readings above 10.0 mg/L may decrease in value.

For the optional 0-15 mg/L range the reading mentioned above are extended to 15.00
mg/L.

5.1 Routine Measurement (No Control Options)

Using this model instrument the CLX-XT will continuously operate and provide one
reading every cycle. It is important to note that the only way to stop the instrument is by
manually placing the instrument in SERVICE mode. If the power is interrupted the
instrument will automatically start in the AUTO (cycle) mode.
First, ensure that all plumbing and electrical connections are complete before continuing.
The following steps describe how to measure the value of chlorine of a sample using this
instrument:
1. Apply power to the instrument and allow the unit to warm up (typically 45 minutes to
one hour on initial commissioning).
2. When a continuous process stream is flowing through the instrument, the instrument
will display the measured chlorine level of the sample by displaying it on the LCD
screen. In addition, the equivalent signal is provided on the analog (4-20 mA) output,
or the digital (RS-485) output, depending on the options selected.

5.2 Routine Measurement (Modbus Control Option Cat# 25316)

Most versions of CLX-XT software allow Modbus control. Using this control the system
will provide one cycle and provide one updated reading each time it is prompted. It will
then go into standby mode and await another prompt.
First, ensure that all plumbing and electrical connections are complete before continuing.
The following steps describe how to measure the value of chlorine of a sample using this
instrument:
1. Apply power to the instrument. The instrument will perform a water calibration
(WCAL). This automatic calibration is necessary and will only be performed once on
power up.
2. When the instrument has completed the WCAL it will enter standby mode and is
ready to run a measurement cycle.
3. Subsequent measurement cycles must be initiated from Modbus using the Coil
Address 00005. The default is False (0). Setting this address to True (1) initiates the
cycle.
4. Each cycle will take about 60 seconds after which the reading screen will be updated.
The 4-20 mA and alarms will be representative of this reading.

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 At any time the standby status can be checked by either Modbus Coil Address 00005 or
Input Address 10005. False (0) indicates standby True (1) indicates measurement cycle
active. Control is only possible through Modbus Coil Address 00005.
5.3 Routine Measurement (Remote Standby Control Option Cat # 25264)
The CLX-XT can operate using Remote Standby Control. Using this optional hardware
control the system will provide one cycle and provide one updated reading each time it is
prompted. It will then go into standby mode and await another prompt. The prompt is a
24VDC signal applied to two contacts.

First, ensure that all plumbing and electrical connections are complete before continuing.
The following steps describe how to measure the value of chlorine of a sample using this
instrument:
1. Apply power to the instrument. The instrument will perform a water calibration
(WCAL). During this time the RSO contact will be closed, indicating the system is
busy. This automatic calibration is necessary and will only be performed once on
power up.
2. When the system has completed the WCAL, the RSO contacts will open indicating
that it is in standby mode and is ready to take a measurement.
3. Application of 24VDC to the RSI connections will initiate a read cycle. The
RSO contact will close to indicate the system is busy.
4. At the completion of the cycle, the RSO contacts will open & the measured chlorine
level of the sample will be displayed on the LCD screen. In addition, the equivalent
signal is provided on the analog (4-20 mA) output, or the digital (RS-485) output,
depending on the options selected.
5. The system is now ready to take a new measurement.
Continuous application of 24VDC to the RSI will result in continuously updated
readings.
The instrument needs to take one reading first before proper operation. After the first
reading the operation will continue as below:
 Whenever the instrument is in standby the reading will be 0.00 this means the
associated 4-20mA signal will be representative of this reading. If the alarm is set
to LO or HI it will respond to this 0.00 reading.
 Whenever the instrument is taking a reading the 4-20mA output and alarm
response will be representative of the reading on the LCD screen.
 New readings will be updated as long as 24VDC is applied to the RSI connections.

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 5.4 Operating Screens
During normal operation, the instrument will have the
arrow beside AUTO highlighted with the current scale
displayed on the lower row of the display and the
measured reading on the upper row of the display (see
screen shown).

The screen shown to the right indicates that the system

has just been started or just entered AUTO mode from
Service mode and no readings have been taken yet.

Please note that calibrations will not be allowed until a reading is posted.

5.5 Security Access Feature

The instrument is equipped with a security access code feature that can be activated in the
configuration mode. If the security feature is enabled, the screen shown in the illustration
below will appear when the MODE/EXIT button is pressed.
The security code (333) must be entered to gain access to CAL or CONFIG menus.
Notice that the first number in the code is flashing. The
flashing indicates that this is the number to be changed.
Use the  or  arrows to select the first of the three
numbers in the code and then press the  button to
accept the first number of the code. Now enter the
second number in the code. Proceed as with the first
number followed by . Then repeat the process for the
third number in the access code, and finish with the  button.
If the valid access code has been selected, the instrument will be directed to the calibration
mode. If the wrong access code is selected, the instrument will return to the AUTO mode.
Refer to section 7.5 Enabling the Security Access for more information.

5.6 The White LED

A white LED is used to illuminate the measurement cuvette for easy viewing of the
instrument operations. During the Zeroing portion of the cycle and the Measurement
portion of the cycle, when the green LED is active, the white LED is turned off to lower
interference. This normal operation for the instrument and does not represent an error or
problem.

The white LED is also used to draw attention to a problem as described in section 9.1
CLX-XT Fault Detection. In these instances the white LED blinks at a constant rate
dependant on the severity of the problem, but is still turned off as described above. Please
note that any fault is always posted to message queue on the lower portion of the LCD.

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6.0 Instrument Calibration
The instrument was tested & calibrated prior to leaving the factory. Since it operates from
a pre-determined calibration curve, no further calibration is required.
If the procedure for calibration is necessary please contact HF scientific or HF scientific
representative before undertaking the procedure.

6.1 Restore Factory Settings

If the CLX-XT displays a CAL error or the calibration was incorrectly performed, it may
be preferred to restore the factory calibration. All factory defaults settings including the
factory calibration can be reset by holding down the  button and then pressing and
releasing the  button then releasing the  button.

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7.0 Instrument Configuration (CONFIG mode)
The instrument has been designed to provide the ability to customize the instrument
according to needs at any time during normal operation. This mode has been split into
sub-menus to facilitate instrument configuration. This section describes how to use each
of the sub-menus to configure the instrument. While in the configuration mode, the
instrument has a time-out feature that automatically returns the system operation to the
AUTO mode after a fifteen (15) minute period of no button pushes.
Enter the CONFIG mode of the instrument by pressing the MODE/EXIT button until the
arrow beside CONFIG is illuminated, then press the  button to scroll through the sub-
menus.
To exit the CONFIG mode, press the MODE/EXIT button any changes that were
made will be saved.

7.1 Setting the 4-20 mA Output

The first configuration selection is 4-20 for the 4-20 mA
output. Select the either On or OFF using the  and 
buttons. Once the desired output has been set, press the
 button to accept it. The next prompts will depend on
the output selected. Also see sections 7.13 & 7.14.

If the 4-20 mA output was turned On, prompts to set the

4mA (4MA) and 20mA (20MA) chlorine limits will be
displayed. There will also be a menu to adjust the error
level (ERLV). The first prompt will be the chlorine limit
assigned to the 4 mA output level:
Select the chlorine level to assign to the 4MA using the
 and  buttons.
Once the desired level has been set, press the  button to accept it.
The 4MA can be set higher than 20MA level to invert the output current if required.
This may be required to control a dosing pump.

The next prompt will be the chlorine level assigned to the

20MA. Select the chlorine level using the  and 
buttons. Once the desired level has been set, press the
 button to accept it.

7.2 Configuring the Error Level

In case of an error in the CLX-XT, the 4-20 mA reading
can be used to indicate a problem by sending the current
to either 4.00 mA, 2.00 mA or 0 mA. The factory
default setting is OFF. Select the desired ERLV by using
the  and  buttons then press the  button to accept
the desired error response.

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 7.3 Configuring the RS–485 Port
The instrument is equipped with an RS 485 port which
operates in Simple bus or Modbus. Prompts will appear
for setting the baud rate, the address and the Modbus
transmission mode (RTU or ASCII).

Select the correct baud rate (1200, 2400, 4800, 9600, or

19200) for operation of the I/O port by pressing the  or  buttons to change the
displayed baud rate.
Press the  button to continue on and select the desired
instrument address using the  or  buttons. Once the
selection is satisfactory, press the  button.
To use the Modbus mode, select ASCII or RTU. See
section 8.1.2.

7.4 Configuring the Alarms

Two relays are provided that are designed to operate as two independent programmable
alarms or as a system problem alarm. Please note that changes to alarms will not be
recognized until the start of the next cycle. Two settings must be selected to fully program
each alarm:
1. The alarm function (HI, LO, OFF or Error)
2. The alarm set point (level at which the alarm activates)

These items are described below:

Alarm Function: The alarms can either be turned OFF or selected to operate in one of
three different manners:
1. HI alarm: the relay changes state when the measured chlorine level is higher than the
programmed alarm level (set point).
2. LO alarm: the relay changes state when the measured chlorine level is lower than the
programmed alarm level (set point).
3. Error alarm: If there is a system fault or problem the alarm will change states.
Alarm Set Point: The level at which an alarm activates is called the alarm set point. On
the instrument, the alarm set point is designated as “S/P”. The set point is adjustable to
any valid chlorine level over the range of the instrument in steps of 0.01 mg/L. This
setting is not available if the Error function is chosen.

7.4.1 Alarm 1
Alarm 1 Function: The ALM1 is displayed and the display indicates the current
function of alarm 1 (HI, LO, OFF, or Error). Use the  or  buttons to cycle
through and select the desired function. Press the  button to accept the selection.
If the alarm was turned OFF, a prompt will appear to set up alarm 2 (go to section
7.4.2).

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 Alarm 1 Set Point: This prompt is used to select the set point for this alarm; this
is indicated by “S/P” shown on the lower row of the display. Select the desired
alarm level by using the  and  buttons. Once the desired set point has been set,
press the  button to accept it.

7.4.2 Alarm 2
Repeat the procedure listed in section 7.4.1 to set up the parameters for alarm 2. If
a selection was made to turn the alarm OFF, the next selection for the speed of
response RESP is shown.
The use of the Remote Standby Option 25264 limits the relays to a single Normally
open connection. Follow Alarm 1 Instructions.

Due to the cyclic nature of the CLX-XT, relay chatter is not an issue. There is no
need for alarm delays or hysteresis.

7.5 Enabling the Security Access

The instrument is equipped with a security access. If this option is turned on, the user is
required to input the access code into the instrument to
get to any mode other than AUTO. The only code is 333.
This code may not be changed. See section 5.2 for more
information on this security feature. The security key
icon will be visible and flashing on the display whenever
the access option is selected using the  or  buttons.
(On or OFF).

7.6 Extended Settings

The last settings are grouped together to prevent them
from being adjusted by accident. To gain access to the
extended settings, select On using the  or  buttons
and press the  button.

If extended settings are set to OFF, pressing the  button will save all settings and the
CLX-XT will automatically return to the normal AUTO mode of the instrument.

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 7.7 Units of Measurement
The unit of measure can be set to either mg/L (milligrams per liter) or PPM (parts per
million). The factory setting is mg/L. Select the desired UNIT using the  and  buttons
and press the  button to accept it.

mg/L screen PPM screen

7.8 Averaging and Filtering

The CLX-XT can display and output averaged readings to help smooth out the response
and eliminate large reading variation in rapidly changing processes. There are 5 settings
for the averaging feature:

1 = No averaging, each reading is in “real time”.

2 = The current reading and previous reading are averaged.
3 = The current reading and previous 2 readings are averaged.
4 = The current reading and previous 3 readings are averaged.
5 = The current reading and previous 4 readings are averaged.

The factory setting is averaging of 2. Select the desired AVG using the  and  buttons
and press the  button to accept it.

In addition to averaging, the CLX-XT has a software filter that limits the change between
consecutive readings to 20%. For example, the reading following a reading of 1.00 ppm
could not be displayed as higher than 1.20 ppm or lower than 0.80 ppm. This filter also
helps smooth out large changes and eliminate reading
spikes. After 3 consecutive readings, it is assumed that
the large change in the readings is "real", and the filter
will be disabled. For example, the change between
reading 1 & 2, and readings 2 & 3 will be limited to
20%, but the change between readings 3 & 4 will not be
limited.
This software filter is completely disabled when the averaging (AVG) is set to 1.

7.9 LCD Backlight Brightness

The LCD backlight brightness may need to be adjusted. This is of particular interest if
multiple instruments are located in the same area and it is desired for the entire group to
have the same appearance. Ten levels are available. The
factory setting brightness is 8.

Change the brightness by pressing the  or  button.

When the desired brightness has been selected, press the
 button.

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 7.10 RS-485 Parameters
These menus will only appear if the RS-485 is enabled (see 7.3). The factory setting is 8
Bit, no (nOnE) Parity, 1 Stop Bit.

Make selections using the  and  buttons then press the  button to move to the next
menu.

7.11 Cycle Time

The cycle time can be changed using this menu. Please note that changing this menu
will directly affect the volume of reagent that will be consumed. The default is set to
60 seconds (1 minute).

Make selections using the  and  buttons then press

the  button. Allowable setting is from 60 to 600
seconds (10 minutes).

The indicator reagent has a defined life after being mixed regardless of the cycle time
setting. If the reagent is kept in the powered cooling chamber the life is 90 days.

7.12 Water Conservation ( if available)

To conserve water, the flush time can be adjusted use as little water as possible.

This feature is generally not used in ballast water applications and should be set to
OFF.

The instrument requires 110 seconds to complete its

normal operations, when the WCON is turned On, at the
factory cycle time the instrument sits idle for about 40
seconds. This results in about a 25% water savings. The
actual amount of water conservation is dependent on the
incoming water pressure and the cycle time setting.

The use of this option may result in some slight loss of accuracy. The factory setting for
this option is OFF.

Make selections using the  and  buttons then press the  button to exit to AUTO
mode and save all configuration settings. If the 4-20 mA in section 7.1 is turned ON, there
are two additional menus that will appear before returning to AUTO mode.

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 7.13 4mA Adjustment
If the 4-20 mA setting is turned ON (7.1 Setting the 4-20 mA Output), the following two
menus will appear. The first menu outputs a constant 4
mA while allowing for a small amount of adjustment.
The adjustment can be made using the  and  buttons.
This adjustment will allow the operator to make the
CLX-XT agree with a PLC or SCADA system. The
adjustment limits are ± 200 counts or about ± 0.2 mA.

This setting will be slightly different on each instrument as each CLX-XT will be factory
set to 4.00mA. Press the  button when adjustments are complete to save this setting and
move on to the 20mA adjustment.

7.14 20mA Adjustment

This menu operates similar to the previous menu. This menu outputs a constant 20 mA
while allowing for a small amount of adjustment. The adjustment can be made using the
 and  buttons. The adjustment limits are ± 1000 counts or about ± 1 mA.

This setting will be slightly different on each instrument

as each CLX-XT will be factory set to 20.00mA.

When complete with the 20mA adjustment, press the  button to exit to AUTO mode and
save all configuration settings.

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8.0 Additional Features and Options

8.1 RS-485 Outputs

The CLX-XT has the capability to operate in two different RS-485 modes. Included are a
simple communication mode and Modbus communications. Both modes will
automatically configure and do not require any changes or selections

8.1.1 Simple Communication

The CLX-XT can provide basic communications over simple programs such as the
Hilgraeve HyperTerminal that is included with most Microsoft Windows packages.
The user could also use Visual Basic or other programs. The factory setting
communication parameters are 8 bits, no parity and 1 stop bit. These can be
changed in the Extended CONFIG menus 7.10 RS-485 Parameters.
The master computer will send out:
 Byte #1 the attention character “:” in ASCII or 3A Hex
 Byte #2 the address of the CLX-XT being queried
 Byte #3 & 4 CR LF or 0D 0A in hex
The CLX-XT will respond with:
The CLX-XT will respond with:
 The same attention character “:” in ASCII or 3A Hex
 The address of the CLX-XT
 The Reading
 The Unit (mg/L)
A sample communication would look like this:
(Master computer requesting a report from address #1) :1 CRLF
(CLXB set to address #1 Response) :001 0.0249mg/L

8.1.2 Modbus Communication

Modbus protocol communication is included with this instrument. The Modbus
address list is available from HF scientific or online at www.hfscientiifc.com.
8.2 Remote Panel Meter (Catalog # 19609)
The remote panel meter allows for remote indication of the mg/L reading using the 4-20
mA loop of the CLX-XT. No external power is required, as the meter is run off of the 4-20
mA source of the CLX-XT.

8.3 Desiccant Cartridge Option (Catalog #09944)

An optional desiccant cartridge kit can be purchased for use in applications where
condensation on the glass cuvette may compromise accuracy. The desiccant changes color
from blue to pink when expended. Instructions for replacement are included with the kit.

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 8.4 Standby Reagent Purge (Software Option Cat #25316)
During times when the CLX-XT is not being operated such as in voyage between
ballasting and deballasting no reagent moves past the check valves. In some instances this
can cause these parts to clog. To prevent this occurrence a single pump action is enabled at
a timed interval.

It is important that the unit remain in Standby Mode and power is always applied.

This software feature is available on select software packages where either Modbus or the
Hardware Remote Standby feature is used.

Every time the instrument is placed in standby mode a timer starts. Once the set time has
elapsed a single action of the reagent pump occurs to keep the check valves clear. This
single will inject about 25 µL of each reagent into the chamber. This is performed with a
special pulse width modulation to prevent the reagent from splattering and staining the
measurement glass.

Note that for the timer to be active, power must be constantly applied to the instrument. If
the power is removed or a power disturbance occurs the timer is reset.

The default factory time setting is once every 24 hours. This time period can be adjusted if
desired at Modbus Address 40025 which is an integer. The allowable setting range is 1
hour to 100 hours.

8.5 Reset Reading to Zero (Software Option Cat # 25316)

If there is a need to reset the reading to Zero this can be accomplished in most software
packages through Modbus. The address is 00006. The default setting is false (0) setting
this to true (1) will set the reading to Zero and the completion on the next cycle. This
setting also affects the 4-20mA output and alarms.

8.6 AutoPurge (Hardware option Cat# 25279)

If power is removed from the CLX-XT without stopping the unit first, there is a good
chance that sample water and possibly reagents are left in the optics. Over a period of time
this can stain the cuvette. This factory installed option stores a charge in a super-capacitor.
During an unexpected removal of power the stored charge is used to open Purge solenoid.

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9.0 Troubleshooting
9.1 CLX-XT Fault Detection
The CLX-XT performs continuous diagnostic monitoring. In the CLX-XT, there are 4
severity levels of fault detection. Level 4, 3 & 2 will allow normal operation, but warn of
the problem. Level 1 is an instrument failure and the instrument will not operate. Any
faults are displayed in a queue form in the bottom row of the LCD.

A level 4 fault is simply a screen indication that one of the alarm levels has been activated.
This fault level will not affect the 4-20 mA and will only affect the alarm activated. The
sample back light blinks at a rate of once every 4 seconds.

A level 3 fault indicates a failure or a problem that usually can be corrected by the
operator. Refer to the chart below. If any of these errors occur, the instrument will still
display readings and probably will operate correctly. These faults will self-clear when the
problem is corrected. If any of these faults occur, they may affect the 4-20mA and any
alarm dependent on fault detection setting (Error). See sections 7.2 & 7.41 for error
settings. The sample back light blinks at a rate of once every 2.5 seconds to indicate a
level 3 fault.
Level 3 (Self-Clearing) fault conditions
Message Description of Fault Corrective Action
MA 4-20 mA enabled & loop open Check 4-20 mA wiring or turn off 4-
20mA if not used
CAL Calibration invalid –not accepted Recalibrate if needed
WATR No water flowing Check water flow
FAST Intake water flow too fast Set flow rate (see section 9.2)
SLOW Sample cuvette filling too slowly Set flow rate (see section 9.2)
PURG Sample cuvette has slow purge Check drain lines
NPRG Sample cuvette not purging Check drain lines
ISOL Problem with intake solenoid Check wiring, check for clogged solenoid
PSOL Problem with purge solenoid Check wiring, check for clogged solenoid
GLAS Dirty cuvette Replace or clean cuvette
WCAL Water Level Calibration Invalid Clear fault (see section 9.3)

A level 2 fault indicates a severe problem that will usually require technical assistance
from HF scientific customer service (see section 9.6). The queued display will show
POST. If this fault occurs it will affect the 4-20mA and any alarm set for fault detection
(Error). The sample back light blinks at rate of once every 1 second.

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 A level 1 fault is a system fault. This is NOT a problem that the operator can correct, and
the unit must be returned to the factory for service (see section 9.5). These failures consist
of failures in the CPU, A/D, EEPROM or other devices internal to the instrument. The
queued display will show FAIL, the upper display will show a four or five digit fault code.
If this fault occurs, it will affect the 4-20mA and any alarm set for fault detection (Error).
The instrument will not operate with this fault. The sample back light blinks at rate of
once every 0.4 seconds.
If any fault condition occurs, the message indicating the fault will be shown on the lower
row of the display.

9.2 Setting Flow Rate

The flow rate on the CLX-XT was factory adjusted and usually should not need
adjustment. Installation variances may affect the flow. The optimal flow rate through the
CLX-XT may be adjusted if needed. The flow is adjusted by removing regulator vinyl cap
and turning the adjustment screw on the pressure regulator. To assist in this adjustment
follow the procedure shown below:
1. Press the SERVICE button.
2. Wait for the display to read HOLd, then press Mode/ Exit.
3. Display will show FLOW with the number 0. Press either the  or  button.
4. CLX-XT will drain, and then pulse in water while a count is displayed on the screen.
5. The display will show one of three messages HI, LO or Good.
The flow test determines if the flow rate is suitable for proper operation. Loosen the
locking nut then adjust the pressure regulator using a coin or a large flat blade screwdriver.
Press either the  or  button while in the FLOW routine to display a new flow rate.
Please note that only ¼ turn incremental adjustments should be made to the regulator on
each attempt.
If the message is LO, turn the regulator control clockwise. If the message is HI, turn the
regulator counterclockwise. If the message is Good, no adjustment is required. Tighten the
locking nut after adjustment and replace the regulator vinyl cap. To return to normal
operation, press the  button.

9.3 Clearing Faults

Every time SERVICE mode is exited, all faults are cleared. If the original fault or a new
fault occurs, it will be posted.
In the case of WCAL, it is possible the power was enabled before a water sample was
available. Ensure a water sample is available and then press PRIME to force another
Water Calibration (WCAL). The Water Calibration occurs automatically at the completion
of the 75 PRIME stokes.

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 9.4 Reagent Clogs
If reagents fail to flow or Prime it may be due to a clog in either the tubing or at a check
valve. To alleviate this you may have to flush the system with Chlorine Free water,
preferably Deionized water. See section10.3 Check Valve Flushing Kit.

9.5 Diagnostic Chart

Symptom Cause Cure
Lower display shows MA 4-20 mA loop open Check wiring. See sections
4.3.4 and 7.2
Lower display shows FAIL Major system fault Refer to section 9.1
Readings are erratic (1) Bubbles in solution (1) Install bubble elimination
chamber.
(2) Debris in flow (2) Clean T-strainer
Readings are lower than expected (1) Condensate or leaky (1) Install desiccant cartridge
measurement cuvette kit
(2) Measurement cuvette (2) Replace or clean cuvette
dirty
(3) Reagents bad or expired (3) Replace reagents
(4) Buffer reagent not being
dispensed (4) Check buffer lines and
check valves.
Upper display flashes Sample Over-Range Check sample. Sample may be
too high to read.
Upper display shows nOnE while No current reading displayed Wait for CLX-XT to post a
attempting to calibrate reading

9.6 Technical and Customer Assistance

If for any reason assistance is needed regarding this instrument please do not hesitate to
contact either the HF scientific Technical Service Department or the HF scientific
Customer Service Department:

HF scientific
3170 Old Metro Parkway
Fort Myers, Florida 33916-7597
Phone: (239) 337-2116
Toll Free (888) 203-7248
Fax: (239) 332-7643
Email: [email protected]
www.hfscientific.com

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10.0 Routine Maintenance
10.1 Maintenance Schedule
The recommended schedule is shown below. It is important to replace the reagents to get
reliable accurate readings from the CLX-XT. The Buffer supplied can last for up to one
year*. Each mixed indicator reagent will last for up to 90 days* when kept in cooling
chamber. The one year kit includes one buffer bottle and four sets of indicator reagents. A
convenient mounting clip for the indicator reagent box is located in the lower left corner
of the cabinet. The Buffer reagent mounts above the indicator reagents in another clip and
is further held with a Velcro strap. See section 10.2 for more information on the reagents.

The CLX-XT is shipped with one CLX-XT Tubing/Cuvette kit, HF part # 09950XT. The
kit consists of the following:
Qty Part
1 Spare Buffer Cap Assembly
1 Spare Indicator Cap Assembly
8 Pump Tubes
1 Spare Cuvette

Two replacement sets of reagent cap/tubing assemblies are supplied with the CLX-XT;
one for the buffer and one for the indicator.

Additional kits can be ordered from your local HF scientific distributor or representative.
It is recommended to keep one kit on hand at all times.

Generally, both pump tubes should be replaced annually. Spare cap assemblies for both
the buffer and the indicator are supplied and can be replaced when needed.
Every 30 days
1. Check for leaks and proper operation of the instrument in general.
2. Check the T-strainer for debris. Clean if needed.
3. Check the cooling chamber operation using a non-contact IR thermometer. This
should be 25°C or lower.
Every 90 days
1. The indicator reagent required for operating this instrument must be changed at least
every 90 days. The buffer reagent can be used up to one year.
2. The internal strainer should be checked and cleaned if necessary.
3. The glass cuvette should be inspected. Check for excessive debris on the inside
surface of the glass. It is suggested to keep a spare cuvette to replace when required.
The old cuvette may be cleaned, if possible, for future replacement.

Flushing the System

Press the SERVICE button to stop the water flow. Remove old reagents and discard. Place
the suction tubes in a small container of clean water. Press SERVICE to return to
operation mode, press PRIME and then  to flush the system with water. Remove the
suction tubes from the water Press PRIME and then  to remove most of the water.

CLX-XT (28652) (12/16) Page 29

REV 3.83
 After a PRIME the CLX-XT will perform a water calibration (WCAL). It will take a
few minutes to complete this procedure.

*The 1 year buffer and 90 day indicator reagent life is primarily used on ballast water
applications. The assumption is based on the factory default of a 60 second cycle and up
to 24 hours total operation per month.
Pump Tubing Replacement
The black pump tubes may need replacement more often due to the fact that they are
subject to wear. The inline check valves should not need to be replaced and should be
saved. Please note that the check valves are directional as shown below.

FLOW
INLET OUTLET
CHECK VALVE DETAIL

Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Remove and retain the thumb screw on top of the pump; pull the pump hammer and
spring up and out of the way. There is no need to completely remove the hammer and
spring.
4 Working on one reagent side at a time. Replace the black tubing between optics inlet
and the check valve OUTLET. Discard the old tubing.
5 Ensure the check valve is placed into its seat.
6 Repeat steps 4 & 5 for the other reagent.
7 Replace the hammer and spring back into place and secure with the thumb screw.
8 Check the drawing on the following page to ensure correct installation.
9 Return to operation as described.

Cap Assembly Replacement

When the Cap Assemblies needs to be changed follow the procedure shown below. It is
recommended that both assemblies are changed at the same time.

Steps:
1 Flush the system as described above to reduce personal contact with the reagents.
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
3 Remove the buffer cap assembly from the cabinet vent and the connection at the check
valve.
4 Replace the buffer cap (blue or black cap) assembly. Note that the vent tube is not
centered and does not connect to the suction tube.
5 Repeat steps 3 & 4 for the indicator side (white cap).
6 Replace reagents, prime and return to service.

CLX-XT (28652) (12/16) Page 30

REV 3.83
 Cuvette Replacement
Check the condition of cuvette and change if it appears badly soiled or discolored. Follow
the steps below.
Steps:
1. Replace the two Cap Assemblies.
2. Turn the knurled top on the optics system counterclockwise (as viewed for the top)
until the cuvette just “pops” out, but do not remove the top.
3. When the cuvette “pops” out, move the retaining o-ring & remove the cuvette. You
may need a stiff wire such as a bent paper clip to grasp the cuvette. Retain this cuvette
for future use if it can be cleaned.
4. Install the new cuvette by pushing it firmly in place and turning the knurled top
clockwise until the cuvette is held securely.
5. Check the drawing on the following page to ensure correct installation.
6. Return to operation as described.

T-Strainer Cleaning
The T-strainer is integral to the instrument and must be checked
occasionally. When necessary it must be removed and cleaned. The
strainer screen may require replacement after a period of time.
Steps:
1. Press SERVICE to stop the flow of sample water and drain the
cuvette.
2. Ensure the source water is turned off.
3. The T-strainer is clamped to the intake regulator. The removal
requires the use of a flat blade screwdriver as shown in the photo.
Once the two clamps are opened the T-strainer can be removed.
4. Disconnect the top of the T-strainer and regulator from the
tubing and clear of the case.
5. Clean the T-strainer screen and replace.
6. Be sure to tighten the bowl of the strainer.
7. Be certain the clamps are tightened fully and the tubing
connections are complete. Pliers may be required to close the
clamps.
8. Turn source water back on.
9. Return to normal operation.
10. Check for any leaks.

Return to Normal Operation

Press the SERVICE button to return sample flow to the system. Check for leaks. If a leak
occurs press SERVICE again, repair leak and try again. Once the system is operating
correctly, return or replace reagents and press PRIME and then  one time to restart
reagent flow. The system will automatically return to normal operation.

Tubes may darken due to contact with the reagent. This condition does not affect the
performance of these parts.

CLX-XT (28652) (12/16) Page 31

REV 3.83
 10.2 Replacing or Installing the Reagents
Reagent kits are available from HF scientific for Total Chlorine Refer to section 11.0
Replacement Parts and Accessories for the appropriate Catalog number. There are two
reagents required, for the instrument to operate; the buffer and the indicator.
The reagents are provided “wet” and the buffer is ready to use and will last up to one year.
The smaller indicator reagent does require the addition of the DPD power to activate it.
Once activated it starts to oxidize. This process is slowed by keeping it in the cooling
chamber.

When commissioning the CLX-XT it is recommended to follow the procedure in

section 10.3. This procedure only needs to be done once when the instrument first
commissioned.

Indicator Reagent Preparation

Remove the cap of the small liquid indicator reagent and add the contents of the DPD
powder bottle (small brown bottle). Cap and shake to fully dissolve the powder.

Once mixed the indicator has an expected life of up to 90 days if kept in the powered
cooling chamber. Write the mixing date on the reagent bottle labels in the area
provided. Dispose of expired reagents correctly.

To replace the reagents, press the SERVICE button; this will empty the cuvette and stop
any flow of water. Remove the cap on both bottles replace with the cap supplied with the
CLX-XT. The buffer is installed on the left and the indicator is installed in the cooling
chamber. The suction tube for both reagents will reach the bottom of the bottles.
To complete the replacement procedure, press the PRIME button and then the  button.
This will draw enough of each reagent to completely prime the tubes and replace any old
solution. The system will automatically return to normal operation after it has primed.

Use caution when changing the reagents as they are corrosive. These reagents may
stain clothing. After changing the reagents, operators should wash their hands.

CLX-XT (28652) (12/16) Page 32

REV 3.83
 10.3 Check Valve Flushing Kit
Sometimes upon initial commissioning, the check valves stick and require manual priming.
This should not be needed after commissioning. Be careful when using this kit to use only
chlorine free water. Complete instructions are included in the kit.

10.4 Instrument Storage

If the CLX-XT is relocated or will be inactive for long periods of time, remove the
reagents. Flush the reagent system as describe in 10.1 Maintenance Schedule. Or use the
flush kit to rinse out unused reagents. Place the instrument in Service mode to drain the
system then remove power by disconnecting the mains power plug. It is usually a good
idea to disconnect or shut off the source water.

10.5 Cleaning the CLX-XT

Flush the system as mentioned in section 10.1 Maintenance Schedule. When the flushing
is finished, press the SEVICE button wait until the display reads HOLd.

As a mater of safety, always disconnect any power source to the CLX-XT prior to
attempting any cleaning. It is recommended that the source water is also shut off.

Isopropyl alcohol (rubbing alcohol) on a soft cotton cloth works very well in removing
reagent stains from plastic parts, the keypad and the display. Use care when cleaning
around electrical components. Do not use any harsh cleaning agents as these may cause
damage to the instrument components. Do not allow the alcohol to touch the Strainer as it
may be damaged.

Ensure that the system is dry prior to applying power.

CLX-XT (28652) (12/16) Page 33

REV 3.83
 11.0 Accessories and Replacement Parts List
The items shown below are recommended accessories and replacement parts.

Accessory Catalog Photo

Number
Check Valve Flushing kit 25096

Reagent Kit – Total Chlorine 12 09991

month supply

Operating Manual CLX-XT 28652 N/A

Tubing/Cuvette Kit 09950XT

Replacement Cuvette 25018S

Check Valve Kit 25017S

CLX-XT (28652) (12/16) Page 34

REV 3.83
Ferrite for 4-20mA or RS-485 24560

Strainer & Regulator Assembly 25357

Replacement T-strainer Screen 28625

Intake Assembly (solenoid, 28411

regulator & T-strainer)

To order any accessory or replacement part, please contact the HF scientific Customer
Service Department. If for any reason technical assistance is needed regarding this
instrument, please do not hesitate to contact the HF scientific Technical Services
Department.

HF scientific
3170 Old Metro Parkway
Fort Myers, Florida 33916-7597
Phone: (239) 337-2116
Toll Free: (888) 203-7248
Fax: (239) 332-7643
Email: [email protected]
www.hfscientific.com

CLX-XT (28652) (12/16) Page 35

REV 3.83
12.0 Warranty
HF scientific inc., as vendor, warrants to the original purchaser of this instrument that it
will be free of defects in material and workmanship, in normal use and service, for a
period of two years from date of manufacture. HF scientific inc.’s obligation under this
warranty is limited to replacing, at its factory, the instrument or any part thereof. Parts,
which by their nature are normally required to be replaced periodically, consistent with
normal maintenance, specifically reagent, desiccant, sensors, electrodes and fuses are
excluded. Also excluded are accessories and supply type items.
Original purchaser is responsible for return of the instruments, or parts thereof, to HF
scientific’ inc.’s factory. This includes all freight charges incurred in shipping to and from
HF scientific inc.’s factory.
HF scientific inc .is not responsible for damage to the instrument, or parts thereof,
resulting from misuse, environmental corrosion, negligence or accident, or defects
resulting from repairs, alterations or installation made by any person or company not
authorized by HF scientific inc.
HF scientific inc. assumes no liability for consequential damage of any kind, and the
original purchaser, by placement of any order for the instrument, or parts thereof, shall be
deemed liable for any and all damages incurred by the use or misuse of the instruments, or
parts thereof, by the purchaser, its employees, or others, following receipt thereof.
Carefully inspect this product for shipping damage, if damaged, immediately notify the
shipping company and arrange an on-site inspection. HF scientific inc cannot be
responsible for damage in shipment and cannot assist with claims without an on-site
inspection of the damage.
This warranty is given expressly and in lieu of all other warranties, expressed or implied.
Purchaser agrees that there is no warranty on merchantability and that there are no other
warranties, expressed or implied. No agent is authorized to assume for HF scientific inc.,
any liability except as set forth above.
HF scientific, inc.
3170 Old Metro Parkway
Fort Myers, Florida 33916-7597
Phone: (239) 337-2116
Fax: (239) 332-7643
Toll free: 888-203-7248
Email: [email protected]
Website: www.hfscientific.com

CLX-XT (28652) (12/16) Page 36

REV 3.83
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX B：OPERATING MANUAL

Pro-series Model C3 Conductivity Transmitter

Page 186 of 209 Manual Rev: 1.56 BalClor® BWMS

 JUMO CTI-500
Inductive Conductivity/Concentration and
Temperature Transmitter with switch contacts
Type 202755

B 202755.0
Operating Instructions

V1.00/EN/00444870
WARNING:
A sudden failure of the instrument or of a sensor connected to it could result in dangerous
overdosing. Please take suitable precautionary measures for this case.

All the nececssary settings are described in this manual. However, if any difficul-
ties should arise during start-up, please do not carry out any unauthorized mani-
pulations. You could endanger your righs under the instrument warranty!
Please contact the nearest subsidiary or the head office in such a case.

Resetting the LC display

If the brightness/contrast setting is such that the text in the display is not reada-
ble, the basic setting can be restored as follows:
✱ Switch off the supply voltage.
✱ Switch on the supply voltage and immediately keep the keys and held
down.
Resetting the operating language to "English"
If the operating language has been set and you cannot understand the text of the
display, the language can be set to "English" with the Administrator password
7485. Thereafter, the desired language can be set in ADMINISTRATOR LEVEL /
DEVICE DATA / ....
Contents
1 Typographical conventions ...................................................... 5
1.1 Warning signs ..............................................................................................5
1.2 Note signs ....................................................................................................5

2 General ....................................................................................... 6
2.1 Preface .........................................................................................................6
2.2 Design of the measuring transmitter ............................................................6

3 Inductive conductivity measurement ...................................... 7

3.1 Area of application .......................................................................................7
3.2 Function .......................................................................................................8

4 Device identification ................................................................. 9

4.1 Nameplate ....................................................................................................9
4.2 Type designation ........................................................................................10
4.3 Head-mounted transmitter .........................................................................10
4.4 Transmitter with separate sensor ...............................................................12

5 Device description .................................................................. 14

5.1 Transmitter technical data .........................................................................14

6 Mounting .................................................................................. 18
6.1 General .......................................................................................................18
6.2 Head-mounted transmitter .........................................................................19
6.3 Split version (separate sensor) ...................................................................20

7 Installation ............................................................................... 25
7.1 General ......................................................................................................26

8 Setup program ........................................................................ 29

8.1 Function .....................................................................................................29

9 Commissioning ....................................................................... 30
9.1 Head-mounted transmitter or split version ................................................30
9.2 Replacement sensor ..................................................................................30
Contents
10 Operation ................................................................................. 31
10.1 Controls ......................................................................................................31
10.2 Principle of operation .................................................................................33
10.3 Principle of operation .................................................................................35
10.4 Measurement mode ...................................................................................36
10.5 Operator level .............................................................................................36
10.6 Administrator level .....................................................................................44
10.7 Calibration level ..........................................................................................46
10.8 The dilution function ...................................................................................47

11 Calibration ............................................................................... 51
11.1 General .......................................................................................................51
11.2 Calibrating the relative cell constant ..........................................................51
11.3 Calibrating the temp. coefficient of the sample solution ...........................52

12 Maintenance ............................................................................ 60
12.1 Cleaning the conductivity sensor ...............................................................60

13 Eliminating faults and malfunctions ...................................... 61

13.1 Checking the device ..................................................................................61

14 Appendix .................................................................................. 66
14.1 Before configuration ...................................................................................66
 1 Typographical conventions
1.1 Warning signs
Danger
This symbol is used when there may be danger to personnel if the
instructions are ignored or not followed correctly!

Caution
This symbol is used when there may be damage to equipment or data if the
instructions are ignored or not followed correctly!

1.2 Note signs

Note
This symbol is used when your special attention is drawn to a remark.

abc1 Footnote
Footnotes are remarks that refer to specific points in the text. Footnotes
consist of two parts:
A marker in the text, and the footnote text.
The markers in the text are arranged as continuous superscript numbers.

✱ Action instruction
This symbol indicates that an action to be performed is described.
The individual steps are marked by this asterisk.
Example:
✱ Remove crosspoint screws.

5
2 General
2.1 Preface
Please read these operating instructions before commissioning the
instrument. Keep the manual in a place that is accessible to all users at all
times.

2.2 Design of the measuring transmitter

Examples
Head-mounted version: Split version:
Transmitter combined with Transmitter with
conductivity sensor, separate sensor,
Type 202755/xx... Type 202755/xx...

(1) (1)

(5)
(2)

(3)

(4)

(2)

(4) (3)

(1) Transmitter (4) Inductive conductivity sensor

(2) Process connection (5) With or without graphics LC display
(3) Exposed temperature sensor

6
 3 Inductive conductivity measurement
3.1 Area of application
General The inductive measurement method permits largely maintenance-free
acquisition of the specific conductivity, even in difficult media conditions.
Unlike the conductive measurement method, problems such as electrode
decomposition and polarization do not occur.

Brief The instrument is used for the measurement/control of conductivity or

description concentration in liquid media. It is particularly recommended for use in media
where severe deposits of dirt, oil, grease or gypsum/lime precipitates are to be
expected. The integrated temperature measurement enables fast and
accurate temperature compensation, which is of particular importance when
measuring conductivity.
Two built-in switching outputs can be freely programmed to monitor limits for
conductivity / concentration and / or temperature. It is also possible to assign
alarm and control functions (dilution).
The instrument is operated either from the membrane keypad and plain-text
graphics display (operator language can be changed over) or through the user-
friendly PC setup program. Simply rotating the housing cover makes it
possible to read the display, regardless of whether the installation is in
horizontally or vertically arranged pipes. By using the setup program, the
instrument configuration data for plant documentation can be saved and
printed out. To prevent any tampering, the instrument can also be supplied
without keypad or display. In this case, the setup program is needed for
programming.
The measuring transmitter is available either as a combined unit (transmitter
and measuring cell together in one unit) or as a split version (transmitter and
cell connected by cable). The split version is particularly suitable for plant
subjected to strong vibration and/or significant heat radiation at the point of
measurement, or for installation on sites that are difficult to access. Immersion
models up to 2000 mm are available for application in open containers or
sluices.

Typical areas of - freshwater and wastewater engineering

application - HVAC systems and cooling tower monitoring (dilution control)
- flushing baths (e.g. monitoring electroplating baths)
- inlet and final control in on-site sewage treatment plants
- concentration monitoring
- vehicle washing plant

7
3 Inductive conductivity measurement
3.2 Function
of the The transmitter has been designed for use on site. A rugged housing protects
transmitter the electronics and the electrical connections from corrosive environmental
conditions (IP67 enclosure). As standard, the device has one analog signal
output each for conductivity/concentration and temperature respectively.
Further processing of the standard signals can take place in a suitable display/
control device, or, for example, directly in a PLC.
The output signals are electrically isolated from one another and from the
medium.

of the The conductivity is measured using an inductive probe. A sinusoidal a.c.

measuring cell voltage feeds the transmitting coil. Depending on the conductivity of the liquid
to be measured, a current is induced in the receiver coil. This current is
proportional to the conductivity of the medium. The cell constant of the
inductive probe depends on its geometry. The cell constant can also be
affected by components in the immediate vicinity.

(1)

(2)

(3)
(1a)
(4)

(1) Temperature sensor, exposed (1a) optionally:

internal temperature sensor
(2) Measuring cell body in PP (3) Measurement coils
(4) Liquid loop

8
 4 Device identification
4.1 Nameplate
on the
transmitter
JUMO GmbH & Co. KG
Fulda, Germany
www.jumo.net
JUMO CTI-500
Typ: 202755/15-168-0-82/000,000
VARTN: 20/00445843
F-Nr.: 00909467 01 0 0517 0001
DC 19...31 V ⱕ 3W

on the
connecting
cable
(only with
separate F-Nr.: 00909467 01 0 0517 0001

sensor)

For devices with a separate sensor (type code extensions (2) /60 or /65), the
transmitter and detached sensor are matched to one another at the factory!
When connecting the components, please note that the serial number of the
external sensor (marked on the label attached to the connecting cable) must
match the serial number marked on the nameplate of the transmitter!

The date of manufacture is coded in the “F-Nr.” (serial number):

0517 means manufactured in year 2005 / calendar week 17

9
4 Device identification
4.2 Type designation

4.3 Head-mounted transmitter

(1) Basic type
202755 Inductive transmitter/switching device for
conductivity/concentration and temperature
(2) Basic type extensions
10 head-mounted transmitter without display/keypad 1
15 head-mounted transmitter with display/keypad
(3) Process connection
o o 168 PVC union nut G11/2A 2,6
o o 169 Stainless steel union nut G11/2A 2
o o 607 screwed pipe connection DN50, DIN 11 851
(MK DN50, milk cone)
o o 617 clamp 21/2", ISO 28527
o o 690 SMS 2"
(4) Immersion length
o o 000 see dimensions
(5) Electrical connection
o o 82 cable glands
o o 83 M12 plug / socket connector
(instead of cable glands) 3
o o 84 two M16 cable glands and one
blanking plug
(6) Extra codes 4
x x 000 no extra code
o o 268 internal temperature sensor
o o 580 1 set M12 plug/socket connectors
o o 768 Measurement cell material PVDF 5
o o 844 Voltage supply AC 24 V

x = standard
o = available as an option
(1) (2) (3) (4) (5) (6) (6)
Order code / - - - / , ...
Order example 202755 / 10 - 168 - 000 - 82 / 000 ,

1 The PC setup program is required for programming the instrument,

see accessories
2 Special tee is not included in delivery, see accessories
3 If required, order extra code /580
4
Indicate the type code extension in succession separated by a comma.

10
 4 Device identification
5 Only in case of process connection 168 and 169 in combination with type
code extension 268.
6
Maximum medium temperature 60°C.
7
Assembly material (holding clamp) not part of the supplied kit. If required,
please order additionally ( accessories).

11
4 Device identification
4.4 Transmitter with separate sensor
(1) Basic type
202755 Inductive transmitter/switching device for
conductivity/concentration and temperature
(2) Basic type extensions
20 replacement transmitter without display/keypad
(without sensor) 1
25 replacement transmitter with display/keypad
(without sensor) 7
60 transmitter without display/keypad
including sensor (cable length: 10 m) 1
65 transmitter with display/keypad
including sensor (cable length: 10 m)
80 replacement with 10 meter cable
without transmitter, including adjustment set 3,7
(3) Process connection
x x 000 not available
o o o 168 PVC union nut G11/2A 2, 8
o o o 169 Stainless steel union nut G11/2A 2
o o o 607 screwed pipe connection DN50, DIN 11 851 5
(MK DN50, milk cone)
o o o 617 clamp 21/2", ISO 28523
o o o 690 SMS 2"
o o o 706 immersion version
(4) Immersion length
x x 0000 not available
o o o 0500 0500 mm
o o o 1000 1000 mm
o o o 1500 1500 mm
o o o 2000 2000 mm (maximum)
o o o xxxx special length (in 250 mm steps;
e.g. 0250; 0750; 1250; 1750)
(5) Electrical connection
x 21 fixed cable with M12 socket connector on separate sensor
o o o o 82 cable glands on the operating unit
o o o o 83 M12 plug/socket connectors on operating unit 4
o o o o 84 two M16 cable glands and one blanking plug
(6) Extra codes 5
x x x x x 000 no extra code
o o o 268 internal temperature sensor
o o o o 580 1 set M12 plug/socket connectors
o o 768 Measurement cell material PVDF 6
o o o o 844 Voltage supply AC 24 V

12
 4 Device identification

(1) (2) (3) (4) (5) (6) (6)

Order code / - - - / , ...
Order example 202755 / 65 - 706 - 1000 - 82 / 000 ,

x = standard
o = available as an option

1 The PC setup program is required for programming the instrument,

see accessories.
2 A tee is not included in delivery.
3 Mounting items (union/ring nuts, holding clamp) are not included in
delivery.
If required, please include in order, see accessories
4 If required, order extra code /580
5
Show type extension codes in succession separated by a comma.
6
Only in case of process extension 168 and 169 in combination with type
extension code 268.
7
A balancing set is urgently required for commissioning. If required, please
order additionally (accessories).
7
Maximum medium temperature 60°C.

13
5 Device description
5.1 Transmitter technical data
5.1.1 General

A/D converter resolution: 15-bit

sampling time: 500 msec = 2 measurements/sec

Supply For operation in SELV- and PELV-circuits!

Serienmäßig:
19 — 31 V DC (24 V DC nominal), with reverse-polarity protection
Typenzusatz 844:
AC 24 V ±10%, 50...60 Hz
ripple: < 5%
power consumption with display: ≤ 3W
power consumption without display: ≤ 2.6 W

Rating of the U < 50 V AC/DC

solid-state I ≤ 200 mA
relays

Electrical plug-in screw terminals 2.5 mm2 or M12 plug/socket connector

connection

Display (option) graphics LCD with background lighting; adjustable contrast

dimensions: 62 x 23 mm

Permissible -5 to +50°C
ambient max. 93% relative humidity, no condensation
temperature
(transmitter)

Permissible -10 to +75°C

storage max. 93% relative humidity, no condensation
temperature
(transmitter)

Enclosure IP67
protection
(transmitter)

Housing Polyamide

Weight depending on version and process connection

approx. 0.3 — 2 kg

14
 5 Device description
5.1.2 Conductivity/ concentration transmitter

Concentration - NaOH (caustic soda)

measurement 0 — 15 % by weight or 25 — 50 % by weight
(implemented in - HNO3 (nitric acid); check chemical resistance of the sensor !
the device 0 — 25 % by weight or 36 — 82 % by weight
software)
- customer-specific concentration curve
freely programmable through the setup program (see “special functions”)

Calibration adjustable: 0 — 999 days (0 = off)

timer

Output 0 — 10 V / 10 — 0 V
signal 2 — 10 V / 10 — 2 V
Conductivity/ 0 — 20 mA / 20 — 0 mA
concentration 4 — 20 mA / 20 — 4 mA
The output signal is freely scalable.

Burden ≤ 500Ω for current output

≥ 2kΩ for voltage output

Analog output Low (0 mA / 0 V / 3.4 mA / 1.4 V) or

for “Alarm” High (22.0 mA / 10.7 V) or
a value with a fixed setting (safe value)

Measuring Four ranges can be selected.

ranges One of these ranges can be activated via an external switch or a PLC.
Tolerance
Measurement ranges
(in % of range
Transmitter
span)
0 — 500 µS/cm
0 — 1000 µS/cm
0 — 2000 µS/cm
0 — 5000 µS/cm
0 — 10 mS/cm
0 — 20 mS/cm
≤0.5%
0 — 50 mS/cm
0 — 100 mS/cm
0 — 200 mS/cm
0 — 500 mS/cm
0 — 1000 mS/cm
0 — 2000 mS/cm 1
1
not compensated for temperature
Note:
The overall tolerance is made up of the tolerance of the transmitter + the
tolerance of the sensor.

15
5 Device description
5.1.3 Temperature transmitter

Temperature manually -20.0 — 25.0 — 150°C/°F

acquisition or
automatically

Temperature -20 — 150°C/°F

measurement
range

Characteristic linear

Tolerance ≤ 0.5% of range

Output signal 0 — 10 V / 10 — 0 V
for temperature 2 — 10 V / 10 — 2 V
0 — 20 mA / 20 — 0 mA
4 — 20 mA / 20 — 4 mA
The output signal is im Bereich -20...+200°C freely scalable.
The sensor can be used in the range -10...+100°C.

Burden ≤ 500Ω for current output

≥ 2 kΩ for voltage output

Analog output Low (0 mA / 0 V / 3.4 mA / 1.4 V) or

for “Alarm” High (22.0 mA / 10.7 V) or
a value with a fixed setting (safe value)

5.1.4 Temperature compensation

Reference 15 to 30°C, adjustable

temperature

Temperature 0.0 to 5.5 %/°C, adjustable

coefficient

Compensation -20 to 100°C

range

Function - Linear compensation (constant temperature coefficient).

This type of compensation can be used with normal water with an
acceptable level of accuracy. The temperature coefficient used is then
about 2,2 %/K.
- Natural water (DIN EN27888 or ISO 7888 as the case may be).
In this case, a so-called non-linear temperature compensation is used.
According to the above standard, the corresponding type of compensation
can be applied in the case of natural ground water, mountain spring water
and surface warter.

16
 5 Device description
The conductivity of the water is compensated in the range from 0°C to
36°C.
- non-linear (learning function, see special functions)
Here, the actual graph of the temperature coefficient during a heating-up or
cooling-down process is determined by the transmitter.

5.1.5 Sensor

Material PP (polypropylene)
Note:
Temperature, pressure and sample medium affect the cell operating life.

Temperature of
the sample Process connection maximum medium temperature
medium 168
60 °C
706
169
607 80 °C
617 short-term100 °C
690
Note the limiting values (ambient temperature) of the device.

Pressure 10 bar max. at 20°C

06 bar max. at 60°C

Tolerance
Measurement range
(in % of range
Sensor
span)
0 — 500 µS/cm
≤1%
0 — 1000 µS/cm
0 — 2000 µS/cm
0 — 5000 µS/cm
0 — 10 mS/cm
0 — 20 mS/cm
≤0.5%
0 — 50 mS/cm
0 — 100 mS/cm
0 — 200 mS/cm
0 — 500 mS/cm
0 — 1000 mS/cm
≤1%
0 — 2000 mS/cm 1

1 not compensated for temperature

17
6 Mounting
6.1 General
Mounting site Make sure that the site is readily accessible, for calibration at a later time.
The fixing must be secure and free from vibration.
Avoid direct sunlight!
Take care that there is adequate flow through and around the sensor (1) !
If the device is to be mounted in a pipeline, there must be at least 20 mm
clearance between the sensor and the wall of the pipe.
If it is not possible to achieve this minimum clearance, then a limited
compensation can be made through the “Mounting factor” parameter.
For submerged operation in basins, a location must be chosen that is
representative of the typical conductivity or concentration.

Mounting The measuring transmitter can be mounted in any position.

position
min. 20 mm

(1)
min. 20 mm

Screwing in and The cable must not be twisted!

unscrewing the Avoid putting tension on the cable. In particular, avoid tugging it.
detached
sensor

Sensor details

18
 6 Mounting
6.2 Head-mounted transmitter
Installation
variations

19
6 Mounting
6.3 Split version (separate sensor)
Transmitter
head

Drilling jig for

wall-mounting

20
 6 Mounting

Sensor
component

21
6 Mounting
6.3.1 Separate sensor as immersion model

Optional accessory:
Flange DN 32,
part no. 00083375

Fixing screw
Feststellschraube
100 +5
0
60

Sliding
Flansch
flange
verschiebbar
18
3

Ø18

Ø125
Ø165

Optional accessory:
Flange DN 50,
part no. 00083376

22
 6 Mounting
6.3.2 Examples of installation
Version with Version with
process connection 168 process connection 168

Union nut (PVC) Insert nut Union nut (PVC)

Insert nut G11/2"
1
G1 /2" (PVC)

Tee 90°
DN32 (PVC) Tee 90°
Optional accessories DN40 (PVC)
Sales No.: 20/00439247 Optional accessories
Sales No.: 20/00439249

Weld-on threaded connection

DN50, DIN 11 851
(Counterpart for process connection -607)
part no.: 00085020

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SURFHVVFRQQHFWLRQ
6FUHZHGSLSHILWWLQJ'1
',1 PLONFRQH

3URFHVVFRQQHFWLRQ
0.'1 7KUHDGHGSLSH
6ORWWHGXQLRQQXW  DGDSWRU',16'1
'1 

'1

'1

'1

5HGXFHU7HH WREHSURYLGHGE\WKHSODQWRSHUDWRU
OPU
TVQQMJFE
CZ
UIF
EFWJDF
NBOVGBDUVSFS
',1VKRUW666'1'1'1 

23
6 Mounting
6.3.3 Pipe assembly set
30...50 mm

(1)

(2)

(1)

The screws (1) M5 x 30 are used for pipe diameters from 30 to 40 mm.
The screws (2) M5 x 40 are used for pipe diameters from 40 to 50 mm.
The pipe assembly set is also suitable for horizontal pipes..

24
 7 Installation

The electrical connection must only be carried out

by properly qualified personnel!

❏ The choice of cable, the installation and the electrical connection must
conform to the requirements of VDE 0100 “Regulations on the Installation
of Power Circuits with Nominal Voltages below 1000 V” or the appropriate
local regulations.
❏ The electrical connection must only be carried out by qualified personnel.
❏ If contact with live parts is possible while working on the device, it must be
completely disconnected from the electrical supply.
❏ The electromagnetic compatibility conforms to EN 61326.
❏ Run input, output and supply cables separately and not parallel to one
another.
❏ The device is not suitable for use in areas with an explosion hazard (Ex
areas).
❏ Apart from faulty installation, incorrect settings on the instrument may also
affect the proper functioning of the subsequent process or lead to damage.

25
7 Installation
7.1 General
Opening the
operating unit It is only necessary to open the housing for devices with cable
glands.
Devices with M12 plug/socket connectors should not be opened!

(1)

✱ Remove four screws (1) and take off the cover

Connecting up
the cables

(1)

(2)

To connect the single conductors, pull off the pluggable screw

terminals (1) in the operating unit.
Pass the connecting cables through the cable glands (2).

26
 7 Installation

Wiring

For devices with a separate sensor (type code extensions (2) /60 or /65), the
transmitter and detached sensor are matched to one another at the factory!
When connecting the components, please note that the serial number of the
external sensor (marked on the label attached to the connecting cable) must
match the serial number marked on the nameplate of the transmitter!

Caution:
On devices with a
separate sensor
and M12 plug/
socket
connectors, the
screw terminals are
sealed inside the
device.
Removal of this
sealing will
invalidate the
warranty!

27
7 Installation

Connections
for the Connections Screw Conn./pin
transmitter terminals
Supply voltage
Supply voltage 1 L+ I/1
19 — 31 V DC 2 L- I/2
(with reverse-polarity protection)
Outputs
Analog signal output 3+ I/3
Conductivity/concentration 4- I/4
0 — 20 mA resp. 20 — 0 mA or
4 — 20 mA resp. 20 — 4 mA
or
0 — 10 V resp. 10 — 0 V or
2 — 10 V resp. 10 — 2 V
(electrically isolated)
Analog signal output 5+ II / 1
Temperature 6- II / 2
0 — 20 mA resp. 20 — 0 mA or
4 — 20 mA resp. 20 — 4 mA
or
0 — 10 V resp. 10 — 0 V or
2 — 10 V resp. 10 — 2 V
(electrically isolated)
Switching output K1 7 II / 3
(floating) 8 II / 4
Status indication
7 8
LED K1
Switching output K2 9 II / 5
Status indication 10 II / 6
LED K2
9 10

Binary inputs
Binary input E1 11 12 11 II / 7
12 I/5

Binary input E2 13 14 13 II / 8
14 I/5

28
 8 Setup program
8.1 Function
Configurable The setup program, which is available as an option, can be used for easy
parameters adaptation of the transmitter to specific requirements.
- Setting the measurement range and the range limits.
- Setting the response of the output to an out-of-range signal.
- Setting the functions of the switched outputs K1 and K2.
- Setting the functions of the binary inputs E1 and E2.
- Setting up special functions (e.g. the dilution function).
- Setting up a customer-specific characteristic,
- etc.

Data transmission from or to the transmitter can only take place

when it is connected to the electrical supply see Chapter 7
"Installation", Page 25ff.

Connections
The setup interface is not electrically isolated. When connecting
the PC interface cable, it is therefore absolutely essential to ensure
that either the supply of the transmitter or of the PC is not
electrically earthed (for instance, use a battery-powered notebook).

Plug-on adapter
(included in setup set)

Interface cable
(95/00350260)

Supply voltage

29
9 Commissioning

The transmitter has been tested in the factory for fault-free

functioning, and is delivered ready for operation.

9.1 Head-mounted transmitter or split version

✱ Mounting the device, see "Mounting", Page 18.
✱ Connecting the device, see "Installation", Page 25.

For devices with a separate sensor (type code extensions (2) /60 or /65), the
transmitter and detached sensor are matched to one another at the factory!
When connecting the components, please note that the serial number of the
external sensor (marked on the label attached to the connecting cable) must
match the serial number marked on the nameplate of the transmitter!

9.2 Replacement sensor

✱ Connect up the sensor as described in the operating instructions for the
replacement sensor.
✱ Calibrate the sensor as described in the operating instructions for the
replacement sensor.

30
 10 Operation
10.1 Controls
Device without
LC display

(6)

Device with
LC display

(1)

(6) (2)
(5) (3)
(4)

(1) Grafik LC display, back-lit

(2) PGM key, confirm entries/select menu
(3) EXIT key, cancel entry without saving/cancel calibration go back one
menu level
(4) key, increase value/step on in selection
(5) key, reduce value/step on in selection
(6) LEDs K1 and K2 show the states of the switched outputs.
In normal operation, the LED lights up if the corresponding output is
active.
If the pulse function is active, the LED only indicates the status.
The K1 LED blinks during calibration.
In fault condition, the LED K1 and LED K2 blink.

31
10 Operation

LC display
(1) (2) (3) (4) (5) (6) (7)

(11)
(8)

(10) (9)

(1) Output K1 is active (7) Output mode

(2) Output K2 is active - Hand (manual operation)
- Hold (hold operation)
(3) Binary input 1 is
activated (8) Conductivity/concentration
measurement
(4) Binary input 2 is
activated (9) Unit for conductivity/
concentration measurement
(5) Keypad is inhibited
(10) Temperature of the medium
(6) Device status (indications)
- Alarm (e.g overrange) (11) Device status e.g.
- Calib blinking (calibration - Measurement (normal)
timer has run down - Dilution (dilution function)
- Calib (customer calibration - Dosing (dilution function)
is active) - Inhibited (dilution function)
- Calibration status

32
 10 Operation
10.3 Principle of operation
10.3.1 Operation in levels
Measurement mode, see Chapter 10.4 "Principle of operation" page 35

OPERATOR LEVEL, see chapter 10.6 "Operator level", page 36

INPUT CONDUCTIVITY MEASUREMENT RANGE 1...4
TEMPERATURE COMPENSATION
TEMP. COEFFICIENT 1...4
REFERENCE TEMPERATURE
REL. CELL CONSTANT
MOUNTING FACTOR
CONCENTR. MEASUREMENT
CONCENTR. RANGE
OFFSET
FILTER TIME
CALIBR. INTERVAL
OUTPUT CONDUCTIVITY SIGNAL TYPE
SCALING START 1...4
SCALING END1...4
IN CASE OF ALARM
DURING CALIBRATION
SAFETY VALUE
MANUAL OPERATION
MANUAL VALUE
INPUT TEMPERATURE UNIT
MEAS. VALUE ACQUISITION
MANUEL SPECIFICATION
OFFSET
FILTER TIME
OUTPUT TEMPERATURE SIGNAL TYPE
SCALING START
SCALING END
IN CASE OF ALARM
DURING CALIBRATION
SAFETY VALUE
MANUAL OPERATION
MANUAL VALUE
OUTPUT BINARY 1 FUNCTION
LIMIT VALUE
HYSTERESIS
DISTANCE
MANUAL OPERATION
DURING HOLD
IN CASE OF ALARM/CALIBR.
SWITCH-ON DELAY
SWITCH-OFF DELAY
PULSE DURATION
OUTPUT BINARY 2 FUNCTION
LIMIT VALUE
HYSTERESIS
DISTANCE
MANUAL OPERATION
DURING HOLD
IN CASE OF ALARM/CALIBR.
SWITCH-ON DELAY
SWITCH-OFF DELAY
PULSE DURATION
INPUT BINARY 1 FUNCTION
INPUT BINARY 2 FUNCTION
DILUTION REDUCTION
DOSING TIME
LOCK TIME

33
10 Operation
DEVICE DATA LANGUAGE
CONTRAST
LIGHTING
INVERTING LCD

ADMINISTR. LEVEL, see chapter 10.6, "Operator level", page 36

Password
PARAMETER LEVEL, see chapter 10.6.1 "CONDUCTIVITY IN" (conduc-
tivity input) page 37
INPUT CONDUCTIVITY
OUTPUT CONDUCTIVITY
INPUT TEMPERATURE
OUTPUT TEMPERATURE
OUTPUT BINARY 1
OUTPUT BINARY 2
INPUT BINARY 1
INPUT BINARY 2
DILUTION FUNCTION
DEVICE DATA

ENABLE LEVEL, see chapter 10.6.2 "CONDUCTIVITY OUT" (conducti-

vity output), page 38
INPUT CONDUCTIVITY
OUTPUT CONDUCTIVITY
INPUT TEMPERATURE
OUTPUT TEMPERATURE
OUTPUT BINARY 1
OUTPUT BINARY 2
INPUT BINARY 1
INPUT BINARY 2
DILUTION FUNCTION
DEVICE DATA

CALIBRATION ENABLE, see chapter 10.6.3 "TEMPERATURE IN", page

39
REL. CELL CONSTANT
TEMP. COEFF. LINEAR
TEMP. CO. NON-LINEAR

CALIBRATION LEVEL, see chapter 10.7 "Administrator level" page 44

REL. CELL CONSTANT
TEMP. COEFF. LINEAR
TEMP. CO. NON-LINEAR

DILUTION FUNCTION, see chapter 10.8 "Calibration level" page 46

REDUCTION
DOSING TIME
LOCK TIME

34
 10 Operation
10.4 Principle of operation
Operation in
levels

35
10 Operation
10.5 Measurement mode
Representation In measurement mode, the conductivity is shown (compensated for the
reference temperature) or the concentration and temperature of the medium
being measured.

(1)

(3)

(2)

(1) MEASUREMENT -> Measurement mode

(2) 20.5°C -> Temperature of the sample medium
(3) 203 mS/cm -> conductivity of the medium (compensated for the
reference/comparison temperature – usually 25°C)

10.6 Operator level

All the parameters that have been enabled by the administrator (administrator
level) can be edited in this level. All other parameters (marked by a key )
can only be read.
✱ Press the PGM key for at least 3 seconds.
✱ Select OPERATOR LEVEL.

36
 10 Operation
10.6.1 CONDUCTIVITY IN (Conductivity input)

RANGE 1 — 4 1
0 — 500 µS/cm
0 — 1000 µS/cm
0 — 2000 µS/cm
0 — 5000 µS/cm
0 — 10 mS/cm
0 — 20 mS/cm
0 — 50 mS/cm
0 — 100 mS/cm
0 — 200 mS/cm
0 — 500 mS/cm
0 — 1000 mS/cm
0 — 2000 mS/cm UNC2

1 Measurement ranges 2, 3 and 4 are only used if

BINARY INPUT is configured to RANGE/TEMPCO
2 This measurement range is not temperature-compensated.

TEMP. COMPENSATION
LINEAR
NON-LINEAR (see "Non-linear temperature coefficient (ALPHA)", Page 55)
NATURAL WATER (permissible temperature range 0 to 36°C to EN 27 888)

TEMPCO 1 — 4 1
0 — 2.20 — 5.5%
1 Ranges 2, 3 and 4 are only used if
BINARY INPUT is configured to RANGE/TEMPCO.

REFERENCE TEMP.
15.0 to 25.0 to 30°C

REL. CELL CONSTANT

80.0 — 100.0 — 120%

MOUNTING FACTOR
80.0 — 100.0 — 120%
If it is not possible to achieve the minimum clearance of 20 mm between the
sensor and the outer wall, then a limited compensation can be made through
this parameter.

CONC. MEAS. TYPE

NO FUNCTION
NaOH
HNO3

37
10 Operation
CUSTOMIZED (values can only be entered by using the optional
setup program)

CONC. MEAS. For HNO3

RANGE 0 — 25 % BY WEIGHT
36 — 82 % BY WEIGHT
For NaOH
0 — 15 % BY WEIGHT
25 — 50 % BY WEIGHT

OFFSET
-100 to 0 to +100 mS/cm (+/- 10% of range)

FILTER TIME
00:00:00 — 00:00:01 — 00:00:25 H:M:S

CALIB. INTERVAL
0 — 999 DAYS (0 = switched off)

10.6.2 CONDUCTIVITY OUT (conductivity output)

SIGNAL TYPE
0 — 20 mA
4 — 20 mA
20 — 0 mA
20 — 4 mA
0 — 10 V
2 — 10 V
10 — 0 V
10 — 2 V

SCALING START 1 — 41
0 µS/cm = 4 mA
Can be set in the range being used, depending on the signal type.
1
Ranges 2, 3 and 4 are only used if
BINARY INPUT is configured to RANGE/TEMPCO.

SCALING END 1 — 41
1000 µS/cm = 20 mA
Can be set in the range being used, depending on the signal type.
1Ranges 2, 3 and 4 are only used if
BINARY INPUT is configured to RANGE/TEMPCO.

38
 10 Operation

DURING ALARM
LOW (0 mA / 0 V / 3.4 mA / 1.4 V)
HIGH (22 mA / 10.7 V)
SAFE VALUE (depending on the signal type)

DURING CALIBRATION
MOVING
FROZEN
SAFE VALUE

SAFE VALUE
0.0 — 4.0 — 22.0 mA (depending on the signal type)
0 — 10.7 V

MANUAL MODE
OFF
ON

MAN. VALUE
0.0 — 4.0 — 22.0 mA (depending on the signal type)
0 — 10.7 V

10.6.3 TEMPERATURE IN

DIMENS. UNIT
°C
°F

MEAS. MODE
SENSOR
MANUAL

MANUAL VALUE
-20.0 to 25.0 to 150°C

OFFSET
-15.0 to 0.0 to 15.0°C

FILTER TIME
00:00:00 — 00:00:01 — 00:00:25 H:M:S

39
10 Operation
10.6.4 TEMPERATURE OUT

SIGNAL TYPE
0 — 20 mA
4 — 20 mA
20 — 0 mA
20 — 4 mA
0 — 10 V
2 — 10 V
10 — 0 V
10 — 2 V

SCALING START
-20.0 to 0.0°C = 4 mA (depending on the signal type)

SCALING END
+200 to 150.0°C = 20 mA (depending on the signal type)

DURING ALARM
LOW (0 mA / 0 V / 3.4 mA / 1.4 V)
HIGH (22 mA / 10.7 V)
SAFE VALUE (depending on the signal type)

DURING CALIBRATION
MOVING
FROZEN
SAFE VALUE

SAFE VALUE
0.0 — 4.0 — 22.0 mA (depending on the signal type)
0 — 10.7 V

MANUAL MODE
OFF
ON

MAN. VALUE
0.0 — 4.0 — 22.0 mA (depending on the signal type)
0 — 10.7 V

40
 10 Operation
10.6.5 BINARY OUTPUT 1 and BINARY OUTPUT 2

FUNCTION
NO FUNCTION
MIN. CONDUCT.
MAX. CONDUCT.
LK1 CONDUCT.
LK2 CONDUCT.
MIN. TEMP.
MAX. TEMP.
LK1 TEMP.
LK2 TEMP.
CALIB. TIMER
ALARM

MAX limit comparator MIN limit comparator

LK1 alarm window LK2 alarm window

Pulse contact Pulse contact

Trigger condition longer than Trigger condition shorter than
pulse duration pulse duration

41
10 Operation

LIMIT
-20.0 — 0.0 — 999.0 (depending on the function, see above)

HYSTERESIS
0.0 — 0.5 — 999.0 (depending on the function, see above)

SPACING
0.0 — 999.0 (depending on the function, see above)

MANUAL MODE
OFF
ON

FOR HOLD
INACTIVE
ACTIVE
FROZEN

FOR ALARM / CALIB.

INACTIVE
ACTIVE
FROZEN

ON-DELAY
00:00:00 — 01:00:00 H:M:S

OFF-DELAY
00:00:00 — 01:00:00 H:M:S

PULSE DURATION
00:00:00 — 01:00:00 H:M:S (see above: “Function, Pulse contact”)

42
 10 Operation
10.6.6 BINARY INPUT 1 and BINARY INPUT 2

FUNCTION
NO FUNCTION
HOLD/LOCK KEY
RANGE/TEMPCO.
DILUTION

Setting parameters Binary input 1 Binary input 2

Range / Range 1 / open open
temperature TC 1
coefficient Range 2 / closed open
changeover TC 2
Range 3 / open closed
TC 3
Range 4 / closed closed
TC 4
Lock keys closed X
Hold function X closed
Start dilution function close (0 - 1 edge) open
Stop dilution function open close (0 - 1 edge)

10.6.7 DILUTION (description: see "The dilution function", Page 47)

REDUCE
0 — 10 — 50%

DOSING TIME
0:00:00— 00:01:00— 18:00:00 H:M:S

LOCK TIME
0:00:00— 00:01:00— 18:00:00 H:M:S

43
10 Operation
10.6.8 DEVICE DATA

LANGUAGE
GERMAN
ENGLISH
FRENCH
ITALIAN
DUTCH
POLISH
PORTUGUESE
RUSSIAN
SWEDISH
SPANISH

Entering the password 7485 in the administrator level will reset the
operating language to English.

CONTRAST 0 — 6 — 11

LIGHTING
OFF
ON
IF OPERATED (approx. 50 s after the last key operation:
the lighting will be switched off)

LCD INVERSE
OFF
ON

10.7 Administrator level

- All parameters can be edited (altered) in this level.
- In this level, you can also define which parameters can be edited (altered)
by a “normal” user, and/or which calibration actions are permitted.
Editable parameters can be edited in the operator level.
Non-editable parameters are marked in the operator level by a key symbol

You can access the administrator level as follows:

✱ Press the PGM key for at least 3 seconds.
✱ Use the or key to select ADMINISTRATOR LEVEL.
✱ Use or to enter the password 300.
✱ Press the PGM key.

44
 10 Operation

Levels within
the
administrator
level

10.7.1 Parameter level

The administrator can edit all parameters for the operator level in this level.
The structure “Parameter level” within the administrator level is identical to the
operator level, see "Operator level", Page 36 and the following.

10.7.2 Enable level

In this level, the administrator can define which parameters can be altered/
edited by the operator in the operator level.
The available options are READ ONLY and EDIT.
The structure “Parameter level” within the administrator level is identical to the
operator level,
see "Operator level", Page 36 and the following.

10.7.3 Calibration enable (CALIB. ENABLE)

In this level, the administrator can define whether the operator can access
- the relative cell constant
- the linear temperature coefficients
- the non-linear temperature coefficients
for calibration i.e. alteration.

45
10 Operation
10.8 Calibration level
All the calibrations that have been enabled by the administrator (administrator
level) can be carried out in this level.

✱ Press the PGM key for at least 3 seconds.

✱ Use the or key to select CALIBRATION LEVEL.

10.8.1 REL. CELL CONSTANT (relative cell constant)

If this function has been enabled by the administrator, then the operator can
calibrate the relative cell constant of the device here;
see "Calibrating the relative cell constant", Page 51.

10.8.2 TEMPCO LINEAR (linear temperature coefficient)

If this function has been enabled by the administrator, then the operator can
calibrate the device for liquids with a linear temperature coefficient;
see "Linear temperature coefficient (ALPHA)", Page 52.

10.8.3 TEMPCO NON-LIN. (non-linear temperature coefficient)

If this function has been enabled by the administrator, then the operator can
calibrate the device for liquids with a non-linear temperature coefficient;
see "Non-linear temperature coefficient (ALPHA)", Page 55.

46
 10 Operation
10.9 The dilution function
Brief For cooling water, the conductivity is used to deduce the total salt content. If a
description conductivity limit is reached (at the maximum permissible salt content/
concentration), then the cooling water must be diluted. A dilution valve is
opened, the concentrated water flows out, and is replaced by fresh water.
When the conductivity of the cooling water has fallen below the limit, the
dilution valve is closed again.

Addition of A biocide is added to the cooling water, to prevent biological growth in the
biocide cooling system. There is no ideal setting for the amount used and the timing of
the biocide dosing. In most cases, the dosing time is used as the controlled
variable. The dosing quantity is therefore defined by the pumping rate and
duration (system-specific). The success of the biocide treatment must be
checked at regular intervals.

Dilution before If a biocide that increases conductivity is added to the cooling water, this
biocide addition could increase the conductivity to beyond the limit. This would cause the
dilution valve to be opened, and a portion of the added biocide would be
discharged into the waste water (possibly contravening regulations!).
To prevent this, the conductivity in the cooling system is reduced by dilution,
to, for example, 10% below the limit, before the biocide is added. The dilution
valve is then temporarily blocked.

Dilution inhibit After adding the biocide, the dilution should be inhibited for a while, until the
biocide that is present in the cooling system is mostly decomposed (observe
the statutory regulations!).

Implementation - The dilution function is only available in the “Conductivity measurement”

mode – not for concentration measurement.
- When the dilution function is activated, all the parameters that are irrelevant
for this function are switched off.
- The dilution function can be started through binary input 1 and stopped
through binary input 2, see "BINARY INPUT 1 and BINARY INPUT 2", Page
43.
The dilution function can also be stopped by using the EXIT key.
- The present status of the dilution function will be shown in the display.
- The dilution valve is controlled by output K1.
- The addition of biocide valve is controlled by output K2.
- After dilution, K1 goes to the configured hold state (dilution inhibit).

47
10 Operation
- The dilution factor can be adjusted through binary input 1, over a range
1 — 50% below the limit value. The preset value is 10% below the limit.

10.9.1 Stop dilution

All the parameters are system-dependent, and must be adjusted to suit
system requirements.

✱ Press the PGM key for at least 3 seconds.

✱ Use the or key to select OPERATOR LEVEL; use the PGM key to
confirm the selection.

✱ Use the or key to select BINARY INPUT; use the PGM key to confirm
the selection.

48
 10 Operation
✱ Use the or key to select DILUTION; use the PGM key to confirm the
selection.

✱ Change to the operator level, using the EXIT key.

✱ Use the key to select DILUTION.

✱ Confirm the selection with the PGM key.

✱ Use the and/or keys to set the dilution factor in the range from
1 — 10 — 50% below the limit value.
✱ Confirm the selection with the PGM
key.
✱ Use the or key to select DOSING TIME; use the PGM key to confirm
the selection.

✱ Set the dosing time with the and keys in the range from
0:00:00 — 00:01:00— 18:00:00 H:M:S.
✱ Confirm the setting with the PGM
key.

49
10 Operation
✱ Use the or key to select LOCK TIME; use the PGM key to confirm the
selection.

✱ Set the lock time with the and keys in the range from
0:00:00 — 00:01:00— 18:00:00 H:M:S.
✱ Confirm the setting with the PGM
key.

If there is an interruption in the supply voltage during dilution, the

function will be canceled.
The dilution function will have to be restarted if it is to be
continued.

50
 11 Calibration
11.1 General
The device offers various calibration options to increase the precision.

The conductivity sensor should be cleaned and calibrated at

regular intervals (depending on the medium being measured).
The K1 LED blinks during calibration.

11.2 Calibrating the relative cell constant

In order to meet enhanced demands for precision, the cell constant must first
be calibrated.

Requirements - The supply voltage for the device must be present.

see Chapter 7 "Installation", Page 25ff.
- The sensor must be connected to the transmitter (applies to the split
version).
- The transmitter is in the measurement mode.

✱ Immerse the conductivity sensor in a reference solution with a known

conductivity.

The temperature of the sample solution must remain constant

during calibration!

✱ Press the PGM key for at least 3 seconds.

✱ Use the and keys to select CALIBRATION LEVEL; use the PGM key to
confirm the selection.

51
11 Calibration
✱ Use the and keys to select REL. CELL CONSTANT; use the PGM key
to confirm the selection.

✱ When the measurement is stable, press the PGM key.

✱ Use the and keys to correct the indicated uncompensated
conductivity to match the known value for the reference solution.
✱ Press PGM .
The relative cell constant calculated by the device is displayed.

✱ To accept the relative cell constant that has been determined -> press the
PGM key for at least 3 seconds or

to reject the value -> press the EXIT key.

The transmitter is in the calibration menu.
✱ Press the EXIT key;
The transmitter is now in the measurement mode, and shows the
compensated conductivity of the reference solution.

11.3 Calibrating the temp. coefficient of the sample solution

11.3.1 Linear temperature coefficient (ALPHA)
The conductivity of any sample solution will change according to its individual
temperature coefficient.
We therefore recommend carrying out a calibration of the temperature
coefficient.

Requirements - The supply voltage for the device must be present.

see Chapter 7 "Installation", Page 25ff.

52
 11 Calibration
- The sensor must be connected to the transmitter (applies to the split
version).
- The transmitter is in the measurement mode.

✱ Immerse the conductivity sensor in a sample of the solution to be

measured.
✱ Press the PGM key for at least 3 seconds.
✱ Use the and keys to select CALIBRATION LEVEL; use the PGM key to
confirm the selection.

✱ Use the and keys to select TEMPCO LINEAR; use the PGM key to
confirm the selection.

✱ Use the and keys to enter the working temperature; confirm with the
PGM key.

The working temperature must be at least 5°C above or below the

reference temperature (25.0°C).

53
11 Calibration

(1)

(2)

(3)

The LC display now shows

- at top (1): the selected working temperature (blinking)
- in the middle (2): the reference temperature (blinking)
- below (3): the present sensor temperature (steady)
✱ Warm up the sample medium until both the reference and the working
temperatures have been reached (the corresponding values no longer
blink).

During calibration, the rate of change of temperature for the

sample solution must not exceed
10°C/min for the device with exposed temperature sensor, or
1°C/min for the device with an internal temperature sensor.

As soon as one of the target temperatures has been reached, its

display becomes static (no longer blinking).

Calibration can also be carried out through a cooling procedure

(falling temperature). In this case, it starts above the working
temperature and finishes below the reference temperature.

The LC display now shows the derived temperature coefficient in %/°C.

To accept the temperature coefficient that has been determined -> press the
PGM key for at least 3 seconds or

to reject the value -> press the EXIT key.

The transmitter is in the calibration menu.
✱ Press the EXIT key.
The transmitter is now in the measurement mode, and shows the
compensated conductivity of the reference solution.

54
 11 Calibration
11.3.2 Non-linear temperature coefficient (ALPHA)

General Since the temperature coefficient of some media is not constant over a
sizeable temperature range, the device provides the option of subdividing a
temperature range (TStart to TEnd) into 5 sections. A different TC value can be
used for compensation in each of these range sections. This “TC curve” can
be
- edited with the setup program and transmitted to the device.
- or calibration can be performed automatically on the device.

Determining the
TC curve

Calculation of a
temperature
coefficient

α = temperature coefficient (TC)

γ = uncompensated conductivity

55
11 Calibration

TC curve

Temperature The present temperature of the medium is applied to the TC curve to

compensation determine the corresponding temperature coefficient,
with the TC see "TC curve", Page 56.
curve Intermediate values, e.g. (αx at Tx) between two known values (α3 at T3) and
(α4 at T4) are derived through a linear interpolation.
The derived TC is used to calculate the compensated conductivity, in the
same way as with the linear compensation.
If the measured temperature is lower than the start temperature,
the first TC is used for compensation.
If the measured temperature is higher than the end temperature,
the last TC is used for compensation.

Sequence for The TC curve is automatically recorded over a temperature range that has
automatic been defined by the user. The temperature range between the start and end
calibration temperatures is subdivided into 5 sections of equal size.
The temperature range must be larger than 20°C, and cover the reference
temperature.
Example: Reference temperature 25°C, start temperature 18°C and end
temperature 50°C.

56
 11 Calibration

The rate of change of the temperature must not exceed

- 10°C / min. for an exposed temperature sensor, and
- 01°C / min for an internal temperature sensor.

Requirements - The supply voltage for the device must be present.

see Chapter 7 "Installation", Page 25ff.
- The sensor must be connected to the transmitter (applies to the split
version).
- The transmitter is in the measurement mode.

✱ Immerse the conductivity sensor in a sample of the solution to be

measured.
✱ Press the PGM key for at least 3 seconds.
✱ Use the and keys to select CALIBRATION LEVEL; use the PGM key to
confirm the selection.

✱ Use the or key to select TEMPCO NON-LIN.; use the PGM key to
confirm the selection.

57
11 Calibration
✱ Use the and keys to enter the start temperature; confirm with the
PGM key.

The start temperature must be lower than the reference

temperature (25.0°C).

✱ Use the and keys to enter the end temperature; confirm with the PGM

key.

The end temperature must be at least 20°C above the start

temperature.

The transmitter will define the fixed temperature points itself. The LC display
now shows
- at top (1): the next target temperature (blinking)
- below (2): the present sensor temperature (steady)

(1)

(2)

✱ Warm up the sample medium until is it above/below the temperature that is

blinking.

58
 11 Calibration
The next target temperature is displayed as blinking.

During calibration, the rate of change of temperature for the

sample solution must not exceed
10°C/min for the device with exposed temperature sensor, or
1°C/min for the device with an internal temperature sensor.

As soon as one of the target temperatures has been reached, its

display becomes static (no longer blinking).

✱ Warm up the sample medium until is it above the temperature that is

blinking.
✱ Repeat the procedure as often as required, until the device has determined
all 6 temperature coefficients.

The LC display now shows the derived temperature coefficients in %/°C.

✱ To accept the temperature coefficients that have been determined -> press
the PGM key for at least 3 seconds or
to reject the values -> press the EXIT key.
The transmitter is in the calibration menu.
✱ Press the EXIT key.
The transmitter is now in the measurement mode, and shows the
compensated conductivity of the reference solution.

59
12 Maintenance
12.1 Cleaning the conductivity sensor

Do not use solvents.

Hard-to-remove crusts and deposits can be softened and removed
with dilute hydrochloric acid.
Observe the safety regulations!

Deposits Deposits on the sensor section can be removed with a soft brush (e.g. a bottle
brush).

60
 13 Eliminating faults and malfunctions
Error t

possibilities Problem Possible cause Measures

no measurement display supply voltage supply voltage
or missing should be checked,
current output also check terminals
measurement display sensor not immersed in top up the reservoir
000 or medium,
current output 4 mA reservoir level
too low
flow-through fitting flow-through fitting
is blocked should be cleaned
sensor is faulty see "Checking the
device", Page 61
wrong or sensor not immersed top up the reservoir
unstable deeply enough
measurement display inadequate mixing ensure good
mixing
for sensor: all-round
free space of approx.
5 mm
ensure all-round flow
air bubbles check mounting site,
see "General", Page 18.
Measurement value dis- Conductivity measure- Select suitable measure-
play 8888, ment range overshoo- ment range.
temperature display ting or conductivity mea- Replace conductivity
"ok", surement probe faulty. measuring transmitter.
blinking

Measurement value dis- Temperature measure- The temperature of the

play 8888, ment range overshoo- measuring medium must
temperature display ting or undershooting or be in the range from
8888 short circuit or interrupti- 0...150°C.
blinking on of the temperature Replace the conductivity
sensor. measuring transmitter.
Send the device for re-
pairs.

13.1 Checking the device

General The device is calibrated at the factory, and is maintenance-free. If,
nevertheless, measurement deviations appear with no apparent cause, the
transmitter can be tested as follows.

61
13 Eliminating faults and malfunctions
13.1.1 Resistance loop test

Position of the
resistance loop During calibration, do not touch the sensitive part of the cell or put
it down on any surface, otherwise the measurement will be
falsified.

✱ Lead a wire through the cell (see diagram)

✱ Connect a resistor R to the wire

Calculating the Formula for calculating the resistance of the resistance loop:
resistance R = Resistance of the resistance loop
N2· K
R=
Lf N = No. of turns in the loop
K = Cell constant
Lf = Required display in S/cm
Note: 1 mS/cm = 1·10-3 S/cm
1 µS/cm = 1·10-6 S/cm
For display values up to 49 mS, the loop must have 1 turn.
For display values above 50 mS, the loop must have 3 turns.

The cell constant of the device is 6.25 1/cm.

Example 1 The measuring transmitter is to show 20 mS:

12·6.25 1/cm
R= = 312.5 Ω
20·10-3 S/cm
To achieve a display of 20 mS/cm, the resistance loop (with 1 turn) must have
a resistance of 312.5 Ohm.

62
 13 Eliminating faults and malfunctions

Example 2 The measuring transmitter is to show 500 mS:

32·6.25 1/cm
R= = 112.5 Ω
500·10-3 S/cm

To achieve a display of 500 mS/cm, the resistance loop (with 3 turns) must
have a resistance of 112.5 Ohm.

Precalculated
values
Number of
Required display Required resistance
turns
0 µS/cm 0 no resistance
625 µS/cm 1 10000 Ω
1000 µS/cm 1 6250 Ω
2000 µS/cm 1 3125 Ω
5000 µS/cm 1 1250 Ω
10 mS/cm 1 625 Ω
20 mS/cm 1 312.5 Ω
50 mS/cm 3 1125 Ω
100 mS/cm 3 562.5 Ω
200 mS/cm 3 281.3 Ω
500 mS/cm 3 112.5 Ω
1000 mS/cm 3 56.3 Ω
2000 mS/cm 3 28.1 Ω

Test ✱ Calculate the test resistance.

sequence
✱ Wire up the device, see Chapter 7 "Installation", Page 25.
✱ Select the corresponding measurement range, see Chapter 10.6.1
"CONDUCTIVITY IN (Conductivity input)", Page 37 -> RANGE 1 — 4
✱ Set TC to 0%/°C, see Chapter 10.6.1 "CONDUCTIVITY IN (Conductivity
input)", Page 37 -> TEMPCO
✱ Fit the resistance loop as shown in the diagram.

63
13 Eliminating faults and malfunctions
13.1.2 Reference liquid test

Immerse in test
solution

Test ✱ Prepare the conductivity test solution in a container of adequate size.

sequence
✱ Wire up the device, see Chapter 7 "Installation", Page 25.
✱ Select the range appropriate to the conductivity test solution, see Chapter
10.6.1 "CONDUCTIVITY IN (Conductivity input)", Page 37 -> RANGE 1 — 4
✱ Set TC to 0%/°C, see Chapter 10.6.1 "CONDUCTIVITY IN (Conductivity
input)", Page 37 -> TEMPCO
✱ Immerse the cell in the container, and do not move it any more during the
measurement.

64
 13 Eliminating faults and malfunctions
13.1.3 Reference measuring instrument test

Immerse in test
solution

Test ✱ Prepare the conductivity test solution in a container of adequate size.

sequence
✱ Wire up the device, see Chapter 7 "Installation", Page 25.
✱ Select the range appropriate to the conductivity test solution, see Chapter
10.6.1 "CONDUCTIVITY IN (Conductivity input)", Page 37 -> RANGE 1 — 4
✱ Set TC to 0%/°C, see Chapter 10.6.1 "CONDUCTIVITY IN (Conductivity
input)", Page 37 -> TEMPCO
✱ Set the TC for the reference instrument to 0%/°C as well (see operating
instructions for the reference instrument). If this is not possible, then the
sample liquid must be tempered to the reference temperature for the
reference instrument.
✱ Immerse the cell under test and the cell for the reference instrument in the
container, and do not move them any more during the measurement.
✱ The output and display of the device under test or the attached indicator
must match the indication of the reference instrument, taking into account
acceptable device deviations.

65
14 Appendix
14.1 Before configuration
If a number of instrument parameters have to be modified in the instrument,
then it is advisable to note them in the table below, and then modify these
parameters in the sequence given.
The following list shows the maximum number of parameters that
can be altered.
Depending on the configuration, some of the parameters will not
be alterable (editable) for your device.

Parameter Selection / value range New see page

Factory setting adjustment
Conductivity input
Range 1 0 — 500 µS/cm
0 — 1000 µS/cm
0 — 2000 µS/cm
0 — 5000 µS/cm
0 — 10 mS/cm
0 — 20 mS/cm
37
0 — 50 mS/cm
0 — 100 mS/cm
0 — 200 mS/cm
0 — 500 mS/cm
0 — 1000 mS/cm
0 — 2000 mS/cm (uncompensated)
Temperature linear 37
compensation non-linear
natural water
Temperature coefficient 1 0.0 to 5.5%/°C 37
Reference temperature 15.0 to 25.0 to 30°C 37
Relative cell constant 80.0 — 100.0 — 120.0% 37
Mounting factor 80.0 — 100.0 —120.0% 37
Concentration No function 37
measurement NaOH
HNO3
customer-specific
Offset -200 to 0 to +200 mS/cm 38
Filter time 00:00:00 — 00:00:25 H:M:S 38
Calibration interval 0 — 999 days 38
Conductivity output
Signal type 0 — 20 mA 38
4 — 20 mA
20 — 0 mA
20 — 4 mA
0 — 10 V
2 — 10 V
10 — 0 V
10 — 2 V

66
 14 Appendix
Parameter Selection / value range New see page
Factory setting adjustment
Scaling start 0 — 90% = 4 mA (e.g.) 38
of range span
Scaling end 100 — 10% = 20 mA (e.g.) 38
of range span
During alarm low 39
high
safe value
During calibration moving 39
frozen
safe value
Safe value 0.0 — 4.0 — 22.0 mA 39
Manual mode off 39
on
Manual value 0.0 — 4.0 — 22.0 mA 39
Temperature input
Unit °C 39
°F
Measurement mode Sensor 39
manual
Manual value -20.0 to 25 to 150°C 39
Offset -15.0 to 0.0 to +15°C 39
Filter time 00:00:00 — 00:00:01 — 00:00:25 39
H:M:S
Temperature output
Signal type 0 — 20 mA 38
4 — 20 mA
20 — 0 mA
20 — 4 mA
0 — 10 V
2 — 10 V
10 — 0 V
10 — 2 V
Scaling start -20.0 to 183°C = 4 mA 38
(0 — 90% of range span)
Scaling end -3 to 150 to 200°C = 20 mA 38
(100 — 10% of range span)
During alarm low 38
high
safe value

67
14 Appendix
Parameter Selection / value range New see page
Factory setting adjustment
During calibration moving 38
frozen
safe value
Safe value 0.0 — 4.0 — 22.0 mA 38
Manual mode off 38
on
Manual value 0.0 — 4.0 — 22.0 mA 38
Binary output 1 or binary output 2
Function No function 41
Conductivity MIN contact
Conductivity MAX contact
Conductivity LK1
Conductivity LK2
Temperature MIN contact
Temperature MAX contact
Temperature LK1
Temperature LK2
Calibration timer
Alarm
Limit value -20.0 — 9999.0 42
Hysteresis 0.0 — 0.5 — 999.0 42
Spacing 0.0 — 999.0 42
Manual mode off 42
on
For hold inactive 42
active
frozen
For alarm/calibration inactive 42
active
frozen
Switch-on delay 00:00:00 — 01:00:00 42
H:M:S
Switch-off delay 00:00:00 — 01:00:00 42
H:M:S
Pulse duration 00:00:00 — 01:00:00 42
H:M:S
Binary input
Function No function 43
Key lock/hold
Meas. range/temperature
coefficient
Dilution function
Dilution function
Reduction 0 — 10 — 50% 43
Dosing time 00:00:00 — 00:01:00 — 18:00:00 43
H:M:S
Lock time 00:00:00 — 00:01:00 — 18:00:00 43
H:M:S

68
 14 Appendix
Parameter Selection / value range New see page
Factory setting adjustment
Device data
Language German 44
English
French
Italian
Dutch
Polish
Portuguese
Russian
Swedish
Spanish
Contrast 0 — 6 — 11 44
Lighting off 44
on
during operation
LCD inverse off 44
on

69
JUMO GmbH & Co. KG JUMO Instrument Co. Ltd. JUMO Process Control, Inc.
Street address: JUMO House 6733 Myers Road
Moritz-Juchheim-Straße 1 Temple Bank, Riverway East Syracuse, NY 13057, USA
36039 Fulda, Germany Harlow - Essex CM20 2DY, UK Phone: 315-437-5866
Delivery address: Phone: +44 1279 63 55 33 1-800-554-5866
Mackenrodtstraße 14 Fax: +44 1279 63 52 62 Fax: 315-437-5860
36039 Fulda, Germany E-mail: [email protected] E-mail: [email protected]
Postal address: Internet: www.jumo.co.uk Internet: www.jumousa.com
36035 Fulda, Germany
Phone: +49 661 6003-0
Fax: +49 661 6003-607
E-mail: [email protected]
Internet: www.jumo.net
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX C.1：Operator’s Manual for BS-Series Models

(Filtersafe)

Not Applicable

Page 187 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX C.2：Operation Manual for SRF Series

Automatic Back-flushing Filter (Luoyang Sunrui)

Not Applicable

Page 188 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX C.3：Operation instructions for automatic filter

Type 6.18.3 (BOLLFILTER)

Page 189 of 209 Manual Rev: 1.56 BalClor® BWMS

Operating instructions for automatic filter

Type 6.18.3
Nominal diameter DN 200-DN900
Filter element Filter candle

Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.de

Date Version Language Order no. Item

03.2019 001 en

1 / 62
Table of Contents
1 Foreword .................................................................................. 4
1.1 General ...................................................................................... 4
1.2 Warranty and liability ................................................................ 4
1.3 Copyright ................................................................................... 5
2 Basic safety instructions .......................................................... 6
2.1 Proper use .................................................................................. 6
2.2 Warning signs and symbols ....................................................... 6
2.3 Target group .............................................................................. 7
2.4 Obligations of the user/operator ................................................ 7
2.5 Selection and qualifications of staff .......................................... 8
2.6 Organisational measures ............................................................ 9
2.6.1 General ...................................................................................... 9
2.6.2 Maintenance and servicing ........................................................ 9
2.7 Consumables.............................................................................. 9
2.7.1 Filtered media ............................................................................ 9
2.7.2 Cleaning agent ........................................................................... 9
2.8 Safety instructions for operating personnel ............................... 9
2.8.1 Personal safety clothing and equipment .................................. 10
3 Transportation and storage .................................................. 11
3.1 Transportation.......................................................................... 11
3.2 Storage ..................................................................................... 11
3.3 Packaging material .................................................................. 11
4 Scope of delivery .................................................................... 12
5 Technical data ........................................................................ 13
5.1 Type plate ................................................................................ 14
5.2 Tightening torques lubricants for gaskets................................ 14
5.3 Overview of assembly groups ................................................. 15
6 Installation ............................................................................. 21
6.1 Special safety instructions ....................................................... 21
6.2 Filter installation ...................................................................... 22
6.2.1 Floor fastening ......................................................................... 22
6.2.2 Installation diagram ................................................................. 23
6.2.3 Identifying the flow direction .................................................. 24
6.2.4 Filter inlet/outlet pipe connections .......................................... 24
6.2.5 Flushing line pipe connection .................................................. 24
6.2.6 Compressed air supply connection (on pneumatically actuated
flushing valves only) ............................................................... 24
6.2.7 Installing the gear motor .......................................................... 25
6.2.8 Electrical connections .............................................................. 27
6.2.9 Potential equalisation............................................................... 28
7 Operation ............................................................................... 29
7.1 Functional description of the filter .......................................... 29
7.1.1 Filter housing ........................................................................... 29
7.1.2 Controller ................................................................................. 29
7.1.3 Differential pressure monitoring system ................................. 29

2 / 62
7.1.4 Gear motor ...............................................................................30
7.1.5 Flushing valve ..........................................................................30
7.1.6 Control for flushing valve ........................................................30
7.1.7 Filtration stage with filter candles............................................31
7.1.8 Backflushing stage with filter candles .....................................33
7.2 Filter insert ...............................................................................35
7.2.1 Filter insert with filter candles .................................................36
7.2.2 Functional description of the filter insert with filter candles ...37
7.3 Commissioning ........................................................................38
7.4 Removal from service ..............................................................41
7.4.1 Short-term removal from service .............................................41
7.4.2 Longer term removal from service / removal ..........................41
7.4.3 Disposal....................................................................................41
8 Maintenance and servicing ......................................................42
8.1 Contact for spare parts and service ..........................................42
8.2 Special safety instructions........................................................43
8.3 Cleaning agent .........................................................................45
8.4 Standard tools ...........................................................................46
8.5 Special tools .............................................................................46
8.6 Maintenance intervals ..............................................................47
8.7 Cleaning/replacing filter elements ...........................................50
8.7.1 Preparatory work ......................................................................50
8.7.2 Removing the filter insert ........................................................51
8.7.3 Removing the filter candles .....................................................53
8.7.4 Cleaning the filter insert with filter candles .............................55
8.7.5 Installing the filter candles .......................................................56
8.7.6 Installing the filter insert ..........................................................58
8.8 Inspecting the optional sacrificial anode..................................60
8.9 Manually backflushing the filter in the event of power failure 61
8.10 Remedying faults .....................................................................62
8.10.1 Trouble shooting ......................................................................62

3 / 62
1 Foreword
1.1 General
These operating instructions are designed to make it easier to get to
know the BOLL & KIRCH filter and make use of its proper intended
uses.
The operating instructions contain all important instructions on how to
operate the filter safely, properly and economically. Adherence to the
operating instructions helps to prevent hazards, repair costs and reduce
down times and increase the reliability and even the serviceable life of
the filter. Read the operating instructions carefully and attentively.
Supplement the operating instructions with any instructions required due
to existing national and international accident prevention regulations and
environmental protection regulations. Make sure that the operating
instructions are always available in the place of use for the filter. The
operating instructions must be read and applied by every person given
the task of performing the following work:
• transportation,
• installation,
• operation,
• maintenance and servicing,
• Disposal.

1.2 Warranty and liability

The general terms and conditions of purchase of Boll & Kirch Filterbau
GmbH apply.
Boll & Kirch Filterbau GmbH shall not recognise any warranty or
liability claims for personal and material damages if they can be
attributed to one or more of the following causes:
• improper use of the filter,
• failure to comply with the information and instructions in the
operating instructions,
• Improper commissioning operation, servicing, maintenance, repair
and installation of the filter.
• arbitrary constructional modifications to the filter,
• insufficient monitoring of parts which are subject to wear and tear
(e.g. filter elements and seals),
• maintenance/repair work performed improperly or too late,
• disasters caused by external influences or an act of God.
All the information in these operating instructions is provided to the best
of our knowledge based on our prior experience. We reserve the right to
make technical changes as part of further technical development.
The text and graphic illustrations do not necessarily correspond exactly
to the actual delivery. Reference to any deviations is made in the
respective place if required for comprehension. The graphic illustrations
are not true to scale.
A list of spare parts is enclosed with the operating instructions for spare
parts orders.

4 / 62
1.3 Copyright
These operating instructions are a certified document as per the terms of the
law against unfair competition.

The copyright of the document is held

by Boll & Kirch Filterbau GmbH
Siemensstraße 10 - 14
50170 Kerpen
Germany

These operating instructions are for the user of the filter and the user's staff.
They contain text and drawings which, without the express permission of
the manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or
in part. Contravention will require compensation.

5 / 62
2 Basic safety instructions

2.1 Proper use

The filter is constructed with state-of-the-art technology and according to
the recognised rules of safety. However, use of the filter may result in
risks to the life and limb of the user or third parties and/or damage to the
filter or other objects of material value.
Only use the filter if it is in a technically perfect condition and only use it
properly; paying due attention to safety and hazards, and in adherence to
the operating instructions. It is particularly important to remedy any
faults (or have them remedied), which may compromise safety.
The filter is designed only for liquid media filtration. The filter is
designed for installation in pipes. The type of medium agreed on in the
order, and the limit values for operating pressure and temperature as
defined in the technical data must be adhered to. Any other type of use or
use going beyond this use, is regarded as improper use. The
manufacturer/supplier shall not be liable for any damage caused as a
result of improper use. The user bears the sole risk.
Proper use includes observance of the operating instructions and
adherence to the inspection and maintenance conditions.
Operationally safe function is only ensured if all the instructions, settings
and performance limits for the filter, are adhered to.

2.2 Warning signs and symbols

The following designations and symbols are used in the operating
instructions to denote particularly important information:
DANGER!
Denotes immediate hazard with high risk which will cause death or
serious physical injury if not avoided.

WARNING!
Denotes possible hazard with medium risk which may cause death or
serious physical injury if not avoided.

CAUTION!
Denotes a hazard with low risk which could cause light or medium
physical injury or material damages if not avoided.

NOTE

Denotes special user tips and other particularly useful or important

information.

6 / 62
 DISPOSAL
Denotes special measures for environmental protection.

2.3 Target group

The operating instructions apply for use by qualified specialist staff only.
2.4 Obligations of the user/operator
• Always keep the operating instructions at hand at the place of use of the
filter.
• Adhere to general legal and other binding accident prevention
regulations and environmental protection, and provide supplementary
instructions in the operating instructions accordingly. This type of
obligation can apply to the handling of hazardous substances or the
provision/wearing of personal safety clothing and equipment, for
instance.
• Supplement the operating instructions with your own instructions,
including supervision and reporting obligations for specific
operational matters, e.g. with regard to organisation of work,
working sequences and the appointed staff.
• Only trained personnel who are familiar with the basic rules of
occupational safety and who have been instructed in handling the
system may be assigned to work on it.
• The filter may only be operated, serviced, and repaired by personnel
specifically commissioned by the user.
• Unauthorised access to the filter area is prohibited.
• Observe all existing safety instructions and hazard warnings on the
filter.
• Keep all existing safety instructions and danger signs on the filter
complete (in number) and in a legible condition.
• Do not make modifications of any kind to the filter which may
compromise safety, without the permission of the manufacturer.
• The spare parts which are used must comply with the technical
requirements set out by the manufacturer. This is always guaranteed
by the use of original spare parts.
• The user is responsible for the selection of materials and the
chemical resistance of the installed components, internal linings and
coatings. The user must specify the technical details when ordering
the filter.
• Note the description for any attachments and auxiliary equipment
provided. This also includes the supplier documentation and separate
documentation of external manufacturers.

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2.5 Selection and qualifications of staff
• All work on the filter must be performed exclusively by reliable staff.
Staff must not be under the influence of drugs or medication. Adhere
to the legal minimum age requirement.
• Only appoint trained staff or staff who have received appropriate
instruction. Clearly delegate the areas of responsibility of staff for
installation, operation and maintenance and servicing.
The following qualifications for various activity areas are specified in
these operating instructions:
• Instructed persons were taught by the user about the work they are to
perform and possible dangers due to improper conduct and about the
required safety devices and precautions in an instruction session.
• By reason of their professional training, knowledge and experience,
and knowledge of the relevant regulations, specialist staff are able to
perform the work assigned to them and to independently recognise
and avoid possible hazards.
• By reason of their professional training, knowledge and experience,
and knowledge of the relevant standards and regulations, electricians
are able to perform work on electrical systems and to independently
recognise and avoid possible hazards. The electrician is trained for the
special place of use where they are working and knows the relevant
standards and regulations.
Internal instruction must be provided taking into account the professional
qualifications of each person.
Along with the safety instructions in these operating instructions,
compliance must be ensured with the following requirements and
regulations:
• the relevant accident prevention regulations
• occupational health requirements
• generally recognised rules of safety
• national regulations in the country of use
• the documentation of attachments
• the documentation enclosed with the system by the manufacturer
• the manufacturer's data (safety data sheets) for consumables,
chemical substances
• proper use
Moreover, these requirements and regulations can also be supplemented
by internal factory or company regulations.

8 / 62
2.6 Organisational measures

2.6.1 General

• Follow the respective valid national and international accident

prevention regulations.
• Avoid direct contact with the surfaces. Depending on the operating
temperature, there may be a risk of burns.
2.6.2 Maintenance and servicing

• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of
parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and
testing organisation, with regard to temperature, steam pressure and
the dangerousness of the medium, the inspection periods must be
adhered to by the user.
NOTE

Filter elements and seals are wear parts

During all maintenance, check the filter elements and seals for damage
and replace these.
Boll & Kirch Filterbau GmbH recommends that you keep a complete set
of filter elements and seals in stock.

2.7 Consumables
• Observe the regulations for environmental protection. Make sure that
consumables are disposed of properly and in an environmentally
friendly manner.
2.7.1 Filtered media

• When handling media which are to be filtered, make sure you follow
the respective safety regulations for the media.
2.7.2 Cleaning agent

• When handling the cleaning agents, make sure you follow the
respective safety regulations for the cleaning agents.
2.8 Safety instructions for operating personnel
Refrain from every manner of working which
– endangers the life and limb of the user or third parties,
– can damage the filter or other assets,
– impair the filter's safety and function,
– are contra to the safety instructions listed.

9 / 62
2.8.1 Personal safety clothing and equipment

The protective clothing and equipment required by the company must be

worn for all work on the filter. These include protective ear wear, safety
shoes, safety helmet (with face guard if required), protective clothing,
protective gloves, and face guard.

10 / 62
3 Transportation and storage
3.1 Transportation

DANGER!

Risk of accidents from falling loads

During transportation of the filter, accidents may occur due to sizes and
weights.
• Exercise extreme caution when transporting the filter in order to
prevent damage to or deformation of the filter.
• Avoid impacts, e.g. the load falling into the slinging gear.
• Only use suitable means of transport and lifting gear with sufficient
load- bearing capacity.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• Wear the appropriate protective clothing.

NOTE

You can find detailed information about transport and lifting procedures
in the "Technical data" chapter of these operating instructions.

3.2 Storage

CAUTION!

Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and soiling, for example,
may
cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and soiling during
storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one
year, check that all seals are fully functional before installation.

3.3 Packaging material

CAUTION!

Risk of explosion from electrostatic charge

Packaging material, such as paper or plastic, can become statically
charged and generate sparks when discharged.
• Remove the packaging material before transportation into an
explosive atmosphere.

11 / 62
 DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally
friendly manner.
4 Scope of delivery
Immediately after receiving the delivery, check that the content is not
damaged and that it corresponds to the scope of the order. In case of
discrepancies, contact the manufacturer.

12 / 62
5 Technical data

NOTE

You will find the technical data in the appendix of these operating
instructions.

NOTE

Only fasten the transport chains or ropes to the suspension points.

• The crane hooks must be positioned above the centre of gravity for the
lifting process in order to keep the load balanced. For the centre of
gravity, please see the Technical data sheet in the appendix.
• Avoid impacts, e.g. the load falling into the slinging gear.

NOTE

The national requirements of the country of use must also be adhered to.

2x 2x

Fig. 5-1 Suspension points

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5.1 Type plate
The type plate is placed on the filter. You can read the maximum
permitted operating pressure and the maximum / minimum operating
temperature from the type plate.

NOTE
When making enquiries or ordering spare parts, always indicate the
information mentioned on the type plate.

5.2 Tightening torques

lubricants for gaskets
The tightening torques for screws and lubricants can be found on our
website Bollfilter.com under Downloads/Services or via the following
link:
https://www.bollfilter.com/de/downloads/serviceunterlagen.html

14 / 62
5.3 Overview of assembly groups

NOTE

The description of assembly groups can be found in the "Operation"

chapter of these operating instructions.
Applies to DN 200 - DN 400

1
13

12 2

3
11

10

6
7
8

Fig. 5-2 Overview of assembly groups

1 Gear motor 8 Measuring connection

2 Automatic venting 9 Lower section of
3 Suspension point 10 Measuring connection
4 Type plate 11 Upper section of
5 Differential 12 Cover
pressure
monitoring system
6 Solenoid valve 13 Measuring connection
7 Flushing valve

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Applies to DN 200 - DN 400

16

15

14

Fig. 5-3 Overview of assembly groups

14 Draining
15 Sacrificial anode
16 Measuring connection

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Applies to DN 200 - DN 400 with filter candles

1
2
3
4

11 5

N2

10

9
8
6
7

N1

N3

Fig. 5-4 Overview of assembly groups (cross sectional view)

1 Drive shaft 8 Bottom sieve

2 Claw 9 Filter candle
3 Top flushing arm 10 Spacer pipe
4 Flushing plate 11 Top sieve plate
5 Connecting pipe N1 Filter inlet
6 Bottom flushing arm N2 Filter outlet
7 Flushing line socket N3 Flushing line

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Applies to DN 500 - DN 900

12
2
3
11

10

6
7
9
8

Fig. 5-5 Overview of assembly groups (cross sectional view)

1 Drive shaft 8 Bottom sieve

2 Claw 9 Filter candle
3 Top flushing arm 10 Spacer pipe
4 Flushing plate 11 Top sieve plate
5 Connecting pipe N1 Filter inlet
6 Bottom flushing arm N2 Filter outlet
7 Flushing line socket N3 Flushing line

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Applies to DN 500 - DN 900

15

14

Fig. 5-6 Overview of assembly groups

14 Draining
15 Sacrificial anode

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Applies to DN 500 - DN 900 with filter candles

1
2
3

11
4

N2
5
10

8
6

N1 N3

Fig. 5-7 Overview of assembly groups (cross sectional view)

1 Drive shaft 8 Bottom sieve

2 Claw 9 Filter candle
3 Top flushing arm 10 Spacer pipe
4 Flushing plate 11 Top sieve plate
5 Connecting pipe N1 Filter inlet
6 Bottom flushing arm N2 Filter outlet
7 Flushing line socket N3 Flushing line

20 / 62
6 Installation

6.1 Special safety instructions

DANGER!

Risk of accidents from improper

installation
Incorrect installation and failure to follow the listed safety instructions can
lead to accidents or damage to property.
Make sure of the following:
• The filter must be installed by qualified specialist staff or persons
who have received appropriate instruction.
• Wear the appropriate protective clothing.
• Use of the lifting gear is only permitted for authorised persons who
have received appropriate instruction.
• Cordon off the working and suspending area against access before
lifting the load.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Proceed with extreme caution when handling the loads.
• Use lifting gear in such way that the filter does not become damaged.
• Raise the filter evenly. Avoid tilting.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• As there is a risk of crushing, all limbs must be kept away from
separating joints.
• Additional devices to prevent maximum temperatures being
exceeded and temperatures dropping below the minimum and for
compensation and relief of overpressure, must be provided by the
user throughout the entire system of the plant. Observe the minimum
and maximum permitted operating temperatures and pressure values
for the filter.
• Additional devices for monitoring the ambient temperature of the
filter must be provided by the user throughout the entire system of
the plant.
• Install a ground cable with a cross section of at least 10 mm² as a
potential equalisation for the filter.

NOTE

Contact the manufacturer with any special questions you may have
regarding the installation. The contact data for the respective national
subsidiaries can be found in the appendix of the operating instructions.

21 / 62
6.2 Filter installation

CAUTION!

Risk of damage to the filter housing

The filter housings are designed exclusively for internal overpressure.
• The housing and connection flanges of the filter must not be exposed
to any external force or moment.

6.2.1 Floor fastening

1
2

Fig. 6-1 Automatic filter with support leg for floor fastening

1 Lower section of housing

2 Fastening point

▶ Make sure the foundation has sufficient load-bearing strength.

▶  Make sure that there is sufficient space in the vicinity of the filter for
maintenance and servicing work.
▶ Align the filter.

▶ Screw the filter housing to the fastening points. When fastening the
filter in place, the filter housing must not be twisted.

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6.2.2 Installation diagram

11

8 10

3
9

10

12
10

2 5 7
1

Fig. 6-2 Installation diagram

1 Grating/suction strainer 7 Flushing line

2 Pump (or geodetic feed) 8 Bypass line
3 Filter 9 Bypass filter (optional)
4 Controller 10 Shut-off valve
5 Flushing valve 11 Scope of delivery (standard)
6 to the consumer 12 Flushing valve control
(valve- related)
NOTE

• Depending on the type of contamination BOLL & KIRCH Filterbau

GmbH recommends using a grating or protective pump sieve for pre-
filtering.
Filter with sieve cylinder
- overall size 273 up to incl. 356: 20 mm pre-filter
- overall size 419 up to incl. 600: 35 mm pre-filter
- overall size 750: 60 mm pre-
filter filter with filter candle: 10 mm pre
filter
filter with fine sieve cylinder: 5 mm pre-filter
These values are subject to an application test by Boll & Kirch
Filterbau GmbH
• In the case of extensive soiling, the filter can be flushed out through
the N8 connection.
23 / 62
6.2.3 Identifying the flow direction

NOTE

• The direction of flow is shown in the technical data sheet which is

included in the appendix of these operating instructions.

6.2.4 Filter inlet/outlet pipe connections

▶ Make sure that there is sufficient space in the vicinity of the filter
for maintenance and servicing work.
▶ Establish the connections between the filter and piping.
▶ Use the appropriate seals.

▶ The pipes for the filter inlet and outlet may need to be provided with
additional supports, depending on the installation conditions. When
installing the piping, the filter housing must not be twisted.
6.2.5 Flushing line pipe connection

▶ Establish the connection between the flushing line and piping.

▶ Use the appropriate seal.

▶ The pipe may need to be provided with additional supports, depending

on the installation conditions. When installing the piping, the housing
must not be twisted.
Installation
▶ The available pressure gradient between the filter outlet and the
flushing valve must be between 2 and 3 bar, in order for the filter to
achieve a good flushing effect and not damage components.
▶ The flushing line must be laid in such a way that the previous section
is fulfilled. For this, the pressure loss of the flushing line including
further valves, deflections, the overboard valve etc., must be
calculated for the specified flushing quantities.
▶ When installing the filter on a ship, the influence of the maximum
draft (hydrostatic back pressure) must also be taken into account.
NOTE

Please ensure that you follow the design sheet from Boll & Kirch Filterbau
GmbH when laying the pipe, which was provided to you as an attachment
along with the quote and order confirmation.

6.2.6 Compressed air supply connection (on pneumatically actuated

flushing valves only)

▶ Connect the plant's compressed air supply to the solenoid valve.

24 / 62
6.2.7 Installing the gear motor

Fig. 6-3 Gear motor installation

1 Hand winch 4 Cover

2 Screw 5 Differential
pressure
3 Gear motor 6 Shaft

WARNING!

Risk of accidents from heavy component

During installation of the gear motor, accidents may occur due to sizes
and weights.
• Lift the gear motor using suitable lifting gear.
• Do not lift the gear motor onto the junction box.

▶ Clean cover and gear motor flange.

25 / 62
NOTE

• Install the gear motor so that the electrical connections of the gear
motor and the differential pressure monitoring system point in the
same direction.

▶ Place the gear motor on the cover. Ensure that the feather key slides
into the groove of the shaft.
▶ Fasten the gear motor in place with the screws provided. Tighten the
screws evenly, gradually tightening opposite screws step-by-step.
NOTE

Pay attention to the rotation of the motor.

The drive shaft of the gear motor rotates clockwise when the motor fan
turns counterclockwise.

▶ Carry out a functional test of the drive:

▶ Attach the hand winch to the shaft end of the gear motor.
▶ Rotate the hand winch three turns in the direction of the arrow (see
figure below) and release the hand winch immediately.
▶ Check the position of the hand
winch. It must remain in the
current position.
NOTE

If you detect that the hand winch turns back automatically, there may be a
mechanical fault.
Resolve the causes of the fault and finally, repeat the functional test.

▶ Remove the hand winch from the gear motor.

Fig. 6-4 Direction of rotation of the motor

26 / 62
6.2.8 Electrical connections
DANGER!

Risk of accidents from electric shock

When connecting to the power supply, the supply voltage can cause
accidents from electric shock.
• All the electrical connections on the filter must be made by a
qualified electrician and in line with the rules of electrical
engineering.

Controller
NOTE

If you are using a Boll & Kirch Filterbau GmbH controller, you will
find more detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller,
the respective documentation must be followed.

Differential pressure monitoring system, electrical

NOTE

You will find more detailed information on the differential pressure

monitoring system in the appendix of these operating instructions or in the
manufacturer's documentation.

NOTE

Boll & Kirch Filterbau GmbH differential pressure indicators have

potential-free contacts.

CAUTION!

Risk of malfunction or damage to the filter or plant

Failure to react to the alarms can lead to malfunctions or damage to the
filter or
the plant.
• Connect the differential pressure monitoring system so that the
alarms are issued.
• It is imperative to react to any active alarms and remedy the cause
immediately.

Gear motor
You will find more detailed information on the gear motor in the appendix
of these operating instructions or in the manufacturer's documentation.

27 / 62
6.2.9 Potential equalisation

▶ For potential equalisation, install a ground cable with a cross section

of at least 10 mm² on the filter.
▶ Connect the ground cable to the fastening screw on the filter. If
necessary, prior to the installation of the ground cable, remove the
paint from the fastening point to ensure sufficient electrical contact.

CAUTION!

Without the potential equalization (top housing to bottom housing and

cover), the anodic protection does not work.
• For BWT applications, fresh water must be filled in at every
standstill.

28 / 62
7 Operation
7.1 Functional description of the filter
The filter is used for particle filtration from media in order to protect the
downstream parts of the plant. The filter is used especially for difficult
applications caused by high levels of dirty cargo, soiling which is
difficult to remove or low operating pressures.
The two-way regeneration effect of the filter candles optimised for these
applications makes for a high level of cleaning during backflushing
which in turn keeps the pressure loss on the filter constant.
It can be used as a main flow filter or partial flow filter.
The filter candles are cleaned automatically so that the plant does not
have to be switched off for cleaning.
7.1.1 Filter housing

The filter housing contains all the pipe connections, the venting, drain
hole and the connection points for the pressure monitoring system. The
lower section of housing is screwed to the upper section of housing,
which is screwed to the cover. The gear motor is fastened to the cover.
The inside of the filter is fitted with an internal lining/coating. To protect
the inner parts, a sacrificial anode is used in the filter.
7.1.2 Controller
The controller regulates and monitors all automatic filter
functions.
NOTE

If you are using a Boll & Kirch Filterbau GmbH controller, you will
find more detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller,
the respective documentation must be followed.

7.1.3 Differential pressure monitoring system

The differential pressure monitoring system measures the pressure

difference between the filter inlet and filter outlet. As the soiling in the
filter candles increases, the differential pressure in the filter also
increases.
The controller processes the electrical signals from the differential
pressure monitoring system and triggers a backflushing procedure or
issues an alarm if the differential pressure continues to rise despite
backflushing having been performed. In case of an active alarm the filter
has to be taken out of service and cleaned and/or serviced.

29 / 62
 NOTE

• You will find more detailed information on the differential pressure

monitoring system in the appendix of these operating instructions or
in the manufacturer's documentation.
• The differential pressure can also be displayed optically on the
differential pressure monitoring system.
• The control line for the differential pressure monitoring system is
fitted with shut-off valves (e.g. ball valves).

7.1.4 Gear motor

If the pressure gradient between the dirty side and the clean side reaches
a predefined value due to the growing layer of dirt on the filter material,
the filter element cleaning function is triggered automatically.
To do so, the gear motor turns the flushing device at constant speed until
the gear motor is switched off automatically after a set time.
7.1.5 Flushing valve

The pneumatically or electrically actuated flushing valve opens and

closes the flushing line at the start and end of the backflushing stage,
respectively.
NOTE

Depending on the type of actuation used for the flushing valve, the
flushing valve can be actuated manually if required, e.g. to manually
backflush the filter in case of power failure. For more detailed
information, see section 9 of these operating instructions.

7.1.6 Control for flushing valve

Pneumatically actuated flushing valves are controlled by a solenoid valve.
Depending on the filter design/control medium shut-off valves, one-way
restrict or valves or pressure controllers, for instance, can be connected
upstream of the solenoid valve.

30 / 62
7.1.7 Filtration stage with filter candles

N2

N1

Fig. 7-1 Filtration stage

1 Gear motor N1 Filter inlet

2 Filter candle N2 Filter
3 Flushing valve
4 Spacer pipe

31 / 62
In filtering mode, the medium being filtered flows into the housing via
the inlet flange.
The spacer pipe guides a partial current of the unfiltered medium into the
upper area of the housing. It flows through the two ends into the filter
candles and flows through the filter candles from the inside out. Any
particles in the medium are caught on the filter mesh of the filter candles.
The cleaned medium proceeds to the filter outlet.
The flushing valve is closed.
The gear motor is switched off.

32 / 62
7.1.8 Backflushing stage with filter candles

2
9
3

8
4

N2

N1

N3
5

Fig. 7-2 Backflushing stage

1 Gear motor 7 Differential pressure

monitoring system
2 Top flushing arm 8 Hydrodynamic
3 Flushing bush 9 Connecting pipe
4 Filter candle N1 Filter inlet
5 Flushing valve N2 Filter outlet
6 Bottom flushing arm N3 Flushing line

33 / 62
The particles caught on the filter elements generate a growing
differential pressure between the filter inlet and outlet.
Backflushing is triggered by the controller when the differential pressure
reaches a certain value.
NOTE

Backflushing is triggered by the controller at set time intervals in order to

prevent the backflushing device from seizing up and to prevent
encrustations from building on the filter elements, even when the
maximum permitted differential pressure has not been reached.

During the backflushing stage the filter candles are cleaned one by one
by the upper and lower flushing arms alternately.
The gear motor turns the flushing arm (which is displaced by 90°) with
the flushing plates past the individual filter candles. At the same time the
flushing valve is opened. Afterwards, this causes a high axial flow in the
filter candle and the captured particles of dirt are rinsed off.
The medium flowing lengthways through the filter candles (cross-flow
backflushing) conveys the particles of dirt out of the filter.
The hydrodynamic element which is positioned in the middle of the filter
candles increases the speed of the flow.
The dimensions of the internal parts and the additional cross-flow
backflushing generate a high backflushing effect to ensure that the filter
candles are regenerated properly. After a predefined period of time and
after the flushing arms have completed a full rotation, the control unit on
the gear motor turns off. The flushing valve is closed.
The filter is cleaned.
The full throughput volume is maintained even during the regeneration
stage.
NOTE

• With displacement pumps the throughput is reduced by the

backflushing quantity. This backflushing quantity is only
effective during the backflushing stage.
• With centrifugal pumps or buffered systems there is no drop in
throughput at the filter outlet during the backflushing stage.

The control valve (installed by the customer) installed in the flushing

line allows the backflushing quantity to be optimised depending on the
pressure and type of contamination.
NOTE

If you are using a Boll & Kirch Filterbau GmbH controller, you will find
more detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller,
the respective documentation must be followed.

34 / 62
7.2 Filter insert

NOTE

Always ensure that the filter insert is not placed on the lower bush or
flushing arm shaft outside the filter housing and that the upper and lower
seal of the filter insert are not damaged.
These seals have to be removed to perform maintenance work on a filter
insert.
• When installing a filter insert, be sure to install the seals at the top and
bottom of the filter insert before installing it.
• Replace any damaged seals.

35 / 62
7.2.1 Filter insert with filter candles

1 2 3 4 5

13 12 11

10

Fig. 7-3 Construction of the filter insert with filter candles

1 Socket 8 Flushing device

2 Seal 9 Bottom sieve
3 Seal 10 Seal
4 Top sieve plate 11 Seal
5 Seal 12 Seal
6 Filter candle 13 Socket
7 Anchor

36 / 62
7.2.2 Functional description of the filter insert with filter candles

Filter inserts with filter candles are used for filtration. The flow runs
from the inside to the outside through the individual filter candles.
Particles of dirt in the flow are thus filtered off by the filter candles. The
cleaned medium exits from the side of the filter candles and is fed back
into the plant.
The filter insert with filter candles comprises several filter candles
arranged in parallel. The filter candles all have the same dimensions;
they are interchangeable and can also be removed separately. The open
ends of the filter candles are pressed into the bottom sieve plate and top
sieve plate. The cover plate secures the filter candles to prevent them
from sliding out upwards.
The type, version and number of filter candles used depends on the
medium being filtered.
The gap between the top sieve plate and the bottom sieve plate is
determined by the length of the spacer pipe and the anchors.
The dirty side is sealed off from the clean side by seals on the top and
bottom sieve plate or at the ends of the filter candles.
The dirt particles caught on the filter element are cleaned off using the
flushing device, which is stored in the filter element by means of the
sockets.

37 / 62
7.3 Commissioning

CAUTION!

Risk of damage to the filter from improper filling

If the filter is filled improperly, the filter elements may be damaged.
• Filling the filter against the indicated direction of flow of the filter
elements is not permitted.

CAUTION!

Risk of contaminating the filter elements due to improper filling

During the initial commissioning of the ballast water treatment system,
the filter must be bypassed (bypass). This will prevent residue (e.g.
welding beads) in the lines from depositing on the surface of the filter
elements.

NOTE

If you are using a Boll & Kirch Filterbau GmbH controller, you will find
more detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller,
the respective documentation must be followed.

▶ Check whether all connections have been made properly.

▶ On filters with a pneumatically controlled flushing valve, open the

shut-off valves (if fitted) that are installed upstream of the solenoid
valve.
▶ On filters with a pneumatically controlled flushing valve, check the
pressure of the control medium and adjust it as needed.
▶ Open the shut-off valves in the control line to the differential pressure
monitoring system.
▶ Open the control valve (if fitted) in the flushing line.
▶ Switch on the filter controller.
DANGER!

Risk of accidents from expelled medium

Hot medium (air, vapour or liquid) may be expelled during opening of the
automatic vent.
• Proceed with extreme caution.
• Wear the appropriate protective clothing.
• Keep a safe distance from the outlet opening.

38 / 62
 DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is
disposed of properly and in an environmentally friendly manner.

▶ Bleed the filter as follows:

▶ Close the shut-off valve in the bypass line.
▶ Open the shut-off valve at the filter outlet.
▶ For displacement pumps: Completely open the shut-off valve at
the filter inlet.
▶ For centrifugal pumps: Open the shut-off valve at the filter inlet
only partially and after switching on the centrifugal pump
gradually open the shut-off valve at the filter inlet completely.
This way you prevent pressure surges in the plant.
 ▶ Manually trigger backflushing on the controller. The gear motor
turns in accordance with the set time and the flushing valve is
activated.
 ▶ Two bar is recommended for the pressure gradient between the
filter outlet and the flushing valve in order for the filter to achieve
a good flushing effect and not damage any components.
▶ The filter is ready for operation.
NOTE

The filter is a pressure vessel and requires checking according to local

regulations and rules.

DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is
disposed of properly and in an environmentally friendly manner.

▶ If the differential pressure between the filter inlet and filter outlet
increases during operation, backflushing is triggered automatically.
The backflushing procedure ends automatically once the set time
elapses.
NOTE

Backflushing is triggered by the controller at set time intervals in order to

prevent the backflushing device from seizing up, even when the
maximum permitted differential pressure is not reached.

▶ If the differential pressure is not reduced by any great degree once

backflushing has been performed, either the pressure downstream of
the filter is too low or the backflushing quantity is too low as a result
of excessive throttling by the control valve in the flushing line.

39 / 62
▶ If the differential pressure increases again despite correct backflushing,
an alarm is issued. If this is the case, remove the filter from service
by opening the shut-off valve in the bypass line and closing the shut-
off valves on the filter. Remove and thoroughly clean the filter insert.

40 / 62
7.4 Removal from service

7.4.1 Short-term removal from service

NOTE

The flushing device has to be moved every 24 hours while the

backflushing valve is closed so as to ensure that it can be operated and
restarted.

▶ Depressurise and drain the filter, see chapter 8, section "Preparatory

work". When using the filter in watery media, it is imperative to adhere
to the following:
CAUTION!

Bachflushing of the filter after ballast water filtration

On competition of the ballast water filtration, it is recommended to carry out
the backflush cycle three times. Afterwards, it is imperative to fill the filter
with fresh water (not salt water) to prevent dirt deposits on the mesh and then
hardens. Running the filter to empty must be avoided in any event.

7.4.2 Longer term removal from service / removal

NOTE

The flushing device has to be moved every 24 hours while the

backflushing valve is closed so as to ensure that it can be operated and
restarted.

▶ Depressurise and drain the filter, see chapter 8, section "Preparatory

work".When removing the filter and removing it from service for longer
periods, pay attention to the following points in order to prevent crevice
corrosion:
NOTE

• The filter must be completely drained.

• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or
similar) dummy plugs.

7.4.3 Disposal

DISPOSAL
When the filter or individual components and consumables are finally
disposed of, make sure that they are disposed of in an environmentally
friendly manner.

41 / 62
8 Maintenance and servicing
8.1 Contact for spare parts and service
Should you require any spare parts, please contact spare-
[email protected]. Should you require service, please contact our service
team at +49 2273/562-222 or [email protected].

42 / 62
8.2 Special safety instructions

DANGER!

Risk of accidents from improper maintenance and servicing

Incorrect maintenance and servicing and failure to observe the listed
safety
instructions can lead to accidents and damage to property. Make sure of
the following:
• Maintenance and servicing work must only be carried out by
qualified specialist staff or persons who have received appropriate
instruction.
• When performing any work on the filter, always wear the appropriate
protective clothing.
• Use of the lifting gear is only permitted for authorised persons who
have received appropriate instruction.
• Cordon off the working and suspending area against access before
lifting the load.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Proceed with extreme caution when handling the loads.
• Use lifting gear in such a way that the filter or the components do not
become damaged.
• Raise the filter or the components evenly. Avoid tilting.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• As there is a risk of crushing, all limbs must be kept away from
separating joints.
• Only perform maintenance and servicing work when the filter is
cooled, depressurised and drained. Depending on the operating
temperature, there may be a risk of burns.
• Ensure the highest levels of cleanliness when opening the filter. No
foreign substances, e.g. tools, cleaning cloths, impurities, etc., must
be allowed to remain in the filter.
• Visually inspect all seals during maintenance and replace them as
necessary.
• Clean all sealing surfaces thoroughly before assembly.
• Self-locking connecting elements (self-locking screws/nuts) should
not be reused after disassembly. Replace them with the appropriate
new parts.
• On completion of the maintenance work, re-fit all available safety
equipment properly.
• Filling the filter against the indicated direction of flow of the filter
elements is not permitted.

43 / 62
• Remove the filter from service if the inspection periods (if indicated)
have elapsed.
• Filter elements are sensitive to pressure and impact. Always exercise
extreme caution when installing and removing the filter elements.
Before installation, check all filter elements/seals and replace any
damaged filter elements/seals.

44 / 62
8.3 Cleaning agent

CAUTION!

Risk of damage to the filter from incorrect use of cleaning agents

The components of the filter may become damaged if cleaning agents are
used incorrectly. The correct cleaning agent is selected in accordance with
the type of medium being filtered and the associated soiling.
• Boll & Kirch Filterbau GmbH recommends BOLL CLEAN 2000
cleaning agent. For more detailed information, see the appendix of
these operating instructions.
• With liquid cleaning agents, ensure that after cleaning, the filter
components are only reinstalled when completely dry.

45 / 62
8.4 Standard tools
The following standard tools are needed for maintenance
(sample representations of various sizes):

Open-end spanner Hex key

Circlip pliers Screwdriver

Torque wrench

8.5 Special tools

The manufacturer provides the following special tools (example
illustration) for the filter:

Key for opening the controller (if it is

included in the scope of delivery)

Hand winch for actuating the filter in case

46 / 62
8.6 Maintenance intervals
Even automatic filters have to undergo regular checks and maintenance.
It is particularly important to note that the filter material on the filter
elements may become blocked over time despite regular backflushing.
This depends largely on the quality of medium and the available partial
flow cleaning function. The soiling can be removed by cleaning the filter
elements by hand using a suitable cleaning agent. Descale any calcified
filter elements.
NOTE

Boll & Kirch Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.

You can tell that the filter elements are becoming increasingly blocked
because the flushing intervals become shorter and shorter.
The number of backflushing cycles performed is recorded by the
controller.
CAUTION!

Risk of damage to the filter and the plant from damaged filter elements
If the flushing intervals suddenly become longer, this may indicate that
the filter elements are damaged.
• In such an event, check all filter elements for damage immediately.
Replace any damaged filter elements.

47 / 62
In order to make sure the filter continues to operate properly, observe
the following points for maintenance:
• Regularly check:
– the differential pressure,
– the leak tightness of the filter, especially all connections and seals
and
– the filter for corrosion and other damage and
– the condition of all screw connections and whether they are firmly
tightened.
• Check the condition of the optional sacrificial anode at least 2x per
year. Replace the sacrificial anode when the zinc mass has worn in
such a way that the carrier frame can be seen.
• Check filters at least 1x per year or filters with an ATEX rating 2x per
year for the following:
– the condition of all seals,
– the condition of all lines,
– the condition of the filter elements,
– the condition of the bearing and the bearing bush,
– the condition of all flushing bushes and
– the condition of the potential equalisation and its fastening.
Replace any damaged components.
• Check filters with an inner lining/coating for internal corrosion and
any material abrasion caused by medium contamination each time
you open the filter element or at least 1x annually. Boll & Kirch
Filterbau GmbH is to be consulted in the event that damaged surfaces
have to be repaired. The contact data for the respective national
subsidiary can be found in the appendix of the operating instructions.
• Replace all seals when overhauling the filter.
NOTE

Detail information regarding the recommended checks on the filter and

the recommended replacement of filter elements and seals can be found in
“ Maintenance schedule” section.

NOTE
The filter elements are subject to wear from two-way strain. It is therefore
recommendable to keep a complete set of filter elements in stock.

NOTE

The filter is a pressure vessel and requires checking according to local

regulations and rules.

48 / 62
 8.6.1 Maintenance schedule
NOTE

The following tables described the recommended checks and replacement

intervals.
The recommended replacement intervals depend on the application.

NOTE

Defective components must be replaced immediately. Only original

BOLL&KIRCH spare parts ensure safe operation and low maintenance.

Recommended checks During 50 h after the EVERY 6 EVERY 12

initial last months or months or
commissioni maintenance 2200 flushes 4300 flushes
ng or repair
Differential pressure indicator X X X
Screw connections and lines X X X
Leak tightness of the filter X X
Corrosion and other damage X X X
Condition of the sacrificial anode X X
(optional)
Condition of bearing and bearing bush X
Condition of all flushing bushes X
Condition/ secure seat/ electrical X
resistance of the potential
Proper function of the venting system X X
Filter element X

Evey 6 Evey 12 Evey 24 Evey 36

months or months or months or months or
2200 4300 8600 13000
flushes flushes flushes flushes
Sacrificial anode X X X
Bearing, bearing bush, sliding profile, X X
flushing plates
Socket X X
Springs X X
Filter element X
Seals X X X
Roller diaphragm for the differential X X
pressure indicator (optional)
Solenoid valve (optional) X X
Spare parts package for the 0301192 0301193 0301194
maintenance intervals after operating 8,000 h 16,000 h 24,000 h
hours
49 / 62
8.7 Cleaning/replacing filter elements

8.7.1 Preparatory work

NOTE

If you are using a Boll & Kirch Filterbau GmbH controller, you will find
more detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller,
the respective documentation must be followed.

▶ Take the plant out of operation or open the shut-off valves of the by-pass
line.
▶ Switch off the controller.
DANGER!

Risk of accidents due to controller being switched on unintentionally

During maintenance accidents may be caused if the controller is switched
on unintentionally, e.g. by starting up the drives or from expelled medium.
• Secure the controller to prevent it from being switched on
unintentionally, e.g. by attaching a lock.

▶ On filters with a pneumatically or hydraulically controlled flushing

valve close the shut-off valves (if fitted) for the control medium.
Secure the control line to prevent it from being switched on
unintentionally.
▶ Close the shut-off valves on the connection lines. Secure the shut-off
valve to prevent it from being switched on unintentionally.
DANGER!

Risk of accidents from expelled medium

Hot medium can be expelled during depressurisation.
• Proceed with extreme caution.
• Wear the appropriate protective clothing.

DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is
disposed of properly and in an environmentally friendly manner.
▶ Depressurise the filter.
DANGER!

Risk of accidents from expelled medium

Hot medium may be expelled when opening the drain hole.
• Proceed with extreme caution.
• Wear the appropriate safety equipment and clothing.

50 / 62
 • Collect the expelled medium in a suitable container.

DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is
disposed of properly and in an environmentally friendly manner.
▶ Drain the filter.
▶ The filter is now drained and depressurised.
8.7.2 Removing the filter insert
▶ Unscrew the cover screws (1).
▶ Lift off the cover (2).
▶ Lift the filter insert (3) out at the marked points.
NOTE
• Remove the seals at the bottom and top of the filter element.
• Do not set down the filter on the lower socket or on the flushing arm shaft.

Fig. 8-1 Filter insert (example illustration)

1 Cover screws 3 Filter

2 Cover 4 Marking

51 / 62
8.7.2.1 Removing the filter insert with limited removal space

(applies to DN 200 - DN 400)

If the filter’s installation location does not allow the filter insert to be pulled out due
to its limited height (as described previously), it is possible to remove the filter
insert as follows:
 Remove the nuts (5).
 Lift off the mid filter housing section with the cover.
 Place the filter housing with the cover on a suitable surface.

 Select a surface that allows the mid filter housing section to be placed on the
flange side.

CAUTION!

Setting down the filter unit on the flushing arm shaft protruding from below can
damage the filter insert.

Fig. 8-2 Removing the filter insert with limited removal space

 Continue removing the insert as described in the “Removing the filter insert”
chapter.

 Re-assembly is performed by carrying out the steps for disassembly in

reverse order.

52 / 62
8.7.3 Removing the filter candles

1
2

Fig. 8-3 Remove the flushing arm

1 Screws
2 Plate

▶ Loosen the screws (1) on the flushing arm.

▶ Move the plate (2) in the direction of the arrow.

53 / 62
 3 1
4
2

Fig. 8-4 Removing the filter candle

1 Screws 5 Plate
2 Plate 6 Seal
3 Top flushing arm 7 Filter
4 Screws

▶ Remove the upper flushing arm (3).

▶ Remove the screws (4) on the filter element.
▶ Lift off the plate (5).
▶ Remove all seals (6).
▶ Pull all filter candles (7) out vertically.
NOTE
No more than three filter candles may be stacked on top of each other.

54 / 62
8.7.4 Cleaning the filter insert with filter candles
CAUTION!
Under normal operating conditions it is not necessary to clean the filter
insert manually. The automatic filter cleaning function keeps the
pressure loss in the filter constant. if the pressure loss increases above the
permitted value, the filter elements need to be cleaned manually.

CAUTION!

Risk of damage to the filter insert from improper cleaning

If the filter insert is cleaned or handled improperly, the filter insert may
become damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must
not exceed 24 hours.
• The cleaning temperature, when using "BOLL CLEAN 2000" must
not exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not
exceed a maximum of 60 bar. When cleaning using a high-pressure
cleaner, keep a sufficient distance (at least 20 cm) from the surface of
the filter material to prevent damage.
• Particles of dirt must not be allowed to enter the clean side of the
filter element.

NOTE

Boll & Kirch Filterbau GmbH recommends BOLL CLEAN 2000

cleaning agent. For more detailed information, see the appendix of these
operating instructions.
▶ Remove the filter elements.
▶ Place the filter elements in a container of cleaning agent.

▶ Remove loose particles which float on the top of the cleaning agent
during the soaking stage.
▶ Clean the individual filter elements using a high-pressure cleaner
over the entire length and in both directions. From the outside to the
inside in the final working process.
▶ Then rinse out the filter elements in fresh cleaning agent.

▶ Allow the filter elements to dry with one opening pointing

downwards or blow the filter elements dry with compressed air.
▶ Remove any soiling from the other components of the filter element
before inserting the filter insert.

55 / 62
8.7.5 Installing the filter candles

Fig. 8-5 Filter insert with filter candles

1 Flushing arm 6 Seal

2 Screws 7 Seal
3 Plate 8 Seal
4 Seal 9 Seal
5 Filter candles

▶ Check all filter elements and seals for damage. Replace any damaged
filter elements or seals.
▶ Insert the filter candle (5) vertically into the housing from above.
▶ Make sure that all seals are properly in place.
▶ Place the plate (3) on top.
▶ Attach the screws (2).
▶ Lubricate the seal (7).
▶ Attach the flushing arm (1).

56 / 62
 1

Fig. 8-6 Flushing arm

1 Screws
2 Plate

▶ Move the plate (2) in the direction of the arrow.

▶ Tighten the screws (1).
▶ Mount the upper and lower gaskets (6 + 9) on the filter insert.

▶  Make sure that the upper and lower seal (6 + 9) are properly seated
at the filter insert.
NOTE

Mounting the lower seal

The countersunk screws on the bottom of the filter insert must be
loosened by two rotations. Now the seal can be mounted. Re-tighten the
hexagon nuts.

57 / 62
8.7.6 Installing the filter insert

▶ Clean any soiling which has collected on the inside of the filter.
▶ Check all the seals for damage. Replace any damaged seals.
▶ Unfasten the nuts (5).
▶ Lubricate the upper and lower seals before Installation on the filter
insert.
NOTE

Mounting the lower seal

The countersunk screws on the bottom of the filter insert must be loosened
by two rotations. Now the seal can be mounted. Re-tighten the hexagon
nuts.

▶ Make sure that all seals are properly in place.

▶ Lift up the filter insert (3) at the marked points (4).

▶ Before installing the filter element, lubricate the top and bottom seals
on the filter element.
▶ Place the filter insert (3) into the filter.
▶ Check that the backflushing device moves easily.
▶ Attach the cover (2).
▶ Make sure that the seal is properly in place.
▶ Fasten the cover (2) with screws (1) and tighten evenly crosswise.
▶ Tighten the nuts (5) evenly, in a crosswise manner.
▶ Close the drain hole.
▶ Put the filter back into operation. See chapter 7, section
"Commissioning".

58 / 62
 1
2

Fig. 8-7 Filter insert (example illustration)

1 Cover screws 4 Markin

2 Cover 5 Nut
3 Filter insert

59 / 62
8.8 Inspecting the optional sacrificial anode

NOTE

The sacrificial anode (3) is fastened to the inner side of the inspection
opening cover (2).

▶ Remove the nuts on the inspection opening cover (2).

▶ Pull the inspection opening cover out of the housing along with the
sacrificial anode (3).
▶ Inspect the condition of the sacrificial anode (3). The sacrificial
anode (3) must be replaced when the zinc mass has worn down
enough for the carrier frame to be seen.
▶ Check the seal for damage. Replace any damaged seals.

▶ Place the inspection opening cover (2) in front of the inspection

opening along with the inspected or new sacrificial anode (3).
▶ Make sure that the seal is properly in place.

▶ Fasten the inspection opening cover (2) with nuts and tighten evenly
crosswise.

1 2

Fig. 8-7 Sacrificial anode (example illustration)

1 Ground connection 3 Sacrificial anode

2 Inspection opening cover
CAUTION!
Without the potential equalization (top housing to top housing
and cover),the anodic protection does not work.
• For BWT applications,fresh water must be filled in at every
standstill.

60 / 62
8.9 Manually backflushing the filter in the event of power failure

WARNING!

Risk of accidents caused by the filter starting back up

When the electrical power returns, the filter may start up again and the
rotating movement of the hand winch attached to the gear motor may
injure you.
• Before manually actuating the filter, first switch off the controller.
• Before switching on the controller, remove the hand winch from the
shaft end of the gear motor.

DANGER!

Risk of accidents due to controller being switched on unintentionally

When manual backflushing is being performed accidents may be caused if
the controller is switched on unintentionally, e.g. by starting up the drives.
• Secure the controller to prevent it from being switched on
unintentionally, e.g. by attaching a lock.
▶ Switch off the controller.
▶ Open the flushing valve on filters with
▶  a pneumatically or hydraulically actuated flushing valve by
turning the emergency actuation screw on the solenoid valve or
▶ an electrically actuated flushing valve - see further information on
manual actuation in the appendix to these operating instructions
or in the manufacturer's documentation.
▶ Attach the hand winch to the shaft end of the gear motor.
▶ Carry out filter backflushing by turning the hand winch.
NOTE

Approximately 300 - 400 turns are required to completely backflush the

filter depending on the gear motor.

▶ As soon as the differential pressure has been reduced, remove the

hand winch from the gear motor.
▶ Close the flushing valve on filters with
▶  a pneumatically or hydraulically actuated flushing valve by
turning the emergency actuation screw on the solenoid valve back
into the original position or
▶ an electrically actuated flushing valve - see further information on
manual actuation in the appendix to these operating instructions
or in the manufacturer's documentation.
▶ Switch on the controller.

61 / 62
8.10 Remedying faults

NOTE

In case of any faults or repairs which are not listed here, contact
the BOLL & KIRCH customer services department.

8.10.1 Trouble shooting

Fault Possible cause Remedy

Flushing High level of Determine the cause
performed often soiling in the of soiling in the plant
Filter elements Change / clean the
blocked filter elements
The gear motor does Flushing arm blocked Open the filter and
not turn remove the cause of
the blockage
No power supply Check the power supply
Controller is set Correct the setting
incorrectly or is or replace the
Differential pressure Filter elements Change / clean the
will not reduce blocked filter elements
The pressure Set the pressure,
downstream of the increase the
filter is too low or the backflushing quantity
backflushing quantity
is too low
Flushing valve does Check function / clean /
not open replace
No differential Shut-off valves in Open shut-off valves
pressure indicator control line closed
Differential pressure Check/replace the
monitoring system differential
faulty pressure
Filter with pneumatically / hydraulically actuated flushing valve
The solenoid valve Shut-off valve in Open shut-off valve
does not activate the supply line
Control pressure too Check / set the pressure
Controller is set Correct the setting
incorrectly or is or replace the
Filter with electrically actuated flushing valve
Flushing valve does No power supply Check the power supply
not switch Controller is set Correct the setting
incorrectly or is or replace the

62 / 62
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX C.4：KBW instruction manual (Kanagawa filter)

Not Applicable

Page 190 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX D：Flow Diagram of BalClor® BWMS (for

BC150-BC8000)
(Ver. 1.3, updated to 2017-07-19)

Page 191 of 209 Manual Rev: 1.56 BalClor® BWMS

 Ballast Process
Freshwater plan
Note
Only one ballast pump Can be used
 Ballast Process

Note
Only one ballast pump Can be used
Deballast Process-WBT
by pump-3
Deballast Process-WBT
by pump-4
Deballast Process-WBT
by pump-5
Deballast Process-APT
by G. S. PUMP or/and
FIRE & BILGE PUMP
 Deballast Process-WBT
by Gravity
Note:
Only two neutralization point can be
used together
Deballast Process-Stripping
 Deballast Process-WBT
by pumps-2
Note:
Only two pumps point can be used
together
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX E：Material Safety Data Sheet

SODIUM THIOSULFATE

Page 192 of 209 Manual Rev: 1.56 BalClor® BWMS

 Page 1/5
Safety data sheet
according to 1907/2006/EC, Article 31
Printing date 15.01.2015 Version number 15 Revision: 15.01.2015

* SECTION 1: Identification of the substance/mixture and of the company/undertaking

· 1.1 Product identifier
· Trade name: Sodium Thiosulfate Pentahydrate
· Article number: 3946-01
· EC number:
231-867-5
· Registration number 01-2119531537-38-XXXX
· 1.2 Relevant identified uses of the substance or mixture and uses advised against
No further relevant information available.
· Application of the substance / the mixture : For Laboratory, Research or Manufacturing use.
· 1.3 Details of the supplier of the safety data sheet
· Manufacturer/Supplier:
Avantor Performance Materials B.V. Tel:(+31) (0)570 - 687500
P.O.Box 1 Fax:(+31) (0)570 - 687574
7400 AA Deventer E-mail : [email protected]
The Netherlands
· Informing department:
E-mail : [email protected]
Avantor Performance Materials Sales Office Tel.: +31(0) 570 687500
· 1.4 Emergency telephone number:
Environment Health & Safety department
during normal opening times (8 am till 5.30 pm) tel: (+31)(0) 570 687500

* SECTION 2: Hazards identification

· 2.1 Classification of the substance or mixture
· Classification according to Regulation (EC) No 1272/2008
The substance is not classified according to the CLP regulation.
· Classification according to Directive 67/548/EEC or Directive 1999/45/EC void
· Information concerning particular hazards for human and environment: void
· 2.2 Label elements
· Labelling according to Regulation (EC) No 1272/2008 Void
· Hazard pictograms Void
· Signal word Void
· Hazard statements Void
· 2.3 Other hazards
· Results of PBT and vPvB assessment
· PBT: Not applicable.
· vPvB: Not applicable.

* SECTION 3: Composition/information on ingredients

· 3.1 Chemical characterisation: Substances
· CAS No. Designation:
Sodium Thiosulfate Pentahydrate
· Identification number(s):
· EC number: 231-867-5

* SECTION 4: First aid measures

· 4.1 Description of first aid measures
· General information No special measures required.
· After inhalation Supply fresh air; consult doctor in case of symptoms.
· After skin contact The product is not skin irritating.
· After eye contact Rinse opened eye for several minutes under running water.
· After swallowing Rinse out mouth
(Contd. on page 2)
GB

40.0
 Page 2/5
Safety data sheet
according to 1907/2006/EC, Article 31
Printing date 15.01.2015 Version number 15 Revision: 15.01.2015

Trade name: Sodium Thiosulfate Pentahydrate

(Contd. of page 1)
· 4.2 Most important symptoms and effects, both acute and delayed No further relevant information available.
· 4.3 Indication of any immediate medical attention and special treatment needed
No further relevant information available.

* SECTION 5: Firefighting measures

· 5.1 Extinguishing media
· Suitable extinguishing agents
CO2, extinguishing powder or water jet. Fight larger fires with water jet or alcohol-resistant foam.
· For safety reasons unsuitable extinguishing agents Water with a full water jet.
· 5.2 Special hazards arising from the substance or mixture No further relevant information available.
· 5.3 Advice for firefighters
· Protective equipment: Wear full protective suit.

* SECTION 6: Accidental release measures

· 6.1 Personal precautions, protective equipment and emergency procedures Not required.
· 6.2 Environmental precautions: No special measures required.
· 6.3 Methods and material for containment and cleaning up: Collect mechanically.
· 6.4 Reference to other sections
No dangerous materials are released.
See Section 7 for information on safe handling
See Section 8 for information on personal protection equipment.
See Section 13 for information on disposal.

* SECTION 7: Handling and storage

· 7.1 Precautions for safe handling No special measures required.
· Information about protection against explosions and fires: no special requirements
· 7.2 Conditions for safe storage, including any incompatibilities
· Storage
· Requirements to be met by storerooms and containers: No special requirements.
· Information about storage in one common storage facility: Store away from oxidising agents.
· Further information about storage conditions:
Store under dry conditions.
This product is hygroscopic.
· 7.3 Specific end use(s) No further relevant information available.

* SECTION 8: Exposure controls/personal protection

· 8.1 Control parameters
· Components with critical values that require monitoring at the workplace:
· Additional information: The lists that were valid during the compilation were used as basis.
· 8.2 Exposure controls
· Personal protective equipment
· General protective and hygienic measures
The usual precautionary measures should be adhered to in handling the chemicals.
· Breathing equipment: Not required.
· Protection of hands:
The glove material has to be impermeable and resistant to the product/ the substance/ the preparation.
Due to missing tests no recommendation to the glove material can be given for the product/ the preparation/
the chemical mixture.
(Contd. on page 3)
GB

40.0
 Page 3/5
Safety data sheet
according to 1907/2006/EC, Article 31
Printing date 15.01.2015 Version number 15 Revision: 15.01.2015

Trade name: Sodium Thiosulfate Pentahydrate

(Contd. of page 2)
Selection of the glove material on consideration of the penetration times, rates of diffusion and the
degradation
· Material of gloves
The selection of the suitable gloves does not only depend on the material, but also on further marks of quality
and varies from manufacturer to manufacturer.
· Penetration time of glove material
The exact break trough time has to be found out by the manufacturer of the protective gloves and has to be
observed.
· Eye protection: Not required.
· Body protection: Protective work clothing.

* SECTION 9: Physical and chemical properties

· 9.1 Information on basic physical and chemical properties
· General Information
· Appearance:
Form: Crystalline
Colour: White
· Smell: Odourless
· Odour threshold: Not determined.
· pH-value: Not applicable.
· Change in condition
Melting point/Melting range: 48 °C
Boiling point/Boiling range: Not determined
· Flash point: Not applicable
· Inflammability (solid, gaseous) Product is not inflammable.
· Ignition temperature:
Decomposition temperature: Not determined.
· Self-inflammability: Not determined.
· Danger of explosion: Product is not explosive.
· Critical values for explosion:
Lower: Not determined.
Upper: Not determined.
· Steam pressure: Not applicable.
· Density at 20 °C 1 g/cm³
· Relative density Not determined.
· Vapour density Not applicable.
· Evaporation rate Not applicable.
· Solubility in / Miscibility with
Water at 20 °C: 701 g/l
· Partition coefficient (n-octanol/water): Not determined.
· Viscosity:
dynamic: Not applicable.
kinematic: Not applicable.
· 9.2 Other information No further relevant information available.

* SECTION 10: Stability and reactivity

· 10.1 Reactivity
· 10.2 Chemical stability
· Thermal decomposition / conditions to be avoided: Heat,boiling temperatures.
· 10.3 Possibility of hazardous reactions Reacts with oxidizing agents
(Contd. on page 4)
GB

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Safety data sheet
according to 1907/2006/EC, Article 31
Printing date 15.01.2015 Version number 15 Revision: 15.01.2015

Trade name: Sodium Thiosulfate Pentahydrate

(Contd. of page 3)
· 10.4 Conditions to avoid No further relevant information available.
· 10.5 Incompatible materials: No further relevant information available.
· 10.6 Hazardous decomposition products: No dangerous decomposition products known

* SECTION 11: Toxicological information

· 11.1 Information on toxicological effects
· Acute toxicity:
· Primary irritant effect:
· on the skin: No irritant effect.
· on the eye: redness
· Sensitisation: No sensitizing effect known.
· Additional toxicological information:
When used and handled according to specifications, the product does not have any harmful effects according
to our experience and the information provided to us.
The material is not subject to classification according to EC lists in the last version.

SECTION 12: Ecological information

· 12.1 Toxicity
· Aquatic toxicity: No further relevant information available.
· 12.2 Persistence and degradability No further relevant information available.
· 12.3 Bioaccumulative potential No further relevant information available.
· 12.4 Mobility in soil No further relevant information available.
· Additional ecological information:
· General notes: Generally not hazardous for water.
· 12.5 Results of PBT and vPvB assessment
· PBT: Not applicable.
· vPvB: Not applicable.
· 12.6 Other adverse effects No further relevant information available.

* SECTION 13: Disposal considerations

· 13.1 Waste treatment methods
· Recommendation
Must not be disposed of together with household garbage. Do not allow product to reach sewage system.
· Uncleaned packagings:
· Recommendation: Disposal must be made according to official regulations.

* SECTION 14: Transport information

· 14.1 UN-Number
· ADR, ADN, IMDG, IATA Void
· 14.2 UN proper shipping name
· ADR, ADN, IMDG, IATA Void
· 14.3 Transport hazard class(es)
· ADR, ADN, IMDG, IATA
· Class Void
· 14.4 Packing group
· ADR, IMDG, IATA Void
(Contd. on page 5)
GB

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 Page 5/5
Safety data sheet
according to 1907/2006/EC, Article 31
Printing date 15.01.2015 Version number 15 Revision: 15.01.2015

Trade name: Sodium Thiosulfate Pentahydrate

(Contd. of page 4)

· 14.5 Environmental hazards:

· Marine pollutant: No
· 14.6 Special precautions for user Not applicable.
· 14.7 Transport in bulk according to Annex II of
MARPOL73/78 and the IBC Code Not applicable.
· UN "Model Regulation": -

* SECTION 15: Regulatory information

· 15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture
· Labelling according to Regulation (EC) No 1272/2008 Void
· Hazard pictograms Void
· Signal word Void
· Hazard statements Void
· 15.2 Chemical safety assessment: A Chemical Safety Assessment has not been carried out.

SECTION 16: Other information

These data are based on our present knowledge. However, they shall not constitute a guarantee for any
specific product features and shall not establish a legally valid contractual relationship.
· Department issuing data specification sheet: EHS
· Contact: Paweł Skiba
· Abbreviations and acronyms:
RID: Règlement international concernant le transport des marchandises dangereuses par chemin de fer (Regulations Concerning the
International Transport of Dangerous Goods by Rail)
IATA-DGR: Dangerous Goods Regulations by the "International Air Transport Association" (IATA)
ICAO: International Civil Aviation Organisation
ICAO-TI: Technical Instructions by the "International Civil Aviation Organisation" (ICAO)
ADR: Accord européen sur le transport des marchandises dangereuses par Route (European Agreement concerning the International
Carriage of Dangerous Goods by Road)
IMDG: International Maritime Code for Dangerous Goods
IATA: International Air Transport Association
GHS: Globally Harmonised System of Classification and Labelling of Chemicals
EINECS: European Inventory of Existing Commercial Chemical Substances
CAS: Chemical Abstracts Service (division of the American Chemical Society)
· * Data compared to the previous version altered.
GB

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 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX F：Material Safety Data Sheet

SODIUM HYPOCHLORITE

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MATERIAL SAFETY DATA SHEET

chemical co.

REVISED 1/19/09 ISO 9001:2000 COMPANY

6465 Eastland Road
Brook Park, Ohio 44142
440.234.3200

SECTIO I CHEMICAL PRODUCT AD COMPAY IDETIFICATIO

BleachTech LLC EMERGENCY RESPONSE

NUMBER:

8929 Ryan Rd. 1-330-769-5000 (24 hours)

Seville, Ohio 44273

1-330-769-5000

SUBSTANCE: SODIUM HYPOCHLORITE

TRADE NAME: Bleach 12.5 – 16.5% by weight

CHEMICAL NAME/SYNONYMS: Sodium Hypochlorite Solution, Bleach Solution, Bleach Liquor,

Hypo-solution, Bleach, and Liquid Bleach.

CAS NUMBER: 7681-52-9

CHEMICAL FAMILY: Alkali

FORMULA: NaOCl

DOT PROPER SHIPPING NAME: Hypochlorite Solution

DOT HAZARD CLASS: 8 (Corrosive) PG III; PG II (For solutions greater than 16% available chlorine)

DOT IDENTIFICATION NO: UN1791

RQ: 100 pounds

DOT EMERGENCY GUIDE NO: 154

SECTIO II COMPOSITIO, IFORMATIO O IGREDIETS

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INGREDIENT (S):

Sodium Hypochlorite (NaOCl) 10.0 - 20.0% wt

Sodium Hydroxide (NaOH) 0.1 - 1.1% wt

Water (H2O) 79.7 - 89.9% wt

SECTIO III HAZARDS IDETIFICATIO

NFPA CLASSIFICATION (SCALE 0-4): Health=2 Fire=0 Reactivity=1

EC CLASSIFICATION (ASSIGNED): C (Corrosive)

EMERGECY OVERVIEW

COLOR: Yellow PHYSICAL FORM: Liquid ODOR: Chlorine Odor

MAJOR HEALTH HAZARDS: Respiratory Tract Burns, Skin Burns, Mucous Membrane Burns, and Eye
Irritation

HAZARDOUS MIXTURES WITH OTHER LIQUIDS, SOLIDS, and OR GASES: Reacts violently with acids
liberating chlorine gas. Also reacts with organic substance. When heated, gives off oxygen that may increase
fire hazard.

POTETIAL HEALTH EFFECTS

INHALATION:

· SHORT TERM EXPOSURE: Irritation to respiratory tract. May have same as effects reported in other
routes of exposure, burns, blisters, nausea, difficulty breathing, and lung congestion.

· LONG TERM EXPOSURE: Same as effects reported in short term exposure.

SKIN CONTACT:

· SHORT TERM EXPOSURE: Irritant, reddening of the skin. May have burns, blisters, and itching

· LONG TERM EXPOSURE: Same as effects reported in short term exposure.

EYE CONTACT:

· SHORT TERM EXPOSURE: Irritation (possibly severe), possible eye damage

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· LONG TERM EXPOSURE: Same as effects reported in short term exposure.

INGESTION:

· SHORT TERM EXPOSURE: Burns, vomiting stomach pain, disorientation, bluish skin color,
convulsions, coma

· LONG TERM EXPOSURE: Same as effects reported in short term exposure.

CARCIOGE STATUS OSHA:  TP: 

IARC: 

SECTIO IV FIRST AID MEASURES

INHALATION: Remove from exposure and get fresh air. Use bag valve mask or similar device to perform artificial respiration
(rescue breathing) if needed. Keep warm and at rest. Get medical attention immediately if artificial respiration required.

SKIN CONTACT: Remove contaminated clothing, jewelry, and shoes immediately. Flush affected area with large amounts of water,
preferably a safety shower. Use soap or mild detergent and large amounts of water until no evidence of chemical remains (at least
15-20 minutes). For burns, cover affected area securely with sterile, dry, loose fitting dressing. If skin is burned, get medical
attention immediately.

EYE CONTACT: Wash eyes immediately with large amounts of water, occasionally lifting upper and lower lids, until no evidence
of chemical remains (at least 15 minutes). Continue irrigating with a normal saline solution until ready to transport to physician.
Cover with sterile bandages. Get medical attention immediately.

INGESTION: Rinse mouth with water. Drink large quantities of milk (water if no milk is available). Milk of magnesia may be
helpful. DO OT USE ACIDIC ATIDOTES SUCH AS SODIUM BICARBOATE. When vomiting occurs, keep head lower
than hips to help prevent aspiration. If person is unconscious, do not induce vomiting and turn their head to the side. Never make an
unconscious person vomit or drink fluids. Get medical attention.

NOTE TO PHYSICIAN: For inhalation, consider oxygen. For ingestion, avoid gastric lavage, emesis, sodium bicarbonate and acid
solutions. Consider the use of antacids.

SECTIO V FIRE FIGHTIG MEASURES

FLASH POINT: Non-flammable FLAMMABLE LIMITS: Non-flammable

FIRE AND EXPLOSION HAZARDS: Negligible fire hazard. Oxidizer. This material will react with some metals and cause
liberation of oxygen. May ignite or explode on contact with combustible materials. Toxic fumes can be liberated by contact with
acid or heat.

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EXTINGUISHING MEDIA: Regular dry chemical, carbon dioxide, water, or foam suitable for surrounding fire. For large fires, use
regular foam or flood with fine water spray.

FIRE FIGHTING: Wear self-contained breathing apparatus and full protective clothing. Move container from fire area if it can be
done without risk. Cool containers with water spray until well after the fire is out. Stay away from the ends of tanks. Use
extinguishing agents appropriate for surrounding fire. Do not get water directly on material. For large fires, flood with fine water
spray. Reduce vapors with water spray. Apply water from a protected location or from a safe distance. Avoid body contact or
inhalation of material or combustion by-products. Stay upwind and keep out of low areas.

SECTIO VI ACCIDETAL RELEASE MEASURES

OCCUPATIONAL RELEASE: Do not touch spilled material. Stop leak if possible without personal risk. For small spills, collect
spilled material in appropriate container for disposal and consider absorbing with sand or other non-combustible material (e.g., do
not use sawdust or other combustible material). Be advised, however, that the use of absorbing material is creating hazardous waste
and this absorbing material must now be disposed of properly. Collect spilled material in appropriate container for disposal. For
small dry spills, move containers away from spill to a safe area. For large spills, dike for later disposal. If possible, do not allow
material to enter sewers, streams, ponds or storm conduits as concentrated solutions will seriously injure aquatic life. Keep
unnecessary people away, isolate hazard area and deny entry. Contain in as small an area as possible, such as a holding area for
dilution and neutralization. Contain spill in plastic drums when available. Dispose of in accordance with Federal, State, and local
regulations. Personnel engaged in cleanup operations must be equipped with NIOSH approved respirator protection, rubber boots,
gloves, and clothing to avoid body contact. Reportable Quantity (RQ ): 100 pounds. Notify Local Emergency Planning Committee
and State Emergency Response Commission for release greater than or equal to RQ (U.S. SARA Section 304). If release occurs in
the U.S. and reportable under CERCLA Section103, notify the National Response Center at (800) 424-8802(USA) or (202) 426-2675
(USA).

ADVANCE PLANNING: Plan in advance for an occupational release and have necessary equipment and neutralization agents
on-site. Contact Odyssey Manufacturing for assistance.

SECTIO VII HADLIG AD STORAGE

Store in vented, closed containers that provide protection from direct sunlight. Keep separated from
incompatible substances and do not store near acids, heat, or oxidizable materials or organics. When
handling, do not mix with other cleaning agents that may liberate chlorine gas vapors (e.g., acidic agents).

Store and handle in accordance with all current regulations and standards including NFPA 430 Code for the
Storage of Liquid and Oxidizing Materials.

SECTIO VIII EXPOSURE COTROLS AD PERSOEL PROTECTIO

EXPOSURE LIMITS: 2 mg/m3 AIHA recommended STEL 15 minute(s) for Sodium Hypochlorite

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VENTILATION: Provide local exhaust ventilation system. Ensure compliance with applicable exposure
limits.

EYE PROTECTION: Splash goggles are preferred to a faceshield. Another option is to wear splash resistant
safety goggles with a faceshield. Provide an emergency eye wash fountain and quick drench shower in the
immediate work area.

CLOTHING: It is recommended to wear appropriate chemical resistant clothing to avoid body contact such as a rubber apron or rain
suit. Boots are preferred for footwear.

GLOVES: Wear appropriate chemical resistant gloves.

RESPIRATOR: Under conditions of frequent use or heavy exposure, respiratory protection may be needed. Respiratory protection is
ranked in order from minimum to maximum. Consider warning properties before use.

· Any chemical cartridge respirator with organic vapor cartridge(s).

· Any chemical cartridge respirator with a full facepiece and organic vapor cartridge(s)

· Any air-purifying respirator with a full facepiece and an organic vapor canister

· Any supplied-air respirator with full facepiece and operated in a pressure-demand or other positive-pressure mode in
combination with a separate escape supply (Use for Unknown Concentrations or those that may be Immediately Dangerous to Life or
Health)

· Any self-contained breathing apparatus with a full facepiece (Use for High Concentrations or those which are immediately
Dangerous to Life or Health)

SECTIO IX PHYSICAL AD CHEMICAL PROPERTIES

PHYSICAL APPEARANCE: Liquid APPEARANCE AND ODOR: Clear - Chlorine odor like household
bleach. COLOR: Greenish –Yellowish cast MOLECULAR WEIGHT: 74.44 MOLECULAR
FORMULA: Na-O-Cl

BOILING POINT: Degrades at 230 Degrees Fahrenheit FREEZING POINT: -14 Degrees Fahrenheit
for 12.5% weight

And 25 degree Fahrenheit for 16.5 % by weight.

SPECIFIC GRAVITY: 1.18 - 1.27 at 60 Degrees Fahrenheit PH: Approximately 11 - 13

VAPOR PRESSURE (mm HG): Vapor Pressure of water + decomposition product Vapor Pressure

VAPOR DENSITY: Not Available SOLUBILITY IN WATER: Complete VOLATILITY: Not Available

EVAPORATION RATE: >1 COEFFICIENT OF WATER /OIL DISTRIBUTION: Not Available

SECTIO X STABILITY AD REACTIVITY

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REACTIVITY: Stable at normal temperatures and pressure.

CONDITIONS TO AVOID: Avoid heat, flames, sparks and other sources of ignition. Dangerous gases may accumulate in confined
spaces. May ignite or explode on contact with combustible materials.

INCOMPATIBLES: Acids, metals, amines, combustible materials, reducing agents. Specific reactions with sodium hypochlorite
include the following:

ACIDS: Violent reaction. ALUMINUM: Corrosive action. AMINES: Form explosive chloramines.

AMMONIA: Form explosive chloramines. AMMONIUM SALTS: May form explosive product.

BENZYL CYANIDE (ACIDIFIED): Explosive reaction. CELLOLOSE: Violent reaction

ETHYLENEIMINE: Forms explosive 1-chloroethyleneimine. FORMIC ACID: Explosive mixture.

METHANOL: May form explosive compound. NITROGEN COMPOUNDS: Forms explosive N-chloro compounds.

ORGANIC AND COMBUSTIBLE MATERIALS: Fire and explosion hazard. OXALIC ACID: Intense reaction

REDUCING AGENTS: Fire and explosion hazard ZINC: Corrosive

HAZARDOUS DECOMPOSITION: Thermal decomposition products – Chlorine and Hydrochloric Acid Vapors. Decomposition
Products – Hypochlorous Acid Vapors POLYMERIZATION: Will not polymerize.

SECTIO XI SODIUM HYPOCHLORITE TOXILOGICAL IFORMATIO

IRRITATION DATA: 10 mg eyes – rabbit moderate

TOXICITY DATA:

1gm/ kg oral-woman; TDLo; 45mg/kg intravenous-man TDLo; 5800 mg/ kg oral-mouse LD5O; 140 mg/ kq/9 week(s) continuous
oral-rat TDLo

CARCINOGEN STATUS: According to the IARC, animal inadequate evidence, human no adequate data, Group 3 (Hypochlorite
salts)

LOCAL EFFECTS:

Corrosive: inhalation, skin contact, eye, ingestion hazards

ACUTE TOXICITYLEVEL:

Slightly Toxic if ingested

MUTAGENIC DATA:

Mutation in micro organisms – Salmonella typhimurium 1mg / plate (-S9); DNA repair – Escherichiacoli 20ug/ disc; DNA damage –
Esoherichiacoli 420 umol/L; phage inhibition capacity – Esoherichiacoli 103 ug/ well; micronucleus test - non-mammalian species
multiple 200 ppb; cytogenetic analysis - non-mammalian species multiple 120 ug/ L; cytogenetic analysis – human lymphocyte 100
ppm 24hour(s); sister chromatid exchange – human embryo 149 mg/ L; cytogenetic analysis – hamster lung 100 mg/ L

HEALTH EFFECTS:

IHALATIO

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ACUTE EXPOSURE: May cause severe bronchial irritation, sore throat with possible blistering, coughing, stomatitis, nausea,
labored breathing, shortness of breath and pulmonary epedema. 10-20 mg/m3 causes burning of the nose and throat; 40-60 mg/m3
may be fatal. If sufficient amounts are absorbed, may cause effects as detailed in acute ingestion.

CHRONIC EXPOSURE: No data available.

SKI COTACT

ACUTE EXPOSURE: Extent of damage depends on concentration, pH, volume of solution & time of contact. May cause redness,
pain, blistering, itchy eczema & chemical burns. Sensitization reactions possible in previously exposed persons.

CHRONIC EXPOSURE: Effects depend on concentration and duration of exposure. Repeated or prolonged contact with corrosive
substances may result in dermatitis or effects similar to acute exposure. Allergic dermatitis has also been reported.

EYE COTACT

ACUTE EXPOSURE: May cause redness, pain, & blurred vision. Solutions of 5% splashed in human eyes have caused a burning
sensation and later only slight superficial disturbance of the corneal epithelium which cleared completely in the next day or two
without special treatment. However, one animal study reports a 5% solution causing only moderate irritation with clearing within 7
days. A higher concentration of 15% tested on rabbit eyes caused immediate severe pain, hemorrhages, rapid onset of ground-glass
appearance of the corneal epithelium, moderate bluish edema of the whole cornea, chemosis and discharge for several days. Such
eyes have sometimes healed in 2-3 weeks with slight or no residual corneal damage but they had neovascularization of the
conjunctiva and distortion of the nictitating membrane by scarring.

CHRONIC EXPOSURE: Depending on concentration and time of exposure, symptoms may be as those of acute exposure.

IGESTIO

ACUTE EXPOSURE: May cause irritation and erosion of the mucous membranes, vomiting (possibly bloody) and abdominal pain
and spasms. A drop in blood pressure, shallow respiration, edema (possibly severe) of pharynx, larynx, and glottis, confusion,
convulsions, delirium and coma may occur. Cyanosis and circulatory collapse are possible. Esophageal or gastric perforation and
strictures are rare. Death may occur, usually due to complications of severe local injury such as toxemia, shock, perforations,
hemorrhage, infection and obstruction. Massive ingestions may produce fatal hyperchloremic metabolic acidosis or aspiration
pneumonitis.

CHRONIC EXPOSURE: Sensitization reactions are reported in individuals who are exposed in small amounts through their water
supply. High doses have caused sperm abnormality in mice.

SECTIO XII ECOLOGICAL IFORMATIO

ECOTOXICITY DATA:

FISH TOXICITY: 94.0 ug/L 96h hour(s) LC5O (Mortality) Cutthroat trout (Oncorhynchus clarki)

INVERTEBRATE TOXICITY: 31.6 ug/L 7 hour(s) 1C50 (Species Diversity) Protozoan phylum (Protozoa)

ALGAL TOXICITY: 90 ug/L 96 hour(s) LC5O (Mortality) Algae, phytoplankton, algai mat (Algae)

PHYTOTOXICITY: 230-ug/L 35 hour(s) (Biomass) Curled pondweed (Potamogeton crispus)

OTHER TOXICITY: 2.1 ug/L 28 day(s) (Chlorophyll) Aquatic community (Aquatic community)

ENVIRONMENTAL SUMMARY: Highly toxic to aquatic life.

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SECTIO XIII DISPOSAL COSIDERATIOS

Subject to disposal regulations: U.S. EPA 40 CFR 262. Hazardous Waste Number(s): D001. Dispose in accordance with all
applicable regulations.

SECTIO XIV TRASPORT IFORMATIO

U.S. DOT 49 CFR 172.101 SHIPPING NAME-UN NUMBER: Sodium Hypochlorite) - UN1791

U.S. DOT 49 CER 172.101 HAZARD CLASS OR DIVISION: 8

U.S. DOT 49 CFR 172 .101 PACKING GROUP: III(less than 16% available chlorine) / II(16% or more available chlorine)

U.S. DOT 49 CFR 172.101 AND SUBPART E LABELING REQUIREMENTS: Corrosive

U.S. DOT 49 CFR 172.101 PACKAGING AUTHORIZATIONS:

EXCEPTIONS: 49 CFR 173.154

NON- BULK PACKAGING: 49 CFR 173.203 (less than 16% available chlorine) / 49 CFR 173.202 (16% or more
available chlorine)

BULK PACKAGING: 49 CFR 173.241 (less than 16% available chlorine) / : 49 CFR 173.242 (16% or more available
chlorine)

U.S. DOT 49 CFR 172.101 QUANTITY LIMITATIONS:

PASSENGER AIRCRAFT OR RAILCAR: 5 LITERS / (less than 16% available chlorine) / 1 LITERS (16% or more available
chlorine)

CARGO AIRCRAFT ONLY: 60 LITERS / (less than 16% available chlorine) / 30 LITERS (16% or more available
chlorine)

SECTIO XV REGULATORY IFORMATIO

U.S. REGULATIONS

TSCA INVENTORY STATUS: Y TSCA 12(b) EXPORT NOTIFICATION: Not listed.

CERCLA SECTION 103 (40CFR302.4): Y SODIUM HYPOCHLORITE: 100 LBS RQ

SARA SECTION 302 (40CFR355.30): N SARA SECTION 304 (40CFR355.40) : N
SARA SECTION 313 (40CFR372.65): N
SARA HAZARD CATEGORIES, SARA SECTIONS 311/312 (40CFR370.21):
ACUTE: Y CHRONIC: N FIRE: N REACTIVE: N SUDDEN RELEASE: N
OSHA PROCESS SAFETY (29CFR1S1O.119): N
STATE REGULATIONS: California Proposition 65: N
EUROPEAN REGULATIONS: EC NUMBER (BINECS) : 231-668-3

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EC RISK AND SAFETY PHRASES:

R 31 Contact with acids liberates toxic gas.
R 34 Causes burns.
S½ Keep locked-up and out of reach of children.
S 28b After contact with skin, wash immediately with plenty of soap and water.
S 45 In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible)
S 50 Do not mix with incompatible materials.

CONCENTRATION LIMITS:

C>10% C R 31-34

5%<=C<=l0% Xi R 31-36/38

GERMAN REGULATIONS: WATER HAZARD CLASS (WGK) : 2 (Official German Classification)

SECTIO XVI OTHER IFORMATIO

For additional information, contact our technical service department.

Information contained in this MSDS refers only to the specific material designated and does not relate to any
process or use involving other materials. This information is based on data believed to be reliable, and the
Product is intended to be used in a manner that is customary and reasonably foreseeable. Since actual use
and handling are beyond our control, no warranty,

express or implied, is made and no liability is assumed by BleachTech LLC in connection with the use of this
information.

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ANNEX C：Maintenances record list

Item Date Operator

10

11

12

13

14

15

16

17

18

19

Page 192 of 196 Manual Rev: 1.56 BalClor® BWMS

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ANNEX D：TRC and Models of BalClor ® BWMS with

Boll Filters
Automatic Back-flushing Automatic
filter Electrolytic Disinfection Unit Neutralizatio
Treatme
(AFU) (EDU) n Unit
nt Rated
BWMS (Maker：Boll&Kirch) (ANU)
Capacity
Model flow rate
(TRC) Maximum Maximum Type&
AFU EDU range of
(m3/h) flow flow volume
Model model EDU inlet
（m3/h） （m3/h） (m3)
(m3/h)
aquaBoll ANU-A/B/C
54 BC-150 54 EDU-150 170 4.2~7.2
6.18.3 size 80 0.5/1.0/1.5
aquaBoll ANU-A/B/C
80 BC-150 80 EDU-150 170 4.2~7.2
6.18.3 size 125 0.5/1.0/1.5
aquaBoll ANU-A/B/C
150 BC-150 150 EDU-150 170 4.2~7.2
6.18.3 size 150 0.5/1.0/1.5
6.18.3C
Size200/ ANU-A/B/C
170 BC-150 320 EDU-150 170 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 200
6.18.3C
Size200/ ANU-A/B/C
320 BC-300 320 EDU-300 350 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 200
6.18.3C
Size250 / ANU-A/B/C
350 BC-300 425 EDU-300 350 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 250
6.18.3C
Size250/ ANU-A/B/C
425 BC-500 425 EDU-500 600 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 250
6.18.3C ANU-A/B/C
600 BC-500 640 EDU-500 600 4.2~7.2
Size300 0.5/1.0/1.5
6.18.3C ANU-A/B/C
640 BC-1000 640 EDU-1000 1200 7~12
Size300 0.5/1.0/1.5
6.18.3C ANU-A/B/C
1200 BC-1000 1200 EDU-1000 1200 7~12
Size400 0.5/1.0/1.5
6.18.3C ANU-A/B/C
1700 BC-1500 1800 EDU-1500 1700 11.2~19.2
Size500 0.5/1.0/1.5
1800 BC-2000 6.18.3C 1800 EDU-2000 2200 11.2~19.2 ANU-A/B/C

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Size500 0.5/1.0/1.5
6.18.3C ANU-A/B/C
2200 BC-2000 2200 EDU-2000 2200 11.2~19.2
Size600 0.5/1.0/1.5
6.18.3C ANU-B/C
2800 BC-2500 3280 EDU-2500 2800 22.4~36
Size700 1.0/1.5
6.18.3C ANU-B/C
3200 BC-3000 3280 EDU-3000 3200 22.4~36
Size700 1.0/1.5
6.18.3C ANU-B/C
3280 BC-3500 3280 EDU-3500 3800 25.2~40
Size700 1.0/1.5
6.18.3C ANU-B/C
3800 BC-3500 4000 EDU-3500 3800 25.2~40
Size800 1.0/1.5
6.18.3C ANU-B/C
4000 BC-4000 4000 EDU-4000 4300 25.2~40
Size800 1.0/1.5
6.18.3C ANU-B/C
4300 BC-4000 4730 EDU-4000 4300 25.2~40
Size900 1.0/1.5
6.18.3C ANU-B/C
4730 BC-5000 4730 EDU-5000 5500 31.5~50
Size900 1.0/1.5
6.18.3C ANU-B/C
5500 BC-5000 3280x2 EDU-5000 5500 31.5~50
Size700x2 1.0/1.5
6.18.3C ANU-B/C
6300 BC-6000 3280x2 EDU-6000 6300 50.4~80
Size700x2 1.0/1.5
6.18.3C ANU-B/C
6560 BC-7000 3280x2 EDU-7000 7300 50.4~80
Size700x2 1.0/1.5
6.18.3C ANU-B/C
7300 BC-7000 4000x2 EDU-7000 7300 50.4~80
Size800x2 1.0/1.5
6.18.3C ANU-B/C
8000 BC-8000 4000x2 EDU-8000 8500 50.4~80
Size800x2 1.0/1.5
6.18.3C ANU-B/C
8500 BC-8000 4730x2 EDU-8000 8500 50.4~80
Size900x2 1.0/1.5
NOTE: BWMS Treatment Rated Capacity (TRC) depends on Maximum treatment flow of
AFU and EDU, whichever is the lower.

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 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX E: Power consumption of BalClor® BWMS

Normal system power Total Max. power
System Max. system power
consumption a) consumption of Optional
model consumption b)
components c)
（KW） （KW）
(kW)
BC-150 9.2 13.1 4.4

BC-300 14.0 21.8 4.4

BC-500 20.5 34.0 5.4

BC-1000 36.3 63.3 7.2

BC-1500 52.9 91.2 10.2

BC-2000 66.0 115.5 12.6

BC-2500 87.6 150.6 13.8

BC-3000 98.1 170.1 13.8

BC-3500 113.9 199.4 18

BC-4000 127.0 223.7 18

BC-5000 166.0 289.7 19.8

BC-6000 189.4 331.1 22.2

BC-7000 215.6 379.9 27

BC-8000 247.1 438.4 36

Note:
a) The normal power consumption is based on 30 PSU and 20°C seawater;
b) The max. power consumption is based on 15 PSU and 5°C seawater;
c) The optional components refer to the components listed in BOM including pumps and
electrical cabinets etc. This power consumption is only applicable when relevant
components are installed and used.

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 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX G：Maintenances record list

Item Date Operator

10

11

12

13

14

15

16

17

18

19

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ANNEX H.1：TRC and Models of BalClor ® BWMS with

Filtersafe Filters with standard, turbo (-T) and superturbo
(-ST) configuration
Automatic Back-flushing Automatic
filter Electrolytic Disinfection Unit Neutralizatio
Treatmen
(AFU) (EDU) n Unit
t Rated
BWMS (Maker：Filtersafe) (ANU)
Capacity
Model flow rate
(TRC) Maximum Maximum Type&
AFU EDU range of
(m3/h) flow flow volume
Model model EDU inlet
（m3/h） （m3/h） (m3)
(m3/h)
ANU-A/B/C
50 BC-150 BS-025H/V 50 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
70 BC-150 BS-031H/V 70 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
125 BC-150 BS-050H/V 125 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
140 BC-150 BS-061H/V 150 EDU-150 170 4.2~7.2
0.5/1.0/1.5
BS-061H/V-T ANU-A/B/C
170 BC-150 180 EDU-150 170 4.2~7.2
BS-070H/V 0.5/1.0/1.5
ANU-A/B/C
200 BC-300 BS-061H/V-ST 200 EDU-300 350 4.2~7.2
0.5/1.0/1.5
BS-100H/V ANU-A/B/C
250 BC-300 250 EDU-300 350 4.2~7.2
BS-101H/V 0.5/1.0/1.5
BS-100H/V-T ANU-A/B/C
300 BC-300 300 EDU-300 350 4.2~7.2
BS-101H/V-T 0.5/1.0/1.5
ANU-A/B/C
350 BC-300 BS-101H/V-ST 350 EDU-300 350 4.2~7.2
0.5/1.0/1.5
BS-150H/V ANU-A/B/C
375 BC-500 375 EDU-500 600 4.2~7.2
BS-151H/V 0.5/1.0/1.5
BS-150H/V-T ANU-A/B/C
450 BC-500 450 EDU-500 600 4.2~7.2
BS-150H/V-T 0.5/1.0/1.5
BS-200H/V ANU-A/B/C
500 BC-500 500 EDU-500 600 4.2~7.2
BS-201H/V 0.5/1.0/1.5
ANU-A/B/C
525 BC-500 BS-151H/V-ST 525 EDU-500 600 4.2~7.2
0.5/1.0/1.5
BS-200H/V-T ANU-A/B/C
600 BC-500 600 EDU-500 600 4.2~7.2
BS-201H/V-T 0.5/1.0/1.5

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ANU-A/B/C
700 BC-1000 BS-201H/V-ST 750 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
750 BC-1000 BS-300H/V 750 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
900 BC-1000 BS-300H/V-T 900 EDU-1000 1200 7~12
0.5/1.0/1.5
BS-300H/V-ST ANU-A/B/C
1000 BC-1000 1000 EDU-1000 1200 7~12
BS-400H/V 0.5/1.0/1.5
ANU-A/B/C
1200 BC-1000 BS-400H/V-T 1200 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
1400 BC-1500 BS-400H/V-ST 1400 EDU-1500 1700 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
1500 BC-1500 BS-603H/V 1500 EDU-1500 1700 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
1700 BC-1500 BS-603H/V-T 1800 EDU-1500 1700 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
1800 BC-2000 BS-603H/V-T 1800 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2000 BC-2000 BS-804H/V 2000 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2100 BC-2000 BS-603H/V-ST 2100 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2200 BC-2000 BS-804H/V-T 2400 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-B/C
2400 BC-2500 BS-804H/V-T 2400 EDU-2500 2800 22.4~36
1.0/1.5
ANU-B/C
2500 BC-2500 BS-1004H/V 2500 EDU-2500 2800 22.4~36
1.0/1.5
ANU-B/C
2800 BC-2500 BS-804H/V-ST 2800 EDU-2500 2800 22.4~36
1.0/1.5
BS-1004H/V-T
ANU-B/C
3000 BC-3000 BS-1204H/V 3000 EDU-3000 3200 22.4~36
1.0/1.5
BS-1206H/V
ANU-B/C
3200 BC-3000 BS-1406H/V 3500 EDU-3000 3200 22.4~36
1.0/1.5
ANU-B/C
3500 BC-3500 BS-1406H/V 3500 EDU-3500 3800 25.2~40
1.0/1.5
BS-1204H/V-T
ANU-B/C
3600 BC-3500 3600 EDU-3500 3800 25.2~40
BS-1206H/V-T 1.0/1.5

ANU-B/C
3800 BC-3500 BS-1406H/V-T 4200 EDU-3500 3800 25.2~40
1.0/1.5
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 Sunrui Marine Environment Engineering Co., Ltd.

BS-1204H/V-S
T
ANU-B/C
4200 BC-4000 BS-1206H/V-S 4200 EDU-4000 4300 25.2~40
1.0/1.5
T
BS-1406H/V-T
BS-1406H/V-S ANU-B/C
4300 BC-4000 4900 EDU-4000 4300 25.2~40
T 1.0/1.5
BS-1406H/V-S ANU-B/C
4900 BC-5000 4900 EDU-5000 5500 31.5~50
T 1.0/1.5
BS-1204H/V
x2 ANU-B/C
5500 BC-5000 6000 EDU-5000 5500 31.5~50
BS-1206H/V 1.0/1.5
x2
BS-1204H/V
x2 ANU-B/C
6000 BC-6000 3000x2 EDU-6000 6300 50.4~80
BS-1206H/V 1.0/1.5
x2
BS-1406H/V ANU-B/C
6300 BC-6000 3500x2 EDU-6000 6300 50.4~80
x2 1.0/1.5
BS-1406H/V ANU-B/C
7000 BC-7000 3500 x2 EDU-7000 7300 50.4~80
X2 1.0/1.5
BS-1204H/V-S
Tx2
BS-1206H/V-S ANU-B/C
7300 BC-7000 4200 x2 EDU-7000 7300 50.4~80
Tx2 1.0/1.5
BS-1406H/V-T
x2
BS-1204H/V-S
Tx2
BS-1206H/V-S ANU-B/C
8400 BC-8000 4200 x2 EDU-8000 8500 50.4~80
Tx2 1.0/1.5
BS-1406H/V-T
x2
BS-1406H/V-S ANU-B/C
8500 BC-8000 4900x2 EDU-8000 8500 50.4~80
Tx2 1.0/1.5
NOTE: BWMS Treatment Rated Capacity (TRC) depends on Maximum treatment flow of
AFU and EDU, whichever is the lower.

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ANNEX H.2：TRC and Models of BalClor ® BWMS with

Luoyang Sunrui Filters
Automatic Back-flushing Automatic
filter Electrolytic Disinfection Unit Neutralizatio
Treatme
(AFU) (EDU) n Unit
nt Rated
BWMS (Maker：Luoyang Sunnrui) (ANU)
Capacity
Model flow rate
(TRC) Maximum Maximum Type&
AFU EDU range of
(m3/h) flow flow volume
Model model EDU inlet
（m3/h） （m3/h） (m3)
(m3/h)
ANU-A/B/C
60 BC-150 SRF-60H/V 60 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
100 BC-150 SRF-100H/V 100 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
170 BC-150 SRF-200H/V 200 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
200 BC-300 SRF-200H/V 200 EDU-300 350 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
350 BC-300 SRF-400H/V 400 EDU-300 350 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
400 BC-500 SRF-400H/V 400 EDU-500 600 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
600 BC-500 SRF-600H/V 600 EDU-500 600 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
800 BC-1000 SRF-800H/V 800 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
1200 BC-1000 SRF-1200H/V 1200 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
1600 BC-1500 SRF-1600H/V 1600 EDU-1500 1700 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
1700 BC-1500 SRF-2000H/V 2000 EDU-1500 1700 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2000 BC-2000 SRF-2000H/V 2000 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2200 BC-2000 SRF-2500H/V 2500 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-B/C
2500 BC-2500 SRF-2500H/V 2500 EDU-2500 2800 22.4~36
1.0/1.5
ANU-B/C
2800 BC-2500 SRF-3000H/V 3000 EDU-2500 2800 22.4~36
1.0/1.5

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ANU-B/C
3000 BC-3000 SRF-3000H/V 3000 EDU-3000 3200 22.4~36
1.0/1.5
ANU-B/C
3200 BC-3000 SRF-3500H/V 3500 EDU-3000 3200 22.4~36
1.0/1.5
ANU-B/C
3500 BC-3500 SRF-3500H/V 3500 EDU-3500 3800 25.2~40
1.0/1.5
SRF-2000H/V ANU-B/C
3800 BC-3500 2000x2 EDU-3500 3800 25.2~40
x2 1.0/1.5
SRF-2000H/V ANU-B/C
4000 BC-4000 2000x2 EDU-4000 4300 25.2~40
x2 1.0/1.5
SRF-2500H/V ANU-B/C
4300 BC-4000 2500x2 EDU-4000 4300 25.2~40
x2 1.0/1.5
SRF-2500H/V ANU-B/C
5000 BC-5000 2500x2 EDU-5000 5500 31.5~50
x2 1.0/1.5
SRF-3000H/V ANU-B/C
5500 BC-5000 3000x2 EDU-5000 5500 31.5~50
x2 1.0/1.5
SRF-3000H/V ANU-B/C
6000 BC-6000 3000x2 EDU-6000 6300 50.4~80
x2 1.0/1.5
SRF-3500H/V ANU-B/C
6300 BC-6000 3500x2 EDU-6000 6300 50.4~80
x2 1.0/1.5
SRF-3500H/V ANU-B/C
7000 BC-7000 3500x2 EDU-7000 7300 50.4~80
x2 1.0/1.5
SRF-2500H/V ANU-B/C
7300 BC-7000 2500x3 EDU-7000 7300 50.4~80
x3 1.0/1.5
SRF-2500H/V ANU-B/C
7500 BC-8000 2500x3 EDU-8000 8500 50.4~80
x3 1.0/1.5
SRF-3500H/V ANU-B/C
8500 BC-8000 3500x3 EDU-8000 8500 50.4~80
x3 1.0/1.5
NOTE: BWMS Treatment Rated Capacity (TRC) depends on Maximum treatment flow of
AFU and EDU, whichever is the lower.

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 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX H.3：TRC and Models of BalClor ® BWMS with

Boll Filters
Automatic Back-flushing Automatic
filter Electrolytic Disinfection Unit Neutralizatio
Treatme
(AFU) (EDU) n Unit
nt Rated
BWMS (Maker：Boll&Kirch) (ANU)
Capacity
Model flow rate
(TRC) Maximum Maximum Type&
AFU EDU range of
(m3/h) flow flow volume
Model model EDU inlet
（m3/h） （m3/h） (m3)
(m3/h)
aquaBoll ANU-A/B/C
54 BC-150 54 EDU-150 170 4.2~7.2
6.18.3 size 80 0.5/1.0/1.5
aquaBoll ANU-A/B/C
80 BC-150 80 EDU-150 170 4.2~7.2
6.18.3 size 125 0.5/1.0/1.5
aquaBoll ANU-A/B/C
150 BC-150 150 EDU-150 170 4.2~7.2
6.18.3 size 150 0.5/1.0/1.5
6.18.3C
Size200/ ANU-A/B/C
170 BC-150 320 EDU-150 170 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 200
6.18.3C
Size200/ ANU-A/B/C
320 BC-300 320 EDU-300 350 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 200
6.18.3C
Size250 / ANU-A/B/C
350 BC-300 425 EDU-300 350 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 250
6.18.3C
Size250/ ANU-A/B/C
425 BC-500 425 EDU-500 600 4.2~7.2
aquaBoll 0.5/1.0/1.5
6.18.3 size 250
6.18.3C ANU-A/B/C
600 BC-500 640 EDU-500 600 4.2~7.2
Size300 0.5/1.0/1.5
6.18.3C ANU-A/B/C
640 BC-1000 640 EDU-1000 1200 7~12
Size300 0.5/1.0/1.5
6.18.3C ANU-A/B/C
1200 BC-1000 1200 EDU-1000 1200 7~12
Size400 0.5/1.0/1.5
6.18.3C ANU-A/B/C
1700 BC-1500 1800 EDU-1500 1700 11.2~19.2
Size500 0.5/1.0/1.5
1800 BC-2000 6.18.3C 1800 EDU-2000 2200 11.2~19.2 ANU-A/B/C

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Size500 0.5/1.0/1.5
6.18.3C ANU-A/B/C
2200 BC-2000 2200 EDU-2000 2200 11.2~19.2
Size600 0.5/1.0/1.5
6.18.3C ANU-B/C
2800 BC-2500 3280 EDU-2500 2800 22.4~36
Size700 1.0/1.5
6.18.3C ANU-B/C
3200 BC-3000 3280 EDU-3000 3200 22.4~36
Size700 1.0/1.5
6.18.3C ANU-B/C
3280 BC-3500 3280 EDU-3500 3800 25.2~40
Size700 1.0/1.5
6.18.3C ANU-B/C
3800 BC-3500 4000 EDU-3500 3800 25.2~40
Size800 1.0/1.5
6.18.3C ANU-B/C
4000 BC-4000 4000 EDU-4000 4300 25.2~40
Size800 1.0/1.5
6.18.3C ANU-B/C
4300 BC-4000 4730 EDU-4000 4300 25.2~40
Size900 1.0/1.5
6.18.3C ANU-B/C
4730 BC-5000 4730 EDU-5000 5500 31.5~50
Size900 1.0/1.5
6.18.3C ANU-B/C
5500 BC-5000 3280x2 EDU-5000 5500 31.5~50
Size700x2 1.0/1.5
6.18.3C ANU-B/C
6300 BC-6000 3280x2 EDU-6000 6300 50.4~80
Size700x2 1.0/1.5
6.18.3C ANU-B/C
6560 BC-7000 3280x2 EDU-7000 7300 50.4~80
Size700x2 1.0/1.5
6.18.3C ANU-B/C
7300 BC-7000 4000x2 EDU-7000 7300 50.4~80
Size800x2 1.0/1.5
6.18.3C ANU-B/C
8000 BC-8000 4000x2 EDU-8000 8500 50.4~80
Size800x2 1.0/1.5
6.18.3C ANU-B/C
8500 BC-8000 4730x2 EDU-8000 8500 50.4~80
Size900x2 1.0/1.5
NOTE: BWMS Treatment Rated Capacity (TRC) depends on Maximum treatment flow of
AFU and EDU, whichever is the lower.

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ANNEX H.4：TRC and Models of BalClor ® BWMS with

Kanagawa Filters
Automatic Back-flushing Automatic
filter Electrolytic Disinfection Unit Neutralizatio
Treatme
(AFU) (EDU) n Unit
nt Rated
BWMS (Maker：Kanagawa) (ANU)
Capacity
Model flow rate
(TRC) Maximum Maximum Type&
AFU EDU range of
(m3/h) flow flow volume
Model model EDU inlet
（m3/h） （m3/h） (m3)
(m3/h)
ANU-A/B/C
170 BC-150 KBW-200 300 EDU-150 170 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
300 BC-300 KBW-200 300 EDU-300 350 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
350 BC-300 KBW-300 470 EDU-300 350 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
470 BC-500 KBW-300 470 EDU-500 600 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
600 BC-500 KBW-500 680 EDU-500 600 4.2~7.2
0.5/1.0/1.5
ANU-A/B/C
680 BC-1000 KBW-500 680 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
880 BC-1000 KBW-750 880 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
1140 BC-1000 KBW-1000 1140 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
1200 BC-1000 KBW-1500 1830 EDU-1000 1200 7~12
0.5/1.0/1.5
ANU-A/B/C
1700 BC-1500 KBW-1500 1830 EDU-1500 1700 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
1830 BC-2000 KBW-1500 1830 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2200 BC-2000 KBW-2000 2500 EDU-2000 2200 11.2~19.2
0.5/1.0/1.5
ANU-A/B/C
2500 BC-2500 KBW-2000 2500 EDU-2500 2800 11.2~19.2
0.5/1.0/1.5
ANU-B/C
2800 BC-2500 KBW-2500 3100 EDU-2500 2800 22.4~36
1.0/1.5
ANU-B/C
3100 BC-3000 KBW-2500 3100 EDU-3000 3200 22.4~36
1.0/1.5
3200 BC-3000 KBW-3000 3900 EDU-3000 3200 25.2~40 ANU-B/C

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1.0/1.5
ANU-B/C
3800 BC-3500 KBW-3000 3900 EDU-3500 3800 25.2~40
1.0/1.5
ANU-B/C
3900 BC-4000 KBW-3000 3900 EDU-4000 4300 25.2~40
1.0/1.5
ANU-B/C
4300 BC-4000 KBW-3500 4350 EDU-4000 4300 25.2~40
1.0/1.5
ANU-B/C
4350 BC-5000 KBW-3500 4350 EDU-5000 5500 31.5~50
1.0/1.5
ANU-B/C
4900 BC-5000 KBW-4000 4900 EDU-5000 5500 31.5~50
1.0/1.5
ANU-B/C
5500 BC-5000 KBW-2500x2 3100x2 EDU-5000 5500 31.5~50
1.0/1.5
ANU-B/C
6200 BC-6000 KBW-2500x2 3100x2 EDU-6000 6300 50.4~80
1.0/1.5
ANU-B/C
6300 BC-6000 KBW-3000x2 3900x2 EDU-6000 6300 50.4~80
1.0/1.5
ANU-B/C
7300 BC-7000 KBW-3000x2 3900x2 EDU-7000 7300 50.4~80
1.0/1.5
ANU-B/C
7800 BC-8000 KBW-3000x2 3900x2 EDU-8000 8500 50.4~80
1.0/1.5
ANU-B/C
8500 BC-8000 KBW-3500x2 4350x2 EDU-8000 8500 50.4~80
1.0/1.5
NOTE: BWMS Treatment Rated Capacity (TRC) depends on Maximum treatment flow of
AFU and EDU, whichever is the lower.

Page 203 of 209 Manual Rev: 1.56 BalClor® BWMS

 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX J：Bill of Materials for BalClor® BWMS

（BC150-BC8000）
(Ver. 1.25, updated to 2020-02-24)

Page 204 of 209 Manual Rev: 1.56 BalClor® BWMS

 Corresponding
No. Name Specification Unit Qty
tag
UNITS
1 Electrolysis unit BC-3000 set 1 EDU
2 Neutralization unit Tank volume:1.0 m³ set 1 ANU
3 Auto back flushing filter Type: Size700 set 1 AFU
4 Heat exchanger Type:P60-0.69-4.0-HE set 1 EQ37-1#
4.1 Steam trap valve DN32 PN10 pcs 1 ST001
5 TRO Sampling Unit TSU set 2 TSU01/02
6 TRO Drain Unit TDU set 1 EQ40

7 Oxidant Dosing Unit Flow rate: 36 m3/h，head 40m set 1 ODU

ELECTRICAL EQUIPMENTS
1 Rectifier SCR-01G1 set 1 EQ07
2 System control cabinet SCC-1 set 1 EQ08
3 Motor control cabinet MCC-1 set 1 EQ25
4 Remote junction box JCR-1 set 1 EQ24
PUMPS

Flow rate: 326m3/h，head 15m，

1 Sludge pump set 1 EQ02
518kw;
1.1 Vacuum& pressure gauge set 1

Flow rate: 36m3/h，head 25m，6.6

2 Seawater booster pump set 1 EQ04
kw
2.1 Vacuum& pressure gauge set 1
INSTRUMENTS
1）DN500
1 Flow meter set 1 FT01
2）Including transmitter and sensor;
2 TROAnalyzer Type: CLX-XT； set 1 TR01
3 Hydrogen sensor Type: XCD-STD pcs. 1 HS01
VALVES
Pneumatic regulating
1 DN450 PN10 set 1 PV001
butterfly valve
Pneumatic open/close
2 DN200 PN10 set 1 PV101
butterfly valve
 Corresponding
No. Name Specification Unit Qty
tag
Pneumatic regulating 1) DN65 PN10;
3 set 2 PV201/401
butterfly valve 2) Medium: NaClO solution
DN15 PN10; setting pressure:
4 Relief valve set 2 RV501
0.5bar
DN15 PN10; setting pressure:
5 Relief valve set 2 RV502
1.0bar
OTHERS
1 Sodium thiosulphate 25kg/bag bag 20 --
2 EDU injecting pipe DN80 PN10 pcs 1
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX K：Assembly drawing of BalClor® BWMS

（for BC150-BC8000）
(Ver. 1.22, updated to 2020-03-04)

Page 205 of 209 Manual Rev: 1.56 BalClor® BWMS

 d5
d1~3
d4

2020-06-17
2020-06-17

2020-06-17

2020-06-16

2020-06-16
AFU01
2020-10-15
2020-10-15

2020-10-14

2020-10-12

2020-10-12
01/02
01
2021-03-09
2021-03-09

2021-03-09

2021-03-09

2021-03-08
2020-08-14
2020-08-14 02
2020-08-14

2020-08-13

2020-08-13
2020-08-14
2020-08-14 04
2020-08-14

2020-08-13

2020-08-13
2020-01-03
2020-01-03

2020-01-03

2020-01-03

2020-01-02
TR01/02
2020-08-21
2020-08-21

2020-08-21
PV001
2020-08-21

2020-08-20
2020-08-21
2020-08-21

2020-08-21

2020-08-21 101
2020-08-20
2020-08-21
2020-08-21

2020-08-21

2020-08-21 PV201/PV401
2020-08-20
 －－画画画l
1. 归 如 、墨 气E

A A

NOTE:
1. THIS VALVE SHOULD BE INSTALLED UPWARD·
2. THE RELEASE PRESSURE CAN BE RESET BY ADJUSTING THE SPRING (PART 6) ,BUT THIS OPERATION
α3
IS NOT RECOMMENDED BECAUSE ACCURATE PRESSURE SETIING NEED SPECIAL TOOLS;
3. RELIEF VA山E SETIING PRESSURE VALUE IS 0.5 BAR AND BACK PRESSURE VALVE IS 1.0 BAR.
4. THE CONNECTION OF INLET/OUTLET FLANGE WITH VA山E BODY ARE SCREWED CONNECTION, SO
THE LENGTH DIMENSION IS NOT FIXED.

11 CAP GASKET PTFE

B ��11 们俨斗｜户、�I ｜｜
10 S日L Pb
OUTL� 9 LOCK NUT C 3604
8 ADJUST SCREW C 3604
7 SPRING SEAT(LOW,UP) SEE TABLE 2
6 SPRING swosc
5 VALVE STEM SUS 304
4C O RING VITON
SPRING C 3604
015 ｜｜ r-----1 I 4A DISC GUIDE C 3604
c 65 士 1 4 DISC C 3771 IC
3 CAP C 3771
2 I BONNET BC 6
BODY C 3771

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’
NO PART NAME MATERIAL Q TY I REMARK

s x s E v A T z
RV501/502
BV501/502 e
口。IUor\V bALLAj I VYA ItK MAl�AGtMtl� I川j\t_M IP口A口W口F口STAGE

No, I SPECIFICATION 1( ) I SPECIFIC盯ION 2( DESCRIPTION Reviewed L主圳 ， ｜，，牛，， A DIMENSIONAL DRAWING OF

DN15 PN10 DIN 15A 1 OK JIS WATER INL盯 一－ RELIEF/BACK-PRESSURE VALVE

DWG.NO
DN15 PN10 DIN 15A 1 OK JIS WATER OUTLET
晶贺辈革励精密③⑥电贯 绳’… ． 在 " ＇古JC- ，�「寸可区→－ ＝气 「 ,. 革面τ ��； η 「
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→－一一…←每P-· lgfily ←
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一－「？三7一←千万 气 ’← •. ' －.，，，.‘：； · ·- ··: －亏←
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叮 主三 －－一→→←
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飞气 ， 「�盯式÷？一.. ←→
Page
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 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX L： Electrical Wiring Drawing of BalClor®

BWMS (for BC150‐BC8000)
(Ver. 2.0, updated to 2016-12-2)

Page 206 of 209 Manual Rev: 1.56 BalClor® BWMS

³
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX M：SUNRUI BalClor® Ballast Water

Management System Installation Manual
(Ver. 1.1, updated to 2016-11-20)

Page 207 of 209 Manual Rev: 1.56 BalClor® BWMS

 INSTALLATION REQUIREMENTS

BalClor® BWMS Installation Requirements

 INSTALLATION REQUIREMENTS

1. AFU
Model Guidance

AFU is applied to remove particles or organisms larger than 50micron in ballast water before leading to
Function
ballast tanks.

Location AFU shall be located downstream of ballast pump and prior to EDU oxidant injection point. AFU shall
requirement be located as low as applicable to avoid gas traps and to ensure at least 2.0 bar back-flushing pressure.

Piping 1.The housing and connection flanges of the filter must not be exposed to any external force or impact.
Installation 2. the size of back-flushing piping shall be determined according to back-flushing flow to guarantee the
Requirement velocity lower than 2m/s.

1.Beams or lifting eye shall be fitted at the roof above the filter for hanging the Chain block for lifting
the filter lid and screens.
Additional
2.The main ballasting piping including AFU inlet and outlet piping shall be the thoroughly cleaned and
Requirements
cleared from debris and large objects before initial water filling to avoid any debris or residue block the
screen or damage the internal parts of the filter.
 INSTALLATION REQUIREMENTS

2. EDU
Model Guidance

When ballasting, produce oxidant by electrolyzing seawater to kill the residual planktons, pathogens,
Function
larva or spores.

1. Installed in safety zone and make sure ventilating well ;

Location
2. Installed away from equipments which can generate large amount of heat and vibration, for
requirement
example: boiler, generator, main engine. Recommend to arrange in the fourth platform or above.

1. Pipe fittings and Valves from N22 to injecting pipe should be carbon steel with PE coating or
other equivalent corrosion material which can resistance to 1% NaClO solution.
2. Gaskets from N22 to injecting pipe should be PTFE, EPDM or other equivalent corrosion material
Piping which can resistance to 1% NaClO solution.
Installation 3．The welding of ventilation piping leading diluted hydrogen to the open deck shall preferably be
Requirement done by full penetration butt welding.

4. The ventilation piping leading diluted hydrogen gas shall be ascending, to avoid gas traps. In
addition, this piping shall be marked with tape coloured; yellow, blue, yellow. Guidelines for similar
marking are given in ISO14726 T49(ref/10/).
 INSTALLATION REQUIREMENTS

Additional 1.Install a pulley and/or a winch for maintenance and service purposes above the unit;
Requirements 2. Drip tray should be installed around EDU.

3.ANU
Model Guidance

Automatic neutralization unit is used to neutralize residual chlorine in the treated ballast water
Function
during de-ballasting process.

1. ANU is preferred to be placed close to the neutralizer injection point to reduce the length of the
dosing tube and shorten the injection time of the neutralizer. The lines from ANU to the neutralizer
Location
injection point is recommended to be vertically downward or horizontally to avoid gas traps.
requirement
2. In the case of neutralization tank and metering pump not in the same module, the distance of the
two modules should be less than 1m.

Piping Installation
The material of the pipe and valve after ANU should be SS316.
Requirement

1. Install a pulley and/or a winch for maintenance and service purposes above the unit;
Additional
2. Drip tray should be installed around ANU.
Requirements
3. It is forbidden to tread on ANU piping.
 INSTALLATION REQUIREMENTS

4.ODU
Model Guidance

Function Suction oxidant for EDU and inject to ballast pipe.

Location Install the ODU within 2 meters to the outlet of EDU, and at the same level or lower than EDU
requirement outlet (N22).

1. The length of the pipe between EDU and ODU shall be no more than 2m.
Piping Installation
2. The pipe before and after ODU shall be carbon steel with PE coating or GRE or other equivalent
Requirement
corrosion resistance type.
 INSTALLATION REQUIREMENTS

5.Pump
Model Guidance

EQ02 Deliver back-flushing water to overboard.

Function
EQ04 Deliver seawater to EDU.

1. The installation base of pump must be firm and permanent.

Location 2. The seawater must reach the pump body by gravity, and the pressure loss and back pressure along the
requirement delivery line must be under the delivery head. If the reducer will be set before or behind the pump, the
distance between the reducers and that between reducer and pump shall be as close as possible.

Piping
Without rain-proof cover, the pump is not recommended to be installed under deck. Keep a friendly
Installation
Vertical space for gauge observing and lifting plan.
Requirement

Cable Cabling and grounding according to the electrical diagram. Cable glands must be well sealed during
Requirement installation.

1. EQ02 sludge pump discharge is recommended to lead to an independent overboart

Additional 2. Pump should be properly protected against vibration. The pump must be free of stress from inlet and
Requirements outlet piping. Clean the pipe before commissioning.
Horizontal
3. Details for bulkhead pump shall be confirmed at approval stage.
 INSTALLATION REQUIREMENTS

6. TRO and TSU

Model Guidance

TRO Monitoring the total residual chlorine.

Function
TSU Take sampling water to TRO from sampling point.

Piping
Installation
Requirement

TRO
 INSTALLATION REQUIREMENTS

TSU

The height difference between sampling point “C1/C2”and TSU should be less than 2m in order to help
sampling pump suction water from ballast pipe.
 INSTALLATION REQUIREMENTS

7.Flow Meter
Model Guidance

Function Measure the flow rate when ballasting.

Install in the discharge pipe of ballast pump, and make sure it’s filling with liquid when in operation.

Avoid the following locations:

●Highest point of a pipeline. Risk of air

Sensor accumulating!
Location ●Directly upstream from a free pipe
requirement outlet in a vertical pipeline.

●For partially filled pipes or pipes with

downward flow and free outlet, the flow
Transmitter meter should be located in a U-Tube.
 INSTALLATION REQUIREMENTS

PERFECT (ACCURACY: 0.5%)

Piping
Installation
Requirement
ACCEPTABLE (ACCURACY: 2%)

If the flow meter is installed horizontally,

make sure the sensor head is upside or
Additional
rotates as showed in the right picture to
Requirements
avoid the influence of gas or sediments in
the pipe.

Cable
Senor and transmitter should be less than 20m.
Requirement
 INSTALLATION REQUIREMENTS

8. Pneumatic Butterfly Valve

Model Guidance

Function Open/close or regulating water flow.

1. If possible, the valve should be located 6 x Pipe Diameter from other pipe fittings, including
elbow, pump, valves and etc.

2. For the medium which contain particles and sediments, it is recommended to install the valve
horizontally to prevent sludge builds up on the disc.

Location
requirement

3. For normal situations, it is recommended to install the valve with stem remaining vertical; and
with actuator and control part installed vertically above the valve. Valve is not recommended to be
installed upside-down unless the space is very limited;
 INSTALLATION REQUIREMENTS

1. Make sure the pipe and flange face is clean. Any debris such as pipe scale, welding slag, metal
fragment may block the valve disc from opening or cause damage to the valve seat.

2. For the valve with resilient valve seat(not metal seat), flange gaskets is not recommended;

3. Place the valve between two pipe flanges; thread all the bolts through the valve body without
Piping
tightening them;
Installation
Requirement Caution!!! Close the valve before putting it between two pipe flanges or valve disc may collides
with pipeline and cause damage to disc edge.

4. Slowly open the valve disc to 100% and make sure the disc will not encounter with the inside
diameter of nearby flange and pipe. Tighten the bolts.

Caution!!! Make sure the pipe is in good alignment. Or it may cause encounter of valve disc and
 INSTALLATION REQUIREMENTS

inside diameter of pipeline; damage the edge of the disc and cause leakage. In addition, incorrect
alignment will lead to improper sealing and cause leakage.

Caution!!!For plastic flange, bolts should be appropriately tightened; too much strength while
tightening may cause the deformation of the flange.

5. Close and open the valve to 100% several times to make sure adequate clearance between valve
disc and pipeline.
 INSTALLATION REQUIREMENTS

For pneumatic regulating valve, compressed air is required to pass through the air filtration regulator
before entering the actuator or control part.

Caution!!! Use only instrumental air supply that is free from water and oil!
Additional Caution!!! Before connecting the air pipe to valve, ensure that all pipes are cleared from water and
Requirements debris, or it could damage the control part of the valve and cause malfunction; Caution!!! Always
make sure the air filtration regulator is installed vertically.

Caution!! Before installation, make sure the threshold dimension of valve disc is smaller than the
inside diameter of flange and pipe. Or the valve may not be able to 100% open.
 INSTALLATION REQUIREMENTS

9. Hydrogen Sensor
Model Guidance

Function To detect the concentration of hydrogen.

Hydrogen sensor shall be installed above the EDU and in the ventilation pipe.

Location
requirement

Additional
Allow easy access to the hydrogen sensor for maintenance purpose;
Requirements
 INSTALLATION REQUIREMENTS

10.Ventilation Head
Model Guidance

Arranged on up deck pipe which connected to vent outlet of “EDU”.

1.Leading to open deck at least 2m above deck.

2.At least 4.5m horizontal distance from ventilation inlets, opening to accommodation and service
Location spaces. （ABS: A spherical volume with a radius of 3 meters， with the ventilation exhaust outlet as
requirement the center is to be considered as hazardous（Zone 2））.

3.Outlets must not be located in places where personnel/passengers stay. If this is necessary due to the
layout of the ship, such outlets shall have visible signs informing that the air coming out contains H2.
 INSTALLATION REQUIREMENTS

11. Electrical Equipments

Code Model Guidance

Function Provide DC power for electrolysis and control system.

1 DC power cable from Rectifier to electrolyzer should be less than 50m

EQ07 2 Keep enough maintenance space

Requirements 3 Air vent for rectifier

4 Rectifier ground points shall be installed separately to avoid the

electromagnetic interference to other BWMS signals
 INSTALLATION REQUIREMENTS

Function Control the entire system and display the system operating status

1 Easy to operate and maintenance.

2 Power cable which produces strong electromagnetic field, such as

generator main supply cable or any heavy consumers are connected from
MSBD, is prohibited to be passed through the bottom or above of the
EQ08 system control cabinet.
Requirements
3 System ground points shall be installed separately to avoid the
influence form electromagnetic noise produced by other heavy
consumers.

4 Signal cable marked ‘Sxx’ need to be shield to ground.

5 Keep air vent space

 INSTALLATION REQUIREMENTS

Code Model Guidance

Function Control all of the motors manually.

1 Easy to operate and maintenance.

2 System ground points shall be installed separately to avoid the

EQ25 influence form electromagnetic noise produced by other heavy
Requirements
consumers.

3 Signal cable marked ‘Sxx’ need to be shield to ground.

4 Keep air vent space

Function Remote operation and display.

1 Easy to operate and maintenance.

EQ24 2 System ground points shall be installed separately to avoid the

Requirements influence form electromagnetic noise produced by other heavy
consumers.

3The installation must be firm.

 INSTALLATION REQUIREMENTS

12. Sampling And Injecting Point

Code Model Guidance

1. Enough space must be reserved to remove or maintain the

injecting pipe.

2. Ensure that the holes on the injection pipe are vertical to the ballast
water flow direction. The installation mark can be used to guide
installation.
"a"
3.3mm EPDM or PTFE gaskets of total 3 should be used on all
flange faces.

4. The distance requirements should be followed as the flow diagram

description.

5. Point "a" shall be located at the downstream pipe of flow meter.

 INSTALLATION REQUIREMENTS

1. Enough space must be reserved to maintain the injecting pipe.

"b" 2. The neutralization injection point is best injected vertically
downward into the horizontal pipe.

Recommend

1. The enough space must be reserved to maintain the sampling pipe.

2. The distance requirements should be followed as the flow diagram

"c" description.

3. There shall be at least 1.5D straight pipe for point "c".

4. It's better to set "c" point at horizontal pipe.

Recommend
 INSTALLATION REQUIREMENTS

1. The design of sampling port is based on IMO G-2 standard.

2. The length of the straight sample pipe facing into the flow should
"d" not be less than one diameter of the sampling pipe.

3. Diaphragm valve is best choice to reduce negative influence on

organism survival and should be opened as much as possible.
 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX N: installation, maintenance and repair

procedures for valves

Page 208 of 209 Manual Rev: 1.56 BalClor® BWMS

RESILIENT SEATED BUTTERFLY VALVES
OPERATION AND MAINTENANCE MANUAL
Table Of COnTenTs:

Page

VALVE .......................................................................................................................................... 1

SAFET INSTRUCTIONS - DEFINITION Of TERMS................................................................................ 1

Shipment & Storage ......................................................................................................................... 2

Installation Considerations .............................................................................................................. 2

Valves with Spring Return Actuators ............................................................................................... 3

3. Valve Location .............................................................................................................................. 4

4. Valve Orientation ......................................................................................................................... 4

Installation of Bray PTFE Seated Butterfly Valves in Plastic Flanges.............................................. 11

Maintenance and Repair ............................................................................................................... 11

Appendix A..................................................................................................................................... 13

Disassembly/Assembly Instructions .............................................................................................. 13

Appendix B ..................................................................................................................................... 15

Disassembly/Assembly Instructions .............................................................................................. 15

Appendix C ..................................................................................................................................... 17

Disassembly/Assembly Instructions .............................................................................................. 17

Appendix D .................................................................................................................................... 19

Disassembly/Assembly Instructions .............................................................................................. 19

Appendix E ..................................................................................................................................... 22

Disassembly/Assembly Instructions .............................................................................................. 22

Series 35/36 Resilient Seated Butterfly Valves .............................................................................. 22

(Internal Spline or Keyed Disc/Stem Connection) ......................................................................... 22

PNEUMATIC ACTUATOR ................................................................................................................ 28

Safety Information - Definition of Terms ....................................................................................... 28

Description of Operation ............................................................................................................... 29

 Operating Medium ........................................................................................................................ 29

Operating Temperature ................................................................................................................. 29

Installation ..................................................................................................................................... 30

Mounting the Actuator to the Valve.............................................................................................. 31

Setting the Travel Stops ................................................................................................................. 31

Maintenance .................................................................................................................................. 32

Troubleshooting............................................................................................................................. 33

Assembly ........................................................................................................................................ 33

Disassembly ................................................................................................................................... 35

Adding Spring Cartridges ............................................................................................................... 35

Removing Spring Cartridges........................................................................................................... 36

General Pneumatic System Recommendations............................................................................. 37

Dimensional Data........................................................................................................................... 37

Series 92/93 Parts Diagram ........................................................................................................... 38

CERTIFICATION .............................................................................................................................. 39

ABS certificate of type approval .................................................................................................... 39

BV certificate of type approval ...................................................................................................... 40

CCS certificate of type approval..................................................................................................... 42

DNV certificate of type approval ................................................................................................... 47

LR certificate of type approval ....................................................................................................... 48

KR certificate of type approval ...................................................................................................... 51

 VALVE

SAFET INSTRUCTIONS - DEFINITION Of TERMS

READ AND FOLLOW THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.

used without the safety alert symbol indicates a potential

situation which, if not avoided, may result in an
undesirable result or state, including property damage.
Introduction
Historical Experience
Based on over twenty years experience in the butterfly industry, Bray can state
without question the majority of all feld problems for resilient seated butterfly valves
are directly related to poor installation procedures. For this reason, it is very important
all distributor salespeople educate their customers regarding proper installation of
resilient seated butterfly valves.
Butterfly Valve Seat / Disc Function
Before reviewing the proper installation, maintenance, and repair procedures for
resilient seated butterfly valves, let’s discuss the seat-disc function of a butterfly valve.
The seat in a resilient seated butterfly valve has molded o-rings on its flange face. As
a result, no gaskets are required as these o-rings serve the function of a gasket. The
flange face and molded orings of the seat extend beyond the body face-to-face to
ensure sealing at the flange faces. The seat material, which extends past the face is
compressed in installation and flows toward the center of the valve seat I.D.
In essence, the elastomer seat acts as a liquid, and the displaced elastomer moves
toward the point of least resistance. The seat I.D. of all resilient seated butterfly valves
is smaller than the disc O.D. This difference, the disc-seat interference, plus the
increased interference due to the elastomer movement toward the seat center after
installation,has been engineered so as to be the basis for pressure rating capability and
the related seating/unseating torques. Any change in this interference due to improper
installation directly affects the pressure rating and seating/unseating torques.
Finally, unlike many valve types, the resilient seated butterfly valve’s disc actually
extends beyond the face of the valve body at given angles of opening (say, 30° or
more) when installed between flanges.

Page 1
It is very important before installation to ensure the critical chord dimension of the
disc at the full open position is less than the adjacent pipe flange I.D.
Shipment & Storage
A. The seat, disc, stem and bushing of the resilient seated butterfly valve should be
coated with silicone lubricant unless specifed otherwise as recommended by Bray
Technical Bulletin 1028.
B. The disc should be positioned at 10° open. Note: See page 2 for special
considerations for valves with spring return actuators.
C. Valves should be stored indoors with a preferred temperature range from 40° F
(4°C) to 85° F (29°C).
D. When valves are stored for a long time, open and close the valves once every 3
months.
E. Ship and store valves so that no heavy loads are applied to the bodies.
Installation Considerations – Piping and Valve Orientation and Placement
Piping and Flanged Compatibilities
Piping
These valves have been engineered so that the critical disc chord dimension at the full
open position will clear the adjacent inside diameter of most types of piping,including
Schedule 40, lined pipe,heavy wall, etc.
Metal Flanges
Resilient seated butterfly valves have been designed to be suitable for all types of
flanges (ASME, DIN,JIS and other international flange standards), whether flat-faced,
raised face, slip-on, weld-neck, etc. Proper alignment of any butterfly valve between
flanges is critical to good performance of the valve. The flange bolts must also be
evenly tightened around the circumference of the valve, providing consistent flange
compression of the molded o-ring in the seat face.
Since Bray does not recommend the use of gaskets between flanges on resilient seated
butterfly valves,a uniform flange face is critical to proper valve sealing. Most weld-
neck and slip-on flanges conforming to ASME specifcations have an appropriate
flange face. Types A and B butt-weld stub-end flanges also provide a suitable mating
surface for the molded o-ring.
It should be noted that Type C butt-weld stub-end flanges have an “as formed” flange
face. The varying surface of this flange face can create sealing problems between any
resilient-seated butterfly valve and the flange face. For this reason, Type C flanges are
not recommended for use with resilientseating butterfly valves.

Page 2
Non-Metallic Flanges
When non-metallic flanges, such as plastic or PVC, are used with resilient seated
butterfly valves, care must be taken not to over-tighten the flange bolts. The inherent
flexibility of these non-metallic flange materials allow them to be over-tightened
relatively easily. Flexing caused by this over-tightening can actually reduce the
compression of the valve between the flanges, causing leaks between the valve and
the flange face. Proper alignment and frm, even, but not excessive tightening of flange
bolts are especially important with non-metallic flanges. In some cases, non-metallic
flanges of low quality will not mate tightly with butterfly valves regardless of the care
taken during installation.
Valves with Spring Return Actuators
1. Fail Closed Assemblies
If the valve is supplied with an actuator, the butterfly valve is shipped in the full
closed position (as no air pressure is present to compress the springs and open the
disc).

Installing the valve with the disc in the full closed position may create a compression
set on the seat causing higher than expected torques or premature seat failure. It is
recommended to:
• Remove the actuator. Be sure to scribe the valve and actuator to ensure the re-
installed actuator is in the exact same quadrant as originally confgured
• Install the valve per the attached installation tag instructions
• Re-install the actuator ensuring it is in the proper quadrant
2. Fail Open Assemblies
If the valve is supplied with an actuator, the butterfly valve disc is shipped in the full
open position (as no air pressure is present to compress the springs and close the valve
disc.) The sealing surface, or disc edge, is therefore exposed. Damage to that surface
will cause premature seat failure.

Use caution installing the valve being careful not to damage the disc edge. It is
recommended to:
• Remove the actuator. Be sure to scribe the valve and actuator to ensure the re-
installed actuator is in the exact same quadrant as originally confgured
• Install the valve per the attached installation tag instructions
• Re-install the actuator ensuring it is in the proper quadrant

Page 3
3. Valve Location
a. Resilient seated butterfly valves should be installed if possible a minimum of 6 pipe
diameters from other line elements, i.e., elbows,pumps, valves, etc. of course, 6 pipe
diameters are not always practical, but it is important to achieve as much distance as
possible.
b. Where the resilient seated butterfly valve is connected to a check valve or pump,
use an expansion joint between them to ensure the disc does not interfere with the
adjacent equipment.
4. Valve Orientation
a. In general, Bray recommends the resilient seated valve be installed with the stem in
the vertical position and the actuator mounted vertically directly above the valve;
however,there are those applications as discussed below where the stem should be
horizontal. NOTE: Bray does not recommend valves be installed in an upside-down
position.

b. For slurries, sludge, mine tailing, pulp stock, dry cement, and any media with
sediment or particles, Bray recommends the resilient seated valve be installed
with the stem in the horizontal position with the lower disc edge opening in the
downstream direction.
Valve Orientation (Continued)
c. Resilient seated butterfly valve located at the discharge of a pump should be riented
as follows:

Page 4
Valve Orientation (Continued)
d. Butterfly valves located downstream of a bend or pipe reducer should be oriented
as follows:

Page 5
Valve Orientation (Continued)
e. Butterfly valves in combination for control/isolation applications should be
installed as follows:

Page 6
Combination with all valve stems in the same direction accelerates possible noise,
vibration, & erosion problems.

Combination with the stem of the control valve at right angle to those of other valves
tends to cancel the drift of the fluid, and reduces noises, vibration, and erosion.
Installation Procedure
A. General Installation
1. Make sure the pipeline and pipe flange faces are clean. Any foreign material such
as pipe scale, metal chips, welding slag, welding rods, etc., can obstruct disc ovement
or damage the disc or seat.
2. The Bray elastomer seat has molded o-rings on the face of the seat. As a result, no
gaskets are required as these o-rings serve the function of a gasket.
3. Align the piping and then spread the pipe flanges a distance apart so as to permit
the valve body to be easily dropped between the flanges without contacting the pipe
flanges (see fgure 1 page 6).
4. Check to see that the valve disc has been positioned to a partially open position,
with the disc edge about 1/2 inch to 3/8 inch inside the face of the seat,
approximately 10° open) (see fgure 1 page 6)
Note: See page 2 for special consideration for valves with spring return actuators.
5. Insert the valve between the flanges as shown in fgure 1 of page 6, taking care not
to damage the seat faces. Always pick the valve up by the locating holes or by using a
nylon sling on the neck of the body.

Page 7
Never pick up the valve by the actuator or operator mounted on top of the valve.
Figure 1 – Insert Resilient Seated Butterfly Valve Between Flanges

Pipe not spread, disc opened beyond valve body face; Results; Disc edge damaged
when it hits pipe flange.
Pipe spread and aligned, disc rotated;Results; no undesirable beginning
seating/unseating torque, disc edge protected.
6. Place the valve between the flanges, center it,and then span the valve body with all
flange bolts,but do not tighten the bolts. Carefully open the disc to the full open
osition, making sure the disc does not hit the adjacent pipe I.D. Now systematically
remove jack bolts or other flange spreaders, and hand-tighten the flange bolts as
shown in Figure 2
below. Very slowly close the valve disc to ensure disc edge clearance from the
adjacent pipe flange I.D. Now open the disc to full open and tighten all flange bolts
per specifcation as shown in Figure 2. Finally, repeat a full close to full open rotation
of the disc to ensure proper clearances (See fgures 3 & 4 page 7).
INCORRECT INSTALLATION CORRECT INSTALLATION
Figure 2 – Flange Bolt Tightening Pattern

Page 8
 Figure 3 – Initial Centering & Flanging of Valve

Disc in closed position; gaskets used; Results – Seat distorted and over-compressed
causing high initial unseating torque problems.

Bolts snugged, not torqued tight, disc edge within body face-to-face but not fully
closed,no flange gaskets; Results: No disc edge damage, proper sealing allowed.
Figure 4 – Final Aligning & Tightening of Flange Bolts

Page 9
Piping misaligned; Results Disc O.D. strikes pipe I.D. causing disc edge damage,
increased torque & leakage. Seat face o-rings will not seal properly with incorrectly
aligned piping.

Piping aligned properly when bolts tightened,disc in full open position; Results – disc
clears adjacent pipe I.D., seat face seals properly, no excessive initial torque.
When resilient seated butterfly valves are to be installed between ASME welding type
flanges, care should be taken to abide by the following procedure to ensure no damage
will occur to the seat:
1. Place the valve between the flanges with the flange bores and valve body aligned
properly.The disc should be in the 10° open position.
2. Span the body with the bolts.
3. Take this assembly of flange-body-flange and align it properly to the pipe.
4. Tack weld the flanges to the pipe.

Page 10
5. When tack welding is complete, remove the bolts and the valve from the pipe
flanges and complete the welding of the flanges. Be sure to let the pipe and flanges
cool before installing the valve.

Never complete the welding process (after tacking) with the valve between pipe
flanges. This causes severe seat damage due to heat transfer.
Installation of Bray PTFE Seated Butterfly Valves in Plastic Flanges.
Bray recommends the following guidelines when PTFE Seated Valves are installed
between plastic flanges:
1. The valve body should be coated with epoxy, not nylon. The extra thickness of the
nylon coating slightly reduces the seat compression, and every advantage to maximize
seat compression should be taken with plastic flanges.
2. The plastic flange can be either one piece construction, or two piece construction
comprised of a stub end and a backup ring.
3. The plastic flange style can be butt-weld, socket or slip-on, but butt-weld and
socket are preferred.
4. The plastic flange face must be flat. Concave and convex flange faces are not
acceptable. This includes flange faces that were originally flat but later distorted into a
concave shape by over tightening the flange bolts.
5. The plastic flange face surface may have grooves or serrations, provided the
grooves do not exceed .100” (2.54 mm) in width or .020” (.508 mm) in depth. If the
grooves are less than .100” (2.54 mm) in width, the groove depth must not exceed the
width. However, fne conentric or “phonograph record” grooves are acceptable
regardless of the groove depth.
6. Flange gaskets must not be used with PTFE seats,since they create an uncontrolled
over compression that can buckle the PTFE and damage the seat.If a damaged face, a
flange gasket can appear to cure the leak to atmosphere, while simultaneously
damaging the PTFE seat and creating a second leak across the disc or up the stem hole.
Leaks across the plastic flange must be cured without the use of gaskets, by proper
selection and installation of the flange.
7. The bolts holding plastic flanges should be installed in strict conformance to the
recommended practices of the plastic flange manufacturer. This usually involves
aligning the flanges accurately, using lubricated bolts, and tightening the bolts in the
proper sequence and to the specifed torque. Uniform stress across the flange prevents
leakage.
Maintenance and Repair
The many Bray features minimize wear and maintenance requirements. No routine
lubrication is required. All components – stem, disc, seat, bushing, stem seal, etc., are
feld replaceable, no adjustment is required. If components require replacement, the

Page 11
valve may be removed from the line by placing the disc in the near closed position,
then supporting the valve and removing the flange bolts.

No valve maintenance, including removal of manual or power actuators, should be

performed until the piping system is completely depressurized.

Page 12
 Appendix A
Disassembly/Assembly Instructions
Series 20/21 Resilient Seated Butterfly Valves
Disassembly
1. Remove handle, gear operator or power actuator from actuator mounting flange.
2. Remove the body bolts and pull the lower body half away from the seat.
3. Pull the seat and disc stem from the upper body half.
4. Remove bushing and seal from the upper body.
5. Push the seat into an oval shape and remove the disc stem by withdrawing the short
stem end frst.
Assembly
1. Push the long stem end of the disc into the seat.
2. Then push the seat over the disc’s short stem.
3. Place the disc stem and seat into the upper body half.
4. Align the lower body with the upper body and position lower body in the seat.

The body halves have a matching casting node on one side only to ensure correct
assembly of body halves.
5. Replace the body bolts and tighten.
6. Install the stem seal, then the stem bushing.
Note: It is recommended that the stem bushing be coated with a light amount of
silicone grease before installation in the valve body. This coating of silicone
grease will assist in keeping the stem bushing in the valve body until an actuator
is mounted on the valve.
7. Replace handle, manual gear operator or power actuator on the actuator mounting
flange.

Page 13
 Appendix A

Page 14
 Appendix B
Disassembly/Assembly Instructions
Series 30/31 Resilient Seated Butterfly Valves
Disassembly –
1. Remove the handle, gear operator, or power actuator from actuator mounting flange.
2. Remove the “Spirolox”® retaining ring and the two C-ring stem retainers from the
stem hole.
3. Then remove the stem, bushing and seal.
4. Remove the disc from the seat, protecting the disc edge at all times.
5. Push the seat into an oval shape, and then remove the seat from the body.
Assembly –
1. Push the valve seat into an oval and push it into the body with seat stem holes
aligned to body stem
holes.

When installing the seat the larger hole should be on top and the smaller hole should
be on bottom.
2. Insert stem seal and bushing.
3. Push stem into the stem hole of the body until the bottom of the stem is flush with
the inner top edge of the seat.
4. Install a light coating of silicone or grease on the I.D. of seat. Insert the disc into the
seat by lining up the disc holes with the stem holes of the seat.
Note: The broached double “D” flats in the disc must be toward the bottom of
the valve body.
5. With a downward pressure and rotating the stem back and forth, push the stem until
the stem touches the bottom of the body stem hole.
6. Make certain that when pushing the stem through the disc bottom, the broached
flats of stem and disc are aligned.
7. Replace the stem bushing and two stem retainers, then replace the “Spirolox”®
retaining ring back into position.
8. Replace handle, manual gear operator or power actuator on the actuator mounting
flange.

Page 15
Page 16
 Appendix C
Disassembly/Assembly Instructions
Series 3A/3AH Resilient Seated Butterfly Valves
Disassembly –
1. Remove the handle, gear operator, or power actuator from actuator mounting flange.
2. Remove the “Spirolox”® retaining ring and the two C-ring stem retainers from the
stem hole.
3. Then remove the stem, bushing and seal.
4. Remove the disc from the seat, protecting the disc edge at all times.
Note: The seat is bonded to the body and is not easily feld replaceable. Please
contact your local Bray representative for seat replacement.
Assembly –
1. Insert stem seal and bushing.
2. Push stem into the stem hole of the body until the bottom of the stem is flush with
the inner top edge of the seat.
3. Install a light coating of silicone or grease on the I.D. of seat. Insert the disc into the
seat by lining up the disc holes with the stem holes of the seat.
Note: The broached double “D” flats in the disc must be toward the bottom of
the valve body.
4. With a downward pressure and rotating the stem back and forth, push the stem until
the stem touches the bottom of the body stem hole.
5. Make certain that when pushing the stem through the disc bottom, the broached
flats of stem and disc are aligned.
6. Replace the stem bushing and two stem retainers, then replace the “Spirolox”®
retaining ring back into position.
7. Replace handle, manual gear operator or power actuator on the actuator mounting
flange.

Page 17
Page 18
 Appendix D
Disassembly/Assembly Instructions
Series 32/33 Resilient Seated Butterfly Valves
Disassembly –
1. Remove the gear operator or power actuator from the actuator mounting flange.
2. Secure the valve in a horizontal position with the taper-pin nuts facing upward.

Prior to removal of the valve stem the valve disc must be secured and supported to
insure it does not drop out of the valve body once the stem is removed. Lay the valve
down with two wood blocks located under the disc at the 6 o’clock and 12 o’clock
positions making sure the blocks are in close contact with the disc but not supporting
the valve.
3. Remove the packing gland by removing the retaining screws and sliding the gland
off the top of the stem.
4. Remove bottom plate and thrust bearing to expose bottom of stem.
5. Remove nuts and washers from ends of taper pins and drive taper pins out of the
disc. Avoid damaging the disc coating or surface when removing taper-pins.
6. Once taper-pins are removed, drive the stem, bushing, and packing out of the valve
body through the top.
7. Remove the disc from the seat, protecting disc edge at all times.
8. Push the seat into an oval shape, and then remove the seat from the body.

Page 19
 Appendix D (Cont’d)
Disassembly/Assembly Instructions
Series 32/33 Resilient Seated Butterfly Valves
Assembly –
1. Replace bottom thrust bearing and plate.
2. Push the seat into an oval and push it into the body with seat stem holes aligned to
body stem holes.
3. De-bur taper-pin grooves in the stem.
4. Push stem into stem hole of body until the bottom of the stem is flush with the inner
top edge of the seat.
Note: The end of the stem containing the keyway must be toward the top of the
valve body.
5. Install a light coating of silicone or grease on the I.D. of the seat.
6. Insert the disc into the seat by lining up the disc hole with the upper stem hole of
the seat.
7. With a downward pressure and rotating the stem back and forth, push the stem until
the stem touches the bottom of the body stem hole.
Note: Make certain that when pushing the stem to the bottom of the body, the
taper-pin grooves in the stem line up with the holes in the disc face.
8. Tap the taper-pins into their holes from the large side of the hole, making sure the
pins ft tightly in the hole and allow no movement of the stem in the disc.
Note: Ensure that the taper-pin o-rings are in place before completing valve
assembly.
9. Replace the washers and nuts on the ends of the taper-pins.
10. Replace bushing, packing, and packing gland, and then tighten the retaining
screws snugly.
11. Replace manual gear operator or power actuator on the actuator mounting flange.

Page 20
Page 21
 Appendix E
Disassembly/Assembly Instructions
Series 35/36 Resilient Seated Butterfly Valves
(Internal Spline or Keyed Disc/Stem Connection)
Disassembly –
1. Remove the gear operator or power actuator from the actuator mounting flange.
2. Secure the valve in a horizontal position.

Prior to removal of the valve stems the valve disc must be secured and supported to
insure it does not drop out of the valve body once the stems are removed. Lay the
valve down with two wood blocks located under the disc at the 6 o’clock and 12
o’clock positions making sure the blocks are in close contact with the disc but not
supporting the valve.
3. Removal of the lower valve stem:
a. Remove the bottom plate screws, bottom plate, bottom plate gasket and thrust
bearing.
b. Remove the locking nut from the tie bolt.
c. Remove the stem retainer.
d. Secure a hoist to the lower stem (end is imperial threaded).
e. Then use the hoist to remove the lower stem from the valve body.
f. Remove the stem bearing.
4. Removal of the upper valve stem:
a. Remove the packing gland by removing the retaining screws and sliding the gland
off the top of the stem.
b. Secure a hoist to the upper stem (end is imperial threaded).
c. Then use the hoist to remove the upper stem including the tie bolt from the valve
body.
5. Removal of the valve disc:
a. Remove the wood blocks noted above from below the disc.
b. Using a rubber hammer, pound one area of the disc (ex. 12 o’clock position)
repeatedly until the disc clears the face of the valve body.

Page 22
 Appendix E(Cont’d)
Disassembly/Assembly Instructions
Series 35/36 Resilient Seated Butterfly Valves
(Internal Spline or Keyed Disc/Stem Connection)
Disassembly –
6. Removal of packing and bearings:
a. Remove the stem packing.
b. Use a slotted screwdriver to carefully remove the upper and lower stem bearings.
7. Removal of the valve seat:
Note: Valves 54” and larger are provided with the seat bonded to the body and
therefore is not easily feld replaceable. Please contact your local Bray
representative for seat replacement.

a. Set the valve body in an upright position and secure it in a floor vice capable of
handling the weight of the valve body and seat.
Note: Be sure to not clamp the seat in the vice.
b. Insert a slotted screwdriver into the space between the body and the seat on the face
of the valve at the 12 o’clock position.
c. Carefully leverage the seat away from the body.
d. Push the seat into an oval shape and remove the seat from the body.
Assembly –
1. Installation of the valve seat:
Note: Valves 54” and larger are provided with the seat bonded to the body and
therefore is not easily feld replaceable. Please contact your local Bray representative
for seat replacement.

a. Set the valve body in an upright position and secure it in a floor vice capable of
handling the weight of the valve body and seat.
Note: Be sure to not clamp the seat in the vice.
b. Check to assure the interior surface of the valve body is clean.

Page 23
c. Install a light coating of silicone lubricant on the interior surface of the valve body.
d. Push the seat into an oval and push it into the body with seat stem holes aligned to
the body stem holes.

Page 24
 Appendix E(Cont’d)
Disassembly/Assembly Instructions
Series 35/36 Resilient Seated Butterfly Valves
(Internal Spline or Keyed Disc/Stem Connection)
Assembly –
2. Installation of the valve disc:
Note: Before installing the disc, check to assure the upper and lower stems are
matched to the upper and lower stem holes in the disc.
a. With the valve still in the vice in a vertical position, hoist the upper stem with the
splined end or the double keyed end pointing upward.
b. Push the upper stem into the stem hole of the upper body until the bottom of the
stem exceeds the upper stem hole of the seat by 20-50 mm.
c. Apply a light coating of silicone or grease on the I.D. of the seat.
d. Insert the disc into the seat with the splined end or the double keyed end up.
e. Push the disc into the seat while inserting the upper stem into the upper stem hole in
the disc.
f. Adjust the disc to assure the lower stem hole of the disc is properly aligned with the
lower body stem hole.
3. Installation of the lower stem:
a. Close the valve so that the disc is inside the edge of the seat.
b. Carefully place the valve in a horizontal position assuring that there is no damage
to the body and disc coatings and disc edge.
c. Insert the stem bearing into the bottom stem hole of the body.
d. Insert the lower stem into the body and disc.
Note: The cone-shaped end of the lower stem should be toward the center of the
disc.

Page 25
 Appendix E(Cont’d)
Disassembly/Assembly Instructions
Series 35/36 Resilient Seated Butterfly Valves
(Internal Spline or Keyed Disc/Stem Connection)
Assembly –
4. Installation of the upper stem:

a. Hoist the valve to an angle and secure it (be careful not to go to high so the lower
stem does not drop out).
b. Remove the upper stem from the valve.
c. Screw the tie bolt with lock nut to the splined or the double keyed end of the upper
stem,tighten the lock nut and insert the upper stem into the valve with the tie bolt end
frst.
Note: The tie bolt will go through the disc and reach to the bottom of the valve
Note: During this step, the keyway of the upper stem should be vertical to the
front face of the valve.
5. Installation of packing and bearings (upper valve stem):
a. Insert the stem bearing into the top hole of the body followed by the stem packing
and packing gland follower.
b. Use two hexagon bolts to fasten the packing gland.
6. Installation of packing and bearings (lower valve stem):
a. Insert the stem retainer into the bottom hole of the body using a nut to fasten it.
b. Install the locking nut on the tie bolt.
c. Install the thrust bearing, bottom plate gasket and bottom plate follower.
d. Use four hexagon bolts to fasten the bottom plate tightly.

Page 26
 2.

Page 27
 PNEUMATIC ACTUATOR

Safety Information - Definition of Terms

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

indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury.

used without the safety alert symbol indicates a potential

situation which,if not avoided, may result in an undesirable
result or state, including property damage.

Hazard-free use
This device left the factory in proper condition to be safely installed and operated in
a hazard-free manner. The notes and warnings in this document must be observed
by the user if this safe condition is to be maintained and hazard-free operation of the
device assured.
Take all necessary precautions to prevent damage to the actuator due to rough
handling, impact, or improper storage. Do not use abrasive compounds to clean the
actuator, or scrape metal surfaces with any objects.
The control systems in which the actuator is installed must have proper safeguards
to prevent injury to personnel, or damage to equipment, should failure of system
components occur.
Qualified Personnel
A qualified person in terms of this document is one who is familiar with the
installation, commis-sioning and operation of the device and who has appropriate
qualifications, such as:
• Is trained in the operation and maintenance of pneumatic equipment and systems
in accor-dance with established safety practices
• Is trained or authorized to energize, de-energize,ground, tag and lock electrical and
pneumatic circuits and equipment in accordance with established safety
practices
• Is trained in the proper use and care of personal protective equipment (PPE) in
accordance with established safety practices
• Is trained in first aid
• In cases where the device is installed in a potentially explosive (hazardous)
location – is trained in the operation, commissioning, operation and maintenance
of equipment in hazardous locations Correct and safe operation of this actuator is
depen-dent upon proper transport, storage and installation in addition to proper
operation and maintenance.

Page 28
The actuator must only be installed, commissioned, operated and repaired by qualified
personnel. The device generates large mechanical force when pressurized with air,
and/or powered by springs. The actuator stores a large amount of energy when
pressurized with air, and/or when the springs are compressed.
To prevent injury, installation, commissioning, operation and maintenance must be
carried out under strict observation of the safety regulations. Reference is specifically
made here to observe the applicable safety regulations for actuators installed in
potentially explosive (hazardous) locations.
Description of Operation

The Bray Series 92/93 Pneumatic Actuators fea-ture a double piston, rack and pinion
mechanism designed to automate quarter-turn valves. In the Series 92 Double-Acting
Actuator, pressure intro-duced through Port A (the left port when facing the ports) forces
the pistons away from each other and causes the pinion to rotate in a counterclock-wise
direction. Pressure introduced through Port B (the right port when facing the ports) is
directed through an internal passage to the opposite side of the pistons, which forces the
pistons together and rotates the pinion in a clockwise direction. Normally, the clockwise
rotation (pistons moving together) closes the attached valve, and the coun-terclockwise
rotation (pistons moving apart) opens the attached valve.
In the Series 93 Spring-Return Actuators, spring car-tridges have been added to push the
pistons together by spring force in the event the compressed air pres-sure is lost. This spring
force normally closes the attached valve. However, in the event that the valve is required to
open under spring force, refer to the fail open portion of the Installation section below.
Operating Medium
NOTICE

The recommended operating medium is clean, dry industrial compressed air, 40 - 140
psig (3 - 10 bar.) An air line lubricator is suggested for fast cycling applications, i.e.
more than 10 cycles per minute. Other media such as hydraulic oil, water, or certain
other inert gases may also be used in some instances, but the factory should be consulted
for specific applications.
Operating Temperature
NOTICE

The recommended operating temperature range is -15°F to 200°F (-25°C to 95°C).

Below 32°F (0°C) care must be taken to prevent condensed moisture from freezing in
the air supply lines. Consider the use of an air dryer if the device is installed in a cold
location. The air dryer must be capable of lowering the dew point of the air to a
temperature 36°F (20 °C) lower than that of the surrounding environment. The air
dryer must be properly maintained and kept in operation.

Page 29
Installation

Bray Series 92/93 Actuators are designed to mount directly on the top plate of Bray
Valves. Before the actuator is mounted on a valve, it is a good practice to lubricate
the output bore of the actuator with thick grease. The grease will make it easier to
remove the actuator from the valve stem, even after years of service.
Normally, the actuator is mounted with its long side parallel to the pipeline. A double acting
actuator will normally rotate the valve stem clockwise to close, and counterclockwise to
open. Spring return actua-tors will normally rotate the valve stem clockwise to close with
the spring stroke, and counterclockwise to open with the air stroke. The normal operation of
the spring cartridges is therefore fail closed.
Direction of operation may be changed to fail open by any one of several different
methods. Refer to the Assembly Instructions and Exploded View in Figure 3 on
page 12 for more details.
Fail Open Method 1 – Mounting the Actuator Perpendicular to the Pipeline
NOTICE

Fail Open Method 1 – Mounting the Actuator Perpendicular to the Pipeline –

works only with concentric disc valves such as the Bray Series 20/21, 22/23
and 30/31 or other valves that allow the disc to be swung through the seat.
Turn the actuator so the long side is perpendicular to the pipeline. This will allow the
spring cartridges to rotate the valve stem clockwise to open, and the air stroke to rotate
the valve stem counterclockwise to close. This is the easiest method if there is suf-
ficient room to mount the actuator.

Fail Open Method 2 – Rotating the Pinion

NOTICE

Fail Open Method 2 – Rotating the Pinion - works only with concentric disc valves
such as the Bray Series 20/21, 22/23 and 30/31 or other valves that allow the disc to
be swung through the seat.
See Assembly (Page 6) for detailed instructions on reinstalling the travel stop cam on
the pinion.
Before disassembly of the actuator, the pneumatic air supply
must be completely disconnected from the actuator, and all
compressed air stored within the actuator must be released.
Auxiliary devices connected to the actuator, such as tubing,
ball valves, solenoid air valves, valve positioners, etc. can block the release of air from
within the actuator. Do not rely upon the features or controls of any auxiliary device to
release the air from inside the actuator and render it safe for disassembly.
Some actuators may have spring cartridges installed. Before disassembly, all spring
cartridges must be placed into the relaxed (fully extended) position. All compressed air
must be removed from inside the actuator (See warning above) and the actuator pinion
must be allowed to rotate so the springs may be relaxed. Care must be taken to verify that
any device connected to the actuator, such as a valve mounted underneath, is not
preventing the move-ment of the springs to the relaxed position.

Page 30
Remove the end caps, spring cartridges and pistons from the actuator. Remove the pinion,
rotate it 90°, and reinstall the pinion in the actuator. This will also allow the spring
cartridges to rotate the valve stem clockwise to open, and the air stroke to rotate the valve
stem counter-clockwise to close. This is the second easiest method, and allows the
actuator to be mounted with its long side parallel to the pipeline.
Fail Open Method 3 – Reversing the Pistons
NOTICE

Fail Open Method 3 – Reversing the Pistons – works for all valves, but must be
used with offset disc valves such as the Bray Series 40/41, 42/43 and 44/45, or
other offset disc valves where the disc may only turn clockwise to close.
See Assembly (Page 6) for detailed instructions on reinstalling the travel stop cam on
the pinion.
Remove the end caps, spring cartridges and pistons from the actuator. Rotate the pistons so
that the racks turn the pinion counterclockwise as the pistons move toward each other. (With
the air input ports of the actuator body facing you, the left hand piston rack should be on the
side with the air ports.) This is the third easiest method, and allows the actuator to be
mounted with its long side parallel to the pipeline, and clockwise to close rotation to be
maintained.
Mounting the Actuator to the Valve

The actuator is attached to the valve by means of the studs and nuts furnished in the
mounting kit. Thread the studs into the proper holes in the actua-tor, before installing the
actuator on the valve. The studs should be snug in the bottom of the tapped holes; there is no
need to torque them. Install the actuator on the valve making sure that the base of the actuator
fits flat against the valve mounting flange. Use the nuts and washers from the kit to complete
the installation. Torque the nuts in a diagonal pat-tern to assure equal loading of the studs.

Setting the Travel Stops

The final step in the installation process is to check the travel stop settings. The travel stops
are set for 90° of travel at the factory; however, each installation is different so they should
be checked before putting the valve in service. The actuators are designed with a nominal 5°
over or under travel at each end of rotation. A screwdriver, an open end or box end wrench
and a hex wrench, all of the appropriate size, are the only tools required to make the
necessary adjustments. Refer to Figure 1 below.
Before setting the travel stops, the pneumatic air supply
must be completely disconnected from the actuator, and
all compressed air stored within the actuator must be
released. Auxiliary devices con-nected to the actuator,
such as tubing, ball valves, solenoid air valves, valve positioners, etc. can block the
release of air from within the actuator. Do not rely upon the features or controls of any
auxiliary device to release the air from inside the actuator and render it safe for
disassembly.
Remove the black position pointer to expose the wrench flats on the top of the
pinion.
Rotate the valve to the desired position using a wrench on the pinion.

Page 31
Loosen the lock nut on the travel stop screw. It is not necessary to remove the nut
completely. Us-ing the hex wrench, turn the screw in or out until the desired travel
stop position is reached. While holding the screw with the hex wrench, tighten the
lock nut with the wrench.
Replace the position indicator making certain the pointer is aligned with the position
of the valve, open or closed.
Replace the position indicator making certain the pointer is aligned with the position
of the valve, open or closed.

Some valves or operating conditions require that the actuator have more that 5o of
travel adjustment. For these conditions, the Series 92/93 actuator can be fitted with
extended travel stops in the end caps. (See Pg. 10 for instructions on finding
dimensional data) Consult the Bray distributor in your area for this option.
Spring return actuators may be operated with only one air supply connected to Port
A, since the spring cartridges will move the pistons when the air pres-sure in
removed. This operation, however, will draw the surrounding atmosphere into the
spring chambers through Port B.
NOTICE

To prevent contamination from entering the spring chamber, actuators configured

to operate with only one air supply connected to Port A should be equipped with a
40 micron (or finer) filter element installed in Port B.
Even better service may be obtained on spring return actuators by installing a four-
way solenoid, cover-ing both Port A and Port B. A four-way solenoid will fill the
spring chambers with compressed air from the plant air supply with each stroke.
The plant air supply is often cleaner than the surround-ing atmosphere, especially in
heavy industrial or chemical areas.

Maintenance

The rugged components and factory lubrication combine to ensure a long and
trouble-free service life for Series 92/93 actuators. Dirt, rust and water are the most
common causes for shortened service life, and they typically enter the actuator
through the air supply line.
NOTICE

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 To lengthen service life, it is strongly recommended that an adequately sized filter with a 40
micron (or fine) element be installed adjacent to the inlet of the directional control (solenoid
air) valve. Air lubricators are recommended for rapid cycling applications (10 cycles or
more per minute.)
Routine maintenance of Series 92/93 actuators consists primarily of maintaining the
air supply system by changing filter elements before they start by-passing, adding oil
to lubricators before they run dry, and preventing water from entering the air lines.
The second most common cause of shortened service life is misalignment between the valve
and the actua-tor. This can cause premature failure due to excessive side loads on the
bearings and gear teeth.
NOTICE

To lengthen service life, the mechanical connec-tion between the actuator and the
valve should be verified to be properly aligned and free to rotate throughout the full
range of valve travel.
Troubleshooting

Table 1 shows several common symptoms and their remedies.

Symptom Probable Cause Check Remedy

Loss of Power Low air supply pressure, or Air supply pressure at Boost air supply pres-
damaged O-rings actuator, leakage across sure, repair air supply line
O-rings leaks, replace O-rings
Binding between Misalignment of coupling Alignment Realign coupling
valve and actuator
Valve “pops” out of Valve torque too high, Valve torque, actuator Repair valve, use proper
seat and slams open actuator sized too small, or sizing calculations, size size actuator, use larger
insufficient air supply flow of air supply lines and/ air supply lines and/or so-
or solenoid valve lenoid valve with higher
flow

Assembly

To identify component names and shapes, refer to the Exploded View of the actuator shown
on Figure 4, pg. 11. The numbers in parentheses ( ) refer to the numbered bubbles in Figure 3.
Easiest assem-bly will result from lubricating all bearings and seals as they are installed. The
lubricant should be a high pressure or extreme pressure petroleum grease with a lithium
based thickener which meets the NLGI grade 2. Grease which meets this specification should
be available from any automotive supply store.
Pinion (3) - Install bearing rings (6 & 7) and o-rings (18 & 19) in their appropriate grooves.
Insert the pinion through the large hole in the center of the body (1). With the pinion part of
the way into the body, slide the cam (23) over the pinion being careful to align the punch
mark on the cam with the punch mark(s) on the pinion. For normal installation and rotation
(Fail Close), align the single marks. For Fail Open operation described in Method 2 above,
align the single mark on the cam with the two marks on the pinion. For Fail Open operation
described in Method 3 above, align the single marks. Next, install the spacer (24) above the

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cam. Then insert the pinion through the hole at the top of the body and secure it with the
washer (9) and retaining ring (8).
Travel Stop Screws (13) - Slip the o-ring (14) over the flat end of the screw until it is 5-
7 threads from the end. Thread the screw into the hole in the body, flat end first. Repeat
these steps for the second screw. Thread the lock nuts (12) onto the screws and tighten
the nuts against the body. This will seal the threads for testing. It is not necessary to set
the travel stops at this time, as they may have to be reset when the actuator is installed
on the valve.
Pistons (2) - Install the bearing pad (10) on the back of the rack and the o-ring (16) and
guide ring (11) in their appropriate piston grooves. The o-ring goes in the groove
nearest the rack. With the ports on the actuator body toward you, turn the pinion so that
the slot is approximately 45° to the right of perpendicular with the long side of the body.
Grasp the pistons in the spring pockets so that the piston in the right hand has the
bearing pad toward you and the piston in the left hand has the bearing pad away from
you. Slide the pistons into the body so that they both engage the teeth on the pinion at
the same time. Apply enough steady force to compress the o-ring into the body bore. At
this point, you may continue pushing or use a wrench on the top of the pinion to pull the
pistons into the body.
NOTICE

Three important parameters must be verified before assembly may be continued.

1. The pinion must turn clockwise as the pistons moved toward the center of the body.
2. The 4 mm slot in the top of the pinion must be within a few degrees of perpendicular
to the long side of the body.
3. The piston faces must both be the same distance from the end of the body.
If all three parameters above have been verified, the end caps may be installed.
If any parameter above is not verified, use a wrench on the pinion to drive the pistons out of
the body and repeat the insertion process. It is not necessary to remove the pistons from the
body unless the answer to the first question is no. It is only necessary to disengage the piston
rack from the pinion.
NOTICE

The assembly procedure described here is the standard Fail Close method. For Fail Open
actuators, refer to Method 2 or Method 3 above.
End Caps (4) - Install the o-ring (17) in the groove. Attach the end cap to the body with the 4
bolts (15) and washers (20) making certain that the straight part of the o-ring groove is toward
the bottom of the body. The air pressure will not flow to the outboard side of the pistons if the
straight part of the o-ring groove is at the top.
Position Indicator (21) - Install the position indicator pointer on the top of the pinion and
secure it with the flat head screw (22). Normally, the long axis of the pointer will be parallel
to the groove in the pinion. If the actuator is installed across the pipe line, as described in
Method 1 above, the indicator should be turned so that it is in line with the butterfly valve
disc or port in the ball or plug valve.
Final Assembly and Testing
Do not connect a compressed air supply to the actuator that
exceeds the pressure rating of the actuator (140 psig / 10
barg.)

Connect the compressed air supply to the actuator input ports and cycle the actuator fully open
and fully closed to check for proper travel and absence of air leaks. Air supply lines should have a

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minimum inside diameter of 0.250” (6 mm). Restricted air supply lines, or any portion of the air
supply system powering the actuator (such as solenoid air valves or valve manifolds) can reduce
actuation time, cause unexpected popping of the valve, or even malfunction.
If compressed air is applied to Port A and the actuator reaches the end of travel, there should be
no air flow out of Port B, and vice versa. There should be no air flow between the end caps and
the body, through the travel stops, or out the top or the bottom of the pinion. A solu-tion of soap
and water applied to the sealing points can indicate leaks that are too small to be audible.

Disassembly
Before disassembly of the actuator, the pneumatic air supply
must be completely disconnected from the actuator, and all
compressed air stored within the actuator must be released. Auxiliary devices con-nected to
the actuator, such as tubing, ball valves, solenoid air valves, valve positioners, etc. can block
the release of air from within the actuator. Do not rely upon the features or controls of any
auxiliary device to release the air from inside the actuator and render it safe for disassembly.

Some actuators may have spring cartridges installed. Before

disassembly, all spring cartridges must be placed into the relaxed
(fully extended) position. All compressed air must be removed from
inside the actuator (See warn-ing above) and the actuator pinion
must be allowed to rotate so the springs may be relaxed. Care must be taken to verify that any device
connected to the actuator, such as a valve mounted underneath, is not preventing the movement of the
springs to the relaxed position.
If the actuator is installed on a valve, remove the actuator from the valve, and move the actuator to a
clean work area. Remove the indicator pointer. Remove both end caps by loosening the hex head end
cap bolts. Remove both pistons by rotating the pinion counterclockwise until the piston heads are
protruding from the body. Pull the pistons out. Using snap-ring pliers, remove the pinion retaining ring
and acetal washer, then remove the pinion from the body. The pinion bearings, o-rings, cam and spacer
may then be removed.
Adding Spring Cartridges

Before disassembly of the actuator, the pneumatic air sup-ply must

be completely disconnected from the actuator, and all compressed air
stored within the actuator must be released. Auxiliary devices
connected to the actuator, such as tubing, ball valves, solenoid air
valves, valve positioners, etc. can block the release of air from within the actuator. Do not rely upon
the features or controls of any auxiliary device to release the air from inside the actuator and render
it safe for disassembly.
Move the pinion to the fully closed (0°) position. Remove the end caps and insert the
desired number of spring cartridges into the end cap pockets, up to a maximum of six
cartridges per end cap.
NOTICE

For proper operation, actuators equipped with Spring Cartridges should have the spring
cartridges installed in accordance with the positions shown in figure 2.
Align the end cap with the body so the spring car-tridges fit into the piston pockets.
Attach the end caps to the body with the hex head end cap bolts. Tighten the bolts
gradually in a diagonal sequence.
Proceed to Final Assembly and Testing.

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Removing Spring Cartridges
Before disassembly of the actuator, the pneumatic air
supply must be completely disconnected from the actuator,
and all compressed air stored within the actuator must be
released. Auxiliary devices connected to the actuator, such
as tubing, ball valves, solenoid air valves, valve positioners, etc. can block the release of
air from within the actuator. Do not rely upon the features or controls of any auxiliary
device to release the air from inside the actuator and render it safe for disassembly.
Before disassembly, all spring cartridges must be placed
into the relaxed (fully extended) position. All compressed
air must be removed from inside the actuator (See warning
above) and the actuator pinion must be allowed to rotate
so the springs may be relaxed. Care must be taken to verify that any device connected
to the actuator, such as a valve mounted underneath, is not preventing the move-ment
of the springs to the relaxed position.
An actuator with spring cartridges installed and no compressed air connected will move to
the spring fail position if the pinion is free to rotate. This may be either fully closed (0°) or
fully open (90°). In either case, when the spring fail position is reached, remove the end
caps by gradually loosening the hex head end cap bolts in a diagonal sequence.
When removing end caps from an actuator con-taining
spring cartridges, the end cap bolts must be loosened
gradually in a diagonal sequence until the spring
cartridges are completely relaxed (fully extended.) The
spring cartridges should reach the completely relaxed (fully extended) position while all
four end cap bolts still have some thread en-gagement with the actuator body. Do not
remove three end cap bolts completely from the body and expect the remaining single
bolt to hold the spring cartridges in a compressed position.
Remove the spring cartridges. Replace the end caps and tighten the end cap bolts
gradually in a diagonal sequence.
When replacing end caps onto an actuator contain-ing spring
cartridges, the end cap bolts must be tightened gradually in a
diagonal sequence until the spring cartridges are slightly
compressed into their fail position. The spring cartridges
should reach the slightly compressed fail position while all four end cap bolts have some

Page 36
 thread engagement with the actuator body. Do not attempt to tighten a single end cap bolt
fully and compress the spring cartridges while the other three bolts have not been installed.
Proceed to Final Assembly and Testing.
General Pneumatic System Recommendations

To maintain maximum efficiency with the Series 92/93 actuator, as well as many
other pneumatic devices, the following suggestions are offered:
• Air supply lines should be run in accordance with a Standard Piping Practice, and should
not have exaggerated loops, which may trap condensate.
• All pipe ends should be thoroughly cleaned and deburred after cutting to ensure
that the pipeline is clear of cuttings.
• Where air pipelines are subjected to extremes of temperature, the system should
be fitted with air drying equipment.
• If pipelines are hydraulically tested, the lines should be “blown down” with high
pressure air to clear all water prior to connecting the lines to the actuator.
• Where a system is dependent on air filter equipment, the air filters should be in
posi-tions that allow easy access for maintenance and/or draining.
• Where pneumatic valve positioners or pneu-matic controllers are installed in a valve
actuator assembly, oil mist lubricated air should not be used unless the manufacturer
states specifically that the positioner or controller is compatible with lubricated air. In
general, lubricated air is not recommended for a positioner.
• Where pipe fitting sealants or tapes are used, they should be applied to the male threads
only, and limited to the first three threads. When applied to female threads, excess
compound or tape can be transmitted into the actuator control lines and cause
malfunctions in downstream equipment.
• Lubricators should be installed downstream of regulators.
• Eliminate or minimize sharp bends in the air supply lines.
Dimensional Data

For Dimensions see Bray ES Drawings: ES11A-0460 and ES11A- 0533 on

www.bray.com or www.braycontrols.com

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Series 92/93 Parts Diagram

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 CERTIFICATION
ABS certificate of type approval

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BV certificate of type approval

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Page 41
CCS certificate of type approval

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Page 45
Page 46
DNV certificate of type approval

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LR certificate of type approval

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KR certificate of type approval

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 Sunrui Marine Environment Engineering Co., Ltd.

ANNEX P: Power consumption of BalClor® BWMS

Normal system power Total Max. power

System Max. system power
consumption a) consumption of Optional
model consumption b)
components c)
（KW） （KW）
(kW)
BC‐150 9.2 13.1 4.4

BC‐300 14.0 21.8 4.4

BC‐500 20.5 34.0 5.4

BC‐1000 36.3 63.3 7.2

BC‐1500 52.9 91.2 10.2

BC‐2000 66.0 115.5 12.6

BC‐2500 87.6 150.6 13.8

BC‐3000 98.1 170.1 13.8

BC‐3500 113.9 199.4 18

BC‐4000 127.0 223.7 18

BC‐5000 166.0 289.7 19.8

BC‐6000 189.4 331.1 22.2

BC‐7000 215.6 379.9 27

BC‐8000 247.1 438.4 36

Note:
a) The normal power consumption is based on 30 PSU and 20°C seawater;
b) The max. power consumption is based on 15 PSU and 5°C seawater;
c) The optional components refer to the components listed in BOM including pumps and
electrical cabinets etc. This power consumption is only applicable when relevant
components are installed and used.

Page 209 of 209 Manual Rev: 1.56 BalClor® BWMS