Schenker MODULAR 60 User manual

COD: 60M12/24.D.2018
Installation, use and maintenance manual
Model.: Modular 60
Matriculation number: 60M12/24D
Year of construction: 2000
Schenker Italia
Via Delle Repubbliche Marinare, 67
80147 Naples Italy
Tel. [phone]
Fax. [phone]
E-mail: i[email protected]t
www.schenkerwatermakers.com
THE PRESENT MANUAL BELONGS TO - Schenker Italia -ALL RIGHTS RESERVED
MODULAR 60
Digital 12/24 V dc

COD: 60M12/24.D.2018
THE PRESENT MANUAL BELONGS TO - Schenker Italia -ALL RIGHTS RESERVED
INDEX
1. LAYOUT OF MANUAL ......................................................................................................................................4
1.1 STRUCTURE OF THE MANUAL ............................................................................................................................4
1.2 DESCRIPTION OF THE PICTOGRAMS.................................................................................................................4
2. GENERAL WARNINGS AND INFORMATION TO THE RECIPIENT .....................................................5
2.1 IMPORTANT INFORMATION ................................................................................................................................5
2.2 SAFETY WARNINGS ............................................................................................................................................5
2.3WARRANTY..........................................................................................................................................................6
2.4IDENTIFICATION OF THE UNIT ..........................................................................................................................7
2.5LEGISLATIVE REFERENCE ..................................................................................................................................7
2.5.1 DIRECTIVES AND STANDARDS CONCERNING MACHINE SAFETY.................................................................7
2.5.2 RESPECT FOR THE ENVIRONMENT –REQUIREMENTS FOR REMOVAL AND DISPOSAL...............................7
3. PRODUCT PRESENTATION ............................................................................................................................9
3.1 TRANSPORT AND MATERIAL HANDLING ...........................................................................................................9
3.2 STOCK ...............................................................................................................................................................10
3.3 PACKAGING.......................................................................................................................................................10
3.3.1 PACKAGING CONTENTS.................................................................................................................................10
3.4 ATTACHED DOCUMENTS ..................................................................................................................................11
3.5 TECHNICAL DATA .............................................................................................................................................11
3.6 FEATURES OF THE PRODUCT ...........................................................................................................................12
3.7 ADVANTAGES OF THE ENERGY RECOVERY SYSTEM ......................................................................................13
3.8 COMPOSITION OF THE MACHINE ....................................................................................................................14
3.8.1 PUMP GROUP ..................................................................................................................................................14
3.8.2 WATERMAKER GROUP....................................................................................................................................15
3.8.3 ACCESSORIES ................................................................................................................................................20
4. MOUNTING AND INSTALLATION...............................................................................................................21
4.1 GENERAL CRITERIA ..........................................................................................................................................21
4.2 COMPONENTS MOUNTINGS .............................................................................................................................22
4.2.1 PUMP GROUP..................................................................................................................................................22
4.2.2 WATERMAKER GROUP ...................................................................................................................................22
4.2.3 ACCESSORIES................................................................................................................................................22
4.3 INSTALLATION ..................................................................................................................................................22
4.3.1 WATER INTAKES AND DISCHARGES ............................................................................................................22
4.3.2 SEAWATER INTAKE........................................................................................................................................23
4.3.3 FRESH WATER INTAKE FOR WASHING.........................................................................................................24
4.3.4 BRINE DISCHARGE ........................................................................................................................................24
4.4 HYDRAULIC CONNECTIONS .............................................................................................................................25
4.5 ELECTRIC CONNECTIONS.................................................................................................................................28
4.5.1 REMOTE CONTROL PANEL MOUNTING .........................................................................................................28
4.5.2 ELECTRIC CONNECTIONS:WIRES (MODULAR 60 12/24V DC).............................................................29
4.5.3 ELECTRIC LAYOUT SCHEME (12/24V DC)................................................................................................31
5. FUNCTIONING AND USE..............................................................................................................................32
5.1 COMMAND DESCRIPTION.................................................................................................................................32
5.2 INTRODUCTION –BY PASS MODE...................................................................................................................36
5.3 FIRST START-UP PROCEDURE .........................................................................................................................36
5.3.1 PRELIMINARY CHECKS BEFORE PROCEEDING WITH THE START-UP PROCEDURE ...................................36
5.3.2 START-UP.......................................................................................................................................................37

COD: 60M12/24.D.2018
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5.4 NORMAL OPERATING PROCEDURE ..................................................................................................................38
5.4.1 NORMAL OPERATING PROCEDURE WITH FINAL FLUSHING (RECOMMENDED).........................................38
5.4.2 NORMAL OPERATING PROCEDURE WITH TIMER AND FINAL FLUSHING ....................................................38
5.4.3 SINGLE WASHING OPERATION.....................................................................................................................39
5.4.4 PERIODIC WASHING......................................................................................................................................39
5.5 RESET PROCEDURE ..........................................................................................................................................40
6. MAINTENANCE (ROUTINE AND SPECIAL).............................................................................................42
6.1 CHECK FOR FILTER CLEANLINESS...................................................................................................................42
6.2 CHECK THE PLANT WORKING PRESSURE .......................................................................................................43
6.3 CHECK FOR LEAKS............................................................................................................................................43
6.4 CHECK FOR MEMBRANES REPLACEMENT ........................................................................................................43
6.5 SHUTDOWN PROCEDURE .................................................................................................................................43
6.5.1 NECESSARY EQUIPMENT ..............................................................................................................................44
6.5.2 SHUTDOWN OPERATING PROCEDURE..........................................................................................................45
6.6 ANTIFREEZE PROCEDURE (WINTERIZING PROCEDURE IN COLD CLIMATE -UNDER 5°C).......................47
6.7 PERIODIC MAINTENANCE.................................................................................................................................48
6.7.1MEMBRANE REPLACEMENT............................................................................................................................48
6.8 ADJUSTMENTS ..................................................................................................................................................48
7. TROUBLESHOOTING......................................................................................................................................49
7.1 TROUBLESHOOTING CHART.............................................................................................................................49
7.2 ELECTRONIC ISSUES AND THEIR SOLUTION..................................................................................................50
8. SUGGESTED SPARE PARTS.........................................................................................................................51
8.1 SHORT TERM CRUISING...................................................................................................................................51
8.2 LONG TERM CRUISING .....................................................................................................................................51
8.3 ERS SPARE PARTS ...........................................................................................................................................52
8.4 ADDITIONAL SPARES .......................................................................................................................................53

1 –LAYOUT OF MANUAL COD.60M12/24.D.2018
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1. LAYOUT OF MANUAL
1.1 Structure of the manual
The manual is divided into chapters, which gather all the information necessary to use the system without risk.
Within each chapter there is a subdivision in paragraphs to focus on essential points; each paragraph can be
pointed out with a subtitle and a description.
At the top of each page the heading section is reported in order to remind the reader the field of the page.
Within the chapter, for example chapter 1, we will have:
1 Chapter title
1.1 Paragraph title
1.1.1 Subtitle
1.1.1.1 Further subtitles
The numbering of the pages, figures and tables, is reset to each chapter; therefore, we will find the prefix
indicating the chapter and the page number, figure or table in progressive that starts from number 1 at the
beginning of each chapter.
1.2 Description of the pictograms
The following symbols will be used in the manual to highlight particularly important indications and warnings:
ATTENTION:
This symbol indicates accident prevention regulations for the operator and / or for any exposed
persons.
CAUTION:
This symbol indicates that there is the possibility of damaging the system and / or its components.
NOTE:
This symbol indicates useful information.

2 - GENERAL WARNINGS & INFORMATION TO THE RECIPIENT COD.60M12/24.D.2018
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2. GENERAL WARNINGS AND INFORMATION TO THE RECIPIENT
2.1 Important information
To safeguard the operator's safety and to avoid possible damage to the machine, before carrying out any
operation on the machine, it is essential to read carefully all the instructions manual.
This manual must be complete and legible in its entirety, every operator involved in the use of the machine, or
responsible for maintenance or adjustment operations, must know its location and must have the possibility to
consult it at any time.
All rights of reproduction of this manual are reserved to SCHENKER ITALIA. This manual cannot be transferred
to third parties without the written authorization of SCHENKER ITALIA.
The text cannot be used in other printed matter without the written permission of SCHENKER ITALIA.
The descriptions and illustrations provided in this publication are not binding.
SCHENKER ITALIA reserves the right to make any modifications it deems appropriate.
© SCHENKER ITALIA
THIS MANUAL IS PROPERTY OF SCHENKER ITALIA, ANY REPRODUCTION, EVEN PARTIAL, IS
PROHIBITED.
This manual was drafted according to the requirements of the 2006/42 / EC Machinery Directive.
2.2 Safety warnings
•Wear protective equipment suitable for service operation.
•Clothing must be tight to the body, and resistant to the products used for cleaning.
•Do not remove safety devices or accident prevention protection.
•To check if the plant is correctly installed contact a Schenker service point.
•Verify that the electric and hydraulic connections are in keeping with the indicated specifications.
•Avoid using the plant if the sea water is polluted.
•Children and inexperienced people shall not touch or operate the plant.
•Check periodically that no leaks are present. Avoid installing the plant where a leak may cause damage
and/or jeopardize the safety of the vessel.
•Maintenance should only be carried out by suitably qualified persons or Schenker personnel.

2 - GENERAL WARNINGS & INFORMATION TO THE RECIPIENT COD.60M12/24.D.2018
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ATTENTION
Any technical changes or operating conditions indicated that affect the correct operation or
safety of the machine must only be carried out by the manufacturer's technical staff or by
technicians formally authorized by the manufacturer. Otherwise, SCHENKER ITALIA declines
any responsibility for changes or damages that may result from it.
2.3 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 per-formed at a Schenker service
point.
The guarantee covers faults, defect of materials and parts. It is limited to the replacement or re-pair 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 cannot 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.
ATTENTION
SCHENKER ITALIA declines any responsibility for improper use of the machine, for damages
caused as a result of operations not covered by this manual or unreasonable use.

2 - GENERAL WARNINGS & INFORMATION TO THE RECIPIENT COD.60M12/24.D.2018
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2.4 Identification of the unit
All the watermakers manufactured by Schenker Italia can be identified by a serial number printed on a label
which is pasted upon the aluminium frame near the manometer. The same serial number is also recorded on
the central black block of the energy recovery system (ERS).
Serial number
Fig. 2-1
2.5 Legislative reference
2.5.1 Directives and standards concerning machine safety
•Machinery Directive 2006/42 / EC, in force since December 29, 2009;
•Low Voltage Directive 73/23 / EEC and subsequent amendments and additions: 93/68 / CEE
implemented by the Law of 18 October 1997 n. 791.
•Electromagnetic Compatibility Directive 89/336 / EEC and subsequent amendments and additions:
93/31 / CEE implemented with D.L. December 4, 1992 n. 476.
•Standards UNI EN 292/1 and 292/2 (safety of machinery);
2.5.2 Respect for the environment –requirements for removal and disposal
ATTENTION
Removal and disposal of materials, as result of the decommissioning of the machine, must be
performed in accordance with the regulations in force, for the safeguard and protection of the
environment
With regard to removal and disposal, it should be noted that the materials of which the machine is made of are
not of a dangerous nature and consist essentially of:
- Stainless Steel;
- Aluminium;
- Plastic;
- Carbon fibre;
- Motors, cables and consumable electrical materials;
- Rubber and polyurethane seals.

2 - GENERAL WARNINGS & INFORMATION TO THE RECIPIENT COD.60M12/24.D.2018
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After dismantling the machine, the various materials must be segregated according to the regulations of the
country in which the machine has been removed.
The machine does not contain dangerous components or substances that require special removal procedures.
ATTENTION
Different legislations are in force in the different countries, therefore the prescriptions imposed
by the laws and by the agencies designated by the Countries must be observed.

3 –PRODUCT PRESENTATION COD.60M12/24.D.2018
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3. PRODUCT PRESENTATION
ATTENTION
Be sure to follow general safety instructions.
•Wear protective equipment suitable for the transport and handling operations.
•Lift the machines with equipment appropriate to the weight and size of the box, taking the utmost care
and following carefully the instructions on the present use and maintenance manual (attachment points
for loading devices, etc.).
•Make sure that the lifting equipment used is in good condition and correctly maintained.
•Do not stand or pass under the groups to be moved during lifting or transport operation.
3.1 Transport and material handling
The watermaker unit is transported in a cardboard box. In the following table dimension and weight are
indicated.
MATERIALS HANDLING
fig. 3-1
Packaging dimensions and weight
tab.3-1
Model
L cm.
W cm.
H cm.
Weight Kg.
Modular 60
120
47
47
52

3 –PRODUCT PRESENTATION COD.60M12/24.D.2018
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3.2 Stock
ATTENTION
To avoid damage to the system, store the unit in a dry place at a temperature of between 5°C
and 40°C. Very cold temperatures could led to a freezing of the fluid inside the system with the
consequence of a permanent damage of the system.
3.3 Packaging
3.3.1 Packaging contents
PACKAGING
FIG. 3-2
Modular 60
Watermaker
Pump group
Active carbon filter with electrovalve
White filter key
Mesh filter
Non-return valve with Tee fitting
Remote panel with electric box
10 mt extension cable for remote panel
Intallation kit
Small metal parts
6x8 hose for production
Hose fittings