Aquatec KC 150 User manual

Manual
Aquatec Watermaker KC 150/190/ 240
Compact 230 or 400 volt 50 Hz
Version 25 -10.2019

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.
To ensure total satisfaction, please read this user manual carefully and observe all instructions.
Warranty will be void if the installation does not meet this requirement.
Disregarding the warnings / instructions in the User Guide and incorrect installation can lead to serious
health damage or possibly the loss of the vessel.
Attention:
Aquatec Watermakers are designed for permanent installation on ships. Operation of the system is
only permitted with clean seawater.
The maximum working pressure of 55 bar must not be exceeded.
When exceeding the specified product water quantity (seawater with lower salt content, brackish
water), the working pressure must be reduced.
Like any piece of mechanical equipment the system will require inspection and service from time to
time. For easy access to enable a simple regular monitoring and proper maintenance do not place the
components in inaccessible areas.
The necessary thru-hull must guarantee under all conditions uninterrupted inflow of seawater without
mixing in air. The best place is about mid-ships behind the keel.
Install all components in a dry area and easily accessible to allow simple regular monitoring during
operation.
Install the high-pressure pump in a dry area which allows an exchange of air necessary for cooling the
motor-pump unit.
The pumps may not be operated if explosive or flammable Materials are present.
Do not operate your Aquatec Watermaker unattended and from trained personnel only.
Note:
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 soon as possible.
In case of doubt, the German original manual applies.
Download latest manual at: www.aquatec-watermaker.de/downloads_E.html
Manufacturing and marketing by AQUATEC-Watermaker, Owner Joachim Matz,
Buergerm.-Schinkel-Str. 10a , 25348 Glueckstadt, Germany
web: www.aquatec-watermaker.de
Copyright Joachim Matz

3
Table of contents
2 Hints
4 Introduction reverse osmosis
5 Overview scope of delivery
6 - 7 Operating instructions
8 - 9 Switch off the system fresh water flush
10 - 11 Long term preservation (mothballing), antifreeze
12 Membrane cleaning
13 - 15 Installation guide
16 - 17 Electrical connection
18 Important: Maintance
19 Membrane replacement
20 – 21 Troubleshooting
22 – 23 Clamping torques / Spare parts
24 Specification / hose dimensions
25 Dimensions
26 Connection diagram membranes

4
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.
RO Membrane
If one mixes different liquids, like in this case water with different salinities, they aim to equalize their
concentration. That way, the seawater would be thinned out and the drinking water would be enriched
with salts. The effect would be a less concentrated, homogeneous dissolution. Pouring sea- and fresh
water in equal amounts into a container where both liquids are separated by an adequate semi-
permeable membrane, there would be one side with seawater that is highly loaded with salts, on the
other side more or less “clean” water without or with little dissolved components.
The natural tendency of both liquids to equalize their salinity leads to the migration of water molecules
from the fresh water side towards the seawater side. As a result, the volume of water on the fresh
water side decreases while it increases on the seawater side. This process of osmosis takes place
until the pressure on the seawater side is in accordance with the osmotic pressure. Then it stops. In
this case, the osmotic pressure is around 30 bar.
The described process however is reversible by exposing the liquid on the seawater side to
mechanical pressure. At a pressure of 30 bar, the osmotic process cannot take place or would rather
be reversed. When pressure is increased beyond 30 bar, for instance 60 bar, water molecules from
the seawater side migrate to the fresh water side. All other components of the seawater dissolution
are not able to pass the membrane. As a result, the dissolution on the seawater side remains highly-
concentrated while there is a gain of fresh water on the other side of the membrane. This process is
referred to as reverse osmosis (R.O.)
The seawater is delivered to the pressure pipe’s entry side of a RO-system by a high-pressure pump.
The osmotic membrane is located in the pressure pipe and is merely permeable for the vehicle “water“
(solvent) and detaining the soluted substances. When the pressure difference is more than leveling
out the osmotic head, the water molecules are able to pass the membrane that works like a filter, while
the “unpurified” molecules are detained. In opposite to a classic membrane-filter, osmosis membranes
do not have continuous pores. In fact, the ions and molecules are migrating through the membrane by
diffusing through the membrane material. Inside of the membrane, the permeate-tube is located which
transports the fresh water through one of the two end caps of the pressure pipe towards the fresh
water tank. The excess seawater, now referred to as concentrate (brine), is drained off overboard
through the outlet of the pressure pipe by a pressure control valve.

5
Overview
1 6 9 11
10 3 7 8 2 5 4
1 Membranes 2 up to 4 pc. depending on the plant
2 three-way valve switchover test outlet / fresh water tank
3 Valve fresh water flush
4 Sediment filter (20 / 5 Micron) pre filter sea water
5 Pressure regulation valve
6 Flow meter, shows liter/h. product water quantity
7 Switch feed pump
8 Switch high pressuer pump
9 Gauge feed pressure
10 Charcoal filter for fresh water flush
11 Gauge working pressure
Scope of delivery
Aquatec Watermaker compact plant (fully assembled), connection cable 1.5 meter,
External feed pump (inc. 4 meter connection cable and waterproof plug), 1 pc. valve 3/4" (inc. tee), 5
meter pvc hose 3/4", 5 meter pvc hose 1/2" and hose clamps. 3 way valve, tank for conservation and
cleaning.
Equipment (option 1)
4 filter-cartridges 5 Micron, 4 filter-cartridges 20 Micron, 2 filter- cartridges charcoal.
Detergents Acid and Alkaline as well as Biocide for preservation.
1 set low- and high-pressure gasket for hp pump,
1 set of hp pump valves (6 pc.). O-ring spares part kit for hp pump and membrane.

6
Operating instructions
Attention
Do not operate your water maker with unpurified seawater (oil, chlorine or other chemicals).
The R.O. membranes are conserved with a dissolution that, when ingested, can cause irritations of the
gastrointestinal tract. For that reason, the product water must not be consumed within the first 30
minutes of operating time, beforehand it has to be drained over the test-outlet. This applies
accordingly after temporary shutdown or cleaning of the membranes with the cleaning chemicals.
Placing into operation
Important: Check oil level and condition of the oil of the high-pressure pump daily.
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.
Attention: 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.
An open pressure control valve can be seen when the first
two threads of the valve body becoming visible by turning
the pressure control wheel. (see picture left )
3) Turn three-way valve (No. 4) according to the flow diagram to position fresh water production.
Turn three-way valve (No. 2) to position test-outlet.
4) Switch on the feed pump. De-aerate the plant if necessary. The gauge feed water (9) must show
positive pressure. De-aerate the pre filter system and control the drain water. To prefill the
system, a short fresh water flush via the onboard pressure water pump can be useful.
5) Switch on the high-pressure pump. Inspect the whole system for leakages.
6) Increase the pressure at the pressure control valve by slowly turning it clockwise to about 30 bars.
Let the system work for about 30 seconds. There should not be any air pockets visible in the
system.
7) Increase the pressure stepwise up to the maximum working pressure (55 bar, 800 psi). Test
the product water by tasting from the test outlet (at daily operation, the product water should be
salt-free after about 60 seconds). By shifting the three-way valve no. 2, the product water is fed
into the fresh water tank.
Attention:
Never turn the pressure regulation knob completely out while the system is running. The pressure
pushes out the parts inside, which can result in injury and loss.
Note:
If the system is operated in brackish water, seawater with a lower salt content or higher water
temperature the fresh water production must not exceed the displayed value! In this case, regulate the
pressure under continuous observation of the produced amount of water until the normal level of fresh
water production is reached. (e.g. Baltic Sea about 35 bar or 490 psi)

7
Flowdiagram fresh water production, working pressure max. 55 bar
1 Valve for circulation 7 Onboard pressure water pump
2 three-way valve product water 8 Feed pump
3 Valve fresh water flush 9 Gauge feed pressure
4 three-way valve 10 Sea cock
5 Pressure regulation valve 11 Gauge working pressure
6 Flow meter product water 15 High pressure pump
Note:
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.
A discrepancy up to 10% +/- is within the usual range. At current consumption, discrepancies of up to
5% +, especially in the first 50 hours of operation, are usual.
At seawater temperatures below 25 ° C, the product water quantity is reduced by the following values.
Data (approx.) In %.
Water temperature 15°C - 20%
Water temperature 5° C - 35%

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.
4) Switch off the high-pressure pump first and then the feed pump.
5) Close the sea water intake valve.
6) Open valve (no. 3). The fresh water pressure pump of the boat should turn on now flush the
system. Duration of flushing time see “flushing time”.
7) Close valve (no. 3).
Description fresh water flush
The fresh water rinse is activated by opening valve (no.3). For this, the seacock must be closed. When
that valve is open, fresh water could drain to the sea.
At least 10-15 liters of fresh water is required per membrane A charcoal filter removes any existing
chlorine inside the fresh water tank which destroys the membrane.
Caution:
The carbon filter ensures a chlorine separation up to 4 litres/minute. If necessary, the performance of
the on-board pressurized water system must be reduced to avoid damaging the membranes by
prevent chlorine. This note only applies when chlorine is used in the drinking water tank.
Membrane and HP pump reduce the flushing rate by their internal resistance.
Flushing time:
The time needed for the fresh water rinse depends on the board-side performance of the fresh water
pump and the condition of the membranes and therefore cannot be stated on factory side.
Please find out the required amount of flushing water by discharging the rinsing water into a bucket
once after a normal operation (take off the hose at the thru-hull fitting) and check the salinity
constantly by tasting. During the process, stop the time to find out the time requirement of future
flushes. By collecting it in a bucket, you also find out the needed amount of flushing water.
Hint:
A run with the HP pump accelerates the rinsing, but can only be used when no chlorine is present.
Also, the onboard fresh water pump must provide sufficient flow (KC 150- 240, 15 Litre/Minute).
Note:
Fresh water flushing of the Aquatec is recommended after each operation. It reduced biological growth
in the membrane and preserves the life span and the reliability of the entire system.
After each operation, the Aquatec should be rinsed with fresh water. After fresh water flushing, the
system may remain unused for 7-14 days. This process can be repeated as desired to avoid the use
of chemicals.
Caution:
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 (mothballing) of the plant”.

9
Flowdiagram fresh water flush. Working pressure 0 bar.
1 Valve for circulation 7 Onboard pressure water pump
2 three-way valve product water 8 Feed pump
3 Valve fresh water flush 9 Gauge feed pressure
4 three-way valve 10 Sea cock
5 Pressure regulation valve 11 Gauge working pressure
6 Flow meter product water 15 High pressure pump

10
Long term preservation (mothballing) of the plant (1)
Attention: Working pressure 0 bar.
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.
Attention:
The conservation chemical no. 3 is a Biocide. Please consider the hazard notes on the canisters.
Working with chemicals, please wear protective glasses, breathing protection and rubber gloves for
your own safety.
Follow instructions below to avoid that chemical get into your fresh water tank.
Caution:
If there is the risk of frost, the entire pressure pipe with internal membrane in the pipe should be
dismounted (after necessary preservation) and be stored frost-proof with closed hose connections.
Can the membrane not be removed alternatively 20%- 50% glycerin in food quality can be added as
an antifreeze to the biocide at preservation. The plant has to be drained (filter housings, pumps,
hoses). Remove filter cartridges.
Instruction for mothballing of the Aquatec. Working pressure 0 bar!!!
Attention:
Make sure that you follow the following instructions carefully so that no cleaning chemical gets into
your fresh water tank.
1) Close the sea water intake valve.
2) Open the pressure control valve entirely, turn the product water three-way valve (no. 2) to
position test-outlet to avoid that chemicals get into the drinking water tank.
3) Rinse the system with fresh water as described in “Fresh water flushing”.
4) Turn the three-way valve (no. 4) according to the flow diagram “Long term preservation
(mothballing) of the plant”. Open valve (no.1).
5) Dissolve the stated amount of biocide (no. 3) completely in 10 litres of water and pour it into
the tank for conservation. (To avoid negative pressure, do not close the cap tightly) As a result of
the water already in the system, (each pre-filter= 1 litre, each membrane= 1.5 litres) together with
these 10 litres, the result will now be the maximum permitted concentration of 0.5% by weight.
A level teaspoon corresponds to 5 grams Biocide (Natriummetabisulfit).
6) Switch on the feed pump and the high-pressure pump. Let the Biocide circulate through the
system for about 2-3 minutes. Perform possibly exiting the test outlet liquid back into the
preservative tank.
7) The Biocide in the tank can be discharged overboard after turning the three-way valve (no. 4). It
should be noted that the system gets no air. Switch pumps off.
KC 150 max. 75 gr. KC 240 max. 90 gr.
KC 190 max. 82 gr. Amount of biocide
Note: For preservation times of approx. 2 months, half of the chemical is sufficient.

11
Long term preservation (mothballing) of the plant (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.
A standard 1/2” hose can be used for this purpose, which should be fitted onto the HP threaded
connector of the high pressure pump to drain the water out into a bucket. Then drain the all the water
from the pump, which is important if there is a risk of frost, if possible it is also preferable to blow
pressurized air through it in the direction of flow, for this purpose remove the sea water intake hose
from the HP pump.
Leakage of the preservative liquid from the pressure pipes is harmless. It is important that membranes
with the preservative liquid are well moistened and can not dry out.
Caution:
At every recommissioning after cleaning or mothballing, divert the product water over the test-outlet for
the first 30 minutes to rinse the chemical completely out of the system.
Flow diagram long term preservation (mothballing) and cleaning
Attention: Working pressure 0 bar.

12
Membrane cleaning. Working pressure 0 bar!!!
Description:
When the fresh water production decreases more than 15 %, the membrane should be cleaned
chemically.
Caution:
Cleaning chemical no. 1 is alkaline and cleaning chemical no. 2 is an acid. Please consider the hazard
notes on the canisters. Working with chemicals, please wear protective glasses, breathing protection
and rubber gloves for your own safety. Do must not mix different chemicals.
Follow instructions below to avoid that chemical get into your fresh water tank.
Instruction for cleaning
Cleaning of membranes. Working pressure 0 bar!!!
Attention:
Make sure that you follow the following instructions carefully so that no cleaning chemical gets into
your fresh water tank.
1) Close the seawater intake valve.
2) Open the pressure control valve entirely, turn the product water three-way valve (no. 2) to
position test-outlet to avoid that chemicals get into the drinking water tank.
3) Rinse the system with fresh water as described in “Fresh water flushing”.
4) Turn the 3 three-way valve (no. 4) according to the flow diagram “Long term preservation
(mothballing) of the plant”. Open valve (no. 1).
5) Blend about 10 liters warm chlorine-free fresh water, temperature app. 25° Celsius (77°
Fahrenheit), with chemical no. 1 (Alkaline), according to the instructions on the package. Since
there are about 1,5 litres of water already in each membrane and 1 litre of water in each filter,
please add the according amount of chemical to the water that has to be blended in every
membrane and filter.
6) Switch on the feed pump and the high-pressure pump. The unit is run for about 5 minutes to
circulate the solution through the membrane. Temperature of the solution must not exceed more
then 45° Celsius. Then allowed to rest for an hour, and then run again for 5 minutes. Perform
possibly exiting the test outlet liquid back into the preservative tank.
7) The chemical in the tank can be discharged overboard after turning the three-way valve (no. 4). It
should be noted that the system gets no air. Switch pumps off.
8) After this, the system is put back into service, unpressurized, and run for 15 minutes or so to
clear out the cleaning solution, before being returned to regular service. Once again, the initial
product water will need to be discharged for 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).
Attention:
Prior to a longer period of shutdown, the Aquatec has to be preserved with Biocide after cleaning and
flushing.
Caution:
At every recommissioning after cleaning or mothballing, divert the product water over the test-outlet for
the first 30 minutes to rinse the chemical completely out of the system.

13
Installation guide page 1
Note:
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 soon as possible.
Installation of the plant:
Install the plant horizontally and safe on a flat and vibration-free underlay. Install the high-pressure
pump in a dry area which allows an exchange of air necessary for cooling the motor-pump unit. It
should be easily accessible roundly to make service and inspection work as comfortable as possible.
Caution:
Hose connections below the water line should secured with 2 hose clamps.
All hose clamps must checked time to time and tighten if need.
During assembly of the hose nozzles and fittings, few windings of Teflon-tape have to be wrapped
around the screw thread against screw direction as tightly as possible. The grommets may not be
screwed too tightly in the filters or valves. If possible, install hoses moved upward from the thru-hull
fitting to the filters and up to the high-pressure pump. This will prevent accumulation of air in the
hoses.
Thru-hull fitting, Strainer and feed pump
The thru-hull fitting, coarse filter and the feed pump have to be located in an area that will always be
under the waterline when the boat is used under normal running conditions. Install the feed pump
close as possibly to the thru-hull fitting.
Install a thru-hull fitting and sea-cock, preferably deep under water line. The best place is about mid-
ships behind the keel.
Install afterwards a coarse filter for protection the feed pump. To avoid mechanical stress, do not
mount the strainer directly to the sea-cock.
The feed pump must be flooded before turn on, otherwise the bearings will be destroyed by drought.
The system has to be fully de-aerated by means of the feed pump. To allow any air to escape, switch
the pump on and off few times and open air release valve at pre filter.
Mounting position of the feed pump
OK OK not permitted
Caution:
Do not connect the feed pump directly to a filter
housing, tap or similar.
Only connect to other components with the enclosed hose
nozzles and hose.
The following installation position must be observed in
order to make it difficult to set deposits and to allow the
escape of air.
Note:
Depending on the type of boat, there might occur problems with the seawater intake at a speed of
more than about 8 knots.
Depending on the used thru-hull fitting, hull shape and speed, the inflow of seawater can be hampered
or even be impossible. Damages to the plant due to insufficient or missing seawater inflow will not be
covered by the warranty or guarantee.
Connection of the seawater inflow
Connect the feed pump with a hose 3/4“=19 mm inner diameter to the access (A3) of the plant.

14
Installation guide page 2
Connection concentrate (brine)
Connect the access (A4) of the plant to a thru-hull fitting on-board with a hose 1/2“=13 mm inner
diameter.
Attention: This thru-hull fitting has to be located above the waterline and must not be closable. The
material for the thru-hull fitting may not be made of acetal.
Product water
Connect the product water-connection (A1) with the drinking water tank on-board. Connect the product
water-connection (A2) with the test outlet on-board.
Hose 1/2“ = 13 mm inner diameter.
Advice:
A good place for the test-outlet is the sink or basin, where it can be installed by an additional water
outlet without cut off cock.
At this position, an easy control of the product water is possibly, furthermore you can bottle your
drinking water here directly. This ensures that the quality of the drinking water will be best, since it
does not have to follow a detour over the drinking water tank on-board.
Hose connection
Nr. Anschlussbeschreibung Hose inside diameter
A1 On-board water tank 1/2" = 13 mm
A2 Test outlet and filling of trinking bottles 1/2" = 13 mm
A3 Feed, comming from feed pump 3/4" = 19 mm
A4 Concentrate ( Brine) Drain overboard 1/2" = 13 mm
A5 Onboard pressure water system 1/2" = 13 mm
A1
A2
A3
A4
A5

15
Installation guide page 3
Attention:
If the inlet is installed below the tank waterline chlorinated water (that possibly entered the tank at the
last shore water fill up) might flow back from the tanks into the membranes. As chlorine destroys the
R.O. membranes, a return flow from the tank has to be avoided. A return from the water tank is not
possible if the 3-way valve no. 2 in the control panel is switched to the teat outlet postion. A non-return
valve must not be used.
Fresh water flush:
Connect your pressurized water system on-board with the charcoal filter of the plant with the
connection (A5). Hose 1/2“=13 mm inner diameter.
Attention: The maximum pressure in the inlet (seawater, fresh water flushing) must not exceed 2.5
bar. If necessary install a pressure reducer.
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.
If necessary, the tank can be provisionally connected and
stored separately if necessary.
Note: Hose Nr.7 not required for AC 65 and AC 110.
For pressure equalization, you find a 2 mm hole in the center of
the tank cover.
An oblique mounting from the tank allows complete emptying
(1) Flow to valve no. 1
(2) coming from pressure valve
(3) over board
(4) Three- way- valve no. 4
(5) 13 mm hose connection.
(6) Webbing tank mount.
(7) Shown short hose No. 7 must
be installed to avoid air-bubbles
during circulation.
Note: Hose Nr.7 not required for AC 65 and AC 110

16
Electrical connection
Caution:
It is obligatory that an electrician has to make the connection. Incorrect connection is dangerous to life.
In the connection box of the motor, there are 2 short cables (brown and blue). These cables are left
from the test run and show the right connection. Remove them before connecting the new cables.
Connection cables, fuses and possibly necessary on-board main power switch of the distribution on
board to the system are not included in the scope of delivery and have to be supplied on-board.
Required cable cross-sections up to 15 meter cable length, longer wires have to be enlarged:
From board’s main distribution to the junction box:
230 Volt 50 Hz: 3 G 2.5 mm² (AWG 13) / 115 Volt 60 Hz: 3 G 10 mm² (AWG 7)
400 Volt 50 Hz: 3 G 1.5 mm² (AWG 15)
From the junction box to the motor high pressure pump:
230 Volt 50 Hz: 3 G 2.5 mm² (AWG 13) / 115 Volt 60 Hz: 3 G 10 mm² (AWG 7)
400 Volt 50 Hz: 3 G 1.5 mm² (AWG 15), direction of rotation arbitrary.
Supply line from the junction box to the feed pump: 3 G x 1 mm² (AWG 17)
Fuse:
230 Volt 50 Hz, 16 Ampere
115 Volt 60 Hz, 32 Ampere
230 Volt Circuit diagram for Aquatec- Watermaker KC 150 / KC 190 / KC 240

17
Electrical connection
400 Volt Circuit diagram for Aquatec- Watermaker KC 150 / KC 190 / KC 240
3 phase 400 Volt motor star circuit connection
AC motor connection diagrams.
Single phase motor 230V 50 Hz. Run capacitor
(C) without start capacitor.
Single phase motor 230V 50 Hz Run capacitor
(C) and start capacitor (CS)
Three-phase motor 400/440V 50/60 Hz.
Star circuit connection.
Direction of rotation is CLOCKWISE as seen on
the drive-end.

18
Maintenance
Daily control if there are possible leakages or if the oil has a whitish discoloration is necessary.
In operation, regularly check all hose connections and hp pump for leaks.
Important: Check oil level and condition
of the oil of the high-pressure pump
daily.
If condensation occurs (continuous
operation, warm environment) change oil
immediate.
Dipstick full
screwed into
crankcase
Öl level
Filter Maintenance Time interval
Coarse filter Cleaning as required
Prefilter Replacement of filter elements as required
Charcoal filter Replacement of filter element every 3 months
High-pressure
pump
up to 25°C engine oil SAE 10-40
over 25°C and continuous duty:
gear oil SAE 80W-90
quantity 0,36 litre = mid sight glass
initial oil change after 50 hours, then
Every 300 operating hours at the latest
or once a year. Eearlier when the oil
gets a white color by condensation
water.
Service pressure regulation valve.
Maintenance is limited to cleaning and silicone
grease lubrication after 12-24 months.
The O-ring (5) has only to be changed in case
of leakage.
To take the pressure pin out of the valve body,
unscrew the adjusting knob (1). Then take off
the spring (2) with pressure disk (3). Now you
see the pressure (4) pin with a M3 tapped hole
and pull it out by screwing in a M3 screw.
Service high-pressure pumpe
To work comfortable on the pump head of the
HP pump in case of a leakage, the electronic
box can be taken out forward out of the front
plate. For this, just loosen lightly 2 screw nuts
wrench size 8.
The screw nuts are located on the left side of
the box behind the front plate, easily accessible
after you have taken off the charcoal filter.
The electronic box can be fixed above easily,
e.g. with a hammer as you see on the picture,
so that it doesn’t disturb the work.
Position retaining nuts of the electronic box

19
Replacement of membrane
Attention !!!
The membrane is preserved with a chemical. During unpacking and inserting, please wear protective
gloves for your own safety. On contact with the preservative liquid, the affected skin areas have to be
rinsed thoroughly with water.
Important:
To avoid that the new membrane dries out, it may only be removed from the plastic packaging just
before commissioning the plant. The manufacturer's label on the membrane must not be removed.
Before installing a new membrane, the accompanying rubber
V-cup seal must be mounted on the side of the planned sea
water entry. (Depending on the manufacturer, the ring could
already be mounted.)
In doing so, the open side of the V-ring must point toward the
sea water entry side.
For easy installation, all sealing rings and membrane
connectors should be greased with a light coating of glycerine
or Vaseline.
Demounting the membrane:
For demounting the membranes, screw off the M6x20 screws each at both ends at the AQUATEC
pressure vessel. (Screw tightening torque for the holding clips 3 Nm). Then take off the stainless steel
holding clamps. 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.
The membrane has to be shoved out of the pressure pipe in flow direction of sea water, because the
dihedral rubber V-ring of the membrane prevents lateral movements against the flow direction.
According to this, during assembly, the membrane has to be shoved into the pressure pipe in flow
direction. When mounted, necessarily watch the O-rings to avoid damage. Before installation of the
membranes, first fit the end cap on the side of the concentrate in order to thereupon shove the
membrane against this cap.
Note:
The product water connection can be located on any side of the pressure tube and is independent of
the flow direction seawater.
The product water connection can be located on any side of the pressure tube and is
independent of the flow direction seawater.
seawater
product water
concentrate
(
brine
)
R
ubbe
r V-
cup
sea
l
,
th
e
ope
n
s
i
de
m
us
t
p
o
int t
o
w
a
r
d
th
e
sea
w
a
t
e
r
e
ntr
y
s
i
de
.

20
Troubleshooting
Noisy operation, vibrations, unsteady pressure.
Air in system **
Intake clogged
Prefilter dirty
Feed pump defective
Valve defective or soiled ***
Pressure regulation valve dirty
Bleed system **
Clean intake
Clean or replace filter
Replace feed pump
Open valve caps and check valves, replace valves ***
Clean valve
Production falls
Less voltage
Membrane defective or dirty
Check voltage direct at motor connections
Clean or replace membrane
Motor does not turn / Motor drones
Motor drones
No voltage, fuse defective
Motor protection switch activated due to overload
Motor protection switch activated, no overload
Open pressure-valve, motor capacitor defective
Check voltage, replace fuse
Reduce pressure
Adjust or replace motor protection switch
Motor protection switch located inside connection box
Oil eakage between pump head and crankcase
Crankcase gasket rings defective Replace gasket rings
Water leakage between pump head and crankcase
Plunger(s) defective / o-rings plunger defective
HP / LP seals defective
Replace plunger(s)/ replace o-rings
Replace seals
Water in pump case
High humidity (mostly), wrong oil. Reduce oil change interval, use right oil
** 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.
*** None or large fluctuations in pressure,
simultaneously loud noise and a strongly vibrating
high pressure hose are indications of usually a
disturbed inlet with air in the system, also a
defective or only dirty valve of the high-pressure
pump is possible. The fault is in one of the 6
valves in the pump head.
Which of the 6 valves is causing a problem is not
visible from the outside.
To repair the error, the 6 hexagonal 22 mm or 19
mm screws must be unscrewed with a wrench to
take out the valves.
Since the smallest, barely visible piece of dirt can
lead to this problem, it is often the case that no
visible dirt can be seen. Often, dismantling and
reassembling the valve is enough to resolve the
failure. Occasionally, the valve must be replaced
even though no fault can be seen.
This error may also occur after prolonged
downtime. Before the valves are removed, it
sometimes helps to operate the system at lower
pressure for several minutes to remove the dirt.
Note: Possibly, the pressure control valve can
also be dirty.
Note: Grease the thread of the valve screws with metal-free anti seize paste for stainless to prevent
seizure.
serial numbe
r
Valve screw
O-
r
in
g
Valve bod
y
Valve s
p
rin
g
Valve
p
late
Valve seat
O-Rin
g