TECNICOMAR BICOMPACT, Instructions For The Installation, Use And Maintenance

Page 1: ... maintenance of the watermaker in order to warrant the operators safety and the equipment maximum efficiency Identification The Tecnicomar watermaker carries a plate with the following data a Manufacturer TECNICOMAR SpA C da Berbaro n 145 D 91025 Marsala ITALY Tel 0923 969409 Fax 0923 960235 b CE logo c Type d Serial number e Year of manufacture f Voltage Revision 1 2009 Revision 2 07 2011 Revisio...

Page 2: ...contains the process description and system components identification Section 3 contains information about installation Section 4 contains information about first start up procedure Section 5 contains information about routine operation Section 6 contains the emergency operation and the long period shutdown information Section 7 contains maintenance and setting instruction of the safety components...

Page 3: ... 5 4 Operation in low or high salinity areas 5 19 5 5 Operation in cold areas 5 19 6 Special procedures 6 20 6 1 System normal operation 6 20 6 2 Emergency operation 6 20 6 3 Preservation of membrane modules in very cold areas 6 22 6 4 Optionals 6 22 6 4 1 Automatic flushing system 6 22 6 4 2 Remote control 6 23 6 4 3 Touch screen 6 23 6 4 4 UV sterilizer 6 23 6 4 5 Multimedia sand filter or TFD f...

Page 4: ...31 8 6 Normal operation of the watermaker and overload failure shutdown 8 32 8 7 UNSAFE warning message during normal operation 8 32 8 8 The watermaker runs normally but the produced water does not reach the tanks 8 32 9 Technical characteristics and spare parts 9 33 9 1 Electrophysical characteristics 9 33 9 2 A typical analysis of produced water 9 33 9 3 Spare part list 9 34 9 3 1 High pressure ...

Page 5: ...nner to equalize their concentration A water with less salt naturally diffuses into a water with higher salt Sea water or brackish water cannot naturally diffuse through a semipermeable membrane to provide potable water A man made process REVERSE OSMOSIS overcomes this natural phenomenon By forcing sea or brackish water under high pressure through a semipermeable membrane potable water can be real...

Page 6: ...king and packaging content 1 1 Storage prior to unpacking Do not store in direct sunlight Do not freeze see paragraph 6 3 Do not store above 50 C 122 F Store only on base with arrows up 1 2 Checking packaging content In the package there are the following components SAILOR compact version SAILOR slim version ...

Page 7: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 1 7 SAILOR modular version ...

Page 8: ... installation use and maintenance of Tecnicomar watermaker 1 8 MINIMAR PLUS compact version Installation kit Clamps Manual Tank connection fitting Inlet hose Filters wrench Discharge and Fresh water hoses Discharge fitting ...

Page 9: ...ave the drinking water quality Through the three way solenoid valve N the electric box automatically switches the water coming from membranes either to the discharge or to the fresh water tank The water quality is checked by the salinity sensor M The temperature sensor M1 compensates the reading according to temperature The salinity and temperature sensor require periodic maintenance see MAINTENAN...

Page 10: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 2 10 Flow diagram in case of supply c w manual pressure regulator see also attached drawing DISSALATORI WATERMAKERS ...

Page 11: ... For preservation of membrane modules in very cold areas see par 6 3 For correct installation of SAILOR in compact and modular version Connect the SEA WATER INLET A2 with the T1 side of the manual three way valve T using the supplied hose of dia 20 mm Connect the outlet of the low pressure pump A with the inlet of the prefilters B Connect the Auto Flushing system if supplied to the tee fitting on ...

Page 12: ...supply line to the electric control box Use terminals Nos 1 and 3 if the watermaker is single phase type refer to the id plate on the watermaker motors and main frame and terminals Nos 1 2 and 3 for the three phase systems fig 3 Close the electric box cover by tightening well the four bolts on its front Fig 2 Connect the watermaker steel structure to the ground using the grounding lug identified b...

Page 13: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 3 13 Figure 2 control box Figure 3 Single phase power supply connection Three phase power supply connection ...

Page 14: ...n The correct oil level must reach the red point on the glass bezel F1 in the rear of the pump Use the valve F2 to change oil refer to the MAINTENANCE section Remove the sticker from the pump oil plug ONLY FOR CAT PUMP To ensure good lubrication the PUMP must be installed in an horizontal base Use oil supplied by Tecnicomar only Figure 4 oil valve and level mark on CAT pump ...

Page 15: ...If the unit is equipped with a motorized valve to auto regulate the pressure we recommend to run and stop the unit ONLY by the START and STOP keypads If by chance you have pushed the EMERGENCY STOP red button we recommend to unlock the button by turning it counter clockwise but NOT TO RUN immediately the unit WAIT AT LEAST 2 MINUTES BEFORE PUSHING START This is to prevent the unit from starting wh...

Page 16: ...t panel The alphanumeric display can show the following information HObar high pressure HIbar high pressure if the unit is equipped also with a sensor before the membranes Lbar low pressure T water temperature L m lt minute of product water LP total product water since last starting H hours minutes of running AMP System electrical consumption in Amps SAL product water salinity microsiemens cm AVV ...

Page 17: ...g appears this key allows to cancel it push for 4 sec When a failure occurs the RESET key allows to switch off the acoustic alarm and to reset the control box WARNINGS ON THE DISPLAY Unsafe Water The unit is producing unsafe water that is being discharged outboard VISUAL and SOUND ALARMS High Pressure The unit stops for high working pressure Push RESET to re start it Check section 8 Troubleshootin...

Page 18: ...itch off the power supply Close the sea water inlet A2 5 2 Routine operation c w manual pressure regulator device After having carried out the first start up section 4 the everyday start up and operation of the watermaker will be simple and fast Follow the START UP steps listed below Open the sea water inlet valve A2 Make sure that the pressure control valve I is open ignore this point if the unit...

Page 19: ...valve I until reading 60 bar on the display HObar Stop procedure Push STOP and turn back the handle top of the motorized valve I Move back the selector automatic manual located onto the motorized valve I in automatic position 5 4 Operation in low or high salinity areas Tecnicomar watermakers may also operate in areas with unknown feed water salinity like lake or river waters In low salinity areas ...

Page 20: ...CH THE INSIDE PARTS OF THE ELECTRIC BOX If there is a problem on the electric box the system can be operated in EMERGENCY conditions without the support of automatic electronic controls This mode of operation is normally not recommended Only in cases of extreme necessity and strictly following the instructions given below it is possible to operate the system In case of automatic pressure regulator...

Page 21: ... bolts Switch on the power supply Check that the low pressure be at least 0 5 bar Pressurize the system by turning clockwise the pressure control valve I ignore this step if the unit is equipped with the automatic pressure regulator device until the pressure reaches 60 bar 850 psi Check the system and be sure that the minimum pressure does not fall below the operating minimum value and that the ma...

Page 22: ...s life This system will flush automatically the membranes whenever the operator wants The Automatic Membrane Flushing System has a special electronic control unit connected to the mother board see AMF drawing Follow this procedure to operate it Shut off the system by pressing the STOP key Start the automatic flushing system by pushing the button F2 for 4 seconds The system will be automatically fl...

Page 23: ...ed by Tecnicomar can be installed in any watermaker and guarantees the sterilization of the stored water The UV sterilizer may be installed at the tank outlet to ensure purity of the fresh water Models available 4 8 30 liters per minute 6 4 5 Multimedia sand filter or TFD filter Waters containing impurities which cannot be filtered out by the normal prefilters supplied with the watermaker require ...

Page 24: ...ining oil or chlorine 7 1 2 High pressure circuit From time to time it is advisable to check the high pressure fittings and hosings The user may carry out a first inspection of the system checking the integrity of the piping and the fittings It is important to check for leaks in fittings or piping when the system is in full operation An accurate maintenance work must be carried out periodically by...

Page 25: ...the unit and close the sea water inlet Unscrew the filter sump B 30 micron BLUE using the special wrench supplied until they come off fig 8 Hold the sump from the lower part Empty the sump and take out the filter cartridge part 1 Clean the sump inside USE NEUTRAL DETERGENTS PH 7 TO PREVENT DAMAGE TO THE SUMP Replace the filter cartridge and make sure that the O ring part 3 is well setted and lubri...

Page 26: ...ystem is not used for a long period of time membranes may get seriously damaged by a bacteriological attack If the system must be out of operation for more than a week the LONG PERIOD SHUT DOWN procedure should be performed If the environment is very hot or humid this procedure must be carried out when the watermaker is not used for more than three days Referring to drawing 2 washing storage follo...

Page 27: ...the watermaker is not used for more than three days Referring to drawing 2 washing storage follow the steps below With the system shut down fully open the pressure control valve I by turning it counterclockwise ignore this point if the unit is equipped with the automatic pressure regulator device Close the sea water inlet valve A2 Empty the prefilters B and C and wash them using a normal dish wash...

Page 28: ... chlorinated water or water produced by the watermaker Turn the manual three way valve T in the FLUSHING position T2 drawing 3 and connect to the container X with a piece of hose Start up only the low pressure pump by pressing F1 key for 4 seconds Feed the system with all the 40 liters of water then stop it do not let the system dry out Prepare the solution by dissolving 2 800 grams of the FL 411A...

Page 29: ... in microSiemens cm After replacing or cleaning the salinity sensor 7 6 Maintenance kit The maintenance kit allow to have on board a sufficient stock of filter cartridges and other parts that may be required for the ordinary system maintenance A complete Maintenance Kit contains No 8 prefilter cartridges 30 micron No 8 prefilter cartridges 5 micron No 2 active carbon cartridges No 1 FL 403 membran...

Page 30: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 7 30 ...

Page 31: ...arm Do not repeat the start up more than twice If the problem persists check that The filter sumps are tightened correctly The O rings are in well setted The filter sumps are filled with water Problem the watermaker starts up but it shuts down after several seconds with the HIGH PRESSURE alarm on Check make sure that the pressure control valve is open turn counterclockwise 8 3 Low pressure failure...

Page 32: ...y of produced water If it is fresh the salinity sensor requires maintenance To deliver the produced water to the accumulation tank when the UNSAFE warning is on it is necessary to act manually on the three way solenoid valve as indicated in Section 6 in case of emergency operation paragraph 6 2 If the produced water is salted in case of a multi membrane system check the produced water quality of e...

Page 33: ...ter Desalinated water Ammonia mg l no traces no traces Bicarbonate mg l 63 4 9 Boron mg l 4 0 0 4 Bromide mg l 85 0 85 Calcium mg l 315 0 8 Carbonate mg l no traces no traces Chloride mg l 17600 183 Fluoride mg l 0 8 0 1 Hydroxide mg l no traces no traces Iron mg l 0 3 0 1 Magnesium mg l 1300 2 6 Manganese mg l 0 1 0 1 Nitrate mg l 2 0 2 0 Potassium mg l 418 6 4 Silicon as Si02 mg l 10 7 5 0 Sodiu...

Page 34: ...omplete Control box Tiny 2 460V complete BC20 BCM20 BC22E BCM22E Feeding pump 230 V 400 V 3 phase Feeding pump 230 V 1 phase Feeding pump 230 V 400 V 3 phase Feeding pump 230 V 1 phase 201RPT0108PTFE Plastic Hose HTR Dia 8 x 10 TB 009 Plastic Hose Dia 20 M 2521 Membrane 300 Gpd A Membrane 275 Gpd B M 2540 Membrane 700 Gpd A Membrane 650 Gpd B PV 2521 PV 2540 Vessel 1000 PSI A14TP1F0DU0025 End plug...

Page 35: ...l 1 Hole A14TP1F0DU0025 1 3 End plug for vessel 2 Holes A14TP2F0DU0025 1 4 Adaptor for vessel A14RP212AD3237 2 5 Membrane SW30 2521 gpd 211SW025210000 1 6 Half moon secure plate 3mm 211LV00003TVIX 4 7 Screw M6x10 AX TE TF DIN933 202VT00610TE00 4 8 O ring for vessel 2521 2540 211PV00R020000 2 9 Elbow m f 201RXMF014GNPT 2 10 Elbow 7 16 201RX71614GNJI 2 11 High pressure hose 1 4 fittings THP 1 4 2 12...

Page 36: ...0 1 6 Cartridge 30 µm 2801C155017030 1 7 Cartridge 5 µm 2801C255482430 1 8 Tee fff 201ROFFF12TC00 1 9 Reduction 201RO01214RC00 1 10 Hose barb m 20 201ROM1220PC00 1 11 Straight m 10 1 4 201RPM1014DNPT 1 12 O ring 280OR151121000 2 When Automatic Membranes Flushing system isn t installed 5 8 9 11 are substituted by A Elbow mf 201RXMF012G000 1 Models SAILOR 200 400 600 1000 1500 SAILOR S 1 21 2 21 3 2...

Page 37: ...be 3 8 A14SS000000000 1 a for models SAILOR C 1000 1500 2000 2 40 3 40 BICOMPACT b for models SAILOR C 200 400 600 1 21 2 21 3 21 MINIMAR PL 200 400 600 ELECTRONIC BOARDS fig 6 No PART NAME ITEM CODE QTY 1 Tiny2 mother board 230V A14SB0000TINY2 1 1 Tiny2 mother board 400 415V A14SB0400TINY2 1 1 Tiny2 mother board 440 V A14SB0440TINY2 1 1 Tiny2 mother board 460V A14SB0460TINY2 1 2 Tiny2 cover board...

Page 38: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 9 38 fig 2 Motorized valve group fig 3 Prefilter group ...

Page 39: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 9 39 fig 4 Solenoid valve group fig 5 Flowmeter and salinity probe group control box rear view ...

Page 40: ...Instructions for the installation use and maintenance of Tecnicomar watermaker 9 40 fig 6 Control box Tiny2 mother board and cover board 1 TINY2 mother board 2 TINY2 cover board ...

Page 41: ...hnical service outlets Such expenses shall be charged to the purchaser i Any transportation freight importation or insurance costs downtime costs etc No claim shall be considered and warranty shall be considered null and void if a other than the parts supplied by Tecnicomar have been used within the system components as replacement parts or accessories b the system has been installed using differe...

Page 42: ...sary inspection and repair or replacement which may be conducted at the facilities of Tecnicomar provided such service is covered under this warranty RETURN PRODUCT TO TECNICOMAR ONLY AFTER RECEIVING FACTORY AUTHORIZATION INCLUDING THE ASSIGNMENT OF A RETURN MATERIAL AUTHORIZATION NUMBER THIS NUMBER MUST BE CLEARLY MARKED ON THE OUTSIDE OF THE BOX WHEN SHIPPING Buyer shall pay for all related labo...