220323 - Maintenance,Troubleshooting Book for Crews (3rd Edition) - CI리뉴얼 - Eng

Maintenance &
Troubleshooting Book for Crews

(3rd Edition)
All rights are reserved to TECHCROSS. Unless otherwise specified, no part of this
publication may be reproduced or utilized in any form or by any means, electronic
or mechanical, including photocopying and microfilm, without permission in writing
from TECHCROSS.
2 Maintenance & Troubleshooting Book for Crews(3rd Edition)
ECS Main equipment and Function

1. CPC(Control PC) ...................................................................................................................................08
2. PDE(Power Distributor Equipment) ............................................................................................09
- RTU, PMU, RCM, MC, BCM, CIM & AIM
3. TSU(TRO Sensor Unit) .......................................................................................................................10

- XGT, PLC, APU, CLX, Solenoid Valve
4. ANU(Auto Neutralization Unit) ......................................................................................................11

- XGT, PLC, Metering Pump, Agitator, Solenoid Valve
5. FTU & HEU ..............................................................................................................................................12

- Freshwater Tank Unit & Heat Exchanger Unit
6. ECU(Electro Chamber Unit) ............................................................................................................13

- PRU(Power Rectifier Unit)
- EPJ(ECU Power Junction Box)
- ESJ(ECU Signal Junction Box
- EM(Electrode Module)
- EWU(EM Washing Unit)
7. Sensor.......................................................................................................................................................14
- GDS (Gas Detection Sensor)
- FTS (Fresh Water Temperature Sensor)
- CSU (Conductivity Sensor Unit)
- FMU (Flow Meter Unit)
- T-Strainer
- PS/PI, TS/TI, VLS
8. Mixing Operation .................................................................................................................................15

- Mixing Pump, FCV, VCU, PCU
Maintenance & Troubleshooting Book for Crews(3rd Edition) 3
HMI & ECS Operation Guide

1. HMI . ..........................................................................................................................................................16
1.1 Menu ............................................................................................................................................................................. 16
2.1 Operation Menu ....................................................................................................................................................... 16
3.1 HOME ............................................................................................................................................................................ 17
2. Ballasting & De-Ballasting Operation Guide .........................................................................18

2.1 Operation preparation . ......................................................................................................................................... 18
2.2 Ballasting Operation ............................................................................................................................................... 19
2.3 De-Ballast Operation .............................................................................................................................................. 19
Maintenance Main equipment maintenance guide
1. ECU ..........................................................................................................................................................22
1.1 EM Cleaning ................................................................................................................................................................ 22
1.2 P.S(Pressure Switch), TS(Temperature Switch) .......................................................................................... 24
1.3 PRU Cooling Strainer Cleaning . ......................................................................................................................... 25
2. TSU ..........................................................................................................................................................26
2.1 Local Operation Guide ........................................................................................................................................... 26
2.2 How to check if Ex-CLX Purge Air is supplied ................................................................................................ 28
2.3 How to check CLX reagents ................................................................................................................................. 29
• CLX Flushing
• CLX Cuvette Cleaning
2.4 How to replace CLX reagents .............................................................................................................................. 30
• Non-ex CLX
• Ex CLX
2.5 Solenoid Valve ........................................................................................................................................................... 32
• Solenoid Valve Cleaning
• Solenoid Valve check guide
2.6 How to use Pocket Colorimeter(MD 100)........................................................................................................ 33
2.7 APU ................................................................................................................................................................................ 34
• APU check guide
• Disassembling APU
• APU Flushing
3. ANU ..........................................................................................................................................................36
3.1 Local Operation Guide............................................................................................................................................ 36
3.2 Filling of sodium thiosulfate ................................................................................................................................ 38
3.3 Assembling & Disassembling ANU tank level sensor................................................................................ 39
3.4 Solenoid Valve ........................................................................................................................................................... 40
3.5 ANU Flushing ............................................................................................................................................................. 41
4. PDE&CPC . .............................................................................................................................................42
4.1 How to check GPS Signal (Hyper Terminal) ................................................................................................. 42
5. HMI & Sensor .......................................................................................................................................44

5.1 How to extract Log file at HMI.............................................................................................................................. 44
5.2 GDS Zero Calibration .............................................................................................................................................. 45
5.3 CSU Zero Calibration (Air Set) ............................................................................................................................. 47
6. BWMS Maintenance list of major equipment / inspection period and method ..................48
Trouble Shooting
1. [COD100] ECU ......................................................................................................................................52
1.1 [CODE100] (Current Different Error) ................................................................................................................. 52
1.2 [CODE100] (P.S Pressure High) ........................................................................................................................... 53
1.3 [CODE100] (T.S Temperature High) .................................................................................................................. 53
1.4 [CODE100] (No Load Fail) . .................................................................................................................................... 55
1.5 [CODE100] VLS Water Level Low ....................................................................................................................... 56
1.6 [CODE100] ECU(Communication Fail) (PRU) ............................................................................................... 57
1.6.1 ESJ check guide ............................................................................................................................................... 57
1.6.2 PRU check guide ............................................................................................................................................. 59
2. [CODE200~299] TSU ........................................................................................................................66

2.1 [CODE200] TRO Concentration Low ................................................................................................................ 66
2.1.1 In case sampling water flow into cuvette of CLX normally ............................................................... 66
a. Priming
b. Flushing
c. Cuvette Cleaning
2.1.2 In case sampling water doesn’t flow into the cuvette of CLX ........................................................... 69
a. Sampling line Check
b. Check If APU works
c. TSU Sol V/V Cleaning
d. CLX Regulator adjustment
e. CLX Intake Sol V/V cleaning
2.1.3 In case ECU effciency is lower than before ............................................................................................. 74
2.2 [CODE201] TRO Concentration High................................................................................................................... 75
2.2.1 Alarm occurs during Ballasting .................................................................................................................. 75
2.2.2 Alarm occurs during De-Ballastting .......................................................................................................... 76
a. Check if ANU metering pump work.
b. Check setting of ANU metering pump
c. Voyage period or De-Ballast Tank TRO modification
2.3 [CODE202] CLX Sensor Power Fail / [CODE210] CLX Communication Fail ..................................... 79
2.3.1 Communication failure between PLC in TSU and CLX (Non-Ex, Ex) . ............................................ 79
2.3.2 Due to malfunction of purge in Ex-CLX, the pressure doesn’t’ keep............................................... 80
2.4 [CODE220] Sensor Fail : No intake Water . .................................................................................................... 81
2.5 [CODE240] Sensor Fail : Purge Clogged ........................................................................................................ 82
3. [CODE300] ANU .................................................................................................................................84

3.1 [CODE301] ANU Tank Level F.W INI.FILL.(Add Sodium) .......................................................................... 84
3.2 [CODE302] ANU Tank Level Low. ...................................................................................................................... 85
3.3 [CODE303] ANU Tank Level High. ..................................................................................................................... 86
4. [CODE400] PDE & CPC ....................................................................................................................88

4.1 [CODE402] 440V MC Fail [MC Code] ................................................................................................................. 88
4.1.1 Alarm occurs during Ballasting Operation ............................................................................................. 88
4.1.2 Alarm occurs during not-Ballasting Operation ..................................................................................... 90
5. [CODE500] FTU ..................................................................................................................................91

5.1 [CODE500] S.W P/P Abnormal, [CODE501] F.W P/P Abnormal
[CODE503] S.W/F.W Pump Confirmed ...............................................................................................91
5.2 [CODE501] F.W Tank Level Low. ........................................................................................................................ 93

5.2.1 Lack of Fresh water in FTU ........................................................................................................................... 93
5.2.2 Malfunction of FTU Tank Level Switch . ................................................................................................... 94
6. [CODE600] Sensor ............................................................................................................................96

6.1 [CODE603] F.W TEMP High .................................................................................................................................. 96
6.1.1 In case of Central Cooling system (FTU & HEU not installed) .......................................................... 97
6.1.2 In case FTU & HEU is installed ..................................................................................................................... 97
6.2 [CODE604] FMU Flow Rate Low, [CODE605] FMU Flow Rate High ..................................................... 98
6.2.1 Flow rate is higher / lower than necessary one : Check flow rate at HMI ..................................... 98
6.2.2 In case FMU value is different from one at HMI ..................................................................................... 99
7. [CODE700] Communication Fail .............................................................................................102

7.1 [CODE701] Communication Fail ....................................................................................................................104
7.1.1 Check the communication status between HMI and electrical equipment ........................... 104
7.1.2 Check PDE LAN communication ............................................................................................................ 105
7.1.3 Check RTU communication ..................................................................................................................... 107
7.1.4 Check CIM communication ...................................................................................................................... 108
7.1.5 Check AIM communication ...................................................................................................................... 109
7.1.6 Check local equipment (Case of ANU, TSU)........................................................................................ 110
7.1.7 Check local equipment (Case of ECU) .................................................................................................. 111
7.2 [CODE701] Communication Fail(GDS) ........................................................................................................112
7.2.1 GDS Sensor Communication ...................................................................................................................112
7.3 [CODE701] Communication Fail (FMU) ......................................................................................................114
7.3.1 How to Check Alarm Message at FMU .................................................................................................. 114
7.3.2 How to Check output current of FMU .................................................................................................. 115
7.3.3 FMU Cartridge, Backplate-board swap and setting guide . ........................................................... 116
7.3.4 How to Check FMU board ......................................................................................................................... 118
BWMS Main equipment
and Function
Aftersales Service Team

433 Noksansaneopbuk-ro, Gangseo-gu, Busan, Korea (46758)
Tel: +82-51-601-4500
Fax: +82-51-603-3599
Homepage: www.techcross.com
E-mail: as@techcross.com
BWMS Main equipment and Function
1. CPC (Control PC)
CPC
Windows / Linux-based PC and installed with HMI.

Remote PC : Installed at CCR.
Local PC : Installed at PDE.
2. PDE(Power Distributor Equipment)

- PDE distributes power to all equipment of ECS and monitor / control all equipment..
Control module is installed in PDE.
PDE Main component Photo Description
RTU PLC which can communicate

(Remote Terminal Digital Input, Digital Output,
Unit) Analog Input signals.
Information which voltage,

PMU
current, electric power are
(Power Meter
consumed by BWMS is
Unit)
displayed.
Information which voltage,

RCM
current are consumed by ECU.
(Rectifier Control
By RCM, ECU can be operated
Unit)
(Only Techcross engineer).
MC
Component which AC440V
(Magnetic
supplies ECU.
Contact)
Component which power

BCM
supplied ECU when Ballast
(Ballast Check
Pump or Valve signal is satisfied
Module)
with operation condition.
CIM : Connected with

communication cable for ECU,
CIM&AIM PMU, TSU, ANU, GPS and
(Communication communicated with HMI.
Interface Module)
(Analogue AIM : Connected with GDS,
Interface Module) FTS, CSU, FMU, FCV and
received DC 4-20mA which is
forwarded to HMI.
3. TSU(TRO Sensor Unit)

- To measure TRO(Total Residual Oxidant), TSU controls Solenoid V/V, APU and CLX
- There are Ex-Proof Type and Non Ex-proof Type.

Display TSU components (Sol
XGT
V/V, APU, CLX) and TRO value.
(TSU or ANU
By XGT, local operation of TSU
Display Pannel)
is possible.
Communicate with HMI.

PLC
Control CLX, Sol V/V, APU
(Programmable
and check the status through
Logic Controller)
lamps at the top left.
Non Ex-Proof Type Consist Air Regulator with Air

[Integrated control APU Pump.
panel and components (Air Pump Unit) Transfer treated water to CLX
(CLX, Sol V/V) installed.] from Sampling Port.
To measure TRO.
Ballast Normal Range :
CLX 5~10ppm
De-Ballast Normal Range : <
0.1ppm
In case of Ex-Type, purge air is

Ex-CLX supplied for keeping internal
pressure.
Solenoid Valve
(Ex Type)
Control the flow of treated
Ex-Proof Type water, which is controlled by
[Control panel and PLC.
Solenoid Valve
components (CLX,
Sol V/V) installed
separately.]
4. ANU(Auto Neutralization Unit)

- To neutralize TRO during De-Ballasting operation.

Display ANU components
(Sol V/V, Metering Pump)
XGT
and quantity of discharging
(TSU or ANU
neutralizer.
Display Panel)
By XGT, local operation of
ANU is possible.
Communicate with HMI.

PLC Control Sol V/V, Metering
(Programmable Pump, Agitator and check the
Logic Controller) status through lamps at the
top left.
Pump for discharging

Metering Pump
neutralizer in ANU Tank.
To help the neutralizer

Agitator
dissolve in fresh water.
Control the flow of inletting

F.W and discharging
Solenoid Valve
neutralizer, which is controlled
by PLC.
5. FTU&HEU(Fresh Water Tank Unit & Heat Exchanger Unit)

- Cooling for PRU at ECU, in case cooling system in the vessel cannot use
FTU(Fresh Water Tank Unit) HEU
Filled with Fresh Water for cooling PRU. Fresh water that cooled the PRU passes
Circulate “FTU ￫ PRU ￫ HEU ￫ FTU” by pump through HEU, and the sea water is used to
installed below cool the fresh water.
6. ECU(Electro Chamber Unit)

- ECU can use during Ballast Operation and when sea water passes through ECU, electrolysis hap-
pens, which creates TRO. Consist EM(Electro-module) and PRU.
Component that converts

PRU
AC440V to DC and supply
(Power Rectifier
converted voltage / current
Unit)
with EM.
EPJ Component that supplies

(ECU Power AC440V with PRU. Power is
Junction box) provided from PDE.
Component that control the

ESJ
connected PRUs.
(ECU Signal
Communicate with HMI and
Junction box)
forward the feedback to HMI.
EM Installed in ECU.
(Electrode DC power from PRU makes
Module) electrolysis, and TRO creates.
For removal of EM’s scale.

EWU
Every 100 hrs operation time,
(EM Washing Unit)
EM should be clean with EWU.
7. Sensor
Photo Description
Measure H2 gas
concentration during
GDS
electrolysis.
(Gas Detection
(H2 Gas makes very little
Sensor)
volume and vent at ballast
tank.)
FTS
(Fresh Water Measure temperature of
Temperature PRU Cooling Water.
Sensor)
Measure conductivity of sea

CSU water.
(Conductivity The higher the conductivity,
Sensor Unit) the better the electrolysis
efficiency.
CSU Ex CSU
Measure the flow rate.

FMU Based on the flow rate,
(Flow Meter current of ECU and
Unit) neutralizer of ANU is
controlled by HMI.
Component for protection

of EM in ECU for external
T-Strainer
substance.
3∳ mesh is installed.
8. Mixing Solution
- Components for adjusting conductivity between 1.35~2.00 PSU during ballasting operation at
fresh water zone.
- For Mixing ballasting operation, the tank filled with sea water (normally A.P.T.) should be designat-
ed.
Photo Description
VCU : U
nit to control FCV..
By VCU, local
operation of FCV is
VCU(Valve
possible.
Control Unit)
&
PCU : U
nit to control Mixing
PCU(Pump
Pump..
Control Unit)
By PCU, local
operation of Mixing
VCU PCU Pump is possible.
Mixing Pump
FCV : V
alve for adjusting the
FCV
sea water flow during
Mixing Ballasting
Mixing Pump operation.
& FCV(Flow
Control Valve) Mixing Pump : .
Pump to supply sea water
in S.W Tank to main ballast
pipe.
HMI & ECS Operation Guide
1. HMI
1.1 Menu
Operation time of each line
Click it to control HMI ON/

OFF
Click it to return to the
Home screen
Click it to check the log
history
Click it to check the alarm /
ttrip status
Click it to check the opera-
tion conditions
Click it to check the analog
/ digital signal
Click it to check the com-
munication condition
between each equipment
Click it to set and check the
enable / disable status
2.1 Operation Menu

HMI Remote / Local Selection
(Check the possibility of control)
Greenwich mean Time (GMT)
(If it not connect to GPS of the vessle, display time of PC)
Run : Run ECS Operation // Stop : Stop ECS Operation // Alarm ACK :
Stop Alarm ( Buzzer)
Reset : Abnormal Reset ( Unless it’s an ALARM clear situation, you
can’t reset)
Operation status of each line

3.1 HOME
TRO value of each TSU sampling line
Inject neutralizer
Click it to check the status of TSU operation

(Sampling Port, Communication )
Click it to check the status of ANU operation
(Injection of the Metering Pump, Communication )
Click it to Check the status of PRU operation
(Current and Voltage of PRU, communication status)
Ballast Pump, Flow Control Valve, Ballast Valve : If they are on,
it’s marked as GREEN
FMU : If FMU detects normal Range, it’s marked as GREEN
PMU : Check Input voltage and Power
CSU : Check Conductivity of Sea Water
STS : Check Temperature of Sea Water
TS : Check Cooling F.W of PRU
GDS : Check H2 GAS
2. Ballasting & De-Ballasting Operation Guide

2.1 Operation preparation
1) Click OP Mode. 1) Match Ship’s Signal (ship’s conditions) with

2) Click appropriate operation mode at Select Required Signal.
Operation Mode. 2) Check if Flow is detected in normal Range,
3) Match Ship’s Signal (ship’s conditions) with “Current” is on.
Required Signal. 3) Check if Selected Operation Status turns
4) If Flow is detected in normal Range, “Cur- into Green.
rent” is on.
2.2 Ballasting operation Ballasting Check Point
1) Check “Ballast Ready” 1) Click ECU and check each voltage / current
2) Click “Run” of PRUs.
3) Select IMO or USCG 2) Click T1, T2… to check TRO value..
4) Click “Yes” for starting Ballast Operation. (Normal Range : 5 ~10ppm)
2.3 De-Ballasting operation De-Ballasting Check Point
1) Check “De-Ballast Ready” 1) Click T1, T2… to check TRO value..

2) Click “Run” (Normal Rage .
3) Select “IMO/USCG” - IMO Mode : below 0.1ppm.
4) Select “Refresh” at Feedback Control Re- - USCG Mode : below 0.07ppm)
fresh and “Voyage Select” (As long as you 2) Click A1, A2..to check usage of neutralizer .
select, usage of neutralizer decreases)
5) Click “Yes” for staring De-Ballast Operation.
Main equipment
maintenance guide

Tel: +82-51-601-4500
Fax: +82-51-603-3599
Maintenance Main equipment maintenance guide
1. ECU
1.1 EM Cleaning
F.W volume( ℓ ) Citric acid (㎏)

ECS 150B 100 ℓ 15kg
ECS 300B 150 ℓ 15kg
ECS 450B 185 ℓ 19kg
ECS 600B 220 ℓ 22kg
ECS 1000B 310 ℓ 31kg
1. Be filled with F.W in EWU Tank. 2. Melt the citric acid with F.W by circulating
the water with a ration of citric acid(cleaning
agent) by pump during 20 min.
3. Connect EWU, Pump and ECU with hoses. 4. After that, circulate water by pump during 1
Make ECU full with water melted with clean- hour.
ing agent and keep the water during 1 hour
after closing ECU Inlet & Outlet Valve. .
(Cleaning for Ex-ECU can Air Pump can be
used for cleaning of EX-ECU.)
5. After completion of cleaning, drain the water 6. Clean ECU inside by using F.W service line
to BILGE WELL or BILGE HOLDING TANK. during 15 minutes.
1.2 PS(Pressure Switch), TS(Temperature Switch) maintenance
Refer to “Trouble Shooting_1.2 [CODE100] (P.S Pressure High)”.

1.3 PRU Cooling Strainer cleaning
Refer to “Trouble Shooting_6.1 [CODE603] F.W TEMP High”.

2. TSU
2.1 Local operation guide
1. Press “ESC” button and change to “Mainte- 2. Explanation of each symbol in XGT.
nance Mode”. CLX : TRO Sensor .
S1 ~ S4 : Sampling Sol V/V..
D.P : Air Pump for DTU discharge .
S.P : Not use.
3. By using button at XGT, activate each com- 4. If S1~S4 are on, relay power and sol v/v and
ponent.. APU are “On” inside TSU.
F1, F3 : Left, Right .
F2, F4 : On, Off
5. Check if Sol V/V is activated. 6. Check if CLX is activated

TSU : There are sol’ v/v inside TSU. Cursor at XGT moves to CLX and operate
EX-TSU : Control panel is at Safety zone and CLX by pressing “F2” button.
CLX, Sol V/V are installed at Hazardous zone.
7. Press “ESC” button and change to “Remote

Mode”.
2.2 How to check if Ex-CLX Purge Air is supplied.
Refer to “Trouble Shooting_ 2.3 [CODE202] CLX Sensor Power Fail”.

2.3 How to check CLX reagents.
▪CLX Flushing
Refer to “Trouble Shooting_2.1 [CODE200] TRO Concentration Low”.
▪CLX Cuvette check
Refer to “Trouble Shooting_2.1 [CODE200] TRO Concentration Low.”
2.4 How to replace of CLX reagents.
▪Non-ex CLX
▪Replacement interval – 2 month
1. Buffer solution, Chlorine Indicator, DPD 2. Put the DPD power into chlorine indicator.
powder and distilled water shall be pre-
pared.
3. Shake the bottle of chlorine indicator and buffer solution well after pouring distilled water
to the fill-line.
4. Put the new bottles in their places without 5. Check water flows into the cuvette of
twist of hoses. CLX, referring to “Trouble Shooting_2.1
[CODE200] TRO Concentration Low.”
▪Ex CLX
▪Replacement interval
– Buffer Solution : 6 month, Chlorine Indicator : 3 month
1. Buffer solution, Chlorine Indicator, DPD 2. Put the DPD power into chlorine indicator.
powder and distilled water shall be pre-
pared.
3. Put the new bottles in their places without 4. Check water flows into the cuvette of
twist of hoses. CLX, referring to “Trouble Shooting_2.1
[CODE200] TRO Concentration Low.
2.5 Solenoid Valve
▪Solenoid Valve Cleaning
1. TSU power is “Off”, and 2. Disassemble actuator. 3. Check condition of plung-

detach Sol V/V connector. er and reassemble in the
reverse order.
▪Solenoid Valve check guide

- Refer to “Maintenance_2.1 Local Operation Guide”
2.6 How to use Pocket Colorimeter(MD100)
1. Check components of col- 2. Turn the pocket calorimeter 3. Set desired conditions by
orimeter kit. on by pressing "ON/OFF" pressing "MODE" button.
button. - CL2 : 0.02~2ppm
- CL8 : 0.1~8ppm
4. Inject sampling water(5ml) 5. Round sampling cell for CL2, 6. Conduct zero calibration
into a sampling cell. Angular sampling cell for CL8 by pressing "ZERO" button.
Throw away the sampling
water after calibration.
7. Put CLX reagent into the 8. Inject sampling water into 9. Shake well for 20 seconds
sampling cell. One packet the sampling cell immedi- and wait for 3 to 6 minutes.
for CL2 and two packet for ately. .
CL8 CL2 : 10ml, CL8 : 5ml
10. Fit the sampling cell into 11. Check measured value 12. Repeat 3 to 5 times and
the calorimeter hole. Be after pressing "ZERO/TEST" compare to CLX value for
cautious of direction of button. calibration.
sampling cell.
2.7 APU
▪APU check guide
1. Check if air is supplied 2. Check if AC 220V at Sol V/V is 3. Check if Air Pump outlet is
through Regulator. supplied. clogging.
▪Assembling & Disassembling APU.
1. Remove inlet & outlet manifold. 2. Remove side clamp.
3. Check the status of APU after removing dia- 4. Check whether defective item exists.
phragm.
▪APU Flushing
1. Open flushing v/v at APU Suction.. 2. Do flushing during 10 minutes by operation
(Do not open the v/v during BWMS opera- Sol’ v/v, CLX , referring to ‘Maintenance_2.1
tion) TSU Local operation guide’. After comple-
tion, close Flushing Valve.
3. ANU
3.1 Local operation guide
1. Press "ESC" button and change to "Mainte- 2. Explanation of each symbol in XGT.
nance Mode". AG1, AG2 : Agitator of each Tank.
S1, S2 : Sol V/V for supplying fresh water.
S3, S4 : Sol V/V for discharging neutralizer.
S5, S6 : Sol V/V for flushing
P#1, P#2 : Neturalizer Metering Pump
3. By using button at XGT, activate each com- 4. Check operating status of Agitator..
ponent.. AG1, AG2 : Check operating status of Agita-
F1, F3 : Left, Right // F2, F4 : Start Stop tor in each tank.
S1 S3 S4 S2
S5 S6
5. Check operating status of neutralizer Meter- 6. Check operating status of Sol V/V.
ing Pump S1 ~ S6 : Check if lamp of each Sol V/V is “ON”
P#1, P#2 : Check operating status of neutral-
izer Metering Pump.
7. Change to Remote Mode by pressing "ESC"

button.
3.2 Filling of sodium thiosulfate.
Refer to “TroubleShooting_3.1_[CODE301] ANU Tank Level[F.W INI.FILL(Add Sodium)”.

3.3 Assembling & Disassembling ANU tank level sensor.
1. Open level sensor top cover and remove 2. Check if level sensor float is stuck.
cables.
3. Confirm if a DMM receives signal by moving the float. (Low , Normal, High)
3.4 Solenoid Valve
Refer to “Maintenance_2.1 TSU Local operation guide

3.5 ANU Flushing
S1 S3 S4 S2
S5 S6
1. Referring to "Maintenance_2.1 TSU Local 2. Explanation of each sol’ v/v

operation guide" - S1, S2 : Sol V/V for supplying fresh water.
- F1, F3 : Left, Right // F2 : On // F4 : Off - S3, S4 : Sol V/V for discharging neutralizer.
- By pressing “F1&F3”, “Left,&right” side - S5 : Internal Flushing Sol Valve
move. By pressing “F2&F4”, “On&Off” set - S6 : External Flushing Sol Valve
at desired location(cursor).
- P#1, P#2 : Discharging rate should be set.
S3 S4
S5 S6
P1
3. Internal Flushing Guide 4. External Flushing Guide

① S5 is “On”(Valve for supplying fresh water ① S5 is “On”(Valve for supplying fresh water
is “On”) is “On”)
② S3, S4 are “On” during 5 seconds and ② S5 is “On” during 60 seconds and then
then “Off”.Caution : keep the time be- “Off”.
cause fresh water is supplied into ANU
tank through S3, S4.
③ Under condition that S5 is “On”, P#1, P#2
are “On”. And set the discharging rate as
800.
④ Check metering pump operation and
keep it during 10 seconds.
⑤ P#3, P#4, S5 are “Off” And change to
Remote Mode by pressing "ESC" button.
4. PDE & CPC

4.1 How to check GPS Signal.(Hyper Terminal)
1. Press “ ” key and search /execute “Hyper- 2. In “Name”, enter “aa” and click “OK” (Any
tm”. work is ok)
3. In “Connect Using”, select “COM2”. 4. Set as above photo.

5. Check GPS receiving status. 6. Measure voltage of GPS(Terminal No. 1, 2)

GPGGA and GPZDA should be displayed. at COM-TB in PDE.
(GPGGA : Location, GPZDA : Time)  ➡ 1V ~ 3.0V is normal.
 ➡ If voltage cannot be measured, it seems
to be GPS itself(vessel).
.
5. HMI & Sensor

5.1 How to extract Log file at HMI.
1. Click “LOG” at HMI. 2. Set the period to extract LOG DATA.
3. Set the data type at “CREATE PDF FILES” 4. If LOG DATA creates as PDF normally, popup
and click “CREATE”. window is display as above photo.
- Event : Alarm Message
- Operation Time : BWMS operation, volume.
- DATA : Data value of equipment and sensors
during BWMS operation.)
- ALL : Output all three kinds of files into one file.
5. Extracted Log can be found at “C:/Tech-

cross/ECS/LOG” folder..
(USB drive is connected at CPC, automati-
cally copy to USB drive.)
5.2 GDS Zero Calibration
Magnetic key
Check GDS operation status. GDS magnetic key
- If GDS value is not “0” % LEL after sufficient ventilation, please do zero calibration as follows;.
- Be cautious that threads are free from foreign substances during covering open and
assembling.
*If zero calibration is required.

① Check display screen of GDS.
1
※If mark shows up in the upper right corner of the
screen, zero calibration is required.
① Please touch button for 5 seconds with the

enclosed magnetic bar.
2
② Once mark shows up, please detach the magnetic
bar from the screen.
① Once “Set CAL” shows up on the screen, please touch

3
“ ”.
① After “ZERO SETTING” shows up, the screen will be

4
changed.
① Please wait for 3~5 minutes for stabilization of zero

5 point.
② Once zero point is stabilized, please tough “ ”.
① Please check if “ZERO PASS” shows up.

6 ② The screen will be automatically changed after 1
minute.
7 ① After the purge completion, please touch “ ” to

move to next screen.
① Please complete the calibration by touching “ ” on

8
“Quit” screen.
9 ① After completion of calibration, please check if “ ”

shows up.
5.3 CSU Zero Calibration (Air Set)
Dismantle CSU after closing valves at the both sides. .

1
※ Be cautious of cable damage.
Check if conductivity is shown with ㎲/㎝.

2
select key // , move key
3 Press and move to “Calibration”
4 Press “ ” at “Calibration” and move to “Airset”.
5 Press “ ” at “Calibration” and move to “Keep sensor

in air”.
6 Press “ ” at “Keep sensor in air” and “Wait calib”

shows for 1 minute.
If display is changed to “Save calib data?”, move to “Yes”

7
and press “ ” “Calib successful” shows.
6. BWMS Maintenance list of major equipment / inspection period and

method.
y: Year m : Month h : Hour
No. Equipment Main Checkpoint Interval Remark
Equipment visual
inspection
1m -
(Leakage, Damage,
Contamination etc.)
Cable jack and Electric

1 General 3m -
part tightening
Refer to “HMI&ECS Operation”.

Please follow long term storage
ECS Operation 100 h
procedure if ECS is not in use
more than 3month
Refer to “Maintenance_1.1 EM
EM Cleaning 100 h
Cleaning”
PS/PI visual check

and function test
(PS ; Pressure Switich) 1m
(PI : Pressure
Indicator)
2 ECU
TS/TI visual check and Temp. Indicator
function test
(Wall mount type)
(TS : Temperature
1m
Switch)
(TI : Temperature
Indicator)
▶ Above image can be different from actual system.

Non-Ex type
Buffer/Chlorine
:2m
Replacement of Refer to “Maintenance_2.4 How
TRO Sensor reagent Ex type to replace of CLX reagents.
Buffer: 6 m,
Chlorine : 3 m
Before ECS
operation, Refer to “TroubleShooting_‘2.1
TRO Sensor Priming whenever [CODE 200] TRO Concentration
reagent is Low”
replaced.
3 TSU
Refer to “TroubleShooting_2.1
TRO Sensor
If necessary [CODE 200] TRO Concentration
Cuvette cleaning
Low”
Filter cleaning If necessary
* Clean CLX Filter and Check

leakage
Y-strainer cleaning If necessary
* Clean the Y-Strainer at

Sampling line
4 APU
APU overhaul 100 h Refer to “Maintenance_2.7 APU”
Filter regulator
50 h
cleaning

TSU Solenoid Valves Refer to “Maintenance_2.5

50 h
overhaul Solenoid Valve”
ANU Solenoid Valves Refer to “Maintenance의 3.4

50 h
overhaul Solenoid Valve”
APU Solenoid Valves

50 h
overhaul
Solenoid
5
valve
* Check the Sol V/V of APU after
power Off
Filter cleaning If necessary
* Check the Sol V/V of APU after

power Off
6 ANU Tank cleaning 2 year
1 year or
in case
pressure
7 T-strainer Cleaning
differential is
over than 0.5
bar
8 HEU HEU cleaning 1 year
All drain out & renew Refer to “TroubleShooting_6.1

9 FTU C.F.Water 1 year [CODE 603] F.W TEMP High
and tank cleaning Alarm”

Trouble Shooting

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Fax: +82-51-603-3599
1. [CODE100] ECU
1.1 [CODE100] (Current Different Error)
Cause : Current difference among PRUs.

Troubleshooting :
1. Check the PRU status during ballasting op- 2. Check if PRUs are normal..
eration. Ex) No.8 PRU is abnormal..
Please refer to the “Trouble Shooting_1.6
[CODE100] ECU(Communication Fail)
(PRU)”
1.2 [CODE100] (P.S Pressure High)
1.3 [CODE100] (T.S Temperature High)
Cause : Pressure or Temperature in ECU are higher than standard value..

(Standard Press’ : below 4.5 bar, Standard Temp : below 45℃ ) Malfunction of Pressure
Switch, Temperature Switch or ESJ Board.
Troubleshooting :
1. Check the pressure and temperature by 2. In case of over pressure & temperature,
Pressure & Temperature Indicator. check if ECU Outlet & Inlet Valve open.
(Press’ : below 4.5 bar, Temp : below 45℃ )
3. In case of below 4.5 bar or below 45℃ , 4. In case of the resistance of P.S or T.S is “O.L”
please measure the resistance of switch ➡ signal board is defective
terminal ➡ swap-test with normal ESJ signal board
➡ If the resistance of P.S or T.S is 0Ω, it is need-
ed to be replaced.
➡ If cable connector is disconnected, it can be
used temporarily.
5. Open ESJ and check signal board. 6. Carry out the swap test with normal ESJ
- Non-ex ECU : ESJ is installed at ECU. Board.
- EX-ECU : ESJ is installed at Safety zone. At that time, Dip switch setting (red box) is
also swapped.
1.4 [CODE100] (No Load Fail)
Cause : If there is no flow or ballasting operation is in the fresh water zone.

Troubleshooting :
(abnormal) (normal)
1. Check PRU Voltage and Current at HMI 2. Check if ECU Inlet & Outlet Valve open and
there is flow inside ECU.
3. Check if CSU is below 1PSU at HMI.

1.5 [CODE100] VLS Water Level Low
Cause : There is no flow inside ECU or malfunction of VLS.

Troubleshooting : Replacement based on the VLS function check.
1. VLS is installed at ballast pipe of rear end of 2. Check Dip Switch setting and connection.
ECU or at level switch at Ex-FTU. If function ※ Standard Setting : all Off (refer to the photo)
test is normal, refer to “Trouble Shooting_ ※ Power(DC24V) : Terminal No. 1, 2
1.2 [CODE100] P.S Pressure High) ※ Signal(Dry contact) : Terminal No. 3, 4
3. If Ballast Pipe is empty, only Green lamp is on.

※ Resistance value is below 5Ω by DMM.
4. If there is a flow in Ballast Pipe, Green lamp, Red lamp are on.
※ Resistance value is O.L(Over Load) by DMM.
1.6 [CODE100] ECU (Communication Fail) (PRU)
Cause : Malfunction of PRU or ESJ.

Troubleshooting :
1.6.1 ESJ check guide.
- Check when ESJ Power is on.
1. Open ESJ and check signal board. 2. After removal of the protection cover of
- Non-ex ECU : ESJ is installed at ECU. inside ESJ, crew can check signal board.
- EX-ECU : ESJ is installed at Safety zone.
3. Check the lamps at above photo.

█ Red box : Lamp for communication status of PRUs connected with ESJ.
█ Yellow box : Power Lamp of ESJ, the lamp is on if ESJ Power is on.
█ White box : Lamp for communication status with HMI.
█ Blue box : Lamp of communication status with RCM.
█ Green box : All Dip Switch should be set like marked direction.
4. Check communication status of PRUs con-

nected with ESJ.
a. Check the lamp in red box.
- Blue lamp : Communication from ESJ to
PRU..
(If lamp is off, ESJ signal board is needed
to be replaced.)
- Yellow Lamp : Communication from PRU
to ESJ..
(If lamp is off, PRU control board swap test
is required.)
- Based on ESJ ‘Capacity’ Dip Switch set-
ting, number of blue lamp (Number of
PRU = Number of blue lamp)
b. If communication status with connected
PRUs is normal, blue & yellow lamp is lit.
5. Check communication status of HMI.
- If lamp is on at white box, communication
status is normal between HMI and ESJ
6. If it is sure that ESJ signal board is defective,
carry out the swap test with normal ESJ Sig-
nal Board.
(Refer to “Trouble Shooting_ 1.2 [CODE100]
P.S Pressure High)
1.6.2 PRU Check guide.

※ There are three type of PRU. Each type has different control board inside PRU.
※ During below working, PRU power should be off.
Case 01) Control Board Model : PRU-24_DSP CONT
Case 02) Control Board Model : BREC-24, BREC18
Case 03) Control Board Model : BWMS24 CON-VER, BWMS18 CON-VER

Case 01) Model “PRU-24_DSP CONT”
1. Check PRU output diode

a. Disassemble the flexible bus bar
at PRU, and set DMM with Diode
Mode.
b. Measure diode .
[(+) → (+)Busbar, (-) → (-)Busbar]
In case of abnormal (0V, O.L), PRU
should be replaced.
DMM Black DMM Red Normal Abnormal
(+) Output (-) Output 0.1V ~ 0.2V 0V , O.L
2. Check PRU Low Insulation.

a. Open PRU Cover. As Cover and
Body are connected by the cable,
so carefully separate them.
b. Check the resistance for Outer body
(④) and the rear end of Fuse(①,②,
③).
c. O.L(Over Load) is normal.
3. PRU internal element check
1) Bridge Diode(upper), Inrush Resistor check
a. Set DMM with Diode Mode.

b. Check the rear end of (①,②,③)Black
Wire → A, Red Wire → rear end.
c. Check if value is normal (0.4V ~
0.6V).
DMM Black wire DMM Red wire
Normal Abnormal
(Diode Value) (Diode Value)
0.4V ~
A (DC +) After Fuse R, S, T 0V or O.L
0.6V
Measuring
1 A , 2 A , 3 A
Point
2) Bridge Diode(lower), Inrush Resistor


b. Check the rear end of (①,②,③)
Black Wire → B, Red Wire → rear
end
0.6V).
Normal Abnormal
0.4V ~
B (DC -) After Fuse R, S, T 0V or O.L
0.6V
Measuring
1 B , 2 B , 3 B
Point
4. PRU Control Board replacement

- If there is no finding from check guide “1~3”, carry out the swap test with normal PRU control
board. .
And then do ballasting operation.
Case 02) Model “BREC-24”, “BREC-18”
1. PRU Output Diode check (refer to Case 01)
2. PRU Low Insulation check (refer to Case 01)
3. PRU internal element check
1) Bridge Diode(upper), Inrush Resistor check

Black Wire → A, Red Wire → rear
end.
0.6V).
Normal Abnormal
0.4V ~
A (DC +) After Fuse R, S, T 0V or O.L
0.6V
Measuring
1 A , 2 A , 3 A
Point
2) Bridge Diode(lower), Inrush Resistor check

Black Wire → B, Red Wire → rear
end
0.6V).
Normal Abnormal
0.4V ~
B (DC -) After Fuse R, S, T 0V or O.L
0.6V
Measuring
1 B , 2 B , 3 B
Point
4. PRU Control Board replacement

- If there is no finding from check guide “1~3”, carry out the swap test with normal PRU control
board. .
And then do ballasting operation.
Case 03) Model “BWMS24 CON-VER”, “BWMS18 CON-VER”
a. Check PRU output diode

b. Disassemble the flexible bus bar at
PRU, and set DMM with resistance
Mode.
c. Measure the resistance[ (+) → (+)
Busbar, (-) → (-)Busbar ] If value is 47
~ 50Ω, it is normal. Otherwise, PRU
should be replaced.
DMM Black DMM Red Normal Abnormal
(+) Output (-) Output 47 ~ 50 Ω 0Ω , O.L
2) PRU Low Insulation check (refer to Case 2)
IDU Board
Control Board
DC-DC Board
2. Carry out the swap test with normal PRU by replacing the defective board.
BWMS24-CON-Ver has three boards. (IDU Board, Control Board, DC-DC Board)
BWMS-18-CON-Ver has two boards (IDU+Control) Board, DC-DC Board)
3. If there is no finding from check guide “1~3”, PRU should be replaced.

02. TSU
(TRO Sensor Unit)

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Fax: +82-51-603-3599
2. [CODE200~299] TSU (TRO Sensor Unit)

2.1 [CODE200] TRO Concentration Low
Cause : In case sampling water doesn’t flow into the cuvette of CLX..
In case of malfunction of APU, Sol V/V, CLX
Troubleshooting :
2.1.1 In case sampling water flows into cuvette of CLX normally.
- Follow up “a ~ c” in order
a. Priming (Sampling water in cuvette changes into red if CLX reagent and sampling water mix
during Ballasting.)
1. Check the power status of CLX. If CLX Power 2. Press “PRIME” button and press “ENTER”.
is “Off”, refer to”Maintenance_2.1 TSU Local
Operation Guide”
3. Check if reagent flows into the cuvette and 4. Repeat the pumping 2 or 3 times.
hose normally.
5. Color of treated water into cuvette during Ballasting..

The higher TRO, the more red. The more lower TRO, the more transparent it is.
b. Flushing (Check reagent pumping tube condition and “Check Valve”.)
1. Remove indicator and buffer solution from 2. Inject distilled water into hoses of the indica-
the CLX. tor and buffer solution by a syringe.
3. If not, check if check valves are clogged. 4. Overhaul and clean Check valve inside. After
completion of Flushing, do “a.priming”
c. Cuvette Cleaning (Even Sampling Water changes into red, TRO is low)
1. Loosen Knurled Top counterclockwise 2. Lower an outer protection O-ring of the

cuvette.
3. If flushing cannot, check if check valves are 4. Clean the cuvette and put it back.
clogged.
2.1.2 In case sampling water doesn’t flow into the cuvette of CLX.
- Follow up “a ~ f” in order
a. Sampling line Check
1. Check if valve after Sampling port opens. 2. Clean Y-Strainer at Sampling Line.
b. Check if APU works
1. Check if APU is supplied by 2. Check if SOL valve for APU 3. Check if discharge line of
air by confirming a regula- works properly. APU is clogged.
tor gauge.
c. c. TSU Sol V/V Cleaning
1. Turn the TSU power off. De- 2. Remove an actuator by us- 3. Check condition of plunger
tach power connector from ing a screw driver as a lever. & Reassemble in reverse
the Sol valve. order.
d. CLX Regulator adjustment.
1. Press "SERVICE" button in CLX display. 2. Check if "FLOW" message is indicated after
pressing "MODE/EXIT" button.
3. Wait until "HOLD" message is indicated. 4. Press "▲" button and check “LO” in display.
5. After adjust the pressure regulator clock- 6. Until “Good” displays, repeat 2~4.
wise, press “▲” and check the flow.
e. CLX Intake Sol’ V/V cleaning
1. Loosen bolts. 2. Disconnect CLX power cable.
3. Detach Intake Sol’ 4. Overhaul & clean Intake Sol’.
5. Reassemble in reverse order.

2.1.3 In case ECU efficiency is lower than before.

- Refer to “Maintenance_ 1.1 EM cleaning”
2.2 [CODE201] TRO Concentration High
Cause : Mistake for Ballast Line-up by Operator or in case neutralizer is not discharged.
Troubleshooting :
2.2.1 Alarm occurs during Ballasting.
- Check Valve Line-up for ballasting and leakage/stuck of valve.
- Wrong Sea Water circulation. (In case treated water does not flow into Ballast tanks, treated
water flow into ECU again.)
2.2.2 Alarm occurs during De-Ballasting.

a. Check if ANU metering pump works well.
1. Check ANU Injection order in HMI. 2. Check if Metering Pump works well at XGT.
3. Check if Metering Pump works well at local. 4. Remove air by opening Check Valve slightly
after Metering Pump.
5. Check if white balls inside the Check valves are moving.

b. Check setting of ANU metering pump
1. Operate Metering pump. Refer to “Mainte- 2. Move to “WAIT MODE” by pressing “START/
nance_3.1 ANU local operation guide” and STOP”.
check setting value.
3. Check setting value by pressing “EXT & ▲” at 4. Move to “WAIT MODE” by pressing “START/
the same time. Set “ANA” by using “▲,▼” key. STOP”.
5. Check setting value by pressing “EXT & ▲” at the same time and check if setting values are
same like photos.
6. Check other setting value by pressing “EXT”.
7. If setting value is different from above photos, change it by pressing “▲,▼” key.
8. Move to “WAIT MODE” by pressing “START/ 9. Return to initial display by pressing “EXT”
STOP” after setting. button.
c. Voyage period or De-Ballast Tank TRO modification

※ Choose one of two method.
1. Prepare De-Ballast Operation. Press “Run” 2. Choose days at “Voyage Select” and press
and check popup window. “YES”..
The longer the voyage period, the less neu-
tralizer is used.
1. Unless activating “Voyage Select” display, 2. At “DeBallast TRO”, modify “Tank TRO”.
click “ADMIN” and input Password (3500). (range : 0.1 ~ 8.0 ) Click “APPLY” and start
※ Do not modify except “De-Ballast Tank De-Ballast operation. The less the TRO val-
TRO” ue, the less neutralizer is used.
2.3 [CODE202] CLX Sensor Power Fail

[CODE210] CLX Communication Fail
Cause : Communication failure between PLC in TSU and CLX.

Due to malfunction of purge in Ex-CLX, the pressure inside Ex-CLX doesn’t keep.
Troubleshooting :
2.3.1 Communication failure between PLC in TSU and CLX (Non-EX, EX)
- Check PLC referring to “Troubleshooting 7.1”, operate CLX locally referring to “Mainte-
nance_2.1 TSU Local Operatio Guide”
- If local operation cannot, replace CLX PCB.
2.3.2 Due to failure for proper pressure inside Ex-CLX, purge controller
doesn’t supply power.
- Before following up the below guide, set the Ex-CLX with Bypass Mode.
Lamps at Purge Controller.

a. Pressure : Green lamp on when air over
4.5~6bar supplies and no Air Leakage oc-
curs.
b. Timer : If 5 minutes keeps after Pres-
sure Lamp turn to Green, Timer lamp is
on(Green). It means Purging completed.
c. BYPASS : If Red lamp is On, Bypass Mode
can be used.
1. Check lamp status of Purge Controller.
2. Check if air is supplied to inside of EX-CLX by 3. Check if air escapes from the air regulator
air regulator. after opening the EX-CLX cover.
4. Check the status of gasket inside the EX-CLX 5. Check if the upper lamp changes to green 5
cover. minutes after closing the EX-CLX cover and
turning operation key to On-line mode.
2.4 [CODE220] Sensor Fail : no intake Water
Cause : In case sampling water doesn’t flow into CLX.

Troubleshooting : Refer to “Troubleshooting 2.1 [CODE200] TRO Concentration Low”
2.5 [CODE240] Sensor Fail : Purge Clogged
Cause : In case of clogging / malfunction of Purge Sol V/V for CLX Draining.
Troubleshooting :
1. Check if cable connector for PURGE Sol 2. Remove Reagent Pump and bracket.
valve is connected properly.
3. Detach Purge Sol V/V. 4. Disassemble Purge Sol valve and clean it
after checking if it is clogged. Reassemble in
reverse order considering Sol valve direc-
tion.
03. ANU

Tel: +82-51-601-4500
Fax: +82-51-603-3599
3. [CODE300]ANU
3.1 [CODE301] ANU Tank Level F.W INI.FILL(Add Sodium)
Cause : When F.W is filled upto Normal Level in ANU tank. / Malfunction of level sensor
Troubleshooting :
1. Check alarm and ANU XGT. 2. Check alarm at XGT.
3. Check filling of F.W in tank and add the sodi- 4. Reset alarm by ESC at ANU XGT. Start the
um.. agitator by F1, F3..
[(5T : 50kg, 10T : 100kg (each Tank)) (F1 : No.1 Tank // F3: No.2 Tank)
5. When level sensor is malfunction, refer to “Maintenance_3.3 Assembling & Disassembling

ANU tank level sensor”
3.2 [CODE302] ANU Tank Level Low
Cause : In case neutralizer in ANU tank run out / F.W input solenoid valve clogging / Malfunction
of level sensor
Troubleshooting :
1. Check if ANU tank is automatically re-filled 2. Check LED light of F.W Input Sol valve.
with F.W upto Normal Level.
3. Overhaul and clean F.W Input sol’ v/v. 4. When level sensor is malfunction, refer to
“Maintenance_3.3 Assembling& Disassem-
bling ANU tank level sensor”
3.3 [CODE303] ANU Tank Level High
Cause : Due to overflow of F.W / Malfunction of level sensor

Troubleshooting :
1. Check LED light of F.W Input Sol valve. 2. ANU power Off, dissemble Sol V/V connec-
tor.
3. Dissemble actuator 4. Check condition of plunger and assemble

again vice versa.
5. When level sensor is malfunction, refer to “Maintenance_3.3 Assembling & Disassembling

ANU tank level sensor”
04. PDE
05. FTU

Tel: +82-51-601-4500
Fax: +82-51-603-3599
4. [CODE400] PDE, [CODE500] FTU

4.1 [CODE402] MC Fail[MC Code2]
Cause : Mis-match between ECU run order(Digital Output) and ECU run confirmation(Digital Input).
Troubleshooting :
4.1.1 Alarm occurs during Ballasting operation.
※ Should check during Ballasting operation. Every single vessel has each drawing and HMI.
1. Click ”Status” → “Digital Output” at HMI and 2. Click “Status → Digital Input” at HMI and
check if “Rectifier 440V OUT STATUS” ON check if “Rectifier 440 VOLTAGE POWER” ON
3. Digital Input and Digital Output should be “On” during ballasting operation.
4. In case Digital Output is “Off”

→ Check the operation status (Relay, MC, MCB and etc.) inside PDE, referring to ‘PRU Circuit’
page in PDE.
→ Check the lighting status of relays for “ECU Power on Command”, referring to “RTU-PLC
Circuit”.
※ MC(Magnet Contact) supplies AC440V

power to ECU. Through MC contact, MC
sends “Power on Signal” to HMI.
5. In case Digital Input is “Off” and Digital Ouput is “ON”

➡ Check the “a” contact of MC and the lighting status of RTU(XGI-D22A), referring to “Digital
Input” at ‘PRU Circuit’ in drawing for PDE.
4.1.2 Alarm occurs during not-Ballasting operation.
1. Click ”Status -> Digital Output” at HMI and 2. Click “Status → Digital Input” at HMI and
check if “Rectifier 440V OUT STATUS” OFF check if “Rectifier 440 VOLTAGE POWER”
OFF
3. Digital Input and Digital Output should be “Off” during not-ballasting operation.
4. Check if Operation Key at PDE RCM sets

“Remote”.
5. [CODE500] FTU
5.1 [ CODE500] S.W Pump Abnormal, [CODE501] F.W P/P Abnormal
[CODE503] S.W/F.W Pump Confirmed
Cause : Malfunction of S.W. Pump or F.W. Pump during ballasting operation

Troubleshooting :
F.W & S.W Pump MCCB(AC 440V) F.W S.W Pump MCB(AC 220V)
1. Check if F.W & S.W Pump’s MCCB in PDE is 2. Check if F.W & S.W Pump’s Control MCB in
“On” PDE (AC220V) is “On”.
3. Try to start F.W & S.W Pump after switch sets 4. At that time, check if F.W Pump at FTU is
“Em’cy mode”. operated. .
After that, turn the switch to “Remote”.
5. Click “Status → Digital Input” at HMI. 6. Click Status → Digital Output” at HMI.
Check if “HEU Pump Start” is “ON”. Check if HEU Remote/Local” is “ON” & “HEU
(For 5, 6 items should be checked during Pump Run” is “ON” & “HEU Pump TRIP” is
ballasting operation) “OFF”.
7. Check if Fault Lamp of F.W/S.W Pump at PDE 8. Reset OCR.

is “ON”.
5.2 [CODE501] F.W Tank Level Low
5.2.1 Lack of Fresh water in FTU.
1. Click “Status → Digital Input” at HMI. 2. If FTU Low Level is “On”, check if fresh water
Check if FTU Low Level is “Off”. is filled. Otherwise, fresh water is supplied.
5.2.2 Malfunction of FTU Tank Level Switch.
1. Drain the F.W in FTU and clean the tank.. 2. Check cable connection. (Terminal No. 6, 8)
Open Junction Box and check contact.
3. If Level Switch is located at “Low”. 4. If Level Switch is located at “High”.
➡ Measure below 5Ω DMM for resistance ➡ Measure O.L(Over Load) for resistance
value by DMM. value by DMM.
06. Sensor

Tel: +82-51-601-4500
Fax: +82-51-603-3599
6. [CODE600] Sensor
6.1 [CODE603] F.W TEMP High
Cause : Temperature of PRU Cooling Water is over 43℃

Troubleshooting :
6.1.1 In case of Central Cooling system (FTU & HEU not installed)
1. Check if valves for cooling line open and 2. Clean the Strainer in Cooling Pipe.
circulation status is normal.
3. Close the outlet valve (red circle) for cooling 4. Dismantle outlet tube of each PRU and
line. check with ball v/v whether cooling line is
clogging. If line is cloggling, clean it by air
blowing.
6.1.2 In case FTU & HEU is installed.
1. Check if fresh water is supplied in FTU. 2. If water in FTU is dirty, drain it out and refill
the fresh water. Otherwise FTU is activated,
check FTU, referring to “Trouble Shoot-
ing_5.1 [CODE500]”.
3. Check if Cooling Line Valves open. 4. Clean the Strainer in Cooling Pipe.
6.2 [CODE604] FMU Flow Rate Low & [CODE605] FMU Flow Rate High
Cause : Flow rate is higher / lower than necessary one or Malfunction of FMU.
Troubleshooting :
6.2.1 Flow rate is higher / lower than necessary one : Check flow Rate at HMI.
1. Check proper Flow Rate.

1) Click OP MODE at HMI.
2) Choose required operation mode at “Se-
lect Operation Mode”.
3) Check if Flow rate is in normal range. If
not, adjust pump valve.
6.2.2 In case FMU value is different from one at HMI.
1. Check each value of FMU and HMI, which should be same.
2. How to check Q-max value at HMI. .

Please follow up numbering like the right
photo.
3. How to check Q-max value at FMU.
a. Press “▶”
key.
b. By direction
key(▲, ▼), .
Select “Stan-
dard”.
d. Check or modify the value of Q-max(FMU)

c. Select “Easy-
same as Q-max (HMI) , which is Easy setup
Setup” and
sub-item. (Attention : Other setting value
press “▶”.
except Qmax should be same as photo.
07. Communication Fail

Tel: +82-51-601-4500
Fax: +82-51-603-3599
7. [CODE700] Communication Fail

Systematic chart and kinds of signals for ECS.
※ There are two types on if the CIM/AIM is installed or not.
PDE- RTU AIM/CIM
1. If CIM/AIM in PDE are not installed.

- Check Card Slot at RTU in PDE.
LOCAL GPS CPC(HMI)
PDE HUB
CSU
RTU
PRU ECU RTU-RS485 RTU AI
Card Card FMU
CLX TSU RTU DIDO
Card FTS
ANU PMU
GDS
DO Signal DI Signal
LAN :Via Hub, Remote/Local PC, RTU in PDE communicate one after another.
CAN : ECU can be controlled by RCM with EM'CY mode. (one way comm' : RCM ESJ).
Communication
RS-485 : The method for controlling equipment (ESJ, ANU, TSU, PMU) connect-
ed with RTU. And transfer the feedback.
(Two-way communication : HMI ← CIM → ESJ, ANU, TSU, PMU)
DI(DIGITAL INPUT) : Receive ON, OFF SIGNAL and check equipment status.
SIGNAL DO(DIGITAL OUTPUT) : Send ON, OFF SIGNAL and operate equipment.
AI(ANALOG INPUT) : DC 4 ~ 20 mA signal

2. If CIM/AIM in PDE are installed.
LOCAL GPS CPC(HMI)
CSU
FMU
FTS HUB RTU
AIM
GDS
DI Signal
RTU DIDO
PRU ECU CIM
Card DO Signal
CLX TSU PMU
ANU
LAN : LAN :Via Hub, Remote/Local PC, RTU, CIM in PDE communicate one after
another.
Communication CAN : ECU can be controlled by RCM with EM'CY mode. (one way comm' : RCM → ECU)
RS-485 : The method for controlling equipment (ESJ, ANU, TSU, PMU) connect-
ed with CIM. And transfer the feedback.
(Two-way communication : HMI ← CIM→ ESJ, ANU, TSU, PMU)
DI(DIGITAL INPUT) : Receive ON, OFF SIGNAL and check equipment status.
SIGNAL DO(DIGITAL OUTPUT) : Send ON, OFF SIGNAL and operate equipment
AI(ANALOG INPUT) : DC 4 ~ 20 mA signal, change into value.

7.1 [CODE701] Communication Fail.(RTU, ECU, TSU, ANU)
Cause : Communication failure between HMI and electrical equipment.

Troubleshooting :
7.1.1 Check the communication status between HMI and electrical equipment.
1. Click “COMM” at HMI.. 2. █ Abnormal comm’ status between proper

Check after 5 minutes, since HMI is “On”. equipment and HMI.
█ Normal comm’ status between proper
equipment and HMI..
※ ECU communicates HMI during only
Ballasting .
7.1.2 Check PDE LAN communication.

※ To check for contact defects, LAN Cable is connected properly.
1. Check if HUB, PC, RTU are communicated 2. Check if lamp for LAN Port at the rear side is
with HUB. (Lamp flashing) flashing
3. Check LAN Cable contact in PDE-RTU. 4. Check if lamp for LAN Port at CIM is flashing.
a. Remote PC의 IP address : 192.168.1.54

b. Local PC의 IP address : 192.168.1.100
c. PDE-RTU의 IP address : 192.168.1.54
d. PDE-CIM의 IP address : 192.168.1.57
5. Do Ping Test at Remote & Local PC. 6. Do Ping Test for each equipment.
1) HMI is Off (password : 3500) 1) Ping “IP address to be checked.”
2) Input “CMD” and press “Enter” key like 2) There is the vessel which CIM is not in-
photo stalled.
7.1.3 Check RTU communication.
1. Click “COMM” at HMI.. 2. Check the lighting condition for Power

Check after 5 minutes, since HMI is “On”. Check, Error Lamp at PDE-RTU.
3. If Error Lamp is “On”, RST switch move to left

for 3 seconds and check if Err Lamp disap-
pears.
7.1.4 Check CIM communication.

※ If CIM is not installed, this check guide can be skipped.
※ Each vessel has each PDE drawing. The below guide is for your reference.
1. Click “COMM” at HMI.. 2. Check if lamp for LAN Port at CIM is flashing.
Check after 5 minutes, since HMI is “On”.
3. Check electrical equipment referring to “COM-TB” at PDE drawing.
1) Equipment (ECU, TSU, ANU, PMU and so on) connected at CH1~8 communicates via RX/TX.
2) If communication status is normal. RX/TX’ s lamps are “On”.
※ In above photo, CH5 and CH6 are normal.
※ HMI on Remote/Local PC should be “On” while checking RX/TX lamp at CIM.
4. Check if RX/TX Lamps are “On”. (If RX/TX lamps are “On”, it is normal)
7.1.5 Check AIM communication.

※ If AIM is not installed, this check guide can be skipped.
※ Each vessel has each PDE drawing. The below guide is for your reference.
1. Click “COMM” at HMI. Check after 5 minutes 2. By referring AI-TB at PDE drawing, check CH
since HMI is “On”. connected with each Sensor. If DC4-20mA
inputs from Sensor, Lamp is flashing. If
flashing speed is fast, current is high.
3. Check if CIM channel status connected with AIM is normal (Refer to page for CIM at PDE draw-
ing.)
※ In photos, CIM CH5(RX5, TX5) is connected with AIM, status can be checked by RX/TX
Lamp at AIM.
※ If RX/TX Lamp at CIM/AIM are flashing, it is normal.
※ HMI on Remote/Local PC should be “On” during RX/TX lamp at CIM.
7.1.6 Check Local equipment (Case of ANU, TSU)
1. Check PLC status in XGT. 2. If PLC Err Lamp is “On”, turn the TSU power
Normal : Ver, Addr, Date are displayed. off and turn on (PLC reset takes 20~30 sec-
Abnormal : Ver, Addr, Date are displayed onds).
with “0000”.
3. Check burn damage at communication card.

7.1.7 Check Local equipment(Case of ECU)

- Refer to “Ttrouble Shooting_1.6 [CODE100] ECU (Communication Fail).”
7.2 [CODE701] Communication Fail (GDS)
7.2.1 GDS Sensor Communication
센서 소켓
Cartridge
Dsiplay
고정링
Cartridge 덮개
1. Check each value for GDS, HMI. Both values 2. Refer to the photo for GDS components.
should be “0%LEL”..
(If GDS displays over “0%LEL”, carry out Zero
Calibration. (Refer to “Maintenance _5.2 GDS
Zero Calibration)
3. GDS Alarm 4. About 180 seconds is required for booting.

- After GDS booting, check “Alarm Code” Time can be checked by Timer of GDS.
5. GDS Alarm Code Cause & Troubleshooting
(1) F-01 1) Cause : Internal component damage due to external noise.

Troubleshooting : GDS power reset. If it is not solved, replace Display Module.
(2) F-02 1) Cause : Sensor failure due
Or to external circumstances.
F-04 2) Troubleshooting
a. GDS power off, disman-
tle Cartridge.
b. Check sensor pin and
resistance.
c. Pin damage : replace
Cartridge..
Resistance defect : re-
place GDS.
Port Resistance(Ω)
Output and –VE
Normal : below 20 Ω
Output and +VE
(3) F-03 1) Cause : Zero Drift due to circumstances and toxic substance.
2) Troubleshooting : After Zero Calibration, and Reset. If it is not solved, replace GDS.
(4) F-06 1) Cause : Abnormal supply

Or voltage to GDS.
F-13 2) Troubleshooting
a. GDS power is “Off”, dis-
mantle Display Module.
b. Check voltage (DC 18 ~
32V)
(5) F-11 1) Cause : Defect for Sensor,

Cable. Abnormal resis-
tance value.
2) Troubleshooting
a. GDS power is “Off”, dis-
mantle Display Module.
b. Check if resistance at
Cable Connector is
removed.
c. Check if cable between PDE
and GDS is disconnected.
d. If all are normal, replace
GDS.
7.3 [CODE701] Communication Fail (FMU)
7.3.1 How to see FMU Alarm Message
1. Press “◀” key.

2. Select “Diagnostics” and press “▶” key.
3. Check Alarm Code / Alarm Message.
7.3.2 How to check output ampere from FMU
1. Open rear cover of FMU head and measure 2. Must show DC 4mA if flow is “0”.
DC 4~20mA. If flow is bigger than “0”, you
can see the DC4~20mA .
3. If DC 4-20mA can be measured : Malfunction of AI module(Adam6017, RTU-AI Card, AIM) .

If DC 4-20mA cannot be measured : Malfunction of FMU cartridge & backplate board.
4. Check / Swap cartridge & backplate board with normal one.
7.3.3 FMU Cartridge, Backplate swap,setting guide.

a. How to swap Cartridge, Backplate board..
- If there are more than two FMUs installed or there are spare Cartridge, Backplate
board. Swap test is possible
1. Check guide after swap. 2. Attention

1) After swap only Cartridge, check values 1) During assembling FMU front/rear cover,
for FMU / HMI. check the particle at threads.
2) After swap only Backplate board, check 2) Pay attention to pin damage at rear side.
values for FMU / HMI. during assembling Cartridge.
3) After swap both Cartridge and Backplate 3) During assembling/disassembling Back-
board, check values for FMU / HMI. plate, pay attention to cable damage.
4) After checking 1) ~ 3), try to find defective
component.
Cartridge Backplate board
3. Open front cover and loosen 3 bolts (green 4. Open the front cover and disconnect con-
circle). Detach the cartridge. nector cable in the green circle.
(Pay attention not to cutting the cable)
Detach the installed backplate by loosening
the bolts in the yellow circles.
b. FMU setting guide.

- In case of replacing backplate board only.
1. Press “▶” key and move to setting screen.
2. Select the service by using “▲” and “▼” key.
Input Password (6000) and press “OK” to acti-

3.
vate setting
4. Select the service by using “▲” and “▼” key.
Select “Sensor”
5. Refer to setting value as attached sticker on
FMU Head and set.
<PARAMETER Tree >
SENSOR SENSOR ID
SAP/ERP NO.
SENSOR TYPE (PM300)
SENSOR SIZE (DN 000)
MAIN FREQUENCY ( 00 Hz )
EXCITATION FREQ. ( 00 Hz )
EXCITATION CURRENT
Pre. Amp (No PreAmp)
Sensor TFE Function (Without TFE)
Zero SZ ( Sz : 00000 )
Span SS ( Ss : 00000 )
Reynold corr. Pipe size constant
Current Term Max
Sens Run Hours Reset
Calibration First …
…
Cal. Mode (PM/HM)
Cal. Status (Calibrated)
Properties Electrode Material (Hstelly C-4)
Lining Material (HARDRUBBER
7.3.4 How to check FMU Board
1. Check if fuse connected to Back Plate 2. Check the burnt damage on Driver Fuse.
Board opens or not. (Also, check the backside of board)
3. Measure the insulation and resistance

value in marked Electrode Coil.
→ Normal value of Insulation : ∞ .
(Measure one line of Cable and body
earth each)
→ Normal value of resistance : 10~ 50 Ohm
(Measure two cables)
MEMO

220323 - Maintenance,Troubleshooting Book for Crews (3rd Edition) - CI리뉴얼 - Eng

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220323 - Maintenance,Troubleshooting Book for Crews (3rd Edition) - CI리뉴얼 - Eng

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Maintenance &

Troubleshooting Book for Crews

ECS Main equipment and Function

3. TSU(TRO Sensor Unit) .......................................................................................................................10

4. ANU(Auto Neutralization Unit) ......................................................................................................11

5. FTU & HEU ..............................................................................................................................................12

6. ECU(Electro Chamber Unit) ............................................................................................................13

8. Mixing Operation .................................................................................................................................15

HMI & ECS Operation Guide

2. Ballasting & De-Ballasting Operation Guide .........................................................................18

Maintenance Main equipment maintenance guide

5. HMI & Sensor .......................................................................................................................................44

2. [CODE200~299] TSU ........................................................................................................................66

3. [CODE300] ANU .................................................................................................................................84

4. [CODE400] PDE & CPC ....................................................................................................................88

5. [CODE500] FTU ..................................................................................................................................91

5.2 [CODE501] F.W Tank Level Low. ........................................................................................................................ 93

6. [CODE600] Sensor ............................................................................................................................96

7. [CODE700] Communication Fail .............................................................................................102

Aftersales Service Team

BWMS Main equipment and Function

1. CPC (Control PC)

Windows / Linux-based PC and installed with HMI.

2. PDE(Power Distributor Equipment)

PDE Main component Photo Description

RTU PLC which can communicate

Information which voltage,

Information which voltage,

Component which power

CIM : Connected with

3. TSU(TRO Sensor Unit)

PDE Main component Photo Description

Communicate with HMI.

Non Ex-Proof Type Consist Air Regulator with Air

In case of Ex-Type, purge air is

4. ANU(Auto Neutralization Unit)

PDE Main component Photo Description

Communicate with HMI.

Pump for discharging

To help the neutralizer

Control the flow of inletting

5. FTU&HEU(Fresh Water Tank Unit & Heat Exchanger Unit)

FTU(Fresh Water Tank Unit) HEU

6. ECU(Electro Chamber Unit)

PDE Main component Photo Description

Component that converts

EPJ Component that supplies

Component that control the

For removal of EM’s scale.

Measure conductivity of sea

Measure the flow rate.

Component for protection

HMI & ECS Operation Guide

Operation time of each line

Click it to control HMI ON/

2.1 Operation Menu

Operation status of each line

TRO value of each TSU sampling line

Click it to check the status of TSU operation

2. Ballasting & De-Ballasting Operation Guide

1) Click OP Mode. 1) Match Ship’s Signal (ship’s conditions) with

2.2 Ballasting operation Ballasting Check Point

1) Click OP Mode. 1) Match Ship’s Signal (ship’s conditions) with

1) Check “De-Ballast Ready” 1) Click T1, T2… to check TRO value..

7. Press “ESC” button and change to “Remote

1. TSU power is “Off”, and 2. Disassemble actuator. 3. Check condition of plung-

1. Remove inlet & outlet manifold. 2. Remove side clamp.

7. Change to Remote Mode by pressing "ESC"

1. Referring to "Maintenance_2.1 TSU Local 2. Explanation of each sol’ v/v

3. Internal Flushing Guide 4. External Flushing Guide

5. Check GPS receiving status. 6. Measure voltage of GPS(Terminal No. 1, 2)

5. Extracted Log can be found at “C:/Tech-

① Please touch button for 5 seconds with the

① Once “Set CAL” shows up on the screen, please touch

① After “ZERO SETTING” shows up, the screen will be

① Please wait for 3~5 minutes for stabilization of zero

7 ① After the purge completion, please touch “ ” to

① Please complete the calibration by touching “ ” on

9 ① After completion of calibration, please check if “ ”

6. BWMS Maintenance list of major equipment / inspection period and