Schenker MODULAR 500 Installation, Use And Maintenance Manual

Digital 380 vac

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COD: 500M380.D.2018

Installation, use and maintenance manual

MODULAR 500

Digital 380 Vac

Schenker 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

Schenker Italia

THE PRESENT MANUAL BELONGS TO -

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Page 1 COD: 500M380.D.2018 Installation, use and maintenance manual MODULAR 500 Digital 380 Vac Schenker 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 Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 2: Table Of Contents
..........................25 4.5 E LECTRIC CONNECTIONS ..........................28 4.5.1 R EMOTE CONTROL PANEL MOUNTING ......................28 4.5.2 E MODULAR 500 380V AC ........29 LECTRIC CONNECTIONS WIRES THREE PHASE 4.5.3 E 380V AC) ................30 LECTRIC LAYOUT SCHEME THREE PHASE 4.5.4 D...
Page 3 7. SUGGESTED SPARE PARTS ......................... 55 7.1 S HORT TERM CRUISING ........................... 55 7.2 L ONG TERM CRUISING ............................. 55 7.3 ERS SPARE PARTS ............................56 7.4 A DDITIONAL SPARES ............................57 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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 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...
Page 9: Product Presentation
The watermaker unit is transported in a wooden 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 500 Packaging dimensions and weight tab.3-1 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 10: Stock
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...
Page 11: Attached Documents
Do not store the unit under temperature of 5°C and above 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
On the pump inlet there is a T fitting, where is connect the electrovalve for the automatic washing of the unit. PRE-PUMP 380 VAC FIG. 3-6 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 15: Pre-Filtration Unit
The pressure switch calibration is approximately 0,6 bar PRE FILTRATION UNIT FIG. 3-7 Low pressure switch 20 micron big blue cartridge filter 0-6 bar manometer Non-return valve 5 micron big blue cartridge filter Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 16: 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 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 17 The device has to be pre-charged with air through the specific valve. The air pressure precharge is about 14 Bar. The pressure dimmer is charged in factory at the right pressure. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 18 High pressure switch. It Is hydraulically connected downstream the pump 2. It stops the system if the pump 2 pressure exceeds 18 bar. In this case a high-pressure alarm is activated on the control panel. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 19 On the front side It is possible to find the emergency stop push button. To stop the unit suddenly push the emergency stop button at least for 2-3 seconds. ELECTRIC BOX EMERGENCY STOP FIG. 3-14 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 20: Accessories
Electrovalve. It has the function of switching from seawater intake to fresh water tank when washing the watermaker. 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
Filtration grade of the strainer is 50 (not provided) 45 lit/min) mesh. 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
4 – MOUNTING AND INSTALLATION COD: 500M380.D.2018 4.4 Hydraulic connections HYDRAULIC CONNECTION AND HOSES FIG. 4-1 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 26 Watermaker outlet (waste water) To be connected to tee Watermaker outlet tee(waste water) To be connected To diverting valve and out board WATERMAKER INTAKE AND DISCHARGE FIG. 4-2 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
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 500 Three Phase 380V Ac
500M380.D.2018 4.5.2 Electric connections: wires MODULAR 500 three phase 380V AC The power supply of the unit must be connected to an electric line 380 VAC 50 Hz three phase with ground connector. The section of the cable depends on the length of the lines and must be calculated, considering a maximum electric consumption of 3 Kw/h, according to the local law.
Page 30: Electric Layout Scheme (Three Phase 380V Ac)
4 – MOUNTING AND INSTALLATION COD: 500M380.D.2018 4.5.3 Electric layout scheme (three phase 380V AC) ELECTRIC MAIN BOX SCHEME MODULAR 500 380V AC FIG. 4-5 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 31 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 (pushed) before starting the watermaker. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 32: Drive Frequency Inverter Settings
(8) 7-seg LED Shows each parameter, monitors etc. BUTTON FUNCTION COMMAND FUNCTION (11) ESC Move through the parameters (12) 1 Move the parameter value up Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 33: Electronic Connections: Remote Panel
Move the parameter value down (14) SET Confirm the parameter setting The Drive Frequency Inverter is set by Schenker’s technicians during the test of the unit. In the following list, the main parameters and respective values are reported for appropriate knowledge. PARAMETER...
Page 34: 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 36 TOTAL HOURS 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). Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 37 If the origin of the problem is just a malfunctioning of the signal pressure switch, it is possible to start again the unit, activating the bypass. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 38 When the start-up is performed the valve diverts the fresh water to discharge. When automatic or manual flushing is performed the fresh water is sent to the fresh water tank. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 39: Preliminary Check - Motors Rotation
CAUTION Please, avoid to use the bypass mode if not strictly necessary. In this mode all the main electronic controls of the watermaker and automatic sensors are disabled. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 40: First Start-Up Procedure
3. The controller starts pump 1 first, and initially the message low pressure will be on. When the pressure will get 2 bar, pump 2 will start automatically (after 5 seconds) and the ERS starts its commutations. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 41: 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. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 42: Normal Operating Procedure With Final Flushing (Recommended)
Before pressing START to run the watermaker again, be sure to individuate the cause of the anomaly and solve the issue. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 43: Single Washing Operation
Note: in order to avoid false and continuous starts/stops, as result of the pitching of the vessel, the computer recognizes the command of the level switch only after 60 seconds of stable state. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 44: Reset Procedure
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 at least are needed. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 45 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...
Page 46: Maintenance (Routine And Special)
100-120 working hours. cartridge filter Once replaced the filters it is necessary to purge the air from the system, opening for 2-3 minutes the depressurization valve. 20 micron 5 micron Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 47 Replace the big blue Once per year active carbon filter Purge air from the system periodically by opening for 2-3 minutes Every 15-20 days the depressurization valve. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 48: Check The Plant Working Pressure
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 49 NOTE The available products for 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;...
Page 50: Shutdown Operating Procedure
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. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 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. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 52 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 -...
Page 53: 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 54: 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 55: Suggested Spare Parts
CRK23 MEMBRANE 4040 M4040 PORTABLE SALINITY TESTER SIGNAL PRESSURE SWITCH 200-300 PSSM20 PUMP PRESSURE SWITCH 500 PSP50 SPARE SEALS KIT 50 SS50-2.0 MECHANICAL SEAL PRE-PUMP MECHANICAL SEAL MAIN-PUMP Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 57: Additional Spares
END CUP VESSEL 4” DOUBLE CONNECTION “C” END CUPS 4 CONNECTION FITTING 500 CEV4-50 SMP50 PRESSURE ACCUMULATOR 500 LIT M25B MANOMETERS 0-25 EV4-3/4-2 CEV4-50 EV4-3/4 EV4-3/4-2 HPH5 SMP50 PSP50 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...

Schenker MODULAR 500 Installation, Use And Maintenance Manual

1 Layout of Manual

2 General Warnings and Information to the Recipient

3 Product Presentation

4 Mounting and Installation

5 Functioning and Use

6 Maintenance (Routine and Special)

7 Suggested Spare Parts

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