RESTRICTED

Order Number: 185275-79 Dt.23.10.19.

Yard: 1233-37.

THE INFORMATION GIVEN IN THIS HANDBOOK IS NOT TO BE

PUBLISHED OR COMMUNICATED EITHER DIRECTLY OR
INDIRECTLY TO THE PRESS OR TO ANY PERSON NOT HOLDING
AN OFFICIAL POSITION IN THE SERVICE OF THE GOVERNMENT
OF INDIA

SYSTEM HAND BOOK FOR

IMPRESSED CURRENT ANTI FOULING SYSTEM
FOR 105M OPV.

THIS SYSTEM HANDBOOK DOES NOT CONSTITUTE AUTHORITY

FOR REPAIRS OR REPLACEMENT OF COMPONENTS BY USERS.
REPAIRS BY DIFFERENT AGENCIES WILL ONLY BE CARRIED OUT
AS LAID DOWN IN PERMISSIBLE REPAIR SCHEDULES PUBLISHED
Prepared
AS EMERs OR EQUIVALENT FROMandTIME
Published by:
TO TIME.
SARGAM METALS PRIVATE LIMITED

Prepared and Published by:

SARGAM METALS PRIVATE LIMITED

Block -1,Unit-1,Ground Floor,
SIDCO Electronics Complex,
Guindy,Chennai – 600032.
EMAIL: mailto:cp@sargammetals.com

Under the Authority of Secretary,

DECEMBER 2019 Ministry of Defence, Govt. of India

RESTRICTED
 RECORD OF CHANGES

Change Incorporated by “Name

Initials with
Notice Authority & Rank” in Block
Date
Number Letters
ASSOCIATED HAND BOOKS & OTHER SUPPLIERS HAND BOOKS

--- NOT APPLICABLE---

 SAFETY
WARNING
The Voltages employed in this Equipment are
sufficiently high to endanger human life.

230V AC
POWER
MUST BE SWITCHED OFF
before servicing the equipment.

GREAT CARE
must be taken
when making internal adjustments etc.

FOR FIRST AID IN CASE OF ELECTRIC SHOCK SEE OVERLEAF

 FOR FIRST AID, IN CASE OF ELECTRIC SHOCK

1. SWITCH OFF. If this is not possible, PROTECT with

dry insulating material and pull the victim clear of the
conductor. DO NOT TOUCH THE VICTIM WITH
YOUR BAREHANDS until he is clear of the
conductor, but DO NOT WASTE TIME.

2. Place the victim in the supine position. Keep the air

passages of the victim clear by turning the victim’s
head to one side. Open the victim’s mouth and clear
it of water, saline, mucus, or blood, a lot of which
might have accumulated in the back of the throat.
(FIG.1.)

3. If the jaw is rigid try to force the mount open by

pressure on the gum behind the last molar tooth of
the lower jaw. When the upper air passages are thus
cleared, tilt the victim’s head backward and force the
jaw forwards from the angles of the jaw in front of
the ears. This would prevent mechanical
obstructions to the upper air passage. (FIG.2 and
FIG.3)

4. Holding the chin of the victim up and forward with

one hand, pinch the nostrils of the victim with the
other. (FIG. 4)

5. Take a very deep breath and apply your mouth to

that of the victim and blow into his mouth, until the
chest of the victim expand and move up indicating
filling of lungs. (NEVER ALLOW THE CHIN TO SAG).
HAVE SOMEONE ELSE (FIG. 4)
SENT FOR A DOCTOR.
KEEP PATIENT WARM AND LOOSEN HIS CLOTHING.
DO NOT GIVE LIQUIDS
6. UNTIL
When THE VICTIM
the chest IS CONSCIOUS.
has moved up, withdraw your mouth
and allow the chest to slink back.

Repeat this process every three to four seconds until

the victim begins to breathe again or until he is taken
over by a medical attendant. This method can be
continued in an ambulance during transit of the
patient from the site of the accident to the nearest
medical centre.

HAVE SOMEONE ELSE SENT FOR A DOCTOR

KEEP PATIENT WAM AND LOOSEN HIS CLOHING
DO NOT GIVE LIQUIDS UNTIL THE PATIENT IS CONSCIOUS
 DEMOLITION OF MATERIAL
TO PREVENT ENEMY USE

(a) General
The demolition procedure outlined below will be used to prevent the enemy
from using or salvaging this equipment. Demolition of the equipment will
be done only on order of the commanding Officer.

Methods of Destruction
(b) Use all any or all of the following methods to destroy the equipment.

(i) Smash: Smash the crystals, controls, semiconductors, coils, switches,

transformers and headsets; use sledges, hand-axes, pickaxes,
hammers, crowbars or heavy tools.

(ii) Cut: Cut the cords, headsets and wiring; use axes, hand-axes or
hatches.

(iii) Burn: Burn the cords, resistors, capacitors, coils, wiring, technical
manuals; use gasoline, kerosene, oil, flame throwers or incendiary.

(iv) Bend: Bend the panels, Cabinet and chassis.

(v) Explode: If explosives are necessary, use fire arms, grenades or TNT.

(vi) Dispose: Bury or scatter the destroyed parts in slit trenches, foxholes
or other holes, or throw them into streams.
 LIST OF CONTENTS

Chapter I Leading Particulars and General Data ...............................................

1.1 Introduction ........................................................................................... 1
1.2 Salient Features and Facilities .............................................................. 1
1.3 System Configuration ............................................................................ 2
1.4 Technical Specifications ........................................................................ 2
1.4.1 Sea Water System particulars ............................................................... 2
1.4.2 System Design ...................................................................................... 3
1.4.3 System Parts ......................................................................................... 3
1.4.4 System Specifications ........................................................................... 3
1.5 Power Supply Requirements ................................................................. 4
1.6 Dimensons & Weights ........................................................................... 4

Chapter II Brief Technical Description and Specifications ................................

2.1 Introduction ........................................................................................... 5
2.2 System Description ............................................................................ 5-6
2.3 16 Way ICAF System Connection Description...??????. ?........ 7

Chapter III Unpacking and Removal of Preservatives ..........................................

3.1 Introduction ........................................................................................... 8
3.2 Unpacking ............................................................................................ 8
3.3 Initial Checks ......................................................................................... 8
3.4 Removal of Preservatives ..................................................................... 8

Chapter IV Preparation for Use and Installation Specifications ..........................

4.1 Introduction ........................................................................................... 9
4.2 Initial Instructions .................................................................................. 9
4.3 Setting Instructions ................................................................................ 9
4.4 Interconnections .................................................................................. 10
4.4.1 16-way ICAF System connecton description .................................. 10-12

4.5 Installation Tool List ?????????????????????. 13

4.6 Installation ???.. .................................................................. ???13
4.7 Installation Check List ??????????????????? 13-14

Chapter V Operating Instructions .........................................................................

5.1 Introduction ......................................................................................... 15
5.2 Precautions and Safety measures ...................................................... 15
5.2.1 Precautions to use .............................................................................. 15
5.3 Control and Indicator details................................................................ 15
5.4 Setting Instructions .............................................................................. 15
5.4.1 Control Unit .................................................................................... 15-16
5.4.2 Anodes ................................................................................................ 16
5.4.3 Electrical Connections .................................................................... 16-17
5.5 Sequence of Operations ..................................................................... 17
5.5.1 Commissioning.................................................................................... 17
5.5.2 Installation of Anodes .......................................................................... 17
5.5.3 Panel Electrical connections ............................................................... 18
5.5.4 Setting to work .................................................................................... 19
5.5.5 Procedure for Replacing anodes ......................................................... 19
5.5.6 Testing ........................................................................................... 19-20

Chapter VI User’s / Operator’s Servicing and Maintenance Instructions ...........

6.1 Introduction ......................................................................................... 21
6.2 Preventive Maintenance ...................................................................... 21
6.3 Fault Diagnosis .................................................................................... 22

Chapter VII Miscellaneous .......................................................................................

7.1 SECTION 1 ......................................................................................... 23
7.1.1 Introduction ????????????????????????.. 23
7.1.2 Station List .......................................................................................... 23
7.1.3 List of Tools ......................................................................................... 23
7.2 SECTION 2 ......................................................................................... 24
7.2.1 Introduction ......................................................................................... 24
7.2.2 Handling & Packing ............................................................................. 24
7.2.3 Storage & Transportation .................................................................... 24

Appendix-A Illustrations .......................................................................................... 25

Appendix-B ATP / TP ........................................................................................ 33-34

Performance Reports .......................................................................................... 35-40

Feedback Information Cards .................................................................................... 41
Log sheet ??????????????????????????????..? 42
 LIST OF TABLES

Table 1: Abbreviations
Table 2: List of Drawings
Table 3: System Configuration.......................................................................................... 2
Table 4: Strainer details ................................................................................................... 2
Table 5: Anode sizes ........................................................................................................ 3
Table 6: System Specifications ......................................................................................... 3
Table 7: Power Supply requirements ................................................................................ 4
Table 8: Dimensions and Weights .................................................................................... 4
Table 10: Recommendation for anode current settings ????????????? 5-6
Table11: Testing .......................................................................................................... 19-20
Table12: Preventive Maintenance ................................................................................... 21
Table13: Fault Diagnosis ................................................................................................. 22
Table14: Station list ......................................................................................................... 23
Table15: Log Sheet ......................................................................................................... 42
 LIST OF ABBREVIATIONS

Sl.No. ABBREVIATION FULL FORM

1. ICAF Impressed Current Anti Fouling
2. Cu Copper
3. CR Cold Roll
4. DGS Directorate General of Supplies
5. EMI Electro Magnetic Interference
6. HDG Hot Dip Galvanised
7. ID and OD Inner Dia and
Outer Dia
8. LFH Limited Fire Hazard
9. MCB Miniature Circuit Breaker
10. NES Naval Engineering Standard
11. OBS On Board Spares
12. SWG Standard Wire Gauge
13. SOTR Statement of Technical Requirements
14. SMPS Switched Mode Power Supply
15. CGRPT Coast Guard Refit & Production Team
Table 1
 LIST OF DRAWINGS

Drawing Page
Drawing Name Drawing No.
Sl.No. No.
Block Diagram of 16-Way ICAF
Figure 1 - 6
System
Block Diagram of 16-Way ICAF
Figure 2 - 10
System & control panel.
DRG.1 16-Way Control Panel. SM17-03-01-03 26
16-Way Inter Connection Cable
DRG-2 SM17-03-05-03 27
Diagram.
DRG-3 16-Way panel Internal Wiring Diagram SM17-03-05-031 28
DRG-4 16 Way Terminal Block Detail SM17-03-06-10 29
DRG-5 Strainer Anode Assembly SM17-03-02-07 30
DRG-6 Anode Location & Dimension Detail SM17-03-02-07L 31
DRG-7 Junction Box Assembly SM17-03-09-ANJ 32
Table 2
 CHAPTER- I
LEADING PARTICULARS AND GENERAL DATA
 CHAPTER I
LEADING PARTICULARS AND GENERAL DATA

1.1 Introduction
This System Hand Book gives an overall view of the ICAF System. This Chapter-I
covers salient features, system configuration, technical specifications, power
supply requirements, environmental specifications, and the dimensional & weight
details.

The ICAF System offers the most efficient and simple-to-operate form of reducing
marine fouling. Installation is easy to carry out involving only minimal costs to the
shipyard in modifications and cabling. The system has been developed from
years to experience of electrolytic based protection, but improved to offer a more
effective system than ever before. The system is suitable for all types of seawater
installations, from ships and barges to offshore structures and power stations.

This system will protect seawater systems against fouling by crustaceans such as
mussels, barnacles, and algae. It is safer and cheaper to run than systems such
as chemical treatment which requires more maintenance and involves greater
overall operating and replacements costs.

1.2 Salient Features and Facilities

ICAF System is electrolytic in action, utilizing specially alloyed anodes which
release low levels of copper into the seawater. Ionic products hostile to marine
growth are formed at the anodes and dissolve into the seawater to form a
gelatinous ‘floc’ which is then carried by the flow of water throughout the system.
This heavier floc tends to settle out into the slower-moving areas where marine
growth is most likely to be a problem. The amounts of copper required for this
purpose are very small (typically less than 2 µg/1 each).

The number and composition of anodes fitted varies in accordance with the size
and type of system requiring protection. They are generally positioned at the
entrance of the seawater system, although additional or ‘booster’ anodes are
sometimes fitted downstream of the primary anodes.

In this project for 105mts OPV class of ships the anodes are installed in strainer as
per the requirement, taking into consideration the space constraints, etc.

The current feed to the anodes is regulated by a Control Panel which includes
instrumentation to monitor and control anode performance.

Mains voltage current is converted by the panel SMPS to low voltage DC, passing
through the control module board to the anodes.

SYSTEM HAND BOOK FOR ICAF - 105M OPV 1

1.3 System Configuration

ICAF System consists of the following sub units and accessories:

Sl. Description Quantity Part Number

a Cu 80Dx300L Anode complete with Nylon
Cofferdam assembly; 10 mts 3C x 2.5 2 nos. CPS206916W014
sq.mm cable of NES STD.521-8511.
b Cu 45Dx75L Anode complete with Nylon
Cofferdam assembly; 10 mts 3C x 2.5 12 nos. CPS206916W015
sq.mm cable of NES STD.521-8511.
c Cu 80Dx75L Anode complete with Nylon
Cofferdam assembly; 10 mts 3C x 2.5 2 nos. CPS206916W016
sq.mm cable of NES STD.521-8511.
e Junction boxes 16 nos. CPS202216W016
ANODE STUD SPANNER
f 1no. CPS1026M10020
16/17 Tubular spanner.
g 16way Control Panel 1no. CPS106316W036
Table 3

1.4 Technical Specifications

The Pipeline carrying Sea water needs to be kept free from fouling organisms.The
entire sea water services requiring treatment are pipe line strainers. The above
services are to be covered by Copper based electrolytic anti-fouling systems.

1.4.1 Sea Water System Particulars:

The strainer details are given below.
STRAINER
Sl.No. SEA WATER SERVICE STRAINER NB Flow Rate (m3/hr)
TYPE
1 Main engine room cooling
Simplex 300 Approx.400
pump(p)
2 Main engine room cooling
Simplex 300 Approx.400
pump(s)
3 Gear box driver sea water
Duplex 100 Approx.55
cooling pump(p)
4 Gear box driver sea water
Duplex 100 Approx.55
cooling pump(s)
5 Motor Driven gear box
Simplex 100 Approx.45
stand by cooling pump (p)
6 Motor Driven gear box
Simplex 100 Approx.45
stand by cooling pump (s)
7 Main DG No.1 Duplex 65 Approx.24
8 Main DG No.2 Duplex 65 Approx.24
9 Main DG No.3 Duplex 65 Approx.24
10 Main DG No.4 Duplex 65 Approx.24
Table 4

SYSTEM HAND BOOK FOR ICAF - 105M OPV. 2

1.4.2 System Design:
Based on the Flow rates as given above and also taking into account all these
factors the following design was proposed.

The sizes of the anode are arrived at so as to provide sufficient treatment to the
estimated quantity of water and at the same time have a replacement life of 1 year
for the strainer anodes. The following are the anode sizes arrived at for the
different systems:
Anti Estimated
Sl. No. SEA WATER SERVICE
Fouling anode (mm) Life
Main engine room cooling
a. 80Dx300L 1 year
pump(p)
Main engine room cooling
b. 80Dx300L 1 year
pump(s)
Gear box driver sea water
c. 45Dx75L 1 year
cooling pump(p)
Gear box driver sea water
d. 45Dx75L 1 year
cooling pump(s)
Motor Driven gear box stand
e. 80Dx75L 1 year
by cooling pump (p)
Motor Driven gear box stand
f. 80Dx75L 1 year
by cooling pump (s)
g. Main DG No.1 45Dx75L 1 year
h. Main DG No.2 45Dx75L 1 year
i. Main DG No.3 45Dx75L 1 year
j. Main DG No.4 45Dx75L 1 year

Table 5
1.4.3 System Parts:
The ICAF System is provided for all of the above sea water services groups. The
ICAF System configuration is -
1x 16 Way Control unit
Single Anode – Copper with nylon type cofferdam
• IP -66 FRP. Junction boxes
• Cable – NES 521- 8511 standard 3c x 2.5 sq mm – 10 meters length from
anodes up to junction box.
1.4.4 System Specifications:
Control panel specification- 16-way
No. of control unit : 1 x 16 way
Input supply : 230V, 50Hz, Single Phase, AC
Output supply : 0 to 12V DC
No. of anodes : 16
Size of control unit : 650mm H x 250mm D x 750mm W.
Wt. of control unit : 37 Kg.
Mounting : Bulk head
IP compliance : IP 44
Digital meter to read individual anode DC output
Metering : voltage & individual anode DC output current.
Controls : Individual anode current control.
Anodized. Instruction Plates and other Tallies
Tally Plates :
will be provided as per requirement.
Table 6
SYSTEM HAND BOOK FOR ICAF-105M OPV 3
1.5 Power Supply Requirements:
Mains Power Supply Voltage : 230V Single Phase
Mains Power Supply Frequency : 50 Hz
Power Consumption : 1.25kw.
Heat Dissipation for the Unit : 600 Watts.
Table 7

1.6 Dimensions & Weights:

The following are the dimension & weight details of the components of the ICAF
System:
Weight Per Unit
Item description Dimensions-mm
Kgs (±5%)
650 x 750 x 250
16W control panel 37
HxWxD
Cu Anode Type-1 80Dx300L 15
Cu Anode Type-2 80Dx75L 4.5
Cu Anode Type-3 45Dx75L 2.2
Junction box 120 x 122 x 90 1
Table 8

SYSTEM HAND BOOK FOR ICAF - 105M OPV 4

 CHAPTER-II
BRIEF TECHNICAL DESCRIPTION
 CHAPTER II
TECHNICAL DESCRIPTION AND SPECIFICATIONS

2.1 Introduction:
This Chapter gives details of technical information of ICAF System and its
associated components. In this chapter the following topics are covered:
(a) System description and (b) Sub system description.

The above topics are explained with the help of functional block diagrams and the
depth of coverage is to help the operator to understand and operate the System.

2.2 System Description (Refer : Drg. SM17-03-01-03).

The Control Unit is made of 12/14 Standard Wire Gauge (SWG)
Aluminium sheet with provision at the rear for bulkhead mounting. The unit is
powder coated in RAL7032 and provided with front hinged doors. The external
door is lockable. The doors have see-through areas for seeing the current and
voltage measurements. Opening the front door provides access to the INPUT
MCB, current settings and anode voltage selector key. While opening the inner
door provides access to the terminals for installation and maintenance.

The Control Unit draws from the ship’s 230V AC power (single phase) and
converts it to12V DC to feed the anodes. The control unit is designed to control
sixteen number of anodes individually. In other words the current to each anode
can be individually set. The control unit gives an output of 0-12V DC and a
maximum current of 2 amps per anode connection. Each anode connection is
commonly referred to as a ‘way’ and hence, as there are sixteen anodes controlled
by each panel. The panel is called a 16-way system.

The current to each anode can be varied independently by using individual

“current adjust”– one for each anode. The current being fed to each anode is
displayed on independent digital displays above the “current adjust”.

Recommendations for anode current settings

Recommen Min.
Max.
Sl. Sea Water Service Flow Rate Number ded Current
Anode type Current
No. Identification m3/Hr of Anode Current (Amps)
(Amps)
(Amps) approx.
1 Main engine room 2.0 0.1
Approx.400 80Dx300L 1 0.7
cooling pump(p)
2 Main engine room 2.0 0.1
Approx.400 80Dx300L 1 0.7
cooling pump(s)
3 Gear box driver sea
water cooling Approx.55 45Dx75L 2 0.1 2.0 0.1
pump(p)
4 Gear box driver sea
water cooling Approx.55 45Dx75L 2 0.1
2.0 0.1
pump(s)
5 Motor Driven gear
box stand by Approx.45 80Dx75L 1 0.1
2.0 0.1
cooling pump (p)
6 Motor Driven gear
box stand by Approx.45 80Dx75L 1 0.1
2.0 0.1
cooling pump (s)

SYSTEM HAND BOOK FOR ICAF-105M OPV 5

 Recommen Min.
Max.
Sl. Sea Water Service Flow Rate Number ded Current
Anode type Current
No. Identification m3/Hr of Anode Current (Amps)
(Amps)
(Amps) approx.
7
Main DG No.1 Approx.24 45Dx75L 2 0.1
2.0 0.1
8
Main DG No.2 Approx.24 45Dx75L 2 0.1
2.0 0.1
9 Main DG No.3 Approx.24 45Dx75L 2 0.1 2.0 0.1
10 Main DG No.4 Approx.24 45Dx75L 2 0.1 2.0 0.1

Table 10

The recommendations for anode current settings should be followed for effective
performance of the system. Higher current setting will result in reduced anode life
while lower current settings can result in fouling of the sea water system.

The connection terminals that are at the rear bottom of the panel and accessible
on opening the inner door, are identified for easy of making connections. The
cables are led into and out of the control unit through a removable gland plate at
the bottom of the unit. The cable connections are detailed in the inter connection
cable diagram in this manual.

The ICAF System has the following facilities:

*Under/Over current indication facility that gives an audio and visual alarm when
an anode current is less than 0.1Amps or more than 2.0Amps. The audio alarm
can be turned off but the visual alarm will remain as a reminder till the anode
current is more than 0.1Amps or less than 2.0Amps.
*Short circuit indication facility that gives an audio and visual alarm when an
anode output short circuit to hull. The audio alarm can be turned off but the visual
alarm will remain as a reminder till the short circuit rectify.

Figure - 1

SYSTEM HAND BOOK FOR ICAF - 150M OPV 6

2.3 16-way ICAF system Connection description

This 16 way ICAF system also consists of 8 functional blocks. The functional block of
16 way ICAF systems are, input protection circuit, SMPS1&2 power card with display
circuit 1 to 8, output connector and protection circuit, junction box, anode nylon safety
cap, strainer ICAF anode, and alarm circuit.

(a) Input protection circuit consists of fuse and MCB protects internal circuits from
excess input current and voltage.
(b) SMPS block consist of rectifier section and it converts 230V AC supply in to
require 15V DC.
(c) Power Card block receive rectified 15V DC supply from SMPS block
and it converts in to require 2x12VDC/2A supply. It displays the anode
Current/voltage. Normally display the anode current, it also receives the signals
from anode output short circuit, under current/over current and it will give visual
alarm, also send signals to alarm circuit.
(d) Alarm circuit receives the respective alarm signals from the power module and
drives the audio alarm with acknowledge circuit.
(e) Output connector block consist of output connectors and protection circuits; this
block connects output supply voltage and output current to the panel output
terminal.
(f) Junction box is made up of die cast FRP, IP66, and grey colour. The box
consists of terminals connected from panel to the anode safety cap through wago
feed through connectors. The junction box consist PG-16 PVC type glands.
(g) Anode safety cap is used for mounting the anodes. These are mounted on
strainer lid.
(h) Strainer ICAF anode: Copper anode used for anti fouling. This material is used
for marine growth control of the pipelines.

SYSTEM HAND BOOK FOR ICAF - 150M OPV 7

 CHAPTER-III
UNPACKING AND REMOVAL OF PRESERVATIVES
 CHAPTER III
UNPACKING AND REMOVAL OF PRESERVATIVES

3.1 Introduction:
This Chapter describes the details of general instruction and step-by-step
procedure for unpacking cases containing the items required. This Chapter also
covers the checks to be made after unpacking.

3.2 Initial checks:

The exterior of the shipping box is to be inspected for evidence of any damage
that might have occurred during transportation.

3.3 Unpacking:
The components and the unit will be neatly placed in a wooden crate. Before
unpacking, ensure that the container is placed vertically upwards and follow the
procedure given below to unpack.

Step-1 Remove the wooden planks in the top and sides of the unit,
one by one.

Step-2 Detach the unit from the base and remove the hay.

Step-3 Remove the gunny bag and packing covers.

Step-4 Clean the surface with a piece of soft dry cloth. .

Step-5 Check for damages on the surface.

Step-6 Check the contents of the box with the packing documents.

3.4 Removal of Preservatives:

The item should be always kept inside a covered enclosure during temporary
storage after unpacking and before installation. It should be ensured that no
unwanted things such as insects, any conductive or non-conductive materials get
into the unit. It should also be ensured that the items does not come in contact
with Water, Fire, Sunlight or any abnormal conditions that will harm the
performance of the items. When this box is handled for transportation, it should
not be rolled. The unit should be lifted carefully with top facing up all the time and
moved. The preservatives should be removed only at the time installation.

SYSTEM HAND BOOK FOR ICAF - 150M OPV 8

 CHAPTER- IV
PREPARATION FOR USE AND INSTALLATION
SPECIFICATIONS
 CHAPTER IV
PREPARATION FOR USE AND INSTALLATION SPECIFICATIONS

4.1 Introduction
This Chapter gives information on the details about the initial inspection of the
System prior to installation. This also talks about the preparation required for
installation; inter connection details and the details installation procedure.

4.2. Initial Instruction

a) The units are shipped securely and safely packed to withstand transit handling.
However, as a measure of precaution check the units visually on unpacking to
ensure there is no damage.
b) Mount the control units at the chosen location.
c) It is recommended that the unit be mounted as close to the anode location as
possible to ensure that there are no large voltage drops and also to ensure cabling
requirements are minimum. Being an electronic unit, it will help if the location is in
an air-conditioned environment though it is not a must. The unit is to be mounted
on the bulkhead using the shock mounts at the rear of the unit. BOLTS/STUDS for
shock mounting ARE PART OF SUPPLY. It is recommended that M12 mild-steel
studs be used for fixing.

4.3. Setting Instructions

(a) The cables are to be brought into the unit through the bottom. A removable gland
plate is available at the bottom. One gland is required for the Main input cable.
(b) Bring the input single phase AC power supply wires through the cable gland and
connect to the terminal marked INPUT (see Wiring Diagram with this manual). It is
recommended that 1.5 sq. mm x 2 core copper cable is used at the minimum for
the input connection.
(c) Ensure that (230V AC-2line) and earth connections are made. The earth is
internally grounded to the panel.
(d) It is important that anodes are mounted in the vertical position is specified clearly
in the drawings.
(e) Care must be taken to identify the strainer and ensure the correct anodes are
mounted in the correct sea water service.
(f) Determine and mark the position of the anodes (centre of anodes) on the strainer
lid.
(g) Make a hole of 20.5 mm dia on the Strainer top plate. Fix the neoprene gasket on
the strainer lid and insert the nylon cofferdam assembly.
(h) At the time of inserting the anode stud from the bottom of lid through nylon
cofferdam, insert the M10 plate washer inside the cofferdam and put the M10 full
nut, tighten the M10 full nut by tubular spanner, take adequate care not to damage
the coating on the anodes.
(j) Connect the cable to the anode connecting brass lug, relevant screw terminal,
and coffer dam earth.
(k) Remove the plastic-cling wrap cover on the anode.
(l) Check the anodes to ensure that the mastic coating is intact. If there are gaps in
the coating please paint over with any suitable mastic or coal tar epoxy.
(m) Ensure the M10 lock nut tightened with the tubular spanner.
(n) Ensure the cable leads are connected as follows before fixing the anode
connecting lug.

SYSTEM HAND BOOK FOR ICAF – 105M OPV 9

(p) Gently tighten the Cu.anode bolt terminal.
(q) Connect the negative return link bolt to strainer body in Drg. No.SM21-03-02-
07,Item. No.13.

4.4 Inter Connections

Figure – 2

4.4.1 16-way ICAF system description ;

This 16 way ICAF system also consists of 5 functional blocks. The functional
block of 16 way ICAF systems are, input protection circuit, SMPS 1&2 power card
1 to 8, output connector and protection circuit and alarm circuit.

(a) Input protection circuit: consists of fuse and MCB protects internal circuits
from excess input current and voltage.
(b) SMPS block consist of rectifier section and it converts 230V AC supply in to
require 15V DC.
(c) Power card block:
This system uses advanced PWM controller current display and linear controls
for the regulation of current.

SYSTEM HAND BOOK FOR ICAF – 105M OPV 10

 Brief description about the system and the detailed specifications -

Specification:
Q Input Voltage: 15 VDC
Q Output Current: 0.1mA to 2000mA. Analogue
Q User Input:
Q 2 potentiometer Anode current for Increase & Decrease

Q Display:
Q 2x3 Seven Segment display for Current.
Q LEDs for Under/Over current.

Q Control:
Q Single Chip PWM controller with Digital Loop Control for
Precision control.

SYSTEM HAND BOOK FOR ICAF – 105M OPV 11

 Advantage:
Q More than 75% conversion efficiency.
Q Integrated Alarms for each Power section.

The recommendations for anode current settings should be followed for effective
performance of the system. Higher current setting will result in reduced anode life
while lower current settings can result in fouling of the sea water system.

ADDITIONAL FEATURES INCORPORATED AS PER THE REQUIREMENT

• Audio Visual alarm to indicate Under/Over current &Short circuit.

• Short circuit --- This will get activated if there is a shorting between
Anode and the Structure( Hull)
• Under & Over Current – This will become on when the current to
anode is above maximum limit -2.01 Amps Or less than 0.1Amps.

(d) Alarm circuit receives the respective alarm signals from the power card and
drives the audio alarm with acknowledge circuit.

(e) Output connector block consist of output connectors and protection circuits;
this block connects output supply voltage and output current to the panel
output terminal.

SYSTEM HAND BOOK FOR ICAF – 105M OPV 12

4.5 Installation Tool List
(a) 16/17 Tubular spanner – 1 no.
(b) 10/11 Double head spanner - 1 no.
(c) PYE screw driver set – 1 no.
(d) Nose player – 1 no.

4.6 Installation
(a) The electrical connections are to be made as given in the interconnection
cable diagram (16-way interconnection cable diagram Drawing No.SM17-03-
05-03).
(b) Each anode is to be connected to a junction box and from there to the
control panel.
(c) The anode current controls in the power card are identified as A1, A2, etc. It is
recommended that the anodes installed in different strainer are also similarly
identified to ensure the operator knows which anode he is setting the current
for. The junction boxes are used to connect the anodes to the control panel,
mount the junction boxes close to the strainer. One junction box is required
per strainer.
(d) Each junction box can accommodate 3 leads on the input side (that is leading
from the anodes). These leads are: - Anode connection to anti-fouling anode,
structure return from each safety cap,Standby.
(e) The cable from the anodes (to a length of 10m) is supplied with the anodes
and can be used. One lead is from the Cu.Anode, second lead is from the
Structure return, third lead is standby. Ensure that the leads are connected to
the appropriate terminals – Cu1 to the Cu anode.
(f) The structure connection is from the bolt mounted inside of the Cofferdam.
The structure returns from the cofferdam are to be connected to the same
structure return terminal in the junction box.
(g) Next the connections from the junction box to the Control panel is to be made
using cables recommended in the wiring diagram in this manual (16-way
interconnection cable diagram Drawing No.SM17-03-05-03).
(h) Ensure that the correct anodes are connected to the correct terminal block in
the control panel, using a number identification(Cable tag number) at the
beginning and end of the cable – for example Cu1, Cu2, etc.
(j) The connections are to be done as indicated in the wiring diagram in this
Manual (16-way interconnection cable diagram Drawing No.SM17-03-05-03)

4.7 Installation Check List

(a) Before flooding the anode space check the insulation between the anode and
the nearest hull structure, between the anode wear probe and the anode and
between anode wear probe and the hull using a Meg-ohm meter(200V). This
should be done for each anode installation. The insulation value if properly
installed should be above 20M-ohms.
(b) Once the strainer is flooded, prior to switching on the system
remove the anode from the terminals at the control panel one-by-one using a
milli-volt meter(Digital Multi meter) measure the potential of each of the
anodes with respect to the hull. This can be done either by connecting the
meter’s terminals to the panel terminal and a hull ground point or by
disconnecting the wires from the panel terminals and connecting to the meter.
Every anode should register a positive potential with respect to the hull.

SYSTEM HAND BOOK FOR ICAF – 105M OPV 13

 (c) Finally check the ground point with reference to the hull. This should also
register zero potential.
(d) If any of the above measurements are not as given above, the entire
connections should be rechecked from the anode point. Carry out the same
checks at the anode point, at the junction box input and out points and trace
down to the panel. If the connections are proper, anodes should register a
positive voltage with reference to the hull, the ground point also zero voltage as
it should be at the same potential as the hull. As a cross check the insulation
between the anode point and the hull.

SYSTEM HAND BOOK FOR ICAF – 105M OPV 14

 CHAPTER-V
OPERATING INSTRUCTIONS
 CHAPTER V
OPERATING INSTRUCTIONS

5.1 Introduction
This Chapter explains the safety measures (Do’s & Do not’s), control and
indicators which operator has to be aware of, setting instructions and the
sequence of operation.

5.2. Precautions and Safety Measures

5.2.1 Precautions to Use

(a) Higher the current setting shorter the anode life. Ensure recommended current
settings are followed.
(b) When current is being increased or decreased, ensure that this is done in small
steps of 0.05 – 0.1 amps at a time.
(c) Ensure the System is switched off before any work is carried out on the
anodes.
(d) When removing nuts/fasteners from the cofferdam, care must be taken to
avoid anodes falling creating accidental fall to the personnel.

5.3 Control and Indicator details

(a) Control unit draws from the ship’s 230V AC power (single phase) and convert it
to 12V DC to feed the anodes.
(b) Current to each anode can be varied independently by using individual current
by operating “current adjuster” – for each anode.
(c) The current being fed to each anode is displayed on independent digital
displays above the “current adjuster”.
(d) Under/Over current & short circuit facility that gives an audio and visual alarm
when an anode get less than 0.1A,greater than 2.0A & short circuit to hull. The
audio alarm can be turned off but visual indication will remain till the problem
rectified.

5.4 Setting Instructions

5.4.1 Control Unit

(a) The units are shipped securely and safely packed to withstand transit handling.
However, as a measure of precaution check the units visually on unpacking to
ensure there is no damage.
(b) Mount the control units at the chosen location.
(c) It is recommended that the unit be mounted as close to the anode location as
possible to ensure that there are no large voltage drops and also to ensure
cabling requirements are minimum. Being an electronic unit, it will help if the
location is in an air-conditioned environment though it is not a must. The unit is
to be mounted on the bulkhead using the shock mounts at the rear of the unit.
BOLTS/ STUDS for shock mounting ARE PART OF SUPPLY. It is
recommended that M12 mild-steel studs be used for fixing.
(d) The cables are to be brought into the unit through the bottom. A removable
gland plate is available at the bottom. One gland is required for the Main input
cable.

SYSTEM HAND BOOK FOR ICAF-105M OPV 15

 (e) Bring the input single phase AC power supply wires through the cable gland
and connect to the terminal marked INPUT (see Interconnection cable
Diagram with this manual). It is recommended that 1.5 sq.mm X 2 core copper
cable is used at the minimum for the input connection.
(f) Ensure that (230V AC-2line) and earth connections are made. The earth is
internally grounded to the panel.

5.4.2 Anodes
It is important that anodes are mounted in the vertical position unless otherwise
agreed differently with the customer to meet user requirement and is specified
clearly in the drawings.

(a) Care must be taken to identify the strainer and ensure the correct anodes are
mounted in the correct sea water service.
(b) Determine and mark the position of the anodes (centre of anodes) on the
strainer. Anodes should preferably be in the line of suction.
(c) Make a hole of 20.5 mm dia on the Strainer top plate. Fix the neoprene gasket
on the strainer lid and insert the nylon cofferdam assembly.
(d) (h) At the time of inserting the anode stud from the bottom of lid through nylon
cofferdam, insert the M10 plate washer inside the cofferdam and put the M10
full nut, tighten the M10 full nut by tubular spanner, take adequate care not to
damage the coating on the anodes.
(e) Connect the cable to the anode bolt terminal, and coffer dam earth.
(f) Remove the plastic-cling wrap cover on the anode.
(g) Check the anodes to ensure that the mastic coating is intact. If there are gaps
in the coating please paint over with any suitable mastic or coal tar epoxy.
(h) Ensure the M10 lock nut tightened with the tubular spanner.
(i) Connect the negative return link bolt to strainer body in Drg. No.SM17-03-02-
07, Item. No.13.

5.4.3 Electrical Connections

(a) The electrical connections are to be made as given in the inter connection
cable drawings.
(b) Each anode is to be connected to a junction box and from there to the control
panel.
(c) The anode current controls in the control section are identified as A1,A2,etc. It
is recommended that the anodes installed in different strainer are also similarly
identified to ensure that operator knows which anode he is setting the current
for. The junction boxes are used to connect the anodes to the control panel,
mount the junction boxes close to the strainer. One junction box is required per
strainer.
(d) Each junction box can accommodate 3 leads on the input side (that is leading
from the anodes). Theses leads are – Anode connection to antifouling anode,
structure return or earth connection from each safety cap.

SYSTEM HAND BOOK FOR AFAC (P28) 16

 (e) The cable from the anodes (to a length of 10m) is supplied with the anodes
and can be used. One lead is from the Cu.anode, second lead is from the
structure return. Ensure that the leads are connected to the appropriate
terminals – Cu1 to the Cu anode and do similar checks for all anodes.
(f) The earth connection is from the bolt mounted inside the Cofferdam. The earth
returns from the cofferdam are to be connected to the same earth terminal in
the junction box.
(g) Next the connections from the junction box to the Control panel is to be made
using cables recommended in the inter connection cable diagram in this
manual.
(h) Ensure that the correct anodes are connected to the correct terminal block in
the control panel, using a cable tag number identification at the beginning and
end of the cable – for example Cu1, Cu2 etc.
(j) The connections are to be done as indicated in the wiring diagram in
this manual.

5.5 Sequence of Operations

5.5.1 Commissioning
Prior to switching on the panel circuit breaker, check and ensure that -
(a) A.C. supply voltage is correct
(b) Check integrity of earthing arrangement
(c) Tightness of all connections.

5.5.2 Installation of Anodes

It is important that anodes are mounted in the vertical position unless otherwise
agreed differently with the customer to meet user requirement and is specified
clearly in the drawings.
(a) Care must be taken to identify the strainer and ensure the correct anodes are
mounted in the correct sea water service.
(b) Determine and mark the position of the anodes (centre of anodes) on the sea
chest. Anodes should preferably be in the line of suction.
(c) Make a hole of 20.5 mm dia on the Strainer top plate. Fix the neoprene gasket
on the strainer lid and insert the nylon cofferdam assembly.
(d) At the time of inserting the anode stud from the bottom of lid through nylon
cofferdam, insert the M10 plate washer inside the cofferdam and put the M10
full nut, tighten the M10 full nut by tubular spanner, take adequate care not to
damage the coating on the anodes.
(e) Connect the cable to the anode connecting brass lug, relevant screw terminal,
and coffer dam earth.
(f) Remove the plastic-cling wrap cover on the anode.
(g) Check the anodes to ensure that the mastic coating is intact. If there are gaps
in the coating please paint over with any suitable mastic or coal tar epoxy.
(h) Ensure the M10 lock nut tightened with the tubular spanner.
(i) Ensure the cable leads are connected as follows before fixing the anode.
(j) Connect the negative return link bolt to strainer body in Drg. No.SM17-03-02-
07, Item. No.13.

SYSTEM HAND BOOK FOR ICAF-105M OPV 17

5.5.3 Panel Electrical Connections
(a) The electrical connections are to be made as given in the inter connection
cable drawings.
(b) Each anode is to be connected to a junction box and from there to the control
panel.
(c) The anode current controls in the control section are identified as A1,A2,
etc. It is recommended that the anodes installed in different strainer
are also similarly identified to ensure the operator knows which anode
he is setting the current for. The junction boxes are used to connect
the anodes to the control panel, mount the junction boxes close
to the strainer. One junction box is required per strainer.
(d) Each junction box can accommodate 3 leads on the input side (that is
leading from the anodes). These leads are: - Anode connection to anti-fouling
anode, structure return or earth connection from each safety cap,One for
standby.
(e) The cable from the anodes (to a length of 10m) is supplied with the anodes and
can be used. One lead is from the Cu.anode, second lead is from the structure
return. Ensure that the leads are connected to the appropriate terminals – Cu1
to the Cu anode.
(f) The earth connection is from the bolt mounted inside the Cofferdam. The earth
returns from the cofferdam are to be connected to the same earth terminal in
the junction box.
(g) Next the connections from the junction box to the Control panel is to be made
using cables recommended in the inter connection cable diagram in this
manual.
(h) Ensure that the correct anodes are connected to the correct terminal block in
the control panel, using a cable tag number identification at the beginning and
end of the cable – for example Cu1, Cu2, etc.
(j) The connections are to be done as indicated in the wiring diagram in this
manual.
(k) Before flooding the anode space check the resistance between the anode
and the nearest hull structure using a Meg-ohm meter. This should be done for
each anode installation. The resistance value if properly installed should be
above 20M-ohms.
(l) Check the ground point with reference to the hull. This should also register
zero potential.
(m) If any of the above measurements are not as given above the entire
connections should be rechecked from the anode point. Carry out the same
checks at the anode point, at the junction box input and out points and trace
down to the panel. If the connections are proper anodes should register a
positive voltage with reference to the hull, and the ground point also zero
voltage as it should be at the same potential as the hull. As a cross check the
insulation between the anode point and the hull.

SYSTEM HAND BOOK FOR ICAF-105M OPV 18

5.5.4 Setting to work
(a) Ensure that all connections are made as described in the previous section.
(b) Ensure that the strainers are flooded – that is ensuring that the anodes are fully
immersed in seawater.
(c) Open the front door. Switch the mains power on in the control panel using the
breaker (MCB) inside the front door. The displays will light up to register system
on.
(d) Check the polarity of the anodes with respect to the hull. [All anodes are to be
positive with respect to a negative hull.]
(e) Set the current to the recommended level (Table 10) by operating the “current
adjust” control.The current adjuster for each anode in turn. Ensure that the
digital meter display changes correspondingly.
(f) If the vessel is in fresh or brackish water, the digital display may not reach the
recommended current settings, which may cause the ‘U/O LED’ to light up. This
can be ignored and should correct itself when the vessel is at sea.

5.5.5 Procedure for Replacement of Anodes

(a) Remove the Lid of the Cofferdam.
(b) Disconnect the cable connection from Anode; structure Return.
(a) Disassemble the old anode clean, taking care not to damage the
machined faces matching with the nylon cofferdam.
(b) Discard the remaining unconsumed portion of the anode.
(c) RemoveM10 nuts, M10 steel washer from the new anode.
(d) Fit Cofferdam onto the steel M10 stud of the new anode.
(e) Assemble parts inside nylon safety cap- Cofferdam in the following order:
- Apply sealing compound to spigot face of PVC insulating anode.
- Place M10 steel washer
- Screw M10 steel full nut;
(h) Fit M10 steel lock nut; tighten lock nut.
(j) Test for good insulation (greater than 1 Mega ohm) between anode
material and strainer lid.
(k) Reconnect cable to anode stud inside nylon cofferdam & structure return
connections.
5.5.6 Testing

Sl. Electrical Inspection/Functional checks of ICAF Remarks

No Instruction/Procedure
(a) Switch Off the unit and turn Off the mains AC power
(b) Connect the unit to single phase with earth mains AC power
Connect suitable fixed load (dummy load) at appropriate
(c) terminals of the unit to obtain 2A (±0.2A) current @ 12 V DC
(±1.0 V).
(d) Turn On input supply to the unit.
(e) Turn on the input MCB of the unit.
(f) Check for System on indicator.
Ensure that the AC mains voltage is 230 V AC ± 5%. This can
(g)
be checked on the External Digital multi-meter.
Operate the “current adjust” on the control section to set zero
(h)
Amps.

SYSTEM HAND BOOK FOR ICAF-105M OPV 19

 Sl. Electrical Inspection/Functional checks of ICAF Remarks
No Instruction/Procedure
(i) Now increase the individual anode current by operating the
“current adjust” on the control section to check the output
voltage and current reach Max 12V DC (By operating the
‘Anode Volt meter’)and 2Amps within the Tolerance.[2A
(±0.2A) current @ 12 V DC (±1.0 V)].
Safety Features
(j) Check for operation of “Over current” indication when the
output current Reaches 2.01 Amps the individual anode ‘U/O’
LED and buzzer indicate.
(k) Check for “Under current” indication when the output current
Reaches less than 0.1 Amps the individual anode ‘U/O’ LED
and buzzer indicate.
(l) The individual anode ‘S/C’ indication and buzzer When the
output short circuited.
(m) Reset push button will acknowledge the buzzer Alarm
indication.
(n) Potential to be check between Hull to Copper Anode in mV
DC
(o) Negative return path which connected to strainer body.
(p) Junction box connectivity to be ensure respective anode.
Table 11

SYSTEM HAND BOOK FOR ICAF-105M OPV 20

 CHAPTER VI
USER’S / OPERATOR’S SERVICING AND
MAINTENANCE INSTRUCTIONS
 CHAPTER VI
USER’S / OPERATOR’S SERVICING AND MAINTENANCE
INSTRUCTIONS

6.1 Introduction
This Chapter describes the Preventive Maintenance checks and the fault
diagnosis and trouble shooting of the System and its associated accessories.

6.2 Preventive Maintenance

Periodicity Type of Procedures Tools/ Appli- Remarks

Routines Accessories cable
Required Units
Check the Record the
Reading on the anode current in
Daily AFAC Panel. the log sheet. To
Record the read the anode
Readings in current, refer –
log sheets control section
front view Page
No.11. It shows
individual anode
current as
default. To
record anode
voltage by
voltage selector
switch.
Auto Control Blow the dust
Every Three Unit internal using a vacuum
months cleaning cleaner without
disturbing the
arrangements
inside the ACU.
Do this exercise
with caution
Every Routines on Check for water Use
Drydock mechanical seepage. appropriate
assembly of Inspect the spanners
cofferdams cofferdam by
removing the lid.
Every Inspection of Visual No tools are
Drydock Hull parts – inspection. Do required
ICAF Anode not require any
special
procedure-
consumption
checks.
Table 12

SYSTEM HAND BOOK FOR ICAF-105M OPV 21

 6.3 Fault Diagnosis

No. Fault Possible Cause

1 ‘System ON’ indicator a) Check the input connector fuse and replace
and meter display if blown.
don’t light up switch on
the panel.
a) Check the fuse in the terminal of the
2 Unable to feed a particular anode and replace as required.
current to an anode. b) If the fuse is not blown, trace the cable from
U/O indication. the terminal through to the anode to ensure
there is no disconnection of cable
anywhere.

Table 13

SYSTEM HAND BOOK FOR ICAF-105M OPV 22

CHAPTER VII - MISCELLANEOUS
 CHAPTER VII
MISCELLANEOUS

7.1 SECTION 1

7.1.1 Introduction
This Chapter gives information on details of accessories and parts with their
description, part number and list of tools required for user maintenance.

7.1.2 Station List

The following are the list of deliverables supplied per ship.

Sl. Description Quantity Part Number

a Cu 80Dx300L Anode complete with Nylon
Cofferdam assembly; 10 mts 3C x 2.5 2 nos. CPS206916W014
sq.mm cable of NES STD.521-8511.
b Cu 45Dx75L Anode complete with Nylon
Cofferdam assembly; 10 mts 3C x 2.5 12 nos. CPS206916W015
sq.mm cable of NES STD.521-8511.
c Cu 80Dx75L Anode complete with Nylon
Cofferdam assembly; 10 mts 3C x 2.5 2 nos. CPS206916W016
sq.mm cable of NES STD.521-8511.
e Junction boxes 16 nos. CPS202216W016
ANODE STUD SPANNER
f 1no. CPS1026M10020
16/17 Tubular spanner.
g 16way Control Panel 1no. CPS106316W036

Table 14

7.1.3 List of Tools:

This ICAF System is a very simple system and as such no special tools are
required except during initial installation of anodes and during the replacement of
anodes after they are consumed. The following tools are supplied with the
equipment.

(a) 16/17 Tubular spanner – 1 no.

(b) 10/11 Double head spanner - 1 no.
(c) PYE Screw driver set – 1 no.
(d) Nose Player - 1no.

SYSTEM HAND BOOK FOR ICAF-105M OPV 23

7.2 SECTION 2

7.2.1 Introduction
This Section gives details for general handling of the equipment and procedures
for storage; repacking (if any) and transportation instructions.

7.2.2 Handling and Packing

The components and the unit will be neatly placed in a wooden crate. Before
unpacking, ensure that the container is placed vertically upwards and follow the
procedure given below to unpack.

a) Remove the wooden planks in the top and sides of the unit, one by one.
Detach the unit from the base.
b) Remove the hay, gunny bag and packing covers
c) Clean the surface with a piece of soft dry cloth.
d) Check for damages on the surface
e) Check the contents of the box with the packing documents.

Visual Inspection-
After unpacking and clearing the debris ensure the unit is free from–
a) Breakage of side covers and doors, any damage in front acrylic doors
b) Damage in the panel displays.
c) Damage in shock mounts and cable glands.
d) Ensure all accessories are in good condition.
e) Open the front door and ensure there is no damage inside the unit.

Installation -
a) Fix the lifting hooks on top of the unit.
b) Lift the unit and place it along the wall where it is to be mounted.
c) Fix the shock mounts with lock plate (Qty 4)) supplied along with the unit
at the rear of the unit with the M12 bolts and nuts provided.
d) Fix the unit on to the walls with help of 4 shock mounts with M12 bolts and
nuts.

7.2.3 Storage and Transportation - The unit should be always kept inside covered
enclosure during temporary storage before installation. It should be ensured that
no unwanted things such as insects, any conductive or non-conductive materials
get into the unit. It should also be ensured that the unit does not come in contact
with Water, Fire, Sunlight or any abnormal conditions that will harm the
performance of the unit. When this crate is handled for transportation, it should not
be rolled. The unit should be lifted carefully with top facing up all the time and
moved.

SYSTEM HAND BOOK FOR ICAF-105M OPV 24

DIAGRAMS
 Appendix ‘A’ - Illustrations

Drawing Page
Drawing Name Drawing No.
Sl.No. No.
Block Diagram of 16-Way ICAF
Figure 1 - 6
System
Block Diagram of 16-Way ICAF
Figure 2 - 10
System & control panel.
DRG.1 16-Way Control Panel. SM17-03-01-03 26
16-Way Inter Connection Cable
DRG-2 SM17-03-05-03 27
Diagram.
DRG-3 16-Way panel Internal Wiring Diagram SM17-03-05-031 28
DRG-4 16 Way Terminal Block Detail SM17-03-06-10 29
DRG-5 Strainer Anode Assembly SM17-03-02-07 30
DRG-6 Anode Location & Dimension Detail SM17-03-02-07L 31
DRG-7 Junction Box Assembly SM17-03-09-ANJ 32

SYSTEM HAND BOOK FOR ICAF-105M OPV 25

 Appendix ‘B’ - ATP / TP
Acceptance Test Procedure for Impressed Current Antifouling (ICAF) System is given below.

1. Visual Inspection of ICAF System

Sl. No. Requirement Result
Cubicles are to be manufactured of 12/14 SWG thickness Aluminium
1 Sheet
2 Unit shall be suitable for Bulk Head mounting.
3 All operations controls adjustable with opening the front door.
Indicators and set points can read from out side with out open the front
4
door.
Digital Display to be provided to read the Anode current & Voltage (0.05 -
5
2A / 0.05-12V DC).
6 Current adjust to be provided for adjusting the Anode current.
7 Anode voltage selector switch to be provided to read anode voltage.
8 SYSTEM ON Indicator to be provided.
9 BUZZER ACK switches to be provided to acknowledge audio alarm.
10 Input Circuit breaker to be provided.
11 Fuse protection to be provided for Input and output.
Visual Inspection of ICAF system.
1 LED indication to be provided for over/under current (U/O).
2 LED indication to be provided for output short circuit condition (SC).
Cable markers should be used for identification of cables wherever
3
possible / required.

2. Electrical Inspection / Functional checks of AFAC System

Sl. No Instruction/Procedure Result
1 Switch Off the unit and turn Off the mains AC power
Connect the unit to single phase with earth mains AC power (230 V AC
2
±10%)
Connect suitable Dummy Load at anode terminals of the unit to obtain 2A
3
(±0.2A) current @ 12 V DC (±2.0 V).
4 Turn On the input supply of unit.
5 Turn on the input MCB of unit.
6 Check for SYSTEM ON indicator (Red color).
Ensure that the AC mains voltage within the range. (230 ±10% VAC)
7
using DMM .
Operate Current adjust and ensure the anode current and voltage
8 minimum to maximum. ( 0.10A to 2.00 A ± 0.2A & voltage is based on
load resistance 0-12V)
9 Ensure the output anode current step variation (± 0.05A)
Ensure the individual Anode current and voltage to reach Max 2A/ 12
10
VDC. (±0.2A/±0.2VDC)

SYSTEM HAND BOOK FOR ICAF-105M OPV 33

 Anode output Voltage in volt (DC)

Output Set
Current in
Sl. No.

Amps

AV10
AV11
AV12
AV13
AV14
AV15
AV16
Result

AV1
AV2
AV3
AV4
AV5
AV6
AV7
AV8
AV9
01 00A
02 0.5A
03 1.0A
04 1.5A
05 2.00A

3. Safety Features
Sl No Fault Indications Result

Check the operation of “Over current” (U/O) indicator when the output
1
current above 2.10 A the corresponding LED will glow.
2 Check the operation of “Under current” (U/O) indicator when the output
current goes to below 0.10 A the corresponding LED will glow.
Check the operation of “Short circuit” (SC) indicator when the output is
3
shorted to ground, the corresponding LED will glow.
Check the operation of Audio alarm/ acknowledgment for above all fault
4
conditions (ACK. For only audio alarm)

SYSTEM HAND BOOK FOR ICAF-105M OPV 34

 Performance Reports
RESTRICTED CARD NO. I

PERFORMANCE REPORTS
(RECEIPT / INSTALLATION INSPECTION BY CONSIGNEE
DEPOT / ESTABLISHMENT)

A tick mark is to be placed in appropriate box.

A. To be filled in by Manufacturer.
1. Equipment (Service Designation) ?????????.
Initials: ??..

2. Cat Part No. (Pattern No./Ref. No.) ?????????..

3. Indent No. and Date ?..????????

4. Date of Expiry of Warranty Period* ???????.??.

Defence Serial No. of equipment:??? Date Report Submitted:???

5. Defence Serial No. of Equipment ?????????..

6. Manufacturer ??????????
COUNTERFOIL

*This entry is to enable prompt initiation of claim for free

replacement in case of defect during Warranty period.

B. To be filled in by Depot/Establishment receiving the Equipment.

7. Date of Receipt of Equipment ??????????.

8. Receiving Depot/Unit ??????????.

9. Date of Opening Packages ??????????..

10. Mode of Transportation: Train - Goods Passenger

Road Post Air
11. Condition of Packages (Give details): Undamaged Damaged

12. Condition of Delivery Normal Open

13. Suggestion for Improvement in Packing/Packages if any:

CARD NO. I

Date: Signature and Designation

C. To be filled in by Maintenance / Technical Authority.

14. Condition of Equipment:

(a) Physical (Give details): Undamaged Damaged

(b) Functional: Serviceable Repairable Unserviceable

P.T.O.

SYSTEM HAND BOOK FOR ICAF-105M OPV 35

 (D) Repairs / adjustments carried out:

Fault* Assembly/ Repair action

Component Circuit Ref.
Subassembly taken

*Any deviations noted from specifications should also be listed here.

Additional remarks if any:

Address:

Date: INSPECTING OFFICER

(Signature and Designation)

SYSTEM HAND BOOK FOR ICAF-105M OPV 36

 RESTRICTED CARD NO. II

PERFORMANCE REPORT
(PRE-ISSUE INSPECTION BY DEPOT)
A tick mark is to be placed in appropriate box.
Initials: A. To be filled in by Manufacturer.

1. Equipment (Service Designation) ?????????.

2. Cat Part No. (Pattern No./Ref. No.) ????..????..

Defence Serial No. of equipment:??? Date Report Submitted:???

3. Indent No. and Date ?????????

4. Date of Expiry of Warranty Period* ?????????.

COUNTERFOIL

5. Defence Serial No. of Equipment ?????????..

6. Manufacturer .?????????

*This entry is to enable prompt initiation of claim for free replacement in case
of defect during Warranty period.

B. To be filled in by Issuing Equipment Depot.

7. Issued to (Name of Unit) ??????????.

8. Issuing Depot ??????????.

9. Date of Issue ??????????..

CARD NO. II

Date: Signature and Designation

??..

C. To be filled in by Maintenance / Technical Authority.

10. Remarks on Effects of Storage/Condition of Preservation (Give details of

effects on finishes, fungus growth etc.)

11. Condition of Equipment:

(a) Physical (Give details): Undamaged Damaged

(b) Functional: Serviceable Repairable Unserviceable

P.T.O.

SYSTEM HAND BOOK FOR ICAF-105M OPV 37

 D) Repairs / adjustments carried out:

Fault* Assembly/ Repair action

Component Circuit Ref.
Subassembly taken

*Any deviations noted from specifications should also be listed here.

Additional remarks if any:

Address:

Date: INSPECTING OFFICER

(Signature and Designation)

SYSTEM HAND BOOK FOR ICAF-105M OPV 38

 RESTRICTED CARD NO. III
PERFORMANCE REPORT (PERIODIC)
A tick mark is to be placed in appropriate box.
A. To be filled in by Manufacturer.

1. Equipment (Service Designation) ?????????.

2. Cat Part No. (Pattern No./Ref. No.) ?????????..

3. Indent No. and Date ???????..??

4. Date of Expiry of Warranty Period* ?????????.

5. Defence Serial No. of Equipment ?????????..

6. Manufacturer ??????????

*This entry is to enable prompt initiation of claim for free replacement in case of defect
during Warranty period.
Initials: ??..

B. To be filled in by Holder of Equipment.

7. Periodic Performance Report #

1st 2nd 3rd 4th

8. Date of Receipt/Installation in unit .??.??????..?.

Defence Serial No. of equipment:??? Date Report Submitted:???

9. Name of Unit ?????????????????.?????.

10.Employement of Equipment as: Static Mobile

COUNTERFOIL

Manpack Truck-Ground Ship-Borne Air-Borne

11. Protection in Use: Protected Partially Protected Exposed

12. Environment: Plains Mountains

Sea-Coast Highly Damp Desert

Dusty Extreme Hot Extreme Cold

High Altitude??????????????...Above MSL

13. Number of Hours run:

(a) Total to date ???.?.
(b) Till Date of last report ???..?.
(c) Total down time ?????

(Reasons in brief
CARD NO. III

Date: Signature and Designation

# Strike out except relevant one depending upon whether it is Ist,2nd 3rd or 4th Periodic
Report. & 13(b) will be completed from the counterfoil of previous “Periodic
Report”.
P.T.O

SYSTEM HAND BOOK FOR ICAF-105M OPV 39

 C) Repairs / adjustments carried out:

Fault* Assembly/ Repair action

Component Circuit Ref.
Subassembly taken

*Any deviations noted from specifications should also be listed here.

Additional remarks if any:

Address:

Date: INSPECTING OFFICER

(Signature and Designation)

SYSTEM HAND BOOK FOR ICAF-105M OPV 40

 Feedback information cards

OBJECT :

The object of this feedback information system is to provide

information on the indigenous equipments / systems regarding the
general performance, the defects occurring in transportation, storage
and use, to the Defence Inspection Organization, R & D, Design
Authority and Production Agency with a view to effect improvements in
the same or similar equipment / systems.

Authority:

SYSTEM HAND BOOK FOR ICAF-105M OPV 41

Log Sheet

ICAF Panel location

Number of way
Panel serial number

Sl Anode Anode Month :

Parameter I week II week III week IV week V week
1 A1
A2
A3
A4
A5
A6
A7
Anode A8
voltage A9
A10
A11
A12
A13
A14
A15
A16
2 A1
A2
A3
A4
A5
A6
A7
A8
A9
Anode
A10
current
A11
A12
A13
A14
A15
A16

Table 15

SYSTEM HAND BOOK FOR ICAF-105M OPV 42