Modular Series SM30 60Hz 1.0 Hp

Transcription

1 2015 Modular Series SM30 60Hz 1.0 Hp Cruise RO Water 2448 Carroll Lane Escondido, California USA Manufacturing Facility: Sales & Technical Support: Fax: On the Web: Skype contact at: CruiseROwater 1

2 Table of Contents Introduction... 5 SeaMaker Warranty... 5 General Cautions and Warnings... 6 Tubing and Fitting Installation and Design Philosophy... 7 Low Pressure Fittings... 7 GA Murdock Installation Instructions... 8 RECOMMENDED MAINTENANCE... 9 Tubing Removal from Fittings... 9 Tubing Color Coding... 9 Tubing Cutter High Pressure Fittings Swagelok Fitting Design Fitting Components Installation Instructions New Fitting Tightening Instructions Fitting Re tightening Instructions SeaMaker 30 Specifications Production Rate: 30 gallons/hour Product Water Total Dissolved Solids (TDS) range: RO Membranes: Electrical Power Requirements: High Pressure Sea Water Pump: Electric Motor: Sea Water 12 VDC Boost Pump: Optional Sea Water 115 VAC Boost Pump: High Pressure RO Membrane housings: Pre filter and Backwash Filter housings: System Flow Diagram Low Pressure Seawater Flow Diagram with V & C Assembly Installation Instructions Module 1: High Pressure Pump and Motor Assembly Module 2: RO Pressure Vessel Assembly RO Pressure Vessels Remote Panel Front Side Remote Panel Backside Remote Panel Standard Option Pre filter and Boost Pump Assembly Boost Pump & Fan Bracket Module 4: Valving and Cleaning Assembly AC Motor Low Voltage Electrical System Schematic AC Motor High Voltage Electrical System Schematic with AC Control Relay

3 AC Motor High Voltage Electrical System Schematic with DC Control Relay DC Motor Boost Pump Electrical System Schematic AC Motor Boost Pump Electrical System Schematic Initial SeaMaker Commissioning Procedure SeaMaker Initial Start up and Shutdown Procedure Startup Shutdown Normal Start up and Operation Procedure Normal Operation Procedure Normal Shut down Procedure Freshwater flush Procedure Preserving the SeaMaker for Longer Term Storage Membrane Cleaning Procedures Winterizing the SeaMaker System Field Testing Data Table Parts List and Equipment Exploded Views See PDF Attachments Optional Remote Valving and Cleaning Panel Optional Low Pressure Seawater Flow Diagram with Remote V & C Assembly Table of Figures Figure 1: Fitting, locking Clip, and Tubing Installation... 8 Figure 2: Tubing Removal Assist Tool for ¼, 3/8, and ½ Tubing... 9 Figure 3: Tubing Colors, Sizing, and Pressure Ratings Figure 4: Tubing Cutter Figure 5: Swagelok Fitting Cross Section View Figure 6: Swagelok Fitting Blow Apart Figure 7: Process Flow Diagram Figure 8: Low Pressure Seawater with Valving & Cleaning Assembly Figure 9: 1.6 gpm Pump and 1 HP Motor Figure 10: End View of Membrane Assembly Figure 11: Remote Panel Front View for Control of Membrane Assembly Figure 12: Remote Panel Back View for Membrane Assembly Control Figure 13: Pre filter Assembly 20 micron & 5 Micron Figure 14: Boost Pump with Fan Bracket Top View Figure 15: Boost Pump with Fan Bracket Side View Figure 16: Valving and Cleaning Assembly Figure 17: 115 VAC Motor Low Voltage Wiring Installation Drawing Figure 18: VAC Motor High Voltage Wiring Installation Drawing with AC Control Relay Figure 19: VAC Motor High Voltage Wiring Installation Drawing with DC Control Relay

4 Figure 20: DC Motor Boost Pump Wiring Installation Diagram Figure 21: AC Motor Boost Pump Wiring Installation Diagram Figure 22: Hose Assembly before Pickling Figure 23: Hose Assembly During & After Pickling Figure 24: Field Testing Data Table Figure 25: Remove Valving and Cleaning Panel Front and Backside Figure 26: Low Pressure Seawater with Remote Valving & Cleaning Assembly

5 Introduction The team at Cruise RO Water thanks you for your purchase of the SeaMaker reverse osmosis watermaker. The SeaMaker design is based on real world product testing and engineering, and we trust that you will be completely satisfied with your new unit. We are ready to stand behind our product with an industry leading warranty and customer support. We will assist you in your installation, start-up, and operation of your SeaMaker watermaker. The SeaMaker series of water makers were designed with real life cruisers in mind, so the system modules are designed for easy installation, operation, and maintenance. We strongly encourage our customers to spend time reading through our installation, operation and maintenance manual before starting their installation process and contacting us via , phone, or even Skype for support if they have any questions about their particular installation or general operation of their new watermaker. Spending some time talking to the people that actually designed and built your watermaker can quickly help answer any question, from installation to operation. SeaMaker Warranty Due to our simple design and use of commercial quality parts and assembly methods, Cruise RO Water is proud to offer the best warranty in the watermaker business. The SeaMaker RO system is guaranteed to be free of manufacturer defects and to perform within the stated specification for a period of three years (36 months) from the date of shipment, while specific elements of the SeaMaker systems are guaranteed for LIFE to the original purchaser of the system! The components with a lifetime guarantee are the following: All Swagelok Stainless Steel fittings: including the Pressure Regulating Needle valve. RO Pressure Vessels (Does not include Clamp Rings and Plugs) High Pressure Stainless Steel Pump Head and Body In the event of a defective component or failure during the term of the warranty, Cruise RO Water will inspect the defective part and repair or replace, with all the shipping charges being the responsibility of the purchaser to and from their location to our offices in Escondido, California. As a condition of the warranty, the purchaser is responsible for conducting the recommended maintenance according to Cruise RO Water s stated schedule of maintenance and operating their unit within the operational parameters outlined in this manual. 5

6 The warranty does not extend to parts that have failed due to misuse, improper installation, modification, and operations outside of those defined Cruise RO Water. The warranty does not cover parts where the serial number has been removed or defaced and the warranty does not apply to the normally recurring consumables or wear and tear items as defined below: Pre-filter elements 5 and 20 micron Activated carbon back-flush filter element High pressure pump crankcase lubrication oil Boost pump flexible impeller High Pressure Pump Valves, Packing, and Ceramic Plungers Cruise RO Water s liability under this warranty shall be limited to repair or replacement of the Cruise RO Water watermaker at Cruise RO Water s option. Under no circumstances shall Cruise RO Water be liable for consequential damages arising out of or in any way connected with the failure of the system to perform as set forth herein. General Cautions and Warnings There are several things which the installer or operator of the SeaMaker can do incorrectly, which can seriously damage the SeaMaker water maker, dramatically shorten the operational life span of the various system modules, and in some cases cause personal injury. Knowing the things to avoid is critical to a good SeaMaker installation and operation. We will cover the following items again in greater detail during the appropriate section later in the manual, however, due to their importance it is worth giving the following items extra attention. 1. Never allow Chlorinated water to come in contact with the RO membranes, Oxidants such as Chlorine and/or bleach water will permanently destroy the RO membrane. 2. Never run the SeaMaker in oily water, as oil will permanently destroy the RO membrane. 3. Never run the high pressure pump dry or operate outside the inlet supply pressure and flow design parameters. 4. In brackish water, such as in an estuary or river, never allow the product water production flow rate to exceed the units rated output. In such cases, simply turn down the system pressure or RO membrane damage will occur. 5. Never exceed a system operational pressure of 950 PSI. 6. Do not install the RO Membrane Module in an area where the RO membranes can become heat soaked to temperatures above 120 F while in 6

7 operation and 140 F while not in operation, doing so will cook and destroy the RO Membrane. 7. The high pressure pump is shipped with an oil plug cap installed to prevent crankcase oil spillage, before initial operation of the high pressure pump, replace the plug cap with the supplied vented cap. 8. The RO Membrane Module is shipped containing a storage/preservative solution; allow a minimum of 30 minutes of initial operation before sampling the product water in order to properly flush out the preservative. 9. The high pressure pump is capable of creating a stream of pressurized sea water up to 1500 PSI. Under no circumstances should the high pressure pump be operated without the supplied pressure relief valve in place or with the high pressure lines not properly connected. 10. While performing a system freshwater rinse, be sure that the pressure regulating valve is in the completely open position, which can be verified by turning the pressure regulating valve counterclockwise until it physically stops. Running fresh water or brackish water at elevated pressures through the RO membranes will permanently destroy the membrane. 11. The high pressure pump and motor assembly is powered by 9.3 amps at 115 VAC at full load. A proper 115 VAC grounded electrical connection is mandatory for safe system operation. Do not install the high pressure pump and motor assembly in a location that will be at risk of exposure to sea or fresh water. Tubing and Fitting Installation and Design Philosophy Low Pressure Fittings All of the pressure fittings are Push-to-Connect, high grade, double O ring, NSF 58 certified, lead free, polypropylene G.A. Murdock fittings. The SeaMaker 30 system comes with the push-to-connect fittings pre-installed on all components. Additional fittings are supplied for ease of installation as there maybe situations where one might need a 90 degree fitting or an additional union to route tubing for a cleaner installation. Push-to-Connect fitting, locking clip, and tubing. The The photos below show the 7

8 Figure 1: Fitting, locking Clip, and Tubing Installation locking clip is installed as shown in the middle photo. The locking clip goes between the fitting body and collet retaining ring. The tubing is then pushed into the fitting until the tubing seats into the internal stop of the fitting. The tubing cannot be pulled out while the clip is in place. GA Murdock Installation Instructions Mur-lok Fitting Installation Instructions MAKE A CLEAN TUBE CUT Cut the tube squarely and if using plastic tubing, ensure that the cut has not made the tube out of round. Also ensure that the tube has a smooth outside diameter without any burrs or score marks prior to inserting it into the fitting. INSERT TUBE INTO FITTING Insert the safety clip which is not shown between the collet and the fitting housing. Push the tubing through the collet and dual o-rings until it bottoms out against the tube stop. The collet and safety clip holds the tube in place and the dual o- rings provide a leak resistant seal. TEST AND INSPECT Push and pull the tubing toward and away from the fitting to ensure that it has been installed properly. Test and inspect the installation for any leaks. TUBE REMOVAL Relieve pressure from the tubing and fitting. Remove safety clip and push uniformly with the tubing removal tool around the collet using the flange against the fitting body while pulling the tubing away from the fitting to release it. 8

9 RECOMMENDED MAINTENANCE It is recommended that installations are inspected at least annually and parts replaced as needed. Tubing Removal from Fittings To remove the tubing from the fitting the locking clip must be removed. Using the tubing removal assist tool, press the proper size opening against the collet of the fitting and while holding the collet up against the fitting securely, pull on the tube until it is removed from the fitting housing. Figure 2: Tubing Removal Assist Tool for ¼, 3/8, and ½ Tubing Tubing Color Coding The low pressure tubing has been color coded depending upon where it is used in the system. All plastic tubing is linear low density polyethylene tubing (LLDPE) approved for drinking water use. Green ½ tubing is used for all the inlet raw water plumbing from the ship s sea strainer, to the Valving and Cleaning Assembly, to the low pressure DC pump, to the pre-filters, and finally to the high pressure pump. Red ¼ tubing is used for the sea water reject (or brine) discharging from the Pressure Regulating valve and is discharged over board, via an above waterline through hull. The high pressure pump relief valve discharge is plumbed using ¼ red tubing to a T fitting in the brine reject line. Additionally, the position marked Water Sample on the Product Water Selector valve is plumbed to a sample location and to drain using ¼ Red tubing. Blue ¼ tubing is used for the fresh water product discharge from the RO membrane assembly which is connected to the inlet of the flow rotometer on the system control 9

10 panel. The three-way Product Water Selector valve on the control panel has two outlets. The outlet marked Water Tank uses ¼ blue tubing and is plumbed to the ship s fresh water drinking tank. The outlet marked Water Sample uses ¼ red tubing and is routed to the tee from the brine outlet and plumbed to drain or other convenient access point for water sampling. Figure 3: Tubing Colors, Sizing, and Pressure Ratings OD PSI F 1/4" /2" Tubing Cutter A tubing cutter is supplied with every SeaMaker system. This cutter allows the tubing to be cut squarely to allow for a leak free seal on every Push-to-Connect fitting. The following photos show the correct placement of the tubing into the tubing cutter. The cutter has a hinge on one end and once the tubing is placed in the cradle the ends are squeezed together to cut the tubing. Figure 4: Tubing Cutter 10

11 High Pressure Fittings Swagelok Fitting Design Features Live-loaded, two-ferrule design. Easy to install. No torque is transmitted to tubing during installation. Swagelok gap inspection gauge ensures sufficient. pull-up upon initial installation. During assembly of the advancedgeometry design (below), the front ferrule is driven into the fitting body and the tubing to create primary seals, while the back ferrule hinges inward to create a strong grip on the tubing. The back ferrule geometry allows for an improved engineering hinging-colleting action that translates axial motion into radial Back ferrule Hinge point Front ferrule Fitting body Figure 5: Swagelok Fitting Cross Section View Two-Ferrule, Mechanical Grip Design The two ferrules separate sealing and tube gripping functions; each ferrule is optimized for its function. The front ferrule creates a seal: against the fitting body on the tubing outside diameter. As the nut is turned, the back ferrule: axially advances the front ferrule radially applies an effective tube grip. Advanced-Geometry, Hinging- Colleting Back Ferrule Design This design is standard on all 1/4 to 1/2 in. and 6 to 12 mm Swagelok stainless steel tube fittings to help installers make more consistent, leak-tight tube connections. In these sizes, a patented case hardening process and patented recessed and contoured geometry provide unique engineering to the Swagelok back ferrule. The hinging-colleting back ferrule design expands on the already robust performance of the traditional ferrule design and provides: excellent gas-tight sealing and tube-gripping action easily achieved proper installation consistent remakes excellent vibration fatigue resistance and tube support full compatibility with original Swagelok stainless steel tube fittings of identical sizes. 11

12 Fitting Components All genuine Swagelok fittings have a nut, back ferrule, and a front ferrule. Care must be used to make sure that they are in the proper order and direction. The back ferrule has a small lip that must face away from the front ferrule for proper installation. Figure 6: Swagelok Fitting Blow Apart Installation Instructions Swagelok tube fittings 1 or 25 mm and smaller can be installed quickly, easily, and reliably with simple hand tools. Over 1 or 25 mm sizes require use of a hydraulic swaging unit to swage the ferrules onto the tubing. Safety Precautions Do not bleed system by loosening fitting nut or fitting plug. Do not assemble and tighten fittings when system is pressurized. Make sure that the tubing rests firmly on the shoulder of the tube fitting body before tightening the nut. Use the correct Swagelok gap inspection gauge to ensure sufficient pull-up upon initial installation. Always use proper thread sealants on tapered pipe threads. Do not mix materials or fitting components from various manufacturers tubing, ferrules, nuts, and fittings bodies. Never turn fitting body. Instead, hold fitting body and turn nut. Avoid unnecessary disassembly of unused fittings. Use only long reducers in female Swagelok end connections. 12

13 New Fitting Tightening Instructions These instructions are for fittings up to 1 inch in diameter. These instructions apply both to traditional fittings and to fittings with advanced back-ferrule geometry. Fully insert the tube into the fitting and against the shoulder; rotate the nut finger-tight. High-pressure applications and high Safety-factor systems: Further tighten the nut until tube will not turn by hand or move axially in the fitting. Mark the nut at the 6 o clock position. While holding the fitting body steady, tighten the nut one and one-quarter turns to the 9 o clock position. For 1/16, 1/8, and 3/16 inch; 2, 3, and 4 mm tube fittings, tighten the nut threequarters turn to the 3 o clock position. 13

14 Fitting Re tightening Instructions These reassembly instructions pertain to all sizes of fittings. You may disassemble and reassemble Swagelok tube fittings many times. Always depressurize the system before disassembling a Swagelok tube fitting. Prior to disassembly, mark the tube at the back of the nut; mark a line along the nut and fitting body flats. Use these marks to ensure that you return the nut to the previously pulled-up position. Insert the tube with pre-swaged ferrules into the fitting until the front ferrule seats against the fitting body. Over 1 inch sizes only: If needed, reapply lubricant lightly to the body threads and the rear surface of the back ferrule. While holding the fitting body steady, rotate the nut with a wrench to the previously pulledup position, as indicated by the marks on the tube and flats. At this point, you will feel a significant increase in resistance. Tighten the nut slightly. Do not over tighten. Slightly should be around 1/8 turn. 14

15 SeaMaker 30 Specifications Production Rate: 30 gallons/hour Product water production and Reverse Osmosis (RO) performance varies with pressure, salinity, and sea water inlet temperature, mainly as a function of kinetics. Warmer water molecules are moving at a faster rate than cooler molecules and this increased motion leads to a greater number of water molecules moving through the reverse osmosis membrane. The rated performance of the SeaMaker 30 was determined in the San Diego, California Bay with a sea water temperature of 68 F, a sea water TDS of 33,200 parts per million, and a system operating pressure of 800PSI. For testing data specifics, see the Field Testing Data Table. As stated in Dow Chemical s Filmtec RO Membrane specification, product water production can vary by up to +/- 20% of the rated flow rate for individual elements. Product Water Total Dissolved Solids (TDS) range: Less than 500 ppm TDS RO Membranes: The SeaMaker 30 watermaker is equipped with two 2.5 x 40 DOW Filmtec RO Membrane. Membrane Type: Polyamide Thin-Film Composite Part No: SW Range of Operating Pressures 700 to 900 psig Normal Operating Pressure 800 psig Salt Rejection rate 99.4% Membrane Active Area 29ft 2 Maximum Flow Rate 6 GPM Maximum Operating Temperature 113 F (45 C) Minimum Storage/Operating Temp: 32 F (0 C) Maximum Operating Pressure 1,000 psi, (69 bar) Maximum Pressure Drop 15 psi ph Range, Continuous Operation 2-11 ph Range, short-term cleaning 1-12 Free Chlorine Tolerance <0.1ppm Permeate flows for individual elements may vary +/- 20%, as per Dow s technical specifications. Salt rejection rates based on the following test conditions: 32,000 ppm NaCl, 800 PSI, 77 F (25 C) and an 8% recovery rate. 15

16 Electrical Power Requirements: VAC with an 800 PSI set point for continuous steady state operation for the high pressure pump motor. (4.6 amps at 220VAC) 8.2 amps at 13.8 VDC for the sea water boost pump. High Pressure Sea Water Pump: A General Pump Company high pressure triplex plunger pump with a 316 stainless steel manifold and wetted parts, solid ceramic plungers and an anodized aluminum crankcase. Model No: WM1516C or WM1516CL Maximum Flow rate: 1.6 gallon per minute at 1500psi Maximum Inlet pressure: up to 50 psi Maximum Inlet Vacuum: -5 psi Maximum Discharge Pressure: 1500 psi Maximum water temperature: 140 F Operating RPM: 1750 RPM Pump Dimensions: 9 x 7.5 x 6.0 Crankcase Oil Capacity: 12.0 oz (.35L) Relief Valve Preset to crack at 900 psig Electric Motor: Leeson Watt Saver TEFC sealed motor mechanically coupled to the high pressure pump Hz: 60 RPM: 1725 Volts: dual 115 VAC / HP / KW: 1.0 / 0.75 Max 115 / VAC: 9.6 amps / 4.7 Recommended fuse / breaker size: 15 amps (115 VAC) Use Only a Two-Pole breaker size: 10 amps ( VAC) 16

17 Sea Water 12 VDC Boost Pump: Self-priming Commercial Diaphragm Pump, PAR-MAX4, 12 VDC Model No: Motor: Permanent magnet type, fully enclosed, stainless steel shaft Pump Body: Glass Filled Polypropylene Pump Desgn: Multi-Chamber Diaphragm Seal type: Check Valve Max dry prime suction lift 10 feet Max operating pressure 10 psi Amp draw range (12v) 9-10 Amps (depending on system plumbing) Typical Amp draw (12v) 9.2 Amps (as testing in San Diego Bay) Recommended fuse size 15 amps Optional Sea Water 115 VAC Boost Pump: Self-priming SHURflo Diaphragm Pump Model No: Motor: Permanent magnet, thermally protected Voltage: 115 VAC Nominal Pressure Switch: Adjustable from 30 to 50 PSI. Factory 45 PSI Shut-Off, Turn on PSI Liquid Temperature: 130 Degrees F. (54 Degrees C) Max Prime: Self-priming up to 9.0 ft. vertical Duty Cycle: Intermittent Check Valve: (1-Way Operation) Prevents Reverse Flow High Pressure RO Membrane housings: Filament wound fiberglass/epoxy compound with non-metallic wetted surfaces Max pressure Normal operating pressure 1000 psi 800 psi Pre filter and Backwash Filter housings: Industry standard, 10 inch, clear, plastic, filter housings. Accepting 9.75 by 2.5 filter elements. 17

18 System Flow Diagram 3/8" AC Motor 60 Hz 1725 RPM 1.0 Hp Piston Pump 1.6 gpm Figure 7: Process Flow Diagram 18

19 Low Pressure Seawater Flow Diagram with V & C Assembly Figure 8: Low Pressure Seawater with Valving & Cleaning Assembly 19

20 Installation Instructions Prior to beginning the actual installation process, please read the entire installation procedure and take a moment to consider the following installations notes to insure the best performance, life, ease of operation, and maintenance of your SeaMaker system. After reading the entire installation directions, if any questions arise, please contact us so that we can assist you in the proper installation of your system. We are here to help you, so there s no need to proceed with the installation if you have any doubts or questions. We would much rather walk you through any questions you have now, than after everything mounted in place and screw holes are drilled into your boat! When selecting a module mounting location, take into account parts that will require periodic access, such as the pre-filters, the valving and backwashing filter assembly, and changing of the high pressure lubricating pump oil. The electrical connections should be performed by a person with proper knowledge and experience in the installation of 115 VAC or VAC and 12 VDC systems. The boost pump requires a 12 VDC, 20 amp fuse or breaker. The high pressure pump motor requires a single pole 20 amp breaker or fuse if wired for low voltage 115 VAC or a two pole, 15 amp breaker if wired high voltage VAC. Both legs of the motor if wired for high voltage must be circuit protected. Do not use fuses when wiring the motor for high voltage. Serious injury and/or property/system damage can result from an improper 115 VAC or VAC and 12 VDC installations. The motor must be grounded at all times. Both the high pressure and low pressure water lines must be routed through the boat in such a way that does not expose them to chafing or with tight radius bends that could cause the lines to kink and inhibit flow. Do not use any type of pipe dopes or sealing thread paste compounds in the installation of any water line fittings. This material can clog the RO membranes and reduce your product water output. The RO membranes can have their life shortened by exposure to high temperatures. So select a mounting location where they will not be exposed to ambient temperatures in excess of 120 F during SeaMaker operation or 140 F when the SeaMaker is non-operational. All of the module and assembly inlets and outlets are labeled clearly in the manual making the assembly process as plug and play as possible. Refer to the installation schematic for a detailed pictorial flow chart of the assembly. As with most projects on a boat, the key to a good installation is planning and component layout. We recommend 20

21 that the modules first be loosely dry fit in place for verification before permanently mounting the modules. The SeaMaker utilizes double O-ring push connectors for the low pressure waterline connections. All of the modules have these push connectors already mounted on the various inlet and outlet water connections. A tubing cutter and tubing removal tool are included along with locking clips. Figure 9: 1.6 gpm Pump and 1 HP Motor Module 1: High Pressure Pump and Motor Assembly The pump and motor assembly needs to be mounted on a horizontal platform that can properly support the unit s weight and provide for a secure bolt-on location that will be free from either sea water or fresh water splashes. During operation the electric motor will generate heat and will become hot to the touch, so be sure to allow for ventilation of the mounting location. There must be at least six inches clearance behind the motor fan to allow for cooling of the motor. When selecting a location for the high pressure pump and motor assembly consider the routing paths of the two sea waterlines to and from the pump. The high pressure line needs to reach the RO pressure vessel without trimming, while the inlet sea water line can be cut to any desired length. Access to the motors electrical junction box 21

22 needs to be maintained for electrical installation; alternatively, if the pump and motor assembly needs to be mounted in such a way that limits access to the electrical junction box, consider the feasibility of first landing the electrical connections prior to mounting the pump. Keep in mind that the high pressure pumps crankcase lubricating oil will need to be changed at regular intervals. The high pressure pump is shipped with the correct amount of non-detergent crankcase lube oil and a non-vented red cap on the top of the pump. This cap MUST be replaced with a vented cap once the unit is installed. CAUTION: Remove shipping plug on top of pump and replace with supplied vented breather plug. Failure to remove plug could damage pump. The current draw of the 1.0 Hp motor is 9.3 Amps at 115 VAC and an appropriate sized fuse or breaker or fuse of 20 amps maximum must to be installed. If the 1.0 Hp motor is wired for high voltage at VAC than only use a two pole breaker of 15 amps maximum must be installed. Both legs of the motor if wired for high voltage must be circuit protected. The motor must be grounded at all times. The inlet fitting is ½ plastic push connect and the outlet is a 3/8 high pressure stainless steel braided hose with compression fittings. We have included a wiring diagram for the 115 VAC pump motor, but such connections should only be performed by trained electrical personnel with experience in making the proper 115 VAC connections to a 1.0 Hp motor. Customers seeking information should contact Cruise RO Water or a licensed electrical contractor. The pump is supplied with a pressure relief valve that has a 3/8 female NPT exit port which is fitted with a 3/8 male NPT to ¼ push plastic fitting. This port needs to be plumbed to the brine line which exits the boat overboard as shown in the process flow diagram, Figure 7 on page 18. Caution: The relief valve is preset and does not need to be adjusted. Only qualified and trained personnel in the adjustment and setting of relief valves should test or replace valve. 22

23 Module 2: RO Pressure Vessel Assembly Figure 10: End View of Membrane Assembly RO Pressure Vessels The RO membrane assembly can be mounted in any location within reach of the remote panel flex lines supplied. The membrane assembly can be mounted in any orientation when a remote panel is supplied as this is a pressure feed system. When selecting the mounting location for the RO pressure vessel with the system controls located on a local panel affixed to the membrane assembly, select an area that will be convenient to access each time the unit is in operation, as adjustment and monitoring of the system controls is required. The RO pressure vessel can be mounted in any orientation that best allows for easy access to the controls, however, in units with a manual flow rotometer, the orientation of the flow meter needs to be vertical. 23

24 Remote Panel Front Side Figure 11: Remote Panel Front View for Control of Membrane Assembly 24

25 Remote Panel Backside Figure 12: Remote Panel Back View for Membrane Assembly Control 25

26 Remote Panel Standard Option The remote panel can be mounted in any location within reach of the membrane assembly due to the length of high pressure line that is needed. The typical standard length supplied is 60 inches. All other lines to and from the remote panel are LLDPE plastic lines. When mounting the panel, four holes are provided in each corner to affix the panel to a wall. The flow rotometer must be in the vertical position to read accurately the water flow produced by the membranes. Give consideration to the different water lines that will be going to and from the remote panel and the RO Pressure Vessel which are the: 1. High pressure sea water inlet, coming from the high pressure pump. 2. Brine seawater reject which will be routed off the boat from the panel. 3. Fresh drinking water from the RO membrane to the remote panel. 4. Fresh drinking water line, coming from the 3-way product water selector valve on the remote panel. 5. The Fresh water sample line, also coming from the 3-way product water selector valve on the remote panel, but used to verify the water quality prior to routing the fresh water to the ships water tanks. The Inlet and outlet connection on the RO Pressure vessel assembly are all labeled with tags detailing where the tubing runs should be directed. 26

27 Pre filter and Boost Pump Assembly Figure 13: Pre filter Assembly 20 micron & 5 Micron 27

28 Boost Pump & Fan Bracket Figure 14: Boost Pump with Fan Bracket Top View Figure 15: Boost Pump with Fan Bracket Side View 28

29 An important Consideration for mounting the components in module 3 is the accessibility both for visual inspection and changing out the pre-filter elements. The boost pump is self-priming and can be mounted above or below the waterline allows for mounting on any axis. To make future maintenance easier, try to mount the pump in such a way that leaves access for impeller replacement without having to remove the entire pump. The diaphragm boost pump motor must be run with the fan turning at all times to keep the DC motor cool. Therefore, mount the boost pump in a location that will provide adequate cooling air volume. Do not locate the boost pump near other hot equipment. Use only 10 gage or larger wire. A maximum rated 15 Amp, 12 VDC fuse or breaker is required for the installation of the Jabsco boost pump circuit protection. The wiring color code is listed on the top of the boost pump motor. The pre-filter assembly can also be mounted above or below the waterline. Keep in mind that access will be needed to the filter assemblies for changing the pre-filter elements periodically, when they become fouled by particulate matter in the incoming sea water. The pre-filter assembly is designed to be mounted vertically using the integral mounting bracket. Be sure to leave enough room below the assembly to allow for opening of the pre-filter housing for filter element replacement, which is approximately 3 inches. A good location would also be one where the pre-filter assembly can be easily viewed, for a quick visual observation on the state of the filter elements. The inlet and outlet connection on the pre-filter assembly and boost pump are all identified in Figures 13, 14, and 15 detailing where the tubing runs should be directed. 29

30 Module 4: Valving and Cleaning Assembly Figure 16: Valving and Cleaning Assembly The valving and cleaning assembly can also be mounted above or below the waterline and is designed to be mounted vertically using the integral mounting bracket. Be sure to leave enough room below the assembly to allow for opening of the activated carbon filter housing for element replacement, which is approximately 3 inches. The control valves mounted on the assembly will need to be accessed each time the watermaker is in operation to perform the system freshwater flush and for pickling the watermaker for longer term storage. The valving and cleaning assembly as shown above has the two three way valves in the normal operating configuration. The inlet and outlet connection on the valving and cleaning assembly are all identified in the above Figure 14 detailing where the tubing runs should be directed. 30

31 AC Motor Low Voltage Electrical System Schematic Figure 17: 115 VAC Motor Low Voltage Wiring Installation Drawing 31

32 AC Motor High Voltage Electrical System Schematic with AC Control Relay Figure 18: VAC Motor High Voltage Wiring Installation Drawing with AC Control Relay 32

33 AC Motor High Voltage Electrical System Schematic with DC Control Relay Figure 19: VAC Motor High Voltage Wiring Installation Drawing with DC Control Relay 33

34 DC Motor Boost Pump Electrical System Schematic Figure 20: DC Motor Boost Pump Wiring Installation Diagram 34

35 AC Motor Boost Pump Electrical System Schematic Figure 21: AC Motor Boost Pump Wiring Installation Diagram 35

36 Initial SeaMaker Commissioning Procedure The following steps should be followed for the initial commissioning of the SeaMaker. Failure to follow these steps can result in serious damage to the RO Membranes and the High Pressure pump. The main goal of the commissioning procedure is not to actually start producing freshwater, but to ensure that the system is wired and plumbed correctly, air purged from the system, pump broken in, verify that the connections are leak free, and becoming familiarized with the SeaMaker s valving and controls. CAUTION: Starting the SeaMaker without the pressure regulating valve in the fully opened counter clockwise position will result in a surge of high pressure watering going to the RO Membrane and can cause catastrophic failure and tearing of the membranes!!! CAUTION: Do not run the boost pump without the fan operational. The fan is designed to cool the boost pump motor and provide a longer life span. Always check to make sure the fan is running when the boost pump motor is running. 1. Once the electrical and plumbing connections have been made, verify the setting of the valves on the Valving and Cleaning Assembly to allow for seawater to enter the assembly and leave the assembly to the boost pump. Refer to the Valving and Cleaning Assembly section for valve settings. 2. Open the ships through hull valve and verify that there are no system leaks. 3. The first item to check is that the boost pump is operational and turning in the correct direction. The wiring color code is listed on the top of the boost pump motor, so first verify that the proper positive to positive and negative to negative wire connections have been made or the pump will run backwards. Verify that the boost pump fan wiring is also connected to the motor positive and negative. The fan red wire is positive and the black wire is negative. 4. Open the boost pump pressure regulating valve that is located on the remote control panel full counter clockwise which is in the full open position. 5. Close the ¼ boost pump shutoff valve that is located across the inlet and outlet of the boost pump main seawater lines. CAUTION: The boost pump shutoff valve is only closed during the priming of the system. After priming of the system and before the HP pump motor is started the boost pump shutoff valve shall be opened and remain open. 36

37 6. Next turn on the breaker and you should hear the pump run as it self-primes and begins to push water to the pre-filter assembly. The boost pump fan should also turn on at the same time. Verify that the fan is pushing air down onto the top of the motor housing. The boost pump will fill the pre-filters and then will send sea water downstream to the high pressure pump and through the membrane. We have included an on/off valve and T fitting to install in the Sea Water line exiting the pre-filter assembly. This valve should be opened to help purge the air from the pre-filters during initial start-up or following a filter element change. When the air is purged, close the valve. 7. Continue running the boost pump until water is observed exiting the brine discharge and the air bubbles have been forced out of the pre-filter assembly. This may take several minutes to purge air from the membrane assembly. 8. With the boost pump still running, make a visual inspection of the sea water connections to ensure that the connections are all leak free. Never accept a leaky connection, as a small leak now can turn into a much larger problem in the future, possibly resulting in not only damage to the SeaMaker but putting your boat at risk of sinking! 9. Ensure that the high pressure pump crank case shipping plug has been changed out and the larger vented plug installed. This allows the pump crankcase to breathe. 10. Open the boost pump shutoff valve and leave the valve open from this point on as the system has been primed with seawater. 11. It s now time to bump the high pressure pump and motor and to again verify the rotation pump/motor rotation. With the boost pump running, quickly turn on and then off the high pressure pump while watching the high pressure pump shaft in the clear view plate located at the end of the high pressure pump. The correct rotation of the shaft is in the COUNTER CLOCKWISE direction. With the verification of leak free connections, operation of the boost pump and fan, purging of air from the system, and verification of proper rotation of the high pressure pump, the system is now ready for the initial start-up as detailed in the section entitled, SeaMaker Initial Start-up Procedure below. The product water output line should not be blocked when the unit is in operation. The Water Selector Valve we use is a special non-blocking valve that will not allow the membrane product water to ever be blocked. Installing valving downstream between this valve and the ships water tank is not allowed unless it is a non-blocking valve. The ships water tank should be vented so as not to have the membrane product water to ever be blocked. This prevents the ships water storage system from ever being pressurized which could cause failure of components and/or injury to personnel. 37

38 SeaMaker Initial Start up and Shutdown Procedure The following instructions must be followed for the initial SeaMaker water maker startup. Failure to follow these steps can result in serious damage to the RO Membranes and the High Pressure pump. Startup 1. Open the boat s seawater through hull and ensure that the raw water sea strainers are free of debris. 2. Turn the Inlet water selector 3-way valve on the Valving and Cleaning Assembly to sea water intake position. (the handle of the 3-way valve will point to the open pathway) The Inlet water selector 3-way valve is the top valve on the valving and cleaning assembly, so the handle should point to the left when looking at the unit. 3. Verify that the Pickling 3-way valve is in the normal operations mode, which means the handle should be pointing in the up position. The Pickling 3-way valve is the lower of the two 3-way valves on the valving and cleaning assembly. 4. Verify that the Product Water Selector 3-way valve mounted on the Remote Panel is in the sample position and not in the To Tanks position. You don t want the initial production water going into your water tanks until you have checked it using the hand held TDS Meter. 5. Verify that the Swagelok system pressure regulating valve on the remote panel is fully open. You will know the pressure regulating valve is fully open by completely turning it in a counterclockwise direction. 6. Verify that the boost pump pressure regulating valve on the remote panel is fully open. You will know the pressure regulating valve is fully open by completely turning it in a counterclockwise direction CAUTION: Starting the SeaMaker without the pressure regulating valve in the fully opened position will result in a surge of high pressure watering going to the RO Membrane and can cause catastrophic failure and tearing of the membranes!!! Note: Due to design parameters there will be 100 to 200 PSI even with the pressure regulating valve fully open in the counterclockwise direction. This is acceptable for startup. 38

39 7. Visually inspect the SeaMaker for any signs of damage, broken lines, or items of concern since its last use. Ensure that the oil level in the high pressure pump is at the appropriate level in the sight glass which is half-way up the plastic housing on the end of the pump furthest from the motor. 8. Turn ON the sea water boost pump and let it run for 2 minutes, or until no noticeable bubbles exist in the pre-filter assembly and verify sea water exiting the brine discharge. 9. Verify again that the system pressure regulating valve is in the open position by turning it all the way counterclockwise. 10. Turn on the high pressure pump motor. 11. Immediately adjust the boost pump pressure regulating valve for 10 psig on the boost pump pressure gauge. You will have to turn the valve clockwise to increase the boost pressure. CAUTION: Do not run the boost pump pressure high than 10 psig while running the water maker during water making operation. This will cause an overload on the boost pump motor and could damage the motor. 12. Let the system run for approximately 5 minutes to ensure that air bubbles have been flushed from the system. 13. Slowly increase the system operating pressure by turning the pressure regulating valve in a clockwise direction. Slowly increase the system pressure up to 600 PSI. Allow the pump and motor assembly to run at 600 PSI for a ten minute break-in period. This allows the high pressure pump to break-in and not cause an over amperage condition on the motor. NOTE: You will observe fresh water starting to flow through the flow Rotometer on the control panel at very low rates once you reach approximately PSI. 14. Once the system is stable at 600 PSI for ten minutes, slowly increase the pressure up to the standard system pressure of 800 PSI. CAUTION: Never operate the SeaMaker at a system pressure above 950 PSI. While the pressure relief valve will bleed off the pressure, damage to the RO membranes can occur. Normal operating pressure is 800 psi. 15. Once the system is stable at 800 PSI, let the water maker run for 15 minutes to thoroughly flush out the shipping preservative from the RO Membrane. 39

40 16. Collect a sample of the product drinking water and check the TDS using the hand held TDS meter. Once the TDS reading is acceptable (below 500 ppm) the water is ready to be sent to the ships tank. A normal initial TDS reading will range from 150 to 300 ppm. Note: In colder seawater RO systems produce lower total dissolved solids (TDS) product water and in warmer seawater RO systems produce higher TDS product water. Also, in colder seawater RO systems produce less product water but cleaner and in warmer seawater RO systems produce more product water. As a general rule for every one degree centigrade up or down in temperature you get 5% more or less product water production. 17. Turn the product water selector 3-way valve on the remote control panel to the Water Tank position and begin filling your water tank. 18. Continue to monitor the system pressure and adjust if necessary to maintain the system pressure at 800 psig and the boost pressure at 10 psig. Shutdown 1. Shutdown the unit as outlined in the Normal Shutdown Procedure section of the manual. 40

41 Normal Start up and Operation Procedure 1. Open the boat s seawater through hull and ensure that the raw water sea strainers are free of debris. 2. Turn the Inlet water selector 3-way valve on the Valving and Cleaning Assembly to sea water intake position. The valve will be in the off position when the water maker is not in use. The Inlet water selector 3-way valve is the top valve on the valving and cleaning assembly, so the handle should point to the left when looking at the unit. 3. Verify that the pickling 3-way valve is in the normal operations mode, which means the handle should be pointing in the up position. The pickling 3-way valve is the lower of the two 3-way valves on the valving and cleaning assembly. 4. Verify that the Product Water Selector 3-way valve mounted on the Remote Panel is in the sample position and not in the Water Tank position. You don t want the initial production water going into your water tanks until you have checked it using the hand held TDS Meter. 5. Verify that the Swagelok system pressure regulating valve on the remote panel is fully open. You will know the pressure regulating valve is fully open by completely turning it in a counterclockwise direction. CAUTION: Starting the SeaMaker without the pressure regulating valve in the fully opened position will result in a surge of high pressure watering going to the RO Membrane and can cause catastrophic failure and tearing of the membranes!!! Note: Due to design parameters there will be 100 to 200 PSI even with the pressure regulating valve fully open in the counterclockwise direction. This is acceptable for startup. 6. Verify that the boost pump pressure regulating valve on the remote panel is fully open. You will know the pressure regulating valve is fully open by completely turning it in a counter clockwise direction. 7. Visually inspect the SeaMaker for any signs of damage, broken lines, or items of concern since its last use. Ensure that the oil level in the high pressure pump is at the appropriate level in the sight glass which is half-way up the plastic housing on the end of the pump furthest from the motor. 41

42 8. Turn on the seawater boost pump and let it run until no noticeable bubbles exist in the pre-filter assembly and verify sea water exiting the brine discharge. Depending on your installation, this can take 30 seconds to several minutes. 9. Turn on the high pressure pump motor. 10. Immediately adjust the boost pump pressure regulating valve for 10 psig on the boost pump pressure gauge. You will have to turn the valve clockwise to increase the boost pressure. 11. Run the HP pump motor without increasing the system pressure to ensure that air bubbles have been flushed from the system. The length of time needed will vary based on your installation, but typically should take 30 seconds to 1 minute. 12. Slowly increase the system pressure up to the standard system pressure of 800 PSI. It should take about 30 seconds to 1 minute to slowly increase the system pressure from the starting point of about 150PSI up to 800 PSI. CAUTION: Never operate the SeaMaker at a system pressure above 950 PSI. While the pressure relief valve will bleed off the pressure, damage to the RO membranes can occur. Normal operating pressure is 800 psi. 13. Once the system is stable at 800 psig, wait one minute and then collect a sample of the product drinking water and check the TDS using the hand held TDS meter. Once the TDS reading is acceptable (below 500 ppm) the water is ready to be sent to the ships tank. 14. Turn the product water selector 3-way valve to the Water Tank position and begin filling your water tank. 15. Continue to monitor the system pressure and the boost pressure and adjust if necessary to maintain the system pressure at 800 psig and the boost pressure at 10 psig. 16. Shutdown the unit as outlined in the Normal Shutdown Procedure section of the manual. 42

43 Normal Operation Procedure Once the watermaker is up to operational pressure (800 PSI) the system only needs to be monitored for the duration of the operational cycle to verify water flow and the pressure set-points. When starting the unit after the initial startup you do not need to wait the ten minutes at the different pressure levels. Slowly build pressure up to 800 psi. The product water output line should not be blocked when the unit is in operation. The Water Selector Valve is a special non-blocking valve that will not allow the membrane product water to ever be blocked. Installing valving downstream between this valve and the ships water tank is not allowed unless it is a non-blocking valve. The ships water tank should be vented so as not to have the membrane product water to ever be blocked. This prevents the ships water storage system from ever being pressurized which could cause failure of components and/or injury to personnel. While the SeaMaker watermaker can operate continuously without user adjustments for many hours at a time, it is good operational practice to not leave the SeaMaker in operation unattended. Normal Shut down Procedure The following instructions must be followed each time the SeaMaker system is shut down. Failure to follow these steps can result in serious damage to the RO Membranes and the High Pressure pump. 1. Turn the Product Water Selector 3-way valve to the sample position, which stops the fresh water from flowing to the ships tanks. When the SeaMaker is not in use the Product Water Selector 3-way valve should always be kept in the sample position. 2. Slowly lower the system operating pressure by turning the Pressure Regulating valve counterclockwise until the valve is completely opened. Decreasing the system pressure from the 800 PSI set-point to about 150 PSI should take about 30 seconds. 3. Turn the boost pump regulating valve on the remote control panel full counter clockwise to reduce the boost pressure to 0 psig on the boost pump pressure gauge. 4. Turn off the high pressure pump motor. You will then see a rise in the boost pressure. This is normal as the HP pump is now not taking flow from the seawater boost system which increases back pressure on the boost system. 5. Turn off the boost pump. 43

44 6. Close the ships sea water intake through hull. 7. Again verify that the boost pump pressure regulating valve on the remote panel is fully open. You will know the pressure regulating valve is fully open by completely turning it in a counter clockwise direction. 8. Turn the Inlet Water Selector 3-way valve located on the Valving and Cleaning assembly to the fresh water flush position. (the valve handle will be pointing to the right when facing the unit) Rather than pulling in sea water from the ships through hull, turning this valve to the fresh water position draws fresh water from the ships tanks through the activated carbon filter and flushes the sea water out of the system. CAUTION: The RO membranes will be destroyed if chlorinated water, bleach water, or some other type of oxidant is flushed through the membranes. Never perform a system back wash without a fresh (less than 6 month old) activated carbon filter in place 9. Verify that the system pressure regulating valve is completely open by turning the valve until it stops counterclockwise. (You never want to start the high pressure pump without the pressure regulating valve being in the fully open position, turned to the stop counterclockwise.) 10. Turn on the boost pump. (Verify flow by seeing water exiting the brine discharge.) 11. Verify that the system pressure regulating valve is completely open by turning the valve until it stops counterclockwise. (You never want to start the high pressure pump without the pressure regulating valve being in the fully open position, turned to the stop counterclockwise.) 12. Turn on the high pressure pump. 13. If your pressurized fresh water system does not provide 10 psig of boost pressure adjust the boost pump pressure to read 10 psig on the boost pump pressure gauge by turning the boost pump pressure regulating valve clockwise until 10 psig. 14. Run the high pressure pump for approximately 3 minute. We say approximately 3 minutes because the system needs to be run long enough to purge out the seawater. The user needs to determine the actual run time based on their installation by sampling the brine discharge and running the pump until fresh water is exiting the system. 44

45 15. If you have had to increase the boost pressure by turning the boost pump pressure regulating valve clockwise now turn the boost pump regulating valve fully counter clockwise to reduce the boost pressure as far as it will drop. 16. Turn off the high pressure pump. 17. Turn off the boost pump 18. Turn the Inlet Water Selector 3-way valve to the middle Off position, which shuts off any water flow to the inlet of the system. The SeaMaker can now sit idle for up to 3 to 5 days before: 1) its next use, 2) an additional freshwater flush or, 3) pickling for extended system storage. The 3 to 5 day window exists because the rate of biological growth varies with seawater composition and temperature, so the user will need to monitor his system and adjust the time period accordingly. The freshwater flush inhibits biological growth which could lead to membrane and pre-filter element fouling. 45

46 Freshwater flush Procedure If the SeaMaker has not been operated for more than 3 to 5 days since its last freshwater flush, the system will need an additional freshwater flush to inhibit the growth of biological organisms. If left unchecked, these organisms could lead to membrane and pre-filter element fouling and a rotten-egg smell in the product water. The rotten-egg smell comes from the waste product (hydrogen sulfide) of the anaerobic biological organisms. If your system has this unmistakable rotten-egg smell, don t panic, it s just time for a system sanitizing which is explained in the next section on Pickling and preparing the SeaMaker for longer term storage. 1. Verify that the Product Water Selector 3-way valve is in the sample position. (which is where is should always be kept when the SeaMaker is not in use) 2. Turn the Inlet Water Selector 3-way valve from the middle Off position to the freshwater flush position. (You will be pulling water from your ships freshwater tanks, so be sure there is adequate fresh water in the tank for the freshwater flush or you run the risk of running the system dry) 3. Verify that if you are drawing from your ship s pressurized water system that you pressurized system water pump is powered up. 4. Verify that the pickling 3-way valve is in the normal making water operations mode, which can be visually verified by making sure the handle, is in the up position. 5. Verify that the system pressure regulating valve on the remote control panel is completely open by turning the valve until it stops counterclockwise. (you never want to start the high pressure pump without the pressure regulating valve being in the fully open position, turned to the stop counterclockwise) 6. Turn the boost pump regulating valve on the remote control panel full counter clockwise which is wide open. 7. Turn on the boost pump and let run for at least 1 minute. (Verify freshwater flow by seeing water exiting the brine discharge.) 8. After confirming water flow exiting the brine, turn on the high pressure pump. 46

47 CAUTION: Do not run freshwater through the RO pressure vessel at high pressure, always make sure the Pressure Regulating valve is completely open (turn counterclockwise until the valve stops). Running fresh water through the RO membranes at elevated pressure will rupture the membrane(s) and destroy them. 9. If your pressurized fresh water system does not provide 10 psig of boost pressure adjust the boost pump pressure to read 10 psig on the boost pump pressure gauge by turning the boost pump pressure regulating valve clockwise until 10 psig. 10. Run the high pressure pump for approximately 3 minute. We say approximately 3 minutes because the system needs to be run long enough to purge out the seawater. The user needs to determine the actual run time based on their installation by sampling the brine discharge and running the pump until fresh water is exiting the system. 11. If you have had to increase the boost pressure by turning the boost pump pressure regulating valve clockwise now turn the boost pump regulating valve fully counter clockwise to reduce the boost pressure as far as it will drop. 12. Turn off the high pressure pump. 13. Turn off the boost pump 14. Turn the Inlet Water Selector 3-way valve to the middle off position, which shuts off any water flow to the inlet of the system. The SeaMaker can now sit idle for up to 3 to 5 days before: 1) its next use, 2) an additional freshwater flush or, 3) pickling for extended system storage. 47

48 Preserving the SeaMaker for Longer Term Storage The introduction of a preservative material to the SeaMaker can allow the system to sit unused for an extended period of time. Or if Biological growth contamination has occurred, a preservative flush can sterilize the system. The preservative chemical is Sodium Metabisulfite and is commonly used in the beer and wine industries to sterilize equipment. The following procedure should be followed to prepare a 5-gallon batch of preservative solution and introduce it into the SeaMaker. 1. First perform a fresh water flush using the Freshwater-Flush Procedure as outlined above. 2. Verify that the Product Water Selector 3-way valve on the control panel is in the sample position. (If you leave the Product Water Selector 3-way valve in the to tanks position, you will be putting preservative material into your water tank during the pickling process.) 3. Fill a 5-gallon bucket with RO quality water and add two tablespoons of the Sodium Metabisulfite preservative per gallon of water. (10-tablespoons for a full 5-gallon bucket) and stir to dissolve the chemical. CAUTION: Never use chlorinated water, bleach water, or a water containing an oxidant to flush your watermaker, as it will Destroy the RO Membranes! 4. Turn the Inlet Water Selector three-way valve handle on the valving and cleaning module to the center position which turns off the seawater inlet and also turns off the fresh water inlet. 5. Turn the lower three-way Pickling Selector 3-way valve from normal operating position (straight up) to the pickling position, which is straight down. (You will now be pulling water from the whip-line attached to the bottom of the Valving and Cleaning assembly which you will place in the bottom of the 5-gallon bucket) 6. Verify that the Pressure Regulating valve is completely open by turning the valve until it stops counterclockwise. (you will not be starting the high pressure pump.) 7. Turn the boost pump regulating valve on the remote control panel full counter clockwise which is wide open. 8. Attach the 3/8 plastic pickling by-pass line to the purge valve that is located between the high pressure pump and the pre-filter assembly as shown in Figure 21 below. 48

49 Figure 22: Hose Assembly before Pickling Figure 23: Hose Assembly During & After Pickling 49

50 9. Close the seawater shutoff valve that is located between the HP pump and the purge valve that you just connected the 3/8 pickling by-pass line to as shown in figure Remove the high pressure hose from the discharge port of the high pressure pump as shown in Figure Remove the brass cap from the stainless steel fitting that is on the end of the 3/8 pickling plastic line and install it on the HP pump discharge port that you removed the high pressure hose from as shown in Figure Install the high pressure hose that you just removed from the high pressure pump and connect it to the 3/8 stainless steel fitting that is attached to the end of the 3/8 plastic pickling line as shown in Figure Open the air purge valve as shown in Figure Place the whip-line tube that exits the bottom of the Valving and Cleaning assembly into the 5-gallon bucket of mixed preservative. Turn on the boost pump and let it pull in the 5-gallon buckets contents into the SeaMaker. CAUTION: Do not run the preservative through the RO pressure vessel at pressure, always make sure the Pressure Regulating valve is completely open (turn counterclockwise until the valve stops). Running the preservative water through the RO membranes will rupture the membrane and destroy them. Use only the boost pump. 15. As the water level in the 5-gallon bucket nears end, turn off the boost pump. Use caution to not suck in any air into the system. 16. Turn the Pickling 3-way valve back to the vertical normal operations position. 17. Leave the Inlet Water Selector 3-way valve to the middle off position, which shuts off any water flow to the inlet of the system. The SeaMaker watermaker is now sterilized and or pickled and can sit unused for a prolonged period of time. If performing this procedure to rid the system of the rotten-egg sulfur smell that was the result of biological growth contamination, let the unit sit for 24 hours before your next use. When you are ready to use the SeaMaker again restore the system as shown in Figure 21. Make sure the high pressure pump shutoff valve is open and the air purge valve is closed. Restore the brass cap onto the 3/8 stainless steel fitting on the 3/8 pickling line. You may now perform a standard startup procedure of the water maker. 50

51 Membrane Cleaning Procedures After consulting with the technical team at Cruise RO Water it may be determined that scale deposits or organic contamination is reducing your SeaMaker s fresh water output and a chemical membrane cleaning is needed to restore the membrane fresh water production. Your membranes could require cleaning if you see a 10% drop in your product water production rate or an increase in your TDS levels. The membrane cleaning procedure is a two-step process that first uses an acidic solution to dissolve and remove scale deposits followed by an alkali solution to remove any organic fouling. For safety and ease of operation, we recommend using only cleaning cartridges containing the appropriate acid and base chemicals. To use the cleaning cartridges, the 5 micron filter element is simply removed and the cartridge is inserted, keeping the user from having to handle the chemical reagents. The following steps outline the cleaning procedure utilizing the scale and organics cleaning cartridges available from Cruise RO Water. CAUTION: The membrane cleaning process utilized acids and bases and proper personal protective equipment should be worn at all time when handling the cleaning cartridges and brine and product water discharge. Acid and base resistant gloves and eyewear is critical to personal safety. 1. Verify that the Product Water Selector 3-way valve is in the to sample position. You do not want the cleaning chemicals to enter your ships fresh water tanks! 2. Use the supplied pre-filter housing wrench to open the 5 micron filter housing and remove the 5 micron filter element. 3. While wearing chemical resistant gloves, remove the scale cleaning cartridge from its shrink-wrapped bag and place it in the 5 micron filter housing, using the filter housing wrench to tighten the filter housing. There is an arrow on the plastic element indicating the proper vertical orientation. 4. Turn the Inlet Water Selector 3-way valve from the middle Off position to the freshwater flush position. (You will be pulling water from your ships freshwater tanks, so be sure there is adequate fresh water in the tank for the freshwater flush or you run the risk of running the system dry) 5. Verify that the Pickling 3-way valve is in the normal operations position with its handle in the up position. 6. Verify that the Pressure Regulating valve is completely open by turning the valve until it stops counterclockwise. 51

52 Caution: You never want to start the high pressure pump without the pressure regulating valve being in the fully open position, turned to the stop in the full counterclockwise. 7. Turn on the Boost Pump and monitor the system until the boost pump has reprimed the system and water is flowing out of the brine discharge. 8. Turn on the high pressure pump for approximately seconds to allow the chemical reagent to dissolve and be pulled into the RO pressure vessels. 9. Turn off the high pressure pump 10. Turn off the boost pump 11. Turn the Inlet Water Selector 3-way valve to the middle off position and allow the membrane to sit in the cleaning solution for a time ranging from 2 hours to overnight. After the cleaning solution has been allowed to remain in contact with the membrane for the desired length of time, the standard Freshwater Flush Procedure is used to rinse out the cleaning chemical. The procedure is outlined below. CAUTION: Be sure that the Product Water Selector 3-way valve is in the to sample position. You do not want the cleaning chemicals to enter your ships fresh water tanks! 12. Verify that the Product Water Selector 3-way valve is in the sample position. 13. Turn the Inlet Water Selector 3-way valve from the middle Off position to the freshwater flush position. (You will be pulling water from your ships freshwater tanks, so be sure there is adequate fresh water in the tank for the freshwater flush or you run the risk of running the system dry) 14. Verify that the Pickling 3-way valve is in the normal operations mode, which can be visually verified by making sure the handle, is in the up position. 15. Verify that the Pressure Regulating valve is completely open by turning the valve until it stops counterclockwise. (you never want to start the high pressure pump without the pressure regulating valve being in the fully open position, turned to the stop counterclockwise) 16. Turn on the boost pump and let it run for at least 1 minute. (Verify freshwater flow by seeing water exiting the brine discharge.) 52

53 17. After confirming water flow exiting the brine, turn on the high pressure pump for 5 minutes. CAUTION: Do not run fresh water through the RO pressure vessel at pressure; always make sure the Pressure Regulating valve is completely open (turn counterclockwise until the valve stops). Running fresh water through the RO membranes will rupture the membrane and destroy them. 18. Turn off the high pressure pump. 19. Turn off the boost pump 20. Turn the Inlet Water Selector 3-way valve to the middle off position, which shuts off any water flow to the inlet of the system. 21. Remove the spent cleaning cartridge from the 5 micron pre-filter housing and replace it with a new 5 micron filter element or if necessary, proceed to inserting an organics cleaning cartridge. The exact procedure as outlined above can now be preformed again using the organics cleaning cartridge. Winterizing the SeaMaker System The entire system can be preserved in place by using an antifreeze. The procedure that is used for this is a modified Freshwater-Flush Procedure. The one modification to the procedure requires that the freshwater ½ plastic line into the Valving and Cleaning Assembly filter housing should be removed and a whip line installed to a five gallon bucket. This will separate the water tank from the inlet to the watermaker system. You can purchase antifreeze typically in ranges of 25 to 60 percent. Check the temperature rating of the antifreeze and make sure that it will be sufficient for the low temperatures that your system may encounter. Use the entire five gallons of solution to ensure the entire system is completely saturated with antifreeze. When complete move the seawater/freshwater three-way valve to the off position. Remove the whip line and install a ½ shipping plastic plug into the inlet of the carbon filter housing of the Valving and Cleaning Assembly. Use only a freshwater Propylene Glycol antifreeze. Do not use Ethylene Glycol which is an automotive antifreeze. 53

54 The following procedure should be used to winterize the SeaMaker water maker system. 1. Verify that the Product Water Selector 3-way valve is in the sample position. (which is where is should always be kept when the SeaMaker is not in use) 2. Turn the Inlet Water Selector 3-way valve from the middle Off position to the freshwater flush position. Remove the plastic ½ plastic line coming from the ships water tank to the inlet of the carbon filter of the Valving and Cleaning Assembly. Install a whip line from the inlet of the carbon filter housing to a five gallon bucket of the antifreeze solution. Fill the bucket with the appropriate concentration of antifreeze solution. 3. Verify that the pickling 3-way valve is in the normal operations mode, which can be visually verified by making sure the handle, is in the up position Verify that the Pressure Regulating valve is completely open by turning the valve until it stops counterclockwise. (you never want to start the high pressure pump without the pressure regulating valve being in the fully open position, turned to the stop counterclockwise) 6. Turn on the boost pump. 7. After confirming antifreeze solution level is dropping in the bucket, turn on the high pressure pump until bucket is almost empty. CAUTION: Do not run the antifreeze solution through the RO pressure vessel at high pressure, always make sure the Pressure Regulating valve is completely open (turn counterclockwise until the valve stops). Running antifreeze solution through the RO membranes will rupture the membrane and destroy them. 8. Turn off the high pressure pump. 9. Turn off the boost pump 10. Turn the Inlet Water Selector 3-way valve to the middle off position, which shuts off any water flow to the inlet of the system. 11. Remove the whip line from the inlet of the carbon filter housing and install a ½ plastic shipping plug to seal the system. 54

55 12. When the user is ready to return the system to producing fresh drinking water again the ½ plastic plug should be removed from the inlet of the carbon filter housing and the freshwater tank supply line should be reattached. 13. Follow the Freshwater-Flush Procedure to purge the system of antifreeze. 14. Follow the Initial SeaMaker Startup Procedure to return the system to normal water production mode. Field Testing Data Table The rated performance of the SeaMaker-30 was determined in the San Diego, California Bay with a sea water temperature of 68 F and a sea water TDS of 33,200 parts per million. The unit was operated at the following system pressures while collecting process performance data. The data demonstrates the link between system pressure, amp usage, and fresh water output. The design system operational pressure for the SeaMaker 30 is 800 PSI and this data is presented below. SeaMaker 30 Two 2.5" x 40" DOW Filmtec Membranes, 1.6 GPM Pump and 1.0 Hp Motor System Pressures are Based Upon a Five Foot 3/8" Hose from Membrane to Remote Panel Pressure Regulator PSI Amps Temp Inlet GPM GPH Figure 24: Field Testing Data Table Parts List and Equipment Exploded Views See PDF Attachments 55

56 Optional Remote Valving and Cleaning Panel Figure 25: Remove Valving and Cleaning Panel Front and Backside The Remote Valving and Cleaning Panel allows the operator to conveniently clean, flush, or pickle the system after producing water without having to access the standard valving and cleaning carbon filter module. With the selector valve pointed to the Seawater Inlet and the other valve in the Pickling off direction the system is setup for normal water making operation. After producing water the right hand valve is moved to the Fresh Water Flush position and the left hand valve is moved to the Pickling Off position. This allows water to be drawn from the ship s tank through the carbon filter for possible chlorine and particulate removal and into the water maker to flush out any seawater from the system components. Some boats are equipped with a pressurized drinking water system. The inlet to the carbon filter can be plumbed into this system or directly to the ship s fresh water tank. When pickling the membrane for preservation the right hand valve should be moved to the off position and the left hand valve moved to the Pickling On position. This allows the boost pump to draw the pickling solution into the system for preservation. Leave the right hand valve in the Off position after pickling and return the left hand valve to Pickling off position. The valves should be left in these positions until the system makes water again. 56

57 Optional Low Pressure Seawater Flow Diagram with Remote V & C Assembly Figure 26: Low Pressure Seawater with Remote Valving & Cleaning Assembly 57