Schenker ZEN 30, Installation, Use And Maintenance Manual

Page 1: ...COD 30Z12 24 B 2021 Installation use and maintenance manual ZEN 30 12 24 V dc ...

Page 2: ...10 3 6 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 INSTALLATION 17 4 1 GENERAL CRITERIA 17 4 2 COMPONENTS INSTALLATION 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 INTAKE...

Page 3: ...INE AND SPECIAL 35 6 1 CHECK FILTER CLEANLINESS 35 6 2 CHECK THE WATERMAKER 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...

Page 4: ...ph can be found with a subtitle and a description In each chapter for example chapter 1 we have 1 Chapter title 1 1 Paragraph title 1 1 1 Subtitle 1 1 1 1 Further subtitle 1 2 Description of the symbols The following symbols shall be used in the manual to highlight important indications and warnings ATTENTION This symbol indicates accident prevention regulations for the operator and or for any exp...

Page 5: ...nts without 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 considered 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 Machine...

Page 6: ... the replacement or repair of faulty parts The charge for the disconnecting and reinstalling on the vessel as well as the transport from or to our Service Point or our factory shall be at the customers own expenses The under warranty delivered parts transport shall be at customer s own risk In case of repairs under warranty performed by our technicians on the customer s vessel the faulty parts rep...

Page 7: ...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 in accordance w...

Page 8: ...ded according to the regulations of the country where the machine has been uninstalled 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 observed ...

Page 9: ...ing the utmost care 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 properly maintained Do not stand under the package during lifting or transport operations 3 1 Transport and material handling The watermaker unit is transported in a cardboard box Dimensio...

Page 10: ...45 C Very cold temperatures could led to a freezing of the fluid inside the system and as a clear consequence a permanent damage of the latter 3 3 Packaging 3 3 1 Packaging contents PACKAGING FIG 3 2 ZEN 30 Watermaker Pump group Active carbon filter with electrovalve 5 microns filter with accumulator Net filter Non return valve with Tee fitting Remote panel 10 mt extension cable for remote panel I...

Page 11: ...ectric and hydraulic 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 FIG 3 3 3 5 Technical data WATERMAKER WATER...

Page 12: ...n filter 2 32 x 5 Power supply 12 VDC 15 30Z12 version 24 VDC 15 30Z24 version Average electric consumption 110 Watt h average Nominal fresh water production 30 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 CEE electric safety requirements 3 6 Features of ...

Page 13: ...e 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 use the ENERGY RECOVERY SYSTEM patented device which amplifies the pressure of common low pressure pumps and recover all the hydraulic energy back from the membranes allowing a high energy efficiency The ...

Page 14: ...ridge filter and accumulator Pump box with controller Diaphragm pump Pressure transducer Pressure transducer It Is hydraulically connected to the pump group It stops the system if the pump pressure exceeds 9 5 bar or if it doesn t reach 0 8 bar Pump box Plastic Box with all the electric connections for the power supply of motor motherboard pressure switches remote panel and electrovalve Accumulato...

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 Positioner knob Depressurization valve Manometer Antishock ...

Page 16: ... 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 bleeding of air The valv...

Page 17: ...zed system of the boat and the electro valve on the filter holder A manual valve positioned on the filter inlet allows replacement of the cartridge without depressurizing the fresh water system of the vessel Electrovalve or solenoid valve It has the function of switching from seawater intake to fresh water tank when washing the watermaker Non return valve or check valve It stops water flowing out ...

Page 18: ...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 must be positioned and arranged on ...

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

Page 20: ... 24 B 2021 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 19 INSTALLING PROCEDURE FIG 4 3 POSSIBLE CONFIGURATIONS FIG 4 4 For a complete installation antivibration rubber stickers are provided ok ok NO NO ...

Page 21: ...lease follow the instruction to install the unit an incorrect installation could damage the lateral manifolds of the watermaker If the unit is installed horizontally it is recommended to connect the manometer horizontally in order to be visible This can be done by making use of the fittings provided HORIZONTAL FIXING FIG 4 6 3 8 Nipple 3 8 male to 1 8 female reducer 3 8 90 Degree Elbow Manometer ...

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 fi...

Page 23: ... hose clamps An easily 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 ...

Page 24: ...AL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 23 4 4 Hydraulic connections HYDRAULIC CONNECTION AND PIPES FIG 4 8 Plumb to pressure side of boat fresh water system Brine discharge Armorvin type hose int dia 16 mm Reinforced hose PN10 min int dia 16 mm ...

Page 25: ... An inadequate 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 16mm internal diameter Connection between the discharge of the watermaker through hull discharge fittings of the vessel Armorvin reinforced...

Page 26: ...n the right side of the watermaker marked IN WATERMAKER OUTLET Discharge outboard Make use for this connection of the holder located on the right side 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 small hose supp...

Page 27: ...ons width 100 mm height 66 mm It can be fixed on any internal boat panel provided that the area behind is free of moisture and condensation and there is enough depth to house the rear part of the panel approx 50 mm The cut to be performed on the boat 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 thr...

Page 28: ...e See the diagram of the recommended sections below Voltage Automatic Cable length switch up to 3 mt 3 7 mt 7 10 mt Volt Ampere mm2 AWG mm2 AWG mm2 AWG 12 16 4 11 10 7 16 5 24 10 2 5 13 4 11 4 11 The connection diagram in the computer box is the following Clamp connect to cable section Negative battery see table Positive battery see table EV Electrovalve on the AC filter 2 5 mm2 EV Electrovalve on...

Page 29: ...4 INSTALLATION COD 30Z12 24 B 2021 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 28 ELECTRIC MAIN BOX SCHEME ZEN 30 12 24V DC FIG 4 10 ...

Page 30: ...y Underpressure 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 a...

Page 31: ...dy 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 beeps twice the button flashes quickly and the procedure starts The unit can be stopped at any time by pushing the ON OFF but...

Page 32: ...nd that the grey valve on the active carbon filter is open 5 3 1 Normal operating procedure without final flushing 1 Push ON OFF to start the watermaker 2 Push ON OFF to stop the watermaker CAUTION The watermaker produces periodic beats during its functioning due to the movement of the internal parts A pressure peak is shown on the pressure gauge during these beats Avoid to shut down the watermake...

Page 33: ...ny time by pushing the ON OFF button CAUTION If during normal running operation the system detects an irregular condition high pressure etc the system switches off automatically Before restarting the watermaker again be sure to identify the cause of the anomaly and resolve the issue 5 4 Reset procedure If the watermaker has sucked in air or if other problems occur the automatic hydraulic valve may...

Page 34: ...ESERVED 33 1 Open the reset valve lever in horizontal position 2 Open slightly the depressurization valve 3 Screw the positioner knob until it can be moved no further Normally 18 complete turns at least are needed 4 Unscrew the positioner knob back to its original position until it can be turned no more ...

Page 35: ... USE COD 30Z12 24 B 2021 EN THE PRESENT MANUAL BELONGS TO Schenker Italia ALL RIGHTS RESERVED 34 5 Close the reset valve lever in vertical position 6 Close the depressurization valve screw the valve 7 Restart the system ...

Page 36: ...lustrated hereby OPERATION FREQUENCY PROCEDURE Check and clean the strainer Every 5 days Visual inspection and washing Replace the 5 micron cartridge filters It depends on the working conditions and the turbidity of the sea water In average conditions the replacement of the cartridge is recommended every 80 100 working hours Once replaced the filters it is necessary to purge the air from the syste...

Page 37: ...h the chemical SC1 If the cleaning with SC1 is not enough to reduce the pressure it might be necessary an alkaline washing with the cleaning SC2 6 3 Check for leaks It is necessary to perform this verification at every watermaker start up and frequently as possible leaks due to accidental causes hose bursting hose clamp loosening equipment failure etc may occur causing possible damages 6 4 Check f...

Page 38: ...ngs 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 depress...

Page 39: ...g procedure 1 Prepare the solution carefully mixing the bottle of SC1 or SC2 in about 15 litres of unchlorinated water 2 Connect the 2 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 in order 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 ou...

Page 41: ...e The total volume of the solution must be about 15 litres The procedure is similar to the one used for chemical washing with SC1 and SC2 products 1 Prepare the solution carefully by mixing the propylene glycol with 15 litres of unchlorinated water and 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...

Page 42: ...e quality of water usually decreases whereas the working pressure increases If chemical washings do not produce significant improvements it is recommended to replace the membranes 6 8 Adjustments Accumulator This is a cylindrical plastic receptacle of air that has the function of damping the pressure oscillations during the commutations of the watermaker The accumulator is factory loaded at a pres...

Page 43: ...suddenly blocks in high pressure Hydraulic block Dirty filters Perform reset procedure Replace filters High pressure variations during commutation 0 2 Bar Low pressure in the accumulator Load at a pressure of about 4 bar Low production normal or low pressure Low battery Air within the system Check battery charge Purge air by opening for a while the pressure valve Low production high pressure 9 Bar...

Page 44: ...DUCT SC1 SC2 WASHING PRODUCT SC2 CLEANING KIT SC1 SC2 CK 5 MICRON CARTRIDGE 5 F5R ACTIVE CARBON FILTER CARTRIDGE 5 Z30CA 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 SC1 S...