ECS Manual

Date Doc. No. Ver.
2012-12-18 1.0
Written by Reviewed by Approved by QC
Title Doc. Type

BALLAST WATER MANAGEMENT SYSTEM Technical Document
BALLAST WATER MANAGEMENT SYSTEM
MODEL : Electro-CleenTM System
Techcross
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Date Doc. No. Ver.
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Title Doc. Type

Table of Contents
1. General ......................................................................................................... 12
1.1. General Specifications of Electro Cleen System (ECS)Revision History ........................ 12
1.2. Operation Range of Electro Cleen System (ECS) ........................................................... 12
1.3. Introduction of ECS Equipments ...................................................................................... 13
2. ECS Equipments ............................................................................................. 14
2.1. Electro-Chamber Unit (ECU) ........................................................................................... 14
2.1.1. Non ex proof ECU-300A ....................................................................................... 14
2.1.2. Ex proof ECU-300A ............................................................................................... 15
2.1.3. Non ex proof ECU-600A ....................................................................................... 16
2.1.4. Ex proof ECU-600A ............................................................................................... 17
2.1.5. Non ex proof ECU-1000A ..................................................................................... 18
2.1.6. Non ex proof ECU-150B ....................................................................................... 19
2.1.7. Ex proof ECU-150B ............................................................................................... 20
2.1.8. Non ex proof ECU-300B ....................................................................................... 21
2.1.9. Ex proof ECU-300B ............................................................................................... 22
2.1.10. Non ex proof ECU-450B ....................................................................................... 23
2.1.11. Ex proof ECU-450B ............................................................................................... 24
2.1.12. Non ex proof ECU-600B ....................................................................................... 25
2.1.13. Ex proof ECU-600B ............................................................................................... 26
2.1.14. Non ex proof ECU-1000B ..................................................................................... 27
2.1.15. Ex proof ECU-1000B ............................................................................................. 28
2.2. Power Rectifier Equipment(PRE) ..................................................................................... 29
2.3. Power Rectifier Unit(PRU) ............................................................................................... 30
2.3.1. PRU ....................................................................................................................... 30
2.3.2. Ex proof PRU ........................................................................................................ 31
2.4. Power Control Unit (PCU) ................................................................................................ 31
2.5. Power Distributor Equipment (PDE-A2) ........................................................................... 32
2.6. Power Distributor Equipment(PDE-A4) ............................................................................ 33
2.7. Power Distributor Equipment(PDE) ................................................................................. 34
2.8. Control PC (CPC) ............................................................................................................. 35
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2.9. TRO Sensor Unit (TSU) ................................................................................................... 36

2.9.1. Non ex proof TSU.................................................................................................. 36
2.9.2. Ex proof TSU ......................................................................................................... 37
2.9.2.1. CLX sensor .................................................................... 37
2.9.2.2. Control Panel ................................................................. 38
2.9.2.3. Ex proof solenoid valve (S.V) ............................................ 39
2.10. Auto Neutralization Unit (ANU) ........................................................................................ 40
2.10.1. Non ex proof ANU-5T ............................................................................................ 40
2.10.2. Non ex proof ANU-10T .......................................................................................... 41
2.11. Flow Meter Unit(FMU) ...................................................................................................... 42
2.11.1. Non ex proof FMU ................................................................................................. 42
2.11.2. Ex proof FMU ........................................................................................................ 43
2.12. Conductivity Sensor Unit(CSU) ........................................................................................ 44
2.12.1. Non ex proof CSU ................................................................................................. 44
2.12.2. Ex proof CSU ........................................................................................................ 45
2.12.2.1. Sensor (Probe) ............................................................... 45
2.12.2.2. Transmitter ..................................................................... 46
2.13. Freshwater / Seawater Temperature Sensor (FTS/STS) ................................................. 47
2.13.1. Non ex proof FTS/STS .......................................................................................... 47
2.13.2. Ex proof FTS/STS ................................................................................................. 48
2.14. Vibration Level Sensor (VLS) ........................................................................................... 49
2.15. Gas Dector Sensor (GDS) ............................................................................................... 50
2.16. Ex proof Freshwater pump - option .................................................................................. 51
2.17. Heat Exchanger Unit (HEU) – option ............................................................................... 52
2.18. Freshwater Tank Unit (FTU) – option ............................................................................... 53
3. ECS Operation ............................................................................................... 54
3.1. Preparation for Operation................................................................................................. 54
3.2. Operation Overview ......................................................................................................... 60
3.2.1. Normal Treatment Operation................................................................................. 60
3.2.1.1. Ballasting ....................................................................... 60
3.2.1.2. Deballasting ................................................................... 62
3.2.2. Algorithm of Treated Ballast Water Discharge ...................................................... 63
3.2.3. System Monitoring Equipment .............................................................................. 64
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3.2.3.1. System Self-Check ......................................................... 64

3.2.3.2. Brief Diagram of Monitoring Equipment .............................. 64
3.3. ECS Operation ................................................................................................................. 66
3.3.1. HMI Screen Overview ........................................................................................... 66
3.3.2. Automatic Operation ............................................................................................. 68
3.3.3. Manual Operation .................................................................................................. 73
3.3.4. Setting and Checking ECS .................................................................................... 76
3.3.5. Reading operation signs of HMI ............................................................................ 83
3.3.6. Stopping ECS Operation ....................................................................................... 91
3.4. Emergency Operation ...................................................................................................... 95
3.4.1. Emergency Ballasting ........................................................................................... 95
3.4.2. Operation Procedure of Emergency Ballasting ..................................................... 95
3.4.3. Emergency Deballasting ....................................................................................... 99
3.4.4. Operation Procedure of Emergency Deballasting ................................................. 99
3.5. After power outage during ballasting ............................................................................. 103
3.6. Operation in low salinity water ....................................................................................... 103
3.7. Maintenance procedures and procedures for discharge of untreated water in the
event of malfunction of BWMS ............................................................................................... 104
3.7.1. Vessel with dual ballast pump operation ............................................................. 104
3.7.2. Partial malfunction of electrolysis module ........................................................... 104
3.7.3. If repairs and replacement are possible during voyage or inflow of ballast water104
3.7.4. Discharge procedures for untreated ballast water because of malfunction ........ 104
3.7.5. Emergency measures for securing safety of vessel ........................................... 104
3.7.6. Emergency measures for structural defects ....................................................... 104
3.7.7. Emergency measure for electric defects ............................................................. 105
3.7.8. Proper information for error detection ................................................................. 105
3.7.9. System Self-Test ................................................................................................. 105
4. TECHNICAL INSTALLATION .......................................................................... 107
4.1. Electro-Chamber Unit (ECU) ......................................................................................... 107
4.1.1. Non ex proof ECU ............................................................................................... 107
4.1.2. Ex proof ECU ...................................................................................................... 107
4.1.2.1. Horizontal Installation .................................................... 108
4.1.2.2. Vertical Installation ........................................................ 110
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4.2. Power Rectifier Equipment (PRE) ...................................................................................113

4.3. Power Rectifier Unit (PRU) .............................................................................................114
4.3.1. Ex proof PRU .......................................................................................................114
4.4. Power Control Unit (PCU) / Power Distributor Equipment (PDE-A2 / PDE-A4/PDE) .....117
4.5. TRO Sensor Unit (TSU) ..................................................................................................118
4.5.1. Ex proof TSU ........................................................................................................119
4.5.1.1. CLX Sensor .................................................................. 119
4.6. Auto Neutralization Unit (ANU) ...................................................................................... 120
4.7. Flow Meter Unit(FMU) .................................................................................................... 121
4.8. Conductivity Sensor Unit (CSU) ..................................................................................... 122
4.8.1. Non ex proof CSU ............................................................................................... 122
4.8.2. Ex proof CSU ...................................................................................................... 123
4.8.2.1. Sensor......................................................................... 123
4.8.2.2. Transmitter ................................................................... 125
4.9. Vibration Level Sensor (VLS) & Ex proof Vibration Level Sensor ................................. 128
4.10. Ex proof Gas Dector Sensor (GDS) ............................................................................... 131
4.11. Ex proof Freshwater Pump – Option .............................................................................. 139
5. System Limitations ........................................................................................ 140
5.1. Limitations of Installation ................................................................................................ 140
5.2. Range of ECS Flow Capacity ........................................................................................ 141
5.2.1. ECS-150B ........................................................................................................... 141
5.2.2. ECS-300A/B ........................................................................................................ 141
5.2.3. ECS-450B ........................................................................................................... 141
5.2.4. ECS-600A/B ........................................................................................................ 141
5.2.5. ECS-1000A/B ...................................................................................................... 142
5.3. Characteristics of installation location, system arrangement information, relation with
ballast water management plan .............................................................................................. 143
6. Routine maintenance and trouble-shooting procedures ..................................... 144
6.1. General information........................................................................................................ 144
6.1.1. Purpose ............................................................................................................... 144
6.1.2. Application ........................................................................................................... 144
6.1.3. Inspection/Maintenance Cycle and Allowance Criterion ..................................... 144
6.1.4. Procedure of PMS ............................................................................................... 145
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6.1.5. Report and Management of Defect ..................................................................... 145

6.1.6. Check out the Execution of Planned Maintenance ............................................. 145
6.1.7. Maintenance Schedule Sheet ............................................................................. 146
6.1.8. Equipment History Card ...................................................................................... 147
6.2. Routine maintenance of Equipments ............................................................................. 148
6.2.1. Electro-chamber Unit (ECU) ............................................................................... 148
6.2.2. Power Rectifier Equipment (PRE) ....................................................................... 149
6.2.3. Power Distributor Equipment (PDE).................................................................... 150
6.2.4. Control PC (CPC) ................................................................................................ 151
6.2.5. Tro Sensor Unit (TSU)......................................................................................... 152
6.2.6. Auto Neutralization Unit (ANU) ........................................................................... 153
6.2.7. Local Operation Panel (LOP) .............................................................................. 154
6.2.8. Flow meter unit (FMU) ........................................................................................ 155
6.2.9. Conductivity Sensor Unit (CSU) .......................................................................... 156
6.2.10. Freshwater / Seawater Temperature Sensor (STS / FTS) .................................. 157
6.2.11. Gas Dector Sensor(GDS) ................................................................................... 158
6.3. TROUBLE SHOOTING .................................................................................................. 159
6.3.1. Major ECS Component ....................................................................................... 160
6.3.1.1. Power Rectifier Equipment (PRE) .................................... 160
6.3.1.2. Power Distributor Equipment (PDE) ................................. 161
6.3.1.3. Control PC (CPC) .......................................................... 162
6.3.1.4. TRO Sensor Unit (TSU) .................................................. 163
6.3.1.5. Auto Neutralization Unit (ANU) ........................................ 164
6.3.1.6. Vibration Level Sensor (VLS) & Ex proof Vibration Level Sensor
165
6.3.1.7. Gas Dector Sensor(GDS) ............................................... 166
6.4. Alarm Log ....................................................................................................................... 167
6.5. Error message ................................................................................................................ 168
6.6. Fault message ................................................................................................................ 173
6.7. Detailed Emergency Actions for Discharging Untreated Water and Repairing, and
Ship Safety in case of System Malfunction ............................................................................ 175
6.7.1. How to Discharge Untreated Water due to BWMS Malfunction.......................... 175
6.7.1.1. In Case of Electrolytic Disinfection Module Malfunction ...... 175
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6.7.1.2. Procedure for Untreated Ballast Water Discharge due to

System Error 175
6.7.2. Emergency Action for Ship Safety....................................................................... 175
6.7.2.1. Emergency Action in case of System Defect or Leakage .... 175
6.7.2.2. Emergency Action in case of Electrical Defect .................. 176
6.8. Log Viewer ..................................................................................................................... 177
7. Monitoring System and Electrical/Electronic Wiring Diagrams ............................. 185
7.1. Monitoring System ......................................................................................................... 185
7.1.1. Basic flow chart ................................................................................................... 185
7.1.2. Ballasting flow chart ............................................................................................ 186
7.1.3. Deballasting flow chart ........................................................................................ 187
7.1.4. Stripping flow chart .............................................................................................. 188
7.2. Electrical/Electronic Wiring Diagrams ............................................................................ 189
7.2.1. ECS Equipments ................................................................................................. 189
7.2.1.1. Power Rectifier Unit (PRU) ............................................. 189
7.2.1.2. Power Control Unit (PCU) ............................................... 190
7.2.1.3. Power Distributor Equipment (PDE-A2) ............................ 199
7.2.1.4. Power Distributor Equipment (PDE-A4) ............................ 205
7.2.1.5. Power Distributor Equipment (PDE) ................................. 213
7.2.1.6. Control PC (CPC) .......................................................... 234
7.2.1.7. TRO Sensor Unit (TSU) .................................................. 235
7.2.1.8. Auto Neutralization Unit (ANU) ........................................ 237
8. Calibraion .................................................................................................... 240
8.1. TRO Sensor ................................................................................................................... 240
8.2. Conductivity Sensor Unit (CSU) ..................................................................................... 241
8.3. Gas Dector Sensor (GDS) ............................................................................................. 243
9. Shop Testing and Onboard Testing Documentation ........................................... 244
9.1. Shop Test Document ...................................................................................................... 244
9.2. Onboard test document.................................................................................................. 253
10. Certificate of ISO 9001 ............................................................................ 264
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Appendix 1 - CLX_-EX(_Control_Document_28815A)_Rev_1.6_(updated)
Appendix 2 - TCL_4_ECS-EX(28815TB)_Techcross_Rev_1.5
Appendix 3 - EH 50WXX-UX TI046DEN_1109
Appendix 4 - EH TI00182CEN_1412.
Appendix 5 - Sensepoint XCD Technical Manual
Appendix 6 - SIMENSE 1MJ6096
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Record History Of Revisions
Rev no. Description DATE
1.0 Approved 2012/12/18
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Abbreviations
BWMS Ballast Water Management System
ECS Electro CleenTM System
ECU-****A A type Electro-Chamber Unit
Ex-ECU-***A Ex proof type of ECU-****A
ECU-****B B type Electro-chamber Unit
Ex-ECU-***B Ex proof type of ECU-****B
ECM Electro-Chamber Module
EM Electrode Module
ESJ ECU Signal Junction Box
EPJ ECU Power Junction Box
PRE Power Rectifier Equipment
PRU Power Rectifier Unit
Ex-PRU Ex proof type of PRU
PCU Power Control Unit
PDE Power Distributor Equipment
CPC Control PC
TSU TRO Sensor Unit
Ex-TSU Ex proof type of TSU
ANU Auto Neutralization Unit
FMU Flow Meter Unit
Ex-FMU Ex proof type of FMU
CSU Conductivity Sensor Unit
Ex-CSU Ex proof type of CSU
FTS/STS Fresh/Sea Water Temperature Sensor
Ex-FTS/STS Ex proof type of Fresh/Sea Water Temperature Sensor
GDS Gas Dector Sensor
HEU Heat Exchanger Unit
FTU Freshwater Tank Unit
HMI Human Machine Interface
AV Auto (Remote) Valve
TRO Total Residual Oxidants
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PSU Practical Salinity Unit

F.W. Freshwater
S.W. Seawater
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1. General
1.1. General Specifications of Electro Cleen System (ECS)Revision History

Specifications
Name ECS (Electro-CleenTM System)

Type ECS-300A/Ex-ECS-300A/ECS-600A/Ex-ECS-600A/ECS-1000A
ECS-150B/Ex-ECS-150B/ ECS-300B/Ex-ECS-300B
ECS-450B/Ex-ECS-450B/ ECS-600B/Ex-ECS-600B
ECS-1000B/Ex-ECS-1000B
Biological Efficacy Compliance with D-2 performance standard regulated by
IMO
Operation Performance Less than TRO 10mg/L (Average 6~10 mg/L)
Neutralization Performance Less than TRO 0.1mg/L after neutralization before
discharging
Neutralization Method Automatic input of Neutralization solution
Neutralizing Agent Sodium Thiosulfate
Operation Method Manual / Automatic operation by CPC
Operation S/W HMI (Human Machine Interface)
1.2. Operation Range of Electro Cleen System (ECS)

Standard Specification Remark
Treatment Rated Capacity 150m3/h ~ 6000m3/h +10%
TRO Concentration 6 ~ 10 mg/L Less than 10 mg/L
Input Voltage 3 phases, AC440V±10%
Input Frequency 50/60Hz ±5%
Operation Ambient Temperature 0 ~ 45°C
Treatment Seawater Temperature Over 0°C Not frozen
Coolant Seawater 0 ~ 36°C Not frozen
Coolant Freshwater 0 ~ 40°C Not frozen
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1.3. Introduction of ECS Equipments

Component Description
Control PC
ㆍ Control of ECS
Control (With HMI S/W installed)
ㆍ Dual system (Control room and PCU or PDE)
(CPC)
Power Control Unit ㆍ Control communication signal

(PCU) ㆍ Supply input power to HEU and FTU
ㆍ Control communication signal

Power Distributor Equipment ㆍ Supply input power to PRE/PRU (3Φ AC440V, 60Hz)
(PDE-A2/PDE-A4) ㆍ Supply control power to each equipments (2Φ AC220V,
Power 60Hz)
ㆍ Supply current to Electro-Chamber Unit (ECS-A Type)
Power Rectifier Equipment
ㆍ Input : 3Φ AC440V, 60Hz
(PRE)
ㆍ Output : DC10V / 3,000A
ㆍ Supplycurrent to Electro-Chamber Unit (ECS-B Type)
Power Rectifier Unit (PRU) ㆍ Input : 3Φ AC440V, 60Hz
ㆍ Output : DC10V / 1,100A
Heat Exchanger Unit

ㆍ Heat transfer between seawater and coolant water
(HEU)
Cooling
Freshwater Tank Unit
ㆍ Circulating coolant water of rectifier
(FTU)
Electrode Module (EM) ㆍ Electrode module

Electrolysis Electro-Chamber Module (ECM) ㆍ Chamber for the Electrode module
Electro-Chamber Unit (ECU) ㆍ Combination Unit (ECM and EM)
Monitoring TRO Sensor Unit (TSU) ㆍ Measure concentration of TRO (TRO sensor system)
ㆍ Decrease TRO concentration of treated water before

Neutralization Auto Neutralization Unit (ANU)
discharge
Conductivity Sensor Unit (CSU) ㆍ Measure salinity of seawater (Conductivity of seawater)
Gas Sensor Unit (GSU) ㆍ Hydrogen gas detection
Fresh/Seawater Temperature
Sensor ㆍ Measure water temperature
Sensor (FTS/STS)
Flow Meter Unit (FMU) ㆍ Measure flow rate of ballast water
ㆍ Measure flow of ballast water in pipe line

Vibration Level Sensor (VLS)
ㆍ Only required for Ex proof type

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2. ECS Equipments
2.1. Electro-Chamber Unit (ECU)
2.1.1. Non ex proof ECU-300A
ECU, a core equipment of Electro CleenTM System, consists of four electro modules.
ECU disinfects micro organisms through electrolysis with salinity and current.
ECU receives DC voltage and current through PRE or PRU
Specifications
Flange type JIS 10K 200A (Inlet / Outlet)
Water Treatment Capacity 300m3/hr (Max.+10%)
Design pressure 5bar
Material Body - SM490A T=9 / Other - SS400
Painting Epoxy (Inner : 300㎛ over / Outer : 150㎛ over)

Install area Safety area / Horizontal & Vertical Mount
Dimensions W1840mm x D690mm x H537mm
Ingress protection ECM+EM – IP67

ECU cover – IP2X
Weight Approx. 380Kg

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2.1.2. Ex proof ECU-300A

This ex-proof electro-chamber unit is specially designed ECU-Ex for dangerous zone (Zone 1, 2) and for
vessels carrying explosives and combustibles. Since it is installed for special environments, its main
purpose is to maintain a safe environment and prevent accidents. This electrolysis system satisfies all
system control requirements by getting rid of technical explosive environments and securing safety
conditions. Moreover, ECU is designed with increased safety ex-proof structure (in case of installation in
Zone 1 and 2) to prevent fire or explosive risk resulting from inflowing of combustible gas into the
inside of ECU.
Specifications
Installation area Hazardous area zone 1,2 / Horizontal/Vertical Mount
ECM+EM – IP67
Ingress protection
ECU cover – IP54
Ex CODE Ex e II T5

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Specifications
Installation area Safety area / Horizontal & Vertical Mount

ECU cover – IP2X

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2.1.4. Ex proof ECU-600A
Specifications
ECM+EM – IP67
Ingress protection
ECU cover – IP54
Ex CODE Ex e II T5

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Specifications

ECU cover – IP2X

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2.1.6. Non ex proof ECU-150B
Specifications
ECM+EM – IP67
Ingress protection
PRU – IP54

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2.1.7. Ex proof ECU-150B
Specifications
Installation area Hazardous area zone1,2 / Horizontal/Vertical Mount
ECM+EM – IP67
Ingress protection
ECU cover – IP54
T amb” 0℃ ~ 45℃
Ex CODE Ex de IIB T4 Gb
Ex-Certificate Number IECEx KGS 12.0008X
IEC60079-0:2007, IEC60079-1:2007
Applied standards or regulations
IEC60079-7:2006

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Specifications
ECM+EM – IP67
Ingress protection
PRU – IP54

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Specifications

ECM+EM – IP67
Ingress protection
ECU cover – IP54
T amb” 0℃ ~ 45℃

IEC60079-0:2007, IEC60079-1:2007
IEC60079-7:2006

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Specifications
ECM+EM – IP67
Ingress protection
PRU – IP54

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Specifications

ECM+EM – IP67
Ingress protection
ECU cover – IP54
T amb” 0℃ ~ 45℃

IEC60079-0:2007, IEC60079-1:2007
IEC60079-7:2006

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Specifications
ECM+EM – IP67
Ingress protection
PRU – IP54

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Specifications

ECM+EM – IP67
Ingress protection
ECU cover – IP54
Ex CODE Ex de IIb T4 Gb
T amb” 0℃ ~ 45℃
IEC60079-0:2007, IEC60079-1:2007
IEC60079-7:2006

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Specifications
ECM+EM – IP67
Ingress protection
PRU – IP54

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Specifications
Material Body - SM490A T=12/ Other - SS400
ECM+EM – IP67
Ingress protection
ECU cover – IP54

Ex CODE Ex de IIb T4 Gb
T amb” 0℃ ~ 45℃
Applied standards or regulations IEC60079-0:2007, IEC60079-1:2007

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IEC60079-7:2006
2.2. Power Rectifier Equipment(PRE)

In order to make electrolysis possible, PRE provides electric current (maximum 10V/3,000) to ECU.
PRE is operational by receiving power from PDE (Power Distributor Equipment). PRE receives AC
power from PDE and provides DC power to EM (Electrode Module) of ECU.
Specifications
Input power AC 440V 3P3W, AC220V
Output voltage Under DC 10V 3000A
Output signal RS-485 / CAN (RCM)
F.W Inlet pressure Max 5bar (Normal 2~3bar)
Inlet flowrate Over 12liter/min
Componemt AC/DC rectifier,Stack1(IGBT),Stack2(output)
Material Housing-SS400
Painting Powder coat’g
Installation Safety area / Stand alone
Ingress protection IP44
Weight About 225Kg

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2.3. Power Rectifier Unit(PRU)

2.3.1. PRU
Specifications
Input phase 3 phase
Input frequency 60Hz
Input voltage 440V
Output voltage Under +10V
Output current Under 1100A
Output signal RS-485
Freshwater temp Under 40℃
Flow rate Over 6liter/min
F.W Inlet pressure Max 5bar (Normal 2~3bar)
Enclosure IP44
T amb” 0℃ ~ 45℃
Weight Under 55Kg
Material Aluminum
Install Safety area

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2.3.2. Ex proof PRU

2.4. Power Control Unit (PCU)
PCU provides power to FTU and controls overall communication of Electro CleenTM System including
Pump and Alarm signals by CPC installed in PCU.
Specifications
Input power AC 440V 3P3W
Output signal Ethernet(RJ-45)
RTU, CPC, HUB

Components
F.W Pump / S.W pump control (Option)
Weight About 180Kg

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2.5. Power Distributor Equipment (PDE-A2)

Power Meter of PDE consists of RCM (Rectifier Control Module) and provides 220V/440V power to PRE.
RCM through HMI (Human Machine Interface) automatically controls the electric voltage and electric
current for normal operation. The electric voltage and electric current level of PRE can also be controlled
manually.
Specifications
MCCB / Noise filter

RCM 2EA(Rectifier control module)
Components Transformer
Converter (485-LAN / DI-DO) / Hub
Magnet Contactor (PRE Power on/off)
Output signal Ethernet (RJ-45)

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Weight About 200Kg

2.6. Power Distributor Equipment(PDE-A4)
Specifications
Components MCCB /Noise filter
EMI Filter
RCM 4EA(Rectifier control module)
Transformer
Converter (485-LAN / DI-DO)
Hub
Install Safety area / Stand alone
Weight About 385Kg

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2.7. Power Distributor Equipment(PDE)
Specifications

RTU, CPC, HUB
F.W Pump / S.W pump control (Option)
MCCB /Noise filter
EMI Filter
Components RCM 4EA (Rectifier control module)
Transformer
Converter (485-LAN / DI-DO)
Hub
Weight About 310Kg

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2.8. Control PC (CPC)

CPC is operated by HMI (Human Machine Interface) software and is designed to be controlled both
automatically and manually. The Master CPC is installed in the Cargo Control Room. A second CPC is
installed on the front of PCU. CPC installed on PCU operates as Slave CPC but can operate as Master
CPC if the Master CPC in the Cargo Control Room becomes out of order.
CPC OUTLINE
Specifications
CPU Intel Pentium M 1.4GHz, 2M Cache
RAM 1Gbytes
HDD 32Gbytes, Vibration protection
Operating System Window XP
Control HMI Software
INPUT POWER AC220V 3PHASE
Components 15" LCD Display (Touch Screen)
Internal speaker
External Ports Ethernet, USB, RS422 (GPS)
Material Housing – SS400
Installation Wall or Panel Mounting
Dimensions W383mm x D119.5mm x H507mm
Weight About 5Kg

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2.9. TRO Sensor Unit (TSU)

2.9.1. Non ex proof TSU
TSU monitors TRO (Total Residual Oxidant) levels thus controlling adequate amount of electricity
required during ballasting, and also controlling injection amount of neutralizing agent during
deballasting. TSU is automatically operated by the HMI. Manual operation of TSU is possible if TSU’s
automatic system becomes out of order.
Specifications
INPUT POWER AC100~240V
Control PLC Logic Program
Output signal RS-485
Components Display panel / CLX sensor-2ea (Parallel system)
Sampling (Treatment) water Feeder Pump
Solenoid valve / PLC
Material Housing – SUS304 /SS400

Dimensions W383mm x D119.5mm x H507mm
Weight About 100Kg

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2.9.2. Ex proof TSU

2.9.2.1. CLX sensor
Specifications
Manufacturer HF SCIENTIFIC Inc.
Type/Model CLX-Ex (28031)
Input power 240 VAC (130 to 240Vac)
USEPA accepted DPD method of analysis for Measuring Total

Method
Residual Chlorine
0-6 mg/l - ±5%
Accuracy
6-10 mg/l - ±10%
Resolution 0.01 mg/l
Flow Rate to Waste 200~400 ml/min
Ambient temperature 0℃ ~ 55℃
Output signal DI, RS-485
Material Housing - SUS

Ex code Ex px IIC T4
Installation area Hazardous area zone 1
Ex-Certificate Number IECEx BVS 07.0011X
Applied standards or regulations EN60079-0:2009, IEC60079-2:2007
Weight 27kg

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2.9.2.2. Control Panel
Specifications
INPUT POWER AC100~240V
Components Display panel
PLC
Relay
Terminal block
Material Steel
Installation Safety area / Wall mount
Weight About 50Kg

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2.9.2.3. Ex proof solenoid valve (S.V)
Specification
Manufacturer PARKER Lucifier S.A
Type/Model 321K4506-495905B8 / solenoid valve
Ambient temperature -40℃ ~ 65℃
Ex code Ex d mb IIC T4
Ex-Certificate Number LCIE 03 ATEX 6451X/03
Applied standards or regulations EN 60079-0:2006, EN 60079-1:2004, EN60079-18:2004

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2.10. Auto Neutralization Unit (ANU)

2.10.1. Non ex proof ANU-5T
ANU is the equipment for neutralizing TRO density still remaining in the ballast water during discharge.
ANU automatically controls the proper amount of neutralizing agent required and discharges the agent
directly into pipe line. ANU receives power and communication line by PCU/PDE-24A.
Specifications
Input power AC100~240V
Output Signal RS-485
Components Display panel, Tank, Metering Magnet Pump
Level sensor, Solenoid valve, PLC
F.W. Inlet pressure 0.5~3bar (Max : 3bar)
Neutralizer Sodium thiosulfate
Max. Input Neutralizer Approx. 50kg
Tank Capacity Approx. 100Liter (Both : 200Liter)
Mixture Ratio 2 (Fresh water) : 1 (Counteractive)

Injection Flow Rate Max. 530ml/min or Max. 1200ml/min
Weight Dry : About 220Kg /Wet : About 340Kg

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2.10.2. Non ex proof ANU-10T
Specifications
Input power AC100~240V
Output Signal RS-485
Components Display panel, Tank, Metering Magnet Pump
Level sensor, Solenoid valve, PLC
F.W. Inlet pressure 0.5~3bar (Max : 3bar)
Neutralizer Sodium thiosulfate
Max. Input Neutralizer Approx. 100kg
Tank Capacity Approx. 200Liter (Both : 400Liter)
Mixture Ratio 2 (Fresh water) : 1 (Counteractive)

Injection Flow Rate Max. 530ml/min or Max. 1200ml/min
Weight Dry : About 308Kg /Wet : About 550Kg

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2.11. Flow Meter Unit(FMU)

2.11.1. Non ex proof FMU
FMU detects water flow volume in pipe line. The detected water flow volume is used to calculate
adequate power control of PRE.
Specifications
Input power AC220V
Measuring range 0.1m/sec ~ 10m/s
Flow velocity 0.3m/sec ~ 10m/s
±0.5%F.S. ( 0.3m/sec ~ 10m/s)

Accuracy
±1.0%F.S. ( 0.01m/sec ~ 0.3m/s)
Fluid temperature -10℃ ~ 60℃
Output signal DC 4~20mA
Material Flange (SUS304) / Body (Hard rubber coat’g)
Display LCD Display
Flange size 50A-800A / DIN or JIS

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2.11.2. Ex proof FMU
Specifications
Manufacturer Endress+Hauser GmbH
50W**-U*1A1BA0ABAA
Type/Model
Electromagnetic flow measuring system
Input power AC220V
Measuring range 0.1m/sec ~ 10m/s
Flow velocity 0.3m/sec ~ 10m/s
±0.5%F.S.( 0.3m/sec ~ 10m/s)

Accuracy
±1.0%F.S.( 0.01m/sec ~ 0.3m/s)
Material Flange(steel) / Body(Hard rubber coat’g)
Display LCD Display
Flange size 50A-800A / DIN or JIS
Ex code Ex de[ia] IIC/IIB T6
Installation area Hazardous area zone1
Ex-Certificate Number IECEx BVS 07.0011X
IEC60079-0:2004, IEC60079-1:2003
IEC60079-11:2006, IEC60079-7:2001

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2.12. Conductivity Sensor Unit(CSU)

2.12.1. Non ex proof CSU
During ballasting, CSU measures electric conductivity of the incoming ballast water and delivers the
result to HMI which then calculates the correct starting and operating voltage of PRE.
Fig 14. FMU OUTLINE

Specifications
Input power DC 24V
Measuring range 0.2 ~ 1000mS/cm
Operation temperature 0℃ ~ 100℃
Operation pressure 10bar / 60℃
6bar / 100℃
Material Housing – PBT
Sensor – PP GF-30
Display LCD Display
Connection DIN11851 DN50 NUT

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2.12.2. Ex proof CSU

2.12.2.1. Sensor (Probe)
Specifications
Type/Model CLS50-G4B2 / Inductive Conductivity Sensor
Material PFA (Teflon)
Flange size JIS 10K 50A or ANSI 2”
Ex code Ex ia IIC T6
Ex-Certificate Number DMT 99 ATEX E 075X
Applied standards or regulations EN 50014:1997, EN50020:1994, EN 50284:1999

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2.12.2.2. Transmitter
Specifications
Type/Model CM42-IGA100EAE00 / Two-wire Transmitter
Input power AC 220V
Ex code Ex ia/ib IIC T6
Ex-Certificate Number EX5 05 03 30266 012 / TUV
Applied standards or regulations EN 50020 : 2002

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2.13. Freshwater / Seawater Temperature Sensor (FTS/STS)

2.13.1. Non ex proof FTS/STS
FTS & STS measure temperature of freshwater and seawater. The measured temperature is sent to HMI.
Specifications
Input power DC 24V
Measuring range -10℃ ~ 100℃
Output signal DC 4~20mA (2 Wire)
Housing – AL
Material
Sensor – SUS316L
Display LCD Display
Connection PT 1/2”

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2.13.2. Ex proof FTS/STS
Specifications
Manufacturer WISE Control Inc.
Type/Model R941 / Temperature Transmitter
Input power AC 220V
Ex code Ex d IIC T6
Ex-Certificate Number IECEx KGS 05.0001
Applied standards or regulations IEC 60079-0:2000, IEC 60079-1:2001

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2.14. Vibration Level Sensor (VLS)
Specifications
Type/Model FTL50-KB82AA4G5A / Liquid Level Switch
Output signal Dry contact
Material SUS 316L
Flange size JIS 10K 50A
Ex code Ex d IIC T6
Ex-Certificate Number IECEx BKI 08.0009

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2.15. Gas Dector Sensor (GDS)
Specifications
Manufacturer Hoenywell Analytics
Type/Model Sensepoint XCD / SPXCDALMTXF / Gas Dector
Output signal 4~20mA
Material Aluminum
Measuring gas H2
Ex code Ex d IIC T6
Ex-Certificate Number IECEx BAS 08.0072

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2.16. Ex proof Freshwater pump - option
Specifications
Manufacturer SIMENSE Co
Type/Model 1MJ6096-2CA90-Z
Input Power 440Vac / 3.2A(1.61Kw)
Rated Motor Speed 3600rpm/min
Vibration Class A
Insulation Class F
Ex code Ex d IIC T4
Ex-Certificate Number PTB 07 ATEX 1034X
Applied standards or regulations EN 60079-0:2004, EN 60079-1:2004

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2.17. Heat Exchanger Unit (HEU) – option
Fig 17. HEU OUTLINE
Specifications
Freshwater Seawater
INLET TEMPERATURE (℃) 40 32
OUTLET TEMPERATURE (℃) 36 34.6
CONNECTION MATERIAL Rubber spool Rubber spool
CONNECTION DIAMETER 50A/100A 50A/100A
CONNECTION STANDARD JIS 5K JIS 5K
DESIGN TEMPERATURE (℃) 85 85
DESIGN/TEST PRESSURE (bar.g) 4.0 / 6.0 4.0 / 6.0
FLUID VOLUME (L) 1.0 1.0
HEAT EXCHANGED, DUTY (Kcal/hr) 20,000 ~200,000

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2.18. Freshwater Tank Unit (FTU) – option
Fig 18. FTU OUTLINE
Specifications
Input Water Freshwater
Tank capacity Max : 85Liter, Min : 25Liter
5K 40A Flange Type

Inlet/outlet Connection
5K 25A Flange Type – Fill’g line
Tank : SUS304
Material
Frame : SS400
Dry : 80Kg
Weight
Wet : 165Kg

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3. ECS Operation
3.1. Preparation for Operation
Checklist of Components
Checklist 참고
1. Remove any conductive articles from ECS components to avoid short circuiting.
2. Remove any unnecessary tools or devices around ECS.
3. If any moisture remains in ECS components, make sure to dry out the inside/outside of ECS
components.
4. Check the state of components comprising ECS; Power Cables, Communication Cables and Connector.
5. Check whether or not FTU tank is full of clean water. If not sufficient, manually replenish with clean
water.
6. Check whether CLX reagent (Chlorine indicator and Buffer solution) is in proper state.
7. Power On ECS
7. Check whether TSU, ANU, and RCM are set to operate in Remote Mode.
8. Check whether ANU Fresh Water Tank contains sufficient amount of neutralization solution.

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1) Remove any conductive articles from ECS components to avoid short circuiting
2) Remove any unnecessary tools or devices around ECS system
3) If any moisture remains in ECS components, make sure to dry out the inside/outside of
ECS components
4) Check the state of components comprising ECS; Power Cables, Communication Cables,
and Connector
5) Check whether or not FTU tank is full of clean water. If not sufficient, manually replenish
with clean water
6) Check FTU window to confirm full level of fresh water
7) Check whether CLX reagent (chlorine indicator and Buffer solution) is in proper state
① Check whether the reagent is under one month old.

② Check whether the reagent bottles are empty.
③ Check whether the reagent has discolored to dark brown

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8) Starting ECS Operation
Start up
440V MCCB power on of PDE
Check CPC power on in CCR

(Cargo Control Room and HMI auto start)
Decide whether or not setting Remote

Mode of
HEU and RCM (Caution*)
CPC power on of PDE

(Start HMI application)
Power should be supplied only during ECS operation and vice versa.

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① Turn on 440V MCCB power of PDE.
② Turn on 440V MCCB power of PDE and then, turn on CPU power.
③ Set PDE as Remote Mode by using HEU REMOTE/LOCAL switch of PDE. (option)
Manually operate an alternate pump (eg. General Service Pump or Emergency Fire
Pump) for the application of HEU Sea Water Pump.

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④ Set RCM as Remote Mode by using RCM REMOTE/LOCAL switch of PDE.
If the buzzer installed inside RCM sounds, terminate it by pressing STOP/RESET and
check the alarm message indicated on HMI. For possible measures against HMI alarm
Caution messages, refer to Chapter 9 Troubleshooting.
⑤ Turn on CPC installed in CCR (Cargo Control Room) and check whether HMI functions automatically.
⑥ Turn on CPC inside PDE and initiate HMI. Now, Slave CPC is recognized.
⑦ Check whether CPC installed in CCR and CPC inside PDE are ready to control ECS operation.
If two HMIs are operated together, the Master CPC controls ECS operation while every
operation data is saved automatically in both the Slave CPC as well as the Master CPC. If
the Master CPC should come into fault, the Slave CPC recognizes it and then takes over as
the Master.

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1) Check whether TSU, ANU and RCM are set to operate in Remote Mode
TSU is automatically set to remote mode when power turns on. Make sure that it turns into
REMOTE mode on XGT screen of TSU.
2) Check whether ANU Fresh Water Tank contains sufficient amount of neutralization
solution
Left-side Tank Right-side Tank

Ready Ready
Make sure that status is REMOTE mode on XGT control panel of ANU.
Make sure that left and right side tanks of ANU are ready.

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3.2. Operation Overview
3.2.1. Normal Treatment Operation
3.2.1.1. Ballasting
The operating parts of ECS during ballasting are composed of controller part, rectifier part, power
distribution part, electrolysis part, and sensor part.
1) Turn on the power of ECS BWMS PDE/PCU/CPC.

2) Run HMI software of CPC.
Turn on auto mode on HMI.
When ballast pump is operating, seawater goes through seachest, ballastline, and FMU.
Ballast pump signal is sent to PCU(PDE-24A)/CPC and BWMS status turns to ’READY’ on HMI.
When seawater flows through FMU, ballast water flux displays on monitor and the signal is sent to
PCU(PDE-24A)/CPC through LOP and data is sent to HMI.
3) When ballast water passes through from FMU to CSU, the salinity is measured and the measured
value is sent to PCU(PDE-24A)/CPC through LOP.
4) Ballast water from CSU goes through auto valves (AV1/AV2) and the signals of AV1/AV2 are sent to
PCU/CPC through LOP.

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Push START BUTTON when READY BUTTON is activated.

Auto valve(AV4) shall be off without fail.
5) Ballast water according to CPC goes through ECU and PRE sending DC current to EM.
Based on flux of FMU and conductivity of CSU, PRE sends initial current capacity to ECU. TRO
concentration of the treated water is measured by TSU. The current of PRE decreases if the initial
TRO concentration is high and increases if it is low. Normal BWMS is operating with TRO levels of
10ppm and under.

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3.2.1.2. Deballasting
The operating parts of ECS during deballasting are composed of controller part, power distribution
part, sensor part, auto neutralization part.
1) Turn on the power of ECS BWMS PDE/PCU/CPC.

Run HMI software of CPC.
Turn on auto mode of HMI.
2) When ballast pump is operating, ballast water flows from ballast tank to FMU through ballast
pump.
When turning on auto valve (AV4), the valve signal is sent to PCU/CPC through LOP and then
deballast mode shall be pushed on HMI. In this case, auto valves (AV1/AV2) shall be signal off
without fail.
When seawater flows in FMU, ballast water flux displays on monitor, the signal is sent to
PCU/CPC through LOP, and data is sent to HMI.
The remaining TRO in ballast tank is measured based on the flux. The measured value is sent to
PCU/CPC through LOP, and then measured TRO concentration displays on HMI. HMI software
controls ANU for neutralizer injection to neutralize TRO.

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3.2.2. Algorithm of Treated Ballast Water Discharge

ECS measures TRO concentration of treated water at the time of discharge and injects appropriate
amount of neutralizer in order to achieve TRO levels of under 0.1 mg/L.

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3.2.3. System Monitoring Equipment

In case of malfunction, the real-time automatic monitoring system instantly sends notice and alarms so
that user can react with speed and ease.
3.2.3.1. System Self-Check

In case of malfunction, the central control system continuously monitors the status of all equipment and
displays on screen any system not functioning properly. It shows which parts are malfunctioning and
advises on how to fix it.
3.2.3.2. Brief Diagram of Monitoring Equipment
- Ballasting flow chart
YES Start
NO
Wait
Pump Check
Current = (Target TRO * Emergency Stop

Flow) / CSU
Subtract Current Fault Check
TRO > Target
Shut Down
Add Current Alarm Check
Alarm Display
TRO < Target Ballast End
Stop

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- Deballasting flow chart
YES Start
NO
Wait
Pump Check
Emergency Stop
Injection = TRO * Flow
Subtract Injection Fault Check
TRO < 0.1 Shut Down
Add Injection Alarm Check
Alarm Display
TRO > 0.1 Deballast End
Stop

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3.3. ECS Operation
3.3.1. HMI Screen Overview

HMI (Human Machine Interface) screen displays the overall operation status of ECS. Automatic/Manual
mode can be selected on HMI screen; since operation status lamps for each ECS component are located
on the screen, errors can be easily identified. In addition, the detailed flow of ballast water during ECS
operation is also displayed on the HMI screen.
HMI Image in manual may be slightly different from HMI on your vessel due to continued
improvement.

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No. Name Description
① Top Message Operation status and alarm messages

② Operation mode Selection Automatic / Manual
③ ECS Operation Selection Ballasting / Deballasting / Stripping
④ Power button Power ON / OFF
⑤ PDE Input power and operation status of distribution board
⑥ ECU Current supplied to each EM / ECU current status
⑦ 1 ANU Injection amount of neutralization solution / ANU operation status
⑧ TSU TSU operation status
First powered CPC’s HMI is displayed as MASTER; the next powered
⑨ HMI duplication status
CPC’s HMI is displayed as SLAVE.
⑩ Operation start button ECS operation start-up
⑪ Operation stop button ECS operation stop
⑫ Menu button Operation status of ECS components and ECS operation log
⑬ Status indicator ECS operation status
⑭ ECU group Checking the status of two ECU’s by grouping
HMI (Human Machine Interface), the operating software of CPC which controls ECS

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3.3.2. Automatic Operation

1) Automatic ballasting procedure
① Select “Automatic” in the top left.

② Click “START” button to start ECS auto operation.
③ In case FMU (Flow m3/h) does not detect any flow rate of ballast water, ECS remains waiting as below.

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④ FMU detects the flow rate of ballast water and ECS automatically starts operation.
The RCU current value displayed on HMI screen is the value of the current provided to
ECU

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2) Automatic deballasting procedure

③ Deballasting automatically starts when the signal and flow rate of OVBD value are detected.
Do not operate Ballast mode and Deballast mode at the same time.

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3) Standby mode
Standby mode refers to a state when system is running but operating is on hold until the pumping
conditions are met.
Under conditions as follows, ECS automatically stops operating and enters into standby mode (operation
automatically restarts when conditions are back to normal):
① If the water flow of FMU (flow m3/h) is zero.

② There is no signal from ballast pump and inlet/outlet valve
If the standby mode lasts more than 5 minutes, ECS will be shutdown.

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4) Automatic stripping mode procedure

③ When the pumping status meets stripping conditions, ECS starts stripping.

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3.3.3. Manual Operation

If the signal from overboard valve doesn’t reach HMI, or it is malfunctioning during operation, or there is
problem with automatic mode, you can operate ECS in manual mode. The information about anomalies
can be checked on LOG message list.
1) Manual ballasting procedure
① Click “Automatic” Button in the top left and then it will be changed to Manual
(Green light is not on for manual mode.)
(When you want to go back to automatic mode, please click “Manual” button again.)
② Select “Ballasting”.
③ Click “START” button to start ECS manual operation.
Ballast mode, Deballast mode, Stripping mode cannot be selected simultaneously.

Manual operation is an operation mode that does not sense valve and pump signals.
Therefore, make sure that value and pump conditions are normal before operation.
2) Manual deballasting procedure

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① Select “Manual”.
② Select “DeBallasting”.
Ballast mode, Deballast mode, St Ballast mode, Deballast mode, Stripping mode cannot
be selected simultaneously.
Manual operation is an operation mode that does not sense valve and pump
signals. Therefore, make sure that value and pump conditions are normal before
operation.

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3) Manual stripping mode procedure
① Select “Manual”.
② Select “Stripping”.
Ballast mode, Deballast mode, Stripping mode cannot be selected simultaneously.

Manual operation is an operation mode that does not sense valve and pump signals.
Therefore, make sure that value and pump conditions are normal before operation.

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3.3.4. Setting and Checking ECS
Additional functions are the functions that are not controlled nor viewed on the main HMI screen. An
operator may view RTU operation state, log file, communication state between PDE and ECS components,
operation status of ECU component and values. These functions set and check ECS operating conditions.
(1) RTU signal check

(2) Operation log check
(3) Communication state check
(4) Each sensor value check
(5) Operation time check
(6) Operation View
(7) Unit Disable
① Click “MENU” button on the bottom right of HMI screen.
② Click the item you want on the item list.
③ Select the cancel button to remove the item list.

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1) RTU (Remote Terminal Unit)
RTU is a function that checks the pressure and output signal state needed for ECS operation.
① Click “MENU” button on the bottom right of HMI screen

② RTU window appears after clicking “RTU” on MENU window screen.
③ To see the actually interfaced data packet, click “Raw Data” button.
④ Return to HMI basic screen after clicking “Close” button.

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2) Log
Operation status log

It shows a list of operation status information recorded during ECS operation.

② Alarm list appears after clicking “Log” on MENU screen.
③ If one of four items on Query Condition I (All, Normal, Warning, Fault) is clicked, the messages will be
displayed for related alarm
A. If “ALL” button is clicked, all log level information will be sorted & displayed.
B. If “Normal” button is clicked, only the NORMAL part of log level information will be sorted &
displayed
C. If “Warning” button is clicked, only the WARNING part of log level information will be sorted &
displayed.
D. If “Fault” button is clicked, only the FAULT part of log level information will be sorted & displayed.
④ If “ALL” button is clicked on Query Condition II, it will show every alarm information during
operation.
If “TODAY” button is clicked it will show every alarm which occurred “today”.
⑤ If “Close” button is clicked, it will go back to HMI’s main menu.
3) Comm. Status (Communication Status)

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It monitors the communication state between and among ECS components, which are connected to PDE,
in real time.

② Alarm list appears after clicking “Comm. Status” on MENU screen.
③ Green( ) means normal operation while Red( ) means abnormal operation Pink( ) means
‘not used’.
④ To return to HMI basic screen, click “OK” button.

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4) Detailed View
It shows the status or numbers/values of ECS components, all of which does not appear in the basic HMI
screen of CPC, in detail and real time.

② Detail View window appears after clicking “Detail View” on MENU window
③ Numbers/values and status of ECS components are displayed. To see the status of ESJ, ANU and PDE,
click “Next” button.

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5) Configuration of Detailed View
① ESJ : State of ESJ connected to PDE

l Voltage : Voltage supplied to ECU
l Current : Current supplied to ECU
② TSU : Measurements by TSU
l CLX#1 on TSU : TRO concentration measured by CLX#1
l CLX#2 on TSU : TRO concentration measured by CLX#2
③ SENSORS : Measurements by sensor
l GSU : H2 concentration measured by GSU
l FMU : Flow rate of ballast water measured by FMU
l CSU : Ballast water conductivity measured by CSU
④ PDE : Alarm state of voltage/current supplied to PDE
l Alarm : PDE alarm status
l GDR : Electricity leakage status
⑤ ANU : Operation status of ANU and amount of netrualizer being injected
l RDY1, RDY2 : Neutralization water discharged from Left (#1) or Right (#2) tank or not
l ETY1, ETY2 : Neutralization solution is empty or not in Left (#1) or Right (#2)
l OVR1, OVR2 : Overflow of neutralization solution in Left (#1) or Right (#2) or not
⑥ HEU (option) : Seawater temperature
Operation status (RUN) and Pump error status (FAULT)
⑦ F/W : Freshwater temperature
Operation status (RUN) and Pump error status (FAULT)
⑧ Operation : ECS operation mode
Green lamp ON – Ballasting, Green lamp OFF - deballasting
⑨ LOCATION (GPS) : Location of ship received from GPS (latitude/longitude)
Recorded with ECS operation record
⑩ Administration : Password window to enter Administration mode of ECS system appears.
After password is input correctly, system administration mode is entered.
⑪ Close : Return to HMI screen.

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6) Operation Time
ECS records each time of ballasting, deballasting and stripping.

② Detail View window appears after clicking “Operation Time” on MENU window

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3.3.5. Reading operation signs of HMI

ECS can check the specific operation status of ECS components thru HMI.
For troubleshooting relating to Alarm Messages, refer to Troubleshooting.
1) PDE (Power Distributor Equipment)
① Operation signs of PDE
(1) PDE Indicator Lamp

(2) Input current of main power
(3) Input voltage of main power.

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② Alarms on PDE
When the current provided to ECS increases beyond the limit and the voltage increases beyond the
allowed limit, the system shuts down.
If clicking PDE Indicator lamp that is blinking, the detailed alarm message window appears. The alarm
message and code can be checked on the alarm message window.

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2) ECU
① Alarms on ECU
If ESJ is in fault during ballasting, ECS temporarily stops. Then, alarm sounds from HMI and buzzer
sounds while PDE alarm lamp is ON. To stop alarm, click “ShutDown”.
You can check the comment of the alarm by using "Top Message".
Then click to stop the alarm.
② Operation signs of ECU
ECU Indicator Lamp (Run / Stop Status)

③ Current consumption of ECU
If power is supplied to ECU during ballasting, ECU indicator lamp is ON.

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3) TSU (TRO Sensor Unit)
① Operation signs of TSU
① TSU Indicator Lamp (blinking if alarm occurs)

② TRO sensor (CLX#1)
③ TRO sensor (CLX#2)
④ TRO concentration during ballasting (operating range: 6~10 ppm)
④ TRO concentration during deballasting (operating range: 0~0.1 ppm)
Two CLX sensors are installed on TSU while HMI calculates TRO concentration measured by these two
CLX sensors. If either sensor is in fault, it shows the TRO concentration from only the normal CLX.
Operation Sign Status Description
CLX Stop CLX power turns off during TSU stoppage
CLX Run CLX power turns on during TSU operation
② Alarms on TSU
If TSU alarm occurs in case of communication failure or failing to measure TRO concentration, you can
check the comment of the alarm by using "Top Message".

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4) ANU (Auto Neutralization Unit)
① Operation signs of ANU
① ANU Indicator Lamp (blinking if alarm occurs)

② State of neutralization solution in the left Fresh Water Tank
③ State of neutralization solution in the right Fresh Water Tank
④ Injection of neutralization solution in Port#1
⑤ Injection of neutralization solution in Port#2
⑥ ANU Group
There are two tanks in ANU that stores neutralizing solution. If one tank is used to inject neutralizing
solution and the solution is fully discharged, fresh water is automatically injected into the empty tank.
When the fresh water goes up to a certain level, the tower lamp of the tank lights up. Then, the
operating personnel can input neutralizer and start running agitator.

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Operation sign Status Description
F/W Supplied Only contains freshwater
Detection of upper water Supply of freshwater stops as it is filled up

level to the upper water level
Request to inject Freshwater supply completes and directs

neutralizing agent to inject neutralization agent
Valve or sensor is malfunctioning causing

F/W Overflow
excessive freshwater supply
Insufficient water. Freshwater is

Insufficient F/W
immediately supplied
② Error on ANU
You can check the comment of the alarm by using "Top Message".

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5) Sensors
Sensors installed on ECS consists of CSU and GSU displayed on PDE, and FMU displayed on itself. These
and other sensors are also displayed on HMI screen as follows.
Sensor Operation range Description
CSU 1PSU ~ Conductivity Sensor Unit
Detection of ballast water flow rate

FMU 15% ~ 110%
(m3/h)
FTS ~ 38°C Freshwater Temperature Sensor
GDS 0 ~ 25 %LEL Gas Detected Sensor

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6) C/C (Central Cooling)
① Operation signs of Central cooling
① Central cooling operation status

② Operation status of central cooling Freshwater
Operation sign Status Description
Normal F/W Normal Level of freshwater tank level
F/W Overflow Overflow from excessive freshwater supply
Insufficient F/W Insufficient freshwater

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3.3.6. Stopping ECS Operation

1) ECS Stop Procedure : Automatic Mode
Follow the procedure in order to stop ECS operation.
Stop ballast pump and close ballast valve
Click STOP button on HMI screen of CPC

in Cargo Control Room
Check whether ECS stops
Turn off CPC in Cargo Control Room.
Turn off CPC of PDE.
Turn off 440V MCCB power of PCU
Turn off PDE 440V MCCB power
End

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① Stop ballast pump and close ballast valve.

② Click “STOP” button on HMI screen of CPC in Cargo Control Room.
③ ECS automatically stops.
④ Click button on HMI screen of CPC. A message, ‘Quit The Operation?’ appears and HMI closes
after clicking “YES”.
⑤ Click “STOP” button in HMI screen of CPC. After clicking button, a message, ‘Turn Off HMI?’
appears. Then, HMI closes after clicking “YES”.
⑥ Turn off 440V MCCB power of PDE.

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2) ECS Stop Procedure : Manual Mode
Click STOP button on HMI screen of CPC
Stop ballast pump and close ballast valve
Check whether ECS stops
Turn off CPC in Cargo Control Room
Turn off CPC in PDE.
Turn off 440V MCCB power of PCU
Turn off 440V MCCB power of PDE
End
Carelessness in any of the above may cause fatal error of ECS due to the residual
current.

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① Click “STOP” button in HMI screen of CPC

② Stop ballast pump and close ballast valve.
③ Check whether ECS stops or not and stop HEU seawater pump manually. (option)
④ Click button on HMI screen of CPC. A message, ‘Quit The Operation?’ appears and HMI closes
after clicking “YES”.
⑤ Click “STOP” button in HMI screen of CPC. After clicking button, a message, ‘Turn Off HMI?’
appears. Then, HMI closes after clicking “YES”.
⑥ Turn off 440V MCCB power of PDE.

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3.4. Emergency Operation

3.4.1. Emergency Ballasting
1) Requirement for Emergency Ballasting
Required Status Operation Method
PDE ○ Set RCM as local mode
PRU ○ Controlled by RCM
ECU ○ Conduct electrolysis with supplied current from PRU
FTU ○ Connect power cable for the fresh water pump of FTU
TSU △ Measure TRO concentration if possible after setting as local mode
Portable TRO Sensor ○ Measure TRO concentration using Pocket ColorimeterTM II
3.4.2. Operation Procedure of Emergency Ballasting

1) Start procedure
① Turn on 440V MCCB of PDE.
② Check whether RCM of PDE can recognize PRU with no error code.

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2) Operation Procedure
① Set the local mode by using REMOTE/LOCAL switch of PDE and then press ON button. Then, set Heat
Exchange REMOTE/LOCAL of PDE as Local Mode and press ON button. After that, freshwater pump
starts operating.
② To operate the fresh water pump of FTU, connect the power cable and operate FTU manually.
③ Execute ballast valve line-up for ballast work and start ballast pump.
④ Set RCM to local mode by using RCM REMOTE/LOCAL switch of PDE and select PRU to operate. Press
ON button of PDE to start PRU.

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⑤ Set RCM of PDE as 5V 2,700A and press ON button of RCM. Check whether voltage and current
gradually reach up to 2,700A.
⑥ Measure TRO concentration of ballast water using Pocket ColorimeterTM, every 10 minutes. If the
concentration of TRO is 5mg/L and lower, it is recommended to increase the current of RCM
gradually; if the concentration is 10mg/L and higher, it should be gradually lowered.
⑦ If TSU works normally, press of TSU XGT to set TSU to local mode. To measure the
concentration of TRO, press to select the ballast pump valve. To operate TSU, press .
Check the concentration of TRO every 10 minutes and adjust RCM current depending on TRO
concentration.

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3) Stop procedure
① Upon completion of ballasting, press OFF button of RCM. If RCM operation stops, PRU operation
stops in about 15 seconds.
② When ballast valve is closed, stop the operation of ballast pump.
③ To stop the operation of HEU seawater pump, press OFF button of PDE.
If seawater pump of HEU is not installed at the request of shipowner, HEU

REMOTE/LOCAL switch of PDE should not be used to operate HEU in remote or
local mode. In this case, a substitute pump for the SEAWATER PUMP of HEU (i.e.
General Service Pump or Emergency Fire Pump) should be manually operated. To
Caution
accurately understand the pump out, refer to ECS drawings. Negligence to the
above may cause fatal damage to ECS.

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④ To stop the operation of FTU, disconnect the power cable of freshwater pump of FTU.
⑤ Once TSU starts operation, press of TSU XGT Panel to stop the operation.
⑥ To stop the operation of ECS, turn off 440V MCCB of PDE, in series to stop the operation.
3.4.3. Emergency Deballasting
1) Requirement for Emergency Deballasting Operation
Required Status Operation Method
PDE ○ Set RCM as local mode

ANU ○ Set RCM as local mode
TSU △ Measure TRO concentration if possible after setting as local mode
Portable TRO Sensor ○ Measure TRO concentration using Pocket ColorimeterTM II
3.4.4. Operation Procedure of Emergency Deballasting
1) Start Procedure
① Turn on 440V MCCB of PDE.
② After ANU is powered on, check whether at least one of two freshwater tanks has enough
neutralization solution. If both tanks are empty, first prepare neutralization solution.

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2) Operation Procedure
① Press of ANU XGT Panel in the Menu screen. Press selection 2, Local Mode and then, press to save
the changes.
② Press of AUX XGT Panel to select the direction inputting P#1 or P#2 neutralization solution,
determining the valve. To deselect the valve, press button.
(P#1 and P#2 refer to metering pump)
③ Discharge volume of P#1 metering pump can be set if pressing to set the volume. Then, if
pressing and press , the volume of P#2 metering pump can be also set. After then,
pressing and press , the changes are saved.
( buttons are used to increase the volume while buttons are used to change the digit
of value.)

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④ After executing ballast valve line-up for deballasting, operate the ballast pump.
⑤ Press of ANU XGT Panel to start injecting neutralization solution.
⑥ Measure the TRO concentration of neutralized ballast water every 10 minutes by using Pocket
ColorimeterTM II. If the concentration of TRO is 0.1mg/L and higher, the amount of neutralization
solution should be gradually increased.
For detailed information about ColorimeterTM II, refer to Appendix - Pocket

TM
Colorimeter II.
⑦ If TSU starts working normally, press of TSU XGT Panel to set as Local Mode. To select the
valve of ballast pump of which TRO concentration is to be measured, press . Press
to operate TSU. Check the concentration of TRO every 10 minutes and if TRO concentration is
0.1ml/L and higher, press of ANU XGT Panel to adjust the injection amount of neutralization
solution.

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3) Stop Procedure
① Close the ballast valve for deballasting and stop the operation of ballasting pump.
② To stop the operation of ANU, press of ANU XGT Panel.
③ If TSU is running, press of TSU XGT Panel to stop the operation.
④ To stop the operation of ECS, turn off 440V MCCB of PDE.

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3.5. After power outage during ballasting
① Make sure that PDE Main MCCB is turned on.

② Make sure that every part of ECS is turned on.
③ Make sure that CPC is turned on.
(If power is not turned on, use power switch to turn it on.)
④ See the message on HMI to check that ECS operation conditions are met, and start operating
according to ECS operating method
3.6. Operation in low salinity water
The system operates in waters as low as 1 PSU. When ECS is operated in water under 1 PSU, it may
shutdown as TRO concentration does not meet 6 ppm. Please note that there is no route for VLCC’s in
waters under 1 PSU.
In case VLCC has to operate ECS in waters under 1 PSU, please contact Techcross and ask for emergency
procedure as only water as low as 1 PSU is guaranteed under the contract.

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3.7. Maintenance procedures and procedures for discharge of untreated water in the event of
malfunction of BWMS
Countermeasures for breakdown and malfuction of ECS are necessary since it can interrupt ballast
water discharging. ECS guarantees ballast water discharging, even under conditions of various
malfunctions.
3.7.1. Vessel with dual ballast pump operation

N/A
3.7.2. Partial malfunction of electrolysis module

Since the electrolysis chamber is separated into 4 units of electrode modules, control system
malfunction can be classified as complete malfunction and partial malfunction. In case of partial
malfunction of electrode modules, the operation satisfies D-2 standards by controlling inflow of
ballast water with the management system. In this case, more time is required for ballast water
management. Repairs and replacement are possible in a timely fashion because malfunction
conditions are detected by the management system.
3.7.3. If repairs and replacement are possible during voyage or inflow of ballast water
N/A
3.7.4. Discharge procedures for untreated ballast water because of malfunction

When untreated ballast water has to be discharged unavoidably because above methods are
unattainable, it shall be conducted in conformity with prescribed procedures. That is, the location
of untreated ballast water discharge, discharged amount, discharge time, discharged active
substance, its concentration, and malfunction type shall be recorded. The system managers shall
take actions for repairs and replacement of BWMS for normal operation as soon as possible.
3.7.5. Emergency measures for securing safety of vessel

Possible emergency situations with ECS are classified into structural situations (such as ballast pipe
damage and leakage of electrolysis module) and electrical situations (such as electricity overload
and emergency situation such as fire).
3.7.6. Emergency measures for structural defects

The actions for structural defects such as leakage from defective ballast pipe or electrolysis
modules are as follows:
1) Notice the emergency situation from emergency alarm
2) Shut down the power to stop ballast pump operation

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3) Block inflow and outflow ballast water with valves installed in front and rear of electrolysis
module
4) Discharge ballast water by opening bypass valve
5) Send notice to professional organizations and take any additional necessary actions
6) Check for electric leakage and consider restoration plan with related organization
3.7.7. Emergency measure for electric defects

The actions for electric defects such as BWMS overload, system shut-down from overheating, and
fire are as follows:
1) Notice the emergency situation from emergency alarm
2) Shut down the ballast water treatment system
3) Shut down the main curcuit breaker of BWMS
4) Extinguish fire using fire extinguisher
5) Send notice to professional organizations and take any additional necessary actions
6) Check for electric leakage and consider restoration plan with related organization
3.7.8. Proper information for error detection

ECS has a real-time error detection system so that operators can easily and quickly deal with any
situation.
3.7.9. System Self-Test

If the system does not operate normally, the main control part examines the system and displays if
the operation is normal or abnormal. Also, if the system is malfunctioning or operateing abnormally,
it displays the type of malfunction and proper actions required. The types of malfunction and
proper actions are as follows:
Type Display Discription Actions
R phase of power input is

R Phase
disconnected or shorted.
S phase of power input is Check the power using a tester and make
S Phase
disconnected and shorted. sure the power is on.
Primary
T phase of power input is
Power T Phase
disconnected and shorted.
When the power is out on the input line,
440V OFF when the power is out check if the main power distributor is
shut down.
RTU Communication error with - Check the connection of communication
Communication
Communication RTU cable

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Error - Check the communication circuit

- Check the RTU power lamp
- Check the connection of communication
RTU
Communication error with cable
Communication
RTU - Check the communication circuit
Error
Rectifier#N
Communication error with
Communication
Rectifier#N
Communication Error
- Check the connection of communication
TSU
Communication error with cable
Communication
TSU#N - Check the communication circuit
Error
ANU
Communication error with
Communication
ANU#N
Error

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4. TECHNICAL INSTALLATION
4.1. Electro-Chamber Unit (ECU)
4.1.1. Non ex proof ECU

Output pipe should be higher than input pipe on pipeline to retain water in the chamber. (※Vertical
type is exception.)
4.1.2. Ex proof ECU

Output pipe should be higher than input pipe on pipeline to retain water in the
chamber. (※Vertical type is exception.)
EX-ECU-B is designed to be installed in Zone 1 or Zone 2 areas, which are risky area according to IEC
60079.
When verifying the inside of the product, it should only be done in a safe location with trained expert.
When moving the product to a safer location, related regulations and procedures must be followed. To
maintain the product’s overall integrity, related standards must be followed.
When replacing module, power rectifier unit, cover, or busbar, additional caution should be made in
order to not cause any damage.
When using anti-seize compounds on screw threads, please apply only thin amount of certified
chemicals (for instance, petroleum jelly) that does not consist of silicon.
To reduce the explosion risk in the atmosphere, any closed area should be vented and all power sources
should be unplugged prior to opening the external cover of any electrical device. While using any piece
of equipment, all screws of the equipment should maintain the condition of being tightly fastened.
In potentially explosive risky environments where power is supplied; opening, replacing, or repairing of
any instrument is not allowed.
To maximize electrical safety and minimize frequency interference, PRU should be grounded.
Ground connector of the PRU is provided outside of the instrument. Internal ground connection is

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used as a basic instrument ground connection. External ground connection can be used only in a place
authorized by the person-in-charge, and only used as a supplementary connection terminal.
Wrong ground connection may cause a misoperation or alarm.
When using any instrument/equipment, please verify if there is any corrosion.
Do not expose instrument/equipment to conditions outside of indicated range of temperatures.
Do not expose Ex-ECU-B to any explosive liquid or organic solvent.
Waste disposal must follow environmental law and waste disposal requirements of applicable area.
Used EM can be safely wrapped and returned to Techcross Inc.
EM may discharge toxic gas; thus, disposal is not allowed.
4.1.2.1. Horizontal Installation

Correct Installation
When installing EX-ECU-B, inlet and outlet of ballast water should be located higher
than EX-ECU-B installation area. Also, level sensor should be located higher than EX-ECU-B installation
area.
Level sensor installation area
Inlet Outlet

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Level sensor installation area Outlet
Inlet
Wrong Installation

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4.1.2.2. Vertical Installation
Level sensor installing area

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Busbar Connection
BUSBAR
(POSITIVE : +)
BUSBAR
(NEGATIVE : +)
HEXAGON
HEADBOLT
M12x50
Torque value
- 800kgm(78Nm)
HEXAGON NUT
M12

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l Notice : M12x50 BOLT Torque value : 800~1000 kgm

Cover Connection
EM
GASKET
HEXAGON HEADBOLT COVER
M6x20 GASKET
PRU
Torque value GASKET
- 100kgm
l Notice : M6x20 BOLT Torque value : 80~100 kgm

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4.2. Power Rectifier Equipment (PRE)

Secure 600mm maintenance space from the front of PRE and 300mm from left and right side of PRE
when reflecting FTU installation design.
- In reflecting installation design, remove any interference factor because electric cable
(150SQX16ea), which is supplied to ECU, is connected above PRE.
- PRE is interlocked with ECU and reflect installation space nearby ECU.
- In reflecting installation design, remove any interference factor because distilled water pipe, which
cools down heat generated from PRE, is installed at the lower part of PRE.
- Check length & specification of pipe & flange supplied from makers and then reflect installation
design.
- Avoid shock during transportation. PRE is electrical equipment and if shocked, damage to PRE can
occur.

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4.3. Power Rectifier Unit (PRU)

4.3.1. Ex proof PRU
Ex-PRU is designed to be installed in Zone 1 or Zone 2 area which are risk area category standard of IEC
60079.
Only trained experts should handle the wire connections of the product.
When moving the product to a safer place, related laws, regulations, and procedure must be followed.
Related standards should be followed for maintaining the overall certification of the product.
When replacing Electro module, power rectifier unit, cover, and busbar, additional caution should be paid
not to cause any damage to the product.
When using anti-seize compounds on screw threads, please apply only thin amount of certified
chemicals (for instance, petroleum jelly) that does not consist of silicon.
To reduce the explosion risk in the atmosphere, any closed area should be vented and all power sources
should be unplugged prior to opening the external cover of any electrical device. While using any piece
of equipment, all screws of the equipment should maintain the condition of being tightly fastened.
In potentially explosive risky environments where power is supplied; opening, replacing, or repairing of
any instrument is not allowed.
To maximize electrical safety and minimize frequency interference, PRU should be grounded.
Ground connecting terminal of PRU is supplied on the outside of the instrument.
Internal ground connection is used to provide basic ground connection to the instrument. External
ground connection can be used only in a place where person-in-charge considers necessary and only
used as a supplementary connection terminal.
Wrong ground connection may cause misoperation or alarm.
When using instrument/equipment, please verify for presence of any corrosion.
Waste disposal must follow environmental law and waste disposal requirements of applicable area.

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Wiring Connection
Power cable
Connection
Terminal
Signal cable Connection Terminal
l Notice : PRU Cover Torque value : 100~120 kgm
PRU Power
“R” “S” “T”

Phase Phase Phase

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PRU Signal
485 +
485 -
GND
Cable Glands & Cables

Only use cable glands (Donga bestec-a2f) provided by Techcross Inc.
Shipboard coated cables approved by international standards and within acceptable limitations of PRU
should be used.
After inserting cable into cable gland, ensure that the cable is properly tightened in the cable gland.
Ground Connection
Ground Connection of cables is quite significant in blocking electric interference.
When installing, connect ground connecting cable that was provided by Techcross Inc. in between PRU
and ECM as below.

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4.4. Power Control Unit (PCU) / Power Distributor Equipment (PDE-A2 / PDE-A4/PDE)
Secure 800mm maintenance space in front of PDE.
In determining installation design space, remove any interference of equipments near Cable Entry
located at the bottom (for example, pipe & cable of other marine equipments).
Do not expose shock to equipment during transportation. PDE is electrical equipment and if shocked,
damage to PDE can occur.

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4.5. TRO Sensor Unit (TSU)
Secure 700mm maintenance space in front of TSU when determining TSU installation design.
In determining installation design space, remove any interference near the bottom of the equipment
which is connected to the sampling port.
No. 1, 2, and 3 sampling ports are for taking samples of treated ballast water. These sampling points
should be installed within 45m from TSU.
Please refer to page on detailed design of ballast pipe sampling points of the above three ports.
No. 4 and 5 sampling ports function as treated sampling water drains. If pipeline contains area of
reverse pressure, drainage will not properly occur. In determining installation design, please avoid any
section where reverse pressure can occur.
Check length & specification of flexible hose supplied from makers in determining proper installation
design.
Please install strainer at 1, 2, & 3 sampling ports.

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4.5.1. Ex proof TSU
4.5.1.1. CLX Sensor
See “4.0 Purge Control X-Purge Controller Operation“ in the Appendix 1 - TCL_4_ECS-
EX(28815TB)_Techcross_Rev_1.5.pdf (Page 5 - 6)

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4.6. Auto Neutralization Unit (ANU)
Secure 700mm maintenance space in front of ANU and 300mm above of ANU in determining ANU
installation design space.
In determining installation design space, remove any interference near the bottom of ANU which is
connected to a sampling port.
Please check the page on detailed design of discharge point of Port 2 and 3 ballast pipe neutralization
agent.
Avoid shock during transportation. ANU is electrical equipment and if shocked, damage
to ANU can occur.
Check length & specification of flexible hose supplied from makers in determining proper installation
design.

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4.7. Flow Meter Unit(FMU)
See “Performance characteristics“ in the Appendix 3 - EH 50WXX-UX TI046DEN_1109.pdf (Page 13 - 19)

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4.8. Conductivity Sensor Unit (CSU)

4.8.1. Non ex proof CSU
Place the device with the sensor in the opening of the piping carrying the medium, or directly in the
tank.
Place the sensor opening in the middle of the pipe diameter.
Observe a minimum distance of 10mm from the pipe wall.
Orientate the instrument in a way that the double arrow marks the flow direction so that the sensor
opening is aligned with the proper flow direction.

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4.8.2. Ex proof CSU
4.8.2.1. Sensor
Cable connection

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4.8.2.2. Transmitter

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Installation In Ex area
Mount palte

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Weather Protection Cover

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4.9. Vibration Level Sensor (VLS) & Ex proof Vibration Level Sensor

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Handling

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4.10. Ex proof Gas Dector Sensor (GDS)

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Mounting and Location
Mounting and transmitter

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Mounting Arrangement

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Installing the Sensor

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Electric Connection

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Date Doc, No. Ver.
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Cabling
Grounding
Controller Grounding
System Grounding

Date Doc, No. Ver.
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Grounding Terminal Wiring

Date Doc, No. Ver.
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4.11. Ex proof Freshwater Pump – Option
See in the Appendix 6 - SIMENSE 1MJ6096.pdf (Page 1 - 28)

Date Doc, No. Ver.
` 2012-12-18 1.0
5. System Limitations
5.1. Limitations of Installation
The following conditions shall be considered when arranging and installing equipments.
1) ECS must not be installed on opendeck where exposed to the environment

2) ECS may be installed in exposure area with IEC 600529 below ;
Hazardous Area of installation : Zone 1 or Zone 2

Date Doc, No. Ver.
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5.2. Range of ECS Flow Capacity
5.2.1. ECS-150B
ECS-150Bx2set
5.2.2. ECS-300A/B
- ECS-300A/B : (ECU-300A/B 1ea)
- ECS-600A/B : (ECU-300A/B 2ea)
- ECS-900A/B : (ECU-300A/B 3ea)
- ECS-1200A/B : (ECU-300A/B 4ea)
- ECS-1500A/B : (ECU-300A/B 5ea)
- ECS-1800A/B : (ECU-300A/B 6ea)
- ECS-2100A/B : (ECU-300A/B 7ea)
- ECS-2400A/B : (ECU-300A/B 8ea)
- ECS-2700A/B : (ECU-300A/B 9ea)
- ECS-3000A/B : (ECU-300A/B 10ea)
5.2.3. ECS-450B
- ECS-450B : (ECU-450B 1ea)
- ECS-900B : (ECU-450B 2ea)
- ECS-1350B : (ECU-450B 3ea)
- ECS-1800B : (ECU-450B 4ea)
- ECS-2250B : (ECU-450B 5ea)
- ECS-2700B : (ECU-450B 6ea)
5.2.4. ECS-600A/B
- ECS-600A/B : (ECU-600A/B 1ea)
- ECS-1200A/B : (ECU-600A/B 2ea)
- ECS-1800A/B : (ECU-600A/B 3ea)
- ECS-2400A/B : (ECU-600A/B 4ea)
- ECS-3000A/B : (ECU-600A/B 5ea)
- ECS-3600A/B : (ECU-600A/B 6ea)
- ECS-4200A/B : (ECU-600A/B 7ea)
- ECS-4800A/B : (ECU-600A/B 8ea)
- ECS-5400A/B : (ECU-600A/B 9ea)
- ECS-6000A/B : (ECU-600A/B 10ea)

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5.2.5. ECS-1000A/B
- ECS-1000A/B : (ECU-1000A/B 1ea)
- ECS-2000A/B : (ECU-1000A/B 2ea)
- ECS-3000A/B : (ECU-1000A/B 3ea)
- ECS-4000A/B : (ECU-1000A/B 4ea)
- ECS-5000A/B : (ECU-1000A/B 5ea)
- ECS-6000A/B : (ECU-1000A/B 6ea)

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5.3. Characteristics of installation location, system arrangement information, relation with

ballast water management plan
Installation and arranagement for ballast water management are related to ballast water pumps and
pipes. Since there is little difference between ballast water pump structures, it is possible to install a
bwms in almost any vessel. However, it is much easier to find space in a large vessel as compared to a
small vessel. Although installation space for electrolysis module is sufficient even for a small vessel,
sometimes installation space for rectifier and cooling system is very limited. If installation space is not
enough, the electrolysis module, rectifier, and heat exchanger can be installed in different locations from
each other. However, connection of communication equipments between engine room and pump room
needs to be sometimes complemented. This can be done by using a repeater between communication
cables. Thus, a sound ballast water management plan should have minimal problems of BWMS
installation, operation, communication, and maintenance.

Date Doc, No. Ver.
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6. Routine maintenance and trouble-shooting procedures
6.1. General information

1) Establish an individual maintenance plan according to PMS relating to the functions supported by
ECS installed on a ship. Based on the plan, efficient inspection/maintenance can be executed.
2) It is important to secure the reliability of functions relating to ECS Emergency operation by
regular or intermittent inspection/maintenance.
6.1.1. Purpose
To prevent any potential accidents during ECS operation as a result of operating by a systematic
maintenance plan
6.1.2. Application
1) ECS main components
6.1.3. Inspection/Maintenance Cycle and Allowance Criterion

1) The inspection/maintenance of ECS components is based on the inspection/maintenance intervals
recommended by ECS maker.
For detailed information about PMS of ECS, refer to Maintenance.
2) Pass/Failure of the results of operating ECS after inspection/maintenance depends on the normal
operation values of ECS manual provided by ECS maker.
For detailed information about normal operation of ECS, refer to ECS manual.

Date Doc, No. Ver.
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6.1.4. Procedure of PMS
1) Maintenance
The maintenance plan of each ECS component should be systematically executed, based on PMS.
Details of maintenance should be filled out in Remarks, which should be retained for later
maintenance.
① Establishment and review of maintenance plan
② Execution of maintenance plan
2) Defect repair
ECS operation or ECS component inspection should follow PMS and Non-PMS; any defect found
should be repaired.
3) Inspection of spare parts
Periodically inspect spare parts so that spare parts can be maintained in normal condition.
6.1.5. Report and Management of Defect
1) Definition of defect
Damage or malfunction of ECS component is regarded as a defect
2) Scope of reporting defect

Report defects to check the defect of ECS component and request support from ECS maker.
Report the defect and parts that are responsible for the unstable current conditions.
① Defect that may be solved without support from ECS maker

② Defect that may not be solved without support from ECS maker
6.1.6. Check out the Execution of Planned Maintenance
A person in charge should check maintenance schedule sheet and equipment history card to determine
whether it is being executed as planned.
For detailed information about Maintenance Schedule Sheet,

refer to Maintenance Schedule Sheet.
For detailed information about Equipment History Card,

refer to Equipment History Card.

Date Doc, No. Ver.
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6.1.7. Maintenance Schedule Sheet

1) Fill in Maintenance Schedule Sheet
Maintenance Schedule Sheet (Sample)
Person in charge : Position / Name
Inspection / Prior Latest Expected

No. ECS Component Name Maintenance Interval Maintenanc Maintenanc Maintenanc
List e Date e Date e Date
1 MM/DD/YY MM/DD/YY MM/DD/YY
Before filling out this form, please read the following comments carefully.
① Person in charge
Fill in the position and name of the person in charge
② No.
Fill in the number
③ ECS Component Name
Fill in the name of ECS component to inspect or maintain through Ch. 7 Maintenance of the ECS
manual provided.
④ Inspection / Maintenance List
Fill in the inspection / maintenance parts of ECS equipment
⑤ Interval
Fill in the interval of inspection / maintaining ECS equipment based on inspection / maintaining
intervals recommended by maker.
⑥ Prior / Latest / Expected Maintenance Dates
Fill in the date of inspection / maintenance in the form of MM/DD/YY

Date Doc, No. Ver.
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6.1.8. Equipment History Card

1) Fill in Equipment History Card
Equipment History Card (Sample)
Card No. : Page :

Person in charge : Position /
ECS Component Name :
Name
1. Model Name :
2. Serial No. :
3. Maker : ex) TECHCROSS
4. Instruction Book : ex) ECS Manual
5. Spare Parts Storage : ex) E/R 3rd Deck Store
Date Summary of inspection / Maintenance
MM/DD/YY
Before filling out this form, please read the following comments carefully.
A. Card No.
Fill in the no. of ECS equipment in the maintenance schedule sheet.
B. Page
Fill in the page number.
C. ECS Component Name
Fill in the name of ECS component.
D. Person in charge
Fill in the position and name of the person in charge.
E. Model Name
Fill in the model name of ECS equipment.
F. Serial No.
Fill in the serial no. of ECS equipment.
G. Maker
Fill in the maker of ECS equipment.
H. Instruction Book
Fill in the instruction book name of ECS equipment.
I. Spare Parts Storage

Fill in the spare part storage location of ECS equipment.
J. Date
Fill in the date of inspection / maintenance in the form of MM/DD/YY
K. Summary of inspection / Maintenance

Date Doc, No. Ver.
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6.2. Routine maintenance of Equipments
6.2.1. Electro-chamber Unit (ECU)

Interval
Code Description Main Check Points Countermeasures
(M)
Weekly Appearance status of ECM Cleaning it with soft cloth
Weekly Appearance status of drain bolt If broken, replace it with spare part.
Electro-Chamber If drain gasket is defective, replace it with

ECU-M-001 Weekly Appearance status of drain gasket
Module spare part
Weekly Appearance status of name plate Cleaning it with soft cloth
3 Check if painting of ECM is damaged Painting
Connection status of
Weekly Tightening bolts and nuts with washer
ECM protector cover with ECM
Weekly Appearance status of electric label Cleaning it with soft cloth

ECM
ECU-M-002
Protector Cover Appearance status of
Weekly Cleaning it with soft cloth
general avoidance label
Weekly Appearance status of name plate Cleaning it with soft cloth

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6.2.2. Power Rectifier Equipment (PRE)

Interval
(M)
Appearance status of name
PRE-M-001 Name Plate Weekly Cleaning it with soft cloth
plate
Appearance status of Tightening bolts and nuts.

PRE-M-002 Side Door - R Weekly
side door – R Cleaning it with soft cloth
Operation status of If defective, replace it with

PRE-M-003 Front Door Weekly
front door open / close spare part
If defective, replace it with
PRE-M-004 Handle Weekly Operation status of handle
spare part
Connection status of joint and Reconnecting quick coupler socket with quick
check if joint is leaking coupler plug.
Joint Check for leaks on PRE piping
PRE-M-005 Weekly
(20A-Water In) assembly (Flange, Flexible If defective, replace it with
Hose, Female Plug, Socket, spare part
Plug, Coupling)
Connection status of joint and Reconnecting quick coupler socket with quick
check if joint is leaking coupler plug.
Joint Check for leaks on PRE piping
PRE-M-006 Weekly
(20A-Water Out) assembly (Flange, Flexible If defective, replace it with
Hose, Female Plug, Socket, spare part
Plug, Coupling)
Appearance status of side door Tightening bolts and nuts.

PRE-M-007 Side Door - L Weekly
–L Cleaning it with soft cloth
Power Rectifier Cleaning it with air brushing and
PRE-M-008 Weekly Appearance status of PRE
Equipment soft cloth
Emergency Stop Operation status of If defective, replace it with

PRE-M-009 1
Switch emergency stop switch spare part
Operation status of run light
spare part
PRE-M-010 Run Light Weekly
Appearance status of If broken, replace it with spare part. Cleaning it
run light cover with soft cloth

Operation status of alarm light
spare part
PRE-M-011 Alarm Light Weekly
Appearance status of If broken, replace it with spare part. Cleaning it
alarm light cover with soft cloth
Connection status of If power cable is defective,

PRE-M-012 Power Terminal Weekly
power terminal replace it with spare part
Communication Connection status of If communication cable is defective,

PRE-M-013 Weekly
Terminal communication terminal replace it with spare part
Cooling Water Cleaning cooling water inlet Cleaning it with air brushing by
PRE-M-014 24
Inlet Hose hose air compressor
Power Rectifier Cleaning it with air brushing and

PRE-M-015 24 Cleaning PRE

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6.2.3. Power Distributor Equipment (PDE)

Interval
(M)
Weekly Operation status of alarm light
spare part
PDE-M-001 Alarm Light
Appearance status of If broken, replace it with spare part.
Weekly
alarm light cover Cleaning it with soft cloth

Weekly Operation status of square light
spare part
PDE-M-002 Square Light
Weekly
alarm light cover Cleaning it with soft cloth
Cleaning it with air brushing and

PDE-M-003 Digital Power Meter Weekly Appearance status of LCD display
soft cloth
Cleaning it with air brushing and

PDE-M-004 ECS-RCM Weekly Appearance status of RCM
soft cloth
PDE-M-005 Selector Switch Weekly Operation status of selector switch
spare part

PDE-M-006 Switch On / Off Weekly Operation status of switch on / off
spare part

PDE-M-007 Switch On / Off Weekly Operation status of switch on / off
spare part
PDE-M-008 PB Switch Weekly Operation status of PB switch
spare part

spare part
spare part
PDE-M-011 Name Plate Weekly Appearance status of name plate Cleaning it with soft cloth
Power Distributor Cleaning it with air brushing and

PDE-M-012 Weekly Appearance status of PDE
Attachment status of
PDE-M-013 Electric Sub Assembly Weekly Tightening bolts and nuts
electric sub assembly
Appearance status of
PDE-M-014 PCB Connection Weekly Tightening bolts and nuts
PCB connection
Power Cable and Insulation status of power cable and If defective, replace it with
PDE-M-015 Weekly
Communication Cable communication cable spare part
Power Distributor Cleaning it with air brushing and

PDE-M-016 24 Cleaning PDE

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6.2.4. Control PC (CPC)

Interval
(M)
LCD Display Operation status of LCD display Cleaning it with air brushing
CPC-M-001 Weekly
(Touch Screen) (Touch Screen) and soft cloth
If LAN Port is defective,

CPC-M-002 LAN Port Weekly Connection status of LAN port
replace it with spare part
If USB Port is defective,

CPC-M-003 USB Port Weekly Connection status of USB port
replace it with spare part
Operation status of If defective, replace it with
CPC-M-004 Power On/Off Switch Weekly
power on/off switch spare part
CPC-M-005 Name Plate Weekly Appearance status of name plate Cleaning it with soft cloth

CPC-M-006 Cable Entry Weekly Appearance status of cable entry
spare part
Attachment status of
CPC-M-007 Wall Mount Bracket Weekly Tightening bolts and nuts
wall mount bracket
Appearance status of If defective, replace it with

CPC-M-008 A/Vibration Rubber Weekly
anti-vibration rubber spare part

CPC-M-009 Cable Gland Weekly Appearance status of cable gland
spare part
Overhaul CPC by
CPC-M-010 Control PC 24 Overhaul
ship’s service engineer

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6.2.5. Tro Sensor Unit (TSU)

Interval
(M)
Tightening bolts and nuts.
TSU-M-001 Hinge Weekly Appearance status of hinge
Cleaning it with soft cloth
TSU-M-002 Body Weekly Appearance status of body Cleaning it with soft cloth
TSU-M-003 Name Plate Weekly Appearance status of name plate Cleaning it with soft cloth
TSU-M-004 Door Weekly Appearance status of door Cleaning it with soft cloth
TSU-M-005 Handle Weekly Operation status of handle If defective, replace it with spare part.

TSU-M-006 Control Panel Cover Weekly
control panel cover Cleaning it with soft cloth
Connection status of WASTE Reconnecting coupling of flexible hose with

Weekly
male connector and flexible hose WASTE male connector
Connection status of BYPASS Reconnecting coupling of flexible hose with

Weekly
male connector and flexible hose BYPASS male connector
Connection status of DISCHARGE Reconnecting coupling of flexible hose with
TSU-M-007 Male Connector Weekly
male connector and flexible hose DISCHARGE male connector
Connection status of STARBOARD Reconnecting coupling of flexible hose with

Weekly
male connector and flexible hose STARBOARD male connector
Connection status of PORT Reconnecting coupling of flexible hose with

Weekly
male connector and flexible hose PORT male connector
1 Operation status of pump If defective, replace it with spare part.
TSU-M-008 Pump
24 Overhaul Overhaul pump by ship’s service engineer
2-Way Solenoid Operation status of

TSU-M-009 Weekly If defective, replace it with spare part.
Valve 2-way solenoid valve
If leaking, replace fittings of TSU with spare
TSU-M-010 TRO Sensor Unit Weekly Check for leaks in TSU
part
Connection status of Tightening bolts and nuts. If defective,

CLX OnLine Weekly
inline T-strainer replace it with spare part
TSU-M-011 Residual Chlorine
Refer to ECS appendix. Cleaning it with air
Monitor 1 Cleaning inline T-strainer
brushing by air compressor
See “11.0 Routine Maintenance “ in the Appendix 2 - TCL_4_ECS-EX(28815TB)_Techcross_Rev_1.5.pdf

(Page 30 - 34)

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6.2.6. Auto Neutralization Unit (ANU)

Interval
(M)
ANU-M-001 Front Door Weekly Appearance status of front door

ANU-M-002 Inbox Assembly Weekly
inbox assembly Cleaning it with soft cloth

ANU-M-003 Side Door Weekly Appearance status of side door
Weekly
T/Body, B/Frame T/body, B/frame assembly Cleaning it with soft cloth
ANU-M-004
Assembly
24 Cleaning F.W Tank Cleaning F.W tank with fresh water

ANU-M-005 Tank Top Cover Weekly
tank top cover Cleaning it with soft cloth
Tightening bolts and nuts. Cleaning it with
ANU-M-006 Tower Lamp Weekly Appearance status of tower lamp soft cloth, If tower lamp is defective, replace
it with spare part
XGT Housing Appearance status of

ANU-M-007 Weekly Cleaning it with air brushing and soft cloth
Assembly XGT housing assembly
Tightening bolts and nuts. Cleaning it with

ANU-M-008 Sensor Cover Weekly Appearance status of sensor cover soft cloth.
If broken, replace it with spare part
Appearance and operation status Tightening bolts and nuts.

ANU-M-009 Torque Hinge Weekly
of torque hinge If broken, replace it with spare part
ANU-M-010 Draw Latch Weekly
of draw latch If broken, replace it with spare part
Cleaning it with soft cloth.

ANU-M-011 Tank Window Weekly Appearance status of tank window
If broken, replace it with spare part

ANU-M-012 Window Plate Weekly Appearance status of window plate
ANU-M-013 Level Sensor 1 Operation status of level sensor If defective, replace it with spare part
ANU-M-014 Agitator 1 Operation status of agitator If defective, replace it with spare part
If broken, replace it with spare part. Contact

1 Operation status of quantity pump manufacturer when quantity pump is
ANU-M-015 Quantity Pump broken.
Overhaul quantity pump by
24 Overhaul
ship’s service engineer

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6.2.7. Local Operation Panel (LOP)

Interval
(M)
LOP-M-001 LOP Base Assembly Weekly Cleaning it with soft cloth
LOP base assembly

LOP-M-002 LOP Door Assembly Weekly
of LOP door assembly Cleaning it with soft cloth
Connection status of Tightening bolts and nuts.

LOP-M-003 Terminal Block Weekly
terminal block If broken, replace it with spare part
LOP-M-004 Cable Duct Weekly Appearance status of cable duct
spare part

LOP-M-005 SMPS Weekly Attachment status of SMPS If defective, replace it with
spare part

LOP-M-006 ELB Weekly Appearance status of ELB If defective, replace it with
spare part
Weekly Cleaning it with soft cloth.
front base cover
LOP-M-008 Front Base Cover
LOP-M-009 Name Plate Weekly Appearance status of name plate Cleaning it with soft cloth.
LOP-M-010 Manual Pocket
Appearance status of Cleaning it with soft cloth.
Weekly
manual pocket If broken, replace it with spare part
Local Operation Cleaning it with air brushing and soft cloth

LOP-M-011 24 Cleaning LOP
Panel
Cleaning flexible hose connected Cleaning it with air brushing by
LOP-M-012 Gas Flexible Hose 24
GSU air compressor

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6.2.8. Flow meter unit (FMU)

Interval
(M)
Tightening nuts and bolts.
FMU-M-001 Flange Weekly Connection status of flange If gasket is defective, replace it with spare
part
FMU-M-002 Body Weekly Appearance status of body Cleaning it with soft cloth
FMU-M-003 Head Weekly Appearance status of head Cleaning it with soft cloth
Cleaning it with air brushing and soft cloth.

Appearance and operation status
FMU-M-004 LCD Display Weekly If LCD display is defective, replace it with
of LCD display (Screen Display)
spare part
Appearance status of lining.
FMU-M-005 Lining Weekly If defective, replace it with spare part
(Hard Rubber) Check for leaks
Electrode Signal Insulation status of
FMU-M-006 Weekly If defective, replace it with spare part
Cable electrode signal cable
Appearance status of grounding

FMU-M-007 Grounding Ring Weekly ring. Check if the status of If defective, replace it with spare part
grounding is normal
FMU-M-008 Gasket 60 Gasket of flange Replace gasket every dock
1 Operation status of TMS program Conducting self function test

FMU-M-009 KTM Detector Adjust flow rate and flow velocity by
Weekly Adjust flow rate and flow velocity
maker’s service engineer every dock

Date Doc, No. Ver.
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6.2.9. Conductivity Sensor Unit (CSU)

Interval
(M)
Weekly Operation status of CSU If defective, replace it with spare part
Weekly Appearance status of CSU Cleaning it with soft cloth

Conductivity Sensor
CSU-M-001
Unit Connection and leakage status of If teflon is defective, replace it with spare
Weekly
CSU with ECM part
Cleaning it with air brushing by air

6 Cleaning CSU
compressor
Weekly Appearance status of CSC Cleaning it with air brushing and soft cloth
Conductivity Sensor
CSU-M-002
Unit
Weekly Connection status of CSC Tightening bolts and nuts
Conductivity Sensor
CSU-M-003 Weekly Appearance status of FTS Cleaning it with air brushing and soft cloth
Unit

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6.2.10. Freshwater / Seawater Temperature Sensor (STS / FTS)

Interval
(M)
F.W. Temperature Appearance status of
FTS-M-001 Weekly If defective, replace it with spare part
Input Cable F.W. temperature input cable
F.W. Temperature
FTS-M-002 Weekly Appearance status of FTS Cleaning it with air brushing and soft cloth
Sensor
S.W. Temperature Appearance status of

STS-M-003 Weekly If defective, replace it with spare part
Input Cable S.W. temperature input cable
S.W. Temperature
STS-M-004 Weekly Appearance status of STS Cleaning it with air brushing and soft cloth
Sensor

Date Doc, No. Ver.
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6.2.11. Gas Dector Sensor(GDS)
See “11 General Maintenance“ in the Appendix 5 - Sensepoint XCD Technical Manual.pdf (Page 32 - 33)

Date Doc, No. Ver.
` 2012-12-18 1.0
6.3. TROUBLE SHOOTING
General
Once alarm sounds during ECS operation, an operator should promptly refer to alarm messages
specified in Troubleshooting and take steps to restore ECS as soon as possible
PURPOSE
Troubleshooting is intended to promptly solve alarm messages, which you may encounter during ECS
operation. Once encountering a trouble, a user should read Ch. 9 Troubleshooting to seek the
troubleshooting. Notwithstanding, if you fail to find it, please contact TECHCROSS.
APPLICATION
1) Major ECS Component
Contact Information
• Head Office/Factory
25-1 Kwanam-ri, Inju-myun Asan-si, Chungcheongnam-do, Korea. (336-833)
Tel : +82-41-420-9032(Rep.) Fax : +82-41-420-9090
e-mail : ecs@techcross.com Homepage : http://www.techcross.com
• Technical Support Center

3F Hanjin Shipping Bldg., 79-9, Jungang-dong 4-ga, Jung-gu, Busan, Korea.
(600-755)
Tel : +82-51-603-3500(Rep.) Fax : +82-51-603-3535

Date Doc, No. Ver.
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6.3.1. Major ECS Component

6.3.1.1. Power Rectifier Equipment (PRE)
Inspection Measuring
Trouble Cause Troubleshooting Procedure
Part Instrument
Detection of out of Abnormal (not rated) voltage and current
allowable operating EM failure EM inspection 1) Disassemble the power cable between PRE and ECM
voltage protective cover.
2) Dissemble EM and check the state (record the damage)
AC/DC
3) Acid clean with 5% hydrochloric acid
Detection of out of Clamp Meter
→ Water clean → Air clean
allowable operating EM failure EM inspection
4) ECU test after re-assembling
current
5) If the test result shows the same symptom, EM is out of
order (Contact manufacturer)
1) Check whether the tank is filled with enough freshwater

(if insufficient, replenish water)
2) Check the piping of FTU, PRE and HEU and butterfly
valve openness
3) Tighten nuts and bolts and if leaking, replace gasket
Max. allowable HEU, FTU & 4) Check any leakage from the connection of FTU, HEU and
Freshwater
operating PRE Piping None PRE
circulation failure
temperature Inspection 5) If leaking, tighten the connection, replace teflon on
socket and reconnect quick coupler socket to quick coupler
plug
6) PRE test after inspection
7) If the test result shows the same symptom, PRE is out of
1) Inspect the connection between and among power cable,

communication cable and connector
2) If damaged, repair the connection between cable and
RCM CAN
AC/DC connector
No signal communication RCM CAN
Clamp Meter (requiring the confirmation of electrician)
failure
3) PRE test after inspection
4) If the test result shows the same symptom, PRE is out of
1) Inspect the operation state of FMU and ballast pump.

2) Inspect the open/close of ballast valve during ballasting
work
3) Inspect the connection of power cable, COM cable and
Detection of connector
VLS on error,
out of 4) If damaged, repair the connection between cable and
Lack of ballast PRE & VLS AC/DC
allowable connector
water in ECU communication Clamp Meter
operating (requiring the confirmation of electrician)
failure
current 5) Convert RCM to local mode to operate PRE in local mode
6) Turn off RCM, re-operate RCM and turn on HMU again
7) VLS test after inspection
8) If the test result shows the same symptom, VLS is out of

Date Doc, No. Ver.
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6.3.1.2. Power Distributor Equipment (PDE)

Measuring
Trouble Cause Inspection Part Troubleshooting Procedure
Instrument
1) If the measured master input voltage is same as that of

digital power meter
Abnormal master Check master AC/DC (Normal: below ±10%, Warning: between ±15% and
input voltage input voltage Clamp Meter ±20%, Failure: Over ±20%), PDE is normal.
2) ECS stops operation if master input voltage is beyond
Detection of out of the operating range.
allowable operating 1) Check whether the manually measured master input
master input voltage is lower than AC 440V
voltage. (Normal: below ±10%, Warning: between ±15% and
±20%, Failure: Over ±20%).
* Refer to Digital power Digital power 2) Check whether master input voltage is normally
AC/DC
Error Message meter meter displayed on digital power meter
Clamp Meter
failure inspection 3) Check the communication state of RS-485.
4) Digital power meter test after inspection
5) If the test result shows the same symptom, digital power
meter is out of order
(Contact manufacturer)

Date Doc, No. Ver.
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6.3.1.3. Control PC (CPC)

Measuring
Instrument
1) Inspecting power terminal and communication terminals.

If damaged, repairing the connector between and among
power terminal, COM terminal and connectors
Inspecting CPC
CPC failure or (requiring confirmation by electrician)
& power
communication None 2) After turning on CPC, check whether the entire
terminal and
The Communication failure information of HMI is displayed normally
COM terminal
Failure has 3) In case of the same symptoms after test, it is probably
occurred. CPC failure
Equipment name (Contact the manufacturer)
(No GPS signal) 1) Inspecting power terminal and COM terminals.
2) Repairing, if damaged, the connection between and
* Refer to Inspecting GPS, among power terminal, COM terminal and connectors
Error Message Communication CPC & power (requiring the confirmation of electrician)
failure or CPE terminal and None 3) Inspecting GPS operation state
failure communication 4) If failing to detect GPS signal, HMI software might not
terminals recognize GPS
5) In case of same symptoms after test, contact the
TECHCROSS service engineer.

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6.3.1.4. TRO Sensor Unit (TSU)

Measuring
Instrument
1) FMU operation inspection

2) Check whether approved voltage/current is supplied to
ECU (comparing the measurement of AC/DC clamp meter to
that of HMI)
Max. allowable Abnormal voltage 3) Check whether PRE provides ECU with approved
ECU, PRE & FMU AC/DC
operating TRO / Current supply voltage/current (comparing the measurement of AC/DC
inspection Clamp Meter
concentration. etc clamp meter to that of RCM)
4) Clean up the straighter connected to TSU male
5) TSU test after inspection
6) If the test result shows the same symptom, TSU is out of
1) FMU operation inspection

2) Check whether approved voltage/current is supplied to
ECU (comparing the measurement of AC/DC clamp meter to
that of HMI)
3) Inspect PRE voltage/current (comparing the measurement
Min. allowable Abnormal voltage ECU, PRE, FMU of AC/DC clamp meter to that of RCM)
AC/DC
operating TRO / Current supply & ballast pump 4) Inspect whether the change in ballast water flow rate is
Clamp Meter
concentration. etc inspection normal and measure the ballast time (check whether the
max. measurable capacity is normal)
5) Clean up the straighter connected to connector
1) Check whether the reagent in the above is enough.

Exchanges of
Insufficient 2) Prepare chlorine indicator.
Lack of reagent two kinds of None
reagent of TSU 3) Prepare buffer solution.
reagents
4) Replenish reagent in CLX monitor.
1) Inspect power cable, communication cable and

connection.
2) If damaged, repair the connection between cable and
Communication TSU & con- connector (requiring the confirmation of electrician)
AC/DC
No signal failure or TSU nection parts 3) After power is connected, check whether XGT panel is
Clamp Meter
failure inspection displayed normally.
See “10.0 Troubleshooting“ in the Appendix 2 - TCL_4_ECS-EX(28815TB)_Techcross_Rev_1.5.pdf (Page 27 -

29)

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6.3.1.5. Auto Neutralization Unit (ANU)

Measuring
Instrument
Insufficient
Lack of neutraliza-
neutralization 1) Check whether #1 F.W. tank is filled with enough F.W.
tion solution in No.1 F.W. tank None
solution in 2) Add a bag of neutralization agent to #1 F.W. tank
No.1 F.W. tank
No.1 F.W. tank
Insufficient
Lack of neutraliza-
neutralization 1) Check whether #2 F.W tank is filled with enough F.W.
tion solution in No.2 F.W tank None
solution in 2) Add a bag of neutralization agent to #2 F.W. tank
No.2 F.W tank
No.2 F. W tank
1) Check whether F.W. tank is filled with enough F.W.

2) Check whether Level Sensor is working normally
Insufficient
3) Add 1 bag of neutralization agent to each F.W. tank
Both ANU F.W. Freshwater in Level sensor,
None 4) Check whether or not agitator works
tanks are not ready. F.W. tank, agitator
5) ANU test after inspection
agitator Failure
6) If the test result shows the same symptom, ANU is out of
1) Check the connection between power cable and

communication cable
Communication ANU & 2) If damaged, repair the connection between cable and
No signal failure, connection parts None connector (requiring the confirmation by electrician)
ANU failure inspection 3) ANU test after inspection
4) If the test result shows the same symptom, ANU is out of

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6.3.1.6. Vibration Level Sensor (VLS) & Ex proof Vibration Level Sensor

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6.3.1.7. Gas Dector Sensor(GDS)
See “12 Servicing“ in the Appendix 5 - Sensepoint XCD Technical Manual.pdf (Page 33 - 36)

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6.4. Alarm Log

1) Alarm log consists of time, device, description, and alarm level.
2) Composition of Alarm log
① Query Condition I
Arrangement along Alarm_Level (Normal / Warning / Fault)
② Query Condition II
As divided into Today and All, today’s alarms can be checked by pressing TODAY button
③ Time
Present time is indicated in a form of Year-Month-Day Hour:Minute:Second
④ Device
Indicating a device from which ALARM occurs.
⑤ Description
Description of Normal / Warning / Fault (Normal shows normal operation state)
⑥ Level
Level of each alarm situation

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6.5. Error message

Error Message Warning Fault Measures
The amount of TRO concentration TRO concentra- TRO • Supplying abnormal (not rated) voltage/current
is over the regulated standard. tion concentration
TRO [valve], Pump [number] in ballasting in ballasting FMU operation inspection
(max. allowable TRO concentration) > 10 mg/L > 11 mg/L → Check whether approved voltage/current is supplied to
ECU (comparing the measurement of AC/DC clamp meter
with HMI)
→ Check whether PRE supplies approved voltage/current to
The amount of TRO concentration TRO concen- TRO
ECU (comparing clamp meter measurement with those of
is over the regulated standard. tration concentration
RCM)
TRO [valve], Discharge in deballasting in deballasting
→ Cleaning straighter connected TSU male connector
(max. allowable TRO concentration) > 0.1mg/L > 0.2mg/L
→ TSU test after completing inspection
→ TSU fault if a test shows the same result
(Contact the manufacturer)
• Supplying abnormal (not rated) voltage/current
FMU operation inspection

→ Check whether approved voltage/current is supplied to
ECU (comparing the measurement of AC/DC clamp meter
with HMI)
The amount of TRO concentration TRO TRO → Check whether PRE supplies approved voltage/current to
is below the regulated standard. concentration concentration ECU (comparing clamp meter measurement with those of
TRO [valve], Pump [number] in ballasting in ballasting RCM)
(min. allowable TRO concentration) < 6mg/L < 5mg/L → Inspect whether or not the change in ballast water flow
rate is normal. Measuring ballasting time (check whether or
not the max. process capacity is normal)
→ Cleaning straighter connected TSU male connector
→ TSU test after completing inspection
→ TSU fault if a test shows the same result
(Contact the manufacturer)
• Lack of TSU reagent
Replace the reagent of CLX sensor.

Lack of TSU Check whether reagent is enough on CLX monitor
CLX [number]
reagent → Chlorine indicator preparation
(lack of reagent)
→ Buffer solution preparation
→ Check whether reagent is enough on CLX monitor
There is no sample water flowing
Check whether TSU is normal
of CLX sensor. Lack of no. of TSU
→ Check whether TSU piping is normal
CLX [number] samples
→ Check whether ballast pump works normally
(lack of no. of samples)
Add the neutralizing agent.

Lack of Sodium Add sodium thiosulfate into the freshwater tank and start the
ANU [1/2], TANK [left/right],
Thiosulfate in agitator with the above water.
Pump [number]
freshwater tank → Check whether or not ANU is normal
(lack of sodium thiosulfate)
The neutralization solution is lower Lack of neutral- Check whether freshwater tank is filled with enough
than the regulated standard. ization solution in freshwater
ANU [1/2], TANK [left/ right], freshwater tank → Check whether Level sensor is normal

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Pump [number] → Add a bag of neutralization agent into each freshwater

(lack of neutralization solution) tank
→ Check whether or not agitator works normally
→ ANU test after completing inspection
→ If the ANU test result shows the same symptom, ANU is
out of order (Contact manufacturer)
The amount of freshwater supply is

Excessive
over the regulated standard. Turn off the freshwater valve
freshwater in
ANU [1/2], TANK [left/ right], → Check ANU freshwater supply valve
freshwater tank
Pump [number] → Discharging excessive freshwater
detected
(excessive freshwater in F.W. tank)
The discharge rate of neutralization
solutions is over the regulated
Max. allowable
standard.
neutralization Check whether or not TSU is normal
ANU [1/2],
solution vol. is → Check whether or not ANU is normal
Value [discharge vol. > 1600]
detected
(min. allowable neutralization
solution vol.)
• Master input voltage is abnormal
If the measured master input voltage is as same as the value

of digital power meter (Normal: below ±10%, Warning:
between ±15% and ±20%, Failure: Over ±20%), PDE is
normal
→ if since master input voltage is beyond the operating
range, ECS automatically stops operation
The input voltage is lower than the
Master input Master input
regulated standard.
voltage voltage
PMU [number], Value[ ] • Digital power meter failure
< 440V-15% < 440V-20%
(in case master input voltage is
(374V) (352V)
low) Check whether manually measured master input voltage is
within AC 440V (Normal: below ±10%, Warning: between
±15% and ±20%, Failure: Over ±20%)
→ Check whether or not master input voltage is normal on
digital power meter
→ Check the communication state of RS-485
→ Digital power meter test after inspection
→ If the test result shows the same symptom, digital power
meter is out of order (Contact manufacturer)
• COM failure or CPC failure
Inspect power terminal and communication terminals

The communication failure has → If damaged, repair the connection between and among
occurred. [device name] COM failure CPC failure power terminal, communication terminals and connectors
(failing to communicate) (requiring the confirmation of electrician)
→ Turn on CPC and check whether or not every information
is displayed on HMI
→ If the test result shows the same symptom, CPC is out of

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Check whether or not ECS components are supplied with

rated power
Failure of
→ Check whether or not network cable is normally
communication
connected
between ECS
→ Check whether or not PDE power is normal
equipments
→ Check whether or not HUB is normal
→ Check whether or not LAN IP is normal
Inspect power cable, COM cable and connectors

→ If damaged, repair the connections between cable and
connector
→ After power connection, check whether or not XGT panel
COM failure TSU failure
is normally displayed
→ TSU test after inspection
→ If the test result shows the same symptom, TSU is out of
Inspect power cable, COM cable and connectors

→ If damaged, repair the connections between cable and
connector (requiring the confirmation of electrician)
COM failure ANU failure
→ ANU test after inspection
→ If the test result shows the same symptom, ANU is out of
• COM failure or CPC failure
Inspect power terminal and communication terminals

→ If damaged, repair the connections between power cable,
communication terminals and connectors (requiring the
COM failure GPS failure confirmation of electrician)
→ Check GPS operation state
→ HMI software may not recognize GPS unless GPS signal is
detected
→ If the test result shows the same symptom, contact
TECHCROSS service engineer
• Abnormal seawater temperature

If seawater temperature is same as measured by
thermometer (within ±10%), HEU is normal
→ If temperature is higher than the max. allowable seawater
temperature, ECS operation stops.
The seawater temperature is higher • Seawater sensor fails
Sea water
than the regulated temperature. Sea water temp.
temp.
HEU [1], Value [ ] > 35℃ Check whether manually measured temperature is between
> 40℃
(max. allowable sea water temp.) 35℃ (±10%)
→ Check whether seawater sensor indicator accurately
displays temperature.
→ If damaged, repair the connection between cable and
connector (requiring the confirmation of electrician)→ HEU
test after inspection

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→ If the test result shows the same symptom, seawater

temp. sensor is out of order
• Abnormal freshwater temperature
Inspect the piping of HEU, PRE and FTU and check whether
or not butterfly valve is opened (incl. motor)
→ FTU inspection after test
→ If the test result shows the same symptom, freshwater
The freshwater temperature is (Contact manufacturer)
Freshwater
higher than the regulated tempera- Freshwater temp. • Freshwater temp. sensor failure
temp.
ture. HEU [1], Value [ ] > 35 ℃ Check whether freshwater temp. indicator displays
> 40 ℃
(max. allowable freshwater temp.) temperature accurately
connector (requiring the confirmation by electrician)
→ FTU inspection after test
→ If the test result shows the same symptom, freshwater
Freshwater
Check the seawater / freshwater
pump / seawa- Check whether freshwater/seawater pump are normal
pump signal. HEU [1]
ter pump → Check the power supply of PDE
(freshwater/seawater pump of PDE)
failure
The freshwater is insufficient.

Insufficient Check the freshwater level in tank
FTU [1]
freshwater in tank → Manually replenish freshwater in tank
(insufficient freshwater in tank)
Check the operation of seawater pump

→ Check the seawater piping and butterfly valve openness
Seawater pump → HEU test after inspection
failure → If the test result shows the same symptom, seawater
pressure sensor is out of order
An error has occurred during the (Contact manufacturer)
seawater operation. HEU [1] Check whether seawater pressure indicator displays pressure
(seawater pressure sensor not correctly
detected) → Repair the connection between cable and connector
Seawater sensor requiring the confirmation by electrician
failure → HEU test after inspection
→ If the test result shows the same symptom, seawater
Check the operation of freshwater pump

→ Inspect freshwater and butterfly valve openness
An error has occurred during the
Freshwater pump → FTU test after inspection
freshwater operation. HEU [1]
failure → If the test result shows the same symptom, freshwater
(Freshwater pressure not detected)

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The flow rate is above the

regulated standards. FMU [1], Value
Flow velocity Flow velocity
[ ] Check whether or not FMU is normal
(max. allowable velocity for FMU
operation)
The flow rate is below the
regulated standards. FMU [1], Value
Flow velocity Flow velocity
[ ] Check whether or not FMU is normal
(min. allowable velocity for FMU
operation)
• Over seawater conductivity
The electric conductivity is below
Seawater Seawater
the regulated standard.
conductivity conductivity> If the seawater conductivity is same as the measurement of
CDT [1], Value[ ]
> 60mS/cm 60mS/cm conductivity meter (within ±10%), CSU is normal
(max. allowable conductivity of sea
(> 10 PSU) (> 8 PSU) → If conductivity of sea water is out of operation range, ECS
water)
is stopped automatically.
• CSU failure
Check whether the manually measured conductivity of
seawater is 60mS/cm (± 10%)
→ Check whether CSC displays the conductivity of seawater
correctly
connector (requiring the confirmation of electrician)
→ CSU test after inspection
→ If the test result shows the same symptom, CSU is out of
The bypass operation has been
started up. If bypass is on during ballasting operation
Mode [Ballast] Valve [Number]

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6.6. Fault message

Description Conditions Measures
• Check whether IGBT instantaneous current
occurs
The IGBT instantaneous current is over
→ Reduce the excessive current
the regulated standard. PRE [Rectifier]
• Check the powerline
(instantaneous IGBT (DC / DC) over Instantaneous IGBT current > 150A
→ If damaged, repair the connection between
current)
cable and connector
(IGBT built in PRE)
• Check for any damages on IGBT (DC / DC)
→ Replace if damaged
• Check whether the input voltage of IGBT (DC /
The IGBT input voltage is over the
DC) Vdc is changed
regulated standard. PRE [Rectifier] Input voltage > 530Vac
→ If changed, reduce the input voltage of IGBT
(IGBT (DC / DC) Vdc over current)
(DC / DC) Vdc.
The output voltage is over the regulated • Check the output voltage
standard. PRE [Rectifier] Output voltage > 10Vdc → If abnormal (not rated) output voltage is
(over voltage output) supplied, apply proper output voltage
• Check any change in IGBT (DC / DC) Vdc input

The IGBT input voltage is lower than the
voltage
regulated standard. PRE [Rectifier] Input voltage < 320Vac
→ if changed, increase IGBT (DC / DC) Vdc input
(IGBT (DC / DC) Vdc low voltage)
voltage
The temperature of pulse transformer is

over the regulated standard. PRE
Pulse Transformer Heat Sink Temp. • Check the coolant
[Rectifier]
switch operating → repair it if damaged
(Pulse Transformer Heat Sink over
temperature)
The IGBT temperature is over the

regulated standard. PRE [Rectifier] IGBT (DC / DC) Heat Sink temp. switch • Check the coolant
(IGBT (DC / DC) Heat Sink over operating → repair if damaged
temperature)
• Inspect power cable, COM cable and connector

→ If damaged, repair the connection between
cable and connector (requiring the confirmation
by electrician)
The communication failure has occurred
RCM CAN COM failure duration > 4 → PRE test after inspection
between PRE and RCM.
secs → If the test result shows the same symptom,
(PRE [Rectifier], RCM CAN COM failure)
PRE is out of order
The PRE operation has been stopped by

• Check the state of emergency switch of RCM or
an operator as an emergency measure. Check emergency stop switch on/off
PRE
PRE [Rectifier]
An error has occurred in the temperature • Check the communication line connection
/ humidity sensor. PRE internal temp. / humidity sensor → Check the state of temp./humidity sensor
PRE [Rectifier] failure • If HMI shows the same fault message,
(temp./humidity sensor fault) “Temperature / Humidity sensor fault” after CPC

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rebooting, replace temperature / humidity sensor
• Check whether IGBT instantaneous current

occurs
→ Reduce the excessive current
The IGBT fails in running driver. • Check the powerline
PRE [Rectifier] IGBT drive circuit failure → If damaged, repair the connection between
(Fatal IGBT (DC / DC) drive failure) cable and connector
• Check any damage on IGBT (DC / DC) drive
circuit
→ Replace if damaged
• Check the open/close state of ballast valve for

ballast water flow rate and ballast work
ECU has not been filled with enough → Converting RCM to local mode to operate PRE
Insufficient water inside ECU
water. PRE [Rectifier] in local mode
→Turn off RCM and re-operate RCM remotely
→ Turn off and re-operate HMI for ballasting.
An error has occurred during the PRE

software program operation. Replace DSP PCB if HMI shows fault message
Program on error
PRE [Rectifier] after CPC rebooting
(Divide by zero on error)

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6.7. Detailed Emergency Actions for Discharging Untreated Water and Repairing, and Ship
Safety in case of System Malfunction
6.7.1. How to Discharge Untreated Water due to BWMS Malfunction

Countermeasures against factors that may hinder ballast water discharge in case of ECS malfunction or
misoperation are a vital part of operating ECS. ECS can assure safe ballast water discharge under various
system malfunctions and misoperations.
6.7.1.1. In Case of Electrolytic Disinfection Module Malfunction

The electrolytic disinfection module is divided into unit electrode modules which can have two types of
malfunctioning: complete sytem malfunction and partial system malfunction. In case of partial system
malfunction, the control system automatically adjusts ballast water intake flow rate to meet D2 standards.
This adjustment causes a longer operation time than usual but produces required end results. All
malfunctions are monitored by the control system to enable for timely repair and/or replacement.
6.7.1.2. Procedure for Untreated Ballast Water Discharge due to System Error
When untreated water has to be inevitably discharged and is unable to apply guidelines mentioned
above, follow the procedure below:
Write down untreated water discharge location, discharge amount, discharge time, discharged types of
active substances and concentration, and details of the malfunction. It is recommended that the person-
in-charge promptly take action to repair or replace the ballast water control system.
6.7.2. Emergency Action for Ship Safety

Emergencies caused by this ballast water system can be divided into structural situations (such as ballast
pipe breakage), electrical situations (such as electrolyte disinfection module leakage), and emergency
situations (such as fires).
6.7.2.1. Emergency Action in case of System Defect or Leakage

Following are steps to take in case of leakage due to ballast pipe defect and/or leakage in the
electrolytic disinfection module connections:
1) Sound the emergency alarm to inform others of the situation.
2) Cut off power in order to stop ballast pumps and BWMS.
3) Stop ballast water intake and ballast water discharge to and from the the electrolytic disinfection
modules by closing the valves attached in front and behind the electrolytic disinfection modules.
4) Open the bypass valves for water to bypass the BWMS.
5) Inform system expert for further actions.
6) Check for any leakage and repair any required parts.

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6.7.2.2. Emergency Action in case of Electrical Defect

Following are steps to take in case of electrical overload of the ballast water treatment system causing
overheating or fire:
1) Sound the emergency alarm to inform others of the situation.
2) Stop the ballast water treatment system.
3) Turn off the main circuit breaker of the ballast water treatment system.
4) Use fire extinguisher in case of fire.
5) Inform system expert for further actions.
6) Check for any leakage of power and repair any required parts.

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6.8. Log Viewer

ECS Log
ECS records logs pertaining to operations. This information is stored for two years in accordance with
the BWM Convention. The logs are encoded before being stored in order to prevent malicious editing.
Viewing of the logs is possible with a special viewer program offered with ECS. This section explains how
to view the logs.
HMI Log Viewer

There are two ways to view the log. One of the methods is to view it within the HMI program which
offers a simple and quick look at the log.
How to View Logs in the HMI program

In order to view logs in the HMI program, the program must be first activated. Then a window as below
will display:
ECS HMI Main UI
Press the button on the right bottom of the ECS HMI Main UI. The menu will appear as the
picture below.
Menu List

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By clicking the button in the menu, a log window will appear as below.
HMI Log Viewer
HMI Log Viewer contains TODAY function and Query function (sorting function by alarm level) for quick
and easy view.
Log Backup
ECS HMI provides Log Backup function for data protection. The Backup function offers for log viewing
on a personal computer as well. This section explains how to backup logs to a USB memory stick.
How to Backup Logs

HMI log backup requires a USB memory stick. Follow the procedures below:
1) Activate the ECS HMI program.

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ECS HMI Main UI
Then a window will pop up as above.
2) Click the MENU button on the right bottom.
When the button is pressed, the menu will appear as below:
Menu Dialog

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3) Click the Log Backup button.
Click the button.

Then “ECSOperationLog_DATE.csv” file will be created in the “C:\ECS_Backup\” folder.
4) Insert USB memory stick to the USB port, and copy the file “ECSOperationLog_DATE.csv” to the
memory stick using Windows Explorer (File Explorer)
5) Now backup is complete and user can leave the log data for storage or view the backup data on ECS
Log Viewer.
ECS Log Viewer

ECS Log Viewer enables users to view backup logs on their personal computers. Users can view, explore,
and print logs.
Main Screen
The picture below shows the first screen the program displays which consists of Menu Window and View
Window. Menu Window contains three functions which are Open log in USB, Filter log, and Print log.
View Window displays logs with its dates, messages, and alarm levels.
Main Window

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A – Log View
Menu of the Log window.
B - Open log
It opens backup logs saved on USB memory stick. When the memory stick is inserted into a PC, the USB
drive automatically appears in the list box and user can open the log file by clicking the Open button.
C - Filter Log
It filters log data by date, showing logs between “Date 1” and “Date 2”
D- Print Log
It allows users to preview and to print log data.
E - View Window
It displays logs with its dates, messages, and alarm levels.
F - Line Information Status Bar

It displays number of logs shown in the View Window and row number of currently selected log.
How to Use the Program

This section explains how to use Open log, Filter log, and Print log (Preview log and Print Log).
Open Log
Have USB memory stick which contains backup log files ready. Activate the program and insert the USB
memory stick into the PC. Then the USB port drive will appear on the right bottom of the combo box of
the Open log. Next, click the drive and then the Open button to display the log
data in the View Window as below.

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Open Log
Filter Log
In order to filter logs by date, click the arrow in the combo box ,then the calendar will
appear in which user can choose dates. Otherwise, user can click year, month, or
date in the input box and enter date directly using number keys on keyboard. Once two
dates are chosen, click the Query button to view the filtered data.

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Preview Log
In order to preview what is going to be printed, click the Preview button. Then the preview screen
will appear as below.
Print Preview
In Preview, user can enlarge or reduce the view of the document to be printed or see multiple pages at
the same time.
Print Preview Menu

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Print Log
In order to print log, click the Print button. Then a screen will display as below.
Print Window
Choose printer and print range and then click OK. In case user is not sure what page number to print,
refer to Preview.

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7. Monitoring System and Electrical/Electronic Wiring Diagrams

7.1. Monitoring System
Summary flow chart of ballasting and deballasting operation of ECS in logic diagram
7.1.1. Basic flow chart

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7.1.2. Ballasting flow chart

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7.1.3. Deballasting flow chart

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7.1.4. Stripping flow chart

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7.2. Electrical/Electronic Wiring Diagrams

7.2.1. ECS Equipments
7.2.1.1. Power Rectifier Unit (PRU)

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7.2.1.2. Power Control Unit (PCU)

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7.2.1.3. Power Distributor Equipment (PDE-A2)

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7.2.1.4. Power Distributor Equipment (PDE-A4)

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7.2.1.5. Power Distributor Equipment (PDE)

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7.2.1.6. Control PC (CPC)

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7.2.1.7. TRO Sensor Unit (TSU)

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7.2.1.8. Auto Neutralization Unit (ANU)

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8. Calibraion
8.1. TRO Sensor
See “7.0 Instrument Calibration“ in the Appendix 2 - TCL_4_ECS-EX(28815TB)_Techcross_Rev_1.5.pdf (Page

18 - 19)

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8.2. Conductivity Sensor Unit (CSU)

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8.3. Gas Dector Sensor (GDS)
See “10 Response Check and Calibration“ in the Appendix 5 - Sensepoint XCD Technical Manual.pdf
(Page 28 - 31)

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9. Shop Testing and Onboard Testing Documentation

9.1. Shop Test Document
ECS (Electro-CleenTM System)
SHOP TEST PLAN & REPORT
HULL No. :
TYPE : ECS –
OWNER :
CLASS :
SHIP YARD :
Owner :
Ship Yard : Maker :
Date: 20 . . .
TECHCROSS INC.

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TEST PROCEDURE
1. Main specification of ECS ----------------------------
2. Inspection of appearance & construction -----------------
3. Hy’d test -----------------------------------------
4. Insulation resistance measurement & High voltage test ----
4-1) Insulation resistance measurement
4-2) High voltage test
5. Operation and Safety device function test ----------------
5-1) Operation test
5-2) Safety device function test

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1. Main Specifications of ECS
Key Specifications
Type
Purpose Ballast Water Treatment System
Method Electrolysis disinfection
Capacity
Compliance with D-2 performance standard

Biological Efficacy
regulated by IMO
Less than or equal to TRO 10mg/L

Operation Performance (at the inside of Electro-Chamber Unit, average
6~10mg/L)
Total Power consumption
Operating Temperature 0°C ~ + 45°C (Install in enclosed location)
Salinity Condition
Seawater Temperature in Heat

Exchanger (HEU)
Freshwater Temperature in Heat

Exchanger (HEU)
Automatic input of Sodium thiosulfate

Neutralization
neutralization solution
Manual/Semi-automatic operation by Control PC

Operation Method
(CPC)
Operation S/W Human Machine Interface (ECS-HMI)
Equipment Color

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2. Inspection of Appearance & Construction

Each equipment (PCU, PDE, HEU, PRE, TSU, LOP, DTU, ANU, ECU) are to be inspected in
accordance with approved drawings.
No Inspection of Appearance & Construction Spec Actual Remark
1 Paint color of the panels
2 Arrangements & color of indicator lamps - As per DWG
3 Confirmation of name plates - As per DWG
As per DWG
4 Dimensions check - with check
sheet
5 Inspection of external appearance -

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3. ECU Hy’d test
Equipment SPL Design Standard Actual Result

Item Q’ty
Q’ty Value value Value
ECU Hy’d

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4. Insulation resistance measurement & High voltage test
4-1) Insulation resistance measurement:
Insulation resistance between the whole conductive parts and earth Metal is measured with DC
1,000V megger and it shall be confirmed more than 10MΩ.
⊙ Result of Shop test
AC440V Feeder / 220V Equipment UNIT : MΩ
Between Phase & Earth metal

Cold Hot
condition condition
SPL
Equipment. Q’ty Check Point Earthing
Q’ty
“R”,”S” “T”
PCU 1 1 “E”
Phase
“R”,”S” “T”
PDE 3 1 “E”
Phase
“R”,”S” “T”
PRE 12 4 “E”
Phase
TSU 1 1 “P”, “N” Phase “E”
LOP 1 1 “P”, “N” Phase “E”
ANU 1 1 “P”, “N” Phase “E”

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4-2) High Voltage Test
High voltage is sent between the whole conductive part and earth part for 1 minute as follows:
⊙ Result of shop test
AC440V Feeder / 220V Equipment
High voltage: 2,000(V), 60(Hz), 1Minute
Between Phase & Earth metal Result
Equipment. Q’ty SPL Check Point Earthing

Q’ty
“R”,”S” “T”
PCU “E”
Phase
“R”,”S” “T”
PDE “E”
Phase
“R”,”S” “T”
PRE “E”
Phase
“P”, “N”
TSU “E”
Phase
“P”, “N”
LOP “E”
Phase
“P”, “N”
ANU “E”
Phase

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5. Operation and Safety Device Function Test
5-1) Operation Test
No. Item Result Remark
1 Automatic Ballasting Test
2 Manual Ballasting Test
3 Automatic Discharge Test
4 Manual Discharge Test

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5-2) Safety Device Function Test
Actual
No. Item Design Value Value Remark
1 TRO 10 mg/L above Alarm
Trip
2 TRO 11 mg/L above
(Error after 10min.)
3 Emergency switch operation Trip
During operation, Freshwater

4 shortage in Freshwater Tank Alarm
Unit
Conductivity measure above
5 Alarm
60mS
Rectifier (PRE/PRU) Output
6 Alarm
above +10V
7 Alarm
above

8 Trip
above
Input power meter 440V ±10%
9 Alarm
(below 396V or above 484V)
Input power meter 440V ±15%
10 Trip
(below 374V or above 506V)
11 Freshwater temp. above 35℃ Alarm
12 Freshwater temp. above 40℃ Trip
13 H2 gas average change 2% Alarm
H2 gas average change above

14 Trip
4%
15 Neutralization solution shortage Alarm

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9.2. Onboard test document

ECS (Electro-CleenTM System)
ONBOARD TEST PLAN & PROCEDURE
HULL No. :
TYPE :
OWNER :
CLASS :
ORDERER :.
SHIPYARD
SIGNATURE
Owner : APPROVED BY :
Ship Yard : REVIEWED BY :
Class : WRITTEN BY :
Date: . . .
TECHCROSS INC.

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ECS (Electro-CleenTM System) ONBOARD TEST PLAN & PROCEDURE
Messrs. . Date
Hull No. Class Tested by Checked by
Room
Type ℃
Temperature
Room
Supply No. %
Humidity
Input Power Consumption AC440 3Ø, 60Hz, A(Max)
1. Onboard Test schedule

Date :
Place :
2. Attendant
1) Ship Owner - person
2) Classification Society - person
3) Shipbuilder - person
4) Maker - person
3. Test Plan
(1) Explanation on ECS units.
(2) Inspection of appearance & construction.
- Check the installed ECS system in accordance with approved drawings.
- Check power “ON” of all units. (Ready for Ballast Pump operation)
(3) Explanation on Control PC.
(4) Normal operation test and Abnormal operation test
- All units are operated by Control PC. The status of all units and those results can be checked on
Control PC.
- Control PC is installed in ballasting control room and Power Distributor Equipment as well. All
participants will move to Control PC at PDE and test its operation.
- Check Abnormal operation at ballasting (All ECS system exclude Auto Neutralization Unit)
- Check Normal operation and Abnormal operation at discharging. (Operating Auto Neutralization
System Unit)
- Interface with ballast pump operation.
* Total expected time : 2 hours

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4. System Operation Test Procedure

(1) Normal Operation Test
Normal Operation Test is a test for checking the operation ability of ECS. Test the ECS as
followed steps.
No. Item Pass criteria Method
Switch on the 440V/220V MCCB of
Normal ECU Press LAMP TEST button and
1 Equipment lamp condition
operation check alarm lamps are lighted up
on upper side of PDE.
Press automatic mode button on
HMI screen. And press START.
( ) ㎥/h disinfection Automatic operation start ->
2 6~10 mg/L
efficiency (Pump 1) Ballasting the Pump #1 -> 10
minutes later, check the TRO
concentration of Pump #1
( ) ㎥/h disinfection Automatic operation start ->
3 6~10 mg/L
efficiency (Pump 2) Ballasting the Pump #2 -> After 10
minutes, check the TRO
concentration of Pump #2
Automatic operation start->
( ) ㎥/h disinfection
4 6~10 mg/L Ballasting both Pump #1 and
efficiency (Pump 1, 2)
Pump #2 -> After 10 minutes,
check the TRO concentration of
Pump #1 and Pump #2
Check the normal operation
Disinfecting at the time of Normal
5 without shutdown during
HMI operation condition operation
operation.
Check whether the main
Equipment by display Normal
6 equipment status on HMI screen is
condition operation
lit up green.
Normal
7 HMI operation at deballasting Then, Automatic operation start->
operation
Deballasting begins -> Check the
neutralizing solution flows from the

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neutralization unit.
( )㎥/h at deballasting
Below Automatic operation start->
8 Neutralization efficiency
0.1mg/L Deballasting the Pump #1 -> 5
(Pump 1)
minutes later, check the discharge
TRO concentration of TSU.
Below 0.1 Automatic operation start->
9 Neutralization efficiency
mg/L Deballasting Pump #2 -> 5
(Pump 2)
minutes later, Check the discharge
TRO concentration of TSU.
Then, automatic mode on HMI.
( )㎥/h at deballasting Below And press the START button. Then,
10 Neutralization efficiency 0.1mg/L Automatic operation start->
(Pump 1, 2) (Error ± 10%) Deballasting Pump #1 and Pump
#2 -> 5 minutes later, check the
discharge TRO concentration of
TSU.
On HMI screen, press the Menu ->
HMI random access control Normal Detail View -> Admin -> Check
11
function operation whether Password is typed
properly.
Turn on the CPC and check
Normal
12 Output function whether automatically printed
operation
properly.

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(2) Abnormal Operation Test

Abnormal operation test can create serious problems on the system. So Abnormal operation test
needs to be tested with ECS Simulator.
No. Item Pass criteria

Method
Set up the TRO concentration as

above 10 mg/L during simulator
1 TRO 10 mg/L Alarm Operation
operation-> Check alarm is
working properly.
Set up the TRO concentration
System stop above 11 mg/L during simulator
2 TRO 11 mg/L above
(Alarm) operation -> Check system is
stopped properly.
During simulator operation the
Emergency switch System stop FAULT status on PRE will be taken
3
operation (Alarm) place -> Check whether system is
stopped properly.
during simulator operation, the
Neutralization solution Alarm Operation FAULT status on PRE will be taken
4
shortage place -> Check system is stopped
properly.
During operation, distilled Cause the distilled water shortage
Alarm Operation
5 water shortage in Distilled status by ECS simulator -> Check
water Tank Unit alarm is working properly.
Set up the Conductivity sensor
Conductivity sensor above Alarm Operation above 60mS with ECS simulator ->
6
60mS Check whether alarm is working or
not.
Set up the output power of
Rectifier (PRE/PRU) above Alarm Operation Rectifier (PRE/PRU) above 10V with
7
+10V ECS simulator -> Check whether
alarm is working properly.
Set up the output power of
Rectifier (PRE/PRU) A System stop Rectifier (PR/PRUE) above ( )A
8
above (Alarm) with simulator -> Check system is
stopped properly.
Rectifier (PRE/PRU) A Alarm Operation Set up the Rectifier (PRE/PRU)
9
above output power above ( )A ~

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( )A with simulator -> Check

alarm is working properly.
Set up the input power of Power
Input power meter 440V Alarm Operation
10 Meter below 374V or above 484V -
10%~15% (374V)
> Check alarm is working properly.
Set up the input power of Power
Input power meter 440V System stop Meter below 352V or above 502V -
11
15%~20% (352V) (Alarm) > Check system is stopped
properly.
Set up as distilled water
Heat Exchanger distilled Alarm Operation temperature above 35℃ on Heat
12
water temp. above 35℃ Exchanger -> Check alarm is
working properly.
Set up the distilled water
Heat Exchanger distilled System stop temperature above 40℃ in
13
water temp. above 40℃ (Alarm) simulating operation-> Check
system is stopped properly.
Set up the neutralizing solution as
Neutralizing solution above 800mL/min during discharge
14 Alarm Operation
amount above 800mL/min with ECS simulator -> Check alarm
is working properly.

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TEST PROCEDURE
Result
1. Main specification of ECS ----------------------------------- ( )
2. Inspection of appearance & construction ----------------------- ( )
3. Insulation resistance measurement & withstand voltage test ------ ( )
4. Normal operation test and Abnormal operation test --------------- ( )
1. Specification of ECS
Division Key specifications
Type
Purpose Ballast Water Management System
Method Electrolysis disinfection
Capacity ㎥/h ( ㎥/h Pump x sets capacity)
Biological Efficacy Compliance with D-2 performance standard regulated by IMO
Less than or equal to TRO 10mg/L

Operation Performance
(on the inside of Electro-Chamber Unit, average 6~10 mg/L)
Less than or equal to TRO 0.1mg/L after neutralization with sodium

Neutralization Performance
thiosulfate solution before discharging
Total Power consumption kW Max.(Salinity Condition: ‰( mS) ~ ‰( mS))
Operating Temperature 0~45°C (Install in enclosed location)
Salinity Condition
Seawater Temperature in Heat

Exchanger (HEU)
Freshwater Temperature in
Power Rectifer (PRE)
Neutralization Automatic input of Sodium thiosulfate neutralization solution
Operation Method Manual/Semi Automatic operation by Control PC
Operation S/W Exclusive software for ECS (ECS-HMI)

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2. Inspection of appearance & construction

Appearance dimension and insulation resistance are to be inspected in accordance with
approved drawings.
2-1) Paint color of the panels
2-2) Arrangements & color of indicator lamps
2-3) Confirmation of name plates
2-4) Dimensions check
2-5) Inspection of external appearance
3. Insulation resistance measurement & withstand voltage test

3-1) Insulation resistance measurement:
Insulation resistance between the whole conductive parts and earth Metal is measured with DC 500V
megger and it shall be confirmed more than 10MΩ.
We are going to measure megger test 2 times as such below table.
⊙ Result of Self test

AC440V Feeder
UNIT : MΩ.
Between Phase & Earth metal Between Phase & Phase
Che ◈ Before ◈ After Chec ◈ Before ◈ After
ck Result of Withstand Withstand k Result of Withstand Withstand
Poin Self Test Voltage Voltage Poin Self Test Voltage Voltage
t test test t test test
R-E 1,000 1,000 1,000 R-S 1,000 1,000 1,000
S-E 1,000 1,000 1,000 S-T 1,000 1,000 1,000
T-E 1,000 1,000 1,000 T-R 1,000 1,000 1,000

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3-2) Withstand voltage test

High voltage is sent between the whole conductive part and earth part for 1 minute as follows:
(Please confirm that nothing is wrong before continuing.)
⊙ Result of shop test

AC440V Feeder
High voltage: 2,800(V), 60(Hz), 1Minute
Between Phase & Earth metal Result

High voltage ◈ Shop
No. Earthing Self Test
supply Test
1 “R”,”S” Phase “T” Phase Pass Pass
2 “S”,”T” Phase “R” Phase Pass Pass
4. Normal operation test and Abnormal operation test

ECS Test consists of Normal operation test and Abnormal operation test.
The main test feature of Normal operation test is for checking the disinfection efficiency of ECS at
Ballasting and chlorine neutralization efficiency at deballasting. Abnormal operation test checks whether
the system acts safely during emergency circumstances. Also, in order to inspect disinfection efficiency,
one needs to check whether there are activating micro-organisms including plankton in the sampling
ballast water after treating the ballast water. Hereupon is the test procedure as followed by the IMO G2
standards.
Normal Operation Test
No. Item Pass criteria Self Test ◈Onboard

1 Equipment lamp condition Normal operation
㎥/h disinfection efficiency (Pump Below 9 mg/L
2
1) (Error ± 10%)
3
2) (Error ± 10%)
4
1, 2) (Error ± 10%)
Disinfecting at the time of HMI
5 Normal operation
operation condition

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6 Equipment by display condition Normal operation
7 HMI operation at deballasting Normal operation

( )㎥/h at deballasting Below 0.1mg/L
8
Neutralization efficiency (Pump 1) (Error ± 10%)
( )㎥/h at deballasting Below 0.1 mg/L
9
Neutralization efficiency (Pump 2) (Error ± 10%)
Below 0.1mg/L
10 Neutralization efficiency (Pump 1,
(Error ± 10%)
2)
HMI random access control
11 Normal operation
functional
12 Output function Normal operation
Abnormal Operation Test
No. Item Pass criteria Self Test ◈Onboard

Alarm Operation
1 TRO 10 mg/L
(Error ± 10%)
System stop (Alarm)
2 TRO 11 mg/L above
(Error ± 10%)
3 Emergency switch operation System stop (Alarm)
Neutralization solution Alarm Operation

4
shortage (Error under 5 sec.)
During operation, distilled
Alarm Operation
5 water shortage in Distilled
(Error under 5 sec.)
Water Tank Unit
Conductivity sensor above Alarm Operation
6
60mS (Error ± 10%)
Alarm Operation
7 Rectifier (PRE) above +10V
(Error ± 10%)
Rectifier (PRE/PRU) ( )A System stop (Alarm)
8
above (Error ± 10%)
Rectifier (PRE/PRU) ( )A Alarm Operation
9
above (Error ± 10%)
Input power meter 440V Alarm Operation
10
10%~15% (374V) (Error ± 5%)

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Input power meter 440V System stop (Alarm)

11
15%~20% (352V) (Error ± 5%)
Heat Exchanger distilled water Alarm Operation
12
temp. above 35℃ (Error ± 10%)
Heat Exchanger distilled water System stop (Alarm)
13
temp. above 40℃ (Error ± 10%)
Neutralizing solution amount Alarm Operation
14
above 800mL/min (Error ± 10%)

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10. Certificate of ISO 9001

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Date Doc. No. Ver.

Title Doc. Type

BALLAST WATER MANAGEMENT SYSTEM

MODEL : Electro-CleenTM System

Title Doc. Type

Title Doc. Type

2.9. TRO Sensor Unit (TSU) ................................................................................................... 36

Confidential Document iii

Title Doc. Type

3.2.3.1. System Self-Check ......................................................... 64

Title Doc. Type

4.2. Power Rectifier Equipment (PRE) ...................................................................................113

Title Doc. Type

6.1.5. Report and Management of Defect ..................................................................... 145

Title Doc. Type

6.7.1.2. Procedure for Untreated Ballast Water Discharge due to

Confidential Document vii

Title Doc. Type

Confidential Document viii

Title Doc. Type

Record History Of Revisions

Rev no. Description DATE

1.0 Approved 2012/12/18

Title Doc. Type

Title Doc. Type

PSU Practical Salinity Unit

1.1. General Specifications of Electro Cleen System (ECS)Revision History

Name ECS (Electro-CleenTM System)

1.2. Operation Range of Electro Cleen System (ECS)

Treatment Rated Capacity 150m3/h ~ 6000m3/h +10%

TRO Concentration 6 ~ 10 mg/L Less than 10 mg/L

Input Voltage 3 phases, AC440V±10%

Input Frequency 50/60Hz ±5%

Operation Ambient Temperature 0 ~ 45°C

Treatment Seawater Temperature Over 0°C Not frozen

Coolant Seawater 0 ~ 36°C Not frozen

Coolant Freshwater 0 ~ 40°C Not frozen

Confidential Document 12/264

1.3. Introduction of ECS Equipments

Power Control Unit ㆍ Control communication signal

ㆍ Control communication signal

Heat Exchanger Unit

Electrode Module (EM) ㆍ Electrode module

ㆍ Decrease TRO concentration of treated water before

Conductivity Sensor Unit (CSU) ㆍ Measure salinity of seawater (Conductivity of seawater)

Gas Sensor Unit (GSU) ㆍ Hydrogen gas detection

Flow Meter Unit (FMU) ㆍ Measure flow rate of ballast water

ㆍ Measure flow of ballast water in pipe line

Confidential Document 13/264

Water Treatment Capacity 300m3/hr (Max.+10%)

Design pressure 5bar

Material Body - SM490A T=9 / Other - SS400

Painting Epoxy (Inner : 300㎛ over / Outer : 150㎛ over)

Dimensions W1840mm x D690mm x H537mm

Ingress protection ECM+EM – IP67

Confidential Document 14/264

2.1.2. Ex proof ECU-300A

Water Treatment Capacity 300m3/hr (Max.+10%)

Design pressure 5bar

Material Body - SM490A T=9 / Other - SS400

Painting Epoxy (Inner : 300㎛ over / Outer : 150㎛ over)

Installation area Hazardous area zone 1,2 / Horizontal/Vertical Mount

Dimensions W1840mm x D565mm x H458mm

Weight Approx. 430Kg