Sea Clear G-20 User manual

Watermaker Manual
For Electric / Generator-Driven Models G-20 & G-40
Installation, Operation and Maintenance
401.400.2226 | [e-mail]
36 Harrison Street, Bristol, RI 02809 | www.seaclearwatermakers.com Version 1.1-G

TABLEOFCONTENTS
Introduction ...................................................................................................................Page 3
Watermaker Diagrams ....................................................................................................Page 4
Operating Manual........................................................................................................... Page 7
Quick Guide To Operation..........................................................................Page 8
StartingYour Watermaker....................................................................... Page 10
Shutting DownYour Watermaker............................................................. Page 13
Long Term Storage ................................................................................. Page 14
Maintenance Manual..................................................................................................... Page 16
Pre-filters............................................................................................... Page 17
High Pressure Pump ............................................................................... Page 17
Installation Manual ....................................................................................................... Page 22
System Diagram..................................................................................... Page 23
What’s Included InYour Kit...................................................................... Page 24
Control Panel Installation........................................................................ Page 25
Pre-filter Installation .............................................................................. Page 26
High Pressure Pump Installation.............................................................. Page 27
Membrane Installation............................................................................ Page 29
Seawater Lift Pump Installation .............................................................. Page 29
Running Tubing and Hoses ...................................................................... Page 30
Initial System Start-up ............................................................................ Page 33
Appendices ............................................................................................................. Page 35
High Pressure Pump Repair ..................................................................... Page 36
Troubleshooting Guide............................................................................ Page 37

INTRODUCTION
We’d like to thank you for selecting a Sea Clear Watermaker™ to supply fresh, pure water for your vessel
and your crew. Because this system was designed specifically for cruisers by cruisers, we’re confident
that you will be happy with your choice.
It’s important that you familiarize
yourself with the watermaker and
that you have a solid understanding
of how it works. This manual will
introduce you to the system and will
walk you through its installation,
operation and maintenance.
By taking proper care of your
watermaker, you’ll not only extend
the life of your investment, but you
should also be able to easily diagnose
any issues that may arise.
If you have any questions about
the installation, operation or
maintenance of your Sea Clear
Watermaker, please feel free to
contact us any time.
Sea Clear Watermakers™
36 Harrison Street
Bristol, RI 02809
401.400.2226
[email protected]
www.seaclearwatermakers.com
Sea Clear Watermakers™ Manual - Version 1.1-G Page 3
* Pump shown is for G-40 model.

WATERMAKER DIAGRAMS
Control Panel (Front)
Sea Water Valve
Fresh Water
Valve
Pressure
Adjustment
Needle Valve
Membrane
Pressure
Gauge
Sea Water Lift
Pump Switch
High Pressure
Pump Switch
Pre-filter
Pressure
Gauge
Fuses
Product Water Gauge
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Control Panel (Back)
Pre-filter Pressure Gauge
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Membrane
High Pressure Pump
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Dipstick
Pressure Relief
Valve
To Second Brine
Discharge Port on
Control Panel
Output to
Membrane
Input from
Pre-filter
Housing
End Cap
High Pressure Tubing to
Pressure Adjustment Needle
Valve on Control Panel
Product Water Hose
Electric Motor
* Pump shown is for G-40 model.

OPERATINGMANUAL
Quick Guide to Operation ........................................Page 8
StartingYour Watermaker ..................................... Page 10
Shutting DownYour Watermaker ........................... Page 13
Long Term Storage (more than 5-7 days without use)............... Page 14
Sea Clear Watermakers™ Manual - Version 1.1-G Page 7

❻Turn on Seawater
Lift Pump
❼Turn on High
Pressure Pump
and let system
run for 1 minute
to purge air
❽Slowly turn
Pressure
Adjustment
Needle Valve
clockwise,
increasing
to operating
pressure of 800
psi
❶Start generator, bringing it up to operating
temperature and steady RPM
❷Turn Seawater
valve to
“Seawater intake”
position
❸Turn Fresh Water
valve to “Flush
tank” position
❹Place hose labeled “To flush tank” into 5
gallon bucket
❺Turn Pressure
Adjustment
Needle Valve
counterclockwise
2 times
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QUICK GUIDE TOOPERATION

❾When bucket is
full and water
ok, turn Fresh
Water valve to
“To storage tank”
positionand set
full bucket aside
❿Monitor Membrane pressure and level of
water in tanks
⓫When finished
making water,
slowly turn
Pressure
Adjustment
Needle Valve
counterclockwise
until pressure
drops to zero psi
⓬Place “Flush water intake” hose into bucket
of product water
⓭Turn Seawater
valve to “Flush
water intake”
position
⓮Turn offSeawater
Lift Pump
⓯Let water flow through system until bucket
is almost empty
⓰Turn offHigh
Pressure Pump
⓱Return Seawater
valve to
“Seawater intake”
position and
Fresh Water valve
to “To flush tank”
position
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STARTINGYOURWATERMAKER
❶Start your generator and let it warm up, adjusting it until it’s running at a steady speed.
►►►Never run your generator above
your maximum allowable generator
speed. It’s critical that the pressure
of the membrane remain constant;
because this is directly affected by
your generator speed, do not vary the
generator RPM while running your
watermaker.
❷When the generator has reached operating
temperature, turn the Sea Water valve to the
“Seawater Intake” position and turn the Fresh
Water valve to the “Flush Tank” position. (See
Figure 1.)
❸Place the hose labeled “To flush tank” into a clean
5 gallon bucket.
Before starting your watermaker:
• Oil, chlorine and other chemicals will do permanent damage to your watermaker
membrane. Always confirm that your feed water source is free of chemicals before
starting the system.
• If the watermaker has been in storage and this is the first start-up since pickling the unit,
follow the normal start-up procedure, but discard all product water for the first 15 - 20
minutes of operation to ensure that the biocide solution has been completely flushed
from the system. Ingestion of the solution will cause gastrointestinal issues.
My maximum allowable generator speed:
RPM
(Determined during installation; refer to chart on page 25 .)
Sea Clear Watermakers™ Manual - Version 1.1-G Page 10
FIGURE 1

❹Turn the Pressure Adjustment NeedleValve counterclockwise 2 times to decrease pressure.
❺Turn on the Seawater Lift Pump using the switch on the panel labeled “Seawater Lift Pump.”
❻Verify the following:
• Water is running through the system and is being discharged overboard;
• The Membrane Pressure Gauge on the right side of the panel indicates zero pressure;
• The generator is still running smoothly at a steady speed
❼Start the High Pressure Pump by using the switch on the panel labeled “H.P. Clutch.”You should see
the flow of water through the system increase.
❽Let the watermaker run for a few minutes to clear any air from the system and to be sure that a
steady flow of water is being discharged overboard.
❾Very slowly, turn the Pressure Adjustment Needle Valve on the panel in a clockwise direction until
the pressure increases to 700 psi. Let the system stabilize. Product water should now be flowing into
your bucket.
❿Verify that everything is running properly and that the pressure is being maintained at 700 psi. Now
turn the Pressure Adjustment Needle Valve in a clockwise direction again to increase the pressure to
its final rate (the actual pressure will depend upon water temperature, salinity, etc.).
►►►Never go above 850 psi.
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Your watermaker output will vary based on the temperature and salinity of the sea water. The
properties of the water will change based on temperature; the rule of thumb is the colder the
water, the lower the output at a given pressure. The same is true for a higher salt content; in
warmer climates, a higher output can be expected.
It is critical that the pressure remain constant at 800 PSI at all times. Do NOT increase the
pressure to attempt to achieve a higher product output.

⓫Let the bucket fill with water; while you’re waiting, take a moment to do a routine check for any leaks
in the system. When you are satisfied with the product water, turn the Fresh Water valve to the “To
storage tank” position (valve should be vertical). Remove and coil the hose and put the full bucket
aside for use during shut down.
⓬Check the Membrane Pressure Gauge on the right side of the panel occasionally to verify that the
pressure is constant.
⓭Monitor the level of water in your tank. When the tank is full or when you are finished making water,
proceed to the shut down process on the following page.
Sea Clear Watermakers™ Manual - Version 1.1-G Page 12

SHUTTINGDOWNYOURWATERMAKER
❶When your tanks are full or you are finished making water, slowly turn the Pressure Adjustment
Needle Valve counterclockwise. The pressure on the gauge above should decrease to zero PSI and
the product water should stop flowing.
❷Turn the Fresh Water valve to the “Flush tank” position (valve should be horizontal), so that it’s ready
for the next time you make water.
❸Put the hose labeled “Flush water intake” into the bucket of product water (set aside during start-up)
and turn the Sea Water valve to the “Flush water intake” position (valve should be horizontal).
❹Turn offthe Seawater Lift Pump using the switch on the panel labeled “Seawater Lift Pump.”
❺The water will flow from the bucket back through the system; let it run until the bucket is almost
empty.
❻Turn offthe High Pressure Pump using the switch on the panel labeled “H.P. Clutch.”
►►►Do not let the pump run dry for more than a few seconds as this will damage your system.
Upon shut down, organic matter will remain in the system, which will cause microorganisms
to grow that can clog/damage your membrane. Flushing the system with product water after
shut down eliminates most organic matter and keeps your membrane clean.
►►►If your watermaker will be inactive for more than 7 days, the membrane must be
pickled (see “Long Term Storage”).
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Never let the pump run dry and never turn offthe Seawater Lift Pump while the High Pressure
Pump is running and the Seawater valve is in the “Seawater Intake” position. When shutting
down the system, always switch the Seawater valve to the “Flush water intake” position
before turning offthe Seawater Lift Pump.

LONGTERM STORAGE
If you do not intend to use your watermaker again within the next 7 days (5 days in hotter climates), the
watermaker should be pickled. Pickling introduces chemicals into the system to prevent the growth of
microorganisms that will damage the membrane.
The pickling process will preserve the membrane for up to 6 months. If the watermaker will be inactive
for longer durations, the pickling process must be repeated every 6 months.
❶Using the 5 gallons of product water made during start-up*, add 5 tablespoons of sodium
metabisulfite to the bucket and mix until dissolved. (Sodium metabisulfite is readily available
wherever you find beer brewing supplies.)
❷Put the hose labeled “Flush water intake” into the bucket and turn the Sea Water valve to the “Flush
water intake” position (valve should be horizontal).
❸Turn offthe Seawater Lift Pump using the switch on the panel labeled “Seawater Lift Pump.”
❹The pickling solution will flow from the bucket back through the system. When the bucket is empty,
let the watermaker run for an additional 5 seconds before shutting down.
❺Turn offthe High Pressure Pump using the switch on the panel labeled “H.P. Clutch.”
►►►Do not let the pump run dry for more than a few seconds; this will damage your system.
If the watermaker may be exposed to freezing temperatures, antifreeze must be introduced
into the system. Please follow “Cold Weather Storage” procedure on the next page.
Sea Clear Watermakers™ Manual - Version 1.1-G Page 14
* If for any reason you are unable to operate the watermaker (e.g., during haul out) and you
do not have 5 gallons of product water available, you may use clean tap water instead.
However, the tap water must be run through a charcoal filter first to eliminate all chlorine,
as this will damage your membrane.

Cold Weather Storage
If the watermaker will be exposed to freezing temperatures, it is necessary to introduce antifreeze.
Propylene glycol antifreeze (also known as RV antifreeze or potable water antifreeze) can be used for
cold storage or storage up to 1 year.
❶Starting with the watermaker off, fill your 5 gallon bucket with propylene glycol antifreeze.
❷Put the hose labeled “Flush water intake” into the bucket and turn the Sea Water valve to the “Flush
water intake” position (valve should be horizontal).
❸With the generator at operating RPM, turn on the High Pressure Pump by using the switch on the
panel labeled “H.P. Clutch.”
❹Watch the brine dump and turn offthe High Pressure Pump as soon as you see antifreeze.
►►►Keep a close watch on the 5 gallon bucket to be sure it does not run dry.
►►►Depending upon Seawater Lift Pump installation, it may be necessary to drain water from hoses
and lift pump before exposing to freezing temperatures.
Sea Clear Watermakers™ Manual - Version 1.1-G Page 15

MAINTENANCE MANUAL
Pre-filters............................................................. Page 17
High Pressure Pump.............................................. Page 17
Sea Clear Watermakers™ Manual - Version 1.1-G Page 16

PRE-FILTERS
►►►Use only 5-micron 10” polyester filter elements, such as Katadyne 8012861. These can be found
at most marine and water supply stores.
Pre-filters should be replaced regularly. To determine the status of your Pre-filter element, use the Pre-
filter Pressure Gauge on the Control Panel. This gauge should stay at or above zero PSI when the system
is in operation. If the gauge shows a negative pressure or a vacuum, it’s time to replace the element.
Replacement Procedure
❶Shut down the system and ensure that the Sea Water Lift Pump is OFF and through-hull is closed.
❷Unscrew the Pre-filter Housing and remove the Pre-filter element.
❸Discard the used element and install a new 5-micron polyester element.
❹Reassemble by securely screwing the Pre-filter Housing back together.
❺When restarting the system, be sure to check the Pre-filter Housing for leaks.
HIGH PRESSURE PUMP
Your watermaker system includes an AR North America High Pressure Pump. Designed for long life, the
pump should provide years of trouble-free operation if maintained and inspected regularly.
During installation, the gear case was filled with 9.81 oz. ISO 100 - NA 30 weight hydraulic oil and the
bolts and belts were adjusted. It is good practice to inspect the belt and check the gear case oil every 20
hours of operation.
See the following pages for information regarding the electric motor.
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Sea Clear Watermakers™ Manual - Version 1.1-G Page 18
1HP Electric Motor Datasheet (Standard Kit Model G-20)
Horsepower 1
RPM / poles 1800 / 4
Voltage / phase 115 / 208-230V / 1
Frame 56C
Enclosure TEFC
Frequency 60Hz
Rated speed 1725 RPM
Full load amps 13.6 / 7.5 - 6.8 A
Duty cycle Continuous
Service factor 1.15
Insulation class F
Base type C-Face - Removable
Shaft Keyed
DE bearing 6205
ODE bearing 6203
Mounting F1
Rotation Clockwise / Counterclockwise
Overload Manual
Start capacitor Ø42 x 80mm2/ 300 uF / 125V
Run capacitor ---
Wire type Loose Wire
Wire housing Junction Box
Connection diagram 115 / 208 - 230V - 6 Lead
Approx. weight 34 lbs.
FL efficiency 68.0%

Sea Clear Watermakers™ Manual - Version 1.1-G Page 19
1HP Electric Motor Dimensions (Standard Kit Model G-20)
* All dimensions are in inches.
MOUNTING
E 2F1 2F2 H BA A B CDGJ LPAA AB
2.44 3 5 0.34 2.75 6.5 6.5 13.4 3.5 0.12 1.73 8.07 6.9 1/2 5.35
KEY KEYSEATFLANGE SHAFT TERMINAL BOX
BCESS RAJAKBB BFN-W UXBXCXDXE
0.19 1.41 0.188 0.517 5.875 4.5 0.16 ³/8-16 1.88 0.625 1.65 3.7 3.23 285

Sea Clear Watermakers™ Manual - Version 1.1-G Page 20
2HP Electric Motor Datasheet (Premium Kit Model G-40)
Horsepower 2
RPM / poles 1800 / 4
Voltage / phase 115 / 208-230V / 1
Frame 56C
Enclosure TEFC
Frequency 60Hz
Rated speed 1725 RPM
Full load amps 20.0 / 11.1 - 10.0 A
Duty cycle Continuous
Service factor 1.15
Insulation class F
Base type C-Face - Removable
Shaft Keyed
DE bearing 6205
ODE bearing 6203
Mounting F1
Rotation Clockwise / Counterclockwise
Overload Manual
Start capacitor Ø42 x 80mm2/ 400 uF / 165V
Run capacitor Ø45 x 90mm2/ 40 uF / 450V
Wire type Loose Wire
Wire housing Junction Box
Connection diagram 115 / 208 - 230V - 6 Lead
Approx. weight 43 lbs.
FL efficiency 73.0%