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COD: 60M12/24.D.2018
Installation, use and maintenance manual
MODULAR 60
Digital 12/24 V dc
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: info@schenker.it
www.schenkerwatermakers.com
Schenker Italia
THE PRESENT MANUAL BELONGS TO -
- ALL RIGHTS RESERVED
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Summary of Contents for Schenker Modular 60
- Page 1 COD: 60M12/24.D.2018 Installation, use and maintenance manual MODULAR 60 Digital 12/24 V dc 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: info@schenker.it...
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Page 2: Table Of Contents
........................36 5.3 F IRST START UP PROCEDURE ......................... 36 5.3.1 P RELIMINARY CHECKS BEFORE PROCEEDING WITH THE START UP PROCEDURE ........36 5.3.2 S TART ............................... 37 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... - Page 3 8. SUGGESTED SPARE PARTS ......................... 51 8.1 S HORT TERM CRUISING ........................... 51 8.2 L ONG TERM CRUISING ............................. 51 8.3 ERS SPARE PARTS ............................52 8.4 A DDITIONAL SPARES ............................53 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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Page 4: Layout Of Manual
This symbol indicates accident prevention regulations for the operator and / or for any exposed persons. CAUTION: This symbol indicates that there is the possibility of damaging the system and / or its components. NOTE: This symbol indicates useful information. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 5: General Warnings And Information To The Recipient
All rights of reproduction of this manual are reserved to SCHENKER ITALIA. This manual cannot be transferred to third parties without the written authorization of SCHENKER ITALIA. -
Page 6: Warranty
In case of repairs under guarantee performed by our technicians on the customer vessel, the faulty parts replacement cost will be at Schenker's expense, while manpower and travel expenses will be charged to the customer. The guarantee does not include faults caused by negligence in operating, maintenance and installation of the device (if not carried out by an authorised Schenker Service point). -
Page 7: Identification Of The Unit
2.4 Identification of the unit All the watermakers manufactured by Schenker Italia can be identified by a serial number printed on a label which is pasted upon the aluminium frame near the manometer. The same serial number is also recorded on the central black block of the energy recovery system (ERS). - Page 8 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. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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Page 9: Product Presentation
The watermaker unit is transported in a cardboard box. In the following table dimension and weight are indicated. MATERIALS HANDLING fig. 3-1 Model L cm. W cm. H cm. Weight Kg. Modular 60 Packaging dimensions and weight tab.3-1 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 10: Stock
40°C. Very cold temperatures 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... -
Page 11: Attached Documents
• Do not store the unit under temperature of 5°C and 40°C. DOCUMENTS INCLUDED IN THE PACKAGING FIG. 3-3 3.5 Technical data WATERMAKER GROUP WATERMAKER DIMENSIONS FIG. 3-4 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 12: Features Of The Product
3.6 Features of the product The water produced by a Schenker plant, produced from clean seawater has a purity of between 350 & 450 parts per million Totally dissolved solids (TDS/PPM), but the potability may not be guaranteed as bacterium may be present in the watermaker, caused by non-observance of shutdown and cleaning procedures. -
Page 13: Advantages Of The Energy Recovery System
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 efficiency. -
Page 14: Composition Of The Machine
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 switch Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 15: 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 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... - Page 16 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 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
- Page 17 In normal condition they have to be switched off. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
- Page 18 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 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
- Page 19 3 – PRODUCT PRESENTATION COD. 60M12/24.D.2018 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 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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Page 20: Accessories
Mesh filter: The machine is equipped with a strainer to protect the pump from macro sediments. It is placed between the seacock and pre-pump. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 21: Mounting And Installation
Once individuate the correct installation solution, it is recommended to first make a schematic draft of the hydraulic and electric connection, and attach them to the present manual for future needs as first reference. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 22: Components Mountings
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. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 23: Seawater Intake
• No air is collected in the filter INSTALLATION NOTES The filter has to be connected next to the through-hull fittings, and must be easily accessible for inspection. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 24: Fresh Water Intake For Washing
It is possible to use offtakes from existing water discharge apparatuses, provided that: • (alternatively) It is not the engine cooling water drain or apparatuses that drain out water with elevated pressure. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 25: Hydraulic Connections
– 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 safety of the vessel. Schenker Italia THE PRESENT MANUAL BELONGS TO -... - Page 26 The pump has to be placed as close as possible to the seawater intake and as low as possible respect to the seawater level; furthermore, it is recommended to avoid long and convoluted path of the connection hoses. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
- Page 27 Another option is to Tee into the tank air vent hose. This is only possible if the breather hose section is more than 16 mm. dia. There are no particular limits on the connection length. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
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Page 28: Electric Connections
It is possible to adapt the panel to a longer distance by adding a one more cable in series to the one provided. REMOTE CONTROL PANEL FIG. 4-3 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 29: Electric Connections: Wires (Modular 60 12/24V Dc)
60M12/24.D.2018 4.5.2 Electric connections: wires (Modular 60 12/24V DC) The electric connectors are positioned inside the small electric box connected to the computer box. The power supply, coming from the service batteries, needs to be connected to the terminals – and + . The connection to the vessel panel needs to be performed downstream the voltmeter and the ammeter of the vessel panelboard. - Page 30 4 – MOUNTING AND INSTALLATION COD. 60M12/24.D.2018 Automatic circuit breaker WIRING LOGIC SCHEME12-24 VDC fig. 4-4 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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Page 31: Electric Layout Scheme (12/24V Dc)
4 – MOUNTING AND INSTALLATION COD. 60M12/24.D.2018 4.5.3 Electric layout scheme (12/24V DC) ELECTRIC MAIN BOX SCHEME MODULAR 60 12/24V DC FIG. 4-5 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 32: Functioning And Use
On his turn the START push button allows to scroll the different options of the single menu. The system recognizes the current value without any further command. The STOP push button allows to exit from the MENU function. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... - Page 33 “ SYSTEM BLOCKED”, not as consequence of a real hydraulic problem, but just as consequence of the malfunctioning of the probe). Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
- Page 34 It indicates that the total, progressive working time of the watermakers. • SYSTEM WASHING It indicates that the unit is in washing mode (pumps and electrovalve on). • SYSTEM BLOCKED The message must be acknowledged pushing STOP. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
- Page 35 In this last case, please stop the watermaker and schedule a service. TIME. It is the time from the starting. If the timer function has been used the time will indicate the remaining time to stop. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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Page 36: Introduction - By Pass Mode
6. Be sure the valve on the active carbon filter is opened. 7. Be sure the fresh water tank is full enough (at least 50lt) to perform washing procedure. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 37: Start-Up
The procedure lasts about 3 minutes, and it can be stopped at any time pushing STOP. After completed the procedure the system is ready to start normally. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 38: Normal Operating Procedure
The system will stop when the selected time is reached, and then will perform the automatic washing. However, the system can be stopped at any time by pushing STOP. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 39: Single Washing Operation
Exit from the menu by pushing STOP button Push the WASHING button for 3 seconds NOTE In case the power supply is removed, it is necessary to set again the parameter. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 40: Reset Procedure
4. Screw the positioner know clockwise until it can be moved no further. Normally 10 turns at least are needed. 5. Unscrew the positioner knob up to the original position, until when it is blocked back. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... - Page 41 5 – FUNCTIONING AND USE COD. 60M12/24.D.2018 6. Close the reset valve (lever in vertical position). 7. Restart the system 8. After some seconds close the depressurization valve. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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Page 42: Maintenance (Routine And Special)
2- 3 minutes the depressurization valve. Unscrew the filter housing cup counter clockwise by using the specific key provided Replace the active Once per year carbon fiber filter Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 43: Check The Plant Working Pressure
It is necessary to 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. -
Page 44: Necessary Equipment
3. A bottle of powder SCHENKER CLEANING 1 (SC1). The solution must be prepared following the instruction indicated on the product label, and using chlorine free water (water produced by the system can be an option). -
Page 45: Shutdown Operating Procedure
Hoses under the free water surface 3. Check they are well dipped in the solution and don't inhale air. 4. Open the depressurization valve (turn counterclockwise). Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... - Page 46 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. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
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Page 47: Antifreeze Procedure (Winterizing Procedure In Cold Climate - Under 5°C)
Before proceeding with any kid of service it is strongly recommended to read carefully the instruction contained in this manual. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 48: Periodic Maintenance
Reverse osmosis membranes have an average lifetime of about 7 years If correctly maintained. It is anyway recommended to check the efficiency of the membranes after 5 years of functioning and verify the needed of a replacement. Please, refer to a certified Schenker service center for this operation. 6.8 Adjustments... -
Page 49: Troubleshooting
(> 9 Bar) Clogged membranes Perform washing procedure Cold inlet water Contact a customer service Loss in the system Loose fittings Tighten fittings ERS leaks Contact a customer service Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 50: Electronic Issues And Their Solution
2 cables to a meter in ohm position. The pressure switch must give, under normal conditions, a closing signal followed by an opening signal, every 3-4 seconds. If the signal is always open or always closed, the pressure switch must be replaced. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 51: Suggested Spare Parts
SPARE PUMP SM-MOD 30/60 24V SP36/24 MEMBRANE 2521 M2521 PORTABLE SALINITY TESTER SIGNAL PRESSURE SWITCH MOD30/60/100 PSSM361 PUMP PRESSURE SWITCH 30/60/50 PSP36 SPARE SEALS KIT 2.0 SS152-2.0 SP36/12-24 PSSM361 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 52: Ers Spare Parts
8 –SUGGESTED SPARE PARTS COD.60M12/24.D.2018 8.3 ERS spare parts Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED... -
Page 53: Additional Spares
END CUP VESSEL 2,5” SINGLE CONNECTION EV2,5 EV2,5-2 END CUP VESSEL 2,5” DOUBLE CONNECTION “C” END CUPS 2,5 CONNECTION FITTING CEV2,5 M16B MANOMETERS 0-16 CEV2,5 EV2,5 EV2,5-2 M16B Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...