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

2 1. Introduction 1.1 General Thank you for choosing a Schenker Watermaker, and we are sure that the plant will contribute to make your cruises more comfortable and more pleasant. As all the equipment aboard, the knowledge of operating and maintenance procedures allows to use the system in the best way, and to guarantee a perfect functioning throughout the years. We invite you to read carefully this manual and to keep it aboard for a quick reference. The Smart systems, as alternative to the high pressure pumps of traditional plants, 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 and the possibility to supply the watermaker directly from the batteries. The ENERGY RECOVERY SYSTEM operating components are reduced to the minimum, thanks to 2 international patented solutions that eliminate the necessity of pilot valves. The lack of high-pressure pumps makes the system silent and vibrations free, and enormously simplify the use because no adjustment is necessary for its operating. 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 118 cm 24 cm 24 cm 21 Kgs. holder for hose int. diam. 16 mm. holder for hose int. diam. 16 mm. compression fitting for hose int. diam. 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. holder for hose int. diam. 16 mm. holder for hose int. diam. 16 mm. 5 micron polyestere pleated type Power supply: 12 Vdc +/- 20% (version 60M12) 24 Vdc +/- 20% (version 60M24) Power consumption: average of 240 Watt Production performance: Seawater temperature range: Quality of water produced: 60 Lit/h +/- seawater 25 C - salinity ppm 13 C - 35 salinity ppm average of 450 ppm TDS CEE conformity: In compliance with directives 89/392 CEE sect.1 (general safety machines requirements), 89/336 CEE (electromagnetic compatibility). 3

4 1. Introduction 1.3 System description The Smart systems are based on 2 main units: PUMPS AND FILTER GROUP 1. In 2. Out 3. Pumps relays box 4. Electric connections 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. 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. Pressure switch detail 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. Reset valve Depressurization valve Positioner knob The watermaker group is constituted of the following components: Reverse osmosis membrane, installed inside blue color high-pressure vessel. Its job is to separate the intake high-pressure seawater into two flows: one for the salt-water drain and one for the fresh water production. Energy Recovery System. It has the function to amplify the pressure supplied by the pump and recover 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 is constituted of 2 cylinders, and a central body containing the hydraulic valves necessary for the system functioning. Manometer. It is located on the front of the ERS, and it measures the pump running pressure. Depressurization valve. It is utilized only during the air bleeding phase, at the first plant startup. It is recognizable by a bleu lever and it is located on back side of the watermaker. Its function is to depressurize the system and the bleed the air. The valve must be closed during normal working conditions and opened during the air bleeding operations. It is suggested to open the lever only halfway (45 ) during the air bleeding operations. Pulsation dimmer It is installed on the left of the ERS. It is a black cylindrical unit and 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 about 3 BAR This can be recharged using the valve on the unit and a tyre pump. It may be worthwhile checking this pressure when first starting up of the watermaker after installationand has the function to dampen the pumps pressure oscillations during the watermaker functioning. 5

6 Positioner: It is a stainless steel threaded arm, with a black knob, located on the right side of the unit. Its function is to reset the unit in case the system blocks during the restart. Reset valve. It is installed on the left of the ERS and it is recognizable by the little blue plastic lever. The valve must be closed during normal functioning (lever perpendicular to the valve). Such valve has the function to allow the reset in case of a system block. It must be opened before acting on the valve positioner. 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 emer- Remote panel cable connector Electric connections Signal pressure switch (probe). It is a little steel device, mounted on the left, top side of the ERS, close the reset valve. It must be connected inside the computer box, throw the cables PS / PS. Its function is check that the cycling of the machine is correct. Signal pressure switch 6

7 2. Installation 2.1 General criteria It is important to plan carefully the activity prior to start the installation works, evaluating any possible alternative solution. The fundamental choices to make are: Finding of seawater intakes and any necessary fittings. Positioning of main units. Pipes and electric cables laying. A well-done installation is the maximum optimization between functionality, accessibility, installation saving and esthetic. All plant components have been designed to achieve this target. It is suggested to draw a schematic electric and hydraulic connections layout once an installation solution is chosen, and enclose it into the manual for further quick reference. 2. Installation 2.2 Components mounting Pump 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. Th pump group needs to be installed inside to adequately ventilated room, with the purpose to facilitate the cooling of the pump and not subject to condenses or drippings. Avoid the contact or the proximity with inflammable material or liquid, since the pump surfaces can reach elevated temperatures. Avoid locating the pump wherever a possible loss of water can involve damages or jeopardize its safety. It is necessary to foresee the necessary space to be able to unscrew the filter container for replacing the cartridge. The pump group must be installed on a base sufficiently horizontal, suitable to sustain the weight of the group. It could be necessary to realize a suitable wooden or fiberglass structure if an horizontal support is not available. The base of the pump group is equipped with vibration-damping devices, but however it is preferable to not install the pumps on a plan particularly subject to vibrations. It is preferable to install the pump in an acoustically isolated room since they constitute the principal source of noise, although modest, of the plant. Possible locations of the pump group are: engine compartment, sink closets, peak tank. The unit is normally fixed on the support structure using the screw furnished with the equipment or the passing bolts with die and washer, if the inferior part of the support structure is accessible. Watermaker group. The watermaker unit is totally hydraulic, as electric devices are not present. Therefore, it is also possible to install the unit inside spaces that can be exposed to humidity, to condense, or to the presence of inflammable vapors. There are not height limits in comparison to the seawater level. 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 positioned, in the standard version, on the left of the unit. Therefore, it is necessary to foresee a minimum distance of 20 cm. to allow the pipes laying. The watermaker unit must be installed on a base sufficiently horizontal, suitable to sustain the weight of the group (approx. 25 Kg). It could be necessary to realize a suitable wooden or fiberglass structure if an horizontal support is not available. The watermaker unit is equipped with vibration-damping devices, but however it is preferable to not install the unit on a plan particularly subject to vibrations. Possible locations of the watermaker group are: engine compartment, closets, and peak tank. It is advisable to install the unit in such position to make the instrumentation easily visible, and make the valves (located on the right of the unit) easily accessible. 7

8 The unit is normally fixed on the support structure using the screw furnished with the equipment or the passing bolts with die and washer, if the inferior part of the support structure is accessible. Non return valve. The non return valve must be installed vertically, as close as possible to the water inlet. 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 scoop 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. It is necessary to use a offtake downstream the boat sanitary water pressurization system (fresh water pump). The following conditions must be respected during the operation: the washing operations have to be always executed with the fresh water pump on, the fresh water pump pressure doesn't have to exceed 2,5 BAR. Salt-water drain. The salt-water drain shall be ½ minimum size and it has to be preferably above the seawater level. It is possible to use offtakes from existing apparatuses, provided that it is not the engine cooling water drain or uses that drain with elevated heads. 8

9 2. Installation 2.4 Hydraulic connections Exhausted discharge OUT Plumb to pressure side of boat fresh water sys- IN Reinforced hose PN15 min int. dia. 16 mm. Connection to the fresh water tank (use the small 6X8 hose). Armovin The connection has to be made, using the small hose type hose furnished with the equipment, and relevant endowed fittings. 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. 9

10 The hydraulic connections are the followings: Low pressure -connections sea water inlet- net filter - max 3 bar 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) PUMP CONNECTIONS: Connect the in/out hoses to the pump as follows: WATERMAKER CONNECTIONS: Connect the in/out hoses to the watermaker as follows: OUT Fresh water IN Connection to the fresh water tank (use the small 6X8 hose). The connection has to be made, using the small hose furnished with the equipment, and relevant endowed fittings. The connection has to be made between the little grey fitting located on the right side of the silver vessel, 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 where to connect the endowed male connector. An ulterior possibility is to draw a T derivation on the tank air drain hose. This is possible if the breather pipe section is enough larger (16 mm.) to avoid that the water flow from the watermaker can block the leak, creating functional problems to the fresh water pump. 10

11 There are no particular limits on the connection length. The bending radius of the hose doesn't have to be less than 50 mm. 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.) 11

12 Wiring connection diagram Pressure switch Electrovalve 12

13 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. 13

14 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 after the 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. 14

15 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. After the procedure the system is ready to start normally. 15

16 3. Operation 3.3. Normal operation procedure It is always strictly recommended to select the automatic washing, pushing WASH- ING. 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. 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. 16

17 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 17

18 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. 18

19 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 Check the working pressure Check the pressure on the manometer located on the front of the unit. 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. 19

20 4. MAINTENANCE 4.3 SYSTEM TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Pressure switch burned or disconnected Restore Pumps do not start 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) Electronic failure System is blocked Dirty filter Dirty membranes Trouble in the cycling system Pump pressure switch not calibrated Dirty filter or membranes Cold sea water Exhausted batteries Air in the plant Seal system leak Cold sea water Dirty membranes Activate the pumps with the miscoswitches Perform Reset Replace cartridge Perform cleaning cycle Contact a Schenker service point Calibrate pressure switch Clean or replace Calibrate pressure switch Check battery charge Perform bleeding Contact a Schenker service point Normal condition Perform cleaning cycle Leaking in the plant Loose connectors ERS loss Tighten connectors Contact a service point 20

21 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. 21

22 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 22

23 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. 23