Schenker MODULAR 500 User manual

COD: 500M380.D.2018
Installation, use and maintenance manual
Schenker Italia
Via Ferrante Imparato 501 - Condominio Genesis
80146 Naples (Italy)
Tel. [phone]
Fax. [phone]
E-mail: in[email protected]
www.schenkerwatermakers.com
THE PRESENT MANUAL BELONGS TO - Schenker Italia -ALL RIGHTS RESERVED
MODULAR 500
Digital 380 Vac

COD: 500M380.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 PRE-PUMP ......................................................................................................................................................14
3.8.2 PRE-FILTRATION UNIT ..................................................................................................................................15
3.8.3 WATERMAKER GROUP ...................................................................................................................................16
3.8.4 ACCESSORIES................................................................................................................................................20
4. MOUNTING AND INSTALLATION...............................................................................................................21
4.1 GENERAL CRITERIA ..........................................................................................................................................21
4.2 COMPONENTS MOUNTINGS .............................................................................................................................22
4.2.1 PRE-PUMP (PUMP 1).....................................................................................................................................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 500 THREE PHASE 380V AC .......................................29
4.5.3 ELECTRIC LAYOUT SCHEME (THREE PHASE 380V AC) ............................................................................30
4.5.4 DRIVE FREQUENCY INVERTER SETTINGS ...................................................................................................32
4.5.5 ELECTRONIC CONNECTIONS:REMOTE PANEL ............................................................................................33
5. FUNCTIONING AND USE..............................................................................................................................34
5.1 COMMAND DESCRIPTION.................................................................................................................................34
5.2 PRELIMINARY CHECK –MOTORS ROTATION .................................................................................................39

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5.3 INTRODUCTION –BY PASS MODE...................................................................................................................39
5.4 FIRST START-UP PROCEDURE .........................................................................................................................40
5.4.1 PRELIMINARY CHECKS BEFORE PROCEEDING WITH THE STAR-UP PROCEDURE .....................................40
5.4.2 START-UP.......................................................................................................................................................40
5.5 NORMAL OPERATING PROCEDURE ..................................................................................................................41
5.5.1 NORMAL OPERATING PROCEDURE WITH FINAL FLUSHING (RECOMMENDED).........................................42
5.5.2 NORMAL OPERATING PROCEDURE WITH TIMER AND FINAL FLUSHING ....................................................42
5.5.3 SINGLE WASHING OPERATION.....................................................................................................................43
5.5.4 PERIODIC WASHING......................................................................................................................................43
5.5.5 AUTOMATIC FUNCTIONING WITH LEVEL CONTROLS (OPTIONAL)............................................................43
5.5.6 RESET PROCEDURE .......................................................................................................................................44
6. MAINTENANCE (ROUTINE AND SPECIAL).............................................................................................46
6.1 CHECK FILTER CLEANLINESS ..........................................................................................................................46
6.2 CHECK THE PLANT WORKING PRESSURE .......................................................................................................48
6.3 CHECK FOR LEAKS............................................................................................................................................48
6.4 CHECK FOR MEMBRANES REPLACEMENT ........................................................................................................48
6.5 SHUTDOWN PROCEDURE .................................................................................................................................48
6.5.1 NECESSARY EQUIPMENT ..............................................................................................................................48
6.5.2 SHUTDOWN OPERATING PROCEDURE..........................................................................................................50
6.6 ANTIFREEZE PROCEDURE (WINTERIZING PROCEDURE IN COLD CLIMATE -UNDER 5°C).......................53
6.7 PERIODIC MAINTENANCE.................................................................................................................................54
6.7.1 MEMBRANE REPLACEMENT............................................................................................................................54
6.8 ADJUSTMENTS ..................................................................................................................................................54
7. SUGGESTED SPARE PARTS.........................................................................................................................55
7.1 SHORT TERM CRUISING...................................................................................................................................55
7.2 LONG TERM CRUISING .....................................................................................................................................55
7.3 ERS SPARE PARTS ...........................................................................................................................................56
7.4 ADDITIONAL SPARES .......................................................................................................................................57

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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.

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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.

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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.

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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 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;

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- Rubber and polyurethane seals;
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.

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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 wooden 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 500
162
82
98
310

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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 500
Watermaker
Pre-pump with Tee fitting and electrovalve
Active carbon filter with ball valve, key filter
Cartridge big blue filter group, black key filter
Remote panel with electric box
10 mt extension cable for remote panel
Intallation kit
Small metal parts
10x12 hose for production
Hose fittings

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3.4 Attached documents
The packaging contains the technical documentation (use and maintenance manual, electric and hydraulic
scheme, warnings and instructions).
ATTENTION
•Lift the system only using the aluminium
structure and not trough the Inox SS fittings.
•Read carefully the use and maintenance
manual before installing the system.
•Use only recommended material for the
installation (especially hoses, fittings and
seals) in accordance with the present manual.
•Do not store the unit under temperature of
5°C and above 40°C
DOCUMENTS INCLUDED IN THE PACKAGING
FIG. 3-3
3.5 Technical data
WATERMAKER GROUP
WATERMAKER DIMENSIONS
FIG. 3-4

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Weight (including pumps): 195 Kg
Hydraulic Connection
Seawater inlet: 1’’ fitting, 30mm internal diameter reinforced hose.
Exhaust: ¾’’ fitting, 25mm internal diameter reinforced hose.
Fresh water: 3/8’’ fitting, 10x12mm hose.
Pumps: Pre-pump type: Centrifugal multistage pump
Feed pump type: Centrifugal multistage pump
Pressure amplifier type: Carbon fibre pressure amplifier
Prefilter unit: n. 1 Pleated big blue filter 20 microns 4-1/2" x 20" (59 mm x 508 mm)
n. 1 Pleated big blue filter 5 microns 4-1/2" x 20" (59 mm x 508 mm)
n. 1 Active carbon filter Big Blue 4-1/2" x 9-3/4"
Power supply: 380 Vac, 50 Hz three phase
Average electric consumption: 3,5 kWatt/h average
Nominal fresh water production: 500 Lit/h +/- 20% @ seawater 25 °C salinity 35.000 ppm
Fresh water quality: Under 500 ppm TDS average
CEE conformity: In compliance with directives 89/392 CEE sect.1 (general safety machines
requirements), 89/336 CEE (electromagnetic compatibility), 73/23 CEE
(electric safety requirements)
3.6 Features of the product
The water produced by a Schenker plant, produced from clean seawater has a purity of between 350 & 450
parts per million Totally dissolved solids (TDS/PPM), but the potability may not be guaranteed as bacterium
may be present in the watermaker, caused by non-observance of shutdown and cleaning procedures. It is
essential that correct shut down and storage procedures are followed to ensure continued purity of the product
water. UV treatment of the product water may be beneficial.

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3.7 Advantages of the Energy recovery system
Introduction
Thank you for choosing a Schenker Watermaker.
As all the equipment, 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 for a quick reference.
Functioning principles
The Schenker watermakers, as alternative to the high-pressure pumps of traditional systems, 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 a high energy efficiency.
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.
FUNCTIONING SCHEME
FIG. 3-5

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3.8 Composition of the machine
The machine is composed of the following parts:
1. PRE-PUMP
2. PRE-FILTRATION UNIT
3. WATERMAKER GROUP
3.8.1 Pre-pump
This pump has the duty of picking the sea water up and send it to the pump 2, through the pre filtering unit.
On the pump head there is a nut, used to purge the air, or introduce water in the inlet connection, to facilitate
the suction of the pump at the first start-up. On the pump inlet there is a T fitting, where is connect the
electrovalve for the automatic washing of the unit.
PRE-PUMP 380 VAC
FIG. 3-6

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3.8.2 Pre-filtration unit
The pre-filtration unit is positioned between the pre pump (pump 1) and the watermaker, and it is composed
by one big blue 20 microns and one big blue 5 microns, a low pressure switch, a 0-6 bar manometer and a
plastic non return valve. A white push-button, positioned on the top of the filter housings, allows to purge out
the air during the start-up operations.
The Low pressure switch stops the watermaker if the water flow rate is too low avoiding cavitation of the
main pump. The pressure switch calibration is approximately 0,6 bar
PRE FILTRATION UNIT
FIG. 3-7
Low pressure switch
20 micron big blue cartridge filter
0-6 bar manometer
Non-return valve
5 micron big blue cartridge filter

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3.8.3 Watermaker group
WATERMAKER GROUP –FRONT VIEW
FIG. 3-8
Manometer
Reverse osmosis membranes
Flowmeter
Depressurization valve
WATERMAKER GROUP –SIDE VIEW
FIG. 3-9
Energy recovery system
SS Accumulator
Multistage centrifugal pump
High pressure switch
1
3
4
2
4
2
3
1

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The watermaker group is composed of the following parts:
•Reverse osmosis membranes
•Energy Recovery System
•Manometer
•Flowmeter
•Accumulator
•Depressurization valve
•Positioner
•Reset valve
•High pressure switch
•Probe (pressure switch)
•Diverting valve
•Electric box
Reverse osmosis membranes. They are installed inside the glass fibre high-pressure housing. Membranes
are n.4 x SW4040 type. Their purpose is to separate the intake high-pressure seawater in two flows: one for
the salt-water drain and one for the fresh water production.
Energy Recovery System. It is the black, carbon fibre unit. It has the function to amplify the pressure supplied
by the pumps and to recoup 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 based on cylinders and a central body containing the hydraulic
valve necessary for the system functioning.
WATERMAKER GROUP, ERS VIEW
FIG. 3-10
Manometers. There are 2 manometers: one is positioned downstream the filters. It checks the inlet pressure
to the main pump. The second one is located on the front panel of the watermaker, and it measures the working
pressure of the watermaker.
Flowmeter. It is located on the front panel, and it measures the fresh water instantaneous capacity sent to the
tank. The device accuracy is +/- 20%.
Accumulator. It is a stainless-steel reservoir of air, installed close to the ERS. Its function is to reduce and
stabilize the pressure peaks during the watermaker functioning. The device has to be pre-charged with air
through the specific valve. The air pressure precharge is about 14 Bar. The pressure dimmer is charged in
factory at the right pressure.

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Depressurization valve. It is used for the air bleeding of the unit. It is recognizable by a blue lever and it is
located on the right SS fitting of the third membrane. Its function is to depressurize the system and to allow the
bleeding of air. The valve must be closed during normal working conditions (vertical position), and it is opened
during the air bleeding operations (horizontal position).
Positioner. It is a stainless steel threaded arm, with a black knob, located on the right side of the top of the
ERS. Its function is to reset the unit in case of hydraulic block.
WATERMAKER GROUP, POSITIONER VIEW
FIG. 3-11
Reset valve. It is installed on the top 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 of the ERS in case of a system block. It must be opened before acting on the valve positioner.
WATERMAKER GROUP, VALVE VIEW
FIG. 3-12
High pressure switch. It Is hydraulically connected downstream the pump 2. It stops the system if the pump
2 pressure exceeds 18 bar. In this case a high-pressure alarm is activated on the control panel.
Reset valve
Depressurization
valve
Probe switch
Positioner

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Probe (pressure switch). It is a device, hydraulically connected to the left side on the main valve of the Energy
Recovery System. Its function is check that the cycling of the machine is correct. The signal pressure switch
calibration is approximately 4 bar.
Diverting valve. It is a solenoid valve that diverts the fresh water flow according to the value measured by a
salinty probe, avoiding the salty water to be sent to the production tank.
The 2 cables of the probe must be connected on the clamps SAL of the electric box.
The 2 cables of the valve must be connected on the clamps DV of the electric box.
DIVERTING VALVE
FIG. 3-13
Electric box. It contains all the electric and electronic devices necessary for the functioning of the system and
the protection of the components.
On the front side It is possible to find the emergency stop push button. To stop the unit suddenly push the
emergency stop button at least for 2-3 seconds.
ELECTRIC BOX EMERGENCY STOP
FIG. 3-14
Diverting valve

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3.8.4 Accessories
The main accessories of the watermaker are the following:
•Active carbon filter
•Non-return Clapet valve
•Electrovalve
ACCESSORIES
FIG. 3-15
Active carbon filter
Electrovalve
Non-return Clapet valve
Active carbon filter (big blue filter). This filter is connected between the fresh water pressurized system of
the vessel and the electro valve on the pump 1. On the filter inlet is positioned a manual valve that allows to
replace the cartridge without depressurize the fresh water system of the vessel.
Non-return Clapet valve. It avoids the emptying of the inlet hoses. It must be installed vertically. It avoids also
the leak of fresh water from the seacock while washing procedure.
Electrovalve. It has the function of switching from seawater intake to fresh water tank when washing the
watermaker.