2008-02 - ICAF Installation Manual CWC 1.0 Eng

INSTALLATION MANUAL
Anodes
ICAF System
(MGPS)
IMPRESSED CURRENT ANTI FOULING

Corrosion & Water-Control bv Page 2
ICAF Installation manuals CWC 1.0 Eng.
Corros
sion & Water
r-Conttrol b.v
v.
P.O. Box 47
P
NL-2750
0 AA Moeerkapellle
The
e Netherllands
Tel. (+3
31) 79 - 5931295
5
Fax: (+3
31) 79 - 593187
71
Websitee:
www
w.corros
sion.nl
Genneral em
mail :
info@corrosion.nl
Serrvice em
mail :
servic
ce@corroosion.nl
Corrosion & Water-Control bv

C Page
P 3
I
ICAF Installa
ation manua
als CWC 1.0 Eng.
Index
1 Installation of the ICAF system 7

1.A ICAF anode description 7
1.B Boxcoolers 8
1.C Sea water intake 10
1.D Strainers 12
2 Cable Feed Through (CFT) 15
3 Power Unit 16
4 Connection – Anode to Plugbox 17
5 Connection – Plugbox to Digital Processing Unit 17
6 Current requirements 17
Att. A - d0 Anode (CT Cofferdam) 18
Att. B - d1 Anode 19
Att. C - d2 Anode 20
Att. D - d3 Anode 21
Att. E - d4 Anode 22
Att. F - Installation for Ø60 - Ø70 mm anodes 23
Att. G - Installation for Ø80 - Ø90 – Ø100 mm anodes 24
Att. H - Installation d0 M20 25
Att. I - Installation d0 M30 26
Att. J - Installation d0 + NW125 CT Cofferdam M20 27
Att. K - Installation d0 + NW125 CT Cofferdam M30 28
Att. L - Installation d0 + NW150 CT Cofferdam 29
Att. M - Tightening torques 30
Att. = Attachment

1 Installation of the ICAF system
An ICAF system can be applied on Boxcoolers, Sea water intakes, Strainers and other
cooling systems that need protection from fouling.
* This installation manual is for all the applications as mentioned

above. Please use the part that is suitable for your system.
Locations for anodes are determined by the yard / owners in collaboration with the
engineers of Corrosion & Water-Control bv. The anodes must be mounted according
the mounting specifications of Corrosion & Water-Control bv.
Corrosion & Water-Control bv can supply these mounting specification if needed. The
positions of the boxcoolers are determined by the yard / Owner.
1.A ICAF anode description
Example :
Cu-70/1200d3
Cu = Material of the anode:

Cu = Copper;
Al = Aluminium;
Fe = Iron.
70 = Diameter of the anode (Ø 70mm)
1200 = Length of the anode (1200mm)
d3 = Quantity of support rings

1.B Boxcoolers
Anodes must be mounted in support rings, on angle steel supports, with the help of U-
clamp fixings. The angle steel supports are welded between the boxcooler frames. The
amount of angle steel supports depends on the anode length.
• Drill holes for the u-clamp fixings in the steel angle supports, before welding the
steel angle supports in the seachest;
• Weld the steel angle supports on a suitable location underneath the boxcooler inside
the boxcooler chest, according the installation drawings attached to this manual.
The steel angle supports should be welded perpendicular to the length of the
boxcooler. Now the anodes and cathode plates can be installed linear to the
boxcooler (length). The anodes should be centred underneath the boxcooler,
according the installation drawings attached to this manual.
• Weld the cathode plates on the steel angle supports. The cathode plates must be
aligned with the anodes. The minimal cathode plate length is equal to the anode
length.
The dimensions of the cathode plates are:
Ø60 & Ø70 mm anodes = 80 x 8 x anode length (mm);
Ø80, Ø90 & Ø100 mm anodes = 120 x 12 x anode length (mm).
* Note :
All welds should meet structures classification society rules.
* Attention :
The cathode plates and steel angle supports are yard delivery.
* Attention :
Do not coat the cathode plates. This can cause malfunction.
Corrosion & Water-Control bv will not guarantee the protection
against fouling if the cathode plates are coated.
• Slide the support rings over the anodes and mount them on the steel angle supports
with the u-clamps. Centre the anodes under the boxcooler before tightening the u
clamps. The support rings must be centred on the angle supports. Tighten the u-
clamp bolts to secure the anodes.
For the tightening torques we refer to Attachment M.
U-clamp Support ring

Cathode
plate
Anode
Angle steel
Sideview of boxcooler with ICAF Sectional view of boxcooler
anodes. with ICAF anodes.
Fig. 1

* Attention :
The dimensions of the steel angle support, whereto the support rings
are mounted, cannot be bigger than 50mm (See fig. 2). If the steel
angle support is bigger it can cause system malfunction.
against fouling if the steel angle supports are bigger than 50mm.
Support ring
U-clamp
Sideview of boxcooler with ICAF

anodes.
Maximal allowed
dimension is 50mm
Fig. 2

1.C Sea water intake
The anodes must be mounted inside the seachest in such a way that the anodes are in
front of the suction pipe. If 2 anodes are delivered (Copper, Aluminium or Iron) the copper
anode should always be mounted closest to the suction side (See Fig. 3).
Copper anode
Aluminium / Iron anode
Water inlet
Crossover
pipe Inlet grid
Sea Chest
Water Balast Tank
Fig. 3 Inlet grid
• Before cutting a hole in the seachest surface, make sure that the positions of the
counter flange are determined so that the anode(s) will fit inside the seachest. Also
make sure that the anodes are positioned in front of sea water inlet pipe.
• Cut a hole in the seachest with the same diameter as the diameter of the counter
flange;
• Weld the counter flange into the seachest (See Fig. 4). The surface of the counter
flange must be equal to the seachest surface.
* Note :
• After welding the counter flange into the sea chest surface clean the surface and coat
the counter flange with the ships paint system. Make sure that the threaded studs
are not coated. Also paint the top part of the CT cofferdam construction with the
ships paint system. Do not coat the anode surface.
* Attention :
Do not coat the anode surface. This can cause malfunction.
against fouling if the anodes are coated.
* Attention :
Do not coat the threaded studs. The nuts for tightening the top part
cannot be fixed to the studs if paint is on the threaded studs.
• After the paint of the CT cofferdam is dried please place the gasket (See Fig. 4)
before mounting the top part of the CT cofferdam construction to the counter flange.
* Attention :
Make sure that the area where the gasket makes contact with both
flanges is clean and has a flat surface in order to guarantee a water
tight connection.

Minimal space between Nuts
the flanges is 25mm. Washers
Top part
with anode
Gasket
Counter flange
Counter flange surfase

must be welded equally
to the welded surface.
Fig. 4
• After fixing the top part to the counter flange please fix the washers and nuts to the
threaded studs and tighten the nuts according the torque as described in
attachments M.
• Open the lid of the cofferdam top part and connect the anode cable to the M8 bolt
inside.
• Close the lid of the cofferdam top part and tighten the M6 bolt on top of the lid using
the torque as described in Attachment M.
• Please tighten the cable gland cup according the torque as described in
attachments M.
• Connect the anode cable to the corresponding terminal inside the plug box.
• The system is now ready for use.
* Attention :
The CT cofferdam construction and anodes are delivery of CWC.

1.D Strainers
• First determine the positions of the anode(s) on the strainer cover and check if the
anode(s) fit inside the strainer basket.
• The anodes must be mounted inside the strainer in such a way that the anodes are
inside the strainer basket. When 1 anode is delivered the anode must be positioned
in the centre of the strainer basket. If 2 anodes are delivered (Copper, Aluminium or
Iron) the copper anode should always be mounted closest to the suction side (See
Fig. 5).
Copper anode
Strainer top plate

Outlet Inner diam.
Inlet
Position single anode =
Basket center strainer basket
Strainer
Fig. 5
If 2 anodes are used, the positions are determined by using the following calculation:
The pitch of where the anodes must be mounted is calculated as follows :
Mounting pitch = Internal diameter of the basket x 0,5 (See Fig. 6)
Example :
The internal diameter of the basket is Ø 600mm.
Mounting pitch = Ø 600mm x 0,5 => Ø 300mm.
Copper anode
Outlet Strainer top plate Pitch anodes (2x)
0,5 x Inner diam.
basket
Inlet Inner diam.

Basket
Strainer
Fig. 6

• Before making a hole in the strainer cover please check the diameter of the anode
stud (Ø 20mm / Ø 30mm). If the diameter is Ø 20mm please make a hole of
Ø 24mm (+0,2mm) and if the stud is Ø 30mm make a hole of Ø 38mm (+0,2mm).
• The isolator tube must be shortened in order to tighten the anode assembly to the
strainer cover. The size of the isolator tube must be adjusted to the thickness of the
strainer cover minus 4 mm (measured above the top gasket). (see Fig. 7)
Example :
The strainer cover thickness is 15mm.
Isolator tube length = 15mm – 4mm => 11mm
* When a CT cofferdam is used it is not necessary to shorten the

isolator tube.
Strainer cover
thickness - 4mm
Isolator tube
Top gasket
Isolator Bottom gasket
Anode
Fig. 7
• Mount the anodes on the strainer cover and tighten the mounting bolts. For the
tightening torques we refer to attachment M.
• Place the strainer cover on top of the strainer and tighten the strainer bolts according
suppliers standard.
• Connect the anode cable to the M8 bolt on the anode stud.
• Connect the anode cable to the corresponding terminal inside the plug box.
• The system is now ready for use.
A strainer anode can also be deliver with a CT cofferdam construction (See Fig. 8). This is
usually requested when the strainer is very big and the strainer cover is too heavy to be
lifted. The installation of a CT cofferdam is described in chapter 1.C Sea water intake.
The advantage of using a CT cofferdam is that when the anodes need replacement, the
strainer cover does not need to be lifted.

Copper anode
Strainer top plate
Outlet Pitch anodes
0,5 x Inner diam.
basket
Inlet Inner diam.

Basket
Strainer
Fig. 8
If, for some reasons, it is impractical to fit a component in the specified position. Please
contact a Corrosion & Water-Control bv representative for advise with determining a
new suitable location.

2 Cable Feed Through (CFT)
Hull plating
Feed through socket
Cable gland NPT 1/2"
Anode cable
Use treat sealant when

tighting inside the feed
trough socket
(Versagem / Loctite)
Fig. 9
• A Ø38mm hole must be made in order to mount the feed through socket. If possible
place the hole as close to the anode as possible.
• Remove the cable glands from the feed through socket (ANSI) and secure it by a
continuous filled weld. Weld on the inside and also on the outside of the hull plating.
• Each individual anode requires one Cable Feed Through (CFT).
• Install the anodes, with the use of the delivered support rings and the U-clamps, on
the angle steel supports.
• Make sure that the anode cable is not damaged. If the cable is damaged it can cause
short circuit or leakage. If the cable is damaged please contact a Corrosion &
Water-Control bv representative for advice. Prior to transport, the cables of the
anodes are pressurized to check against leakage.
• Re-install the cable glands in the feed through construction and secure them by
using the Loctite or Versachem thread sealant.
• Pass the anode cable through the cable gland and tighten the screw cap fully.
For the tightening torques we refer to Attachment M.
• When the distance between the anode and feed-trough is longer than 20 cm the
cable must be secured in the sea chest to avoid damage.
* Note :
* Note :
When tightening the cable with tie-wraps, only use 100% plastic tie-
wraps. This is to avoid damage to the cable.
* Note :
Make sure, there is enough space available below the anode rack. If
the anodes need replacement, space is needed in order to mount the
anodes.

3 Power Unit
The power unit is equipped with:
• Power supply;
• Anode control prints (ACP);
• DPU (Touch screen operation);
• Primary and secondary fuses;
• Connection terminals;
• On / off main switch.
The main power supply for the power unit must be connected to the primary terminal
marked with L1 and N.
Each anode connection has its own specific cable (colour / number). The cable of the
anode must correspond with terminal number inside the DPU. The data for the anodes and
terminals is given by Corrosion & Water-Control bv.
Power unit
Menu
ICAF ICCP
m
i p ress ed cu rre nt m
i p re sse d curre nt
an t fi o ul n
i g syst em c at ho dic p rot ect o
i n
Plugbox
Cable feed through

1
Power cable Multicore cable Anode cable
Grounding cable
Anode cable
Alarm cable
Anode
Multicore cable Anode cable
Anode cable
Fig. 10

4 Connection – Anode to Plugbox
The cable from the anodes must be connected via the cable feed through to the terminals
inside the plugbox. Please make use of the pre-installed cable glands and terminals.
A plugbox 4/1 means :

4 anode cable in (input) and 1 multicore cable out (output).
Corrosion & Water-Control bv can supply plugboxes with 1 to 10 inputs.
5 Connection – Plugbox to Digital Processing Unit

From the terminals in the plugbox, a multi-core cable must be connected to the
corresponding terminals in the DPU. Double check the multicore cable if the cables on both
end correspond with the correct terminals.
The powerunit is pre installed with a ground cable. The yard should prepared a connection
on the structures hull to connect a cable to.
6 Current requirements
The current requirements of each output / anode are pre-programmed by Corrosion &
Water-Control bv.

Att. A - d0 Anode (CT Cofferdam)
d0 Anode (CT Cofferdam)
Mounting bolt M20 or M30.

M20 or M30 depents on the
anode thickness.
L
D
The CT Cofferdams are designed for mounting the D0 anode

inside a sea chest. A CT cofferdam can be delevered by CWC.
For more detaled information we refer you to the specific
mounting method.
CT Cofferdam
Anode length - (mm)

The length of these anode are from
L
350 mm up to 1200 mm
Anode Ø (mm)
Ø 60
Ø 70
Ø 80
Ø 90
Ø 100
Ø 120
Ø 150

Att. B - d1 Anode
d1 Anode
Mounting bolt M20 or M30.

M20 or M30 depents on the
anode thickness.
L
D
0,2 x L
Anode length - (mm)

500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
1200
1250
Anode Ø (mm)
Ø 60
Ø 70
Ø 80
Ø 90
Ø 100

Att. C - d2 Anode
d2 Anode
L 6 Mtr.
D
0,2 x L 0,2 x L
Anode length - (mm)

500
550
600
650
700
750
800
850
900
950
1000
1050
Anode Ø (mm)
Ø 60
Ø 70
Ø 80
Ø 100
Ø 90

Att. D - d3 Anode
d3 Anode
L 6 Mtr.
D
0,2 x L 0,2 x L
0,5 x L
Anode length (mm)

1100
1150
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
1700
Anode Ø (mm)
Ø 60
Ø 70
Ø 80
Ø 100
Ø 90

Att. E - d4 Anode
d4 Anode
L 6 Mtr.
0,2 x L 0,2 x L
D
0,4 x L 0,4 x L
Anode length - (mm)

1750
1800
1850
1900
1950
2000
Anode Ø (mm)
Ø 60
Ø 70
Ø 80
Ø 100
Ø 90

Att. F - Installation for Ø60 - Ø70 mm anodes
Installation Ø 60 - Ø 70 mm Anode
A Section A-A
50 - 200 mm
B
DETAIL A
Third anode support is

A deivered when anodes are
longer than 1050 mm.
Section B-B
Anode cable to plugbox
Cable Feed Through
DETAIL A
Isolator U-clamp
Angle steel Cathode plate
50 x 50 x 8 mm 80 x 8 mm Steel
89 Anode
M10
75
Attention :
150
The dimensions of the steel angle support,
whereto the support rings are mounted, may not
be bigger than 50mm.
The cathode plates and steel angle supports are

yard delivery.
Do not coat the cathode plates.
Do not over-tighten the nuts on the U-clamps, as

the support rings (isolation rings) are made of
plastic. All bolt and cable gland must be tightened
with a torque wrench.
We refer to Att. M for the tightening torques.
When tightening the cable with tie-wraps, only

use 100% plastic tie-wraps.
Make sure, there is enough space available below

the anode rack. If the anodes need to be replaced
space is needed to mount the anodes easily.

Att. G - Installation for Ø80 - Ø90 – Ø100 mm anodes
Installation Ø80 - Ø90 - Ø100 mm Anode

A Section A-A
50 - 200 mm
B
DETAIL A Third anode support is

A deivered when anodes are
longer than 1050 mm.
Section B-B
Anode cable to plugbox
Cable Feed Through
DETAIL A
Isolator U-clamp
Cathode plate
120 x 12 mm Steel
Angle steel
50 x 50 x 8 mm
126 Anode
M12
115
Attention :
230
The dimensions of the steel angle support,
whereto the support rings are mounted, may not
be bigger than 50mm.
The cathode plates and steel angle supports are

yard delivery.
Do not coat the cathode plates.
Do not over-tighten the nuts on the U-clamps, as

the support rings (isolation rings) are made of
plastic. All bolt and cable gland must be tightened
with a torque wrench.
We refer to Att. M for the tightening torques.
When tightening the cable with tie-wraps, only

use 100% plastic tie-wraps.
Make sure, there is enough space available below

the anode rack. If the anodes need to be replaced
space is needed to mount the anodes easily.

Att. H - Installation d0 M20
Installation d0 anodes M20
M20
Detail A
Strainer cover
Ø60 - Ø90
Detail A
M8 Bolt
washer
Stud
Nut M20
Washer
PVC Washer
Gasket
Before mounting a do anode, with a M20 Attention :

stud, to the cover of the strainer a hole Before mounting the do anode, with a M20 stud,
of Ø 24mm must be drilled. to the cover of the strainer a hole of Ø 24mm
must be drilled.
All bolt and cable gland must be tightened with

a torque wrench. We refer to Att. M for the
tightening torques.
Ø24

Att. I - Installation d0 M30
Installation d0 anodes M30
M30
Detail A
Strainer cover
Ø80 - Ø150
Detail A
M8 Bolt washer
Stud Low nut M30
Nut M30
Washer
PVC Washer
Gasket
Before mounting a do anode, with a M30 Attention :

stud, to the cover of the strainer a hole Before mounting the do anode, with a M30 stud,
of Ø 38mm must be drilled. to the cover of the strainer a hole of Ø 38mm
must be drilled.

tightening torques.
Ø38

Att. J - Installation d0 + NW125 CT Cofferdam M20
Installation d0 anodes
(CT Cofferdam NW125)
M20
Ø115
Detail A
Cover
Gasket
Stud Cable gland
154
Washer Nut M16

Top flange 22mm
Gasket
Gasket Bottom flange 22mm
Detail A
M8 Bolt
washer
Stud
Nut M20
Washer
Ø60 - Ø90 PVC Washer
Gasket
Ø250
Bottom flange Attention :
Weld the bottom flange in position.
All welds should meet structures classification

society rules.

tightening torques.
Ø140 22
Ø250

Att. K - Installation d0 + NW125 CT Cofferdam M30
M30
Ø115
Detail A
Cover
Gasket
Stud Cable gland
154
Washer Nut M16

Top flange 22mm
Gasket
Gasket Bottom flange 22mm
Detail A
M8 Bolt washer
Stud Low nut M30
Nut M30
Washer
Ø80 - Ø120 PVC Washer
Gasket
Ø250

society rules.

tightening torques.
Ø140 22
Ø250

Att. L - Installation d0 + NW150 CT Cofferdam
Ø115
Detail A
Cover
Gasket
Stud Cable gland M32
158
Washer Nut M20

Top flange 20mm
Gasket
Bottom flange 20mm
Gasket
Detail A
M8 Bolt washer
Stud Low nut M30
Nut M30
Washer
Ø150 PVC Washer
Gasket
Ø285

society rules.

tightening torques.
168 22
285

Att. M - Tightening torques
CFT cable gland NPT ½” 70 Nm

CFT cable gland cup “ 25 Nm
M32 cable gland M32 x 1,5 100 Nm

M32 cable gland cup “ 70 Nm
Studs CT Cofferdam NW 125 M16 (8x) 80 Nm
Studs CT Cofferdam NW 125 M20 (8x) 100 Nm
U-clamp M10 20 Nm
U-clamp M12 35 Nm
Anode Ø
do stud M20 Nut 60 75 Nm

70 75 Nm
80 75 Nm
90 75 Nm
M30 Nut 80 100 Nm

90 100 Nm
100 120 Nm
120 140 Nm
150 180 Nm
M30 Low nut - 100 Nm


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INSTALLATION MANUAL

IMPRESSED CURRENT ANTI FOULING

Corrosion & Water-Control bv

1 Installation of the ICAF system 7

Corrosion & Water-Control bv Page 5

* This installation manual is for all the applications as mentioned

1.A ICAF anode description

Cu = Material of the anode:

70 = Diameter of the anode (Ø 70mm)

1200 = Length of the anode (1200mm)

d3 = Quantity of support rings

Corrosion & Water-Control bv Page 7

For the tightening torques we refer to Attachment M.

U-clamp Support ring

Corrosion & Water-Control bv Page 8

Sideview of boxcooler with ICAF

Corrosion & Water-Control bv Page 9

Water Balast Tank

Fig. 3 Inlet grid

Corrosion & Water-Control bv Page 10

Counter flange surfase

• The system is now ready for use.

Corrosion & Water-Control bv Page 11

Strainer top plate

The pitch of where the anodes must be mounted is calculated as follows :

Mounting pitch = Internal diameter of the basket x 0,5 (See Fig. 6)

Inlet Inner diam.

Corrosion & Water-Control bv Page 12

* When a CT cofferdam is used it is not necessary to shorten the

• Connect the anode cable to the M8 bolt on the anode stud.

• The system is now ready for use.

Corrosion & Water-Control bv Page 13

Inlet Inner diam.

Corrosion & Water-Control bv Page 14

Use treat sealant when

• Each individual anode requires one Cable Feed Through (CFT).

For the tightening torques we refer to Attachment M.

Corrosion & Water-Control bv Page 15

Cable feed through

Power cable Multicore cable Anode cable

Multicore cable Anode cable

Corrosion & Water-Control bv Page 16

A plugbox 4/1 means :

Corrosion & Water-Control bv can supply plugboxes with 1 to 10 inputs.

5 Connection – Plugbox to Digital Processing Unit

Corrosion & Water-Control bv Page 17

d0 Anode (CT Cofferdam)

Mounting bolt M20 or M30.

The CT Cofferdams are designed for mounting the D0 anode

Anode length - (mm)

Corrosion & Water-Control bv Page 18

Mounting bolt M20 or M30.

Anode length - (mm)

Corrosion & Water-Control bv Page 19

Anode length - (mm)

Corrosion & Water-Control bv Page 20

Anode length (mm)

Corrosion & Water-Control bv Page 21

Anode length - (mm)

Corrosion & Water-Control bv Page 22

Third anode support is

Cable Feed Through

The cathode plates and steel angle supports are