TECNICOMAR MINIMAR PLUS User manual

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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INSTRUCTIONS FOR THE INSTALLATION, USE AND MAINTENANCE OF

TECNICOMAR WATERMAKERS

Models

MINIMAR PLUS

SAILOR

BICOMPACT

NOTE

The indications contained in this Manual must be strictly followed during installation, operation and

maintenance of the watermaker in order to warrant the operators' safety and the equipment

maximum efficiency.

Identification

The Tecnicomar watermaker carries a plate with the following data:

a) Manufacturer: TECNICOMAR SpA, C/da Berbaro n.145/D –91025 Marsala –ITALY –

Tel.0923-969409 / Fax 0923-960235;

b) CE logo;

c) Type

d) Serial number

e) Year of manufacture

f) Voltage

Revision

2009

Revision

07/2011

Revision

03/2012

Revision

03/2013

Revision

12/2014

Revision

08/2015

CONTROL BOX TINY2 DESCRIPTION UPDATED

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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Dear Customer,

We would like to thank you for choosing a TECNICOMAR WATERMAKER.

This watermaker has been designed by expert technicians and manufactured with care for all its

aspects and in respect of the European standards.

Our widespread commercial organization guarantees accurate and prompt assistance and

maintenance service to our Customers.

This Manual provides the User with the illustrated, step-by-step instructions on how to install and

use the watermaker. It also contains all the necessary information for the maintenance.

WARNING !

TECNICOMAR S.p.A. declines any and all liability for failure to observe the safety and

accident prevention standards described in this manual, for damage dued to the improper

use of the equipment and for modifying it without the authorization of Tecnicomar S.p.A.

Contents of the Instruction Manual:

Section 1 contains information for storage before unpacking.

Section 2 contains the process description and system components identification.

Section 3 contains information about installation.

Section 4 contains information about first start-up procedure.

Section 5 contains information about routine operation.

Section 6 contains the emergency operation and the long period shutdown information.

Section 7 contains maintenance and setting instruction of the safety components.

Section 8 contains useful troubleshooting information.

Section 9 contains the technical characteristics of the equipment.

Signs used throughout the Manual

Warning

These instructions should be followed carefully to operate the watermaker correctly.

Danger

These instructions should be followed carefully to avoid damage to the watermaker or

to the operator.

Note or Information

The notes contain important information and useful hints for the watermaker

operation.

If not specified otherwise, letters used in the text refer to the functional diagram shown in the

drawings situated at the end of this Manual.

* * * * * * * * * * * *

This Manual is intellectual property of Tecnicomar S.p.A. Any reproduction of contents or

drawings –unless authorized by Tecnicomar S.p.A. –is not permitted and will be prosecuted.

©Tecnicomar

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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TABLE OF CONTENTS

1Storage prior to unpacking and packaging content............................................................................................1-6

1.1 Storage prior to unpacking..............................................................................................................................1-6

1.2 Checking packaging content............................................................................................................................1-6

2Process description and system components identification................................................................................2-9

3Installation Procedure.........................................................................................................................................3-11

3.1 Components supplied by owner .....................................................................................................................3-11

3.2 Plumbing connections....................................................................................................................................3-11

3.3 Power connection ..........................................................................................................................................3-12

4First Start-up procedure .....................................................................................................................................4-15

4.1 Shut down procedure .....................................................................................................................................4-16

4.2 TINY 2 microprocessor control box. Description and operation...................................................................4-16

5Routine operation ................................................................................................................................................5-18

5.1 Routine operation (c/w automatic pressure regulator device).......................................................................5-18

5.2 Routine operation (c/w manual pressure regulator device)...........................................................................5-18

5.3 Manual running mode (c/w automatic pressure regulator device)................................................................5-19

5.4 Operation in low- or high-salinity areas .......................................................................................................5-19

5.5 Operation in cold areas.................................................................................................................................5-19

6Special procedures...............................................................................................................................................6-20

6.1 System normal operation. ..............................................................................................................................6-20

6.2 Emergency operation.....................................................................................................................................6-20

6.3 Preservation of membrane modules in very cold areas.................................................................................6-22

6.4 Optionals........................................................................................................................................................6-22

6.4.1 Automatic flushing system ....................................................................................................................6-22

6.4.2 Remote control.......................................................................................................................................6-23

6.4.3 Touch screen..........................................................................................................................................6-23

6.4.4 UV sterilizer...........................................................................................................................................6-23

6.4.5 Multimedia sand filter or TFD filter ......................................................................................................6-23

7Maintenance.........................................................................................................................................................7-24

7.1 Ordinary Maintenance...................................................................................................................................7-24

7.1.1 Preservation and care of the semipermeable membrane modules..........................................................7-24

7.1.2 High-pressure circuit..............................................................................................................................7-24

7.1.3 Oil changing in the CAT high-pressure pump .......................................................................................7-24

7.1.4 Prefilters maintenance............................................................................................................................7-25

7.1.5 Carbon filter replacement ......................................................................................................................7-25

7.2 Extraordinary maintenance ...........................................................................................................................7-26

7.2.1 Replacement of membrane modules......................................................................................................7-26

7.2.2 Salinity and temperature sensors (M+M1).............................................................................................7-26

7.3 Long-period shut down procedure.................................................................................................................7-26

7.3.1 In case of automatic pressure regulator device ......................................................................................7-26

7.3.2 In case of manual pressure regulator device ..........................................................................................7-27

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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7.4 Membrane flushing with FL/411A and FL/412B chemicals ..........................................................................7-28

7.5 General maintenance plan.............................................................................................................................7-29

7.5.1 Prefiltering circuit..................................................................................................................................7-29

7.5.2 Pressurizing circuit ................................................................................................................................7-29

7.5.3 Controls and produced water circuits.....................................................................................................7-29

7.6 Maintenance kit..............................................................................................................................................7-29

8Common problems and troubleshooting ...........................................................................................................8-31

8.1 First start-up..................................................................................................................................................8-31

8.2 Start-up after the replacement of filter cartridges .........................................................................................8-31

8.3 Low pressure failure......................................................................................................................................8-31

8.4 Low pressure failure during normal operation..............................................................................................8-31

8.5 Operation with vessel in navigation, rough sea and LOW PRESSURE alarm on .........................................8-31

8.6 Normal operation of the watermaker and overload failure shutdown...........................................................8-32

8.7 UNSAFE warning message during normal operation ...................................................................................8-32

8.8 The watermaker runs normally but the produced water does not reach the tanks ........................................8-32

9Technical characteristics and spare parts .........................................................................................................9-33

9.1 Electrophysical characteristics......................................................................................................................9-33

9.2 A typical analysis of produced water.............................................................................................................9-33

9.3 Spare part list ................................................................................................................................................9-34

9.3.1 High pressure pump...............................................................................................................................9-34

9.3.2 Other spare parts....................................................................................................................................9-34

9.4 Warranty for Tecnicomar equipments ...........................................................................................................9-41

Annexes

DRAWINGS

Drawing 1 FLOW DIAGRAM

Drawing 2 CLEANING/STORAGE

Drawing 3 WIRING DIAGRAM

Drawing 4 AUTOMATIC PRESSURE REGULATOR

Drawing 5 ELECTR. CONNECTIONS

Drawing 6 AUTOMATIC FLUSHING SYSTEM

Drawing 7 PRESSURE VESSEL

HIGH PRESSURE PUMP (Parts list –exploded view)

LOW PRESSURE PUMP (Parts list –exploded view)

Test certificate

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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What is Reverse Osmosis

Osmosis is the diffusion of two mixable solutions through a semipermeable membrane in such a

manner to equalize their concentration. A water with less salt naturally diffuses into a water with

higher salt.

Sea water or brackish water cannot naturally diffuse through a semipermeable membrane to

provide potable water.

A man-made process, REVERSE OSMOSIS, overcomes this natural phenomenon. By forcing

sea or brackish water (under high pressure) through a semipermeable membrane, potable water can

be realized !

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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1Storage prior to unpacking and packaging content

1.1 Storage prior to unpacking

Do not store in direct sunlight.

Do not freeze (see paragraph 6.3).

Do not store above 50°C (122°F).

Store only on base with arrows up.

1.2 Checking packaging content

In the package there are the following components:

SAILOR (compact version)

SAILOR (slim version)

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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SAILOR (modular version)

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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MINIMAR PLUS (compact version)

Installation kit

Clamps - Manual - Tank connection fitting - Inlet hose - Filters wrench - Discharge and Fresh water

hoses - Discharge fitting

Instructions for the installation, use and maintenance of Tecnicomar watermaker

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2Process description and system components identification

The watermaker has four main sections:

Prefiltration section where salt water, supplied by the booster pump (A), is filtrated passing through the two

prefilters (B and C). Feed water pressure is taken by the low pressure sensor (E) and shown on the display of the

electric box (Lbar);

High pressure section in which sea water is pressurized by the high-pressure pump (F). The high-pressure sensor

(G), electrically connected to the electric box, shuts down the system automatically if the operating pressure exceeds

the preset level. The unit can be equipped with automatic pressure regulator valve (I) or can be run also in manual

mode and the working pressure adjusted manually by the pressure regulator valve (I) located on top of the

motorized valve. The high-pressure tubes and their fittings require periodic (see MAINTENANCE section).

Salt water (BRINE) discharge section. In this section the brine is discharged. The fresh water is also discharged out

of board if it does not have the drinking-water quality. Through the three-way solenoid valve (N), the electric box

automatically switches the water coming from membranes either to the discharge or to the fresh water tank. The

water quality is checked by the salinity sensor (M). The temperature sensor (M1) compensates the reading

according to temperature. The salinity and temperature sensor require periodic maintenance (see MAINTENANCE

section).

Freshwater section. This is the most important section of the system, the section where the physical process of

reverse osmosis takes place. The main components of this section are the semipermeable membranes which separate

sea water in two flows: one with concentrated salts which goes to the discharge (R) and the other with fresh water

(U) which goes to the fresh water tank. The fresh water flow is taken by the flow sensor (L) before reaching the

three-way solenoid valve (N) and shown on the display. The three-way solenoid valve (N) switches the flow,

depending on its salinity, to the discharge or to the tank. The semipermeable membranes are very sensitive

components and require strict observance and care (see PROTECTION AND CARE OF SEMIPERMEABLE

MEMBRANES in Maintenance section).

Flow diagram (in case of supply c/w automatic pressure regulator)-see also attached drawing-

DISSALATORI-WATERMAKERS

Instructions for the installation, use and maintenance of Tecnicomar watermaker

2-10

Flow diagram (in case of supply c/w manual pressure regulator) -see also attached drawing-

DISSALATORI-WATERMAKERS

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