For Every Corner of Your World.

AQUAMATIC MANUAL

HWASEUNG R&A (Wilson Walton Korea)

I.C.C.P. SYSTEM
(Impress Current Cathodic Protection)
INSTRUCTION/OPERATION MANUAL

HWASEUNG R&A
WILSON WALTON KOREA
147-1, GYO-DONG, YANGSAN, GYEONGNAM 626-210, KOREA
(82)55-370-3380~8, FAX: (82)55-389-0153
E-mail: wwcorrpr@chol.com

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CONTENTS

SECTION 1 GENERAL DESCRIPTION

SECTION 2 INSTALLATION

Check List

Good & Bad Example

SECTION 3 OPERATION

SECTION 4 SYSTEM SET-UP & FUNCTION

CHECKS AND FAULT FINDING

SECTION 5 CHECK SHEET

CREW DEMOSTRATION MANUAL

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AQUAMATIC MANUAL

SECTION 1

GENERAL DESCRIPTION

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INSTRODUCTION

Corrosion or deterioration of the metals used in the construction of ship’s hulls has posed a problem to ship
owners for many years. Of all the various anti-corrosion systems used by the ship building industry, cathod-
ic protection is one of the most efficient, being a positive and economical solution to the multiple corrosion
problems encountered on the underwater structures of ships. The AQUAMATIC Impressed Current Cathod-
ic Protection System incorporates the most up to date and advanced features in this field of corrosion engi-
neering.

FUNDAMENTAL CORROSION PROBLEMS

The metals comprising a ship’s hull lying below the waterline are affected by electrolytic /galvanic corrosive
action. This is the result of electric current flowing between one metal and another in a solution. In this case
the solution is the sea water surrounding the hull and the metals are the dissimilar metal areas and ap-
pendages of the hull. This arrangement may represented by a simple corrosion cell which comprises two
different metals electrically connected and immersed in an electrolytic solution such as sea water. (Fig 1)

The electro-chemical characteristics of the respective metals and their place in the galvanic series govern
the direction of a resultant current flow. Current will flow in the electrolyte from the anode to the cathode.

The current flow from the anode results in the loss of anodic metal (the process known as corrosion) while
the cathodic metal receiving the current will remain intact and corrosion free. (See Fig II)

These anodic and cathodic areas exist in the structure of ship’s hulls due to several conditions which in-
clude the coupling of metals of different potentials, physical differences in the grades or compositions of the
metals forming the hull, deterioration or non-uniformity of paintwork etc. There may even be spontaneous
formation of inseparable anodes and cathodes on an otherwise uniform metal surface. Corrosion currents
can also be produced by inconsistencies in the composition of the surrounding seawater. It follows that
elimination of anodic areas of metallic components is of paramount importance to the successful perfor-
mance of ships.

A most efficient method of overcoming this corrosion problem is the introduction of an additional metal,
more anodic than the existing anodic areas on the vital metallic ship components. This is the basis of ca-
thodic protection. The additional anode which will ultimately be sacrificed may consist of a metal at the
negative end of the galvanic series such as an alloy of aluminium, zinc or magnesium.

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THE I.C.C.P (AQUAMATIC) SYSTEM

The I.C.C.P (AQUAMATIC) System consists essentially of several Anodes, Reference Electrodes and a
Controller Power Unit. These items are inter-connected as shown in Fig III. The types and sizes of the
components and their positions in and around the hull are specified according to design parameters making
allowance for the fluctuations in protection current demand which may be experienced due to changes in
environmental conditions during sea-going service.

With the main hull structure protected, consideration must be given to the propeller, any exposed shafting
and the rudder. The propeller and exposed shaft are protected by grounding the shaft to the hull structure
with a shaft slipring to make these appendages electrically common with the ship’s hull. The rudder is
grounded by bonding the rudder stock to the ship’s hull and in this way the rudder is also protected by the
I.C.C.P system.

The I.C.C.P System of cathodic protection has considerable advantages over those systems utilizing sacri-
ficial galvanic anodes since it employs anode materials which are relatively inert and through which a DC
current may be passed. This protective current is generated and controlled within the system by a com-
bined Controller Power Unit.

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SECTION 2

INSTALLATION

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AQUAMATIC MANUAL

INSTALLATION INSTRUCTION FOR CONTROLLER POWER UNIT

CONTROLLER POWER UNIT

a) It is important that the place of installation should be reasonably cool, dry and well ventilated, and
should be away from any corrosive fumes or apparatus such as heaters, steam pipes, etc., which
will generate excessive heat.

b) Free access for cooling air must be permitted, allowing a minimum of 500mm above and 300mm
clear from the unit panels. The flow of air should not be restricted. The unit must be located in
such a position that the maximum temperature will not exceed 50℃.

c) To ensure accurate readings are obtained during periodic operation check, the cabinet should be
mounted with its instrumentation readily visible. Provide a suitably fabricated support for unit size,
mounting details and weight.

d) Provide and install appropriate input power supply cables to the controller power unit as shown on
the installation drawing. Check that the AC power supply source conforms to the voltage. Phase
and frequency specifications given on the nameplate.

e) Provide and install suitable cable (With regard to the maximum cathodic protection current), be-
tween the HULL (-) terminal in the Controller Power Unit and a suitable area of the main hull struc-
ture. * Note this connection must be capable of carrying full rated output of unit.

f) The positive output bus bar is made to facilitate the attachment of a varying number and size of
output fuses. The actual number and size (to be consistent with the rated output of the unit) is de-
termined by the actual installation. The anode cables are connected to the lower end of the output
fuses and secured using the internal cable tie bar provided.

g) The unit can operate with zero, one or two or four reference electrodes connected to the electrode
terminal block. The single core cables from the reference electrodes should be terminated at the
terminal block provided. Screened cables should be used throughout and the screen(s)
terminated to the hull negative connection at the power unit end only i.e. not at the electrode end, if
no reference electrodes are connected to the unit, operation is possible only in the ‘manual’ mode.

h) Connect a low current lead to the cubicle earth stud using a minimum conductor size of 4㎟. This is
essentially a non-current carrying cable used to provide the earth potential essential for correct op-
eration of the control circuitry.

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* IMPORTANT NOTE *

The transformer rectifier contains semi-conductors-high voltage and megger tests

should not be performed.

ICCP ANODES & REFERENCE CELL / BEFORE LAUNCHING

a. Resistant condition between Anode to Hull & Reference Cell to Hull, should be over than 1.0Mohm.
Can cause wrong value reading, when attached tape or dirty thing on Anode surface (or wet).
In case of wet, there can reading DC mV value only. (As same to seawater)

b. Should be attached Epoxy putty for ICCP Anode install

To be attached Anodes behind side (back plate)

c. Anode useful (front) surface should be kept clean / free from Epoxy or Paint and scratch.
d. Anode holding bolt should be covered by Epoxy after finish ICCP Anode install.
e. Dielectric shields surface should be Flat & smooth.

GOOD BAD

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ICCP SYSTEM INSTALLTION CHECKS / AFTER LAUNCHING

a. Measure a DC voltage between Anodes to Hull. Normal range: 500mv~2000mv (Before power on).

b. Measure a DC Volt Between Reference Cells to Hull. Normal: not around “0”mV

c. Check a cable connected condition on the J/B & Cofferdam.

d. Check a seawater leakage in Cofferdam or J/B inside.

e. . Comparison a cable connected condition between drawings to Panel inside.

(Anode, Ref.Cell, Alarm, Communication, Remote Power supply, etc.)

f. Should be kept panel inside.

g. Check the main hull cable electronic bonding condition. (Between -VE to Hull)
Normal Range: less than 1.0ohm

h. Measure Input Power & Power Cable connection.

ICCP SYSTEM OPERATION CHECKS

Change an operation mode to Manual mode.

a. Check an Ampere output, and comparison to set Ampere.

Output Ampere should not fluctuation.

b. Each Anodes output Ampere should be same always.

c. Actual output Ampere is must to be same to Display.

d. Measure DC volt on Reference Cell terminal

Reading value should not have fluctuation. But during welding job, can Fluctuation.

e. Value gap between Ref.Cell 1 & 2 are should be lower than 100mV.

f. Comparison a Reference Cell value between measure & Display.

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Change an operation to "Automatic Mode" operation.

*You can not start below test until 10min, from Manual Mode Test.

a. Check a reading value of Ampere, output Volt, Reference Cell value.

b. Load Sharing of Anodes output Ampere. Each anodes output Amp should be same always.

c. Actual output Ampere is must to be same to Display.

d. In case of Reference cell damaged, reading value will be constant, even they have Ampere
output or not.

e. Comparison a Reference Cell value between Measured to Display.

SHAFT EARTHING

The shaft slip-ring is supplied as a complete unit with silver band and clamping arrangement which
can be easily installed by competent ship’s engineering personnel, in the following order:

Select a suitable position on the shaft to install the slip-ring which should be close to a pedestal or
convenient piece of ships structure where the brush holder can be installed.

a. Then thoroughly clean the shaft in the area where the slip ring is to be fitted ensuring that all
grease and dirt on the shaft are removed.

b. The slip rings are manufactured slightly oversized to allow for small variations in shaft diameter.
When installing, the excess material should be removed by filing or cutting the joint faces be-
fore securing the clamping arrangements.

c. After removing the excess material the two band clamps are tightened so that the silver strip is
a close tight fit around the shaft.

d. Remove any excess banding strip from the assembly and ensure that this strip is cut back to
the housing.

e. Install a 25㎜ diameter rod (brush holder spigot) on a convenient piece of ships structure or
pedestal bearing’s that it is center parallel to the shaft center in both planes.(The mounting
bracket and rod are ship or shipyard supply items.)
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f. It is essential that the complete brush holder assembly should provide a good electrical con-
tract between the shaft and the hull, therefore the brush holder spigot support, should either be
welded to the ships structure or if bolted, a short length of 50~70㎟ bonding cable should be
connected between the brush holder and ships structure.

g. The brush holder should be clamped to this rod and aligned centrally over the silver track.

h. Install the silver graphite brushes and the brush holder and check that the clearing between
the silver track and the brush holder is approx. 4~6㎜.

i. Connect the silver graphite brushes to their connections and check all bolts and nuts for tight-
ness and that the brush pressure is set.

NOTE
TO PREVENT BRUSH ‘BOUNCE’ AND ENSURE MAXIMUM UTILIZATION OF THE SILVER
GRAPHITE BRUSHES, IT IS ESSENTIAL THAT THE JOINTS FORM A SMOOTH, FLUSH PRO-
FILE OVER THE FULL EXTENT OF THE SLIPRINGS.
GOOD BAD

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SLIPRING INSTALLTION CHECKS

1. Confirm slip-ring brush is installed as per drawing? YES/NO

2. Confirm that wiring is completely same to drawing? YES/NO

3. Is assembly clean and free from oil and grease? YES/NO

4. Are joints a good fit with no gap? YES/NO

5. Is brush holder secure on its shaft? YES/NO

6. Confirm that brush holder and its mounting are

solid and that it will not be affected by vibration. YES/NO

7. Confirm that brushes faces are tangential to slip-ring. YES/NO

8. Confirm that brushes are free to move in their holders YES/NO

SLIP RING MAINTENANCE

This grounding assembly should be checked every day for cleanliness. If there has been a build-up of oil /
dirty on the slip-ring face this should be removed with a degreaser. Inspect and clean the brushes and
brush holder to prevent blocking from dirt. Inspect the brush copper leads (pig tails) to ensure they have not
become loose or corroded. The brush wear-down should be noted and the compression of the hold-down
springs on the brushes should be adjusted to ensure good electrical contact.

INSTALLATION INSTRUCTIONS FOR RUDDER STOCK BONDING CABLE

RUDDER STOCK BOND

a) Provide install 70~100㎟ flexible cable of sufficient length between the rudder stock and the main
hull structure.

b) It is essential that low resistance connections are made and for this reason it is preferable to weld
the cable lugs directly to the main ship structure and rudder stock head. If this is not possible, and
bolts are used, the area under the cable lugs must be thoroughly cleaned to dry metal.

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COMMUNICATION SYSTEM SETTING
a. ID CHECK / UNDER SYSTEM SET MODE

b. CABLE CONNECTION CHECK

AFT FWD

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SECTION 3

OPERATION

INSTRODUCTION

AQUAMATIC SYSTEM OERATION

PERIODIC MAINTENANCE

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DRAWINGS
Layout & Assembly of CPU
Circuit Diagram

INTRODUCTION

Some of the fundamental causes of corrosion problems to which all sea going vessels are subject are ex-
plained in the General Description Section of this Manual. The AQUAMATIC Cathodic Protection System
overcomes these problems and has been developed to provide considerable advantages over those sys-
tems utilizing sacrificial galvanic anodes.
The AQUAMATIC System employs relatively inert anode materials through which DC current is applied
from external source of power.

I.C.C.P SYSTEM OPERATION

The Controller Power Unit is supplied with AC power from the vessel’s electrical system. This AC power is
rectified in the rectifier section and is distributed to the anodes form where it flows through the surrounding
sea water to return through the hull, thus making the entire hull structure cathodic or more negative with
respect to the anodes.

Tests have shown that there is an optimum value for protection current. Increasing the value above this op-
timum provides no further protection and wastes power. Excessive protection current may even cause
damage to the hull paintwork. To ensure adequate protection, yet prevent “over protection” at all times,
the protection current must be controlled according to changes in environmental conditions.

The Zinc Reference Electrodes develop and maintain a relatively constant electrical potential in natural wa-
ters and may therefore be used as a reference for measuring the potential of the adjacent steel hull struc-
ture. With Zinc Reference Electrodes the normal hull-to reference potentials are in the order of 400 to
600mV, the hull being positive with respect to the Reference electrode. To provide the optimum amount of
protection, the hull-to-Reference Potential must be maintained at approximately 220mV.

The Reference Electrodes are connected by screened cable to control section in the Controller Power Unit.
The control section is a single solid state plug-in printed circuit board which incorporates all the monitoring
and control functions.

In order to provide the correct protection current flow and maintain the hull-to-reference potential at 220mV,
the signal from the Reference Electrodes is compared with a “desired setting corresponding to 220mV. The
“Desired” Setting is adjusted by the appropriate figure being selected on the display in the “SET UP” mode
in the computer sequences.

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The unit is also provided with CURRENT LIMIT and VOLTAGE LIMIT controls, which again are adjusted by
the appropriate figure being selected on the display in the “SET UP” mode in the computer sequence. The
‘set potential’, current limit and voltage parameters are initially set during commissioning and should not
require re-adjustment by anyone other than a representative of Wilson Walton Korea.
The difference between the hull-to-reference potential and the “desired” setting is amplified and a signal
corresponding to this difference is applied to the control circuits of thyristors which cause a corresponding
variation in output from the transformer rectifier and hence the DC protection current is adjusted in accord-
ance with the Cathodic Protection requirements. (See later section for detailed Controller Power Unit opera-
tion).

The control board is designed to monitor high internal impedance to the reference electrode input circuits.
This is necessary to prevent the potential measuring circuit from drawing too much current from the refer-
ence electrodes which could cause them to become unstable. The reference electrodes are large enough to
tolerate a current drainage of 50 micro amperes. The circuitry of the control section restricts the current flow
to within these parameters thus ensuring that the reference electrode potential will remain stable.

The front panel of controller power unit is provided with an on/off switch (triple pole moulded case circuit
breaker) and a neon indicator which is illuminated when a mains power supply is connected and the circuit
breaker switched on. Access to all internal components is via the hinged front door which is lockable. A
window is provided in the front door to allow the operator to periodically view the performance indicators
which are situated on the internally mounted P.C.B. control unit.

The lead crystal display is mounted at the top center of the P.C.B. and indicates when indexed.

- Total Current Output flowing through all anodes

- Hull to reference potential of reference electrode 1 & 2 / 3 & 4 (if presented)

- Output Voltage of unit.

- The propeller shaft potential.

- The cabinet temperature.

- Any alarm condition that may be enunciated.

It follows that the readings given by the indicators for each reference electrode may vary slightly.

However, all the Reference Electrodes are directly connected all times to the control section, so that the
highest numerical hull-to-reference potential (indicating the lowest level of protection) determines the cur-
rent output through the anodes.

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Readings of current output amperes are an indication of the amount of current required to achieve protec-
tion and therefore the amount of bare steel in contact with the sea water. It follows that the current will in-
crease as coating lost. Other depolarizing factors will alter the current output requirements. These include
the speed and turbulence of water past the hull and the amount of oxygen it contains.
Output voltage will increase as the need for protective current increases. To drive more current through the
anodes a higher voltage will be required. Output voltage will also be affected by the resistance of the sea
water through which the current is flowing between anodes and hull. Sea water resistivity varies with tem-
perature and salinity. Typical values of sea water from 25 to 50 ohm/㎝ may be encountered, whilst fresh
water resistivity may be 1,000 ohm/cm. Output voltage will therefore also rise in cold sea water and be at a
maximum (full scale deflection) in fresh water.

Since the I.C.C.P System is automatic in operation, no further adjustment to any of the controls is neces-
sary after the system has been commissioned and initially energized. To determine that the I.C.C.P System
is functioning correctly and to check that no minor faults exist, system log sheets are supplied on which the
readings of the indicators in the Controller Power Unit must be recorded daily. The log sheets provide a
continuous record of the level of protection as well as a means of diagnosing any malfunction in the system.
The one copy of each log sheet, when completed, must be returned to eh Head Office of Wilson Walton
Korea Ltd, who will assess the information and advice on the performance of the system. Further copies
should be sent to owner’s office and copy retained for record purposes on board.

The system log sheets must be completed in the following manner.

1. The vessel’s name, voyage number and the starting and finishing dates must be entered across the top
of the log sheet.

2. The location of the vessel must be entered in the first column starting from day one.

3. Read the indicators of the Controller Power Unit and under the heading Aft System 1 and the su-
heading Output, enter the digital read out for Amps and Volts (fig.3.1) readings in the Amp and Volt col-
umns respectively.

4. The next group of columns under the heading Potential (MV) must be completed by entering the read-
ing of the first Reference Electrode position. Enter the reading given by the indicator in the first col-
umn under the heading Potential (MV). Next observe the reading of the second electrode position and
enter the mill-volt reading of the next column.

5. The group of columns under the heading Aft System 2 (if fitted) and Fwd System (if fitted) had been
provided for vessels fitted with more than one Controller Power Unit. The readings given for the appro-
priate indicators, must be entered into the relevant columns as detailed under steps (3) and (4) above.

6. Any observations should be made at the bottom of the log sheet under the heading “Remarks”.

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PERIODIC MAINTENANCE

General

The I.C.C.P System contains some of the best electrical equipment and hull units available, and is specifi-
cally designed to withstand the rigours of shipboard environment.

While the components of the system are designed to operate with a minimum of attention, it is advised that
the I.C.C.P System is serviced at scheduled Dry-docking of the vessel by Wilson Walton Korea engineers,
when overhaul of the hull units can be carried out. Electrical tests and check on the Controller power Unit
are best carried out with the vessel afloat. The only component requiring periodic attention by ships staff is
the shaft slipring. This should be cleaned regularly to remove all traces of grease and dust. Replace-
ment brushes are easily fitted and are immediately available from any of the Wilson Walton Agents and
Stockiest.

Controller Power Unit

Because a solid state power regulator and control system is used in this equipment only very limited routine
maintenance is necessary.

At regular intervals the following should be carried out: -

ⅰ) Check ventilation grilles (bottom and top sides) to ensure that they are not obstructed in any way.

ⅱ) Check that all electrical connections are secure.

ⅲ) Clean out the inside of the cubicle to remove harmful dust and dirt deposits.

ⅳ) Clean the window in the front door of the equipment

ⅴ) Check that the equipment is dry.

ⅵ) Check that the fan control relay is securely plugged into socket.

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SECTION 4

CHECKS AND FAULT FINDING

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INSTLLATION CHECKS

With the vessel in dry-dock or before launching…..

a) Inspect the installation of all anodes and reference electrodes. Ensure that welds are correct and that
prepared areas have been adequately coated with protective paint.

b) Ensure that the stud holes of all anodes and reference cell have been properly cleaned and filled.

c) Inspect all conduit runs, and arrange pressure test as necessary. Open up all cofferdams and junction
boxes, ensure correct fitting of cable glands.

d) Inspect cable joints and termination for appropriate insulation and tightness and ensure continuity and
termination of the appropriate terminals at the Controller Power Unit. RE-seal all junction boxes and
cofferdams.

e) Check that the silver insert of the slipring assembly fitted to the propeller shaft is clean and free from
grease or paint and that the gaps are filled and polished flush.

f) Check the brush holder installations and ensure that the brushes are held in contact with the slipring by
the correct spring pressure. If necessary adjust the ratchet levers on the brush holder.

g) Check that the bonding cable connections at the brush gear clamping block and the main hull structure
are secure.

h) Check the welded connections of the ground cable between the rudder stock and the main hull struc-
ture.

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FAULT FINDING

FAULT PROBABLE CAUSE REMEDIAL ACTION

1. Disconnect the anode cable tail from

the anode cofferdam. And check an
Low anode to hull potential, Damaged Anode or Anode cable, insulation condition of Anode cable
normally obtained when load flooded cable connection or faulty first.
sharing checks indicate low an- insulation between the anode and
If not find any problem from Anode
ode circuit resistance i.e. high the hull structure.
Cable, measure a DC Volt between
current with low voltage. Anode to Hull. After disconnect con-
nected cable.

You can conclude as require renew-

al ICCP Anode on next Dry-Dock, if
you find any make of water leakage
on cofferdam inside or J/B inside.

2. Damaged reference electrode cable Disconnect the reference electrode

or faulty insulation between the ref- cable in the junction box adjacent to
Low or Zero reference electrode erence electrode and the main hull the hull entry cofferdam. Test the
potential (Ref.Cell) reading. cable for continuity and insulation
structure, or painted electrode.
from ground between its termina-
Missing zinc block: potential meas- tions at the Combined Controller
Power Unit and the junction box.
or ured that of copper to steel.
Renew the cable or repair the insu-
lation as necessary. With the ship in
drydock and external hull dry check
Reference electrode reading a reference electrode for insulation
NOTE: On new vessel, can reading
negative value. from ground. If a low reading is
low Reference cell value.
obtained the reference electrode is
Reason: Good painting condition & faulty and must be renewed. If paint-
ing suspect clean electrode in
Sacrifice Anode (Zinc / Al).
drydock or trim ship and clean. If
cell missing replace at drydocking.

3.

Circuit BREAKER ON. P.C.B control card damaged. Require contact to Maker.
No increase Ampere output as
reference electrodes potential or
increase. Should be renewal ICCP Anode, if
Anodes useful surface missing.
there damaged.
(Anode problem)
(by Diver / on next D-Dock)

5.
a) Loose connections at Hull Earth
No/Low indication on output Connection. Check/Re-tighten
current with indication of output
volts. (Normal with vessel in b) Anode cable disconnected or
Check anode cables and fuses
fresh water) damaged/felled anode fuse

c) Anodes useful surface missing.

Anode Renewal.

6.
a) Power or input circuit failure.
Circuit Breaker On but no out- Check “Power” LED ramp, If not

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put on MANUAL or AUTO con- illuminated check mains supply and
trol. b) Voltage/Current Limit Controls circuit breaker for fault.
incorrectly set.
Reset in accordance with instruc-
c) Auto/Manual Controls incorrectly
tions.
set.
d) “Set Potential” level incorrectly
Reset in accordance with instruc-
set. tions.
e) Output fuse(s) blown.
f) Thyristor or Diode Unit blown. Reset in accordance with instruc-
g) Anode damaged. tions.

Check for short circuit and/or over-

load before replacing.

Check fuses and replace as neces-

sary

7.
Reset in accordance with instruc-
Reference electrode too high or “Set Potential” level incorrect
tions
too low.

a) Good painting condition with Sac-

Change an “Over Protection” alarm
8. rifice Anode melting.
setting accordingly.
Over Protection Alarm activate b) Reference Cell damaged. Measure reference cell value after
without Ampere output
take off cable on cofferdam.
c) P.C.B control card damage
Measure actual value.

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SYSTEM SET UP AND FUNCTION

CONTENTS

PART 1 INTRODUCTION

PART 2 OPENING SCREEN

2.1 Power on
2.2 Keypad

PART 3 DISPLAY UNDER ALARM CONDITIONS

4.1 Display of Faults

PART 4 SET-UP
5.1 Operation mode select
5.2 Mode of system setting

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PART 1

INTRODUCTION

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1.0 INTRODUCTION

Menu Arrangement

POWER ON

OPERATION SELECT MODE SELECTION

SYSTEM SET- ADJUST OF THE

MANUAL MODE AUTOMATIC MODE
ZERO VALUES.
TING

DISPLAY
READINGS

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PART 2

OPENING SCREEN

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2.0 OPENING SCREEN

2.1 Power On

When power supply is switched on, LCD display screen will show four different start screens one by
one, starting with company name screen.
(This will happen when system is set to normal conditions)

If settings are not correct during start up, two methods can be enforced.
-Simply turn of power and turn back on again.
-Remove reset jumper to reset position for one second then return reset jumper to the non connector
position.

*** WILSON WALTON KOREA ***

*** I.C.C.P SYSTEM ***

Fig 1.

After soon, the Wilson Walton screen has been display, the ICCP system screen will appear.
In this instance the computer has been initialized. If the setting values are wrong, initialized the setting
value and display as Fig 2.

*** WILSON WALTON KOREA ***

*** I.C.C.P SYSTEM ***
** Wrong system setting, Reset setting **
Fig 2.
Next, Fig 3. indicates the system setting conditions.
i.e-number of cells, input power phase, system capacity, operation mode and temp of fan run.

*** ICCP SYSTEM STATUS ***

* CELL No.: 2 EA * MODE : AUTO *
* PHASE : 3 * FAN RUN : 50 ‘C*
* CAPACITY: X00 A * VOLTAGE : 24.0 V*
Fig 3.

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(Fig 4.) is showed when in the manual setting mode.

i.e setting value:
-. Mode: manual, 100 Amp
-. Number of cells: 2 ea
-. Using shaft: NO

>> MANUAL << MODE: X00 A *TEMP: 23 'C

*CURRENT : 100 Amp *VOLTAGE : 12.3 V
*CELL. 1: 212 mV *CELL. 2: 221 mV
* CELL. 3: UNUSED *CELL. 4: UNUSED

Fig 4.
If the system is connected with 4 numbers of reference cell, LCD is displayed as Fig.5.
i.e setting value:
-. Mode: manual, 100 Amp
-. Number of cells: 4 ea
-. Using shaft: NO

>> MANUAL << MODE: 100 A *TEMP: 23 'C

*CURRENT : 100 Amp *VOLTAGE : 12.3 V
*CELL. 1: 212 mV *CELL. 2: 221 mV
* CELL. 3: 220 mV *CELL. 4: 210 mV

Fig 5.

If the system is connected with shaft earting device, LCD is displayed as Fig.65.
i.e setting value:
-. Mode: manual, 100 Amp
-. Number of cells: 2 ea
-. Using shaft: YES

>> MANUAL << MODE: 100 A *TEMP: 23 'C

*CURRENT : 100 Amp *VOLTAGE : 12.3 V
*CELL. 1: 212 mV *CELL. 2: 221 mV
* SHAFT 1: 43 mV *SHAFT 2: 0 mV

Fig 6.
Fig 7.) is showed when in the automatic setting mode.
i.e setting value:
-. Mode: automatic, 220 mV
-. Number of cells: 2 ea

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For Every Corner of Your World.
AQUAMATIC MANUAL
-. Using shaft: NO

>>AUTOMATIC << MODE: 220 mV *TEMP: 23 'C

*CURRENT : 100 Amp *VOLTAGE : 12.3 V
*CELL. 1: 212 mV *CELL. 2: 221 mV
* CELL. 3: UNUSED *CELL. 4: UNUSED

Fig 7.

2.2 The Keypad

All input data and value changing to be carried out, only through computer keypad.

During either the automatic or manual operation, if the escape button is pressed, LCD
ESCAPE
display will indicate the mode selection. If the escape button is depressed a second
time, the initial start screen will appear. The set-mode (A or M) will then return. The
escape button can also be used to view previous selected screen.

▲ ▼ The UP and LEFT cursor button is used to change increasing val-

UP DOWN
ues, and move cursor. DOWN and Right cursor button is used to
◀ ▶ change decreasing values, and move cursor.
LEFT RIGHT
WN

The enter key is used during the mode selection display in order to set/lock.
This screen in its new state, once the<*> icon has been moved, in order to have
ENTER
locked state, simply press escape button. And the key is used when move manu.

ESCAPE
▲ ENTER
UP

◀ ▼ ▶
LEFT DOWN RIGHT

ARRANGEMENT OF SWITCHES ON KEYPAD

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For Every Corner of Your World.
AQUAMATIC MANUAL

PART 3

DISPLAY UNDER ALARM CONDITIONS

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For Every Corner of Your World.
AQUAMATIC MANUAL
3.0 DISPLAY UNDER ALARM CONDITIONS

3.1 DISPLAY OF FAULTS

Should an abnormal condition occur, the alarm scenario will be activated. At this point, once enter key
is pressed this will display first alarm message.
If the LEFT or RIGHT key is continually pressed, the LCD display will skip through all alarm message
screens in chronological order. At this point, all abnormal conditions should be removed.
Should the said abnormal condition exceed the set alarm time (i.e.- 3 minute-if so set) then only at this
point will the alarm be activated and not before.
Once the system starts to re-operate then new alarm time setting is no longer required. Once the alarm
is set to it’s off position then extreme caution must be taken as no alarm will now occur.

3.1.1 ALARM- UNDER PROTECTION

Fig 10 displays when cell #1,#2,#4’s is under protection status.

Alarm type

Setting value
ALARM -UNDER PROTECTION. Limit: 350 mV
Cell No. of
-.Ref. Cell No : 1 , State value: 512 mV Existing value
alarm status.
-.Ref. Cell No : 2 , State value: 522 mV

Fig 10.

3.1.2 ALARM – OVER PROTECTION

Fig 11 displays when cell #1,#2,#3’s is over protection status.

ALARM -OVER PROTECTION. Limit: 50 mV

-.Ref. Cell No : 1 , State value: 42 mV
-.Ref. Cell No : 2 , State value: 42 mV

Fig 11.

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For Every Corner of Your World.
AQUAMATIC MANUAL
3.1.3 ALARM – OVER OUTPUT VOLTAGE

Fig 12 displays when output voltage is alarm status. The alarm is occurred when output voltage is above
then limit voltage.

Alarm type
ALARM – OVER OUTPUT VOLATE
Setting value Existing value
-.Limit value: 24.0 V, State value: 24.5 V

Fig 12.

3.1.4 ALARM – OVER OUTPUT CURRENT

Fig 13 displays when output current is alarm status. The alarm is occurred when output current is above
then limit current.

Alarm type
ALARM – OVER OUTPUT CURRENT
Setting value Existing value
-.Limit value: 350 A, State value: 356 A

Fig 13.

3.1.5 ALARM – OVER TEMPERATURE

Fig 14 displays when internal temperature is alarm status. The alarm is occurred when internal tempera-
ture of the power control unit is above then limit. Limit value of temperature is fixed the internal program,
and can not changed the value. The limit value is 70 C.

Alarm type
ALARM – OVER TEMPERATURE
Setting value Existing value
-.Limit value: 70 ‘C, State value: 72 ‘C

Fig 14.

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For Every Corner of Your World.
AQUAMATIC MANUAL

PART 4

SET-UP

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For Every Corner of Your World.
AQUAMATIC MANUAL
4.0 SET-UP

4.1 OPERATION MODE SELECT

The (Fig 15.) screen will be displayed once the ESCAPE key has been pressed during the automatic or
manual operation status. Whilst at the Fig 15.display, if icon is set at operating set and the return key
pressed then Fig 15. will be displayed.

>>> Operation Set Mode <<<

<*> AUTOMATIC – CELL REFERENCE : 220 mV

<> MANUAL – OUTPUT CURRENT : 10 A
Fig 15.

Change the AUTOMATIC/MANUAL mode is used the UP/DOWN key.

At the Fig 15. screen whilst at the automatic operating position, if the ENTER key is pressed, the cursor
is moved on the value as Fig 15. Using the UP/DOWN & LEFT/RIGHT key can be changed the value.
UP/DOWN key is changed 10 steps and LEFT/RIGHT key is 100 steps. If you press the ENTER key,
cursor is moved as Fig 15. Change the MANUAL mode is same as AUTOMATIC mode. But UP/DOWN
key is changed 1 step, and LEFT/RIGHT is 10 steps.
-. Automatic mode – General value : 220 mV

>>> Operation Set Mode <<<

<*> AUTOMATIC – CELL REFERENCE : 220 mV

<> MANUAL – OUTPUT CURRENT : 10 A
Fig 16.
You can either reset all values or press ESCAPE to display Fig 17.
If you want to save the new values, press the enter key, else you don’t want to save, press the ESCAPE
key.

-. Save the values. Press <ENTER> key

-. Not Save the values. Press < ESC > key

Fig 17.

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For Every Corner of Your World.
AQUAMATIC MANUAL
4.2 MODE OF SYSTEM SETTING

If you press the LEFT & RIGHT key at the same time, enter the mode of system setting as Fig 18.
There is two manus. One is system setting mode, the other is adjust zero value of the sensors. If you
want to enter system set mode, press the RIGHT key, and if you want to enter the mode of adjust zero val-
ue, press the LEFT key.
If you want to escape the screen, press the ESCAPE key.

>>> select Set Mode <<<

-. System Set mode, Press <RIGHT> key

-. Adjust Zero Value, Press <LEFT> key

Fig 18

4.2.1 SYSTEM SET MODE

If you press the RIGHT key, enter the system set mode as Fig 19. the mode is able to change the alarm
point, system capacity, point of fan running temp, system id, phase and etc.

>Set mode< *ID: 1 *PHASE: 3 *CAP’TY: X00 A

*FAN TEMP: 50 'C *SHAFT: NO *CELL.NO: 2EA
ALM*OVER: 50 mV *UNDER: 350 mV *DELAY:180s
* MAX CURRENT: X00 A *MAX VOLTAGE:24.0V

Fig 19.

Position of cursor can be moved using the ENTER key.

Values can be changed using UP / DOWN and LEFT/ RIGHT key.

Description of menu as following;

-. ID : system id, Number ‘1’ is indicated AFTER system, and ‘2’ is FORWARD system.
-. PHASE : Phase of input power source, you can select 1 or 3.
-. CAP’TY : System output capacity. Shunt(current sensor) is outputted 0 ~ 75 mV.
You can select 100 ~ 900 A. Caution: It means the values when Shunt outputs 75mV
-..FAN TEMP : Can be selected the point of the fan running temperature.
-. SHAFT : Display the shaft earthing device or not.
YES – Display the milli-voltage of the shaft earthing device.
If the value is YES, reference cell is only displayed two values.
NO – Don’t display the milli-voltage of the shaft earthing device.

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For Every Corner of Your World.
AQUAMATIC MANUAL
-. CELL : Reference cell number(2 or 4)
If number of the cell is 4 ea, milli-voltage of the shaft earthing device can not display.
ALM line;
-. OVER : Limited voltage of the over protection.(general value: +50mV except new vessel)
-. UNDER : Limited voltage of the under protection(general value: +350 mV)
-. DELAY : Delay time for alarm.(general delay: 180 seconds)
-. MAX CURRENT : limited value of the output current.
-. MAX VOLTAGE : Limited value of the output voltage.

Once all values are finalized we can use the ESCAPE key to exit this display. At this point we will return
to the mode selection screen as Fig 18. We move the save screen Fig 20 if you press the ESCAPE key
once more. If you want to save the new values, press the ENTER key, else you don’t want to save,
press the ESCAPE key.

-. Save the values. Press <ENTER> key

-. Not Save the values. Press < ESC > key

Fig 20.

4.2.1 ADJUST ZERO VALUE

If you press the LEFT key at the Fig 18, enter the adjust zero value of the sensors as Fig 21. The mode
is able to change the zero value of the sensor( output current, output voltage, and reference cell1~4.).

# ADJUST ZERO VALUE OF THE SENSOR #

OUTPUT * VOLTAGE: 0V * CURRENT: 0A
*CELL.1: 0 mV *CELL.2: 0mV
*CELL.3: 0 mV *CELL.4: 0mV
Fig 21.

Example;
If the actual value of current value is 12 Amps and display value on the LCD is 20 Amps, the value dif-
ference is - 8 amps(actual value – display value). Therefore the adjust value is –8 amps.
Position of cursor can be moved using the ENTER key. The menu is rotated as following there.
VOLTAGE  CURRENT  CELL.1  CELL.2  CELL.3  CELL.4  VOLTAGE  …
Values can be changed using UP / DOWN key. The value is changed by 1 step.
Description of menu as following;

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For Every Corner of Your World.
AQUAMATIC MANUAL

-. VOLTAGE : Output voltage. Changed the ranges: -9.9 V ~ +9.9 V

-. CURRNET: Output current. Changed the ranges: -99 A ~ +99 A
-. CELL.1 : Voltage of the reference cell no.1. Changed the ranges: -99 mV ~ +99 mV
-. CELL.2 : Voltage of the reference cell no.2. Changed the ranges: -99 mV ~ +99 mV
-. CELL.3 : Voltage of the reference cell no.3. Changed the ranges: -99 mV ~ +99 mV
-. CELL.4 : Voltage of the reference cell no.4. Changed the ranges: -99 mV ~ +99 mV

Once all values are finalized we can use the ESCAPE key to exit this display. At this point we will re-
turn to the mode selection screen as Fig 18. We move the save screen Fig 22 if you press the ESCAPE
key once more. If you want to save the new values, press the ENTER key, else you don’t want to save,
press the ESCAPE key.

-. Save the values. Press <ENTER> key

-. Not Save the values. Press < ESC > key

Fig 22.

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Do Better Tomorrow

FOR FINAL
CUSTOMER HYUNDAI SAMHO HEAVY INDUSTRIES CO., LTD.

PROJECT NO. S 584 / 85 / 86 / 87

SHIP TYPE 3,600TEU CONTAINER CARRIER

CATHODIC PROTECTION
Impressed Current System

Dec.12,2012- Dec.12,2012-
2 FOR FINAL
H.K.LEE J.I.JIN
Nov.02,2011- Nov.02,2011-
1 FOR APPROVAL
H.K.LEE J.I.JIN
N
DRAWN BY APPROVED BY REMARK
O

HWASEUNG R&A
[WILSON WALTON KOREA]
147-1, GYO-DONG, YANGSAN, GYEONGNAM 626-210, KOREA
(82)55-370-3380~8, FAX: (82)55-389-0153
E-mail: wwcorrpr@chol.com
Do Better Tomorrow

Design Criteria
1. Wetted surface area : 9,670㎡ for Hull, 127㎡ for Propeller
2. Current density capability : 35mA/㎡ for Hull, 600 mA/㎡ for Propeller
3. Maximum current capacity : 450 Amps (Aft. sys : 300 Amp + Fwd.sys : 150 Amp)
4. Intermediate shaft diameter :Φ575 ㎜

Scope of supply

Fwd System

Item 1. One(1) Electric automatic controller power unit DC rated output of 150Amps, 24V.
A computer controlled PCB provided.
Power supply : 440V AC, 1 PH, 60 HZ
Paint : RAL 7032
Degree of protection for enclosure : IP 44

Supplied with earthing cable with cable glands

Item 2. Two(2) Recessed MMO/ Ti circular anodes assembly with cofferdam.

Max rated capacity : 75 Amps per anode at 24V
Cable glands and 70m cable for each anode

Item 3. Two(2) High purity zinc reference electrodes with cofferdam unit.
Cable glands and 70m cables for each ref. cell

Item 4. One(1) water resistant grease for FWD cofferdam 15kg/set

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Aft System

Item 5. One(1) Electronic automatic controller power unit DC rated output of 300Amps,
24V. A computer controlled PCB provided.

Power supply : 440V AC, 1 PH, 60 HZ

Paint : RAL 7032

Degree of protection for enclosure : IP 23

Supplied with earthing cable

Item 6. Two(2) MMO/ Ti circular anodes assembly with cofferdam unit.

Max rated capacity : 150 Amps per anode at 24V

Cable glands.

Item 7. Two(2) Rigid plate for di-electric shield.

Item 8. Two(2) High purity zinc reference electrodes with cofferdam unit.
Cable glands.

Item 9. One(1) Remote monitor panel for each fwd & aft controller power unit.

Item 10. Rudder stock grounding assembly , 5m length

Item 11. Two(2) Epoxy putty, 10kgs/set

Item 12. One(1) set of spares

Item 13. Instruction manuals

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Propeller Shaft Grounding Device

Item 14. One(1) intermediate shaft grounding assembly

- Double brush holder
- Spindle with insulation sleeve
- Brush
- Earthing cable
-
Item 15. One(1) intermediate shaft potential monitoring assembly
- Single brush holder
- Spindle with sleeve
- Brush
- Digital Milli-voltmeter
-
Item 16. Two(2) band clamp assembly
- Silver alloy plate
- Clamp
Item 17. One(1) Set spare brush

Operation
The millivoltmeter normally reads 300mV full scale. If readings are above 80mV, alarm outputs.
The clean the surface of slip-ring and the contact face of brush with a clean cloth.
The millivoltmeter will read ”0” when shaft is at rest because the current entering the propeller will
return to the hull through the bearing and turbine reduction gears.
A millivoltmeter reading of “0” when shaft is turning at sea indicates a faulty millivoltmeter
installation. Checks for connections of all the terminals and tightness of all the fittings are required.

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Maintenance
This grounding assembly should be checked every seven days for cleanliness. If there has been a
build-up of oil on the slip-ring face this should be removed with a degreaser. Inspect and clean the
brushes and brush holder to prevent blocking from dirt. Inspect the brush copper leads (pig tails) to
ensure they have not become loose or corroded. The brush wear-down should be noted and the
compression of the hold-down springs on the brushes should be adjusted to ensure good electrical
contact.

Guarantee
The equipment will be guaranteed against defective component design, workmanship and materials
for a period of 13 months after delivery of vessel.
This guarantee is based on the system being installed according to HWASEUNG R&A
installation procedures.
Any parts replaced within the guarantee period will be replaced to FOB(Free On Board Pusan)
free of charge.

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