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Aquatec Watermaker AC 55 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
Modular AC 55 - AC 240
Version 83 - 06.2023
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 Watermaker AC 55

  • Page 1 Manufacture and distribution by North-Marine Handels GmbH Papenreye 61, D 22453 Hamburg. Contact sup@aquatec-watermaker.de, Tel: +49 (0)40-36850306 www.aquatec-watermaker.de 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...
  • 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 Notes / Info Scope of delivery Safety warnings Introduction reverse osmosis Operating 6 - 7 Start plant 8 - 9 Shutdown, fresh water flush. 10 - 11 Long term preservation (mothballing), antifreeze 12 - 13 Membrane cleaning Installation 14 –...
  • 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 Operating instructions Never operate your Aquatec Watermaker unsupervised and leave the operation only to trained persons. Please note: If there are any leaks, the boat can fill up with water and sink, thereby Warning! endangering the life of the people on board.
  • Page 7 Flow diagram water production. (5) Pressure regulation valve (6) Flowmeter product water (7) ships fresh water pump (8) Feed pump (9) Gauge feed pressure (10) Seacock, not scope of delivery. The drinking water production changes according to the salinity, the temperature of the seawater and the age of the R.O.
  • 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! (5) Pressure regulation valve (6) Flowmeter product water (7) ships fresh water pump (8) Feed pump (9) Gauge feed pressure (10) Seacock, not scope of delivery.
  • 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 Flow diagram for cleaning HP- Pump always pressureless!!! (Pressure control valve (5) open). The only application with working pressure is the production of product water. Note!
  • Page 14 Installation guide page 1 The thru hull/ seacock, strainer, valves 1 and 3, and feed pump must be deep as possible below the waterline. Strainer and feed pump as close to the through-hull fitting as possible. For trouble-free operation and to prevent air accumulation, the installation must be designed to incline up to the feed pump or at least horizontally.
  • Page 15 Installation guide page 2 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. Note! Flow diagram AC 190 Flow diagram AC 240...
  • Page 16 Installation guide page 3 For assembly, the threads of all hose nozzles / fittings must be wrapped with a few turns of Teflon tape as strongly as possible against the screw-in direction. Very good alternative to Teflon, liquid thread sealant LOCTITE SI 5331. Hint Fittings must not be screwed too tightly into the filters or taps.
  • Page 17 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 18 Installation guide page 5 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 19 Installation guide page 6 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 20 Installation guide page 7 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 21 Remove them before connecting the new cables. The Aquatec Control Panel is ready for connection and is simply connected to the pre-wired connection box. Power supply cables from the on-board electrical distribution, motor connection cable, fuses and possibly necessary on-board main switch are not included in delivery and must be placed on board.
  • Page 22 Electrical circuit diagram Aquatec AC 55 up to AC 240 Single phase 230 50 Hz 115 Volt 60 Hz 2 pole motor protection switch Aquatec AC 55 up to AC 240 Single phase 230 5Hz or 115 Volt 60 Hz 3 pole motor protection switch...
  • Page 23 HP-pump / feed pump 3 phase 208/ 230/ 400/ 440 Volt 50/ 60 Hz Aquatec AC 150 up to AC 240 HP-pump 3 phase 208/ 230/ 400/ 440 Volt 50/ 60 Hz, Feed pump 1 phase 230 Volt 50/ 60 Hz...

  • Page 24: 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 25 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 26: 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 27 Troubleshooting Product water quantity 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/ litre at a temperature of 25º Celsius (77° Fahrenheit) at the new membrane. A discrepancy up to +/- 10% also in the power consumption, especially in the first 50 hours of operation, Note! are usual.
  • Page 28 Tightening torques and spare-part-numbers of high-pressure-pump typ 1. Type 1, crankcase color grey When ordering spare parts please state Pump-Head Serial No. Note! Serial-number Screw No. 16C secure with Loctite 243 Tightening torque 22,5 Nm Washer 16D on both sides Tightening torque / mounting: seal with Loctite 577.
  • Page 29 Spare part numbers of high-pressure-pump type 1 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...
  • Page 30 Tightening torques and spare-part-numbers of high-pressure pump 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 31 Spare part-numbers of high-pressure-pump 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 32 Low pre-pressure reduces the service life of the pre-filter. Note! Feed pumps with higher head are optionally available. Feed pump Aquatec type 40 Magnetically coupled centrifugal pump, Power 140/ 200 Watt Voltage 1 ~ 220-240 Volt 50/ 60 Hz, Insulation class E, IP 44. Thermal Protected.

  • Page 33: Pressure Regulation Valve

    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 (6), unscrew the adjusting knob (1). Then take off the spring (2) with pressure disk (3).
  • Page 34 Specification Aquatec Watermaker are designed for permanent installation on ships. Operation of the system is only permitted with clean seawater. Warning! Technical data AQUATEC Watermaker AC 55 - AC 110 Membrane type Seawater SW 2540 Working Pressure max. 55 bar Minimum Salt Rejection Up to 99.5%...
  • Page 35 Specification Dimensions 1~ Motor pump unit AC 55...
  • Page 36 Dimensions 1~ Motor pump unit AC 65/ AC 110/ AC 75 / AC 135 1~ Motor pump unit AC 150 / AC 190 1~ 230V/ 50Hz - Motor 1.85 KW (115V/ 60Hz - Motor 2.2 KW - 20 mm longer).
  • Page 37 Dimensions 3~ Motor pump unit AC 150 3~ 400V/ 50 Hz or 3~ 440V/ 60Hz – Motor 1.5 KW. 3~ Motor pump unit AC 190 / AC 240 1~ 2.2 KW 230V/ 50 Hz, 3~ 2.2 KW, 400V/ 50 Hz or 3~ 440V/ 60Hz – Motor 2.2 KW.

  • Page 38: Part List

    Partlist AC 55 - AC 65 - AC75 - AC 110 - AC 135 Description Quantity Description Quantity Motor Pump Unit Tank 141255 Motor Pump Unit 230 V 50 Hz 128002 Tank 10 Liters 141256 Motor Pump Unit 230 V 50 Hz 130091 Tank Connection 1/2"...
  • Page 39 Partlist AC 150 - AC 190 - AC 240 Page 1 of 2 Quantity Description Motor Pump Unit 141688 Motor Pump Unit 115 V 60 Hz 141674 Motor Pump Unit 230 V 50 Hz 141689 Motor Pump Unit 230 V 50 Hz 141686 Motor Pump Unit 400 V 50 Hz 141687...
  • Page 40 Partlist AC 150 - AC 190 - AC 240 Page 2 of 2 Description Quantity Description Quantity Control Panel Sediment Prefilter 131182 Straight Adaptor 1/2" x 3/8" Tube 130141 Hexagon Nipple 1/2" PP 130150 Hose Tail 3 part 1/2 "x 13 mm 130110 Hose Barb 1/2"...

This manual is also suitable for:

Watermaker ac 240Watermaker ac 65Watermaker ac 110Watermaker ac 75Watermaker ac 135Watermaker ac 150 ... Show all