Schenker 60M12/24D Installation, Use And Maintenance Manual Download Page 1

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COD: 60M12/24.D.2018

Installation, use and maintenance manual

Model.: Modular 60

Matriculation number: 60M12/24D

Year of construction: 2000

Schenker Italia

Via Delle Repubbliche Marinare, 67

80147 Naples Italy

Tel. +39 081 5593505

Fax. +39 081 5597372

E-mail: [email protected]

www.schenkerwatermakers.com

THE PRESENT MANUAL BELONGS TO -

Schenker Italia

MODULAR 60

Digital 12/24 V dc

Summary of Contents for 60M12/24D

Page 1: ...mber 60M12 24D Year of construction 2000 Schenker Italia Via Delle Repubbliche Marinare 67 80147 Naples Italy Tel 39 081 5593505 Fax 39 081 5597372 E mail info schenker it www schenkerwatermakers com THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED MODULAR 60 Digital 12 24 V dc ...

Page 2: ...RES OF THE PRODUCT 12 3 7 ADVANTAGES OF THE ENERGY RECOVERY SYSTEM 13 3 8 COMPOSITION OF THE MACHINE 14 3 8 1 PUMP GROUP 14 3 8 2 WATERMAKER GROUP 15 3 8 3 ACCESSORIES 20 4 MOUNTING AND INSTALLATION 21 4 1 GENERAL CRITERIA 21 4 2 COMPONENTS MOUNTINGS 22 4 2 1 PUMP GROUP 22 4 2 2 WATERMAKER GROUP 22 4 2 3 ACCESSORIES 22 4 3 INSTALLATION 22 4 3 1 WATER INTAKES AND DISCHARGES 22 4 3 2 SEAWATER INTAKE...

Page 3: ...ILTER CLEANLINESS 42 6 2 CHECK THE PLANT WORKING PRESSURE 43 6 3 CHECK FOR LEAKS 43 6 4 CHECK FOR MEMBRANES REPLACEMENT 43 6 5 SHUTDOWN PROCEDURE 43 6 5 1 NECESSARY EQUIPMENT 44 6 5 2 SHUTDOWN OPERATING PROCEDURE 45 6 6 ANTIFREEZE PROCEDURE WINTERIZING PROCEDURE IN COLD CLIMATE UNDER 5 C 47 6 7 PERIODIC MAINTENANCE 48 6 7 1 MEMBRANE REPLACEMENT 48 6 8 ADJUSTMENTS 48 7 TROUBLESHOOTING 49 7 1 TROUBL...

Page 4: ... example chapter 1 we will have 1 Chapter title 1 1 Paragraph title 1 1 1 Subtitle 1 1 1 1 Further subtitles The numbering of the pages figures and tables is reset to each chapter therefore we will find the prefix indicating the chapter and the page number figure or table in progressive that starts from number 1 at the beginning of each chapter 1 2 Description of the pictograms The following symbo...

Page 5: ...TALIA The descriptions and illustrations provided in this publication are not binding SCHENKER ITALIA reserves the right to make any modifications it deems appropriate SCHENKER ITALIA THIS MANUAL IS PROPERTY OF SCHENKER ITALIA ANY REPRODUCTION EVEN PARTIAL IS PROHIBITED This manual was drafted according to the requirements of the 2006 42 EC Machinery Directive 2 2 Safety warnings Wear protective e...

Page 6: ...e pair of faulty parts The expense for the disconnecting and reinstalling on the vessel and transport of the equipment from or to our Service Point or our factory will be at the customers own expense The under guarantee delivered parts transport will be at customer s own risk In case of repairs under guarantee performed by our technicians on the customer vessel the faulty parts replacement cost wi...

Page 7: ...ent amendments and additions 93 68 CEE implemented by the Law of 18 October 1997 n 791 Electromagnetic Compatibility Directive 89 336 EEC and subsequent amendments and additions 93 31 CEE implemented with D L December 4 1992 n 476 Standards UNI EN 292 1 and 292 2 safety of machinery 2 5 2 Respect for the environment requirements for removal and disposal ATTENTION Removal and disposal of materials ...

Page 8: ... must be segregated according to the regulations of the country in which the machine has been removed The machine does not contain dangerous components or substances that require special removal procedures ATTENTION Different legislations are in force in the different countries therefore the prescriptions imposed by the laws and by the agencies designated by the Countries must be observed ...

Page 9: ...e and following carefully the instructions on the present use and maintenance manual attachment points for loading devices etc Make sure that the lifting equipment used is in good condition and correctly maintained Do not stand or pass under the groups to be moved during lifting or transport operation 3 1 Transport and material handling The watermaker unit is transported in a cardboard box In the ...

Page 10: ...ratures could led to a freezing of the fluid inside the system with the consequence of a permanent damage of the system 3 3 Packaging 3 3 1 Packaging contents PACKAGING FIG 3 2 Modular 60 Watermaker Pump group Active carbon filter with electrovalve White filter key Mesh filter Non return valve with Tee fitting Remote panel with electric box 10 mt extension cable for remote panel Intallation kit Sm...

Page 11: ...tions ATTENTION Lift the system only using the aluminium structure and not trough the Inox SS fittings Read carefully the use and maintenance manual before installing the system Use only recommended material for the installation especially hoses fittings and seals in accordance with the present manual Do not store the unit under temperature of 5 C and 40 C DOCUMENTS INCLUDED IN THE PACKAGING FIG 3...

Page 12: ...on Average electric consumption 250 Watt h average Peak electric consumption 500 Watt Nominal fresh water production 60 Lit h 20 seawater 25 C salinity 35 000 ppm Fresh water quality Under 500 ppm TDS average CEE conformity In compliance with directives 89 392 CEE sect 1 general safety machines requirements 89 336 CEE electromagnetic compatibility 73 23 CEE electric safety requirements 3 6 Feature...

Page 13: ...ears We invite you to read carefully this manual and to keep it for a quick reference Functioning principles The Schenker watermakers as alternative to the high pressure pumps of traditional systems utilizes the ENERGY RECOVERY SYSTEM patented device which amplifies the pressure of common low pressure pumps and recoup all the hydraulic energy back from the membranes allowing a high energy efficien...

Page 14: ...UP 2 WATERMAKER GROUP 3 8 1 Pump group This pump has the duty of picking the sea water up and send it to the watermaker group through the pre filter The pump group is composed of the following parts 5 micron cartridge filter Diaphragm pump High pressure switch Pump box Accumulator PUMP GROUP AND FILTER 12 24 V DC FIG 3 6 5 micron cartridge filter Pump box with relays Diaphragm pump High pressure s...

Page 15: ...nker Italia ALL RIGHTS RESERVED 15 3 8 2 Watermaker group WATERMAKER GROUP FIG 3 7 Manometer Reverse osmosis membranes Flowmeter Electric connection box WATERMAKER GROUP LATERAL VIEW FIG 3 8 Reset valve Remote panel IN Depressurization valve Positioner knob Fresh water discharge 7 ...

Page 16: ...KER GROUP BACK VIEW FIG 3 9 Computer box Signal pressure switch CONCENTRATE OUTLET OUT AND SEAWATER INLET IN FIG 3 10 The watermaker group is composed of the following parts Reverse osmosis membranes Energy Recovery System Manometer Flowmeter Depressurization valve Positioner Reset valve Probe pressure switch Electric box ...

Page 17: ...recognizable by a blue lever and it is located on the right fitting of the third membrane Its function is to depressurize the system and to allow the bleeding of air The valve must be closed during normal working conditions vertical position and it is opened during the air bleeding operations horizontal position Positioner It is a stainless steel threaded arm with a black knob located on the right...

Page 18: ...NUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 18 COMPUTER BOX WITH SWITCHES FIG 3 11 Salinity probe optional It checks the conductivity of the fresh water the remote panel gives ad advice in case the fresh water quality is not good SALINITY PROBE FIG 3 12 ...

Page 19: ...ON COD 60M12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 19 The 2 cables of the probe must be connected on the PCB of the electric box clamps Cond and SALINITY PROBE CONNECTIONS FIG 3 13 ...

Page 20: ...ed system of the vessel and the electro valve on the filter holder On the filter inlet is positioned a manual valve that allows to replace the cartridge without depressurize the fresh water system of the vessel Electrovalve It has the function of switching from seawater intake to fresh water tank when washing the watermaker Non return valve It avoids the emptying of the inlet hoses It must be inst...

Page 21: ... way that no air could be aspirated The non return valve has to be installed under the seawater level and as close as possible to the through hull fitting in vertical position The pump must be installed as low as possible respect to the seawater level and as close as possible to the seawater intake through hull fitting The watermaker unit must be horizontally positioned and arranged on an adequate...

Page 22: ...erever any possible leak may cause damages to the vessel or jeopardize its safety since possible leaks due to accidental causes hose bursting hose clamp loosening equipment failure etc may cause water losses The hydraulic intake and outlet connections are positioned on the left of the unit Therefore it is necessary to foresee a minimum distance of 20 cm to allow the hoses laying The watermaker uni...

Page 23: ...led over Must be far from WC discharge CAUTION Do not use the pre existing water inlet of the cooling system dedicated to the motor Size 3 4 INSTALLATION NOTES Allow a minimum 3 4 on off ball valve on the water intake The hose connections especially if under the seawater level must be secured with double hose clamps An easily inspected mesh type filter will be required close to the water intake Th...

Page 24: ...fresh water pump must be min 12 lit min Flushing must always be performed with the pressure water system ON Min flow rate must be 12 lit min at 1 bar 4 3 4 Brine discharge Salt water discharge The salt water drain shall be minimum size and it has to be preferably above the seawater level Minimum size Pre existing salt water discharge alternatively It is possible to use offtakes from existing appar...

Page 25: ...let All the hydraulic connections to exception of the fresh water production have to be realized with a 16 mm int diam hose and a holder The hydraulic section that is continuously under consistent pressure is the pump outlet 5 m filter watermaker inlet connections For this section is necessary to use a good quality PN 10 min reinforced hose An inadequate hose could burst jeopardizing seriously the...

Page 26: ... connections max 10 bar Connections fresh water pressurized system carbon filter backflow valve outlet pump inlet Connections pump outlet 5 microns filter watermaker inlet Rubber reinforcedhose PN 10 minimum internal diameter 16 mm Low pressure connections max 3 bar Watermaker fresh water tank fittings Small plastic blue hose 6x8mm provided within the scope of supply PUMP CONNECTIONS Connect the i...

Page 27: ...ain outlet on the vessel is positioned below the watermaker unit in order to guarantee a water head PRODUCTION FRESH WATER CONNECTION The connection has to be made using the small hose supplied with the equipment The connection has to be made between the polyethylene hose that comes out the watermaker unit on the right and the upper side of the tank on a outlet if available It is possible in case ...

Page 28: ...height 116 mm It can be fixed on any internal vessel panel provided that the area behind is free of humidity and condensation and there is enough depth to house the rear part of the panel approx 8 cm The cut to be performed on the vessel covering panel to encase the remote control panel has the following dimensions width 115 mm height 97 mm The remote control panel can be connected through the pre...

Page 29: ...l wires connection scheme between the external devices and the main electric box is the following Voltage Automatic Cable lenght switch up to 3 mts 3 7 mt 7 10 mt Volt Ampere mm2 AVG mm2 AVG mm2 AVG 12 32 10 7 16 5 25 3 24 16 4 11 4 11 6 9 Electric cables and switches selection table The connection general diagram is the following Clamp Position connect to cable section Pump box negative battery s...

Page 30: ...4 MOUNTING AND INSTALLATION COD 60M12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 30 WIRING LOGIC SCHEME12 24 VDC fig 4 4 Automatic circuit breaker ...

Page 31: ...NTING AND INSTALLATION COD 60M12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 31 4 5 3 Electric layout scheme 12 24V DC ELECTRIC MAIN BOX SCHEME MODULAR 60 12 24V DC FIG 4 5 ...

Page 32: ...d to stop the system The system once pushed STOP usually doesn t stop suddenly It awaits the correct positioning of the internal valve 2 3 seconds and then stops automatically If the automatic washing is activated washing light on the system once pushed STOP will perform the automatic washing 1 min before stops The push button STOP is used as well to exit from the menu function WASHING Used to rin...

Page 33: ...se the production will be about 30 lit h and the electric consumption will be about 100 watt P1 P2 the system works with both pumps In this case the production will be about 60 lit h and the electric consumption will be about 240 watt WORKING TIME timer It allows to select the working time of the watermaker 1 6 hours The timer is activated if the START button is pushed for more than 3 seconds only...

Page 34: ...is function allows a periodic automatic rinsing every 6 up to 10 days with fresh water It can be used before long inactivity periods The single washing operation will last about 1 minute The consumed fresh water for every washing is about 12 liters Therefore it is suggested to evaluate if the fresh water reservoir is enough for the programmed cycles Selecting NO the function will be disabled To ac...

Page 35: ...sabled CHANGE PUMP FILTERS This is a blinking message that must be acknowledged pressing the key STOP This message suggests to replace the filter of the pump group Display indications during production During the normal functioning of the watermaker the display gives the following indications Pump 1 OFF ON Pump 2 OFF ON Messages related to the salinity meter optional S wait This means that the sal...

Page 36: ...electronic controls of the watermaker and automatic sensors are disabled 5 3 First start up procedure The first start up procedure is necessary to start a new plant for the first time or to restart it after having performed the laying up procedure The purpose of the start up procedure is to essentially purge the air contained in the system 5 3 1 Preliminary checks before proceeding with the start ...

Page 37: ... air from the system 3 Activate the start up procedure through the function of the MENU select the specific function in the menu mode exit from menu mode pushing STOP and start the procedure pushing START 4 Close the depressurization valve when the display shows the specific message and wait for the completion of the procedure The procedure lasts about 3 minutes and it can be stopped at any time p...

Page 38: ...will show the increasing production time 2 Select WASHING pushing shortly the related push button 3 Push the Stop button to stop the unit after the working cycle The system will start the washing procedure and then will stop automatically after around 1 minute The fresh water consumed for the automatic washing is about 12 lt 5 4 2 Normal operating procedure with timer and final flushing 1 Select t...

Page 39: ...en recognized Before pressing START to run the watermaker again be sure to individuate the cause of the anomaly and solve the issue 5 4 3 Single washing operation To perform a single washing operation which flushes the system with fresh water for around 10 minutes in order to avoid membranes to remain full of salt for long time it is necessary to Select the pump mode P1 P2 Push the WASHING button ...

Page 40: ... After approx 20 sec the computer recognizes the problem turn off the pumps and the SYSTEM BLOCKED message starts flashing In this case is necessary to reset the valve with the following simple procedure 1 Turn off the system 2 Open the reset valve lever in horizontal position 3 Open the depressurization valve 4 Screw the positioner know clockwise until it can be moved no further Normally 10 turns...

Page 41: ...SE COD 60M12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 41 6 Close the reset valve lever in vertical position 7 Restart the system 8 After some seconds close the depressurization valve ...

Page 42: ...Y PROCEDURE Check and cleaning of the strainer Every 5 days Visual inspection and washing Replacing of the 5 micron cartridge filters It depends on the real working condition and the turbidity of the sea water In average conditions the replacement of the cartridge is recommended every 100 120 working hours Once replaced the filters it is necessary to purge the air from the system opening for 2 3 m...

Page 43: ...o perform the shutdown procedure if the membranes result dirty If cleaning also results insufficient it could be necessary to perform an alkaline washing using the chemical product SCHENKER CLEANING 2 SC2 It is recommended to contact a Schenker certified service center 6 3 Check for leaks It is necessary to perform this verification at every plant start up and however often since possible leaks du...

Page 44: ...or the shutdown procedure are the following 1 SCHENKER CLANING 1 SC1 Acid product to remove the inorganic components and preserve the watermaker during winter break 2 SCHENKER CLEANING 2 SC2 Alkaline product to remove the organic components mould and bacteria when already deposited in this case the system becomes stinky Whether the system needs acid or alkaline cleaning will depend on the type of ...

Page 45: ...e 1 Prepare the solution carefully mixing the bottle of SC1 in about 15 liters of unchlorinated water 2 Connect the 2 hoses to the pump group and watermaker as indicated above and dip them in the solution 3 Check they are well dipped in the solution and don t inhale air 4 Open the depressurization valve turn counterclockwise Hoses under the free water surface ...

Page 46: ...ave the unit running for approx 20 minutes checking that the hoses are properly positioned in the recipient so that to avoid inhaling air 7 Shut the plant off and connect the original hoses CAUTION It is necessary to perform the first start up procedure when restarting the plant after a shutdown procedure in order to purge the air and drain out board the chemicals in the systems ...

Page 47: ...the propylene glycol with 15 liters of unchlorinated water by following the concentration suggested above 2 Disconnect the drain hose and the pumps suction hose 3 Connect two hose pieces to the drain and to the pump suction 4 Insert the end side of the hoses into the bucket verifying that the hoses have been properly dipped in the solution and that they don t inhale air 5 Open the depressurization...

Page 48: ...tch The main pump is equipped with a high pressure switch set at around 9 5 Bar The pressure switch can be calibrated with a screwdriver To calibrate the pressure switch pull out the plug remove the security nut and engage the small internal screw with a small screw driver Turning clockwise the calibration of the pressure switch increases while turning anticlockwise the calibration decreases Accum...

Page 49: ...ice During operation the pump temporarily switches off giving rise to a start and stop phenomenon Pump pressure switch not correctly set Dirty filters or membranes Set pump pressure switch see pag 47 Clean or replace Metal noise of the pump Pump cavitation Check the causes of the absence of water flow at the pre pump inlet Low production normal or low pressure Low battery Air within the system Los...

Page 50: ... indicated in the manual and restart the system If still the system does not start it goes on the block after about 20 seconds activate the system manually by inserting the by pass If the system works correctly normal pressure normal output it could be just a probe issue In this case disconnect the 2 cables of the pressure switch from the PCB of the controller then connect the 2 cables to a meter ...

Page 51: ...2 CKBIG 5 MICRON CARTRIDGE 9 F5 ACTIVE CARBON FILTER CARTRIDGE CA 8 2 Long term cruising For long term cruising it is advisable to have onboard a cruising kit three 5 micron cartridge filter one active carbon filter one cleaning kit big and a signal pressure switch Other additional spares are listed below with their codes Spare part name Code SC1 WASHING PRODUCT SC1 SC2 WASHING PRODUCT SC2 CRUISIN...

Page 53: ...come necessary in order to ensure the normal operating condition of the watermaker other common spares are listed below with relative images and codes Spare part name Code COUPLE HIGH PRESSURE HOSE SM 30 60 80 HPH END CUP VESSEL 2 5 SINGLE CONNECTION EV2 5 END CUP VESSEL 2 5 DOUBLE CONNECTION EV2 5 2 C END CUPS 2 5 CONNECTION FITTING CEV2 5 MANOMETERS 0 16 M16B CEV2 5 4 EV2 5 EV2 5 2 M16B HPH ...

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