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Installation, Commissioning & Maintenance

Installation Instructions

Three separate stages are involved:

  1. Installation of the Power Control Unit
  2. Connecting Cables/Junction Box
  3. Anode/Cofferdam/Flange

1. Power Control Unit

The control panel should be located as near as possible to an AC power supply and the anode locations (to minimize the DC cable length and voltage drop). The control panel location should meet the following requirements:

  1. Maximum ambient temperature of 50° C (unit rated to 55° C)
  2. Adequate space around unit to ensure proper ventilation
  3. Mounted at head height (max) to facilitate reading and output adjustment or servicing
  4. Easily accessible location
  5. Safe, non-hazardous environment
  6. Bulkhead mounted and/or secured to a suitable base

2. Cable Connections: Power Control Unit, Junction Box, Anodes

Input AC cable connection points and earthing cable connections are clearly marked in the power control unit. Similarly positive output terminals on each module are evident with a common negative cable connection. Cable sizing and specification for AC input and DC output are described here.
The DC supply cable to the anodes should be connected to the intermediate junction box.
A junction box is provided with shrouded gland (DC) Inputs and anode/sea chest output connections.
Anode cables and negative return should be connected to the DC supply in the Junction Box.

3. Anode, Cofferdam, Flange

Anodes should be installed in the position specifically shown or advised for each vessel. The anodes are installed in the selected compartments, namely sea chests, or injection strainers.

Looking up from sea chest through aperture. Notice aperture diameter is slightly (5-10mm) larger than inside diameter of mounting ring (shown). This disparity allows room for a  weld bead securing the underside of mounting ring to sea chest that does not interfere with the insertion of the anode through the aperture.

Looking down at mounting ring through aperture and into the sea chest.
  1. The agreed positions for the 135-140mm apertures for the cofferdam entry points should be marked and burnt/cut out. Take precautions to protect surrounding equipment with heat resistant blankets etc. A standby fire extinguisher should be provided.
  2. The mating flange to receive the anode and cofferdam flange should be welded in position with welding on both inside and outside joints.
  3. All weld scale should be removed and any damaged paintwork reinstated.
  4. The anode cofferdam screw cap should be removed and the anode cable disconnected. Remove the compression gland and screw the anode cap back onto the cofferdam. Hand tighten only.
    Carefully lift the anode/cofferdam/flange assembly by means of the eyebolts provided and lower the anode onto the sea chest or strainer mating flange, making sure that the rubber gasket is in position. Evenly tighten down the anode flange bolts. (THIS PROCESS IS REPEATED FOR ALL ANODES)
    Note: All threaded sections of nuts, bolts and the cofferdam lid, including the anode connection, must be lightly coated with WWI Marine Guard.
  5. After installing the anode assembly, feed back the anode cable and compression gland. Reconnect the anode cable to the anode bolt. Replace the cofferdam cap, securing tightly onto the uppermost O-ring. Finally tighten the cable compression gland and fit the gland shroud.
  6. Secure anode cables and take back for connection in the junction box.
  7. When vessel is afloat, carryout leakage tests by checking for ingress of water into the cofferdam.

Looking up from sea chest at installed anode.

Looking down at completed assembly.

4. Commissioning

Note: Only to be carried out when the vessel is afloat.

  1. Check all cable connections at power control unit, terminal box and anodes.
  2. Identify each positive output and relevant anode, and record the same.
  3. Switch on AC supply and then the panel on/off switch.
  4. Switch on all power supplies then switch on Remote Administration Display (RAD).
  5. Record all status messages and record all system readings.

5. Maintenance

Maintenance requirements are minimal. The system operates at constant current output and therefore does not require adjustment. A weekly recording of current outputs on each anode is recommended (a log sheet is provided). This provides a record of the system's operation, an indication of any changes in function, and a reminder when anode replacements are scheduled. A complete loss of current on any anode should be investigated by checking all cable connections and power panel fuses.

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