ANFOMATIC INSTRUCTION MANUAL Rev 8.1
ANFOMATIC INSTRUCTION MANUAL Rev 8.1
ANFOMATIC INSTRUCTION MANUAL Rev 8.1
04/02
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ANFOMATIC
INSTRUCTION MANUAL
INDEX
1.0 INTRODUCTION
1.1 General System Description
1.2 Safety Precautions
4.0 COMMISSIONING
6.0 MAINTENANCE
9.0 NOTES
1.0 INTRODUCTION
Principle of Operation.
Marine fouling and biological fouling commonly occur in seawater circulation systems.
This involves the establishment of marine plants and animals, and bacterial growths.
These fouling organisms enter the system in microscopic and macroscopic form, e.g.
larvae and spats, settle and develop into adult forms wherever favourable
environmental conditions exist.
Hard fouling by mussels, barnacles etc. most commonly occurs in seawater circuits and
can result in interference in flow conditions, blockage and increased corrosion.
Traditional chemical methods of water treatment to prevent fouling are now less
favoured particularly, for example, chlorination. Chlorine accelerates corrosion rates,
usually by causing pitting attack on steel, is environmentally unacceptable and
treatment requires continuous monitoring and control.
WW - Cuproline: Anti-fouling
WW - Aloline: Reduction in corrosion of steel materials.
WW - Ferroline: Reduction in corrosion of copper based materials.
The following is given as a guideline only and the operators own safety rules
and regulations should be followed at all times.
Non-energised Equipment
1. Isolate the supply, carry out the Tag Out system drill or equivalent as
specified by the operators own safety procedures.
3. Ensure that any capacitors associated with the equipment are fully
discharged, fitting shorting straps if necessary.
Energised Equipment
3. Use insulated tools if practicable taking particular care that tools do not
cause short circuits.
8. Do not work alone. Make sure your assistant knows the electric shock
procedure, also where and how to isolate the power supply in an
emergency.
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2.1 Electrical
The Mk IV modular control unit is a variable voltage, constant current unit designed
for single-phase input power supplies of between 90v to 260v or 350 to 450v AC at
50-60Hz and is available in two cabinet sizes. The smaller cabinet (AM1528) can
accommodate between one and five control modules with the larger cabinet (AM1529)
being able to accommodate between six and ten. Each two-channel control module is
rated at a maximum 65-Watts power output with each output channel having a
maximum output of 3.5 amps DC at 12 volts.
Refer to drawings AM1528 & AM1529
2.1.2 Cable
(a) Input
All input cables and shrouds are of shipyard supply. Fittings, terminations,
glands, etc are also usually of shipyard supply. The AC supply cable size is
rated according to the maximum DC output of the power unit. Usually, a very
small conductor size is adequate but for physical and electrical reasons, it is
preferable to use a larger cable conductor size than the nominal current
capacity needed. Cable insulation, armouring and sleeving is dictated by ship
classification requirements.
Single core, 6mm2 cable is generally adequate for DC distribution to the anodes
without any significant voltage drop or alternatively multi-core cables may be
used. For convenience many systems utilise 3 core cable per module output
with two positive to anti-fouling and corrosion mitigation anodes respectively
and one negative to the sea chest (see Drawing No. AM 1164).
(c) Earthing
An intermediate junction box facilitates separation of individual anodes from the supply
thus avoiding interference with the rest of the system during inspection or anode
replacement.
A typical anode assembly, complete with cofferdam and mounting flange is shown in
drawing No. AM1500. The anode can be separated from the cofferdam and flange as
shown in drawing AM1503
Anode size and material type is indicated by an alphanumeric code identifying the
model, material & dimensions of each anode.
Typical examples of minimum anode material required for anti-fouling are given below
for various flow rates at 2, 3 and 5 year dry docking cycles.
The control panel should be located as near as possible to a suitable AC power supply
and the anode locations in order to minimise the DC cable length and voltage drop.
(c) Approx. head height to facilitate ease of reading display, current adjustment in
operation or servicing.
3.2 Cable Connections - Power Control Unit, Junction Box & Anodes
Input AC cable connection points and earthing cable connections are clearly marked
inside the power control unit. Positive output terminals for connection to the anodes
and a common negative cable connection are clearly marked inside the unit. If a power
failure relay is installed, connections will be clearly marked.
Refer to drawings:
The DC supply cable to the anodes should be connected to the intermediate junction
box provided. This is supplied complete with gland inputs and connection terminals.
Refer to drawings:
AM 1513, AM1514, AM1515 (polymer enclosures types 1 to 3)
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The anodes are installed in the selected compartments, usually sea chests, injection
strainers, crossover channels or specially designed reaction vessels.
(a) The agreed positions for the apertures for the cofferdam entry points should be
clearly marked and burnt or cut out taking precautions to protect surrounding
equipment with heat resistant blankets etc. A stand-by fire extinguisher and fire
sentry should be provided.
(b) The mating flange to receive the anode and cofferdam flange should be welded
in position with continuous welds on both inside and outside joints and
inspected by the relevant certifying authority at the time of installation.
(c) To provide a connection point for the negative return, a screw or suitable
alternative connection can be welded onto the sea chest mounted flange or to
any other convenient location in direct and continuous electrical contact with
the sea chest or hull to obtain a zero resistance connection.
(d) All weld scales should be removed and any damaged paint work reinstated.
Carefully lift the anode & cofferdam assembly and lower the anode into the sea
chest or strainer. Ensure that the cofferdam flange lines up correctly with the
mating flange welded to the hull and making sure that the rubber gasket is in
the correct position. Evenly tighten down the anode cofferdam flange nuts
taking care not to exceed the maximum rating of 244 Nm.
Note: All threaded sections of nuts, bolts and the cofferdam lid must be
lightly coated with marine lubricant.
(g) Make the negative cable connection onto the welded flange. AFTER making
this connection, the stud and nut assembly should be completely covered with a
light coating of Marine Lubricant.
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(h) Secure anode cables and negative single cable together and take back for
connection in the junction box.
Note: Cable colour scheme is indicative only and refers only to Corrpro
Companies (Europe) Ltd. standard supply cable. Where client specified
cable is supplied it may not be possible to match this colour scheme.
(i) When vessel is afloat, carry out leakage tests by checking for ingress of water
into the cofferdam.
Power to the anodes must be switched off before carrying out the following procedure.
Vessel must be in dry dock or the sea chest completely sealed off to prevent ingress of
water.
(b) Unscrew cofferdam lid and slide along the cable until the lid is clear of the
cofferdam.
(c) Disconnect the cable from the anode support stud. Secure cable and lid safely.
(g) Remove the lock nut and main securing nut from the support stud. Carefully
remove all accompanying washers.
(i) Ensure that the cofferdam is clean and then fit to the new replacement
assembly.
(j) Replace washers in correct sequence and secure cofferdam with nuts supplied.
The main securing nut should set to a minimum torque of 100 lbs./ft.
(k) Using a suitable test meter ensure that the anode is electrically isolated from the
cofferdam mounting.
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(l) Locate complete assembly in the sea chest and secure with the eight (8)
cofferdam flange nuts. Ensure gasket is in position and tighten down evenly.
(m) Connect anode positive cable, re-fit lid and tighten cable gland.
A specific data sheet for each vessel stating anode sizes, locations and operating conditions is
provided (Section 7.0). This data sheet is for completion on board by the vessels engineers
after installation and testing of the equipment has been carried out. All anodes are designed
with a +20% margin allowing for overrun and higher current settings if required.
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4.1 Commissioning
a) Check all cable connections at power control unit, terminal box and anodes.
b) Identify each positive output and relevant anode, and record the same.
LCD displays on all modules Blown control fuse. Check internal fuses and
fail to illuminate. Power on replace as necessary.
LED remains illuminated.
LCD displays on all modules 1. Blown power supply fuse. Check internal fuses and
fail to illuminate. Power on replace as necessary.
LED fails to illuminate.
2. Power supply failure. Check power supply.
Bio-fouling growing in sea Incorrect current output Check settings and adjust as
water cooling system. settings. necessary.
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Each Mk IV plug-in module controls two individual output channels. The Mk V and
VI models have a fixed number of output channels with displays configured in the same
way as the modular units.
The new style Power Module has a new look front plate that comprises of a graphic
LCD display and four control buttons. The buttons function left to right as follows:
Function: Symbol
On initial power up the LCD will display the manufacturers logo for a period of 4
seconds, or until any function button is pressed. The display will then default to the
main indicator screen, which shows actual current on both output channels with
channel 1 at the top and channel 2 below.
To the right of the current digits there is an indicator icon which in normal condition
shows the anode material identifier. This identifier can be set to show Cu for
Cuproline, Al for Aluminium or Fe for Ferrous on either channel. A fourth option
exists should only one output channel be required to operate on a module and selecting
BLANK for either channel from the anode identification menu will remove the
output reading from the main display.
From the main screen pressing the ENTER button allows the user to set the desired
anode currents. At the first press of the ENTER button the word SET will appear
next to channel 1, and the user can use the UP and DOWN buttons to increase or
decrease the desired value. If a button is held down it will accelerate the increase or
decrease count.
If no other button is pressed for 4 minutes or the CANCEL button is pressed next
the display will return to the main screen.
Pressing the ENTER button a second time will result in the word SET appearing
next to channel 2. The desired current can then set for channel 2 in the same way as for
channel 1
This screen will display a menu of three items, OPTIONS, HOUR COUNTS and
VOLTAGES. The module software version is also displayed in the bottom right
corner of the screen.
The user can move through the menu using the UP and DOWN buttons to
highlight each menu item and then press ENTER to select the function.
Pressing CANCEL or not pressing a button for 4 minutes will return to the main
screen.
The Options menu shows a further five items to allow the user to set the shutdown
current percentage, material identifier and shutdown input.
In each of the Shutdown screens the UP and DOWN buttons can be used to set
the percentage of the normal current that should flow when the module shutdown
input is connected to ground or the manual shutdown is selected. Pressing ENTER
is required to confirm changes. CANCEL will discard the changes and return to the
Options menu.
In each of the Anode ID screens the UP and DOWN buttons can be used to select
the anode material from one of Cu for Copper, Al for Aluminium, Fe for
Ferrous or BLANK for no display. Pressing OK is required to confirm changes.
CANCEL will discard the changes and return to the Options menu.
In the Shutdown Input screen the UP and DOWN buttons can both be used to
toggle the shutdown input between SIGNAL and MANUAL to select either the
volt-free contact signal input or manual shutdown control.
The hour counters show four items. All are accurate to 1/10th hour (6 minutes).
Line 1: shows the total number of anode run hours since the last reset.
Line 2: shows channel 1 total Ampere hours since the last reset.
Line 3: shows channel 2 total Ampere hours since the last reset.
Line 4: shows the total module hours run since manufacture and can not be reset.
When the anodes are replaced the user can enter this screen and pressing both the
UP and DOWN buttons simultaneously will reset the anode counters. Pressing
CANCEL will return to the Status menu.
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This screen shows anode voltages, the module internal temperature and the total power
consumption for that module. Voltages are accurate to 0.1V, the module temperature
is accurate to 5C and the power is in watts.
Shutdown Operation
Each module can be set to respond to either manual control or a remote input signal.
If Manual shutdown mode is selected then the UP and DOWN buttons can be
used to go between normal operation (UP) and shutdown mode (DOWN).
If Signal shutdown mode is selected then the module will only respond to an
external input signal such as pump running/pump stopped. In this mode UP and
DOWN for selecting between normal running and shutdown are disabled
Abnormal Condition
In abnormal condition a warning symbol is displayed. This warning icon will show
if the set output current on a channel cannot be maintained or if the total power
consumption for the module exceeds the maximum safe value rated at 57W per
module.
If the power limit is exceeded for more than 8 seconds the warning icon will appear
next to both channels, and the module will reduce the output current for each channel
to 35% of the set value. The module will stay at a reduced output for a period of 4
minutes, or until CANCEL is pressed. The module will then attempt to return to
100% of the set current value. If the power limit is exceeded again it will cycle in this
way until the problem is removed.
Each module has a CAN bus network interface brought out to the backplane connector
enabling monitoring and control through another linked anti-fouling unit, a remote
terminal or even PC interface. The module transmits data onto the bus every second,
giving information on each anode current, voltage, power and temperature. The
module can also be commanded to output a specific current which overrides but does
not alter, the module stored set current.
6.0 MAINTENANCE
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The maintenance requirement for the Anfomatic system is minimal. The system
operates at constant current output and does not therefore require adjustment unless
the operational requirements specifically require regular adjustments to be made.
A weekly recording of current outputs on each anode is recommended for which a log
sheet is provided as enclosed.
A complete loss of current on any anode should be investigated by checking all cable
connections, power panel fuses or by interchanging modules.
Regular electrical maintenance should be carried out according to the operators own
procedures and planned maintenance system.
Anodes should be replaced at the end of their designed life span or during each dry
docking of the vessel according the procedure laid down in the manual.
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VESSEL NAME
INSTALLATION DETAILS
AC INPUT CABLE
JUNCTION BOX
NEGATIVE CABLE
VESSEL NAME
INSTALLATION DETAILS
INSTALLATION DATE/LOCATION
OPERATION PERIOD
See over.
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Corrpro
Companies
Europe Limited Anfomatic System Log
"A Commitment to Excellence"
Adam Street, Bowesfield Lane
Stockton on Tees, Cleveland. TS18 3HQ
Telephone (01642) 614106 (8 lines)
Telex 587388
Fax (01642) 614100
9
.0 NOTES
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9.0 NOTES..Cont.
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Power Unit:
Cofferdam AN/CD-1500
Cofferdam Lid AN/CD(L)-STD
Mounting Boss AN/CD(MB)-STD
Mounting Boss Gasket AN/G-MB
O Ring Seal AN/G-OX
M.16 Galvanised Stud AN/ST(MB)-M16
M.16 Galvanised Nut AN/NF-M16
M.16 Galvanised Washer AN/WF-M16
Cable Gland M.16 entry AN/CG-M16
Cofferdam AN/CD-SB
Cofferdam Lid AN/CD(L)-SB
Mounting Boss AN/CD(MB)-SB
Mounting Boss Gasket AN/G-MB(SB)
O Ring Seal AN/G-OX
M.12 Galvanised Stud AN/ST(MB)-M12
M.12 Galvanised Nut AN/NF-M12
M.12 Galvanised Washer AN/WF-M12
Cable Gland M.16 entry AN/CG-M16
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Replacement Anodes:
State either three letter identifier code (e.g. AM1501-SJT) or anode dimensions & material.
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7. AM 1528-1 Modular CPU Terminal Connections (Mk IV units only, 2-10 channel)
8. AM 1529-1 Modular CPU Terminal Connections (Mk IV units only, 12-20 channel)