Village Marine LITTLE WONDER Series Assembly instructions

THE LITTLE WONDER SERIES
USER GUIDE &
REFERENCE MANUAL
Village Marine Tec.
Fresh Water from the Sea
Corporate Sales Office/Manufacturer
2000 W. 135th St., Gardena, CA 90249
[phone] / [phone] Fax: [phone]
http:www.villagemarine.com
e-mail: [email protected]
FACTORY SHOWROOM AND SERVICE FACILITIES
SAN DIEGO, CALIFORNIA FT. LAUDERDALE, FLORIDA WEST PALM BEACH, FLORIDA
2820 Shelter Island Drive 802 S.E. 17TH Street 155 Blue Heron Blvd.
San Diego, CA 92106 Ft. Lauderdale, FL 33316 Riviera Beach, FL 33404
[phone] / [phone] [phone] / [phone] [phone] / (561)-844-3320
Fax: [phone] Fax: [phone] Fax: [phone]
SEATTLE, WASHINGTON PORTSMOUTH, VIRGINIA
1540 N.W. 46TH Street 100 Seventh Street, Suite 102
Seattle, WA 98107 Portsmouth, VA 23704
[phone] / [phone] [phone] / [phone]
Fax: [phone] Fax: [phone]

TABLE OF CONTENTS
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1.0 INTRODUCTION 1
1.1 UNPACKING AND HANDLING 2
1.2 PERFORMANCE SPECIFICATIONS 2
1.3 ENVIROMENTAL REQUIREMENTS 2
1.4 CONSUMABLES 2
1.5 TEST EQUIPMENT 3
2.0 INSTALLATION 5
LITTLE WONDER FRAME
2.1ATO INSTALL LITTLE WONDER FRAME UNIT 5
2.1BTO CONNECT PLUMBING 6
2.1CTO CONNECT THE ELECTRICAL 9
LITTLE WONDER FRAME 350
2.2ATO INSTALL LITTLE WONDER FRAME 350 11
2.2BTO CONNECT PLUMBING 12
2.2CTO CONNECT THE ELECTRICAL 15
LITTLE WONDER MODULAR
2.3ATO INSTALL LITTLE WONDER MODULAR UNIT 17
2.3BTO CONNECT PLUMBING 18
2.3CTO CONNECT THE ELECTRICAL 21
LITTLE WONDER MODULAR 350
2.4ATO INSTALL LITTLE WONDER MODULAR 350 23
2.4BTO CONNECT PLUMBING 24
2.4CTO CONNECT THE ELECTRICAL 27
LITTLE WONDER VERTICAL INTEGRATED PACKAGE (VIP)
2.5ATO INSTALL LITTLE WONDER VIP UNIT 29
2.5BTO CONNECT PLUMBING 30
2.5CTO CONNECT THE ELECTRICAL 33
3.0 GENERAL THEORY OF OPERATION 35
3.1 REVERSE OSMOSIS THEORY 35

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3.3 PRODUCT WATER QUALITY STANDARDS 36
3.4 FACTORS AFFECTING PERMEATE PRODUCTION 36
3.4ATEMPERATURE CORRECTION FACTOR 37
4.0 OPERATION 39
LITTLE WONDER FRAME
4.1ATO START LITTLE WONDER FRAME UNIT 39
4.1BTO SHUT DOWN UNIT 40
LITTLE WONDER FRAME 350
4.2ATO START LITTLE WONDER FRAME 350 UNIT 41
4.2BTO SHUT DOWN UNIT 42
LITTLE WONDER MODULAR
4.3ATO START LITTLE WONDER MODULAR UNIT 43
4.3BTO SHUT DOWN UNIT 44
LITTLE WONDER MODULAR 350
4.4ATO START UNIT LITTLE WONDER MODULAR 350 (NON-ELECTRONICS PACKAGE) 45
4.4BTO SHUT DOWN UNIT (NON-ELECTRONICS PACKAGE) 46
4.4CTO START UNIT LITTLE WONDER MODULAR 350 (WITH ELECTRONICS PACKAGE) 47
4.4DTO SHUT DOWN UNIT (WITH ELECTRONICS PACKAGE) 48
LITTLE WONDER VERTICAL INTEGRATED PACKAGE (VIP)
4.5ATO START LITTLE WONDER VIP UNIT 49
4.5BTO SHUT DOWN UNIT 50
5.0 MAINTENANCE 51
FRESHWATER FLUSH / SHORT TERM STORAGE 51
LITTLE WONDER FRAME
5.1 TO FLUSH LITTLE WONDER FRAME UNIT 52
LITTLE WONDER FRAME 350
5.2 TO FLUSH LITTLE WONDER FRAME 350 UNIT 53
LITTLE WONDER MODULAR
5.3 TO FLUSH LITTLE WONDER MODULAR UNIT 54

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LITTLE WONDER MODULAR 350
5.4ATO FLUSH LITTLE WONDER MODULAR 350 UNIT (NON-ELECTRONICS PACKAGE) 55
5.4BTO FLUSH LITTLE WONDER MODULAR 350 UNIT (WITH-ELECTRONICS PACKAGE) 55
LITTLEWONDER VERTICAL INTEGRATED PACKAGE (VIP)
5.5 TO FLUSH LITTLE WONDER VIP UNIT 56
5.6 CHEMICAL CLEANING PROCEDURE 57
5.7ACLEANING STEPS FOR CHEMICAL #1 AND #2 58
5.7BLONG TERM STORAGE / PRESERVATION PROCEDURE 59
5.8 STEPS FOR PRESERVATION CHEMICAL #3 60
5.9 OIL CHANGE PROCEDURE 61
6.0 MEMBRANE REPLACEMENT 63
6.1 PRESSURE VESSEL DISASSEMBLY 63
6.2 PRESSURE VESSEL ASSEMBLY 64
7.0 SYSTEM/EQUIPMENT DRAWINGS AND DIAGRAMS 65
8.0 PLUMBING DIAGRAMS 75
9.0 PARTS REFERENCE 83
10.0 MANUFACTURER’S LITERATURE 87

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SYSTEM START UP LOG
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Village Marine Tec.
Fresh Water from the Sea
SYSTEM START UP LOG
SYSTEM INFORMATION:
MODEL NUMBER:
SERIAL NUMBER:
DATE OF PURCHASE:
PURCHASED FROM:
INSTALLATION DATE:
START UP PERFORMANCE READINGS:
MEASURE AFTER 3 AND 24 HOURS OR PRESSURIZED TIME IN SIMILAR CONDITIONS
3 Hours 24 Hours
FEED WATER TEMPERATURE:
FEED WATER SALINITY (IF KNOWN):
BATTERY VOLTAGE:
VOLTAGE AT UNIT:
AVERAGE AMP DRAW (IF KNOWN):
OPERATING PRESSURE:
PRODUCT WATER FLOW: (GPH)(GPH)
REJECT WATER FLOW (IF KNOWN): (GPH)(GPH)
PRODUCT WATER QUALITY (IF KNOWN): (ppm)(ppm)

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1.0 INTRODUCTION
SYSTEM DESCRIPTION
Village Marine Tec’s (VMT) the Little Wonder is a well-engineered reverse osmosis (RO) system, designed and built
for simple operations and maintenance for the cruising sailor, sport fisherman, and vessels where space is at a
premium.Theseself-contained 110/220 Volts AC and 12/24 Volts DC desalination systems will produce eight to
sixteen gallons per hour (GPH) of freshwater from the sea (gallon production will vary based upon water temperature,
salinity, and model of the RO system).
The Little Wonder unit produces water, meeting or surpassing drinking water guidelines with seawater salt
concentrations as high as 32,000 parts per million (ppm). World Health Organization guidelines stipulates drinking
purified water salt concentrations be at 500 ppm.
HOW TO USE YOUR MANUAL
This User Guide & Reference Manual contains important information about the safe operation and maintenance of
your Little Wonder Frame, Little Wonder Modular, and Little Wonder Vertical Integrated Package (VIP) units.
We advise you to please read through the entire User Guide & Reference Manual carefully to ensure you familiarize
yourself with the operation of your RO system and follow the recommendations within the manual, to help make your
water producing experiences trouble-free and enjoyable.
SAFETY WARNINGS
Throughout this User Guide & Reference Manual you will see many important statements or labels indicated on the
product with the following words:
Indicates a strong possibility of severe personal injury or death if
warning instructions are ignored.
Indicates hazards or unsafe practices of product may cause
minor personal injury or may cause property damage.
NOTE:Text specifies useful information.

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1.1 UNPACKING AND HANDLING
The Little Wonder reverse osmosis unit is shipped pre-assembled. There are no special instructions
towards unpacking and handling of the watermaker system. Inspect the RO unit to verify it was not
damaged in transit. Also, please refer toSection 8.0: PLUMBING DIAGRAMS to verify all components
for the watermaker are shipped prior to installation. Be sure to mark and record all hose locations for
reference, if disconnection of hose is necessary.
DO NOT EXPOSE THE RO UNIT TO FREEZING TEMPERATURES WITHOUT PROPER STEPS TO
TREAT THE RO UNIT FOR SUB-FREEZING TEMPERATURES.
1.2 PERFORMANCE SPECIFICATIONS
Parameter Specification
Raw water temperature (minimum) 33°F (1°C)
Raw water temperature (nominal) 77°F (25°C)
Raw water temperature (maximum) 113°F (45°C)
Min. raw water inlet pressure Static suction pressure
Max. raw water inlet pressure* 20 psi
Flush water recommended max. pressure 35 psi
Design RO element pressure 800 psi
Max. RO element pressure 1000 psi
Max. feedwater chlorine residual < 0.1 ppm
Cleaning solution pH range 10-11 (chem. 1), 2-3 (chem. 2)
Membrane type Thin film composite
Table 1.0 -Performance Characteristics
*For inlet pressure greater than recommended limits, consult VMTtechnicalservice.
NOTE: REGARDING WATER PRODUCTION:
The RO series number (i.e. LW200, LWM350, or LWVIP 250) refers to gallons per day (GPD)
production produced with new membranes at design optimum conditions. To achieve optimum
production, the feed flow must be unrestricted (positive water pressure at the inlet toHP Pump),
seawater temperature at 77°F (25°C), and seawater salinity at 32,000 parts per million (ppm) total
dissolved solids (TDS). Direct current (DC) units should be at charging voltage (13.8 volts for a 12 volt
system) and wire size should be 6 gauge.
Variation of conditions and normal aging of membranes will decrease production. Normal membrane
fouling will be partially recovered by chemical cleaning, but 100% recovery should not be expected.
Production rates from membranes to membrane can vary +15%.
1.3 ENVIROMENTAL REQUIREMENTS
Parameter Specifications
List (Permanent):
Trim (Fore and Aft):
Pitch:
Roll:
15°
+ 30°
6108(6 sec cycle)
6308(12 sec cycle)
Table 1.1 -Nominal Operating Conditions
1.4 CONSUMABLES
Table 1.2 lists the consumables required for any six month operation of the RO unit. UseONLYVillage
Marine Tec. approved filters and chemicals.

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Description QTY LW 200/250/300/350/400
Chemical Cleaning Cartridge Kit #1, #2 1ea/box 85-0102
Preservative Cartridge Kit 2/box 85-0103
Filter, 5 micron, 10 sq-ft. 2/box 33-5010
Filter, Carbon, 10 sq-ft. 1ea/box 33-0311
Aqua Pro HP Pump Oil 1 qt 85-0050
Table 1.2 –VMT Approved Consumables
1.5 TEST EQUIPMENT
Table 1.3 lists the test equipment required for performance verification and maintenance of the RO unit.
Description VMT Part No.
Meter, Hand Held, 0-5000 ppm 40-5000
10X Range extender for meter 40-5001
Solution, calibration, 30,000 ppm 90-1301
Solution, calibration, 300 ppm 90-1301
Economy Mini Water Tester, TDS 99-1990
Table 1.3 –Required Test Equipment

INTRODUCTION
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INSTALLATION
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2.0 INSTALLATION
Village Marine Tec. recommendsALL Little Wonder models (as with all other VMT model RO units) beINSTALLED
BELOW the vessel’s waterline, to ensure a flooded suction intake to the unit.
NOTE: If the Little Wonder unit cannot mount below waterline, an additional low pressure boost pump
may be required. Contact your Little Wonder place of purchase or dealer, for further technical
advisement.
2.1a TO INSTALL LITTLE WONDER FRAME UNIT
Step 1:Village Marine Tec. recommends installing the RO unit in a dry sheltered location at or aft of midship,
with drainage underneath (to draw off standing water when performing routine maintenance or service).
Also, the RO unit should be installedBELOW waterline (Refer to Figure 1). Give consideration to extra
space around the RO unit, allowing access for the unit’s maintenance (i.e. membrane replacement, oil
change, prefilter replacement, or other service).
Figure 1: Recommended Installation Location -BELOW waterline.
If theLittle Wonder FRAME requires above waterline installation, CONSULTwith watermaker place of
purchase or dealer for further technical advisement.
Step 2:Locate or create a ½” dedicated through-hull for the feedwater intake of the RO unit. The through-hull
must be attached with a screen and ball valve (seacock).
The Little Wonder FRAME CANNOT SHARE a through-hull feedwater intake. Village Marine Tec.
recommends the Little Wonder HAVE its OWNdedicated through-hull to properly feed water into
the RO. Avoid connecting the inlet piping to any water line which services an engine or other
equipment. Air could be drawn through the unit causing damage to the RO unit’s pumps, as well
as VOIDING the RO unit’s warranty with VMT.
Step 3:Drill a minimum of four mounting holes through the frame and/or mounting base. When drilling,
ALWAYS CHECKfor the drill bit from puncturing/damaging any component of the watermaker and the
surrounding mounting area.
Step 4:Optionally, mount and secure theLittle Wonder FRAME with four mounting supports (not supplied
with RO unit). The supports (Refer to Figure 2) minimize noises and vibrations when RO unit is in use.
Figure 2: RO Mount Support -Isometric View.

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2.1b TO CONNECT PLUMBING
Step 1:Refer toPAGES 76 for the EXPANDED detailedLittle Wonder FRAMEplumbing diagram.
Figure 3: Little Wonder FRAME Plumbing Diagram.
Step 2:Refer to Figure 4 for theLittle Wonder FRAMEmanifold port identification.
Figure 4: Little Wonder FRAME Manifold –Left View.
FEEDWATER INTAKE
Step 1:Mount the sea strainer BELOW the vessel’s waterline.
Step 2:Mount the three-way manual Freshwater Flush Valve (attached to the Carbon Filter Housing) BELOW
waterline. Refer to Figure 5 for views of the Carbon Filter and Freshwater Flush Valve.
Figure 5: Carbon Filter with Freshwater Flush Valve –Isometric Views.
NOTE:Village Marine Tec. recommends the Manual Freshwater Flush Assembly be installed BELOW
waterline. The valve can be removed from the filter housing and relocated below waterline.
Doing so, a hose can be plumbed to the filter housing from the valve, so that the valve is below
waterline. It is MANDATORY for the Freshwater Flush Valve be installed BELOW waterline to
avoid trapping air and creating a problem in the feedwater path.

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Step 3:Locate your RO unit’s dedicated feedwater intake through-hull that isBELOW waterline.
Step 4:Connect a ½” inner diameter PVC hose, from the RO’s dedicated intake through-hull, to the sea
strainer’s INLET.
Step 5:Connect a shielded PVC hose ½” inner diameter from the sea strainer’s OUTLET, to one side of the
three-way flush valve (a ½” gray valve) mounted BELOW waterline. Refer toPAGE 76 for detailed
connection and Figure 5 for view of the Freshwater Flush Valve.
Step 6:Connect a ½” hose from the center of the flush valve (½” gray valve) to the ½” tee before the Low
Pressure Boost Pump. Refer to Figure 6.
Figure 6: Freshwater Flush Connection to Tee and Low Pressure Boost Pump.
BRINE DISCHARGE
Step 1:Locate a convenient spot in the boat to install an overboard through-hull with an ½” inner diameter hole.
Discharge line is required to beABOVEwaterline. Refer to Figure 1.
Step 2:Connect a ½” inner diameter PVC hose from the overboard through-hull to the discharge port of the
Cleaning Valve discharge elbow. Also, connect a ½” inner diameter PVC hose fromthe reject outlet of the
manifold on the RO unit, to the cleaning valve. Refer toPAGE 76 and Figures 4 and 7.
Figure 7: LITTLE WONDER FRAME Brine Connection Overboard.
PRODUCT WATER AND SAMPLE WATER
Step 1:On both elbows off of the sample valve, connect a ¼” inner diameter hose shielded PVC hose (or
potable water hose) Refer to Figure 8. One hose is for product water sampling and the other hose is for
feeding the ship’s Freshwater Tank. The product tank hose off of the sample valve is to be fed into the
top of the product tank.

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Figure 8: LITTLE WONDER FRAME Sample Valve Connection
The product water hose line must go into the top of the product tank to prevent any possible back flow.
Village Marine Tec. recommends teeing into the tank vent or fill line.
If a fitting connection cannot be made to the top of the Freshwater Tank, Tee into the Deck Water Fill.
Leave enough hose length to RUN the sample hose portion to a sink, bilge, or overboard, to sample the
product water.
NOTE:Village Marine Tec. recommends running the sample line to a galley sink and installing a
dedicated water spigot, free flowing, always open (i.e. a ‘cane shaped’ fixture as used in a
manual galley pump). This allows easy sampling at a sink, a drain overboard and the capability
to fill extra water bottles, while your Little Wonder produces water for all purposes.
FRESHWATER FLUSH
Step 1:Tap into your boat’s freshwater pressure system. (Tee into the cold pressurized side).
Step 2:Run a ½” hose from the tee to the carbon filter inlet (Refer to Figure 9).
Figure 9: Connecting the Freshwater Hose into Freshwater Flush Assembly Inlet.
Step 3:If the Freshwater Flush Valve is ATTACHED to the Carbon Filter Assembly:
Proceed to the next section.
If the Freshwater Flush Valve is SEPARATED from the Carbon Filter Assembly:
Connect a ½” hose from the carbon filter outlet to one side of the ½” gray flush valve (Refer to Figure
10) and proceed to the next section.

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Figure 10: Connecting the Carbon Filter Outlet to the Separated Freshwater Flush Valve
2.1c TO CONNECT THE ELECTRICAL
TURN OFF ALL ELECTRICAL POWER FOR USE WITH THE RO UNIT PRIOR TO CONNECTING TO
THE RO POWER SOURCE. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH
TO 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 is 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.
Step 1:Verify all power switches and power sources are in theOFF position.
Step 2 Connect power source wire (Positive +) to line side on RO unit’s breaker.
Step 3:AC POWERED 110V/220V Little Wonder FRAME:
Connection will be from the separate control box to the vessel’s main control breaker.
DC POWERED 12V/24V Little Wonder FRAME:
DC units require6 gauge wire. A circuit breaker is built within theLittle Wonder FRAMEunit. Connect
RO unit’s power supply wire (Positive +) from load side of unit’s breaker, to power input on theLittle
Wonder FRAME’s terminal strip (Refer to Figure 11).
Step 4:Connect a negative wire from the ground bus bar behind main breaker panel to negative power source
input on unit.
Step 5:With the boost pump mounted out of frame unit, connect positive wire to switch (+) for boost pump
positive terminal and negative to negative power source input terminal.
Figure 11: Little Wonder FRAME Electrical Interface Views.

INSTALLATION
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INSTALLATION
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2.2a TO INSTALL LITTLE WONDER FRAME 350
Step 1:Village Marine Tec. recommends installing the RO unit in a dry sheltered location at or aft of midship,
with drainage underneath (to draw off standing water when performing routine maintenance or service).
Also, the RO unit should be installedBELOW waterline (Refer to Figure 12). Give consideration to extra
space around the RO unit, allowing access for the unit’s maintenance (i.e. membrane replacement, oil
change, prefilter replacement, or other service).
Figure 12: Recommended installation BELOW waterline.
If theLittle Wonder FRAME 350 requires above waterline installation, CONSULT with watermaker
place of purchase or dealer for further technical advisement.
Step 2:Locate or create a ¾” dedicated through-hull for the feedwater intake of the RO unit. The through-hull
must be attached with a screen and ball valve (seacock).
The Little Wonder FRAME 350 CANNOT SHAREa through-hull feedwater intake. Village Marine
Tec. recommends the Little Wonder HAVE itsOWN dedicated through-hull to properly feed
water into the RO. Avoid connecting the inlet piping to any water line which services an engine
or other equipment. Air could be drawn through the unit causing damage to the RO unit’s
pumps, as well asVOIDINGthe RO unit’s warranty with VMT.
Step 3:Drill a minimum of four mounting holes through the frame and/or mounting base. When drilling,
ALWAYS CHECKfor the drill bit from puncturing/damaging any component of the watermaker and the
surrounding mounting area.
Step 4:Optionally, mount and secure theLittle Wonder FRAME 350 with four mounting supports (NOT
SUPPLIED WITH RO UNIT). The supports (Refer to Figure 13) minimize noises and vibrations when
RO unit is in use.
Figure 13: RO Mount Support -Isometric View.

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2.2b TO CONNECT PLUMBING
Step 1:Refer toPAGES 77 for the EXPANDED detailed Little Wonder FRAME 350plumbing diagram.
Figure 14: Little Wonder FRAME 350 Plumbing Diagram.
Step 1:Refer to Figure 15 for theLittle Wonder FRAME 350 manifold port identification.
Figure 15: Little Wonder FRAME 350 Manifold -Right View.
FEEDWATER INTAKE
Step 1:Mount the sea strainer BELOW the vessel’s waterline.
Step 2:Mount the three-way manual Freshwater Flush Valve (attached to Carbon Filter Housing) BELOW
waterline. Refer to Figure 16 for views of the Carbon Filter and the Freshwater Flush Valve.
Figure 16: Carbon Filter with Freshwater Flush Valve –Isometric Views.
NOTE:Village Marine Tec. recommends the Manual Freshwater Flush assembly be installed BELOW
waterline. The valve can be removed from the filter housing and relocated below waterline.
Doing so, a hose can be plumbed to the filter housing from the valve, so that the valve is below
waterline. It is MANDATORY for the Freshwater Flush Valve be installed BELOW waterline to
avoid trapping air and creating a problem in the feedwater path.