COD: 100M12/24.B.

2021

Installation, use and maintenance manual

MODULAR 100
BASIC 12/24 VDC

Schenker Italia
Via Ferrante Imparato 501 - Condominio Genesis
80146 Naples (Italy)
Tel. +39 081 5593505
Fax. +39 081 5597372
E-mail: info@[Link]
[Link]
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 COD: 100M12/24.B.2021

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
2.3 WARRANTY ..........................................................................................................................................................6
2.4 IDENTIFICATION OF THE UNIT ..........................................................................................................................7
2.5 LEGISLATIVE 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 ................................................................................................................................................17
4. MOUNTING AND INSTALLATION...............................................................................................................18
4.1 GENERAL CRITERIA ..........................................................................................................................................18
4.2 COMPONENTS MOUNTINGS .............................................................................................................................19
4.2.1 PUMP GROUP ..................................................................................................................................................19
4.2.2 WATERMAKER GROUP ...................................................................................................................................19
4.2.3 ACCESSORIES ................................................................................................................................................19
4.3 INSTALLATION ..................................................................................................................................................19
4.3.1 WATER INTAKES AND DISCHARGES ............................................................................................................19
4.3.2 SEAWATER INTAKE ........................................................................................................................................20
4.3.3 FRESH WATER INTAKE FOR WASHING .........................................................................................................21
4.3.4 BRINE DISCHARGE ........................................................................................................................................21
4.4 HYDRAULIC CONNECTIONS .............................................................................................................................22
4.5 ELECTRIC CONNECTIONS.................................................................................................................................25
4.5.1 REMOTE CONTROL PANEL MOUNTING .........................................................................................................25
4.5.2 ELECTRIC CONNECTIONS: WIRES (MODULAR 100 12/24 VDC) .......................................................26
5. FUNCTIONING AND USE ..............................................................................................................................28
5.1 COMMAND DESCRIPTION .................................................................................................................................28
5.1.1 ALARMS DESCRIPTION ..................................................................................................................................28
5.2 FIRST START-UP PROCEDURE .........................................................................................................................28
5.2.1 PRELIMINARY CHECKS BEFORE PROCEEDING WITH THE START-UP PROCEDURE ....................................29
5.2.2 START-UP .......................................................................................................................................................29
5.3 NORMAL OPERATING PROCEDURE ..................................................................................................................30

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5.3.1 NORMAL OPERATING PROCEDURE WITH TIMER AND FINAL FLUSHING ....................................................30
5.3.2 NORMAL OPERATING PROCEDURE WITH FINAL FLUSHING (RECOMMENDED) .........................................31
5.3.3 WORKING CYCLE WITH TIMER .....................................................................................................................31
5.3.4 LONG FLUSHING PROCEDURE.......................................................................................................................31
5.4 RESET PROCEDURE ..........................................................................................................................................32
6. MAINTENANCE (ROUTINE AND SPECIAL) .............................................................................................34
6.1 CHECK FILTER CLEANLINESS ..........................................................................................................................34
6.2 CHECK THE PLANT WORKING PRESSURE .......................................................................................................35
6.3 CHECK LEAKS ...................................................................................................................................................35
6.4 CHECK FOR MEMBRANES REPLACEMENT ........................................................................................................35
6.5 SHUTDOWN PROCEDURE .................................................................................................................................35
6.5.1 NECESSARY EQUIPMENT ..............................................................................................................................36
6.5.2 SHUTDOWN OPERATING PROCEDURE ..........................................................................................................37
6.6 ANTIFREEZE PROCEDURE (WINTERIZING PROCEDURE IN COLD CLIMATE - UNDER 5°C) .......................39
6.7 PERIODIC MAINTENANCE .................................................................................................................................40
6.7.1 MEMBRANE REPLACEMENT............................................................................................................................40
6.8 ADJUSTMENTS ..................................................................................................................................................40
7. TROUBLESHOOTING ......................................................................................................................................41
7.1 TROUBLESHOOTING CHART .............................................................................................................................42
8. SUGGESTED SPARE PARTS.........................................................................................................................42
8.1 SHORT TERM CRUISING ...................................................................................................................................42
8.2 LONG TERM CRUISING .....................................................................................................................................42
8.3 ERS SPARE PARTS ...........................................................................................................................................43
8.4 ADDITIONAL SPARES .......................................................................................................................................44

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 1 – LAYOUT OF MANUAL COD: 100M12/24.B.2021 EN

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
[Link] 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.

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;

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- Carbon fibre;
- Motors, cables and consumable electrical materials;
- 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 COD: 100M12/24.B.2021 EN

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

Model L cm. W cm. H cm. Weight Kg.

Modular 100 82 64 47 82

PACKAGING DIMENSIONS AND WEIGHT

tab.3-1

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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 (photo is purely for information)

FIG. 3-2

MODULAR 100
Watermaker Pump group
Active carbon filter with electrovalve White filter key
Mesh filter Non-return valve with Tee fitting
Remote panel 10 mt extension cable for remote panel
Installation kit Small metal parts
6x8 pipe for production Pipe 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 pipes, fittings and
seals) in accordance with the present
manual.
• Do not store the unit under temperature of 5°
and above 40°C.

DOCUMENTS INCLUDED IN THE PACKAGING (photo is purely for information)

FIG. 3-3

3.5 Technical data

WATERMAKER GROUP

WATERMAKER DIMENSIONS
FIG. 3-4

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 3 – PRODUCT PRESENTATION COD: 100M12/24.B.2021 EN

Weight: 47 Kg

Hydraulic Connection
Seawater inlet: ¾’’ fitting, 20mm internal diameter reinforced pipe.
Exhaust: ½’’ fitting, 16mm internal diameter reinforced pipe.
Fresh water: ¼’’ fitting, 6x8mm pipe.

PUMP GROUP

Dimensions
Length: 37 cm
Width: 15 cm
Height: 23 cm
Weight: 11 Kg

Hydraulic Connection
Water inlet: ¾’’ fitting, 20mm internal diameter reinforced pipe.
Water outlet: ¾’’ fitting, 20mm internal diameter reinforced pipe.

Feed pump type: Rotative pump

Filters: n. 1 Cartridge filter 5 microns 2.32" x 9 ¾’’

n. 1 Active carbon filter 2.32" x 9 ¾’’

Power supply: 12 VDC +/- 15% (100Z12 version)

24 VDC +/- 15% (100Z24 version)

Average electric consumption: 400 Watt/h average

Nominal fresh water production: 100 Lit/h +/- 20% @ seawater 25 °C salinity 35.000 ppm

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 high purity 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. PUMP GROUP
2. WATERMAKER GROUP

3.8.1 Pump group

This pump has the duty of picking the sea water up and send it to the watermaker group, through the pre filter.
The pump group is composed of the following parts:
• 5 micron cartridge filter
• Pressure transducer
• Pump box
• Accumulator

PUMP GROUP
FIG. 3-6

5 micron filter + accumulator Pump head + motor

Pressure transducer Pump box

Pressure transducer. It Is hydraulically connected to the pump group. It stops the system if the pump pressure
exceeds 11 bar or if it doesn’t reach 0,8 bar.

Pump box. Plastic Box with all the electric connections for the power supply of motor, motherboard, pressure
transducer, remote panel and electrovalve.

Accumulator. This is a polypropylene air reservoir. 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 Schrader valve. The
pressure is about 6 Bar. The accumulator is preloaded in factory to the correct pressure.
On some versions it might be installed on the unit.

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3.8.2 Watermaker group

WATERMAKER GROUP
FIG. 3-7

Manometer Reverse osmosis membrane

Flowmeter

WATERMAKER GROUP (TOP VALVE VIEW)

FIG. 3-8

Reset valve Reset positioner

Depressurization valve Fresh water hose

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CONCENTRATE OUTLET (OUT) AND SEAWATER INLET (IN)

FIG. 3-9

IN
The watermaker group is composed of the following parts:

• Reverse osmosis membranes

• Energy Recovery System
• Manometer
• Flowmeter
• Accumulator
• Depressurization valve
• Positioner
• Reset valve

Reverse osmosis membrane. It is installed inside the glass fibre high-pressure housing. Membrane type is
n.2 x SW4021 type. Its 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.

Manometer. Located on the front panel, it measures the working pressure of the watermaker.

Accumulator. It is a grey PVC reservoir of air, installed in the watermaker. 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 6 Bar. The pressure dimmer is charged in factory at the
right pressure.

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%.

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 top valve of the ERS. Its function is to depressurize the system and to allow the bleeding of air.

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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 watermaker.
Its function is to reset the unit in case of hydraulic block.

Reset valve. It is installed on the watermaker 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.

3.8.3 Accessories
The main accessories of the watermaker are the following:

• Active carbon filter

• Electrovalve
• Non-return valve
• Mesh filter (strainer)

ACCESSORIES
FIG. 3-13
Non-return valve Active carbon filter
Mesh filter (strainer) Elettrovalve

Active carbon filter. This filter is connected between the fresh water pressurized system of the vessel and
the electro valve on the filter holder. On the filter inlet is positioned a manual valve that allows to replace the
cartridge without depressurize the fresh water system of the vessel.

Electrovalve. It has the function of switching from seawater intake to fresh water tank when washing the
watermaker.

Non-return valve. It avoids the emptying of the inlet pipes. It must be installed vertically. It avoids also the
leak of fresh water from the seacock while washing procedure.

Mesh filter. The machine is equipped with a strainer to protect the pump from macro sediments. It is placed
between the seacock and pre-pump.

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4. MOUNTING AND INSTALLATION

4.1 General criteria

Before starting with the installation, it is important to carefully plan all the activities, by evaluating all the possible
solution to be adopted. The main points to focus on are the following:

• Individuate the seawater inlet

• Positioning of the main units (pump group, watermaker group, active carbon filter).
• Positioning of the thermal-magnetic circuit breaker.
• Passage of the pipes and electric cables.

CAUTION
For a correct installation of the watermaker, in order to avoid issues along the different ways
of operating condition, please follow carefully the general instruction below:

• Consider to install the through-hull fitting in a central and deep position, in the way that no air
could be aspirated.
• The non-return valve has to be installed under the seawater level and as close as possible to
the through-hull fitting, in vertical position.
• The pump must be installed as low as possible respect to the seawater level and as close as
possible to the seawater intake (through-hull fitting).
• The watermaker unit must be horizontally positioned, and arranged on an adequate support
which is able to sustain the weight (about 40 Kg).

CAUTION
The pump group must be installed in a ventilated place, in order to facilitate the cooling. In
addition to this, a place not exposed to condensation and dripping should be adopted.

ATTENTION
The external surface of motor and pump can reach high temperature; therefore, it is
recommended to avoid any contact with inflammable liquids and materials.

NOTE
Once individuate the correct installation solution, it is recommended to first make a schematic
draft of the hydraulic and electric connection, and attach them to the present manual for future
needs as first reference.

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4.2 Components mountings

4.2.1 Pump group

The rotary vane pump must be installed below the sea level and as close as possible to the water inlet;
furthermore, the pump cannot run dry.
The pump group should be installed in an adequately ventilated room, with the purpose to facilitate the cooling
of the motor, and not subject to condensation or drippings. The max permitted room temperature must not
exceed 40°C.
Avoid the contact or the proximity with inflammable material or liquid, since the motor surfaces can reach
elevated temperatures. Avoid locating the pump wherever a possible loss of water can involve damages or
jeopardize its safety. The pump must be installed on a base sufficiently horizontal, suitable to sustain the
weight of the group. The pump is normally fixed on the support structure by passing bolts.

4.2.2 Watermaker group

Concerning the watermaker unit installation there are not height limits respect to the seawater level. Anyway,
it should be installed above both pumps.
Avoid to install the system wherever any possible leak may cause damages to the vessel or jeopardize its
safety, since possible leaks due to accidental causes (pipe bursting, pipe clamp loosening, equipment failure,
etc.) may cause water losses.
The hydraulic intake and outlet connections are positioned 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. The max allowed room temperature
must not exceed 40°C. 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. The watermaker is normally
fixed on the support structure by passing bolts.

4.2.3 Accessories
The non-return valve has to be installed vertically as close as possible to the seawater intake, following the
direction of the arrow.
The active carbon filter (and the attached electrovalve) has to be placed next to the pump group, if possible,
on a vertical side easily accessible.

4.3 Installation

4.3.1 Water intakes and discharges

For a correct installation of the watermaker it is necessary to arrange the following water intake and discharge
out of the board:

• Seawater intake.
• Fresh water intake for washing.
• Brine discharge.

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4.3.2 Seawater intake

Seacock with It is ideal a specific sea water intake, size ¾’’ Size 3/4”
through-hull minimum in a central position, well under the water
fitting surface even when the vessel is well heeled over.
The skin fitting is recommended. It must be oriented
to the bow of the vessel.
In case of high speed vessel (over 15 knot) it is
advised to make some holes on the backside of the
shape, in order to reduce dynamic prevalence during
navigation.
Pre-existing As alternative, it is possible Tee into a pre-existent Size 3/4”
seacock water inlet as long as the following conditions are
adapting met:
(alternatively) • 3/4’’ minimum size;
• No air can be introduced into the system
from other use ie: salt water taps in galley;
• Must always be under the water surface
even when the vessel is well heeled over.
• Must be far from WC discharge.

CAUTION
Do not use the pre-existing water inlet of
the cooling system dedicated to the
motor.

INSTALLATION NOTES
• Allow a minimum 3/4” on-off ball valve on the water intake.
• The pipe connections, especially if under the seawater level, must be secured with double pipe clamps.
• 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.
• The seawater intake must be at least 3/4” size.
• Downstream the seawater intake must be installed a strainer and a non-return valve. The water flow
inhaled by the watermaker is about 20 lit/min.

Mesh Filter
Strainer on In case of seawater intake with pre-existing net Filtration grade of the strainer is 50
existing hull filter, it is possible to use it as long as the following mesh.
(alternatively) conditions are met:
• Flow rate capacity of the filter is
adequate to the whole intakes it serves.

INSTALLATION NOTES
The filter has to be connected next to the through-hull fittings, and must be easily accessible
for inspection.

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4.3.3 Fresh water intake for washing

Fresh water Tee in downstream of the vessel's fresh water
intake for pressure system.
washing The following conditions must be respected:
• The flow of the existing fresh water pump Min. flow rate must be 20 lit/min.
must be min 20 lit/min. at 1 bar.
• Flushing must always be performed with
the pressure water system ON.

4.3.4 Brine discharge

Salt water The salt-water drain shall be ½’’ minimum size
discharge and it has to be preferably above the seawater Minimum size ½’’
level.

Pre-existing salt It is possible to use offtakes from existing

water discharge apparatuses, provided that:
(alternatively) • It is not the engine cooling water drain or
apparatuses that drain out water with
elevated pressure.

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4.4 Hydraulic connections

“Armorvin”
type hose
int. dia. 16 mm.
Exhausted
discharge

Reinforced hose
PN16 min int. dia.
20 mm.
Plumb to
pressure
side of
vessel “Armorvin”
fresh water type hose
system int. dia. 20
mm.

HYDRAULIC CONNECTION AND HOSES

FIG. 4-1

Pressurized fresh water valve Pump group

Elecrovalve Non return valve
5 micron filter Mesh filter
Swan neck upward - Discharge Water inlet
Watermaker Active carbon filter
Fresh water outlet

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 16 min. reinforced
pipe. An inadequate pipe could burst, jeopardizing seriously the safety of the vessel.

The hydraulic connections are:

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Low pressure • Connection between seawater intake – mesh Armorvin reinforced pipe PN6
connections – filter – non-return valve inlet – pump group with 20 mm internal diameter
max 3 bar
• Connection between the discharge of the Armorvin reinforced pipe PN6
watermaker – through hull discharge fittings of with 16 mm internal diameter
the vessel
Medium pressure • Connections fresh water pressurized system– Rubber reinforced pipe PN 16
connections – carbon filter-backflow valve outlet–pump inlet minimum, internal diameter
max 13 bar • Connections pump outlet-5 microns filter– 20 mm.
watermaker inlet.

Low pressure • Watermaker - fresh water tank ¼’’ fittings, Small plastic blue
connections - pipe 6x8mm provided within
max 3 bar the scope of supply

PUMP CONNECTIONS:
Connect the in/out pipe to the pump as follows:

PUMP IN AND OUT

FIG. 4-2

CAUTION
The pump has to be placed as close as possible to the seawater intake and as low as
possible respect to the seawater level; furthermore, it is recommended to avoid long and
convoluted path of the connection hoses.

ATTENTION
The use of an improper pipe can cause a break which prevent the security of the vessel.

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WATERMAKER CONNECTIONS:

WATERMAKER INLET (Sea water inlet from the pump):

Make use of the external holder located on the left side of the watermaker (marked IN).

WATERMAKER OUTLET (Discharge outboard):

Make use, for this connection, of the holder located on top of the pressure amplifier, inside the watermaker
unit (marked OUT). Create a Swan neck upward, when the drain outlet on the vessel is positioned below the
watermaker unit, in order to guarantee a water head.

PRODUCTION FRESH WATER CONNECTION

The connection has to be made using the small pipe supplied with the equipment. The connection has to be
made between the polyethylene pipe that comes out the watermaker unit (on the right), and the upper side of
the tank, on a ¼” outlet if available.
It is possible, in case of metal tanks, to make a ¼” threaded hole to connect the supplied male connector.
Another option is to Tee into the tank air vent [Link] are no particular limits on the connection length.

FRESH WATER

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4.5 Electric connections

ATTENTION
These steps have to be performed by a qualified technician/operator, by referring to the
electrical drawings provided within this document.

4.5.1 Remote control panel mounting

The remote control panel has the following dimensions:
width 100 mm. height 66 mm.
It can be fixed on any internal vessel panel, provided that the area behind is free of humidity and condense
and there is enough depth to house the rear part of the panel (approx. 8 cm.).

The cut to be performed on the vessel covering panel, to encase the remote control panel, has the following
dimensions:
width 80 mm. height 50 mm.

The remote control panel can be connected through the pre-wired multiple cable of a 10mt standard length
provided. It is possible to adapt the panel to a longer distance by adding a one more cable in series to the one
provided.

REMOTE CONTROL PANEL

FIG. 4-3

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4.5.2 Electric connections: wires (MODULAR 100 12/24V DC)

The electric connectors are positioned inside the small electric box connected to the computer box. The power
supply, coming from the service batteries, needs to be connected to the terminals – and + . The connection
to the vessel panel needs to be performed downstream the voltmeter and the ammeter of the vessel
panelboard. The connecting terminal must be suitable to support the plant electric load (approx. 500 Watt). A
63 Ampere automatic circuit breaker for 12V DC systems must be installed on the power supply, while a 32
Ampere for 24VDC systems.
The general wires connection scheme (between the external devices and the main electric box) is the following:

Voltage Automatic Cable lenght

switch up to 3 mts 3 - 7 mt. 7-10 mt.
Volt Ampere mm2 AWG mm2 AWG mm2 AWG
12 63 16 5 25 3 25 3
24 32 10 7 10 7 10 7

The manual microswitches allow to turn on the pump and the electrovalve. They can be used to turn on the
watermaker in emergency. They have to be on the OFF position during the normal functioning condition.
The overload current of the fuse is 400mA.

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.)

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CENTRAL BOX MODULAR 100 12/24V DC

FIG. 4-10

IN RED: CONNECTIONS TO BE MADE DURING THE INSTALLATION

Electrovalve (EV) Pump negative

Pressure transducer Battery positive
Connection to remote panel Battery negative
Pump microswitch EV microswitch
Pump positive

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 5 – FUNCTIONING AND USE COD: 100M12/24.B.2021 EN

5. FUNCTIONING AND USE

5.1 Command description

Remote control panel

Fig. 5.1

KEYBOARD FEATURES
The panel keyboard has a total of 2 switch buttons. The functions of the buttons are:

ON/OFF Used to start and stop the pumps of the system.

FLUSHING Used to activate the electrovalve and let the system rinse with fresh water.

5.1.1 Alarm description

The system has three different types of alarm, recognizable by the flashing of the two LEDs.

• Unit stalled: the pressure is under the threshold value during the start – the system goes on alert after
5 seconds and the pushing buttons flash 2 times quickly;
• Underpressure: the pressure drops under the threshold value during the functioning – the system
goes on alert and the pushing buttons flash 3 times quickly.
• Overpressure: the pressure raises over the threshold value during the functioning – the system goes
immediately on alert and the pushing buttons flash 4 times quickly.
• Low battery: power supply is not sufficient - the system goes immediately on alert and the pushing
buttons flash 5 times quickly.
• Control failure: the pressure transducer is faulty or not properly connected - the system goes
immediately on alert and the pushing buttons flash 6 times quickly.

In all three cases the alarm has to be stopped by pressing the button ON/OFF; then it is necessary to
recognize and eliminate the problem before starting again the watermaker.

5.2 First start-up procedure

The first start-up procedure is necessary to start a new plant for the first time or to restart it after performed a
chemical washing.
The purpose of the start-up procedure is to essentially purge the air contained in the system.

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5.2.1 Preliminary checks before proceeding with the start-up procedure

Perform the following checks before proceeding with the start-up procedure:

1. Verify all components and hoses are connected correctly.

2. Verify the 5 micron and active carbon cartridges are installed.
3. Check the seawater inlet valve and salt water drain valve (if existing) are open.
4. Check the reset valve is closed (lever orthogonal to the body valve) and the positioner completely
unscrewed.
5. Check the fresh water pressurizing pump of the boat is on.
6. Check the grey valve on the active carbon filter is open.

5.2.2 Start-up

1. Open the depressurization valve (unscrew the

valve).

2. Push Flushing for 5 seconds.

The panel emits 2 beeps, the push buttons
blinks quickly, and the sequence for purging
starts. After about 3 minutes the sequence will
finish. The sequence can be stopped at any time
pushing ON/OFF.

3. Start the unit again pushing ON/OFF.

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4. Close the depressurization valve. The system

starts going under pressure and the fresh water
production begins. Check the working pressure
of the unit is correct (7,5–8,5 bar).

[Link] a while push FLUSHING in order to flush

the unit before stopping it.
Then the unit will stop after about 1 minute.

The procedure lasts about 3 minutes, and it can be stopped at any time pushing STOP. After completed the
procedure the system is ready to start normally.

5.3 Normal operating procedure

Preliminary checks:
1. Reset valve closed (lever orthogonal to the body valve) and the positioner completely unscrewed.
2. Depressurization valve closed and grey valve on the active carbon filter open.

5.3.1 Normal operating procedure without final flushing

1. Push ON/OFF to start the watermaker.

2. Push ON/OFF to stop the watermaker.

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5.3.2 Normal operating procedure with final flushing (recommended procedure)

1. Push ON/OFF to start the watermaker.

2. Push FLUSHING to flush and stop the

watermaker. The watermaker will activate a
flushing cycle then it will stop itself after 1 minute.

5.3.3 Working cycle with timer

1. Keep ON/OFF pressed for a while, then you

will hear 1-2-3-beeps. Once released ON/OFF
the watermaker will work for 1-2-3 hours then
will flush and will stop.

2. The unit can be stopped at any time by

pushing the ON/OFF button (without final
flushing) or the FLUSHING button (with final
flushing).

5.3.4 Long flushing procedure

1. Push FLUSHING. A 3-minute flushing

procedure with fresh water will start. Both
ON/OFF and FLUSHING buttons’ lights will be
on.

2. The unit can be stopped at any time by pushing

the ON/OFF button

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5.4 Reset procedure

If the watermaker gets air (or if some other problems occur), the automatic hydraulic valve may stop in a central
position. This means that the working pressure goes up suddenly. After approx. 20 sec. the computer
recognizes the problem and turns off the pumps.

In this case is necessary to reset the valve with the following simple procedure:

1. Turn off the system

2. Open the reset valve (lever in horizontal
position).

3. Open the depressurization valve.

4. Screw the positioner know clockwise until it can

be moved no further. Normally 10 turns at least
are needed.

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5. Unscrew the positioner knob counterclockwise

up to the original position, until when it is
blocked back.

6. Close the reset valve (lever in vertical position).

7. Restart the system.

8. After some seconds close the depressurization

valve.

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 6 – MAINTENANCE (ROUTINE AND SPECIAL) COD: 100M12/24.B.2021 EN

6. MAINTENANCE (ROUTINE AND SPECIAL)

6.1 Check filter cleanliness

It is very important to inspect filters condition periodically.
The following filters are present in the system:
1. Mesh filter (strainer)
2. Pump filter (5 micron cartridge filter)
3. Active carbon filter

follow the instructions given in the table below:

OPERATION FREQUENCY PROCEDURE

Visual inspection and washing

Check and cleaning of

the strainer Every 5 days

Unscrew the filter housing cup

It depends on the real working counter clockwise by using the
condition and the turbidity of the specific key provided
sea water. In average conditions
the replacement of the cartridge is
Replacing of the 5 micron recommended every 100-120
cartridge filters working hours. Once replaced the
filters it is necessary to purge the
air from the system, opening for 2-
3 minutes the depressurization
valve.

Unscrew the filter housing cup

counter clockwise by using the
specific key provided

Replace the active

carbon fiber filter Once per year

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Purge air from the

system periodically by
opening for 2-3 minutes Every 15-20 days
the depressurization
valve.

6.2 Check the plant working pressure

It is necessary to read the pressure on the manometer

located on the equipment front panel in order to
perform this verification.
The working pressure depends on many factors such
as water temperature, salinity level of seawater,
effective batteries voltage, membranes cleaning
degree, typology of installation.
The pressure, in normal working conditions, is
approx. 7,5 – 8,5 Bars. There is a small pressure lost
head, in the range of 0,4 bar, during the cycle.

If the average pressure exceeds the above ranges it is necessary to check the membranes cleaning degree.
It is necessary to perform the shutdown procedure if the membranes result dirty. If cleaning also results
insufficient it could be necessary to perform an alkaline washing using the chemical product SCHENKER
CLEANING 2 (SC2). It is recommended to contact a Schenker certified service centre.

6.3 Check for leaks

It is necessary to perform this verification at every plant start-up and however often, since possible leaks due
to accidental causes (pipe bursting, pipe clamp loosening, equipment failure, etc.) may occur, even plentiful,
with the consequence of possible damages.

6.4 Check for membranes replacement

The reverse osmosis membranes have a 7 years average working life. It is recommended therefore, after 5
years of operation, to verify the possible necessity of substitution and however to perform the substitution after
7 years.

6.5 Shutdown procedure

It is necessary to perform the shutdown procedure before standstills longer than 3 months, for instance before
the winter laying up.
The purpose of the shutdown is to flush the system from possible organic and inorganic sediments, and inhibit
the growth of bacteria that could reduce the reverse osmosis membranes efficiency.

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6.5.1 Necessary Equipment

The following equipment is necessary to perform the shutdown operation:
1. 1 tank of fill with at least 15 liters of fresh water
2. 3 pipes to be connected to:
- inlet of the pre-pump
- discharge of the watermaker
- fresh water production of the watermaker.
3. A bottle of powder SCHENKER CLEANING 1 (SC1). The solution must be prepared following the
instruction indicated on the product label, and using chlorine free water (water produced by the
system can be an option).
4. Tools for dismounting the system's pipes (screwdrivers, pliers, etc.)

HYDRAULIC SCHEME FOR SHUTDOWN PROCEDURE

FIG. 6-1

NOTE
The available products for the shutdown procedure are the following:
1) SCHENKER CLANING 1 (SC1 – Acid product) to remove the inorganic components and preserve the
watermaker during winter break
2) SCHENKER CLEANING 2 (SC2 – Alkaline product) to remove the organic components (mould and
bacteria) when already deposited; in this case the system becomes stinky.
Whether the system needs acid or alkaline cleaning will depend on the type of foulant suspected.
However, both are needed and it is recommended to start with the alkaline cleaning then follow with
the acid cleaning after the system has been flushed.

NOTE
Normally only SC1 is required, but in case of strong smell it is recommended to use also the SC2.
The sequence in this case will be SC2 first, then a washing of the system. Finally the SC1, then again
washing of the system.
It is advisable to replace the filters after performing shutdown procedure with new ones.

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6.5.2 Shutdown operating procedure

1. Prepare the solution carefully mixing the bottle of

SC1 in about 15 lit of unchlorinated water.

2. Connect the 3 pipes to the pre-pump and

watermaker as indicated above, and dip them in
the solution.

Pipes under the free water surface

3. Check they are well dipped in the solution and

don't inhale air.

4. Open the depressurization valve

(turn counter clockwise).

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Manually start the watermaker through the

microswitches inside the pump box (switch down).

Leave the unit running for approx. 20 minutes,

checking that the hoses are properly positioned in
the recipient, so that to avoid inhaling air.

Manually stop the unit through the microswitches

inside the pump box (switch up) and connect the
original hose.

CAUTION
It is necessary to perform the first start-up procedure when restarting the plant after a shutdown
procedure, in order to purge the air and drain out board the chemicals in the systems.

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6.6 Antifreeze procedure (Winterizing procedure in cold climate - under 5°C)

It is recommended to first perform the normal shutdown procedure by using SC1 in order to clean the system
properly and prevent bacteria growth and inorganic material deposit.
After this operation, Then the system must be flushed and filled with an antifreeze.
The recommended antifreeze product is a solution of propylene glycol and unchlorinated water.
The ideal concentration of propylene glycol is
- 45% (for temperatures up to - 20°)
- 55% (for temperatures up to - 30°).

ATTENTION
Do not use ethylene glycol as this substance is toxic and non-degradable.

The total volume of the solution must be about 15 lit.

The procedure is similar to that used for chemical washing with SC1 and SC2 products:

1. Prepare the solution carefully mixing the propylene

glycol with 15 lit of unchlorinated water by following
the concentration suggested above.
2. Disconnect the drain pipe and the pumps suction pipe.
3. Connect two pipe pieces to the drain and to the pump
suction.
4. Insert the end side of the pipes into the bucket, verifying
that the pipes have been properly
dipped in the solution and that they don't inhale air.
5. Open the depressurization valve.
6. Start the watermaker with the by-pass activated.
7. Leave the unit running for approx. 15/20 minutes,
checking that the pipes are properly positioned in the HYDRAULIC SCHEME FOR
recipient, so that to avoid inhaling air or spilling the WINTERIZING PROCEDURE
liquid into the FIG. 6-2
vessel.
8. Shut the plant off and connect the original pipes taking
care of not empty the system daring out the solution.

ATTENTION
It is necessary to perform the first start-up procedure when restarting the plant after a shutdown
procedure, in order to purge the air and drain out board the chemicals in the systems.

Before proceeding with any kind of service it is strongly recommended to read carefully the instruction
contained in this manual.

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6.7 Periodic maintenance

6.7.1 Membrane replacement

Reverse osmosis membranes have an average lifetime of about 7 years If correctly maintained. It is anyway
recommended to check the efficiency of the membranes after 5 years of functioning and verify the needed of
a replacement. Please, refer to a certified Schenker service centre for this operation.

6.8 Adjustments

Accumulator

It is a reservoir of air that has the function of damping the

pressure oscillations during the commutations of the
watermaker. The accumulator is factory loaded at a pressure
of about 6 bar. The charge level must be periodically checked
in order to guarantee a correct functioning to the watermaker.
On some versions it might be installed on the unit.

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 7 –TROUBLESHOOTING COD.100M230.B.2020 EN

7. TROUBLESHOOTING

7.1 Troubleshooting chart

Issue Cause Remedy

Pump pressure switch disconnected Restore or replace the pump
Pump doesn’t start or burned pressure switch

Electronic issue Activate the by-pass

Pump starts but the system Hydraulic block Perform reset procedure
suddenly blocks in high pressure Dirty filters Replace filters
Obstruct membranes Perform washing procedure
Commutation system block Contact a customer service

During operation, the pump Pump pressure switch not correctly Set pump pressure switch
temporarily switches off, giving set
rise to a start and stop
phenomenon
Dirty filters or membranes Clean or replace

Metal noise of the pump Pump cavitation Check the causes of the absence
of water flow at the pre-pump inlet

Low production / normal or low Low battery Check battery charge

pressure Air within the system Purge the air out of the system
Loss of sealing systems Contact a customer service

Low production / high pressure Clogged filters Replace filters

(> 13 Bar) Clogged membranes Perform washing procedure
Cold inlet water Contact a customer service

Loss in the system Loose fittings Tighten fittings

ERS leaks Contact a customer service

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 8 –SUGGESTED SPARE PARTS COD: 100M12/24.B.2021 EN

8. SUGGESTED SPARE PARTS

8.1 Short term cruising

For short term cruising it is advisable to have onboard a cleaning kit (one SC1 and one SC2 cleaning product)
as well as one 5 micron cartridge filter. Other additional spares are listed below with their codes:

Spare part name Code

SC1 WASHING PRODUCT SC1

SC2 WASHING PRODUCT SC2
CLEANING KIT (SC1+SC2) CK
5 MICRON CARTRIDGE 9 ¾’’ F5
ACTIVE CARBON FILTER CARTRIDGE CA

8.2 Long term cruising

For long term cruising it is advisable to have onboard a cruising kit (three 5 micron filter cartridges, one active
carbon filter, one cleaning kit) and the two pressure switches. Other additional spares are listed below with
their codes:

Spare part name Code

SC1 WASHING PRODUCT SC1

SC2 WASHING PRODUCT SC2
CRUISING KIT CRK136
PUMP HEAD 100/150 L SP10
PUMP MOTOR 80/100 220V MP10/220
MEMBRANE 4021 M4021
PORTABLE SALINITY TESTER PST
PUMP LOW PRESSURE SWITCH 80/100 PSSS361
PUMP HIGH PRESSURE SWITCH 80/100 PSP10
SPARE SEALS KIT 2.0 SS100-2.0

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8 –SUGGESTED SPARE PARTS COD: 100M12/24.B.2021 EN

8.3 ERS spare parts

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8.4 Additional spares

For extraordinary maintenance intervention that might become necessary in order to ensure the normal
operating condition of the watermaker, other common spares are listed below with relative images and codes:

Spare part name Code

COUPLE HIGH PRESSURE PIPE SM 100/150/200 HPH2

END CUP VESSEL 4” SINGLE CONNECTION EV4
END CUP VESSEL 4” DOUBLE CONNECTION EV4-2
“C” END CUPS 4’’ CONNECTION FITTING CEV4
MANOMETERS 0-16 M16B

EV4 EV4-2

M16B HPH2

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