Schenker SMART 100, Installation, Use And Maintenance Manual

Page 1: ...mber 100S12 24D Year of construction 2006 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 THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED SMART 100 Digital 12 24 V dc ...

Page 2: ... DATA 11 3 6 CHARACTERISTIC OF THE PRODUCT 12 3 7 ADVANTAGES OF THE ENERGY RECOVERY SYSTEM 13 3 8 COMPOSITION OF THE MACHINE 14 3 8 1 PUMP GROUP 14 3 8 2 WATERMAKER GROUP 15 3 8 3 ACCESSORIES 18 4 MOUNTING AND INSTALLATION 19 4 1 GENERAL CRITERIA 19 4 2 COMPONENTS MOUNTINGS 20 4 2 1 PUMP GROUP 20 4 2 2 WATERMAKER GROUP 20 4 2 3 ACCESSORIES 20 4 3 INSTALLATION 20 4 3 1 WATER INTAKES AND DISCHARGES ...

Page 3: ... 41 6 1 CONTROL OF FILTER CLEANING CONDITION 41 6 2 CHECK THE PLANT WORKING PRESSURE 42 6 3 CHECK FOR ABSENCE OF LEAKS 42 6 4 CHECK FOR MEMBRANES REPLACEMENT 42 6 5 SHUTDOWN PROCEDURE 42 6 5 1 NECESSARY EQUIPMENT 43 6 5 2 SHUTDOWN OPERATING PROCEDURE 44 6 6 ANTIFREEZE PROCEDURE WINTERIZING PROCEDURE IN COLD CLIMATE UNDER 5 C 47 6 7 PERIODIC MAINTENANCE 48 6 7 1 MEMBRANE REPLACEMENT 48 6 8 ADJUSTME...

Page 4: ...for 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 sy...

Page 5: ... 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 equipment suitable for service operation Clothing must be tight to the body and resistant to the products used for cleaning Do not remove safety devices or accident prevention protecti...

Page 6: ...fect of materials and parts It is limited to the replacement or re 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 techni...

Page 7: ... 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 6 2 Respect for the environment requirements for demolition and disposal ATTENTION Evacuate and dispose of materials as result of the demolition of the machine must be performed in accordance with the regulations in force for the safeguard ...

Page 8: ...D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 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 ...

Page 9: ...ollowing 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 carton box In the following ...

Page 10: ...oldest temperature could led to a freeze of the fluid inside the system with the consequence of a permanent fault of the system 3 3 Packaging 3 3 1 Packaging contents PACKAGING FIG 3 2 SMART 100 Watermaker Pump group Active carbon filter with electrovalve White filter key Net filter Non return valve with Tee fitting Remote panel with electric box 10 mt extension cable for remote panel Intallation ...

Page 11: ...m Use only recommended material for the installation especially pipes fittings and seals in accordance with the present manual 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 SMART 100 12 24V Digital version WATERMAKER GROUP Dimensions Length 120 cm Width 35 cm Hight 27 cm Weight ...

Page 12: ...der 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 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...

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 an high energy efficie...

Page 14: ...MAKER GROUP 3 8 1 Pump group This pump has the duty of picking the sea water up and send it to the watermaker group through the pre filter The pump group is composed by the following components 5 micron cartridge filter Diaphragm pump High pressure switch Pump box Pulsation dampener PUMP GROUP AND FILTER 12 24 V DC FIG 3 5 5 micron cartridge filter Pump box with relays Pump head with CC motor High...

Page 15: ...TS RESERVED 15 3 8 2 Watermaker group WATERMAKER GROUP FIG 3 6 Manometer Fresh water production grey plastic fitting Pulsation dampener Positioner knob Reverse osmosis membranes WATERMAKER GROUP TOP VALVE VIEW FIG 3 7 Reset valve Concentrate water discharge Depressurization valve Signal pressure switch ...

Page 16: ... valve necessary for the system functioning Manometers It is located on the front panel of the watermaker and it measures the working pressure of the watermaker Pulsation dampener is a grey PVC cylinder installed in the watermaker Its function is to reduce and stabilize the pressure peaks during the watermaker functioning The device has to be pre charged with air through the specific valve The air...

Page 17: ...e main valve of the Energy Recovery System Its function is check that the cycling of the machine is correct It is set at 1 3 bar Computer box It is an external unit It has to be installed relatively close to the watermaker in a position protected from water It is connected to the remote panel and controls the functions of the watermaker automatically The microswitches P1and EV allow the direct com...

Page 18: ...ized system of the boat and the electro valve on the filter holder On the filter inlet is positioned a manual valve that allows to replace the cartridge without depressurize the fresh water system of the boat Electrovalve It has the function of switching from seawater intake to fresh water tank when washing the watermaker Non return valve It avoids the emptying of the inlet pipes It must be instal...

Page 19: ...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 support which is able to sustain the weight about 50 Kg Provide to leave a s...

Page 20: ...n there are not height limits respect to the seawater level Anyway it should be installed above both pumps Avoid to install the system wherever any possible leak may cause damages to the boat or jeopardize its safety since possible leaks due to accidental causes pipe bursting hose clamp loosening equipment failure etc may cause water losses The hydraulic intake and outlet connections are positione...

Page 21: ...Do not use the pre existing water inlet of the cooling system dedicated to the motor Size 3 4 INSTALLATION NOTES Allow a minimum 3 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 inspected mesh type filter will be required close to the water intake The filter has to be of 50 microns It is possible...

Page 22: ...e must be 18 20 lit min at 2 5 bar CAUTION Pressurized tank Min flow rate must be 18 20 lit min at 2 5 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 apparatuses provided that It is not the engine c...

Page 23: ...r inlet Watermaker Active carbon filter Fresh water outlet The hydraulic section that is continuously under consistent pressure is the pump outlet 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 Plumb to pressure side of boat fresh water system Exhauste...

Page 24: ...ure connections max 13 bar Connections fresh water pressurized system carbon filter backflow valve outlet pump inlet Connections pump outlet 5 microns filter watermaker inlet Rubber rinforced pipe PN 16 minimum internal diameter 20 mm Low pressure connections max 3 bar Watermaker fresh water tank fittings Small plastic blue pipe 6x8mm provided within the scope of supply PUMP CONNECTIONS Connect th...

Page 25: ...amplifier inside the watermaker 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 small hose supplied with the equipment The connection has to be made between the polyethylene pipe that comes out the watermaker unit on the ...

Page 26: ... mm height 116 mm It can be fixed on any internal boat 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 boat 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 wir...

Page 27: ...s The general wires connection scheme between the external devices and the main electric box is the following Voltage Automatic Cable lenght switch up to 3 mts 3 7 mt 7 10 mt Volt Ampere mm2 AVG mm2 AVG mm2 AVG 12 63 16 5 25 3 25 3 24 32 10 7 10 7 10 7 Electric cables and switches selection table The connection general diagram is the following Clamp Position connect to cable section Pump box negat...

Page 28: ...4 MOUNTING AND INSTALLATION COD 100S12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 28 WIRING LOGIC SCHEME12 24 VDC FIG 4 4 ...

Page 29: ... MOUNTING AND INSTALLATION COD 100S12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 29 4 5 3 Electric layout scheme 12 24V DC ELECTRIC SCHEME SMART 100 12 24V DC FIG 4 5 ...

Page 30: ...to stop the system The system once pushed STOP usually doesn t stop suddenly It awaits for 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 r...

Page 31: ... pushing STOP BY PASS It allows to exclude the sensor signal pressure switch that detects the correct cycling of the ERS The operation with the by pass is necessary only in case of malfunctioning of the signal pressure switch in example if the system gets blocks with the message SYSTEM BLOCKED not as consequence of a real hydraulic problem but just as consequence of the malfunctioning of the probe...

Page 32: ...ed before long inactivity periods The single washing operation will last about 1 minute The consumed fresh water for every washing is about 30 liters Therefore it is suggested to evaluate if the fresh water reservoir is enough for the programmed cycles Selecting NO the function will be disabled To activated the function select the days 6 to 10 exit from the menu pushing STOP and then push WASHING ...

Page 33: ...s 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 messages means that an hydraulic 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 and investigate on the possible hydraulic origi...

Page 34: ...maker the display gives the following indications Pump 1 OFF ON Pump 2 OFF ON S wait This means that the salinity meter is still completing calculations S OK Quality of the produced water good micro Siemens 0 1500 S MED Quality of the produced water medium micro Siemens 1500 2000 S BAD Quality of the produced water bad micro Siemens over 2000 In this last case please stop the watermaker and schedu...

Page 35: ...ss mode guarantees the normal functioning of the watermaker manually through the use of the pump1 selector In this circumstance it is not possible to perform the automatic washing 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 5 3 First start up procedure The first start up pro...

Page 36: ...ng pump of the boat 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 washing procedure 5 3 2 Start up 1 Open the depressurization valve lever horizontal 2 Push for 20 30 sec the red button on the active carbon filter housing cup in order to purger the air from the system 3 Activate the start up procedure throw t...

Page 37: ...shing has been selected the system will start the washing procedure and then will stop automatically after around 1 minute The fresh water consumed for the automatic washing is about 20 25 lt 5 4 2 Normal operating procedure with timer 1 Select the needed timing 1 to 6 hours throgh the specific timer within the menu option the system will hold as well the previous setting 2 Push the button START f...

Page 38: ...system rinsing automatically with a desired frequency please follow the instruction below Select the days between 6 and 10 in the periodic washing option within the menu 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 5 4 5 Automatic functioning with level controls optional To activa...

Page 39: ...n this case the system has to be manually restarted An evidence of this effect is confirmed by a working pressure going up suddenly After approx 20 sec the computer recognizes the problem turn off the pumps and the red led start flashing 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 Turn off the system ...

Page 40: ...5 FUNCTIONING AND USE COD 100S12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 40 7 Close the depressurization valve 8 Restart the system ...

Page 41: ...ousinh 3 Active carbon filter follow the instructions given in the table below OPERATION FREQUENCY PROCEDURE Check and cleaning of the strainer Every 5 days Visual inspection and washing Replacing of the 5 micron cartridge filters Every 200 working hourse Once replaced the filters it is necessary to purge the air from the system opening for 2 3 minutes the depressurization valve Unscrew the filter...

Page 42: ...sult 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 6 3 Check for absence of leaks It is necessary to perform this verification at every plant start up and however often since possible leaks due to accidental causes pipe bursting hose...

Page 43: ...OTE 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 in this case the system becames stinky Whether the system needs acid or alkaline cleaning...

Page 44: ...ing procedure 1 Disconnect the production pipe and collect about 20 liters of fresh water within a tank 2 Switch off the system by pushing the stop button 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 ...

Page 45: ...LONGS TO Schenker Italia ALL RIGHTS RESERVED 45 5 Check they are well dipped in the solution and don t inhale air 6 Open the depressurization valve turn counterclockwise 7 Start the watermaker with the by pass activated see pag 32 for bypass activation Pipes under the free water surface ...

Page 46: ...for approx 20 minutes checking that the hoses are properly positioned in the recipient so that to avoid inhaling air 9 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 47: ...the propylene glycol with 15 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...

Page 48: ...ound 13 Bar The pressure switch can be calibrated with a 2 mm hexagonal key To have access to the calibration screw it is necessary to operate on the screw that blocks the electrical connector of the pressure switch and then introduce the hexagonal key even without removing the electrical connector itself Turning the key clockwise increases the calibration of the pressure switch while turning the ...

Page 49: ...During operation the pump temporarily switches off giving rise to a start and stop phenomenon Pump pressure switch not correctly set Dirty filters or membranes Set pump pressure switch see pag 47 Clean or replace Metal noise of the pump Pump cavitation Check the causes of the absence of water flow at the pre pump inlet Low production normal or low pressure Low battery Air within the system Loss of...

Page 50: ... to the insufficient battery charge Charge the batteries and try again If the system does not start check all the electrical connections between the remote panel and microcomputer again and replace the microcomputer box or the connection cable or the remote panel if necessary Pressing the start button the system starts but goes into alarm after about 25 seconds Check if the watermaker is in hydrau...

Page 51: ...E 9 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 5 micron cartridge filter one active carbon filter one cleaning kit big as well as one 4040 SW membrane and a signal pressure switch Other additional spares are listed below with their codes Spare part name Code SC1 WASHING PRODUCT SC1 SC2 WASHING PRODUCT SC2 ...

Page 52: ...8 SUGGESTED SPARE PARTS COD 100S12 24 D 2018 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 52 8 3 ERS spare parts ...

Page 53: ...t might become necessary in order to ensure 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 100 150 200 HPH2 END CUP VESSEL 4 SINGLE CONNECTION EV4 END CUP VESSEL 4 DOUBLE CONNECTION EV4 2 C END CUPS 4 CONNECTION FITTING CEV4 MANOMETERS 0 16 M16B EV4 EV4 2 M16B HPH2 ...