ECH2O Tec. MODULAR AC Series User manual

MODULAR AC SERIES
390-AML-1 / 430-AML-1 / 690-AML-2 / 780-AML-2
1200-AML-2 / 960-AML-2S / 1300-AML-3S / 1500-AML-4
310-AMS-2 / 510-AMS-3 / 910-AMS-4
OWNERS MANUAL
PAGES
2
Introduction
3
Specifications
4-5
Standard System Features, Options and Accessories
6
Flow Diagram
7-10
Installation Instructions
11
Installation Instructions Options
12-13
System Operation, Shut Down and Flush Procedure
14
Membrane Storage and Cleaning Procedure
15
Maintenance Timetable
16
Troubleshooting Guide
17
Membrane Element and End Plug Service Instructions
18-20
High Pressure Pump Service Instructions
21-22
Warranty

2
INTRODUCTION
ECHO MARINE LTD.
1st Avenue South, Chaguaramas, Trinidad W.I.
Telephone: [phone] Fax: [phone]
E-mail: [e-mail]
www.echotecwatermakers.com
Rev.9.2015
Congratulations on the purchase of your ECHOTec Watermaker. We trust that you will be
completely satisfied with our product. We thoroughly bench test every desalination system
before shipping and are confident that we have manufactured the finest watermaker on
the market.
Your watermaker will provide you with clean and safe drinking water for many years to
come if you follow the simple instructions in this owners’ guide. The purpose of this manual
is to allow you to become familiar with each component of your new ECHOTec
Watermaker.
By understanding the function, importance and normal operation of each part in the
system, the operator can readily diagnose problems when they first develop. Such
problems are easily corrected and require minor adjustments. If left unattended, a small
problem in one component may affect the rest of the system and can lead to an expensive
repair.
If you have any questions regarding the installation, operation or maintenance of your
watermaker please contact us. We are always happy to assist!

3
SPECIFICATIONS
RATED PERFORMANCE:
ECHOTec Model
Gallons per hour
Liters per hour
390 –AML –1
18
70
430 –AML –1
20
76
690 –AML –2
29
110
780 –AML –2
31
120
960 –AML –2S
38
145
1200 –AML –2S
50
190
1300 –AML –3S
55
210
1500 –AML –4
70
260
310 –AMS –2
17
65
510 –AMS –3
25
95
910 –AMS –4
37
140
Reverse Osmosis performance varies with the feed water temperature and salinity.
The rated performance is tested at 26C / 80F water temperature and 33g NaCl/ltr.
RO MEMBRANE TYPE:
Standard size high rejection TFC Polyamide, thin film composite, spiral wound, single pass reverse osmosis
element.
PRODUCT WATER QUALITY: minimum 500 ppm TDS
FEED WATER SALINITY RANGE: up to 50,000 ppm TDS ( NaCl )
CHLORINE TOLERANCE: 1000 ppm hours
FEED WATER PRESSURE: 5”Hg to 60 psi
OPERATING PRESSURE: 800 to 850 psi
FEED WATER TEMPERATURE RANGE: min. 33F / 0.5C, max 113F / 45C
ELECTRICAL POWER REQUIREMENTS:
ECHOTec Model
amps @ 115V /60Hz
amps @ 230V/60Hz
amps @ 230V/50Hz
390 –AML –1
n/a
n/a
4.2
690 –AML –2
n/a
n/a
4.2
430 –AML –1
8.4
4.2
n/a
780 –AML –2
8.4
4.2
n/a
960 –AML –2S
12.9
6.5
8.0
1200 –AML –2
16.4
8.4
9.5
1300 –AML –3S
12.9
6.5
8.0
1500 –AML –4
16.4
8.4
9.5
310 –AMS –2
8.4
4.2
4.2
510 –AMS –3
8.4
4.2
4.2
910 –AMS –4
12.9
6.5
6.5

4
STANDARD SYSTEM FEATURES
1) PVC sea strainer with bracket and barbed hose connections
2) Pre-Filter/s complete with service valve and bracket/s, 20 micron cartridge (5 and 20 micron with
Optional boost pump)
Filter wrench
3) High-pressure pump unit
4) Pressure vessel/s with reverse osmosis membrane element/s on mounting bracket
390 –AML –1
one
40” vessel
430 –AML –1
one
40” vessels
690 –AML –2
two
40” vessels
780 –AML –2
two
40” vessels
960 –AML –2S
two
40” vessels
1200 –AML –2
two
40” vessels
1300 –AML –3S
three
40” vessels
1500 –AML –4
four
40” vessels
310 –AMS –2
two
21” vessels
510 –AMS –3
three
21” vessels
910 –AMS –3
four
21” vessels
5) Stainless steel control panel completely assembled with
1 Pressure control valve
1 High pressure gauge
1 Product flow meter
1 Diverter (3-way) valve
1 Low-voltage breaker (without boost pump) or
2 Low-voltage breakers (with boost pump) wired with
6 feet cable to pump motor controller box
6) Pump motor controller box for main power and pump connections
7) Hardener / pH neutralizer kit with mineral element with stainless bracket and fittings
8) 15 feet / 4.5 meter high pressure hose with 2 x stainless steel high pressure fittings attached
2 x stainless steel field attachable high pressure fittings
9) 20 feet / 6 meter 3/8” blue product water tubing
10 feet / 3 meter 5/8” wire coil reinforced hose (without boost pump only)
10 feet / 3 meter 1/2” braided hose + 3 feet 5/8” wire coil reinforced hose (with boost pump)
10 feet / 3 meter 1/2” braided reject hose
10) 8 x 3/4” Stainless steel hose clamps and
9 x 5/8” Stainless steel hose clamps (with boost pump) or
9 x 3/4” Stainless steel hose clamps and
3 x 5/8” Stainless steel hose clamps (without boost pump)
10) Handheld TDS Meter
11) 1 Membrane storage solution
2 Membrane cleaning solutions

5
OPTIONS AND ACCESSORIES
If the high-pressure pump is installed less than 1 foot below the waterline or an additional 5micron pre-
filter is added, the installation of an optional boost pump is recommended. The boost pump also extents
pre-filter element life, reduces maintenance and assists in priming the system after pre-filter changes.
Boost pump with intake hose barb, outlet hose barb, 4 feet / 1.2 meter wire reinforced intake hose, 10 feet
/ 3 meter braided feed hose, 5 micron pre-filter option.
5 Micron Pre-filter Housing (1 filter housing, 1 pre-filter cartridge, 1 bracket, 1 3/4” NPT nipple)
An additional 5 micron pre-filter is only recommended in connection with the optional boost pump.
Note: The 5micron filter must be installed as a second filter in flow direction
Maintenance Kit
10 Pre-filters, 5 and/or 20 microns
1 Spare sea strainer screen
2 Active carbon filters (fresh water flush)
1ltr. High pressure pump oil
Extended Maintenance Kit
1 Acid cleaning compound
1 Alkaline cleaning compound
2 Storage compounds (Biocide)
1 Complete spare seal and O ring kit (except high pressure pump)
Fresh water flush kit for installation with boost pump
(filter housing, charcoal cartridge, stainless steel
bracket, 8 screws, shut off valve, 2 x 5/8” hose barb
connectors, 5/8” tee, 10ft 5/8” braided hose, 5 x 5/8”
hose clamps)
Fresh water flush kit for installation without boost
pump (filter housing, charcoal cartridge, stainless steel
bracket, 8 screws, shut off valve, 2 x 5/8” hose barb
connectors, 3/4” x 1/2” tee, 10ft 1/2” braided hose, 3 x
5/8” hose clamps, 2 x 3/4” hose clamps
Low pressure gauge
The low pressure gauge indicates when the pre-filters have to be
changed. Select pressure range according to freshwater pressure.

6
FLOW DIAGRAM
Shown with Optional Equipment

7
INSTALLATION INSTRUCTIONS
HIGH PRESSURE PUMP/MOTOR UNIT
Mount the high pressure pump/motor unit horizontally in a dry and ventilated location. Maximum ambient
temperature for continuous duty is 40˚C / 104˚F.
CAUTION: Motor gets hot during prolonged operation.
PRESSURE VESSEL (MEMBRANE HOUSING)
Mount the pressure vessel(s) with the provided brackets vertical (with the flow upwards) or horizontal
in a convenient location away from the heat of the engine as close as possible to the high pressure pump.
The membrane is sealed within its housing by plugs at both ends. Inside the housing is a small amount
of preservative to keep the membrane moist and prevent bacterial growth. The shelf life of the
preservative, under best conditions, is one year.
When all other components and hoses/tubes are completely assembled, remove the caps on the high
pressure fittings and the sealed tube from the product water outlet on the membrane housing/s and
then finish making all final hose/tube connections. This will insure that the membrane is kept moist.
CONTROL PANEL
Mount the control panel preferable trough a bulkhead or on any panel in an easily accessible
location as close as practical to the membrane housing(s).

8
SEA STRAINER
Mount the sea strainer with the provided 3/4" NPT nylon nipple directly to the
intake of the 20 micron pre-filter housing. If an optional boost pump is
required (refer to “Available Options and Accessories”), mount the sea strainer
under the waterline in a serviceable location in between the sea-cock of your
choice and the boost pump.
CAUTION: To avoid excessive mechanical stress, do not mount the sea
strainer directly to the sea-cock.
Connect the barbed fittings with the supplied coil reinforced intake hose and secure all hoses below water
level with two hose clamps. Avoid air pockets in the hose run. For boost pump installation refer to the
“Installation Instructions” (Optional equipment).
FILTER HOUSINGS
Mount the pre-filter in a serviceable location and connect the bottom port of the cleaning / storage valve
with the 5/8” reinforced vinyl hose to the bottom intake hose fitting of the high-pressure pump. Secure the
hose with hose clamps.
If the optional 3/4" nylon tee with flush/storage valve is supplied, connect the 3/4" hose fitting on the nylon
tee to the bottom intake fitting of the high pressure pump.
CAUTION: Install all plumbing to eliminate any air pockets in the system.
CAUTION: Use a maximum of three wraps of Teflon tape on all threads to prevent leakage, if you have to
re-seal fittings. Always keep the tape back from the end of the fittings (at least two threads). Do not allow
any tape to enter the system.
HIGH PRESSURE HOSE
The high pressure hose has factory mounted high pressure couplings on each end (also included are two field
attachable fittings). This hose comes in a 15 feet / 4.5 m length, so it may be cut to suit your needs. Leave a
little extra length of hose to avoid stress on the system components.
CAUTION: Never bend the high pressure hose tighter than a 6”/15 cm radius.
Assembly instructions for the stainless steel field attachable high-pressure couplings
1) Cut the hose in a clean 90angle preferably with a cutting disc or fine tooth hacksaw.
2) Un-assemble the coupling (remove threaded inner part from outer part).

9
3) Rotate the socket (outer part) anti clock wise on to the hose until hose bottoms. Back the hose out
½ turn to allow for expansion of the hose during assembly.
4) Apply dishwashing liquid mixed 1:1 with water on to the nipple (inner part) of the high-pressure fitting
and the inside of the hose.
5) Hold the socket preferably in a vice and screw the nipple all the way into the hose. The straight fitting
is supplied with a hexagonal plug as an assembly tool.
Run one of the high-pressure hoses from the output of the HP pump (O ring sealed fitting) to the O ring sealed
fitting at the end of the membrane that is marked IN.
CAUTION: A minimum hose length of 3 feet / 1 m is required for pulsation dampening. The hose can be
coiled where needed.
Run the second high-pressure hose from the outlet of the RO membrane housing to the pressure control
valve in the control panel. Do not over tighten the high pressure fittings. They are O-ring sealed and need
little torque to lock only.
CAUTION: When connecting the high pressure hose to the membrane housing (s), avoid over tightening.
The fitting is O-ring sealed and does not require much torque.
PRODUCT WATER TUBING
Connect the blue product water tubing or the 1/2" vinyl hose from the center fittings of the membrane
housing(s) to the bottom inlet of the flow meter, in the control panel. Connect the tubing or hose from each
output port of the 3-way valve to your water tank and to the taste/test station of your choice.
CAUTION: Under no circumstances should the product water line be allowed to become blocked while the
system is running. Do not install shut-off valves anywhere in this line.
CAUTION: Do not allow chlorinated water from your storage tank to flow back into the R.O. membrane.
You may directly “T” your product water line into the tank vent (Refer to the Flow Diagram). This avoids
chlorinated water to back flow from your water tanks into the R.O. membrane and does not require a new
fitting in your tank. This solution requires a vent of sufficient diameter as the product water will have to flow
against the escaping air. If the product line must be installed below tank water line, an optional non- return
valve should be installed.
An existing hand pump style spigot, with a check valve only can be used as test station. If using this type of
spigot for two sources (tank and test), install low-pressure non-return valves in the tank- and product line
and “T” both into the existing hand pump spigot.

10
HARDENER / PH NEUTRALIZER KIT
THOUGH-HULL FITTING (not supplied)
ELECTRICAL INSTALLATION
The electrical installation should only be done by a professional electrician according to the local
regulations with regards to safety. Connect the main power supply, the high pressure pump and if
installed, the optional boost pump according to the attached labels.
The ECHOTec post treatment element contains a mixture of
minerals that returns bicarbonate alkalinity, correcting pH
only enough to reach a neutral equilibrium. This
dramatically reduces corrosion on metal tanks, boilers,
washing machines and plumbing due to acidic product
water.
Install the hardener / pH neutralizer housing at a serviceable
location in line with the product water tubing from the
diverter valve on the control panel to the freshwater
storage tank. (Refer to flow diagram on page 6)
Note: Observe the flow direction indicated on the housing.
REJECT WATER TUBING / HOSE (BRINE)
Connect the outlet of the pressure control valve on the
control panel with a reject thru-hull of your choice
(preferably above the water line as an indication for proper
operation of the system).
The boat’s designated intake thru-hull should be located in
an area that will always be in the water when the boat is
used under normal running conditions,
A trough hull fitting with strainer scoop could be helpful.
Installed with the opening facing the bow, it typically
generates a small amount of pressure while moving through
the water. It is important not to place the thru-hull fitting
directly forward of a speedometer pickup. It is also wise not
to place the intake thru-hull slightly aft or outboard of a
holding tank, head or galley sink overboard discharge.

11
INSTALLATION INSTRUCTION –OPTIONAL EQUIPMENT
BOOST PUMP
Install the boost pump with the electric motor sideways (horizontal) in a dry location (submergible pumps
are also available) below the water line, in between the sea strainer and the pre-filter(s). The intake is at the
center of the pump. The outlet should ideally point upwards to prevent air pockets.
Avoid elbows/90˚fittings in your plumbing if possible. The complete pump head can be turned in case the
outlet direction is not suitable for your installation. Avoid air pockets in the hose run.
The ECHOTec “Orbital” Magnetic Drive Pumps eliminate the conventional shaft seals found in most pumps.
This means that there is no rotating seal to wear and allow the liquid being pumped to leak out.
We rely on the liquid being pumped to lubricate the impeller-magnet assembly spinning on the stationary
spindle. If the pump is run dry for longer than 10 minutes, the assembly may “freeze” onto the spindle.
All pumps can be serviced with the use of a screwdriver. The only moving part in the pump other than the
motor is the impeller-magnet assembly. This assembly rotates on a stationary spindle and up against a thrust
washer.
5 MICRON PRE-FILTER HOUSING
Connect the filter housing with the supplied ¾” nylon nipple to the standard filter housing and reconnect
the reinforced vinyl hose (assembled when delivered with the optional boost pump). The 5 micron
cartridge has to be installed as the second filter in flow direction.
5 MICRON PRE FILTER HOUSING WITH LOW PRESSURE GAUGE
The optional 5 micron pre filter housing with low pressure gauge has to be installed as a second filter in
flow direction.
FRESHWATER FLUSH SYSTEM
Install the active carbon filter housing at an easily accessible location close to your seawater intake line
and any pressurized water line. Connect the fitting on the shut off valve on the carbon filter housing to
your boats’ pressurized water line.
Connect the filter outlet to the supplied T-connector. Connect the two remaining ports of the T-
connector to the outlet of the storage/cleaning valve on the pre-filter housing and to the intake of the
high pressure pump (refer to the flow diagram).
Note: The active carbon cartridge has to be exchanged every six month to guaranty removal of chlorine
from the tank water. If only product water is used for the flush procedure, the element can be removed
temporary.

12
SYSTEM OPERATION INSTRUCTIONS
CAUTION: The reverse osmosis membrane contains a preservative solution to prevent microbiological
growth. If ingested, it may cause irritation of the gastro-intestinal tract. Therefore, discard all the product
water for at least thirty minutes of initial operation or after system storage before drinking or before use in
food preparations!
CAUTION: Do not operate the system using contaminated feed water sources (oil, chlorine or other
chemicals).
CAUTION: Check proper oil level with dipstick or show glass (center of show glass).
CAUTION: Have you removed the shipping plug from the high pressure pump and replaced with the enclosed
breather oil cap? Failure to do so may damage the crankshaft oil seals of the pump.
1) Open the seawater intake valve (sea cock).
2) Open the pressure control valve, on the control panel, all the way counter-clockwise.
CAUTION: Never start the system with the high-pressure control valve closed.
3) Set the cleaning/storage valve to the pre-filter position (towards the filter).
4) Set the diverter valve to sample position (left).
5) Switch on the boost pump (optional).
6) Switch on the high pressure pump.
7) Flush the air out of the system. Crack open pre- filter housings if needed.
Check for brine discharge at the output location.
CAUTION: Never allow any leaks in your hose or tube connections.
CAUTION: Do not attempt to re-seal the stainless steel product water outlet fitting on the membrane vessel
end cap by further tightening as this could damage the thread of the plug. Remove the fitting, apply new
Teflon tape, insert the fitting and hand tighten plus ¼ turn.
8) Close the pressure control valve slowly clockwise to allow air bubbles to work themselves
out of the system.
9) Adjust the water pressure to achieve the specified product output with a maximum reading of
850 PSI on the pressure gauge in the control panel. If you operate the watermaker in brackish
or lake water, adjust the working pressure not to exceed the specified product water rate.
10) Taste the product water at your sample station or check the quality with the supplied
TDS meter. If the water is pure, switch the diverter valve to fill your storage tank.

13
SYSTEM SHUT DOWN PROCEDURE
1) Switch the diverter valve to sample station.
2) Open the pressure control valve all the way counter-clockwise.
3) Switch off the electric motor and the boost pump (if installed).
4) Close the seawater intake valve.
FRESH WATER FLUSH PROCEDURE
The fresh water flush prepares your watermaker for a shut down period of ten days. It can be repeated
indefinitely as an alternative to the chemical long term storage of the membrane element.
CAUTION: The boats fresh water pressure should not exceed the range of the low pressure gauge.
1) Open the pressure control valve all the way (two full rounds after the spring releases) counter
clockwise.
2) Close the sea water intake valve or switch the cleaning/storage valve to the closed position.
3) Open the fresh water flush valve.
Your boats’ fresh water supply pump should now turn on (larger fresh water pumps will cycle on and off).
Allow fresh water to flow until all salt water is flushed out of the RO System. For the next flush procedure,
test how long it takes until the brine at the outlet becomes fresh.
PRE-FILTER BACKWASH PROCEDURE
As part of a long term storage, you may remove the pre-filter cartridges from the housings or perform a pre-
filter backwash procedure. If there is no momentary shortage of fresh water, the back wash may also be
useful to reduce product water discharge time until the product is free of odor after each start up.
1) Open the seacock and switch the cleaning/storage valve to the sea water position.
2) Allow fresh water to flow until all salt water is flushed out of the pre-filter(s), boost pump and the
sea strainer (approximately 30 seconds, depending on the flow rate of your vessel’s fresh water
pump).
3) Close the seacock.
MEMBRANE STORAGE PROCEDURE
If you intend to store your watermaker for more than ten days, growth of micro-organism may degrade the
RO membrane(s) performance and the RO membrane(s) should be flushed with a biocide solution. This will
preserve the membrane for long-term storage of up to ten months.
If you have installed the optional fresh water flush system, it is recommended to back flush the pre-filter(s),
the boost pump and the sea strainer with fresh water (see above). Close the seawater intake valve (sea
cock) and remove the pre-filter cartridge(s).

14
1) In a clean plastic container, mix 2.5 gallons / 10 liters of un-chlorinated fresh water with 100 grams
(1/3 container) of ECHOTec membrane preservative # 3 (Metabisulfite) for one and two 40”
membrane systems. Mix 4 gallons / 15 liters of water with 150 grams (1/2 container) of preservative
for three and four 40” membrane systems.
2) Switch the three-way valve to the cleaning/storage position.
3) Switch the diverter valve to the sample position.
4) Open the pressure control valve all the way counter clockwise (two full rounds after the spring
releases).
5) Use a funnel (avoiding air to enter the system) to pour the solution into the cleaning/storage hose or
lead the hose into an elevated plastic container while running the high-pressure pump. When the
solution has been infused, switch off the watermaker.
Your watermaker is now prepared for a shut down period of ten months.
CAUTION: After storage, discard the product water for at least thirty minutes of initial operation before
drinking or before use in food preparations.
MEMBRANE CLEANING PROCEDURE
ECHO Tec membrane element/s may be chemically cleaned when the product water output drops by 15%
of the specified amount. The frequency of this occurring will vary greatly depending upon feed water
quality. Fouling of the membrane will naturally occur during normal usage. Increased amounts of fouling
without proper cleaning of the membrane will reduce the performance of your water maker. A drop in
production of approximately 10% is normal and expected during the first year of operation.
Note: Do not clean when TDS reads high. Clean only to restore output!
CAUTION: The use of chemicals or cleaning methods other than those outlined in the cleaning instructions
will void the ECHO Tec Warranty.
CAUTION: Cleaning chemical #1 is an alkaline detergent. See warning label on side of the container and
observe all safety precautions on label.
CAUTION: Cleaning chemical #2 is an acid, a mineral scale remover. See warning label onside of container
and observe all safety precautions on label.
CAUTION: Do not mix different cleaning chemicals together. Do not use different cleaning chemicals
together at the same time.
To clean the ECHO Tec. reverse osmosis membrane mix a solution of 1.5 to 2 % by weight with warm non-
chlorinated water (113° F / 45° C) in a clean plastic container. Use 10 ltr / 2.5 gal (with 200 g or 2/3 container
cleaning agent) for one 40” membrane. Use 4 ltr / 1 gal (with 40 g cleaning agent) for every additional
membrane.
For safety reasons we do not recommend to install a 3 way re-circulating valve to accommodate the service.
Disconnect the intake and reject water hose and lead them in the plastic container. Re-circulate the solution
intermittent without pressure for up to 60 min. There will be no flow at the fresh water outlet.
CAUTION: Observe the maximum operating temperature of 113° F / 45° C. The high-pressure pump
might over heat the solution on re-circulating.

15
It is important that most of the fresh water remaining from the last flush is dumped before the reject hose is
led in the cleaning bucket for re-circulation in order to avoid diluting the solution. Use cleaning chemical #1
first. Only if the performance does not improve, use the acid cleaner #2 at the same ratio and instruction.
MAINTENANCE TIMETABLE
The following maintenance timetable is an estimate of the time intervals at which maintenance may be
required only. This schedule must be adjusted to the regularity of usage, the condition of the intake water,
the length of time the system is exposed to seawater and the total running time following each system
cleaning.
COMPONENT
MAINTENANCE REQUIRED
TIME INTERVAL (INTERMITTENT DUTY)
Sea Strainer
Inspect and clean
screen and housing…
every 200 hrs. or when clogged. Observe low
pressure gauge if installed.
Pre filters(s)
Replace or clean element(s) and
clean housing(s)…
Boost pump: when pressure is lower than 0
PSI. No Boost pump: pressure lower than
5”Hg
Hardener / pH
neutralizer
Replace or refilled with the mineral
mix of another cartridge…
when 25% of the content has been dissolved
to guaranty sufficient contact surface
Carbon flush
filter
Replace element…
every 6 months
High pressure
pump
Change
crankcase oil…
12oz./0.35L SAE 30Wt non-
detergent
Initial change after 50 hrs.
every 300 operating hours or 12 months
High pressure
pump
Change seals and O-rings…
every 5000 hrs. or 3 years.
R.O. Membrane
Clean with acid and/or alkaline
cleaning compound…
Replace…
Note: Do not clean when TDS reads
high. Clean only to restore output!
when production decreases by 15%.
when cleaning does not
increase production.
Flow meter
*Infuse muriatic acid and rinse
well…
when discolored/dirty
* Set the diverter valve to the sample position. Disconnect the product water tubing from the product port
at the membrane vessel and carefully infuse Muriatic acid, KR1 or Ospho with a syringe into the product
water tubing. Once the discoloring has cleared, re-connect the tubing, run the system and rinse the
flow meter with the product water. CAUTION: Adhere to the safety advises of the cleaning agents

16
TROUBLESHOOTING GUIDE
MALFUNCTION
CAUSE
REMEDY
Inability to build up
pressure…
...with high pressure
gauge fluttering.
…with loud noise from
HP-pump.
(Low pressure gauge
reads below 10”Hg)
…during navigation
Air enters intake plumbing.
Air in intake system
High pressure pump valve
stuck after long storage time.
Seacock closed
Seacock clogged (Barnacles?)
Strainer, filter/s fouled
Through hull fitting in wrong
location (suction trough
movement).
Tighten all hose clamps.
Allow more time to prime. If no boost pump is
installed, perform freshwater flush to assist
priming.
Open one by one all six hexagonal valve
covers. Inspect valves for movement.
Open seacock
Clean seacock
Clean strainer, change/clean filter/s.
Use strainer scoop (page 11).
Pressure drops
frequently with change
of noise…
…during navigation
Air enters intake plumbing.
Air enters sea water intake
during navigation.
Tighten all hose clamps. Reseal NPT fittings.
Move through hull fitting to lower location.
Excessive leakage
between the high
pressure pump head
and crankcase…
…with water in
crankcase
Worn high pressure seals
Cracked ceramic plunger
Cracked ceramic plunger
and/or worn HP/oil seals
Replace high pressure seals
Inspect for hairline crack. Replace plunger
and HP seals (page 20).
Inspect for hairline crack. Replace plunger (if
needed), high pressure seals and oil seals.
Product salinity reads
above 500 ppmTDS.
Membrane element has
reached its service life time.
Replace membrane element. See instructions
on page 17.
Product output below
specification.
Membrane element clogged
or reached its service life
time.
Clean membrane element (page 14).
Replace membrane element (page 17).
Leak on pressure
vessel end cap from -
salt water…
…fresh water
O-ring worn
Product port Teflon seal worn
Remove and inspect plug (page 17). Change O-
ring/s as needed.
Remove port, re-seal, install hand tight + ¼
turn

17
MEMBRANE ELEMENT AND END PLUG SERVICE INSTRUCTIONS
1) Remove the high pressure hoses and product tubing from the pressure vessel
2) If needed remove the complete vessel/s
3) Remove the three M6 bolts with a 5 mm allen key on both sides of the vessel.
4) Remove the three locking plates (locks) on both sides.
5) Holding the product port, pull the product port end plug in one fast pull out of the vessel.
Note: Should the plugs O-ring (PL01) get stuck in the locks groove of the pressure vessel, it will be more
difficult to pull the plug. Tap the plug in and pull more vigorously.
If the product port is mounted on the high pressure OUT side:
6) Using a needle nose pliers, pull the membrane element on the product tube in flow direction.
6b) Push out the remaining end plug from the opposite side with a pipe, boat hook, etc.
If the product port is mounted on the high pressure IN side:
6) Using a short pipe or wooden support, push out the membrane element together with the
remaining end plug.
Inspect the end plugs for hairline cracks or damages on the O-rings and O-ring grooves.
7) Insert the new membrane element, observing the correct position and direction of the lipped
seal ring: High pressure entry side of the membrane, lip against flow direction.
8) If needed, clean the product port and end plug threads from remaining Teflon sealant and
re-apply 3 wraps only.
11) Insert the end plugs and reassemble all components visa versa.
CAUTION: Do not over tightening the product port/s. Hand tide plus ¼ turn. Thread may damage!

18
HIGH PRESSURE PUMP PARTS AND SERVICE INSTRUCTIONS
View Pump Service Instructions at
http://youtu.be/lafVYzGPQuc
GPQuc
8.0

19
4
SERVICING THE VALVES
1) Using a 3/8” allen wrench, remove valve cap. Examine
threads and o-ring. Replace o-ring if there is any evidence of
cuts, abrasions, distortion or wear.
2) Remove valve assembly (retainer, spring, valve, valve seat
From valve cavity using a needle nose pliers.
3) Remove valve seat o-ring from valve cavity.
4) Inspect pump head for contamination or debris.
5) Install new o-ring in valve cavity.
6) Insert valve assembly into valve cavity.
7) Coat the threads of the valve cap with silicone grease and
reinstall valve cap. Torque to 10.8 Nm (8.0 Ft-Lbs).
NOTE: Only one valve kit is necessary to repair all the valves in the
pump. The kit includes new o-rings, valve seat, poppet, spring and
retainer. All are pre-assembled.
REMOVING/INSTALLING THE MANIFOLD
1) Remove the 8 bolts on the high pressure pump head
manifold using a 5 mm allen wrench.
2) Separate manifold from crankcase.
Note: It may be necessary to rotate the crankshaft, or use pry bars
to remove the manifold from crankcase (image 5).
CAUTION: When sliding head from crankcase use caution not to
damage plungers.
3) The seal assemblies may come off with the manifold. At this
point examine the ceramic plungers. Plunger’s surface
should be smooth and free from scoring, pitting, or cracks;
if not, replace.
4) Coat each plunger with silicone grease.
5) Align outside plungers in the forward position (image 6).
6) Reinstall manifold and torque manifold bolts to 10.8 Nm
(8.0 Ft-Lbs) per sequence shown on image 7.
1
2
3
5
4
6
7
8
5

20
REPLACING HIGH PRESSURE SEALS
1) Remove pump head manifold from crankcase.
2) Insert 18 mm extractor collet through main seal
retainer. Tighten collet and extract retainers and
packings. For field repairs push seals out from outside.
3) Apply silicone grease to the seal assembly before
installing in cylinders.
4) Place supplied insertion tool in cylinder and install
seal assembly and low pressure seal retainer using
the supplied insertion tool.
5) Repeat this sequence for each cylinder.
6) Align outside pistons in forward position (image 6).
7) Coat each plunger with silicone grease.
8) Install manifold and torque retainers to 10.8 Nm
(8.0 Ft-Lbs).
REPLACING CERAMIC PLUNGERS
1) Using a 1/2” wrench or socket, remove the stainless steel
fasteners retaining the plungers.
2) Remove stainless steel washer and ceramic plunger from
piston rod.
3) If copper slinger washer comes off with plunger, be certain
this is replaced before new plunger is installed.
4) Install new o-ring and Teflon back-up ring on piston rod.
Note: A film of silicone grease on the outside of the o-ring insures a
better installation.
5) Slide new plunger over the piston rod, install stainless steel
washer.
6) Apply a drop of removable anaerobic (Loctite 243 or similar)
thread sealant to threads of piston rod.
7) Install the stainless steel fasteners retaining the plungers
and torque to 9.9 Nm (7.3 Ft-Lbs).