Schenker MODULAR 500 Installation, Use And Maintenance Manual Download

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COD: 500M380.D.2018

Installation, use and maintenance manual

Schenker Italia

Via Ferrante Imparato 501 - Condominio Genesis

80146 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 500

Digital 380 Vac

Summary of Contents for MODULAR 500

Page 1: ...chenker Italia Via Ferrante Imparato 501 Condominio Genesis 80146 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 500 Digital 380 Vac ...

Page 2: ...ODUCT 12 3 7 ADVANTAGES OF THE ENERGY RECOVERY SYSTEM 13 3 8 COMPOSITION OF THE MACHINE 14 3 8 1 PRE PUMP 14 3 8 2 PRE FILTRATION UNIT 15 3 8 3 WATERMAKER GROUP 16 3 8 4 ACCESSORIES 20 4 MOUNTING AND INSTALLATION 21 4 1 GENERAL CRITERIA 21 4 2 COMPONENTS MOUNTINGS 22 4 2 1 PRE PUMP PUMP 1 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 ...

Page 3: ... PERIODIC WASHING 43 5 5 5 AUTOMATIC FUNCTIONING WITH LEVEL CONTROLS OPTIONAL 43 5 5 6 RESET PROCEDURE 44 6 MAINTENANCE ROUTINE AND SPECIAL 46 6 1 CHECK FILTER CLEANLINESS 46 6 2 CHECK THE PLANT WORKING PRESSURE 48 6 3 CHECK FOR LEAKS 48 6 4 CHECK FOR MEMBRANES REPLACEMENT 48 6 5 SHUTDOWN PROCEDURE 48 6 5 1 NECESSARY EQUIPMENT 48 6 5 2 SHUTDOWN OPERATING PROCEDURE 50 6 6 ANTIFREEZE PROCEDURE WINTE...

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 symbol...

Page 5: ...LIA 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 equ...

Page 6: ...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 will...

Page 7: ...nd subsequent 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 ...

Page 8: ...ous materials 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 obse...

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 wooden box In the fol...

Page 10: ...d 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 500 Watermaker Pre pump with Tee fitting and electrovalve Active carbon filter with ball valve key filter Cartridge big blue filter group black key filter Remote panel with electric box 10 mt extension cable for remote panel Intall...

Page 11: ...s 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 above 40 C DOCUMENTS INCLUDED IN THE PACKAGING FIG...

Page 12: ... Vac 50 Hz three phase Average electric consumption 3 5 kWatt h average Nominal fresh water production 500 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 Features of the prod...

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: ...TERMAKER GROUP 3 8 1 Pre pump This pump has the duty of picking the sea water up and send it to the pump 2 through the pre filtering unit On the pump head there is a nut used to purge the air or introduce water in the inlet connection to facilitate the suction of the pump at the first start up On the pump inlet there is a T fitting where is connect the electrovalve for the automatic washing of the...

Page 15: ...re switch a 0 6 bar manometer and a plastic non return valve A white push button positioned on the top of the filter housings allows to purge out the air during the start up operations The Low pressure switch stops the watermaker if the water flow rate is too low avoiding cavitation of the main pump The pressure switch calibration is approximately 0 6 bar PRE FILTRATION UNIT FIG 3 7 Low pressure s...

Page 16: ...a ALL RIGHTS RESERVED 16 3 8 3 Watermaker group WATERMAKER GROUP FRONT VIEW FIG 3 8 Manometer Reverse osmosis membranes Flowmeter Depressurization valve WATERMAKER GROUP SIDE VIEW FIG 3 9 Energy recovery system SS Accumulator Multistage centrifugal pump High pressure switch 1 3 4 2 4 2 3 1 ...

Page 17: ...makes periodic cycling by a hydraulically controlled automatic valve The cycles are noticeable through a beat issued periodically by the watermaker unit The unit is based on cylinders and a central body containing the hydraulic valve necessary for the system functioning WATERMAKER GROUP ERS VIEW FIG 3 10 Manometers There are 2 manometers one is positioned downstream the filters It checks the inlet...

Page 18: ...cated on the right side of the top of the ERS Its function is to reset the unit in case of hydraulic block WATERMAKER GROUP POSITIONER VIEW FIG 3 11 Reset valve It is installed on the top of the ERS and it is recognizable by the little blue plastic lever The valve must be closed during normal functioning lever perpendicular to the valve Such valve has the function to allow the reset of the ERS in ...

Page 19: ...rding to the value measured by a salinty probe avoiding the salty water to be sent to the production tank The 2 cables of the probe must be connected on the clamps SAL of the electric box The 2 cables of the valve must be connected on the clamps DV of the electric box DIVERTING VALVE FIG 3 13 Electric box It contains all the electric and electronic devices necessary for the functioning of the syst...

Page 20: ...lter This filter is connected between the fresh water pressurized system of the vessel and the electro valve on the pump 1 On the filter inlet is positioned a manual valve that allows to replace the cartridge without depressurize the fresh water system of the vessel Non return Clapet valve It avoids the emptying of the inlet hoses It must be installed vertically It avoids also the leak of fresh wa...

Page 21: ...hat 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 suppo...

Page 22: ...he system wherever 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 wa...

Page 23: ...st always be under the water surface even when the vessel is well heeled 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 1 1 4 INSTALLATION NOTES Allow a minimum 1 1 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...

Page 24: ...resh water pump must be min 30 lit min Flushing must always be performed with the pressure water system ON Min flow rate must be 30 lit min at 2 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 appara...

Page 25: ...4 MOUNTING AND INSTALLATION COD 500M380 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 25 4 4 Hydraulic connections HYDRAULIC CONNECTION AND HOSES FIG 4 1 ...

Page 26: ...on Connection between seawater intake mesh filter non return valve pump 1 inlet Connection between water pressurized system active carbon filter electro valve Section of the hoses use a 1 internal diameter 30 mm PN 10 reinforced hose for the following connection Connections between pump 1 outlet 20 microns filter 5 microns filter pump 2 inlet WATERMAKER INTAKE AND DISCHARGE FIG 4 2 Watermaker inle...

Page 27: ... 5 micron cartridge filter Pump 2 inlet 1 fittings Rubber reinforced hose PN 10 minimum internal diameter 30 mm Low pressure connections max 3 bar Watermaker fresh water tank 3 8 fittings Small plastic blue hose 10x12 mm provided within the scope of supply INSTALLATION NOTE Watermaker waste water connection The connection has to be made using the holder located on top of the pressure amplifier ins...

Page 28: ...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 wired multiple cable of a 10mt s...

Page 29: ...r all the protection including a differential switch All the ground wires must be connected ATTENTION In case of current overload a 6 3 Amps motor protection is installed to safety the Inverter The general wires connection scheme between the external devices and the main electric box is the following Device wire number wire section min POWER SUPPLY 380vac T U1 V1 W1 4 mm2 PUMP 1 T U1 V1 W1 2 5 mm2...

Page 30: ...G AND INSTALLATION COD 500M380 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 30 4 5 3 Electric layout scheme three phase 380V AC ELECTRIC MAIN BOX SCHEME MODULAR 500 380V AC FIG 4 5 ...

Page 31: ...0 and 100 on the mother board These switches P1 and EV controls directly pump 1 and the electro valve The switches 50 and 100 controls pump 2 in the following way 100 normal operating condition 50 washing and start up They can be used to run manually the system in case of total fault of the electronic controls Besides be sure that the black Start button on the motor protection switch the is on pus...

Page 32: ...her with a list of led indicators and button functions LED INDICATORS ITEM DESCRIPTION 1 POWER LED Turns ON Green while the inverter is powered up 2 ALARM LED Turns ON Red when the inverter trips 3 Program LED Turns ON Green when the display shows changeable parameter Blinks when there is a mismatch in setting 4 RUN LED Turns ON Green when the inverter is driving the motor 5 Monitor LED Hz Turns O...

Page 33: ...ed for appropriate knowledge PARAMETER Description Value for M500 H003 Motor power kW 3 0 H004 N of pole 2 b012 Current Ampere 6 5 b091 Inverter control 00 A021 Washing frequency Hz 25 A022 Operating frequency Hz 50 A082 Input voltage V 380 F002 Time start sec 5 F003 Time stop sec 7 The parameters above must not be changed for any reason unless differently specified by Schenker 4 5 5 Electronic co...

Page 34: ... 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 rins...

Page 35: ...YSTEM BLOCKED not as consequence of a real hydraulic problem but just as consequence of the malfunctioning of the probe The bypass is used also during special operation like the shut down procedure washing with chemicals The bypass activation is automatically removed after one single production cycle Don t activate the by pass if not necessary AUTOMATIC START UP This function activates automatical...

Page 36: ...e disabled To activate the function select the days 6 to 10 exit from the menu pushing STOP and then push WASHING for 3 seconds The display will indicate the remaining day before the first rinsing The function is anyway disabled pushing STOP or after a normal production cycle LEVEL CONTROL OPTIONAL It is an optional function For activating the automatic start stop from floating switches select the...

Page 37: ...gh PRESSURE block of the machine occurred and then the pumps has been switched off as safety procedure In this case is suggested to perform a reset procedure checking again the functioning of the unit SYSTEM BLOCKED Push STOP to acknowledge the message This message means that a hydraulic block of the machine occurred and then the pumps has been switched off as safety procedure In this case is sugg...

Page 38: ...GE message is displayed For 1 minute the fresh water production is diverted to discharge When the measured value is 50 µS cm the message S is displayed instead of S OK After 60 seconds the unit goes into alarm state with the message CHECK SALINITY PROBE The system can be reset by pressing STOP When the measured value is 2000 µS cm for 15 seconds the message DIVERT TO DISCHARGE is displayed and the...

Page 39: ...ach other the connections to L1 and L3 and check again Motors rotation check Fig 5 2 5 3 Introduction by pass mode The by pass mode disables the low pressure and the cycling controls Then the watermaker can work but not in a safe condition and has to be directly and continuously monitored The bypass mode has to be activated only in the following situations 1 Chemical washing The by pass is necessa...

Page 40: ...ectly 3 Be sure the seawater inlet valve and salt water drain valve are opened If existing 4 Be sure the reset valve is closed lever orthogonal to the body valve and the positioner completely unscrewed 5 Be sure the fresh water pressurizing pump of the vessel is on 6 Be sure the valve on the active carbon filter is opened 7 Be sure the fresh water tank is full enough at least 200lt to perform wash...

Page 41: ...play shows the specific message and wait for the completion of the procedure 5 5 Normal operating procedure Please be sure to perform all the following checks before proceeding normal operating procedure 1 Be sure the reset valve is closed lever orthogonal to the body valve and the positioner completely unscrewed 2 Be sure the depressurization valve is closed ...

Page 42: ...the previous setting 2 Push the button START for more than 3 seconds The display will show the decreasing production time The system will stop when the selected time is reached and then perform the automatic washing if previously selected However the system can be stopped at any time by pushing STOP NOTE It could occur that the system doesn t stop immediately when stop button is pushed but it rath...

Page 43: ... 5 5 5 Automatic functioning with level controls optional To activate the automatic start stop from floating switches please enter in the menu and set Level Control to ON Then exit from the menu by pushing STOP 1 Push START for starting the watermaker functioning under the floating switches control Now the start stop is under the control of the floating switches Once the tank is full the watermake...

Page 44: ...ns that the working pressure goes up suddenly 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...

Page 45: ... BELONGS TO Schenker Italia ALL RIGHTS RESERVED 45 5 Unscrew the positioner knob up to the original position until when it is blocked back 6 Close the reset valve lever in vertical position 7 Restart the system 8 After some seconds close the depressurization valve ...

Page 46: ...lter housing 4 Active carbon filter follow the instructions given in the table below OPERATION FREQUENCY PROCEDURE Check and cleaning of the strainer not provided Every 5 days Visual inspection and washing Replacing of the 20 and 5 micron big blue cartridge filter It depends on the real working condition and the turbidity of the sea water In average conditions the replacement of the cartridge is r...

Page 47: ...Schenker Italia ALL RIGHTS RESERVED 47 Replace the big blue active carbon filter Once per year Unscrew the filter housing cup counter clockwise by using the specific key provided Purge air from the system periodically by opening for 2 3 minutes the depressurization valve Every 15 20 days ...

Page 48: ...ossible leaks due to accidental causes hose bursting hose clamp loosening equipment failure etc may occur even plentiful with the consequence of possible damages 6 4 Check for membranes replacement The reverse osmosis membranes have a 7 years average working life It is recommended therefore after 5 years of operation to verify the possible necessity of substitution and however to perform the subst...

Page 49: ...organic 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 NOTE Normally only SC1 is required but in case of strong smell it is recommended to use also the SC2 The sequence in this case will be SC2 first then a washing of the system Fi...

Page 50: ...50 6 5 2 Shutdown operating procedure ATTENTION Avoid inhaling product powders it is recommended to wear a protective mask 1 Prepare the solution carefully mixing the bottle of SC1 in about 30 liters of unchlorinated water 2 Connect the 3 hoses to the pre pump and watermaker as indicated above and dip them in the solution ...

Page 51: ...NT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 51 3 Check they are well dipped in the solution and don t inhale air 4 Open the depressurization valve turn counterclockwise 5 Start the watermaker with the by pass activated Hoses under the free water surface ...

Page 52: ...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 53: ...e propylene glycol with 35 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 v...

Page 54: ...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 Pump high pressure switch The main pump is equipped with a high pressure switch set at around 18 Bar The pressure switch can be calibrated with a screwdriver To calibrate the pressure switch pull out the plug remove t...

Page 55: ...R CARTRIDGE H 20 2018 FBB5L 20 MICRON BIG BLUE FILTER CARTRIDGE H 20 FBB20L ACTIVE CARBON FILTER CARTRIDGE 10 x10 CA10 7 2 Long term cruising For long term cruising it is advisable to have onboard a cruising kit three big blue 5 micron cartridge filter three big blue 20 micron cartridge filter one big blue active carbon filter one cleaning kit big and a signal pressure switch Other additional spar...

Page 57: ...re 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 MOD 500 HPH5 END CUP VESSEL 4 SINGLE CONNECTION EV4 3 4 END CUP VESSEL 4 DOUBLE CONNECTION EV4 3 4 2 C END CUPS 4 CONNECTION FITTING 500 CEV4 50 PRESSURE ACCUMULATOR 500 LIT SMP50 MANOMETERS 0 25 M25B EV4 3 4 2 EV4 3 4 2 CEV4 50 M25 ...

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