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Aquatec DD 500 Technical Manual

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Papenreye 61, D 22453 Hamburg.
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All contents of this manual, in particular texts, photographs and graphics are subject to German copyright law.
Copyright held by North Marine Handels GmbH. Duplication, editing, distribution and any kind of use outside
the limits of copyright law require the written approval of the author.
Technical Manual
for installation, operation and maintenance of
Modular DD 500, 12 or 24 Volt
Version 68 - 02.2023
Download latest manual at:
www.aquatec-watermaker.de/downloads_E.html
In case of doubt, the German original manual applies.
AQUATEC- Water maker,
Manufacture and distribution by North-Marine Handels GmbH
sup@aquatec-watermaker.de, Tel: +49 (0)40-36850306
www.aquatec-watermaker.de

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Summary of Contents for Aquatec DD 500

  • Page 1 Technical Manual for installation, operation and maintenance of Modular DD 500, 12 or 24 Volt Version 68 - 02.2023 Download latest manual at: www.aquatec-watermaker.de/downloads_E.html In case of doubt, the German original manual applies. AQUATEC- Water maker, Manufacture and distribution by North-Marine Handels GmbH Papenreye 61, D 22453 Hamburg.
  • Page 2 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 3 This instruction includes important safety information and instructions for commissioning, operation and maintenance of the Aquatec Watermaker components. It is essential therefore, that the responsible specialist refers to it before starting any work on the machinery as well as prior to commissioning.

  • Page 4: Table Of Contents

    Table of contents Scope of delivery Warnings / Hints Introduction reverse osmosis 6 - 7 Operation 8 - 9 Shutdown, fresh water flush. 10 - 11 Long term preservation (mothballing), antifreeze 11 - 12 Membrane cleaning Memos 14 - 18 Installation Electrical connection Important: Inspection - maintenance - oil change...
  • 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. Note: Hose connections for high pressure pump can be made on the left, right or diagonally (as shown). Inlet seawater at the bottom, high pressure at the top. Hose dimensions (inner diameter) see specification (5) Pressure regulation valve (6) Flowmeter product water (7) ships fresh water pump (8) Feed pump...
  • Page 8 7-14 days. This process can be repeated as desired to avoid the use of chemicals. Prior to a longer period of shutdown (without flushing), the Aquatec has to be preserved with the chemical no. 3 (Biocide). For instructions, see “Long term preservation Attention! (mothballing) of the plant”.
  • Page 9 Flow diagram fresh water flush HP- Pump always pressureless!!! (Pressure control valve (5) open). The only application with working pressure is the production of product water. Note! Note: Hose connections for high pressure pump can be made on the left, right or diagonally (as shown). Inlet seawater at the bottom, high pressure at the top.
  • 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 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 Attention! recommend installing and using the Watermaker as soon as possible. Hose connections below the water line should secured with 2 hose clamps.
  • Page 15 Inserting the Aquatec pressure vessel into the mounting clamp. 1) Insert pressure vessel into the clamp. 2) Push pressure vessel firmly into the bottom of the clamp.
  • 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. The high-pressure hose must not be installed with a radius less than 60 mm.
  • 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 high-pressure hose Attention! 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: Important: Inspection - Maintenance - Oil Change

    Inspection – maintenance – oil change Important: Check the oil level and condition of the high-pressure pump oil daily. In the event of condensation in the oil (whitish/ greyish discoloration due to continuous Attention! operation, warm environment), change the oil immediately. Regularly check hose connections and HP pump for leaks.
  • Page 21 Note! 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. Thereafter, pull the end caps out of the pressure pipe with a slight pull at the stainless steel-fittings of the pressure hoses and slightly sidewise movements.

  • Page 22: Troubleshooting

    Troubleshooting Noisy operation, vibrations, unsteady pressure. Prolonged operation with the above error leads to failure of other components. Warning! Noisy running, pulsating, unsteady and possibly low working pressure, banging or strongly vibrating of high-pressure hose. Air in system To bleed air from the system a fresh water flush via the on-board pressurized water system is often optimal for removing existing air from the system.
  • Page 23 Voltage low at hp-motor. to specification too low? Voltage OK? Probably dirty or defective valve. DD 500 12V = about.44 Ampere Carbon brushes (4 pieces) Motor HP pump stuck or faulty contact or used up. DD 500 24V = about.22 Ampere Please refer to the previous page.
  • Page 24 Parts diagram high pressure pump When ordering spare parts please state Pump-Head Serial No. Note! Type 1, crankcase color grey Serial- number Tightening torque / mounting: Screws No. 3/5/6/10 – Torque 10 Nm Screw No. 16C Valve screws No. 32 - Torque 25 Nm secure with Loctite 243 Head-Screws No.
  • Page 25 Spare part numbers high pressure pump Type 1, crankcase color grey When ordering spare parts please state Pump-Head Serial No. Note! Order No. Description 141609 Crankcase 141610 Oil Dipstick 141611 Crankcase Cover 141612 Oil Drain Plug Assy 141613 O-Ring 141614 Plug Assy 141615 Cylinder Screw M6 x 16...
  • Page 26 Clamping torques and high-pressure pump spare part-numbers typ 2 Type 2, crankcase color black When ordering spare parts please state Pump-Head Serial No. Note! Nut no. 35 secure with Loctite 2701 No. 52 replaced no. 13/14 After year 2018/2019 To unscrew nut no. 35 heat up to about 200°C. Secure nut no.
  • Page 27 High-pressure pump spare part-numbers typ 2 Type 2, crankcase color black When ordering spare parts please state Pump-Head Serial No. 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...
  • Page 28 Exploring Diagram Pressure regulation valve Maintenance (only as required) is limited to cleaning and greasing. The O-ring (5), (7,5x2 NBR 70), has only to be changed in case of leakage. To take the pressure pin out of the valve body, unscrew the adjusting knob (1).

  • Page 29: Specification Dimensions

    Specification / Dimensions Hose dimensions inner diameter 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...
  • Page 30 Dimension Motor pump unit DD 500...

  • Page 31: Part List

    Partlist AQUATEC Watermaker DD 500 Description Quantity Description Quantity Motor Pump Unit Tank 120114 12V Motor Pump Unit 128002 Tank 10 Liters 120115 24V Motor Pump Unit 130091 Tank Connection 1/2" x 13 mm 130150 Hose Tail 3 part 1/2" x 13 mm 130150 Hose Tail 3 part 1/2 "...

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