Polatrak CP-Gun User manual

CORROSION TESTING PROBE
Deepwater Corrosion Services Inc.
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©2023 Deepwater Corrosion Services Inc. Specications subject to change without notice
CP-GUN™
DIVER-HELD CP PROBE
OPERATION MANUAL
Twin reference
electrodes verify
calibration during use
Ultra-bright LED
displays for limited
visibility conditions
On-off switch
for season-long
battery life

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Table of contents
1 Overview 5
2. Scope 5
3. Health and safety 5
4. Risk assessments 5
4.1. General hazards 5
4.2. Specic hazards 6
4.3. Environmental hazards 6
5. Reference documents 6
5.1. Drawings 6
5.2. Photos 6
5.3. MSDS documents 6
6. Components 7
6.1. Main body 7
6.2. Reference electrodes 7
6.3. Voltmeter 8
6.4. Bulkhead connector 8
6.5. Lens 8
6.6. Contact tips 8
6.7. On/off power switch 9
6.8. Spare parts and accessories 9
7. Calibration 9
7.1. Bucket calibration check 9
7.2. Underwater online calibration 11
7.3. Measuring potentials 11
7.4. Data interpretation 13
8. Maintenance 14
8.1. Overview 14
8.2. Tip replacement 14
8.3. Electrode element replacement 14
8.4. Battery replacement 16

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9. Troubleshooting 17
9.1. Electrode element replacement 17
9.2. Battery replacement 19
10. Appendix 19
List of tables
Table 1 - Normal cathodic protection ranges for bare
carbon steel in seawater 13
Table 2 - Troubleshooting quick guide 18
Table 3 - CP Gun™ spare parts list 19
List of figures
Figure 1 - Kit components 4
Figure 2 - Probe components 4
Figure 3 - Calibration coupon attachment 10
Figure 4 - Bucket calibration readings 11
Figure 5 – Seacon RMG-3FS wiring diagram 15
Figure 6 – Calibration schematic 20

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CP-Gun™
Figure 1
Kit components
Calibration
coupon
Lens cover
Spare
reference
electrode
Tips
Replacement O-rings
Batteries
Screws
Float
Lanyard
Transit
case
CP Gun
O-ring
lubricant
Insulating
compound
3/16”
Allen
key Spare parts
storage
Figure 2
Probe components
Pressure
housing
Reference
electrodes
O-rings
LED
readout
unit
Readout
lens
Readout
lens
retaining
screws
Contact
tip
Nose cone
assembly
Electrode
harness
Element
housing
On/off
switch
Handle

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1. Overview
The CP Gun™ is designed for situations where a few contact CP read-
ings are required. This diver-held probe can be stored easily on a tool
belt when not needed by the diver. The CP Gun™ outperforms all other
bathycorrometer-type devices on the market in accuracy and con-
venience. Longer battery life, interchangeable freshwater / seawater
electrodes and ultra-bright LED displays (for limited visibility situa-
tions) make the CP Gun™ the most user-friendly diver-held CP probe
available. The dual electrodes and readouts allow verication of the
reference electrodes even as the diver works.
2. Scope
The purpose of this document is to instruct the user how to use and
maintain the CP Gun™, including taking potential readings and replac-
ing the elements and batteries.
3. Health and safety
3.1 General
It is the intention of Deepwater Corrosion that all test and inspec-
tion procedures are to be carried out in a safe manner in accord-
ance with the Health and Safety at Work Act and any other relevant
legislation. If required by the client, Deepwater personnel will
attend any site safety induction courses before carrying out on-site
work.
3.2 MSDS
Where applicable, substances hazardous to health shall be listed
and itemized in the form of a register. Health and safety data sheets
for all hazardous substances shall be kept in a le for reference.
Site personnel shall be issued copies of health and safety data
sheets relevant to their work activities.
4. Risk assessments
4.1 General hazards
4.1.1 Site safety - There are various risks associated with work-
ing on any site. Regulations required by the site owner/operator
should be observed.
4.1.2 Personal Protective Equipment (PPE) - Eye protection

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and disposable rubber gloves should be worn as a minimum of
personal protective equipment when maintaining the CP Gun™,
in addition to any other equipment required by the site operator
or deemed necessary by the task.
4.2. Specific hazards
4.2.1 Measuring potentials - The contact tip of the probe is very
sharp and can cause serious damage to the user if not handled
with care. It should NEVER be used to remove marine growth or
coatings.
4.2.2 Impressed Current Cathodic Protection (ICCP) is present-
Transformers should be turned off BEFORE any person enters
the water in that area.
4.3 Environmental hazards
The copper (II) sulphate, deionized gel solution contained within
the Cu / CuSO4reference electrodes is potentially hazardous.
Observe all federal, state and local regulations when disposing
of this substance. Please ensure that proper personal protective
equipment (PPE) is worn during disposal. For further information,
please refer to the MSDS.
5. Reference documents
5.1 Drawings
5.1.1 Figure 4: Bucket calibration readings
5.1.2 Figure 5: SEA CON® RMG-3FS connector pin diagram
5.1.3 Figure 6: Bucket calibration check with Zn coupon
5.2 Photos
5.2.1 Figure 1: Kit components
5.2.2 Figure 2: Probe components
5.2.3 Figure 3: Calibration coupon attachment
5.3 MSDS documents
5.3.1 Parker Seals - Parker O Lube MSDS – O-ring lubricant
http://www.parker.com (search for: MSDS Super O-Lube)
5.3.2 Dow Corning – 4 Electrical Insulating Compound MSDS
(Connector sealant)
http://www.dowcorning.com/applications/search/products/De-

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tails.aspx?prod=01903128&type=PROD
5.3.3 McMiller – Leak Stop Gel – Copper (II) sulphate electrolyte
MSDS http://documents.mcmiller.com/msds.html
Please contact your Polatrak representative for any questions and/or
issues regarding this manual.
6. Components
The probe components are shown in Figure 2 along with a parts list in
Table 3. The CP Gun™ with handle weighs 6.3 lb (2.86 kg) in air and 1.5
lb (0.68 kg) in water. The following is a description of the major compo-
nents:
6.1 Main body
The rugged thermoplastic main body of the CP Gun™ comprises two
sections: a water-tight pressure housing which contains the LED
readout unit, batteries and electronic circuitry, and a free-ooding
element housing, which contains the reference electrodes, contact
tip and wiring harness. These two halves are separated by unscrew-
ing counterclockwise. This allows access to the probe contact tip
connection and the reference electrodes. The tip connector attaches
to the electrode harness, and once it’s unplugged, the entire elec-
trode housing can be removed. The electrode elements and contact
tip can be replaced as necessary. Please see Table 3 for part num-
bers and ordering information.
6.2 Reference electrodes
The CP Gun™ uses two replaceable silver/silver chloride (Ag/AgCl)
reference electrodes. Alternatively, copper/copper sulfate (Cu/
CuSO4) elements can be used for potential measurements taken in
fresh water. The electrodes are plugged into the electrode harness
via pressure-resistant connectors. To ensure proper function of the
reference cells, several points should be observed:
6.2.1 Any time the elements are replaced, a thin layer of connector
sealant should be applied to the rubber shoulder of the male end,
ensuring no sealant is applied to the copper pin. Please refer to the
MSDS before handling. All appropriate Personal Protective Equip-
ment (PPE) shall be worn, including safety glasses and disposable
gloves as a minimum.

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6.2.2 NEVER immerse the CP Gun™ with any of the connectors
un-mated.
6.2.3 Take care when handling reference electrode elements —
NEVER get oil or grease on them.
6.2.4 NEVER touch elements with your ngers. Do not use solvent
cleaners on the electrode; use only fresh water to clean.
6.2.5 After every use, soak the CP Gun™ in fresh water for at least
1 hour. This will extend the life of the electrodes.
6.3 LED readout unit
Each reference electrode is connected to its own voltmeter LED
readout. Both voltmeters are contained in a pressure housing fac-
ing the rear of the CP Gun™. Power is supplied to these voltmeters
by two standard, replaceable PP3 9-volt alkaline batteries. To ac-
cess, see Section 8, maintenance.
6.4 Bulkhead connector
The probe tip and reference cells are connected to the voltmeters
via a Seacon 3-pin bulkhead connector. Before use, ensure that the
connector is properly tightened. A thin layer of connector sealant
should be applied to the rubber shoulder of the male end, ensuring
no sealant is applied to the copper pin. Please refer to the MSDS
before handling. All appropriate Personal Protective Equipment
(PPE) shall be worn including safety glasses and disposable gloves
as a minimum.
6.5 Lens
The lens is made from a clear, acrylic material. The only reason to
remove the lens is to replace the 9-volt batteries which power the
LED readout unit.
6.6 Contact tips
Tips should be replaced once a stable potential reading can no
longer be obtained.
Tips should not be sharpened with a le or hammered into a point.
To replace, remove the existing tip with a 7/16” (or 10mm) wrench;

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ats are best. Ensure that the new tip is tight, but do not overtighten
(max torque 50 inch-lbs).
6.7 On/off power switch
The CP Gun™ is powered on with the red rotational magnetic
switch. With the switch in the rear (off) position, rotate the switch to
the on (forward) position. If the meter does not power on, check the
batteries (Section 8, maintenance). When the CP Gun™ is not in use,
switching it off will extend the life of the batteries, enabling use of
the CP Gun™ throughout an entire survey season without the need
to replace the batteries.
CAUTION
The contact tip has been machined to a very sharp point to enable
easier readings through coatings. This point can also easily cut or
poke through human skin. Please handle with care.
6.8 Spare parts and accessories
The CP Gun™ is shipped in a waterproof transit case and includes
the following spares and accessories. Please contact your Deepwa-
ter representative to order additional spares if required.
• Zinc calibration block (1) • Silicone connector lube (1)
• Contact tip (3) • Ag/AgCl electrode element (1)
• Lens retaining screw (4) • Lens back-up ring (2)
• O-Ring lube (1) • Lens O-ring (4)
7. Calibration test
(Please also refer to schematic in Fig. 6)
7.1 Bucket calibration check
7.1.1 Fill a clean, non-metallic bucket or container with enough
seawater or simulated seawater to completely submerge the
probe unit. Ensure the bucket has been completely degreased and
rinsed.
7.1.2 Place the probe in the bucket with the tip pointing up to ll
body with seawater. The entire probe, including the tip, must be
immersed. Make sure there is no trapped air in the unit.

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7.1.3 With a le or sandpaper, remove any layer of oxide from the
zinc coupon before placing it in the bucket.
7.1.4 Wait 30 minutes for the electrode elements to reach equi-
librium.
7.1.5 Unscrew the contact tip using a 7/16” (or 10mm) wrench
(ats are best) from the nose cone and attach the zinc calibration
block’s ring terminal over the contact tip threads. (See Fig. 3.)
Reattach the contact tip as shown. (Alternatively, the zinc block
can be stabbed directly with the contact tip.)
7.1.6 Quickly ip the CP Gun™ over so the nose points down.
Rotate the red switch forward to turn on the LED readouts.
7.1.7 Read the two display lines on the LED readout. The two
voltages should be between (-) 1030 and (-) 1070 mV and should
match each other to within 5 mV. See Fig 4.
7.1.8 If the readings are not within this range, please see the
troubleshooting section.
Figure 3:
Calibration
coupon
attachment

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7.1.9 Note: If the probe has
not been used in a while, it
may take another 15 – 30
minutes for the electrode ele-
ments to reach equilibrium.
7.1.10 Remove the zinc
calibration block if attached,
and using a 7/16” (or 10mm)
wrench (ats are best), ensure
that the contact tip is tightly
reattached on the nose cone.
7.1.11 Ensure that the tip is
sharp.
7.2. Underwater online
calibration check
7.2.1 The CP Gun™ reference calibration can be checked while
underwater by stabbing a reference piece of zinc and ensur-
ing the potential is between -1,030 and -1,070 mV, and that the
measurements are within 5mV of each other. If the readings are
not within 5 mV of one another, the probe unit is out of calibra-
tion. The survey can continue, provided the diver records both
readings until the CP Gun™ can be brought back to the surface
to recalibrate against the zinc block.
7.3 Measuring potentials
To obtain accurate CP readings from the CP Gun™, follow these
steps:
7.3.1 When underwater, switch the unit on by moving the red
switch forward.
7.3.2 Ensure the instrument calibration is valid (Sections 7.1 and
7.2).
7.3.3 Stab the tip contact probe onto the structure where the
reading is required. Ideally, this should be bare steel or a desig-
Figure 4:
Bucket calibration readings
Readings should be between
(-)1030 mV and (-)1070 mV and
within 5 mV of one another

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nated CP test point.
7.3.4 When a good contact is made, the reading will be steady.
It may take some effort to stab and break through coatings or
marine growth. If marine growth is thick and hard, it will need to
be properly removed before a measurement can be taken.
7.3.5 Do NOT use the CP Gun™ to remove marine growth.
7.3.6 The two readouts should give a steady result and should be
within 5 mV of each other.
7.3.7 If the readings are not within 5 mV of one another, the CP
Gun is out of calibration.
CAUTIONS
• The contact tip has been machined to a very sharp point to en-
able easier readings through coatings. This point can also easily
cut or poke through human skin. Please handle with care.
• The CP Gun™ should be attached to the diver’s belt with the tip
facing downward when not in use.
• Avoid stabbing painted or coated surfaces. Whenever possible,
try to take readings on bare steel or on spots specially designated
for CP measurement.
• Avoid trying to stab through heavy, hard marine growth.
• If the readings are not steady or don’t match the criteria in the
table below, it’s probably due to a high-resistance contact (a bad
stab). DO NOT RECORD THESE NUMBERS; continue to stab until
readings are in specication. See Section 9, troubleshooting, if
problems persist.
• Take care not to shove the CP Gun™ nose into mud, as this may
contaminate a reference electrode and shorten its life. If this does
occur, rinse with fresh water. Verify the instrument calibration ac-
cording to the bucket calibration procedure in section 7.

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• When a job is complete, turn off the CP Gun™ and soak in fresh
water for at least 1 hour. Let dry, replace the lens cover and stow in
case.
7.4. Data interpretation
7.4.1 For carbon steel structures in seawater, the readings
obtained should be within the ranges in Table 1. Exceptions may
occur if the probe is stabbed onto an isolated section of a corro-
sion-resistant alloy such as stainless steel, copper or nickel. In
these cases, readings less negative than the indicated range may
be noted. If this is the case, ensure that the readings are steady
and within the 5 mV allowable range.
Range (mV) Interpretation Action
-500 or more
positive Error
Remake contact & verify
Measure two other points
around the component
Abort & refer to
troubleshooting section
-501 to -649 Isolated from cathodic
protection Remake contact & verify
Record data-650 to -799 Not cathodically protected
-800 to -849 Marginal cathodic protection
-850 to -1049 Cathodically protected Record data
-1050 to -1149 Anode potential for Al or Zn
-1150 or more
negative Error (unless Mg anode)
Remake contact & verify.
Measure two other points
around the component
Abort & refer to
troubleshooting section
Table 1 -
Normal cathodic protection ranges for bare carbon steel in seawater

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8. Maintenance
8.1 Overview
8.1.1 This section covers general operational maintenance; do
not attempt any tasks not described in this section, as it may
damage the system.
8.1.2 Please contact your Deepwater representative if you have
any questions.
8.2 Tip replacement
8.2.1 Tips should be replaced once a stable reading can no
longer be obtained. Remove the old tip with a 7/16” (or 10mm)
wrench (ats are best). Replace with the provided spare. Addi-
tional spare parts may be obtained from Polatrak as needed (see
table 3). Ensure that the new tip is tight, but do not overtighten
(max torque 50 in-lb).
CAUTION
The contact tip has been machined to a very sharp point to enable
easier readings through coatings. This point can also easily cut or
poke through human skin. Please handle with care.
8.3 Electrode element replacement
8.3.1 Take the CP Gun™ to a clean area.
8.3.2 Unscrew and gently remove the element housing (Figure
2) of the CP Gun™ to expose the electrode elements. Try to avoid
un-mating the tip connector.
8.3.3 Visually inspect to ensure that the connector is properly
mated and that the wire or element is not damaged.
8.3.4 Disconnect the electrode harness from the bulkhead con-
nector by unscrewing counter-clockwise.
8.3.5 Repeat a bucket calibration test as described in section 7.1,
but only immerse the element housing and reference electrodes.
The electrode connector on the harness should remain dry.

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8.3.6 Using a digital voltmeter set on 2.00 VDC range, stab the
large pin socket (pin 1) with the positive voltmeter lead and stab
pin socket 2 (rst clockwise of large pin) with the negative lead
(conguration A below) and note reading. Then repeat, stabbing
pin socket 3 with the negative lead (conguration B below) and
note the reading. The faulty electrode will be the one that gives
the lowest (more positive) reading.
8.3.7 Ensure that the electrode housing is drained of seawater.
8.3.8 DO NOT handle the small electrode pellet with bare hands
or otherwise contaminate it.
8.3.9 Remove the bad electrode and discard according to appropri-
ate local environmental procedures.
8.3.10 Take the new electrode and carefully place a small
amount of connector sealant on the shoulder, being careful
not cover the copper pin. Please refer to the MSDS in appendix
before handling sealant. All appropriate Personal Protective
Equipment (PPE) shall be worn, including safety glasses and
disposable rubber gloves as a minimum.
8.3.11 Plug the new electrode into the connector.
8.3.12 Plug the electrode harness back into the bulkhead con-
nector. Apply a small amount of connector sealant onto the
Pin socket 1: Contact tip
Pin socket 2: Reference electrode #1 (R1)
Pin socket 3: Reference electrode #2 (R2)
A B
Figure 5 - SEA CON® RMG-3FS
connector pin diagram

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shoulder of the bulkhead connector as previously described.
8.3.13 Check that all connectors are fully mated and carefully
put the electrodes back into the element housing and slowly
screw it back on by hand, clockwise.
8.3.14 Repeat the calibration check as described in section 7.1.
(Note: A new, dry reference electrode may take an additional 30
minutes to reach equilibrium)
8.4 Battery replacement
Batteries will need replacement after approximately 48-60 hours of
operation or when the displays begin to fade. To replace batteries,
the readout must be removed from the unit in a clean, dry location.
This is best done in a workshop.
8.4.1 Remove all four (4) 10-24 stainless steel Phillips retaining
screws.
8.4.2 Rotate the lens approximately 10 degrees in either direction.
This will prevent future damage to the threads on the housing.
8.4.3 Next, screw in the four (4) ¼” – 20 stainless steel Allen
screws evenly to draw lens out.
8.4.4 Carefully and evenly pull the lens out by the four Allen
screws.
8.4.5 Remove the four (4) ¼” – 20 stainless steel Allen screws
from the lens.
8.4.6 Carefully remove the voltmeter module from the housing.
There is enough slack cable to allow this. Remove and replace
the two (2) PP3 9 volt batteries.
8.4.7 Carefully re-insert the voltmeter module and illuminate
the photocells by rotating the switch forward to ensure that the
display is receiving power before replacing the lens.

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8.4.8 The lens has two grooves: The outer groove (closest to
the external, convex surface of the lens) and the inner groove
(closest to the internal surface of the lens). The inner groove is
designed for one round O-ring to be seated next to one backup
ring (square cross-section). The outer groove contains a single
round O-ring.
8.4.9 Replace all O-rings and backup rings with the provided
spares. NEVER REUSE O-RINGS. Additional spares can be ob-
tained from Polatrak (see table 3).
8.4.10 Make sure the new O-rings are properly installed and
seated and that the backup ring is not twisted.
8.4.11 Apply a small amount of O-Ring lubricant to the lens and
the inside wall of the pressure housing and smooth out into a
thin layer. Do not apply lubricant to the internal or external face
of the lens. Please refer to the MSDS in the appendix before han-
dling. All appropriate Personal Protective Equipment (PPE) shall
be worn with eye protection and gloves as a minimum.
8.4.12 Gently push the lens in until the second ring is just above
the rim of the pressure housing.
8.4.13 Line up the lens holes with the holes in the pressure
housing using the four (4) 10-24 stainless steel retaining screws.
Properly seat the lens against the pressure housing by tightening
them with a Phillips-head screwdriver in an alternating pattern
to avoid tilting the lens.
9. Troubleshooting
9.1 General
If the two displays are not reading within 5 mV of one another,
check the following:
9.1.1 Repeat the calibration check (section 7.1). The electrode
with the more positive reading is probably in error.
9.1.2 Remove the reference electrode elements and replace with

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spares, being careful not to touch the silver/silver chloride pellet
with bare or greasy hands. Please see section 8, maintenance,
for details.
9.1.3 After any replacement or repair, check calibration by fol-
lowing the bucket calibration check described in section 7.1.
Symptom Possible problem Action
Instrument will
not calibrate
One electrode is bad
Zinc coupon is pas-
sivated (formed an
oxide coating)
Electrodes are dry
See section 9.1.2
Remove zinc and clean with rasp
Soak in seawater for 30 minutes and
retry
Both electrodes
reading low Tip wire damaged
Remove probe element housing,
unplug tip wire, remove nose cone,
inspect tip wire and repair with
ScotchKote as temporary measure.
Order replacement nose cone.
Readings are not
steady and con-
tinue to change.
Voltmeter batteries
are low
Poor structure contact
Replace voltmeter batteries
Re-stab to ensure contact.
One reading sud-
denly reads less
negative
Connector is ooded. Check connectors
LED readouts are
blank
Switch not in position
Batteries are dead
Pressure housing is
ooded
Verify switch position (Forward: on,
Rear: off).
Replace batteries
Go to backup; return unit to Polatrak.
If a problem persists or is not listed, please call our hotline at [phone]
and ask for Polatrak technical support.
Table 2 - Troubleshooting quick guide

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10. Appendix
Table 3 - CP Gun™ spare parts list (Please see page 3 for photo reference)
Part no. Description No. required No. spares
ROV0004 Contact tip 1 3
ROV0016 Nose cone assembly 1 0
MLT0004 Replaceable silver/silver chloride reference element 2 1
CPG0006 Replaceable copper/copper sulphate reference element 0 0
MLT0011 Pressure housing 1 0
MLT0010 LED readout unit 1 0
MPT0001 CP Gun on/off switch 1 0
MLT0014 Readout lens 1 0
GSK0009 Lens O-ring 2 4
GSK0008 Lens backup O-ring 1 2
FAS0104 Lens retaining screws 4 0
MFR0015 Lens cover 1 0
352-MN01-ENG Instruction manual 1 0
GSK0006 Tube O-ring lubricant 1 0
EOR0015 Tube silicone grease insulating compound 1 0
ROV0018 Zinc calibration coupon 1 0
CALL Transit case 1 0
CALL Transit case O-ring 1 0
CALL Transit case foam pack 1 0
Please contact [phone] or [e-mail] for ordering parts.
9.2 Both displays reading low (more positive) voltages
If both electrodes read low during a stab (more positive than (–)500
mV), the problem is likely with the contact tip wire attached to the
nose cone assembly. If the tip wire is damaged, a temporary soft-
splice repair can be made using ScotchKote® sealant (not included)
and splicing tape. However, prolonged operation in this manner is
not recommended. Order a new nose cone assembly at once (see
Table 3).

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13813 FM 529 Rd, Houston, TX 77041 | US [phone] | Email: [e-mail]
©2023 Deepwater Corrosion Services Inc.
20SMB-008 CP-Gun Manual Rev. 2
CP-GUN™ MANUAL
CP GUN
Figure 6
BUCKET CALIBRATION CHECK
WITH ZN COUPON
CP GUN™ CALIBRATION SCHEMATIC
LED readouts
Both readings should be between (-)1030 mV and
(-)1070 mV and be within 5 mV of one another.
Seawater solution
Non-metallic bucket
Zn calibration coupon