USER’S HANDBOOK

INSTALLATION / OPERATION / MAINTENANCE /

TECHNICAL MANUAL WITH DRAWINGS FOR

TEST PANEL

CLIENT : GOA SHIPYARD LIMITED

P.O. NO : 185159 DATED: 03.08.2017

YARD NO : 1234

USER : INDIAN COAST GUARD

YEAR OF PUBLICATION – 2019

FABRICONS
74, MAROL CO-OP. INDUSTRIAL ESTATE,
M.VASANJI ROAD, SAKINAKA, ANDHERI – (E),
MUMBAI – 400 059.
Telephone No. 022 – 42060300-306
E-mail: enquiry@fabricons.in

1
 RESTRICTED

INDEX

SRL. DESCRIPTION PAGE

NO. NO.

1. PRODUCT ORDER REFERENCE 3

2. UNPACKING, STORAGE & HANDLING 4

3. TECHNICAL MANUAL 5

4. CPIL / PIL 7

5. INSTALLATION, OPERATION & USER’S MANUAL 10

6. MAINTENANCE & FAULT-FINDING PROCEDURE 12

7. AS MADE DRAWINGS 13
TITLE DRG. NO SHEETS

GENERAL ALARM SYSTEM

1) Contents 17 014 01-1 1

2) Revision Details 17 014 01-2 1

3) General Notes 17 014 01-3 1

4) Part List 17 014 01-6 2

5) Name Plate Details 17 014 01-7 1

6) Dim. & Gen. Arrangement Drag. 17 014 01-8 1

7) Circuit Diagram 17 014 01-9 1

8. TEST CERTIFICATES MANUFACTURE 23

RESTRICTED
2
 SECTION – 1.0

PRODUCT ORDER REFERENCE

1.1 EQUIPMENT

TEST PANEL

1.2 CLIENT

M/s. GOA SHIPYARD LTD

YARD No. - 1234

Order No. - 185159

1.3 INSPECTION AUTHORITY

OEM’s Q

1.4 MANUFACTURER

FABRICONS
74, MAROL CO-OP. INDUSTRIAL ESTATE,
M.V. ROAD, ANDHERI – (E), MUMBAI – 400 059.
Telephone No. 022 – 42060300-306
E-mail: enquiry@fabricons.in

3
 SECTION – 2.0

UNPACKING, STORAGE & HANDLING

2.1 UNPACKING

A visual inspection to ascertain that no damage has been suffered by the equipment
during transist, should be done. In case any damage is observed, same should be
brought to the notice of M/s. FABRICONS.

2.2 STORAGE

Equipment should be stored in clean, moisture-free place and checked periodically.

Special precaution should be taken when equipment is stored for a period longer than
60 days & kept idle, to avoid corrosion of hardware / metallic parts. Before switching
on equipment should be thoroughly cleaned using vaccum cleaner.

2.3 HANDLING

Test Panel contains parts like VOLTMETER, LAMPS & AMMETER and therefore
should be handled carefully.

4
 SECTION – 3.0

TECHNICAL MANUAL

3.1. PURPOSE

The purpose of test panel is to provide various Power for testing of equipment and / or
components such as fuse links and lamps.

3.1 MECHANICAL CONSTRUCTION

The test panel is bulkhead mounting type with totally enclosed, fabricated from 14
SWG aluminum sheet. Internal rubber shock absorbers are used between chassis
plate and test panel body in view of light weight of panel. Hence external shock
mounts are not applicable. Doors are covered with neoprene gasket all around to
make it dust and vermin proof. All meters and lamps are visible through transparent
window on the front door. All operating components are mounted on inside door.
For operating MCB’s front door need to be opened. The resp. supply to be taken out
through cable glands.

3.3 PAINTING

Final coat of Polyester based powder coating of light battle ship grey finish (IS 632
Dark admiralty grey )

3.4 DIMENSIONS AND WEIGHT

HEIGHT : 725 mm

WIDTH : 650 mm

DEPTH : 300 mm

WEIGHT : 25 KG.

5
ELECTRICAL SPECIFICATION:

SYSTEM VOLTAGE : 415V AC , 230V AC , 24 V DC

INTERNAL WIRING: All internal wiring is done with LFH cables.

CABLE GLAND

The Gland plate is of non-removable type for Test Panel and cable glands 3 nos.
Single compression chromium cable glands suitable for 16 mm2 & 22mm2 cable.

6
 SECTION – 4.0

CPL / PIL

4.1 “As made Drawings” are provided for Test Panel. The As made drawings provide
essential design data, constructional details etc.

For detailed CPIL / PIL refer following drawing no.

1) 17 014 01 -6

7
8
9
 SECTION –5 .0

INSTALLATION, OPERATION & USER’S MANUAL

5.1 INSTALLATION:

The Test Panel may be installed on an angle frame welded to a bulk head.
The mounting dimensions are:
650mm (L)*725mm (H)

5.2 ELECTRICAL CONNECTION:

The cable glands to be fitted on removable bottom plate and incoming / outgoing
cables to be passed through gland. The connections are to be made as per wiring diagram.

For details refer drawing no. i) 17 014 01-9

5.3 OPERATION

415 V ,16 A System :

The system voltage and current can be checked on meters provided. 415V, 3Ph, 50
Hz, 10A supply can be taken out through a 16A, 3 Ph metal clad plug and socket for
testing 415V equipment or system.

230V ,10 A System :

The system voltage and current can be checked on meters provided. The system
voltage and current can be checked on meters provided. 230V, 1Ph, 50Hz, 10A supply
can be taken out through a 10A, 1Ph for testing 230V equipment or system.

24V DC,10 A System :

The system voltage and current can be checked on meters provided. 24V DC 10A
supply to be taken through banana terminals for testing 24V DC equipment. It will
have facility to test fuses from 2-125A links. The fuses to be tested need to be inserted
in the appropriate fitting.
The lamp will glow if the fuse is healthy.

SBC & BC Type lamp testing :

It will have SBC and BC type Holders for testing 24V Pin type and thread type lamps.

10
11
 SECTION –6 .0

SECTION –6 .0
MAINTENANCE & FAULT-FINDING PROCEDURE

6.1 MAINTENANCE

The panel is very simple to operate and does not require major maintenance. Routine
and periodic cleanliness from dust and tightening of the contacts be done as part of
maintenance.

12
 SECTION –7 .0

AS MADE DRAWINGS

AS MADE DRAWINGS

8.1 “As made Drawings’’ are provided for Test Panel. The
Drawing provide construction details, circuit details etc.

13
14
15
16
17
18
19
20
21
22
 SECTION –8.0

TEST
TESTCERTIFICATES
CERTIFICATES

The system is factory prior to dispatch. The system is tested by manufacturer’s QC

department. Following checks are carried out:-
1) Physical check and dimensions of each panel.
2) Painting shade and workmanship
3) Continuity Check
4) I.R.Test
5) H.V.Test

Only after through test the panels are delivered. Following certificates are attached.

1) Manufacturer’s Test Certificates

23
 B*' f'

(74,Marol Co-op Ind.Estate, M.Vasanji Road, Sakinaka, Mumbai : 400 059)

MANU FACTU R ER TEST CERTI FICATE

Client Goa shipvard Ltd.

Purchase Order 185159 Dated 03.08.2017
Yard No. r234
Equipment Electrical Test Panels for SCGOPV
ltem Code 3317011000
Serial No. 037132
Reference Drawing No. 17 01.4 01-0 to 77 01.4 01-9 R1
Quantity 01 set per ship
Date of Test 26th March,2019

List of Calibration certificates for Standard Equipment.

Sr. I)escription of
No. lnstrument and
Rang,e/
Sr.No.
Certificate Calibratio Status /
LC] no. n due on I{emark
Ilquipment
1 Iape & Scale 0-3000 M-780926-
MT-01 28.09.2079
Calibrator mm 18-2
2 Coating 'llhickness s0-800 M-780926-
28.09.2079
Gauge (Pen Type) micron 77281 18-5
In Good
O-3 KV A/82302/ M-180926- conditiorr
Analog Tester 27.09.2079
AC AUG/ 87 18-1 working
4 Analog Insulation 0-2000 LK/M/Er 74.06.2079
satisfacto
162579
Tester MN /41236 ri1y.
5 Std. Vernier 0-300 LK/M/DM 74.06.2079
7768
Caliper mm / 67787
6 KM8Ol -L
Multimeter 110198 22.08.2019

rf Lr''q
24
 2

Physical Check
8 Verification of Dimensions Verified as per Approved drawing and
found Satisfactorv
9 Verification of Paint shade Paint shade checked and found in order.

1 Verification of Component Verified as per Approved drawing and

Assemblv and accessibiliW found satisfactory

1. Verification of BOM for Verified and found satisfactory

quantity and model number

1 Verification of Label, Name Verified and found satisfactory as per

plate; Requirement

1 Check for proper Door Setting Checked and found satisfactory

and Gasket fitting

1 Check for Gland Plate size Verified and found satisfactory

Electrical Check

2. Check Earth continuity Checked Test Panel continuity with

multimeter and found to be satisfactory

25
 3

2 Megger Test with 500/.000 (BEFORE)

The test performed with 1000V Megger and

IR tested between
Phase & Neutral / Positive & Negative > 100 MQ
Phase & Earth / Positive & Earth > 100 Mo
Neutral & Earth / Negative & Earth > 100 MQ
3 High Voltage Test

The test performed with 0-3 KV High

Voltage Test Set. The voltage of
7000V /2000V applied for one minute The panel withstands the said
between HV and found satisfactory
Phase & Neutral / Positive & Negative
Phase & Earth / Positive & Earth
Neutral & Earth / Negative & Earth.
4 Megger Test after High Voltage Test Practically same tests were
(AFTtsn) obtained as per above.

5 Functional Test
Apply 230V and 415 V at input terminal and Found satisfactory
check the voltage at output Terminals.

Apply 24V DC at input Terminal and check Found Satisfactory

the voltage at output Terminals
Test Certificates
Identification of the equipment
Terminals, Wire, CT, Voltmeter,
Ammeter, MCB & Calibration
Certificates.
As per Serial Number 037132

For IjABRIC

u.{, Kt'
Dharrr6ndr
QC Engineer

26
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7 4, Marol Co-operative Indl. Estate,
Mathurdas Vasanji Road,
Sakinaka, Andheri (East),
Mumbai 400 059

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27
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(rlr'w (rff € qtaur *-c (q.d), MSME TESTING CENTRE (W.R),

qe_a,ag t.s rrL-{fr 3q{q FiTrd-q, Ministry of Micro, Small & Medium Enterprises,
Government of India,
8rr{ils{siR, , Kurla Andhcri Road, Saki Naka,
T-dt 3rtffi d-s, ilErflrnr {r-g - 400 072' Mumbai - 40O Q72.
2flqifa: 022 - 28570588,28576998 rel.: 022 - 28570588,28576998
trf,€ .022 - 28s72238. Fax:022 - 78512238.
Web: www. msmetcm umbai.gov.in
e-mail : dctc-wr@dcmsme.gov.in

qtqpr nd€
TEST REPORT
- glflI / totalPage Nos'
R l n"port ruo- | ilrft-FTi ssue
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frfr / oate ; 13.02.2013

E. I 3. .t- / M/s. FABRICONS,

7 4, Marol Co-operative Indl. Estate,

l! Mathurdas Vasanji Road,
4.qiTI / Address Sakinaka, Andheri (East),
Mumbai 400 059
o
FAlMSME/rP

06.02.2013

16227
13.02.2013

I r{rfl srfr / lssued by

.?

N.B.:
1 This report pcrtains to the particular sample submitted for test.
2. This report shall not be reproduced in part or full'
3. I he I'est / Calibration Report shall not be used for Legal purpose and shall not be produced in the court
of law.
4. I'ested sample(s) should be collected within 30 days from issue of this report failing which no claim whatsoever & no
28
Corrcspondence in matter shall be entertained and such samples(s) will be disposed as pcr Govt. Procedure

4
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Rrfrf *.lneport No. TC-M U M/C SC tELt402t 02/20 I 2- 1
/7,lv
q\
frf,i+. /Date 13.02.2013

+Fqd- qdqrfrfoal FABRICONS make

Sample ldentification Mark

+F.rd - ffiq / DC Distribution Board.Size . 600 x 1200 x 300

Sample Description :
Drg. No. .1204301-8 Sr. No. .126575

qFn /Quantity: 1 No.

fu-qr erqr qfterur I As Per Customer's Requirement

Test Conducted
qfru"r fdftTEc / 1) IEC -60529:1999 International Standard for Degree of
Test Specification protection provided by Enclosures(lp Code)
2) As per Customer's Requirement

3|t|-ilIfid / Observations
6}I :SFqI qfrerur Ffi+tur
Sr. No.
ql;I.fi' FdflSTtd trftsrur qfturrrT M
_ _lq!!P9:!cl[qqt _ _9_tl_q44td Slccifi calion 'I'cst_Rcs_ults
____ Ilcmarks
1

Degree of Protection Against Protected against solid

Ingress of Solid Foreign foreign objects of 1.0 mm.
object (lP aX): dia. and greater:
(l"tCharacteristic) The ob.ject probe of 1 0 mm Object did not penetrate Satisfactory
Cl 132, Table 2 & Tabte 7 of dra shall not penetrate at all at all
rEc-60s29-1999

Degree of Protection Against Protected against vertically

Water (lP X2): falling water drops when
(2no Characteristic) enclosure titted up to 150
C1.14 2, Tabte-3 & Tabte B of
I EC-60529-1 999
Vertrcally falling drops shall No harmfuleffect Satisfactory
have no harmful effect when observed on the samole
the enclosure is tilted at an "after
the test
angle up to 15 o on either side
of vertical

:-i - no )
lrrrr,f l,r t6t5,/
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llcport No. :TC-MUM/CSC/EL|4OZ|02/201 2'1 3

3ffiilIfid / Obserwations
st'qr
iF.-q
Sr'. No.

13 At 500 v Dc
18x10omeg-ohm

14
Withstood 2000V ac rms Satisfactory
without any flashover or
breakdown

21

Object did not penetrate Satisfactory

at all

ll

No harmfuleffect
observed Satisfactory

After lP-44 test

lnsulation Resistance Test
As per Customer's N At 5OO V DC
requrrement 18x10ameg-ohm

z1 High Voltage Test

As per Customer's Shall withstand 2000V ac rms Withstood 2000V ac rms Satisfactory
requirement between i)terminals, without any flashover or
ii) terminals & enclosure breakdown
without any flashover or
breakdown

lP-54 Test

?1 Degree of Protection Against Dust Protected

Ingress of Solid Foreign
Object (Dust Protected)
(lP 5X): (1"t Characteristic)
Cl X3 4. Table 2 & Table 7 of
I I EC-60529-1 999
I
Dust shall not penetrate in a Dust did not penetrate -Satrsfactory
quantity to interfere with inside the enclosure
satisfactory operation of the
apparatus or to impair safety

30

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\lS\lll li,rlino {'t'rttr-t.. i,irrt. tf' lrttli:t \liri lrl \lS\Fl'. \ii:ttrlr;rr J{!!i s'):.
Il.cport No. :TC-M U M/CSC/EL/402t 02/201 2-1 3

3|t|iltfia / Observataons
1 - I - *tte*tqfi'"nn -i--ffi
tll
I tion_t_ _ _I.lt_t_BS!qtr __ l_ Bgnl"_tkt
{

JI Degree of Protection Against I Protected against splashing

Water (lP Xa): water
(2no Characteristic)
Cl14 2, Table-3 & Table 8 of i Water splashed against the I No harmful effect I Satisfactory
shall have no harmful effect
After lP-54 test
z3 lnsulation Resistance Test
As per Customer's I Nil I At 500 V DC
requrrement | | '1 8x'loameg-ohm Nrl

24 High Voltage Test | |

As per Customer's I Snatt withstand 2000V ac rms
I

I Withstood 2000V ac rms I Satisfactory

requirement' I between i)terminals, I without any flashover or
ii) terminals & enclosure I breakdown
wrthout any flashover or
breakdown

General Remarks: The sample meets the requirement of IEC 60529 :1999 specification and Customer's requirement
with resoect to the test carried out

31

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