Schenker ZEN 150 Installation, Use And Maintenance Manual Download Page 1

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COD: 150Z230.B.2021

Installation, use and maintenance manual

ZEN 150

230 V ac

Summary of Contents for ZEN 150

Page 1: ...COD 150Z230 B 2021 Installation use and maintenance manual ZEN 150 230 V ac ...

Page 2: ...FEATURES OF THE PRODUCT 11 3 7 ADVANTAGES OF THE ENERGY RECOVERY SYSTEM 12 3 8 COMPOSITION OF THE MACHINE 13 3 8 1 PUMP GROUP 13 3 8 2 WATERMAKER GROUP 14 3 8 3 ACCESSORIES 16 4 MOUNTING AND INSTALLATION 17 4 1 GENERAL CRITERIA 17 4 2 COMPONENTS MOUNTINGS 18 4 2 1 PUMP GROUP 18 4 2 2 WATERMAKER GROUP 18 4 2 3 ACCESSORIES 21 4 3 INSTALLATION 21 4 3 1 WATER INTAKE AND DISCHARGE 21 4 3 2 SEAWATER INT...

Page 3: ...UTINE AND SPECIAL 35 6 1 CHECK FILTER CLEANLINESS 35 6 2 CHECK THE PLANT WORKING PRESSURE 36 6 3 CHECK FOR LEAKS 36 6 4 CHECK FOR MEMBRANES REPLACEMENT 36 6 5 SHUTDOWN PROCEDURE 36 6 5 1 NECESSARY EQUIPMENT 37 6 5 2 SHUTDOWN OPERATING PROCEDURE 38 6 6 ANTIFREEZE PROCEDURE WINTERIZING PROCEDURE IN COLD CLIMATE UNDER 5 C 40 6 7 PERIODIC MAINTENANCE 41 6 7 1 MEMBRANE REPLACEMENT 41 6 8 ADJUSTMENTS 41...

Page 4: ...xample 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 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 symbols will ...

Page 5: ...hout the written permission of SCHENKER ITALIA 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 Direct...

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 s vessel the faulty parts replacement cost w...

Page 7: ...8 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 as result of the decommissioning of the machine must be performed ...

Page 8: ...rious 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 ob...

Page 9: ...re 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: ...es 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 picture for purely information FIG 3 2 ZEN 150 Watermaker Pump group Active carbon filter with electrovalve 5 microns filter with accumulator Mesh filter Non return valve with Tee fitting Remote panel 10 mt extension cable for remote pa...

Page 11: ...ic scheme warnings and instructions ATTENTION 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 manual Do not store the unit under temperature below 5 C and above 45 C DOCUMENTS INCLUDED IN THE PACKAGING picture for purely information FIG 3 3 3 5 Technical data WAT...

Page 12: ...n 1 Active carbon filter 2 32 x 9 Motor power supply 230 V AC single phase 100S230 version Computer power supply 12 24 VDC 15 Average electric consumption 600 Watth average Nominal fresh water production 150 Lit h 20 seawater 25 C salinity 35 000 ppm CEE conformity In compliance with directives 89 392 CEE sect 1 general safety machines requirements 89 336 CEE electromagnetic compatibility 73 23 CE...

Page 13: ...years We invite you to read carefully this manual and to keep it for a quick reference Functioning principles The Schenker watermakers as an 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 effi...

Page 14: ...micron filter accumulator Pump head motor Pressure transducer Pump box Pressure transducer It Is hydraulically connected to the pump group It stops the system if the pump pressure exceeds 14 bar or if it doesn t reach 1 3 bar Pump box Plastic Box with all the electric connections for the power supply of motor motherboard pressure switches remote panel and electrovalve Accumulator This is a polypro...

Page 15: ... ALL RIGHTS RESERVED 14 3 8 2 Watermaker group WATERMAKER GROUP SIDE VIEW W O COVER FIG 3 7 Watermaker outlet discharge Watermaker inlet Reverse osmosis membranes Fresh water production WATERMAKER GROUP FRONT VIEW W O COVER FIG 3 8 Reset valve Manometer Depressurization valve Positioner knob ...

Page 16: ...er unit The unit is based on cylinders and a central body containing the hydraulic valve necessary for the system to function Manometer Located on the right side of the watermaker it measures the working pressure of the watermaker Depressurization valve It is used for the air bleeding of the unit It is located on the top of the watermaker Its function is to depressurize the system and to allow the...

Page 17: ...e boat and the electro valve on the filter holder On the filter inlet is positioned a manual valve that allows replacement of the cartridge without depressurizing 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 stops water flowing out of the inlet hose It must be installed ve...

Page 18: ...f The non return valve has to be installed under seawater level and as close as possible to the through hull fitting in vertical position The pump must be installed as low as possible in respect of the waterline and as close as possible to the seawater intake through hull fitting No more that 2m away unless a positive feed is achieved by locating the pump below the waterline The watermaker unit mu...

Page 19: ...ts safety The pump must be installed on a base sufficiently horizontal suitable to sustain the weight of the group The pump is normally fixed on the support structure by passing bolts 4 2 2 Watermaker group Install the watermaker above the pump The max permitted room temperature must not exceed 40 C It can be placed either horizontally or vertically The watermaker must lie completely on a flat sur...

Page 20: ...OD 150Z230 B 2021 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 19 MOUNTING PROCEDURE FIG 4 2 POSSIBLE CONFIGURATIONS FIG 4 3 For a complete installation antivibration rubber stickers are provided ok ok NO NO ...

Page 21: ...NTION Please follow the instruction to install the unit an incorrect mounting could damage the lateral manifolds of the watermaker If the unit is installed horizontally it is recommended connect the manometer horizontally as well in order to be visible This can be done making use of the fittings provided HORIZONTAL FIXING FIG 4 5 3 8 Nipple 3 8 male to 1 8 female reducer 3 8 90 Degree Elbow Manome...

Page 22: ... attached electrovalve has to be placed next to the pump group if possible vertically and easily accessible 4 3 Installation 4 3 1 Water intake and discharge For a correct installation of the watermaker it is necessary to arrange the following water intake and discharge out of the board Seawater intake Fresh water intake for washing Brine discharge 4 3 2 Seawater intake Seacock with through hull f...

Page 23: ...ily inspected mesh type filter will be required close to the water intake The filter has to be of 50 Mesh It is possible to use filters from existing outlets The seawater intake must be at least 3 4 size INSTALLATION NOTES The strainer has to be connected close to the through hull and must be easily accessible for inspection 4 3 3 Fresh water connection for flushing Fresh water connection for flus...

Page 24: ...T MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 23 4 4 Hydraulic connections HYDRAULIC CONNECTION AND PIPES FIG 4 7 Plumb to pressure side of boat fresh water system Brine discharge Armorvin type hose int dia 16 mm Reinforced hose PN16 min int dia 20 mm ...

Page 25: ...uate hose could burst seriously jeopardizing the safety of the vessel The hydraulic connections are Low pressure connections max 3 bar Connection between seawater intake mesh filter non return valve inlet pump group Armorvin reinforced pipe PN 6 with 20mm internal diameter Connection between the discharge of the watermaker through hull discharge fittings of the vessel Armorvin reinforced pipe PN6 ...

Page 26: ...f the holder located on the right side of the watermaker marked IN WATERMAKER OUTLET Discharge outboard Make use for this connection of the holder located on right of the unit marked OUT Create a Swan neck upward when the drain 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 sm...

Page 27: ...mm height 66 mm It can be fixed on any internal vessel panel provided that the area behind is free of humidity and condense 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 80 mm height 50 mm The remote control panel can be connected through the pre wi...

Page 28: ...ill be powered 12 24V directly from the service batteries or through a 230 12 24 charger The connection general diagram is the following Clamp Position connect to cable section T Pump box 230 V power generator ground 2 5 mm2 min F Pump box 230 V power generator phase 2 5 mm2 min N Pump box 230 V power generator neuter 2 5 mm2 min N1 Pump box Pump 2 5 mm2 F1 Pump box Pump 2 5 mm2 EV Computer box El...

Page 29: ...lia ALL RIGHTS RESERVED 28 PUMP BOX 230VAC 12 24 VDC FIG 4 10 IN RED CONNECTION TO BE MADE DURING INSTALLATION Electrovalve EV Connection to the pump Pressure transducer Battery negative Connection to the remote panel Battery positive Power supply EV manual microswitch Pump manual microswitch ...

Page 30: ...ssure the pressure drops under the threshold value during the functioning the system goes on alert and the pushing buttons flash 3 times quickly Overpressure the pressure raises over the threshold value during the functioning the system goes immediately on alert and the pushing buttons flash 4 times quickly Low battery power supply is not sufficient the system goes immediately on alert and the pus...

Page 31: ...valve and salt water drain valve if existing are open 4 Check the reset valve is closed lever orthogonal to the body valve and the positioner completely unscrewed 5 Check the fresh water pressurizing pump of the boat is on 6 Check the grey valve on the active carbon filter is open 5 2 2 Start up 1 Open the depressurization valve unscrew the valve 2 Push Flushing for 5 seconds The panel emits 2 bee...

Page 32: ... in order to flush the unit before stopping it Then the unit will stop after about 1 minute After completed the procedure the system is ready to start normally 5 3 Normal operating procedure Preliminary checks 1 Reset valve closed lever orthogonal to the body valve and the positioner completely unscrewed 2 Depressurization valve closed and grey valve on the active carbon filter open 5 3 1 Normal o...

Page 33: ... 1 minute 5 3 3 Working cycle with timer 1 Keep ON OFF pressed for a while then you will hear 1 2 3 beeps Once released ON OFF the watermaker will work for 1 2 3 hours then will flush and will stop 2 The unit can be stopped at any time by pushing the ON OFF button without final flushing or the FLUSHING button with final flushing 5 3 4 Long flushing procedure 1 Push FLUSHING A 3 minute flushing pro...

Page 34: ...igh pressure without cycling After few seconds the computer recognizes the problem and turns off the pump In this case the system has to be manually reset This event besides being very unusual does not damage the system but it is necessary to reset the valve with the following simple procedure 1 Open the reset valve lever in horizontal position 2 Open slightly the depressurization valve 3 Screw th...

Page 35: ...O Schenker Italia ALL RIGHTS RESERVED 34 4 Unscrew the positioner knob counterclockwise back to its original position until it can be turned no more 5 Close the reset valve lever in vertical position 6 Restart the system 7 After some seconds close the depressurization valve ...

Page 36: ...ean 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 minutes the depressurization va...

Page 37: ...rm a cleaning with the chemical SC1 If the cleaning with SC1 is not enough to reduce the pressure could be necessary an alkaline washing with the cleaning SC2 6 3 Check for leaks It is necessary to perform this verification at every plant start up and frequently as possible leaks due to accidental causes hose bursting hose clamp loosening equipment failure etc may occur with the consequence of the...

Page 38: ... following 1 SCHENKER CLEANING 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 and or the water produce a bad eggs smell Allow a period of 20 mins for both acid alkaline cleaning It is important that the ...

Page 39: ... procedure 1 Prepare the solution carefully mixing the bottle of SC1 or SC2 in about 15 litres of unchlorinated water 2 Connect the 3 hoses to the pump and watermaker as indicated above and dip them in the solution 3 Check they are well submerged in the solution and don t suck air 4 Open the depressurization valve Pipes under the free water surface ...

Page 40: ...he unit running for approx 20 minutes checking that the hoses are properly positioned in the recipient so that to avoid inhaling air 7 Manually stop the unit through the microswitches inside the pump box switch up and connect the original hose 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...

Page 41: ...must be about 15 litres The procedure is similar to that used for chemical washing with SC1 and SC2 products 1 Prepare the solution carefully mixing the propylene glycol with 15 litres 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 th...

Page 42: ... decrease and or the working pressure increases If chemical washings don t produce significant improvements it is recommended to replace the membranes 6 8 Adjustments Accumulator It is a polypropylene reservoir of air that has the function of damping the pressure oscillations during the commutations of the watermaker The accumulator is factory loaded at a pressure of about 6 bar The charge level m...

Page 43: ... reset procedure Replace filters During operation the pump temporarily switches off giving rise to a start and stop phenomenon Dirty filters or membranes Clean or replace High pressure variations during commutation 0 4 Bar Low accumulator pressure low Inflate at a pressure of 6 Bar Low production normal or low pressure Low battery Air within the system Check battery charge Purge air opening for a ...

Page 44: ...WASHING PRODUCT SC1 SC2 WASHING PRODUCT SC2 CLEANING KIT SC1 SC2 CK 5 MICRON CARTRIDGE 5 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 x 5 microns cartridge filter one active carbon filter one cleaning kit Other additional spare parts are listed below with their codes Spare part name Code SC1 WASHING PRODUCT ...

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