Installation - Atlantis Marine Power
Contents
1. 55 NOVA SNOYWAONVA THM LI SV LNO YALVM 54 44 AHL NO dV L V Lid LON OG uogesado 0 yey v yue onseuoq 8 JBUIEASESS 8 suonoun pue uogeruesaid Buunp pesn 8joN 2 90 UWAN 6 VOJAN SZ jquiess Ped Pd 0 9 pue Buunp Aju Sad E dung einsseJd ufi Z dung SUIS JOM 2 A rr E A 55444 MOVE 4Sn V2 THM LI SV LNO YALVM 54 44 AHL NO V Lid LON OG 4 Installation Guide Supplied Components Main Panel High Pressure HP Pump Low Pressure LP Pump Dual Pre Filter Housings and Filters Remote Control Touchscreen Remote Control Cable Installation amp Service Manual Operators Manual Optional Components Oil Water Separator Safi Valve Check Valve Carbon Filter Semi Automatic Flushing Pre Filters Power Requirements The AFDXXXXAC Series watermakers use standard AC motors to power the LP and HP Pumps and as such consideration must be given to both running power requirements and motor start inrush requirements Power requirements vary depending on the model of the watermaker but running current will be stated on the control box of your model Inrush current cannot be measured or calculated exactly but an inrush of 42. ii IVOLLTHOHHL 5 17 IEIS 2406 o0 MOE 09 A906 081 Mo0SI 081 9 051 9 01 9 06 9 09 ALOE 06 D rA NES LR eee A 6007 SONY uv22Q elm o09 o0 o0 o0 Mo0 Mo09 Mo06 Mo0TI 061 0081 3051 8061 906 909 HOt SSq AUes enuu y 6 The Importance of Using De Chlorinated Water Freshwater containing chlorine will damage your watermaker membranes When flushing or preserving your system always use fresh de chlorinated water This can be obtained by a Running a freshwater hose through a carbon filter available from Aquafresh Watermakers b Using water already produced by your watermaker c Leaving an open bucket of fresh tap water to stand for 24 hours to allow the chlorine to evaporate CAUTION Chlorine damage to your membranes will invalidate the warranty 19 7 Maintenance The unexposed interiors of the RO membranes can promote algae growth in sea water and this can have the effect of reducing the output from the system There is a greater risk of algae growth in warmer waters If the unit is to be left unused a period of 7 to 14 days the system can be flushed with fresh de chlorinated water to prevent fouling of the membranes If the unit is to be left unused for a period greater than 14 days up t
3. 3 phase only check motor is rotating in the correct direction if not reverse connection of any two incoming supply wires Check liquid connections are on the right way round Check the pump has a flooded suction and is primed If a suction lift exists fit a Stuart foot valve strainer and ensure suction is airtight Prime the pump and suction pipe 40 20 High Pressure Pump Maintenance SERVICING THE VALVES Disassembly 1 2 3 Remove the four 4 Socket Head Bolts and Spring Washers from end of Manifold Support the Discharge Manifold from the underside and tap with a soft mallet to separate from the Inlet Manifold Carefully place Discharge Manifold on work surface with crankcase side up From the three 3 smaller diameter and shallow inlet chambers remove the Inlet Valve Adapters with inner and outer O Rings These adapters are not held securely in position and may fall out as the Discharge Manifold is removed Next remove the Valve Seats Valves Springs and Retainers from the Inlet Chambers From the three 3 larger diameter and deeper discharge chambers remove the Discharge Valve Spacers with inner and outer O Rings These spacers generally remain with the Discharge Manifold as it is removed Insert two screwdrivers under the lip of the Spacer and pry the Spacers from the Manifold chamber Next remove the Valve Seats Valves Springs and Retainers from the discharge chambers NOTE
4. 1 Watermaker Principles Dictionary definitions Osmosis n 1 The tendency of the solvent of a less concentrated solution of dissolved molecules to pass through a semi permeable membrane into a more concentrated solution until both solutions are of the same concentration Osmotic pressure n the pressure necessary to prevent osmosis into a given solution when the solution is separated from the pure solvent by a semi permeable membrane When the pressure on a concentrated solution of dissolved solids is increased then reverse osmosis takes place and molecules of the pure solvent water in our case pass through the membrane from the concentrated solution The pressure required to achieve this phenomena is proportional to the concentration of dissolved solids l e a 1 solution of salt requires approximately 100 psi 7 Bar and sea water at 35 000 ppm requires approximately 800 psi 55 Bar It is this principle that is used in the operation of your Aquafresh reverse osmosis water maker 2 Working Parts and Function Aquafresh AFD series Watermakers are AC powered units they consist of the following main components AC Driven Low Pressure LP Pump AC Driven High Pressure HP Pump AC Driven Main Panel inc Processor Passive Pre filter Assembly 5 amp 30 Micron LCD Remote Digital Panel Optional Components DC Driven Flush Valve SAFI Active Carbon Filter Assembly System Function Standard Sea Water Sea water is drawn
5. The inlet and discharge use the same Retainers springs Valve Seats and Valves The O Rings and valve spacers adapters are different Keep parts in order as they are removed Reassembly Discharge Note For certain applications apply liquid gasket to O Ring crevices and seal surfaces See Tech Bulletin 53 for model identification Place the crankcase side of the Discharge Manifold up Examine the Spring for fatigue or breaks and place the new Spring into the Retainer Then insert the new Springs into the Retainers over the plastic center guide and place the Valve Spring Retainers in the deeper valve chambers They will rest on the machined ridge in each chamber Examine the Valves for wear or pitting and replace if necessary Install valves over springs with concave side down Examine Valve Seat O Rings for wear and replace Place O Rings on lip of retainers Carefully square O Rings in valve chamber to avoid cutting O Ring when Valve is installed Examine Valve Seats for pitting scale or ridges and replace if necessary Install Valve Seat with concave side down so O Ring fits snugly into groove on Seat 7 Examine both inner and outer O Rings on the Discharge Valve Spacer and replace if necessary Lubricate O Rings and fit into grooves on outside of spacer Apply liquid gasket to the O Ring crevices on the O D of Discharge Valve Spacers and carefully press into valve chambers with small diameter side down until Spacer
6. Using Single Use Cleaning Cartridges Continued Place cleaning filter 1 into either filter housing and screw into place Press the SERVICE switch to start the Priming pump Let the pump run for 30 minutes to allow the chemical to circulate After 30 minutes depress the SERVICE switch the LP pump will stop Remove the cleaning filter and screw empty housing back into place Empty the bucket of chemical solution and refill with fresh de chlorinated water Press the SERVICE switch and Flush the unit for 5 minutes Press SERVICE switch the LP pump will stop Refill the bucket with Fresh de chlorinated water then return to step 7 This time using 2 cartridge carry out steps 7 8 and 9 then go to step 11 It is essential that both organic and inorganic cleaning procedures are carried out same time 1 and then 2 To return the unit to normal operation return the L port valves to their normal position and remove the 1 2 inch hoses Place NEW micron filters into their appropriate housings Using the SERVICE switch to start the LP pump bleed the system by depressing the button situated on top of the filter housings On completion switch off using the SERVICE switch 28 14 Cleaning Cartridge 1 Information Product I nformation Sheet CLEANING CARTRIDGE 1 Hazardous Material Active Ingredient Hazard Data Threshold Limit Value TLV Lethal Dosage LD50 Lethal Concentration LC50 Appearance and
7. shown in Fig 5 3 Disassemble cable gland as shown in Fig 7 and insert cable into position ensuring O ring item 1 is placed over the cable before the clamping insert item 2 is tightened 4 Consolidate the stranded conductor ends by twisting and shape the earth conductor as shown in Fig 6 item 3 5 Remove earth terminal post clamping components and assemble as shown in Fig 6 ensuring shaped conductor is orientated as shown and all strands of the conductor are clamped between the washers 6 Insert and secure live and neutral conductors ensuring all conductor strands are clamped 7 Confirm cable routing is as shown in Fig 7 and assemble and secure terminal box lid Dims in mm Fig 5 12 Installation Guide Continued HIGH PRESSURE PUMP Using the anti vibration mounts supplied fit the pump and motor on a level base ensuring that the oil level in the pump will be horizontal Ensure that there is adequate ventilation available to prevent the motor overheating minimum 100mm space behind the motor fan The crankcase will already be filled with the correct amount of oil The HP pump must not be allowed to run dry as damage to the pump will occur The HP pump is supplied with a short cable and junction box to facilitate easy connection the cable from the main panel control box cables Remove Label on Oil Filler Cap to ensure the breather hole in the oil cap is not covered SYSTEM
8. 6 times the running current is normal and can last from 250ms 750ms Your power source must be able to cope with this Most conventional synchronous generators 3 5kW or greater and shore power systems are able to provide this power Asynchronous generators or generators using inverter outputs will have to be sized accordingly as most cannot provide more than their rated current even for a short period It is not recommended to run an AFDXXXXAC series watermaker off an inverter that cannot provide at least 6 times running current of all components 10 Installation Guide Continued MAIN PANEL The main panel unit is a heavy unit and as such must be mounted on a substantial structure or bulkhead it must be mounted horizontally unless you have a bespoke version No electrical equipment should be mounted beneath the main panel as spillage is likely to occur whilst winterising or servicing the unit The system control box is mounted on the unit and is pre wired with cables for Power Supply LP Pump HP Pump SAFI Valve Tank Full and Remote Touchscreen Each cable is identified by a label at the cable entry gland Holes for mounting bolts are placed at the top and bottom edge of the panel PI PEWORK See section 3 for an installation layout example It is recommended that care is taken on installation and that all recommendations are followed All pipe work should be able to cope within a high pressure system If you are unsure about a
9. Discharge Manifold removed from the pump remove the two 2 Socket Head Bolts and spring washers from end of Inlet Manifold Rotate Crankshaft to loosen Inlet Manifold Support Inlet Manifold from underside and tap with a soft mallet to separate Manifold from Crankcase With crankcase side of manifold down remove Hi Pressure Seals using a reverse pliers 5 Invert Inlet Manifold so crankcase side is up and with reverse pliers remove Lo Pressure Seals 41 Reassembly Note For certain applications apply liquid gasket to O Ring crevices and seal surfaces See Tech Bulletin 53 for model identification Examine Lo Pressure Seal for wear or spring failure and replace if necessary With crankcase side of inlet manifold up press the new Lo Pressure Seal into the Valve Chamber with Garter Spring down Carefully square seal into position Examine Hi Pressure Seal for wear and replace if necessary Invert Inlet Manifold with crankcase side down and press the new seal into the Manifold chamber with v side up metal side down until completely seated Rotate the Shaft so the two 2 outside Plungers are extended and lined up Examine O Rings on both the Discharge Spacer and Inlet Valve Adapter for cuts or wear and replace as needed Lubricate Plungers and carefully slide the Inlet Manifold over the Plungers and press into the Crankcase Replace two 2 M10 Inlet Manifold Socket Head Bolts and Washers hand tight
10. a time anti clockwise to reduce the operating pressure until cycling of the HP pump ceases Increase the system pressure to the normal operating pressure by adjusting the pressure regulating valve and repeat the above procedure if necessary Remember setting this switch below 3 psi will potentially irreversibly damage your HP Pump and motor assembly Some models of Aquafresh water maker have a high pressure safety switch installed on the HP outlet to the HP pump to prevent pressurising the system above 1000 psi other models use a mechanical pressure relief valve PRV This switch is factory set to open circuit at a pressure above 950 psi and does not require user adjustment The control voltage operates the HP interlock on the p c b in the control box It is important when making any adjustment to this switch not to exceed 1000 psi Slowly increase the system pressure to 950 psi and ensure that the pressure remains steady before making any adjustments If the system switches off before reaching 950 psi then short the two connections on the low pressure switch to make sure that the system is not being controlled by this switch If the system still fails to pressurise up to 950 psi then rotate the adjusting screw on the high pressure switch clockwise a quarter of a turn at a time Remember that if the unit is being controlled by the switch it will take up to 20 seconds to re start If the pressure can be adjusted passed 950 psi then set the pre
11. hours of system for any routine maintenance which may be due Check system sea water strainer for debris and clean as required Visually inspect system for leaks and take remedial action as necessary Visually inspect the high pressure flexible pipe for chafe or bulging Replace if defective If bulging is seen do NOT run the watermaker as a high pressure burst may occur Contact Aquafresh Ltd for a replacement Check HP pump oil level and top up if required Check condition of both system micron pre filters If badly discoloured replace them Under normal use offshore you can expect 100 hours or more use unless plankton or sediment is prevalent When replacing filters always clean the clear filter bowls DO NOT use a detergent as this could contaminate the RO membranes If the filter bowls are opened then you MUST bleed any air from the system by operating the SERVICE switch and depressing the bleed vents on top of the filter bowls only then operate the normal on off switch which will allow the HP pump to function DO NOT ATTEMPT TO BLEED THE SYSTEM WITH THE HP PUMP RUNNING Periodic Maintenance First 50 hours Change HP pump oil Every 500 hours or annually Change HP pump oil Use approved CAT High Viscosity Index Hydraulic Crankcase Oil Obtainable from Aquafresh Ltd NOTE Do NOT use engine oil 26 13 Membrane Cleaning After Long Term Use Using Single Use Cleaning Cartridges DO NOT REMOVE REVERSE OSMOSIS ELEMENTS FROM TH
12. line Hose from inlet too small HP pump valve sticking Cavitating Worn seals High pressure regulating valve out of adjustment or faulty High pressure safety relief valve out of adjustment or faulty Belt slip Engine driven models only Air ingress Pressure gauge fault Leaking hoses Remedy Open sea cock Tighten all connections and re seat strainer cap Check L port valve for leak Remount low pressure pump and hoses below waterline Hose size must not be less than specified for size of system Contact Aquafresh for assistance Clean or replace valves Check low pressure system for leaks or restrictions Replace pump seals Adjust high pressure regulating valve or replace Carefully adjust valve to blow off at 950 psi Under no circumstances allow pressure to exceed 1000 psi Refer to Aquafresh Watermakers for service information Tighten or replace belt drive Rectify leaks in LP system Replace Replace or repair 36 Symptom Water leakage under HP pump manifold Oil leakage between manifold and crankcase Oil leakage around crankshaft Oil leakage from rear of crankcase Frequent packing failure or HP pump run dry LCD control not powered up Main circuit breaker keeps tripping LP pump will not run HP pump does not start Possible Cause Worn seals Worn oil seals Worn seal or O ring Unserviceable bea
13. water quality and machine monitoring system that will detect most problems and display a simple error message that will indicate the cause of any failure Your watermaker can display various message that can help diagnose maintenance issues including operational errors and faults Tank Full Optional Tank Full Shutdown Press ACCEPT to clear Your watermaker is fitted with an optional tank full switch and the unit will automatically stop once your tanks are full if used The above message will be displayed Press the ACCEPT ICON to clear the message Change PLC Battery Change PLC Battery System warning message it is very important the PLC internal battery is changed Please refer to service manual SAFI Valve Failure SAFI Valve Failure Investigate cause of alarm Press RESET ALARM to clear If your watermaker has the optional flush system installed this error will be displayed if a problem occurs with the SAFI valve Inspect clean repair or replace SAFI valve 33 Troubleshooting Continued Salinity Probe Error Salinity Probe Module Fault Investigate cause of alarm Press RESET ALARM to clear This error indicates a problem with the salinity probe or module Check probe clean or replace probe and or module Low Pressure Alarm Low Pressure Alarm Investigate cause of alarm Press RESET ALARM to clear This is a common alarm and indicates a loss of pressure in the low pressure circuit
14. AQUAFRESH WATERMAKERS AFDXXXX AC Series Installation and Service Manual Please read this manual thoroughly before attempting to install and commission your water maker E amp OE 09 13 Danger High Voltage AFDXXXX AC Series water makers operate on a 240VAC electricity supply and must not be opened disassembled or repaired by unauthorised or unqualified service people Improper operation or repair of your water maker could result in serious injury or death Danger Safety Information The water maker is a high pressure device operating at up to 1000psi PRV set point and must NOT be tampered with disassembled or repaired by unauthorised or unqualified service people Improper operation or repair of your water maker could result in serious injury or death Before attempting to operate your water maker ensure that the seawater intake seacock is fully open and that all pre filters are clean and unblocked Visually check the unit before running for leaks loose fittings and corrosion Do not operate watermaker if you are unsure Always ensure the water maker is running at the desired pressure for your area of operation and seawater temperatures If unsure please set running pressure to 825 psi The adjustment is made on the water maker not at the control panel Never attempt to run the watermaker above 950psi AFD Series watermakers are not designed for and will be permanently damag
15. EIR HOUSINGS UNDER ANY CIRCUMSTANCES Under normal operation the RO membranes can be fouled by mineral scale dirt and biological matter Deposits can build up over a period of time causing lower output of fresh water and or lack of salt rejection The system should be cleaned when the output of fresh water drops by more than 15 from the flow rate determined at time of commissioning The output figure should however be adjusted for any temperature difference by reference to the Theoretical Membrane Output graph WARNING Caustic and acid solutions are used in the cleaning procedures and great care should be taken when handling Rubber gloves and protective clothing should be worn Spills and splashed areas should be treated immediately with copious volumes of fresh water Irritation will be caused to the eyes by inhalation and by ingestion Wash skin with soap amp water Irrigate eyes with water for at least 15 minutes and obtain medical advice If inhaled blow nose and wash nasal passages obtain medical advice If ingested rinse out mouth Give water to drink seek medical advice If large amounts of this fluid are ingested then induce vomiting seek medical advice When flushing the unit always use Fresh De chlorinated Water Do NOT carry out the following treatments if Sodium Metabisulphite is in the system first flush the system with fresh de chlorinated water or use the de winterising cycle Procedure Membrane Cleaning for
16. FILTERS INLET Two filters are normally supplied a 25 micron and 5 micron filter respectively from the priming pump The filters should be mounted allowing adequate space for removal and replacement of the filter bowls No electrical equipment should be mounted beneath the filters as spillage is likely to occur when changing the filter elements or cleaning the bowls The low pressure gauge is fitted to the top of the filter system If the optional Oil Water separator is to be used this should be installed after the micron filters Note It is important that the hose connections between the sea cock the LP pump System Filters and the HP pump run in a steady incline with no peaks or troughs that can cause air locks A seacock and strainer of not less than 3 4 inch diameter is required mounted as low in the bilge as possible to minimise the risk of surface debris and oil ingestion The system should have its own inlet On no account should the inlet to the water maker be shared with any other system e g engine generator toilet system or air conditioning etc Care should be taken to place inlet away from other system outlet such as grey water or sea toilet outlets Do not use any ferrous materials in the inlet system On steel hulls change to non ferrous fittings as soon as possible and ensure that the ferrous metal is painted to protect the watermaker as ferrous fouling will irreparably damage the membranes DISCHARGE A discharge o
17. Odour Solubility in Water pH of 2 4 Solution Fire and Explosion data Reactivity Data Incompatibility Hazardous Polymerization Toxicity Mixture contains no hazardous materials Phosphates organic acids None White Powder odourless Complete 11 0 5 No hazard exists Stabile Avoid contact with aluminium Will not occur No TLVs have been established for this mixture Health Hazard Information a Oral Ingestion b Eye Contact c Skin Contact d Inhalation Not considered a primary route of contact Considered a moderate irritant Considered a mild irritant Not considered a primary route of contact Emergency First Aid a Oral Ingestion b Eye Contact c Skin Contact d Inhalation Not applicable Flush eye immediately with large volume of water Get medical attention Flush contacted area with water Launder clothing before reuse Not applicable Spill or leak Steps to be taken in case material is released or spilled a Vacuum or sweep shovel into salvage containers b Flush area with water to remove final traces Waste Disposal Method a Material may be diluted with water and flushed into an approved drain b Comply with all applicable federal state and local regulations Special Protection Information a Respiratory Protection b Ventilation c Protective Gloves d Eye Protection None required None required Standard work gloves Saf
18. Organics amp Particulates These cleaning cartridges contain irritants Avoid contact with skin eyes and clothing Do not inhale dust Refer to relevant Health and Safety Data Sheet 1 Connect a 1 2 inch hose to the input L port valve on the priming pump and fill the pipe with de chlorinated water before placing your thumb over the end and placing the hose end into a bucket of fresh de chlorinated water Do NOT open the valve to this inlet at this stage 2 Connect a 1 2 inch hose to the output FLUSH L port valve placing the hose end into the Freshwater Do NOT open the valve to this inlet 3 Remove the filters from their bowls clean DO NOT use detergent and replace the now empty bowls 4 Press the SERVICE switch Open the L port valve on the LP pump to allow Freshwater to enter the system and allow approximately 1 3 of the freshwater to discharge overboard before opening the output flush L port valve Allow the unit to be flushed for approximately 10 minutes 5 Adjust the pressure regulating valve to show a pressure of no more than 80 psi No product water should be produced a Note During this process ensure that the level of liquid in the container is maintained above the 1 2 inch hose connected to the input L port valve on the LP pump 6 After 10 minutes depress the SERVICE switch to stop the Priming pump running 27 10 NOTE at the 11 12 13 Membrane Cleaning After Long Term Use
19. arranty does not extend to the reverse osmosis membranes due to the possibility of unintentional damage by the user Instead of warranty Aquafresh Watermakers offer the customer an exchange service whereby Aquafresh Watermakers will at any time during the system life replace any defective membrane or clean any fouled membrane for a charge equal to 75 of the then current list price for the membrane The subject membrane shall be returned to Aquafresh Watermakers with full payment enclosed including transportation costs and Aquafresh Watermakers shall expedite the appropriate service This warranty extends to the original purchaser only and is in lieu of all other express or implied warranties including those of merchantability and fitness for a particular purpose Original Purchaser Name Address Installed On Vessels Name and Type Purchased From Name Address Installation date Model No Serial No 49 EU DECLARATION OF CONFORMITY According to ISO Guide 22 and EN 45014 Manufacturers Name Aquafresh Watermakers Ltd Manufacturers Address Western Wood Way Langage Science Park Plymouth England Declares that the product Product Name Aquafresh Watermaker 240v AC Models Model Number AFD AC AII models Product Options Standard or Auto Flush Conforms to the following Product Specifications LVD 73 23 EEC MD 98 37 EC EMC 89 336 EEC Emissions Harmonized CISPR Standard Immunity Harmonized Basic Stan
20. dard Supplemental Information The product herewith complies with the requirements of the Low Voltage Directive 73 23 EEC and the EMC Directive 89 336 EEC and carries the C marking accordingly Lewis Prouse Marine Systems Engineer EU Atlantis Electrical Systems Ltd Date 30 June 2012 Plymouth U K 50 51
21. e advisable to send the chemical structure of the product or a one litre sample for testing For the pressure vessels we warn against use of a cleaning solution with 7096 methanol indicated by some membranes manufacturers for the disinfection Generally the customer shall check that the recommendations given by membranes manufacturers meet our recommendations All the cleaning solutions with recommendations that would not meet ours shall be avoided or we should be consulted before every application 5 2 Preservation and storage The use of Formaldehyde concentrated from 0 5 to 196 is possible until a maximum temperature of 30 C In the case of a use of sodium bisulphite the solution will consist of NaHSO3 from 1 to 1 596 neutralized pH 6 to 7 and buffered with 500 ppm NaHCO3 solution The inside of the pressure vessel shall be free of air in order to avoid an oxidation process of the sodium bisulphite moreover the pH will be checked once per week and shall never be inferior to 3 The solution will be renewed at least each month PREPARING PLUGS I FITTING MEMBRANES 111 FITTING HEADS IV FITTING TI E RODS V CONNECTING PI PEWORK VI SAFETY PRECAUTI ONS 45 PREPARING PLUGS A For single pipe shell 1 1 Lubricate the O ring seal 5 and 6 and fit it on the plugs 3 and 4 For multi pipes shell 1 2 Lubricate the O ring seal 12 and fit it on the plugs 11 1 3 Fit it the fitting port 11 on the con
22. ed if operated in brackish or freshwater areas Sections St 28 28 NNNNRPRPRPRPRPRPP RP HP WNP OSOMNAURWNEO INDEX Water Maker Principles Working Parts amp Function Installation Layouts Installation Guide Theoretical Membrane Production Graph The Importance Of Using De chlorinated Water Maintenance Flushing The System With Fresh Water Autoflush Only Flushing The System With Fresh Water Manual Short Period Lay Up Instructions Preservative Chemical Cartridge Safety Information Routine Maintenance Membrane Cleaning Instructions Cleaning Chemical 1 Information Cleaning Chemical 2 Information Commissioning Troubleshooting Low Pressure Safety Switch Low Pressure Pump Explained High Pressure Pump Maintenance Pressure Vessel Maintenance Spares kit And Parts Information Warranty Aquafresh Reverse Osmosis Watermaker Installation and Service Manual AFDXXXX AC Models Owners and operators of Aquafresh watermakers are urged to read this manual thoroughly as by understanding the principles of reverse osmosis operational problems will be avoided and satisfaction with your unit will be realised All elements of the system are described in detail to give you a working knowledge of their function in order that minor defects may be overcome before they lead to major problems and expensive repairs or worse Please read this manual through before attempting to install connect or run the system
23. en and then torque per chart Then carefully slip the Discharge Manifold onto Plungers and press the exposed Discharge Valve Spacers into the Inlet Manifold Tap with a soft mallet until flush Replace the four 4 M10 Discharge Manifold Socket Head Bolts and Washers and hand tighten Then torque per chart SERVICI NG THE PLUNGERS Disassembly 1 2 3 Remove Discharge and Inlet Manifold as described Using a wrench loosen Plunger Retainers approximately three 3 to four 4 turns Grasp Ceramic Plunger and push towards Crankcase until Plunger Retainer with stud pops out Remove Plunger Retainer with O Ring Back up Ring and Gasket Next slip Ceramic Plungers Keyhole Washer and Barrier Slingers from each Plunger Rod Examine Crankcase Seal for deterioration and replace if needed Consult Aquafresh Watermakers Ltd for crankcase servicing Reassembly 1 Replace Barrier Slinger if damaged when removing and position onto Plunger Rod with concave facing out Then examine the Keyhole Washer and place on the Plunger Rod with the slot down 10 Carefully examine Ceramic Plunger for scoring or cracks and replace if worn Slip onto Rod Ceramic Plunger can only be installed one direction front to back Do not force onto Rod Examine O Ring and Back up Ring on Plunger Retainer and replace if worn or cut Lubricate O Ring for ease of installation and to avoid damage to O Ring First install NEW copper Gasket on Pl
24. essure vessels are designed to be used with osmosis or filtration membrane with pressures mentioned for each reference All membranes models can be easily adapted on vessels with specific adaptors supplied with the vessel All gaskets must be lubricated while setting up For lubrication of o ring seals and membranes use only a lubricating stuff recommended by the membranes manufacturer The different parts must be set up without any special tool Tie bars nuts must be set up by hand and with glue type Loctite to avoid any release by vibrations Screwing of nuts must be made so that plates should be perfectly perpendicular to tie bars axis The holding couple must not exceed 0 5 mdaN for 2 5 vessel diameter 0 5 mdaN for 4 vessel diameter and 1 mdaN for 8 vessel diameter I JOINTI NG amp FIXING Despite their high resistance pressure vessels in fibre and resin get out of shape with pressure you must therefore let distortion freedom fitting on supports osmorack supports enable this distortion Fitting on inlets and outputs gas thread or NPT must be realized by a screwing by hand followed by one fourth rotation with a chuck key In case of leak do not try to reduce it by an additional screwing You must not apply important vertical load to connections 43 111 PRESSURI SATION The pressurisation circuit must include adapted devices to prevent important variations of working pressure and enabling not to exceed t
25. ety glasses Handling and Storing Conform to normal warehousing conditions Product Information Alkaline detergent is a powder cleaner specifically designed for the removal of organics silt and other particulate deposits from polyamide membrane surfaces 29 15 Cleaning Cartridge 2 Information Product Information Sheet CLEANING CARTRIDGE 2 Hazard Data Threshold Limit Value TLV Lethal Dosage LD50 Lethal Concentration LC50 Appearance and Odour Solubility in Water pH of 24 Solution Fire and Explosion data Reactivity Data Hazardous Polymerization Toxicity 500 mg 24 hours on skin Rabbit moderate irritation 750 mg 24 hours in eye Rabbit severe irritation White Powder with a sweetish odour Complete 3 0 5 No hazard exists Stabile Will not occur No TLVs have been established for this mixture Health Hazard Information a Oral Ingestion b Eye Contact c Skin Contact d Inhalation Not considered a primary route of contact Considered a moderate irritant Considered a mild irritant Not considered a primary route of contact Emergency First Aid a Oral Ingestion b Eye Contact c Skin Contact d Inhalation Not applicable Flush eye immediately with large volume of water Get medical attention Flush contacted area with water Launder clothing before reuse Not applicable Spill or leak Steps to be taken in case ma
26. f at least 1 2 inch diameter is required to be fitted at least 150mm 6 inches above the waterline 13 Installation Guide Continued LOW PRESSURE PIPELINE CONNECTIONS Use good quality reinforced NON TOXIC PVC hose Ensure that hose will not flatten either by adjacent objects or structures or by having bends which are too tight Clip all connections with stainless steel hose clips double clipping all connections which are below the waterline HIGH PRESSURE CONNECTIONS Aquafresh Watermakers High Pressure Pipe and or Reinforced Flexible Pipe to connect the high pressure components of the system It is important to avoid the possibility of chafing use pipe clips which have rubber sleeving This also minimises the transmission of HP pump noise to the structure of the vessel FRESH WATER TANK CONNECTION Use only non toxic pipe connected to the storage tank in such a way that no back pressure will be caused by the vessels storage system Tanks must be fitted with a vent which discharges overboard when the tank is full Venting into the bilge is not recommended as this may cause flooding When commissioning the unit or after lay up all water produced during the first 20 minutes should be discharged overboard as the preservative used in the membranes can cause minor intestinal irritation Under no circumstances can the freshwater outlet be restricted it must be open to atmosphere via the ships tank vent Closing this outlet will
27. his pressure Opening and closing of the valves shall not generate any hammer blow in pipes While the pressurisation a loosening can appear between the pipe end and the plug or the plate You must not tighten tie bars nuts to eliminate this loosening The end closure of pipes and particularly metallic parts must be kept dry and their possible corrosion must be checked IV CONVEYED LIQUIDS PLASTICON FRANCE pressure vessels are designed to treat sea water or brackish water The customer must check compatibility of materials with other liquids PLASTICON FRANCE advises the Customer to choose other raw materials in case of particular use See annex 1 for storage and cleaning 44 ANNEX 1 Chemical cleaning and storage solutions recommended for the pressure vessels 5 1 Cleaning Main membranes manufacturers recommend the cleaning solutions hereafter They are also recommended for the pressure vessels Solution nbr 1 0 196 NaOH 0 196 Na EDTA Solution nbr 2 0 196 NaOH 0 0596 Na DDS Solution nbr 3 1 096 STP 1 0 TSP 1 Na EDTA Solution nbr 4 0 296 Hcl Solution nbr 5 0 596 H3 PO4 Solution nbr 6 2 096 NH2 SO3H Solution nbr 7 1 096 NaS204 The percentages are understood in weight value Working temperature being less than or equal to 30 C Using of a cleaning solution from retail trade is subjected to an agreement from PLASTICON FRANCE beforehand In order to be able to consider special requests it will b
28. ilters by depressing the buttons situated on top of each of the filter housing Ensure that water is being discharged from the hull fitting and that no air is seen bubbling inside the filter housings Should the pressure regulating valve be closed then discharge overboard will not occur Press the SERVICE switch to STOP the LP pump From the remote LCD control panel run the de winterising procedure This is a 20 minute programme Ensure operating pressure is set to zero Once complete run the de winterise programme for a 2 time only this time raise the operating pressure to 825 psi Inspect system for leaks taking remedial action as necessary Pay particular attention to any leaks around the vessel end caps as these can be easily damaged From control panel start the watermaker using the normal start procedure shown in the operator s manual Your Aquafresh AFDXXXX series is fully automated at this point and will start to produce high quality water within a few minutes You can then fine tune the operating pressure in accordance with your local seawater temperatures and salinity however 825 875 psi will work fine in nearly all areas Operating pressure should not exceed 900psi PLEASE NOTE THE AFD SERIES IS NOT FOR USE IN FRESHWATER OR BRACKI SH WATER ENVIROMENTS 31 Troubleshooting Repair amp Service Information For Your Aquafresh Watermaker 17 Troubleshooting Your Aquafresh water maker is fitted with a sophisticated
29. in material and workmanship under the conditions of normal use and service for a period of twelve months from the date of installation or fourteen months from date of dispatch of the goods from the factory whichever is the earlier Liability under this warranty shall be limited to repair or replacement of the defective system or component at the option of Aquafresh watermakers and under no circumstances shall Aquafresh watermakers be liable for consequential incidental or other damages arising out of or in any way connected with the failure of the system to perform as set out herein In the unlikely event of a defect malfunction or failure of the system during the warranty period Aquafresh Watermakers will repair or replace at its option without charge to the customer the system or component which upon examination by Aquafresh Watermakers shall appear to be defective or not up to specification To obtain this service the defective component must be returned to Aquafresh Watermakers together with proven date of purchase or delivery Aquafresh Watermakers shall not be liable for any transportation or travel expenses This warranty does not extend to any system or component part which has been subject to misuse neglect accident improper installation or subject to use in violation of the maintenance or operating instructions furnished by Aquafresh Watermakers nor does it extend to products on which serial numbers have been removed or defaced This w
30. into the system by the low pressure centrifugal priming pump LP Pump via a 3 4 inch inlet sea cock strainer and L port valve The other position on the L port valve is a 1 2 inch SERVICE connection for the intake of cleaning and disinfecting solutions this connection may also be used to prime the LP Pump when necessary The output of the LP Pump feeds 2 micron filters The condition of the filters can be inspected through the transparent filter bowls In service the filters will darken from their natural white colour becoming almost black when badly contaminated and in need of changing The water passes through a 25 micron filter and then a 5 micron filter The sea water is fed at low pressure of at least 3 psi to the inlet manifold of a positive displacement high pressure pump This can create a pressure of up to 1400 psi however the pressure can be adjusted manually from 0 1000 psi but is capped at 1000 psi by a pressure relief safety valve and the excess sea water is discharged overboard via the salt water discharge port The pressurised flow of sea water passes through the Reverse Osmosis Membranes RO membranes the number in the system being dependent upon system size and is then discharged via the Pressure Regulating Valve and salt water discharge port It is essential for a flow of salt water proportional to its salinity to pass over the membranes at the correct rate and pressure The pressure regulating valve control
31. nector plugs 4 Put these plugs into the plates 2 in order to centre the pipes 11 FITTING MEMBRANES 2 1 Lubricate the membrane seals correctly 2 2 Make sure you get the membranes the right way round as indicated by the manufacturer 2 3 Slide the membranes one after the other connecting them together with the connectors 13 supplied by the membranes manufacturer 11 FITTING HEADS 3 1 Position the head to match the pipework connections in your premises 3 2 Push the plugs 3 and 4 into the end of the pipe If necessary use a mallet and a wooden block for this but make sure the plate remains perpendicular to the pipe 46 IV FITTING TIE RODS 4 1 Put the plates 2 on the plugs already fit it on the end of the pipes 4 2 Slide the tie rods 7 through the holes in the plates 2 4 3 Fit the washers 8 and nuts 9 onto the ends of the tie rods 4 4 Screw all the nuts down onto the plate 4 5 Tighten with a spanner do not exceed the torque load 0 5 m daN See document SAV E 01 4 6 Fix the screwed joints with glue or jointing compound 4 7 f you use PLASTICON FRANCE supports optional supply you must stick the rubber seal before sliding the tie rods through the support Then put the supports in position by following the measurements A and B given in the technical document for the type of pressure vessel you have ordered Fix the upper with the lower supports Fit it the connecting piece between supp
32. nsidered a mild irritant Considered a moderate irritant 3 Emergency First Aid Do not induce vomiting If conscious give lots of water or milk Get a Oral Ingestion immediate medical attention Flush eye immediately with large volume of water for 15 minutes b Eye Contact lifting eyelids occasionally Get medical attention c Skin Contact Wash contacted area with soap amp water Launder clothing before reuse d Inhalation Remove o fresh air Give artificial respiration if not breathing Get immediate medical attention 4 Spill or leak Steps to be taken in case material is released or spilled a Sweep shovel into salvage containers b Flush area with water to remove final traces 5 Waste Disposal Method a Material may he diluted with water and flushed into an approved drain b Comply with all applicable federal state and local regulations 6 Special Protection Information a Respiratory Protection NI OSH approved respirator b Ventilation Local mechanical exhaust c Protective Gloves Acid resistant gloves d Eye Protection Chemical goggles Contact lenses should not be worn is Handling and Storing Conform to normal warehousing conditions 8 Product Information Membrane preservative is a mild acidulating and reducing agent for use as a bleach antichlor antiseptic in the fermentation industries and food preservative 25 12 Routine Maintenance Daily checks Check running
33. ny parts of the installation method it is recommended that you contact your supplier for professional advice 11 Installation Guide Continued LP PRIMING PUMP The priming pump must be mounted below the waterline between the inlet strainer and the system filters If the pump is mounted above the waterline then problems with priming the pump will be experienced It should be as close to the seacock as possible and located in a dry well ventilated position Use only 3 4 inch non toxic reinforced hose to connect the priming pump to the seacock and system filter housings and secure with double hose clips The priming pump is fitted with an L port valve for Service use and space must be available for access to this inlet The pump must be fitted on a flat surface NOT upright on a bulkhead and under no circumstances rotate the head of the pump from the supplied position The LP pump has an integral electrical connection box mounted on the top this facilitates quick and easy connection to the main panel control box cables Cable Gland amp Supply Cord Fitting Instructions Single phase The cable gland assembly Fig 7 items 1 amp 2 provides the necessary protection against ingress of solid objects and moisture as well as providing cable retention Assembly instructions are as follows 1 Ensure selected cable sheath diameter is within the permitted range 6 5 to 9 5 mm 2 Strip and prepare the cable sheath and insulators as
34. o NOT open this valve to allow flow via the container as it is necessary to flush the water already in the system overboard first done at the next stage Depress the SERVICE switch on the side of the main electrical control box noting that the LP pump runs Open the input L port valve on the LP PUMP and allow approximately 1 3 of the freshwater to discharge overboard before opening the output FLUSH on the L port valve to circulate the fresh water through the system for 10 minutes After 10 minutes close the output Flush L port valve to DISCHARGE and allow all but the last drop of freshwater to discharge overboard before switching off the SERVICE switch Close the inlet and discharge seacocks then close inlet L port valve on the LP pump The system is now flushed and can be left for up to 14 days 23 10 Short Period Lay Up Maximum up to 3 months Manual and Autoflush systems Note This procedure must not be carried out with either organic or inorganic cleaner in the system Use either water produced by your Aquafresh Watermaker or water that has been passed through a carbon filter WARNING This procedure uses Sodium Metabisulphite Spills and splashed areas should be treated immediately with copious volumes of fresh water Do not inhale or ingest Wash skin with soap amp water If in contact with eyes rinse eyes immediately with water and obtain medical advice If inhaled blow nose and wash nasal pa
35. o a maximum of 3 months there is a greater risk of fouling which should be prevented using a Preservative cartridge available from Aquafresh Ltd see section 22 If the system is to be laid up where there is a possibility of freezing then the system MUST be filled with a special solution This solution should contain Propylene Glycol 2096 Sodium Metabisulphite 196 and Purified Water to 100 NOTE ON NO ACCOUNT MUST THE MEMBRANES BE ALLOWED TO BECOME DRY OR FREEZE THI S WILL CAUSE IRREPARABLE DAMAGE 20 8 Flushing the system with freshwater Autoflush Systems Only SPECIAL NOTES This systems requires that the vessels pressurised fresh water supply is switched on and that there is plenty of freshwater available to complete the flushing cycle for however long it may be required This system will use freshwater from your vessels water tanks and will use approximately 3 7 litres of water per minute At no time should chlorinated water be allowed to enter the watermaker via the vessels freshwater system and it is essential that the carbon filter is replaced regularly Between 3 and 6 months depending on use Note The screen has a sleep timeout facility wake the screen by a single touch to any area of the screen With the machine in the stopped mode Unit Stopped Press the DOWN ARROW Membrane button Fresh Water Flush Set Time Enter desired flush time between 2 and 9 minutes Touch the Set Time area on the
36. of the watermaker Common causes Blocked or closed seawater intakes Blocked pre filters Collapsed Low Pressure Hose Air lock in the low pressure circuit Air Leaks in the low pressure circuit LP Pump not running LP sensor or wiring fault Shipside water system pressure too low only in flush mode optional Incorrect installation Your watermaker will not function properly and may shut down and show this fault if it is supplied by an incorrect power source An example of this may be if an Inverter is being used to power the system See section 4 High Pressure Alarm High Pressure Alarm Optional Investigate cause of alarm Press RESET ALARM to clear Indicates over pressure in the high pressure circuit of the watermaker Common causes Blockage in the high pressure circuit Blockage in the overboard discharge Operating pressure adjusted to high Failure of high pressure sensor 34 Troubleshooting Continued No Fresh Water No Fresh Water Investigate cause of alarm Press RESET ALARM to clear Indicates no freshwater was produced for 1 hour Common causes Salinity probe failure or dirty One or more membranes has failed 35 Additional Troubleshooting Symptom System not priming Water weeping from membrane end Pulsation Insufficient pressure Possible Cause Inlet sea cock closed Air leak between inlet and LP pump Low pressure pump and associated pipework above water
37. orts if you order a multi pipes shell V CONNECTING PIPEWORK 5 1 Connect to the pipework taking care to do this in such a way that no vertical strain is placed on the ports and that the body is free to expand under pressure see document SAV E 01 VI SAFETY PRECAUTIONS 6 1 Before placing under pressure check that the tie rods are tightened raise the pressure gradually 6 2 Do not make adjustments to any equipment under pressure 6 3 Follow the procedures for installation and use document SAV E 01 Failure to follow these precautions may put lives at risk 47 22 Service Kit and Parts Available service kit AFCK2 includes items below Product code Description Quantity AF AC21 25 Filter 25 Micron 3 AF AC21 5 Filter 5 Micron 3 AFCO1 Oil 1L Cat Pump 1 AFC10 Pump HP Seal Kit 1 AFLPS LP Pressure Switch 1 AFST11 Pump LP Seal Kit 1 AFVM03 Cartridge Preservation 2 Pack 1 02 Cartridge Cleaning pack 1 6 2 1 NOTE Individual product codes are for 1 off the item Parts All other AFDXXXXAC series watermaker parts are available on request Please contact Aquafresh Ltd if you are after a specific item If you should require any form of the above please initially visit www atlantismarine co uk Alternatively you can contact Aquafresh Ltd for parts on 44 1752 208810 48 23 Warranty AQUAFRESH WATERMAKERS warrants to the original purchaser only that the Aquafresh system will be free from defects
38. result in 1000psi back pressure to the plastic hoses and membranes see section 3 DISCHARGE Use suitable 1 2 inch reinforced PVC hose Ensure that the hose run cannot be kinked as back pressure can cause damage to the system Under no circumstances can the saltwater outlet be restricted it must be open to atmosphere via the overboard discharge drain Closing this outlet will result in 1000psi back pressure to the plastic hoses and membranes LCD TOUCHSCREEN REMOTE CONTROL This unit must be mounted in a dry position A cable is provided with plugs at either end to enable simple connection to the main control box ELECTRICAL CONNECTIONS Observe polarity when making all connections AC driven units use mains voltages observe the same precautions Note Attention should be made to the length of cable runs so that the voltage drop cannot affect correct operation of the system Cable sizes of not less than 2 5mm are recommended All cables should be clipped at regular intervals to prevent chafe Cable sizing should be in accordance with ABYC or RCD standards At the vessels distribution board circuit breakers for the system must be capable of carrying loads required to run the appropriate water making system used Circuit breakers on vessels main distribution board should reflect the following 240 Volt 50Hz Single Phase systems 16 Amps 14 Installation Guide Continued The above circuit breaker rating should include a C ra
39. ring Damaged oil gauge cover drain plug or O ring Damaged or worn pistons Fuse Blown Supply voltage too low Short circuit in system Main circuit breaker unserviceable or of incorrect rating Motor overload tripped or fuse blown No voltage to start contactor or relay coil after normal 10 15 second delay Contactor relay unserviceable Remedy Replace seals Replace seals Replace seal or O ring Replace bearing Rectify damage replace O ring Replace pistons Do not run pump dry Replace Investigate cause Investigate cause Replace Investigate Reset overload or change fuse Use fuse of correct rating Timing circuit on salinity p c b unserviceable replace with serviceable item Replace The HP pump is powered up approximately 10 seconds after switching the system on 37 18 Low Pressure Safety Switch To prevent operation of the High Pressure pump when no water is present at the inlet a Low Pressure switch is installed in the low pressure inlet feed to the HP pump If a low pressure fault Occurs repeatedly or unexpectedly it may be necessary to adjust the switch To adjust the switch expose the screw and contacts by lifting the protective boot Ensure that water is flowing normally by observing the discharge overboard with the HP regulator valve fully open With the system running normally rotate the adjusting screw on the pressure switch a quarter of a turn at
40. s back pressure which can be adjusted up to 900 psi depending on salinity and water temperature and indicated on the high pressure gauge The sea water is then discharged overboard via the salt water discharge port Fresh Water The fresh water connections on the end of the RO membranes are interconnected and pass via the digital salinity sensor to a solenoid operated divert valve Water which has been analysed by the digital sensor and logic controller that is deemed satisfactory is then diverted to the ships tanks via the automatically controlled divert valve Water flow that does not pass this test is diverted to the salt water discharge circuit and sent back overboard The salinity sensing circuitry of your AFD series water maker is fully automatic and temperature compensated to ensure accurate operation at all times in any region of the world 3 Installation Layouts Note The following diagrams do NOT include all optional components See section 4 for more information uoneredo uupos jubieu unu v asoy eunsseid 0 yue Jayem 9nseuoQ 6 8 suogoung Bujuea pue Buunp Aju AON 1 G uo1 Sz A qUiaSs y J9yi 94 xejdng 9 dung aunssaig u amp i 2 gt dung eunssaig BUILIOJOM ain a H
41. screen and enter the flush time required using the ESC SHIFT UP DOWN and ENTER buttons on the touch screen Note The system will not accept less than 2 minutes as a flush time Start Flush Press START FLUSH ICON to initiate the timed flush Flush Time Remaining Once the flushing is complete the unit will return to the normal Stopped screen Note The unit flushing can be stopped at any time by pressing STOP 21 8 Freshwater Flushing Continued Autoflush Systems Only Unit Stopped Restart Inhibited Short Delay while internal pressures equalise Unit Stopped The system is now flushed and can be left for up to 14 days 22 Note 9 Flushing the system with freshwater Manual Systems You MUST use either water produced by your Aquafresh watermaker or water that has been passed through a carbon filter This operation will require a large bucket and around 15 litres of fresh de chlorinated water and some inch hose Connect a plastic 1 2 inch hose to the input L port valve of the LP Pump and fill with water so that no air remains in the pipe Then holding your thumb over the end of the pipe place the end of the hose into a bucket of fresh de chlorinated water Do NOT open the valve at this stage Connect a 1 2 inch hose to the sea water output FLUSH port on the L port valve situated on the unit at the left hand side and lead the hose to the bucket containing the fresh de chlorinated water D
42. snaps tightly into position Reassembly Inlet 1 Insert Valve Springs into Retainers over plastic center guide and place Valve Spring Retainers into the shallow Valve Chambers They will rest on the machined ridge in each chamber Inspect the Valves for wear ridges or pitting and replace if necessary Insert Valves over the Springs with concave side down Examine Valve Seat O Rings for wear and replace Lubricate and place O Rings on lip of retainers Carefully square O Rings in Valve Chamber to avoid cutting O Ring when Valve Seat is installed Examine Valve Seats for pitting scale or ridges and replace if necessary Install Valve Seat with concave side down so O Ring fits snugly into groove on Seat Examine both the inner and the outer O Rings on the Inlet Valve Adapter and replace if worn Lubricate O Rings and fit into grooves on outside of adapters Apply liquid gasket to the O Ring crevice of the O D of Inlet Valve Adapter and press into chamber Carefully square Inlet Valve Adapter into chamber to avoid cutting or extruding O Rings Replace Discharge Manifold over Plunger ends matching Discharge Valve Spacers with Inlet Manifold Chambers and press into position Tap with a soft mallet until Inlet and Discharge Manifolds are flush Replace all four 4 Washers and Socket Head Bolts Hand tighten each Then torque per chart SERVICING THE SEALS Disassembly 1 w N 4 With
43. ssages obtain medical advice If ingested rinse out mouth Give water to drink seek medical advice If large amounts of this fluid are ingested then induce vomiting seek medical advice Connect a plastic 1 2 inch hose to the input L port valve of the LP pump and fill with de chlorinated water so that no air remains in the pipe Then holding your thumb over the end of the pipe place the end of the hose into a bucket of fresh de chlorinated water Do NOT open the valve at this stage Connect a 1 2 inch hose to the sea water output FLUSH on the L port valve situated on the unit at the left hand side and lead the hose to the bucket containing the fresh de chlorinated water Do NOT open this valve to allow flow via the container as it is necessary to flush the water already in the system overboard first done at the next stage Remove both of the filters from their bowls and screw back into place Depress the SERVICE switch on the main electrical control box noting that the LP pump runs Open the input L port valve on the LP pump and allow approximately 1 3 of the freshwater to discharge overboard before opening the output FLUSH on the L port valve to circulate the fresh water through the system for a further 10 minutes After 10 minutes close the output Flush L port valve to DISCHARGE and allow all but the last drop of freshwater to discharge overboard before switching off the SERVICE switch Place a Preservative car
44. ssure to 950 psi and rotate the adjusting screw on the switch anti clockwise a quarter of a turn at a time until the unit switches off 38 Technical Specification Pump body Impeller Pump shaft Seal options Pump connection size Inlet Outlet Motor options Enclosure rating Motor Rating Operating Conditions Max liquid temp Min liquid temp Max suction lift Max ambient air temp Max viscosity Dimensions 19 Low Pressure Pump Brass Brass Stainless steel Nitrile carbon ceramic Nitrile carbon silicon Viton carbon silicon G 34 female G 34 female 230 1 50 IP44 Induction type permanent capacitor thermally protected Continuous S1 80 C 4 C 4 6 metres 40 C 50 secs redwood no 1 9 5 centistokes 39 Low Pressure Pump Continued Trouble Shooting Guide Symptoms Probable Cause Recommended Action Pump will not start Electrical supply Starter thermal overload tripped Integral motor thermotrip activated Pump runs but no Air locked flow No water feed Motor running backwards Connections reversed No flooded suction Check power to motor Check the circuit breaker is set Check overload in starter if applicable Investigate cause of problem Wait for thermotrip to cool and auto reset Investigate cause of problem Bleed pipe work and pump to clear air Check the supply valves are turned on Check outlet not restricted or blocked
45. ted breaker to allow for any inrush current taken by the pumps on start up Connection of the LP pump is straightforward with terminations marked clearly inside the motor cover and or interconnection box see page 12 The HP pump has a junction box fitted onto a lead The following image shows the connections that need to be made Note The LP Pressure Switch is situated on the HP Pump Neutral Earth Live LP Pressure Switch LP Pressure Switch Please ensure that all electrical connections are made by a qualified installer and that they are not in an area which is subject to water ingress 15 SNOIL23NNOO 31872 L X08 10102 NOLD3NNOO 38055384 18155 16 38055389 131100 HSM V3S OL u31VM 315VM 12010084 16 5 Theoretical Production Graph l 51151132 5334930 SZ 40 3un1v 33431 QIWNSSV NO 035 8 51105184 51 00052 55 SQL Wdd 18 Ad VA SINVUGWIW 1 01 1031 3 5334930 JUNLVYIdWIL dH31VM SN011V9 AN 220 38117 0 0 0 0 0 0 0 m em 01 02 5 01 02 w 5 02 m 75 oi oz of op 09 08 D ov 08 Ls toe 09 021 05 3 d 05 001 e 092 m 02 09 08 1 021 23 0L 071 m TE Sz os 001 002 e 08 091 06 o 09 06 1 06 08 Ove 00 sie eg T 6 Tozi 68 001 002 011 opi 082 011 022 00 ooziv 00 1 0094Y 0084Y 002147 00911Y 081 LINA 071
46. terial is released or spilled a Vacuum or sweep shovel into salvage containers b Flush area with water to remove final traces Waste Disposal Method a Material may be diluted with water and flushed into an approved drain b Comply with all applicable federal state and local regulations Special Protection Information a Respiratory Protection b Ventilation c Protective Gloves d Eye Protection None required None required Standard work gloves Safety glasses Handling and Storing Product Information Conform to normal warehousing conditions Acid Cleaner is a powder cleaner specifically designed for the removal of metal hydroxides calcium carbonate and other similar scales from polyamide membrane surfaces 30 16 Commissioning On completion of equipment installation plumbing and electrical connection the system can be commissioned using the following procedure 1 gr ae cu M 10 11 12 Open inlet and outlet seacocks manually bleeding the system starting from the inlet end It may be necessary to bleed the low pressure pump Inspect all connections below waterline for obvious leaks Switch on power to the system at the vessels distribution board The remote LCD panel should power up Fully open the pressure regulating valve Press the SERVICE switch located on the watermaker control box This will operate only the LP pump Bleed ALL air from the f
47. tridge into either filter housing and screw into place Refill the bucket with fresh de chlorinated water Press the service switch to start the Priming pump Let the pump run for 30 minutes allowing the preserving chemical to circulate fully After 30 minutes depress the SERVICE switch the LP pump should stop Close the inlet and discharge seacocks then close inlet L port valve on the LP pump The system will now be full of the Preserving solution Remove the 1 2 inch hoses and discard any chemical solution that remains flushing away with copious amounts of water The suggested time for the unit to be stored is for up to 3 months after the use of this cartridge If the unit will sit for more than 3 months repeat this procedure every 3 months Before using the watermaker again follow the de winterising procedure in the operations manual 24 11 Preservative Cartridge Safety Information Product Information Sheet PRESERVATIVE CARTRIDGE 1 Hazard Data Moderate health hazard irritant Appearance and Odour Coarse white granules with sulphur dioxide odour Solubility in Water Complete pH of 1 Solution s 4 5 Fire and Explosion data No hazard exists Reactivity Data Minimal Hazardous Polymerization Will not occur Toxicity TLV 5 2 Health Hazard Information fa Oral Not considered a primary route of contact 6 Eve Contact Considered a moderate irritant ke Skin Contact Co
48. unger Retainer then O Ring then Back up Ring Apply Loctite 242 to threads and install short threaded end of Stud into Plunger Retainer Apply Loctite 242 to threads and thread Plunger Retainer and Stud assembly with long threaded end of Stud into plunger rod Torque per chart Exercise caution not to over torque the Plunger Retainer Re install the Seal Retainers with the slots to the top and bottom Rotate Shaft until the two 2 outside Plungers are extended and lined up Lubricate O D of Plungers Then carefully slip Inlet and Discharge Manifold assembly onto Plungers and tap with soft mallet until flush with Crankcase Replace the two 2 Inlet Manifold Socket Head Bolts and Washers and hand tighten Then torque per chart Then torque the four 4 Discharge Manifold Socket HeadBolts in sequence per chart SERVI CING CRANKCASE SECTI ON 1 2 While Inlet Manifold Plungers and Seal Retainers are removed examine Crankcase Seals for wear Check oil for proper level and for evidence of water or other contaminants in oil Rotate Crankshaft by hand to feel for smooth bearing movement Examine Crankshaft Oil Seal externally for drying cracking or leaking Consult Aquafresh Watermakers Ltd if crankcase service is required 21 Assembly and Maintenance Instructions for Plasticon Vessels SETTING UP I JOINTI NG AND FIXING 111 PRESSURI ZATION IV CONVEYED LIQUIDS ANNEX 1 SETTING UP Pr
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