TCM_S9633-A3-MMA-010_1.pdf

TECHNICAL MANUAL

FOR

WATERJET IMPRESSED CURRENT

CATHODIC PROTECTION SYSTEM

MAINTENANCE AND OPERATION

SUPERSEDURE NOTICE: THIS MANUAL SUPERSEDES S9633-A3-MMA-010,

DATED 15 NOVEMBER 2014, AND ALL CHANGES THERETO.

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND

THEIR CONTRACTORS; ADMINISTRATIVE/OPERATIONAL USE; 15 NOVEMBER 2014. OTHER U.S.

REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO NSWC PHILADELPHIA, CODE 944.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE

ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2751, ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979 (TITLE 50, U.S.C., APP 2401 ET SEQ.), AS AMENDED. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH THE

PROVISIONS OF DOD DIRECTIVE 5230.25.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS

OR RECONSTRUCTION OF THIS DOCUMENT.

S9633-A3-MMA-010

REVISION 1

TITLE-1 / (ii Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

*0910LP1184926* 26 AUG 2018

TITLE-2

@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

REV NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY

0 15 NOV 2014 INITIAL ISSUE.

1 26 AUG 2018 PARAGRAPH:1-4.2

FIGURES:B-7 andB-9

INCORPORATION OF TMDER N65540-17-LG01, N65540-18-LG00

FOR OPTIMAL VIEWING OF THIS TECHNICAL MANUAL THE PAGE LAYOUT IN ADOBE ACROBAT

READER SHOULD BE SINGLE PAGE. CONTINUOUS PAGE DISPLAY CAN CAUSE PROBLEMS WITH

LINK REFERENCES AND THE BOOKMARKS.

S9633-A3-MMA-010

FOREWORD

This technical manual provides description, operation, maintenance, troubleshooting, repair and parts list information for the Waterjet Impressed Current Cathodic Protection System. This technical manual is intended for guidance of and use by personnel operating and maintaining the equipment described herein.

This manual consists of eight chapters and three appendices as follows:

Chapter 1- General Information and Safety Precautions

Chapter 2- Operation

Chapter 3- Functional Description

Chapter 4- Scheduled Maintenance

Chapter 5- Troubleshooting

Chapter 6- Corrective Maintenance

Chapter 7- Parts List

Chapter 8- Installation

Appendix A - System Check Procedure

Appendix B- Drawings

Appendix C- Glossary

Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER

CODE 310 TMDERs

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY BLDG 1389

PORT HUENEME, CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting there-from. One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency submittals via the Naval Systems Data Support Activity Web site located at:

https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm i / (ii Blank)

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . 1-1

1-1. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3. EQUIPMENT DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4. SYSTEM COMPONENTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-4.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-4.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-4.3 Anode Assembly (P/N CA9-1A09964-501). . . . . . . . . . . . . . . . . . . . 1-4 1-4.4 Reference Electrode Assembly (P/N CA7-1A09941-501). . . . . . . . . . . . 1-4 1-4.5 Shaft Grounding Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-5. SYSTEM DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-6. EQUIPMENT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2. CONTROLS AND INDICATORS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2.1.1 ON/OFF Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.1.2 Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2.1.3 Overview Screen.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2.1.3.1 Water Jet Overview Screen.. . . . . . . . . . . . . . . 2-3 2-2.1.3.2 Power Supply Unit Overview Box. . . . . . . . . . . 2-4 2-2.1.3.3 Date and Time. . . . . . . . . . . . . . . . . . . . . . 2-4 2-2.1.3.4 Reference Electrode Text Box. . . . . . . . . . . . . . 2-4 2-2.1.3.5 Anode Output Box. . . . . . . . . . . . . . . . . . . . 2-4 2-2.1.3.6 Centralized Controller Overview Box. . . . . . . . . . 2-5

2-2.1.4 Individual Power Supply Unit Screen. . . . . . . . . . . . . . . . . 2-5 2-2.1.4.1 Power Supply Unit View. . . . . . . . . . . . . . . . . 2-5 2-2.1.4.2 Alarm Indicator. . . . . . . . . . . . . . . . . . . . . . 2-5 2-2.1.4.3 Alarm Text. . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-2.1.4.4 Configuration Settings. . . . . . . . . . . . . . . . . . 2-6 2-2.1.4.5 Date and Time. . . . . . . . . . . . . . . . . . . . . . 2-6

2-2.1.5 Centralized Controller Screen.. . . . . . . . . . . . . . . . . . . . . 2-6 2-2.1.5.1 Alarm LED Indicator. . . . . . . . . . . . . . . . . . . 2-6 2-2.1.5.2 Alarm Indicator. . . . . . . . . . . . . . . . . . . . . . 2-6 2-2.1.5.3 Alarm Text. . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-2.1.6 Individual Power Supply Unit Configuration Screen. . . . . . . . . 2-6 2-2.1.6.1 Configuration Description. . . . . . . . . . . . . . . . 2-7 iii

TABLE OF CONTENTS - Continued

2-2.1.6.2 Present Value. . . . . . . . . . . . . . . . . . . . . . . 2-7 2-2.1.6.3 Editing Box. . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-2.1.6.4 Copy Across Button. . . . . . . . . . . . . . . . . . . 2-7 2-2.1.6.5 Write Button.. . . . . . . . . . . . . . . . . . . . . . . 2-7 2-2.1.6.6 Returns to Overview Screen Button. . . . . . . . . . . 2-7

2-2.1.7 System Configuration Screen. . . . . . . . . . . . . . . . . . . . . . 2-8 2-2.1.7.1 System Information. . . . . . . . . . . . . . . . . . . . 2-8 2-2.1.7.2 Power Supply Configuration. . . . . . . . . . . . . . . 2-8 2-2.1.7.3 Reference Configuration. . . . . . . . . . . . . . . . . 2-8 2-2.1.7.4 Log File Configuration. . . . . . . . . . . . . . . . . . 2-9 2-2.1.7.5 Monitor Log File Configuration. . . . . . . . . . . . . 2-9 2-2.1.7.6 Change Time/Date Button. . . . . . . . . . . . . . . . 2-9 2-2.1.7.7 Return To Main Screen Button. . . . . . . . . . . . . 2-9

2-2.1.8 Logging Maintenance Screen. . . . . . . . . . . . . . . . . . . . . . 2-9 2-2.1.8.1 Local Drive (Source). . . . . . . . . . . . . . . . . . . 2-10 2-2.1.8.2 List of Available Alarm or Log Files. . . . . . . . . . 2-10 2-2.1.8.3 USB Drive (Destination). . . . . . . . . . . . . . . . . 2-10 2-2.1.8.4 Location Files Will Be Copied To. . . . . . . . . . . . 2-10

2-2.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-2.2.1 ON-OFF Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-2.2.2 Keypad Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2-2.2.3 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2-2.2.4 LED Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-2.2.5 Power Supply Control Module Display. . . . . . . . . . . . . . . . 2-12

2-2.2.5.1 Mode.. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-2.2.5.2 Demand. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-2.2.5.3 Current Output. . . . . . . . . . . . . . . . . . . . . . 2-13 2-2.2.5.4 Voltage.. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-2.2.5.5 Alarm Text. . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-2.2.5.6 Instruction Text. . . . . . . . . . . . . . . . . . . . . . 2-13 2-2.2.5.7 Reference Electrode Value. . . . . . . . . . . . . . . . 2-13 2-2.2.5.8 Set mV. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-3. SYSTEM OPERATION - STANDBY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-3.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-3.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-4. SYSTEM OPERATION - AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2-4.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-4.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 2-17

2-5. SYSTEM OPERATION - MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 2-5.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2-5.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 2-19

2-6. SYSTEM OPERATION - CONFIGURATION MODE. . . . . . . . . . . . . . . . . . 2-19 2-6.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 iv

2-6.1.1 Individual Power Supply Unit Configurations. . . . . . . . . . . . . 2-19 2-6.1.1.1 Controlling Reference Electrode. . . . . . . . . . . . . 2-21 2-6.1.1.2 Protection Trip. . . . . . . . . . . . . . . . . . . . . . 2-21 2-6.1.1.3 Display Scroll. . . . . . . . . . . . . . . . . . . . . . . 2-21 2-6.1.1.4 Ramp Speed. . . . . . . . . . . . . . . . . . . . . . . . 2-21 2-6.1.1.5 LCD Backlight. . . . . . . . . . . . . . . . . . . . . . 2-22 2-6.1.1.6 Configuration Code. . . . . . . . . . . . . . . . . . . . 2-22 2-6.1.1.7 Under Protection Alarm (Under Protect). . . . . . . . 2-22 2-6.1.1.8 Over Protection Alarm (Over Protect).. . . . . . . . . 2-22 2-6.1.1.9 Current Limit. . . . . . . . . . . . . . . . . . . . . . . 2-23 2-6.1.1.10 Set mV. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2-6.1.1.11 Monitor Protection (Monitor Protect). . . . . . . . . . 2-23

2-6.1.2 Centralized Controller Configuration. . . . . . . . . . . . . . . . . . 2-24 2-6.1.2.1 System Information. . . . . . . . . . . . . . . . . . . . 2-24 2-6.1.2.2 Power Unit Identification.. . . . . . . . . . . . . . . . 2-24 2-6.1.2.3 Reference Configuration. . . . . . . . . . . . . . . . . 2-24 2-6.1.2.4 Log File Configuration. . . . . . . . . . . . . . . . . . 2-25 2-6.1.2.5 Monitor Log File Configuration. . . . . . . . . . . . . 2-25 2-6.1.2.6 Change Time/Date Button. . . . . . . . . . . . . . . . 2-25

2-6.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-6.2.1 Configuration Code. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-6.2.2 Changing Configuration Set Points. . . . . . . . . . . . . . . . . . . 2-26 2-6.2.3 Controller ID.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 2-6.2.4 IP Address (Controller IP). . . . . . . . . . . . . . . . . . . . . . . 2-27 2-6.2.5 Electrode Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 2-6.2.6 Monitor Protection.. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 2-6.2.7 Current Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-6.2.8 Number of Anodes. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-6.2.9 Anode Current Rating. . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-6.2.10 Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-6.2.11 Set mV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-6.2.12 Control Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 2-6.2.13 Under Protection (Under Protect). . . . . . . . . . . . . . . . . . . 2-29 2-6.2.14 Over Protection (Over Protect). . . . . . . . . . . . . . . . . . . . . 2-29 2-6.2.15 Protection Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 2-6.2.16 LCD Backlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 2-6.2.17 Display Scroll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 2-6.2.18 Ramp Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 2-6.2.19 Real Time Clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 2-6.2.20 Exit Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-7. SYSTEM OPERATION - MONITORING. . . . . . . . . . . . . . . . . . . . . . . . . 2-30 2-7.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 v

3-2. PRINCIPAL AND THEORY OF OPERATION. . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.1 Concept of Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.1.1 Galvanic Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.1.2 Cathodic Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2.1.2.1 Sacrifical Anode Cathodic Protection. . . . . . . . . . 3-2 3-2.1.2.2 Impressed Current Cathodic Protection. . . . . . . . . 3-2

3-2.1.3 Optimum Reference Cell Potential. . . . . . . . . . . . . . . . . . . 3-3 3-2.1.4 Polarization Determination. . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. OVERALL SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-3.1 System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-3.2 Automatic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-3.3 Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-4. MAJOR EQUIPMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-4.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-4.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4.2.1 Control PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-4.2.2 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-4.2.3 Main Control PCB.. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-4.2.4 Thyristor PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4.3 Anode Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-4.4 Reference Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-4.5 Propeller Shaft Isolation/Grounding System (SIGS). . . . . . . . . . . . . . . 3-9

4 SCHEDULED MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2. PLANNED MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-3. GENERAL INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-3.1 Cathodic Protection Logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-3.1.1 Monthly Data Download. . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-3.1.1.1 Alarm Logs. . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-3.1.1.2 Period Logs. . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-3.1.1.3 Monitor Logs. . . . . . . . . . . . . . . . . . . . . . . 4-2 4-3.1.1.4 Monitor Decode Utility. . . . . . . . . . . . . . . . . . 4-3

4-3.2 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. POWER SUPPLY UNIT LOCAL ALARMS. . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-2.1 Troubleshooting Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-2.2 Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 vi

5-2.2.1 Controller Initialization Alarms.. . . . . . . . . . . . . . . . . . . . 5-5 5-2.2.1.1 Hardware Alarm. . . . . . . . . . . . . . . . . . . . . 5-5 5-2.2.1.2 PSU Alarm. . . . . . . . . . . . . . . . . . . . . . . . 5-5 5-2.2.1.3 Initialization Alarm. . . . . . . . . . . . . . . . . . . . 5-5 5-2.2.1.4 Module Failure. . . . . . . . . . . . . . . . . . . . . . 5-5

5-2.2.2 Controller Communication Alarms. . . . . . . . . . . . . . . . . . . 5-5 5-2.2.2.1 Network Alarm. . . . . . . . . . . . . . . . . . . . . . 5-5

5-2.2.3 Controller Operational Alarms. . . . . . . . . . . . . . . . . . . . . 5-6 5-2.2.3.1 Output Limited. . . . . . . . . . . . . . . . . . . . . . 5-6 5-2.2.3.2 Voltage Limited. . . . . . . . . . . . . . . . . . . . . . 5-6 5-2.2.3.3 Under Protection Alarm. . . . . . . . . . . . . . . . . 5-6 5-2.2.3.4 Over Protection Alarm. . . . . . . . . . . . . . . . . . 5-7 5-2.2.3.5 Anode X Fail Alarm. . . . . . . . . . . . . . . . . . . 5-7 5-2.2.3.6 Reference X Fail Alarm. . . . . . . . . . . . . . . . . 5-7 5-2.2.3.7 Demand Error Alarm. . . . . . . . . . . . . . . . . . . 5-8 5-2.2.3.8 Overcurrent. . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-2.2.3.9 Monitor Protection. . . . . . . . . . . . . . . . . . . . 5-8

5-2.2.4 Controller Trip Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5-2.2.4.1 Protection Trip Alarm.. . . . . . . . . . . . . . . . . . 5-9 5-2.2.4.2 Temperature Trip Alarm. . . . . . . . . . . . . . . . . 5-9

5-3. CENTRALIZED CONTROLLER LOCAL ALARMS. . . . . . . . . . . . . . . . . . . 5-10 5-3.1 Troubleshooting Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5-3.2 Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-3.2.1 Initialization Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5-3.2.1.1 Power Alarm. . . . . . . . . . . . . . . . . . . . . . . 5-13 5-3.2.1.2 Watchdog Alarm. . . . . . . . . . . . . . . . . . . . . 5-13

5-3.2.2 Network Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5-3.2.3 Centralized Controller Operational Alarms. . . . . . . . . . . . . . 5-13 5-3.2.4 General Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-4. POWER SUPPLY UNIT DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5-4.1 Failure of the System to Switch On. . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-4.1.1 Power ON Fault Check List. . . . . . . . . . . . . . . . . . . . . . 5-14 5-4.2 AC Power Supply Fuse Checks.. . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5-4.3 AC Power Supply Checks.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. GENERAL REPAIR INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2.1 Replacement of Power Supply Components. . . . . . . . . . . . . . . . . . . . 6-1

6-2.1.1 Replacement of Control Module. . . . . . . . . . . . . . . . . . . . 6-1 6-2.1.2 Replacement of 20 Amp 24 Volt Transformer. . . . . . . . . . . . . 6-3 6-2.1.3 Replacing the 20 Amp Inductor. . . . . . . . . . . . . . . . . . . . 6-4 6-2.1.4 Replace 20 Amp Thyristors. . . . . . . . . . . . . . . . . . . . . . . 6-4 vii

6-2.1.5 Replace Thyristor Fan. . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-2.1.6 Replace Thyristor Trigger Module. . . . . . . . . . . . . . . . . . . 6-6 6-2.1.7 Replace Control Transformer. . . . . . . . . . . . . . . . . . . . . . 6-6 6-2.1.8 Replace Isolator On/Off Switch. . . . . . . . . . . . . . . . . . . . 6-7 6-2.1.9 Replace WSI6/2 Fuse Holder. . . . . . . . . . . . . . . . . . . . . . 6-8 6-2.1.10 Replace CXFU015 2 Amp Fuse and CXFU016 10 Amp Fuse.. . . 6-9 6-2.1.11 Replace CMS101 Fuse Holder. . . . . . . . . . . . . . . . . . . . . 6-10 6-2.1.12 Replace CXFU056 20 Amp Fuse . . . . . . . . . . . . . . . . . . . 6-11 6-2.1.13 Replace WPE6 and EW35 Terminals. . . . . . . . . . . . . . . . . 6-11 6-2.1.14 Replace WDU6 Terminals. . . . . . . . . . . . . . . . . . . . . . . 6-12 6-2.1.15 Replace the 20 Amp Shunt. . . . . . . . . . . . . . . . . . . . . . . 6-13 6-2.1.16 Replace the Air Vent Grill. . . . . . . . . . . . . . . . . . . . . . . 6-14

6-2.2 Replacement of Centralized Control Unit Components. . . . . . . . . . . . . . 6-15 6-2.2.1 Replace Mini ITX Motherboard. . . . . . . . . . . . . . . . . . . . 6-15 6-2.2.2 Replace the LAN Extension Card. . . . . . . . . . . . . . . . . . . 6-16 6-2.2.3 Replace 15” XGA Display. . . . . . . . . . . . . . . . . . . . . . . 6-17 6-2.2.4 Replace the Keyboard. . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 6-2.2.5 Replace the Interface PCB. . . . . . . . . . . . . . . . . . . . . . . 6-18 6-2.2.6 Replace The Power Supply Unit. . . . . . . . . . . . . . . . . . . . 6-19 6-2.2.7 Replace the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 6-2.2.8 Replace the Molex Ethernet Connector. . . . . . . . . . . . . . . . 6-21 6-2.2.9 Replace the Molex USB Connector. . . . . . . . . . . . . . . . . . 6-21

7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. PARTS LIST EXPLANATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.1 Description Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.2 Quantity Per Assembly Column. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.3 Contractor and Government Entity Code Column.. . . . . . . . . . . . . . . . 7-1 7-2.4 Part or Drawing Number Column. . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2. INSTALLATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-2.1 Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-2.2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2.2.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-2.2.2 Transformer Rectifier Power Supply. . . . . . . . . . . . . . . . . . 8-1 8-2.2.3 Anode Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-2.2.4 Reference Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-2.2.5 Shaft Grounding Assembly. . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2.3 Unpacking and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 viii

8-3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8-3.1 Centralized Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8-3.2 Power Supply Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-4. CABLE SIZES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-5. EQUIPMENT CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

APPENDIX A SYSTEM CHECK PROCEDURE: IMPRESSED CURRENT CATHODIC

PROTECTION (ICCP) DEMONSTRATION . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

APPENDIX C GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 ix

LIST OF TABLES

Table Title Page

1-1 Equipment Supplied for LCS 2 Class Ships. . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2-1 Controlling Reference Electrode Values . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-2 Reference Cell Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-3 Power Supply Unit Controller ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

3-1 Power Supply Unit Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

5-1 Troubleshooting Chart - Power Supply Controller Initialization Alarms . . . . . . . . 5-2

5-2 Troubleshooting Chart - Power Supply Communication Alarms. . . . . . . . . . . . . 5-2

5-3 Troubleshooting Chart - Power Supply Operational Alarms . . . . . . . . . . . . . . . 5-2

5-4 Troubleshooting Chart - Power Supply Trip Alarms . . . . . . . . . . . . . . . . . . . 5-4

5-5 Troubleshooting Chart - Centralized Controller General Alarms. . . . . . . . . . . . . 5-10

5-6 Troubleshooting Chart - Centralized Controller Initialization Alarms . . . . . . . . . . 5-10

5-7 Troubleshooting Chart - Centralized Controller Communication Alarms . . . . . . . . 5-11

5-8 Troubleshooting Chart - Centralized Controller Operational Alarms . . . . . . . . . . 5-12

5-9 Troubleshooting Chart - Centralized Controller Trip Alarms. . . . . . . . . . . . . . . 5-13

5-10 Power Supply Unit Input Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

7-1 System Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 Centralized Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3 Transformer Rectifier Power Supply Control Panel . . . . . . . . . . . . . . . . . . . . 7-2

7-4 Anode Assembly, Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-5 Reference Electrode, Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-6 Shaft Grounding Relay, Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-7 List of Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

8-1 Maximum Length of Anode Cable (Feet) . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-1A Maximum Length of Anode Cable (Feet) . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 x

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Impressed Current Cathodic Protection System, LCS 2 Class (Relationship of Units). 1-2

2-1 Centralized Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Indication LED Lights on Centralized Controller . . . . . . . . . . . . . . . . . . . . . 2-2

2-3 Centralized Controller Overview Screen. . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-4 Water Jet Overview Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-5 Individual Power Supply Unit Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-6 Centralized Controller Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-7 Individual Power Supply Unit Configuration Screen . . . . . . . . . . . . . . . . . . . 2-7

2-8 System Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-9 Logging Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-10 Transformer Rectifier Power Supply - Main ON/OFF Switch . . . . . . . . . . . . . . 2-11

2-11 Transformer Rectifier Power Supply - Control Module ON/OFF Switch . . . . . . . . 2-11

2-12 Power Supply Control Module Display . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-13 Standby Mode Selection of Individual Power Supply Unit through Centralized Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-14 Automatic Mode Selection of Individual Power Supply Unit from Centralized Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-15 Manual Mode Selection of Individual Power Supply Unit from Centralized Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-16 System Information Box in System Configuration Screen . . . . . . . . . . . . . . . . 2-24

2-17 Power Unit Identification Text Box in System Configuration Screen . . . . . . . . . . 2-24

3-1 Galvanic Series (Seawater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Impressed Current Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-3 Protection Levels for Aluminum versus Silver/Silver Chloride Reference Electrode. . 3-4

3-4 LCS 2 Class System Block Diagram (LCS 2 Only) . . . . . . . . . . . . . . . . . . . 3-5

3-4A LCS 2 Class System Block Diagram (LCS 4 and Follow) . . . . . . . . . . . . . . . . 3-6

3-5 Impressed Current Cathodic Protection System Control Loop . . . . . . . . . . . . . . 3-7

4-1 Log File Configuration Section of System Configuration Screen . . . . . . . . . . . . 4-2 xi

LIST OF ILLUSTRATIONS - Continued

4-2 Monitor Interval Section of System Configuration Screen . . . . . . . . . . . . . . . . 4-3

4-3 Alarm Log Decode Utility Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5-1 Power Supply Unit Mains Input Terminals and Fuse Holders . . . . . . . . . . . . . . 5-16

5-2 Power Supply Unit Control Transformer and Output Fuse Holders . . . . . . . . . . . 5-16

5-3 Power Supply Unit - Control Transformer. . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-4 Power Supply Unit - Trigger Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-5 Power Supply Unit - Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

6-1 Controller Input Terminals and Perspex Screen Fixing Points . . . . . . . . . . . . . . 6-2

6-2 Controller Fixing Screw Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Power Supply Components - Transformer Connections . . . . . . . . . . . . . . . . . 6-3

6-4 Power Supply Components - Transformer Mountings . . . . . . . . . . . . . . . . . . 6-4

6-5 Power Supply Components - Thyristor Stack . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-6 Power Supply Components - Thyristor Fan . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-7 Power Supply Components - Thyristor Trigger Module . . . . . . . . . . . . . . . . . 6-6

6-8 Power Supply Components - Control Transformer . . . . . . . . . . . . . . . . . . . . 6-7

6-9 Power Supply Component - Isolator ON/OFF Switch . . . . . . . . . . . . . . . . . . 6-8

6-10 Power Supply Component - Isolator ON/OFF External Arrangement . . . . . . . . . . 6-8

6-11 Power Supply Components - WSI6/2 Fuse Holder . . . . . . . . . . . . . . . . . . . . 6-9

6-12 Power Supply Components - WSI6/2 Fuse Carrier . . . . . . . . . . . . . . . . . . . . 6-10

6-13 Power Supply Components - RT18-63 Fuse Holder . . . . . . . . . . . . . . . . . . . 6-10

6-14 Power Supply Components - CMS101 Fuse Carrier . . . . . . . . . . . . . . . . . . . 6-11

6-15 Power Supply Components - WPE6/EW35 Terminals . . . . . . . . . . . . . . . . . . 6-12

6-16 Power Supply Components - WDU6 Terminals . . . . . . . . . . . . . . . . . . . . . . 6-13

6-17 Power Supply Components - 20 Amp Shunt . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-18 Power Supply Components - Fan Louvre . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-19 Power Supply Components - Fan Grill Fixing Points . . . . . . . . . . . . . . . . . . 6-15 xii

LIST OF ILLUSTRATIONS - Continued

6-20 Centralized Control Unit Component - Mini ITX Motherboard . . . . . . . . . . . . . 6-16

6-21 Centralized Control Unit Component - LAN Extension Card . . . . . . . . . . . . . . 6-16

6-22 Centralized Control Unit Component - 15” XGA Monitor . . . . . . . . . . . . . . . . 6-17

6-23 Keyboard Cable Routing within Centralized Control Unit . . . . . . . . . . . . . . . . 6-18

6-24 Keyboard Fixings within Centralized Control Unit . . . . . . . . . . . . . . . . . . . . 6-18

6-25 Centralized Control Unit Components - Interface PCB Fixing Screws . . . . . . . . . 6-19

6-26 Power Supply Unit within Centralized Control Unit . . . . . . . . . . . . . . . . . . . 6-20

6-27 Centralized Control Unit Components - Rear Mounting Plate Fixings . . . . . . . . . 6-21

8-1 Installation Drawing, ICCP System LCS 2 Class . . . . . . . . . . . . . . . . . . . . . 8-3

8-1A Installation Drawing, Relay Enclosure (LCS 2 Only) . . . . . . . . . . . . . . . . . . 8-4

8-1B Installation Drawing, Relay Enclosure (LCS 4 and Follow) . . . . . . . . . . . . . . . 8-5 xiii / (xiv Blank) xiv

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the general or spe-cific safety precautions, the commanding officer or other authority will issue orders as deemed necessary to cover the situation. No work shall be undertaken on energized equipment or circuits until approval of the commanding officer is obtained, and then only in accordance with Naval Ships’ Technical Manual (NSTM) S9086-KC-STM- 010/Chapter 300.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances shall repair or adjustment of energized equipment be attempted alone. The imme-diate presence of someone capable of rendering first aid is required. Before making adjustments, be sure to pro-tect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to attempting repairs. Equipment should be deenergized and properly tagged out according to the ship’s Standard Operating Procedures.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a metal-cased test meter must be held, ground the case of the meter before starting measurement. Do not touch live equipment or personnel working on live equipment while holding a test meter. Do not ground any measuring devices; these devices should not be held when taking measurements.

INTERLOCKS-SAFETY DEVICES

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended. Never tamper with or render ineffective any safety device, interlock, ground strap or similar device intended to protect operators or the equipment without specific approval of the Commanding Officer. Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at the distribution source..

MOVING EQUIPMENT

Personnel shall remain clear of moving equipment. If equipment requires adjustment while in motion, a safety watch shall be posted. The safety watch shall be qualified to administer CPR, have a full view of the operations being performed, and have immediate access to controls capable of stopping equipment motion.

FIRST AID

An injury, no matter how slight, shall never go unattended. Always obtain first aid or medical attention immediately, and file an injury report in accordance with OPNAVINST 5102.1 series, subj: Mishap Investigation and Reporting.

xv

SAFETY SUMMARY - Continued

RESUSCITATION

Personnel working with or near high voltage shall be familiar with approved methods of resuscitation.

Should someone be injured and stop breathing, begin resuscitation immediately. A delay could cost the victim’s life. Resuscitation procedures shall be posted in all electrically hazardous areas.

GENERAL PRECAUTIONS

The following general precautions are to be observed at all times.

1. Install and ground all electrical components associated with this system/equipment in accordance with applicable Navy regulations and approved shipboard practices.

2. Ensure that all maintenance operations comply with Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 series.

3. Observe precautions set forth in NSTM S9086-KC-STM-010/Chapter 300 with respect to electrical equipment and circuits.

4. Ensure that protective guards and shutdown devices are properly installed and maintained around rotating parts of machinery and high voltage sources.

5. Do not wear loose clothing while working around rotating parts of machinery.

6. Ensure that special precautionary measures are employed to prevent applying power to the system/ equipment any time maintenance work is in progress.

7. Do not make any unauthorized alterations to equipment or components.

8. Before working on electrical system/equipment, use the correct tag out procedure and check with voltmeter to ensure that system is not energized.

9. Consider all circuits not known to be″dead,″ ″ live″ and dangerous at all times.

10. When working near electricity, do not use metal rules, flashlights, metallic pencils, or any other objects having exposed conducting material.

11. Deenergize all equipment before connecting or disconnecting meters or test leads.

12. When connecting a meter to terminals for measurement, use range higher than expected voltage.

13. Before operating equipment or performing any tests or measurements, ensure area is dry of water or other liquid conductive material and that frames of all motors and starter panels are securely grounded.

14. Ensure that area is well-ventilated when using cleaning compound or solvent. Avoid prolonged breathing of fumes and compound or solvent contact with skin or eyes.

xvi

SAFETY SUMMARY - Continued

WARNINGS AND CAUTIONS

Specific warnings and cautions applying to the system/equipment covered by this manual are summarized below. These warnings and cautions appear elsewhere in the manual following paragraph headings and immedi-ately preceding the text to which they apply. They are repeated here for emphasis.

Warnings pertain to an operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in injury to or death of personnel.

Page 1-1

Live 115 VAC is present within the transformer rectifier unit. Internal measure-ments should be carried out by qualified personnel only.

Pages 2-13, 2-15

Ensure the AC power supply is isolated at the switchboard prior to entering the power supply unit. 115 VAC will be present within the power supply unit unless isolated at the switchboard. Local isolation at the unit is not sufficient.

Pages 5-8, 5-15

Observe vessel procedures for working on live equipment. Ensure clear and safe access is available and all non essential personnel are cleared from the area of the power supply unit power to energizing.

Page 5-17 xvii

Listen if the fan is running or feel for airflow on the outlet grill on the outside of the power supply cabinet. Do not place fingers in the fan.

Page 5-18

Ensure the AC power supply is isolated at the switchboard prior to entering the power supply unit. 115 VAC will be present with the power supply unit unless isolated at the switchboard. Local isolation at the unit is not sufficient.

Pages 5-18, 5-19, 5-19, 5-19

Ensure the AC power supply is isolated at the main switchboard prior to enter-ing the power supply unit. 115 VAC will be present within the power supply unit unless isolated at the switchboard. Local isolation at the unit is not sufficient.

Page 6-1

Ensure the AC power supply is isolated at the switchboard prior to entering the centralized control unit. 115 VAC will be present within the power supply unit unless isolated at the switchboard. Local isolation at the unit is not sufficient.

Page 6-15

Cautions refer to an operation or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in damage to or destruction of equipment or loss of mission effectiveness.

Page 1-1 xviii

Misuse of this screen and the use of out of range variables can cause failure of the transformer rectifier unit. If any doubt as to the use of this screen, contact NSWC via the log inbox email ICCP_Log.NSWCCD@navy.mil.

Page 2-20

Only set to the values listed above. Any other value can cause damage to the power supply unit controller.

Pages 2-21, 2-22

Only set to the values listed in the range above. Any other values can cause damage to the power supply unit controller.

Pages 2-21, 2-22, 2-22, 2-23, 2-23, 2-23, 2-24, 2-25

The reference cell value(s) must not exceed -1200 mV as over protection which is potentially damaging to the aluminum water jet would be possible at values above this

Page 2-23

Higher values (more negative) will allow over protection conditions to occur which is potentially dangerous to the aluminium hull.

Page 2-28 xix

The value must be set per the default of 20 Amps. Alteration of this value can cause damage to the Control panel.

Page 2-28

Only use the correct size fuses and authorized spare parts. Incorrect fuse sizing can cause damage to the power supply units and effects electrical safety.

Page 5-15

Follow the tag numbers applied when the controller was removed. Use the sche-matic wiring diagrams if unsure. Always re-check the connections. Incorrect connections can cause irrepairable damage to the controller.

Page 6-2

Follow the tag numbers applied when the controller was removed. Use the sche-matic wiring diagrams if unsure. Always re-check the connections. Incorrect connections can cause irreparable damage to the controller.

Pages 6-3, 6-4, 6-4, 6-5, 6-6, 6-6, 6-7, 6-9, 6-10, 6-11, 6-12, 6-13, 6-15, 6-16, 6-19, 6-19, 6-20

Ensure the replacement shunt is rated for the same amperage as the shunt being removed. If the rating on the shunt is not the same it can negatively affect the system.

Pages 6-9, 6-11, 6-13 xx

CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. SAFETY PRECAUTIONS.

The Impressed Current Cathodic Protection (ICCP) system requires the use of dangerous electrical potentials which may exist when the power control is in either the ON or OFF position. All personnel operating or servic-ing this equipment should familiarize themselves with the precedingSafety Summarywhich provides additional information about warning and cautions. The following definitions are provided:

Warnings pertain to an operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in injury to or death of personnel.

Cautions refer to an operation or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in damage to or destruction of equipment or loss of mission effectiveness.

Notes pertain to an essential operations or maintenance procedure, precondition, or statement, which must be highlighted. Notes are included that are essential to the operation and maintenance of the equipment but constitute neither warnings nor cautions.

1-2. INTRODUCTION.

The purpose of this manual is to provide the technical information needed for the maintenance and the operation of Impressed Current Cathodic Protection (ICCP) Systems in general and, specifically, the ICCP sys-tem used onboard LCS 2 Class ships. This manual does not include design guidance for ICCP systems (see Naval Ships’ Technical Manual S9086-VF-STM-010, Chapter 633, Cathodic Protection, for system design information).

The manual does include a brief technical discussion of electrochemical theory pertaining to corrosion and how this theory applies to the ICCP system. This information is included to provide an understanding of how the sys-tem functions leading to more efficient use of the system by the operators and to simplify the location and cor-rection of system malfunctions. The manual includes detailed information on each unit comprising the ICCP sys-tem and how the units interrelate (Figure 1-1). Installation and maintenance information is also included.

1-1

This technical manual is in effect upon receipt. Extracts from this publication may be made to facilitate preparation of other Department of Defense publications. The information included in this manual is in accor-dance with military specifications MIL-M-24784/12 and Naval Ships’ Technical Manual S9086-VF-STM-010, Chapter 633, Cathodic Protection.

Navy practice is to provide impressed current systems for ships’ underwater hull protection where the demand for cathodic protection current is large and variable. Where velocity effects or similar factors that cause chang-ing electrical current requirements are not present, as in the interior of a tank, sacrificial anodes may be used.

Such practices will not be discussed in detail in this manual (see “Naval Ships’ Technical Manual S9086-VF- STM-010, Chapter 633, Cathodic Protection”).

Assistance with the operation and maintenance of cathodic protection system can be provided by Naval Technical Support Center Atlantic, NTSCLANT; and Naval Technical Support Center Pacific, NTSCPAC; and Naval Surface Warfare Center, Carderock Division, NSWCCD Code 614; and Naval Sea Systems Command, Code 05P2. Address problems with the cathodic protection systems aboard ship to their attention.

1-3. EQUIPMENT DESCRIPTION.

Corrosion, for the purposes of discussing the ICCP system, is an electrochemical process. For this electro-chemical process to occur, areas of unequal electrical potential are electrically connected and submerged in an electrolyte (e.g. seawater). These electrical connections are often inherent in the structure of the material, such as

Figure 1-1 Impressed Current Cathodic Protection System, LCS 2 Class (Relationship of Units)

1-2 localized areas containing metallurgical variations in the steel comprising the hull. They often inadvertently occur as constructional features, like a bronze propeller adjacent to the ship’s hull. These differences in electrical potential comprise a galvanic couple. This generates an electric current through the water and the electrical con-nection between the two areas. This causes simultaneous dissolution of the steel hull. The entire process is com-monly termed corrosion. The ICCP system nullifies or minimizes this corrosion by deliberately supplying an electric current (conventional DC) into the ship’s hull via a chemically inert electrode immersed in the adjacent water. The magnitude of this current is automatically controlled by signals from reference electrodes through a controller to provide optimum protection for the ship’s hull. It should be understood that the ICCP system is designed to supplement the corrosion protection provided by the underwater hull paint system, and it is not designed to protect a bare hull or one with excess bare metal exposed by paint damage of wear, nor is it designed to remove corrosion products, such as rust. It merely minimizes corrosion while the hull is afloat, thereby help-ing the hull plates remain smooth assuring maximum speed throughout the life of the ship and minimum fuel consumption at all speeds. Dry dock frequencies are decreased along with reduced time and cost of repair because repainting is easier on a clean hull.

There are two types of cathodic protection systems used on LCS 2 Class ships. The ICCP system is used to protect the water jet inlet tunnels. A sacrificial anode system is used to protect the underwater hull and append-ages. The sacrificial system is based on the principle that when a more reactive metal is installed near a less reac-tive metal submerged in an electrolyte such as seawater, the more reactive metal will generate a potential of a sufficient magnitude to protect the less reactive metal. In this process, the more reactive metal is sacrificed. Sac-rificial anodes attached to a ship’s hull slowly oxidize and generate current that protects the hull and appendages.

1-4. SYSTEM COMPONENTS.

The water jet inlet tunnel ICCP system for LCS 2 Class ships is comprised of eight reference cells (four con-trolling and four monitoring), one centralized control unit, four transformer rectifier power supplies, four ellipti-cal anodes, four dielectric shields, and four propeller shaft grounding assemblies. The system is designed to oper-ate continuously and fully automatically. The power supplies and anodes are used in multiple numbers to produce the current capacity and current distribution necessary to achieve these objectives. The system is completely self-contained and does not require any input from other shipboard equipment.

The ICCP system described in this manual is shown inFigure 1-1. The system is designed to provide cathodic protection while the ship is in seawater or brackish water under all operating conditions. It will not provide full cathodic protection to the hull in fresh water under all conditions of speed and paint loss because of the low con-ductivity of fresh water. The system will not provide cathodic protection to the sea chests and internal seawater circulation pipes of the ship, nor will the systems reduce the fouling on the hull, except in the immediate vicin-ity of an anode. Cathodic protection will minimize the corrosion which undercuts paint. This system only pro-tects water jet inlet tunnel surfaces.

1-4.1 Centralized Controller. The centralized controller continuously monitors and records the level of protec-tion of all four water jet inlet tunnel surfaces and sends a signal to the four power supply units to adjust the amount of anode current to maintain the specified level of protection.