Aquatec DD 500 User manual

Technical Manual
for installation, operation and maintenance of
Modular DD 500, 12 or 24 Volt
Version 68 - 02.2023
Download latest manual at:
www.aquatec-watermaker.de/downloads_E.html
In case of doubt, the German ori
g
inal manual applies.
AQUATEC- Water maker,
Manufacture and distribution b
y
North-Marine Handels GmbH
Papenre
y
e 61, D 22453 Hambur
g
.
Contac
t
sup
@
aquatec-watermaker.de, Tel: +49
(
0
)
40-36850306
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 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.

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.
Recommendation for using your Aquatec reverse osmosis system.
Daily use is preferable to a one-time weekly use.
The system produces 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.
Scope of delivery Seawater R.O. AQUATEC DD 500:
• Pump head duplex stainless steel 1.4462
• Pressure regulation-valve duplex stainless steel 1.4462
• Stainless-steel High-pressure gauge
• Stainless-steel Low-pressure gauge for feed flow
• Efficient feed pump
• Control panel cpl. mounted
• 2 pieces stainless-steel high-pressure fittings for self- assembly
• Detailed manual in German or English
• 10-liter tank for preservation and cleaning
Connection cable, through-hull fittings and sea cock must be provided on-board.
See last page for complete part list.
Option: Cruising kit DD 500
4 filter-cartridges 5 Micron, 2 filter- cartridges charcoal.
Detergents: Acid, Alkaline, Biocide (500, 400, 600 Gr.) for preservation and cleaning.
1 set low- and high-pressure gasket for hp pump,
1 set of hp pump valves (6 pc.).
O-ring spare part kit for hp pump and membrane.
This option eliminates the smaller amount of biocides included in the standard delivery.

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.
Furthermore, this instruction must always 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.
Please note the following information.
Wa
r
nin
g
!
Damage to pumps and system parts due to dry running or insufficient water supply are
not covered by warranty.
Wa
r
nin
g
!
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, thereby
endan
g
erin
g
the life of the people on board.
Warning!
The maximum working pressure of 55 bar (800 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.
Wa
r
nin
g
!
The installation of the hoses to the components of the system must be carried out in
compliance with the bending radii without stress and vibration (risk of breakage).
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 installin
g
and usin
g
the Watermaker as soon as possible.

4
Table of contents
2 Scope of delivery
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 Important: Inspection - maintenance - oil change
21 Change of membranes
22 – 23 Troubleshooting
24 – 27 Exploring diagram high-pressure-pump
28 Exploring diagram regulation-valve / HP-pump motor
29 - 30 Specification Dimensions
31 Part Lis
t

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 cleaning of the membranes with the cleaning
chemicals.
Placing into operation
Attention!
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
operation, warm environment
)
, chan
g
e the oil immediatel
y
.
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, “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 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.
8) Important: During operation, check the entire system for leaks and smooth running. Operation is not
permitted if the s
y
stem is in a fault
y
condition.
Wa
r
nin
g
!
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
(
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/ 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, 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%
Note: Hose connections for high pressure pump can
be made on the left, right or diagonally (as shown).
Inlet seawater at the bottom, high pressure at the top.

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
)
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:
If there is no chlorine present in the fresh water tank, 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. Note: the onboard fresh water pump must provide sufficient flow. Performance
flow DD 500 ca. 3,3 litre/ 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!
HP- Pump always pressureless!!! (Pressure control valve (5) open).
The only application with working pressure is the production of product water.
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
(
10
)
Seacock
Note: Hose connections for high pressure pump can
be made on the left, right or diagonally (as shown).
Inlet seawater at the bottom, high pressure at the top.

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.
Attention!
Before preservation and longer downtime. The oil of the high-pressure pump must be
changed in order to remove any possibly existing condensation water from the oil. This
prevents corrosion of the bearin
g
s and surface of the crankshaft
Warning!
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
g
loves for
y
our own safet
y
.
Note!
If there any risk of frost, the entire pressure pipe with internal membrane in the pipe
should be dismounted (after preservation) and be stored frost-proof with closed hose
connections. The liquid present in the pressure pipe can be drained. Can the
membrane not be removed alternatively 20%- 50% glycerin in food quality can be
added as an antifreeze to the biocide at preservation (glycol is not permitted as
antifreeze). The plant has to be drained (filter housings, pumps, hoses). Remove filter
cartrid
g
es.
Instruction for mothballing.
Wa
r
nin
g
!
Make sure that you follow the following instructions carefully so that no cleaning
chemical gets into your fresh water tank.
Note!
HP- Pump always pressureless!!! (Pressure control valve (5) open).
The only application with working pressure is the production of product water.
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 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 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.
Wa
r
nin
g
!
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
Note!
HP- Pump always pressureless!!! (Pressure control valve (5) open).
The only application with working pressure is the production of product water.
Note: Hose connections for high pressure pump can
be made on the left, right or diagonally (as shown).
Inlet seawater at the bottom, high pressure at the top.

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 safety. Do must
not mix different chemicals.
Instruction for cleaning of membranes.
Wa
r
nin
g
!
Make sure that you follow the following instructions carefully so that no cleaning
chemical gets into your fresh water tank.
Note!
HP- Pump always pressureless!!! (Pressure control valve (5) open).
The only application with working pressure is the production of product water.
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) 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 and pour it into the tank for
conservation. (To avoid negative pressure, do not close the cap tightly) Since there are about 1,5 litre 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 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.
Wa
r
nin
g
!
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
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 fittings may
not be screwed too tightly 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!
Observe flow direction. 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!
Observe flow direction. The feed pump is not self-priming and must be flooded before switching
on, otherwise the bearing will be destroyed by dryness.
To allow air to escape, switch the pump on and off several times and, if necessary, open the
vent valves on the prefilter.
If necessary, remove the high-pressure hose to the membrane at the high-pressure pump and
close it again after the water has escaped while the feed pump is running. This also ensures that
the HP pump is filled with water.
The system can also be vented by flushing with fresh water.
If necessary, refer to the further notes under Troubleshooting.
Mounting position of feed pump
Warning!
A flexible hose and the enclosed hose fittings must be used to connect the
feed pump to other components (risk of breakage).
Care must be taken to ensure that the installation is free of tension and
vibration.
Permissible system pressure for fresh water flushing 2 bar max.
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
polarit
y
destroys the pump and is not covered by warrant
y
.
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 guarantee.
Filter housing: Observe flow direction. Mount the filter housing and feed-pressure gauge as vertically as
possible, head of filter-housing at the top in an easily accessible location. For a good seal of the filter housing,
grease the O-rings of the filter pots with acid-free silicone grease or Vaseline. Use a PVC hose to connect
the filter inlet to the outlet of the feed pump and the filter outlet with the mounted feed-pressure gauge to the
high-pressure pump. The feed-pressure gauge can also be mounted anywhere between the filter housing
outlet and the HP pump inlet.
Secure all hose connections with stainless steel clamps.

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
Warnung!
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.
For hose connection note flow-diagram (operation of plant).
Attention!
After mounting, replace the yellow or red plastic-screw on top of the crankcase with the
oil dipstick with ventilation.
Depending on the installation situation, the hose connections of the high-pressure pump can be
freely selected. Left, right or diagonal are possible. Seawater inlet at the bottom, high-pressure
connection at the top. Please refer to the flow diagrams.
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 must be at the top. For
horizontal installation, the fresh water outlet can be mounted at any side of the
membrane housing.
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.
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 flexibl
y
.
Note: In case of connection problems, we optionally supply 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) Wet the inside of the hose with a lubricant e.g. Dishwashing liquid.
3) 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.
Attention!
The hose nipple threads are treated with metal-free anti- seize paste for stainless steel
on delivery. This prevents seizing of the threads when being screwed together.
4) Hold the sleeve nut with a wrench and screw the thread nipple with a second wrench into the hose.
5) 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.
6) 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-ring sealing 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.
(
1
)
(
2
)
(
3
)
(
4
)
(
5
)
Hose connections on the control panel
(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 as vertically as possible, pressure gauge on top. Optimal accessibility from the rear
for connection and regular control of the hose connections.
The control panel can be installed into a wall, or it can be mounted in front of a wall or vertically free-standing
by using the brackets to be provided on board.
Fresh water flushing system
Observe flow direction. Mount the filter housing for the charcoal filter as vertically as possible in an
easily accessible location between your fresh water pressure system and the valve (3). Install the
hose connections according to the flow diagram.
Warning!
In order to avoid damaging the feed pump during fresh water flushing via the onboard
pressurized water system, observe the permissible system pressure of 2 bar.
A pressure reducer may need to be installed in front of 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.
Wa
r
nin
g
!
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.
Wa
r
nin
g
!
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, up 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.
Attention!
In order to avoid unnecessary back pressure in the product water line, only use the
blue 3/8 "product water pipe up to a length of approx. 6 m. If necessary, use the
supplied adapters from the PE pipe to a 13 mm PVC hose.
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
Warning!
Danger for life! It is obligatory that an electrician has to make the connection. Incorrect
connection is dangerous to life.
Warning!
Danger for life! For the connection of the cables, suitable press cable lugs and the correct
pressing tool must be used.
Warning!
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.
Total length 12V / 24V
5 metres 10 / 6 mm² (AWG 7 / 9)
10 metres 16 / 10 mm² (AWG 5 / 9)
15 metres 25 / 16 mm² (AWG 3 / 5)
20 metres 35 / 16 mm² (AWG 2 / 5)
25 metres 50 / 25 mm² (AWG 1 / 3)
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: 40 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 12 volt
10- 24 VDC 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
Inspection – maintenance – oil change
Attention!
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
operation, warm environment
)
, chan
g
e the oil immediatel
y
.
Attention!
Regularly check hose connections and HP pump for leaks. During operation, check the entire
system for possible leaks and smooth running.
Operation is not permitted if the system is faulty.
Select the high-pressure pump of your plant
High-pressure-pump type 1, crankcase color grey. Serial number from S21001
First oil change after 50 hrs, any condensed water, change the oil immediately, then every 200 hrs or after 6 months at
the latest.
Oil type: Gear oil ISO VG 220, alternatively automotive gear oil SAE 90 GL4.
Oil change instruction
of high-pressure pump:
The oil can be drained via the drain plug at
the rear of the crankcase. The drain plug
(wrench size 19 mm) or Hexagon socket 8
mm under the crankcase. Sealed of copper
ring.
Alternatively, the oil can be extracted
through the oil dipstick opening using a
suction pump.
Dipstick full screwed
into crankcase
.
Oil level
Slightly below center
sight glass
Quantity
0,24 Liter
High-pressure-pump type 2, crankcase color black.
Serial number from 201000 to 202085 or B201000 to B202073
First oil change after 50 hrs, any condensed water, change the oil immediately, then every 200 hrs or after 6 months at
the latest.
Oil type: Gear oil ISO VG 220, alternatively automotive gear oil SAE 90 GL4.
Oil change instruction
of 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). Sealed by a reusable
O-ring (10.82 x 1.78 NBR 70).
Alternatively, the oil can be extracted
through the oil dipstick opening using a
suction pump.
Dipstick full screwed
into crankcase
Oil level
center of
sight glass
Quantity
0,36 Liter
Filter Maintenance Time interval
Coarse filter Cleaning as required
Prefilter Replace filter elements as required, or pre-pressure seawater below 0.2 bar
Charcoal filter Replace filter element every 3 months