WARNING!!!

PLEASE BE ADVISED THAT KOCOUR 110

VOLT HULL CELLS ARE ONLY RATED FOR
USE WITH 110 VOLT AC POWER SUPPLY.
DAMAGE TO THE HULL CELL AND/OR FIRE
ISO 9001 CERTIFIED CAN OCCUR!

220 VOLT HULL CELLS ARE AVAILABLE!

Operating Instructions for TCCG & TCACG

267 & 1000 ML Heated & Non-Heated Hull Cells

The heated hull cell provides a simple, accurate method for making plating tests on any baths, such as
bright nickel, high speed copper, tin, etc. which require an elevated operating temperature. The hull cell is
equipped with a thermostatically controlled circuit guard heater which will maintain the bath temperature
to a maximum of 150°F. To avoid damage to the hull cell do not exceed 150°F. The standard hull cell
is not equipped with a heating element and operates at room temperature without the need to preheat the
solution. Hexavalent chromium plating solutions cause the Lucite hull cells to craze and eventually leak.
Do not use Lucite cells with Hexavalent Chromium solution. A PTFE hull cell is recommended for use
with hexavalent chromium solutions.

Operating Procedure:
1. Analyze all plating solution components (e.g., metals chlorides, boric acid, specific gravity, pH
etc.) and make adjustments as required.
Note: If preheating the solution is not required, withdraw a sample to be tested and transfer directly
into the hull cell. Fill to the bottom of the red printed triangle. Then proceed to Step #5.
WARNING: DO NOT LEAVE UNATTENDED OR OPERATE WITHOUT LIQUID
2. Withdraw approximately 1500 ml of solution to be tested and transfer into a 2000 ml beaker.
Place the beaker on a heat source and then preheat the solution to the proper operating
temperature. (Periodically check the temperature with the thermometer).

3. After reaching the desired temperature, remove beaker from heat source and fill the hull cell with
the preheated solution to the bottom of the red printed triangle in either the 267 ml or 1000 ml
hull cell.

4. Plug the heater into the short jumper connector cord and slide the boot cover over the connection.
Plug in the power cord and turn the control knob fully clockwise, the red indicator light should
now be on. When the desired temperature is reached slowly turn the control knob
counterclockwise until the light goes off. This will turn off the heater and maintain the preheated
solution temperature within ±5°F of the desired operating range. (Periodically check the
temperature with the thermometer).

5. If agitation is required, use either the air or mechanical system. Use the system that duplicates
your production process.

Page 1 of 4

KOCOUR COMPANY INC. • 4800 SOUTH ST. LOUIS AVENUE • CHICAGO, IL 60632 USA
TEL (773)847-1111 • FAX (773)847-3399 • www.kocour.net
EMAIL: [email protected]
 6. Using the table below as a guide, select the proper anode and connect it to the red lead (+) from
the rectifier. Again, using the table, select the proper cathode, clean according to the instructions
on the package, then connect it to the black lead (-) from rectifier.
Note: Kocour rectifier model 5D is recommended for the 267 ml hull cell and the model 15D is
recommended for the 1000 ml hull cell. Do not use rectifiers with greater than 3% ripple.
______ Amperage______ Plating Time
Plating Bath Agitation Anode Cathode
267 mL 1000 mL (min)
Acid Copper Air Phos. Copper Copper/Brass 3 5 5
Pyro Copper Air Copper Copper/Brass 2 3 5
Cyanide Copper Copper Copper/Brass/Steel 2 3 5
Cadmium Barrel Cadmium Steel 2 3 5
Cadmium Rack Cadmium Steel 1 3 5
Acid Zinc Rack Air or Mech. Zinc Steel 3 3 5
Acid Zinc Barrel Zinc Steel 1 3 5
Alkaline Zinc Rack Zinc Steel 3 3 5
Alkaline Zinc Barrel Zinc Steel 1 3 5
Cyanide Zinc Zinc Steel 2 3 5
Hexavalent Chromium Lead Steel/Copper 5 5 2
Trivalent Chromium Pt. Titanium Copper/Brass/Steel 10 10 1
Nickel (All) Air or Mech. Nickel Copper/Brass/Steel 2 3 5
Acid Tin Rack Mech. Tin Copper/Brass/Steel 2 5 5
Acid Tin Barrel Tin Copper/Brass/Steel 1 - 5
Silver Mech. Silver Copper/Brass/Steel 0.75 - 5
Gold Pt. Titanium Copper/Nickel plated Brass 0.25 - 1
Brass Brass Steel 1 - 5
Lead Lead Copper/Brass/Steel 2 3 5

7. Plate the cathode for the specific time and amperage recommended by the plating process
supplier or use the general plating times and amperages listed above.

8. After plating, remove the cathode and rinse thoroughly with water, then dry. Use the plastic hull
cell scale (or Figure 2) to determine the current density at variously points along the plated panel.

9. If any additions are required, calculate the amount from the chart below:

2 g/267mL Hull Cell = 1 oz/gal = 7.5 g/L

2 mL/267mL Hull Cell = 0.96 fl oz/gal = 7.5 mL/L
7.5 g/1000mL Hull Cell = 1 oz/gal = 7.5 g/L
7.5 mL/1000mL Hull Cell = 1fl oz/gal = 7.5 mL/L

Page 2 of 4

KOCOUR COMPANY INC. • 4800 SOUTH ST. LOUIS AVENUE • CHICAGO, IL 60632 USA
TEL (773)847-1111 • FAX (773)847-3399 • www.kocour.net
EMAIL: [email protected]
 10. After testing is complete, unplug the heater and allow the heating element to cool before
removing the solution.

Maintenance:
1. Clean hull cell thoroughly with water when testing various solutions or after additions have been
made. Residues left in the cell can affect the results. ELECTRICAL HAZARD. Unplug power
cord before cleaning.

2. It is strongly recommended to use different hull cells for different solutions. This reduces the risk
of contaminating the plating solution.

3. The hull cell is not waterproof. To avoid damaging the heating element and thermostat, DO NOT
IMMERSE IN WATER.

Electrolytic Purification of Baths:

It is frequently necessary to electrolyze plating baths to remove metallic impurities. The manner in which
this is accomplished in the hull cell is to electrolyze the bath sample at a low current density with the
anode and cathode parallel, i.e., the cathode plate adjacent to the longest side of the hull cell, with the
anode opposite. Agitation may be used if desired. The amount of electrolysis required to give a good test
plate in the regular manner can then be translated to the plating tank.

As an example, 5 amperes per ft2 on the cathode (3.938” long by 2” deep (immersed)), calculate as:
3.938 in x 2 in x 5 amp/ft 2
= 0.27 ampere through the hull cell
144 in2 /ft 2
If 20 minutes electrolysis removes the impurities satisfactorily, the total electrolysis is 20 min x 0.27 amp
= 5.4 amp-minutes. Therefore, since 3,785 ml equals 1 gallon, 5.4 amp-minutes for 267 ml calculates as
follows:
3.785 ml 5.4 amp − min
x = 1.27 amp − hr per gal of plating solution
267 ml 60 min⁄hr

Proprietary Process:
When using hull cell control on proprietary plating baths, it is usually advisable to contact the
manufacturer of the particular process for their recommendations. These recommendations may suggest a
change in the amperage or time of the hull cell test in order to better illustrate the bath parameters to be
controlled. Some processes also use special addition agents, which have a pronounced effect on
appearance of the hull cell panel.

Page 3 of 4

KOCOUR COMPANY INC. • 4800 SOUTH ST. LOUIS AVENUE • CHICAGO, IL 60632 USA
TEL (773)847-1111 • FAX (773)847-3399 • www.kocour.net
EMAIL: [email protected]
 Figure 1: Methods of Testing

Figure 2: Current Density in Amps per Square Foot

PANEL
EDGE

1 AMP 40 30 25 20 15 12 10 8 6 4 3 2 1 0.5

80 60 50 40 30 24 20 16 12 8 6 4 2 1
2 AMPS

TOTAL
CURRENT

3 AMPS 120 90 75 60 45 36 30 24 18 12 9 6 3 1.5

5 AMPS 200 150 125 100 75 60 50 40 30 20 15 10 5 2.5

PANEL
EDGE

3 AMPS 90 60 45 36 30 24 18 15 12 9 6 3 0.6

150 100 75 60 50 30 25 20 15 10 5 1
5 AMPS 40

Page 4 of 4

KOCOUR COMPANY INC. • 4800 SOUTH ST. LOUIS AVENUE • CHICAGO, IL 60632 USA
TEL (773)847-1111 • FAX (773)847-3399 • www.kocour.net
EMAIL: [email protected]