Headway BWMS - Technical Manual

OceanGuard®
Ballast Water Management System

Handbook
(Short manual for basic knowledge, for all details read the full manual)
This documentation is short manual for basic knowledge, for more details please read the User Manual.
Table of Contents
Table of Contents .......................................................................................................................................... 2
1 Overview .................................................................................................................................................. 4
2 System Operation ..................................................................................................................................... 5

2.1 Menu Navigation ......................................................................................................................... 5
2.2 Ballasting Process ........................................................................................................................ 6
2.2.1 Ballasting Start Operation ................................................................................................. 6
2.2.2 Ballasting Stop Operation ................................................................................................. 6
2.3 De-Ballasting Process .................................................................................................................. 7
2.3.1 De-Ballasting Start Operation ........................................................................................... 7
2.3.2 De-Ballasting Stop Operation ........................................................................................... 7
2.4 Bypass Process ............................................................................................................................. 7
2.4.1 Bypass Start Operation ..................................................................................................... 7
2.4.2 Bypass Stop Operation ...................................................................................................... 7
2.5 Coping the System Log ................................................................................................................ 8
2.6 Parameter Setting ......................................................................................................................... 9
3 System Maintenance .............................................................................................................................. 10

3.1 Filter Maintenance(ZF) .............................................................................................................. 10
3.1.1 Replacing the Element .................................................................................................... 11
3.1.2 Cleaning Big Impurity Particles...................................................................................... 14
3.1.3 Filter Maintenance(HMT-F) ................................................................................................... 15
3.2 Monitoring Unit Maintenance.................................................................................................... 17
3.2.1 Notes Regarding the Chemical ....................................................................................... 17
3.2.2 Replacing the Indicator Reagent ..................................................................................... 18
3.2.3 Replacing the Buffer Reagent ......................................................................................... 18
3.3 Neutralization Unit Maintenance ............................................................................................... 19
4 Troubleshooting ..................................................................................................................................... 21
4.1 Filter & FCB Alarms ................................................................................................................. 21
4.1.1 Filter Differential Pressure High Alarm ......................................................................... 21
4.1.2 Filter Motor Error Alarm ................................................................................................ 25
4.1.3 Back-Flushing Pump Error Alarm .................................................................................. 26
4.2 EUT & PE Alarms ..................................................................................................................... 27
4.2.1 EUT temperature communication fail Alarm ................................................................. 27
4.2.2 EUT temperature high Alarm ......................................................................................... 27
4.2.3 EUT leak sensor Alarm ................................................................................................... 28
4.2.4 EUT Pressure Switch Alarm ........................................................................................... 29
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4.2.5 EUT Power Communication Fail Alarm ........................................................................ 30
4.2.6 EUT Power “ON” Error Alarm....................................................................................... 33
4.2.7 EUT Power in Manual Mode Alarm ............................................................................... 33
4.2.8 EUT Power Abnormal Alarm ......................................................................................... 34
4.3 MU & MCB Alarms .................................................................................................................. 36
4.3.1 TRO Communication Alarm........................................................................................... 36
4.3.2 TRO Status: No Intake Water Alarm .............................................................................. 36
4.3.3 TRO Status: Purge Is Slow Alarm .................................................................................. 37
4.3.4 TRO Status: Purge Is Clogged Alarm ............................................................................. 37
4.3.5 TRO Pressure Abnormal Alarm...................................................................................... 37
4.3.6 Salinity Meter Communication Fail Alarm .................................................................... 38
4.3.7 Salinity low (below 0.85 PSU) Alarm ............................................................................ 38
4.4 NU Alarms ................................................................................................................................. 39
4.4.1 Low Level (Neutralization Unit) Alarm ......................................................................... 39
4.4.2 Low Level (Neutralization Unit) Alarm ......................................................................... 39
4.4.3 NU Pump dry run protection........................................................................................... 40
4.4.4 NU Pump Error Alarm .................................................................................................... 40
4.5 Flow meter Alarms .................................................................................................................... 41
4.5.1 Flow meter Communication Alarm ................................................................................ 41
4.5.2 High Flow Rate Alarm .................................................................................................... 41
4.5.3 Low Flow Rate Alarm .................................................................................................... 41
4.6 Valves Alarms ............................................................................................................................ 42
4.6.1 Filter Angle Valve (FV2) Communication Fail Alarm................................................... 42
4.6.2 FV2 Error Alarm ............................................................................................................. 42
4.6.3 Valve 1/2/3/4/5/6 Alarm ................................................................................................. 43
4.7 CL、PDU、RC & MCB Alarms .............................................................................................. 43
4.7.1 CL Lost Power Alarm ..................................................................................................... 43
4.7.2 Emergency Switch is Pressed Alarm .............................................................................. 43
4.8 Operation & Processing Alarms ................................................................................................ 44
4.8.1 Repair / Maintenance Alarm ........................................................................................... 44
4.8.2 Emergency ON / Bypass ON Alarm ............................................................................... 44
4.8.3 Ballast TRO Low And High Alarm or Ballast TRO Adjust Overtime Alarm................ 44
EUT: ____ V , ____ A ............................................................................................................... 48

4.9 GPS、Echosounder & AIS Alarms ........................................................................................... 49
4.9.1 GPS Communication Fail Alarm .................................................................................... 49
5 Notes ...................................................................................................................................................... 54
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1 Overview
The BWMS is single treatment, this means the ballast water is fully treated during ballasting. The ballast
water can be Sea water / Brackish water / Fresh water.
When the ballast mode is selected, the water is treated by a 50-micron filter and the EUT. The EUT uses
the process Electro Catalysis to form a large amount of Hydroxyl radicals (∙OH). These Hydroxyl
radicals (OH) exist for a short amount of time, during this time they will react with the (micro) organisms
which are left in the ballast water and kill them. A by-product of the Electro-Catalysis process is a small
amount of TRO (Chlorines) which is measured by the Monitor Unit. The TRO target value is between 1.8
ppm and 2.2 ppm and is used to regulate the current output to the EUT.
When the de-ballast mode is selected, the ballast water goes directly overboard, only the TRO value will
be measured. The TRO value during de-ballasting must be lower than 0.1 ppm. If the TRO value exceeds
0.1 ppm the Neutralization Unit will start automatically and inject to “Sodium Thiosulfate Pentahydrate”
to neutralize the TRO.
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2 System Operation
2.1 Menu Navigation
The screen above you see on the control unit (CL) or on the remote-control panel (RC) when you
turn on the power distribution unit (PDU) and press start on the control unit (CL).
On the screen you can press the following buttons:
PIPE
This screen shows the general flow diagram of the Ballast Water Management System. When
the system is active you can see the following data on this screen:
System Mode, Valve Status, TRO Value, Flow, EUT Power and Current, Salinity, GPS data
and when the Back-Flushing / Neutralization / Ballast-pump is active.
In this screen you can choose additional modes, generally this will be the “repair” mode.
ALARM
This screen shows the “Real Time Alarms”, “Historical Alarms” and “Warnings” This screen
includes a “Help” function which is useful for trouble shooting.
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LOG
This screen shows the “Operation log”, “Data record” and “Valve log”
The log is saved on a SD card inside the screen.
INFO
This screen shows several topics (System principle, Ballast On/Off, De-Ballast On/Off,
By-pass On/Off, Maintenance MU/NU, how to copy the log files, Company info.
SETTING
Here you can see the general configuration for your BWMS. (Settings can only be viewed!)
Here you can make a copy of the log files.
2.2 Ballasting Process
2.2.1 Ballasting Start Operation

1) Turn on the power of the Power Distribution Unit and the Control Unit.
2) Press the key “Ballast”.
3) Check the system, make sure there is no alarm.
4) Start the ballast pump.
5) During ballasting the water is treated by the 50-micron filter and the EUT Unit.
6) Check if the flow is correct for the BWMS.
2.2.2 Ballasting Stop Operation

1)Stop the ballast pump
2) Press the key “Ballast” again, the BWMS will stop the ballasting process
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2.3 De-Ballasting Process
2.3.1 De-Ballasting Start Operation

2) Press the key “De-Ballast”.
3) Check the system, make sure there is no alarm.
5) During De-ballasting the Monitor Unit will check the amount of TRO in the water.
6) If the TRO value is higher than 0.1 PPM the Neutralization Unit starts automatically.
2.3.2 De-Ballasting Stop Operation

1) Stop the ballast pump.
2) Press the key “De-Ballast” again, the BWMS will stop the De-ballasting process.
2.4 Bypass Process
2.4.1 Bypass Start Operation

1) Only use this function if there is a problem with the BWMS!
3) Press the key “Bypass”, and select Ballast Bypass or De-Ballast Bypass.
5) During the Bypass process the water will bypass the BWMS and will not be treated.
6) During the Bypass process the alarm “Bypass on” will appear.
2.4.2 Bypass Stop Operation

1) Stop the ballast pump
2) Press the key “Bypass” again, the BWMS will stop the Bypass process
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2.5 Coping the System Log
Step Operation
Plug a USB disk(lower than 8GB and file system is“FAT32”) into the USB port located on
1 the bottom of HMI.
Turn on the power of the Power Distribution Unit and the Control Unit.
Press the button “setting”.

To enter the setting interface, you need enter the following user and password: User1
The Log data is saved in a RDB format in the HMI.

This extension cannot be opened on the computer.
If you want a copy (excel file) press the 4 buttons from left to right:
The system will make a copy to the SD card automatically and will mention at information
if the copy was successful. (in normal situations)
Than power off the system and take out the USB card,
4
If you no use the USB card ,put the SD card in a computer and copy the excel files
5 Important: Do not delete files from the SD card.
In case of a re-occurring alarm or problem these logs can be send to Headway.
6
We can analyses the log and send our recommendations
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2.6 Parameter Setting
Step Operation
1 Turn on the power of the Power Distribution Unit and the Control Unit.
Press the button “setting”.

2 To enter the setting interface, you need enter the
following user and password: Hdw
“Sea Water Set TRO”, “TRO Adj”, and “Fresh

Water Set TRO” are standard, and their value are
2.0, 0.2, and 2.0.
“Max Current”, “Standard Flow”, and “Max Flow”

3 are base on the actual system parameter, don’t
change normally.
“Initial Current” and “Current Adj” are the

parameters related the ballasting processing, and can
be adjust according actual situation.
Finally, press the “Save Data to HMI internal
storage” button, and press the “Sure” button to save
the parameter.
4
Do the same operation on the Remote Panel if the
system have one Remote Unit.
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3 System Maintenance
3.1 Filter Maintenance(ZF)
The raw water flow into the filter from the inlet, through the filter screen, then flow out from the
outlet.
As the accumulation of various contaminants inside the screen, the filtration channel is blocked.
And the differential pressure between inlet and outlet increases gradually. When the pressure
reaches to the pre-set value, the system will start the stroke motor and booster pump automatically.
Meanwhile, the shaft with driving device and suction nozzle will rotate and move back and forth
horizontally inside the screen. And at the same time, the cleaning device and the shaft run
synchronously. And the movements are correspondingly. At the premise without interrupting
producing water, it can run the cleaning function by a small part of the product water. The cleaning
water flows through the filter screen, together with the impurities from the filter screen. And they
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are quickly inhaled into the dirt collector by the nozzle, sent to the shaft, and finally discharged from
the drain.
After one cleaning process, the pressure differential is down. All the parts recover to the initial state.
And the system will go back to the normal operation state again.
3.1.1 Replacing the Element
When the filter is running properly, there is no need to wash the filter element manually. The
element will be cleaned during the automatic back flushing.
If the intervals of the automatic back flushing get shorter, this indicates that the filter element is
blocked more and more by impurities.
If the pressure difference keeps on raising to the pre-set alarm value, the filter element needs to
be washed manually.
Note
pressure difference >0.3 bar = start back flushing
pressure difference >1.5 bar = overpressure alarm
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Steps for replacing the filter element
Step Operation
1 Power off the system, drain the water, disconnect the cables.
Remove the 4 M10 bolts to disassemble the

2
motor.
3 Remove the 2 M16 bolts to open the maintenance entrance, if available.
4 Remove the (20) M20 bolts to open the cover.
Lift up the cover about 80mm. (use proper

5
lifting equipment)
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6 When the cover is lifted (See view A)
7 Loosen 2 M8 screws (item4) so the ring (item5) falls down to shaft sleeve (item6)
8 If the ring (item5) is on the shaft sleeve (item6), tighten (2)M8 screws (item4).
9 Remove the (4) M8 bolts (item1)
Pull up retaining nail (item 2), then rotate and

10
extract the pin (item3).
Remove the top cover, and take out the two

11
flushing arms.
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Remove the bolts around filter top cover to remove top cover and move out driving
12
shaft.
13 Remove the filter element
Clean the filter element with a pressure water gun.
When the filter element is being cleaned with a high-pressure water gun, the
14
pressure must not exceed 60 bar and the distance between the nozzle of the water
gun and the filter element must not be less than 200 mm
15 The filter element can be dried by air or compressed air
16 Clean the inside of the filter housing.
17 Before installation check the filter element, if there is any damage replace this part.
18 Put everything back together in a reverse order and restart the system.
19 Make sure the limit switches are correctly mounted and connected!
3.1.2 Cleaning Big Impurity Particles
There is a drain at the lower shell of the filter.
Generally, after the filter has worked for 300 hours or once a year, the drain must be opened. In
this way big impurity particles inside the lower shell of the filter will flush out.
When the slag is being removed, the vent at the upper shell of the filter must be opened. After
the slag is removed, the vent can be closed.
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3.1.3 Filter Maintenance(HMT-F)
When the filter is running properly, there is no need to wash the filter elements manually. The
elements will be cleaned during the automatic back flushing.
If the intervals of the automatic back flushing get shorter,
this indicates that the filter elements are blocked more and more by impurities. If the pressure
difference keeps on raising to the pre-set alarm value,
the filter elements need to be washed manually.
(pressure difference > 0.6 bar = start back flushing, pressure difference >1.5 bar = overpressure
alarm)
STEPS FOR CLEANING OR REPLACING THE FILTER ELEMENTS (see drawings below)
1 Close the valves which are connected to the filter

2 Turn off the power of the filter control box
3 Release the pressure in the filter by opening the air vent on top of the filter
4 Carefully open the drain at the bottom of the filter
5 Remove the filter cover (use proper lifting equipment)
6 Remove the bolts from the drain branch
7 Remove the drain branches
8 Remove the spiral retaining rings above the filter elements
9 To remove the filter elements use pliers to clamp the beam, use a clockwise + counter clockwise
twisting force and vertical force evenly, and take the filter element out slowly
10 Put the filter elements in a cleaning basin and soak them in water (add detergent)
11 While soaking the elements in the water, remove the floating impurities first
12 Clean the filter elements one by one with a pressure water gun.
When the filter elements are cleaned with a high pressure water gun,
the pressure must not exceed 60 bar and the distance between the nozzle of the water gun and
the filter elements must not be less than 200 mm
13 Put the filter elements in a cleaning basin and wash them again in water (add detergent)
14 The filter elements can be dried by air or compressed air
15 Before installation check the filter elements and the seal rings, if there is any damage replace
these parts. Also clean the inside of the filter housing.
16 Put everything back together in a reverse order and restart the system.
CLEANING BIG IMPURITY PARTICLES IN THE LOWER SHELL OF THE FILTER (AT LEAST 1X / YEAR)
There is a drain at the lower shell of the filter.
Generally, after the filter has worked for 300 hours or once a year, the drain must be opened.
In this way big impurity particles inside the lower shell of the filter will flush out.
When the slag is being removed, the vent at the upper shell of the filter must be opened.
After the slag is removed, the vent can be closed.
GEAR MOTOR OF THE FILTER (OIL CHANGE)
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The first oil change must be done after about 2000 hours or 3 years at the longest.
The following oil changes must be done every 3 year or every 10000 hours.
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3.2 Monitoring Unit Maintenance
The MU is a very important part of the BWMS, all the feedback from the MU is used by the BWMS
to make the right adjustments so it works correctly.
During the commissioning of the BWMS a lot of time is spent for the correct adjustment of the MU,
so don’t change the settings, if the MU is not working properly contact the manufacturer.
The following maintenance is very important to do.
3.2.1 Notes Regarding the Chemical
Change the Indicator reagent at least every 3 months!
Change the buffer reagent at least e every 12 months!
The reagent kits (Free Chlorine) are available from Headway.
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3.2.2 Replacing the Indicator Reagent
Steps for replacing the indicator reagent (at least 3 mouths)

Steps Operation
1 Open the MU
Take out the reagent kit. Open it and take one small white bottle and one brown
2
DPD tube.
3 Open the small white bottle and add 100 ml deionized water, close it and shake it.
4 Open the small white bottle and add one brown DPD tube, close it and shake it.
Open the small white bottle and add deionized water until it is filled up to the bottle
5
neck.
6 Replace the old indicator reagent with the new one.
3.2.3 Replacing the Buffer Reagent
Steps for replacing the buffer reagent (every 12 mouths)
Steps Operation
When a reagent kit is ordered, it contains 1 buffer and 4 indicator bottles. Take the
1
big buffer bottle and add 400 ml deionized water, close it and shake it.
2 Open the MU
3 Open the TRO meter
4 Replace the old buffer reagent with the new one.
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3.3 Neutralization Unit Maintenance
When the NU is running properly, there is no need for maintenance. After you receive an alarm
“Low Level Alarm (Neutralization Unit)”, the NU must be refilled.
Steps for refilling the Neutralization Unit
Steps Operation
Get the right amount of Sodium Thiosulfate Pentahydrate (see list below), open the
1 feeding port cover of the NU, put all the Sodium inside the NU and close the feeding
port cover.
2 Check if the freshwater supply valve to the NU is open.
Press “mixing”, the NU will automatically add fresh water until the right level is
3 reached, the NU will mix the Sodium Thiosulfate Pentahydrate and the water for 10
minutes.
Start Neutralization unit operation manually:
①Start the deballast；
②Press the “pump” key on the neutralization unit;
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Size old NU Amount Sodium BWMS Model Size new NU Amount Sodium
HMT-20N 6 KG HMT-50 HMT-60N 10 KG
HMT-60N 10 KG HMT-600 HMT-100N 18KG
HMT-100N 18KG HMT-1000 HMT-300N 60 KG
HMT-100N 25 KG HMT-1500 HMT-300N 54KG
HMT-2000 HMT-300N 72KG
HMT-2500 HMT-600N 90KG
HMT-3000 HMT-600N 108KG
HMT-4000 HMT-600N 138KG
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4 Troubleshooting
4.1 Filter & FCB Alarms
4.1.1 Filter Differential Pressure High Alarm

Claim: Filter differ pressure high alarm, filter leak water
Description Filter Differential Pressure High (> 1.5 Bar) Alarm
:
Tools:
Background:
① The system may continuously back-flushing to keep the filter clean;
② The filter differential pressure has been maintained above 0.3bar;
③ Observe whether the current waters are muddy;
Solution:
1.System reduced flow operation
①Stop the ballast pump and stop the ballasting of the system;
②Manually close the manual valve at the outlet of the filter (open about 10%);
③Press the "Ballast" button to turn on the ballast water system and start the
ballast pump;
④Press the "Manual" button on the panel of the filter control box for 3
seconds(Figure 7-1 ④) to start the backflushing system of the filter, and repeat the
operation for 5 times to thoroughly clean the filter element;
⑤Keep down to flow rate about 30~40% to run the system, when the back
Solution: flushing can automatically start and stop, and the pressure difference is steady.
Then can start to open slowly the valve at the outlet of the filter while observing the
pressure difference change: increased the flow rate slowly when the pressure
difference is normal.
2.Filter element cleaning with clean water（if filter already clogged）

If the filter is blocked and the ballast pump is stopped, the specific steps for
cleaning the filter element are as follows:
① Open the drain port of the filter and drain the water inside the filter
completely;
② Close the manual valve at the outlet of the HAV1 and the filter;
③ Open the fresh water injection pipe of the filter and fill the filter with fresh
water;
④ The filter can be filled with clean water treated in the cabin or filled with
clean fresh water. It is advisable to submerge the top of the filter element; you can
open the outlet valve on the exhaust valve at the upper end of the filter(Figure 1) or
connect the upper part of the differential pressure transmitter to the L end of the
drain. The air valve(Figure 2) checks the water level, as long as the water is
continuously discharged, the water level required for cleaning can be met;
⑤Turn off the power of the backflushing pump (QF12 in PDU) and power on
the system. After the control unit is started, you can see that the Filter Control
Box is already working. Press the Manual backflushing button and repeat the
automatic cleaning of the filter element more than 5 times;
After the above operation, the sewage needs to be discharged:
(1). Turn on QF12(for back flushing pump) in the PDU, turn off QF52(for
cleaning pump), turn on the power of the backflushing pump, and turn off the
cleaning pump at the same time
(2). Open the manual valve of the backflushing pipeline, press the manual
backflushing button after the system is powered on, discharge most of the
sewage through the sewage pipe, and discharge the remaining sewage in the
filter from the slag outlet into the sewage well;
Restore the power supply of the QF52 cleaning pump, open the filter outlet
manual valve to the preset optimal flow position (about 5%-20%) to start
ballasting according System reduced flow operation.
How to find the best flow rate point:

Each time you turn on the ballast mode, you must control the frequency
conversion ballast pump or manual valve to make the filter flow from small to
large, and slowly increase the flow. Remember not to open the filter flow at
one time, which will cause the false alarm of high-pressure difference and
make the ballast unable to run. The engine room and the centralized control
room should use manual valves or frequency conversion to control the flow.
Turn the handle to increase the flow and observe the value of the pressure
difference digital display. When the control pressure difference value is
relatively stable, even if the filter reaches the continuous backwash state, the
pressure difference When the value does not continue to rise, it is the best flow
rate. You can mark it on the manual valve. Next time you encounter
heavy-load water, you can fine-tune the handle within a certain range of the
mark to obtain the best flow rate this time. Due to the different water quality in
different places, the best flow rates each time is not a certain value, so it needs
to be explored in multiple debugging; because the water level of the general
berthing port is relatively shallow, try to use high submarine gates and avoid
water refueling ships, bunkering ships, and supply ships. Wait for the ship to
turn on the ballast when it agitates near the bottom door.
If the filter still has a high-pressure difference after cleaning with clean water,
you can choose to soak the filter element directly with oxalic acid. The soaking
time is generally about 2 to 6 hours. Generally, oxalic acid is selected as
H2C2O4.2H2O≥99.5%
ERP NO. Name type Quantity

Spares:
If the above mechanical and electrical faults have been eliminated and the
pressure difference continues to rise, it may be that the filter element
Remark
is blocked and the filter element needs to be stopped for self-cleaning
or manual cleaning.
4.1.2 Filter Motor Error Alarm
Claim: Filter Motor Error Alarm

Description Something is wrong with the filter motor
:
Special
Tools:
1,The power supply has an open-circuit
①Check the main power supply to the PDU
②Check the fuse for the motor in the AF
2，The motor protection has been activated
①Reset the thermal protection inside the PDU Check the setting of the thermal
Solution: protection,
②the setting must be I-nom from motor name plate
3,The motor is broken
Check the motor, if it is burned find the cause and replace the motor
4,The back flushing arm is stuck
Open the filter and solve the problem that causes the equipment being stuck
ERP NO. Name type Quantity Remark
Spares:
Remark
4.1.3 Back-Flushing Pump Error Alarm
Claim: Back-Flushing Pump Error Alarm
Description: Something is wrong with the back-flushing pump

Special Tools:
1,The power supply has an open-circuit
①Check the main power supply to the PDU
②Check the fuse for the pump in the PDU
2，The motor protection has been activated
①Reset the thermal protection inside the PDU Check the setting of the thermal
Solution: protection,
②the setting must be I-nom from motor name plate
3,Back flushing pump motor is broken
Check the motor, if it is burned find the cause and replace the motor
4,After long-time use parts of the pump are worn
Replace the worn parts
Spares:
Remark
4.2 EUT & PE Alarms
4.2.1 EUT temperature communication fail Alarm
Claim: EUT temperature communication fail Alarm
Description: Communication error

Special Tools:
1,Loose wire (signal line)
①Check the cable connections to see if they are correct and reliable.
Solution:
2，The sensor is broken

①Check the sensor, if it is broken replace the sensor

Spares:
Remark
4.2.2 EUT temperature high Alarm
Claim: EUT temperature communication fail Alarm
Description: The seawater temperature inside the EUT is too high (above 45 degree)
Special Tools:
1,If the EUT is installed horizontal and higher than the ballast tanks, falling water can
cause the EUT to not be completely filled with water.
①In many cases backpressure can be created with valve HMV 1 or a valve to the
ballast tanks to make sure the EUT is completely filled all the time.
②During installation also measures should have been taken to make sure the EUT is
completely filled all the time.
Solution:
2，Flow is too low
①Find the reason for the low flow and make sure the flow is adjusted to system
capacity.
3，Temperature sensor
①Check the sensor, if it is broken replace it.

Spares:
Remark
4.2.3 EUT leak sensor Alarm
Claim: EUT leak sensor Alarm
Description: The EUT leak sensor detects water or leak sensor is broken
Special Tools:
1,The sealing parts of the EUT anodes are aging.
①Make sure the BWMS is completely powered off. Open the cover of the EUT. Check
the origin of the leakage and replace relevant parts.
2，The leak sensor
①Check the sensor, if it is broken replace the sensor.
3, The leak sensor needs coil protection
Solution:
Spares: ERP NO. Name type Quantity Remark
Remark
4.2.4 EUT Pressure Switch Alarm
Claim: EUT Pressure Switch Alarm
“Pressure switch Alarm” was active.

Description:
EUT power will be power off.
Special Tools:
1,The automatic valves before & after EUT unit was not completely closed. .
①Check the piping, confirm the high-pressure resource, then ensure the automatic
valve is working properly.
②If the high pressure was active by accident, disassemble the switch pipe and release
the pressure, then all will normal.
2，The main piping was connecting with the fire piping, and the pressure came from the
fire piping.
①Close the valve which connecting the fire piping with the ballast main piping when
the fire pump running. Or, fully open the valves on the ballasting main piping, make
sure the pressure will not reach 6 bar when the fire pump running.
3, Check the pressure Switch wiring.
Solution:
Spares:
Remark
4.2.5 EUT Power Communication Fail Alarm

Claim: EUT Power Communication Fail Alarm
The EUT power unit does not turn on
Description:
The control unit does not detect the signal. Information is displayed on the EUT power unit
Special No
Tools:
A:EUT Power communication failed:
1,First, check whether the communication wire of EUT POWER UNIT(PE) is loose, the wires which
connected to terminal 94,95 of Control Unit;
2,If there is a serial port tool on board, you can detect the data of 94,95, and the baud rate is 9600.
If you don't have serial port tools, please check the EUT power REMOTE/PANEL lamp for flicker, as
follows: If flicker, it can be preliminarily determined there is data communication.
Solution:
3,When checking item 2, if there is no power in the Control Box of PE, it is necessary to check the power
supply of the PE and the internal condition of the PE at this time.
(1) For EUT power supply query, please refer to the following drawing: (it also attached in PDU)
(2) If the 440VAC power supply of PE is normal, it is necessary to check the internal 150W
switching power showed below,pls check its input and output are normal.
4,If the above inspections are normal, it may be caused by the program of Control Unit(this possibility is
very low), which needs the assistance of professional boarding.
5,In the above inspection, if any device is found damaged, please refer to the following ERP application
parts; When replacing, record the wires number mark then replace it directly.

Spares:
Remark
4.2.6 EUT Power “ON” Error Alarm
Claim: The EUT Power Unit is turned On in non-Ballast mode

Description:
Special Tools:
The main power supply to the EUT Power Unit cannot be and must not be on if the
Ballast-On mode is not selected
Solution:
Check KM10 in the Power Distribution Unit. If something is wrong with KM10 replace
it.
Spares:
Remark
4.2.7 EUT Power in Manual Mode Alarm
Claim: EUT Power in Manual Mode Alarm

Description:
Special Tools:
1,Someone is changing or has changed the EUT Power Unit settings
①The settings are set correct during the commissioning. Changing the settings will never
solve a alarm. So, do not make any changes.
Solution:
②Note: DO NOT change settings of the EUT Power Unit!
2，Check the EUT Power Control Panel，make sure running in remote mode.
REMOTE light is on or flicker
Spares:
Remark
4.2.8 EUT Power Abnormal Alarm

Claim: EUT Power Abnormal Alarm
Description:
Special Tools:
1,The EUT power unit with overheats
①The temperature of the environment is too high (>60°C)
②Cleaning the Y filter in cooling pipe
③Check if cooling-water inlet temperature is not higher than 45 degree
④The cooling-water flow is too low
A:Check circulation pump
B:Check valves in cooling system
C:Check EUT power unit heat-exchanger tubes sometimes de-scaling is necessary
D:Check if there is no TRO overtime alarm, if there is, check the indicator (DPD)
fluid
2,The EUT power unit with water leakage
①Water leakage is detected some water in EUT Power，
②Electromagnetic interference cause，you must add magnet

Solution:
3，When all of the above is ok，you can disconnect the cables of Alarm，
90C1 and 90C2
Spares: ERP NO. Name type Quantity Remark

Remark
4.3 MU & MCB Alarms
4.3.1 TRO Communication Alarm
Symptom Cause Measure
Loose wire Check the cable connections to see if they are

The control unit does
(signal line) correct and reliable.
not detect the signal.
The settings are set correct during the commissioning.
Information is displayed
The settings Changing the settings will never
on the TRO meter.
(power supply) correct and reliable.
If the Monitor Unit (MU) is Ex-Proof the Monitor Unit
No information is Control (MUC) controls the power supply. The
Power supply
displayed on the TRO start-up time for the MUC is 18 minutes. For the
interrupted
meter. Ex-Proof MU it is important to have air supply
to create the necessary overpressure in the MU.
Make a copy of the log and send it to the
TRO meter is broken
manufacturer if problem remains
4.3.2 TRO Status: No Intake Water Alarm

Open the ball valves to the Monitor Unit
Pipeline jam Check the pipes / connectors to the Monitor Unit
Check the pipes / connectors in the monitor Unit
Inlet/outlet solenoid Check the solenoid valves inside the Monitor Unit.
No water (WATR)
valve broken If a valve is broken replace it.
During De-Ballasting the pressure at the sample point
Pressure can be low, creating some backpressure
with the overboard valve can solve the alarm.
Intake water (SLOW) The factory set up flow Set the flowrate with the pressure regulator inside the
Intake water (FAST) has changed TRO meter
4.3.3 TRO Status: Purge Is Slow Alarm
Sample cuvette has No flow in Monitor Check the drain pipe. If this one is blocked there
slow purge (PURG) Unit drain pipe will be slow or no purge
4.3.4 TRO Status: Purge Is Clogged Alarm
Sample cuvette has no No flow in Monitor Check the drain pipe. If this one is blocked there
purge (NPRG) Unit drain pipe will be slow or no purge
4.3.5 TRO Pressure Abnormal Alarm
The Ex-proof monitor Check the valves

Pressure loss
Unit (MU) is Ex-proof Check the (amount of) air supply
because of a constant The start-up time for the MUC is 18 minutes.
overpressure inside the The MU is flushing These 18 minutes are used to flush the Monitor Unit.
box. If this alarm is During flushing the alarm will be active.
active the TRO control Overpressure too low / Check pressure value on
box does not detect the too high the display in the MUC.
overpressure Normal pressure value is
between 300 and 1200 The
overpressure can be
regulated with the flow
control valve on the right
top of the MU
Check the display of the
flow meter on the right top
of the MU. When the air
supply is normal the green
Air flow too low
led must be ON. If not
adjust the flowmeter
setting by turning the
coper screw clockwise.
Other faults
4.3.6 Salinity Meter Communication Fail Alarm
The control unit does Loose wire Check the cable connections to see if they are
not detect the signal. (signal line) correct and reliable.
Information is displayed Make a copy of the log and send it to the
Other faults
on the salinity meter. manufacturer if problem remains
If the Monitor Unit (MU) is Ex-Proof the Monitor Unit
No information is Control (MUC) controls the power supply. The
Power supply
displayed on the salinity start-up time for the MUC is 18 minutes. For the
interrupted
meter. Ex-Proof MU it is important to have air supply
to create the necessary overpressure in the MU.
Other faults
4.3.7 Salinity low (below 0.85 PSU) Alarm
Salinity is low Salinity is low If the ballast water has a salinity below 3 PSU the flow
should be regulated to the “standard flow”.
(the “standard flow” is mentioned in “settings”)
If a mixing pump is installed and the salinity is below
0.85 PSU it will start to add seawater (with a high
salinity) from a storage tank to the ballast pump
(intake) until ballasting is stopped. The amount of
seawater which is mixed can be regulated with a
discharge valve behind the mixing pump. If the salinity
in the ballast water is above 0.85 PSU after mixing the
seawater this alarm will disappear.
4.4 NU Alarms
4.4.1 Low Level (Neutralization Unit) Alarm
The liquid level in the Refill the neutralization unit with Sodium Thiosulfate
neutralizer has reached Pentahydrate.
the low level For right amount see maintenance NU
Check the cable connections to see if they are
Neutralization unit has The liquid level is correct and reliable.
Low level alarm alright but there is alarm
anyway The level sensor or floater is broken, if so replace
relevant parts.
Other faults
4.4.2 Low Level (Neutralization Unit) Alarm
During refilling the

The Neutralization Unit Neutralization Unit, the Do not fully open the manual valve for the fresh
has an overflow flowrate of the fresh water supply to limit the flowrate.
water is too high
During refilling the If the flowrate of the fresh water is too high it is
Neutralization Unit, the possible the level switch does not detect the high level
fresh water solenoid position. Do not fully open the manual valve for the
valve did not close, then fresh water supply to limit the flowrate.
the high level was Something is wrong with the fresh water solenoid
reached valve. Check or replace the solenoid valve.
The liquid level is Check the cable connections to see if they are correct
alright but there is alarm and reliable.
anyway. Check the level switch, if it is broken replace the it.
4.4.3 NU Pump dry run protection
Dry running protection

The liquid level in the Refill the neutralization unit with Sodium Thiosulfate
is active. The fluid in
neutralizer has reached Pentahydrate.
Neutralization Unit is
the low level For right amount see maintenance NU
completed.
4.4.4 NU Pump Error Alarm
The power supply has

Check the fuse for the motor in the NU
an open-circuit
Reset the thermal protection inside the NU Check the
Something is wrong The motor protection
setting of the thermal protection,
with the NU pump has been activated
the setting must be I-nom from motor name plate
Check the pump, if it is broken find the cause and
The pump is broken
replace the pump
4.5 Flow meter Alarms
4.5.1 Flow meter Communication Alarm

(signal line) correct and reliable.
The settings are set correct during the commissioning.
Information is displayed
The settings Changing the settings will never
on the flowmeter.
No information is
The fuse is blown Check the main power supply to the PDU.
displayed on the
(power supply) Check the fuse for the flowmeter in the PDU.
flowmeter.
The voltage is low Check if the power supply in the PDU,
(power supply) meets the requirements.
Inaccurate measurement (signal line) correct and reliable.
or alarm for blank pipe Check if there is sufficient flow, the measuring
No liquid
pipe of the sensor should be full of liquid.
4.5.2 High Flow Rate Alarm
Adjust backpressure and regulate flow to system

Backpressure too low
Flow is higher than capacity with valve HMV1
system If the ballast water has a salinity below 3 PSU the
treatment capacity Low salinity flow should be regulated to the “standard flow”. (the
“standard flow” is mentioned in “settings”)
4.5.3 Low Flow Rate Alarm
Flow is lower than the Adjust backpressure and regulate flow to system
minimum system Backpressure too high capacity with valve HMV1
capacity The filter is clogged, start the backflush cycle or
clean the elements
A BWMS controlled valve does not work. Make sure

there is hydraulic or air supply
to open / close the valve.
Valves A BWMS controlled valve is broken.
Fix the valve.
Tank valves which are not controlled by the
BWMS are closed. Open 1 valve to a ballast tank
Ballast-on selected but
Stop BWMS mode or start ballast pump
ballast pump is off
4.6 Valves Alarms
4.6.1 Filter Angle Valve (FV2) Communication Fail Alarm
Loose wire Check the cable connections to see if they are correct
(signal line) and reliable.
(power supply) and reliable.
The angle valve is not
Valve FV2 does not Check valve, make sure there is hydraulic or air supply
working
open or close to open the valve
Valve broken Replace broken parts
4.6.2 FV2 Error Alarm
The angle valve (signal line) and reliable.
position is not correct. Loose wire Check the cable connections to see if they are correct
During Ballast-On this (power supply) and reliable.
valve should be open at Valve FV2 does not Check valve, make sure there is hydraulic or air supply
least 30% but it is not. open or close to open the valve
4.6.3 Valve 1/2/3/4/5/6 Alarm
Loose wire Check the cable connections

(signal line) Check the end switches of the valve
The BWMS has an option to monitor the position of
The control unit does the valve to the ballast tank (BTV) and overboard
not receive feedback. (OBV). These 2 valves are controlled by another
Operation
system. There will be an alarm If the position of these
valve is not correct for the
selected BWMS mode.
The valves are not
The valve does not Check valve, make sure there is hydraulic or air
working
open or close supply to open / close the valve
4.7 CL、PDU、RC & MCB Alarms
4.7.1 CL Lost Power Alarm
Power failure No power Check the power supply and restart the BWMS.
4.7.2 Emergency Switch is Pressed Alarm
Something is wrong
with the BWMS but The Emergency On Fix the problems with the BWMS and select
Ballasting or De- button is selected normal operation again.
Ballasting is needed
4.8 Operation & Processing Alarms
4.8.1 Repair / Maintenance Alarm
After the maintenance press the “Repair” button in

The “Repair Mode” is The BWMS is being “Pipe 2” again.
selected in “Pipe 2” maintained Note: This option can only be turned On and Off if the
BWMS is on “Remote control”
4.8.2 Emergency ON / Bypass ON Alarm
Something is wrong
with the BWMS but The Emergency On Fix the problems with the BWMS and select normal
Ballasting or button is selected operation again.
De-Ballasting is needed
4.8.3 Ballast TRO Low And High Alarm or Ballast TRO Adjust
Overtime Alarm
Claim: Ballast TRO Low And High Alarm or Ballast TRO Adjust Overtime Alarm
1，TRO Low alarm (ballast)
Description: 2，TRO High alarm（ballast）
3，TRO2 High alarm（Deballast）
Special
Tools:
1，First of all, make sure that TRO reagent is not expired, so as not to guarantee,
replace the new reagent.
Attention: Once mixed, the indicator reagent has an expected life of 90 days if kept
Solution: under 25°C and 30 days if kept under 40°C.
2，Run and check the unit equipment, check the water intake in the reaction room,
check whether the flow rate of CLX is OK, details as follows：
3, The above is the setting of TRO . There is also a manual valve at the outlet of the
monitoring unit to improve the pressure in the monitoring unit and manual valve in
CLX, so that TRO can get water better. If have “TRO status: No intake water
alarm”, reduce the outlet valve opening. Meanwhile, do not forget to clean the water
pipe and TRO filter screen in the monitoring unit.
4, After finish last step, if also have alarm, remove the inlet manual valve to make
sure the water can flow out from the inlet pipe.
5, Confirm the below 4 electromagnetic valves is OK. And confirm the drain water for
sample is normal. If sampling water is obstructed, Open the screw, keep the Seal
Ring well, and please note that the electromagnetic valves water direction.
6, After this, can try step2 again and run BWTS again.
7,To observe whether the TRO meter cuvette can be filled with water during detectio
n. During normal operation the TRO METER 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
If an error occurs, a message is posted to the message queue on the LCD screen.
Different message description as follow:
8,Make sure that the reagents can be injected into the cuvette.
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 deionizer water.
9,If the above operation is no problem and TRO value is stable above 1.0,you can set as follow:
LOW SALINITY（TRO） EMERGENCY PROCEDURE
1) Turn on the power of the Power Distribution Unit and the Control Unit;
2) Press the button ”setting” e log in with user ”Hdw” and password ”Hdw”;
3) Take a picture of the setting page (commissioning setting);
You can add 50A in current valve ,for example: Initial Current 700 A change to 750A.
When next time you can add 50A from 750A to 800A
4) Press the hidden button at the top right corner for 2-3 seconds
And you the following page will be shown.
5) Increase the value of “Flow-to-Current ratio” adding 5%, i.e. if “Flow-to-Current” is set at 70%,
please change it to 75.0%;
6) Press the button “Back and press Sure to Save”;
7) Press the button “Save Date to HMI internal storage”;
8) Click “Sure” to save.
9) It is necessary to change the same setting in control unit and in the remote control unit.
Please run the system for ballasting operation and record the following data.
SW temp. = ____ °C
Salinity = ____ ppt
TRO = ____ ppm
Flow rate = ____ m3/h
EUT: ____ V , ____ A
It is necessary to run the system with this setting for at least 10 minutes, so in case TRO LOW alarm is
activated during this range of time, please stop the system and start it again.
After 10 minutes running with this setting, if TRO LOW alarm is activated again, please follow the
steps 1-9 again, increase the value of “Flow-to-Current ratio” adding 5% more and start the system for
ballasting operation. The same data requested above should be recorded.
The maximum value of “Flow-to-Current ratio” is 120%.
The maximum value of “Initial Current” is Max Current*80%.

Spares:
Remark
4.9 GPS、Echosounder & AIS Alarms
4.9.1 GPS Communication Fail Alarm

Description: GPS Communication Alarm
The paremeter ''GPGLL'' inside the machine for sending GPS signal at bridge
Cause:
is not open.
GPS signal contains many sentences such as ''GPZDA, GPGLL, and
GPGGA’’ and so on. Please follow the setting instruction of the GPS machine at brid ge to
open the GPGLL setting. While send the signal the alarm will go.
Below GPS setting for JRC for your reference:
(1) OPEN JRC the setting screen， press and 3 seconds， in JRC’s Main
Menu chose”0”as follows:
Solution:
(2) move up and down to chose” 0” Equip SET”，press enter，as follows:
(3) Then enter to “7，DATA I/O” as follows:
(4) Enter “DATA OUT1：NMEA”，as follows:

Claim： Recover the LOG data in HMI SD card
One of local or remote HMI lost log record
1. Since the LOG in one SD card is intact, local or remote HMI, so you can recover the
LOG record by copying the file of the intact LOG into the SD with incomplete LOG.
Description: 2. If method 1 does not work, please compress the two card backups and send them back
to us.
Special
Tools:
1，Power off to shut down the system.
Solution:
2，Press to unplug the HMI SD card of both local and remote HMI,and make a mark to separate
local or remote.
3，Plug the two SD cards to computer,and back-up all the files to computer.
4，After back-up, delete all the files in incomplete SD card and copy the files in intact SD to the
incomplete one.
5，Plug the two SD cards to HMI ,and power on to check if the LOG recovered.
6，Any queries please contact us,thanks！
Note: If you need to replace the program files in the SD card, please directly delete the folder and
file, and copy the new files into it, do not format, format the SD card will scrap it!!
注意：如果需要更换卡中的文件，请直接把文件夹和文件删除，并复制新文件进去，一定不
要格式化，格式化后 SD 卡就报废了！！
5 Notes
HEADWAY TECHNOLOGY GROUP (QINGDAO) CO., LTD.

Add.: No. 32, Keyuan Jing 6 Rd., Qingdao, China
Tel: +86 532-8310 7818 Fax: +86 532-8310 7816
http://www.headwaytech.com E-mail:AS-BWMS@headwaytech.com
BWMS@headwaytech.com

Headway BWMS - Technical Manual

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OceanGuard®

Ballast Water Management System

Table of Contents .......................................................................................................................................... 2

2 System Operation ..................................................................................................................................... 5

3 System Maintenance .............................................................................................................................. 10

EUT: ____ V , ____ A ............................................................................................................... 48

2.1 Menu Navigation

On the screen you can press the following buttons:

2.2 Ballasting Process

2.2.1 Ballasting Start Operation

2.2.2 Ballasting Stop Operation

2.3.1 De-Ballasting Start Operation

2.3.2 De-Ballasting Stop Operation

2.4 Bypass Process

2.4.1 Bypass Start Operation

2.4.2 Bypass Stop Operation

1 the bottom of HMI.

Press the button “setting”.

The Log data is saved in a RDB format in the HMI.

Press the button “setting”.

“Sea Water Set TRO”, “TRO Adj”, and “Fresh

“Max Current”, “Standard Flow”, and “Max Flow”

“Initial Current” and “Current Adj” are the

3.1 Filter Maintenance(ZF)

3.1.1 Replacing the Element

pressure difference >0.3 bar = start back flushing

pressure difference >1.5 bar = overpressure alarm

Remove the 4 M10 bolts to disassemble the

3 Remove the 2 M16 bolts to open the maintenance entrance, if available.

4 Remove the (20) M20 bolts to open the cover.

Lift up the cover about 80mm. (use proper

9 Remove the (4) M8 bolts (item1)

Pull up retaining nail (item 2), then rotate and

Remove the top cover, and take out the two

13 Remove the filter element

Clean the filter element with a pressure water gun.

15 The filter element can be dried by air or compressed air

16 Clean the inside of the filter housing.

3.1.2 Cleaning Big Impurity Particles

There is a drain at the lower shell of the filter.

If the intervals of the automatic back flushing get shorter,

the filter elements need to be washed manually.

1 Close the valves which are connected to the filter

The following maintenance is very important to do.

3.2.1 Notes Regarding the Chemical

Change the Indicator reagent at least every 3 months!

Change the buffer reagent at least e every 12 months!

The reagent kits (Free Chlorine) are available from Headway.

Steps for replacing the indicator reagent (at least 3 mouths)

6 Replace the old indicator reagent with the new one.

3.2.3 Replacing the Buffer Reagent

Steps for replacing the buffer reagent (every 12 mouths)

3 Open the TRO meter

4 Replace the old buffer reagent with the new one.

Steps for refilling the Neutralization Unit

Start Neutralization unit operation manually:

①Start the deballast；

②Press the “pump” key on the neutralization unit;

HMT-20N 6 KG HMT-50 HMT-60N 10 KG

HMT-20N 6 KG HMT-100 HMT-60N 10 KG

HMT-20N 6 KG HMT-200 HMT-60N 10 KG

HMT-60N 10 KG HMT-300 HMT-60N 10 KG

HMT-60N 10 KG HMT-450 HMT-100N 15 KG

EUT: V , A ............................................................................................................... 48