ElectroMaax Marine Watermaker Series Installation, Operation & Maintenance Manual
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ElectroMaax Marine Watermaker Series Installation, Operation & Maintenance Manual

12 or 24 volt system
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INSTALLATION, OPERATION
MAINTENANCE MANUAL
US Customers
Electromaax
6405 Inducon Drive West
Unit 5
Sanborn NY 14132
1
ElectroMaax
Marine Watermaker Series
SolarMaax 340
12 or 24 Volt System
&
Toll Free: 1-866-945-8801
Fax:
1-905-563-8806
Web: www.electromaax.com
Email: sales@electromaax.com
Canadian and
International Customer
Electromaax
5552 King Street
Lincoln,
ON, L3J 1N6
V1.4

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Summary of Contents for ElectroMaax Marine Watermaker Series

  • Page 1 ElectroMaax Marine Watermaker Series SolarMaax 340 12 or 24 Volt System INSTALLATION, OPERATION & MAINTENANCE MANUAL US Customers Canadian and Toll Free: 1-866-945-8801 Electromaax International Customer Fax: 1-905-563-8806 Electromaax 6405 Inducon Drive West 5552 King Street Unit 5 Web: www.electromaax.com...

  • Page 2: Table Of Contents

    Table of Contents Introduction __________________________________________________ 3 General Warnings and Notices _____________________________________ 4 Specifications _________________________________________________ 5 Parts List ______________________________________________________ 7 Configurations _________________________________________________ 8 System Overview________________________________________________ 9 Installation Instructions___________________________________________ 10 Component Descriptions in order of water flow _______________________ 11 Intake Seacock ________________________________________________ 11 Sea Strainer ____________________________________________________ 11 Freshwater Flush Filter Assembly__________________________________ Feed Pump Assembly____________________________________________ 13...

  • Page 3: Introduction

    INTRODUCTION The team at ElectroMaax thanks you for your purchase of our SolarMaax 340 reverse osmosis watermaker with Auto Flush, and the latest in energy recovery technology; the Enhanced Clark Pump. The addition of a low energy watermaker can be a life changing upgrade for your cruising experience.

  • Page 4: General Warnings And Notices

    GENERAL WARNINGS AND NOTICES There are several things which the installer or operator of the SolarMaax 340 can do incorrectly, which can seriously damage the SolarMaax 340 water maker, dramatically shorten the operational life span of the system, and in some cases cause personal injury. Knowing the things to avoid is critical to a good SolarMaax 340 installation and operation.

  • Page 5: Specifications

    4.0 – 10.0 amps @ 25.0 – 28.8 VDC The Enhanced Clark Pump Hydraulic Pressure Intensifier: Manufactured by ElectroMaax for marine and military use. The Enhanced Clark Pump uses the Feed pump flow pressure to intensify the pressure of the flow through the RO membranes high enough for reverse osmosis to occur.
  • Page 6 Feed Pumps: Motor: Permanent magnet type, fully enclosed, 1/8 hp Pump Body: Thermoplastic Pump Type 3 chamber diaphragm Typical Amp Draw each: 8 to 10 amps, 12VDC 4 to 5 amps 24VDC Recommended fuse size: 25 amps, 12VDC 15 amps, 24VDC Open Flow Rate : 1.6 gpm (6.05 lpm) one pump, 3.2 (12.1 lpm) two pumps Pressure Vessel:...

  • Page 7: Parts List

    PARTS LIST: 1) Clark Pump and Pressure Vessel Assembly 2) RO Membrane Element(s) 3) Feed Pump Assembly (Feed Pump, Prefilter, Pump Control Module) 4) Control Panel 5) Carbon Filter with Solenoid Valve for Automatic Freshwater Flush 6) Accumulator Tank with fittings (depressurized for shipping) 7) 3/4”...

  • Page 8: Configurations

    CONFIGURATIONS: The SolarMaax 340 can be purchased with 2 different Clark Pump/Membrane configurations. All configurations are sent with the Clark Pump and the Membrane(s) mounted together on a base frame and plumbed together with High Pressure hoses. If a frame assembly cannot be reasonably mounted as a unit, the Clark Pump and Membrane can be separated for custom mounting.

  • Page 9: System Overview

    SYSTEM OVERVIEW: The SolarMaax 340 is simple to install. When all the components are connected in the right order the system will perform as designed and give all the freshwater you need for years. Every install is going to be different in where and how the components are mounted so forethought is necessary for the ideal layout for your installation.

  • Page 10: Installation Instructions

    Every boat is different, if any questions arise, please contact us via email (support@electromaax.com). 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! In this Manual, step by step instructions are numbered, Notes are lettered.

  • Page 11: Component Descriptions In Order Of Water Flow

    COMPONENTS IN ORDER OF WATER FLOW: In this section, each component’s function and how it is installed is explained INTAKE SEACOCK: Figure 2: ¾” Intake Seacock and Scoop, Owner Supplied Install a dedicated ¾” seacock with a forward-facing scoop, placed as low and in the middle of the boat as possible.

  • Page 12: Freshwater Flush Filter Assembly

    FRESHWATER FLUSH ASSEMBLY: Ships Fresh Water Pressure To Flush Tee Carbon Filter (We ship with filter installed) Use the 10’ Flush Valve Carbon Filter (we ship with Cable between the filter installed) PCM outputs (right) and the Flush Valve (left) Figure 4: Freshwater Flush Assembly The Auto-Flush function is used to flush seawater out of the system after use.

  • Page 13: Feed Pump Assembly

    FEED PUMP ASSEMBLY Feed Pumps Filter Status Gauge connections on the inlet and outlet of the prefilter Filter Feed Outlet to Accumulator Tank Tee Seawater Inlet from Flush Tee 5 Micron Filter Element inside the Pre-Filter Sump Feed Pumps Manual Feed Pump Switches Pump Control Power Switch...
  • Page 14 Mounting the Feed Pump Assembly Figure 7: Feed Pump Assembly Foot Mount Drawing To mount the Feed Pump Assembly, remove the 4 rubber feet by removing the four 5/16” nuts and use the following drawing to pre-mount the feet first then locate the pump module back onto the 4 rubber feet.

  • Page 15: Prefilter Status Gauge

    FILTER STATUS GAUGE: Figure 8: Pre-Filter Status Gauge The Pre-Filter is equipped with a “Status Gauge” to indicate when replacement is required….it is connected using ¼” tubing to both the inlet and outlet of the Pre-Filter. Note flow direction through Status Gauge. Mount where it can easily be seen during operation. Double sticky foam or Alien tape works good for mounting or can be fastened to a bulkhead ACCUMULATOR TANK Water Inlet...

  • Page 16: Clark Pump 3G

    ENHANCED CLARK PUMP Brine Out Ports, Left and Right Inlet Pressure Gauge assembly Usually only one is used Pressure Relief Valve Feed Inlet with shipping plug Figure 10: Front View High Pressure inlet High Pressure Fittings From Pressure Vessel Swivel 360° Flow Direction Flow Direction High Pressure Outlet...

  • Page 17: Membrane And Pressure Vessel

    PRESSURE VESSEL AND RO MEMBRANE ASSEMBLY: Outlet Flow Flow Inlet Figure 12: Pressure Vessel and RO Membrane Assembly The RO Membrane Elements are shipped separately in factory sealed bags. Install them into the pressure vessel(s) just before commissioning. The Membrane element(s) should never be allowed to dry out.

  • Page 18: Control Panel

    OPERATOR CONTROL PANEL SolarMaax 340 is equipped with a basic electronic control system with a manual override. The manual override allows for emergency operation of the system in event of an electronic failure. The Operator Control Panel (OCP) communicates with the Pump Control Module (PCM) to control the Feed Pump and Auto Flush Mode as required.

  • Page 19: Way Service Valves

    3-WAY SERVICE VALVES: Handle can be repositioned as needed U clamps are provided for surface mounting Common Port Figure 14: 3-way Service Valves Two 3-way service valves are provided for access to the seawater Feed Line and Brine Discharge Line. They are used to facilitate membrane storage and cleaning procedures. They should be placed so their alternant Service Tubes can reach a Service Pail at the same time.

  • Page 20: Optional Tank Selector Valve

    TANK FILL SELECTOR VALVE To Tank 1 Product Flow Inlet To Tank 2 Figure 16: Optional Tank fill Selector Valve If more than one tank needs to be filled, a Product Water 3-way Valve can be installed in the product line from the panel. A Product Water 3-way Valve is a specific type of valve that cannot block the Product flow in any valve position (non-dead heading) Caution: Do not use any type of selector valve that can block the flow in any way, even momentarily, or damage to the system will happen.
  • Page 21 HANDHELD TDS TESTER MEASUREMENT INSTRUCTIONS: 1. Start and run the system, making, and diverting the product water, for at least a minute. 2. Remove the protective cap. 3. Turn the TDS meter on. The ON/OFF switch is located on the panel. 4.

  • Page 22: Mounting The Components

    MOUNTING THE COMPONENTS: A. Dimensions for the Clark Pump Module and the Feed Pump Assembly are on page (41). B. Follow the flow diagram and the mounting notes in the component descriptions. Note how the 3-way valves are plumbed, they will always introduce a 90° turn in the flow. A set of U brackets are supplied to mount the valve to a bulkhead if desired.

  • Page 23: System Plumbing Diagram

    PLUMBING: Figure 18: Complete Plumbing Diagram V1.4...

  • Page 24: Low Pressure Tube Fittings

    LOW PRESSURE TUBE AND FITTINGS: Plastic Pipe Threads: Use 3 to 4 wraps of Teflon Tape on the threads, leaving the first thread bare. Tighten fittings until snug. Over tightening will bottom out the fittings and leak. If a pipe thread is too loose and bottoms out easily, use Loctite 55 thread cord to build up the threads.
  • Page 25 TUBING CONNECTION: All low-pressure fittings are “Push-to-Connect”, high grade, double “O” ring, NSF 58 certified, lead free, polypropylene G.A. Murdock fittings. The SolarMaax 340 system comes with the push-to-connect fittings pre-installed on the larger components. Additional fittings are supplied to be able to customize installation as needed. The figure below shows the “Push-to- Connect fitting, locking clip, and tubing.

  • Page 26: Electrical

    ELECTRICAL: Figure 22: Electrical Diagram Proper wiring is important to minimize voltage drop between the batteries and the Feed Pumps. Use Marine grade tinned multi strand wire. Pick one of the methods above, taking power from a breaker on the panel or wire an inline breaker directly from the house batteries, whichever is closer.
  • Page 27 Flush Valve on the Carbon filter. 10’ extensions for both cables are available for purchase through ElectroMaax. Figure 23: Operator Control Panel Cable Connector...
  • Page 28 CONTROL SYSTEM: Pump Control Module (PCM level 1: Remote Pump Operation and Flush) Manual Pump Power Switches Flush Cycle LED Power Switch for the PCM and OCP with LED Figure 25: Pump Control Module (PCM) Control Operation: Turn on the power feed from the ship’s batteries. Test Manual Feed Pump function by momentarily activating each Manual Pump Power Switch on the top of the PCM enclosure.

  • Page 29: System Control

    Figure 26: Operator Control Panel (OCP) Detail Pump Power Switches on the OCP: The Feed Pumps and Flush function are remotely controlled by the Panel switches. The Power Switch on the PCM activates the Panel switches Freshwater Flush: (Auto and Single) It is recommended to fresh water flush the system after use.

  • Page 30: Commissioning

    COMMISSIONING: The Commissioning Procedure should be performed at a new system start up. The main function is to prime the Feed Pump, look for leaks, and purge the system of chemicals. 1. Open the watermaker intake and discharge through hull valves. 2.

  • Page 31: Normal Start Up And Run

    NORMAL START UP: Note: If there is any question about the service history of the system, perform a “Restart after Long Term Storage” (pg. 33) procedure first. 1. Turn on the Ship’s Main and PCM power. 2. Check the boat’s Inlet and Brine Through Hulls are open and the sea strainer is free of debris. 3.

  • Page 32: Shut Down And Flush Options

    SHUT-DOWN PROCEDURES: ORMAL RESHWATER LUSH 1. Turn off the system with the Pump Power buttons on the Panel. Main and PCM power can stay on. 2. Turn the Product Diversion Valve to the “Test” position. 3. The Pressure Relief Valve can be left closed. 4.

  • Page 33: Long Term Storage And Restart

    PICKLING FOR LONG-TERM STORAGE: 1. Make 2 gallons of product water or pour 2 gallons of distilled water into the Service Pail. 2. Perform a freshwater Flush as detailed in the Freshwater Flush procedure. 3. Wearing gloves, thoroughly mix an 8 oz package of Memstor Storage Chemical into the water in the Service Pail.

  • Page 34: Prefilter Service

    PREFILTER SERVICE O-Ring Seal Figure 27: Micron Pre-Filter The Clark Pump and the RO Membrane must only operate on 5 Micron filtered Feed Water. Not all “5 Micron” filter elements are the same. Some come with Carbon in them which can let off Carbon “fines”...

  • Page 35: Membrane Cleaning

    MEMBRANE CLEANING PROCEDURES: Your membranes could require cleaning if you see a 10 psi. rise in the feed pressure over the baseline and/or an increase in your TDS levels. The membrane cleaning procedure is a two-step process that first uses an alkaline solution to remove any organic fouling followed by an acid solution to dissolve and remove scale deposits.

  • Page 36: Membrane Replacement

    MEMBRANE REPLACEMENT: The easiest way to replace the membrane is to remove the Pressure Vessel from its mounts for the procedure. It can be done in place but only if there is room enough on the outlet end of the Pressure Vessel to pull the membrane out.
  • Page 37 The Pressure Vessel does not have to be removed if there is room off Remove the 4 Bolts the Outlet end for the Membrane holding the Pressure Element to come out. Vessel Mount Caps Figure 30: Removing the Pressure Vessel 1-Grab Metal Ring of 2-Unscrew until the ring hits the fitting...
  • Page 38 Figure 32: Pulling the Membrane Element Out Using your hand, grab the white Product Collecting tube in the middle of the membrane to put. If it doesn’t want to come it’s because the Brine and Product Collecting Tube seals are holding it.
  • Page 39 2-Place Seal into the Tube at an angle 1-Insert Membrane into the Outlet end of the Pressure Vessel Tube 3-Press the lip into the Tube 4-Align the Membrane with the Tube and push the rest of the way in Figure 34 Inserting the New Membrane Reinstall the Inlet End Cap on the Pressure Vessel Tube if it was removed (see Reinstalling End Cap instructions).
  • Page 40 1-Line up the Ring and start threading on 2-Thread the Ring on until the End Cap the Tube Seal contacts the Tube 4-Finish threading the Ring on and hand 3-Twist and push the End Cap until the tighten just snug Seal goes in the Tube Figure 35: Reinstalling the End Cap Lightly lube the O-ring in the center bore of the end cap and the inner edge of the Vessel Tube...

  • Page 41: Module Dimensions

    MODULE DIMENSIONS: Figure 36: Feed Pump Assembly Dimensions and Weight V1.4...
  • Page 42 Figure 37: High Pressure Module 40” Membrane Dimensions and Weight Figure 3: High Pressure Module Duel 21” Membrane Dimensions and Weight V1.4...

  • Page 43: Troubleshooting

    TROUBLE SHOOTING: Symptom Cause Remedy No Product Flow Pressure Relief Valve open Close the Pressure Relief Valve Feed Pump not primed Open the Pressure Relief Valve until the system primes then close the valve. Feed Pump won’t prime, air getting into Check all connections and Strainer the feed line before the Feed Pump, Bowl Seal in front of the Boost...

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Solarmaax 340

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