Schenker MODULAR 35 Installation, Use And Maintenance Manual

Digital 12/24 v dc

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COD: 35M12/24.D.2018

Installation, use and maintenance manual

MODULAR 35

Digital 12/24 V dc

Model.: Modular 35

Matriculation number: 35M12/24D

Year of construction: 2001

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 -

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Page 1 COD: 35M12/24.D.2018 Installation, use and maintenance manual MODULAR 35 Digital 12/24 V dc Model.: Modular 35 Matriculation number: 35M12/24D Year of construction: 2001 Schenker Italia Via Delle Repubbliche Marinare, 67 80147 Naples Italy Tel. +39 081 5593505 Fax. +39 081 5597372 E-mail: info@schenker.it...
Page 2: Table Of Contents
5.2 I – NTRODUCTION BY PASS MODE ........................36 5.3 F IRST START UP PROCEDURE .......................... 36 5.3.1 P RELIMINARY CHECKS BEFORE PROCEEDING WITH THE STARTUP PROCEDURE ........36 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 3 8. SUGGESTED SPARE PARTS ......................... 53 8.1 S HORT TERM CRUISING ........................... 53 8.2 L ONG TERM CRUISING ............................. 53 8.3 ERS SPARE PARTS ............................54 8.4 A DDITIONAL SPARES ............................55 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 4: Manual Consulting
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: Start -U P
Otherwise, SCHENKER ITALIA declines any responsibility for changes or damages that may result from it. 2.3 Start-Up The system MODULAR 35 test and validation takes place at the end of the assembly at Schenker Italia production site. 2.4 Warranty The equipment and the relevant accessories are guaranteed 12 months from delivery.
Page 7: Identification Of The Unit
2.5 Identification of the unit All the watermakers manufactured by Schenker Italia can be identified trough a serial number printed on a laberl which is pasted upon the aluminum 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...
Page 9: Product Presentation
The watermaker unit is transported in a carton box. In the following table dimension and weight are indicated. MATERIALS HANDLING fig. 3-1 Model L cm. W cm. H cm. Weight Kg. Manual Electron 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 35 Watermaker Pump group Active carbon filter with electrovalve White filter key Net filter Non-return valve with Tee fitting...
Page 11: Attached Documents
Do not stock the unit under temperature of 5°. DOCUMENTS INCLUDED IN THE PACKAGING FIG. 3-3 3.5 Technical data NOTE: The following technical data refers to the watermaker Modular 35 12/24V Digital version WATERMAKER GROUP Dimensions Length: 74 cm Width:...
Page 12: Characteristic Of The Product
The machine uses sea water to produce fresh water. The water produced by the Schenker plant, starting from clean sea water, is potentially drinkable. The requisite of potable water cannot be guaranteed, however, because in some parts of the system there may be a bacterial charge, especially in the event of non-observance of the cleaning and storage 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 an high energy efficiency.
Page 14: Composition Of The Machine
Pump box • Pulsation dampener PUMP GROUP AND FILTER 12-24 V DC FIG. 3-5 5 micron cartridge filter High pressure switch Diaphragm pump Pulsation dampener Pump box with relays Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 15: Watermaker Group
35M12/24.D.2018 3.8.2 Watermaker group WATERMAKER GROUP FIG. 3-6 Manometer Reverse osmosis membranes Flowmeter WATERMAKER GROUP (LATERAL VIEW) FIG. 3-7 Reset valve Positioner Depressurization valve Fresh water production hose Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 16 The watermaker group is composed by the following components: • 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 18 3 – PRODUCT PRESENTATION COD. 35M12/24.D.2018 Emergency microswitches Remote panel Electric cable connector connections COMPUTER BOX WITH SWITCHES FIG. 3-10 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 19: Accessories
Net 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 20: 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 21: 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 disharge. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 22: Seawater Intake
Flow rate capacity of the filter is adequate to the whole intakes it serves. 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 23: Fresh Water Intake For Washing
If the discharge is upon the seawater level, it is recommended to provide a valve along the pipe. CAUTION Do not run the system when the discharge valve is closed. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 24: Hydraulic Connections
– 5 m. filter – watermaker inlet connections . For this section is necessary to use a good quality PN 16 min. reinforced hose. An inadequate hose could burst, jeopardizing seriously the safety of the boat. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 25 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 windy path of the connection hoses. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 26 Another option is to Tee into the tank air vent hose. This is only possible if the breather pipe section is more than 16 mm. dia. There are no particular limits on the connection length. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 27: Electric Connection
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 28: Electric Connections: Wires (Modular 35 12/24V Dc)
35M12/24.D.2018 4.5.2 Electric connections: wires (Modular 35 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 boat panel needs to be performed downstream the voltmeter and the ammeter of the boat panelboard.
Page 30: Electric Layout Scheme (12/24V Dc)
4 – MOUNTIND AND INSTALLATION COD. 35M12/24.D.2018 4.5.3 Electric layout scheme (12/24V DC) ELECTRIC MAIN BOX SCHEME MODULAR 35 12/24V DC FIG. 4-5 Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 31: 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 32 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. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 33 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 34 • BYPASS WARNING This message advice or remember that the unit is working in bypass mode (then some safety functions are disabled). 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...
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 anyway be stopped anytime 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
This behaviour is absolutely normal because the electronic central unit waits for the hydraulic clock signal before switching off in order to avoid hydraulic system block. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 39: Single Washing Operation
If not restarted manually, the watermaker will restart automatically when the level in the tank will be very- low. The watermaker can anyway be stopped at anytime pushing STOP. Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 40 Note: in order to avoide false and continuos starts/stops, as conseguence of the pitching of the boat, the computer recognizes the command of of the level switch only after 60 seconds of stable state. Schenker Italia THE PRESENT MANUAL BELONGS TO -...
Page 41: 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 42 5 – FUNCTIONING AND USE COD. 35M12/24.D.2018 6. Close the reset valve (lever in vertical position). 7. Close the depressurization valve. 8. Restart the system Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 43: Maintenance (Routine And Extraordinary)
2-3 minutes the depressurization valve. Unscrew the filter housing cup Replace the active Once per year counter clockwise by using the carbon fiber filter specific key provided Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 44: 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 45: 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 46: Shutdown Operating Procedure
3. Prepare the solution carefully mixing the bottle of SC1 in about 20 liters of unchlorinated water. 4. 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 47 COD. 35M12/24.D.2018 Pipes under the free water surface 5. Check they are well dipped in the solution and don't inhale air. 6. Open the depressurization valve (turn counterclockwise). Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 48 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 49: 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 50: 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 51: Troubleshooting
(> 9 Bar) Obstruct 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 52: Electronic Issues And Their Solution
3-4 seconds. If the signal is always open or always closed, the pressure switch must be replace Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...
Page 53: 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 55: 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 EV2,5-2 CEV2,5 EV2,5 M16B Schenker Italia THE PRESENT MANUAL BELONGS TO - - ALL RIGHTS RESERVED...

Schenker MODULAR 35 Installation, Use And Maintenance Manual

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