OPERATION AND MAINTENANCE MANUAL

Transcription

1 OPERATION AND MAINTENANCE MANUAL 1. Introduction 1.1. General 1.2. Technical data 1.3. System description 2. Installation 2.1. General criteria and material required 2.2. Components mounting 2.3. Water intake 2.4. Hydraulic connections 2.5. Electric connections 3. Operating procedures 3.1. Remote panel commands 3.2. First start-up procedure 3.3. Normal operations 4. Maintenance 4.1. Shutdown procedure 4.2. Maintenance and recurrent inspections 4.3. Troubleshooting 5. Safety cautions 6. Warranty 1 Rev. 2011

2 1. Introduction 1.1 General Thank you for choosing a Schenker Watermaker which we know will give you years of service, making life onboard more enjoyable. To ensure the maximum efficiency of your Schenker Watermaker and its trouble free working, Please read this manual and to keep it onboard for reference. The Modular 60 watermaker uses Schenker s patented ENERGY RECOVERY SYSTEM which amplifies the pressure of common low pressure pumps, and recoups all the hydraulic energy back from the membrane. This saves on the use of power, allowing the Modular 60 to be run directly from the vessels batteries. The ENERGY RECOVERY SYSTEM operating components are reduced to a minimum, thanks to two internationally patented solutions that eliminate the need for pilot valves. The lack of high-pressure pumps ensure that the system is silent and vibration free. It also means that no adjustments are required when the system is started up. Another system feature of the Modular 60 is operating flexibility; the watermaker is equipped with two independent pumps, allowing the regulation of water production according to the owner's needs. 30 litre/hour water production can be obtained by starting just one pump, consuming only 100 Watt, whereas with both pumps running 60 litre/hour water is produced with a consumption of 240 Watt. 2

3 1. Introduction 1.2 Technical data WATERMAKER GROUP Dimensions Length: Width: Height: Net weight: Connections: Seawater intake Salt water outlet Fresh water outlet 67 cm 30 cm 30 cm 28 Kgs fitting for hose int. dia. 16 mm. fitting for hose int. dia. 16 mm. compression fitting for hose int. dia. 6 mm. int. X 8 mm. external PUMPS GROUP Dimensions Length: Width: Height: Net weight: Connections: Seawater intake Salt water outlet Filter: 34 cm 19 cm 35 cm 10 Kg fitting for hose int. dia. 16 mm. fitting for hose int. dia. 16 mm. 5 micron type Power supply: 12 Vdc +/- 20% (version 60M12) 24 Vdc +/- 20% (version 60M24) Power consumption: 250 Watt average Production performance: Quality of water produced: CEE conformity: 60 Lit/h +/- seawater 25 C - salinity ppm (Parts per million) average of 400 ppm TDS (Totally dissolved solids) In compliance with directives 89/392 CEE sect.1 (general safety machine requirements), 89/336 CEE (electromagnetic compatibility). 3

4 1. Introduction 1.3 System description The Modular systems are based on 2 units: PUMPS AND FILTER GROUP 1. In 2. Out 3. Pumps relays box 4. Electric connections Pumps group This unit picks-up the sea water up and sends it to the watermaker at pressure (about 7,4 7,8 Bar). The filter housing contains a 5 micron filter cartridge, and its job is to filter impurities that may damage the watermaker unit. A red push-button is positioned on the top of the housing to help to purge air from the filter. Pressure switch detail The pumps are fitted with a safety cut off switch, calibrated at about 9 Bar. The pressure switch can be adjusted by an 2 mm. allen key. To make the allen key adjustment to the pressure switch pictured, the cover to the connector must be removed. This gives access to make an adjustment by inserting the allen key without removing the connector itself. Turning the allen key clockwise increases the preset pressure, and turning anti clockwise decreases the preset pressure. The movement required is very small. (1/4 turn = 1 BAR). This action will not be required in normal circumstances as the unit has been pre calibrated at the factory. The grey box contains the power relays that activate the pumps electric motors. Pump relay box 4

5 WATERMAKER GROUP 1. Reverse osmosis membranes 2. Manometer 3. Flow meter The watermaker group is based on the following main components: Reverse osmosis membranes, inside the silver high-pressure vessel are used to separate the intake high-pressure seawater into two flows: one for the salt-water waste and one for fresh water production. Energy Recovery System. Amplifies the pressure supplied by the pump and recovers the hydraulic energy back from the membranes. The ERS device makes periodic cycling by a hydraulically controlled automatic valve. The cycles are noticeable through a beat issued periodically by the watermaker unit. The unit contains two cylinders, and a central body housing the hydraulic valves. Manometer is located on the front panel, and it measures the running pressure of the pumps. Flowmeter is located on the front panel, and measures the flow of produced fresh water coming out of the unit. This is only indicative as the accuracy of the flowmeter is +/- 20%. 5

6 1. Depressuruzation valve 3. Reset valve 3. Positioner Depressurization valve. Is used for purge the air from the system. This is a blue lever located to the rear of the watermaker. Its function is to depressurize the system and allow air bleeding. The valve must be closed during normal working conditions and is opened only during the air bleeding operations. It is suggested to open the lever halfway (45 ) during air bleeding operations. Positioner: A stainless steel threaded arm, with a black knob, located on the right side of the unit. Its function is to reset the unit if it is hydraulically blocked. Reset valve. Is installed on the front right hand corner of the watermaker unit. It is a small blue plastic lever. The valve must be closed during normal functioning (lever perpendicular to the valve). This valve allows resetting in case of a system failure It must be opened before using the valve positioner. Pressure switch and accumulator Pressure switch. It is a little electric device, positioned on the rear, below the 3 rd membrane. It is connected to the computer throw the cables PS / PS. Its function is check that the cycling of the machine is correct. Accumulator unit. Is a cylindrical unit located behind the ERS ( Main Black body of the watermaker unit) its purpose is to dampen the pump's pressure oscillations during the watermaking. The accumulator is factory pre charged with air to a pressure of 3.0 BAR. Check the pressure periodically (at least every year) and adjust it. 6

7 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 P1, P2, and EV allow the direct command of pump1, pump2 and the electrovalve respectively. They can be used, as an emergency solution, for starting the watermaker in case of total failure of the electronic computer. In normal condition they have to be switched off. Emergency microswitch Remote panel cable connector Electric connections 7

8 2. Installation 2.1 General criteria A planned installation will make both fitting and operation of your Modular 60 watermaker easier. Details below need to be taken into account with your installation: An appropriate seawater intake with necessary fittings. Positioning of Pump & Watermaker units. Pipework and cable laying. A good installation needs to be easy to use, easy to access for maintenance and filter changes. All Watermaker components have been designed to achieve all of this. Draw a schematic electric and hydraulic connection diagram when the installation plan is complete and keep it with this manual for reference. 2. Installation 2.2 Components mounting Pumps group The pumps are self-priming type. Anyway it suggested to install the pumps group below the watermaker, as low as possible respect the sea level, and as close as possible respect the sea water intake. The pumps need to be installed in an adequately ventilated area to allow cooling and avoiding condensation. Do not install the pumps unit close to inflammable liquids, as the pump surfaces can become warm. Avoid locating the pump where a loss of water can cause damage or jeopardize its safety. Allow sufficient space for access to the casing containing the filter cartridge. The pump must be installed horizontally on a suitable base strong enough to support its weight when the filter housing is full of water. It may be necessary to create a suitable wooden or fiberglass structure for the unit if an existing one not available. The base of the pump is equipped with vibration-damping devices, but avoid installing it on a surface susceptible to vibration. The pumps unit can be a little noisy in operation. Possible areas for siting are: sink closets, under berth lockers, wardrobe bases (creating a false floor above it.) It is not recommended to fit the pumps unit in the engine compartment. The unit can be fixed on the supporting structure using the screws supplied with the equipment or the bolts with nuts and washers. Watermaker unit. The watermaker unit is hydraulic. It can be installed in areas inside exposed to humidity. It can be installed at any height inside the vessel. Avoid installing the system where a leak will cause damage to the boat or jeopardize its safety. The hydraulic intake and outlet connections are positioned in the standard version, on the left hand side of the unit. It is necessary to leave a minimum distance of 20 cm. to allow for pipe laying. Possible locations of the watermaker group are: engine compartment, under berth lockers, cockpit lockers. Install the unit where access to valves and instrumentation is visible. The unit is fitted with rubber mountings to prevent vibration, avoid fitting the watermaker in an area where there is a lot of vibration. The unit can be fixed on the supporting structure using the screws supplied with the equipment or the bolts with nuts and washers. Non return valve. The non return valve must be installed vertically, as close as possible to the water inlet. 8

9 2. Installation 2.3 Water intakes The necessary hydraulic intakes are: Seawater intake It is ideal a specific sea water intake, size ¾ min. in a central position, well under the water surface even when the vessel is well heeled over. The skin fitting is recommended. It must be oriented to the bow of the boat. As alternative it is possible Tee into an water inlet as long as the following conditions are met: - 3/4 minimum size, - No air can be introduced into the system from other use ie: salt water tap in galley -Must always be under the water surface even when the vessel is well heeled over. Allow a minimum ½ on-off ball valve on the water intake. The hose connections, especially if under the seawater level, must be secured with double hose clamps. It is not advisable to Tee into the engine cooling water intake as it may impair the cooling of the engine. 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 to use filters from existing outlets. Fresh water intake for washing. Tee in downstream of the vessel's fresh water pressure system (Domestic water from tank). IMPORTANT Flushing must always be carried out with the pressure water system ON. The pressure water system must NOT exceed 2.5 BAR. Salt-water waste. (After passing through the watermaker) The salt-water reject fitting must be ½ minimum and preferably above the seawater level. Again, if required you can tee into an existing skinfitting ie: sink water out, one way valves may need to be considered. The watermaker waste pipe must be unobstructed when the machine is in use. 9

10 2. Installation 2.4 Hydraulic connections Exhausted discharge Plumb to pressure side of boat fresh water Reinforced hose PN15 min int. dia. 16 mm. Armovin type hose int. dia. 16 mm. Pressurized fresh water valve Pump Elecrovalve Non return valve 5 micron filter Net filter Swan neck upward - Disharge Water inlet Watermaker Active carbon filter Fresh water outlet All the hydraulic connections (to exception of the fresh water production) have to be realized with a 16 mm. int. diam. hose and a ½ holder. 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 15 min. reinforced hose. An inadequate hose could burst, jeopardizing seriously the safety of the boat. The hydraulic connections are the followings: Low pressure max 3 bar -connections sea water inlet- net filter - backflow valve inlet. -connection watermaker s exhaust discharge - drain outlet. PN 5 stainless steel spring type hose 16 mm int. diam Medium pressure max 13 bar Low pressure - max 3 bar -connections fresh water pressurized system carbon filter-backflow valve outlet pump inlet -connections pump outlet-5 microns filter watermaker inlet. PN 15 reinforced hose 16 mm int. diam.) - Connection to the fresh water tank Small 6X 8 blue pipe (furniched) 10

11 PUMP CONNECTIONS: Connect the in/out hose to the pump as follows: WATERMAKER CONNECTIONS: IN (sea water inlet from the pump) Make use, for this connection, of the external holder located on the left side of the watermaker (marked IN). OUT (Discharge outboard) Make use, for this connection, of the holder located on top of the pressure 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 right), and the upper side of the tank, on a ¼ outlet if available. It is possible, in case of metal tanks, to make a ¼ threaded hole to connect the supplied male connector. Another option is to Tee into the tank air vent hose.there are no particular limits on the connection length. 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. 11

12 2.Installation 2.5 Electric connections Remote control panel mounting The remote control panel has the following dimensions: width 135 mm. height 116 mm. It can be flush mounted on any surface, providing the area behind is free of moisture and condensation and there is enough depth to house the rear part of the panel (approx. 8 cm.). To cut on the mounting surface will have the following dimensions: width 115 mm. height 97 mm. Wiring Power Supply The Power supply, coming from the service batteries, needs to be connected to the terminals + and of the Pump Box. An automatic circuit breaker (32A for 12VDC systems and 16A for 24VDC systems) must be installed on the power supply. The section of the cables must be adequate. See the table below: Voltage Automatic Cable lenght switch up to 3 mts 3-7 mt mt. Volt Ampere mm2 AVG mm2 AVG mm2 AVG Connections between the pump box and the computer box 4 cables (section 2,5 mm2) will connect the pump box with the computer box. The cables + / - will provide the power to the computer box. The cables P1 and P2 will provide the commands to the two pumps of the systems. Connections between the computer box and pressure switch and electrovalve The pressure switch, positioned on the watermaker, has to be connected to the clamps PS/PS in the computer box (section 2,5 mm2) The electrovalve, positioned on the active carbon filter has to be connected to the clamps EV/EV in the computer box (section 2,5 mm2) Connection between the computer box and remote panel. Connect the remote panel to the computer box using pre wired cable supplied (standard length 10 mts.) 12

13 Wiring connection diagram Pressure switch Electrovalve 13

14 3. Operation 3.1. Remote panel commands KEYBOARD FEATURES The panel keyboard has a total of four push button. The display light switches off after 15 minutes of not use. Pushing any button, the display will light again, without activate any other command. The functions of the push buttons are: START Used to start the system. If it is pushed shortly the system starts and the unit will run indefinitely until will be pushed STOP. If it is pushed for at least 3 seconds the system starts, and will stop automatically after the working hours selected with the timer (see menu functions). It can anyway be stopped before, pushing STOP. It is used as well to scroll the different options in the single menu. STOP Used to stop the system. The system, once pushed STOP, usually doesn t stop suddenly. It automatically await 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 rinse the system automatically with fresh water. If it is pushed shortly the system will get ready to perform an automatic washing (1 minute long) once the system will be stopped. If it is pushed for at least 3 seconds the system will just perform a 10 minutes rinsing, without suck up sea water. MENU Used to enter into the MENU mode and modify some parameters. Pushing it repeatedly the different MENU options can be scrolled. 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. 14

15 Menu options: PUMPS. 4 options are available: P1 the system works with pump1 only. In this case the production will be about 30 lit/h and the electric consumption will be about 100 watt P2 the system works with pump2 only. In this case the production will be about 30 lit/h and the electric consumption will be about 100 watt P1&P2 the system works with one pump only, alternating p1 and P2 every 20 minutes in order to balance the wearing of the two pumps. Even in this case the production will be about 30 lit/h and the electric consumption will be about 100 watt. P1+P2 the system works with both pumps. In this case the production will be about 60 lit/h and the electric consumption will be about 240 watt WORKING TIME (timer) It allows to select the working time of the watermaker (1-6 hours). The timer is activated if the START button is pushed for more than 3 seconds only. 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. 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. AUTOMATIC START-UP. This function activate automatically the first start up procedure. The procedure is necessary when a new machine is started for the first time, or a after filter cartridge replacement, or a general service. The procedure allows to purge completely the air from the system, and from the seawater and the washing fresh water hoses. The depressurization valve must be opened before start the procedure. PERIODIC WASHING This function allows a periodic automatic rinsing (every 6-10 days) with fresh water. It can be used before long inactivity periods. The single washing operation will last about 1 minute. The consumed fresh water, for every washing, is about 10 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 (6-10), exit from the menu, pushing STOP, and then push WASHING for 3 seconds. The display will indicate the remaining day before the first rinsing. The function is anyway disabled pushing STOP, or after a normal production cycle. 15

16 MESSAGES SYSTEM STANDBY It indicates that the system is ready to be set and started. 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). SYSTEM BLOCKED The message must be acknowledged pushing STOP. 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 origins of the problem. 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. BYPASS WARNING This message advice or remember that the unit is working in bypass mode (then some safety functions are disabled). CHANGE PUMP FILTERS This is a blinking messages that must be acknowledged pressing the key STOP This messages suggest to replace the filter of the pump group. 3. Operation 3.2. First start-up procedure The first start-up procedure is necessary to start the first time a new system, just installed. The purpose of the procedure is basically purge out the air from the system. It can be used as well after a filter replacement, or after other maintenance operations. Preliminary checks: Verify that all components are connected correctly. Verify that the filters cartridges are installed. Verify that the seawater valve, and the possible drain valve, are opened. Verify that the reset valve is closed (lever orthogonal to the body valve) and the positioner completely unscrewed. Verify that the small gray valve on the active carbon filter is opened and the fresh water pump of the boat is on. Verify that the fresh water tanks are full enough (at least 50 liters) to perform the first washing operations. Start-up procedure: 1. Open halfway the depressurization valve (45 ). 2. Activate the start up procedure throw the function of the MENU (select the specific function in the menu mode, exit from menu mode pushing STOP, and start the procedure pushing START). 3. Close the depressurization valve when the display shows the specific message. The procedure lasts about 3 minutes. It can anyway stopped anytime pushing STOP. 16

17 After the procedure the system is ready to start normally. 3. Operation 3.3. Normal operation procedure It is always strictly recommended to select the automatic washing, pushing WASHING. Production without timer. -Select the pump mode (P1, P2, P2&P2, or P1+P2) throw the specific pump menu (the system anyway will hold the previous setting, even if the electric power is switched off). -Push the button START. The control will open the depressurization valve, helping the inlet pump hose to get filled with water. Then the pump(s) will start after 5 seconds. The display will show the increasing production time. -Push STOP to stop the unit. If the washing has been selected, the system will start the washing procedure, and then will stop automatically after 1 minute. Production with timer. -Select the pump mode (P1, P2, P2&P2, or P1+P2) throw the specific pump menu (the system anyway will hold the previous setting, even if the electric power is switched off). -Select the timing (1-6 hours) throw the specific timer menu (the system will hold as well the previous setting.) -Push the button START for more than 3 seconds. The display will show the decreasing production time. The system will stop after the selected hours, performing before, if selected, the automatic washing. Anyway the system can be stopped at any time pushing STOP. Single washing operation (10 min. last) -Select the pump mode P1+P2 -Push washing for more than 3 seconds. The display will indicate the remaining time. It is possible anyway to stop the operation at anytime pushing STOP. Single washing operation (10 min. last) -Select the pump mode P1+P2 -Push washing for more than 3 seconds. The display will indicate the remaining time. It is possible anyway to stop the operation at anytime pushing STOP. Periodic washing -Select the days (6-10) in the washing menu - Exit from the menu pushing STOP - Push WASHING for 3 seconds. The display will indicate the remaining day before the first rinsing. The function is anyway disabled pushing STOP, or after a normal production cycle. 17

18 ATTENTION If the watermaker get air, (or if some other problem occurs) the automatic hydraulic valve may stop in a central position. This means that pressure on both sides of the valve are the same and the unit is effectively stalled and has to be manually restarted. In this case the working pressure goes up suddenly (up to 8-9 Bar) and the pumps are switched off from the pumps pressure switch. The pumps then have the tendency to try to restart when the pressure decreases, and then to jam again, resulting in a typical start-stop noise. After approx. 20 sec. the computer recognize the problem, and turn off the pumps, and the message WARNING SYSTEM BLOCKED is displayed. This event, besides being very unusual, does not damage the system, but it is necessary to reset the valve with the following simple procedure: RESET PROCEDURE 1. Turn the system off. 2. Open the reset valve (lever in horizontal position). 3. Screw the positioner knob clockwise until it can be moved no further. 10 turns at least are necessary. 4. Unscrew the positioner knob up to the original position, until when it is blocked back. 5. Close the reset valve (lever in vertical position). 6. Restart the system 18

19 4. Maintenance 4.1 Shutdown procedure It is necessary to perform the shutdown procedure before effecting standstills longer than 3 months, for instance before laying up for winter. The purpose of the shutdown is to clean the unit of possible deposits of limestone, and to inhibit the growth of microorganisms that may reduce the reverse osmosis membrane's efficiency. The following equipment is necessary in order to perform the shutdown operation: 1 ea. recipient 20 liters minimum capacity (a bucket of such capacity could also be suitable). Two 16 mm. linen hoses of a length that allow them to be fed into the same container A prepared shutdown solution SCHENKER CLEANING 1. Tools for de-assembling hoses (screwdrivers, pliers, etc.) Hydraulic connections diagram to perform the shutdown The shutdown procedure is: 1. Collect approx. 15 liters of unchlorinated fresh water into the bucket. The water produced by the watermaker itself could be fine. 2. Empty the entire content of the SCHENKER CLEANING 1 solution into the picked water, and mix carefully following the indications on the pack. Wear a protection mask in order to avoid inhaling product dusts. The water temperature doesn't have to be lower than 25 C preferably. 3. Close the grey valve on the active carbon filter. 4. Disconnect watermaker unit drain hose and the pumps suction hose. 5. Connect two hose pieces to the drain and to the pump suction. 6. 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. 7. Open the depressurization valve at Start the watermaker (with both pumps, and bypass activated ) and leave the system on for approx. 30 min., checking that the hoses are properly positioned in the container, so as to avoid drawing air or spilling the liquid into the boat. 9. Turn the watermaker off, disconnect hose pieces, and connect the pump suction, drain and water production original hoses. Chemical Cleaning Kits: Schenker No 1 is an acid based organic cleaner. This is used for 'pickling' the watermaker when not in use and as part of the general cleaning process. See 4.1 Shutdown procedure Schenker No 2 is an alkaline base organic cleaner. If the watermaker has been left standing without pickling or has a 'bag egg smell, cleaning with Schenker No2 will remove this. 19

20 4. Maintenance 4.2 Verifications and periodic maintenance The following periodic procedures are to be followed to maintain trouble free operation: OPERATION EVERY PROCEDURE Check and clean Strainer check and cleaning Every 5 days 5 micron cartridge replacement Every days in average conditions (4 hours/day usage). Anyway replace it when the message CHANGE PUMP FILTERS appears. Unscrew anticlockwise the filter holder. Active carbon filter replacement Every 6 months Close the grey valve before open the filter Purge periodically the air from the system, opening at 45 for a couple of minutes the depressurization valve Every 15 days 20

21 Check the pressure on the manometer located on the front panel. The working pressure depends on many factors such as water temperature, salinity level of seawater, battery voltage, cleanliness of membranes and type of installation. The pressure, under mid range working conditions is approx. 5,6 BAR with one pump on, and approx. 7,6 BAR with two pumps on. There is a small pressure loss, in the range of 0,2 Bars, during the cycle. Membrane replacement The reverse osmosis membranes have an average working life of 7 years. After 5 years they may start to degrade. If in doubt as to their condition contact a Schenker service point and replace as a matter of course after 7 years. 21

22 4. MAINTENANCE 4.3 SYSTEM TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Pump pressure switch burned or Restore Pumps do not start disconnected Electronic failure Activate the pumps with the miscoswitches Pumps start but stop at high pressure While functioning the pumps momentarily shuts down Low production / normal or low pressure Low production / high pressure (> 8 Bar) Leaking in the plant System blocked for air Dirty filter Trouble in the cycling system Pump pressure switch not calibrated Dirty filter or membranes Cold sea water Low battery voltage Air in the plant Seal system leak Cold sea water Dirty membranes Loose pipe connections ERS loss Perform Reset procedure Replace cartridge Contact a Schenker service point Calibrate pressure switch Clean or replace See 4.2 Calibrate pressure switch Check battery voltage Perform bleeding Contact a Schenker service point Normal condition Calibrate Pressure switch Perform cleaning cycle 4.2 Tighten connections Contact a service point 22

23 ELECTRONIC TROUBLESHOOTING Probe (system pressure switch ) troubleshooting: If the system goes frequently in blocked position (generating the message SYSTEM BLOCKED) without hydraulic problems, this could possible that the origin of fault is a malfunctioning of the probe (pressure switch) The pressure switch can be tested with following procedure: 1. De-connect the pressure switch cables. 2. Activate the by-pass and start the system. 3. Check with a meter in ohm position, between the cables PS/PS, the functioning of the pressure switch. If working, the pressure switch closes and open the circuit alternatively each 3-4 seconds. 4. If the pressure switch is always close or open during the functioning of the watermaker, it is out of service and must be replaced. 23

24 5. SAFETY WARNINGS Ensure the watermaker is correctly installed by contacting a Schenker service point. The water produced by a Schenker Modular 60 watermaker using clean sea water will have an average quality of 400 ppm TDS. Unless the correct cleaning procedures are carried out in accordance with this manual, there may be bacteria present in the produced water. Avoid using the watermaker where seawater is polluted (ports, or close to built-up areas, etc.) Do not locate near the pumps unit in areas that can reach elevated temperature. Ie: Engine compartments or where inflammable substances are stored. This will adversely affect the working of the pumps and may present a fire risk. Do not touch the pumps and pump fans when the unit is working. Children and those unfamiliar with the watermaker shall not touch or operate the unit. Check periodically for leaks. Do not operate the watermaker when the vessel is left unattended. Avoid installing the watermaker where a leak may go unnoticed and jeopardize the safety of the boat. Unqualified and non-schenker personnel shall not perform any maintenance work on the watermaker 24

25 6. WARRANTY The equipment and the relevant accessories are guaranteed 12 months from delivery. The guarantee does not include consumable items (filters, carbon filters, membranes, etc.). The ERS pressure amplification device is guaranteed 36 months, provided that the annual maintenance is performed at a Schenker service point. The guarantee covers faults, defect of materials and parts. It is limited to the replacement or repair 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 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). Dismantling by non-authorized personnel will render void all guarantees. Schenker Italia can not be held liable for any direct or indirect damage caused by the malfunctioning equipment, limiting its responsibility to the repair and replacement of faulty parts. 25