Pure Water NO FRILLS 500 GPD Manual

Mounting-instruction, User - and maintenance-handbook
For the series NO FRILLS modular COMFORT, 230 Volts 50 Hz
PureWater. H. Fehlemann - Desalination
Bodelschwinghstr. 37
33142 Büren Germany
Tel: [phone]
Fax: [phone]
Mobile: [phone]
Internet: www.watermaker.de e-mail: [e-mail]

Your Freshwater-Source
We are happy that you decided in favor of one of our reversion-osmosis-installation (RO
unite) and you greet in the growing circle of the users of desalination-installations.
We will do everything in order to satisfy you also after your purchase.
This handbook contains, exact instructions, as you fit in your installation, use it and keep it
maintained.
If you should have further questions in addition, you don't hesitate to call us.
In order to gain an optimal performance and a long lifespan of your installation, you read
alertly through this handbook before the mounting; if you should require further help, you let it
know us.
PureWater –Desalination

Index of contents
System-bases........................................................................................ 1
Performance data............................................................................. 2
Membrane-Performance......................................................................... 2
Electric connection-values...................................................................... 3 .
Pressure regulation................................................................................... 4
Before mounting. .................................................................................... 5
Description of the individual parts. ......................................................... 6-7
Mounting the pressure vessels. .................................................................8
Motor and pump. ..................................................................................... 9
Factors affecting Temperature and
Pressure......................................................................................... 10
Flow-diagram. ........................................................................................ 12
Pressure Regulator................................................................................... 13
Electrical installation............................................................................... 14
Starting the System................................................................................. 15-16
Maintenance....................................................................................... 16
How to Flush................................................................ 17
Cleaning............................................................................................... 18
Storage............................................................................................... 19
Membrane Change.....................................................................................20+20a
Manufactures Literature............................................................................. 21-23
Logbook..................................................................................................... 24
Quality Monitor…………………………………………………………………. 25
John Guest System…………………………………………………………… 26
Wiring ………………………………………………………………………….. 27

NO FRILLS 500/800 Guide
System-bases
Introduction into the reversion - osmosis
Reverse-osmosis is a process, with which a membrane divides one water-flow in two water
flows. One part is fresh-water and amounts about 7-10 percent of the entire water-quantity,
the other flow is concentrated saltwater, which is washed away. Since saltwater is a solution
of H²O and different solved materials (salt), the membrane acts like a filter. In order to be
able to remove these solved materials from the water, the pores of the membrane must be
smaller than the solved materials that should be taken away. The pores of a membrane are
so small that they can be seen only by one electron microscope. (0,0001 micron), that
means, that the sea-water must be pressed through the membrane. This pressure must have
the strength of 800 Psi (56 bar) approximately. How high the current pressure must be exact,
is a result from the water-temperature and the salt content of the water.
This temperature / pressure-relationship later will be explained later in this handbook.
See chapters: Temperature - Pressure - Correction.
As you know, each filter can become blocked or damaged. A reverse-osmosis-membrane is
no exception. Your System is designed that surplus particles are rinsed with the Brine flow.
Nevertheless, there are conditions, which contaminates, blocked or damage the membrane.
With regular maintenance, as it is described in this handbook, the possibility of a failure of a
membrane can be minimized and costly substitute be avoided. Regular maintenance is
comparatively affordable, gets the effectiveness and extends the lifespan of the installations.
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NO FRILLS 500/800 Handbook
Performance Data
Membrane-performance*
Model gallons per hour liter per hour
200 GPD 8,30 GPH 31,41 LPS
400 GPD 16.60 GPH 62,83 LPS
500 GPD 20,80 GPH 78,20 LPS
600 GPD 25,00 GPH 94,50 LPS
800 GPD 38,00 GPH 145,00 LPS
1000 GPD 52,90 GPH 200,00 LPS
1300 GPD 54,20 GPH 205,14 LPS
1800 GPD 75,00 GPH 283,81 LPS
2000 GPD 83,33 GPH 315,40 LPS
3000 GPD 125,00 GPH 473,12 LPS
Salt-Rejection = Minim. 99,2%
Water-quality = above WHO standard
•Sea-water-temperature, pressure and salt content have strong influence on the performance
and quality of the product-water. Details you find in the chapter Operation.
Test-conditions
Pressure 800 PSI
Sea-water-temperature 25° C
Salinity 35,000 PPM (parts of million))
Pump-performance
Operating-pressure 700 - 1000 PSI
Total flow
200-800 GPD systems 2.90 GPM
1000-1800 GPD systems 3.7/4.76 GPM
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NO FRILLS 500/800 guides
Electric connection-values
230-volt
SERIES Ampere KILOWATT
NO FRILLS 500/600 GPD 9,5 1,5
NO FRILLS 800/900 GPD 9,5 1,5
NO FRILLS 1000-1800 GPD 16 1,85/2,2
Electric wiring
The connection should be carried out by a qualified electrician.
Control box inside:
Motor connection for CAT Pumps
See attached CD. For Identification of the wires at the pump, we left a short piece of wire out
of the box at the motor. However, you are free to connect the wires inside the box. The build
in switch is not needed. If you leave the switch, make sure, it is in the ON position. The
connection schematic is inside the cup of the box.
Electrical connections should be done by a qualified electrician.
Cable Identification: NO 1 = L - brown NO 2= N –blue, yellow –green is GND
3
Power relay
Fuse 2A for LP Pump
Test Button –pull
Reset Button
Motor protection relay

NO FRILLS 500/800 Guides
The NO FRILLS 500/800 modular COMFORT is delivered in following implementation.
Motor and HP Pump Main Controlpanel Pressure Vessel and Membrane NF 500
Fresh Water flush system Pre-Filter and PH Stabilizer LP Pump
Pressure Regulation and Flow distribution
Pump switches
Flush Button
(Option)
Quality Monitor
4
Pressure indicator
High Pressure Bypass Valve
Position: No pressure, cleaning
flushing
CLEANING VALVE: Position: NORMAL FLOW: for desalination and
flushing. Brine Flow over board.
Position: CLEANING: for cleaning and preservation. The flow is returned
to the “T” at the pre filter. See flow diagram.

NO FRILLS 500/800 Guides
Before mounting!!
Please pay attention to the following points before you fit in your NO FRILLS installation and
take in operation!
1. The installation should be taken in operation within 12 months after delivery
2. The installation should about every 7 days, in very hot areas, every 3 days, operated
with sea water or flushed with fresh-water.
3. If the installation is for a long time out of order, it should at the latest after 12 months
flushed and preserved again.
4. Never operate the system in harbors or in areas where fuel and oil is in the sea-water.
5. If you use the system in fresh - or brackish water, the operating-pressure must be
adjusted, that the output of fresh water is within the operating limits.
6. Protect the installation from freezing.
7. Don't let the membrane dry out. If you take out the membrane for any reason, it has to
be sealed immediately.
8. The sea-water- inlet must be shaped so that the sea-water is pressed in during cruise.
Attention!!
The quantity of the produced drinking water is very strong dependent on the temperature of
the sea-water. All accomplishment-statements are based on a temperature of the sea-water
of 25°C. Per 1°C below 25°C, the production loses 3 percent of performance.
As well, the salinity of the sea water is a factor. Higher salinity, lower performance.
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NO FRILLS 500/800 Guide
The general scopes of the NO FRILLS desalination-installations
The NO FRILLS RO systems are laid out according to the last realizations of the revers-
osmosis-technology. These installations enjoy ever more severe popularity with Cruisers,
sport-fishers and on boats, where mounting space is limited.
The NO FRILLS systems are simple to use and uncomplicated in maintenance.
The NF 500 produces about. 78 liters / h, the NF 800 produces, about. 145 liters / h. See the
reduced performance with temperatures below 25°C.
2.2 descriptions of the individual parts
The 230 V boost-pump. (LP Pump)
The boost-pump is required to feed the sea-water, if the high-pressure-pump is built-in at or
above the waterline. The booster-pump must be installed below the waterline. The booster-
pump supports the start-process, trapped air is fast removed.
Hand-water-test-appliance (Optional) N.A. on COMFORT and COMPACT Models
The hand-water-Tester measures how much ppm of the TDS is still in the water. The value
from the World-Health-Organization, WHO, for good drinking water, is 500 ppm.
ppm = parts per million TDS (total dissolved Solids)
Pressure gauges
The pressure gauge shows how much pressure the high pressure-pump delivers. The work-
area is between 800 and 950 psi.
High pressure-pump
The high pressure-pump pumps waters through the membrane
Flow meter
How much drinking water is produced in the hour shows the flow-meter.
(In U.S. gallons per hour) 1 U.S. Gallon = 3.78 liters. 2
Pressure Regulator
The pressure control allows the operator to regulate the pressure. 800 psi is normal.
Sea-water-filters (option) for BASIC and STANDARD
The sea-water-filter keeps back coarse particles and spares the booster-pump and the pre-
filter consequently.
Pre-filter
The pre-filter has a permeability of 20/5 microns and filters the fine particles.
Sample Valve (option) N. A. for COMFORT and COMPACT Models
The sample-valve enables to take a water-test directly at the exit of the system. This is to the
control the water quality so that one can prevent the influx of bad water.
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NO FRILLS 500/800 Guides
Cleaning-valve (mounted at the pressure regulation)
This valve enables, either a flow over board (Normal Flow), or a recirculation for cleaning and
preservation. (Cleaning Flow) See flow diagram.
Fresh-water –flush system (FWS)
The fresh-water –flush system provides flushing the system when not in use, with fresh
water, just with a turn of the handle at the selector valve. The build in changeable carbon
filter cartridge prevents that chloride exits the membrane. The handle must be installed below
the waterline if you install the system acc. Page 12. When installing acc. Page 12a all
components except the boost pump can be mounted over the waterline. Flushing the system
extends the lifetime of the membrane and is used for short time storage. (up to10 days)
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NO FRILLS 500/800 guides
Mounting the pressure vessels
The pressure vessels are individually packed and have to be mounted on the brackets.
All PV (pressure vessels) are marked with an arrow –feed flow direction -.
The PV’s are marked also with PV 1 and PV 2.
From 2015 the Pressure Vessels are pre-mounted. However, for installation you have
to separate the Pressure vessels.
PV1 HP Connection
PV2 Product Water
JG Product
HP Hose to Pressure Regulation
HP Hose from HP Pump
Connect the high pressure hose from the HP pump with PV 1, where the yellow spot is
located.( only Phoenix vessels ) On Super Duplex Vessels there is a Mark “HP Hose to
Pump” or PV1
Connect the high pressure hose from the pressure regulation to PV 2, there is no yellow spot
located, but a mark PV2 or “HP Hose to Panel”
Connect the short HP hose, delivered in a plastic bag, to the both right HP hose connections
at PV 1 and PV 2. See picture above. From 2015 there is a 316SS Elbow pre-mounted.
Last step is to connect the fresh water hose assy. to the both 3/8” hose barbs or John Guest
connections at the PV, right side. How to use the John Guest connections you find at the end
of this manual. The Product water connection could be a hose barb, or John Guest
connection. That is upon customer’s request.
NOTE!!
All high pressure connections have seals. Don’t tighten the connections to strong,
this could damage the seal. Just a little click with the key is enough.
8
Product Flow Feed Flow
Feed Flow Product Flow

NO FRILLS 500/800 Guides
1 Motor See water inlet
High pressure connection
2 High pressure pump
Attention: On Interpumps: Before starting the Pump, change the red safety
transportation cap to the yellow cap with the mark: OIL. This will provide crank
shaft ventilation.
For CAT Pumps (blue) remove the tape over the red oil filler cap. The Oil could
be removed for transportation by air. Check if oil is in the pump!!!!
Recommended is normal non-synthetic 15W40 o
9
Motor and HP Pump

NO FRILLS 500/800 Guide
Installation
The Installation on a boat is very much dependent on the situation. Generally, there is no limitation in length for
water hoses. The most common installation is the installation above the waterline. Ref. to the respective diagram.
However, some parts have to be placed below the waterline. This is the Sea Water Filter (Strainer) and the LP
Pump. The HP Pump should be in a dry place. For better understanding the position of the hoses is marked at
the back side of the main Panel. See picture below.
Over board: A ½” hose connected at the main panel must free flow to an outlet well above the waterline.
Return Cleaning: This hose connection has to be connected with the “ T “ at the Fresh Water Flush system
(FWF System)
Product Water from
Membrane: A ½” hose or a John Guest Tube from the product water outlet to the respective connection at
the main panel.
This is to measure the water firs, before entering the Tank.
To Tank: This is the connection which is the outlet for your product water. Draw a hose to the PH
Stabilizer and from there to your product water storage tank.
Attention!! Always enter your storage Tank from the top!!!
Panel back side
HP Hose from
Membrane
Product water to Tank (PH Stabilizer) - over board - return Cleaning - product water from Membrane (could be a JG pipe)
Normal Flow = The Brine water flows over board
Cleaning Flow = For cleaning and preservation, activates a circuit flow
Cleaning flushing = For all operations where no pressure is needed (fresh water flush, preservation
and cleaning.
RO Mode Pressure = to rise the pressure for normal desalination
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NO FRILLS 500/800 Guide
FACTORS AFFECTING PERMEATE PRODUCTION
VARIATIONS IN TEMPERATURE, PRESSURE, AND SALINITY
The following table illustrates how the quality and quantity of permeate produced by a RO
system is affected by changes in temperature, salinity and pressure:
* If the feed water salt concentration decreases, the product water flow rate should not be
allowed to increase more than 20% above rated flow. Feed pressure may need to be lowered
to maintain rated flow in brackish water or tap water applications.
** Feed pressure shall not be increased above 950 psi.
The RO system can be adjusted to maintain a constant permeate output when feed water
temperature and salinity is other than nominal. The operator can do this by controlling
system pressure manually via the backpressure regulation valve located in the system brine
piping. As permeate flow decreases, the operator can throttle the pressure regulation valve
closed to increase system pressure. This, in turn, will increase the permeate output and
mitigate the effect of a decrease in temperature or an increase in
salinity. Conversely, the operator can open the pressure regulation valve to reduce pressure
and permeate flow in areas of excessively high temperature or low salinity.
IN FRESH OR BRACKISH FEEDWATER CONDITIONS, MAKE SURE TO REDUCE
PRESSURE BY TURNING REGULATOR. SET PRESSURE SO, THAT PRODUCT FLOW
IS NO MORE THAN 120% Of DESIGNED FLOW; TO PREVENT MEMBRANE DAMAGE.
TEMPERATURE CORRECTION FACTOR
As previously described, the output capacity of any RO unit is highly dependent on feed
water temperature. In order to quantify this relationship, operational data has been utilized to
develop Temperature Correction Factors (TCF). The TCF (which is compensated to
25°C/77°F) is used to determine what part of any change in system output flow is due to
variations in feed water temperature alone. This, in turn, allows the operator to establish the
baseline flow for a given temperature, allowing more accurate troubleshooting. The
procedure for calculating the TCF and the temperature compensated flow is as follows:
1) Measure raw water temperature.
2) Determine the corresponding correction factor from Table 3.2 based on the measured
temperature.
3) Note the product flow rate at the Product Flow meter.
4) Multiply the measure (uncorrected) product flow meter flow rate by the correction factor
from Table.
10
With constant and increasing TDS Capacity
Salinity and pressure Temperature increasing increasing
Temperature and pressure Salinity increases decreases
Temperature and salinity Pressure decreases increases

NO FRILLS 500/800 Guide
Example:
Raw water temp: 15°C
TCF: 1.47
Uncorrected product flow: 12.75 (gph)
Calculation: 12.75 x 1.47 = 18.743 (gph)
Corrected product flow: 18.7 (gph)This is the normal flow for a NF500
(
11

NO FRILLS 500/800 Guide
Flow diagram (Installation above Waterline)
12

NO FRILLS 500/800 Guide
Mounting and connections
On the picture below, you see pressure regulator, looking from the top. This could be
adjusted with a 27mm key.
Pressure Regulator
The pressure regulator is a fixed set up type; however, it can be adjusted. The regulator is factory set to 800-
820psi (56bar). It might be necessary to adjust. That depends on salinity and temperature. Refer to Temperature
and salinity adjustment. But anyhow, the unit will operate with 800psi pressure within the operational limits.
For units equipped with low energy membranes (from 2015) the factory pressure setting is lower than 800psi.
Adjust the pressure according to the product flow. If you reach the rated product flow, this pressure is enough.
To adjust the pressure, you must loosen the counter screw below the regulator.
Mounting the system:
Find good positions for the components. Motor and Pumps should be in a dry place.
Accessible parts are the pressure regulation, the pre-filters and the fresh water flush system.
Keep a little space below the filters for changing the filter elements. Install a seacock in the
feed water line.
Mount the system according to the flow diagram. All sea water lines are ¾” hoses. Don’t use
transparent hoses. All freshwater hoses are 3/8” or ½” We recommend hose qualities which
have drinking water grade. The LP pump has to be placed under the waterline. With the
installation on Page 12 you can place all parts, which are not marked red, above the
waterline.
13
Pressure Regulator

NO FRILLS 500/800 Guide
TO CONNECT THE ELECTRICAL
TURN OFF ALL ELECTRICAL POWER FOR USE WITH THE RO UNIT PRIOR TO
CONNECTING TOTHE RO POWER SOURCE. FAILURE TO DO SO MAY RESULT IN
SERIOUS INJURY OR DEATHTO PERSONS HANDLING THE UNIT.
NOTE: Adhere to all electrical codes and regulations governing the installation and
wiring of electrical equipment. Typical codes specify the type and size of conduit, wire
diameter, and class or wire insulation depending upon the amperage and
environment.
NOTE: The power supply should always be of greater service rating than the
requirements of the RO unit. This will assure proper voltage even if power supply
voltage is slightly less than required.
Never connect the RO unit to a line that services another electrical device.
THE RO UNIT SHOULD HAVE ITS OWN INDEPENDENT POWER SUPPLY.
NOTE: We recommend use of a 15 amp fuse or circuit breaker for 230 Volts AC units.
Cable Identification: N0.1= L - brown No.2 = N –blue
The Cables are guided outside the control box at the panel.
We recommend installing a waterproof box between each cable. This makes it easy to
dismount the unit.
14

NO FRILLS 500/800 Guide
Starting the System
Step 1: Verify all power switches and power sources are in the OFF position.
Step 2: Turn the High Pressure Bypass Valve (Black Valve) to CLEANING/FLUSHING
Position. This procedure allows release of the high pressure air trapped within the
system.
Verify the Cleaning Valve (Grey Valve) is positioned to NORMAL FLOW discharge.
Also check the grey Freshwater Flush Valve is positioned for seawater intake, NOT
freshwater.
FAILURE TO OPEN THE HIGH PRESSURE BYPASS VALVE, WHICH IS REQUIRED TO
RELEASE ANY TRAPPED AIR, COULD RESULT IN HYDRAULIC SHOCK TO THE
SYSTEM.
Step 3: Verify the seawater intake is open at the through-hull. This allows the feed seawater
to flow into the unit.
Start-up time can be expedited by filling the pre-filter housing with non-chlorinated
freshwater, before the RO unit is turned on.
Step 4: Switch ON the breaker at main breaker panel to power up unit.
Step 5: Upon start-up inspect all plumbing connections in the unit for leakage. Varying
temperatures during shipment may cause plumbing connections to seep when
starting the RO unit for the first time. Secure the unit and repair any leaks before
proceeding. Once the leaks are repaired, open the raw water source and restart the
unit. Starts the LP pump first, then HP Pump.
Step 6: Observe the Brine Flow over board, to ensure all air and bubbles exited the RO
system before proceeding to next step.
Step 7: Gradually turn the High Pressure Bypass Valve (Black Valve) to
RO MODE/ PRESSURE position. The pressure gauge should steadily rise to a
reading of 700-820 psi.
Step 8: Observe the system pressure on the High Pressure Gauge. During RO production,
the indicated pressure should be at 700-850 psi (depending on Seawater
temperature) If the pressure reading is not at 700-850 psi, adjust the pressure
regulator.
NOTE: If the RO unit is used for other than seawater purification (in freshwater or
brackish water applications), reduce pressure as necessary to achieve product flow
no greater than 120% of design flow to avoid membrane damage.
RO pressure production should NEVER EXCEED 950 psi, doing so risks damage to RO
unit which would VOID factory warranty.
Step 9: Taste the water quality or test it with a hand-held test meter to determine water
quality. If quality is good allow the water to flow into the Tank. N.a. for COMFORT and
COMPACT systems there is a controller and you can read the quality.
Step 10: Check the RO unit for water leakage periodically at the initial start-up. Observe
Product Flow meter.
Record the product flow after 48 hours of operation (use the sample log sheet
provided).
4.2 TO SHUT DOWN UNIT
Step 1: As the RO unit operates, turn the High Pressure Bypass Valve (Black Valve) to
CLEANING/FLUSHING Position. (Counter clockwise), when RO unit is running. This
will release the high pressure within the RO system.
Step 2: Turn OFF your power at the control box.
The RO unit may be left in this “stand by” condition with the seawater for up to seven
days or three days in hot, tropical climates. If the RO unit will be out of service for
extended time periods, please refer to the Maintenance section of this manual.
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NO FRILLS 500/800 Guide
MAINTENANCE
The service life of most system equipment is directly related to the raw water inlet conditions.
Improper maintenance will also significantly reduce the life expectancy of the major unit
components (such as the membranes, filters and pumps) as well as the reliability of the unit
as a whole. Under normal conditions, and with proper maintenance, a reverse osmosis
membrane (which is the major consumable item) should have an effective service life
somewhere between 4 and 6 years.
NOTE: The RO unit must be cleaned when product water output drops by 20%.
Table 5.1: Maintenance Task Chart.
** Change pump oil after first 100 hours of RO use. After the first oil change at 100 hours,
change the pump oil every 500 hours thereafter or once annually which ever interval comes
first.
FRESHWATER FLUSH / SHORT TERM STORAGE
Ideally, the No Frills performs optimally when the RO unit is used regularly. The likelihood of
bacterial and biological growth in the membranes increases, when stagnant seawater (in
extended periods) is in contact with the membranes. A freshwater flush procedure is
necessary to prevent clogging and growth of organic contaminants in the RO system and its
membranes. This method pushes out older stagnant seawater (saltwater) out of the
membranes and replacing it with freshwater (non-saltwater), leaving less chance of fouling
the membranes. The freshwater flush procedure should be used when the unit will be placed
idle or in “stand by” condition for more than several days OR idle for three days in hot,
tropical climates. Although they do not attack the membranes or other system components
directly, high concentrations of biological matter can block enough of the product water
channels to cause a reduction of as much as 40% of the total system capacity.
16