Aquatec DD 500 User manual

Technical Manual
for installation, operation and maintenance of
Modular DD 500, 12 or 24 Volt
Version 35 - 03.2020
Download latest manual at: www.aquatec-watermaker.de/downloads_E.html
In case of doubt, the German original manual applies.
A
QUATEC- Watermaker, Inh. Joachim Matz
Buer
g
erm.-Schinkel-Str. 10a, 25348 Glueckstadt, German
y
.
Contac
t
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.

2

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.
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 commissionin
g
. Furthermore, this instruction must alwa
y
s be available on site.
To ensure total satisfaction, please read this user manual carefully. 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.
The following symbols and their meaning must be observed throughout the manual. Please follow
the instructions and take appropriate measures.
EXPLANATION OF SYMBOLS
Warning!
Immediate danger that
can lead to serious
injury to persons or
damage to the
machine or the loss of
the vessel.
Warning!
Warnings regarding
electric power equipment.
Non-observance of safety
instructions
could lead to danger of
life or limb:
Attention!
Indicates an
instruction
that requires
special
attention.
Warning!
Aquatec Watermaker are designed for permanent installation on ships.
Operation of the system is only permitted with clean seawater.
Warning!
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,
thereb
y
endan
g
erin
g
the life of the people on board.
Warning!
The maximum working pressure of 55–60 bar (800-870 psi) must not be
exceeded.
When exceeding the specified product water quantity (seawater with lower salt
content, brackish water
)
, the workin
g
pressure must be reduced.
Warning!
Install the high-pressure pump on a stable substrate . 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.
Please note: The motors and pumps develop high temperatures during
operation. Touchin
g
it can cause burns.
Attention!
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.
It should be easily accessible roundly to make service and inspection work as
comfortable as possible.
Attention!
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.

4
Table of contents
3 Warnings / Hints
5 Introduction reverse osmosis
6 - 7 Operation
8 - 9 Shutdown, fresh water flush.
10 - 11 Long term preservation (mothballing), antifreeze
11 - 12 Membrane cleaning
13 Memos
14 - 18 Installation
19 Electrical connection
20 Maintance
21 Change of membranes
22 – 23 Troubleshooting
24 – 25 Clamping torques / Spare parts
26 Specification / Hose dimensions
27 Dimensions
/
Scope of deliver
y
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.
Important: The drinking water must be bottled from the test outlet of the system during operation,
ideally after filling the on-board water tank. Only fill the required amount until the next operation of the
plant. Clean the drinking water bottle regularly.
If the product water from the on-board water tank is used as drinking water, follow-up-treatment is
recommended. No further treatment is usually necessary as service water.

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.
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.

6
Operating instructions
Attention!
Do not operate your water maker with unpurified seawater (oil, chlorine or other
chemicals).
Warning!
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 cleanin
g
of the membranes with the cleanin
g
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.
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.
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. The gauge (no.9 Option, “pressure feed water”) must show positive
pressure. De-aerate the pre-filter system if necessary 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.
6) Increase the pressure at the pressure control valve (no. 5) 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 (55-60 bar, (800-870 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.
8
)
Inspect the whole s
y
stem for leaka
g
es.
Warning!
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.
Attention!
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
Flow diagram water production.
Hose dimensions (inner diameter) see specification
(
5
)
Pressure re
g
ulation valve
(
6
)
Flowmeter product water
(
7
)
ships fresh water pump
(
8
)
Feed pump
(
9
)
Gau
g
e feed pressure, option
(
10
)
Seacock
Attention!
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% also in the power consumption, 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
below “flushing time”.
7
)
Close valve
(
no. 3
)
to finish the fresh water flush.
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.
Attention!
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 flushin
g
rate b
y
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:
Running the feed pump and HP pump can accelerate the fresh water flushing. Thanks to the well-known
pump performance of the HP-pump, the necessary flushing time can be precisely adjusted. Performance
HP-pump DD 500, 3.5 liter / minute.
Attention!
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.
Attention!
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
(
mothballin
g)
of the plant”.

9
Flow diagram fresh water flush
Note! Flushing working pressure 0 bar!!!
Hose dimensions (inner diameter) see specification
(
5
)
Pressure re
g
ulation valve
(
6
)
Flowmeter product water
(
7
)
ships fresh water pump
(
8
)
Feed pump
(
9
)
Gau
g
e feed pressure, option
(
10
)
Seacock

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.
Warning!
The conservation chemical no. 3 is a Biocide. Please consider the hazard notes
on the canisters. Working with chemicals, please wear protective glasses,
breathin
g
protection and rubber
g
loves for
y
our own safet
y
.
Note!
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 cartrid
g
es.
Instruction for mothballing.
Warning!
Make sure that you follow the following instructions carefully so that no
cleaning chemical gets into your fresh water tank.
Note! Working pressure 0 bar!!!
1) Close the sea water intake valve.
2) The pressure control valve must be open. 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 5 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 5 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 s
y
stem
g
ets no air. Switch pumps off.
Amount of biocide DD 500 max. 37 gr. Biocide
Note! For preservation times of approx. 2 months, half of the chemical is sufficient.

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.
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 cannot dry out.
Warning!
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 s
y
stem.
Flow diagram long term preservation (mothballing) and cleaning
Note! Working pressure 0 bar!!!

12
Membrane cleaning.
Description:
When the fresh water production decreases more than 15 %, the membrane should be cleaned
chemically.
Warning!
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 safet
y
. Do must not mix different chemicals.
Instruction for cleaning of membranes.
Warning!
Make sure that you follow the following instructions carefully so that no cleaning
chemical gets into your fresh water tank.
Note! Working pressure 0 bar!!!
1) Close the sea water intake valve.
2) The pressure control valve must be open. 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 5 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 liters of water already in each membrane and 1 liter 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 10 minutes to
circulate the solution through the membrane. Temperature of the solution must not exceed more
than 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 chan
g
e 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.
Warning!
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 s
y
stem.

13
Memos

14
Installation guide page 1
Attention!
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.
Warning!
Hose connections below the water line should secured with 2 hose clamps.
All hose clamps must check 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 fittin
g
sma
y
not be screwed too ti
g
htl
y
in the filters or valves.
Thru-hull fitting, Strainer and feed pump
Install a thru-hull fitting and sea-cock, preferably deep under water line. The best place is about mid-
ships behind the keel. Install strainer and feed pump close as possibly to the sea-cock.
Attention!
To avoid mechanical stress, do not mount the strainer directly to the sea-cock.
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.
In order to avoid accumulation of air, if possible, install hoses moved upward
from the thru-hull fitting to the filters and up to the high-pressure pump.
From the sea-cock outlet to the feed pump inlet, the installation must be
horizontal or better rising. In order to stay as deep as possible below the
waterline, a 90 ° hose nozzle at the sea-cock outlet can be helpful.
Attention!
Avoid connecting to an existing inlet e.g. Main machine air conditioning.
Common operation is usually not possible because the existing hose cross-
sections prevents sufficient inflow.
Attention!
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. The system can also be vented by a
short fresh water flush.
Mounting position of the feed pump Warning! 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.
Warning!
For 24 Volt systems, the 24 V -12 V voltage transformer supplied with the feed pump
must be installed. Connection feed pump: 12 volts red = positive (+), black = negative (-
). Wrong polarity destroys the pump and is not covered by warranty.
Attention!
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
g
uarantee.
Filter housing: For a good sealing of the filter housing, please lubricate the O-rings in the filter bowls
with acid-free silicone grease.
Mount the filter housing at an easily accessible place. Connect the filter inlet with the outlet of the feed
pump and the filter outlet via PVC hose with the high-pressure pump. Secure all hose connections with
stainless steel hose clamps. Install all hose connections in a way that air accumulations are avoided.

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. If necessary, the tank can be provisionally
connected and stored separately if necessary.
For pressure equalization, you find a 2 mm hole in the
center of the tank cover.
sich eine Belüftungsbohrung 2 mm zum
Druckausgleich.
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.
High-pressure pump unit
Warning!
Install the plant horizontally (motor feed down), stable and safe on a flat and
vibration-free substrate. 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.
Wa
r
nin
g
!
After mounting, exchange the upper red plastic-screw in the crankcase for the
dipstick with ventilation
Membrane housing (pressure vessel)
For the installation of the membrane housings athwart ships, inclined or vertical, the housings have to
be secured in the retainers so that they don’t get out of place. Standard installation is horizontal, but any
other angle is possible. For an inclined or vertical installation, the product water outlet and brine outlet
have to be at the top. For horizontal installation, the fresh water outlet can be mounted at any side of
the membrane housing.
Hose connections pressure vessel
The pressure pipe is sealed with plastic-caps on the high-pressure connections. The product water
connection is closed with a plastic plug that has to be replaced by the provided screw-in fitting for product
water tube after connection of the high-pressure hoses.
This prevents a drying-out of the membrane which is impregnated with preservative liquid. The plastic-
caps and the plug have not to be removed until immediately before commissioning to connect the high-
pressure hoses and the product water hose.

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.
Warning!
The high-pressure hose must not be installed with a radius less than 60 mm.
Avoid contact points or if necessary protect the HP hose at these points against
damage and fix it flexibly.
Note: For connection problems, we supply on request individual high-pressure
hoses with pressed-on 45 ° or 90 ° connection nipples.
Assembly instruction for the stainless high-pressure hose fittings:
1) Cut the hose with a clean 90 ° cut, using, for example, a hacksaw or angle grinder with a cutting disc.
2) Screw the sleeve nut anti-clockwise onto the hose. Leave a distance of 2 mm between the hose
and the inner shoulder of the sleeve nut to allow the hose to expand in length when screwing in the
thread nipple.
3) Wet the inside of the hose with a lubricant e.g. Dishwashing liquid.
4)
Attention!
It is very important to lubricate the insert thread nipple before screwing into the
ferrule to avoid seizing of the threads (best metal-free anti seize paste for
stainless
)
.
5) Hold the sleeve nut with a wrench and screw the thread nipple with a second wrench into the hose.
6) Connect the pressure connection of the high-pressure pump and the entrance of the membrane
housing with a hose. The flow direction of the seawater is indicated with an arrow on the pressure
housing of the membrane.
7) The second high-pressure hose connects the outlet of the membrane housing with the inlet at the
pressure control valve on the control panel.
HP Hose Sleeve nut, hose
site left thread
Thread nipple
must be well lubricated
done, good and acceptable done, very good

17
Installation guide page 4
Attention!
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 with a 17 mm open-ended wrench with approx. 10 Nm. Due
to the O-rin
g
sealin
g
it is not necessar
y
to ti
g
hten the union nut with much force.
Attention!
Avoid over winding the body fittings in the plastic-end caps of the pressure pipe
when attaching the high-pressure fittings to the membrane housing. The end
caps can be dama
g
ed b
y
over windin
g
the fittin
g
s.
Connection hp hose and product water pipe:
After the connection of the self-sealing high-pressure hoses, exchange the 1/4“screw plug that seals the
one-sided product water connection in the end cap for the supplied fitting.
High pressure connection /
Product water connection
Note:
The high-pressure fittings
and high-pressure hose
connections are self-sealing
by pre-assembled O-rings.
.
Attention:
Only use cylindrical tread
fittings (¼ “BSP) in the
plastic-end caps of the
pressure vessel. Taper
threads may cause cracks.
Hose connections on the control panel (1) (2) (3) (4) (5)
(1) ¼ “High-pressure hose, concentrate coming from outlet pressure pipe.
(2) ½ “13 mm PVC hose, concentrate (brine), overboard.
(3) Product water to freshwater tank.
(4) Product water to test-outlet.
(5) Product water, coming from freshwater-outlet pressure pipe
Control panel.
Mount the control panel with vertical gauge at an easily accessible place.
It always should be possible to control the hose connections.
Fresh water flushing system
Mount the filter housing for the charcoal filter at an easily accessible place between the fresh water
pressure system and valve (3). Install the hose connections corresponding to the flow diagram.
Warning!
In order to avoid damaging the feed pump during fresh water flushing via the
onboard pressurized water system, the pressure must not exceed 2.0 bar.
It may be necessary to install a pressure reducer before the flushing
connection.

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.
Warning!
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.
Fresh water pipe
Direct the PE-fresh water pipe from the fresh water outlet at the membrane housing to the inlet at the
flow meter in the control panel.
From the three-way valve (no. 2), direct one pipe to the test-outlet and one pipe from the outlet to the
fresh water tank.
Warning!
Never block the product water line (valve etc.). This damages the membrane
and leads to bursting of the product water line.
EASY TO MAKE A CONNECTION
Cut the tube square and remove burrs and sharp edges.
Ensure the outside diameter is free of score marks.
Push the tube 20 mm into the fitting, to the tube stop.
To disconnect, ensure the system is depressurized,
push the collet square against the fitting. With the collet
held in this position the tube can be removed.
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.
Attention!
If the product water 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 test outlet
position.
A
non-return valve must not be used.

19
Electrical connection
Wa
r
nin
g
!
Danger for life! It is obligatory that an electrician has to make the connection.
Incorrect connection is dangerous to life.
Wa
r
nin
g
!
Danger for life! For all work on electrical components, the entire system must
be switched off and a message must be left on the shutdown device.
Note: As the output power of the plant depends on the
tension of the driving motor, in the
calculation of the wire cross sections a voltage drops of
maximum 4% should be estimated to provide for the
maximum continuous output.
The required cross section in mm² refers to the cable
total length which results from the addition of the plus
and minus cable lengths.
mm² 12V / 24V
5 10 / 6
(
AWG 7 / 9
)
10 16 / 10
(
AWG 5 / 9
)
15 25 / 16
(
AWG 3 / 5
)
20 35 / 16
(
AWG 2 / 5
)
25 50 / 25
(
AWG 1 / 3
)
Total length in meter there and back
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
6 - Switch relay high-pressure pump
7 - High current relay
8 - High pressure pump, connection red=
positive +, pump turns clockwise.
9 - Feed pump
Supply line for the switches feed pump and relay control
1,5 to 2,5 mm²
Connecting cables are not included in scope of delivery.
Switches in the control panel, high current relay, fuse
holder and fuses are included.
Electrical connection for 24-volt systems
Wa
r
nin
g
! Install the supplied 24VDC to 12 VDC converter for 12-volt DC feed pump
1 - Battery
2 - Fuse for high-pressure pump
(DD 500 = 24 V: 35 A)
3 - Car fuse for control and feed pump 5 A
4 - Aquatec operator panel
5 - Switch feed pump
6 - Switch relay high-pressure pump
7 - High current relay
8 - High pressure pump, connection red=
positive +, pump turns clockwise.
9 - Feed pump 12 volt
10- 24VDC to 12 VDC converter for feed pump
Supply line for the switches feed pump and relay control
1,5 mm²
Connecting cables are not included in scope of delivery.
Switches in the control panel, high current relay, fuse
holder and fuses are included.

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
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
middle of
crankcase
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.
Instructions for changing the oil of the high-pressure pump:
The oil can be drained via the drain plug at the rear of the crankcase. The drain plug (wrench size
17 mm) is sealed with a reusable O-ring (10.82 x 1.78 NBR 70).
A
lternativel
y
, the oil can be extracted throu
g
h the oil dipstick openin
g
usin
g
a suction pump.
Service pressure regulation valve.
Maintenance is limited to cleaning and silicone
grease lubrication after 12-24 months.
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). 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.