Components in Detail

Controller Power Unit

The ClearFlo controller power unit is state-of-the-art switch-mode type, utilizing the same sophisticated computer-controlled, network-based intelligence as the acclaimed Aquamatic III ICCP system. Each unit is capable of controlling four (4) anodes. The continuous current capacity ranges from 0 amps to 2 amps output per channel (or anode), at 0-12 volts. AC input requirement is 85-264 VAC, 1-phase, 47-63Hz, 17 amps.

The power supply is bulkhead-mounted, small (5¼x10x12"), and lightweight (20 lbs). The internal power supply is fully conformal coated within a Type 316 stainless steel enclosure for enhanced corrosion resistance. All components are modular for simplified service.

The controller regulates to 100th of an amp to each anode, and it provides continuous diagnostics for fault detection. The computer-controller monitors the anode consumption rate, and indicates the number of days' life remaining for each anode, to eliminate user uncertainty. The controller automatically detects "flow" and "no-flow" conditions via auxiliary contacts on pumps. This significantly increases anode life, and relieves the crew of the responsibility of manually adjusting anode outputs at-sea and in-port.

Remote Administration Display (RAD) Unit

This unit monitors and displays readings from each and every power unit of the system, up to four (4) power units. The display is an intelligent scrolling alphanumeric type which provides a snapshot of the system status for quick and easy assessment by the crew. This is the default display which reports either all anodes and all power supplies are working properly, or, if not, which component(s) has malfunctioned. Any faulty item(s) is reported on the summary display, with a brief description of the fault accompanied by suggestions for repair.

The Log Display reports the basic operational data for daily logging by the crew, including the following:

Sea chest or strainer location
Anode type (copper, aluminum, or iron)
Anode output current
Anode output voltage
Anode life remaining in days

The Service Anode reports detailed operational and programming data for diagnostic purposes, including the following, in addition to the above Log Display data:

Anode program current regulation set point
Controller D/A drive voltage
Flow contact program usage

The Remote Administration Display (RAD) unit is the same physical size as the Power Unit cabinet, but weighs less (15 lbs), and it will monitor all of the system's readings in a single convenient location, such as the control room or bridge. Other features include a Version Display which reports the embedded software version numbers, and Global Reset which invokes an entire system re-initialization and self-test cycle.

Also, more than one display can be connected to a system for identical readouts to be available at several locations. AC input requirement is the same as the power supply: 85-264 VAC, 1-phase, 47-63 Hz, 4 amps.

Antifouling Anodes

The antifouling anode consists of a copper alloy rod. Always used in conjunction with the anticorrosion anode, it combines with seawater to create an adverse environment to the spread of encrusting organisms (e.g. balanus barnacles, mussels, etc.). Lengths vary from 8" to 30" according to the pump flow rates and time between drydockings. Only in exceptional circumstances will anode weight be such that it surpasses the handling capabilities of one man.

In addition to the anode, components supplied for installation are the mounting ring, cofferdam, insulating sleeve, washers, nuts, terminals, etc. Anode stainless steel studs and cross-linked polyolefin shrink sleeves have been lengthened to reduce the risk of metal chunks "breaking off" at the neck of the anode and becoming lodged in the strainers. Anode insulation has been improved with the addition of double neoprene O-rings in between rigid PVC washers, to prevent "shorting out" of anodes.

Anticorrosion Anodes

Depending on its place of application, the anticorrosion anode will be an aluminum alloy rod or, for copper alloyed piping systems, iron. It combines with seawater to form a product which is deposited on the structure. This deposit creates a physical barrier which is electrochemically more negative than underlying material and thus either acts as a sacrificial anode or reinforces the passivating layer covering the structure. Lengths vary from 8" to 30" according to the pump flow rates and time between drydockings. Only in exceptional circumstances will anode weight be such that it surpasses the handling capabilities of one man.

In addition to the anode, components supplied for installation are mounting ring, cofferdam, insulating sleeve, washers, nuts, terminals, etc. Anode stainless steel studs and cross-linked polyolefin shrink sleeves have been lengthened to reduce risk of metal chunks "breaking off" at the neck of the anode and becoming lodged in the strainers. Anode insulation has been improved with the addition of double neoprene O-rings in between rigid PVC washers, to prevent "shorting out" of anodes.

Cables

Anode cable tails are supplied by Wilson Walton (as an option) or the shipyard. They are type LSDSGU-4, two-conductor, low-smoke, cross-linked polyolefin insulated, non-halogenated thermoplastic jacketed, unarmored, and flame retardant. Size is AWG #14, nominal outer diameter is 0.29 inches, and weight is approximately 62 lbs. per 100 ft. Cable is USCG, ABS and DNV approved, and U.L. listed for Marine Shipboard Cable. Anodes are supplied complete with cable tails to enable electrical connection between the anode and the junction box.

Anode feeder cables are supplied by Wilson Walton (as an option) or the shipyard, to enable electrical connection between the junction box and the power supply. This cable should be low smoke, 2-conductor, unarmored and size AWG #14 to conform with junction box glands.

AC input cables are supplied by Wilson Walton (as an option) or the shipyard, to enable electrical connection between the ship's distribution panel and the power supplies. This cable should be low smoke, 3-conductor, unarmored, and size AWG #10.

Power ground cables are supplied by Wilson Walton (as an option) or the shipyard, to provide a ground between each power supply and the hull. This cable should be low smoke, 1-conductor, unarmored, and size AWG #10. No ground is required at junction box or anode cofferdam. The Remote Administration Display (RAD) unit does not require separate ground cable. However, one core of the 3-conductor AC input cable should be used as the ground.

Data transmission cables are supplied by Wilson Walton (as an option) or the shipyard, to enable electrical connection between the Power Unit(s) and the Remote Administration Display (RAD) unit. This cable should be unshielded, bonded twisted pair, size AWG #16. Unshielded cable exhibits better capacitance than armored cable, which is especially important over longer distances. Bonded cable possesses better strength and signal integrity characteristics. Uniform conductor-to-conductor spacing is maintained, providing consistent electrical performance. The twisted pair configuration reduces Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI).

Using cable with different properties may have an adverse effect on data performance, up to and including communication failure. Wilson Walton recommends Belden 8471 for optimal performance.

Junction Boxes

Wilson Walton supplies special junction boxes, upgraded to heavy duty Pauluhn marine bronze type, with special marine grade bronze cable gland bodies and nuts. An intermediate junction box facilitates the separation of anodes from the supply, thus avoiding interference with the remainder of the installation during inspection or anode replacement periods. It is also necessary where anode assemblies are provided as a separate unit complete with pre-connected cable. Precisely-sized neoprene grommets are designed to grip the cable and create a watertight seal into the junction box. Each box is also supplied complete with a 4-point terminal block, and three (3) pieces of ½" N.P.T. cable glands. The gland nut is hex-shaped for easy tightening. Each box with cover measures 4 x 4 x 2-3/16" and weighs 4¼ lbs.

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