MAN026-R5-CO.026 Magic3 ICAF.pdf

www.mme-group.com

A Longer Life

Manual ICAF system

ICAF system manual

MAN026 R5

Page I

MME GROUP | Head office: Rietdekkerstraat 16 | 2984 BM Ridderkerk (The Netherlands) | P.O. Box 4222 2980 GE Ridderkerk Tel: +31 (0) 180 48 28 28 | E-mail: info@mme-group.com | Website: www.mme-group.com

Foreword

Dear customer, Thank you for purchasing from Materiaal Metingen Europe BV (MME).

We have put a lot of effort in designing and fabricating this equipment.

Please carefully study this manual as it will assist you in installing, operating, maintaining and repairing the equipment. This manual is meant for all personnel working with or servicing this equipment.

You will find answers, tips and information about your system. Should you require any further assistance, do not hesitate to contact us. Contact details are indicated below.

Sincerely yours, Materiaal Metingen Europe B.V.

Visiting address:

Rietdekkerstraat 16 2984 BM Ridderkerk The Netherlands

Correspondence address:

P.O. Box 4222 2980 GE Ridderkerk The Netherlands

Tel.: +31(0)180- 48 28 28 Fax reception: +31(0)180- 46 22 40 Fax direct: +31(0)180- 46 22 41

E-mail: sales.mme@mme-group.com Web: www.mme-group.com http://www.mme-group.com/

Page II

MME GROUP | Head office: Rietdekkerstraat 16 | 2984 BM Ridderkerk (The Netherlands) | P.O. Box 4222 2980 GE Ridderkerk Tel: +31 (0) 180 48 28 28 | E-mail: info@mme-group.com | Website: www.mme-group.com

Safety Precautions

Read this manual and study the appropriate drawings carefully.

Warnings and notices used in this manual

Warning: Information that draws attention to risk(s), which can result in personal injury or death or damage the equipment or the surroundings.

Caution: Information that draws attention to risk(s), which can result in damage of the equipment, the surroundings or the process.

Note: Used to relay additional information or clarify subjects.

Notes pertain to the preceding text.

Skill and requirements of personnel Repairs, maintenance, changes and commissioning shall only be executed by qualified and well-trained engineers, familiar with procedures and equipment. Before attempting intrusive procedures, ensure that the system and its components are electrically insulated to avoid electric shock.

When connected to the MME power unit The electrical equipment of this system can be dangerous if not operated and maintained correctly. Always maintain and operate the equipment in accordance with this manual and any extra instructions which may be received by Materiaal Metingen Europe B.V.

Warning: Electrical shock can cause injury or death. Make sure all personnel working with, maintaining, repairing or inspecting equipment which is live are thoroughly familiar with the risks and the emergency procedures in case of electrical shock.

The electrical cabinet is designed so it can be operated with an open door. When mains are connected and live, an open door will expose components which can cause electrical shock or short circuit.

The ICCP power unit is fitted with Integrated Circuit (IC) components. Megger testing and other high voltage tests should not be performed on these systems.

Page III

1 SYSTEM DESCRIPTION

ICAF

HMI unit

System layout

ICAF power unit

ABS junction box

ICAF welding flange

ICAF anode ICAF anode 0501/1501 ICAF anode 2501/2504

ICAF Cathode

2 INSTALLATION

HMI unit Storage, handling and marking Environmental conditions for use Main power supply Back side sticker Electrical system considerations Installation of the HMI unit Power unit connection Vessel Management System (VMS) connection Ethernet connection

ICAF power unit Storage, handling and marking Environmental conditions for use Main power supply Type plate Electrical system considerations Installation of the power unit HMI connection

ABS junction box

ICAF welding flange ICAF 0501/1501 welding flange

ICAF anode ICAF anode 0501/1501 ICAF anode 2501/2504

Table of Contents

Page IV

ICAF cathode General cathode installation Typical sea chest installation Typical strainer installation Typical horizontal installation Typical treatment tank installation

3 CHECKLISTS

Installation checks HMI unit ICAF Power unit ABS junction box ICAF welding flange ICAF anode

Dry-dock/pre-launch checks HMI unit ICAF Power unit ICCP & ICAF cofferdam ABS junction box ICAF welding flange ICAF anode

Commissioning Visual Inspection and photo checklist ICAF anodes HMI communication ICAF power unit HMI unit Finalising

4 OPERATION

HMI unit

Using the HMI for the first time

Checking status ICAF Screen overview ICCP Screen overview ICAF Status tab ICCP Status tab

Maintenance tab

Logsheets tab

Settings tab ICAF pre-sets ICCP pre-sets Power units tab Anodes tab Ship tab Display tab

Page V

System settings Operation through web interface

Notifications tab

Alarm handling and troubleshooting Alarms definition Alarms troubleshooting Alarm handling

General troubleshooting Shaft grounding

5 MAINTENANCE AND INSPECTION SCHEDULE

AKBv3 – HMI unit

ICAF power unit

ABS junction box

ICAF welding flange

ICAF anode

ICAF cathode

6 DECOMMISSIONING/DISCARDING

HMI unit

ICAF Power unit

ABS junction box

ICAF welding flange

ICAF anode

ICAF cathode

1 SYSTEM DESCRIPTION

ICAF

ICAF principles The system is based on an impressed current system. Through the anodes a low direct current (DC) is passed. The current is generated and controlled by a MAGIC3 power unit.

The system is designed to give continuous and trouble-free protection against marine growth. It will provide protection against marine growth during the calculated anode life, providing the anode currents are maintained at the correct setting.

The main categories of fouling being:

• Hard fouling: barnacles, mussels, etc.

• Soft fouling: plants, animal organisms, etc.

• Slimes: micro-organisms (aerobic, anaerobic, etc).

The presence of bacteria could increase corrosion rates leading to severe problems.

This system will effectively reduce the hard fouling, in most cases avoid the formation of soft fouling.

Note: The ICAF system does not replace the need for cathodic protection. Sufficient sacrificial anodes must be installed inside the seachest.

Copper ICAF anodes When a DC is passed between a copper anode and a steel cathode, copper ions will be formed. These ions will flow through the system creating an environment which prevents micro-organisms to settle.

Aluminium ICAF anodes When a DC is passed through anodic polarised aluminium, this will dissolve in water to form poorly soluble, highly voluminous hydrated aluminium hydroxide released in flock formations. While carried downstream, the aluminium complex will bond with the copper ions and form a layer on the internal cathodic surfaces. The aluminium anode is used in a system with predominantly steel pipes.

Iron ICAF anodes For corrosion reduction in non-ferrous components in seawater systems, e.g. Cupronickel condensers, CuNiFer piping, alloyed valves etc., an iron anode will be installed instead of an aluminium anode. The iron dissolution will release low concentration of iron ions.

These ions react with sulphur oxide ions in seawater, resulting in the formation of ferrous sulphate. This will effectively form and restore the oxidation film on the Cupronickel alloys.

ICAF application The MAGIC3 system as supplied is suitable for the protection of open and/or closed cooling water system only. In some situations, it could also be used for other applications. When a vessel has a special type of cooling system, please consult MME for options.

The protection provided only applies to the parts of the cooling system as specified in this chapter.

Open water-cooling systems For standard situations in open water-cooling systems, anode type 0501 or 1501 will be supplied.

Normally, the anodes are in the sea chest top plating, in a vertical position.

Any other applications or environmental conditions are to be consented and/or supervised by MME, under full disclosure of the applicable data.

Figure 1 Open cooling water system.

If positioning in sea chests is not possible or when no sea chests are installed, placement of the anodes in the top cover plate of strainers is one alternative. In this situation anodes are replaceable and therefore independent of dry-docking intervals.

The advantage of strainer placement is that anodes can also be renewed independent of dry-docking intervals, and the anode size can be kept to an acceptable dimension.

Closed cooling systems - Boxcooler For standard situations in closed cooling systems, anode type 2501 will be supplied.

Normally the anodes are located horizontally underneath the box coolers.

This can be supplemented by vertical anodes for applications under severe conditions or complicated flow patterns.

Figure 2 Closed cooling water system - Boxcooler.

HMI unit TTo monitor and operate the power units an HMI unit is required.

HMI Features

• Dark and light mode

• ICAF Pre-sets for anode-groups

• Adjustable copper dosage per anode group

• Automatic log sheet generation

• Multiple power units visible on one display

• Pump contact mode, for automatic fouling regulation

• Access via Ethernet connection

• Integration with VMS

• 7’’ LCD TFT display

• USB type A slot

• Micro SD card slot

The HMI unit is connected to the data communication of the power units and can be located at any desired place.

System layout Multiple ICAF and ICCP power units can work together with the same HMI. A typical AKBv3 ICCP system layout is shown below.

ICCP System hardware Below an example of a typical ICCP system is shown and consists of the following:

• HMI (1pce)

• Power unit (PU) (2pce)

• Anode (A1-A4) (4pce)

• Reference cell (R1-R4) (4pce)

• Shaft grounding (S1 + S2) (2pce)

Figure 3 AKBv3 typical ICCP system layout

ICAF System hardware

Below an example of a typical ICAF system is shown and consists of the following:

• HMI (1pce)

• Power unit (PU) (2pce)

• Anode groups (AG1, AG2 and AG3 (3pce)

• Strainers (STR1 and STR2) (2pce)

Figure 4 AKBv3 typical ICAF system layout

ICAF power unit The MAGIC3 ICAF system is composed of 1 or more interconnected power units, depending on the size of the system. The power unit is fully microprocessor controlled and can be configured to various situations.

For open cooling water systems, the system is controlled by an I-high and an I-low setting.

These settings are based on pumping capacities:

• High is the current for the maximum flow. It dissolves 2 parts per billion (ppb) copper ions in the water. The I-high settings for the aluminium or ferro anode are based on the same principle.

• The I-low current setting is the minimum current necessary to keep the sea chest free of marine growth.

On request, the system can switch automatically between I-High and I-Low by means of pump contacts (this arrangement it is not standard).

For the application with box coolers the system is controlled by a “Spike and Boost” setting, which varies the current output through time. This protects the box coolers more adequately with a lower anode consumption which increases anode efficiency.

The entire system is fully automated and does not require manual operation. The actual values of the system can be read out on the display.

Features

• Rugged design (IP65 or IP54, please refer to datasheet for your model details)

• No subscription fees

• Free log sheet service

• Spike & Boost function for maximum protection with low copper consumption

• Programmable operational presets

• Graphical system overview

• Control over both ICAF and ICCP systems

Optional

• Wall mounting brackets

• Other output voltages and output currents on request

• Other colours

• Switching based on potential free contacts

• Isolated outputs

• Remote access through website if directly connected with ethernet cable

ICAF power unit versions

Power unit Amount of channels Max. rated output Max. rated Power

MAGIC3 10 4 10A 80W

MAGIC3 20 8 20A 160W

MAGIC3 30 12 30A 240W

MAGIC3 40 16 40A 320W

MAGIC3 10 Isolated 4 10A 80W MAGIC3 20 Isolated 8 20A 160W MAGIC3 30 Isolated 12 30A 240W MAGIC3 40 Isolated 16 40A 320W

Table 1 Power unit types

MAGIC3

These types are the standard power units built for typical antifouling and includes all basic functionalities to prevent fouling. The output current of the unit is divided to different channels; each channel can output a maximum of 2.5A. This means that the 10A power unit will have four channels, a 20A will have eight channels and so on. For each channel it’s possible to connect an anode, when it’s necessary to output more than 2.5A there is a possibility of combining channels.

MAGIC3 Isolated These types of power units have an isolated return current connection. In this way the return current path is determent. This option is mostly used on aluminium vessels where stray currents must be avoided.

Note: Isolated cathodes are required for the MAGIC3 Isolated system

ABS junction box This section covers the description, operating description and other features to install, commission, operate and dispose the junction box. Read this manual carefully and store it near the power/operating unit. The junction box is used to connect parts to the power unit.

This section is applicable for product codes:

• JU.001-01: 1x M25 & 3x M16 with 3x terminal clamps 6mm2

Figure 5 AF junction box

ICAF welding flange To mount ICAF Anodes type 0501 and 1501, a welding flange is required.

This flange can be welded onto the vessel’s strainer lid or seachest. With the studs on the flange the steel anode cofferdam can be mounted.

There are two different welding flange sizes. Standard (0501) and DIN (1501).

Figure 6 welding flange Isometric view

Figure 7 standard size welding flange (0501)

Figure 8 DIN size welding flange (1501)

ICAF anode ICAF anode 0501/1501

These anodes are equipped with a steel cofferdam, for mounting directly in the ship’s construction, using a welding flange.

There are two different flange sizes. Standard (0501) and DIN (1501).

Figure 9 Type 0501 with Cofferdam Figure 10 Type 1501 with DIN Cofferdam

ICAF anode 2501/2504

Horizontal anodes (2501) are equipped with a cable tail, directly connected to the anode material for underwater placement. The anode is mounted with isolation sleeves and clamps to the anode support frames which is welded onto the ship’s construction.

These anode types are typically used for box cooler fouling prevention.

In small areas, double casted anodes type 2504 can be installed, to prevent salt bridges on the end of the anode.

Figure 11 Type 2501 horizontal anode: only one side has a casted POM

Figure 12 Type 2504 Double Casted horizontal anode: both sides have fixed POMs

ICAF Cathode General The ICAF system is based on an impressed current principle and passes a low DC current through the anodes to the cathode. The ship’s construction can act as a cathode, but to avoid stray currents through the cooler and for homogeneously dissolving of the anode bar, MME advices to install cathode plates or a cathode frame welded to the ship’s construction.

The cathodes are to be located on both sides of the anode and can be constructed from an uncoatedsteel strip, angled bar or any other steel profile.

2 INSTALLATION

HMI unit

Storage, handling and marking

The HMI unit consist of some components being sensitive to environmental influences and/or mechanical damage. Therefore, please adhere to the specified storage, packing and handling conditions as specified in this chapter.

HMI unit The HMI unit is packed either in a cardboard box or built into the power unit.

Storage The HMI unit should be stored in the pre-packed cardboard box, in a well-ventilated, dry place. The unit may be stored in the upright position or laying on its back on a flat surface.

Following environmental conditions should not be exceeded:

• Maximum ambient air temperature: -13 °C to 55 °C

• Maximum relative humidity: 90% non-condensing

Handling The HMI should be handled with great care. Protect the unit during handling from mechanical impact and environmental conditions such as rain and moist.

Environmental conditions for use

Note: This manual covers the standard temperature range. Your specific power unit may have different specifications. Please refer to the datasheet for more details.

The power unit may be used under the following environmental conditions:

• Maximum ambient air temperature: 0 °C to 40 °C

• Maximum relative humidity: 70% non-condensing

These values are based on the HMI unit being installed in a well-ventilated area and not in the vicinity of heat sources.

At ambient temperatures over 50 °C the HMI unit can be operated at lower ratings. On request MME can supply systems to be used under other environmental conditions.

The power unit is designed for a maximum G-force of 2G. Furthermore, the power unit should be protected against heavy vibrations caused by other installed shipboard components e.g. generators, combustion engines, pumps etc.

On request MME can supply systems which can be used at alternative environmental conditions.

Main power supply

The main power supply for the HMI unit must be between 6-36VDC (15W). Failure to do so could damage the HMI unit.

The main power supply should be free of interference and with minimal distortion.

In case substantial EMF over the main supply is to be expected, installation of filters is recommended. Please contact MME for technical specifications.

Back side sticker

A sticker is installed on the back side of every HMI unit. It will read the following data:

Figure 13 Back side sticker

Electrical system considerations

Cables for an HMI unit can be divided into two categories:

1. Power supply

2. Signal cables

Supply cables The supply power cables should be designed to take the full power load of the HMI unit.

The voltage rating of the cables should be in accordance with the power supply voltage rating of the HMI unit as specified on the back side sticker.

Signal cables Signal cables are used to connect the communication to the power units and/or vessel management systems.

We recommend twisted pair shielded cables to be used as specified on the electrical layout drawing (3001).

Installation of the HMI unit

The HMI unit must be installed in a suitable place, away from moisture environments and heat sources.

It is advisable to install the HMI unit inside the engine control room (with sufficient ventilation) or a regularly accessed location as readings must be taken at regular intervals to check the operational parameters of the system. For this reason, it is also recommended to place the unit with the display at eye level. Optional the HMI unit can be (pre-)installed in one of the power units.

The HMI unit is ideally mounted into a cut out of a door to easy access the USB and SD Card slot. Installation location of the HMI unit should have the lowest feasible vibrations.

Minimum installation requirements

• A panel with a free surface area to fit a panel with a width of 220 mm and a height of 153 mm

• A minimum depth of 60mm

• A 230VAC power socket for an adapter or alternatively a 0,5A fused 24 VDC power supply.

• The communication cables from the remote units must be able to connect to the connector of the HMI

Installation steps

1. Determine the exact location

2. Cut out a hole with dimensions of:

a. Width: 201.5 ±1.0 mm

b. Height: 134.5 ±1.0 mm

3. Install the HMI unit

4. Connect the electrical connections

Power unit connection

Every MME power unit must be connected to one HMI to control and monitor the systems.

When multiple power units are connected, the data of all units can be presented on the HMI unit or via the web browser on a computer connected with an ethernet cable.

The communication between MME power units is established by a CAN bus protocol. The CAN bus communication signal is a two-wire signal in combination with a ground wire.

The signal is therefore highly resistant to noise and or other interference. This signal type does not require screened cables. The maximum total length of the cable between the first and the last unit is about 200 meter and a maximum of 5 power units and 1 HMI. Since the CAN bus protocol is a bus protocol, all signals can be connected parallel.

CAN bus communication is used for two purposes

1. Connect an HMI unit to the power unit(s).

2. Connect multiple ICCP and ICAF power units together.

CAN end termination - power unit The first and last power unit on the CAN bus requires an end termination. In the first power unit this is done by connecting a 120W resistor between the terminals H1–L1, on the last power unit it will be connected between the L2–H2 terminal as shown in Figure 15.

Figure 14 shows an overview of the connection:

Figure 14 Overview CANC connection

In case of a single power unit, a 120W resistor between H1–L1 and H2–L2 terminals is required as shown in Figure 16.

Figure 15 Last power unit end termination Figure 16 Single power unit end termination

CAN end termination - HMI When the HMI unit is at the end or start of the CAN bus, a wire bridge between terminal 2 and 5 must be connected a shown in Figure 17.

Figure 17 HMI end termination

CAN end termination check

Verify that the HMI and all power units are switched off.

Measure the resistance between the H and L terminals on a random power unit or the HMI. When the CAN bus is connected and terminated correctly a resistance of 60 ohm will be measured.

Vessel Management System (VMS) connection

The HMI unit can be connected to the VMS to control and monitor the ICCP and ICAF power unit(s). For the connection between the HMI and the VMS, Modbus over TCP-IP is used.

The connection is established over an RJ45 connection. This industrial standard is very noise resistant although it is a voltage signal. However, it is advised to use a screened cable.

ICCP and ICAF power units cannot be directly connected to the VMS, but always through the HMI.

HMI to VMS connection is used for two purposes:

1. Connect different MME devices to a vessel management system for data logging.

2. Connect different MME devices to a vessel management system to control the set points of the antifouling system.

Figure 18 Can communication example

Ethernet connection

The HMI unit can be connected to the Ethernet/LAN of the vessel to control and monitor the ICCP and ICAF power unit(s). The connection is established by an RJ45 connection.

ICCP and ICAF power units cannot be directly connected to an Ethernet/LAN.

HMI to LAN connection is used for two purposes:

1. Operate and monitor ICCP and ICAF power units.

2. Direct download of log sheets.

Storage, handling and marking

The MAGIC3 ICAF system consist of some components being sensitive to environmental influences and/or mechanical damage. Therefore, please adhere to the specified storage, packing and handling conditions as specified in this chapter. This project does not necessarily contain all components referred to.

Power Unit The power units are supplied in a ISPM box and are packed in a cardboard box.

Storage The power unit should be stored in a well-ventilated, dry place. The unit may be stored in the upright position or laying on its back on a flat surface.

Following environmental conditions should not be exceeded:

• Maximum ambient air temperature: -13 °C to 55 °C

• Maximum relative humidity: 90% non-condensing

Handling The power units usually weights about 20 kg so it can be handled by hand. If packed inside an ISPM box then it can be handled by forklift or crane. The units may only be transported in the upright position or lying flat with the door facing upwards.

Protect the units during handling from mechanical stresses and environmental conditions such as rain and moisture.

Marking In case of multiple units for one project, the units will be marked with project specific markings indicating the installation location of the unit.

Environmental conditions for use

Note: This manual covers the standard temperature range. Your specific power unit may have different specifications. Please refer to the datasheet for more details.

The power control unit may be used under the following environmental conditions:

• Maximum ambient air temperature: 0 °C to 40 °C

• Maximum relative humidity: 70%

These values are based on the power unit being installed in a well-ventilated area and not in the vicinity of heat sources.

Furthermore, the power unit should be protected against heavy vibrations caused by other installed shipboard components e.g. generators, combustion engines, pumps etc.

Main power supply

The main power supply for the power unit must be in accordance with the type plate.

Failure to do so can cause loss of power on the output side or could damage the power unit.

The main power supply should be free of interference and should produce a pure sine wave with minimal distortion with a clear zero crossing.

In case substantial EMF over the main supply is to be expected, installation of filters is recommended.

Please contact MME for technical specifications.

Note: The DC voltage is generated via a transformer. This set up requires pure sine waves and clear zero crossings for optimal performance. When the sine wave is too distorted or the zero crossing is not clear, this will affect the control of the output current leading to an unstable system and reduced service life.

Type plate

The name plate of the power unit is installed in front of the door of every power unit. It will read the following data:

Figure 19 Type plate

Input voltage: The mains supply voltage in VAC. Tolerance ±5% Phases: The number of phases of the mains which are connected inside the power unit Frequency: Frequency of the mains supply. Tolerance ±3% Power load: Maximum continuous power load of the power unit.

Note: The power load is based on a maximum continuous rating. However, as the power unit is fitted with a transformer, at start up a power surge may occur which exceeds the specified power load.

Serial: Unique number for this power unit. The number is related to the year and month of manufacturing and configuration in combination with a sequential number. The letter on the end refers to the number of current control modules.

Type: Description of the power unit.

Caution: Make sure that on a system with multiple power units, the location of each unit corresponds with the location and serial number mentioned on the installation drawing.

Failure to do so could cause damage to the anodes and cooling system.

Configuration: The system can be configured for high/low setting, automatic spike & boost and MAGIC3 as described in paragraph 2.1.3 Controller power unit

Anode material: Describes the material and number of anodes.

Electrical system considerations

Cables used for the impressed current system are divided into two categories:

• Power cables

• Signal cables

Power cables

• The supply power cables should be designed to take the full power load of the power unit. The voltage rating of the cables should be in accordance with the power supply voltage rating of the power units as mentioned in the type plate. We suggest however a minimum rating of 0.6/1.0 kV.

Anode and cathode cables

• These cables connect the power unit with the steel construction and the anodes.

The cables only carry DC current, but at very high amperages. We recommend a minimum amperage rating for each interconnecting cable to be at least equal to the total output of each power unit. The voltage rating must be a minimum of 0.6/1.0 kV.

Signal cables

• Signal cables are used to connect the reference cells, shaft measuring, alarm signal and data communication signals to the power units, HMI units and/or vessel management systems.

• We recommend twisted pair shielded cables to be used as specified on the Electrical layout drawing.

Installation of the power unit

The power control unit must be installed in a suitable place, away from moist environments and heat sources, see chapter 2.2.2 ‘’Environmental conditions for use”.

The unit is fitted with ventilation openings depending on the model.

It is advisable to install the power control unit inside the engine control room (with sufficient ventilation) or a regularly accessed location as readings must be taken at regular intervals to check the operational parameters of the system. For this reason, it is also recommended to place the unit with the display at eye level.

Note: The door is hinged on the right side when facing the power unit. Keep enough clearance to open the door and to insert the cables via the bottom cable gland plates.

The power unit is ideally bolted onto a sub frame which is bolted or welded to a rigid structure such as a bulkhead. Installation location of the power control unit should be as free of vibrations as possible.

HMI connection

MME power units must be connected to a HMI to control and monitor the systems. When multiple power units are connected, the data of all units can be presented on the HMI unit.

The communication between MME devices is established by a CAN bus protocol. The CAN bus communication signal is a two-wire signal in combination with a ground wire. The signal is therefore highly resistant to noise and or other interference. This signal type does not require screened cables. The maximum total length of the cable between the first and the last unit is about 200 meter and a maximum of 6 power units and 1 HMI. Since the CAN protocol is a bus protocol, all signals can be connected parallel.

CAN bus communication is used for two purposes

1. Connect an HMI unit to the power unit(s).

2. Connect multiple ICCP and ICAF power units together.

ABS junction box

1. Determine the location for the junction box. It should be in a dry area and as close as possible to the anode/reference cell. Verify that the distance to the anode/reference cell will not be more than the cable length. The placement of the junction box should be easily accessible for inspection.

2. The orientation of the junction box should be as shown in Figure 20.

3. Mount the junction box to a wall or mounting brackets using 4 bolts.

Figure 20 AF junction box orientation

4. Connect the cables according to the specific 3001 drawing.

5. Seal off any unused cable gland using blind plug(s). (Supplied with junction box)

6. Close the junction box lid. After tightening screws, seal using supplied seal caps.

ICAF 0501/1501 welding flange

Figure 21 Weld detail AF0501

Figure 22 Weld detail AF1501

1. Find the exact locations to install the anodes according the AF3001 layout drawing.

Note: The efficiency of the system is highly influenced by the location of the anodes. Installing the anodes in the flow (i.e. in front of the main inlet) will improve the efficiency of the system.

When in doubt consult MME.

Note: The free distance around the anode must be at least 1x the diameter of the anode. Place the copper aonde closest to the inlet.

2. Cut out a hole from the plating with the diameter for the applicable anode (0501 / 1501) as shown in Figure 21 or Figure 22.

3. Remove nuts and washers from the installation flange.

4. Cover the studs before welding and painting.

5. Weld the flange in place using an approved weld detail. Ensure that minimal heat input into the unit is obtained and that excessive warping is avoided.

6. Paint all welded parts

ICAF anode 0501/1501

Figure 23 Type 1501 with DIN Cofferdam

2.5.1.1 General anode installation method

1. Find the exact locations to install the anodes according the AF3001 layout drawing.

2. Remove nuts and washers from the welding flange.

3. Verify that a gasket is in place

4. Hoist the anode onto the welding flange by using the lifting eye

5. Install washers and nuts (hand tighten)

6. Tighten each nut in a crosswise pattern to the correct torque value. (according Table 2)

Connecting the anode cable

1. Remove cofferdam lid

2. Guide the cable through the cable gland and install the cable gland according to Figure

3. Connect the anode cable with a suitable cable eye to the M6 bolt connection inside the anode cofferdam.

4. Tighten the back nut to the correct torque value (according Table 2)

Warning: Do not over tightened the cable gland back nut

5. Closing the cofferdam:

a. Install gasket

b. Place cofferdam lid

c. Install washers and bolts

d. Tighten each bolt in a crosswise pattern to the correct torque value. (according to Table 2)

6. Run the anode cable to junction box as shown on AF3001 layout drawing.

Note: in some situations, the cable might be installed by MME.

Table 2 Torque values Type 0501 & 1501 anodes Item Torque values Cable gland, Cable entry (see Figure 24) ± 35 Nm Cable gland, Back nut (see Figure 24) ± 16 Nm M16 Nut for type AF0501 (for flange) ± 70 Nm M22 Nut for type AF1501 (for flange) ± 90 Nm M6 Bolt (for cable connection) ± 5 Nm M10 Bolt (for cofferdam lid) ± 24 Nm

Figure 24 Cable Gland exploded view and 3D

2.5.1.2 Typical sea chest installation

It is recommended to install the copper anode in the water flow in front of the pipe inlet.

Cathodes are required to ensure correct consumption of anode material. See chapter 2.5 for more information. In case of high turbulence of the flow1, it is recommended to position the cathodes in such way to prevent direct flow on the anode(s). This will prevent excessive erosion of the anode. However, it is important to allow the copper ions to flow in the suction pipe and or/in the heat exchanger.

It is advised to install sacrificial anode(s) lower than the anti-fouling anodes.

Figure 25 Type 0501 installation example.

1 Turbulence highly depends on water conditions, geometry and other factors. In general, local flow velocity near the anode above 1.5 m/s can be considered turbulent.

2.5.1.3 Typical strainer installation

Figure 26 Typical strainer installation

Notes on placement: it is recommended to install the anodes in the water flow in front of the pipe inlet (strainer outlet).

Cathodes are strongly recommended (even mandatory in case the basket consists of plastic). See chapter Cathodes for more information. Note that it is common practise to fit the anode cables with connectors for ease of maintenance of the strainer. Connectors are available at MME-Group on request.

It is essential for all strainer components to be electrically connected (grounded) to the structure.

The components which must be connected electrically to the hull are:

• Strainer housing

• Strainer lid

• Valve(s)

• Basket (not necessary for plastic)

• Pipes and or other metal components

Warning: There is a significant risk of corrosion when the electrical grounding requirements are not met.

Warning: When the strainer or hull is not made from steel, there needs to be an evaluation of risks associated with connecting different materials in combination with current from the Antifouling anodes before electrically connecting everything together.

Warning: The antifouling anode(s) work by outputting current and thereby creating gasses through electrolysis. These gasses must be vented directly to the outside air.

Warning: The amount of flow through the suction pipe should be at ≥5% of the seachest flow or at least 5 m3/hr.

2.5.1.4 Typical horizontal installation

It is recommended to install the copper anode in the water flow in front of the pipe inlet.

For horizontal mounting, it is required to support the anode.

Figure 27 Type 0501 mounted horizontal.

Warning: Support structure must be properly coated to ensure correct consumption of anode

See Table 3 for recommended U-bolt sizes for fixing anode to support structure.

Table 3 U-bolt

Anode Ø Anode length POM bus [OD]x[Length]

Advised U-bolt

[A]x[B] Article no.

< 500 Ø90x60

M12x104 AMSHOR075.M12

> 500 Ø90x120

< 500 Ø110x60

M12x124 AMSHOR100.M12 > 500 Ø110x120

< 500 Ø130x60

M16x148 AMSHOR120.M16 > 500 Ø130x120

Warning: Cathodes are required to ensure correct consumption of anode material.

Note: It is recommended to install sacrificial anode(s) lower than the anti-fouling anodes.

When the ICAF anodes are installed underneath a box cooler then the SA should be placed above ICAF anodes.

2.5.1.5 Typical treatment tank installation

It is essential for all treatment tank components to be electrically connected (grounded) to the structure.

The components which must be connected electrically to the hull are:

• Housing

• Lid

• Valve(s)

• Pipes and or other metal components

Warning: There is a significant risk of corrosion when the electrical grounding requirements are not met.

Warning: The outgoing piping can contain high concentrations of copper, which could lead to an accelerated corrosion speed. The advice is that the outgoing piping material is Rubber lined GRP or thick-walled steel.

Note on placement: it is recommended to install the anodes in the water flow in front of the pipe inlet (treatment tank outlet).

The inside of the treatment tank functions as a cathode and is not to be coated. Cathodes should only be used when the treatment tank is coated on the inside. See chapter Cathodes for more information.

Warning: The antifouling anode(s) work by outputting current and thereby creating gasses through electrolysis. These gasses must be vented directly to the outside air (indicated by the ‘de-aeration’).

Figure 28 Type 0501 in a treatment tank.

Warning: The minimum amount of flow for a treatment tank should be at least 20 m3/hr, higher is advised up to 30 m3/hr, to avoid debris build-up.

ICAF anode 2501/2504

Figure 29 2501/2504

1. Find the exact locations to install the anodes according to the AF3001 layout drawing.

2. Install the anode support frames. See Figure 29 for an example.

3. Install the anodes as shown on the AF3001 layout drawing:

A good reference is to keep the diameter the anode free around the anode.

The total free area around a Ø100mm anode will then be at least 100mm.

a. Place the anode on top of support beams.

b. Install the isolation sleeves centred on the support beams to avoid short circuits.

Caution: When the sleeves are not centred above the supports, short circuits can occur due to salt bridges or dirt. This will cause the system to malfunction or the anode to be consumed locally.

c. Fix the anode to the support beams by U-bolts with correct dimensions.

Drill holes in the support beams to mount the U-bolts.

d. Fix the anode cable to the support beam without slack.

4. Install the anode cable through conduit pipe or cable strip and shell penetration unit.

Caution: When the cable is not properly fixed the cable can be damaged and/or break due to vibrations caused by the turbulence in the sea chest.

5. Fix the cable glands of the shell penetration unit. Do not over-tighten when screwing the back nut of the gland in place!

6. Run the anode cable to junction box as shown on the AF3001 layout drawing and label it with the anode number provided on the AF3001 drawing.

Caution: In combination with open seachest, sacrificial anodes must be placed below the vertical ICAF anodes.

Caution: In combination with box coolers, sacrificial anodes must be placed as high as possible inside the seachest, close to the boxcooler flanges.

ICAF cathode General cathode installation

1. Determine the exact locations of the anode according the AF3001 layout drawing.

2. Install the cathode plates with a light angle as shown in Figure 30.

3. Keep a distance of 1x anode diameter between the cathode and the anode

4. Keep a distance of 1,5x anode diameter between any metal and the anode

5. Keep the cathode length the same as the length of the anode

6. Weld the cathode plates directly to the structure in the correct location.

Note: MME recommends the use of angled bars or ridged strips as cathode for anode type 0501 / 1501.

Table 4 Recommended cathode dimensions Diameter anode Cathode / flat bar dimension Cathode / angle bar dimension Ø75 90x10 60x60x6 Ø80 90x10 70x70x7 Ø100 110x10 80x80x8 Ø120 130x10 100x100x10 Ø140 150x10 120x120x10

Warning: The flatbar must only be used for horizontal placement/installation

Warning: The cathode must never be painted

Warning: When the strainer or hull is not steel, there needs to be an evaluation of risks associated with welding and/or connecting a cathode to the structure.

Typical sea chest installation

Figure 30 shows the typical layout of the cathodes as an example, in addition to the general cathode installation requirements.

Figure 30 Vertical cathode frame

Typical strainer installation

Figure 36 and Figure 37 show the typical layout of the cathodes as an example.

Distance between anode and cathode D*: Must be in the range of 0.75 x D and 1 x D.

D stands for diameter of the anode.

Warning: The lifting eye is not meant to lift anything other than the anode.

Typical horizontal installation

Figure 33 and Figure 34 show the typical layout of the cathodes as an example, in addition to the general cathode installation requirements.

Figure 33 Cathodes mounted horizontal 0501/1501 anode

Figure 34 Cathodes mounted horizontal 2501/2504 anode

Figure 32 Custom made strainer lid by MME side view Figure 31 Custom made strainer lid by MME top view

Typical treatment tank installation

Figure 35 shows the typical layout of the cathodes as an example, in addition to the general cathode installation requirements.

Distance between anode and cathode D*: Must be in the range of 0.75 x D and 1 x D.

D stands for diameter of the anode.

Figure 35 Cathodes inside treatment tank.

Note: MME advises to install cathodes if the inside of the treatment tank is coated.

3 CHECKLISTS

Installation checks

Note: These installation checks are meant as template for each component type that is installed and must be filled in directly after installation. Multiple components of the same type will use the same checklist.

All checklists should be stored by the client and or send to MME Group.

Warning: The commissioning of the system should be done by trained personnel only.

Notice there always is a risk of electrical shock.

General data

Vessel name : ________________________________

Vessel IMO : ________________________________

Power unit S/N : ________________________________

Power unit location : ________________________________

Vessel is in: □ Dry-dock

□ Fresh water

□ Brackish water

□ Salt water

Outcome □ Failed for the following reasons:

□ Passed with following notes:

NOTES

Date: Name and signature engineer:

HMI unit

Table 5 HMI unit installation checks

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.1.1.1 Check if the HMI unit is in an easily accessible location. X X

3.1.1.2 Verify that the unit is correctly installed and free of heavy vibrations

X X

3.1.1.3 Verify that the ground connection (terminal 1) is connected to ground X X

3.1.1.4 In case of a shielded CAN cable, verify that the shield is connected to terminal 3 or ground.

X X

3.1.1.5

Verify that the CANbus is connected correctly.

Note: When the HMI unit is connected to the end or start of the CAN bus, a bridge between terminal 2 and 5 is required.

X X

ICAF Power unit

Table 6 ICAF power unit installation checks

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.1.2-1 Check if the power unit is in a well-ventilated location. The cooling fins and ventilation grids should be accessible freely for both ventilation and maintenance. Keep a minimum distance of 20 cm

≥20cm

3.1.2-2 Environmental temperature should never exceed limits

≤40ºC

3.1.2-3 Verify with the serial number and AF3001 drawing that right power unit is connected to the designated sea chest/box cooler/location.

3.1.2-4 Verify that a return current cable is connected and suitable for the total amount of anode current (terminal 28)

≥10 mm2

3.1.2-5 Verify that all cabling is secured and connected according to the AF3001 installation drawing. X X

3.1.2-6 Verify that all cable glands are fully tightened and the cables can’t be moved by hand

X X

3.1.2-7 Verify that all unused cable glands are sealed / closed with blind plugs X X

ABS junction box

Table 7 Junction box installation check

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.1.3.1 Is the junction box placed in a dry area? X X

3.1.3.2 Is the junction box easily accessible? X X

3.1.3.3 Is the orientation of the junction box according to

installation instruction?

3.1.3.4 Is the junction box installed using 4 bolts? X X

3.1.3.5 Are all cables connected according to the specific

3001 drawing?

X X

3.1.3.6 Are all unused cable glands sealed with blind

plugs? X X

3.1.3.7 Is the junction box lid closed and are the seal caps

in place?

X X

3.1.3.1 Before welding

Table 8 Cofferdam installation check – before welding

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.1.3.8 Are the stud isolation sleeves present and in good

condition?

X X

3.1.3.9 Are all threaded holes shielded X X

3.1.3.10 Check the angle between the cofferdam and

horizontal plane (advised between 90° and 60° from 60° to 45° is acceptable but not recommended)

45° - 90°

3.1.3.11 Is the weld detail / procedure approved by the

classification society? X X

3.1.3.2 After welding

Table 9 Cofferdam installation check – after welding

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.1.3.12 Is all splatter / slag removed? X X

3.1.3.13 Visually check the cofferdam for cracks, warping

and/or other impurities X X

3.1.3.14 Is the weld grinded flush with the hull including

gasket?

ICAF welding flange

Table 10 ICAF welding flange installation checks

ICAF anode

Anode checks

Table 11 Anode installation checks

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.1.5-1 Verify installation is according to drawing 3001 X X

3.1.5-2 Measure with a multimeter the resistance between anode and hull, to verify the anode is isolated from the hull.

≥ 1 MΩ

3.1.5-3 Verify that all isolation sleeves are centred on the support frame so the risk for calcium bridges is reduced.

3.1.5-4 Verify that all anodes are installed in the water flow from the inlet grid to the suction pipe

X X

3.1.5-5 Measure the free distance between each anode and surroundings and verify that it is the same as at least 1x the diameter of the anode.

≥ 1x anode diameter

3.1.5-6 Verify that there is a dedicated uncoated cathode surface according Table 4

X X

3.1.5-7 Verify for each anode that is installed under the designated boxcooler or in the seachest as mentioned on the AF3001 drawing

3.1.5-8 Verify that there are sufficient cable supports in and or outside the seachest to the junction box or power unit.

3.1.5-9 Mark each anode cable with the anode ID according the AF3001 drawing

X X

3.1.5-10 Visually inspect that there is a proper cable connection between anode and junction box or power unit and that there is now water ingress.

3.1.5-11 Verify that all cable glands are installed and tightened.

no. Check Description Required value

Measured value

Acceptable Yes No Skipped

3.1.4-1 Verify that all flanges are installed according to the AF3001 layout drawing

X X

3.1.4-2 Verify that all bolts and nuts are present and are not damaged during the welding process.

X X

3.1.4-3 Verify that the gasket is present and is in proper condition

In combination with open seachest, sacrificial anodes must be placed below the vertical ICAF anodes.

In combination with box coolers, sacrificial anodes must be placed as high as possible inside the seachest, close to the boxcooler flanges.

Dry-dock/pre-launch checks

Note: When the vessel is in dry-dock, the below checks are required for existing components.

These dry-dock checks are meant as template for each component type that is previously installed and must be filled in during dry-dock. Multiple components of the same type will use the same checklist.

All checklists should be stored by the client and or send to MME Group.

For new installed components the installation checklist is to be used.

Warning: Only switch on the power unit during dry-dock for testing purposes.

General data

Power unit S/N : ________________________________

HMI unit location : ________________________________

Installation checklist present □ yes (must be done before first launch)

□ no

Vessel is in: Dry-dock

Outcome □ Failed for the following reasons:

HMI unit

Table 12 HMI unit installation checks

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.2.1.1 Repeat all checks in Table 11 X X

ICAF Power unit

Table 13 ICAF PU inspection

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.2.2.1 Clean the outside, the cooling fins and

ventilation grids of the power unit(s) with a soft cloth. Remove dust or any foreign matter.

3.2.2.2 Replace or clean the air filters that are

inside the ventilation grids (if present)

X X

3.2.2.3 Clean any foreign matter which may

have accumulated inside the cabinet X X

3.2.2.4 Check incoming cables on terminals for

tightness and damage. Repair as appropriate.

3.2.2.5 Visually check cables inside power unit

for damage and tightness. In case faults are found contact MME

3.2.2.6 Check fuses and replace with same type

fuse if necessary X X

3.2.2.7 Repeat installation checks shown in

Table 13 (ICAF)

Table 14 Photo checklist - Power unit

no. Check Description Before After

3.2.2.8 Outside cabinet and surroundings, accessibility. □ □

3.2.2.9 Cleaned cabinet □

3.2.2.10 Cabinet type plate □

3.2.2.11 Power Unit operational: each display □ □

3.2.2.12 Inside cabinet overview including details. □ □

3.2.2.13 Close-up terminal block □ □

3.2.2.14 Inside cabinet door overview □ □

3.2.2.15 Close-up control circuit board with serial number. □ □

3.2.2.16 Close-up of return current to GND connection. □ □

3.2.2.17 Close-up of repaired parts □

3.2.2.18 Any repair / changes □

3.2.2.19 Inspection sticker □ □

ICCP & ICAF cofferdam

Table 15 Cofferdam inspection

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.2.3.1 Check if all cable glands are still

tightened

X X

3.2.3.2 Open the lids of the cofferdams to

inspect the inside of the cofferdam for water ingress. In case water ingress is found, the leak could be caused by an anode and/or leaking cable gland.

Replace, as necessary.

3.2.3.3 Visually check the cable coming out of

the cofferdam cofferdams for damage. X X

ABS junction box

Table 16 ABS junction box inspection

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.2.4.1 Open all IAF junction boxes and check

for water ingress.

3.2.4.2 >1k ohm

Table 17 Photo checklist – junction box

no. Check Description Before After

3.2.4.3 Take photo of each JB location □ □

no. Check Description Before After

3.2.4.4 Take photo of each JB open □

Table 18 ICAF welding flange installation checks

Anode checks

Table 19 Anode installation checks

no. Check Description Required value Measured value

Acceptable Yes No Skipped

3.2.6-1 Verify that there is no excessive calcium build-up on the…