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Aquatec DD 500 Technical Manual

12 or 24 volt
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Technical Manual
for installation, operation and maintenance of
Modular DD 500, 12 or 24 Volt
Download latest manual at: www.aquatec-watermaker.de/downloads_E.html
In case of doubt, the German original manual applies.
AQUATEC- Watermaker, Inh. Joachim Matz
Buergerm.-Schinkel-Str. 10a, 25348 Glueckstadt, Germany.
Contact
sup@aquatec-watermaker.de, Tel: +49(0)151 50933262
Web
www.aquatec-watermaker.de
All contents of this manual, in particular texts, photographs and graphics are
subject to German copyright law. Copyright held by Aquatec J. Matz. Duplication,
editing, distribution and any kind of use outside the limits of copyright law require
the written approval of the author.
Version 35 - 03.2020

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Summary of Contents for Aquatec DD 500

  • Page 1 All contents of this manual, in particular texts, photographs and graphics are subject to German copyright law. Copyright held by Aquatec J. Matz. Duplication, editing, distribution and any kind of use outside the limits of copyright law require the written approval of the author.
  • Page 3 Thank you to choose an AQUATEC Watermaker for the provisioning of fresh water on your boat. AQUATEC equipment is made from high-quality components exclusively and has proven its reliability on long cruising-yachts. We are convinced that our product will serve you for many years without interferences.

  • Page 4: Table Of Contents

    Clamping torques / Spare parts Specification / Hose dimensions Dimensions / Scope of delivery Recommendation for using your Aquatec reverse osmosis system. Daily use is preferable to a one-time weekly use. The system produces drinkable water with a neutral taste and very good quality.
  • Page 5 Introduction The principle of reverse osmosis (RO) In natural sciences and technology, osmosis is perceived as the directed migration of molecules through a semi permeable membrane. The chemical and physical structure of the membrane determines which molecules are able to pass and which are not. For this reason, it is called semi-permeable, which means as much as halfway or partial permeability.
  • Page 6 1) Open the seawater intake valve (no.10). 2) The pressure control valve (no.5) in the control panel has to be fully opened by turning counter clockwise. Warning! Never start your Aquatec with closed pressure control valve! Starting with a closed valve destroys the pressure reading and possibly essential parts of the equipment.
  • Page 7 Flow diagram water production. Hose dimensions (inner diameter) see specification (5) Pressure regulation valve (6) Flowmeter product water (7) ships fresh water pump (8) Feed pump (9) Gauge feed pressure, option (10) Seacock The drinking water production changes according to the salinity, the temperature of the seawater and the age of the R.O.
  • Page 8 Switch off the system, fresh water flush. 1) Open the pressure control valve until the plant runs without pressure. 2) Run the Aquatec several minutes to remove the concentrated salt from the membranes. 3) Turn three-way valve (no. 2) to position test-outlet.
  • Page 9 Flow diagram fresh water flush Flushing working pressure 0 bar!!! Note! Hose dimensions (inner diameter) see specification (5) Pressure regulation valve (6) Flowmeter product water (7) ships fresh water pump (8) Feed pump (9) Gauge feed pressure, option (10) Seacock...
  • Page 10 Long term preservation (mothballing) of the plant (Page 1 of 2) Description: Prior to a longer period of shutdown, the Aquatec has to be preserved with chemical no. 3 (Biocide). After mothballing, the plant can be shut down for 6 months, depending on the environmental conditions.
  • Page 11 Long term preservation (mothballing) of the plant. (Page 2 of 2) Hint: In order to avoid possible deposits in the pumps, it is advantageous after preserving the membranes to remove the high-pressure hose at the outlet of the HP pump and to wash out the system with fresh water again, this time without the connected membrane.

  • Page 12: Membrane Cleaning

    30 minutes over the test outlet. 9) If there is no change in freshwater output, repeat the procedure 1 to 7 with chemical no. 2 (Acid). Prior to a longer period of shutdown, the Aquatec has to be preserved with Biocide after cleaning and flushing.

  • Page 13: Memos

    Memos...

  • Page 14: Installation

    Installation guide page 1 The already assembled membranes can be stored for approx. 5 months in the sealed pressure tube, preferably cool, but preferably not above 20 ° ambient temperature. However, we recommend installing and using the Watermaker as Attention! soon as possible.
  • Page 15 Installation guide page 2 Tank for membrane conservation and cleaning The tank has to be mounted above the feed pump to ensure the flow to the plant. If this is not possible, an additional feed pump has to be installed. The tank can be fastened to any plane surface with the help of the enclosed webbing and the plastic long eyelets.
  • Page 16 Installation guide page 3 High-pressure hose, to be cut into two parts according to your needs. To allow a flexible assembly, the high-pressure hose is provided as one piece of 4 meters (13.1 feet) with a V4A high-pressure fitting at both ends. Please fit the required lengths accurately before cutting the hose.
  • Page 17 Installation guide page 4 Secure the high-pressure connection fittings in the plastic end caps of the pressure pipe against twisting with a 19 mm open-ended wrench (not necessary on end caps fittings secured with metal strips) and tighten the union nut of the Attention! high-pressure hose with a 17 mm open-ended wrench with approx.
  • Page 18 Installation guide page 5 Connection concentrate (Brine): Connect the outlet on the pressure control valve in the control panel to an on-board outlet through a hose 1/2 "= 13 mm inner diameter. This on-board outlet must be above the waterline and must not be lockable. The material for the thru-hull must not be made of acetal.

  • Page 19: Electrical Connection

    Electrical connection for 12-volt systems 1 - Battery 2 - Fuse for high-pressure pump (DD 500 = 12 V: 60 A 3 – Car fuse for control and feed pump 10 A 4 - Aquatec operator panel 5 - Switch feed pump...
  • Page 20 Maintenance Check daily for possible leaks and the oil for whitish discoloration. In operation, regularly check all hoses connections and hp pump for leaks. Important: Check oil level and condition Dipstick full of the oil of the high-pressure pump screwed into daily.
  • Page 21 (brine) Demounting the membrane: For demounting the membranes, screw off the screws M6x20 at both ends of the AQUATEC pressure vessel. (Screw tightening torque for the holding clips 3 Nm). Then take off the stainless-steel holding clamps. Push the end caps in a little before pulling them out to loosen the possibly stuck O-rings.

  • Page 22: Troubleshooting

    Troubleshooting Noisy operation, vibrations, unsteady pressure. Prolonged operation with the above error leads to failure of other components. Warning! Air in system ** Bleed system ** Intake clogged Clean intake Prefilter dirty Cean or replace filter Feed pump defective Replace feed pump Valve defective or soiled *** Open valve caps and check valves, replace valves Pressure regulation valve dirty...
  • Page 23 HP pump performance in liters per minute at 55 bar working pressure: DD 500, 3-3.5 liter / minute The drinking water production changes according to the salinity, the temperature of the seawater and the age of the R.O. membrane. The data regarding the fresh water production apply to a salinity of 35 grams/liter at a temperature of 25ºCelsius (77°Fahrenheit) at the new membrane.
  • Page 24 Clamping torques and spare part-numbers high-pressure pump Note: When ordering spare parts, please name the serial number of the pump head necessarily. Crankcase 14 15 Secure with Loctite 270 built up No.13 right side to 2018 for belt drive only To unscrew nut no.
  • Page 25 Spare part-numbers high-pressure pump When ordering spare parts, please name the serial number of the pump head necessarily. Note! Order Order Description Description 141565 Drain plug ¼“ x 9 Pump head ss 1.4462 141410 Typ DC320-500-800, DD500, AC65-110 141483 Gib 141411 Typ AC75-135, AC/KC150-190-240 141453 Rosette 141554 Screw 8 x 60 or 8 x 55 ss...

  • Page 26: Specification / Hose Dimensions

    Specification / Dimensions Aquatec Watermaker are designed for permanent installation on ships. Operation of the system is only permitted with clean seawater. Warning! Specification – AQUATEC Watermaker DD 500 Hose dimensions (inner diameter) Diameter thru-hull fitting 3/4", 19 mm recommended Thru-hull fitting up to high pressure pump 1/2“...

  • Page 27: Dimensions / Scope Of Delivery

    Dimension / Scope of delivery Scope of delivery Seawater R.O. AQUATEC: Connection cable, through-hull fittings and sea cock must be provided on-board.  High-pressure pump with electric motor, pump head in Duplex-stainless steel 1.4462.  Feed pump 12VDC, 24V plants incl. 24/12VDC DC inverter.