OPERATION AND MAINTENANCE MANUAL

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. First start-up procedure 3.2. Normal operating procedure 4. Maintenance 4.1. Shutdown procedure 4.2. Maintenance and recurrent inspections 4.3. Troubleshooting 5. Safety cautions 6. Most frequent operations summary table. 7. Warranty 1

Rev. 2014 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 Smart 30 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 Smart 30 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 the system is silent and vibration free. It also means that no adjustments are required when the system is started up. 2

1. Introduction 1.2 Technical data WATERMAKER GROUP Dimensions Length: Width: Height: 68 cm 24 cm 24 cm Net weight: 18 Kgs. Connections: Seawater intake Salt water outlet Fresh water outlet 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 PUMP GROUP Dimensions Length: Width: Height: Net weight: Connections: Seawater intake Salt water outlet Filter: 34 cm 19 cm 35 cm 7 Kg. Fitting for hose int. dia. 16 mm. Fitting for hose int. dia. 16 mm. 5 micron polyester pleated type Power supply: 12 Vdc +/- 20% (version 30S12) 24 Vdc +/- 20% (version 30S24) Power consumption: average of 110 Watt Production performance: Seawater temperature range: Quality of water produced: 30 Lit/h +/- 20% @ seawater 25 C - salinity 35.000 ppm 15 C - 35 C @ salinity 35.000 ppm average of 450 ppm TDS CEE conformity: Complies: 89/392 CEE sect.1(general safety machines requirements) 89/336 CEE (electromagnetic compatibility). 3

1. Introduction 1.3 System description The SMART system comprises of two separate units: PUMP AND FILTER GROUP. This unit have the duty of picking the sea water up and send it to the watermaker unit at a certain pressure (about 7,5 8 Bar). The pump is equipped with a pressure switch for high-pressure shutdowns, calibrated at about 9 Bar. Pressure switch detail The filter is based on a 5 micron filtering cartridge. It filters the impurities that may cause damage to the watermaker. A red push-button air purge is sited on top of the filter unit to allow the removal of air at the beginning of start-up operations. Close to the pump is the pressure accumulator.(similar to that used on your domestic pressure water system) This equalizes the water pressure during the watermaker cycles. The accumulator is pre-charged to a pressure of 2.8 Bar. WATERMAKER GROUP. Reset valve Depressurization valve Positioner knob The watermaker group comprises of the following components: The Reverse osmosis membrane, inside the silver high-pressure vessel is used to separate the intake high-pressure seawater into two flows: one for the salt-water waste and one for fresh water production. 4

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. It is located on the front of the ERS, and it measures the pump running pressure. Depressurization valve. Is used during the air bleeding operations, mainly at the first plant start-up. This is a blue lever located on the rear of the watermaker. Its function is to depressurize the system and allow air bleeding. The valve remains closed during normal working conditions and is opened only during the air bleeding operations. The lever need only be opened 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 in start up failure. Reset valve. Is installed on the left of the ERS and it is a small little 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. Accessories: Active carbon filter with electrovalve: It removes the chlorine from the pressurized flushing fresh water (the chlorine could damage the reverse osmosis membranes). It is fitted with an electrovalve, controlled from the selector flushing of the remote panel. Srainer: The strainer (installed on the suction of the pump) protects the pump from gross sediments that could damage the pump head. Non return valve. It avoids the emptying of the suction pipe of the pump, and allows to perform the rinsing of the unit. It must be installed vertically and as close as possible to the water inlet. 2. Installation 2.1 General criteria A planned installation will make both fitting and operation of your Smart 30 watermaker easier. Below need to be taken into account with your installation: An appropriate seawater intake with necessary fittings. Positioning of Pump & Watermaker units. Positioning of pump operation automatic circuit breakers. Pipework and cables 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 installation solution is complete and keep it with this manual for reference. 5

2. Installation 2.2 Components mounting Pump group. The pump is partially self-priming. Anyway it is strictly recommended to install the pump below the watermaker, and as low as possible respect the sea level, and as close as possible respect the sea water intake. The pump needs to be installed inside to adequately ventilated room to allow the cooling of the pump and avoiding condensation. Do not install the pump unit close to inflammable liquids, as the pump surfaces can become heated. 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 pump unit can be a little noisy in operation. Possible are: sink closets, under berth lockers, wardrobe bases (creating a false floor above it.) 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 totally hydraulic and needs no electricity. It can be installed in areas inside exposed to humidity, or to the presence of inflammable vapors. It can be installed at any height inside the vessel. Avoid installing the system wherever 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 pipe laying. The pump must be installed horizontally on a suitable base, strong enough to support its weight. (20kg) The base of the pump is equipped with vibration-damping devices, but avoid installing it on a surface susceptible to vibration. 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 can be fixed on the supporting structure using the screws supplied with the equipment or the bolts with nuts and washers. 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: 6

- 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 flushing. Tee in downstream of the vessel's fresh water pressure system (Domestic water from tank). The following conditions must be respected : The flow of the existing fresh water pump must be min 5 lit/min. Flushing must always be carried out with the pressure water system ON, and the grey valve on the AC filter opened. Salt-water waste. (After passing through the watermaker) 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 apparatuses that drain out water with elevated pressure. 7

2. Installation 2.4 Hydraulic connections Exhausted discharge Plumb to pressure side of boat fresh water system 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 (strainer) 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. 8

The hydraulic connections are: 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 (furnished) PUMP CONNECTIONS: Connect the in/out hose to the pump as follows: WATERMAKER CONNECTIONS: 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 supplied with the watermaker to the tank. The connection has to be made between the grey plastic fitting located on the right side of the membrane, 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 to the male connector. Another option is to Tee into tank air vent hose. There are no particular limits on the connection length. 9

2.Installation 2.5 Electric connections Remote control panel mounting The remote control panel has the following dimensions: width 100 mm. height 75 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. 70 mm.). The cut on the mounting surface will have the following dimensions: width 80 mm. height 50 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 (16A for 12VDC systems and 10 A 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. 7-10 mt. Volt Ampere mm2 AVG mm2 AVG mm2 AVG 12 16 4 11 10 7 16 5 24 10 2,5 13 4 11 4 11 Electric cables and switches selection table. Connections between the pump box and the remote panel 3 cables (section 2,5 mm2 - AVG 13 ) will connect the pump box with the remote panel. Connections between the remote panel and electrovalve The electrovalve, positioned on the active carbon filter has to be connected to the clamps EV/EV of the remote panel (section 2,5 mm2 - AVG 13) 10

Remote panel. Rear electric clamps. Electrovalve Wiring connection diagram 11

3. Operation 3.1 Remote panel selectors. The selctor PUMP of the remote panel starts the pump of the watermaker when switched on (turned clockwise) The selctor FLUSHING opens the fresh water electrovalve, allowing the flushing cycle of the watermaker. 3. Operation 3.2. First start-up procedure The first start-up procedure is necessary to start a new system for the first time or to restart it after having performed the laying up procedure. The purpose of the procedure is basically to purge the air from the system. Preliminary checks: Verify that all components are connected correctly. Verify that 5 micron filter cartridge is installed in the cartridge holder, and screwed correctly. Verify that the seawater ball valve is opened. Verify the service batteries voltage is fine. Verify that the fresh water pump is on. Verify the small grey valve on the AC filter is opened Start-up procedure: 1. Open the depressurization valve at about half run (45 50 ). 2. Switch on both selectors PUMP and FLUSHING. 3. After about 1 minute switch off the selector FLUSHING (leaving on the selector PUMP). 4. After 3-4 minutes close the depressurization valve. The system starts going under pressure and the fresh water production begins. Verify that there are no water leaks in the hose connections. In such case, fasten the hose clamps further. 5. After a while switch on the selector FLUSHING, in order to wash the unit before stopping it. 6. After about 1 minute switch off both selectors PUMP and FLUSHING at once. 12

3. Operation 3.3. Normal operations Fresh water production Preliminary checks: Depressurization and reset valve closed Operations: 1. Switch on the PUMP and verify the watermakert is working normally (pressure between 7 and 8 bar). 2. After produced the needed amount of fresh water, switch off the selector PUMP Fresh water production with final flushing (recommended procedure) Preliminary checks: Depressurization and reset valve closed Small grey valve on the AC filter is opened Operations: 3. Switch on the PUMP and verify the watermakert is working normally (pressure between 7 and 8 bar). 4. After produced the needed amount of fresh water, switch on the selector FLUSHING, in order to flush the unit before stopping it. 5. After about 1 minute switch off both selectors PUMP and FLUSHING at once. 13

ATTENTION If the watermaker is stopped just on the beat (on the pressure peak), or if some air is in the system, 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. The symptoms of this are when the pumps are turned on, the manometer reaches an elevated pressure (approx. 9 Bar) and the pumps shutdown automatically by the pressure switches intervention. 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 noisethis phenomenon, besides being very rare, does no harm to the system, but it is necessary to reset the valve with the following simple procedure: RESET PROCEDURE 1. Turn pump 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 14

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. Disconnect watermaker unit drain hose and the pumps suction hose. 3. Connect two hose pieces to the drain and to the pump suction. 4. Insert the end side of the hoses into the bucket, verifying that the hoses have been properly dipped in the solution and that they don't inhale air. 5. Open the depressurization valve at 45. 6. Start the watermaker and leave it on for approx. 20-30 min., checking that the hoses are properly positioned in the container, so as to avoid drawing air or spilling the liquid into the boat. 7. Turn the watermaker off, disconnect hose pieces, and connect the pump suction, drain and water production original hoses. 8. 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. 15

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 15-20 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 Purge periodically the air from the system, opening at 45 for a couple of minutes the depressurization valve Every 15 days 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. 7,5-8,5 BAR. There is a small pressure loss, in the range of 0,2 Bars, during the cycle. 16

4. MAINTENANCE 4.3 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Pumps do not start Pump pressure switch broken Restore Pump starts but stops at high pressure System blocked Dirty filter Dirty membranes Trouble in the cycling system Perform Reset Replace cartridge Perform cleaning cycle Contact a Schenker service While normal functioning the pump periodically start/stop Pump pressure switch is not calibrated Dirty filter or membranes point Calibrate pressure switch Clean or replace High pressure heads during commutation (> 0,2 Bar) Accumulator pressure low Inflate at a pressure of 2,8 Bar Low production / normal or low pressure Low production / high pressure (> 8,5 Bar) Leaks Low battery Air in the system Cold sea water Dirty membranes Loose connectors ERS loss Check battery charge Perform bleeding Normal condition Perform cleaning cycle Tighten connectors Contact a service point 17

5. SAFETY WARNINGS. Check if the plant is correctly installed by contacting a Schenker service point. The water produced 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 plant where water is polluted (ports, or close to built-up areas, etc.) Do not locate near the pumps (which can reach high temperatures) objects either inflammable or that can deteriorate if exposed to high temperature. Do not touch the pump and the relevant fans when the plant is functioning. Children and inexperienced people shall not touch or operate the plant. Check periodically that no leakage is present. Do not switch on the plant when the boat is unattended. Avoid installing the plant where an eventual leakage may cause damages and jeopardize the safety of the boat. Unqualified and non-schenker personnel shall not perform any maintenance work. 18

6. Most frequent operations summary table. Fresh water production with final flushing 1. Switch on the PUMP and verify the watermakert is working normally (pressure between 7 and 8 bar). 2. After produced the needed amount of fresh water, switch on the selector FLUSHING, in order to wash the unit before stopping it. 3. After about 1 minute switch off both selectors PUMP and FLUSHING at once. Reset procedure: (If the plant gets blocked at re-start) 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 19

7. 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. 20